Vacon NXP HXL300 Cooling Unit Installation Manual

Commissioning and Maintenance Manual
HXL300 cooling unit, SS-Piping and PVC-C Piping

Version 2.0
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.
1. Check that delivery corresponds to your order.
2. Before starting commissioning, read carefully the safety instructions in Chapter 1 SAFETY.
3. Check that the specified installation location and ambient conditions comply with the
specifications. Refer to Chapter 2.3.2, Required ambient conditions.
4. Any customer made piping must be thoroughly flushed before connecting to the HX-unit.
5. Check that the liquid quality is approved. Refer to Chapter 2.3.1, Liquid quality.
6. Connect the mechanical and electrical couplings. Refer to Chapter 3.1.2, Pipe connections
and 3.2 STEP 2, ELECTRICAL PART.
7. Adjust the HX control unit parameters to match the specific project requirements. Refer to
Chapter 3.3.2, Application parameter list.
8. Perform a pressure test to the primary circuit and secondary circuit connections. Refer to
Chapter 3.1.4, Pressure test.
9. Add coolant to the circuits and de-air them according to the instructions in 3.1.6, Adding liquid
and de-airing.
10. 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 switch point of the FTSA11.
11. Do not energize the main drives before the HX-unit has been running for 30 min without any
alarms. Refer to 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 +358 (0)40 837 1150 Email: [email protected]
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 use the electronic version, you benefit from the following
features:
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.
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.
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vacon 5
VOCABULARY
Primary circuit,
HXL300-PS01
Secondary circuit,
HXL300-PS02
HX-unit
Drive
Main drive
HX control unit
A closed circuit filled with coolant that connects the drive to the HXunit.
A circuit filled with coolant that connects the HX-unit to the customer
piping.
HXL300 cooling unit (see the front picture of the manual). The
ordering code for the unit on the front page is HXL-M-300-N-S, but it
is referred to as HXL300 or just plain HX-unit for short.
Liquid cooled frequency converters or inverters that are connected to
the HX-unit.
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 0016 used in the HX-unit. The main drive concept might
also include other liquid cooled electrical equipment.
The air-cooled NXP 0016 drive that is placed inside the HX-unit for
the purpose of controlling and monitoring the primary circuit pump
and instruments.
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INDEX
1.
SAFETY ...................................................................................................................................8
1.1
1.2
2.
USE OF SYMBOLS ..............................................................................................................8

GENERAL WARNINGS AND NOTES WHEN WORKING WITH THE HX-UNIT ...................9
INTRODUCTION ....................................................................................................................10
2.1
2.2
ABOUT THIS MANUAL ......................................................................................................10

PROCESS AND INSTRUMENTATION ..............................................................................11
2.2.1
Primary circuit components and function .................................................................12
2.2.2
Secondary circuit components and function ............................................................12
2.2.3
Control unit .............................................................................................................13
2.2.4
Instruments and their function .................................................................................13
2.2.5
Control / supervision parameters.............................................................................13
2.2.6
HX-unit electrical box ..............................................................................................15
2.3
INSTALLATION SPECIFICATIONS....................................................................................15
2.3.1
Liquid quality ...........................................................................................................15
2.3.2
Required ambient conditions ...................................................................................16
3.
COMMISSIONING .................................................................................................................18
3.1
STEP 1, MECHANICAL PART ...........................................................................................18

3.1.1
General installation instructions...............................................................................18
3.1.2
Pipe connections.....................................................................................................18
3.1.3
Pipe flushing ...........................................................................................................19
3.1.4
Pressure test ...........................................................................................................19
3.1.5
Setting up the primary circuit ...................................................................................20
3.1.6
Adding liquid and de-airing ......................................................................................22
3.1.7
Adding corrosion inhibitor when using a fresh water system ...................................23
3.2
STEP 2, ELECTRICAL PART .............................................................................................23
3.2.1
Power supply ..........................................................................................................23
3.2.2
Signal cables...........................................................................................................24
3.3
STEP 3, CONTROL UNIT SETUP ......................................................................................24
3.3.1
Basic setup .............................................................................................................24
3.3.2
Application parameter list ........................................................................................26
3.3.3
Parameter description .............................................................................................27
3.3.4
General information about alarms and shutoff limits ................................................28
3.3.5
FTSA11 flow switch function ...................................................................................28
3.3.6
Temperature set points ...........................................................................................30
3.3.7
Temperature alarm settings ....................................................................................35
3.3.8
Low pressure alarm.................................................................................................36
3.3.9
Leak switch alarm specifications .............................................................................36
3.3.10
Three-way valve / two-way valve actuator settings ..................................................37
3.4
STEP 4, ADJUSTING THE FLOW ......................................................................................37
3.4.1
Starting the pump....................................................................................................37
3.4.2
Adjusting the system flow and setting the switch point of the FTSA11 ....................39
3.4.3
Checklist before starting main NX drives .................................................................40
4.
UNIT MAINTENANCE............................................................................................................41
4.1
GENERAL MAINTENANCE................................................................................................41
4.1.1
Renewing liquid in the primary circuit ......................................................................41
4.1.2
Maintenance schedule ............................................................................................41
4.2
MAINTENANCE BY COMPONENT ....................................................................................41
4.2.1
Pump ......................................................................................................................41
4.2.2
Heat exchanger.......................................................................................................43
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4.2.3
5.
TROUBLESHOOTING ...........................................................................................................46
5.1
6.
Pressure vessel ......................................................................................................45
Alarms and shutoffs ............................................................................................................46

5.1.1
Flow fault ................................................................................................................46
5.1.2
Temperature alarms and shutoffs............................................................................47
5.1.3
Low pressure alarm.................................................................................................49
5.1.4
Leak alarms ............................................................................................................50
TECHNICAL SPECIFICATION ..............................................................................................51
APPENDIX 1 .....................................................................................................................................53
8 vacon
1.
SAFETY
SAFETY
This chapter contains the general safety instructions, which you must follow when installing,
commissioning, operating and maintaining the HX-unit. Read the safety instructions before you start
to work on the unit.
1.1
USE OF SYMBOLS
For your own safety, please pay special attention to the instructions marked with the following
symbols:
Risk of death. Instructions on preventing a possible severe

hazard to persons or equipment.
DANGER
Risk of damage. Instructions on preventing possible damage

to equipment.
WARNING
HOT SURFACE
Hot surface. Instructions on preventing a possible minor

hazard to persons or equipment.
Notification
NOTE
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SAFETY
1.2
vacon 9
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 Users 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.
1
2
DANGER
3
4
5
WARNING
6
HOT SURFACE
7
8
1
2
3
NOTE
4
5
6
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 while the drives are online. If you
suspect a coolant leak in the drive section, shut down the drives and
disconnect the power to them before opening the drive section cubicle
doors.
When working with the HX-unit together with the frequency converter,
also follow the Vacon NX Liquid Cooled Drive Users Manual safety
instructions to prevent any accidents.
Any installation work on the HX-unit must be done with power off. The
power must not be reconnected before the installation work is complete.
The primary cooling circuit can contain hot coolant (over +50C) 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)
during operation. Release the pressure in the HX-unit before performing
maintenance. Use safety goggles.
The HX-unit must be positioned in a non-hazardous area where it cant
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 customers and/or end-users responsibility to provide flow and
temperature control to the secondary circuit. If the project specified flow
and temperature for the secondary circuit is not met the warranty is not
valid.
Retain these operating instructions during the entire life cycle of the HXunit.
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.
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INTRODUCTION
2.
INTRODUCTION
2.1
ABOUT THIS MANUAL
This manual provides information on commissioning and maintenance issues of the HXL300 cooling
unit. The manual is intended to be used by Vacons 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
mechanics and electrics.
WARNING
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 SERVICE 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 help the user identify and solve a problem
when the HX control unit (air-cooled Vacon NXP 0016) has an active alarm or fault.
Chapter 6 TECHNICAL SPECIFICATION
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INTRODUCTION
2.2
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PROCESS AND INSTRUMENTATION
The HX-units 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-users 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 customers and/or end-users responsibility.
Primary circuit, HXL300-PS01 (green colour in the Figure

