Data Bulletin Raleigh, NC, USA ALTIVAR FLEX58 Chassis Drive Controllers Class 8806 INTRODUCTION The ALTIVAR FLEX58 chassis drive controller offers OEMs, panel builders, integrators, and users a unique method of reducing heat dissipation inside a NEMA Type 1 or 12 enclosure. The thermal management techniques used with the FLEX58 drive controller provides 80% heat dissipation outside the enclosure. This is accomplished by mounting the FLEX58 chassis drive controller heatsink outside an enclosure. Mounting heatsinks outside enclosures can provide significant benefits when mounting electronic power equipment such as AC drive controllers inside enclosures. Thermal management of electronic equipment is the most critical element for reliable operation. In many cases the enclosure containing the AC drive controller and associated equipment can be smaller if the thermal buildup inside the enclosure is reduced. FLEX58 chassis drive controllers with heatsinks mounted outside the enclosure provide one of the most significant and cost effective methods for OEMs and panel builders to provide added value and increase reliability for their customers. Figure 1: FLEX58 Family of Chassis Drive Controllers Figure 2: Fan Kits for FLEX58 Chassis Drive Controllers DESIGN CONCEPT Square D Company offers unique thermal management concepts to support its ALTIVAR FLEX58 chassis drive controllers. The first concept has eliminated the need for heatsink fans on drive controllers rated for 1 7.5 hp. This improvement is a result of changing the orientation of the power converter or, where the controller is mounted, to eliminate thermal stacking. Thermal stacking occurs when the power components on the bottom of the drive controller dissipate heat and the heat rise increases the ambient temperature of the devices above these power components. In any AC drive controller configuration the heatsink fan is the only moving part and the first item considered for maintenance, when required. The benefits of not having heatsink fans on drive controllers rated for 1 7.5 hp are increased reliability and maintenance-free drive controller applications. The second concept is an industry first that addresses the serviceability of the heatsink fans for maintenance or replacement on AC drive controllers rated for 10 hp and above. On AC drive controllers larger than 10 hp, heatsink fans maintain industry expected pricing and reduce the drive 1
ALTIVAR FLEX58 Chassis Drive Controllers Design Concept controller size. Without fans, AC drive controllers would quickly become cost and size prohibitive. Competitive chassis and panel mounted drive controllers use fans that are tightly integrated into the heatsink assembly making maintenance and replacement difficult and very time consuming. By de-coupling the heatsink fans and mounting them on a separate removable panel, maintenance and replacement, if required, can be performed from the front, without removing the entire AC drive controller from the enclosure. All other manufacturers require the drive controller to be removed from the enclosure or to have rear access to the enclosure. Rear access is not practical because most enclosed drive applications are wall mounted. To determine the horsepower ratings for Figures 3 6, refer to the corresponding heatsink fan kit in Table 3 on page 4. Figure 3: Figure 5: 2 Controllers without a Fan Kit Controllers with Fan Kit 31158-296-51 Figure 4: Controllers with Fan Kit 31158-296-50 Figure 6: Controllers with Fan Kit 31158-296-52
ALTIVAR FLEX58 Chassis Drive Controllers Specifications SPECIFICATIONS ALTIVAR FLEX58 chassis drive controllers are North American rated for 460 Vac and 230/208 Vac 60 Hz operation only. Table 1: Environmental Specifications type Resistance to vibrations Resistance to shocks FLEX58 chassis drive controller is rated IP00. Purchaser installation inside an enclosure. According to IEC 60068-2-6: 1.5 mm zero to peak from 3 13 Hz 1 gn from 13 200 Hz According to IEC 60068-2-27: 15 g, 11 ms FLEX58U29M2 D12M2 and FLEX58KU18N4 D23N4: Pollution degree 2 conforming to IEC 60664-1, EN50718, and NEMA ICS-1. Ambient pollution degree Maximum relative humidity User-supplied enclosure maximum ambient temperature Altitude Operational position FLEX58D16M2 D46M2 and FLEX58KD28N4 D79N4: Pollution degree 3 according to IEC 60664-1, EN50718, and NEMA ICS-1. Protect the drive controller against dust, corrosive gas, and falling liquid. 95% maximum, non-condensing and without dripping according to IEC 60068-2-3. Provide a heating system if there is possible condensation. Storage: -13 to +149 F (-25 to +65 C) Operation: +14 to +104 F (-10 to +40 C) 3300 ft (1000 m) maximum without derating; derate the output current by 1% for each additional 330 ft (100 m) Vertical, ±10, with heatsink fins vertical. Table 2: Electrical Specifications Input voltage 208 V ±10% 230 V ±10% 460 V ±10% Input frequency 60 Hz ±5% Output voltage Three-phase output, maximum voltage equal to input voltage Galvanic isolation Galvanic isolation between power and control (inputs, outputs, and power supplies) Output frequency 0.1 to 500 Hz (factory setting of 60 Hz maximum) Switching frequency All FLEX58 chassis drive controllers ship from the factory set for variable torque at 8 khz. The ratings published in this instruction bulletin and listed on the nameplate are based on: Variable torque at 8 khz Constant torque at 4 khz Above the listed rating, select the next