BONFIGLIOLI ACU 401, ACU 410, ACU 510, ANG 410, ACU 610 Complement To Operating Instructions

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Liquid cooling

Complement to the operating instructions

Frequency inverters ACTIVE CUBE Frequency inverters ACTIVE NEXT GENERATION Mains unit AEC

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Liquid Cooling ACU/ANG/AEC

TABLE OF CONTENTS

1 General Information about the Documentation ............................................... 5

1.1 This document ........................................................................................ 5

1.2 Warranty and liability ............................................................................ 5

1.3 Obligation .............................................................................................. 6

1.4 Copyright ............................................................................................... 6

1.5 Storage................................................................................................... 6

2 General safety instructions and information on use ......................................... 6

2.1 Designated use....................................................................................... 6

2.2 Misuse .................................................................................................... 7

2.3 Residual risks ......................................................................................... 7

2.4 Safety and warning signs on device ....................................................... 8

2.5 Warning information and symbols used in the Operating Instructions . 8

2.5.1 Hazard classes .............................................................................................. 8

2.5.2 Hazard symbols ............................................................................................. 8

2.5.3 Prohibition signs ............................................................................................ 8

2.5.4 Personal safety equipment ............................................................................. 9

2.5.5 Recycling ...................................................................................................... 9

2.5.6 Grounding symbol ......................................................................................... 9

2.5.7 ESD symbol................................................................................................... 9

2.5.8 Information signs .......................................................................................... 9

2.5.9 Font style in documentation ........................................................................... 9

2.6 Directives and guidelines to be adhered to by the operator .................. 9

2.7 Operator's general plant documentation ............................................. 10

2.8 Operator's/operating staff's responsibilities ....................................... 10

2.8.1 Selection and qualification of staff ................................................................. 10

2.8.2 General work safety ..................................................................................... 10

2.8.3 Ear protectors ............................................................................................. 10

2.9 Organizational measures ..................................................................... 10

2.9.1 General ...................................................................................................... 10

2.9.2 Use in combination with third-party products ................................................. 10

2.9.3 Handling and installation .............................................................................. 11

2.9.4 Electrical connections ................................................................................... 11

2.9.4.1 The five safety rules ................................................................................................. 11

2.9.5 Safe operation ............................................................................................. 11

2.9.6 Maintenance and service/troubleshooting ...................................................... 12

2.9.7 Final decommissioning ................................................................................. 13

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2.10 Safety Instructions on Function “Safe Torque Off” (STO) .................... 13

3 Device identification ....................................................................................... 15

3.1 Identifier structure .............................................................................. 15

3.2 Available devices .................................................................................. 15

3.3 Cooling and installation types by assemblies ....................................... 16

3.4 Storage................................................................................................. 16

4 Technical data ................................................................................................ 16

4.1 General technical data ......................................................................... 16

4.2 Technical data - Liquid Cooling, general .............................................. 16

4.3 Technical data - Liquid Cooling, assembly-specific .............................. 17

4.4 Hydrological data ................................................................................. 17

4.5 Operation diagrams ............................................................................. 18

5 Mechanical installation ................................................................................... 19

5.1 Size 5 (liquid-cooled) ........................................................................... 20

5.2 Size 6 (liquid-cooled) ........................................................................... 22

5.3 Size 7 and 8 (liquid-cooled) ................................................................. 23

6 Coolant connection ......................................................................................... 24

6.1 Size 6 ................................................................................................... 24

6.2 Size 7 ................................................................................................... 25

6.3 Size 8 ................................................................................................... 25

6.4 Protection of heat sink against condensation ...................................... 27

6.4.1 Supply of temperature-controlled coolant ...................................................... 27

6.4.2 Coolant supply control ................................................................................. 28

6.5 Measures against soiling of coolant and frost ...................................... 28

7 Electrical installation ...................................................................................... 29

8 Commissioning of frequency inverter ............................................................. 29

9 Maintenance ................................................................................................... 29

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1 General Information about the Documentation

The present documentation was prepared with great care and it was subjected to extensive and repeated reviews. For reasons of clarity, it was not possible to include all details of all types of the product in the documentation. Neither was it possible to consider all conceivable installation, operation or maintenance situations. If you require further information or if you meet with specific problems which are not dealt with in sufficient detail in the documentation, contact your local BONFIGLIOLI agent.

