Altivar Installation Manual. English 07/2013 ST /2013.

Transcription

1 Altivar 1200 Installation Manual English 07/2013 ST /2013

2 The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer must perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage Schneider Electric. All rights reserved. 2 ST /2013

3 Table of Contents About this manual... 4 CHAPTER 1: Before you begin - safety information Qualification of personnel Intended use Hazard categories Basic information...7 CHAPTER 2: Technical data and features Technical data Presentation Key interlock system Purchase order...22 CHAPTER 3: Steps for setting up CHAPTER 4: Transportation, storage and disposal Transport and storage conditions Storage and handling instructions for spare parts Unpacking and inspection Disposal of packaging materials and components Lifting and transport...25 CHAPTER 5: Mechanical Installation Overview of installation work General notes on installation Cabinet Installation Integrated transportation Connecting cabinets together Power Cell Installation Cooling Fan Installation Alertor installation HMI installation...33 CHAPTER 6: Electrical Wiring Overview of installation work Transformer connection Top cooling fan power cables Power Cell Wiring Connection of bypass cabinet Connection between Main Circuit Breaker and Drive Connection between main circuit breaker and bypass cabinet (optional) Inspection...40 CHAPTER 7: Routine Maintenance Service and Maintenance Performing visual drive inspection Cleaning the drive Conducting wiring inspection Cleaning and replacement of filters Power cell replacement Maintenance intervals...45 APPENDIX A: Units and conversion tables APPENDIX B: Medium Voltage Drive System Conventional Inspection APPENDIX B: Medium Voltage Drive System Conventional Inspection APPENDIX C: Connection between medium voltage drive system I/O Interfaces APPENDIX D: Medium Voltage Drive System Maintenance Form ST /2013 3

4 About this manual Document Scope The purpose of this document is: to give you mechanical and electrical information related to the ATV1200 drive. to show you how to install and wire this drive. Validity Note This documentation is valid for the Altivar 1200 drive. Related Documents Title of Documentation ATV1200 Catalog ATV1200 Programming manual Reference Number 8P02 640EN.00/00 ST03197 You can download the latest versions of these technical publications and other technical information from our Website at Standard and terminology Technical terms, terminology and the corresponding descriptions in this manual are intended to use the terms or definitions of the pertinent standards. In the area of drive systems, this includes, but is not limited to, terms such as "safety function", "safe state", "fault", "fault reset", "failure", "error", "error message", "warning", "warning message", etc. Among others, these standards include: IEC 61800: "Adjustable speed electrical power drive systems" IEC 61158: "Digital data communications for measurement and control-fieldbus for use in industrial control systems" ICE 61784: "Industrial communication networks-profiles" IEC 61508: "Functional safety of electrical/electronic/programmable electronic safety-related systems" 4 ST /2013

5 CHAPTER 1: Before you begin - safety information What's in this Chapter? This chapter contains the following topics: Topic Page 1.1 Qualification of personnel Intended use Hazard categories Basic information Qualification of personnel Only appropriately trained persons who are familiar with and understand the contents of this manual and all other pertinent product documentation are authorized to work on and with this product. In addition, these persons must have received safety training to recognize and avoid hazards involved. These persons must have sufficient technical training, knowledge and experience and be able to foresee and detect potential hazards that may be caused by using the product, by changing the settings and by the mechanical, electrical and electronic equipment of the entire system in which the product is used. All persons working on and with the product must be fully familiar with all applicable standards, directives, and accident prevention regulations when performing such work. 1.2 Intended use This product is a Medium Voltage drive system for three-phase servo motors and intended for industrial use according to this manual. The product may only be used in compliance with all applicable safety regulations and directives, the specified requirements and the technical data. Prior to using the product, you must perform a risk assessment in view of the planned application. Based on the results, the appropriate afety measures must be implemented. Since the product is used as a component in an entire system, you must ensure the safety of persons by means of the design of this entire system (for example, machine design). Operate the product only with the specified cables and accessories. Use only genuine accessories and spare parts. The product must NEVER be operated in explosive atmospheres (hazardous locations, Ex areas). Any use other than the use explicitly permitted is prohibited and can result in hazards. Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. ST /2013 5

6 CHAPTER 1: Before you begin - safety information 1.3 Hazard categories Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists, which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death, serious injury, or equipment damage. CAUTION CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in injury or equipment damage. NOTICE NOTICE indicates a potentially hazardous situation, which, if not avoided, can result in equipment damage. 6 ST /2013

7 CHAPTER 1: Before you begin - safety information 1.4 Basic information Read and understand these instructions before performing any procedure on this drive. PLEASE NOTE The word "drive" as used in this manual refers to the controller portion of the adjustable speed drive as defined by NEC. Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this product Schneider Electric. All Rights Reserved. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH Only appropriately trained persons who are familiar with and understand the contents of this manual and all other pertinent product documentation and who have received safety training to recognize and avoid hazards involved are authorized to work on and with this drive system. Installation, adjustment, repair and maintenance must be performed by qualified personnel. The system integrator is responsible for compliance with all local and national electrical code requirements as well as all other applicable regulations with respect to grounding of all equipment. Apply appropriate personal protective equipment (PPE). Many components of the product, including the printed circuit boards, operate with mains voltage. Do not touch. Use only electrically insulated tools. Do not touch unshielded components or terminals with voltage present. Motors can generate voltage when the shaft is rotated. Prior to performing any type of work on the drive system, block the motor shaft to prevent rotation. AC voltage can couple voltage to unused conductors in the motor cable. Insulate both ends of unused conductors of the motor cable. Before performing work on the drive system : - Always verify that red LED of each power cell is ON when mains voltage is present. LED status can be checked when doors are locked through the holes of the doors. If one or more of the red power cell LEDs is OFF, contact your local Schneider Electric representative. - Disconnect all power, including external control power that may be present. - Place a "Do Not Turn On" label on all power switches. - Lock all power switches in the open position. - Wait 20 minutes to allow the DC bus capacitors of the power cells to discharge. The DC bus LEDs located on each power cell are not an indicator of the absence of DC bus voltage. - If one or more of the red power cell LEDs remains ON 20 minutes after the mains voltage has been disconnected: - Do not repair or operate the product. - Contact your local Schneider Electric representative. Always use a properly rated voltage sensing device to confirm power is off. Install and close all devices, doors and covers before turning on power to this equipment. Failure to follow these instructions will result in death or serious injury. UNEXPECTED EQUIPMENT OPERATION WARNING Drive systems may perform unexpected movements because of incorrect wiring, incorrect settings, incorrect data or other errors. Carefully install the wiring in accordance with the EMC requirements. Do not operate the product with unknown and unsuitable settings or data. Perform a comprehensive commissioning test. (refer to "System Commissioning" chapter in the programming manual ST03197) Failure to follow these instructions can result in death or serious injury. ST /2013 7

