Aradex VECTOPOWER VP5000-DC User manual

VECTOPOWER
VP5000-DC/DC60, VP5000-DC/DC200-HL
Date of issue: 2019-02-08
Version: 1.4
Language: English
Read carefully before use – keep for reference
Installation manual

Manufacturer and customer service address
ARADEX AG
Ziegelwaldstraße 3
73547 Lorch – Germany
Goods acceptance:
Hohenstaufenstraße 34
73547 Lorch - Germany
Telephone: [phone] – 0
Fax [phone] – 91
E-mail: [email protected]
Internet: www.aradex.com

VP5000-DC/DC60, VP5000-DC/DC200-HL
Contents
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Contents
Installation manual...................................................................................................................................... 1
1About the manual ......................................................................................................................... 7
Validity of the manual for the following devices............................................................................... 71.1 Document history ........................................................................................................................... 71.2 Language of the original manual ..................................................................................................... 71.3 Objective of the manual.................................................................................................................. 71.4 Other applicable documents and software ...................................................................................... 81.5 Conventions in this manual............................................................................................................. 81.6 Applicable standards and directives................................................................................................ 91.7 Copyright, brand names.................................................................................................................. 91.8
2Safety ..........................................................................................................................................10
Proper use .................................................................................................................................... 102.1 This manual is part of the device................................................................................................... 102.2 Legibility of signs and inscriptions on the device........................................................................... 102.3 Structure of the safety instructions............................................................................................... 112.4 Used symbols ............................................................................................................................... 122.5 Hazards ........................................................................................................................................ 122.6
2.6.1 Electricity...................................................................................................................................... 12
2.6.2 Residual electrical voltage after switch-off .................................................................................... 13
2.6.3 Hot surfaces ................................................................................................................................. 13
2.6.4 Operating noises........................................................................................................................... 13
2.6.5 Weight .......................................................................................................................................... 13
2.6.6 Coolant......................................................................................................................................... 14
Personnel requirements................................................................................................................ 142.7
2.7.1 Qualified electrician ...................................................................................................................... 14
2.7.2 Programmer.................................................................................................................................. 15
2.7.3 Installer......................................................................................................................................... 15
2.7.4 Carrier .......................................................................................................................................... 15
2.7.5 Warehouse clerk ........................................................................................................................... 15
2.7.6 Sobriety is a prerequisite .............................................................................................................. 15
3Product description ....................................................................................................................16
Identification................................................................................................................................. 163.1
3.1.1 Device designation ....................................................................................................................... 16
3.1.2 Rating plate .................................................................................................................................. 17
Functional description .................................................................................................................. 183.2
3.2.1 General function ........................................................................................................................... 18
3.2.2 Structure and function of the VECTOPOWER VP5000-DC/DC60.................................................. 18
3.2.3 Structure and function of the VECTOPOWER VP5000-DC/DC200-HL .......................................... 20
3.2.4 Operating modes: Buck converter / boost converter.................................................................... 23
Technical data .............................................................................................................................. 253.3
3.3.1 Electrical data - Power connections .............................................................................................. 25
3.3.2 Electrical data for operation as a buck converter .......................................................................... 25
3.3.3 Electrical data for operation as a boost converter......................................................................... 27
3.3.4 Electrical data - voltage ripple ....................................................................................................... 29
3.3.5 Electrical data - [ST1] - [ST4] logical connections ......................................................................... 29
3.3.6 Interfaces ..................................................................................................................................... 31
