Curso Altivar

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The document discusses safety procedures and equipment for working with electrical drives and switchgear.

Safety training, helmet, protective clothing, insulating gloves, safety shoes and insulating mats are required safety equipment.

Arc flash rating measures the potential energy released by an electric arc in units of cal/cm^2 and is used to determine the appropriate protective equipment.

Altivar Process

Technical Training
Schneider Electric Drives Activity

Vienna
15.07.2015 – 16.07.2015
FELBER Robert
Altivar Process Drive Systems
Contents

Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
SAFETY FIRST
Safety
Required Safety Equipment

> Safety training for working under voltage (EN50110)

> Helmet with visor

> Accidental arc protected safety clothes

> Insulating gloves (1000V)

> Safety shoes

> Area insulating mat for neighboring energized parts

Confidential Property of Schneider Electric 6


Safety
Required Safety Equipment

Use the right equipment


for the performed work

Confidential Property of Schneider Electric 7


Safety
Required Safety Equipment

You have to request the right equimpent for your function.


Schneider Electric has to provide the equipment!

There is no discussion about it!

Confidential Property of Schneider Electric 8


Safety
Safety Equipment Rating

Arc flash can reach up to 20000°C (35000°F)

Copper has an expansion of 67000 times when it turns to a vapor

High pressures from an Arc Blast can rupture ear drums, collapse lungs,
explode the switchgear and destroy a wall 3 meters away

The molten material can travel more than 1100km/h (>700mph)

Most hospital admissions due to electrical accidents are from


Arc Flash burns, not electrical shock
Confidential Property of Schneider Electric 9
Safety
Safety Equipment Rating

Electrical PPE is always rated


to the maximum energy it can withstand

The amount of energy that can result from an


electric arc flash is measured in cal/cm2
Calorie (cal) definition:
One calorie is the energy required to raise one gram of water one degree Celsius at one atmosphere.
The onset of second-degree burns may occur at 1.2 cal/cm² squared per second.

This is equal to holding your finger over the tip of the flame of a lighter for one second
Confidential Property of Schneider Electric 10
Safety
Helmet Labeling – Some Examples (European Standards)

A helmet for electrical work has to be a special type including the exact labeling

Helmet label with remarks about the helmet


type for EN397 as:
Production Quarter (09 – 12) -30°C / MM-Melted metall / 440V Electrician
The user can write his name and the start
date of usage (To identify the time of usage)

Production Year (2007) and


Material (HDPE)
Electrical isolation classification
EN50365 Class 0 = 1000VAC / 1500VDC
VDE 1000v a.c = 1000VAC / 1500VDC
Material (HDPE)

CE-Sign Cost confirmation (C3xx = Russian standard)

Confidential Property of Schneider Electric 12


Safety
Accidental Arc Flash Protection Clothes

Winter Jacket Trouser and Jacket Overall T-Shirt Boxer shorts


40 cal/cm² 12,4 cal/cm² 12,4 cal/cm² 10,9 cal/cm² 10,9 cal/cm²

Confidential Property of Schneider Electric


http://www.charnaud.eu/arc-flash-workwear/ 13
Safety
Hazard at a Short Circuit

Confidential Property of Schneider Electric 14


Safety
Hazard at a Short Circuit

Confidential Property of Schneider Electric 15


Safety
5 Safety Rules

1. De-energize
…by switching off all power supplies.

2. Secure against restarting


…by locking the switch by your personal lock and marking it with your name and
date. Don not forget to take the key with you.

3. Ensure dead supply


…by measuring the supply at the plant/device.

4. Ground and short circuit


…to cause a automatically switch-off,
if somehow the supply gets under voltage.
Confidential Property of Schneider Electric 16
Safety
5 Safety Rules

5. Cover neighboring energized parts or provide it with gates


…by covering it with an insulating mat or inhibit contact by closing doors or
mounting barriers.

Neighboring energized parts are more dangerous than an energized


mains supply!
People do not reckon with that.
Confidential Property of Schneider Electric 17
Safety
Safety Categories of Measurement Tools
REAR
CAT III 1000V
CAT IV 600V

FRONT

Confidential Property of Schneider Electric 18


Safety
Safety Categories of Measurement Tools

Confidential Property of Schneider Electric 19


Safety
Safety Categories of Measurement Tools

Voltage to
permissible transient voltage [Vpeak]
ground [VAC]
CAT I CAT II CAT III CAT IV
300V 1500V 2500V 4000V 6000V
600V 2500V 4000V 6000V 8000V
1000V 4000V 6000V 8000V 12000V

The permissible transient voltage is the maximum value CAT III 1000V
the measurement tool can withstand without damage. CAT IV 600V

If the voltage is too high you can have a very high short circuit current
through the probes and your measurement tool which is very dangerous
Confidential Property of Schneider Electric 20
Safety
Switching Responsibility

The switching responsibility for the LV-voltage power supply


has always the end-user.

NEVER
A SCHNEIDER ELECTRIC FSE

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Safety
Arc Flash as a Result of a Short Circuit

Confidential Property of Schneider Electric 22


Safety
Power behind a Short Circuit

Confidential Property of Schneider Electric 23


Questions - Safety

Who is responsible for power switching procedures?


Never the Schneider Electric FSE
Only an authorized person from the customer or a contractor

Name the 5 safety rules in some words!


Switch off, Lock out, Measure, Ground and short circuit,
Cover neighbored energized components

What does the safety category of measurement tools define?


The maximum permissible transient voltage the tool can handle without a damage!
For example CATIII 1000V / CATIV 600V means max. 8000V transient voltage.
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
VSD Principle
Block Diagram

A frequency converter consists out of 3 main power electronic parts


> Rectifier
> DC-Link capacitors
> IGBT-Inverter bridge

Confidential Property of Schneider Electric 26


VSD Principle
Diode

Cathode

Anode
Confidential Property of Schneider Electric 27
VSD Principle
Thyristor

Cathode
Gate

Anode
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VSD Principle
Capacitor

Confidential Property of Schneider Electric 29


VSD Principle
IGBT – Insulated Gate Bipolar Transistor

Collector

Gate

Emitter
Confidential Property of Schneider Electric 30
VSD Principle
Rectifier

Depending on the power range the rectifier components


V1, V3 and V5 are diodes or thyristors
Confidential Property of Schneider Electric 32
VSD Principle
Rectifier

L1 L2 L3

L1/L2 L1/L3

L2/L1 L3/L1

L2 L3 L1 Current L1
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VSD Principle
IGBT – Inverter Bridge

Two IGBTs for each output phase

Confidential Property of Schneider Electric 34


VSD Principle
Output PWM (Pulse Width Modulation)

UDC+
Voltage pulses

Reference sine wave

t [ms]

UDC-
Confidential Property of Schneider Electric 35
VSD Principle
Output PWM (Pulse Width Modulation)

UDC+ [V]

UD0 t [ms]

UDC- [V]
Confidential Property of Schneider Electric 36
VSD Principle
Harmonics – Multipulse Solution

6 pulse solution (THDi < 48%) L1

Confidential Property of Schneider Electric 41


VSD Principle
Harmonics – Multipulse Solution

12 pulse solution (THDi < 10%) L1.1 L1.2

Confidential Property of Schneider Electric 42


VSD Principle
Harmonics – Multipulse Solution

18 pulse solution (THDi < 5%) L1.1 L1.2 L1.3

Confidential Property of Schneider Electric 43


VSD Principle
Harmonics – Multipulse Solution

24 pulse solution (THDi < 3%) L1.1 L1.2 L1.3 L1.4

Confidential Property of Schneider Electric 44


VSD Principle
Input Current vs. Output Current

> Why is the input current sometimes smaller than the output current?
> The diagram shows the input and output values depending on the output frequency at
a constant torque

Input curve Output curve

Confidential Property of Schneider Electric 47


Mains Topology
Overview

Earthing Systems:

> International standard IEC 60364


> Regulation of of earthing arrangements using the
two-letter codes (TN, TT, and IT)

> The first letter


> indicates the connection between earth and the power-supply equipment (generator or transformer)
T……direct connection of a point with earth
I….…no point is connected with earth (isolated)

> The second letter


> indicates the connection between earth and the electrical device
T……direct connection with earth
N……connection to earth via the supply network

Confidential Property of Schneider Electric 48


Mains Topology
TT-Earthing System

TT-Earthing System:

> Protective earth (PE) connection of the consumer is


> provided by a local connection to earth
> is independent of any earth connection at the generator

> Big advantage of the TT Earthing system


> Clear of high and low frequency noises that come through the
neutral wire from various electrical equipment connected to it
> No risk of a broken neutral

Confidential Property of Schneider Electric 49


Mains Topology
TT-Earthing System

TT-Earthing System:

> Protective earth (PE) connection of the consumer is provided by a local connection to earth
and is independent of any earth connection at the generator.

