Instruction Bulletin E-Flex™ and Econo-Flex AC

Instruction Bulletin E-Flex™ and Econo-Flex AC
30072-453-08
12/2009
Raleigh, NC, USA
Instruction Bulletin
E-Flex™ and Econo-Flex® AC Drives
Environmental Enhancement Kits
Retain for future use.
Kit Description
This bulletin contains procedures for installing optional environmental
enhancement kits on the Type 3R Enclosed Class 8839 E-Flex™ and
Econo-Flex® drives, 1–50 hp 208 V, 1–50 hp 230 V, and 1–100 hp 460 V.
The kits contain the following equipment:
•
•
•
•
•
•
Plenum ventilation hood
Enclosure ventilation hood
Exhaust hood gasket
Seismic label
Mounting hardware
Enclosure bonding
We recommended that you install all the parts in the kit. See Table 1 on
page 2 for kit selection by power rating and voltage and detailed kit
contents. See Figure 1 for location of parts.
Figure 1:
E-Flex/Econo-Flex 3R Component Identification
Plenum
ventilation
hood
Exhaust
hood
Seismic label
(Mod U09)
Enclosure
ventilation
hood
(replaces
heater hood)
© 2009 Schneider Electric All Rights Reserved
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Related Documentation
Table 1:
208 V
1–5 hp
7.5–10 hp
15–25 hp
30–50 hp
Related Documentation
NOTE: This documentation is available in the
Technical Library at www.schneider-electric.us.
Kit Selection and Contents
230 V
1–5 hp
7.5–10 hp
15–25 hp
30–50 hp
480 V
1–7.5 hp
10–25 hp
30–50 hp
60–100 hp
Kit Contents
Qty.
Part
(1)
Plenum hood top
(1)
Plenum hood base
(1)
Ventilation hood assembly
(1)
Seismic label
(1)
Exhaust hood gasket
(26)
10-32 X 1/2 Torx screws
w/ plastisol washer
(1)
Enclosure bonding
(1)
Plenum hood top
(1)
Plenum hood base
(1)
Ventilation hood assembly
(1)
Seismic label
(1)
Exhaust hood gasket
(26)
10-32 X 1/2 Torx screws
w/ plastisol washer
(1)
Enclosure bonding
(1)
Plenum hood top
(1)
Plenum hood base
(1)
Ventilation hood assembly
(1)
Seismic label
(1)
Exhaust hood gasket
(30)
10-32 X 1/2 Torx screws
w/ plastisol washer
(1)
Enclosure bonding
(1)
Plenum hood top
(1)
Plenum hood base
(1)
Ventilation hood assembly
(1)
Seismic label
(1)
Exhaust hood gasket
(30)
10-32 X 1/2 Torx screws
w/ plastisol washer
(1)
Enclosure bonding
Kit Number
80461-254-50
80461-254-51
80461-254-52
80461-254-53
For additional product information and operating instructions, refer to the
latest revisions of the following documents:
•
•
•
•
•
•
•
2
30072-453-08
12/2009
E-Flex® Adjustable Speed Drive Controllers for HVAC and Pumping
Applications, document 30072-451-51
Econoflex Adjustable Speed Drive Controllers for HVAC and Pumping
Applications, 1–100 hp, 460 V and 1–50 hp, 208/230 V,
document 30072-450-10
Econoflex AC Drives: Preventive Maintenance for Type 3R Enclosures,
document 30072-451-34
Altivar® 61 Installation Manual 0.5 to 100 HP, module no. 1760643.
Supplementary Instructions to ATV61 Variable Speed Drives Installation
Manual—Low Horsepower, document no. 30072-452-63.
Altivar® 61 Installation Manual 75 to 900 HP, module no. 1760655.
Supplementary Instructions to ATV61 Variable Speed Drives Installation
Manual—High Horsepower, document no. 30072-452-49.
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
Before You Begin
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Before You Begin
Read and follow these precautions before performing any procedure with
this drive.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand this bulletin in its entirely before installing or
operating the drive. Installation, adjustment, repair, and maintenance
must be performed by qualified personnel.
• The user is responsible for compliance with all international and national
electrical code requirements with respect to grounding of all equipment.
• Many parts of this drive, including the printed circuit boards, operate at
the line voltage. DO NOT TOUCH. Use only electrically insulated tools.
