10 Example of Cooling System, Exchanger, Heat | J. T. Eaton LCX9000

Exchanger

LCX9000 Liquid-Cooled Drives User Manual

January 2007

To facilitate the cleaning and venting of the coolant circulation, installation of a bypass valve in the main line and valves at each drive inlet is recommended. Open the bypass valve and shut the valves to the drive when cleaning and airing the system. At start-up, the bypass valve must be closed and the valves to the converters opened.

Figure 2-10shows a simpliﬁed example of the cooling system as well as an example of the connections between the drives and the cooling system.

				TE
				30.0°C	18.0°C
	*	*	*	*	Exchanger
		FE	FE	FE
		=	=	=
	=			≈	Heat
	=
	*	*	*	*
	*	*	*	*
				34.5°C	26.1°C

Figure 2-10: Example of Cooling System

Eaton recommends equipping the cooling system with pressure and ﬂow supervision (FE). The ﬂow supervision can be connected to digital input function External fault. If the coolant ﬂow becomes too low, the drive will be stopped.

The ﬂow supervision and other actuators, e.g. a constant ﬂow valve, are available as options. The options should be mounted at the junction of the main line and the branching line to the element, indicated with an asterisk (*) in Figure 2-10.

2-10

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MN04005001E

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J. T. Eaton LCX9000 user manual 10 Example of Cooling System, Exchanger, Heat

