Aradex VECTOPOWER VP5000-DC Installation Manual
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Aradex VECTOPOWER VP5000-DC Installation Manual

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Installation manual

VECTOPOWER
VP5000-DC/DC60, VP5000-DC/DC200-HL
Date of issue: 2019-02-08
Version: 1.4
Language: English
Read carefully before use – keep for reference

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Summary of Contents for Aradex VECTOPOWER VP5000-DC

  • Page 1: Installation Manual

    Installation manual VECTOPOWER VP5000-DC/DC60, VP5000-DC/DC200-HL Date of issue: 2019-02-08 Version: 1.4 Language: English Read carefully before use – keep for reference...
  • Page 2 Manufacturer and customer service address ARADEX AG Ziegelwaldstraße 3 73547 Lorch – Germany Goods acceptance: Hohenstaufenstraße 34 73547 Lorch - Germany Telephone: +49 (0) 7172 9181 – 0 +49 (0) 7172 9181 – 91 E-mail: service@aradex.com Internet: www.aradex.com...

  • Page 3: Table Of Contents

    Rating plate ..........................17 Functional description ........................18 3.2.1 General function ........................... 18 3.2.2 Structure and function of the VECTOPOWER VP5000-DC/DC60 ..........18 3.2.3 Structure and function of the VECTOPOWER VP5000-DC/DC200-HL .......... 20 3.2.4 Operating modes: Buck converter / boost converter ..............23 Technical data ..........................
  • Page 4 [ST2] design and pin assignment ....................47 3.7.3 [ST3] design and pin assignment ....................49 3.7.4 [ST4] design and pin assignment of the VECTOPOWER VP5000-DC/DC60 ........51 Design of the connections ......................52 3.8.1 Required connections (minimum configuration) ................52 3.8.2...
  • Page 5 Protecting connections externally ....................85 4.3.11 Optionally integrating [ST4] with VECTOPOWER VP5000-DC/DC60 ..........85 4.3.12 Integrating a brake chopper [BR+/-] with VECTOPOWER VP5000-DC/DC200-HL ......86 4.3.13 Providing a precharging circuit with the VECTOPOWER VP5000-DC/DC60 ........87 4.3.14 Providing a precharging circuit for VECTOPOWER VP5000-DC/DC200-HL ........89 4.3.15...
  • Page 6 VP5000-DC/DC60, VP5000-DC/DC200-HL About the manual 6.4.4 Initial commissioning with an existing parameter set..............138 6.4.5 Commissioning for a series application ..................141 Forming after storage for more than 6 months ................143 6.5.1 Preparing forming ........................144 6.5.2 Performing the forming ....................... 145 Operation ..........................

  • Page 7: About The Manual

    Validity of the manual for the following devices This installation manual applies to the VECTOPOWER units from HW version 1.0 listed below. Type Article number VECTOPOWER VP5000-DC/DC60 VP5000-DC18W130-6C.1.22.04.50 VECTOPOWER VP5000-DC/DC200-HL VP5000-DC18W140-6A.1.22.04.81 Table 1: Types and article numbers to which this manual applies Document history For the document history, see chapter 12 Document history.

  • Page 8: Other Applicable Documents And Software

    Link for downloading VEConfig from the ARADEX homepage, including operating manuals Conventions in this manual Abbreviations and terms The terms "VECTOPOWER" and "device" refer to a VECTOPOWER VP5000-DC/DC of the types and article numbers listed above. The terms "system", "application", and "components" refer to the application in which the VECTOPOWER is integrated.

  • Page 9: Applicable Standards And Directives

    – even in part – is prohibited without the written permission of ARADEX AG. All figures are from ARADEX AG if no other source is indicated in the caption. VECTOPOWER, VECTONUM Embedded, VECTODRIVE, VECTOBUS, VECTONET, and VECTOVISION are registered trademarks of ARADEX AG.

  • Page 10: Safety

    VP5000-DC/DC60, VP5000-DC/DC200-HL Safety Safety Proper use The VECTOPOWER is a bidirectional DC/DC converter for all types of applications without electrically isolated inputs and outputs. It is intended for use in mobile applications (e.g., in vehicles) and for stationary systems. When the VECTOPOWER is integrated in an electrical system, the applicable regulations and legal provisions for the respective area of application must be observed.

  • Page 11: Structure Of The Safety Instructions

    VP5000-DC/DC60, VP5000-DC/DC200-HL Safety Structure of the safety instructions Safety information warns against general dangers in order to protect persons, property, or the environment from damage or injury. The described measures to prevent danger must be observed. DANGER! Type/source of danger. Danger warning against an immediate, life-threatening danger.

  • Page 12: Used Symbols

    Disconnect voltage Hazards The following information on averting danger has been compiled according to the findings of ARADEX AG. The system integrator must supplement these rules with the safety rules applicable to the location and type of application. 2.6.1 Electricity Voltages up to 800 V can be present inside the VECTOPOWER;...

  • Page 13: Residual Electrical Voltage After Switch-Off

    The housing of the VECTOPOWER can heat up to 95 °C / 203 °F during operation. In the HL version (VECTOPOWER VP5000-DC/DC200-HL), a chopper IGBT is integrated for installing a brake chopper. The external braking resistor can also heat up during operation.

  • Page 14: Coolant

    VP5000-DC/DC60, VP5000-DC/DC200-HL Safety Only use suitable lifting equipment that is approved for the weight (e.g. forklift trucks) and lifting gear. Keep people and body parts away from under the suspended load during lifting, transport, or assembly. Wear suitable personal protective equipment such as safety shoes. 2.6.6 Coolant The coolant consists of a mixture of water and glycol.

  • Page 15: Programmer

    VP5000-DC/DC60, VP5000-DC/DC200-HL Safety In the field of vehicle technology in Germany, for example, it is necessary to observe the information leaflet BGI/GUV-I 8686 "Qualification for work on vehicles with high-voltage systems" from the DGUV (Deutsche Gesetzliche Unfallversicherung - German statutory accident insurance). 2.7.2 Programmer Tasks: Planning the system, commissioning it, operating it, eliminating faults.

  • Page 16: Product Description

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Product description Identification 3.1.1 Device designation The article numbers are structured according to the following scheme. For the available types, see chapter 1.1 About the manual, Validity of the manual for the following devices. Figure 1: Article numbers of the VECTOPOWER Last edited 2019-02-08 Filename 16 / 173...

  • Page 17: Rating Plate

    Rating plate The following information can be found on the rating plate of the VECTOPOWER. The date of manufacture can be determined by ARADEX AG via the serial number. Figure 2: VECTOPOWER rating plate This installation manual refers to different hardware versions of the VECTOPOWER. Information on the hardware version of your VECTOPOWER can be found on the rating plate (HW Vx.x).

  • Page 18: Functional Description

    3.2.1 General function The VECTOPOWER is a bidirectional DC/DC converter. 3.2.2 Structure and function of the VECTOPOWER VP5000-DC/DC60 The following schematic diagram gives an overview of the hardware of the VECTOPOWER VP5000- DC/DC60. Figure 4: VECTOPOWER VP5000-DC/DC60 diagram The [DC+ and [DC-] connections shown on the left in the diagram are the connection to the DC link.
  • Page 19 Protective earthing conductor Function: DC/DC converter The VECTOPOWER VP5000-DC/DC60 consists of three separate, nested DC/DC converters connected in parallel. The three DC/DC converters are phase-shifted by 120° to minimize the effective current ripple on the output side. The DC/DC converter is a two-quadrant converter. It can have two directions of operation. The current on the output side can be positive (current flows from [DC+] to [OUTPUT+] = buck converter) as well as negative (current flows from [OUTPUT+] to [DC+] = boost converter).

