A Compact, Liquid-Cooled Variable Speed Drive for High Horsepower Applications

Size: px

Start display at page:

Download "A Compact, Liquid-Cooled Variable Speed Drive for High Horsepower Applications"

Lesley Townsend
5 years ago
Views:

A Compact, Liquid-Cooled Variable Speed Drive for High Horsepower Applications The Reliance Electric LiquiFlo AC drive combines high-performance variable speed drive technology with a patented

1 A Compact, Liquid-Cooled Variable Speed Drive for High Horsepower Applications The Reliance Electric LiquiFlo AC drive combines high-performance variable speed drive technology with a patented liquid-cooling design in a compact, stand-alone solution for high-horsepower applications in even the most demanding environments. PRIMARY APPLICATIONS LiquiFlo drives can be used in any high horsepower ( HP at 460 VAC) applications where mounting space is at a premium and a cooling liquid is available. Primary application examples include: compressors large chilled extruders water pumps water/wwtp pumping petrochemicals power generation mining pelletizers electric vehicles pulp and paper Challenging environments may have made it impossible to consider variable speed for some high horsepower applications in the past. With over 80% of the heat generated by LiquiFlo drives dissipated through the cooling liquid, they can be totally sealed to protect the sensitive electronics from even the harshest conditions. In addition, applications in the HP range, traditionally controlled by costlier medium voltage drives, are ideal for LiquiFlo drives. PRODUCT BENEFITS Variable Speed Control for Maximum Efficiency Variable speed control means varying motor speed to match load requirements. Here are a few of the many demonstrated advantages of variable speed control over fixed speed control in high horsepower applications: Reduced energy consumption. Use only as much power as your process load requires. The energy portion of your utility charges will be reduced because of the improved efficiency of variable speed control during times of less than 100% load requirements. This means a faster payback for installing variable speed control. (Some utilities even offer rebates or other incentives for installing variable speed control.) Longer mechanical system life. Variable speed control brings the motor up to speed without the high starting current and torque caused by motor starters. This means less wear and tear on mechanical parts such as gears, belts, and sheaves. Soft starters can reduce wear and tear on the mechanical system when starting, but they can t vary motor speed over the motor s full range efficiently the way that variable speed drives can. Fewer mechanical components and less maintenance required. Variable speed control means fewer contactors, motor current transformers, overload relays, and wiring. Fewer components that wear out means less work to maintain and less cost to replace. Variable Speed Control with No Penalty in Cost or Size Traditional fixed-speed motor starters and reduced voltage starters no longer have a size or cost advantage over variable speed control. LiquiFlo drives have a smaller footprint than both types of starters, as well as conventionallycooled AC and DC drives. In fact, LiquiFlo drives have the industry s smallest HP/square inch footprint 60% smaller compared to air-cooled drives. D-61 AC Drives Analog DC Drives Digital DC Drives Options & Accessories and Training Modified Standard V*S

Modified Standard V*S and Training Options & Accessories Digital DC Drives Analog DC Drives AC Drives In addition to being as small as or smaller than most starters installed, LiquiFlo drives cost

