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Eaton Liquid-Cooled Drives LCX9000 manual

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Table of contents for the manual

  • Page 1

    MN04005001E For more information visit: www .EatonElectrical.com LCX9000 Liquid-Cooled Drives User Manual January 2007 Supersedes September 2006[...]

  • Page 2

    [...]

  • Page 3

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www .EatonElectrical.com i January 2007 Important Notice — Please Read The product discussed in this literature is subject to terms and conditions outlined in Eaton Electrical Inc. selling policies. The sole source governing the rights and remedies of any purchaser o[...]

  • Page 4

    LCX9000 Liquid-Cooled Drives User Manual ii For more information visit: www .EatonElectrical.com MN04005001E January 2007 T able of Contents LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii LIST OF T ABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 5

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www .EatonElectrical.com iii January 2007 List of Figures Figure 1-1: Liquid-Cooled Drive Principal Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Figure 2-1: Lifting Points for Drives Consisting of One Module (Left) and Several Modules . . . . . .[...]

  • Page 6

    LCX9000 Liquid-Cooled Drives User Manual iv For more information visit: www .EatonElectrical.com MN04005001E January 2007 List of Figures (Continued) Figure 4-18: Remove Cover to Access Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Figure 4-19: Optical Cable Adapter Board . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 7

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www .EatonElectrical.com v January 2007 List of T ables T able 1-1: LCX9000 Liquid-Cooled Adjustable Frequency Drive Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 T able 1-2: Power Ratings and D[...]

  • Page 8

    LCX9000 Liquid-Cooled Drives User Manual vi For more information visit: www .EatonElectrical.com MN04005001E January 2007 List of T ables (Continued) T able 5-11: System Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 T able 5-12: Counter Pages . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 9

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www .EatonElectrical.com vii 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 t[...]

  • Page 10

    LCX9000 Liquid-Cooled Drives User Manual viii For more information visit: www .EatonElectrical.com MN04005001E January 2007 Warnings, Cautions and Notices Read this manual thoroughly and make sure you understand the procedures before you attempt to install, set up, or operate this Cutler -Hammer ® LCX9000 Drive from Eaton’ s electrical business.[...]

  • Page 11

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www .EatonElectrical.com ix January 2007 WARNING The motor terminals U, V , W and the DC-link/brake resistor terminals are live when the Liquid-Cooled drive is connected to mains, even if the motor is not running . WARNING After disconnecting the drive from the mains, [...]

  • Page 12

    LCX9000 Liquid-Cooled Drives User Manual x For more information visit: www .EatonElectrical.com MN04005001E January 2007 Grounding and Ground Fault Protection The LCX9000 drive must always be grounded with a ground conductor connected to the ground terminal. The ground fault protection inside the drive only protects the drive against ground faults [...]

  • Page 13

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www .EatonElectrical.com 1-1 January 2007 Chapter 1 — Overview Receiving and Inspection The standard delivery of Cutler -Hammer ® Liquid-Cooled Drives from Eaton’ s electrical business includes all or part of the following components: ● power unit ● control un[...]

  • Page 14

    LCX9000 Liquid-Cooled Drives User Manual 1-2 For more information visit: www .EatonElectrical.com MN04005001E January 2007 T able 1-1: LCX9000 Liquid-Cooled Adjustable Frequency Drive Catalog Numbering System L C X 0 1 6 A 0 –4 A 2 B 1 Keypad A = Alphanumeric Software Series A = Standard Brake Chopper Options N = No Brake Chopper Circuit B = Inte[...]

  • Page 15

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 1-3 January 2007 Storage and Shipping If the drive is to be kept in storage before use, make sure that the ambient conditions are acceptable: Storing temperature -40 – 158°F (-40 – 70°C) (no cooling liquid inside cooling element allowed be[...]

  • Page 16

    LCX9000 Liquid-Cooled Drives User Manual 1-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 The Motor and Application Control Block is based on microprocessor software. The microprocessor controls the motor based on the information it receives through measurements, parameter settings, control I/O and control keypad. Th[...]

  • Page 17

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 1-5 January 2007 Figure 1-1: Liquid-Cooled Drive Principal Block Diagram Control I/O Motor and Application Control Control Keypad Control Module PE Power Module RS-232 Control I/O Measurements Motor Control ASIC Gate Drivers Power Supply Charg. [...]

  • Page 18

    LCX9000 Liquid-Cooled Drives User Manual 1-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Power Ratings The Cutler -Hammer Liquid-Cooled product range consists of (AC input, AC output) drives. The following tables show the drive output values for both in I th (current) and shaft power (electrical) as well as the driv[...]