3.3.7 General data and environmental data ........................................................................................... 31

VP5000-DC/DC60, VP5000-DC/DC200-HL
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3.3.8 Data for cooling ............................................................................................................................ 32
Installation dimensions and distances........................................................................................... 333.4
3.4.1 Dimensions of the VECTOPOWER VP5000-DC/DC60................................................................... 34
3.4.2 Dimensions of the VECTOPOWER VP5000-DC/DC200-HL ........................................................... 35
3.4.3 Minimum distances from neighboring components to be observed............................................... 37
3.4.4 Installation position....................................................................................................................... 39
Position and designations of the power, signal, and cooling connections...................................... 393.5
3.5.1 VECTOPOWER VP5000-DC/DC60................................................................................................ 40
3.5.2 VECTOPOWER VP5000-DC/DC200-HL ........................................................................................ 41
Power connections ....................................................................................................................... 423.6
3.6.1 VECTOPOWER VP5000-DC/DC60................................................................................................ 42
3.6.2 VECTOPOWER VP5000-DC/DC200-HL ........................................................................................ 42
3.6.3 Wire cross-section of the ground wire acc. to EN 62477-1 ........................................................... 43
3.6.4 Table of EMC cable glands from Pflitsch, blueglobe TRI type......................................................... 43
Logical connections...................................................................................................................... 443.7
3.7.1 [ST1] design and pin assignment .................................................................................................. 45
3.7.2 [ST2] design and pin assignment .................................................................................................. 47
3.7.3 [ST3] design and pin assignment .................................................................................................. 49
3.7.4 [ST4] design and pin assignment of the VECTOPOWER VP5000-DC/DC60................................... 51
Design of the connections ............................................................................................................ 523.8
3.8.1 Required connections (minimum configuration) ............................................................................ 52
3.8.2 [ST1] and [ST2] version of the digital inputs designed as low-active input ..................................... 55
3.8.3 [ST1] digital outputs designed as low-side switches ...................................................................... 55
3.8.4 [ST2] digital outputs designed as low-side switches ...................................................................... 56
3.8.5 [ST2] and [ST4] connections for an external precharging circuit for VECTOPOWER VP5000-
DC/DC60..................................................................................................................................... 56
3.8.6 [ST1] connections for a firmware update ...................................................................................... 59
3.8.7 [ST3] connections to a VECTOBUS system ................................................................................... 59
Characteristic curves for current, voltage, and power ................................................................... 603.9
3.9.1 VECTOPOWER VP5000-DC/DC60................................................................................................ 60
3.9.2 VECTOPOWER VP5000-DC/DC200-HL ........................................................................................ 62
Characteristic curves for derating................................................................................................. 643.10
3.10.1 VECTOPOWER VP5000-DC/DC60................................................................................................ 64
3.10.2 VECTOPOWER VP5000-DC/DC200-HL ........................................................................................ 65
Characteristic curves for efficiency............................................................................................... 663.11
3.11.1 VECTOPOWER VP5000-DC/DC60................................................................................................ 67
3.11.2 VECTOPOWER VP5000-DC/DC200-HL ........................................................................................ 69
Scope of supply ............................................................................................................................ 723.12 Accessories that can be obtained from ARADEX AG ..................................................................... 723.13
3.13.1 Overview of the required quantities............................................................................................... 73
3.13.2 EMC cable glands [DC+/-], [OUTPUT+/-], [BR+/-] ....................................................................... 74
3.13.3 Cable lugs for [DC+/-], [OUTPUT+/-], [BR+-/], ground wires, and Nord-Lock lock washers.......... 74
3.13.4 Mating connectors for [ST1] ......................................................................................................... 74
3.13.5 Mating connectors for [ST2] and [ST3] ......................................................................................... 75
3.13.6 Mating connector for [ST4] ........................................................................................................... 76
3.13.7 Cooling water connection ............................................................................................................. 76
3.13.8 Connection interface .................................................................................................................... 77
3.13.9 Other accessories......................................................................................................................... 77
Accessories that the customer must provide ................................................................................ 773.14
3.14.1 Cables/wires and terminals (specification) ................................................................................... 77
3.14.2 Wire for [DC+/-], [OUTPUT+/-], and, if required, [BR+/-].............................................................. 78

VP5000-DC/DC60, VP5000-DC/DC200-HL
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3.14.3 Cable for [ST1].............................................................................................................................. 78
