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vacon nx commissioning and maintenance manual

1. Figure 3 3 6 Example 3 Dew Point chart for ambient temperatures between 10 50 1013 mbar 15 C 20 C 25 C 30 C 35 C 40 C 45 C Relative humidity 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 Primary circuit water temperature C Chart 3 3 1 Dew point chart No condensation is allowed inside the main drive If condensation occurs the warranty is no longer valid WARNING Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 37 Note that some Vacon liquid cooled drives have a maximum ambient temperature of 40 C that would make a scenario with an ambient temperature over 40 C impossible In a case like this it is recommended to add a water air condenser with built in fan to reduce the temperature inside the main drive cubicle If a water air condenser is used to regulate the temperature inside the main drive cubicle the drive must be made airtight e g IP54 A last resort is to install an air conditioner that can regulate both the humidity and the temperature at the installation electrical room This is a safe but usually a very expensive option If the temperature of the liquid in the secondary circuit is lower than the room temperature and the relative humidity is high condensation might occur on the secondary circuit piping and the plate heat exchanger inside the HX unit This is not dangerous however nor is it desirable I
2. When performing a pressure test on the HX unit generally acknowl edged safety standards EU directives and national regulations must also be followed Use safety goggles DANGER Unless national regulations say otherwise the pressure during the pressure test should be 1 5 times the maximum work pressure The maximum pressures are as follows Primary circuit AISI 304 piping 6 bar therefore the test pressure is 9 bar Secondary circuit AISI 304 piping 10 bar therefore the maximum test pressure is 15 bar Option Secondary circuit AISI 304 piping 16 bar therefore the maximum test pressure is 24 bar Primary circuit PVC C piping 6 bar therefore the test pressure is 9 bar Secondary circuit PVC C piping 10 bar therefore the maximum test pressure is 15 bar If the customer only uses a PN6 piping system on the secondary circuit the pressure test can be done with pressurized air to 9 bar If the secondary circuit is pressure tested higher than 10 bar the test must be done with water Compressed air should not be used at pressures over 10 bar due to the risk of high speed debris at a compressed pipe failure DANGER The pressures mentioned here are only valid for the HX unit The customer and or end user are responsible for all other piping made to either the primary or secondary circuit If the customer and or end user make any changes to the WARNING piping on the HX unit they are responsible
3. 31 To change the parameters of the Unifl ow SW6000 Figure 3 3 1 the device has to be in setting mode More information regarding the FTSA11 Uniflow SW6000 flow switch can be found in the Component Specifications and Maintenance Instructions at the end of the Commissioning and Maintenance folder that is supplied with the HX unit Figure 3 3 2 shows the hierarchy of the parameters found in the FTSA11 flow switch An example on how to edit the flow switch point is found in table 3 3 2 high range HI low range switching point temperature SPt Figure 3 3 1 measurement actual switching point OFF standard normally closed nic normally open normall closed a normally open n standard hysteresis HuS End Figure 3 3 2 FTSA11 parameter hierarchy 24 hour support 4358 0 40 837 1150 Email vacon vacon com 32 vacon COMMI SSI ONI NG Table 3 3 2 shows an example on how to set the flow switching point to 68 Description Push buttons Display 1 Change to setting mode 2x 2 14 gt A SO switching output 4 Display hundred digit 050 hundred digit is flashing actual flow Table 3 3 2 Setting flow switching point The settings on the FTSA11 should be the following Measuring range HI high range 30 to 300 cm s Hysteresis h05 5 hysteresis Switching order n c nor
4. More information can be found in chapter 3 3 7 Temperature alarm settings P2 10 9 is a FTSA11 high temperature alarm limit The default setting for this is set at 28 C More information can be found in chapter 3 3 7 Temperature alarm settings P2 10 10 is a FTSA11 high temperature trip limit The default setting for this is set at 35 C This means that the drive will shut down cooling OK signal going to the main drives will be disconnected when the temperature is over 35 C The HXM unit will stay online pump running More information can be found in chapter 3 3 7 Temperature alarm settings P2 10 11 the default setting is 169 hours If the setting is between 1 168 hour the system will try to change the pumps according to the time setting This is to be used ONLY when operating the HX series model HXM120 double pumps If this value is set to Oh the pump change will occur every 30 seconds This is useful for testing and commissioning purposes because all shutoffs are also deactivated during these 30 seconds The value 169 will deactivate the attempt to change the pump and should be used when operating the HXL040 or HXL120 P2 10 12 is the parameter that sets the delay time between when the parameters are exceeded and the activation of a warning shutdown The value can be varied from 1 to 5 seconds The default setting is 5 seconds During commissioning and maintenance the value is to be set to 5 seconds P2 11 1 8 are pa
5. 2 2 3 which removes air from the primary circuit without letting the water out The centrifugal pumps PU11 12 red parts in Figure 2 2 3 circulate the primary circuit liquid The pumps are run in sequence never at the same time The pumps are as default setup making a sequence switch every 168 hours The flow can be adjusted to match the need of the connected drives by changing the frequency of the pump motor The main function of the pump is to deliver enough flow for an optimal liquid to liquid heat transfer of the Vacon NX Liquid Cooled series Other significant parts are the safety valve V120 orange and the instruments flow switch FTSA11 light blue pressure transmitter PT11 brown and the pressure gauge P111 yellow The valves used for maintenance such as filling or de airing are described in chapter 3 1 6 Adding liquid and de airing Figure 2 2 3 2 2 2 Secondary circuit components and function The secondary circuit transports the heat load from the primary circuit to a customer specific object Through the plate heat exchanger the heat load from the drives is transferred to the secondary circuit The HX unit does not have a control supervision system for the secondary circuit therefore the customer should use a suitable option to control supervise the secondary circuit s flow and temperature e g flow meter and temperature sensor A 3 way valve V130 black part in Figure 2 2 4 placed in the secondary circuit co
6. A change of 1 C minute should not be exceeded Check the temperature by comparing the FTSA11 temperature with the secondary circuit temperature indicator TI21 The temperature of FTSA11 should be higher than the TI21 temperature Replace the FTSA11 if necessary If a TI21 is not installed then check the primary circuit temperature using a portable measuring device and compare it to FTSA11 To get an accurate value the portable temperature gauge must be connected close to the FTSA11 Replace the FTSA11 if necessary Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TROUBLESHOOTI NG vacon 53 5 1 3 Low pressure alarm If the low pressure alarm is active acc to panel below the HX unit is still online and the Cooling OK signal to the main drive is connected The yellow and green indicator lights on the electrical box door are also active Check the following issues to solve why the alarm has been activated F1 l Oter 82 InletPressLow A 11397165 Figure 5 1 4 Low pressure alarm on the NXP panel Malfunction Reasons for malfunction Correction measures Leak in the primary e Loose connection e Tighten the connection until the leak stops circuit outside the Add liquid to the primary circuit until the HX unit correct pre pressure is reached Follow the instructions in chapter 3 1 6 Adding liquid and de airing e Faulty connection e Replace the broken parts Then add liquid to the primary circuit unt
7. control unit panel will show the text A83 OverTempA And both the red and the yellow indicators on the electrical box will be active Example over temperature fault The primary circuit temperature set point is set to 35 degrees then the over temperature fault parameter P2 10 10 should be set to 45 degrees The HX unit over temperature fault is designed to work as protection in case of a sudden change in the primary circuit for example if the flow in the secondary circuit for some reason is stopped 24 hour support 4358 0 40 837 1150 Email vacon vacon com 38 vacon COMMI SSI ONI NG The low temperature alarm e Activates a function that will activate the yellow indicator light on the HX unit electrical box The parameter is set to 3 C lower than the primary circuit temperature set point The default setting of the high temperature shutoff is 22 C e Whenthis alarm is activated the HX control unit panel will show the text A86 LowTemp Example low temperature alarm The primary circuit temperature set point is set to 35 degrees and then the low temperature alarm should be set to 32 degrees Example all temperature values A primary circuit temperature set point of 35 C has been calculated for a specific installation The temperature parameters should be adjusted the following way e The primary circuit temperature set point parameter P 3 5 is set to 35 C e Newover temperature alarm value parameter 2 10 9 38 C
8. e New low temperature alarm value parameter 2 10 8 32 C e Newover temperature fault value parameter 2 10 10 gt 45 C The parameters are modified by using the HX Control box interface Vacon NXP frequency converter panel Instructions on how to access and modify the parameters can be found in the Vacon NXP User s Manual that is supplied with the HX unit 3 3 8 Low pressure alarm The function of the pressure sensor placed on the pump suctions side is to give the user a warning of low pressure before the FTSA11 flow switch generates a sudden unwanted shutdown If there is a leak in the primary circuit outside of the HX unit the pressure starts to reduce in the system The set point for the pressure sensor is 0 5 bar so if the pressure on the primary circuit suction side goes under 0 5 bar the yellow indicator light on the electrical box will activate The correct system pre pressure is found in the chapter 3 1 6 Adding liquid and de airing If the suction pressure in the primary circuit is reduced due to a leak the flow in the circuit will within a short period of time be insufficient and therefore activate a FTSA11 flow switch shutdown WARNING The low pressure parameter number is P2 10 4 Follow the instructions in the Vacon NXP User s Manual on how to access and modify the parameters 3 3 9 Leak switch alarm specifications The leak sensor is a free standing sensor on to the leakage plate in the floor of the HX
9. follow the instructions in this manual the reader must have a reasonable knowledge of mechanics and electrics Only a qualified and authorized mechanic is allowed to perform commissioning or maintenance of the HX unit A qualified and authorized electrician should accompany the mechanic performing maintenance or commissioning on the WARNING unit This manual is divided into following chapters Chapter 1 SAFETY explains the symbols used in this manual and contains the general safety instructions Read the safety instructions before continuing Chapter 2 INTRODUCTION explains how the HX unit is built by looking into the unit process and instrumentation The idea is to give the reader a basic understanding of the process and control philosophy This chapter also includes specifications on correct ambient conditions for the HX unit Chapter 3 COMMISSIONING provides information on how to install and how to start up the unit The chapter explains among other things how the unit is to be filled with liquid and how the system is to be de aired The chapter also shows the user the correct valve positions for start up and how to set up the HX control unit Chapter 4 UNIT SERMCE explains required maintenance and some repair instructions for the components inside the cooling unit More unit maintenance instructions can be found in the component maintenance handbooks They are found at the end of the HX unit Commissioning and Maintenan
10. follow when installing commissioning operating and maintaining the HX unit Read the safety instructions before you start to work on the unit 1 1 USE OF SYMBOLS For your own safety please pay special attention to the instructions marked with the following symbols Risk of death Instructions on preventing a possible severe hazard to persons or equipment DANGER MN Risk of damage Instructions on preventing possible damage to equipment WARNING Hot surface Instructions on preventing a possible minor hazard to persons or equipment HOT SURFACE AN Notification NOTE Tel 4358 0 201 2121 Fax 4358 0 201 212 205 SAFETY vacon 9 1 2 GENERAL WARNINGS AND NOTES WHEN WORKING WITH THE HX UNIT These safety instructions are intended for all who work on the HX unit These instructions include only a part of the complete safety instructions Read the Vacon NX Liquid Cooled User s Manual safety instructions as well Ignoring the instructions can cause physical injury or death It can also cause serious malfunctions to the HX unit that is not covered by the warranty When working on the HX unit generally acknowledged safety standards EU directives and national regulations must also be followed 24 hour support 4358 0 40 837 1150 Email vacon vacon com 10 vacon SAFETY 1 Only qualified and authorized electricians and mechanics are allowed to carry out the installation and maintenance work on t
