999.

6000

Hardware Description

Bakker Sliedrecht

Installing, Operation and Maintenance Manual

ACS800 Liquid Cooling System

Date : 28-03-2008
Version : 1
Doc.no. : PEE-6500
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Sub Project : Installing, Operation and Maintenance Date : 28-03-2008

Manual
Subject : ACS800 Liquid Cooling System Written by : APvdV

TABLE OF CONTENTS Page

1 GENERAL ........................................................................................................................ 6
1.1 Safety instructions ......................................................................................................... 6
1.2 Address ......................................................................................................................... 7
2 INSTALLATION INSTRUCTIONS ..................................................................................... 8
2.1 Storage instructions ....................................................................................................... 8
2.2 Transport status ............................................................................................................. 8
2.3 Air demand ................................................................................................................... 8
2.4 Temperature limits ........................................................................................................ 8
2.5 Place of installation ........................................................................................................ 8
2.6 Covering during installation ............................................................................................ 8
2.7 External liquid cooling connection (outside) ................................................................... 8
3 CONTROL AND DIAGNOSTIC OF THE COOLING SYSTEM .......................................... 9
3.1 Control of the three way valve........................................................................................ 9
4 SPECIFICATIONS OF INTERNAL AND EXTERNAL COOLING CIRCUIT ....................... 9
4.1 Internal cooling circuit data ............................................................................................ 9
4.1.1 Temperature limits ...................................................................................................... 9
4.1.2 Pressure limits ......................................................................................................... 10
4.1.3 Internal Liquid quality ............................................................................................... 10
4.1.4 Freeze protection and corrosion inhibition ................................................................ 11
4.1.5 Connecting of the internal piping .............................................................................. 12
4.1.6 Materials .................................................................................................................. 12
4.2 External cooling circuit data ......................................................................................... 12
4.2.1 Liquid quality ............................................................................................................ 12
4.2.2 Temperature and pressure limits .............................................................................. 13
4.2.3 Connecting of the external piping ............................................................................. 13
4.2.4 Heat exchanger type ................................................................................................ 13
5 OPERATION, COMMISSIONING AND MAINTENANCE ............................................... 13
5.1 Filling and bleeding the cooling liquid circuit ................................................................ 14
5.2 Draining the internal liquid cooling system ................................................................... 15
5.3 Maintenance of liquid cooling motor/pump ................................................................... 15
5.4 Replacing the liquid cooling pump ............................................................................... 15
5.5 Replacing the PT100 sensor ........................................................................................ 16
5.6 Replacing the pressure sensor .................................................................................... 17
5.7 Replacing of the expansion vessel ............................................................................... 17
5.8 Replacing of the plate heat exchanger ......................................................................... 18
5.9 Replacing of the 3-way valve ....................................................................................... 19
6 MAINTENANCE / SERVICE ........................................................................................... 19
6.1 Pressure Inspection ..................................................................................................... 19
6.2 liquid cooling pump inspection ..................................................................................... 20
6.3 Visual inspection .......................................................................................................... 20
6.4 Three way valve maintenance ..................................................................................... 20
6.5 Add inhibitor to the internal cooling system ................................................................. 20

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The contents of this specification are the property of Bakker Sliedrecht and may not be brought to the knowledge of third parties in original nor by reproduction of parts or whole.
6.6 Maintenance intervals .................................................................................................. 20
7 TROUBLE SHOOTING .................................................................................................. 20
8 WASTE DISPOSAL OF WATER COOLING CABINET OR PARTS OF IT ....................... 22
APPENDIX A – FUNCTIONAL WATER COOLING CIRCUIT DIAGRAM
ONE PUMP ......................................................................................................................... 23
APPENDIX B – FUNCTIONAL WATER COOLING CIRCUIT DIAGRAM
TWO PUMPS .................................................................................................................. 24
APPENDIX C – 3D ARRANGEMENT EXPLODED VIEW – ONE PUMP ........................ 25
APPENDIX D – 3D ARRANGEMENT EXPLODED VIEW – TWO PUMPS ..................... 26
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Version Date Chapter Description

1

APPROVAL

Bakker Sliedrecht Electro Industrie BV Principal

Name A.P. van der Velde Name R. Dekker

Date 08-10-08 Date 10-10-08

Signed Signed:

DISTRIBUTION

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Foreword
This manual describes the functioning of a liquid cooling system which is used in
combination with a electrical power drive system. The cooling unit forms a closed-loop
cooling system (internal circuit) together with the piping and heat exchanger in the supply,
inverter and brake units of the drive. The coolant is pumped through the drive units and
cooled by a liquid to liquid heat exchanger and the heat is transferred to the ships closed
loop cooling system. A short description of the external cooling system is given only up to
and including the connection flanges of the cooling cabinet.

