GE CS300 User Manual

GEH-6639 (Draft)

GE Industrial Systems

CS300

Half Controlled Power Supply for Inverter DC-Link

User‘s Guide

GEH-6639

© 2001 General Electric Company, USA.
All rights reserved.

These instructions do not purport to cover all details or variations in equipment, nor to provide every possible
contingency to be met during installation, operation, and maintenance. If further information is desired or if
particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be
referred to GE Industrial Systems, Salem, Vir ginia, USA.

This document contains proprietary information of General Electric Company, USA and is furnished to its
customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the equip­ment described. This document shall not be reproduced in whole or in part nor shall its contents be disclosed
to any third party without the written approval of GE Industrial Systems.

CS300 is a trademark of General Electric Company. USA.
National Electric code and NEC are registered trademarks of the National Fire Protection Association.

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CS300

SAFETY SYMBOL LEGEND / LÉGENDE DES SIGNES DE SÉCURITÉ

WARNING! Commands attention to an operating procedure, practice, condition, or statement which, if

not strictly observed, could result in personal injury or death.

Attire l’attention sur les modes d’utilisation et les pr océdés et conditions d’exploitation qui,
en cas d’inobservation, pourraient entraîner des blessures corporelles ou la mort.

CAUTION! Commands attention to an operating procedure, practice, condition, or statement which, if

not strictly observed, could result in damage or destruction of equipment.
The seriousness of the injuries and of the damages which could be caused by the non- obser-

vance of such indications, depends on the different conditions. Anyway, the instructions
given below should always be followed with the highest attention.

Attire l’attention sur les modes d’utilization et les procédés et conditions d’exploitation qui,
en cas d’inobservation, pourraient entraîner la détérioration ou la destruction des appareils.

La gravité des blessures et des dommages matériels possibles dépendent de différ ent facteurs.
Toutefois, les instructions mentionées ci-dessous devraient êtr e toujours suivies avec la plus
grande attention.

NOTE! Commands attention to an operating procedure, practice, condition, or statement that must

be highlighted.

Attire l’attention sur les modes d’utilization et les procédés et conditions d’exploitation qui
présentent un intéret particulier.

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GEH-6639

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CS300

TABLE OF CONTENTS

SAFETY SYMBOL LEGEND / LÉGENDE DES SIGNES DE SÉCURITÉ ......................3

CHAPTER 1 - SAFETY PRECAUTIONS .................................................................... 7

CHAPTER 2 - COMPONENT IDENTIFICATION AND SPECIFICATION ................. 11

2.1 GENERAL DESCRIPTION ..................................................................................................... 11

2.2 POWER SUPPLY .................................................................................................................. 11

2.3 DESCRIPTION OF POWER TERMINALS ............................................................................... 11

2.4 DESCRIPTION OF CONTROL TERMINALS............................................................................12

2.5 PROTECTIONS..................................................................................................................... 12

2.5.1 Internal Protection Components ...................................................................................12

2.5.2 Internal Fuses .............................................................................................................. 12

2.5.3 External AC Mains Fuses .............................................................................................13

2.5.4 AC Mains Choke.......................................................................................................... 13

2.6 CONVERTER SIZE SELECTION .............................................................................................14

2.6.1 Output Rated Currents for the Two Functioning Classes ................................................14

2.6.2 Drive DC Current (DC Link Circuit) ................................................................................ 15

CHAPTER 3 - SELECTION OF THE CS300 CONVERTER........................................16

3.1 DIP-SWITCHES AND JUMPER ............................................................................................. 16

3.2 USE OF S1 SWITCH .............................................................................................................16

3.3 USE OF S2 SWITCH .............................................................................................................18

3.4 USE OF S3 SWITCH .............................................................................................................18

3.5 USE OF S4 AND S5 DIP SWITCH .........................................................................................19

3.6 USE OF CV JUMPER ............................................................................................................19

CHAPTER 4 - CONTROL DESCRIPTION ................................................................20

4.1 OK RELAY............................................................................................................................. 20

4.2 PRECHARGE ENABLING CONTROL ...................................................................................... 20

4.3 MLP SIGNAL ........................................................................................................................ 20

4.4 ML SIGNAL ..........................................................................................................................20

CHAPTER 5 - CONVERTER DIMENSIONS ............................................................ 21

CHAPTER 6 - CONVERTER OPERATION ...............................................................22

6.1 EXAMPLE OF TERMINAL STRIP CONNECTION .................................................................... 22

6.2 SIGNAL DIAGRAM ...............................................................................................................23

Figure A ........................................................................................................................................................ 23

Figure B ........................................................................................................................................................ 23

6.3 COMMON BUS MULTI-INVERTER SYSTEM.......................................................................... 24

CHAPTER 7 - REPLACEMENT PARTS .................................................................. 25

CHAPTER 8 - WARRANTY PARTS AND SERVICE................................................27

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GEH-6639

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——————— INSTRUCTION MANUAL ————————

CS300

Chapter 1 - SAFETY PRECAUTIONS

NOTE! The terms “Inverter”, “Controller” and “Drive” are sometimes used interchangably through-

out the industry. We will use the term “Drive” in this document

Les mots “Inverter”, “Controller” et “Drive” sont interchangeables dans le domaine
industriel. Nous utiliserons dans ce manuel seulement le mot “Drive”.

