©2004 Rockwell Automation. All rights reserved.

What the Kit Contains

External Resistor Kit M/N 180788-A02 can be used only with B-frame (414A) LiquiFlo AC drives, model numbers: 41L4060, 41LR4060 and LF150414W4. Verify that you have the correct resistor assembly by verifying that the harness is labeled, “414AMP EXT BUS RESIS KIT.”

This kit is for field upgrade only. You should not use it if you are replacing the drive. If you replace the drive in the future, you should remove the resistor kit from the drive system.

!ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: Do not install or remove modification kits with power applied to the drive. Disconnect and lock out incoming power before attempting such installation or removal. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

!ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution could result in severe bodily injury or loss of life.

Quantity: Description1 Resistor Assembly6 M4 x 16 Mounting Screws with captive locking hardware1 Protective Cover1 Drilling Template / Cabinet Guard

External Bus Resistor Kitfor LiquiFlo AC Drives

Drive M/N’s 41L4060, 41LR4060, LF150414W4

Instruction Manual D2-3535

2 Instruction Manual D2-3535

What You Need to Do To install the external bus resistor kit you need to:

❐ Step 1: Verify that the DC Bus Capacitors are discharged

❐ Step 2: Identify a mounting location for the resistor assembly

❐ Step 3: Drill mounting holes for the resistor assembly, using the template

❐ Step 4: Mount the resistor assembly

❐ Step 5: Unplug connectors P1 and P2, and route harness

❐ Step 6: Connect the ground wire

❐ Step 7: Connect the harness

❐ Step 8: Verify installation

❐ Step 9: Register installation

Step 1: Verifying the DC Bus Capacitors are Discharged

!ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

Task DescriptionTurn off and lock out input power. Wait five minutes

Verify that there is no voltage at the drive’s input power terminals

Remove front cover

Measure the DC bus potential with a voltmeter while standing on a non-conductive surface and wearing insulated gloves (1000V)

A

B

C

D

Made in USA

BARCODE

U31

FUSE1C50D66

D65D64

C49

C44U35C43C42 C45

U36

C39

D60

C41

D56

T11

Q6

D49 D50

R37

C35

U21

D52D51

C36

C31

C32

FUSE2

U29C40

R42

R40

U30

R38

L2

C37 C38

ASSY

D48

C47

TP4TP5TP6 TP3

C46

U37

J8 D63

D61

R43

R41U32

U33

R39 D57 D58

C34

U22 U23

U16 U17

D59

D62

DS2

U34

C48

DS3 DS4

U24

U27

D54

U18

U26

D45

D53

D47

U19

C30

D46

U28

D55

U25

U20

R15

C27

Q5

R35

T10

U14DS1

R36

D29

D24

U6

C22

D26

C23

T3

L1

C20

C33

U15

D43 D44

T9

R29 R30

D38

D36 U13

C24

D33

D27 D28

T4 T5

R31

D10

D16Q4

T1

R19D12

T2

D11U1 C13

C7

C5

C4

C1

Q2Q1

C2 C3

R23C14D17 R22 D18 C15

C8

D19 C16 R24

C9

RV5

RV3

D6

D1

RV4

J6

J1

R1

RV1

R2 R3

J2

R4

R14

J3

D42

C29

C25

D35D34

D31

U8

D30 D32

U9

R28

D20

TP1 TP2

U3

R32

U10

D39

C28

D40D41

D37

C26

U11

R33

U7

D25

T6

C21

U4 U5

T7 T8

U2

Q3

R20

R21

D13 D14

D2 D3

D7 D8 D9

D4 D5

D15

D21

C10

D22R25C17 C18 R26

C11 C12

C6

RV6 RV7

R34

U12

C19D23 R27

J7

RV8

RV2

R16 R17

R8 R9 R10

R18

J4

R5R11 R12 R13 R6

J5

R7

1

TP2TP1

D

Test Points for initial DC Bus Voltage Measurement

Pos(+)

Neg(-)

Instruction Manual D2-3535 3

Step 2: Identifying the Mounting Location

Consider the following factors when choosing the location for the resistor assembly:

