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5

CFW-11M RB |5-1

First Time Power-Up and Start-Up

5 FIRST TIME POWER-UP AND START-UP

This chapter describes how to:
- Check and prepare the converter before power-up.
- Power-up the converter and check the result.

5.1 PREPARATIONS FOR THE START-UP

The converter shall have been already installed according to the
recommendations listed in Chapter 3 – Installation and Connection.
The following recommendations are applicable even if the application design is different from the suggested
control connections.

DANGER!

Always disconnect the main power supply before performing any converter connection.

5.1.1 Procedures for the First Time Power-up/Start-up

1. Verify all the panel connections.

2. Search for short-circuits at the input, DC link, etc.

3. Make sure all the cables are correctly connected between the control and power units.

4. Verify the condition of all the fuses.

5. Inspect all the ground connections (panel, the door where the control is installed, etc.).

6. Remove all the material rests from the converter or panel interior.

7. Close the converter or panel covers.

8. Energize the control (+24 Vdc power supply).

9. The HMI must indicate undervoltage with the control energized and the power units deenergized. The

electronics of the power units stay without power (SMPS off) and the DC link monitoring signal remains
at 0 V.

10. Measure the line voltage making sure it is inside the permitted range.

11. Verify if the automatic hardware identification has correctly recognized the converter current and voltage.

The converter current must be compatible with the number of installed power units.

12. Command the drive, perform the DC link pre-charge and close the main contactor/circuit breaker keeping

the converters always connected to the DC link with the PWM pulses disabled.

13. Verify the proper operation of the fans. The fan control configuration is done via software through the

parameter P0352 (refer to the CFW-11 RB programming manual). The power units do not have internal

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Содержание CFW-11M RB

Страница 1: ...Frequency Inverter CFW 11M RB Motors Automation Energy Transmission Distribution Coatings User s Manual...

Страница 2: ...Series CFW 11M RB Language English Document 10000874747 02 Models 600 2850 A 380 480 V 470 2232 A 500 600 V 427 2028 A 660 690 V REGENERATIVE FREQUENCY CONVERTER MANUAL 04 2019...

Страница 3: ...Summary of Revisions The information below describes the reviews made in this manual Versi n Revision Description R00 First edition R01 Updating of the tables notes and general revision R02 General re...

Страница 4: ...d 3 8 3 4 ELECTRICAL INSTALLATION 3 8 3 4 1 Pre charge Circuit 3 8 3 4 2 Bus Bars 3 10 3 4 3 DC Link Fuses 3 10 3 4 4 General Connection Diagram and Layout 3 11 3 4 5 UP11 Connections 3 19 3 4 6 UC11...

Страница 5: ...TO A PC 5 6 5 6 FLASH MEMORY MODULE 5 6 6 TROUBLESHOOTING AND MAINTENANCE 6 1 6 1 OPERATION OF THE FAULTS AND ALARMS 6 1 6 2 FAULTS ALARMS AND POSSIBLE CAUSES 6 2 6 3 SOLUTIONS FOR THE MOST FREQUENT P...

Страница 6: ...e of protecting the user against dead serious injuries and considerable material damage ATTENTION The procedures recommended in this warning have the purpose of avoiding material damage NOTE The text...

Страница 7: ...DANGER Always disconnect the main power supply before touching any electrical component associated to the converter Several components can remain charged with high voltages and or in movement fans ev...

Страница 8: ...tric energy systems such as transformers converters motors and cables generate electromagnetic fields EMF posing a risk to people with pacemakers or implants who stay in close proximity to them Theref...

Страница 9: ...1 4 CFW 11M RB 1 Safety Instructions...

Страница 10: ...st type amplifier that converts the AC voltage from the power supply to a DC voltage DC Link It has the capability of absorbing the energy of the power supply AC or to recover the energy back to the p...

Страница 11: ...rease used as a temperature sensor in power modules HMI Human Machine Interface it is a device that allows the visualization and modification of the converter parameters The CFW 11 HMI presents keys f...

Страница 12: ...er 746 Watts unit of power used to indicate the mechanical power of electrical motors Hz hertz in inch kg kilogram 1000 grams kHz kilohertz 1000 Hertz l s liters per second lb pound m meter mA miliamp...

Страница 13: ...advantages Low input current harmonic distortion Capacity of recovering energy back to the power supply regeneration allowing high braking torque levels The CFW 11M RB line presents a modular structu...

Страница 14: ...UC11 the cable set needed for the connection between the IPS1 board and the power units and the ribbon cable to connect the IPS1 board to the CC11 RB board UP11 UP11 Capac Bank Capac Bank DC Bus Bar...

