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J. T. Eaton LCX9000 user manual Company Information, Eaton Electrical Inc

Models: LCX9000

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Company Information

Eaton’s electrical business is a global leader in electrical control, power distribution, and industrial automation products and services. Through advanced product development, world-class manufacturing methods, and global engineering services and support, Eaton’s electrical business provides customer-driven solutions under brand names such as Cutler-Hammer®, Powerware®, Durant®, Heinemann®, Holec® and MEM®, which globally serve the changing needs of the industrial, utility, light commercial, residential, and OEM markets. For more information, visit www.EatonElectrical.com.

Eaton Corporation is a diversiﬁed industrial manufacturer with 2006 sales of $12.4 billion. Eaton is a global leader in electrical systems and components for power quality, distribution and control; ﬂuid power systems and services for industrial, mobile and aircraft equipment; intelligent truck drivetrain systems for safety and fuel economy; and automotive engine air management systems, powertrain solutions and specialty controls for performance, fuel economy and safety. Eaton has 60,000 employees and sells products to customers in more than 125 countries. For more information, visit www.eaton.com.

Eaton Electrical Inc.

1000 Cherrington Parkway Moon Township, PA 15108-4312

USA

tel: 1-800-525-2000 www.EatonElectrical.com

© 2007 Eaton Corporation

All Rights Reserved

Printed in USA

Publication No. MN04005001E/CPG

January 2007

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J. T. Eaton LCX9000 Company Information, Eaton Electrical Inc, Eaton Corporation All Rights Reserved Printed in USA

