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WCIII Operating Instructions

Introduction

1

Safety Notes

2

Description

3

Preparing for Use

4

Assembly

5

Electrical Connections

6

Commissioning

7

Operation

8

Maintenance

9

Spare parts

10

Disposal

11

Manual

AA

A5E32043214A

Service and Support

A

Technical Data

B

Quality

C

Abbreviations

D

Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

A5E32043214A Ⓟ 05/2013 Technical data subject to change

Copyright © Siemens AG 2013. All rights reserved

Table of contents 1

Introduction...................................................................................................................................................9

2

Safety Notes...............................................................................................................................................11

3

4

2.1

General Safety Information..........................................................................................................11

2.2

Safety Concept............................................................................................................................12

2.3

Observing the Five Safety Rules.................................................................................................12

2.4

Safety Information and Warnings................................................................................................13

2.5

ESD-sensitive Components.........................................................................................................15

2.6

Electromagnetic Fields in Electrical Power Engineering Installations ........................................17

Description..................................................................................................................................................19 3.1

Key Interlocks..............................................................................................................................19

3.2

Supply Scope .............................................................................................................................19

3.3

WCIII Cabinet Details..................................................................................................................20

3.4

Input Power Cabinet....................................................................................................................21

3.5

Transformer Cabinet....................................................................................................................21

3.6

Fuse/Precharge/Control (FPC) Cabinet......................................................................................22

3.7

Cell Cabinet.................................................................................................................................24

3.8

Output Power Cabinet.................................................................................................................25

3.9

Coolant Cabinet...........................................................................................................................25

3.10

Output Reactor Cabinet...............................................................................................................25

3.11

Exciter Cabinet............................................................................................................................26

3.12

Coordinated Input Protection Scheme.........................................................................................26

Preparing for Use........................................................................................................................................29 4.1

Overview of Proper Installation Techniques ...............................................................................29

4.2

Safety Precautions for Transportation.........................................................................................29

4.3

Shipping Guidelines.....................................................................................................................30

4.4

Receiving.....................................................................................................................................32

4.5

Off-loading...................................................................................................................................32

4.6

Shipping Splits.............................................................................................................................32

4.7

Weight Estimates.........................................................................................................................32

4.8 4.8.1 4.8.1.1

Handling......................................................................................................................................32 Transportation with Crane...........................................................................................................33 Lifting Method for Standard Shipping Section 2 and 3................................................................34

WCIII Operating Instructions Manual, AA, A5E32043214A

3

Table of contents

5

6

7

4.8.1.2 4.8.2 4.8.3

Lifting Methods for Standard Shipping Section 1........................................................................37 Transportation with Roller Dollies................................................................................................38 Transportation with Pipe Rollers .................................................................................................40

4.9

Storage........................................................................................................................................41

4.10

Unpacking....................................................................................................................................42

4.11

Final Placement...........................................................................................................................43

Assembly....................................................................................................................................................45 5.1

Anchoring Cabinets to Floors and Walls.....................................................................................45

5.2

Securing the Cabinets Together..................................................................................................46

5.3

Protective Earthing Bars Connection...........................................................................................48

Electrical Connections................................................................................................................................49 6.1

Reconnecting Wiring and Plumbing............................................................................................49

6.2

Installation of I/O External Wiring................................................................................................50

6.3

Electrical Requirements...............................................................................................................51

6.4

EMC Installation Guidelines for Perfect Harmony ......................................................................53

6.5

Cable Gland Plates Removal and Installation Guidelines...........................................................56

6.6

Circuit Breaker (provided by the customer).................................................................................57

Commissioning...........................................................................................................................................59 7.1

Residual Current Device (RCD) Compatibility.............................................................................59

8

Operation....................................................................................................................................................61

9

Maintenance...............................................................................................................................................63

4

9.1 9.1.1

Door Access................................................................................................................................63 Mechanical Interlock System.......................................................................................................64

9.2 9.2.1 9.2.2

Preventive Maintenance..............................................................................................................64 Six Month Inspection...................................................................................................................64 Preventive Maintenance Checklist..............................................................................................66

9.3 9.3.1 9.3.2

Cleaning......................................................................................................................................66 Contact for Cleaning Measures...................................................................................................66 Removing Dust Deposits.............................................................................................................66

9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7

Repair and Replace.....................................................................................................................67 Safety-relevant Checks...............................................................................................................67 Maintenance and Earthing Procedure.........................................................................................68 Replacing Parts...........................................................................................................................70 Replacing the Door-mounted Keypad.........................................................................................71 Replacing the CompactFlash Card..............................................................................................72 Replacing Cell Input Power Fuses..............................................................................................73 Replacing Printed Circuit Boards (PCBs)....................................................................................74

9.5 9.5.1 9.5.2 9.5.3

Power Cell Removal....................................................................................................................80 Isolating and Positioning of Power Cell.......................................................................................80 Purging Power Cell......................................................................................................................82 Removing and Transporting Power Cell......................................................................................85


Table of contents

10

11

9.5.4 9.5.5

Preparing Banding for Power Cell...............................................................................................87 Banding and Crating of Power Cell.............................................................................................91

9.6 9.6.1 9.6.2 9.6.3 9.6.4

Power Cell Installation.................................................................................................................93 Prerequisites for Installing Power Cell.........................................................................................94 Transporting Power Cell via Cell Lifter........................................................................................96 Transporting Power Cell via Transportation Device..................................................................100 Inserting Power Cell..................................................................................................................101

9.7

Cell Cabinet Construction and Maintenance.............................................................................111

Spare parts...............................................................................................................................................119 10.1

NXGII Control............................................................................................................................120

10.2

Power Cell.................................................................................................................................121

10.3

Optional Components................................................................................................................122

Disposal....................................................................................................................................................123 11.1

Disposing of Device Components.............................................................................................123

11.2

Disposing of Packaging.............................................................................................................123

11.3

Disposing of Old Services.........................................................................................................123

A

Service and Support.................................................................................................................................125

B

Technical Data..........................................................................................................................................127

C

D

B.1

WCIII System Technical Specifications.....................................................................................127

B.2

WCIII Storage, Transport and Operation Ambient Conditions...................................................129

B.3

WCIII Power Cell Specifications................................................................................................130

B.4

WCIII Current Parameters.........................................................................................................130

B.5

Power Cell Output Current Rating Deration Parameters ..........................................................131

B.6

Ingress Protection (IP) Ratings..................................................................................................132

Quality.......................................................................................................................................................135 C.1

CE Marking and Directives for Perfect Harmony Products........................................................135

C.2

CE Marking on Power Drive Systems (PDS).............................................................................136

C.3

Directives that apply to the Power Drive System (PDS)............................................................137

C.4

CE Marking................................................................................................................................138

Abbreviations............................................................................................................................................139 Glossary....................................................................................................................................................145 Index.........................................................................................................................................................157

Tables Table 6-1

Torque Values for Electrical Connections (as per Regulation Document NKN-MF-0019)..........51

Table 6-2

Torque Values for Raised Face to Raised Face or Flat Face to Flat Face non-CPVC Connections (as per Regulation Document NKN-MF-0008)............................................................................51


5

Table of contents

Table 6-3

Power Cabling Cross Sections....................................................................................................52

Table 6-4

Conductor Dimensioning.............................................................................................................52

Table 10-1

NXGII Control Recommended Spare Parts...............................................................................120

Table 10-2

Power Cell Recommended Spare Parts....................................................................................121

Table 10-3

Optional Components Recommended Spare Parts (if furnished with drive).............................122

Table B-1

WCIII Parameters and Ratings..................................................................................................127

Table B-2

General Ambient Conditions......................................................................................................129

Table B-3

WCIII Power Cell Specifications................................................................................................130

Table B-4

WCIII 880 Amp Cell Type Specifications...................................................................................130

Table B-5

WCIII 1250 Amp Cell Type Specifications.................................................................................131

Table D-1

Commonly Used Abbreviations.................................................................................................139

Figures Figure 2-1

ESD Protective Measures...........................................................................................................17

Figure 3-1

WCIII VFD...................................................................................................................................20

Figure 3-2

Standard TIMV Hardwired Control Signal Interface ...................................................................27

Figure 4-1

Displaced Center of Gravity.........................................................................................................30

Figure 4-2

Strap and Cradle Method of Lifting..............................................................................................34

Figure 4-3

Transportation with Crane using Single Spreader Bar................................................................35

Figure 4-4

Transportation with Crane using H-shaped Spreader Bar...........................................................36

Figure 4-5

Standard Lifting Method..............................................................................................................37

Figure 4-6

Optional Lifting Method................................................................................................................38

Figure 4-7

Proper Placement of Roller Dollies..............................................................................................39

Figure 4-8

Proper Use of Pipe Rollers in Handling Cabinets........................................................................41

Figure 5-1

Proper Anchoring Technique for Cabinets..................................................................................46

Figure 5-2

Connecting the Cabinets.............................................................................................................47

Figure 6-1

Perfect Harmony Drive System...................................................................................................53

Figure 6-2

Recommended Cable Segregation.............................................................................................55

Figure 9-1

Meter Connection on Cell DC Bus...............................................................................................69

Figure 9-2

Location of CompactFlash card on the NXGII Microprocessor Board.........................................72

Figure 9-3

Bussmann Blown Fuse Indicator.................................................................................................73

Figure 9-4

Ferraz Blown Fuse Indicator........................................................................................................73

Figure 9-5

NXGII Master Control Chassis....................................................................................................77

Figure 9-6

Power Cell pulled out to First Removal Position..........................................................................82

Figure 9-7

Cell Water Purge Kit....................................................................................................................83

Figure 9-8

Bucket positioned under Hose End to collect fluids.....................................................................84

Figure 9-9

Inserting Cell Water Purge Kit Hoses to Supply and Return Ports (Snap-on) to drain liquids.... 84

Figure 9-10

Power Cell Correct Position on Cell Lifter...................................................................................86

6


Table of contents

Figure 9-11

Valox Insulation Locations...........................................................................................................86

Figure 9-12

Methods for Transporting Power Cell..........................................................................................87

Figure 9-13

Wooden Pallet.............................................................................................................................88

Figure 9-14

Covering Pallet with Cardboard...................................................................................................88

Figure 9-15

Preparing Power Cell for Lifting...................................................................................................89

Figure 9-16

Lacing Lifting Lanyards through Lifting Brackets.........................................................................89

Figure 9-17

Positioning Power Cell on Pallet..................................................................................................90

Figure 9-18

Styrofoam Spacer between Power Cells.....................................................................................91

Figure 9-19

Power Cells with Cardboard Corner Protectors...........................................................................91

Figure 9-20

Lacing the Banding Material........................................................................................................91

Figure 9-21

Typical Banding Tool...................................................................................................................92

Figure 9-22

Properly Banded Power Cells......................................................................................................92

Figure 9-23

Crate built to ship Power Cells....................................................................................................93

Figure 9-24

New Power Cells.........................................................................................................................94

Figure 9-25

Utility Cart with Plywood Boards placed on top...........................................................................95

Figure 9-26

Hydraulic Cell Lifter with Lifting Device.......................................................................................95

Figure 9-27

Rotating Power Cell Forward for Loading....................................................................................96

Figure 9-28

Cell Lifter Manual Brake in Locked Position................................................................................97

Figure 9-29

Cell Lifting Device Upper Roller Bar Installed with Locking Pins.................................................97

Figure 9-30

Slide Rail Positioned Away from Upper Roller Bar to Accommodate Power Cell.......................97

Figure 9-31

Power Cell Front Flange Positioned in Guides on Cell Lifter Slide Rail......................................98

Figure 9-32

Valox Insulation Locations...........................................................................................................98

Figure 9-33

Slide Rail Locking Pin Inserted....................................................................................................99

Figure 9-34

Power Cell Properly Positioned on Cell Lifter for Installation or Transport..................................99

Figure 9-35

Cell Lifter Manual Brake Release Position..................................................................................99

Figure 9-36

Power Cell Ready to Transport.................................................................................................101

Figure 9-37

Power Cell Aligned for insertion into Capacitor Bucket.............................................................102

Figure 9-38

Teflon Insulation Strip Locations on Top of Guide Rail in Capacitor Bucket.............................102

Figure 9-39

Slide Rail Locking Pin Inserted..................................................................................................103

Figure 9-40

Guide Pins.................................................................................................................................104

Figure 9-41

Power Cell Positioned Corectly prior to removing Cell Lifter.....................................................104

Figure 9-42

Power Cell stopped by Locking Tab..........................................................................................105

Figure 9-43

Hand Position for Cell Insertion.................................................................................................105

Figure 9-44

Power Cell Fully Inserted...........................................................................................................106

Figure 9-45

Capacitor Bank Connections with Proper Hardware Arrangement...........................................106

Figure 9-46

Capacitor Mounting Bolts..........................................................................................................107

Figure 9-47

Valox Insulation Locations.........................................................................................................108

Figure 9-48

Installing Capacitor Bank Cover Plate.......................................................................................108

Figure 9-49

Inserting Inlet and Outlet (Snap-on) Water Hoses.....................................................................109


7

Table of contents

Figure 9-50

Fiber Optic Plug.........................................................................................................................110

Figure 9-51

Power Cell Ready for Operation................................................................................................110

Figure 9-52

9 Cell Cabinet............................................................................................................................112

Figure 9-53

9 Cell Cabinet with Front and Top Blower Covers Removed (for service)................................113

Figure 9-54

9 Cell Cabinet with Doors, Blowers and HEX Removed...........................................................114

Figure 9-55

9 Cell Cabinet with Cells, Majority of Capacitors and Capacitor Buckets Removed.................115

Figure 9-56

Bypass Contactor with T1-T2 Removed from Rear Panel.........................................................116

Figure 9-57

12 Cell Cabinet with Rear Panel Removed and Bus Exposed..................................................117

Figure 9-58

9 Cell Cabinet with Rear Panels Removed and only Verticals and Water Manifolds Installed. 118

Figure C-1

Power Drive System..................................................................................................................136

Figure C-2

Overview of PDS containing the Perfect Harmony BDM and CDM...........................................137

Figure C-3

CE Marking................................................................................................................................138

8


1

Introduction

About This Manual This manual provides customer documentation for the Perfect Harmony™ Water-Cooled III (WCIII) Variable Frequency Drive (VFD). The content of this manual provides WCIII VFD standard information including safety warnings and notes, preparation for use, assembly/installation, electrical, commissioning, operation, maintenance, spare parts, and disposal information. The latter pages of this manual contain appendices for specific technical documents, support services information and other relevant data. This manual is intended for use by trained personnel having unique job functions and qualifications since there are areas on the VFD that are hazardous and therefore may cause death or serious bodily harm to personnel and also cause serious damage to the drive. The manual is also intended for use by planners, project engineers, installation personnel, programmers, commissioning personnel, operators, service and maintenance personnel. WARNING Familiarity with the Product Documentation Only the complete product documentation will allow you to assemble and install the equipment, to put it into operation and to maintain it correctly and safely. Incorrect work on the equipment can result in death, severe injury or material damage. Always refer to the Operating Instructions manual when working on the equipment. Find the Operating Instructions manual, and other necessary equipment information about your product, on the CD supplied with the drive. Refer to the NXG Control Operating manual for information relating to the NXG Control System and the related hardware and user interfaces. Refer to the WCIII Cooling System manual for coolant cabinet specific information.

Variable Frequency Drive Overview A variable frequency drive (VFD) system controls the rotational speed and torque of an alternating current (AC) electric motor by adjusting the frequency and voltage of the electrical power supplied to the motor. In an AC motor, frequency determines the motor speed.


9

2

Safety Notes 2.1

General Safety Information

Proper Use Perfect Harmony™ Medium Voltage Drives must always be installed in closed electrical operating areas. The Drive is connected to the industrial network via a circuit-breaker. The specific transport conditions must be observed when the equipment is transported. The equipment shall be assembled/installed and the separate cabinet units connected properly by cable and/or busbar in accordance with the assembly/installation instructions. The relevant instructions regarding correct storage, EMC-compliant installation, cabling, shielding and grounding and an adequate auxiliary power supply must be strictly observed. Fault-free operation is also dependent on careful operation and maintenance. Refer to the Drive's Operating Instructions Manual, Section EMC Installation Guidelines for Perfect Harmony. WARNING Potential Arc Hazard ● Arcing can result in damage to property, serious injury and even death. ● The equipment has not been tested for resistance to internal arcing. ● Avoiding arc hazard risks is dependent upon proper installation and maintenance. ● Incorrectly applied equipment, incorrectly selected, connected or unconnected cables, or the presence of foreign materials can cause arcing in the equipment. ● Follow all precautionary rules and guidelines as used in working with Medium Voltage switchgear. ● The equipment may be used only: – for the applications defined as suitable in the technical description. – in combination with equipment and components supplied by other manufacturers which have been approved and recommended by Siemens. The power sections are designed for variable-speed drives use with synchronous and asynchronous motors. Operating modes, overload conditions, load cycles, and ambient conditions different to those described in this document are allowed only by special arrangement with the manufacturer. Commissioning may only be carried out by trained service personnel in accordance with the commissioning instructions. System components such as circuit-breaker, transformer, cables, cooling unit, motor, speed sensors, etc., must be matched to VFD operation. System configuration may only be carried out by an experienced system integrator.


11

Safety Notes 2.3 Observing the Five Safety Rules

2.2

Safety Concept The medium-voltage variable frequency drive (VFD) and its components are subject to a comprehensive safety concept which, when properly implemented, ensures safe installation, operation, servicing, and maintenance. The safety concept encompasses safety components and functions to protect the device and operators. The VFD is also equipped with monitoring functions to protect external components. The VFD operates safely when the interlock and protection systems are functioning properly. Nevertheless, there are areas on the medium-voltage drive that are hazardous for personnel and that can cause material damage if the safety instructions described in this section and throughout the product documentation are not strictly observed.

2.3

Observing the Five Safety Rules There are five safety rules that must always be observed to assure not only personal safety, but to prevent material damage as well. Always obey safety-related labels located on the product itself and always read and understand each safety precaution prior to operating or working on the drive. The five safety rules: 1. Disconnect the system. 2. Protect against reconnection. 3. Make sure that the equipment is de-energized. 4. Apply grounding means. 5. Cover or enclose adjacent components that are still live.

DANGER Danger Due to High Voltages High voltages cause death or serious injury if the safety instructions are not observed or if the equipment is handled incorrectly. Potentially fatal voltages occur when this equipment is in operation which can remain present even after the VFD is switched off. Ensure that only qualified and trained personnel carry out work on the equipment. Follow the five safety rules during each stage of the work.

12


Safety Notes 2.4 Safety Information and Warnings

2.4

Safety Information and Warnings DANGER Hazardous Voltage! ● Always follow the proper lock-out/tag-out procedures before beginning any maintenance or troubleshooting work on the VFD. ● Always follow standard safety precautions and local codes during installation of external wiring. The installation must follow wiring practices and insulation systems as specified in IEC 61800-5-1. ● Always work with one hand, wear electrical safety gloves, wear insulated electrical hazard rated safety shoes, and safety goggles. Also, always work with another person present. ● Always use extreme caution when handling or measuring components that are inside the enclosure. Be careful to prevent meter leads from shorting together or from touching other terminals. ● Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements (that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the instrument). ● Never assume that switching off the input disconnector will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnector. Also, there may be voltages present that are applied from other external sources. ● Never touch anything within the VFD cabinets until verifying that it is neither thermally hot nor electrically alive. ● Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points beneath the shields. ● Never operate the VFD with cabinet doors open. The only exception is the control cabinet which contains extra low voltages (ELV). ● Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the system. ● Never connect or disconnect any meters, wiring, or printed circuit boards while the VFD is energized. ● Never defeat the instrument’s grounding. ● Only qualified individuals should install, operate, troubleshoot, and maintain this VFD. A qualified individual is "a person, who is familiar with the construction and operation of the equipment and the hazards involved." ● Hazardous voltages may still exist within the VFD cabinets even when the disconnect switch is open (off) and the supply power is shut off. ● When a system is configured with VFD bypass switchgear (e.g. contactors between line and motor, and VFD and motor), these switches should be interlocked so that the line voltage is never applied to the VFD output if the medium input voltage is removed from the VFD.


13

Safety Notes 2.4 Safety Information and Warnings Additional safety precautions and warnings appear throughout this manual. These important messages should be followed to reduce the risk of personal injury or equipment damage. WARNING Obey Rules to Avoid Risk of Death ● Always comply with local codes and requirements if disposal of failed components is necessary (for example, CPU battery, capacitors, etc.). ● Always ensure the use of an even and flat truck bed to transport the VFD system. Before unloading, be sure that the concrete pad is level for storage and permanent positioning. ● Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the VFD system. Dropping the cabinet or lowering it too quickly could damage the unit. ● Never disconnect control power while medium voltage is energized. This could cause severe system overheating and/or damage. ● Never store flammable material in, on, or near the drive enclosure. This includes equipment drawings and manuals. ● Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure that the fork truck tines fit the lifting tubes properly and are the appropriate length.

Ethylene Glycol Safety Information and Warnings WARNING Ethylene glycol must be treated as a hazardous waste material. Ethylene glycol is: ● Harmful if swallowed. ● A skin and respiratory irritant. ● Severe eye irritant. ● Reproductive toxin. ● Always wash hands after handling ethylene glycol. ● Always consult the Material Safety Data Sheet (MSDS) for complete information regarding safety and handling of ethylene glycol. ● Always clean up spills promptly. Ethylene glycol is a sweet tasting liquid that can kill pets if ingested.

14


Safety Notes 2.5 ESD-sensitive Components Propylene Glycol Safety Information and Warnings WARNING Propylene glycol is: ● Slight eye irritant. ● Mist may cause respiratory irritation. ● Wash hands after handling propylene glycol. ● Always consult the Material Safety Data Sheet (MSDS) for complete information regarding safety and handling of propylene glycol. ● Always clean up spills promptly.

2.5

ESD-sensitive Components

Guidelines for Handling Electrostatic Sensitive Devices (ESD) NOTICE ESD Sensitive Equipment ● Always be aware of electrostatic discharge (ESD) when working near or touching components inside the VFD cabinet. The printed circuit boards contain components that are sensitive to electrostatic discharge. Handling and servicing of components that are sensitive to ESD should be done only by qualified personnel and only after reading and understanding proper ESD techniques. The following ESD guidelines should be observed. Following these rules can greatly reduce the possibility of ESD damage to printed circuit (PC) board components. ● Always transport static sensitive equipment in antistatic bags. ● Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuumstyle plunger or copper braid when desoldering. ● Ensure that anyone handling the printed circuit boards is wearing a properly grounded static strap The wrist strap should be connected to ground through a 1 Megohm resistor. Grounding kits are available commercially through most electronic wholesalers. ● Static charge build-up can be removed from a conductive object by touching the object with a properly grounded piece of metal. ● When handling a PC board, always hold the card by its edges. ● Do not slide printed circuit boards (PCBs) across any surface (e.g., a table or work bench). If possible, perform PCB maintenance at a workstation that has a conductive covering that is grounded through a 1 Megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is an excellent substitute. ● Avoid plastic Styrofoam™, vinyl and other non-conductive materials. They are excellent static generators and do not give up their charge easily. ● When returning components to Siemens Industry, Inc. always use static-safe packing. This limits any further component damage due to ESD.


