Vacon NXP Hardware Manual
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Vacon NXP Hardware Manual

Liquid cooled enclosed solutions
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Summary of Contents for Vacon NXP

  • Page 1 ® ac drives liquid cooled enclosed solutions hardware manual...
  • Page 3 • 1 Table 1. Manual revision history Revision Release date Changes/updates 27.06.2014 First version 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 4: Table Of Contents

    5.2.5 ) < OL( ) for constant power load............43 base ® Technical specifications for VACON NXP liquid cooled drives ........44 6. Supplied documentation ................... 48 Documentation examples ....................49 6.1.1 Cable connection table ..................49 6.1.2 Parts list........................ 50 6.1.3...

  • Page 5: Vacon

    • 3 7. Appenix ........................55 Power line circuit diagram....................55 P&ID drawings ........................56 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 6: Introduction

    The high power liquid cooled regenerative low harmonic enclosed solution is available in protection degree IP54. The single NXP Ch64 enclosed solution can be used with AC motors in power sizes up to 1550kW. The power range can be extended up to 5MW by using the innovative VACON DriveSync control concept for running four Ch64 enclosed solutions in parallel.

  • Page 7: Available Drive Sizes

    Introduction vacon • 5 Available drive sizes ® VACON NXP liquid cooled enclosed solutions are available in the voltage ranges 400-500V 525-690V . The available drive sizes are listed below. Table 3. Technical data for available drive sizes Electrical output...

  • Page 8: Enclosed Solution Sections

    • 6 Enclosed solution sections NCLOSED SOLUTION SECTIONS Figure 1. NXP liquid cooled enclosed solutions sections NXP Liquid cooled enclosed solutions includes the following sections: • +01: Incoming section • +02: Drive section • +03: DU/dt and internal cooler section •...

  • Page 9: Incoming Section

    -C1: LCL capacitor -F1: AC fuses -L1: LCL -V3, V4: Cooling fans -X1...: Terminal blocks >L1,>L2,>L3: Mains connection L1, L2, L3 -TR1 -V3,V4 >L1 >L2 >L3 -X1... Figure 2. Incoming section 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 10: Drive Section

    • 8 Enclosed solution sections Drive section ® The drive section includes the VACON NXP liquid cooled AFE and INU modules. As standard the section includes the following: -U1: AFE power module -U2: INU power module -F2: DC fuses -L2: LCL >U, >V, >W: Motor connection...

  • Page 11: Du/Dt And Internal Cooler Section

    This section includes a dU/dt filter and an internal cooler. As standard the section includes the following: -COOL1: Internal cooler -V1,V2: Cooling fans -L3: dU/dt filter -COOL1 -V1,V2 Figure 4. DU/DT and internal cooler section 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 12: Heat Exchanger Section

    • 10 Enclosed solution sections Heat exchanger section ® The section includes a VACON HXL/HXM 120 heat exchanger. This section is available as an option. As standard the section includes the following: -HEX1: Heat exchanger, HXL/HXM -IN, OUT: DN50 flanges DIN2642, coolant in/out...

  • Page 13: Installation

    9000.emf Before connecting the drive to mains make sure that the drive front and cable covers as well as the cabinet doors are closed. 9000.emf 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 14: Warnings

    13006.emf Do not perform any measurements when the AC drive is connected to mains. 13006.emf The touch current of Vacon AC drives exceeds 3.5 mA . According to standard EN61800-5-1, a reinforced protective ground connection must be ensured. See Chapter 3.1.3.

  • Page 15: Earthing And Earth Fault Protection

    Do not perform any voltage withstand tests on any part of the AC drive. There is a certain procedure according to which the test shall be performed. Ignoring this procedure may result in a damaged product. 13006.emf 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 16: Storage

    • 14 Installation Storage If the frequency converter is to be kept in store before use, make sure that the ambient conditions are acceptable: • Storing temperature –40…+70°C (no cooling liquid inside cooling element allowed below 0ºC) • Relative humidity <96%, no condensation The environment should also be free from dust.

  • Page 17: Lifting And Moving The Cabinets

    Figure 7. Moving the cabinets Switchgear parts can easily topple backwards when manoeuvring on rollers or manual trolleys because their centre of gravity is typically located high up at the rear of the unit. 13006.emf 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 18: Fixing The Cabinets

    • 16 Installation Fixing the cabinets Before starting the installation work make sure that the level of the floor is within acceptable limits. The maximum deviation from the basic level can be no more than 5 mm over a 3 m distance. The maximum acceptable height difference between cabinet front and rear edges should be within +2/-0 mm limit.