L1
L2
L3
N

PE
L1 L2 L3 N

Confidential Property of Schneider Electric 50


Mains Topology
TN-Earthing System

TN-Earthing System:

> One point in the transformer is connected with earth


(usually the star point in a three-phase system)

> The electrical device is connected with earth via the transformer.

> The conductor that connects the exposed metallic parts of


the consumer is called protective earth (PE).

> The conductor that connects to the star point in a


> three-phase system, or that carries the return current in a single-phase system, is called
neutral (N).

> There are three different TN-Systems.

Confidential Property of Schneider Electric 51


Mains Topology
TN-Earthing System

TN-Earthing System:
> TN-C Earthing System

Combined PE and N conductor all the way from the transformer


to the consuming device.

L1
L2
L3

PEN

PE
L1 L2 L3 N

Confidential Property of Schneider Electric 52


Mains Topology
TN-Earthing System

TN-Earthing System:
> TN-S Earthing System

Protective Earth (PE) Neutral (N) are separate conductors


They are connected together only near the power source.

L1
L2
L3
N
PE

PE

L1 L2 L3 N

Confidential Property of Schneider Electric 53


Mains Topology
TN-Earthing System

TN-Earthing System:
> TN-C-S Earthing System

Combined PE-N conductor from transformer to building distribution point. Separation of PE


and N conductors in fixed indoor wiring

L1
L2
L3
N
PEN PE

PE

L1 L2 L3 N

Confidential Property of Schneider Electric 54


Mains Topology
TN-Earthing System

TN-C-S Earthing System:

L1
L2
L3
N
PEN PE

PE

L1 L2 L3 N

Confidential Property of Schneider Electric 55


Mains Topology
IT-Earthing System

IT-Earthing System:

> The distribution system has no connection to earth (or it has only a high impedance connection)
> In such systems, an insulation monitoring device is used to monitor the impedance

L1
L2
L3

PE
L1 L2 L3

Confidential Property of Schneider Electric 56


Mains Topology
Corner Grounded-Earthing System

This system is out of date but still existing.

It is not allowed for Y-range drives !

L1

L2
L3

PE
L1 L2 L3

Confidential Property of Schneider Electric 57


Motor cables and EMC
Unsymmetrical Capacities

Cable duct

Confidential Property of Schneider Electric 58


Motor cables and EMC
Overview of different Types

Confidential Property of Schneider Electric 59


Motor cables and EMC
Motorcable without Shielding

> The high frequent leakage current flows through the motor cable shield back to the
FC where the RFI-Filter closes the loop of the HF-circuit.
> Only a small HF-current flows back to the transformer star point.
Confidential Property of Schneider Electric 60
Motor cables and EMC
Motorcable with Shielding

> The high frequent leakage current flows through the motor cable shield back to the
FC where the RFI-Filter closes the loop of the HF-circuit.
> Only a small HF-current flows back to the transformer star point.
Confidential Property of Schneider Electric 61
Motor cables and EMC
Shield Connections – Skin Effect (Frequency dependent Skin depth δ at a Copper Cable)

Frequency δ
50Hz 9,38mm
60Hz 8,57mm
1kHz 2,10mm
5kHz 0,94mm
10kHz 0,66mm
50kHz 0,30mm
100kHz 0,21mm
500kHz 94 µm
1MHz 66µm
10MHz 21µm
100MHz 6,6µm
1GHz 2,1µm
10GHz 0,7µm
100GHz 0,2µm
Confidential Property of Schneider Electric 62
Motor cables and EMC
Shield Connections – Cable Gland

Confidential Property of Schneider Electric 63


Motor cables and EMC
Shield Connections – How to connect on the right Way

Confidential Property of Schneider Electric 64


Confidential Property of Schneider Electric 65
Confidential Property of Schneider Electric 66
Questions - Basics
What does PWM mean?
Pulse width modulation
What are the advantages/disadvantages of shielded cables?
Shielded cables reduce the disturbances in the environment,
but increase the leakage current which means than we have
limited cable length compared to unshielded cables!

What is the difference between TN and IT-Systems?


TN: Terra – Neutral
The transformer star point is grounded and the neutral and PE
are connected to the application by a cable
IT: Isolated – Terra
The transformer star point is isolated and the application
is connected to ground.
An insulation monitoring device will detect a leakage in the system.
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Offer Overview – ALTIVAR Process
Products and Drive Systems

Products Products Drive Systems


MCP – Motor Control Products FSP– Floor Standing Products MCE – Motor Control Equipment

Offer presentation Offer presentation


• Dedicated offer for Water (Utilities) • 110 up to 315kW Worldwide offer
• 0,75 up to 160kW • Drive System based • 110kW up to 800kW
• IP21 / Nema Type 1 • Without extension option • Modular design
• IP55 / Wall mount • IP21 / IP54 solutions based on bricks

• Low Harmonic Drive 30 to 90kW

Configurable with
standard options
• Circuit breaker
• Circuit breaker with
motor drive
• Low harmonic
• Control options
• Light options
• Output filters
• 12-puls supply

Confidential Property of Schneider Electric 70


Offer Overview
Commercial Reference

ATV 660 C 11 Q4 X 1
Products (wide voltage range)
ATV Altivar M3 200V (208 … 240V)
N4 400V (380 … 480V)
S6 600V (500 … 600V)
Product Line 6xx (Utility) Y6 690V (500 … 690V)
610 Medium offer product
630 Standard product offer Drive Systems
640 Low Harmonic product offer Q4 400V (380 … 415V)
650 Harsh environment product offer R4 440V
660 Compact Drive Systems offer T4 480V (460V motor)
680 Low Harmonic Drive Systems offer N5 500V (500 … 525V)
X6 600V (575V motor)
Product Line 9xx (Industry) Y7 690V
930 Standard product offer
Power (value x factor for power rating)
940 Regernerative product offer
950 Harsh environment product offer Factor for power rating
960 Compact Drive Systems offer U power x 0,1
980 Regenerative Drive Systems offer D power x 1
990 Multi-Drive offer C power x 10
M power x 100
T power x 1000
Confidential Property of Schneider Electric 71
Offer Overview
Commercial Reference

ATV 660 C 11 Q4 X 1

Variants / Hardware design


-- Standard product
B Basic keypad
C Product w/o braking unit
E With switch
F Floor standing product ATV630 and ATV650
S For specific modifications (like step-up solution)
Z w/o keypad
X Drive Systems with possibility of additional options Local standards (Drive Systems)
Q Water-cooled 1 CE (European Conformity)
M Marine air cooled 2 UL (Underwriters Labratories)
L Marine water cooled 3 CCC (China Compulsory Certification)
4 India
5 Brasilia
D DNV (Det Norske Veritas)
A ABS (American Bureau of Shipping
B BV (Bureau Veritas)

Confidential Property of Schneider Electric 72


Size 6
Offer Overview – Product 55 – 75kW
110 – 160kW
Dimensions IP21 – 240V and 400V
Size 5
30 – 45kW
Power in grey = 240V 55 – 90kW
Power in blue = 400V
Size 4
15 – 22kW
30 – 45kW
Size 3
7,5 – 11kW
15 – 22kW 1155
Size 2
Size 1 5,5kW
0,75 – 4kW 7,5 – 11kW 922

0,75 – 5,5kW
673

546

405
320

203 231 232 271 322 374


144 173 211 226 290 300

4,7kg 7,7kg 14,3kg 28,7kg 58,5kg 80,0kg


Offer Overview – Product
Dimensions IP21 – 690V

Size 5
30 – 90kW
Size 3
2,2 – 22kW

546 922

232 322
211 290

Confidential Property of Schneider Electric 74


Offer Overview – Product
Dimensions IP55 – 380V-480V

Size A / B / C are IP55 housings for the drives in IP00 design. Size C
All dimensions are without load switch. 55 – 90kW
Size B
30 – 45kW

Size A
0,75 – 22kW

910

674 1250

298 340 375

250 290 345

Confidential Property of Schneider Electric 75


Offer Overview – Product
IP55 Housing

Example:
Size A could have a size 1, size 2 or size 3 inside (IP00: without the housing)
Size A Size B Size C
0,75 – 22kW 30 – 45kW 55 – 90kW
S1

S5
S4
S2

S3

Confidential Property of Schneider Electric 76


Offer Overview – Product
IP55 Housing -Drawings

Size A Size B & Size C

Confidential Property of Schneider Electric 77


Offer Overview – Product
New: High Temperature Limit – UVP (Unique Value Proposition)

The drives in the complete power range can be operated up to 50°C without de-rating and
up to 60°C with de-rating. The de-rating depends on the ambient temperature, the mounting
position and the switching frequency (see installation manual).
≥X ≥X

With top cover (IP21):


xx mm on each side
up to 50°C without de-rating

Without top cover (IP20):


Drives pushed together
up to 50°C without de-rating

Confidential Property of Schneider Electric Drive Systems can be operated up to 40°C without de-rating and up to 50°C with derating 79
Offer Overview – Product
Floor Standing Product IP21/IP54

IP54
IP21

Filter
pads

10%
(filtered)
100%
90%
Floor standing products are Drive Systems without any extension option.
Confidential Property of Schneider Electric 80
Offer Overview – Drive Systems
Motor Control Equipment – Design Concept

The Drive Systems are based on a “modular brick design” with a width of 222mm

There are 3 different type of bricks: Low harmonic brick

Inverter brick

Rectifier brick

Confidential Property of Schneider Electric 82


Offer Overview – Drive Systems
Motor Control Equipment – Design Concept – Inverter Brick

Inverter board IGBTs (U / V / W) Output current tansformer

Supply board

DC-Bus connections Active current balancing board DC-Link capacitors


Confidential Property of Schneider Electric 83
Offer Overview – Drive Systems
Motor Control Equipment – Design Concept – Rectifier Brick

Common DC-Bus connections Thyristor / Diode – Bricks

AC-Supply connections Snubber board

Confidential Property of Schneider Electric 84


Offer Overview – Drive Systems
Motor Control Equipment – Design Concept

With increasing required power there are more bricks in parallel.