  • Page 20: Structure And Function Of The Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.2.3 Structure and function of the VECTOPOWER VP5000-DC/DC200-HL The following schematic diagram gives an overview of the hardware of the VECTOPOWER with optional components. Figure 5: VECTOPOWER VP5000-DC/DC200-HL diagram Legend: (1) DC/DC converter (2) Buffer capacitor and series choke at [DC+/-]...
  • Page 21 VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Function: DC/DC converter (1) The VECTOPOWER VP5000-DC/DC200-HL consists of two separate, nested DC/DC converters (1) connected in parallel. The two DC/DC converters are phase-shifted by 180° to minimize the effective current ripple on the output side.

  • Page 22: Figure 6: Schematic Diagram Of Precharging Contactor (4A) And Main Contactor (4B)

    This causes the external braking resistor to heat up. Function: Precharging circuit at [OUTPUT+] The VECTOPOWER VP5000-DC/DC200-HL is equipped with an additional precharging circuit (4) at the [OUTPUT+] connection. Process: When the VECTOPOWER is de-energized, the precharging contactor (4A) and the main contactor (4B) are open.

  • Page 23: Operating Modes: Buck Converter / Boost Converter

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description External function: Logical connections [ST1] – [ST3] The VECTOPOWER provides 3 connections for signal exchange. The logical connection [ST1] must always be connected. The hardware enable (via pin 1, 2, and 3) and usually the software enable (via CAN bus or RS-232) as well are effected via [ST1]. The logical connection [ST2] is used for the optional connection of external temperature sensors to the VECTOPOWER.

  • Page 24: Figure 8: Application Example: Buck Converter Operating Mode

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 8: Application example: buck converter operating mode Last edited 2019-02-08 Filename 24 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 25: Technical Data

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Technical data 3.3.1 Electrical data - Power connections VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL Power rating 60 kW 200 kW Max. power losses ~2 kW ~4 kW Internal capacitance of DC 120 µF Hardware version 1.0: 4,400 µF; link [DC+/-] hardware version 1.1 and higher: 3,700 µF Maximum permissible...
  • Page 26 VP5000-DC/DC60, VP5000-DC/DC200-HL Product description VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL Recommended DC link 650 V DC rated voltage [DC+/-] Maximum DC link voltage 770 V DC [DC+/-] Switch-off threshold 1 DC Hardware version 1.0 720 V DC triggering level link voltage [DC+/-] Hardware version 1.1 and higher: 800 V DC triggering level Switch-off threshold 2 DC 820 V DC...

  • Page 27: Electrical Data For Operation As A Boost Converter

    Table 5: Electrical values for operation as a buck converter 3.3.3 Electrical data for operation as a boost converter For operation as a boost converter, it must be checked whether a ballast is required for the VECTOPOWER VP5000-DC/DC60. VECTOPOWER VECTOPOWER VP5000-DC/DC60...
  • Page 28 VP5000-DC/DC60, VP5000-DC/DC200-HL Product description VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL > 110% Example: [OUTPUT+/-] 650 V DC, of which 110% = [DC+/-] 715 V DC Recommended DC link 650 V DC rated voltage [DC+/-] Maximum DC link voltage Hardware version 1.0: 680 V DC [DC+/-] Hardware version 1.1: 770 V DC Switch-off threshold 1 DC...

  • Page 29: Electrical Data - Voltage Ripple

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL precharging (only with the permissible external capacitance VECTOPOWER VP5000- must be reduced to prevent DC/DC200-HL) overloading of the PTC resistors Table 6: Electrical values for use as a boost converter 3.3.4 Electrical data - voltage ripple The voltage ripples that occur depend on the operating mode, the operating point, and the selected parameters of the control.

  • Page 30: Table 9: Electrical Data - [St1]: Analog Voltage Input

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description [ST1]: Analog voltage input VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL Measuring range ±10 V Impedance 50 kΩ Accuracy 2.5% Table 9: Electrical data - [ST1]: analog voltage input [ST1]: Analog current input VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL Measuring range ±20 mA 50 Ω...

  • Page 31: Interfaces

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description [ST2]: Digital output 5 and 6 VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL Maximum output voltage 24 V (depending on the supply voltage for the logical connections) Maximum current 1.7 A (connected to ground) Impedance (connected to 220 mΩ ground) Table 13: Electrical data - digital output 5 and 6 to [ST2] 3.3.6...

  • Page 32: Data For Cooling

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL This information is found on the rating plate. Table 15: General data and environmental data 3.3.8 Data for cooling VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL Cooling temperature -25 °C to +65 °C / -13 °F to 149 °F Maximum cooling 35 °C / 95°F temperature without...

  • Page 33: Installation Dimensions And Distances

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Cooling pressure drop Druckabfall [bar] Durchfluss [l/min] Figure 9: Cooling system pressure drop Installation dimensions and distances All dimensions in the drawings are given in millimeters. Last edited 2019-02-08 Filename 33 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 34: Dimensions Of The Vectopower Vp5000-Dc/Dc60

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.4.1 Dimensions of the VECTOPOWER VP5000-DC/DC60 Figure 10: Top view of the VECTOPOWER VP5000-DC/DC60 Figure 11: Side view of the VECTOPOWER VP5000-DC/DC60 with cooling connections Last edited 2019-02-08 Filename 34 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 35: Dimensions Of The Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 12: Front view of the VECTOPOWER VP5000-DC/DC60 with power and logical connections 3.4.2 Dimensions of the VECTOPOWER VP5000-DC/DC200-HL Figure 13: Top view of the VECTOPOWER VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 35 / 173 by Sonja Scheunert...

  • Page 36: Figure 14: Side View Of The Vectopower Vp5000-Dc/Dc200-Hl With Cooling Connections

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 14: Side view of the VECTOPOWER VP5000-DC/DC200-HL with cooling connections Figure 15: Front view of the VECTOPOWER VP5000-DC/DC200-HL with power and logical connections Last edited 2019-02-08 Filename 36 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 37: Minimum Distances From Neighboring Components To Be Observed

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.4.3 Minimum distances from neighboring components to be observed The specified minimum distances apply to all the VECTOPOWER devices described here. Observe the minimum distances to adjacent components. It may also be necessary to maintain longer distances. A longer distance makes it easier to open and close the covers of a device, for example.

  • Page 38: Figure 16: Minimum Distances, Vectopower Front View

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 16: Minimum distances, VECTOPOWER front view Figure 17: Minimum distances, VECTOPOWER side view Last edited 2019-02-08 Filename 38 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 39: Installation Position

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Dime Minimum distance Note nsio in millimeters (mm) The distance depends on the installation of the cooling tube and the size of the cooling connection. Observe the permissible bending radius of the cooling tube. The distance depends on the size of the connectors and cables/wires that are connected.

  • Page 40: Vectopower Vp5000-Dc/Dc60

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.5.1 VECTOPOWER VP5000-DC/DC60 Figure 18: Power and logical connections of the VECTOPOWER VP5000-DC/DC60 Connection designation Function Power connections [DC+] DC link DC+ [DC-] DC link DC- [OUTPUT+] Output DC+ [OUTPUT-] Output DC- Ground wire Logical connections...

  • Page 41: Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.5.2 VECTOPOWER VP5000-DC/DC200-HL Figure 19: Power and logical connections of the VECTOPOWER VP5000-DC/DC200-HL Connection designation Function Power connections [DC+] DC link DC+ [DC-] DC link DC- [OUTPUT+] Output DC+ [OUTPUT-] Output DC- [BR+]* Brake chopper DC+...

  • Page 42: Power Connections

    VECTOPOWER VP5000-DC/DC60 The VECTOPOWER is supplied without EMC cable glands. ARADEX can help you design the wire cross-sections and offers you a connection set configured for your application. EMC cable glands from Pflitsch of the blueglobe TRI type must be used. These EMC cable glands provide electromagnetic compatibility and the IP protection class.

  • Page 43: Wire Cross-Section Of The Ground Wire Acc. To En 62477-1

    If a cable or wire is used whose external diameter is smaller than the smallest sealing area of the EMC cable gland, suitable reducers must be used. ARADEX can help you design the cable or wire cross-sections and offers you a connection set configured for your application.