2.2-1)
Secondary circuit, HXL300-PS02 (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 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
V162
AD11
HX11
S4
EV11
S1
HX_300-P001-4
V230
V301
V31x
V31x+2
V31x+4
HXA11
DRAIN DRAIN
V160
DRAIN
V180
V204
V203
MF22
HX_300-PS01-2, Primary circuit
S2 S3
V140
CUSTOMER
OUTLET
V205
V130
V31x+1
HXL300-PS01-1
PU11
PS02-2
V231
V170
PS02-3, Secondary circuit
V120
V202
V201
CUSTOMER
INLET
MF21
NXP0016 5
HXL300-PS01-3
PS02-1
DRAIN
V150
V232
V302
V31x+3
V31x+5
DRAIN
V161
FILLING
DRAIN DRAIN
Figure 2.2-2 Piping and instrumentation diagram (P&ID)
A larger P&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
instruments I/O (input/output) signals depending on the parameter settings. The HX control unit
interface panel allows the user to access these settings. The settings are found as editable
parameters in the HX control unit application. Apart from the leak sensor, LS11, which is placed on
the HX-unit floor, all instruments are placed in the primary circuit. Therefore the temperature and
flow monitoring in the secondary circuit is the responsibility of the customer and/or end-user.
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2.2.1
INTRODUCTION
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
Users 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 the highest
position on the primary pipe is the automatic de-airing valve (AD11,
violet part in Figure 2.2-3), which removes air from the primary
circuit without letting water out.
The centrifugal pump (PU11, red 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, orange)
and the instruments; 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 circuits temperature increases,
and vice versa.
The default valve regulation set point is +30C. If the
temperature drops below the set point, the 3-way valve starts to
reduce the flow through the plate heat exchanger and directs
more liquid through the bypass. Keeping the temperature as
high as possible in the primary circuit, with regards to the type
and load of the main drive, lowers the risk of condensation
inside the drive cubicle.
Figure 2.2-4
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INTRODUCTION
2.2.3
vacon 13
Control unit
The frequency converter, Vacon NXP-series (Figure 2.2-5), works as a control/supervision unit for
the primary circuits 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 Users Manual that is supplied with
the cooling unit.
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 Users Manual that is supplied with the HX-unit.
Figure 2.2-5
2.2.4
Instruments and their function
The flow switch FTSA11 (Figure 2.2-6) measures the speed of the flow inside the pipe. This flow
speed is shown as 0-100% 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 % on the FTSA11 can easily be modified to flow (l/min)
by using the converting formula in chapter 3.4.2, Adjusting the system flow and
setting the switch point of the FTSA11. Note that this converting formula is
correct only when using the FTSA11 high measuring range (30-300 cm/s) and
the original pipe inner diameter.
This flow meter (Uniflow SW600H-RSB-S4/T) is suitable for concentration of
maximum 25% glycol (75% water). If there is more glycol than 25%, a different
type of flow meter must be used (e.g. Uniflow SW600K-RSB-S4/T).
Figure 2.2-6
The other instruments found on the HX-unit are a pressure transmitter (PT11) and a pressure gauge
(PI11). The pressure transmitter sends a 4...20mA signal to the HX control unit. The control unit
application then converts this signal into pressure (bar). This pressure input is then used to
monitoring the pump inlet pressure. The idea is to give the user an early warning in case there is a
leak in the primary circuit somewhere outside of the HX-unit. The pressure gauge is used when filling
the primary circuit with liquid or when performing a pressure test on the unit. It can also be used to
get a pressure reference value if the pressure transmitter is thought to be malfunctioning.
2.2.5
Control / supervision parameters
When the HX-unit is working within the pre-set limits, it sends a cooling OK signal to the main
drives. The HX-unit supervision system is programmed to generate alarms to alert the user to a
malfunction in the unit. If the malfunction is more severe, the control unit removes the cooling OK
signal to the main drive and takes them offline.
14 vacon
INTRODUCTION
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 HX-unit 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 420mA signal, which is then sent to the actuator
(FV11) on valve V130.
The temperature parameters are adjusted at commissioning, depending on the maximum
temperature of the inlet secondary circuit liquid and the ambient temperature in the main drive area.
If the temperature drops below the set point in the primary circuit, the valve on the secondary circuit
decreases the amount of liquid going through the plate heat exchanger (HX11) in order to increase
the temperature in the primary circuit.
The temperature signal from FTSA11 also generates low- and high-temperature alarms and hightemperature 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 45C.
The leak switchs 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.
NOTE
The HX-unit provides no control of the temperature or flow in the secondary

circuit. It is strongly recommended that the customer and/or end-user add a
temperature and flow control on the secondary circuit piping outside the HX-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.
NOTE
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.
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INTRODUCTION
2.2.6
vacon 15
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.
Main power switch (red/yellow in Figure 2.2-7) is connected to

the motor protection relay. Positions 0 (zero) and 1. The
contact breaker controls the main power to the HX-unit,
including the HX control unit.
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
by turning the switch to position 1, and stopped by turning it
back to position 0.
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:
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.
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.
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 Users Manual that is supplied with the
unit.
2.3
2.3.1
INSTALLATION SPECIFICATIONS
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
contact your local distributor for additional information regarding a load reduction for the main drive.
16 vacon
INTRODUCTION
To prevent corrosion, add the corrosion inhibitor Cortec VpCI-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
pH
Hardness of liquid
Conductivity
Chlorine, Cl
Iron, Fe
Maximum particle size
Unit
dH
S/cm
mg/l
mg/l
m
Value
68
< 10
< 10
< 10
< 0,1
< 300
Table 2.3-1, Liquid quality
The secondary circuit liquid quality is not expected to be as clean as the primary circuit liquid bearing
in mind that clean liquid will prolong the time between cleaning the plate heat exchanger (HX11). If
the customer and/or end-user are using a natural source of water for the secondary circuit, one can
assume that the water will include some kind of organic sediment. This organic sediment will attach
itself to the plates inside the HX11 and therefore the 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 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 2 mm. 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 +5...+50C. It is the customer
and/or end-users responsibility to ensure that the temperature remains within this limit during
operation. The HX-unit is not built to withstand rain, sand- or snowstorms. If the HX-unit is positioned
outside it must be placed inside a cubicle that is equipped with temperature and humidity control.
There is no condensation allowed in the main drive. As the primary circuit piping is located inside the
same cubicle as the main drive it is vital that the primary circuit water temperature doesnt go below
the dew-point temperature. The primary circuit temperature is set accordingly to ambient
temperature and relative humidity. The most secure way of preventing condensation inside the main
drives is to keep the water temperature in the primary circuit higher than the ambient temperature.
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INTRODUCTION
vacon 17
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.
18 vacon
COMMISSIONING
3.
COMMISSIONING
3.1
STEP 1, MECHANICAL PART
Only qualified and authorized mechanics are allowed to perform mechanical

work on the HX-unit.
WARNING
3.1.1
General installation instructions
The HX-unit is delivered with a self-supporting frame as shown in Figure 3.1-1. Therefore the
customer can place the HX-unit in the cubicle of their choice. The unit is designed to fit inside a Rittal
1200x800x2000 mm (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 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
customers and/or end-users 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. Rittal, it must be positioned in
a non-hazardous area where it cant pose a threat to any main
systems or persons. If required, e.g. by national regulations or
generally acknowledged safety standards, additional protection
must be added to the unit, e.g. warning signs or additional
protective gear.
Figure 3.1-1
3.1.2
Pipe connections
Standard connections are DN80 flanges according to
DIN2642.
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.
Figure 3.1-2
Figure 3.1-3
The wall penetration is made according to IP54

requirements.
Figure 3.1-4
Figure 3.1-5
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COMMISSIONING
vacon 19
If the HX-unit isnt 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 1.0 bar. If the calculated pressure loss is higher than 1.0 bar then the HX-unit will not be
able to produce the maximum flow of 900 l/min that is specified for the HXL300.
HXL-R-300
Secondary circuit
inlet/outlet
Additional piping between