11. is located in the last two chapters of this manual For further information contact your local distributor 24 hour support 4358 0 40 837 1150 Email vacon vacon com 44 vacon UNI T MAI NTENANCE 4 UNIT MAINTENANCE 4 1 GENERAL MAINTENANCE 4 1 1 Renewing liquid in the primary circuit The liquid in the primary circuit should be renewed once every 5 years The liquid in the primary circuit will be contaminated with particles from the different units and therefore the conductivity of the liquid will increase When the conductivity of the liquid increases the risk of electrochemical reactions between the different alloys in the primary system also increases Changing the liquid in the circuit every 5 years will reduce the risk of malfunction due to corrosion 4 1 2 Maintenance schedule There are a few systematic maintenance tasks that have to be followed to ensure a trouble free operation of the HX unit They are presented in the diagram below Once a month Once a year Every 2 years Every 5 years Checking adding the Air expansion vessel pre pressure waa f x O Changing the primary circuitliquid Jo x Monthly inspection x o Diagram 4 1 1 Maintenance schedule The monthl y inspection includes the following tasks e Opening the HX unit cubicle door and checking that no visible leaks can be found If a leak is found the unit has to be shut down and the leak repaired e Checkin
12. on the Internet at WWW Vacon com Manual authoring documentation dvacon com Vacon Plc Document ID Runsorintie 7 65380 Vaasa Finland D P D 0O 1 3 08 A Subject to change without prior notice 2013 Vacon Plc Rev A
13. starts to come out of the drain hose connected to the valve V162 During the first minutes you will hear a rattling sound in the pipes This is the air transported out of the system by the water After it rattling sound stops you should open the filling valve V161 to 100 5 Keepthe water flowing until you can t hear any more rattles and then close the V161 valve Also close all the main drive valves V310 V3xx both the inlet and the outlet valves Now it is time to de air the drives De air the main drives one hose pair at a time for example V310 and V311 See figure 2 2 2 6 Open valve V310 first then valve V311 this means that this path will be the only way for the water to pass when you continue filling Then open the filling valve V161 The water will again come out from the hose connected to the manual de airing valve V162 Keep the water running until the rattling sound disappears that is to say the air has been removed after which the V161 filling valve is closed again 7 Close the valve V310 first and then the valve V311 This procedure will leave the specific drive section filled with water 24 hour support 4358 0 40 837 1150 Email vacon vacon com 24 vacon COMMI SSI ONI NG If the external water system used for the filling can produce more than 6 bars there is a risk of the safety valve V120 opening This might cause unnecessary problems if some particles are left on the sealing surface of the safet
14. that no particles larger than 0 3 mm can enter the primary circuit The temperature of the liquid going to the main drives must never be lower than the ambient temperature in the cabinet at the point of a start up of the main drives If the system is shut down during a cold period and the liquid runs a risk of freezing a maximum of 2096 of glycol can be added to the primary circuit system If more glycol than 2096 is needed to keep the liquid from freezing then contact your local distributor for additional information regarding a load reduction for the main drive To prevent corrosion add the corrosion inhibitor Cortec VpCl 649 to the primary circuit liquid Use the additive according to the product specification found in the Component Specifications and Maintenance Instructions section of the Commissioning and Maintenance folder Primary circuit liquid quality Unit Value TI A NEED Hardness of liquid Chlorine Cl Iron Fe Maximum particle size Table 2 3 1 Liquid quality The secondary circuit liquid quality is not expected to be as clean as the primary circuit liquid bearing in mind that clean liquid will prolong the time between cleaning the plate heat exchanger HX11 If the customer and or end user are using a natural source of water for the secondary circuit one can assume that the water will include some kind of organic sediment This organic sediment will attach itself to the plates inside the HX11 and therefore the liqui
15. the HX unit offline according to the Vacon NX Liquid Cooled User s Manual 4 Shut down the power to the HX unit by first turning both the pump control switches to 0 therefore shutting down the pump then turning the main power switch to position O refer to Figure 2 2 7 5 Check that there is no power coming to the pumps by removing the cover of the pump electrical connection box and measuring the voltage No work on the unit is allowed when the power is connected 6 Disconnect the electrical cables from the pump that is to be changed Write down the order of the phases for later use 7 Close the maintenance valves of the pump that is to be maintained V140 V143 Refer to the P amp ID in Figure 2 2 2 or the project specific P amp ID if one is available If the liquid contains corrosion inhibitors or other additives then check national or local ecological directives for information on how to dispose of the drained liquid Information regarding the recommended corrosion inhibitor Cortec is found in the end of the Commissioning and Maintenance folder that is supplied NOTE o with the unit 24 hour support 4358 0 40 837 1150 Email vacon vacon com 46 vacon UNI T MAI NTENANCE 8 Remove the bolts and nuts from the pump motor flange Therefore leaving the pump housing in place Figure 4 2 1 Note that there is a pre pressure of 1 5 bars in the system use safety goggles 9 Lift out the pu
16. unit The function of the switch is only to alert the user by switching on the yellow alarm indicator placed on the control box The leak sensor generates an alarm if there is liquid on the floor plate inside the HX unit due to a leak in the unit If there is condensation inside the HX unit the leak switch can generate false leak alarms Note that no condensation is allowed However if the relative humidity within the cubicle is high and the ambient temperature is higher than the secondary circuit inlet temperature condensation will occur on the secondary circuit piping Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 39 If the secondary circuit inlet liquid temperature is not temperature controlled by the customer there is arisk of condensation on the secondary circuit inlet piping Example If the secondary circuit liquid inlet is 10 C and the ambient relative humidity inside the HX unit cubical is 25 with a temperature of 20 C condensation starts to occur in the secondary circuit inlet piping These values can be found on a Mollier diagram that shows the behaviour of moist air in normal 1 013 bar pressure If any condensation occurs the customer must add insulation on the HX11 heat exchanger and on the secondary circuit piping or increase the temperature in the secondary circuit inlet liquid The maximum temperature of the secondary circuit inlet liquid is 25 C without having to r
17. valve e The 3 way valve V130 is e Run the actuator calibration V130is malfunctioning and according to the instructions found malfunctioning therefore not directing in the HX unit folder that is supplied enough flow through the with the unit i e set the actuator plate heat exchanger to Dip switch 1 to On position If the ensure a satisfactory heat actuator is not moving during this transfer between the procedure it is broken and has to be primary and secondary replaced circuit The FTSA11 setup values Check the project parameters refer have been wrongly Table 3 3 1 Parameter list and adjusted during compare it with the actual commissioning temperature Table 5 1 2 High temperature fault detection If the high temperature shutoff is active same panel layout as high temperature alarm the HX unit is online but the Cooling OK signal to the main drive has been disconnected The yellow and red indicator lights on the electrical box door are active The reasons for this shutoff are the same as for the high temperature alarm If the low temperature alarm is active acc to panel below the HX unit is still online and the Cooling OK signal to the main drive is connected The yellow and green indicator lights on the electrical box door are also active Check the following issues to solve why the alarm has been activated F1 86 LowTemp A T1 gt T16 gt Figure 5 1 3 Low temperature alarm on the NXP panel Malfunction Re
18. 2 2 3 So Ride A 14 2 2 4 Instruments and their funclon e eee aea ns 14 2 2 5 Control supervision parameters eeeessssseeeeeeenne nennen nnne nnne 15 2 2 6 alado cea ll AA 16 INSTALLATION SPECIFICATIONS turis 17 2 3 1 Liquid quilla 17 2 3 2 Required ambient conditions s ud tt e annene 18 COMMISSIONIN c arar rara pri 19 STEP F MECHANICAL PA obo b em 19 3 1 1 General installation INSENUCHONS cada dad dd 19 3 1 2 Pipe CONReCU DNS cesen ad csi dd de os dls ON 19 3 1 3 lo lo A a o re PI nn AA AA rarer UA AAE AE EEA 20 3 1 4 Pressure testa mem 20 3 1 5 Setting up the primary E O 22 3 1 6 Adding liquid 2273 as i 3 0 D NR RR 23 3 1 7 Adding corrosion inhibitor when using a fresh water system ssssss 25 STEP Z ELECTRICAL PAMT eite e e t he e teu a i RR EAR 26 3 2 1 Power supply eh e ha e a e ase et s 26 3 2 2 Signal cables 4 445 5 a DD ad a e 26 SIEP S CONTROL UNITE SETUP 222032 3000 iind dd do i 8 ask 27 3 3 1 Basic Seton o PP 27 3 3 2 Application parameter loto aee tine euo estet ead un ttd und odas 27 3 3 3 Parameter cescripboris seti essit tiae cipehaotac faepidir eati pai Mira Pp fte 28 3 3 4 General information about alarms and shutoff limits sssssss 30 3 3 5 FISATEHONWSWIICh TUTO ba eiie dta eaa as MAL de Do ee 30 3 3 6 Temperature set points vivian salis 32 3 3 7 Temperature alarm settings e lili 37 3 3 8 Low pressure a
19. 20 360l min Empty weight of HX unit e 240kg PVC C Maximum input power e 36kW Supply pressure Supply distance primary circuit e 07bar 25 m 25 m straight pipe 24 hour support 4358 0 40 837 1150 Email vacon vacon com 56 vacon TECHNI CAL SPECI FI CATI ON Liquid volume primary side e 25 5liter Concentration of gl ycol e maximum 25 Maximum flow secondary circuit e 360l min Pressure drops on customer circuit secondary circuit see Appendix 1 Note Combined nominal flow of frequency converters must not exceed 90 of the maximum rate of flow Maximum straight pipe distance between HX unit and drive for achieving maximum fl ow El bows and other components will reduce the pipe distance Pipeline to frequency converter 25 m and back 25 m If customer pipelines are long size of the pipelines must be DN32 or DN40 The pressure before 3 or 2 way valve must be at least 2 bar to prevent cavitations See cavitations diagram in Components Specifications and Maintenance Instructions n o 2 TAC Venta page 2 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TECHNI CAL SPECI FI CATI ON vacon 57 APPENDIX 1 Pressure drops on customer circuit HX_120 100 FLOW 360 l min Plate heat Pressure drop Pressure exchanger plate heat drop 3 way route Flow Bypass route Flow
20. 3 2 STEP 2 ELECTRICAL PART turn the main power switch the red yellow switch in Figure 2 2 7 to position 1 It is recommended that the parameter P2 10 1 be changed to 30 Hz at first start up Later when the HX unit is completely de aired the P2 10 1 should be set to the correct value refer to chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 Start up the pump PU11 or PU12 by turning the pump control switch to position 1 the black and red switch in Figure 2 2 7 The liquid starts to circulate in the primary circuit Run the pump for max 30 sec then do the same to the other pump Wait for 5 min and open the manual de airing valve V162 to let out any air that might have been stuck in the pump housing Add water to get the pressure back up to 1 5 bars Then start one of the pumps again and leave it running The LED display on the FTSA11 should register that there is flow in the system If not stop the pump and re check that all valves are open e g in the drive section in the HX unit and if there is piping valves made by customer in the primary circuit then check them also The flow switch is set to 50 as default and has a 5 second delay the 5 second delay is programmed into the HX control unit application What this means is that the flow has to get over the 50 limit within 5 seconds of starting the pump or the HX control unit will shut down the pump If the pump is shut down and the HX
21. Cooled drive User s Manual that is supplied with the main drives Figure 3 2 4 A 24V auxiliary voltage from the main drive is sent through the cable to the HX unit If the HX unit is working within the preset parameters then the signal is rerouted back to the main drive When the signal is active in the main drive basic I O board NXOPTA1 terminal number 14 then the main drive application will activate a Cooling OK function that will allow starting and operating the main drive Run Enable When a flow fault or high temperature fault is active in the HX unit the digital output cooling OK contact in the HX control unit will disconnect the 24V signal and the main drives will shut down The main drive cannot be brought online before the flow fault or high temperature fault is removed Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 27 3 3 STEP 3 CONTROL UNIT SETUP 3 3 1 Basic setup The control unit application includes Flow control parameters that have to be modified for every project Primary circuit inlet temperature and primary circuit flow are two equally important quantities that have to be monitored at all times How to calculate the optimum flow is found in chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 How to correctly set up temperature alarms and shutoffs is found in chapter 3 3 6 Temperature set points If the customer and or end