  • Page 44: Logical Connections

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Connection thread of Sealing area without Sealing area with inlet Shield diameter EMC cable gland inlet max./min. Æ mm max./min. Æ mm max./min. Æ mm M12x1.5 8.0 - 5.0 - / - 5.0 - 3.0 M16x1.5 11.0 - 7.0 - / - 9.0 - 5.0...

  • Page 45: St1] Design And Pin Assignment

    See chapter 3.13 Product description, Accessories that can be Figure 20: Pin assignment [ST1] obtained from ARADEX AG and chapter 3.14 Product description, Accessories that the customer must The pin assignment on the device connector is provide.

  • Page 46: Table 24: Pin Assignment [St1]

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Pin no. Description Function CAN_H CAN bus high COM1_TxD RS-232 interface TxD COM1_RxD RS-232 interface TxD #EN_CONF Digital input to allow a firmware update CAN_GND CAN bus ground COM_GND RS-232 interface ground Digi_In1 Digital input no. 1 Digi_In2 Digital input no.

  • Page 47: St2] Design And Pin Assignment

    Connector design: 17-pin, type "P" Please note that the VECTOPOWER is delivered without mating connectors. See chapter 3.13 Product description, Accessories that can be obtained from ARADEX AG and chapter 3.14 Product description, Accessories that the customer must Figure 21: Pin assignment [ST2] provide.
  • Page 48 VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Pin no. Pin type Description Function Available for VP5000-DC/ on the DC60 DC200-HL device Female Digi_In9 GND Ground of digital input 9. Connect the auxiliary contact here as a normally open contact of the precharging contactor. Female Digi_Out6- Open collector...

  • Page 49: St3] Design And Pin Assignment

    Connector design: 17-pin, type "P" Please note that the VECTOPOWER is delivered without mating connectors. See chapter 3.13 Product description, Accessories that can be obtained from ARADEX AG and chapter 3.14 Product description, Accessories that the customer must Figure 22: Pin assignment [ST3] provide.

  • Page 50: Table 26: Pin Assignment [St3]

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Pin no. Pin type on Description Function the device Female VBIn_VCC DC 5 V supply voltage for the VECTOBUS master Female VBIn_SM- Inverted logic signal of the master output Female VBIn_SM+ Logic signal of the master output Female VBIn_MS+ Logic signal of the master input...

  • Page 51: St4] Design And Pin Assignment Of The Vectopower Vp5000-Dc/Dc60

    Connector design: Size 1 Please note that the VECTOPOWER is delivered without mating connectors. See chapter 3.13 Product description, Accessories that can be obtained from ARADEX AG and chapter 3.14 Product description, Accessories that the customer must Figure 23: Pin assignment [ST4] provide.

  • Page 52: Design Of The Connections

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Design of the connections 3.8.1 Required connections (minimum configuration) VECTOPOWER VP5000- VECTOPOWER VP5000- DC/DC60 DC/DC200-HL Required connections · · Power connections [DC+/-], Power connections [DC+/-], [OUTPUT+/-] [OUTPUT+/-], [BR+/-] · · Supply and hardware enable Supply and hardware enable [ST1] pin 1, 2, 3 [ST1] pin 1, 2, 3 ·...

  • Page 53: Figure 24: Minimum Configuration Of The Vectopower Vp5000-Dc/Dc60 Variant With Can Bus And

    Figure 25: Minimum configuration of the VECTOPOWER VP5000-DC/DC60 variant with RS-232 interface Figure 24: Minimum configuration of the VECTOPOWER VP5000-DC/DC60 variant with CAN bus and optional voltage measurement at [ST4] Figure 26: Minimum configuration of the VECTOPOWER VP5000-DC/DC60 variant with VECTOBUS...

  • Page 54: Figure 27: Minimum Configuration Of The Vectopower Vp5000-Dc/Dc200-Hl Variant With Can Bus

    Product description Figure 28: Minimum configuration of the VECTOPOWER VP5000-DC/DC200-HL with RS-232 interface variant Figure 27: Minimum configuration of the VECTOPOWER VP5000-DC/DC200-HL variant with CAN Figure 29: Minimum configuration of the VECTOPOWER VP5000-DC/DC200-HL with VECTOBUS variant Last edited 2019-02-08 Filename...

  • Page 55: St1] And [St2] Version Of The Digital Inputs Designed As Low-Active Input

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.8.2 [ST1] and [ST2] version of the digital inputs designed as low-active input The digital inputs in the VECTOPOWER are internally implemented as a low-active input. Figure 30: [ST1] and [ST2] digital inputs implemented as a low-active input 3.8.3 [ST1] digital outputs designed as low-side switches The digital outputs at [ST1] are internally implemented in the VECTOPOWER as low-side switches...

  • Page 56: St2] Digital Outputs Designed As Low-Side Switches

    [ST2] and [ST4] connections for an external precharging circuit for VECTOPOWER VP5000-DC/DC60 The VECTOPOWER VP5000-DC/DC60 has no integrated precharging circuit. An external precharging circuit is usually required for operation as a boost converter. Check whether a precharging circuit is necessary for your application.

  • Page 57: Figure 33: Schematic Diagram Of The Precharging Contactor (A) And The Main Contactor (B)

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 33: Schematic diagram of the precharging contactor (A) and the main contactor (B) The precharging circuit prevents damage to the VECTOPOWER and the components connected to [OUTPUT+/-] in a particular operating condition: If the voltage on the [DC+/-] side is lower than the voltage on the [OUTPUT+/-] side when the system starts, the free-wheeling diodes in the power semiconductor cause an uncontrolled current.

  • Page 58: Figure 34: Connections Of The Precharging Contactor And The Main Contactor To [St2]

    The voltage measurement is connected to the logical connection [ST4]. [ST4] pin no. Description Function OUTPUT+ Voltage measurement of [OUTPUT+]; the second pole [OUTPUT-] is wired internally. Table 30: Logical connection [ST4] for the VECTOPOWER VP5000-DC/DC60 Last edited 2019-02-08 Filename 58 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 59: St1] Connections For A Firmware Update

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Schematic diagram of the voltage measurement at [ST4] Figure 35: Example of an external precharging circuit of the VECTOPOWER VP5000-DC/DC60 at [OUTPUT+/-] 3.8.6 [ST1] connections for a firmware update The pins for the CAN bus or the RS-232 interface are available at the logical connection [ST1] for a firmware update.

  • Page 60: Characteristic Curves For Current, Voltage, And Power

    VECTONUM control. Figure 36: Wiring diagram for a VECTOBUS system [ST3] Characteristic curves for current, voltage, and power 3.9.1 VECTOPOWER VP5000-DC/DC60 The following characteristic curves indicate the output voltage and output current under the following conditions: · Ambient temperature 35 °C / 95 °F with sufficient coolant flow.

  • Page 61: Figure 37: Dc Current Characteristic Curve As A Function Of The Output Voltage For Vp5000-Dc/Dc60

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 37: DC current characteristic curve as a function of the output voltage for VP5000-DC/DC60 Last edited 2019-02-08 Filename 61 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 62: Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 38: Output power characteristic curve as a function of the output voltage for VP5000-DC/DC60 3.9.2 VECTOPOWER VP5000-DC/DC200-HL The following characteristic curves indicate the output voltage and output current under the following conditions: · Ambient temperature 35 °C / 95 °F with sufficient coolant flow.

  • Page 63: Figure 39: Dc Current Characteristic Curve As A Function Of The Output Voltage For Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 39: DC current characteristic curve as a function of the output voltage for VP5000-DC/DC200-HL Figure 40: Output power characteristic curve as a function of the output voltage for VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 63 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 64: Characteristic Curves For Derating

    The derating depends on the inlet temperature of the coolant and the selected DC link voltage [DC+/-]. 3.10.1 VECTOPOWER VP5000-DC/DC60 Figure 41: Derating characteristic curve at 450 V for VP5000-DC/DC60 Figure 42: Derating characteristic curve at 650 V for VP5000-DC/DC60...

