Liquid-to-Liquid Heat Exchanger
Contents
1. 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 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 Figure 1 8 PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Installation 1 11 Figure 1 7 Control Board Component Locations OOOOOOOOOOO 230 VAC Operation Plug Position OO igi oND AUN 1110987654321 O POWER Indicator J1 we OO mee STATUS Indicator S1 25250855 J3 G2 259555555 pu O 1 O 3 M5VAC US Operation O 6 u Plug Position TS J4 9 FU1 7 1 ON Down J5 J6 J7 J8 O 1 5 1 10 1 8 O N2. 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 EH er i Dimensions are in millimeters and inches 619 Max FILL TUBE 688 Max 24 4 O 27 1 127M T Jj ax 0 0 60 B d Data POWER TOR Nameplate Electrical TRUE POWER FROM DRIVE OUTLET Fluid Level Box aiie CONTROL 616 Max 781 Max 38 Indicator WIRING 4 80 77 4025 0 00 i i Y Y 4 ee 15 o o Hh a F _ d TODRIVE _ C 5 0 xis g Des 289 29 11 38 L E i rd 20 l RETURN TO s c9 SUPPLY s 5 o o DRIVE SUPPLY Ga E 102 Min tm ales DRAIN DRAIN 4 4 0 INLET FROM SUPPLY La 304 Strainer shipped loose PRIME SWITCH 12 0 REAR FRONT Approximate Weight Heat Exchanger Empty no coolant 20L LL13K P75A 113 kg 250 Ibs 20L
3. 1 6 Drive Loop from Heat Exchanger to Drive 1 6 Supply Loop from Heat Exchanger to Cooling Liquid Source 1 7 Removing Top and Side Panels 1 8 AC Supply Source Considerations 1 9 Fuses and Circuit Breakers 1 9 Input Power Conditioning 1 9 General Grounding Requirements 1 9 Wiring the Heat Exchanger 1 9 Power Witing eios eed nu e a eee ob ae ee 1 10 Control Win oco aa Eyed era IHE sra d ore ee stg 1 12 Setting the DIP Switches 1 14 SI DIP Switch Settings eser Cee erbe xen RR Pe Red eA e 1 14 S2 DIP Switch Settings 23 una rates dns nds ree ce rre doe URS ed 1 15 CE Conformity 3252 ae sa Si kV de SER doy Rey QE pre Be dire din 1 16 Low Voltage Directive 73 23 EEC 0 0 ccc ete ees 1 16 EMC Directive 89 336 EEC 1 16 Pressure Equipment Directive 97 23 EC 1 16 Essential Requirements for CE Compliance 1 16 C Tick Contormity coa cua pa ae eee eee IDA ee sat attire 1 16 PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual
4. ontrol Heat Exchanger Interlock Contact 30 VDC 10A Max 0 Not Used OOOOOOO OO 00000000000 2 EE Heat Exchanger Control Board Ji 1110987654321 1110987654321 Ji 00 J3 S1 S2 BBBAGERE PowerFlex 70 Cassette 1 0 BBBSB688 J4 J7 J8 10 1 8 3 Wire Control Internal Supply Required PowerFlex 700 Vector Control Parameter Changes None 0 Vector Control Terminal Block Heat Exchanger Interlock Contact 30 VDC 10A Max O0000000000 1110987654321 Ji Figure 1 11 Control Interlock Wiring for Drive with PowerFlex 700S Phase II Control 2 Wire Control 24V DC Internal Supply Required PowerFlex 700S Ph Il Control Parameter Changes P829 Dig In5 Sel 7 Run 00000000000 O J5 Heat Exchanger Control Board S i FU1 1110987654321 Ji oa J3 RBBB GBBB 2 seaeeses aL J6 J7 J8 5 EE O 3 Wire Control Internal Supply Required PowerFlex 700S Ph Il Control Parameter Changes P828 Dig In4 Sel 5 Start PowerFlex 700S Ph II Control Cassette TB2 P829 Dig In5 Sel 14 Normal Stop PowerFlex 700S Ph II
5. Figure 2 1 Fill Line PRIME SWITCH and Indicators STATUS Indicator PRIME FLUID SWITCH POWER LEVEL Indicator m Abso tractuy o o DRIVE SUPPLY DRAIN DRAIN 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 is important to not let the tank empty Running the heat exchanger without 7 ATTENTION In Step 8 the fluid level in the tank will decrease rapidly It enough coolant may damage the unit and void the warranty 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 4 full turn off the PRIME SWITCH 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 Figure 2 1 PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 2 4 Operation Draining Supply Side Cooling Loop for Periodic Maintenance 9 Entrapped air must be removed for the heat exchanger to function properly Remove the fill tube cap a
6. B wa Allen Bradley Powe Liquid to Liquid Heat Exchanger User Manual Automation 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 th
