User manual

LCX9000 Liquid-Cooled Drives User Manual
MN04005001E
For more information visit: www.eaton.com
iii
September 2007
List of Figures
Figure 1-1: Liquid-Cooled Drive Principal Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-2: Liquid-Cooled Drive DC Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 2-1: Lifting Points for Drives Consisting of One Module (Left)
and Several Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2: LCX9000 Liquid-Cooled Drive, CH3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-3: LCX9000 Liquid-Cooled Drive, CH4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4: LCX9000 Liquid-Cooled Drive, CH5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-5: LCX9000 Liquid-Cooled Inverter, CH5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-6: LCX9000 Liquid-Cooled Drive, CH61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7: LCX9000 Liquid-Cooled Inverter, CH61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-8: LCX9000 Liquid-Cooled Inverter, CH62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-9: LCX9000 Liquid-Cooled Drive, CH72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-10: Drive Mounted Inside Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-11: LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 . . . . . . . . . . . . 2-8
Figure 2-12: LCX9000 Liquid-Cooled Inverter with Mounting Bracket, CH63 . . . . . . . . . 2-9
Figure 2-13: LCX9000 Liquid-Cooled Inverter with Mounting Bracket, CH64, IP90 . . . . . 2-10
Figure 2-14: LCX9000 Liquid-Cooled Drive, CH74, IP00 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-15: Example of Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-16: Example PI-Diagram of Cooling System and Connections . . . . . . . . . . . . . 2-15
Figure 2-17: Safe Operating Conditions in Relation to Condensation . . . . . . . . . . . . . . . 2-17
Figure 2-18: Aluminum Hose Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-19: External Thread of Hose Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-20: Pressure Loss — CH6x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Figure 2-21: Pressure Loss — CH7x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Figure 2-22: Flow Switch: Hose Connection, Fast Connector (Electrical),
Fast Connector Lock Screw, Cable Seal and Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Figure 2-23: Direction of Coolant Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Figure 2-24: Example of Input Chokes for Liquid-Cooled Sizes Up to 62A . . . . . . . . . . . 2-25
Figure 2-25: Example of Input Chokes for Liquid-Cooled
Sizes 87 – 145A and 590A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Figure 2-26: Example of Input Chokes for Liquid-Cooled Sizes 261 – 1150A . . . . . . . . . . 2-27
Figure 2-27: Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Figure 3-1: Maximum Terminal Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-2: Installation Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-3: Grounding Terminal on Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 4-1: Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-2: Basic and Option Board Connections of the Control Board . . . . . . . . . . . . . . 4-2
Figure 4-3: Drives Connected in Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-4: Connection of Control Board Cable from the Power Board
WRONG: Terminal J1 (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-5: Connection of Control Board Cable from the Power Board
CORRECT: Terminal J2 (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-6: I/O Terminals of the Two Basic Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-7: General Wiring Diagram of the Basic I/O Board (OPT-A9) . . . . . . . . . . . . . . . 4-5
Figure 4-8: General Wiring Diagram of the Basic Relay Board (OPT-A2) . . . . . . . . . . . . . 4-5
Figure 4-9: Galvanic Isolation Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-10: Positive/Negative Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-11: Jumper Blocks on OPT-A9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-12: Jumper Selection for OPT-A9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-13: Control Unit Mounting Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10