HX-unit and the main drives
Figure 3.1-6
If the HX-unit is delivered as a part of NX Liquid Cooled switchgear, therefore being in the same lineup, 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.
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.
NOTE
The safety valve V120 (marked orange in Figure 2.2-3) in the primary circuit is
set to 6 bar and has to be removed during the pressure test. The V120 valve
connection must be plugged during this pressure test.
During the pressure test the de-airing valve AD11 (Figure 3.1-7) has to be
closed. The threaded top plug must be replaced with tight plug or add an extra
seal under the top plug. After the test change back the originally plug, tighten to
end and then open 360 degrees.
To ensure that every site connection is sufficiently tightened, it is recommended that a

pressure test be performed for the primary circuit using pressurized air. The pressurized
air can be added through the liquid filling point of the unit, e.g. at valve V161 in the
primary circuit.
Figure 3.1-7
20 vacon
COMMISSIONING
DANGER
When performing a pressure test on the HX-unit, generally acknowledged 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.
DANGER
WARNING
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.
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 V160V162 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 positions before pre-filling the system are as following:
Valves V161...V162
open (violet colour in Figure 3.1-8)
Valve V160
lever down (brown colour in Figure 3.1-8)
Valve V140
closed (yellow colour in Figure 3.1-8)
Valves V230, V232
closed (orange colour in Figure 3.1-8)
Valves V301...V302
closed (see P&ID, Figure 2.2-2)
Valves V310...V31x
open (see P&ID, Figure 2.2-2)

Figure 3.1-8
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COMMISSIONING
vacon 21
A hose must be connected to the manual de-airing valve, V162 that is positioned on the highest
position on the primary pipe. 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.
Connect a suction pump outlet to the filling

valve V161. Secure the connections with a
hose clamp.
Connect the drain hose to the manual deairing valve V162 and put the other end of
the hose in the tank. Secure the connection
with a hose clamp.
Secure the drain hose to the tank so it wont

jump out during the filling and de-airing.
If corrosion inhibitors are used they can be

mixed, in the right amount, with the water in
the tank.
Depending on the system size there has to

be 90-550 litres of liquid in the tank.
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.
Connect the hose from the faucet to the

filling valve V161. Secure the connections
with a hose clamp.
Connect the drain hose to the manual deairing valve V162 and put the other end of
the hose into a drain. Secure the
connection with a hose clamp.
Secure the drain hose to the drain so it

wont jump out during the filling and deairing.
For adding corrosion

chapter 3.1.7.
inhibitor
read
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-users responsibility to check that the coolant mix can be
disposed of through the local sewer system.
22 vacon
3.1.6
COMMISSIONING
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 HXL300-PS01 (See P&ID in figure 2.2-2):
1. Prepare the unit according to the recommendations in chapter 3.1.5 Setting up the primary
circuit. Use valve V161 to regulate the flow during the filling and de-airing of the unit.
2. It is recommended that the flow, from the external pump or water supply system, is low in the
beginning of the filling process. This ensures that a minimum amount of air pockets is left in
the piping.
3. Close valve V161. Open the faucet or start the external pump depending on which filling
system you are using. Slowly open valve V161 to a 30-50% of maximum.
4. After a short while liquid 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 the rattling sound stops you should open the filling valve
V161 to 100%.
5. Keep the water flowing until you cant hear any more rattles, and then close the V161 valve.
Also close all the main drive valves, V310V3xx, both the inlet and the outlet valves.
Now it is time to de-air the drives. De-air the main drives one hose pair at a time, for example V310
and V311 (See figure 2.2-2):
6. Open valve V310 first then valve V311, this means that this path will be the only way for the
water to pass when you continue filling. Then open the filling valve V161. The water will again
come out from the hose connected to the manual de-airing valve V162. Keep the water
running until the rattling sound disappears, that is to say the air has been removed after
which the V161 filling valve is closed again.
7. Close the valve V310 first, and then the valve V311. This procedure will leave the specific
drive section filled with water.
WARNING
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 valve and
therefore causing a leak. If this happens the safety valve must be cleaned.
8. Repeat this procedure until every frequency converter/inverter is de-aired, that is, open the
valve V312 and V313 next and so on.
9. After all the main drive hoses have been de-aired and closed, open valve V140 and then
open the filling valve V161. After no more rattling can be heard due to air in the system, close
valve V162, the manual de-airing valve.
10. When valve V162 is closed the pressure (see at the PI11, pressure indicator) will start to rise
in the primary system. When the pressure in the primary system has raised to two (2) bar
close the V161 filling-valve. If you are using an external pump for adding the water it can now
be turned off.
11. Keep the two (2) bar pressure for about 10 minutes, letting the air bubbles in the system rise
up to the HX11 heat exchanger. Then open the manual de-airing valve V162 to let the
pressure back down to 1.5 bar. Close valve V162.
12. Now the system is almost completely de-aired. After this the pump 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 the rest of the de-airing instructions.
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COMMISSIONING
vacon 23
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).
1. The corrosion inhibitor should be added after all the main drives have been de-aired. Check
that all the main drive valves, V310...V3xx, are closed.
2. Lower the liquid level in the plate heat exchanger HX11 by opening the valve V301 (or V230)
and letting out 6 litres of water. This will lower the level inside the HX11 and make the
necessary space for the corrosion inhibitor.
3. Remove the hose from the valve V162 and replace it with a one (1) meter long hose.
Connect a funnel to the loose end of the hose.
4. Keep the funnel higher up than the heat exchanger HX11, and pour the corrosion inhibitor
into the HX11 using a jug. Refer to the Cortec VpCl-649 product description for calculating
the right amount of corrosion inhibitor
(refer to the technical specifications for
Cortec found in the Commissioning and
Maintenance folder).
5. After all the corrosion inhibitor is added
use the same jug to fill the HX11 all the
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.
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
3.2
STEP 2, ELECTRICAL PART
Only qualified and authorized electricians are allowed to perform electrical work
on the HX-unit.
WARNING
3.2.1
Power supply
The HX-unit uses 3 ~, 440 VAC (50Hz) or 3 ~, 440

VAC (60Hz), 16 A power supply. There are two
alternatives to bring the supply cables to HX-unit:
from under or from above (Figure 3.2-1, Figure 3.22).
Figure 3.2-1
Figure 3.2-2
24 vacon
COMMISSIONING
Connect the power supply to the motor protection relay (marked green in
Figure 3.2-3) in the HX-unit electrical box.
Figure 3.2-3
3.2.2
Signal cables
A signal cable must be connected between the main drive and the HX-unit
electrical box. It should be connected from the main drive basic I/O board
NXOPTA1, terminal number 6 or 12 (24V out) to the HX-unit X1 terminal
block (marked green in Figure 3.2-4) terminal number 16 (cooling OK in), and
back from X1, terminal number 17 (cooling OK out) to the main drive, terminal
number 14 (DI 4). For more information refer to the project specific electrical
diagram and to the Vacon NX Liquid Cooled drive Users 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.
3.3
STEP 3, CONTROL UNIT SETUP
3.3.1
Basic setup
The control unit application includes Flow control parameters that have to be modified for every
project. Primary circuit inlet temperature and primary circuit flow are two equally important quantities
that have to be monitored at all times. How to calculate the optimum flow is found in chapter 3.4.2,
Adjusting the system flow and setting the switch point of the FTSA11. How to correctly set up
temperature alarms and shutoffs is found in chapter 3.3.6, Temperature set points.
WARNING
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.
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COMMISSIONING
vacon 25
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 Users 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 Users Manual that
is supplied with the HX-unit.
26 vacon
3.3.2
COMMISSIONING
Application parameter list
The application parameters and their default values are shown in table 3.3-1. The project specific
parameters are calculated using the rules found in chapters 3.3.6 to 3.3.7. The values that are used
when setting up the HX-unit during commissioning should be written down in the Custom, settings
column. If the values must be changed at a later time the new value should be written in the last
column (Changes, customer). The parameters that must be edited at commissioning are marked
with a *) in the table 3.3-1. More information about these parameters is found in chapter 3.3.3,
Parameter description.
Parameter
code
P2.10.1 *)
P2.10.2
P2.10.3
P2.10.4
P2.10.5
P2.10.6
P2.10.7
P2.10.8 *)
P2.10.9 *)
P2.10.10 *)
P2.10.11
P2.10.12
P2.11.1
P2.11.2
P2.11.3
P2.11.4
P2.11.5
P2.11.6
P2.11.7
P2.11.8
P3.5 *)
Parameter description
Frequency to PU11 when PID
enabled
PT11 pressure transmitter low
pressure setting, scaling
PT11 pressure transmitter high
pressure setting, scaling
PT11 pressure error, low
pressure alarm
Inlet pressure supervision
FTSA11 temperature
transmitter low temperature
setting, scaling
FTSA11 temperature
transmitter high temperature
setting, scaling
FTSA11 temperature error, low
temperature alarm
FTSA11 temperature error,
high temperature alarm
FTSA11 temperature error,
high temperature shutoff
Pump automatic changing
sequence time
Fault delay setting
Fieldbus outlet 1
Fieldbus outlet 2
Fieldbus outlet 3
Fieldbus outlet 4
Fieldbus outlet 5
Fieldbus outlet 6
Fieldbus outlet 7
Fieldbus outlet 7
FV11 reference temperature
Default
setting
50Hz
Custom,
settings
Changes
(Customer)
0 bar
10 bar
0.5 bar
1
0 C
100 C
22 C
28 C
35 C
169 h
5s
1501
2
45
1511
1
4
5
37
25
Table 3.3-1, Parameter list
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COMMISSIONING
3.3.3
vacon 27
Parameter description
The table 3.3-1 includes parameters made to monitor and control the HX-unit. This chapter includes
short explanations on what the different parameters are used for.
P2.10.1 is the actual frequency that the pump motor will run at when producing the required flow in
the system. The speed of the pump frequency should be optimized according to the required flow
(see Chapter 3.4.2, Adjusting the system flow and setting the switch point of the FTSA11). This will
reduce the wear of the cooling system and therefore extend the MTBF (mean time before failure) of
the 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 0 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 PT11 low temperature, alarm limit. The default setting for this is set at 0.5 bar. More
information can be found in chapter 3.3.8, Low-pressure alarm.
P2.10.5 is a selection parameter that should be set to 1. If the PT11 pressure transmitter
malfunctions the parameter can be set to 0 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
0C.
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
100C.
P2.10.8 is a FTSA11 low-temperature, alarm limit. The default setting for this is set at 22C. 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 28C. 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 35C. This
means that the drive will shut down (cooling OK signal going to the main drives will be
disconnected) when the temperature is over 35C. The H XL unit will stay online (pump running).
More information can be found in chapter 3.3.7, Temperature alarm settings.
P2.10.11 the default setting is 169 hours. If the setting is between 1-168 (hour) the system will try to
change the pumps according to the time setting. This is to be used ONLY when operating the HXseries model HXM300 (double pumps). If this value is set to 0h, 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 HXL300.
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.
28 vacon
COMMISSIONING
P2.11.1-8 are parameters for the Fieldbus (Profibus) output. The customer and/or end-user can
choose any 8 of the NXP 0016 parameters to be sent out to a higher control system for external
monitoring. The default values are as follows:
-
P2.11.1, Primary side temperature from FTSA11 (C)

