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Siemens 6SR41 series Product User Manual
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Siemens 6SR41 series Product User Manual

Siemens 6SR41 series Product User Manual

Medium-voltage ac-converter robicon perfect harmony geniv
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Medium-Voltage AC-Converter
ROBICON Perfect Harmony
GenIV
Product User Manual
Type 6SR41
Operating Instructions · 12/2009
ROBICON Perfect Harmony

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Summary of Contents for Siemens 6SR41 series

  • Page 1 Medium-Voltage AC-Converter ROBICON Perfect Harmony GenIV Product User Manual Type 6SR41 Operating Instructions · 12/2009 ROBICON Perfect Harmony...
  • Page 3 Preface Safety Precautions and Warnings Overview Medium-Voltage AC-Converter Theory ROBICON Perfect Harmony GenIV Product User Manual GenIV Specifications Product Description Operating Instructions Application and Operation Application Specific Features Abbreviations Appendix Version AE 12/2009 A5E01454341C...
  • Page 4 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.

  • Page 5: Preface

    Preface About this Manual Scope of manuals for Perfect Harmony series This manual is one component in a series of manuals intended for use with the Perfect Harmony series of adjustable speed AC motor drives. Each manual is intended for use by trained personnel with unique job functions and qualifications.

  • Page 6: Version Ae

    Preface Conventions used in this manual ● This manual is intended for use with the Perfect Harmony series. ● Test points and terminal block designations are shown in uppercase, boldface, Arial fonts (e. g. -X2). ● Safety information which can cause personal injury is highlighted with a safety alert symbol.

  • Page 7: Table Of Contents

    Table of contents Preface ..............................3 Safety Precautions and Warnings......................13 Overview..............................17 Purpose............................18 Introduction ..........................19 2.2.1 Clean Power..........................20 2.2.2 High Power Factor ........................20 2.2.3 Nearly Perfect Sinusoidal Output Voltages..................21 Perfect Harmony Features......................22 2.3.1 Harmony VFD Family Features ....................22 2.3.2 VFD Scalability..........................24 2.3.3 VFD Output Ratings........................24...
  • Page 8 Table of contents 5.3.6 Control Wire Way Section ......................90 5.3.7 Cooling ............................92 Long Cable Filters ........................97 5.4.1 Reactors and Capacitors......................97 Synchronous Transfer Reactors ....................100 Motor Compatibility ........................101 IEEE 519 Conformance ......................102 Ride Through ..........................103 Application and Operation........................
  • Page 9 Table of contents 6.10 Data Logs...........................132 6.10.1 Fault Log ............................132 6.10.2 Historic Log ..........................132 6.10.3 Event Log ...........................132 6.11 Faults and Alarms ........................133 6.12 Motor Overload ..........................134 6.13 Input Side Monitoring and Protection..................136 6.13.1 One Cycle Protection .........................137 6.13.2 Excessive Drive Losses ......................138 6.14 Cell Bypass ..........................141 6.14.1...
  • Page 10 Table of contents Abbreviations............................173 Appendix..............................179 Reader Comments Form......................179 Notes ............................181 Startup/Warranty Registration and Service Solutions............... 183 Glossary ..............................185 Index..............................197 Tables Table 4- 1 General Ambient conditions ......................46 Table 5- 1 GenIV Core Configurations: ......................52 Table 5- 2 Table "Nine Cell 4160 V Output GenIV, 200 - Hp...............
  • Page 11 Table of contents Table 5- 25 Twenty-four Cell Output Filter, Inductance ..................98 Table 5- 26 Fifteen Cell Output Filter, Inductance ..................99 Table 5- 27 Nine Cell Output Filter, Inductance....................100 Table 5- 28 Fifteen Cell Output Filter, Inductance ..................100 Table 5- 29 Twenty-Four Cell Output Filter, Inductance ................100 Table 6- 1 Signal Polarities .........................107...
  • Page 12 Table of contents Figure 5-11 Cell Installation and Latching System ..................73 Figure 5-12 Nine Cell Mounting Structure ...................... 74 Figure 5-13 Bypass Contactors and Bus Connections................... 74 Figure 5-14 GenIV Power Cell with Board Shown ..................75 Figure 5-15 GenIV Cell, 40-140 Amp, Anatomy.....................

  • Page 13: Product User Manual Operating Instructions, Version Ae 12/2009, A5E01454341C

    Table of contents Figure 6-15 Inverse Time-To-Trip Curves Left - Idle State, Right - Run State..........139 Figure 6-16 Typical Power Cell with Bypass Contactor ................143 Figure 6-17 A Simplified Diagram of a 15 Cell Drive..................144 Figure 6-18 Drive Output with 2 Cells Bypassed ..................145 Figure 6-19 Drive Output Re-Balanced by Bypassing Functional Cells............145 Figure 6-20...

  • Page 15: Safety Precautions And Warnings

    Safety Precautions and Warnings The Siemens Perfect Harmony (PH) series of Medium Voltage (MV) Pulse Width Modulated (PWM) Variable Frequency Drives (VFD) are designed with considerable thought to personal safety. However, as with any piece of high power equipment, there are numerous internal connections that present potentially lethal voltages.
  • Page 16 Safety Precautions and Warnings DANGER Electrical Hazards! • Always follow the proper lock-out/tag-out procedures before beginning any maintenance or troubleshooting work on the drive. • Always follow standard safety precautions and local codes during installation of external wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any other wiring as specified in IEC61800-5-1.
  • Page 17 , vinyl and other non-conductive materials. They are excellent static generators and do not give up their charge easily. • When returning components to Siemens LD A, always use static-safe packing. This limits any further component damage due to ESD.

  • Page 19: Overview

    Overview The Siemens Perfect Harmony series of Medium Voltage (MV) Pulse Width Modulated (PWM), Variable Frequency Motor Drives (VFD) are designed and manufactured by Siemens LD-A, New Kensington, PA, USA with additional manufacturing facilities in Europe, Asia, and South America. The Harmony VFD is intended for use with standard medium- voltage three-phase AC induction, synchronous, wound rotor, permanent magnet, or super conducting motors.

  • Page 20: Purpose

    Overview 2.1 Purpose Purpose This manual defines the configuration and capabilities of the Perfect Harmony family of Medium Voltage Variable Frequency Drives and specifically addresses the GenIV configuration. Detailed descriptions of the common features of the Harmony drive family are defined in the following manuals: Companion Manuals: GenIV Commissioning and Maintenance Manual...

  • Page 21: Introduction

    Overview 2.2 Introduction Introduction The Perfect Harmony VFD is based on a patented (U.S. patent #5,625,545) multi-level output topology. Medium voltage levels are obtained by adding together the outputs of multiple low-voltage power cells. The low-voltage power cells are simplified variations of standard PWM motor drives for low-voltage service, which have been built in high volume for many years.

  • Page 22: Clean Power

    Overview 2.2 Introduction 2.2.1 Clean Power Prior to the introduction of the Perfect Harmony Drive, other solutions with variable frequency output power conversion created unwanted line disturbance (refer to Figure "Harmonic Distortion Waveform Comparisons", six-pulse and twelve-pulse input waveforms). The Perfect Harmony drive system mitigates power quality issues by: ●...

  • Page 23: Nearly Perfect Sinusoidal Output Voltages

    The Robicon Perfect Harmony series of Medium Voltage (MV) Pulse Width Modulated (PWM), Variable Frequency Motor Drives (VFD) are designed and manufactured by Siemens LD-A, New Kensington, PA, USA with additional manufacturing facilities in Europe, Asia, and South America. The Harmony VFD is intended for use with standard medium- voltage three-phase AC induction, synchronous, wound rotor, permanent magnet, or super conducting motors.

  • Page 24: Perfect Harmony Features

    Overview 2.3 Perfect Harmony Features Perfect Harmony Features The features of the Perfect Harmony family of Medium Voltage drives are summarized as follows: ● Truly Scalable Technology with modular construction – Air Cooled: GenIV, GenIIIe, GenIII NBH – Liquid Cooled: WCIII, HV ●...
  • Page 25 Overview 2.3 Perfect Harmony Features GenIV: (Refer to Table 4-1 for full GenIV product range) 200 to 5600 Hp (150 - 4100 kW) ● 2.3 to 11 kV Output ● 2.4 to 13.8 kVAC 50/60 Hz Input ● Air Cooled ●...