15

Safety Notes 2.5 ESD-sensitive Components Components that can be destroyed by electrostatic discharge (ESD) NOTICE Electrostatic discharge Electronic components can be destroyed in the event of improper handling, transporting, storage, and shipping. Pack the electronic components in appropriate ESD packaging; e.g. ESD foam, ESD packaging bags and ESD transport containers. To protect your equipment against damage, follow the instructions given below. ● Avoid physical contact with electronic components. If you need to perform absolutely essential work on these components, then you must wear one of the following protective gear: – Grounded ESD wrist strap – ESD shoes or ESD shoe grounding strips if there is also an ESD floor. ● Do not place electronic components close to data terminals, monitors or televisions. Maintain a minimum clearance to the screen (> 10 cm). ● Electronic components should not be brought into contact with electrically insulating materials such as plastic foil, plastic parts, insulating table supports or clothing made of synthetic fibers. ● Place components in contact with ESD-suited materials e.g. ESD tables, ESD surfaces, ESD packaging. ● Measure on the components only if one of the following conditions is met: – The measuring device is grounded with a protective conductor, for example. – The measuring head of a floating measuring device has been discharged directly before the measurement. The necessary ESD protective measures for the entire working range for electrostatically sensitive devices are illustrated once again in the following drawings. Precise instructions for ESD protective measures are specified in the standard DIN EN 61340-5-1.

16


Safety Notes 2.6 Electromagnetic Fields in Electrical Power Engineering Installations

d

d

b

d

b

e

e f

c

f

a

f c

c

a

1

Sitting

2

Standing

3

Standing/sitting

a

Conductive floor surface, only effective in conjunction with ESD shoes or ESD shoe grounding strips

b

ESD furniture

c

ESD shoes or ESD shoe grounding strips are only effective in conjunction with conductive flooring

d

ESD clothing

e

ESD wristband

f

Cabinet ground connection

Figure 2-1

2.6

a

f

f

ESD Protective Measures

Electromagnetic Fields in Electrical Power Engineering Installations WARNING Electromagnetic fields "electro smog" when operating electrical power engineering installations Electromagnetic fields are generated during operation of electrical power engineering installations. Electromagnetic fields can interfere with electronic devices, which could cause them to malfunction. For example, the operation of heart pacemakers can be impaired, potentially leading to damage to a person's health or even death. It is therefore forbidden for persons with heart pacemakers to enter these areas. The plant operator is responsible for taking appropriate measures (labels and hazard warnings) to adequately protect operating personnel and others against any possible risk. ● Observe the relevant nationally applicable health and safety regulations. For example, in Germany, "electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance institution. ● Display adequate hazard warning notices on the installation. ● Place barriers around hazardous areas.


17

Safety Notes 2.6 Electromagnetic Fields in Electrical Power Engineering Installations ● Take measures, e.g. using shields, to reduce electromagnetic fields at their source. ● Ensure personnel are wearing the appropriate protective gear.

18


3

Description 3.1

Key Interlocks As a standard all high voltage access points require a special tool to gain access. Key and/or mechanical interlocks are available as an additional protection to access various compartments in the VFD. Key interlocks are intended to interlock the VFD high voltage sections with the customer input circuit breaker when needed to perform maintenance. Note A door is defined as a hinged panel, as opposed to a bolt-on panel. DANGER The Perfect Harmony™ drive as standard does not provide isolation from MV power. Separate, user supplied isolating methods are required. Consult the key interlocking schematic diagram furnished with each drive’s factory production drawing set to determine the interlocking supplied with the drive. NOTICE For a CSA or UL listed Perfect Harmony™ drive, the listing is void if the drive’s MV sections are not mechanically interlocked with the main upstream disconnecting means.

3.2

Supply Scope The WCIII Perfect Harmony™ series of MV Pulse Width Modulated (PWM) VFDs incorporate the patented Perfect Harmony™ power topology in concert with NXGII hardware and Eagle software. WCIII drives are used to power both induction and synchronous motors. The WCIII design is the third generation of Siemens LD Perfect Harmony™ water cooled MV drive. The NXGII hardware is the second generation of the Siemens LD NeXtGeneration control platform for Perfect Harmony™. NXGII hardware operates with embedded Eagle software. A liquid coolant (deionized water and glycol mix) removes rejected heat from the WCIII drive. The coolant path in the system is closed loop and pressurized, powered by fixed speed or variable speed pumps. Rejected heat is typically removed from the coolant through a forced air finned tube (liquid-to-air) or plate and frame (liquid-to-liquid) heat exchanger. Typically, this heat exchanger is furnished by Siemens with the drive. The standard WCIII drive consists of three shipping sections comprised of the following cabinets:


19

Description 3.3 WCIII Cabinet Details ● Shipping Section 1: Input power and transformer cabinets ● Shipping Section 2: Fuse/precharge/control (FPC), cell, and output power cabinets ● Shipping Section 3: Coolant cabinet Shipping Section 3 can also contain one or both of the following optional cabinets: ● Output Reactor Cabinet: Furnished when drive operates in parallel with other WCIII units, or performs closed synchronous transfer. This cabinet inserts in the standard WCIII lineup between the output power and coolant cabinets. ● Exciter Cabinet: Furnished when the drive powers a synchronous motor. This cabinet inserts at the end of the standard WCIII lineup to the right of the coolant cabinet. The standard WCIII drive outline dimensions vary depending upon the size of the coolant cabinet, input line voltage and frequency, motor type, motor nameplate ratings, motor overload requirements, and whether or not parallel operation or closed synchronous transfer is required. Reference the connection and lifting diagrams furnished with your particular drive for outline dimension, electrical and piping connection gland plate, weight, and center of gravity details.

3.3

WCIII Cabinet Details The components furnished in a WCIII drive vary, depending upon individual customer requirements. Reference the Schematic “S” and Wiring “W” diagrams furnished with your particular drive assembly.

Figure 3-1

20

WCIII VFD


Description 3.5 Transformer Cabinet

3.4

Input Power Cabinet The standard WCIII input power cabinet is a IP 53 (NEMA 12) painted steel enclosure with a hinged three-point latching door. The door has provision for key interlocking, and mounting of an optional input power quality meter. The following optional component may be mounted on the door: ● Siemens 9510 or GE Multilin PQMII power quality meter. The input power cabinet houses the following standard components: ● Customer input MV line terminals L1/L2/L3. ● Stainless steel ground pads, which are welded to the cabinet and provide a means to bond the drive lineup to the customer’s plant grounding grid. ● Input line current transformers, which provide scaled analog current signals to NXGII control and optional input power quality meter. ● Input line voltage attenuator resistors, which provide scaled analog voltage signals to NXGII control. ● Input line surge arresters. Cooper Power Systems UltraSIL™ heavy duty distribution class are standard. The input power cabinet houses the following optional components: ● Input line voltage transformer, which provides scaled analog voltage signals to: – optional input power quality meter. – optional sync-check and phase rotation relays for type 6 pre-charge. ● Fixed point medium voltage protective earthing.

3.5

Transformer Cabinet The standard WCIII transformer cabinet is a IP 53 (NEMA 12) painted steel enclosure with bolton access panels. The transformer cabinet houses the following standard components: ● Perfect Harmony™ multi-winding power transformer. The transformer primary and secondary windings are built with copper tubing for the drive coolant flow (liquid innercooled electrical windings). The transformer assembly includes 80°C and 90°C thermal switches to monitor individual transformer winding coolant discharge temperatures and may also include a coolant diverter valve to regulate coolant flow through the transformer. The ratings of this transformer vary, based upon individual customer input supply frequency and voltage, drive power cell redundancy requirements, and motor requirements. ● Five finned tube forced air heat exchangers to remove transformer and associated power cable rejected heat from the cabinet. Each heat exchanger has two fans (total of ten fans). The loss of any one fan out of ten does not result in a loss of required heat transfer capability. ● 70°C and 75°C thermal switches to monitor ambient air temperature within the cabinet.


21

Description 3.6 Fuse/Precharge/Control (FPC) Cabinet

3.6

Fuse/Precharge/Control (FPC) Cabinet The standard WCIII FPC cabinet is a IP 21 (NEMA 1) painted steel enclosure with hinged overlapping opposed front doors secured by a three point latch. An inner low voltage control panel swings out through these doors to provide access to the MV compartment behind. Quarter-turn fasteners secure this inner panel. The inner panel has provision for key interlocking. DANGER Failure to follow standard safety precautions can result in severe injury or death. When their primary circuits are energized the PT and CT secondary circuits are capable of generating lethal voltages and currents. Follow standard safety precautions while performing any installation or service work (removing PT fuses, shorting secondaries, etc.). The following components may be mounted on the left front door: ● Standard drive HMI keypad ● Optional drive HMI touch screen panel PC The following standard components are mounted on the right front door: ● Emergency Stop (E-Stop) pushbutton ● Speed Demand Mode selector switch (Local-Remote or Off-Local-Remote) ● RJ45 ethernet port (temporary connection for walk-up communication with drive via ethernet Modbus™ or Siemens LD ToolSuite) The low voltage (front) compartment of the FPC cabinet houses the following standard components:

22


Description 3.6 Fuse/Precharge/Control (FPC) Cabinet ● Circuit breaker CB1, which sources customer-supplied single phase 120 VAC control power ● Customer control signal terminal strips TB2 and TB2ELV ● Key-interlockable NXGII control panel with the following items: – NXGII Digital Card Rack (DCR) with Modbus™ RTU interface via DB9 connector – NXGII Control Power Supply (CPS) – NXGII Signal Conditioning Board (SCB) – NXGII I/O Breakout Board, which provides interface for critical customer remote hardwired analog and digital control signals via terminal strips TB2 and TB2ELV (refer to Figure Standard TIMV Hardwired Control Signal Interface in this chapter). – Drive HMI keypad (unless mounted on front door) – Latch Fault relay (LFR) to lock-out drive in IDLE state if a medium voltage power circuit fault occurs within the drive. Key Reset (KR) switch resets drive to resume operation after fault has been cleared. – Contactors CIMV (Close Input MV) and TIMV (Trip Input MV). These contactors provide a CLOSE and TRIP hardwired signal interface to the drive input line circuit breaker. – Ethernet switch with ST fiber optic and RJ45 interfaces for customer interface (permanent connection for remote communication with drive via ethernet Modbus™ and/ or Siemens LD ToolSuite). The low voltage (front) compartment of the FPC cabinet houses an optional Wago™ 750 Series Fieldbus. This provides interface for non-critical customer remote hardwired analog and digital control signals via terminal strips TB2 and TB2ELV. The MV (rear) compartment of the FPC cabinet houses the following standard components: ● Power cell input line fuses ● One finned tube forced air heat exchanger to remove heat rejected within the compartment by bus and fuses. This heat exchanger has two fans. The loss of one fan does not result in a loss of required heat transfer capability. ● Output line Hall Effect current sensors, which provide scaled analog current signals to NXGII control ● Output line voltage attenuator resistors, which provide scaled analog voltage signals to NXGII control ● Circuit breaker CB2, which sources customer-supplied three-phase AC power for power cell precharge, transformer cabinet heat exchanger fans, cell cabinet cooling blowers, and optional drive cabinet space heaters. This circuit breaker can be key interlocked.


23

Description 3.7 Cell Cabinet ● Power cell pre-charge circuit series capacitors C1/ C2/ C3/ C4/ C5/ C6, series resistors R1/ R2/ R3, and capacitor discharge resistors PCR1/ PCR2/ PCR3/ PCR4/ PCR5/ PCR6 ● Power Distribution Panel with the following items: – Contactors M2, M3, and M4 for power cell pre-charge – Circuit breakers CBA/ CBB/ CBC/ CBD/ CBE/ CBH and contactors CBM1/ CBM2/ CBM3/ CBM4 to source cell cabinet cooling blowers BLWR1/ BLWR2/ BLWR3/ BLWR4. The total number of these circuit breakers and contactors varies, based on the total number of power cells. – Control relays CBM1/ CBM2/ CBM3/ CBM4 for cell cooling blower thermal overload status. The total number of these relays varies, based on the total number of power cells. – Circuit breaker CBD and Control Power Transformer CPT to source transformer cabinet heat exchanger fans. The MV (rear) compartment of the FPC cabinet houses the following optional components: ● Control board (BCC) and power supply (BPPS), providing control interface for optional power cell bypass ● Circuit breaker CBH, contactor CB7, and Control Power Transformer CPT2 (mounted on Power Distribution Panel) to source optional drive cabinet space heaters

3.7

Cell Cabinet The standard WCIII cell cabinet is a IP 53 (NEMA 12) painted steel enclosure with hinged three point latching doors. The doors have provision for key interlocking. The cell cabinet houses the following standard components: ● Power cells A1/ B1/ C1 … A6/ B6/ C6. The total number of power cells varies based upon individual customer cell redundancy and motor requirements. Each power cell is comprised of a power chassis (containing power electronic devices and associated control) and a set of integral cell DC bus filter capacitors. ● Cell cabinet cooling blowers and accompanying finned tube heat exchangers. The blowers are configured as follows: – 9 power cells: Two blowers (BLWR1 and BLWR2). The loss of one blower does not result in a loss of required heat transfer capability. – 12 power cells: Three blowers (BLWR1, BLWR2, and BLWR3). The loss of one blower does not result in a loss of required heat transfer capability. – 15 power cells: Three blowers (BLWR1, BLWR2, and BLWR3). The loss of one blower does not result in a loss of required heat transfer capability. – 18 power cells: Four blowers (BLWR1, BLWR2, BLWR3, and BLWR4). The loss of one blower does not result in a loss of required heat transfer capability. Reference Appendix Technical Data for a complete listing of the types and ratings of standard WCIII power cells. The cell cabinet houses optional power cell bypass contactors BPKA1/ BPKB1/ BPKC1 … BPKA6/ BPKB6/ BPKC6. There is one bypass contactor for each power cell.

24


Description 3.10 Output Reactor Cabinet

See also Technical Data (Page 127)

3.8

Output Power Cabinet The standard WCIII output power cabinet is a IP 53 (NEMA 12) painted steel enclosure with a hinged three point latching door. The door has provision for key interlocking and mounting of an optional motor protection relay. An optional Siemens 7UM61/ 7UM62 or GE Multilin 369/ 469 relay may be mounted on the door. The output power cabinet houses the following standard components: ● Customer output medium voltage line terminals T1/T2/T3 ● Stainless steel ground pads. These pads are welded to the cabinet and provide a means to bond the drive lineup to the customer’s plant grounding grid. The output power cabinet houses the following optional components: ● Output line current transformers. Provide scaled analog current signals to optional motor protection relay. ● Output line voltage transformer. Provides scaled analog voltage signals to optional motor protection relay. ● Fixed point medium voltage protective earthing.

3.9

Coolant Cabinet The standard WCIII coolant cabinet is a IP 21 (NEMA 1) painted steel enclosure with overlapping opposed front doors secured by a three point latch. Reference Siemens WCIII Cooling System manual for a complete description of the components housed in the coolant cabinet.

3.10

Output Reactor Cabinet The optional WCIII output reactor cabinet is a IP 53 (NEMA 12) painted steel enclosure with a hinged three point latching door. The door has provision for key interlocking. The output reactor cabinet houses the following standard components: ● Three single-phase iron core reactors (inductors) with copper windings inner-cooled by drive coolant. ● When an output reactor cabinet is furnished, the customer output medium voltage line terminals T1/ T2/ T3 move from the output power cabinet to the output reactor cabinet. The output reactor cabinet houses the following optional component:


25

Description 3.12 Coordinated Input Protection Scheme ● Fixed point medium voltage protective earthing.

3.11

Exciter Cabinet The optional WCIII exciter cabinet is a IP 21 (NEMA 1) painted steel enclosure with a hinged three point latching door. The components furnished in this cabinet vary depending upon individual customer requirements.

3.12

Coordinated Input Protection Scheme Drives require an appropriate input current interrupting device (typically a circuit breaker) installed upstream of the drive. This device must be connected between the power source (input line) and the drive input connections (L1, L2, and L3). The input current interrupting device is considered an integral part of the drive safety and pre-charge systems. It is required that the input current interrupting device be interlocked to the control system so that input medium voltage can be interrupted upon the rare event of a transformer secondary side fault. DANGER Secondary Circuit Fault It is required that the drive medium voltage switchgear be interlocked to the control system so that the input medium voltage can be interrupted upon the rare event of such a fault. Failure to integrate a medium voltage circuit breaking device, or contactor, may cause death, serious personal injury, and damage to the drive. The control of the input current interrupting devices also ensures that input power is applied only after pre-charging the cell DC links. The "close input MV" contact (CIMV), when closed, allows the application of medium voltage power to the drive. A separate check-back signal (dry contact) must be provided from the input current interrupting device to confirm that the device is closed. Check-back signal delay must not exceed 500 milliseconds. A dry contact "trip input MV" (TIMV) output is supplied standard with each drive to trip open the input current interrupting device. This contact changes status whenever a drive input protection occurs. The TIMV contact should act immediately and directly, without any coupling relays involved. Additional delays tripping the input current interrupting device must be avoided. The input protection is defined in the NXG Control Operating manual. DANGER Trip Input Medium Voltage (TIMV) The TIMV contact must be integrated with input current interrupting device to deactivate the drive input medium voltage upon the rare event of a secondary circuit fault. Failure to integrate this contact as specified may cause death, serious personal injury and damage to the drive.

26


Description 3.12 Coordinated Input Protection Scheme When a drive input protection occurs a dedicated NXGII I/O digital output (IDO-15) is closed as a one-shot pulse latches the LFR coil. This causes the 'Normally Closed' (N.C.) LFR contact to open, and the NXGII I/O digital output IDO-14 to open. This logic results in the operation of relay contact "trip input MV" (TIMV) at the customer control signal interface within the drive. Refer to the following figure. &XVWRPHUVLJQDO WHUPLQDOEORFN 7ULS'ULYH09,QSXW&LUFXLW%UHDNHU

Notes:

7,09

● Contact rating 125 VDC 20 A ● This signal MUST be integrated into the drive main input line circuit breaker. ● Dashed line = wiring by customer

Figure 3-2


Standard TIMV Hardwired Control Signal Interface

27

Preparing for Use 4.1

4

Overview of Proper Installation Techniques NOTICE Read this chapter prior to installing the Perfect Harmony™ VFD. Be sure to follow the procedures as indicated. When installing Perfect Harmony™ drives, it is essential to understand the proper techniques associated with the following: ● Transport / shipping ● Receiving ● Off-loading ● Shipping splits ● Weight estimates ● Handling ● Storage ● Unpacking ● Final placement ● Anchoring and securing ● Reconnecting wiring Each of these topics is discussed, respectively, in the following chapters: Preparing for Use, Assembly and Electrical Connections. Refer to Appendix Technical Data for further information relating to transport and storage requirements.


4.2

Safety Precautions for Transportation ● Be sure to read all safety-related instructions provided. ● Perform procedures as instructed. ● Comply with all transportation and handling procedures to help ensure that no components are bent and/or no alterations were made to the isolating distances, all doors/panels are closed or installed and the unit is stablized to prevent tilting.


29

Preparing for Use 4.3 Shipping Guidelines

WARNING Transportation Not in Accordance with Proper Procedures The transportation unit/cabinet is heavy. The equipment may tip over if it is not transported correctly or if an unpermitted means of transport is used. Death, serious injury, or material damage can result. Ensure that the transportation unit/cabinet is transported by trained personnel only. Only use permitted means of transport and lifting equipment. Always position the cabinet in the proper upright position. Never tip the cabinet. WARNING Improperly Placing / Setting Equipment Serious mechanical shocks during transportation or when placing/setting can damage the equipment and destroy the internal insulation material. This can result in insufficient insulation with respect to ground leading to a ground flashover. Death, serious injury, or material damage can result. Avoid mechanical shocks and impacts when placing the equipment.

Center of Gravity of the Transportation Unit / Cabinet Always take the center of gravity into account when lifting and installing the cabinet.

)URQWYLHZ

Figure 4-1

4.3

6LGHYLHZ

Displaced Center of Gravity

Shipping Guidelines The guidelines shown below are based on a maximum transit time of eight weeks. 1. Siemens references IEC 607213-2 2M1 standards. The WCIII drive is designed for truck and ocean transport. It meets all 2M2 conditions with the exceptions of free fall, and pitch and roll. 2. Climatic conditions for transport follow IEC 60721-3-2 2K2. Low air temperature is -25° C and high temperature is +60° C. 3. Ensure precautions are made to minimize the risk of exposure of embedded and other sensitive electronics to water and chemicals.

30


Preparing for Use 4.3 Shipping Guidelines

Truck Transport 1. Use air ride trailers when they are available. 2. Completely cover uncrated cabinets in plastic (minimum 4 mil) and stretch wrap seal around the cabinet sides. 3. Use full length tarps to completely cover the load (crated or uncrated). 4. If securing over the top of uncrated cabinets, position the straps toward the four corners of the shipping split to prevent bending. 5. If using chains through the fork pockets, use chain protectors to minimize damage to the finish/paint.

Ocean Transport 1. Obey the guidelines as specified in the preceding section Truck Transport when transporting to and from the port. 2. Do NOT stack large crates. 3. Stow cargo shipping via open top container, flat rack, mafi, or breakbulk below deck. 4. Do NOT breach or alter crates while securing.

Rail Transport ● Ensure that crates in transit are fully covered by tarp. ● Ensure that Siemens is notified prior to the design phase when transport by rail is to be used for transport.

Securing the Load Secure the load in the following ways: ● Use retaining straps. ● Use positive locking on the loading surface, e.g., by wedging the transportation unit/cabinet on the truck loading surface. ● Properly fit spacers. Note Warranty Disclaimer Failure to follow these guidelines will void your Siemens Industry, Inc. warranty coverage. If you are unsure of your specific warranty requirements, contact Siemens Industry, Inc.


31

Preparing for Use 4.8 Handling

4.4

Receiving The proper receiving procedure consists of the following steps: 1. Verify that the proper items have been shipped. 2. Inspect all items for damage that may have occurred during shipping. 3. File a claim with the shipping carrier if any damage is present.

4.5

Off-loading Due to the size and weight of the components, it is important to carefully plan all handling operations when off-loading. Siemens recommends that prior considerations be made for ceiling heights, door widths, and ease of installation. Off-loading from the truck is often the most critical operation because of the limited access. Advance planning and coordination among the manufacturer, the carrier, the installation contractor, and the owner are vital. Precautions Prior to Moving the Unit Verify the following prior to moving the unit: ● The unit doors are closed. ● The unit is in an upright position. ● The unit is stabilized to prevent tilting.

