10-ABB AC Drive LCU Description

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Training Solutions

1

ACS800 Liquid Cooling Unit


Training Solutions

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Objectives

Describe the connections of the cooling unit

Describe the functionality of the RMIO board

Locate the components of the cooling unit

Describe the use of the control panel for local controls and read actual values and alarms

Upon the completion of this module,you will be able to


Training Solutions

3

Liquid Cooling Unit

D

Presenter

Presentation Notes

The liquid cooling unit (LCU) is the cabinet which is marked “D” in the picture. The liquid cooling unit forms a closed-loop liquid cooling system for a complete drive. It consists of two separate circuits, an internal closed liquid circuit and an external liquid circuit. The heat from the drives is removed to the external liquid circuit through the heat exchanger. One or two centrifugal pumps are used to circulate the liquid.


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Dimensions

There are two LCU cabinet sizes The 300 mm wide, 70 kW cooling

power with single pump, about 100 l/min depending on the system pressure.

The 600 mm wide, 195 kW cooling power with redundant pumps, about 300 l/min depending on the system pressure.

600mm

(630mm as separate unit)

600mm

2000mm

195kW unit

Presenter

Presentation Notes

There is an external pipe connection to the side or bottom A 70kW unit can only be connected on the right side A 3-way valve is optional, outside the cabinet It can be controlled by RMIO or fieldbus in an LCU If the unit is connected to a cabinet line, one 15mm-wide side plate will do, but with a stand-alone unit, two side plates are needed. The frame is 600mm deep and if you add the 10mm-thick back wall and a 34mm thick door, it is 644mm altogether. The Marine-handle comes with an additional 74mm outwards from the door.


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PI-diagram of the 195kW unit

GA-102 GA-101

PIA202

PIA203

PI204

TIA201

External coolingreturn

Input fromExternal cooling

Internal coolingreturn from cabinets

Internal coolingto cabinets

V307V306

EA-100

PA-102

V301

V302

V303

V304 V305

V308

V309

V310

V311

V312 V313

V314

V315V316

Expansion tank

Pump

Presenter

Presentation Notes

The heat losses are transferred from the internal circuit to the external circuit in a heat exchanger. A centrifugal pump circulates the cooling liquid in the internal circuit. If the second pump is present the pump used can be alternated. The internal circuit is equipped with an expansion tank which damps the pressure variations due to liquid volume changes with temperature. The expansion tank is located at the inlet of the pump to provide stable inlet pressure for the pump. In 70 kW unit only one pump is included. GA-101Circulation Pump 1 GA-102Circulation Pump 2 EA-100Heat exchanger PA-102Expansion tank PIA-202Pressure transmitter, internal liquid from cabinets PIA-203Pressure transmitter, internal liquid to cabinets PI-204Pressure gauge, internal liquid to cabinets TIA-201Temperature sensor with high and low limit alarms V301Bleed valve at the top of the circuit V302Shut-off valve for PIA-202 V303Shut-off valve for the expansion tank V304Shut-off valve for pump 2 inlet V305Shut-off valve for pump 1 inlet V306Shut-off valve for pump 2 outlet V307Shut-off valve for pump 1 outlet V308Shut-off valve for PIA-203 V309Shut-off valve for PI-204 V310Drain / filling valve V311The heat exchanger can be bypassed by opening valve V311. V312The primary water can be restricted with valve V312. V313Bleed valve V314Bleed valve V315Drain valve for the expansion tank V316Internal cooling flow adjusting valve (Factory adjusted)


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Internal Cooling System Diagram

Air-to-Coolant Heat

Exchanger

A-to-C-

Heat Exch.

Air-to-Coolant Heat

Exchanger

Air-to-Coolant Heat

Exchanger

Air-to-Coolant Heat

Exchanger

A-to-C-

Heat Exch.

A-to-C-

Heat Exch.

Inlet and outlet valves

(a and b)

Drain and bleed valves

(c and d)

Presenter

Presentation Notes

The diagram shows how the coolant circulates in the supply, inverter and brake units of a drive system. The modules in each cabinet can be isolated from the main cooling circuit by closing the inlet (a) and outlet valves (b). Each cabinet is also equipped with a drain valve (c) and a bleed valve (d).


Training Solutions

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Component Layout

Internal liquidconnection

Expansion tank

Internal liquidconnection

Motor protective circuit breakers

External liquidconnection

RDCU

Heat exchanger

Base pan which is able tohold 4 to 6 liters of liquid

Bleed valve

Pressure gauge

Drain / filling valve

Pump

Presenter

Presentation Notes

In the picture, the location of the components in a two pump liquid cooling unit can be seen.