• DO NOT touch unshielded components or terminal strip screw
connections with voltage present.
• DO NOT short across terminals PA/+ and PC/– or across the DC bus
capacitors.
• Before servicing the drive:
— Disconnect all power, including external control power that may be
present.
— Place a “DO NOT TURN ON” label on all power disconnects.
— Lock all power disconnects in the open position.
— WAIT 15 MINUTES to allow the DC bus capacitors to discharge.
Then follow the “Bus Voltage Measurement Procedure” on page 5
to verify that the DC voltage is less than 42 V. The drive LED is not
an indicator of the absence of DC bus voltage.
• Install and close all covers before applying power or starting and
stopping the drive.
Failure to follow these instructions will result in death or serious
injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E.
• This equipment must only be installed and serviced by qualified
electrical personnel.
• Turn off all power supplying this equipment before working on or inside
equipment.
• Always use a properly rated voltage sensing device to confirm power is
off.
• Replace all devices, door, and covers before turning on power to this
equipment.
• Voltage may still be present on the line side terminals of the circuit
breaker when off, use caution when working in this area.
Failure to follow these instructions will result in death or serious
injury.
© 2009 Schneider Electric All Rights Reserved
3
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Tools Required
Tools Required
The following tools are required for the installation:
•
•
•
•
•
•
•
4
30072-453-08
12/2009
T-20 Torx® driver
Flathead screw driver
Class 3 (1000 V rated) multimeter
5/16 in. hex-head socket driver
3/8 in. hex-head socket driver
1/4 in. socket driver extension
Cordless drill and size 17 (0.173 in.) drill bit
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Bus Voltage Measurement
Bus Voltage Measurement
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the DC Bus Voltage Measurement Procedure
before performing the procedure. Measurement of bus capacitor
voltage must be performed by qualified personnel.
• DO NOT short across capacitors or touch unshielded components or
terminal strip screw connections with voltage present.
• Many parts in this drive, including printed wiring boards, operate at line
voltage. DO NOT TOUCH. Use only electrically insulated tools.
Failure to follow these instructions will result in death or serious
injury.
The DC bus voltage level is determined by monitoring the PA/+ and PC/–
terminals. The location of these terminals varies by power converter model
number. Read the model number of the power converter from the
nameplate, and identify the location of the corresponding PA/+ and PC/–
terminals from the appropriate ATV61 installation manual (see page 2).
To measure the DC bus capacitor voltage:
1. Observe the lockout / tag-out procedures as identified in OSHA
Standard 29 CFR, Subpart J covering:—1910.147: The control of
hazardous energy (lockout/tagout)—1910.147: App A, Typical minimal
lockout procedures.
2. Be sure to remove all external control power that may be present such
as on the control board and the option board terminals.
3. Wait fifteen minutes for the DC bus capacitors to discharge.
4. Open the door of the drive.
5. Set the voltmeter to the 1000 Vdc scale. Measure the voltage between
the PA/+ and PC/– terminals.
6. Verify that the DC bus voltage has discharged below 42 V before
servicing the drive. If the DC bus capacitors will not discharge below
42 V, contact your local Schneider Electric representative. Do not
operate the drive.
7. After servicing the drive, close and secure door.
© 2009 Schneider Electric All Rights Reserved
5
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Plenum Ventilation Hood Installation
Plenum Ventilation Hood
Installation
30072-453-08
12/2009
Before installing the plenum ventilation hood, refer to bulletin 30072-451-34
for instructions on inspecting the enclosure for leaks and for missing or
removed hardware that may allow water to enter the enclosure.
Seismic Label Considerations
If the seismic option (U09) appears on the nameplate and is supplied with
the drive, installation of the plenum ventilation hood assembly will block or
displace the seismic label. Apply the seismic label included with the kit on
the front surface of the new plenum ventilation hood top. Do not block any
ventilation openings when applying the label.
Installing the Plenum Ventilation
Hood on 1–10 hp (208/230 V) and
1–25 hp (480 V) Drives
1. Thoroughly clean the top of the enclosure.
2. Place the hood base over the top of the enclosure, fitting the rear flange
of the base into the plenum area of the enclosure.
NOTE: When properly positioned, the front of the hood base should
project over the top of the enclosure door (See Figure 2 on page 7) and
not interfere with opening and closing the door.
