operating_manual_alspa_md2000_27_kva_..._336_kva_500_v

Operating Manual ALSPA MD2000 27 kVA . 336 kVA - 500 V 94 kVA . 365 kVA - 690 V Safety and Operating Instructions for Frequency Converters according to Low Voltage Directive 73/23/EEC 1. General During operation, frequency converters can have live, rotating or moving parts and their surfaces may become hot, depending on the protection class involved. There is a risk of severe physical injury or material damage if any of the covers are removed or the unit is installed, used or operated incorrectly. Further details are given in the documentation. All transport, installation, commissioning and maintenance work must be carried out by qualified specialist personnel (according to IEC 60364, CENELEC HD 384 or DIN VDE 0100 and IEC 60664 or DIN VDE 0110 and national safety regulations). Qualified specialist personnel in the sense of these safety instructions are persons who are experienced in the installation, erection, commissioning and operation of the product and have the qualifications required for such work. 2. Correct use Converters are intended for installation in electrical plant or machinery. When installed in machines the converter may not be commissioned (i.e. operation of the converter may not be started) until it is evident that the machine complies with EC directive 98/37/EC (Machine Directive) (formerly 89/392/EEC). Also EN 60204 must be observed. Commissioning (i.e. operation) is only permitted in compliance with the EMC directive (89/336/EEC). Our converters satisfy the requirements of low voltage directive 73/23/EEC. The standards of the series EN 50178 / DIN VDE 0160 in conjunction with EN 60439-1 / VDE 0660 Part 500 and EN 60146 / VDE 0558 are applicable to drive converters. The technical data and the connection conditions are shown on the rating plate and in the documentation. They must be observed. 3. Transport and storage The instructions for transport, storage and correct handling must be observed. Climatic conditions are to be maintained according to EN 50178. 4. Installation The installation and cooling must be in accordance with the relevant documentation. All converters must be protected against undue mechanical shocks or stress. In particular no components may be bent and/or no insulation spacing may be altered during transport and handling. Do not touch electronic components or contacts. Converters contain components susceptible to electrostatic discharge (ESD) which are easily damaged by static electricity or incorrect handling. Do not damage mechanically or destroy electrical components (health hazard possible). 5. Electrical connection The appropriate national safety regulations (e.g. BVG A2) must be observed when working on converters which are connected to the electricity supply. The electrical installation must be executed in accordance with the relevant regulations (e.g. cable cross-sections, fuses, earthing). Additional instructions are given in the documentation. Instructions on EMC compliant installation, such as screening, earthing, filters and cable routing, are also given in the converters documentation. These also apply to converters bearing the CE mark. Compliance with the limits specified in EMC legislation is the responsibility of the plant or the machinery manufacturer. 6. Operation If necessary, plant or machinery in which converters are fitted must be equipped with additional monitoring and safety facilities in accordance with the relevant regulations, e.g. the law on technical equipment, the appropriate safety regulations etc. Do not touch any parts of the equipment which may be live or any power connections even after the converter has been isolated from the electricity supply, as capacitors may remain charged. Follow the instructions given on warning labels. All covers and doors must be kept closed during operation. 