3.14.4 Cables for [ST2] and [ST3] ............................................................................................................ 79
3.14.5 Cable for [ST4].............................................................................................................................. 79
4Notes on planning.......................................................................................................................81
Qualification of the planner........................................................................................................... 814.1 Checklist for system integration of the VECTOPOWER .................................................................. 814.2 Notes on system integration ......................................................................................................... 834.3
4.3.1 Observing standards, directives, and statutory provisions ............................................................. 83
4.3.2 Selection: Observe the derating.................................................................................................... 83
4.3.3 Minimizing residual risks ............................................................................................................... 83
4.3.4 Considering project planning scenarios ........................................................................................ 84
4.3.5 Allowing sufficient space............................................................................................................... 84
4.3.6 Providing secure fastening ............................................................................................................ 84
4.3.7 Providing adequate cooling ........................................................................................................... 84
4.3.8 Application of a higher voltage to [DC+/-] .................................................................................... 85
4.3.9 Providing a device or method to make sure that no voltage is present.......................................... 85
4.3.10 Protecting connections externally ................................................................................................. 85
4.3.11 Optionally integrating [ST4] with VECTOPOWER VP5000-DC/DC60 ............................................. 85
4.3.12 Integrating a brake chopper [BR+/-] with VECTOPOWER VP5000-DC/DC200-HL ........................ 86
4.3.13 Providing a precharging circuit with the VECTOPOWER VP5000-DC/DC60 .................................. 87
4.3.14 Providing a precharging circuit for VECTOPOWER VP5000-DC/DC200-HL ................................... 89
4.3.15 Protection against large currents when switching on .................................................................... 90
4.3.16 Measuring current ripple and voltage ripple .................................................................................. 91
4.3.17 Using external capacitors and chokes to attenuate the voltage ripple and current ripple .............. 91
4.3.18 Ensuring electromagnetic compatibility (EMC) .............................................................................. 93
4.3.19 Use of Y capacitors in the DC link [DC+/-] ................................................................................... 94
5Packaging, transport, storage....................................................................................................95
Qualification of personnel ............................................................................................................. 955.1 Packaging ..................................................................................................................................... 955.2 Transport ...................................................................................................................................... 955.3
5.3.1 Transport lock............................................................................................................................... 96
5.3.2 Storage......................................................................................................................................... 96
6Installation and commissioning .................................................................................................97
Qualification of personnel ............................................................................................................. 976.1 Receipt ......................................................................................................................................... 976.2 Installation .................................................................................................................................... 976.3
6.3.1 Mounting on a vertical mounting plate .......................................................................................... 97
6.3.2 Mounting on a horizontal mounting plate .................................................................................... 100
6.3.3 Connect the cooling unit............................................................................................................. 104
6.3.4 Preparing the [DC+/-], [OUTPUT+/-], and, if necessary, [BR+/-] wires for power connections ... 105
6.3.5 Preparing the [ST1] cable............................................................................................................ 112
6.3.6 Preparing the [ST2] and [ST3] cable............................................................................................ 115
6.3.7 [ST4] cable preparation for VECTOPOWER VP5000-DC/DC60.................................................... 117
6.3.8 Establishing electrical connections on the VECTOPOWER VP5000-DC/DC60 ............................ 119
6.3.9 Establishing electrical connections on the VECTOPOWER VP5000-DC/DC200-HL..................... 126
Commissioning ........................................................................................................................... 1336.4
6.4.1 Test system for testing................................................................................................................ 133
6.4.2 Tests before initial commissioning .............................................................................................. 133
6.4.3 Initial commissioning for an application ...................................................................................... 135

VP5000-DC/DC60, VP5000-DC/DC200-HL
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-HL_installation_manual_v1-4en.docx
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6.4.4 Initial commissioning with an existing parameter set................................................................... 138
6.4.5 Commissioning for a series application....................................................................................... 141
Forming after storage for more than 6 months............................................................................ 1436.5
6.5.1 Preparing forming ....................................................................................................................... 144