The internal cooling circuit is equipped with an expansion tank which damps the pressure
variations due to liquid volume changes with temperature. The location of the expansion tank
is at the inlet side of the circulation pump to provide stable pressure for the pump.
The external cooling circuit is equipped with a three way valve which functionality is to avoid
condensation in the internal closed-loop cooling system, inner cabinet, cooling pipes and
drive parts.
There are different variants of the cooling cabinets:
One circulation pump
Two (one redundant) circulation pumps, one pump running at the time
Electrical- or pneumatic controlled three way valve
Maximum transferable power is about 100kW depending on liquid temperatures and
flow ratings
This manual is intended for people who install, commissioning, use and service the liquid
cooling system. Read the manual before you work on the liquid cooling system. The reader is
expected to know the fundamentals of electricity and wiring as well as liquid cooling and
materials. Instructions are given how to handle generally, how to commission/maintain and
repair the liquid-cooling section as a part of a liquid-cooled frequency converter. This in a way
that works can be done safely.

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1 GENERAL
The cooling system of a liquid-cooled drive consists generally of two circuits. Firstly the internal
cooling circuit (closed loop) that covers the heat-generation from electrical components and transfers
the heat to the cooling unit. Secondly the external cooling circuit that is usually a part of a larger
external cooling system. This can be an industrial or marine cooling system. We may call the internal
cooling section the warm side and the external cooling section the cold side of the cooling system.

Manual is written for the following types liquid cooling circuits:

• Standard nr. 9996000 – 6115 • Standard nr. 9996000 – 6153
• Standard nr. 9996000 – 6116 • Standard nr. 9996000 – 6154
• Standard nr. 9996000 – 6117
• Standard nr. 9996000 – 6118
• Standard nr. 9996000 – 6119
• Standard nr. 9996000 – 6120
• Standard nr. 9996000 – 6121
• Standard nr. 9996000 – 6122

1.1 Safety instructions

Warning: Only qualified electricians and/or people with knowledge of liquid cooled systems
are allowed to install and maintain the system.

Warning: Several components and assemblies are heavy weighting. If lifting of heavy items
is necessary, extreme caution shall be exercised. Safe, reliable mechanical lifting shall be
used wherever possible. Under no circumstances shall items be lifted by means of straps,
ropes, chains etc. connected to piping or other system components.

Warning: to allow maintenance work, make sure that the equipment has been electrically
isolated before maintenance work is started.
In case two pumps are available in a liquid cooling system, redundancy, one motor can be
switched off in the auxiliary control panel and the other pump motor is still running. Also
make sure that the motor to work on has been electrically isolated before maintenance work
is started.

Warning: take care of the ac-heating if available. To avoid contact with hands and electrical
disturbance switch off the ac-heating before starting maintenance work.

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1.2 Address
Bakker Sliedrecht Electro Ind. Phone: +31 (0)184 436 666
P.O. Box 25 Fax: +31 (0)184 436 677
3360 AA Sliedrecht Internet: www.bakkersliedrecht.com
The Netherlands

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2 INSTALLATION INSTRUCTIONS

2.1 Storage instructions

In order to maintain the equipment in good condition after the delivery and to keep the
warranty valid during the warranty period the following items must be taken care of:

2.2 Transport status

The equipment must be inspected when received to find out possible transport damages and
in that case immediately report Bakker Sliedrecht Electro Industry.

When the converter will be delivered in one piece, the cooling system is normally not filled
with liquid. When on customer specification the cooling system must be transported with a
filled cooling system, 0,5% corrosion inhibitor and glycol must be added to the liquid.