  • Page 65: 3.10.2 Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.10.2 VECTOPOWER VP5000-DC/DC200-HL Figure 43: Derating characteristic curve at 450 V for VP5000-DC/DC200-HL Figure 44: Derating characteristic curve at 650 V for VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 65 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 66: Characteristic Curves For Efficiency

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 45: Derating characteristic curve at 750 V for VP5000-DC/DC200-HL 3.11 Characteristic curves for efficiency The following characteristic curves show the typical efficiency at several selected operating points. Please note that the specific values for your application may differ from those shown. These values depend on many variables.

  • Page 67: Vectopower Vp5000-Dc/Dc60

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.11.1 VECTOPOWER VP5000-DC/DC60 Figure 46: Efficiency characteristic curve at 100 V DC at [OUTPUT+/-] for VP5000-DC/DC60 Figure 47: Efficiency characteristic curve at 200 V DC at [OUTPUT+/-] for VP5000-DC/DC60 Last edited 2019-02-08 Filename 67 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 68: Figure 48: Efficiency Characteristic Curve At 300 V Dc At [Output+/-] For Vp5000-Dc/Dc60

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 48: Efficiency characteristic curve at 300 V DC at [OUTPUT+/-] for VP5000-DC/DC60 Figure 49: Efficiency characteristic curve at 400 V DC at [OUTPUT+/-] for VP5000-DC/DC60 Last edited 2019-02-08 Filename 68 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 69: Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 50: Efficiency characteristic curve at 500 V DC at [OUTPUT+/-] for VP5000-DC/DC60 3.11.2 VECTOPOWER VP5000-DC/DC200-HL Figure 51: Efficiency characteristic curve at 100 V DC at [OUTPUT+/-] for VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 69 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 70: Figure 52: Efficiency Characteristic Curve At 200 V Dc At [Output+/-] For Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 52: Efficiency characteristic curve at 200 V DC at [OUTPUT+/-] for VP5000-DC/DC200-HL Figure 53: Efficiency characteristic curve at 300 V DC at [OUTPUT+/-] for VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 70 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 71: Figure 54: Efficiency Characteristic Curve At 400 V Dc At [Output+/-] For Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description Figure 54: Efficiency characteristic curve at 400 V DC at [OUTPUT+/-] for VP5000-DC/DC200-HL Figure 55: Efficiency characteristic curve at 500 V DC at [OUTPUT+/-] for VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 71 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 72: Scope Of Supply

    3.13 Accessories that can be obtained from ARADEX AG These accessories can be obtained from ARADEX AG. The specified cable glands must be used. The electromagnetic compatibility of the device is only achieved with these cable glands. The exact specification of the accessories can be found in the following chapters. See also chapter 3.14 Product description, Accessories that the customer must provide.

  • Page 73: Overview Of The Required Quantities

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.13.1 Overview of the required quantities The following table shows the required accessories and the respective quantities. VECTOPOWER VECTOPOWER VP5000-DC/DC60 VP5000-DC/DC200-HL The following accessories are required for each VECTOPOWER Cable glands for the power 4 pcs. 4 pcs.

  • Page 74: Emc Cable Glands [Dc+/-], [Output+/-], [Br+/-]

    3.13.2 EMC cable glands [DC+/-], [OUTPUT+/-], [BR+/-] [BR+/-] only for VECTOPOWER VP5000-DC/DC200-HL. Due to the wide range of applications for the device, different wire cross-sections and wire types can be used. You must use EMC cable glands with the appropriate reducers from Pflitsch, blueglobe TRI type.

  • Page 75: Mating Connectors For [St2] And [St3]

    Please note: If you need [ST2] and [ST3], order the mating connector and crimp contacts twice. For a specific offer for your application, please contact our sales department. ARADEX order no.: / figure Description Material for mating connectors [ST2] and...

  • Page 76: Mating Connector For [St4]

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description 3.13.6 Mating connector for [ST4] [ST4] optional for VECTOPOWER VP5000-DC/DC60. For a specific offer for your application, please contact our sales department. ARADEX order no.: / figure Description Material for mating connector [ST4], VP_040145 consisting of: ·...

  • Page 77: Connection Interface

    Cables/wires and terminals (specification) In general, the design of the cables and wires depends on the requirements of the respective application. Due to the wide range of applications for the VECTOPOWER, ARADEX AG cannot specify any special types. Please note the following requirements when making your selection: All cables, wires and terminals ·...

  • Page 78: Wire For [Dc+/-], [Output+/-], And, If Required, [Br+/-]

    The cable lugs must be suitable for the respective cross-section of the wire. · ARADEX AG recommends the use of cable lugs for switchgear connection. These have a narrower flange and can be inserted through the EMC cable gland. 3.14.3...

  • Page 79: Cables For [St2] And [St3]

    Link to the assembly manual for series 623 on the Intercontec homepage 3.14.5 Cable for [ST4] [ST4] optional for VECTOPOWER VP5000-DC/DC60 only Specification of the cables for the crimp contacts for [ST4] In addition to the general requirements for the cables, it is also important to note the following: ·...

  • Page 80: Table 42: Specifications Of The Cables For The Crimp Contacts For [St4]

    VP5000-DC/DC60, VP5000-DC/DC200-HL Product description · The number of conductors per cable depends on the number of occupied pins. · The size of the conductors depends on the size of the respective crimp contacts. · The crimp contacts are supplied with the mating connector. The cable is not included in the scope of delivery.

  • Page 81: Notes On Planning

    VP5000-DC/DC60, VP5000-DC/DC200-HL Notes on planning Notes on planning Qualification of the planner Hardware planning for integration into a system may only be carried out by a qualified electrician as defined in this manual. See chapter 2.7.1 Safety, Personnel requirements, Qualified electrician. Software planning for integration into a system may only be carried out by a programmer as defined in this manual.
  • Page 82 - If necessary, install Y capacitors Optionally connect [ST4] to [OUTPUT] for voltage measurement 3.8.1, 3.8.5, 4.3.11, 6.3.7 when the VECTOPOWER VP5000-DC/DC60 controls an external precharging circuit. If necessary, make further logical connections [ST2] - [ST4] General: 3.2.2, 3.2.3, 3.3.5, [ST2]: 3.7.2, 3.8.2, 3.8.4,...

  • Page 83: Notes On System Integration

    VP5000-DC/DC60, VP5000-DC/DC200-HL Notes on planning Take the following into account when planning the system For further information see chapter The versions of the VE firmware, the VEConfig software, the VEConfig operating manual parameter set, and the software in the higher-level control must VE operating manual be compatible.

  • Page 84: Considering Project Planning Scenarios

    Prevent the formation of condensation in the VECTOPOWER. Condensation can form when the temperature of the coolant drops below the ambient temperature. ARADEX recommends installing the following components in the coolant circuit: · A flow monitor helps to detect whether a lack of coolant flow is the cause of derating or an error.

  • Page 85: Application Of A Higher Voltage To [Dc+/-]

    Plan sufficient external protection for [DC+/-], [OUTPUT+/-], and [BR+/-] connections if required. ARADEX AG recommends the use of high-speed semiconductor fuses. The fuses must be suitable for the DC voltage and rated current of your application. The values differ depending on the operating mode as a buck converter or boost converter.

  • Page 86: Integrating A Brake Chopper [Br+/-] With Vectopower Vp5000-Dc/Dc200-Hl

    4.3.12 Integrating a brake chopper [BR+/-] with VECTOPOWER VP5000- DC/DC200-HL The VECTOPOWER VP5000-DC/DC200-HL is equipped with a chopper-IGBT [BR+/-] for setting up a brake chopper. Install a brake resistor Install an external braking resistor with sufficient power so that it can permanently carry the full current in the worst case.

