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Dimensioning of AC Drives

1. pete oid odisti Me cere cae ae hated a aaa cite Ee 111 10 3 Liquid cooled NXP IP00 module configurations 0 112 10 3 1 Chassis 3 Chassis 4 and Chassis 5 sseeem emere 112 10 3 2 Chassis 6T and Chassis 69 iti Spei toting cian date boo bietet 112 103 37 chassis 02 and CaSSIS bi nette E pr nid 113 10 3 4 Chassis 72 and Chassis 74 sque bee no mue desc loe 114 10 3 5 2 X Chassis 64 and 2 X Chassis 74 costes eap ote tom Eta Hae S epe 114 10 4 ACCChOKGS tue ee EUER au en UR an ate natalie 115 10 5 Lifting the power module sssssssssssseseneeeee nennen ennemis 117 10 6 Installing the power module nnns 118 10 7 Cooling air Cooled uni tSn wrest etui rra ee errare eer ue neve RYE C ea e i ees 119 10 8 Cooling lig idicooled units ee n te dti eere lores 121 10 9 Dimensions and layout examples nnns 122 10 9 1 Dimensions of the supply 5 eene 122 10 9 2 Dimensions and layout of FRA FR5 and FR6 frequency converters 123 10 9 3 Dimensions and layout of FR7 FR8 and FR fre
2. 4 2 2 2 Mechanical theory Power amp Torque Motor s power is normally given in kW hp and motor s speed in rpm Power in kW 9 2xumxn kW Pz Txn 60x1000 9550 P T AW Torque in Nm _ Px9550 n T Nm Where P Power in kW T Torque in Nm and n Rotational sped in rpm 4 2 2 3 Characteristics of an asynchronous motor Asynchronous AC motors have a slip sp which is defined at the nominal duty point s n n n x10096 n Synchronous speed n ee 2x fnx60 S rpm pole rpm Vacon Engineered Drives VACON 18 DRIVE SYSTEM DIMENSIONING Where pole is the pole number of the motor Nominal speed nj Breakdown torque Locked rotor torque pullout r starting torque c Pull up torque pull in Full load torque He 3 g s zs 3 E 5 t g Do a l No load speed SONS 1 50 Percent of synchronous speed Figure 14 Typical torque speed curve of an asynchronous motor at DOL duty 4 2 3 SELECT THE MOTOR e Check the supply voltage e Check the speed range e Check the constant torque and start up torque e Check the effect of acceleration duration and inertia Choose the motor so that the required torque is below the thermal loadability curve self or separate ventilation 4 2 3 1 Motor s loadability Motor s thermal loadability decreases as the speed ventilation decreases In field weakening the loadability
3. AO UO9E A aan ee vum ae ev palo nes sindino Aejay Su 4 cies Deen testers ta 2193059 90 00 10d snqljOld 1x Broto Figure 109 Supply section contro wiring Y gv 2 a Lo D En 0 c D c Lu c o O o gt VACON 153 COMMISSIONING snquold 3100 aC tregua 2140 XN i Jopoou 4 Pr PF Y vars suos EN GEF GEF eee Toe PULSO MOXXM 4 9 uxUD 2 208 Qv 9 C9 QS a Sy Beale gt t 2005 0108 z snq wajs s St 2E NYO ame 2 ear ME 5225 q A me es Hz VAL aca 49g SNA NYD 90JB vBd vi Blt 9C i PIPARI nin soe Tr v3782t 9 JE w 3 SUCRE AMDAN IPAS euJa x3 S 1900 IKN te Itc uw gt 1 L 8i g 9t gt DANK ae Ar LN Cw seat vi Y9JMS indu 00 72 2 06 Figure 110 Inverter section control wiring Y o m a Es o un o o c D Lu c o o o gt VACON 154 COMMISSIONING 13 1 3 CHECKING THE SETTINGS As a part of the preliminary phase the various settings of the drive system must be checked Such setting include for example the following Relays of the emergency stop circuit Timer relay e Overload relay thermal overload relays etc Breaker settings e Earth leakage current protection c
4. Dimensioning of front end for drive systems Calculating the values sssssssssssssssseseeneeeeeeeeen eene enne nennen 26 4 5 1 26 0 060 060666000006 6600 Examples of how to calculate the DC 4 5 2 28 Derating due to high ambient 28 1 1 1 1 Derating nennen nere r nennen 28 Thermal 4 7 1 hizo Electric TSU LAL LOIN 1 1 1 1 a 28 APP 1 1 1 1 1 1 eoa Ie dd ete s a tct fe on ed Dm 30 nteol messe oisi A a ata e ea h aaa E i et 30 483 eene ener 30 Mechanical theory 4 8 2 Mechanical theory Torque cccccescccceceeseceeeceeeeceeeeeeceeceeaeeeeeeeeseeeeeeesesnsneeetees 31 4 8 3 eee 31 Mechanical theory Inertia 4 8 4 32 Mechanical theory Power at constant speed 4 8 5 tasto d Neo ts 32 Mechanical theory Acceleration 4 8 6 33 EMC principles and practices ere C EM 33 MS a Essential requirements c cccccccececcec
5. VACON 84 NXP BASED DRIVE UNITS Table 17 Safety functions as defined in the EN IEC 61800 5 2 Safety function Safe Braking and Holding System sps Safely limited Torque SLT Safe Torque Range STR Safe Motor Temperature SMT Safe Cam SCA 1 Not defined in the IEC 61800 5 2 9 3 4 CERTIFIED FUNCTIONAL SAFETY FUNCTIONS FOR VACON NXP AC DRIVES For other than NXP products check the availability and instructions for use of the functional safety functions from the product manual Together with the NXP control platform the OPT AF option board provides the following safety functions Safe Torque Off STO Safe Stop 1 SS1 and Motor Thermistor Overtemperature protec tion in accordance with ATEX For detailed instructions see the OPT AF User s Manual Wc d s A E 7 t ys y E 7 Ea i i i c M Ue E rn STO inputs two Rm 1 independent channels Thermistor input Jumper X10 for selecting f Thermistor Input Thermistor thermistor short circuit D supervision active 4000 ohm After being M Bu i Je H active the fault can be reset if resistance is gt 2000 ohm EXC B m a 35 y 1 E H 24V t of e gt l 0 24V D 7 a 2 f 24V 5 24V SD2 D2 e waa Programmable Relay NO NC Programmable de A b Relay z x NO P 4 BAL e d Eu Ae VA es a y pt Figure 59 Layout of the OPT AF board MIT EE
6. 40 Ambien te mp C eo 100 90 80 70 50 50 40 30 20 10 0 Electric room relative humidity Figure 99 Safe operating area Example If the temperature of the electric room is 30 C the relative humidity is 40 and the temperature of the cooling liquid is 20 C the lowest curve in the figure Safe operating area then the drive oper ating conditions are safe However if the room temperature were to rise to 35 C and the relative humidity to 60 then the operating conditions of the drive would no longer be safe In this case to reach safe operating con ditions the air temperature should be cooled to 28 C or lower If itis not possible to lower the room temperature then the temperature of the cooling liquid should be raised to at least 25 C Vacon Engineered Drives MOTOR CABLES AND OUTPUT FILTERS VACON 141 12 MOTOR CRBLES RND OUTPUT FILTERS Motors and cables are subject to certain phenomena that include voltage reflections current spikes resonances high rate of change of output voltage i e dU dt and bearing currents There are three different types of filters that can be connected to the output of a frequency converter to reduce these potentially harmful effects e the dU dt filter e the sine filter e the common mode filter 12 1 OUTPUT FILTERS 12 1 1 DU DT FILTER A du dt filter is essentially an LC low pass filter whose cut off frequency exceeds the switching fre quency of the c
7. DN 57 42 4 ACICE EIKT E s e AA 57 7 2 2 Moulded case circuit breakers ener nennt 57 7 2 3 Miniature circuit breakerS oooccccccccnnnccnnnnnnnncicnnnnonenicancnnnnnncrnnnnnnnncncnnnnonanecaninnnns 58 USCS ctetur dett Uri 000000000000 59 4 3 1 Selecting the Tus s e 59 Supply network and power cables 11e esee nennen 61 Supply network types ssesssssssssssseseeenene nennen enne nn nennen neret nnn enne nennen 61 8 13 IE HORWORK s i teet eee cede et er AT tete 61 81 27 a Tp pet WOE km nd ies A set eite da secos A doces 62 PH ro MEN Hora 1 1 0 01000000 ita 63 STA TNSGOnetWoFIC iu a sedeo open estu 63 8 1 5 TLI NE bWOTIK 1 A eR ene oe Ae ast ee te oe er Eee ee dudas 64 8 1 6 Corner grounded network ener nnne 64 Power CABLING xc seat t rtt e deett Le a 65 Conductor maternal ziii io se A ae 65 Voltage O e RON RIEN T BIEN 66 Insulation dnatertal 1 1 1 10 1 tbe a deae eene da ee dabei Deed 66 Typical cable type sssssssssssssssseseeeneemeneee enne neren rennen enn nnne nnne 66 Thermal dimensioning of cables nnne 66 8 7 1 Thermal dimensioning
8. The recommendation starts from the allowed voltage distortion as a function of SCR the ratio of the short circuit power available at the PCC to the nominal load at the PCC These voltage requirements are translated into current requirements The higher is the ratio of short circuit power to rated power the higher is the allowed current emission Vacon Engineered Drives VACON 48 HARMONICS Table 7 Current distortion limits for general distribution systems 120v Through 69 OOOV from the standard IEEE 519 1992 Maximum harmonic current distortion on percent of J Individual harmonic order Odd harmonics Teel ly lt 11 11 h 17 17 h 23 23 h 35 35 h TDD 20 4 0 2 0 1 5 0 6 0 3 5 0 25 50 7 0 3 5 2 5 1 0 0 5 8 0 50 100 10 0 4 5 4 0 1 5 0 7 12 0 100 lt 1000 12 0 5 5 5 0 2 0 1 0 15 0 gt 1000 15 0 7 0 6 0 2 5 1 4 20 0 Even harmonics are limited to 25 of the odd harmonic limits above Current distortions that result in a dc offset e g half wave converters are not allowed All power generation equipment is limited to these values of current distortion regardless of actual Isc 1 where Isg maximum short circuit current at PCC Ij maximum demand load current fundamental frequency component at PCC The demand load current is the total fundamental frequency current i e including all linear and non linear loads at the PCC Vacon Engineered Dr
9. The rectifier takes apparent power S from the supply network Apparent power includes a reactive power component Q and an active power component P The rectifier can only transfer active pow er to the DC link The power factor of the rectifier determines how much reactive power is taken from the supply network The power factor of an AFE is 0 99 and the power factor of an NFE is 0 93 When you calculate the DC link power you must take into account the efficiency of the rectifier S V3 xU x In P V3 xU x In xcosa V3 x xIn xsina Front End Poc V3 x U xX In X COSA X Mrect In is the nominal current of the unit and Nrect is the efficiency of the rectifier Figure 21 Calculating the DC link power Vacon Engineered Drives VACON 26 DRIVE SYSTEM DIMENSIONING If you connect rectifiers in parallel there is an unbalance between the rectifier modules When you calculate the DC link power you must take this unbalance into account by derating 5 for each rec tifier You can only connect same type of rectifiers AFE and AFE or NFE and NFE in parallel 4 5 1 CALCULATING THE VALUES Determine the required shaft power Calculate the required motor input power by dividing the required shaft power by the effi ciency of the motor Calculate the required output power of the inverter Divide the required motor input power by the efficiency of the output filter Calculate the required DC power Divi
10. Vacon Engineered Drives VACON 60 CONTACTORS BREAKERS AND FUSES Vacon Engineered Drives SUPPLY NETWORK AND POWER CABLES VACON 61 8 SUPPLY NETWORK AND POWER CABLES 8 1 SUPPLY NETWORK TYPES International standard IEC 60364 distinguishes three families of earthing arrangements using the two letter codes TN TT and IT The first letter indicates the connection between earth and the pow er supply equipment generator or transformer e T Direct connection of a point with earth Latin terra Nopoint is connected with earth isolation except perhaps via high impedance The second letter indicates the connection between earth and the electrical device being supplied e T Direct connection of a point with earth e N Direct connection to neutral at the origin of installation which is connected to the earth TN S and TT networks are more EMC friendly than IT and especially TN C networks In TN C net works the neutral and PE conductors are the same which is why unbalanced and circulation cur rents are common For the same installation geometry the unbalanced current generates a magnetic field of at least two orders of magnitude higher than of a TN S network There is no dif ference on immunity between networks when faced with high frequency interference 8 1 1 IT NETWORK IT network is a specific type of network encountered in industry and special environments like ships and hospitals The main feature of this
11. ery Front End B BCU Brake Chopper Unit F FFE Fundamental Front End l INU Inverter N Non regenerative Front End Product generation Figure 75 Air cooled inverter unit s type code frames FI9 FI14 Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 105 NXP 0000 5 AON 1 SWV A1A20000C3 Option boards each slot is represented by two characters where A basic V O board B expander 1 0 board C fieldbus board D special board Hardware modifications Supply Mounting Boards F Fiber connection standard from CH61 G Fiber connection varnished from CH61 S Direct connection standard V Direct connection varnished W Liquid cooled module Inverter unit DC supply S Standard supply 6 pulse connection with chokes N Standard supply 6 pulse connection without chokes T 12 pulse connection with chokes U 12 pulse connection without chokes Brake chopper 0 no brake chopper 1 internal brake chopper CH3 only EMC emission level N No EMC emission protection to be installed in enclosures T Fulfils standard 61800 3 for IT networks Enclosure class 0 IP00 Control keypad A standard alpha numeric B neutral no local control keypad F dummy panel Nominal mains voltage 3 phase 5 380 500Vac 6 525 690Vac All 3 phase Nominal current low overload 0007 7A 0022 22 A 0205 205 A etc Product range NXP high performance NXB brak
12. 11 2 DESIGNING AND DIMENSIONING THE COOLING SYSTEM FOR LIQUID COOLED DRIVES 11 2 1 How TO SELECT VACON S HX HEAT EXCHANGER TYPE When choosing between Vacon s HXL 040 HX 120 or HX300 Heat exchangers consider the follow ing factors Calculate the total heat load of the AC drive system including LC chokes LC output filters and air to liquid heat exchangers Calculate the total flow requirement that consists of nominal flow a margin of 10 20 Check the following things regarding the needed cooling power e Evaporator power amp efficiency Maximum coolant AT rise in customer process circuit e Derating oversizing Check the ratio of water and glycol in the coolant The ratio affects the nominal flow requirement of the AC drive Select the heat exchanger unit based on the maximum flow and maximum cooling power Check how long the distribution piping is It must be within the following values HXL 040 Ap 0 3 bar 10 m 10m straight pipe DN25 HXL 120 Ap 1 0 bar 40 m 40 m straight pipe DN50 HXM 120 Ap 0 7 bar 25 m 25 m straight pipe DN50 HXS 070 Ap 1 0 bar 40 m 40 m straight pipe DN50 HXT 070 Ap 0 7 bar 25 m 25 m straight pipe DN50 HXL 300 Ap 1 0 bar 40 m 40 m straight pipe DN 80 HXM 300 Ap 0 7 bar 25 m 25 m straight pipe DN80 Table 43 Vacon Heat Exchanger types HXL M V R 040 HXL M M V R HXS T M V R 070 HXL M M R 300 N N P 120 N P N P P Cooling power 0 40 kW 0 120
13. ENGINEERED DRIVES MANUAL VACON DRIVEN BY DRIVES 2 1 22 3 1 3 2 3 3 3 4 4 1 4 2 4 3 4 4 4 5 4 6 4 8 5 2 5 3 5 5 Vacon Engineered Drives VACON 9 1 Introduction to the engineered drives manual eeeese 1 uS 3 vL ECL EE vag QN Processus the Keys anco codd evbu asd Customers installation environment os o etae tal e resto ve dab aus 3 en enne 5 nnne Drive system configuration Drive Systems osa 1 1 2 2 1 0 7 a dpt tt ieu an 7 ANYS 51106 8 Typical single drive applications 3 1 1 eie e rd ode E dte ride 9 bus drive Systems ricas Common 9 00 00 60 1163110195 3 Typical common DC bus system 3 2 1 11 Common AC bus drive systems 11 Typical AC bus
14. Functional safety of safety related electrical electronic and programmable electronic control systems IEC 61508 Functional safety of electrical electronic programmable electronic safety related systems e EN 954 1 Safety of machinery Safety related parts of control systems replaced by EN ISO 13849 The EN IEC 61800 5 2 is a product family standard and as such takes precedence over the generic standards In the EU harmonised standards are used to demonstrate compliance with the Machinery Direc tive Outside EU you must always verify that the standards are accepted by the local legislation 9 3 2 MACHINE DESIGN IS THE STARTING POINT First of all it is the machine builder s responsibility to use the means of design to make the machine safe to use After that a risk analysis has to be carried out and where risks are identified the risk level must be defined and the risks must be reduced to an acceptable level The risk analysis con sists of e g finding out how severe accidents could happen what is the likelihood that they happen and how often the risk situations occur The required level of the safety function results from the risk analysis The performance of the safety system can be evaluated using two different approaches the SIL lev el approach as defined in the IEC 61508 or the PL approach as defined in the ISO 13849 1 e SIL Safety Integrity Level e PL Performance Level Vacon Engineered Drives NX
15. dt filter This is because the desired frequency characteristics require the use of larger inductance and capacitance The sine filter typically causes a 7 10 voltage drop This may require boosting the output voltage of the frequency converter When used in the field weakening range the pull out torque drops fast er than without a sine filter The sine filter allows the use of considerably longer motor cables However not all common mode voltage and EMC interference is eliminated which means that the motor cable must be shielded Vacon Engineered Drives MOTOR CABLES AND OUTPUT FILTERS VACON 143 Both du dt filters and sine filters are a possible source of noise sine filters more than du dt filters If you use third party du dt or sine filters verify for which switching frequency the filter has been designed and make sure that the drive s settings are correct Also check the loadability of 690V drives if the switching frequency is higher than the default setting 12 1 3 COMMON MODE FILTERS Common mode filters are used to reduce bearing and ground currents High frequency common mode filtering can be achieved using toroidal cores of ferromagnetic ma terial in other words by slipping a ferrite ring on to a cable A cable carrying a current has a mag netic field around it The effect of the ferrite is to concentrate this field and hence to increase the cable s inductance by several hundred times If a ferrite is put on to
16. 35 126 110 103 101 100 98 50 152 132 125 122 120 119 70 196 170 160 156 154 153 95 237 206 194 190 187 185 120 274 239 225 220 217 214 150 318 276 261 254 251 248 185 363 316 298 290 287 283 240 429 373 351 343 339 334 300 495 431 406 396 391 386 Table 11 Current capacities for aluminium cables installed on a tray and side by side Correction factor k due 0 87 0 79 0 78 to number of cables Conductor size mm Loadability of one cable A 16 61 53 50 49 48 48 25 78 68 64 62 62 61 35 96 83 79 77 76 75 50 117 101 96 93 92 91 70 149 130 123 120 118 117 95 182 159 150 146 144 142 120 212 184 173 169 167 165 150 244 213 200 196 193 191 185 279 243 229 223 221 218 240 329 286 270 263 260 257 300 380 330 311 304 300 296 Vacon Engineered Drives VACON 70 SUPPLY NETWORK AND POWER CABLES 8 7 5 PARALLEL CABLES The following tables consider the effect of parallel connected cables The installation method the reference standard and ambient temperature are the same as with previous cases The number of cables installed in a layer next to each other is nine The first table is presented for copper cables and the latter for aluminium cables Table 12 Current capacities for parallel connected copper cables installed on a tray and next to other ones nine in total Number of cables in parallel Combined loadability of cables A Conduc
17. Category 3 The function also corresponds to an uncontrolled stop in accordance with stop category 0 EN 60204 1 2006 The STO safety function has been certified by the IFA The STO safety function of the OPT AF board allows the drive output to be disabled so that the drive cannot generate torque in the motor shaft For STO the OPT AF board has two separate galvani cally isolated inputs SD1 and SD2 Vacon OPT AF board has a dual input solution This simplifies the work of the system designer gives built in fault tolerance and redundance With the competing single input solutions the reach ing of corresponding safety level requires more evaluation and design work to prove that the system really is safe Both SD1 and SD2 inputs are normally closed for the drive to be in enable state The STO safety function is achieved by disabling the drive modulation The drive modulation is disabled through two independent paths controlled by SD1 and SD2 so that a single fault in any of the safety related parts will not lead to the loss of the safety function This is done by disabling the gate driver signal outputs to the driver electronics The gate drive output signals control the IGBT module When gate drive output signals are disabled the drive will not generate torque in the motor shaft If either of the STO inputs is not connected to a 24V signal the drive will not go to the RUN state IFA Instutut f r Arbeitsschutz der Deutche Gesetzlichen U
18. Depending on the motor type the values may deviate slightly from those presented in the table Vacon Engineered Drives VACON 76 NXP BASED DRIVE UNITS 9 2 DRIVE SYNCH Vacon Drive Synch is a control concept for paralleling high power drives to control an AC motor The conceptis suitable for single or multiple winding motors DriveSynch allows you to build high power AC drives of up to 5MW using standard low voltage drive modules Vacon Drive Synch can be used with both air cooled and liquid cooled drives Frequency converters or inverters in a common DC bus configuration can be used with the Vacon DriveSynch concept Us ing Drive Synch you can synchronise up to 4 drives that have identical power ratings to produce the same PWM pattern at the output to control a single AC motor Use a dU dt filter at the output of each individual drive to ensure further load balancing DU dt fil ter s inductance must be at least 1 596 Filters with lesser inductance values must not be used in DriveSynch installations In case of a multiple winding motor a dU dt filter may not be required Vacon DriveSynch works in both open loop and closed loop motor control modes With closed loop motor control the encoder feedback needs to be wired only to the master drive In case redundancy is required it may be necessary to wire the encoder feedback also to an alternative master using double encoder option board OPTA7 as a repeater System bus communication
19. PE Earth Consumer i Figure 48 TN S network 8 1 4 TN C NETWORK A combined PEN conductor fulfils the functions of both a PE and an N conductor This is rarely used This system is not permitted for conductors of less than 10 mm or for portable equipment The TN C system requires an effective equipotential environment within the installation with dispersed earth electrodes spaced as regularly as possible since the PEN conductor is both the neutral con ductor and at the same time carries phase unbalance currents as well as 3rd order harmonic cur rents and their multiples Generator or transformer IN YN L1 7 L2 L3 PEN Earth Consumer Figure 49 TN C network Vacon Engineered Drives VACON 64 SUPPLY NETWORK AND POWER CABLES 8 1 5 TN C S NETWORK Part of the system uses a combined PEN conductor which is at some point split up into separate PE and N lines The combined PEN conductor typically occurs between the substation and the entry point into the building and separated in the service head In the UK this system is also known as protective multiple earthing PME because of the practice of connecting the combined neutral and earth conductor to real earth at many locations to reduce the risk of broken neutrals with a similar system in Australia being designated as multiple earthed neutral MEN Generator or transformer LEMON L1 LY YN L2 L3 N
20. 506 385 578 ayaa NXI 05205 F10 520 572 460 690 828 NXI 05905 F112 590 649 520 780 936 NXI_06505 F112 650 715 590 885 1062 NXI 07305 F NXI 08205 F NXI 09205 F NXI 10305 F NXL 1505 F NXI 13005 F NXI_1450 5 Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 23 4 2 5 AMBIENT CONDITIONS Any drive system has to handle different environmental stresses such as moisture or electrical dis turbances The squirrel cage motor is very compact and can be used in very hostile conditions The IP 54 degree of protection guarantees that it can work in a dusty environment and that it can bear sprinkling water from any direction The frequency converter usually has an IP 21 degree of protection This means that it is not possible to touch the live parts and that vertically dripping water will not cause any harm If a higher degree of protection is required it can be obtained for example by installing the drive inside a cabinet with the required degree of protection In such cases it is essential to ensure that the temperature in side the cabinet will remain within the allowed limits Air humidity and risk of condensation must be taken into account The humidity limit is 95 If the drive is placed outdoors it must be protected from condensation Cabinet heaters are not sufficient as the air must be dry not hot and humid Another important environmental feature is electromagnetic compatibility EMC It is very impor ta
21. DC sides Select the fuses in accordance with the instructions in the product man uals When paralleling you must pay attention to the sufficient short circuit capacity of the system Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 93 The derating of Non Regenerative Front End units connected in parallel is 5 of the DC power take this into account when dimensioning the front end capacity If you need to isolate an NFE unit from the AC and DC voltages while other Non Regenerative Front End units are connected in parallel you must use separate isolators in the AC input and DC output You can isolate the AC input using a compact circuit breaker an ordinary circuit breaker or a fuse switch Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position You can isolate the DC output using a fuse switch Both load isolation switch and safety isolation switch are suitable You can also connect an NFE unit to the mains even when the other NFE units connected in parallel are already connected to the DC bus and running 9 5 2 ACTIVE FRONT END Active Front End AFE is a bidirectional regenerative power converter for the front end of a com mon DC bus drive line up Protection class of all AFE modules is IP00 The Vacon NX Active Front End is used to transfer power between the AC input and intermediate DC circuit One of the major advantages of using Vacon NX Active Front End is the very low co
22. PE Earth Consumer Figure 50 TN C S network 8 1 6 CORNER GROUNDED NETWORK Corner grounded networks are met mainly in old installations in the US A corner grounded net work is a system in which one corner of the transformer s delta connected secondary is grounded The usage of this network has decreased and is rarely used in modern installations One of the rea sons for the decline is the popularity of delta wye transformers instead of delta delta transformers in power transmission systems Figure 51 Corner grounded network Vacon Engineered Drives SUPPLY NETWORK AND POWER CABLES VACON 65 Grounding of one phase usually denoted phase B stabilizes the voltages of the other phases A and C in regard to ground The phase to phase voltage in the system is the same as the phase to ground voltages of the ungrounded phases When operating in corner grounded system user should always ensure that the drive is suitable for use in the particular network as corner grounded networks have different voltage levels 8 2 POWER CABLING In power drive systems cables are used at the input to connect the power supply to the drive and at the output to connect the frequency converter to the motor The basic parameters for cable selection are voltage rating and the current the cable is required to carry Choosing correct voltage rating is straightforward especially for input cables as the re quired voltage strength is the supply volt
