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VP5000-DC/DC60, VP5000-DC/DC200-HL

Maintenance and repair

Last edited 2019-02-08
by Sonja Scheunert

Filename
VP5000_DCDC60_200-HL_installation_manual_v1-4en.docx

155 / 173

Maintenance and repair

Qualification of personnel

8.1

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

Spare parts and repair

8.2

No spare parts are available for the VECTOPOWER.

For repair , contact the customer service in Lorch, Germany. The manufacturer and customer
service address is found on the back of the cover sheet.

Commissioning after maintenance and repair

8.3

The procedure is the same as with normal commissioning. See chapter 6.4 Installation and
commissioning, Commissioning.

Summary of Contents for VECTOPOWER VP5000-DC

Page 1: ...VECTOPOWER VP5000 DC DC60 VP5000 DC DC200 HL Date of issue 2019 02 08 Version 1 4 Language English Read carefully before use keep for reference Installation manual...

Page 2: ...r service address ARADEX AG Ziegelwaldstra e 3 73547 Lorch Germany Goods acceptance Hohenstaufenstra e 34 73547 Lorch Germany Telephone 49 0 7172 9181 0 Fax 49 0 7172 9181 91 E mail service aradex com...

Page 3: ...after switch off 13 2 6 3 Hot surfaces 13 2 6 4 Operating noises 13 2 6 5 Weight 13 2 6 6 Coolant 14 Personnel requirements 14 2 7 2 7 1 Qualified electrician 14 2 7 2 Programmer 15 2 7 3 Installer 15...

Page 4: ...ersion of the digital inputs designed as low active input 55 3 8 3 ST1 digital outputs designed as low side switches 55 3 8 4 ST2 digital outputs designed as low side switches 56 3 8 5 ST2 and ST4 con...

Page 5: ...ding a precharging circuit for VECTOPOWER VP5000 DC DC200 HL 89 4 3 15 Protection against large currents when switching on 90 4 3 16 Measuring current ripple and voltage ripple 91 4 3 17 Using externa...

Page 6: ...e system 149 7 5 4 Maintenance work Checking electrical connections 150 7 5 5 Maintenance work Checking cooling connections 150 7 5 6 Maintenance work Checking the coolant 150 Behavior in the event of...

Page 7: ...cle number VECTOPOWER VP5000 DC DC60 VP5000 DC18W130 6C 1 22 04 50 VECTOPOWER VP5000 DC DC200 HL VP5000 DC18W140 6A 1 22 04 81 Table 1 Types and article numbers to which this manual applies Document h...

Page 8: ...Config The operating manual also contains troubleshooting information VEConfig software Software for initial commissioning and parameterization of the VECTOPOWER Data sheets manuals and the like for t...

Page 9: ...VEConfig software are mentioned they are written in pointed brackets for example File Exit Applicable standards and directives 1 7 Designation Title EN 62477 1 Safety requirements for power electronic...

Page 10: ...pplication requires electrical isolation between inputs and outputs It must not be used in potentially explosive areas either It must also not be used outside of the technical specifications The VECTO...

Page 11: ...n immediate life threatening danger Failure to observe this will lead to death or severe injury Instructions for avoiding the danger WARNING Type source of danger Danger warning for a dangerous situat...

Page 12: ...applicable to the location and type of application 2 6 1 Electricity Voltages up to 800 V can be present inside the VECTOPOWER short term voltage peaks can be even higher Touching any part inside the...

Page 13: ...F during operation In the HL version VECTOPOWER VP5000 DC DC200 HL a chopper IGBT is integrated for installing a brake chopper The external braking resistor can also heat up during operation Touching...

Page 14: ...qualified personnel are not aware of the dangers involved in handling the VECTOPOWER and may therefore endanger themselves and others All work must be carried out by qualified and trained personnel T...

Page 15: ...er has the technical training and experience to carry out non electrical engineering work This person knows all relevant standards and directives He or she can also identify dangers early and react ac...

Page 16: ...L_installation_manual_v1 4en docx 16 173 3 Product description Identification 3 1 3 1 1 Device designation The article numbers are structured according to the following scheme For the available types...

Page 17: ...ing plate The following information can be found on the rating plate of the VECTOPOWER The date of manufacture can be determined by ARADEX AG via the serial number Figure 2 VECTOPOWER rating plate Thi...

Page 18: ...ER VP5000 DC DC60 The following schematic diagram gives an overview of the hardware of the VECTOPOWER VP5000 DC DC60 Figure 4 VECTOPOWER VP5000 DC DC60 diagram The DC and DC connections shown on the l...