  • Page 26: Vfd Scalability

    Overview 2.3 Perfect Harmony Features 2.3.2 VFD Scalability The Perfect Harmony Power cells provide truly scalable technology that is provided by the wide range of output power configurations offered by the power cells, and the ability to connect up to 8 cells in series for each output phase. When connected in series, the current rating for each phase is simply equal to the output current rating of the cells;...

  • Page 27: Rectifier Configuration

    Overview 2.3 Perfect Harmony Features VFD Rating (KVA) = 1.732 * VAVAILABLE * Power Cell Continuous Current Rating. Note The VFD integral isolation transformer and cell frame are chosen in agreement with the load ratings, i.e., site conditions, cable length, and motor nameplate data (power factor efficiency, frequency, and service factor).

  • Page 28: Transformer Winding Configuration

    Overview 2.3 Perfect Harmony Features 2.3.6 Transformer Winding Configuration Each transformer secondary winding sees typical 6-Pulse Harmonics. The transformer secondaries are wound with varying phase angles, resulting in a multi-pulse reaction. The input transformer primary winding and the line sees between 18 to 48 Pulse Harmonics, as defined by the power cell configuration.
  • Page 29 Overview 2.3 Perfect Harmony Features ● Control confirms firing from: – Output voltage divider – Output Hall Effect current transducer ● No two cells ever switch at the same time ● Cell switching rate is low compared to effective switching frequency of VFD: –...

  • Page 30: Applications

    Overview 2.4 Applications Applications ● Oil and gas (including long cables) ● Municipal water ● Power Generation ● HVAC ● Cement ● Chemicals ● Research Evolution Historic Milestones: 1994: World’s 1 fully integrated voltage source inverter (VSI) medium voltage motor drive using IGBTs that meet IEEE 519 for input current distortion and NEMA/IEC for motor HVF (without using output step-up transformers or line/load filters).

  • Page 31: Ce Marking And Directives For Perfect Harmony ™ Products

    ● ATEX - Explosive Atmospheres – 94/9/EC – Does not apply to Siemens Industry, Inc. IDT LDA Perfect Harmony™ designs that are installed in ordinary [non-explosive] atmospheres. May apply to a motor if the "Ex" option for the motor is specified by the purchaser EU Norms ●...

  • Page 32: Figure 2-4 Power Drive System

    Siemens Industry, Inc. IDT LDA Perfect Harmony™ designs always include the Basic Drive Module [BDM] consisting of a Perfect Harmony™ transformer, converter/inverter [power cell] section, and control section. Depending on the Siemens Industry, Inc. IDT LDA scope of supply, the Perfect Harmony™ Complete Drive Module [CDM] may include optional components such as a motor excitation unit, output line filter, output line reactor, or earthing switches.
  • Page 33 The Machinery includes the drive shaft, gear box and the driven equipment (not shown). As stated previously, The components of the machinery, including gear boxes and the driven equipment is the end user’s responsibility and outside the scope of Siemens Industry, Inc. IDT LDA’s responsibility from a Machinery Directive standpoint.
  • Page 34 Overview 2.7 CE Marking and Directives for Perfect Harmony ™ Products EC Declaration of Conformity and Declaration of Incorporation There are three categories which require consideration: ● Partly completed machinery Such equipment (as defined in Article 2(g) of Directive 2006/42/EC) requires a "Declaration of Incorporation"...

  • Page 35: Theory

    Theory Introduction The Harmony series drives provide variable speed operation by converting utility power at fixed frequency and fixed voltage to variable frequency, variable voltage power. This conversion is done electronically, without moving parts. Unlike older drive types, the Harmony series does not force the user to accept unpleasant by-products of this conversion process.

  • Page 36: The Power Circuitry

    Theory 3.2 The Power Circuitry The Power Circuitry Note The examples used in this section refer to drives having 750 V cells. High-Voltage cell systems (1375 V) and GenIIIe (690 V) will have different values. The Harmony series drives achieve this uncompromising performance by employing well- proven technology in a modular configuration.
  • Page 37 Theory 3.2 The Power Circuitry The power cells all receive commands from one central controller. These commands are passed to the cells over fiber optic cables to maintain electrical isolation. The transformer secondaries that supply the power cells in each output phase are wound to obtain a small difference in phase angle between them.

  • Page 38: Figure 3-1 Topology Of Perfect Harmony Vfd (3 Cells)

    Theory 3.2 The Power Circuitry Figure 3-1 Topology of Perfect Harmony VFD (3 Cells) Whenever the reference is greater than the first (unshifted) carrier, the signal L1 is high; otherwise L1 is low. L1 is used to control the pair of transistors Q1 and Q2 in cell A1 (see the left pair of transistors in Figure "Schematic of a Typical Power Cell").

  • Page 39: Figure 3-2 Schematic Of A Typical Power Cell

    Theory 3.2 The Power Circuitry Figure 3-2 Schematic of a Typical Power Cell Finally, the reference signal is compared with the third carrier (shifted 240 degrees) and its inverse to generate control signals L3 and R3 for the transistors in cell A3. The output waveform of cell A3 is shown as A3.

  • Page 40: Figure 3-4 Waveforms For Phase B

    Theory 3.2 The Power Circuitry Figure 3-4 Waveforms for Phase B Figure " Waveforms for Phase B" shows the same signals for Phase B. The 3 carriers are identical to Figure " Waveforms for Phase A", except each is shifted by 20 degrees from its Phase A equivalent (see following note).

  • Page 41: Figure 3-6 Harmony Output Waveforms, 2400 Volt Drive At Full Load

    Theory 3.2 The Power Circuitry Note The phase shift of the carrier signals between phases is determined by the number of cells in the system, the equation being Phase shift = 180 degrees / total number of cells. In this case (3 ranks or 9 cells), the carrier signal phase shift phase to phase is (180 / 9) = 20 degrees.

  • Page 42: Figure 3-7 Motor A-B Voltage And Current In Phase C At Full Load For A Harmony Drive

    Theory 3.2 The Power Circuitry Harmony Input Waveforms for a Drive at Full Load Note in Figure "Harmony Input Waveforms for a Drive at Full Load" that the input current lags behind the input voltage by less than 15 degrees at full load. This represents a power factor better than 96 percent.
  • Page 43 Theory 3.2 The Power Circuitry The above figure shows the input voltage and current for the same drive and load. Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 44: The Control System

    Theory 3.3 The Control System The Control System The block diagram in Figure "Block Diagram of Harmony Control Structure" shows the implementation of the Harmony Control System. The Control System consists of the following functional blocks: Signal Interface and Conditioning, an A/D Converter, a Processor, a Digital Modulator, and Fiber Optic Interfaces.

  • Page 45: Figure 3-9 Block Diagram Of Harmony Control Structure

    Theory 3.3 The Control System When advanced cell bypass is included with a drive, the modulator communicates with the bypass controller and monitors hardware faults such as IOC, ESTOP, and power supply faults. The Bypass Controller is configured to control the cell bypass (mechanical) contactors.

  • Page 47: Geniv Specifications

    0 - 3300 ft. without derating Cooling Ventilated, forced air-cooled with integrated fans For high speed projects (> 300 Hz), consult Siemens concerning trade sanctions Consult factory for availability of auxiliary voltages other than shown Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 48: General Ambient Conditions For Storage, Transport And Operation

    GenIV Specifications 4.2 General Ambient conditions for Storage, Transport and Operation General Ambient conditions for Storage, Transport and Operation Table 4- 1 General Ambient conditions Storage Transport Operation Climatic ambient conditions Ambient temperature –5 °C to +45 °C –25 °C to +70 °C +5 °C to +40 °C Relative air humidity <...

  • Page 49: Power Cell Specifications

    GenIV Specifications 4.3 Power Cell Specifications Power Cell Specifications Cell Frame FRAME1 FRAME2 Output Nameplate 40 A 70 A 100 A 140 A 200 A 260 A Current Input Voltage 750 V ± 10%, 3 phase, 50/60 Hz Input Current 28 A 48 A 73 A...