1p... 110 – 160kW


2p… 200 – 315kW
3p… 355 – 500kW
4p… 560 – 630kW
5p… 710 – 800kW

1p
2p
3p
4p
5p
Confidential Property of Schneider Electric 87
Offer Overview – Drive Systems
Motor Control Equipment – Design Concept (e.g. 3p System)

dU/dt-Filter choke

Equal power units parallel


Inverter brick

DC-Bus bar

Low number of spare parts


Rectifier brick
due to the parallel connection

Power electronic fan

Line choke
Common design
from 110kW – 1500kW
Superfast fuses

AC-Bus bar
Offer Overview – Drive Systems
Motor Control Equipment – Design Concept (Example 400V-System)

For cost efficiency there are 3 different inverter bricks available (only 1 common spare part).

MCE- Power Range Inverter Bricks Rectifier bricks


Type [kW] [pcs x kW] [pcs x kW]
1p 110 kW 1 x 110 kW 1 x 160kW
1p 132 kW 1 x 132 kW 1 x 160kW
1p 160 kW 1 x 160 kW 1 x 160kW
2p 200 kW 2 x 110 kW 2 x 160kW
2p 250 kW 2 x 132 kW 2 x 160kW
110kW 132kW 160kW
2p 315 kW 2 x 160 kW 2 x 160kW
3p 400 kW 3 x 132 kW 3 x 160kW
One common rectifier brick for all drive systems.
3p 500 kW 3 x 160 kW 3 x 160kW
4p 630 kW 4 x 160 kW 4 x 160kW
160kW 5p 800 kW 5 x 160 kW 5 x 160kW

Confidential Property of Schneider Electric 89


Offer Overview – Drive Systems Most compact offer
on the market!
Motor Control Equipment - Frame Size Description (@400V) – IP23/IP54

1p 2p 3p 4p 5p
110-160kW 200-315kW 355-500kW 560-630kW 710-800kW

Confidential Property of Schneider Electric 90


Offer Overview – Drive Systems Most compact offer
on the market!
Motor Control Equipment - Frame Size Description (@400V) – IP23/IP54

1p 2p 3p 4p 5p
110-160kW 200-315kW 355-500kW 560-630kW 710-800kW

Confidential Property of Schneider Electric 91


Offer Overview – Drive Systems
Motor Control Equipment IP23/IP54

IP54
IP23

Filter
pads

10%
(filtered)
100%
90%

Confidential Property of Schneider Electric 92


Energy Efficiency
Stop and Go Function

The „Stop and Go“ function reduces the consumed energy when the motor is
stopped and the power supply of the drive is switched on

60% energy saving at stop (*) UVP


Altivar process switches off…
• Power section (rectifier, DC-Bus)
• Fans
STOP • Backlight of graphic keypad

• Stop & Go control


• Automatic when not running
• Through communication network
• Adjustable via a parameter

• 0.00 € additional investment


GO • no line contactor required
• no 24V external supply required
(*) above 22kW drives

Confidential Property of Schneider Electric 93


Harmonic Mitigation
Basic Architecture

Double DC choke for M3 and N4 products Single DC choke for Y6 products


DCL DCL

EMC EMC
Filter M Filter M
DCL

All Drive Systems have as standard already embedded line chokes


LC MC

EMC
Filter M

Confidential Property of Schneider Electric 94


Harmonic Mitigation
Chokes embedded as Standard

Perfect Harmonic mitigation embedded


@ 80% load • THDi < 44% @ full load
• THDi < 48% @ 80% load
• No Power Factor penalty
Other drives Altivar Process
THDi < 52% THDi < 48% • Line current < motor current
• Less transformer losses

Conditions:
• 230V/50Hz for 220/240V range
• 400V/50Hz for 400/480V range
• RSCE>120
• 80% of the motor load corresponds
to a usual sizing (pump design point)

Power quality to avoid penalties

Confidential Property of Schneider Electric 95


Control Electronics – ATV600 Advanced HMI
Overview
Basic HMI

One control electronic


for all drives
Confidential Property of Schneider Electric 100
Control Electronics – ATV600
Overview

Basic I/O terminal RJ45 Ethernet port

RJ45 Modbus port


for HMI and Computer
Sink-Ext-Source switch

Fieldbus and
I/O module slot I/O module slot

Confidential Property of Schneider Electric 101


Control Electronics – ATV600
Basic I/O-Terminal

> 6 digital inputs


> 2 STO (Safe Torque Off) – SIL3
> 3 analog inputs
> 3 relays
> 2 analog outputs
> 1 switch for configuration (Sink/Source)
> 3 RJ45 connectors for communication Removable connectors
(cabling memory)
> 1 color per I/O group
> Wire cross section 0,5mm²-1,5mm²
(relays 0,75mm²-1,5mm²)

Confidential Property of Schneider Electric 102


Control Electronics – ATV600
Safe Torque Off (STO) – Function and Signal Path

STO is a drive integrated function that ensures by a complex hardware circuit that
there is no torque on the motor.

2 STO inputs (STOA, STOB)


Hardware Hardware Hardware
Powerboard Gatedriver Power IGBT
Conformed Standards:
> IEC61508/IEC62061 SIL3

STOA

STOB
Input

Input
> PLe ISO13849-1

Feedback STOA

Feedback STOB
M
no torque

Software
Monitoring

Confidential Property of Schneider Electric 103


Control Electronics – ATV600
Expansion Cards
Slot A
> Slot A (right):
> Legacy communication options
> Advance Ethernet
> IO Standard
Slot B
> IO Relays

> Slot B (left):


> IO Standard
> IO Relays

> Control electronic size does not change (even with 2 expansion cards used)

It is not possible to use the same expansion card twice and


maximum one communication card is allowed
Confidential Property of Schneider Electric 104
Control Electronics – ATV600 – Drive Systems
Cabinet I/O in Drive Systems

The MCE has integrated I/Os for “Drive System Internal Functionalities”
additional to the “Standard Expansion Cards” in the control electronic.
Therefore the expansion cards are fully available for the customer.

> 10 digital inputs Relays

> 6 digital outputs (Linked to relays) Powerboard


with
„Integrated
> 2 digital outputs for drive I/O“
and cabinet fan control
Standard
MCE – Control panel Control
Electronics
Relays isolate the Power-
board
Control
Electronic
internal electronic SLOT B
Terminals

from the external signals Relays SLOT A

Terminals
Confidential Property of Schneider Electric 105
Advanced HMI Functionalities
IP65/Nema12
Improved graphic functions Real time clock
- QR-Code
- Trend graphics
- Energy meter HOME-Button

INFO-Button

Capacitive wheel

Screenshot-function (F1+F4)

HMI connectors
- Mini USB for file exchange with PC The display color
- RJ45-Modbus connector on the changes to red
bottom for comfortable HMI handling in fault status
during parametersetting

Backup battery
Confidential Property of Schneider Electric 107
Advanced HMI Functionalities
USB Fileserver

The USB port has 2 main functions:


> Download screenshot-files
> Upload program files (e.g. languages)

Confidential Property of Schneider Electric 108


Advanced HMI Functionalities
IP65/Nema12

It is not possible to connect


Computer and Drive at
the same time to the HMI

Confidential Property of Schneider Electric 109


Advanced HMI Functionalities
Parameter backup – Save Files on the HMI

With the function [File management]  [Transfer config file]


it is possible to save/load the actual configuration directly on/from the HMI.

File name renameable before saving


Download the files via USB to the computer

Confidential Property of Schneider Electric 110


Parameterizing
Menu Structure

Enter the Menu with the buttons „OK“, „ESC“ or „HOME“

Select with the wheel

New implemented into the software are tabs which can be selected via the function keys „F1“ – „F4“
There is a capacitive wheel to select and adjust parameters which can be used also
for navigation and adjustment by pushing the „arrows“
Confidential Property of Schneider Electric 111
Door Mounting Kit
IP65/Nema12 – for “Basic HMI” and “Advanced HMI”

> Easy installation through a 22mm hole


> RJ45/RJ45 adaptor for standard connection to the drive

Confidential Property of Schneider Electric 112


Questions – Offer Overview
What is the maximum number of parallel connected power units?
In the first step the maximum is 5, in the second step it will be
maximum 12 parallel connected power units.