Page 19: ...m OUTPUT to DC boost converter Function Firmware software The VECTONUM Embedded firmware is parameterized using the VEConfig software Both are described in separate operating manuals Function Temperat...

Page 20: ...own on the left in the diagram are the connection to the DC link The higher voltage must be applied on this side during operation These connections are referred to as DC in this manual The OUTPUT and...

Page 21: ...apacitance in the DC link DC This increased capacitance in the DC link DC attenuates the voltage ripple which results from the PWM frequency of the power semiconductor and the control loop of the volt...

Page 22: ...precharging contactor 4A opens During operation the main contactor 4B is closed and the precharging contactor 4A is open Figure 6 Schematic diagram of precharging contactor 4A and main contactor 4B Th...

Page 23: ...enable can also be effected via the VECTOBUS system 3 2 4 Operating modes Buck converter boost converter During operation as a buck converter a higher input voltage is converted into a lower output v...

Page 24: ...60 VP5000 DC DC200 HL Product description Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 24 173 Figure 8 Application example buck converter ope...

Page 25: ...t is integrated Precharging at DC must be done externally Max 32 000 F Precharging resistor 11 ohms at 0 V and 25 C 6 ohms at 800 V and 25 C Internal capacitance on the output side OUTPUT 2 040 F 800...

Page 26: ...Maximum 90 of the actual DC link voltage DC but at least 20 V DC lower than the actual DC link voltage DC and not more than 750 V DC maximum DC 48 V DC to 199 V DC minus 20 V DC Example DC link DC 50...

Page 27: ...ending on input and output values Depending on the external network in the DC link DC and on the output side OUTPUT See chapter 3 3 4 Product description Technical data Electrical data voltage ripple...

Page 28: ...5 C 95 F and 45 C 113 F ambient temperature Max positive negative continuous current with derating on the output side OUTPUT 90 A DC at 650 V DC in the DC link DC 30 l min 8 gpm coolant at 65 C 95 F a...

Page 29: ...5000 DC DC200 HL Operation as buck converter Upp here means voltage peak to peak DC is typically below Upp 10 V OUTPUT is typically below Upp 10 V DC is typically below Upp 10 V OUTPUT is typically be...

Page 30: ...VECTOPOWER VP5000 DC DC200 HL Measuring range 20 mA Impedance 50 Accuracy 2 5 Table 10 Electrical data ST1 analog current input ST1 Digital input VECTOPOWER VP5000 DC DC60 VECTOPOWER VP5000 DC DC200...

Page 31: ...2 A each 2 2 Table 14 Interfaces 3 3 7 General data and environmental data VECTOPOWER VP5000 DC DC60 VECTOPOWER VP5000 DC DC200 HL Weight 33 kg 72 8 lb 75 kg 165 3 lb Ambient temperature 25 C to 45 C...

Page 32: ...rature 25 C to 65 C 13 F to 149 F Maximum cooling temperature without derating 35 C 95 F Maximum cooling temperature with derating 65 C 149 F Coolant flow rate at full load 30 l min 8 gpm at35 C 95 F...

Page 33: ...name VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 33 173 Cooling pressure drop Figure 9 Cooling system pressure drop Installation dimensions and distances 3 4 All dimensions in the drawings ar...

Page 34: ...2 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 34 173 3 4 1 Dimensions of the VECTOPOWER VP5000 DC DC60 Figure 10 Top view of the VECTOPOWER VP5000 DC DC60 Figur...

Page 35: ...nja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 35 173 Figure 12 Front view of the VECTOPOWER VP5000 DC DC60 with power and logical connections 3 4 2 Dimensions of the VECT...

Page 36: ...02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 36 173 Figure 14 Side view of the VECTOPOWER VP5000 DC DC200 HL with cooling connections Figure 15 Front view of...

Page 37: ...specified minimum distances apply to all the VECTOPOWER devices described here Observe the minimum distances to adjacent components It may also be necessary to maintain longer distances A longer dista...

Page 38: ...L Product description Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 38 173 Figure 16 Minimum distances VECTOPOWER front view Figure 17 Minimum...

Page 39: ...nd cables wires that are connected Observe the permissible bending radius for the respective cables wires AF 10 The distance is for a completely connected VECTOPOWER If the terminals of the power conn...

Page 40: ...ction designation Function Power connections DC DC link DC DC DC link DC OUTPUT Output DC OUTPUT Output DC Ground wire Logical connections ST1 CAN RS 232 hardware enable digital inputs outputs analog...