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Pumps

In a two-pump system, the selection of automatic alternation of the pumps is recommended

prevents drying out and ensures a longer life of the pumps

The pumps are prefilled with a water-glycol-inhibitor mixture

Without liquid the pump must not be rotated at all

Presenter

Presentation Notes

In a two-pump system it is possible to use an automatic alternation of the pumps (note the default setting of the Parameter 33.01 PUMP CHANGE TYPE). This ensures that the gaskets and seals in the pumps will not dry up. This leads to a longer life of the pumps. The pumps are prefilled with a water-glycol-inhibitor mixture, which prevents corrosion. This also enables a very short (< 5 s) run of the rotation direction check. Without liquid, the pump must not be rotated at all.


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Specifications

GRUNDFOS CRN 10-2 A-P-G-E-HQQE

Flow, Q: 10 m3/h

Head, H: 97 m max 117 m

Liquid temp.: –40 C to +180 C

Operation pres.: 16 bar / 120 C

Rotation direction: CCW

Motor: 50 Hz 60 Hz3 kW 4 hp380 - 415 V, D

660 - 690 V, Y

380 - 480 V, D

660 - 690 V, Y2900 – 2920 rpm

3470 – 3520 rpm

Presenter

Presentation Notes

The whole pump motor is installed in the vertical position. In the picture 195kW pump is presented.


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Temperature Sensor

Type: PT100

Installed in AISI316 sensor pocket

¼” thread

Presenter

Presentation Notes

The temperature sensor can be changed while the system is running.


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Pressure Sensor Sensor: Thick film on

ceramic

Measuring Range: 0...10 bar

Output/ Supply Voltage:4...20 mA/24 (9...30) VDC

Operating Temperature:Usupply = 24 VDC: -25 ...+85 C

Media Temperature ≤ 60 bar: -25 ...+85 C

Torque Moment Pressure Connection: 15...20Nm

PI

+

-

┴

Us positive supply

Us Negative supply

Earth

Presenter

Presentation Notes

Pressure measurements are an essential part of the liquid cooling unit operation.


Training Solutions

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Liquid Leakage Detector

Type: VVA 1

Installation in collecting trays

Protection class IP54

Presenter

Presentation Notes

The leakage detector is located in the bottom of the cabinet.


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Pressure Levels

Base pressure

recommended base pressure is from 100 to 150 kPa

maximum base pressure is 200 kPa

Operating pressure

base pressure + pressure created by the pump

maximum operating pressure is 600 kPa

Pressure gauge PI 204 monitors the system pressure

Base pressure of the expansion tank should be 40kPa

Presenter

Presentation Notes

Base pressure means the pressure of the system compared to the atmospheric pressure when the cooling circuit is filled with coolant. Operating pressure means the pressure of the system when the pump is running. Pressure is the base pressure plus the pressure created by the pump. Base pressure of the expansion tank means the air pressure of the tank when there is atmospheric pressure at the water side of the expansion tank.


Training Solutions

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Temperature Levels

Internal cooling system: Minimum inlet temperature: 5 C (41 F)

Maximum inlet temperature: 42 C (107 F)

Maximum temperature variation: 4 C ( 7 F)

Maximum temperature rise: 13 C (23 F); depends on mass flow.

External cooling system: Minimum inlet temperature: 5 C (41 F)

Maximum inlet temperature: 38 C (100 F)

Delta T max. 11 C (52 F)

Maximum temperature variation: 7 C ( 45 F)

Presenter

Presentation Notes

Internal and external cooling systems must not exceed the specified minimum or maximum limits.


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Temperature Control

ACS800-1007LC 195 kW

EA-100

V311Closed

V313

V312Fully Open

TIA201

V310

External coolingreturn

Input fromExternal cooling

TC

RDCU

RAIO

ACS800-1007LC cabinet

Temperature0 (4)…20 mA

Presenter

Presentation Notes

The temperature controller and valve are not included in the ABB delivery. The temperature value for the valve control can be taken from analogue I/O extension module RAIO.