What are the two inputs STOA and STOB used for?
They are certified Safe Torque Off inputs which ensure that the
frequency converter can’t produce any torque on the motor.
STOA switches the upper part of the inverter bridge off and
STOB switches the lower part of the inverter bridge off

What is the difference between Products and Drive Systems?


Products are wall mounted products without enclosure.
Drive Systems are drives in an enclosure design (Floor standing)
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Service
QR Code

The QR code gives you a direct link to the Schneider Electric support homepage
with dedicated information to your message on the HMI

QR-Code Scanner

Link:
http://go2se.com/web/guest/tpd
s/doc/troubleshooting_doc/ref=
ATV630U07N4/sn=4004000HL
441736006/ts=SCF5

Confidential Property of Schneider Electric 117


Service
Webserver

Confidential Property of Schneider Electric 118


Service
Webserver

In all Altivar Process drives is an embedded Webserver as a standard


which can be accessed via the embedded Ethernet port.

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Service
Webserver – Login

User data for the first login:


> User Name: ADMIN
> Password: ADMIN

If you forgot the password you can reset it with the parameter
[My preferences]  [Webserver]  [Reset EmbWeb Passw.]
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Service
Webserver – Password Change

After the first login you will be


asked to change the password
> As a standard we ADMIN
change it to „ADMIN123“
ADMIN123

ADMIN123

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Service
Webserver

The Webserver can be disabled with the parameter


[My preferences]  [Webserver]  [Enable FTPserver] (restart required)

If you forgot the password you can reset it with the parameter
[My preferences]  [Webserver]  [Reset EmbWeb Passw.]

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Service on Drive Systems
Brick Exchange Philosophy

> Replacement onsite only on subassembly level


(PCBA / brick exchange) to ensure a quick and sufficient repair.
> Bricks can be basically exchanged by 1 technician
For bricks heavier than 25kg (Inverter and AFE brick), a second person or a simple
lifting device is necessary for lifting
> Low number of different spare parts  Easy and low costs

Confidential Property of Schneider Electric 124


Service on Drive Systems
Fan Replacement and Control Panel Disassembling

> Easy fan replacement without disassembling other components


> Exchange within 5 minutes
> Direct access
> Plug in fan power supply
> Quick access for heat sink cleaning

> Plug in Terminals


> All internal and external signals and supplies to the control panel
are connected via plugs in connections that it is easy to remove it.
> Two “hooks” on the control panel makes it easy to remove it

> No special tools required for disassembling


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Service on Drive Systems
Fan Replacement and Control Panel Disassembling

> Easy fan replacement without


disassembling other components
> Exchange within 5 minutes
> Direct access
> Plug in fan power supply
> Quick access for heat sink cleaning

Confidential Property of Schneider Electric 126


Questions – Service Functions

What is the QR-Code for?


The QR-Code contains a link to a Schneider Electric Homepage
with useful information about the drive and fault messages

What can you do if you forget the Webserver password?


It is possible to reset the password by a parameter function:
[My preferences]  [Webserver]  [Reset EmbWeb Passw.]

Which components do you have to change in case of an IGBT fault?


It is only necessary to exchange the complete inverter brick.
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Parameter Settings on ATV600
Practical Work

Practical work on the demo devices

Confidential Property of Schneider Electric 130


Questions – Parameter Settings

What is “My menu”?


“My menu” is a menu in the “Simply Start” menu
which can be modified on the users demand.

What is the “Diagnostics” menu?


In the „Diagnostics“ menu you can find information about
errors and warnings and drive identification.
It is also possible to start automatic test procedures.

Can you set one of the function keys for “Local/Remote” function?
No! For the local remote function is a separate button on the HMI!
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Every Application is Special

Confidential Property of Schneider Electric 134


Commissioning of High Power Drives
Commissioning HHP drives includes also the transformer, cables, inverter, motor and application.
Please check the whole system before power up the inverter!

Confidential Property of Schneider Electric 135


Commissioning
…by Commissioning Procedure

1. Identification

2. Technical data

3. Equipment & documents used

4. Pre-commissioning

5. Commissioning

6. Documentation

7. Remarks

8. Commissioning certificate & acceptance of plant

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Commissioning
1. Identification

> Which drive do you have?


Altivar Process Altivar 61 / Altivar 71 Altivar 312 / Altivar 212

> For what kind of application is the drive used for?


Commissioning
1. Identification

> Transformer
> Power cables
> Variable speed drive
> Motor

Following information is necessary:


Type Ser. Nr. Manufacturer Year of production
FBX-E/24-20/T2 234784 Schneider Electric 2012

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Commissioning
2. Technical Data

> 2.1 Application requirements

Rated torque 2000Nm


Rated speed 1487rpm
Load characteristic square

Mechanical safety clutch gear shaft application


Max allowed torque 3000Nm 2800Nm 4000Nm >4000Nm => 2800Nm
Max allowed speed >2000rpm 2300rpm >2000rpm 1600rpm => 1600rpm
Min speed (if necessary)

If you take wrong values this will cause big problems


 high costs for Schneider Electric
The customer has to provide you the mechanical information
Confidential Property of Schneider Electric 139
Commissioning
2. Technical Data

> 2.2 Transformer

Prim. voltage 10 kV
Sec. voltage 690 V
Prim. current 195A
Sec. current level depending
Vector group Dd0
Apparent power 1290kVA

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Commissioning
2. Technical Data

> 2.4 Frequency converter

Nom. input voltage 690V


Nom. input current 300A
Nom. output voltage 690V
Nom. output current 290A
Line frequency 50Hz
Protection degree IP…

Confidential Property of Schneider Electric 141


Commissioning
2. Technical Data

> 2.5 Motor

Nom. power 315kW


Nom. voltage 690V
Nom. current 400A
Nom. frequency 50Hz
Nom. speed 1486rpm
Protection degree IP55
Star or delta Delta

PTC/PT100 for windings and/or bearings


Method of cooling:
Self cooled, forced liquid cooled or forced air cooled

Confidential Property of Schneider Electric 142


Commissioning
2. Technical Data

> 2.5 Motor Method of cooling:

> Self cooled


Max. air temp. 45°C

> Forced liquid cooled:


Liquid max. temp. 55°C
Liquid min. flow rate 1500l/h
Max. liquid pollution level xx ppm
Mixing ratio of water / glycol 60% / 40%

Confidential Property of Schneider Electric 143


Commissioning
2. Technical Data

> 2.5 Motor Method of cooling:

> Forced air cooled:


For protection you will need:
Nom. power 1,5kW
Nom. voltage 400V
Nom. current 2,3A
Nom. frequency 50Hz
Nom. speed 1484rpm
Protection degree IP55
Star or delta Delta
Max. air temp. 45°C

Confidential Property of Schneider Electric 144


Commissioning
3. Equipment and Documents used

> 3.1 Documents used

> All drive documents must be provided


For the drive itself and for all components which are supplied by another factory
(e.g. UPS supplied by APC)

> Assemble drawing, circuit diagram, manuals, mounting, others.

If there are no documents available on side, in case of a service intervention, after


years the downtime will rise because you have to organise the documents first!

Confidential Property of Schneider Electric 145


Commissioning
3. Equipment and Documents used

> 3.2 Equipment

Multimeter
Oscilloscope
mA-Source
Clamp-on ampere meter
Thermo camera
Others

Following information is necessary:


Type Ser. Nr. Manufacturer Last calibration
Fluke 187 12478 Fluke Mai 2012

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Commissioning
4. Pre-Commissioning

> 4.1 Preconditions for start up

> Auxiliary voltages & main voltage available and connected


> If the drive is liquid cooled, fill up the system

Following information is necessary:


Used for Required voltage Breaker/fuse at customers side
Main supply 690V 500A

Confidential Property of Schneider Electric 147


Commissioning
4. Pre-Commissioning

> 4.2 Preconditions for start up

> Bearing, gear oil and cooling water system available and connected
> In and outlets for cooling existing

Following information is necessary:


Required flow pressure min./ max temp. max. humidity
100l/min, 30000m³/h 1.5bar 0°C / 54°C 90%

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Commissioning
4. Pre-Commissioning

> 4.3 Check of main circuit

> Restore of transport connections (mechanical & electrical)


Motor, drive, application

> Check of insulation, that the tongue is proper installed and


that the screws are tightened correct

> Cables from transformer to the frequency converter


> Cables from frequency converter to motor
> Aux. voltage cables

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Commissioning
4. Pre-Commissioning

> 4.5 Check of inverter & motor - Mechanical and electrical assembly

> Check of mechanical damages


> Check if the interface is connected according to the wiring diagram
> Check grounding type (Inverter, motor, input transformer, cooling fan, control transformer,
transducer)
> Control electronics visually checked
> Power electronics visually checked

