Cooling Loop Installation. Allen-Bradley PowerFlex 700L
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Chapter
4
Cooling Loop Installation
Proper liquid cooling is critical to drive operation and reliability. This chapter provides information about the types of drive cooling loops, drive coolant requirements, and cooling loop connections for the PowerFlex 700L
Liquid-Cooled drive power structure.
Topic
Explanation of Cooling Loop Types
Cooling Loop Application Guidelines
Page
Explanation of Cooling
Loop Types
PowerFlex 700L
Flow
Indicator
Drive
Inlet
Drive
Outlet
Liquid-to-Liquid Heat Exchanger
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 4.1 Drive and Liquid-to-Liquid Heat Exchanger Plumbing Arrangement
Hose Kit
Liquid-to-Liquid
Heat Exchanger
From
Drive
Outlet
To
Drive
Inlet
Return
To
Supply
In
From
Supply
Customer
Supplied Piping
To Facility Water
= hose or pipe connection
Figure 4.2
shows a cooling loop diagram for a typical liquid-to-liquid heat exchanger.
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Cooling Loop Installation
Figure 4.2 Liquid-to-Liquid Heat Exchanger Plumbing Diagram
Ambient Sensor
TE
Supply
Process
Water
Drive Coolant Temp.
TE
Flow Switch
FS
Strainer
Control
Valve
IN OUT
IN
Level Switch
LS
OUT IN
Reservoir
OUT
Drive
Pump
The main components of the liquid-to-liquid heat exchanger cooling loop are listed below.
Part Description
Strainer
Control Valve
Filters particles from the supply water.
Controls the supply loop water flow.
Heat Exchanger Plate
Ambient Sensor
Drive Coolant Temperature Sensor
Drive Coolant Flow Switch
Transfers heat from the drive loop to the supply loop.
Senses the ambient temperature used for the dew point control.
Senses the drive coolant temperature used for the dew point control.
Measures the drive coolant flow rate.
Level Switch
Reservoir
Pump and Motor
Senses the level of coolant in the reservoir.
Stores drive coolant.
Circulates drive coolant.
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Liquid-to-Air Heat Exchanger
The liquid-to-air heat exchanger uses radiator technology to transfer heat from a liquid to surrounding air. This is a simple closed loop system—it does not require a water supply from the user. However, this system requires surrounding air that is 5-10 °C below the maximum operating temperature of the drive.
Figure 4.3 Drive and Liquid-to-Air Heat Exchanger Plumbing Arrangement
PowerFlex 700L
Drive
Inlet
Drive
Outlet
Hose Kit
From
Drive
Outlet
Liquid-to-Air
Heat Exchanger
To
Drive
Inlet
Radiator
Flow
Indicator
= hose or pipe connection
Figure 4.4
shows a cooling loop diagram for a typical liquid-to-air heat exchanger.
Figure 4.4 Liquid-to-Air Heat Exchanger Plumbing Diagram
Ambient
Sensor
TE
Drive Coolant Temp.
TE
Flow Switch
FS
Fan
On/Off
Control
OUT
IN
Level Switch
LS
IN
Reservoir
OUT
Drive
Pump
The main components of the liquid-to-air heat exchanger cooling loop are listed below.
Part Description
Fan Blows air across the radiator.
Radiator
Ambient Sensor
Transfers heat from liquid to air.
Senses the ambient temperature used for the dew point control.
Drive Coolant Temperature Sensor
Drive Coolant Flow Switch
Level Switch
Reservoir
Pump and Motor
Senses the drive coolant temperature used for the dew point control.
Measures the drive coolant flow rate.
Senses the level of coolant in the reservoir.
Allows for expansion of coolant.
Circulates drive coolant.
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Cooling Loop Installation
Flow
Indicator
Chiller
The chiller uses refrigerant to transfer heat from a liquid to air. This is a simple closed loop system—it does not require a water supply from the user. A chiller can achieve almost any coolant temperature required.
Coolant temperature should be at or above ambient temperature to avoid condensation on drive components.
Figure 4.5 Drive and Chiller Plumbing Arrangement
PowerFlex 700L Chiller
Drive
Inlet
Drive
Outlet
Hose Kit
From
Drive
Outlet
To
Drive
Inlet
Radiator
= hose or pipe connection
Figure 4.6
shows a cooling loop diagram for a typical chiller.
Figure 4.6 Chiller Plumbing Diagram
Condenser/Subcooler
Fan
Compressor
Thermostatic
Expansion Valve
Sight Glass
Filter-Drier
SOL
Level
Switch
LS
Reservoir
Out
Drive
In
FS
Flow
Switch
TE
Ambient
Sensor
TE
Drive Coolant
Temperature
Pump
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The main components of the chiller cooling loop are listed below.
Part Description
Compressor
Fan
Forces the refrigerant into a smaller space.
Blows air across the condenser/subcooler.
Condenser/Subcooler
Filter-Drier
Sight Glass
Thermostatic Expansion Valve
Cools the refrigerant.
Filters the refrigerant.
Allows viewing of the level of drive coolant in the reservoir.
Allows for expansion of the refrigerant.