Page 41: ...200 HL Connection designation Function Power connections DC DC link DC DC DC link DC OUTPUT Output DC OUTPUT Output DC BR Brake chopper DC BR Brake chopper DC Ground wire Logical connections ST1 CAN R...

Page 42: ...of blueglobe TRI EMC cable glands Connection Recommended wire cross section and material Thread for cable gland Fastening thread of the wire terminal DC link DC 50 mm 1 AWG Cu M32 M8 Output OUTPUT 50...

Page 43: ...of the ground wire depends on the cross section of the supply line The supply line and the ground wire are made of the same material Supply line cross section in mm Minimum ground wire cross section...

Page 44: ...7 0 M25x1 5 20 0 16 0 16 0 11 0 16 0 10 0 M32x1 5 25 0 20 0 20 0 15 0 20 0 13 0 M40x1 5 32 0 26 0 26 0 20 0 28 0 20 0 M50x1 5 42 0 35 0 35 0 31 0 37 0 28 0 M63x1 5 54 0 46 0 46 0 41 0 46 0 37 0 M75x1...

Page 45: ...sories that the customer must provide Function This connection is the standard connection of the VECTOPOWER motherboard Application The following pins must be connected for the power supply Pin 1 KL_3...

Page 46: ...2 interface TxD 13 EN_CONF Digital input to allow a firmware update 14 CAN_GND CAN bus ground 15 COM_GND RS 232 interface ground 16 Digi_In1 Digital input no 1 17 Digi_In2 Digital input no 2 18 NTC GN...

Page 47: ...customer must provide Function application The pins 1 8 are used to connect an optional external precharging circuit for the VECTOPOWER VP5000 DC DC60 Pins 1 8 are not assigned on the VECTOPOWER VP500...

Page 48: ...Female Digi_Out6 Supply voltage of digital output 6 Yes Connect the positive pole of the main contactor here 7 Male Digi_In10 Digital input 10 Yes Connect the auxiliary contact here as a normally open...

Page 49: ...type A ST A 035 Connector design 17 pin type P Please note that the VECTOPOWER is delivered without mating connectors See chapter 3 13 Product description Accessories that can be obtained from ARADEX...

Page 50: ...In_SM Logic signal of the master output 9 Female VBIn_MS Logic signal of the master input 10 Female VBIn_MS Inverted logic signal of the master input 11 Female VBIn_GND Ground for the VECTOBUS master...

Page 51: ...ct description Accessories that can be obtained from ARADEX AG and chapter 3 14 Product description Accessories that the customer must provide Function application The ST4 connection is used to measur...

Page 52: ...WER VP5000 DC DC200 HL Required connections Power connections DC OUTPUT Supply and hardware enable ST1 pin 1 2 3 Software enable ST1 CAN bus or ST1 RS 232 interface or ST3 VECTOBUS Optional Voltage me...

Page 53: ...on_manual_v1 4en docx 53 173 Figure 24 Minimum configuration of the VECTOPOWER VP5000 DC DC60 variant with CAN bus and optional voltage measurement at ST4 Figure 25 Minimum configuration of the VECTOP...

Page 54: ...HL_installation_manual_v1 4en docx 54 173 Figure 27 Minimum configuration of the VECTOPOWER VP5000 DC DC200 HL variant with CAN bus Figure 28 Minimum configuration of the VECTOPOWER VP5000 DC DC200 H...

Page 55: ...designed as low active input The digital inputs in the VECTOPOWERare internally implemented as a low active input Figure 30 ST1 and ST2 digital inputs implemented as a low active input 3 8 3 ST1 digi...

Page 56: ...the digital outputs ST2 as low side switches 3 8 5 ST2 and ST4 connections for an external precharging circuit for VECTOPOWER VP5000 DC DC60 The VECTOPOWER VP5000 DC DC60 has no integrated prechargin...

Page 57: ...battery it is advisable to connect the precharging circuit to both OUTPUT and OUTPUT connections This is shown light in the illustration The controller for the external precharging circuit is connect...

Page 58: ...ntact of the main contactor Table 29 Logical connections ST2 for the external precharging circuit for the VECTOPOWER VP5000 DC DC60 Schematic diagram of the connections of the precharging contactor an...

Page 59: ...CAN_GND RS 232 Pin 11 COM1_TxD Pin 12 COM1_RxD Pin 15 COM_GND To force VECTOPOWER to start in bootloader mode pin 13 EN_CONF must be grounded This pin is queried when the device is switched on 3 8 7 S...

Page 60: ...control The pin VBIn_SM designates the signal output of the VECTOPOWER to the higher level VECTONUM control Figure 36 Wiring diagram for a VECTOBUS system ST3 Characteristic curves for current voltage...

