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Commissioning and Maintenance Manual

1. seen 13 2 2 3 Control e OP Pasa DU dasa bal ch ceases LC LL Le E 14 2 2 4 Instruments and their funclon eee eee atus 14 2 2 5 Control supervision parameters esssseseeeeeeennenn enne nnne 14 2 2 6 alado cea ODDO Esse eos me on A desides A 16 INSTALLATION SPECIFICATIONS turista 16 2 3 1 Liquid quilla 16 2 3 2 Required ambient conditions OS 17 ie niicie Tc apostar pro 19 SIEP T MECHANICAE PA ao 19 3 1 1 General installation INSENUCHONS 20 44 ceeded de adds 19 3 1 2 Pipe connecti OS cesen duisi idoli ied ede iac Aer 19 3 1 3 Messi em o AA AA H UA AA A EEA 20 3 1 4 Pressure testa Temm 21 3 1 5 Setting up the primary Circuit NE TEE 22 3 1 6 Adding liquid and Chee AVE 3 0 D NR dt a ad da 24 3 1 7 Adding corrosion inhibitor when using a fresh water system ssssss 25 STEP Z ELECTRICAL PAR T eite et he ete d a i laa ui ln ines 27 3 2 1 Power supply e e a e a a e et a 27 3 2 2 Signal cables usada dod toast 27 SIEP S CONTROL UNIT SETUP didi indidem iind 28 3 3 1 Basic Seton O PP 28 3 3 2 Application parameter SE ee iia 28 3 3 3 Parameter descripto sette e tae csipehaptac apii eda riadas 30 3 3 4 General information about alarms and shutoff limits sssssss 31 3 3 5 FISATLHONWSWIChTUTGcHOEba eee MAL de Nn 31 3 3 6 Temperature set points vivian c c ke c ck kic sek ck Re ET 34 3 3 7 Temperature alarm settings e cct e c Ee a eeu
2. 1 Check that the HX unit flow and temperature are within the given parameter values no alarms 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 Check that the PI11 pressure gauge is at about 1 5 bar Check that the maintenance valves to the converters in use V310 V3lxare open 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 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 46 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 pa
3. 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 43 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 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 Add liquid to increase the pressure back to 1 5 bar on the PI11 pressure gauge Close valve V161 and remove the hose 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 t
4. 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 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 piping on the HX unit they are responsible for them 24 hour support 4358 0 40 837 1150 Email vacon vacon com 22 vacon COMMI SSI ONI NG 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 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 V161 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 valve The valve handle posi
5. 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 cooling circuit The coolant consists of liquid propy ene 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 To change a pump i 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 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 Take the main drives connected to the HX unit offline according to the Vacon NX Liquid Cooled User s Manual Shut down the power to the HX unit by first turning the pump control switch to 0 therefore shutting down the pump then turning the main power switch to position 0 refer to Figure 2 2 7 Check that there is no power coming to the pump by removing the cover of the pump s electrical connection box and measuring the voltage No work on the unit is allowed when the power is conn
6. 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 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 Keep the 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 remove
7. 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 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 31 7 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 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
8. Conductivity uSem 10 HI aa al 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 is 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 liquid 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 strongly 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
9. HX unit 6 Connect the clean unit in reverse order using the instructions above Add liquid and de air the unit 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 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 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 1 Remove the plug on valve V160 and replace it with a hose connector 2 Place a five 5 litre jar under the valve if the expansion vessel air nozzle or membrane is broken there might be up to 5 litres in the vessel Figure 4 2 6 3 Turn the lever marked violet in Figure 4 2 6 on valve V160 90 so that it points down This will close off the pr
10. 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 PC 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 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 HXL unit will stay online
11. 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 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 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 r
12. 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 24 hour support 4358 0 40 837 1150 Email vacon vacon com 32 vacon COMMI SSI ONI NG 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 white 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 To change the parameters of the Uniflow 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 Figure 3 3 1