  • Page 87: Providing A Precharging Circuit With The Vectopower Vp5000-Dc/Dc60

    Providing a precharging circuit with the VECTOPOWER VP5000- DC/DC60 The VECTOPOWER VP5000-DC/DC60 has no integrated precharging circuit. Depending on the application, a precharging circuit may be required at the [OUTPUT+] or [DC+] connections. If the external precharging circuit is to be controlled by the VECTOPOWER, a voltage measurement must be implemented with [ST4].

  • Page 88: Figure 59: Schematic Diagram Of The Precharging Contactor (A) And The Main Contactor (B)

    VP5000-DC/DC60, VP5000-DC/DC200-HL Notes on planning Figure 59: Schematic diagram of the precharging contactor (A) and the main contactor (B) Precharging circuit at [DC+] In many cases, no precharging circuit is required at the [DC+] connection for operation as a buck converter.

  • Page 89: Providing A Precharging Circuit For Vectopower Vp5000-Dc/Dc200-Hl

    Providing a precharging circuit for VECTOPOWER VP5000- DC/DC200-HL The VECTOPOWER VP5000-DC/DC200-HL is equipped with an internal precharging circuit at the [OUTPUT+] connection. Observe the maximum permissible external capacitance for the DC link [DC+/-]. Exceeding the maximum permissible capacitance will damage the VECTOPOWER.

  • Page 90: Protection Against Large Currents When Switching On

    The "discharge" command refers to a function of the VE module for the DCDC operating mode. Recommendations for configuration in different applications ARADEX recommends implementing the following proposed control. The implementation can take place either with VE or the higher-level control, depending on the type of application.

  • Page 91: Measuring Current Ripple And Voltage Ripple

    4.3.16 Measuring current ripple and voltage ripple Due to the wide range of possible applications, ARADEX AG cannot make any general statements about the strength of the current ripple and voltage ripple for your specific application. ARADEX AG recommends measuring current and voltage on the integrated VECTOPOWER during operation.
  • Page 92 Measures for the output side [OUTPUT+/-] If the measured ripple current (from peak to peak) is greater than 40 A, ARADEX AG recommends using external capacitors. Use an additional series choke to separate the capacitors inside the VECTOPOWER from the external capacitors.

  • Page 93: Ensuring Electromagnetic Compatibility (Emc)

    Use EMC cable glands for the power connections [DC+/-], [OUTPUT+/-], and, if required, [BR+/-]. See chapter 3.13.2 Product description, Accessories that are available from ARADEX AG, EMC cable glands [DC+/-], [OUTPUT+/-], [BR+/-]. · The connector for [ST1] is not shielded. Provide a shield rail, shielding collar, shield clamp, or similar that will be used near [ST1] for your application.

  • Page 94: Use Of Y Capacitors In The Dc Link [Dc+/-]

    VP5000-DC/DC60, VP5000-DC/DC200-HL Notes on planning If you require further information on the subject of electromagnetic compatibility, please contact us. See also the manual on project planning for VP600 / VP5000, chapter EMC installation notes. 4.3.19 Use of Y capacitors in the DC link [DC+/-] There are no Y capacitors installed in the VECTOPOWER itself.

  • Page 95: Packaging, Transport, Storage

    VP5000-DC/DC60, VP5000-DC/DC200-HL Packaging, transport, storage Packaging, transport, storage Qualification of personnel Packing and storage may only be carried out by a warehouse clerk as defined in this manual. See Chapter 2.7.5 Safety, Personnel requirements, Warehouse clerk. The transport may only be carried out by a carrier as defined in this manual. See chapter 2.7.4 Safety, Personnel requirements, Carrier.

  • Page 96: Transport Lock

    VP5000-DC/DC60, VP5000-DC/DC200-HL Packaging, transport, storage 5.3.1 Transport lock The terminal block for the supply wires [DC+/-], [OUTPUT+/-], and, if available, [BR+/-] must be secured for renewed transport. Use the supplied screws for the cable lugs for this purpose. Tighten the screws with the permissible torque of 15.0 Nm. 5.3.2 Storage Store the VECTOPOWER in accordance with the ambient conditions specified in the technical...

  • Page 97: Installation And Commissioning

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Installation and commissioning Qualification of personnel Installation may only be carried out by an installer as defined in this manual. See chapter 2.7.3 Safety, Personnel requirements, Installer. The electrical installation may only be carried out by a qualified electrician as defined in this manual.
  • Page 98 VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning · Two guide pins are screwed in that can bear the weight of the VECTOPOWER. They serve as aids for mounting the VECTOPOWER. · 4 screws with suitable lock washers are available. They are used for secure fastening of the VECTOPOWER.

  • Page 99: Figure 63: Crane Eyes On The Housing Of The Vectopower Vp5000-Dc/Dc60

    The VECTOPOWER has four crane eyes: one at each corner of the housing. Figure 63: Crane eyes on the housing of the VECTOPOWER VP5000-DC/DC60 Figure 64: Crane eyes on the housing of the VECTOPOWER VP5000-DC/DC200-HL 3. Place the guide holes (2) of the VECTOPOWER on the two guide pins.

  • Page 100: Mounting On A Horizontal Mounting Plate

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning tightening torque. 6. Remove the guide pins. Figure 66: Mounting points on the housing of the VECTOPOWER VP5000-DC/DC200-HL Result: · The VECTOPOWER is mounted. 6.3.2 Mounting on a horizontal mounting plate Prerequisites: · The VECTOPOWER is present. It is in a technically perfect condition.
  • Page 101 VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Procedure: CAUTION! Risk of injury due to high weight Tilting or dropping the VECTOPOWER can cause injuries such as crushing or bruising. · Only use lifting equipment that is suitable and approved for the weight (e.g., forklifts, lift trucks) and lifting gear.

  • Page 102: Figure 67: Crane Eyes On The Housing Of The Vectopower Vp5000-Dc/Dc60

    The VECTOPOWER has four crane eyes: one at each corner of the housing. Figure 67: Crane eyes on the housing of the VECTOPOWER VP5000-DC/DC60 Figure 68: Crane eyes on the housing of the VECTOPOWER VP5000-DC/DC200-HL 3. Place the VECTOPOWER above the mounting location.

  • Page 103: Figure 70: Mounting Points On The Housing Of The Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Figure 70: Mounting points on the housing of the VECTOPOWER VP5000-DC/DC200-HL Result: · The VECTOPOWER is mounted. Last edited 2019-02-08 Filename 103 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 104: Connect The Cooling Unit

    2. Connect the cooling cables. · When connecting, observe the markings at the connections: Figure 71: Cooling connections of the IN = coolant flow VECTOPOWER VP5000-DC/DC60 OUT = coolant return · Observe the specifications of the cooling system manufacturer. ·...

  • Page 105: Preparing The [Dc+/-], [Output+/-], And, If Necessary, [Br+/-] Wires For Power Connections

    The procedure for using cable lugs for switchgear connections is described here. ARADEX recommends using cable lugs for switchgear connections so that the pre-assembled wires can be inserted through the EMC glands. Tip: Check whether the cable lug fits through the double nipple of the EMC cable gland. The double nipple is screwed into the housing.

  • Page 106: Figure 73: Position Of The Support Surface For The Emc Cable Gland On The Cable Shield

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Dimensions for the wires The dimensions are shown here using the example of an EMC cable gland from Pflitsch, blueglobe TRI type. · The length (a) is the length from the center of the cable gland of the mounted cable lug to the end of the support surface of the spring in the EMC cable gland.
  • Page 107 - EMC cable glands: These require the pressure screw with the sealing insert. - Cable lugs for switchgear connections. · ARADEX AG recommends using EMC cable glands from Pflitsch, blueglobe TRI type. See chapter 3.13.2 Product description, Accessories that are available from ARADEX AG, EMC cable glands [DC+/-], [OUTPUT+/-], [BR+/-].