4.6

Shipping Splits The Perfect Harmony™ drive system is a customized product, therefore shipping split configurations vary from system to system. Refer to the lifting diagrams provided with your system to determine the shipping split configuration for your particular system.

4.7

Weight Estimates The Perfect Harmony™ drive system is a customized product, therefore exact weights of systems vary. Refer to the lifting diagrams provided with your system regarding estimated weight and center of gravity for your particular system.

4.8

Handling Note Siemens does not provide lifting and handling equipment.

32


Preparing for Use 4.8 Handling The following sections describe the allowable methods for handling cabinets. NOTICE Transportation with Fork-lift Lifting with a fork-lift is not recommended due to size and weight distribution of the equipment. If the tines are too short, the transportation unit/cabinet may tip over resulting in death, serious injury, or damage to the cabinet. The customer assumes all responsibility for any damage incurred if a fork-lift is used to lift the unit. NOTICE Final Lifting Liability ● The final lifting is the liability of personnel lifting the structures. Siemens provides general descriptions for each permissible handling method and does not provide custom handling descriptions. ● The lifting analysis presented in this manual was prepared without knowing the specific equipment to be used on site, therefore tailored lifting descriptions cannot be made. To help assure proper lifting of cabinets, Siemens suggests the following actions: ● Verify that the equipment used is sized appropriately according to forces to which they will be subjected. ● Continuously monitor the actual lifting process. ● Use slow movements and low lifting heights where possible. Note The drive contains many cable entry and exit locations. For complete details, refer to the system drawings supplied with the drive.

4.8.1

Transportation with Crane

WARNING Failure to Transport in Accordance with Proper Procedures If not properly transported with crane, the transportation unit/cabinet may tip over or fall. This may result in death, serious injury, or equipment damage.


33


Setup Procedure 1. Read all available safety information about crane transportation before using a crane for transporting units/cabinets. 2. Ensure that the lifting equipment is undamaged. 3. Do not exceed the permissible transportation weight of crane. 4. Locate the center of gravity for the transportation unit/cabinet and lift using a spreader bar (refer to figures in the following section). In most cases, the center of gravity will be offcenter and this must be taken into account before lifting. 5. Adjust sling length to compensate for a displaced center of gravity.

4.8.1.1

Lifting Method for Standard Shipping Section 2 and 3 The recommended lifting method for standard Shipping Section 2 and Section 3 is the strap and cradle method. The strap and cradle method of transportation employs the use of fabric slings through the lifting openings in the cabinet base to lift cabinets. Refer to the following figure. The length and tensile strength of the slings are crucial to this method of lifting.

Figure 4-2

Strap and Cradle Method of Lifting

WARNING Improper Use of Strap and Cradle Ensure that the load carrying capacity of the hoisting equipment is adequate for the weight specified in the order specific lifting diagram furnished by Siemens. Death, serious injury, or damage to the cabinet/unit may result if the load carrying capacity of the equipment is inadequate.

34


Preparing for Use 4.8 Handling CAUTION Potential Damage to Drive Cabinets To prevent buckling of the drive cabinets, the slings must be of adequate length and spreader bars of appropriate strength must be used. Strap and Cradle Procedure 1. Ensure that slings are at least 1.3 m (51 ") above the top of the enclosure. 2. Use spreader bars (single or H-shaped depending on cabinet size) to prevent damage to the cabinet/unit. 3. Ensure that the strength of the sling is adequate for the weight specified in the dimension drawings. 4. Lift the transportation unit/cabinet using the sling. 5. Avoid distorting cabinet or displacing the center of gravity. 6. Ensure that cabinet/unit is parallel to the ground.

1

Single Spreader Bar

2

Centroid

3

Center of Gravity

Figure 4-3


Transportation with Crane using Single Spreader Bar

35


1

H-shaped Spreader Bar

2

Centroid

3

Center of Gravity

Figure 4-4

Transportation with Crane using H-shaped Spreader Bar

Note Weight of Populated Drives Exact weights of systems vary based on the ratings of the drive and the included options. For customized drives having switchgear or transitions cabinets, refer to the project drawings supplied with the drive. Approximate weights of the WCIII core configuration are shown in Appendix Technical Data. WARNING Center of Gravity Offset Ensure great care is taken when determining the length and positions of the lifting straps. Death, serious injury, or damage to the cabinet/unit may result if determinations for strap length and position are not correctly determined.

36



4.8.1.2

Lifting Methods for Standard Shipping Section 1

Standard Lifting Method for Standard Shipping Section 1 The standard lifting method for standard Shipping Section 1 is shown in the following figure. The lift points with this method are located on the transformer frame. 6SUHDGHUEDU

Figure 4-5

Standard Lifting Method

CAUTION Damage to the Transformer Allowing water or debris to enter the transformer cabinet can result in damage to the transformer. Ensure care is taken to prevent water and debris from entering the cabinet and causing damage to the Perfect Harmony™ transformer. Where possible, remove the lifting access panels on the roof of the transformer cabinet when the cabinet is indoors in a clean, dry location.


37


Optional Lifting Method for Standard Shipping Section 1 An optional lifting method for standard Shipping Section 1 is shown in the following figure. The lift points with this method are located on the transformer cabinet roof. These lift points are sealed to prevent dust and water from entering the cabinet.

Figure 4-6

Optional Lifting Method

Note The optional lifting method for standard Shipping Section 1 must be specified at the time the drive is purchased.

4.8.2

Transportation with Roller Dollies WARNING Improper Drive Foundation Ensure that the ground is stable and the foundation for the drive is level and flat. Any sloping can produce uncontrolled drive movement. If the ground is soft and unlevel, lay a "trackway" by using rails, bars, or boards. If the foundation is unstable or unlevel, death, serious injury, or damage to the cabinet/unit may result.

38



Lifting Cabinet from Pallet When space constraints prohibit using a crane, lift the cabinet from the pallet onto rollers. Note Weight Rating Be sure that the weight rating on the roller dolly complies with the dimension drawings shipped with the drive.

Roller Dollies Procedure 1. Place roller dollies under the front and rear channels of the base, just outside the fork tubes as shown in the following figure. 2. Raise the transportation unit/cabinet and then place the lifting wheels under it. 3. Push the angle plates of the lifting wheels from both sides into the position of the center of gravity of the load. 4. Roll the transportation unit/cabinet to the installation location. Take into account safety information, precautions, and warnings.

Figure 4-7


Proper Placement of Roller Dollies

39


4.8.3

Transportation with Pipe Rollers The use of pipe rollers is the least preferred method of transportation. WARNING Improper Drive Foundation Ensure that the ground is stable and the foundation for the drive is level and flat. Any sloping can produce uncontrolled drive movement. If the ground is soft and unlevel, lay a "trackway" by using rails, bars, or boards. If the foundation is unstable or unlevel, death, serious injury, or damage to the cabinet/unit may result.

Lifting Cabinet from Pallet When space constraints prohibit using a crane, lift the cabinet from the pallet onto rollers. It is possible to set the enclosure on many parallel pipe sections placed on the floor and then move it by rolling. Note Pipe Rollers Use thick-walled steel pipes. Other suitable pipes are round steel, round timber, or concretelined pipes. Ensure pipes are at least 6 cm (2.36 ") thick and are at least one fifth longer than the depth of the transportation unit/cabinet. The pipes must be spaced no more than 45.72 cm (18 ") apart. Attach equipment only in places that have load-bearing capability in the direction of tension, such as on the transport rails.

Pipe Rollers Procedure 1. Raise the transportation unit/cabinet. 2. Place pipes under the unit/cabinet. 3. Roll the unit/cabinet to the installation location. Take into account safety information, precautions, and warnings. 4. Raise the unit/cabinet slightly and remove the pipes.

40


Preparing for Use 4.9 Storage

PD[

Figure 4-8

4.9

Proper Use of Pipe Rollers in Handling Cabinets

Storage The following section provides information for storage of the drive after completion of the inspection. Indoor Storage ● Choose an indoor storage location that is clean, flat, and dry. ● Store the drive in an ambient air temperature range of +5 °C to +40 °C. Storage Requirements Note Siemens may require periodic inspection of equipment in storage. ● Ensure that climatic conditions for storage comply with IEC 60721-3-1 1K3. Low air temperature is +5° C and high temperature is +40° C. ● Avoid exposure to corrosive gasses particularly, but not exclusively, hydrogen sulfide and chlorine. ● Avoid exposure to excessive moisture, such as relative humidity greater than 95% steam and condensation. ● Avoid exposure to conductive dust such as coal dust, metal dust, etc. ● Avoid exposure to abrasive dust, oil vapors, explosive mixtures, explosive gases and salt air. ● Avoid exposure to vibration, shocks, or tilting as it may result in the early failure of Siemens components. Perfect Harmony™ drives are designed to withstand shocks/vibrations to a displacement amplitude of 1.5 mm (2-9 Hz), an acceleration amplitude of 5 m/s2 (9-200 Hz) and a shock response value of 40 m/s2. ● Avoid exposure to magnetic fields, nuclear radiation and high levels of radio frequency interference (RFI) from communication transmitters. ● Ensure that drives are completely clean and dry before beginning the commissioning process.


41

Preparing for Use 4.10 Unpacking

Note Warranty Disclaimer Failure to follow these guidelines will void your Siemens Industry, Inc. warranty coverage. If you are unsure of your specific warranty requirements, contact Siemens Industry, Inc.

4.10

Unpacking Note Comply with All On-Site Requirements Siemens recommends that the operating areas be dry and free of dust. The air supplied should not contain any electrically conductive gas, vapors, or dust, which could impair operation. Upon receipt of the drives: 1. Perform a visual inspection to assure shipment is undamaged. 2. Verify that all items are received. 3. Perform the following steps to ensure that no damage occurs to open mounting parts. 4. If applicable, carefully remove the foil and load securing devices. 5. If applicable, remove the packaging immediately prior to installation. 6. If applicable, discard the packaging material in accordance with the applicable countryspecific guidelines and rules. 7. Protect the cabinets against dust by covering the ventilation opening and keeping the doors closed, until commissioning is realized. 8. Do not remove crane instructions from the cabinet(s). Note Damage During Shipment If damage occurs during shipment, contact the shipping carrier to file a claim.

42


Preparing for Use 4.11 Final Placement

4.11

Final Placement After final inspection, promptly move the drive to its final position or dry indoor storage area. Comply with the steps indicated below: 1. Place the equipment in a clean, dry, and level place. 2. Allow enough clearance to easily access the front of the drive with doors open. Allow at least 36 " (915 mm) of clearance in front of the unit for intake cooling air that enters the drive through front-mounted ventilation grilles and is exhausted through the crate mount on top of the enclosure. Do not place the drive where the intake/exhaust paths could be blocked. 3. Ensure stored equipment is protected from dirt and ambient influences. This rule is essential for long periods of storage time. Refer to Appendix Technical Data for additional storage data. NOTICE Mounting Information Mount the drive on a flat surface. Use shims to level the cabinet to assure proper door operation. Mounting to an uneven surface may cause the drive cabinets to buckle, causing the cabinet doors to be misaligned and/or to not open and close properly. Note Mounting Specifications The drive mounting surface must satisfy a floor flatness number (Ff) of 38 (min. local, 32) and a floor levelness number (Fl) of 25 (min. local, 20) per ACI 117-90, Section 4.5.6.1 (as measured in accordance with ASTM E 1155-87). Adjacent mounting surfaces must qualify as Class A per ACI 117-90, Section 4.5.4. Comparable values from comparable standards, such as DIN 18202-Table 3, CSN EN 15620, or appropriate non-concrete substrate standards, will suffice.



43

5

Assembly

Prior to performing any type of work on the equipment, be sure to read and understand all information presented in the Safety Notes chapter of this manual.

Assembly of the Perfect Harmony Drive Adhere to the following general information with respect to installation: ● The cabinets must be installed (and cooled) in accordance with the guidelines in this manual. ● Protect the VFD against excessive stress and loading.

See also Safety Notes (Page 11)

5.1

Anchoring Cabinets to Floors and Walls Holes for anchor bolts are located on the base mounting channel typically 0.75 " from the front and back edges, and 3 " from the sides. Refer to supplied drawings for mounting details. When anchoring the cabinets to the floor, Siemens recommends that the installer use cemented J-bars on all corners. Holes in the base of the drive cabinets are 0.81 " in diameter and easily accept 0.5 " threaded J-bars. If the drive is mounted against a wall, top angles may be used to secure the drive to the back wall in lieu of the rear J-bar connections to the floor. Refer to Figure Proper Anchoring Technique for Cabinets for an overview. Exact dimensions are given in the drawings supplied with the drive. Note Refer to the system drawings provided with the drive for the type of base structure used with each cabinet as well as the exact connection locations.


45

Assembly 5.2 Securing the Cabinets Together

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5.2

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Proper Anchoring Technique for Cabinets

Securing the Cabinets Together Ensure that access to the holes on the bottom of the cabinets is unobstructed. Remove the gland plates. Be sure the materials listed below are located in the shipment: ● Sealing strips, self-adhesive ● Hexagon-head bolts ● Hexagon nuts ● Snap rings ● Washers ● Contact washers NOTICE Before operating the drive, verify cabinets are sealed together using supplied gaskets. Do not operate the drive if the gaskets are damaged or absent. If a gap exists or gaskets are damaged or absent, use 100% silicone caulking to completely seal the gaps between cabinets. Failure to seal all gaps between cabinets will inhibit the drive's cooling system and/or cause internal contamination.

Reconnecting the Shipping Splits Tie bolts are used to connect the individual cabinets to each other, such as the transformer cabinet and the control cabinet. Each section should be bolted to the next using the gasket sealing strips to prevent creating air gaps. Holes for tie bolts are located along the front and back edge of each cabinet section.

46


Assembly 5.2 Securing the Cabinets Together Bolts must be installed to secure the cabinets to each other: four bolts (top, two middle, and bottom) in the front and four bolts in the back. The front connections can be made easily using a 1/2-13 hex-head bolt with a lock washer for each of the four locations. The rear bolts can be installed by removing the rear panels and installing the same hardware as in front. The control wires are connected with plugs. These plugs are located in the front of the drive near the control terminals located to the left of the control box. %ROWDQGZDVKHU

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Note Before using hand tools, tie one end of a string to the tool and the other to your wrist. This prevents loss of the hand tool if accidentally dropped into the drive. If any hardware is accidentally dropped into the drive during reconnection, it must be removed prior to application of control and medium voltage.


47

Assembly 5.3 Protective Earthing Bars Connection

5.3

Protective Earthing Bars Connection DANGER Grounding the Drive The VFD must be grounded to allow safe operation. If not sufficiently grounded during operation, the protection and monitoring functions can fail. Death, serious injury, or material damage will result. ● Always take the appropriate precautions and observe the five safety rules before carrying out any work on the converter. ● Follow these steps when grounding the machine: – Make the connections to the PE busbars within a cabinet. – Ensure that the connections to the PE busbars are made over several cabinets. – Set up the ground connection for the whole plant immediately.

Connecting the Protective Earthing (PE) Bars (for several cabinets) Note Each cabinet in the lineup is bonded together, generally via 1/0 cable.

48


Electrical Connections

6

Prior to performing any type of electrical work on the equipment, be sure to read and understand all vendor supplied information and all information presented in the Safety Notes chapter of this manual.


6.1

Reconnecting Wiring and Plumbing Reconnect the power wiring, control wiring, and plumbing between the control/cell cabinet, transformer cabinet, input-output cabinet, and pump cabinet. The cell input power cables in the transformer cabinet connect to the cell input bus in the back of the cabinet. These can be accessed by removing the cabinet rear panels. The transformer power wire label must match the labels on the cell cabinet bus work. Power wire must be firmly attached to the transformer supports that are located in the transformer cabinet. The transformer has a set of ±5% voltage taps for compensating the primary voltage source. The drive is shipped with the +5% taps connected, meaning that the VFD secondary cell voltages are at the nominal 750 VAC (for example) for an input voltage of 5% above primary nominal rating. Customer-supplied medium voltage (MV) power enters an access plate in the top or bottom of the input section. Customer-supplied AC power for both control and pumps enters an access plate in the top or bottom of the control and liquid coolant cabinet section. Output connections for the motor exit through an access plate in the top or bottom of the output section located to the right of the power cells. DANGER Ensure that the entire system is earth grounded at its Protective Earth (PE) ground point. Failure to do so will cause death and damage to the drive. Ground bonding jumpers are factory-made. Reconnect ground bonding between cabinets at shipping splits.


49

Electrical Connections 6.2 Installation of I/O External Wiring NOTICE Do not bond the transformer primary winding neutral point to ground. The transformer primary winding neutral point is designed to operate floating (ungrounded). Failure to adhere to this instruction will cause large, unbalanced currents to circulate in the ground/neutral path of the drive’s input source system during drive energization. Note EMC Compliance To maintain EMC compliance, input medium voltage wiring must be installed in metallic electrical conduit and routed through the approved access plates. Customer supplied low voltage I/O cabling #12-#22 AWG must be routed separately from power cables / medium voltage cables. Shielded low voltage cables shall maintain shield integrity for the length of the cable including all inter-connections and the shield shall be grounded only at the source. NOTICE Shielded Cable Requirement If the output motor leads are shielded cable, the shields must be terminated at the drive end only. Failure to do so will cause unwanted drive and system problems. The input and output medium voltage terminals (L1, L2, L3 and T1, T2, T3) are offset from one another and have two NEMA one-hole pattern configurations (vertical and horizontal) to facilitate top or bottom cable termination. MV terminations are provided for 3/8" fasteners.

6.2

Installation of I/O External Wiring Refer to the project drawing C set for the customer I/O connection interface (#12 - #22 AWG). All hardwired I/O cabling should be routed and terminated prior to commissioning. CAUTION Electrical Hazard! Standard safety precautions and local codes must be followed during installation of external wiring. Protection separation must be kept between extra low voltage (ELV) wiring and any other wiring as specified in the CE safety standard IEC 61800-5-1.

50


Electrical Connections 6.3 Electrical Requirements

6.3

Electrical Requirements Mechanical Connections Unless otherwise specified on the drawing, Siemens standard is to use the American Institute for Steel Construction (AISC)’s definition of snug fit for all mechanical connections. Snug fit is defined as the force exerted by a standard operator using ordinary hand tools. The spring washer or locking mechanism should be fully engaged in the base metal to provide a solid connection but not necessarily in continuous contact. These connections do not require the use of a torque wrench and do not require a torque mark. However, if a torque specification for a mechanical connection is called out in the assembly drawings, then the assembler or technician will properly torque the fastener and mark the connection with orange paint. Torque specifications for the Perfect Harmony™ drive are listed in the following tables.

Table 6-1

Torque Values for Electrical Connections (as per Regulation Document NKN-MF-0019) Fastener Size

English

Metric

Tightening Torque Value Newton-Meters (Nm)

Ft-lb

In-lb

2-56**

M2

0.4

3.0

4-40**

M3

0.7

6.0

6-32**

M3.5

1.4

12.0

8-32**

M4

2.5

22.0 (15.0)***

10-32

M5

4.0

36.0

1/4-20

M6

8.0

72.0

8.0

72.0

1/4-28 5/16-18

M8*

17.0

156.0

3/8-16

M10*

31.0

276.0

31.0

276.0

3/8-24 1/2-13

76.0

56.0

5/8-11

M12

153.0

112.0

3/4-10

270.0

198.0

1-8

600.0

480.0

*

These values do not apply when this hardware is used on power modules (IGBT, diodes, etc.) For the required torque values in these instances refer to the drawings. ** These sizes are only torqued when used on ground wire. *** #8 bolts used in secondary connections on CTs are torqued to 15 in-lbs. Table 6-2

Torque Values for Raised Face to Raised Face or Flat Face to Flat Face non-CPVC Connections (as per Regulation Document NKN-MF-0008)

Description

Gasket Part Number

Bolt Diameter

Grade 5 bolt torque

Grade 8 bolt torque

1/2 " 150# flange

A1A0100925

1/2

19 ft-lb

25 ft-lb

3/4 " 150# flange

A1A0100926

1/2

19 ft-lb

25 ft-lb

1 " 150# flange

A1A0100927

1/2

20 ft-lb

25 ft-lb


51

Electrical Connections 6.3 Electrical Requirements Description

Gasket Part Number

Bolt Diameter

Grade 5 bolt torque

Grade 8 bolt torque

1.5 " 150# flange

A1A0100928

1/2

20 ft-lb

26 ft-lb

2 " 150# flange

A1A0100929

5/8

39 ft-lb

50 ft-lb

2.5 " 150# flange

A1A0100930

5/8

40 ft-lb

51 ft-lb

3 " 150# flange

A1A0100931

5/8

41 ft-lb

52 ft-lb

4 " 150# flange

A1A0100932

5/8

22 ft-lb

27 ft-lb

For Table Torque Values for Raised Face to Raised Face or Flat Face to Flat Face non-CPVC Connections, the following assumptions apply to the calculations for the listed torque values: ● Values are for ANSI Class 125 and 150 pound flanges. ● Torque calculations are based on Grade 5 and Grade 8 bolts of listed size and using listed gasket. Deviation from these components requires the torque value be recalculated. ● A calibrated torque wrench is used and the proper tightening procedure is followed per Siemens LD Document A5E02550752A. Power Cabling Cross Sections Table 6-3

Power Cabling Cross Sections

Motor Voltage

Shaft Output

Cable Cross Sections: Line-side, max. connectable per phase with M10 screw1 preliminary

Cable Cross Sections: Motor-side, max. connectable per phase with M10 screw1 preliminary

PE connection: Max. connection cross section at enclosure with M12 screw1 preliminary

kV

hp

kW

AWG/MCM mm2 (NEC, CEC) (DIN VDE)



3.3

4400 – 8133

2984 – 6067

2 x 1000 MCM

2 x 500

2 x 1000 MCM

2 x 500

1000 MCM

500

4.0 / 4.16

4500 – 8660

3357 – 7354

2 x 1000 MCM

2 x 500

2 x 1000 MCM

2 x 500

1000 MCM

500

4.6 / 4.8

4500 – 11830

3357 – 8825

2 x 1000 MCM

2 x 500

2 x 1000 MCM

2 x 500

1000 MCM

500

6.0

7000 – 14787

5222 – 11031

2 x 1000 MCM

2 x 500

2 x 1000 MCM

2 x 500

1000 MCM

500

6.6

8000 – 16266

5968 – 12134

2 x 1000 MCM

2 x 500

2 x 1000 MCM

2 x 500

1000 MCM

500

6.9 / 7.2

8000 – 17744

5968 – 13237

2 x 1000 MCM

2 x 500

2 x 1000 MCM

2 x 500

1000 MCM

500

Maximum installable size per phase

1

Table 6-4

Conductor Dimensioning

Object

Length

Cable Length (motor side)

● No output filters are required up to 2.2 km (7500 ft). ● Over 2.2 km (7500 ft) permissible only with output filters. ● Cables must be shielded.