8 CHAPTER 1: Safety information LOSS OF CONTROL WARNING The designer of any control scheme must consider the potential failure modes of control paths and, for critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop, overtravel stop, power outage and restart. Separate or redundant control paths must be provided for critical control functions. System control paths may include communication links. Consideration must be given to the implications of unanticipated transmission delays or failures of the link. Observe all accident prevention regulations and local safety guidelines. (1) Each implementation of the product must be individually and thoroughly tested for proper operation before being placed into service. Failure to follow these instructions can result in death or serious injury. (1) For USA: Additional information, refer to NEMA ICS 1.1 (latest edition), Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control and to NEMA ICS 7.1 (latest edition), Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems. 8 ST /2013

9 CHAPTER 2: Technical data and features What's in this Chapter? This chapter contains the following topics: Topic Page 2.1 Technical data Presentation Key interlock system Purchase order Technical data Power specifications for output voltage 3.3 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard High overload overload 120% 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 3.3 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-1 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. ST /2013 9

10 CHAPTER 2: Technical data and features Power specifications for output voltage 4.16 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard overload 120% High overload 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 4.16 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-2 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. 10 ST /2013

11 CHAPTER 2: Technical data and features Power specifications for output voltage 5.5 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard overload 120% High overload 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 5.5 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-3 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. ST /

12 CHAPTER 2: Technical data and features Power specifications for output voltage 6.0 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard overload 120% High overload 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 6.0 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-4 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. 12 ST /2013

13 CHAPTER 2: Technical data and features Power specifications for output voltage 6.3 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard overload 120% High overload 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 6.3 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-5 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. ST /

14 CHAPTER 2: Technical data and features Power specifications for output voltage 6.6 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard overload 120% High overload 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 6.6 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-6 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. 14 ST /2013

15 CHAPTER 2: Technical data and features Power specifications for output voltage 10 kv Model 1) Type rating 2) [kva] Motor power 3) [kw] Nominal Continuous current [A] Standard overload 120% High overload 150% Power cell current [A] Number of Power cells Number of Input Pulses Voltage class: 10 kv ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A ATV1200-A Table 2-7 Weight 4) [kg] 1)... Please contact Schneider Electric for other combinations of input and output voltage. 2)... For higher drive capacity please contact Schneider Electric. 3)... Values are calculated with a power factor of 0.88 and efficiency of 95%. The real value must come from the used equipment. 4)... Values valid only for standard efficiency. ST /

16 CHAPTER 2: Technical data and features General technical data Input pulse diode rectifier bridge Output Multilevel PWM with 2 level low-voltage IGBT inverter cells Input voltage 2.4kV, 3.0kV, 3.3kV, 4.16kV, 5.5kV, 6.0kV, 6.3kV, 6.6kV, 6.9kV, 10kV, 11kV, 13.8 kv Variation: standard±10% Allowable voltage fluctuation The drive is subject to de-rating operation when the voltage drop of power supply is within -25% Input frequency 50/60 Hz ±5% Acceleration / deceleration time s Overload capability Standard overload 120% 60s/10 min and 150% 3s/10 min, instant trip threshold 200% High overload 150% 60s/10 min, 185% 3s/10 min, instant trip threshold 250% Total harmonics THD(i) Comply with the requirements of power quality standard of IEEE Frequency resolution 0.01 Hz Trigger signal transmission Fiber optic transmission Input power factor 0.96 from 20 % to 100 % of speed The efficiency of the drive including input transformer 96% or over 96.5% depending on Efficiency at rated power product Inverter efficiency without transformer is 98.5% Type of motor Asynchronous motor, synchronous motor Three-phase output voltage for motor connection V V V V V V V V V V V Output frequency 120Hz for V/f, 70Hz for Vector Control Input transformer Indoor type integrated in the frequency variable device, the dry phase-shifting transformer can be supplied with pulse rectifier Control power supply 220 VAC, 3 kva capacity, other voltage on request, with UPS 30 min autonomy Protection class Standard: IP31 Option: IP41, IP42 Cooling fan power supply Internal from the drive transformer secondary (does not require additional auxiliary supply) Paint RAL 7032 Cooling Forced air ventilation Reference standard IEC EN , IEC EN , IEC EN , IEC EN , IEC EN 60529, IEEE 519 and other optional ones Environment features Storage temperature -10 C to 60 C Working temperature 0-40 C, up to 50 C possible with derating Cooling method Forced air cooling Relative humidity 90% (without condensate), Optional: maximum up to 95% Altitude 1000 m without derating. With derating of 0.6% every 100m up to 2000 meters, can be customized for high altitude Vibration Acceleration: 4.9 m/s² acceptable (10-50 Hz) Noise level 80 db (A) (including the noise of the cooling fans on the cabinet top) Pollution Degree Degree 2 of IEC61800 (Adjustable speed electrical power drive systems Part 5-1:Safety requirements Electrical, thermal and energy) Over Voltage Category Category II of IEC61800 (Adjustable speed electrical power drive systems Part 5-1:Safety requirements Electrical, thermal and energy) Table 2-8 Ambient conditions for operation such as temperature, relative humidity, air contamination, shock and vibration must be in compliance with the maximum permissible levels. HAZARD OF EXPLOSION AND ARC FLASH DANGER The product must NEVER be operated in explosive atmospheres and where vibrations and inductive bursts occur. Failure to follow these instructions will result in death or serious injury. Contact Schneider Electric if the condition of the installation site is not within the specifications. 16 ST /2013