Confidential Property of Schneider Electric 150


Commissioning
5. Commissioning

> 5.1 Parameter setting / Auxiliary supply on (24V)

> Set all parameters in HMI or with SoMove (some parameters with WebServer)
Motor data, drive regulating data, etc.
All analogue/digital input and output settings (scaling, signal type)
Relevant application parameters: Speed ramp, Min speed, Max speed, etc.
User settings: Password, User type

Confidential Property of Schneider Electric 151


Commissioning
5. Commissioning

> 5.2 Start up with main supply

> Check if the drive charging was successful


DC voltage, Line voltage, Voltage indicator
> Sense of rotation of cooling pump and cooling fans on converter checked

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Commissioning
5. Commissioning

> 5.3 Start up with main supply

> Internal and external protection devices adjusted (if available)


Motor circuit breaker, time relays, door limit switch

> Test of all aux. equipment mounted/supplied in/from the converter


Cubical heating system, cubical light, motor heater, etc. (if available)

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Commissioning
5. Commissioning

> 5.4 Start up with main supply

> Check the interfaces for process control


1. Digital Signals
> Check the digital inputs

2. Analog Signals
> Check and scale analog signals

3. Fieldbus

> Slave adress / set actual values

Confidential Property of Schneider Electric 154


Commissioning
5. Commissioning

> 5.5 No load run

> You need the permission to start the motor without load
Motor fixed, uncoupled and nobody around the shaft

> Perform the “auto tuning” with a cold motor


Check if motor runs in right direction
Speed up to max. speed in local mode and check if the current and voltage is normal

> Check the remote control function


Start the inverter in remote control and
speed up to max. speed

Confidential Property of Schneider Electric 155


Commissioning
5. Commissioning

> 5.6 Load run

> The motor has to be coupled with the application


> You need the permission to start the motor with load
speed up slowly to max. speed and check the output current symmetry
Further you have to check if there are vibrations in the system
> Remote control function checked
> Final parameter adjustments

Confidential Property of Schneider Electric 156


Commissioning
6. Documentation

> Parameter files backup


Download the parameter file with SoMove
Save the configuration directly in the HMI

> Circuit Diagram


Document all changes in the circuit diagram with your name and date.

> Assembly drawing of the cubicle

> Other documents


Service Manuals etc.

Confidential Property of Schneider Electric 157


Commissioning
7. Additional Remarks

> Remark all open points after commissioning


Motor, Transformer, Cables, Cooling system, etc.

> Remark all issues which were not solved, but customer decided to go on
Buttons at motor were not installed, PLC bus communication not working, etc.

If there were any safety issues which can cause dangerous situations,
you have to stop the commissioning! You go on when the problems were solved.

Everybody has only one life.

Confidential Property of Schneider Electric 158


Commissioning
8. Certificate & Plant Acceptance

> After you have finished the commissioning handle over all documents to the customer

> After the final signature of the customer the normal lifecycle of the drive will start

> Be aware that the customer acceptance releases the last turn of payment

Confidential Property of Schneider Electric 159


Questions – Commissioning

Why is it important to know the cooling method of the motor?


It is not allowed to operate a motor long time at low speed,
if a motor is self cooled. At long time low speed operation
the motor can burn due to too less cooling.

Why is it useful to test the drive at a “No Load Run”?


During a “No Load Run” you can check noise, vibration and
unstable operation without coupled application.
If there are problems during “Load Run” you know
that it worked without application.

What is the most important thing during commissioning?


Safety!!!
Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Maintenance
Overview
> Inspection
> General visual check of the drive condition
> Pollution of door filter pad and the drive itself
> Check door gasket and cable inlet sealing
> Check if the wires and cables are tightened
> Check the wires and cables for visible insulation damages
> Measure the current symmetry on the input and output
> Ensure spare part availability and their condition

> Clean (if necessary)


> Clean the door filter pad
> Clean the drive
> Clean the heat sink of the drive

> Exchange
> Power electronic fans after 40.000 hours
> Change door filter pad depending on the pollution

Confidential Property of Schneider Electric 162


Reforming Process

If you have devices with capacitors, not on power for a longer time you have to do a
„Reforming Process“ before you can use them.
Otherwise you can or will damage the equipment.
Un
100%

If there was no power for…

Ready for operation


75%
< 1 year Switch on directly
50% 1-2 years Switch on the nominal voltage for 1 hour
and than you can use it
25% > 2 years Perform reforming process before usage

t (t1 = t2 = t3 = t4 = 30min.)
t1 t2 t3 t4

Confidential Property of Schneider Electric 164


Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
Troubleshooting on Altivar Process
Automatic Test Procedures

The Altivar Process has 6 automatic test procedures integrated which are accessible
via HMI, SoMove and WebServer
> Supply power diagnostic
> Led’s diagnostic
> IGBT diagnostic with motor
> Supply control diagnostic
> IGBT diagnostic without motor
> Fan diagnostic
Troubleshooting on Altivar Process
Automatic Test Procedures – LED and Supply Control Diagnostic

LED diagnostic test


> All LEDs will be switched on for 1s
> All LEDs will be switched off for 1s

> Visual check by the technician

Supply control diagnostic:


During the automatic test procedure the drive tests the internal power supply levels and
shows the result in the „Service section“ of SoMove.

Confidential Property of Schneider Electric 167


Troubleshooting on Altivar Process
Automatic Test Procedures – Fan Diagnostic

> Software function to force the fan control


> [5 Complete settings]  [5.12 Maintenance]  [Fan management]
 [Fan mode]  „Standard“ or „Always“

> Fan types:


> 24VDC-Fans (Product)
> 48VDC-Fans (Drive System)

> Automatic test procedure


> The drive will run the fans for 30s
> Then it will check the fan speed and will indicate which fan has a problem
> Fan will be stopped and has to be at 0rpm after 10s
Confidential Property of Schneider Electric 168
Troubleshooting on Altivar Process
Automatic Test Procedures - New Thyristor / Transistor Test Procedure

> Thyristor test


> …faster test procedure

> …discharges the DC-Bus on the motor

> Transistor test procedure (IGBT-Test)


>Clear test feedback
>Test is also without motor possible
>Step by step transistor test possible (Automatic and manual trigger)
(U upper ON  U lower ON  V upper ON  …)

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Service Instructions
Fault Messages, Troubleshooting …

The ATV600 service instruction supports a lot of information


about fault massages and steps of troubleshooting

XXX: Fault code and name Automatic Restart: Yes / No


Principle • Describes the principle of the fault (how it works)
Probable cause • A list of different possibilities for that fault message

Remedies • Hints to solve the problem (what you can do to solve


this problem)
Field report • If there is an experience from the field with strange
reasons for that fault it will be mentioned in that column

Confidential Property of Schneider Electric 173


Fault Reasons
Why do Frequency Converters have Problems?
Incorrect parameters
Damages on External (Emergency operation)
Terminals incorrectly used
devices (BU, Bus, …)
Permanent operation
Motor Bypass (or DY) above the specification
Transport
damage
Harsh environment Damaged motor
or cables
Conductive
Wire strand in the drive components

Incorrect spare part


Humidity
Unprofessional
Mechanical problems repairing

End of lifetime (Years) Early component fault

Animals NO TRAINING Dust


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Fault Reasons
Components inside the drive

Confidential Property of Schneider Electric 175


Fault Reasons
Conductive Dust

Confidential Property of Schneider Electric 176


Fault Reasons
Environmental Conditions

Confidential Property of Schneider Electric 177


Fault Reasons
Aggressive Air

Confidential Property of Schneider Electric 178


Fault Reasons
High Humidity

Confidential Property of Schneider Electric 179


Fault Reasons
Loosen Screws

Confidential Property of Schneider Electric 180


Fault Reasons
Loosen Screws

Confidential Property of Schneider Electric 181


Fault Reasons
Loosen Screws

Confidential Property of Schneider Electric 182


Fault Reasons
Unprofessional Connection

Confidential Property of Schneider Electric 183


Fault Reasons
Unprofessional Handling

Confidential Property of Schneider Electric 184


Fault Reasons
Unprofessional Connection

Confidential Property of Schneider Electric 185


Fault Reasons
Unprofessional Repair – Loosen Screws

Confidential Property of Schneider Electric 186


Fault Reasons
Unprofessional Repair – Loosen Screws

COOL WARM HOT


Confidential Property of Schneider Electric 187
Fault Reasons
Wire Strand between two Connections