  • Page 51: Product Description

    AC motor. The core unit contains a wide range of expandable features, enabling it to meet the demands of many types of industrial applications. Siemens GenIV (also known as MicroHarmony) may be purchased in one of three configurations. Product User Manual...
  • Page 52 – Agency approval (UL, CSA, CE) ● Custom: These selections are not readily available as pre-engineered options for the GenIV; however, our Siemens engineering staff has experience in designing these configurations in transition cabinets as an add-on to the drive line-up (see list below): –...
  • Page 53 Product Description 5.1 Drive Family Description – IP42 and NEMA 3R enclosures – Customer specified enclosure paint colors – Harsh-environment duty packages – Expansion I/O and PLC capabilities – Control houses – Heat exchanger systems – 24 DC Control Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 54: Cabinet Outlines

    Product Description 5.2 Cabinet Outlines Cabinet Outlines The cabinet configurations of the GenIV Perfect Harmony drives vary, depending upon the project requirements for input and output voltage, and output power and amperage. The GenIV, in its core configuration, consists of a single cabinet with multiple sections. Single cabinet units are shipped with their blower cage(s) removed.

  • Page 55: Cell, 4160 V Output, 200-1100 Hp

    Product Description 5.2 Cabinet Outlines 5.2.1 9 cell, 4160 V Output, 200-1100 Hp Figure " GenIV 4160 V Output 200 - 1100 Hp General Arrangement" details the GenIV 4160 V output 200 - 1100 Hp drive, and Figure "GenIV 4160 V Output 200 - 220 Hp, Sectional View"...

  • Page 56: Figure 5-2 Geniv 4160 V Output 200-1100 Hp Sectional View

    Product Description 5.2 Cabinet Outlines Figure 5-2 GenIV 4160 V Output 200-1100 Hp Sectional View Table "Nine Cell 4160 V Output GenIV, 200 - 1100 Hp" gives detailed mechanical and electrical information for the core configuartion. (Note the assumptions.) Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 57: Table 5- 2 Table "Nine Cell 4160 V Output Geniv, 200 - Hp

    Product Description 5.2 Cabinet Outlines Table 5- 2 Table "Nine Cell 4160 V Output GenIV, 200 - Hp Voltage Losses (kW) Ventilation Footprint Weight (lbs) 4160 5.25 4352 4250 CFM @1.3 " 66 " Wide, 42 " Deep, 4160 8.00 4890 110 "...
  • Page 58 Product Description 5.2 Cabinet Outlines Voltage Losses (kW) Ventilation Footprint Weight (lbs) 4160 32.50 8245 4160 39.25 8517 4160 45.50 8789 4160 52.25 9061 4160 58.75 9333 4160 64.75 9814 6600 8.00 4600 CFM @ 144 ´´ or 164 ´´ 6980 0.96 ´´...
  • Page 59 Product Description 5.2 Cabinet Outlines Voltage Losses (kW) Ventilation Footprint Weight (lbs) 6600 26.25 9530 6600 32.75 6250 CFM @ Note: Shipping 11225 1.62 ´´ H height is 90.1 " (80 ´´ Transformer when blower Section) assembly is removed. 6600 39.50 11575 6600...
  • Page 60 Product Description 5.2 Cabinet Outlines Voltage Losses (kW) Ventilation Footprint Weight (lbs) projects the pressure 10000 26.25 head availability is 0.85 ´´ for Cell Section and 0.0 ´´ for Transformer Section Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...
  • Page 61 Product Description 5.2 Cabinet Outlines Voltage Losses (kW) Ventilation Footprint Weight (lbs) 10000 .32.75 10000 39.50 10000 45.75 10000 52.50 10000 59.00 10000 65.50. 10000 72.25 10000 78.50 10000 91.50 10000 105.00 10000 118.00 10000 131.00 Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...
  • Page 62 Product Description 5.2 Cabinet Outlines Voltage Losses (kW) Ventilation Footprint Weight (lbs) 10000 144.25 10000 157.25 Drive Rated Hp Losses are shown as 2.59 kW per 100 Hp, rounded up to the nearest ¼ value EC Blower operates at 80% speed typically (100% speed with Duct Interface) Subject to change without notice For 4160 V, 40-140 A add 160 lbs for redundant blower and 75 lbs for cell bypass For 4160 V, 200-260 A add 200 lbs for redundant blower and 75 lbs for cell bypass...

  • Page 63: Cabinet Details

    Product Description 5.3 Cabinet Details Cabinet Details The GenIV core enclosure is NEMA 1 Ventilated (IP 31 degree of protection) and is provided with top and bottom cable access plates (see Figure "GenIV Enclosure (4160 V Output, 200- 1100hp)"). The doors are hinged and mechanical key interlock provisions are provided. Figure 5-3 GenIV Enclosure (4160 V Output, 200-1100 hp) Note...

  • Page 64: Input/Output Section

    Product Description 5.3 Cabinet Details 5.3.1 Input/Output Section The Input/Output section is located behind the control section as shown in Figure "I/O Section". Component Label Part Description L1, L2, L3 Medium Voltage Input Connections T1, T2, T3 Medium Voltage Output Connections CT1, CT2 Input B and C Phase Current Transformers IATTA, IATTB, IATTC...

  • Page 65: Figure 5-4 I/O Section

    Product Description 5.3 Cabinet Details Figure 5-4 I/O Section All medium voltage terminations and control terminal blocks are accessible from the front of the drive when the control section panel is in the open position. Side and rear access is not required for field installation;...

  • Page 66: Figure 5-5 Medium Voltage Terminations (L1, L2, L3, Or T1, T2, T3)

    Product Description 5.3 Cabinet Details The input and output medium voltage terminals (L1, L2, L3 and T1, T2, T3) are offset from one another and have two NEMA one-hole pattern configurations (vertical and horizontal) to facilitate top or bottom cable termination (see Figure " Medium Voltage Terminations (L1, L2, L33, or T1, T2, T3").

  • Page 67: Transformer Section

    Product Description 5.3 Cabinet Details Figure 5-6 Output Hall Effect Current Transducers (HEB1, HEC1) 5.3.2 Transformer Section The Transformer section is located in the bottom half of the GenIV enclosure and contains the following components: Table 5- 3 Transformer Section Components Component Label Part Description Integral Isolation Transformer...
  • Page 68 Some transformers are equipped with secondary winding coolers for improved thermal performance. The transformer is wound with 220°C winding insulation and the BIL level depends on the input voltage rating. During Siemens' assembly, the transformer and polyglass baffling are installed through the top of the transformer section enclosure.

  • Page 69: Figure 5-7 Typical Geniv 4160 V 40-140 Amp Transformer

    Product Description 5.3 Cabinet Details Figure 5-7 Typical GenIV 4160 V 40-140 Amp Transformer Note In the unlikely event of a transformer failure requiring replacement, the drive must be disassembled, allowing for top removal from the transformer section. Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 70: Table 5- 6 Geniv Transformer Sizing And Derating Factors1*,2

    Product Description 5.3 Cabinet Details Figure 5-8 Typical GenIV 4160V, 200-260 A Transformer The transformers are sized on a 1000 VA per Hp basis (as shown in Chapter 1, and further shown below); however, other factors must be considered, such as motor lead length, motor service factor, environment ambient and altitude, and power cell redundancy (N+1 3300 V project).

  • Page 71: Figure 5-9 Cut-Out View Of Fuse Assembly

    Product Description 5.3 Cabinet Details 4. If Redundant N+1 operation is required, then the transformer size is increased by: = kVA * 1.125 (3300 V projects) = kVA * 1.08 (6000 V projects) = kVA * 1.25 (N+3, 4160 V projects using 6600 V drive) = kVA * 1.05 (N+3, 4160 V projects using 6600 V drive) 5.

  • Page 72: Cell Section

    Product Description 5.3 Cabinet Details secondary short circuit protection and are sized to accommodate power cell charging currents upon initial energizing. Note A mixture of the three fuse vendors are permitted in terms of fuse replacement as long as any two fuses protecting the secondary windings are matched (i.e., FA1A and FA1C should be from the same vendor).

  • Page 73: Table 5- 9 Cell Section Components 6600 V, 40-260 Amp

    Product Description 5.3 Cabinet Details Table 5- 9 Cell Section Components 6600 V, 40-260 Amp Component Label Part Description A1, A2, A3, A4, A5, B1, B2, B3, B4, B5, C1, C2, C3, C4, C5 GenIV Power Cells (40, 70, 100, 140, 200, or 260 Amp types) BPKA1, BPKA2, BPKA3, BPKA4, BPKA5, BPKB1, BPKB2, Mechanical Cell Bypass Contactors (Optional)

  • Page 74: Figure 5-10 Geniv 40-140 A Power Cell Frame

    This K2 key should be interlocked with a keyed lock located in the incoming switchgear (coordinated with the Siemens project engineer). Only when the incoming switchgear is mechanically and electrically opened should the K2 key be released for use at the GenIV drive.