23. VDC 525 690 V AC 640 1100 VDC CH62 250 500 kW 200 450 kW CH64 700 1500 kW 560 1550 kW Vacon Engineered Drives VACON 114 CABINET INSTALLATION 10 3 4 CHASSIS 72 AND CHASSIS 74 Figure 87 CH72 and CH74 frequency converters The CH72 and CH74 frequency converters are available in both 6 and 12 pulse versions The CH74 6 pulse version contains three parallel rectifiers and thus they can be used to compile an 18 pulse solution too They need an external AC choke The CH72 brake chopper option is available in the 6 pulse version only The CH74 brake chopper option is available in both 6 and 12 pulse versions Table 33 Power ranges for CH72 and CH74 a 400 500 VAC 465 800 VDC 525 690 V AC 640 1100 VDC CH72 250 500 kW 200 450 kW CH74 700 1500 kW 560 1550 kW 10 3 5 2 X CHASSIS 64 AND 2 X CHASSIS 74 The 2 x CH64 and 2 x CH74 frequency converters each consist of one control unit and two power modules that are connected together using a star coupler board In case a brake chopper is used in the 2 x chassis 74 the intermediate DC circuits must be connect ed together because the brake chopper is not synchronised This guarantees the operation of the braking system For more details see the product manuals Table 34 Power ranges for 2xCH64 and 2xCH74 NEHX 400 500 VAC 465 800 VDC 525 690 V AC 640 1100 VDC 2 X CH64 1300 2700 kW 1250 2800 kW 2 X CH74 1300 2700 kW 1250 2800
24. ah 148 13 cComimissionifii a A s iet agente MEE 149 13 1 Typical commissioning process ssssssssssssssseeeeemeneenennner eene 149 13 141 Sate work practices iii 1 1 1 1 Re Wet RR t i ndun 149 13 1 2 Checking the installation and connections 149 13 14 37 Checking the setting S cmo talar 154 13 1 4 Gathering drive system and process specific 0313 0 0 0 154 131 5 Connecting 6010 81 ects ade cdi eels at is e E nies God 154 13 16 ocumerntallgfia dl sd ad 155 T5 Abbreviations arias 157 Vacon Engineered Drives INTRODUCTION TO THE ENGINEERED DRIVES MANUAL VACON 1 1 INTRODUCTION TO THE ENGINEERED DRIVES MRNURL In the engineered drives business it is essential that the sales organisation as well as the actual project team have sufficient access to the information that is needed to assure the drive system s optimal operation and high delivery quality The purpose of this document is to highlight the factors that must be taken into account when drive system contracts are negotiated drive system delivery is designed and the drive system is commis sioned Detailed information is contained in the user s manuals and other technical documentation This documentis written mainly for Vacon s sales personnel syst
25. any other items connected between the frequency converter and the motor In case a 360 earthing is not possible the distance between the peeling point of the cable shield and the earthing point must be as short as possible for example shorter than 3 4 cm in order to minimise the inductance in the earthing circuit So called pigtail earthing is not recommended due to high impedance Figure 106 Symmetrical cable e Use asymmetrical cable Most common cable type is 3core separate concentric earth low PE wire potential e Connect the motor and machine frame together using low hf impedance to prevent high voltage potential difference 12 2 3 2 Isolated bearings Bearing currents can also be prevented by lifting the breakdown voltage value of the bearings to a safe level to eliminate any EDM bursts from happening Usually this is carried out by using either isolated bearings end shield or possibly a bearing with ceramic balls Motor manufacturers offer various options for their products 12 2 3 3 Use of output filters As low cost filter especially for bearing currents you can use a so called common mode filter which is formed by ferrite rings installed around the phase conductors Other filters such as dU dt filter sine filter and AC choke that are used mainly to protect the mo tor s insulation also attenuate or diminish to some extent the risk of bearing currents However as they are usually constructed on three
26. charging circuit Need for disconnection and reconnection of inverters to a live DC bus defines if you need an isola tion switch or direct connection with fuses e fyou need to disconnect and reconnect an inverter that contains integrated pre charging to a live DC bus you can use a fuse switch e If you need to disconnect and reconnect an inverter that does not contain integrated pre charging you need a charging switch or an alternative pre charging method e fyou do not need to disconnect and reconnect the inverter to a live DC bus direct fuse con nection is sufficient 9 5 4 2 Inverter Pre charging switches Pre charging switch is used for connecting and disconnecting inverter modules from the live DC busbar The pre charging circuit needs also resistors and fuses Select the fuses for the pre charg ing circuit according to the pre charging currents in tables below The pre charging switches are available with different control voltages V1 means that control volt age for the coil is 110VAC and V2 that control voltage for the coil is 230VAC Vacon Engineered Drives VACON 102 NXP BASED DRIVE UNITS For connection instructions see the product manuals Pre charging switch type codes CHAR SWITCH INU FI9 FI10 V1 CHAR SWITCH INU FI9 FI10 V2 CHAR SWITCH INU FI12 V1 CHAR SWITCH INU FI12 V2 CHAR SWITCH INU FI13 V1 CHAR SWITCH INU FI13 V2 Charging resistor type codes CHAR RESIS INU 11R CHAR RESIS INU 20R C
27. decreases in relation to 1 n and maximum torque decreases in relation 1 n Motor s thermal time constant varies from minutes hours by size The loadability curve defines the load points of a motor at frequency converter duty where the temperature rise is the same as at nominal load with direct online supplied DOL motor Recommended margin between the maximum short time torque and theoretical breakdown torque is approximately 30 Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 19 300 Tmax THEM a eee 1 Continuous thermal loadability 2 Maximum short time torque 3 Theoretical breakdown torque 200 s s Forced ventilation 100 a m 70 40 1 2 n nN Figure 15 Loadability curve of a typical motor Choose the motor so that the required continuous torque is below the thermal loadability curve The short term required torque must also be below the maximum short time torque of the motor Cal culate the current in the extreme load points and assume that current is linear or at least not high er Jes T Nm 4 b 1 Continuous torque required by the load 2 Motors continuous torque capacity 5 3 Max short term torque required by the load 1 4 Motor s max short term torque n rpm Figure 16 Continuous and short term torque Vacon Engineered Drives VACON 20 DRIVE SYSTEM DIMENSIONING 4 2 3 2 Calculating of load current 50 f fn Compe
28. if ambient temperature is different from the reference temperature cables are installed in close proximity to each other e method of installation reduces cooling Calculate the current capacity J using the correction factor k and original load current Ip I Ik 8 7 2 AMBIENT TEMPERATURE The following table summarises the correction factors for different ambient temperatures present ed in the standards EN 60204 1 and IEC 60364 5 523 40 C is the default temperature for the standard EN 60204 1 and 25 C for the standard IEC 60364 5 523 Table 8 Correction factors for ambient temperatures EN 60204 1 IEC 60364 5 523 10 1 15 1 11 15 1 10 1 07 20 1 05 1 04 25 1 00 1 00 30 1 15 0 94 0 96 35 1 08 0 88 0 92 40 1 00 0 82 0 88 45 0 91 0 75 0 84 50 0 82 0 67 0 79 55 0 71 0 58 0 73 60 0 58 0 47 0 68 65 0 62 70 0 56 75 0 48 80 0 39 Vacon Engineered Drives VACON 68 SUPPLY NETWORK AND POWER CABLES 8 7 3 INSTALLATION METHOD Standards EN 60204 1 and IEC 60364 5 52 present tables with correction factors for various instal lation methods Select the standardised method that is most suitable compared with the actual in stallation The following table presents current ratings for copper and aluminium cables when the cables are installed on a tray The ratings of both standards EN 60204 1 and IEC 60364 5 523 are presented Insulation material is PVC tempe
29. interest to provide accurate and adequate information on the installation environment and local interfaces Vacon Engineered Drives VACON 4 PROCESS IS THE KEY Figure 2 Ambient conditions must be considered Environmental factors that must be considered include ambient temperature altitude of the instal lation premises air quality presence of for example dust and chemicals These are discussed in more detail in the corresponding chapters of this document Vacon Engineered Drives PROCESS IS THE KEY VACON 5 2 2 DRIVE SYSTEM CONFIGURATION Successful drive system implementation Is based on thorough planning and accurate dimensioning of the drive system The actual savings are generated during the years of use when the drive sys tem s dimensioning and configuration are optimal for the purpose The implementation of a com mon AC or DC bus drive system is often an engineering project that results in a project specific drive switchgear solution consisting of one or more drive line ups and in some cases also stand alone drive units Figure 3 Acommon DC bus line up Each customer has a unique process which means that each drive system is equally unique and must be designed in accordance with the requirements of the customer s process The purpose of this document is to point out the factors that you must consider when defining a drive system for a customer Vacon Engineered Drives VACON 6 PROCESS IS THE
30. kW Vacon Engineered Drives CABINET INSTALLATION VACON 115 10 4 AC CHOKES The input choke is needed as an essential component for motor control to protect the input and DC link components against abrupt changes of current and voltage as well as to function as a protec tion against harmonics Input chokes are included in the standard delivery of Vacon liquid cooled frequency converters not inverters However you can also order your frequency converter without the choke Figure 88 AC chokes Table 35 Input chokes for 6 pulse supply Converter types Converter teed Thermal Nominal Calculated loss 400 500VAC Choke type current inductance m A uH A B 0016 0022 0012 0023 CHKO023N6A0 1900 145 0031 0038 0031 0038 CHK0038N6A0 1100 170 0045 0061 0046 0062 CHK0062N6A0 62 700 210 0072 0087 0072 0087 CHK0087N6A0 87 480 250 0105 0140 0105 0140 CHKO145N6A0 145 290 380 0168 0261 0170 0261 CHK0261N6A0 261 139 187 460 0325 0385 0300 0385 0820 1180 CHKO400N6A0 400 90 126 610 1850 2340 Vacon Engineered Drives VACON 116 CABINET INSTALLATION Table 35 Input chokes for 6 pulse supply Converter types ConVeriertvn s Thermal Nominal Calculated loss 400 500VAC 690VACI Choke type current inductance m A uH A B 0416 0502 Dena 1300 1500 CHKO520N6A0 520 65 95 810 2
31. over optical bus is typically used with NXP drives for Load sharing be tween master and follower drives Since DriveSynch uses this optical bus for the PWM synchroni zation of the paralleled drives the master follower load sharing feature is not available with drives using DriveSynch Maximum switching frequency for drives using DriveSynch is 3 6 kHz NXP control card must be VB00661 or later Mains supply Optical bus Figure 54 NXP frequency converters are synchronized to control a low voltage high power mo tor Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 77 Mains supply Front End Supply Unit ee Optical bus Figure 55 NXI inverters are synchronized to control a low voltage high power motor in a com mon DC bus system Mains supply eee Optical bus Multiple winding motor Figure 56 Individual NXP frequency converters are synchronized to control a low voltage high power multiple winding motor Vacon Engineered Drives VACON 78 NXP BASED DRIVE UNITS Front End Supply Unit eee Optical bus Multiple winding motor Figure 57 NXI inverters are synchronized to control a low voltage high power multiple winding motor in a common DC bus system Use the DriveSynch with the following hardware and software components Standard frequency converter or inverter identical power ratings max 4 pieces DU dt filter for each frequency converter or inverter OPT D2 system bus CAN bus adapte
32. rules cee 66 8 7 2 Ambient temperature enne n 67 8 7 3 Installation method ee Lashes Deby ha dodi eet eec ed etae 68 8 7 4 Cables installed next to each other nnne 68 827 5 Parallelca bles vec e ecce tte donde sra cec ee 70 8 7 6 Requirement for 8 enne 71 Effectof BartrielleSus ie iioc 1 cete ioter teet lola titan eode el eese e edere die oriri eiue 71 NXP based drive Units 1 1 2 2 2 2 ER nO kh ada dida 73 The NXP CONTO LOL AAA AA AAA TA 73 DIME A ee ET 76 Vacon Engineered Drives VACON 3 9 2 1 Engineering 80185 nnne 79 9 2 2 Motor with isolated and multiple windings sss 79 9 2 3 System redundancy 0 60 79 9 9 FUN CtIONALSST SLY A A E 82 poo MES ppc EC
33. signals galvanically isolated as a group 2 analogue signals galvanically isolated separately Line voltage measurement lt Co Q o 3 m 3 a 3 o D 3 n eL j a lt o wn SLINN 38130 G3SU8 dXN NXP BASED DRIVE UNITS VACON 9 75 The following table is only an approximation The values presented in the table are valid under nor mal conditions with an optimal system configuration Table 15 Vacon drives based on the NXP platform Frequency resolution 0 01 Hz 0 01 Hz Torque resolution 0 1 of Ty motor 0 1 of Ty motor Speed accuracy 1096 of motor nominal slip 0 0196 static error of motor nominal speed Torque accuracy gt 5 static error of Ty motor for gt 3 static error of Ty motor for speed up to motor nominal speed up to motor nominal speed speed Above nominal speed 5 Speed range 1 25 e g 2 Hz for 50 Hz motor No limit from drive side Torque step rise time gt 5ms gt 5 ms Dynamic response 0 3 to 0 5 sec with Ty motor 0 1 to 0 2 sec with Ty motor Field weakening set point 8 Hz 320 Hz 8 Hz 320 Hz Field weakening area 300 300 of ny 300 300 of ny Notes Torque related data is dependent on drive dimensioning related to the motor The drive needs to be provided with accurate motor name plate data Open loop data is taken after the automatic identification run Closed loop performance is valid for an encoder with PPR 1024
34. start stop commands to more complicated PID control commands You must find out what the con trol needs are to be able to select the software application If the application you have does not sup port the required control functions you can change it to a more suitable one quite easily Even if the software application supports certain controls the fieldbus profile may limit the com munication as there are normally exact definitions of what data may be transmitted In some cases when the software application is suitable for the purpose but fieldbus profile limits the communi cation you may be able to use a ByPass mode The use of ByPass mode is possible with certain spe cialised applications only ByPass makes the application more flexible and allows you to use the drive in more complex ways as there are no limits to what data is transmitted Vacon Engineered Drives VACON 14 DRIVE SYSTEMS Most fieldbus systems have a configurable communication speed You need to find out what the re quired communication speed is If the drive controls for example the liquid level of a huge tank the required communication speed is quite low If the drive controls a process that requires quick re sponse time for example in milliseconds the communication speed must be very high Communi cation speed has an effect on the installation too For example the faster communication speed required the shorter cable length is allowed 3 4 3 FIELDBUS IN
35. system applications 3 3 1 rr 12 1 5 ol cele e tdi end 13 Bad Fieldbus cormiltcatlolissei s cde ode to eene nennen 13 Data transmission capacity 3 4 2 ai 14 co weldbus installababi iet 3 43 15 Drive system dimensioning Process requirements and importance of diMensiONiNQ ccccccooocccccnncnonccnncnnnnncnnnnnannnos 15 ttrt AnE Ettn EEEE Erret E Enrere EEEa 16 Main Check the supply voltage and frequenCyY ocooocccccncinonccnncncnnnoncnnnnnnnnannnnnnnnonannnnnnos 16 4 2 1 Define the required load data 16 4 2 2 Select the O 0000 separ ea ob easet a aaa 18 424 enn 21 Select Vacon frequency CONVerte TP 4 2 4 Ambient condition ca A eE E a is 23 420 24 Dimensioning of inverter unit for drive systems Type of front end it fete cg E a ce o ERR ER NER 24 25
36. y used as Follower same setting as in same setting as in no meaning the Master the Master If used as No meaning inter nally handled Rec ommended to use same setting as in the Master Magnetizing current needed only for closed loop motor con trol Motor s nominal magnetizing cur rent Number of drives in parallel using Vacon Drive Synch Motor s nominal magnetizing cur rent Number of drives in parallel using Vacon Drive Synch Motor s nominal magnetizing cur rent Number of drives in parallel using Vacon Drive Synch Motor s nominal magnetizing cur rent Number of drives in parallel using Vacon Drive Synch Switching fre Max 3 6 KHz Same as in the Same as in the Same as in the winding motor name plate name plate quency Master Master Master Modulator tvoe software Same as in the Same as in the Same as in the yp i Master Master Master Follower Phase shift single 0 degrees 0 0 0 winding motor Follower Phase shiitImultipie Odegr es As per motor s As per motor s As per motor s name plate Vacon Engineered Drives VACON 82 NXP BASED DRIVE UNITS 9 3 FUNCTIONAL SAFETY Machinery must be safe to operate It is the responsibility of the machine builder to try to eliminate all risks by careful and efficient design However there is no such thing as totally risk free machin ery Functional safety refers to deali
37. 1 is the stray capacitance from the motor s windings to the rotor circuit motor shaft and C2 is from rotor circuit to the motor s frame Voltage over the motor s bearings is the same as over the capacitor C2 If this voltage U bearing in the figure exceeds the breakdown voltage of the bearing s lubricant film a small EDM current takes place inside the bearing Usually the values of C1 and C2 are very small and thus the resulting energy of the EDM current is also very small For this reason this type of bearing current usually does not cause premature dam age to the bearings Windings C1 D Mut su U bearing C2 Motor frame Figure 103 Capacitive voltage sharing 12 2 2 2 Circulating currents Asymmetrical leakage current in the motor s frame induces voltage on the motor s shaft If the volt age is high enough a current loop is formed through bearings This is a problem with big motors typically gt 110kW When the frequency converter is modulating motor s supply voltage at the moment when the semi conductors are switching on or of generating rising or falling edge of voltage the stator windings potential changes causing asymmetrical capacitive currents inside the motor These leakage cur rents induce a voltage U in the rotor circuit between the ends of the motor s shaft If this voltage exceeds the breakdown voltage of the bearings EDM takes place The amplitude of the induced vo
38. 3 3 1 TYPICAL AC BUS SYSTEM APPLICATIONS A common AC bus drive system is a relevant choice for a process where you need a set of drives that are operated separately independent of each others with no need for transferring power be tween the drives or back to the mains network Typical applications for a common AC bus drive sys tem include high power pump stations or locations where multiple fans are controlled by frequency converters A common AC bus system consists of separate frequency converters that are connected to a com mon AC bus which is fed from a single mains connection Vacon Engineered Drives VACON 12 DRIVE SYSTEMS 3 4 DRIVE CONTROL There are three ways to operate a drive or a drive system manually using the panel e using 0 e through fieldbus Operating of a drive using the drive s own keypad Is possible but rarely feasible In case the control need is simple start stop commands and there is easy access to the drive it may be an option Often even in cases where simple start stop commands are enough it still makes sense to use a separate switch with an I O connection to the drive A typical example is lowering and lifting the an chor of a ship where it is good to have a large ON OFF switch on the deck of the ship while the ac tual drive that controls the operation may be located in a more protected environment In complex industrial environments where a drive line up controls complicated production
39. 700 3100 0590 0650 0590 0650 1640 1700 1900 CHK0650N6AO0 650 51 71 890 0730 0750 CHKO750N6A0 750 45 61 970 2060 0820 2300 CHK0820N6A0 820 39 53 1020 0920 1030 CHK1030N6A0 1030 30 41 1170 1150 CHK1150N6A0 1150 26 36 1420 2470 2950 CHK0520N6A0 520 65 95 810 3710 CHKO650N6A0 650 51 71 890 4140 CHK0750N6AO0 750 45 61 970 NOTE Converter types written in italics require three chokes per unit Table 36 Input chokes for 12 pulse supply Convertertypes Converter Choke types Thermal Nominal Calculated 400 500VAC types 2 chokes current inductance loss W 690VAC needed A uH A B 0460 0520 0325 0502 CHKO261N6A0 261 139 187 460 0590 0730 0590 0750 CHKO4OON6A0 400 90 120 610 0820 1030 09920 1030 cuxos20meao 520 65 95 810 1850 1150 2300 1180 1300 ciK0650N amp AO0 650 51 71 890 2120 2340 2470 1370 1370 ae ee CHKO750N6A0 750 45 61 970 1640 1500 CHKO820N 6A0 820 39 53 1020 3100 2060 1700 1900 CHK1030N6A0 1030 30 41 1170 3710 4140 CHK1150N6A0 1150 26 36 NA NOTE Converter types written in italics require two chokes per unit in total 4 Vacon Engineered Drives CABINET INSTALLATION VACON 117 10 5 LIFTING THE POWER MODULE The power module of an air cooled drive unit weighs typically over 100 kg which means that you need a specific lifting device for lifting and moving it to the place nee
40. 705 eX eed 0 96 1 0 97 The DC power of the rectifier should exceed the calculated value If accurate efficiency values are not available you can calculate the required DC power using the following formula ES 0 9 If more than one inverter is connected to the same DC bus the total DC power requirement is the sum of the required power of the inverters You must dimension the rectifier so that it can handle that power Pac Pena X S If the rectifiers are connected in parallel to the same AC supply the total rectifier DC power is the sum of the DC power of the rectifiers To get the total DC power the sum has to be derated by 5 If the system has inverters which are used for motoring purposes and other inverters which are used for regenerating purposes then the required DC power can be calculated by using the follow ing formula Pro MP NE x 0 9 motor gen 5 Where Ppc the DC power needed from the rectifier Pshaft the motoring power needed 1 motor the regenerative power needed Vacon Engineered Drives VACON 28 DRIVE SYSTEM DIMENSIONING 4 6 DERATING DUE TO HIGH AMBIENT TEMPERATURE The current rating of an air cooled Vacon NXP drive unit is valid for ambient temperatures up to 40 C If the drive unit is to be used in higher ambient temperatures its current rating must be sub jected to derating in order to keep the thermal load of the main components below the specified level The derating coeffi
41. C Rr TITLE T 82 9 3 2 Machine design is the starting point 82 9 3 3 The safety functions defined for drives 83 9 3 4 Certified functional safety functions for Vacon NXP AC drives 84 9 30 Othermsatety fUNCtlon S22 ee feet tee teh dia 89 9 4 AC supplied IP00 frequency converter modules 90 9 5 0611506100515 modules disci eed ortu e tied eee pee esas 91 9 5 1 Non regenerative Front End eene 9 9 5 2 1 0000 93 oss MCT FUG E RS CE uberi Elbe cu td T 97 2 94 Inverter Unt O 101 9 5 5 Brake chopper unit amp brake resistors 105 9 6 Wiring diagram examples sssssssssssseseseeeeee eene nenne nennen nnne eres nennen 106 10 Cabinet mstallatlOIi iia no 109 10 1 Products included in an IPOD drive delivery 109 10 2 Air cooled NXP IPOO module configurations 110 1021 Frames 10 and Ii see dicas tee a Ai 110 10122 Frame AZ saut oe eat Ml ante ae Na Saeed lur erae hres 110 10 23 Frames and IA
42. CS VACON 43 6 HARMONICS Power systems are designed for 50 60 Hz operation based on the assumption that all loads are lin ear and thus all currents are beautiful sine waves In reality many of today s devices are nonlinear they have input currents that are far from sinusoidal they contain harmonics Harmonic currents are multiples of the basic frequency i e at 100 150 200 Hz f t Y A sin nat 0 Typical sources of harmonic currents include all devices containing switching power supplies or rectifiers i e TVs computers copiers etc A strong source of harmonics is fluorescent lighting either with electronic ballasts switch mode power supply or with conventional ballasts In the in dustry the main sources are power electronics AC and DC drives arc furnaces etc For normal rectifiers the amplitude of the harmonic decreases with increasing frequency Theo retically for a square wave l1 n the amplitude of the n th harmonic fundamental current divided by the number n of the harmonic Power electronics generate only odd harmonics even harmonics are excluded as long as the pos itive and negative halves of the current cycle are identical In three phase systems only harmonics with the order v k p 1 exist for a six pulse system these are the 5th 7th 11th 13th etc v multiple of basic frequency e k 1 2 3 e p pulse number of the rectifier bridge 6 12 18 etc In single phase sys
43. Drives CONTACTORS BREAKERS AND FUSES VACON 57 7 2 BREAKERS Several different types of circuit breakers can be used in the main power circuit and the auxiliary circuit of a frequency converter In drive systems the most common types are air circuit breakers ACB and moulded case circuit breakers MCCB In addition there are vacuum circuit breakers VCB and miniature circuit breakers MCB Schneider Schneider C60N C60N c6 1 C4 1 230 400V 230 400V 6000 16000 18 3 3j 24309 2 24308 2 Electric Figure 44 A moulded case circuit breaker and a single pole MCB 7 2 1 AIR CIRCUIT BREAKERS Air circuit breakers can break high voltages and currents typically up to 6 000 A Typical applica tion for an air circuit breaker is the main breaker of a switchgear because it has high short circuit breaking capacity The dimensioning is based on the capacity of the busbars and thus the power of the whole switchgear When an ACB is used with a frequency converter the drive system has to in clude a device that quickly cuts each frequency converter s power off in case of a short circuit Usu ally an ultrafast fuse is used for that purpose since an ACB is not fast enough An ACB can be equipped with several types of electronic relays which are used for selecting the breaking curve Also spring loading motor opening closing and under voltage coils are used when ACB opening and closing must be controlled electrically Opening an ACB
44. EE E RI E Re Repeated dade d 41 Harmon 6 12 2 tamed ened 1212 2 2 2 A Esa aie rea ed US 43 Effects of harmonics on MoO S e a a A EEE AEEA AONA ETRE 45 Standards E T RR EA Mein EAT M MdL ee ad 46 5 21 Prod uctstandards eui fons 1 2 12 01 1212 A a nete 46 6 2 2 System standard IEEE 3519 1992 0 0000 46 Reducing Harmonics iu ad eel a 49 O ll tach A th te eds ODE 49 6 3 2 Tuhnedfilteresii AN 49 63 3 ACUM Front E dos tee ettet dee te tenetur tee ducted ete LEE 50 6 3 4 Multipulse 110195 nen 50 5 3 57 E 1 E 1 101 10 1 0 1 1 0 te Certe eee EA AE AE ENEA 52 623 6 te eus 53 Contactors breakers and f ses eri 55 Contatori dl de cel c Pesos 55 7 1 1 DIMENSIONING nne 56 7 1 2 Auxiliary contacts eterne nnne trii ere near dris eene arare erede nnn 56 RA