Confidential Property of Schneider Electric 188


Fault Reasons
Animals in the VSD

Confidential Property of Schneider Electric 189


Fault Reasons:
Animals in the VSD

Confidential Property of Schneider Electric 190


Fault Reasons
Animals in the VSD

Confidential Property of Schneider Electric 191


Fault Reasons
Animals in the Cubicle

Confidential Property of Schneider Electric 192


Fault Reasons
Transport Damage

Confidential Property of Schneider Electric 193


Fault Reasons
Wrong Overcurrent Setting of M.V. Curcuit Breaker

Confidential Property of Schneider Electric 194


Fault Reasons
Wrong Spare Parts

Confidential Property of Schneider Electric 195


Fault Reasons
Unprofessional Handling

Confidential Property of Schneider Electric 196


Fault Reasons
No Fuses

Confidential Property of Schneider Electric 197


Fault Reasons
Harsh Environment

Confidential Property of Schneider Electric 198


Fault Reasons
Harsh Environment

Confidential Property of Schneider Electric 199


Watercooled Drive… without Words

Confidential Property of Schneider Electric 200


Analyze
Analytical Approach

Fault localization

Device External Device Internal

Chemical Problem Mechanical Problem Subsequent Fault Worthy to Repair Not Worthy to Repair

• Aggressive air • Bearing (grease) • ext. harmonic filter • Fans • Completely burned drive
• Conductive dust • Coupling • Cable short-circuit • Control electronics • Massive arc flashes
• High humidity • V-belts • Indirect lightening • Keypad • Transport damage
• Oily air • Vibrations • Fieldbus problems • Option cards • Exploded components
• Grime • Cooling system • Current transformer • Liquid inside the drive
• Fine dust (<20um) • Printed circuit boards

Consider that the


frequency converter is the most „intelligent device“ in the system
Therefore it recognizes also problems at the mechanical and electrical components which are
connected to the drive. The customer often recognizes an external problem as a drive problem.
Confidential Property of Schneider Electric 201
Analyze
Analytical Approach

Fault reasons

Commissioning Normal operation

>97% customer problems <3% factory related problems Environmental conditions System changes Real drive faults

• Transport damages • Semi conductor damage • Aggressive air • Parameters changed • Statistic
component fault
• Incorrect or bad cabling • Quality issues • Conductive dust • Motor changed
• Fans
• Control wiring • Production mistake • High humidity • Application changed
• Power electronics
• Mechanical problems • Main voltage issues • More drives on supply
• Control electronics
• EMC problems • Mechanical problems • Repair on the drive
• Cooling system
• Cooling system • EMC • PLC program changed

If the problem occurs during commissioning you can focus more on customer problems.
At problems during long time operation you have to ask the customer for system changes.

Confidential Property of Schneider Electric 202


Analyze
Analytical Approach

Inspection of the whole system

Search without voltage Search with voltage

• Visual check Without motor // „pulse lock“ Without motor // „run“ With motor

• Fuses
• Measure the input voltages • Check the line voltage • Thyristor test – “faster”
• Circuit breaker
• DC-VOLTAGE including • Measure the pulses on the (discharging at the motor)
• Short-circuit in the DC-link
symmetry at the capacitors drive output (U/V/W) • IGBT test with motor
• Diode measurement
• Analysis via LEDs • Analysis via LEDs • Input voltage
• Thyristor measurement including gate
• Fault memory • Start test procedures in the • Input current
• Inverter measurement (IGBTs)
[Diagnostics] – menu • Motor voltage
• Charging circuit
• Motor current
• Motor isolation

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Analyze
Steps of Troubleshooting

Search for the fault

Search for the reason for the fault

Exchange the defect part

Protect the drive against the same fault

Restart the system

Confidential Property of Schneider Electric 204


Think first … than change!

Confidential Property of Schneider Electric 205


Main voltage OFF
Analyze Motor disconnected
Step 1: Visual Check (Check the complete System)

Confidential Property of Schneider Electric 206


Main voltage OFF
Analyze Motor disconnected
Step 2: Check the Fuses (do not secure immediately)

Important: You have to check all fuses!

Confidential Property of Schneider Electric 207


Main voltage OFF
Analyze Motor disconnected
Step 3: Check the Rectifier (DMM: Diode Measurement)

5 - 20Ω 0,3 – 0,5V

Confidential Property of Schneider Electric 208


Main voltage OFF
Analyze Motor disconnected
Step 3: Check the Rectifier (Thyristor Brick not in the Drive)

Build a circuit as shown in Close the switch: Open the switch:


the diagram and connect a The lamp starts to The lamp stays on until
battery with 4,5VDC illuminate you disconnect the battery
from the Anode

If you measure the gate resistance with a digital multimeter you


will get a value between 5Ω to 20Ω. (Gate to Cathode)
Confidential Property of Schneider Electric 209
Main voltage OFF
Analyze Motor disconnected
Step 4: Check the Inverter (DMM: Diode Measurement)

This measurement tests the DIODE (antiparallel connected to the transistor)!

0,25 – 0,6V

OL/locked 0,25 ... 0,6V


OL/locked * OL/locked *

OL/locked 0,25 ... 0,6V


OL/locked * OL/locked *

* In a built-in state, the measurement results can fluctuate between 0,25V and 0,6V as the components
at the Gate driver are also measured.
Confidential Property of Schneider Electric 210
Main voltage OFF
Analyze Motor disconnected
Step 5: Check the DC-Link for Short-Circuit

Important: You will measure a changing resistance


because you will charge the DC-Link
capacitors with the battery of the digital
Confidential Property of Schneider Electric
multimeter 211
Main voltage ON
Analyze Pulse inhabitation active
Step 6: Power up the Drive // Step 7: Check Fan Operation Motor disconnected

Switch on the mains voltage


> Check that the drive can’t start (Disable STO) before you switch ON
> Use a variable DC supply for the first power up (Connection between DC+ and DC-)
> If you have a Low Harmonic drive or an AFE in front of your motor inverter you have to start
the AFE to power up the drive. In this case remove the STO only of the inverter unit.
> Measure the actual DC voltage with your digital multimeter and compare it with the shown
value in the parameter “DC-Voltage”
VDC
After the DC-Link is charged you have to do following checks
> Red LED is on (more than 60VDC in the DC-Link)
LED does not exist in Drive Systems

Confidential Property of Schneider Electric 212


Main voltage ON
Analyze Pulse inhabitation active
Step 8: DC-Bus Symmetry Motor disconnected

VDC VDC

The two voltages from UD0 to DC+ and DC- must be UDC/2
The DC voltage must be Line voltage mulipied by √2 (in no load condition)

Confidential Property of Schneider Electric 213


Main voltage ON
Analyze Pulse inhabitation active
Step 9: IGBT Measurement Motor disconnected

VDC

The three voltages must be approx. 0 Volt


If not … there is a defect IGBT, PB, GD, MC…

Confidential Property of Schneider Electric 214


Main voltage ON
Analyze Pulse inhabitation active
Step 10: Fault History – [Diagnostics] – F1 „Diagnostic Data“ Motor disconnected

Main menu
„Diagnostic data“

Error history with


the last 15 errors

Warning history with


the active warnings
Confidential Property of Schneider Electric 215
Main voltage ON
Analyze Pulse inhabitation active
Step 10: Fault History – [Diagnostics] – F2 „Errors“ Motor disconnected

OK F1
„Help“

Confidential Property of Schneider Electric 216


Main voltage ON
Analyze Pulse inhabitation active
Step 10: Fault History – [Diagnostics] – F3 „Warnings“ Motor disconnected

OK

OK

OK

Confidential Property of Schneider Electric 217


Main voltage ON
Analyze Pulse inhabitation active
Step 11: LED Diagnosis Motor disconnected

Security advice
> The red LED 1 indicates the charging state of the DC link capacitors (> 60V DC)
Below 60V the red LED 1 is off, but also if it is not connected or damaged.

ATTENTION
Always measure the DC-Link
The LED could be disconnected or damaged

The capacitors still can be on power…even after several hours

Confidential Property of Schneider Electric 218


Analyze
Step 12: Thyristor Test Procedure (only with SoMove)

Depending on the power range the rectifier components


V1, V3 and V5 are diodes or thyristors
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Main voltage ON
Analyze Motor disconnected
Step 12: Thyristor Test Procedure (only with SoMove)

UDC+ T1 T2 T3
OK OK OK

DC/Bus voltage
during the
thyistor test

SCR1 fired

SCR2 fired

SCR3 fired
Discharging on
the motor
t
Main voltage ON
Analyze Motor disconnected
Step 12: Thyristor Test Procedure

L1 L2 L3

Voltage difference between


the two phases with the
highest and the
lowest voltage.

Green = Highest Difference


Blue = Smallest Difference

L2 L3 L1
Confidential Property of Schneider Electric 221
L1 L2 L3
Analyze
Step 12: Thyristor Test Procedure

L1/L2 L1/L3

L2/L1 L3/L1 6 pulses


L2 L3 L1 Current L1

In the diagram you can see 6 pulses during one input phase period.
Therefore a B6-rectifier bridge is also called 6 pulse rectifier
Main voltage ON
Analyze Motor disconnected
Step 12: Thyristor Test Procedure

L1 L2 L3

L1/L2 L1/L3

L2/L1 L3/L1

L2 L3 L1 Current L1
Confidential Property of Schneider Electric 223
Main voltage ON
Analyze Motor connected
Step 13: Transistor Test Procedure without Motor

Voltage measurement for short-circuit-Test

Confidential Property of Schneider Electric 226


Main voltage ON
Analyze Motor connected
Step 14: Transistor Test Procedure with Motor

Voltage measurement for short-circuit-Test


Current measurement for Open-Loop-Test

Confidential Property of Schneider Electric 227


Main voltage ON
Analyze Motor connected
Step 14: Transistor Test Procedure with Motor

? ? ? ?

