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WEG UR11 Rectifier User`s Manual

1. OK OK Peter lomo ON Gee Orr lO kor oe metes 1 MIN AL pre charge in progress Et Phase fault or undervoltage Phase fault at the input power 2 2 3 dias Tun T lt T JOFF ON ON ON OFF OFF OFF OFF E eoe e Open circuit breaker Ed Heatsink temperature OK OK Completed 17 lt T ON JOFF ON ON ON ON ON OFF higher than 80 C 176 F alarm temperature M Heatsink overtemperature Tea lt T J OFF OFFJOFF ON ON higher than 90 C 194 F fault temperature lore OFF OFF OFF OFF or lon oe 24 Vdc power supply M Heatsink undertemperature OK OK OFF De Dei OFF ON OFF ON OFF OFF OFF ON smaller than 9 C 16 F Defective or opened NTC Note 1 Temporary operation condition 2 Phase fault undervoltage detective rectitier bridge 1 refer to figure 2 5 3 Phase fault undervoltage defective rectifier bridge 2 refer to figure 2 5 4 The monitoring temperatures are High temperature alarm active with T 80 C TEMP_ALARM Overtemperature fault active with Teau 90 C TEMP_FAULT Undertemperature fault active with Ty 9 C TEMP_FAULT 5 The input state is not decisive for the outputs state 9 2 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Troubleshooting and Maintenance 5 3 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS Table 5 3 Solutions for the most frequent problems Point to
2. C to 45 C 14 F to 113 F nominal conditions measured around the rectifier From 45 C to 55 C 113 F to 131 F 2 current derating tor each Celsius degree Air relative humidity from 5 to 90 non condensing Altitude up to 1000 m 3 300 ft standard conditions From 1000 m to 4000 m 3 300 ft to 13 200 ft 1 of current derating for each 100 m or 0 3 each 100 ft above 1000 m 3 300 ft altitude From 2000 m to 4000 m 6 600 ft to 13 200 ft 1 1 of maximum voltage derating for each 100 m or 0 33 each 100 tt above 2000 m 6 600 ft up to 4000 m 13 200 ft maximum altitude Pollution degree 2 according to EN50178 and UL508C with non conductive pollution Condensation shall not originate conduction through the accumulated residues E KE E E E 3 2 LIST OF COMPONENTS The UR11 rectifier was developed to perform the rectification of the incoming three phase power supply and provide the proper DC link voltage to the CFW 11M line It replaces the pre charge circuit and the line reactor or the interphase reactor when the 12 pulse configuration is required It is possible to add rectifier units in parallel for applications that demand higher currents than the rated current of one rectifier unit see tables 3 1 to 3 3 Table 3 1 Currents and configuration in 380 480 V Nominal Current A Number of Power Units UR11 in parallel Phone 800 894 0412 Fax 888 723 4773 Web ww
3. Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 21 Installation and Connection 3 5 3 Emission and Immunity Levels Table 3 10 Emission and immunity levels EMC Phenomenon Basic Standard Emission Mains Terminal Disturbance Voltage Without external filter C4 Category Frequency Range 150 kHz to 30 MHz With external filter C2 or C3 Category Electromagnetic Radiation Disturbance Frequency Range 30 kHz to 1 GHz Immunity Electrostatic Discharge ESD IEC EN61000 4 2 4 kV for contact discharge and 8 kV for air discharge 2 kV 5 kHz coupling capacitor power input cables IEC EN61800 3 Fast Transient Burst IEC EN61000 4 4 1 kV 5 kHz control cables and remote keypad cables 2 kV 5 kHz coupling capacitor motor output cables 0 15 to 80 MHz 10 V 80 AM 1 kHz is O Ode PANDO Motor cables control cables and remote keypad cables 1 2750 us 8 20 us Surge Immunity IEC EN61000 4 5 1 kV line to line coupling 2 kV line to ground coupling 80 to 1000 MHz Radio Frequency Electromagnetic Field IEC EN61000 4 3 10 V m 80 AM 1 kHz 3 5 4 External RFI Filters 3 22 To be used only if necessary to comply with conducted emission levels category C2 or C3 according to IEC EN61800 3 For the CFW 11M inverters the connection diagram for 6 pulses configuration presented at figure 3 25 should be used and the connection diagram for 12 pulses conf
4. Util LUV UOAAIAALAA A AI HUAI A HUTT HINT PUUE Mn lt oe ele HN allt WNL AN LT j sates 1 MI HH MUAHHH AA III MULL Meee PHAN ATT TALL Dee O E LA NIII LA wiii Hl Ty ACTA POCA AMAIA HAH ASOMAN AD A EL NAAA AE NNT it ILL LIT DENN A TULLE EN IASl gt WS IM Figure 3 2 Mounting of the URI 1 side by side without lateral spacing PANEL FAN WHEN REQUIRED Wii PRADA HTT TTL LIL UVTI TELL LLL HT AHIHI 150 6 9 E VENTILATION OPENINGS ON FRONTAL PANEL SURFACE Figure 3 3 Ventilation clearances in mm in The total air outflow of the power unit is 1150 m3 h 320 l s 677 CFM lt is recommended an outflow of 1350 m8 h 375 l s 795 CFM per power unit at the air exhaustion Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 3 3 Installation and Connection 210 5 8 29 174 5 6 87 1497 6 58 96 582 75 22 94 450 17 72 550 6 21 68 10 8 0 42 yl 18 8 18 7 0 74 0 74 192 5 7 58 WHEELS BALL BEARINGS COVERED WITH NYLON FOR MOVEMENT IN THE CABINET Figure 3 4 URI 1 bottom view and the side cut view mm in The UR11 wheels facilitate its insertion into and withdrawal trom the panel figure 3 4 Figure 3 5 Fixing holes of the rectifier unit 3 4 Phone 800 894 0412 Fax 888 723 4773 Web www ct
5. 1 cceccceccce cece cece sceeecee esse seseeeseesseesesesesaessaesseseeeeeeaeetaeeeas 2 8 2 9 Howto opeciiy ihe URI Model omar Cole vrai rnnr eena NEEE REEERE RREN 2 9 210 NECE IA CNG MOTO E T 2 10 CHAPTER 3 Installation and Connection at Pty Pomme el SONG ONS eA dcpasaceaaenedeccnnasecanncuancatnaneecasneaessccuiasndasedsancdsccuancasnaasnere 3 1 S L E gE o TIEPE ETETETT 3 1 Mechanical Sata 3 2 5 o doom sosasanesavoseeseansasosanensiesssoseseuanceanenaaen 3 5 A Pr O USO II E 3 5 E Uae E EE Coal 0 anne eT oT ETO ee ee 3 6 Dw USCS O o e OE ES UR UP UU E E o A 3 O PPP A E A 3 8 3 4 4 1 Operation as 6 Pulse Rectifier oocccoocccnocccnocccnorccnnccnnoroconononoconnnonnnncnnnocnnnnonnnonoss 3 8 3 4 4 2 Operation as 12 Pulse Rectifier ooocccoocccnocccnocnnnnrcnnoronnrononononoconnocnnnoconnncnnnaross 3 9 O ANA o A o y e EI 3 11 3A l Ponellayout and Comec Serriera teisia cto TAEAE 3 11 3 4 5 2 Power C nnechons vcuundoanancodianrandraisdciicd ndice 3 12 A ONE CONS scassc scan ccancsnscasacssssasanaaieaaiecisentiantiatddansdssdieriaenaetaneascnenneess 3 14 A 3 15 A CORTO CORE ros 3 16 A A o Po POCO OO PO RI 3 18 3 5 Installation According to the European Directive of Electromagnetic Compatibility 3 20 5 0 Conlara lnsialaion With me Cal Miera 3 20 A EE E E EA 3 21 Sr Emisora nun level eee eee nee e ieia e ieia i a ee eR 3 22 ee GIR Ae PI 3 22 Phone 800 894 0412 Fax 888
6. 1 Put the box on the floor 2 Open the wood crate 3 Remove all the packing material the cardboard or styrofoam protection before removing the UR1 1 Check the following items once the rectifier is delivered Verify that the product identification label corresponds to the model number on your purchase order Inspect the product for external damaging during transportation Report any damage immediately to the carrier that delivered your product If the products were note installed immediately store them in a clean and dry place temperature between 25 C and 60 C 77 F and 140 F with a cover in order to avoid the contamination with dust TIE aT 191 AHA ber ni Figure 2 10 Do not tilt the rectifier units 2 10 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection 3 INSTALLATION AND CONNECTION This chapter provides information on installing and wiring the UR11 The instructions and guidelines listed in this manual shall be followed in order to guarantee personnel and equipment safety as well as the proper operation of the rectifier 3 1 ENVIRONMENTAL CONDITIONS Avoid installing the UR11 in an area with Direct exposure to sunlight rain high humidity or sea air Inflammable or corrosive gases or liquids Excessive vibration Dust metallic particles and oil mist Environment conditions for the operation Temperature 10