WARNING! / ATTENTION!

According to the EEC standards the CS300 and accessories must be used only after checking that the machine
has been produced using those safety devices required by the 89/392/EEC set of rules.

Drive systems cause mechanical motion. It is the responsibility of the user to insure that any such motion does
not result in an unsafe condition. Factory provided interlocks and operating limits should not be bypassed or
modified.

Never open the device or covers while the AC Input power supply is switched on. Minimum time to wait before
working on the terminals or internal devices is 5 minutes.

If the front plate has to be removed because the ambient temperature is higher than 40 degrees, the user has to
ensure that no occasional contact with live parts will occur.

Always connect the Drive to the protective ground (PE) via the marked connection terminals (PE2) and the
housing (PE1). Adjustable Frequency Drives and AC Input filters have ground discharge currents greater than

3.5 mA. EN 50178 specifies that with discharge currents greater than 3.5 mA the protective conductor ground
connection (PE1) must be fixed type and doubled for redundancy.

The drive may cause accidental motion in the event of a failure, even if it is disabled, unless it has been discon­nected from the AC input feeder.

Selon les normes EEC, les drives CS300 et leurs accessoires doivent êtr e employés seulement après avoir verifié
que la machine ait été produit avec les même dispositifs de sécurité demandés par la réglementation 89/392/
EEC concernant le secteur de l’industrie.

Les systèmes provoquent des mouvements mécaniques. L’utilisateur est responsable de la sécurité concernant
les mouvements mécaniques. Les dispositifs de sécurité prévues par l’usine et les limitations operationelles ne
doivent être dépassés ou modifiés.

Ne jamais ouvrir l’appareil lorsqu’il est suns tension. Le temps minimum d’attente avant de pouvoir travailler
sur les bornes ou bien à l’intérieur de l’appareil est 5 minutes.

Si la plaque frontale doit être enlevée pour un fonctionnement avec la température de l’environnement plus
haute que 40°C, l’utilisateur doit s’assurer, par des moyens opportuns, qu’aucun contact occasionnel ne puisse
arriver avec les parties sous tension.

Effectuer toujours des connexions de terre (PE) par le biais des bornes (PE2) et du chassis (PE1). Le courant de dispersion
vers la terre est supérieur à 3,5 mA. Selon EN 50178 il faut prévoir dans ces cas une double connexion à terr e.

WARNING! - ELECTRICAL SHOCK AND BURN HAZARD /
ATTENTION! – DÉCHARGE ÉLECTRIQUE ET RISQUE DE BRÚLURE :

When using instruments such as oscilloscopes to work on live equipment, the oscilloscope’s chassis should be
grounded and a differential amplifier input should be used.

Care should be used in the selection of probes and leads and in the adjustment of the oscilloscope so that
accurate readings may be made. See instrument manufacturer’s instruction book for proper operation and
adjustments to the instrument.

Lors de l’utilisation d’instruments (par example oscilloscope) sur des systémes en marche, le chassis de
l’oscilloscope doit être relié à la terre et un amplificateur différentiel devrait être utilisé en entrée.

Les sondes et conducteurs doivent être choissis avec soin pour effectuer les meilleures mesures à l’aide d’un
oscilloscope. Voir le manuel d’instruction pour une utilisation correcte des instruments.

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WARNING! - FIRE AND EXPLOSION HAZARD / ATTENTION! – RISQUE D’INCENDIES ET D’EXPLOSIONS:

Fires or explosions might result from mounting Drives in hazardous areas such as locations where flammable or
combustible vapors or dusts are present. Drives should be installed away from hazardous areas, even if used
with motors suitable for use in these locations.

L’utilisation des drives dans des zônes à risques (présence de vapeurs ou de poussières inflammables), peut
provoquer des incendies ou des explosions. Les drives doivent être installés loin des zônes dangeureuses, et
équipés de moteurs appropriés.

WARNING! - STRAIN HAZARD:

Improper lifting practices can cause serious or fatal injury . Lift only with adequate equipment and trained personnel.

Une élévation inappropriée peut causer des dommages sérieux ou fatals. Il doit être élevé seulement avec des
moyens appropriés et par du personnel qualifié.

WARNING! - ELECTRIC SHOCK HAZARD / ATTENTION! - CAS DE DECHARGE ELECTRIQUE:

- Drives and motors must be grounded according to NEC (for USA) and EN 60204 (for Europe).

- Replace all covers before applying power to the Drive. Failure to do so may result in death or serious injury .

- Adjustable frequency drives are electrical apparatus for use in industrial installations. Parts of the Drives are
at high voltage during operation. The electrical installation and the opening of the device should therefore
only be carried out by qualified personnel. Improper installation of motors or Drives may therefore cause
the failure of the device as well as serious injury to persons or material damage. Follow the instructions
given in this manual and observe the local and national safety regulations applicable.

- Tous les moteurs et les drives doivent être mis à la terre selon le Code Electrique National ou équivalent.

