DC Link Test without Motor | J. T. Eaton LCX9000 manual

DC Link Test (without Motor)

LCX9000 Liquid-Cooled Drives User Manual

January 2007

DC Link Test (without Motor)

WARNING

There will be dangerous voltages present during this test!

1.Carefully read the safety instructions in the front of this manual and above and follow them.

2.Connect a variable DC power supply to DC+ and DC- terminals. Make sure that all polarities are correct.

3.Slowly charge up the DC link to nominal voltage. Allow the system to remain at this level for at least one minute and check current.

4.If possible, continue increasing the DC link voltage up to the trip limit. Fault F2 (see Table A-1) should occur at 911V DC (400 – 500V units) and at 1200V DC (525 – 690V units). Do not increase the voltage over the trip limit.

5.Bring the power supply voltage back to zero. Allow sufﬁcient time for the capacitors to discharge.

6.Check the DC bus voltage with a multimeter. When you read zero volts, disconnect the power supply and reconnect all wires to the phase module.

7.If the phase module has been de-energized for an extended period of time (six months or longer) allow this voltage to remain for a minimum of 30 minutes — even 4 hours if time permits.

Through the above test procedure, two things are achieved: 1) It allows the caps to partially reform due to storage and shipping; 2) It allows any device failures to evidence themselves with a low power failure.

MN04005001E

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J. T. Eaton LCX9000 user manual DC Link Test without Motor

