Allen-Bradley PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Allen-Bradley PowerFlex 700L Liquid-to-Liquid Heat Exchanger is a compact and efficient cooling solution for PowerFlex 700L Liquid-Cooled drives and power modules. This heat exchanger utilizes liquid-to-liquid heat transfer technology, which involves transferring heat from the drive’s coolant loop to a user-supplied cooling source. The user is responsible for providing and maintaining the cooling source, while the heat exchanger ensures efficient heat dissipation from the drive system.
Advertisement
Advertisement
Liquid-to-Liquid Heat
Exchanger
User Manual
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety considerations.
!
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and understanding of the product.
!
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid the hazard, and recognize the consequences.
Shock Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
Allen-Bradley and PowerFlex are registered trademarks of Rockwell Automation, Inc.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Summary of Changes
This is the first release of the PowerFlex 700L Liquid-to-Liquid Heat
Exchanger User Manual.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
soc-ii
Summary of Changes
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Preface
Chapter 1
Table of Contents
Overview
Installation
Supply Loop Liquid Quality, Maintenance, and Precautions . . . . . . . . . . . . . . . . . . . . 1-5
Supply Loop (from Heat Exchanger to Cooling Liquid Source) . . . . . . . . . . . . . . . . . 1-7
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
ii
Table of Contents
Chapter 2
Operation
Appendix A
Supplemental Heat Exchanger Information
Appendix B
Heat Exchanger Schematic
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Preface
Overview
The purpose of this manual is to provide you with the installation and operating information for the PowerFlex 700L Liquid-to-Liquid Heat
Exchanger used with PowerFlex 700L Liquid-Cooled drives and power modules.
For information on…
See page…
Who Should Use this
Manual?
Technical Support and
Service
This manual is intended for qualified personnel. You must be able to install, wire, and operate Adjustable Frequency AC Drive devices.
For Allen-Bradley Drives Technical Support online: www.ab.com/support/abdrives
For service or replacement parts, contact:
Dimplex Thermal Solutions in Kalamazoo, Michigan
1-800-968-5665 detailed PowerFlex 700L drive information:
What Is Not in this Manual
This manual is designed to provide only heat exchanger information. For
Title Publication
PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual
PowerFlex 700L Active Converter Power Module User Manual
20L-UM001…
PFLEX-UM002…
Publications can be obtained online at http://www.rockwellautomation.com/literature .
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
P-2
Overview
Reference Materials
Introduction
The following manuals are recommended for general drive information:
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001…
Preventive Maintenance of Industrial Control and Drive System Equipment
PowerFlex 70/700 Reference Manual
DRIVES-TD001…
PFLEX-RM001…
Safety Guidelines for the Application, Installation, and Maintenance of Solid State
Control
SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams
Guarding Against Electrostatic Damage
0100-2.10
8000-4.5.2
Operating Principle
The operating principle of the heat exchanger is based on liquid-to-liquid transfer of heat ( Figure P.1
). The drive loop transports the heat load from the drive to the heat exchanger. The supply loop flows through the heat exchanger to collect the heat load and transports it to the user’s cooling system liquid source. The use and choice of a system for disposing of the heat load is the user’s responsibility.
Figure P.1 Liquid Flow Heat Transfer Diagram
Drive Loop Supply Loop
Drive
Inlet
PowerFlex 700L
Drive
Outlet
The liquid-to-liquid heat exchanger uses a heat transfer plate to transfer heat from one liquid to another. This method requires a stable water supply from the user.
Figure P.2 Drive and Heat Exchanger Plumbing Arrangement
Liquid-to-Liquid
Heat Exchanger
From
Drive
Outlet
To
Drive
Inlet
Return
To
Supply
In
From
Supply
Hose Kit
Customer
Supplied Piping
To Facility Water
= hose or pipe connection
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Overview
P-3
Component Details
shows a cooling loop diagram for a typical liquid-to-liquid heat exchanger.
Figure P.3 Liquid-to-Liquid Heat Exchanger Plumbing Diagram
Ambient Sensor
TE
Drive Coolant Temp.
TE
Flow Switch
FS
Strainer
Control
Valve
IN OUT
IN
Supply
Process
Water
Level Switch
LS
General Precautions
OUT IN
Reservoir
OUT
Drive
Pump
The main components of the cooling loop include:
Part Description
Strainer Filters particles from the supply water.
Control Valve
Heat Exchanger Plate
Controls the supply loop water flow.
Transfers heat from the drive loop to the supply loop.
Ambient Sensor
Drive Coolant Temperature
Sensor
Senses the ambient temperature used for the dew point control.
Senses the drive coolant temperature used for the dew point control.
Drive Coolant Flow Switch
Level Switch
Reservoir
Pump and Motor
Measures the drive coolant flow rate.
Senses the level of coolant in the reservoir.
Stores drive coolant.
Circulates drive coolant.
!
!
ATTENTION: An incorrectly applied or installed heat exchanger can result in component damage or a reduction in product life.
Wiring or application errors, such as, undersizing the heat exchanger, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/ or equipment damage.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
P-4
Overview
Catalog Number
Explanation
Code
20L
1-3 4 5-6
20L – LL
a b
a
Drive
Type
PowerFlex 700L
Position
7-9 10 11
13K – P75
c d
Code
LL
b
Heat Exchanger
Type
Liquid-to-Liquid
c
Rating
Code
13K
24K
Watts
13,000
24,000
12
A
e
Code
P75
1P0
d
Hose Connection
Size
0.75 inch NPT
1.0 inch NPT
Code
A
e
Option
Description
Reserved
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Chapter
1
Installation
This chapter provides information on installing and wiring the PowerFlex
700L Liquid-to-Liquid Heat Exchanger.
For information on…
Connecting Hoses to the Heat Exchanger
AC Supply Source Considerations
See page…
Installation Specifications Required Ambient Conditions
The heat exchanger is designed to work within these ambient temperatures:
Heat Exchanger
When Used With
Drive Size
Ambient
Temperature Range
20L-LL13K-P75A Frame 2
20L-LL13K-P75A Frame 3A
20L-LL24K-1P0A Frame 3B
0-50°C (32-122°F)
0-40°C (32-104°F)
0-40°C (32-104°F)
It is the user’s responsibility to ensure that the temperature remains within this limit during operation. Condensation cannot be allowed to form in the drive. The easiest way of preventing condensation inside the drive is by keeping the water temperature in the supply loop higher than the ambient temperature. Circulate coolant through the drive only when the drive is
powered – except as described in Adding Coolant to the Drive Loop for
.