- Remettre tous les capots avant de mettre sous tension le drive. Des erreurs peuvent provoquer de sérieux
accidents ou même la mort.

- Les drives à fréquence variable sont des dispositifs électriques utilisés dans des installations industriels.
Une partie des drives sont sous tension pendant l’operation. L’installation électrique et l’ouverture des
drives devrait être executé uniquement par du personel qualifié. De mauvaises installations de moteurs ou
de drives peuvent provoquer des dommages materiels ou blesser des personnes.On doit suivir les instruc­tions donneés dans ce manuel et observer les régles nationales de sécurité.

CAUTION! / PRECAUTION!:

- Do not connect power supply voltage that exceeds the standard specification voltage fluctuation permissi­ble. If excessive voltage is applied to the Drive, damage to the internal components will result.

- Do not operate the Drive without the ground wire connected. The motor chassis should be grounded to earth
through a ground lead separate from all other equipment ground leads to prevent noise coupling.

- The grounding connector shall be sized in accordance with the NEC or Canadian Electrical Code. The
connection shall be made by a UL listed or CSA certified closed-loop terminal connector sized for the wire
gauge involved. The connector is to be fixed using the crimp tool specified by the connector manufacturer.

- Do not perform a megger test between the Drive terminals or on the control circuit terminals.

- Because the ambient temperature greatly affects Drive life and reliability, do not install the Drive in any
location that exceeds the allowable temperature. Leave the ventilation cover attached for temperatures of
104° F (40° C) or below.

- Be sure to remove the desicant dryer packet(s) when unpacking the Drive. (If not removed these packets
may become lodged in the fan or air passages and cause the Drive to overheat).

- The Drive must be mounted on a wall that is constructed of heat resistant material. While the Drive is
operating, the temperature of the Drive's cooling fins can rise to a temperature of 194° F (90°C).

- Do not touch or damage any components when handling the device. Changing of isolation gaps or removing
the isolation covers is not permissible.

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CS300

- Protect the device from disallowed environmental conditions (temperature, humidity, shock etc.)

- The electrical commissioning should only be carried out by qualified personnel, who are also responsible

for the provision of a suitable ground connection and a protected power supply feeder in accordance with
the local and national regulations. The motor must be protected against overloads.

- No dielectric tests should be carried out on parts of the frequency inverter . A suitable measuring instrument

(internal resistance of at least 10 kΩ/V) should be used for measuring the signal voltages.

- No voltage should be connected to the output of the drive (terminals C, D).

- Ne pas raccorder de tension d’alimentation dépassant la fluctuation de tension permise par les normes.

Dans le cas d’ une alimentation en tension excessive, des composants internes peuvent être endommagés.

- Ne pas faire fonctionner le drive sans prise de terre. Le chassis du moteur doit être mis à la terre à l’aide

d’un connecteur de terre separé des autres pour éviter le couplage des perturbations.

- Le connecteur de terre devrait être dimensionné selon la norme NEC ou le Canadian Electrical code. Le

raccordement devrait êtr e fait par un connecteur certifié et mentionné à boucle fermé par les normes CSA et
UL et dimensionné pour l’épaisseur du cable correspondant. Le connecteur doit être fixé a l’aide d’un
instrument de serrage specifié par le producteur du connecteur.

- Ne pas exécuter un test megger entre les bornes du drive ou entre les bornes du circuit de contrôle.

- Étant donné que la température ambiante influe sur la vie et la fiabilité du drive, on ne devrait pas installer

le drive dans des places ou la temperature permise est dépassée. Laisser le capot de ventilation en place
pour températures de 104°F (40°C) ou inférieures.

- Lors du déballage du drive, retirer le sachet déshydraté. (Si celui-ci n’est pas retiré, il empêche la ventila-

tion et provoque une surchauffe du drive).

- Le drive doit être monté sur un mur construit avec des matériaux résistants à la chaleur . Pendant le fonctionnement

du drive, la température des ailettes du dissipateur thermique peut arriver à 194°F (90°).

- Manipuler l’appareil de façon à ne pas toucher ou endommager des parties. Il n’est pas permis de changer

les distances d’isolement ou bien d’enlever des matériaux isolants ou des capots.

- Protéger l’appareil contre des effets extérieurs non permis (température, humidité, chocs etc.).

- La mise en service électrique doit être effectuée par un personnel qualifié. Ce dernier est responsable de

l’existence d’une connexion de terre adéquate et d’une protection des câbles d’alimentation selon les pre­scriptions locales et nationales. Le moteur doit être protégé contre la surcharge

- Il ne faut pas éxécuter de tests de rigidité diélectrique sur des parties du convertisseurs. Pour mesurer les

tensions, des signaux, il faut utiliser des instruments de mesure appr opriés (résistance interne minimale 10
k

Ω

/V).

- Aucune tension ne doit être appliquée sur la sortie du convertisseur (bornes C, D).

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CS300

Chapter 2 - COMPONENT IDENTIFICATION AND SPECIFICATION

2.1 GENERAL DESCRIPTION

CS300 is a half-controlled three phase AC/DC converter for supplying DC link voltage to a series of AC Drives,
with C and D terminals parallel connected.

