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Cell Control Board - 10000432

MicroHarmony Cell Sizes 40 - 260A Manual

5-6

19001467: Version 1.0

s

5

Notes:

1.

These conditions generate a Cell Fault which disables all output IGBTs and is annunciated by Down Bit 2 in
Mode 00

2.

These conditions do not generate a Cell Fault and can only be monitored by Down Bit packet in Mode 00

3.

These conditions can only be monitored in the Non Run Mode 11 and are for cell diagnostic purposes only.

5.6 Communication

The cell control board communicates to the Perfect Harmony control system via a duplex fiber optic cable on a
proprietary communication protocol. See Chapter 11,

Communication Protocol

, for details.

∇

∇

∇

Communication
Fault

1

CMFLT

This is complimentary meaning of LINK ON, which is displayed on CCB
by means of LED lamp. Therefore, if LINK ON is off then CMFLT is
active. CMFLT becomes active after either parity error occurred or QValid
from EPLD is not active. CMFLT is active low.

Cell Protection

CCB Board

Ref. Signal

Description and Thresholds

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Summary of Contents for Eupec

Page 1: ...Large Drives A ROBICON 500 Hunt Valley Road New Kensington PA USA 15068 Phone 724 339 9500 Customer Support Phone 724 339 9501 24 hours Fax 724 339 9562 Customer Support Fax 724 339 9507 Web Customer Support E mail documentcontrol siemens com MICROHARMONY CELL SIZES 40 260A MANUAL www robiconperfectharmony com ...

Page 2: ...0424 040 70A BOM 10000424 070 100A BOM 10000424 100 140A BOM 10000424 140 200A BOM 10000494 200 260A BOM 10000494 260 40 140A Assembly D10000424A ALL 40 140A Schematic D10000424S ALL 200 260A Assembly D10000494A ALL 200 260A Schematic D10000494 S ALL Production Test Specification TSI 062 Ratings and Test Parameters TSF 058 Repair Test Specification TSI 063 Traceability Standard QSF 013 Wiring Prac...

Page 3: ...nk Design 1 5 Enclosure 1 5 Increased input voltage rating 1 5 Multiple Sources 1 5 Simple Design 1 5 Electrolytic Capacitors with Plastic Mounting Tray 1 5 Chapter 2 Physical Description 2 1 Mechanical Specifications 2 1 Connections 40 260A 2 2 Environmental Specifications 2 2 40 140A Outline 2 4 200 260A Outline 2 5 Access and Connections 2 6 Indicators and Labels 2 7 Key Components 2 8 Bill of ...

Page 4: ...res 5 1 Outline Mounting and Connections 5 1 Power Supply 5 2 Gate Drive 5 3 Typical Gate Drive Circuit 5 3 Gate Drive Propagation Delay and Dead Time 5 3 OOS Detection Latch 5 4 Bus Voltage Sensing and Protection 5 4 Protection Features 5 5 Communication 5 6 Chapter 6 Gate Clamp Board 6 1 Chapter 7 Testing 7 1 Documents for Testing Cells 7 1 Testing Equipment 7 1 Required Tests 7 1 Chapter 8 Repa...

Page 5: ...s Output Current 9 8 Capacitor Losses vs Output Current 9 9 Total Cell Losses 9 10 Heat Sink Temperature Monitor 9 11 Exiting Air Temperature 9 14 Capacitors 9 14 Flammability 9 14 Shelf Life and Reforming 9 14 Failure Modes 9 15 Useful Life Calculations 9 15 Disposal 9 16 Output Voltage Capability 9 16 Normal Operation 9 16 Output Voltage capability after bypass 9 17 Example of calculating Drive ...

Page 6: ...3 Mode 00 Data 11 4 Modulator to CCB 11 4 CCB to Modulator 11 5 Mode 01 Data 11 6 Modulator to CCB 11 6 CCB to Modulator 11 6 Mode 10 Data 11 7 Modulator to CCB 11 7 CCB to Modulator 11 7 Mode 11 Data 11 8 Modulator to CCB 11 8 Device Testing 11 8 Device Test Control Data 11 8 CCB to Modulator 11 9 NOTES N 1 ...

Page 7: ...ements that is isolation is provided inside the instrument not provided by isolating the chassis ground of the instrument Never assume that switching off the input disconnect will remove all voltage from internal compo nents Hazardous voltage is still present on the terminals of the input disconnect Also there may be voltages present that are applied from other external sources Allow at least 5 8 ...