7. 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 e 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 run during an alarm it is the user s responsibility to analyze the ATTENTION Since the heat exchanger pump continues to alarm condition and take appropriate action Table 1 G S1 DIP Switch Settings Function SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1 Temperature Setpoint T ambient default 0 0 0 T ambient 3 C i 0 01 1 T ambient 6 C ele Oe 0 T ambient 10 C Lb qo pn Taam SC ee Mode 0 on off B 0 0 1 Motor Operated Valve default 1 EM 0 1 2 2 level EN 1 0 3 3 level 1 1 Temperature Alarm 45 C default 0 0 55 C 0 val 65 C 1 s 75 C 1 1 1 Mode switches SW4 and SW5 must be set to mode 1 Motor Operated Valve for correct operation o
8. Drive Loop for Periodic Replacement 7 Operation 2 5 After flow stops push the PRIME SWITCH for 8 seconds to open the motorized valve see Figure 2 2 PRIME SWITCH longer than 20 seconds may damage the pump ATTENTION Risk of equipment damage exists Pressing the 10 11 12 13 if the drive loop is already drained Clean off any old thread sealer from inside the pipe located on the heat exchanger and the removed plug Apply PTFE Teflon9 thread sealing tape or pipe thread sealant compound to threads on the plug 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 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 Turn on flow to IN FROM SUPPLY connection Dispose used fluid according to local state and federal regulations recommended to drain the supply side before draining the drive ATTENTION Risk of equipment damage exists It is side to avoid any possible damage to the pump Disconnect power from the heat exchanger Remove the fill tube cap from the top of the tank Place a 5 gallon container under the pipe marked DRIVE DRAIN on the front of the heat exchanger Figure 2 1 Use a 9 16 inch or adjusta
9. Figure P 3 Liquid to Liquid Heat Exchanger Plumbing Diagram Ambient Sensor E Control Drive Coolant Temp Flow Switch Valve f Supply Strainer Process D gt tt pla gt B Water IN 5 OUT IN ge E Level Switch lt OUT IN lt G Reservoir ours Drive General Precautions Pump The main components of the cooling loop include Part Strainer Control Valve Heat Exchanger Plate Description Filters particles from the supply water Controls the supply loop water flow Transfers heat from the drive loop to the supply loop Ambient Sensor Senses the ambient temperature used for the dew point control Drive Coolant Temperature Senses the drive coolant temperature used for the dew point control Sensor Drive Coolant Flow Switch Measures the drive coolant flow rate Level Switch Senses the level of coolant in the reservoir Reservoir Stores drive coolant Pump and Motor Circulates drive coolant A A 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 ins
10. 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 SWA 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 SW8 SW7 SW6 SW5 SW4 SW3 SW2 SW1 Start Input edge triggered default e level may start on power up Cool Down disabled 0 enabled default 1 o D TD Ambient Sensor external default 838 8 0 on board l3 53 l3 1 Low Temperature Alarm disabled default LOS ES 0 enabled i oe E Monitor Type temporary ANSI terminal default 0 LCD module 1 PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 1 16 Installation CE Conformity C
11. TOS S Swivel Nut NOTE If connecting heat exchanger Hose 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 elbow listed on page 1 6 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 Publication 20L UM002A EN P 1 8 Installation Removing Top and Side Panels Captive Hardware 6 Places Sheet Metal Screw 4 places Flush Handle 2 places 1 M10 x 1 5 Nut M10 Lock Washer PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 ae Minimum Supply Loo Heat Exchanger Drive Size Flow Rate Pe oop 20L LL13K P75A Frame2 15 1 LPM 4 GPM 20L LL13K P75A Frame 3A 22 7 LPM 6 GPM 20L LL24K 1P0A Frame 3B 56 8 LPM 15 GPM Connect the two supply loop hoses from the heat exchanger to the supply source The top panel and side panels Figure 1 5 can be removed from the heat exchanger to access internal comp