2.3 Air demand

The cabinet should be stored in their original packings in a dry (relative humidity less than
95%), vermin proof area or room. The air may not include corrosive gases, salt or other
impurities that may damage electronic equipment. No condensation is allowed inside the
cabinet. In case of doubt call Bakker Sliedrecht.

2.4 Temperature limits

The storage temperature range is +5...+70°C, or approximately –20...+70°C when the
cooling system is filled with tap water and glycol and corrosion inhibitor.
Freezing of the liquid cooling system is not allowed. If ambient temperature is below +5°C.
add antifreeze and corrosion inhibitor to the cooling liquid. For more specific information
about antifreeze and inhibitor see section 4.4.
Operation at temperatures below zero is not permitted, not even with antifreeze.

2.5 Place of installation

At least 800mm of space must be reserved in front of the cabinet door to help installation and
component changing. From the front side of the cabinet one has access to all the necessary
components in the cabinet for maintenance and repair, but it is recommended to reserve at
least 400mm of space behind the frequency converter to help maintenance and repair. At the
side of the cabinet where the liquid connections are placed it is recommended to reserve
500mm space.

2.6 Covering during installation

To protect the equipment in the cabinet against dust and damage, keep the cabinet doors
closed as much as possible.

2.7 External liquid cooling connection (outside)

Data for the external liquid cooling system can be found on the Bakker Sliedrecht electrical
drawings, with subject ‘dimensions’ of the concerning frequency converter.

Marine application:
A flexible connection must be fitted between the drive liquid cooling system pipe connection

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joints and the outside (ships) liquid cooling pipes.

3 CONTROL AND DIAGNOSTIC OF THE COOLING SYSTEM

3.1 Control of the three way valve

Pump and three-way valve control is embedded in a PLC system, which normally can be
found in the auxiliary control panel.
Control of the three-way valve is based on the temperature measurement in the internal
cooling system.

If the room temperature is low and the humidity high, condensation can occur. See also
section 4.1.1 Temperature limits. Normally the cold liquid side of the cooling system is
equipped with a three way motor controlled valve, which creates a by-pass circuit in parallel
over the heat exchanger. The three-way valve is controlling the flow in such away that the
internal liquid cooling temperature does not differ to much from the inside cabinet
temperature to avoid condensation. Protection for high- or low temperature, high- or low
pressure and pressure difference over the pump are programmed in the PLC software.

Diagnostics

In most cases the PLC system, which is controlling and monitoring the liquid cooling system,
will be coupled to a display which is mounted on the cabinet door of the aux. control panel.
This display gives status, alarm or fault message information. For more detailed information
see also the PLC program for the specific drive. Behind the door of the liquid cooling panel
the Nominal-, Alarm- and Fault settings are written down on a covered sheet.

4 SPECIFICATIONS OF INTERNAL AND EXTERNAL COOLING CIRCUIT

4.1 Internal cooling circuit data

4.1.1 Temperature limits

Minimum coolant inlet temperature: Condensation is not allowed. The minimum coolant

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temperature to avoid condensation (at an atmospheric pressure of 1 bar or 100kPa) is shown

below as a function of the relative humidity and the ambient temperature.

! ! "#
$%"&
'

Not allowed as standard, the coolant temp. must be 5°C or

above

4.1.2 Pressure limits

Recommended base pressure: 1,2……1,5 bar (120 …150kPa).
Maximum base pressure: 2 bar (200kPa).
Base pressure is the pressure of the internal (filled) cooling system compared with the
atmospheric pressure with the circulation pump in off state.

Maximum design pressure: 6 bar (600kPa).

Maximum test pressure: 8 bar (800kPa).

Design Temperature pipes and components: 60°C. Max Allowed continuous temperature is
70 °C.

Pre-filling pressure of the expansion tank: 0,5 bar (50kPa).

Pressure drop external liquid cooling circuit: 0,5……1 bar (50…..100kPa).

4.1.3 Internal Liquid quality

Use of tap water is allowed. Tap water must fulfil the requirements of the Council Directive
98/83/EC of 3/11/98 on the quality of water intended for human consumption. Corrosion
inhibition with 0,5% by volume Cortec VCI-649 is required

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( ) !*

4.1.4 Freeze protection and corrosion inhibition

Freeze protection
A water-glycol solution is allowed for freeze protection. The glycol must be pure Propylene
Glycol.
Note: if more than 25% glycol is added, the pressure loss in the system increases. An
operation pressure of more than 1,5 bar is required for sufficient flow.
Example: Dow Propylene glycol; Cas number 57-55-6 ; available from the Dow Chemical
Company, www.dow.com).