7. 12V_ON must light The remaining LEDs must be off 4 Command the panel perform the DC link pre charge and close the main contactor circuit breaker 5 Verify the proper operation of the fans 6 Observe the existence of faults alarms at the relay outputs and LEDs In case of any fault or alarm verify the possible causes and solve the problem 7 Check the input current of each rectifier unit with a current meter The current must be smaller than 5 the ND rated current as the rectifier is under no load 8 De energize the panel Then connect the inverters without load Check the inverter connections and if the current and voltage are according to the UR 1 9 Command the panel perform the DC link pre charge and close the main contactor circuit breaker 10 Enable inverters output and check the input current of each phase of the UR11 the maximum current unbalance of each phase must be 5 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 4 1 First Time Power Up and Start Up 4 2 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Troubleshooting and Maintenance 5 TROUBLESHOOTING AND MAINTENANCE This chapter El Lists all faults and alarms that may occur El Indicates the possible causes of each fault and alarm El Lists most frequent problems and corrective actions El Presents instructions for periodic inspe
8. Adjustable speed electrical power drive systems Part 2 General requirements Rating specitications for low voltage adjustable trequency AC power drive systems ELECTROMAGNETIC COMPATIBILITY EMC EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods EN 5501 1 Limits and methods of measurement of radio disturbance characteristics of industrial scientific and medical ISM radio frequency equipment CISPR 11 Industrial scientific and medical ISM radio frequency equipment Electromagnetic disturbance characteristics Limits and methods of measurement EN 61000 4 2 Electromagnetic compatibility EMC Part 4 Testing and measurement techniques Section 2 Electrostatic discharge immunity test EN 61000 4 3 Electromagnetic compatibility EMC Part 4 Testing and measurement techniques Section 3 Radiated radio frequency electromagnetic field immunity test EN 61000 4 4 Electromagnetic compatibility EMC Part 4 Testing and measurement techniques Section 4 Electrical fast transient burst immunity test EN 61000 4 5 Electromagnetic compatibility EMC Part 4 Testing and measurement techniques Section 5 Surge immunity test EN 61000 4 6 Electromagnetic compatibility EMC Part 4 Testing and measurement techniques Section 6 Immunity to conducted disturbances induced by radio frequency fields MECHANI
9. a R2 S2 T2 PE 220V Ext UW 4 U LL Fa F9 F10 e coa r A qi m R S T GND PE Figure 3 9 General connection diagram of a 6 pulse rectifier configuration with three parallel URI 1 units The figure 3 9 presents the general connection diagram using three parallel UR11 units operating as a 6 pulse rectifier For the operation with a reduced number of parallel UR11 units consider the connection in the ascending order 3 8 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection 3 4 4 2 Operation as 12 Pulse Rectifier 24 Vdc Ext 24 Vdc Ext 24 Vdc Ext 12 3 123456789 iJ2 3 123456789 lej 123456789 RGA XC2 UD UD 24 Vdc RLI RL2 RL3 10 output relays XGI xc2 UD UD 24 Vdc RL1 RL2 RL3 10 output relays XC1 XC2 UD UD 24 Vdc RL1 RL2 RL3 10 output relays 300 mA 300 mA 300 mA external external external power UR 1 power UR1 1 power UR 1 supply supply supply O 2 Ri 51 T1 XC4 R2 52 T2 PE GND ha 51 T1 2H R2 52 T2 PE R S T GND PE Figure 3 10 General connection diagram of a 12 pulse rectifier configuration with three parallel UR11 units The figure 3 10 presents the general connection diagram using three parallel UR1 1 units operating as a 12 pulse rectifier The figure 3 11 presents the general
10. default setting The DIP switch S1 1 is set to OFF and the DIP switch S1 2 is set to ON as factory default Follow instructions below for the proper installation of the control wiring Wire gauge 0 5 mm 20 AWG to 1 5 mm 14 AWG Maximum tightening torque 0 5 N m 4 50 Ibt in Use shielded cables for the 24 Vdc power supply connections of the CIR11 board if necessary The proper cable shield connection is shown in figure 3 21 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 3 17 Installation and Connection Isolate with tape os Rectifier side IRA SA SS Sarasa EEN ASe ess ME RSS RAS ie RS ROY States SS Q SORA DOK Do not ground Figure 3 21 Cable shield connection Relays contactors solenoids or coils of electromechanical brakes installed close to the inverter may eventually create interferences in the control circuit To eliminate this effect RC suppressors with AC power supply or free wheel diodes with DC power supply must be connected in parallel to the coils of these devices 3 4 6 Typical Connections In order the CFW 11M inverter can monitor the rectifier it is recommended the interconnection between the fault and or alarm signals available at the relays outputs in the CIR 1 board with the DIM and DIM2 digital inputs of the CFW 11M located at the IPS board of the CFW 11M Control Unit UC
11. done by means of twelve M12 x 30 bolts tightening torque 60 Nm each reactor uses 6 bolts 2 bolts per phase The bus bars are of 40 x 10 mm 1 57 x 0 39 in and the fastening is done through M12 nuts inserted into the bar as presented at figure 3 15 9 12 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection INPUT BAR RI ANPUT BAR S1 INPUT BAR R2 40 1 57 Figure 3 15 UR 1 input bus bar power supply input connections mm in Use two cables in parallel with the recommended gauge indicated in the table 3 5 for connecting each UR 1 input reactor to the input bus bar power supply Table 3 5 R S T Input cable Minimum cable Current A Voltage V Overload cross section area T El err 2 ww OO a 427 500 600 660 690 NOTE The cables are designed for 75 C 167 F ambient temperature with PVC isolation In case using cables with different isolating material they must be sized according to the local standards Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 13 Installation and Connection It is necessary to provide 220 V external power supply for the two fans of the UR11 unit 220 V INPUT CONNECTOR Figure 3 16 Fans supply terminals 220 V 4 A 3 4 5 3 Grounding Connections ATTENTION The neutral conductor of the network
12. must be solidly grounded however this conductor must not be used to ground the rectifier ATTENTION The rectifier must be obligatorily connected to a protective ground PE Use cables with the recommended gauge indicated in the table 3 6 Local standards should be followed in case different gauges are requested The rectifier grounding connection must be connected to the protective ground PE The fastening of the UR11 ground cable connections is done with M12 x 30 bolts tightening torque 60 Nm as presented at figure 3 17 Table 3 6 Grounding cables Minimum cable Current A Voltage V Overload cross section area mm 380 480 ids 660 690 3 14 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection prev TT tebe bee bakd rar Wallets l f I ae i i OD es E aran MATE Aida Hittin hata i iajgiij ffei lia I P ERTER a MN if prij FRONT GROUNDING arem WITH M12 BOLT T Figure 3 17 URI 1 ground connection point 3 4 5 3 1 IT Network ATTENTION In order to use the rectifier unit in IT networks not grounded or grounded via high impedance or grounded delta networks delta corner earth it is necessary to disconnect the grounding cable located atthe CLR1 board of the XEl connector and connect it to the XIT connector located in the same board CLR1 XE1 BOARD GROUNDING Fig