  • Page 19: Fixing The Cabinet To The Floor Or Wall

    The vibration dampeners are not provided in the delivery. Figure 9. Fixing the cabinets to the floor Figure 10. Fixing the cabinets in marine and off-shore installations 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 20: Cabling

    • 18 Installation Cabling Before connecting any cables, use a multimeter to check that the cables to be connected are not live. 9000.emf 3.5.1 Earthing PE conductors are connected to the PE busbar. The PE busbars in each section are connected and the PE busbars must be connected to earth.
  • Page 21 Installation vacon • 19 Figure 11. Input and output cabling front view (left), side view of output cabling (right) and cable gland locations in the bottom of the cabinet (below). 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 22: Cooling Pipe Connections

    3.5.3 Cooling pipe connections The cooling pipes are connected to the internal cooler section. See the NXP liquid cooled user manual for more information. If a heat exchanger is installed, the cooling pipes are connected to that section. See the HXL/HXM installation manual for more information.

  • Page 23: Control Connections

    For more detailed cabling instructions, see the corresponding user manual (see Table 2 on page 4). Figure 14. Control unit, control board (right) and option boards (A-E) 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 24: Screw Tightening Torques

    • 22 Installation Screw tightening torques The tightening torques of all power connections (cables and busbars) for different screw and bolt sizes are given in table below. Table 6. Tightening and checking torques of power connections Screw/bolt size Checking torque (Nm) Tightening torque (Nm) The tightening torques for control unit terminals are given below.

  • Page 25: Service

    PLC general terms and conditions of sale). The local distributor may grant a warranty time different from the above. This warranty time shall be specified in the distributor's sales and warranty terms. Vacon assumes no responsibility for any other warranties than that granted by Vacon itself.
  • Page 26 Service Item Maintenance actions interval interval Check that installation and environment condi- Conditions of tions are within Vacon specification. E.g. heat, installation 1 year 1 year dust, moisture, vibration etc. Corrective actions environment based on findings. If required the product will be cleaned with an...
  • Page 27 1 year heat exchanger inspection opens and closes completely. Possible biologi- cal residue clogging the heat exchanger on customer side, clean heat exchanger according manufacture instructions. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 28 • 26 Service Table 8. Proactive maintenance schedule Inspection Service Item Maintenance actions interval interval Cabinet, auxil- iary devices According to Replace parts according to service schedule or (contactors, 1 year manufacturer based on maintenance report recommenda- switches, relays, information tion.

  • Page 29: Replacement Instructions

    Service vacon • 27 Replacement instructions Servicing is only permitted to be carried out by Vacon-trained service personnel! 13006.emf 4.3.1 Drives Open the cabinet doors. Release the locking mechanism (1) for the dropdown service rails and pull them down from the handle (2).
  • Page 30 • 28 Service Remove the middle support plate. It is attached with two M5x10 (1) and two M6x10 (2) screws. Figure 16. Middle support plate mounting screws Remove the touch protection cover. It is attached with six M5x10 screws.
  • Page 31 NOTE! Only use tools on the bolt heads. The nuts are pressed into the busbar and tools are only to be used in the unlikely event of loosening. Figure 19. DC busbar mounting screws (X) 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 32 • 30 Service Release the top parts of the drive(s) from the cabinet. Each drive is attached with four M8x20 bolts. NOTE! Only use tools on the bolt heads. The nuts are pressed into the busbar and tools are only to be used in the unlikely event of loosening.
  • Page 33 To release the drives, remove the holder brackets (two for each drive). The brackets are attached with two M6x10 screws (1) from the front and two M6x12 bolts (2) from the sides. Figure 23. Drive holder brackets 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 34 • 32 Service Pull out the drives from the cabinet. Figure 24. Pulling the drives from the cabinet Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 35: Fuses

    There are three 2400A fuses, one for each phase, and each fuse is attached with eight M10 nuts (four on each side of the fuse). Figure 26. AC fuses 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 36: Cabinet Fans For Du/Dt And Internal Cooler

    • 34 Service 4.3.3 Cabinet fans for dU/dt and internal cooler Open the cabinet door and remove the touch cover. It is attached with five M5x10 screws. Figure 27. Removing the touch cover 1. Disconnect the fan supply wire from connector +03-XV1.
  • Page 37 Service vacon • 35 Pull out the whole fan assembly. Figure 29. Pulling out the fan assembly The fan capacitors are located under the fan assembly. Figure 30. Fan capacitors (C) 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 38: Internal Cooler

    • 36 Service 4.3.4 Internal cooler Remove the cabinet fans (see Chapter 4.3.3). Close the coolant supply to and from the internal cooler. The taps (-FVL01 and - FVL03, see Figure 48 on page 57) are located below the cooler.
  • Page 39 Remove the eight M6x10 screws holding the internal cooler (four above and four below the cooler). Figure 33. Internal cooler mounting screws (X) above (left) and below (right) the cooler Pull out the internal cooler. Figure 34. Pulling out the internal cooler 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 40: Technical Information

    0.5% or full torque control at all speeds is required, motor control based on feedback from an encoder is a necessity. This capability is incorporated into the NXP drive. In addition to the current measurement system used, the NXP drive utilizes feedback values from the encoder to determine the motor state.