Contents

MN04005001E LCX9000 Liquid-Cooled DrivesUser Manual January Supersedes September Page Important Notice - Please Read Contents CHAPTER 4 - CONTROL WIRING AND INTERNAL CONNECTIONSTable of List of Figures List of Figures Continued List of Tables List of Tables Continued Table 5-13 Resettable CountersTable A-1 Fault Codes Table 5-11 System Menu Functions Hazardous High Voltage SafetyDeﬁnitions and Symbols Warnings, Cautions and Notices Warnings Cautions Grounding and Ground Fault Protection Motor and Equipment Safety Chapter 1 - Overview Receiving and Inspection L C X 0 1 6 A 0 - 4 A 2 B Storage and Shipping MaintenanceTechnical Data LCX9000 Liquid-Cooled Drives User Manual Figure 1-1 Liquid-Cooled Drive Principal Block Diagram Power Ratings DrivesPage Page Speciﬁcations Table 1-4 Technical Information Table 1-4 Technical Information Continued 1-10 Lifting the Drive Chapter 2 - InstallationMounting Liquid-Cooled Dimensions Table 2-1 One-Module Drive Dimensions Mounting Base IncludedDrives Consisting of One Module Figure 2-2 LCX9000 Liquid-Cooled Drive, CH3 Figure 2-3 LCX9000 Liquid-Cooled Drive, CH4 Figure 2-4 LCX9000 Liquid-Cooled Drive, CH5Bottom View Top View Figure 2-5 LCX9000 Liquid-Cooled Drive, CH61 Figure 2-6 LCX9000 Liquid-Cooled Drive, CH72 Figure 2-7 Drive Mounted Inside Mounting Bracket Table 2-2 Several Module Drive Dimensions Mounting Bracket IncludedDrives Consisting of Several Modules Figure 2-8 LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 Figure 2-9 LCX9000 Liquid-Cooled Drive, CH74, IP00 Bottom6-Pulse Supply 12-Pulse Supply Cooling Drinking Water SpeciﬁcationTable 2-3 Drinking Water Chemical Speciﬁcation Table 2-4 Drinking Water Quality Recommendations - Maximum Values Table 2-5 Drinking Water Quality Recommendations - Desired Values Table 2-6 Process Water Speciﬁcation Heat Figure 2-10 Example of Cooling SystemExchanger Figure 2-11 Example PI-Diagram of Cooling System and Connections Table 2-7 Information About Cooling Agent and Its Circulation Table 2-9 Coolant Volumes and Temperatures Condensation Figure 2-12 Safe Operating Conditions in Relation to Condensation Table 2-10 Liquid Connector Types All Pressure Values at Nominal Flow Cooling System ConnectionsFigure 2-13 Aluminum Hose Adapters Figure 2-14 External Thread of Hose Outﬂow Hoses and Pressure Losses Table 2-11 Pressure Losses - CH6xFigure 2-15 Pressure Loss - CH6x Table 2-12 Pressure Losses - CH7x Figure 2-16 Pressure Loss - CH7xThe following main line hose materials are acceptable plastic PVC rubber EPDM only aluminium other stainless and acid-proof materials Installation of Flow Switch About Flow Switch InstallationFigure 2-17 Flow Switch Hose Connection, Fast Connector Electrical Fast Connector Lock Screw, Cable Seal and Clamp Figure 2-18 Direction of Coolant Circulation External Cooling Fan for CH4 Drive Derating Table 2-16 Input Choke Dimensioning, 6-Pulse Supply Input Chokes Installation of Input Choke Figure 2-19 Example of Input Chokes for Liquid-Cooled Sizes Up to 62AFigure 2-20 Example of Input Chokes for Liquid-Cooled Sizes 87 - 145A and 590A Table 2-17 Choke Dimensions Sizes 23 - 145A and 590A January Table 2-18 Choke Dimensions Sizes 261 - 1150A LCX9000 Liquid-Cooled Drives User Manual Chapter 3 - Power Wiring Power ConnectionsMains Cable Motor Cable Table 3-2 Cable Sizes 400 Table 3-1 Cable Types Required to Meet StandardsCable Data Table 3-2 Cable Sizes 400 - 500V Continued Units with 6-pulse supplyUnits with 12-pulse supply Three grounding terminals per mounting plate, see Page See the tightening torques of bolts in Table Table 3-3 Cable Sizes 525Table 3-4 Tightening Torques of Bolts Fuse Sizes, Drives Table 3-5 Fuse Sizes for LCX9000 Liquid-Cooled 500V Drives Table 3-6 Fuse Sizes for LCX9000 Liquid-Cooled 690V Drives Fuse information 4. If cable insulation checks are needed, see Page Cable Installation InstructionsThe maximum length of the motor cables is 984 feet 300m Figure 3-1 Maximum Terminal Stresses Installation Space Figure 3-2 Installation Space Figure 3-3 Grounding Terminal on Mounting Plate Grounding of Power UnitCable Installation and the UL Standards Cable and Motor Insulation Checks 3-12 Chapter 4 - Control Wiring and Internal Connections Figure 4-1 Control Board Figure 4-2 Basic and Option Board Connections of the Control Board Figure 4-3 Drives Connected in Parallel Control Board Power-Up Figure 4-4 Connection of Control Board Cable from the Power BoardSee Figures 4-4 and WRONG Terminal J1 Upper Figure 4-5 Connection of Control Board Cable from the Power Board Control ConnectionsCORRECT Terminal J2 Lower Figure 4-6 I/O Terminals of the Two Basic Boards Figure 4-7 General Wiring Diagram of the Basic I/O Board OPT-A9 Figure 4-8 General Wiring Diagram of the Basic Relay Board OPT-A2 Figure 4-9 Galvanic Isolation Barriers Control CablesGalvanic Isolation Barriers Control Terminal Signals Table 4-1 Control I/O Terminal Signals Digital Input Signal Inversions Figure 4-10 Positive/Negative LogicJumper Selections on