  • Page 19

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 1-7 January 2007 T able 1-2: Power Ratings and Dimensions of Liquid-Cooled Drive, Supply V oltage 380 – 500V AC (Continued) I th = Thermal maximum continuous RMS current. Dimensioning can be done according to this current if the process does n[...]

  • Page 20

    LCX9000 Liquid-Cooled Drives User Manual 1-8 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 1-3: Power Ratings and Dimensions of Liquid-Cooled Drive, Supply V oltage 525 – 690V AC I th = Thermal maximum continuous RMS current. Dimensioning can be done according to this current if the process does not require a[...]

  • Page 21

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 1-9 January 2007 Specifications T able 1-4: T echnical Information Description Specification Mains Connection Input voltage U in 400 – 500V AC; 525 – 690V AC; (-10% – 10%) 465 – 800V DC; 640 – 1100V DC; (-0% – 0%) Input frequency 4[...]

  • Page 22

    LCX9000 Liquid-Cooled Drives User Manual 1-10 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 1-4: T echnical Information (Continued) Description Specification EMC Immunity Fulfils all EMC immunity requirements Emissions EMC level N; EMC level T for IT networks Safety Approvals EN50178, EN60204-1, CE, UL, CUL, [...]

  • Page 23

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-1 January 2007 Chapter 2 — Installation Mounting Liquid-cooled drive modules must be installed into an enclosure. The drives consisting of one module will be mounted on the mounting plate. The drives that include two or three modules are mou[...]

  • Page 24

    LCX9000 Liquid-Cooled Drives User Manual 2-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Liquid-Cooled Dimensions Drives Consisting of One Module T able 2-1: One-Module Drive Dimensions (Mounting Base Included) Figure 2-2: LCX9000 Liquid-Cooled Drive, CH3 Approximate Dimensions in Inches (mm) Chassis Approximate Dim[...]

  • Page 25

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-3 January 2007 Figure 2-3: LCX9000 Liquid-Cooled Drive, CH4 Approximate Dimensions in Inches (mm) Figure 2-4: LCX9000 Liquid-Cooled Drive, CH5 Approximate Dimensions in Inches (mm) 19.41 (493) Dia. .39 (10) 7.60 (193) 7.48 (190) 3.35 (85) .47 [...]

  • Page 26

    LCX9000 Liquid-Cooled Drives User Manual 2-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 2-5: LCX9000 Liquid-Cooled Drive, CH61 Approximate Dimensions in Inches (mm) Figure 2-6: LCX9000 Liquid-Cooled Drive, CH72 Approximate Dimensions in Inches (mm) UV W M12 1.57 (40) 1.30 (33) 2.56 (65) 2.56 (65) 9.21 (234) [...]

  • Page 27

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-5 January 2007 Drives Consisting of Several Modules Liquid-cooled drives consisting of several modules are mounted in a mounting bracket as presented in Figure 2-7 . Figure 2-7: Drive Mounted Inside Mounting Bracket T able 2-2: Several Module [...]

  • Page 28

    LCX9000 Liquid-Cooled Drives User Manual 2-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 2-8: LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 Approximate Dimensions in Inches (mm) 13.98 (355) Dia. .43 (11) Dia. .55 (14) 19.88 (505) Bottom T op .98 (25) 1.77 (45) 4.06 (103) 3.94 (100) .20 (5) 34.41 (87[...]

  • Page 29

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-7 January 2007 Figure 2-9: LCX9000 Liquid-Cooled Drive, CH74, IP00 Approximate Dimensions in Inches (mm) Bottom To p 6-Pulse Supply 12-Pulse Supply 28.39 (721) 1.18 (30) .59 (15) .39 (10) 7.87 (200) 9.69 (246) 9.69 (246) 7.87 (200) 29.29 (744)[...]

  • Page 30

    LCX9000 Liquid-Cooled Drives User Manual 2-8 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Cooling Instead of using air for cooling, Cutler -Hammer Liquid-Cooled drives are cooled with liquid. The liquid circulation of the drive is usually connected to a heat-exchanger (liquid-liquid/ liquid-air) which cools down the [...]

  • Page 31

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-9 January 2007 T able 2-5: Drinking Water Quality Recommendations — Desired V alues  No aggressive water allowed.  T o be approved by user and no unusual changes. The cleanness of the heat exchanger , and therefore the heat exchanging [...]

