Danfoss VACON 1000 Operating guide

Operating Guide

VACON® 1000

drives.danfoss.com

VACON® 1000
Operating Guide	Contents

Contents

1 Introduction		8
1.1	Purpose of this Operating Guide	8
1.2	Additional Resources	8
1.3	Manual Version	8
1.4	Disposal	8

2 Safety		9
2.1	Safety Symbols	9
2.2	Qualified Personnel	9
2.3	Danger and Warnings	9
2.4	Cautions and Notices	10

3 Product Overview				13
3.1	Product Characteristics			13
3.2	Applications			13
3.3	System Hardware			14
	3.3.1	Control Cabinet		15
		3.3.1.1	Controls and Indicators	17
	3.3.2	Power Cell Cabinet		18
	3.3.3	Transformer Cabinet		20
	3.3.4	Junction Cabinet		21
	3.3.5	Start-up Cabinet		21
	3.3.6	Output Filter Cabinet		23
	3.3.7	Bypass Cabinet		24
		3.3.7.1	Manual Bypass Cabinet	24
		3.3.7.2	Automatic Bypass Cabinet	25
		3.3.7.3	Synchronous Transfer Cabinet	28
3.4	System Operation			29
	3.4.1	Main Circuit		29
	3.4.2	Power Cells		30
	3.4.3	Control System		31
3.5	Type Code Description			33
3.6	Available Options			34
	3.6.1	Cabinet Bypass		36
	3.6.2	Input Devices		36
	3.6.3	Output Devices		37
	3.6.4	Mechanical Options		37
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VACON® 1000
Operating Guide				Contents
	3.7	VACON® 1000 PC Tool		37
4	Receiving the Delivery			38
	4.1	Checking the Delivery		38
	4.2	Storage		38
	4.3	Lifting and Moving the Drive		38
		4.3.1 Lifting the Standalone Cabinets		38
		4.3.2 Lifting the Line-up Cabinets		40
		4.3.3	Using a Forklift	40
5	Mechanical Installation			42
	5.1	Operating Environment		42
	5.2	Cabinet Installation		42
		5.2.1	Attaching the Cabinets	42
		5.2.2	Mounting the Cabinets	44
	5.3	Installing the Power Cells		44
	5.4	Dimensions of the Enclosed Drive		45
	5.5	Cooling and Free Space Around the Enclosed Drive		45
		5.5.1	Air Ducting Guidelines	46
6	Electrical Installation			47
	6.1	The Main Circuit		47
	6.2	Main Circuit Breaker and Fuses		47
	6.3	Galvanic Isolation Between the MV and LV Sections		47
	6.4	Terminals		47
		6.4.1 Terminal Locations in the Standalone Cabinet		47
		6.4.2 Terminal Locations in the Line-up Cabinet		48
	6.5	Cable Entry and Termination		49
		6.5.1 Power Cable Entry of Standalone Cabinet		49
		6.5.2 Power Cable Entry of Line-up Cabinet		50
		6.5.3	Power Cable Termination	51
		6.5.4	Control Cable Entry	51
	6.6	Grounding		53
	6.7	Power Cable Selection		53
	6.8	Additional Instructions for Cable Installation		54
	6.9	Control Wiring		54
		6.9.1	Control Cable Selection	54
		6.9.2	Control Power Wiring	54
		6.9.3	Control Circuit Wiring	55
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VACON® 1000
Operating Guide				Contents
		6.9.4	Application Wiring Example	59
		6.9.5	PLC Configuration	60
			6.9.5.1 PLC Basic Configuration	60
			6.9.5.2 Options and Customized Designs	61
7	Human-Machine Interface			63
	7.1	The VACON® 1000 HMI		63
	7.2	HMI Homepage		63
		7.2.1	System Status	63
		7.2.2	Dashboard	64
		7.2.3	Single-line Diagram	64
	7.3	Control Panel		64
	7.4	Status		65
		7.4.1	Power Cell	65
		7.4.2	Cooling Fan	65
	7.5	Graphs & Reports		65
	7.6	Setup & Service		66
		7.6.1	Operation Mode	67
		7.6.2	Motor Parameter	67
		7.6.3	Functions	68
		7.6.4	Protections	68
		7.6.5	PID Setup	68
		7.6.6	System Configuration	69
	7.7	Events		69
		7.7.1	Warning & Fault	69
		7.7.2	Event Log	70
	7.8	Administration		71
	7.9	Tool Settings		72
		7.9.1	Language	72
		7.9.2	Software Version	72
		7.9.3	HMI Set	72
8	Commissioning			74
	8.1	Safety Checks before Starting the Commissioning		74
	8.2	Personnel Requirements		74
	8.3	Commissioning Checks		74
	8.4	Commissioning Report		76
	8.5	Operating the Drive		76
		8.5.1	Powering the Drive	76
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VACON® 1000
Operating Guide			Contents
	8.5.2	Starting the Drive	76
	8.5.3	Stopping the Drive	77
	8.5.4 Powering Off the Drive		77
8.6	Interlocking System		78
	8.6.1	Electromagnetic Interlocking System	78
	8.6.2	Mechanical Interlocking System	78
9 Maintenance			79
9.1	Safety		79
9.2	Standard Maintenance Process		80
9.3	Maintenance Schedule		80
	9.3.1	Daily Maintenance	80
	9.3.2	Yearly Maintenance	81
9.4	Replacing the Air Filters		82
	9.4.1 Air Filters of Standalone Cabinets		82
	9.4.2 Air Filters of Transformer and Power Cell Cabinets		83
	9.4.3 Air Filters of Control Cabinet		84
9.5	Replacing the HMI Battery		84
9.6	Replacing the Cooling Fans		85
	9.6.1 Diagram of the Cooling Fan Replacement		86
9.7	UPS Battery		86
	9.7.1 Replacing the UPS Battery		86
	9.7.2	UPS Battery Maintenance	86
9.8	Power Cells		87
	9.8.1	Power Cell Maintenance	87
	9.8.2 Replacing the Power Cells		88
		9.8.2.1 Diagram of the Power Cell Replacement	89
	9.8.3 Reforming the Power Cell Capacitors		90
		9.8.3.1 Reforming with an AC Supply	90
		9.8.3.2 Reforming with a DC Supply	91
9.9	Dielectric Withstand Test		91
	9.9.1 Testing Input and Output Together		92
	9.9.2 Testing Input and Output Separately		92
10 Fault Tracing			94
10.1	Fault Types		94
10.2	Fault Response Configuration		94
10.3	Faults and Alarms		94