Glycol Concentration
Fig. 2 shows the required glycol concentration in weight percentage according to
ambient/storage temperature T.

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( Glycol concentration % (weight)

Caution: operation at temperatures below 0°C is not permitted even with antifreeze.

Note: if more then 25% of DOW Propylene Glycol is added, then the pressure loss in the
ystem increased. An operation pressure of more than 105kPa is required for sufficient
flow.

Corrosion inhibition
Corrosion inhibition with 0,5% (volume) VCI 649 (by Cortec Corporation;
www.cortecvci.com).
Life cycle of the inhibition is two years.

4.1.5 Connecting of the internal piping

Connection of the internal cooling circuit piping with the electrical drive system cooling pipes
is done with Straub couplings. These kind of couplings must be fastened with a torque
wrench. The tight torque can be reed from the couplings itself.

4.1.6 Materials
Materials used in the internal cooling circuit are:

Stainless steel AISI 316L

Heavy gauge aluminium
Plastic materials such as PA, PP-R and Teflon
Rubber gaskets NBR / EPDM.

Caution: connecting external piping to the internal cooling circuit, use only materials that are
specified above. Copper and brass must not be used under any circumstances. The liquid
may not contain any zinc at all because zinc would react with the inhibitor.

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4.2 External cooling circuit data

4.2.1 Liquid quality

Industrial liquid suitable for stainless steel AISI 316L piping material or Plastic Poly Propylene
(PP-R) piping material. The Plastic piping is a product of Aquatherm GmbH.
The liquid must not contain sediment, organic or chemically active matter.
For use of any kind of inhibitor contact Bakker Sliedrecht.

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% ) ! ) *

No salt or seawater may be used as cooling liquid in the external circuit!

4.2.2 Temperature and pressure limits

Requirements external cooling circuit

Minimum inlet temperature (°C) 5
Maximum inlet temperature (°C) 38
Maximum design pressure (bar) 10
Maximum temperature rise (°C) 10

4.2.3 Connecting of the external piping

Coupling type Material Dimension Boult fixing moment

Flange AISI 316L – DIN2633 DN 40 – ND 16 M12 = 70Nm en M16 =
160Nm.
Flange PP-R (plastic with iron 40mm – PN10 / 20Nm
core) DIN 16962 DN40

4.2.4 Heat exchanger type

Special type heat-exchanger by Klima Thermo Tech B.V.
Plate material choice is AISI 316.
Detailed information can be found in the user/service manual of Klima.

5 OPERATION, COMMISSIONING AND MAINTENANCE

Note: consult chapter specifications for information what kind of liquid that may be used.
The functional drawings of the liquid cooling system is given in appendix A. Information

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of the position of valves in the running state can be obtained from the functional diagram.
Filled valve symbols on the diagram indicate valves in close position.

5.1 Filling and bleeding the cooling liquid circuit

Caution: bleeding the liquid-cooling circuit is very important and has to be done with great
care. Air bubbles in the cooling circuit may reduce or completely block coolant flow and lead
to overheating. This can lead to persisting damage on drive components.

Caution: do not run the circulation pump(s) if the cooling circuit is empty or not de-aerated.
Not even for a short time! If a pump runs dry, the pump seals will be damaged immediately.

Filling up and bleeding instructions:

Before filling the internal cooling system, the frequency converter and the liquid must be at
room temperature.