22. S11 All alarm and shutoff limits have a default value These default values should if needed be modified at the commissioning phase Refer to the Vacon NX USER S MANUAL to change the parameters Only authorized personnel are allowed to make modifications to the parameters NOTE The parameters and their settings can be found in chapter 3 3 2 Application parameter list When you change the default settings during commissioning you should write down the new setting including the date and your name to keep track of changes Write down the new parameters to the custom setting column of the flow control parameter table 3 3 1 3 3 5 FTSA11 flow switch function The flow switch is set to shut down the HX unit if the flow does not meet the requirements refer to chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 The unit settings should be modified during commissioning through the switch interface panel The default setting for the switch is 50 050 Adjusting the FTSA11 flow switch 1 Turn the pump power switch the black and red switch in Figure 2 2 7 to the position 1 to connect the power to the HX unit This will activate the FTSA11 2 When the power is connected the display flashes for approximately 30 seconds with 888 for initialization When the flashing stops the device is ready for programming Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon
23. VACON NX AC DRIVES HXM 120 COOLING UNIT SS PIPING AND PVC C PIPING VERSION 3 0 COMMISSIONING AND MAINTENANCE MANUAL VACON DRIVEN BY DRIVES vacon 3 QUICK START UP GUIDE THE FOLLOWING STEPS OF THE QUICK START UP GUIDE MUST BE PERFORMED DURING THE INSTALLATION AND COMMISSIONING If any problems occur contact your local distributor 10 11 Check that the delivery corresponds to your order Before starting commissioning read carefully the safety instructions in Chapter 1 SAFETY Check that the specified installation location and ambient conditions comply with the specification Refer to Chapter 2 3 2 Required ambient conditions Any customer made piping must be thoroughly flushed before connecting to the HX unit Check that the liquid quality is approved Refer to Chapter 2 3 1 Liquid quality Connect the mechanical and electrical couplings Refer to Chapter 3 1 2 Pipe connections and 3 2 STEP 2 ELECTRICAL PART Adjust the HX control unit parameters to match the specific project requirements Refer to Chapter 3 3 2 Application parameter list Perform a pressure test to the primary circuit and secondary circuit connections Refer to Chapter 3 1 4 Pressure test Add coolant to the circuits and de air them according to the instructions in 3 1 6 Adding liquid and de airing Adjust the primary circuit flow and temperature to match the project requirements Refer to Chapter 3 4 2 Adjusting the syste
24. al ve V162 that is positioned on top of the HX11 plate heat exchanger The other end of this hose should be pointed into a drain or into a tank depending on which system is used for the filling procedure The system used for filling should be able to produce at least 2 bar and delivery at least 15 l min There are many ways of adding water to a piping system like the primary circuit The two most common ways of filling are presented next Which of these are used depend on if the site has a fresh water system or if the water has to be filled from a tank Figure 3 1 9 shows how to connect the hoses to the HX unit if there is no pressurized fresh water system at hand cas fh e Connect a suction pump outlet to the Ts filling valve V161 Secure the connections with a hose clamp e Connect the drain hose to the manual de airing valve V162 and put the other end of the hose in the barrel Secure the connection with a hose clamp e Secure the drain hose to the barrel so it won t jump out during the filling and de airing e f corrosion inhibitors are used they can be mixed in the right amount with the water in the barrel e Depending on the system size there has to be 20 200 litres of liquid in the barrel Figure 3 1 9 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 23 Figure 3 1 10 shows how to connect the hoses to the HX unit if there is a pressurized fresh water system at hand e Connect the
25. an be found in the Vacon NXP User s Manual that is supplied with d the cooling unit Sy e The frequency converter includes a Fieldbus link card By connecting to this card the customer can view eight different values parameters e g primary circuit temperatures pressures warnings and shutoffs This is very useful if the HX unit is not monitored locally Information regarding the connection type is found in the Vacon NXP User s Manual that is supplied with the HX unit Figure 2 2 5 2 2 4 Instruments and their function The flow switch FTSA11 Figure 2 2 6 measures the speed of the flow inside the pipe This flow speed is shown as 100 of the measuring range of the instrument The FTSA11 has two different flow measuring ranges to choose from 15 150 cm s or 30 300 cm s of which the higher range is used in the HX units The unit also sends the primary circuit temperature as a 4 20mA signal to the FV11 3 way valve actuator Both the analogue temperature signal and the on off switch signal are sent to the HX control unit The analogue signal is used to control the temperature in the primary circuit and also to generate temperature alarms and shutoffs The PNP switch output that monitors the flow is used to generate a shutdown command The flow speed shown in 96 on the FTSA11 can easily be modified to flow l min by using the diagram in chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 N
26. asons for malfunction Correction measures The regulating valve e The 3 way valve V130 e Run the actuator calibration according to V130 refer to the is malfunctioning and the instructions found in the HX unit P amp ID is therefore directing too manual that is supplied with the unit i e malfunctioning much flow through the set the actuator Dip switch 1 to On plate heat exchanger position If the actuator is not moving during this procedure it is broken and has to be replaced 24 hour support 4358 0 40 837 1150 Email vacon vacon com 52 vacon TROUBLESHOOTI NG The FTSA11 refer to the P amp ID flow sensor with the analogical temperature outlet is malfunctioning The inlet temperature on the secondary circuit is decreasing too fast and the 3 way valve is not able to adjust the flow in the secondary circuit fast enough The FTSA11 flow sensor with the analogical temperature outlet is broken Table 5 1 3 Low temperature fault detection Wait for two minutes and see if the alarm is reset automatically If the alarm is active longer than two minutes check the 3 way valve s function If the 3 way valve or the valve actuator is malfunctioning it must be replaced If the temperature in the primary circuit is too low it will result in condensation in the main drive section No condensation is allowed The temperature in the secondary circuit should not be allowed to decrease or increase too fast
27. at exchanger cleaning instructions found in the end of the Commissioning and Maintenance folder that is supplied with the HX unit If the liquid used in the secondary circuit contains biological or chemical residue it is recommended that a spare heat exchanger be stored locally When the flow in the secondary circuit is too low the HX unit should be shut down and the heat exchanger replaced The dirty heat exchanger should be cleaned according to manufacturer s instructions and placed in storage for the next time HX11 needs to be changed Tel 4358 0 201 2121 Fax 4358 0 201 212 205 UNI T MAI NTENANCE vacon 47 The HX11 can if needed be removed without removing the HX unit from the cubicle l Drain both the primary circuit and the secondary circuit The secondary circuit is drained through the V163 valve marked yellow in Figure 4 2 2 The primary circuit is drained through the valves V301 and V302 refer to the P amp ID in Figure 2 2 2 HXM 120 AISI Disconnect the primary and secondary circuit connections marked violet in Figure 4 2 2 from the unit The connections can be opened with a box wrench HXM120 PVC C The connections can be opened by hand or if needed use oil filter remover used to remove the oil filter from cars Be careful not to damage the connections 2 Remove the one M8 nut from underneath the heat exchanger marked violet in Figure 4 2 3 3 Carefully pull lift t
28. at show how the primary circuit temperature is calculated depending on which of the three above mentioned factors is the deciding one Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 33 Example 1 high ambient temperature If the customer and or end user have a high ambient temperature 35 C at the main drive that would require the primary circuit temperature to be equal or higher than 35 C This would normally require a load reduction of the main drive If the maximum relative humidity at the main drive is known the dew point chart Chart 3 3 1 can be used to determine a more optimized temperature for the primary circuit Ambient temperature 35 C Maximum relative humidity 60 Acc to chart 3 3 1 gt Dew point is 26 C It is recommended to use a 2 C safety margin Therefore the primary circuit temperature should in this case be set to 28 C 26 C 2 C In this case no reduction of load in the main drive is needed even if the ambient temperature is high due to a rather low maximum relative humidity Maximum ambient temperature 35 C Maximum ambient relative humidity 60 02 03 04 05 M VACON LIQUID COOLED NX DRIVE HXM120 can Ss Secondary circuit E maximum 23 C 28 C 5 C ej A i a Primary circuit
29. ay up with water When no more water will go into the HX11 then close the manual de airing valve V162 and remove the hose 6 Now open the filling valve V161 and increase the pressure back to 1 5 bar The corrosion inhibitor will get mixed when the pump is rotated for a while Figure 3 1 11 24 hour support 4358 0 40 837 1150 Email vacon vacon com 26 vacon COMMI SSI ONI NG 3 2 STEP 2 ELECTRICAL PART Only qualified and authorized electricians are allowed to perform electrical work on the HX unit WARNING 3 2 1 Power supply The HX unit uses 3 400VAC 50Hz or 3 440VAC 60Hz 16 A power supply There are two alternatives to bring the supply cables to HX unit from under or from above Figure 3 2 1 Figure 3 2 2 Figure 3 2 1 Figure 3 2 2 Connect the power supply to the motor protection relay marked green in Figure 3 2 3 in the HX unit electrical box Figure 3 2 3 3 2 2 Signal cables A signal cable must be connected between the main drive and the HX unit electrical box It should be connected from the main drive basic I O board NXOPTA1 terminal number 6 or 12 24V out to the HX unit X1 terminal block marked green in Figure 3 2 4 terminal number 16 cooling OK in and back from X1 terminal number 17 cooling OK out to the main drive terminal number 14 DI 4 For more information refer to the project specific electrical diagram and to the Vacon NX Liquid
30. ce folder that is supplied with the unit Chapter 5 TROUBLESHOOTING includes fault tracing to help the user identify and solve a problem when the HX control unit air cooled Vacon N XP 0009 has an active alarm or fault Chapter 6 TECHNICAL SPECIFICATION 24 hour support 4358 0 40 837 1150 Email vacon vacon com 12 vacon NTRODUCTI ON 2 2 PROCESS AND INSTRUMENTATION The HX unit s principle of operation is based on liquid to liquid transfer of heat The primary circuit transports the heat load from the frequency converter to the plate heat exchanger The secondary circuit liquid flowing through the plate heat exchanger then collects the heat load and transports it to an external condenser This external condenser which does not appear on the diagram is part of the customer and or end user s existing cooling system Another way to dispose of the heat load is to use existing natural resources e g a lake or river The use and choice of a system for disposing of the heat load is the customer s and or end user s responsibility e Primary circuit HXM120 PSO1 green colour in the Figure 2 2 1 e Secondary circuit HXM120 PSO2 red colour in the Figure 2 2 1 The FTSA11 flow switch which monitors the flow in the primary circuit also includes a temperature sensor This temperature sensor controls the primary circuit temperature This sensor sends out an analogue signal to the HX control unit The control unit application adjusts
31. control unit display is registering a flow fault reset the fault from the Vacon NXP control panel turn the pump control switch back to position O and try again refer to the NXP All in one manual on how to work the panel If the pump does not stay online after three 3 attempts de airing has not been done correctly or some of the valves mentioned in step 1 and 2 are still closed De air the system again refer to Chapter 3 1 6 Adding liquid and de airing Check that all valves except V161 V163 and V301 V302 are open If the pump does not stay online after a new de airing try to temporarily lower the flow switching point for the FTSA11 to 1096 5096 as default Information on how to modify the FTSA11 switching point is found in chapter 3 3 5 FTSA11 flow switch function Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 41 14 If the pump stays online run it for 15 minutes and then change the flow switch point back to the project specific setup value The flow switch point can be changed during operation During the first days of operation the pre pressure decreases because some air might be left in the system after de airing To adjust the pressure 1 Connect a filling hose to valve V161 De air the filling hose before adding liquid to avoid air getting into the primary circuit 2 Addliquid to increase the pressure back to 1 5 bar on the PI11 pressure gauge Close valve V161 and remove the h