  • Page 75: Figure 5-11 Cell Installation And Latching System

    Product Description 5.3 Cabinet Details Figure 5-11 Cell Installation and Latching System The cell mounting infrastructure consists of a polyglass backplane, cell mounting rails, and horizontal polyglass supports. Each of the nine Power Cell’s three-phase AC input connections exit at the top right of the Transformer Section, and are routed to the cell via three large adalets (right enclosure wall) and two lexan wire trays.
  • Page 76 Product Description 5.3 Cabinet Details Figure 5-12 Nine Cell Mounting Structure Cell Connection and Bypass Contactor Figure 5-13 Bypass Contactors and Bus Connections Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...
  • Page 77 Product Description 5.3 Cabinet Details Cell Construction GenIV MicroHarmony 750V Cells frames (40, 70, 100, and 140 Amp) have an identical footprint, see Figure "GenIV Power Cell with Board Shown" (dimensions and mass are detailed further in Chapter 3 of this manual). GenIV 750 V (200 and 260 Amp) cells also have identical footprints.
  • Page 78 Product Description 5.3 Cabinet Details Shown with full population of electrolytic capacitors Figure 5-15 GenIV Cell, 40-140 Amp, Anatomy The GenIV cells use an uncontrolled diode rectifier to convert the three-phase secondary voltage to DC. Since power can only flow from the transformer to the cells, the converter is considered a two quadrant type (2Q).
  • Page 79 Product Description 5.3 Cabinet Details Cells are typically switched at 600 Hz per pole, with an output switching frequency of 1200 Hz per cell. The total effective drive output switching frequency with 9 cells is 3600 Hz (6000 Hz for 15 cells). At this switching frequency, the output (motor) frequency can increase to 167 Hz.

  • Page 80: Table 5- 11 Geniv Cell Current De-Rate Factors 1*, 2

    Product Description 5.3 Cabinet Details Figure 5-17 Indicators and Labels WARNING The power cells include discharge resistors to dissipate stored energy after the input voltage is removed. The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes.
  • Page 81 Product Description 5.3 Cabinet Details If F is operated continuously below 10 Hz, de-rate cell current as: = (0.5 + F / 20) BASE 2 If altitude exceeds 3300 FASL, then de-rate cell current as: = (1-0.00003*[ALT-3300]) BASE 3 If ambient temperature exceeds 45 °C, then de-rate cell current as: = ([55 - T ]/15)^0.57 BASE 4...

  • Page 82: Control Section

    Product Description 5.3 Cabinet Details Figure 5-19 Cell Bypass Operation 5.3.4 Control Section The Control Section is located in front of the I/O Section and contains the NXG II Controller, low voltage apparatus, and the auxiliary voltage disconnect switch; the Control Door is considered part of this section in reference to the "A"...
  • Page 83 Product Description 5.3 Cabinet Details Component Label Part Description GND1 Grounding Pad Emergency Stop Pushbutton Keypad ENET Ethernet Port Mode Selector Switch ANYBUS1, ANYBUS21 Network 1 and Network 2 communication cards (optional) These expansion boards plug into the communications board in slot 8 of the DCR Control Tub The control tub contains all the components shown in Figure "GenIV Control Tub".
  • Page 84 Product Description 5.3 Cabinet Details Figure 5-20 GenIV Control Tub (4160 V Drives) Figure 5-21 GenIV Control Tub (6600 V Drives) NXG II Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 85: Table 5- 13 Analog And Digital Input/Output

    (refer to Tables "Nine Cell, GenIV, Core Hardwired I/O Assignments"). The remaining SPARE I/O can be used in agreement with the Siemens project engineer for customer related signalization using the SOP. Table 5- 13...

  • Page 86: Table 5- 15 15 Cell, Geniv, Core Hardwired I/O Assignments

    Product Description 5.3 Cabinet Details Signal Type Signal Name Function Digital Input IDI-1B SW1-Remote/Auto Digital Input IDI-2B Output Reactor Winding Temperature, High (Else SPARE) Digital Input IDI-3B Output Reactor Winding Temperature, High-High (Else SPARE) Digital Input IDI-0C SPARE Digital Input IDI-1C SPARE Digital Input...

  • Page 87: Table 5- 16 Twenty-Four Cell, Geniv, Core Hardwired I/O Assignments (Subject To Change. Always Refer To The Project "A" And "B" For I/O Assignments)

    Product Description 5.3 Cabinet Details Signal Type Signal Name Function Digital Input IDI-2B Output Reactor Winding Temperature, High (Else SPARE) Digital Input IDI-3B Output Reactor Winding Temperature, High-High (Else SPARE) Digital Input IDI-0C Cabinet Door Interlock (Else SPARE) Digital Input IDI-1C SPARE Digital Input...
  • Page 88 Product Description 5.3 Cabinet Details Signal Type Signal Name Function Digital Input IDI-2A Remote Stop Digital Input IDI-3A Remote Fault Reset Digital Input IDI-0B SW1-Off Digital Input IDI-1B SW1-Remote/Auto Digital Input IDI-2B Output Reactor Winding Temperature, High (Else SPARE) Digital Input IDI-3B Output Reactor Winding Temperature, High-High (Else SPARE) Digital Input...

  • Page 89: Figure 5-22 Input Protection Interface For Trip Contacts

    Product Description 5.3 Cabinet Details Coordinated Input Protection Scheme Input currents and voltages to the drive input transformer are measured and processed continuously by the control system. Information such as efficiency, power factor, and harmonics are available to the user. The input monitoring also protects against transformer secondary side faults that cannot be seen by typical primary protection relaying.
  • Page 90 Product Description 5.3 Cabinet Details This circuit is repeated in the "C" set of drawings. Contact ratings are shown for resistive switching. Note Given the amperage rating of the components used in the Coordinated Input Protection Scheme, an additional customer pilot relay may be required. Terminal Blocks The core drive uses 8mm 600 V terminal blocks for auxiliary input three-phase voltage (TB4).

  • Page 91: Upstream Device Ratings

    Product Description 5.3 Cabinet Details Figure 5-23 E-Stop Circuits (Deck 1 and Deck 2) Figure 5-24 Control Door (control arrangement may vary) Figure 5-25 Keypad 5.3.5 Upstream Device Ratings Description VFDs require an appropriate Input Current Interrupting device installed upstream of the VFD. This device must be connected between the power source (input line) and the VFD input Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 92: Control Wire Way Section

    Product Description 5.3 Cabinet Details connections (L1, L2, L3). The input current interrupting device is considered an integral part of the VFD safety system. Requirements The required interrupting device will accept an "ENABLE TO CLOSE" as an OPEN command from a VFD dry contact ("MV ENABLE"). This contact, when open, causes the input current interrupting device to open and then prevents the reapplication of input power.

  • Page 93: Figure 5-26 Control Wire Way Section (With All Options)

    Product Description 5.3 Cabinet Details Component Label Part Description F33, F34, F35 Blower CBLW2 Fuses (Optional) CB10 Blower TBLW1 Circuit Breaker CB11 Blower TBLW2 Circuit Breaker (Optional) CB12 Blower CBLW1 Circuit Breaker CB13 Blower CBLW2 Circuit Breaker (Optional) STR21, AUX21, SUPP21 Motor Starter for Blower TBLW1, auxiliary contact, and AC coil suppressor STR22, AUX22, SUPP22...

  • Page 94: Cooling

    Product Description 5.3 Cabinet Details reactor. The line reactor is then connected to a motor starter that is controlled through the SOP of the NXG II controller. The output of the motor starter connects to a quick disconnect plug associated with that blower. Fault logic is fed back through the plug back into the I/O system of the NXG II controller.