52


Electrical Connections 6.4 EMC Installation Guidelines for Perfect Harmony

Note Input Conductor Sizing Conductor sizes for input medium voltage termination may vary based on the size of the drive and dynamics of the system. The customized system schematic (included with your drive) shows the conductor size used on the main transformer taps. The size of the input conductors usually matches or exceeds this size. Be sure to size the input conductors appropriately for your particular application, taking into account the length of the input power feed and local standards and electrical codes. Labels located near connections recommend the use of 75 °C conductors.

6.4

EMC Installation Guidelines for Perfect Harmony These guidelines cover the basic points to be considered when installing a Perfect Harmony™ motor drive with minimum Radio Frequency Interference (RFI) impact on the surrounding environment. A drive that limits RFI to within specified levels has achieved Electromagnetic Compatibility (EMC). There are four key areas that need to be addressed to achieve EMC: ● Earthing ● Screening ● Filtering ● Wiring. 7UDQVIRUPHU ,QSXW6HFWLRQ

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Perfect Harmony Drive System

Earthing The Perfect Harmony™ drive has provisions for the customer to bond Protective Earth (PE) to the drive cabinets. These connection points are identified with a ↓ symbol in the drive


53

Electrical Connections 6.4 EMC Installation Guidelines for Perfect Harmony assembly. The PE connections are provided adjacent to the L1/L2/L3 power input and T1/T2/ T3 power output terminals in the drive. All sections of the drive are internally PE bonded by green/yellow conductor or black conductor with green and yellow tape. All customer PE connections to the drive should be as short as physically possible and comply with all local safety regulations regarding earthing. Siemens Industry, Inc recommends PE bonds be at only one point on the drive to prevent circulating ground currents. All PE bonds should be checked as part of routine drive maintenance.

Screening (Shielding) The purpose of screening [shielding] is to prevent any unwanted radio frequency electromagnetic radiation from escaping or entering a system. To accomplish this, the screening must be part of the cabinets or enclosures as well as the connecting input and output cables. The Perfect Harmony™ drive, with its switching elements and microprocessor controllers, is a source of RFI. However, the enclosures of the Perfect Harmony™ drive have been engineered and tested to provide an effective "Faraday Cage" that limits the amount of RFI escaping from the drive. This cage also helps prevent unwanted RFI from entering the drive. All cables in and out of the drive [power/mains and control/signal] must be shielded to limit RFI emissions. The motor housing is typically an effective RFI screen. To achieve EMC, the three screens – cabinet, cable, motor housing – must be bonded together to effectively form one screen. No interruptions in the cable shielding are permitted. The connections in the screening system must have a low impedance in the megaHertz (MHz) range. Special connectors are designed for this purpose and recommended.

Filtering An internal EMC line filter is installed in the Perfect Harmony™ drive on the customer control power inputs. The customer's control power connections to the drive must be in metallic tubing and must not be in close proximity with the internal EMC line filter.

Wiring Control and Signal Cables The control cabling is a part of the Faraday Cage as described in the screening section above. ● Use shielded cables for all analog and digital control connections whenever possible. Twisted pairs are an effective alternative to shielded cables. ● If twisted pairs are used the twist should be carried as close as possible to the appropriate terminals. If possible avoid the use of a common return for different analog signals. ● Always separate digital and analog signals. Never mix 110 / 230 Volt signals in the same cable as 24 Volt signals. A conventional screened or armored cable should be used for 110 / 230 V signals. ● Double-shielded cables will give the best performance. ● Control and signal cables must be separated from power cables.

54


Electrical Connections 6.4 EMC Installation Guidelines for Perfect Harmony ● Route control and signal cables in separate cable trunks at least 200 mm (8 in) away from motor and power cables. ● If control and signal cables must cross power cables, it must be at an angle as near to 90 degrees as possible. Refer to the following figure.

r

!

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!

1

Motor cable

2

Mains cable

3

Signal/control cables

Figure 6-2

Recommended Cable Segregation

Power (Mains/Motor) Cables Siemens Industry, Inc. recommends the input and output medium voltage power cable, regardless of operating voltage, used for all Perfect Harmony™ drives be shielded to mitigate RFI and achieve EMC. The cable shield should be electrically continuous for the entire cable length and constructed of nonmagnetic metal, a tape shield is preferred. Cable armor and nontape shields, such as Unishield, also serve to limit RFI emissions. Both of these types of cable have been successfully applied with Perfect Harmony™ drives, but they may not be as effective as a tape shield in limiting RFI. ● The cable manufacturer’s recommendations for maximum pulling tension and minimum bend radius should always be followed when installing cable. ● No other cable shields, power or control/signal, should be bonded to the motor cable shield. Very high levels of electrical noise will be induced in such cables. ● Siemens Industry, Inc. recommends all drive input [mains] and output [motor] power cable shields be bonded to PE at one end only. ● Whenever armored cables are used, they should be properly terminated with a gland, the armor contacting the gland through all 360 degrees, and the gland circumferentially grounded to the gland plate and bonded to PE. Serial Communication Cables The signal transmission standard (RS232, RS485, Ethernet, etc.) and protocol standard (Profibus, ControlNet, Modbus, etc.) will recommend suitable cable types. Follow the recommendations. Encoder Cables Pulse encoders may be galvanically connected to the motor rotor. It is important that any bearing insulation not be bridged. The recommendations of the encoder supplier, such as cable


55

Electrical Connections 6.5 Cable Gland Plates Removal and Installation Guidelines type, should always be strictly followed. The cable run from the encoder to the drive should be a continuous length and not interrupted by screw terminals. Note Complete Guideline on EMC Installation ● Go to the Gambica website at: http://www.gambica.org.uk/ ● Download the Variable Speed Drives and Motors - Installation Guidelines for power Drive Systems - User Guide No. 3 from the publications link.

6.5

Cable Gland Plates Removal and Installation Guidelines Removal of gland plates is necessary to complete output power cable installation. Gland plates are attached to the drive enclosure and can be removed by unfastening the hardware. Gland Plate Installation Preparation and Procedure: 1. Place the unfastened hardware in a safe place so that it may be easily located when reinstalling the gland plates. 2. Verify that the gland plates have a rubber gasket seal (prevents weather ingress) located on the inside of the plate. 3. If cable size permits, make holes for drilling cable entries. 4. Do not drill the gland plate while it is still mounted to the enclosure. NOTICE Gland Plate Drilling Do not drill the gland plate while it is mounted to the enclosure. Drilling the plate while it is mounted leads to metal dust accumulation on sensitive electronics that are located inside of the unit, which may cause loss of component integrity and possibly affect system operability. Gland Plate Drilling Guidelines 1. Take care not to damage the rubber gasket seal material during the drilling process. 2. Fit the cable entries with rubber gasket material to form a proper seal. 3. Ensure that gland plates are properly fastened to the drive with the original hardware. 4. Be sure to check the integrity of the rubber gasket seal prior to installing the gland plate.

56


Electrical Connections 6.6 Circuit Breaker (provided by the customer)

6.6

Circuit Breaker (provided by the customer) To ensure adequate protection for VFDs, the circuit breaker provided by the customer must fulfill the following requirements: ● The maximum time between when the circuit breaker trips, to when a no-current state (I=0) is reached, is 100 ms. ● The circuit breaker must be equipped with an undervoltage tripping function. ● There must be a check-back signal for the circuit breaker states CLOSED and OPEN. The check-back signals must not be delayed, i.e. they must not be carried via coupling relays. ● The circuit breaker is activated and enabled by the VFD closed-loop controller. It must never be switched on by electrical or external mechanical means without having been enabled. ● An overcurrent protection device is provided to protect the VFD transformer.


57

Commissioning

7

When commissioning the drive, be sure to read and understand all safety warnings as detailed in the Safety Notes chapter. Obey all warnings and safety material presented in each chapter. DANGER Potential for Drive Damage, Serious Injury or Death Improperly commissioning the drive can cause damage to property, serious injury, and possible death. Only qualified service personnel are permitted to commission a Perfect Harmony™ drive. Refer to the WCIII Cooling System manual supplied along with this manual for cooling system related commissioning information. ln addition, refer to the WCIII Commissioning manual supplied at the conclusion of the commissioning process. Note Contact Siemens customer service for commissioning documentation.


7.1

Residual Current Device (RCD) Compatibility CAUTION RCD Incompatibility Connecting this device to a power supply protected by a residual-current device can result in damage to property and minor personal injury. This product can produce a DC current in the grounding conductor. When using a Residual Current Device (RCD) in cases where direct or indirect contact can be made, only a Type-B RCD shall be permissible on the line side of this product. If this is not possible, an alternative means of protection must be applied. Isolation from the environment through double or reinforced insulation, or isolation from the power supply using a transformer, is an example of alternative means of protection.


59

Commissioning 7.1 Residual Current Device (RCD) Compatibility Note The master mechanical interlock key must be coordinated with the input voltage switchgear.

60


8

Operation

When operating the drive, be sure to read and understand all safety warnings as detailed in the Safety Notes chapter. Obey all warnings and safety material presented in each chapter. DANGER Potential for Drive Damage, Serious Injury or Death Improperly operating the drive can cause damage to property, serious injury, and possible death. Only qualified service personnel are permitted to operate a Perfect Harmony™ drive. Refer to the NXG Control Operating manual supplied along with this manual for operating information and a complete listing of faults and alarms and unexpected output conditions to use in troubleshooting. ln addition, refer to the WCIII Cooling System manual supplied along with this manual for cooling system related operating, and alarm and fault information.

See also Safety Notes (Page 11) Control power must always be applied prior to application of medium voltage. CAUTION Active Cooling System NEVER energize the drive without an active and fully functional cooling system (cooling pumps and external and internal heat exchanger fans). The drive contains components that have losses in the idle state. Without air flow, these losses may heat and eventually damage components. The damaged components over time, may cause the drive to become damaged as well. Applying medium voltage without air flow will result in a trip from the coordinated input protection scheme.


61

Operation

NOTICE Addressing Faults Ensure that all faults are properly addressed prior to application of medium voltage. Doing so helps to ensure the drive runs efficiently. In addition, ensure that control power is not removed while MV is applied. Failure to comply with this may result in cell damage.

62


9

Maintenance

The Perfect Harmony™ drive is designed, built, and tested to provide long, trouble-free service. Keeping the drive working reliably, minimizing system down time, and maintaining safety, requires periodic maintenance. Prior to performing any type of maintenance, be sure to read all relevant safety and product information. Perform procedures as indicated. Refer to the Safety Notes chapter in this manual. DANGER Electrical Hazard! Handling the equipment with main input power connected will cause death or severe injuries. Always switch off the main input power to the equipment before attempting inspection or maintenance procedure. WARNING Potential for Drive Damage, Serious Injury or Death Only qualified service personnel are permitted to maintain Perfect Harmony™ equipment and systems. Failure to use qualified personnel may result in damage to property, serious injury, and possible death. Refer to Appendix Service and Support for customer service contact information.

See also Safety Notes (Page 11) Service and Support (Page 125)

9.1

Door Access The drive can be locked either mechanically or electromechanically. Opening the Power Unit Doors The doors must not be opened until the following statuses are present:


63

Maintenance 9.2 Preventive Maintenance ● The DC link voltage has been de-energized: – DC bus voltage indicator LED, located on the front of each cell's cell control board, must NOT be illuminated. An illuminated DC bus voltage indicator LED shows that more than 50 VDC is present on the DC bus. This indicator light may not be visible until the cell doors are opened. – Do not touch, remove or service the cell if the indicator is illuminated. ● The EMERGENCY-OFF switch on the cabinet has been activated.

9.1.1

Mechanical Interlock System The doors can also be protected using a key transfer system. Once the primary-side (customer) circuit breaker has opened, a coded key for enabling the key in the key transfer unit can be removed. Operation 1. Switch off the primary-side (customer) circuit breaker. 2. The coded key for the key transfer unit, which is in the circuit breaker, can now be removed. 3. Use the key to unlock the keys in the key transfer unit. 4. Remove the keys and release the locks on the cabinet doors. Note Closing the Circuit Breaker The circuit breaker cannot be closed again until the keys have been returned to the key transfer unit, the key transfer unit has been locked, and the coded key is back in the circuit breaker.

9.2

Preventive Maintenance The purpose of an inspection is to ascertain and evaluate the current status of the equipment. An inspection mainly comprises visual checks. Inspections should be carried out based on a schedule that meets the needs of the special ambient conditions at the site of installation. The following servicing and inspection instructions are used as the basis for regular inspection of the equipment.

9.2.1

Six Month Inspection Perform visual inspections as indicated for specific site installation requirements. Siemens recommends doing so every six months.

64


Maintenance 9.2 Preventive Maintenance The basic equipment required for a visual inspection is a mirror and a flashlight. Inspect the following: 1. Check operation of fans in the top portion of the cell cabinet. 2. Check door filters on the control cabinet and the pump cabinet. Replace if necessary. 3. Inspect cooling system for leaks. Repair or replace components as necessary. 4. Use touch-up paint, as needed, on any rusty or exposed parts on the cabinet enclosure. 5. Test coolant for presence of required glycol concentration. Refer to Appendix Technical Data of this manual. Note A minimum of 5% Glycol concentration by weight is recommended to control bacteria. 6. Check for contamination and dirt damage. NOTICE Contamination and dirt can damage the device. For levels of contamination falling within the specifications specific to your site, perform a visual inspection once a year, taking into account specified ambient conditions. Depending on ambient conditions, visual inspections may need to be performed on a more frequent basis. Component

Comments

Insulating clearances

Slight, dry, non-conducting contamination is permitted. Contamination caused by dust in conjunction with high relative humidity must be removed. In particular the surfaces of the ceramic semiconductors and the support insulators must be clean and dry.

Air filter

Check the air filters in the cabinet doors for contamination.

7. Check electrical connections and fiber-optic connections Component

Comments

Contacts

Carry out a visual inspection of the contacts to check that they are seated correctly and not corroded.

Note Fiber-Optic Conductors for Gating Boards The fiber-optic conductors for the gating boards must be properly inserted in the connectors.


65

Maintenance 9.3 Cleaning

9.2.2

Preventive Maintenance Checklist Use the following table as a guide for performing preventive maintenance tasks. Maintenance

Frequency

Comments

Clean the cabinet (exterior).

As required

Visual check, clean if required.

Clean the cabinet (interior).

Annually

Visual check, clean if required.

Check the electrical connections (external power and test connections) and check the cable/ screw terminals.

After 1 year

Check the internal connections.

After 1 year

Check the cable and screw terminals and then every 6 months or as needed regularly to ensure that they are secure. If they are not secure, tighten them according to specifications. Visual check, clean if required.

and then every 6 months or as needed Carry out inspection and visual check.

Annually

Visually inspect the insulation.

Annually

Cooling system related tasks.

Refer to the WCIII Cooling System manual for cooling system related preventive maintenance tasks.

9.3

Cleaning

9.3.1

Contact for Cleaning Measures

See the specifications in the operating manual.

If contamination occurs, contact Siemens customer service. Refer to Appendix Service and Support. Note Proper Cleaning Agents Be sure to use cleaning agents that do not cause corrosion. Using cleaning agents that may cause corrosion can produce unwanted equipment damage.

See also Service and Support (Page 125)

9.3.2

Removing Dust Deposits Dust Deposits Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once a year) by qualified personnel in line with the relevant safety regulations.

66


Maintenance 9.4 Repair and Replace The unit must be cleaned using a brush and vacuum cleaner, and dry compressed air (max. 1 bar) for areas that cannot be easily reached. Ventilation The ventilation openings in the cabinet must never be obstructed. The fan must be checked to make sure that it is functioning correctly. Cable and Terminal-Screws ● Check the cable and terminal-screws regularly to ensure that they are secure. Tighten them if necessary. ● Check the cabling for defects ● Replace any defective parts immediately. Note The actual intervals at which maintenance procedures are to be performed depend on the installation conditions (cabinet environment) and the operating conditions. Siemens offers its customers support in the form of a service contract. For further details, contact your regional office or sales office.

9.4

Repair and Replace

9.4.1

Safety-relevant Checks WARNING Visual Check of Cable Insulation Improperly laid or damaged cables and incorrectly attached cable shieldings can heat up in places and cause fires or short-circuits wherever they make contact. ● Make sure that the cable shields are intact and insulate any that are damaged. ● Make sure that a short-circuit cannot occur on the power cables due to failure of the insulation as a result of incorrect cable installation. Note Component Replacement Unless otherwise indicated by Siemens, always replace components with the same part number and revision level.


67

Maintenance 9.4 Repair and Replace Note Drive Failure When the power supply is switched off, data about error message statuses is lost. Inadequate diagnostic and error rectification measures can result in damage to the Drive. For additional technical support, please contact the Siemens Service Center. Note Door Interlock Failure Please contact Siemens Service Center for technical support.

See also Service and Support (Page 125)

9.4.2

Maintenance and Earthing Procedure WARNING Qualified Personnel Only Due to the modularity of the Perfect Harmony™ VFD design, the maintenance and earthing procedure does not cover all variations of equipment types or installations. Siemens strongly recommends that only qualified personnel be allowed to perform maintenance on Perfect Harmony™ Systems. 1. Stop drive operation, either through remote or local controls. 2. De-energize input voltage by opening incoming switchgear and locking to OPEN position with mechanical interlock. Apply lock-out/tag-out principles as required by local code. 3. De-energize control voltages for synchronous motor field/exciter controls. 4. If applicable, close all make-proof grounding switches and lock into the CLOSE position. If make-proof grounding is not available, check connection points with a non-contact voltage probe and apply green/yellow insulated ground cables from L1/L2/L3 and T1/T2/T3 to protective earth (PE).

68


Maintenance 9.4 Repair and Replace 5. Wait ten minutes to allow stored energy to dissipate from the drive. WARNING Discharging Resistors The power cells include discharge resistors to dissipate stored energy after the input voltage is removed. The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes. Ensure you follow all safety precautions to avoid risk of death, serious personal injury, and equipment damage. 6. Use correct PPE, electrical safety (rubber) gloves/leathers must be worn. 7. Open the cell cabinet door and visually inspect several cells to confirm the charging light is off. – If any lights are on wait until they have gone out. 8. Proceed to open the hinged cover on the front of the cell to access the capacitor connection points. 9. Set voltmeter to DC setting to >1000 VDC scale. 10.Identify connection points on the cell (shown in the following figure), and working with one hand only, connect leads.

Figure 9-1

Meter Connection on Cell DC Bus

11.Verify the capacitor banks are fully discharged. 12.Perform maintenance as required.


69

Maintenance 9.4 Repair and Replace 13.Remove the grounding device. 14.Close the doors in reverse sequence, and replace interlock key into input switchgear.

9.4.3

Replacing Parts Replacement of component parts may be the best method of troubleshooting when spare parts are available. When any sub-assembly is to be replaced, always check that the part number of the new unit matches that of the old unit (including the revision letter). NOTICE Proper Disposal of Failed Components The disposal of any failed components (capacitors, etc.) must be done in accordance with local codes and requirements. ● Failures traced to individual PC boards within the control cabinet are best serviced by replacement of the entire board. ● Failures traced to individual power cells are best serviced by replacement of the entire cell. Report power cell failures to Siemens customer service. ● Perform yearly inspection of hoses after seven years of service and/or during maintenance outages. The service life of hoses varies based upon a variety of circumstances including but not limited to: – Type of hose – Amount of electrical voltage across hose – Exposure to UV light or chemical contaminants – System pressure transients (pump switchovers, pressure testing, hours of operation, etc.) – Mechanical stress (cable ties, clamps, walked on, vibration, etc.) – Exposure to high temperatures ● Immediately address an indication of hose damage, such as cracking, bulging, embrittlement or discoloration. Siemens recommends that all hoses within the drive be replaced if any hose has indications of damage. Deionizer Tank Replacement The coolant conductivity High Alarm level is customer-programmable, with factory default at 1 microSiemens/cm. The coolant conductivity High-High Alarm level is fixed at 5 microSiemens/ cm. Replace the deionizer tank with a new (fully charged) unit once conductivity exceeds 5 microSiemens/cm. Refer to Section Deionizer Tank of the WCIII Cooling System manual for deionizer tank description and the tank replacement procedure.

70


Maintenance 9.4 Repair and Replace

9.4.4

Replacing the Door-mounted Keypad To replace the door-mounted keypad: 1. Switch off the main circuit breaker. 2. Open the cabinet. 3. Remove the Macrolon cover. 4. Disconnect the ribbon cable at J2 from the keypad. 5. Unscrew the four hexagon-head screws. 6. Pull the keypad out to the front. 7. Fit a new keypad. 8. Screw in the four hexagon-head screws. 9. Reconnect the ribbon cable at J2 on the keypad. 10.Reattach the Macrolon cover.


71


9.4.5

Replacing the CompactFlash Card Copy the stored data of the old CompactFlash card to the new original Siemens card. Refer to the following figure.

)ODVK'LVN

Figure 9-2

Location of CompactFlash card on the NXGII Microprocessor Board

Perform the following steps to replace the CompactFlash card. 1. Remove the fiber-optic link from the fiber-optic control board. 2. Remove the enclosure cover from the NXGII card rack. 3. Remove the power cable and the SUB-D cable. 4. Loosen the fastener screw on the card. 5. Withdraw the card from the NXGII card rack. 6. Remove the old Compact Flash card. 7. Insert the new Siemens CompactFlash card. 8. Reinsert the card back into the NXGII card rack. 9. Retighten the fastener screw on the card. 10.Reconnect the power cable and the SUB-D cable.

72


Maintenance 9.4 Repair and Replace 11.Reattach the enclosure cover to the NXGII card rack. 12.Reconnect the fiber-optic link to the fiber-optic control board.

9.4.6

Replacing Cell Input Power Fuses Currently, the approved fuse sources are Ferraz and Bussmann (additional vendors may be added at a later date). Only two phases of each transformer secondary (power cell input) are fused. Blown Cell Input Power Fuse Indicator Each fuse has visual blown indication, making it easy to diagnose a fuse’s condition. Refer to the following figures for the locations of the fuse indicator for each manufacturer. ● On the Bussmann fuse, the blown fuse indicator is located on the right side of the fuse when viewed from the front of the cabinet.

Figure 9-3

Bussmann Blown Fuse Indicator

● On the Ferraz Shawmut fuse, the blown fuse indicator is located on the top of the fuse as installed.