32. corner of the HX unit electrical box door Try to wipe off the sensor and the leakage plate with a dry cloth If the yellow light is still on then the sensor is most likely broken and will need to be replaced Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TECHNI CAL SPECI FI CATI ON vacon 55 6 TECHNICAL SPECIFICATION Physical size without cubicle Dept e Width 705mm 982mm e Height 1885mm AISI304 1872 PVC C e Depth 540mm 603mm Liquid connections e Primary circuit Rp 2 ISO 7 1 or DN50 DIN 2642 e Secondary circuit Rp 2 ISO 7 1 or DN50 DIN 2642 PN10 DIN 2633 PN16 Height Electrical supply e 3 400VAC 50Hz or 3 440VAC 60Hz 16 A e 3 400 500VAC 50 60Hz 16A when sinifilter Depth Width Other electrical connection e 24V auxiliary voltage between HX unit and main drive e Option Fieldbus Profibus connection from the HX control unit to customer monitoring system Ambient conditions e 45 450 C e RH5 96 no condensation allowed Pressure ratings e Primary circuit PN6 e Secondary circuit customer piping PN10 Option PN16 for AISI 304 piping Temperature ratings e Primary circuit 45 4509C e Secondary circuit 45 502C Storage temperature rating e 40 4609C e All liquid must be removed from the unit during storage if the temperature is below O9C Cooling capacity e 120kW Rate of flow range e 1
33. ction The modes are either normal control OP off or calibration ADJ on In mode calibration ADJ the actuator runs a sequence reads end positions and adjusts itself to the valve it is mounted on The value of the end positions are stored in a non volatile memory i e the positions are not lost when power supply is lost When the calibration sequence is finished the actuator halts until the switch is reset to OFF position OP OP is the position of the switch at normal control 24 hour support 4358 0 40 837 1150 Email vacon vacon com 40 vacon COMMI SSI ONI NG 3 4 STEP 4 ADJ USTING THE FLOW 3 4 1 Starting the pump Note that de airing of the unit has to be done before the HX pump can be started To start the pumps for the first time WARNING The pumps must not be run dry under any circumstances Running the pump dry even for a short period of time might cause the shaft seal in the pump to start leaking AM BF WN 10 11 12 13 Open the maintenance valves for the main drives V310 to V31x that are to be used Check that the valves V140 V143 are open and that V160 has the lever turned downwards Check that the valve V161 and V162 is closed And that the pre pressure is at 1 5 bar If the customer has added some valves these must also be in checked Check that there are no visible leaks If the electrical cables have been connected and checked refer to chapter
34. d to liquid heat transfer between the primary circuit and the secondary circuit will over time be less efficient Another problem with this organic sediment is that the pressure loss over the HX11 will also increase and therefore the flow will decrease which will also lead to poor liquid to liquid heat transfer between the primary and secondary circuit Because of possible organic sediment in the liquid circulation it is strongl y recommended that flow measuring equipment or a pressure difference measurement be installed on the secondary circuit This equipment should generate an alarm if the flow is below requirements When there is a need to clean the heat exchanger refer to the Alfa Laval AlfaCaus Heat Exchanger Cleaning material found in the Component Specifications and Maintenance Instructions section of the Commissioning and Maintenance folder In the secondary circuit the liquid should not contain particles larger that 2 mm If there are larger particles in the liquid circulation the 3 way valve or the heat exchanger might clog within a short period of time Therefore it is strongly recommended that a filter MF21 be installed at the secondary circuit inlet which will filter out particles larger than 2mm For more information regarding this filter unit please contact our local distributor 24 hour support 4358 0 40 837 1150 Email vacon vacon com 18 vacon NTRODUCTI ON The secondary circuit liquid should not include a
35. ded The HX control unit will generate a Low pressure alarm if the pre pressure is below 0 5 bar Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 25 3 1 7 Adding corrosion inhibitor when using a fresh water system If you are using a fresh water system to add water it is more difficult to add the corrosion inhibitor The corrosion inhibitor can be added through the manual de airing valve V162 To do this the water level has to be lowered in the HX11 and a funnel has to be used Figure 3 1 11 1 The corrosion inhibitor should be added after all the main drives have been de aired Check that all the main drive valves V310 V3xx are closed 2 Lower the liquid level in the plate heat exchanger HX11 by opening the valve V301 and letting out 2 litres of water This will lower the level inside the HX11 and make the necessary space for the corrosion inhibitor 3 Remove the hose from the valve V162 and replace it with a one 1 meter long hose Connect afunnel to the loose end of the hose 4 Keep the funnel higher up than the heat exchanger HX11 and pour the corrosion inhibitor into the HX11 using a jug Refer to the Cortec VpCl 649 product description for calculating the right amount of corrosion inhibitor refer to the technical specifications for Cortec found in the Commissioning and Maintenance folder 5 After all the corrosion inhibitor is added use the same jug to fill the HX11 all the w
36. educe the load in the main drive More information regarding the secondary circuit temperature is found in chapter 3 3 6 Temperature set points 3 3 10 Three way valve two way valve actuator settings Please check the DIP switch positions in the valve actuator There are five switches and their positions are as follows N o 1 gt 0n N o 2 gt on N 0 3 off N 0 4 gt off N o 5 To be run once at on so that the valve actuator finds min and max movement values then off Detailed description about DIP switch positions N o 1 Selection of control signal type Y The control signal might either be a voltage level V off or a current level mA on N o 2 Input control signal operating range The input signal can either start at O V mA i e no offset off or at 2 V 4mA with offset on A new setting will be recognized after a new calibration run ADJ N o 3 Operating direction of actuator The actuator can either give a movement downwards at increasing control signal 096 at opening in upper position off or increasing control signal giving a movement upwards 096 opening in lower position on A new setting will be recognized after a new calibration run AD N o 4 Running time selection The running time can be set to either 120 seconds off or 240 seconds on for a 20mm stroke A new setting will be recognized after a power off followed by a reference run N o 5 Working mode sele
37. erature It is recommended that the primary circuit temperature is higher than the ambient temperature but in Some cases this will cause an unnecessary reduction of load in the main drive If this is the case the maximum relative humidity RH at the installation must be specified When the maximum RH and the maximum ambient temperature have been determined the Dew Point Chart found in chapter 3 3 6 Temperature set points can be used to define the minimum primary circuit temperature Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 19 3 COMMISSIONING 3 1 STEP 1 MECHANICAL PART Only qualified and authorized mechanics are allowed to perform mechanical work on the HX unit WARNING 3 1 1 General installation instructions The HX unit is delivered with a self supporting frame as shown in Figure 3 1 1 Therefore the customer can place the HX unit in the cubicle of their choice The unit is designed to fit inside a VEDA or Rittal 800x600x2000mm W x D x H cubicle If the customer and or end user are using another kind of cubicle it is their responsibility to ensure that the HX unit fits inside the cubicle of choice The unit can be delivered pre fitted to a VEDA or Rittal cubicle on request For more information regarding this option contact your local distributor If the customer positions the HX unit in their own cubicle it is the customer s and or end user s responsibility to make sure that
38. exchanger valve Total pressure drop 100 360 l min 0 0 0 5 bar 1 83 bar 2 33 bar 75 270 l min 25 90 l min 0 25 bar 1 83 bar 2 08 bar 50 180 l min 50 180 l min 0 116 bar 1 83 bar 1 95 bar 25 90 l min 75 270 l min 0 03 bar 1 83 bar 1 86 bar 0 0 100 360 l min 1 83 bar 1 83 bar gt Pressure drop varies between 1 83 bar 2 33 bar 75 FLOW 270 l min Plate heat Pressure drop Pressure exchanger plate heat drop 3 way route Flow Bypass route Flow exchanger valve Total pressure drop 75 270 l min 0 0 0 25 bar 1 03 bar 1 28 bar 5096 180 l min 25 90 l min 0 116 bar 1 03 bar 1 146 bar 2596 90 l min 50 180 l min 0 03 bar 1 03 bar 1 06 bar 096 0 7596 270 l min 1 03 bar 1 03 bar gt Pressure drop varies between 1 03 bar 1 28 bar 50 FLOW 180 l min Plate heat Pressure drop Pressure exchanger plate heat drop 3 way route Flow Bypass route Flow exchanger valve Total pressure drop 5096 180 l min 096 0 0 116 bar 0 46 bar 0 58 bar 2596 90 l min 2596 90 l min 0 03 bar 0 46 bar 0 49 bar 096 0 5096 180 l min 0 46 bar 0 46bar gt Pressure drop varies between 0 46 bar 0 58 bar 24 hour support 4358 0 40 837 1150 Email vacon vacon com 58 vacon NOTES Tel 4358 0 201 2121 Fax 4358 0 201 212 205 VACON DRIVEN BY DRIVES Find your nearest Vacon office
39. f there appears condensation inside the HX unit it might trigger the leak sensor LS11 on the HX unit floor and therefore giving some false leak alarms In a case like this it is recommended that the customer insulate the secondary circuit piping and the plate heat exchanger inside the HX unit to stop the condensation and therefore avoid any more false alarms On request the HX unit secondary circuit and the plate heat exchanger can be insulated before delivery 3 3 7 Temperature alarm settings The temperature alarm levels depend on the primary circuit temperature set point Refer to chapter 3 3 6 Temperature set points The over temperature alarm e Activates a function that will activate the yellow indicator light on the HX unit electrical box The value is set to 3 C higher than the primary circuit temperature set point The default setting of the high temperature shutoff is 28 C e When this alarm is activated the HX control unit panel will show the text A83 OverTempA Example over temperature alarm The primary circuit temperature set point is set to 35 degrees then the over temperature alarm parameter P2 10 9 should be set to 38 degrees The over temperature fault e Activates a function that will shut down the drives but will keep the HX unit running is set to 10 C higher than the primary circuit temperature set point The default setting of the high temperature shutoff is 40 C e When this alarm is activated the HX
40. for them The pressure in the primary circuit can be monitored from the pressure indicator PI11 during the pressure test If the pressure remains constant for 15 minutes the system is airtight If the pressure is decreasing look for the leak by soaking the pipe connections with soap liquid When the leak is located tighten the connection and redo the pressure test If the pressure test is done with water the leaks can be located visually therefore no soap water is necessary 24 hour support 4358 0 40 837 1150 Email vacon vacon com 22 vacon COMMI SSI ONI NG 3 1 5 Setting up the primary circuit Before filling the system with liquid check that all pipes and hoses are connected The maintenance valves V160 V162 are plugged so that no accidents can occur during operation During maintenance these plugs must be replaced with hose nipples or similar parts so that a hose can be connected to the val ve The valve handle positions before pre filling the system are as following e Valves V161 V162 X open violet colour in Figure 3 1 8 e Valve V160 lever down brown colour in Figure 3 1 8 e Valves V140 V141 closed yellow colour in Figure 3 1 8 e Valves V142 V143 open orange colour in Figure 3 1 8 e Valves V301 V302 closed see P amp ID Figure 2 2 2 e Valves V310 V31x open see P amp ID Figure 2 2 2 Figure 3 1 8 A hose must be connected to the manual de airing v
41. g might in some cases help to prevent an unexpected shutdown of the drive 24 hour support 4358 0 40 837 1150 Email vacon vacon com 16 vacon NTRODUCTI ON 2 2 6 HX unit electrical box The electrical box inside the HX unit consists of a motor protection relay circuit breakers contactors 400 24 V DC power supply and a terminal There are four switches attached to the electrical box door main power switch two pump power switches and leak sensor reset switch e Main power switch red yellow in Figure 2 2 7 is connected to the motor protection relay Positions O zero and 1 The contact breaker controls the main power to the HX unit including the HX control unit e Pump power switch black and red in Figure 2 2 7 positions 0 zero and 1 The contact breaker controls the power to the HX unit pumps PU11 and PU12 The pump can be started by turning the switch to position 1 and stopped by turning it back to position O If both switches are in position 1 then the pumps are automatically working in sequence changing every 168 hours or acc to project specific value e LS11 leak sensor reset switch white in Figure 2 2 7 resets the leak alarm To reset the alarm the liquid must first be removed from the sensor on the HX unit leakage plate Figure 2 2 7 There are also five indication lights on the electrical box door The colours indicate the following e Red indicates that the HX