The precharge of the drive capacitors (time setting set via dip-switches) is done by partializing the mains
voltage via a thyristors bridge. A diagnostic circuit allows detection of a mains power supply dip for
system use.

NOTE! The direct parallel connection of the outputs (U2,V2,W2 terminals) of two or more inverters

is not possible !

2.2 POWER SUPPLY

CS300 converter can be connected to the three phase power supply having the following characteristics:

400V-15% up to 480+10%
50 or 60 Hz (Dip-switch selectable)

The maximum input power of the internal switching power supply is 100W, and the supplied voltages are:

+/-15V 500mA Control card
+24 V 2A Fan power supply (if present) and auxiliary functions (regulator

terminals power supply)

2.3 DESCRIPTION OF POWER TERMINALS

Terminals Function

U, V, W Power supply via AC mains, 3Ph (400V –15% up to 480V +10%)

C Positive terminal to be connected to the inverter DC-LINK

D Negative terminal to be connected to the inverter DC-LINK

U3, V3

Supply for internal fan (only for 1050A size and higher)
(1Ph, 230V ± 15%)

cs010

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GEH-6639

2.4 DESCRIPTION OF CONTROL TERMINALS

Terminals Function Voltage, Current

23 Input of the precharge enable control (15 - 35V, 5 - 11mA)
32 Output of the MLP static signal (low - active signal) (5 … 35V, 20mA source)
33 (Common) Ground of the MLP and ML static signals -
34 Reference point for Power supply +24V -
35 Power supply output +24V (32V / 300mA max)
36 Output of the ML signal (low - active signal) (5 … 35V, 20mA max sink)
37 Power supply of the ML and MLP signals (35V max)
52 (Common) Ground of the precharge enable control -

70, 72 OK Relay (max 250V, 1A – AC11)

2.5 PROTECTIONS

2.5.1 Internal Protection Components

cs020

Converter Designation Varistors

6KCS3185-480
6KCS3280-480
6KCS3420-480 575 V / 220 J
6KCS3650-480 Ø 20 mm

6KCS310H-480

6KCS315H-480

2.5.2 Internal Fuses

Converter Designation Fuses

6KCS3185-480
6KCS3280-480 16 A / 500 V
6KCS3420-480 fast6x32mm
6KCS3650-480

6KCS310H-480 25 A / 500 V
6KCS315H-480 fast 6 x 32 mm

F1, F2, F3

V1, V2, V3

cs025

Designation Fuses for Fuses

F4 Power supply protection 4 A, 250 V fast 6,3 x 32

F5 +24V protection 1 A, 250 V slow5x20

cs030

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2.5.3 External AC Mains Fuses

CS300

Converter Ref. Pieces

6KCS3185-480

6KCS3280-480

6KCS3420-480

6KCS3650-480

6KCS310H-480

6KCS315H-480

A 3 S00üF1/80/200A/660V SKF4G23 A70QS200-4K FWP200A PDFP7V200ABLADE

B 1+1 S1üF1/110/250A/660V SKF4G28 A70QS300-4 FWP300A PDFP7V300ABLADE

A3S1üF1/110/315A/660V SKF4G30 A70QS350-4 FWP350A PDFP7V350ABLADE

B 1+1 S1üF1/110/315A/660V SKF4G30 A70QS350-4 FWP350A PDFP7V350ABLADE

A3S2üF1/110/500A/660V SKF4E30 A70QS500-4 FWP500A PDFP7V500ABLADE

B 1+1 S2üF1/110/500A/660V SKF4E30 A70QS500-4 FWP500A PDFP7V500ABLADE

A3S2üF1/110/630A/660V SKF4E31 A70QS600-4 FWP600A PDFP7V600ABLADE

B 1+1 S3üF1/110/800A/660V SKF4H02 A70QS800-4 FWP800A PDFP7V800ABLADE

1

A(

)

1

)

B(

1

)

A(

1

B(

)

3 170M5466 (1000A/700V) SKS827B SKS827B

3S2üF1/110/630A/660V SKF4E31 A70QS600-4 FWP600A PDFP7V600ABLADE

3 G3MUEF1/1000A/660V SKF4G76 SKF4G76

(1+1)+

(1+1)

S3üF1/110/1000A/660V SKF4H03 A70P1000 FWP1000 SKS7812

Europe

Type Code Code

Ref: A: External fuses for the input side power supply bridge

B: External fuses for the DC link output

1

(

): Fuses integrated in the device

USA

Type

170M5466 (1000A/700V)

G3MUEF1/1000A/660V

cs041

Fuse manufactures: S… , G… Jean Muller, Eltville

A70… Ferraz Shawmutt
FWP…, 170M.. Bussmann

2.5.4 AC Mains Choke

Main Main three-phase inductance

Converter

6KCS3185-480 50/60 0.148 173 350
6KCS3280-480 50/60 0.082 360 540 KLR 420 CCB
6KCS3420-480 50/60 0.082 360 540 KLR 420 CCB

6KCS3650-480 50/60 0.053 560 840 KLR 600 CCB
6KCS310H-480 50/60 0.033 900 1350 KLR 950 CCB
6KCS315H-480 50/60 0.019 1425 2138

NOTE! The use of AC mains choke on the power supply input is MANDATORY

frequency Rated inductance Rated AC Saturation

[Hz] [mH] current [A] current [A]

Type

cs050

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GEH-6639

2.6 CONVERTER SIZE SELECTION

Within the specified voltage field, the CS300 converter supplies the same rated direct current independently of
the voltage itself. The increase of the output voltage causes an increasing in the transferred power, whereas
inverters are devices with a typically constant transferred power (the supplied current decreases with the increasing
of the output voltage).