Contents

User Manual January Supersedes September LCX9000 Liquid-Cooled DrivesMN04005001E Page Important Notice - Please Read Table of CHAPTER 4 - CONTROL WIRING AND INTERNAL CONNECTIONSContents List of Figures List of Figures Continued List of Tables Table 5-11 System Menu Functions List of Tables ContinuedTable 5-13 Resettable Counters Table A-1 Fault Codes Deﬁnitions and Symbols SafetyHazardous High Voltage Warnings Warnings, Cautions and Notices Cautions Motor and Equipment Safety Grounding and Ground Fault Protection Receiving and Inspection Chapter 1 - Overview L C X 0 1 6 A 0 - 4 A 2 B Technical Data MaintenanceStorage and Shipping LCX9000 Liquid-Cooled Drives User Manual Figure 1-1 Liquid-Cooled Drive Principal Block Diagram Drives Power RatingsPage Page Table 1-4 Technical Information Speciﬁcations 1-10 Table 1-4 Technical Information Continued Mounting Chapter 2 - InstallationLifting the Drive Figure 2-2 LCX9000 Liquid-Cooled Drive, CH3 Liquid-Cooled DimensionsTable 2-1 One-Module Drive Dimensions Mounting Base Included Drives Consisting of One Module Top View Figure 2-3 LCX9000 Liquid-Cooled Drive, CH4Figure 2-4 LCX9000 Liquid-Cooled Drive, CH5 Bottom View Figure 2-6 LCX9000 Liquid-Cooled Drive, CH72 Figure 2-5 LCX9000 Liquid-Cooled Drive, CH61 Drives Consisting of Several Modules Table 2-2 Several Module Drive Dimensions Mounting Bracket IncludedFigure 2-7 Drive Mounted Inside Mounting Bracket Figure 2-8 LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 12-Pulse Supply Figure 2-9 LCX9000 Liquid-Cooled Drive, CH74, IP00Bottom 6-Pulse Supply Table 2-4 Drinking Water Quality Recommendations - Maximum Values CoolingDrinking Water Speciﬁcation Table 2-3 Drinking Water Chemical Speciﬁcation Table 2-6 Process Water Speciﬁcation Table 2-5 Drinking Water Quality Recommendations - Desired Values Exchanger Figure 2-10 Example of Cooling SystemHeat Table 2-7 Information About Cooling Agent and Its Circulation Figure 2-11 Example PI-Diagram of Cooling System and Connections Table 2-9 Coolant Volumes and Temperatures Figure 2-12 Safe Operating Conditions in Relation to Condensation Condensation Figure 2-14 External Thread of Hose Table 2-10 Liquid Connector Types All Pressure Values at Nominal FlowCooling System Connections Figure 2-13 Aluminum Hose Adapters Figure 2-15 Pressure Loss - CH6x Pressure Losses Table 2-11 Pressure Losses - CH6xOutﬂow Hoses and rubber EPDM only aluminium other stainless and acid-proof materials Table 2-12 Pressure Losses - CH7xFigure 2-16 Pressure Loss - CH7x The following main line hose materials are acceptable plastic PVC Fast Connector Lock Screw, Cable Seal and Clamp Installation of Flow SwitchAbout Flow Switch Installation Figure 2-17 Flow Switch Hose Connection, Fast Connector Electrical External Cooling Fan for CH4 Figure 2-18 Direction of Coolant Circulation Drive Derating Input Chokes Table 2-16 Input Choke Dimensioning, 6-Pulse Supply Sizes 87 - 145A and 590A Installation of Input ChokeFigure 2-19 Example of Input Chokes for Liquid-Cooled Sizes Up to 62A Figure 2-20 Example of Input Chokes for Liquid-Cooled January Table 2-17 Choke Dimensions Sizes 23 - 145A and 590A Table 2-18 Choke Dimensions Sizes 261 - 1150A LCX9000 Liquid-Cooled Drives User Manual Motor Cable Chapter 3 - Power WiringPower Connections Mains Cable Cable Data Table 3-1 Cable Types Required to Meet StandardsTable 3-2 Cable Sizes 400 Three grounding terminals per mounting plate, see Page Table 3-2 Cable Sizes 400 - 500V ContinuedUnits with 6-pulse supply Units with 12-pulse supply Table 3-4 Tightening Torques of Bolts Table 3-3 Cable Sizes 525See the tightening torques of bolts in Table Table 3-5 Fuse Sizes for LCX9000 Liquid-Cooled 500V Drives Fuse Sizes, Drives Fuse information Table 3-6 Fuse Sizes for LCX9000 Liquid-Cooled 690V Drives The maximum length of the motor cables is 984 feet 300m Cable Installation Instructions4. If cable insulation checks are needed, see Page Figure 3-1 Maximum Terminal Stresses Figure 3-2 Installation Space Installation Space Cable Installation and the UL Standards Grounding of Power UnitFigure 3-3 Grounding Terminal on Mounting Plate Cable and Motor Insulation Checks 3-12 Figure 4-1 Control Board Chapter 4 - Control Wiring and Internal Connections Figure 4-3 Drives Connected in Parallel Figure 4-2 Basic and Option Board Connections of the Control Board WRONG Terminal J1 Upper Control Board Power-UpFigure 4-4 Connection of Control Board Cable from the Power Board See Figures 4-4 and Figure 4-6 I/O Terminals of the Two Basic Boards Figure 4-5 Connection of Control Board Cable from the Power BoardControl Connections CORRECT Terminal J2 Lower Figure 4-8 General Wiring Diagram of the Basic Relay Board OPT-A2 Figure 4-7 General Wiring Diagram of the Basic I/O Board OPT-A9 Galvanic Isolation Barriers Control CablesFigure 4-9 Galvanic Isolation Barriers Table 4-1 Control I/O Terminal Signals Control Terminal Signals Figure 4-11 Jumper Blocks on OPT-A9 Digital Input Signal InversionsFigure 4-10 