Page 61: ...HL Product description Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 61 173 Figure 37 DC current characteristic curve as a function of the out...

Page 62: ...stic curve as a function of the output voltage for VP5000 DC DC60 3 9 2 VECTOPOWER VP5000 DC DC200 HL The following characteristic curves indicate the output voltage and output current under the follo...

Page 63: ...a Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 63 173 Figure 39 DC current characteristic curve as a function of the output voltage for VP5000 DC DC200 HL Figure 40 Output p...

Page 64: ...ion_manual_v1 4en docx 64 173 Characteristic curves for derating 3 10 The derating depends on the inlet temperature of the coolant and the selected DC link voltage DC 3 10 1 VECTOPOWER VP5000 DC DC60...

Page 65: ...08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 65 173 3 10 2 VECTOPOWER VP5000 DC DC200 HL Figure 43 Derating characteristic curve at 450 V for VP5000 DC DC200 HL...

Page 66: ...tput side OUTPUT The efficiencies at different output voltages OUTPUT and DC link voltages DC are considered Notes on the characteristic curves The losses depend on the DC link voltage DC the output v...

Page 67: ...nja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 67 173 3 11 1 VECTOPOWER VP5000 DC DC60 Figure 46 Efficiency characteristic curve at 100 V DC at OUTPUT for VP5000 DC DC60 F...

Page 68: ...2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 68 173 Figure 48 Efficiency characteristic curve at 300 V DC at OUTPUT for VP5000 DC DC60 Figure 49 Efficie...

Page 69: ...Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 69 173 Figure 50 Efficiency characteristic curve at 500 V DC at OUTPUT for VP5000 DC DC60 3 11 2 VECTOPOWER VP5000 DC DC200 HL F...

Page 70: ...9 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 70 173 Figure 52 Efficiency characteristic curve at 200 V DC at OUTPUT for VP5000 DC DC200 HL Figure 53 Efficie...

Page 71: ...9 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 71 173 Figure 54 Efficiency characteristic curve at 400 V DC at OUTPUT for VP5000 DC DC200 HL Figure 55 Efficie...

Page 72: ...ps for connectors ST2 ST3 ST4 ST2 ST3 Integrated chopper IGBT precharging circuit at OUTPUT buffer capacitor incl choke discharge unit at DC no yes Table 31 VECTOPOWER scope of delivery Accessories th...

Page 73: ...al VECTOPOWERs Crimping pliers for ST1 ST2 ST3 ST4 3 ST1 ST2 ST3 3 USB RS 232 connection cable Yes5 Yes5 USB CAN bus connection cable Yes5 Yes5 1 The size of the cable glands depends on the cables or...

Page 74: ...EMC cable glands Link to the Pflitsch homepage https www pflitsch de en cable glands tools 3 13 3 Cable lugs for DC OUTPUT BR ground wires and Nord Lock lock washers For a specific offer for your app...

Page 75: ...3 source Intercontec Material for mating connectors ST2 and ST3 consisting of Connector housing Insulating body E 17 female pins crimp contacts crimping pliers required 17 male pins crimp contacts Thi...

Page 76: ...he mating connector for ST4 For the specifications of the supplied crimp contacts see Chapter 3 14 5 Product description Accessories that the customer must provide Cable for ST1 Crimping pliers are re...

Page 77: ...ries For further accessories such as chokes and filters please contact our sales department Accessories that the customer must provide 3 14 3 14 1 Cables wires and terminals specification In general t...

Page 78: ...f up to at least 800 V DC Single core wires must be used The cable lugs must be suitable for the respective cross section of the wire ARADEX AG recommends the use of cable lugs for switchgear connecti...

Page 79: ...es it is also important to note the following The number of conductors per cable depends on the number of occupied pins The size of the conductors depends on the size of the respective crimp contacts...

Page 80: ...pective crimp contacts The crimp contacts are supplied with the mating connector The cable is not included in the scope of delivery Description Value Conductor cross section 0 5 1 5 mm Cu 16 21 AWG Cu...

Page 81: ...cklist and add any additional requirements necessary for your application Take the following into account when planning the system For further information see chapter General principles Standards dire...

Page 82: ...nd or OUTPUT Realize if necessary 3 2 2 3 2 3 3 8 5 4 3 13 4 3 14 Check whether further measures are required to damp the current ripple and voltage ripple at DC and OUTPUT Perform measurements If nec...

Page 83: ...T3 VECTOBUS interface 3 7 1 3 7 3 3 8 1 Connections At least DC OUTPUT the ground wire and ST1 must be connected and integrated 3 8 1 Table 43 Checklist for system integration Notes on system integrat...