The present document was created in German. Other language versions are translations.

1.1 This document

This document complements the applicable Operating Instructions by providing information on assembly, installation, commissioning and operation of liquid-cooled devices.

Compliance with this document contributes to avoiding risks, minimizing repair cost and downtimes and increasing the reliability and service live of the device.

Read this document and the relevant Operating Instructions of the device carefully.

IMPORTANT:

Compliance with the documentation is required to ensure safe operation of the frequency inverter. Bonfiglioli Vectron MDS GmbH shall not be held liable for any damage caused by any non-compliance with the documentation.

In case any problems occur which are not covered by the documentation sufficiently, please contact the manufacturer.

This document contains additional information on liquid-cooled frequency inverters and mains units (in the following referred to as: devices) of the following series of devices:

 ACU 401  ACU 410 / 510 / 610  ANG 410 / 510 / 610  AEC 401

1.2 Warranty and liability

Bonfiglioli Vectron MDS GmbH would like to point out that the contents of these Operating Instructions do not form part of any previous or existing agreement, assurance or legal relationship. Neither are they intended to supplement or replace such agreements, assurances or legal relationships. Any obligations of the manufacturer shall solely be based on the relevant purchase agreement which also includes the complete and solely valid warranty stipulations. These contractual warranty provisions are neither extended nor limited by the specifications contained in this documentation.

The manufacturer reserves the right to correct or amend the specifications, product information and omissions in these operating instructions without notice. The manufacturer shall not be liable for any damage, injuries or costs which may be caused by the aforementioned reasons.

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Furthermore, Bonfiglioli Vectron MDS GmbH excludes any warranty/liability claims for any personal and/or material damage if such damage is due to one or more of the following causes:

 inappropriate use of the device,  non-compliance with the instructions, warnings and prohibitions contained in the documentation,  unauthorized modifications of the device,  insufficient monitoring of parts of the machine/plant which are subject to wear,

 repair work at the machine/plant not carried out properly or in time,  catastrophes by external impact and force majeure.

1.3 Obligation

The Operating Instructions and this additional information must be read before commissioning liquidcooled devices and complied with. Anybody entrusted with tasks in connection with the

 transport,  assembly,  installation and  operation

of the device must have read and understood the Operating Instructions and additional information on liquid cooling, and especially the safety instructions. In this way, personal and material damage/losses can be avoided.

1.4 Copyright

In accordance with applicable law against unfair competition, this document is a certificate. Any copyrights relating to it shall remain with

Bonfiglioli Vectron MDS GmbH Europark Fichtenhain B6 47807 Krefeld Deutschland

This document is intended for the operator of the device. Any disclosure or copying of this document, exploitation and communication of its contents (as hardcopy or electronically) shall be forbidden, unless permitted expressly.

Any non-compliance will constitute an offense against the copyright law dated 09 September 1965, the law against unfair competition and the Civil Code and may result in claims for damages. All rights relating to patent, utility model or design registration reserved.

1.5 Storage

The documentation forms an integral part of the device. It must be stored such that it is accessible to operating staff at all times. If the device is sold on to other users, then the documentation must also be handed over.

2 General safety instructions and information on use

The chapter 2 "General safety instructions and information on use" contains general safety instructions for the Operator and the Operating Staff. At the beginning of certain main chapters, some safety instructions are included which apply to all work described in the relevant chapter. Special work-specific safety instructions are provided before each safety-relevant work step.

2.1 Designated use

The frequency inverter is designed according to the state of the art and recognized safety regulations.

The frequency inverters are electrical drive components intended for installation in industrial plants or machines. Commissioning and start of operation is not allowed until it has been verified that the machine meets the requirements of the EC Machinery Directive 2006/42/EC and DIN EN 60204-1.