  • Page 32

    LCX9000 Liquid-Cooled Drives User Manual 2-10 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T o facilitate the cleaning and venting of the coolant circulation, installation of a bypass valve in the main line and valves at each drive inlet is recommended. Open the bypass valve and shut the valves to the drive when clea[...]

  • Page 33

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-11 January 2007 Figure 2-11: Example PI-Diagram of Cooling System and Connections T able 2-7 shows the specifications related to the cooling agent and its circulation. Also see T able 1-4 , T echnical Information on Page 1-9 . T able 2-7: Inf[...]

  • Page 34

    LCX9000 Liquid-Cooled Drives User Manual 2-12 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 2-8 will help you to determine the appropriate flows of cooling agent (GPM) with given power losses (see Page 1-6 ). T able 2-8: Cooling Agent Flow Rates (GPM) in Relation to Power Loss at Certain Glycol/ Water Mixture [...]

  • Page 35

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-13 January 2007 Condensation Condensation on the cooling plate of the liquid-cooled drive must be avoided. Therefore, the temperature of the cooling liquid must be kept higher than the temperature of the electrical room. Use Figure 2-12 to det[...]

  • Page 36

    LCX9000 Liquid-Cooled Drives User Manual 2-14 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Cooling System Connections The external cooling system shall be connected to each one of the cooling elements of the drive. Note: The cooling elements must NOT be connected in series. The cooling elements are equipped with hose[...]

  • Page 37

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-15 January 2007 Pressure Losses T able 2-11: Pressure Losses — CH6x Figure 2-15: Pressure Loss — CH6x CH6x with standard 1.5m hoses and optional fast connectors TEMA V olume Flow Rate (GPM) Pressure Loss TEMA Inflow (psi) Pressure Loss In[...]

  • Page 38

    LCX9000 Liquid-Cooled Drives User Manual 2-16 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 2-12: Pressure Losses — CH7x Figure 2-16: Pressure Loss — CH7x It is strongly recommended that the liquid carrying hoses from the network to the cooling elements of the drive are electrically non-conducting (to avoid[...]

  • Page 39

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-17 January 2007 Installation of Flow Switch As stated on Page 2-10 , Eaton recommends the installation of the flow supervision in the liquid cooling system. If requested, Eaton delivers the flow switch as an option. The application of the ?[...]

  • Page 40

    LCX9000 Liquid-Cooled Drives User Manual 2-18 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 2-18: Direction of Coolant Circulation External Cooling Fan for CH4 In order to provide sufficient cooling for the power board, capacitors and DC-buses in the liquid-cooled drive of chassis CH4, one additional cooling f[...]

  • Page 41

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-19 January 2007 Drive Derating The tables below state the maximum coolant temperatures for Cutler -Hammer liquid-cooled drives at given switching frequencies. Drive derating is required if the maximum temperatures are exceeded. T able 2-14: Ma[...]

  • Page 42

    LCX9000 Liquid-Cooled Drives User Manual 2-20 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Input Chokes The input choke carries out several functions in the Cutler -Hammer liquid-cooled drive. Connection of the input choke is necessary except if you have a component in your system that performs the same tasks (e.g. a[...]

  • Page 43

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-21 January 2007 Installation of Input Choke There are two types of input choke connection in LCX9000 Liquid-Cooled drives. The two smallest sizes (CH31, CH32; up to 61A) have terminal block connection whereas bigger sizes use busbar connection[...]

  • Page 44

    LCX9000 Liquid-Cooled Drives User Manual 2-22 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 2-17: Choke Dimensions Sizes 23 – 145A and 590A Always connect the supply cables to the choke terminals marked with #1 (see Figure 2-21 ). Choose the converter connection according to Figure 2-21 . Choke T ype Approxim[...]

  • Page 45

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 2-23 January 2007 Figure 2-21: Example of Input Chokes for Liquid-Cooled Sizes 261 – 1150A T able 2-18: Choke Dimensions Sizes 261 – 1150A Choke T ype Approximate Dimensions in Inches (mm) Weight in Lbs. (kg) H1 H2 W1 W2 W3 W4 D1 D2 D3 S1 S2[...]

  • Page 46

    LCX9000 Liquid-Cooled Drives User Manual 2-24 For more information visit: www.EatonElectrical.com MN04005001E January 2007 If you have ordered the input chokes for the liquid-cooled drive separately , pay attention to the following instructions: 1. Protect the chokes from dripping water . Y ou may even need to use plexiglass for protection because [...]

