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
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
3 / 173
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
About the manual
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
4 / 173
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
About the manual
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
5 / 173
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
About the manual
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
6 / 173
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
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
7 / 173
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
About the manual
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
8 / 173
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
About the manual
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
9 / 173
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
Last edited 2019-02-08
by
Sonja Scheunert
Filename
VP5000_DCDC60_200
-HL_installation_manual_v1-4en.docx
10 / 173
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.