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The frequency inverters meet the requirements of the low voltage directive 2006/95/EEC and DIN EN 61800-5-1. CE-labeling is based on these standards. Responsibility for compliance with the EMC Directive 2004/108/EC lies with the operator. Frequency inverters are only available at specialized dealers and are exclusively intended for commercial use as per EN 61000-3-2.

No capacitive loads may be connected to the frequency inverter.

The technical data, connection specifications and information on ambient conditions are indicated on the rating plate and in the documentation and must be complied with in any case.

2.2 Misuse

Any use other than that described in "Designated use" shall not be permissible and shall be considered as misuse.

For, example, the machine/plant must not be operated

 by uninstructed staff,  while it is not in perfect condition,  without protection enclosure (e.g. covers),  without safety equipment or with safety equipment deactivated,  when general requirements, such as operating conditions and technical data, are not met.

The manufacturer shall not be held liable for any damage resulting from such misuse. The sole risk shall be borne by the operator.

2.3 Residual risks

Residual risks are special hazards involved in handling of the frequency inverter which cannot be eliminated despite the safety-compliant design of the device. Residual risks are not obviously identifiable and can be a potential source of injury or a health hazard.

Typical residual hazards include:

 Electrical hazard  Danger of contact with energized components due to a defect, opened covers or enclosures or

improper working on electrical equipment.

 Danger of contact with energized components in frequency inverter if no external disconnec-

tion device was installed by the operator.

During operation, all covers must be installed correctly, and all electrical cabinet doors must be closed to minimize electrical hazards.

When LEDs and other indicating elements on the frequency inverter go out, this does not necessarily mean that the device is deenergized. Before carrying out any work on the device where contact with energized parts might be possible, it must be checked in any case, i.e. irrespective of the status of any indicating elements that may be installed, if the device is deenergized.

Charged capacitors in DC link

Sizes 1 through 7 (up to 132 kW): The DC-link may have dangerous voltage levels even up to 3 minutes after shutdown.

Size 8 (as from 160 kW): The DC-link may have dangerous voltage levels even up to 8 minutes after shutdown.

Electrostatic charging

Touching electronic components entails the risk of electrostatic discharges.

Thermal hazards

Risk of accidents by hot machine/plant surfaces, e.g. heat sink, transformer, fuse or sine filter.

Danger of equipment falling down/over, e.g. during transport

Center of gravity may not lie in the middle of the electrical cabinet modules.

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2.4 Safety and warning signs on device

 Comply with all safety instructions and danger information provided on the device.  Safety information and warnings on the device must not be removed.

2.5 Warning information and symbols used in the Operating Instruc-

tions

2.5.1 Hazard classes

The following hazard identifications and symbols are used in the Operating Instructions to mark particularly important information:

DANGER

Identification of immediate threat holding a high risk of death or serious injury if not avoided.

WARNING

Identification of immediate threat holding a medium risk of death or serious injury if not avoided.

CAUTION

Identification of immediate threat holding a low risk of minor or moderate physical injury if not avoided.

NOTICE

Identification of a threat holding a risk of material damage if not avoided.

2.5.2 Hazard symbols

Symbol

Meaning

Symbol

Meaning

General hazard

Suspended load

Electrical voltage

Hot surfaces

Danger of crushing

2.5.3 Prohibition signs

Symbol

Meaning

No switching; it is forbidden to switch the machine/plant, assembly on

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2.5.4 Personal safety equipment

Symbol

Meaning

Wear body protection

Wear ear protectors

2.5.5 Recycling

Symbol

Meaning

Recycling, to avoid waste, collect all materials for reuse

2.5.6 Grounding symbol

Symbol

Meaning

Ground connection

2.5.7 ESD symbol

Symbol

Meaning

ESD: Electrostatic Sensitive Devices, i.e. components and assemblies sensitive to electrostatic energy

2.5.8 Information signs

Symbol

Meaning

Tips and information making using the frequency inverter easier.