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RMIO Board ConnectionsTerminal Block X21 RMIO board

1 VREF Reference voltage +10 V DC max. 10 mA

2 GND

3 AI1+ Analogue Input 1

Temperature TIA-201 0...10 V4 AI1-


Pressure PIA-202 (0)4 ... 20mA 6 AI2-


Pressure PIA-203 (0)4 ... 20mA 8 AI3-

9 AO1+ Analogue Output 1

Current source for TIA-201 0 ... 20 mA 10 AO1-

11 AO2+ Analogue Output 2

0 … 20 mA12 AO2+

Terminal Block X22

1 DI1 Pump 1 MCB

2 DI2 Pump 2 MCB

3 DI3 Leakage Detector

4 DI4 Fan Control Relay

5 DI5 Line Up Stand By

6 DI6 Start / Stop

7 +24 VDC + 24 VDC max. 100 mA

8 +24 VDC

9 DGND1 Digital ground

+ 24 VDC max. 100 mA10 DGND2

11 DI7 (DI IL) Reset

Terminal Block X23

1 +24 VDC Aux. voltage output 24 VDC, 250 mA or 130 mA if NLMD-01 option included2 GND

Terminal Block X25

1 RO11 Relay output 1

Pump 12 RO12

3 RO13

Terminal Block X26


Pump 22 RO22

3 RO23

Terminal Block X26


LCU Fault2 RO32

3 RO33

K1

N

L

K2

To cooledunits

F10

F1F2

VVA1K3

TIA-201

PIA-202

PIA-203

21

21

Presenter

Presentation Notes

If the ACS800-1007LC is fastened next to the drive cabinets at the factory, the RMIO board connections are factory installed. If the ACS800-1007LC is installed apart from the drive cabinets, connect digital inputs DI5 and DI6 and relay output RO3.


Training Solutions

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Instrument Diagram

Presenter

Presentation Notes

The following instruments are connected to analogue I/O channels A PT202 Pressure transmitter with a low limit alarm (PIA-202) for the inlet water A PT203 Pressure transmitter for the outlet water with a high limit alarm (PIA-203) A TE201 Temperature sensor with high and low limit alarms (TIA-201) An alternative connection for the Temperature sensor TE201 is the RAIO extension board


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Signals Signals connected to digital inputs from 1 to 4 generate

following alarm messages:

PUMP 1 MCB, The motor protective circuit breaker of pump 1 (F1) has tripped

PUMP 2 MCB, The motor protective circuit breaker of pump 2 (F2) has tripped

LIQUID LEAKAGE, Leakage sensor has detected liquid (DI3 =0)

FAN CONTROL RELAY , Fan control relay K3 is not active.Terminal Block X22

1 DI1 Pump 1 MCB

2 DI2 Pump 2 MCB

3 DI3 Leakage Detector

4 DI4 Fan Control Relay

5 DI5 Line Up Stand By

6 DI6 Start / Stop

7 +24 VDC + 24 VDC max. 100 mA

8 +24 VDC

9 DGND1 Digital ground

+ 24 VDC max. 100 mA

10 DGND2

11 DI7 (DI IL) Reset

F1

F2

VVA1K3

Presenter

Presentation Notes

If the parameter 33.01 CONTROL TYPE is set to Local, digital inputs 5 and 6 are used for starting and stopping the pumps.


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Outputs

Relay output 1 is used to start / stop pump 1

Relay output 2 is used to start / stop pump 2

If the parameter 33.01 CONTROL TYPE is set to Local, relay output 3 is used for fault indication to cooled units

Presenter

Presentation Notes

Relay outputs are used for pump control and fault indication.


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LCU Control Places

An overriding system can control ACS800-1007LC.

ACS800-1007LC is connected to other systems in the same way as drive units

See the drive or inverter unit hardware manual of your delivery

ACS800-1007LC can also be controlled locally via its digital inputs

Service controls via Control Panel (CDP 312R)

Presenter

Presentation Notes

The liquid cooling unit can be controlled from three different places; from the overriding system, local control from the digital inputs or service control from the panel.


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LCU Control Functions This table lists how some control functions are performed

Function is performed viaControl place selection (i.e. whether the ACS800-1007LC is controlled by an overriding system, via Control Panel or digital inputs)

Parameter 33.01 CONTROL TYPE

Parameter setting (including warning and trip limits)

The control panel or PC-Tool

Monitoring fault and warning messages, state information and measured signals

The control panel and an overriding system

Communication with an overriding system

Parameter 7.01 CONTROL WORD

Control of the ACS800-1007LC without an overriding system

Digital output RO3 and digital inputs DI5 and DI6. RO3 indicates a fault, DI5 indicates that the system is ready for start (when Par. 33.03 STAND-BY USE is set to YES), DI6 starts/stops the LCU.

Presenter

Presentation Notes

The table is a list of control functions and control places.

Documents

10-ABB AC Drive LCU Description