  • Page 47

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 3-1 January 2007 Chapter 3 — Power Wiring How the power connections of LCX9000 Liquid-Cooled units are implemented depends on the size of the unit. The smallest liquid-cooled unit (CH3) has terminal blocks for the connections. In all other uni[...]

  • Page 48

    LCX9000 Liquid-Cooled Drives User Manual 3-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 3-1: Cable T ypes Required to Meet Standards Cable Data T able 3-2: Cable Sizes 400 – 500V  Number of bolt connections = 2.  Number of bolt connections = 4.  See Main T erminal Cable Size. Cable T ype Level N/T[...]

  • Page 49

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 3-3 January 2007 T able 3-2: Cable Sizes 400 – 500V (Continued)  Due to insufficient number of terminal bolt connections for required number of cables, the cabinet must be equipped with an external flexible cable connection block at both [...]

  • Page 50

    LCX9000 Liquid-Cooled Drives User Manual 3-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 3-3: Cable Sizes 525 – 690V  Due to insufficient number of terminal bolt connections for required number of cables, the cabinet must be equipped with an external flexible cable connection block at both mains and mo[...]

  • Page 51

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 3-5 January 2007 Fuse Sizes, Drives The fuse sizing in the tables below is based on Bussman aR fuses. W e recommend use of these fuses. Sufficient protection against short circuit cannot be guaranteed if other fuse types are used. T able 3-5: F[...]

  • Page 52

    LCX9000 Liquid-Cooled Drives User Manual 3-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 3-6: Fuse Sizes for LCX9000 Liquid-Cooled (690V) Drives  Tj = 77°F (25°C).  SHT fuses can be assembled into DIN fuse base of the corresponding size. Note: Data in italic refer to drives with 12-pulse supply . Fuse[...]

  • Page 53

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 3-7 January 2007 Cable Installation Instructions 1. Before starting the installation, check that none of the components of the drive is live. 2. LCX9000 Liquid-Cooled drive must always be installed in an enclosure, a separate cubicle or an elect[...]

  • Page 54

    LCX9000 Liquid-Cooled Drives User Manual 3-8 For more information visit: www.EatonElectrical.com MN04005001E January 2007 6. Liquid cooling connection: The standard delivery of the LCX9000 Liquid-Cooled drive includes hoses on the cooling element 4.9 feet (1.5m) in length and .59 inches (15 mm) in diameter . The hoses are inserted in 55 inch (1400 [...]

  • Page 55

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 3-9 January 2007 Installation Space Enough free space must be left above and below the drive to ensure practical and appropriate electrical and cooling connections. The minimum dimensions are given in the table below . No space is required to th[...]

  • Page 56

    LCX9000 Liquid-Cooled Drives User Manual 3-10 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Grounding of Power Unit The mains cables are connected to the protective ground of the switchgear enclosure. W e recommend connecting the motor cables to the common PE of the cabinet/cabinet system. For grounding of the drive i[...]

  • Page 57

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 3-11 January 2007 Cable and Motor Insulation Checks 1. Motor cable insulation checks Disconnect the motor cable from terminals U, V and W of the drive and from the motor . Measure the insulation resistance of the motor cable between each phase c[...]

  • Page 58

    LCX9000 Liquid-Cooled Drives User Manual 3-12 For more information visit: www.EatonElectrical.com MN04005001E January 2007[...]

  • Page 59

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-1 January 2007 Chapter 4 — Control Wiring and Internal Connections The control unit of the Cutler -Hammer Liquid-Cooled drive is installed into a mounting box. It contains the control board and additional boards (see Figures 4-1 and 4-2 ) co[...]

  • Page 60

    LCX9000 Liquid-Cooled Drives User Manual 4-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 4-2: Basic and Option Board Connections of the Control Board Usually , when the drive is delivered from the factory , the control unit includes at least the standard compilation of two basic boards (I/O board and relay bo[...]

  • Page 61

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-3 January 2007 Control Board Power -Up The control board can be powered (+24V) in two different ways: either 1) directly from the power board ASIC, terminal X10; or 2) externally using the customer’ s own power source. This voltage is suffi[...]

  • Page 62

    LCX9000 Liquid-Cooled Drives User Manual 4-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 4-5: Connection of Control Board Cable from the Power Board CORRECT : T erminal J2 (Lower) Control Connections The basic control connections for boards A9 and A2 are shown in T able 4-1 on Page 4-7 . The signal descriptio[...]