Positive/Negative Logic Jumper Selections on the OPT-A9 Basic Board AO1 Mode Figure 4-12 Jumper Selection for OPT-A9AI1 Mode AI2 Mode Figure 4-13 Control Unit Mounting Box Installing the Control Unit Mounting BoxFigure 4-14 Control Unit Installed into the Mounting Box Control Unit Mounting Box Table 4-2 Installing the Control Unit Mounting Box January MN04005001E Table 4-2 Installing the Control Unit Mounting Box Continued Internal Connections Connections between Power Unit ASIC and Driver Boards X29 Flow supervision input Figure 4-15 Terminals and Connections between ASIC and Driver BoardCH61, CH62 and CH72 Table 4-3 Terminals CH61, CH62 and CH72 X9 OEVA feedback X15 Charging relay output X6 DC terminal Connect to WL on Phase V/W driver board Table 4-4 Terminals CH63 Table 4-5 Terminals between Driver Boards CH64 and CH74 Connections with Optical Cable Connections between Power Unit ASIC and the Control UnitFigure 4-18 Remove Cover to Access Power Unit Connections with Round Cable Control board connection Figure 4-19 Optical Cable Adapter BoardTable 4-6 Terminals on Adapter Board Supply voltage 24Vin from power unit Figure 5-1 Control Keypad and Drive Status Indications Indicators on the Keypad DisplayChapter 5 - Menu Information Keypad Operation Table 5-2 Control Place Indicators Drive Status IndicatorsTable 5-1 Drive Status Indicators Control Place Indicators Text Lines Keypad PushbuttonsStatus LEDs Green - Green - Red Table 5-3 Status LEDs Green - Green - Red Table 5-5 Button Descriptions Figure 5-3 Keypad Display Data Menu NavigationMonitor Figure 5-4 Keypad Navigation Chart Figure 5-5 Monitoring Menu Monitoring Menu M1 Parameter Menu M2 Table 5-6 Monitored Signals Keypad Control Menu M3 Figure 5-6 Parameter Value Change ProcedureTable 5-7 Keypad Control Parameters, M3 Figure 5-7 Selection of Control Place Keypad Reference Selection of Control PlaceKeypad Direction Figure 5-8 Normal State, No Faults Active Faults Menu M4STOP Button Activated Fault Type Symbol Fault TypesFigure 5-9 Fault Display Table 5-8 Fault Types Fault Time Data Record Table 5-10 Real Time Record Table 5-9 Fault Time Recorded DataFault History Menu M5 Real Time Record System Menu M6 Figure 5-10 Fault History Menu Table 5-11 System Menu Functions 5-16 Table 5-11 System Menu Functions Continued Figure 5-11 Selection of Language Application Selection Selection of LanguageFigure 5-12 Change of Application Upload parameters to keypad To keypad, S6.3.2 Copy ParametersParameter Sets S6.3.1 Figure 5-13 Storing and Loading of Parameter Sets Figure 5-14 Parameter Copy to Keypad Automatic Parameter Backup P6.3.4Download parameters to drive From keypad, S6.3.3 Figure 5-15 Parameter Comparison Parameter ComparisonP2.1.2= 20.0 Hz Figure 5-16 Password Setting Password S6.5.1Security Figure 5-18 Activation of Start-Up Wizard Parameter Lock P6.5.2Figure 5-17 Parameter Locking Start-Up Wizard P6.5.3 Figure 5-21 Default Page Function Keypad SettingsFigure 5-20 Keypad Settings Submenu Default Page P6.6.1 Contrast Adjustment P6.6.4 Default page in the operating menu P6.6.2Timeout Time P6.6.3 Figure 5-22 Timeout Time Setting HMI Acknowledge Timeout P6.7.3 Hardware SettingsFigure 5-23 HMI Acknowledge Timeout Table 5-12 Counter Pages Number of retries to receive HMI acknowledgement P6.7.4System info Total Counters Software S6.8.3 Table 5-13 Resettable CountersFigure 5-24 Counter Reset Trip Counters Hardware S6.8.5 Applications S6.8.4Table 5-15 Applications Information Pages Figure 5-25 Applications Info Submenu Expander Board Menu M7 Expander Boards S6.8.6Figure 5-26 Expander Board Information Menus Debug Menu S6.8.7 Figure 5-27 Expander Board Information Menu Further Keypad FunctionsExpander Board Parameters Table 5-17 Expander Board Parameters Board OPTA1 Chapter 6 - Start-Up Safety Precautions Sequence of Operation Page January Table A-1 Fault Codes Appendix A - Fault Codes Table A-1 Fault Codes Continued Table A-1 Fault Codes Continued Load Test with Motor DC Link Test without Motor January Figure B-1 Main Circuit and Control Diagram, CH3 Main Circuit and Control DiagramsAppendix B - Technical Reference ATerm Figure B-2 Main Circuit and Control Diagram, CH4Figure B-3 Main Circuit and Control Diagram, CH5 Term H8...H13 Figure B-4 Main Circuit and Control Diagram, CH61Figure B-5 Main Circuit and Control Diagram, CH61, Control SPF1 Figure B-7 Main Circuit and Control Diagram, CH63, Module Figure B-6 Main Circuit and Control Diagram, CH63, ModuleVB00491 Figure B-9 Main Circuit and Control Diagram, CH72 Figure B-8 Main Circuit and Control Diagram, CH63, Control Figure B-11 Main Circuit and Control Diagram, CH74, Phase U Figure B-10 Main Circuit and Control Diagram, CH72, Control Figure B-12 Main Circuit and Control Diagram, CH74, Control Figure B-13 Fan Mounting Pallet - Hot Dip Zinc Coated Fan DimensionsFigure B-14 Fan Support January B-10 Page Publication No. MN04005001E/CPG January Company InformationEaton Electrical Inc 2007 Eaton Corporation All Rights Reserved Printed in USA