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J. T. Eaton LCX9000 user manual Cooling System Connections, 13 Aluminum Hose Adapters

Models: LCX9000

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Cooling System Connections

LCX9000 Liquid-Cooled Drives User Manual

January 2007

Cooling System Connections

The external cooling system shall be connected to each one of the cooling elements of the drive.

Note: The cooling elements must NOT be connected in series.

The cooling elements are equipped with hoses (Technobel Noir Tricoﬂex, P/N 135855) 1.5m in length and 16 mm in diameter (CH5, CH6, CH7). The hoses are inserted in 1400 mm UL94V0 approved conduits (type HFX40). These hoses have screw type connectors with internal thread. The connection of the hoses is made on the aluminum adapter (external thread) of the cooling element. Avoid any twisting of the hose on the element while connecting the line hose.

Figure 2-13: Aluminum Hose Adapters	Figure 2-14: External Thread of Hose
	Adapter

For all other chassis (CH3, CH4), the standard delivery includes fast connectors of type “Tema”, series 1300 or 1900. The fast connectors are also available as an option also for CH5, CH6, CH7.

Table 2-10: Liquid Connector Types (All Pressure Values at Nominal Flow)

	Thread on
	Element		Thread		Pressure Loss	Pressure Loss
	(Internal)	Connector Type or	(Cust.)	Max. Pressure	(Fast Connector +	(Hoses +
Chassis	BSPP	Hose Type	BSPP	(Entire System)	Element)	Element)


CH3	G3/8"	1300NE2 1/4"	—	87 psi (6 bar)	3.6 psi (.25 bar)	—

CH4	G3/8"	1300NE2 1/4"	—	87 psi (6 bar)	3.6 psi (.25 bar)	—

CH5	G3/4"	Technobel 16*23.5	G1/2"	87 psi (6 bar)	—	2.9 psi (.2 bar)

CH6	G3/4"	Technobel 16*23.5	G1/2"	87 psi (6 bar)	—	7.3 psi (.5 bar)

CH7	G3/4"	Technobel 16*23.5	G1/2"	87 psi (6 bar)	—	10.2 psi (.7 bar)

Use sealing (e.g. Usit-R Metal washer-rubber sealing) for this type of connection.

Use sealant or sealing tape for this type of connection.