Figure 9-4


Ferraz Blown Fuse Indicator

73


Cell Input Power Fuse Replacement Procedure To replace an open cell input fuse: 1. Power down the system, following the standard shut-down procedure and obeying all standard electrical and safety instructions. Refer to Section Maintenance and Earthing Procedure in this chapter. 2. Open the doors to access the cell input fuse section. Note This section varies based on the drive output voltage and cell size. Reference the customer specific documentation to locate the cell input fuse. 3. Use an appropriately sized AC voltage detector to ensure that the power is removed. WARNING Electrical Hazard The secondary rating of a WCIII transformer to the input of the cell power fuse is 750 VAC. Qualified personnel must obey all safety precautions. Risk of death, serious personal injury, and equipment damage can occur. 4. Use the appropriate tools to remove the bolts holding the power bus. 5. Remove the open fuse and replace with a spare cell input power fuse. 6. Reconnect the bus and apply a new torque mark to the bolt. Note Torque the hardware per Section Electrical Requirements in Chapter Electrical Connections of this manual.

See also Maintenance and Earthing Procedure (Page 68) Electrical Requirements (Page 51)

9.4.7

Replacing Printed Circuit Boards (PCBs) Follow the procedures as indicated in the following sections when replacing PCB(s) on the: ● Digital card rack ● Signal conditioning board ● I/O breakout board

74


Maintenance 9.4 Repair and Replace Digital Card Rack 1. Power down the system, following the standard shut-down procedure and obeying all standard electrical and safety instructions. Refer to Section Maintenance and Earthing Procedure in this chapter. 2. Use an appropriately sized AC voltage detector to ensure all power is removed to the NXG Control. Note The drive can accommodate up to a 240 VAC power for the NXG Control. 3. Prior to servicing any printed circuit board (PCB), ensure proper ESD protection is followed. – All circuit boards shipped by Siemens are done so in an ESD protective bag. They must stay inside this bag during transport and storage. They can only be removed after placing the bag on a dissipative ESD workbench surface. – Before removal from the ESD protective bag, the personnel handling the PCB must be properly grounded. Proper grounding is accomplished by using a heel grounder on a dissipative floor surface or a wrist strap connected to a proper ground. Note ESD sensitive components can be identified by symbols being present on the component or the component packaging.


75

Maintenance 9.4 Repair and Replace 4. The NXG Control has a digital card rack with 8 slots and is mounted within the respective control tub. The following PCB locations, from right to left when facing the unit, are within the digital card rack: – Slot 1: Keypad interface board – Slot 2: Single board computer (CPU) board – Slot 3: BGA digital modulator board – Slot 4: Fiber optic interface board (6600 V and 10000 V unit only) – Slot 5: DB37 connector – Slot 6: System I/O board – Slot 7: DB50 connector – Slot 8: Communication board with up to two Anybus modules.

76


Maintenance 9.4 Repair and Replace 7REUHDNRXWERDUG 7RVLJQDOFRQGLWLRQLQJERDUG &RPPXQLFDWLRQVERDUG

7REUHDNRXWERDUG %*$GLJLWDOPRGXODWRUERDUG

$Q\EXV PRGXOHV

.H\SDGDGDSWHU ERDUG

6\VWHP,2ERDUG

)LEHURSWLFLQWHUIDFH ERDUG 1HZPLFURSURFHVVRUERDUG 1HZSRZHUVXSSO\

Figure 9-5

NXGII Master Control Chassis

5. Identify which board requires service, and disconnect all connections to that specific board. The board may include fiber optic cables, 50 pin connectors, 37 pin connectors, ribbon cables, and a wire harness. 6. Use a Phillips-head screwdriver to remove the screws holding the PCB into the ISA bus on the backplane. Remove the PCB. Note Slide the PCB slowly out of the DCR being sure not to bend the board.


77

Maintenance 9.4 Repair and Replace 7. Install the spare PCB. Note Slide PCB into slot and be sure it seeds in the backplane firmly being careful not to bend the board. 8. Replace all of the removed screws, connectors, and cables. Note It is imperative that fiber optic connectors are installed back into their original location. Failure to do so may lead to catastrophic damage. Validation can be performed using an external light source and checking both ends of the fiber for transmission. The system I/O Board has two 50 pin cables tied to it. Care needs to be taken to ensure proper reconnection. Catastrophic damage may occur if improperly connected. 9. Place the removed PCB into the empty ESD protective bag if the PCB is being returned to Siemens for analysis. Signal Conditioning Board and I/O Breakout Board 1. Power down the system, following the standard shut-down procedure and obeying all standard electrical and safety instructions. Refer to Section Maintenance and Earthing Procedure in this chapter. 2. Power down all low voltage feeds (24 V-690 V) to the drive. Note Low voltage feeds vary per customer design. Reference the customer specific documentation to identify all low voltage feeds. 3. Use an appropriately sized AC voltage detector to ensure all power is removed to the NXG Control. Note The drive can accommodate up to a 240 VAC power for the NXG Control.

78


Maintenance 9.4 Repair and Replace 4. Prior to servicing any printed circuit board (PCB), ensure proper ESD protection is followed. – All circuit boards shipped by Siemens are done so in an ESD protective bag. They must stay inside this bag during transport and storage. They can only be removed after placing the bag on a dissipative ESD workbench surface. – Before removal from the ESD protective bag, the personnel handling the PCB must be properly grounded. Proper grounding is accomplished by using a heel grounder on a dissipative floor surface or a wrist strap connected to a proper ground. Note ESD sensitive components can be identified by symbols being present on the component or the component packaging.

5. The Signal Conditioning Board (SCB) and the I/O Breakout Board (IOB) are din-rail mounted within the respective control tub. Note Reference the customer specific documentation to identify the location of the Signal Conditioning Board (SCB) or the I/O Breakout Board (IOB). 6. Identify which board requires service and disconnect all connections to that specific board. The board may include 50 pin connectors, 37 pin connectors, ribbon cables, a wire harness, and single control wire connections. Note All control wire terminations require a flat-head screwdriver for removal. 7. Use a flat-head screwdriver to depress the two tabs on the board for removal of the PCB from the din-rail. 8. Install the spare PCB on the din-rail. 9. Replace all of the removed connectors, ribbon cables, and wire harnesses. 10.Place the removed PCB into the empty ESD protective bag if the PCB is being returned to Siemens for analysis.

See also Maintenance and Earthing Procedure (Page 68)


79

Maintenance 9.5 Power Cell Removal

9.5

Power Cell Removal This section provides the instructions to remove a power cell from the cell cabinet for troubleshooting, maintenance, or return for repair, in the following subsections: ● Isolating and positioning of power cell ● Purging power cell ● Removing and transporting power cell ● Preparing banding for power cell ● Banding and crating of power cell CAUTION Avoid personal injury Workers must always wear proper Personal Protective Equipment (PPE) electrical safety gloves, safety shoes (composite or steel toe with an electrical hazard rating), and safety glasses whenever performing the procedures in this chapter.

9.5.1

Isolating and Positioning of Power Cell DANGER Lethal Voltages Possible death, serious injury to personnel and damage to equipment is possible. Ensure the system is electrically isolated and no hazardous voltages are present before proceeding. This applies only to power cells still located in the drive unit compartment. To remove a WCIII power cell from the cell cabinet, the cell chassis must be disconnected from its integral capacitor bank located below the cell chassis. The power cell has a threephase nominal 750 VAC input which produces a nominal DC bus voltage, (+) to (-) across the capacitor bank, of 1,060 VDC. Even after waiting ten minutes and observing that the DC bus voltage-indicator LED on the front of the power cell is extinguished, never assume that the capacitor bank is completely

80


Maintenance 9.5 Power Cell Removal discharged. A residual charge may still be present on the DC bus (across the capacitor bank). To prevent a shock hazard take a reading to assure not residual charge is present. DANGER Lethal Voltages The cell should not be touched, removed, or serviced if the indicator is illuminated. The cell chassis is not grounded and when energized can float to lethal voltages. Touching the ungrounded chassis will result in death and damage to equipment. WARNING Existing Voltage May Still Be Present A DC bus voltage-indicator LED on the front of the power cell that is not extinguished indicates that power is present. Even if the LED is extinguished, voltage may still be present and must be checked with an appropriately sized multimeter. The power cells include discharge resistors to dissipate stored energy after the input voltage is removed. The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes Connecting a temporary grounding cable to the exterior metal case of the power cell that still has voltage present, can cause personal injury and damage to the equipment. 1. Power down the WCIII System, obeying all standard electrical and safety instructions. Refer to the Section Maintenance and Earthing Procedure located in this chapter of the manual. 2. Open the doors to access the power cells. 3. Make sure that the DC bus LED is unlit. 4. Be sure to wear Cat 1 gloves. 5. Open the access panel and verify with a multimeter that the DC bus is less than 10 VDC before removing capacitor bolts. 6. Remove all of the DC bus capacitor bolts. CAUTION Stop both pumps before removing the power cell hose! Lines are pressurized. 7. When the power cell is fully de-energized and all electrical hazards have been isolated, disconnect the hose connections from the supply and return ports of the power cell. 8. Remove the fiber optic communications cable to the power cell control board. Ensure the fiber optic communications cable is secured away from the path of the cell to be removed to avoid the possibility of damage to the fiber.


81

Maintenance 9.5 Power Cell Removal 9. Next, pull the power cell out to the first removal position in the drive unit compartment (refer to below figure). This is done by pulling the right and left side edge of the power cell, while lifting the cell out of the locking tabs and pulling until the cell is disengaged from the rear power stab connections. NOTICE While sliding the power cell forward on the guide rail, use extra caution to avoid damage to the DC bus insulation along the bottom edge of the cell frame. After the cells have been removed, visually inspect the DC Bus insulation to ensure there has been no damage.

1

Danger DC Bus light

2

DC Bus measurement: Place meter leads of a properly rated and scaled voltmeter between the top plate and the center terminal, being careful not to inadvertently short the center terminal to the top plate, with the meter leads.

3

Label: DANGER! High Energy Filter. Do not disconnect bolts until DC Voltage is less than 10 V.

Figure 9-6

Power Cell pulled out to First Removal Position

10.Proceed to the Purging Power Cell Section.

See also Maintenance and Earthing Procedure (Page 68)

9.5.2

Purging Power Cell NOTICE All coolant must be purged from power cell prior to shipping. Materials Required Prior to purging coolant from the power cell, obtain the following items:

82


Maintenance 9.5 Power Cell Removal ● Cell Water Purge Kit P/n A5E02240940 containing two 3-foot lengths of silicone hose with a colder coupling receptacle installed on one end of each hose. One hose has a hose clamp on the opposite end of the hose, to be used for attaching the low pressure air source. Refer to Figure Cell Water Purge Kit.

1

One hose clamp to connect low pressure air source.

2

Colder coupling receptacles at one end of each hose.

Figure 9-7

Cell Water Purge Kit

● One large bucket or retainer is needed to collect the coolant. Refer to Figure Bucket

Positioned Under Hose End to Collect Fluids.

● Material Safety Data Sheet (MSDS) for glycol prior to connecting hoses and draining liquids. Safety Data for Polypropylene and Ethyl Glycol* Toxicology

Harmful if swallowed. May be harmful by inhalation or in contact with the skin. May act as skin and respiratory irritant. Severe eye irritant. Reproductive hazard.

Transport Information

Non-hazardous for air, sea and road freight.

Personal Protection

Safety glasses, rubber gloves, adequate ventilation

This information is provided to help you work safely, but is not intended to be used in place of a full MSDS. Obtain the proper MSDS from site safety or download it from the internet.

Procedure With the power cell de-energized and pulled out to the first removal position, drain the power cell by completing the following steps:


83

Maintenance 9.5 Power Cell Removal 1. Place bucket under hose prior to connecting to supply/return port. CAUTION Avoid Spillage Place bucket under hose prior to connecting to supply/return port to avoid spillage. Some drainage may occur due to gravitational flow.

Figure 9-8

Bucket positioned under Hose End to collect fluids

2. Connect one cell water purge kit hose to either the supply or return port while keeping the bucket positioned under the hose end. When the power cell has been disconnected, either the supply or return port can be used for the pressure input and/or drainage. CAUTION Glycol must be treated as a hazardous waste material. Do not discard glycol into waste drains or on the ground. For power cells containing any form of glycol, ALWAYS follow site safety and applicable MSDS requirements for proper handling and disposal of these liquids.

1

Return

2

Supply

3

Press and push

Figure 9-9

Inserting Cell Water Purge Kit Hoses to Supply and Return Ports (Snap-on) to drain liquids

3. Locate a low pressure (≤ 20 psi recommended) air source (instrument air, nitrogen) to be used to purge fluids from the power cell. 4. Secure the low pressure air source to the remaining cell water purge kit hose, using hose clamp for connection (refer to insert in Figure Cell Water Purge Kit).

84


Maintenance 9.5 Power Cell Removal 5. Connect the second silicone hose from the kit with the low pressure air source, to remaining supply/return port. CAUTION Avoid Splashing Slowly apply low pressure air to avoid splashing of liquid while discharging fluids into bucket. 6. Proceed until discharge flow of liquid is no longer visible. NOTICE Do not reuse contaminated fluids. Discard per MSDS requirements. 7. Remove and bag the cell water purge kit hoses. 8. Proceed to the Removing and Transporting Power Cell Section.

9.5.3

Removing and Transporting Power Cell 1. Place cell lifter in front of power cell to be removed. 2. Raise up the cell lifter until the rollers touch the bottom of the power cell. CAUTION Avoid Personal Injury Serious injury to personnel and damage to equipment is possible. Prior to placing the power cell on the cell lifter the following safety precautions must be observed: ● Ensure that cell lifter manual parking brake is in the locked position. ● Ensure cell lifting device upper roller bar is installed with locking pins inserted. ● Verify that lower slide rail is extended away from upper roller bar. 3. Raise the power cell approximately 1/8 inches so that the cell lifter is supporting the weight of the front of the cell.


85

Maintenance 9.5 Power Cell Removal 4. Slide the power cell completely out of the cabinet and onto the cell lifter (refer to the following figure).

Figure 9-10

Power Cell Correct Position on Cell Lifter

NOTICE Avoid Damage to Insulation Material When handling or removing the power cell, take care not to damage the Valox FR-1 thermoplastic dielectric insulation material located as shown in the below figure. The Valox film provides an insulation barrier between the dielectric material between the plates on the capacitor bus. The thin membrane of the material must not come into contact with the transport device, cell lifter, pallet, or technicians hands. Preventing damage to this material reduces replacement cost and repair time. If the insulation becomes damaged the power cell should be returned to Siemens for replacement.

1

Valox insulation material located around DC Bus capacitor bolts.

2

Valox insulation material located at bottom of power cell.

Figure 9-11

Valox Insulation Locations

5. Secure power cell onto the cell lifter using the front and rear locking pins.

86


Maintenance 9.5 Power Cell Removal 6. Transport the power cell to the staging area for banding and crating using the cell lifter or move the power cell from the cell lifter to an appropriate transportation device, such as utility cart as shown below.

1

Power cell on cell lifter.

2

Power cell on utility cart.

Figure 9-12

Methods for Transporting Power Cell

7. Proceed to the Preparing Banding for Power Cell Section.

9.5.4

Preparing Banding for Power Cell Materials Required ● Large pallet (wood, plastic, fiberglass, etc.), large enough to accommodate two power cells. Refer to Figure Wooden Pallet. ● Cardboard. Refer to Figure Covering Pallet with Cardboard. ● Crane or other lifting device (optional) ● Lifting hooks and lanyards/straps (optional) ● Banding tool and banding material. Refer to Figure Typical Banding Tool in next section. NOTICE Do not use steel banding. Steel bands can deform the exterior casing of the power cell.


87

Maintenance 9.5 Power Cell Removal Power Cell Lifting and Positioning Procedure 1. Ensure that area is clear of any debris or obstructions to avoid tripping. 2. Place pallet on a level surface as shown in the following figure.

Figure 9-13

Wooden Pallet

3. Cover pallet with cardboard to protect painted surface of power cell as shown in the following figure.

Figure 9-14

Covering Pallet with Cardboard

CAUTION Exercise Caution Lifting Power Cell A power cell transported by either a cell lifter or transportation device must be rotated 180 degrees, with the bottom (metallic side) facing up for shipment. Two technicians are required to rotate the power cell by hand (refer to Figure Preparing Power Cell for Lifting). The unit is extremely heavy and must be lifted using extreme caution to avoid damage or injury. 4. Each technician should stand at opposite ends of the power cell as shown in following figure.

88


Maintenance 9.5 Power Cell Removal 5. In unison, slowly roll the power cell 180 degrees until fully resting on top (painted surface) using caution not to damage the Valox insulation material or dent/scratch the outside panel.

7XUQSRZHUFHOO

Figure 9-15

Preparing Power Cell for Lifting

6. Place lifting lanyards through the lifting brackets located on the bottom side of the power cell as shown in following figure.

1

Lifting bracket locations

Figure 9-16

Lacing Lifting Lanyards through Lifting Brackets

Power Cell is ready to be lifted.


89

Maintenance 9.5 Power Cell Removal 7. Slowly and carefully lift, move, and lower the power cell onto the pallet as shown in following figure.

Figure 9-17

Positioning Power Cell on Pallet

8. Remove the lifting lanyards once the power cell is placed into position. Note Repeat all previous sections/steps for the second power cell, prior to banding/crating. Only two power cells can be crated on one pallet. 9. Proceed to the Banding and Crating of Power Cell Section.

90


Maintenance 9.5 Power Cell Removal

9.5.5

Banding and Crating of Power Cell 1. Prior to placing a second power cell beside the first power cell, ensure a Styrofoam™ spacer and cardboard corner protectors are placed along the outer edge of both power cells. Refer to the following figures. NOTICE Do not exceed number of power cells on pallet. Limit of two power cells per pallet only.

1

Styrofoam spacer location

Figure 9-18

Styrofoam Spacer between Power Cells

Figure 9-19

Power Cells with Cardboard Corner Protectors

2. Lace the banding material through the pallet and back through the lifting brackets of both power cells as shown in the following figure.

1

Lacing banding material through wooden pallet.

2

Lacing banding material through lifting brackets.

Figure 9-20


Lacing the Banding Material

91

Maintenance 9.5 Power Cell Removal 3. Continue banding power cells to pallet using the instructions provided with the type of banding tool and material used. A typical banding tool is shown in the following figure.

Figure 9-21

Typical Banding Tool

4. After completing Step 2 and Step 3, continue with application of the second band. 5. Lace the second band through the pallet as done with the first band, then bring the band around the power cell just in front of lifting brackets. Final installation of both bands should look like the power cells shown in the following figure.

1

Styrofoam insulation between cells.

2

Cardboard corner protectors placed under bands.

3

First band placed in front of lifting brackets.

4

Second band placed in front of lifting brackets.

Figure 9-22

Properly Banded Power Cells

6. Power cells are ready for crating.

92


Maintenance 9.6 Power Cell Installation 7. Build a sturdy crate around the power cells, using wooden boards (2 x 4 or 1 x 3) and cardboard sheets as shown in the following figure.

Figure 9-23

Crate built to ship Power Cells

8. The power cell(s) is ready for return to Siemens.

9.6

Power Cell Installation This section provides the instructions to install a power cell, in the following subsections: ● Prerequisites for installing power cell ● Transporting power cell via cell lifter ● Transporting power cell via transportation device ● Inserting power cell CAUTION Avoid personal injury Workers must always wear proper Personal Protective Equipment (PPE) electrical safety gloves, safety shoes (composite or steel toe with an electrical hazard rating), and safety glasses whenever performing the procedures in this chapter.


93

Maintenance 9.6 Power Cell Installation

9.6.1

Prerequisites for Installing Power Cell Prior to installing a power cell, perform the following steps: 1. Remove power cells from shipping crate. Carefully remove crating material and all packing materials. Using caution cut and remove banding material around power cells using the proper cutting tool. Refer to the following figure. CAUTION Avoid personal injury Wear proper work gloves and safety glasses when cutting and removing banding material from around power cells.

1

Banding to be removed

Figure 9-24

New Power Cells

2. Visually inspect the new power cells for any damage that may have occurred during shipment. Note Record any damage found in writing and with photos.

94


Maintenance 9.6 Power Cell Installation 3. Prior to placing the power cell on a transportation device such as a utility cart, place precut 2 x 4 plywood boards on top of the utility cart to prevent damage to insulation material on the bottom of the power cell, as shown in the following figure.

Figure 9-25

Utility Cart with Plywood Boards placed on top

4. The power cell is ready to be placed on the transportation device or a cell lifter.

1

Cell lifting device

Figure 9-26


Hydraulic Cell Lifter with Lifting Device

95

Maintenance 9.6 Power Cell Installation 5. The power cell is shipped with the top of the cell resting on a wooden pallet, as shown in the following figure. When lifting the power cell for transport, the power cell must be rotated 180 degrees forward (bottom of cell to be facing floor).

5RWDWHSRZHUFHOO IRUZDUGGHJUHHV

Figure 9-27

Rotating Power Cell Forward for Loading

6. Proceed to Transporting Power Cell via Cell Lifter Section to transport cell via cell lifter. Proceed to Transporting Power Cell via Transportation Device Section to transport cell via transportation device.

See also Transporting Power Cell via Cell Lifter (Page 96) Transporting Power Cell via Transportation Device (Page 100)

9.6.2

Transporting Power Cell via Cell Lifter The following procedure is to load a power cell onto a cell lifter in the side-lift position only. A power cell can also be transported in the front-lift position. CAUTION Avoid Personal Injury Serious injury to personnel and damage to equipment is possible. Prior to placing the power cell on the cell lifter the following safety precautions must be observed, as shown in the figures that follow: ● Ensure that cell lifter manual parking brake is in the locked position. ● Ensure cell lifting device upper roller bar is installed with locking pins inserted. ● Verify that lower slide rail is extended away from upper roller bar.

96



3UHVVSHGDOWR ORFNEUDNH

Figure 9-28

Cell Lifter Manual Brake in Locked Position

1

Locations to insert locking pins

Figure 9-29

Cell Lifting Device Upper Roller Bar Installed with Locking Pins

1

Slide lower rail to forward position

Figure 9-30


Slide Rail Positioned Away from Upper Roller Bar to Accommodate Power Cell

97

Maintenance 9.6 Power Cell Installation 1. Place power cell onto cell lifter by placing front flange of power cell in slide rail guides while gently setting the rear of power cell on the upper roller bar rollers. Refer to the following figure.

Figure 9-31

Power Cell Front Flange Positioned in Guides on Cell Lifter Slide Rail

NOTICE Avoid Damage to Insulation Material When handling or removing the power cell, take care not to damage the Valox FR-1 thermoplastic dielectric insulation material located as shown in the below figure. The Valox film provides an insulation barrier between the dielectric material between the plates on the capacitor bus. The thin membrane of the material must not come into contact with the transport device, cell lifter, pallet, or technicians hands. Preventing damage to this material reduces replacement cost and repair time. If the insulation becomes damaged the power cell should be returned to Siemens for replacement.

1

Valox insulation material locations

Figure 9-32


2. Position the slide rail forward until the rail comes in contact with the front stops. Insert locking pin for safe transport, as shown in the following figure.

