Advanced Water Cooling Systems for Power Electronics High performance at heat source High reliability in cooling solutions

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Kellie Cummings
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1 Advanced Water Cooling Systems for Power Electronics High performance at heat source High reliability in cooling solutions Water Cooling Stations Compact Cooling Stations Cabinet Cooling Stations SVC Cooling Stations High Performance Cold Plates Leak Detectors THERMAL MANAGEMENT Rev Advanced Water Cooling Systems

2 2 Advanced Water Cooling Systems for Power Electronics

Design & Components of Water Cooling Loops Water cooling stations for MV and HV up to 2 MW Our cooling stations for medium and high voltage applications such as static var compensators feature high

One of the high-lights is the integrated system check during commissioning or maintenance, that includes preforming and leakage test of heat exchanger and converter.

The pressurized systems are designed for 0 kg/a coolant loss and clean water for years. Corrosion is virtually non-existent. This is achieved by careful selection of wetted materials.

3 Design & Components of Water Cooling Loops Water cooling stations for MV and HV up to 2 MW Our cooling stations for medium and high voltage applications such as static var compensators feature high reliability and long maintenance intervals. One of the high-lights is the integrated system check during commissioning or maintenance, that includes preforming and leakage test of heat exchanger and converter. Other features are continuous catastrophic and very sensitive leakage detection systems and fully redundant sensor and control systems among others. The pressurized systems are designed for 0 kg/a coolant loss and clean water for years. Corrosion is virtually non-existent. This is achieved by careful selection of wetted materials. Corrosion free, clean water and minimal loads on the purifi cation loop have been observed over many years. Compact water cooling stations up to 300 kw Space and footprint are valuable in the nacelle of a wind turbine or a marine application. Our compact water cooling stations make use of multi functional manifolds that save space and still allow for easy maintenance. Features include automatic internal de-aeration, short commissioning time, leakage detection and PLC controls. Optional available are compact redundant pump systems, touchscreen HMI and others. Simulation tool for cooler plates and heat exchangers Maximum junction temperature and ambient air temperature are key parameters for a cooling system for power electronics. Where the maximum junction temperature is a given, heat load and sometimes allowable ambient temperature are to be pushed to the limits for a given size or budget. Our design tool for cooler plates and heat exchangers gives quick answers to thermo and fl uid dynamic behavior of a cooling system. Air Blast Coolers A variety of tubes pattern, fi n spacing, turbulence promotors and circuit arrangements allow custom designs that meet of virtually any thermal and hydraulic performance requirements. Our customized stainless steel tube coils are made to weather any condition. Their quality is proven since decades and manufacturing complies with international standards. Advanced Water Cooling Systems for Power Electronics 3

Water Cooling Module CCDM Compact Cooling Module CCDMseries Compact Cooling Module for closed loop water cooling systems are designed for industrial and marine applications.

The use of space is most efficient and the width of the single pump Cooling Module is only 226 mm, height 446 mm and depth 472 mm.

Operation The cooling station circulates coolant between cooled power electronics and heat exchanger.

4 Water Cooling Module CCDM Compact Cooling Module CCDMseries Compact Cooling Module for closed loop water cooling systems are designed for industrial and marine applications. The station is designed to be powerful compact cooler for applications where easy installation is needed. The use of space is most efficient and the width of the single pump Cooling Module is only 226 mm, height 446 mm and depth 472 mm. The maintenance is easy which is a big advantage especially in marine applications. Both single and double pump versions are available. Operation The cooling station circulates coolant between cooled power electronics and heat exchanger. The water to water heat exchanger can be integrated to the station or external water to air heat exchanger can be mounted. The station includes integrated 3-way valve ensuring the constant temperature. The size and power combined with economical investment makes CCDM-series superior in the market. Benefits Minimum dimensions Stainless steel industrial pumps and copper free materials ensure long and reliable function Manifold technique minimizes the risk of leak Fast and easy commissioning Picture 1: CCDM5S-3-E Technical details: Cooling capacity Coolant flow Coolant Materials Instrumentation Coolant connections Options: Heat Exchanger Water connections up to 125 kw up to 250 l/min Water-glycol mixture Stainless steel and aluminum All materials are copper free and carbon steels are not used Temperature sensor Pressure sensor G 1½" female Water to water heat exchanger mounted on the module Pipe 48,3 mm (DN40) Main dimensions Width / Height / Depth Single pump CCDM Double pump CCDM With pump / 306 / 459 (mm) 385/ 356 / 473 (mm) With pump / 346 / 459 (mm) 385/ 396 / 473 (mm) With pump / 446 / 474 (mm) 385 / 496 / 473 (mm) Dimensions without sensors and heat exchanger. There are several instrumentation positions in the manifold. Typical installations 4 Advanced Water Cooling Systems for Power Electronics