17 CHAPTER 2: Technical data and features 2.2 Presentation Drive topology Its simple two level power cell design reduces the complexity of multilevel architecture and makes it into an understandable technology. This helps to save your maintenance cost because the crew will easily understand Altivar The core component of ATV1200 is the Power cell. This Power cell is a single phase, two level output switching device, supplied by a 700V low voltage winding of a transformer. Input power 3-phase AC Power cell Power cell Power cell Power cell Power cell Power cell Power cell Power cell Power cell VFD Controller Industrial control (Analog, Digital, Fieldbus) The advantage of this is, that the switching elements are LV components. By putting this AC - supplies in series, higher voltages are achieved. The number of Power cells determines the output voltage. Every cell provides a small step of motor supply, resulting in a smooth waveform. Phase shifting can be done on the secondary windings of transformer, allowing an elimination of harmonics of input. Power cell Power cell M Power cell HMI The cells create the right part of the drive and the transformer the left section of the drive. The drives regulation system and control is installed in front of the drive to provide an optimized footprint. The transformer and cell section can be separated for easy installation. Adequate cooling fans on top of the panel are supplied by additional secondary windings of the integrated transformer. This avoids additional 3phase supplies for the drive. Powercell Schneider Electric offers this transformer in a standard efficiency as well as in increased high efficiency. Figure 2-1 ATV1200 multilevel architecture Voltage Current Figure 2-2 Typical output waveform of a single power cell ST /

18 CHAPTER 2: Technical data and features Control- and Transformer cabinet Modular arrangement of control section in front of transformer. This section with independent access allows the integration of additional components according to your personal needs. Figure 2-3 Control- and transformer cabinet Power cells cabinet The power cells cabinet contains the inverter function of the ATV1200. It is a modular cabinet that can be used with the transformer cabinet according to the implementation requirements. The power cells are placed onto a fast-rack system providing a convenient access to it. Figure 2-5 Power cell Figure 2-4 Power cells cabinet 18 ST /2013

19 CHAPTER 2: Technical data and features Cooling concept Innovative transformer design with optimized cooling arrangement without the need of additional bottom blowers, keeping maintenance costs low and increasing the availability due to reduced number of fans. A reduced number of fans in ATV1200 also improves the total efficiency. Small fans should be avoided. The bottom transformer blowers can be replaced by an innovative air duct system for a better cooling system. The airflow circulation inside the transformer cabinet avoids hotspots. This increases the transformer lifetime. Figure Standard cooling Air inlet grid for transformer cabinet. 2. Air outlet with fans. 3. Guided air flow to avoid internal air short-circuit between transformerand power cell cabinet. 4. Air inlet grid for power cell cabinet. 5. Air outlet with fans Figure Cooling with air duct channel (as an option) 4 The ATV1200 can be equipped with the air duct system to exhaust losses outside the electrical room. This solution optimizes the design of the air conditioning system. Clean air has to be provided in the drive air inlets Air inlet grid for transformer cabinet. 2. Guided air flow to avoid internal air short-circuit between transformerand power cell cabinet. 3. Air inlet grid for power cell cabinet. 4. Air duct channel Figure 2-8 Drive with air duct channel Audible noise silencer (as an option) 4 The ATV1200 can be equipped with a silencer to reduce the audible noise generated by the drive. This solution mitigates the noise generated by the fan cooling system (on the top) and provides a better comfort to the surroundings. With this option the audible noise reaches 76db(A) during drive operation Air inlet grid for transformer cabinet. 2. Guided air flow to avoid internal air short-circuit between transformerand power cell cabinet. 3. Air inlet grid for power cell cabinet. 4. Air duct channel with audible noise silencer. ST / Figure 2-9 Drive with air duct channel 19

20 CHAPTER 2: Technical data and features 2.3 Key interlock system Main Features Key interlock system is used to prevent to open a door when the mains voltage is present. It prevents also to apply mains voltage when a door is still unlocked. (Only the control parts are not locked when the mains voltage is present) Key box are used to mechanically lock electrical installations. The basic functionalities are: - The lock must function with the intended key only. - The lock must self- lock (i.e. cannot rotate) in the absence of a key being present. - The lock must not function when using an unintended key or simple tools i.e. - flat blade screw driver for instance. - The lock must trap the key (i.e. it cannot be removed) when the key is turned in the locked position. - The lock must not eject the key. Hereunder take 5 keys product as an example. Figure Description Figure : Free key 1,2,3,4,5: Captive key 20 ST /2013

21 CHAPTER 2: Technical data and features Free Captive Free Captive Figure 2-12 Figure Power on procedure Step1: After installation completed, close all the doors and take out the captive key from each door. Closed door The free key 0 only can be released when the captive keys 1,2,3,4,5 have been turning in captive position. Figure 2-14 Step2: Put the captive keys into the corresponding key box which should be mounted on the transformer cabinet and then turn to captive position. Step3: Take out the free key after all the captive keys are in the captive position. Step4: Switch off the grounded switch of the Main circuit breaker, lock the free key with main circuit breaker. Step5: Wait for the commissioning engineer to give Permission to power on Power off procedure (for maintenance) Step1: Switch on the grounded switch of main circuit breaker. Step2: Take out the free key from the main circuit breaker. Step3: Put the free key into the key box and turn to captive position. Step4: Turn the captive keys to free position and then take them out to open the corresponding door for maintenance. Opened door The 1,2,3,4,5 keys may be released when the free key 0 has been turned to the captive position. Figure 2-15 If the lock we provide can not fit the Main Circuit Breaker, it's mandatory required to have the free key of drive and key of Main Circuit Breaker's band together and never be separated. ST /