6.5.2 Performing the forming ............................................................................................................... 145
7Operation ..................................................................................................................................147
Qualification of personnel ........................................................................................................... 1477.1 Switching on and off ................................................................................................................... 1477.2 Control ....................................................................................................................................... 1477.3 Cleaning ..................................................................................................................................... 1477.4 Inspection and maintenance....................................................................................................... 1487.5
7.5.1 Daily visual inspection................................................................................................................. 149
7.5.2 Annual maintenance ................................................................................................................... 149
7.5.3 Maintenance work: Checking the ground wire system ................................................................ 149
7.5.4 Maintenance work: Checking electrical connections .................................................................. 150
7.5.5 Maintenance work: Checking cooling connections ..................................................................... 150
7.5.6 Maintenance work: Checking the coolant ................................................................................... 150
Behavior in the event of faults..................................................................................................... 1507.6 Fault rectification........................................................................................................................ 1507.7
7.7.1Fault rectification procedure....................................................................................................... 150
7.7.2 Checklist for malfunctions .......................................................................................................... 152
7.7.3 Visible damage ........................................................................................................................... 153
7.7.4 Problems with firmware .............................................................................................................. 153
8Maintenance and repair ...........................................................................................................155
Qualification of personnel ........................................................................................................... 1558.1 Spare parts and repair ................................................................................................................ 1558.2 Commissioning after maintenance and repair ............................................................................. 1558.3
9Decommissioning .....................................................................................................................156
Qualification of personnel ........................................................................................................... 1569.1 Decommissioning ....................................................................................................................... 1569.2
10 Disassembly and disposal........................................................................................................158
Qualification of personnel ........................................................................................................... 15810.1 Removing the device................................................................................................................... 15810.2 Disposing of recyclable materials................................................................................................ 15910.3
11 Glossary ....................................................................................................................................160
12 Document history .....................................................................................................................163
13 List of figures ............................................................................................................................164
14 List of tables .............................................................................................................................167
15 Index..........................................................................................................................................169

VP5000-DC/DC60, VP5000-DC/DC200-HL
About the manual
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Filename
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-HL_installation_manual_v1-4en.docx
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1About the manual
Validity of the manual for the following devices1.1
This installation manual applies to the VECTOPOWER units from HW version 1.0 listed below.
Type
Article number
VECTOPOWER VP5000-DC/DC60 VP5000-DC18W130-6C.1.22.04.50
VECTOPOWER VP5000-DC/DC200-HL
VP5000-DC18W140-6A.1.22.04.81
Table 1: Types and article numbers to which this manual applies
Document history1.2
For the document history, see chapter 12 Document history.
Language of the original manual1.3
The original manual is in German.
Objective of the manual1.4
This installation manual provides product-specific information on the application, mechanical and
electrical installation, commissioning, and operation of the VECTOPOWER.

VP5000-DC/DC60, VP5000-DC/DC200-HL
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Other applicable documents and software1.5
To commission the VECTOPOWER, you need the following documents and software in addition to
this installation manual:
Description / filename
Contents
Project planning manual for the VECTOPOWER
The manual provides important information on
how to plan projects and set up an application
with the VECTOPOWER.
VEConfig operating manual The VECTOPOWER is commissioned and
parameterized with the VEConfig software.
This manual guides you through the initial
commissioning with the wizard in VEConfig.
VE operating manual
This operating manual guides you through the
process of optimizing the settings that were
made during initial commissioning with the
wizard in VEConfig. The operating manual also
contains troubleshooting information.
VEConfig software
Software for initial commissioning and
parameterization of the VECTOPOWER.
Data sheets, manuals, and the like for the other
components in your individual application
Characteristics such as the maximum speed of
the motor
Optional: Parameter set
If an individual parameter set has been
created for your application at ARADEX AG,
you will need this as a VECSG file for
commissioning.