42. g that the primary circuit pressure at the PI11 is between 1 0 and 1 5 bar If the pressure is too low it must be rectified e Check that the FTSA11 flow switch LED display is reading the same value as lasting the previous month If the flow switch is showing lt 5 reduction of the installed value at commissioning then refer to chapter 5 1 1 Flow fault for advice e Check the temperature of the primary circuit by pressing the button on the FTSA11 marked once Check the temperature value with the value set at commissioning Press it once more to go back to reading the flow percentage The indicator lights on the HX electrical box should be monitored at all time If the HX unit is placed at a position were it isn t possible to monitor the indicators continuously the Fieldbus interface of the HX control box can used to re route the alarms to a place were they are monitored at all times If it isn t possible to use the Fieldbus interface then the indicators on the HX electrical box must be moved to a position were they can be monitored at all times 4 2 MAINTENANCE BY COMPONENT 4 2 1 Pump The pumps PU11 12 refer to the P amp ID do not require regular service During the life cycle of the HX unit it is likely that the shaft seal will have to be changed at some point The shaft seal between the pump housing and the motor is the most probable cause for leak on the centrifugal pump When changing the shaft seal follow the pump maintenance rules in t
43. garding the load reduction of the drives refer to the Vacon NX Liquid Cooled User s Manual that is supplied with the main drive Maximum ambient temperature 40 C Maximum ambient relative humidity 8096 02 03 04 05 VACON LIQUID COOLED NX DRIVE HXM120 R cun cau ca Secondary circuit maximum 33 C 38 C 5 C o e E loe P TT M euius Primary circuit minimum 38 C 36 C 2 C Figure 3 3 4 Example 2 The secondary circuit maximum temperature should always be 5 C lower that the primary circuit temperature to ensure a good thermal load transfer between the two circuits In example 2 this means that the secondary circuit should be between 5 433 C during operation The 3 way valve in the secondary circuit will then keep the primary circuit temperature at 38 C regardless of the main drive load Example 2b reducing the ambient relative humidity If the load reduction isn t acceptable for the specified drive it is recommended that a humidity remover be installed that can reduce the maximum RH to an acceptable level In example 2 a reduction of the maximum RH from 80 to 50 will allow the primary circuit temperature to be 30 C and therefore give the possibility to run t
44. he HX unit Do not open the drive section doors while the drives are online If you suspect a coolant leak in the drive section shut down the drives and disconnect the power to them before opening the drive section cubicle AN When working with the HX unit together with the frequency converter also follow the Vacon NX Liquid Cooled Drive User s Manual safety DANGER instructions to prevent any accidents Any installation work on the HX unit must be done with power off The power must not be reconnected before the installation work is complete N El The primary cooling circuit can contain hot coolant over 450 C during WARNING normal operation Serious burns are possible Before performing maintenance switch off the unit and allow it to cool down The primary cooling circuit can contain high pressure coolant 6 bar during operation Release the pressure in the HX unit before A performing maintenance Use safety goggles HOT SURFACE 7 The HX unit must be positioned in a non hazardous area where it can t pose a threat to any main systems or persons The coolant consists depending on the project of plain drinking water or of a mix of water propylene glycol and corrosion inhibitors Glycol and corrosion inhibitors are dangerous to health If you get coolant mixed with glycol or corrosion inhibitors in your eyes on your skin or in your mouth seek medical advice It is the customer s and or end user s responsibility to provide flo
45. he main drive at full load Ambient temperature 40 C Maximum relative humidity 80 50 Acc to chart 3 3 1 gt Dew point is 28 C When adding the safety margin of 2 C the primary circuit temperature can be set to 30 C In this case a reduction of the maximum RH from 8096 to 5096 by using a humidity remover will allow the primary circuit temperature to be set to 30 C therefore allowing the main drives to be run at full load Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 35 Maximum ambient temperature 40 C Maximum ambient relative humidity 5096 02 03 04 05 VACON LIQUID COOLED NX DRIVE HXM120 Ca Ca Secondary circuit maximum 25 C 30 C 5 C E o e PF din ee Primary circuit minimum 30 C 28 C 2 C Figure 3 3 5 Example 2b The secondary circuit maximum temperature should always be 5 C lower than the primary circuit temperature to ensure a good thermal load transfer between the two circuits In example 2b this means that the secondary circuit should be between 45 425 C during operation The 3 way valve in the secondary circuit will then keep the primary circuit temperature at 30 C regardless of the main drive load Example 3 high sec
46. he pump service instructions found in the Commissioning and Maintenance folder that is supplied with the HX unit It is recommended that a reserve pump be stored locally in order to restore the operation quickly when a pump needs to be maintained There should also be a shaft seal in storage to facilitate changing a broken or leaking shaft seal at site Tel 4358 0 201 2121 Fax 4358 0 201 212 205 UNI T MAI NTENANCE vacon 45 When the pump is leaking remove the broken pump and replace it with a reserve pump The broken pump should be fixed immediately and stored for later use in case a similar pump failure occurs Purchase a new shaft seal from the unit manufacturer and keep this in storage as well High pressure hot coolant 6 bar 460 C may be present in the primary WARNING cooling circuit The coolant consists of liquid propylene glycol and corrosion inhibitors depending on the project Glycol and corrosion inhibitors are damaging for the eyes If you get coolant in your eyes on your skin or in your mouth seek medical advice Use safety goggles HOT SURFACE To change a pump 1 Check that it is safe to turn off the drives connected to the HX unit and that there is enough time reserved for the maintenance N Prepare the HX unit for liquid filling by connecting a hose to the filling valve V161 Read Chapter 3 1 6 Adding liquid and de airing before continuing 3 Take the main drives connected to
47. hose from the faucet to the filling valve V161 Secure the connections with a hose clamp e Connect the drain hose to the manual de airing valve V162 and put the other end of the hose into a drain Secure the connection with a hose clamp e Secure the drain hose to the drain so it won t jump out during the filling and de airing e For adding corrosion inhibitor read chapter ALI Figure 3 1 10 If a local sink or floor drain is used and corrosion inhibitors are added to the liquid in the primary circuit then it is the customer and or end user s responsibility to check that the coolant mix can be disposed of through the local sewer system 3 1 6 Adding liquid and de airing Follow the instructions for the pre filling process before starting the pump at commissioning or after maintenance How to fill the primary circuit HXM120 PSO1 See P amp ID in figure 2 2 2 l Prepare the unit according to the recommendations in chapter 3 1 5 Setting up the primary circuit Use valve V161 to regulate the flow during the filling and de airing of the unit 2 It is recommended that the flow from the external pump or water supply system is low in the beginning of the filling process This ensures that a minimum amount of air pockets is left in the piping 3 Close valve V161 Open the faucet or start the external pump depending on which filling System you are using Slowly open valve V161 to a 30 50 of maximum 4 After a short while liquid
48. il the correct pre pressure is reached Follow the instructions in chapter 3 1 6 Adding liquid and de airing e Hose failure in the e Replace the hose Refer to the NX Liquid main drive section Cooled User s Manual Then add liquid to the primary circuit until the correct pre pressure is reached Follow the instructions in chapter 3 1 6 Adding liquid and de airing Pressure vessel e The gas air or e Check and refill the pre pressure EV11 refer to the nitrogen has escaped according to the instructions in chapter P amp ID is without through the butyl 4 2 3 Pressure vessel pre pressure rubber membrane into the primary circuit e The EV11 filling valve e Replace the valve and refill the pre is broken and pressure according to the instructions in therefore letting out chapter 4 2 3 Pressure vessel gas e The butyl membrane e Replace the expansion vessel and refill the inside the expansion pre pressure according to the instructions vessel is broken in chapter 4 2 3 Pressure vessel Other reason e Faulty pressure sensor e Compare the value from the pressure gauge PI11 with the value from the pressure transmitter PT11 If the pressure transmitter is broken it has to be replaced Table 5 1 4 Pressure fault detection 24 hour support 4358 0 40 837 1150 Email vacon vacon com 54 vacon TROUBLESHOOTI NG 5 1 4 Leak alarms If the leak alarm is active acc to panel below the HX unit is still online and
49. l ARNG eed ed aa LL d ase 38 3 3 9 Leak switch alarm specifications 3 35 4 sd addidi dido odd e 38 3 3 10 Three way valve two way valve actuator settings see 39 STEP 24 ADI USTING THE FLOW ooo 40 3 4 1 A eG e cette tie er LI ISI bd ae 40 3 4 2 Adjusting the system flow and setting the switch point of the FTSAT1 41 3 4 3 Checklist before starting main NX drives eeeeeeeeeeeee 42 UNIT MAINTENANCE 5 ssupaiavins Ria ese QA has ventana Fee pibe a 44 GENERAL MAINTENANCE o caen tcs tl dt He C eeepc e 44 4 1 1 Renewing liquid in the primary circuit eeeeeeeenemeeeeenene 44 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 vacon 7 4 1 2 Maintenance schedule e oos o 44 4 2 MAINTENANCE BY COMPONENT tot htt tt e i ea n EE I ai 44 4 2 1 ung o eR 44 4 2 2 Heat exchanger i544 000 od oo coda ob adobes 46 4 2 3 Pressure A dE 48 5 TROUBLESHOOTIN cemere riada et 49 LTEM en 49 5 1 1 Lear lA PR o MIU QUID IO UU P a 49 5 1 2 Temperature alarms and Shutoffs iet eite tei rarae teen su ta eee acto iei 50 5 1 3 Mode posce Eoi RO 53 5 1 4 Leak al aL IIIS usto ocius ia A CR AA EE D ERU T SEDE 54 6 TECHNICAL SPECIFICATION arman oa 55 APPENDIX Diana AAA AA ARA AAA AAN 57 24 hour support 4358 0 40 837 1150 Email vacon vacon com 8 vacon SAFETY 1 SAFETY This chapter contains the general safety instructions which you must
50. lug on valve V160 and replace it with a hose connector Place an eight 8 litre jar under the valve if the expansion vessel air nozzle or membrane is broken there might be up to 8 litres in the vessel Turn the lever marked violet in Figure 4 2 5 on valve V160 90 so that it poi you points towards the back wall This will close off the au primary circuit and therefore only the liquid in the NO expansion vessel will come out There is line mark in the end of the stem where you can also ensure the right position of the 3 way valve This mark shows the open flow direction nts M away from 3 When the pressure vessel is drained check the pre pressure with a portable pressure gauge The air nozzle can be found under the black rubber top on the vessel The portable pressure gauge should have a similar interface to that used to fill a car tyre Figure 4 2 5 The pressure can be added with a nitrogen tank pressure over 2 bar or if air is used then a compressed air system or even a hand pump can be used Refill pressure if necessary The pressure should be 100 kPa 1 bar Use nitrogen if possible otherwise air can also be used Reconnect the plug to valve V160 change the plug O ring if necessary 8 Turn back the lever on valve V160 90 so that it points down 10 The pressure in the primary circuit will decrease due to the water that is removed during this process Therefore water must be added thro
51. m flow and setting the switch point of the FTSA11 Do not energize the main drives before the HX unit has been running for 30 min without any alarms Refer to the Chapter 3 4 3 Checklist before starting main NX drives Vacon Plc is not responsible for the use of its products contrary to these instructions 24 hour support 4358 0 40 837 1150 Email vacon vacon com 4 vacon ABOUT THE VACON HX UNIT MANUAL The Commissioning and Maintenance Manual provides you with the necessary information about the maintenance and commissioning of a Vacon HX unit We recommend that you carefully study these instructions before powering up a Vacon liquid cooled drive and HX unit for the first time This manual is available both in paper and electronic editions We recommend you use the electronic version if possible If you usethe electronic version you benefit from the following features e The manual contains several links and cross references which make it easier for the reader to move around in the manual to check and find things faster e The manual contains hyperlinks to web pages To visit these web pages through the links you must have access to the Internet and have an Internet browser installed in your computer Tel 4358 0 201 2121 Fax 4358 0 201 212 205 vacon 5 VOCABULARY Primary circuit A closed circuit filled with coolant that connects the drive to the HX HXM120 PSO1 unit Secondary ci