Page 8: ...When transporting the drive system the truck bed must be even and flat Before unloading be sure that the concrete pad is level for storage as well as permanent positioning ESD Sensitive Equipment IGBT gate emitter leads should be shorted when not installed in the cell or for transportation Avoid exposure to corrosive gases and dust Always be aware of electrostatic discharge ESD when working near o...

Page 9: ...ckness Excessive or inadequate compound application may cause an insufficient thermal connection between base plate and heat sink that may damage the cell Electrolytic capacitors are polarized Installing a capacitor with the incorrect polarity will damage the cell If cell sits idle for 6 months or more the capacitor bank requires reforming Failure to follow reforming procedures and guidelines may ...

Page 10: ...Safety Precautions and Warnings MicroHarmony Cell Sizes 40 260A Manual viii 19001467 Version 1 0 s ...

Page 11: ... MicroHarmony Cell The latest air cooled power cells are available in 6 frames 40A 70A 100A 140A 200A and 260A All cells in the 40 140A frame have an identical footprint and internal design Only the number of parallel capacitors and IGBT kit part numbers change from one cell to the next The same applies to the 200 260A frame Figure 1 2 40 140A Cell Anatomy Top Lid not shown CHAPTER 1 Cell Overview...

Page 12: ...Cell Overview MicroHarmony Cell Sizes 40 260A Manual 1 2 19001467 Version 1 0 s 1 Figure 1 3 200 260A Cell Anatomy Top Lid not shown ...

Page 13: ...d clockwise to pull the cell into place Once the latches are in the vertical position the cell is properly aligned and locked into place To remove the latches are pulled back down to the horizontal position High temperature foam forms an air tight seal between the cell chassis and backplane at the rear of the cell not shown 1 2 2 Rear Blind Mate Power Connections No hardware is required for making...

Page 14: ...perly 1 2 5 Cell Control Board A new cell control board based on the 10000092 series has been developed All MicroHarmony cells sizes 40 140A and 200 260A use the same part number cell control board This reduces parts inventory and allows the board to be purchased with all of the necessary resistor values and jumper settings This reduces labor costs 1 2 6 Gate Clamp Board A gate clamp board is inst...

Page 15: ... faulted cell protecting adjacent cells from any collateral damage The top of the cell can be removed for heat sink and capacitor access The bottom of the cell houses the cell control board and can be easily removed 1 2 10 Increased input voltage rating All MicroHarmony cells operate with a nominal 750Vrms input This allows a 9 cell system to produce a 4160V motor voltage with only 9 cells Overmod...

Page 16: ...Cell Overview MicroHarmony Cell Sizes 40 260A Manual 1 6 19001467 Version 1 0 s 1 ...

Page 17: ...stone Envelope Dimensions 13 496 W x 10 255 H x 22 086 D 342 8 x 260 48 x 560 98 mm Chassis Dimensions 12 62 W x 9 55 H x 21 77 D neglecting latches and bolt heads 320 55 x 242 57 x 552 96 mm Volume 2623 74 in 3 1 518 ft 3 4 3 m 3 90 866 pints 10000494 200 260 Weight 102 8 Lbs 46 63 kg 7 34 stone 112 6 Lbs 51 07 kg 8 04 stone Envelope Dimensions 13 998 W x 13 117 H x 25 885 D 355 55 x 333 17x 657 ...

Page 18: ...ontrol Connections Front access fiber optic Maximum Elevation 3300 FASL 1006 masl without de rating 6563 FASL 200masl MAX Maximum Ambient 45 C 113 F 318 15 K up to 60 C with de rating Note that over load and capacitor life are less above 40 C Storage Ambient 30 C 22 F minimum 60 C 140 F maximum Ambient Humidity High humidity 93 95 RH is not a concern unless there is a possibility of condensation f...

Page 19: ...0 0 18 0 12 175 0 25 0 17 200 0 32 0 22 225 0 41 0 27 250 0 51 0 34 275 0 61 0 41 300 0 73 0 49 325 0 86 0 57 350 0 99 0 66 375 1 14 0 76 400 1 30 0 86 Air Flow vs Pressure Drop 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 Air Flow ft 3 min Pressure drop inH2O 40 140A R 8 1E 6 200 260A R 5 39E ...

Page 20: ...ical Description MicroHarmony Cell Sizes 40 260A Manual 2 4 19001467 Version 1 0 s 2 2 4 40 140A Outline Refer to Installation Section for mounting and bus connection information Figure 2 1 40 140A Outline ...