  • Page 95: Table 5- 18 Blower Components (6600 V Drives)

    Product Description 5.3 Cabinet Details Table 5- 18 Blower Components (6600 V Drives) Component Label Part Description TBLW1 Transformer Blower #1 RTBLW1*, DTBLW1* Blower command; resistor and zener diode TBLW2 Transformer Blower #2 (Optional) RTBLW2*, DTBLW2* Blower command; resistor and zener diode (Optional) CBLW1 Cell Cabinet Blower #1 RCBLW1*, DCBLW1*...
  • Page 96 Product Description 5.3 Cabinet Details cell. The male connecting bus is located in line with the exhaust air of the cell. For systems with mechanical cell bypass, the contactors are mounted on an additional bus, located in the rear common exhaust air plenum. All of the bus and the contactors are therefore forced-air cooled, but at an elevated ambient due to cell and transformer losses.
  • Page 97 Product Description 5.3 Cabinet Details Figure 5-28 AC Blower and Cage Cutaway Figure 5-29 GenIV 500 mm EC Blower Cage Assembly Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...
  • Page 98 Product Description 5.3 Cabinet Details Note Never energize the drive without operational blowers providing air flow. The drive contains components that have losses in the IDLE state. Without air flow, these losses may heat up components and eventually damage the drive over time. Applying Medium Voltage without air flow will result in a trip from the Coordinated Input Protection Scheme.

  • Page 99: Long Cable Filters

    Product Description 5.4 Long Cable Filters Long Cable Filters For GenIV, output filters are typically required when cable lengths on the output of the drive exceed 7500 feet. At this distance and beyond, the effective switching frequency harmonics and sidebands may excite a cable resonance, resulting in transmission line over-voltages at the motor terminals.

  • Page 100: Table 5- 22 Nine Cell Output Filter, Inductance

    Product Description 5.4 Long Cable Filters Table 5- 22 Nine Cell Output Filter, Inductance Cell Size L, Inductance L % @ 50Hz L % @ 60Hz CT Ratio (# of turns) 40 A 13.5 mH 7.33 70 A 6.8 mH 6.46 7.76 100 A...

  • Page 101: Table 5- 26 Fifteen Cell Output Filter, Inductance

    Product Description 5.4 Long Cable Filters Table 5- 26 Fifteen Cell Output Filter, Inductance Cell Size L, Inductance L % @ 50Hz L % @ 60Hz CT Ratio (# of turns) 40 A 37.90 mH 7.50 9.00 70 A 22.00 mH 7.62 9.14 100 A...

  • Page 102: Synchronous Transfer Reactors

    Product Description 5.5 Synchronous Transfer Reactors Synchronous Transfer Reactors When the GenIV requires the SYNCH TRANSFER feature, the output of the drive is equipped with a reactor and switchgear (contactors). These reactors cannot be packaged into the core configuration due to space limitations; therefore, they are housed in transition cabinets.

  • Page 103: Motor Compatibility

    25 . The nine cell GenIV drive was factory tested at Siemens and was found to meet NEMA MG-1 for Harmonic Voltage Factor (HVF) < 0.03 and, therefore, motors do not need to be derated.

  • Page 104: Ieee 519 Conformance

    5.7 IEEE 519 Conformance IEEE 519 Conformance The eighteen-pulse nine cell GenIV drive was factory tested at SIEMENS and was found to meet IEEE 519 for the most stringent TDD limits. The pre-existing voltage distortion was less than 2% and the primary current contained a K-factor of less than 2.

  • Page 105: Ride Through

    "Ride Through," the drive will trip on a "No Medium Voltage Fault." The eighteen-pulse nine cell GenIV drive was factory-tested at SIEMENS for input line voltage immunity. The drive was shown to have a ride through capability of 5 cycles or more (line voltage was removed and then re-applied 7.5 cycles later).

  • Page 107: Application And Operation

    Application and Operation This chapter provides an overview of some of the features, applications, and operating issues of the Siemens LD-A Perfect Harmony VFD. Detailed descriptions and setup of many NXG Control Manual, of these features are provided in the 19001588.

  • Page 108: Signal Frame Of Reference For Motor Control

    Application and Operation 6.1 Signal Frame of Reference for Motor Control Signal Frame of Reference for Motor Control The control signals used for controlling the motor must be assigned a polarity for use over four quadrants of control to maintain consistency of the algorithms. This section clarifies what they are and what their polarities mean in the various quadrants.

  • Page 109: Signal Polarities

    Application and Operation 6.1 Signal Frame of Reference for Motor Control constant, the motor will slow to zero and then accelerate in the forward direction, passing back into quadrant I. The injection frequency must always be opposing the direction of rotation and is only used in the case of braking or negative energy flow.

  • Page 110: The Control Modes

    Application and Operation 6.2 The Control Modes The Control Modes Harmony drives use vector control to control induction and synchronous motors. Vector control provides a framework that is simple to implement, but performs nearly as well as a DC motor. Figure "Block Diagram of Vectors Control Algorithmus for Induction and Synchronous Motor Control"...

  • Page 111: Table 6- 2 List Of Symbols Used In Figure "Block Diagram Of Vectors Control Algorithmus For Induction And Synchronous Motor Control

    Application and Operation 6.2 The Control Modes frame). A phase-locked loop (PLL) within the motor model tracks the (stator) frequency and angle of the flux vector. Motor flux amplitude is controlled by the flux regulator; its output forms the command for the magnetizing (or flux producing) component.

  • Page 112: Open Loop Vector Control (Olvc)

    Application and Operation 6.2 The Control Modes 6.2.1 Open Loop Vector Control (OLVC) This control mode should be used for most applications with single induction motors. In this method, the control estimates motor slip as a function of load torque, and provides a performance that matches a vector controlled drive (with speed sensor/transducer) above a certain minimum speed.

  • Page 113: Induction And Synchronous Motor Control

    Application and Operation 6.2 The Control Modes The overall control strategy is similar to Open Loop Vector Control, except for the flux regulator implementation as shown in Figure "Block Diagram of Vector Control Algorithms for Induction and Synchronous Motor Control". For synchronous motors, the flux regulator provides two current commands, one for the field exciter current, and another for the magnetizing component of stator current.

  • Page 114: Volts/Hertz Control (V/Hz)

    Application and Operation 6.2 The Control Modes ● Only Stage 1 Auto-Tuning can be used with synchronous motors. ● When you are performing Stage 1 Auto-Tuning, you must short the field winding to get a proper setup of the stator resistance. CAUTION Never use Stage 2 Auto-tuning with synchronous motors.

  • Page 115: Closed Loop Control (Clvc Or Csmc)

    Application and Operation 6.2 The Control Modes 6.2.5 Closed Loop Control (CLVC or CSMC) In some applications, when stable, low speed (below 1 Hz) operation under high torque conditions is required, an encoder may be used to provide speed feedback. The control diagram of Figure "Block Diagram of Vector Control Algorithms for Induction and Synchronous Motor Control"...

  • Page 116: Frequency Regulator

    Application and Operation 6.2 The Control Modes With slip compensation, the slip frequency is subtracted from the output frequency (f ) to ensure that the mechanical speed matches the desired speed. In simple terms, this is done by taking the per unit (P ) Torque (T ) times the slip and subtracting it from the speed feedback (in frequency), effectively adding it to the speed reference:...

  • Page 117: Torque Current Regulator

    Application and Operation 6.2 The Control Modes 6.2.8 Torque Current Regulator The Torque Current Regulator generates the motor’s Q-axis motor voltage. The Torque Producing Motor Current Reference (Iqs_ref) is generated from the output of the Frequency Regulator. The Torque Producing Current Feedback (Iqs) comes from Motor Current D-Q converter.

  • Page 118: High Performance Control

    Application and Operation 6.3 High Performance Control High Performance Control When applying the Harmony drives, applications requiring high starting torque or low speed operation are considered as "High performance" control. 6.3.1 Low Speed Operation In some applications, when stable, low speed (below 1 Hz) operation under high torque conditions is required, an encoder may be used to provide speed feedback.

  • Page 119: Figure 6-4 Drive Operation In High Starting Torque Mode

    Application and Operation 6.3 High Performance Control The control then ramps the output from rated slip to the minimum speed limit while maintaining rated current. At minimum speed, the control holds the speed ramp for one second at this value, reduces the torque current (Iqs), and enables the speed loop. One second later, the flux loop is enabled and the drive resumes acceleration to the desired speed demand.