13. operation of motors that are not subjected to high torque loads with respect to the motor rated torque during its operation starting acceleration or deceleration Inverter rated current for use with the normal duty ND cycle nom ND Overload 1 1 xl 1 minute Heavy Duty Cycle HD Inverter duty cycle that defines the maximum continuous operation current and soni the overload current 150 for 1 minute It is selected according to the programming of the inverter connected to the rectitier output This duty cycle shall be used for the operation of motors that are subjected to high torque with respect to the motor rated torque during its operation starting acceleration or deceleration Inverter rated current for use with the heavy duty HD cycle nom HD Overload 1 5 xl 1 minute Current Unbalance Pea Unbalance at rectitier unit X phase Y i x 100 YAVG o FLA Ip YAVG N Where N number of power units yw Y phase current R S or T of the rectifier unit N Lac Y phase average current Rectifier Input circuit of inverters that transtorms the AC input voltage in DC voltage It is composed of power diodes Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 2 1 General Instructions 2 2 Pre charge Circuit Transitional stage of the UR11 operation which starts when the power is applied to the input phases a
14. table 2 2 according to the input rated voltage In order to check other data refer to the technical specifications at table 7 1 Table 2 1 Smart code Rectifier Model Refer to chapter 7 for a list of models for the UR1 1 series and the rectifiers technical specification UR11 E AE A O ASES E A Field Market identification WEG Rectifier Rated input Number of Rated input Option kit Character that description defines the manual Unit 11 series current for use input phases voltage identifies language with the Normal the code end Duty ND cycle Available options T three phase 4 380 480 V S standard 5 500 600 V product 6 660 690 V Table 2 2 Nominal currents at normal overload regime ND 380 480 V 1140 1140 A 500 600 V 0893 893 A 660 690 V 0811 811 A E g UR111140T4SZ corresponds to a 1140 A three phase UR 1 rectifier with 380 V to 480 V input voltage input power supply A 500 600 V rectifier would be specified as UR110893T55Z and a 660 690 V would be specified as UR110811T6SZ Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 2 9 General Instructions 2 6 RECEIVING AND STORAGE The UR11 rectifier units are supplied packed in wooden boxes refer to the figure 2 9 Figure 2 9 URI 1 packing There are identification labels outside these boxes identical to the ones fixed on the product In order to open the box
15. 1 1 UR1 1 UC11 CFW11M NA 1 DIM 1 P 832 6 C1 COM NF 1 NA2 DIM2 PQ 833 4 CIR11 c2 com lt Ore O NO Normally open contact C Common NC Normally closed contact Figure 3 22 Application example with active high signal at the Dls of the CFW 1 1M 3 18 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection UR1 1 UC11 CFW11M NA 1 DIM 1 01 COM P0832 6 NF 1 NA2 DIM2 PQ 833 4 CIR11 c2 com lt Ore PEO NO Normally open contact C Common NC Normally closed contact Figure 3 23 Application example with active low signal at the Dls of the CFW 11M NOTE Make sure the CFW 11M inverter has the 2 0x software version or above For more details refer to the CFW 11M user manual and the CFW 11 programming manual The examples of figure 3 22 and figure 3 23 show that the DIM and DIM2 digital inputs are set to Without External Rectifier Fault P0832 6 and Without External Rectifier Overtemperature P0833 4 respectively On both examples the CFW 11M will show F414 External Rectifier Fault if DIM1 input and therefore the RLI output relay UCD1_ OK UDC2 OK of the CIR11 opens when the DC bus voltage is higher than the undervoltage level and the CFW 11M PWM is enabled or it will display F412 External Rectitier Ove
16. 1 and the panel DC bus copper bus as presented at figure 3 13 ATTENTION The braided cable presented at figure 3 7 used by WEG was designed to withstand half the UR1 1 output DC current see UR11 specifications at table 7 1 Therefore two parallel braided cables are necessary for each connection UD and UD It is necessary to consult the braided cable manutacturer for proper sizing in case it is desired to use only one braided cable per connection 3 6 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection 3 4 3 Fuses ATTENTION It is necessary to use individual fuses at the input of each UR11 diode bridge for the proper protection of the rectifier units The fuses should be connect according to the figure 3 8 and sized to protect and withstand the individual current of each individual module of the rectifier bridge UD UD UR111140T4SZ Figure 3 8 Example of 6 pulse configuration with one rectifier unit The table 3 4 presents WEG values according to the configuration presented at figure 3 8 6 fuses per UR 1 Table 3 4 Recommended Fuses Nominal Maximum Fuse lt volcan ND Current A Fuse A 25 C Ars 380 480 1140 900 1 445 000 500 600 0 1 445 000 660 690 1 445 000 The fuses must be sized according to the voltage supply of the rectifier in order it can be capable of providing the arc extinction an
17. 23 4773 Web www ctiautomation net Email info ctiautomation net First Time Power Up and Start Up 4 FIRST TIME POWER UP AND START UP This chapter describes how to Check and prepare the rectifier before power up Power up the rectifier and check the result Set the rectifier for the operation with the power supply chosen for the application 4 1 PREPARE FOR START UP The rectifier must have been already installed according to the recommendations listed in Chapter 3 Installation and Connection The following recommendations are applicable even if the application design is different from the suggested control connections DANGER Always disconnect the main power supply before performing any connection 4 1 1 Precautions During the Energization Start up 2 3 4 9 6 Verify all the connections of the panel Search for short circuits at the input DC bus etc Verify the condition of all the fuses Inspect all the ground connections panel the door where the control is installed etc Remove all the remaining extra material from the inverter or panel interior xa SoA SA SA SA SA Close the rectifier or panel covers 4 2 START UP 1 Set the power supply voltage according to the rectifier model as presented in table 3 9 through the DIP switches located in the CIR11 board 2 Measure the line voltage making sure it is inside the permitted range 3 Energize the control 24 Vdc power supply The LED
18. 723 4773 Web www ctiautomation net Email info ctiautomation net Summary CHAPTER 4 First Time Power Up and Start Up o Pe PU UP E O OOOO OOA OEO ETOO OOA 4 All Precautions during the Energzalon OM rod 4 LA a 4 CHAPTER 5 Troubleshooting and Maintenance 5 1 Operation of the Faults and Alarms oococoocccnnocncnnncccnnncnnnnnccnnnnnononornnnnnonnnnnonnnnnonnnnnnnnnnnnnnnnnnnnnnnos 5 1 5 2 Faults Alarms ond Possible C GUS as 5 2 5 SOUNONS for ihe Most Frequent PRG SINS cicc2cane ncuscnecestceetsenssaiseutcsstacedtimenaraegnemenncueanssenaeasquemenaceeat 5 3 5 4 Inionnanon Tor Coniocing Technical SUPPO kennas 5 3 5 5 Preventive Ti I siii 5 3 Sul CISMA Ms MOTON rise ricardo 5 5 CHAPTER 6 Option Kits and Accessories 6 1 Option Kits 6 2 Accessories 6 1 6 2 1 Rack Panel Assembly CHAPTER 7 Technical Specifications 7 1 Power Data E E eee E AE E E A EE AEE A EE AA sd 7 2 Eledirical General PE cc OUNAE 7 2 AS zo oo A A S tern eT tte tener nCh E trey tert renee tent lteter nets 72 7 3 Mechanical Data cooccocccocccnccncccnccnncnnncnnnonoronocononnnrnnnr corr e rP nor nnnr nero nn rn nnrnnrn ner rnnennrnnnrnnncnnraninnnos 7 3 Pal WE Pidal dto 7 3 a MENO US A NA ENDS 7 3 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Safety Instructions 1 SAFETY INSTRUCTIONS This manual provides information for the proper installation and operation of the Rectifier Unit U