2.5.9 Font style in documentation

Example

Font style

Use

1234

bold

Representation of parameter numbers

Parameter

inclined, font: Times New Roman

Representation of parameter names

P.1234

bold

Representation of parameter numbers without name, e.g. in formulas

Q.1234

bold

Representation of source numbers

2.6 Directives and guidelines to be adhered to by the operator

The operator must follow the following directives and regulations:

 Ensure that the applicable workplace-related accident prevention regulations as well as other ap-

plicable national regulation are accessible to the staff.

 An authorized person must ensure, before using the frequency inverter, that the device is used in

compliance with its designated use and that all safety requirements are met.

 Additionally, comply with the applicable laws, regulations and directives of the country in which

the frequency inverter is used.

 For liquid cooled frequency inverters, comply with the cooling water guideline VGB-R 455 P.  Any additional guidelines and directives that may be required additionally shall be defined by the

operator of the machine/plant considering the operating environment.

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2.7 Operator's general plant documentation

 In addition to the Operating Instructions, the operator should issue separate internal user manu-

als for the frequency inverter. The Operating Instructions of the frequency inverter must be included in the Operating Instructions of the whole plant.

2.8 Operator's/operating staff's responsibilities

2.8.1 Selection and qualification of staff

 Any work on the frequency inverter may only be carried out by skilled personnel. The staff must

not be under the influence of any drugs. Note the minimum age required by law. Define the staff's responsibility pertaining to all work on the frequency inverter clearly.

 Work on the electrical components may only be performed by a qualified electrician according to

the applicable rules of electrical engineering.

 The operating staff must be trained for the relevant work to be performed.

2.8.2 General work safety

 In addition to the Operating Instructions of the machine/plant, any applicable legal or other regu-

lations relating to accident prevention and environmental protection must be complied with. The staff must be instructed accordingly. Such regulations and/or requirements may include, for example, handling of hazardous media and materials or provision/use of personal protective equipment.

 In addition to this Operating Instructions, issue any additional directives that may be required to

meet specific operating requirements, including supervision and reporting requirements, e.g. directives relating to work organization, workflow and employed staff.

 Unless approved of expressly by the manufacturer, do not modify the frequency inverter in any

way, including addition of attachments or retrofits.

 Only use the frequency inverter if the rated connection and setup values specified by the manu-

facturer are met.

 Provide appropriate tools as may be required for performing all work on the frequency inverter

properly.

2.8.3 Ear protectors

 The frequency inverter produces noise. Due to noise development, frequency inverters should

only be installed in normally unstaffed areas.

 Noise emission in operation is < 85 dB(A) in the case of sizes 1 through 7.  Noise emission in operation is approx. 86 dB(A) in the case of size 8. Ear protectors must be used

when staying near the frequency inverter.

2.9 Organizational measures

2.9.1 General

 Train your staff in the handling and use of the frequency inverter and the machine/plant as well

as the risks involved.

 Use of any individual parts or components of the frequency inverter in other parts of the opera-

tor's machine/plant is prohibited.

 Optional components for the frequency inverter must be used in accordance with their designated

use and in compliance with the relevant documentation.

2.9.2 Use in combination with third-party products

 Please note that Bonfiglioli Vectron MDS GmbH will not accept any responsibility for compatibility

with third-party products (e.g. motors, cables or filters)..

 In order to enable optimum system compatibility Bonfiglioli Vectron MDS GmbH offers compo-

nents facilitating commissioning and providing optimum synchronization of the machine/plant parts in operation.

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 If you use the frequency inverter in combination with third-party products, you do so at your own

risk.

2.9.3 Handling and installation

 Do not commission any damaged or destroyed components.  Prevent any mechanical overloading of the frequency inverter. Do not bend any components and

never change the isolation distances.

 Do not touch any electronic construction elements and contacts. The frequency inverter is

equipped with components which are sensitive to electrostatic energy and can be damaged if handled improperly. Any use of damaged or destroyed components will endanger the machine/plant safety and shall be considered as non-compliance with the applicable standards.

 Only install the frequency inverter in a suitable operating environment. The frequency inverter is

exclusively designed for installation in industrial environments.