  • Page 120: System Program (Sop)

    Application and Operation 6.4 System Program (SOP) System Program (SOP) The Harmony Series of digital drives contain customized programmable logic functions that define many features and capabilities of the drives. These logic functions are combined into a system program (SOP) that can be edited either at the factory or in the field. Examples of logic functions include start/stop control logic, reference signal handling, input/output control logic (e.g., annunciators, interlocks, etc.), drive-to-machinery coordination and more.

  • Page 121: Command Generator

    Application and Operation 6.5 Command Generator Command Generator This section defines the Command generator functional blocks shown in Figure " Command Generator" Figure 6-5 Command Generator 6.5.1 Raw Speed Reference The NXG Control includes provisions for output speed demand entry as required for a specific application.

  • Page 122: Speed Profile

    Application and Operation 6.5 Command Generator Set Point Sources Set Points are internal menu entries that are static values based on user entry, keypad settings, or remote demand from a network communication interface. There are a total of eight inputs that are menu entries from remote communications. There are two special additional entries that are reserved for safety override and jog level set points.

  • Page 123: Speed Limit

    Application and Operation 6.5 Command Generator established by the end user. Provisions are included for multiple sets of acceleration and deceleration settings. The control provides a means to use any one of three separate menu- defined acceleration/deceleration sets, or PLC network control as selected by the SOP. 6.5.6 Speed Limit The Speed Limit simply limits the final output of the demand shaping chain to within preset...

  • Page 124: Energy Saver

    Application and Operation 6.6 Energy Saver Energy Saver The NXG Control includes provisions for output speed demand entry as required for a specific application. The active reference source is configured per specific system requirements and can be dynamically changed. This is implemented via the drive’s "System Program"...
  • Page 125 Application and Operation 6.6 Energy Saver ● Jog – Set to maximum active speed limit, intended for test purposes to "bump" motor ● Communication Network – Digital Value as set per external communication interface to a PLC/DCS Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 126: Drive Output Torque Limiting

    Application and Operation 6.7 Drive Output Torque Limiting Drive Output Torque Limiting The drive uses measured voltages and currents to implement torque-limit (rollback) conditions. Under one or more of these conditions, the drive will continue to operate, but at a lower output torque (or current) level.

  • Page 127: Input Under-Voltage Rollback

    Application and Operation 6.7 Drive Output Torque Limiting 6.7.2 Input Under-Voltage Rollback When the input line voltage drops below 90% of its rated value, the drive limits the amount of power (and hence the torque) that can be delivered to the load. The maximum allowable drive power as a function of line voltage is shown in Figure "...

  • Page 128: Input Single-Phase Rollback

    Application and Operation 6.7 Drive Output Torque Limiting 6.7.3 Input Single-Phase Rollback With Next Gen Control, input voltage unbalance (E ) is used for rolling back the drive unbalance output torque. Figure "Drive Power (Pmax) as Function of Input Unbalance Voltage (Eunbalance)"...

  • Page 129: Cell Current Overload

    Application and Operation 6.7 Drive Output Torque Limiting 6.7.6 Cell Current Overload The NXG Control provides a power cell (current) overload setting. A cell can operate at this overload value for 1 minute out of every 10 minutes. When the current is between the cell rating and the overload rating, the time spent at that level is inversely proportional to the overload current setting.

  • Page 130: Drive Tuning

    Application and Operation 6.8 Drive Tuning Drive Tuning Section "Auto Tuning" describes the Auto Tuning feature provided by the NXG control and its use in determining motor and control parameters. Section "Spinning Load" describes the setup of the Spinning Load function. This feature is used by the drive control to detect motor speed by scanning the output frequency over the operating range of the application.

  • Page 131: Spinning Load

    Application and Operation 6.8 Drive Tuning DANGER LETHAL VOLTAGES! Lethal voltages will appear on the drive outputs during both stages (1 and 2) of Auto Tuning. Auto Tune Stage 1 Stage 1 determines the Stator Resistance and Leakage Inductance. This stage of auto tuning does not require the motor to be de-coupled from the load.
  • Page 132 Application and Operation 6.8 Drive Tuning The second stage consists of a scan feature during which a preset level of current of varying frequency is applied to the motor. The control monitors the measured motor flux, and when the motor flux exceeds a programmable flux threshold, the control assumes that the applied frequency is equal to the rotating speed of the motor.

  • Page 133: User Io

    Application and Operation 6.9 User IO User IO The VFD provides terminal strips as required for end-user connection of isolated analog and digital input/output signals to the drive. Specific I/O implementation is customized for each drive where the end user must refer to drawings provided with the drive. The NXG control interfaces each of these IO points via either built-in or expansion IO modules.

  • Page 134: Data Logs

    Application and Operation 6.10 Data Logs 6.10 Data Logs The NXG control includes 3 separate data loggers to record events detected by the software. Each of these logs are stored in non-volatile memory and can be captured by the user via the VFD’s serial debug port or the Ethernet Port.

  • Page 135: Faults And Alarms

    Application and Operation 6.11 Faults and Alarms 6.11 Faults and Alarms If a fault or alarm condition exists, it will be annunciated on the keypad and recorded in both the Fault and Event Logs. External hardwire indicators are also set as defined in the System Program.

  • Page 136: Motor Overload

    Application and Operation 6.12 Motor Overload 6.12 Motor Overload NXG Perfect Harmony control provides Motor Thermal Overload (TOL) protection to prevent the motor from being subjected to excessive temperatures. TOL protection of the motor can be set up using the NXG control menu system. The "overload select" parameter allows one of three options to be selected for motor protection.
  • Page 137 Application and Operation 6.12 Motor Overload manufacturer normally provides data for this curve. The control software uses the allowable current level to determine the cooling capability of the motor. If the user’s preference is to enter a fixed value of an allowable current level other than 100% (as with the "straight inverse time"...

  • Page 138: Input Side Monitoring And Protection

    Application and Operation 6.13 Input Side Monitoring and Protection 6.13 Input Side Monitoring and Protection The NXG Control monitors input side voltages and currents, as well as those on the output side. This allows the control to monitor and respond to events on the input side of the drive. RMS values of the input currents and voltages are available, along with input power, kVA, energy, and power factor.

  • Page 139: One Cycle Protection

    Application and Operation 6.13 Input Side Monitoring and Protection Table 6- 4 List of Symbols Used in Figure "Block Diagram of Input-Side Monitoring" Name Description Average rms voltage (of all 3 phases) Amplitude of voltage taking the transformer tap setting into account. This represents the actual voltage being provided to the cells.

  • Page 140: Excessive Drive Losses

    Application and Operation 6.13 Input Side Monitoring and Protection Transformer Model The Transformer Model block in Figure "Implementation of One Cycle Protection" provides the maximum value of the input reactive current for a given value of transformer constant, Ktr, as given below: = 1.10 * (0.05 + Ktr * I Real 2 Reactive,Max...

  • Page 141: Figure 6-15 Inverse Time-To-Trip Curves Left - Idle State, Right - Run State

    Application and Operation 6.13 Input Side Monitoring and Protection Implementation The follwing Figure shows the implementation of the Drive Loss fault circuit. Figure 6-14 Implementation of the Drive Loss Fault Circuit Inverse Time Curve The follwing Figure shows the inverse time-to-trip curves as a function of Drive Losses. Each plot shows two curves –...
  • Page 142 Application and Operation 6.13 Input Side Monitoring and Protection Internal Threshold The internal threshold is a function of the rated drive input power. For example, in Run State, the internal threshold is given as: Internal Threshold = 0.07 * rated Drive Input Poser (Watts) = 0.07 * √3 * Rated Input Voltage * Rated Input Current Note...

  • Page 143: Cell Bypass

    Application and Operation 6.14 Cell Bypass 6.14 Cell Bypass 6.14.1 Fast Bypass Up time is an important factor in many processes. A Medium Voltage drive is often a critical part of the process and even small interruptions in output torque of a Medium Voltage drive can cause the process to stop.
  • Page 144 Application and Operation 6.14 Cell Bypass 4. NXG control detects cell fault(s) 5. NXG control monitors motor back EMF until it is within "safe" voltage 6. Control issues commands to bypass faulted cell(s) 7. Brief delay to allow mechanical contactors to fully close 8.