12. exchanger Table 2 A lists its possible indications Table 2 A Heat Exchanger Operating Status Indications STATUS Indicator LED Indication Description Action Red Steady Internal fault that is non resettable Cycle power to the heat exchanger state internal fault Replace the controller board Flashing No flow for greater than 10 seconds and Correct the heat exchanger supply Fast the run input is active state stopped loop fault and verify that the drive is fault The heat exchanger is not ready to properly operating run Flashing No flow for greater than 10 seconds Restart the drive Slow 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 Verify that sensor wires are securely detected connected and not damaged Replace the sensor if necessary Flashing A temperature alarm has occurred Causes for the alarm can be e Low drive loop coolant level Add coolant to the fill line Check for drive loop leaks Replace the hose and or connector if necessary e Ambient temperature is greater than or Increase the alarm temperature equal to the alarm temperature set by setting or decrease the ambient S1 DIP switches SW6 and SW7 temperature e Drive loop coolant temperature is Increase the alarm temperature greater than or equal to the alarm setting temperature set
13. 20L UM002A EN P B 2 Heat Exchanger Schematic To GND 12 AWG Green Yellow r S x E 5 Term Block i va qmm FRAME GND ower Connections ACPOWER PANEL GND Laud j Field Installation PE GND 12 AWG Green Yellow GND o i NEUTRAL o Term Block N HOT E e N 12 AWG White mm 109CON iLi 12 AWG Black me ae um es ies as Term Li T Block L1 GND 12 AWG Green Yellow _ N 12 AWG White 1L1 12AWGBlack Transformer Input Wiring GND 12 AWG Green Yellow Voltage Primary N 12 AWG White 120VAC H1 H2 Li 12 AWG Black 230 VAC H1 H4 A Term Block 1 Orange a Yellow gt z 3 16 AWG Black 16 AWG Red Xi a oit Rd 107CON E amp Term Block Q 8 Black 2 Brown White gt g 4 16 AWG White 16 AWG Red x2 109T Term Block 40VA H1 1MV 5 16 AWG White Valve Motor 6 16 AWG Green 12 VDC 120 VA 7 16 AWG Black 0 ir Flow Switch p Bs c Maximum 1I3FLS NO Yelow o L8 16 AWG Black e e o To PE Term Block Term Block GND 0 25A Q120 VAC 9 16 AWG Black 30VA Level Swich COM O T10 16 AWG Black Maximum 114FS NO GND 11 24 AWG White Ambient Temperature G 115NTC Q GL 24 AWG White 13 24 AWG White Water Temperature Q SIENTO Q Gl 24 AWG White PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM
14. Contact lg 7 fece een 2 p 16 AWG COM la 8 o swus J1 1 25 eme NO Alarm Contact O o POWER O Field Installation O Supplied by Drive See Setting the DIP Switches on page 1 14 for S1 and S2 switch settings PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P B 4 Heat Exchanger Schematic Notes PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives www rockwellautomation com Power Conirol and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 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 E Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20L UM002A EN P May 2007 351605 P01 Copyright 2007 Rockwell Automation Inc All rights reserved Printed in USA
15. Control Cassette TB2 Heat Exchanger Interlock Contact 30 VDC 10A Max OOOOOOO OO J1 1110987654321 Heat Exchanger Interlock Contact 30 VDC 10A Max O0000000000 1110987654321 J1 PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 e SWI 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 ajarm 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 e SWA 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
16. Publication 20L UM002A EN P ii Table of Contents Chapter 2 Appendix A Appendix B Operation Drive Interaction i iones seed Rhet Sm ee eoe exon e obo ose sob toe ds 2 1 Normal Operation a oie aaah vus a wi ee acia dia od d e bad doen 2 1 Loss of Flow Operation 2 1 PRIME SWITCH Operation 2 2 Operating Status Indications 2 2 Adding Coolant to the Drive Loop for Start Up 2 3 Draining Supply Side Cooling Loop for Periodic Maintenance 2 4 Draining Coolant from the Drive Loop for Periodic Replacement 2 5 Supplemental Heat Exchanger Information Specifications i d duree hee bbe Hu ER ee he seo he ek hee ee A 1 Control Board Replacement Fusing A 1 Heat Exchanger Schematic PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Who Should Use this Manual Technical Support and Service What Not in this 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 Manua