19. 73 Web www ctiautomation net Email info ctiautomation net Technical Specifications 7 TECHNICAL SPECIFICATIONS This chapter describes the technical specifications electrical and mechanical of the UR11 Rectifier Unit 7 1 POWER DATA Power supply Maximum rated input voltage 480 V for 380 480 V models 600 V tor 500 600 V models and 690 V for 660 690 V models up to 2000 m altitude The voltage derating for higher altitudes is 1 1 for each 100 m above 2000 m maximum altitude 4000 m Voltage tolerance 15 to 10 Table 7 1 URI 1 technical specifications arma ND overload Maximum Motor 124 CV kW 900 700 900 710 1000 800 HD overload Maximum Motor 124 CV kW 800 600 800 630 800 630 Note 1 Application with one UR11 rectifier unit feeding a CFW 11M with the same power rating 2 Add more UR11 for bigger motor power ratings according to item 3 2 3 Nominal current in permanent regimen at the following conditions Temperature around the rectifier 10 C to 45 C 14 F to 113 F The rectifier is able to operate in environments with temperatures up to 55 C 131 F if a reduction of 2 in the output current is applied for each Celsius degree or 1 11 each F above 45 C 113 F Relative humidity 5 to 90 without condensation Altitude 1000 m 3 300 ft Above 1000 m up to 4000 m 3 300 ft to 13 200 ft the output current must be reduced in 1 for each 100 m or 0 6 each 100
20. C1 amp UDC2 OK UDC1 DC bus of the rectifier bridge 1 UDC2 DC bus of the rectifier bridge 2 Contacts rating 1A Maximum voltage 240 Vac NC Normally closed contact C Common NO Normally open contact RL3 digital output with No Temperature Fault function 3 16 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection The RL1 RL2 and RL3 relay digital outputs of the CIR11 board figure 3 20 are used to monitor the operation status of the UR11 and the alarm and fault conditions of the temperature The NO position indicates that the UR11 is under regular operation and the NC position indicates a fault alarm situation Reter to item 5 2 for more details XC XC2 CIR11 BOARD STATUS LEDs DIP SWITCH S1 Figure 3 20 CIR 1 board connection points The XC3R XC3S XC3T connectors located in the CIR11 board receive the NTCs signals that monitor the heatsink temperatures The CIR11 board sets the rated operation voltage of the UR11 through the DIP switch S1 The 400 V model UR111140T4SZ can be set to tour different voltage levels 380 V 400 V 415 V 440 V 460 V and 480 V refer to table 3 9 Table 3 9 Configuration of the DIP switch S1 DIP switch Rated voltage UR111140T4 Line 400 V UR110893T5 Line 500 V UR110811T6 Line 690 V 440 V 460 V 550 V 575 V 660 V 690 V 500 V 525 V 380 V Factory
21. CAL STANDARDS EN 60529 Degrees of protection provided by enclosures IP code UL 50 Enclosures for electrical equipment 1 2 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 7 3 MECHANICAL DATA 7 3 1 Weight The UR11 net weight is 286 kg 630 5 Ib 7 3 2 Dimensions The UR11 dimensions are presented at figure 7 1 o Q X Xe x 5 47 e 46 3 1 82 7 24 579 1 22 8 556 7 21 Ag eN EN 230 ge 1506 4 59 31 Figure 7 1 URI 1 dimensions in mm in Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Technical Specifications 7 3
22. Motors Automation Energy Transmission amp Distribution Coatings Rectifier Unit Unidad Rectificadora Unidade Retificadora URI User s Manual Manual del Usuario Manual do Usu rio IE EEE tT Py Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net NED UR11 RECTIFIER UNIT MANUAL Series UR Language English Document 10001149720 00 Models 1140 A 380 480 V 893 A 500 600 V 811 A 660 690 V 04 201 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Summary of Revisions Pot itedion NET Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Summary CHAPTER I Safety Instructions l l salei Warnings m the a 1 1 1 2 Satety Warnings in the Prod a cacenssesnsavscasscacssemasesedusssasesedsenscenenseurseenenseurseecenseqrasecouseursaecenseqennecs 1 3 Preliminary Recommendations sccscccscoreccocereesncesecnssnncaneonraossagesaseansounconscersonestneaieensoussonneongennoeneoinons 12 CHAPTER 2 General Instructions AR o e o PO 2 1 2 2 Terms and Definitions Used in the Manual oocccocccnncnnncnnnccnnccnnaconaconnnanonononononcnnnccnnnononononcnnninos 2 1 AR URT Msc cuoneraucianansegeacansua ceaeeecuancue cu cea aee angeaneo eye enere ans ancuanceeaneanevareua enaecnanaecueeanaen 2 4 2 4 Identification Label for the URT
23. R11 board connections than 9 C and NTCs Replacement of the defective UR11 Open or defective NTC 5 4 INFORMATION FOR CONTACTING TECHNICAL SUPPORT A NOTE UL For technical support and servicing it is important to have the following information in hand Rectifier model Serial number and manufacturing date that are listed in the product nameplate refer to item 2 4 Application data and rectifier settings 5 5 PREVENTIVE MAINTENANCE DANGER Always turn off the mains power supply before touching any electrical component associated to the rectifier High voltage may still be present even after disconnecting the power supply To prevent electric shock wait at least 10 minutes after turning off the input power for the complete discharge of the power capacitors Always connect the equipment frame to the protective ground PE Use the adequate connection terminal in the rectifier ATTENTION The electronic boards have electrostatic discharge sensitive components Do not touch the components or connectors directly lf needed first touch the grounded metallic frame or wear a ground strap Do not perform any withstand voltage test If needed consult WEG Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 3 Troubleshooting and Maintenance The rectifiers require low maintenance when properly installed and operated Besides the periodic cleaning of the heats
24. R11 developed to perform the rectification for the CFW 11M product line Only trained and qualitied personnel should attempt to install start up and troubleshoot this type of equipment 1 1 SAFETY WARNINGS IN THE MANUAL The following satety warnings are used in this manual DANGER The procedures recommended in this warning have the purpose of protecting the user against dead serious injuries and considerable material damage ATTENTION The procedures recommended in this warning have the purpose of avoiding material damage NOTE The text supplies important information for the correct understanding and good operation of the product 1 2 SAFETY WARNINGS IN THE PRODUCT The following symbols are attached to the product and require special attention High voltages are present Components sensitive to electrostatic discharge Do not touch them Mandatory connection to the protective ground PE Connection of the shield to the ground Hot surface Pi ors Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 1 1 Safety Instructions 1 3 PRELIMINARY RECOMMENDATIONS DANGER Only trained personnel with proper qualifications and familiar with the UR11 and associated machinery shall plan and implement the installation starting operation and maintenance of this equipment The personnel shall follow all the safety instructions described in this manual an
25. TR URU E m Sai 5 EA YU LLL TT amin E 1 Hi q pi i pe i i RET EETT i T ji M iii PAM MHI ERR HEHH WITTE TANI ili HIN AAN UT ji ULUL E i it Tt TUNI TELEL PIY EA LALLLLLLLI METIN a ll i nti e UNA HI FDO MAA WAIT 7 AAA IN VA Hid i EE II Will UATH ints ATMA POELEADEARD 101440 Tt itt POWER SUPPLY GND PE Figure 3 13 Example of adequate panel installation layout The figure 3 13 presents the adequate installation layout for three parallel UR11 rectifier units Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 3 11 Installation and Connection 3 4 5 2 Power Connections ATTENTION The power supply that feeds the rectifier must have a grounded neutral In case of IT networks follow the instructions described in item 3 4 5 3 1 NOTE The voltage must be compatible to the rectifier rated voltage Refer to item 3 4 5 4 for the configuration of the UR11 rated operation voltage The fastening of the URI 1 output connections is done with four M12 x 25 bolts tightening torque 60 Nm as presented at figure 3 14 Refer to item 3 4 2 for more information EGATIVE OUTPUT BAR UD 234 9 21 POSITIVE OUTPUT BAR UD OA Ep a a oe Figure 3 14 UR 1 output bus bar DC connections mm in The input connections at the internal reactances are