Страница 15: ...ircuit protection to the ground since each UP11 module has its own internal protection Keypad Front cover Control rack IPS1 shield IPS1 shield base IPS1 board interface between power and control Figur...

Страница 16: ...rrent 4 A Figure 2 5 UP11 Connections between the IPS1 and the CIM1 interface boards UD UD XP XN XC3 XC5 XC5 XC3 15 V 5 V 20 V PSB1 CIM1 XP XN UD UD Figure 2 6 UP11 Connections between the CIM1 interf...

Страница 17: ...4 5 5 8 8 10 11 11 11 10 10 Figure 2 8 UP11 Connections between the CIM1 interface board gate driver boards modules and sensors for the output voltage and output current NOTE The synchronism connectio...

Страница 18: ...er of power phases rated currents for use with Normal Duty ND and Heavy Duty HD cycles overload currents for 1 min and 3 s and frequency range Maximum surrounding air temperature Manufacturing date 24...

Страница 19: ...n 1 Ex CFW11M0470T5ORBZ corresponds to a CFW 11M RB regenerative braking converter 470 A three phase with power supply voltage from 500 V to 600 V An converter for 380 480 V would be specified as CFW...

Страница 20: ...rresponds to the model number on your purchase order Inspect the product for external damage during transportation In case of any damage immediately report it to the carrier responsible for delivering...

Страница 21: ...2 2 12 CFW 11M RB General Instructions...

Страница 22: ...F nominal conditions measured around the converter From 40 C to 55 C 104 F to 131 F 2 current reduction for every Celsius degree or 1 11 each F above 40 C 104 F Humidity from 5 to 90 non condensing A...

Страница 23: ...h cables are for the connections between the IPS1 board control unit and the CIM1 board power unit Table 3 4 Cable sets Weg Part Number Optical Fiber Length mm in DB 25 Cable Length mm in 10411757 235...

Страница 24: ...s 250 VENTILADOR DO PAINEL QUANDO NECESS RIO SA DA DE AR SA DA DE AR 150 ENTRADA DE AR ABERTURA DE NA SUPERF CIE PAI 22 5 hoisting eyes weight 171 kg 377 lb Figure 3 1 UP11 hoisting eyes 250 VENTILADO...

Страница 25: ...ensions in mm in Figure 3 3 Clearence requirements for air circulation The UP11 wheels facilitate its insertion into and withdrawal from the panel figure 3 4 Note dimensions in mm in 584 9 56 5 221 9...

Страница 26: ...for top fixing of the module 14 5 0 6 14 5 0 6 25 3 1 24 9 1 509 8 20 1 195 7 7 195 7 7 97 5 3 8 125 4 9 9 2 0 4 100 5 4 100 5 4 Note dimensions in mm in Figure 3 6 Supports for top fixing Mounting of...

Страница 27: ...3 3 6 CFW 11M RB Installation and Connection CFW 11 Interface card power control 143 mm 5 62 in Figure 3 7 Example of the mounting of the control rack and its base Figure 3 8 Final mounting aspect...

Страница 28: ...rack fixing and the necessary cuts Note dimensions in mm in M6 4x for the IPS1 module fixing 283 6 11 17 41 5 1 63 292 11 5 Figure 3 10 IPS1 module base fixing The IPS1 module base is fixed with four...

Страница 29: ...electrical installations DANGER Make sure the AC power supply is disconnected before starting the installation ATTENTION The CFW 11M RB can be connected in circuits with symmetrical short circuit cap...

Страница 30: ...ower units the CFW11M RB power units plus the output CFW11M power units which are fed by the CFW11M RB In case the CFW11M RB is feeding other converter WEG must be consulted E g The following values a...

Страница 31: ...must be set for the protection of the auxiliary circuit resistors rectifier bridge This function is carried out by a timer relay with a normally closed on delay contact represented as RT1 in the figur...

Страница 32: ...00 600 V 470 A 700 A 660 690 V 427 A 700 A Fuse examples 400 V line 6 9URD33TTF0900 FERRAZ Other lines 6 9URD33TTF0700 FERRAZ 3 4 4 General Connection Diagram and Layout Figure 3 15 presents a general...

Страница 33: ...agram The electrical power connections of the panel must assure equal impedance at the DC bus and input connections Refer to the example in the figure 3 16 and to the lateral section views in figures...

Страница 34: ...resented at table 8 1 The figure 3 19 presents an example of flat braided cable used by WEG using a fuse at UD Alternatively fuses at both connections UD and UD can be used NOTE It is important that a...