As for the choice, therefore, the calculation is based on a common unit, the direct current of the intermediate
circuit, which, as for the inverters, is not mentioned into the product instruction manual and has therefore to be
calculated. Furthermore, the confrontation between the two foreseen functioning classes has to be homogeneous
(IEC 146 class 1 and 2).

2.6.1 Output Rated Currents for the Two Functioning Classes

Converter

6KCS3185-480
6KCS3280-480
6KCS3420-480

6KCS3650-480
6KCS310H-480
6KCS315H-480

* Continuous service

** Service with overload possibility of 150% for 60 seconds

DC link current (Terminals C / D)

IEC 146 Class 1 * IEC 146 Class 2 **

185 A 150 A
280 A 225 A
420 A 340 A

650 A 540 A
1050 A 850 A
1500 A 1300 A

cs060

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——————— INSTRUCTION MANUAL ————————

2.6.2 Drive DC Current (DC Link Circuit)

CS300

Rated motor Motor Current Current Fuses

power efficiency

P

Mot

[kW] [A] [A] [A]

0,55 0,71 1,56 2,12 6 4003 4003
0,75 0,74 2,04 2,77 6 4003 4003

1,1 0,75 2,95 4,01 6 4003 4003
1,5 0,75 4,02 5,47 8 4003 4003
2,2 0,79 5,60 7,61 10 4003 4003

3 0,81 7,44 10,12 16 4003 4003

4 0,83 9,68 13,17 16 4005 4005
5,5 0,84 13,16 17,90 20 4005 4007
7,5 0,86 17,53 23,83 30 4007 4011

11 0,88 25,12 34,16 40 4011 4015
15 0,89 33,87 46,06 63 4015 4022

18,5 0,905 41,08 55,87 63 4022 4022

22 0,912 48,48 65,93 80 4022 4030
30 0,918 65,67 89,32 100 4030 4037
37 0,923 80,56 109,56 125 4037 4045
45 0,93 97,24 132,25 160 4045 4055
55 0,935 118,21 160,77 200 4055 4075
75 0,943 159,83 217,37 250 4075 4090

90 0,946 191,19 260,02 315 4090 4110
110 0,947 233,43 317,46 350 4110 4132
132 0,951 278,94 379,35 450 4132 4160
160 0,955 336,69 457,90 500 4160 4250
200 0,958 419,54 570,58 630 4250 4250
250 0,96 523,33 711,74 800 4250 4315
315 0,963 657,35 893,99 1000 4315
355 0,963 740,82 1007,52
400 0,965 833,00 1132,88



Mot

Dclink I

Continuous class 1 Overload class 2 Superfast class 1 class 2

DCL

DClink I

DCL

DClink

AV300 -…

cs070

The following table states the direct current values of the dc-link according to the rated power of the motor
connected to the inverter The current is calculated on the basis of the following:

- 4-pole “standard” motor

- “typical” efficiency for “standard” motors (η

- the “typical” inverter efficiency is considered equal to 0.97 (η

Mot

)

)

I

- mains power supply voltage 3 x 380V (conservative value if referred to a rated voltage of 3 x 400V)

- there are two value columns referring to a continuous functioning (class 1) or to a functioning during an
overload phase (class 2) (150% for 60 seconds).

The current value in column 1 is calculated as

I

= P

DCL

where for column „Current Dclink I

/ (h

Mot

——————— Half controlled power supply for inverter DC-Link ————————

x hI x ULN x 1.35)

Mot

Overload class 2“ it is obtained multiplying by 1.36.

DCL

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GEH-6639

Chapter 3 - SELECTION OF THE CS300 CONVERTER

The CS300 converter has to be chosen so that the sum of the inverter DC-link currents, both for class 1 and 2, is
lower or equal to the corresponding ones stated in chapter 2.6.1.

3.1 DIP-SWITCHES AND JUMPER

On R-SM3-L card

S1.1-4 Selection of the delay for thyristor disabling during mains dip.
S2.1-3 Selection of the undervoltage threshold.
S3.1-4 Selection of the capacitors precharge time
S4 - S5 Selection of the AC mains frequency: 50 or 60 Hz
CV Selection of the ML signal function

3.2 USE OF S1 SWITCH

Relevant only for limited application cases

If the system functioning allows a limited dip voltage value of the DC-LINK, (a condition obtainable by handling
the DC-LINK with a suitable software or with additional external capacitors) it is possible, during a mains dip
with a maximum duration time of 10mS, to prevent the thyristor switching off, of the CS300, during the detection
of the voltage drop (repeating then the precharging sequence once the voltage is restored).