17. Shock 10G peak for 11 ms duration 1 0 ms Vibration 0 152 mm 0 006 in displacement 1G peak 5 5 Hz Electrical Input Input VAC 115 230 230 VAC 10 1 Phase Pump HP 1 0 1 0 1 0 Frequency 60 60 50 Hz Maximum Input Amps 15 8 8 2 8 4 Amps Short Circuit Rating 5 000 Amps Drive Loop Heat Dissipation 13 000 Watts 13 000 Watts 24 000 Watts Flow Pressure 30 3 LPM at 1 58 bar 30 3 LPM at 1 58 bar 56 8 LPM at 2 07 bar 8 GPM at 23 PSI 8 GPM at 23 PSI 15 GPM at 30 PSI Temperature Range 0 50 C 32 122 F 0 40 C 32 104 F 0 40 C 32 104 F Supply Loop Minimum Flow Pressure 15 1 LPM at 0 83 bar 22 7 LPM at 0 83 bar 56 8 LPM at 0 83 bar 4GPMat12PSI 6GPMat12PSI 15 GPM at 12 PSI Maximum Pressure 8 62 bar 125 PSI 8 62 bar 125 PSI 8 62 bar 125 PSI Temperature Range 0 40 C 32 104 F 0 85 C 32 95 F 0 35 C 32 95 F Control Board Replacement The control board replacement fusing is 0 5A Time Delay MDL Fusing PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P A 2 Supplemental Heat Exchanger Information Notes PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 Publication
18. outputs to monitor the operating state of the heat exchanger if desired Figure 1 9 Control Run Wiring 120 VAC Frame s Converter TB5 1 3A 3B To Converter TB5 3 Neutral Drive 12 VDC 1b 5 12V Common 1b 6 Frame 2 To TB1 Drive ToTB1 PRIME SWITCH on electrical box cover al Com N C Fault Contact 30 VDC 10A Max Alarm Contact 30 VDC 10A Max Com Jr 1110987654321 J1 00000000000 Q 110987654321 Q J1 oo 4 Heat Exchanger Control Board J3 S1 pssaaeea S2 peneeeen fi FU1 5 L J5 J6 J7 J8 O hs 1 v 1 O PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 P362 Digital In2 Sel 7 Run Control Interlock Wiring The interlock contact output on the Installation 1 13 heat exchanger control board can be interlocked Figure 1 10 or Figure 1 11 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 PowerFlex 700 Vector C Cassette I O Terminal Block Drive with PowerFlex 700 Vector Control
19. 002A EN P NOTE Default factory wiring is for operation at 115VAC 60Hz Pump Wiring 115V 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 Heat Exchanger Schematic B 3 Pump Wiring 230V Goulds Pump ITT P Series MCS Size 1x 1 1 4 6 7 779 GND p Cat No 1MS1E4D4 Impeller Dia 4 3 4 zd White i Orange L q Brown Noe ae See Figure 1 7 1 11 ss ee Figure 1 7 on page 1 air for 115 or 230 VAC operation 5 J2 jumper settings 0 5A 250V Type 3AG Fuse J2 Field Installation 1 Es 2 J5 Remote Start Contact Q 3 Field Installation High Voltage l4 Remote Start Contact Supplied by Frame 3A or 3B Drive Low Voltage eo de 25 Supplied by Frame 2 Drive 12 12 2 ue E s me E 2 8 4 181052 A01 e B o S S Cooling Loop t T abs 7 Control Board S E 8 E Sl Q 9 8 2 amp D 10 z 112PB S Prime Switch l1gl 1 311 16 AWG Red 2 2 J7 10 MEETS 9 IQ 17 Be 16 AWG Red 1o S Si 3 ple 6G l19 2 J98 5 Am 7 p Ha 16ANG 13 LIES S 6 ql20 16AWG COM UE Dl 4 EX el 5 6A 16AWG NC xx Fault Contact dio 5 i B 4 2 16 AWG COM lg 6 3 NE 16 AWG N O i Interlock
20. 30009 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 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 Figure 1 2 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 Publication 20L UM002A EN P Installation 1 5 Supply Loop Liquid Quality Maintenance and Precautions suitable for use in a potable water system Do not connect the ATTENTION The single walled heat exchanger is not 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 scr