!
ATTENTION: Risk of equipment damage exists. Failure to keep the coolant temperature in the drive loop higher than the ambient temperature may result in condensation accumulating on the drive heatsink and/or circuit boards, which could damage the drive.
Location Requirements
Place the heat exchanger in a suitable location not more than 9.1 m (30 feet) from the drive. The location must be on the same level (altitude) as the drive to prevent increasing the load on the heat exchanger coolant pump. Refer to
Figure 1.1
for overall dimensions of the heat exchanger and locations of hose connections for the drive loop and supply loop.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-2
Installation
Lifting Instructions
The heat exchanger can be lifted off the shipping skid by removing the packing material from the unit and unscrewing the mounting brackets lag screws from the skid.
Using a Lift Truck
Forks a can be inserted between the exchanger legs from the front or sides as long as the forks extend beyond the opposite surface. Note: Bottom sections of the exchanger are open.
Using Rigging Straps
Rigging straps should be placed under the unit and along the sides to lift from the top. These straps should be long enough to provide fill tube clearance on the top.
Figure 1.1 Heat Exchanger Dimensions and Coolant Connections
619 Max.
(24.4)
FILL TUBE
688 Max.
(27.1)
127 Max.
(5.0)
TOP
FROM DRIVE OUTLET
CONTROL
WIRING
POWER
289
(11.38)
740 Max.
(29.1)
781 Max.
(30.77)
TO DRIVE
INLET
616 Max.
(24.3)
258
(10.18)
RETURN TO
SUPPLY
172
(6.8)
304
(12.0)
REAR
102 Min.
(4.0)
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Heat Exchanger
20L-LL13K-P75A
20L-LL24K-1P0A
INLET FROM SUPPLY
(Strainer shipped loose)
Approximate Weight
Empty (no coolant)
113 kg (250 lbs.)
113 kg (250 lbs.)
31 Max.
(1.25)
Dimensions are in millimeters and (inches).
Data
Nameplate
Fluid Level
38
+0.25/
-0.00
(1.5)
Electrical
Box
STATUS
Indicator
POWER
Indicator
DRIVE
DRAIN
SUPPLY
DRAIN
PRIME SWITCH
FRONT
Installation
1-3
Drive Coolant Requirements
lists approved sources and recommended coolants with appropriate corrosion inhibitors for the drive loop:
Table 1.A Recommended Drive Loop Coolants
Source
Interstate Chemical http://www.interstatechemical.com/ contact.htm
Koolant Koolers/Dimplex Thermal
Solutions http://www.koolantkoolers.com/ index.php/nic=contact
Dow Chemical http://www.dow.com
Coolant
• NFP-50
(1)
; a 50/50 premix of propylene glycol and distilled water
• NFE-50
; a 50/50 premix of ethylene glycol and
distilled water
; ethylene glycol (available premixed with
distilled water)
also available
• Dowtherm
®
SR-1
(2)
; ethylene glycol
• Dowfrost
®
; propylene glycol
Dowtherm and Dowfrost are registered trademarks of the
Dow Chemical Company
(1)
Available in 5 gallon pails.
(2)
Not premixed with distilled water, and may not be available in 5 gallon quantities.
Non-diluted coolants require a coolant-to-water mix ratio of 50% by volume. Table 1.B
lists the estimated amount of coolant needed for the drive loop based on the drive frame size.
Table 1.B Estimated Coolant Amount for the Drive Loop
Drive Size
Frame 2
Frame 3A
Frame 3B
Estimated Amount of Coolant
(1)
15.1 liters (4 gal.)
19 liters (5 gal.)
19 liters (5 gal.)
(1)
The estimated amount of coolant is based on the heat exchanger using 1.2 m
(4 ft.) hoses. Longer hoses require more coolant. The maximum hose length of 9.1 m (30 ft.) would require up to an additional 2.8 liters (3/4 gal.).
Important: Since coolant performance slowly degrades over time, the drive loop coolant should be replaced every two years and/or
whenever the loop is drained for servicing. See Draining
Coolant from the Drive Loop for Periodic Replacement on page 2-5 for instructions.
If an approved coolant is not used, the drive coolant must consist of clean water with a corrosion inhibitor. An approved corrosion inhibitor is
Chemtool, Inc. (www.chemtool.com) part number Watertool 4435-C. The recommended concentration of the inhibitor is 8-10% by volume. Deionized water is prohibited. Use distilled water or water with less than 50 ppm concentrations of:
• Sulfate and chloride
• Hard water ions such as Mg++ and Ca++
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-4
Installation
!
ATTENTION: Ethylene and propylene glycols must be inhibited and silicate free. Use of common silicate-containing,
automotive-type ethylene glycol solutions is prohibited as they may damage the heat exchanger and/or drive and cooling module equipment.
The drive coolant must be compatible with the following materials:
• Copper
• Brass
• Aluminum
• Arimid fiber gasket with nitrile binder (Garlock, Inc. Blue-Gard 3000 ®
)
Blue-Gard 3000 is a registered trademark of Garlock, Inc.
Connecting the Elbow/Strainer Assembly (shipped loose)
1. Apply PTFE (Teflon
®
) thread sealing tape or pipe thread sealant compound to threads on the "IN FROM SUPPLY" pipe nipple. Avoid excessive tape or compound which may come loose in the cooling loop.
Apply only to threads that will contact mating parts.
Teflon is a registered trademark of DuPont.
2. Hold the pipe nipple with a pipe wrench and tighten the elbow/strainer assembly onto the "IN FROM SUPPLY" pipe nipple with a second pipe wrench (
). The strainer should be installed with the flow
direction as indicated on its body, in a vertical down or horizontal pipeline. INSTALLATION IS NOT POSSIBLE WITH UPWARD
FLOW. The strainer must be accessible for periodic removal of accumulated debris from its screen.
Figure 1.2 Connecting Strainer/Elbow
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Installation
1-5
Supply Loop Liquid Quality, Maintenance, and Precautions
!
ATTENTION: The single walled heat exchanger is not suitable for use in a potable water system. Do not connect the supply return to a potable water system.
The supply loop liquid quality is not expected to be as clean as the drive loop liquid. Clean water will prolong the time needed between cleanings and/or replacement of the plate heat exchanger. A strainer with screen element is provided on the input of the supply loop. This screen element is a 20 Mesh, meaning it has 0.5 mm (0.020 in.) openings. When using a natural or municipal source of water for the supply loop, sediments could clog the strainer and openings between the exchanger plates causing the heat transfer between the drive and supply loop to degrade over time. Scheduled yearly maintenance to check, clean or replace the strainer element is recommended.