P2.11.2, HX pump motor speed (rpm)
P2.11.3, HX pump motor current (A)
P2.11.4, Primary side pump inlet pressure (bar)
P2.11.5, Output frequency to HX pump motor (Hz)
P2.11.6, Motor torque as % (+1000 equals +100%)
P2.11.7, Motor shaft power in % (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.
NOTE
3.3.4
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.
General information about alarms and shutoff limits
Apart from the standard NXP frequency converter alarms, found in the Vacon NXP Users 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 USERS MANUAL to change the parameters. Only

authorized personnel are allowed to make modifications to the parameters.
NOTE
The parameters and their settings can be found in chapter 3.3.2, Application parameter list. When
you change the default settings during commissioning, you should write down the new setting
including the date and your name to keep track of changes. Write down the new parameters to the
custom setting column of the flow control parameter table 3.3-1.
3.3.5
FTSA11 flow switch function
The flow switch is set to shut down the HX-unit if the flow does not meet the requirements, refer to
chapter 3.4.2, Adjusting the system flow and setting the switch point of the FTSA11. The unit
settings should be modified, during commissioning, through the switch interface panel. The default
setting for the switch is 50% (050).
Adjusting the FTSA11 flow switch:
1. Turn the pump power switch (the black and 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.
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COMMISSIONING
vacon 29
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
high range
"HI"
measurement
range
"rAn"
low range
"L0"
"2" 2
actual switching
point
"12"
"on"
"1" 2
switching point
temperature
"SPt"
"oFF"
(standard)
normally closed
"n.c."
normally open /
normally closed
"0-C"
normally open
"n.o."
(standard)
small hysteresis
"h05"
hysteresis
"HuS"
standard
hysteresis
"h10"
End
1 "3" 3
switching output
"S0"
Start
switching point
"SP"
actual switching
point
"123"
2x
2x
2x
Figure 3.3-2 FTSA11 parameter hierarchy
"1" 2 3
1 "2" 3
1 2 "3"
1 "2"
30 vacon
COMMISSIONING
Table 3.3-2 shows an example on how to set the flow switching point to 68.
Description
1. Change to setting mode
Push buttons
2.
1x
SP (switching point)
3.
1x
050 (actual switching point)
4. Display hundred digit
1x
5. Display ten digit
1x
050 (ten digit is flashing)
6. Increase ten digit
1x
060 (ten digit is flashing)
7. Display one digit
1x
060 (one digit is flashing)
8. Increase one digit
8x
068 (one digit is flashing)
9. Save new switching point
4x
068, SP, SO, 123 (actual

flow)
2x
,2x
,2x
Display
SO (switching output)
050 (hundred digit is flashing)
Table 3.3-2 Setting flow switching point
The settings on the FTSA11 should be the following:
3.3.6
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.
Temperature set points
If the primary circuit temperature isnt set correctly the main drive might malfunction because of
condensation. The default setting of the parameter P3.5 in the HX control unit application is 25C.
This means that the 3-way valve adjusts the flow in the secondary circuit to keep the primary circuit
liquid temperature at 25C (measured by the FTSA11 b efore the drives).
There are three factors that will affect the nominal temperature of the primary circuit:
Ambient maximum temperature at the main drive installation
Ambient maximum relative humidity at the main drive installation
Secondary circuit maximum temperature
All of these factors have to be taken into consideration when calculating the primary circuit
temperature set point.
If the humidity is high, condensation will occur in the piping inside the main drives and
therefore cause a malfunction.
If the ambient temperature is too high the load of the drive must be reduced.
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:
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Example 1, high ambient temperature

If the customer and/or end-user have a high ambient temperature, 35C, at the main drive that would
require the primary circuit temperature to be equal or higher than 35C. 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 = 35C
Maximum relative humidity = 60%
Acc. to chart 3.3-1 Dew point is @ 26C
It is recommended to use a 2C safety margin. Therefore the primary circuit temperature should in
this case be set to 28C (26C +2C). In this case no red uction 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 +35C
Maximum ambient relative humidity 60%
HXL300
VACON LIQUID COOLED NX DRIVE
Secondary circuit
maximum +23C
(28C-5C)
Primary circuit minimum +28C (26C+2C)
Figure 3.3-3 Example 1
The secondary circuit maximum temperature should always be 5C lower that the primary circuit
temperature to ensure a good thermal load transfer between the two circuits. In example 1 this
means that the secondary circuit should be between +5...+23C during operation. The 3-way valve in
the secondary circuit will then keep the primary circuit temperature at 28C regardless of the main
drive load.
Example 2, high ambient relative humidity
If the customer and/or end-user have a high ambient temperature, 40C, at the main drives that
would require the primary circuit temperature to be equal or higher than 40C. 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.
32 vacon
COMMISSIONING
It is recommended to use a 2C safety margin. Therefore the primary circuit temperature should in
this case be set to 38C (36C +2C). Using a 38C temp erature, instead of 40C, 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 Users Manual that is supplied with
the main drive.
HXL300
Secondary circuit
maximum +33C
(38C-5C)
The secondary circuit maximum temperature should always be 5C lower that the primary circuit
temperature to ensure a good thermal load transfer between the two circuits. In example 2 this
drive load.
Example 2b, reducing the ambient relative humidity
If the load reduction isnt 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 30C
and therefore give the possibility to run the main drive at full load.
Maximum relative humidity = 80% 50%
When adding the safety margin of 2C the primary circu it temperature can be set to 30C. In this
case a reduction of the maximum RH from 80% to 50%, by using a humidity remover, will allow the
primary circuit temperature to be set to 30C therefor e allowing the main drives to be run at full load.
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vacon 33