The disadvantage of such function is obviously the presence of a high current inside the CS300 once the voltage
is restored. For this reason it is necessary to take appropriate countermeasures by checking the decreasing slope
of the DC-LINK voltage during the mains dip. Therefore, knowing the value of the connected capacitors and the
maximum current supplied by the CS300, it is possible to calculate the maximum “mains dip” bearable by the
converter itself.

Example:

Calculate the maximum “mains dip” bearable by a converter size 185A, whose mains choke has the following
values: 0.148mH 173 rated A and 350A of saturation current. The converter supplies 8 inverters AV300- 3011
(the internal capacitors value of each inverter is equal to 470µF); using an oscilloscope, it has been stated that
during a normal functioning, in case of a mains dip, the DC-LINK discharges 70V after a 3-mS mains dip.

The aim is to state whether such “mains dip” can be overcome without the precharging phase.
Considering a series resistance (sum of the capacitor parasite drag and of the connection contact resistances)

equal to 100mOHM (0.1 OHM), act as following:

DATA: R = 0.1 W C = 3760 mF

L = 0.14 mH e = 2.718
V = 70V

16

——————— INSTRUCTION MANUAL ————————

1)

CS300

2

R

)

L*2

ω

=

1

-

(

C*L

Having as a unit of measure the “L” inductance in Henry, the “C” capacitor in Farad and the “R” resistance in
Ohm, according to the above mentioned data:

ω

= 1331.21 rad/S

2)

R

=α

L*2

from which:

3)

α

= 357.14

=

t

M

π

ω

*2

from which: t

= 0.00117 s

M

( tM states the time needed by the current to reach its maximum value )

4) the peak current can be calculated with the following formula:

(=

I

P

from which : I

V

ω

= 572.3A

P

α

*

t

M

*)

e

L*

It is obvious that considering a 70V discharge of the DC-LINK (3-mS mains dip) the current is too high for the
converter. As a consequence, it is necessary to consider a lower voltage reduction (corresponding to a shorter

mains dip). Therefore, with a voltage reduction of 35V (1.5-mS mains dip), the new value will be:

IP= 286.1 A

Such value meets the needing of both the converter (which for short periods is able to bear a current value two
times the rated one) and the inductance, whose saturation current is higher than 300A.

Table of S1.1-4 Delay for thyristor switching off during mains dip.

——————— Half controlled power supply for inverter DC-Link ————————

17

GEH-6639

Delay in the thyristor disabling

1.1mS +/- 10% OFF ON ON OFF

2.2mS +/- 10% OFF ON OFF ON

3.3mS +/- 10% OFF ON OFF OFF

4.4mS +/- 10% OFF OFF ON ON

5.5mS +/- 10% OFF OFF ON OFF

6.6mS +/- 10% OFF OFF OFF ON

7.7mS +/- 10% OFF OFF OFF OFF

S1.1 S1.2 S1.3 S1.4

ON OFF OFF OFF

cs080

From the above table, considering the example, a delay of 1.1mS is selected by setting:

S1.1 OFF - S1.2 ON - S1.3 ON - S1.4 OFF.

NOTE! With S1.1 ON the delay circuit for the thyristors switching of f is disabled. In this case when

a mains dip occurs, the thyristors will be switched off; once mains dip is elapsed, the capacitor
precharging sequence will be executed again (default configuration).

3.3 USE OF S2 SWITCH

Via the S2 switch it is possible to select the undervoltage threshold, which depends on the AC main voltage of
the converter. Dip S2.4 not used

Power supply voltage S2.1 S2.2 S2.3 Threshold of the PS drop

460V -10%÷480V+10% (Default) ON OFF OFF

400V +/-15% OFF ON OFF

( 230 +10/-10% ) OFF OFF ON



370 Vdc



300 Vdc



180 Vdc

cs090

3.4 USE OF S3 SWITCH

The S3 switch is able to set the precharge time for the DC link capacitors (the higher precharge time, the
lower will be the current during the precharging phase to the supplied capacitors).

Time (Seconds) S3.1 S3.2 S3.3 S3.4

18 S +/-15% OFF OFF OFF OFF

11 S +/-15% (Default) OFF OFF ON OFF

7 S +/-15% ON OFF OFF OFF
4 S +/-15% OFF ON OFF OFF
2 S +/-15% OFF OFF OFF ON

cs100

Use the following way to select the precharge time:

18

——————— INSTRUCTION MANUAL ————————

CS300

1) Set all the switches in off position (18-seconds ramp time), use a current probe able to detect a current

≤≤

peak

≤10mS between the C or D terminal of the DC-LINK.

≤≤

2) At this point read the measuring of the maximum peak current present on the DC-LINK during the precharging
phase.

3) If the measured peak current is much lower than twice the value of the CS300 rated current, it is possible to
select the switch for a lower ramp time (SW3.4 - 8- second ramp time). Go back to point 2.

Such operation will be repeated till the measured peak current is equal or lower than twice the value of the
converter rated current.

3.5 USE OF S4 AND S5 DIP SWITCH

The S4 and S5 dip switches are used to select the AC mains frequency.