13. 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 2 2 5 Control supervision parameters Tel 4358 0 201 2121 Fax 4358 0 201 212 205 NTRODUCTI ON vacon 15 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 flow 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 pump 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
14. i holm Maximum 33 C 88 C 5 C E E a 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 the 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
15. 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 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
16. main drives to be run at full load Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 37 Maximum ambient temperature 40 C Maximum ambient relative humidity 5096 02 03 04 05 VACON LIQUID COOLED NX DRIVE E E u o Secondary circuit t maximum 25 C 30 C 5 C n 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 5 25 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 secondary 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
17. ne 39 3 3 8 Low pressure al ARNG icd ed aa Ld d aedis 40 3 3 9 Leak switch alarm specifications tion dd Ane eet ds 40 3 3 10 Three way valve two way valve actuator settings sse 41 STEP 24 AD USTING THE FLOW ooo 42 3 4 1 A O 42 3 4 2 Adjusting the system flow and setting the switch point of the FTSAT1 43 3 4 3 Checklist before starting main NX drives eene 44 UNIT MAINTENANCE orar eX eA Sha sq C ci cR Fre piae Ra 46 GENERAL MAINTENANCE oe e hl ett dt He Cete o 46 4 1 1 Renewing liquid in the primary circuit eeeeeeeneemeemeeeneene 46 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 vacon 7 4 1 2 Maintenance Schedule o oos o 46 4 2 MAINTENANCE BY COMPONEN Tesi 46 4 2 1 uno o RT 46 4 2 2 Heat exchanger 25 4554 oodd o ood o Lo od es 49 4 2 3 Pressure A da E 50 5 TROUBLESHOOTING 0 riada ata 52 51 Alarms and SNUTON S Emm 52 5 1 1 UUM Fea s coated etu ou a att a MIU tcl aa a Te 52 5 1 2 Temperature alarms and SMUPOTS mscciciconicconnlacicnica lcd 54 5 1 3 Low pressure alar NR S 57 5 1 4 Leak alal MS crenn usui eni A AA AA A DE T 58 6 TECHNICAL SPECIFICATION rana oa FER ara Rr adv Pasa Fal Rua YIN GCSE P Ri 59 APPENDIX NM AAA AA ARANA 61 24 hour support 358 0 40 837 1150 Email vacon vacon com 8 vacon SAFETY l SAFETY This chapter contains the general safety instructions which you must follow when instal
18. 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 40 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 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
19. 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 31 series model HXM 120 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 HXLO4O 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 parameters 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 moto
20. 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 Note 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
21. 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 38 vacon COMMI SSI ONI NG Maximum ambient temperature 30 C Maximum ambient relative humidity 95 02 03 04 0S VACON LIQUID COOLED NX DRIVE HXL040 Lid cojo Lu Secondary circuit E o E lo maximum 40 C E 2 Primary circuit minimum 45 C 40 C 5 C Figure 3 3 6 Example 3 Dew Point chart for ambient temperatures between 10 50 1013 mbar 10 C 15 C 20 C 30 C 0 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 C
22. 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 42 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 pump for the first time Au B5 WN c 10 11 12 13 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 Open the maintenance valves for the main drives V310 to V31x that are to be used Check that the valves V140 is open and that V160 has the lever turned towards you 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 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 by tur
23. with coolant that connects the HX unit to the HXL040 PS02 customer piping HX unit HXLO40 cooling unit see the front picture of the manual The ordering code for the unit on the front page is HXL M 040 N S but it is referred to as HXLO40 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 cjue M 8 USE OF SYMBOLES conces tedio o Se er d uU 8 GENERAL WARNINGS AND NOTES WHEN WORKING WITH THE HX UNIT nsee 9 INTRODUCTION cecid exxsus cu erben ee dor eerie intesa e eed x non ra Ex E 11 ABOUT THIS MANUAL c cee See et EU ec Pan Cen ete oU eec AAA oe LO on Ere Ee eee 11 PROCESS ANDINSTRUMENTATON Ss a dtt ttt te toties 12 2 2 1 Primary circuit components and TUNCUON s eodein 13 2 2 2 Secondary circuit components and function
24. 2x Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 33 high range p measurement range An low range fang t yA actual switching es 1 2 1 switching point temperature SPt OFF standard normally closed n c normally open normall iy losed normally open standard small hysteresis h05 hysteresis HuS standard hysteresis h 10 switching point hing p Figure 3 3 2 FTSA11 parameter hierarchy 24 hour support 4358 0 40 837 1150 Email vacon vacon com 34 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 normally 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 correc