Water Cooling Module CCDM CODE KEY FOR CCDMx4S CCDM x4 S - 3 - E - D 5 Pump selection curves Pump size Look Table 1 Number of pumps Single Douple Bypass valve 3-way valve included

5 Water Cooling Module CCDM CODE KEY FOR CCDMx4S CCDM x4 S E - D 5 Pump selection curves Pump size Look Table 1 Number of pumps Single Douple Bypass valve 3-way valve included Heat exchanger External Water to water included Voltage and frequency 3x V, 50Hz Look at Table1, 60Hz S D E W D 5 E6 Picture 2: CCDM53R-3-E Table 1 Table 1 Pump 50 Hz 60 Hz size El. power Voltage El. power Voltage 1-4 0,46 kw V 0,74 kw V 3-4 0,46 kw V 0,74 kw V 5-4 0,85 kw V 1,7 kw V The pump selection curves are for single pump cooling station and are only advisory. The pressure loss caused by heat exchanger is not taken into account. Advanced Water Cooling Systems for Power Electronics 5

6 Main dimensions CCE Width (mm) 592 Depth (mm) 583 Height (mm) Advanced Water Cooling Systems for Power Electronics

7 CODE KEY FOR CCE CCE 10x R E - P0 - H - D5-3 - xx - 00 Pump size Number of pumps Bypass valve Heat exchanger Control Data communication Voltage and frequency Heater Directions of coolant connections Options and Specialities Pump size Look Table 1 Number of pumps Redundant R Bypass valve 3-way valve included 3 Heat exchanger External E Water to water included W Control / Wiring Connection box (internal wiring made) C0 Connection box + Converter CI PLC P0 PLC + Frequency converter PI Data communication Nothing 0 Hard wired I/O H Hard wired I/O + Profibus B Voltage and frequency 3x V, 50Hz D5 3x V,60Hz E6 Heater No 0 3 kw 3 Directions of coolant connections Contact dealer Options and specialties Nothing 00 Options included L0 Specialties included 0S Options and specialties LS The pump selection curves are for single pump cooling station VCB10xS and are only advisory. The pressure loss caused by heat exchanger is not taken into account. Table ,75 kw 1,5 kw 103 1,1 kw 2,2 kw 104 1,5 kw 3,0 kw Advanced Water Cooling Systems for Power Electronics 7

8 Width (mm) Height (mm) Depth (mm) Advanced Water Cooling Systems for Power Electronics

9 CODE KEY FOR VCB10x VCB 10x S E - PS - H - D5-3 - xx - 00 Pump size Number of pumps Bypass valve Heat exchanger Control Data communication Voltage and frequency Heater Directions of coolant connections Options and Specialities Pump size Look Table 1 Number of pumps Single S Redundant R Bypass valve No 0 2-way valve included 2 3-way valve included 3 Heat exchanger External E Water to water included W Control / Wiring Connection box (internal wiring made) C0 Connection box + Converter CI PLC P0 PLC + Soft starter PS PLC + Converter PI Data communication Nothing 0 Hard wired I/O H Hard wired I/O + Profibus B Voltage and frequency 3x V, 50Hz D5 3x V,60Hz E6 Heater No 0 3 kw 3 Directions of coolant connections Contact dealer Options and specialties Nothing 00 Options included L0 Specialities included 0S Options and specialties LS The pump selection curves are for single pump cooling station VCB10xS and are only advisory. The pressure loss caused by heat exchanger is not taken into account. Pump sizes / Electrical power 50 Hz 60 Hz 102 0,75 kw 1,5 kw 103 1,1 kw 2,2 kw 104 1,5 kw 3,0 kw Advanced Water Cooling Systems for Power Electronics 9