 If seals are removed from the case, this can result in the warranty becoming null and void.

2.9.4 Electrical connections

 The five safety rules must be complied with.  Never touch live terminals. In sizes 1 through 7, the DC-link may have dangerous voltage levels

up to 3 minutes after shutdown. In size 8, the DC-link may have dangerous voltage levels up to 8 minutes after shutdown.

 When performing any work on/with the frequency inverter, always comply with the applicable na-

tional and international regulations/laws on work on electrical equipment/plants of the country in which the frequency inverter is used.

 The cables connected to the frequency inverters may not be subjected to high-voltage insulation

tests unless appropriate circuitry measures are taken before.

 Only connect the frequency inverter to suitable supply mains. The frequency inverter may be op-

erated in TN, TT and IT grid types. Precautions must be taken for operation in IT grids, see Chapter 7 "Electrical installation". Operation in a corner-grounded TN grid shall not be permissible.

2.9.4.1 The five safety rules

When working on/in electrical plants, always follow the five safety rules:

1 Isolate 2 Secure to prevent restarting 3 Check isolation 4 Earth and short-circuit 5 Cover or shield neighboring live parts

2.9.5 Safe operation

 During operation of the frequency inverter, always comply with the applicable national and inter-

national regulations/laws on work on electrical equipment/plants.

 Before commissioning and the start of the operation, make sure to fix all covers and check the

terminals. Check the additional monitoring and protective devices according to the applicable national and international safety directives.

 During operation, all covers must be installed correctly, and all electrical cabinet doors must be

closed. During operation, never open the machine/plant.

 No connection work shall be carried out while power supply is on.  The machine/plant holds high voltage levels during operation, is equipped with rotating parts

(fan) and has hot surfaces. Any unauthorized removal of covers, improper use, wrong installation or operation may result in serious injuries or material damage.

 Some components, e.g. the heat sink or braking resistor, may be hot even some time after the

machine/plant was shut down. Don't touch any surfaces directly after shutdown. Wear safety gloves where necessary.

 The frequency inverter may hold dangerous voltage levels until the capacitor in the DC link is dis-

charged. After shutdown, wait for at least 3 minutes (sizes 1 through 7) and at least 8 minutes

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(size 8) before starting any electrical or mechanical work on the frequency inverter. Even after this waiting time, make sure that the equipment is deenergized in accordance with the safety rules before starting the work.

 In order to avoid accidents or damage, only skilled personnel and electricians may carry out the

work such as installation, commissioning or setup.

 In the case of a defect of terminals and/or cables, immediately disconnect the frequency inverter

from mains supply.

 Persons not familiar with the operation of the frequency inverter and children must not have ac-

cess to the device.

 Do not bypass nor decommission any protective devices.  The frequency inverter may be connected to power supply every 60 s. This must be considered

when operating a mains contactor in jog operation mode. For commissioning or after an emergency stop, a non-recurrent, direct restart is permissible.

 After a failure and restoration of the power supply, the motor may start unexpectedly if the Auto-

Start function is activated. If staff are endangered, a restart of the motor must be prevented by means of external circuitry.

 Before commissioning and the start of the operation, make sure to fix all covers and check the

terminals. Check the additional monitoring and protective devices according to EN 60204 and applicable the safety directives (e.g. Working Machines Act or Accident Prevention Directives).

2.9.6 Maintenance and service/troubleshooting

 Visually inspect the frequency inverter when carrying out the required maintenance work and in-

spections at the machine/plant.

 Perform the maintenance work and inspections prescribed for the machine carefully, including the

specifications on parts/equipment replacement.

 Work on the electrical components may only be performed by a qualified electrician according to

the applicable rules of electrical engineering. Only use original spare parts.

 Unauthorized opening and improper interventions in the machine/plant can lead to personal injury

or material damage. Any repair work may only be carried out by the manufacturer or persons approved/licensed by the manufacturer. Any repair work must be carried out by qualified electricians. Check protective equipment regularly.