25. 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 1is 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 HXL unit and the main drives 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 HXL unit and the main drives 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 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
26. 3 OverTempA A T1 gt T16 gt Figure 5 1 2 High temperature alarm on the NXP panel Malfunction Reasons for malfunction Correction measures The flow in the The customer filter Clean the filter secondary circuit is outside the HX unit MF21 too low refer to the P amp ID is clogged The plate heat exchanger e Clean the heat exchanger Refer to HX11 refer to the P amp ID is the cleaning instructions found in clogged on the secondary the HX unit folder that is supplied side with the unit Instructions on how to remove the plate heat exchanger are found in chapter 4 2 2 Heat exchanger The customer pump inthe Maintain or replace the customer circuit secondary circuit is pump malfunctioning and therefore not able to produce enough flow The temperature of Maintaining the HXunit e The temperature of the liquid in the the secondary circuit cannot solve the reason for secondary circuit inlet has to be 5 liquid is too high this malfunction 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 The regulating valve The 3 way valve V130 is Run the actuator calibration V130is malfunctioning and according to the instructions found malfunctioning therefore not directing in the HXunit manual that is enough flow through the supplied with the unit i e set the plate heat exchanger to actuator Dip s
27. 8 Xinglong Street SIP Suchun Industrial Square Suzhou 215126 telephone 86 512 62836630 fax 86 512 62836618 Naturno Italy Vacon S R I Via Zone Industriale 11 39025 Naturno sales companies and representative offices finland Helsinki Vacon Pic Ayritie 8 01510 Vantaa telephone 4358 0 201 212 600 fax 4358 0 201 212 699 Tampere Vacon Plc Vehnamyllynkatu 18 33580 Tampere telephone 4358 0 201 2121 fax 4358 0 201 212 750 australia Vacon Pacific Pty Ltd 5 66 74 Micro Circuit Dandenong South VIC 3175 telephone 461 0 3 9238 9300 fax 461 0 3 92389310 austria Vacon AT Antriebssysteme GmbH Aum hlweg 21 2544 Leobersdorf telephone 443 2256 651 66 fax 43 2256 651 66 66 belgium Vacon Benelux NV SA Interleuvenlaan 62 3001 Heverlee Leuven telephone 432 0 16 394 825 fax 432 0 16 394 827 brazil Vacon Brazil Alameda Mamor 535 Alphaville Barueri SP Tel 455 11 4166 5707 Fax 455 11 4166 5567 canada Vacon Canada 221 Griffith Road Stratford Ontario N5A 6T3 telephone 1 519 508 2323 fax 1 519 508 2324 china Vacon Suzhou Drives Co Ltd Beijing Branch A528 Grand Pacific Garden Mansion 8A Guanghua Road Beijing 100026 telephone 86 10 51280006 fax 86 10 65813733 czech republic Vacon s r o Kodanska 1441 46 110 00 Prague 10 telephone 420 234 063 250 fax 420 234 063 251 ger many Vacon GmbH Gladbecker Strasse 425 45329 Essen
28. 96 60 l min 50 60 l min 0 13 bar 1 3 bar 1 43 bar 2596 30 l min 75 90 l min 0 036 bar 1 3 bar 1 33 bar 096 0 100 120 l min 1 3 bar 1 3 bar gt Pressure drop varies between 1 3 bar 1 88 bar 75 FLOW 90 l min Plate heat Pressure drop Pressure exchanger plate heat drop 3 way route Flow Bypass route Flow exchanger valve Total pressure drop 7596 90 l min 096 0 0 3 bar 0 7 bar 1 0 bar 5096 60l min 25 30 l min 0 13 bar 0 7 bar 0 83 bar 2596 30 l min 50 60 l min 0 036 bar 0 7 bar 0 74 bar 096 0 7596 90 l min 0 7 bar 0 7 bar gt Pressure drop varies between 0 7 bar 1 0 bar 5096 FLOW 60 l min Plate heat Pressure drop Pressure exchanger plate heat drop 3 way route Flow Bypass route Flow exchanger valve Total pressure drop 50 60 l min 0 0 0 13 bar 0 33 bar 0 46 bar 25 30 l min 25 30 l min 0 036 bar 0 33 bar 0 37 bar 0 0 50 60 l min 0 33 bar 0 33 bar gt Pressure drop varies between 0 33 bar 0 46 bar 24 hour support 358 0 40 837 1150 Email vacon vacon com 62 vacon NOTES Tel 4358 0 201 2121 Fax 4358 0 201 212 205 head officeand production Vaasa Vacon Pic Runsorintie 7 65380 Vaasa firstname lastname vacon com telephone 4358 0 201 2121 fax 4358 0 201 212 205 production Suzhou China Vacon Suzhou Drives Co Ltd Building 11A 42
29. A11 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 44 vacon COMMI SSI ONI NG Diagram 3 4 1 Converting table for the FTSA11 flow switch PVC C Converting formula for the FTSA11 flow switch HXL 040 AISI x 1 4 y 14 7 where y FTSA11 display x flow l min HXL 040 PVC C x 1 4 y 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 brought 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 45 Before starting the drives
30. OMMI SSI ONI NG vacon 39 No condensation is allowed inside the main drive If condensation occurs the warranty is no longer valid 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 If 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 seco
31. X 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 58 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 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 solv
32. 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 REQUENCY ONVERTERS ea HXL040 PS01 2 Primary girncuit CUSTOMER INLET gt ean SSH l i OPTION SHUTOFF VALVE for CUSTOMER v205 DUTLET SESS SSS SSS SX XL040 PS01 1 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 temperature 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 temper
33. al 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 unit 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 21 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 The safety valve V120 marked red 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