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VACON® 1000
Operating Guide	Contents

11 Specifications			108
11.1	Technical Data		108
11.2	Power Ratings and Dimensions		111
	11.2.1	IEC Ratings	111
	11.2.2	UL Ratings	119
11.3	Internal Cables and Terminals		133
11.4	Replacement Fuses		135
11.5	Standards		136
11.6	Abbreviations		140

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VACON® 1000

Operating Guide	Introduction

1 Introduction

1.1 Purpose of this Operating Guide

This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel.

Read and follow the instructions to use the drive safely and professionally.

Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive. VLT® is a registered trademark for Danfoss A/S.

1.2 Additional Resources

Other resources are available to understand advanced AC drive functions, programming, and options.

•The VACON® 1000 Application Guide provides greater detail on how to work with the application and how to set the parameters of the AC drive.

•User guides for product options.

Supplementary publications and manuals are available from Danfoss. See www.danfoss.com for listings.

1.3 Manual Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.

Table 1: VACON® 1000 Operating Guide Version

Version	Release date	Remarks
B	29.06.2021	Updates to dimensions and weights

1.4 Disposal

Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with local and currently valid legislation.

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VACON® 1000

Operating Guide	Safety

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

•Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

•Are familiar with the basic regulations concerning health and safety/accident prevention.

•Have read and understood the safety guidelines given in all manuals, especially the instructions given in the operating guide of the unit.

•Have good knowledge of the generic and specialist standards applicable to the specific application.

•Are familiar with the structure and operation of medium-voltage drives and the related risks. Special training for medium-volt- age installations may be necessary.

2.3 Danger and Warnings

D A N G E R

SHOCK HAZARD FROM POWER UNIT COMPONENTS

The power unit components are live when the drive is connected to mains. Contact with this voltage can result in death or serious injury.

-Do not touch the components of the power unit when the drive is connected to mains. Do not do any work on live equipment.

Before doing any work on internal drive components, follow proper lock out and tag out procedure.

Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

D A N G E R

SHOCK HAZARD FROM TERMINALS

The motor terminals U, V, W, and the DC-link terminals must be treated as live when the drive is connected to mains. Contact with this voltage can lead to death or serious injury.

-Do not touch the motor terminals U, V, W, or the DC terminals when the drive is connected to mains. Do not do any work on live equipment.

Before doing any work on the drive, follow proper lock out and tag out procedure.

Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

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VACON® 1000

Operating Guide	Safety

D A N G E R

SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE

The terminal connections and the components of the drive can be live several minutes after the drive is disconnected from the mains and the motor has stopped. The load side of the drive can also generate voltage. A contact with this voltage can lead to death or serious injury.

-Do not do touch the main circuit of the drive or the motor before the system is powered off and grounded. Disconnect the drive from the mains and make sure that the motor has stopped.

Disconnect the motor.

Lock out and tag out the power source to the drive.

