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The PowerFlex 700 offers outstanding performance in an easy-to-use drive that covers a wide range of horsepower ratings. This drive is designed to control three-phase. 4 PowerFlex 700 Adjustable Frequency AC Drive Quick Start Essential Requirements for CE Compliance Conditions 1-6 listed belowmust be satisfied for PowerFlex drives to.
Technical Data Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex 700. PowerFlex 700 AC Drives. PowerFlex® 700 AC Drives are available in a wide range of horsepower ratings. These drives control three-phase induction motors in. Technical Data PowerFlex 700 Adjustable Frequency AC Drive Topic Product Overview Certifications and Specifications Design Considerations Drive, Fuse and Circuit Breaker Ratings Cable Recommendations Power Wiring I/O Wiring Mounting Dimensions and Weights PowerFlex 700 Packaged Drives Drive Options Page 2 7 12 24 33 34 44 49 53 77 78 PowerFlex 700 Adjustable Frequency AC Drive Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource PowerFlex 700 Adjustable Frequency AC Drive Installation Instructions – Frames 0…6, publication 20B-IN0019 PowerFlex 700 Adjustable Frequency AC Drive Installation Instructions – Frames 7…10, publication 20B-IN0014 PowerFlex 700 Standard Control User Manual, publication 20B-UM001 PowerFlex 700 Vector Control User Manual (v4.001 & up), publication 20B-UM002 PowerFlex 70 and PowerFlex 700 Reference Manual, publication PFLEX-RM001 PowerFlex 70 Enhanced Control and PowerFlex 700 Vector Control Reference Manual, publication PFLEX-RM004 Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, publication SGI-1.1 Preventive Maintenance of Industrial Control and Drive System Equipment, publication DRIVES-TD001 Guarding Against Electrostatic Damage, publication 8000-4.5.2 Product Certifications website, http://ab.com Provides detailed information on: • Parameters and programming • Faults, alarms, and troubleshooting Provides detailed application specific information for programming and configuring the PowerFlex 700 drive. Provides basic information needed to properly wire and ground PWM AC drives. Provides general guidelines for the application, installation, and maintenance of solid-state control. Provides a guide to performing preventive maintenance. Provides practices for guarding against electrostatic damage (ESD). Provides declarations of conformity, certificates, and other certification details. Description Provides detailed information about installation and start-up. You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Product Overview The PowerFlex 700 AC drive offers outstanding performance in an easy-to-use drive that you have come to expect from Rockwell Automation. This world-class performance comes in a small and competitively priced package. The PowerFlex 700 AC drive is designed to control three-phase induction motors in applications with requirements ranging from the simplest speed control to the most demanding torque control. The drive has volts per hertz, sensorless vector and vector control. Vector control includes Allen-Bradley’s patented Force™ Technology which provides world class motor control. Flexible Packaging and Mounting • IP20, NEMA / UL Type 1 – For conventional mounting inside or outside a control cabinet. Conduit plate is removable for easy installation and replacement without disturbing conduit. • IP54, NEMA / UL Type 12 – Stand-alone, wall mount drives are available for dust tight applications with power ratings from 75 to 200 Hp (Frames 5 & 6). • IP54, NEMA / UL Type 12 – Flange mount drives with an IP00, NEMA / UL Type Open front. These can be installed in a user supplied cabinet to meet IP54, NEMA / UL Type 12. This allows the majority of heat to be exhausted out the back of the cabinet while keeping the cabinet protected. Power ratings range from 75 to 700 Hp (Frames 5…10). • Zero Stacking™ – Frame 0…6 drives can be mounted next to each other with no reduction of surrounding air temperature rating (50°C). This unique bookshelf design also allows access to one drive without disturbing another. 2 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Space Saving Hardware Features • Integral EMC Filtering plus built-in DC bus choke common mode cores and common mode capacitors provides a compact, all-in-one package solution for meeting EMC requirements, including CE in Europe. Frames 0…6 only (Frames 7…10 meet CE when installed per recommendations). • Internal Communications allow the user to integrate the drive into the manufacturing process. Status indicators for all internal communication options are visible on the cover for easy setup and monitoring of drive communications. Users can easily manage information from shop floor to top floor and seamlessly integrate their complete system as they control, configure and collect data. • Integral Dynamic Brake Transistor delivers a cost effective means of switching regenerative energy without costly external chopper circuits. These internal transistors are available in power ratings from 0.5 to 200 Hp. • Internal Dynamic Brake Resistor (up to 25 Hp) requires no extra panel space, and supplies a large amount of braking torque for short periods. Easy to Use Human Interface Tools The PowerFlex 7-Class AC drives provide common Human Interface tools that are familiar and easy to use. These include the LCD Human Interface modules and PC-based configuration tools. • LCD Human Interface modules provide: – Large and easy to read 7 line x 21 character backlit display – Variety of languages (English, French, German, Italian, Spanish, Portuguese, Dutch) – Alternate function keys for shortcuts to common tasks – “Calculator-like” number pad for fast and easy data entry (Full Numeric version only) – Control keys for local start, stop, speed, and direction – Remote versions for panel mount application Outstanding Control and Performance Torque (Per-Unit) Closed Loop Performance 3.0 2.5 Multiple motor control algorithms allow performance matched to the application need: • Volts/Hertz for simple Fan and Pump applications. • Sensorless Vector for high torque production over a wide speed range. • Vector for outstanding torque regulation and excellent low speed/zero speed performance (w/Vector Control cassette). The PowerFlex 700 drive's Vector Control uses Allen-Bradley's patented Force™ Technology which provides excellent low-speed performance - whether it is operated with or without feedback. While this industry-leading control provides the highest level of drive performance, it is as easy to use as any general purpose drive available. 2.0 1.5 1.0 0.5 0.0 -2 0 2 4 6 8 10 12 Frequency (HZ) Open Loop Performance 3.0 2.5 Torque (Per-Unit) 2.0 1.5 1.0 0.5 0.0 0 2 4 6 Frequency (HZ) 8 10 12 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 3 PowerFlex 700 Adjustable Frequency AC Drive Drives Features • Fast-acting Current Limit and Bus Voltage Regulation result in maximum accel/decel without tripping. • High speed analog inputs improve drive response to torque or speed commands. • Programming flexibility allows parameters to be linked within the drive. • Flying Start delivers smooth and instantaneous connection into rotating loads, regardless of commanded direction, without the need for any speed feedback. • Integral Process PI Control can eliminate the need for a separate process loop controller. • Inertia Ride-Through offers tripless operation during a prolonged power outage by using the rotating energy stored in high inertia, low-friction loads. • Position Indexer/Speed Profiler uses a 16 step indexer to provide point-to-point positioning or velocity profiling based on encoder counts, digital inputs, parameter levels or time. • TorqProve™ assures control of the load when transferring control between the drive and a mechanical brake. • Speed Regulation - Open Loop or Closed Loop – Slip Compensation delivers a minimum 0.5% speed regulation without feedback hardware. – Droop allows drives to load share without fighting each other. – Encoder Feedback provides up to 0.001% speed regulation for the tightest application requirements. • Torque Regulation - Open Loop or Closed Loop – Open Loop torque regulation provides ±5% regulation. – Encoder Feedback provides ±2% regulation and the ability to hold full load at zero speed. Unsurpassed Capability in Network Communications PowerFlex drives are fully compatible with the wide variety of Allen-Bradley DPI™ communication adapters, offering the following benefits: Remote I/O (1) EtherNet/IP™ ControlNet™ Modbus RTU DeviceNet™ PROFIBUS™ LonWorks™ RS485 DF1 BACnet® USB ✔ ✔ ✔ Description (Unconnected Messaging) permits other network devices (e.g. PanelView™) to communicate directly to a drive without routing the communication through the network scanner. ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Adapter Routing - Plug PC into one drive and talk to all other Allen-Bradley drives on same network, without being routed through network scanner. Access to 100% of all parameters over the network. AutoBaud capability makes initial connections less problematic. Change of State significantly reduces network traffic by configuring control messages to be sent only upon customer defined states. Very flexible configuration for each node (Example: “reference must change by more than 5%”). ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Peer Control provides master-slave type control between drives, where one or more slave drives (consumers) can run based on the status of a master drive (producer), which can also significantly reduce network traffic. ADR (Automatic Device Replacement) saves significant time and effort when replacing a drive, by allowing the scanner to be configured to automatically detect a new drive and download the required parameter settings. ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Flexible Fault Configuration - Adapters can be programmed to take fault based actions as ramp to stop, coast-to-stop and hold last state, as well as send user configurable logic control and speed reference values. In addition, different actions can be taken based on whether the network experienced a serious problem (broken cable etc.) versus network idle condition (PLC set to “Program”). (1) This item has Silver Series status. For information, refer to http://www.ab.com/silver. 4 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Catalog Number Explanation 20B a D b a Drive Code 20B 2P1 c1…c5 A d 3 e A f Y g c2 ND Rating N h A i E j C k 0 l c3 ND Rating NN m AD n Type PowerFlex 700 Code 1P3 2P1 3P5 5P0 8P7 Frames 0…6 0…10 0…10 0…6 5…6 5…6, 10 5…6, 10 5…6 5…9 5…9 5…6 5…6 011 015 022 030 037 043 056 072 085 105 125 140 170 205 260 N N Y Y Y Y Y Prechg. 400V, 50 Hz Input Amps 1.3 2.1 3.5 5.0 8.7 11.5 15.4 22 30 37 43 56 72 85 105 125 140 170 205 260 292 325 365 415 481 535 600 730 875 kW 0.37 0.75 1.5 2.2 4.0 5.5 7.5 11 15 18.5 22 30 37 45 55 55 75 90 110 132 160 180 200 240 280 300 350 400 500 Frame 0 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 5 6 6 6 7 7 8 8 8 8 8 9 10 Code 1P1 2P1 3P4 5P0 8P0 011 014 022 027 034 040 052 065 077 096 125 156 180 248 292 325 365 415 481 535 600 730 875 480V, 60 Hz Input Amps 1.1 2.1 3.4 5.0 8.0 11 14 22 27 34 40 52 65 77 96 125 156 180 248 292 325 365 415 481 535 600 730 875 Hp 0.5 1.0 2.0 3.0 5.0 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 250 300 350 400 450 500 600 700 Frame 0 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 6 6 6 7 7 8 8 8 8 8 9 10 b Voltage Rating Code B C D E F H J N P R T W Voltage 240V AC 400V AC 480V AC 600V AC 690V AC 540V DC 650V DC 325V DC 540V DC 650V DC 810V DC 932V DC Ph. 3 3 3 3 3 - c1 ND Rating 208/240V, 60 Hz Input Code 2P2 4P2 6P8 9P6 015 022 028 042 052 070 080 104 130 154 192 260 208V Amps 240V Amps 2.5 4.8 7.8 11 17.5 25.3 32.2 48.3 56 78.2 92 120 130 177 221 260 2.2 4.2 6.8 9.6 15.3 22 28 42 52 70 80 104 130 154 192 260 Hp 0.5 1.0 2.0 3.0 5.0 7.5 10 15 20 25 30 40 50 60 75 100 Frame 0 0 1 1 1 1 2 3 3 4 4 5 5 6 6 6 292 325 365 415 481 535 600 730 875 c4 ND Rating 600V, 60 Hz Input Code 1P7 2P7 3P9 6P1 9P0 011 017 022 027 032 041 052 062 077 099 125 144 Amps 1.7 2.7 3.9 6.1 9.0 11 17 22 27 32 41 52 62 77 99 125 144 Hp 1.0 2.0 3.0 5.0 7.5 10 15 20 25 30 40 50 60 75 100 125 150 Frame 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 6 6 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 5 PowerFlex 700 Adjustable Frequency AC Drive 20B a D b c5 ND Rating 2P1 c1…c5 A d 3 e A f Y g f Documentation N h A i E j C k 0 l k Control & I/O NN m AD n 690V, 50 Hz Input Code 052 060 082 098 119 142 Amps 52 60 82 98 119 142 kW 45 55 75 90 110 132 Frame 5 5 5 6 6 6 Code A N Q Type Manual No Manual No Shipping Package (Internal Use Only) Code A B C D N Control Standard ♦ Standard ♦ Vector Δ Vector Δ Standard I/O Volts 24V DC/AC 115V AC 24V DC 115V AC None g Brake Code w/Brake IGBT ‡ Yes No Δ Vector Control Option utilizes DPI Only. ♦ Frame 0…6 drives only. d Enclosure Code A F♠ Enclosure IP20, NEMA/UL Type 1 Open/Flange Mount Front: IP00, NEMA/UL Type Open Back/Heatsink: IP54, NEMA Type 12 Open/Flange Mount Front: IP00, NEMA/UL Type Open Back/Heatsink: IP54, NEMA 12 Stand-Alone/Wall Mount IP54, NEMA/UL Type 12 Roll-In Front: IP00, NEMA/UL Type Open Back/Heatsink: IP54, NEMA 12 Frames 8 & 9 Only Y N l Feedback Code 0 1 Type None Encoder, 12V/5V ‡ Brake IGBT is standard on Frames 0-3, optional on Frames 4-6 and not available on Frames 7…10. h Internal Braking Resistor Code Y N Not available for Frame 3 drives or larger. w/Resistor Yes No N♣ G♠ m Future Use U n Special Firmware (Frames 0…6 Only) ♠ Only available for Frame 5 & Frame 6 drives, 400…690V. ♣ Only available for Frames 7…10. Code A i Emission CE Filter § Yes Yes No CM Choke Yes No No Code AD ♦ AE ♦ AX ♦ BA ♦ Type 60 Hz Maximum Cascading Fan/Pump Control 82 Hz Maximum Pump Off (for pump jack) e HIM Code 0 3 J♦ K♦ Operator Interface Blank Cover LCD Display, Full Numeric Keypad Remote (Panel Mount), IP66, NEMA/UL Type 12 Full Numeric LCD HIM Remote (Panel Mount), IP66, NEMA/UL Type 12 Prog. Only LCD HIM B# N § Note: 600V class drives below 77 Amps (Frames 0-4) are declared to meet the Low Voltage Directive. It is the responsibility of the user to determine compliance to the EMC directive. Frames 7…10, 400/480V AC drives (Voltage Rating codes "C" and "D") meet CE certification requirements when installed per recommendations. # Only available for 208…240V Frame 0-3 drives. ♦ Must be used with Vector Control option C or D (Position k). Positions m-n are only required when custom firmware is supplied. ♦ Available with Frames 5…6 Stand-Alone IP54 drives (Enclosure Code "G"). Code C D E N j Comm Slot Network Type ControlNet (Coax) DeviceNet EtherNet/IP None 6 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Certifications and Specifications Certifications Frames 0…4 Certification (1) ABS CE Description American Bureau of Shipping MA Certificate 08-HS303172B-3-PDA for auxiliary services on AB Classed vessels and offshore platforms Certified by Rockwell Automation to be in conformity with the essential requirements of the applicable European Directives and the standards referenced below have been applied: 2006/95/EC (Low Voltage Directive) EN 50178 Electronic Equipment for use in Power Installations 2004/108/EC (EMC Directive) EN 61800-3 Adjustable Speed electrical power drive systems - Part 3: EMC requirements and specific test methods. RCM c-UL-us EAC EPRI /SEMIF47 Functional Safety Korean KC Registration Lloyd’s Register Trentec Certified by Rockwell Automation to be in conformity with the requirements of the applicable Australian legislation and the standards referenced: IEC 61800-3. Listed to UL508C and C22.2 No. 14. Packaged drives may be listed to UL508A. Low Voltage TR CU 004/2011 EMC TR CU 020/2011 EPRI Quality Star Certificates SEMIF47.115 and SEMIF47.127 for SEMI F47 compliance, only 480V units tested EC-Type-Examination Certificate TUV 05 ATEX 7153 for directive 94/9/EC: Safe turn off of certified ATEX motors used in Group II Category (2) GD potentially explosive atmospheres. KCC-REM-RAA-20B Refer to the certificate of registration for specific drive catalog numbers that have this certification. Lloyd’s Register Type Approval Certificate 08-HS303172B-3-PDA (marine certification) Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Components and 2003 International Building Code for worst-case seismic level for USA excluding site class F CMAA Specification #70 (Crane Manufacturers of America Assoc.) NFPA 70 – US National Electrical Code NEMA ICS 7.1 – Safety Standards for Construction and Guide for Selection, Installation, and Operation of Adjustable Speed Drive Systems IEC 61800-2 – Adjustable Speed Electrical Power Drive Systems - Part 2: General Requirements - Rating specifications for low voltage adjustable frequency AC power drive systems. ✔ ✔ ✔ ✔ ✔ ✔ ✔ (2) 230…480V 600V ✔ 5…6 ✔ 7…10 ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Designed to Meet Applicable Requirements ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ (1) See the product certifications website, http://www.rockwellautomation.com/products/certification for declarations of conformity, certificates, and other certification details. (2) Frames 7…10 provided as IP00 or NEMA / UL Open style must be installed in a supplementary enclosure which provides adequate attenuation of radiated emissions in order to be compliant with EN 61800-3. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 7 PowerFlex 700 Adjustable Frequency AC Drive Environmental Category Environment Specification Altitude: Maximum Surrounding Air Temperature without Derating - IP20, NEMA / UL Type Open: Frames 0…6 Frames 7…10 Storage Temperature (all const.): Atmosphere: 1000 m (3300 ft) max. without derating 0…50 °C (32…122 °F), typical. See Installation Instructions for details. 0…40 °C (32…104 °F) for chassis (heatsink) 0…65 °C (32…149 °F) for control (front of backplane) -40…70 °C (-40…158 °F) Important: Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive 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 to 95% non-condensing 15G peak for 11ms duration (±1.0 ms) 0.152 mm (0.006 in.) displacement, 1G peak All enclosures acceptable. Enclosure that meets or exceeds IP54, NEMA / UL Type 12 required. Relative Humidity: Shock: Vibration: Surrounding Environment Pollution Degree Pollution Degree 1 & 2: Pollution Degree 3 & 4: (See page 11 for descriptions of each pollution degree rating.) Sound: Frame 0 1 2 3 4 5 6 7 8 9 10 Inv. 10 Cnv. Fan Velocity 30 CFM 30 CFM 50 CFM 120 CFM 190 CFM 200 CFM 300 CFM 756 CFM 1200 CFM 2800 CFM 1850 CFM 1200 CFM Sound Level 58 dB 59 dB 57 dB 61 dB 59 dB 71 dB 72 dB 74 dB 78 dB 82 dB 78 dB 78 dB Note: Sound pressure level is measured at 2 meters. 8 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Technical Specifications Category Protection Specification Drive AC Input Overvoltage Trip: AC Input Undervoltage Trip: Bus Overvoltage Trip: Bus Undervoltage Shutoff/Fault: Nominal Bus Voltage: All Drives Heat Sink Thermistor: Drive Overcurrent Trip Software Overcurrent Trip: Hardware Overcurrent Trip: Line transients: Control Logic Noise Immunity: Power Ride-Thru: Logic Control Ride-Thru: Ground Fault Trip: Short Circuit Trip: Electrical Voltage Tolerance: Input Frequency Tolerance: Input Phases: Monitored by microprocessor overtemp trip 200% of rated current (typical) 220…300% of rated current (dependent on drive rating) up to 6000 volts peak per IEEE C62.41-1991 Showering arc transients up to 1500V peak 15 milliseconds at full load 0.5 seconds minimum, 2 seconds typical Phase-to-ground on drive output Phase-to-phase on drive output See page 12 for full power and operating range 47…63 Hz Three-phase input provides full rating for all drives. Single-phase operation possible on certain drives and provides 50% of rated current (see Installation Instructions for details). Frames 0…7: Drive can be supplied as 6 pulse or 18 pulse in an engineered package. 0.98 across entire speed range 97.5% at rated amps, nominal line volts 200,000 Amps symmetrical Determined by AIC rating of installed fuse/circuit breaker Recommended not less than 1:2 ratio Recommended not greater than 2:1 ratio 200…208V 285V AC 120V AC 405V DC 153V DC 281V DC 240V 285V AC 138V AC 405V DC 153V DC 324V DC 380/400V 570V AC 233V AC 810V DC 305V DC 540V DC 480V 570V AC 280V AC 810V DC 305V DC 648V DC 600V Frames 0…4 716V AC 345V AC 1013V DC 381V DC 810V DC 600/690V Frames 5…6 818V AC 345V AC 1162V DC 437V DC 932V DC Displacement Power Factor: Efficiency: Maximum Short Circuit Rating: Actual Short Circuit Rating: Drive to Motor Power Ratio Minimum Maximum Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 9 PowerFlex 700 Adjustable Frequency AC Drive Category Control Specification Method: Sine coded PWM with programmable carrier frequency. Ratings apply to all drives (refer to the Derating Guidelines in the PowerFlex Reference Manual). The drive can be supplied as 6 pulse or 18 pulse in a configured package. 2, 4, 8, and 10 kHz. Drive rating based on 4 kHz. See the Input Protection Device tables in the Installation Instructions for exceptions. 0 to rated motor voltage Standard Control – 0 to 400 Hz., Vector Control – 0 to 420 Hz Within ±0.01% of set output frequency Within ±0.4% of maximum output frequency Speed Regulation - w/Slip Compensation (Volts per Hertz Mode) 0.5% of base speed across 40:1 speed range, 40:1 operating range 10 rad/sec bandwidth Speed Regulation - w/Slip Compensation (Sensorless Vector Mode) 0.5% of base speed across 80:1 speed range, 80:1 operating range 20 rad/sec bandwidth Speed Regulation - w/Feedback (Sensorless Vector Mode) 0.1% of base speed across 80:1 speed range, 80:1 operating range 20 rad/sec bandwidth Speed Control: Speed Regulation - w/o Feedback (Vector Control Mode) 0.1% of base speed across 120:1 speed range, 120:1 operating range 50 rad/sec bandwidth Speed Regulation - w/Feedback (Vector Control Mode) 0.001% of base speed across 120:1 speed range, 1000:1 operating range, 250 rad/sec bandwidth Torque Regulation: Torque Regulation - w/o Feedback ±5%, 600 rad/sec bandwidth Torque Regulation - w/Feedback ±2%, 2500 rad/sec bandwidth Selectable Motor Control: Stop Modes: Accel/Decel: Intermittent Overload: Current Limit Capability: Motor Overload Protection Frames 0…6 Standard Control: Sensorless Vector with full tuning. Standard V/Hz with full custom capability. PF700 adds Vector Control. Multiple programmable stop modes including - Ramp, Coast, DC-Brake, Ramp-to-Hold and S-curve. Two independently programmable accel and decel times. Each time may be programmed from 0…3600 seconds in 0.1 second increments. 