  • Page 63

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-5 January 2007 Figure 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 -A2) 20 19 18 17 16 15 14 13 12 11 10 9 8 24V GND [x [x 24V GND + 0 (4)/20 mA RC<500 Ω U<[...]

  • Page 64

    LCX9000 Liquid-Cooled Drives User Manual 4-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Control Cables The control cables should be at least 20 A WG (.5 mm 2 ) screened multicore cables, see T able 3-1 . The maximum terminal wire size is 14 A WG (2.5 mm 2 ) for the relay terminals and 16 A WG (1.5 mm 2 ) for other [...]

  • Page 65

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-7 January 2007 Control T erminal Signals T able 4-1: Control I/O T erminal Signals T erminal Signal T echnical Information OPT -A9 1 +10 V ref Reference voltage Maximum current 10 mA 2 AI1+ Analog input, voltage or current Selection V or mA wi[...]

  • Page 66

    LCX9000 Liquid-Cooled Drives User Manual 4-8 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Digital Input Signal Inversions The active signal level depends on which potential the common inputs CMA and CMB (terminals 11 and 17) are connected to. The alternatives are either +24V or ground (0V). See Figure 4-10 . The 24V [...]

  • Page 67

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-9 January 2007 Figure 4-12: Jumper Selection for OPT -A9 Note: If you change the AI signal content also remember to change the corresponding board parameter in menu M7. Jumper Block X1: AI1 Mode AI1 Mode: 0...20mA; Current Input A B C D A B C [...]

  • Page 68

    LCX9000 Liquid-Cooled Drives User Manual 4-10 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Control Unit Mounting Box Figure 4-13: Control Unit Mounting Box Approximate Dimensions in Inches (mm) Installing the Control Unit Mounting Box The control unit of the LCX9000 Liquid-Cooled drive is mounted into a metal box whi[...]

  • Page 69

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-11 January 2007 T able 4-2: Installing the Control Unit Mounting Box 1. If the keypad sits in its place on the control unit, remove the keypad. 2. Connect the male end of the keypad cable to the D-connector of the control unit. Use RS-232 cabl[...]

  • Page 70

    LCX9000 Liquid-Cooled Drives User Manual 4-12 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 4-2: Installing the Control Unit Mounting Box (Continued) 5. Mount the control unit mounting box in the front-left corner of the enclosure using two screws. Note: Do not install the mounting box floating (with e.g. plas[...]

  • Page 71

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-13 January 2007 T able 4-2: Installing the Control Unit Mounting Box (Continued) Internal Connections As a general rule, all internal electrical and communications connections are made at the factory . However , if modules have to be moved, fo[...]

  • Page 72

    LCX9000 Liquid-Cooled Drives User Manual 4-14 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 4-15: T erminals and Connections between ASIC and Driver Board (CH61, CH62 and CH72) T able 4-3: T erminals (CH61, CH62 and CH72) T erminal Description T erminal Description T erminals on ASIC Board T erminals on ASIC Bo[...]

  • Page 73

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-15 January 2007 Figure 4-16: T erminals and Connections between ASIC and Driver Board (CH63) T able 4-4: T erminals (CH63) T erminal Description T erminal Description T erminals on ASIC Board T erminals on ASIC Board (Continued) X9 OEV A feedb[...]

  • Page 74

    LCX9000 Liquid-Cooled Drives User Manual 4-16 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 4-17: T erminals and Connections between ASIC and Driver Boards (CH64 and CH74) T able 4-5: T erminals between Driver Boards (CH64 and CH74) T erminal Description T erminal Description T erminals on ASIC Board T erminals[...]

  • Page 75

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 4-17 January 2007 Connections between Power Unit ASIC and the Control Unit The communication connections between the liquid-cooled drive power unit and the control unit (see Page 6-1 ) can be established using either the conventional round cable[...]

  • Page 76

    LCX9000 Liquid-Cooled Drives User Manual 4-18 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 4-19: Optical Cable Adapter Board T able 4-6: T erminals on Adapter Board Note: The minimum optical cable bending radius is 1.97 inches (50 mm). Note: T erminals X2 and X3 can be in use simultaneously . However , if the [...]

  • Page 77

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-1 January 2007 Chapter 5 — Menu Information Keypad Operation The control keypad is the link between the LCX9000 drive and the user . The control keypad features an alphanumeric display with seven indicators for the Run status (RUN, counter -[...]

  • Page 78

    LCX9000 Liquid-Cooled Drives User Manual 5-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Drive Status Indicators The drive status symbols tell the user the status of the motor and the drive. In addition, they tell about possible irregularities detected by the motor control software in motor or drive functions. T abl[...]