Page 84: ...twisting Mechanical stresses in a vehicle for example are caused by vibrations during operation The surface of the VECTOPOWER can heat up to 95 C 203 F during operation The mounting plate must withst...

Page 85: ...n load variation 4 3 9 Providing a device or method to make sure that no voltage is present The VECTOPOWER is not equipped with an on off switch Plan suitable measures and procedures to disconnect the...

Page 86: ...rake chopper and the VECTOPOWER fulfill their functions as long as an enable is given from the hardware The following is required for a hardware enable ST1 pin 1 and pin 2 The supply voltage is presen...

Page 87: ...for example when starting a generator When used as a boost converter without a precharging circuit an uncontrolled current flow can occur during starting This current flow distorts the results of the...

Page 88: ...rrent must remain within the permissible limits when switched on If a precharging circuit is only required for precharging it is sufficient to set this up at DC This is shown dark in the illustration...

Page 89: ...cuit is required at the DC connection for operation as a buck converter A precharging circuit at DC is necessary if the VECTOPOWER is connected to an existing power supply in the DC link DC The curren...

Page 90: ...tion means that in the event of a voltage drop the contactors remain closed for some time before they are opened by VE If voltage is switched on during this time without an external precharging circui...

Page 91: ...pple Due to the wide range of possible applications ARADEX AG cannot make any general statements about the strength of the current ripple and voltage ripple for your specific application ARADEX AG rec...

Page 92: ...ries choke Measures for the output side OUTPUT If the measured ripple current from peak to peak is greater than 40 A ARADEX AG recommends using external capacitors Use an additional series choke to se...

Page 93: ...measurement signal cables and wires The cable shield must be connected to a ground wire at both ends Use EMC cable glands for the power connections DC OUTPUT and if required BR See chapter 3 13 2 Prod...

Page 94: ...are no Y capacitors installed in the VECTOPOWER itself Depending on the earthing concept of the devices in the DC link DC the DC potential can fluctuate around the earth potential when the power semic...

Page 95: ...Transport 5 3 CAUTION Risk of injury due to high weight Tilting or dropping the VECTOPOWERcan cause injuries such as crushing or bruising Only use lifting equipment that is suitable and approved for t...

Page 96: ...missible torque of 15 0 Nm 5 3 2 Storage Store the VECTOPOWER in accordance with the ambient conditions specified in the technical data Protect the VECTOPOWER from dust and dirt with suitable packagin...

Page 97: ...ackaging immediately to the transport company and the supplier Check the housing of the VECTOPOWER for visible external damage such as dents or cracks A VECTOPOWER with a damaged housing must not be p...

Page 98: ...use injuries such as crushing or bruising Only use lifting equipment that is suitable and approved for the weight e g forklifts lift trucks and lifting gear No persons or body parts may be under the s...

Page 99: ...t The VECTOPOWER has four crane eyes one at each corner of the housing Figure 65 Mounting points on the housing of the VECTOPOWER VP5000 DC DC60 3 Place the guide holes 2 of the VECTOPOWER on the two...

Page 100: ...fect condition The installation manual is available Suitable lifting gear and means of transport that can bear the weight of the VECTOPOWER are available See chapter 3 3 7 Product description Technica...

Page 101: ...ht e g forklifts lift trucks and lifting gear No persons or body parts may be under the suspended load during lifting transport or assembly Wear suitable personal protective equipment such as safety s...

Page 102: ...suitable lifting gear to lift it out The VECTOPOWER has four crane eyes one at each corner of the housing Figure 69 Mounting points on the housing of the VECTOPOWER VP5000 DC DC60 3 Place the VECTOPO...

Page 103: ...on and commissioning Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 103 173 Figure 70 Mounting points on the housing of the VECTOPOWER VP5000 D...

Page 104: ...s of the VECTOPOWER VP5000 DC DC60 Figure 72 Cooling connections of the VECTOPOWER VP5000 DC DC200 HL 1 Remove the stopples from the connections 2 Connect the cooling cables When connecting observe th...

Page 105: ...switchgear connections so that the pre assembled wires can be inserted through the EMC glands Tip Check whether the cable lug fits through the double nipple of the EMC cable gland The double nipple is...

Page 106: ...e The length a is the length from the center of the cable gland of the mounted cable lug to the end of the support surface of the spring in the EMC cable gland The measure a is composed of b Support s...

Page 107: ...h blueglobe TRI type for dimensions see chapter 3 6 4 EMC cable glands Dimension a 66 mm Prerequisites Required tools Sharp cable pliers to cut the wire Knife for stripping Crimp pliers Shrink tubing...