Additional supply liquid filtering may be required if water quality is poor and supply loop fouling causes drive faults due to overheating. For
instructions to drain the supply loop for maintenance, see Draining Supply
Side Cooling Loop for Periodic Maintenance on page 2-4
.
Pre-Connection Pipe Flushing
All piping to the drive or supply loop made by the user must be flushed to remove debris before being connected to the heat exchanger.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-6
Installation
Connecting Hoses to the
Heat Exchanger
Drive Loop (from Heat Exchanger to Drive)
Depending on the location of the heat exchanger relative to the drive, the following drive cooling loop hose kits are available:
Table 1.C Drive Cooling Loop Hose Kits
Used With
Frame 2 and
13 kW heat exchanger
Frame 2 and
13 kW heat exchanger
Frame 3A and
13 kW heat exchanger
Frame 3A and
13 kW heat exchanger
Frame 3B and
24 kW heat exchanger
Frame 3B and
24 kW heat exchanger
Hose Kit
Catalog Number
20L-GH10-B1
20L-GH30-B1
20L-GH10-A2
20L-GH30-A2
20L-GH10-A1
20L-GH30-A1
Hose
Length
3 m
(10 ft.)
9.1 m
(30 ft.)
3 m
(10 ft.)
9.1 m
(30 ft.)
3 m
(10 ft.)
9.1 m
(30 ft.)
(1)
All drive side hose kit fittings are 37 degree flare.
Hoses in Kit
Drive Side
(1)
Coupling Size
2 0.75 inch
2
2
2
2
2
0.75 inch
1 inch
1 inch
1 inch
1 inch
Heat Exchanger Side
Coupling Size
0.75 inch
0.75 inch
1 inch with 90° elbow
1 inch with 90° elbow
1 inch
1 inch
Alternately, the following parts can be obtained from an appropriate supplier to fabricate specific length hoses which must not exceed 9.1 m (30 ft.).
• 1-inch inside diameter hose Parker Hannifin p/n 801-16
• 1-inch swivel hose fitting female JIC (Joint Industrial Council) 37°
Parker Hannifin p/n 30682-16-16B
• 3/4-inch inside diameter hose Parker Hannifin p/n 801-12
• 3/4-inch swivel hose fitting female JIC (Joint Industrial Council) 37°
Parker Hannifin p/n 30682-12-12B
• 1-inch elbow Parker Hannifin p/n 16 CTX-B
!
ATTENTION: Risk of equipment damage exists. Hose fittings must be brass or stainless steel. Use of plated steel fittings is prohibited.
To attach a coupling to a hose, lubricate the inside of the hose end with a small amount of liquid soap. Set the coupling down on a solid surface and push the hose onto the coupling — in one firm push — until the hose end is flush against the plastic bushing on the coupling. Stopping before the hose is fully on may make it difficult to push the hose completely onto the coupling.
Connect the two drive cooling loop hoses from the heat exchanger to the drive. Mating hose connections for the drive loop are shown in Figure 1.3
and Figure 1.4
. The mating process includes the following steps:
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1. Assemble the mating version of the fitting (with swivel nut) to each drive fluid fitting, and tighten to wrench resistance or 3.3 N-m (30 lb.-in.).
Installation
1-7
2. Using a backup wrench on the drive loop or drive fitting, tighten the swivel nut fitting by either of the following two methods:
– Hex flats from wrench resistance method (recommended): one (1) hex flat from wrench resistance.
– Torque method: 103 to 109 N-m (or 76 to 81 lb.-ft.).
Figure 1.3 Connecting Drive Side Hose
DRIVE SIDE
(INLET or OUTLET)
Backup Wrench
(use to prevent twisting during swivel nut tightening)
1-5/8" Wrench Flats
Do not use
Backup Wrench on fitting locknut
37˚ Flare Fitting
Swivel Nut
1-1/2" Wrench Flats
Hose
Figure 1.4 Connecting Heat Exchanger Side Hose
HEAT EXCHANGER SIDE
(INLET or OUTLET)
37° Flare Fitting
Backup Wrench
(use to prevent twisting during swivel nut tightening)
Swivel Nut
Hose NOTE: If connecting heat exchanger p/n 20L-LL13K-P75 to a Frame 3A drive, you must remove the 3/4-inch elbow and replace it with the 1-inch
TO HEAT EXCHANGER
1-3/8" Wrench Flats
1-1/2" Wrench Flats
Supply Loop (from Heat Exchanger to Cooling Liquid Source)
The use and choice of connections for the supply loop is the user’s responsibility. However, brass or stainless steel fittings must be used to prevent corrosion on the inside of the heat exchanger. The pipe connections for the supply loop are 1-inch NPT. Note that the heat exchanger has a
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-8
Installation pressure drop of 5.00 to 6.00 PSI on the supply side, and flow must be provided per Table 1.D
.
Table 1.D Supply Loop Minimum Flow Rates
Heat Exchanger
20L-LL13K-P75A
20L-LL13K-P75A
20L-LL24K-1P0A
Drive Size
Frame 2
Frame 3A
Frame 3B
Minimum Supply Loop
Flow Rate
15.1 LPM (4 GPM)
22.7 LPM (6 GPM)
56.8 LPM (15 GPM)
Connect the two supply loop hoses from the heat exchanger to the supply source.
Removing Top and Side
Panels
Captive Hardware
(6 Places)
The top panel and side panels ( Figure 1.5
) can be removed from the heat exchanger to access internal components. To do so, proceed in this order:
1. Remove the fill tube cap from the top of the tank.
2. Remove the top panel by loosening four captive hardware screws.
3. Remove each side panel by unfastening/removing two sheet metal screws and loosening one captive hardware screw. Then use the flush handle to lift the side panel up and out.
Figure 1.5 Top and Side Panel Removal
Top Panel
FILL TUBE WARNING:
Fill with approved fluid or equipment damage may result.
See Instruction Manual.
Dimensions are in millimeters and (inches).
