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J. T. Eaton LCX9000 user manual Safety, Deﬁnitions and Symbols, Hazardous High Voltage

Models: LCX9000

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Safety

LCX9000 Liquid-Cooled Drives User Manual

January 2007

Safety

Deﬁnitions and Symbols

WARNING

This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you and other persons operating this equipment. Read the message and follow the instructions carefully.

WARNING

This symbol is the “Safety Alert Symbol.” It occurs with either of two signal words: CAUTION or WARNING, as described below.

WARNING

Indicates a potentially hazardous situation which, if not avoided, can result in serious injury or death.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, can result in minor to moderate injury, or serious damage to the product. The situation described in the CAUTION may, if not avoided, lead to serious results. Important safety measures are described in CAUTION (as well as WARNING).

Hazardous High Voltage

WARNING

Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing drives and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock.

Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery.

MN04005001E

For more information visit: www.EatonElectrical.com

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J. T. Eaton LCX9000 user manual Safety, Deﬁnitions and Symbols, Hazardous High Voltage

Contents

LCX9000 Liquid-Cooled Drives User Manual January Supersedes SeptemberMN04005001E Page Important Notice - Please Read CHAPTER 4 - CONTROL WIRING AND INTERNAL CONNECTIONS Table ofContents List of Figures List of Figures Continued List of Tables Table 5-13 Resettable Counters List of Tables ContinuedTable A-1 Fault Codes Table 5-11 System Menu FunctionsSafety Deﬁnitions and SymbolsHazardous High Voltage Warnings Warnings, Cautions and NoticesCautions Motor and Equipment Safety Grounding and Ground Fault ProtectionReceiving and Inspection Chapter 1 - OverviewJanuary L C X 0 1 6 A 0 - 4 A 2 BMaintenance Technical DataStorage and Shipping LCX9000 Liquid-Cooled Drives User Manual LCX9000 Liquid-Cooled Drives User Manual Figure 1-1 Liquid-Cooled Drive Principal Block DiagramJanuary MN04005001EDrives Power RatingsPage Page Table 1-4 Technical Information SpeciﬁcationsTable 1-4 Technical Information Continued LCX9000 Liquid-Cooled Drives User Manual1-10 Chapter 2 - Installation MountingLifting the Drive Table 2-1 One-Module Drive Dimensions Mounting Base Included Liquid-Cooled DimensionsDrives Consisting of One Module Figure 2-2 LCX9000 Liquid-Cooled Drive, CH3Figure 2-4 LCX9000 Liquid-Cooled Drive, CH5 Figure 2-3 LCX9000 Liquid-Cooled Drive, CH4January MN04005001EFigure 2-6 LCX9000 Liquid-Cooled Drive, CH72 Figure 2-5 LCX9000 Liquid-Cooled Drive, CH61LCX9000 Liquid-Cooled Drives User Manual JanuaryDrives Consisting of Several Modules Table 2-2 Several Module Drive Dimensions Mounting Bracket IncludedFigure 2-7 Drive Mounted Inside Mounting Bracket LCX9000 Liquid-Cooled Drives User ManualFigure 2-8 LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 LCX9000 Liquid-Cooled Drives User ManualJanuary January Figure 2-9 LCX9000 Liquid-Cooled Drive, CH74, IP00MN04005001E BottomDrinking Water Speciﬁcation CoolingTable 2-3 Drinking Water Chemical Speciﬁcation Table 2-4 Drinking Water Quality Recommendations - Maximum ValuesTable 2-6 Process Water Speciﬁcation Table 2-5 Drinking Water Quality Recommendations - Desired ValuesFigure 2-10 Example of Cooling System ExchangerHeat Table 2-7 Information About Cooling Agent and Its Circulation Figure 2-11 Example PI-Diagram of Cooling System and ConnectionsTable 2-9 Coolant Volumes and Temperatures Figure 2-12 Safe Operating Conditions in Relation to Condensation CondensationCooling System Connections Table 2-10 Liquid Connector Types All Pressure Values at Nominal FlowFigure 2-13 Aluminum Hose Adapters Figure 2-14 External Thread of HosePressure Losses Table 2-11 Pressure Losses - CH6x Figure 2-15 Pressure Loss - CH6xOutﬂow Hoses and Figure 2-16 Pressure Loss - CH7x Table 2-12 Pressure Losses - CH7xLCX9000 Liquid-Cooled Drives User Manual The following