34. anch Seberiniho 1 821 03 Bratislava Tel 4421 243 330 202 Fax 4421 243 634 389 spain Vacon Drives Ib rica S A Miquel Servet 2 P I Bufalvent 08243 Manresa telephone 434 93 877 45 06 fax 434 93 877 00 09 Sweden Vacon AB Anderstorpsvagen 16 171 54 Solna telephone 46 0 8 293 055 fax 446 0 8 290 755 thailand Vacon South East Asia 335 32 5th 6th floor Srinakarin Road Prawet Bangkok 10250 Tel 466 0 2366 0768 ukraine Vacon Drives Ukraine Branch 42 44 Shovkovychna Str Regus City Horizon Tower Kiev 01601 Ukraine Tel 4380 44 459 0579 Fax 4380 44 490 1200 united arab emirates Vacon Middle East and Africa Block A Office 4A 226 P O Box 54763 Dubai Airport Free Zone Dubai Tel 4971 0 4 204 5200 Fax 4971 0 4 204 5203 united kingdom Vacon Drives UK Ltd 18 Maizefield Hinckley Fields Industrial Estate Hinckley LE10 1YF Leicestershire telephone 44 0 1455 611 515 fax 44 0 1455 611 517 united states Vacon Inc 3181 Black Gap Road Chambersburg PA 17202 telephone 1 877 822 6606 fax 41 717 267 0140
35. ass 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 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 can be found in the Vacon NXP User s Manual that is supplied with P the cooling unit C p 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
36. ature 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 2 2 3 which removes air from the primary circuit without letting the water out The centrifugal pump PU11 black chrome part in Figure 2 2 3 circulates the primary circuit liquid 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 red and the instrume
37. ck down to 1 5 bar Close valve V162 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 added The HX control unit will generate a Low pressure alarm if the pre pressure is below 0 5 bar 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 24 hour support 4358 0 40 837 1150 Email vacon vacon com 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 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 Remove the hose from the valve V162 and replace it with a one 1 meter long hose Conn
38. d 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 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 safety val ve and therefore causing a leak If this happens the safety valve must be cleaned Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 25 10 11 12 Repeat this procedure until every frequency converter inverter is de aired that is open the valve V312 and V313 next and so on After all the main drive hoses have been de aired and closed open valve V140 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 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 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 ba
39. e 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 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 like
40. ect afunnel to the loose end of the hose 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 After all the corrosion inhibitor is added use the same jug to fill the HX11 all the way up with water When no more water will go into the HX11 then close the manual de airing valve V162 and remove the hose 26 vacon COMMI SSI ONI NG 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 27 3 2 STEP 2 ELECTRICAL PART Only qualified and authorized electricians are allowed to perform electrical work on the HX unit 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 suppl y 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 paman D Figure 3 2 3 3 2 2 Signal cables A signa
41. ected Disconnect the electrical cables from the pump Write down the order of the phases for later use Close the maintenance valves V140 and V160 and the valves inside the drive cubicle that is V310 V31x Refer to the P amp ID in Figure 2 2 2 or the project specific P amp ID if one is available Connect a hose to the drainage valve V302 and put the other end of the hose into a drain pit or a bucket It is recommended that the amount of liquid removed is measured to be able to calculate how much corrosion inhibitor if inhibitor is used must be added when refilling the unit 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 with the unit 24 hour support 4358 0 40 837 1150 Email vacon vacon com 48 vacon UNI T MAI NTENANCE 9 Open the valve V302 and let all the liquid come out Open the manual de airing valve V162 to speed up the process 10 Close V302 11 HXLO40 AISI Remove the pipe HXL040 PS01 1 from the unit marked in yellow in Figure 4 2 1 The AISI threaded connections can be opened with a box wrench HXL040 PVC C Remove the pipe HXLO40 P 001 1 from the unit marked in yellow in Figure 4 2 1 The PVC C threaded connect
42. elative 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 41 If the secondary circuit inlet liquid temperature is not temperature controlled by the customer there is a risk 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 reduce 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 on N 02 gt on N 0 3 off N 0 4 gt off N o 5 To be r
43. emperature 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 57 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 until 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 N