Страница 35: ...ded cable Besides the panel constructive form some precautions must be taken regarding the connection of the input cables from the input filter in order to assure equal impedances among the UPs connec...

Страница 36: ...ive Power Units Inverter UD UD T S R GND PE Filter Figure 3 21 Example of adequate installation layout for 5 UP11 NOTE The connection of the input cables from the filter at points different from the p...

Страница 37: ...3 3 16 CFW 11M RB Installation and Connection UD UD T S R GND PE Filter Inverter Figure 3 22 Example of inadequate installation layout for 5 UP11...

Страница 38: ...3 CFW 11M RB 3 17 Installation and Connection UD UD Inverter Filter R S T GND PE Figure 3 23 Example of inadequate installation layout for 5 UP11...

Страница 39: ...Figure 3 24 Example of adequate installation layout for 3 UP11 NOTE The connection of the motor cables from the filter at points different from the presented in the figure 3 24 the figure 3 25 presen...

Страница 40: ...ing of the UP11 output connections is done by means of four M12 x 25 bolts tightening torque 60 Nm refer to figure 3 26 Note dimensions in mm in Negative output bar UD Positive output bar UD 60 61 3 2...

Страница 41: ...87 4 40 55 2 20 40 BARRA DE SA DA U BARRA DE SA DA V BARRA DE SA DA W 22 5 0 9 hoisting hole Input bar S Input bar T Input bar R 95 3 7 20 0 8 95 3 7 55 2 2 2 40 1 6 87 4 3 4 40 1 6 Figure 3 27 UP11...

Страница 42: ...NTAL COM PARAFUSO M12 Front grounding with a M12 bolt Figure 3 28 UP11 ground connection point Use cables with the recommended gauge indicated in the table 3 8 for grounding the UP11 power units Table...

Страница 43: ...trol cables on the UP11 Keep the optic fiber bending radius bigger or equal to 35 mm 1 38 in If the control is mounted on the panel door let a curvature that causes a minimum stress on the optic fiber...

Страница 44: ...ND Reference Grounded via the IPS board shield 4 DIM2 Isolated digital input DIM2 programmable at P0833 Refer to the programming manual High level 18 V Low level 3 V Maximum input voltage 30 V Input c...

Страница 45: ...f makes its ground connection This is done in several points Grounding point Figure 3 33 IPS1 board grounding The IPS1 shield securing screws must assure the electric contact between the shield and th...

Страница 46: ...filters 3 4 7 1 Basic Definitions The proper operation of the regenerative converter demands the use of a three phase reactance between the input and the power supply This three phase reactance is kn...

Страница 47: ...S and T terminals of the regenerative converter L1 Regenerative converter Point of common coupling High voltage power supply Other loads Low voltage power supply Inverter Panel Motor Filter 1 L1 HV LV...

Страница 48: ...3 4 7 4 Filter 2 The filter 2 is the connection of two three phase inductances L1 and L2 between the power supply and the R S and T terminals of the regenerative converter Among these inductance is a...

Страница 49: ...tion Synchronism transformer Regenerative converter Low voltage power supply Inverter Motor L1 L2 DC Link UC11 UC11 RB R S T U V W Filter 2 RT RS RR CR CS CT A B C Figure 3 42 Simplified connection dr...

Страница 50: ...er 2 should be used whenever it is possible because it prevents high frequency currents flow on the main power supply eliminating potential interference with other equipment The filter 1 can be used o...

Страница 51: ...0 1 min 10 min 150 1 min 10 min 150 1 min 10 min Power units 1 2 3 4 5 Model Current Voltage Overload 470 500 600 893 500 600 1340 500 600 1786 500 600 2232 500 600 ND HD ND HD ND HD ND HD ND HD Rated...

Страница 52: ...0 ND HD 1786 500 600 ND HD 2232 500 600 ND HD Rated output current A 470 380 893 722 1340 1083 1786 1444 2232 1805 L2 Inductor LF Inductance at rated current H 76 4 40 2 26 8 20 1 16 1 Saturation indu...

Страница 53: ...3 37 2 46 5 Voltage 530 Vrms 530 Vrms 530 Vrms Recommended model Epcos B25834 D5107 K004 B25834 D5107 K004 B25834 D5107 K004 C4 CAPACITOR Capacitance F 100 0 100 0 Current Arms 37 2 46 5 Voltage 530 V...

Страница 54: ...in simulation and the recommended power for these components Table 3 14 RR S T Resistor data Model Current Voltage Overload 600 380 480 ND HD 1140 380 480 ND HD 1710 380 480 ND HD 2280 380 480 ND HD...