45. EEDBACK RELAY Oz Oct E lt Ou g a o x9 x15 25 26 21 22 23 Figure 74 FI9 FI10 Basic wiring diagram with charging Vacon Engineered Drives VACON 104 NXP BASED DRIVE UNITS 9 5 4 3 INU unit s type code CS S 0 Option boards each slot is represented by two characters where A basic Y O board B expander 1 0 board C fieldbus board D special board Hardware modifications Module type S Boards S Direct connection standard boards FR4 8 V Direct connection varnished boards FR 8 F Fiber connection standard boards G Fiber connection varnished boards Sz Standard air cooled drive A Standard air cooled power unit transformer supply for main fan U Standard air cooled power unit external supply for main fan C INU with integrated charging circuit l INU no charging circuit N Standard 6 pulse no chokes S Standard 6 pulse connection with chokes 2 AFE madule 5 AFE module LCL filter 3 FFE module 6 FFE module AC choke 8 BCU Brake chopper unit 0 NA no brake chopper EMC emission level T fulfils standard EN61800 3 for IT networks Enclosure class 2 1P21 FR4 7 0 IP00 FRB FI9 14 Control keypad standard alpha numeric B na local control keypad F dummy keypad G graphic display Nominal supply voltage 3 phasel 5 380 500Vac 455 800V dc 6 525 690Vac 640 1100Vdc Nominal current low overload 0004 4A 0520 520A etc
46. HAR RESIS INU 35R CHAR RESIS INU 47R Table 28 Pre charging components for 380 500VAC inverter units Charging Peak OEVA Resistor Resistance Charging current current time s FI9 CHAR SWITCH INU FI9 FI10 CHAR RESIS INU 35R 35ohm 0 558 3 9 7 7 FI10 CHAR SWITCH INU FI9 FI10 CHAR RESIS INU 35R 35ohm 1 115 3 9 7 7 FI12 CHAR SWITCH INU FI12 2x CHAR RESIS INU 35R 35ohm 1 115 3 9 7 7 FI13 CHAR SWITCH INU FI13 CHAR RESIS INU 11R 11ohm 1 052 12 4 24 5 FI14 CHAR SWITCH INU FI13 2x CHAR RESIS INU 11R 11ohm 1 052 12 4 24 5 The resistor type code refers to two resistors Thus a delivery of 2 x CHAR RESIS INU 35R contains 4 resis tors Table 29 Pre charging components for 525 690VAC inverter units Charging Peak OEVA Resistor Resistance time s FI9 CHAR SWITCH INU FI9 FI10 CHAR RESIS INU 47R 47ohm 0 565 5 0 9 9 FI10 CHAR SWITCH INU FI9 FI10 CHAR RESIS INU 47R 47ohm 1 130 50 99 FI12 CHAR SWITCH INU FI12 2 x CHAR RESIS INU 47R 47ohm 1 130 50 99 FI13 CHAR SWITCH INU FI13 CHAR RESIS INU 20R 20ohm 1 442 11 7 23 3 FI14 CHAR SWITCH INU FI13 2x CHAR RESIS INU 20R 20ohm 1 442 11 7 23 3 The resistor type code refers to two resistors Thus a delivery of 2 x CHAR RESIS INU 35R contains 4 resis tors Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 103 cgo CONTROL lt CHARGING CHARGING zl F
47. I9 13 Control keypad A standard alpha numeric Nominal supply voltage 5 380 500VAC 465 800VDC 6 25 690VAC 640 1100VDC Nominal current low overload 0261 261A 1030 10304 etc Module type A AFE Active Front End Product generation Table 22 AFE current and power ratings supply voltages 380 500 VAC Low overload AC current DC Power continuous 500V mains ILcont LA 400V mains P kW PIkW NXA 0261 5 176 220 Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 95 Table 22 AFE current and power ratings supply voltages 380 500 VAC Low overload A 500V mains a prey mams P EKW PIkW 388 NXA 0460 5 FI11 460 310 NXA 13005 FI13 1300 876 1095 Table 23 AFE current and power ratings supply voltages 525 690 VAC Low overload AC Unit DC power continuous current NXA_0170 6 FI9 170 198 NXA 0325 6 F110 325 378 NXA_1030 6 F113 1030 1199 9 5 2 2 Pre Charging circuit An Active Front End unit requires an external pre charging circuit The purpose of the pre charging unit is to charge the capacitance in the intermediate circuit to a voltage level sufficient for connect ing the Active Front End unit to the mains The charging time depends on the capacitance of the in termediate circuit and the resistance of the charging resistors Technical specifications of Vacon s standard pre charging circu
48. IL S E IE H 328H 723 0003 PN In order to exclude any external influence on the safety circuit the enclosure class of the control unit where the OPT AF board is installed must be at least IP54 when the safety functions STO or SS1 are used For the control unit of a frequency converter using only the Motor Thermistor Over temperature protection function there are no specific IP class requirements Choose the correct IP class for the frequency converter control box or final cabinet assembly in ac cordance with the guidelines below to comply with the requirements Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 85 Table 18 IP class requirements for the OPT AF board IP class requirements for the IP class requirements for the ATEX FC s IP class Safe Torque Off Thermistor IP54 cabinet IP00 or No additional IP class requirements IP54 control box IP54 cabinet IP21 or No additional IP class requirements IP54 control box IP54 Mo additional No additional IP class requirements IP class requirements 9 3 4 1 Safe Torque Off STO STO is a hardware based Safe Torque Off safety function to prevent the drive from generating torque on the motor shaft The STO safety function has been designed for use in accordance with the fol lowing standards EN 61800 5 2 Safe Torque Off STO SIL2 EN ISO 13849 1 2006 PL d Category 3 EN 62061 2005 SILCL2 IEC 61508 2000 SIL2 EN 954 1
49. KEY Vacon Engineered Drives DRIVE SYSTEMS VACON 9 7 3 DRIVE SYSTEMS 3 1 SINGLE DRIVES A single drive usually refers to a complete 6 or 12 pulse frequency converter Single drives include compact wall mountable drives cabinet drives and IP00 drive modules that need cabinet installa tion A frequency converter mechanically consists of a power unit control unit and possibly one or more chokes All Vacon s frequency converters are delivered with chokes AC and DC chokes carry out several functions in Vacon s frequency converters An input AC choke is needed as an essential component for motor control to protect the input and DC link compo nents against abrupt changes of current and voltage as well as to function as a protection against harmonics DC choke covers the same functions except for the protection of input and DC link com ponents The power unit contains diodes for rectifying the input voltage capacitors and IGBT inverter which produces a symmetrical 3 phase PWM modulated AC voltage to the motor The control unit contains a microprocessor with firmware and application software The micropro cessor controls the motor basing on the information it receives through measurements parameter settings control I O and control keypad Control panel is a link between the user and the frequency converter It is used for setting parameters reading status data and giving control commands Control panel is detachable and can be oper
50. Moment of inertia J kg m Shaft power Pm kW Gear ratio i Angular velocity o rad s Angular acceleration a rad s Rotational speed n rpm Flow Q m s Speed V m s Pressure P Pa 4 8 2 MECHANICAL THEORY FORCE Unit of force is kg m s At constant speed the force F mx gx sina uxcosa Acceleration force is F mxa F mxg FR p x Fix cos a H friction coefficient Figure 22 Force Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 9 31 4 8 3 MECHANICAL THEORY TORQUE Unit of torque is Nm Constant speed T PFxr Acceleration angular velocity rad s a Angular acceleration rad s 2 J Inertia kg m T Jxa T2 4 29 dt Figure 23 Torque 4 8 4 MECHANICAL THEORY INERTIA Mass and inertia have a damping effect on acceleration Unit of inertia is kg m7 Inertia of a solid roll MxR Solid roll p J Inertia of an empty cylinder _Mx R R 2 J Cylinder Figure 24 Inertia Vacon Engineered Drives VACON 32 DRIVE SYSTEM DIMENSIONING 4 8 5 MECHANICAL THEORY POWER AT CONSTANT SPEED Power is the work obtained by the force over a certain length per unit of time Work Rotational work W Fxs W 09 Power Rotational power P Fxv P Tx0 4 8 6 MECHANICAL THEORY ACCELERATION Acceleration torque is the extra torque needed to accelerate from speed 0 to Nmax at a given accel eration time t 7 Jx 9 70
51. NIG OND Arc WWO NIG ZNIO INIG GNO 82 viv OGArz 7 od 0 SNINOLINON HOLOVINOS NIVIA Add Ads DGAPT TVNH31X3 TCINIV b Viv Jao 1 E N OVAOPZ Wiring diagram for a control unit Figure 79 Vacon Engineered Drives CABINET INSTALLATION VACON 109 10 CABINET INSTALLATION Drive modules of protection class IP00 must always be installed in an installation cabinet or enclo sure The actual protection class of the entire drive system can be adjusted by selecting an appro priate installation cabinet type The enclosure must provide sufficient shielding for contact of the live parts IP2x The switchgear design must allow enough space for all connection cables and auxiliary devices for example ferrites There must also be room for making the cable connections Module installation within the switchgear must allow service operations such as changing the fans and external fuses as well as checking and re tightening of electrical connection points The switchgear design installation and mounting must comply with local laws and regulations In addition you need to find out the requirements that the installation premises set to the switchgear configuration These requirements include ambient conditions and the size of the actual installation space The cooling system as well as the busbars and cables need to be dimensioned in accordance with the worst case scenario of continuous temperature and load When choosi
52. NODUA NOILIUTIULSNI L3NIGU lt m o o 5 m 5 a 5 o o F o a U a z D v 10 9 4 DIMENSIONS AND LAYOUT OF FR10 AND FR11 FREQUENCY CONVERTERS 1000 9 1200 5 E 1 TULLIA LULA FR10 has one external choke FR11 can have one or two external chokes Choke is positioned on top of the frequency converter where it is cooled by the airflow coming from the frequency converter s cooling fan DU dt filter is in these installations in an auxiliary cabinet If the auxiliary cabinet s protection class is IP23 there is no need for a separate cooling system to cool the filter If the cabinet s protection class is higher than IP21 a fan is needed to cool the filter For cooling switch fuse and cabling see chapter Dimensions and layout of FRA FR5 and FR frequency converters on page 123 SZT e 103 NOILIUTIULSNI L3NIGU lt m o o 5 m 5 a 5 o o m o U a z D v 10 5 DIMENSIONS AND LAYOUT OF FR12 FREQUENCY CONVERTER 1600 FR12 has always two chokes Chokes are po sitioned on top of the frequency converter where they are cooled by the airflow coming from the frequency converter s cooling fan DU dt filter is in these installations in an auxiliary cabinet If the auxiliary cabinet s protection class is IP23 there is no need for a separate cooling system to cool the filter If the cabinet s protection class is higher than IP23 a fan is needed to cool t
53. Ory Nm T Jx TNn Nm t 3 60xt Acceleration power at Nmax P T x 0 i Jxn y a a 7 P Jx W P m kW E t 91189xt Vacon Engineered Drives EMC PRINCIPLES AND PRACTICES VACON 33 5 EMC PRINCIPLES AND PRACTICES Electromagnetic compatibility EMC is an important part of drive system design The high frequen cy components of frequency converter s output voltage and current due to the high switching speeds can cause significant problems for example control system malfunction and communica tion errors if EMC is not taken care of A device can be described as electromagnetically compatible if its emissions are at an acceptable level and its immunity to interference is appropriate Electromagnetic compatibility EMC in cludes both immunity to external interference and low emitted interference Level of required immunity Tr Margin uud c eee Level of allowed emissions Figure 25 Acceptable EMC level Electromagnetic immunity to interference defines the operational reliability of the device in its in tended environment It describes how the device behaves under the influence of electromagnetic interferences coming from an external source The electromagnetic emissions of a device define its capability to interfere with other electric cir cuits devices and systems located in the same environment Any electric device can simultaneously be a source and a target of electromagnetic interference Wit
54. P BASED DRIVE UNITS VACON 83 Probability of hazardous failure per hour EN ISO 13849 1 10 10 107 10 v y y 1 NW GC E AE correspondence EN 61508 Low contribution High contribution to risk reduction to risk reduction Figure 58 Comparison of the PL and SIL approaches In addition to the required SIL PL level it is important to recognise the type of the risk and thus the required safety function To be able to define this it is necessary to understand how the machine behaves what sort of a process it is used in and what is the safest way for example to stop the machine if a risk has actualised 9 3 3 THE SAFETY FUNCTIONS DEFINED FOR DRIVES The product standard EN IEC 61800 5 2 defines the most common functionality needed for fre quency converters The safety functions and their commonly used abbreviations are listed in the ta ble below Table 17 Safety functions as defined in the EN IEC 61800 5 2 Safety function Safe Torque Off STO Safe Stop 1 SS1 Safe Stop 2 S92 Safe Operating Stop SOS Safely monitored Acceleration Deceleration SMA SMD Safely limited Acceleration SLA Safe Acceleration Range SAR Safely limited Speed SLS Safe Speed Range SSR Safe Speed Monitor SSM Safe Maximum Speed sms Safely limited Increment SLI Safe Direction SDI Safely limited Position SLP Safe Position Switches sps Safe Brake Control SBC Vacon Engineered Drives
55. STALLATION It is very important that the fieldbus system is installed in accordance with the instructions given in the manuals With fieldbus communication even 9796 of the problems are caused by faulty instal lation The bus does not work correctly and communication fails Selecting of cable type earthing place of cables peeling and connecting must be done exactly as instructed in the manual Ignoring the instructions may cause expensive repair work if you have the wrong cable type and need to re place several hundred meters of cable Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 15 4 DRIVE SYSTEM DIMENSIONING First decision to make when starting to plan a drive system is whether it makes sense to build up a common DC bus system or use AC drives either separately or with a common AC supply You also need to decide the drive system s cooling whether it should be air cooled or water cooled The following dimensioning guidelines are applicable for any drive system Separate drive units can always be dimensioned one by one but in a common DC bus system the dimensioning is more complicated as the process that the drive system should control has a considerable effect on the dimensioning In a common DC system the total Load of the motors is the main defining factor in the front end dimensioning 4 1 PROCESS REQUIREMENTS AND IMPORTANCE OF DIMENSIONING Processes can be roughly divided into groups as follows e Basic sh
56. TIONING You must plan the enclosure layout as well as internal and external cabling so that the power con trol and signal cables are spatially separated In order to be efficient a shield must have good conductivity continuity no gaps and grounding Proper grounding of signal cables is often the key to EMC All external cables connected to the en closure except the supply cable must be shielded Signal cables should be shielded and have both ends 360 grounded In addition signal cables should not run close to power cables and never in parallel If they have to cross the angle should be 90 degrees For distances between the cables see the figure below Vacon Engineered Drives VACON 42 EMC PRINCIPLES AND PRACTICES Vacon AC drive Supply cable Motor cable Figure 33 Cable positioning and distances Connect the shield of I O cables to ground at the drive end If necessary ground the non drive end via a 10nF capacitor Ground the fieldbus cable shield at each node The end of the grounded shield so called pigtail must be kept as short as possible In order to reduce current in the shield long cables can have multiple grounding or an additional conductor may be used If signal cable s isolation level is less than 230 VAC you must not place the cables on the same cable tray with power cable or any other cables For more details on filters see the Filter manual Vacon Engineered Drives HARMONI
57. Table 19 Air cooled NXP IPOO frequency converter product range 6 pulse 160 1200 kW 200 2000 kW 12 pulse 160 1200 kW 200 2000 kW Table 20 Liquid cooled NXP frequency converter product range Vacon NXP liquid cooled 380 500 VAC 525 690 VAC frequency converters 6 pulse 7 9 5150 kW 110 5300 kW 12 pulse 250 5150kW 200 5300 kW With the Drive Synch control concept it is possible to increase the total power of the drive system by paralleling up to four drive modules that have identical power ratings See chapter Drive Synch on page 76 5 AON 0 SSF 2_2 3 Option boards each slot is represented by two characters where A basic I O board B expander 1 0 board C fieldbus board D special board Hardware modifications Supply Mounting Boards SSF pulse connection air cooled standard board TSF 12 pulse connection air cooled standard board Brake chopper 0 No brake chopper 12 With integrated brake chopper EMC emission level N No EMC emission protection requires cabinet assembly to comply with level L T fulfils standard EN61800 3 for IT networks Enclosure class 0 IP00 module only Control keypad A standard alpha numeric Nominal mains voltage 3 phase 5 380 500Vac 6 525 690Vac Nominal current low overload e g 1300 1300A etc Product range NXP haq rc26 T Figure 66 NXP IPOO type code key Vacon Engineered Drive
58. a cable which includes all three phases it will have no effect on the differen tial mode current but it will increase the impedance of common mode currents This is because the differential currents by definition sum to zero and therefore there is no net magnetic field The common mode currents produce a net magnetic flux and this flux is concentrated in the bulk of the ferrite resulting in an increased impedance for common mode currents only This is also why only phase conductors are slipped through the rings The PE Protective Earth con ductor must be separated All ferrites are conductive so it is important that cables passing through them are sufficiently well insulated A common mode filter does not provide any significant dU dt filtering A commo mode filter should be installed directly after the drive output before any other output filters Ferrite rings Metallic wall of cabinet Screen connected to earth through 360 connection Cable clamp Motor cables PE rail ud101 1k7 fh8 Figure 101 Ferrite rings Vacon Engineered Drives VACON 144 MOTOR CABLES AND OUTPUT FILTERS 12 2 BEARING CURRENTS The output voltage of a frequency converter has a high frequency common mode voltage compo nent In some cases this common mode voltage may cause bearing currents that can produce harmful effects on the motor bearings The resulting erosion of the bearing races and bearing balls causes rapid deteriorat
59. ad re quirements 4 2 1 CHECK THE SUPPLY VOLTAGE AND FREQUENCY Keep in mind that according to the IEC 60038 1 a typical network requirement for voltage variation is between 10 10 The corresponding frequency variation is 5 4 2 2 DEFINE THE REQUIRED LOAD DATA 4 2 2 1 Load types Load types vary greatly between different processes The figure below presents some typical load types and process examples Compressors cranes lifts conveyors Constant torque continuous web Constant power Winders Constant power torque Unwinders winders Square torque Pumps fans High starting torque demand Extruders mixers cement kilns Power mm mm mm Torque Figure 13 Load types Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 17 Table 1 Process data nmin Minimum continuous speed RPM Speed RPM at the end of the constant torque and at the starting point nbase of constant power nmax Maximum continuous motor speed RPM Base power kW motor s shaft power at the end of the continuous con P nbase stant torque This is also motor s shaft power at the starting point of continuous constant power Base torque Nm motor s continuous constant shaft torque Also T nbase motor s shaft torque at the starting point of the continuous constant power Overload 96 the relation of short time max torque to the base torque pi 100 no overload
60. aft turners Processes with high starting torque requirements Processes with accurate torque limiting requirements e High dynamics applications accurate speed and or torque control Typically the process requires mainly force torque or power Force is needed when there is linear movement like in conveyors cranes lifts and escalators Torque is needed in rotating machines and tools like winders extruders and tooling machines Power is needed in pumps fans wind mills and compressors The drive and the motor together must be able to fulfil the demands of the process If the drive is too small it cannot produce the required force torque or speed Overdimensioning of the drive system decreases the control accuracy of the drive and increases the costs of the frequency converter and the electrical room where the drive line up is installed also other items included in the drive system such as supply transformer and cabling circuit breaker switchgear motor cabling and the motor itself G gxm Figure 12 Example of physics behind a main hoist Vacon Engineered Drives VACON 16 DRIVE SYSTEM DIMENSIONING 4 2 MAIN STEPS FOR DIMENSIONING The system must be dimensioned in accordance with the steps described in the following chapters It is important that the system is dimensioned in a logical sequence The most important factors are the process where the drive system will be used electrical properties of the supply and lo
61. age The load current of the drive system defines the required current capacity Parameters affecting cross section dimensioning include e Conductor material e Insulation material e Installation method e Ambient temperature e Current harmonics e Voltage drop e Short circuit protection e Economic considerations In addition issues like EMC grounding required cable type and safety influence the final decision on the cable type 8 3 CONDUCTOR MATERIAL Materials used in cables are copper and aluminium The choice depends on cost and technical re quirements including dimension and weight requirements Technically copper is a more suitable material excluding weight aluminium is lighter The resis tivity of aluminium is nearly 1 6 times that of copper However aluminium is a considerably cheaper metal and thus often is the most cost efficient solution A few general statements regarding aluminium and copper e Fora fixed cross section copper has better conductivity but aluminium is lighter e Fora fixed price aluminium offers larger cross section and better conductivity e For round conductors that heat up to the same temperature copper has smaller cross sec tion taking up less space but aluminium is lighter and cheaper Usually copper is more favour able compared to aluminium when the cable is small and voltage is large When mounting aluminium cables you must take into account a phenomenon called cold flow C
62. ance with earthing impedances If the device controlled by the motor for example a fan has a conductive connection to the motor s shaft and the earthing impedance is smaller than the earthing impedance of the motor s frame there is a danger that the voltage over the bearing exceeds the breakdown voltage value and the leakage cur rents go through the bearing to the shaft and that way through the device to the earthing circuit In this case there is a risk of premature bearing damage There is also a risk that the leakage currents go through the device s bearing or bearings and they may get damaged as well L1 L2 ac L3 ac Figure 105 Shaft earth current Vacon Engineered Drives MOTOR CABLES AND OUTPUT FILTERS VACON 147 12 2 3 PREVENTIVE MEASURES 12 2 3 1 Cables and cabling In order to minimise the common mode voltage it is recommended to use a symmetrical cable with three 3 phase conductors and a separate shield as show in the figure below Symmetrical cable To minimise the high frequency impedance of the earthing chain the concentric shield must be connected to earth or to the frequency converter s frame or the motor s frame using so called 360 C earthing This 360 C earthing must be done all through the motor cable in other words at the motor end frequency converter end and at any possible safety switches connection boxes or
63. and control circuit The trip level of an MCB is usually not adjustable but fixed for each breaker Typical short circuit breaking capacity is up to 6kA The most important parameters include breaking voltage and current as well as nominal voltage and current The choice of an MCB depends on the load type and the MCB s trip characteristics The most com mon breaker types are Type B Type B is used for resistive Loads which do not cause large switching currents It is suitable for pro tection of a low power frequency converter Type C Type C covers also loads that are slightly inductive or capacitive and can have larger switching cur rents than type B It is also suitable for protection of low power frequency converter but its tripping time is more slow than that of type B Type C is the most common MCB used to protect auxiliary circuits Vacon Engineered Drives CONTACTORS BREAKERS AND FUSES VACON 59 7 3 FUSES Fuses protect electric equipment under overload and short circuit conditions providing a similar function as circuit breakers The main benefit of a fuse is that it is usually able to cut off current considerably faster and thus limit overcurrent and subsequent damage better than a circuit break er On the other hand you can reset a circuit breaker after it has tripped but a fuse is destroyed in the process and has to be replaced Figure 45 Bolt type fuses In correctly dimensioned frequency converter systems
64. ange supply voltages 525 690VAC air cooled Low overload AC DC Power current po Dedicated LCL filter s code ERE 6 170 ELLE LCL01706 A B ORO11T NXA 0325 6 FI10 325 378 LCL03256 A B ORO11T NXA 1030 6 FI13 1030 1499 LCL10306 A B ORO11T A DC fan without DC DC power supply B DC fan with integrated DC DC power supply Table 27 Dedicated LCL product range liquid cooled RCL 0385 6 0 385 x RCL 0520 6 0 520 X X RCL 0750 6 0 750 x x RCL 0920 6 0 920 x x RCL 1180 6 0 1180 x x RCL 1640 6 0 1640 x x RCL 2300 5 0 2300 x Vacon Engineered Drives VACON 100 NXP BASED DRIVE UNITS Figure 72 An LCL filter Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 101 9 5 4 INVERTER UNIT Inverter unit is a bidirectional DC fed power inverter for the supply and control of AC motors Pro tection class of air cooled inverter units up to FR 7 is IP21 or IP54 Bigger air cooled and all liquid cooled inverters are IP00 Driver 1 4 j O 0 VO VO vo Slot A Slot B Slot C Slot D Slot E 1 64_11 AAA A A AA ee A A A AA A AAA A AA A M M AA AA Figure 73 NXI block diagram 9 5 4 1 Fuses and pre charging Inverter units from FR4 to FR8 contain an integrated pre charging circuit Bigger units and all liquid cooled inverter units do not contain an integrated pre
65. ant to see that the air goes out from the lower part of the cabinet and does not heat up the de vices in the upper part of the cabinet See chapter Cooling Air cooled units on Cooling air cooled units on page 119 On the supply side there is a lockable switch fuse for protection of the inverter and for safe voltage separation If there is no dU dt filter the motor cables are connected directly to the frequency converter s output terminals If a dU dt is used the motor cables are connected either directly to the filter terminals or separate terminals The motor cables must be 360 grounded for elimination of EMC disturbance The motor and supply cables must be kept separate from the control cables to avoid disturbance in the control cables Auxiliary components and terminals and cable trays if they are used must be placed so that they do not get heated up and can be safely reached for measure ment purposes Different voltages wires cables and components must be sep arated due to safety reasons and to avoid disturbances FR4 FR8 inverters have integrated pre charging circuit 9827 e NO9UA NOILIUTIULSNI L3NIGU lt Co Q o 3 m 3 e 3 o D 3 o a c s lt o n 10 9 8 DIMENSIONS AND LAYOUT OF FRa FR9 AND FR10 INVERTER UNITS FR9 10 Inv unit FR8 FI9 and FI10 all require one full height cabinet With FI9 and FI10 the dU dt filter requires an additional cabinet For cooling switch fuse and cabli