44. erefore directing too much flow through the plate heat exchanger 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 Reasons for malfunction Correction measures Run the actuator calibration according to the instructions found in the HX unit manual that is supplied with the unit i e set the actuator Dip switch 1 to On position If the actuator is not moving during this procedure it is broken and has to be replaced 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 A change of 1 C minute should not be exceeded 56 vacon TROUBLESHOOTI NG The FTSA11 refer to the P amp ID flow sensor with the analogical temperature outlet is malfunctioning The FTSA11 flow sensor with the analogical temperature outlet is broken Table 5 1 3 Low temperature fault detection Check the temperature by comparing the FTSA11 temperature with the secondary Circuit temperature indicator TI21 The t
45. hanics 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 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 Maintenance folder that is supplied with the unit Chapter 5 TROUBLESHOOTING includes fault tracing to he
46. he 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 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 3 The primary circuit is drained through the valves V301 and V302 refer to the P amp ID in Figure 2 2 2 2 HXLO40 AISI Disconnect the primary and secondary circuit connections marked violet in Figure 4 2 3 from the unit The connections can be opened with a box wrench HXLO40 PVC C The connections can be opened by hand or if needed use an oil filter remover used to remove the oil filter from cars Be careful not to TERT the connections Figure 4 2 3 TT marked violet in Figure 4 2 4 p n LA 7 E 3 Remove the two M8 nuts from underneath the heat exchanger Figure 4 2 4 4 Carefully pull lift turn out the HX11 Figure 4 2 5 24 hour support 4358 0 40 837 1150 Email vacon vacon com 50 vacon UNI T MAI NTENANCE Figure 4 2 5 5 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
47. he 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 1096 see example Example If you are using a Ch74 drive the nominal flow according to the NX Liquid drive manual is 105 l min The flow should then be set to nominal flow x 10 e Adjust the flow to 115 l min 105 x 1 1 that is 82 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 82 The value shown on the FTSA11 is somewhat irregular in the beginning e The setting point for FTSA11 should be set at the nominal required flow 1096 The nominal flow for a Ch74 is 105 l min therefore the switch point should be set to 95l min 105 x 0 9 From the Diagram 3 4 1 we can establish that 95 l min corresponds to 69 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 64 set point 69 5 hysteresis the FTSA11 flow switch will open the switch when the FTS
48. ication 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 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 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 ca
49. imary circuit and therefore only the liquid in the 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 4 Whenthe 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 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 6 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 val ve V160 change the plug O ring if necessary 8 Turn back the lever on valve V160 90 so that it points towards you 9 Thepressure in the primary circuit will decrease due to the water that is removed during this process Therefore water must be added through the filling valve V161 until the pressure on Tel 4358 0 201 2121 Fax 4358 0 201 212 205 UNI T MAI NTENANCE vacon 51 the pressure gauge P111 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 10 Due to the small amount of liquid removed during this process it is not neces
50. ions can be opened by hand If the connections don t open by hand then use an oil filter remover used to remove oil filters from cars to loosen up the connection Because of the risk of damaging the PVC C parts itis not recommended that any kind of metal pliers be used 12 Remove the pipe HXLO40 PS01 5 like shown Figure 4 2 2 using a suitable box wrench The pressure vessel safety valve pressure transmitter and pressure indicator are connected to this pipe Be careful not to damage these components The electrical cable going to the pressure transmitter must also be disconnected from the sensor head This can be done using a screwdriver with a star quad head Figure42 2 13 Disconnect the pump by removing the 4 bolts holding it to the HX unit frame and replace it with the new pump Be very careful not to damage the FTSA11 flow switch If necessary then remove the FTSA11 or the pipe it s connected to before removing the pump The cable which has a threaded socket going to the FTSA11 can be disconnected by hand Before removing the flow switch or the pipe drain that side of the primary circuit by connecting the drain hose to the valve V301 and letting out 3 litres of water 14 Connect the electrical cables to the new pump motor 15 Connect the pressure side pipe HXLO40 PSO1 1 and the suction pipe HXLO04O PSO1 5 Remember to reconnect the pressure transmitter cable 16 Close valve V162 a
51. l 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 13 cooling OK in and back from X1 terminal number 14 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 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 24 hour support 4358 0 40 837 1150 Email vacon vacon com 28 vacon COMMI SSI ONI NG 3 3 STEP 3 CONTROL UNIT SETUP 3 3 1 Basic setup The control unit appl