  • Page 145: Figure 6-16 Typical Power Cell With Bypass Contactor

    Application and Operation 6.14 Cell Bypass Figure 6-16 Typical Power Cell with Bypass Contactor Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 146: Neutral Point Shift During Bypass

    Application and Operation 6.14 Cell Bypass 6.14.3 Neutral Point Shift during Bypass Since the cells in each phase of a Perfect Harmony Drive are in series, bypassing a cell has no effect on the current capability of the drive, but the voltage capability will be reduced. Usually the required motor voltage is roughly proportional to speed, so that the maximum speed at which the drive can fulfill the application requirements will also be reduced.
  • Page 147 Siemens calls this approach Neutral-Shift, and has a US Patent (5,986,909) that covers it. This approach is equivalent to introducing a zero-sequence component into the voltage command vectors for the cells.
  • Page 148 Application and Operation 6.14 Cell Bypass Figure 6-20 Drive Output Re-Balanced by Adjusting Phase Angles (Neutral Shift) The same neutral-shift approach can be applied to more extreme situations, as is illustrated by Figure "Drive Output after Loss of 3 Cells" and Figure "Drive Output after Loss of 5 Cells" 2.
  • Page 149 Application and Operation 6.14 Cell Bypass in Figure "Drive Output after Loss of 5 Cells", only the faulted cells are bypassed. The phase angles of the cell voltages have been adjusted so that phase A is displaced from phase B by 61.1°...
  • Page 150 Application and Operation 6.14 Cell Bypass With Neutral-Shift Without Neutral-Shift Original Number of Modules per Phase Figure 6-23 Available Voltage after One Cell Bypass The drive control uses the information of faulted cells to automatically calculate the phase angles of cell voltages to maintain balanced motor voltages. During neutral-shift, each phase of the drive operates with a different power factor.

  • Page 151: Tool Suite

    Application and Operation 6.15 Tool Suite 6.15 Tool Suite 6.15.1 Drive Host The NXG Drive Host is a PC-based application software package that provides a remote graphical user interface for Medium Voltage Perfect Harmony NXG series drives. With the Drive Host tool, the user can navigate through a drive’s features using a PC and a mouse, allowing monitoring and control of the drive’s functions quickly and easily.

  • Page 152: Nxg Debug Utility

    Application and Operation 6.15 Tool Suite Status ● Programmable display variables – Pick list selectable variables, same as drive keypad display list – First 4 synchronized to keypad display ● Fault and Alarm indicators (traffic lights: red = fault, yellow = alarm, green = none) Control (** only if enabled by SOP) ●...

  • Page 153: Dual Frequency Braking

    Like DC injection braking, this approach is implemented in software and requires no additional hardware that can reduce the reliability of the drive. Siemens has a patent on Dual Frequency Braking (US 6,417,644). 6.16.2 Operation...
  • Page 154 Application and Operation 6.16 Dual Frequency Braking frequency is always in opposite rotation to the applied motor electrical frequency (speed and direction of the machine). Figure "Dual Frequency Voltages Being Added Together with the Normal Three-Phase Voltages" is a block diagram showing how the two voltage vectors (normal VA1 and loss- inducing VA2) are added together to produce the braking function.

  • Page 155: Limitations

    With high efficiency motors and inverter duty motors, the braking torque that can be achieved with DFB is lower than the values shown in Figure 5-26. Contact Siemens Engineering with the following motor-related data to determine the braking torque capability...
  • Page 156 Application and Operation 6.16 Dual Frequency Braking ● Rated HP ● Rated Voltage ● Rated Frequency ● Full/Half load speed ● Full/Half load efficiency ● Locked Rotor Torque and Current ● Pull out torque ● Critical frequencies of the mechanical system Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 157: Debug Functionality

    Application and Operation 6.17 Debug Functionality 6.17 Debug Functionality The Serial Debug function of the NXG control serves as a means for the user to connect to an interactive menu that allows a user to capture VFD run-time data, including debug data described in Section 5.15.2.

  • Page 159: Application Specific Features

    Application Specific Features Control Mode Summary The NXG Control provides six control modes for the Perfect Harmony drive family. These modes are described as follows: ● CLVC - Closed Loop Vector Control CLVC provides flux vector control for an induction machine utilizing an encoder for speed feedback.

  • Page 160: Control Loops

    Application Specific Features 7.2 Control Loops Control Loops The NXG Control includes three main control loops that are defined in the following sections. 7.2.1 Current Loop The current loops form the innermost loop of the NXG control system. It is essential that these loops are stable.

  • Page 161: System Program

    Application Specific Features 7.3 System Program System Program The System Program, as described in Section 5.4, is developed for each drive application to configure the VFD to function as desired by the end user. The System Program allows the end user to define the drive operation, where possible, so that system response and I/O configuration is configured for the application.

  • Page 162: Speed Droop

    Application Specific Features 7.4 Speed Droop Speed Droop Speed Droop is the decrease in the speed of a motor with a constant voltage and frequency when the motor is under load. The difference between the synchronous (unloaded) speed of the motor and the full load speed is known as slip. Normally, slip compensation increases the output frequency of the VFD as the motor speed attempts to decrease.

  • Page 163: Long Cable Applications

    ¼ cycle at the effective switching frequency, which Siemens LD A defines as the critical length. In this case, the reflected waves from successive steps reinforce each other, and the worst step size on the motor can become many times higher than the step size from the drive.

  • Page 164: Output Filters

    Application Specific Features 7.6 Output Filters Output Filters Output filters are required for down-hole pumping with long cables and also must be considered when shielded output cables are used. When required, the filter completely avoids any problem with cable reflections. NXG control supports output filters for all control modes.

  • Page 165: Synchronous Transfer

    7.7.2 VFD Synchronous Transfer Implementation Synchronous transfer is inherent to NXG control. To optimize this feature, Siemens engineering should always be involved (regardless of scope of supply) in the switchgear configuration and logic sequencing for both equipment and personnel safety. Siemens engineering can supply switchgear and reactors as part of the drive, or provide recommendations as needed.
  • Page 166 A PLC is recommended for multi-motor synchronous transfer applications. This PLC and its logic can be supplied by Siemens engineering to coordinate the transfer sequence and also control the switchgear. In addition, motor protection relays are recommended since the VFD cannot protect a motor operating from the line.

  • Page 167: Input/Output Signals For Sync Transfer

    Application Specific Features 7.7 Synchronous Transfer Note It is not required that all motors connected to a drive configured for synchronous transfer have matching ratings. If mis-matched motors are implemented, the drive must be sized for the worst case load. "Smaller" motor loads can be mechanized via parameter read/write functionality or the NXG Control Multiple Configuration file capability, as described in NXG Communications Manual (902399) and NXG Control Manual (19001588), respectively.
  • Page 168 Application Specific Features 7.7 Synchronous Transfer velocity reference and adjusting the VFD output voltage to match the line. Both functions are automatically implemented by the NXG control when an "Up Request" is received. The active acceleration ramps and torque limits set in the control are used during this period. Note Mismatched line/motor voltages are permitted when careful consideration is given to the configuration of the VFD (including step up/down transformers between the line and the...

  • Page 169: Down Transfer Implementation

    Application Specific Features 7.7 Synchronous Transfer 6. Once the Motor Line Contactor is closed and acknowledged at the VFD, the VFD will disable its output. 7. Once the VFD Output is disabled, the run request should be removed and the VFD output contactor must be opened.
  • Page 170 Application Specific Features 7.7 Synchronous Transfer 5. Once the output current from the VFD reaches a predetermined level, the VFD signals that the line contactor can be opened. The output current will be limited to the maximum torque limit set in the NXG control. Note The VFD will remain in the Down Transfer state as long as the "Down Transfer Request"...

  • Page 171: Parallel Control

    Application Specific Features 7.8 Parallel Control Parallel Control The Perfect Harmony drive family design includes the ability to combine multiple drives in parallel to provide a higher power output than is available from a single drive. Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 172: Communication Interfaces

    Application Specific Features 7.9 Communication Interfaces Communication Interfaces 7.9.1 Available Networks At present, the NXG control supports the following industry standard PLC networks: ● Modbus RTU ● Modbus Ethernet ● Profibus DP ● ControlNet ● DeviceNet ● Modbus Plus Note Note: Modbus RTU or Modbus Ethernet is available as Network 1 without additional hardware.