26. al Instructions Switching Frequency Frequency of the IGBTs switching in the inverter bridge normally expressed in kHz Heatsink Metal device designed to dissipate the heat generated by the power semiconductors Amp A Amperes C Celsius degree AC Alternated Current DC Direct Current CFM Cubic Feet per Minute unit of flow cm Centimeter hp Horse Power 746 Watts unit of power used to indicate the mechanical power of electrical motors Hz Hertz I s Liters per second kg Kilogram 1000 grams kHz Kilohertz 1000 Hertz m Meter mA Miliamp re 0 001 Amp re min Minute ms Millisecond 0 001 seconds Nm Newton meter unit of torque rms Root mean square effective value rpm Revolutions per minute unit of speed s Second V Volts Q Ohms Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 2 3 General Instructions 2 3 ABOUT THE UR11 2 4 The rectifier unit UR11 provides DC voltage to feed the CFW 11M inverters The UR11 can also be used to provide power to other devices that require DC link voltage The main feature of this product is the two built in complete semi controlled rectifier bridges which have the advantages presented next DC link pre charge control provided by the control of the thyristors firing angle through a microcontroller the pre charge provides a linear voltage ramp avoiding high currents and e
27. be Verified Corrective Action 12 V LED ON does not light 24 Vdc supply cable connection inverted loose 1 Connect the 24 Vdc cabling with the proper 12 Vdc power supply does not start connection or broken wiring polarity to the XC1 connector of CIR11 board Rectifier does not start Power supply connections R1 S1 T1 R2 S2 T2 1 Provide 24 Vdc supply to the CIR11 control 24 Vdc connections input fuses input circuit 2 Provide proper voltage to R S and T breaker DIP Switch S1 configuration at CIR 1 3 Setting S1 DIP Switch at CIR11 board board according to the input power supply Phase fault or undervoltage at the input Input power supply fuses circuit breaker and Replace damaged fuses power connections Check main circuit breaker switching Provide proper voltage to R S and T High temperature alarm in the heatsink UR11 fans cleaning of the heatsink fins Phase Provide proper voltage to the fans temperature higher than 80 C 176 F current balance of the UR11 input Cleaning of the heatsink fins according to Check if the current waveform is typical to a item 5 5 1 Heatsink overtemperature temperature 19 pulse rectifier if all pulses are present at all 3 Replacement of the fans higher than 90 C the input phases R1 S1 T1 R1 S2 and T2 Replacement of the defective UR11 Heatsink Undertemperature smaller CIR11 board connections XC3R XC3S XC3T Tightening of the CI
28. commanded by the DC Link level through the output inverter R Se T Arm It is a set of one diode and one thyristor of the R S and T phases of the rectifier input Power Modules U V and W Set of two IGBTs of the inverter output phases U V and W Bridge 1 and bridge 2 It is a set of three thyristors and three diodes making a semi controlled rectitier unit 6 Pulses Rectifier Three phase rectifier configuration where each power diode operates for 120 and commutates every 60 performing six commutations in one cycle of the power supply 12 Pulses Rectifier Six phase rectifier configuration regularly available through a phase shifting transtormer with two secondaries connected in delta and star where each power diode operates for 120 and commutates every 30 performing twelve commutations in one cycle of the power supply PTC Resistor which resistance value in ohms increases proportionally to the temperature increase used as a temperature sensor in electrical motors NTC Resistor which resistance value in ohms decreases proportionally to the temperature increase used as a temperature sensor in power modules PE Protective Earth RFI Filter Radio Frequency Interference Filter for interference reduction in the Radio Frequency range PWM Pulse Width Modulation pulsed voltage that feeds the motor Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Gener
29. connection diagram using two parallel UR11 units operating as a 12 pulse rectifier and the figure 3 12 presents the general connection diagram using one UR11 unit operating as a 12 pulse rectifier Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 3 9 Installation and Connection 24 Vdc Ext 11213 123456789 R1 S1 T1 XC4 R2 52 T2 24 Vdc Ext 1T2l3 123456789 UD UD UD UD XC1 XC2 XC1 XC2 24 Vdc RLI RL2 RL3 24 Vde RL1 RL2 RL3 10 output relays 10 output relays 300 mA 300 mA external external ower UR11 cower UR11 supply supply GND PE GND PE R S T GND PE Figure 3 11 General connection diagram of a 12 pulse rectifier configuration with two parallel URI 1 units UD UD 24 Vdc Ext 11213 123456789 XC1 xC2 24 Vdc RL1 RL2 RL3 10 output relays 300 mA external power UR11 supply UD UD GND R1 S1 T1 XxC4 R2 S2 T2 PE R S T GND PE Figure 3 12 General connection diagram of a 12 pulse rectifier configuration with one UR 1 unit 3 10 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection 3 4 5 UR11 Connections 3 4 5 1 Panel Layout and Connections INVERTER b pi ber ja si A P n y 3 Y o e a4 A CTET COOLE 3 EE l i i E KERIN UA
30. ctions and preventive maintenance in the equipment 5 1 OPERATION OF THE FAULTS AND ALARMS When the high temperature alarm is detected The status LED TEMP ALARM yellow lights There is no blocking of the thyristors gate pulse the rectifier remains in operation When a fault is detected Thyristors gate pulse blocking The LED s UDC1 2 OK turns off showing which rectifier unit is under fault condition The RL1 output relay opens In case of overtemperature heatsink temperature higher than 90 C 194 F the TEMP_FAULT LED red lights In this case E E E RL3 relay output opens simultaneously to RL TEMP_ALARM LED must be light previously indicating alarm as well as RL2 should be open In case of undertemperature heatsink temperature smaller than 9 C 16 F or the NTC cables rupture the TEMP FAULT LED red lights In this case RL3 relay output opens simultaneously to RL The rectitier is back to the normal operation right after the fault is solved in case it is properly connected to the power supply Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 1 Troubleshooting and Maintenance 5 2 FAULTS ALARMS AND POSSIBLE CAUSES The table 5 1 summarizes the faults and alarms operation The monitoring signals that can indicate fault alarm and the status outputs are presented at table 5 2 Table 5 1 Operation of fault
31. d or defined by the local regulations Failure to comply with the safety instructions may result in death serious injury and equipment damage NOTE For the purpose of this manual qualified personnel are those trained and able to 1 Install ground power up and operate the UR11 according to this manual and to the current legal safety procedures 2 Use the protection equipment according to the established regulations Provide first aid DANGER Always disconnect the main power supply before touching any electrical device associated with the rectifier Several components may remain charged with high voltage and or in movement fans even after the AC power supply has been disconnected or turned off When there is a capacitive load connected to the UR11 output e g frequency inverters fed directly from the DC link wait at least 10 minutes to guarantee the fully discharge of capacitors Always connect the equipment frame to the protection earth PE at the suitable connection point ATTENTION The electronic boards contain components sensitive to electrostatic discharges Do not touch the components and terminals directly If needed touch first the grounded metal frame or wear an adequate ground strap Do not perform a withstand voltage test on any part of the rectifier unit If needed please consult WEG NOTE Rectifiers may cause interference in other electronic devices Follow the recommendations listed in Cha