Page 108: ...e fine wires do not fan out during stripping 2 Strip the cable along the length a See figure 1 3 Cut off the cable shield so that the length b c remains See figure 2 Figure 76 Mounting the cable lug 4...

Page 109: ...cx 109 173 Figure 77 Crimping the cable lug 7 Crimp the cable lug See figure 5 Figure 78 Applying shrink tubing 8 Secure the wire terminal and the cable shield with shrink tubing See figure 6 Make sur...

Page 110: ...ling areas are on the flag f Figure 80 Example Plugging on an EMC cable gland Pflitsch blueglobe TRI type 11 Push the pressure screw with the globe sealing insert over the cable Here shown using the e...

Page 111: ...VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 111 173 12 Repeat the procedure for all wires of the power connections For the VECTOPOWER VP5000 DC DC60 for DC DC OUTPUT and OUTPUT connections Fo...

Page 112: ...m ARADEX AG Mating connectors for ST1 Additional tools if required Required material Shielded cable that is suitable for your application Mating connectors and crimp contacts for ST1 see chapter 3 13...

Page 113: ...VP5000 DC DC60 VP5000 DC DC200 HL Installation and commissioning Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 113 173...

Page 114: ...ssioning Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 114 173 Figure 81 Assembly manual for ST1 AMPSEAL series 770680 mating connector pages...

Page 115: ...ST3 Required material Shielded cable that is suitable for your application Mating connectors and crimp contacts for ST2 and ST3 see chapter 3 13 5 Product description Accessories that can be obtained...

Page 116: ...ted 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 116 173 Figure 82 Assembly manual for ST2 and ST3 mating connectors series 623 connector crown clamp for...

Page 117: ...pliers to cut the cable Stripping pliers or knife for stripping Crimp pliers see chapter 3 13 6 Product description Accessories that can be obtained from ARADEX AG Mating connectors for ST4 Required m...

Page 118: ...ert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 118 173 Figure 83 Assembly manual for ST4 mating connector series 923 connector crown clamping for crimp contacts page 1 source Interc...

Page 119: ...They are labeled on the housing Figure 84 Position of the electrical connections on the VECTOPOWER VP5000 DC DC60 Overview of the tightening torques of the screws for the housing cover Cable gland Tig...

Page 120: ...F81 80 0 Nm 708 1 inlb M85 WF95 100 0 Nm 885 1 inlb Source Pflitsch product catalog Link to the product page on the Pflitsch homepage Table 46 Tightening torques of EMC cable glands from Pflitsch blue...

Page 121: ...xternally the DC and OUTPUT connectors are equipped with the appropriate fuses All required cable wires are prepared Required tools Special tool for tightening the EMC cable glands with torque measure...

Page 122: ...n EMC cable gland from Pflitsch blueglobe TRI type 1 Screw the double nipple 2 with the thread a into the respective opening of the housing 2 Tighten the double nipple with the torque specified by the...

Page 123: ...er the cover 2 6 Open the screws for the covers 1 2 7 Remove the covers 1 2 Figure 88 DC and OUTPUT connections on the VECTOPOWER VP5000 DC DC60 Connect DC and OUTPUT The position of the connections i...

Page 124: ...e 2 on the housing Here shown using the example of an EMC cable gland from Pflitsch blueglobe TRI type 14 Tighten the pressure screw 6 with the torque specified by the manufacturer 15 Repeat the proce...

Page 125: ...rosswise with a tightening torque of 1 Nm 8 9 inlb 18 Put on the other cover 2 19 Tighten the screws for the cover 2 according to the same procedure and with the same tightening torques as for the fir...

Page 126: ...ghten the screw with 15 Nm 132 8 inlb Result The VECTOPOWER is electrically connected 6 3 9 Establishing electrical connections on the VECTOPOWER VP5000 DC DC200 HL Information All electrical connecti...

Page 127: ...n thread width across flats WF Tightening torque M12 WF17 5 0 Nm 44 3 inlb M16 WF20 8 0 Nm 70 8 inlb M20 WF24 10 0 Nm 88 5 inlb M25 WF30 15 0 Nm 132 8 inlb M32 WF36 15 0 Nm 132 8 inlb M40 WF45 20 0 Nm...

Page 128: ...d preparations The VECTOPOWER is mechanically mounted All live cable wires are de energized Externally the DC and OUTPUT connectors are equipped with the appropriate fuses The BR connection is equippe...

Page 129: ...e housing 2 Tighten the double nipple with the torque specified by the manufacturer 3 Repeat the procedure until all double nipples 2 are screwed into the device Figure 97 Example of a screwed in doub...