Make sure that no external source generates unintended voltage during work. Ground the drive for work.

Wait at least 15 minutes for the DC-link capacitors to discharge fully before opening the cabinet door or the cover of the AC drive.

Use a measuring device to make sure that there is no voltage.

W A R N I N G

SHOCK HAZARD FROM CONTROL TERMINALS

The control terminals can have a dangerous voltage also when the drive is disconnected from mains. A contact with this voltage can lead to injury.

-Make sure that there is no voltage in the control terminals before touching the control terminals.

W A R N I N G

ACCIDENTAL MOTOR START

When there is a power-up, a power break, or a fault reset, the motor starts immediately if the start signal is active, unless the pulse control for Start/Stop logic is selected. If the parameters, the applications or the software change, the I/O functions (including the start inputs) can change. If you activate the auto reset function, the motor starts automatically after an automatic fault reset. See the Application Guide. Failure to ensure that the motor, system, and any attached equipment are ready for start can result in personal injury or equipment damage.

-Disconnect the motor from the drive if an accidental start can be dangerous. Make sure that the equipment is safe to operate under any condition.

W A R N I N G

ELECTRICAL SHOCK HAZARD - LEAKAGE CURRENT HAZARD >3.5 MA

Leakage currents exceed 3.5 mA. Failure to connect the drive properly to protective earth (PE) can result in death or serious injury.

-Ensure reinforced protective earthing conductor according to IEC 60364-5-54 cl. 543.7 or according to local safety regulations for high touch current equipment. The reinforced protective earthing of the drive can be done with:

-a PE conductor with a cross-section of at least 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al.

-an extra PE conductor of the same cross-sectional area as the original PE conductor as specified by IEC 60364-5-54 with a minimum cross-sectional area of 2.5 mm2 (14 AWG) (mechanical protected) or 4 mm2 (12 AWG) (not mechanical protected).

-a PE conductor completely enclosed with an enclosure or otherwise protected throughout its length against mechanical damage.

-a PE conductor part of a multi-conductor power cable with a minimum PE conductor cross-section of 2.5 mm2 (14 AWG) (permanently connected or pluggable by an industrial connector. The multi-conductor power cable shall be installed with an appropriate strain relief).

-NOTE: In IEC/EN 60364-5-54 cl. 543.7 and some application standards (for example IEC/EN 60204-1), the limit for requiring reinforced protective earthing conductor is 10 mA leakage current.

2.4 Cautions and Notices

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VACON® 1000

Operating Guide	Safety

C A U T I O N

DAMAGE TO THE AC DRIVE FROM INCORRECT SPARE PARTS

Using spare parts that are not from the manufacturer can damage the drive.

-Do not use spare parts that are not from the manufacturer.

C A U T I O N

DAMAGE TO THE AC DRIVE FROM CHANGES TO DRIVE COMPONENTS

Doing electrical or mechanical changes to the drive components can cause malfunctions and can damage the AC Drive.

-Do not make electrical or mechanical changes to the drive components.

C A U T I O N

DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING

Not using a grounding conductor can damage the drive.

-Always ground the AC drive with a grounding conductor that is connected to the grounding terminal that is identified with the PE symbol.

C A U T I O N

DAMAGE TO THE AC DRIVE DUE TO DISCONNECTED CONTROL POWER

Disconnecting the control auxiliary power when the AC drive is connected to mains or when the power indicator is on can cause abnormalities in the function of the power cells and damage the cells.

-Do not disconnect the control auxiliary power supply when the AC drive is connected to mains or if the power indicator is on.

C A U T I O N

CUT HAZARD FROM SHARP EDGES

There can be sharp edges in the AC drive that can cause cuts.

-Wear protective gloves when mounting, cabling, or doing maintenance operations.

C A U T I O N

BURN HAZARD FROM HOT SURFACES

Touching surfaces, which are marked with the 'hot surface' sticker, can result in injury.

-Do not touch surfaces which are marked with the 'hot surface' sticker.

N O T I C E

DAMAGE TO THE AC DRIVE FROM STATIC VOLTAGE

Some of the electronic components inside the AC drive are sensitive to ESD. Static voltage can damage the components.

-Use ESD protection when working with electronic components of the AC drive. Do not touch the components on the circuit boards without proper ESD protection.

N O T I C E

DAMAGE TO THE AC DRIVE FROM INCORRECT EMC LEVEL

The EMC level requirements for the AC drive depend on the installation environment. An incorrect EMC level can damage the drive.

-Before connecting the AC drive to the mains, make sure that the EMC level of the AC drive is correct for the mains.

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VACON® 1000

Operating Guide	Safety

N O T I C E

MAINS DISCONNECTION DEVICE

If the AC drive is used as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN 60204-1).