  • Page 41: Pump And Fan Load

    (current calculation according to ”optimized flux curve” is not available). max load cont. load 1000 1200 1400 1600 Spe ed [rpm ] Figure 35. Example: pump and fan load 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 42: Ol( Base ) > Ol

    • 40 Technical information 5.2.2 ) > OL( ) for constant torque load base It is possible to set the overload at base speed smaller than the overload at maximum speed, i.e. ) < OL( base This can be useful when selecting the correct AC drive for constant torque drives where the overload demand at low speeds is higher than at high speeds.

  • Page 43: Starting Torque >> Ol( Max ) For Constant Torque Load

    The benefit from this can be the possibility to use a size smaller AC drive. 1200 1000 max load cont. load 1000 1200 1400 1600 Spe ed [rpm ] Figure 37. Example: Starting torque >> OL(n ) for constant torque load 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 44: N Max ) For Constant Power Load

    • 42 Technical information 5.2.4 ) > OL( ) for constant power load base Some constant power drives require less overload at max speed than at lower speeds. It is therefore possible to set the relative overload at base speed higher than the relative overload at maximum speed, i.e.

  • Page 45: Max ) For Constant Power Load

    The benefit from this can be the possibility to use a size smaller AC drive. 3000 max load 2500 cont. load 2000 1500 1000 1000 1200 1400 1600 Spe ed [rpm ] Figure 39. Example: OL(n ) < OL(n ) for constant power load base 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 46: Technical Specifications For Vacon ® Nxp Liquid Cooled Drives

    • 44 Technical information ® Technical specifications for VACON NXP liquid cooled drives Table 9. Technical specifications NX_5: 400-500V (–10%…+10%); 465-800V (–0%…+0%) Input voltage U NX_6: 525-690V (–10%…+10%); 640-1100V (–0%…+0%) Mains Input frequency f connection 45-66 Hz Connection to mains Once per minute or less Voltage class 500V: 32400 μF...
  • Page 47 Technical information vacon • 45 Table 9. Technical specifications –10°C (no frost)…+50°C (at I Ambient operating The NXP Liquid Cooled drives must be used in a temperature heated indoor controlled environment. Installation 0...+70°C temperature Storage temperature –40°C…+70°C; No liquid in heatsink under 0°C...
  • Page 48 • 46 Technical information Table 9. Technical specifications 0…+10V, R = 200kΩ, (–10V…+10V joystick control) Analogue input voltage Resolution 0.1%, accuracy ±1% 0(4)-20mA, R = 250W differential Analogue input current Positive or negative logic; 18-24V Digital inputs (6) +24V, ±10%, max volt. ripple < 100mVrms;...
  • Page 49 Cooling agent flow rates See user manual System max. working 6 bar pressure System max. peak 30 bar pressure Pressure loss (at nom. Varies according to size. See user manual flow) 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 50: Supplied Documentation

    ® VACON delivers technical documentation for the switchgear assembled AC drives according to VACON Plc’s design standard. The documentation is provided in english. VACON Plc’s scope of supply regarding documentation does not include: • Special requirements • Delivery specific requirements •...

  • Page 51: Documentation Examples

    Supplied documentation vacon • 49 Documentation examples 6.1.1 Cable connection table Figure 40. Example: Cable connection table 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 52: Parts List

    • 50 Supplied documentation 6.1.2 Parts list Figure 41. Example: Parts list Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 53: Wiring List

    Supplied documentation vacon • 51 6.1.3 Wiring list Figure 42. Example: Wiring list 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 54: Circuit Diagram

    • 52 Supplied documentation 6.1.4 Circuit diagram Figure 43. Example: Circuit diagram Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 55: Switchgear Layout Drawing

    Supplied documentation vacon • 53 6.1.5 Switchgear layout drawing Figure 44. Example: Switchgear layout drawing 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 56: Device Layout Drawing

    • 54 Supplied documentation 6.1.6 Device layout drawing Figure 45. Example: Device layout drawing Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 57: Appenix

    Appenix vacon • 55 PPENIX Power line circuit diagram Figure 46. Power line circuit diagram, revision 1 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...

  • Page 58: P&Id Drawings

    • 56 Appenix P&ID drawings Figure 47. P&ID drawing, page 1, revision 1 Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 285...
  • Page 59 Appenix vacon • 57 Figure 48. P&ID drawing, page 2, revision 1 24-hour support +358 (0)201 212 575 • Email: service@vacon.com...
  • Page 60 Find your nearest Vacon office on the Internet at: www.vacon.com Document ID: Manual authoring: documentation@vacon.com Vacon Plc. Runsorintie 7 65380 Vaasa Finland Rev. A Subject to change without prior notice © 2014 Vacon Plc.

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