7. Service and maintenance All instructions given in the documentation must be observed. KEEP THESE SAFETY INSTRUCTIONS IN A SAFE PLACE Controlboard for ALSPA MD2000 Ref. No. 029.228 500 ALSPA MD2000 frequency inverters are to be equipped with this controlboard with the reference number 029.228 500. This controlboard replaces the previous versions with the reference numbers 029.144 457, 029.209 439 and 029.218 005. Note: Operation of ALSPA MD2000 units with the controlboard with the reference number 029.228 500 requires the use of the unit’s software version 3.0. Former software versions cannot be run on this controlboard. On the other hand it is not possible to run the unit software version 3.0 on versions 029.144 457 and 029.209 439 of the controlboard. The functions realized in the unit software version 3.0 correspond with the functions of version 2.2. The default settings of this software do not differ from those of version 2.2. All functions giving additional possibilities of handling have to be parameterized explicitly. Additional possibilities are given by the following enhancements of the hardware and software: Hardware: The controlboard with reference number 029.228 500 provides a CAN-Interface. Software: The most important enhancements of the unit software version 3.0 are: • CANopen ability • parameterset switchover between up to 6 parametersets • remote diagnostics via modem • new unit types Questions as a consequence of the enhancements of hardware and software are to be asked our service team or the product management team of ALSPA MD2000. Service team Berlin: Tel.: +49 30 / 7496-3724 Fax: +49 30 / 7622-3734 Service hotline Tel.: 0180 / 3 23 45 72 Product Management ALSPA MD2000 produktmanager.md2000@powerconv.alstom.com Tel.: +49 30 / 7496-2679 Fax: +49 30 / 7622-2591 Power Conversion UK West Avenue, Kidsgrove, Stoke-on-Trent Staffordshire, ST7 1TW Tel.: +44 (0) 1782 781000 Fax: +44 (0) 1782 781001 UK Boughton Road, Rugby Warwickshire, CV21 1BU Tel.: +44 (0) 1788 563563 Fax: +44 (0) 1788 560767 USA 610 Epsilon Drive Pittsburgh, PA 15238 Tel.: +1 412 967 0765 Fax: +1 412 963 7660 Germany Culemeyerstra β e 1 D-12277 Berlin Tel.: +49 (0) 30 7496 2656 Fax: +49 (0) 30 7496 2494 France 9, rue Ampère 91345 Massy Cedex Tel.: +33 1 60 13 29 54 Fax: +33 1 60 13 29 72 Order No. 029.214 923/11.12.01 Contents ALSPA MD2000 0 Notes, Warnings and Instructions 0-1 1 Brief description . 1-1 1.1 General 1-1 1.2 Basic operation . 1-2 1.3 Main features . 1-3 2 Technical data 2-1 2.1 Key to types, rating plate 2-1 2.2 Series of types . 2-2 2.2.1 Technical data at rated current 2-6 2.2.2 Technical data at basic load current 2-7 2.2.3 Power loss and cooling air volumes . 2-8 2.3 System data 2-10 2.3.1 Observed standards, certificates and approbations 2-16 2.3.1.1 Standards applicable As per 01.1997 2-16 2.3.1.2 Certifications .2-17 2.3.2 CE mark . 2-18 2.4 Supply components 2-20 2.4.1 Components for 3AC supply 2-20 2.4.1.1 Fuses for 3AC mains connection 2-20 2.4.1.2 Mains chokes (3-phase chokes) 2-22 2.4.1.3 Line fuses for operation class gL and cable cross-sections 2-26 2.4.1.4 Fuse circuit breakers . 2-28 2.4.1.5 Mains contactor 2-30 2.4.2 DC supply . 2-32 2.5 Options 2-33 2.5.1 Keypad (BDE) 2-33 2.5.2 Brake chopper (Option 31) Braking resistors . 2-35 2.5.2.1 Brake chopper Option E31 2-37 2.5.2.2 Braking resistors . 2-38 2.5.2.3 Thermal overcurrent relay . 2-40 2.5.2.4 Overcurrent relay for braking resistors 2-41 2.5.3 Mains filters and common mode chokes 2-43 2.5.4 Motor filters and output chokes . 2-46 2.5.4.1 Motor filters . 2-46 2.5.4.2 Output chokes . 2-50 2.5.5 Optional assemblies for A10 control board . 2-52 2.5.5.1 Relay outputs 230 V Option E81 . 2-52 2.5.5.2 Optocoupler Option E80 2-54 2.5.6 Option boards for ALSPA MD2000 2-56 2.5.6.1 Encoder interface Option E83 . 2-60 2.5.6.2 I/O Interface Option E24 2-66 2.5.6.3 Field bus coupler ALSPA F8000 (FIP) Option E11 2-73 2.5.6.4 Field bus coupler PROFIBUS-FMS/DP Option E11 2-73 2.5.6.5 Field bus coupler INTERBUS-S Option E11 2-74 2.5.6.6 Field bus coupler Modnet1/MB+ (Modbus Plus) Option E11 2-74 2.5.6.7 Field bus coupler Modnet1/MB+ (Modbus Plus Broadcast) Option E11 2-75 2.5.6.8 Field bus coupler Modnet1/SFB (Bitbus) Option E11 2-75 2.5.6.9 Field bus coupler Modnet1/SN1 (SNET1) Option E11 2-76 2.5.6.10 Technology coprocessor Option E20 . 2-77 2.5.6.11 Additional power supply NG3 / Option E85 . 2-78 2.5.6.12 Connection kit Option E13 2-80 2.5.6.13 Connection kit Technology coprocessor Option E14 2-81 Contents ALSPA MD2000 2.5.6.14 Electronics auxiliary supply Option E49 . 