  • Page 79

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-3 January 2007 Status LEDs (Green – Green – Red) The status LEDs light up in connection with the READY , RUN and F AUL T drive status indicators. T able 5-3: Status LEDs (Green – Green – Red) T ext Lines The three text lines provide th[...]

  • Page 80

    LCX9000 Liquid-Cooled Drives User Manual 5-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 5-5: Button Descriptions Indicator Description RESET This button is used to reset active faults (see Page 5-11 ). SELECT This button is used to switch between the two latest displays. This may be useful when you want to s[...]

  • Page 81

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-5 January 2007 Menu Navigation The data on the control keypad is arranged in menus and submenus. The menus are used for the display and editing of measurement and control signals, parameter settings and reference value and fault displays. Thro[...]

  • Page 82

    LCX9000 Liquid-Cooled Drives User Manual 5-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 5-4: Keypad Navigation Chart Expa n der boards G1 G5 A : OPT A1 G1 G1 A : Parameters P1 P3 La n guage E n glish Cha n ge value Browse S ystem Me n u S 1 S 9 Output Freque n cy 13.95 Hz Mo n itor V1 V15 No editi n g ! 11 O[...]

  • Page 83

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-7 January 2007 Monitoring Menu (M1) Y ou can enter the Monitoring menu from the Main menu by pressing Menu Button Right when the location indication M1 is visible on the first line of the display . Figure 5-5 shows how to browse through the m[...]

  • Page 84

    LCX9000 Liquid-Cooled Drives User Manual 5-8 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 5-6: Monitored Signals Note: Applications may embody more monitoring values. Parameter Menu (M2) Parameters are the way of conveying the commands of the user to the drive. Parameter values can be edited by entering the Pa[...]

  • Page 85

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-9 January 2007 Y ou can return to the Main menu any time by pressing Menu Button Left for 1 to 2 seconds. The basic application package includes seven applications with different sets of parameters. Y ou will find the parameter lists in the a[...]

  • Page 86

    LCX9000 Liquid-Cooled Drives User Manual 5-10 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Selection of Control Place There are three different places (sources) where the drive can be controlled. For each control place, a different symbol will appear on the alphanumeric display: ● I/O terminals ● Keypad (panel) ?[...]

  • Page 87

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-11 January 2007 STOP Button Activated By default, pushing the STOP button will always stop the motor regardless of the selected control place. Y ou can disable this function by giving parameter 3.4 the value 0. If the value of this parameter i[...]

  • Page 88

    LCX9000 Liquid-Cooled Drives User Manual 5-12 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Fault T ypes The drive has four types of faults. These types differ from each other on the basis of the subsequent behavior of the drive. See T able 5-8 . Figure 5-9: Fault Display T able 5-8: Fault T ypes Note: Fault Codes are[...]

  • Page 89

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-13 January 2007 The data available are: T able 5-9: Fault T ime Recorded Data  T ells the user if the drive was at zero speed (<0.01 Hz) when the fault occurred Real T ime Record If real time is set to run on the drive, the data items T1[...]

  • Page 90

    LCX9000 Liquid-Cooled Drives User Manual 5-14 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure 5-10: Fault History Menu System Menu (M6) Y ou can enter the System menu from the Main menu by pressing Menu Button Right when the location indication M6 is visible on the first line of the keypad display . The controls[...]

  • Page 91

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-15 January 2007 T able 5-11: System Menu Functions Code Function Min Max Unit Default Cust Selections S6.1 Selection of language English English Deutsch Suomi Svenska Italiano S6.2 Application selection Basic Application Basic Application Stan[...]

  • Page 92

    LCX9000 Liquid-Cooled Drives User Manual 5-16 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able 5-11: System Menu Functions (Continued ) Code Function Min Max Unit Default Cust Selections P6.7.3 HMI acknowledg. 200 5000 ms 200 P6.7.4 HMI: no. of retries 1 10 5 S6.8 System information S6.8.1 T otal counters C6.8.10.[...]

  • Page 93

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-17 January 2007 Selection of Language The control keypad allows you to control the drive through the keypad in the language of your choice. Locate the language selection page under the System menu. Its location indication is S6.1. Press Menu B[...]

  • Page 94

    LCX9000 Liquid-Cooled Drives User Manual 5-18 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Copy Parameters The parameter copy function is used when the operator wants to copy one or all parameter groups from one drive to another or to store parameter sets in the internal memory of the drive. All the parameter groups [...]