N O T I C E

MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES

Because there are high capacitive currents in the AC drive, it is possible that the fault current protective switches do not operate correctly.

N O T I C E

VOLTAGE WITHSTAND TESTS

If done improperly, doing voltage withstand tests can damage the drive.

-Megohmmeter testing is the only recommended test type for field installations. Only a qualified field service engineer is allowed to perform this test.

Refer to the proper high potential/megohmmeter testing instructions in the service guide.

N O T I C E

WARRANTY

If the power modules are opened, the warranty is not valid.

-Do not open the power modules.

N O T I C E

PERSONAL PROTECTIVE EQUIPMENT AND APPROVED TOOLS

When doing electrical work on the AC drive, always use personal protective equipment (PPE) and tools which are approved for work with medium-voltage devices.

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VACON® 1000

Operating Guide	Product Overview

3 Product Overview

3.1 Product Characteristics

The VACON® 1000 medium-voltage drive is an alternating current speed regulating device from Danfoss. The drive features include excellent performance, easy and convenient operation, and a wide range of applications using IGBT power devices and complete digital control.

High efficiency and low distortion

•The used multi-pulse input rectification transformer technology efficiently lowers the content of the input side distortion current to less than 5%. It meets the IEEE 519-1992 standard and the strict requirements of electric grids for distortion, and enhances the power factor to more than 0.96 lagging.

•With the used cell-cascaded multilevel technology, there is normally no need for an output filter, and the output voltage waveform is similar to a sine-wave.

•System efficiency >98.5% (at rated frequency, excluding transformer).

Tolerant to power disturbances and wide applicable scope

•When the input voltage is as low as 70%, the system can still continue derated operation.

•With automatic output voltage adjusting function, when the input voltage fluctuates between 90–110%, the output voltage can still be kept steady. Thus, safe and steady operation of the motor is possible.

High reliability

•SOA (Service-oriented architecture) design ensures that the system operates in a wide safe range:

-Sufficient design margin makes sure that each device operates in the middle area of the safe operating area.

-Optimized thermal design ensures temperature margin for the devices.

-The DC-link capacitors are designed for long lifetime service.

•Redundant auxiliary control power.

•The system provides a self-diagnosis function to show the position and type of failure and warn the user about the fault occurrence.

•Automatic detection and warning function for cooling fan failure or excessive dust in the inlet air filter notifying the user to conduct maintenance.

•Production quality management, control flow process, and perfect test equipment and methods ensure the effective implementation of each test item for devices, components, and units during the manufacturing process at Danfoss.

Site flexibility

•The compact structure and high power density of VACON® 1000 can reduce the space requirements on site.

•The electric connections between the cabinets use highly reliable connectors which are easy to install and maintain.

•Easy-to-operate human-machine interface.

•Sufficient communication interfaces, which can be professionally configured in accordance with the application requirements.

•All PCBs are coated to avoid problems with pollution and corrosive environments.

3.2 Applications

VACON® 1000 is used for the speed control of square torque loads such as fans, pumps, and compressors, as well as for mills, crushers, and conveyor belts that require constant torque operation over the entire speed range. Accurate speed and torque controls result in better energy saving, improved process quality, and prolonged equipment lifetime. Various industries that require reliable and stable operation can benefit from the high performance of VACON® 1000.

•Power generation: Coal mills, blower fans, and water pumps.

•Metallurgy: Conveyor belts, positive displacement pumps, fans, and water pumps.

•Mining: Crushers, conveyor belts, PD pumps, fans, and water pumps.

•Petrochemical: Compressors, PD pumps, centrifugal pumps, fans, and water pumps.

•Cement and materials: Crushers, mixers, extruders, rotary kilns, drying furnaces, fans, and water pumps.

•Sugar and ethanol: Mills, pumps, and fans.

•Municipal works: Water supply pumps, sewage pumps, heat network pumps.

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VACON® 1000

Operating Guide	Product Overview

3.3 System Hardware

The VACON® 1000 medium-voltage drive consists of a controller cabinet, power cell cabinet, transformer cabinet, and junction cabinet. Other cabinets can be configured in accordance with customer requirements in the actual application.

