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Objectives
After completing this lesson you should be able to: Understand basic drive startup guidelines Locate detailed drive installation information Avoid electrostatic damage to drive components
Objectives
After completing this lesson you should be able to: Identify electric measuring and installation equipment Identify protective clothing and PPE (personal protective equipment) Recognize hardware and installation implications when correcting line disturbances:
Harmonics Reflective wave Common mode ground current Motor noise
Verify where all the drives are located Verify the drives are ready for start up
Is all power and control wiring complete Has direction of rotation been verified
Who is responsible for all control and interlock decisions? Who do you contact before the first rotation of the motors?
Typically is superintendent of construction or someone they have assigned
Who is the person that will sign you out when finished?
Typically is superintendent of construction or someone they have assigned
Make sure hole saw metal shavings are not inside the relays and contactors.
Tip: Verify connections are tight now to prevent a big problem later.
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You must have a 100% direction check in both VFD and bypass
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To avoid a shock hazard, ensure all power to the drive has been removed before continuing. Also, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. The DC bus voltage at the DC+ and DC- power block terminals must be zero.
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Remember to always follow all safety precautions. If in doubt about any procedure, equipment, or step, please see your instructor before continuing.
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5. Verify that all board mounting screws are tight and that all sheet metal is properly secured.
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The wires connecting the motor and the drive MUST be disconnected on the drive side before performing the next step. If the wires are still connected to the drive, severe damage may result to the drive.
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The higher voltage and current a megger can produce may result in injury and equipment damage if the megger is used incorrectly. Always follow the direction of the operation manual for the megger.
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Tip: If a torque screwdriver is available, torque the screws to the AC input and motor leads to proper torque specifications.
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Do not stand in front of the drive when applying power for the first time.
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Tip: The input voltage should equal the drive rated input voltage specified on the drive's nameplate within +/-10%.
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To perform this check, the motor must be running and fully loaded.
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7. Using a multimeter, measure the DC voltage of the bus at TB1, measure terminals DC+ and DC-.
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Causes of ESD
The electric field causing ESD can be produced by the following events: Discharge: The transfer of a charge between items at different electrical potentials such as a positively charged hand and an electronic component. Induction: The interaction between a moving electric field and a stationary electronic component that generates an electric current within the component. Polarization: A form of induction caused by the attraction of a stationary electronic component to a nearby stationary positively charged nonconductor. Tip: Subsequent handling of the component first charges and then discharges it to result in damage to the component.
Copyright 2009 Rockwell Automation, Inc. All rights reserved. 34
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Do not use a ground strap until you have verified that no power is present in the equipment you are servicing. Personal injury and/or equipment damage may result.
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Before attaching the wrist strap to ground, verify that the point you have chosen is truly grounded. Not establishing a known safe grounding point could result in electrocution if an individual were to accidentally come into contact with a live electrical voltage.
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The wrist grounding strap is not a safety device against electric shock to the wearer. It only serves to prevent ESD to electronic components.
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Remove the wrist grounding strap when power is applied to the workstation. Failure to do so may result in personal injury and/or equipment damage.
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Tip: Avoid storing or packing electronic components and modules in boxes with foam peanuts because it can be very damaging.
Remove electronic components and modules from protective static shielding packages only in a static-safe work area Use proper handling procedures with all electronic components and modules, even those that are to be returned for repair
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Tip: For more information on how to prevent ESD in your workplace, visit the Electrostatic Discharge Association's (ESDA) Web site at www.esda.org.
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Non-melting, flammable 4.5 - 7 materials (i.e., untreated cotton, wool, rayon, or silk, or blends of these materials) with a fabric weight of at lest 4.5 oz/yd2 (1) FR shirt and FR pants, or FR coverall (1) 4.5 - 8
(Continued)
Copyright 2009 Rockwell Automation, Inc. All rights reserved. 52
Cotton underwear plus FR 9 - 12 shirt and FR pants (1 or 2) Cotton underwear plus FR 16 - 20 shirt and FR pants plus FR coverall (2 or 3) Cotton underwear plus FR 24 - 30 shirt and FR pants plus double-layer switching coat and pants (3 or more)
Copyright 2009 Rockwell Automation, Inc. All rights reserved.
