Curso Altivar
Curso Altivar
Curso Altivar
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
High pressures from an Arc Blast can rupture ear drums, collapse lungs,
explode the switchgear and destroy a wall 3 meters away
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
1. De-energize
…by switching off all power supplies.
FRONT
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
NEVER
A SCHNEIDER ELECTRIC FSE
Cathode
Anode
Confidential Property of Schneider Electric 27
VSD Principle
Thyristor
Cathode
Gate
Anode
Confidential Property of Schneider Electric 28
VSD Principle
Capacitor
Collector
Gate
Emitter
Confidential Property of Schneider Electric 30
VSD Principle
Rectifier
L1 L2 L3
L1/L2 L1/L3
L2/L1 L3/L1
L2 L3 L1 Current L1
Confidential Property of Schneider Electric 33
VSD Principle
IGBT – Inverter Bridge
UDC+
Voltage pulses
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
> 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
Earthing Systems:
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
TN-Earthing System:
> The electrical device is connected with earth via the transformer.
TN-Earthing System:
> TN-C Earthing System
L1
L2
L3
PEN
PE
L1 L2 L3 N
TN-Earthing System:
> TN-S Earthing System
L1
L2
L3
N
PE
PE
L1 L2 L3 N
TN-Earthing System:
> TN-C-S Earthing System
L1
L2
L3
N
PEN PE
PE
L1 L2 L3 N
L1
L2
L3
N
PEN PE
PE
L1 L2 L3 N
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
L1
L2
L3
PE
L1 L2 L3
Cable duct
> 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
Configurable with
standard options
• Circuit breaker
• Circuit breaker with
motor drive
• Low harmonic
• Control options
• Light options
• Output filters
• 12-puls supply
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
0,75 – 5,5kW
673
546
405
320
Size 5
30 – 90kW
Size 3
2,2 – 22kW
546 922
232 322
211 290
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
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
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
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
Inverter brick
Rectifier brick
Supply board
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
DC-Bus bar
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).
1p 2p 3p 4p 5p
110-160kW 200-315kW 355-500kW 560-630kW 710-800kW
1p 2p 3p 4p 5p
110-160kW 200-315kW 355-500kW 560-630kW 710-800kW
IP54
IP23
Filter
pads
10%
(filtered)
100%
90%
The „Stop and Go“ function reduces the consumed energy when the motor is
stopped and the power supply of the drive is switched on
EMC EMC
Filter M Filter M
DCL
EMC
Filter M
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)
Fieldbus and
I/O module slot I/O module slot
STO is a drive integrated function that ensures by a complex hardware circuit that
there is no torque on the motor.
STOA
STOB
Input
Input
> PLe ISO13849-1
Feedback STOA
Feedback STOB
M
no torque
Software
Monitoring
> Control electronic size does not change (even with 2 expansion cards used)
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.
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
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”
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
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
If you forgot the password you can reset it with the parameter
[My preferences] [Webserver] [Reset EmbWeb Passw.]
Confidential Property of Schneider Electric 120
Service
Webserver – Password Change
ADMIN123
If you forgot the password you can reset it with the parameter
[My preferences] [Webserver] [Reset EmbWeb Passw.]
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
1. Identification
2. Technical data
4. Pre-commissioning
5. Commissioning
6. Documentation
7. Remarks
> Transformer
> Power cables
> Variable speed drive
> Motor
Prim. voltage 10 kV
Sec. voltage 690 V
Prim. current 195A
Sec. current level depending
Vector group Dd0
Apparent power 1290kVA
Multimeter
Oscilloscope
mA-Source
Clamp-on ampere meter
Thermo camera
Others
> Bearing, gear oil and cooling water system available and connected
> In and outlets for cooling existing
> 4.5 Check of inverter & motor - Mechanical and electrical assembly
> 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
2. Analog Signals
> Check and scale analog signals
3. Fieldbus
> You need the permission to start the motor without load
Motor fixed, uncoupled and nobody around the shaft
> 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.
> 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
> Exchange
> Power electronic fans after 40.000 hours
> Change door filter pad depending on the pollution
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%
t (t1 = t2 = t3 = t4 = 30min.)
t1 t2 t3 t4
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
Fault localization
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
Fault reasons
>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.
• 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
0,25 – 0,6V
* 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
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)
VDC
Main menu
„Diagnostic data“
OK F1
„Help“
OK
OK
OK
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
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
L2 L3 L1
Confidential Property of Schneider Electric 221
L1 L2 L3
Analyze
Step 12: Thyristor Test Procedure
L1/L2 L1/L3
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
? ? ? ?
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.
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
Snubberboard
Customer terminals
Input Output
4 wires STOA+B
2 wires transmit
2 wires receive
Input Output
Input Output
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
Supply board
PCB is supplied by
external 24VDC or by the DC-Bus
Measurement circuits
(Motor voltage, DC-Bus voltage, Input voltage)
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
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
Balances the
Voltage on the
DC-Bus capacitors
Supplyboard
Powerboard
Control electronics
Relays
There are relays on the control unit (controlled by the powerboard) who will switch
the power electronic fans and the cubicle fans seperately
The snubber board will control the thyristor in the rectifier bridge for the precharging process
1p 2p 3p 4p 5p
110-160kW 200-315kW 355-500kW 560-630kW 710-800kW
> Software:
> Easy PC-Connection via RJ45-Port
(Ethernet and Modbus)
“Locate Device”
switches the
“Status-LED”
to orange.
Only trained and certified people on Altivar Process will have access.
> 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.
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.
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
> The file “Hyp_Keypad_adv.*******.mot” is the firmware file for the keypad
Right click
Set 115200bps
Right click
The message
flashing procedure
Copy the files from the folder “UMAS” to the Keypad folders
and overwrite all existing files via the USB connection
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.