32. d the I t must be smaller than the 12t of each thyristor 1 445 000 A s as indicated at table 3 4 Example of fuses used by WEG 400 V line 6 JURD33TTFO900 FERRAZ 900 A 690 V 12t 700 000 A s Other lines 6 JURD33TTF0700 FERRAZ 700 A 690 V 2t 300 000 A s Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 Installation and Connection 3 4 4 Configurations of the Rectifier The configuration of the UR11 to operate as 6 pulses and 12 pulses rectifier are presented in this section NOTE Several additional items are needed for the complete panel assembly such as output inverters AC tuses DC link fuses for the output power units protection circuit breaker or disconnect switch at the input and in case of 12 pulse configuration is also necessary to provide a phase shitting transformer 3 4 4 1 Operation as 6 Pulse Rectifier 24 Vdc Ext 24 Vdc Ext 1 213 123456789 XC1 XC2 24 Vdc RLI RL2 RL3 10 output relays 24 Vdc Ext 11213 123456789 XC2 24 Vdc RLI RL2 RL3 10 output relays XC1 XC2 UD UD 24 Vdc RLI RL2 RL3 10 output relays UD UD UD UD 300 mA 300 mA 300 mA external external external power UR 1 power UR1 1 power UR 1 supply supply supply GND R1 51 T1 xXC4 R2 52 T2 PE GND XC4 R2 S2 T2 PE GND R1 51 T1
33. dicated transformer Categories Category C1 inverters with a voltage rating less than 1000 V and intended for use in the First Environment Category C2 inverters with a voltage rating less than 1000 V intended for use in the First Environment not provided with a plug connector or a movable installations They must be installed and commissioned by a professional Note a professional is a person or organization familiar with the installation and or commissioning of inverters including their EMC aspects Category C3 inverters with a voltage rating less than 1000 V and intended for use in the Second Environment only not designed for use in the First Environment Category C4 inverters with a voltage rating equal to or greater than 1000 V or with a current rating equal to or greater than 400 Amps or intended for use in complex systems in the Second Environment EN 55011 Threshold values and measuring methods for radio interference from industrial scientific and medical ISM high frequency equipment Class B equipment intended for use in the low voltage power supply network residential commercial and light industrial environments Class Al equipment intended for use in the low voltage power supply network Restricted distribution Note it must be installed and commissioned by a professional when applied in the low voltage power supply network Class A2 equipment intended for use in industrial environments
34. e installation instructions as presented in the inverter manual 3 5 1 Conformal Installation with the CFW 11M When the CFW 11M is installed according to the user s manual instructions presented at chapter 3 5 Installation according to the European directive of electromagnetic compatibility and all the next recommendations are followed for the UR11 installation the complete panel will be in accordance with IEC EN 61800 3 Adjustable Speed Electrical Power Drive Systems category C4 UR11 installation recommendations 1 UR11 grounding according to the instructions on item 3 4 5 3 of this manual 2 Shielded control cables on XC1 3 20 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection 3 5 2 Standard Definitions IEC EN 61800 3 Adjustable Speed Electrical Power Drives Systems Environment First Environment includes domestic premises lt also includes establishments directly connected without intermediate transformer to a low voltage power supply network which supplies buildings used for domestic purposes Example houses apartments commercial installations or offices located in residential buildings Second Environment includes all establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes Example industrial area technical area of any building supplied by a de
35. ft above 1000 m 3 300 ft Environment with pollution degree 2 according to EN50178 and UL508C 4 The motor ratings are merely a guide for 440 V 400 V line 575 V 500 V line and 690 V 600 V line IV pole WEG motors The adequate rectifier sizing shall be based on the rated current of the motor used 5 The information provided about the rectifier losses is valid for the rated operating condition i e for rated output current Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net PA Technical Specifications 7 2 ELECTRICAL GENERAL SPECIFICATIONS POWER SUPPLY EXTERNAL 24 Vdc 300 mA 10 power supply CIR1 1 board OUTPUTS RELAY 3 relays with NO NC contacts 240 Vac 1 A CIR1 1 board SAFETY PROTECTION Input power under overvoltage Overtemperature 7 2 1 Codes and Standards SAFETY STANDARDS UL 508C Power conversion equipment UL 8340 Insulation coordination including clearances and creepage distances for electrical equipment EN61800 5 1 Satety requirements electrical thermal and energy EN 50178 Electronic equipment for use in power installations EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements Note the final assembler of the machine is responsible for installing an safety stop device and a supply disconnecting device EN 60146 IEC 146 Semiconductor converters EN 61800 2
36. iautomation net Email info ctiautomation net Installation and Connection SUPPORTS FOR TOP FIXING OF na THE UNIT nun L L AIN S N O D HRCI MHI E 2 0 36 MU it 14 8 0 58 sa i MEPE 0 59 ANI Lioos 100 5 HATH 3 96 3 96 AMARA RIO F AHHH 1H si LLII bith ome Figure 3 6 Supports for top fixing mm in 3 4 ELECTRICAL INSTALLATION DANGER The following information is merely a guide for proper installation Comply with applicable local regulations tor electrical installations DANGER Make sure the AC power supply is disconnected before starting the installation ATTENTION The UR11 can be connected in circuits with symmetrical short circuit capability up to 150000 Arms 480 V 690 V maximum ATTENTION Branch circuit protection must be provided in accordance with applicable local codes DANGER A switching device must be provided in order to pertorm the power supply connection disconnection This device must be able to disconnect the power supply trom the rectitier whenever necessary e g under maintenance Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 3 9 Installation and Connection The main circuit breaker must be sized to withstand the inverter rated current and its short circuit level must be compatible to the application see AFW11M mounting guide for more details When
37. iguration presented at figure 3 26 should be used Refer to the CFW 11M user s manual for the external filters and more information ATTENTION Use the listed filters only in lines with a solidly grounded neutral point Do not use them in IT networks lines that are not grounded or grounded via a high impedance ATTENTION The filters presented in the CFW 11M user s manual are for low voltage power supply When the filter is to be used in the primary of the input power transformer in case the UR1 1 is set for 12 pulse rectifier operation and its input voltage is medium or high voltage contact the filter manufacturer EPCOS or other in order to check possible contigurations Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection Controling and Signal Wiring l l l l QI Filter r Transformer Panel or Metalic Enclosure ae Protective Grounding PE Figure 3 25 External RFI filter connection for 6 pulse configuration Controling and Signal Wiring l l Transformer Panel or Metalic Enclosure Sodi Protective Grounding PE PE Grid or Building Steel Structure Figure 3 26 External RFI filter connection for 12 pulse configuration Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 3 23 Installation and Connection 3 24 Phone 800 894 0412 Fax 888 7
38. ink fins it is recommended to exchange the fans after 50 000 hours operation Figure 5 1 shows the UR11 fans exchanging procedure lt is recommended periodic inspections to be performed every 6 months after rectifier start up Table 5 4 Recommended periodic inspections Every months Terminals connectors Loose screws Tighten Loose connectors Check the fan connection Blocked fan Abnormal vibration Dust in the cabinet air filter Cleaning or replacement Printed circuit boards Accumulation of dust ol humidity ee Power module Accumulation of dust ol humidiy ee Power connections Heatsink Dust accumulation Cleaning RAILS FOR FAN SLIDING J LOCK SYSTEM FOR FAST FAN REPLACEMENT Figure 5 1 Fan replacement 9 4 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Troubleshooting and Maintenance 5 5 1 Cleaning Instructions When it becomes necessary to clean the rectifier follow the instructions below Ventilation system Cut off the rectifier supply and wait 10 minutes Remove the dust accumulated at the ventilation inlets with a plastic brush or a flannel Remove the dust accumulated on the heatsink fins and on fan blades using compressed air Electronic boards Cut off the rectifier supply and wait 10 minutes Remove the dust accumulated on the boards using an anti static brush or ionized compressed air E g Charges Burtes lon Gun non nuclear refe