3. Mark drill hole locations for mounting the hood base on the top of the
enclosure (see Figure 2).
4. Remove the hood base from the enclosure. Open the enclosure and
inspect the area to be drilled for electrical conductors or components
that may be damaged when drilling holes for the hood base mounting.
Tie any loose conductors back away from the drill area.
To prevent metal shavings from falling into the enclosure and electrical
components, cover the drive inverter and mask off the drill area with
tape or other suitable material.
CAUTION
DAMAGE TO AC DRIVE AND SURROUNDING COMPONENTS
Do not allow shavings or other debris to fall into the enclosure or electrical
components.
Failure to follow this instruction can result in equipment damage.
5. Using a size 17 bit, drill four 0.173 in. diameter holes in the top of the
enclosure in the locations marked in Step 3 above.
6. Using a vacuum cleaner, remove shavings and debris from the
enclosure. Do not use compressed air to blow out the equipment
because it may not remove all debris. Ensure that the modified area is
free of metal shavings and burrs.
7. Place the hood base back on top of the enclosure and align the
mounting holes. Using four of the 0-32 x 1/2 Torx screws included in the
kit, attach the hood base on each side of the enclosure. Tighten the
screws to 3.1–3.7 N•m (28–33 lb-in). To prevent displacement of the
rubber washers, do not over tighten the screws.
8. Remove the covers and mask applied in Step 4 above, being careful not
to let any metal shavings or debris fall into the enclosure or electrical
components.
Remove any cable ties or restraints that were put in place for drilling.
Ensure that the hood mounting screws do not interfere with components,
wire routing, or wire insulation.
6
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Plenum Ventilation Hood Installation
9. Fit the hood top over the hood base. The hood top should fit securely
down inside the plenum area, covering the plenum area.
10. Align the mounting holes on the left and right side of the hood top with
the holes in the hood base.
11. Attach the hood top to the sides of the enclosure with eight of the
10-32 x 1/2 Torx screws included in the kit. Tighten the screws to
3.1–3.7 N•m (28–33 lb-in). To prevent displacement of the rubber
washers, do not over tighten the screws.
Figure 2:
Plenum Ventilation Hood, 1–10 hp (208/230 V) and
1–25 hp (480 V)
Plenum
ventilation
hood top
Seismic
label (Mod U09)
© 2009 Schneider Electric All Rights Reserved
Plenum
ventilation
hood base
7
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Plenum Ventilation Hood Installation
Installing the Plenum Ventilation
Hood on 15–50 hp (208/230 V) and
30–100 hp (480 V) Drives
30072-453-08
12/2009
1. Remove the eight 10-32 x 1/2 Torx screws securing the existing plenum
ventilation hood to the enclosure and remove the hood. See Figure 3 on
page 9.
2. Thoroughly clean the top of the enclosure, removing all gasket material
and adhesive. Ensure that no debris falls into the enclosure.
3. Install two of the 10-32 x 1/2 Torx screws included in the kit into the front
mounting holes to close the holes. These holes will not be accessible
after the plenum ventilation hood base is installed.
4. Place the hood base over the top of the enclosure, fitting the rear flange
of the base into the plenum area of the enclosure, and aligning the
mounting holes with the existing holes in the top of the enclosure.
NOTE: When properly positioned, the front of the hood base should
project over the top of the enclosure door (See Figure 3) and not interfere
with opening and closing the door.
5. Attach the hood base to the top of the enclosure with six of the
10-32 x 1/2 Torx screws included in the kit. Tighten the screws to
3.1–3.7 N•m (28–33 lb-in). To prevent displacement of the rubber
washers, do not over tighten the screws.
If one or more of the holes becomes stripped, secure the mounting
screw with a 10-32 nut and washer. Be sure to place screws in all of the
mounting holes to prevent water from entering the enclosure.
6. Fit the hood top over the hood base. The hood top should fit securely
down inside the plenum area, covering the plenum area.
7. Align the mounting holes on the left and right side of the hood top with
the holes in the hood base.
8. Attach the hood top to the sides of the enclosure with eight of the
10-32 x 1/2 Torx screws included in the kit. Tighten the screws to
3.1–3.7 N•m (28–33 lb-in). To prevent displacement of the rubber
washers, do not over tighten the screws.