the OPT-A9 Basic Board Figure 4-11 Jumper Blocks on OPT-A9 Figure 4-12 Jumper Selection for OPT-A9 AI1 ModeAI2 Mode AO1 Mode Installing the Control Unit Mounting Box Figure 4-14 Control Unit Installed into the Mounting BoxControl Unit Mounting Box Figure 4-13 Control Unit Mounting Box Table 4-2 Installing the Control Unit Mounting Box Table 4-2 Installing the Control Unit Mounting Box Continued January MN04005001E Connections between Power Unit ASIC and Driver Boards Internal Connections Figure 4-15 Terminals and Connections between ASIC and Driver Board CH61, CH62 and CH72 Table 4-3 Terminals CH61, CH62 and CH72X9 OEVA feedback X15 Charging relay output X6 DC terminal X29 Flow supervision input Table 4-4 Terminals CH63 Connect to WL on Phase V/W driver board Table 4-5 Terminals between Driver Boards CH64 and CH74 Connections between Power Unit ASIC and the Control Unit Figure 4-18 Remove Cover to Access Power UnitConnections with Round Cable Connections with Optical Cable Figure 4-19 Optical Cable Adapter Board Table 4-6 Terminals on Adapter BoardSupply voltage 24Vin from power unit Control board connection Indicators on the Keypad Display Chapter 5 - Menu InformationKeypad Operation Figure 5-1 Control Keypad and Drive Status Indications Drive Status Indicators Table 5-1 Drive Status IndicatorsControl Place Indicators Table 5-2 Control Place Indicators Keypad Pushbuttons Status LEDs Green - Green - RedTable 5-3 Status LEDs Green - Green - Red Text Lines Table 5-5 Button Descriptions Monitor Menu NavigationFigure 5-3 Keypad Display Data Figure 5-4 Keypad Navigation Chart Monitoring Menu M1 Figure 5-5 Monitoring Menu Table 5-6 Monitored Signals Parameter Menu M2 Table 5-7 Keypad Control Parameters, M3 Figure 5-6 Parameter Value Change ProcedureKeypad Control Menu M3 Keypad Direction Selection of Control PlaceFigure 5-7 Selection of Control Place Keypad Reference STOP Button Activated Active Faults Menu M4Figure 5-8 Normal State, No Faults Fault Types Figure 5-9 Fault Display Table 5-8 Fault TypesFault Time Data Record Fault Type Symbol Table 5-9 Fault Time Recorded Data Fault History Menu M5Real Time Record Table 5-10 Real Time Record Figure 5-10 Fault History Menu System Menu M6 Table 5-11 System Menu Functions Table 5-11 System Menu Functions Continued 5-16 Figure 5-12 Change of Application Selection of LanguageFigure 5-11 Selection of Language Application Selection Copy Parameters Parameter Sets S6.3.1Figure 5-13 Storing and Loading of Parameter Sets Upload parameters to keypad To keypad, S6.3.2 Download parameters to drive From keypad, S6.3.3 Automatic Parameter Backup P6.3.4Figure 5-14 Parameter Copy to Keypad P2.1.2= 20.0 Hz Parameter ComparisonFigure 5-15 Parameter Comparison Security Password S6.5.1Figure 5-16 Password Setting Parameter Lock P6.5.2 Figure 5-17 Parameter LockingStart-Up Wizard P6.5.3 Figure 5-18 Activation of Start-Up Wizard Keypad Settings Figure 5-20 Keypad Settings SubmenuDefault Page P6.6.1 Figure 5-21 Default Page Function Default page in the operating menu P6.6.2 Timeout Time P6.6.3Figure 5-22 Timeout Time Setting Contrast Adjustment P6.6.4 Figure 5-23 HMI Acknowledge Timeout Hardware SettingsHMI Acknowledge Timeout P6.7.3 Number of retries to receive HMI acknowledgement P6.7.4 System infoTotal Counters Table 5-12 Counter Pages Table 5-13 Resettable Counters Figure 5-24 Counter ResetTrip Counters Software S6.8.3 Applications S6.8.4 Table 5-15 Applications Information PagesFigure 5-25 Applications Info Submenu Hardware S6.8.5 Expander Boards S6.8.6 Figure 5-26 Expander Board Information MenusDebug Menu S6.8.7 Expander Board Menu M7 Further Keypad Functions Expander Board ParametersTable 5-17 Expander Board Parameters Board OPTA1 Figure 5-27 Expander Board Information Menu Safety Precautions Chapter 6 - Start-Up Sequence of Operation Page MN04005001E Appendix A - Fault Codes Table A-1 Fault Codes Table A-1 Fault Codes Continued Table A-1 Fault Codes Continued Load Test with Motor DC Link Test without Motor MN04005001E Appendix B - Technical Reference Main Circuit and Control DiagramsFigure B-1 Main Circuit and Control Diagram, CH3 Figure B-2 Main Circuit and Control Diagram, CH4 Figure B-3 Main Circuit and Control Diagram, CH5Term ATerm Figure B-4 Main Circuit and Control Diagram, CH61 Figure B-5 Main Circuit and Control Diagram, CH61, ControlSPF1 H8...H13 VB00491 Figure B-6 Main Circuit and Control Diagram, CH63, ModuleFigure B-7 Main Circuit and Control Diagram, CH63, Module Figure B-8 Main Circuit and Control Diagram, CH63, Control Figure B-9 Main Circuit and Control Diagram, CH72 Figure B-10 Main Circuit and Control Diagram, CH72, Control Figure B-11 Main Circuit and Control Diagram, CH74, Phase U Figure B-12 Main Circuit and Control Diagram, CH74, Control Figure B-14 Fan Support Fan DimensionsFigure B-13 Fan Mounting Pallet - Hot Dip Zinc Coated MN04005001E B-10 Page Company Information Eaton Electrical Inc2007 Eaton Corporation All Rights Reserved Printed in USA Publication No. MN04005001E/CPG January