  • Page 108: Figure 75: Wire Stripping

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Procedure: 1. Cut the wire to the required total length. · Tip: Use sharp cable pliers for cutting. A smooth cut surface ensures that the fine wires do not fan out during stripping. 2. Strip the cable along the length (a). See figure (1).

  • Page 109: Figure 77: Crimping The Cable Lug

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning 7. Crimp the cable lug. See figure (5). Figure 77: Crimping the cable lug 8. Secure the wire terminal and the cable shield with shrink tubing. See figure (6) Make sure that the cable shield remains free along the length (b).

  • Page 110: Figure 79: Example Of Globe Sealing Insert, Pflitsch, Blueglobe Tri Type Shown

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning 10. Prepare the EMC cable gland. (Here shown using the example of an EMC cable gland from Pflitsch, blueglobe TRI type.) · For smaller cable diameters you need both inserts from the blue globe sealing insert. ·...
  • Page 111 VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning 12. Repeat the procedure for all wires of the power connections · For the VECTOPOWER VP5000-DC/DC60 for [DC+], [DC-], [OUTPUT+], and [OUTPUT-] connections · For the VECTOPOWER VP5000-DC/DC200-HL for the [DC+], [DC-], [OUTPUT+], [OUTPUT-], [BR+], and [BR-] connections.

  • Page 112: Preparing The [St1] Cable

    - Shielded cable that is suitable for your application. - Mating connectors and crimp contacts for [ST1], see chapter 3.13.4 Product description, Accessories that can be obtained from ARADEX AG, Mating connectors for [ST1] - Shielding collar, shield clamp, or similar for establishing electromagnetic compatibility.
  • Page 113 VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Last edited 2019-02-08 Filename 113 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 114: Figure 81: Assembly Manual For [St1] Ampseal Series 770680 Mating Connector, Pages 1+2, Source: Te

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Figure 81: Assembly manual for [ST1] AMPSEAL series 770680 mating connector, pages 1+2, source: TE Connectivity Result: · The cable is prepared. Last edited 2019-02-08 Filename 114 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 115: Preparing The [St2] And [St3] Cable

    Required material: - Shielded cable that is suitable for your application. - Mating connectors and crimp contacts for [ST2] and [ST3], see chapter 3.13.5 Product description, Accessories that can be obtained from ARADEX AG, Mating connectors for [ST2] and [ST3] ·...

  • Page 116: Figure 82: Assembly Manual For [St2] And [St3] Mating Connectors Series 623, Connector Crown Clamp, For

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Figure 82: Assembly manual for [ST2] and [ST3] mating connectors series 623, connector crown clamp, for crimp contacts, page 1, source: Intercontec Result: · The cables are prepared. Last edited 2019-02-08 Filename 116 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 117: St4] Cable Preparation For Vectopower Vp5000-Dc/Dc60

    [ST4] cable preparation for VECTOPOWER VP5000-DC/DC60 Information: With the VECTOPOWER VP5000-DC/DC60, [ST4] is required for voltage measurement at [OUTPUT+/-] if an external precharging circuit is to be controlled by the VECTOPOWER. To create EMC compatibility, the cable shield must be connected to a ground wire at both ends.

  • Page 118: Figure 83: Assembly Manual For [St4] Mating Connector Series 923, Connector Crown Clamping, For Crimp

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Figure 83: Assembly manual for [ST4] mating connector series 923, connector crown clamping, for crimp contacts, page 1, source: Intercontec · Check the finished cable according to the specifications in DIN EN 62477-1 for insulation testing.

  • Page 119: Establishing Electrical Connections On The Vectopower Vp5000-Dc/Dc60

    All electrical connections are located on one side of the VECTOPOWER. They are labeled on the housing. Figure 84: Position of the electrical connections on the VECTOPOWER VP5000-DC/DC60 Overview of the tightening torques of the screws for the housing cover:...

  • Page 120: Table 46: Tightening Torques Of Emc Cable Glands From Pflitsch, Blueglobe Tri Type

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Note on material damage If the permissible tightening torque is exceeded when the screws are tightened, the threaded inserts for [DC+/-] and [OUTPUT+/-] in the terminal block may loosen. Loose thread inserts lead to malfunctions of the VECTOPOWER. ·...
  • Page 121 - EMC cable glands: The double nipple and the spring are required here. - Nord-Lock wedge lock washer pairs · ARADEX AG recommends using EMC cable glands from Pflitsch, blueglobe TRI type. See chapter 3.13.2 Product description, Accessories that are available from ARADEX AG, EMC cable glands [DC+/-], [OUTPUT+/-], [BR+/-].

  • Page 122: Figure 85: Example Of Double Nipple From Pflitsch, Blueglobe Tri Type

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Procedure: Screw the EMC cable gland into the housing: (Here shown using the example of an EMC cable gland from Pflitsch, blueglobe TRI type.) 1. Screw the double nipple (2) with the thread (a) into the respective opening of the housing.

  • Page 123: Figure 87: Covers On The Vectopower Vp5000-Dc/Dc60

    The position of the connections is shown in the adjacent figure. The connections are labeled on the housing. Figure 88: [DC+/-] and [OUTPUT+/-] connections on the VECTOPOWER VP5000-DC/DC60 8. Open the screw (3). 9. Insert the corresponding wire through the double nipple (2) in the housing.

  • Page 124: Figure 91: Example Of Emc Cable Gland (Pflitsch, Blueglobe Tri Type)

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning 11. Insert the screw (3) with a pair of Nord- Lock wedge lock washers (4). 12. Tighten the screw (3) with 15 Nm / 132.8 inlb. Figure 90: Installation examples: Screw connections with wedge lock washer, source: Nord-Lock data sheet 13.

  • Page 125: Figure 92: Covers On The Vectopower Vp5000-Dc/Dc60

    Figure 93: Logical connections on the 21. Establish EMC compatibility for [ST1] with VECTOPOWER VP5000-DC/DC60 a shield bus, shield clamp, shield terminal, or similar. You can connect the shielding to one of the two ground wires on the VECTOPOWER housing.

  • Page 126: Establishing Electrical Connections On The Vectopower Vp5000-Dc/Dc200-Hl

    All electrical connections are located on one side of the VECTOPOWER. They are labeled on the housing. Figure 95: Position of all electrical connections on the VECTOPOWER VP5000-DC/DC200-HL Overview of the tightening torques of the screws for the housing cover:...

  • Page 127: Table 48: Tightening Torques Of Cable Lug Screw Fittings

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Overview of the tightening torques of the screws for the cable lugs: Cable gland Tightening torque Screws for cable lug for the [DC+/-], [OUTPUT+/-], and 15.0 Nm / 132.8 inlb ground wire connections Table 48: Tightening torques of cable lug screw fittings Note on material damage If the permissible tightening torque is exceeded when the screws are tightened, the thread inserts for [DC+/-], [OUTPUT+/-], and [BR+/-] in the terminal block may loosen.
  • Page 128 - EMC cable glands: The double nipple and the spring are required here. - Nord-Lock wedge lock washer pairs · ARADEX AG recommends using EMC cable glands from Pflitsch, blueglobe TRI type. See chapter 3.13.2 Product description, Accessories that are available from ARADEX AG, EMC cable glands [DC+/-], [OUTPUT+/-], [BR+/-].

  • Page 129: Figure 96: Example Of Double Nipple From Pflitsch, Blueglobe Tri Type

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Screw the EMC cable gland into the housing: (Here shown using the example of an EMC cable gland from Pflitsch, blueglobe TRI type.) 1. Screw the double nipple (2) with the thread (a) into the respective opening of the housing.

  • Page 130: Figure 99: [Dc+/-] And [Output+/-] Connections On The Vectopower Vp5000-Dc/Dc200-Hl

    The position of the connections is shown in the adjacent figure. The connections are labeled on the housing. Figure 99: [DC+/-] and [OUTPUT+/-] connections on the VECTOPOWER VP5000-DC/DC200-HL 8. Open the screw (3). 9. Insert the corresponding wire through the double nipple (2) in the housing.