66. ated externally and connected via a cable to the fre quency converter Instead of the control panel also a PC can be used to control the frequency con verter if connected through a similar cable A single drive is normally ready to use without installation of any auxiliary devices Vacon s single drive product range covers all needs from compact low power drives to high performance drives used in industry 6 gt A gt W Figure 4 6 and 12 pulse single drives Vacon Engineered Drives VACON 8 DRIVE SYSTEMS 3 1 1 TYPICAL SINGLE DRIVE APPLICATIONS A stand alone drive is the simplest possible configuration for a frequency controlled motor The drive has its own supply and an output to the motor Frequency converter can be placed anywhere between the supply and the motor either in an electrical room or even close to the process Single drives can be used with simple open loop systems where the drive gets no feedback from the motor but also in complex industrial processes together with a common DC bus system Single drives are applicable for a variety of purposes such as pumps fans HVAC etc A single drive has always fixed specifications such as power output current and frame size Single drives are documented standard products which can be modified using standard options and option boards A single drive is a good solution for a process where you do n
67. by positive electrical pulse opening coil is not recommended as it is not failsafe In most applications it is even against the rules Using an undervoltage coil for opening is recommended 7 2 2 MOULDED CASE CIRCUIT BREAKERS Moulded case circuit breakers can break only lower voltages and currents typically up to 1000 A and are used in smaller applications Also the short circuit capacity may be a limiting factor if you think of using an MCCB as switchgear s main switch Typical applications include overload and short circuit protection of frequency converter or main switch of a compact size switchgear Some MCCB s operate fast and thus ultrafast fuses may not be needed if only one frequency converter is fed by the MCCB Vacon Engineered Drives VACON 58 CONTACTORS BREAKERS AND FUSES Similarly to an ACB also an MCCB can be equipped with a spring loading motor opening closing and undervoltage coils for electrical control of opening and closing Opening an MCCB by positive electrical pulse opening coil is not recommended as it is not failsafe In most applications it is even against the rules Using an undervoltage coil for opening is recommended 7 2 3 MINIATURE CIRCUIT BREAKERS Miniature circuit breakers MCBs can be used to protect low power electric circuits current rat ings up to 100 A In general the breakers can be used for overload and short circuit protection and mainly in low power main circuit and auxiliary
68. c I O cards OPT A lt OPT A1 OPT A2 OPT A3 OPT A4 OPT A5 OPT A7 2 enc input 1 enc output OPT A8 1 OPT A9 2 5 mm terminals OPT AE DO Divider Direction OPT AF EN954 1 cat 3 ATEX therm OPT AK 3 1 Sin Cos Marker OPT AN 6 2 2 Limited support 1 0 expander cards OPT B OPT B1 Selectable DI DO OPT B2 OPT B4 2 OPT B5 OPT B8 OPT B9 OPT BB Sin Cos EnDat OPT BC Encoder out Resolver simulation OPT BE EnDat SSl Fieldbus cards OPT C OPT C2 RS 485 Multiprotocol Modbus N2 OPT C3 Profibus DP OPT C4 LonWorks OPT C5 Profibus DP D9 type connector OPT C6 CANopen slave OPT C7 DeviceNet OPT C8 RS 485 Multiprotocol D9 type connector Modbus N2 OPT CG SELMA 2 protocol OPT CI Modbus TCP Ethernet OPT CJ BACNet RS485 OPT CP Profinet I O Ethernet OPT CQ Ethernet IP Ethernet Communication cards OPT D OPT D1 System Bus adapter 2 x fiber optic pairs OPT D2 System Bus adapter 1 x fiber optic pair amp CAN bus adapter galvanically decoupled OPT D3 RS232 adapter card galvanically decoupled used mainly for application engineering to connect another keypad OPT D6 CAN bus adapter galvanically decoupled NO9UA OPT D7 Allowed slots for the board are marked in blue 1 analogue
69. ccordance with the EN 61800 3 Table 4 EMC emission suppression in Vacon AC drives Type Compliance N None Complies with the industrial environment requirements of the generic 5 standard and also with the 1st environment C2 requirements Complies with the commercial environment requirements of the 9 generic standard and also with the 1st environment C1 requirements Designed for IT networks L Complies with the C3 and C4 requirements for the 2nd environment Drives of type H are usually suitable for all applications The C type is recommended for use in hospitals and laboratories etc External filters can be used to provide additional reduction of EMC emissions Residential area Hospital Optional C Optional C Commercial area Required H Required H Required H gt awe j aan gt LK f 2 i s si po pS nn minm gt Heavy industry Light industry Optional H Optional H Required L Required L Required when IT network T Figure 29 Environments and Vacon s EMC classes Vacon Engineered Drives EMC PRINCIPLES AND PRACTICES VACON 39 5 8 1 MOTOR CABLE AND GROUNDING The most basic guideline within installations is to optimise the physical separation between inter ference sources and potentially sensitive equipment In drive systems shielded cables are often the key to appropriate protection as motor cables are the main source of interference Groundi
70. ceceeeneceeeeeecesneeeeeeesesneeeeeeesesesaeeeesseseaeeeeeees 34 5 1 1 DIE RR RE RE ERR teed 34 mes 196 60110119 5 1 2 Standards ln europeos treat o tete Pte er d ne iet EE eR 34 ens 34 Standards outside europe nennen nemen nnn M A i ede bats d Ee au d itg 39 ERVIFORITIGBES tarini an e hace ka cll 35 l FirstenvironMment odisse ceri Scares topi e 35 Second envi ontfieb isse epa Aricent se dana tc 05 42 eene 35 0 06 61800 30000006 Four drive categories by EN 36 EN 61800 3 versus generic standards 5 5 1 36 an E A 55 2 VACON 2 5 6 5 7 5 8 7 2 7 3 8 2 8 3 8 4 8 5 8 6 8 7 8 8 9 1 9 2 Conducted emission levels A E EE A TEET E T 37 Elo LRA nR En e essen earn essa 37 Good engineering practices regarding 0 0 0 060 38 5 8 1 Motor cable and grounding 000000006 39 5 8 2 AN 1 da 1 151
71. cient is typically 1 5 1 C Maximum ambient temperature is 50 C For more detailed instructions regarding the derating of both air cooled and liquid cooled Vacon NXP drives see the relevant product manuals 4 7 DERATING DUE TO HIGH ALTITUDE In higher altitudes air is thinner Thin air has poor thermal capacity i e temperature rise per ab sorbed energy at fixed volume Thin air also has poor ability to withstand electric field breakdown voltage distance Full thermal performance of Vacon frequency converters has been designed for the altitude of up to 1000 m air cooled units and electric insulations have been designed for the altitude of up to 2000 m Vacon NX Vacon 100 and 1000 If you need to install Vacon s drives to a higher altitude follow the guidelines given in the following chapters The rules are based on user safety 4 7 1 THERMAL PERFORMANCE The power losses of a frequency converter are generally proportional to the output current This is why the thermal performance is given as a percentage of the rated full output current The full ther mal performance of Vacon s frequency converters is achieved at installation altitudes up to 1000 m When the installation altitude is above this limit the maximum load current must be decreased by 196 for each 100m Thus at the altitude of 2500 m the load current must be limited down to 85 of the rated output current 100 2500 m 1000 m 100 m x 1 85 The installa
72. d Drives VACON 4 11 2 Designing and dimensioning the cooling system for liquid cooled drives 138 11 2 1 How to select Vacon s HX heat exchanger type 138 11 2 2 Example of heat exchanger selection 139 MiS eei cl M E X p RR ce ee 140 12 Motor cables and output filters eesseeeeeeee 141 12 4 Output OS 141 TAT MOU IET ER A aar eaaa inni 141 1212 5106 TUO perenne A M E RED C URE en MER E EE 142 121 3 Common mode PHEBES cad dt 143 A AS ide tete 000000 144 12 2 1 What actually happens in the bearings 144 12 2 2 Three main categories of bearing currents en 144 T2 2 3 Preventive Measures alioli caret tained 147 12 3 MEIC OC A afar 148 12 3 1 Encoders that deliver incremental 0318 148 12 3 2 Encoders that deliver both incremental and absolute data ssss 148 12 3 3 Encoders that deliver only absolute data 148 123 4 installati M eee id pte Hotte cadat od p e
73. d at 250 V up to the altitude of 4866 m and e OPT BF can be used at 250 V up to the altitude of 3800 m and at 150 V above that Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 29 The relay output signals at standard I O boards and option boards when another relay circuit on the same board is connected to a low voltage circuit e g 24 Vdc can be used up to 150 V voltage up to the altitude of 4888 m with the following exceptions e OPT AC can be used at 150 V up to the altitude of 3000 m and at 100 V above that e OPT AF and OPT Bb can be used at 250 V up to the altitude of 2000 m and at 150 V above that High voltage digital inputs at option boards are specified for the range from 42 250 Vac at the al titude of 2000 m and can be used at the range of 42 150 Vacat the altitude of up to 4866 m with the following exception e on OPT B board if the relay output next to the HV input is connected to a low voltage circuit e g 24 Vdc the voltage at this input must be limited to 150 V up to the altitude of 2000 m and 100 V above that Thermistor inputs at option boards are specified for the nominal motor voltages up to 690 V and they can be used at the same voltage level and altitudes as specifies in the chapter Mains Voltage Vacon Engineered Drives VACON 30 DRIVE SYSTEM DIMENSIONING 4 8 APPENDIX 4 8 1 UNITS OF MEASURE Table 2 Units of measure Torque T Nm Force F N
74. de the required output power of the inverter by the effi ciency of the inverter e The DC power of the rectifier must exceed the calculated value e Calculate the required AC current You can calculate the DC power of the AFE based on the cont current you find in the manuals If you need to calculate the power for the _ current you can use the current ratio 7 cont Lu con T oon x L cont For Py min you must use the overloadability ratio E 1 1 x Eon OR Bats zi 1 5 x Pa min cont 4 5 2 EXAMPLES OF HOW TO CALCULATE THE DC POWER Motor s load is 270 kW with the speed of 1700 rpm and the load type is constant torque You need a 280 kW motor and an inverter The efficiency of the motor is 0 96 and that of the inverter is 0 98 If you need an output filter you musttake that into account too The rated DC powers of Vacon Front End Units can be found in the product manuals The required DC power can be calculated using the following formula 1 1 1 gt Z TI motor 7 filter 1 Nu Pro P shaft x Where Ppc the DC power needed from the rectifier Pshaft the motor shaft power needed Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 27 motor the efficiency of the motor filter the efficiency of the output filter if not used then 1 Tinu the efficiency of the inverter In the example no output filter is used thus the required DC power from the rectifier is P 50
75. ded The power module has lifting lugs at the top See the product manual for more detailed handling instructions Max 45 Figure 89 Lifting angle Table 37 Weight of air cooled drive units FR10 123 FR11 210 Fl 65 F110 100 F112 200 F113 302 Table 38 Dimensions of liquid cooled NXP drives consisting of one module C CH4 193 493 257 35 CH5 246 553 264 40 CH61 62 246 658 372 55 CH63 505 923 375 120 CH64 746 923 375 180 CH72 246 1076 372 90 CH74 746 1175 385 280 Mounting base of the drive unit is included in the dimensions of the above table but AC chokes are not Vacon Engineered Drives VACON 118 CABINET INSTALLATION 10 6 INSTALLING THE POWER MODULE The power module can be mounted in a vertical position on the back plane of a cubicle See the product manual for more detailed installation instructions AC choke Figure 90 Installation of the power module Table 39 Cabinet measurements Supporting bar Recommended cabinet 500 600 FR10 A 50mm FR11 709 A 20mm 800 FI9 239 A 50mm 400 FI10 239 A 50mm 400 FI12 478 A 50mm 600 FI13 708 A 50mm 800 Vacon Engineered Drives CABINET INSTALLATION VACON 119 10 7 COOLING AIR COOLED UNITS When planning the placement of the drive unit and auxiliary components to the sections of a drive line up you must carefully consider the v
76. dedicated LCL filter on the mains side Vacon s product range includes both air and liquid cooled LCL filters LCL FILTER 71 3e l AAAA aps 1 Figure 71 Main circuit of an LCL filter Vacon Engineered Drives VACON 98 NXP BASED DRIVE UNITS Vacon LCL filters for AFE Type code raductranqe E Current ES Voltage D Vorrio Reorerve L2 LCL caulina fan EN Manufacturer 2 a gt gt tol a 3 3 c c e IP clars a Stand Types available 388 gt gt E Manufacturer T Trafotek LCL cooling fan 1 DC fan Reserve Reserve Reserve Enclosure Class 0 IP00 Version Hardware A DC fan without DC DIC power supply B DC fan with integrated DC DC power supply Nominal Current 0460 4604 1030 10304 etc Product range LCL LCL filter for AFE Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 99 Table 25 Dedicated LCL filter product range supply voltage 380 500VAC air cooled Low overload 8 AC current DC Power continuous f Dedicated LCL filter s 400V mains 500V mains code Code Frame l1 cont A P kW P kW NXA 02615 FI9 261 176 220 LCL02615 A B 0111 NXA 0460 5 FI10 460 310 388 LCL04605 A B 0111 NXA 13005 FI13 1300 876 1095 LCL13005 A B BORO11T A DC fan without DC DC power supply B DC fan with integrated DC DC power supply Table 26 Dedicated LCL filter product r
77. direct on line motors The har monic voltages existing in the system might have significant influence on motor heating The fifth harmonic creates a counter rotating torque the seventh one rotating in the original direction The current drawn might be significant the situation for the motor is as if it was starting with a large slip all the time its impedance is low hence even a low voltage might create high currents In rare cases with high voltage distortion this effect has been known to overheat motors Vacon Engineered Drives VACON 46 HARMONICS 6 2 STANDARDS 6 2 1 PRODUCT STANDARDS IEC has written two standards for the allowed harmonic content of the input currents of products connected to public supplies supplies where anybody can connect anything e EC 61000 3 2 for currents gt 16 A per phase e EC 61000 3 12 for currents gt 16 A and gt 75 A per phase Typically the allowed values depend on the short circuit power of the transformer the smaller the transformer is the lower the allowed harmonics According to the IEC 61000 3 2 drives are considered to be professional equipment for which no limits apply NOTE No IEC standards exist for private industrial networks Table 4 Current emission limits for balanced three phase equipment under specified conditions Admissible individual Minimal R harmonic current I I 2 The relative values of even harmonics up to order 12 shall not exceed 16 n Even
78. e chopper unit nkw3 1 158 NXA AFE unit NXI inverter unit Figure 76 Liquid cooled inverter unit s type code Inverter product range includes both air and liquid cooled units in two voltage ranges For detailed information see the product brochures and manuals 9 5 5 BRAKE CHOPPER UNIT amp BRAKE RESISTORS The BCU Brake chopper unit is a unidirectional power converter for the supply of excessive energy from a common DC bus drive line up to resistors where the energy is dissipated as heat External resistors are needed By using two brake resistors the braking power of the brake chopper is dou bled Vacon Engineered Drives VACON 106 NXP BASED DRIVE UNITS 9 6 WIRING DIAGRAM EXAMPLES D Ei Lu 0 4 MAIN CIRCUIT Figure 77 Wiring diagram for FI9 and FI10 Vacon Engineered Drives VACON 107 BASED DRIVE UNITS NXP uoppoy vh EL 9 S bre Qi Lo AQ uooeA OMA pue gja Sav EVID AL 2325102 SNIOSVHO HOIOVINOO SNIONHVHO NIYIN MOIOVINOO OVA OrZ 1 318n0G 31051 GALVINSNI 0 e c ym eno amena psc Figure 78 Wiring diagram for FI13 Vacon Engineered Drives m AQ uo9BA NXP BASED DRIVE UNITS VACON 108 vios 9 IVOG LvOV LvOV 9105 S9NIG 0 N OVAOFZ TOWA0re 81013 oW vi dOXN 830196 SEx penge 1183 aogy agay 03837 Y
79. e degradation of its intended use 5 1 2 COMPLIANCE If a relevant harmonised standard exists and is listed in the Official Journal of the EU compliance with this is considered compliance with the essential requirements 5 2 STANDARDS IN EUROPE There are several standards that may be relevant for frequency converters The actual standard documentation is available for purchasing on the internet www iec ch webstore IEC standards are global standard of International Electrotechnical Commission EN is European Norm EN stan dards if they are listed in the EMC directive represent a European law on the matter e IEC EN 61800 3 for power drive systems EC EN 61000 6 1 and 2 for generic cases regarding immunity public and private networks e IEC EN 61000 6 3 and 4 for generic cases regarding emissions EN 55011 the basic standard for EMC CISPR 11 Of the above listed EN61800 3 is a product family standard and as such takes precedence over the generic standards EN55011 EN61000 6 1 2 3and 4 With drives the generic standard is more demanding than the product family standard which is usually not the case For drives the less de manding product family standard has been accepted because drives are much less numerous than household equipment such as TV s radios computers etc Therefore the impact of drives on the electromagnetic environment is much less 5 3 STANDARDS OUTSIDE EUROPE The body responsible for regulatio
80. e protection function is an overtemperature detection using thermistor located on the OPT AF option board It can be usedas atripping device for ATEX certified motors The thermistor tripping function is certified by VTT according to ATEX directive 94 9 EC IFA Institut f r Arbeitsschutz der Deutsche Gesetzlichen Unfallversicherung Germany VTT Technical Research Centre of Finland 9 3 5 OTHER SAFETY FUNCTIONS Other safety functions can be implemented by the safety system designer by using external pre certified third party safety relays For more information on combining safety related sub systems see the OPT AF board s user documentation PAUUO ER UD Mes UN arredi Tw SS Pee MARKT NU MO ARO D Le GETS Ded chua Vg gt q Other safety functions Safety Relay NX Safe Torque Off STO Subsystem sarety Relay Subsystem sto Figure 65 Other safety functions Vacon Engineered Drives VACON 90 NXP BASED DRIVE UNITS 9 4 AC SUPPLIED IPOO FREQUENCY CONVERTER MODULES AC supplied IP00 frequency converter modules need always cabinet installation The IP00 frequen cy converters include both air and liquid cooled drive modules The product range includes both 6 and12 pulse frequency converters The IP00 modules are by default delivered with chokes that are separate modules For IP00 frequency converter configurations see chapter Cabinet installation on page 109
81. eat exchanger type Is cooling water available em Is max ambient Liquid to liquid Hx temp 7 C lt max coolant temp o d Radiator Hx Chiller Figure 94 Choosing the heat exchanger type Vacon Engineered Drives VACON 134 COOLING SYSTEM OF LIQUID COOLED VACON AC 11 1 1 LIQUID TO LIQUID HEAT EXCHANGER Vacon s product range includes several liquid to liquid heat exchanger types The HX unit s princi ple of operation is based on liquid to liquid transfer of heat The primary circuit transports the heat load from the frequency converter to the plate heat exchanger The secondary circuit liquid flowing through the plate heat exchanger then collects the heat load and transports it to an external con denser This external condenser is part of the customer and or end user s existing cooling system Another way to dispose of the heat load is to use existing natural resources e g a lake or river The use and choice of a system for disposing of the heat load is the customer s and or end user s re sponsibility e Primary circuit green colour in the figure right lighter colour in black and white Secondary circuit red colour in the figure right darker colour in black and white Figure 95 Primary and secondary circuit of the HX heat exchanger The flow switch which monitors the flow in the primary circuit also includes a temperature sensor This sensor control
82. ed by its location in the electric circuit The cur rent values of AC1 and AC3 are available in technical contactor catalogue When a contactor is on the network side K1 dimensioning is based on contac tor s ACT current because coso of input current is close to 1 and frequency is typically 50 60Hz At motor side cosp is lower typically about 0 85 and current has low and high frequencies so output side contactor K2 must be dimen sioned by the AC3 current with additional current reserve A by pass contactor is dimensioned in the same way as a direct on line DOL which is used typically without a frequency converter Dimensioning is based on the AC3 current and the contactor must be equipped with an overload protec tion relay The control voltage of a contactor can be chosen in accordance with the control voltage of the system typically 24VDC 115VAC or 230VAC Keep in mind that control voltage and main voltage must be properly separated for safety rea sons 7 1 2 AUXILIARY CONTACTS Contactors have typically 3 main contacts for switching the power on and off In addition they may have a number of auxiliary contacts These may be normally open or normally closed and they may be used for other controls which operate simultaneously with the main contacts Typical use for an auxiliary contact is contactor feedback for the run input of the drive or emergency stop relay K1 K2 Q Vacon Engineered
83. em integrator partners and panel builders but it offers a useful introduction to engineered drives to other readers too For further development of this type of documentation it is very important that you give us feedback on our work Feedback address is documentation dvacon com Vacon Engineered Drives VACON 2 INTRODUCTION TO THE ENGINEERED DRIVES Vacon Engineered Drives PROCESS IS THE KEY VACON 3 2 PROCESS IS THE KEY The most important factor when starting to define a drive system configuration is the customer s process where the drive system will be used Customer is the starting point also when defining a drive system You must first familiarise yourself with the customer s process requirements torque speed and load cycle Only thorough knowledge of the customer s process can guide you to find out what is the optimal drive system type and configuration in each case Figure 1 Pulp and paper manufacturing 2 1 CUSTOMER S INSTALLATION ENVIRONMENT Customers are unique also in the way that the installation environments are different When defin ing the drive system delivery it is important to find out that the customer s installation environment is suitable forthe drive system Defining a drive system requires two way communication You must inform the customer about the requirements that the drive system sets to the installation premises but also make sure that the customer understands that it is of their own best
84. emperature Indicating Controller FV Flow Valve P Pressure Indicator Pressure vessel Ball valve PT Pressure Transmitter Pump Vacon Engineered Drives VACON 136 COOLING SYSTEM OF LIQUID COOLED VACON AC 11 1 3 CHILLER Chiller type heat exchangers are available from Vacon The process water to be chilled passes through the heat exchanger which is cooled by a separate refrigerant unit The refrigerant circuit ensures that the pre adjusted temperature is reached See the manufacturer s documentation for further details Figure 98 Chiller 11 1 4 MATERIALS AND COMPONENTS OF THE COOLING SYSTEM The default temperature of the cooling agent entering the drive module s is 35 C While circulating inside the cooling element the liquid transfers the heat produced by the power semiconductors and the capacitors The default temperature rise of the cooling agent during the circulation is less than 5 C Typically 95 of the power losses is dissipated in the liquid We advise you to equip the cooling agent circulation with temperature supervision The heat exchanging equipment can be located outside the electrical room in which the frequency converters are The connections between these two are made on site In order to minimize the pres sure drops the pipings must be as straight as possible We further recommend that a regulating valve equipped with a measurement point is mounted This makes the measurement and regulati
85. ent is made of aluminium or nickel coated aluminium As cooling liquid you can use drinking water with inhibitor demineralised water with inhibitor or a mixture of water and gly col There are two different circulation system types e closed system e open system In a closed system the piping is completely air tight and there is pressure inside the pipes The pipes must be made out of metal or specific plastic or rubber that includes oxygen barrier Pre venting of oxygen diffusion in the coolant diminishes the risk of electrochemical corrosion of metal parts and generation of rust deposits An open system has no pressure and it allows free contact between the liquid and air Always use a closed system with Vacon NX Liquid Cooled AC drives In case there is no other option than using a semi open system you must take several precautions Use glycol or inhibitor in the coolant examine the water quality regularly and add inhibitor accordingly You must check once a year that the properties of the cooling liquid are in accordance with the specification in the device manual 11 1 CHOOSING THE COOLING SYSTEM TYPE The drive s liquid circulation is connected to a heat exchanger which cools down the liquid There are three main heat exchanger types for cooling down the heat from the circulating liquid liquid to liquid using a heat exchanger liquid to air using a radiator e chiller using compressor technology Choosing the h
86. entilation and cooling of each section The drive unit as well as the auxiliary components of a drive heat up the space they are installed in The drive line up must be designed so that the ambient conditions inside each section are in accor dance with Vacon s specifications for Vacon products Temperature within each section must stay below the maximum operating temperature Repeated overheating will compromise the operation and shorten the lifetime of the frequency converter The need of cooling of the frequency converter varies greatly with load and output frequency as well as with the switching frequency used For dimensioning of cooling or ventilation equipment for electrical rooms the following generic formula gives a good approximation of the heat losses for standard 6 and 12 pulse frequency converters at nominal conditions Ploss kw Pinot kW x 0 025 NOTE Always check the heat loss data from the relevant product manuals Ventilation and air flow are important both within the cabinet and outside the cabinet You can use either a duct or an air barrier to make sure that the outgoing air does not mix with incoming cooling air Figure 91 Steering the internal air flow In the sections containing drive module modules the module s own fan is usually enough to provide sufficient cooling air flow within that section when the openings for inlet and outlet of air are de signed in accordance with the requirements In sections that d