Sheet Metal Screw
(4 places)
Flush Handle
(2 places)
See DETAIL A
Shipping/Field Installation
Mounting Angle (4 places)
M10 x 1.5 Nut
M10 Lock Washer
M10 Flat Washer
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
DETAIL A
M10 Flat Washer
M10 x 1.5 x 35
Hexagonal Head Screw
Side Panel
(2 places)
25.4
(1.0)
50.8
(2.0)
22.2
(0.88)
44.5
(1.75)
22.2
(0.88)
22.2 x 12.7
(0.875 x 0.5) Slot
22.2 x 12.7
(0.875 x 0.5) Slot
47.6
(1.88)
76.2
(3.0)
AC Supply Source
Considerations
Installation
1-9
PowerFlex 700L Liquid-to-Liquid Heat Exchangers are suitable for use on a circuit capable of delivering up to a maximum of 5,000 rms symmetrical amperes or used on a circuit in conjunction with the appropriate current limiting devices.
Fuses and Circuit Breakers
Installation wiring requires the addition of circuit protection and disconnects as required by code.
• Recommended Fuse Types: UL Class J, CC, T or Type BS88
• Recommended Circuit Breakers: Inverse time or instantaneous trip circuit breakers or equivalent
Maximum Operating Input Amps
115 VAC, 1 Phase, 15.8 amps
230 VAC, 1 Phase, 8.4 amps
Minimum Recommended
Protection Rating (See Nameplate)
20 amps
12 amps
Input Power Conditioning
Certain events on the power system supplying the heat exchanger can cause component damage or shortened product life. They are:
• The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company.
• The power source has intermittent voltage spikes in excess of 6000 volts.
These spikes could be caused by other equipment on the line or by events such as lightning strikes.
• The power source has frequent interruptions.
General Grounding Requirements
The heat exchanger Safety Ground - PE must be connected to system
ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.
The Safety Ground - PE is the safety ground for the heat exchanger that is required by code. This point must be connected to adjacent building steel
(girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.
Wiring the Heat Exchanger
To access terminals for electrical connections, open the electrical box door by using a flat blade screwdriver to turn its locking mechanism counterclockwise one-quarter turn.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-10
Installation
Power Wiring
Connect line power to the power terminal block’s L1, N, and PE terminals
( Figure 1.6
). Refer to Table 1.E
for power terminal specifications.
Important: The heat exchanger is configured and shipped for 120 VAC operation. However, its configuration can be changed to
operate on 230 VAC. For details, see Configuring for 230 VAC
Name
Table 1.E Power Terminal Specifications
Wire Size Range
(1)
Description
Input Power Terminals —
PE, N, and L1
Input AC line power
Maximum Minimum
3.3 mm
2
(#12 AWG)
0.05 mm
2
(#30 AWG)
(1)
Maximum/minimum sizes that the terminals will accept - these are not recommendations.
Recommended
Tightening
Torque (+10%)
Wire Strip
Length
N/A
(Spring-Loaded)
10 mm
(0.4 in.)
Figure 1.6 Power Terminal Block Electrical Connections
Wire #3
(115 VAC Line
Power Connection)
Wire #3
(230 VAC Line
Power Connection)
Configuring for 230 VAC Operation
1. Open the cover of the electrical box ( Figure 1.1
) and set the J2 jumper on the control board ( Figure 1.7
) to the 230 VAC position (terminals 1-7).
2. On the power terminal block ( Figure 1.6
), disconnect wire #3 from terminal H2 and reconnect it to terminal H4 for 230 VAC operation.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
3. Remove the heat exchanger’s top panel first and then its left side panel to access the pump motor conduit box. Remove the conduit box cover and change the motor winding connections for 230 VAC operation as shown in
.
Installation
1-11
Figure 1.7 Control Board Component Locations
1
J2
11 10 9 8 7 6 5 4 3 2 1
J1
230 VAC
Operation
Plug Position
7
8
9
5
6
1
2
3
4
POWER Indicator
STATUS Indicator
9
J3
S1
S2
S1
8 7 6 5 4 3 2 1
N O
FU1
115 VAC
Operation
Plug Position
7
8
9
3
4
5
6
1
2
J4
8
J6
1 10
J7
1
J5
5
NOTE: Terminal blocks J3, J4, J5, J6, J7, and J8 do
not require electrical connections by the user.
J8
1
Figure 1.8 Motor Winding Connections for 230 VAC Operation
S2
8 7 6 5 4 3 2 1
1 = ON = Down
N O
MOTOR CONNECTIONS
115 VAC Operation 230 VAC Operation
Blue
Brown
L1 (Black)
Insulate
Blue
Brown
Orange
L1 (Black)
Insulate
Insulate
Orange
White
N (White)
White
Yellow
N (White)
Yellow
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-12
Installation
Control Wiring
Connect “run” and “interlock” control wiring from the PowerFlex 700L
drive to the J1 connector on the control board. Refer to Table 1.F
terminal specifications.
Name
Table 1.F Control Board Terminal Specifications
Coolant Controller Control
Wiring Terminal Block — J1
Wire Size Range
(1)
Description
Control wiring for run, fault and alarm (optional), and interlock
Maximum Minimum
3.3 mm
2
(#12 AWG)
0.2 mm
2
(#24 AWG)
(1)
Maximum/minimum sizes that the terminals will accept - these are not recommendations.
Recommended
Tightening
Torque (+10%)
Wire Strip
Length
0.55 N-m
(5 lb.-in.)
7 mm
(0.3 in.)
Run Wiring
The run output signal from the PowerFlex 700L drive must be connected to the heat exchanger control board (
automatically starts when the drive is started.
The heat exchanger J1 connector provides fault and alarm contact outputs to monitor the operating state of the heat exchanger if desired.
Figure 1.9 Control Run Wiring
120 VAC
Frame
3A/3B
Drive
To Converter TB5-1
To Converter TB5-3
Run
Neutral
Frame 2
Drive
To TB1 (1b-5)
To TB1 (1b-6)
+12 VDC
12V Common
PRIME SWITCH
(on electrical box cover)
Com
N.C.
Fault Contact
(30 VDC @
10A Max.)
Com
Alarm Contact
N.O.
(30 VDC @
10A Max.)
11 10 9 8 7 6 5 4 3 2 1
J1
9
1
J2
FU1
J5
1 5
Heat Exchanger
Control Board
11 10 9 8 7 6 5 4 3 2 1
J1
J3
S1
S2
J4
J6
1 10
J7 J8
1 8
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Installation
1-13
Control Interlock Wiring
The interlock contact output on the heat exchanger control board can be interlocked ( Figure 1.10
) with the PowerFlex 700L drive to
prevent the drive from running when the heat exchanger is in a faulted state.