52. lculated 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 description Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 29 Changes Parameter Parameter description Default Custom Customer code setting settings Frequency to PU11 when PID 50Hz enabled pressure setting scaling PT11 pressure transmitter 10 bar high pressure setting scaling P2 10 4 PT11 pressure error low 0 5 bar 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 d transmitter high temperature setting scaling low temperature alarm high temperature alarm P2 10 10 FTSA11 temperature error 35 C ee Pere P2 10 11 Pump automatic changing 169 h e aS P2 11 8 Fieldbus outlet 7 P3 5 FV11 reference temperature 5 Table 3 5 1 Parameter list N Ui R R N R U Oje Y l Uw o H O o o O m p 24 hour support 4358 0 40 837 1150 Email vacon vacon com 30 vacon COMMI SSI ONI NG 3
53. le 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 When working with the HX unit together with the frequency converter also follow the Vacon NX Liquid Cooled Drive User s Manual safety instructions to prevent any accidents Any installation work on the HX unit must be done with power off The 2 power must not be reconnected before the installation work is complete El The primary cooling circuit can contain hot coolant over 450 C during 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 B during operation Release the pressure in the HX unit before performing maintenance Use safety goggles 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 flow and temperature control to the secondary circuit If the project specified flow and te
54. ling 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 Risk of damage Instructions on preventing possible damage to equipment Hot surface Instructions on preventing a possible minor hazard to persons or equipment Notification 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 358 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 the HX unit Do not open the drive section doors whi
55. lp 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 HXLO40 PSO1 green colour in the Figure 2 2 1 e Secondary circuit HXL040 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 the secondary circuit flow through the plate heat exchanger HX11 by adjusting the 3 way valve
56. ly broken and will need to be replaced Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TECHNI CAL SPECI Fl CATI ON vacon 59 6 TECHNICAL SPECIFICATION Depth Physical size without cubicle Width 305mm 507mm e Height 1907mm AISI304 1885mm PVC C e Depth 540mm 566mm Liquid connections e Primary circuit Rp 1 ISO 7 1 or DN25 DIN 2642 e Secondary circuit Rp 1 ISO 7 1 or DN25 DIN 2642 PN10 DIN 2633 PN16 Height Electrical supply 3 400VAC 50Hz or 3 440VAC 60Hz 16 A Other electrical connection mem r 24V auxiliary voltage between HX unit and main drive Option Fieldbus Profibus connection from the HX control unit to customer monitoring system Ambient conditions 45 450 C RH 5 96 no condensation allowed Pump CHI 8 25 If the ambient temperature is between 440 450 C it is allowed to use only 90 of the pump capacity Pressure ratings Primary circuit PN6 Secondary circuit customer piping PN10 Option PN16 for AISI 304 piping Temperature ratings Primary circuit 5 50 C Secondary circuit 5 502C Storage temperature rating 40 4609C All liquid must be removed from the unit during storage if the temperature is below O9C Cooling capacity 40 kW Rate of flow range 30 120 l min Empty weight of HX unit 120 kg AISI304 100 kg PVC C Maximum input power L8kW 24 hour support 4358 0 40 837 1150 Email vacon vaco
57. mperature 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 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 vacons 11 2 INTRODUCTION 2 1 ABOUT THIS MANUAL This manual provides information on commissioning and maintenance issues of the HXLO40 cooling unit The manual is intended to be used by Vacon s own personnel as well as the customer and or end user To follow the instructions in this manual the reader must have a reasonable knowledge of mec
58. n com 60 vacon TECHNI CAL SPECI FI CATI ON Supply pressure Supply distance primary circuit 0 3 bar 10 m 10 m straight pipe Liquid volume primary side 10 liter Concentration of glycol maximum 25 Maximum flow secondary circuit 1201 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 flow Elbows and other components will reduce the pipe distance Pipeline to frequency converter 10 m and back 10 m If customer pipelines are long size of the pipelines must be DN32 or DN40 The pressure before 3 or 2 way val ve must be at least 1 5 bar to prevent cavitations See cavitations diagram in Components Specifications and Maintenance Instructions n o 3 TAC Venta page 2 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TECHNI CAL SPECI FI CATI ON vacon 61 APPENDIX 1 Pressure drops on customer circuit HXLO40 100 FLOW 120 l min Plate heat Pressure drop Pressure exchanger plate heat drop 3 way route Flow Bypass route Flow exchanger valve Total pressure drop 100 120 l min 096 0 0 58 bar 1 3 bar 1 88 bar 7596 90 l min 2596 30 l min 0 3 bar 1 3 bar 1 6 bar 50
59. nd open valves V140 and V160 17 Refill and de air the pipes according to the instructions in chapter 3 1 5 and 3 1 6 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 UNI T MAI NTENANCE vacon 49 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 heat 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 t