22 CHAPTER 2: Technical data and features BLOCKS DIAGRAM (OUT OF SERVICE) RING Medium Voltage Main Circuit Breaker M QMMV QTMV A B A KEYS BOX ATV120 Free Key Captive Keys Keys for doors opening MOTOR M 3~ Figure Interlock with main circuit breaker The main circuit breaker can be switched on only if the free key 0 is taken out from the key box and locked with the main circuit breaker. Once the main circuit breaker is power is on, the free key is trapped and cannot be taken out, so that the doors cannot be opened. Only when the main circuit breaker is grounded, the free key can be taken out from the main circuit breaker to open the door for maintenance purposes, if any door is opened the main circuit breaker cannot be powered on. 2.4 Purchase order The product designation of the Altivar frequency inverters consists of several points of reference (characters and figures). The meaning of each point is illustrated in the following example. ATV1200 -A A 3 S Serial Name Cooling type: Drive(kVA) Input voltage*): Outputvoltage: Style: IP: Drive efficiency: "A" for air cooled "24" kv "24" kv "A"... Async. motor control "3"...IP31 Drive efficiency "30" kv "30"...3.0kV "B"... Async. motor control "4"...IP41 "S"... Standard efficiency ( 96%) "33" kv "33" kv with Powercell bypass "5"...IP42 "42" kv "42" kv "S"... Sync. motor control "H"... High efficiency ( 96.5%) "55" kV "55" kV "Y"... Sync. motor control "60" kv "60" kv with Powercell bypass "63" kv "63" kv "66" kv "66" kv "69" kv "69" kv "10" kv "10"...1 0kV "11" kv "11" kv "14" kv 22 ST /2013

23 CHAPTER 3: Steps for setting up What's in this Chapter? This chapter contains the following topics: Topic Steps for setting up 23 Page 1. Check the delivery of the drive Check that the part number printed on the label is the same as that on the purchase order. Remove the Altivar from its packaging and check that it has not been damaged in transit. 2. Check the line voltage compatibility Check that the voltage range of the drive is compatible with the supply voltage. 3. Mount the drive Steps 1 to 4 must be performed with the power off. The drive MUST be mounted level- on a flat surface. Mount the drive in accordance with the instructions in this document. Install the HMI,alertor and cooling fans according to chapter Wire the drive Connect the line supply and ensure the drive is grounded whilst the power supply is off. Connect the motor, ensuring that it meets requirements for the corresponding voltage. Connect the control wires according to the drawing. PROGRAMMING 5. Please refer to the programming manual ST /

24 CHAPTER 4: Transportation, storage and disposal What's in this Chapter? This chapter contains the following topics: Topic Page 4.1 Transport and storage conditions Storage and handling instructions for spare parts Unpacking and inspection Disposal of packaging materials and components Lifting and transport 25 INCORRECT DISMOUNTING CAUTION The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment. Failure to follow these instructions can result in injury or equipment damage. 4.1 Transport and storage conditions The product should be protected from rain and excessive sun exposure. The room where the drive is stored should be wellventilated, ensure that there is no corrosive gas in the storage room. The following relative temperature is permissible during transportation and storage: Temperature [ C] The changing of the temperature should be less than 5 o C/hour. The following relative humidity is permissible during transportation and storage: Relative humidity (non-condensing) [%] <90 The variance rate of the humidity should be less than 5%/hour. Ensure that there is no corrosive gas in the storage room. If the product is stored for more than 6 months, the oxidation and aging of cabinets and components of the medium voltage drive system must be inspected completely. Prior to installation all components of the medium voltage drive must be thoroughly inspected. 4.2 Storage and handling instructions for spare parts Check the spare parts immediately after receipt for damages. Report any damage to the shipping company and Schneider Electric. Observe the following to maintain spare parts in good condition and to keep the warranty valid during the warranty period: Storage place requirements: Protected against vibration and shocks. Free from dust, sand, vermin and insects. Free from corrosive gases, salt and other impurities that could damage electronic equipment. Dry; no condensation Relative air humidity: 5 to 90%. Keep spare parts in their original packaging. Store printed circuit boards in antistatic bags or boxes. Storage temperature range: -10 C to + 60 C (14 F to 140 F). The storage conditions and the packaging should be checked regularly. Any damage that occurs during the storage period should be repaired immediately. Handling requirements: Do not touch components without wearing a wrist grounding strap. Put the component on a grounded working surface protected against electrostatic discharges. Hold components only at their edges. 24 ST /2013

25 CHAPTER 4: Transportation, storage and disposal NOTICE RISK OF COMPONENT DAMAGE DUE TO INCORRECT HANDLING Static electricity can damage printed circuit boards. - Apply static-sensitive precautions when handling these components. Failure to follow these instructions can result in equipment damage 4.3 Unpacking and inspection Proceed as follows: 1). Remove all packaging material carefully. Do not use sharp or pointed tools. 2). Check the drive and accompanying equipment for damages. 3). Compare the complete delivery with the purchase order and the packing list. 4). If parts are missing or damaged, immediately inform the shipping company and Schneider Electric. Reserve the package of spare parts that can be recycled for transportation in case of repair is required. The User must record any such damage in detail, obtain a confirmation signature from the carrier, take photos of the damaged components and report details to Schneider Electric. INCORRECT DISMOUNTING Do not use sharp tools to open the packaging. CAUTION Failure to follow these instructions can result in injury or equipment damage. 4.4 Disposal of packaging materials and components Dispose of the packaging materials and the components at the end of the life time of the drive according to local regulations. 4.5 Lifting and transport Check the size and weight of medium voltage drive system components to choose proper lifting equipment. It is recommended to have the General layout drawing which contains relevant dimensions and weight information of the product before it is transported. WARNING RISK OF INCORRECT TRANSPORTATION AND HANDLING Select lifting equipment with sufficient capacity. During the transportation and handling the goods must not be exposed to moisture, overturned, inverted, tilted or subjected to shock. The goods should not be tilted more than 30 degrees. Failure to follow these instructions can result in death or serious injury ST /