1. Switch off the auxiliary supply in the control panel to prevent the internal liquid cooling
pump from starting.
2. Check that the pipe joints are in place, properly adjusted and the locking bolts are
tightened.
3. Check that all valves are in position as given on the functional diagram; Appendix A.
4. Lead the bleed hoses after the valves V11, V26 and ..V4 into buckets or other suitable
containers. Extend the standard hoses if necessary (appendix A).
5. Open the bleed valves V11, V26 and the valve …V4 on the top of the “upper” distribution
pipe, which is placed in the drive cabinet at the other side then where the liquid-cooling
panel is placed.
Air relief plug

Drain plug

%
* !! + **+
*

6. Mix inhibitor to a suitable amount of coolant, see section 4.1.4.

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7. Connect the portable liquid-filling pump between the filling connection (W1) and the liquid
barrel. Avoid pumping air into the liquid-cooling circuit.
8. Fill the system, using valve V25, with coolant until the pressure gauge reads 2 bar.
9. When there is sufficient amount of coolant in the circuit, it will begin to flow from the bleed
hoses. Let some coolant flow out before closing the bleed valves (check that there are no
air bubbles visible in the bleed hose).
10. Bleed the circulation pump(s). The air relief nipple is located on the top of the pump just
between the motor and pump housing (see fig. 3).
11. Refill the system if the pressure drops below 1,5 bar till the pressure is about 2 bar.
12. Start the circulation pump and check direction of rotation (arrow on top of pump).
If two pumps are available check direction of both pumps.
13. Start the pump for about 1 minute. Stop the pump and de-aerate the pump(s) as stated
under item 9 and also the cooling system with bleed valves V11, V26 and …V4. Add
liquid if needed.
14. Repeat steps 9 to12 a few times so that all air is let out of the cooling system.
15. When de-aeration has been finished stop the pump and refill the system to a base
pressure of 1,5 bar (P1).
16. Close valve V25 and disconnect the filling pump.

5.2 Draining the internal liquid cooling system

Be sure that the circulation pump is switched off. The drain hoses after the bleed valves V12
and V18 must be lead into buckets or other suitable containers. Extend the standard hoses if
necessary. Open the valves V12 and V18. If the pressure (P1) is zero also open the de-
aeration valve V11 for air intake. After emptying the cooling system close all mentioned
valves.

If required, dry the piping with compressed oil-free air of less than 6 bar. Before doing this it
is recommended to close the expansion vessel with valve V13 or opening drain valve V15.

5.3 Maintenance of liquid cooling motor/pump

The circulation liquid cooling pump is of the low maintenance type. Pump bearings and shaft
seal are maintenance free.
Also see “CRN installation and operating instructions manual” of the liquid cooling pump
(Grundfos).

5.4 Replacing the liquid cooling pump

When two pumps are used the valve numbers needed for the second pump are placed
between brackets.
Switch off the auxiliary supply in the control panel to prevent the pump from starting.

1. Close the valves V16 and V20 or when redundant pump available the valves V17 and
V23.
2. Lead the drain hose after the valve V18 (V21) into a bucket or other suitable container.
3. Open the drainage valve V18 (V21) to let the liquid out.
4. Open the de-aeration nipple on the top of the pump to let air in.
5. Loosen the drain plug at the lower side (front) of the circulation pump (see figure 3).
6. Loosen the victaulic couplings at both sides of the circulation pump.
7. Disconnect the motor cable.
8. Replace the circulation pump and install the victaulic couplings.

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9. Connect the motor cable.

10. Close the drainage valve V18 (V21).
11. Open the valves V20 (V23).
12. Refill the system with the liquid filling pump by way of filling connection W1 and shut off
valve V25 till 2.0 bar.
13. De-aerate the system with the air relief screw at the topside of the circulation pump (see
figure 3 and section 5.1 item 9).
14. Refill the system if needed to ca. 1.5bar.
15. Open valve V16 (V17).
16. Check for leaks. If circulation pump leaks, shut off the pump as stated under item 1.
17. Dry the possible drops of cooling liquid.
18. Switch on the auxiliary supply in the control panel and the liquid cooling circulation pump
will start.
19. Check the rotation of the circulation pump!
20. Start the pump for about 1 minute. Stop the pump and de-aerate the pump(s) as stated
under section 5.1 item 9 and de-aerate also the cooling system with bleed valves V11
and …V4. Add liquid if needed.
21. When de-aeration has been finished stop the pump and refill the system to a base
pressure of 1,5 bar (P1).
22. Cooling system is ready for use.