Page 130: ...in the housing When connecting observe the polarity of the respective connection 10 Place the cable lug 5 on the terminal block Figure 101 Installation examples Screw connections with wedge lock wash...

Page 131: ...is located between the globe sealing insert and the wire the IP protection class of the EMC cable gland is not achieved This can cause moisture and dirt to enter the device and cause damage When usin...

Page 132: ...hten the screws for the cover 2 according to the same procedure and with the same tightening torques as for the first cover 1 Figure 105 Example for the logical connections Connect the logical connect...

Page 133: ...h a newly designed system It is used to determine the specific parameters for the VECTOPOWER The following checklist indicates tests which are generally carried out before initial commissioning Furthe...

Page 134: ...been defined for establishing voltage free operation 4 3 9 Only with VECTOPOWER VP5000 DC DC200 HL Is the braking resistor connected to BR 3 5 2 3 6 2 4 3 12 Has the need for an external precharging...

Page 135: ...ct torque Are the screws secured against unintentional loosening 4 3 6 Is the IP protection class of the housing suitable for the application 3 3 7 Has sufficient space been provided around the VECTOP...

Page 136: ...s Required protective devices are present and functioning For example when the emergency stop button is pressed the power stage of the device is switched off To connect the CAN bus to the USB you need...

Page 137: ...ual Measure the current and voltage values at DC and OUTPUT Depending on the system and application further measurements and actions may be required before the system can function satisfactorily For i...

Page 138: ...recommended If the commissioning is for a series application an existing parameter set is transferred to another device The procedure is somewhat different from the one described here See chapter 6 4...

Page 139: ...ion processes Required protective devices are present and functioning For example when the emergency stop button is pressed the power stage of the device is switched off To connect the CAN bus to the...

Page 140: ...r which the parameter set and the modules were created 1 Follow the instructions in the VEConfig operating manual chapter Commissioning and parameterization of a device Commissioning Initial commissio...

Page 141: ...ated in VE These are specially adapted to a VE version If the VE version is changed the modules are not executed correctly and the I Os are not called or stored correctly These problems usually occur...

Page 142: ...tions may occur during operation Prerequisites The system is set up The VECTOPOWER is installed and integrated into the system All required power and logical connections are established All necessary...

Page 143: ...nstructions in the VEConfig operating manual chapter Commissioning and parameterization of a device Commissioning Commissioning for a series application CAUTION Danger from noise The VECTOPOWER genera...

Page 144: ...elay A relay with a changeover contact that can switch 800 V DC at the power contacts is recommended It is possible to connect another relay contact in series to achieve the rated voltage Table 51 Req...

Page 145: ...stored electricity in the capacitors Touching the power contacts may result in death or serious injury Wait at least 5 minutes after switching off the relay before opening the housing of the VECTOPOWE...

Page 146: ...d commissioning Last edited 2019 02 08 by Sonja Scheunert Filename VP5000_DCDC60_200 HL_installation_manual_v1 4en docx 146 173 Figure 111 Schematic sequence for forming Results The electrolytic capac...

Page 147: ...ents Programmer Switching on and off 7 2 During operation the VECTOPOWER is switched on and off via the higher level system in which it has been installed The VECTOPOWER does not have an on off switch...

Page 148: ...uring operation Keep heat sensitive objects and easily flammable substances at a safe distance Inspection and maintenance 7 5 Carry out the following work at regular intervals The intervals must be ad...

Page 149: ...VECTOPOWER Cabls wires pipes hoses and their connections Is there any damage such as chafing points or areas that have been burned Have connectors or connections come loose Is coolant leaking Immediat...

Page 150: ...Checking cooling connections Check the correct tightening torque of the cable glands See the manufacturer s technical data for the connections 7 5 6 Maintenance work Checking the coolant Check the coo...

Page 151: ...vice and the connection cables wires for visible damage See chapter 7 7 2 Operation Fault rectification Checklist for malfunctions 2 Keep away from visible damage Do not touch the damaged component Av...

Page 152: ...e mating connectors of the logical connections tight Are the crimp contacts and mating connectors installed correctly 6 3 8 6 3 9 6 3 5 6 3 6 6 3 7 Check the cable lugs of the power connections Are th...

Page 153: ...aborted firmware update for example Prerequisites A computer with VEConfig and a connection to the VECTOPOWER is present You can download the software from the ARADEX homepage To connect the RS 232 i...