26 CHAPTER 4: Transportation, storage and disposal Transformer cabinet Lifting Mounting Steps Key Points Illustration Transformer cabinet with lifting stick Pull out the lifting stick Use lifting belt to lift the cabinet select sufficient capacity lifting tools Table 4-1 Power cell Cabinet Lifting Mounting Steps Key Points Illustration Find the lifting points Disassemble the cover Use a 1.6m long 35mm diameter solid core steel rod Use lifting belt to lift the cabinet select sufficient capacity lifting tools move the medium voltage drive system to the correct location After erection, put the cover back and fasten the screws Table ST /2013

27 CHAPTER 5: Mechanical Installation What's in this Chapter? This chapter contains the following topics: Topic Page 5.1 Overview of installation work General notes on installation Cabinet Installation Integrated transportation Connecting cabinets together Power Cell Installation Cooling Fan Installation Alertor installation HMI installation 33 INCORRECT DISMOUNTING CAUTION All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations. Failure to follow these instructions can result in injury or equipment damage. 5.1 Overview of installation work The installation includes the following work: Preparing the foundation See section Foundation requirements. Fixing the drive to the floor See section Floor fixings. Installing the cooling fan See section 5.7 Fan installation. Installing the alertor See section 5.8 Alertor installation. Installing the HMI See section 5.9 HMI installation. 5.2 General notes on installation When working on the drive, ensure that foreign matter cannot enter the cabinet. Close the doors and cover openings completely when work is discontinued. Any foreign matter which accidentally enters or drops into the cabinet must be retrieved. Metallic dust in particular can cause malfunction and damage when the drive is energized Dimensions, Foundation See General Layout drawing shipped with the drive for information on: Cabinet dimensions Maintenance space Foundation plan ST /

28 5mm 120mm CHAPTER 5: Mechanical Installation Foundation requirements Before installation, the foundation for the medium voltage drive system positioning must be prepared by the User. The floor must be of non-flammable material, with smooth and nonabrasive surface, protected against humidity diffusion, leveled and able to support the weight of the cabinet. The suggestions for the foundation are as follows: a) The pre-buried steel channel must be 5mm higher than the ground level. In order to increase the stressed area, the length of the buried steel channel must be 400mm longer than the base of the medium voltage drive system (200mm longer for both left and right sides respectively), the quality of the pre-buried steel installation must be guaranteed. Installation size chart Side view D Amplification 1:5 Channel steel of VSD ±0.00mm Channel steel of Fundation ±0.00mm 800mm L transformer cabinet depth Figure 5-1 Foundation Plan Figure 5-2 Foundation Plan b) Cable ducts should be of non-flammable material and of a non-abrasive surface. All cable entries and exits should be protected to prevent dust, humidity and animals entering into the drive. Suitable fire protection measures should be applied to prevent fire spreading into the drive Cabinet roof The cabinet roof is not designed as a mounting base for foreign devices, cable ducts etc. Therefore, it is not permitted to install any foreign device on the roof. 28 ST /2013

29 CHAPTER 5: Mechanical Installation Floor fixings To ensure that the drive cabinets are reliably grounded, one of the following two methods detailed below must be followed. The base of medium voltage drive system must be connected to the pre-buried steel channel by spot welding. The cabinet is fitted with specially designed fixing holes at its base which should be used to fix to the floor. Floor fixings are not supplied. Anchor bolts or screws and nuts of size M20 are recommended. DAMAGED DRIVE EQUIPMENT WARNING Do not operate or install any drive or drive accessories that appear to be damaged. Failure to follow these instructions can result in death or serious injury 5.3 Cabinet installation Typical medium voltage drive systems consist of two cabinets: Transformer Cabinet. Power Cell Cabinet. The medium voltage drive system will be disassembled into 2 sections, the transformer cabinet being the heavier of the two. Ensure that the lifting equipment has sufficient capacity. Refer to section 3.6 Lifting and transport when lifting the cabinets. Maln vlew Transformer cabinet Power unit cabinet W Figure 5-3 Front View of the medium voltage drive system 5.4 Integrated transportation ATV1200 designed as integrated transportation, power cell will be fastened with its rail by front and back screws for easy and quick installation. Power cell Reinforcing rib Fastening screws Figure 5-4 Back view of power cell cabinet ST /