Page 21: ...MicroHarmony Cell Sizes 40 260A Manual Physical Description 19001467 Version 1 0 2 5 s 2 2 5 200 260A Outline Figure 2 2 200 260A Outline ...

Page 22: ...ntrol board and power electronics can be accessed and tested at the same time by rotating the cell 90 as shown removing the chassis top cover and a trap door at the base of the cell chassis The cell can be tested in either position however all open areas that are usually covered must be blocked off to allow for proper air flow through the cell The and DC bus can be accessed by removing the top lid...

Page 23: ...icular attention should be paid to the DC bus illumination LED that indicates that more than 50VDC is present on the DC bus The cell should not be touched removed or serviced if the indicator is illuminated Remember that the cell chassis is not grounded and when energized can float to lethal voltages Figure 2 4 Indicators and Labels DC Bus Voltage Indicator 50VDC Fiber Optic Q4 Q3 Q2 Q1 FAULT LINK...

Page 24: ...d CCB 10000424 71 10000424 71 10000424 71 10000424 71 GCB 10000428 03 10000428 03 10000428 04 10000428 00 Capacitance 3S x 1P qty 3 1867μF 1350VDC 3S x 2P qty 6 3733μF 1350VDC 3S x 3P qty 9 5600μF 1350VDC 3S x 4P qty 12 7467μF 1350VDC Capacitors 5600μF 450V electrolytic 144mm 5 7in high x 78mm 3 07in OD Jianghai ECG2WPC562M P N 099545 UCC E36F451CAN562MEE3N P N 099348 BHC ALS30C1048NX P N 0100034 ...

Page 25: ...ROOS 1000 ohm 1000 ohm Cge CCB 10000424 72 10000424 72 GCB 10000428 05 10000428 05 Capacitance 3S x 3P qty 9 10 000μF 1350VDC 3S x 4P Qty 12 13 333μF 1350VDC Capacitors 10 000μF 450V electrolytic 227mm 8 94in high x 78mm 3 07in OD Jianghai ECG2WPC103M P N 099997 UCC E36L451CSN103MEM9N P N 0100786 BHC ALS30C1049NT P N 0100785 Input Rectifiers Eupec DD171N1800 QTY 3 Semikron SKKD162 18 Powerex CD611...

Page 26: ...t Sink P N 11004896 00 QTY 1 135in wide x 8in deep 0 31 base plate 3 41 fins R Theta 11004896 00 ERM 11004896 00 Thermodisc Western Electronic Company WPP4001 24 QTY 1 100 ohm at 25 C 250 ohm at 80 C P N 094595 Power Plugs P N 099416 QTY 5 Tyco 538 17 00100 Anderson Power PCL01 10000494 200 260 ...

Page 27: ...ink wire harnesses power plugs thermodisc and handles 4 Hardware kit screws washers thermal compound bushings etc 5 IGBT kits 6 Reference drawings Figure 2 5 Bill of Material Structure 10000424 140 Capacitor Vendor 1 12 Capacitor Vendor 2 0 Capacitor Vendor 3 0 Capacitor Mounting Tray 2 Common Parts Kit 1 Chassis Bus Kit 1 Glastic Kit 1 Hardware Kit 1 Misc Parts IGBT Kit Fuji 200A 0 IGBT Kit Mitsu...

Page 28: ...which requires the correct board IGBT combinations A label is placed on the cell chassis to identify what components are installed for replacement purposes Important Points NEVER SUBSTITUTE WITH NON APPROVED COMPONENTS ALWAYS ADHERE TO THE LATEST APPROVED BOM NEVER USE NON IDENTICAL MANUFACTURER S OR SIEMENS MDIT NUMBERS FOR IGBTS OR CAPACITORS IN THE SAME POWER CELL Each capacitor vendor has its ...

Page 29: ... performance the specified thermal compound and application procedure must be followed Failure to do so may result in excessive heating and catastrophic cell damage The assembly drawing identifies the approved compound and application procedure which is shown below for the 40 140A cells Thickness to be 0 004 thick using tape as a mask Figure 2 6 Assembly Drawing ...

Page 30: ...e the IGBT s plastic case The ordering of bolt tightening is also important to ensure a uniform thermal bond to the heat sink Likewise proper electrical terminal torque is required Insufficient tightening torque may increase contact resistance and localized heating or the screws may come loose Too much torque can crack the case or damage the internal bond wires The assembly drawing identifies the ...

Page 31: ...ing for capacitor locations This is not an issue on the 140A cell where all slots are filled but is a factor on smaller frames The bus must have rear support and the second row from the front must be occupied Bus inductance is influenced by the distance between the capacitors and the IGBTs Incorrect capacitor location can cause IGBT stress The assembly drawing identifies the proper location and or...