Page 154: ...ual_v1 4en docx 154 173 6 Interrupt the connection to pin 13 EN_CONF at ST1 7 Reboot the VECTOPOWER Results The VECTOPOWER starts in normal mode The VECTOPOWER cannot be parameterized in bootloader mo...

Page 155: ...EX AG Please contact our customer service department The manufacturer and customer service address is found on the back of the cover sheet Spare parts and repair 8 2 No spare parts are available for t...

Page 156: ...ing on the system and application different steps are necessary Procedure 1 Disconnect the VECTOPOWER from the power supply 2 Wait at least 5 minutes until the residual voltage in the VECTOPOWER has d...

Page 157: ...the hot surfaces will cause burns After switching off wait until the surface has cooled down sufficiently Before touching the surface measure the surface temperature with a suitable measuring instrum...

Page 158: ...that can bear the weight of the VECTOPOWER are available See the technical data in chapter 3 3 7 Product description Technical data General data and environmental data Collection containers for escap...

Page 159: ...ng or bruising Only use lifting equipment that is suitable and approved for the weight e g forklifts lift trucks and lifting gear No persons or body parts may be under the suspended load during liftin...

Page 160: ...one jacket Multiple conductors that have no insulation around them would be classified as a single conductor Cable shield The cable shield is a conductive sheath of a cable or wire It protects the con...

Page 161: ...IGBT is a variant of a power transistor The IGBT switches the voltage to either the or of the output generating a current flow IGBT switching generates current ripples Logical connection The logical c...

Page 162: ...s VE is the name of the firmware of the VECTOPOWER Wire Wires and cables are used to transmit electrical energy and information for example as power cables or network cables A wire is a single conduct...

Page 163: ...1 0 1 1 Various changes V 1 3 SScheunert 2018 12 18 1 0 1 1 Chapter 3 3 1 Chapter 3 3 7 hight V 1 2 SScheunert 2018 11 30 1 0 1 1 Revised among others Chapter 3 6 3 8 4 6 3 4 supplemented Chapter 4 3...

Page 164: ...ional voltage measurement at ST4 53 Figure 25 Minimum configuration of the VECTOPOWER VP5000 DC DC60 variant with RS 232 interface 53 Figure 26 Minimum configuration of the VECTOPOWER VP5000 DC DC60 v...

Page 165: ...ounting points on the housing of the VECTOPOWER VP5000 DC DC200 HL 100 Figure 67 Crane eyes on the housing of the VECTOPOWER VP5000 DC DC60 102 Figure 68 Crane eyes on the housing of the VECTOPOWER VP...

Page 166: ...0 DC DC200 HL 129 Figure 99 DC and OUTPUT connections on the VECTOPOWER VP5000 DC DC200 HL 130 Figure 100 Connection of a power wire to the terminal block 130 Figure 101 Installation examples Screw co...

Page 167: ...ECTOPOWER VP5000 DC DC60 42 Table 21 Power connections for the VECTOPOWER VP5000 DC DC200 HL 43 Table 22 Cross section of the ground wire acc to 62477 1 43 Table 23 Data on EMC cable gland from Pflits...

Page 168: ...ightening torques of the housing cover screw fitting 126 Table 48 Tightening torques of cable lug screw fittings 127 Table 49 Tightening torques of EMC cable glands from Pflitsch blueglobe TRI type 12...

Page 169: ...voltage 14 Additional training for work on high voltage systems 14 Air circulation 37 84 Air humidity 31 Altitude above sea level 31 Ambient temperature 31 Area potentially explosive 10 Article number...

Page 170: ...Coolant 14 32 64 Cooling 39 76 84 104 158 Cooling connection DC200 HL 35 DC60 34 Crane eye 99 102 Creepage distance 106 Crimp contacts 78 79 Crimping pliers ST1 75 Crimping pliers ST2 ST3 75 Crimping...

Page 171: ...n 13 137 140 143 148 Heat 13 84 86 147 148 Heat unusual 150 HL version 13 I IGBT 160 161 Interference 93 Internal temperature 19 22 84 IP protection class 31 Isolation electrical 10 L Leakage current...

Page 172: ...56 87 89 Internal 22 Precharging contactor 57 PTC 22 R Rechargeable battery 160 Repair 155 Requirement legal 83 95 Resistor Braking resistor 13 21 86 147 148 Charging resistor 145 Discharge resistor...

Page 173: ...000_DCDC60_200 HL_installation_manual_v1 4en docx 173 173 U Upwards converter 160 Usage intended use 10 V VE162 VECTOBUS 19 23 49 83 Voltage Supply with 45 Voltage measurement 19 Voltage ripple 29 91...

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Aradex VECTOPOWER VP5000-DC, Installation Manual

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