30 CHAPTER 5: Mechanical Installation For front access before mounting against a wall, the fastening screws at the rear of the Power Cell Cabinet should be removed in order to facilitate future repairs (should these be necessary). Carefully read the "CAUTION" note fixed to the back of the drive and proceed as follows: 1) Open the doors located at the back of the unit. 2) Remove fastening screws as described in Figure ) After completion shut doors. 5.5 Connecting cabinets together After anchoring cabinets to foundation, the cabinets need to be connected together. The connection between transformer cabinet and power cell cabinet must be precisely adjacent, ensuring that the doors can still easily be opened and shut. Please note figure 5-5 for bolting procedures. Figure 5-5 The Cabinet Combination Units must be bolted or welded to the pre-buried steel channels (please refer to and 5.2.5). Ensure that the resistance of the pre-buried steel channels is equal or less to 1 Ohm. DANGER ELECTRIC SHOCK CAUSED BY INCORRECT GROUNDING Inadequate or incorrect grounding can lead to serious injury by electric shock or in extreme cases to electrocution. Ensure drive systems are correctly grounded before applying voltage. Verify compliance with all local and national electrical code requirements as well as all other applicable regulations with respect to grounding of all equipment. Do not use conduits as protective ground conductors. The cross section of the protective ground conductor must comply with the applicable standards. Cable shields must not be considered to be protective ground conductors. Failure to follow these instructions will result in death or serious injury. 5.6 Power Cell Installation Power cell inspection: Conduct a careful inspection before installation of power cells: a. Confirm that the reference number on the package of of the power cell is consistent with the nameplate of the medium voltage drive system. b. Confirm that each power cell of the medium voltage drive system is mechanically and electrically identical, (dimensions and capacity) and could be interchanged. 30 ST /2013

31 CHAPTER 5: Mechanical Installation Power Cell positioning: a. Install cells by sliding them into the cabinet channels, ensuring that the power cells are correctly positioned. Figure 5-6 shows the typical installation mode for power cells. Figure 5-6 View of correct configuration of installed power cells. b. Once correctly positioned the cells are to be bolted (supplied washers to be used). Bolts and washers are kept with the spare parts. 5.7 Cooling fan installation For convenience during transportation, cooling fans and alertors are packed individually. Before proceeding with installation of cooling fans, carefully distinguish between those to be fitted to the power cell cabinet and those to be fitted to the transformer cabinet according to supplied drawings and labels Clear any debris from the fan mounting area before installation. Section inlet of cooling fan The top of cabinet Figure Cooling fan installation a. Mount the suction inlet to the top panel of cabinet, ensuring that the small bore diameter is facing upwards. b. Mount the fan and its shield to the cabinet. The face with yellow mark towards front side of cabinet.( The yellow arrow represents direction of fan rotation). Fan and its shield Figure 5-8 ST /

32 CHAPTER 5: Mechanical Installation c. After installation,check there is no rubbing between the blades and shield d. Use M6*20 screws (contained in the spare parts box) to fasten the fan Refer to Table 6.1 for the screw torque Figure 5-9 e. Connection wirings according refer the drawings delivered within the drive package f. Mount the air duct for each fan if there are air ducts provided. (Optional) Fan type Size (mm) Weight (kg) R4D *470* R4D *710* Table 5-1 NOTICE DAMAGED DRIVE EQUIPMENT DUE TO INCORRECT CONNECTION Re-inspect sequence of A/B/C phases to ensure that the fans rotate correctly (the blade rotation direction is shown by the arrow sticker). Failure to follow these instructions can result in equipment damage. 5.8 Alertor installation Mounting Steps Key Points Illustration Install cable gland Ensure that there is no gap between the cable gland and the cabinet surface Install siren Use M3 screws, torque 0.5Nm to fasten Wiring Connect power source cable(12vdc)to alertor, check the polarity before before connecting Table ST /2013

33 CHAPTER 5: Mechanical Installation 5.9 HMI installation Mounting Steps Key Points Illustration HMI positioning 4 screws to fasten the HMI Fasten Use torque screwdriver to fasten (0.2Nm) Wiring Connect power source cable(24vdc) and communication cable, check the polarity before do connection Table 5-3 ST /

34 CHAPTER 6: Electrical Wiring What's in this Chapter? This chapter contains the following topics: Topic Page 6.1 Overview of installation work Transformer connection Top cooling fan power cables Power Cell Wiring Connection of bypass cabinet Connection between Main Circuit Breaker and Drive Connection between main circuit breaker and bypass cabinet (optional) Inspection 40 DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH Only appropriately trained persons who are familiar with and understand the safety instructions in the chapter "Safety Information" may perform the wiring. When the electrical installation is completed, the main and auxiliary power supply to the drive must not be switched on without the consent of the commissioning personnel. Take appropriate measures to prevent main and auxiliary power supply being switched on during installation. Failure to follow these instructions will result in death or serious injury. 6.1 Overview of installation work The electrical installation includes the following wire and cable connections: Transformer cables See section 6.3 Transformer secondary windings connection. Top cooling Fan cables See section 6.4 Top cooling fan power cables. Power cell cables See section 6.5 power cell wiring. Auxiliary power and control cables See section 6.6 Auxiliary power, control and serial communication cables. Torque setting Table Bolt dimension Carbon steel Copper N m lb in N m lb in M M M M M M M M M M Table 6-1 Torque setting Table (1) 1 N m =100 CN m. (2) The maximum deviation of the torque applied should be no more than ±10%. (3) For other torque please refer APPENDIX A: Units and conversion tables 1.6 Torque. 34 ST /2013

35 CHAPTER 6: Electrical Wiring 6.2 Transformer connection Washer Nut 2 Nut 1 Cable terminal Figure 6-1 Proceed as follows: 2 nuts and 1 washer are used for fastening transformer secondary windings, first put the cable terminal, then put washer, use torque spanner to fasten nut 1. When fasten nut 2, use a spanner to lock nut 1 to avoid sliding, then use torque spanner to fasten nut 2. A Torque wrench or torque screwdriver must be used to fasten bolts/screws. To avoid loosening, injury or fracturing, correct torque is applied refer to table Top cooling fan power cables Connect the wiring between the transformer cabinet and the power cell cabinet. 10 pin socket used for door limit switch,16 pin socket used for top cooling fan of power cell cabinet, connect as shown below. Mounting Steps Key Points Illustration Distinguish between 10 and 16 Ensure that pins are straight pin Insert into socket Insert and fasten Inspection Ensure mounting has been reliably performed Table 6-2 ST /