21. LL24K 1P0A 113 kg 250 Ibs PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Installation 1 3 Drive Coolant Requirements Table 1 A lists approved sources and recommended coolants with appropriate corrosion inhibitors for the drive loop Table 1 4 Recommended Drive Loop Coolants Source Coolant Interstate Chemical e NFP 50 a 50 50 premix of propylene glycol and http www interstatechemical com stilled water contact htm e NFE 50 a 50 50 premix of ethylene glycol and distilled water Koolant Koolers Dimplex Thermal K Kool E 1 ethylene glycol available premixed with Solutions distilled water Propylene glycol 1 also available http www koolantkoolers com index php nic contact Dow Chemical e Dowtherm SR 1 12 ethylene glycol http www dow com e 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 diluted coolants require a coolant to water mix ratio of 5096 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 Estimated Amount of Coolant 1 Frame 2 15 1 liters 4 gal Frame 3A 19 liters 5 gal Frame 3B 19 liters 5 gal 1 Th
22. OTE Terminal blocks J3 J4 J5 J6 J7 and J8 do not require electrical connections by the user Figure 1 8 Motor Winding Connections for 230 VAC Operation MOTOR CONNECTIONS 115 VAC Operation 230 VAC Operation Blue L1 Black Blue L1 Black Brown Brown Insulate z Insulate Orange Orange Insulate White White 7 N White Yellow N White Yellow PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 for control terminal specifications Table 1 F Control Board Terminal Specifications Wire Size Range Recommended Wire Strip Name Description Coolant Controller Control Maximum Minimum Tightening Torque 10 Length Control wiring for run fault and 3 3 mm 0 2 mm 0 55 N m 7mm Wiring Terminal Block J1 alarm optional and interlock 12 AWG 24 AWG 5 Ib in 0 3 in 1 Maximum minimum sizes that the terminals will accept these are not recommendations Run Wiring The run output signal from the PowerFlex 700L drive must be connected to the heat exchanger control board Figure 1 9 so that the heat exchanger automatically starts when the drive is started The heat exchanger J1 connector provides fault and alarm contact
23. Tick 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 e EN 60204 1 Safety of Machinery Electrical equipment of machines Part 1 General requirements EMC Directive 89 336 EEC e EN 61000 6 2 Electromagnetic Compatibility EMC Generic standards Immunity for industrial environments e EN 61000 6 4 Electromagnetic Compatibility EMC Generic standards Emission standard of industrial environments Pressure Equipment Directive 97 23 EC e 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 he
24. a flat blade screwdriver to turn its locking mechanism counterclockwise one quarter turn PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 Operation on page 1 10 Table 1 E Power Terminal Specifications Wire Size Range Recommended Wire Strip Tightening Lenoth Torque 10 g Input Power Terminals Input AC line power 3 3 mm 0 05 mm N A 10 mm PE N and L1 12 AWG 30 AWG Spring Loaded 0 4 in 1 Maximum minimum sizes that the terminals will accept these are not recommendations Name Description Maximum Minimum Figure 1 6 Power Terminal Block Electrical Connections Wirex3 f Wire 3 P 79 115 VAC Line 230 VAC Line s o Power Connection Power Connection le Lr O o O QOO OI 9
25. at exchanger 2 System earthing grounding as described on page 1 9 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 TOOL Liquid to Liquid Heat Exchangers C Tick Declarations of Conformity are available online at http www ab com certification c tick index html PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Drive Interaction Chapter 2 Operation This chapter provides information on operating the PowerFlex 700L Liquid to Liquid Heat Exchanger For information on See page Drive Interaction 2 1 PRIME SWITCH Operation 2 2 Operating Status Indications 2 2 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 whe