There are two types of drive enclosure:

•Standalone type with current ratings up to 215 A

•Line-up type with current ratings 215–680 A (IEC ratings up to 11 kV, UL ratings up to 6.9 kV)

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A B

C

D

Illustration 1: Standalone System Structure

A

Control cabinet

C

Junction cabinet

B

Power cell cabinet

D

Transformer cabinet

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VACON® 1000
Operating Guide	Product Overview
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A

B

C

D

Illustration 2: Line-up System Structure

A

Control cabinet

C

Transformer cabinet

B

Power cell cabinet

D

Junction cabinet

3.3.1 Control Cabinet

The control cabinet includes:

•Main control system

•PLC

•HMI

•Battery

•Other accessories

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VACON® 1000
Operating Guide	Product Overview
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A	D
B	E
C	F

Illustration 3: Control Cabinet in VACON® 1000 Standalone Systems

A	Control rack	D	Airflow pressure switch
B	Terminal block	E	PLC
C	UPS	F	Isolation transformer
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D

A

E

B

F

C

G

Illustration 4: Control Cabinet in VACON® 1000 Line-up Systems

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VACON® 1000
Operating Guide			Product Overview
A	Control rack	E	Airflow pressure switch
B	Terminal block	F	DC power supply
C	Battery	G	Isolation transformer
D	PLC

The main control system is mounted in the control rack and consists of:

•Main control board

•I/O board

•A/D board

•Two fiber optical boards (extendable)

•Power supply board

•Bus motherboard, which connects the boards to each other.

A

B

C

D

E

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Illustration 5: Main Control System

A	Power supply board	D	Main control board
B	I/O board	E	Fiber optical boards
C	A/D board

3.3.1.1 Controls and Indicators

The following are mounted on the control cabinet door:

•High voltage power-on indicator: A green indicator, which indicates high voltage applied to the drive.

•Operation indicator: A green indicator, which indicates that the drive is in operation.

•Fault indicator: A red indicator, which indicates that the system is in “failure” state.

•Emergency Stop button (E-stop): This button is used to break the high-voltage power of the drive when the system has an emergency (such as unexpected incidents threatening the safety of the personnel or equipment). The button has a self-locking function. Turn the button clockwise to reset and to turn power on again.

•Human-machine interface: See 7 Human-Machine Interface.

•Mechanical interlocking system: Standard in UL type drives and available as option +MMKI for IEC type drives. See 8.6.2 Mechanical Interlocking System.

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VACON® 1000

Operating Guide

A

C

D

Illustration 6: Controls and Indicators on the Door of the Control Cabinet

A	Line-up cabinet	C
B	Standalone cabinet	D

3.3.2 Power Cell Cabinet

The power cell cabinet contains the power cells and their accessories.

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B

C

Product Overview

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C

D

HMI

Mechanical interlocking system

Illustration 7: Power Cell Cabinet in VACON® 1000 Standalone Systems

ACooling fan

BOutput current Hall sensor

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VACON® 1000

Operating Guide

C	Power cell

A

B

Product Overview

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Illustration 8: Power Cell Cabinet in VACON® 1000 Line-up Systems

ACooling fan

BPower cell

The power cells in the cabinet have the same electrical and mechanical parameters and can be replaced by each other.

A

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B

C

D

E

Illustration 9: Power Cell

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VACON® 1000
Operating Guide			Product Overview
A	Output terminal	COM	Communication fail indicator
B	Heat sink	DRV	Drive fault indicator
C	Handle	UV	Undervoltage indicator
D	Fuse	TMP	Overtemperature indicator
E	Input terminal	PWR	Power indicator
RS	Optical fiber (receive)	OV	Overvoltage indicator
TS	Optical fiber (transmit)	CDL	50 V DC-link voltage indicator

3.3.3 Transformer Cabinet

The transformer cabinet includes the phase-shift transformer and its accessories.

The transformer is integrated with the cabinet base through screws for the convenience of transportation and installation. The system default setting is that, when the transformer temperature exceeds 95°C, the system reports an excessive high temperature alarm but does not shut down. When the temperature exceeds 110°C, the system reports an extra-high temperature fault and shuts down.

In standalone systems, the same fan is used to cool the transformer and power cell cabinets.

A

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B C

Illustration 10: Transformer Cabinet in VACON® 1000 Standalone Systems

A	Cooling fan	C	Input current Hall sensor
B	Phase-shift transformer

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VACON® 1000

Operating Guide

A

B

Illustration 11: Transformer Cabinet in VACON® 1000 Line-up Systems

Product Overview

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C

D

A	Cooling fan	C	Input current Hall sensor
B	Phase-shift transformer	D	Output current Hall sensor

3.3.4 Junction Cabinet

The junction cabinet is used for field cable connections. See 6.5 Cable Entry and Termination.

3.3.5 Start-up Cabinet

The start-up cabinet (+PSTC) is an option for the VACON® 1000 line-up systems. The main function of the start-up cabinet is to depress inrush currents that can lead to a dip in the supply voltage:

•A phase-shifting transformer with a large capacity can produce a magnetizing surge as high as 6–8 times the rated current of the transformer itself.

•The power cells of the drive contain several capacitors, which require a large precharge current when high voltage is applied.