87. erified case by case Dielectric strength is usually not of concern with low voltage cables as only thin insulation layer is needed to achieve the required insulation 8 6 TYPICAL CABLE TYPE Recommended cable type in three phase supply is shielded and symmetrical 3 wire cable as shown below The shield is used for grounding and as it is around the phase wires it beneficial for EMC Figure 52 Shielded and symmetrical 3 wire cable 8 7 THERMAL DIMENSIONING OF CABLES Cables have a temperature limit up to which they are allowed to heat Cable s insulation material determines its temperature limit Thermal dimensioning yields the minimum cross section for specified current rating according to the maximum temperature or the other way round it specifies the maximum current rating for a particular cross section 8 7 1 THERMAL DIMENSIONING RULES Environment has a significant effect on cooling of the cable and thus on the level of current that generates the maximum temperature Cooling is reduced if ambient temperature is increased and cables are installed close to each other Vacon Engineered Drives SUPPLY NETWORK AND POWER CABLES VACON 67 Manufacturers may define current rating for cables Selecting cables according to this is easy However these current ratings are for normal ambient conditions The capacity is stated at a cer tain ambient temperature and with cables having space around them Correction factors need to be used
88. essential also during the commissioning phase Working with any level of voltages requires caution Figure 107 Warning sign Also to avoid any injuries to the personnel or damage to the drive system s components the tools and other equipment used in the commissioning must be appropriate and the premises must be kept clean and tidy 13 1 2 CHECKING THE INSTALLATION AND CONNECTIONS Installation and connections refer to the main control systems auxiliary controls measurements and feedback from the process These are mechanical and electronical connections directly to the drive Further basics that need to be studied before the actual commissioning procedure include trans mission details and mechanics The motor together with the drive give a certain performance How ever the mechanical properties of the system set their own limits and the process where the drive Vacon Engineered Drives VACON 150 COMMISSIONING is used has certain requirements In an optimal commissioning procedure all these are taken into account Drives have a number of functions for monitoring the mechanical operations and feedback These functions need to be commissioned in an appropriate way those that have already been defined in the system specification and those additional ones that can be used to enhance the system s oper ation It is necessary to check that all the drive system s components have been delivered in accordance with the delivery c
89. ges that can be seen through the system These effects can have a severe impact on the transformer and on other devic es connected to the same supply NOTE In DOL applications the sinusoidal motor current is often higher than the input RMS current to a drive due to the low power factor of a motor The drive supplies the required reactive current to the motor It is not taken from the mains In Figure 34 Source of harmonic voltages The most problematical harmonic is the third as the currents created in the three supply phases are added in phase in the neutral conductor and may overload it Balanced three phase loads do not create any 3rd harmonics they are created by nonlinear single phase loads typically UPSs fluorescent lighting and PCs as well as other office equipment Vacon Engineered Drives HARMONICS VACON 45 Additional transformer heating caused by the harmonic currents can be calculated as defined in the standard IEC 61378 1 The derating factor is spectrum dependent i e the spectrum influences the derating A typical ex ample is shown in the figure below Derating of transformer s rated current to the drive s RMS current D c c LS o a oooo ONAQDO N N N Ey a a a 05 Transformer power MVA Figure 35 Derating of transformer typical drive spectrum 6 1 EFFECTS OF HARMONICS ON MOTORS The harmonic currents generated by non linear loads do not affect
90. h drives you normally need to define only the acceptable emission level All Vacon s drives have industrial grade immunity against electromagnetic interference Examples of interference types include high frequency voltages transients electrostatic discharg es and radiating electromagnetic fields Low frequency disturbances are discussed in chapter Harmonics on page 43 5 1 THE EMC DIRECTIVE The EMC directive is a New Approach directive and it is valid for all equipment and apparatus for sale within the EU The directive does not set out detailed technical requirements but only essential ones It also sets out ways of complying with the essential requirements The EMC directive is a public document and it is available on the internet in the Official Journal of the European Union OJEU Detailed requirements are found in the harmonised standards published in the OJEU Vacon Engineered Drives VACON 34 EMC PRINCIPLES AND PRACTICES 5 1 1 ESSENTIAL REQUIREMENTS The directive states two essential requirements Equipment shall be so designed and manufactured having regard to the state of the art as to en sure that the electromagnetic disturbance generated does not exceed the level above which radio and telecommunications equipment or other equipment cannot operate as intended e ithas a level of immunity to the electromagnetic disturbance to be expected in its intended use which allows it to operate without unacceptabl
91. h optical connection the delivery also contains a fixing plate that is needed for installing the control unit to for example a cabinet door Figure 81 FR10 and FR11 10 2 2 FRAME 12 Frame 12 consists of a control unit and two separate power modules that are connected together using a star coupler board The control unit can be separate with optical connection to the power unit or it can be installed on the cover of the power module as in the figures above and below AC chokes are delivered separately Brake chopper is optional and it can be integrated in the frame Thus it does have no effect on the dimensions Frame 12 is available in 6 pulse and 12 pulse versions and the pulse system has no effect on the dimensions or on the amount of chokes An FR12 drive needs always two AC chokes Figure 82 FR12 Vacon Engineered Drives CABINET INSTALLATION VACON 111 10 2 3 FRAMES 13 AND 14 Frame 13 and 14 drives are based on the common DC bus product range There is always one con trol unit The power module consists of NFE Non regenerative Front End units and INU Inverter units A Frame 13 delivery contains always 1 INU and a Frame 14 delivery contains 2 INUs connect ed using a star coupler board Depending on the pulse system 6 pulse or 12 pulse there can be 2 3or 4 NFE units Thus the pulse system has direct effect on the dimensions of the drive system The number of AC chokes depends on the number of NFE unit
92. harmonics above order 12 are taken into account in THD and PWHD in the same way as odd order harmonics Admissible harmonic current distortion factors NOTE Linear interpolation between successive R values is permitted See also Annex B a J reference fundamental current I harmonic current component Figure 36 An extract from the IEC 61000 3 12 standard 6 2 2 SYSTEM STANDARD IEEE 519 1992 IEEE 519 1992 Recommended practices and Requirements for Harmonic Control in Electrical Power Systems This is a recommendation for controlling harmonics in systems and it should not be applied to sin gle products It calls for very low allowed values of harmonic loading typically 5 THD at the point of common coupling PCC The PCC is generally the location in the system where another custom er can be served The basic concept behind this is that no single user should emit harmonics to a degree that can disturb other users Vacon Engineered Drives HARMONICS VACON 47 Other loads Vighting etc Utility Medium voltage Figure 37 Point of Common Coupling Table 6 Basics for Harmonic Current Limits Maximum individual SCR at PCC frequency voltage Related assumption harmonic VA 10 2 5 3 0 Dedicated system 20 2 0 2 5 1 2 large customers 50 1 0 1 5 A few relatively large customers 100 0 5 1 0 5 20 medium size customers 1000 0 05 0 10 Many small customers
93. has been certified by the IFA aes Q C e E 4 o Frequency f Actual Motor deceleration Time Figure 62 The principle of Safe Stop 1 EN 61800 5 2 SS1 type c Vacon Engineered Drives VACON 88 NXP BASED DRIVE UNITS The Safe Stop 1 SS1 safety function consists of two safety related subsystems an external time delayed safety relay and the STO safety function These two subsystems together form the Safe Stop 1 safety function as shown in figure Safe Stop 1 SS1 safety function Safe Stop 1 SS1 Time Delayed Safety Relay NX Safe Torque Off STO Subsystem sarety Relay Subsystem sto Figure 63 Safe Stop 1 SS1 safety function Figure 56 shows the connection principle of Safe Stop 1 safety function The time delayed safety relay outputs are connected to the STO inputs A separate digital output from the safety relay is connected to a general digital input of the NX drive The general digital input must be programmed to detect the drive stop command and initiates without time delay the drive stop function must be set to stop by ramp and causes motor deceleration Safety Relay with timer NXP control Power Unit y UN uu Figure 64 Connection principle of the SS1 function Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 89 9 3 4 3 Motor Thermistor Overtemperature protection according to ATEX The Motor Thermistor Overtemperatur
94. have the risk of a broken neutral In locations where power is distributed overhead and TT is used installation earth conductors are not at risk should any overhead distribution conductor be fractured by say a fallen tree or branch In pre residual current devices era the TT earthing system was unattractive for general use be cause of its worse capability of accepting high currents in case of a live to PE short circuit in com parison with TN systems But as residual current devices mitigate this disadvantage the TT earthing system has become attractive for premises where all AC power circuits are protected by a residual current device Generator or transformer OU NEIN L1 LY YN L2 L3 N A ie Earth Consumer Earth Figure 47 TT network Vacon Engineered Drives SUPPLY NETWORK AND POWER CABLES VACON 63 8 1 3 TN S NETWORK A TN S system is used to separate neutral and protective conductors throughout the system Elec trical installations in buildings used for neutral TN S system in general However in industrial mo tor drives and other symmetrical loads the neutral wire is usually unnecessary and not used PE and N are separate conductors that are connected together only near the power source Three phase systems have normally five 3L N PE or four 3L PE conductors Single phase systems have typically three conductors L N PE Generator or transformer L1 L2 L3
95. he filter FR12 consists of two parallel connected FR10 modules Regardless of the supply voltage two dU dt filters are needed in most installations For cooling switch fuse and cabling see chapter Dimensions and layout of FR4 FR5 and frequency converters on page 123 FZT 03 NOILIUTIULSNI L3NIGU lt m o o 5 m a 5 o o m o U a z D v 10 9 6 DIMENSIONS AND LAYOUT OF THE FI9 FI10 AND FI13 ACTIVE FRONT END UNITS 1200 5 400 400 __ 400 _ 01 02 03 Pre o charge o AFE LCL FI9 FI10 NXA Contactor 29 Switch fuse 2000 600 a 500 s 800 01 02 03 Pre o charge AFE LCL FI13 NXA The switchgear s power capacity can be increased by adding AFE modules Each AFE module re quires a dedicated LCL filter It is recommended to use also a dedicated pre charging circuit with each AFE module This improves the system re dundance In case one AFE unit is being serviced the rest of the switchgear can still be used as long as the AFE that is out of use is electricaly isolated For co
96. he full load current Note that using active filters will cause the drive to generate higher harmonics as the filter creates zero impedance spots at the harmonic frequencies as seen by the drive and this might overheat the input chokes Active filters are available from a number of suppliers The resulting THD is about 2 596 depending on the actual parameters of each specific case Figure 42 Active filter Vacon Engineered Drives VACON 54 HARMONICS Vacon Engineered Drives CONTACTORS BREAKERS AND FUSES VACON 55 7 CONTACTORS BREAKERS AND FUSES All Vacon AC Drives include internal protection against short circuits taking place at the output of the drive for example in motor terminals or motor cables During a short circuit at the output me chanical protection devices at the supply such as circuit breakers fuses or contactors do not show any high currents flowing through them Fault current at the output of the drive is turned off by semiconductor transistors IGBT s in a few microseconds To protect the input cables and also to limit the damages inside the drive in case of an internal fail ure in the drive you need to select a proper protective component You need to know the approximate short circuit rating of the drive s supply grid to select the right components for the protection of the entire electrical drive system The short circuit current from the supply must be high enough to burn the fuses in a
97. hield is greater than 50 of one phase conductor Otherwise use a separate ground conductor If you install com ponents between the motor and the drive make sure that the shield is continuous The standard EN IEC 61800 5 1 defines the requirement of the PE conductor as follows Table 5 Cross section of protective earthing conductor Cross sectional area of phase Minimum cross sectional area of conductors of the PDS CDM BDM S the protective earthing conductor mm mm S lt 16 S 16 S gt 5 16 35 gt 5 S 2 The values are valid only if the protective earthing conductor is made of the same metal as the phase conductors If this is not so the cross sectional area of the protective earthing conductor Vacon Engineered Drives VACON 40 EMC PRINCIPLES AND PRACTICES shall be determined in a manner which produces a conductance equivalent to that which results from the application of the values presented in the table above The cross sectional area of every protective earthing conductor which does not form part of the supply cable or cable enclosure shall in any case be not less than e 2 5 mm if mechanical protection is provided or e 4mm if mechanical protection is not provided For cord connected equipment provisions shall be made so that the protective earthing conductor in the cord shall in the case of fail ure of the strain relief mechanism be the last conductor to be interrupted For special systems to
98. hose directly connected to a low voltage power supply network which supplies buildings used for domes tic purposes Industrial areas technical areas of any building fed from a dedicated transformer are examples of second environment locations Second environment is also known as private networks or industrial environment In EN 55011 Class A limits are applied in this environment 5 5 FOUR DRIVE CATEGORIES BY EN 61800 3 In addition to environments the standard EN 1800 3 defines four categories for power drive sys tems Vast majority of drives today can be considered part of categories 2 4 depending on the cus tomer and application details A Category C1 drive is according to the definitions a movable product equipped with plugs for connecting to the motor supply In practice the emission levels for Category C2 and C3 defined in the standard EN 61800 3 are sim ilar to those required for the industrial environment by EN 55011 class A and the generic standard EN61000 4 PDS Power Drive Systems of category C1 Drive systems with rated voltage of less than 1 000 VAC intended for use in the first environment PDS of category C2 PDS with rated voltage of less than 1 000 VAC which is neither a plug in device nor a movable device and when used in the first environment is intended to be installed and commissioned only by a pro fessional A professional is a person or an organisation having necessary skills in installing and or commissi
99. ine drives or if the supply system has adequate overload and short circuit protection a load switch can be used Example 4 An auxiliary cabinet can contain various components needed in the drive system such as components needed for control voltage distribution measurement and indication of voltage and current DC charging components arc protection relays and other control components that are common to the entire drive system Vacon Engineered Drives lt m o o 5 m 3 a 5 o o i o a U J z D n 10 9 2 DIMENSIONS AND LAYOUT OF FR4 FR5 AND FR FREQUENCY CONVERTERS 400 400 Two FR4 FR5 frequency converters can be installed in one full height cabinet FR6 requires an entire cabinet A dU dt filter is optional and usually fits in the same cabinet with the frequency converter depending on the cabinet type and height Proper ventilation of the cabinet is important Cooling air must be conducted out of the cabinet Inside the cabinet there must normally be an air barrier that keeps the incoming and outgoing air from get ting mixed The incoming air must come from the lower part of the cabinet usually cabinet door so that the airflow goes past the dU dt cooling it on the way In case the cabinet contains two frequency converters it is even more important to see that the air goes out from the lower part of the cab inet and does not heat up the devices in the upper part of the cabinet See chapter Cool
100. ing air cooled units on page 119 On the supply side there is a lockable switch fuse for protection of the frequency converter and for safe voltage separation If there is no dU dt filter the motor cables are connected directly to the frequency converter s output terminals If a dU dt is used the motor cables are connected either directly to the filter terminals or separate termi nals The motor cables must be 360 grounded for elimination of EMC disturbance The motor and supply cables must be kept separate from the control cables to avoid disturbance in the control cables Auxiliary components and terminals and cable trays if they are used must be placed so that they do not get heated up and can be safely reached for measurement purposes Different voltages wires cables and components must be separated due to safety reasons and to avoid disturbances EZT e NODUA NOILIUTIULSNI L3NIGU lt m o o 5 m 5 a 5 o o m o U a z D v 10 9 3 DIMENSIONS AND LAYOUT OF FR7 FR8 AND FR9 FREQUENCY CONVERTERS 800 FR 7 FR8and FR all require one full height cabinet FR9 without auxiliary components and dU dt filter can be fitted in a 600mm but otherwise it requires approximately 800mm wide cabinet as in the draw ing or a separate auxiliary cabinet For cooling switch fuse and cabling see chapter Di mensions and layout of FRA FR5 and FR frequency converters on page 123 YCT
101. ing see chapter Dimensions and layout of FRA FR5 FR6 and FR7 inverter units on page 128 The FI13 inverter unit requires an external pre charging circuit Pre charging can be either inverter specific or via common DC bus With common pre charging the individual inverters must have only DC fuses on the supply side If common DC bus pre charging is used you must not connect inverters to a live bus TET NODUA NOILIUTIULSNI L3NIGU Sang peJeauiBu3 uo2eA 10 9 11 DIMENSIONS AND LAYOUT OF THE FI14 INVERTER UNIT 2200 600 T TAM RR UT LT LLL LLLI LLL LUE ol ADOTTAT D FI14 Inv unit The F114 inverter unit contains two F113 inverter modules With the F114 inverter unit a dU dt filter requires an additional cabinet For cooling switch fuse and cabling see chapter Dimensions and layout of FR4 FR5 FR and FR7 inverter units on page 128 The F114 inverter unit requires an external pre charging circuit Pre charging can be either inverter specific or via common DC bus With common pre charging the individual inverters must have only DC fuses on the supply side If common DC bus pre charging is used you must not connect in verters to a live bus ZET e NODUA NOILIUTIULSNI L3NIGU COOLING SYSTEM OF LIQUID COOLED VACON AC DRIVES VACON 133 11 COOLING SYSTEM OF LIQUID COOLED VACON AC DRIVES Vacon NX Liquid Cooled AC drives are cooled with liquid circulating in the cooling elements of the drive Cooling elem
102. ion of bearings due to material removal The bearing and race wear also re sults in motor noise and vibration When the bearing is operating at normal speeds the lubrication insulates the balls from the bear ing races If a voltage develops across the bearing the electrical field through the film increases as the capacitor is charged until the breakthrough voltage is reached When the film breaks a spark jumps the gap Each spark removes a trace of material from the ball and the race eventually creating a washboard pattern on the bearing race This current is known as the EDM electrical dis charge machining current The bearing lubricant film is typically 0 2 to 2 0 um thick With Low frequencies 50 Hz DOL motors the breakthrough voltage is on the order of a few volts but with fast rise times the instantaneous withstandability of the film can reach values in the 20 to 30 V range at 10 us pulses These values are quite conservative as the actual value is a complicated function of temperature metallic pol lution viscosity and a number of other factors The frequency and magnitude of these currents de termine how quickly the bearing is destroyed The frequency is determined by the switching frequency of the drive and the magnitude of the physical characteristics of the drive the motor and also the earthing In all bearing currents are difficult to control or measure very exactly 12 2 1 WHAT ACTUALLY HAPPENS IN THE BEARINGS Typica
103. ircuit 13 1 4 GATHERING DRIVE SYSTEM AND PROCESS SPECIFIC DATA In order to proceed in the commissioning you need to cross check the data regarding the motor the drive system and the customer process The data such as process speeds directions etc must be in line with the actual process description Based on this data you need to check that the system has been built in accordance with the requirements of the customer s process The details include for example the following e Motor s rating e Encoder e Cooling fan details Motor s temperature measurement device eg Pt100 thermistor over temperature switch etc e Mechanical brake Direction of the rotation of the motor and the corresponding process requirement Maximum motor speed process speed and any other speed requirements Speed factors such as transmission ratio and diameter e Speed ramps e Start Stop method 13 1 5 CONNECTING POWER Make sure that the motor does not start unintentionally when power is connected to the drive Test the motor s temperature sensor and safety switch circuit Verify these connections from the motor end Running with no load with motor disconnected from the load e Set the motor s name plate data encoder related parameters start stop method accelera tion and deceleration ramp times and related lO settings Set the current limit Typically same as the motor s nominal current limit e Start running the motor a
104. ire ments of the motor the load and the process The master unit and the fast optical drive to drive communication must be functional for the Drive Synch to work Auxiliary power 24V must be continuously provided for all the control units in cluding any non functional drive units Vacon Engineered Drives VACON 80 NXP BASED DRIVE UNITS It is also a common practice to use n 1 units where n is the number of units required for the full functionality of the system This way 10096 redundancy is possible even if any one of the follower drives is not functioning Maximum number of units in the DriveSynch is four Table 16 NES Master 1 Follower 2 Follower 3 Follower 4 Hardware settings OPTD2 X5 TX1 TX2 TX2 TX2 Jumper OPE X6 ON ON ON ON Jumper Expander board parameters OPTD2 ds YES YES YES YES OPTD2 ae BUS 12 Mbaud 12 Mbaud 12 Mbaud 12 Mbaud OPTD2 System Bus ID 1 2 3 4 opto yee Bus 2 3 4 1 next ID System Bus OPTD2 Last ID 4 4 4 4 Vacon Engineered Drives NXP BASED DRIVE UNITS Master D1 Follower D2 Follower D3 Follower D4 settings VACON 81 Motor s nomi nal voltage Motor s nominal voltage from its nameplate Motor s nominal voltage from its nameplate Motor s nominal voltage from its nameplate Motor s nominal voltage from its nameplate Motor s nomi nal frequency Motor s nominal fre
105. ised As a result the commissioning team can achieve results that meet and even exceed the customer s expectations Commissioning is one of the last phases of an entire project Project schedule is usually tight and getting tighter towards the end Often it is possible to do some preparations for the commissioning process beforehand such as acquiring materials or even running some tests in a laboratory Com missioning is teamwork involving specialists from various fields of expertise The project manager can provide the members of the commissioning team with an opportunity to do an interface cross check with other participants The customer can again check up their needs and compare them to the planned outcome of the project A preliminary definition of the commissioning helps to see if the schedule and phasing of the commissioning project are sensible This way the work proceeds smoothly as it is possible to have the right people available at the right time 13 1 TYPICAL COMMISSIONING PROCESS Each commissioning process is unique This chapter contains some examples and general descrip tions that are meant to give an overall idea of the scope of commissioning Chapter Checking the installation and connections on page 149 contains some connection diagram examples 13 1 1 SAFE WORK PRACTICES For reasons of personal safety the personnel who carry out the commissioning must have ade quate competence in safety issues Electrical safety is
106. isted pair cables with encoders Use cables that are recommended for encoder feedback Do not mix signals in twisted pairs Always make earthing contact throughout the full circumference of the cable 360 and grounding at the device end only The feedback signals may also suffer from the noise coming from motor and supply cables Use shielded symmetrical motor cables It is recommended to connect the motor cable shield with 360 EMC bushing The motor and supply cables should not be in parallel with the encoder s signal cable Vacon Engineered Drives COMMISSIONING VACON 149 13 COMMISSIONING Installation phase is followed by commissioning of the drive after which the drive system is handed over to the operative personnel It is important to understand the drive s position and role in the customer s process In a complex industrial process there is usually an upper level control architechture which takes care of certain control functions A system specification defines which operations or controls must be handled by this upper level control architecture and which ones belong to the drive This definition must be obeyed In addition there are usually various additional drive functions or properties that can be used to fur ther improve the customer s process Thorough knowledge of the customer s process require ments and the drive s properties allow the commissioning team to figure out how these additional functions may be util