Voltage measurement for short-circuit


Current measurement for IGBT-trigger test:
The IGBT Test will show „OPEN“ If the measured current is less than approximately 10% of the
drives rated current
Confidential Property of Schneider Electric 228
Main voltage ON
Analyze Motor connected
Step 14: Transistor Test Procedure with Motor

IGBT 1 IGBT 3 IGBT 5

IGBT 4 IGBT 6 IGBT 2

Confidential Property of Schneider Electric 229


Questions – Troubleshooting

How many errors are saved in detail and how many in the log-file?
The last 15 errors are saved in the fault history with details and
the last 500 errors are saved in the log file without details.

How does the new “Thyristor test” procedure work?


The drive switches off the thyristors and discharges the capacitors
by switching the output to the motor. Then it will charge the
DC-Link capacitors with “Thyristor 1”. After discharging again it will
charge the DC-Link capacitors with “Thyristor 2”. The same for “T3”

What is the difference between “IGBT test without motor” and “IGBT test with motor”?
The “IGBT test without motor skips the current measurement part of the test procedure.
Troubleshooting
Drive Systems
Component Location
Control unit

Inverterboard Supplyboard

Supplyboard Powerboard

DC-Bus Control electronics

Snubberboard

Customer terminals

Confidential Property of Schneider Electric 232


Drive Systems
Power Part – Size 1p

Input Output

Confidential Property of Schneider Electric 233


Drive Systems
Simplified Diagram – Size 1p

Digi Link (GG45)


4x 2 wires (twisted pairs)

4 wires STOA+B
2 wires transmit
2 wires receive

Input Output

Confidential Property of Schneider Electric 234


Drive Systems
Simplified Diagram – Size 3p

Input Output

Confidential Property of Schneider Electric 235


Digi-Link (8 wires on GG45):
Drive Systems 4 wires: STOA+B by hard wired
Internal supplies and communication 4 wires: Data exchange
(Current, voltage, Temperature,
1p 2p 3p Diagnostic signals, …)

Inverter Control
brick electronics

Power
electronic fans Control
panel
DC-Link

Rectifier
brick
Confidential Property of Schneider Electric 236
Charging Procedure
Drive Systems

The snubber board will control the thyristor in the rectifier bridge for the precharging process

Confidential Property of Schneider Electric 237


Offer Overview – Drive Systems
Motor Control Equipment – Design Concept – Inverter Brick

Inverter board IGBTs (U / V / W) Output current tansformer

Supply board

DC-Bus connections Active current balancing board DC-Link capacitors


Confidential Property of Schneider Electric 238
Offer Overview – Drive Systems
Motor Control Equipment – Design Concept – Rectifier Brick

Common DC-Bus connections Thyristor / Diode – Bricks

AC-Supply connections Snubber board

Confidential Property of Schneider Electric 239


PCB-Function
SPB – Supplyboard
LED 100 = +24VDC output (SPB OK)

Responsible for the internal


electronic power supplies

PCB is supplied by
external 24VDC or by the DC-Bus

Interconnection for the


power electronic fan
(+24VDC/-24VDC/Fan Feedback)

Confidential Property of Schneider Electric 240


PCB-Function
PB – Powerboard

Main board for the control part

Creates internal power supplies

Extension I/Os for Drive Systems

STO-Circuit from CMP6 to GD

Measurement circuits
(Motor voltage, DC-Bus voltage, Input voltage)

Confidential Property of Schneider Electric 241


PCB-Function
PB – Powerboard - LEDs

LED1200
5V source for internal

LED1100
+5V DC-Bus measurement supply

LED1101
+5V Motor voltage sense

LED1102
+5V Main voltage sense

LED1103
-5V Motor voltage sense

Confidential Property of Schneider Electric 242


PCB-Function
CMP6 – Communicatoin board (paralleling)

High speed communication board for the parallel


connected power sections (2x400MBit/s)

Communication between PB and IVBs

Current regulator for parallel connection

STO circuit from the PB to the Digi-Link

Always mounted on the powerboard

Confidential Property of Schneider Electric 243


PCB-Function
CMP6 – Communicatoin board (paralleling) – LEDs

LED102: Configuration of FPGA done

Brick 1:
LED800: Communication OK
LED801: Fault on the IVB - Communication Error
Brick 2: LED803, LED804
Brick 3: LED806, LED807
Brick 4: LED808, LED809
Brick 5: LED810, LED811
Brick 6: LED812, LED813

LED802 / LED805: Only for debugging purposes


Confidential Property of Schneider Electric 244
PCB-Function
PB including CMP6 – One spare part

The PB and the CMP6 are always


delivered together

Never change only 1 card

Confidential Property of Schneider Electric 245


PCB-Function
CMI1 – Communicatoin board (internal)

High speed communication board for each


power section (2x400MBit/s)

STO circuit from Digi-Link to IVB

LED102: Configuration of FPGA done


LED600: Communication error or fault on the IVB
LED601: Communication to CMP6 OK
LED602: CMI1 in configuration mode
LED603: Pulse inhibitation active

Confidential Property of Schneider Electric 246


PCB-Function
IVB – Inverterboard

> Main board on the Inverter Module

> Brick output current measurement

> Temperature measurement

> Transistor feedback detection


> Communication to the SNB
(rectifier brick)

> STO circuit from CMI1 to GD

> Fan feedback detection

Confidential Property of Schneider Electric 247


PCB-Function
IVB – Inverterboard – LEDs

LED900 +15V Current transformer


LED901 -15V Current transformer
LED500 +18V GD supply – phase U upper
LED600 +18V GD supply – phase V upper
LED501 +18V GD supply – phase W upper
LED502 +18V GD supply – phase U lower
LED601 +18V GD supply – phase V lower
LED503 +18V GD supply – phase W lower
LED700 +5V for general purpose
LED1800 Hardware + COM error
LED1801 Green: INDUS mode active
Yellow: CPLD software initialized
LED802 +5V for general purpose
LED801 +24V SNB supply
Confidential Property of Schneider Electric 248
PCB-Function
IVB including CMI1 – One spare part

The IVB and the CMI1 are


always delivered together

Never change only 1 card

Confidential Property of Schneider Electric 249


PCB-Function
RFI – Radio Frequency Interference Filter

Filter for RFI-Signals

Screw for IT/TN setting

Picks up the input voltage for the input


voltage measurement on the PB

Confidential Property of Schneider Electric 250


PCB-Function
SNB – Snubberboard

DC-Bus sensing for


„Thyristor test“

Soft charge circuit


Thyristor control circuit
Thyristor protection circuit

LED601 Charge command


LED602 Charging status
LED701 +5V for general purpose

Confidential Property of Schneider Electric 251


PCB-Function
ACB – Active Current Balancing Board

Balances the

Voltage on the

DC-Bus capacitors

Confidential Property of Schneider Electric 252


PCB-Function
GD including IGBT – Gate Driver Board soldered onto the IGBT (one Spare Part)

IGBT always delivered with the Gate Driver

Temperature sensor in the


IGBT housing integrated

IGBT control and


desaturation protection
Confidential Property of Schneider Electric 253
Drive System
Power Supplies and LEDs
Drive System
Power Supplies and LEDs

Supplyboard

Powerboard

Control electronics

Relays

Confidential Property of Schneider Electric 255


Drive System
Power Supplies and LEDs – IVB

Confidential Property of Schneider Electric 256


Drive System
Power Supplies and LEDs – IVB

Confidential Property of Schneider Electric 257


Fan Supply and Control – Drive Systems
External 48VDC-Supply

There are relays on the control unit (controlled by the powerboard) who will switch
the power electronic fans and the cubicle fans seperately

Confidential Property of Schneider Electric 258


Charging Procedure
Drive Systems

The snubber board will control the thyristor in the rectifier bridge for the precharging process

Confidential Property of Schneider Electric 259


Device Overview
Component Description – Drive Systems

> PB Power board


> SPB Supply board
> IVB Inverter board
> GD Gate driver board
> ACB Active current balancing board
> SNB Snubber board
> RFI Radio frequency interference filter board
> CB Control Board (Control electronic)
> MLB Brick link board

Confidential Property of Schneider Electric 263


Questions – Component details

What is the 48VDC supply used for?


The 48VDC supply is used for the power electronic and cubicle fans.

Is it allowed to change only the CMI1 board?


No! The CMI1 and the IVB are always together because
they have to be calibrated to each other. Never change only
one of these boards.
The same is also for CMP6 and PB_DS

Which parts are already included in the IGBT?