Junction	Startup	Output filter
cabinet	cabinet	cabinet
MCB
HV~		Drive
	KM51

Illustration 12: Start-up Cabinet Primary Side Diagram

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M

Install the start-up cabinet between the high-voltage power input and phase-shifting transformer. When the MCB of the drive is closed, the start-up cabinet limits the magnetizing surge and charge current of the capacitance quickly and efficiently. After the drive is powered up, the current-limiting resistance passes through the KM51 bypass, and the drive can function normally.

The main electrical components of the start-up cabinet are a high-voltage switch (vacuum contactor or vacuum breaker) and a cur- rent-limiting resistor.

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Illustration 13: Start-up Cabinet

The function of current-limiting resistance is to limit the primary current when a high voltage is connected. Each resistor can bear a 30 kJ energy during the power-up. The capacity of the drive defines how much resistance is needed in the start-up cabinet: the larger the capacity, the more current-limiting resistors are needed.

The function of the high-voltage switch is to bypass the current-limiting resistor after the powering-up procedure, making the drive function under normal load. If the rated current is small, a vacuum contactor can be used. If the rated current is large, a vacuum breaker can be used.

Operation process

•Power up the drive.

•The control program confirms if the system is ready and if the cabinet switch is separated or not.

•Power up the start-up cabinet and the control program counts the time it takes to complete the process. The process requires about 5 s.

•The closing of the start-up cabinet switch bypasses the charged resistor and the drive has status 'running allowed'.

When to select the Start-up cabinet option?

The MCB protection at the installation site must not trip because of the inrush current when the drive is powered up or in normal overload conditions. The overcurrent protection of the MCB must be set in the grey area shown in Illustration 14.

If the MCB meets these requirements, the start-up cabinet is not required. It is important to verify this condition, especially in retrofit applications where a circuit breaker is already installed at the motor control center panel.

Even if it is not required, a start-up cabinet can still be installed to:

•Reduce inrush current.

•Reduce stresses in the electrical installation during the drive power-up operation.

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t(I) 20TO

15TO

10TO

5TO

0

0

0.2Iratio

0.4Iratio

0.6Iratio

0.8Iratio

Iratio

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			I/ILN
Illustration 14: Overcurrent Protection Setting Area
I	Inrush current	t(I)	Time of the inrush current decay
I LN	Rated input current of the drive	T O	The basic period: 20 ms for 50 Hz or 16.7 ms for
I ratio	I/ILN		60 Hz

3.3.6 Output Filter Cabinet

The output filter cabinet is an optional cabinet which is connected at the output of the drive, between the inverter and motor. The filter is used to:

•Reduce the dU/dt of the voltage waveform.

•Prevent resonance/overvoltage caused by motor cables.

•Reduce the charging current of the cable.

R71A R72A

R73A R74A

R75A R76A

R77A R78A

L71-a

R71B R72B

R73B R74B

R75B R76B

R77B R78B

To inverter L71-b

R71C R72C

R73C R74C

R75C R76C

R77C R78C

L71-c

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To motor

Illustration 15: Output Filter Cabinet Circuit Diagram

Install the output filter cabinet between the drive and motor. The filter consists of a reactor and paralleling damping resistors. The reactor decreases the rising edge of the PWM. The resistor damps the resonance caused by the reactor and stray inductance.

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Illustration 16: Output Filter Cabinet

When to select the Output Filter cabinet option?

The need for an output filter is application and case specific. Several things must be considered to find out if a dU/dt Filter is required:

•The type of the motor.

•The type of the motor cable.

•The length of the motor cable.

To evaluate if a dU/dt Filter is required, contact Danfoss.

3.3.7 Bypass Cabinet

Different bypass cabinets are available as options:

•Manual bypass cabinet

•Automatic bypass cabinet

•Synchronous transfer cabinet

3.3.7.1 Manual Bypass Cabinet

Illustration 17 shows a typical bypass cabinet configuration, where:

•QS41 is a single-pole isolation switch with a manual grounding knife gate.

•QS42 and QS43 are double-pole double-throw manual knife gate isolation switches.

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MCB	QS41		QS42
				QS43
	DN41

Manual bypass cabinet

Illustration 17: Manual Bypass Cabinet Circuit Diagram

The bypass cabinet includes an isolation switch, which:

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•Realizes the electrical isolation between the phase-shift transformer and the power distribution system.

•Provides the power frequency and variable frequency switching function and related electrical protection measures.

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A

B

Illustration 18: Manual Bypass Cabinet

AManual knife gate switch

BDual-isolation switch panel

3.3.7.2 Automatic Bypass Cabinet

Illustration 19 shows an automatic bypass cabinet configuration, where:

•KM41–KM43, high-voltage vacuum contactors.

•QS41–QS42, manual separation knife switches.