  • Page 95

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-19 January 2007 Figure 5-14: Parameter Copy to Keypad Download parameters to drive (From keypad, S6.3.3) This function downloads one or all parameter groups uploaded to the keypad to a drive provided that the drive is in STOP status. Enter the[...]

  • Page 96

    LCX9000 Liquid-Cooled Drives User Manual 5-20 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Parameter Comparison In the Parameter Comparison submenu (S6.4), you can compare the actual parameter values to the values of your customized parameter sets and those loaded to the control keypad. Y ou can compare the parameter[...]

  • Page 97

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-21 January 2007 Security Note: The Security submenu is protected with a password. Store the password in a safe place! Password (S6.5.1) The application selection can be protected against unauthorized changes with the Password function (S6.5.1)[...]

  • Page 98

    LCX9000 Liquid-Cooled Drives User Manual 5-22 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Parameter Lock (P6.5.2) This function allows the user to prohibit changes to the parameters. If the parameter lock is activated, the text *locked* will appear on the display if you try to edit a parameter value. Note: This func[...]

  • Page 99

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-23 January 2007 Multimonitoring Items (P6.5.4) The alphanumeric keypad features a display where you can monitor up to three actual values at the same time — see Monitoring Menu (M1) on Page 5-7 and the manual of the application you are using[...]

  • Page 100

    LCX9000 Liquid-Cooled Drives User Manual 5-24 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Default page in the operating menu (P6.6.2) Here you can set the location (page) in the Operating menu (in special applications only) to which the display automatically moves to when the set T imeout T ime (see below) has expir[...]

  • Page 101

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-25 January 2007 Hardware Settings Note: The Hardware settings submenu is protected with a password. Store the password in a safe place! In the Hardware Settings submenu (S6.7) under the System menu, you can further control some functions of th[...]

  • Page 102

    LCX9000 Liquid-Cooled Drives User Manual 5-26 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Number of retries to receive HMI acknowledgement (P6.7.4) With this parameter you can set the number of times the drive will try to receive acknowledgement if it does not receive acknowledgement within the acknowledgement time [...]

  • Page 103

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-27 January 2007 T rip Counters T rip counters (menu S6.8.2) are counters the values of which can be reset, i.e. restored to zero. Y ou can use the resettable counters in T able 5-12 . Note: The trip counters run only when the motor is running.[...]

  • Page 104

    LCX9000 Liquid-Cooled Drives User Manual 5-28 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Applications (S6.8.4) At location S6.8.4, you can find the Applications submenu containing information on the application currently in use and all other applications loaded into the drive. The following information is availabl[...]

  • Page 105

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 5-29 January 2007 Expander Boards (S6.8.6) The Expander boards submenu contains information about the basic and option boards (see Chapter 4 ). Y ou can check the status of each board slot by entering the Expander Boards page with Menu Button Ri[...]

  • Page 106

    LCX9000 Liquid-Cooled Drives User Manual 5-30 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Expander Board Parameters T able 5-17: Expander Board Parameters (Board OPT A1) Figure 5-27: Expander Board Information Menu Further Keypad Functions The control keypad contains additional application-related functions. See the[...]

  • Page 107

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 6-1 January 2007 Chapter 6 — Start-Up Safety Precautions Before start-up, note the following directions and warnings: WARNING Internal components and circuit boards of the drive are live when the drive is connected to mains potential. Coming i[...]

  • Page 108

    LCX9000 Liquid-Cooled Drives User Manual 6-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Sequence of Operation 1. Carefully read the safety instructions in the front of this manual and above and follow them. 2. After the installation, make sure that: ● both the drive and the motor are grounded. ● the mains and m[...]

  • Page 109

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com 6-3 January 2007 9. Perform run test without motor . Perform either T est A or T est B: T est A — Controls from the I/O terminals: ● T urn the Start/Stop switch to ON position. ● Change the frequency reference (potentiometer). ● Check in[...]

  • Page 110

    LCX9000 Liquid-Cooled Drives User Manual 6-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007[...]

  • Page 111

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com A-1 January 2007 Appendix A — Fault Codes When a fault is detected by the drive’ s control electronics, the drive is stopped and the symbol F together with the ordinal number of the fault, the fault code and a short fault description appear [...]

  • Page 112

    LCX9000 Liquid-Cooled Drives User Manual A-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able A-1: Fault Codes (Continued)  Programmable.  “A” faults only Fault Code Fault Possible Cause Solution 9 Undervoltage  DC-link voltage is under the voltage limits defined in T able 1-4 . • most probable cau[...]