  • Page 131: Figure 103: [Br+/-] Connections On The Vectopower Vp5000-Dc/Dc200-Hl

    16. Connect the wire to [BR+/-] as previously described for [OUTPUT+/-] and [DC+/-]. · The connections are labeled on the housing. Figure 103: [BR+/-] connections on the VECTOPOWER VP5000-DC/DC200-HL Last edited 2019-02-08 Filename 131 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 132: Figure 104: Covers On The Vectopower Vp5000-Dc/Dc200-Hl

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Close the housing: 17. Put on the other cover (1). 18. Tighten the screws for the cover (1) according to the following procedure: In the first step, tighten the screws crosswise with a tightening torque of < 1 Nm / < 8.9 inlb.

  • Page 133: Commissioning

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Results: · The VECTOPOWER is electrically connected. Commissioning 6.4.1 Test system for testing In the case of a newly designed application, it is advisable to set up a test system for testing purposes. If the test system runs satisfactorily, the measures and parameters can be adopted for the series.
  • Page 134 Have any external devices been used to provide voltage-free 4.3.9 operation? Has a procedure been defined for establishing voltage-free operation? Only with VECTOPOWER VP5000-DC/DC200-HL: Is the braking 3.5.2, 3.6.2, 4.3.12 resistor connected to [BR+/-]? Has the need for an external precharging circuit been tested? 4.3.13, 4.3.14...

  • Page 135: Initial Commissioning For An Application

    The initial commissioning is carried out with a newly designed application. It is used to determine the specific parameters for the VECTOPOWER. Note: If ARADEX AG has created an individual parameter set for your application, the procedure for initial commissioning is somewhat different from that described here. See chapter 6.4.4 Installation and commissioning, Commissioning, Initial commissioning with an existing parameter set.
  • Page 136 · To connect the CAN bus to the USB, you need an appropriate connection cable. See chapter 3.13.8 Product description, Accessories that can be obtained from ARADEX AG, Connection cables. ·...

  • Page 137: Figure 107: Veconfig: Display Of The Can Bus Networks

    All design measures have been determined and implemented. · The VECTOPOWER is ready for operation. · ARADEX AG recommends observing the behavior of the device during real operation and making further adjustments if necessary. Last edited 2019-02-08 Filename 137 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 138: Initial Commissioning With An Existing Parameter Set

    Initial commissioning with an existing parameter set Information: If this is an initial commissioning for a new application for which ARADEX AG has created a parameter set, this procedure is recommended. If the commissioning is for a series application, an existing parameter set is transferred to another device.
  • Page 139 · To connect the CAN bus to the USB, you need an appropriate connection cable. See chapter 3.13.8 Product description, Accessories that can be obtained from ARADEX AG, Connection cables. ·...

  • Page 140: Figure 108: Veconfig: Display Of The Can Bus Networks

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Instructions on how to proceed: Note on malfunctions For each individual application, a parameter set (I/Os with values) and, if required, modules (to extend the functionality) are created in VE. These are specially adapted to a VE version. If the VE version is changed, the modules are not executed correctly and the I/Os are not called or stored correctly.

  • Page 141: Commissioning For A Series Application

    · The VECTOPOWER is ready for operation. · ARADEX AG recommends observing the behavior of the device during real operation and making further adjustments if necessary. Note on malfunctions For each individual application, a parameter set (I/Os with values) and, if required, modules (to extend the functionality) are created in VE.
  • Page 142 · To connect the CAN bus to the USB, you need an appropriate connection cable. See chapter 3.13.8 Product description, Accessories that can be obtained from ARADEX AG, Connection cables. · A computer with VEConfig and a connection to the VECTOPOWER is present.

  • Page 143: Forming After Storage For More Than 6 Months

    · The VECTOPOWER is ready for operation. · ARADEX AG recommends that you record and manage the versions of the firmware, software (VEConfig and higher-level control), parameter set, and modules used. Forming after storage for more than 6 months Note on material damage After storage or a voltage-free period of more than 6 months, the electrolytic capacitors may fail.

  • Page 144: Preparing Forming

    Set up the circuit for the VECTOPOWER that you want to form. Please note that the circuits for the different VECTOPOWER types are designed differently: · The VECTOPOWER VP5000-DC/DC60 is connected to [OUTPUT+/-]. See the figure below. Figure 109: Design of the circuit for VECTOPOWER VP5000-DC/DC60 ·...

  • Page 145: Performing The Forming

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning 6.5.2 Performing the forming Prerequisites: · The circuit is set up as described under "Preparing forming". · The VECTOPOWER is connected. Procedure: DANGER! Danger of electric shock. Touching the exposed electrical contacts may result in death or serious injury. ·...

  • Page 146: Figure 111: Schematic Sequence For Forming

    VP5000-DC/DC60, VP5000-DC/DC200-HL Installation and commissioning Figure 111: Schematic sequence for forming. Results: · The electrolytic capacitors are formed. · The VECTOPOWER is ready for use. Last edited 2019-02-08 Filename 146 / 173 by Sonja Scheunert VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx...

  • Page 147: Operation

    Danger from hot surfaces The housing of the VECTOPOWER can heat up to 95 °C / 203 °F during operation. In the HL version VECTOPOWER VP5000-DC/DC200-HL, the external braking resistor can also heat up during operation. Touching the hot surfaces will cause burns.

  • Page 148: Inspection And Maintenance

    Information on material damage caused by hot surfaces The housing of the VECTOPOWER can also heat up to 95 °C / 203 °F during operation. In the HL version (VECTOPOWER VP5000-DC/DC200-HL), the external braking resistor can heat up during operation.

  • Page 149: Daily Visual Inspection

    VP5000-DC/DC60, VP5000-DC/DC200-HL Operation 7.5.1 Daily visual inspection Component Visual inspection for: Removal VECTOPOWER in Are unusual heat, sounds, odors, or Immediately inform the responsible general anything else unusual noticeable? specialist. Disconnect the VECTOPOWER from the power supply. A qualified electrician must rectify the defects or replace the VECTOPOWER.

  • Page 150: Maintenance Work: Checking Electrical Connections

    Maintenance work: Checking electrical connections Check the correct tightening torque of the connections. For a VECTOPOWER VP5000-DC/DC60 see chapter 6.3.8 Installation and commissioning, Installation, Establishing electrical connections on the VECTOPOWER VP5000-DC/DC60. For a VECTOPOWER VP5000-DC/DC200-HL see chapter 6.3.9 Installation and commissioning, Installation, Establishing electrical connections on the VECTOPOWER VP5000-DC/DC200-HL.
  • Page 151 VP5000-DC/DC60, VP5000-DC/DC200-HL Operation CAUTION! Risk of burns from hot surfaces The housing heats up during operation. · Do not touch the housing until it has cooled sufficiently. CAUTION! Danger from noise The VECTOPOWER generates noise during operation. · If necessary, wear hearing protection when working on or near the VECTOPOWER. CAUTION! Damage to health caused by coolant The coolant contains glycol.

  • Page 152: Checklist For Malfunctions

    Operation · If you need assistance, contact ARADEX customer service. Depending on the effort involved, a visit by a customer service representative may incur costs, for example, if the expert is on site for several days. The manufacturer and customer service address is found on the back of the cover sheet.

  • Page 153: Visible Damage

    Inform the responsible specialist. A qualified electrician can replace damaged cables/wires and connectors. If the housing is damaged, contact ARADEX AG customer service. Only the ARADEX customer service in Lorch, Germany may repair a damaged VECTOPOWER. The manufacturer and customer service address is found on the back of the cover sheet.
  • Page 154 VP5000-DC/DC60, VP5000-DC/DC200-HL Operation 6. Interrupt the connection to "pin 13 #EN_CONF" at [ST1]. 7. Reboot the VECTOPOWER. Results: · The VECTOPOWER starts in normal mode. · The VECTOPOWER cannot be parameterized in bootloader mode. To parameterize, restart the VECTOPOWER without "Pin 13 #EN_CONF". Establish a connection to the VECTOPOWER via the desired interface.