36 CHAPTER 6: Electrical Wiring 6.4 Power Cell Wiring Markings specification a) Each power cell is marked with a part reference, for example: APVa1, APVa2, APVb1, APVb2, APVc1, APVc2, which indicates the location of the cell in the system. For example, APVa1 is the marking of the first cell of A phase. b) Each power cell has three input terminals and two fuses. Each terminal is marked with L1-LV, L2-LV, L3-LV, which indicates the input terminals of each phase. c) Each power cell has two optic fibre sockets J1, J2. For the torque refer to Table Wiring on power cells a) Input line wiring connection: there are three input terminals L1-LV, L2-LV, L3-LV and two input fuses, connect the wiring according to the drawing. b) Communication wirings connection. The power cells are connected with the main controller through fibre optic cables. Connect the optic fiber cable as per drawing. IMPROPER CONNECTION & LAYOUT NOTICE The head of the optic fiber and its socket must be clean and well fixed, never pull or bend it, bending radius no less than 90 degree. The fiber optics heads and sockets must be of matching colour. Failure to follow these instructions can result in equipment damage c) Connection between the power cells: The output termination of each cell is marked as U and V, which provide a single phase AC voltage. The cells of the same phase are connected in series, i.e., the output terminal V of cell APVa1 is connected with the output terminal U of cell APVa2, and so on. For details refer to the drawing provided, the typical connection is shown below (Connection wirings according refer the drawings delivered within the drive package): Figure ST /2013

37 CHAPTER 6: Electrical Wiring d) Connection between the neutral points: The output terminal V of each cell at the end of every phase is connected at neutral point using cables or a copper bus-bar. In a 6 cascade system (as shown below), the output terminal V of cell APVa6, APVb6, APVc6 are connected together using cables or a copper bus-bar. The Hall sensor should be mounted with cable/bus-bar passing through it. For details refer to the drawing provided, the connection is shown below: Figure 6-3 e) Connection of output cables: The output cables are connected to the terminal U of the cells which is the first one in each phase, the cable sign of each is 301U, 301V, and 301W, ie. Cable 301U connected to the output terminal U of Cell APVa1, Cable 301V connected to the output terminal U of Cell APVb1,Cable 301W connected to the output terminal U of Cell APVc1. For detailed connection refer to the drawing provided, and the connection drawing is shown above. Connection cable size according refer the drawings delivered within the drive package. DESTRUCTION DUE TO INCORRECT OPERATION NOTICE All connections for the copper bus-bar, three phase output cables and neutral point connection cables must be connected tightly. The torque setting for each bolt of incoming/out-going cables is shown in table 6-1. Failure to follow these instructions can result in equipment damage. ST /

38 CHAPTER 6: Electrical Wiring 6.5 Connection of bypass cabinet Bypass cabinet cables: The cables between bypass cabinet and transformer cabinet: a. Connection of the input cables: The cables from the bypass cabinet to the transformer cabinet are located in the transformer cabinet when delivered. Connect the three input cables to the bypass cabinet in accordance to the diagrams in the wiring drawings section.(please specify). Cables must be neatly arranged and well tightened. b. Connection of the output cables: The cables from the bypass cabinet leading to the left side of the power cell cabinet are located in the bypass cabinet when delivered. Connect the three output cables to the side plate in accordance with the diagrams described in the wiring drawings section.(please specify). Cables must be neatly arranged and well tightened Wiring between the bypass cabinet and the control cabinet: the control wires are located in the bypass cabinet when delivered: the bypass cabinet wiring has been connected and passes through the cable channel or bridge to the control cabinet, ensure that the wiring numbers do not become detached whilst passing through the cable channel or bridge. The wiring connections to the terminals must be performed as described in the related drawings. 6.6 Connection between Main Circuit Breaker and Drive The main circuit breaker (main circuit breaker) is a major protection device whose primary function is to protect all downstream installations, including the VSD. In case of electrical surges such as excessive current, excessive voltage, short circuit or Drive command, the main circuit breaker must disconnect the main power supply from the VSD immediately. The main circuit breaker is located on the primary side of the VSD s phase-shifting transformer. When the system and the VSD are used in conjunction, the main circuit breaker must remain installed upstream of the installation in order to ensure the protection of the entire system. Grid QF(Main Circuit Breaker) Grid QF(Main Circuit Breaker) KM41 VSD QS41 M 3~ Automatic-B ypass cabinet (optional) VSD KM43 Figure-6-5 Drive without bypass cabinet QS42 KM42 M M 3~ Figure-6-4 Drive with bypass cabinet 38 ST /2013

39 CHAPTER 6: Electrical Wiring Depending on the configuration, the drive can be supplied directly via the main circuit breaker (see Figure 6-5) and/or a bypass cabinet (optional) (see Figure 6-4). In both cases the VSD trip command has to be wired to the main circuit breaker Mains voltage off button When operated, the mains voltage off button stops the VSD. It is requirement to extend a sub-voltage release module on the main circuit breaker to achieve this function. 6.7 Connection between main circuit breaker and bypass cabinet (optional) With a NC (nominal close) contactor main circuit breaker, one of the NC output spaces must be dedicated for controlling the electromagnetic lock of the isolated switch that is mounted in the bypass cabinet. N.B. The connection MUST be hard-wired. Refer APPENDIX C. When the main circuit breaker is closed, the electromagnet will remain in the locked position. This avoids any switching on/off operation of the manual isolated switch with load. When the main circuit breaker is open, the electromagnetic lock can be operated. Figure 6-6 ST /