26. ble wrench to remove the plug from the DRIVE DRAIN pipe There is no need to use a backup wrench on the pipe nipple Allow the coolant to drain 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 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 Publication 20L UM002A EN P 2 6 Operation 10 11 12 13 14 PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Apply PTFE Teflon thread sealing tape or pipe thread sealant compound to threads on the plug 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 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 Reconnect power to the heat exchanger Refill the heat exchanger with new fluid as described in Adding Coolant to the Drive Loop for Start Up on page 2 3 Replace and tighten the fill tube cap
27. by S1 DIP switches SW6 and SW7 e Ambient temperature is less than or Increase the ambient temperature or equal to 2 C S2 DIP switch SW3 set disable the low temperature alarm to enabled e Drive loop coolant temperature is less Increase the ambient temperature or than or equal to 2 C S2 DIP switch disable the low temperature alarm SWS set to enabled Green Steady The heat exchanger is running and no No action required faults or alarms are present state running Flashing The heat exchanger is ready to run No action required Slow state ready Flashing The heat exchanger is in a cool down No action required Fast period following a stop command PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Adding Coolant to the Drive 1 Loop for Start Up 6 Operation 2 3 Make sure all hose connections are completed as described in Drive Loop from Heat Exchanger to Drive on page 1 6 With the top and side covers removed from the heat exchanger make sure all wiring to the heat exchanger is completed as described in Power Wiring on page 1 10 and Control Wiring on page 1 12 respectively Make sure both pipe plugs are tightened on the drains in front of the heat exchanger Remove the fill tube cap from the top of the tank Fill the heat exchanger until the sight glass reaches the fill line with approved coolant see Drive Coolant Requirements on page 1 3
28. e 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 n 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 e Sulfate and chloride e Hard water ions such as Mg and Ca PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 1 4 Installation inhibited and silicate free Use of common silicate containing ATTENTION Ethylene and propylene glycols must be 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
29. een 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 Publication 20L UM002A EN P 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 Hose Kit Hose Hoses Drive Side Heat Exchanger Side Catalog Number Length in Kit Coupling Size Coupling Size Frame 2 and 20L GH10 B1 3m 2 0 75 inch 0 75 i
30. f the liquid to liquid heat exchanger PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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
31. hing 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 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 Ib in PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P 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 Ib ft Figure 1 3 Connecting Drive Side Hose DRIVE SIDE INLET or OUTLET Backup Wrench use to prevent twisting during swivel nut tightening Do not use a 1 5 8 Wrench Flats Backup Wrench on fitting locknut TO HEAT EXCHANGER 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 1 3 8 Wrench Flats 37 Flare Fitting Backup Wrench AE 1 1 2 Wrench Flats use to prevent twisting ur m e E during swivel nut tightening i ER
32. ircuit Breakers Inverse time or instantaneous trip circuit breakers or equivalent Minimum Recommended Protection Rating See Nameplate 115 VAC 1 Phase 15 8 amps 20 amps 230 VAC 1 Phase 8 4 amps 12 amps Maximum Operating Input Amps Input Power Conditioning Certain events on the power system supplying the heat exchanger can cause component damage or shortened product life They are e The power system has power factor correction capacitors switched in and out of the system either by the user or by the power company e 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 e 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 To access terminals for electrical connections open the electrical box door by using