  • Page 173: Process Availability - The Perfect Harmony Advantage

    Application Specific Features 7.10 Process Availability - The Perfect Harmony Advantage 7.10 Process Availability - The Perfect Harmony Advantage Process availability is the primary prerequisite for applying a Medium Voltage VFD system in a process critical application. By combining the capabilities of Perfect Harmony’s unique distributed power architecture with the power of the NXG control and the patented power cell bypass feature, it is possible to deliver unparalleled opportunities for improved process availability.

  • Page 174: Protopstm Implementation

    Application Specific Features 7.10 Process Availability - The Perfect Harmony Advantage 7.10.3 ProToPSTM Implementation With ProToPS™, the four indication categories are provided as separate digital output signals (Alarm, Process Alarm, Trip Alarm, Trip). The concept is to provide the operator, or the process program, with a clear message to indicate a status change in the VFD.

  • Page 175: Abbreviations

    Abbreviations This appendix contains a list of symbols and abbreviations commonly used throughout this manual group. Table A- 1 Commonly Used Abbreviations Abbreviation Meaning • Boolean AND function Addition or Boolean OR ∑ Summation µ Microsecond Amp, Ampere Alternating Current Across-the Line ACFM Actual Cubic Feet per Minute...
  • Page 176 Abbreviations Abbreviation Meaning Derivative (PID), depth Digital-to-analog (converter) Decibel Direct Current Digital Control Rack Distributed Control System decel Deceleration deg, ° Degrees DHMS Down hole monitoring system Division Demand Error Electrically Commutated Extra Low Voltage Electromagnetic Compatibility Electromotive Force Electromagnetic Interference Encoder Power Supply Electrostatic Discharge Electrical Submersible Pump...
  • Page 177 Abbreviations Abbreviation Meaning Identification International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers IGBT Insulated Gate Bipolar Transistor Input In, " Inches Inhibit Input(s)/Output(s) I/O Breakout Board Instantaneous Overcurrent Input Protection 1,000 (e.g., Kohm) KiloHertz Kilo Volts One Thousand Volt Amps Kilowatt Inductor Local Area Network...
  • Page 178 Abbreviations Abbreviation Meaning Next Generation Control NXG II Next Generation Control II oamp Output Current OLVC Open Loop Vector Control Overmodulation Out of Saturation (IGBT) overld Overload Proportional (PID) Pascals Push Button Personal Computer or Printed Circuit Printed Circuit Board Proportional Integral Derivative Programmable Logic Controller Phase Locked Loop...
  • Page 179 Abbreviations Abbreviation Meaning Serial Synchronous Motor Control Sum of Products; System Operating Program Speed stab Stability Standard Switch T1, T2 Output Terminals TI and T2 Terminal Block To Be Determined TCP/IP Transmission Control Protocol/Internet Protocol Total Harmonic Distortion Thermal Overload Test Point trq, τ...

  • Page 181: Appendix

    (or photocopy it) and either mail, E-mail or fax it back to the Documentation Department at Siemens LD A. These are mechanisms through which you can positively effect the documentation that you receive from Siemens. Thank you for your feedback. It is always valued and appreciated.
  • Page 182 Appendix B.1 Reader Comments Form Additional Comments Thank you for your comments. Please mail, fax or e-mail your comments to: Attention: Documentation Control Siemens LD A 500 Hunt Valley Road New Kensington, PA 15068 Phone: (724) 339-9500 Fax: (724) 339-9562 E-mail: DocumentControl@siemens.com...

  • Page 183: Notes

    Appendix B.2 Notes Notes Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...
  • Page 184 Appendix B.2 Notes Product User Manual Operating Instructions, Version AE 12/2009, A5E01454341C...

  • Page 185: Startup/Warranty Registration And Service Solutions

    ❑ Spare Parts Kits ❑ Return this information to Siemens at the address below, or fax it to (724) 339-9562, or call the Technical Support Department at (724) 339-9501. Please visit our web site at www.siemens.com. Attention: Customer Service Operations...

  • Page 187: Glossary

    Glossary "Catch a spinning load" feature "Catch a spinning load" is a feature that can be used with high-inertia loads (e.g., fans), in which the drive may attempt to turn on while the motor is already turning. This feature can be enabled via the NXG menu system.
  • Page 188 Glossary Refer to the glossary term SOP. Comparator A comparator is a device that compares two quantities and determines their equality. The comparator submenus allow the programmer to specify two variables to be compared. The results of the custom comparison operations can be used in the system program. Configuration Update see Tool Suite definition.
  • Page 189 Glossary between the two devices. The use of a PC for downloading requires special serial communications software to be available on the PC, which may link to the drive via RS232 or through the Host Simulator via an ethernet connection. DRCTRY Directory file for system tokens and flags used in the compilation of system programs.
  • Page 190 Glossary Flash Card Non-volatile memory storage device for the NXG control. It stores the drive program, system program, logs, parameters, and other related drive files. FPGA Field Programmable Gate Array. An FPGA is an integrated circuit that contains thousands of logic gates.
  • Page 191 Glossary I/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a computer system. Both inputs and outputs can be classified as analog (e.g., input power, drive output, meter outputs, etc.) or digital (e.g., contact closures or switch inputs, relay outputs, etc.).
  • Page 192 Glossary Loss of signal feature The loss of signal feature is a control scheme that gives the operator the ability to select one of three possible actions in the event that the signal from an external sensor, configured to specify the speed demand, is lost. Under this condition, the operator may program the drive (through the system program) to (1) revert to a fixed, pre-programmed speed, (2) maintain the current speed, or (3) perform a controlled (ramped) stop of the drive.
  • Page 193 Glossary OLTM An acronym for Open Loop Test Mode - One of six control modes of the NXG drive. OLVC An acronym for Open Loop Vector Control, also known as Encoderless Vector Control. OLVC is a flux vector control that is one of six control modes of the NXG drive. The drive computes the rotational speed of the rotor and uses it for speed feedback.
  • Page 194 Glossary Qualified user A qualified user is a properly trained individual who is familiar with the construction and operation of the equipment and the hazards involved. Quick menu Quick menu is a feature of the menu system that allows the operator to directly access any of the menus or parameters, rather than scrolling through menus to the appropriate item.
  • Page 195 (2) SOP, when used as a filename extension, refers to System Operating Program. SOP Utilities The program within the Siemens LD A Tool suite used for converting between text and machine loadable code. It can also be used for uploading and downloading files over the RS232 connection.
  • Page 196 SOP Utility Program with the Siemens LD A Tool Suite. Tool Suite Is the suite of programs developed by Siemens that allows easier access to the NXG drive for programming and monitoring. It is comprised of the following components: ● Tool Suite Launcher - also referred to as Tool Suite; used for coordinating other tools.
  • Page 197 Glossary Is an acronym for Volts per Hertz control, one of six control modes in the NXG drive. This mode is intended for multiple motors connected in parallel. Therefore, it disables spinning load and fast bypass. This is essentially open-loop vector control with de-tuned (smaller bandwidth obtained by reducing the gain) current regulators.

  • Page 199: Index

    Index Limitations, 153 Opertion, 151 A/D Converter, 42 Abbreviations, 173 Application Specific Features, 157 Electrostatic discharge, 15 Applications, 28 Evolution, 28 Available Networks, 170 Excessive Drive Losses Implementation, 139 Internal Theshold, 140 Inverse Time Curve, 139 Blowers # 1 and # 2, 92 Fast Bypass, 141 Fast Bypass Process, 141 Cabinet Details, 61...
  • Page 200 Index Integral Timer, 138 Power Cell Bypass Option, 25 Intellectual Property, 28 Power Circuitry, 34 Internal Threshold, 140 Power factor, 35 Introduction, 17, 19 Product Description, 49 Inverse Time Curve, 139 Protection Features, 77 ProToPSTM Advantage, 172 ProToPS™, 171 ProToPS™ Implementation., 172 Purpose, 18 Link Fault, 42 Lock-out/tag-out procedures, 14...
  • Page 201 Index Terminal blocks, 80 THD, 39 Theory, 33 Tool Suite, 150 Configuration, 149 Control, 150 Drive Host, 149 Graphing, 149 NXG Debug Utility, 150 Status, 150 Topology of Perfect Harmony VFD, 34 Total Harmonic Distortion, 39 Transformer, 138 Transformer Model One Cycle Protection, 138 Transformer Section, 52 Transformer Thermal Rollback, 126...

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