Table 2: Additionally required documents and software
Link for downloading VEConfig from the ARADEX homepage, including operating manuals
Conventions in this manual1.6
Abbreviations and terms
The terms "VECTOPOWER" and "device" refer to a VECTOPOWER VP5000-DC/DC of the types and
article numbers listed above.
The terms "system", "application", and "components" refer to the application in which the
VECTOPOWER is integrated.
The firmware "VECTONUM Embedded" is abbreviated as "VE" in this manual.
The software "VECTONUM Embedded Configuration" is abbreviated as "VEConfig".
The ground wire is indicated by this symbol .

VP5000-DC/DC60, VP5000-DC/DC200-HL
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Use of square and pointed brackets
If information refers to the connections on the VECTOPOWER, the names of the connections are
written in square brackets: e.g., DC link DC+ and DC- = [DC+/-]; output OUTPUT+ and OUTPUT- =
[OUTPUT+/-], as well as the logical connections [ST1], [ST2] ... The names of the connections are
written as they are labeled on the device. If a statement concerns both polarities, + and - are given
together in square brackets, for example [DC+/-]. If a statement only concerns one polarity,
however, only the corresponding polarity is indicated in square brackets, for example, [DC-].
If the names of menu items, buttons, etc. in the VEConfig software are mentioned, they are written
in pointed brackets, for example, <File>, <Exit> ....
Applicable standards and directives1.7
Designation
Title
EN 62477-1
Safety requirements for power electronic
converter systems and equipment - Part 1:
General
Table 3: Applicable standards and directives
Copyright, brand names1.8
Copyright ©ARADEX AG.
This document is protected by copyright. Any reproduction, processing, distribution, or other
utilization of this installation manual – even in part – is prohibited without the written permission of
ARADEX AG.
All figures are from ARADEX AG if no other source is indicated in the caption.
VECTOPOWER, VECTONUM Embedded, VECTODRIVE, VECTOBUS, VECTONET, and VECTOVISION
are registered trademarks of ARADEX AG.
In this manual, other trademarks and designations may be mentioned that are registered and
licensed trademarks of other companies. These are not specially marked. Their use by third parties
may infringe upon the rights of their owners.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Safety
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2Safety
Proper use2.1
The VECTOPOWER is a bidirectional DC/DC converter for all types of applications without
electrically isolated inputs and outputs. It is intended for use in mobile applications (e.g., in
vehicles) and for stationary systems.
When the VECTOPOWER is integrated in an electrical system, the applicable regulations and legal
provisions for the respective area of application must be observed. For example, all relevant
standards and regulations must be complied with when selecting and laying wires/cables and
assembling circuits.
The VECTOPOWER must not be used if the application requires electrical isolation between inputs
and outputs. It must not be used in potentially explosive areas either. It must also not be used
outside of the technical specifications.
The VECTOPOWER may only be installed and operated when it is in a faultless and perfect
condition. Modifications to and conversions of the VECTOPOWER are not permitted.
This manual is part of the device2.2
This installation manual is part of the supplied VECTOPOWER. Keep the installation manual
accessible at all times.
The contents of this installation manual must be made available to the personnel who work with
the VECTOPOWER. Above all, the personnel must be familiar with all important information for
carrying out work on the VECTOPOWER.
Legibility of signs and inscriptions on the device2.3
All signs and inscriptions on the VECTOPOWER must be present and legible. Missing or illegible
signs and inscriptions must be replaced immediately.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Safety
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Structure of the safety instructions2.4
Safety information warns against general dangers in order to protect persons, property, or the
environment from damage or injury. The described measures to prevent danger must be observed.
DANGER!
Type/source of danger.
Danger warning against an immediate, life-threatening danger. Failure to observe this will lead to
death or severe injury.
•Instructions for avoiding the danger.
WARNING!
Type/source of danger.
Danger warning for a dangerous situation. Failure to observe this can result in death or serious
injury.
•Instructions for avoiding the danger.
CAUTION!
Type/source of danger.
Danger warning for a dangerous situation. Failure to observe this can lead to injuries.