Contents

MN04005001E LCX9000 Liquid-Cooled DrivesUser Manual January Supersedes September Page Important Notice - Please Read Contents CHAPTER 4 - CONTROL WIRING AND INTERNAL CONNECTIONSTable of List of Figures List of Figures Continued List of Tables List of Tables Continued Table 5-13 Resettable CountersTable A-1 Fault Codes Table 5-11 System Menu FunctionsHazardous High Voltage SafetyDeﬁnitions and Symbols Warnings, Cautions and Notices WarningsCautions Grounding and Ground Fault Protection Motor and Equipment SafetyChapter 1 - Overview Receiving and InspectionL C X 0 1 6 A 0 - 4 A 2 B JanuaryStorage and Shipping MaintenanceTechnical Data LCX9000 Liquid-Cooled Drives User Manual Figure 1-1 Liquid-Cooled Drive Principal Block Diagram LCX9000 Liquid-Cooled Drives User ManualJanuary MN04005001EPower Ratings DrivesPage Page Speciﬁcations Table 1-4 Technical Information1-10 Table 1-4 Technical Information ContinuedLCX9000 Liquid-Cooled Drives User Manual Lifting the Drive Chapter 2 - InstallationMounting Liquid-Cooled Dimensions Table 2-1 One-Module Drive Dimensions Mounting Base IncludedDrives Consisting of One Module Figure 2-2 LCX9000 Liquid-Cooled Drive, CH3Figure 2-3 LCX9000 Liquid-Cooled Drive, CH4 Figure 2-4 LCX9000 Liquid-Cooled Drive, CH5January MN04005001EFigure 2-5 LCX9000 Liquid-Cooled Drive, CH61 Figure 2-6 LCX9000 Liquid-Cooled Drive, CH72LCX9000 Liquid-Cooled Drives User Manual JanuaryTable 2-2 Several Module Drive Dimensions Mounting Bracket Included Drives Consisting of Several ModulesFigure 2-7 Drive Mounted Inside Mounting Bracket LCX9000 Liquid-Cooled Drives User ManualJanuary Figure 2-8 LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63LCX9000 Liquid-Cooled Drives User Manual Figure 2-9 LCX9000 Liquid-Cooled Drive, CH74, IP00 JanuaryMN04005001E BottomCooling Drinking Water SpeciﬁcationTable 2-3 Drinking Water Chemical Speciﬁcation Table 2-4 Drinking Water Quality Recommendations - Maximum ValuesTable 2-5 Drinking Water Quality Recommendations - Desired Values Table 2-6 Process Water SpeciﬁcationHeat Figure 2-10 Example of Cooling SystemExchanger Figure 2-11 Example PI-Diagram of Cooling System and Connections Table 2-7 Information About Cooling Agent and Its CirculationTable 2-9 Coolant Volumes and Temperatures Condensation Figure 2-12 Safe Operating Conditions in Relation to CondensationTable 2-10 Liquid Connector Types All Pressure Values at Nominal Flow Cooling System ConnectionsFigure 2-13 Aluminum Hose Adapters Figure 2-14 External Thread of HoseOutﬂow Hoses and Pressure Losses Table 2-11 Pressure Losses - CH6xFigure 2-15 Pressure Loss - CH6x Table 2-12 Pressure Losses - CH7x Figure 2-16 Pressure Loss - CH7xLCX9000 Liquid-Cooled Drives User Manual The following main line hose materials are acceptable plastic PVCInstallation of Flow Switch About Flow Switch InstallationFigure 2-17 Flow Switch Hose Connection, Fast Connector Electrical Fast Connector Lock Screw, Cable Seal and ClampFigure 2-18 Direction of Coolant Circulation External Cooling Fan for CH4Drive Derating Table 2-16 Input Choke Dimensioning, 6-Pulse Supply Input ChokesInstallation of Input Choke Figure 2-19 Example of Input Chokes for Liquid-Cooled Sizes Up to 62AFigure 2-20 Example of Input Chokes for Liquid-Cooled Sizes 87 - 145A and 590ATable 2-17 Choke Dimensions Sizes 23 - 145A and 590A January2-23 Table 2-18 Choke Dimensions Sizes 261 - 1150ALCX9000 Liquid-Cooled Drives User Manual LCX9000 Liquid-Cooled Drives User Manual Chapter 3 - Power Wiring Power ConnectionsMains Cable Motor CableTable 3-2 Cable Sizes 400 Table 3-1 Cable Types Required to Meet StandardsCable Data Table 3-2 Cable Sizes 400 - 500V Continued Units with 6-pulse supplyUnits with 12-pulse supply Three grounding terminals per mounting plate, see PageTable 3-3 Cable Sizes 525 Table 3-4 Tightening Torques of BoltsLCX9000 Liquid-Cooled Drives User Manual See the tightening torques of bolts in TableFuse Sizes, Drives Table 3-5 Fuse Sizes for LCX9000 Liquid-Cooled 500V DrivesTable 3-6 Fuse Sizes for LCX9000 Liquid-Cooled 690V Drives Fuse information4. If cable insulation checks are needed, see Page Cable Installation InstructionsThe maximum length of the motor cables is 984 feet 300m Figure 3-1 Maximum Terminal Stresses Installation Space Figure 3-2 Installation SpaceFigure 3-3 Grounding Terminal on Mounting Plate Grounding of Power UnitCable Installation and the UL Standards Cable and Motor Insulation Checks LCX9000 Liquid-Cooled Drives User Manual 3-12January MN04005001EChapter 4 - Control Wiring and Internal Connections Figure 4-1 Control BoardFigure 4-2 Basic and Option Board Connections of the Control Board Figure 4-3 Drives Connected in ParallelControl Board Power-Up Figure 4-4 Connection of Control Board Cable from the Power BoardSee Figures 4-4 and WRONG Terminal J1 UpperFigure 4-5 Connection of Control Board Cable from the Power Board Control ConnectionsCORRECT Terminal J2 Lower Figure 4-6 I/O Terminals of the Two Basic BoardsFigure 4-7 General Wiring Diagram of the Basic I/O Board OPT-A9 Figure 4-8 General Wiring Diagram of the Basic Relay Board OPT-A2January MN04005001EFigure 4-9 Galvanic Isolation Barriers Control CablesGalvanic Isolation Barriers Control Terminal Signals Table 4-1 Control I/O Terminal SignalsDigital Input Signal Inversions Figure 4-10 Positive/Negative LogicJumper Selections on the OPT-A9 Basic Board Figure 4-11 Jumper Blocks on OPT-A9Figure 4-12 Jumper Selection for OPT-A9 JanuaryMN04005001E AI1 ModeInstalling the Control Unit Mounting Box Figure 4-14 Control Unit Installed into the Mounting