Page 32: ...the same vendor with identical MDIT and manufacturer s part numbers Mixing capacitors can cause voltage imbalance and damage the cell IGBTs must be from the same vendor with identical MDIT and manufacturer s part numbers Make sure to use the correct IGBT kit label on the outside of the cell chassis Always use the correct gate clamp and cell control board Mixing IGBTs or using incorrect control boa...

Page 33: ... a power cell If a cell is lifted alone the following procedure should be followed Keep the cell close to your body and lift with the legs not the back Avoid twisting your back Carry the cell close to your body not on extended arms When installing cells in the system always have someone help Never carry the cell by the locking latches They are not designed to support the weight of the cell Always ...

Page 34: ...tches should point towards the front of the drive The cell is then pushed along the rails until the locking latches can be rotated upwards 90 degrees and latch into the mounting rail slot Be sure that the latches slide through the mounting rail slots As the latches are rotated simultaneously the cell will self align and insert the blind mate power plugs into the system I O bus at the rear of the e...

Page 35: ...MicroHarmony Cell Sizes 40 260A Manual Installation 19001467 Version 1 0 3 3 s 3 3 4 System Requirements 40 140A For reference only always refer to latest core design Figure 3 2 System Dimensions ...

Page 36: ...Installation MicroHarmony Cell Sizes 40 260A Manual 3 4 19001467 Version 1 0 s 3 ...

Page 37: ...ER 4 Electrical Description 10000424 040 070 100 140 10000494 200 10000492 260 Rated Output Current Rating1 40Arms 70Arms 100Arms 140Arms 200Arms 260Arms 110 1min 10min CL 1 2 40Arms 70Arms 100Arms 140Arms 200Arms 260Arms 150 1min 10min CL 2 3 40Arms 70Arms 100Arms 130Arms 200Arms 260Arms 200 3sec 10min CL 3 4 40Arms 70Arms 100Arms 130Arms 200Arms 260Arms Nuisance OOS Current5 141Arms 162Arms 198A...

Page 38: ...d of output current 9 Life expectancy of capacitors at a 40 C ambient rated air flow rated input voltage rated output current neglecting over loads Once the life is exceeded the ESR doubles and the capacitance is reduced by 50 The capacitors should be replaced prior to end of life 10 Life expectancy of capacitors at a 40 C ambient rated air flow 110 rated input voltage rated output current neglect...

Page 39: ... each case and select the lowest current rating Tamb 45 C No De Rating overload and Cap life de rated Tamb 45 C Base Current Rating x 60 K37 15 0 67 Note Tamb applies to the inlet air temperature of the cell This can be higher than the actual room ambient depend ing on site conditions FASL 3 300ft No De Rating 3 300ft FASL 6 563ft Base Current Rating x 1 0 005 FASL 3 300 330 Note FASL Feet above s...

Page 40: ...Electrical Description MicroHarmony Cell Sizes 40 260A Manual 4 4 19001467 Version 1 0 s 4 4 3 Schematic 40 140A cells 10000424S ...

Page 41: ...MicroHarmony Cell Sizes 40 260A Manual Electrical Description 19001467 Version 1 0 4 5 s 4 4 4 Schematic 200 260A cells 10000494S ...

Page 42: ...Electrical Description MicroHarmony Cell Sizes 40 260A Manual 4 6 19001467 Version 1 0 s 4 ...

Page 43: ...l input voltage 7 3 used remainder removed 089399 CN3 2 3 1 3 dc bus 4 2 used remainder removed 089397 CN4 dc bus 4 2 used remainder removed 089397 CN8 CN7 CN6 CN5 CN4 CN3 CN2 CN1 CN10 DC BUS INDICATOR Link ON FAULT Q1 Q2 Q3 Q4 12 9in 8in WARNING High Voltage P N S N REV Date Code etc CN9 1 Up to 1200VDC input operation 2 630 690 750V jumpers for high bus voltage fault Jumper is soldered in place ...

Page 44: ... gate drive 5 3 used remainder removed 089398 CN6 Q3 gate drive 5 3 used remainder removed 089398 CN7 Q2 gate drive 5 3 used remainder removed 089398 CN8 Q1 gate drive 5 3 used remainder removed 089398 CN9 Programming port 10 Altera Byte Blaster CN10 Precharge 2 089591 Symbol Description Voltage V Tolerance Level V Minimum Maximum Frequency Switching Frequency 20KHz 19KHz 21KHz VCC gnd 5V for ICs ...