98



Figure 9-33

Slide Rail Locking Pin Inserted

3. The power cell is ready for transport. Refer to the following figure.

1

Rear

2

Front

3

Upper roller rail

4

Lower slide rail

Figure 9-34

Power Cell Properly Positioned on Cell Lifter for Installation or Transport

4. Release the cell lifter manual brake to transport the power cell as shown in the following figure. NOTICE Prevent Damage to Power Cell When transporting power cell via cell lifter, always keep one hand on the component to prevent it from tipping or falling off the lifter.

1

Press release lever to release manual brake.

Figure 9-35

Cell Lifter Manual Brake Release Position

5. Proceed to Inserting Power Cell Section.


99


9.6.3

Transporting Power Cell via Transportation Device The following procedure is to load a power cell onto a transportation device. NOTICE Avoid Damage to Insulation Material Prior to placing the power cell on a transportation device, place pre-cut 2 x 4 plywood boards on top of the utility cart to prevent damage to insulation on the bottom of the power cell as shown in Figure Utility Cart with Plywood Boards placed on top. CAUTION Exercise Caution Lifting Power Cell Two technicians are required to lift and place power cell onto the transportation device due to the weight and size of the component. The unit is extremely heavy and must be lifted using extreme caution to avoid damage or injury. Observe safety rules for bending and lifting heavy objects. Always avoid pinch points. 1. If available engage the manual brake to lock the wheels of the transportation device prior to loading the power cell. 2. If a manual brake is not available, two technicians must carefully walk the power cell into position on the transportation device/utility cart. Carefully place the unit face down onto the 2 x 4 boards as shown in the following figure. 3. Ensure that power cell is securely resting on the transportation device to prevent damage due to tipping. If the power cell is to be stored on the cart for any duration, secure the power cell to the transportation device with banding material.

100


Maintenance 9.6 Power Cell Installation 4. The power cell is ready for transporting with the transportation device as shown in the following figure. NOTICE Prevent Damage to Power Cell When transporting a power cell with a transportation device (utility cart), always keep one hand on the component to prevent it from tipping or falling off the cart. For best transport practice, secure the power cell to the cart with banding material before moving it to the installation location.

Figure 9-36

Power Cell Ready to Transport

5. Proceed to Inserting Power Cell Section.

9.6.4

Inserting Power Cell DANGER Lethal Voltages Possible death, serious injury to personnel and damage to equipment is possible. Ensure the system is electrically isolated and no hazardous voltages are present before proceeding. Ensure electrical power has been removed and the power cell has been isolated per Section Isolating and Positioning of Power Cell. Allow 15 minutes for the cell capacitor bank to bleed down after removal of input power. 1. If the power cell is located on a transportation device, transfer the unit to a cell lifter using the procedure in Section Transporting Power Cell via Cell Lifter. Once the power cell is secured on the cell lifter and VFD power has been electrically isolated you can proceed with positioning the power cell for insertion into the capacitor bucket. 2. Verify location of capacitor bucket where power cell is to be inserted: Section A (Top), Section B (Center), or Section C (Bottom). 3. Visually inspect the capacitor bucket for any loose parts (e.g. guide rails), bent bus stabs, cables or water lines and debris that may impede installation.


101

Maintenance 9.6 Power Cell Installation 4. Push the cell lifter to the front of the capacitor bucket with the rear of the power cell facing the capacitor bucket, then raise the cell lifter to the approximate height of the opening as shown in the following figure.

Figure 9-37

Power Cell Aligned for insertion into Capacitor Bucket

NOTICE Avoid Damage to Insulation Material To prevent damage to the Teflon insulation strips on top of the capacitor bucket guide rails, position the power cell on the upper roller bar of the cell lifter device so that the bottom of the power cell clears the Teflon insulation strips, as shown in the following figure.

1

Teflon insulation locations

Figure 9-38

102

Teflon Insulation Strip Locations on Top of Guide Rail in Capacitor Bucket


Maintenance 9.6 Power Cell Installation 5. Remove the cell lifter slide rail locking pin shown in the following figure.

Figure 9-39


Slide Rail Locking Pin Inserted

103

Maintenance 9.6 Power Cell Installation 6. Paying close attention to the alignment of the rear guide pins and capacitor bucket guide rail, and side-to-side clearance, slowly push the power cell inward until the cell lifter slide rail is aligned with the upper roller bar and power cell is in the correct position. Refer to the following figures. NOTICE Avoid Damage to Insulation Material When inserting the power cell, verify the rear guide pins (on both sides of cell) are aligned below the capacitor bucket guide rails, while ensuring the bottom of the cell does not make contact with the Teflon insulation strips.

1

104

Guide pin locations

Figure 9-40

Guide Pins

Figure 9-41

Power Cell Positioned Corectly prior to removing Cell Lifter


Maintenance 9.6 Power Cell Installation 7. Remove cell lifter. Assure the power cell is locked in place on the guide rail with the guide pins and slowly lower the cell lifter. Note If the power cell lowers with the cell lifter, raise the cell lifter and verify that the guide pins are positioned properly. Slowly lower the cell lifter until upper roller bar clears power cell, while verifying the power cell remains stationary. If the power cell is inserted in Section C (bottom) of enclosure, the upper roller bar must first be removed from the cell lifter by pulling the locking pins and sliding out the upper roller bar to allow for removal of cell lifter. 8. Once the cell lifter has been removed, slide the power cell into the capacitor bucket, while verifying that the front guide pins on the bottom of the power cell are properly aligned below the capacitor bucket guide rails flange. 9. Slowly push the power cell until the locking tabs prevent the power cell from moving farther as shown in the following figure.

1

Locking tab (both sides) stops further insertion

2

Slot in bucket that accepts the locking tab (both sides)

Figure 9-42

Power Cell stopped by Locking Tab

10.Once the power cell is aligned correctly, it can be fully inserted by placing hands at the right and left upper corners of the power cell as shown in the following figure.

Figure 9-43


Hand Position for Cell Insertion

105

Maintenance 9.6 Power Cell Installation 11.Firmly and simultaneously push up and in until the cell tabs on both sides are fully inserted in the slots as shown in the following figure. If the cell tabs do not drop into position as shown, stop and pull the power cell back out, and recheck the front and back guide pins as shown in Step 8. NOTICE Avoid Damage to Components If the power cell stops before both tabs (one on either side of cell) come into contact with the guide rails on the capacitor bucket, this indicates the cell is not properly aligned or the rear power bus stabs are bent or misaligned. DO NOT FORCE the power cell into the capacitor bucket. Pull the power cell back out to mid position and inspect for a problem, then attempt to reinsert. /HIWVLGHRISRZHUFHOO

5LJKWVLGHRISRZHUFHOO

Bottom tab is correctly inserted in slot (both sides)

1

Figure 9-44

Power Cell Fully Inserted

12.Once the power cell is fully inserted into the capacitor bucket, insert bolts with washers into the tapped holes in the capacitor bank as shown in the following figure (eight bolts are used for a 880A cell).

1

5/16" oversize flat washer

2

M8 x 14 mm bolt

3

5/16" split lock washer

Figure 9-45

106

Capacitor Bank Connections with Proper Hardware Arrangement


Maintenance 9.6 Power Cell Installation 13.Torque each capacitor connection as designated below: – P/N A1A099563 Capacitor (AVX): 75.6 in-lbs (8.5 N-m) – P/N A1A0100622 Capacitor (EPCOS): 88.8 in-lbs (10 N-m) – P/N A1A099181 Capacitor (NWL): 52.8 in-lbs (6 N-m). If holes on the power cell do not align with the capacitor holes, loosen the capacitor mounting bolts (see following figure) so that the holes can be aligned. Insert and torque all connection bolts. After torquing connections, retighten capacitor mounting bolts.

1

Capacitor mounting bolt locations

Figure 9-46


Capacitor Mounting Bolts

107

Maintenance 9.6 Power Cell Installation 14.Perform visual inspection to verify that no tears, folds, or contamination has occurred to the Valox insulation. Inspect the Valox insulation at the bottom edge of the capacitor bus for damage. Refer to the following figures. NOTICE Avoid Damage to Insulation Material When handling or installing the power cell, take care not to damage the Valox FR-1 thermoplastic dielectric insulation material located as shown in the below figure. The Valox film provides an insulation barrier between the dielectric material between the plates on the capacitor bus. The thin membrane of the material must not come into contact with the transport device, cell lifter, pallet, or technicians hands. Preventing damage to this material reduces replacement cost and repair time. If the insulation becomes damaged the power cell should be returned to Siemens for replacement.

1

Valox insulation material located around DC Bus capacitor bolts.

2

Valox insulation material located at bottom of power cell.

Figure 9-47


15.Install capacitor bank cover plate as shown in the following figure.

Figure 9-48

108

Installing Capacitor Bank Cover Plate


Maintenance 9.6 Power Cell Installation 16.Install inlet and outlet (snap-on) water hoses to ports on the front of the power cell as shown in the following figure.

1

Press and push

2

Outlet side

3

Inlet side

Figure 9-49


Inserting Inlet and Outlet (Snap-on) Water Hoses

109

Maintenance 9.6 Power Cell Installation 17.Connect the fiber optic plug-in connection to the link port on the front of the power cell as shown in the following figure.

Figure 9-50

Fiber Optic Plug

18.The power cell is ready for operation.

Figure 9-51

Power Cell Ready for Operation

See also Isolating and Positioning of Power Cell (Page 80) Transporting Power Cell via Cell Lifter (Page 96)

110


Maintenance 9.7 Cell Cabinet Construction and Maintenance

9.7

Cell Cabinet Construction and Maintenance Silicone Hose and Clamps Maintenance The WCIII system uses a Thermopol Type THH or Parker Type 6723 single ply silicone heater hose. NOTICE Avoid Coolant Leakage Coolant hoses are fastened to the power cell heat-sinks using a constant tension type hose clamp. The clamps are torqued and marked at 27 in-lbs at the Siemens factory and require no additional adjustment. Tightening beyond the factory setting may result in coolant leakage. Sub-Assemblies The cell cabinet system consists of the following basic sub-assemblies: ● Top hat air-to-water heat exchange system, as shown in Figure 9 Cell Cabinet with Front and Top Blower Covers Removed (for service) and Figure 9 Cell Cabinet with Doors, Blowers and HEX Removed. ● Power cells, as shown in Figure 9 Cell Cabinet with Cells, Majority of Capacitors and Capacitor Buckets Removed. ● Rear panel assembly, as shown in Figure Bypass Contactor with T1-T2 Removed from Rear Panel. ● Bypass contactor assembly, as shown in Figure Bypass Contactor with T1-T2 Removed from Rear Panel and Figure 12 Cell Cabinet with Rear Panel Removed and Bus Exposed. ● Rear supply and return manifold sections, as shown in Figure 9 Cell Cabinet with Rear Panels Removed and only the Verticals and Water Manifolds Installed. Cell Cabinet Maintenance Sequence Access components in the cell cabinet in the opposite sequence from which it is built. This sequence is as follows:


111

Maintenance 9.7 Cell Cabinet Construction and Maintenance 1. The top hat air-to-water heat exchange system is a complete subassembly. It can be unbolted from the top of the cabinet by removing bolts in each corner, which are accessible when the front and rear panels are removed. Refer to the following figures.

1

Front covers

2

Rear cover

Note:

Remove the front and rear covers of the blower section to gain access to the bolts that hold the top hat blower rear covers.

Figure 9-52

112

9 Cell Cabinet


Maintenance 9.7 Cell Cabinet Construction and Maintenance

1

Access the bolts holding the fan power terminal strip and quick connect water connection in this section.

2

Blower is attached to housing by top mounting screws and bottom mounting flanges.

Figure 9-53

9 Cell Cabinet with Front and Top Blower Covers Removed (for service)

2. When the cell cabinet doors are open, the water supplies to the air-water heat exchangers can be disconnected by the self-sealing hose fitting just below the assembly.


113

Maintenance 9.7 Cell Cabinet Construction and Maintenance – At these disconnection points the total system water section can be air purged during the coolant water filling procedure. – A terminal strip supplying power to the fans is accessible when the front cover of the assembly is open. – Access the air-to-water heat exchangers by first removing the fan mounting bracket and then the front metal plenum in which it is mounted, as shown in the following figure.

Figure 9-54

9 Cell Cabinet with Doors, Blowers and HEX Removed

3. The power cells are removed or installed from the capacitor bucket by using the insertion truck. 4. The capacitor bucket can be removed after the cell and capacitors are removed. Tabs at rear of capacitors slide into rear slots of the bucket, while two bolts hold the capacitor in place at the bottom flange of bucket. Note It is recommended, when installing or changing capacitors, that these bolts are left loose until the cell is fully engaged and connected to aid in capacitor-to-cell alignment. The bolts may then be tightened.

114


Maintenance 9.7 Cell Cabinet Construction and Maintenance 5. The capacitor bucket is inserted by hooks that engage the rear glastic panel and 8 bolts that engage the front vertical channels. Refer to the following figure.

1

Buckets hook into these slots.

2

Buckets are secured to the front verticals with 8 bolts.

3

Slots in rear of bracket provide access to lock the back of the capacitors.

4

Mounting bolts for capacitors.

Figure 9-55

9 Cell Cabinet with Cells, Majority of Capacitors and Capacitor Buckets Removed

6. The pigtail hose sub-assemblies connect to the rear supply and return manifolds (refer to Figure 9 Cell Cabinet with Rear Panels Removed and only the Verticals and Water Manifolds Installed).


115

Maintenance 9.7 Cell Cabinet Construction and Maintenance 7. Before removing the ½ inch glastic rear panels: – Disconnect the cell input bus at the front L1, L2, and L3 connections on the panel. – Disconnect the output bus section from the bypass subassembly (refer to the following figure).

1

Leave this rear bus connected to contactor; connectors and panel to be removed.

2

Disconnect right rear bus of contactor to left of panel to be removed.

3

Panels behind cells can be removed completely with connectors and bypass attached once the rear bus on the right side of contactor is disconnected on both the panel to be removed and also on the panel to the left of the panel to be removed.

4

Disconnect L1, L2 and L3 rear bus at these points.

Figure 9-56

116

Bypass Contactor with T1-T2 Removed from Rear Panel


Maintenance 9.7 Cell Cabinet Construction and Maintenance 8. The rear bus system is built in layers starting with bottom C row (C1 through C6) and finishing with top A row (A1 through A6). Bus mounts into horizontal supports, which insert in slots between rear vertical support and rear mullion of cell cabinet. As cell row is built up left to right (from front), a layered bus clamp system that holds the bus together is also built and finally clamped when the cell row is completed. Refer to the following figure.

1

Rear bus comb clamps

2

Rear bus supports

3

Insulating plates between FPC and cell bus

Figure 9-57


12 Cell Cabinet with Rear Panel Removed and Bus Exposed

117

Maintenance 9.7 Cell Cabinet Construction and Maintenance 9. Hose connections between the cell return and the rear supply and return manifolds are mounted along supports shown in the following figure. These supports are designed to maintain at least one inch clearance between the hose OD and metal cabinet/supports.

Figure 9-58

9 Cell Cabinet with Rear Panels Removed and only Verticals and Water Manifolds Installed

10.The bypass twisted pair must also not directly touch the metal cabinet and bus work. Three bypass panduit systems are mounted on rear vertical support for this purpose. 11.Mounted on top of these panduit systems are three small panduits that contain the output voltage lead that connects to the output attenuator in the FPC cabinet. 12.The cell cabinet assemblies just described are all mounted on a series of front and rear vertical insulating support structures.

118


Spare parts

10

Serviceable Parts The customer serviceable spares are listed below. For additional information about how to service these parts, refer to the chapter of this manual titled Maintenance. ● Door Filters ● Power Cells ● Cell Input Fuses ● Control Fuses (includes Blower Fuses) ● Printed Circuit Boards Non Customer Serviceable Parts All other spare parts are NOT customer serviceable. However, they may be serviced by qualified Siemens personnel. These include, but are not limited to the following: ● Fiber-Optic connections ● Blower(s) ● Bypass Contactor(s) ● Bypass Control Board ● Bypass Power Supply ● Input Current Transformers ● Input/Output Voltage Attenuators ● Hall Effect Current Transducers ● NXG Power Supply Refer to the System Outline and System Schematic Drawings, Series A and B respectively for your specific drive. These drawings are contained in the O&M package supplied with the drive. Note Spare Parts for Customized Drives For spare parts lists for customized drives, refer to the custom documentation package shipped with the drive or contact the Siemens Industry, Inc. Customer Service Department. When calling for spare parts information, please have your sales order number and drive part number readily available.


119

Spare parts 10.1 NXGII Control

Note Component Replacement Unless notified differently by Siemens, always replace components with the same P/N and revision level.

See also Maintenance (Page 63)

10.1

NXGII Control

Table 10-1

NXGII Control Recommended Spare Parts

Quantity

LD P/N

Description

1 each

A1A098194

PCA, ISA Backplane

1 each

A1A10000623.00M

PCA, Single Board Computer + Keypad Adapter

1 each

A1A10000423.00M

PCA, System I/O Board

1 each

A1A461D85.00M

1 each

A1A10000350.00M

PCA, Modulator

1 each

A5E03407403

PCA, Communications Board

1 each

A5E02363383 or

Keypad, Siemens, English

A5E02624585 or

Keypad, Siemens, Chinese

A5E02669557 or

Keypad, Siemens, Portuguese

A5E02669580 or

Keypad, Siemens, Russian

A5E026695822

Keypad, Siemens, German

1 each

A5E01649325

PCA, System I/O Breakout Board: 120 VAC DIG IN

1 each

A5E01708486

PCA, Signal Conditioning Board

2 each

A5E02381532

Fan, Axial, 24 VDC

1 each

A1A0100275

Power supply, 700 W

1 each

A1A094519 or

Relay, latching (LFR): 120 VAC coil

A1A0945182

Relay, latching (LFR): 24 VDC coil

1

PCA, Fiber Optic, 12-channel

1

Recommended spare for systems with 15 or more power cells.

2

Verify which P/N is used on the Production Bill of Materials (PBOM) and furnish that one as a spare.

120


Spare parts 10.2 Power Cell

10.2

Power Cell

Table 10-2

Power Cell Recommended Spare Parts

Cell Rating 880 Amp 2 Quadrant

Quantity

LD P/N

Description

1 each

A5E02248613

Cell, 880 A, 2 Quadrant

2 per cell

A1A099563 or

Film Capacitor, 13500 µF, 1300 V

A1A099181 or A1A0100622 or A5E015219691 2 per cell

A1A099557 or A1A0100665

880 Amp 4 Quadrant

Fuse, 700 A, 1000 V

2

1 each

A5E02248617


2 per cell

A1A099563 or



A1A099557 or A1A0100665

1250 Amp 2 Quadrant

Fuse, 700 A, 1000 V

2

1 each

A5E02251463


3 per cell

A1A099563 or



A1A099556 or

Fuse, 1000 A, 1000 V

A1A01006642 1250 Amp 4 Quadrant

1 each

A5E02200053


3 per cell

A1A099563 or



A1A099556 or

Fuse, 1000 A, 1000 V

A1A01006642 1

Verify which P/N is used on the Production Bill of Materials (PBOM) and furnish that one as a spare. Capacitors listed above are form and fit equivalent, not functionally equivalent. Different manufacturer's capacitors must not be mixed on the same cell.

2

Fuses listed above of the same ampacity rating (880 or 1250 Amps RMS) are form, fit and function equivalent.


121

Spare parts 10.3 Optional Components

10.3

Optional Components

Table 10-3

Optional Components Recommended Spare Parts (if furnished with drive)

Quantity

LD P/N

Description

1 each

A5E03036273

PCA, Bypass Control Board (Cell Bypass)

1 each

A5E03448019

Power Supply, 750 V (Cell Bypass)

1 each

A5E31704948

Contactor Assembly, Cell Bypass

1 each

A1A099201

Anybus, Profibus-DP module (serial communication)

1 each

A1A098628

1 each

A1A099202

1 each

A1A099203

1 each

A1A10000441.00

Anybus, DeviceNet module (serial communication) Anybus, Ethernet Modbus module (serial communication)

1

Anybus, ControlNet module (serial communication) 2

PCA, Modbus module (serial communication)

1

Only furnished with drive if dual Ethernet Modbus interface is required.

2

Only furnished with drive if dual Modbus interface is required.

122


11

Disposal 11.1

Disposing of Device Components Before dismantling the Drive, ensure that it is brought to a standstill and grounded. If disposed of properly, none of the material listed below will pose any threat to the environment. Take particular care when disposing of and recycling the following components: ● Batteries ● Capacitors ● PCBs ● Electronic components Be sure to dispose of or recycle in accordance with the applicable country-specific guidelines and regulations.

11.2

Disposing of Packaging The packing is designed in such a way as to pose the minimum risk to the environment. Some of the packaging can be recycled. The disposal of packaging is controlled by country-specific laws. If in doubt, ask local disposal specialists or contact the local authorities. List of Packing Waste Materials ● Wooden frames ● Wooden pallets ● Polyethylene foil ● Plywood ● Plastic ● Silica gel

11.3

Disposing of Old Services

Observance of Applicable National Regulations Dispose of the device in accordance with the applicable national regulations.


123

A

Service and Support

Siemens can provide trained and certified field service representatives to provide technical guidance and assistance for the installation, startup/commissioning, repair and maintenance of Siemens Perfect Harmony™ VFD equipment and systems. Contact your regional service call center or sales office for details. Siemens service call centers can be reached at the regional locations listed below. DANGER Incorrectly Performed Work Certain components described in this documentation may be replaced or repaired only by personnel trained by Siemens. Work incorrectly performed on the drive can result in damage to the equipment, degrade VFD operational integrity, and possibly cause physical injury to personnel or even death. Ensure that only personnel trained by Siemens work on the equipment. Siemens accepts no liability for any damage that occurs because these instructions have not been observed e.g. if an untrained person carries out a repair or replaces components. Technical Support (Hotline) ● America time zone: Johnson City, TN, USA

800 333 7421

+1 423 262 5711

● Asia and Australia time zone: Shanghai, China

+86 1064 719 990

● Europe and Africa time zone: Nuremberg, Germany

+49 911 895 7222

+49 180 5050 222

To find country-specific phone numbers, please visit our internet page: http://support.automation.siemens.com/WW/view/en/16604318 Technical Support (Internet) Send your inquiries directly via the internet to a specialist in technical support: www.siemens.com/automation/support‑request ● Technical support is available round the clock 365 days a year. ● Your inquiries are delivered directly to the responsible specialist. ● Have all relevant data available and technical support can respond to your inquiry as quickly as possible. ● Send records, screen shots and photos to the specialists to support fault analysis.


125

Service and Support

Contacts may change. Please find current contact partners in the Siemens AG A&D service catalog: www.automation.siemens.com/partner

126


B

Technical Data B.1

WCIII System Technical Specifications The specifications shown in the following tables apply to the standard open loop or closed loop vector control system performance for induction or synchronous motors.