33. is 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 gt 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 gt D 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 Publication 20L UM002A EN P soc ii Summary of Changes PowerFlex 700L Li
34. l P 1 Technical Support and Service P 1 What Is Not in this Manual P 1 Reference Materials P 2 Introduction P 2 General Precautions P 3 Catalog Number Explanation P 4 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 This manual is designed to provide only heat exchanger information For detailed PowerFlex 700L drive information Title Publication PowerFlex 700L Liquid Cooled Adjustable Frequency AC Drive User Manual 20L UMO01 PowerFlex 700L Active Converter Power Module User Manual PFLEX UMOQO2 Publications can be obtained online at http www rockwellautomation com literature PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P P 2 Overview Reference Materials The following manuals are recommended for general drive information Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES INO01 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 PowerFlex 70 700 Reference Manual PFLEX RMO001 Safety Guidelines for the Application Installation and Maintenance of Solid State SGI 1 1 Control A Global Refere
35. n 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 Publication 20L UM002A EN P 2 2 Operation PRIME SWITCH Operation Operating Status Indications The PRIME SWITCH Figure 2 1 will start the pump independently from the run state of the heat exchanger The STATUS indicator Figure 2 1 shows the operating status of the heat
36. nce Guide for Reading Schematic Diagrams 0100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 Introduction 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 8 Drive Loop Supply Loop M 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 PowerFlex 700L Liquid to Liquid Heat Exchanger From To Return In Drive Drive Drive Drive To From Inlet Outlet Hose Kit Outlet Inlet Supply Supply BN S i f E bi i oi To Facility Water of i hose or pipe connection PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Overview P 3 Component Details Figure P 3 shows a cooling loop diagram for a typical liquid to liquid heat exchanger
37. nch 13 kW heat exchanger 10 ft Frame 2 and 20L GH30 B1 931m 7 2 0 75 inch 0 75 inch 13 kW heat exchanger 30 ft Frame 3A and 20L GH10 A2 3m 2 1 inch 1 inch with 90 elbow 13 kW heat exchanger 10 ft Frame 3A and 20L GH30 A2 91m 7 2 1 inch 1 inch with 90 elbow 13 kW heat exchanger 30 ft Frame 3B and 20L GH10 A1 3m 2 1 inch 1 inch 24 kW heat exchanger 10 ft Frame 3B and 20L GH30 A1 91m 2 1 inch 1 inch 24 kW heat exchanger 30 ft 1 All drive side hose kit fittings are 37 degree flare 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 e 1 inch inside diameter hose Parker Hannifin p n 801 16 e 1 inch swivel hose fitting female JIC Joint Industrial Council 37 Parker Hannifin p n 30682 16 16B e 3 4 inch inside diameter hose Parker Hannifin p n 801 12 e 3 4 inch swivel hose fitting female JIC Joint Industrial Council 37 Parker Hannifin p n 30682 12 12B e 1 inch elbow Parker Hannifin p n 16 CTX B must be brass or stainless steel Use of plated steel fittings is ATTENTION Risk of equipment damage exists Hose fittings 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 bus
38. nd 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 Ibs recommended to drain the supply side before draining the drive ATTENTION Risk of equipment damage exists It is 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 a5 gallon container under the pipe marked SUPPLY DRAIN on the front of the heat exchanger Figure 2 1 3 Usea 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 PRIME SWITCH longer than 20 seconds may damage the pump ATTENTION Risk of equipment damage exists Pressing the if the drive loop is already drained Figure 2 2 Supply Loop Motorized Valve Open Indication 6 Disconnect the hoses 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 Place the ends of the hoses in a container to drain PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Draining Coolant from the
