Operating Manual ALSPA MD2000 22 kVA ... 275 kVA

tai lieu van hanh cua bien tan ALSTOM

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During op eration, f req uency converters can h ave live, rotating or

m oving p arts and th eir surf aces m ay b ecom e h ot, dep ending on

th e p rotection class involved

T h ere is a risk of severe p h y sical inj ury or m aterial dam age if any

of th e covers are rem oved or th e unit is installed, used or

op erated incorrectly

F urth er details are given in th e docum entation

A ll sy stem design, transp ort, installation, com m issioning and

m aintenance work m ust b e carried out b y q ualif ied sp ecialist

p ersonnel ( according to I EC 6 0 36 4 , CEN ELEC H D 38 4 or DI N

VDE 0 1 0 0 and I EC 6 0 6 6 4 or DI N VDE 0 1 1 0 and national saf ety

regulations)

Q ualif ied sp ecialist p ersonnel in th e sense of th ese saf ety

instructions are p ersons wh o are ex p erienced in th e sy stem

design, installation, erection, com m issioning and op eration of th e

p roduct and h ave th e q ualif ications req uired f or such work

2 C o rrec t u s e

Converters are intended f or installation in electrical p lant or

m ach inery

W h en installed in m ach ines th e converter m ay not b e

com m issioned ( i e op eration of th e converter m ay not b e started)

until it is evident th at th e m ach ine com p lies with EC directive

9 8 /37/EC ( M ach ine Directive) ( f orm erly 8 9 /39 2/EEC) A lso EN

6 0 20 4 m ust b e ob served

Com m issioning ( i e op eration) is only p erm itted in com p liance

with th e EM C directive ( 8 9 /336 /EEC)

O ur converters satisf y th e req uirem ents of low voltage directive

73/23/EEC T h e standards of th e series EN 5 0 1 78 / DI N VDE

0 1 6 0 in conj unction with EN 6 0 4 39 - 1 / VDE 0 6 6 0 P art 5 0 0 and

EN 6 0 1 4 6 / VDE 0 5 5 8 are ap p licab le to drive converters

T h e tech nical data and th e connection conditions are sh own on

th e rating p late and in th e docum entation T h ey m ust b e

ob served

3 T rans p o rt and s t o rag e

T h e instructions f or transp ort, storage and correct h andling m ust

A ll converters m ust b e p rotected against undue m ech anical

sh ock s or stress I n p articular no com p onents m ay b e b entand/or no insulation sp acing m ay b e altered during transp ortand h andling Do not touch electronic com p onents or contacts.Converters contain com p onents suscep tib le to electrostaticdisch arge ( ES D) wh ich are easily dam aged b y static electricity orincorrect h andling Do not dam age m ech anically or destroyelectrical com p onents ( h ealth h az ard p ossib le)

5 E lec t ri c al c o nnec t i o n

T h e ap p rop riate national saf ety regulations ( e g B G V A 2) m ust

b e ob served wh en work ing on converters wh ich are connected to

th e electricity sup p ly

T h e electrical installation m ust b e ex ecuted in accordance with th erelevant regulations ( e g cab le cross- sections, f uses, earth ing)

A dditional instructions are given in th e docum entation

I nstructions on EM C com p liant installation, such as screening,earth ing, f ilters and cab le routing, are also given in th econverters docum entation T h ese also ap p ly to converters b earing

th e CE m ark Com p liance with th e lim its sp ecif ied in EM Clegislation is th e resp onsib ility of th e p lant or th e m ach inery

m anuf acturer

6 O p erat i o n

I f necessary , p lant or m ach inery in wh ich converters are f itted

m ust b e eq uip p ed with additional m onitoring and saf ety f acilities

in accordance with th e relevant regulations, e g th e law ontech nical eq uip m ent, th e ap p rop riate saf ety regulations etc

Do not touch any p arts of th e eq uip m ent wh ich m ay b e live orany p ower connections even af ter th e converter h as b een isolated

f rom th e electricity sup p ly , as cap acitors m ay rem ain ch arged

F ollow th e instructions given on warning lab els

A ll covers and doors m ust b e k ep t closed during op eration

7 S erv i c e and m ai nt enanc e

A ll instructions given in th e docum entation m ust b e ob served

K E E P T H E S E S A F E T Y I N S T R U C T I O N S I N A S A F E P L A C E

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!!! The mains chokes are not included in the ALSPA MD2000 scope of supply!!!

