PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC Drives · 2015. 5. 26. · Rockwell...

Installation Instructions

A Supplement to Publication 750-IN001

PowerFlex® 755 with OEM Liquid Cooling Frame 6 and 7 AC Drives

PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC drives differ from the standard, air-cooled PowerFlex 755 Frame 6 and 7 AC drives, respectively, in that:

• The heatsink is replaced by a chillplate.• Coolant inlet and outlet connections are provided for the chillplate.• A thermal switch is added to the DC inductor.

Key features of the PowerFlex 755 with OEM Liquid Cooling AC drives are:• Provides OEM liquid cooling at 200, 300, and 400 HP (480V) ratings and

132, 200, and 270 kW (400V) ratings.• Provides similar input/output and overload ratings at 2 kHz PWM as the

standard air-cooled PowerFlex 750-Series AC drives (see Table 3).• Provides the same UL 508C certification and CE certifications as the

standard, air-cooled PowerFlex 750-Series AC drives.• Maintains the same ambient air and surrounding air environmental

requirements as the standard, air-cooled PowerFlex 750-Series Frame 6 and 7 AC drives.

• Available as an IP00, NEMA/UL Type Open style that can be converted to a NEMA/UL Type 4X/12 integrity back with a user-installed flange kit.

Use these instructions in conjunction with the publications listed below to install and operate PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC drives.

Reference Materials Title Publication Available Online at…PowerFlex 750-Series AC Drives Installation Instructions

750-IN001

www.rockwellautomation.com/literature

PowerFlex 750-Series AC Drives Programming Manual

750-PM001

PowerFlex 750-Series AC Drive Technical Data 750-TD001Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001Guarding Against Electrostatic Damage 8000-4.5.2

http://www.rockwellautomation.com/literaturehttp://www.rockwellautomation.com/literature

2 PowerFlex® 755 with OEM Liquid Cooling Frame 6 and 7 AC Drives

Catalog Explanation

a

a b c d e f1…f2 g h

Drive

Code Type

20G PowerFlex 755

bOEM Liquid Cooled

cInput Type

Frames

Frames

Code Description

Y

AAC Input w/Precharge,

no DC Terminals6…7

eVoltage Rating

Code Voltage

C 400V ACD 480V AC

f1ND Rating

400V, 50 Hz Input

Code Amps kW Frame

260 260 132 6

7367 367 200477 477 270

7

gFiltering and CM Cap Configuration

Code Filtering Default CM CapConnection

A Yes Jumper Removed

hDynamic Braking

Code Internal Resistor Internal Transistor

N No No

dEnclosure

Code Description

N IP00, NEMA/UL Type Open 6…7

‡ For Frames 6…7 a User Installed Flange Kit isavailable to convert a Code N drive thatprovides a NEMA/UL Type 4X/12 back.

Position

1…3 4 5 6 7 8…10 11 12 13 14 15 16 17 18

20G Y A N X XXX A N 0 N N N N N Q B Q…

f2ND Rating

480V, 60 Hz Input

Code Amps Hp Frame

248 248 200 6

7361 361 300477 477 400

7

‡

Rockwell Automation Publication 20GY-IN001A-EN-P - June 2011

PowerFlex® 755 with OEM Liquid Cooling Frame 6 and 7 AC Drives 3

General Precautions Read the following precautions before you begin installing the drive.

Qualified Personnel

Personal Safety

Product Safety

Class 1 LED Product

Lifting and Mounting the Drive

Use the information in the PowerFlex 750-Series AC Drive Installation Instructions (publication 750-IN001) for the respective drive frame size, and the following dimension drawings to lift and mount the PowerFlex 755 with OEM Liquid Cooling AC drives. These drawings also show the locations of the coolant inlet and outlet connections on the Frame 6 and 7 drives.

After mounting the drive, connect the coolant source to the drive. See Connecting the Coolant Source on page 7 for details.

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.

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Measure the DC bus voltage between the +DC and -DC terminals, between the +DC terminal and the chassis, and between the -DC terminal and the chassis. The voltage must be zero for all three measurement.

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Guarding Against Electrostatic Damage, publication 8000-4.5.2 or any other applicable ESD protection handbook.

ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors.

IMPORTANT The drive must be mounted vertically within ±1 degree allowance from vertical.



Figure 1 - IP00, NEMA/UL Open Type Frames 6 and 7 (Frame 6 Shown)

Dimensions are in millimeters and (inches).