largest size chassis drive controller. If the duty cycle does not exceed 60% (36 seconds maximum for a 60 second cycle), this is not necessary. Speed range 1:100 open loop (for example 0.6 Hz to 60 Hz or 5 Hz to 500 Hz) Speed regulation 1% of rated motor speed without adjustments or feedback. ±0.1% of rated motor speed with optional analog I/O card and appropriate tachometer feedback. ±0.02% of rated motor speed with optional digital I/O card and appropriate encoder feedback. Efficiency 97% at full load typical. Displacement power 98% through speed range. factor Motor control algorithm Sensorless flux vector control with a pulse width modulated (PWM) output wave form. DC injection braking Automatically on stopping as soon as frequency drops below 0.1 Hz for 0.5 seconds. [1] Motor thermal protection can be set between 25 and 136% of the drive controller rating. 3
ALTIVAR FLEX58 Chassis Drive Controllers Specifications Table 2: Electrical Specifications (Continued) Braking torque Transient output current Transient motor torque Drive controller protection Motor protection Codes and standards 30% of nominal motor torque without dynamic braking (typical value). Up to 150% with the dynamic braking option. 160% of nominal NEC rated motor current for 60 seconds (for constant torque ratings). 110% of nominal motor current for 60 seconds (for variable torque ratings). 200% of nominal motor torque (typical value at ±10%) for 2 seconds. 170% of nominal motor torque (typical value at ±10%) for 60 seconds. Protection against short circuits: between output phases between output phases and ground on outputs of internal supplies Thermal protection against overheating and overcurrent. Undervoltage and overvoltage faults. Protection against single-phase input operation on the three-phase drive controllers. Thermal protection integrated in the drive controller by continuous calculation of I 2 t, taking motor speed into account. [1] Motor thermal state is retained during loss of power. Motor thermal protection can be modified with a programming option to correspond to the type of motor cooling. Protection against motor phase loss. Protection by motor thermal sensors with analog option card. UL Listed per UL 508C cul certified Conforms to applicable NEMA ICS, NFPA, IEC, and ISO 9001 standards. [1] Motor thermal protection can be set between 25 and 136% of the drive controller rating. Table 3: Fan Kit Electrical Specifications Fan Kit 31158-296-50 31158-296-51 31158-296-52 460 V Chassis (hp) 7.5 20 CT 10 25 VT 25 40 CT 30 50 VT 50 75 CT 60 100 VT 208/230 V Chassis (hp) Fan Volts 7.5 10 CT or VT 120 Vac 15 20 CT 15 25 VT 25 40 CT 30 50 VT 12 Vdc 12 Vdc 1 5 CT Not required 1 5 CT or VT N/A N/A 1 7.5 VT CT = Constant Torque; VT = Variable Torque Power Source user-supplied (requires 23 VA min.) chassis drive controller chassis drive controller For more details on product selection refer to catalog 8806CT0101, FLEX58 Chassis Drive Controller Product Selection. 4
ALTIVAR FLEX58 Chassis Drive Controllers Mounting Dimensions MOUNTING DIMENSIONS There are four physical sizes of ALTIVAR FLEX58 chassis drive controllers that provide a horsepower range of 1 100 hp. Refer to Table 3 on page 4 for details about which horsepower ratings match the following controllers. The smallest controller does not require a heatsink fan kit. The second size requires a second cutout to support the removable heatsink fan kit. This assembly mounts above the FLEX58 power converter. The third and fourth sizes require a second cutout for this heatsink fan assembly, which is mounted below the power converter. The control power for this assembly is 12 Vdc, provided by the drive controller. standoff brackets determine the distance between the mounting surface and the back of the heatsink assembly. This distance forms a chimney effect for the fan to channel the airflow through the heatsink fins and is a critical installation requirement for Figures 7 and 8. Figures 7 10 show overall dimensions to depict the scope of the installation requirements and are for planning purposes only. Refer to instruction bulletin 30072-450-47 when installing ALTIVAR FLEX58 chassis drive controllers. TOP VIEW 3.25" Wall or flat vertical mounting surface Drive Area 10.05" 32" 10.82" 14" FRONT VIEW SIDE VIEW Tolerance: ±0.02 in. Figure 7: Mounting Dimensions for Controllers without a Fan Kit 5
ALTIVAR FLEX58 Chassis Drive Controllers Mounting Dimensions TOP VIEW 3.25" Wall or flat vertical mounting surface 6.0" 8.27" Fan 1.02" Fans Drive Area 14.82" 10.06" 38" Tolerance: ±0.02 in. 19.5" FRONT VIEW SIDE VIEW Figure 8: Mounting Dimensions for Controllers with Fan Kit 31158-296-50 TOP VIEW 6.0" Wall or flat vertical mounting surface 6.0" 9.52" Drive Area 21.73" 46" 1.52" Fan 3.50" Fans 9.25" Tolerance: ±0.02 in. 20" FRONT VIEW SIDE VIEW Figure 9: Mounting Dimensions for Controllers with Fan Kit 31158-296-51 6
ALTIVAR FLEX58 Chassis Drive Controllers Mounting Dimensions TOP VIEW 6.0" Wall or flat vertical mounting surface 13.85" Drive Area 25.66" 60" 1.52" Fan 4.00" Fans 13.50" Tolerance: ±0.02 25" FRONT VIEW SIDE VIEW Figure 10: Mounting Dimensions for Controllers with Fan Kit 31158-296-52 7
ALTIVAR FLEX58 Chassis Drive Controllers Data Bulletin Square D Company 8001 Highway 64 East Knightdale, NC 27545 1-888-SquareD (1-888-778-2733) www.squared.com Electrical equipment should be serviced only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. 8