107. ists of one or more front end modules and inverter modules con nected together by a DC bus Figure 7 A regenerative common DC bus system 2XNFE Figure 8 A non regenerative common DC bus system Vacon Engineered Drives DRIVE SYSTEMS VACON 11 3 3 COMMON AC BUS DRIVE SYSTEMS A common AC bus drive system consists of separate AC drives with one common supply point Usu ally the drives are located in a row of cabinets with a common AC bus as the power source for the frequency converters Each drive is fed from the common AC bus and from the drive cabinet there is cabling to each motor In an AC drive system the power is fed from the supply to each motor drive but not vice versa A common AC drive system is a cost efficient choice for a process with multiple motors that are constantly on duty and consuming energy independent of each other Reduced cabling and drive line up costs result from using a single common AC input for a number of drives Installation in a separate electrical room if one is available keeps the drive system pro tected from the environmental effects of the actual operational or production premises Each indi vidual frequency converter can have a switch disconnector which means that each frequency converter can be individually isolated from the AC bus for service purposes if this is feasible for the process point of view COMMON AC BUS be O SUPPLY Figure 9 Common AC bus system
108. its are shown in table Pre charging circuit s Min and Max capacitance below Pre charging circuits are suitable for 380 500VAC and 525 690VAC An Active Front End unit must not be connected to mains without pre charging In order to ensure the correct operation of the pre charging circuit the Active Front End must control the input cir cuit breaker or contactor as well as the precharging circuit contactor Circuit diagram showing typical connections Table 24 Pre charging circuit s Min and Max capacitance FI9 2x47R 4950 uF 30000 uF F110 2x20R 9900 uF 70000 uF FI13 2x11R 29700 uF 128000 uF The Active Front End s application software controls the main contactor of the system using the re lay output RO2 see the wiring diagram in the figure below When the intermediate circuit becomes pre charged the relay output RO2 closes the main contactor A digital input by default DIN4 mon itors the status of the main contactor The monitoring of main contactor is ON by default It must not be possible to close the main contactor or breaker before the pre charging is finished Opening of the contactor is only allowed when there is no load NOTE Wirings used for connecting the pre charging circuit to the intermediate circuit have to be double insulated Vacon Engineered Drives VACON 96 NXP BASED DRIVE UNITS 9 5 2 3 Paralleling The power of a supply section can be increased by connecting several Active F
109. ives VACON 49 HARMONICS 6 3 REDUCING HARMONICS 6 3 1 CHOKES The amplitude of the various frequencies naturally decreases with increasing frequency so in order to decrease the harmonics further the impedance at higher frequencies must be increased a choke must be used AC or DC from the point of view of harmonics their effects are similar The expected value of THD can change from about 120 very small or no choke and large transformer down to about 30 large choke and small transformer Current distortion tant du La THDi as 96 of nominal M MM current at full load 80 40 6 pulse rectifier with big choke 28 15 5 96 Figure 38 Typical values for FCs with different rectifier types 6 3 2 TUNED FILTERS Use a tuned filter a trap filter for the 5th and 7th harmonics This usually requires a system anal ysis and a stable system as changes in the supply may cause unwanted resonances Tuned filters are available from many suppliers They usually consist of chokes and capacitors suit ably tuned to the harmonic that must be eliminated Their size is significant as is the cost associ ated Vacon Engineered Drives VACON 50 HARMONICS 6 3 3 ACTIVE FRONT END An effective way to eliminate harmonic currents is to use an active front end AFE It consists of a normal three phase inverter bridge connected via an LCL filter to the supply The IGBTs in the in verter bridge are con
110. kW 0 69 kW 0 300 kW Mains supply 380 440VAC 380 440 VAC 380 440 VAC 380 440 VAC Flow 40 120Umin 120 360 min 120 200 U min 360 900 U min The main pipeline must be dimensioned so that when the liquid is distributed to the individual drives the liquid pressure in each drive is identical When designing and dimensioning the cooling system see the following tables in the Vacon NX Liq uid Cooled Drives User s Manual Table 5 6 Information about cooling agent and its circulation e Tables 5 9 and 5 10 Pressure losses e Tables 5 3 5 4 and 5 5 Water specifications Vacon Engineered Drives COOLING SYSTEM OF LIQUID COOLED VACON AC DRIVES VACON 139 11 2 2 EXAMPLE OF HEAT EXCHANGER SELECTION The following example shows how to calculate the power loss and nominal flow values for a drive system containing one front end unit with an LCL filter and three inverter units and select the HX heat exchanger type based on the calculated values Table 44 Example of a liquid cooled common DC bus drive system Power losses Required Unit ID Chassis Voltage U Current A bie nominal flow to liquid kW l min LCL filter RLC 920 AFE Ch 3 400 920 14 4 50 INU Ch 1 400 385 5 5 25 INU Ch 1 400 300 4 5 25 INUz Ch 1 400 300 4 5 25 Total 34 4 165 In this example the drive system s total power losses to liquid amount to 34 4 kW which
111. l discharge of rotor capacitance is 12V with the duration of 50ns High peak current if from 10 to 100A This heats the steel locally so that a small amount gets vaporized and a small crated is formed The diameter of the crater is below 1 um After the formation of several millions of such craters the balls start to bounce This bouncing creates the wash board pattern The pattern has no connection with the AC drive s frequencies Figure 102 Left miniature craters microscope image right washboard pattern 12 2 2 THREE MAIN CATEGORIES OF BEARING CURRENTS The bearing current phenomenon can be divided into three main categories capacitive voltages circulating currents and shaft earth current Vacon Engineered Drives MOTOR CABLES AND OUTPUT FILTERS VACON 9 145 12 2 2 1 Capacitive voltages In frequency converter s output semiconductors produce a modulation pattern The potential be tween the motor s phases and the motor s stator windings varies between the and voltages of the intermediate circuit depending on which semiconductor is conducting at the time Thus for ex ample the stator windings in a 400 V network can be at 280V compared to the motor s frame at one moment and with other switch positions at 280V compared to the motor s frame This voltage vari ation can be seen also as voltage division in motor constructions in relation with the motor s stray capacitances In the figure below Capacitive voltage sharing C
112. led AC choke if a choke is needed 10 3 1 CHASSIS 3 CHASSIS 4 AND CHASSIS 5 The CH3 CH4 and CH5 frequency converters are available in 6 pulse versions only They need an external AC choke Figure 84 CH3 CH4 and CH5 frequency converters The CH3 CH4 and CH5 brake chopper units do not need an AC choke but they need external brake resistors The CH3 CH4 and CH5 inverter units need a DC supply Table 30 Power ranges for CH3 CH4 and CH5 S 400 500 VAC 465 800 VDC CH3 7 5 37 kW CH4 37 90 kW CH5 90 160 kW 10 3 2 CHASSIS 61 AND CHASSIS 63 The CH61 and CH63 frequency converters are available in 6 pulse versions only They need an ex ternal AC choke Figure 85 CH 61 and CH63 frequency converters Vacon Engineered Drives CABINET INSTALLATION VACON 113 The CH61 and CH63 brake chopper units do not need an AC choke but they need external brake re sistors The CH61 and CH63 inverter units need a DC supply Table 31 Power ranges for CH61 and CH63 400 500 VAC 465 800 VDC 525 690 V AC 640 1100 VDC CH61 160 250 kW 110 250 kW CH63 450 750 kW 400 700kW 10 3 3 CHASSIS 62 AND CHASSIS 64 Figure 86 CH62 and CH64 inverter units The CH62 and CH64 are dedicated inverter units that need a DC supply The CH62 and CH64 brake chopper units do not need an AC choke but they need external brake re sistors Table 32 Power ranges for CH62 and CH64 Poe 400 500 VAC 465 800
113. liquid cooled drives with aluminium heatsink do not use for example copper and brass or iron within the same installation To avoid electrochemical corrosion add an inhibitor in the cooling liquid Table 42 Materials and components of a cooling circuit Material Used in Vacon Liquid Cooled Drives Can be used only in closed circuits if the heatsink and the copper component are separated using non conductive material such as Brass amp Pipes valves plastic or rubber copper and fittings With nickel coated heatsink the re is no need for separation of the copper or brass components Inhibitor must be used Common Permissible in closed circuits with inhibitors check for oxide Pipes steel information regular inspection of water quality recommended Cast steel p Permissible in closed circuits with inhibitors check for oxide Pipes motors f cast iron information regular inspection of water quality recommended PVC PVC C Pipes vane Suitable for drinking water or tap water with inhibitor and glycol and fittings Installation made of dif Pipes valves ferent met and fittings Do not use mixed installation als mixed installation Rubber plastic with Can be used With non Vacon hoses check suitability regarding oxygen bar inhibitor and glycol rier R Seals Can be used rubber Vacon Engineered Drives VACON 138 COOLING SYSTEM OF LIQUID COOLED VACON AC
114. ltage between the bearings on the ends of the motor s shaft de pends on their distance Typically voltage rises as a function of distance Thus the risk of this type of bearing current phenomenon is highest with motors of large frame in other words with big high power motors For this reason the motor manufacturers usually have specific recommendations for the situations when their motors are controlled using a frequency converter These recommen dations may include for example the use of isolated bearings and output filters For example 100kW is often used as the power limit after which it is recommended to provide the motor with in sulated bearings Vacon Engineered Drives VACON 146 MOTOR CABLES AND OUTPUT FILTERS Figure 104 Circulating current 12 2 2 3 Shaft earth current Shaft earth current can occur if voltage potential difference between the motor frame and the ma chine is larger than the break through voltage limit on the bearings During the switching edges of semiconductors the potential of motor s frame tends to make high frequency swings up and down depending on the potential of the windings and earthing impedance In proper installation the voltage swings in the motor frame are prevented by proper earthing of the motor where any capacitive leakage currents are directed to equipotential bonding The route of the leakage currents is divided in accord
115. n 10mm copper or 16 mm aluminium Automatic disconnection of the supply in case of loss of continuity of the protective conduc tor 8 8 EFFECT OF HARMONICS Drive input current usually includes considerable harmonics For conventional drives current THD is about 40 While harmonic components of current do not contribute to the real power of the drive they cause additional heating in the cables due to increased resistive losses Therefore di mensioning of cables has to be done according to the true RMS current not fundamental current component Otherwise cables will be overheated Vacon Engineered Drives VACON 72 SUPPLY NETWORK AND POWER CABLES Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 73 9 NXP BRSED DRIVE UNITS 9 1 THE NXP CONTROL PLATFORM The Vacon NXP is a common control platform for Vacon s high performance products The core of the NXP is a fast microcontroller The NXP can be used in both open loop applications and in applications requiring encoder feedback The NXP platform supports fast drive to drive communication using System Bus which is an optical bus and Can Bus which is a normal RS485 bus Simultaneous monitoring of several drives is possible using the NCDrive tool and a separate monitoring bus based on CAN communication which allows fast monitoring of dynamic events In tegrated data logger allows saving of specified dynamic events for further analysis using the NC Drive tool You can u
116. n of EMC emissions in the USA is the Federal Communications Commission FCC The specific regulations are Part 15 Radio Frequency Devices and Part 18 In dustrial Scientific and Medical Equipment In Canada the tendency is towards following the IEC standard In the rest of the world if any standard is followed it is usually the global IEC standard Note For IT networks conducted emission limits are not defined Due to the nature of the network you cannot measure the disturbance level However the essential requirements of the EMC direc tive are still valid and usually an EMC plan must be created See chapter EMC plan on page 36 Vacon Engineered Drives EMC PRINCIPLES AND PRACTICES VACON 35 5 4 ENVIRONMENTS The standards define two environments the first environment and the second environment 5 4 1 FIRST ENVIRONMENT First environment includes domestic premises It also includes establishments directly connected without intermediate transformers to a low voltage power supply network which supplies buildings used for domestic purposes Houses apartments commercial premises or offices in a residential building are examples of first environment locations First environment is also known as public networks or residential environment In EN 55011 Class B limits are applied in this environment 5 4 2 SECOND ENVIRONMENT Second environment is an industrial environment that includes all establishments other than t
117. network is that a short circuit to ground does not interrupt its operation The system can continue normal operation which is essential in some applications In an IT network there is no direct connection between active conductors and grounded components as the transformer neutral is not grounded i e the network is floating unlike in other networks such as TN C or TN S The cases of electrical equipment used in the network are connected to ground Generator or transformer L1 L2 L3 Consumer i Earth Figure 46 IT network In practice the transformer neutral has a high impedance connection to ground through the stray capacitances of the system The stray capacitances have a major impact on the ground currents in the system and thus on the proper functioning of the whole system Vacon Engineered Drives VACON 62 SUPPLY NETWORK AND POWER CABLES Loads used in the network may contribute to the stray capacitances significantly Therefore there are restrictions in the use of loads designed to be used in other networks The increase in capacitive coupling can result in the IT network being practically altered into a different type of a system Un desired behavior in normal operation or fault situations may follow AC drives need to be designed to be used with IT networks When drives are operated in IT networks itis important that the use does not cause ground currents as this will produce problems with the ground fault moni
118. nfallversicherung Germany Vacon Engineered Drives VACON 86 NXP BASED DRIVE UNITS NXP CONTROL UNIT OPT AF board slot B Control board Thermistor POWER UNIT Figure 60 Operating principle of the STO safety function in an NXP frequency converter with the OPT AF board The figure below shows an example of minimum wiring for the STO function The key criteria for wiring is that the STO inputs must always be used in parallel For more wiring examples see the user s manual of the OPT AF board There may also be additional machinery specific requirements that must be considered Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 87 OPT AF board J p o 9 Ca OO0V Short circuit and 1 earth fault protected supply A ae eee een Figure 61 Partial diagram showing the minimum wiring for the STO function 9 3 4 2 Safe Stop 1 SS1 The safe stop function initiates the motor deceleration and initiates the STO function after an appli cation specific time delay set by the user in accordance with the process requirements The SS1 safety function has been designed for use in accordance with the following standards EN 61800 5 2 Safe Stop 1 SS1 SIL2 e EN ISO 13849 1 2006 PL d Category 3 e EN 62061 2005 SILCL2 e IEC 61508 2000 SIL2 The function also corresponds to a controlled stop in accordance with stop category 1 EN 60204 1 2006 The SS1 safety function
119. ng see chapter Dimensions and layout of FRA FR5 FR6 and FR7 inverter units on page 128 FI and FI10 require an external pre charging circuit Pre charging can be either inverter specific or via common DC bus With common pre charging the individual inverters must have only DC fuses on the supply side If common DC bus pre charging is used you must not connect inverters to a live bus 6 Y 103 NOILIUTIULSNI L3NIGU lt m o o 5 m 3 a 5 D o f a U a z D n 10 9 9 DIMENSIONS AND LAYOUT OF FI12 AND Fl13 INVERTER UNITS FI12 FI12 Inv unit Inv unit With the FI12 inverter unit a dU dt filter requires an additional cabinet For cooling switch fuse and cabling see chapter Dimensions and layout of FRA FR5 FR6 and FR7 inverter units on page 128 The FI12 inverter unit requires an external pre charging circuit Pre charging can be either inverter specific or via common DC bus With common pre charging the individual inverters must have only DC fuses on the supply side If common DC bus pre charging is used you must not connect in verters to a live bus OET e NO2UA NOILIUTIULSNI L3NIGU lt m o o 5 m a 5 o o m o U a z D v 10 9 10 DIMENSIONS AND LAYOUT OF FI13 INVERTER UNIT 1400 i LEAL 01 FI13 Inv unit O 02 ILI O With the F113 inverter unit a dU dt filter requires an additional cab inet For cooling switch fuse and cabl
120. ng also needs special attention The motor cable plays an important role in relation to the electromagnetic interference of the drive system With right cable selection interferences can be avoided The type of the cable is of particular importance for the radiated emission of the cable In the industrial environment a shielded cable is usually sufficient In public environment a cable with a low impedance shield for high frequencies is needed We recommend that you use symmetrical three phase cables with symmetrical phase conductors symmetrical PE conductors and symmetrical shield whenever possible Single core cables are not recommended Recommended symmetrical Not recommended cable types asymmetrical cable Figure 30 Two symmetrical cables and an asymmetrical cable If the cable shield is made of iron it offers protection from EMC disturbance but cannot be used as PE An iron shield cable can only be connected at the inverter end and it must be isolated at the motor end A separate PE conductor must be used For EMC purposes both ends of the motor cable shield must be 360 grounded Grounding may not form a loop but it must be in star configuration If there is a potential difference between the devices it must be equalised by proper grounding Keep the motor cable as short as possible both inside and outside the drive enclosure You can use the shield of the motor cable for grounding purposes when the cross section of the s
121. ng the auxiliary com ponents you need to check the components ratings to avoid breakdown due to for example too high ambient temperature The IP00 modules must be protected from short circuit currents using appropriate AC and or DC fuses or by circuit breakers For fuse selection see the relevant product manuals 10 1 PRODUCTS INCLUDED IN AN IPOO DRIVE DELIVERY AC choke with liquid cooled drives the choke can be excluded from the order but a choke is compulsory as such e The IP00 power module e Control unit Output filter optional Control unit Power module Figure 80 Main items of an IPOO drive unit delivery Vacon Engineered Drives VACON 110 CABINET INSTALLATION 10 2 AIR COOLED NXP IPOO MODULE CONFIGURATIONS 10 2 1 FRAMES 10 AND 11 The power units of FR10 and FR11 drives are contained in a single frame The drive units are avail able in 6 pulse and 12 pulse versions The pulse system has no effect on the dimensions of the drive unit The number of AC chokes depends on the pulse system A 6 pulse drive needs one AC choke and a 12 pulse drive needs two AC chokes The chokes are external and they are delivered sepa rately Brake chopper is optional and it has no effect on the dimensions of the drive unit The control unit can be separate with optical connection to the power unit or it can be installed on the cover of the power module as in the figure below When the control unit is delivered wit
122. ng with risk of hazards that are caused by functional faults or errors in machinery or its control system A frequency converter is not a safety system as such but it can be used as a part of a safety system Frequency converter s role in a safety system is to be an actuator It contains functions that can be certified for use in safety related systems or applications This chapter does not contain instructions on how to build a safety system and neither do other items of Vacon s product documentation The aim of Vacon s product documentation is to explain how Vacon s products behave so that the designers of the safety system can apply them in an ap propriate way to the actual safety system 9 3 1 STANDARDS Standards are used to define the risk levels and to determine the sufficient risk reduction mea sures Machine builders follow the standards of their own field of expertise in their design The fol lowing two standards are the most important ones for frequency converters e EN IEC 61800 5 2 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional Product family standard for drives functional safety require ments e EN ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design In addition to the above mentioned the following standards may sometimes be referred to as re gards frequency converters EN IEC 62061 Safety of machinery
123. nication through optical bus is essential for the DriveSynch The control box must be supplied with an external uninterrupted 24V supply This way the DriveSynch communication is always active and redundancy is achieved Maximum length of optical cable between the units is 10 meters For installation and commissioning see Vacon NX User s Manual 9 2 2 MOTOR WITH ISOLATED AND MULTIPLE WINDINGS If the motor has isolated multiple windings a du dt filter is not required The du dt filter may still be necessary to limit the instability caused by the mutual impedance of the winding This is a proj ect specific solution If two drives are connected in parallel for one winding a du dt filter is required at each drive output Winding insulation has to be suitable for frequency converter usage in general In addition the in sulation level between the winding sets which are wound in parallel has to be at least the same as between the phases A phase difference can exist between the motor windings The DriveSynch technology provides a possibility to program the phase difference in the individual unit supplying each set of winding 9 2 3 SYSTEM REDUNDANCY Paralleled drive units operated using DriveSynch provide a high level of redundancy The system can be made to continue its operation even if one or more of the drive units is not functioning The actual level of redundancy is project specific and must be defined in accordance with the requ
124. nk s temperature does not change appreciably Usually the published currents are chosen to al low some overloadability The overload duty cycle used in Vacon s current ratings tables is defined as 1 min 10 min The RMS value of the current may not exceed the rated thermal current Vacon Engineered Drives VACON 22 DRIVE SYSTEM DIMENSIONING 4 2 4 2 Example of a cyclic load 1 min a 226A 9 min a 202A 2 2 L Ros 226 D x9 2054 1 min d 225A 9 min a 158A 9 2 T AS 255 x1 158 x9 1704 10 I I 380 500 VAC Inverter modules em Unit _Lowoverloadtaccurrent HighoverloadiACcurrent Inu te cae Frame tall nent ill tt NXI_0004 5 0 43 a 33 509 62 NXL 0009 5 Fu 99 959 77 m m NX 00125 m 2 nz 9 ns e NXL 0016 5 nn 31 1 1p wun A eee eee NXL 00225 UBA ug eae s E ea NXL 0031 5 A A eS ee PA pe on Sessor scu NXI 00385 CEN ME AUGE GORGE ES AA REESE ee NXL09455 FRI NXI 00515 FR7 l 67 46 69 92 NXI 00725 FR7 72 79 l 92 122 NXI 0087 5 FR7 87 96 72 108 144 NXI_0105 5 FR7 105 116 87 131 174 NXL 0140 5 FRE 154 105 we 20 NXI 0168 5 FI 0 0 0 280 NXI 02055 FI gt e EA s 336 NXI 02615 FI9 eT 27 w 306 349 w NXI 03005 FI 300 330 245 368 bbb NXL 03855 po ae 44 4 w NXI 04805 F10
125. nomer type of rubber FC Frequency Converter HTL High voltage Transistor Logic HVAC Heating Ventilation and Air Conditioning Hx Vacon s liquid to liquid Heat exchanger unit IEC nternational Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IFA nstitut f r Arbeitsschutz der Deutsche Gesetzlichen Unfallversicherung IGBT nsulated Gate Bipolar Transistor INU nverter Unit IP Protection class ISO nternational Organisation for Standardization LV Low Voltage MCB Miniature Circuit Breaker MCCB Moulded Case Circuit Breaker MEN Multiple Earthed Neutral MV Medium Voltage NBR Nitrile rubber NFE Non regenerative Front End NXI NXis a Vacon AC drive product family comes from Inverter OPT Option board PC Personal Computer PCC Point of Common Coupling PDS Power Drive System PE Protective Earth PID Proportional Integral Derivative PL Performance Level Vacon Engineered Drives VACON 158 ABBREVIATIONS Table 46 Abbreviations of terms used in the Engineered Drives Manual Abbreviation Term PME Protective Multiple Earthing PPR Pulses Per Revolution PVC Polyvinyl Chloride PWM Pulse Width Modulation RMS Root Mean Square RPM Revolutions Per Minute SCR Short Circuit Ratio SIL Safety Integrity Level SS1 Safe Stop 1 SSI Synchronous Serial Interface STO Safe Torque Off THD Total Harmonic Dist
126. nsation for 7 resistive voltage drop Boosting 1 2 n n Constant flux range Field weakening range Figure 17 Max torque voltage and flux as a function of the relative speed Frequency range lt fn constant flux range Frequency range gt fn field weakening range 4 2 3 3 Approximation of load current in constant flux area When the load torque is in the range of 0 8 T 0 7 Tmax I Toad x m T n Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 21 4 2 3 4 Approximation of load current in field weakening area When the load torque Tigaq is in the range of 0 8 n n T 0 7 n n Tmax I cad x Hr TC d n n Where Motor s nominal current Where l4 Motor s current at the required load 4 2 4 SELECT VACON FREQUENCY CONVERTER Criteria for selecting the frequency converter include e Continuous load current e Maximum load current and load cycles Note the derating factors described in the chapter Ambient conditions 4 2 4 1 Current capability A drive is designed for a certain current rating at a specified ambient temperature which is usually 40 or 50 C The basic sizing criteria is thermal i e at the rated current and rated temperature the internal temperatures of the drive do not exceed specified temperature limits In addition the IGBTs are chosen to be able to supply a heavy overload current for a short time during this time the heat si
127. nt that a drive system fulfills the EMC directives of the European Union This means that the drive system can bear conductive and radiative disturbances and that it does not send any conductive or radiative disturbances itself either to the electrical supply or the surrounding environment De rate for temperature above 40 C Be aware of high relative humidity risk of condensation Problematic dusts at e g cement factories and iron mines Vibration especially in marine applications Availability of space d e d d d d Cabinet Q EMC immunity z EMC emissions Q EMC EMC immunity emissions Supply Figure 18 Environmental factors and EMC of the AC drive Vacon Engineered Drives VACON 24 DRIVE SYSTEM DIMENSIONING 4 3 DIMENSIONING OF INVERTER UNIT FOR DRIVE SYSTEMS When dimensioning a drive system consisting of several drives each drive must be separately di mensioned in accordance with the dimensioning steps described in the above chapters 4 4 TYPE OF FRONT END In a common DC bus system you need to select the type of the front end unit When selecting the front end unit type consider the following Type ofthe supply network What is the voltage range e What is the frequency range e What is the acceptable THD level If the acceptable THD level of the supply network is very low lt 5 the front end unit must be Active Front End AFE If the acceptable THD level of the su