HXL300
Secondary circuit
maximum +25C
(30C-5C)
Figure 3.3-5 Example 2b
The secondary circuit maximum temperature should always be 5C lower than the primary circuit
temperature to ensure a good thermal load transfer between the two circuits. In example 2b this
drive load.
Example 3, high secondary circuit temperature
If the customer has an existing cooling system that delivers liquid at a temperature of 40C then the
primary circuit temperature has to be 5C warmer to ma intain a sufficient heat transfer between the
primary and secondary circuit. This means that the primary circuit temperature cannot be colder than
45C. This results in a significant reduction of the main drive load. In this case the only way of
increasing the load of the main drive is to lower the temperature in the secondary circuit by installing
additional coolers or a new cooling system with a lower water temperature. Next the dew point must
be checked.
Secondary circuit maximum temperature = 40C
Primary circuit maximum temperature = 40C (40C+5C)
Because the ambient temperature is beneath the primary circuit temperature there is no risk of
condensation in the main drive.
34 vacon
COMMISSIONING

HXL300
Secondary circuit
maximum +40C

Dew-Point chart for ambient temperatures between +10..+50 @ 1013 mbar
10C
100
15C
20C
25C
30C
35C
40C
45C
50C
95
90
85
80
Relative humidity, %
75
70
65
60
55
50
45
40
35
30
25
20
2
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
Primary circuit water temperature, C
Chart 3.3-1 Dew-point chart
No condensation is allowed inside the main drive. If condensation occurs the

warranty is no longer valid.
WARNING
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COMMISSIONING
vacon 35
Note that some Vacon liquid-cooled drives have a maximum ambient temperature of 40C that
would make a scenario with an ambient temperature over 40C 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 secondary circuit and the plate heat exchanger can be insulated before
delivery.
3.3.7
Temperature alarm settings
The temperature alarm levels depend on the primary circuit temperature set point. Refer to chapter
3.3.6, Temperature set points.
The over temperature alarm
Activates a function that will activate the yellow indicator light on the HX-unit electrical box.
The value is set to 3C higher than the primary circuit temperature set point. The default
setting of the high-temperature shutoff is 28C.
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
Activates a function that will shut down the drives but will keep the HX-unit running, is set to
10C higher than the primary circuit temperature set p oint. The default setting of the hightemperature shutoff is 40C.
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 of a sudden change in
the primary circuit for example if the flow in the secondary circuit for some reason is stopped.
36 vacon
COMMISSIONING
The low temperature alarm

Activates a function that will activate the yellow indicator light on the HX-unit electrical box.
The parameter is set to 3C lower than the primary cir cuit temperature set point. The default
setting of the high-temperature shutoff is 22C.
When this 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 35C has bee n calculated for a specific installation. The
temperature parameters should be adjusted the following way:
The primary circuit temperature set point (parameter P3.5) is set to 35C
New over-temperature alarm value (parameter 2.10.9)
New low-temperature alarm value (parameter 2.10.8)
New over-temperature fault value (parameter 2.10.10)
38C
32C
45C
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
Users Manual that is supplied with the HX-unit.
3.3.8
Low pressure alarm
The function of the pressure sensor placed on the pump suctions side is to give the user a warning
of low pressure before the FTSA11 flow switch generates a sudden unwanted shutdown. If there is a
leak in the primary circuit, outside of the HX-unit, the pressure starts to reduce in the system. The set
point for the pressure sensor is 0.5 bar, so if the pressure on the primary circuit suction side goes
under 0.5 bar the yellow indicator light on the electrical box will activate. The correct system prepressure is found in the chapter 3.1.6, Adding liquid and de-airing.
WARNING
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 Users
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 HXunit due to a leak in the unit. If there is condensation inside the HX-unit, the leak switch can generate
false leak alarms.
NOTE
Note that no condensation is allowed. However, if the relative humidity within the
cubicle is high and the ambient temperature is higher than the secondary circuit
inlet temperature, condensation will occur on the secondary circuit piping.
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COMMISSIONING
vacon 37
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 10C and the a mbient relative humidity inside the HXunit cubical is 25% with a temperature of 20C, conden sation 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 25C 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:o 2 => on
N:o 3 => off
N:o 4 => off
N:o 5 => To be run once at on so that the valve actuator finds min and max movement values, then
off.
Detailed description about DIP-switch positions:
N:o 1: Selection of control signal type Y. The control signal might either be a voltage level [V] (off)
or a current level [mA] (on).
N:o 2: Input control signal operating range. The input signal can either start at 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 (ADJ).
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 nonvolatile memory i.e. the positions are not lost when power supply is lost. When the calibration
sequence is finished the actuator halts until the switch is reset to OFF position (OP). OP is the
position of the switch at normal control.
3.4
3.4.1
STEP 4, ADJUSTING THE FLOW

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:
38 vacon
WARNING
COMMISSIONING
The pump 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.
1. Open the maintenance valves for the main drives (V310 to V31x) that are to be used.
2. Check that the valves V140 is open and that V160 has the lever turned downwards.
3. Check that the valve V161V162, V230 and V232 is closed. And that the pre-pressure is at
1.5 bar.
4. If the customer has added some valves these must also be in checked.
5. Check that there are no visible leaks.
6. 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.
7. 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.
8. Start up the pump PU11 by turning 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.
9. 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.
10. Add water to get the pressure back up to 1.5 bars. Then start the pump again and leave it
running.
11. The LED-display on the FTSA11 should register that there is flow in the system. If not, stop
the pump and re-check that all valves are open, e.g. in the drive section, in the HX-unit and if
there is piping/valves made by customer in the primary circuit then check them also. The flow
switch is set to 50% as default and has a 5 second delay (the 5 second delay is programmed
into the HX control unit application). What this means is that the flow has to get over the 50%
limit within 5 seconds of starting the pump, or the HX control unit will shut down the pump.
12. 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.
13. Check that all valves except V161V162, V230, V232 and V301V302 are open. If the
pump does not stay online after a new de-airing, try to temporarily lower the flow switching
point for the FTSA11 to 10% (50% 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.
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COMMISSIONING
vacon 39
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.
3. 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 the
system flow:
1. Start up the pump and run it at 50 Hz, which is the default value in the HX control unit
application.
2. Check the actual flow speed in percent from the flow switch FTSA11 and convert it into l/min
by using the converting formula.
3. Adjust the frequency of the pump to match the required total nominal flow + 10% (see
example).
Example: If you are using 6 x Ch74 drive, the nominal flow according to the NX Liquid drive manual
is 630 l/min. The flow should then be set to nominal flow x 10%.
Adjust the flow to 693 l/min (630 x 1.1) that is 68% according the converting formula, by
changing the frequency parameter P2.10.1 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 ~68%. The value shown on the FTSA11 is
somewhat irregular in the beginning.
The setting point for FTSA11 should be set at the nominal required flow -10%. The nominal
flow for two Ch74 is 630 l/min, therefore the switch point should be set to 567 l/min (630 x
0.9). From the converting formula we can establish that 567 l/min corresponds to 56% 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.
If the actual flow goes under 51% (set point 56% - 5% hysteresis), the FTSA11 flow switch
will open the switch (when the FTSA11 is set to normally closed, N.C). If the alarm
disappears within 5 seconds, the control unit application filters out the alarm. If the alarm is
still active after 5 seconds, the cooling OK signal to the drives is disconnected, and both the
HX-unit pump and the drives shut down.
Converting formula for the FTSA11 flow switch:
HXL300 AISI
x = 10.2* y
(
y = x / 10.2)
, where y = FTSA11 display (%)

x = flow l/min
y = x / 8.3)
, where y = FTSA11 display (%)

x = flow l/min
HXL300 PVC-C
x = 8.3 * y
(
40 vacon
3.4.3
COMMISSIONING
Checklist before starting main NX drives
After the de-airing, when the control unit setup and the flow adjustment are performed and the HXunit 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.
Before starting the drives:
1. Check that the HX-unit flow and temperature are within the given parameter values (no
alarms).
2. Check that there is no air left in the plate heat exchanger by carefully opening the manual deairing valve V162 and letting out a small amount (about 1 centilitre) of water.
3. Check that the PI11 pressure gauge is at about 1.5 bar.
4. Check that the maintenance valves to the converters (in use) V310V31x are open.
5. Check that the flow (refer to FTSA11 converting formula above) is according to the
connected converter requirements.
6. Check that the primary circuit temperature is according to the setup value.
7. 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 HXunit 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.
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UNIT MAINTENANCE
4.
UNIT MAINTENANCE
4.1
GENERAL MAINTENANCE
4.1.1
vacon 41
Renewing liquid in the primary circuit
The liquid in the primary circuit should be renewed once every 5 years. The liquid in the primary
circuit will be contaminated with particles from the different units and therefore the conductivity of the
liquid will increase. When the conductivity of the liquid increases the risk of electrochemical reactions
between the different alloys in the primary system also increases. Changing the liquid in the circuit
every 5 years will reduce the risk of malfunction due to corrosion.
4.1.2
Maintenance schedule
There are a few systematic maintenance tasks that have to be followed to ensure a trouble free
operation of the HX-unit. They are presented in the diagram below:
Once a month
Air
Checking / adding the
expansion vessel pre-pressure Nitrogen
Changing the primary circuit liquid
Monthly inspection
Diagram 4.1-1 Maintenance schedule
Once a year
x
Every 2 years Every 5 years

x
x
The monthly inspection includes the following tasks:

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.
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.
Check that the FTSA11 flow switch LED display is reading the same value as lasting the
previous month. If the flow switch is showing <5% reduction of the installed value (at
commissioning) then refer to chapter 5.1.1, Flow fault for advice.
Check the temperature of the primary circuit by pressing the button on the FTSA11 marked
once. Check the temperature value with the value set at commissioning. Press it once more
to go back to reading the flow percentage.
The indicator lights on the HX electrical box should be monitored at all time. If the HX-unit is placed
at a position were it isnt 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
isnt 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
4.2.1
MAINTENANCE BY COMPONENT
Pump
The pump PU11 (refer to the P&ID) does not require regular service. During the life cycle of the HXunit, 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.
42 vacon
UNIT MAINTENANCE
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, +60 C) may be present in the primary

cooling circuit. The coolant consists of liquid, propylene glycol and corrosion
inhibitors, depending on the project. Glycol and corrosion inhibitors are
damaging for the eyes. If you get coolant in your eyes, on your skin, or in your
mouth, seek medical advice. Use safety goggles.
WARNING
HOT SURFACE
To change a pump:
1. Check that it is safe to turn off the drives connected to the HX-unit, and that there is enough
time reserved for the maintenance.
2. Prepare the HX-unit for liquid filling by connecting a hose to the filling valve (V161). Read
Chapter 3.1.6, Adding liquid and de-airing before continuing.
3. Take the main drives connected to the HX-unit offline, according to the Vacon NX Liquid
Cooled Users Manual.
4. 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.
5. Check that there is no power coming to the pump by removing the cover of the pumps
electrical connection box and measuring the voltage. No work on the unit is allowed when the
power is connected.
6. Disconnect the electrical cables from the pump. Write down the order of the phases for later
use.
7. Close the maintenance valve V140, and the valves inside the drive cubicle, that is,
V310V31x. Turn the lever on valve V160 90 so that i t points towards you (make sure, that
the plug is in place). Refer to the P&ID in Figure 2.2-2 or the project specific P&ID if one is
available.
8. Connect a hose to the drainage valve V302 (or V232) 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.
NOTE
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.
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UNIT MAINTENANCE
vacon 43
9. Open the valve V302 (or V232) and let all the liquid come out. Open the manual de-airing
valve V162 to speed up the process.
10. Close V302 (or V232).
11. Remove the bolts and nuts from the pump motor flange.
Therefore leaving the pump housing in place (Figure 4.21).
12. Lift out the pump from the HX-unit. Note the pump weight
is about 70kg. It is recommended that there are two
persons present when the pump is removed.
13. Perform the necessary maintenance on the pump and
reconnect the pump to the pump housing. Or simply
replace the pump if a spare pump is available.
14. Connect the electrical cables to the (new) pump motor.
15. Close valve V162 and open valves V140 and V160.
16. Refill and de-air the pipes according to the instructions in
chapter 3.1.5 and 3.1.6.
Figure 4.2-1
There are replacement parts available if there is a leak (e.g. shaft seal), or if the pump is not able to
keep sufficient pressure. Refer to the technical specifications of the pump for the replacement parts.
The specifications can be found in the end of the Commissioning and Maintenance folder that is
supplied with the HX-unit.
4.2.2
Heat exchanger
The heat exchanger does not need regular service. If the primary circuit temperature is too high
(high-temperature alarm is active) and the 3-way valve directs all the liquid through HX11 (by-pass
line closed), the flow is too low in one of the circuits or the temperature in the secondary circuit inlet
is outside the defined parameter values. If the flow in the secondary circuit is too low, there may be
some biological residue clogging the heat exchanger.
Because the primary circuit is filled with clean liquid, it is unlikely that the primary circuits 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 the secondary circuit is too low, the
HX-unit should be shut down and the heat exchanger replaced. The dirty heat exchanger should be
cleaned according to manufacturers instructions and placed in storage for the next time HX11 needs
to be changed.
44 vacon
UNIT MAINTENANCE
The HX11 can, if needed, be removed without removing the HX-unit

from the cubicle:
1. Drain both the primary circuit and the secondary circuit. The
secondary circuit is drained through the V231 valve (marked
yellow in Figure 4.2-2). The primary circuit is drained through
the valves V230 and V232 (marked magenta in Figure 4.22).
2. Drain the expansion vessel, EV11. See instructions in
chapter 4.2.3, points 1 to 3.
3. Remove the attachment clamp (around the expansion
vessel, Figure 4.2-3).
4. Remove the expansion vessel by rotating it counter
clockwise (Figure 4.2-4).
5. Disconnect the primary and secondary circuit flange
connections (marked violet in Figure 4.2-2) from the unit.
Figure 4.2-2
6. Remove the four M12 screw connections from the base of the
heat exchanger (marked violet in Figure 4.2-5).
7. The plate heat exchanger weights about 87 kg. First pull it
carefully to the front edge. Then use a jib crane or a forklift to lift
it away (Figure 4.2-6).
8. Replace the unit with a clean one, or clean the unit according to
the manufacturers instructions found in the end of the
Commissioning and Maintenance folder that is supplied with the
HX-unit.
Figure 4.2-3
9. Connect the clean unit in reverse order using the instructions

above.
10. Connect the expansion vessel in reverse order using the
instructions above.
11. Add liquid and de-air the unit according to the instructions in
chapter 3.1.5 and 3.1.6.
Figure 4.2-4
Figure 4.2-5
Figure 4.2-6
Tel. +358 (0)201 2121 Fax +358 (0)201 212 205
UNIT MAINTENANCE
vacon 45
The manufacturer provides cleaning chemicals that improve the cleaning result. If the secondary
liquid quality is bad, it is 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.
DANGER
To check the pre-pressure:
1. Remove the plug on valve V160 and replace it with a hose connector.
2. Place a 25 litre jar under the valve (if the expansion vessel air nozzle or membrane is broken
there might be up to 18 litres in the vessel).
3. Turn the lever (marked violet in Figure 4.2-7) on valve
V160 90 so that it points towards you. This will clo se off
the primary 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. When the pressure vessel is drained check the prepressure with a portable pressure gauge. The air nozzle
can be found under the black rubber top on the vessel.
The portable pressure gauge should have a similar
interface to that used to fill a car tyre.
Figure 4.2-7
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.
7. Reconnect the plug to valve V160, change the plug O-ring if necessary.
8. Turn back the lever on valve V160 90 so that it p oints down.
9. The pressure 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
the pressure gauge (PI11) is back at 1.5 bar. Remember to de-air the filling hose before you
connect it to valve V161, otherwise the air in the filling hose will enter the unit during filling.
10. Due to the small amount of liquid removed during this process it is not necessary to add any
corrosion inhibitor.
46 vacon
TROUBLESHOOTING
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:
STOP
F1.
FAULT
I/O term
87 FlowFault
F1 F11
Figure 5.1-1, Flow fault on the NXP panel
Malfunction
Reasons for malfunction
The pre-pressure is The pre-pressure in the
too low in the primary
expansion vessel EV11
circuit, i.e. below 0.5
has been reduced.
bar.
There is a leak in the
primary circuit.
The
pump
isnt
delivering
enough
pressure i.e. the flow
is too low.
The FTSA11 is set

incorrectly (this is a
fault that is most likely
to
appear
during
maintenance or at the
commissioning stage).
Correction measures
Check the EV11 pre-pressure and add
pressure if necessary.
Add pre-pressure to the primary circuit
by adding liquid through valve V161.
Check the primary circuit for leaks. If a
leak is found the unit must be drained
and the leak fixed before the unit is
restarted.
A valve in the primary Check if any of the following valves in
circuit is closed.
the primary circuit is closed (refer to
the P&ID):
V140
V3103xx
Any valves in the primary
circuit added by the
customer
The pump is broken.
The flow requirement

has changed after the
commissioning stage.
The
FTSA11
setup
values have been poorly
adjusted
during
commissioning.
Replace the broken pump.