The IGBT always comes with the GD on it. Inside the
IGBT is already a temperature sensor integrated
Troubleshooting
Spare Parts
Spare Part Policy – Definition

> Spare parts:


Due to safety reasons spare parts must be used only by SE or SE certified partners.
All spare parts are managed via MRO.
> Maintenance: standard MRO lead time
> Troubleshooting: MRO service plus lead time
Dedicated spare parts: Control electronic, IGBT, rectifier bridge, PCBA’s

> Ware parts:


Parts that can be changed by the customer (exchange procedure is described in user manual)
> Available via the standard SE supply chain (IDC/RDC)
ATV process related ware parts: drive internal fans, door mounted fans, filter pads

> Standard catalog components:


Schneider Standard components inside MCE are not part of the spare part offer.

Standard Schneider components: motor circuit breakers, contactor, relays

Confidential Property of Schneider Electric 267


Spare Parts
Spare Part Policy for Products
- Standard exchange by a new drive - Exchange on component level
- Control electronics and - Control electronics…
fans (ware part) available - Power electronic components…
- Ware parts…

Size 1 Size 2 Size 3 Size 4


0,75 – 5,5kW 5,5 – 7,5kW 11kW 15 – 22kW
0,75 – 4kW 7,5 – 11kW 15 – 22kW 30 – 45kW

Power in grey = 240V


Power in blue = 400V
Confidential Property of Schneider Electric 268
Spare Parts
Spare Part Policy for Products
- Exchange on component level - Exchange on brick level
- Control electronics… - Rectifier and inverter bricks
- Power electronic components… - PCB’s
- Ware parts… - Ware parts (power electronic fans, enclosure fans)

Size 5 Size 6 Floor standing product


22 – 75kW 110 – 160kW 110 – 315kW
55 – 90kW

Power in grey = 240V


Power in blue = 400V
Confidential Property of Schneider Electric 269
Spare Parts
Spare Part Policy for Drive Systems
- Exchange on brick level for 1p-5p and 1a-5a
- Rectifier and inverter bricks
- PCBA’s (control electronic / filter boards)
- Ware parts (power electronic fans, enclosure fans)

1p 2p 3p 4p 5p
110-160kW 200-315kW 355-500kW 560-630kW 710-800kW

Confidential Property of Schneider Electric 270


Contents
Safety
VSD Basics
Offer Overview
Service Functions
Parameter Settings
Commissioning
Maintenance
Troubleshooting
Software
SoMove – Diagnostic Service Section
Diagnostic Tool – Embedded Service Functions

> Software:
> Easy PC-Connection via RJ45-Port
(Ethernet and Modbus)

Confidential Property of Schneider Electric 273


SoMove – Diagnostic Service Section
Diagnostic Tool – Embedded Service Functions

Locate Device function:


> By activating this function the drive will switch the Status-LED for 5 seconds to orange.
So it is possible to check if the connected drive is the right one in a network.

“Locate Device”
switches the
“Status-LED”
to orange.

Confidential Property of Schneider Electric 274


SoMove – Diagnostic Service Section
Diagnostic Tool – Embedded Service Functions

Only trained and certified people on Altivar Process will have access.

Dedicated service function integrated in SoMove


> Diagnostic parameters
> Drive counters
> Drive auto-tests
> Report generation
> Log files
Confidential Property of Schneider Electric 275
SoMove – Diagnostic Service Section
Diagnostic Tool – Embedded Service Functions

> A dedicated service tool will allow access to services features


> Diagnostic parameters
> Drives counters
> Drives auto-tests
> Reports generation
> Log files

> Only trained and certified people on Altivar Process will have access
> One licensing used to manage password and license rights to certified people
> The tool will not be for sale.

Confidential Property of Schneider Electric 276


Troubleshooting on Altivar Process
Temperature Sensor Measurement

For Altivar Process drives there is a new function integrated in SoMove which enables
a detailed diagnostic of each temperature sensor in drives and drive systems.

Confidential Property of Schneider Electric 278


Troubleshooting on Altivar Process
Easy Diagnostic – SoMove - [Diagnostics] – [Summary]

Confidential Property of Schneider Electric 279


Troubleshooting on Altivar Process
Easy Diagnostic – SoMove - [Diagnostics] – [Errors]

Confidential Property of Schneider Electric 280


Troubleshooting on Altivar Process
Easy Diagnostic – SoMove - [Diagnostics] – [Errors]

Real time clock enables a clear feedback

Last 15 faults are saved with details

Last 500 faults are saved in a log file without details

Confidential Property of Schneider Electric 281


Troubleshooting on Altivar Process
Easy Diagnostic – SoMove - [Diagnostics] – [Active Warning] / [Warning History]

The „Warning History“ saves the


last 15 warnings
Confidential Property of Schneider Electric 282
Troubleshooting on Altivar Process
Easy Diagnostic – SoMove - [Diagnostics] – [Warning Groups]

It is possible to assign the warnings to


multiple “Warning Groups” by
pushing the setting button

Active warning with „warning group“ assignment.

Confidential Property of Schneider Electric 283


Troubleshooting on Altivar Process
Easy Diagnostic – SoMove - [Services] – Hidden Service Section

The hidden “Services” tab can be activated by


the hotkey combination “Ctrl” + “Alt” + “R”

Actual values from the drive

Integrated test procedures

Maintenance and Service Report

Error history and Service log file

Possibility to change the drive identification


Confidential Property of Schneider Electric 284
Firmware Update
Easy via standard Interface

The „KalaFlashTool“ enables a quick and easy firmware upgrade via the modbus and
ethernet port without software installation and without special tools.
The firmware will be provided in a „ZIP-file“ with all required and compatible files.

TCP/IP
 Class C IP @ TCP/IP
 ex: IP @ 192.168.0.1  will be configured by the tool
 ex: IP Mask 255.255.255.0  IP @ 192.168.0.10
 IP Mask 255.255.255.0
24V OR
Power By
Main

TCP

RS485

Confidential Property of Schneider Electric 285


Firmware Update – Advanced Keypad
Software Package File

The software will be provided in a


ZIP-file with all required files for the update
You have to unzip the file
before you continue UNZIP

> The folder “UMAS”


contains the language files and screens

> The file “Hyp_Keypad_adv.*******.mot” is the firmware file for the keypad

Confidential Property of Schneider Electric 286


Firmware Update – Advanced Keypad
Flash Development Toolkit

Switch the “Programming


Adapter” to “PROGRAMMING”.
The flashkit (excl. 12V supply)
can be ordered in Vienna
(SEPD) with the number
8K00121

Connect the HMI with the


“Programming Adapter” to the
computer (Serial connection) and
supply it with the 12VDC supply
12VDC
 The HMI display must stay off
Confidential Property of Schneider Electric 287
Firmware Update – Advanced Keypad
Flash Development Toolkit

Start “Flash Development Toolkit 4.08“ (Not the “Basic” version)

Keep the setting “Create new


project workspace” and click “OK”

Confidential Property of Schneider Electric 288


Firmware Update – Advanced Keypad
Flash Development Toolkit

Enter a “Workspace Name” Select “Generic BOOT Device”

Confidential Property of Schneider Electric 289


Firmware Update – Advanced Keypad
Flash Development Toolkit

Select the COM-Port of your connection Confirm the warning message

Select “RX600 Series (Little Endian)”

Confidential Property of Schneider Electric 290


Firmware Update – Advanced Keypad
Flash Development Toolkit

Enter the Device Settings

CPU crystal frequency 8MHz


Multiplier for main clock frequency (CMK) 8
Multiplier for peripheral clock frequency (CKP) 4

Confidential Property of Schneider Electric 291


Firmware Update – Advanced Keypad
Flash Development Toolkit

Right click

Set 115200bps

Confidential Property of Schneider Electric 292


Firmware Update – Advanced Keypad
Flash Development Toolkit

Select the file from


the software package

Confidential Property of Schneider Electric 293


Firmware Update – Advanced Keypad
Flash Development Toolkit

Right click

The progress bar shows the status of the flashing procedure


Confidential Property of Schneider Electric 294
Firmware Update – Advanced Keypad
Flash Development Toolkit

The message

“Image written to device”


shows a successful

flashing procedure

Confidential Property of Schneider Electric 295


Firmware Update – Advanced Keypad
Update the Language and Configuration Files

Copy the files from the folder “UMAS” to the Keypad folders
and overwrite all existing files via the USB connection

Confidential Property of Schneider Electric 296


Firmware Update – Advanced Keypad
Update the Language and Configuration Files

If it happens that the HMI writes “Files incompatible” on the display while
connecting it to the drive you have to format the USB-Memory on the HMI and
copy the UMAS-Files again.

Format USB memory

If the computerdoes not recognize the HMI as a USB-Memory you have to


re-flash the HMI with the “Flash Development Toolkit”
Confidential Property of Schneider Electric 297
FAQ
©2014 Schneider Electric. All Rights Reserved.
All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective owners.

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