2 Modified Standard V*S and Training Options & Accessories Digital DC Drives Analog DC Drives AC Drives In addition to being as small as or smaller than most starters installed, LiquiFlo drives cost little more than a typical reduced voltage starter, with all the advantages of variable speed. Installing LiquiFlo drives means dramatic savings from the first day of operation. Proven Control Technology Paired with Leading-Edge Cooling Design The core of a LiquiFlo drive is the power section and regulator board of the flagship Reliance Electric GV3000/SE drive. The GV3000/SE drive power section and regulator were designed onto the patented LiquiFlo heatsink to optimize power device ratings as well as use of material. The GV3000/SE, a U.S.- designed drive that has sold over 65,000 units since its introduction in 1994, is a market leader due to its steady evolution in control schemes and ease of use. The LiquiFlo drive is normally sold as a chassis. It can be mounted in optional NEMA 1, NEMA 12, or NEMA 4X/12 enclosures. Additional options, such as input fuses, disconnects, line reactors, and controls, can be configured with the LiquiFlo drive to meet specific application needs. Liquid Cooling Design Features LiquiFlo cooling technology is optimized for heat dissipation for each frame size, and varies from a hermetically sealed aluminum casting with cooling passageways to a heatsink single-cast around copper tubing. By design, all major heat producing components, such 643 A LiquiFlo mounted in an enclosure as IGBTs and diodes, are mounted within the LiquiFlo heatsink itself, resulting in an extremely compact drive package. Virtually any available liquid which can be pumped through copper tubing can be used as the cooling medium. See the pressure, flow, and temperature specifications for acceptable cooling liquids later in this document. Single pipe in and out connection for easy mounting and maintenance Both pipe in and out connections are located for easy access and protection against accidental leakage Uses standard size 10, SAE 37 o flare female fittings Drive Features 3-Phase, 50/60 Hz, VAC Digital regulator provides three types of variable speed control: V/Hz, closed-loop vector, and sensorless enhanced vector control Overload: - In vector mode: 150% overload of continuous amp rating for 5 seconds - In V/Hz mode: 110% continuous overload of continuous amp rating with no time limit PWM (pulse-width-modulated) output for smooth AC waveforms IGBT (insulated gate bi-polar transistors) power technology Full power rating at 2 khz carrier frequency Open chassis model rated for 55 o C operating temperature, NEMA 1 up to 40 o C Standard DC bus inductor (choke) for reduced line harmonics Standard 12-pulse input configuration for line harmonic attenuation ( Amp units only), with 6-pulse available via jumper connections Wireless construction for increased reliability Expanded I/O for additional drive logic control fault relays, run relays, preset speeds, and PI control RS-232 serial port for connecting to personal computer using optional CS3000 drive configuration and control software Optional network communication boards D-62

3 LIQUIFLO DRIVE POWER RATINGS LiquiFlo Drive Model Numbers Continuous Amp Rating at 2 khz in V/Hz or Vector Mode ENVIRONMENTAL SPECIFICATIONS COOLANT SPECIFICATIONS V/Hz Mode HP (kw) Rating at 460 V Vector Mode V/Hz 110% Continuous Overload Capacity REQUIREMENTS FOR TYPICAL USER-SUPPLIED CIRCULATING LOOP WATER SYSTEM Vector Mode 150% for 5 sec. 41L Amps 350 (229) 350 (229) 455 Amps 621 Amps 50LW Amps 400 (230) 400 (230) 550 Amps 750 Amps 64LW Amps 500 (295) 500 (295) 707 Amps 964 Amps 120L Amps 1000 (750) 1000 (750) 1320 Amps 1800 Amps Condition Operating Temperature Inside Cabinet (Ambient) Storage Temperature (Ambient) Humidity Coolant Type Specifications Inlet Coolant Temperature Range Specification 0 to +55 C (32 to 131 F) -40 to 65 C (-40 to +149 F) 5 to 95% (non-condensing) Model Number 41L4060 Clean water with no additives 15 to 40 C (60 to 104 F) Model Numbers 50LW4060 and 64LW4060 Clean water with no additives 15 to 40 C (60 to 104 F) Model Number 120L4060 Potable water with approved corrosion inhibitor 15 to 40 C (60 to 104 F) Minimum Coolant Flow Rate at Full Load 7 gpm 5 gpm 8 gpm Differential Coolant Pressure at Minimum Flow Rate 3 psi 34 psi 5 psi Maximum Inlet Pressure 450 psi 450 psi 50 psi Maximum Heat Load 16,000 BTU/hour 25,000 BTU/hour 40,000 BTU/hour AC Drives Analog DC Drives Digital DC Drives Options & Accessories 1. Strainer used to capture contaminants, if required due to water source. 2. Optional flow switch used to protect against water loop failure. Could be wired into function loss input at drive. 3. Optional thermal expansion valve used to control flow based on heatsink temperature. D-63 and Training Modified Standard V*S

4 Modified Standard V*S and Training Options & Accessories Digital DC Drives Analog DC Drives AC Drives DRIVE DIMENSIONS Model Number Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Weight 41L (475) (800) (357) (397) (711) (39) (20) (125) 50LW (583) (971) (347) (464) (787) (28) (25) (168) 64LW (583) (971) (347) (464) (787) (28) (25) (170) 120L (1010) (1245) (360) (838) (1200) (28) (25) (385) inches (mm) pounds (kg) D-64 Model Numbers 41L LW LW4060 Model Number 120L4060