39. on the top of the tank Dispose used fluid according to local state and federal regulations Appendix A Supplemental Heat Exchanger Information Specifications Cat dor Specification Heat Exchanger Catalog Number gory P 20L LL13K P75A 20L LL13K P75A 20L LL24K 1POA Used with PowerFlex 700L Frame 2 Frame 3A Frame 3B Agency Listed to UL1995 UL778 CAN CSA C22 2 No 236 and CAN Certification Wu CSA C22 2 No 108 01 CE 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 Environment Ambient Temperature 0 to 50 C 32 to 122 F 10 to 40 C 32 to 104 F 0 to 40 C 32 to 104 F Storage Temperature 40 to 85 C 40 to 185 F Atmosphere 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 Relative Humidity 5 95 non condensing
40. onents To do so proceed in this order 1 2 3 Remove the fill tube cap from the top of the tank Remove the top panel by loosening four captive hardware screws 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 j equipment damage may result See Instruction Manual Dimensions are in millimeters and inches d Side Panel 2 places Ly 222 0 88 Um 22 2 x 12 7 25 4 10 0 875 x 0 5 Slot 22 2 x 12 7 et 0 875 x 0 5 Slot MJ 50 8 S 2 0 See DETAIL A Shipping Field Installation Mounting Angle 4 places f 222 0 88 44 5 M10 Flat Washer 1 75 M10 x 1 5 x 35 yy Hexagonal Head Screw DETAIL A AC Supply Source Considerations Wiring the Heat Exchanger 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 e Recommended Fuse Types UL Class J CC T or Type BS88 e Recommended C
41. quid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Preface Chapter 1 Table of Contents Overview Who Should Use this Manual P 1 Technical Support and Service P 1 What Is Not in this Manual P 1 Reference Materials oce secrete o ea RA REPE e eu eR Pace Fed era wy P 2 Introduction uiae cog iad eas tbe merca eed tec ede ema eds P 2 Operating Principle P 2 Component Detalls isese sain ber e ae eer rene Gin RC ER RE dt P 3 General Precautions P 3 Catalog Number Explanation P 4 Installation Installation Specifications 1 1 Required Ambient Conditions 1 1 Location Requirements 1 1 Lifting Instructions aie scsi e eerte ERR hig ie lela eh wea sd 1 2 Drive Coolant Requirements 1 3 Connecting the Elbow Strainer Assembly shipped loose 1 4 Supply Loop Liquid Quality Maintenance and Precautions 1 5 Pre Connection Pipe Flushing 1 5 Connecting Hoses to the Heat Exchanger
42. tallation 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 Publication 20L UM002A EN P P 4 Overview Catalog Number Position Explanation 13 4 56 79 10 11 12 20L LL 13K P75 A a b c d e a d Drive Hose Connection Code Type 20L PowerFlex 700L 0 75 inch NPT 1 0 inch NPT b e Heat Exchanger Option Code Type Code Description Liquid to Liquid A Reserved c Rating PowerFlex 700L Liquid to Liquid Heat Exchanger User Manual Publication 20L UM002A EN P Installation Specifications Chapter 1 Installation This chapter provides information on installing and wiring the PowerFlex TOOL Liquid to Liquid Heat Exchanger For information on See page Installation Specifications 1 1 Connecting Hoses to the Heat Exchanger 1 6 Removing Top and Side Panels 1 8 AC Supply Source Considerations 1 9 Wiring the Heat Exchanger 1 9 Setting the DIP Switches 1 14 CE Conformity 1 16 C Tick Conformity 1 16 Required Ambient Conditions The heat exchanger is designed to work within these ambient temperatures Heat Exchanger Ha y d ie M Range 20L LL13K P75A Frame 2 0 50 C 32 122 F 20L LL13K P75A Frame 3A 0 40 C 32 104 F 20L LL24K 1P0A _ Frame 3B 0 40 C 32 104 F It is the user s responsibility to ensure that the
43. 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 Start Up on page 2 3 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 ATTENTION Risk of equipment damage exists Failure to 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 Publication 20L UM002A EN P
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