  • Page 155: Maintenance And Repair

    Qualification of personnel Maintenance and repair work on the VECTOPOWER may only be carried out by specialists from ARADEX AG. Please contact our customer service department. The manufacturer and customer service address is found on the back of the cover sheet.

  • Page 156: Decommissioning

    VP5000-DC/DC60, VP5000-DC/DC200-HL Decommissioning Decommissioning Qualification of personnel Decommissioning may only be carried out by a qualified electrician as defined in this manual. See chapter 2.7.1 Safety, Personnel requirements, Qualified electrician. Decommissioning Prerequisites: · It is ensured that the VECTOPOWER can be safely decommissioned. Depending on the system and application, different steps are necessary.
  • Page 157 Danger from hot surfaces The housing of the VECTOPOWER can heat up to 95 °C / 203 ° F duri ng operati on.   In the HL version (VECTOPOWER VP5000-DC/DC200-HL), the external braking resistor can heat up during operation. Touching the hot surfaces will cause burns.

  • Page 158: Disassembly And Disposal

    VP5000-DC/DC60, VP5000-DC/DC200-HL Disassembly and disposal Disassembly and disposal 10.1 Qualification of personnel Mechanical disassembly may only be carried out by an installer as defined in this manual. See chapter 2.7.3 Safety, Personnel requirements, Installer. 10.2 Removing the device Prerequisites: · The cables/wires of all signal and power connections are removed.

  • Page 159: Disposing Of Recyclable Materials

    5. Remove the VECTOPOWER. Results: · The VECTOPOWER is removed. · Send the VECTOPOWER back to ARADEX AG. ARADEX AG takes care of the disposal. 10.3 Disposing of recyclable materials Send the VECTOPOWER back to ARADEX AG for scrapping. Last edited 2019-02-08...

  • Page 160: Glossary

    VP5000-DC/DC60, VP5000-DC/DC200-HL Glossary Glossary Battery A battery is a portable power source. It generates electrical energy from a chemical reaction. In the field of automotive technology, a starter battery is a starter for combustion engines and a traction battery is an energy source for electric vehicles.
  • Page 161 In the second step, the screws are tightened in the same order as before with the maximum permitted torque. is the internal ARADEX designation for the voltage supply of the logical connections. This corresponds to the terminal KL_30B in automotive engineering.
  • Page 162 VP5000-DC/DC60, VP5000-DC/DC200-HL Glossary VEConfig VEConfig is the software for parameterizing the VE firmware. The current version can be downloaded from the ARADEX AG homepage. Link for downloading VEConfig on the ARADEX homepage VECTONUM Embedded VECTONUM Embedded, abbreviated as VE, is the name of the firmware of the VECTOPOWER.

  • Page 163: Document History

    VP5000-DC/DC60, VP5000-DC/DC200-HL Document history Document history Version Reviser Date HW version Comments/changes V 1.4 SScheunert 2018-01-17 1.0 + 1.1 Various changes V 1.3 SScheunert 2018-12-18 1.0 + 1.1 Chapter 3.3.1 Chapter 3.3.7 hight V 1.2 SScheunert 2018-11-30 1.0 + 1.1 Revised, among others, Chapter 3.6, 3.8.4, 6.3.4 supplemented Chapter 4.3.15 “Precharging circuit, external...

  • Page 164: List Of Figures

    Figure 10: Top view of the VECTOPOWER VP5000-DC/DC60 ..............34 Figure 11: Side view of the VECTOPOWER VP5000-DC/DC60 with cooling connections ......34 Figure 12: Front view of the VECTOPOWER VP5000-DC/DC60 with power and logical connections ... 35 Figure 13: Top view of the VECTOPOWER VP5000-DC/DC200-HL .............. 35 Figure 14: Side view of the VECTOPOWER VP5000-DC/DC200-HL with cooling connections .....
  • Page 165 Figure 62: Example of electrolytic capacitors connected in series with symmetry resistors connected in parallel ................................ 93 Figure 63: Crane eyes on the housing of the VECTOPOWER VP5000-DC/DC60 ......... 99 Figure 64: Crane eyes on the housing of the VECTOPOWER VP5000-DC/DC200-HL ........99 Figure 65: Mounting points on the housing of the VECTOPOWER VP5000-DC/DC60........
  • Page 166 Figure 92: Covers on the VECTOPOWER VP5000-DC/DC60 ..............125 Figure 93: Logical connections on the VECTOPOWER VP5000-DC/DC60 ..........125 Figure 94: Ground wire connection on the outside of the housing of the VECTOPOWER VP5000-DC/DC60126 Figure 95: Position of all electrical connections on the VECTOPOWER VP5000-DC/DC200-HL ....126 Figure 96: Example of double nipple from Pflitsch, blueglobe TRI type ............

  • Page 167: List Of Tables

    Table 29: Logical connections [ST2] for the external precharging circuit for the VECTOPOWER VP5000- DC/DC60 ..............................58 Table 30: Logical connection [ST4] for the VECTOPOWER VP5000-DC/DC60 ..........58 Table 31: VECTOPOWER scope of delivery ....................72 Table 32: Required accessories for VECTOPOWER ..................73 Table 33: Specification of the mating connector for [ST1] ................
  • Page 168 VP5000-DC/DC60, VP5000-DC/DC200-HL List of tables Table 46: Tightening torques of EMC cable glands from Pflitsch, blueglobe TRI type ......... 120 Table 47: Tightening torques of the housing cover screw fitting ..............126 Table 48: Tightening torques of cable lug screw fittings ................127 Table 49: Tightening torques of EMC cable glands from Pflitsch, blueglobe TRI type .........

  • Page 169: Index

    VP5000-DC/DC60, VP5000-DC/DC200-HL Index Index [ST1] ............................19, 23, 45, 83, 86, 125, 132 [ST2] ..............................19, 23, 47, 57, 125, 132 [ST3] ..............................19, 23, 49, 125, 132 [ST4] ..................................19, 58, 125 203°F ................................13, 84, 147, 148 800V ....................................12 95°C................................
  • Page 170 VP5000-DC/DC60, VP5000-DC/DC200-HL Index Choke ....................................13 Series choke ................................21, 92 Chopper IGBT ................................ 13, 21, 86 Compatibility Electromagnetic ..............................77, 161 Condensation................................. 84, 95, 96 Condition, faultless ................................10 Condition, proper ................................12 Connection interface ................................. 77 Contact details..................................2 Contactor Main contactor ................................
  • Page 171 VP5000-DC/DC60, VP5000-DC/DC200-HL Index Firmware ................................19, 21, 162 does not boot ................................153 Update aborted ................................153 Firmware update ................................59 Freewheeling diode ..............................22, 57, 85 Fuse ....................................85 Glycol ..................................14, 32 Grounding ..................................12, 94 Hardware version ................................17 Hearing protection ..........................
  • Page 172 VP5000-DC/DC60, VP5000-DC/DC200-HL Index Odor, unusual .................................. 150 Oscillation ..................................21, 92 Overvoltage category ................................. 31 Pair of wedge lock washers ............................124, 130 Parameter ..................................19, 21 PMW frequency ................................13, 21 Power connection ................................161 DC200-HL ..................................35 DC60 ..................................... 34 Power semiconductor ............................
  • Page 173 VP5000-DC/DC60, VP5000-DC/DC200-HL Index Upwards converter ................................160 Usage, intended use ................................10 VE 162 VECTOBUS............................... 19, 23, 49, 83 Voltage Supply with ..................................45 Voltage measurement ................................ 19 Voltage ripple ............................... 29, 91, 160 Weight ................................... 13, 31, 84 wire ....................................162 Wire ....................................

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