• the resistor assembly must be mounted inside the drive cabinet• the resistor assembly must be mounted vertically, with the closed part of

the protective cover pointing towards the front of the enclosure• the wiring harness must be able to reach connectors P1 and P2 inside the

drive• the wiring harness must not pass over unprotected sharp edges or hot

surfaces• the resistor assembly must not be mounted on the enclosure door

ProtectiveCover

Towards

Enclosure

Door

Resistor assembly shown without harness for clarity

4 Instruction Manual D2-3535

Step 3: Drilling the Mounting Holes

!ATTENTION: Metal debris or other foreign matter must be kept from falling into the drive. Metal debris or other foreign matter may become lodged in the drive circuitry resulting in component damage. Failure to observe this precaution could result in severe bodily injury or loss of life and/or damage to, or destruction of, equipment.

Task DescriptionProtect internal components from drilling debris

Using the template, mark locations for six mounting holes

Drill six 5mm (3/16 inch) mounting holes

A

B

C

Drilling Template /Cabinet Guard

A

B

B

B

B

B

B

TIP: The template is symmetrical, so you have the options of drilling from the outside or inside of the enclosure. Drilling outside reduces the risk of debris falling into the drive.

Instruction Manual D2-3535 5

Step 4: Mounting the Resistor Assembly Task Description

Using a Phillips screw driver, install and tighten the six M4 x 16 mounting screws (torque 12 in-lb)

!ATTENTION: The cabinet can be very hot where the resistor assembly is mounted. HOT surfaces can cause severe burns. You must install the cabinet guard to protect personnel from accidental contact with the hot cabinet surface.

A

Resistor assembly shown without harness for clarity

Enclosure Wall

Mounting Screwsinserted from outside

of enclosure

AA

AA

AA

Resistor assembly mounted on inside of enclosure

Cabinet Guard

6 Instruction Manual D2-3535

Step 5: Unplugging Connectors P1 and P2 and Routing the Wiring Harness

Locate the P1 and P2 Connectors near the upper-left part of the power structure and unplug them.

Important: The harness connections are considered power level wiring. Run them separately from I/O and signal wiring.

P1 and P2

To Resistor Assembly

Push Here

to Release

Connector

Instruction Manual D2-3535 7

Step 6: Connecting the Ground Wire

Star Washer

BoltPaint Free Area

Welded StudGround Lug

Ground Lug

Star Washer

Star Washer

Component Ground Conductor

NutStar Washer

Nut Component Ground Conductor

Typical installations can use the existing ground stud originally intended for grounding the enclosure door.

This figure illustrates recommended practices for connecting grounds to an enclosure.

8 Instruction Manual D2-3535

Step 7: Connecting the Harness Task Description

Plug P1A into P1

Plug P2A into P2A

B

P1

P2

Wires

to

DriveP2A

P1A

Harness to Resistor Assembly

Wires

from

Drive

B

A

Instruction Manual D2-3535 9

Step 8: Verifying the Installation

Follow the normal steps for verifying drive installation and operation. Refer to the drive Hardware Reference and Software Start-up manuals.

Performing Continuity Tests

In these tests you are verifying continuity, a short circuit, between the two test points. The continuity mode on a digital multi-meter provides the easiest method for performing this test. Place one meter lead on the first test point and the meter should beep when you place the other lead on the second test point.

If your meter does not have a continuity mode, you can use a resistance mode. Place one meter lead on the first test point and the meter should indicate a short circuit (read approximately zero ohms) when you place the other lead on the second test point.

Task DescriptionDisconnect J4 from PMC Board

Confirm continuity between the points specified in Table A

Reconnect J4 to PMC Board

A

B

C

Table A J4 Continuity Tests

Test Points(1)

(1) If you are unfamiliar with continuity tests, refer to Performing Continuity Tests on page 9.

Meter ReadingJ4 End of CableResistor Assembly End of Cable(2)

(2) See Wiring Diagram for Reference on page 11.