52. mally closed Temperature switch OFF no temperature switch point used Flow switch point according to calculations in chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 3 3 6 Temperature set points If the primary circuit temperature isn t set correctly the main drive might malfunction because of condensation The default setting of the parameter P3 5 in the HX control unit application is 25 C This means that the 3 way valve adjusts the flow in the secondary circuit to keep the primary circuit liquid temperature at 25 C measured by the FTSA11 before the drives There are three factors that will affect the nominal temperature of the primary circuit e Ambient maximum temperature at the main drive installation e Ambient maximum relative humidity at the main drive installation e Secondary circuit maximum temperature All of these factors have to be taken into consideration when calculating the primary circuit temperature set point e If the humidity is high condensation will occur in the piping inside the main drives and therefore cause a malfunction e If the ambient temperature is too high the load of the drive must be reduced e And if the customer and or end user have an existing cooling system which is going to be connected to the secondary circuit the temperature of this circuit might be the deciding factor The primary circuit temperature is individual for every project Here are three examples th
53. minimum 28 C 26 C 2 C Figure 3 3 3 Example 1 The secondary circuit maximum temperature should always be 5 C lower that the primary circuit temperature to ensure a good thermal load transfer between the two circuits In example 1 this means that the secondary circuit should be between 5 423 C during operation The 3 way valve in the secondary circuit will then keep the primary circuit temperature at 28 C regardless of the main drive load Example 2 high ambient relative humidity If the customer and or end user have a high ambient temperature 40 C at the main drives that would require the primary circuit temperature to be equal or higher than 40 C This would normally require a significant load reduction of the main drive If the maximum relative humidity at the main drive is known the dew point chart can be used to determine a more optimized temperature for the primary circuit Ambient temperature 40 C Maximum relative humidity 80 Acc to chart 3 3 1 gt Dew point is 36 C 24 hour support 4358 0 40 837 1150 Email vacon vacon com 34 vacon COMMI SSI ONI NG It is recommended to use a 2 C safety margin Therefore the primary circuit temperature should in this case be set to 38 C 36 C 2 C Using a 38 C temperature instead of 40 C on the primary circuit will reduce the required load reduction of the main drive For more information re
54. mp from the HX unit Note the pump weight is about 50kg It is recommended that there are two persons present when the pump is removed 10 Perform the necessary maintenance on the pump and reconnect the pump to the pump housing Or simply replace the pump if a spare pump is available 11 Connect the electrical cables to the new pump motor 12 Open the maintenance valves V140 V143 13 Refill and de air the pipes according to the instructions in chapter 3 1 5 and 3 1 6 Figure 4 2 1 There are replacement parts available if there is a leak e g shaft seal or if the pumps are not able to keep sufficient pressure Refer to the technical specifications of the pump for the replacement parts The specifications can be found in the end of the Commissioning and Maintenance folder that is supplied with the HX unit 4 2 2 Heat exchanger The heat exchanger does not need regular service If the primary circuit temperature is too high high temperature alarm is active and the 3 way valve directs all the liquid through HX11 by pass line closed the flow is too low in one of the circuits or the temperature in the secondary circuit inlet is outside the defined parameter values If the flow in the secondary circuit is too low there may be some biological residue clogging the heat exchanger Because the primary circuit is filled with clean liquid it is unlikely that the primary circuit s side of the heat exchanger clogs Refer to the he
55. n 24 hour support 4358 0 40 837 1150 Email vacon vacon com 28 vacon COMMI SSI ONI NG 3 3 3 Parameter description The table 3 3 1 includes parameters made to monitor and control the HX unit This chapter includes short explanations on what the different parameters are used for P2 10 1 is the actual frequency that the pump motor will run at when producing the required flow in the system The speed of the pump frequency should be optimized according to the required flow see Chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 This will reduce the wear of the cooling system and therefore extend the MTBF mean time before failure of the HXM unit and the main drives Changes Customer Parameter Parameter description Default Custom code setting settings P2 10 1 Frequency to PU11 when PID 50Hz enabled pressure setting scaling P2 10 3 PT11 pressure transmitter 10 bar high pressure setting scaling pressure alarm P2 10 5 Inlet pressure supervision P2 10 6 FTSA11 temperature transmitter low temperature setting scaling P2 10 7 FTSA11 temperature 100 C transmitter high temperature setting scaling low temperature alarm high temperature alarm high temperature shutoff sequence time P2 10 12 ZE P2112 P2 11 3 P2 11 4 P2115 P2 11 6 P2 11 7 P2 11 8 Fieldbus outlet 7 P3 5 FV11 reference temperature 5 Table 3 5 1 Parameter list N ul Hie N RP U Oje Y Ald Uli o M O
56. nit If the pipes have been welded with a TIG it is sufficient to clean the pipes by blowing pressurized air through them If the welding has been done by other means the pipes have to be thoroughly flushed with water at a minimum of 3 m s for 5 minutes 3 1 4 Pressure test A pressure test has already been performed on the HX unit before delivery but because some of the connections are made on site additional pressure testing is required The pressure test performed on site should be done according to EU directives or national regulations whichever has priority on site Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 21 The safety valve V120 marked orange in Figure 2 2 3 in the primary circuit is set to 6 bar and has to be removed during the pressure test The V120 valve connection must be plugged during this pressure test During the pressure test the de airing valve AD11 Figure 3 1 7 has to be closed The threaded top plug must be replaced with tight plug or add an extra seal under the top plug After the test change back the originally plug tighten to end and then open 360 degrees NOTE To ensure that every site connection is sufficiently tightened it is recommended that a pressure test be performed for the primary circuit using pressurized air The pressurized air can be added through the liquid filling point of the unit e g at valve V161 in the primary circuit Figure 3 1 7
57. ntrols the temperature of the primary circuit The valve is regulated by an analogue temperature signal delivered by the flow switch FTSA11 The main function of the valve is to adjust the flow through the plate heat exchanger HX11 in the secondary circuit and thereby control the temperature in the primary circuit By reducing the flow through the heat exchanger the primary circuit s temperature increases and vice versa The default valve regulation set point is 430 C If the temperature drops below the set point the 3 way valve starts to reduce the flow through the plate heat exchanger and directs more liquid through the bypass Keeping the temperature as high as possible in the primary circuit with regards to the type and load of the main drive lowers the risk of condensation inside the drive cubicle Figure 2 2 4 24 hour support 4358 0 40 837 1150 Email vacon vacon com 14 vacon NTRODUCTI ON 22 3 Control unit The frequency converter Vacon NXP series Figure 2 2 5 works as a control supervision unit for the primary circuit s temperature and flow and adjusts the frequency of the cooling pump motor PU11 12 The frequency converter is programmed to read the I O signals from the flow switch FTSA11 pressure sensor PT11 and leak switch LS11 Information on the alarms and how to calculate their limits is found in chapter 3 3 STEP 3 CONTROL UNIT SETUP Information on how to modify the control unit parameters c
58. ny chemical residue that might be harmful for the material used in the HX unit e g high amounts of chloride chlorine oil etc The HX unit with the PVC C pipes uses EPDM rubber seals that will deteriorate if they come in contact with oil 2 3 2 Required ambient conditions The HX unit is designed to work within ambient temperatures between 45 450 C It is the customer and or end user s responsibility to ensure that the temperature remains within this limit during operation The HX unit is not built to withstand rain sand or snowstorms If the HX unit is positioned outside it must be placed inside a cubicle that is equipped with temperature and humidity control There is no condensation allowed in the main drive As the primary circuit piping is located inside the same cubicle as the main drive it is vital that the primary circuit water temperature doesn t go below the dew point temperature The primary circuit temperature is set accordingly to ambient temperature and relative humidity The most secure way of preventing condensation inside the main drives is to keep the water temperature in the primary circuit higher than the ambient temperature If the temperature in the drive room is higher than the temperature of the liquid in the primary circuit piping it can depending on the relative humidity of the air cause condensation on the piping as well as inside the drive A dew point chart can be used to optimize the primary circuit minimum temp
59. o o O E rm P2 10 2 is the min value of the range of the pressure transmitter PT11 It is used to scale the pressure transmitter PT11 low pressure point The PT11 has a min measure point at O bar Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 29 P2 10 3 is the max value of the range of the pressure transmitter PT11 It is used to scale the pressure transmitter PT11 high pressure point The PT11 has a max measure point at 10 bar P2 10 4 is a PT11low temperature alarm limit The default setting for this is set at 0 5 bar More information can be found in chapter 3 3 8 Low pressure alarm P2 10 5 is a selection parameter that should be set to 1 If the PT11 pressure transmitter malfunctions the parameter can be set to O therefore overriding the pump suction side pressure supervision The pressure transmitter MUST BE REPLACED as soon as possible the warranty is not valid if this parameter is set to 0 P2 10 6 is the min value of the range of the temperature transmitter FTSA11 It is used to scale the temperature transmitter FTSA11 low temperature point The FTSA11 has a min measure point at 0 C P2 10 7 is the max value of the range of the temperature transmitter FTSA11 It is used to scale the temperature transmitter FTSA11 high temperature point The FTSA11 has a max measure point at 100 C P2 10 8 is a FTSA11 low temperature alarm limit The default setting for this is set at 22 C
60. ominal required flow 10 The nominal flow for a Ch74 is 315 l min therefore the switch point should be set to 283 l min 315 x 0 9 From the Diagram 3 4 1 we can establish that 283 l min corresponds to 70 on the FTSA11 Information on how to modify the switch point of the FTSA11 is found in chapter 3 3 5 FTSA11 flow switch function e Ifthe actual flow goes under 65 set point 70 5 hysteresis the FTSA11 flow switch will open the switch when the FTSA11 is set to normally closed N C If the alarm disappears within 5 seconds the control unit application filters out the alarm If the alarm is still active after 5 seconds the cooling OK signal to the drives is disconnected and both the HX unit pump and the drives shut down 24 hour support 4358 0 40 837 1150 Email vacon vacon com 42 vacon COMMI SSI ONI NG D o o gt S o um o T lt o LE LL 200 Flow l min Diagram 3 4 1 Converting table for the FTSA11 flow switch PVC C Converting formula for the FTSA11 flow switch HXM 120 AISI x 5 y 147 where y FTSA11 display x flow l min HXM 120 PVC C x 5 y 60 where y FTSA11 display x flow l min 3 4 3 Checklist before starting main NX drives After the de airing when the control unit setup and the flow adjustment are performed and the HX unit has been running for 30 minutes without any alarms the main drive can be brough
61. ondary circuit temperature If the customer has an existing cooling system that delivers liquid at a temperature of 40 C then the primary circuit temperature has to be 5 C warmer to maintain a sufficient heat transfer between the primary and secondary circuit This means that the primary circuit temperature cannot be colder than 45 C This results in a significant reduction of the main drive load In this case the only way of increasing the load of the main drive is to lower the temperature in the secondary circuit by installing additional coolers or a new cooling system with a lower water temperature Next the dew point must be checked Secondary circuit maximum temperature 40 C Primary circuit maximum temperature 40 C 40 C 5 C Ambient temperature 30 C Maximum relative humidity 95 Because the ambient temperature is beneath the primary circuit temperature there is no risk of condensation in the main drive 24 hour support 4358 0 40 837 1150 Email vacon vacon com 36 vacon COMMI SSI ONI NG Maximum ambient temperature 30 C Maximum ambient relative humidity 9596 02 03 04 05 T VACON LIQUID COOLED NX DRIVE HXM120 mum o o m Secondary circuit E o Q hb maximum 40 C g Primary circuit minimum 45 C 40 C 5 C