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MCB	KM41	QS41	QS42	KM42

DN41

Manual bypass cabinet

KM43

Automatic bypass/Synchronous transfer cabinet

Illustration 19: Automatic Bypass Cabinet Circuit Diagram

When the drive is running:

•QS41 and QS42 are closed.

•KM41 and KM42 are closed.

•KM43 is open.

When the drive is bypassed:

•KM41 and KM42 are open.

•KM43 is closed.

When maintenance is performed on the drive:

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•QS41 and QS42 are open.

•KM41 and KM42 are open.

•KM43 is closed.

The sequence in which the drive is switched from running to bypassed:

•1. KM41 is opened.

•2. KM42 is opened.

•3. KM43 is closed.

Secondary Control Logic

The three switches KM41–KM43 use assistant contact interlock to ensure that the time course is followed.

•KM41 does not open and KM42 does not act when the normally closed contactor of KM41 is connected into the opening circuit of KM42.

•The normally closed contactor of KM42 is connected to the MCB-closed circuit of KM43.

•The normally closed contactor of KM43 is connected to the MCB-closed circuit of KM42.

•KM43 is not able to close the MCB when KM42 is not opening.

•KM42 is not able to close MCB when KM43 is not opening.

The status of the five switches KM41–KM43 and QS41–QS42 is monitored through the PLC.

•If any switch is not at the right working position, the system does not allow the MCB to close, and powering up high voltage to the system is forbidden.

•If the drive goes into fault, the system breaks the switch automatically to cut off the HV input for safety, if KM41 is not able to open during the process of VF switching to working frequency automatically.

The two switches KM42 and KM43 control the function of reserving postponed action in the circuit, which can adjust the action interval of the switch during the process of VF switching to working frequency. It can be more convenient to calibrate the machine on site according to the status of the electric motor and load, to switch speed reasonably to avoid an overcurrent malfunction because of the electric motor remanence.

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AC/DC 220 V

AC 220 V

501

503

ZK1

Micro breaker

504

505

Fuse

FU21

KA12

SF1

543 KA1-I

415

417

542

PF auto transfer switch

SF2

1 SF12

KT2

KA1-II

548

VF to PF manual transfer switch SF2

5

6

7

8

KM43 closing coil

KT1

415

KM42 527

528

KM43 close command

SA3

KM43

KM43 close push button

KM43 close switch

415

KA1

530

KM41

SF1

Operation mode switch SF1

KM41 close switch

KM41 opening

3

4

KM41 open push button SB1

SB1

coil

415

KM41537

KA1

532 KM42

KM42 open command

KM42 opening coil

SB2

KM42 open switch

KM42 open push button SB2

415

1 SF2 2

538

539 KA2-I

PF to VF manual transfer switch SF2

KA1544KA2

KT3

KA2-II

KA2 self-lock circuit

415

415

K4

413

KA2

533

KM43

KM43 open command

KM43 opening switch

KM43 opening coil

KM43 open push button SB3

415

KM43

540

KT3 SB3

KM42

Time relay

541

KM42 close command

KA2

KM42 close coil

KM42 close switch

KM42 close push button SA2

SA2

KM41

KM41 close command

415

KA2

524

KM41 close switch

SA1

KM41 close coil

KM41 close push button SA1

415

KA1

536

KT1

415

KT1

535

KT2

Time relay circuit

415

KA2

546

KM43 534

KT3

Illustration 20: Secondary Control Logic Diagram of VF Switching to PF

Operation Mode Switches

Switch SF1 is used to select the working mode to prevent incorrect operation.

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•Auto: Allows switching to PF bypass automatically when the drive is in a serious fault.

•Manual: Allows manual switching to working-frequency bypass according to the real production requirements when the drive is normally running.

•Forbidden: If the production conditions do not allow the switching to working-frequency bypass, this mode can be selected to prevent incorrect operation.

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Illustration 21: Working Mode Selection Switch SF1

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Switch SF2 is used to select between variable-frequency (VF) and power-frequency (PF) switching.

•When the automatic bypass cabinet is in manual operation mode, and switch SF2 is in PF position, the drive switches the system to PF bypass status automatically.

•When switch SF2 is in VF position, the drive can switch from power-frequency bypass status to variable-frequency mode automatically (QS41 and QS42 must be closed). This function needs the coordination of engine racing starting-up. Therefore, engine racing must be enabled and must comply with all the related electric motor parameters.

•VF logic sequence:

-KM41 is closed.

-If self-detection shows normal after 10 s, bypass switch KM43 is opened.

-KM42 is closed.

-Automatic engine racing of the drive starts up.

-PF is switched to VF.