Check the current flow requirements,
they might have changed if e.g. a
converter is taken offline (and its
valves
closed)
because
of
maintenance.
Check the required flow values for the
converters and readjust the alarm set
point on the FTSA11 (refer to chapter
3.4.2 Adjusting the system flow and
setting the switch point of the
FTSA11).
Table 5.1-1, Flow fault detection

Tel. +358 (0)201 2121 Fax +358 (0)201 212 205
TROUBLESHOOTING
5.1.2
vacon 47
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:
RUN
F1.
READY ALARM
I/O term
83 OverTempA
T1 T16
Figure 5.1-2, High temperature alarm on the NXP panel
Malfunction
Correction measures
The flow in the The customer filter, outside Clean the filter.
secondary circuit is
the HX-unit, MF21 (refer to
too low.
the P&ID) is clogged.
The plate heat exchanger

HX11 (refer to the P&ID) is
clogged on the secondary
side.
The customer pump in the

secondary
circuit
is
malfunctioning
and
therefore not able to
produce enough flow.
Maintaining the HX-unit
cannot solve the reason for
this malfunction.
The temperature of
the secondary circuit
liquid is too high.
The regulating valve

V130 is
malfunctioning
The 3-way valve V130 is

malfunctioning
and
therefore
not
directing
enough flow through the
plate heat exchanger to
ensure a satisfactory heat
transfer
between
the
primary and secondary
circuit.
The FTSA11 setup values
have
been
wrongly
adjusted
during
commissioning.
Table 5.1-2 High temperature fault detection
Clean the heat exchanger. Refer to

the cleaning instructions found in
the HX-unit folder that is supplied
with the unit. Instructions on how to
remove the plate heat exchanger
are found in chapter 4.2.2, Heat
exchanger.
Maintain or replace the customer
circuit pump.
The temperature of the liquid in the

secondary circuit inlet has to be 5
degrees lower than the primary
circuit temperature set point, e.g. if
the primary circuit temperature set
point is set to 35C then the
secondary circuit inlet temperature
must be 30C or lower.
Run
the
actuator
calibration
according to the instructions found
in the HX-unit folder 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.
Check the project parameters (refer
Table 3.3-1, Parameter list) and
compare it with the actual
temperature.
48 vacon
TROUBLESHOOTING
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:
RUN
F1.
READY ALARM
I/O term
86 LowTemp
T1 T16
Figure 5.1-3, Low temperature alarm on the NXP panel
Malfunction
Reasons for malfunction Correction measures
The regulating valve The 3-way valve V130 Run the actuator calibration according to
V130 (refer to the
is malfunctioning and
the instructions found in the HX-unit
P&ID)
is
therefore directing too
manual that is supplied with the unit, i.e.
malfunctioning
much flow through the
set the actuator Dip-switch 1 to On
plate heat exchanger.
position. If the actuator is not moving
during this procedure it is broken and has
to be replaced.
The inlet temperature Wait for two minutes and see if the alarm is
on
the
secondary
reset automatically. If the alarm is active
circuit is decreasing
longer than two minutes, check the 3-way
too fast, and the 3-way
valves function. If the 3-way valve or the
valve is not able to
valve actuator is malfunctioning it must be
adjust the flow in the
replaced. If the temperature in the primary
secondary circuit fast
circuit is too low it will result in
enough
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 1C / minute
should not be exceeded.
The FTSA11 (refer The
FTSA11
flow Check the temperature by comparing the
to the P&ID) flow
sensor
with
the
FTSA11 temperature with the secondary
sensor
with
the
analogical temperature
circuit temperature indicator TI21. The
analogical
outlet is broken.
temperature of FTSA11 should be higher
temperature outlet is
than the TI21 temperature. Replace the
malfunctioning.
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.
Table 5.1-3, Low temperature fault detection
Tel. +358 (0)201 2121 Fax +358 (0)201 212 205
TROUBLESHOOTING
5.1.3
vacon 49
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:
RUN
F1.
READY ALARM
I/O term
82 InletPressLow
T1 T16
Figure 5.1-4, Low pressure alarm on the NXP panel
Malfunction
Leak in the primary Loose connection.
circuit outside the
HX-unit.
Faulty connection.
Hose failure in the

main drive section.
Pressure
vessel
EV11 (refer to the
P&ID) is without prepressure.
Other reason.
Correction measures
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 prepressure
is
reached.
Follow
the
and de-airing.
Replace the hose. Refer to the NX Liquid
Cooled Users Manual. Then add liquid to
the primary circuit until the correct prepressure
is
reached.
Follow
the
and de-airing.
Check and refill the pre-pressure according
to the instructions in chapter 4.2.3
Pressure vessel.
The
gas
(air
or
nitrogen) has escaped
through
the
butyl
rubber membrane into
the primary circuit.
The EV11 filling valve
is
broken
and
therefore letting out
gas.
The butyl membrane
inside the expansion
vessel is broken.
Faulty pressure sensor
Replace the valve and refill the prepressure according to the instructions in
chapter 4.2.3 Pressure vessel.
Replace the expansion vessel and refill the
pre-pressure according to the instructions
in chapter 4.2.3 Pressure vessel.
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
50 vacon
5.1.4
TROUBLESHOOTING
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 solve why the alarm has been activated:
RUN
F1.
READY ALARM
I/O term
51 External Fault
F1 F12
Figure 5.1-5, Leak alarm on the NXP panel
Malfunction
Leak

Loose connection.
Faulty connection.
Condensation
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
alarm is still active.
Correction measures
Tighten the connection until the leak stops.
Add liquid to the primary circuit until the
correct pre-pressure is reached. Follow the
and de-airing.
Replace the broken parts. Then add liquid
to the primary circuit until the correct prepressure
is
reached.
Follow
the
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 likely
broken and will need to be replaced.
Figure 5.1-5, Leak fault detection
Tel. +358 (0)201 2121 Fax +358 (0)201 212 205
TECHNICAL SPECIFICATION
6.
vacon 51
(Depth)
Physical size (without cubicle):

Width, 1100 mm
Height, 1898 mm AISI304, 1911 mm PVC-C
Depth, 740 mm (750 mm)
Height
Liquid connections:
Primary circuit, DN80 DIN 2642
Secondary circuit DN80 DIN 2642 (PN10),
DIN 2633 (PN16)
Electrical supply:
3 ~, 440VAC (50Hz) or 3 ~, 440VAC (60Hz), 16 A
Depth
Width
Other electrical connection:

24V auxiliary voltage (between HX-unit and main drive)
Option, Fieldbus (Profibus) connection from the HX-control unit to customer monitoring
system
Ambient conditions:
+5..+50C
RH 5..96%, no condensation allowed
Pressure ratings:
Primary circuit, PN6
Secondary circuit (customer piping), PN10 (Option; PN16 for AISI 304 piping)
Temperature ratings:
Primary circuit, +5..+50C
Secondary circuit, +5..+50C
Storage temperature rating:
-40..+60C
All liquid must be removed from the unit during storage if the temperature is below 0C.
Cooling capacity:
300 kW
Rate of flow range: 1)
360-900 l/min
Maximum input power:
8.5 kW
Supply pressure / Supply distance (primary circuit): 2)
1.0 bar / 40 m + 40 m straight pipe 3)
Liquid volume, primary side:
70 liter
52 vacon
Concentration of glycol
maximum 25%
Maximum flow secondary circuit: 4)
650 l/min
Pressure drops on customer circuit (= secondary circuit), see Appendix 1.
1) Note! Combined nominal flow of frequency converters must not exceed 90% of the maximum rate
of flow.
2) Maximum straight pipe distance between HX-unit and drive for achieving maximum flow. Elbows
and other components will reduce the pipe distance.
3) Pipeline to frequency converter (40 m) and back (40 m).
4) The pressure before 3- or 2-way valve must be at least 2 bar to prevent cavitations.
See cavitations diagram in Components Specifications and Maintenance Instructions n:o 2 , TAC,
page 2.
Tel. +358 (0)201 2121 Fax +358 (0)201 212 205
vacon 53
APPENDIX 1
Pressure drops on customer circuit. HX_300
100% FLOW = 640 l/min
Plate heat
exchanger
route
Flow
Pressure drop
plate heat
exchanger
Pressure
drop 3-way
valve
Flow
Bypass route
Total pressure drop
100%
640 l/min
0%
0,214 bar
0,37 bar
0,58 bar
75%
480 l/min
25%
160 l/min
0,135 bar
0,37 bar
0,51 bar
50%
320 l/min
50%
320 l/min
0,066 bar
0,37 bar
0,44 bar
25%
160 l/min
75%
480 l/min
0,019 bar
0,37 bar
0,39 bar
0,37 bar
0,37 bar
Pressure
drop 3-way
valve
Total pressure drop
0%
0
100%
640 l/min => Pressure drop varies between 0,37 bar 0,58 bar
75% FLOW = 480 l/min