Page 1 7 5

5 3 M a in s a n d m otor c on n ec tion

Pl eas e r ef er t o t h e o p er at i n g m an u al " S o f t w ar e V 3 0 " R ef N o 0 2 9 2 0 8 8 8 9 f o r a

c o m p r eh en s i v e d es c r i p t i o n o f p ar am et er s an d d i s p l ay s

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1 Brief description 1

1.1 General 1

1.2 Basic operation 2

1.3 Main features 3

2 Technical Data 5

2.1 Key to types, rating plate 5

2.2 Series of types 6

2.2.1 Technical data at rated current 8

2.2.2 Technical data at basic load current 9

2.2.3 Power loss and cooling air volume 10

2.3 System data 11

2.3.1 Standards, operating conditions and certificates 16

2.3.1.1 Standards applicable 16

2.3.1.2 Certificate 17

2.3.1.3 CE Certificate 17

2.3.2 CE mark 18

2.4 Supply components 20

2.4.1 Components for 3AC supply 20

2.4.1.1 Fuses for 3AC mains connection 20

2.4.1.2 Mains chokes (3-phase chokes) 22

2.4.1.3 Line fuses for operation class gL and cable cross-sections 26

2.4.1.4 Fuse circuit breakers 27

2.4.1.5 Mains contactor 28

2.4.2 DC supply 29

2.5 Options 30

2.5.1 Control unit (BDE) 30

2.5.2 Brake chopper and braking resistors 32

2.5.2.1 Brake chopper option E31 33

2.5.2.2 Braking resistors 34

2.5.2.3 Thermal overcurrent relay 36

2.5.2.4 Overload relay for braking resistors 37

2.5.3 Mains filters and push-pull chokes 38

2.5.4 Motor filters and output chokes 39

2.5.4.1 Motor du/dt filters 39

2.5.4.2 Output choke 42

2.5.5 Optional assemblies for A10 Control board 44

2.5.5.1 Relay outputs 220 V Option E81 44

2.5.5.2 Optocoupler, Option E80 46

2.5.6 Option boards for ALSPA MD2000 48

2.5.6.1 Encoder interface Option E83 53

2.5.6.2 I/O Interface Option E24 60

2.5.6.3 Field bus coupler Modnet 1/SFB (Bitbus) Option E11 67

2.5.6.4 Field bus coupler Modnet 1/P (PROFIBUS) Option E11 69

2.5.6.5 Field bus coupler Modnet 1/MB+ (Modbus Plus) Option E11 72

2.5.6.6 Field bus coupler Modnet1/SN1 (SNET) Option E11 75

2.5.6.7 Technology coprozessor 78

2.5.6.8 Additional power supply NG3 79

2.5.6.9 Connection kit 81

2.5.6.10 Connection kit Technology coprocessor 82

2.5.6.11 Electronics auxiliary supply 83

2.5.6.12 Analog isolation module 84

2.5.6.13 Function low voltage 85

2.5.6.14 Through-mounting 86

2.5.6.15 Operation on a mains supply with no earth 88

2.5.7 PC Handling and Operating Software 89

2.5.7.1 ALSPA PCS 89

2.5.7.2 Unit-specific files 90

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2.6 Summary circuit diagrams 95