AC Mains frequency S4 S5

50 Hz (Default) OFF OFF

60 Hz ON ON

cs110

3.6 USE OF CV JUMPER

(See the ML signal function)

With “CV” jumper mounted (on), the signal available on the terminal 36 will be LOW with AC mains voltage
lower than the undervoltage threshold (see figure 3). It will be HIGH, with AC mains voltage higher than the
undervoltage threshold.

With “CV” jumper open (off), the signal on the terminal 36 will indicate, with an impulse of about 150ms, (low
level signal) that the power supply voltage has had a transition at a level lower than the undervoltage threshold.

——————— Half controlled power supply for inverter DC-Link ————————

19

GEH-6639

Chapter 4 - CONTROL DESCRIPTION

4.1 OK RELAY

The OK relay has a normally open contact which close at the end of the precharging phase if no alarm condition
is present (overtemperature, power supply on the regulation card +/-15V).

The contact is closed during the normal functioning of the device and also during an undervoltage situation. The
contact opens when a failure occurs (see the alarm conditions described above) or when the power supply is
switched off and the DC-LINK is completely discharged (C and D terminals).

4.2 PRECHARGE ENABLING CONTROL

Such input allows to delay the precharging phase with respect to the moment in which the power supply (U,V,W
terminals) is applied.

The precharging phase occurs supplying terminals 23 to +24V (available on the terminal strip).
(common on terminal 52).

4.3 MLP SIGNAL

The MLP signal is a digital output available on the terminal 32.
This signal is a sum of the undervoltage threshold (via S2.1-3 set) and the precharging phase.
It will be LOW with a 0.5mS delay after the undervoltage threshold is reached. The digital output will be again

HIGH, at the end of the precharging phase. (This sequence is repeated at every mains dip)
(see chapter 6.2 figure B).

4.4 ML SIGNAL

The ML signal is a digital output available on terminal 36
It is the AC mains voltage monitoring.
With “CV” jumper mounted (on), the ML signal will be LOW when the undervoltage threshold is reached.
The digital output will be HIGH when the voltage is above the threshold (see the above table).
With “CV” jumper not mounted (off), the ML signal will indicate, with a 150mS pulse, an undervoltage value

transition.
When the voltage comes back above the threshold value, this will be not revealed by the ML signal.
(see chapter 6.2 figure B).

20

——————— INSTRUCTION MANUAL ————————

CS300

Chapter 5 - CONVERTER DIMENSIONS

E

A

E

F

D

B

F

C

Form 1

C

B

Form 2

D

A

Converter Form

6KCS3185-480 12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 36.6 [18]
6KCS3280-480 12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 57.3 [26]
6KCS3420-480 12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 66.1 [30]

6KCS3650-480 12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 68.3 [31]
6KCS310H-480 20.63 [525] 21.77 [554] 13.48 [343] 7.86 [200] 19.65 [500] M6 138.8 [63]
6KCS315H-480 21.65 [551] 26.96 [686] 14.93 [380] 7.86 [200] 20.67 [526] M8 187.3 [85]

1

2

ABCDEFWeight

inch [mm] inch [mm] inch [mm] inch [mm] inch [mm] Ø lbs [kg]

cs120

——————— Half controlled power supply for inverter DC-Link ————————

21

GEH-6639

Chapter 6 - CONVERTER OPERATION

6.1 EXAMPLE OF TERMINAL STRIP CONNECTION

L1
L2
L3
N
PE

F1

1

234

5

6

K1M

PE

D

C

F2

L1

UVW

CD

1

Q2

24

PE U3 V3

From 1050
size

PE

Note !

3

5

Fan with external supply

6

only from 1050A size
and higher

OK Relay

72

70

Digital
output

MLP

32 36

ML

PRECHARGE
COMMAND

23

33

Precharge

enable

Common

34

52

35

37

24V

GND 24

MLP&ML

Common

Precharge enable

Power supply of

the ML and MLP

22

——————— INSTRUCTION MANUAL ————————

6.2 SIGNAL DIAGRAM

CS300

AC CONTACTOR U.V.W

PRECHARGE ENABLE

DC-LINK VOLTAGE

PRECHARGE TIME

OK RELAY

150 ms MIN

Figure A

AC POWER

SUPPLY.

MLP signal

TYRISTOR FIRING

PRECHARGE

ML signal " CV ON "

ML signal "CV OFF "

Figure B

——————— Half controlled power supply for inverter DC-Link ————————

23

GEH-6639

6.3 COMMON BUS MULTI-INVERTER SYSTEM

AC

Drive

M

DC BUS

_

+

AC

Drive

M

External
fuses

E

*

DC

E

C

AC

Drive

D

M

CD

CS300

AC MAINS

INPUT

*

AC mains
choke

AC mains
contactor

External
fuses

CD

Braking

unit

External

OPTION

CD

braking
resistor

“Rbr”

* : Fuses for cables protection.

24

——————— INSTRUCTION MANUAL ————————

CS300

Chapter 7 - REPLACEMENT PARTS

CODE

Catalog No.