2-82 2.5.6.15 Analog isolation module Option E26 . 2-83 2.5.6.16 Functional low voltage Option E50 2-84 2.5.6.17 Operation on unearthed mains supply / Option E70 2-84 2.5.7 PC handling and operating software . 2-85 2.5.7.1 ALSPAPCS . 2-85 2.5.7.2 Unit-specific files . 2-86 2.5.7.3 RS232 (V.24) PC connection . 2-87 2.5.7.4 RS422 PC connection . 2-89 2.6 Summary circuit diagrams 2-91 2.6.1 Summary circuit diagram ALSPA MD2000 with 3AC supply 2-91 2.6.2 Summary circuit diagram ALSPA MD2000 with DC supply 2-92 2.7 Connection, terminal wiring . 2-93 2.7.1 Power stack 2-93 2.7.1.1 3AC supply . 2-93 2.7.1.2 DC supply 2-96 2.7.2 Electronics section Control Board A10 2-99 2.7.2.1 Terminal strip wiring X15 and signal functions . 2-100 2.7.2.2 Description of terminal strip inputs / outputs 2-105 2.8 Dimensions, installation drawing, weights 2-109 2.8.1 ALSPA MD2000 built-in unit . 2-109 2.8.1.1 Fan installation . 2-113 2.8.2 Mains chokes for ALSPA MD2000 2-115 2.8.3 Installation drawing for ALSPA MD2000 Keypad . 2-117 2.8.4 Dimensions and installation clearances, Fuse-base for semiconductor fuses class gR with 110 mm fixing length 2-119 2.8.5 Dimensions and installation clearances, Fuse circuit breaker for semiconductor fuses with 110 mm fixing length (DIN 43653) . 2-120 2.8.6 Dimensions and installation clearances, Braking resistor . 2-121 2.8.7 Dimensions and installation clearances, Motor filters 2-122 2.8.8 Dimensions and weights, Motor filters 2-123 2.8.9 Motor chokes 2-124 2.8.10 Mains filter 2-125 2.8.11 Common mode choke (Ferrite core) 2-127 2.8.12 Electronics auxiliary supply 2-128 2.8.13 Dimensions and connection, Thermal overcurrent relay . 2-129 3 Transport, Installation and Connection . 3-1 3.1 Safety instructions 3-1 3.2 Storage 3-2 3.3 Transport . 3-2 3.4 Installation 3-2 3.5 Connection and wiring . 3-3 3.5.1 Potential separation 3-10 3.6 Installation and connection instructions for EMC . 3-12 3.7 Specific measures for ensuring electromagnetic compatibility (EMC) 3-22 Contents ALSPA MD2000 4 Operation and Software . 4-1 4.1 Unit operation . 4-1 4.1.1 Software structure 4-2 4.1.2 Control philosophy . 4-3 4.2 Parameter adjustment . 4-4 4.3 Menu 4-6 4.4 Description of parameters and displays . 4-10 5 Commissioning 5-1 5.1 Safety instructions for commissioning . 5-1 5.2 Commissioning sequence diagram, ALSPA MD2000 built-in unit . 5-3 5.3 General 5-7 5.4 Mains and motor connection 5-7 5.5 Commissioning report / Log Book . 5-8 6 Help in the event of errors 6-1 6.1 First value store for error messages 6-1 6.2 Switching sequence on errors . 6-1 6.3 Event log 6-1 6.4 Events . 6-1 6.5 Error log . 6-4 6.6 Errors 6-4 7Maintenance . 7-1 7.1 Battery for RAM and clock . 7-1 7.1.1 Battery change 7-1 7.1.2 Technical data of battery . 7-1 7.2 Fans 7-1 7.3 Power connections 7-1 7.4 Reforming the link capacitors . 7-2 8 Spare parts 8-1 Appendix Circuit diagrams List of diagrams List of tables User comments DCG/V212/Langer 7.12.99/5.4.00/5.5.00/11.10.00 Contents ALSPA MD2000 0 Notes, Warnings and Instructions ALSPA MD2000 0-1 Used Terms Note: Notes provide important additional information apart from the text. Attention! Attention means that the instructions given must be followed carefully to avoid loss of data or damage to the equipment. Warning! Warning means that the operator may be injured when the instructions are not followed. Limitation of liability Unless agreed otherwise in the contract the latest version of the “General Supply Conditions for Products and Services in the Electrical Industry” is applicable in its prevailing version. The software warranty is limited to the correct storage on the data storage medium (diskette) and that the documentation doesn't contain faults in principle. If the software supplied should prove defective in any way please return the complete software package of the ALSPA MD2000. We are not obliged to provide modifications or software updates, subsequently. Modifications in the sense of an improvement in handling and updates for new types of units can only be offered to registered users at preferential prices. The responsibility of using the software