Frame 6: M6 (#12) mounting hardware recommended. Frame 7: M8 (5/16 in.) mounting hardware recommended.

GE

F

DC 6.4 (0.25)

14.5 (0.57)

A

B

ø6.5 (0.26)

ø14.5 (0.57)Frame 6

Frame 7

8.5 (0.33)

25.0 (0.98)

ø8.5 (0.33)

ø16.0 (0.63)

134.0(5.28) 9.5

(0.37)

23.3(0.92)

Frame A B C D E F G Weight kg (lb)

6 308.0(12.13)

665.5(26.20)

346.4(13.64)

283.0(11.14)

623.0(24.53)

254.0(10.00)

609.0(23.98)

43.6(96.0)

7 430.0(16.93)

881.5(34.70)

349.6(13.76)

380.0(14.96)

838.0(32.99)

330.0(12.99)

825.0(32.48)

83.6(184.0)

IMPORTANT Always install mounting hardware in all four corners of the mounting legs for stability.Only install mounting hardware through the top key holes to help insure the drive is securely fastened to the mounting surface.At the bottom of the mounting legs, either the key holes or optional open mounting slots may be used.

Frame 6 Bottom View

Frame 7 Bottom View

42.0(1.65)

69.5(2.74)

48.2(1.90)INLET OUTLET

INLET OUTLET

67.7(2.67)

55.1(2.17)

52.8(2.08)INLET OUTLET

INLET OUTLET



Figure 2 - Flange Mount Frame 6


208.4(8.20)

346.4(13.64)

308.0(12.13)

665.5(26.20)

162.0(6.38)

24.0(0.94)

262.0(10.31)

362.0(14.25)

462.0(18.19)

562.0(22.13)

600.0(23.62)

624.0(24.57)

26.0 (1.02)

91.0 (3.58)193.0 (7.60)

258.0 (10.16)225.5 (8.88)

284.0 (11.18)

24x: Ø6.4 (Ø0.25)

138.0(5.43)

45.4(1.79)

43.5(1.71)

42.0(1.65)

561.0 +2.0/-1.5(22.09 +0.08/-0.06)

268.0 +2.0/-1.5(10.60 +0.08/-0.06)

8.0(0.30)

62.0(2.44) 31.5

(1.24)

58.5 (2.30)

18.7(0.74) 32.1

(1.26)

IMPORTANT Must use Flange Adapter kit (20-750-FLNG4-F6) to meet enclosure rating.



Figure 3 - Flange Mount Frame 7


875.0(34.45)

430.0(16.93)

208.4(8.20)

32.4(1.28)

44.3(1.74)

138.0(5.43)

53.0(2.09)

67.7(2.67)

31.4(1.24)

509.6(20.06)

28.0(1.10)

431.2(16.98)

352.8(13.89)

274.4(10.80)

196.0(7.72)

117.6(4.63)

588.0(23.15)

666.4(26.24)

744.8(29.32)

784.0(30.87)

812.0(31.97)

39.2(1.54)

768.0(30.24)

50.38 (1.98)151.13 (5.95)

251.88 (9.92)352.63 (13.88)

403.00 (15.87)

32x: Ø7.0 (Ø0.28)

387.0(15.24)

8.0(0.31)

8.0(0.31)

IMPORTANT Must use Flange Adapter kit (20-750-FLNG4-F7) to meet enclosure rating.



Connecting the Coolant Source

Drive Coolant Connections

For locations of the coolant inlet and outlet connections, see Figure 1 on page 4, Figure 2 on page 5 or Figure 3 on page 6.

Coolant connections for PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC drives are made using o-ring face seal connections which have a:

• 3/4-inch nominal size• “-12” SAE dash size• 1-1/16-12 UN/UNF-2B external thread size

The drive coolant connection is shown in Figure 4. Perform the following steps to complete the connection.

1. Verify that the o-ring is properly seated on the male fitting.

2. Using a backup wrench on the drive fitting, tighten the swivel nut fitting to a torque of 81 N•m (60 lb•ft).

Figure 4 - Drive Coolant Connection

Fitting with Face Seal

O-Ring

Backup Wrench

Swivel Nut



Coolant Requirements General Cooling System Requirements

Table 1 lists the required coolant specifications for PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC drives.

Table 1 - Required Coolant Specifications

Non-diluted coolants require a coolant-to-water mix ratio of 50% by volume.