Page 45: ...ply OOS1 is an isolated OOS signal that connects to the EPLD PC5 connects to a start up hold off circuit which prevents firing until the SMPS is fully operational Q1 is the gate drive signal derived from the EPLD 5 4 2 Gate Drive Propagation Delay and Dead Time There is a time delay inherent to the gate drive circuit from the time the EPLD tells the gate to turn on to the actual time in which the ...

Page 46: ...uit In the event that any 1 signal exceeds the scaled threshold 430V for 400V caps and 484V for 450V caps then VCAP_OK annunciates a Cap share Fault and trips the cell Three select resistors are used for trip point scaling 2 Bus Voltage Monitoring P1DET is filtered and scaled for Vbus 255 and compared to a fixed 10V reference that is scaled for the appropriate over voltage trip point In the event ...

Page 47: ... active high when Vbus exceeds 300 30vdc Cap Share Fault1 VCAPOK Voltage across power capacitors is all less than specified upper limit This is set by scaling resistors for either 400 or 450V capacitors VCAPOK is active high when individual capacitor voltages are less than 400V 430 10vdc 450V 485 10vdc Out of Saturation1 OOS1L to OOS4L Voltage between collector and emitter of an IGBT has exceeded ...

Page 48: ...d are for cell diagnostic purposes only 5 6 Communication The cell control board communicates to the Perfect Harmony control system via a duplex fiber optic cable on a proprietary communication protocol See Chapter 11 Communication Protocol for details Communication Fault1 CMFLT This is complimentary meaning of LINK ON which is displayed on CCB by means of LED lamp Therefore if LINK ON is off then...

Page 49: ...eshold is generated by connecting four transorbs in series one 350V and three 400V devices from collector to gate An 18V transorb is connected from gate to emitter to protect the IGBT from short circuit by clamping the gate to emitter voltage to 18V The transorb devices are intended for intermittent operation during out of saturation turn off where peak voltages can exceed the 1700V device rating ...

Page 50: ...D7 10000428 00 1 5KE350CA 1 5KE400CA 1 5KE400CA 1 5KE400CA 1 5KE1BCA 1 5KE350CA 1 5KE400CA 10000428 01 Not Installed Not Installed Not Installed Not Installed Jumper 1 5KE350CA 1 5KE400CA 10000428 02 1 5KE350CA 1 5KE400CA 1 5KE400CA 1 5KE400CA 1 5KE1BCA Not Installed Not Installed 10000428 03 1 5KE350CA 1 5KE400CA 1 5KE400CA 1 5KE400CA 1 5KE1BCA 1 5KE350CA 1 5KE400CA 10000428 04 1 5KE350CA 1 5KE40...

Page 51: ... 2mH in parallel 8mH in series or a suitable equivalent with required minimum inductance and current specification see following table 3 Variable voltage source Variac with a voltage range of at least 0 500Vrms 50 60Hz with at least 30Arms secondary rating 4 Step up transformer 480 720Vrms minimum rating with at least a 2kVA rating P N 164307 00 is recommended 5 Alternatively the step up transform...

Page 52: ...se circuit is properly communicating at the hub control 75 of rated output current is applied with no air flow through the heat sink until the over temperature bit starts to modulate Once modulation is achieved the output current is raised to the 100 base rating until the cell tester disables the cell on over temperature 4 This test ensures adequate isolation between the power electronics control ...

Page 53: ...tance In such events Product Development may suggest alternative components only after sufficient technical review and verification In these instances it will be Product Development s responsibility to generate the required ECR and obsolescence information It will be the repair department s responsibility to make the required label changes and notify Application Engineering and Field Service of th...

Page 54: ... are determined re usable 8 5 1 Non Catastrophic Rectifier Failures If a non catastrophic Rectifier failure occurs it usually results in one upper diode and one lower diode failing short circuit This requires replacing two diode modules The third diode module can be presumed OK if 1 Device passes a 3400VDC for 1700V devices HIPOT all terminals to baseplate 2 Device passes A K check 3 Device passes...

Page 55: ...cedure may help in checking the general health of a capacitor bank following a cell failure due to over voltage 1 Disconnect the bleeder resistor and measure each section with an ohmmeter Verify that resistance is within spec 2 Reconnect the resistor and slowly apply AC voltage to the cell while measuring the voltage across each series capacitor group up to rated AC input voltage If all capacitors...

Page 56: ...Repair Hints MicroHarmony Cell Sizes 40 260A Manual 8 4 19001467 Version 1 0 s 8 ...