Plate heat
exchanger
route
Flow
Bypass route
Flow
Pressure drop
plate heat
exchanger
75%
480 l/min
0%
0,135 bar
0,21 bar
0,35 bar
50%
320 l/min
25%
160 l/min
0,066 bar
0,21 bar
0,28 bar
25%
160 l/min
50%
320 l/min
0,019 bar
0,21 bar
0,23 bar
0,21 bar
0,21 bar
Pressure
drop 3-way
valve
Total pressure drop
0%
0
75%
50% FLOW = 320 l/min

Plate heat
exchanger
route
Flow
Bypass route
Flow
Pressure drop
plate heat
exchanger
50%
320 l/min
0%
0,066 bar
0,09 bar
0,16 bar
25%
160 l/min
25%
160 l/min
0,019 bar
0,09 bar
0,11 bar
0,09 bar
0,09 bar
0%
0
50%
54 vacon
NOTES:
Tel. +358 (0)201 2121 Fax +358 (0)201 212 205
Vaasa
Vacon Oyj (Headquarters and Production)
Runsorintie 7, 65380 Vaasa
[email protected]
tel. +358 (0) 201 2121
fax: +358 (0) 201 212 205
Helsinki
Vacon Oyj
yritie 12, 01510 Vantaa
tel. +358 (0)201 212 600
fax: +358 (0)201 212 699
Tampere
Vacon Oyj
Alasniitynkatu 30, 33700 Tampere
tel. +358 (0)201 2121
fax: +358 (0)201 212 750
Rotatek Finland Oy
Laserkatu 6, 53850 Lappeenranta
tel. +358 (0)5 6243 870
fax: +358 (0)5 6243 871
Vacon Traction Oy
Alasniitynkatu 30, 33700 Tampere
tel. +358 (0)201 2121
fax: +358 (0)201 212 710
sales companies and representative offices:

Austria
Vacon AT Antriebssysteme GmbH
Aumhlweg 21
2544 Leobersdorf
[email protected]
tel. +43 2256 651 66
fax: +43 2256 651 66 66
Italy
Vacon S.p.A.
Via F.lli Guerra, 35
42100 Reggio Emilia
[email protected]
tel. +39 0522 276811
fax: +39 0522 276890
Belgium
Vacon Benelux NV/SA
Interleuvenlaan 62
3001 Heverlee (Leuven)
[email protected]
tel. +32 (0)16 394 825
fax: +32 (0)16 394 827
The Netherlands
Vacon Benelux BV
Weide 40, 4206 CJ Gorinchem
[email protected]
tel. +31 (0)183 642 970
fax: +31 (0) 183 642 971
France
Vacon France s.a.s.
Batiment le Sextant
462 rue Benjamin Delessert
Zl de Moissy Cramayel
BP 83
77 554 Moissy Cramayel
www.vacon-france.fr
tel. +33 (0)1 64 13 54 11
fax: +33 (0)1 64 13 54 21
Germany
Vacon GmbH
Gladbecker Str. 425
45329 Essen
tel. +49 (0)201/80670-0
fax: +49 (0)201/80670-93
Great Britain
Vacon Drives (UK) Ltd.
Unit 11, Sunnyside Park
Wheatfield Way, Hinckley
LE10, 1PJ, Leicestershire
[email protected]
tel. +44 (0)1455 611 515
fax: +44 (0)1455 611 517
Vacon distributor:
Norway
Vacon AS
Langgata 2
3080 Holmestrand
[email protected]
tel. +47 330 96120
fax: +47 330 96130
PR China
Vacon Plc
Beijing Representative Office
A205, Grand Pacific Garden Mansion
8A Guanhua Road
Beijing 100026
www.vacon.com.cn
[email protected]
tel. +86 10 6581 3734
fax: +86 10 6581 3754
Russia
ZAO Vacon Drives
Bolshaja Jakimanka 31
stroenie 18
109180 Moscow
www.ru.vacon.com
tel. +7 (095) 974 1541
fax: +7 (095) 974 1554
ZAO Vacon Drives
2ya Sovetskaya 7, office 210A
191036 St. Petersburg
www.ru.vacon.com
tel. +7 (812) 332 1114
fax: +7 (812) 279 9053
Singapore
Vacon Plc
Singapore Representative Office
102F Pasir Panjang Road
#02-06 Citilink Warehouse Complex
Singapore 118530
[email protected]
tel. +65 6278 8533
fax: +65 6278 1066
Spain
Vacon Drives Ibrica S.A.
Miquel Servet, 2. P.l. Bufalvent
08240 Manresa
www.vacon.es
[email protected]
tel. +34 93 877 45 06
fax: +34 93 877 00 09
Sweden
Vacon AB
Torget 1
172 67 Sundbyberg
tel. +46 (0)8 293 055
fax: +46 (0)8 290 755

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Commissioning and Maintenance Manual

HXL300 cooling unit, SS-Piping and PVC-C Piping

QUICK START-UP GUIDE

24-hour support +358 (0)40 837 1150 Email: [email protected]

ABOUT THE VACON HX-UNIT MANUAL

Tel. +358 (0)201 2121 Fax +358 (0)201 212 205

24-hour support +358 (0)40 837 1150 Email: [email protected]

USE OF SYMBOLS ..............................................................................................................8

ABOUT THIS MANUAL ......................................................................................................10

STEP 1, MECHANICAL PART ...........................................................................................18

Pressure vessel ......................................................................................................45

Alarms and shutoffs ............................................................................................................46

24-hour support +358 (0)40 837 1150 Email: [email protected]

Risk of death. Instructions on preventing a possible severe

Risk of damage. Instructions on preventing possible damage

Hot surface. Instructions on preventing a possible minor

Tel. +358 (0)201 2121 Fax +358 (0)201 212 205

GENERAL WARNINGS AND NOTES WHEN WORKING WITH THE HX-UNIT

Only qualified and authorized electricians and mechanics are allowed to

24-hour support +358 (0)40 837 1150 Email: [email protected]

ABOUT THIS MANUAL

Only a qualified and authorized mechanic is allowed to perform commissioning

This manual is divided into following chapters:

Tel. +358 (0)201 2121 Fax +358 (0)201 212 205

PROCESS AND INSTRUMENTATION

Primary circuit, HXL300-PS01 (green colour in the Figure

Secondary circuit, HXL300-PS02 (red colour in the Figure

HX_300-PS01-2, Primary circuit

PS02-3, Secondary circuit

Figure 2.2-2 Piping and instrumentation diagram (P&ID)

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Primary circuit components and function

Secondary circuit components and function

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Instruments and their function

Control / supervision parameters

The HX-unit provides no control of the temperature or flow in the secondary

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HX-unit electrical box

Main power switch (red/yellow in Figure 2.2-7) is connected to

Pump power switch (black and white in Figure 2.2-7),

LS11 leak sensor reset switch (white in Figure 2.2-7) resets

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Table 2.3-1, Liquid quality

Required ambient conditions

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STEP 1, MECHANICAL PART

Only qualified and authorized mechanics are allowed to perform mechanical

General installation instructions

The wall penetration is made according to IP54

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Additional piping between

To ensure that every site connection is sufficiently tightened, it is recommended that a

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When performing a pressure test on the HX-unit, generally acknowledged safety

Setting up the primary circuit

open (violet colour in Figure 3.1-8)

lever down (brown colour in Figure 3.1-8)