10 Water Cooling Station VCD10x Cabinet Cooling Station Cabinet Cooling Station VCD10x Cabinet Cooling Station VCD for closed loop water cooling systems is built in Rittal TS-8 cubicle (or equal). The station is designed to be situated next to the electrical cabinets and for applications where easy installation is needed. The use of space is most efficient and the width of the station is only 60 or 80 cm. Operation The cooling station circulates coolant between cooled power electronics and heat exchanger. The water to air heat exchanger and two fans are installed into the cabinet. The electrical heater is used during start-up to ensure constant temperature also in cold conditions. The cooling station is operated locally on touch panel and PLC with sophisticated program controls all functions. Profibus connection to upper control system is also available. VCD10x Benefits Technical details Minimum foot print need Cooling capacity up to 35 kw at 55 ⁰C T (ambient) Fast and easy commissioning (automatic de-aeration Coolant flow l/min and visual coolant level indication) Expansion tank 11 liters, GRP with PE coating inside Stainless steel industrial pumps and copper free Water connections DN40 or R1½ materials ensure long and reliable function Instrumentation Temperature sensors Pressure sensors Coolant level indicator Coolant level alarm Materials Stainless steel Aluminum 6000 Main dimensions Single pump Adwatec Cooling power vs. power consumption VCD10xS Adwatec VCD 103 S with fan speed control 4,5 Width (mm) 600 or ,5 Height (mm) Depth (mm) 600 2,5 2 1,5 1 0, Cooling power, kw Total power consumption, kw Width (mm) Height (mm) Depth (mm) Advanced Water Cooling Systems for Power Electronics

11 CODE KEY FOR VCA10x VCA 10x S E - PS - H - D5-3 - xx - 00 Pump size Number of pumps Bypass valve Heat exchanger Control Data communication Voltage and frequency Heater Directions of coolant connections Options and Specialities Pump size Look Table 1 Number of pumps Single S Redundant R Bypass valve No 0 2-way valve included 2 3-way valve included 3 Heat exchanger External E Water to water included W Control / Wiring Connection box (internal wiring made) C0 Connection box + Converter CI PLC P0 PLC + Soft starter PS PLC + Converter PI Data communication Nothing 0 Hard wired I/O H Hard wired I/O + Profibus B Voltage and frequency 3x V, 50Hz D5 3x V,60Hz E6 Heater No 0 3 kw 3 Directions of coolant connections Contact dealer Options and specialities Nothing 00 Options included L0 Specialities included 0S Options and specialities LS The pump selection curves are for single pump cooling station VCA10xS and are only advisory. The pressure loss caused by heat exchanger is not taken into account. Pump sizes / Electrical power 50 Hz 60 Hz 102 0,75 kw 1,5 kw 103 1,1 kw 2,2 kw 104 1,5 kw 3,0 kw Advanced Water Cooling Systems for Power Electronics 11

12 Water Cooling Station VCE10x Cabinet Cooling Station Data sheet 1(2) Cabinet Cooling Station VCE10x Operation Benefits Main dimensions Single pump VCE10xS Redundant pump VCE10xR Width (mm) Height (mm) Depth (mm) Technical details VCE Typical installations 12 Advanced Water Cooling Systems for Power Electronics Advanced Water Cooling

13 Water Cooling Station VCE10x Cabinet Cooling Station Data sheet 2(2) CODE KEY FOR VCE VCE 10x R -3 -W-PS -H -D5-3 -xx -00 Pump size Number of pumps Bypass valve Heat exchanger Control Data communication Voltage and frequency Heater Directions of coolant connections Options and Specialities Pump size Look Table 1 Number of pumps Single S Redundant R Bypass valve 3-way valve included 3 Heat exchanger External E Water to water included W Control / Wiring Nothing 00 Connection box (internal wiring made) C0 Connection box + Converter CI PLC P0 PLC + Soft starter PS PLC + Converter PI Data communication Nothing 0 Hard wired I/O H Hard wired I/O + Profibus B Voltage and frequency 3x V, 50Hz D5 3x V,60Hz E6 Heater No 0 3 kw 3 Directions of coolant connections Contact dealer Options and specialties Nothing 00 Options included L0 Specialities included 0S Options and specialties LS Pump selection curves The pump selection curves are for single pump cooling station VCE10xS and are only advisory. The pressure loss caused by heat exchanger is not taken into account. Flow diagram (VCE10xR-3-W) Table 1 Pump sizes / Electrical power 50 Hz 60 Hz 102 0,75 kw 1,5 kw 103 1,1 kw 2,2 kw 104 1,5 kw 3,0 kw Advanced Water Cooling Systems for Power Electronics 13

14 14 Advanced Water Cooling Systems for Power Electronics

15 , , , , , , , ,0 The flow is reached with above mentioned pressure difference across the pump. The pump selection curves are for single pump cooling station NCU and are only advisory. The pressure loss caused by heat exchanger is not taken into account , , ,5 10, ,5 10, ,5 11, ,5 11,2 131 Advanced Water Cooling Systems for Power Electronics 15

16 16 Advanced Water Cooling Systems for Power Electronics

17 Advanced Water Cooling Systems for Power Electronics 17

Leak Detectors KPK010 and KPK020 Adwatec Leak Detectors are specifically designed for finding leakage in a tested object, e.g. cooling circuit.