Page 57: ... optic 10000424 040 070 100 140 Bussman P N099725 170M4810 1000V 100A P N 099726 170M4812 1000V 160A P N 099727 170M4813 1000V 200A P N 099728 170M4814 1000V 250A Ferraz P N 099717 1021CPURB27 60Q100D 80 1000V 100A P N 099718 1000C4URC160LD80 1000V 160A P N 099719 1000C4URC200LD80 1000V 200A P N 099720 1000C4URC250LD80 1000V 250A Siba P N 099721 2056020 125 1000V 125A P N 099722 2056020 200 1000V ...

Page 58: ...on Vendor P N DD106N1800 SKKD100 18 Siemens P N 099414 0100375 Package Dual 92 x 25 Dual 93 x 20 mm Vrrm 1800 1800 V Ifavm 106 87 A at Tc 100 C Tjmax 150 125 C V to 0 7 0 72 V Rt 2 0 1 8 mohms Rjc 0 39 0 35 C W per arm Rcs 0 08 0 2 C W per arm Mounting Torque 4 5 Nm Terminal Torque 4 3 Nm Baseplate Cu Al oxide ceramic Rsa 180CFM 0 395 0 36 C W Cca 180CFM 110 80 J C ...

Page 59: ...71N1800 SKKD162 18 Siemens P N 088173 0100787 Package Dual 94 x 34 Dual 94 x 34 mm Vrrm 1800 1800 V Ifavm 171 162 A at Tc 100 C Tjmax 150 150 C V to 0 7757 0 88 V Rt 1 166 1 45 mohms Rjc 0 26 0 18 C W per arm Rcs 0 06 0 05 C W per arm Mounting Torque 6 5 Nm Terminal Torque 6 5 Nm Baseplate Cu Al oxide ceramic Rsa 300CFM 0 3 0 28 C W Cca 300CFM 333 115 J C ...

Page 60: ...2 A Tjmax 125 125 125 125 125 C RtJC 0 13 0 1 0 1 0 05 0 0425 C W RdJC 0 28 0 24 0 16 0 08 0 13 C W Rcs 0 012 0 012 0 01 0 01 0 01 C W Rca igbt 0 238 0 226 0 224 0 1468 0 11862 C W Cca igbt 195 182 205 455 476 J C Rsa igbt 0 226 0 214 0 214 0 1368 0 10862 C W Mounting Torque 5 5 3 6 3 6 3 6 Nm Terminal Torque 5 5 2 5 5 2 5 5 2 5 5 Nm Baseplate Cu Cu Cu Cu Cu RgON 20 15 15 15 5 15 5 Ohm RgOFF 25 20...

Page 61: ...current Includes capacitor self inductance bus inductance and IGBT module inductance 10000424 040 070 100 140 10000494 200 10000494 260 Bus Inductance1 229nH 91nH 73nH 63nH 126nH 127nH Power Plug maximum current 300Arms at 55 C plug ambient 25CFM Power Plug useful life Mechanical life test at 250 insertions extractions with no significant change in resistance ...

Page 62: ...rectifier losses per cell multiply the numbers below by 6 Alternatively individual rectifier losses can be estimated as follows 40 140A cells Prect 0 000439 x Iout 2 0 1823 x Iout 0 00244 200 260A cells Prect 0 000286 x Iout 2 0 1958 x Iout 0 03017 0 85 motor power factor 0 95 motor efficiency 105 modulation Iin 0 7 x Iout and DD106N1800 or DD171N1800 dual rectifier modules are assumed Losses vs O...

Page 63: ...igbt 0 01326 x Iout 2 2 758 x Iout 0 14545 200A cell Pigbt 0 00682 x Iout 2 2 59283 x Iout 0 11734 260A cell Pigbt 0 0045 x Iout 2 2 99225 x Iout 0 04933 For individual 40 140A IGBT FWD individual module losses divide PigbtFWD by 4 For individual 200 260A IGBT FWD individual module losses divide PigbtFWD by 8 Losses vs Output Current 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 0 50 ...

Page 64: ...0 00195 x Iout 2 0 45098 x Iout 8 51042 260A cell Pigbt 0 00133 x Iout 2 0 58138 x Iout 6 65728 For total cell IGBT losses FWD losses are neglected multiply Pigbt by 4 Losses vs Output Current 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 0 50 100 150 200 250 300 350 400 450 500 Output Current Arms Losses Watts 40 70A 100A 140A 200A 260A Iout 40 70A 100A 140A 200A 260A 25 22 0 23 0 17 0...