Level Switch
Reservoir
Pump and Motor
Drive Coolant Temperature Sensor
Drive Coolant Flow Switch
Ambient Sensor
Senses the level of coolant in the reservoir.
Allows for expansion of coolant.
Circulates drive coolant.
Senses the drive coolant temperature used for the dew point control.
Measures the drive coolant flow rate.
Senses the ambient temperature used for the dew point control.
Cooling Loop Resources
Cooling loops are available from many suppliers, such as Dimplex Thermal
Solutions, which can be contacted as follows:
USA and Canada: 1-800-968-5665
Elsewhere: 1-269-349-6800
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Cooling Loop Installation
Cooling Loop Application
Guidelines
!
ATTENTION:
Risk of equipment damage exists. Do not use ferrous and plated-ferrous materials for pipe-treated water to the power modules and drive. Use of ferrous materials degrades the performance of the power module chillplate.
This section is intended to provide guidelines for applying the cooling loops.
1.
The allowable drive coolant temperature range is listed below:
•
Frame 2 Drives: 0…50 °C (32…122 °F)
•
Frame 3A and 3B Drives: 0…40 °C (32…105 °F)
When using coolant at a temperature below the dew point of the surrounding air, condensation can accumulate on the drive heatsink and/ or circuit boards, which can damage the drive. In this situation, install a coolant flow regulating device and tube/hose insulation. A flow regulating device modulates the coolant flow rate to a level that permits the drive heatsink temperature to rise above the dew point. Insulation for customer side tube or hose can be closed-cell foam insulation with a minimum 12.7 mm (0.50 in.) wall thickness.
2.
Include a flow switch in the cooling loop on the connection to the drive inlet to turn off the drive if coolant flow drops below the minimum flow required by the drive (see Table 4.C
).
3.
Circulate coolant through the drive only when the drive is also powered.
Failure to do this can result in condensation accumulating on the drive heatsink and/or circuit boards, which could damage the drive.
4.
Use an interlock from the cooling loop to stop the drive when the cooling loop is faulted.
5.
For applications requiring a closed loop coolant system, vent the system to remove air that can otherwise degrade the performance of the drive heatsink.
6.
Install a flow measuring device at the inlet of each Converter and each
Inverter Power Module. Note that flow measuring devices are included in the PF700L Frame 3A and 3B Complete Drive cabinets (13th position in catalog number = A). The coolant flow rate (GPM) must meet the requirements in Table 4.C
.
7.
We recommend the following types of pipe for cooling loop connections:
•
Copper tubing, type L
•
Brass pipe
•
Stainless steel, 300 series
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Important:
Do not use galvanized pipe.
8.
Provide a method in the cooling loop for draining and replacing the coolant.
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Drive Coolant Connections Frame 2 Drive or Frame 3A or 3B Power Module
For locations of the coolant inlet and outlet connections on PowerFlex 700L
Frame 2 drives, see Figure 2.10
. For locations on Frame 3A and 3B Power
Modules, see
The rated working pressure of the Frame 2 drive is 6.89 bar (100 psi). Size coolant supply and return lines for 76 LPM (20 gpm) / 6.89 bar (100 psi) service with a maximum operating temperature of 50 °C (122 °F). The required operating flow rate and pressure drop is specified in Table 4.C
.
The rated working pressure of the Frame 3A or 3B Power Module is 12.76 bar (185 psi). Size coolant supply and return lines for 38 LPM (10 gpm) /
12.76 bar (185 psi) service with a maximum operating temperature of 40 °C
(105 °F). The required operating flow rate and pressure drop is specified in
Table 4.C
.
Coolant connections for Frame 2 drives and Frame 3A and 3B Power
Modules are made using 37 degree flare fittings which have a:
•
3/4-inch nominal size
•
“-12” SAE dash size
•
1-1/16-12 UN/UNF-2B external thread size
The mating connection is shown in Figure 4.7
. To make the mating coolant connection, follow these steps.
1.
Assemble the mating version of the fitting (with swivel nut) to each fluid fitting, and tighten to a wrench resistance of approximately 3.4
N
• m (30 lb
• in).
2.
Using a backup wrench on the Power Module fitting, tighten the swivel nut fitting by either of the following two methods:
–
Hex flats from wrench resistance method (recommended): one and one-quarter (1-¼) hex flat from wrench resistance.
–
Torque method: 69…77 N
• m (51…57 lb
• ft).
Figure 4.7 Power Module Mating Coolant Connection
Wrench Flats
37° Flare Fitting
Backup Wrench
(use to prevent twisting during swivel nut tightening)
Swivel Nut
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Cooling Loop Installation
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Frame 3A or 3B Complete Drive
For locations of the coolant inlet and outlet connections on PowerFlex 700L
Frame 3A Complete Drives, see
locations on Frame 3B Complete Drives, see Figure 3.21
(front and side views).
The rated working pressure of the Frame 3A and 3B Complete Drive is 6.89 bar (100 psi). Size coolant supply and return lines for 76 LPM (20 gpm) /
6.89 bar (100 psi) service with a maximum operating temperature of 40 °C
(105 °F). The required operating flow rate is specified in Table 4.C
.