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Illustration 22: Switching Mode Selection Switch SF2

3.3.7.3 Synchronous Transfer Cabinet

The synchronous transfer function can realize undisturbed transfer between the grid and the drive, and reduce the impact on the motor and grid. The primary circuit is shown in Illustration 23. The switching devices and cabinets are the same as in the automatic bypass cabinet. QS41 and QS42 are for drive maintenance use and are closed during operation.

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MCB	KM41	QS41	QS42	KM42

DN41

Manual bypass cabinet

KM43

Automatic bypass/Synchronous transfer cabinet

Illustration 23: Synchronous Transfer Cabinet Circuit Diagram

Process sequence of load transfer from the drive to the grid

•Initial state: KM41 and KM42 are closed, and KM43 is open.

•Phase lock: The drive runs to grid frequency and starts to lock phase to grid voltage.

•Synchronous transfer: After phase lock, KM43 is closed and the load transfer to grid is started.

•Synchronous transfer finished: After the load transfer, KM42 and KM41 are opened.

Process sequence of load transfer from the grid to the drive

•Initial state: KM41 and KM42 are open, and KM43 is closed.

•Phase lock: KM41 is closed. The drive runs to grid frequency and starts to lock phase to grid voltage.

•Synchronous transfer: After phase lock, KM42 is closed and the load transfer to the drive is started.

•Synchronous transfer finished: After the load transfer, KM43 is opened.

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3.4 System Operation

3.4.1 Main Circuit

The typical main circuit topological structure diagram of VACON® 1000 medium-voltage drive is shown in Illustration 24.

		Power Cells
	24°	≈
		≈
		≈
		≈
		≈
		≈
	12°	≈
		≈
		≈
		≈
		≈
		≈
	0°	≈
Source
		≈
		≈
		≈
		≈
		≈
	-12°	≈
		≈
		≈
		≈
		≈
		≈
	-24°	≈
		≈
		≈
		≈
		≈
		≈

Phase-shift

Transformer

Motor

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Illustration 24: Main Circuit Diagram of VACON® 1000

The phase-shift rectifier transformer is a 3-phase air-cooled dry-type transformer directly connected with the incoming high voltage. The secondary windings use an extended delta connection, which can lower the content of the input side current distortion. The phase-shift angle between the secondary windings can be calculated according to the following formula:

Phase − shift angle =	60°
	Number of power cells

The secondary windings of the transformer provide input power for each power cell respectively. The number of secondary windings and the phase-shift angle between the windings are determined according to the voltage level and structure of the drive, as shown in Table 2.

Table 2: Power Cell Configuration for VACON® 1000

Drive series	Number of power cells per phase	System cell number	Output phase voltage (V)	Output line voltage (V)
2.4 kV	3	9	1385	2400
3 kV	3	9	1732	3000
3.3 kV	3	9	1905	3300
4.16 kV	4	12	2400	4160
6 kV	5	15	3464	6000
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Drive series		Number of power cells per phase	System cell number	Output phase voltage (V)	Output line voltage (V)
6.6 kV		6	18	3810	6600
6.9 kV		6	18	3984	6900
10 kV		8	24	5774	10000
11 kV		9	27	6351	11000

3.4.2 Power Cells

The power cell is the basic module of the medium-voltage drive, which produces a variable voltage and frequency output. It is composed of fast acting fuses, a rectification bridge, DC-link capacitance, IGBT inverting bridge, and so on.

The input terminals of the power cells are connected with the 3-phase winding of the secondary side of the phase-shift transformer. The 3-phase diode provides full-wave rectification to charge the DC-link capacitance, and the voltage on the capacitance is provided to the H-bridge 1-phase bridge inverter circuit formed by 4 IGBTs.

The power cell receives signals through optical fibers, and controls the closing and opening of the S1–S4 IGBTs by using PWM modulation mode to output a 1-phase impulse modulated waveform. Each cell has only 3 possible output states:

•When S1 and S4 are closed, the state of the output voltage VUV is VDC.

•When S2 and S3 are closed, the output voltage VUV is -VDC.

•When S1 and S3 or S2 and S4 are closed, the output voltage VUV is 0.

Illustration 25 shows the waveform diagram of the output voltage of each power cell and the superimposed output phase voltage waveform when 6 cells are connected in series. As shown in the figure, 13 voltage levels are obtained through connecting the 6 power cells in series. The increasing number of the voltage levels reduces the distortion content of the output voltage and simultaneously lowers the risk of damaging the motor insulation caused by dU/dt. Illustration 26 and Illustration 27 are the waveform diagrams of the output voltage and current of the drive when loaded by a motor.

PWM1 PWM2 PWM3 PWM4

PWM5 PWM6

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0	4	8	Time (ms)	12	16	20

Illustration 25: Output and Phase-Voltage Diagrams

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