8
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Plenum Ventilation Hood Installation
Figure 3:
Plenum Ventilation Hood, 15–50 hp (208/230 V) and
30–100 hp (480 V)
Plenum
ventilation
hood top
Seismic
label (Mod U09)
Plenum
ventilation
hood base
© 2009 Schneider Electric All Rights Reserved
9
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Installing the Enclosure Ventilation Hood
Installing the Enclosure
Ventilation Hood
Remove the Heater Hood
30072-453-08
12/2009
The enclosure ventilation hood is designed to fit 1–50 hp (208/230 V) and
1–100 hp (480 V) E-Flex/Econo-Flex drives, with no drilling of the enclosure
sheet metal required. The enclosure ventilation hood includes both a
ventilation fan and a condensation heater.
Before installing the enclosure ventilation hood, remove the existing heater
hood as follows. See Figure 1 on page 1 for heater hood location.
1. Remove the seven 10-32 x 1/2 Torx screws securing the heater hood to
the lower right side of the enclosure and discard the screws. Carefully
disconnect the power connections and bonding jumper.
2. Remove the power connections from terminals XF (red) and X2 (white)
of the control power transformer. See Figures 11–13 on page 17 for the
location of terminals XF and X2.
NOTE: Mark the location of the terminals on the transformer. You will use
them when installing the enclosure ventilation hood.
3. Remove the bonding jumper from the ground bar. See Figures 7–10 on
pages 13–16 for the location of the ground bar.
NOTE: Mark the location of the ground bar. You will bond the enclosure
ventilation hood here.
4. Remove any gasket material from the side of the enclosure and clean
the surface. A new gasket is included with the replacement enclosure
ventilation hood.
Install the Enclosure Ventilation
Hood
The enclosure ventilation hood comes pre-wired and ready to connect, with
supply power and bonding jumper wires factory-installed. Before installing
the hood, verify that the thermostatic control relay (see Figure 5 on page 11)
is set to 60 °F, then install the hood as follows:
1. Connect control power wires to terminals XF (red) and X2 (white) of the
secondary side of the control power transformer at the locations noted in
Figures 11–13 on page 17. Cut and strip the bonding wire to length as
necessary.
2. Connect the green/yellow bonding wire from the enclosure ventilation hood
to the ground bar at the location noted in Step 3 above with one 10-32 X 3/8
hex screw. Tighten the ground bus connection to 4 N•m (35 lb-in). See
Figures 7–10 on pages 13–16.
CAUTION
HEAT DAMAGE TO NEARBY EQUIPMENT
• The surface of the heater guard is potentially hot.
• Avoid contact with the wires and the heater guard.
• Ensure that the wires do not contact the heater surface.
Failure to follow these instructions can result in equipment damage.
3. Position the enclosure ventilation hood so that its mounting holes align
with the mounting holes on the right side of the enclosure. Ensure that
no wires are pinched or interfere with flush mounting and gasket
compression between the enclosure ventilation hood and right side of
the enclosure.
10
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Installing the Enclosure Ventilation Hood
4. Attach the enclosure ventilation hood to the right side of the enclosure
using seven of the 10-32 X 1/2 Torx screws included in the kit. Tighten
the screws to 3.1–3.7 N•m (28–33 lb-in). Uniformly torque the screws to
maintain consistent gasket compression around the enclosure
ventilation hood. To prevent displacement of the rubber washers, do not
over tighten the screws.
Figure 4:
Enclosure Ventilation Hood, Front View
Figure 5:
Enclosure Ventilation Hood, Back View
Thermostatic
switch
© 2009 Schneider Electric All Rights Reserved
11
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Installing the Enclosure Ventilation Hood
Remove the Ventilation Fan
30072-453-08
12/2009
To maintain proper air flow and ventilation, it is necessary to remove the
enclosure ventilation fan. See Figure 6. The ventilation fan is located in the
exhaust hood on the upper left-hand side of the enclosure (see Figure 1 on
page 1). Remove the fan as follows:
1. Remove and discard the seven 10-32 x 1/2 Torx screws securing the
exhaust hood to the enclosure, and carefully disconnect the power
connections and bonding jumper supplying the hood. See Figures 7–10
on pages 13–16 for the location of the ground bar.