Table B-1

WCIII Parameters and Ratings

Parameter

Rating

Input Voltage

2400 to 13800 V / +10%, -5%

Input Frequency

50 or 60 Hz / +10%, -5% input voltage worst case

Input Power Factor

0.95 or better with motor speed 25% rated or higher (not valid for unloaded motor)

Input Current Harmonics

Meets most stringent TDD requirements from IEEE 519

Transformer Windings

Copper

Output Power

4000 Hp / 2984 kW to 19000 Hp / 14169 kW single inverter

Output Voltage

2.3 kV to 8.0 kV

Output HVF

< 0.03

Output dV/dt

< 1000 V/uS

Output Frequency and Drift

0.5 – 330 Hz, +/- 0.5%

Harmonic Voltage Factor

Less than 0.03 per NEMA MG-1

Motor Speed Range

f0 = 0.5 to 166 Hz (motor dependent); 300 Hz ≤ fc ≤ 600 Hz SWF

Motor Speed Range

f0 = 167 to 330 Hz (motor dependent); 1200 Hz ≥ fc ≥ (3.6 x f0) Hz SWF

Output Torque1

2 or 4 Quadrant f0 = 0.5 to 10 Hz derated torque f0 = 10 to 167 Hz full rated torque f0 = 167 to 330 Hz derated torque

Auxiliary Voltage

● 208 V, 60 Hz, 3-phase

(± 10% auxiliary voltage tolerance, per IEC 61800-4. For more information, refer to standard.)

● 230 V, 60 Hz, 3-phase ● 380 V – 400 V – 415 V, 50 / 60 Hz, 3-phase ● 460 V – 480 V, 60 Hz, 3-phase ● 575 V, 60 Hz, 3-phase ● 690 V, 50 Hz, 3-phase If exciter is needed, a separate auxiliary voltage supply is needed.

Acceleration/Deceleration Time

0.5 to 3200 seconds (load dependent)

Cell Frame Sizes

880 Amp and 1250 Amp

Overload Capacity

Refer to WCIII Current Parameters Section.

Efficiency

● Total System 96.5% / Transformer 97.5% + Cells 99.0% (cell redundancy = N+0)

Motor load PF = 1.0


Cells at 100% continuous rating


Enclosure Type

● MV Power Sections: IP 53 (NEMA 12) ● LV Control Sections: IP 21 (NEMA 1)


127

Technical Data B.1 WCIII System Technical Specifications Altitude

● No de-rating up to 3300 feet / 1006 meters above Mean Sea Level. ● Above 3300 feet / 1006 meters, refer to Cell Output Deration Formulas. ● Above 6562 feet / 2000 meters, consult Siemens customer service.

Sound level2

Less than 76 dB at 3 feet (~ 1 meter) from cabinet.

Control Power3

One: single phase, 120 VAC RMS ± 10%, 50 / 60 Hz Three: three phase, 380 VAC RMS ± 10% / 50 Hz or 460 VAC RMS ± 10% / 60 Hz

1

Control

NXGII hardware + Eagle software

Cooling

De-ionized water and glycol mix

Design Life

20 years

Accessibility

Rear access is required for maintenance and installation. For details, contact Siemens customer service.

Refer to deration formulas in Power Cell SpecificationsSection.

2

The WCIII drive generates acoustic noise levels above 70 dB. Hearing protection is not required.

3

Control Power is sourced by the customer in the standard configuration. A fourth three-phase feed (± 10% continuous RMS voltage tolerance) is required if a forced air type drive main heat exchanger is used.

Note Synchronous motor operates at fixed 1.0 (Unity) Power Factor.

128


Technical Data B.2 WCIII Storage, Transport and Operation Ambient Conditions

B.2

WCIII Storage, Transport and Operation Ambient Conditions Refer to the following table to view the ambient conditions of the Perfect Harmony™ WCIII drives. These conditions meet the IEC 60721 and 61800 applicable standards.

Table B-2

General Ambient Conditions Storage

Transport

Operating

–25 °C to +60 °C (no cooling water in the system)

Minimum 32 °F / 0 °C ambient air temperature with minimum inlet water temperature 41 °F / 5 °C. Recommend inlet water temperature be maintained minimum 4 °F / 2 °C above cabinet internal air dew point.

CLIMATIC AMBIENT CONDITIONS Ambient temperature

41 ºF / +5 ºC to 104 ºF / +40 ºC (no cooling water in the system)

Maximum concurrent temperature conditions listed below. Use linear interpolation for intermediate conditions. ● Condition 1: Maximum 104 °F / 40 °C drive ambient air temperature with maximum 117 °F / 47 °C drive inlet water temperature concurrent. ● Condition 2: Maximum 122 °F / 50 °C drive ambient air temperature with maximum 108 °F / 42 °C drive inlet water temperature concurrent. Relative air humidity

< 95 % (VFD must be completely dry before commissioning)

< 95 %

Other climatic conditions in accordance with class

1K3, 1Z2 in accordance with IEC 60721-3-1

2K2 in accordance with IEC 60721-3-2

3K3 in accordance with IEC 60721-3-3

Degree of pollution

2 without conductive pollution in accordance with IEC 61800-5



(VFD must be completely dry before commissioning)

< 95 % (condensation not permitted)

MECHANICAL AMBIENT CONDITIONS STATIONARY VIBRATION, SINUSOIDAL Displacement

1.5 mm (2 to 9 Hz)

3.5 mm (2 to 9 Hz)

0.3 mm (2 to 9 Hz)

Acceleration

5 m/s2 (9 to 200 Hz)

10 m/s2 (9 to 200 Hz) 15 m/s2 (200 to 500 Hz)

1 m/s2 (9 to 200 Hz)

Other mechanical conditions in accordance with class

1M2 in accordance with IEC 60721-3-1



2B1 in accordance with IEC 60721-3-2


OTHER AMBIENT CONDITIONS Biological ambient conditions in accordance with class



129

Technical Data B.4 WCIII Current Parameters Storage

Transport

Operating

Chemical active substances in accordance with class

1C1 in accordance with IEC 60721-3-1



Mechanical active substances in accordance with class

1S1 in accordance with IEC 60721-3-1

2S1 in accordance with IEC 60721-3-2

3S1 in accordance with IEC 60721-3-3 (standard) 3S3 in accordance with IEC 60721-3-3 (in liquid-cooled systems with IP 53 (NEMA 12) MV enclosures)

B.3

WCIII Power Cell Specifications The following tables contains the parameters for each WCIII power cell type.

Table B-3

WCIII Power Cell Specifications

Power Cell Type

880A2

880A4

1250A2

Power cell height

24.75 in / 628.7 cm

Power cell width

22.25 in / 565.2 cm

Power cell depth

32.75 in / 831.9 cm

Power cell weight

Power chassis = 155 pounds / 70.3 kilograms

1250A4

Capacitors = 2 x 130 = 260 pounds / 118 kilograms Capacitors =3 x 130 = 390 pounds / 177 kilograms Electrical connections

Rear access blind connection via power plugs

Cooling flow

4 GPM / 15.1 LPM

Cold-plate pressure drop

6 PSIG / 41.3 kPa

Storage temperature

-13 °F / -25 °C to 140 °F / 60 °C

Ambient humidity

No condensation formation

B.4

WCIII Current Parameters

Table B-4

WCIII 880 Amp Cell Type Specifications

Cell Type Output Current Rating (Io)

880A2

880 Amps RMS Continuous

110% overload for 1 min / 10 min (CL-1)

880 Amps RMS Continuous 968 Amps RMS Overload



Nominal Input Current (Cell Input PF = 1.0)

130

880A4

No overload required



Technical Data B.5 Power Cell Output Current Rating Deration Parameters Cell Type

880A2

Nominal Three-Phase Line-to-Line Input Voltage

750 Volts RMS +10 / -5% at 50 or 60 Hz

Cell Efficiency at 100% Continuous Rated Output Current with Motor Load PF = 1.0

99.0% (no redundant cells) 98.7% (1 rank of redundant cells)

Table B-5

880A4

WCIII 1250 Amp Cell Type Specifications

Cell Type

1250A2

Output Current Rating (Io)

1250A4

No overload required






Nominal Input Current (Cell Input PF = 1.0)


Nominal Three-Phase Line-to-Line Input Voltage

750 Volts RMS +10 / -5% at 50 or 60 Hz

Cell Efficiency at 100% Continuous Rated Output Current with Motor Load PF = 1.0

99.0% (no redundant cells) 98.7% (1 rank of redundant cells)

B.5

Power Cell Output Current Rating Deration Parameters Power Cell Output Current Rating Deration for Drive Maximum Output Frequency [fo] If 330 ≥ fo ≥ 10 Hz → Cell Output Current Rating = Io (from Cell Type Specifications Tables) If 0.5 ≤ fo < 10 Hz → Cell Output Current Rating = Io x [0.5 + (fo / 20)] Power Cell Output Current Rating Deration for Cell Carrier Frequency [fc] ● fc can be assigned any value from 300 to 1200 Hz provided fc ≥ (3.6 x fo) Hz ● For fo < 167 Hz, the default value fc = 600 Hz is typically adequate. A smaller value of fc can be chosen provided 300 Hz ≤ fc ≥ (3.6 x fo) Hz ● For fo = 167 → 330 Hz, select carrier using 1200 Hz ≥ fc ≥ (3.6 x fo) Hz If 300 ≤ fc ≤ 600 Hz → Cell Output Current Rating = Io (from Cell Type Specifications Tables) If 600 < fc ≤ 1200 Hz → Cell Output Current Rating = Io x {1 - { [ (fc - 600) / 600 ] x 0.20}} Power Cell Output Current Rating Deration for Drive Altitude Above Mean Sea Level If Altitude ≤ 3300 feet (1006 meters) → Cell Output Current Rating = Io (from Cell Type Specifications Tables) If 3300 feet (1006 meters) < Altitude ≤ 20000 feet (6096 meters) → Cell Output Current Rating = Io x { 1 - { [ 0.5 x ( Alt - 3300 )] / 16700 }} - Altitude in feet Cell Output Current Rating = Io x { 1 - { [ 0.5 x ( Alt - 1006 )] / 5090 }} - Altitude in meters


131

Technical Data B.6 Ingress Protection (IP) Ratings

B.6

Ingress Protection (IP) Ratings IP ratings are developed by the European Committee for Electro Technical Standardization (CENELEC) (NEMA IEC 60529 Degrees of Protection Provided by Enclosures - IP Code), specifying the environmental protection the enclosure provides. The IP rating normally has two (or three) numbers: ● Protection from solid objects or materials ● Protection from liquids (water) ● Protection against mechanical impacts (commonly omitted, the third number is not a part of IEC 60529). Refer to the following table using the example shown to help in understanding the IP rating as it applies to your equipment. Example - IP Rating ● With the IP rating IP 54, 5 describes the level of protection from solid objects and 4 describes

the level of protection from liquids.

● An "X" can be used for one of the digits if there is only one class of protection (e.g.,IPX1,

which, addresses protection against vertically falling drops of water such as condensation).

IP First Number: Protection against solid objects 0

No special protection.

1

Protected against solid objects over 50 mm e.g. accidental touch by person's hands.

2

Protected against solid objects over 12 mm e.g. person's fingers.

3

Protected against solid objects over 2.5 mm (tools and wires).

4

Protected against solid objects over 1 mm (tools, wires and small wires).

5

Protected against dust limited ingress (no harmful deposit).

6

Totally protected against dust.

IP Second Number: Protection against liquids 0

No protection.

1

Protected against vertically falling drops of water e.g. condensation.

2

Protected against direct sprays of water up to 15 ° from the vertical.

3

Protected against direct sprays of water up to 60 ° from the vertical.

4

Protected against water sprayed from all directions - limited ingress permitted.

5

Protected against low pressure jets of water from all directions - limited ingress.

6

Protected against temporary flooding of water e.g. for use on ship decks - limited ingress permitted.

7

Protected against the effect of immersion between 15 cm and 1 m.

8

Protected against long periods of immersion under pressure.

IP Third Number: Protection against mechanical impacts 0

No protection.

1

Protected against impact of 0.225 joule (e.g. 150 g weight falling from 15 cm height).

2


132


Technical Data B.6 Ingress Protection (IP) Ratings IP Third Number: Protection against mechanical impacts 3


4


5

Protected against impact of 6.0 joule (e.g. 1.5 kg weight falling from 40 cm height).

6

Protected against impact of 20.0 joule (e.g. 5 kg weight falling from 40 cm height).

To comply with the stringent requirements for CE marking machine makers today fit their machines with parts certified according to European Union and international standards.


133

C

Quality C.1

CE Marking and Directives for Perfect Harmony Products The CE marking identifies products that are in compliance with the appropriate EU directives. The CE marking is not a seal of quality. It was created to guarantee end users safe products in the free flow of goods within the European Economic Community (EEC) and the European Community (EC). By applying the CE marking the manufacturer acknowledges the product is in conformance with the applicable EU Directives and the product complies with the “essential requirements” defined in these directives. Based on the Gambica CE Marking and Technical Standardization Guidelines, Edition 3.0, compliance to EN 61800-5-1 is a harmonized standard and confers a presumption of conformity with the essentials of the Low Voltage Directive (LVD).


135

Quality C.2 CE Marking on Power Drive Systems (PDS)

C.2

CE Marking on Power Drive Systems (PDS) To form a basic understanding of the PDS, refer to the following figure.

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BDM Basic drive module consisting of power input, control, and power output sections. CDM Complete drive module consisting of BDM and auxiliary sections, including devices such as incoming switches, input and output transformers and filters, etc., but excluding the motor, cables, and motor-coupled sensors. PDS

Power drive system consisting of CDM, motor and sensors, excluding the driven equipment and sensors.

Figure C-1

Power Drive System

The terminology used throughout IEC and EN standards relating to electrical VFDs is contained in the IEC 61800 series of standards. The IEC 61800 series of standards references other components of the PDS, with respect to the VFD, but those components are covered by different IEC product relevant standards. Siemens Industry, Inc. I DT LD Perfect Harmony™ designs always include the Basic Drive Module (BDM) consisting of a Perfect Harmony™ transformer, converter/inverter (power cell) section, and control section. Depending on the Siemens Industry, Inc. I DT LD scope of supply, the Perfect Harmony™ Complete Drive Module (CDM) may include optional components, such as a motor excitation unit, output line filter, output line reactor, or earthing switches. Refer to the following figure for further detail on this concept.

136


Quality C.3 Directives that apply to the Power Drive System (PDS) /9 SRZHU

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* Optional Components in Perfect Harmony CDM: ● May not be in Siemens scope of supply. ● May be housed separately in stand-alone enclosure. Figure C-2

Overview of PDS containing the Perfect Harmony BDM and CDM

As referenced in Figure Power Drive System, the installation, parts of the installation, the motor or any machinery, including gearboxes and the driven equipment, are outside of the scope of Siemens LD's responsibility.

C.3

Directives that apply to the Power Drive System (PDS) ● LVD: Low Voltage Directive – 2006/95/EEC (formerly 72/23/EEC). Siemens Industry, Inc. I DT LD Perfect Harmony™ designs comply with IEC 61800-5-1 (2007) “Adjustable Speed Electrical Power Drive Systems”, Part 5-1 “Safety Requirements – Electrical, Thermal and Energy.” ● EMC: EMC Directive - 2004/108/EEC (formerly 89/36/EEC). Siemens Industry, Inc. I DT LD Perfect Harmony™ designs comply with IEC 61800-3 (2004) “Adjustable Speed Electrical Power Drive Systems”, Part 3 “EMC Requirements and specific test methods.” Reference Section “EMC Installation Guidelines for Perfect Harmony™” in Siemens Industry, Inc. I DT LD document A5E03091809 (this document). – The Perfect Harmony™ VFD is verified compliant to IEC 61800-3 through type testing of the BDM/CDM itself. Compliance with IEC 61800-3 is a requirement of the EMC Directive; however, the Perfect Harmony™ VFD cannot directly state compliance to the EMC Directive because the directive requires type testing of the complete PDS as it is installed at the customer site.


137

Quality C.4 CE Marking ● MD: Machinery Directive – 98/37/EEC until 29 Dec. 2009, then 2006/42/EEC becomes effective. – Although the Machinery Directive is a recognized directive associated with a PDS, the Perfect Harmony™ VFD cannot directly state compliance to the Machinery Directive. The Machinery Directive provides clear definition for a machine and a partially completed machine. The Perfect Harmony™ VFD does not meet these definitions. This is defined in Section CE Marking. ● PED: Pressure Equipment Directive – 97/23EC. Liquid cooled Siemens Industry, Inc. I DT LD Perfect Harmony™ designs are exempt since they operate at pressures less than ten bars. ● ATEX: Explosive Atmospheres – 94/9/EC. Siemens Industry, Inc. I DT LD does not authorize the use of Perfect Harmony™ designs in an explosive atmosphere.

C.4

CE Marking Applying the CE marking confers the presumption of conformity to the EU directive(s). The CE marking is required for all products which fall in the scope of a European Directive (which foresees the CE marking for those products) which are placed on the market in the European Economic Area.

Figure C-3

CE Marking

Note Access "CE Marking and Technical Standardization - Guidelines for Application to Electrical Power Drive Systems", Edition 3.0, at http://www.gambica.org.uk/ Access EU Directives and Norms at the following link: http://ec.europa.eu/enterprise/policies/european-standards/documents/harmonisedstandards-legislation/list-references/ This site provides access to all European Directives and the appropriate standards according to each manufacturer’s specific products.

138


D

Abbreviations

This appendix contains a list of symbols and abbreviations commonly used throughout this manual group. Table D-1

Commonly Used Abbreviations

Abbreviation

Meaning

•

Boolean AND function

+

Addition or Boolean OR

∑

Summation

µ

Microsecond

A

Amp, Ampere

AC

Alternating Current

ACFM

Actual Cubic Feet per Minute

accel

Acceleration

A/D

Analog to Digital Converter

ADC

Analog to Digital Converter

AI

Analog Input

Alg

Analog

avail

Available

BIL

Basic Impulse Level

BTU

British thermal units

C

Centigrade or Capacitor

cap

Capacitor

CCB

Cell Control Board

ccw

Counter clockwise

CE

Formerly European Conformity, now true definition

CFM

Cubic Feet per Minute

CLVC

Closed Loop Vector Control

cmd

Command

com

Common

conn

Connector

CPS

Control Power Supply

CPU

Central Processing Unit

CSMC

Closed Loop Synchronous Motor Control

CT

Current Transformer

cu

Cubic

curr, I

Current

cw

Clockwise

D

Derivative (PID), depth


139

Abbreviations

Abbreviation

Meaning

D/A

Digital-to-analog (converter)

db

Decibel

DC

Direct Current

DCR

Digital Control Rack

DCS

Distributed Control System

decel

Deceleration

deg, °

Degrees

DHMS

Down hole monitoring system

Div

Division

dmd

Demand

e

Error

EC

Electrically Commutated

ELV

Extra Low Voltage

EMC

Electromagnetic Compatibility

EMF

Electromotive Force

EMI

Electromagnetic Interference

EPS

Encoder Power Supply

ESD

Electrostatic Discharge

ESP

Electrical Submersible Pump

ESTOP, e-stop

Emergency Stop

fb, fdbk

Feedback

ffwd

Feed Forward

FLC

Full Load Current

freq

Frequency

ft, '

Feet

fwd

Forward

GenIIIe

Generation IIIe

GenIV

Generation IV

gnd

Ground

GUI

Graphical User Interface

H

Height

H2O

Water

hex

Hexadecimal

hist

Historic

Hp

Horsepower

hr

Hour

HV

High Voltage

HVAC

Heating, Ventilation, Air Conditioning

HVF

Harmonic Voltage Factor

Hz

Hertz

I

Integral (PID)

ID

Identification

IEC

International Electrotechnical Commission

140


Abbreviations

Abbreviation

Meaning

IEEE

Institute of Electrical and Electronic Engineers

IGBT

Insulated Gate Bipolar Transistor

In

Input

In, "

Inches

INH

Inhibit

I/O

Input(s)/Output(s)

IOB

I/O Breakout Board

IOC

Instantaneous Overcurrent

IP

Input Protection

k

1,000 (e.g., Kohm)

kHz

KiloHertz

kV

Kilo Volts

kVA

One Thousand Volt Amps

kW

Kilowatt

L

Inductor

LAN

Local Area Network

Lbs

Pounds (weight)

LCD

Liquid Crystal Display

ld

Load

LED

Light-emitting Diode

LFR

Latch Fault Relay

Lim

Limit

LOS

Loss Of Signal

lps

Liters Per Second

mA

Milliamperes

mag

Magnetizing

max

Maximum

MCC

Motor Control Center

Mg

Milligram

Min

Minimum, Minute

msec

Millisecond(S)

Msl

Mean Sea Level

MV

Medium Voltage

mvlt

Motor Voltage

MW

Megawatt

NC

Normally Closed

NEMA

National Electrical Manufacturer’s Association

NMI

Non-Maskable Interrupt

No

Normally Open

NVRAM

Non-Volatile Random Access Memory

NXG

Next Generation Control

NXG II

Next Generation Control II

oamp

Output Current


141

Abbreviations

Abbreviation

Meaning

OLVC

Open Loop Vector Control

O-M

Overmodulation

OOS

Out of Saturation (IGBT)

overld

Overload

P

Proportional (PID)

Pa

Pascals

pb

Push Button

PC

Personal Computer or Printed Circuit

PCB

Printed Circuit Board

PID

Proportional Integral Derivative

PLC

Programmable Logic Controller

PLL

Phase Locked Loop

pot

Potentiometer

pp

Peak-to-peak

ppm

Parts per Million

PPR

Pulses per Revolution

PQM

Power Quality Meter

ProToPSTM

Process Tolerant Protection Strategy

PSDBP

Power Spectral Density Break Point

psi

Pounds Per Square Inch

pt

Point

PT

Potential Transformer

PWM

Pulse Width Modulation

Q1,Q2,Q3,Q4

Output Transistor Designations

rad

Radians

RAM

Random Access Memory

ref

Reference

rev

Reverse, Revolution(S)

RFI

Radio Frequency Interference

RLBK

Rollback

rms

Root-mean-squared

RPM

Revolutions Per Minute

RTD

Resistance Temperature Detector

RTU

Remote Terminal Unit

RX

Receive (RS232 Communications)

s

Second(s)

SCB

Signal Conditioning Board

SCR

Silicon Controlled Rectifier

sec

Second(s)

ser

Serial

SMC

Synchronous Motor Control

SOP

Sum of Products; System Operating Program

spd

Speed

142


Abbreviations

Abbreviation

Meaning

stab

Stability

std

Standard

sw

Switch

T1, T2

Output Terminals TI and T2

TB

Terminal Block

TBD

To Be Determined

TCP/IP

Transmission Control Protocol/Internet Protocol

THD

Total Harmonic Distortion

TOL

Thermal Overload

TP

Test Point

trq, τ

Torque

TX

Transmit (RS232 Communications)

UPS

Uninterruptable Power Supply

V

Voltage, Volts

VA

Volt-Amperes

VAC

Volts AC

var

Variable

VDC

Volts DC

vel

Velocity

VFD

Variable Frequency Drive

V/Hz

Volts per Hertz

vlts

Voltage(s), Volts

VSI

Voltage Source Inverter

W

Width, Watts

WAGO

Expansion I/O System

WCIII

Water Cooled III

xfmr, xformer

Transformer


143

Glossary AND AND is a logical Boolean function whose output is true if all of the inputs are true in SOP notation, AND is represented as "∗" (e.g., C=A∗B), although sometimes it may be omitted between operands with the AND operation being implied (e.g., C=AB).