Figure 1.10 Control Interlock Wiring for Drive with PowerFlex 700 Vector Control
2-Wire Control
Non-Reversing
24V DC Internal Supply
Required PowerFlex 700 Vector
Control Parameter Changes:
P190 - [Direction Mode] = “0” (Unipolar)
P361 - [Digital In1 Sel] = “0” (Not Used)
P362 - [Digital In2 Sel] = “7” (Run)
1
J2
Heat Exchanger
Control Board
11 10 9 8 7 6 5 4 3 2 1
J1
S1
S2
J3
9
FU1
J5
1
J6
1 5
J4
10
J7 J8
1 8
3-Wire Control Internal Supply
Required PowerFlex 700 Vector
Control Parameter Changes: None
PowerFlex 700 Vector Control
Cassette I/O Terminal Block
24
25
26
27
28
Run
Heat Exchanger
Interlock Contact
(30 VDC @ 10A Max.)
11 10 9 8 7 6 5 4 3 2 1
J1
PowerFlex 700 Vector Control
Cassette I/O Terminal Block
24
25
26
27
28
Stop
Start
11 10 9 8 7 6 5 4 3 2 1
Heat Exchanger
Interlock Contact
(30 VDC @ 10A Max.)
J1
Figure 1.11 Control Interlock Wiring for Drive with PowerFlex 700S Phase II Control
1
J2
2-Wire Control
24V DC Internal Supply
Control Parameter Changes:
P829 - [Dig In5 Sel] = “7” (Run)
Required PowerFlex 700S Ph. II
11 10 9 8 7 6 5 4 3 2 1
J1
Heat Exchanger
Control Board
9
J3
S1
S2
J4
FU1
J5
1 5
J6
1 10
J7 J8
1 8
3-Wire Control Internal Supply
Required PowerFlex 700S Ph. II
Control Parameter Changes:
P828 - [Dig In4 Sel] = “5” (Start)
P829 - [Dig In5 Sel] = “14” (Normal Stop)
1
2
3
PowerFlex 700S Ph. II
Control Cassette TB2
13
14
15
16
9
10
11
12
Run
1
2
3
PowerFlex 700S Ph. II
Control Cassette TB2
13
14
15
16
9
10
11
12
Stop
Start
Heat Exchanger
Interlock Contact
(30 VDC @ 10A Max.)
11 10 9 8 7 6 5 4 3 2 1
J1
Heat Exchanger
Interlock Contact
(30 VDC @ 10A Max.)
11 10 9 8 7 6 5 4 3 2 1
J1
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-14
Installation
Setting the DIP Switches
Two 8-position DIP switches (S1 and S2 in Figure 1.7
) set the various operating functions for the coolant controller. The DIP switch settings may be changed at any time while power is applied. A “1” indicates the switch is in the ON (down) position.
S1 DIP Switch Settings
See the descriptions below and Table 1.G
for S1 switch settings:
• SW1, SW2, and SW3 (Temperature Setpoint) — Sets the temperature at which the drive loop coolant is maintained by the heat exchanger. The setpoint can be based on ambient temperature or the alarm temperature.
For example, when set to T ambient
+ 3°C, the heat exchanger will attempt to maintain the drive loop coolant at a temperature 3°C above ambient. When set to T alarm
- 5°C, the heat exchanger will attempt to maintain the drive loop coolant at a temperature 5°C below the alarm temperature which is set by SW6 and SW7.
• SW4 and SW5 (Mode) — Sets the mode of operation for the heat exchanger. The mode must be set to “1” (Motor Operated Valve) for the liquid-to-liquid heat exchanger to operate correctly. In mode “0” (on/ off), the run digital input turns the heat exchanger pump on or off.
Modes “2” (2-level) and “3” (3-level) can be used to turn on 2 and 3 solenoids, respectively — and are intended for use with a liquid-to-air heat exchanger to control the number of fans that are running.
• SW6 and SW7 (Temperature Alarm) — Sets the alarm temperature for drive loop coolant. When the alarm temperature is reached, the status
LED will flash amber. When the drive loop coolant drops to 2°C below the alarm temperature, the alarm will automatically reset.
!
ATTENTION: Since the heat exchanger pump continues to run during an alarm, it is the user’s responsibility to analyze the alarm condition and take appropriate action.
Table 1.G S1 DIP Switch Settings
Function
Temperature Setpoint: T ambient
(default)
T ambient
+3°C
T ambient
+6°C
T ambient
+10°C
T alarm
-5°C
Mode: 0 (on/off)
1 (Motor Operated Valve - default)
(1)
2 (2-level)
3 (3-level)
Temperature Alarm: 45°C (default)
55°C
SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1
— — — — 0 0 0
— — — — 0 0 1
— — — — 0 1 0
— — — — 0 1 1
— — — — 1 0 0
— — 0 0 — — —
— — 0 1 — — —
— — 1 0 — — —
— — 1 1 — — —
0 0 — — — — —
0 1 — — — — —
65°C
75°C
1 0 — — — — —
1 1 — — — — —
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
(1)
Mode switches SW4 and SW5 must be set to mode “1” (Motor Operated Valve) for correct operation of the liquid-to-liquid heat exchanger.
Installation
1-15
S2 DIP Switch Settings
See the descriptions below and Table 1.H
for S2 switch settings:
• SW1 (Start Input) — Sets the type of start for the heat exchanger. An edge-triggered (default) start requires a low-to-high transition of the run signal to start the heat exchanger. Since the drive will send the run signal, the edge-triggered start should be used. A level start will cause the heat exchanger to run when the run signal is present and could be used to start the heat exchanger automatically on power up.
• SW2 (Cool Down) – Enables/disables a cool down feature to compensate for thermal soaking following a stop command. When cool down is enabled (default), the heat exchanger will continue to operate for an additional 2 minutes following a stop command, decreasing the coolant temperature. During the cool down period, the STS (Status) indicator will rapidly flash green. When the cool down period has expired, the STS (Status) indicator will return to a slower green flash rate to indicate the heat exchanger is ready to run. The heat exchanger can be restarted at any time during the cool down period at which time the STS
(Status) indicator will become steady green. The cool down period is ignored when a fault occurs and the heat exchanger goes directly to the stopped state.
• SW3 (Ambient Sensor) — Selects the external or on-board ambient temperature sensor. The external temperature sensor is located on the bottom/inside of the heat exchanger cabinet. The external (default) setting should be used with the liquid-to-liquid heat exchanger. The on-board temperature sensor is mounted on the controller board.