110% Overload capability for up to 1 minute, 150% Overload capability for up to 3 seconds. Proactive Current Limit programmable from 20…160% of rated output current. Independently programmable proportional & integral gain. PowerFlex 700 drives with standard control, identified by an N, A, or B in position 15 of the catalog number, only provide Class 10 motor overload protection according to NEC article 430. They do not provide speed sensitive overload protection, thermal memory retention and motor over-temperature sensing according to NEC article 430.126 (A) (2). If such protection is needed in the end-use product, it must be provided by additional means. PowerFlex 700 drives with vector control, identified by a C or D in position 15 of the catalog number, provide class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File E59272. Class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A)(2). UL 508C File E59272. Carrier Frequency: Output Voltage Range: Output Frequency Range: Frequency Accuracy Digital Input: Analog Input: Frequency Control: Frames 0…6 Vector Control: Frames 7…10 Vector Control: 10 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Category Control (continued) Specification Digital/Analog Input Latency Signal Motor Control Latency Min. Digital Input Start FVC SVC Stop FVC SVC Analog Input Torque 4 kHz PWM Torque 2 kHz PWM Speed Speed FVC FVC FVC SVC 8.4 ms 9.2 ms 10.0 ms 10.0 ms 772 µs 1.008 ms 4.6 ms 4.8 ms Max 10.4 ms 16.0 ms 12.4 ms 12.0 ms 1.06 ms 1.46 ms 8.6 ms 12.4 ms Typical 8.4 ms 9.2 ms 10.4 ms 10.4 ms 840 µs 1.256 ms 4.8 ms 6.4 ms Encoder Type: Supply: Quadrature: Duty Cycle: Requirements: Incremental, dual channel 12V, 250 mA. 12V, 10 mA minimum inputs isolated with differential transmitter, 250 kHz maximum. 90°, ±27 degrees at 25 degrees C. 50%, +10% Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 8…15V DC output (4…6V DC when jumpers are in 5V position), single-ended or differential and capable of supplying a minimum of 10 mA per channel. Maximum input frequency is 250 kHz. The Encoder Interface Board accepts 12V DC square-wave with a minimum high state voltage of 7.0V DC. With the jumpers in the 5V position, the encoder will accept a 5V DC square-wave with a minimum high state voltage of 3.0V DC. In either jumper position, the maximum low state voltage is 0.4V DC. Pollution Degree Ratings According to EN 61800-5-1 Pollution Degree 1 2 3 4 Description No pollution or only dry, non-conductive pollution occurs. The pollution has no influence. Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the drive is out of operation. Conductive pollution or dry non-conductive pollution occurs, which becomes conductive due to condensation, which is to be expected. The pollution generates persistent conductivity caused, for example, by conductive dust, rain or snow. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 11 PowerFlex 700 Adjustable Frequency AC Drive Design Considerations Input Voltage Tolerance Drive Rating 200…240 Nominal Line Nominal Motor Voltage Voltage 200 208 240 380…480 380 400 480 500…600 600 (Frames 0…4 Only) 500…690 (Frames 5 & 6 Only) 600 690 200* 208 230 380* 400 460 575* 575* 690 Drive Full Power Range 200…264 208…264 230…264 380…528 400…528 460…528 575…660 575…660 690…759 432…660 475…759 475…759 342…528 Drive Operating Range 180…264 HP @ Motor (Drive Output) Derated Power Range Full Power Range Drive Operating Range Nominal Motor Voltage -10% Nominal Motor Voltage Drive Rated Voltage Drive Rated Voltage +10% Actual Line Voltage (Drive Input) Drive Full Power Range = Nominal Motor Voltage to Drive Rated Voltage +10%. Rated current is available across the entire Drive Full Power Range Drive Operating Range = Lowest* Nominal Motor Voltage –10% to Drive Rated Voltage +10%. Drive Output is linearly derated when Actual Line Voltage is less than the Nominal Motor Voltage 480V rated drive supplied with 342V Actual Line Voltage input. • Actual Line Voltage / Nominal Motor Voltage = 74.3% • 74.3% × 5 Hp = 3.7 Hp HP @ Motor (Drive Output) EXAMPLE Calculate the maximum power of a 5 Hp, 460V motor connected to a 5 Hp 3.7 Hp • 74.3% × 60 Hz = 44.6 Hz At 342V Actual Line Voltage, the maximum power the 5 Hp, 460V motor can produce is 3.7 Hp at 44.6 Hz. 342V 460V 480V 528V Actual Line Voltage (Drive Input) 12 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Approximate Watts Loss The following tables list the watts loss data for drives running at full load, full speed and default carrier frequency. Internal watts are those dissipated by the control structure of the drive and will be dissipated into the cabinet regardless of mounting style. External watts are those dissipated directly through the heatsink and will be outside the cabinet for flange mount and inside the cabinet for other mounting types. Watts Loss – Frames 0…6 Voltage 240V ND Hp/kW 0.5 1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 400V 0.37 0.75 1.5 2.2 4 5.5 7.5 11 15 18.5 22 30 37 45 55 55 90 110 132 External Watts 9 22 38 57 97 134 192 276 354 602 780 860 1132 1296 1716 1837 11 19 31 46 78 115 134 226 303 339 357 492 568 722 821 1130 1402 1711 1930 Internal Watts 37 39 39 41 82 74 77 92 82 96 96 107 138 200 277 418 42 44 45 46 87 79 84 99 91 102 103 117 148 207 286 397 443 493 583 Total Watts Loss(1) 46 61 77 98 179 208 269 368 436 698 876 967 1270 1496 1993 2255 53 63 76 93 164 194 218 326 394 441 459 610 717 930 1107 1527 1845 2204 2513 IP20, NEMA / UL Type 1 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 13 PowerFlex 700 Adjustable Frequency AC Drive Voltage 480V ND Hp/kW 0.5 1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 External Watts 11 19 31 46 78 115 134 226 303 339 357 492 568 722 821 1130 1402 1711 1930 9 14 25 41 59 83 109 177 260 291 324 459 569 630 1053 1467 1400 1668 894 1056 1105 1389 1283 1592 Internal Watts 42 44 45 46 87 79 84 99 91 102 103 117 148 207 286 397 443 493 583 37 40 40 42 83 75 77 93 83 95 95 109 141 195 308 407 500 612 141 195 308 407 500 612 Total Watts Loss(1) 53 63 76 93 164 194 218 326 394 441 459 610 717 930 1107 1527 1845 2204 2513 46 54 65 83 142 157 186 270 343 385 419 569 710 825 1361 1874 1900 2280 1034 1251 1412 1796 1783 2204 600V 0.5 1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 690V 45 55 75 90 110 132 14 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Voltage 480V ND Hp/kW 75 100 125 150 200 External Watts 873 1237 1563 1874 2100 1091 1537 1584 1895 Internal Watts 234 290 282 330 413 270 337 316 385 Total Watts Loss(1) 1107 1527 1845 2204 2513 1361 1874 1900 2280 IP54, NEMA / UL Type 12 600V 75 100 125 150 (1) Worst case condition including Vector Control board, HIM, and Communication Module. Watts Loss – Frames 7…10 Hp Rating Voltage 400/480V Frame ND 250 250 8 300 350 400 450 500 9 600 10 700 HD 200 250 250 300 350 400 450 500 600 Dissipation (Watts) (1) AC Input External 3422 4224 3125 3588 4284 4850 5278 8740 8595 Internal 514 618 569 681 850 1000 2010 2270 2339 Total 3936 4842 3694 4269 5133 5850 7288 11010 10934 DC Input External 3098 3848 2698 3091 3692 4178 4506 7752 7470 Internal 497 599 547 655 816 965 1969 2218 2280 Total 3595 4447 3245 3746 4510 5143 6475 9970 9750 IP20, NEMA / UL Type 1 7 (1) Worst case condition including Vector Control board, HIM, and Communication Module. Derating Guidelines Altitude and Efficiency Frame All Type Altitude % of Drive Rated Amps Derate 100% Frame All Type Efficiency (typical) Derate 100 95 vs. Speed vs. Load % Efficiency 90 85 80 75 10 20 90% 80% 30 40 50 60 70 80 90 100 % Speed/% Load 70% 0 1,000 2,000 3,000 Altitude (m) 4,000 5,000 6,000 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 15 PowerFlex 700 Adjustable Frequency AC Drive Ambient Temperature/Load – 240V AC 240 Volt Power Rating Derating ND Hp 0.5…5.0 HD Hp 0.33…3.0 Cont. Amps 2.2…15.3 None 240 Volt Power Rating 2 kHz 4 kHz ND Hp 7.5 HD Hp 5.0 Cont. Amps 22 Derating 2 kHz 50 Max Ambient Temp (°C) 45 40 35 30 25 20 40 50 4 kHz 60 70 80 % of Rated Continuous Current 90 100 10…15 7.5…10 28…42 None 20 15 52 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 25 20 70 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 30 25 80 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 40 30 104 (80) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 50 40 130 (104) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 60 50 154 (130) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 75 60 192 (154) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 100 75 260 (205) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 16 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Ambient Temperature/Load – 400V AC 400 Volt Power Rating Derating ND kW 0.37…7.5 HD kW 0.25…5.5 Cont. Amps 1.3…15.4 None 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 400 Volt Power Rating Cont. ND kW HD kW Amps 11 7.5 22 Max Ambient Temp (°C) Derating 2 kHz 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 4 kHz 6 kHz 8 kHz 10 kHz 15 11 30 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 18.5 15 37 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 22 18.5 43 None 30 22 56 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 37 30 72 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 45 37 85 (72) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 55 45 105 (85) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 75 55 140 (105) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 90 75 170 (140) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 110 90 205 (170) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 132 110 260 (205) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 160 180 200 240 280 300 350 400 500 150 180 180 200 240 280 300 350 400 292 (263) 325 (325) 365 (325) 415 (365) 481 (415) 535 (481) 600 (535) 730 (600) 875 (700) see 480 Volt, 292 (263) Amp on page 18 see 480 Volt, 325 (325) Amp on page 19 see 480 Volt, 365 (325) Amp on page 19 see 480 Volt, 415 (365) Amp on page 19 see 480 Volt, 481 (415) Amp on page 19 see 480 Volt, 535 (481) Amp on page 19 see 480 Volt, 600 (535) Amp on page 19 see 480 Volt, 730 (600) Amp on page 19 see 480 Volt, 875 (700) Amp on page 19 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 17 PowerFlex 700 Adjustable Frequency AC Drive Ambient Temperature/Load – 480V AC 480 Volt Power Rating ND Hp 0.5…10 HD Hp 0.33…7.5 Cont. Amps 1.1…14 Derating 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 480 Volt Power Rating ND Hp 15 HD Hp 10 Cont. Amps 22 Max Ambient Temp (°C) Derating 2 kHz 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 4 kHz 6 kHz 8 kHz 10 kHz None 20 15 27 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 25 20 34 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 30 25 40 None 40 30 52 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 50 40 65 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 60 50 77 (65) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 75 60 96 (77) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 100 75 125 (96) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 125 100 156 (125) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 150 125 180 (156) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 200 150 248 (180) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 250 200 292 (263) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 18 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive 480 Volt Power Rating ND Hp 250 HD Hp 250 Cont. Amps 325 (325) Max Ambient Temp (°C) 480 Volt Power Rating Derating 2 kHz 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 4 kHz 6 kHz 8 kHz 10 kHz ND Hp 300 HD Hp 250 Cont. Amps 365 (325) Derating 2 kHz 50 Max Ambient Temp (°C) 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 4 kHz 6 kHz 8 kHz 10 kHz 350 300 415 (365) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 400 350 481 (415) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 450 400 535 (481) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 500 450 600 (535) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 600 500 730 (600) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 700 600 875 (700) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 19 PowerFlex 700 Adjustable Frequency AC Drive Ambient Temperature/Load – 600V AC 600 Volt Power Rating ND Hp 1.0…2.0 HD Hp 0.5…1.0 Cont. Amps 1.7…2.7 Derating 600 Volt Power Rating 2 kHz None 4 kHz ND Hp 3.0 HD Hp 2.0 Cont. Amps 3.9 Derating 2 kHz 50 4 kHz Max Ambient Temp (°C) 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 5.0 3.0 6.1 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 7.5 5.0 9 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 10 7.5 11 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 15 10 17 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 20 15 22 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 25 20 27 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 30 25 32 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 40 30 41 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 50 40 52 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 60 50 62 Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 75 60 77 (63) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 100 75 99 (77) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 20 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive 600 Volt Power Rating ND Hp 125 HD Hp 100 Cont. Amps 125 (99) Max Ambient Temp (°C) 600 Volt Power Rating Derating 2 kHz 50 45 40 35 30 25 20 40 50 4 kHz ND Hp 150 HD Hp 125 Cont. Amps 144 (125) Derating 2 kHz 50 4 kHz Max Ambient Temp (°C) 60 70 80 % of Rated Continuous Current 90 100 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 Ambient Temperature/Load – 690V AC 690 Volt Power Rating ND kW 45…55 HD kW 37.5…45 Cont. Amps 52…60 (46…52) Derating 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 690 Volt Power Rating ND kW 75 HD kW 55 Cont. Amps 82 (60) Max Ambient Temp (°C) Derating 2 kHz 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 4 kHz 6 kHz 8 kHz 10 kHz None 90 75 98 (82) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 110 90 119 (98) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 132 110 142 (119) Max Ambient Temp (°C) 50 45 40 35 30 25 20 40 50 60 70 80 % of Rated Continuous Current 90 100 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 21 PowerFlex 700 Adjustable Frequency AC Drive Single-Phase Input Power The PowerFlex 700 drive is typically used with a three-phase input supply. Single-phase operation is possible with output current derated by 50% (at maximum ambient temperature of 25 °C) of the three-phase ratings. 208/240 Volt Single-Phase AC Input Ratings 240V Single-Phase AC Input Frame Drive Catalog Number 20BB2P2 20BB4P2 20BB6P8 20BB9P6 20BB015 20BB022 20BB028 20BB042 20BB052 20BB070 20BB080 20BB104 20BB130 20BB154 20BB192 20BB260 Hp Rating 0.25 0.5 1 1.5 2.5 3.75 5 7.5 10 12.5 15 20 25 30 37.5 50 Input Amps 1.5 2.8 5.1 7.2 11.9 17.3 22.2 33.4 41.3 55.6 63.6 84.6 105.7 125.2 156.1 211.4 Three-Phase Output V AC 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 0-230 Amps 1.1 2.1 3.4 4.8 7.7 11 14 21 26 35 40 52 65 77 96 130 208V Single-Phase AC Input Frame Drive Catalog Number 20BB2P2 20BB4P2 20BB6P8 20BB9P6 20BB015 20BB022 20BB028 20BB042 20BB052 20BB070 20BB080 20BB104 20BB130 20BB154 20BB192 20BB260 Hp Input Rating Amps 0.25 0.5 1 1.5 2.5 3.75 5 7.5 10 12.5 15 20 25 30 37.5 50 1.7 3.2 5.9 8.3 13.6 19.9 25.7 38.5 44.6 62.3 73.3 97.9 106.1 144.4 180.3 212.1 Three-Phase Output V AC 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 0-200 Amps 1.3 2.4 3.9 5.5 8.8 12.7 16.1 24.2 28 39.1 46 60 65 88.5 110.5 130 Temp. °C 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 0 0 1 1 1 1 2 3 3 4 4 5 5 6 6 6 0 0 1 1 1 1 2 3 3 4 4 5 5 6 6 6 380…480 Volt Single-Phase AC Input Ratings 480V Single-Phase AC Input Frame Drive Catalog Number 20BD1P1 20BD2P1 20BD3P4 20BD5P0 20BD8P0 20BD011 20BD014 20BD022 20BD027 20BD034 20BD040 20BD052 20BD065 20BD077 20BD096 20BD125 – 20BD156 20BD180 20BD248 Hp Rating 0.25 0.5 1 1.5 2.5 3.75 5 7.5 10 12.5 15 20 25 30 37.5 50 – 62.5 75 100 Input Amps 0.7 1.4 2.3 3.4 6 8.2 10.9 17.3 21.4 27 31.8 41.3 51.6 62.6 78.1 101.6 – 126.8 146.4 201.6 Three-Phase Output V AC 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 0-460 – 0-460 0-460 0-460 Amps 0.6 1.1 1.7 2.5 4 5.5 7 11 13.5 17 20 26 32.5 38.5 48 62.5 – 78 90 124 380…400V Single-Phase AC Input Frame Drive Catalog Number 20BC1P3 20BC2P1 20BC3P5 20BC5P0 20BC8P7 20BC011 20BC015 20BC022 20BC030 20BC037 20BC043 20BC056 20BC072 20BC085 20BC105 20BC125 20BC140 20BC170 20BC205 20BC260 kW Input Rating Amps 0.2 0.4 0.75 1.1 2 2.75 3.75 5.5 7.5 9.25 11 15 18.5 22.5 27.5 27.5 37.5 45 55 66 1 1.6 2.7 3.9 6.9 9.3 12.5 17.8 24.6 30.3 35.2 45.9 59.7 70.5 87 103.6 117.4 142.6 171.9 220.6 Three-Phase Output V AC 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 0-400 Amps 0.7 1.1 1.8 2.5 4.4 5.8 7.7 11 15 18.5 21.5 28 36 42.5 52.5 62.5 70 85 102.5 130 Temp. °C 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 0 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 – 6 6 6 0 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 5 6 6 6 22 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive 600…690 Volt Single-Phase AC Input Rating 600V Single-Phase AC Input Frame Drive Catalog Number 20BE1P7 20BE2P7 20BE3P9 20BE6P1 20BE9P0 20BE011 20BE017 20BE022 20BE027 20BE032 20BE041 20BE052 20BE062 20BE077 20BE099 20BE125 20BE144 Hp Rating 0.5 1 1.5 2.5 3.75 5 7.5 10 12.5 15 20 25 30 37.5 50 62.5 75 Input Amps 1.1 1.8 2.6 4.6 6.7 8.5 13.3 17.5 21.4 25.4 32.6 41.3 50.4 62.6 80.5 101.6 117.1 Three-Phase Output V AC 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 0-575 Amps 0.9 1.4 2 3.1 4.5 5.5 8.5 11 13.5 16 20.5 26 31 38.5 49.5 62.5 72 690V Single-Phase AC Input Frame Drive Catalog Number – – – – – – – – – – – 20BF052 20BF060 20BF082 20BF098 20BF119 20BF142 kW Rating – – – – – – – – – – – 22.5 27.5 37.5 45 55 66 Input Amps – – – – – – – – – – – 43.1 49.9 68.4 82 100 120.2 Three-Phase Output V AC – – – – – – – – – – – 0-690 0-690 0-690 0-690 0-690 0-690 Amps – – – – – – – – – – – 26 30 41 49 59.5 71 Temp. °C 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 6 6 – – – – – – – – – – – 5 5 5 5 6 6 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 23 PowerFlex 700 Adjustable Frequency AC Drive Drive, Fuse and Circuit Breaker Ratings The PowerFlex 700 can be installed with input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes can determine additional requirements for these installations. The tables on the following pages provide recommended AC line input fuse and circuit breaker information. See Fusing and Circuit Breakers below for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 °C (104 °F) and the U.S. NEC. Other country, state, or local codes can require different ratings. Tables with DC link fuse recommendations for DC input drives are also provided. Fusing The recommended fuse types are listed below. If available current ratings do not match those listed in the tables provided, choose the next higher fuse rating. • IEC – BS88 (British Standard) Parts 1 & 2, EN60269-1, Parts 1 & 2(1), type gG or equivalent must be used. • UL – UL Class CC, T, RK1 or J must be used for Frames 0…6. UL Class T, RK1, J, or L must be used for Frames 7…10. Circuit Breakers The “non-fuse” listings in the following tables include inverse time circuit breakers, instantaneous trip circuit breakers (motor circuit protectors) and 140M self-protected combination motor controllers (Frames 0…6 only). If one of these is chosen as the desired protection method, the following requirements apply: • IEC – Both types of circuit breakers and 140M self-protected combination motor controllers (Frames 0…6 only) are acceptable for IEC installations. • UL – Only inverse time circuit breakers and the specified 140M self-protected combination motor controllers (Frames 0…6 only) are acceptable for UL installations. (1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH. 24 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive 208 Volt AC Input Protection Devices – Frames 0…6 Hp Rating Frame ND 0.5 1 2 3 5 7.5 10 15 20 25 30 40 – 50 – 60 – 75 – 100 – HD 0.33 0.75 1.5 2 3 5 7.5 10 15 20 25 – 30 – 40 – 50 – 60 – 75 PWM Temp. Input Freq. (11) Ratings kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 °C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 45 50 Circuit Motor Dual Element Non-Time Delay Breaker Circuit 140M Motor Protector with Adjustable Current (3) Protector(4) Range (5)(6) Output Amps Time Delay Fuse Fuse Available Catalog Numbers Min. Enclosure 140… (7) Vol. (in.3) (14) Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2) Max. (8) Max. (8) 1.9 0.7 2.5 2.8 3.8 3 6 3 10 15 3 M-C2E-B25 M-D8E-B25 – 7269 3.7 1.3 4.8 5.6 7 6 10 6 17.5 15 7 M-C2E-B63 M-D8E-B63 – 7269 6.8 2.4 7.8 10.4 13.8 10 15 10 30 30 15 M-C2E-C10 M-D8E-C10 M-F8E-C10 7269 9.5 3.4 11 12.1 17 12 20 12 40 40 15 M-C2E-C16 M-D8E-C16 M-F8E-C16 7269 15.7 5.7 17.5 19.3 26.3 20 35 20 70 70 30 M-C2E-C20 M-D8E-C20 M-F8E-C20 7269 23 8.3 25.3 27.8 38 30 50 30 100 100 30 – M-D8E-C25 M-F8E-C25 7269 29.6 10.7 32.2 38 50.6 40 70 40 125 125 50 – – M-F8E-C32 7269 44.5 16 48.3 53.1 72.5 60 100 60 175 175 70 – – M-F8E-C45 13630 51.5 17.1 56 64 86 80 125 80 200 200 100 – – – – 72 25.9 78.2 93 124 90 175 90 300 300 100 – – – – 84.7 30.5 92 117 156 110 200 110 350 350 150 – – – – 113 40.7 120 132 175 150 250 150 475 350 150 – – – – 84.7 30.5 92 138 175 125 200 125 350 300 150 – – – – 141 44.1 130 143 175 175 275 175 500 375 250 – – – – 113 35.3 104 156 175 125 225 125 400 300 150 – – – – 167 60.1 177 195 266 225 350 225 500 500 250 – – – – 141 50.9 150 225 300 200 300 200 500 450 250 – – – – 208 75 221 243 308 300 450 300 600 600 400 – – – – 167 60.1 177 266 308 225 350 225 500 500 250 – – – – 255 91.9 260 286 390 300 575 300 750 750 400 – – – – 199 71.7 205 305 410 225 450 225 600 600 400 – – – – Drive Catalog Number 20BB2P2 20BB4P2 20BB6P8 20BB9P6 20BB015 20BB022 20BB028 20BB042 20BB052 20BB070 20BB080 20BB104 (12) 0 0 1 1 1 1 2 3 3 4 4 5 20BB130 5 (12) 20BB154 6 (12) 20BB192 6 (12) 20BB260 6 (12) See page 29 for notes. 240 Volt AC Input Protection Devices – Frames 0…6 Hp Rating Frame ND 0.5 1 2 3 5 7.5 10 15 20 25 30 40 – 50 – 60 – 75 – 100 – HD 0.33 0.75 1.5 2 3 5 7.5 10 15 20 25 – 30 – 40 – 50 – 60 – 75 PWM Temp. Input Freq. (11) Ratings kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 °C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 45 50 Circuit Motor Dual Element Non-Time Delay Breaker Circuit 140M Motor Protector with Adjustable Current (3) Protector(4) Range (5)(6) Output Amps Time Delay Fuse Fuse Available Catalog Numbers Min. Enclosure 140… (7) Vol. (in.3) (14) Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2) Max. (8) Max. (8) 1.7 0.7 2.2 2.4 3.3 3 6 3 10 15 3 M-C2E-B25 M-D8E-B25 – 7269 3.3 1.4 4.2 4.8 6.4 5 8 5 15 15 7 M-C2E-B63 M-D8E-B63 – 7269 5.9 2.4 6.8 9 12 10 15 10 25 25 15 M-C2E-C10 M-D8E-C10 M-F8E-C10 7269 8.3 3.4 9.6 10.6 14.4 12 20 12 35 35 15 M-C2E-C10 M-D8E-C10 M-F8E-C10 7269 13.7 5.7 15.3 16.8 23 20 30 20 60 60 30 M-C2E-C16 M-D8E-C16 M-F8E-C16 7269 19.9 8.3 22 24.2 33 25 50 25 80 80 30 – M-D8E-C25 M-F8E-C25 7269 25.7 10.7 28 33 44 35 60 35 100 100 50 – – M-F8E-C32 7269 38.5 16 42 46.2 63 50 90 50 150 150 50 – – M-F8E-C45 13630 47.7 19.8 52 63 80 60 100 60 200 200 100 – – – – 64.2 26.7 70 78 105 90 150 90 275 275 100 – – – – 73.2 30.5 80 105 140 100 180 100 300 300 100 – – – – 98 40.6 104 115 175 125 225 125 400 300 150 – – – – 73 30.5 80 120 160 100 175 100 300 300 100 – – – – 122 50.7 130 143 175 175 275 175 500 375 250 – – – – 98 40.6 104 156 175 125 225 125 400 300 150 – – – – 145 60.1 154 169 231 200 300 200 600 450 250 – – – – 122 50.7 130 195 260 175 275 175 500 375 250 – – – – 180 74.9 192 211 288 225 400 225 600 575 250 – – – – 145 60.1 154 231 308 200 300 200 600 450 250 – – – – 233 96.7 260 286 390 300 575 300 750 750 300 – – – – 169 70.1 205 305 410 225 450 225 600 600 250 – – – – Drive Catalog Number 20BB2P2 20BB4P2 20BB6P8 20BB9P6 20BB015 20BB022 20BB028 20BB042 20BB052 20BB070 20BB080 20BB104 (12) 0 0 1 1 1 1 2 3 3 4 4 5 20BB130 5 (12) 20BB154 6 (12) 20BB192 6 (12) 20BB260 6 (12) See page 29 for notes. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 25 PowerFlex 700 Adjustable Frequency AC Drive 400 Volt AC Input Protection Devices – Frames 0…6 Motor Circuit Circuit Input Dual Element Non-Time Delay Breaker Protector 140M Motor Protector with Adjustable Current (3) (4) Ratings Output Amps Time Delay Fuse Fuse Range(5)(6) Available Catalog Numbers Min. Enclosure Vol. (in.3) (14) Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2) Max. (8) Max. (8) 140… (7) 1.1 0.77 1.3 1.4 1.9 3 3 3 6 15 3 M-C2E-B16 – – 7269 1.8 1.3 2.1 2.4 3.2 3 6 3 8 15 3 M-C2E-B25 M-D8E-B25 – 7269 3.2 2.2 3.5 4.5 6 6 7 6 12 15 7 M-C2E-B40 M-D8E-B40 – 7269 4.6 3.2 5 5.5 7.5 6 10 6 20 20 7 M-C2E-B63 M-D8E-B63 – 7269 7.9 5.5 8.7 9.9 13.2 15 17.5 15 30 30 15 M-C2E-C10 M-D8E-C10 M-F8E-C10 7269 10.8 7.5 11.5 13 17.4 15 25 15 45 45 15 M-C2E-C16 M-D8E-C16 M-F8E-C16 7269 14.4 10 15.4 17.2 23.1 20 30 20 60 60 20 M-C2E-C20 M-D8E-C20 M-F8E-C20 7269 20.6 14.3 22 24.2 33 30 45 30 80 80 30 – M-D8E-C25 M-F8E-C25 7269 28.4 19.7 30 33 45 35 60 35 120 120 50 – – M-F8E-C32 7269 35 24.3 37 45 60 45 80 45 125 125 50 – – M-F8E-C45 7269 40.7 28.2 43 56 74 60 90 60 150 150 60 – – – – 53 36.7 56 64 86 70 125 70 200 200 100 – – – – 68.9 47.8 72 84 112 90 150 90 250 250 100 – – – – 81.4 56.4 85 94 128 110 200 110 300 300 150 – – – – 68.9 47.8 72 108 144 90 175 90 275 300 100 – – – – 100.5 69.6 105 116 158 125 225 125 400 300 150 – – – – 81.4 56.4 85 128 170 110 175 110 300 300 150 – – – – 121.1 83.9 125 138 163 150 275 150 500 375 250 – – – – 91.9 63.7 96 144 168 125 200 125 375 375 150 – – – – 136 93.9 140 154 190 200 300 200 400 400 250 – – – – 101 69.6 105 157 190 150 225 150 300 300 150 – – – – 164 126 170 187 255 250 375 250 600 500 250 – – – – 136 103 140 210 280 200 300 200 550 400 250 – – – – 199 148 205 220 289 250 450 250 600 600 400 – – – – 164 126 170 255 313 250 375 250 600 500 250 – – – – 255 177 260 286 390 350 550 350 750 750 400 – – – – 199 138 205 308 410 250 450 250 600 600 400 – – – – Drive Catalog Number 20BC1P3 20BC2P1 20BC3P5 20BC5P0 20BC8P7 20BC011 20BC015 20BC022 20BC030 20BC037 20BC043 20BC056 20BC072 20BC085 (12) (12) (12) (12) (12) (12) (12) kW Rating Frame ND 0.37 0.75 1.5 2.2 4 5.5 7.5 11 15 18.5 22 30 37 45 – 55 – 55 – 75 – 90 – 110 – 132 – HD 0.25 0.55 0.75 1.5 2.2 4 5.5 7.5 11 15 18.5 22 30 – 37 – 45 – 45 – 55 – 75 – 90 – 110 PWM Freq. Temp. kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 °C 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (10)(11) 45 (11) 45 (11) 50 (9) 50 (9) 50 (9) 50 (9) 40 (9) 40 (9) 50 (9) 50 (9) 40 (9) 40 (9) 45 (9) 50 (9) 0 0 0 0 0 0 1 1 2 2 3 3 3 4 20BC105 5 20BC125 5 20BC140 5 20BC170 6 20BC205 6 20BC260 6 See page 29 for notes. 400 Volt AC Input Protection Devices – Frames 7…10 Drive Catalog Number (12) 20BC292 20BC325 20BC365 20BC415 20BC481 20BC535 20BC600 20BC730 20BC875 kW Rating ND HD 160 150 180 180 200 180 240 200 280 240 300 280 350 300 400 350 500 400 PWM Freq. kHz 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Temp. (16) °C 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 Input Ratings Amps kVA 293 203 264 183 326 226 326 226 366 253 326 226 416 288 366 253 483 334 416 288 537 372 483 334 602 417 537 371 702 486 602 417 877 608 877 486 Output Amps Cont. 1 Min. 292 322 263 395 325 358 325 488 365 402 325 488 415 457 365 548 481 530 415 623 535 589 481 722 600 660 535 803 730 803 600 900 875 963 700 1050 Dual Element Time Delay Fuse Min. (1) Max. (2) 375 650 350 550 425 700 425 700 475 800 425 700 525 900 475 800 600 1000 525 900 700 1200 600 1000 750 1300 700 1200 900 1500 750 1300 1100 1900 900 1500 Non-Time Delay Fuse Min. (1) Max. (2) 375 850 350 550 425 950 425 950 475 1000 425 950 525 1200 475 1000 600 1400 525 1200 700 1600 600 1400 750 1800 700 1600 900 2100 750 1800 1100 2600 900 2100 Circuit Breaker (3) Max. (8) 850 750 950 950 1000 950 1200 1000 1400 1200 1600 1400 1800 1600 2100 1800 2600 2100 Motor Circuit Protector (4) Max. (8) 400 400 600 600 600 600 600 600 700 600 700 700 800 700 900 800 1200 900 Frame 7 7 8 8 8 8 8 9 10 3 Sec. 438 526 488 650 548 650 623 730 722 830 803 962 900 1070 1095 1200 1313 1400 See page 29 for notes. 26 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive 480 Volt AC Input Protection Devices – Frames 0…6 Motor Circuit Circuit Input Dual Element Non-Time Delay Breaker Protector 140M Motor Protector with Adjustable Current (3) (4) Ratings Output Amps Time Delay Fuse Fuse Range (5)(6) Available Catalog Numbers Min. Enclosure Vol. (in.3) (14) Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2) Max. (8) Max. (8) 140… (7) 0.9 0.7 1.1 1.2 1.6 3 3 3 6 15 3 M-C2E-B16 – – 7269 1.6 1.4 2.1 2.4 3.2 3 6 3 8 15 3 M-C2E-B25 – – 7269 2.6 2.2 3.4 4.5 6 4 8 4 12 15 7 M-C2E-B40 M-D8E-B40 – 7269 3.9 3.2 5 5.5 7.5 6 10 6 20 20 7 M-C2E-B63 M-D8E-B63 – 7269 6.9 5.7 8 8.8 12 10 15 10 30 30 15 M-C2E-C10 M-D8E-C10 M-F8E-C10 7269 9.5 7.9 11 12.1 16.5 15 20 15 40 40 15 M-C2E-C16 M-D8E-C16 M-F8E-C16 7269 12.5 10.4 14 16.5 22 17.5 30 17.5 50 50 20 M-C2E-C16 M-D8E-C16 M-F8E-C16 7269 19.9 16.6 22 24.2 33 25 50 25 80 80 30 – M-D8E-C25 M-F8E-C25 7269 24.8 20.6 27 33 44 35 60 35 100 100 50 – – M-F8E-C32 7269 31.2 25.9 34 40.5 54 40 70 40 125 125 50 – – M-F8E-C45 7269 36.7 30.5 40 51 68 50 90 50 150 150 50 – – M-F8E-C45 13630 47.7 39.7 52 60 80 60 110 60 200 200 70 – – – – 59.6 49.6 65 78 104 80 125 80 250 250 100 – – – – 72.3 60.1 77 85 116 100 170 100 300 300 100 – – – – 59.6 49.6 65 98 130 80 125 80 250 250 100 – – – – 90.1 74.9 96 106 144 125 200 125 350 350 125 – – – – 72.3 60.1 77 116 154 100 170 100 300 300 100 – – – – 117 97.6 125 138 163 150 250 150 500 375 150 – – – – 90.1 74.9 96 144 168 125 200 125 350 350 125 – – – – 147 122 156 172 234 200 350 200 600 450 250 – – – – 131 109 125 188 250 175 250 175 500 375 250 – – – – 169 141 180 198 270 225 400 225 600 500 250 – – – – 147 122 156 234 312 200 350 200 600 450 250 – – – – 233 194 248 273 372 300 550 300 700 700 400 – – – – 169 141 180 270 360 225 400 225 600 500 250 – – – – (17) Drive Catalog Number 20BD1P1 20BD2P1 20BD3P4 20BD5P0 20BD8P0 20BD011 20BD014 20BD022 20BD027 20BD034 20BD040 20BD052 20BD065 20BD077 (12) Hp Rating Frame ND 0.5 1 2 3 5 7.5 10 15 20 25 30 40 50 60 – 75 – 100 – 125 – 150 – 200 – HD 0.33 0.75 1.5 2 3 5 7.5 10 15 20 25 30 40 – 50 – 60 – 75 – 100 – 125 – 150 PWM Freq. Temp. kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 °C 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (11) 50 (9) 50 (9) 50 (9) 50 (9) 50 (9) 50 (9) 50 (9) 50 (9) 45 (9) 50 (9) 0 0 0 0 0 0 1 1 2 2 3 3 3 4 20BD096 5 (12) 20BD125 5 (12) 20BD156 6 (12) 20BD180 6 (12) 20BD248 6 (12) See page 29 for notes. 480 Volt AC Input Protection Devices – Frames 7…10 Drive Catalog Number (12) 20BD292 20BD325 20BD365 20BD415 20BD481 20BD535 20BD600 20BD730 20BD875 Hp Rating ND HD 250 200 250 250 300 250 350 300 400 350 450 400 500 450 600 500 700 600 PWM Freq. kHz 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Temp. (16) °C 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 Input Ratings Amps kVA 281 233 253 210 313 260 313 260 351 292 313 260 399 331 351 291 462 384 399 331 514 427 462 384 577 479 514 427 673 559 577 479 841 699 673 559 Output Amps Cont. 1 Min. 292 322 263 395 325 358 325 488 365 402 325 488 415 457 365 548 481 530 415 623 535 589 481 722 600 660 535 803 730 803 600 900 875 963 700 1050 Dual Element Time Non-Time Delay Delay Fuse Fuse Min. (1) Max. (2) Min. (1) Max. (2) 375 650 375 850 350 550 350 550 425 700 425 950 425 700 425 950 475 800 475 1000 425 700 425 950 525 900 525 1200 475 800 475 1000 600 1000 600 1400 525 900 525 1200 700 1200 700 1600 600 1000 600 1400 750 1300 750 1800 700 1200 700 1600 900 1500 900 2100 750 1300 750 1800 1100 1900 1100 2600 900 1500 900 2100 Circuit Breaker (3) Max. (8) 850 750 950 950 1000 950 1200 1000 1400 1200 1600 1400 1800 1600 2100 1800 2600 2100 Motor Circuit Protector (4) Max. (8) 400 400 600 600 600 600 600 600 700 600 700 700 800 700 900 800 1200 900 Frame 7 7 8 8 8 8 8 9 10 3 Sec. 438 526 488 650 548 650 623 730 722 830 803 962 900 1070 1095 1200 1313 1400 See page 29 for notes. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 27 PowerFlex 700 Adjustable Frequency AC Drive 600 Volt AC Input Protection Devices – Frames 0…6 (13) Hp Rating Frame HD 0.5 1 2 3 5 7.5 10 15 20 25 30 40 50 – 60 – 75 – 100 – 125 PWM Temp. Input Freq. (11) Ratings kHz 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 °C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 (9) 50 (9) 40 (9) 40 (9) 50 (9) 50 (9) 50 (9) 50 (9) Amps 1.3 2.1 3 5.3 7.8 9.9 15.4 20.2 24.8 29.4 37.6 47.7 58.2 72.3 58.2 92.9 72.3 117 93 135 117 kVA 1.4 2.1 3.1 5.5 8.1 10.2 16 21 25.7 30.5 39.1 49.6 60.5 75.1 60.5 96.6 75.1 122 96.6 141 122 Dual Element Time Delay Fuse 3 Sec. 2.6 4.8 5.9 9.2 13.5 18 25.5 34 44 54 64 82 104 116 126 126 138 188 198 216 250 Min. (1) 2 3 6 9 10 15 20 30 35 40 50 60 80 90 90 125 100 150 125 175 150 Max. (2) 4 6 9 12 20 25 40 50 60 70 90 110 125 150 125 200 175 250 200 300 275 Circuit Motor Non-Time Delay Breaker Circuit 140M Motor Protector with Adjustable Current (3) Protector (4) Range (5)(6) Fuse Available Catalog Numbers Min. Enclosure 140… (7) Vol. (in.3) (14) Min. (1) Max. (2) Max. (8) Max. (8) 2 6 15 3 M-C2E-B16 – – 7269 3 10 15 3 M-C2E-B25 – – 7269 6 15 15 7 M-C2E-B40 M-D8E-B40 – 7269 9 20 20 15 – M-D8E-B63 – 7269 10 35 30 15 – M-D8E-C10 M-F8E-C10 7269 15 40 40 15 – M-D8E-C10 M-F8E-C10 7269 20 60 50 20 – M-D8E-C16 M-F8E-C16 7269 30 80 80 30 – – M-F8E-C25 7269 35 100 100 50 – – M-F8E-C25 7269 40 125 125 50 – – M-F8E-C32 13630 50 150 150 100 – – – – 60 200 200 100 – – – – 80 225 225 100 – – – – 90 300 300 100 – – – – 90 250 250 100 – – – – 125 375 375 150 – – – – 100 300 300 100 – – – – 150 375 375 250 – – – – 125 375 375 150 – – – – 175 400 400 250 – – – – 150 375 375 250 – – – – ND 1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 (12) – 20BE099 5 100 (12) – 20BE125 6 125 (12) – 20BE144 6 150 (12) – 0 0 0 0 0 1 1 2 2 3 3 3 4 5 See page 29 for notes. Drive Catalog Number 20BE1P7 20BE2P7 20BE3P9 20BE6P1 20BE9P0 20BE011 20BE017 20BE022 20BE027 20BE032 20BE041 20BE052 20BE062 20BE077 Output Amps Cont. 1.7 2.7 3.9 6.1 9 11 17 22 27 32 41 52 62 77 63 99 77 125 99 144 125 1 Min. 2 3.6 4.3 6.7 9.9 13.5 18.7 25.5 33 40.5 48 61.5 78 85 94 109 116 138 149 158 188 690 Volt AC Input Protection Devices – Frames 0…6 (13) Drive Catalog Number (12) 20BF052 5 20BF060 20BF082 20BF098 20BF119 20BF142 5 5 5 6 6 kW Rating ND HD 45 – – 37.5 55 – – 45 75 – – 55 90 – – 75 110 – – 90 132 – – 110 PWM Freq. kHz 4 4 4 4 2 2 2 2 2 2 2 2 Temp.(11) °C 50 (9) 50 (9) 50 (9) 50 (9) 50 (9) 50 (9) 40 (9) 40 (9) 50 (9) 50 (9) 50 (9) 50 (9) Input Ratings Amps kVA 46.9 56.1 40.1 48 57.7 68.9 46.9 56.1 79 94.4 57.7 68.9 94.7 113 79 94.4 115 137 94.7 113 138 165 115 137 Output Amps Cont. 1 Min. 52 57 46 69 60 66 52 78 82 90 60 90 98 108 82 123 119 131 98 147 142 156 119 179 Dual Element Time Delay Fuse 3 Sec. Min. (1) Max. (2) 78 60 110 92 50 90 90 80 125 104 60 110 123 100 200 120 80 125 127 125 200 140 100 200 179 150 250 196 125 200 213 175 300 238 150 250 Non-Time Delay Fuse Min. (1) Max. (2) 60 175 50 150 80 225 60 175 100 375 80 225 125 375 100 375 150 400 125 375 175 450 150 400 Circuit Breaker (3) Max. (8) 175 150 225 175 375 225 375 375 – – – – Motor Circuit Protector (4) Max. (8) – – – – – – – – – – – – Frame See page 29 for notes. 28 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Notes (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Minimum protection device size is the lowest rated device that supplies maximum protection without nuisance tripping. Maximum protection device size is the highest rated device that supplies drive protection. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum. Circuit Breaker - inverse time breaker. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum. Motor Circuit Protector - instantaneous trip circuit breaker. For US NEC minimum size is 125% of motor FLA. Ratings shown are maximum. Bulletin 140M with adjustable current range must have the current trip set to the minimum range that the device will not trip. Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or 600Y/ 347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers can vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings. Maximum allowable rating by US NEC. Exact size must be chosen for each installation. UL Type 12/IP54 (flange mount) heat sink ambient temperature rating is 40° C/ambient of unprotected drive portion (inside enclosure) is 55° C. The ambient temperature for the UL Type 12/IP54 standalone drives is 40° C. Must remove top label and vent plate, drive enclosure rating is IP00, NEMA / UL Type Open. Frames 0…4 temperature rating is for NEMA / UL Type Open. The adhesive top label must be removed to operate drive at this temperature. Frames 5 & 6 do not have a top label. Drives have dual current ratings; one for normal duty applications, and one for heavy duty applications. The drive can be operated at either rating. Note: 600V class drives below 77 Amps (Frames 0…4) are declared to meet the Low Voltage Directive. It is the responsibility of the user to determine compliance to the EMC directive. When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations can require a larger enclosure. Frame 7…10 drives are CE Certified for use with 400V AC and 480V AC center grounded neutral power supply systems only. It is the responsibility of the user to determine compliance to the EMC directive. Temperature rating is for IP20, NEMA / UL Type 1. For IP00, NEMA Type Open the temperature rating is 65 °C for the control board and 40 °C for the heat sink entry air. Input current on the drive can be lower than the output current due to the power factor correction in the drive. 325 Volt DC Input Protection Devices – Frames 0…6 Drive Catalog Number 20BB2P2 20BB4P2 20BB6P8 20BB9P6 20BB015 20BB022 20BB028 20BB042 20BB052 20BB070 20BB080 20BN104 (3) 20BN130 (3) 20BN154 (3) 20BN192 (3) 20BN260 (3) Frame Hp Rating ND 0.5 1 2 3 5 7.5 10 15 20 25 30 40 – 5 6 6 6 50 – 60 – 75 – 100 – See page 32 for notes. HD 0.33 0.75 1.5 2 3 5 7.5 10 15 20 25 – 30 – 40 – 50 – 60 – 75 DC Input PWM Freq. Temp. (1) Ratings kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 °C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 45 50 Amps 2 3.8 6.9 9.7 16 23.3 30 45 55 75.3 86.8 114.1 85.8 142.6 114.1 169 142.6 210.6 169 285.3 210.6 Output Amps Cont. 2.2 4.2 6.8 9.6 15.3 22 28 42 52 70 80 104 80 130 104 154 130 192 154 260 205 1 Min. 2.4 4.8 9 10.6 16.8 24.2 33 46.2 63 78 105 115 120 143 156 169 195 211 231 286 305 3 Sec. 3.3 6.4 12 14.4 23 33 44 63 80 105 140 175 160 175 175 231 260 288 308 390 410 Fuse 5 10 15 20 30 45 60 90 100 150 175 200 200 200 200 300 300 350 350 400 400 Non-Time Delay Fuse (2)(11) JKS-5 JKS-10 HSJ15 HSJ20 HSJ30 HSJ45 HSJ60 HSJ90 HSJ100 HSJ150 HSJ175 HSJ200 HSJ200 HSJ200 HSJ200 HSJ300 HSJ300 HSJ350 HSJ350 HSJ400 HSJ400 0 0 1 1 1 1 2 3 3 4 4 5 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 29 PowerFlex 700 Adjustable Frequency AC Drive 540 Volt DC Input Protection Devices – Frames 0…6 Drive Catalog Number 20BC1P3 20BC2P1 20BC3P5 20BC5P0 20BC8P7 20BC011 20BC015 20BC022 20BC030 20BC037 20BC043 20BC056 20BC072 20BC085 (3)(5) Frame kW Rating ND 0.37 0.75 1.5 2.2 4 5.5 7.5 11 15 18.5 22 30 37 45 – 55 – 75 – 90 – 110 – 132 – HD 0.25 0.55 0.75 1.5 3 4 5.5 7.5 11 15 18.5 22 30 – 37 – 45 – 55 – 75 – 90 – 110 PWM Freq. kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 Temp. (1) DC Input Ratings Output Amps °C 50 50 50 50 50 50 50 50 50 50 50 50 50 (7) 45 45 50 (4) 50 (4) 40 (4) 40 (4) 50 (4) 50 (4) 40 (4) 40 (4) 45 (4) 50 (4) Amps 1.3 2.1 3.7 5.3 9.3 12.6 16.8 24 33.2 40.9 47.5 61.9 80.5 95.1 80.5 120.2 95.1 159 120.2 192.3 159 226 192.3 298 226 Cont. 1 Min. 3 Sec. 1.3 2.1 3.5 5 8.7 11.5 15.4 22 30 37 43 56 72 85 72 105 85 140 105 170 140 205 170 260 205 1.4 2.4 4.5 5.5 9.9 13 17.2 24.2 33 45 56 64 84 94 108 116 128 154 158 187 210 220 255 286 305 1.9 3.2 6 7.5 13.2 17.4 23.1 33 45 60 74 86 112 128 144 158 170 190 190 255 280 289 313 390 410 Fuse 3 6 8 10 15 20 25 40 50 70 90 100 125 150 175 175 200 225 225 300 300 350 350 500 500 Non-Time Delay Fuse (2)(11) JKS-3 JKS-6 JKS-8 JKS-10 HSJ15 HSJ20 HSJ25 HSJ40 HSJ50 HSJ70 HSJ90 HSJ100 HSJ125 HSJ150 HSJ175 HSJ175 HSJ200 HSJ225 HSJ225 HSJ300 HSJ300 HSJ350 HSJ350 HSJ500 HSJ500 0 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 6 6 6 20BH105 (3)(5) 20BH140 (3)(5) 20BH170 (3)(5) 20BH205 (3)(5) 20BH260 (3)(5) See page 32 for notes. 540 Volt DC Input with Precharge – Frames 7…10 Drive Catalog Number 20BP292 20BP325 20BP365 20BP415 20BP481 20BP535 20BP600 20BP730 20BH875 No Precharge Frame kW Rating ND 160 150 7 8 8 8 8 8 9 180 180 200 180 240 200 280 240 300 280 350 300 400 350 10 500 400 HD PWM Freq. kHz 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Temp. °C 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 DC Input Ratings Output Amps Amps 342 309 381 381 428 381 487 428 564 487 627 564 703 627 855 703 1025 820 kW 185 166 206 206 231 206 262 231 304 262 338 304 379 338 461 379 553 443 Cont. 1 Min. 3 Sec. 292 263 325 325 365 325 415 365 481 415 535 481 600 535 730 600 875 700 322 395 358 488 402 488 457 548 530 623 589 722 660 803 803 900 963 1050 438 526 488 650 548 650 623 730 722 830 803 962 900 1070 1095 1200 1313 1400 Fuse 500 630 630 800 630 800 800 900 900 1000 1000 1100 1100 1200 1200 1400 (8) (8) (9) (9) Non-Time Delay Fuse (2)(11) 170M6608 (10) 170M6610 (10) 170M6610 (10) 170M6612 (10) 170M6610 (10) 170M6612 (10) 170M6612 (10) 170M6613 (10) 170M6613 (10) 170M6614 (10) 170M6614 (10) 170M6615 (10) 170M6615 (10) 170M6616 (10) 170M6616 (10) 170M6617 (10) 170M6612 (10) 170M6612 (10) 7 2 x 800 2 x 800 See page 32 for notes. 30 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive 650 Volt DC Input Protection Devices – Frames 0…6 Drive Catalog Number 20BD1P1 20BD2P1 20BD3P4 20BD5P0 20BD8P0 20BD011 20BD014 20BD022 20BD027 20BD034 20BD040 20BD052 20BD065 20BD077 (3) 20BR096 (3)(6) 20BR125 20BR156 20BR180 (3)(6) Frame Hp Rating ND 0.5 1 2 3 5 7.5 10 15 20 25 30 40 50 60 – 75 – 100 – 125 – 150 – 200 – HD 0.33 0.75 1.5 2 3 5 7.5 10 15 20 25 30 40 – 50 – 60 – 75 – 100 – 125 – 150 PWM Freq. Temp. (1) DC Input Ratings Output Amps kHz 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 °C 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 (4) 50 (4) 50 (4) 50 (4) 50 (4) 50 (4) 50 (4) 50 (4) 45 (4) 50 (4) Amps 1.0 1.9 3.0 4.5 8.1 11.1 14.7 23.3 28.9 36.4 42.9 55.7 69.7 84.5 69.7 105.3 84.5 137.1 105.3 171.2 137.1 204 171.2 272 204 Cont. 1.1 2.1 3.4 5.0 8.0 11 14 22 27 34 40 52 65 77 65 96 77 125 96 156 125 180 156 248 180 1 Min. 3 Sec. 1.2 2.4 4.5 5.5 8.8 12.1 16.5 24.2 33 40.5 51 60 78 85 98 106 116 138 144 172 188 198 234 273 270 1.6 3.2 6.0 7.5 12 16.5 22 33 44 54 68 80 104 116 130 144 154 163 168 234 250 270 312 372 360 Fuse 3 6 6 10 15 20 30 40 50 60 80 90 100 150 150 175 175 200 200 300 300 400 400 400 400 Non-Time Delay Fuse (2)(11) JKS-3 JKS-6 JKS-6 JKS-10 HSJ15 HSJ20 HSJ30 HSJ40 HSJ50 HSJ60 HSJ80 HSJ90 HSJ100 HSJ150 HSJ150 HSJ175 HSJ175 HSJ200 HSJ200 HSJ300 HSJ300 HSJ400 HSJ400 HSJ400 HSJ400 0 0 0 0 0 0 1 1 2 2 3 3 3 4 5 5 6 6 6 (3)(6) (3)(6) 20BR248 (3)(6) See page 32 for notes. 650 Volt DC Input with Precharge – Frames 7…10 Drive Catalog Number 20BR292 20BR325 20BR365 20BR415 20BR481 20BR535 20BR600 20BR730 20BJ875 No Precharge Frame Hp Rating ND 250 200 7 8 8 8 8 8 9 250 250 300 250 350 300 400 350 450 400 500 450 600 500 10 700 600 HD PWM Freq. Temp. kHz 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 °C 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 DC Input Ratings Output Amps Amps 328 296 365 365 410 365 466 410 540 466 601 540 674 601 820 674 983 786 kW 212 191 236 236 265 236 302 265 350 302 389 350 436 389 533 436 636 509 Cont. 292 263 325 325 365 325 415 365 481 415 535 481 600 535 730 600 875 700 1 Min. 3 Sec. Fuse 322 395 358 488 402 488 457 548 530 623 589 722 660 803 803 900 963 1050 438 526 488 650 548 650 623 730 722 830 803 962 900 1070 1095 1200 1313 1400 500 630 550 800 630 800 700 800 800 900 900 1000 1000 1200 1200 1400 1400 1600 (8) (8) (9) (9) Non-Time Delay Fuse (2)(11) 170M6608 (10) 170M6610 (10) 170M6609 (10) 170M6612 (10) 170M6610 (10) 170M6612 (10) 170M6611 (10) 170M6612 (10) 170M6619 (10) 170M6613 (10) 170M6613 (10) 170M6614 (10) 170M6614 (10) 170M6616 (10) 170M6616 (10) 170M6617 (10) 2 x 170M6611 (10) 2 x 170M6612 (10) 7 See page 32 for notes. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 31 PowerFlex 700 Adjustable Frequency AC Drive 810 Volt DC Input Protection Devices – Frames 0…6 Drive Catalog Number 20BE1P7 20BE2P7 20BE3P9 20BE6P1 20BE9P0 20BE011 20BE017 20BE022 20BE027 20BE032 20BE041 20BE052 20BE062 20BT099 (3) 20BT144 (3) Frame Hp Rating ND 1 2 3 5 7.5 10 15 20 25 30 40 50 60 100 – 6 150 – HD 0.75 1.5 2 3 5 7.5 10 15 20 25 30 40 50 – 75 – 125 PWM Freq. Temp. (1) DC Input Ratings Output Amps kHz 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 °C 50 50 50 50 50 50 50 50 50 50 50 50 50 40 40 50 50 Amps 1.5 2.4 3.5 6.2 9.1 11.5 18 23.6 29 34.3 43.9 55.7 68 108.6 84.5 158 137.1 Cont. 1.7 2.7 3.9 6.1 9 11 17 22 27 32 41 52 62 99 77 144 125 1 Min. 2 3.6 4.3 6.7 9.9 13.5 18.7 25.5 33 40.5 48 61.5 78 109 116 158 188 3 Sec. Fuse 2.6 4.8 5.9 9.2 13.5 18 25.5 34 44 54 64 82 104 126 138 216 250 3 6 6 10 15 20 30 40 50 60 70 90 125 150 150 250 250 Non-Time Delay Fuse (2)(11) JKS-3 JKS-6 JKS-6 JKS-10 HSJ15 HSJ20 HSJ30 HSJ40 HSJ50 HSJ60 HSJ70 HSJ90 HSJ125 HSJ150 HSJ150 HSJ250 HSJ250 0 0 0 0 0 0 1 2 2 3 3 3 4 5 932 Volt DC Input Protection Devices – Frames 0…6 Frame Drive Catalog Number 20BW052 (3) 20BW098 (3) 20BW142 (3) kW Rating ND 45 – 5 6 90 – 132 – HD – 37.5 – 75 – 110 PWM Freq. Temp. (1) DC Input Ratings Output Amps kHz 2 2 2 2 2 2 °C 50 (4) 50 (4) 50 (4) 50 (4) 50 (4) 40 (4) Amps 58.2 46.9 110.7 92.3 162.2 134.9 Cont. 52 46 98 82 142 119 1 Min. 3 Sec. Fuse 57 69 108 123 156 179 78 92 127 140 213 238 100 100 160 160 250 315 Non-Time Delay Fuse (2)(11) 170M3691 170M3691 170M3693 170M3693 170M3695 170M3696 5 Notes (1) (2) Frames 0…4 temperature rating is for NEMA / UL Type Open. The adhesive top label must be removed to operate drive at this temperature. Frames 5 & 6 do not have a top label. The power source to common bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC). Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus. Disconnects: Allen-Bradley Bulletin 1494, 30-400A; 194, 30-400A; or ABB OESA, 600 & 800A; OESL, all sizes. Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory. Drives have dual current ratings; one for normal duty applications, and one for heavy duty applications. The drive can be operated at either rating. UL Type 12/IP54 (flange mount) heatsink ambient temperature rating is 40 °C/ambient of unprotected drive portion (inside enclosure) is 55 °C. The ambient temperature for the UL Type 12/IP54 standalone drives is 40 °C. Also applies to “P” voltage class. Also applies to “J” voltage class. Must remove top label and vent plate, drive enclosure rating is IP00, NEMA / UL Type Open. Two 630A Bussmann 170M6608 can also be used. Two 700A Bussmann 170M6611 can also be used. Bussmann or equivalent. See Fuse Certification and Test Data in PowerFlex AC Drives in Common Bus Configurations Application Guidelines, publication DRIVES-AT002, for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing. (3) (4) (5) (6) (7) (8) (9) (10) (11) 32 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Cable Recommendations Power Cable Types Acceptable for 200…600 Volt Installations A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4mm/0.015 in.). Use Copper wire only. Wire gauge requirements and recommendations are based on 75° C. Do not reduce wire gauge when using higher temperature wire. See table below. Location Standard (Option 1) Rating/Type 600V, 90° C (194° F) XHHW2/RHW-2 Anixter B209500-B209507, Belden 29501-29507, or equivalent Tray rated 600V, 90° C (194° F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent Description • Four tinned copper conductors with XLP insulation. • Copper braid/aluminum foil combination shield and tinned copper drain wire. • PVC jacket. • Three tinned copper conductors with XLPE insulation. • 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield. • PVC jacket. • Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor. • Black sunlight resistant PVC jacket overall. • Three copper grounds on #10 AWG and smaller. Standard (Option 2) Class I & II; Division I & II Tray rated 600V, 90° C (194° F) RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent Unshielded THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire chosen must have a minimum insulation thickness of 15 Mils and should not have large variations in insulation concentricity. Shielded/Armored Cable Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications/ networking are also good candidates for shielded cable. Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment. A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 33 PowerFlex 700 Adjustable Frequency AC Drive Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known. Maximum Motor Cable Lengths For information on maximum motor cable lengths, refer to the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Power Wiring The PowerFlex 700 has the following built in protective features to help simplify installation: • Ground fault protection during start up and running ensures reliable operation • Electronic motor overload protection increases motor life • Removable MOV to ground and common mode capacitors to ground ensure compatibility with ungrounded systems. These devices must be disconnected if the drive is installed on a resistive grounded distribution system, an ungrounded distribution system, a B phase grounded distribution system or impedance grounded system. These devices must also be disconnected if the drive power source is a regenerative unit (such as a bus supply and brake) or is DC fed from an active converter. • 6 kV transient protection provides increased robustness for 380…480V system voltages There are many other factors that must be considered for optimal performance in any given application. The block diagram below highlights the primary installation considerations. Consult the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 for detailed recommendations on input power conditioning, dynamic braking, reflected wave protection and motor cable types. DC Input Input Fuses - Page 24 Input Cable Length - Page 34 Input Power Conditioning - Page 81 Not Used EMC Requirements AC Input Branch Circuit Protective Devices - Page 24 Same as AC LCD Human Interface Module - Page 78 Removable MOV and Caps (underneath cover) Reflected Wave Reduction - Page 80 Cable Requirements - Page 33 Integral Class 10 Motor Overload Motor Recommendations see Allen-Bradley Industrial Motors, publication MOTORS-PP006. Same as AC 34 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Terminal Blocks Terminal Block Specifications Refer to pages 36…38 for typical locations. Wire Size Range - See Note (3) No. Name Block Frame Description Maximum 2 Torque Maximum 1.7 N•m (15 lb.•in.) 1.7 N•m (15 lb.•in.) 3.6 N•m (32 lb.•in.) 1.7 N•m (15 lb.•in.) 4.0 N•m (35 lb.•in.) See Note (5) Recommended 0.8 N•m (7 lb.•in.) 1.4 N•m (12 lb.•in.) 1.8 N•m (16 lb.•in.) 1.4 N•m (12 lb.•in.) 4.0 N•m (35 lb.•in.) Minimum 0.5 mm2 (22 AWG) 0.8 mm (18 AWG) 2.5 mm2 (14 AWG) 0.8 mm2 (18 AWG) 10.0 mm (14 AWG) 4.0 mm2 (8 AWG) 2 2 ➊ Power Terminal 0 & 1 2 3 Input power and motor connections 4.0 mm2 (12 AWG) Input power and motor connections 10.0 mm (8 AWG) Input power and motor connections 25.0 mm2 (3 AWG) BR1, 2 terminals 10.0 mm2 (8 AWG) 2 4 Input power and motor connections 35.0 mm (3 AWG) 50.0 mm2 (1 AWG) Input power, DC+, DC–, BR1, 2, PE, 5 75Hp, 480V motor connections 100Hp, 600V 5 100Hp 6 7 8&9 10 Input power, DC+, DC– and motor BR1, 2, PE terminals Input power, DC+, DC–, BR1, 2, PE, motor connections Input power, DC+, DC–, PE, motor connections Input power, DC+, DC–, PE, motor connections Input power, DC+, DC–, PE, motor connections 70.0 mm2 (2/0 AWG) 50.0 mm2 (1/0 AWG) 150.0 mm2 (300 MCM) see Note (4) 150.0 mm2 (300 MCM) see Note (4) 300.0 mm2 (600 MCM) see Note (4) 300.0 mm2 (600 MCM) see Note (4) 10.0 mm2 (8 AWG) 4.0 mm2 (12 AWG) 2.5 mm2 (14 AWG) 2.5 mm2 (14 AWG) 2.5 mm2 (14 AWG) 2.5 mm2 (14 AWG) 6.0 N•m (52 lb.•in.) 2.7 N•m (24 lb.•in.) 10.0 N•m (87 lb.•in.) 10.0 N•m (87 lb.•in.) 6.0 N•m (52 lb.•in.) 2.7 N•m (24 lb.•in.) 10.0 N•m (87 lb.•in.) 10.0 N•m (87 lb.•in.) ➋ SHLD Terminal ➌ AUX Terminal Block 0…6 0…4 5…6 7…10 Terminating point for wiring shields — Auxiliary control voltage PS+, PS– (1)(2) 1.5 mm2 (16 AWG) 4.0 mm2 (12 AWG) 4.0 mm2 (12 AWG) Signal & control connections 2.5 mm2 (14 AWG) 4.0 mm2 (12 AWG) Encoder power & signal connections User supplied fan voltage 0.75 mm2 (18 AWG) — 0.2 mm2 (24 AWG) 0.5 mm2 (22 AWG) 0.049 mm2 (30 AWG) 0.30 mm2 (22 AWG) 0.049 mm2 (30 AWG) 0.196 mm2 (24 AWG) 1.6 N•m (14 lb.•in.) — 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 1.6 N•m (14 lb.•in.) — 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) ➍ I/O Terminal Block 0…6 7…10 0…10 ➎ Encoder Terminal Block ➏ Fan Terminal Block 5…6 7 8…10 4.0 mm2 (12 AWG) 4.0 mm2 (12 AWG) 4.0 mm2 (12 AWG) 0.5 mm2 (22 AWG) 0.5 mm2 (22 AWG) 0.5 mm (22 AWG) 2 0.6 N•m (5.3 lb.•in.) 0.9 N•m (8.0 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) 0.6 N•m (5.3 lb.•in.) (1) External control power: UL Installation-300V DC, ±10%, Non UL Installation-270…600V DC, ±10% (0…3 Frame-40W, 165 mA, 5 Frame-80W, 90 mA). (2) An Auxiliary Control Power Supply such as the 20-24V-AUX can be used with 400/480 and 600/690 Volt drives with Vector Control. However, consult the factory before using an auxiliary power supply in these instances. Important: The Auxiliary Control Power Supply Must Not be used with any Standard Control drive or any 200/240V PowerFlex 700 drive, Standard or Vector Control. (3) Maximum/minimum sizes that the terminal block will accept - these are not recommendations. (4) If may be necessary to connect multiple wires in parallel to these terminals using multiple lugs. (5) Refer to the terminal block label inside the drive. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 35 PowerFlex 700 Adjustable Frequency AC Drive Typical Terminal Block Location ➌ ! DANGER ➍ BR1 ➍ Optional Communications Module Use 75C Wire Only #10-#14 AWG Torque to 7 in-lbs ➍ WIRE STRIP 75C Cu Wire 6 AWG [10MM2] Max. 12 IN. LBS. 1.4 N-M } TORQUE Optional Communications Module DC– PE U/T1 V/T2 W/T3 R/L1 CONTROL ➎ ➊ ➋ BR2 DC+ ➎ ➌ ➊ ➎ PE B BR1 B AUX IN+ AUX OUT– V/T2 W/T3 PE R/L1 S/L2 T/L3 POWER S/L2 T/L3 SHLD SHLD 75C Cu Wire 6 AWG [10MM2] Max. 12 IN. LBS. 1.4 N-M } TORQUE 75C Cu Wire 3 AWG [25MM2] Max. 16 IN. LBS. 1.8 N-M } TORQUE AUX IN + – BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 Frames 0…1 ➋ Frame 2 PE SHLD ➋ SHLD Frames 3…4 ➋ ➍ Optional Communications Module ➋ ➍ ➎ POWER TERMINAL RATINGS WIRE RANGE: 14-1/0 AWG (2.5-35 MM2) TORQUE: 32 IN-LB (3.6 N-M) STRIP LENGTH: 0.67 IN (17 MM) USE 75 C CU WIRE ONLY GROUND TERMINAL RATINGS (PE) WIRE RANGE: 6-1/0 AWG (16-35 MM2) TORQUE: 44 IN-LB (5 N-M) STRIP LENGTH: 0.83 IN (21 MM) 21 17 Optional Communications Module ➎ 300 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: 22-10 AWG (0.5-4 MM2) TORQUE: 5.3 IN-LB (0.6 N-M) STRIP LENGTH: 0.35 IN (9 MM) 9 0 120 240 VAC VAC VAC ➌ OUTPUT INPUT AC ➌ WIRE STRIP 22-10 AWG 5.3 IN-LB (0.6 N-M) PS+ PS– BR2 BR1 DC+ DC– ➊ Frame 5 ➊ ➏ DC Input Drives Only USE 75C COPPER WIRE ONLY TORQUE 52 IN-LB (6 N-M) USE 75C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M) T1 T2 OUTPUT T3 L1 L2 INPUT L3 ➏ DC Input Drives Only Junction Box see page 59 for details / PE Frame 6 36 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 CONTROL ➊ ➌ PE A WIRE STRIP BR1 BR2 POWER PowerFlex 700 Adjustable Frequency AC Drive Typical Terminal Block Locations (continued) ➊ DC+ ! DANGER ➎ ! CAUTION HOT SURFACES DANGER ! DANGER RISK OF SHOCK REPLACE AFTER SERVICING TB11 25 AMPERES RMS MAXIMUM ➌➍ PE ALLEN-BRADLEY MADE IN U.S.A. ➏ ! DANGER RISK OF SHOCK REPLACE AFTER SERVICING ➏ ! DC Input Only 8 AMPERES RMS MAXIMUM TB9 ➎ DANGER RISK OF SHOCK REPLACE AFTER SERVICING ➊ ! DANGER RISK OF SHOCK REPLACE AFTER SERVICING +DC -DC PE PE R-L1 S-L2 T-L3 U-M1 V-M2 W-M3 25 AMPERES RMS MAXIMUM USE 75° COPPER WIRE ONLY TORQUE LARGE TERMINALS TO 10 N-m (87LB-IN) TB11 ➌➍ TE U DC+ R GND V S T W DC- ➊ Frame 7 Frames 8…9 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 37 PowerFlex 700 Adjustable Frequency AC Drive Typical Terminal Block Locations (continued) DANGER DC+ ➊ ➎ DANGER ! DANGER DANGER RISK OF SHOCK REPLACE AFTER SERVICING ➏ ➌➍ ➊ 8 AMPERES RMS MAXIMUM TB9 120 IN1 120 IN2 3 4 5 6 ! DANGER RISK OF SHOCK REPLACE AFTER SERVICING 25 AMPERES RMS MAXIMUM TB11 PE ! DANGER RISK OF SHOCK REPLACE AFTER SERVICING ! DANGER RISK OF SHOCK REPLACE AFTER SERVICING U V W 120 IN1 120 IN2 3 4 5 6 ➏ 8 AMPERES RMS MAXIMUM TB10 GND ➏ 8 AMPERES RMS MAXIMUM TB10 120 IN1 120 IN2 3 4 5 6 GND Frame 10 AC Input shown, DC Input Drives utilize the Inverter (Left) Bay only 38 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Power Terminals Frame 0…1 BR1 BR2 DC+ DC– PE U (T1) V (T2) W (T3) R (L1) S (L2) T (L3) Terminal Block * Note: Shaded BR1 & BR2 Terminals will only be present on drives ordered with the Brake Option. 2 BR1 BR2 DC+ DC– U V W (T1) (T2) (T3) PE R S T (L1) (L2) (L3) 3…4 BR1 BR2 DC+ DC– U V W R S T (T1) (T2) (T3) (L1) (L2) (L3) AC Input 5 75 Hp, Normal Duty PS– BR1*/ DC– V/T2 BR2* DC+ DC+ U/T1 W/T3 PE PE R/L1 S/L2 T/L3 DC Input 75 Hp, Normal Duty PS– BR1*/ BR2* DC+ DC+ DC– U/T1 V/T2 W/T3 PE 0 240 VAC VAC PE PS+ PS+ 120 VAC 100 Hp, Normal Duty BR1*/ BR2* DC+ DC+ DC– U/T1 V/T2 W/T3 PS– R/L1 S/L2 T/L3 PE PE 100 Hp, Normal Duty BR1*/ BR2* DC+ DC+ DC– PS– U/T1 V/T2 W/T3 PE 0 240 VAC VAC PE PS+ PS+ 120 VAC 6 125…200 Hp, Normal Duty 125…200 Hp, Normal Duty PS+ PS– WIRE STRIP WIRE STRIP 22-10 AWG 5.3 IN-LB (0.6 N-M) BR2 BR1 DC+ DC– 22-10 AWG 5.3 IN-LB (0.6 N-M) PS+ PS– BR2 BR1 DC+ DC– USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M) USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M) TORQUE 52 IN-LB (6 N-M) U T1 V T2 OUTPUT W T3 PE PE R L1 S L2 INPUT T L3 USE 75 C COPPER WIRE ONLY TORQUE 52 IN-LB (6 N-M) FAN INPUT OUTPUT Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 1-PHASE U T1 V T2 W T3 PE PE 22-10 AWG 5.3 IN-LB (0.6 N-M) 0 VAC 120 VAC 240 VAC USE 75 C COPPER WIRE ONLY 39 PowerFlex 700 Adjustable Frequency AC Drive Frame Terminal Block AC Input DC Input 7 DC+ DC– Bus PE PE R-L1 S-L2 T-L3 U-T1 V-T2 W-T3 Input Output 120 USE 75° COPPER WIRE ONLY TORQUE LARGE TERMINALS TO 10 N-m (87 LB-IN) PE DC+ DCBUS U-T1 V-T2 OUTPUT W-T3 8…9 DC+ W DC – DC Bus/Brake (top of drive) DC+* PE DC –* DC – T V S R U DC+ W V U DC Bus/Brake (top of drive) * for DC link choke wiring T L3 S L2 R L1 DC+ R L1 PE 10 DC+ DC – DC Bus/Brake (top of drive) T L3 S L2 DC – DC Bus/Brake (top of drive) W W PE (IP20 Versions Only) V U PE (IP20 Versions Only) V U Fan Circuit Power Supply Some drives utilize a fan transformer to power the internal fan(s). This transformer is sized specifically for the internal fan(s) and must not be used to power other circuitry. If your line voltage is different than the voltage class specified on the drive nameplate, changing the transformer taps will be required. Frames 5…6 Fan Connections Drive Type DC Input Enclosure IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 IP54, NEMA / UL Type 12 AC Input IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 IP54, NEMA / UL Type 12 Rating (120V AC) 100 VA (Frame 5) 138 VA (Frame 6) 100 VA (Frame 5) 138 VA (Frame 6) 100 VA (Frame 5) 138 VA (Frame 6) 100 VA (Frame 5) 138 VA (Frame 6) P3 P2 Primary Fuse 3.5A, 250V No. of Fans 1 1 1 1 Connect at … Power Terminal Block Requires user supplied 120 or 240V AC. See page 36 for TB locations and terminal designations. Red Secondary 115V Red P1 Primary 400/480V 600/690V Terminal P2 P3 P2 P3 Voltage 400 600 480 690 N/A (Connected internally) A transformer matches the input line voltage to the internal fan voltage. If line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing. The transformer is behind the Power Terminal Block. Access is gained by releasing the terminal block from the rail and removing the transformer cover plate. 1. Locate the small metal tab at the bottom of the end terminal block. 2. Press the tab-in and pull the top of the block out. Repeat for the next block if desired. 3. Remove the transformer cover plate. 4. Select the appropriate transformer tap. 5. Replace cover and terminal block. 40 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Frame 7 Drive Type DC Input Enclosure IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 AC Input IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 Rating (120VAC) 250 VA 250 VA 250 VA 250 VA No. of Fans 1 1 1 1 Connect at … Power Terminal Block Requires user supplied 120V AC. See page 40 for location. N/A (Connected internally) Frame 8 Drive Type DC Input Enclosure IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 AC Input IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 Rating (120VAC) 500 VA 500 VA 500 VA 500 VA No. of Fans 1 1 1 1 Connect at … TB9 Requires user supplied 120V AC. See page 37 for TB location and page 42 for terminal designations. TB9 A transformer matches the input line voltage to the internal fan voltage. If line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing. Input Line Voltage 480/400V AC, 50/60 Hz F1 H1 H2 F2 H3 480 400 0 115 F3 X1 JMP XF 0 X2 to TB9 Frame 9 Drive Type DC Input Enclosure IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 Rating (120VAC) 500 VA 500 VA No. of Fans 2 2 Connect at … TB9 Requires user supplied 120V AC for cap. bank fan and phase monitor. Blower Terminal Block Three-phase power must be supplied to the Blower TB. See page 37 for TB locations and page 42 for terminal designations. TB9 A transformer matches the input line voltage to the internal voltage used for the capacitor fan and phase detector module. If the line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing. AC Input IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 500 VA 500 VA 2 2 Input Line Voltage 480/400V AC, 50/60 Hz F1 H1 H2 F2 H3 480 400 0 115 F3 X1 JMP XF 0 X2 to TB9 Frame 9 Blower Operation Frame 9 drives use a single-phase capacitor bank fan and a three-phase blower for cooling. Proper phasing must be supplied to terminals R, S, and T of the Power Terminal Block (AC drives) or the Blower Terminal Block (DC drives) to assure correct blower rotation. To verify this, a Phase Monitor is used. Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 41 PowerFlex 700 Adjustable Frequency AC Drive Frame 10 Drive Type DC Input Enclosure IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 AC Input IP00, NEMA / UL Type Open Rating (120VAC) 1000 VA 1000 VA 1000 VA No. of Fans 2 2 3 Connect at … TB9 & 10 Requires user supplied 120V AC. See page 38 for TB locations and page 42 for terminal designations. TB9, 10 & 12 Requires user supplied 120V AC. See page 38 for TB locations and page 42 for terminal designations. TB9, 10 & 12 A transformer matches the input line voltage to the internal fan voltage. If line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing. H1 IP20, NEMA / UL Type 1 1000 VA 3 Input Line Voltage 480/400V AC, 50/60 Hz F1 H2 F2 H3 480 400 0 115 F3 X1 JMP XF 0 X2 to TB9 Fan/Blower Terminal Blocks - Frames 8…10 TB9, TB10 Line 120V AC Input Neutral 120V 120V N N Blower TB R To Fan(s) TB12 Line 120V AC Input Neutral 120V 120V N N S T To Fan(s) Ground PE PE Ground PE PE NC 7 NC 7 Frames 8…10 Frame 9 Only Frame 10, AC Input, IP20 Only Fan Transformer Specifications/Fusing Recommended Fuses Frame Rating 8…9 10 500 VA 1000 VA Primary (Quantity 2) 2.8A, 600V AC, KLDR/ATQR Type 6A, 600V AC, KLDR/ATQR Type Secondary (Quantity 1) 6.25A, 250V AC, Time Delay 9A, 250V AC, Time Delay Three-Phase Blower Fusing Frame Recommended Fuses (Quantity 3) 9 5A, 600V AC, Time Delay 42 Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 PowerFlex 700 Adjustable Frequency AC Drive Additional Frame 10 Wiring Requirement for IP00 AC Input Drives The Inverter and Converter sections of Frame 10 AC Input IP00, NEMA / UL Type Open drives are shipped separately. Once installed, the following connections are required. 1. DC Link Choke Wiring DC link chokes are supplied loose for customer mounting and wiring in IP00 drives. Refer to DC Link Chokes – Frames 8…10 below. 2. Thermistor Wiring Thermistor wiring is coiled loose in the Converter section for shipping. Locate the wire (labeled “To INV”) and route through the enclosure wall. Connect it to the mating connector above the HIM cradle. 3. Ground the drive chassis. DC Link Chokes – Frames 8…10 DC Link Chokes are supplied with Frame 8…10 AC input drives. Frame 8…9 Type IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 IP00, NEMA / UL Type Open Roll-In 10 IP00, NEMA / UL Type Open IP20, NEMA / UL Type 1 DC Link Choke is supplied … Mounted and wired Mounted and wired Loose without cables Loose without cables Mounted and wired Rockwell Automation Publication 20B-TD001H-EN-P - July 2014 43 PowerFlex 700 Adjustable Frequency AC Drive I/O Wiring 1 16 32 Standard Control Option – Frames 0…6 (1) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Signal Anlg Volts In 1 (–) Anlg Volts In 1 (+) Anlg Volts In 2 (–) Anlg Volts In 2 (+) Pot Common Anlg Volts Out 1 (–) Anlg Volts Out 1 (+) Anlg Current Out 1 (–) Anlg Current Out 1 (+) Reserved for Future Use Digital Out 1 – N.C. (2) Digital Out 1 Common Digital Out 1 – N.O. (2) Digital Out 2 – N.C. (2) (3) (3) Vector Control Option – Frames 0…6 (1) Description Isolated (4), bipolar, differential, ±10V, 11 bit & sign, 88k ohm input impedance. Isolated , bipolar, differential, ±10V, 11 bit & sign, 88k ohm input impedance. For (+) and (–) 10V pot references. Bipolar, ±10V, 11 bit & sign, 2k ohm minimum load. 4-20mA, 11 bit & sign, 400 ohm maximum load. (5) Factory Default (3) Signal Analog In 1 (–) (7) Analog In 1 (+) (7) Analog In 2 (–) (7) Analog In 2 (+) (7) Pot Common Analog Out 1 (–) Analog Out 1 (+) Analog Out 2 (–) Analog Out 2 (+) HW PTC Input 1 Factory Default (3) Description Isolated (9), bipolar, differential, ±10V/0-20 mA, 11 bit & sign. For 0-20 mA, a jumper must be installed at terminals 17 & 18 (or 19 & 20). 88k ohm input impedance when configured for volt. & 95.3 ohm for current For (+) and (–) 10V pot references. Single-ended bipolar (current output is not bipolar), ±10V/0-20 mA, 11 bit & sign, Voltage mode - limit current to 5 mA. Current mode - max. load is 400 ohms. – (3) – (3) – 1.8k ohm PTC, Internal 3.32k ohm pull-up resistor Max. Resistive Load: 240V AC/30V DC – 1200VA, 150W Max. Current: 5A, Min. Load: 10 mA Max. Inductive Load: 240V AC/30V DC – 840VA, 105W Max. Current: 3.5A, Min. Load: 10 mA Placing a jumper across terminals 17 & 18 (or 19 & 20) configures that analog input for current. Fault NOT Fault NOT Run Run (3) Digital Out 2 Common Digital Out 2 – N.O. (2) Anlg Current In 1 (–) Anlg Current In 1 (+) Anlg Current In 2 (–) Anlg Current In 2 (+) –10VDC Pot Ref. +10VDC Pot Ref. Reserved for Future Use +24VDC (6) Digital In Common 24V Common (6) Digital In 1 Digital In 2 Digital In 3 Digital In 4 Digital In 5 Digital In 6 – – – Stop - CF Start Auto/Man. Speed Sel 1 Speed Sel 2 Speed Sel 3 – – (3) Max. Resistive Load: 240V AC/30V DC – 1200VA, 150W Max. Current: 5A, Min. Load: 10mA Max. Inductive Load: 240V AC/30V DC – 840VA, 105W Max. Current: 3.5A, Min. Load: 10mA Isolated , 4-20 mA, 11 bit & sign, 124 ohm input impedance. Isolated (5), 4-20 mA, 11 bit & sign, 124 ohm input impedance. 2k ohm minimum. (4) Digital Out 1 – N.C. (2) Fault Digital Out 1 Common Digital Out 1 – N.O. (2) NOT Fault Digital Out 2 – N.C. (2) NOT Run Digital Out 2/3 Com. Digital Out 3 – N.O. (2) Run Current In Jumper (7) – Analog In 1 Current In Jumper (7) – Analog In 2 –10VDC Pot Ref. +10VDC Pot Ref. HW PTC Input 2 – – – – – – Stop - CF 2k ohm minimum load. See above Drive supplied logic input power. (6) Common for internal power supply. Drive supplied logic input power. (6) Common for internal power supply. 115V AC, 50/60 Hz - Control & I/O Cat. No. option B Opto isolated Low State: less than 30V AC High State: greater than 100V AC, 5.0 mA 24V AC/DC, 50/60 Hz- Control & I/O Cat. No. option A Opto isolated Low State: less than 5V AC/DC High State: greater than 20V AC/DC, 11.2 mA DC Digital Input Impedance: 35k ohm +24VDC (6) Digital In Common 24V Common (6) Digital In 1 (8) 115V AC, 50/60 Hz - Control & I/O Cat. No. option D Opto isolated Digital In 2 (8) Start Low State: less than 30V AC Auto/Man. 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Start Up Preparation & Installation Review Section 6 – Product Specs & Data Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 3 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 4 Section 1 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 5 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 6 Section 1 – Safety Warnings & Precautions Prior to shipment, the following tests are made to assure the customer the highest standards of manufacturing: a) Material inspections b) Manufacturing process inspections c) ASME welding inspection d) ASME hydrostatic test inspection e) Electrical components inspection f) Operating test g) Final engineering inspection h) Crating inspection Rigging your heater into position should be handled by a competent rigger experienced in handling heavy equipment. The customer should examine the heater for any damage, especially the refractories. It is the responsibility of the installer to ensure all parts supplied with the heater are fitted in a correct and safe manner. Warning Operating the heater beyond its design limits can damage the heater, it can also be dangerous. Do not operate the heater outside its limits. Do not try to upgrade the heater performance by unapproved modifications. Unapproved modifications can cause injury and damage. Contact your Fulton dealer before modifying the heater. Warning A defective heater can injure you or others. Do not operate a heater which is defective or has missing parts. Make sure that all maintenance procedures are completed before using the heater. Do not attempt repairs or any other maintenance work you do not understand. Obtain a Service Manual from Fulton or call a Fulton Service Engineer. Warning Thermal Fluid Heaters have high temperature surfaces, that if touched may cause serious burns. Only competent and qualified personnel should work on or in the locality of a thermal fluid heater and ancillary equipment. Always ensure the working area and floor are clear of potential hazards, work slowly and methodically. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 7 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliances. - WHAT TO DO IF YOU SMELL GAS · · · · Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department. - Installation and service must be performed by a qualified installer, service agency or the gas supplier. For Your Safety The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are repeated on these safety summary pages as an example and for emphasis. · · · WARNINGS must be observed to prevent serious injury or death to personnel. CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness. NOTES must be observed for essential and effective operating procedures, conditions, and as a statement to be highlighted. It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment. Note Max. room temperature not to exceed 100oF. Note In no case should any part of the drive side of the pump be insulated. Note Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 8 Max. operating temperature for air cooled pumps varies by manufacturer. Consult instruction manual to verify. Note Non-code tanks cannot be pressurized over 15 psig. Note If the tank is located outdoors nitrogen is required. Warning High temperature thermal fluid, steam and combustible vapors may be vented through the DA vent connection. Warning Once the system has been filled, any modification to the tank or connected piping requires purging of the work area to prevent ignition of potentially flammable vapors. Consult factory prior to beginning work. Consult MSDS for your thermal fluid for flammability limits. Note If the circulating pump motor is not supplied by Fulton Thermal Corporation, the motor starter will not be supplied. Note Unless the system is pressurized, the inlet to the deaerator section must be higher than or equal to the highest point in the system to prevent pockets of air from collecting in system piping. Caution During operation, any leaks are usually detected by a small amount of vapor. Leaks should be attended to as soon as possible because under certain circumstances, such as saturated insulation, thermal fluid can ignite when exposed to air and heat. Note Fulton Thermal Corporation cannot be held responsible in the case of accident or damage resulting from the use of inadequate fluid. Note Unless specially filtered, compressed air will introduce moisture into the system. Dry air or Nitrogen is recommended. Note Some plastics can be dissolved by thermal fluid. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 9 Note Do not use system circulating pump for system filling. Note A pump that has been used for water or a different thermal fluid should not be used prior to extensive cleaning. Thermal fluid can be damaged by contact with moisture or other fluids. Warning Pressurizing a drum to force fluid into the system is not recommended. The drum can easily explode, creating a hazard to personnel and equipment. Note Tanks are non-code as a standard. Non-code tanks cannot be pressurized over 15psig. Tanks built to ASME code Section VIII Div 1 are available upon request. Note Do not run the pump before filling it with fluid. Caution 1. 2. 3. Use extreme caution opening plug when system temperature is elevated. Wear eye and hand protection. Back the plug out slowly to the last two or three threads. Allow any pressure under plug to bleed slowly to prevent a spray of hot oil. Note Flash steam may be generated at any point up to the operating temperature. Watch for gauge fluctuations. Note All of the above maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-7148 or your local Fulton Thermal Representative. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 10 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 11 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 12 Section 2 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 13 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 14 Section 2 – Installation 1. Component View Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 15 2. Placement a) Proper placement of your Fulton Thermal Fluid Heater is essential. Attention paid to the following points will save a great deal of difficulty in the future. Correct placement is the first step to trouble-free installation, operation and maintenance. 3. Location a) Authorities with jurisdiction over any national or local codes which might be applicable to thermal fluid applications should be consulted before installations are made. b) The heater should be located as close as possible to the place where the heat will be used in order to keep pipe work costs to a minimum. c) A level, hard, non-combustible surface is required for a suitable base for mounting the unit. It is suggested that a four inch curb be installed completely around the unit. In the event of a large spill, this will help contain the fluid. d) Approximations for the floor loading of each heater are given in the floor loadings table. Check building specifications for permissible floor loading. e) The heater should be placed in a suitable heater house or well ventilated separate room through which personnel do not normally pass. This is not essential, but the layout should eliminate traffic in potentially hazardous areas. For instance, the service engineer or the operator should not have to pass exposed, hot pipe work to make adjustments to the heater controls. f) Ventilation must be sufficient to maintain a building temperature of 100°F. or less and the panel box temperature must not exceed 125°F. Natural ventilation should be provided by means of grills at floor and ceiling level. 4. Access a) Access around the heater should be provided to facilitate maintenance. Appropriate clearances for all sides follow. b) Place heater with clearances to unprotected combustible materials, including plaster or combustible supports, not less than the following: Heater Front Heater Sides Heater Rear Heater Top (For element removal) 36” 18” 18” 66” (1 m) (.5 m) (.5 m) (1.67 m) 5. Approximate Floor Loadings Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 16 a) Free standing figures take the weight of the heater alone into consideration. Floor loadings for skid mounted units vary with configuration. Model FT-0075N FT-0150N FT-0225N FT-0300N FT-0375N FT-0430N FT-0640N FT-0860N FT-1070N FT-1290N FT-1500N FT-1720N Free-Standing 400 lbs/ft2 300 lbs/ft2 300 lbs/ft2 300 lbs/ft2 300 lbs/ft2 300 lbs/ft2 300 lbs/ft2 300 lbs/ft2 200 lbs/ft2 200 lbs/ft2 200 lbs/ft2 200 lbs/ft2 Skid-Mounted 150 lbs/ft2 150 lbs/ft2 150 lbs/ft2 150 lbs/ft2 150 lbs/ft2 150 lbs/ft2 200 lbs/ft2 200 lbs/ft2 200 lbs/ft2 150 lbs/ft2 150 lbs/ft2 150 lbs/ft2 6. Minimum Clearance for Element Removal Model FT-0075N FT-0150N FT-0225N FT-0300N FT-0375N FT-0430N FT-0640N FT-0860N FT-1070N FT-1290N FT-1500N FT-1720N Inches 46 46 46 46 46 66 66 66 66 66 66 66 Meters 1.2 1.2 1.2 1.2 1.2 1.7 1.7 1.7 1.7 1.7 1.7 1.7 a) All heaters will also require a minimum clearance overhead for personnel access and element removal. In cases where the available height is insufficient, a roof or ceiling trap might be considered. b) Pipes should not be run within ten inches of any control cabinets or combustible material. c) Failure to provide suitable and safe access at the time of commissioning may cause delays, as our Service Engineers are instructed not to commence commissioning if hazardous conditions exist. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 17 7. Circulating Pump a) Installing the pump in accordance with the manufacturer’s specifications and these instructions will prolong the life of the pump and contribute significantly to the successful operation of your Fulton heater system. The pump manufacturer’s installation and operation instructions can be found in Section 5 of this manual. b) Location 1. The pump should be located adjacent to the heater. Its base must be firm, level (preferably concrete), and free from vibration. c) Connections & Piping 1. The pump should be routed as per the manufacturer’s requirements. It should be equipped with flexible connections at the suction and discharge sides. The primary function of these connections are to prevent stresses due to pipe expansion from being placed on the pump and to isolate pump vibrations from the pipe work and the heater. They also allow for expansion and deflection of the pipe work. These connections should be rated for high temperature since they are considered part of the piping system. 2. The suction pipe work must be directly connected to the deaerator section via a vertical run with as few elbows as possible, and should contain the strainer and an isolating valve. The discharge pipe work must be connected directly to the heater inlet, and should contain an isolating Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 18 valve. See that pipe work connections match up accurately with pump flanges. Refer to the pump manufacturer’s recommendations for the specific pump inlet piping requirements. Typically these requirements are that: a. It be a straight run of pipe. b. The straight run from the pump inlet to the first fitting, valve, or flex connector be a minimum of 6-10 pipe diameters in length. c. The pipe used should be the same size as the inlet of the pump. 3. The piping in the immediate vicinity of the pump must not be supported by the pump. The pump is not designed to bear the weight of the piping, and weight on any part of the pump will throw it out of alignment. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 19 d) Typical Fulton Thermal Piping Schematic 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Thermal Fluid Heater Thermal Fluid Circulating Pump Safety Relief Valve Thermometer Pressure Gauge Thermal Fluid Heated Equipment Bypass Valve to maintain full flow to heater Expansion Joints as required Anchor and Pipe Guides as required Expansion Tank Vent Piping should be full size of expansion tank vent Deaerator Tank Deaerator Tank inlet must be highest point of piping Thermal Buffer Tank Catch Tank for drain of pressure relief valve, cold seal, expansion tank, and vent. Locate in safe area. Gate Valve Strainer ¾” System Fill Connection Flexible Connection as necessary Isolating Valve as necessary Manual Low Level Test Line Manual High Level Test Line Buffer Drain 23 20 Full pump design flow must be maintained at all times thru the main piping loop. Low flow will seriously damage heater. Note: Manifold configuration for illustration only. See drawing appropriate to particular model. e) Alignment 1. Proper alignment directly affects bearing, coupling, and seal life expectancy. The pump is properly aligned before it leaves the factory. Because the system expands in operation, pump must be realigned when the system is at operating temperature. 2. The coupling alignment of the pump and driver must be carefully checked for angular and axial alignment. Check pump manufacturers instructions for these specifications. The use of a dial indicator to check the axial and angular alignment is recommended. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 20 f) Lubrication 1. An air cooled pump does not have an oiler. This type of pump has a sleeve bearing which is, like the seals, lubricated by thermal fluid. An air cooled pump has a grease nipple located at the drive end of the pump near the coupling connection. This comes pre-greased, and should be greased at intervals as recommended by the manufacturer. 2. An oiler is shipped with each water cooled pump and it should be filled with a lubricating oil recommended by the manufacturer. The suggested lubricant is usually SAE-30 non-detergent oil. Thermal fluid is not sufficient lubrication for bearings. g) Seals 1. All seals on air cooled pumps are lubricated by thermal fluid, therefore the pump must never be run dry, i.e., without thermal fluid in it. 2. Filling a pump equipped with either a Grafoil packed or mechanical seal with thermal fluid will ensure lubrication. However, in order to be certain that all seals on an air cooled pump are coated with thermal fluid, the pump must be bled. 3. Grafoil packings require a run-in procedure. Typically, pumps with these seals are shipped with four or five rings installed and several rings loose. These extra rings must be on hand for the initial run-in procedure. See manufacturer’s instruction manual for this procedure. h) Air Cooling 1. Allow for free air flow around the entire pump casing at all times. 2. Max. room temperature should be 100°F. 3. In no case should any part of the drive side of the pump be insulated. 4. Max. operating temperature for air cooled pumps varies by manufacturer. Consult instruction manual to verify. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 21 i) Water Cooling 1. A throttling needle valve should be installed on the inlet side of the water cooling passages and adjusted so that the outlet water is between 120°F. and 160°F. Typically this means a flow rate of 2-5 GPM at 40°F inlet temperature. Consult pump manufacturer’s specifications for dimensions of water cooling connection. 2. The throttling valve on a water cooled pump is designed to automatically give the proper flow rate for a 40 PSIG or greater supply. 3. If a minimum of 40 PSIG is not available, consult Fulton Thermal Corporation about resizing the orifice. If the temperature of the cooling water is greater than 55°F to begin with, a correspondingly greater flow rate is required. 4. For automatic operation of water cooling, wire a solenoid valve on the inlet to open whenever the pump motor starter is energized. 5. The outlet flow from the pump must not be restricted in any manner. Therefore, valves are not to be installed on the outlet. Check local codes regarding disposal of hot water. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 22 8. Combination Expansion/Deaerator/Thermal Buffer Tank a) Fulton Thermal’s efficient design combines the operation of the expansion, deaerator, and thermal buffer tanks. Installation is considerably simplified by virtue of this arrangement. b) Expansion Section 1. The expansion section is vital to the thermal fluid system. From ambient to operating temperature, the thermal fluid in the system will typically expand in the range of 30%, and a vessel capable of handling this expansion is mandatory. The customer should confirm the expansion rate of the chosen fluid and system volume. c) Deaerator Section 1. At start up the primary purpose of the deaerator section is to remove all volatiles from the system to avoid pump cavitation. The deaerator section also allows oxygen to be vented from the system on a continuous basis during operation to avoid oxidation of the thermal fluid, and removes other volatile particles generated by the fluid itself during system operation. This section of the tank must be insulated. d) Thermal Buffer Section 1. A system of interconnecting pipe work in the thermal buffer tank section prevents the movement of any oil that has not cooled sufficiently into the expansion section. This avoids contact of very high thermal fluid temperature with oxygen contained in the atmosphere, which causes fluid breakdown. DO NOT insulate this section. e) Sizing The Tank For The System 1. Expansion tank capacity is the total volume of the tank. It is necessary to have some air space available at the top of the tank to avoid spillage or Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 23 overflow. At initial fill (for system volume calculations) the deaerator and cold seal sections must be filled completely and the expansion section must be filled to a level of 4 inches to "make" the liquid level switch. 2. The volume between the initial fill level and the safe "full" level is the amount available for expansion. That volume is used to decide which tank is suitable for the system expansion. f) Sizing Example 1. A system contains 175 gallons, including the heater, but not the tank. You select the FT-200-L, so you add 25 gallons to 175. You must look up the expansion rate for the thermal fluid. (Assume it is 25%). 200 gal. x 1.25 = 250 gallons. 250-200 = 50 gallon expansion. The FT-200-L has only 46 gallons available for expansion, so the correct selection is the FT-500-L. g) Location 1. The tank must be installed in accordance with Fulton Thermal Corporation's specifications. 2. Unless the system is pressurized, the inlet to the deaerator section must be higher than or equal to the highest point in the system to prevent pockets of air from collecting in system piping. 3. The head required at the circulation pump suction inlet must also be taken into account to avoid the possibility of pump cavitation. In systems operating close to maximum fluid temperature, the tank must be elevated enough, possibly well above the highest point in the system to prevent pump cavitation by increasing the static head. An inert pressurizing blanket may be considered as an alternative. See Pressurized Systems. 4. Supports for tank mounting should be provided by the client/contractor. These should be suited for supporting the tank by the side rails. The eyelets fitted to the tank are for lifting only. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 24 Model Capacity (Gallons) Initial Fill (Gallons) 25 40 80 90 145 215 300 Available for Expansion (Gallons) 46 121 232 380 444 717 1168 Max System Volume 184 525 1000 1400 1700 2600 4600 FT-200-L FT-500-L FT-1000-L FT-1500-L FT-2000-L FT-3000-L FT-5000-L 52 132 264 397 528 793 1310 9. Pressurized Systems a) Nitrogen pressurization may be used to advantage where the total system content is very large or in a system operating near or above the vapor pressure of the fluid employed or if the inlet of the DA tank is not the highest point in the piping system. b) In conjunction with this system, an automatic venting device must be fitted to the system expansion tank. Consult Fulton Thermal Corporation for further details. c) The location for the liquid level switch is a 2-1/2” NPT connection on the same end of the tank as the inlet. The liquid level switch is supplied and shipped with the unit, and must be installed by the customer and then wired to the control panel. Note If the tank is located outdoors nitrogen is required. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 25 Liquid Level Switch 10. Connections a) The vent connection must be made in a manner that will prevent penetration of water or foreign bodies into the tank. This connection must always terminate in a safe, well ventilated area and has to be free of obstruction, open to atmosphere, and arranged in such a manner that, in the event of discharge from the system, thermal fluid could drain into a catch tank without danger to personnel or property. Note Non-code tanks cannot be pressurized over 15 psig. Warning High temperature thermal fluid, steam and combustible vapors may be vented through this connection. b) The vent run should be the same size as the tank outlet. It should run pitch down from the outlet of the tank to the catch tank. c) If nitrogen is used on the system, the vent can be reduced and should be piped with a positive closing valve at the catch tank. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 26 d) The connection between the tank outlet and the horizontal pump inlet run should be as close to a vertical drop as possible. It should not contain an excessive number of bends of length of pipe. These faults could encourage pump cavitation. e) As noted, the inlet to the deaerator must be higher than or equal to the highest point in the system or a pressurized system must be used. f) The liquid level switch, supplied and shipped with the unit, must be installed and wired to the control panel by the customer. g) The high and low level test connections are 1/2” NPT, and are located on the end of the tank opposite the inlet. The low level is on the center line of the expansion tank, the high level is next to it, slightly off center. The high level rises up from the bottom of the tank and ends four inches below the top; the low level rises two inches from the bottom of the tank. h) Both the high and low level connections should be piped to a safe catchment. Valves should be installed in these lines at the catch tank. i) j) Installation of the valves should be accomplished in such a manner that any flow will be visible when the valves are open. Flow from the high level test connection indicates a tank that is too full; no flow from the low level test connection indicates too little fluid. k) There is a 300 pound, raised face, flanged drain on the bottom of the thermal buffer section, for the purpose of draining the tank when necessary. This should be piped with a valve in the line, to a safe catchment. The valve specifications outlined above apply to this valve as well. l) An inspection opening is located at the highest point on the tank. Access to this port is recommended but not required. m) Refer to the maintenance schedule for recommendations on draining the buffer tank. For positioning of all connections on tank, see the diagram labeled Combination/Expansion/Deaerator Thermal Buffer Tank. Warning Once the system has been filled, any modification to the tank or connected piping requires purging of the work area to prevent ignition of potentially flammable Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 27 vapors. Consult factory prior to beginning work. Consult MSDS for your thermal fluid for flammability limits. n) Electrical Connections Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 28 1. A wall-mounted, fused disconnect sized for the unit must be provided and fitted by the client/contractor, if a disconnect is not supplied on the panel. 2. Fuses must be sized according to motor name plates and local electrical codes. 3. Heaters and single skid systems are generally shipped completely prewired. The liquid level switch on the expansion tank, when supplied, will be shipped in the parts box and must be installed in the field. Multiple skid systems may require wiring between the skids. 4. If the unit is not skid-mounted at the factory, the client/contractor is required to wire the circulating pump starter. 5. When using a SCR, a Shunt Trip Breaker is required to be installed by the customer. It will be used to remove power to the panel in the event of an over temperature/pressure condition. The Shunt Trip Coil needs to be wired to the boiler electrical panel as indicated on the electrical drawing. Note If the circulating pump motor is not supplied by Fulton Thermal Corporation, the motor starter will not be supplied. o) Voltage & Frequency 1. Normal supply will be 460 volts, 3 phase, 60 Hz, AC unless otherwise specified. 2. Make sure the information on the electrical drawing corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no over-or under-voltage exceeding 10% of the nominal value. 