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Actual AC line input voltage from an application containing AC and DC Copyright 2009 Rockwell Automation, Inc. All rights reserved. harmonics
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IEEE519-1992 Standard
IEEE519-1992 is a North American standard developed from input provided by:
Utilities Electrical equipment manufacturers Power consumers
Total harmonic distortion (THD) limits are recommended based upon the type of installation It is the defacto standard for power utilities and is often required of large consumers and medium voltage systems Becoming increasingly common in low voltage systems
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IEEE519-1992 Standard
Total voltage distortion not to exceed
3% in special applications of power systems (hospitals, airports) 5% in general power systems 10% in dedicated power systems
Special Applications1 General System Dedicated System2 Notch Depth 10% 20% 50% THD (Voltage) 3% 5% 10% Notch Area (AN)3 16 400 22 800 36 500 Note: The value AN for other than 480V systems should be multiplied by V/480. 1 Special applications include hospitals and airports. 2 A dedicated system is exclusively dedicated to the converter load. 3 In volt-microseconds at rated voltage and current.
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IEEE519-1992 Standard
Total current distortion range from 5% to 20% maximum dependent upon Short Circuit Ratio
Maximum Harmonic Current Distortion in Percent of IL Individual Harmonic Order (Odd Harmonics) ISC IL <11 11 h<17 17 h<23 23 h<35 35 h <20 4.0 2.0 1.5 0.6 0.3 20<50 7.0 3.5 2.5 1.0 0.5 50<100 100.0 4.5 4.0 1.5 0.7 100<1000 12.0 5.5 5.0 2.0 1.0 >1000 15.0 7.0 6.0 2.5 1.4 Even harmonics are limited to 25% of the harmonic limits above. Where ISC = maximum short circuit current at PCC IL = maximum demand load current (fundamental frequency component) at PCC
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IEEE519-1992 Standard
Location of total harmonic distortion measurement, commonly called the Point of Common Coupling or PCC, shall be the point where two or more users share a common utility power source.
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IEEE519-1992 Standard
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IEEE519-1992 Standard
THD is dependent upon utility power capacity referred to as Short Circuit Current (lsc), measured at the PCC. For calculation purposes the lsc number must be supplied by the utility. It is dependent upon existing or planned linear and non-linear loads, also called Maximum Demand Load Current (IL), as required by the users system. The ratio of the two quantities above (Isc / IL) is referred to as Short Circuit Ratio.
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IEEE519-1992 Standard
When conducting a drives-based harmonic analysis, establishing the PCC at any point other than where the sharing of utility power occurs is not consistent with the intent of IEEE519-1992 and may lead to the purchase of unnecessary equipment.
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Meets IEEE-519 5% Harmonic Standard at the drive input Terminal Current THD 3.5% full load (typ.), 6 % no load Improves power factor More robust and trouble free than Harmonic Trap filters
Somewhat more expensive than 12-pulse front end Less expensive than active front end rectifiers.
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Invertor
Cap-Bank
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Inverter Bay
Input fuses
18 pulse autotransformer
Copyright 2009 Rockwell Automation, Inc. All rights reserved. 66
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VSI
UTILITY
FEED
XFMR. 7th Filter
AC DRIVE
5th Filter
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Ls Isource
Ifilter
Power Supply
Lf
V1 V3 V5
Cbus
V4
V6
V2
VDC
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A dual-direction converter that ... Supplies forward power to a common DC bus drive system with Sinusoidal input currents Regenerates excess power back to the 3-phase AC line with Sinusoidal input currents
Input Breaker
An active front end must be used with drives that can share a common DC bus.
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MCP
FUSES
Main Contactor
-Bus
Line filter
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MCP
FUSES
Main Contactor
-Bus
Line filter
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Tip: For more detailed information on CM noise currents and techniques to reduce them, see the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives Installation Instructions.
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Motor Noise
In addition to the common mode ground currents we just discussed, motor noise can also be caused by a drive's carrier frequency. The carrier frequency determines how quickly PWM pulses are switched. The PowerFlex 700 VC drive can produce pulses at carrier frequencies of 2 kHz to 10 kHz. Tip: A very large majority of all drive applications perform adequately at 2-4 kHz.
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Motor Noise
Benefits of increasing carrier frequency: Less audible noise Less vibration in motor windings and laminations
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Motor Noise
Drawbacks to increasing the carrier frequency: More motor heating Derating ambient temperature versus load characteristics of the drive Higher cable charging currents Higher potential for common mode noise
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