2.6.1 Summary circuit diagram, ALSPA MD2000 with 3AC supply 95

2.6.2 Summary circuit diagram, ALSPA MD2000 with DC supply 96

2.7 Connection, terminal wiring 97

2.7.1 Power stack 97

2.7.1.1 3AC supply 97

2.7.1.2 DC supply 100

2.7.2 Electronics section, A10 control board :X15 103

2.7.2.1 Terminal strip wiring :X15 and signal functions 104

2.7.2.2 Description of terminal strip inputs / outputs 109

2.8 Dimensions, Installation drawing, weights 113

2.8.1 Alspa MD2000 build-in units 113

2.8.2 Mains chokes for ALSPA MD2000 115

2.8.3 Installation drawing for ALSPA MD2000 control unit BDE 117

2.8.4 Dimensions and installation dimensions Base for semiconductor fuses of operating class gR with 110 mm length 119

2.8.5 Dimensions and installation dimensions Fuse isolator for semiconductor fuses with 110 mm length (DIN 43653) 120

2.8.6 Dimensions and installation dimensions Fuse isolator for encapsulated fuses 27.60 121

2.8.7 Dimensions and installation dimensions Braking resistors 122

2.8.8 Dimensions and installation dimensions, motor du/dt filters 123

2.8.9 Dimensions and weights 125

2.8.10 Output choke 126

2.8.11 Dimensions and weights 127

2.8.11.1 Connection and Installation dimensions, Mains filter 128

2.8.11.2 Connection and installation dimensions, Matching chokes 132

2.8.12 Electronics auxiliary supply 134

2.8.13 Dimensions and connection Thermal overcurrent release 135

3 Transport, Installation and Connection 137

3.1 Safety instructions 137

3.2 Storage 138

3.3 Transport 138

3.4 Installation 138

3.5 Connection and wiring 139

3.5.1 Potential separation 146

3.6 Installation and connection instructions for EMC 148

3.7 Specific measures for ensuring electromagnetic compatibility (EMC) 159

4 Operation and Software 161

4.1 Unit operation 161

4.1.1 Software structure 162

4.1.2 Control philosophy 163

4.2 Parameter adjustment 164

4.3 Menu 166

4.4 Description of parameters and displays 171

5 Commissioning 173

5.1 Safety instructions for commissioning 173

5.2 General 175

5.3 Mains and motor connection 175

5.4 Sequence diagram 176

5.5 Commissioning report 180

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6 Help in the event of errors 189

6.1 First value log for error messages 189

6.2 Switching sequence on errors 189

6.3 Event log 189

6.4 Events 189

6.5 Error log 192

6.6 Errors 192

7 Maintenance 197

7.1 Battery for RAM and clock 197

7.1.1 Battery change 197

7.1.2 Technical data of battery 197

7.2 Fans 197

7.3 Power connections 197

7.4 Reforming the link capacitors 198

8 Spare Parts 201

9 Appendix 205

EU – Declaration of Conformity 233

List of diagrams 235

List of Tables 237

Comments from users 239

c 06-1/01

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Expressions used Note::::

Notes separate important information from the text and give additional information

Limitation of liability Unless anything to the contrary is contractually agreed, the "General Delivery Terms

for Products and Services of the Electrical Industry" ["Allgemeine Lieferbedingungen für Erzeugnisse und Leistungen der Elektroindustrie"] as amended from time to time shall apply

Data, illustrations and descriptions contained in this manual shall not entitle any customer, user or any third party to request any modification whatsoever of equipment previously supplied

In the event of any software modifications and updates, we are not obliged to make such modifications and updates available to customers on a retroactive basis

The contents of this manual were developed and revised with utmost care However, ALSTOM does not accept any liability for any damage or loss whatsoever which might result from any defects in such documentation

The user shall be solely responsible for the proper and correct use of the ALSPA MD2000 frequency inverter ALSTOM disclaims any liability whatsoever for improper or incorrect installation or use

Process information and circuit details contained in this manual shall be deemed as being suggestions only, which shall be subject to verification with regard to their suitability for any given application ALSTOM disclaims any warranty or liability for the suitability of such process information and circuit suggestions with regard to any given application

Data, illustrations, modifications Data and illustrations shall not be deemed as being warranted properties in the legal

meaning

Modifications in the interest of technical progress are reserved

Please let us know if you have any suggestions for improvement or modification

A model form can be found on the last pages of this publication

Training ALSTOM offers training programs for additional and supplementary system knowledge

Without our prior approval, this document shall not be copied or disclosed to any third party in any manner whatsoever The recipient hereof or any third party shall not use this document for any improper purpose whatsoever Translation to any foreign language is not permitted Any data, dimensions, weights, illustrations and other technical information shall be subject to change without notice, particularly in the interest of further perfecting our equipment The data and specifications agreed to in the event of

an order shall be generally deemed as being the binding basis

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1.1 General ALSPA MD2000 units are processor-controlled pulse inverters with a field-orientated

control concept for continuous low-loss speed adjustment of AC motors

The power stack consists of a diode rectifier in a 3-phase bridge circuit on the mains side and an IGBT inverter on the motor side

The basic inverter models are designed for standard applications Through suitable options (eg bus couplers, encoder interface) the units can be integrated into automation systems and can also fulfil highly dynamic requirements

Operation of all units is identical throughout the entire type range Easy familiarisation and operation as well as maximum flexibility were the prime objectives during development

The inverters are operated and parameters adjusted by means of a optional removable control unit (BDE) or using a PC and an PC software package

Connection to automation systems is possible through conventional bus systems (see field bus coupler options)

With a mains voltage range from 380 to 480 V build-in units cover the power range from 22 kVA to 330 kVA

In conjunction with standard asynchronous motors the drive capacities provided are therefore as follows:

- At unit rated current 18.5 kW to 200 kW, 400 V

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1.2 Basic operation The link voltage is generated from the mains supply through the mains rectifier A

3-phase choke connected to the mains supply reduces harmonic currents and serves to decouple the unit from other converters (consumers) on the same supply network ALSPA MD2000 units are connected as standard to an earthed network

The link voltage is smoothed by high quality electrolytic capacitors With the motor converter these provide the magnetising reactive power required by the motor and decouple the converter on the mains side from the inverter on the motor side