Specification DescriptionMaximum Rated Pressure 1275 kPa (185 psig)Minimum Flow Rate 19 liters/min (5 gal/min)Coolant Temperature 0…46 °C (32…115 °F )Coolant Fitting Type Brass #10 o-ring face sealCoolant Fitting Torque 81 N•m (60 lb•ft ) ±10%

Coolant Specification Description

OEM-specific coolants are qualified

Consult factory for details

Water-Glycol Coolants:Interstate Chemicalwww.interstatechemical.com/contact.htm

Use only approved coolant (consult factory for details)• 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

(1) Available in 5 gallon pails.

Koolant Koolers/Dimplex Thermal Solutionswww.koolantkoolers.com/index.php/nic=contact

• K-Kool-E (1); ethylene glycol (available premixed with distilled water)

• Propylene gylcol (1) also available

Dow Chemicalwww.dow.com

• Dowtherm® SR-1 (2); ethylene glycol• Dowfrost® (2); propylene glycol

Dowtherm and Dowfrost are registered trademarks of Dow Chemical Co.

(2) Not premixed with distilled water, and may not be available in 5 gallon quantities.

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.



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:

• Sulfate and chloride• Hard water ions such as Mg++ and Ca++

The coolant for the drive 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)• Neoprene®

Neoprene is a registered trademark of DupontDow.

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.

ATTENTION: Ethylene glycol or propylene gylcol 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 equipment.



Understanding Drive Faults 8 and 168

All drive fault and alarm descriptions for standard air-cooled drives shown in the PowerFlex 750-Series AC Drives Programming Manual (publication 750-PM001) also apply to the PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC drives—except for Faults 8 and 168. Both the standard air-cooled drives and liquid-cooled drives use these faults, but they operate somewhat differently for liquid-cooled drives. See Table 2 for details.

Table 2 - Drive Faults 8 and 168 Operation for PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC Drives

Figure 5 - Temperature Sensor and Thermal Switch Circuit

No. Fault Text Type Description/Action8 Heatsink OvrTemp Resettable

FaultThe heatsink temperature has exceeded 100% of the drive temperature. Heatsink over temperature occurs at 85 °C. This value is stored in drive firmware.

168 HeatSinkUnderTmp Resettable Fault

Heatsink temperature sensor is reporting a value below -18.7 °C (-1.66 °F) or an open thermal switch. Causes include:

1. Air or coolant temperature is excessively cold; raise temperature of drive.

2. DC inductor is over temperature and thermal switch is open; check for blocked or failed power structure fan.

3. Sensor feedback circuit is open; see Figure 5.

J25 onPower PCB

NTCChillplate

DC InductorThermal SwitchNC



Power Wiring Refer to the information in the PowerFlex 750-Series AC Drive Installation Instructions (publication 750-IN001) to wire power to the PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC drives. However, see Table 3 for the recommended AC line input protection devices to use instead of the protection devices listed for the standard, air-cooled PowerFlex 755 Frame 6 and 7 drives in the PowerFlex 750-Series AC Drives Technical Data (publication 750-TD001).

Tabl

e 3

- Rec

omm

ende

d A

C In

put P

rote

ctio

n D

evic

es

Appl

ied

Ratin

g (1

)

(1)

“App

lied

Rat

ing”

refe

rs to

the

mot

or th

at w

ill be

con

nect

ed to

the

drive

. For

exa

mpl

e, a

“C36

7” d

rive

can

be u

sed

in N

orm

al D

uty

mod

e on

a 2

00 k

W m

otor

, or i

n H

eavy

Dut

y m

ode

on a

160

kW

mot

or. A

“C26

0” d

rive

can

be u

sed

in H

eavy

Dut

y m

ode

on a

110

kW

mot

or w

ith th

e sa

me

ratin

gs a

s a

“C20

5.” T

he d

rive

can

be p

rogr

amm

ed fo

r eith

er m

ode.

Wiri

ng

and

fuse

s ca

n be

siz

ed b

ased

on

the

prog

ram

med

mod

e. F

or a

ny g

iven

drive

cat

alog

num

ber,

Nor

mal

Dut

y m

ode

prov

ides

hig

her c

ontin

uous

cur

rent

but

sm

alle

r ove

rload

cur

rent

w

ith re

spec

t to

Hea

vy D

uty

mod

e. S

ee p

aram

eter

306

[Dut

y R

atin

g].