128. ntent of harmonic current distortion THDi The Active Front End configuration consists of the AFE module and a set of external components which you need to take into account when planning the switchgear configuration Of the external components LCL filters both air and liquid cooled and pre charging circuit are included in Vacon s product range For fuse selection tables and circuit breaker guidelines see the product manual POWER MODULE mw 15 fh11 Figure 69 NXA block diagram Vacon Engineered Drives VACON 94 NXP BASED DRIVE UNITS 9 5 2 1 AFE unit types Vacon type designation code is formed of a nine segment code and optional codes Each segment of the type designation code uniquely corresponds to the product and its options The code is of the following format Vacon NX Active Front End Type Code key NX A AAAA A AJ0 T 0 25 F A1 A2 00 00 00 Option boards each slot is represented by two characters where A basic VO board B expander VO board c fieldbus board D special board Hardware modifications module type S Boards F Fiber connection standard boards FI9 FI13 G Fiber connection varnished boards FI9 FI13 5 Standard air cooled drive Standard air cooled power unit external supply for main fan Delivery include 2 AFE module Internal brake chopper 0 N A no brake chopper EMC emission level T T networks EN61800 3 Enclosure class 0 IP00 F
129. o not contain a drive module but for example a choke and or an output filter you must check how much heat is produced and whether a door fan or other separate ventilation system is needed Vacon Engineered Drives VACON 120 CABINET INSTALLATION Figure 92 Ventilation of the cabinet Table below states the required cooling air quantities and the sizes of the openings for inlet and out let of air These values table below are achieved with the unit s own fan when the openings are in accordance with the product specific requirements Table 40 Ventilation requirements Ss Aaa Minimum air hole on switchgear dm Frame Cooling air required m h FR10 2800 13 FR11 4200 19 5 10 5 FI9 1150 5 9 F110 1400 6 5 F112 2800 13 F113 4200 19 5 10 5 Vacon Engineered Drives CABINET INSTALLATION VACON 121 10 8 COOLING LIQUID COOLED UNITS In liquid cooled units most of the excess heat is cooled by the liquid cooling system However in a liquid cooled drive system there are always some heat losses to the air too The heat losses orig inate from the busbars filters chokes and other auxiliary components The drive line up must be designed so that the ambient conditions inside each section are in accor dance with Vacon s specifications for Vacon products Temperature within each section must stay below the maximum operating temperature Repeated overheating will compromise the opera
130. ods used to achieve electromagnetic compliance The plan covers the entire installation including filters installation procedures grounding shielding mechanical construction etc Exact content or structure of an EMC plan has not been defined Vacon Engineered Drives EMC PRINCIPLES AND PRACTICES VACON 37 5 6 CONDUCTED EMISSION LEVELS pa es pea ee EN 61000 6 4 AAA 7 3 OA ANP Industrial environment EN 61800 3 1st environment 66 Average _ EN 55011 class A 66 60 CISPR 11 group 1 class A Quasi peak EN 61000 6 3 50 Residential environment EN61800 3 1st environment Average 46 category C1 EN 55011 Group 1 class B CISPR 11 Group 1 class B 150kHz 0 5 5 30 MHz Figure 27 Comparison of standards regarding conducted emission levels 5 7 RADIATED EMISSION LEVELS dBuV m measured at 10 m from device EN 61000 6 4 Industrial environment EN55011 class A EN61800 category C3 Quasi peak EN 61000 6 3 Residential environment EN55022 class B EN61800 category C2 30 230 MHz Figure 28 Comparison of standards regarding radiated emission levels Vacon Engineered Drives VACON 38 EMC PRINCIPLES AND PRACTICES 5 8 GOOD ENGINEERING PRACTICES REGARDING EMC Find out what type of environment the drive will be used in Choose the drive type accordingly The drive types listed in the following table refer to the type designation code that designates the EMC emission level in a
131. old flow is the property of an aluminium conductor to yield due to pressure exerted by terminal on the conductor This is a problem especially with round conductors The tightening torque used for mounting the cable must be lower than that used with copper conductors You must re tighten the terminal screws after a few days Vacon Engineered Drives VACON 66 SUPPLY NETWORK AND POWER CABLES 8 4 VOLTAGE DROP Calculate and check against allowed limits the voltage drop due to the cable resistance at rated current If cable resistance R is known the line to line voltage drop for three phase system on load current I is U 43R Considering the entire drive system you need to take into account also the voltage drop due to the feeding transformer Usually the maximum input voltage for drives is 110 of nominal voltage and the minimum is 85 9096 of nominal voltage 8 5 INSULATION MATERIAL Insulation material determines the maximum temperature of a cable under normal operation and short circuits Cables used with drives should usually withstand at least 70 C temperature The most common insulation material PVC limits the temperature to 70 C in normal operation XLPE PEX materials have 90 C temperature limit Common short circuit temperature limits are 160 C for PVC and 250 C for XLPE PEX Typically this temperature is allowed for a maximum of 5 seconds in short circuits Temperature limits of cables should be v
132. oling switch fuse and cabling see chapter Dimensions and layout of FRA FR5 FR and FR7 inverter units on page 128 If there is no requirement for regeneration and or low harmonics content it is possible to use NFE Non regenerative Front End units The switch gear s power capacity can be increased by adding NFE modules Each NFE requires dedicated AC and DC fuses and a choke NFE units have an inte grated pre charging circuit 1 x NFE fits in a 400mm cabinet 2 x NFE fit in a 600mm cabinet 3 x NFE fit in a 800mm cabinet It is also possible to place the fuses and chokes to a separate cabinet LTT 034 NOILIUTIULSNI L3NIGU lt m o o 5 m 3 a 5 o o m o U a z D v 10 9 7 DIMENSIONS AND LAYOUT OF FR4 FR5 FR6 AND FR7 INVERTER UNITS Two FR4 FR5 inverters can be installed in one full height cabinet An FR re quires an entire cabinet A dU dt filter is optional and usually fits in the same cabinet with the inverter depending on the cabinet type and height Proper ventilation of the cabinet is important Cooling air must be conducted out of the cabinet Inside the cabinet there must normally be an air barrier that keeps the incoming and outgoing air from getting mixed The incoming air must come from the lower part of the cabinet usually cabinet door so that the airflow goes past the dU dt cooling it on the way In case the cabinet contains two inverters it is even more import
133. on of liquid circulation possible in the commissioning phase In order to prevent dirt particles from accumulating in the connections and thus gradually weaken ing the cooling effect installation of filters is also recommended The highest point of the piping must be equipped with either an automatic or a manual venting de vice The material of the piping must comply with at least AISI 304 AISI 316 is recommended Prior to the actual connection of the pipes the bores must be cleaned thoroughly Cleaning with wa ter is recommended but if water is not available pressured air must be used to remove all loose particles and dust To facilitate the cleaning and venting of the coolant circulation we recommend you to install a by pass valve in the main line and valves at each frequency converter inlet Open the bypass valve and shut the valves to the frequency converter when cleaning and airing the system On commissioning the system the bypass valve must be closed and the valves to the converters opened Vacon Engineered Drives COOLING SYSTEM OF LIQUID COOLED VACON AC DRIVES VACON 137 Vacon recommends to equip the cooling system with pressure and flow supervision FE The flow supervision can be connected to digital input function External fault If the coolant flow is too low the frequency converter stops Choose the materials used in cooling system so that the risk of electrochemical processes is min imised In case you use
134. oning power drive systems including their EMC aspects PDS of category C3 PDS of rated voltage less than 1000 VAC intended for use in the second environment and not in tended for use in the first environment Note that limits change at 100 A PDS of category C4 PDS of rated voltage equal to or above 1000 VAC or rated current equal to or above 400 A or in tended for use in complex systems in the second environment Note that limits change at 100 A Vacon Engineered Drives VACON 36 EMC PRINCIPLES AND PRACTICES 5 5 1 EN 61800 3 VERSUS GENERIC STANDARDS The standards are compared here as regards emission levels Table 3 Comparison of standards Generic standard EN 55011 EN 61800 3 Generic commercial level Class B First environment Category C1 Generic industrial level Class A First environment Category C2 Group 2 equipment Second environment Categories C3 and C4 Vacon NX and Vacon 100 are designed to meet the requirements of the EN 61800 3 and they can be used in any environment if installed by a competent electrician EN 61800 3 Product Standard for PDS y 1st environment public low voltage networks C1 C2 C3 C4 A Ne UE un O 2st environment industrial networks EMC Plan mn Figure 26 Standards environments and classes 5 5 2 EMC PLAN An EMC plan is needed for large installations EMC plan describes the meth
135. ontract and that there is no visible damage to the equipment The following list gives some examples of the items that need to be checked Mechanical and electrical equipment are installed in accordance with the regulations or specifications e All connections are made in accordance with the regulations or specifications Grounding Protective Earth and possibly Technical Earth is checked e All cable and busbar connections are tightened in accordance with the recommended torque and have a correct insulating distance e Settings for the components and cabling related to the emergency stop circuit are checked The equipment and the premises are clean There is no scrap or dust inside the drive cabi net e All tools removed from inside the drive cabinet There are no short circuits between the phases or the ground This can be checked by carry ing out insulation tests If any high voltage insulation tests need to be done they have to be carried out by authorised personnel Vacon Engineered Drives VACON 151 COMMISSIONING Ko UOA we Tre B0 90 v3Tbe 0 90 3TTHEBO seyg e 3TTHERO stueyo z 32 2580 pu3 ju0JJ SANOY yno w Buifieu5 eeyo 77 3t CEE CC 74 eGveun 3t TEERCO Figure 108 The supply section D 2 i A o D s E c D c Lu c o O o gt COMMISSIONING VACON 152
136. onverter The filter increases the rise time of the voltage pulse i e reduces the change rate and high frequen cy content of the frequency converter s output voltage A du dt filter reduces the du dt value below 1kV us This reduces the risk of partial discharges in the winding Partial discharges are caused by exceeding the dielectric strength of the insulation and the discharges slowly degrade the insula tion causing turn to turn faults in the winding A du dt filter also helps to diminish voltage reflections which cause voltage stress to the motor This is also achieved due to an increase in the cable surge impedance which decreases the differ ence between the cable and motor impedances and thus the reflection coefficient Consequently the critical cable length is Longer Reducing the du dt value results in smaller capacitive leakage current A du dt filter reduces also ground currents and lessens the impact of the various sources of bearing currents A du dt filter causes a slight voltage drop in the circuit Therefore the pull out torque limit of the motor may be decreased by a few percent This will not normally have any effect on the process Filter does not reduce radiated emissions The motor cable must therefore be shielded The filter must be installed at the frequency converter s output You must also take care of the fil ter s cooling requirements Motor s insulation requirements are a main issue in determining whether y
137. opera tions fieldbus is the most efficient way to handle the control of the drives In a fieldbus control sys tem all controls go through a single cable from the automation system to the drive line up Fast multiple line monitoring Control system Figure 10 Drive control Vacon Engineered Drives DRIVE SYSTEMS VACON 13 3 4 1 FIELDBUS COMMUNICATION Compatibility with the various different fieldbus communication systems is established using option boards Some drives include support for certain communication options as standard but depending on the communication protocol you may need to acquire the option board that supports the com munication system you use Vacon s drives support a comprehensive selection of fieldbus commu nication systems through separate option boards Monitoring diagnostics and parametrisation Overriding control Profibus DP slot E Control diagnostics and monitoring eT eee Option boards Basic I O slot A Basic I O slot B Encoder slot C Can Monitoring Bus Profibus slot E Figure 11 A fieldbus communication system 3 4 2 DATA TRANSMISSION CAPACITY Data transmission capacity depends on the fieldbus system Fieldbus system uses a certain proto col for data transmission with a drive The amount of data that can be transferred depends on the protocol The drive s software application can be a limiting factor Application contents vary from simple
138. ortion TTL Transistor to Transistor Logic Vacon NXP NXisa Vacon AC drive product family P comes from High Performance VCB Vacuum Circuit Breaker VTT Technical Research Centre of Finland XLPE PEX Cross linked Polyethylene Vacon Engineered Drives VACON DRIVEN BY DRIVES DPDOO 8 3 4 WWW Vacon com Vacon Partner Subject to changes without notice
139. ot need the flexibility and pro cess specific customisation offered by a common DC bus or common AC bus system Figure 5 Typical stand alone drive Vacon Engineered Drives DRIVE SYSTEMS VACON 9 3 2 COMMON DC BUS DRIVE SYSTEMS A common DC bus drive system consists of one or more front end units that convert the mains AC voltage into DC voltage and current providing power to the common DC bus The common DC bus transfers the power to the inverter drives and depending on the type of the front end in some cases back to the mains network too Acommon DC bus drive system may include also a brake chopper unit as a cost effective solution for dissipating the braking energy in cases where regeneration of the power to the network is not feasible Common DC bus configuration can bring significant energy savings when the braking energy is used This is the case when there is more than one drive connected to the DC bus and at least one of them is braking The braking power is directly fed to the other drives via the common DC bus Common DC bus drive systems have different kinds of front end units depending on the require ments of the electricity network and the process where the drives are used From the electricity network s point of view the most important selection criterion is the acceptable level of Total Har monic Distortion THD The process requirements refer mainly to the need of braking and feasibility of regeneration of powe
140. ou need a du dt filter Vacon gives the following recommendation on the use of du dt filters Table 45 Use of du dt filters Supply voltage Need of filter 200 400V No need If the motor is double insulated and can withstand high 440 525V voltage spikes no need Otherwise use a du dt filter From frame size 200kW upwards no need Use du dt or sine filters If the motors are double insu 925 690V lated and specially designed for the purpose no need Vacon Engineered Drives VACON 142 MOTOR CABLES AND OUTPUT FILTERS En a 9 A ecce Figure 100 Du dt filters 12 1 2 SINE FILTER A sine filter is a LC low pass filter whose cut off frequency unlike that of a du dt filter is set to eliminate all the high frequency components of the frequency converter s output voltage It produc es a near perfect sinusoidal voltage waveform With a sine filter the voltage stresses on the motor correspond to those existing in normal DOL di rect on line use with a power source of the same voltage A sine filter is suitable especially for old motors not designed to be used with AC drives Sine filter eliminates bearing currents and voltage reflections and it also reduces motor s noise levels If you use an output transformer the sine filter eliminates high frequency components that could stress the transformer You can always use a sine filter instead of a du dt filter but it is much more expensive than a du
141. pole iron core their common mode inductance is relatively low In order to the above filters to be effective against bearing currents they should be manufac tured using single phase elements 12 2 3 4 Equipotential bonding between the device and the motor s frame In case there is a conductive connection between the device and the motor s shaft you must make sure that their potential is also identical concerning high frequency Usually there is no risk if both have been installed on the same metallic frame or metal plate and the connection points have a conductive connection to the metallic frame If the risk exists an equipotential bonding must be formed in between them This can be carried out using a plate with low inductance for example 10 cm in width A 16 mm earthing conductor used in normal installation is not applicable for this pur pose as high frequency impedance is formed in it Vacon Engineered Drives VACON 148 MOTOR CABLES AND OUTPUT FILTERS 12 3 ENCODERS Encoders deliver data regarding the position of the motor The data can be incremental or absolute 12 3 1 ENCODERS THAT DELIVER INCREMENTAL DATA Incremental data can be used for adjusting the motor In some cases you can use incremental data also for positioning but that requires calibration at start up using for example limit switch Encoder RS422 TTL Encoder 10 24V HTL Double encoder Wide Range SIN COS encoder interface HTL High voltage Tran
142. pologies such as 6 phase motors the PDS designer shall verify the protec tive earthing conductor cross section required For more information see the EN ISO 61800 5 1 Figure 31 Routing of supply and power cables Vacon Engineered Drives EMC PRINCIPLES AND PRACTICES VACON 41 Metallic wall of cabinet Screen connected to earth for EMC protection Motor cable Figure 32 EMC and PE grounding on single motor cable The EMC grounding must be suited to the output cable diameter to give a 360 contact with the ca bles There are also cables in which the mechanical protection shield is made of iron Due to high impedance of the shield you must not use this type of shield for grounding but it must be left open at the motor end With iron shielded cable you always need a separate PE cabling The separate PE cable must be connected to the motor and the drive s PE terminals If a device has been installed between the drive and the motor the motor cable shield must be kept continuous The shield must be connected at the input and output of the device so that a continuous low impedance connection between the two is ensured If necessary the components have to be in stalled in grounded sheet steel enclosures The cables of auxiliary equipment tachometers encod ers or other sensors must be shielded The shield may not be broken by intermediate connectors and must be connected at the drive end only 5 8 2 CABLE POSI
143. pply network is higher gt 5 the type of the front end unit can be either AFE or Non regenerative Front End NFE What kind of process will the drive be used in If braking is needed often and the braking power is relatively high an AFE unit is a relevant option Otherwise an NFE is adequate Process requirements for Front End type Is braking needed Is low THD required Is low THD required NFE 6 pulse THD must be 12 THD must be 12 Regeneration FE 6 BCU ED 12 pulse supply NFE 12 pulse configuration NFE 12 pulse configuration BCU Figure 19 Front End selection guidelines Vacon Engineered Drives DRIVE SYSTEM DIMENSIONING VACON 25 4 5 DIMENSIONING OF FRONT END FOR DRIVE SYSTEMS The dimensioning of the rectifier is based on the shaft power required and on the efficiency of the system The required shaft power is not necessary the same as the sum of the nominal rated motor powers You must know the maximum instantaneous power on the DC bus and consider the direc tion of power motoring generating Input DC Bus Output c A Mechanical Figure 20 Dimensioning the front end Parameters needed for correct dimensioning are Supply voltage Sum of shaft powers including direction of power Efficiency of the inverter unit Efficiency of the output filter s Efficiency of the motor s
144. put rectifiers on the drive The same effect can also be achieved by distributing equal loads on two windings of your feeding transformer Eighteen pulse systems also exist with three phase groups this system eliminates all harmonics up to the 23rd so the existing ones are 23 25 41 43 etc and the resulting THD is about 5 Vacon Engineered Drives HARMONICS VACON 9 51 Medium voltage At l4 l gt gt and 1 0 on primary side Ifl Zb 0 28 li l2 0 9 l 41 Figure 40 Using two transformers to cancel harmonics Vacon Engineered Drives VACON 52 HARMONICS 6 3 5 PASSIVE FILTERS Some manufacturers offer a passive filter to eliminate the harmonics The performance of a passive filter is approximately the same as that of a 12 pulse trafo They consist of chokes and capacitors in a low pass configuration and their size is usually considerable Passive filters are serial devices and thus sized for the full load current OA A M VA Figure 41 Passive filter Vacon Engineered Drives HARMONICS VACON 53 6 3 6 ACTIVE FILTERS You can use an active filter to eliminate the harmonics Active filter diverts the harmonics from the transformer by injecting anti harmonics into the supply This makes the load on the transformer seem fully linear The filter can be sized for the harmonics only as it is connected in parallel with the load and does not need to handle t
145. quency converters 124 10 9 4 Dimensions and layout of FR10 and FR11 frequency converters 125 10 9 5 Dimensions and layout of FR12 frequency converter 126 10 9 6 Dimensions and layout of the FI9 FI10 and F113 active front end units 127 10 9 7 Dimensions and layout of FRA FR5 FR6 and FR7 inverter units 10 9 8 Dimensions and layout of FR8 FR9 and FR10 inverter units sssss 10 9 9 Dimensions and layout of F112 and F113 inverter units 10 9 10 Dimensions and layout of F113 inverter 10 9 11 Dimensions and layout of the 1 4 inverter unit 11 Cooling system of liquid cooled Vacon AC drives 11 1 Choosing the cooling system type nnns 11 1 1 Liquid to liquid heat exchanger PARZ Radiator 1 1 1 1 editae ih docte nitent co deere neds Caes Grete Pade Moto d AER eG Dac A Ak 11 1 4 Materials and components of the cooling system Vacon Engineere
146. quency from its nameplate Motor s nominal frequency from its nameplate Motor s nominal frequency from its nameplate Motor s nominal frequency from its nameplate Motor s nomi nal current Motor s nominal current from its nameplate Num ber of drives in par allel using Vacon Drive Synch Motor s nominal current from its nameplate Num ber of drives in par allel using Vacon Drive Synch Motor s nominal current from its nameplate Num ber of drives in par allel using Vacon Drive Synch Motor s nominal current from its nameplate Num ber of drives in par allel using Vacon Drive Synch Motor s COS PHI Motor s nomi nal power fac Motor s COS PHI from its nameplate Motor s COS PHI from its nameplate Motor s COS PHI from its nameplate Motor s COS PHI from its nameplate tor Master Fol Master DriveSvnch Follower Drive Follower Drive Follower Drive lower mode y Synch Synch Synch Motor Control Open Loop Fre If used as Second ary Master Open No meaning inter nally handled Rec No meaning inter nally handled Rec Motor Control Mode Closed Loop Closed Loop Speed Torque Secondary Master Closed Loop Speed Torque If used as Follower no mean ing No meaning inter nally handled Rec ommended to use same setting as in the Master Mode Open iene Loop Frequency If ommended to use ommended to use Loop q
147. r card for fast drive to drive communication System software NXP00002V171 or later Application software Marine application APFIFF09V100 or later available on the internet e Multi Purpose application APFIF166V423 available on request System Interface application APFIFF10V228 or later Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 79 9 2 1 ENGINEERING NOTES Consider the following points when dimensioning and designing the system li Tota 0 95 X N X li unit lurota 0 95 XN X lp unit where lL Tota Total low overload current for the complete drive system lutotat Total high overload current for the complete drive system N Number of drive units in parallel in DriveSynch IL unit Low overload current of individual drive unit unit High overload current of individual drive unit The 2 voltage loss caused by the du dt filter needs to be considered while designing the system e In order to ensure load balancing the supply connection to the individual drives and the con nection from the drives to the motor must be symmetrical The supply cables or busbars for the individual units must be of equal size and length from the source Also the cable and busbar size and length from the drive unit to motor should be equal In a common DC bus configuration the supply side connections need not be symmetrical Tolerance of 2 in the impedance is usually acceptable e Fast drive to drive commu
148. r to the network COMMON DC BUS FRONT END ive 1 cha INVERTER INVERTER INVERTER CHOPPER os or NFE n i E AC SUPPLY Figure 6 Inverter units are fed from the DC bus and they control the motors in accordance with process needs 3 2 1 TYPICAL COMMON DC BUS SYSTEM APPLICATIONS A common DC bus system is an efficient solution for controlling production lines in various process industries such as pulp and paper factories as well as various steel processing mills and plants A common DC bus system is also applicable for the use of various cranes and winches etc DC bus systems can be divided into two main categories regenerative and non regenerative In a regenerative DC bus system the front end unit is capable of generating power back to the mains network This kind of system is suitable for processes where braking is needed often and the brak ing power is relatively high In a non regenerative system the braking power is redistributed to the other drives in the system via the common DC bus and possible excess power is dissipated as heat using a break chopper unit and brake resistors In small production lines or small paper machines where braking is needed seldom a non regenerative common DC bus system is a cost efficient so lution In applications where excessive power is needed it is possible to parallel multiple front end units Vacon Engineered Drives VACON 10 DRIVE SYSTEMS A common DC bus system cons