main line hose materials are acceptable plastic PVCAbout Flow Switch Installation Installation of Flow SwitchFigure 2-17 Flow Switch Hose Connection, Fast Connector Electrical Fast Connector Lock Screw, Cable Seal and ClampExternal Cooling Fan for CH4 Figure 2-18 Direction of Coolant CirculationDrive Derating Input Chokes Table 2-16 Input Choke Dimensioning, 6-Pulse SupplyFigure 2-19 Example of Input Chokes for Liquid-Cooled Sizes Up to 62A Installation of Input ChokeFigure 2-20 Example of Input Chokes for Liquid-Cooled Sizes 87 - 145A and 590AJanuary Table 2-17 Choke Dimensions Sizes 23 - 145A and 590ATable 2-18 Choke Dimensions Sizes 261 - 1150A LCX9000 Liquid-Cooled Drives User Manual2-23 LCX9000 Liquid-Cooled Drives User Manual Power Connections Chapter 3 - Power WiringMains Cable Motor CableTable 3-1 Cable Types Required to Meet Standards Cable DataTable 3-2 Cable Sizes 400 Units with 6-pulse supply Table 3-2 Cable Sizes 400 - 500V ContinuedUnits with 12-pulse supply Three grounding terminals per mounting plate, see PageTable 3-4 Tightening Torques of Bolts Table 3-3 Cable Sizes 525LCX9000 Liquid-Cooled Drives User Manual See the tightening torques of bolts in TableTable 3-5 Fuse Sizes for LCX9000 Liquid-Cooled 500V Drives Fuse Sizes, DrivesFuse information Table 3-6 Fuse Sizes for LCX9000 Liquid-Cooled 690V DrivesCable Installation Instructions The maximum length of the motor cables is 984 feet 300m4. If cable insulation checks are needed, see Page Figure 3-1 Maximum Terminal Stresses Figure 3-2 Installation Space Installation SpaceGrounding of Power Unit Cable Installation and the UL StandardsFigure 3-3 Grounding Terminal on Mounting Plate Cable and Motor Insulation Checks 3-12 LCX9000 Liquid-Cooled Drives User ManualJanuary MN04005001EFigure 4-1 Control Board Chapter 4 - Control Wiring and Internal ConnectionsFigure 4-3 Drives Connected in Parallel Figure 4-2 Basic and Option Board Connections of the Control BoardFigure 4-4 Connection of Control Board Cable from the Power Board Control Board Power-UpSee Figures 4-4 and WRONG Terminal J1 UpperControl Connections Figure 4-5 Connection of Control Board Cable from the Power BoardCORRECT Terminal J2 Lower Figure 4-6 I/O Terminals of the Two Basic BoardsFigure 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-A9January MN04005001EControl Cables Galvanic Isolation BarriersFigure 4-9 Galvanic Isolation Barriers Table 4-1 Control I/O Terminal Signals Control Terminal SignalsFigure 4-10 Positive/Negative Logic Digital Input Signal InversionsJumper Selections on the OPT-A9 Basic Board Figure 4-11 Jumper Blocks on OPT-A9January Figure 4-12 Jumper Selection for OPT-A9MN04005001E AI1 ModeFigure 4-14 Control Unit Installed into the Mounting Box Installing the Control Unit Mounting BoxControl Unit Mounting Box Figure 4-13 Control Unit Mounting BoxTable 4-2 Installing the Control Unit Mounting Box January MN04005001E Table 4-2 Installing the Control Unit Mounting Box ContinuedConnections between Power Unit ASIC and Driver Boards Internal ConnectionsTable 4-2 Installing the Control Unit Mounting Box Continued CH61, CH62 and CH72 Table 4-3 Terminals CH61, CH62 and CH72 Figure 4-15 Terminals and Connections between ASIC and Driver BoardX9 OEVA feedback X15 Charging relay output X6 DC terminal X29 Flow supervision inputConnect to WL on Phase V/W driver board Table 4-4 Terminals CH63Table 4-5 Terminals between Driver Boards CH64 and CH74 LCX9000 Liquid-Cooled Drives User Manual4-16 Figure 4-18 Remove Cover to Access Power Unit Connections between Power Unit ASIC and the Control UnitConnections with Round Cable Connections with Optical CableTable 4-6 Terminals on Adapter Board Figure 4-19 Optical Cable Adapter BoardSupply voltage 24Vin from power unit Control board connectionChapter 5 - Menu Information Indicators on the Keypad DisplayKeypad Operation Figure 5-1 Control Keypad and Drive Status IndicationsTable 5-1 Drive Status Indicators Drive Status IndicatorsControl Place Indicators Table 5-2 Control Place IndicatorsStatus LEDs Green - Green - Red Keypad PushbuttonsTable 5-3 Status LEDs Green - Green - Red Text LinesLCX9000 Liquid-Cooled Drives User Manual Table 