39. liminating the pre charge circuit of the panels The independent control of each rectifier unit of the UR11 together with the two triphasic chokes with 3 voltage drop allows the use of this product in applications where 12 pulse rectifier configuration is required by simply connecting the power cables properly for details see Chapter 3 Installation and Connection The URI 1 product line with its modular structure book type is very similar to the CFW 1 1M power units UP1 1 which makes it very appropriate for the assembly in panels with the CFW 1 1M inverter line Each rectifier unit is able to provide power to two UP11 power units In order to feed more than two UP11 it is just necessary to add more rectifier units in parallel proportionally Figure 2 1 presents an example of diagram for a 6 pulse rectifier operation and figure 2 2 presents an example of diagram for a 12 pulse rectifier operation Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net General Instructions UD UD e e e e e e O ss e we ewe e e e e e e HH e re Ks UR11 R1 S1 T1 R2 S2 T2 F1 F2 F3 F4 FS F6 f Figure 2 1 Example of diagram of a 6 pulse configuration with one rectifier unit UD UD UR11 i j i i i i i i L1 L2 4 1 l R41 S1 T1 R2 2 T2 r F4 F2 F3 F4 FS F6 f AD A gt Gaus Upply cs Figure 2 2 Example of diagra
40. m of a 12 pulse configuration with one rectifier unit Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 2 5 General Instructions 2 6 The UR11 can be provided together with the complete panel AFW 11M or as a stand alone product to be assembled in a panel For the complete panel all the components are provided in the panel NOTE Several additional items are needed for the complete panel assembly such as output inverters AC fuses DC link fuses for the output power units protection circuit breaker or disconnect switch at the input and in case of 12 pulse configuration is also necessary to provide a phase shifting transtormer The UR11 has an interface board feed by a 24 Vcc external power supply This board presents three output relays for alarm and fault indication five LEDs for fault visualization as well as the rectifier bridges status There are also two DIP switches for the voltage settings of the UR11 power supply according to the model refer to item 3 4 5 4 for more information This board is also responsible for the heatsink temperature monitoring Figure 2 3 shows a simplified block diagram of the UR11 Power section fans E 220 V Exi j LY A Cabinet aux power supply DC Bus DC Link Rectifier Power supply Feedback Feedback DC link voltage input voltage heatsink temperature POWER CPCIT CONTROL Supply board and thyristor c
41. nd ends with the complete charging of the DC link capacitors of the inverter connected to its output This step is controlled by the UR11 which performs the loading of DC link capacitors through a voltage ramp with limited current avoiding high current spikes on the inverter startup DC Link Inverter intermediate circuit with DC voltage and current obtained from the rectification of the AC supply voltage via URI 1 or from an external source it supplies the output IGBTs inverter bridge Inverter Circuit Circuit to modify the DC voltage of the DC Link Diode Basic component of the input rectifier bridge lt works like an electronic key controlled by the voltage polarity of the anode and cathode terminals in the following modes conduction closed switch terminals directly polarized and blocked open switch terminals reversely polarized Thyristor SCR Silicon Controlled Rectifier basic component of the input rectifier It works like a diode but it needs a voltage pulse in the gate terminal to be able to get into the conduction mode besides the proper polarization of the anode and cathode terminals which allows the control of the starting conduction angle IGBT Insulated Gate Bipolar Transistor basic component of the output inverter bridge The IGBT works as an electronic switch in the saturated closed switch and cut off open switch modes Braking IGBT Operates as a switch for the activation of the braking resistor It is
42. nts for Normal Duty ND and Heavy Duty HD cycles overload current for 1 min and 3 s and frequency Current specitications for use with the Normal Duty ND cycle Current specifications for use with the Heavy Duty HD cycle 2 8 MOD EXUR110893T5SZ 13H MAT 11345935 SERIALES 1234567890 OP 12345678 MAX TA 45 C 113 F PESOMEIGHT 286kg 630 51b INPUT LINE ALA AR CEA ERRADA RESE SA DA LINK CC VAC 3 VAC A ND 60 s 3s A HD 60 5 35 893A 1081A 932A 1340A 1083A 1444A r FABRICADO NO BRASIL b HECHO EN BRASIL MADE IN BRAZIL ee mM _ _ Figure 2 7 URI 1 identification label Manufacturing date Serial number Maximum surrounding air temperature Rated output data voltage rated currents for use with Normal Duty ND and Heavy Duty HD Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net General Instructions Figure 2 8 Location of the identification labels 2 5 HOW TO SPECIFY THE UR11 MODEL SMART CODE In order to specify the UR11 model it is necessary to indicate the desired voltage and current values in their respective fields for the nominal supply voltage and the rated input current for normal duty overload ND in the smart code according to the example of the table 2 1 The available options for the rectifier input current on normal duty ND overload are presented at
43. ontrol with the 32 bits RISC CPU Digital Output ee User DOT RL on Ext interface E D RL board IRES Figure 2 3 Block diagram for the UR11 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net General Instructions g q a 7 p m A E e e BOARD RCS4 THYRISTORS DECOUPLING H MI Y CAPACITORS RS gt GM BOARD CIRI BOARD CPC11 A 4 BOARD CIR1 1 SYNCHRONISM TRANSFORMER FUSES A F HEATSINK FANS RCS4 UD UD OBS 6 x RCS4 EXTERNAL 220 V 6 x TD570N A UD L1 L2 R1 S1 T1 R2 S2 T2 Figure 2 5 URI general internal diagram power connections Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 2 General Instructions A E EXTERNAL 24 Vdc 2 RL1 gt UDC1 UDC2 OK xc3s CIR11 RL2 WITHOUT P TEMPERATURE ALARM RL3 WITHOUT TEMPERATURE FAULT Ma kban ple Eph Figure 2 6 URI general internal diagram control connections 2 4 IDENTIFICATION LABEL FOR THE UR11 There are two identification labels one located at the front cover and another inside the UR11 enclosure close to the fans UR11 Model WEG part number UR11 Net weight Rated input data voltage inout phase numbers rated curre
44. pter 3 Installation and Connection to minimize these effects NOTE Fully read this manual before installing or operating the rectifier unit UR11 1 2 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Safety Instructions ATTENTION The operation of this equipment requires installation instructions and detailed operation provided in this manual Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 1 3 Safety Instructions le Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net General Instructions 2 GENERAL INSTRUCTIONS 2 1 ABOUT THE MANUAL This manual presents how to install operate the main features and basic troubleshooting of the UR11 rectifier unit models For more information on other features accessories and operating conditions refer to the following mounting guide RACK 2 RACK 3 mounting guide The mounting guide is available in the CD ROM provided with the rectifier unit or it can be downloaded from WEG website 2 2 TERMS AND DEFINITIONS USED IN THE MANUAL Normal Duty Cycle ND Inverter duty cycle that detines the maximum continuous operation current and NO the overload current 110 for 1 minute lt is selected according to the programming of the inverter connected to the rectifier output This duty cycle shall be used for the