ASCII ASCII is an acronym for American Standard Code for Information Interchange, a set of 8-bit computer codes used for the representation of text.

Baud rate Baud rate is a measure of the switching speed of a line, representing the number of changes of state of the line per second. The baud rate of the serial port of the Perfect Harmony is selected through the Baud Rate parameter in the Communications Menu [9].

Bit Bit is an acronym for BInary digiT. Typically, bits are used to indicate either a true (1) or false (0) state within the drive’s programming.

Boolean algebra A form of mathematical rules developed by the mathematician George Boole used in the design of digital and logic systems.

Carrier frequency Carrier frequency is the set switching frequency of the power devices (IGBTs) in the power section of each cell. The carrier frequency is measured in cycles per second (Hz).

Catch a spinning load "Catch a spinning load" is a feature that can be used with high-inertia loads (e.g., fans), in which the drive may attempt to turn on while the motor is already turning. This feature can be enabled via the NXG menu system.

CLVC An acronym for Closed Loop Vector Control, one of the control modes in the drive. This is flux vector control for an induction machine (IM), utilizing an encoder for speed feedback.


145

Glossary

CMP Refer to the glossary term SOP.

Comparator A comparator is a device that compares 2 quantities and determines their equality. The comparator submenus allow the programmer to specify two variables to be compared. The results of the custom comparison operations can be used in the system program.

Configuration Update see Tool Suite definition.

Converter The converter is the component of the drive that changes AC voltage to DC voltage.

Critical speed avoidance Critical speed avoidance is a feature that allows the operator to program up to 3 mechanical system frequencies that the drive will "skip over" during its operation.

CSMC An acronym for Closed Loop Synchronous Machine (SM) Control, one of the control modes of the drive. This is a flux vector control for a synchronous machine, utilizing an encoder for speed feedback and providing a field excitation command for use by an external field exciter.

DC link The DC link is a large capacitor bank between the converter and inverter section of the drive. The DC link, along with the converter, establishes the voltage source for the inverter.

De Morgan’s Theorem The duality principal of Boolean algebra used to convert system logic equations into sum-ofproducts notation.

Debug Tool see Tool Suite definition.

Downloading Downloading is a process by which information is transmitted from a remote device (such as a PC) to the drive. The term "downloading" implies the transmission of an entire file of information (e.g., the system program) rather than continued interactive communications

146


Glossary

between the two devices. The use of a PC for downloading requires special serial communications software to be available on the PC, which may link to the drive via RS232 or through the Host Simulator via an ethernet connection.

DRCTRY Directory file for system tokens and flags used in the compilation of system programs. It provides a direct lookup table of ASCII names to internal ID numbers. It also identifies whether the flag is a word or bit-field, and also whether it can be used as an input or output only, or can be used for both.

Drive The term "drive" refers to the power conversion equipment that converts utility power into power for a motor in a controlled manner.

ELV ELV is an acronym for extra low voltage, and represents any voltage not exceeding a limit that is generally accepted to be 50 VAC and 120 VDC (ripple free).

EMC EMC is an acronym for electromagnetic compatibility–the ability of equipment to function satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic disturbances to anything in that environment.

ESD ESD is an acronym for ElectroStatic Discharge. ESD is an undesirable electrical side effect that occurs when static charges build up on a surface and are discharged to another. When printed circuit boards are involved, impaired operation and component damage are possible side effects due to the static-sensitive nature of the PC board components. These side effects may manifest themselves as intermittent problems or total component failures. It is important to recognize that these effects are cumulative and may not be obvious.

Fault log Fault messages are saved to memory so that the operator may view them at a later time. This memory location is called the fault log. The fault log lists both fault and alarm messages, the date and time that they occurred, and the time and date that they are reset.

Faults Faults are error conditions that have occurred in the Perfect Harmony system. The severity of faults vary. Likewise, the treatment or corrective action for a fault may vary from changing a parameter value to replacing a hardware component such as a fuse.


147

Glossary

Flash Card Non-volatile memory storage device for the NXG control. It stores the drive program, system program, logs, parameters, and other related drive files.

FPGA Field Programmable Gate Array. An FPGA is an integrated circuit that contains thousands of logic gates.

Function A function is one of four components found in the Perfect Harmony menu system. Functions are built-in programs that perform specific tasks. Examples of functions include System Program Upload/Download and Display System Program Name.

Harmonics Harmonics are undesirable AC currents or voltages at integer multiples of the fundamental frequency. The fundamental frequency is the lowest frequency in the wave form (generally the repetition frequency). Harmonics are present in any non-sinusoidal wave form and cannot transfer power on average. Harmonics arise from non-linear loads in which current is not strictly proportional to voltage. Linear loads like resistors, capacitors, and inductors do not produce harmonics. However, nonlinear devices such as diodes and silicon controlled rectifiers (SCRs) do generate harmonic currents. Harmonics are also found in uninterruptable power supplies (UPSs), rectifiers, transformers, ballasts, welders, arc furnaces, and personal computers.

Hexadecimal digits Hexadecimal (or "hex") digits are the "numerals" used to represent numbers in the base 16 (hex) number system. Unlike the more familiar decimal system, which uses the numerals 0 through 9 to make numbers in powers of 10, the base 16 number system uses the numerals 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, and F to make numbers in powers of 16.

Historic log The historic log is a troubleshooting/diagnostic tool of the Perfect Harmony NXG control. The historic log continuously logs drive status, including the drive state, internal fault words, and multiple user-selectable variables. This information is sampled every slow loop cycle of the NXG control (typically 450 to 900 times per second). If a fault occurs, the log is frozen a predefined number of samples after the fault event, and data samples prior to and after the fault condition are recorded to allow post-fault analysis. The number of samples recorded are user-selectable via the NXG control, as well as the option to record the historic log within the VFD event log.

Host Simulator see Tool Suite definition.

148


Glossary

I/O I/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a computer system. Both inputs and outputs can be classified as analog (e.g., input power, drive output, meter outputs, etc.) or digital (e.g., contact closures or switch inputs, relay outputs, etc.).

IGBT IGBT is an acronym for Insulated Gate Bipolar Transistors. IGBTs are semiconductors that are used in the Perfect Harmony drives to provide reliable, high-speed switching, high-power capabilities, improved control accuracy, and reduced motor noise.

Induction motor An induction motor is an AC motor that produces torque by the reaction between a varying magnetic field (generated in the stator) and the current induced in the coils of the rotor.

Intel hex Intel hex refers to a file format in which records consist of ASCII format hexadecimal (base 16) numbers with load address information and error checking embedded.

Inverter The inverter is a portion of the drive that changes DC voltage into AC voltage. The term "inverter" is sometimes used mistakenly to refer to the entire drive (the converter, DC link, and inverter sections).

Jog mode Jog mode is an operational mode that uses a pre-programmed jog speed when a digital input (programmed as the jog mode input) is closed.

Jumpers Jumper blocks are groups of pins that can control functions of the system, based on the state of the jumpers. Jumpers (small, removable connectors) are either installed (on) or not installed (off) to provide a hardware switch.

Ladder logic (Also Ladder Diagram) A graphical representation of logic in which two vertical lines, representing power, flow from the source on the left and the sink on the right, with logic branches running between, resembling rungs of a ladder. Each branch consists of various labeled contacts placed in series and connected to a single relay coil (or function block) on the right.


149

Glossary

Loss of signal feature The loss of signal feature is a control scheme that gives the operator the ability to select one of three possible actions in the event that the signal from an external sensor, configured to specify the speed demand, is lost. Under this condition, the operator may program the drive (through the system program) to (1) revert to a fixed, pre-programmed speed, (2) maintain the current speed, or (3) perform a controlled (ramped) stop of the drive. By default, current speed is maintained.

LVD LVD is an acronym for Low Voltage Directive, a safety directive in the EU.

Lvl RH This term refers the two security fields associated with each parameter of the system. These fields allow the operator to individually customize specific security features for each menu option (submenu, parameter, pick list, and function). These fields are shown in parameter dumps and have the following meanings. Lvl is the term for the security level. Setting R=1 blocks parameter change, and setting H=1 hides the menu option from view until the appropriate access level has been activated.

Memory Memory is the working storage area for the Perfect Harmony drive that is a collection of RAM chips.

Microprocessor A microprocessor is a central processing unit (CPU) that exists on a single silicon chip. The microprocessor board is the printed circuit board on which the microprocessor is mounted. The drive employs a single-board computer with a Pentium® microprocessor.

NEMA 1 and NEMA 12 NEMA 1 is an enclosure rating in which no openings allow penetration of a 0.25-inch diameter rod. NEMA 1 enclosures are intended for indoor use only. NEMA 12 is a more stringent NEMA rating in which the cabinet is said to be "dust tight" (although it is still not advisable to use NEMA 12 in conductive dust atmospheres). The approximate equivalent IEC rating is IP52.

Normally closed (NC) Normally closed refers to the contact of a relay that is closed when the coil is de-energized.

Normally open (NO) Normally open refers to the contact of a relay that is open when the coil is de-energized.

150


Glossary

OLTM An acronym for Open Loop Test Mode, one of the control modes of the drive.

OLVC An acronym for Open Loop Vector Control, also known as Encoderless Vector Control. OLVC is a flux vector control that is one of the control modes of the drive. The drive computes the rotational speed of the rotor and uses it for speed feedback.

OOS OOS is an abbreviation for out of saturation - a type of fault condition in which a voltage drop is detected across one of the IGBTs during conduction. This can indicate that the motor is drawing current too rapidly or in excess.

OR OR is a logical Boolean function whose output is true if any of the inputs is true. In SOP notation, OR is represented as "+".

Parameter A parameter is one of four items found in the Perfect Harmony menu system. Parameters are system attributes that have corresponding values that can be monitored or, in some cases, changed by the user.

PED PED is an acronym for pressure equipment directive, a directive of the EU relating to pressure vessels.

Pick list A pick list is one of four items found in the Perfect Harmony menu system. Pick lists are parameters that have a finite list of pre-defined "values" from which to choose, rather than a value range used by parameters.

PID PID is an acronym for proportional + integral + derivative, a control scheme used to control modulating equipment in such a way that the control output is based on (1) a proportional amount of the error between the desired setpoint and the actual feedback value, (2) the summation of this error over time, and (3) the change in error over time. Output contributions from each of these three components are combined to create a single output response. The amount of contribution from each component is programmable through gain parameters. By optimizing these gain parameters, the operator can "tune" the PID control loop for maximum efficiency, minimal overshoot, quick response time, and minimal cycling.


151

Glossary

Qualified user A qualified user is a properly trained individual who is familiar with the construction and operation of the equipment and the hazards involved.

RAM RAM is an acronym for Random Access Memory, a temporary storage area for drive information. The information in RAM is lost when power is no longer supplied to it. Therefore, it is referred to as volatile memory.

Regeneration Regeneration is the characteristic of an AC motor to act as a generator when the rotor’s mechanical frequency is greater than the applied electrical frequency.

Relay A relay is an electrically controlled device that causes electrical contacts to change their status. Open contacts will close and closed contacts will open when rated voltage is applied to the coil of a relay.

RS232C RS232C is a serial communications standard of the Electronics Industries Association (EIA).

Set point Set point is the desired or optimal speed of the VFD to maintain process levels (speed command).

Slip Slip is the difference between the stator electrical frequency of the motor and the rotor mechanical frequency of the motor, normalized to the stator frequency as shown in the following equation: Slip =ω S - ω R ω S

Slip compensation Slip compensation is a method of increasing the speed reference to the speed regulator circuit (based on the motor torque) to maintain motor speed as the load on the motor changes. The slip compensation circuit increases the frequency at which the inverter section is controlled to compensate for decreased speed due to load droop. For example, a motor with a full load speed of 1760 rpm has a slip of 40 rpm. The no load rpm would be 1800 rpm. If the motor nameplate current is 100 A, the drive is sending a 60 Hz wave form to the motor (fully loaded); then the slip compensation circuit would cause the inverter to run 1.33 Hz faster to allow the motor to operate at 1800 rpm, which is the synchronous speed of the motor.

152


Glossary

SMC Is an acronym for Synchronous Motor Control, one of the control modes of the drive. This mode computes the rotational speed similarly to open-loop vector control, and controls the field reference or the synchronous motor as in closed-loop synchronous motor control.

SOP - (1) SOP is an acronym for Sum Of Products. The term "sum-of-products" comes from the application of Boolean algebraic rules to produce a set of terms or conditions that are grouped in a fashion that represents parallel paths (ORing) of required conditions that all must be met (ANDing). This would be equivalent to branches of connected contacts on a relay logic ladder that connect to a common relay coil. In fact, the notation can be used as a shortcut to describe the ladder logic. (2) SOP, when used as a filename extension, refers to System Operating Program.

SOP Utilities The program within the Siemens LD A Tool suite used for converting between text and machine loadable code. It can also be used for uploading and downloading files over the RS232 connection. See Tool Suite definition.

Speed Menu function Speed menu is a feature of the menu system that allows the operator to directly access any of the menus or parameters, rather than scrolling through menus to the appropriate item. This feature uses the [Shift] button in conjunction with the right arrow. The user is prompted to enter the four digit ID number associated with the desired menu or parameter.

Stop mode Stop mode is used to shut down the drive in a controlled manner, regardless of its current state.

Submenus A submenu is one of four components found in the Perfect Harmony menu system. Submenus are nested menus (i.e., menus within other menus). Submenus are used to logically group menu items based on similar functionality or use.

Synchronous speed Synchronous speed refers to the speed of an AC induction motor’s rotating magnetic field. It is determined by the frequency applied to the stator and the number of magnetic poles present in each phase of the stator windings. Synchronous Speed equals 120 times the applied Frequency (in Hz) divided by the number of poles per phase.


153

Glossary

System Operating Program The functions of the programmable inputs and outputs are determined by the default system program. These functions can be changed by modifying the appropriate setup menus from the front keypad and display. I/O assignments can also be changed by editing the system program (an ASCII text file with the extension .SOP), compiling it using the compiler program, and then downloading it to the controller through its serial port, all by utilizing the SOP Utility Program with the Siemens LD A Tool Suite.

Tool Suite Is the suite of programs developed by Siemens that allows easier access to the drive for programming and monitoring. It is comprised of the following components: ● Tool Suite Launcher - also referred to as Tool Suite; used for coordinating other tools. ● SOP Utilities - used to launch an editor that compiles or reverse compiles a System Program. It also allows for serial connection to the drive for uploading and downloading System Programs. ● Configuration Update - allows for backing-up, updating, and cloning drives via direct access to the Flash Disk. ● Host Simulator - used for monitoring, programming, and controlling a drive remotely from a PC over the built-in ethernet port of the drive. Parameter changes, status display, and graphing of internal variables are its main functions. ● Debug Tool - this tool is used to display the diagnostic screens of the drive for diagnosing drive problems or improving performance via the built-in ethernet port of the drive.

Tool Suite Launcher see Tool Suite definition.

Torque The force that produces (or attempts to produce) rotation, as in the case of a motor.

Uploading Uploading is a process by which information is transmitted from the drive to a remote device such as a PC. The term uploading implies the transmission of an entire file of information (e.g., the system program) rather than continued interactive communications between the two devices. The use of a PC for uploading requires communications software to be available on the PC.

Variable frequency drive (VFD) A VFD is a device that takes a fixed voltage and fixed frequency AC input source and converts it to a variable voltage, variable frequency output that can control the speed of a motor.

154


Glossary

VHZ Is an acronym for Volts per Hertz control, one of the control modes in the drive. This mode is intended for multiple motors connected in parallel. Therefore, it disables spinning load and fast bypass. This is essentially open-loop vector control with de-tuned (smaller bandwidth obtained by reducing the gain) current regulators.


155

Index A abbreviations, 139 AC power, 49 access plate, 49 alarms, 61 anchor bolts holes, 45 anchoring cabinet, 45 Arcing, 11 assembly drive, 45 Asynchronous motors, 11 Auxiliary power supply, 11

B basic drive module, 136 bolts, 46 bypass contactor, 24

C cabinet cell, 24 coolant, 25 exciter, 26 FPC, 22 input power, 21 output power, 25 output reactor, 25 transformer, 21 cable, 48 control, 54 encoder, 55 power, 55 serial communication, 55 signal, 54 Cable and screw terminals, 67 cable entry location, 33 Cabling, 11 capacitor bucket, 106, 114 mounting bolts, 107 capacitor bank connections, 106


cover plate, 108 CE marking, 135, 138 Gambica guidelines, 135 on Power Drive Systems, 136 cell cabinet, 24 12 cell, 117 9 cell, 112 bypass contactor assembly, 116 construction, 111 maintenance, 111 power cells, 114 rear panel assembly, 116 rear supply and return manifold, 118 sub-assemblies, 111 top hat air-to-water heat exchange system, 112 cell input power fuse fuse replacement, fuse indicator, Bussmann, Ferraz, 73 circuit breaker, 23, 26 customer, 57 cleaning contamination, 66 close input MV contact, 26 commissioning safety, 59 trained personnel, 59 Commissioning, 11 compensating the primary voltage source, 49 components WCIII drive, 20 contact hotline, 125 website, 125 control power, 49, 61 coolant cabinet, 25 cooling blower, 24 cooling system, 61

D derating, 131 dimensions, 45 Disposal of old device, 123 packing waste materials, 123 drive, 9 grounding, 48 Dust deposits, 66

157

Index

E electrical connections, 49 safety, 49 electromagnetic compatibility, 53 earthing, 53 filtering, 54 guideline, 56 shielding, 54 wiring, 54 Electromagnetic fields, 17 electro smog, 17 Electrostatic discharge, 15 Electrostatic Protective Measures, 17 EMC Directive, 137 EMC-compliant installation, 11 emergency stop pushbutton E-Stop, 22 EN standards, 136 ESD guidelines, 15 ethylene glycol safety information, 14 warnings, 14 EU directives, 135, 138 exciter cabinet, 20, 26

F faults, 61, 62 Five safety rules, 12 FPC cabinet, 22 fuse sources blown cell input fuse, 73

G gasket damage, 46 sealing strip, 46 gland plate, 56 drilling, 56 install, 56 removal, 46, 56 Grounding, 11, 48

handling, 32 crane, 34 final lifting liability, 33 fork-lift, 33 strap and cradle method, 34 hazardous waste, 14 heat exchanger, 21, 23, 24 HMI, 22 hose, 111

I IEC standards, 136 Industrial network, 11 ingress protection ratings, 132 input conductor sizing guidelines, 53 input current interrupting device, 26 input line current transformer, 21 input line surge arrester, 21 input line voltage attenuator resistor, 21 input MV line terminals L1/L2/L3, 21 input power cabinet, 21 input protection, 26 inspection, 64 checklist, 66 contamination, 65 damage, 65 visual, 65 installation electrical, 49 mechanical, 45 Installation, 11 installing the VFD, 29

J J-bar, 45

K key interlocks, 19, 60, 63, 64 electrical, 19 mechanical, 19 unlocking, 63

H

L

Hall Effect current sensors, 23

lifting, 32

158


Index

Lock-out / Tag-out procedure, 13 Low Voltage Directive, 135, 137

M Machinery Directive, 138 maintenance safety, 63 trained personnel, 63 maintenance and earthing procedure, 68 manual description, 9 medium voltage, 61

N NXGII control panel, 23

O off-loading, 32 operating safety, 61 trained personnel, 61 operating conditions, 129 outline dimensions, 20 output line voltage attenuator resistor, 23 output medium voltage line terminals T1/T2/T3, 25 output power cabinet, 25 output reactor cabinet, 20, 25

P placement, 43 conditions, 43 mounting, 43 requirements, 43 power cell, 24 banding, 87, 91 banding tool, 87 capacitor discharge resistors, 24 cell lifter, 95, 96, 103 crating, 91 damage, 100, 102, 106, 108 deration parameters, 131 inserting, 101 inspection, 94, 108 installation, 93, 94


isolating, 80, 101 lethal voltages, 80, 101 lifting, 88 pallet, 88 positioning, 80 pre-charge circuit series capacitors, 24 purging, 82 removal, 80, 85 safety, 80, 93, 96, 100 transporting, 85, 96, 100 utility cart, 95, 101 power distribution panel, 24 power quality meter, 21 Pressure Equipment Directive, 138 primary voltage source, 49 propylene glycol safety information, 15 protective earthing, 48

R receiving procedure carrier, 32 damage, 32 inspection, 32 replacement of parts, 70 CompactFlash card, 72 deionizer tank, 70 residual current device, 59 RJ45 ethernet port, 22

S safety glycol, 14 safety precautions handling, 29 moving the unit, 32 transportation, 29 secondary cell voltages, 49 secondary circuit fault coordinated input protection scheme, 26 Shielding, 11 shipping by ocean, 31 by rail, 31 by truck, 31 conditions, 30 guidelines, 30 secure load, 31 standards, 30

159

Index

shipping sections, 19 shipping section 1, 20 shipping section 2, 20 shipping section 3, 20 shipping splits, 32 reconnecting, 46 spare parts NXGII control, 120 optional components, 122 power cell, 121 specifications, 127, 129 speed demand mode selector switch, 22 storage, 41 conditions, 41 indoor, 41 inspection, 41 requirements, 41 symbols, 139 Synchronous motors, 11

Ventilation, 67 VFD, 9, 19 voltage taps, 49

W Wago 750 Series Fieldbus, 23 WCIII drive 1250 amp cell type, 131 880 amp cell type, 130 operating conditions, 129 power cell specifications, 130 specifications, 127 storage condiitons, 129 transport condiitons, 129 weight system, 32

T technical support hotline, 125 website, 125 thermal switch, 21 TIMV contact, 26 top angles, 45 torque specifications, 51 transformer, 21, 49 transformer cabinet, 21 Transport, 11 transportation center of gravity, 30, 36 crane, 34 pipe rollers, 40 roller dollies, 39 standard lifting method, 37 strap and cradle method, 34 trip input medium voltage, 26

U unpacking, 42 damage, 42 inspection, 42

V variable frequency drive, 9 Variable-Speed Drives, 11

160


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Sinamics Perfect Harmony Gh180 Operating Instructions a5e32043214a Aa

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