5 PRICING Continuous Amp Rating at 2 khz Drive Model Number List (1) (1) Contact your nearest Regional Drive Center for order entry and availability. PANEL MOUNTING KITS Use these kits to mount the LiquiFlo chassis drive in an enclosure. These kits include inlet and outlet extension hoses, cabling lugs for power connections, 6-pulse busbar jumpers, and a DC bus inductor cooling fan with brackets (The DC bus inductor cooling fan is not Stocked kits Available for field installation only (1) Contact your nearest Regional Drive Center for order entry and availability. INSTRUCTION MANUALS 414 Amps 41L4060 $21, Amps 50LW , Amps 64LW , Amps 120L ,200 Software: D Hardware: D Panel Mount Kit for Model Number 41L4060: D Panel Mount Kits for Model Numbers 50LW4060 and 64LW4060: D Panel Mount Kit for Model Number 120L4060: D included in kits 41L4060PM and 120L4060PM. The fan is included with the drive). (The 64L4060PM dies not include inlet and outlet tube assemblies.) Drive Model Number Panel Mounting Kit Model Number List (1) 41L L4060PM $1,156 50LW L4060PM 1,240 64LW L4060PM 1, L L4060PM 1,348 AC Drives Analog DC Drives Digital DC Drives Options & Accessories DISCOUNT VS-1AC D-65 and Training Modified Standard V*S

Modified Standard V*S and Training Options & Accessories Digital DC Drives Analog DC Drives AC Drives MODIFIED STANDARD DRIVES s: 460 VAC How to Order: Fax orders with price make-up and ship to/bill

6 Modified Standard V*S and Training Options & Accessories Digital DC Drives Analog DC Drives AC Drives MODIFIED STANDARD DRIVES s: 460 VAC How to Order: Fax orders with price make-up and ship to/bill to instructions to Reliance Drives Product Marketing at: A customer service representative will review and confirm your order. (1) Contact factory. D-66 Base Drive Model Number 41L LW LW L L L4060 Comments HP Rating kHz ,157 1,157 1,157 Base Drive List $21,500 $33,500 $38,400 $61,200 $61,200 $61,200 Enclosure Options: Must select appropriate enclosure adder NEMA 4/12 Cabinet 15,139 15,139 15,139 15,139 18,050 21,760 Drive must be ordered w/cabinet Cooling Options: Must pick one of these options Customer Supplied Cooling - Pressure Regulation Kit Mounts in Cabinet Self-Contained Chiller System Chiller ships separate, includes 20 ft. hoses Input Protection & Disconnect Options Circuit Breaker Disconnect & Flanged Handle (65kA) Standard Standard Standard Standard Standard Standard Door Mounted Operator Devices Drive OIM Viewing Window Standard Standard Standard Standard Standard Standard LCD OIM Door Mounted: NEMA 12 Enclosures Only Replaces Viewing Window with LCD OIM Maintained Start/Stop Switch Momentary Start/Stop Pushbuttons E-Stop Pushbutton (Mushroom Head) Jog Pushbutton Pilot Lights (each) Define Function Contactors, Overloads, Starters, Control Transformers & Line Reactors Input Contactor 2,966 2,966 3,724 7,176 Output Contactor 2,966 2,966 3,724 7,176 Drive Bypass Control 6,763 6,763 9,504 17,973 Consult factory for cabinet size Motor Overload Relay ,426 3,200 Blower Motor Starter Control Transformer: 460:120 VAC, 500 VA Standard Standard Standard Standard Standard Standard 3% Impedance Input Line Reactor 4,018 4,369 4,455 6,110 7,000 8,244 Consult factory for cabinet size Dynamic Braking - Transistor + Resistor: 20% Duty Braking CE Filter for EMC Compliance: CE Filter Installed

A Compact, Liquid-Cooled Variable Speed Drive for High Horsepower Applications

LiquiFlo AC Drives A Compact, Liquid-Cooled Variable Speed Drive for High Horsepower Applications The Reliance Electric LiquiFlo AC drive combines high-performance variable speed drive technology with