Page 65: ...ual capacitor losses divide the total given by the number of capacitors within the cell Alternatively capacitor bank losses can be estimated as follows 40A cell Pcaps 0 0164 x Iout 2 0 002 x Iout 2 13E 14 70A cell Pcaps 0 0082 x Iout 2 0 0018 x Iout 0 075 100A cell Pcaps 0 0055 x Iout 2 0 002 x Iout 0 07 140A cell Pcaps 0 0041 x Iout 2 0 0004 x Iout 0 0429 200A cell Pcaps 0 0103 x Iout 2 0 0012 x ...

Page 66: ...0 2250 2500 2750 3000 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 Output Current Arms Losses Watts 40A 70A 100A 140A 200A 260A Iout 40A 70A 100A 140A 200A 260A 25 273 268 268 244 241 248 50 470 450 436 378 371 379 75 726 680 637 536 524 527 100 1 042 960 873 720 700 692 125 1 416 1 288 1 142 929 900 875 150 1 850 1 665 1 445 1 163 1 124 1 076 175 1 783 1 421 1 371 1 294 200 2 154 1 7...

Page 67: ...the cell hottest cell temperature next to the Q1 Q2 IGBT module Positive Temperature Coefficient PTC thermistors are thermally sensitive semiconductor resistors which exhibit an increase in resistance at a specified temperature Change in the resistance of a PTC thermistor can be brought about either by a change in the ambient temperature or internally by self heating resulting from current flowing...

Page 68: ...ys quickly back down to 4 88V and repeats Period of waveform is 1 667msec The thermodisc resistance varies with temperature The non inverting amplifier U3 B circuit converts this variable resistance into a dc voltage which is compared to the ramp U2 comparator generates a PWM output at TP35 The PWM signal connects to the EPLD which sends this data over the fiber optic link to the main controller T...

Page 69: ...s 40 260A Manual Application Notes 19001467 Version 1 0 9 13 s 9 Figure 9 2 Resistance vs Temperature Figure 9 3 Temperature vs Duty Cycle The control trips the cell when the thermodisc temperature reaches approximately 80 C ...

Page 70: ...ll increase substantially This is due to a drop in the withstand voltage of the dielectric caused by the reaction of the anode oxide layer with the electrolyte At this point the capacitor should not be subjected to full voltage until the leakage current returns to its initial level which can be done by reforming the electrolyte Reforming can be done by applying a voltage that is slowly increased t...

Page 71: ...ant mortals are mostly short circuit failures from weaknesses in the aluminum oxide dielectric Incidence can be reduced with extended aging or burn in Wear Out In the case of large capacitors enduring high levels of ripple current the increasing ESR can cause overheating and short circuit failures as wear out failures Open circuit wear out failures are caused by a loss of electrolyte or ESR increa...

Page 72: ...chloride and perhaps safety vent plugs made of synthetic rubber If incinerated be certain that the temperature is more than 1200 C Disposal is permitted in appropriate landfills 9 9 Output Voltage Capability 9 9 1 Normal Operation The maximum output voltage of the drive in terms of the number of ranks and the secondary side cell voltage is given as Vout 1 78 x N x Vcell x Tap x Vin Vin rated x M L...

Page 73: ... rated line voltage and 4 over modulation N 3 Vcell 750 Tap 1 00 M 1 04 is Vout 1 78 x 3 x 750 x 1 0 x 1 0 x 1 04 4 165 kV Now if after cell bypass the drive has 3 cells operational in phase A 2 cells in phase B and 1 cell in phase C then the maximum voltage that the drive can produce with neutral shift from the above formula is with X 1 2 3 because 1 cell in phase B and 2 cells in phase C are byp...

Page 74: ... MicroHarmony Volt Map Note 1PU maximum cell DC bus voltage MicroHarmony 1200Vpk For RMS divide by 1 414 Internal Cell Components Between cell chassis and output terminals For 4 5 6 7 or 8 series cells continue the counting Any transformer secondary to ground 4 pu 3 typical 2Npu worst case GF ...

Page 75: ...mance of a MicroHarmony Drive With easy to use scroll bars and drop down menus with error messages many of the rather tedious calculations previously shown can be performed in a few short steps Furthermore the program will calculate junction temperatures for over load conditions as well as aid in determining much of the important drive parameters CHAPTER 10 Drive Calc Express ...

Page 76: ...Drive Calc Express MicroHarmony Cell Sizes 40 260A Manual 10 2 19001467 Version 1 0 s 10 ...