5-5 Button DescriptionsMenu Navigation Figure 5-3 Keypad Display DataMonitor LCX9000 Liquid-Cooled Drives User Manual Figure 5-4 Keypad Navigation ChartFigure 5-5 Monitoring Menu Monitoring Menu M1Parameter Menu M2 Table 5-6 Monitored SignalsFigure 5-6 Parameter Value Change Procedure Keypad Control Menu M3Table 5-7 Keypad Control Parameters, M3 Selection of Control Place Figure 5-7 Selection of Control Place Keypad ReferenceKeypad Direction Active Faults Menu M4 Figure 5-8 Normal State, No FaultsSTOP Button Activated Figure 5-9 Fault Display Table 5-8 Fault Types Fault TypesFault Time Data Record Fault Type SymbolFault History Menu M5 Table 5-9 Fault Time Recorded DataReal Time Record Table 5-10 Real Time RecordSystem Menu M6 Figure 5-10 Fault History MenuTable 5-11 System Menu Functions LCX9000 Liquid-Cooled Drives User Manual5-15 Table 5-11 System Menu Functions Continued LCX9000 Liquid-Cooled Drives User Manual5-16 Selection of Language Figure 5-11 Selection of Language Application SelectionFigure 5-12 Change of Application Parameter Sets S6.3.1 Copy ParametersFigure 5-13 Storing and Loading of Parameter Sets Upload parameters to keypad To keypad, S6.3.2Automatic Parameter Backup P6.3.4 Figure 5-14 Parameter Copy to KeypadDownload parameters to drive From keypad, S6.3.3 Parameter Comparison Figure 5-15 Parameter ComparisonP2.1.2= 20.0 Hz Password S6.5.1 Figure 5-16 Password SettingSecurity Figure 5-17 Parameter Locking Parameter Lock P6.5.2Start-Up Wizard P6.5.3 Figure 5-18 Activation of Start-Up WizardFigure 5-20 Keypad Settings Submenu Keypad SettingsDefault Page P6.6.1 Figure 5-21 Default Page FunctionTimeout Time P6.6.3 Default page in the operating menu P6.6.2Figure 5-22 Timeout Time Setting Contrast Adjustment P6.6.4Hardware Settings HMI Acknowledge Timeout P6.7.3Figure 5-23 HMI Acknowledge Timeout System info Number of retries to receive HMI acknowledgement P6.7.4Total Counters Table 5-12 Counter PagesFigure 5-24 Counter Reset Table 5-13 Resettable CountersTrip Counters Software S6.8.3Table 5-15 Applications Information Pages Applications S6.8.4Figure 5-25 Applications Info Submenu Hardware S6.8.5Figure 5-26 Expander Board Information Menus Expander Boards S6.8.6Debug Menu S6.8.7 Expander Board Menu M7Expander Board Parameters Further Keypad FunctionsTable 5-17 Expander Board Parameters Board OPTA1 Figure 5-27 Expander Board Information MenuChapter 6 - Start-Up Safety PrecautionsSequence of Operation LCX9000 Liquid-Cooled Drives User Manual LCX9000 Liquid-Cooled Drives User Manual JanuaryMN04005001E Table A-1 Fault Codes Appendix A - Fault CodesLCX9000 Liquid-Cooled Drives User Manual Table A-1 Fault Codes ContinuedLCX9000 Liquid-Cooled Drives User Manual Table A-1 Fault Codes ContinuedTable A-1 Fault Codes Continued Load Test with MotorDC Link Test without Motor LCX9000 Liquid-Cooled Drives User Manual JanuaryMN04005001E Figure B-1 Main Circuit and Control Diagram, CH3 Main Circuit and Control DiagramsAppendix B - Technical Reference JanuaryFigure B-3 Main Circuit and Control Diagram, CH5 Figure B-2 Main Circuit and Control Diagram, CH4January TermFigure B-5 Main Circuit and Control Diagram, CH61, Control Figure B-4 Main Circuit and Control Diagram, CH61January MN04005001EFigure B-7 Main Circuit and Control Diagram, CH63, Module Figure B-6 Main Circuit and Control Diagram, CH63, ModuleJanuary VB00491Figure B-9 Main Circuit and Control Diagram, CH72 Figure B-8 Main Circuit and Control Diagram, CH63, ControlLCX9000 Liquid-Cooled Drives User Manual JanuaryFigure B-11 Main Circuit and Control Diagram, CH74, Phase U Figure B-10 Main Circuit and Control Diagram, CH72, ControlLCX9000 Liquid-Cooled Drives User Manual JanuaryLCX9000 Liquid-Cooled Drives User Manual Figure B-12 Main Circuit and Control Diagram, CH74, ControlJanuary MN04005001EFigure B-13 Fan Mounting Pallet - Hot Dip Zinc Coated Fan DimensionsFigure B-14 Fan Support JanuaryLCX9000 Liquid-Cooled Drives User Manual JanuaryMN04005001E B-10 LCX9000 Liquid-Cooled Drives User ManualJanuary MN04005001EPage Eaton Electrical Inc Company Information2007 Eaton Corporation All Rights Reserved Printed in USA Publication No. MN04005001E/CPG January