Through optimised pulse width modulation the motor converter generates from the link voltage a sinusoidal 3-phase system with variable frequency and voltage

A power dump (option) in conjunction with a braking resistor allows braking energy to

be used in regenerative operation

Control and regulation of the ALSPA MD2000 are fully digital Different control structures such as, frequency control, speed control with or without encoder and torque control with or without encoder can be selected, depending on the application requirements The field-orientated control concept provides control dynamics directly comparable to those of a DC drive

In addition, various inputs and outputs can be connected individually according to the task involved Thus the drive system can very easily be customised for the

requirements of the specific application

RS 422/485

A D

SAB 80C 187

Options

Encoder Interface

Start Stop Motor Parameter

menu enter

quit error ready run

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1.3 Main features • Consistent range of Types for drives from 15 kW to 250 kW with

IGBT inverters

• Supply voltage ranges:

- 3AC 380 V 460 V +10 %/ -15 % 480 V +6 %/ -15 %

• Standard design for connection to earthed networks

• Output frequency range: 0 300 Hz

• 120 % overload capacity for 60 s based on unit rated current (Unit rated current = 1.25 ∗ unit basic load current)

• 150 % overload capacity for 60 s based on unit basic load current

• Standard asynchronous motors can be used without power reduction

• High dynamics: Torque rise time: tan = 2 to 8 ms

• ALSPA MD2000 units are resistant to idling, short circuit and earth fault

• DC system bus supply for several ALSPA MD2000 through

DC link connection (option)

• 4Q operation (option) through power dump with braking resistor or mains

• Cooling airflow Power stack cooling air circuit can be remote (optional mounting facility)

• Mains supply power connections at top and motor connections at foot

• Motor temperature monitoring by thermistor processing electronics (PTC)

• Easy, user-friendly system structure

• Consistent and easily learned operation via control unit (option) with plain text display (various languages available)

• Extensive additional operating facilities via PC, for example menu control, user-controlled commissioning, oscilloscope function

• RS 422 serial interface as standard

• Consistent operation through control systems (option)

• Connection to automation system through field buses (option):

Bitbus, Profibus, Modbus Plus, SNET

• Control structures available:

- Frequency control

- Speed control with or without incremental rotation encoder

- Torque control with or without incremental rotation encoder

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• Kinetic support on mains failure supports operation of the control electronics using the kinetic energy in the drive systems at speeds close to zero, also suitable for flow machines

• Capture without torque surge (the inverter is applied to the de-excited motor while the motor is running)

• Automatic restart facility after mains failure (Parameter-adjustable up to 15 s as standard)

• Conventional drive through standard terminal strip

- 12 digital potential-separated inputs for control signals (eg Start, Stop etc.),

of which 3 inputs are parameter-adjustable through selection list

- 4 digital potential-free outputs for messages (On, Ready, Error, free output parameter-adjustable through selection list, 1 output "Ready” can be re-assigned via technology)

- 2 free adjustable and scaleable analog outputs

- 2 scaleable analog demand inputs

- 2 parameter sets switchable via control unit or terminal strip

• Expansion of standard terminal strip (I/O interface option)

- 20 configurable digital inputs with separate potential

- 8 configurable digital outputs with separate potential

- 2 configurable analog demand inputs

- 2 configurable analog outputs

• Comprehensive testing and diagnostics facilities:

- Self-test on control electronics and hardware

- Event memory with timings of all binary events with first value error message and documentation

- Error log with timing details

- Protocol log for documenting all parameter changes

- Oscilloscope function (history log) with 4 analog and 8 digital channels, can be processed with the Windows PC Handling Program ALSPA PCS Trigger signal is safe against mains failure

• Comprehensive protection and monitoring facilities

• Co-processor (option), can be customised for user-specific solutions

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2.1 Key to types, The type data includes the following information An example:

ALSPA MD2000 225 / 275 - 400

at rated current

Based on 3AC 400 V supply voltage

Fig 2: ALSPA MD2000 rating plate

The following details are required for identifying the unit:

- Type No :

- Serial No :

- Project No :

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2.2 Series of types ALSPA MD2000 for 3-phase AC connection

ALSPA MD2000 22 275 kVA, 3AC 380 480 V Processor-controlled pulse inverter with field-orientated control concept for continuous low-loss speed adjustment of standard AC motors

ALSPA

MD2000 type

Frame size

Unit input current,

3AC supply 4)

mains current5)

Rated current1)

Basic load current2)

Max current

60 s 3)

Table 2: ALSPA MD2000 frame sizes, AC supply

Scope of supply: Build-in unit, IP20,

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ALSPA MD2000 for DC supply

current 1)

Basic load current 2)

Max current

60 s 3)

Max current for max 60 s overload, cycle time 600 s

Table 4: ALSPA MD2000 frame sizes DC supply

Scope of supply: Build-in unit, IP 20

Important!