• SW4 (Low Temperature Alarm) — Enables/disables the low temperature alarm that detects when the ambient temperature or drive loop coolant temperature is less than or equal to 2°C.
• SW8 (Monitor Type) — Not to be set by the user. Reserved for internal
Rockwell Automation, Inc. use only. This switch setting will not affect the heat exchanger operation.
Table 1.H S2 DIP Switch Settings
Function
Start Input: edge-triggered (default) level (may start on power up)
Cool Down: disabled enabled (default)
Ambient Sensor: external (default) on-board
Low Temperature Alarm: disabled (default) enabled
Monitor Type (temporary): ANSI terminal (default)
LCD module
—
—
—
0
1
SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1
— — — — 0
—
—
—
—
—
—
—
—
—
—
—
0
—
0
1
—
1
—
—
—
— 1 — —
0 — — —
1 — — —
— — — —
— — — —
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
1-16
Installation
CE Conformity
Compliance with the Low Voltage (LV) Directive and Electromagnetic
Compatibility Directive (EMC) has been demonstrated using harmonized
European Norm (EN) standards published in the Official Journal of the
European Communities. PowerFlex 700L Liquid-to-Liquid Heat Exchangers comply with the EN standards listed below when installed according to this
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual.
CE Declarations of Conformity are available online at: http://www.ab.com/certification/ce/docs
Low Voltage Directive (73/23/EEC)
• EN 60204-1 Safety of Machinery – Electrical equipment of machines –
Part 1: General requirements
EMC Directive (89/336/EEC)
• EN 61000-6-2 Electromagnetic Compatibility (EMC) – Generic standards– Immunity for industrial environments
• EN 61000-6-4 Electromagnetic Compatibility (EMC) – Generic standards – Emission standard of industrial environments
Pressure Equipment Directive (97/23/EC)
• The PowerFlex 700L Liquid-to-Liquid Heat Exchanger falls below the limits for applicability of this directive. Good engineering practice has been used in the design and manufacturing.
Essential Requirements for CE Compliance
Conditions 1 and 2 listed below must be satisfied for PowerFlex 700L
Liquid-to-Liquid Heat Exchangers to meet the requirements of EN 60204-1 and EN 61000-6-4:
1. Review important precautions/attention statements throughout this manual before installing the heat exchanger.
2. System earthing (grounding) as described on page 1-9
.
C-Tick Conformity
Compliance of PowerFlex 700L Liquid-to-Liquid Heat Exchangers with the
Australian Radiocommunications Act of 1992 has been demonstrated through compliance with IEC 61000-6-4. The Essential Requirements for
CE Compliance provided above apply to C-Tick compliance for PowerFlex
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
700L Liquid-to-Liquid Heat Exchangers.
C-Tick Declarations of Conformity are available online at: http://www.ab.com/certification/c-tick/index.html
Chapter
2
Operation
Drive Interaction
This chapter provides information on operating the PowerFlex 700L
Liquid-to-Liquid Heat Exchanger.
For information on…
See page…
Adding Coolant to the Drive Loop for Start-Up 2-3
Draining Coolant from the Drive Loop for Periodic Replacement 2-5
Draining Supply Side Cooling Loop for Periodic Maintenance 2-4
Normal Operation
Communications between the drive and the heat exchanger consist of a run output signal from the drive and an interlock output to the drive. The heat exchanger’s run input is controlled by a normally-open relay output from the drive. The heat exchanger interlock relay is de-energized when a fault occurs or power is not present.
The STATUS indicator flashes (slow) green when the heat exchanger is ready to operate and its interlock relay is energized.
Immediately following a valid start sequence in the drive, the drive’s run contact closes, signaling the coolant controller to begin operating the heat exchanger. The coolant pump starts, the STATUS indicator changes to steady green, and coolant flow is monitored.
When the drive is stopped, the heat exchanger continues to run for approximately 2 minutes and the STATUS indicator flashes (fast) green to indicate that the heat exchanger is in a cool down period.
Loss of Flow Operation
If the flow sensor fails to detect flow for more than 10 seconds, the STATUS indicator flashes red to indicate a fault and the pump stops. The interlock relay and STATUS indicator remain in this state until the run output signal from the drive is turned off. Thereafter, the STATUS indicator flashes red at a slower rate to indicate the heat exchanger experienced a loss of flow but is now ready to operate.
Asserting the run input after correcting a heat exchanger fault restarts the heat exchanger and the STATUS indicator changes to steady green.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
2-2
Operation
PRIME SWITCH Operation
) will start the pump independently from the run state of the heat exchanger.
Operating Status
Indications
The STATUS indicator ( Figure 2.1
) shows the operating status of the heat exchanger. Table 2.A
lists its possible indications.
Table 2.A Heat Exchanger Operating Status Indications (STATUS Indicator)
LED Indication Description
Red Steady Internal fault that is non-resettable
(state = internal fault).
Flashing
Fast
Action
Cycle power to the heat exchanger.
No flow for greater than 10 seconds, and the run input is active (state = stopped/ fault). The heat exchanger is not ready to run.
Replace the controller board.
Correct the heat exchanger supply loop fault, and verify that the drive is properly operating.
Flashing
Slow
No flow for greater than 10 seconds during the previous run cycle, and the run input is now inactive (state = faulted). The heat exchanger is ready to run.
Amber Steady A temperature sensor fault has been detected.
Restart the drive.
Verify that sensor wires are securely connected and not damaged.
Replace the sensor if necessary.
Flashing A temperature alarm has occurred.
Causes for the alarm can be:
• Low drive loop coolant level.
Add coolant to the fill line.
• Ambient temperature is greater than or equal to the alarm temperature set by
S1 DIP switches SW6 and SW7.
• Drive loop coolant temperature is greater than or equal to the alarm temperature set by S1 DIP switches
SW6 and SW7.
• Ambient temperature is less than or equal to 2°C (S2 DIP switch SW3 set to enabled).
• Drive loop coolant temperature is less than or equal to 2°C (S2 DIP switch
SW3 set to enabled).
Green Steady The heat exchanger is running, and no faults or alarms are present
(state = running).
Check for drive loop leaks. Replace the hose and/or connector if necessary.
Increase the alarm temperature setting or decrease the ambient temperature.
Increase the alarm temperature setting.
Increase the ambient temperature or disable the low temperature alarm.
Increase the ambient temperature or disable the low temperature alarm.
No action required.
Flashing
Slow
Flashing
Fast
The heat exchanger is ready to run
(state = ready).