Rating

Converter power & quantity per product

185 280 420 650 1050 1500

Regulation card

6KS5V99 R-SM3L 1111 1

6KS5V98 R-SM3-LM 1

Filter cards

6KS5N14 SN5-31 1111

Filter link
6KS5V97 V-SM3 1111
6KS5N15 FL-31 11

SCR MODULE
6KS776F SCR MODULE 116A 1K6V 3
6KS781F SCR MODULE 130A 1K6V 3
6KS79F4 SCR MODULE 210A 1K6V 3
6KS79F6 SCR MODULE 320A 1K6V 3
6KS79F5 SCR MODULE 500A 1K6V 3
6KS714F SCR AT 1007 S16 3

Diode
6KS8T79 DIODES AR1104 S16 3

Fans
6KS7G76 FAN A 024 DC-62/72-B-20/+60 2
6KS7G71 FAN A 024 DC-170-B-20/+75 2 2
6KS7G78 FAN 024 DC-345-B-15/+60 2
6KS7G17 FAN A 230V AC 50HZ 3 3

Thermistors
6KS7G33 BIM. THERM.85°C EC 2
6KS7G29 BIM. THERM.80°C EV 2 2
6KS7G30 BIM. THERM.90°C EC 3 3

BIM. THERM.90°C EC 3

SCR filters
6KS7S58 RC SCR FILTER 18ohm50W 3
6KS8S61 RC SCR FILTER 1mF 850Vac 3

Internal fuses
6KS8B28 FUSES 5X20 T20 1A 250V 111111
6KS8B19 FUSES 6,3X32 4A 500V 111111
6KS8B30 FUSES 6,3X32 1,6A 500V 1 1
6KS820B FAST FUSES 6,3X32 16A 500V 3333
6KS821B FAST FUSES 6,3X32 25A 500V 3 3
6KS827B FUS. PWR GOULD (for Europe only) 1000A 660V 3
6KF4G76 G3MUEF1 JM (for Europe only) 1000A 660V 6
6KS827B FUS. PWR GOULD (for USA only) 1000A 660V 3
6KF4G76 G3MUEF1 JM (for USA only) 1000A 660V 6

External fuses (Europe)

6KFAG23 S00UF1/80/200A/660V 3
6KF4G30 S2UF2/110/315A/660V 3
6KF4E30 S2UF1/110/500A/660V 3
6KF4E31 S2UF1/110/630A/660V 3
6KF4C10 MK MICROSWITCH FUS. JM 6

External fuses (USA)

PDFP7V200ABLADE
PDFP7V350ABLADE
PDFP7V500ABLADE
PDFP7V600ABLADE

6KF4C10 MK MICROSWITCH FUS. JM 6

FAST FUSE CSA 200A 700V 3

FAST FUSE CSA 350A 700V 3

FAST FUSE CSA 500A 700V 3

FAST FUSE CSA 600A 700V 3

——————— Half controlled power supply for inverter DC-Link ————————

25

GEH-6639

Chapter 8 - WARRANTY PARTS AND SERVICE

The purpose of this section is to provide specific in­structions to the user of the standard drive referenced
in this book regarding warranty administration and how
to obtain assistance on both in-warranty and out-of­warranty equipment.

If assistance is required to determine warranty status,
identify defective parts, or obtain the name of your
local distributor, call:

GE Industrial Systems

Product Service Engineering

1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
Phone: + 1 800 533 5885 (United States)

+ 1 540 378 3280 (International)
Fax: + 1 540 387 8606 (All)
(“+” indicates the international access code required

when calling from outside of the USA.)

WARRANTY COVERAGE

The warranty covers all major parts of the drive such
as the main printed circuit boards, transistor modules,
etc. The warranty does not cover replacement of fuses
or of the entire drive.

“Warranty period is 12 months after installation or 18
months after shipment from the Company, whichever
occurs first”.

However, the guarantee will not apply in the following
cases, even if the guarantee term has not expired:

1. Damage was caused by incorrect use or inappro­priate repair or modification.

2. The product was used in an environment outside
the standard specified range.

3. Damage was caused by dropping the product after
purchase or occurred during transportation.

4. Damage was caused by an earthquake, fire, flood­ing, lightning, abnormal voltage, or other natural
calamities and secondary disasters.

Before calling the number at left to determine war­ranty status, the drive serial number will be required.
This is located on the drive nameplate.

OUT-OF WARRANTY PROCEDURES

When the defective part has been identified, contact
your local authorized GE standard drives distributor
to order replacement parts.

MOTORS

Motors repairs on General Electric motors are gener­ally handled by GE Authorized Electric Motor
Servicenters or GE Apparatus Service Shops. For spe­cific instructions on your motor, call the distributor
from which it was purchased and be prepared to furnish
complete nameplate data.

26

——————— INSTRUCTION MANUAL ————————

Notes:

CS300

——————— Half controlled power supply for inverter DC-Link ————————

27

GE Industrial Systems

+ 1 540 387 7000
www.GEindustrial.com

General Electric Company

1501 Roanoke Blvd.
Salem, VA 24153-6492 USA

GEH-6639 (Draft)

010119

SIEI