62. ose 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 The pump flow should be adjusted according to the required flow of the connected drives Before adjusting the flow the primary circuit has to be correctly filled and de aired The target flow can be calculated by adding up the nominal flow for the main drives connected to the HX unit For information on how to calculate the optimum system flow see the example below To adjust the system flow 1 Start up the pump and run it at 50 Hz which is the default value in the HX control unit application 2 Check the actual flow speed in percent from the flow switch FTSA11 and convert it into l min by using the flow speed diagram 3 4 1 or by using the converting formula 3 Adjust the frequency of the pump to match the required total nominal flow 10 see example Example If you are using 3 x Ch74 drive the nominal flow according to the NX Liquid drive manual is 315 I min The flow should then be set to nominal flow x 10 e Adjust the flow to 346 l min 315 x 1 1 that is 80 according to Diagram 3 4 1 by changing the frequency parameter P 2 10 1 in the Flow control part of the control unit application The default value of the parameter is 50Hz Reduce the frequency by 2 Hz at a time until the FTSA11 display shows the value 80 The value shown on the FTSA11 is somewhat irregular in the beginning e The setting point for FTSA11 should be set at the n
63. ote that this diagram is correct only when using the FTSA11 high measuring range 30 300 cm s and the original pipe inner diameter This flow meter is suitable for concentration of maximum 25 glycol 75 water Figure 2 2 6 The other instruments found on the HX unit are a pressure transmitter PT11 and a pressure gauge PI11 The pressure transmitter sends a 4 20mA signal to the HX control unit The control unit application then converts this signal into pressure bar This pressure input is then used to monitoring the pump inlet pressure The idea is to give the user an early warning in case there is a leak in the primary circuit somewhere outside of the HX unit The pressure gauge is used when filling the primary circuit with liquid or when performing a pressure test on the unit It can also be used to get a pressure reference value if the pressure transmitter is thought to be malfunctioning Tel 4358 0 201 2121 Fax 4358 0 201 212 205 NTRODUCTI ON vacon 15 2 2 5 Control supervision parameters When the HX unit is working within the pre set limits it sends a cooling OK signal to the main drives The HX unit supervision system is programmed to generate alarms to alert the user to a malfunction in the unit If the malfunction is more severe the control unit removes the cooling OK signal to the main drive and takes them offline The project specific minimum flow speed is to be set as switching point for the flo
64. penetration is made according to IP54 requirements Figure 3 1 4 Figure 3 1 5 If the HX unit isn t placed in the same line up as the drives therefore creating piping between the HX unit and the main drives the pressure loss of the piping between the HX unit and the drive must not exceed 0 7 bar If the calculated pressure loss is higher than 0 7 bar then the HX unit will not be able to produce the maximum flow of 360 l min that is specified for the HXM120 If the 360 l min is required for the installed main drives e g one Vacon 3xCh74 but the HX unit has to be placed at a point were the calculated pressure loss for the added piping is more than 0 7 bar it is recommended that two units is used instead or 1 I i I 93 va 15 l HXN AZG can can a a L HH Secondary circuit E olo E ojo l M inlet outlet S 0 Additional piping between HX unit and the main drives Figure 3 1 6 If the HX unit is delivered as a part of NX Liquid Cooled switchgear therefore being in the same line up then the connections between the HX unit and the drive are ready and the customer only needs to connect the secondary circuit piping 3 1 3 Pipe flushing All piping in the primary or secondary system made by the customer and or end user must be flushed before being connected to the HX u
65. rameters for the Fieldbus Profibus output The customer and or end user can choose any 8 of the NXP 0009 parameters to be sent out to a higher control system for external monitoring The default values are as follows P2 11 1 Primary side temperature from FTSA11 C P2 11 2 HX pump motor speed rpm P2 11 3 HX pump motor current A P2 11 4 Primary side pump inlet pressure bar P2 11 5 Output frequency to HX pump motor Hz P2 11 6 Motor torque as 96 1000 equals 410090 P2 11 7 Motor shaft power in 96 1000 equals 100 P2 11 8 Fault trip history 24 hour support 4358 0 40 837 1150 Email vacon vacon com 30 vacon COMMI SSI ONI NG P3 5 is the FV11 actuator reference temperature Default value is 25 C This value is the liquid inlet temperature value to the main drives More information can be found in chapter 3 3 6 Temperature set points Only an authorized person is allowed to make changes to the parameter settings If the drive or HXM unit is malfunctioning or if they break due to a customer and or end user parameter setup error the warranty is not valid NOTE 3 3 4 General information about alarms and shutoff limits Apart from the standard NXP frequency converter alarms found in the Vacon NXP User s Manual the HX unit application can generate alarms or shut offs from one flow switch FTSA11 with a built in analogue temperature transmitter a pressure sensor PT11 and one leak sensor L
66. rcuit A circuit filled with coolant that connects the HX unit to the HXM120 PS02 customer piping HX unit HXM120 cooling unit see the front picture of the manual The ordering code for the unit on the front page is HXM M 120 N S but itis referred to as HXM120 or just plain HX unit for short Drive Liquid cooled frequency converters or inverters that are connected to the HX unit Main drive A term used in some contexts for the Vacon NX liquid Cooled converters so that they are more easily separated from the air cooled Vacon NXP 0009 used in the HX unit The main drive concept might also include other liquid cooled electrical equipment HX control unit The air cooled NXP 0009 drive that is placed inside the HX unit for the purpose of controlling and monitoring the primary circuit pump and instruments 24 hour support 4358 0 40 837 1150 Email vacon vacon com 6 vacon 2 3 3 1 3 2 3 3 3 4 4 1 SAFETY qme P 8 USE OF SYMBOLS O p d cay 8 GENERAL WARNINGS AND NOTES WHEN WORKING WITH THE HX UNIT nsee 9 INTRODUCTION cecindeexxr us c eorr ee AA e e c 11 ABOUT THIS MAN UAL aes wa ca c ito ot EUER eL te ene oU eec AAA oe LO don eee Qe etus 11 PROCESS ANDINSTR NMEN EATION 1 itas a dtt ttt tte tutatus 12 2 2 1 Primary circuit components and TUPGBOD s soot 13 2 2 2 Secondary circuit components and function sse 13
67. re pressure and leak supervision The HX control unit application monitors these quantities The application generates alarms or shut offs from the instrument s I O input output signals depending on the parameter settings The HX control unit interface panel allows the user to access these settings The settings are found as editable parameters in the HX control unit application Apart from the leak sensor LS11 which is placed on the HX unit floor all instruments are placed in the primary circuit Therefore the temperature and flow monitoring in the secondary circuit is the responsibility of the customer and or end user Tel 4358 0 201 2121 Fax 4358 0 201 212 205 NTRODUCTI ON vacon 13 2 2 1 Primary circuit components and function The primary circuit is a closed circuit with an expansion vessel EV11 blue part in Figure 2 2 3 that compensates for temperature changes The primary circuit flow and temperature must match the requirements of the drives that they are connected to These requirements can be calculated by following the instructions in the Vacon NX Liquid Cooled Drive User s Manual As mentioned earlier the system includes a plate heat exchanger HX11 copper grey colour in Figure 2 2 3 This unit separates the primary circuit from the secondary circuit so therefore it is actually a part of both the primary and the secondary circuits On top of the HX11 is the automatic de airing valve AD11 violet part in Figure
68. rimary bar circuit by adding liquid through valve V161 e Thereis aleak in the e Check the primary circuit for leaks If a primary circuit leak is found the unit must be drained and the leak fixed before the unit is restarted The pump isn t e A valve in the primary e Check if any of the following valves in delivering enough circuit is closed the primary circuit is closed refer to pressure i e the flow the P amp ID is too low V140 143 V310 3xx Any valves in the primary circuit added by the customer The FTSA11 is set e The flow requirement e Check the current flow requirements incorrectly this is a has changed after the they might have changed if e g a fault that is most commissioning stage converter is taken offline and its likely to appear during valves closed because of maintenance or at the maintenance 24 hour support 4358 0 40 837 1150 Email vacon vacon com 50 vacon TROUBLESHOOTI NG commissioning stage e Check the required flow values for the converters and readjust the alarm set point on the FTSA11 refer to chapter 3 4 2 Adjusting the system flow and setting the switch point of the FTSA11 The FTSA11 setup values have been poorly adjusted during commissioning Table 5 1 1 Flow fault detection 5 1 2 If the high temperature alarm is active acc to panel below the HX unit is still online and the Cooling OK signal to the main drive is connected The yellow and green indica
69. signal to the drive is disconnected The default setting for this parameter is 45 C The leak switch s sensor LS11 is located on the leakage plate at the bottom of the HX unit The function of the switch is to give a signal to the HX control unit in case there is liquid on the leakage plate The liquid can be from a leak in one of the circuits or from condensation on colder pipe surfaces due to high relative humidity of the air The HX unit provides no control of the temperature or flow in the secondary circuit It is strongly recommended that the customer and or end user add a temperature and flow control on the secondary circuit piping outside the HX NOTE unit Depending on the quality of the secondary circuit liquid the plate heat exchanger might clog and affect the efficiency and flow of the unit Because the primary circuit is a closed circuit it contains only a small amount of liquid This means that it will react fast to changes in temperature or flow in the secondary piping If the flow for some reason is shut down in the secondary circuit the HX unit will disconnect the cooling OK signal to the drive within seconds depending on the main drive load due to a high temperature shutoff NOTE If there is no monitoring equipment in the secondary circuit it is harder to determine the reason for a possible alarm from the HX unit Secondary circuit flow or pressure difference and temperature monitorin
70. t online If there is more than one converter it is recommended that they be started up one by one to avoid any sudden changes in the temperature The load of the drives should also be increased step by step otherwise the temperature might change too fast and cause an alarm or in the worst case a drive malfunction Before starting the drives 1 Check that the HX unit flow and temperature are within the given parameter values no alarms Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 43 2 Check that there is no air left in the plate heat exchanger by carefully opening the manual de airing valve V162 and letting out a small amount about 1 centilitre of water 3 Checkthat the PI11 pressure gauge is at about 1 5 bar Check that the maintenance valves to the converters in use V310 V31x are open 5 Check that the flow refer to FTSA11 converting table above is according to the connected converter requirements Check that the primary circuit temperature is according to the setup value Check that there is no condensation in the main drive cubical If there is condensation inside the drive cubicles the drives must be dried out before start up After successfully performing the different steps of commissioning presented in chapter 3 the HX unit and the connected drives are ready to be moved from the commissioning stage to operation mode Troubleshooting information and unit service information
71. the Cooling OK signal to the main drive is connected The yellow and green indicator lights on the electrical box door are also active Check the following issues to solve why the alarm has been activated F1 51 External Fault F F1 gt F125 Figure 5 1 5 Leak alarm on the NXP panel Malfunction Reasons for malfunction Correction measures Leak e Loose connection e e Faulty connection Condensation e The secondary circuit liquid temperature is too low in regard to the ambient temperature and relative humidity Other reason No condensation or leak is found but the alarmis still active Figure 5 1 5 Leak fault detection Tighten the connection until the leak stops Add liquid to the primary circuit until the correct pre pressure is reached Follow the instructions in chapter 3 1 6 Adding liquid and de airing Replace the broken parts Then add liquid to the primary circuit until the correct pre pressure is reached Follow the instructions in chapter 3 1 6 Adding liquid and de airing If the cooling process allows it then increase the secondary circuit inlet liquid temperature until the condensation stops Decrease the humidity or the temperature in the cubicle until the condensation stops If there is condensation on the secondary circuit piping insulate the secondary circuit pipes and the plate heat exchanger HX11 Try resetting the alarm on the reset switch It is the push button in the lower right