Страница 55: ...ound bolt Figure 3 47 Synchronism transformer Table 3 14 shows the main characteristics for the proper specification of the synchronism transformer Table 3 15 Synchronism transformer characteristics C...

Страница 56: ...Example of transformer assembling NOTE Consult WEG for the complete specification of the synchronism transfomer Figure 3 49 shows the CSR11 synchronism board The signals from the synchronism transfor...

Страница 57: ...s shielding according to item 3 4 9 Figure 3 50 CSR11 syncronism board connection Figure 3 51 CSR11 assembly on the UC11 3 4 9 Control Connections The control connections analog inputs outputs and dig...

Страница 58: ...rence 0 V for the 24 Vdc power supply Connected to the ground frame through impedance 940 resistor in parallel with a 22 nF capacitor 12 COM Digital inputs common point connection 13 24 Vdc 24 Vdc pow...

Страница 59: ...resistor in parallel with a 22 nF capacitor 12 COM Digital inputs common point connection 13 24 Vdc 24 Vdc power supply 24 Vdc power supply 8 Capacity 500 mA 14 COM Digital inputs common point connect...

Страница 60: ...puts AO1 and AO2 shall also be programmed according to the DIP switches settings and desired values Follow instructions below for the proper installation of the control wiring 1 Wire gauge 0 5 mm 20 A...

Страница 61: ...cted in parallel to the coils of these devices Example of connection of control cable shield Figure 3 55 Example of shield connection for the control wiring and synchronism 3 4 10 Typical Control Conn...

Страница 62: ...e requirements of the electromagnetic compatibility directive EMC Directive 2004 108 EC 3 5 1 Conformal Installation For the conformal installation use 1 Input filter filter 2 for emission levels in a...

Страница 63: ...rovided with a plug connector or a movable installations and installed and commissioned by a professional Note a professional is a person or organization familiar with the installation and or commissi...

Страница 64: ...o 1000 MHz 10 V m 80 AM 1 kHz 3 5 4 External RFI Filters To be used only if necessary to comply with conducted emission levels Category C2 or C3 according to IEC EN61800 3 The models bellow are from t...

Страница 65: ...ded or grounded via a high impedance Take the usual precautions for EMC filters installation do not cross the filter input cables with the output cables mount the filter on a metallic plate assuring t...

Страница 66: ...his key to increase a parameter value 2 Press this key to select the previous group in the Parameter Groups No function No function No function No function No function 1 Press this key to decrease a p...

Страница 67: ...ide HMI without the battery Install the new battery positioning it first at the left side 7 8 Press the battery for its insertion Put the cover back and rotate it clockwise 1 2 3 Cover for battery acc...

Страница 68: ...nu 400 A 618 V 380 V DC link voltage Volts Monitoring parameters Input current Amps DC link voltage Volts Line voltage Volts P0002 P0205 P0206 and P0207 selection of parameters that will be displayed...

Страница 69: ...vel 0 Level 1 Level 2 Level 3 Monitoring 00 ALL PARAMETERS 01 PARAMETER GROUPS 20 DC Link Voltage 21 Control 90 Current Regulator 91 Reactive Regulator 92 Current Limiting 93 DC Link Regulator 22 HMI...

Страница 70: ...ground connections panel the door where the control is installed etc 6 Remove all the material rests from the converter or panel interior 7 Close the converter or panel covers 8 Energize the control...

Страница 71: ...t inverter according to the instructions described at the specific manual 20 Deenergize the drive and wait until the complete discharge of the DC link capacitors Then connect a motor with power close...

Страница 72: ...to Parameters P0000 5 Press Return left soft key Run RB LOC 618V Return 15 45 Selec Access to Parameters P0000 5 Line Voltage P0002 380V 7 Press Return Run RB LOC 618V Return 15 45 Selec 00 ALL PARAME...

Страница 73: ...tart up 001 Yes 8 At this point the Oriented Start up routine starts and the Config status is displayed at the top left corner of the keypad The parameter Language P0201 English is already selected If...

Страница 74: ...Inputs 6 Parameter Day P0194 is already selected If needed set P0194 according to the actual day To do so press Select and then or to change P0194 value Follow the same steps to set parameters Month P...

Страница 75: ...isolated notebook for the USB connection or a desktop connected to the same Protective Ground PE of the converter 5 6 FLASH MEMORY MODULE Features Stores a copy of the converter parameters Transfers t...

Страница 76: ...AULT opens Some control circuitry data is saved in the EEPROM memory The fault or alarm code that occurred shifts the last nine previous faults and alarms The state of the operating hours counter P004...