60. ndary 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 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
61. ndary 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 24 hour support 4358 0 40 837 1150 Email vacon vacon com 36 vacon COMMI SSI ONI NG Acc to chart 3 3 1 gt Dew point is 36 C 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 regarding 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 q VACON LIQUID COOLED NX DRIVE HXL040 V can lo ja Secondary circuit sa e
62. ning the pump control switch to position 1 the black and white switch in Figure 2 2 7 The liquid starts to circulate in the primary circuit Run the pump for max 30 sec 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 the pump 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 5096 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 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 0 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
63. nts flow switch FTSA11 light blue pressure transmitter PT11 brown and the pressure gauge PI11 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 circuits 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 controls 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 byp
64. outside the HX 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 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 monitoring 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 400 24 V DC power supply and a terminal There are three switches attached to the electrical box door main power switch pump power switch 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 con
65. r 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 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 HXL unit is malfunctioning or if they break due to a customer and or end user parameter setup error the warranty is not valid 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 LS11 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 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
66. r 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 03 VACON LIQUID COOLED NX DRIVE HXL040 E ca yo c3 Secondary circuit maximum 23 C 28 C 5 C o e o E Primary circuit 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 seco
67. rrel 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 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 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 3 1 7 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 24 hour support 4358 0 40 837 1150 Email vacon vacon com 24 vacon COMMI SSI ONI NG 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 HXLO40 PSO1 See P amp ID in figure 2 2 2 1 Prepare the unit according to the recommendations in chapter 3
68. rticles 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 monthly 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 Checking 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
69. s supplied with the unit 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 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 20 of glycol can be added to the primary circuit system If more glycol than 20 is needed to keep the liquid from freezing then Tel 4358 0 201 2121 Fax 4358 0 201 212 205 NTRODUCTI ON vacon 17 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 pH fea Hardness ofliquid di 0
70. sary to add any corrosion inhibitor 24 hour support 4358 0 40 837 1150 Email vacon vacon com 52 vacon TROUBLESHOOTI NG 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 primary 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
71. 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 The secondary circuit liquid should not include any 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 24 hour support 4358 0 40 837 1150 Email vacon vacon com 18 vacon NTRODUCTI ON 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 temperat
72. so the 1 connector parts that are screwed on to the pipes on the primary and secondary connections This is because the total width is about 335mm when the connectors are on and the width door opening on e g Rittals 400mm cubicle is 312mm Figure 3 1 2 Figure 3 1 3 The material of the primary circuit and secondary circuit flanges is AISI 316 It is also possible to get PN16 flanges according to DIN 2633 AISI 304 to secondary circuit The wall penetration is made according to IP54 requirements 24 hour support 4358 0 40 837 1150 Email vacon vacon com 20 vacon COMMI SSI ONI NG 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 3 bar If the calculated pressure loss is higher than 0 3 bar then the HX unit will not be able to produce the maximum flow of 120 l min that is specified for the HXL040 If the 120 l min is required for the installed main drives e g one Vacon Ch74 but the HX unit has to be placed at a point were the calculated pressure loss for the added piping is more than 0 3 bar it is recommended that a HXL 120 with a maximum flow of 360 l min is used instead n vw ow n T a ajo LH ajo y al Secondary circuit E olo S olo JM inlet outlet Addition
73. 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 HXLO40 PSO1 unit Secondary circuit A circuit filled