J4:Pin 1 BUS (+) Continuity or approximately zero ohmsJ4:Pin 3 BUS MID

J4:Pin 5 BUS (-)

Made in USA

BARCODE

U31

FUSE1C50D66

D65D64

C49

C44U35C43C42 C45

U36

C39

D60

C41

D56

T11

Q6

D49 D50

R37

C35

U21

D52D51

C36

C31

C32

FUSE2

U29C40

R42

R40

U30

R38

L2

C37 C38

ASSY

D48

C47

TP4TP5TP6 TP3

C46

U37

J8 D63

D61

R43

R41U32

U33

R39 D57 D58

C34

U22 U23

U16 U17

D59

D62

DS2

U34

C48

DS3 DS4

U24

U27

D54

U18

U26

D45

D53

D47

U19

C30

D46

U28

D55

U25

U20

R15

C27

Q5

R35

T10

U14DS1

R36

D29

D24

U6

C22

D26

C23

T3

L1

C20

C33

U15

D43 D44

T9

R29 R30

D38

D36 U13

C24

D33

D27 D28

T4 T5

R31

D10

D16Q4

T1

R19D12

T2

D11U1 C13

C7

C5

C4

C1

Q2Q1

C2 C3

R23C14D17 R22 D18 C15

C8

D19 C16 R24

C9

RV5

RV3

D6

D1

RV4

J6

J1

R1

RV1

R2 R3

J2

R4

R14

J3

D42

C29

C25

D35D34

D31

U8

D30 D32

U9

R28

D20

TP1 TP2

U3

R32

U10

D39

C28

D40D41

D37

C26

U11

R33

U7

D25

T6

C21

U4 U5

T7 T8

U2

Q3

R20

R21

D13 D14

D2 D3

D7 D8 D9

D4 D5

D15

D21

C10

D22R25C17 C18 R26

C11 C12

C6

RV6 RV7

R34

U12

C19D23 R27

J7

RV8

RV2

R16 R17

R8 R9 R10

R18

J4

R5R11 R12 R13 R6

J5

R7

1

R9 R10

J4

R11 R12

J4

Pin 1AB

C

If you have a... ... refer to these publications:LiquiFlo 1.0 drive • D2-3410, LiquiFlo AC General Purpose (Volts/Hertz) and Vector Duty Drive

Software Start-up • D2-3411, LiquiFlo AC Power Modules Hardware Reference, Installation and

Troubleshooting LiquiFlo 1.5 drive • D2-3494, LiquiFlo 1.5 AC Power Modules Hardware Reference, Installation,

and Troubleshooting • D2-3495, LiquiFlo 1.5 AC General Purpose (Volts/Hertz) and Vector Duty

Drive Software Start-Up and Reference Manual

10 Instruction Manual D2-3535

Step 9: Registering the Installation

Register the installation of the External Bus Resistor kit on the Rockwell Automation Warranty And Returns Processing (WARP) website (http://www.automation.rockwell.com/warp/).

Click on “Field Retrofits”A

BSelect “External Bus Resistor Upgrade” from the drop-downC Click on “Continue”

D

Enter all the required andpertinent information.

E

Click on “Create Registration”F

Click on “Register Retrofit”

Instruction Manual D2-3535 11

Wiring Diagram for Reference

TEM

PSW

1TE

MPS

W2

FAN

PWR

(+)

BLEE

DER

(-)

BLEE

DER

(+)

FAN

PWR

(-)

FAN

P2 1 7 8 9 4 5 6 3 2P1

1 9 8 7 6 5 4 2 3

TEM

PSW

ITC

H

REA

CTO

R

1 2 3

1 2 3

DIS

CH

ARG

E R

ESIS

TOR

10K

Ohm

s

R1

R2

DIS

CH

ARG

E R

ESIS

TOR

10K

Ohm

s

1 9 8 7 6 5 4 2 3P1A

9 8 7 6

P2A

6348

1-10

5SFY

OR

6348

1-10

5SFY

OR

DC

+ BU

S

DC

MID

PT

DC

- BU

SEX

TER

NAL

BU

S R

ESIS

TOR

ASS

EMBL

Y

BUS

MID

RES

ISTO

R 2

4708

-501

-12

BUS

(-)

2600

Ohm

BUS

(+)

2600

Ohm

2470

8-50

1-13

2470

8-50

1-13

4 5

TEM

PSW

ITC

H

CH

ILLP

LATE

Not

e:Th

e ol

d re

sist

ors

and

thei

r co

nnec

ting

wire

s re

mai

n in

the

drive

.

U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives

Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication D2-3535-July 2004 Copyright © 2004Rockwell Automation, Inc. All Rights Reserved. Printed in USA.