Before connecting the coolant hoses to the Complete Drive hose fittings located at the lower-right back corner of the drive enclosure, see Figure 4.8
and perform these steps.
1.
Remove the factory-installed hose fitting plugs and the enclosure wall dome plugs.
2.
Install the factory-supplied snap bushings to the enclosure wall.
Figure 4.8 Frame 3A and 3B Complete Drive Coolant Connection Components
Enclosure Wall
Snap Bushings
Hose Fitting Plugs
OUTLET
INLET
Enclosure Wall
Dome Plugs
Frame 3A and Frame 3B Complete Drive coolant connections are made using 37 degree flare fittings which have a:
•
1-inch nominal size
•
“-16” SAE dash size
•
1-5/16-12 UN/UNF-2B external thread size
The mating connection is shown in Figure 4.9
. To make the mating coolant connection, follow these steps.
1.
Assemble the mating version of the fitting (with swivel nut) to each
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
fluid fitting, and tighten to a wrench resistance of approximately 3.4
N
• m (30 lb
• in).
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2.
Using a backup wrench on the Complete 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…109 N
• m (76…81 lb
• ft).
Figure 4.9 Frame 3A and 3B Complete Drive Mating Coolant Connection
DRIVE SIDE
CONNECTION
37° Flare Fitting
Swivel Nut
USER SIDE
CONNECTION
1 5/8" Wrench Flats
Backup Wrench
(use to prevent twisting during swivel nut tightening)
Do not use Backup Wrench on fitting locknut
Depending on the location of the heat exchanger or chiller relative to the drive, the following drive cooling loop hose kits are available.
Table 4.A Drive Cooling Loop Hose Kits
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)
2
2
2
2
2
Hoses in Kit
2
Drive Side
(1)
Coupling Size
0.75 inch
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
Used With
Frame 2
Frame 2
Frame 3A
Frame 3A
Frame 3B
Frame 3B
Hose Kit
(2)
Catalog Number
20L-GH10-B1
20L-GH30-B1
20L-GH10-A2
20L-GH30-A2
20L-GH10-A1
20L-GH30-A1
(1)
All drive side hose kit fittings are 37 degree flare.
(2)
Each hose kit contains two (2) hoses and the appropriate connectors.
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Cooling Loop Installation
Drive Coolant Requirements Recommended Coolants
Table 4.B
lists approved sources and recommended coolants with appropriate corrosion inhibitors for the drive loop.
Table 4.B 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
(1)
; a 50/50 premix of ethylene glycol and distilled water
•
K-Kool-E
(1)
; ethylene glycol (available premixed with distilled water)
•
Propylene glycol
(1)
also available
•
Dowtherm
®
SR-1
(2)
; ethylene glycol
•
Dowfrost
® (2)
; 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-premixed coolants require a coolant-to-water mix ratio of 50% by volume.
Important:
Since coolant performance slowly degrades over time, we recommend replacing the drive loop coolant every two years and/or whenever the loop is drained for servicing.
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Corrosion Inhibitor
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 these chemical compounds:
•
Sulfate and chloride
•
Hard water ions such as Mg++ and Ca++
!
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 can damage the heat exchanger and/or drive and cooling module equipment.
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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.
•
Synthetic rubber hose (Parker Hannifan Corp 801 General Purpose
Hose)
•
Viton seal (only Complete Drive)
Biocide
A biocide may be needed to control biological growth. Use of a biocide is permitted. For specific recommendations, consult a reputable water treatment company.
3B
3A
2
Drive
Frame Size
Coolant
Drive Cooling Loop Specifications
Table 4.C Coolant Requirements for One Frame 2, 3A or 3B Drive
Temperature Range
Minimum Coolant
Flow Rate
0…50 °C (32…122 °F) 30.3 LPM (8 gpm)
Pressure Drop
(2)
From Drive Inlet to Drive
Outlet at Minimum Coolant Flow Rate
1.58 bar (23 psi)
0…40 °C (32…104 °F) 30.3 LPM (8 gpm)
0…40 °C (32…104 °F) 56.8 LPM (15 gpm)
(1)
0.35 bar (5 psi)
0.48 bar (7 psi)
(1)
Coolant Type
WEG50
WPG50
(3)
(4)
or
(1)
Frame 3B includes separate converter and inverter power modules. A single inverter or converter power module requires a minimum flow rate of 30.3
LPM (8 gpm) at 0.35 bar (5 psi).
(2)
(3)
WEG50 equals good quality or distilled water with approved, inhibited* ethylene glycol, 50% glycol by volume.
(4)
Pressure drop does not include any system connections such as hoses or piping. Cooling systems must be sized to provide minimum flow considering entire system pressure drop.
WPG50 equals good quality or distilled water with approved, inhibited* propylene glycol, 50% glycol by volume.
* Inhibited ethylene glycol or propylene gylcol must contain a corrosion inhibitor. See
Corrosion Inhibitor on page 4-10
for an approved source.
Table 4.D
lists the estimated amount of coolant needed for the drive loop based on the drive frame size. For recommended drive loop coolants, see
Table 4.B
.
Table 4.D 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).
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Cooling Loop Installation
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