correctly, particularly the correct online and offline parameter adjustment of the ALSPA MD2000, lies with the operator. No liability whatsoever can be accepted for incorrect handling. Note: It is not possible to produce software to run perfectly on all types of PCs. In the event of problems please contact ALSTOM. Data, illustrations, revisions Data and illustrations are not final and binding. They may be subject to change without notice for reasons of technical improvement. If you have any suggestions concerning this documentation please do not hesitate to contact us. You may use the printed form on Page A-39 for your comments. Training ALSTOM offers training seminars to provide additional system knowledge. Without prior permission this document may not be duplicated or in any other way be made available to third parties. It may also not be misused in any way by the recipient or third parties. Translation into a foreign language is not permitted. All data, dimensions, weights, illustrations and other technical data may be subject to change without notice, in particular for the further enhancement of our products. The details agreed and confirmed for each order will be final and binding. ã1998 ALSTOM Anlagen und Antriebssysteme GmbH 0 Notes, Warnings and Instructions ALSPA MD2000 0-2 Warranty ALSTOM Anlagen und Antriebssysteme GmbH guarantees a warranty on all electronic equipment against design errors, faulty workmanship or materials for 12 months from the date of dispatch, in accordance with the “General Supply Conditions for Products and Services in the Electrical Industry”. ALSTOM Anlagen und Antriebssysteme GmbH reserves the right to change the content and products information provided in this operating manual. Attention! Read this operating manual carefully and thoroughly. Start with the section on installation and only then continue through to commissioning. The warnings and instructions given below are intended to draw the user’s attention to the safety measures required. They will also help to ensure optimum operation of the equipment. ã1998 ALSTOM Anlagen und Antriebssysteme GmbH All rights reserved. Written permission is required before this document may be made available to other parties, duplicated, translated, microfilmed and stored or processed in electronic systems. 0 Notes, Warnings, and Instructions ALSPA MD2000 0-3 Warning! Installation, commissioning or maintenance of the ALSPA MD2000 frequency inverter must only be carried out by specialized personnel familiar with the equipment and machinery involved. Serious injury or damage to the equipment may result when these instructions are ignored. Work on the equipment is only permitted when completely powered down. The drive motor is to be connected to a suitable protective conductor. Failure to do so may result in electric shock. The units are fitted with high voltage link capacitors. Wait FIVE MINUTES for them to discharge before removing the safety cover. Failure to do so may result in electric shock. Braking resistors operate at high voltages and their surfaces are usually hot. Install any braking resistor so that it cannot be touched or cause fire. Attention! This equipment was factory tested before dispatch. However, always check the unit before installation and commissioning for damage in transit, loose components or remaining packaging material etc. This product complies at minimum with protection class IP20. For safe and reliable operation please observe the safety and environmental conditions on site. High voltage resistance tests on wiring may only be carried out after disconnecting the drive from the circuit to be tested under strict observation of the circuit diagrams. Equipment sensitive to static electricity! This equipment contains components sensitive to electrostatic discharge. Observe the appropriate safety measures when handling, installing and maintaining these products. . Operating Manual ALSPA MD2000 27 kVA ... 336 kVA - 500 V 94 kVA ... 365 kVA - 690 V Safety and Operating Instructions for Frequency Converters. Supply voltage ranges: 3AC 480 V ... 525 V +10 %/ -15 % for ALSPA MD2000 series 500 V 3AC 575 V ... 690 V +10 %/ -15 % for ALSPA MD2000 series 690 V DC