ALSPA MD2000 drives with a DC system bus connection must be designed accordingly Special matching chokes and semiconductor fuses will be required according to the system configuration

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2.2.1 Technical data Overload capacity 1.2 x rated current

The technical data shown in Table 5 applies at a pulse frequency of fp = 3 kHz,

as supplied ex works, and a maximum air supply temperature up to 40 °C

60060

Output current

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2.2.2 Technical data Overload capacity 1.5 x basic load current

at basic load current

The technical data shown in Table 6 applies at a pulse frequency of fp = 3 kHz

as set ex works, and a maximum air supply temperature up to 50 °C

ALSPA MD2000

type

Basic load current

Max current 1)

for max 60 s

Unit apparent power [kVA]

at basic load current

Output current

Fig 4: ALSPA MD2000 Overload capacity 1.5 x basic load current

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2.2.3 Power loss and The rise in temperature of the cooling air at rated current is ∆υ≤ 16 °C for the

cooling air volume cooling air volume stated and when the installation clearances are maintained

ALSPA MD2000 type Frame size Cooling air

volume 2)

Rated current Power loss1)

[kW] at rated current und 3AC supply voltage

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2.3 System data • Mains supply voltage 3AC 400 460 V; +10/-15 % 480 V; +6/-15 %

• Mains frequency 50 60 Hz ±5 %

• Power factor

- Mains base frequency cos ϕ1 > 0.97

- Total at rated current depending on mains

at rated power ≥0.97 on 3-phase supply

• Overload factor 1.2 for max 60 s at rated current Cycle time

• Min operating frequency

• Speed adjustment range For speed control

The adjustment range is 1:20 in regenerative

• Speed accuracy For speed control

• Torque rise times For speed control

• Frequency resolution 10 mHz standard

• Frequency stability for frequency control <0.01 % standard

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• Frequency accuracy for frequency control <0.01 %

• Temperature response

of analog demand <0.01 %/°C

• Overtemperature shutdown Frame size 1 and 2 at >90 °C

• Coolant temperature 0 40 °C at rated current, overload factor 1.2

• Installation altitude ≤1000 m above MSL, up to max 2200 m with

• Protection classes

Cubicle-mounted units IP21 Standard

• Environment class DIN EN 60721 Part 3-3

/ 2K2

- Max relative humidity 85 % at 28 °C, condensation not permitted

- Insulation Contamination Class II to DIN VDE 0110

• Permitted switching Precharging circuit duty cycle = 2 %/180 s,

• Power loss of control ca 80 W (Frame size 1) ca 130 W (frame size 4) electronics with control board, no additional options

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• Mechanical use prEN50178:1994/IPA90 DIN IEC86 T.2-6 10 150 Hz (Vibration)

• Electromagnetic

Interference resistance To IEC1800-3 (IEC22G/21/CDV), EN50082-2,

Radiated interference To IEC1800-3 (IEC22G/21/CDV)

see section 3.7 for optional measures

• Vector frequency adjustable Standard 3 kHz

Maximum Up to 12 kHz

At a vector frequency of fV = 12 kHz a power reduction is done depending on the type

of unit

• Servicing Data memory battery replacement required,

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Power reduction curves

70

80

86

90 100

Installation altitude above msl in m Rated current in %

40 50 60 80

100 90

400 V

Frame size 4; 460 V

Frame size 2; 460 V Frame size 3; 400 V, 460 V Frame size 4; 400 V

60

100

70 80 90

Coolant temperature in C °

Current rating in %

Rated current (3kHz)

Basic load current (3kHz)

Fig 5: Power reduction curves (Derating) ALSPA MD2000 22 275-400

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Efficiency curves

75

80 85 90 95 100

Fig 6: ALSPA MD2000 Efficiency curves 22 275-400

The curves in Fig 6 apply to pulse frequency 3 at a 400 460 V supply voltage

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2.3.1

2.3.1 Standards, operating conditions and certificates

2.3.1.1 Standards applicable As per 06.1996

VDE 0100-540 Installation of heavy current systems with rated voltages up to 1000 V; selection and

installation in electrical equipment, earthing, protective conductor, potential compensation conductor

VDE 0106-100 Protection against electric shock; configuration of actuator components close to parts

which are dangerous to touch

Rating of air gaps and creepage distances

VDE 0160/pr EN50178 Installing electronic equipment on heavy current systems

DIN EN 60146-1-1 (IEC 146-1-1) Semiconductor converters; general requirements and mains-fed converters;

basic requirements (DIN VDE 0558 Part 11: 1994-03)