74. t in the cubicle of their choice The unit is designed to fit inside a VEDA or Rittal 400x600x2000mm 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 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 eg 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 DN25 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 al
75. telephone 49 0 201 806 700 fax 49 0 201 806 7099 Vacon OEM Business Center GmbH Industriestr 13 51709 Marienheide Germany Tel 49 02264 17 17 Fax 49 02264 17 126 india Vacon Drives amp Control Plc Plot No 352 Kapaleeshwar Nagar East Coast Road Neelangarai Chennai 600041 Tel 491 44 244 900 24 25 italy Vacon S p A Via F lli Guerra 35 42100 Reggio Emilia telephone 439 0522 276811 fax 439 0522 276890 the netherlands Vacon Benelux BV Weide 40 4206 CJ Gorinchem telephone 431 0 183 642 970 fax 431 0 183 642 971 nor way Vacon AS Bentsrudveien 17 3080 Holmestrand telephone 447 330 96120 fax 447 330 96130 rumania Vacon Romania Reprezentanta Cuza Voda 1 400107 Cluj Napoca Tel 440 364 118 981 Fax 440 364 118 981 russia ZAO Vacon Drives UI Letchika Babushkina 1 Stroenie 3 129344 Moscow telephone 47 495 363 19 85 fax 7 495 363 19 86 ZAO Vacon Drives 2ya Sovetskaya 7 office 210A 191036 St Petersburg france telephone 7 812 332 1114 Vacon France fax 47 812 279 9053 ZAC du Fresne 1 Rue acquard BP72 production Chambersburg USA 3181 Black Gap Road Chambersburg PA 17202 TB Wood s India Pvt Ltd 27 E Electronics City Hosur Road Bangalore 560 100 India Tel 491 80 30280123 Fax 91 80 30280124 slovakia Vacon s r o Br
76. 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 pump PU11 refer to the P amp ID does 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 the 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 47
77. tions 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 towards you brown colour in Figure 3 1 8 e Valve V140 closed yellow colour in Figure 3 1 8 e Valves V301 V302 closed see P amp ID Figure 2 2 2 e Valves V310 31x open see P amp ID Figure 2 2 2 Figure 3 1 8 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 COMMI SSI ONI NG vacon 23 A hose must be connected to the manual de airing valve 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 e Connect a suction pump outlet 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 in the barrel Secure the connection with a hose clamp e Secure the drain hose to the ba
78. tly 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 that 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 35 Example 1 high ambient temperature If the customer and or end use
79. trol unit e Pump power switch black and white in Figure 2 2 7 positions 0 zero and 1 The contact breaker controls the power to the HX unit pump PU11 The pump can be started byturning the switch to position 1 and stopped by turning it back to position 0 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 three indication lights on the electrical box door The colours indicate the following e Red indicates that the HX 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 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 i
80. un 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 0 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 0 at opening in upper position off or increasing control signal giving a movement upwards 0 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 selection 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
81. ure 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 temperature 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 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 uni
82. vacon DRIVEN BY DRIVES Commissioning and Maintenance Manual HXL040 cooling unit SS Piping and PVC C Piping Version 3 0 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 system flow and setting the
83. 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 V310 3xx Any valves in the primary circuit added by the customer e he pumpis broken e Replace the broken pump 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 Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TROUBLESHOOTI NG vacon 53 commissioning stage e The FTSA11 setup values have been poorly during adjusted commissioning 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 Table 5 1 1 Flow fault detection 24 hour support 4358 0 40 837 1150 Email vacon vacon com setting the switch point of the FTSA11 54 vacon TROUBLESHOOTI NG 5 L2 Temperature alarms and shutoffs 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 indicator lights on the electrical box door are also active Check the following issues to solve why the alarm has been activated F1 8
84. witch 1 to On ensure a Satisfactory heat position If the actuator is not transfer between the moving during this procedure it is primary and secondary broken and has to be replaced circuit Tel 4358 0 201 2121 Fax 4358 0 201 212 205 TROUBLESHOOTI NG vacon 55 The FTSA11 setup values have been wrongly adjusted during commissioning e Check the project parameters refer Table 3 3 1 Parameter list and compare it with the actual 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 Ed 86 LowTemp A 1137165 Figure 5 1 3 Low temperature alarm on the NXP panel Malfunction The regulating valve e V130 refer to the P amp ID is malfunctioning 24 hour support 4358 0 40 837 1150 Email vacon vacon com The 3 way valve V130 is malfunctioning and th

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