2. Remove the exhaust hood from the enclosure, and remove the gasket
from the exhaust hood.
3. Remove the power connections from terminals XF (red) and X2 (white)
of the control power transformer. See Figures 11–13 on page 17 for the
location of terminals XF and X2.
4. Remove the red and white power wires leading to the enclosure
ventilation fan and discard the wires.
5. Loosen two 10-32 nuts securing the fan mounting plate to the exhaust
hood. Remove two 10-32 x 3/8 hex screws, then remove the fan and the
fan mounting plate.
NOTE: Save the fan for future use. It can be used as a replacement for the
fan included in the enclosure ventilation hood if necessary.
6. Remove any gasket material from the side of the enclosure and clean
the surface. Apply the replacement gasket, included in the kit, to the
cleaned surface.
7. Reattach the bonding jumper to the exhaust hood with one 10-32 X 3/8
hex screw. Tighten the screw to 3.1–3.7 N•m (28–33 lb-in).
8. Position the exhaust hood to align with the mounting holes on the left
side of the enclosure. Ensure that no wires are pinched or otherwise
interfere with flush mounting and gasket compression between the
exhaust hood and left side of the enclosure.
9. Attach the exhaust hood to the enclosure with seven of the
10-32 x 1/2 Torx screws included in the kit. Tighten the screws to
3.1–3.7 N•m (28–33 lb-in). Uniformly torque the screws to maintain
consistent gasket compression around the enclosure ventilation hood. To
prevent displacement of the rubber washers, do not over tighten the screws.
10. Verify that all screws, latches, and seals are secure and prepare the
drive to be returned to service.
Figure 6:
12
Ventilation Fan
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
Component Layout
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Component Layout
Figure 7:
Size A (3% DC Choke Shown)
Ground bar and bonding
jumpers
XF and X2 transformer
location. See Figures
11–13 on page 17 for
transformer detail.
© 2009 Schneider Electric All Rights Reserved
13
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Component Layout
Figure 8:
30072-453-08
12/2009
Size B (3% DC Choke Shown)
Ground bar and
bonding jumpers
XF and X2 transformer
location. See Figures
11–13 on page 17 for
transformer detail.
14
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Component Layout
Figure 9:
Size C (3% DC Choke Shown)
Ground bar and
bonding jumpers
XF and X2 transformer
location. See Figures
11–13 on page 17 for
transformer detail.
© 2009 Schneider Electric All Rights Reserved
15
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Component Layout
Figure 10:
30072-453-08
12/2009
Size D (5% Line Reactor Shown)
Ground bar and
bonding jumpers
XF and X2
transformer location.
See Figures 11–13 on
page 17 for
transformer detail.
Ground bar and
bonding jumpers
16
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
Wiring Connections
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Wiring Connections
Figure 11:
208 V Connections
H1
H2
XF node
X2 node
X1
Figure 12:
230 V Connections
H1 H3 H2 H4
XF node
X2 node
X1
Figure 13:
460 V Connections
H1 H3 H2 H4
XF node
X2 node
X1
© 2009 Schneider Electric All Rights Reserved
17
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Product Support
Product Support
For support and assistance, contact the Product Support Group. The
Product Support Group is staffed from Monday through Friday, 8:00 am until
6:00 pm Eastern time, to assist with product selection, start-up, and
diagnosis of product or application problems. Emergency phone support is
available 24 hours a day, 365 days a year.
Toll free:
E-Mail:
Fax:
18
30072-453-08
12/2009
888-SquareD (888-778-2733)
drive.products.support@us.schneider-electric.com
919-217-6508
© 2009 Schneider Electric All Rights Reserved
30072-453-08
12/2009
© 2009 Schneider Electric All Rights Reserved
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Product Support
19
E-Flex™ and Econo-Flex® AC Drives Environmental Enhancement Kits
Instruction Bulletin
Schneider Electric
8001 Knightdale Blvd.
Knightdale, NC 27545 USA
1-888-SquareD (1-888-778-2733)
www.schneider-electric.us
20
30072-453-08
12/2009
Econo-Flex® is a registered trademark of Schneider Electric. Other trademarks used
herein are the property of their respective owners.
Electrical equipment should be installed, operated, serviced, and maintained only by
qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
© 2009 Schneider Electric All Rights Reserved
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