5.5 Replacing the PT100 sensor

Using PT100 sensor (R1) performs measurement of the liquid temperature.
The temperature sensor is located at the low temperature side of the internal cooling circuit
near to the heat exchanger. The temperature transmitter (located in auxiliary control unit)
provides 4-20mA signal output proportional to the temperature 0-100°C. This signal is
connected to a analogue PLC input card.
The PLC supervises the measurement of the liquid temperature and controls the three-way
valve. If the signal is lost, an alarm indication appears. The fault can be either in the PT100
sensor, transmitter or in the wiring. When the wiring is broken or PT100 fails, a text appears
on the text display.
Check that there are no loose-contacts of the PT100 sensor or loose-screw(s) in the terminal
stroke in the cabinet.

Measurement and replacement of the PT100 sensor can be done as follows:

1. Switch off the auxiliary supply in the control panel.

2. Disconnect the leads of the PT100 sensor from connecting terminals (in WCU unit).
3. Measure the resistance of the PT100 sensor between the leads 1 and 3. If the resistance
value is infinite, then the sensor or wire is broken. (100 = 0°C and 137 =100°C)
4. The internal circuit has to be drained as written in section 5.2 before the PT100 sensor
can be taken out of the liquid cooling system..
5. If the circuit is empty the PT100 sensor can be removed by loosen the nut and pulling out
the sensor. Also disconnect the wiring.
6. Replace the PT100 sensor by a new one and reconnect the wiring.
7. Connect the wires of the PT100 sensor to the connecting terminal.
8. Fill and de-aerate the cooling liquid circuit as written in section 5.1

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, --* *

5.6 Replacing the pressure sensor

The pressure of the internal liquid cooling system is measured with two pressure transmitters
U11 and U12. Measuring points are at the suction- (U11) and pressure (U12) side of the
circulation pump. A visual indicator, a pressure gauge, is placed in the pressure side of the
pump. The pressure transmitters are providing 4-20mA which is equal to 0 -10bar. This signal
is connected to a analogue PLC input card.
The PLC supervises the 4 – 20mA signal of the pressure. If the signal is lost, an alarm
indication appears. The fault can be either in the pressure sensor or in the wiring. If the
wiring is broken or the sensor defect, a text appears on the text display.
Check that there are no loose-contacts of the pressure sensor.

Replacing of the pressure sensor can be done as follows:

1. Measure the signal output of the pressure sensor (in WCU unit). This signal output is
proportional to the pressure. When the circulation pump is not running, compare the
signal output of the pressure transmitter with the pressure that the pressure gauge
indicates. If they differ, the fault is probably in the pressure sensor.
2. Switch off the auxiliary supply in the control panel.
3. Close valve V14 or V24.
4. Remove first the electrical connection plug and after that the pressure sensor can be
screwed out. (Note: a little bit of liquid will leak out of the cooling system)
5. Replace the pressure sensor by new one if it is faulty
6. Glue the thread of the new transmitter with Loctite 570 and fit the new sensor. Fit also the
wire connection plug on the pressure transmitter.
7. Open valve V14 or V24.
8. Switch on the auxiliary supply in the control panel.
9. If the pressure gauge is faulty, the replacement of the pressure gauge can be done in the
same way as done for pressure transmitter U12. The thread is filled with Loctite 570.
10. Check the liquid pressure and add liquid to the system if necessary. See section 5.1.

5.7 Replacing of the expansion vessel

A defective expansion vessel can be detected as follows:
Pressure of the internal cooling system has dropped without leakage. (Filling of the cooling
system was needed several times without founded leakage)
The pressure gauge (P1) needle vibrates when the circulation pump is running.

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There is a high difference in pressure between a cold and warm system.

Unscrew the black protection cover on the bottom side of the vessel (fig. 5). Push the filling
pin in the plug for a short time. Look if liquid is coming out. If there is liquid leaking the vessel
is damaged.

How to measure the base or pre-filling pressure of the expansion vessel?

Close valve V13 when the circulation pump is running.

Stop the circulation pump by switching off the auxiliary supply in the control panel.
Drain the liquid with valve V15 in an empty bucket until no liquid is left in this circuit.
Measure the base pressure with a pressure gauge on the plug at the lower side of the
vessel. An air-relief or filling nipple is located under the black cap (fig. 5). The air-pressure
must be 0,5 bar. If not than refill the vessel.
Close valve V15 and open the valve V13 and refill the system as described in section 5.1.