45. rence A6030 6DESCO If necessary remove the boards from the rectifier Use always an ESD wrist strap Inspect the heatsink fins of the power units regularly verifying if there is any dirt accumulation that could impair the rectitier cooling In order to do that remove the power unit side cover HEATSINK FIN CLEANING OPENINGS Figure 5 2 Cover to get access for inspection cleaning of the heatsink fins Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 9 Troubleshooting and Maintenance 9 6 Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Option Kits and Accessories 6 OPTION KITS AND ACCESSORIES This chapter presents The accessories that can be incorporated to the rectifiers Instructions for the installation operation and programming of the accessories are described in their own manuals and are not present in this chapter 6 1 OPTION KITS The UR11 rectifier unit does not have any option kits 6 2 ACCESSORIES 6 2 1 Rack Panel Assembly The UR11 has a mechanical accessory for panel assembly named Rack This accessory is the same one used for the CFW 11M inverter line Refer to the Rack 2 Rack 3 mounting guide for more details Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 6 1 Option Kits and Accessories 6 2 Phone 800 894 0412 Fax 888 723 47
46. rtemperature if DIM2 input and therefore the output relay RL3 Without Temperature Fault of CIR1 1 opens Figure 3 24 shows DIM1 and DIM2 digital inputs set to Without External Rectifier Alarm P0832 5 and Without External Rectifier Overtemperature Fault P0833 4 respectively In this case the CFW 11M will display A415 External Rectifier High Temperature alarm if the DIM1 and therefore the RL2 relay output Without Temperature Alarm of CIR1 1 opens and it will display F412 External Rectifier Overtemperature it the DIM2 input and therefore the RL3 relay output Without Temperature Fault of CIR11 opens Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 19 Installation and Connection UR11 UC11 CFW11M IPS XC 1 NA1 o 4 DIM1 po y CON P0832 5 NF 1 NA2 PQ 833 4 CIR11 c2 NF2 NA3 4 GND_24V C3 NFS J1 Dre PEO NO Normally open contact C Common NC Normally closed contact Figure 3 24 Application example with active high signal at the Dls of the CFW 1 1M 3 5 INSTALLATION ACCORDING TO THE EUROPEAN DIRECTIVE OF ELECTROMAGNETIC COMPATIBILITY ATTENTION The conformity with European directives of electromagnetic compatibility EMC Directive 2004 108 EC also depends on the inverters connected to the URI 1 output Always follow th
47. s and alarms 24 Vdc power supply of the CIR11 board INPUTS R1 S1 T1 R2 S2 and T2 input power connections Pre charge status Not performed In progress or Completed UR 1 heatsink temperature measured through the NTCs Relay output with the pre charge status indication function UDC1 OK amp UDC2_OK lt closes when the two RL UR11 rectifier diode bridges completed the pre charge OUTPUTS Aig Output relay with No Temperature Alarm function It opens under alarm condition Output relay with No Temperature Fault function lt opens under fault condition a V ON Green LED with 12 V ON power supply indication generated at CIR11 from the 24 Vdc UDC 1 OK Green LED with status function indication of one UR11 input rectifier bridge it lights when its pre charge is completed UDC 2 OK Green LED with status function indication of the other UR11 input rectifier bridge it lights when its pre charge is completed TEMP_ALARM _ALARM TEMP_ALARM Yellow LED that lights when the UR11 temperature is too high alarm TEMP_FAULT Red LED that lights under overtemperature or undertemperature fault condition Table 5 2 EA alarms and possible causes LEDs E eee UDC_1 UDC_2 Temp Temp Possible causes E 24 Vdc applied to the control circuit CIR1 1 and OK OFF OFF Tun lt T lt Ta OFF ON ON ON OFF OFF OFF OFF the main power supply R S and T is missing Ready for power energization
48. the circuit breaker is closed power is applied to the UR11 starting at the pre charge of the DC link In case of failure in some inverter or emergency remote or local the circuit breaker can be switched off by the undervoltage release coil protection 3 4 2 Cables Bus Bars The panel bus bars must be sized according to the panel input current and the rectifier output current It is recommend the use of copper bars or cables In case that aluminum bars have to be used it is necessary to clean the contacts and to apply an antioxidant compound If the compound is not used any copper aluminum junction will suffer accelerated oxidation Refer to item 3 4 5 for more information The interconnection between the UR11 output and the DC bus can be done with flat braided cables sized to withstand the UR 1 output DC current see specifications at table 7 1 The figure 3 7 presents an example of flat braided cable used by WEG 80 3 15 80 _ 180 CT 3 15 A1 7 086 T ji IN 1 i f f peng o LO g A LO Q is 4 i ay _20 40 14 7x _ 2 15 0 787 1 575 0 551 7x 7 5 0 984 0 59 1 97 0 984 7 _ 31043 A2 1220 118 8 5 1 0 33 0 039 BRAIDED WIRE GAUGE AWG 40 0 08 mm Note dimensions in mm in Figure 3 7 Example of flat braided cable The cable length represented by A must be sized according to the distance between the UR1
49. ure 3 18 CLRI board grounding point Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net 9 15 Installation and Connection The UR11 rectifier series was developed to be used in application with the CFW 11M Modular Drive inverter series which can be used in IT networks without modifications In these cases consider the following The phase to ground or isolation fault indication must be processed by the user to indicate the failure occurrence and or block the inverter operation In order to use the UR11 for teeding other inverters refer to the inverter respective manual 3 4 5 4 Control Connections Ol aj ee TD ees p LA zi 24 Vdc INPUT LAN T T FI el i n 1 a F hi RELAY OUTPUTS STATUS LEDs Figure 3 19 UR 1 control cables connection points The CIR11 Rectifier Interface Board is presented at figure 3 19 It is necessary to provide a 24 Vdc 10 external power supply to teed this board This external power supply must have 300 mAdc minimum capacity Table 3 7 XC Connector signals of the CIR 1 Standard function 24 Vdc Power supply 2 No function SSS 24 Vdc 300 mA 10 external power supply 3 OV O V reference for the 24 Vdc external power supply High impedance grounded 4 7 MQ Table 3 8 XC2 Connector signals of the CIR 1 Sa Standard foneion RLI digital output with DC bus OK function UD
50. w ctiautomation net Email info ctiautomation net 9 1 Installation and Connection Table 3 2 Currents and configuration in 500 600 V Nominal Current A Number of Power Units UR11 in parallel Number of Power Units UR11 in The other panel components are responsibility of the integrator Among these components we can point out the AC input tuses DC link tuses for power units protection circuit breaker or disconnect switch phase shitting transtormer for 12 pulse configuration bus bars panel fans etc 3 3 MECHANICAL INSTALLATION The power units must be properly secured in the drive cabinet making it possible the easy withdrawal and reinsertion in case of maintenance The fastening must also be done so that it prevents panel transportation damage The panel mounting rack accessory simplifies the mounting of the power units and allows their simple fastening and movement Refer to Rack 2 Rack 3 Mounting Guide Y 22 5 mm 0 89 in HOISTING EYES WEIGHT 286 Kg 630 52 lb j Mit El i ile MT NN WI MANNII AH MUU At HUTT AAA TT DAMA ATT HI TTT TTT PTETEDELEEEL we 3 2 Figure 3 1 URI 1 Hoisting eyes Phone 800 894 0412 Fax 888 723 4773 Web www ctiautomation net Email info ctiautomation net Installation and Connection NE Te E i pan OO Othe Gy Als i E ee ea THA Ilill UA OEI pr iit iH EIEN 0100000 IN Mili IAN A IN

WEG UR11 Rectifier User`s Manual

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