Страница 77: ...supply rated voltage F022 DC Bus Overvoltage DC bus overvoltage condition occurred The input voltage is too high and the DC bus voltage surpassed the maximum permitted value Ud 400 V For 220 230 V in...

Страница 78: ...required to set a digital input to No external alarm Wiring was not connected to the digital input DI1 to DI8 set to No external alarm F091 External Fault External fault via digital input Note It is...

Страница 79: ...sensor NTC of the book 2 W phase IGBT F316 Overtemperature at IGBT W B2 Overtemperature fault measured with the temperature sensor NTC of the book 2 W phase IGBT A318 High temperature at IGBT U B3 Hig...

Страница 80: ...U phase IGBT F364 Overload at IGBT U B3 Overload fault at book 3 U phase IGBT A366 High Load at IGBT V B3 Overload alarm at book 3 V phase IGBT F367 Overload at IGBT V B3 Overload fault at book 3 V p...

Страница 81: ...phase in other book only when the current in this phase is higher than 75 of its nominal value A396 Current Unbalance at Phase U B3 Phase U book 3 current unbalance alarm It indicates a 20 unbalance...

Страница 82: ...oard LEDs The indication is done is done via LEDs that remain on when the failure occurs When a RESET is performed the LEDs are switched off going on again if the fault persists see Figure 6 1 Figure...

Страница 83: ...every 6 months after converter start up Table 6 3 Preventive maintenance Maintenance Interval Instructions Fan replacement After 50000 operating hours 1 Replacement procedure shown in Figure 6 2 Keypa...

Страница 84: ...e Replace fan Refer to figure 6 2 Check the fan connection Blocked fan Abnormal vibration Dust in the cabinet air filter Cleaning or replacement Printed circuit boards Accumulation of dust oil humidit...

Страница 85: ...he converter supply and wait 10 minutes Remove the dust accumulated on the boards using an anti static brush or ionized compressed air E g Charges Burtes Ion Gun non nuclear reference A6030 6DESCO If...

Страница 86: ...ers P0027 P0028 11008162 IOA 01 IOA module 1 voltage current analog input 14 bits 2 digital inputs 2 voltage current analog outputs 14 bits 2 open collector digital outputs 1 FD 11008099 IOB 01 IOB mo...

Страница 87: ...7 7 2 CFW 11M RB Accessories...

Страница 88: ...tage derating will be 1 1 for each 100 m above 2000 m maximum altitude 4000M Voltage tolerance 15 to 10 Frequency 50 60 Hz 48 Hz to 62 Hz Phase imbalance 3 of the rated phase phase input voltage Overv...

Страница 89: ...8 3420 2 5 2622 19 2 1957 1 2935 5 3914 2 5 2251 16 CFW11M 2850 T 4ORB 2850 1 3135 4275 2 5 3278 24 2446 1 3669 4892 2 5 2813 20 CFW11M 0470 T 5ORB 500 600 470 2 517 705 2 5 541 6 380 2 570 760 2 5 43...

Страница 90: ...current is applied for each Celsius degree or 1 11 each F above 40 C 104 F Relative humidity 5 to 90 without condensation Altitude 1000 m 3 300 ft Above 1000 m up to 4000 m 3 300 ft to 13 200 ft the o...

Страница 91: ...ments electrical thermal and energy EN 50178 Electronic equipment for use in power installations EN 60146 IEC 146 Semiconductor converters EN 61800 2 Adjustable speed electrical power drive systems Pa...

Страница 92: ...DATA UP11 58 7 2 3 1460 555 8 578 2 509 8 100 5 100 5 9 2 58 7 62 7 138 9 103 9 230 1506 7 22 5 103 9 4 1 1506 7 59 3 1460 57 5 100 5 4 100 5 4 62 7 2 5 138 9 5 5 230 9 1 22 5 0 9 578 2 22 8 555 8 21...

Страница 93: ...8 8 6 CFW 11M RB Technical Specifications Control Rack 213 1 313 3 180 1 75 5 60 3 85 7 180 1 7 1 213 1 8 4 313 3 12 3 75 5 3 85 7 3 4 60 3 2 4 Figure 8 3 Control rack dimensions in mm in...

Страница 94: ...W 11M RB 8 7 Technical Specifications IPS1 Shielding Metal Case 375 295 7 69 4 47 4 179 5 255 255 10 179 5 7 1 295 7 11 6 375 14 8 69 4 2 7 47 4 1 9 Figure 8 4 IPS1 board metallic case dimensions in m...

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