2-14

For more information visit: www.EatonElectrical.com

MN04005001E

Image 36

J. T. Eaton LCX9000 user manual Cooling System Connections, 13 Aluminum Hose Adapters, 14 External Thread of Hose

Contents

LCX9000 Liquid-Cooled Drives User Manual January Supersedes SeptemberMN04005001E Page Important Notice - Please Read CHAPTER 4 - CONTROL WIRING AND INTERNAL CONNECTIONS Table ofContents 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 FunctionsSafety Deﬁnitions and SymbolsHazardous High Voltage Warnings, Cautions and Notices WarningsCautions Grounding and Ground Fault Protection Motor and Equipment SafetyChapter 1 - Overview Receiving and InspectionL C X 0 1 6 A 0 - 4 A 2 B JanuaryMaintenance Technical DataStorage and Shipping LCX9000 Liquid-Cooled Drives User Manual Figure 1-1 Liquid-Cooled Drive Principal Block Diagram LCX9000 Liquid-Cooled Drives User ManualJanuary MN04005001EPower Ratings DrivesPage Page Speciﬁcations Table 1-4 Technical InformationTable 1-4 Technical Information Continued 1-10Chapter 2 - Installation MountingLifting the Drive Liquid-Cooled Dimensions Table 2-1 One-Module Drive Dimensions Mounting Base IncludedDrives Consisting of One Module Figure 2-2 LCX9000 Liquid-Cooled Drive, CH3Figure 2-3 LCX9000 Liquid-Cooled Drive, CH4 Figure 2-4 LCX9000 Liquid-Cooled Drive, CH5January MN04005001EFigure 2-5 LCX9000 Liquid-Cooled Drive, CH61 Figure 2-6 LCX9000 Liquid-Cooled Drive, CH72LCX9000 Liquid-Cooled Drives User Manual JanuaryTable 2-2 Several Module Drive Dimensions Mounting Bracket Included Drives Consisting of Several ModulesFigure 2-7 Drive Mounted Inside Mounting Bracket LCX9000 Liquid-Cooled Drives User ManualFigure 2-8 LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 LCX9000 Liquid-Cooled Drives User ManualJanuary Figure 2-9 LCX9000 Liquid-Cooled Drive, CH74, IP00 JanuaryMN04005001E BottomCooling Drinking Water SpeciﬁcationTable 2-3 Drinking Water Chemical Speciﬁcation Table 2-4 Drinking Water Quality Recommendations - Maximum ValuesTable 2-5 Drinking Water Quality Recommendations - Desired Values Table 2-6 Process Water SpeciﬁcationFigure 2-10 Example of Cooling System ExchangerHeat Figure 2-11 Example PI-Diagram of Cooling System and Connections Table 2-7 Information About Cooling Agent and Its CirculationTable 2-9 Coolant Volumes and Temperatures Condensation Figure 2-12 Safe Operating Conditions in Relation to CondensationTable 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 HosePressure Losses Table 2-11 Pressure Losses - CH6x Figure 2-15 Pressure Loss - CH6xOutﬂow Hoses and Table 2-12 Pressure Losses - CH7x Figure 2-16 Pressure Loss - CH7xLCX9000 Liquid-Cooled Drives User Manual The following main line hose materials are acceptable plastic PVCInstallation of Flow Switch About Flow Switch InstallationFigure 2-17 Flow Switch Hose Connection, Fast Connector Electrical Fast Connector Lock Screw, Cable Seal and ClampFigure 2-18 Direction of Coolant Circulation External Cooling Fan for CH4Drive Derating Table 2-16 Input Choke Dimensioning, 6-Pulse Supply Input ChokesInstallation 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 590ATable 2-17 Choke Dimensions Sizes 23 - 145A and 590A JanuaryTable 2-18 Choke Dimensions Sizes 261 - 1150A LCX9000 Liquid-Cooled Drives User Manual2-23 LCX9000 Liquid-Cooled Drives User Manual Chapter 3 - Power Wiring Power ConnectionsMains Cable Motor CableTable 3-1 Cable Types Required to Meet Standards Cable DataTable 3-2 Cable Sizes 400 Table 3-2 Cable Sizes 400 - 500V Continued Units with 6-pulse supplyUnits with 12-pulse supply Three grounding terminals per mounting plate, see PageTable 3-3 Cable Sizes 525 Table 3-4 Tightening Torques of BoltsLCX9000 Liquid-Cooled Drives User Manual See the tightening torques of bolts in TableFuse Sizes, Drives Table 3-5 Fuse Sizes for LCX9000 Liquid-Cooled 500V DrivesTable 3-6 Fuse Sizes for LCX9000 Liquid-Cooled 690V Drives Fuse informationCable Installation Instructions The maximum length of the motor cables is 984 feet 300m4. If cable insulation checks are needed, see Page Figure 3-1 Maximum Terminal Stresses Installation Space Figure 3-2 Installation SpaceGrounding of Power Unit Cable Installation and the UL StandardsFigure 3-3 Grounding Terminal on Mounting Plate Cable and Motor Insulation Checks LCX9000 Liquid-Cooled Drives User Manual 3-12January MN04005001EChapter 4 - Control Wiring and Internal Connections Figure 4-1 Control BoardFigure 4-2 Basic and Option Board Connections of the Control Board Figure 4-3 Drives Connected in ParallelControl Board Power-Up Figure 4-4 Connection of Control Board Cable from the Power BoardSee Figures 4-4 and WRONG Terminal J1 UpperFigure 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 BoardsFigure 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-A2January MN04005001EControl Cables Galvanic Isolation BarriersFigure 4-9 Galvanic Isolation Barriers Control Terminal Signals Table 4-1 Control I/O Terminal SignalsDigital Input Signal Inversions Figure 4-10 Positive/Negative LogicJumper Selections on the OPT-A9 Basic Board Figure 4-11 Jumper Blocks on OPT-A9Figure 4-12 Jumper Selection for OPT-A9 JanuaryMN04005001E AI1 ModeInstalling the Control Unit Mounting Box Figure 4-14 Control Unit Installed into the Mounting BoxControl Unit Mounting Box Figure 4-13 Control Unit Mounting