Replacing of the expansion vessel

Caution: check always the pre-filling pressure of new expansion vessels. Normally the pre-
filling pressure is too high and must be de-aerate to 0,5 bar!

Close valve V13

Put the drain hose behind valve V15 in an empty bucket and drain the system with the
valve V15.

Protection cover air

relief or filling nipple

Replace the expansion vessel by a new one (use tape on the thread).
Measure the base pressure of the vessel with a pressure gauge at the lower side of the
expansion vessel. An air-relief nipple is located under the black cap (see figure 5). The base
air-pressure must be 0,5 bar. De-aerate or fill the vessel until the above mentioned pressure
is reached.
Close valve V15 and open V13.
Add liquid to the system until the base pressure measured with P1 is 1,5 bar.
Check that there is no leakage and start the cooling circulation pump.

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5.8 Replacing of the plate heat exchanger

Switch off the auxiliary supply in the control panel.
Mostly outside the cabinet there are placed shut-off valves for isolating the liquid cooling
circuit of the drive with the ships cooling system. If they are available close these valves.
Drain the internal liquid cooling system (see section 5.2) as well as the part of the external
ships liquid cooling system, before removing the heat exchanger. In the cooling-liquid cabinet
there are placed a drain valve (V2) and a de-aeration or bleeding valve (V1). Drain the
external system with V2.
For more instructions see the user/service manual of the plate heat exchanger.
Before the flexible rubber seals are placed, when the heat exchanger is replaced, put some
vaseline on the inner surface of the seal.
Refill the internal system as described in section 5.1. Open the shut-off valves outside the
cabinet.

5.9 Replacing of the 3-way valve

Switch off the auxiliary supply in the control panel and disconnect the electric part of the 3-
way valve.
Mostly outside the cabinet there are placed shut-off valves for isolating the cooling circuit of
the drive with the ships cooling system. If they are available close these valves. In the liquid
cooling cabinet there is placed a drain valve (V2) and a de-aeration or bleeding valve (V1).
Drain the external system with V2.
Note: if the control part of the valve is executed with air pressure closing facility disconnect
the air pressure connection pipes.
Take out the three-way valve. For more information about the three–way valve you can look
for the users manual.
After replacing it is advisable to renew the gaskets.
After return back the three-way valve open the shut-off valves outside the cabinet and
reconnect all disconnected parts.

6 MAINTENANCE / SERVICE
Before any inspection or maintenance procedures, read part “Safety” of this manual.
Inspection and maintenance shall be carried out at a maximum of 12-month intervals. The
purpose of maintenance/service is to keep the Bakker/ABB frequency drive in good condition
and to minimise the risk of different faults.

6.1 Pressure Inspection

Caution: in case of extremely water filling check the expansion vessel.

Read out the pressure gauge placed in the liquid cooling unit to check the pressure of the
internal liquid circulation system.
Bleed the system with valve V26 during inspection. If the pressure differs more than 0,5 bar
of the pressure set in commissioning settings (paper backside cabinet door) or if the
pressure varies more than ±0,5 bar, de-aerate the cooling system. Add water or water/glycol
mixture with inhibitor as described in section 4.1.3 and 4.1.4 if needed. The normal pressure
of the liquid cooling system is approximately 3 bar with pump running. The instructions of
how to de-aerate and refill the cooling system are given in section 5.1.

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6.2 liquid cooling pump inspection

The pump system needs very little maintenance. Pump bearings and shaft seal are
maintenance free. However it is good to check if liquid is leaking along the shaft seal. If liquid
leaking is noticed, the shaft seal must be changed as soon as possible.
If abnormal noise or vibration of the pump motor is noticed, the motor bearings may have to
be changed.

6.3 Visual inspection

It is advisable to have a thorough visible inspection of the cabinets and cable connections
every year. Check for loose connections in control wiring.
Check regular (every month) the mechanical running conditions of the circulation pump.

6.4 Three way valve maintenance

Each year re-lubricate the spindle nut on top of the valve. Use for example Teflon spray.

6.5 Add inhibitor to the internal cooling system

After each two years there must be added new inhibitor to the internal liquid. This must be a
0,5% of the total liquid volume and from the type mentioned in section 4.4. Drain an amount
of the internal liquid in a empty bucket, for example 10 litre, and mix this with the inhibitor and
add it to the cooling system. See instruction in section 5.1.
Take care that the amount of inhibitor will be no more then 0,5% of the total volume of liquid
otherwise the liquid inside the cooling system will foaming.