Frame Con

tinuo

us

Out

put

Amps

Driv

e Si

zed

For N

orm

al

Duty

Driv

e Si

zed

For H

eavy

Du

tyIn

put

Qua

ntiti

esAC

Inpu

t Pro

tect

ion

Devi

ces

Inpu

t Q

uant

ities

DC In

put

Prot

ectio

n

Cata

log

Num

ber

Out

put

Ove

rload

Am

psCa

talo

g Nu

mbe

r

Out

put

Ove

rload

Am

psCo

ntin

uous

AC

Inpu

t

Dual

Ele

men

t Ti

me

Del

ay

Fuse

Non-

Tim

e De

lay

Fuse

Circ

uit

Brea

ker

Max

imum

Si

ze(4

)

(4)

Circ

uit B

reak

er -

inve

rse

time

brea

ker.

For U

S N

EC, m

inim

um s

ize

is 1

25%

of m

otor

FLA

. Rat

ings

sho

wn

are

max

imum

.

Mot

or

Circ

uit

Prot

ecto

r(5

)

(5)

Rec

omm

ende

d M

otor

circ

uit p

rote

ctor

- In

stan

tane

ous

trip

circ

uit b

reak

er. T

he tr

ip s

ettin

g sh

ould

be

set t

o th

e in

put c

urre

nt o

f the

driv

e an

d sh

ould

be

size

d fo

r the

con

tinuo

us

curre

nt o

f the

sys

tem

.

Cont

inuo

us D

C In

put

Non-

Tim

e De

lay

Fuse

x =

GY

1 m

in3

sec

1 m

in3

sec

kVA

Amps

Min

(2)

(2)

Min

imum

pro

tect

ion

devi

ce s

ize

is th

e lo

wes

t rat

ed d

evic

e th

at s

uppl

ies

max

imum

pro

tect

ion

with

out n

uisa

nce

tripp

ing.

Max

(3)

(3)

Max

imum

pro

tect

ion

devi

ce s

ize

is th

e hi

ghes

t rat

ed d

evic

e th

at s

uppl

ies

drive

pro

tect

ion.

For

US

NEC

, min

imum

siz

e is

125

% o

f mot

or F

LA. R

atin

gs s

how

n ar

e m

axim

um.

Min

(2)

Max

(3)

kWAm

ps

400

Volt

AC In

put

540

Volt

DC In

put

110

kW6

205

20x…

C26

030

7.5

390.

013

9.1

200.

827

545

027

560

060

040

0

132

kW6

260

20x…

C26

028

6.0

390.

017

6.5

254.

732

557

532

575

070

040

0

160

kW7

302

20x…

C36

745

3.0

550.

520

5.0

295.

940

067

540

090

090

060

0

200

kW7

367

20x…

C36

740

3.7

550.

520

x…C

477

550.

568

4.0

249.

135

9.5

475

800

475

1000

1100

600

270

kW7

477

20x…

C47

752

4.7

715.

538

8.5

467.

360

010

0060

012

0012

0060

0

480

Volt

AC In

put

650

Volt

DC In

put

150

Hp

618

620

x…D

248

279.

037

2.0

145.

217

4.6

250

400

250

600

550

250

200

Hp

624

820

x…D

248

272.

837

2.0

193.

623

2.8

325

550

325

700

700

400

250

Hp

730

220

x…D

361

453.

054

3.6

235.

728

3.5

400

675

400

900

900

600

300

Hp

736

120

x…D

361

397.

154

1.5

20x…

D47

754

1.5

649.

828

1.8

338.

947

580

047

510

0010

0060

0

400

Hp

747

720

x…D

477

524.

771

5.5

372.

344

7.8

600

1000

600

1200

1200

600

Not

es:



Notes:

www.rockwellautomation.com

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, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, 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

Power, Control and Information Solutions Headquarters

Publication 20GY-IN001A-EN-P – June 2011Copyright © 2011Rockwell Automation, Inc. All rights reserved. Printed in USA.

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: [email protected], Online: www.ab.com/support/abdrives

*PN-115378*PN-115378

PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC DrivesReference MaterialsCatalog ExplanationGeneral PrecautionsQualified PersonnelPersonal SafetyProduct SafetyClass 1 LED Product

Lifting and Mounting the DriveConnecting the Coolant SourceDrive Coolant Connections

Coolant RequirementsGeneral Cooling System RequirementsCorrosion InhibitorBiocide

Understanding Drive Faults 8 and 168Power WiringBack Page/20GY-IN001A-EN-P/June 2011

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PowerFlex 755 with OEM Liquid Cooling Frame 6 and 7 AC Drives · 2015. 5. 26. · Rockwell...

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