BoxTable 4-2 Installing the Control Unit Mounting Box Table 4-2 Installing the Control Unit Mounting Box Continued January MN04005001EConnections between Power Unit ASIC and Driver Boards Internal ConnectionsTable 4-2 Installing the Control Unit Mounting Box Continued 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 inputTable 4-4 Terminals CH63 Connect to WL on Phase V/W driver boardTable 4-5 Terminals between Driver Boards CH64 and CH74 LCX9000 Liquid-Cooled Drives User Manual4-16 Connections between Power Unit ASIC and the Control Unit Figure 4-18 Remove Cover to Access Power UnitConnections with Round Cable Connections with Optical CableFigure 4-19 Optical Cable Adapter Board Table 4-6 Terminals on Adapter BoardSupply voltage 24Vin from power unit Control board connectionIndicators on the Keypad Display Chapter 5 - Menu InformationKeypad Operation Figure 5-1 Control Keypad and Drive Status IndicationsDrive Status Indicators Table 5-1 Drive Status IndicatorsControl Place Indicators Table 5-2 Control Place IndicatorsKeypad Pushbuttons Status LEDs Green - Green - RedTable 5-3 Status LEDs Green - Green - Red Text LinesTable 5-5 Button Descriptions LCX9000 Liquid-Cooled Drives User ManualMenu Navigation Figure 5-3 Keypad Display DataMonitor Figure 5-4 Keypad Navigation Chart LCX9000 Liquid-Cooled Drives User ManualMonitoring Menu M1 Figure 5-5 Monitoring MenuTable 5-6 Monitored Signals Parameter Menu M2Figure 5-6 Parameter Value Change Procedure Keypad Control Menu M3Table 5-7 Keypad Control Parameters, M3 Selection of Control Place Figure 5-7 Selection of Control Place Keypad ReferenceKeypad Direction Active Faults Menu M4 Figure 5-8 Normal State, No FaultsSTOP Button Activated Fault Types Figure 5-9 Fault Display Table 5-8 Fault TypesFault Time Data Record Fault Type SymbolTable 5-9 Fault Time Recorded Data Fault History Menu M5Real Time Record Table 5-10 Real Time RecordFigure 5-10 Fault History Menu System Menu M6Table 5-11 System Menu Functions LCX9000 Liquid-Cooled Drives User Manual5-15 Table 5-11 System Menu Functions Continued LCX9000 Liquid-Cooled Drives User Manual5-16 Selection of Language Figure 5-11 Selection of Language Application SelectionFigure 5-12 Change of Application Copy Parameters Parameter Sets S6.3.1Figure 5-13 Storing and Loading of Parameter Sets Upload parameters to keypad To keypad, S6.3.2Automatic Parameter Backup P6.3.4 Figure 5-14 Parameter Copy to KeypadDownload parameters to drive From keypad, S6.3.3 Parameter Comparison Figure 5-15 Parameter ComparisonP2.1.2= 20.0 Hz Password S6.5.1 Figure 5-16 Password SettingSecurity Parameter Lock P6.5.2 Figure 5-17 Parameter LockingStart-Up Wizard P6.5.3 Figure 5-18 Activation of Start-Up WizardKeypad Settings Figure 5-20 Keypad Settings SubmenuDefault Page P6.6.1 Figure 5-21 Default Page FunctionDefault page in the operating menu P6.6.2 Timeout Time P6.6.3Figure 5-22 Timeout Time Setting Contrast Adjustment P6.6.4Hardware Settings HMI Acknowledge Timeout P6.7.3Figure 5-23 HMI Acknowledge Timeout Number of retries to receive HMI acknowledgement P6.7.4 System infoTotal Counters Table 5-12 Counter PagesTable 5-13 Resettable Counters Figure 5-24 Counter ResetTrip Counters Software S6.8.3Applications S6.8.4 Table 5-15 Applications Information PagesFigure 5-25 Applications Info Submenu Hardware S6.8.5Expander Boards S6.8.6 Figure 5-26 Expander Board Information MenusDebug Menu S6.8.7 Expander Board Menu M7Further Keypad Functions Expander Board ParametersTable 5-17 Expander Board Parameters Board OPTA1 Figure 5-27 Expander Board Information MenuSafety Precautions Chapter 6 - Start-UpSequence of Operation Page LCX9000 Liquid-Cooled Drives User Manual JanuaryMN04005001E Appendix A - Fault Codes Table A-1 Fault CodesTable A-1 Fault Codes Continued LCX9000 Liquid-Cooled Drives User ManualTable A-1 Fault Codes Continued LCX9000 Liquid-Cooled Drives User ManualLoad Test with Motor Table A-1 Fault Codes ContinuedDC Link Test without Motor LCX9000 Liquid-Cooled Drives User Manual JanuaryMN04005001E Main Circuit and Control Diagrams Figure B-1 Main Circuit and Control Diagram, CH3Appendix B - Technical Reference JanuaryFigure B-2 Main Circuit and Control Diagram, CH4 Figure B-3 Main Circuit and Control Diagram, CH5January TermFigure B-4 Main Circuit and Control Diagram, CH61 Figure B-5 Main Circuit and Control Diagram, CH61, ControlJanuary MN04005001EFigure B-6 Main Circuit and Control Diagram, CH63, Module Figure B-7 Main Circuit and Control Diagram, CH63, ModuleJanuary VB00491Figure B-8 Main Circuit and Control Diagram, CH63, Control Figure B-9 Main Circuit and Control Diagram, CH72LCX9000 Liquid-Cooled Drives User Manual JanuaryFigure B-10 Main Circuit and Control Diagram, CH72, Control Figure B-11 Main Circuit and Control Diagram, CH74, Phase ULCX9000 Liquid-Cooled Drives User Manual JanuaryFigure B-12 Main Circuit and Control Diagram, CH74, Control LCX9000 Liquid-Cooled Drives User ManualJanuary MN04005001EFan Dimensions Figure B-13 Fan Mounting Pallet - Hot Dip Zinc CoatedFigure B-14 Fan Support JanuaryLCX9000 Liquid-Cooled Drives User Manual JanuaryMN04005001E LCX9000 Liquid-Cooled Drives User Manual B-10January MN04005001EPage Company Information Eaton Electrical Inc2007 Eaton Corporation All Rights Reserved Printed in USA Publication No. MN04005001E/CPG January