The heat exchanger is in a cool down period following a stop command.
No action required.
No action required.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Operation
2-3
Adding Coolant to the Drive
Loop for Start-Up
1. Make sure all hose connections are completed as described in Drive
Loop (from Heat Exchanger to Drive) on page 1-6
.
2. With the top and side covers removed from the heat exchanger, make sure all wiring to the heat exchanger is completed as described in
, respectively.
3. Make sure both pipe plugs are tightened on the drains in front of the heat exchanger.
4. Remove the fill tube cap from the top of the tank.
5. Fill the heat exchanger until the sight glass reaches the fill line with approved coolant (see
Drive Coolant Requirements on page 1-3 ).
Figure 2.1 Fill Line, PRIME SWITCH, and Indicators
FLUID
LEVEL
PRIME
SWITCH
STATUS
Indicator
POWER
Indicator
!
DRIVE
DRAIN
SUPPLY
DRAIN
6. Loosely install the fill tube cap back on the tank to allow air to escape the system while priming. Use caution as some coolant may splash out of the tank.
ATTENTION: In Step 8 the fluid level in the tank will decrease rapidly. It is important to not let the tank empty. Running the heat exchanger without enough coolant may damage the unit and void the warranty.
7. While viewing the fluid level gauge on the front of the heat exchanger,
turn on the PRIME SWITCH (see Figure 2.1
). Fluid level will decrease rapidly. When the tank level lowers to about ¼ full, turn off the PRIME
SWITCH.
8. Repeat steps 5 through 8 until the tank remains at the fill line. (The drive loop system typically holds up to 5 gallons, depending on length of hoses.) If the tank is not filled to the fill line, an alarm may occur — indicated by a flashing amber STATUS indicator (
).
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
2-4
Operation
9. Entrapped air must be removed for the heat exchanger to function properly. Remove the fill tube cap and depress the PRIME SWITCH for
2-3 minutes.
10. Replace and tighten the fill tube cap on the tank.
11. Reinstall the top and side covers on the heat exchanger. The recommended tightening torque is 0.9 N-m (8 in-lbs.).
Draining Supply Side
Cooling Loop for Periodic
Maintenance
!
ATTENTION: Risk of equipment damage exists. It is recommended to drain the supply side before draining the drive side to avoid any possible damage to the pump.
1. Shut off flow to the “IN FROM SUPPLY” connection of the cooling loop.
2. Place a 5 gallon container under the pipe marked “SUPPLY DRAIN”
on the front of the heat exchanger ( Figure 2.1
).
3. Use a 9/16 inch or adjustable wrench to remove the plug from the
“SUPPLY DRAIN” pipe. (There is no need to use a backup wrench on the pipe nipple.)
4. Allow the fluid to drain.
5. After flow stops, push the PRIME SWITCH for 8 seconds to open the motorized valve (see Figure 2.2
).
!
ATTENTION: Risk of equipment damage exists. Pressing the
PRIME SWITCH longer than 20 seconds may damage the pump if the drive loop is already drained.
Figure 2.2 Supply Loop Motorized Valve Open Indication
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
6. Disconnect the hoses on the rear of the heat exchanger marked “IN
FROM SUPPLY” and “RETURN TO SUPPLY” using the tools and
Operation
2-5
7. After flow stops, push the PRIME SWITCH for 8 seconds to open the motorized valve (see Figure 2.2
).
Draining Coolant from the
Drive Loop for Periodic
Replacement
!
ATTENTION: Risk of equipment damage exists. Pressing the
PRIME SWITCH longer than 20 seconds may damage the pump if the drive loop is already drained.
8. Clean off any old thread sealer from inside the pipe located on the heat exchanger and the removed plug.
9. Apply PTFE (Teflon
®
) thread sealing tape or pipe thread sealant compound to threads on the plug.
10. Use a 9/16 inch or adjustable wrench to reinstall the plug to the
“SUPPLY DRAIN” pipe on the front of the heat exchanger. (There is no need to use a backup wrench on the pipe nipple.)
11. Tighten the connections on the rear of the heat exchanger marked “IN
FROM SUPPLY” and “RETURN TO SUPPLY” using the tools and
method outlined in Connecting Hoses to the Heat Exchanger on page 1-6 .
12. Turn on flow to “IN FROM SUPPLY” connection.
13. Dispose used fluid according to local, state, and federal regulations.
!
ATTENTION: Risk of equipment damage exists. It is recommended to drain the supply side before draining the drive side to avoid any possible damage to the pump.
1. Disconnect power from the heat exchanger.
2. Remove the fill tube cap from the top of the tank.
3. Place a 5 gallon container under the pipe marked “DRIVE DRAIN” on the front of the heat exchanger (
).
4. Use a 9/16 inch or adjustable wrench to remove the plug from the
“DRIVE DRAIN” pipe. (There is no need to use a backup wrench on the pipe nipple.)
5. Allow the coolant to drain.
6. After flow stops, disconnect the hoses on the rear of the heat exchanger marked “TO DRIVE INLET” and “FROM DRIVE OUTLET” using the
tools and method outlined in Connecting Hoses to the Heat
Exchanger on page 1-6 . Place the ends of the hoses in a container to
drain.
7. Clean off any old thread sealer from inside the pipe located on the heat exchanger and the removed plug.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
2-6
Operation
8. Apply PTFE (Teflon
®
) thread sealing tape or pipe thread sealant compound to threads on the plug.
9. Use a 9/16 inch or adjustable wrench to reinstall the plug to the
“DRIVE DRAIN” pipe on the front of the heat exchanger. (There is no need to use a backup wrench on the pipe nipple.)
10. Reconnect the hoses on the rear of the heat exchanger marked “TO
DRIVE INLET” and “FROM DRIVE OUTLET” using the tools and
method outlined in Connecting Hoses to the Heat Exchanger on page 1-6 .
11. Reconnect power to the heat exchanger.
13. Replace and tighten the fill tube cap on the top of the tank.
14. Dispose used fluid according to local, state, and federal regulations.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Appendix
A
Supplemental Heat Exchanger Information
Specifications
Category
Environment
Drive Loop
Supply Loop
Specification
Used with PowerFlex 700L:
Agency
Certification c
®
U
L
US
Electrical Input
Heat Exchanger Catalog Number
20L-LL13K-P75A
Frame 2
20L-LL13K-P75A
Frame 3A
20L-LL24K-1P0A
Frame 3B
Listed to UL1995, UL778, CAN/CSA-C22.2 No. 236, and CAN/
CSA-C22.2 No. 108-01.