  • Page 113

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com A-3 January 2007 T able A-1: Fault Codes (Continued)  Programmable.  “A” faults only . Fault Code Fault Possible Cause Solution 29 Thermistor fault  The thermistor input of option board has detected increase of the motor temperature[...]

  • Page 114

    LCX9000 Liquid-Cooled Drives User Manual A-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 T able A-1: Fault Codes (Continued)  Programmable.  “A” faults only . Load T est with Motor 1. Connect the motor cables and check the right phase order . Also check that the motor rotates freely . 2. Check liquid cooli[...]

  • Page 115

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com A-5 January 2007 DC Link T est (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 sup[...]

  • Page 116

    LCX9000 Liquid-Cooled Drives User Manual A-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007[...]

  • Page 117

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com B-1 January 2007 Appendix B — T echnical Reference Main Circuit and Control Diagrams Figure B-1: Main Circuit and Control Diagram, CH3 DC – W_HI DC + R DC – Measureme n ts Power Board Fa n Co nn ector X17 DC + DC – T erm B T erm B T erm [...]

  • Page 118

    LCX9000 Liquid-Cooled Drives User Manual B-2 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure B-2: Main Circuit and Control Diagram, CH4 Figure B-3: Main Circuit and Control Diagram, CH5 DC- Measureme n ts DC+ DC+ DC+ Te r m A U_HI U_HI V_HI V_HI W_HI W_HI DC- POW Te r m B Te r m A PE 1 3 5 X8 X1 X1 X1 X6 ( S lot [...]

  • Page 119

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com B-3 January 2007 Figure B-4: Main Circuit and Control Diagram, CH61 Figure B-5: Main Circuit and Control Diagram, CH61, Control L1 L2 L3 X41 X4 500/VB00459 690/VB00460 Rectifier Board A S IC/ X2 A S IC/ X6 A S IC/ X3...X5 A S IC/ H8...H13 A S IC[...]

  • Page 120

    LCX9000 Liquid-Cooled Drives User Manual B-4 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure B-6: Main Circuit and Control Diagram, CH63, Module 1 Figure B-7: Main Circuit and Control Diagram, CH63, Module 2 500/VB00530 690/VB00528 Measureme n t Board 1 Te r m U 1 U_Hi U_Lo I_U1 Te r m U 2 V_Hi V_Lo I_V1 Te r m U[...]

  • Page 121

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com B-5 January 2007 Figure B-8: Main Circuit and Control Diagram, CH63, Control Figure B-9: Main Circuit and Control Diagram, CH72 Co n trol Board Optio n Board Optio n Board Optio n Board Optio n Board Optio n Board Co n trol Pa n el X1 9 X7 X2 ( [...]

  • Page 122

    LCX9000 Liquid-Cooled Drives User Manual B-6 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Figure B-10: Main Circuit and Control Diagram, CH72, Control Figure B-11: Main Circuit and Control Diagram, CH74, Phase U Co n trol Board Optio n Board Optio n Board Optio n Board Optio n Board Optio n Board Co n trol Pa n el X1[...]

  • Page 123

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com B-7 January 2007 Figure B-12: Main Circuit and Control Diagram, CH74, Control Co n trol Board Optio n Board Optio n Board Optio n Board Optio n Board Optio n Board Co n trol Pa n el X1 9 X7 X2 ( S lot A) X3 ( S lot B) X4 ( S lot C) X5 ( S lot D)[...]

  • Page 124

    LCX9000 Liquid-Cooled Drives User Manual B-8 For more information visit: www.EatonElectrical.com MN04005001E January 2007 Fan Dimensions Figure B-13: Fan Mounting Pallet — Hot Dip Zinc Coated Approximate Dimensions in Inches (mm) Figure B-14: Fan Support R .23 (5.8) Dia. .43 (11) Dia. .17 (4.2) 28.98 (736) .98 (25) .87 (22) .87 (22) .41 (10.5) 2.[...]

  • Page 125

    LCX9000 Liquid-Cooled Drives User Manual MN04005001E For more information visit: www.EatonElectrical.com B-9 January 2007[...]

  • Page 126

    LCX9000 Liquid-Cooled Drives User Manual B-10 For more information visit: www.EatonElectrical.com MN04005001E January 2007[...]

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    Eaton Electrical Inc. 1000 Cherrington Parkway Moon T ownship, 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 Company Information Eaton’ s electrical business is a global leader in electrical control, power distribution, and i[...]