 Before performing any maintenance work, the machine/plant must be disconnected from mains

supply and secured against restarting. The five safety rules must be complied with.

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2.9.7 Final decommissioning

Unless separate return or disposal agreements were made, recycle the disassembled frequency inverter components:

 Scrap metal materials  Recycle plastic elements  Sort and dispose of other component materials

Electric scrap, electronic components, lubricants and other utility materials must be treated as special waste and may only be disposed of by specialized companies.

In any case, comply with any applicable national disposal regulations as regards environmentally compatible disposal of the frequency inverter. For more details, contact the competent local authorities.

2.10 Safety Instructions on Function “Safe Torque Off” (STO)

The function „Safe Torque Off“ (STO) is a functional safety feature, i.e. it protects staff from damage, provided that projecting, installation and operation are performed properly. This function does not disconnect the plant from power supply.

In order to disconnect the plant from power supply (e.g. for maintenance work), an "Emergency Stop" provision as per EN 60204 must be installed.

WARNING

Uncontrolled Starting

Improper installation of the safety circuitry may result in uncontrolled starting of the drive. This may cause serious injuries and significant material damage or death.

 Safety functions may only be installed and commissioned by skilled personnel.

The STO function is not suitable for emergency stop as per EN 60204. An emergency stop can be realized by installing a mains contactor.

An emergency stop according to EN 60204 must be functioning in all operation modes of the frequency inverter. Resetting of an emergency stop must not result in uncontrolled starting of the drive.

The drive is started again when the function STO is no longer triggered.

Without a mechanical brake, the drive will not stop immediately but coast to a standstill. If this might result in personal or material damage, additional safety measures must be taken.

 If persons may be endangered after disconnection of the motor power supply by

STO, prevent access to the hazard areas until the drive has stopped.

 Check the safety function at regular intervals according to the results of your risk

analysis. Bonfiglioli Vectron MDS GmbH recommends that the check be performed after one year, at the latest.

The STO function is fail-safe. However, on rare occasions, the occurrence of component defects may cause jerking of the motor shaft (max. 180°/pole pair, e. g. jerk by 90° with 4-pole motor, 180°/2).

 Check if this causes a dangerous movement of the machine.  If the STO function is used, the special safety, installation and instructions on use

instructions shall be complied with.

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WARNING!

Dangerous voltage!

The safety function “Safe Torque Off” may only be used if mechanical work is to be performed on the driven machines, not for work on live components.

After disconnection of an external DC 24 V power supply, the DC link of the frequency inverter is still connected to mains supply.

Even if power supply to the motor is disconnected, and the motor is coasting to a standstill or has already stopped, high voltages may still be present on the motor terminals.

Before working (e. g. maintenance) on live parts, the plant must always be disconnected from mains supply (main switch). This must be documented on the plant.

When the function “Safe Torque Off” is triggered, the motor is not isolated from the DC

link of the frequency inverter. High voltage levels may be present at the motor.

 Do not touch live terminals.

The application manual "Safe Torque Off STO" must be complied with, particularly if the safety function described there is used.

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3 Device identification

3.1 Identifier structure

Type key

Device series, e.g. ACU401

Identifier depending on rated power , e.g. -33

Device Size, e.g. 6 (only specified for device series Axx410/510/610)

Cooling and installation code, e.g. L for liquid cooling

3.2 Available devices

Device series

Type identifier

Size1)

ACU401 / AEC401

-27...-49

ACU410

-27...-61

5...8

ACU510

-51...-61

ACU610

-51...-61

ANG410

-27...-61

5...8

ANG510

-51...-61

ANG610

-51...-61

AEC410

-27...-61

5...8

AEC510

-51...-61

AEC610

-51...-61

1) only specified in type key for device series Axx410/510/610

Device series Cooling and

Installation method

ACU401 / AEC401

stainless steel, open cooling circuit (Size 5…8)

standard installation

ACU401 / AEC401

N2):

stainless steel, open cooling circuit (Size 7, 8)

through-hole installation

ACU410 ACU510 ACU610

stainless steel, open cooling circuit (Size 5…8)

standard installation