149. rature limit 70 C Table 9 Current capacities for cables installed on a tray EN 60204 1 IEC 60364 5 523 MON NN NN 1 5 16 19 2 5 22 26 4 30 36 6 37 45 10 52 63 16 70 85 65 25 88 107 83 35 114 134 102 50 123 162 124 70 155 208 159 95 192 202 194 120 221 292 225 150 338 260 185 386 297 240 456 350 300 527 404 8 7 4 CABLES INSTALLED NEXT TO EACH OTHER The following tables consider the effect of installing cables next to other ones which reduces cool ing The installation method used is the same as in the previous case Cables are installed on a tray in one layer and next to other ones with no spacing OIIO Figure 53 Cables installed on a tray side by side Vacon Engineered Drives SUPPLY NETWORK AND POWER CABLES VACON 69 Standard used is IEC 60365 5 523 and insulation material is PVC temperature limit 70 C Ambient temperature is 30 C which is taken into account The first table is presented for copper cables and the latter for aluminium cables Table 10 Current BLTTTIT RENE for copper cables installed on a tray and side by side EM factor k ET to number of cables Conductor size Conductor size mm Loadability of one cable A AN 18 16 15 14 14 14 2 5 24 21 20 20 19 19 4 34 29 28 27 27 26 6 42 37 35 34 33 33 10 59 52 49 47 47 46 16 80 70 66 64 63 62 25 101 88 82 80 79 78
150. ront End units in par allel to the same input transformer No communication between the units is required they work independently Vacon s standard LCL filters must be used for paralleling If filters other than Vacon s standard LCL filters are used in Active Front End units connected in parallel too large circulation currents may be generated between the Active Front End units See the Application manual for specific parame ter settings Each Active Front End unit connected in parallel must have its own short circuit protection on both AC and DC sides When paralleling attention must be paid to the sufficient short circuit capacity of the entire system Derating of Active Front End units connected in parallel is 5 of the DC power take this into account when selecting the input units If you want to isolate an AFE unit from the AC and DC voltages while other Active Front End units connected in parallel are in use you need separate isolators in the AC input and DC output The AC input can be isolated using a compact circuit breaker an ordinary circuit breaker or a fuse switch Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position The DC output can be isolated using a fuse switch You must also isolate the pre charging circuit from the AC input A load isolation switch or safety isolation switch can be used for this An Active Front End unit can also be connected to the mains even
151. s NXP BASED DRIVE UNITS VACON 91 9 5 CoMMON DC BUS MODULES 9 5 1 NON REGENERATIVE FRONT END Non regenerative Front End NFE is a unidirectional power converter for the front end of a com mon DC bus drive line up Protection class of the NFE module is IPOO The Non Regenerative Front End is used to transfer power from the AC input to intermediate DC circuit Power can only be transferred from the AC input to the intermediate DC circuit If braking is needed a brake chopper must be connected to the intermediate DC circuit The Non Regenerative Front End configuration consists of the NFE module and an external AC choke AC fuses main contactor and DC fuses which you must take into account when planning the switchgear configuration For fuse selection tables see the product manual Vacon s NFE product range includes an air cooled NFE module and a choke For more details se the product manual Table 21 NFE current and power ratings Low overload 1 500V mains lLcont A 400V mains P kW PIkW NXN _0650 6 FI9 513 CLOSE PULSE MAIN CIRCUIT PE L1 12 L3 MAIN CONTACTOR L 240VAC_ X2 01 ka E 2 N 240VAC_ L d gt 00 1 2 7D DC Figure 67 Non regenerative front end single unit connections Vacon Engineered Drives VACON 92 NXP BASED DRIVE UNITS 9 5 1 1 NFE unit s type designation code Vacon t
152. s there must be one AC choke for each NFE unit They are delivered separately Brake chopper cannot be integrated it is always external There are no frame specific brake chop pers for FR13 and FR14 You can selected the brake chopper unit from the common DC bus brake chopper range The brake choppers are of different sizes so they have an effect on the drive sys tem s dimensions Control unit is always connected using an optical cable The delivery contains also a fixing plate that is needed for installing the control unit to for example a cabinet door With FR14 two external dU dt filters are delivered by default For other frames they are optional For more details on dimensions and product types IP00 module installation guide gt 5 d Frame 13 Frame 14 Figure 83 Frames 13 and 14 Vacon Engineered Drives VACON 112 CABINET INSTALLATION 10 3 LIQUID COOLED NXP IPOO MODULE CONFIGURATIONS All liquid cooled drives use the NXP control platform The control unit is delivered separately with optical connection to the power unit A fixing plate for installing the control unit to for example a cabinet door is included in the delivery The protection class of all liquid cooled drive modules is always IP00 and they must be installed in a cabinet or other enclosure All liquid cooled drive units that consist of multiple modules are installed in mounting bracket A standard liquid cooled drive delivery contains an air coo
153. s the primary circuit s temperature It sends out an analogue signal to the HX control unit The control unit application adjusts the secondary circuit s flow through the plate heat exchanger by adjusting the 3 way valve to match the primary circuit s temperature setup value This value is project specific and it depends on the ambient temperature in the drive cabinet and the maximum temperature of the secondary circuit s inlet liquid The HX heat exchanger unit has flow temperature pressure and leak supervision in the primary circuit The HX control unit application monitors these quantities and generates alarms or shut offs depending on the parameter settings Monitoring the temperature and flow of the secondary circuit is the responsibility of the user See Vacon s heat exchanger manuals for further details Vacon Engineered Drives COOLING SYSTEM OF LIQUID COOLED VACON AC DRIVES VACON 135 e B i External customer s cooling circuit a 85 Figure 96 Liquid to liquid heat exchanger 11 1 2 RADIATOR Vacon s product range does not include radiator type heat exchangers They are a process specific project Design and dimensioning of radiator heat exchanger must be done with the equipment manufacturer Liquid to air heat exchanger Figure 97 Liquid to air heat exchanger 11 1 2 1 Legend to the flow circuit Automatic M unit FE Flow Supervision TT Temperature Transmitter Th m c M ind TIC T
154. se the NCDrive tool for specifying the event data NXP allows control of Permanent Magnet PM motors NXP control platform allows you to use Va con s Drive Synch control concept which is a way to parallel high power drives to control an AC mo tor See chapter Drive Synch on page 76 A control keypad functions as a link between the user and the frequency converter You can use the control keypad for setting application parameters reading status data and giving control com mands The control keypad is detachable and can be operated externally when connected to the fre quency converter via a communication cable Instead of the control keypad you can use a PC to communicate with the drive if connected using a similar cable VACON RS232PC 1 5M All Vacon s NXP drives contain the All in One software application package by default If needed a process specific software application can be installed at the factory or later as an update Optional I O expander boards that increase the number of inputs and outputs to be used are also available Vacon Engineered Drives Table 14 Option boards Type Card slot 1 O signal DI DO DI Al Al AO AO RO RO 10V Therm 24V pt100 42 240 DI DO DI DO DI Resolver Out 5V Out Out 5V A B C D E DO mA mA mA V mA NO NO EXT VAC ru mu 15V 12W Note VAN isolated isolated NC 24V input 10 24V RS422 1Vp p 24V 24V 15V Basi
155. sistor Logic voltage level is 10V 30V TTL Transistor to Transistor Logic voltage level is 5V RS422 Differential receiver for 6V to 6V signal Compatible with TTL encoders with inverted out puts 12 3 2 ENCODERS THAT DELIVER BOTH INCREMENTAL AND ABSOLUTE DATA Encoders that deliver both incremental and absolute data can be used for adjusting the motor and for more speedy and precise positioning e SSI and ENDAT Encoders with SIN COS e RESOLVER RESOLVER is a rotary transformer where the magnitude of the energy through the resolver wind ings varies sinusoidally as the shaft rotates A resolver contains one primary winding and two sec ondary windings the SIN and the COS windings ENDAT is a bidirectional synchronous serial interface for absolute encoders For example the en coder position data can be read and encoder parameters can be set via ENDAT connection It also forwards the messages related to the encoder functions SSI Synchronous Serial Interface is a single directional interface for transmitting absolute posi tion value Note Sensors that deliver SIN COS data can be used also for slow running of the motor with inter polation 6Hz 12 3 3 ENCODERS THAT DELIVER ONLY ABSOLUTE DATA Encoders that deliver only absolute data can be used for precise positioning when speed require ment is relatively slow e SSI and ENDAT Encoders digital only 12 3 4 INSTALLATION Vacon recommends to use always shielded tw
156. sufficient time but it must not be too high All protective components have limits for maximum short circuit current For fuses this value may be from 10kA to 200kA depending from the fuse series or size and for some miniature circuit breakers it might be as low as just a few kilo amperes It is important to make sure that the short circuit rating of the protective component is high enough Selecting of an underrated protective component may lead into catastrophic damages 7 1 CONTACTORS You can use a contactor to switch frequency converter s power on and off by local or remote control or by emergency stop Typically a contactor is used on the AC power supply side of a frequency con verter but it can also be used on the motor side or even by pass the converter and connect the mo tor directly to the mains network Contactors should have always a protective component in the circuit preventing contacts to be melted in case of short circuit A contactor is seldom used in the DC side of an inverter but technically it is possible However DC contactors with high breaking capacity are rare In these cases contacting the contactor manufac turer for detailed technical information is highly recommended When contactors are used in DC circuit typically 2 or more contacts are connected series Figure 43 A contactor Vacon Engineered Drives VACON 56 CONTACTORS BREAKERS AND FUSES 7 1 1 DIMENSIONING Rating of the contactor is defin
157. t no load gradually up to the full speed Check the encoder feed back and also smooth running of motor through the speed to confirm its correct installation e Perform an ID Identification run tis recommended to perform a complete Identification run During the ID run the motor is typically run to 60 7096 of its nominal speed In some applications load cannot be discon nected from the motor In these cases the identification run can be done with the motor at standstill Set the motor control mode to be Open Loop or Closed Loop with speed or torque control e Set the limits based on the process requirement speed torque and current e Process specific settings tuning of speed controller load drooping acceleration or load compensation Vacon Engineered Drives COMMISSIONING VACON 9 155 e Running with load e Run the motor with load throughout the speed range of the process in both directions This way you can check the stability of the control and smooth running of the process and mechanics within limits 13 1 6 DOCUMENTATION Documentation is needed for maintenance and servicing purposes It must be stored during the drive system s entire lifetime and maintained in a usable format e fany connections were changed during the commissioning the changes must be marked into the circuit diagram All documents and drawings must be updated for the customer and the engineering team e The drive s parameter files must be sa
158. tems all odd harmonics may exist Note that as long as the voltage is not appreciably distorted only the basic frequency transmits power currents at other frequencies just flow technically forming a kind of reactive current For rectifiers the fundamental power factor is approximately 0 95 or higher Generally the power factor can be defined as kW kVA pf cos xv1 THD where cos phi fundamental power factor and THD the THD total harmonic distortion value in percent Vacon Engineered Drives VACON 44 HARMONICS The THD is defined as THD where i n th harmonic and i fundamental current THD is a complex function of the load supply transformer data and components of the frequency converter s circuit Generally a big transformer stiff source leads to higher current distortion and lower voltage distortion and a small transformer soft source leads to lower current distortion and higher voltage distortion As the size of the transformer is considered relative to the drive s load this also means that the current distortion will increase with lower loads for a given source drive combination whereas the voltage distortion will decrease The harmonic currents added to the basic frequency current create a higher RMS current with high er heating effects in the wiring and transformer The harmonic currents also flow through the im pedance of the source transformer or generator creating harmonic volta
159. the drive itself pro vides protection against overloads but additional short circuit protection is required Supply cables should be protected at the supply end against short F2 circuit and overloads gG Typically ultra fast fuses aR are sufficient for protection of frequency con verters against short circuit and they reduce the damage inside the fre quency converter in case a short circuit happens inside the drive Smaller size or low cost frequency converters are protected only with regular speed fuses gG as ultra fast fuses are quite expensive and gG fuses ar more af le fordable A regular speed fuse gG protects from both short circuit and overload so it is suitable for protecting the supply cables too in the feeding E end aR 7 3 1 SELECTING THE FUSES See the Vacon product manuals to select the correct fuse type for your fre quency converter Especially with high power frequency converters you may be able to select from several different fuses that are suitable depending on what kind of fuses are required by the switchgear construction Usually you can choose between using one set of high current fuses typically bolt con nected or using parallel smaller knife type fuses Main parameters for se lecting correct fuses are drive s amperage voltage and required mechanical construction Also frequency converters AC and inverters DC require dif q y q UM ferent fuse types SEL
160. tion and shorten the lifetime of the frequency converter The need of cooling of the frequency converter varies greatly with load and output frequency as well as with the switching frequency used You must check how much the heat losses are in each section of the drive line up and whether a door fan or other separate ventilation system is needed to keep the temperature of the section within the limits A completely air tight cabinet is possible if there is a radiator liquid to air heat exchanger inside the drive cabinet Vacon Engineered Drives VACON 122 CABINET INSTALLATION 10 9 DIMENSIONS AND LAYOUT EXAMPLES 10 9 1 DIMENSIONS OF THE SUPPLY SECTION 1 2 3 4 400 01 Yi Figure 93 Supply section dimensions Example 1 With a supply unit of under 1000A it is possible to use a switch fuse or if the supply system has adequate overload and short circuit protection a load switch can be used The cabinet width is typically 400mm Example 2 With a supply unit of over 1000A both a breaker ACB and an earthing switch can be used The use of an earthing switch depends on the local legislation The cabinet width depends on the size of the switch Typical cabinet widths are as follows Table 41 Cabinet width 1600A 3200A 600mm 4000A 800mm 5000A 1000mm Example 3 With a supply unit of over 1000A the supply section typically contains an earthing switch with a typical exception of mar
161. tion altitude has no effect on the thermal performance of Vacon s liquid cooled frequen cy converters 4 7 2 ELECTRIC INSULATION The installation altitudes of Vacon AC drives have been specified for the worst case conditions at the altitude of 2000 m i e both at the highest value of the rated mains voltage range and corner grounded network system corner grounding is possible for the 500V drives only Higher installation altitudes are possible with the following limitations 4 7 2 1 Mains voltage Maximum installation altitude of the 500 V Vacon NX units 480 V Vacon 10 units and 500 V Vacon 100 1000 units is up to 3000 m at rated voltage if the network is not corner mounted In special cases higher installation altitudes may be possible with certain limitations Maximum installation altitude of the 690 V Vacon NX units is 2000 m At higher locations the mains voltage should be limited to equal or less than 519 V and these products are not designed for this voltage level aux power supply operating voltage range 4 7 2 2 High voltage I O signals The relay output signals at standard I O boards and option boards when all relay circuits are con nected to the same supply voltage are specified for up to 250 V atthe altitude of 2000m OPT A2 and OPT AC are exceptions they can be used only up to 150 V voltage at 2000 m The signals can be used at 150 V up to the altitude of 4866 m with the following exceptions e OPT B5can be use
162. tor size mm2 120 428 642 150 496 743 185 566 849 1132 1415 1698 1981 2264 2547 240 669 1003 1337 1672 2006 2340 2675 3009 300 773 1159 1546 1932 2318 2705 3091 3478 Table 13 Current capacities for parallel connected aluminium cables installed on a tray and next to other ones nine in total Number of cables in parallel Eonductor Combined loadability of cables A size mm 120 330 495 150 381 572 185 436 653 871 1089 1307 1524 1742 1960 240 513 770 1026 1283 1540 1796 2053 2310 300 592 889 1185 1481 1777 2073 2370 2666 Vacon Engineered Drives SUPPLY NETWORK AND POWER CABLES VACON 71 8 7 6 REQUIREMENT FOR PE CABLES The IEC 60204 1 standard sets the following requirement regarding dimensioning PE cables Where electrical equipment has an earth leakage current that is greater than 10 mA AC or DC in any incoming supply one or more of the following conditions for the associated protective bonding circuit shall be satisfied e The protective conductor shall have a cross sectional area of at least 10mm copper or 16 mm aluminium through its total run e Where the protective conductor has a cross sectional area of less than 10 mm copper or 16 mm aluminium a second protective conductor of at least the same cross sectional area shall be provided up to a point where the protective conductor has a cross sectional area not less tha
163. toring systems of the network To achieve this capacitances towards ground need to be minimized in the frequency converter RFI filters are a significant single source of problems and may not be used Also the cabling used should be symmetrical to minimize capacitive coupling Any resistances towards ground need to be on the order of hundreds of megaohms Vice versa the user needs to ensure that fault monitoring systems of the IT network is suitable for AC drives Problems may occur if an input phase of the frequency converter gets grounded in the IT network This will cause modulation frequency component to be seen in the whole network This can bea problem for low power drives in which a diode pump phenomenon may occur The phenomenon causes an increase in the DC bus voltage even when the frequency converter is in stop mode This can be solved by adding a brake chopper which is active also in the stop mode 8 1 2 TT NETWORK In a TT earthing system the protective earth connection of the consumer is provided by a local con nection to earth independent of any earth connection at the generator The big advantage of the TT earthing system is the fact that it is clear of high and low frequency nois es that come through the neutral wire from various electrical equipment connected to it This is why TT has always been preferable for special applications like telecommunication sites that benefit from the interference free earthing Also TT does not
164. trolled so that a sinusoidal current is drawn from or supplied to the supply they can thus also regenerate power back into the supply a feature used in many power generating applications as well as in cases where braking is often required The power factor of the input cur rent can also be changed so an AFE can also be used to compensate phase shifts caused by other loads on the supply within its current rating An AFE is always sized for the full load current Filter Active rectifier Inverter Figure 39 Active front end 6 3 4 MULTIPULSE CONNECTIONS A traditional method to reduce harmonics is to use a multipulse transformer with the windings for multiple three phase groups arranged in such a manner that the harmonics from the groups cancel in the magnetic circuit of the transformer and are eliminated from the input current of the trans former The most common is a 12 pulse system where two phase groups are connected to the load elim inating the 5th and 7th harmonic and leaving the 11 1315 2310 25 etc The resulting THD in the input current is about 10 Note that due to challenges in transformer design in balancing the phase groups the cancellation is rarely perfect some traces of the 5th and the 7 harmonic remain Note that the transformer can be used to change voltage levels from MV to LV at the same time The main drawback is the size weight and cost of the required transformer as well as the need for mul tiple in
165. ved As a result of a successfull commissioning the drive system can be handed over to the customer The customer can start using the system aiming at optimum performance Any feedback from the customer as well as the experiences of the commissioning team should be collected Further pro cess improvement and maintenance rely on the information learned during the commissioning This information is needed also for training of the operating personnel User and installation man uals only define the starting point but every commissioned system is customer project specific A well commisioned drive system is likely to be more reliable and meet the customer s expecta tions even exceed them and thus add to customer satisfaction Commissioning gives one more chance to interpret the customer s real needs and to customise the drive system accordingly Vacon Engineered Drives VACON 156 COMMISSIONING Vacon Engineered Drives ABBREVIATIONS VACON 9 157 14 ABBREVIATIONS Table 46 Abbreviations of terms used in the Engineered Drives Manual Abbreviation Term AC Alternating Current ACB Air Circuit Breaker AFE Active Front End BCU Brake Chopper Unit CAN Controller Area Network CISPR Comit International Sp cial des Perturbations Radio lectriques DC Direct Current DOL Direct OnLine EDM Electric Discharge Machining EMC Electromagnetic Compatibility EN European Norm EPDM Ethylene Propylene Diene Mo
166. when the other Active Front End units connected in parallel are already connected and running In sucha case the isolated AFE unit must first be pre charged When that is done the AC input can be switched on After this the device can be connected to the intermediate DC circuit 9 5 2 4 Common pre charging circuit In case of paralleled Active Front End units one common pre charging circuit can be used Stan dard pre charging circuits can be used if the capacitance of the intermediate circuit does not ex ceed the maximum value For example if you connect three F110 Active Front End units in parallel you can use the pre charging circuit for F113 Active Front End unit If all paralleled Active Front End units have a common circuit breaker the breaker can be con trolled by one of the Active Front End units If each paralleled Active Front End unit has its own cir cuit breaker each Active Front End controls it s own breaker See the figure below Vacon Engineered Drives NXP BASED DRIVE UNITS VACON 97 MAIN CIRCUIT LCL U2 AFE U1 NXA 10000 x axils la AFE U2 NXA xxxx x o DOUBLE INSULATED DOUBLE INSULATED DOUBLE INSULATED DOUBLE INSULATED DC DG 7 7 Figure 70 Active Front End units connected in parallel with own pre charging circuits 9 5 3 LCL FILTER An AFE needs always a
167. would indicate that a HXL M 040 N P unit could be sufficient However the 165 l min flow require ment means that the HXL M 120 N P unit is actually needed Vacon Engineered Drives VACON 140 COOLING SYSTEM OF LIQUID COOLED VACON AC 11 3 CONDENSATION When planning a liquid cooled drive system you must take into account that there must be no con densation inside the drive cabinet and especially on the cooling plate of the NX liquid cooled drive As the coolant piping is located inside the drive cabinet it is vital that the coolant s temperature stays above the dew point The most secure way of preventing condensation inside the drive cabinet is to keep the coolant temperature higher than the ambient temperature inside the drive cabinet Use the graph below to determine if the drive operating conditions combination of room tempera ture humidity and cooling liquid temperature are safe or to choose the allowed temperature for the cooling liquid The conditions are safe when the point is below the respective curve If not take adequate precau tions by decreasing the room temperature and or the relative humidity or increase the cooling liq uid temperature Note that increasing the temperature of the cooling liquid above figures in loadability charts decreases the nominal output current of the drive The below curves are valid at sea level altitude 1013 mbar Condensation Safe operating area 60 Coolant temp C
168. ype designation code is formed of a nine segment code and optional codes Each segment of the type designation code uniquely corresponds to the product and its options The code is of the following format VACON DRIVEN BY ORIVES Vacon NX Non Regenerative Front End Type Code key NX N 0650 e x o T o S S V 00 00 00 00 00 Option boards each slot is represented by two characters where No option board possible Hardware modifications module type S Boards V Direct connection varnished boards S Standard air cooled drive U Standard air cooled power unit external supply for main fan Delivery include N NFE module S NFE module AC choke O Internal brake chopper 0 N A no brake chopper EMC emission level T IT networks EN61800 3 Enclosure class 0 1800 FI9 Control keypad xX standard alpha numeric EMI Nominal supply voltage 6 380 690VAC 513 931VDC Nominal current low overload 0650 650A only Module type N NFE Non Regenerative Front End Product generation Figure 68 NFE Type code key 9 5 1 2 Paralleling You can increase the power of the input group by connecting several Non Regenerative Front End units that have a common AC supply in parallel No communication between the units is required they work independently Each Non Regenerative Front End unit connected in parallel must have its own short circuit pro tection on AC and

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