DIN EN 60146-1-3 (IEC 146-1-3) General requirements and mains-fed converters,

transformers and choke coils (DIN VDE 0558 Part 8: 1994-03)

requirements and test methods (conversion IEC 801-2)

requirements and test methods

IEC 1000-4-4 Resistance to fast electrical transients and bursts (conversion IEC 801-4)

(VDE 0875 Part 11), limits and test methods for radio interference suppression of industrial, scientific and medical high frequency equipment

telecommunications technology (VDE 0878 Part 3), limits and test methods for radio interference suppression on technical information equipment

IEC1800-3/prEN61800-3:1995 EMC product standard for variable speed drives

Meßverfahren

DIN EN 50081-1 Electromagnetic compatibility (EMC); specialist basic standard for radiated

interference;

Part 1: Residential, business and light industry

DIN EN 50081-2 Electromagnetic compatibility (EMC); specialist basic standard, radiated interference;

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DIN EN 60204-1 (IEC 204-1) Machine safety; electrical equipment on machines;

Part 1: General requirements (VDE0113 Part 1: 1993-06)

Part 2: Individual conditions

DIN EN 60721-3 classification of environmental conditions

- Classes of environmental influences and limits

VDE 0660 Part 500 1994-04

2.3.1.2 Certificate

DIN EN ISO 9001 Model for quality assurance in development, design, production, assembly, testing,

sales and maintenance

TÜV-Südwest Audit QM-M-96/732 Certificate Registration No 70 100 M732 Certificate obtainable from ALSTOM Power Conversion GmbH

2.3.1.3 CE Certificate

See appendix for EC Certificate of Conformity

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2.3.2 CE mark The ALSPA MD2000 frequency inverter carries the CE mark This confirms for

monitoring authorities responsible in the European Union (EU) that the unit complies with the low voltage guideline 73/23 EC and the CE mark guideline 93/68/EC The certificate of conformity with the low voltage guideline is available on request

The ALSPA MD2000 frequency inverter is completed into a drive system by the connection of an AC motor and electrical components, safety equipment and external radio interference suppression components Installation must be carried out by experienced personnel in compliance with the relevant rules and regulations

No certificate of conformity is required for the ALSPA MD2000 as an “independently operated unit” in the sense of EMC Directive 89/336/EC The ALSPA MD2000 is classified according to CEMEP2 for use and supply through the industry, trade and other users experienced in the field of electromagnetic compatibility (EMC)

Type tests on electromagnetic compatibility (EMC) were carried out to demonstrate compliance with the documented EMC-relevant IEC standards, DIN EN standards, EMC installation guidelines and specified combinations with optional radio interference suppression components in this operating manual when connected to an earthed mains supply Compliance with the EMC installation instructions in section 3.6

is essential

Section 3.7 provides optional measures for guaranteeing EMC

EMC product standard including specific test methods for

EMC product standard for drive converters;

EMC radiated interference and interference resistance

DIN EN 50082

Specialist basic standard, interference resistance Part 1: Residential, business and light industry connected to the public electricity supply network

(VDE 0839 Part 82-1) Part 2: Industrial 1) VDE 0839 Part 82-2)

DIN EN 50081

Specialist basic standard, radiated interference Part 1: Residential, business and industrial connected to the public electricity supply network

(VDE 0839 Part 81-1) Limit to EN 55011 Group 1 Class B

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EMC interference resistance IEC1800-3/prEN61800-3 (IEC224/21CDV); EN50082-2

The following limits for interference resistance are fulfilled when a mains choke and screened control cables are used

ESD (Static discharge)

IEC1000-4-2 (IEC 801-2) Air discharge (AD) ±8 kV

Contact discharge (CD) ±6 kV Burst

(Transients)

IEC1000-4-4 (IEC 801-4) Mains connection 2 kV, 5 kHzkap

Load connection 2 kV, 5 kHzkap

Limit curves, radio interference voltage

0,01 0,02 0,03 0,04 0,06 0,08 0,1 0,15 0,2 0,3 0,4 0,6 0,8 1 2 3 4 6 8 10 20 30 40

50 60 70 80 90 100

Interference frequency in MHz

EN 55011 Group 1 Class A

Fig 8: Typical interference voltage characteristic at mains input

Fig 8 shows the typical interference voltage characteristic at the mains input in the example of the ALSPA MD2000 27/33-400 with mains filter B84143A50-R, function

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2.4 Supply components The ALSPA MD2000 can be supplied with power through