11. Pipework Systems a) Certain properties of thermal fluid, including low surface tension, make it necessary to pay particular attention to containing the fluid. Good pipework system design, welded Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 29 construction, proper flanging, gaskets, and other appropriate means of eliminating potential leakage must be employed. 12. General a) All components exposed to thermal fluid flow, including pipe, valves, and screens, must not be made out of copper, copper alloys, aluminum, or cast iron. Cast iron is porous to thermal fluids, and copper and aluminum act as catalysts in the degradation of some thermal fluids. Carbon or stainless steel, or ductile iron, are recommended. b) For standard applications, all components must be rated to 650°F unless otherwise stipulated. c) All pipework, valves, and user equipment must be suited to the maximum operating pressure of the heater. The maximum pressure stamped on the heater nameplate is typically 150 psig (690 kPa). d) If an isolating valve is completely closed, the pressure in the system will rise to the deadhead pressure of the pump. Suitably sized pipe will enable the system to withstand the total head generated by the circulating pump, should this occur. In applications where it is desirable to design to pressures lower than 100 psig, an alternative safeguard is to install appropriately sized safety valves. e) Where secondary circulating pumps are installed, the system must be suitable for the aggregate head, against a closed valve, of both pumps. f) During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system. 13. Equipment a) Heaters that are skid mounted with pumps and tanks are equipped with a y-strainer, a flex connector and a valve in the inlet run between the pump and the combination tank. Piping between the discharge of the pump and the inlet of the heater will include a flex connector and a valve. 14. Piping a) All pipework should be constructed from seamless mild steel pipe, conforming to ASME SA 106B or SA 53B, Schedule 40 or equal. b) Expansion joints or properly designed and sited loops should be provided to accommodate thermal expansion. Thermal expansion should be calculated using the maximum possible utilization fluid temperature, regardless of whether the pipe considered is in the feed or return circuit. Steel pipe will expand approximately 1 “ per 100’ over a 100° F. temperature rise (1 mm. per meter over 100°C. rise). Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 30 c) Supports and anchors must be provided for all pipes where necessary to prevent undue stresses from being placed on items of equipment, including pumps, valves, and the heater. Supports and anchors which will not interfere with thermal expansion should be chosen. d) All pipe joints should be of either welded or flanged construction. Screwed joints must be avoided where possible. In no instance should screwed joints be used in the flow circuit. e) All flanges should be welded to the pipe and not screwed. Flanges should be 150# or 300# raised face flanges, SA105. f) Gasketing material suitable for use with thermal fluids at high temperatures should be used to make all flanged joints. Flexible graphite gaskets are suited for most thermal fluids. Recommended gasket thickness is 1/10 - 1/8 inch. g) Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer. 15. Gasket Installation Instructions a) Lubricate nuts, bolts and washers with a graphite/oil mixture. b) Assure that the flange surfaces are clean and free from damage. c) Center gasket properly over flange. In retrofit, use pry bar to spread flange apart enough that the gasket will not be damaged when sliding in place. d) Install all flange nuts and bolts. e) Hand tighten. f) Utilizing a torque wrench, tighten all bolts to 20% final torque specification following a “star” pattern. (This means do not tighten bolts in order as a clock. This will result in a poor seat between 12 o’clock and 1 o’clock.) g) Tighten all bolts to 40% final torque specification following a “star” pattern. h) Tighten all bolts to 60% final torque specification following a “star” pattern. i) j) Tighten all bolts to 80% final torque specification following a “star” pattern. Tighten all bolts to 100% final torque specification following a “star” pattern. specification. l) It is important that all bolts are checked and re-torqued after flanges have been heated and cooled down for the first time. k) Following a sequential pattern, ensure that all bolts are tightened to 100% final torque Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 31 Bolting Sequence for 4 and 8 Bolt Flanges Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 32 Standard gaskets supplied by Fulton are JM Clipper Elastograph for operating temperatures up to 650oF. Recommended Loads for JM Clipper elastograph 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 4 5 6 8 10 Number of Bolts 4 4 4 4 4 4 4 4 8 8 8 8 12 Diameter of Bolts Inches 1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 3/4 3/4 7/8 Preferred Torque Required per Bolt Ft-Lbs. 30 30 30 30 30 60 60 60 60 100 100 100 160 Recommended Loads for JM Clipper elastograph 300# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 4 5 6 8 10 Number of Bolts 4 4 4 4 4 8 8 8 8 8 12 12 16 Diameter of Bolts Inches 1/2 5/8 5/8 5/8 3/4 5/8 3/4 3/4 3/4 3/4 3/4 7/8 1 Preferred Torque Required per Bolt Ft-Lbs. 30 60 60 60 100 60 100 100 100 100 160 245 160 16. Piping a) High point bleeds are to be installed at all high points in the system piping. 1/2” x 12” nipples welded in the top of the piping with ball valves & plugs attached are to be used. b) It will save a considerable amount of time during the cold filtration if the thermal system piping is cleaned prior to assembly. c) The mill scale (the results of oxidation) on the inside of the piping as well as construction debris can foul the oil and cause the need for the filters to be cleaned more than need be. This can range from simply using a rag to ordering pickled pipe. (“Pickling” is a process Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 33 where the piping is first soaked in an acid bath, then soaked in a neutralizing bath, then given a protective oil coating.) d) All pipes should be installed with a pitch to facilitate draining and venting. Note Inspect the system daily for leaking joints. Shut the system down and tighten any leaking flanges or connects immediately. 17. System Connections a) If screwed connections have to be made, e.g. to items of control equipment, then a thread sealant suitable for use with fluids at elevated temperature must be used. Teflon tape, standard pipe dope, or hemp and paste are not acceptable. Screw threads must be carefully and accurately cut. If possible, new tools should be used. Threaded connections larger than 1” are not to be used. It is recommended that GR5 or better tensile steel bolts be used for all flanged joints. Standard gaskets supplied by Fulton for operating temperatures above 650oF are Flexitallic Spiral Wound. Recommended Loads for Flexitallic Spiral Wound Class 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 Number of Bolts 4 4 4 4 4 4 4 4 8 8 8 8 8 12 Diameter of Bolts Inches 1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 3/4 3/4 3/4 7/8 Preferred Torque Required per Bolt Ft-Lbs. 45 45 45 45 45 90 90 90 90 90 150 150 150 240 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 34 Recommended Loads for Flexitallic Spiral Wound Class 300# Gaskets SAE Grade 5 Bolts (typical) or Equal Preferred Torque Required per Bolt Ft-Lbs. 45 90 90 90 150 90 150 150 150 150 150 150 240 368 Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 Number of Bolts 4 4 4 4 4 8 8 8 8 8 8 12 12 16 Diameter of Bolts Inches 1/2 5/8 5/8 5/8 3/4 5/8 3/4 3/4 3/4 3/4 3/4 3/4 7/8 1 Note The system pump is not to be used to fill the system. The system is usually filled from the lowest point, with the aid of a pump. On skidmounted units, a drain and fill connection is provided in the inlet piping to the pump. Drain and Fill Connection 18. Heater Connections a) The outlet of the pump should connect directly to the inlet of the heater via an isolating valve and pump flexible connector. b) The heater outlet should be piped directly to the system, via an isolating valve. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 35 c) A safety relief valve may be shipped in the parts box accompanying the fuel-fired heater, and must be installed in the outlet manifold. On all units, the outlet must be piped to a safe discharge area. The piping from the outlet of the safety valve must be piped to a catch tank. The discharge flow must not be restricted, i.e. no valve should be installed. The weight of the piping must be properly supported in order to prevent damage to the safety valve. If the valve body becomes warped, leakage may result. 19. Gauges a) The range in which readings are expected to fall should comprise mid-scale on the pressure gauge chosen. Pressure gauges must be able to withstand overpressure equal to the rating of the safety relief valves, normally 100 psig. b) Thermometers should read up to 650°F. 20. Valves a) Vent and drain valves should normally be 1/2” or 3/4” with internal seals made from materials suited to use with thermal fluids. They may be of the screw type if installed on stalks not less than 12” long. b) Gasketing material specifically suited to the task must be used. c) Drain valves should be fitted at all low points in the pipework system and ventilating valves should be fitted at all high points in the installation. d) Valves must be fitted with either the conventional packed stuffing box seal or a bellows seal as required. Where the stuffing box is specified, it should be as deep as possible Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 36 and packed with Grafoil packing or equal. The valves should have a back seating to allow re-packing without draining the system. In all units, a “Y” type strainer should be installed in the fluid return line, between the deaerator tank and the circulating pump. e) As previously stated, this strainer is provided on all skid-mounted units. Valves must be provided (unless the heater has been skid-mounted with the tank) so that the strainer can be isolated for cleaning of the element. The strainer element should be 60 mesh and must remain in place during normal operation of the system. f) The pump suction pressure should be checked periodically, under similar operating conditions. A vacuum reading on the suction gauge indicates that the screen must be cleaned. For isolating purposes, globe, wedge, gate, ball, or other shut-off valves should be used. When there is a likelihood that some manual balancing will be required, a ball or globe valve should be used. g) Manual control and isolating valves should be the flanged or weld type, manufactured from cast or forged steel or ductile iron, with internals and gland seals made from materials suitable for use with high temperature fluids. h) When ordering valves, the maximum possible service temperature and type of fluid must be indicated on the order. i) A partial list of manufacturers known to market valves of acceptable quality follows: 1. Jenkins Brothers 2. Lunkenheimer Company 3. Nibco Incorporated 4. Stockham Valves and Fittings Company 5. Velan 6. Vogt Machine Company 7. Worcester Valve Company j) Automatic Fluid Control Valves 1. Because of the widely varied processes Fulton Thermal Fluid Heaters are used in, it is not possible to set down specific rules for the selection of automatic fluid control valves. Generally, these valves must satisfy the materials and construction requirements described above. 2. The type of operation and design of porting are governed by the degree of control required as well as the particular application. k) Bypass Valves 1. When process flow requirements do not match heater flow requirements, a by-pass valve must be installed. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 37 2. If the process flow will vary with the system load, a suitable bypass system can be recommended by Fulton Thermal Corporation. 21. Testing a) Upon completion of the installation, a pneumatic test not exceeding 15 psig should be conducted. Soap tests should be made at all welds and joints to ensure that the system is free from leaks. b) Under no circumstances should the system be filled with water. Make sure that the air supply is as free from moisture as possible. c) The most satisfactory method of testing is to introduce bottled nitrogen through a pressure control valve. Check pressure ratings on all the equipment in the system to make sure that it is capable of withstanding the pressure involved. d) The time needed to be spent during boilout directly corresponds to the amount of moisture in the system. Boilout can take anywhere from two to three days to complete. Pressure testing on the system should be done by means of an inert gas, such as nitrogen, or by an air compressor producing dry air (air with a dewpoint of 50o F or less). Never perform a hydrostatic test on the system. 22. Insulation a) After the appropriate system tests have been satisfactorily completed, all hot pipework, including manifolds on the heater, must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury. b) The deaerator section of the combination tank must be insulated. The expansion section of the combination tank must not be insulated, nor should the thermal buffer section. c) On units operated with inert gas blankets above the fluid in the expansion tank, the entire combination tank, including the expansion and thermal buffer sections, may be insulated, but is not necessary. d) It is recommended that for inspection and maintenance, pumps, flanges, valves, and fittings be left un-insulated but suitably shielded for safety. e) Hot oil pipe insulation should be a minimum of 2” thick, high temperature, laminated, foamglass cellular glass insulation as manufactured by Pittsburgh Corning Corporation, or equal. 23. Thermal Fluids Thermal Fluids at Elevated Temperatures a) Plant engineers must be familiar with the nature of potential hazards when working with thermal fluids at operating temperatures. b) Unlike steam or high-pressure water systems, thermal fluid attains extremely high temperatures without a corresponding increase in pressure. While this lack of high Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 38 pressure in the system yields many advantages, a false sense of security should not be allowed to develop on account of this alone. c) Certain types of thermal fluid may have operating temperatures reaching 650°F (345°C) and above, so all exposed pipework is hazardous and should be insulated, as indicated in the preceding sections. d) Flanged joints must be checked for tightness during and after the first warming up of the system. After these checks, exposed hot flanges, pumps, valves and fittings should be fitted with some sort of shield. e) It is important to remember that there is pressure generated in the system by the circulating pump. Great care should be exercised when opening any drain or vent valves in the system. f) This is especially important during commissioning, when any air trapped in the system is vented at high points, and when water, which will flash into steam, is either expelled from the deaerator vent or drained off at low points. Caution During operation, any leaks are usually detected by a small amount of vapor. Leaks should be attended to as soon as possible because under certain circumstances, such as saturated insulation, thermal fluid can ignite when exposed to air and heat. g) If a fire does occur, extinguish using CO2, foam or dry chemical. DO NOT USE WATER. h) Selecting a Thermal Fluid 1. The selection of the thermal fluid most suited to your application is very important. Factors to be considered include efficiency, thermal stability, adaptability to various systems, and physical properties, including vapor pressure, freezing point, and flash and fire points. 2. Heat transfer fluids of both mineral and synthetic origin have been specially developed to give thermal stability over a very wide range of temperature. A wide variety of thermal fluids have been used successfully in Fulton Thermal Fluid Heater systems, however, your final selection should be made in conjunction with Fulton Thermal Corporation or the fluid manufacturer. 3. The Fulton coil design heater is a fired heat exchanger and the safe control and monitoring of the thermal fluid temperature is of paramount importance. 4. The safe maximum bulk temperature of the fluid must be strictly adhered to. The safe maximum temperature of the fluid varies, but a typical maximum for many types of mineral oil based fluids is 600°F (320°C). Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 39 5. Special care must be taken when consulting fluid manufacturers’ literature, as maximum fluid temperatures quoted are the actual limit to which any of the fluids may be subjected. It is important to remember that in any fired heater there exists a “film temperature” which is higher than the temperature of the “bulk” of the fluid. 6. It is the BULK fluid temperature and NOT the FILM temperature that is indicated by the instruments. 7. As a general guide, the following list of fluids that have given satisfactory service over many years is provided. 8. This is by no means a complete list. Any fluid specifically designed for heat transfer use may be considered; multipurpose oils are not acceptable. a. b. c. d. e. f. g. h. i. j. AMOCO CHEVRON DOW EXXON MOBIL MONSANTO MULTITHERM PARATHERM PETROCANADA SHELL TEXACO Transfer Oil 4199 Teknifax Dowtherm A or G Caloria HT 43 Mobiltherm 603 or 605 Therminol PG1, IG4, IG1 Paratherm NF or HE CalFlo, AF, Purity FG, CalFlo LT Thermia 23 Texatherm k. 9. Any fluid specifically designed for heat transfer use must also exhibit these characteristics: a. Be a stable and homogenous liquid to a temperature of at least 100°F over and above the maximum intended temperature of utilization, compatible with metals used in the installation, and tolerating contact with atmospheric air. b. The absence of any solid matter in suspension. c. Non-toxic in the case of leakage. d. Sufficient lubricity, i.e. not likely to cause seizure. 10. The thermal fluid manufacturer must guarantee the characteristics of the product, and verify that the fluid bulk temperature limitation exceeds the expected operating temperature. 11. After a fluid is selected, refer to the manufacturer’s recommendations, published in compliance with OSHA. 12. If the fluid expansion volume from 50o F to 600°F exceeds 20% of the initial fluid volume, consult Fulton Thermal Corporation. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 40 Note Fulton Thermal Corporation cannot be held responsible in the case of accident or damage resulting from the use of inadequate fluid. i) Routine Analysis of Heat Transfer Fluid 1. Nearly all leading manufacturers of heat transfer fluids provide an after sales service to monitor the condition of the fluid in operation and make recommendations when replacement becomes necessary. 2. Each fluid manufacturer has procedures for regular testing and analysis of the fluid. These usually allow for a sample to be taken and analyzed at least once a year, although actual frequency will depend on operating temperature, number of hours operated weekly, and the results of tests made during the first weeks of system operation. 3. Fulton Thermal Corporation recommends that the thermal fluid in your system be analyzed within the first two months after start-up. 4. During the first few months of operation, sampling may be carried out at frequent intervals to confirm that system performance has been predicted correctly. 5. If the supplier of your thermal fluid does not contact you within four weeks of commissioning, contact the supplier and make certain that the “fill” is registered for routine analysis. j) Thermal Fluid Breakdown 1. The possibilities of thermal fluid breakdown are very slim in a typical closed loop thermal fluid system. Fulton’s D/A tank creates a “cold seal” of fluid that is slightly above ambient temperature. This prevents oxidation that will happen when high temperature fluid contacts air. 2. This will also occur when hot thermal fluid contacts air at a leak in the system piping. Oxidized thermal fluid becomes acidic and will damage the thermal fluid system. Thermal fluid breakdown can occur in sections of piping where there is a low flow condition. A low flow rate through the heater will result in high film temperatures leading to breakdown of the thermal fluid. 3. Multiple pressure switches and a differential pressure switch are used to prevent this condition from occurring. These safeties must not be bypassed at any time. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 41 4. Exceeding the maximum operating temperature of the thermal fluid will also result in thermal fluid breakdown. Fulton heaters are equipped with a temperature limit switch (located on the front of the panel box) to prevent this from occurring. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 42 Section 3 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 43 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 44 Section 3 – Operation 1. Start-Up Preparation & Installation Review a) Check with local authorities where approval for start-up is required. In some localities, final inspection of services may be required. b) Review the installation section of this manual carefully. Confirm accordance with installation guidelines, including: 1. In general, ensure that the heater area is in conformance with established heater room requirements. Review national and local codes. 2. Preparation a) Check for total absence of water in pipework and fluid. To help the system, open all drains; blow air nitrogen if available into a high point bleed through a pressure regulating valve. Note Unless specially filtered, compressed air will introduce moisture into the system. Dry air or Nitrogen is recommended. b) Make sure that there are no obstructions left in the thermal fluid circuit from pressure leak testing such as blanking plates in flanged joints. c) Check that pipework is free to expand naturally when hot. Open all valves to user circuits including air bleed valves at high points and drains at low points in the piping system, and the liquid level test connections in the expansion section of the combination tank. 3. Filling the System a) The viscosity of thermal fluid is generally very high (500 cS) at ambient temperature. Below 50°F (10°C) some fluids become very thick. Fluid should be in a pumpable liquid form prior to filling the system. b) Filling must be carried out from the lowest point in the system in order to prevent air pockets from forming. c) A drain and fill point (generally a 3/4” threaded coupling) is provided on the inlet to the pump suction on skid-mounted units. Typically a portable, high velocity pump, such as the type used for chemical transfer, is appropriate for filling the system. Where only one or two drums of fluid are required, a handheld pump may be practical. Note Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 45 Some plastics can be dissolved by thermal fluid. Note Do not use system circulating pump for system filling. Note A pump that has been used for water or a different thermal fluid should not be used prior to extensive cleaning. Thermal fluid can be damaged by contact with moisture or other fluids. Warning Pressurizing a drum to force fluid into the system is not recommended. The drum can easily explode, creating a hazard to personnel and equipment. Drain and Fill Connection d) Filling Procedure 1. Fill the system slowly, closing all opened bleed and drain valves as fluid reaches them. 2. When the fluid reaches and flows from the expansion tank low level manual test connection, begin slowing down the filling process. 