Page 77: ...a Master Slave mode The Modulator Card serves as the master and the CCB is the slave device This means that the CCB only generates a message in response to receipt of a complete message packet from the Modulator If no message is received the CCB does not transmit any messages This fact in turn causes all cells to be shut down Any communication failures detected by the Modulator also cause a drive ...

Page 78: ... i e 3 or more messages Note that the 890485 02 GAL U31 equations validate parity for each received message QVALID Indicates that data on pins Q0 7 is valid data from Master Link Input for CCB ACTIVITY circuit that verifies message activity from Master Link Generates CCB Communication fault COMFLT if ACTIVITY fault exceeds approximately 15 microseconds ACTIVITY is validated for every message by th...

Page 79: ...any CCB faults when cell diagnostics are performed These CCB faults must remain latched until a Cell Fault Reset is received by the CCB bit 2 of Mode 01 or 10 The parity bit is stripped off at the FOLA before getting to the Modulator cell data registers and replaced with the OR ed value of the parity fault and the link fault CommFault Up Bits Mode 00 Mode 01 Mode 10 Mode 11 0 0 1 0 1 1 0 0 1 1 2 E...

Page 80: ...on is maintained for compatibility Therefore when the CPU enables the Bypass both this bit and the equivalent one in the M V Bypass Control Board are sent Mode 00 also provides a 600 Hz reference signal to be used by the CCB for generating cell temperature response data for simplicity all the modes send this bit but only in mode 00 does the Modulator gets a proper response from the CCB Table 11 5 ...

Page 81: ...e message When this condition occurs the outputs of all installed cells are disabled via dedicated hardware on the Modulator Table 11 6 Mode 00 Data from CCB to Modulator Bit Description 0 0 Mode definition bit 0 1 0 Mode definition bit 1 2 Cell Fault detected by CCB 3 Cell DC Bus Voltage Low Warning 4 Cell Temperature Feedback pwm at 600 Hz car rier 5 Cell Control Input Power Valid 6 Cell Bypass ...

Page 82: ...ow where bit 2 indicates a fault when set high 1 and bits 3 6 indicate a fault when set low 0 Table 11 8 Mode 01 Data from CCB to Modulator Bit Description 0 1 Mode definition bit 1 0 Mode definition bit 1 2 Cell Fault Reset 3 0 not used 4 0 not used 5 0 not used 6 Sync pulse for temperature engine 7 Odd Parity Bit Bit Description 0 1 Mode definition bit 0 1 0 Mode definition bit 1 2 Any Device Ou...

Page 83: ...Mode 10 is shown below where bits 2 through 6 indicate a fault condition when set low 0 Table 11 10 Mode 10 Data from Power Cell to Modulator Bit Description 0 0 Mode definition bit 1 1 Mode definition bit 1 2 Cell Fault Reset 3 0 not used 4 0 not used 5 0 not used 6 Sync pulse for temperature engine 7 Odd Parity Bit Bit Description 0 0 Mode definition bit 0 1 1 Mode definition bit 1 2 Not Q1 Out ...

Page 84: ...s not available so the bypass tests are not performed These device tests are controlled by the Harmony microprocessor and are performed one device at a time and one cell at a time where switching and bypass tests are not performed if any blocking failures are detected 11 11 1 Device Test Control Data Table 11 12 Mode 11 Device Test Control Data Bit Description 0 1 Mode definition bit 1 1 Mode defi...

Page 85: ... Available status bit that the Host can query to determine if the Cell Bypass option is available on the cell The Next Gen Control Software doesn t test this bit because the bypass when it exists is always mechanical Table 11 13 Mode 11 Data from Power Cell to Modulator Bit Description 0 1 Mode definition bit 0 1 1 Mode definition bit 1 2 Q1 Blocking Indicator Blocking 1 3 Q2 Blocking Indicator Bl...

Page 86: ...Communication Protocol MicroHarmony Cell Sizes 40 260A Manual 11 10 19001467 Version 1 0 s 11 ...

Page 87: ...MicroHarmony Cell Sizes 40 260A Manual NOTES 19001467 Version 1 0 N 1 s NOTES ...

Page 88: ...NOTES MicroHarmony Cell Sizes 40 260A Manual N 2 19001467 Version 1 0 s ...

Page 89: ...MicroHarmony Cell Sizes 40 260A Manual NOTES 19001467 Version 1 0 N 3 s ...

Page 90: ...NOTES MicroHarmony Cell Sizes 40 260A Manual N 4 19001467 Version 1 0 s ...

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