- Connection of the units to a 3-phase supply or

- Connection to a DC system bus

Standard components are specified for both possible supply methods Fig 48 and Fig 50 show the basic configuration of ALSPA MD2000 supply components for a 3AC

or DC connection

2.4.1 Components for 3AC supply The components for connecting the ALSPA MD2000 to an AC network are determined

according to the ALSPA MD2000 type rating

The basic components

- semiconductor fuse 3AC main connection (2.4.1.1) with aR characteristic

- mains choke (2.4.1.2)

- mains fuse (2.4.1.3) with gL characteristic

are required to VDE and are shown in the tables below

Minimum cross-sections for mains supply cables with PVC insulation to EN 1:1992 are given at an ambient temperature of ϑ = 40 °C and laying method E

60204-In the event that the supply includes separation points,

- Ferraz fuse isolator, 3-pole, for frame size 1 only (2.4.1.1)

- fuse circuit breaker (2.4.1.4)

- mains contactor / main contactor (2.4.1.3)

are to be used as shown in the following tables

2.4.1.1 Fuses for Mains fuses with aR characteristic (semiconductor protection)

3AC mains connection

ALSPA MD2000

type

Frame size

110 mm DIN 43653

Alternative:

Bussmann fuse

110 mm DIN 43653 Rated

current [A]

Basic load current [A]

Max

current for

60 s [A]

Type 6,6 URD- Ref No

029

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These parts are mounted on the fuse base SI DIN 110630 or are installed in conjunction with the fuse circuit breaker

See section 2.4.1.4 for fuse circuit breakers

Fuses can also be equipped with microswitches for fuse monitoring

Single pole fuse base

3EDV

170 H 3027 +

170 H 0066

029.139 082

029.026 279

Table 10: Semiconductor fuses

As an alternative to fuses to DIN 43653 Ferraz encapsulated fuses 27x60 with the relevant 3-pole fuse isolator can be used on ALSPA MD2000 units of frame size 1 with 3AC mains supply, according to the table below:

Capsule fuse 27x60

Ferraz fuse isolator 3-pole ALSPA MD2000

type

Frame size

Rated current

Basic load current

Max

current for

60 s

Type 6,621 CP URQ

Table 11: Ferraz fuses

Terminal cover per pole Type PS27 029.141 723

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2.4.1.2 Mains chokes If the ALSPA MD2000 is connected to a 3AC mains supply a mains choke is required

(3-phase chokes) in the supply cable to reduce the harmonics and limit commutation failures The mains

chokes for the relevant ALSPA MD2000 types are listed in the table below

Mains chokes are included in the ALSPA MD2000 scope of supply for 3AC mains connection They are supplied loose with the ALSPA MD2000 and are installed outside the ALSPA MD2000 in the cubicle

The mains choke must be allocated individually to each ALSPA MD2000 to guarantee decoupling when several units are operated at the same mains supply point A mains choke of high rating is not suitable for several low power ALSPA MD2000 units Mains chokes improve the overvoltage protection The impedance of the choke forms

a voltage divider with the impedance on the mains side When the choke is not saturated magnetically it limits the current rise when the voltage rises This prevents excessive overvoltages at the ALSPA MD2000 mains input

current

Max current for

Relative short circuit voltage uK = 2,2 %

Operating voltage 380 V 460 V +10/-15 %, 50/60 Hz ±5 %

Environment class DIN EN 60721 Part 3-3 3K3 / 3M2 / 3C2 / 2K2

See section 2.8.2 for dimensions, weights and installation instructions

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Harmonics

The mains converter consists of an uncontrolled 6-pulse bridge circuit (B6) with diodes Capacitors which decouple the mains converter from the motor converter are fitted on the link and maintain the continuous flow of current to the motor converter A varying amount of energy is taken from the link capacitor depending on the load on the motor, whereby the mains converter compensates for the reduction in charging according to the mains voltage characteristic, i.e the phase position of the current, in contrast to the thyristor mains converter, remains almost constant and is not

dependent on the momentary value

The effective mains impedance and the load conditions affect the shape of the mains current curve and therefore the harmonic content, whereby the mains choke and the ratio between the mains short-circuit voltage and the inverter apparent power are decisive for the harmonic content

Mains harmonics

At rated mains voltages of ≥460 V and a ratio between the inverter rated power and the short circuit capacity Sk“) of the ALSPA MD2000 supply point Sk“/ SInverter460V ≥ 300 a special mains choke uk≥ 3.3 % based on a 460 V supply voltage is recommended for limiting mains current harmonics The special mains choke can also be constructed using a series circuit of two standard mains chokes for the ALSPA MD2000

Example:

ALSPA MD2000 22/27-400, main transformer uk=6 % Rated voltage UN=460 V

A special mains choke is required in this configuration if the transformer rated power / mains power exceeds approx 550 kVA