•Instructions for avoiding the danger.
i Note on material damage
Indication of a critical situation. Failure to observe this can lead to damage to property or the
environment.
•Instructions for avoiding the situation.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Safety
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Used symbols2.5
The following warning signs are used in this installation manual and on the VECTOPOWER.
Warning sign
Warning against general hazardous area
Warning against hazardous electrical voltage
Warning against hot surfaces
Instruction notices
Disconnect voltage
Hazards2.6
The following information on averting danger has been compiled according to the findings of
ARADEX AG. The system integrator must supplement these rules with the safety rules applicable
to the location and type of application.
2.6.1 Electricity
Voltages up to 800 V can be present inside the VECTOPOWER; short-term voltage peaks can be
even higher. Touching any part inside the unit during operation will result in an electric shock. This
electric shock will lead to death or severe injury.
Operate the VECTOPOWER only when it is in proper condition.
The housing must be complete and closed. All covers must be mounted correctly. The
VECTOPOWER must not show any damage or obvious defects.
All electrical connections and protective earthing must be carried out properly, in accordance with
the standards and directives applicable at the place of use and for the application. Other
applicable directives must be observed, such as VDE and the relevant safety and accident
prevention regulations.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Safety
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Carry out all work on the VECTOPOWER in accordance with the applicable electrical engineering
rules and regulations. In particular, observe the 5 safety rules for electrical engineering.
2.6.2 Residual electrical voltage after switch-off
The built-in capacitors and internal inductances store energy, even after a switch-off. After the
device is switched off, the stored energy is slowly discharged. Touching the power contacts during
this time may result in death or serious injury.
Wait at least 5 minutes after switching off before opening the housing or working on the wire or
cable connections.
Check that there is no voltage before carrying out any work. Use a suitable 2-pole measuring
device to measure the differential voltages and each pole against ground.
2.6.3 Hot surfaces
The housing of the VECTOPOWER can heat up to 95 °C / 203 °F during operation.
In the HL version (VECTOPOWER VP5000-DC/DC200-HL), a chopper IGBT is integrated for
installing a brake chopper. The external braking resistor can also heat up during operation.
Touching the hot surfaces will cause burns. Avoid touching the surfaces during operation. Measure
the temperature before touching.
Heat-sensitive objects in the vicinity can be damaged. Easily flammable substances may ignite.
Keep sufficient distance from adjacent components.
The mounting plate must withstand these temperatures without losing its stability or catching fire.
2.6.4 Operating noises
The VECTOPOWER has built-in chokes. The chokes generate noise during operation. The
generated noise level depends on the DC link voltage [DC+/-], the output voltage [OUTPUT+/-],
the output current [OUTPUT+/-], and the PWM frequency.
•Take appropriate soundproofing measures.
•If necessary, wear hearing protection when working on or near the VECTOPOWER.
2.6.5 Weight
The VECTOPOWER is heavy. See chapter 3.3.6 Product description, Technical data, General data
and environmental data.
If the VECTOPOWER is tilted or dropped, it can cause injuries such as crushing or bruising.
The VECTOPOWER can be damaged if it tips and falls.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Safety
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Only use suitable lifting equipment that is approved for the weight (e.g. forklift trucks) and lifting
gear.
Keep people and body parts away from under the suspended load during lifting, transport, or
assembly.
Wear suitable personal protective equipment such as safety shoes.
2.6.6 Coolant
The coolant consists of a mixture of water and glycol.
Glycol is harmful to health. When handling glycol coolant, wear tight-fitting safety goggles,
chemical-resistant gloves, and long-sleeved work clothing. Observe the information on the
manufacturer’s safety data sheet.
Glycol must not enter the groundwater, water bodies, or the sewage system. It must not be
disposed of with household waste either. Dispose of glycol-containing coolant and contaminated
objects (e.g. cleaning cloths, pipes) in accordance with local regulations.