Ambient Temperature:
Storage Temperature:
Atmosphere:
Marked for all applicable European Directives
EMC Directive (89/336/EEC)
EN 61000-6-2 Generic standards - Immunity for industrial environments
EN 61000-6-4 Generic standards - Emission standard for industrial environments
Low Voltage Directive (73/23/EEC)
EN 60204-1 Safety of Machinery - Electrical equipment of machines
- Part 1: General requirements
EN 61800-5-1:2007 Adjustable speed drives - Safety requirements: clauses 4.4.5, 5.2.7
0 to 50°C (32 to 122°F) 0 to 40°C (32 to 104°F) 0 to 40°C (32 to 104°F)
-40 to 85°C (-40 to 185°F)
Important: Heat exchanger must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the heat exchanger is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.
5-95% non-condensing
10G peak for 11 ms duration (±1.0 ms)
0.152 mm (0.006 in.) displacement, 1G peak, 5.5 Hz.
115/230/230 VAC ±10%, 1 Phase
Relative Humidity:
Shock:
Vibration:
Input VAC:
Pump HP:
Frequency:
Maximum Input Amps:
Short Circuit Rating:
1.0/1.0/1.0
60/60/50 Hz
15.8/8.2/8.4 Amps
5,000 Amps
Heat Dissipation:
Flow @ Pressure:
13,000 Watts
30.3 LPM at 1.58 bar
(8 GPM at 23 PSI)
0-50°C (32-122°F) Temperature Range:
Minimum Flow @ Pressure: 15.1 LPM at 0.83 bar
(4 GPM at 12 PSI)
Maximum Pressure:
Temperature Range:
8.62 bar (125 PSI)
0-40°C (32-104°F)
13,000 Watts
30.3 LPM at 1.58 bar
(8 GPM at 23 PSI)
0-40°C (32-104°F)
22.7 LPM at 0.83 bar
(6 GPM at 12 PSI)
8.62 bar (125 PSI)
0-35°C (32-95°F)
24,000 Watts
56.8 LPM at 2.07 bar
(15 GPM at 30 PSI)
0-40°C (32-104°F)
56.8 LPM at 0.83 bar
(15 GPM at 12 PSI)
8.62 bar (125 PSI)
0-35°C (32-95°F)
Control Board Replacement
Fusing
The control board replacement fusing is 0.5A Time Delay MDL.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
A-2
Supplemental Heat Exchanger Information
Notes:
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
Appendix
B
Heat Exchanger Schematic
Please refer to pages B-2 and B-3 for the schematic of the PowerFlex 700L
Liquid-to-Liquid Heat Exchanger.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
B-2
Heat Exchanger Schematic
External
Power Connections
AC POWER
Field Installation
GND
NEUTRAL
HOT
PANEL GND
To GND
Term Block
12 AWG Green/Yellow
Term
Block
PE
Term
Block
L1
Term Block N
109CON
L1 T1
FRAME GND
GND
N
1L1
12 AWG Green/Yellow
12 AWG White
12 AWG Black
GND
N
1L1
12 AWG Green/Yellow
12 AWG White
12 AWG Black
Transformer Input Wiring
Voltage Primary
120 VAC H1, H2
230 VAC H1, H4
1
Orange
16 AWG Red
X1
Term Block
H4
GND
N
L1
12 AWG Green/Yellow
12 AWG White
12 AWG Black
107CON
2
16 AWG Red
X2
Brown
109T
40VA
Yellow
Red
H3
Black
White
Term Block
H2
Term Block
H1
4 16 AWG White
(Maximum)
120 VAC
16A
111MV
Valve Motor
Flow Switch
113FLS
+
-
12 VDC
COM (Red)
NC (Blue)
NO (Yellow)
5+
6-
16 AWG White
16 AWG Green
0.25A @120 VAC
30VA
(Maximum)
Level Switch
114FS
Ambient Temperature
115NTC
COM
NO
7 16 AWG Black
8
Term Block
GND
16 AWG Black
To PE Term Block
9
10
16 AWG Black
16 AWG Black
11
12
GND
24 AWG White
24 AWG White
3 16 AWG Black
13
14
24 AWG White
24 AWG White
Water Temperature
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
116NTC
Heat Exchanger Schematic
B-3
NOTE: Default factory wiring is for operation at 115VAC, 60Hz.
Pump Wiring 115V
GND
Brown
Orange
Yellow
White
Blue
Pump Wiring 230V
GND
White
Orange
Brown
Yellow
Blue
Motor:
Emerson SFE06821S
60Hz 50Hz
1.0 HP 1.0
3450 RPM 2850
115/208-230 Volts 220-230
12.2 / 6.4-6.1 FLA 7.3-7.7
Pump:
Goulds Pump, ITT
Series MCS Size 1x 1 1/4-6
Cat. No. 1MS1E4D4 Impeller Dia. 4-3/4
See
for 115 or 230 VAC operation
J2 jumper settings.
0.5A 250V
Type 3AG Fuse
J2
7
8
5
6
9
10
1
2
3
4
1
2
3
4
1
2
5
J5
J6
J7
5
6
7
8
3
4
1
2
J8
F1
S2 S1
J3
181052-A01
Cooling Loop
Control Board
STATUS
POWER
J1
3
2
5
4
1
11
10
9
8
7
6
Field Installation
Remote Start Contact
Low Voltage
(Supplied by Frame 2 Drive)
Field Installation
Remote Start Contact
High Voltage
(Supplied by Frame 3A or 3B Drive)
15
16
17
18
19
20
21
22
23
24
25
16 AWG Red
112PB
Prime Switch
16 AWG
16 AWG Red
16 AWG
16 AWG
16 AWG COM
16 AWG N.C.
16 AWG
16 AWG
16 AWG
16 AWG
COM
N.O.
COM
N.O.
Fault Contact
Interlock Contact
Alarm Contact
Field Installation
(Supplied by Drive)
See
S1 and S2 switch settings.
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
B-4
Heat Exchanger Schematic
Notes:
PowerFlex 700L Liquid-to-Liquid Heat Exchanger User Manual
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters
Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Publication 20L-UM002A-EN-P – May, 2007
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. Printed in USA.
351605-P01

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Liquid-to-liquid heat transfer
- Compact design
- Suitable for PowerFlex 700L drives
- Adjustable flow control
- Integrated strainer
- Multiple hose connection options
- CE and C-Tick compliant
- User-replaceable components