ALSPA MD2000 54/62-400, mains data as above A special mains choke is only required at a transformer rated power of >1.2 MVA

1)

VDEW = Association of German Electricity Supply Companies

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0,2 0,3 0,4

0,5

I1

In

Apparent input power SN

Effective output power PN

Fig 9: Effective values for mains harmonics

- Higher commutation inductance through the use of special mains chokes

- Transformers of different groups for two 6-pulse converters

- Filter circuits for harmonics (choked)

- Increase in mains supply power by using higher rated transformers

- Mains division, use of converter transformers

- Higher number of pulses for mains converter (12-pulse system)

- IGBT mains pulse inverter

The amplitude characteristic for the mains current harmonics shown in Fig 9 can be reduced by increasing the commutation inductance with a 3-phase choke Uk = 3.8 % based on a 400 V supply voltage Under the mains conditions stated, for example, the dominant 5th harmonic can be reduced from approx 43 % to approx 34 % However,

it must be noted that increasing commutation inductance reduces the utilisation of the

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In large industrial plant it is possible to reduce the dominant 5th harmonic in 6-pulse mains converters by connecting some of the converter load through transformers with

a phase shift of 30° electrical in relation to the other transformers Another transformer circuit in switching group Yy0 with a compensation winding could be implemented instead of the Dy5 circuit often used In this configuration, for example, the 5th harmonic can be reduced by more than 50 % provided that both converters have the same overlap angle

Note:

At the planning stage it is not possible to directly analyse the mains voltage harmonics included in commutation failure For this reason the harmonic current is used to estimate the mains feedback effects through commutation failures and mains harmonics

ALSPA MD2000 units operate with an uncontrolled 6-pulse mains converter As long

as its commutation reactance at the mains connection point is better by a factor of 2 than the mains reactance, the harmonic current can be considered approximately as load-independent Fig 9 offers assistance for project design

Thus in general a minimum mains network short circuit capacity in comparison to the overall supply capacity of the ALSPA MD2000 operated at the connection point can

be stated in consideration of mains distortion (duration of commutation) and the level

of commutation reactance (3-phase choke) with a connection involving only ALSPA MD2000 units

For correct operation the AC mains voltage may not deviate from the critical value for the mains voltage base frequency by more than 20 % according to DIN VDE

0160/prEN50178

No limits are exceeded by a ALSPA MD2000-only connection for the correct

application when the mains minimum short circuit power is taken into consideration

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2.4.1.3 Line fuses for Installation instructions for a 3AC ALSPA MD2000 connection in the customer’s low operation class gL and voltage distribution system:

cable cross-sections The NH fuses recommended for operation class gL and the cable cross-sections to be

used for ALSPA MD2000 3AC mains connections are shown in the following table Minimum cross-sections for mains supplies cables with PVC insulation according to

EN 60204-1:1992 are given for an ambient temperature of ϑ = 40 °C and laying method E

current

Basic load current

Max current for 60 s

Type Ref No

029

3-phase cables NYY/ NYM

Niederspannungs-Schaltgeräte und -Anlagen Postfach

24531 Neumünster

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2.4.1.4 Fuse circuit breakers The above semiconductor fuses (aR-Characteristics) with 100 mm length to

DIN 43 653 can be installed as an alternative to fuse bases in conjunction with the hand-operated fuse circuit breaker

This creates a separation point in the 3AC mains supply and all poles of the semiconductor fuses can be switched

Table 15: Fuse circuit breakers

See section 2.8.5 for dimensions and installation distances

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2.4.1.5 Mains contactor Contactors 3 AC 400 V, 50/60 Hz

On 3AC mains supplies which include (automatic) on/off switching of the mains voltage at the ALSPA MD2000 input (eg ALSPA MD2000 units with optional

brake chopper and braking resistor), 3-phase contactors according to the following tables are used

Important!

Note the mains contactor control voltage

Rated current

Basic load current

Table 17: Mains contactors

Mains contactors and accessories are stated for 400 V, 50/60 Hz mains voltage

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2.4.2 DC supply The DC supply components for ALSPA MD2000 with a DC connection (see section

2.7.1.2) must always be project designed because the matching choke on the DC supply of each ALSPA MD2000 must be matched to the configuration of the DC system bus

The components for a DC system bus connection

- Fuse circuit breaker or fuse isolator

project-DC system bus (option)

An 800 A bus or a 2500 A bus can be used for project design according to the current carrying capacity requirements The calibration choke is rated for the electrical characteristics of the bus

Both system buses are installed in different cubicle assemblies

A 200 mm high assembly is used for the 800 A bus and a 300 mm high assembly for the 2500 A bus

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