72. the secondary circuit flow through the plate heat exchanger HX11 by adjusting the 3 way valve actuator FV11 to match the temperature setup value for the primary circuit This temperature setup value is project specific and is adjusted at commissioning The temperature setup value is dependent on the ambient temperature in the drive cubicle and on the maximum temperature of the customer inlet liquid The calculation of this value is explained in chapter 3 3 6 Temperature set points Figure 2 2 1 HXM120 COOLING UNIT FREQUENCY CONVERTERS pice cnc eH exis rir ae po l EE EDD M ECCE Cic S a vc AES E l f l l ga amp l A MEE CUSTOMER PSOB 1 Secondary circuit NET DSS H 2 HX_120 PS01 2 Primar Evi M AS EC PNE E OPTION AIR COOLER amp l Vi6e HXAM ll n AI E l ata puie E qu I i iee Vial VI I Vi43 n OPTION SHUTOFF VALVE QO I L4 4 FILLINGS AH 3 E T CUSTOMER V205 MA Viab ido SN vite osos CSS mecoc0k Ji BUTLET e PULL DRAIN E a HXM120 PSOI 1 i PS02 2 IDRAIN i i i Figure 2 2 2 Piping and instrumentation diagram P amp ID A larger P amp ID is found in the Commissioning and Maintenance folder that is supplied with the unit The HX unit is equipped with flow temperatu
73. the unit is fixed according to requirements The HX unit should be fixed to the cubicle frame with suitable and robust supports to prevent the unit from moving or being damaged by vibrations The HX unit can be fixed to a floor or a wall by itself The frame that the unit is built on is self supporting If the unit is installed without an additional cubicle e g VEDA or Rittal it must be positioned in a non hazardous area where it can t pose a threat to any main systems or persons If required e g by national regulations or generally acknowledged safety standards additional protection must be added to the unit e g warning signs or additional protective gear Figure 3 1 1 3 1 2 Pipe connections Standard connections are DN50 flanges according to DIN2642 Flange adapters are delivered in a separate box When placing the HX unit inside a cubicle it might be necessary to remove also the 2 connector parts that are screwed on to the pipes on the primary and secondary connections This is because the total width is about 716mm when the connectors are on and the width door opening on e g Rittals 800mm cubicle is 712mm Figure 3 1 2 Figure 3 1 3 24 hour support 4358 0 40 837 1150 Email vacon vacon com 20 vacon COMMI SSI ONI NG The material of the primary circuit and secondary circuit flanges is AISI 316 It is also possible to get PN16flanges according to DIN 2633 AISI 304 to secondary circuit The wall
74. tor lights on the electrical box door are also active Check the following issues to solve why the alarm has been Temperature alarms and shutoffs activated F1 83 OverTempA A 17137165 Figure 5 1 2 High temperature alarm on the NXP panel Reasons for malfunction The customer filter outside the HX unit MF21 refer to the P amp ID is clogged The plate heat exchanger HX11 refer to the P amp ID is clogged on the secondary side Malfunction The flow in the secondary circuit is too low The customer pump in the secondary circuit is malfunctioning and therefore not able to produce enough flow Maintaining the HXunit cannot solve the reason for this malfunction The temperature of the secondary circuit liquid is too high Correction measures Clean the filter Clean the heat exchanger Refer to the cleaning instructions found in the HX unit folder that is supplied with the unit Instructions on how to remove the plate heat exchanger are found in chapter 4 2 2 Heat exchanger Maintain or replace the customer circuit pump The temperature of the liquid in the secondary circuit inlet has to be 5 degrees lower than the primary circuit temperature set point e g if the primary circuit temperature set point is set to 35 C then the secondary circuit inlet temperature must be 30 C or lower Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TROUBLESHOOTI NG vacon 51 The regulating
75. ugh the filling valve V161 until the pressure on the pressure gauge PI11 is back at 1 5 bar Remember to de air the filling hose before you connect it to valve V161 otherwise the air in the filling hose will enter the unit during filling Due to the small amount of liquid removed during this process it is not necessary to add any corrosion inhibitor Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TROUBLESHOOTI NG vacon 49 5 TROUBLESHOOTING 5 1 Alarms and shutoffs This chapter provides help in case the HX control unit activates an alarm or fault An alarm or fault is activated because the HX unit is working outside the parameter settings in the HX control unit The pre set parameters for the HX unit are shown in chapter 3 3 2 Application parameter list 5 1 1 Flow fault If the flow fault shutoff is active acc to panel below the HX unit pump has stopped and the Cooling OK signal to the main drive has been disconnected The red indicator light on the electrical box door is also active Check the following issues to solve why the alarm has been activated F1 87 FlowFault F __F1 gt F1l gt Figure 5 1 1 Flow fault on the NXP panel Malfunction Reasons for malfunction Correction measures The pre pressure is e The pre pressure in the e Check the EV11 pre pressure and add too low in the primary expansion vessel EV11 pressure if necessary circuit i e below 0 5 has been reduced e Add pre pressure to the p
76. unit is not working within correct parameter values Either the temperature has reached the high temperature shutoff limit or the flow is too low in the primary circuit This light also indicates that the cooling OK signal to the main drives is disconnected therefore the main drives are offline e Yellow indicates that there is an active alarm in the HX unit meaning that the HX unit is working outside the optimal temperature and or pressure range or that there is a leak inside the unit e Green indicates that the cooling OK signal to the main drives is connected e White indicators show which of the HX pumps are activated during operation The troubleshooting guide is found in chapter 5 TROUBLESHOOTING If the yellow or red indicator is active then you can find more information by accessing the HX control box interface panel Information on how work the panel is found in the Vacon NXP User s Manual that is supplied with the unit Tel 4358 0 201 2121 Fax 4358 0 201 212 205 NTRODUCTI ON vacon 17 2 3 INSTALLATION SPECIFICATIONS 2 3 1 Liquid quality In the primary circuit the quality of the liquid has to be as presented in Table 2 3 1 Liquid quality The liquid should not contain organic sediment or chemically active qualities The liquid can be treated with corrosion inhibitors suitable for AISI pipes PTFE and Tesnit BA S seals When adding liquid to the primary circuit it is recommended that a filter be used so
77. urn out the HX11 Figure 4 2 4 Figure 4 2 4 4 Replace the unit with a clean one or clean the unit according to the manufacturer s instructions found in the end of the Commissioning and Maintenance folder that is supplied with the HX unit 5 Connect the clean unit in reverse order using the instructions above Add liquid and de air theunit according to the instructions in chapter 3 1 5 and 3 1 6 The manufacturer provides cleaning chemicals that improve the cleaning result If the secondary liquid quality is bad itis recommended that these chemicals and a reserve plate heat exchanger be kept in storage 24 hour support 4358 0 40 837 1150 Email vacon vacon com 48 vacon UNI T MAI NTENANCE 4 2 3 Pressure vessel If the vessel is pre pressured with nitrogen the vessel pre pressure needs to be checked every other year If air is used as the pre pressuring gas it has to be checked once a year In time the gas escapes through the butyl rubber membrane into the liquid circuit and gas or air must be added The pre pressure can be checked without draining the primary circuit It is recommended that this procedure be done during a yearly maintenance DANGER When performing maintenance work on a pressurized system generally acknowledged safety standards EU directives and national regulations must also be followed Use safety goggles To check the pre pressure L 2 Remove the p
78. user cause a malfunction in the HX unit or the main drive by neglecting the parameter setup instructions in this manual the warranty is no longer valid WARNING To modify the Flow control parameters one has to be able to use the NXP control panel Information on how to operate the NXP control panel is found in the Vacon NX Liquid Cooled User s Manual that is supplied with the HX unit The control unit also includes a Fieldbus uplink card Profibus The customer can use this uplink to get any of the Vacon NXP parameter values linked to a higher control system By using this uplink the customer can monitor the HX unit from an external interface at a chosen location More information regarding this uplink interface is found in the Vacon NX Liquid Cooled User s Manual that is supplied with the HX unit 3 3 2 Application parameter list The application parameters and their default values are shown in table 3 3 1 The project specific parameters are calculated using the rules found in chapters 3 3 6 to 3 3 7 The values that are used when setting up the HX unit during commissioning should be written down in the Custom settings column If the values must be changed at a later time the new value should be written in the last column Changes customer The parameters that must be edited at commissioning are marked with a in the table 3 3 1 More information about these parameters is found in chapter 3 3 3 Parameter descriptio
79. w and temperature control to the secondary circuit If the project specified flow and temperature for the secondary circuit is not met the warranty is not valid Retain these operating instructions during the entire life cycle of the HX unit The HX unit should always be transported empty that is without coolant to prevent damage caused by low and high ambient temperatures Do not allow any force or vibrations to enter the unit through the secondary circuit pipe connections or through the fixing points of the HX unit This will shorten the MTBF mean time between failure of the HX unit El If the HX unit is purchased without a cubicle place it inside a cubicle of choice and fix the HX unit frame to the cubicle frame If the HX unit is to be without a cubicle it should be fixed to a floor or wall Always install a filter before the HX unit if the secondary circuit cooling liquid contains particles larger than 2 mm If the secondary circuit liquid contains chemical or biological residue the MTTM Mean time to Maintenance is significantly reduced due to clogging in the plate heat exchanger inside the HX unit Tel 4358 0 201 2121 Fax 4358 0 201 212 205 NTRODUCTI ON vacon 11 2 INTRODUCTION 2 1 ABOUT THIS MANUAL This manual provides information on commissioning and maintenance issues of the HXM120 cooling unit The manual is intended to be used by Vacon s own personnel as well as the customer and or end user To
80. w switch FTSA11 The flow switch sends a digital signal to the HX control unit if the flow speed drops under the preset parameter values If the signal is active longer than 5 seconds the HX control unit disconnects the cooling OK signal to the drives This fault fault number F87 also stops the HX unit pumps The flow switch FTSA11 also sends out a temperature signal that controls the 3 way valve in the secondary circuit The FTSA11 sends out a 4 20mA signal which is then sent to the actuator FV11 on valve V130 The temperature parameters are adjusted at commissioning depending on the maximum temperature of the inlet secondary circuit liquid and the ambient temperature in the main drive area If the temperature drops below the set point in the primary circuit the valve on the secondary circuit decreases the amount of liquid going through the plate heat exchanger HX11 in order to increase the temperature in the primary circuit The temperature signal from FTSA11 also generates low and high temperature alarms and high temperature shutoff The high temperature alarm and shutoff functions protect the main drives from overheating and the low temperature alarm protects the main drives from condensation If the temperature goes above the high temperature shutoff limit the cooling OK signal to the drive is disconnected In this case the HX unit cooling pump continues running but the main drive is shut down that is the cooling OK
81. y val ve and WARNING therefore causing a leak If this happens the safety valve must be cleaned 8 Repeat this procedure until every frequency converter inverter is de aired that is open the valve V312 and V313 next and so on 9 After all the main drive hoses have been de aired and closed open valve V140 V141 and then open the filling valve V161 After no more rattling can be heard due to air in the system close valve V162 the manual de airing valve 10 When valve V162 is closed the pressure see at the PI11 pressure indicator will start to rise in the primary system When the pressure in the primary system has raised to two 2 bar close the V161 filling valve If you are using an external pump for adding the water it can now be turned off 11 Keep the two 2 bar pressure for about 10 minutes letting the air bubbles in the system rise up to the HX11 heat exchanger Then open the manual de airing valve V162 to let the pressure back down to 1 5 bar Close valve V162 12 Now the system is almost completely de aired After this the pumps must be run for short periods to get the rest of the air out from the HX unit Refer to chapter 3 4 1 Starting the pump for more the rest of the de airing instructions The pre pressure in the primary circuit should be set to 1 5 bar During operation the pre pressure should be between 1 0 to 1 5 bar If the pre pressure is reduced to below 1 0 bar during operation liquid must be ad

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