Personnel requirements2.7
Inadequately qualified personnel are not aware of the dangers involved in handling the
VECTOPOWER and may therefore endanger themselves and others. All work must be carried out
by qualified and trained personnel.
The contents of this installation manual must be read, understood, and followed completely by all
responsible persons before they work with VECTOPOWER.
2.7.1 Qualified electrician
Tasks: Planning, connecting, commissioning, operating, maintaining, troubleshooting, and shutting
down the system.
A qualified electrician has the technical training and experience to carry out work on electrical
equipment. He or she knows all relevant standards and directives. This person can also identify
dangers early and react accordingly.
A qualified electrician also has the necessary further training to carry out work on high-voltage
systems. Depending on the requirements of the respective application, it may be necessary to be
able to work under voltage.
The additional training depends on various requirements:
- The type of application, for example, in vehicles or stationary systems.
- The location and date of application, for example, government regulations.
- Accident prevention regulations for the respective place of use.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Safety
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In the field of vehicle technology in Germany, for example, it is necessary to observe the
information leaflet BGI/GUV-I 8686 "Qualification for work on vehicles with high-voltage systems"
from the DGUV (Deutsche Gesetzliche Unfallversicherung - German statutory accident insurance).
2.7.2 Programmer
Tasks: Planning the system, commissioning it, operating it, eliminating faults.
A programmer has the professional training and experience to adapt the software parameters of
the VECTOPOWER to the conditions of the application. He or she is familiar with the Windows
operating system and other typical programs. This person knows all relevant standards and
directives. He or she can also identify dangers early and react accordingly.
2.7.3 Installer
Tasks: Carrying out non-electrical engineering work such as assembly, disassembly, disposal,
cleaning, and visual inspections.
The installer has the technical training and experience to carry out non-electrical engineering
work. This person knows all relevant standards and directives. He or she can also identify dangers
early and react accordingly.
2.7.4 Carrier
Tasks: Transporting the VECTOPOWER.
The carrier (e.g. forwarder, truck driver, forklift driver, crane operator) has the professional training
and experience to transport the VECTOPOWER. This person knows all relevant standards and
directives. He or she can also identify dangers early and react accordingly.
Fork-lift truck drivers must be authorized to operate fork-lift trucks in accordance with local
regulations.
Crane operators must be authorized to operate a crane in accordance with local regulations.
Drivers must be authorized to drive the vehicle in question in accordance with local regulations.
2.7.5 Warehouse clerk
Tasks: Packing and storing the VECTOPOWER.
The warehouse clerk has the professional training and experience to pack and store the
VECTOPOWER. This person knows all relevant standards and directives. He or she can also
identify dangers early and react accordingly.
2.7.6 Sobriety is a prerequisite
Personnel must not be overtired or under the influence of alcohol, drugs, or medication.

VP5000-DC/DC60, VP5000-DC/DC200-HL
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VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
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3Product description
Identification3.1
3.1.1 Device designation
The article numbers are structured according to the following scheme. For the available types, see
chapter 1.1 About the manual, Validity of the manual for the following devices.
Figure 1: Article numbers of the VECTOPOWER

VP5000-DC/DC60, VP5000-DC/DC200-HL
Product description
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Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
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3.1.2 Rating plate
The following information can be found on the rating plate of the VECTOPOWER. The date of
manufacture can be determined by ARADEX AG via the serial number.
Figure 2: VECTOPOWER rating plate
This installation manual refers to different hardware versions of the VECTOPOWER. Information on
the hardware version of your VECTOPOWER can be found on the rating plate (HW Vx.x).

VP5000-DC/DC60, VP5000-DC/DC200-HL
Product description
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VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
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Figure 3: Specification of the hardware version on the rating plate
Functional description3.2
3.2.1 General function
The VECTOPOWER is a bidirectional DC/DC converter.
3.2.2 Structure and function of the VECTOPOWER VP5000-DC/DC60
The following schematic diagram gives an overview of the hardware of the VECTOPOWER VP5000-
DC/DC60.