6.6 Maintenance intervals

The table lists the routine maintenance intervals recommended by Bakker Sliedrecht.

Interval Maintenance action Instruction

Every year Three way valve See section 6.4
Circulation pump visual inspection on leaking
Every two years Add corrosion inhibitor to the internal See adding inhibitor section
cooling circuit. 6.5
Check the air pressure in the expansion See section 5.7
tank.
Every 6 years Replace the cooling water pump or See section 5.3 and/or 5.4
seal.
Every 10 years Change the cooing liquid in the internal See section 5.2 and 5.1
cooling circuit.

7 TROUBLE SHOOTING
Fault or Warning messages are presented on a display which is normally a part of the

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electrical drive system.

Faults or Warnings can be under- or overpressure, low or high temperature of the cooling
liquid.

Warning Presumable cause Actions

Liquid leakage Liquid leakage in WCU cabinet Detect leakage and repair. Dry
leakage tray and cabinet
U11 – pressure low Pressure at inlet of pump is low Check internal cooling circuit
due to leaking and repair leakage

Expansion leaking Check expansion vessel as

written in section 5.7
U12 – pressure low Pump impeller Check pump or replace the
pump.
Closed valve Check position valves at in- and
outlet of the pump.
Pressure difference To high flow in the internal cooling Check pressure at in- and outlet
low circuit side of the pump.
Faulty pressure sensor U11 or Replace pressure sensors.
U12.
Impeller problem of the pump Replace the pump.

Warning Presumable cause Actions

Pressure difference Less of flow through internal
high cooling circuit.
Blockage of coolant in drive Checking of flow by measuring.
modules or piping.
Faulty pressure sensor U11 or Check pressure at in- and outlet
U12. side of the pump.
Impeller problem of the pump Replace pressure sensors.

Replace the pump.

U11 – pressure high Base pressure of the system is too Check base pressure of
high due to: expansion tank, see section 5.7.

system filled with too much Check the pressure and drain if
liquid needed.
plates of heat exchanger Check heat exchanger, see
leak. External liquid flows section 5.8
inside.
Temperature low - R1 Liquid temperature of internal Check outside water
circuit low and drive is running temperature.
with low power. Check position and working of
Condensation can occur three way valve.
Check if the pump M1 or M2 is
running.
Temperature high - Liquid temperature of internal

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R1 circuit high due to:

Too low cooling capacity. Increase external flow.
The heat exchanger is Clean heat exchanger, see
blocked up. section 5.8
Three way valve Check working of three way
valve.

Fault Presumable cause Actions

Sensor fault U11 or U12 or Pressure or Temperature Check cabling or sensor
R1 sensor fault itself.
U11 – pressure too low Pressure at inlet of pump is Check internal cooling circuit
low due to leaking and repair leakage

Expansion leaking Check expansion vessel as

written in section 5.7
U12 – pressure too low Pump impeller Check pump or replace the
pump.
Closed valve Check position valves at in-
and outlet of the pump.
Temperature too low - R1 Liquid temperature of internal Check outside water
circuit low and drive is temperature.
running with low power. Check position and working
Condensation can occur of three way valve.
Check if the pump M1 or M2
is running.
Temperature too high - R1 Liquid temperature of internal
circuit high due to:
Too low cooling Increase external flow.
capacity. Clean heat exchanger, see
The heat exchanger is section 5.8
blocked up. Check working of three way
Three way valve valve.

8 WASTE DISPOSAL OF WATER COOLING CABINET OR PARTS OF IT

Waste disposal of used materials and components must be done according the rules of the
local authorities.

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APPENDIX A – FUNCTIONAL WATER COOLING CIRCUIT DIAGRAM

ONE PUMP

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APPENDIX B – FUNCTIONAL WATER COOLING CIRCUIT DIAGRAM

TWO PUMPS

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APPENDIX C – 3D ARRANGEMENT EXPLODED VIEW – ONE PUMP

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APPENDIX D – 3D ARRANGEMENT EXPLODED VIEW – TWO PUMPS

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Last page

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