3. Close the low level connection and continue to fill until the liquid level switch closes. After fluid appears in the low level connection, only a small amount of additional fluid should be required. 4. If fluid is observed coming from the expansion section high level manual test connection, drain fluid from the tank until the level is between the liquid level switch and the high level connection. 5. Filling is complete when the fluid has reached the lowest level in the expansion tank required to actuate the liquid level switch. Check to see that the liquid level switch operates freely. To confirm operation of the Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 46 liquid level switch, manually trip the liquid level switch. Unit should shut down; pump will stop. 4. For Systems Equipped with Inert Blankets a) Follow the instructions listed under “Filling The System”. b) Pay close attention to notes and warnings. c) Inspect the system to be sure all valves are open and all drains are closed. d) Open all high point air vents. e) Do not pressurize the system with nitrogen at this point. f) Inspect the liquid level switch and be sure the switch is functioning properly. g) Begin filling the system. h) Fill the system until the liquid level switch indicates there is oil in the expansion tank. i) Pressurize the system slightly with nitrogen. Leave the high point vent connections open, as the nitrogen should be isolated from the vents by the oil in the system. The pressure required in the system at this point is only 2-3 psi. If too much pressure is applied, the nitrogen will bubble through the oil and vent to atmosphere. If this happens, reduce the pressure. j) Continue filling the system. If liquid level switch is made, be sure to observe the high point vents as oil is now entering the elevated portion of the pipe work. As oil reaches the vent, close it. After all vents have been closed, and you believe the system to be full, stop filling. Start the circulating pump as described under “Cold Circulation.” Leave the fill equipment connected as cleaning the strainer may create the need for more oil in the system. k) The final nitrogen pressure is determined by measuring the difference between the D.A. Tank inlet and the highest point in the system. Divide that number by 2.31 (this will indicate the nitrogen pressure the system should be set for). Adjustment can be made via the regulator mounted on top of the D.A. tank. Note Tanks are non-code as a standard. Non-code tanks cannot be pressurized over 15psig. Tanks built to ASME code Section VIII Div 1 are available upon request. 5. Circulating Pump a) Read manufacturer’s instruction manual thoroughly. If the pump is supplied by Fulton Thermal Corporation, manufacturer’s literature is included in this manual. Note Do not run the pump before filling it with fluid. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 47 b) The pump should never be run without fluid in the casing. For pumps equipped with mechanical or air-cooled seals, air must be bled out of the stuffing box area to ensure that thermal fluid has lubricated all seal and bearing areas. Operation of the pump even a short time without bleeding first will damage the pump. c) Also use the thermal fluid as a barrier fluid. Remove the 3/8” plug at the barrier fluid fill port. Fill the cavity with thermal fluid until it comes out of the overflow tube. Replace the 3/8” plug. d) Mechanical/Air Cooled Seal 1. Open the air bleed connection located directly over the pump shaft. Replace plug when a steady stream of thermal fluid, free of entrained air, flows from the port. 2. If flow has not started after two to five minutes, remove the coupling guard and rotate the pump shaft by hand in the proper direction. This should help move the cold viscous fluid through close tolerance seal areas. Replace plug when flow is steady. 3. If this fails to induce flow, introduce fluid through the bleed port and rotate the shaft by hand to work the fluid around the seal area. Continue to add fluid and rotate the shaft until no more fluid can be added. 4. Replace the plug and run pump for five to ten seconds. Stop the pump, remove the plug and wait for flow to start. If after two minutes flow has not started, add more fluid as described above and run the pump for five minutes. 5. Constantly check the bearing area (located immediately behind the casing) for overheating. Remove the plug and check for flow. 6. If flow has not started at this point, the fluid may be too viscous to move through the seal area. Start the system normally by selecting heat on the control panel, and raise the temperature 50°F. Continue to raise the system temperature by 50°F increments. Keep checking the pump until flow starts. Caution 1. Use extreme caution opening plug when system temperature is elevated. 2. Wear eye and hand protection. 3. Back the plug out slowly to the last two or three threads. Allow any pressure under plug to bleed slowly to prevent a spray of hot oil. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 48 7. The pump should not be subjected to thermal or pressure shock. The thermal fluid should, therefore, be allowed to flow into the casing slowly. 8. Check field work and make sure that all connections have been made in the proper places. Check electrical connections to the motor. 9. Rotate the pump shaft by hand to be sure there is no binding or rubbing within the pump or driver. Correct any problems immediately. 10. Check to see that pump is properly aligned while cold. 11. The pump is properly aligned before it leaves the factory. Because the system expands in operation, the pump must be realigned when the system is at operating temperature. 12. The coupling alignment of the pump and driver must be carefully checked for angular and axial alignment. Check pump manufacturers instructions for these specifications. The use of a dial indicator to check the axial and angular alignment is recommended. 13. Realign at operating temperature, if necessary. 14. Make sure that the pump is properly greased or oiled. e) Pumps with Packed Seals 1. Make sure that the gland is finger tight before filling the system. 6. Initial Start-Up a) These instructions are for use when the unit is being started up for the first time, or after prolonged shutdown. They are to be used in conjunction with the specific procedure information in titled section, “Routine Operation.” 7. Start-Up Service a) If start-up service has been included in the order, the factory should be contacted after the installation has been successfully completed and approved by the client’s representative or engineers. Where possible, contact the factory at least one week before a Fulton service engineer is required on site. b) All procedures covered in Operating Instruction sections “Start-Up Preparation” and Filling the System,” including installation review, air testing of piping, pump alignment, and filling the system must be completed before the service person’s arrival. c) Depending on the size of the system and the amount of service time contracted for, startup service includes firing the heater, boiling out the system, checking, verifying and adjusting all safety settings. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 49 d) Careful preparation can expedite the commissioning of your heater. Most delays can be avoided by following the instructions in this manual. Failure to complete required procedures properly can result in the need for further service time, at extra cost to the customer. e) Service people will not commence start-up if there are obvious system deficiencies. However, start-up service in no way constitutes a system design check or approval of the installation. f) In addition to commissioning the heater, the service person will also familiarize heater room personnel with the operation of all Fulton equipment. Personnel must be qualified to understand the basic operation and function of controls. 8. Cold Circulation a) Turn on the main power switches. b) Check for proper fluid level in the expansion section of tank. c) A centrifugal pump cannot be operated with the discharge valve closed without heating up dangerously. d) The pump should be started with the suction valve full open and the discharge valve open a slight amount. e) Check pump rotation. Operating the pump in reverse rotation may cause extensive damage. f) Turn the three position switch located on the front of the panel box door to “Pump”. should be in the direction of the arrow shown on pump casing. h) If the rotation direction is incorrect, turn the three position switch back to “Off” immediately. Change the wiring connections and recheck. i) j) Check for proper alignment. Realign, at temperature. With the control switch set to “Pump” push and hold the pump start button, check all manual resets on pressuretrols. The circulating pump will run, but the burner will not fire. k) If the pump stops when the button is released, check for proper flow in the system, and review settings of high and low fluid pressure switches and differential pressure switch. Check liquid level switch. l) Check that all pressure gauge readings remain stable. Pressure exceeding 100 PSIG or identical readings at inlet and outlet gauges indicate a closed valve. m) If an extremely high vacuum (i.e.15” Hg or more) is indicated on the compound gauge, the valve between the circulating pump and the combination tank may have been left closed. In this case, little or no pressure will be indicated by other gauges. g) Jog the green pump motor starting button and observe the direction of rotation. Rotation 9. Filtering the System Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 50 a) Initially, readings on the compound gauge will indicate zero or slightly positive pressure. During the first few moments of flow, this reading will go towards vacuum, indicating that the strainer is becoming plugged. b) Typically, a reading of 3” Hg or greater vacuum on the pump suction gauge indicates that the strainer must be cleaned. The strainer screen should be back flushed or pulled, cleaned and replaced. c) Strainers should be cleaned by means of compressed air. A rag will merely force the smaller particles into the mesh of the strainer. It is recommended to place a lint free rag in the center of the strainer and blow air from the outside, trapping the debris in the rag. d) Allow the pump to run again for several minutes and repeat the filtering process until pump suction pressure remains steady after cleaning. The amount of time which must be allotted for filtering varies with the system. e) When the system is initially brought up to temperature, additional pipe scale and welding slag will loosen and enter the fluid stream. This will be trapped in the strainer causing vacuum at the pump suction. This procedure must be followed as necessary in the course of heater operation. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 51 Illustration indicates proper fluid level in the expansion section of the deaerator tank. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 52 10. Energizing the Elements Pressure Gauges a) When the system is initially brought up to temperature, additional pipe scale and welding slag will loosen and enter the fluid stream. This will be trapped in the strainer causing vacuum at the pump suction. This procedure must be followed as necessary in the course of heater operation. b) Check safeties. c) Place three position switch in Position “2”. Elements will begin to cycle on. d) Check gauges indicating pump and circuit pressures. Make sure readings remain stable. In case of pressure fluctuations, turn three position switch to Position “1”, elements will cycle off but pump continues to circulate fluid. When pressures have stabilized, switch to Position “2”. e) Continue in this manner up to the maximum operating temperature. Throughout the initial warm-up, the expansion tank and its overflow pipe must be watched to detect the formation of froth, indicating the presence of water. f) Water in the fluid can provide the ejection of a certain amount of fluid as soon as a temperature of 212°F (100°C) is reached. If this occurs, a temperature of 212°F must not be exceeded until frothing and fluid ejection have completely ceased. Note Flash steam may be generated at any point up to the operating temperature. Watch for gauge fluctuations. g) Continue bringing unit up to temperature slowly, with a temperature rise not exceeding 100°F (38°C) per hour. Do not exceed specified maximum outlet temperature. In the absence of specific information, consult the factory before proceeding. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 53 h) If no liquid level switch is provided on the expansion tank, open the low level manual test connection regularly while brining the unit up to temperature. If a permanent flow of fluid does not result when this valve is opened, stop the heater and the pump and add more thermal fluid to the system. Use only the exact same brand and type of fluid initially used to fill the system. i) Once up to temperature, check the fluid level in the expansion section by opening the high level manual test connection. If a permanent flow of fluid results when this valve is opened, and if all previous precautions have been followed, the expansion tank is too small for the capacity of the fluid in the installation. A larger tank must be installed. j) After fifty hours of operation at operating temperature, check all flanges and connections for tightness. 11. Procedure for First Shutdown a) The heater system should be shut down after no more than 24 hours of operation at full operating temperature. At this time, the following maintenance items will need to be completed to meet warranty conditions. b) While pump is still at operating temperature, align circulating pump(s) to pump manufacturer’s specifications. This should be done by means of a dial indicator. c) Isolate Y-strainer(s) in system and clean regardless of pump suction pressure. Make sure that the temperature is low enough to handle safely or provision has been made to handle materials at high temperature. Generally, temperatures below 150°F are acceptable to perform operation with regular work gloves. d) With piping system cooled to ambient temperature, torque all bolts on skid and throughout system to gasket manufacturer’s specifications using proper flange torquing practices such as incremental torque increases, star pattern, etc. Refer to Installation Section. e) Visually inspect all thread fittings and valve packings. Repair leaks and tighten valve packings to the point of stopping leak. f) Upon putting unit back into operation, check all gauge readings and compare to values given to you by the start-up technician. Note any discrepancies and contact Fulton. 12. Required Pressure Drop Across the Heater a) The thermal fluid pressure drop across your heater is critical. This should be recorded at the completion of start-up. The pressure drop value is obtained by subtracting the heater outlet pressure from the heater inlet pressure when the thermal fluid is at normal operating temperature. b) At the recommended standard flow rates, and .7 sp gr, the pressure drop across the heater should be as shown in the chart on the following page. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 54 c) In the event of an abnormal reading, contact Fulton Service immediately. Failure to take immediate action in the event of reduced fluid flow may result in rapid and serious degradation of the fluid, with possible damage to the heater. 13. Required Flow Through The Heater a) Maintenance of sufficient flow through the thermal fluid heater and system at all times of operation is critical. See table for recommended standard flow rates. b) Note pressure gauge readings at start-up. Record readings in a log book and contact Fulton service immediately in the event of abnormal readings. Failure to take action when fluid flow is reduced may result in serious and rapid degradation of the fluid with possible damage to the heater. Model FT-0075N FT-0150N FT-0225N FT-0300N FT-0375N FT-0430N FT-0640N FT-0860N FT-1070N FT-1290N FT-1500N FT-1720N Recommended GPM 50 50 50 90 90 125 125 150 150 175 200 200 Differential Pressure (PSI) 7 7 7 10 10 10 10 12 12 12 12 15 14. Operating Controls a) The following specifications, data, equipment and operating descriptions apply to typical Coil Design units. These sections are provided for general information purposes only, and do not necessarily reflect the specific details of individual systems. b) Liquid Level Switch-When Combination Tank is Supplied 1. In the event of system fluid loss, the level in the expansion section of the combination tank will drop, and the liquid level switch will shut the unit down. Control power will be lost to the panel. 2. To confirm operation, manually trip the liquid level switch. Unit should shut down; pump will stop. c) Differential Pressure Switch 1. The heater is dependent on proper flow for operation; therefore, a differential pressure switch is used to sense the pressure drop across the Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 55 heater. The differential pressure switch will shut the unit down in the event of loss of flow. 2. The differential pressure switch can be tested while only the pump is running. Remove the metal cover on top of the switch and increase the setpoint until the pump shuts down. Next, decrease the setpoint back to its initial value and depress the pump start button to verify the pump will re-start. d) Pump Motor Starter 1. While firing, actuate the manual trip button on the pump motor starter. Pump and burner will shut down. The blower should continue to run for approximately thirty seconds. Attempt to restart pump by setting the selector switch to “Pump” and depressing the pump start push button. The pump should not start. Reset starter and start pump. e) High and Low Fluid Pressure Switches 1. The only pressure required in the thermal fluid system is the pressure required to maintain the proper flow. Pressure changes are monitored with these switches, which will shut the unit down in case of a change in the fluid flow. 2. With three position switch set to “Pump”, remove the cover from the pressure switch and manually activate. Pump should shut down. 3. Repeat for each switch; replace covers. Note, if the burner was on, it would also stop. 4. To set the low fluid pressure cutout switch, raise the setpoint with the fluid at operating temperature and pump running, until the pump shuts down. Note the setpoint and lower by 10 PSI, then re-start pump. The setpoint at cutout should correspond to the reading on the output pressure gauge. 5. With the unit cold and pump running, lower the high fluid pressure cutout switch until the pump shuts down. Note the setpoint and raise by 10 PSI, then re-start pump. The setpoint at cutout should correspond to the inlet gauge reading. f) Operating Temperature Controls 1. The safe maximum temperature of the fluid must be strictly adhered to. 2. When consulting fluid manufacturer’s literature for the safe maximum fluid temperature, note that the temperatures quoted are the actual limit to which any of the fluids may be subjected. It is important to remember that in any fired heater there exists a “film” temperature which is higher than the temperature of the bulk of the fluid. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 56 3. Temperature controllers measure the bulk temperature and not the film temperature. This must be taken into consideration when setting the temperature controls. 4. These approximate guidelines for temperature settings are not to override the system design parameters. 5. These instructions should be used with information from the system designer. Manufacturer’s literature on the temperature controller is provided in the last section of this manual. 6. Standard primary temperature control sensing point location for On/Off and Modulating heaters is on the heater outlet. 7. When optional inlet location of the primary controls is specified. the following instructions may still be used with some modification. For instance when primary controls are located on the inlet, the dead band range will be much narrower than on heaters with outlet control. In addition, temperature changes will not be as immediately apparent. 8. An indicating temperature controller is used to regulate the thermal fluid temperature. Typically the indicating control is a thermocouple. 9. The thermocouple is directly immersed in the thermal fluid in the heater manifold. The setpoint of the controller is regulated by the keypad. g) High Temperature Limit Switches Safety (All units) 1. All units are fitted with high temperature limit controllers which monitor the fluid temperature at the heater outlet. This limit controller provides over temperature protection. A high temperature limit switch acts as an over temperature safety device. If the high temperature limit shuts down the unit, the manual reset button on the limit switch must be pressed. The red button on the flame programmer must also be pressed to reset the unit before it can be restarted. The high temperature limit controller is factory set to 0°F. This must be set to the lowest of the following: a. Maximum operating temperature of the fluid. b. Maximum operating temperature of the equipment. c. 15°F over maximum system operating temperature. 2. Do not set this controller too close to the normal outlet temperature in order to avoid nuisance lockouts due to small transient over temperatures. 3. Several consecutive lockouts caused by the high temperature limit controller indicate the need for immediate installation review, beginning with fluid level in the expansion tank, firing rate, and circulating pump performance. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 57 h) Operating Limit Controller 1. The limit controller is mounted in the panel box door. This limit controller senses temperature in the outlet manifold. The temperature setpoint in the controller can be adjusted following instructions in the component data sheet section of this manual. i) Pressure Gauges 1. All units have two pressure gauges measuring the thermal fluid pressure at the inlet of the heater and at the outlet of the heater. The difference between the readings of the two gauges indicates the pressure loss across the heater. The difference must not fall below the recommended value. Recommendations are based on heater size and are listed in Section Two. 2. The gauge indicating the pressure of the fluid at the inlet is labeled “Inlet“. The “Outlet” gauge indicates the pressure at the outlet, and in effect indicates the resistance of the external pipework circuit. The pressure gauge indicating pressure at the inlet of the pump is labeled “Suction .” j) Flow Proving Device 1. The heater is dependent on proper flow for operation; therefore, three pressure switches and a differential pressure switch are used to sense flow across the heater. Any one of these switches will shut the unit down in the event of loss of flow. 15. Daily Start-Up a) Check positioning of all system valves to ensure flow is not dead-headed. b) Visually check relative position of minimum level float switch in the combination tank. c) Turn on power supply switches. d) Where applicable, open water cooling valve and check that water flows correctly. (For water cooled pumps only.) e) Open fuel valves. f) Set three position switch to “Pump”. Push and hold manual pump start button, monitoring pressure gauges on heater. g) Push reset on high fluid pressure switch located on the side of the control panel. Release pump start switch. Pump should continue to run. h) When ready to begin heating, move three position switch from “Pump” to “Heat”. After a short delay resulting from the purge period, the burner will ignite. Make sure that the temperature setpoint is as desired. i) On gas units, pilot valve activation will be indicated after pre-purge cycle has completed, followed by main flame activation. Check the presence of the flame by observing flame Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 58 signal strength from flame programmer or testing device. Operator attendance during warm-up is a recommended precaution. j) Start-up is considered complete when the unit begins to throttle back or shutdown on target temperature. 16. Daily Shutdown a) Set control switch to “Pump” pump running, burner off. b) Allow the fluid to circulate for approximately 20-30 minutes and then set the control switch to the “Off” position. c) When using fluid cooled pump, continue to circulate cooling water to pumps for 30 minutes after stopping circulation. d) Open power supply switches. e) Units switched off by an automatic time switch should have an extra relay fitted to allow 20-30 minutes of fluid circulation after stoppage in order to prevent localized over heating of fluid . f) Close fuel valves if required. Closing of system valves is not generally necessary unless maintenance of components requires a partial draining of the system. g) Because of the high temperatures usually applied, leaks are not expected to occur when cool down is achieved, provided pipework is free to contract naturally when cold. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 59 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 60 Section 4 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 61 Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 62 Section 4 – Maintenance Minimum equipment necessary to start and maintain fuel-fired thermal fluid heaters: · Digital Multimeter 1. Required Maintenance at First Shutdown a) The thermal fluid system should be shut down after no more than 24 hours of operation at operating temperature. At this time, the following maintenance items will need to be completed to meet the condition of warranty. b) While pump is still at operating temperature, align circulating pump(s) to pump manufacturer specifications. This should be done by means of a dial indicator. c) Isolate Y-strainer(s) in system and clean regardless of pump suction pressure. Make sure that the temperature is low enough to handle safely or provision has been made to handle materials at high temperature. Generally, temperatures below 150°F are acceptable to perform operation with regular work gloves. d) With piping system at ambient temperature, torque all bolts on skid and throughout system to gasket manufacturer specification using proper flange torquing practices (incremental torque increases, star-pattern, etc). These values are available in the installation section of the manual.. e) Visually inspect all thread fittings and valve packings. Repair leaks and tighten valve packings to the point of stopping leak. f) Upon putting unit back in operation, check all gauge readings and compare to values given to you by the start up technician. Note any discrepancies and contact manufacturer. 2. General Maintenance Schedule Daily a) Complete the log sheet attached at the end of this section at least once per day as a minimum. It is recommended that the log sheet be filled out twice per shift of operation. The log sheet is available from the Fulton Service Department or www.fulton.com b) Make visual inspection of the entire system for leaks. Make repairs as soon as possible. c) In systems utilizing a water cooled thermal fluid circulating pump, check level of lubricating oil in self-leveling reservoir and check cooling water circulation loop for proper operation. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 63 Monthly a) Manually check fluid level in the expansion tank. Drain ½ gallon of thermal fluid from the expansion tank. If water is present, continue to drain ½ gallon until no water is present. b) Check operation of all safeties. Refer to the instructions at the end of this section. c) Review daily log sheets noting any deviations from the norm. d) Check the tightness of all couplings, including the fuel oil pump drive (oil-fired units), fan impeller, circulating pump, etc. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 64 Semi-Annually a) Review daily log sheets noting any deviations from the norm. Annually a) Clean all strainers in the thermal fluid system. b) Take a one quart sample of thermal fluid and return to the thermal fluid manufacturer for analysis. c) Schedule to local Fulton representative or factory service technician to perform an annual preventative maintenance. 3. Maintenance Procedures Lubrication a) Different motor manufacturers recommend various intervals for lubrication schedules. Load variations will dictate the frequency and amount of lubrication required. b) When developing your lubrication schedule, consider the thermal fluid pump and all system pumps. c) If you have a thermal fluid circulating pump with a packed seal, the condition of the pump packing should be checked regularly. If fluid leakage increases, tighten the packing ¼ turn daily. 4. Safety Check Procedures Liquid Level Switch a) Manually turn liquid level switch cam counterclockwise. Micro-switch will open contacts and control voltage will be lost. Release cam and micro-switch will make and control voltage will be restored. Differential Pressure Switch a) With the circulating pump running, observe the difference in pressure between the heater outlet gauge and the heater inlet gauge. Remove the top cover of the differential pressure switch. Note the original setting of the switch and turn adjustment knob clockwise until switch trips. The pointer on the switch should be within 2 psi of the observed pressure difference. Reset switch to the original set point. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 65 Differential Pressure Switch Low Inlet Pressure Switch a) Slowly close the valve on outlet of main circulating pump observing heater inlet pressure gauge. Note the pressure at which the switch trips. This pressure should be roughly the set point of the switch minus any differential that is set. High Outlet Pressure Switch a) Note the original setting of the switch and turn adjustment screw counterclockwise while observing heater outlet pressure gauge until switch trips. The pointer on the switch should be within 2 psi of the observed pressure. Reset switch to the original set point. Outlet Inlet Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 66 High Outlet Pressure Switch Temperature Limit(s) a) Adjust set point(s) of temperature limit(s) down to a point lower than the PV (process variable is typically the current fluid temperature at the heater outlet). Solid-state controls will deactivate a control relay powering a set of n.c. contacts in the interlock circuit. Analog controls will open their contacts in the interlock circuit. Trip temperature should be within 5 degrees of PV temperature. Reset temperature limit if reset exists and reset flame programmer. 5. Recommended Maintenance Schedule (See log sheet) Daily a) Complete log-sheet at least once per day. Twice per shift of operation is recommended. (Log sheet is available from the Fulton Service Department or on the web at www.fulton.com) b) Make visual inspection of entire system for leaks. Repair as soon as possible. Monthly a) Manually check fluid level in expansion tank. b) Check operation of all safeties. Contact Fulton service department for instructions. c) Review log sheets and note any deviations from the norm. d) Drain ½ gal. of oil from thermal buffer section of DA tank. Semi-Annually Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 67 a) Review log sheets and note any deviations from the norm. Annually a) Clean all the strainers in the thermal fluid system. b) Take a quart sample of thermal fluid and have it analyzed per fluid manufacturers instructions. c) Schedule the local representative or factory technician to perform preventative maintenance on the system. Note All of the above maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-7148 or your local Fulton Thermal Representative. 6. Troubleshooting Flow Circuit/Circulating Pump(s) a) The flow circuit is the electrical circuit that enables the circulating pump(s). Your thermal fluid pump(s) will remain on until the flow circuit opens to disable the pump starter or the Off / Pump / Heat switch is turned to the "Off" position. b) Items in the flow circuit may include paddle type flow switches, a high inlet pressure switch, a low inlet pressure switch, a high outlet pressure switch and a differential pressure switch. c) Low Inlet Pressure Switch 1. All N-Model heaters have a Low Inlet Pressure Switch. This is a normally open switch that closes with proper heater inlet pressure. This switch is generally a mercury bulb type switch. Mercury will rest towards the green cap of the mercury bulb in a "made" condition. 2. The purpose of the Low Inlet Pressure Switch is primarily to protect the heater from a low flow condition. The Low Inlet Pressure Switch should be set at 5 psi below normal heater inlet pressure as read at operating temperature assuming that none of the conditions mentioned below are true. A tripped Low Inlet Pressure Switch is an indication of one of the following. 3. If your Low Inlet Pressure Switch is not making, check the following items: d) Plugged circulation pump strainer basket 1. A plugged strainer will result in a decrease of flow through the heater. High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 68 2. A "Pump Suction" gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning. Generally this point is between 0 and -5" Hg. 3. If the strainer is plugged, isolate the strainer and drain that section of piping being mindful of the temperature of the thermal fluid. 4. Remove the strainer and clean with compressed air, high-pressure water or a cleaning solution. Replace and observe new pump suction pressure. e) Failed circulation pump coupling 1. A failed coupling will result in a decreased or no flow condition through the heater. The coupling can be checked by removing the coupling guard between the pump and pump motor. 2. The coupling should not be torn or misshapen. If the coupling needs to be replaced, it is recommended to re-align the circulating pump first at ambient temperature and again when it's at operating temperature. Alignment should be within pump manufacturers' specifications. f) Cavitation of the circulating pump 1. Cavitation occurs when a pump experiences a loss of head or if any low heater flashes to gas at the impeller. During this time, the pump impeller spins without actually circulating any thermal fluid. 2. If Fulton Thermal Corporation provided the heater skid, loss of head to the pump is extremely unlikely with proper fluid level in the combination tank. 3. The most common low heater in a thermal piping system is water, which needs to be boiled out at startup or anytime new piping or fluid is added to the thermal oil system. 4. Once the system has been brought up to full operating temperature, assuming that the entire system has seen flow, there should be no further occurrence of low heater contamination apart from possible heat exchanger failure. g) System is Open 1. Lack of back-pressure. If control valving is improper or pressure drop across the system is too low, the resulting minimal back-pressure may not provide enough resistance for the flow to make the pressure switch. Check the thermal fluid system for proper operation of control valves. h) Blocked sensing line on pressure switch 1. A blocked sensing line will give an inaccurate pressure reading to the pressure switch. A blocked line will need to be replaced or cleaned. Most Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 69 installations have block valves at the heater to facilitate safe isolation and cleaning of the sensing line. i) Improper switch setting 1. The Low Inlet Pressure Switch should be set at 5 psi less than the pressure read on the heater inlet pressure gauge at full operating temperature of the system. j) Faulty Switch 1. If pressure is verified and reads correctly above set point on switch and the sensing line to the pressure switch is open, the pressure switch is faulty. Replace switch, set for desired set point and test for proper operation. k) High Outlet Pressure Switch 1. All N-Model heaters have a High Outlet Pressure Switch. This is a normally closed switch that opens with excessive heater outlet pressure. 2. The purpose of the High Outlet Pressure Switch is primarily to protect the heater from building too much pressure. Typical coil model heaters have a maximum working pressure of 150 psi with 100 psi safety valve(s) on the heater outlet manifold. 3. The High Outlet Pressure Switch should be set at 5 psi over the heater outlet pressure as read at ambient temperature assuming that none of the conditions mentioned below are true. 4. A tripped High Outlet Pressure Switch is an indication of one of the following and will require the manual reset button on the switch to be pushed: l) An obstruction downstream of the heater 1. Any obstruction downstream of the heater will increase the pressure that the heater outlet sees. This obstruction will generally result from an improper valve setting. 2. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user). Observe heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). Bypass regulating valve(s) should be adjusted to equal flow condition through users. 3. Call or e-mail Fulton for further details. It may be possible that an automatic control valve has failed. If this is the case, the valve actuator should be inspected and possibly replaced. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 70 m) Improper switch setting 1. The High Outlet Pressure Switch should be set at 5 psi over than the maximum pressure read on the heater outlet pressure gauge during proper operation at the coldest ambient temperature expected. n) Faulty Switch 1. If pressure is verified and reads correctly below set point on switch and the sensing line to the pressure switch is open, the pressure switch is faulty. Replace switch, set for desired set point and test for proper operation. o) Flow Switches 1. Units older than mid-1993 have Flow Switches on the inlet of the heater. These are normally open switches that close, making a micro-switch, upon flow establishment. 2. The purpose of the Flow Switch(es) is to protect the heater from too high of a temperature and to protect the thermal fluid from exceeding its maximum film temperature. Flow Switches Not Making a) An obstruction downstream of the Flow Switch(es) 1. Any obstruction downstream of the flow switch(es) will increase the pressure that the heater outlet sees. Any increase in outlet pressure will result in diminished flow. This obstruction will generally result from an improper valve setting. 2. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user). Observe heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). 3. Bypass regulating valve(s) should be adjusted to equal flow condition through users. Call or e-mail Fulton for further details. 4. It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced. b) Plugged circulation pump strainer basket 1. A plugged strainer will result in a decrease in flow through the heater. High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail. 2. A "Pump Suction" gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning. Generally this point is -2 psi (5 in. Hg). 3. If the strainer is plugged, isolate the strainer and drain being mindful of the temperature of the thermal fluid. Remove the strainer and clean with Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 71 compressed air, high-pressure water or a cleaning solution. Replace and observe new heater inlet pressure. c) Failed circulation pump coupling 1. A failed coupling will result in a decreased or no flow condition through the heater. The coupling can be checked by removing the coupling guard between the pump and pump motor. The coupling should not be torn or misshapen. If the coupling needs to be replaced, it will be necessary to re-align the circulating pump first at ambient temperature and again when it's at operating temperature. d) Cavitation of the circulating pump 1. Cavitation occurs when a partial vacuum presents itself at the eye of the pump impeller due to loss of head or if any low heater flashes to gas at the impeller. 2. During this time, the pump impeller spins without actually circulating any thermal fluid. If Fulton Thermal Corporation provided the heater skid, loss of head to the pump is extremely unlikely with proper fluid level in the tank. 3. The most common low heater in a thermal piping system is water, which needs to be boiled out at startup. 4. Once the system has been brought up to full operating temperature, assuming that the entire system has seen flow, there should be no further occurrence of low heater contamination apart from heat exchanger failure. e) High inlet pressure switch 1. Units newer than mid-1993 have a High Inlet Pressure Switch. This is a normally closed switch that opens with improper heater inlet pressure. 2. The purpose of the High Inlet Pressure Switch is to protect the heater from building too high of a pressure. 3. Typical electric heaters have a maximum working pressure of 150 psi with 100 psi safety valve(s) on the heater outlet manifold. The High Outlet Pressure Switch should be set at 5 psi over the heater outlet pressure as read at ambient temperature assuming that none of the conditions mentioned below are true. Tripped High Outlet Pressure Switch a) An obstruction downstream of the heater 1. Any obstruction downstream of the heater will increase the pressure that the heater outlet sees. This obstruction will generally result from an improper valve setting. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 72 2. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user). Observe heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). 3. Bypass regulating valve(s) should be adjusted to equal flow condition through users. Call or e-mail Fulton for further details. 4. It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced. b) Improper switch setting 1. The High Inlet Pressure Switch should be set at ambient temperature. The setting should be 5 psi over than the maximum pressure read on the heater outlet pressure gauge during proper operation. c) Differential Pressure Switch 1. Units newer than mid-1993 have a Differential Pressure Switch. This is a normally open diaphragm switch that closes with a proper heater differential pressure between the heater inlet and outlet. 2. The purpose of the Differential Pressure Switch is to protect the heater coil from too high of a temperature and to protect the thermal fluid from exceeding its maximum film temperature. Each heater model number has a specific minimum differential pressure. 3. See Section 1 if you do not know this pressure. This pressure is the difference in pressure between the heater inlet pressure gauge and the heater outlet pressure gauge. Differential Pressure Switch Break a) An obstruction downstream of the heater outlet 1. Any obstruction downstream of the flow switch(es) will increase the pressure that the heater outlet sees. Any increase in outlet pressure will result in diminished flow. This obstruction will generally result from an improper valve setting. 2. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user). Observe heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). 3. Bypass regulating valve(s) should be adjusted to equal flow condition through users. Call or e-mail Fulton for further details. 4. It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual* Version 2010-0423 Page 73 b) Plugged circulation pump strainer basket 1. A plugged strainer will result in a decrease in flow through the heater. High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail. 2. A "Pump Suction" gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning. Generally this point is 5-10 psi (10-20 in. Hg). 3. If the strainer is plugged, isolate the strainer and drain being mindful of the temperature of the thermal fluid. Remove the strainer and clean with compressed air, high-pressure water or a cleaning solution. Replace and observe new heater inlet pressure. c) Failed circulation pump coupling 1. A failed coupling will result in a decreased or no flow condition through the heater. The coupling can be checked by removing the coupling guard between the pump and pump motor. The coupling should not be torn or misshapen. If the coupling needs to be replaced, it will be necessary to re-align the circulating pump first at ambient temperature and again when it's at operating temperature. d) Cavitation of the circulating pump 1. Cavitation occurs when a partial vacuum presents itself at the eye of the pump impeller due to loss of head or if any low heater flashes to gas at the impeller. During this time, the pump impeller spins without actually circulating any thermal fluid. Fujitsu Siemens Loox T830 Manual Arts. (FT-C) Thermal Fluid (hot oil) Heater. Hot Water / Hydronic Boilers & Equipment Steam Boilers & Equipment Thermal Fluid. Fulton Vertical Coil (FT-C) Thermal. The Fulton FT-N Thermal Fluid Heater offers a compact vertical heater design capable of operating temperatures up to 340°C. FT-N Manual 3.55 Mb. Tweet. Steam. Fulton Electric Thermal Fluid Heaters Fulton Thermal Corp. *Vertical Coil Thermal Fluid Manual* Version 2009-0929 Page 3 Table of Contents. Fulton Thermal Fluid Heater Log Sheet Section 5. Fulton Thermal Corp. *Vertical Coil Thermal Fluid Manual. A wide variety of thermal fluids have been used successfully in Fulton Thermal Fluid Heater. Fulton Thermal Corp.*Electric Thermal Fluid. Fulton Thermal Corp.*Electric Thermal Fluid Heaters Manual. Proper placement of your Fulton Thermal Fluid Heater. |
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