Figure 4: VECTOPOWER VP5000-DC/DC60 diagram
The [DC+]and [DC-] connections shown on the left in the diagram are the connection to the DC
link. The higher voltage must be applied on this side during operation. These connections are
referred to as [DC+/-] in this manual.
The [OUTPUT+] and [OUTPUT-] connections shown on the right in the diagram are outputs. The
lower voltage must be applied on this side during operation. These connections are referred to as
[OUTPUT+/-] in this manual.

VP5000-DC/DC60, VP5000-DC/DC200-HL
Product description
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-HL_installation_manual_v1-4en.docx
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The connection designations given here are marked on the VECTOPOWER.
The connection designations reflect the VECTOPOWER function of a buck converter.
Designation on the
VECTOPOWER
Meaning
Designation in
this manual
DC+, DC- DC link [DC+/-]
OUTPUT+, OUTPUT-
Output
[OUTPUT+/-]
ST1 ... ST4
Logical connections
[ST1] ... [ST4]
Protective earthing
conductor
Function: DC/DC converter
The VECTOPOWER VP5000-DC/DC60 consists of three separate, nested DC/DC converters
connected in parallel. The three DC/DC converters are phase-shifted by 120° to minimize the
effective current ripple on the output side.
The DC/DC converter is a two-quadrant converter. It can have two directions of operation. The
current on the output side can be positive (current flows from [DC+] to [OUTPUT+] = buck
converter) as well as negative (current flows from [OUTPUT+] to [DC+] = boost converter).
Function: Firmware / software
The VECTONUM Embedded firmware is parameterized using the VEConfig software. Both are
described in separate operating manuals.
Function: Temperature monitoring of the semiconductors
The temperature of the semiconductors inside the VECTOPOWER is monitored. To protect the
semiconductors, the power is reduced when a certain temperature is exceeded (derating). If the
temperature continues to rise, the VECTOPOWER is switched off.
External function: Logical connections [ST1] - [ST4]
The VECTOPOWER provides 4 connections for signal exchange.
The logical connection [ST1] must always be connected. The hardware enable (via pin 1, 2, and 3)
and usually the software enable (via CAN bus or RS-232) as well are effected via [ST1].
The logical connection [ST2] is used for the optional connection of an external precharging circuit
and external temperature sensors to the VECTOPOWER.
The logical connection [ST3] is used for optional integration of the VECTOPOWER into a
VECTOBUS system. The software enable can also be effected via the VECTOBUS system.
The logical connection [ST4] is used to connect a voltage measurement to [OUTPUT+/-].

VP5000-DC/DC60, VP5000-DC/DC200-HL
Product description
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VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
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3.2.3 Structure and function of the VECTOPOWER VP5000-DC/DC200-HL
The following schematic diagram gives an overview of the hardware of the VECTOPOWER with
optional components.
Figure 5: VECTOPOWER VP5000-DC/DC200-HL diagram
Legend:
(1) DC/DC converter
(2) Buffer capacitor and series choke at [DC+/-]
(3) Brake chopper [BR+/-]
(4) Precharging circuit at [OUTPUT+]
The [DC+]and [DC-] connections shown on the left in the diagram are the connection to the DC
link. The higher voltage must be applied on this side during operation. These connections are
referred to as [DC+/-] in this manual.
The [OUTPUT+] and [OUTPUT-] connections shown on the right in the diagram are outputs. The
lower voltage must be applied on this side during operation. These connections are referred to as
[OUTPUT+/-] in this manual.
The connection designations given here are marked on the VECTOPOWER.
The connection designations reflect the VECTOPOWER function of a buck converter.
Designation on the
VECTOPOWER
Meaning
Designation in
this manual
DC+, DC-
DC link
[DC+/-]
OUTPUT+, OUTPUT-
Output
[OUTPUT+/-]
BR+, BR- Brake chopper [BR+/-]
ST1 ... ST4 Logical connections [ST1] ... [ST4]
Protective earthing
conductor