40 CHAPTER 6: Electrical Wiring 6.8 Inspection This section generally describes the necessary inspection before medium voltage drive system is powered on. Beside other, review the following steps: Steps Description 1 Check that the site power supply meets the requirement of the medium voltage drive system. The rated input voltage of the medium voltage drive system must be equal to the utility grid voltage. 2 The maximum output voltage of the medium voltage drive system must match the rated voltage of the motor which is marked on the motor nameplate. 3 The control power supply (low voltage) must match the rated voltage of control system. 4 The rated power of the medium voltage drive system must be compatible to the power of motor. 5 Make sure that the medium voltage drive system is connected to ground securely. Grounding resistance must be lower than 4 ohm. The control system with a separate ground bus-bar and its resistance must be lower than 1 ohm. 6 Inspect all cables and terminations. Ensure that there is no insulation damage. 7 Inspect and confirm all terminals, components mounting, and other parts are marked or labeled, otherwise notify your supplier or the manufacturer. 8 Ensure that control power supply and main power supply are correctly connected and they comply with local codes and electrical specifications 9 Check that all wiring is tightly and correctly connected. 10 Inspect whether the disconnecting switches in bypass cabinet (optional) are installed tightly and that the mechanical interlock of the disconnecting switch is functional. Make sure that the switch blade is well contacted. 11 Confirm that the input and output medium voltage cables are connected correctly. 12 Be sure that all electrical connections of the transformer are tight including input, output and secondary. 13 Check that the temperature sensors are installed appropriately. 14 Verify that cooling fans on the top of cabinet are connected correctly and tightly, and can rotate freely and in the correct direction 15 Verify that all bolts used to connect transformer output cables; secondary windings; three-phase input cables are tightly connected. 16 Verify that the input and output fibre optic connections are correct (Color and wire number), optical fiber and the fiber terminal is correctly connected, optical head and optical block must be clean with good connections. The fiber length must be correct so that there is no pulling or bending 17 All cables must be fastened. Printed circuit boards in the control box must be plugged into the right place. The boards and control boxes must be fastened tightly by screws. 18 Verify that frequency setting signal is a 4~20mA or 0~10V source signal.. 19 Confirm that the control wiring is separated from power wiring. Table 6-3 If any inspection result is abnormal, seek advice from the supplier or manufacturer. 40 ST /2013

41 CHAPTER 7: Routine Maintenance What's in this Chapter? This chapter contains the following topics: Topic Page 7.1 Service and Maintenance Performing visual drive inspection Cleaning the drive Conducting wiring inspection Cleaning and replacement of filters Power cell replacement Maintenance intervals 45 DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH Only appropriately trained persons who are familiar with and understand the safety instructions in the chapter "Safety Information" may perform troubleshooting or maintenance work. Don t carry out any measurement, spare part replacement or other maintenance work that is not covered or included in this manual. Failure to follow these instructions will result in death or serious injury. 7.1 Service and Maintenance Performing visual drive inspection See section 7.2. Cleaning the drive See section 7.3. Performing wiring inspection See section 7.4. Cleaning and replacement of filters See section 7.5. Power cell replacement See section Performing visual drive inspection The drive must be regularly inspected and cleaned (in accordance to regulations and maintenance schedule). 1. Ensure that the drive exterior and interior as well as the surrounding area are free of dust, sand, vermin and insects. Electrical components such as wiring and circuit boards are prone to overheating and malfunction by build up of dust and moisture. 2. Ensure that the drive exterior and interior has not been affected by corrosive elements such as corrosive gases, salt or other impurities that can damage electrical equipment, structural integrity of the drive or the insulation of cabling. 3. Ensure that there are no signs of over-heating of elements and components (circuit boards, wiring connections etc...), and that cooling fans are correctly mounted and functioning. Ensure that filters are not damaged and free of dust and grime. If necessary replace filters. 4. Ensure that cables are correctly and tightly fastened as well as all other screws, bolts and wiring. 5. Ensure that the area is dry and free of condensation and at suitable relative air humidity level. ST /

42 CHAPTER 7: Routine Maintenance 7.3 Cleaning the drive Dust, sand, moisture, vermin and insects can cause serious damage to electrical components and wiring. It is therefore imperative that the drive (exterior and interior) be regularly checked and cleaned, as well as the surrounding area. Filters and air intake ducts must be free of all obstruction at all times as well as free of dust and grime. Circuit boards are prone to damage from moisture and dust, but also from static electrical discharges. Therefore it is important to exercise care when cleaning sensitive components and to ensure that antistatic cleaning equipment is used. Also please note that chemical cleaners, alcohol and other solvents should not be used for cleaning. 7.4 Conducting wiring inspection The drive is continually in operation and therefore prone to vibrations, which in turn causes loosening of connections and components within. It is essential to regularly check that plugs, sockets, screws, bolts and cabling of the entire drive are connected and tightly fixed. Failure to do so can lead to equipment malfunction, failure and/or short-circuiting. Duties of staff responsible for operation and maintenance MUST regularly take temperature and humidity measurements and record these. Particular attention should be taken to temperature of the transformer windings. Temperature rising from the transformer coils must not exceed 90 degrees Celsius. After commencement of operating life, the transformer must be thoroughly cleaned and the insulation inspected at least once a year. Inspection and tightening of bolts, screws and wiring MUST be conducted every 6 months. 7.5 Cleaning and replacement of filters The filter mats are located at the air intake panels of the following sections: (1) Power cell compartment. (2) Transformer compartment. Figure ST /2013

43 CHAPTER 7: Routine Maintenance Check the filter mats regularly, the inspection intervals depend on the cleanliness of the cooling air. To replace a filter mat, remove the louvered panel of the corresponding section. Figure 7-2 When replacing a filter mat, do not discontinue work for a longer period to prevent foreign matter entering the drive. The dimension of dust filters depend on the capacity of the drive. 1 2 types dust filter on the Power cell cabinet: Specification Dimension mm*395mm mm*395mm Table types dust filter on the Transformer cabinet: Specification Dimension mm*395mm mm*615mm mm*395mm mm*615mm Table 7-2 Figure 7-3 ST /