There are two models available: KPK010 for cooling systems of power electronics and KPK020 for cooling circuits of power electric components.

18 Leak Detectors KPK010 and KPK020 Adwatec Leak Detectors are specifically designed for finding leakage in a tested object, e.g. cooling circuit. They are easy and fast way to measure the pressure and ensure tightness and right flow in a tested object. There are two models available: KPK010 for cooling systems of power electronics and KPK020 for cooling circuits of power electric components. Operation Leak Detectors rinse, pre-form and pressure test the piping of the tested object. They automatically detect leakage and measure flow restriction and finally empty and dry the object. Test fluid is mixture of clean tap water, glycol and corrosion inhibitors. User can create individual procedures of testing steps for each object and save procedures for further use. Leak Detectors are operated by panel PC or laptop. Test reports are saved to panel PC or laptop and optionally ethernet connection can be used to download test results database to upper level database. Benefits Precise leak detection Fast and easy testing Unit is easy to move Test parameters are adjustable User-friendly program interface Individual test procedures Technical Details KPK010 KPK020 Max pressure 12 bar 15 bar Max flow Max. 50 l/min at 10 bar pressure Max. 140 l/min at 6 bar pressure Max. 20 l/min Tank volume 270 litre 60 litre Filtration ratio µm abs 50 µm abs in return line 10 µm abs in high pressure pump inlet Control system Siemens S7-300 PLC HP Probook laptop Siemens S7-300 PLC Siemens 15 touch panel PC Keyboard, mouse and barcode scanner Electrical connection in 3 x 400 VAC, 50 Hz, 32 A 3 x 400 VAC, 50 Hz, 16 A Electrical connection out 2 x 230 VAC, 50 Hz, 10 A 1 x 230 VAC, 50 Hz, 10 A Other connections in Compressed air 6 bar (adjustable) Water filling Ethernet (optional) Compressed air 6 bar (adjustable) Water filling Ethernet (optional) Width x depth x height, mm 1357 x 823 x x 800 x 1900 Weight (empty tank) 330 kg 275 kg 18 Advanced Water Cooling Systems for Power Electronics

19 Advanced Water Cooling Systems for Power Electronics 19

enabling your ideas. Optical, Power and Thermal Management Technologies Germany AMS Technologies AG Fraunhoferstr. 22 82152 Martinsried, Germany Phone +49 (0)89 895 77 0 France AMS Technologies S.A.R.

20 enabling your ideas. Optical, Power and Thermal Management Technologies Germany AMS Technologies AG Fraunhoferstr Martinsried, Germany Phone +49 (0) France AMS Technologies S.A.R.L. Silic 717 Bâtiment Magnolia 16, avenue du Québec Courtaboeuf Cedex Phone +33 (0) Italy AMS Technologies S.r.l. Corso Sempione, 215/B Legnano (MI), Italy Phone Poland AMS Technologies Sp. z o.o. Mogilska 69 St, Floor Krakow, Poland Phone +48 (0) Spain AMS Technologies S.L. C/Muntaner, 200 Atico, 4a Barcelona, Spain Phone +34 (0) Sweden AMS Technologies Nordic Azpect Photonics AB Aminogatan Mölndal, Sweden Phone +46 (0) United Kingdom AMS Technologies Ltd. Unit 11, St Johns Business Park Lutterworth Leicestershire LE17 4HB, UK Phone +44 (0) ISO 9001 DIN EN ISO 9001 TAW Cert Zert.Nr.: Copyright by 2016 AMS Technologies Rev Advanced Water Cooling Systems info@amstechnologies.com

STANDARD HEAT EXCHANGERS

STANDARD HEAT EXCHANGERS THERMAL MANAGEMENT AMS Technologies Thermal Management TUBE-FIN HEAT EXCHANGERS COOLING SOLUTIONS Our tube-fin heat exchangers consist of copper or stainless steel tubes expanded