BoxControl Unit Mounting Box Figure 4-13 Control Unit Mounting BoxTable 4-2 Installing the Control Unit Mounting Box Table 4-2 Installing the Control Unit Mounting Box Continued January MN04005001ETable 4-2 Installing the Control Unit Mounting Box Continued Connections between Power Unit ASIC and Driver BoardsInternal Connections Figure 4-15 Terminals and Connections between ASIC and Driver Board CH61, CH62 and CH72 Table 4-3 Terminals CH61, CH62 and CH72X9 OEVA feedback X15 Charging relay output X6 DC terminal X29 Flow supervision inputTable 4-4 Terminals CH63 Connect to WL on Phase V/W driver board4-16 Table 4-5 Terminals between Driver Boards CH64 and CH74LCX9000 Liquid-Cooled Drives User Manual Connections between Power Unit ASIC and the Control Unit Figure 4-18 Remove Cover to Access Power UnitConnections with Round Cable Connections with Optical CableFigure 4-19 Optical Cable Adapter Board Table 4-6 Terminals on Adapter BoardSupply voltage 24Vin from power unit Control board connectionIndicators on the Keypad Display Chapter 5 - Menu InformationKeypad Operation Figure 5-1 Control Keypad and Drive Status IndicationsDrive Status Indicators Table 5-1 Drive Status IndicatorsControl Place Indicators Table 5-2 Control Place IndicatorsKeypad Pushbuttons Status LEDs Green - Green - RedTable 5-3 Status LEDs Green - Green - Red Text LinesTable 5-5 Button Descriptions LCX9000 Liquid-Cooled Drives User ManualMonitor Menu NavigationFigure 5-3 Keypad Display Data Figure 5-4 Keypad Navigation Chart LCX9000 Liquid-Cooled Drives User ManualMonitoring Menu M1 Figure 5-5 Monitoring MenuTable 5-6 Monitored Signals Parameter Menu M2Table 5-7 Keypad Control Parameters, M3 Figure 5-6 Parameter Value Change ProcedureKeypad Control Menu M3 Keypad Direction Selection of Control PlaceFigure 5-7 Selection of Control Place Keypad Reference STOP Button Activated Active Faults Menu M4Figure 5-8 Normal State, No Faults Fault Types Figure 5-9 Fault Display Table 5-8 Fault TypesFault Time Data Record Fault Type SymbolTable 5-9 Fault Time Recorded Data Fault History Menu M5Real Time Record Table 5-10 Real Time RecordFigure 5-10 Fault History Menu System Menu M65-15 Table 5-11 System Menu FunctionsLCX9000 Liquid-Cooled Drives User Manual 5-16 Table 5-11 System Menu Functions ContinuedLCX9000 Liquid-Cooled Drives User Manual Figure 5-12 Change of Application Selection of LanguageFigure 5-11 Selection of Language Application Selection Copy Parameters Parameter Sets S6.3.1Figure 5-13 Storing and Loading of Parameter Sets Upload parameters to keypad To keypad, S6.3.2Download parameters to drive From keypad, S6.3.3 Automatic Parameter Backup P6.3.4Figure 5-14 Parameter Copy to Keypad P2.1.2= 20.0 Hz Parameter ComparisonFigure 5-15 Parameter Comparison Security Password S6.5.1Figure 5-16 Password Setting Parameter Lock P6.5.2 Figure 5-17 Parameter LockingStart-Up Wizard P6.5.3 Figure 5-18 Activation of Start-Up WizardKeypad Settings Figure 5-20 Keypad Settings SubmenuDefault Page P6.6.1 Figure 5-21 Default Page FunctionDefault page in the operating menu P6.6.2 Timeout Time P6.6.3Figure 5-22 Timeout Time Setting Contrast Adjustment P6.6.4Figure 5-23 HMI Acknowledge Timeout Hardware SettingsHMI Acknowledge Timeout P6.7.3 Number of retries to receive HMI acknowledgement P6.7.4 System infoTotal Counters Table 5-12 Counter PagesTable 5-13 Resettable Counters Figure 5-24 Counter ResetTrip Counters Software S6.8.3Applications S6.8.4 Table 5-15 Applications Information PagesFigure 5-25 Applications Info Submenu Hardware S6.8.5Expander Boards S6.8.6 Figure 5-26 Expander Board Information MenusDebug Menu S6.8.7 Expander Board Menu M7Further Keypad Functions Expander Board ParametersTable 5-17 Expander Board Parameters Board OPTA1 Figure 5-27 Expander Board Information MenuSafety Precautions Chapter 6 - Start-UpSequence of Operation LCX9000 Liquid-Cooled Drives User Manual MN04005001E LCX9000 Liquid-Cooled Drives User ManualJanuary Appendix A - Fault Codes Table A-1 Fault CodesTable A-1 Fault Codes Continued LCX9000 Liquid-Cooled Drives User ManualTable A-1 Fault Codes Continued LCX9000 Liquid-Cooled Drives User ManualLoad Test with Motor Table A-1 Fault Codes ContinuedDC Link Test without Motor MN04005001E LCX9000 Liquid-Cooled Drives User ManualJanuary Main Circuit and Control Diagrams Figure B-1 Main Circuit and Control Diagram, CH3Appendix B - Technical Reference JanuaryFigure B-2 Main Circuit and Control Diagram, CH4 Figure B-3 Main Circuit and Control Diagram, CH5January TermFigure B-4 Main Circuit and Control Diagram, CH61 Figure B-5 Main Circuit and Control Diagram, CH61, ControlJanuary MN04005001EFigure B-6 Main Circuit and Control Diagram, CH63, Module Figure B-7 Main Circuit and Control Diagram, CH63, ModuleJanuary VB00491Figure B-8 Main Circuit and Control Diagram, CH63, Control Figure B-9 Main Circuit and Control Diagram, CH72LCX9000 Liquid-Cooled Drives User Manual JanuaryFigure B-10 Main Circuit and Control Diagram, CH72, Control Figure B-11 Main Circuit and Control Diagram, CH74, Phase ULCX9000 Liquid-Cooled Drives User Manual JanuaryFigure B-12 Main Circuit and Control Diagram, CH74, Control LCX9000 Liquid-Cooled Drives User ManualJanuary MN04005001EFan Dimensions Figure B-13 Fan Mounting Pallet - Hot Dip Zinc CoatedFigure B-14 Fan Support JanuaryMN04005001E LCX9000 Liquid-Cooled Drives User ManualJanuary LCX9000 Liquid-Cooled Drives User Manual B-10January MN04005001EPage Company Information Eaton Electrical Inc2007 Eaton Corporation All Rights Reserved Printed in USA Publication No. MN04005001E/CPG January