GEH-6639 (Draft)
GE Industrial Systems
CS300
Half Controlled Power Supply for Inverter DC-Link
User‘s Guide
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 procédés 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 différent facteurs.
Toutefois, les instructions mentionées ci-dessous devraient être 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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——————— INSTRUCTION MANUAL ————————
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 discon-
nected from the AC input feeder.
Selon les normes EEC, les drives CS300 et leurs accessoires doivent être 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 terre.
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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GEH-6639
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 instruc-
tions 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 permissi-
ble. 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 être 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 pre-
scriptions 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 appropriés (résistance interne minimale 10
kΩ/V).
Aucune tension ne doit être appliquée sur la sortie du convertisseur (bornes C, D).
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GEH-6639
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——————— INSTRUCTION MANUAL ————————
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%
50 or 60 Hz
up to
480+10%
(Dip-switch selectable)
The maximum input power of the internal switching power supply is 100W, and the supplied voltages are:
+/-15V 500mA
+24 V 2A
Control card
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%)
Positive terminal to be connected to the inverter DC-LINK
Negative terminal to be connected to the inverter DC-LINK
Supply for internal fan (only for 1050A size and higher)
(1Ph, 230V 15%)
C
D
U3, V3
cs010
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GEH-6639
2.4 DESCRIPTION OF CONTROL TERMINALS
Terminals
Function
Voltage, Current
23
32
Input of the precharge enable control
Output of the MLP static signal (low - active signal)
(Common) Ground of the MLP and ML static signals
Reference point for Power supply +24V
Power supply output +24V
(15 - 35V, 5 - 11mA)
(5 … 35V, 20mA source)
33
-
34
-
35
(32V / 300mA max)
(5 … 35V, 20mA max sink)
(35V max)
36
Output of the ML signal (low - active signal)
Power supply of the ML and MLP signals
(Common) Ground of the precharge enable control
OK Relay
37
52
-
70, 72
(max 250V, 1A – AC11)
cs020
2.5 PROTECTIONS
2.5.1 Internal Protection Components
Converter
Designation
Varistors
6KCS3185-480
6KCS3280-480
6KCS3420-480
6KCS3650-480
6KCS310H-480
6KCS315H-480
575 V / 220 J
V1, V2, V3
Ø 20 mm
cs025
2.5.2 Internal Fuses
Converter
Designation
Fuses
Designation
Fuses for
Fuses
6KCS3185-480
6KCS3280-480
6KCS3420-480
6KCS3650-480
6KCS310H-480
6KCS315H-480
F4
Power supply protection 4 A, 250 V fast 6,3 x 32
16 A / 500 V
fast 6 x 32 mm
F1, F2, F3
F5
+24V protection
1 A, 250 V slow 5 x 20
25 A / 500 V
fast 6 x 32 mm
cs030
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——————— INSTRUCTION MANUAL ————————
CS300
2.5.3 External AC Mains Fuses
Europe
USA
Converter
Ref. Pieces
Type
Type
Code
Code
A
B
3
1+1
3
S00üF1/80/200A/660V
S1üF1/110/250A/660V
S1üF1/110/315A/660V
S1üF1/110/315A/660V
S2üF1/110/500A/660V
S2üF1/110/500A/660V
S2üF1/110/630A/660V
S3üF1/110/800A/660V
170M5466 (1000A/700V) SKS827B
SKF4G23 A70QS200-4K
SKF4G28 A70QS300-4
SKF4G30 A70QS350-4
SKF4G30 A70QS350-4
SKF4E30 A70QS500-4
SKF4E30 A70QS500-4
SKF4E31 A70QS600-4
SKF4H02 A70QS800-4
FWP200A
PDFP7V200ABLADE
PDFP7V300ABLADE
PDFP7V350ABLADE
PDFP7V350ABLADE
PDFP7V500ABLADE
PDFP7V500ABLADE
PDFP7V600ABLADE
PDFP7V800ABLADE
SKS827B
6KCS3185-480
FWP300A
FWP350A
FWP350A
FWP500A
FWP500A
FWP600A
FWP800A
A
6KCS3280-480
6KCS3420-480
6KCS3650-480
6KCS310H-480
B
1+1
3
A
B
1+1
3
A
B
1+1
3
A (1)
B (1)
A (1)
170M5466 (1000A/700V)
FWP600A
3
S2üF1/110/630A/660V
SKF4E31 A70QS600-4
PDFP7V600ABLADE
SKF4G76
G3MUEF1/1000A/660V
3
G3MUEF1/1000A/660V SKF4G76
6KCS315H-480
(1+1)+
(1+1)
B (1)
S3üF1/110/1000A/660V SKF4H03
A70P1000
FWP1000
SKS7812
cs041
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
Fuse manufactures: S… , G…
Jean Muller, Eltville
Ferraz Shawmutt
Bussmann
A70…
FWP…, 170M..
2.5.4 AC Mains Choke
Main
Main three-phase inductance
Saturation
current [A] current [A]
Converter
frequency Rated inductance Rated AC
Type
[Hz]
50/60
50/60
50/60
50/60
50/60
50/60
[mH]
0.148
0.082
0.082
0.053
0.033
0.019
6KCS3185-480
6KCS3280-480
6KCS3420-480
6KCS3650-480
6KCS310H-480
6KCS315H-480
173
360
360
560
900
1425
350
540
KLR 420 CCB
540
KLR 420 CCB
KLR 600 CCB
KLR 950 CCB
840
1350
2138
cs050
NOTE!
The use of AC mains choke on the power supply input is MANDATORY
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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
DC link current (Terminals C / D)
Converter
IEC 146 Class 1 *
IEC 146 Class 2 **
185 A
150 A
6KCS3185-480
6KCS3280-480
6KCS3420-480
6KCS3650-480
6KCS310H-480
6KCS315H-480
280 A
225 A
420 A
340 A
650 A
540 A
1050 A
850 A
1500 A
1300 A
cs060
*
Continuous service
** Service with overload possibility of 150% for 60 seconds
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CS300
2.6.2 Drive DC Current (DC Link Circuit)
AV300 -…
Rated motor
power
PMot
[kW]
0,55
0,75
1,1
Motor
efficiency
hMot
Current
Current
DClink IDCL
Fuses
DClink
Superfast
[A]
6
Dclink IDCL
Continuous class 1 Overload class 2
class 1
class 2
[A]
1,56
[A]
2,12
0,71
0,74
4003
4003
4003
4003
4003
4003
4005
4005
4007
4011
4015
4022
4022
4030
4037
4045
4055
4075
4090
4110
4132
4160
4250
4250
4315
4003
4003
4003
4003
4003
4003
4005
4007
4011
4015
4022
4022
4030
4037
4045
4055
4075
4090
4110
4132
4160
4250
4250
4315
2,04
2,77
6
0,75
2,95
4,01
6
1,5
0,75
4,02
5,47
8
2,2
0,79
5,60
7,61
10
3
0,81
7,44
10,12
13,17
17,90
23,83
34,16
46,06
55,87
65,93
89,32
109,56
132,25
160,77
217,37
260,02
317,46
379,35
457,90
570,58
711,74
893,99
1007,52
1132,88
16
4
0,83
9,68
16
5,5
0,84
13,16
17,53
25,12
33,87
41,08
48,48
65,67
80,56
97,24
118,21
159,83
191,19
233,43
278,94
336,69
419,54
523,33
657,35
740,82
833,00
20
7,5
0,86
30
11
0,88
40
15
0,89
63
18,5
22
0,905
0,912
0,918
0,923
0,93
63
80
30
100
125
160
200
250
315
350
450
500
630
800
1000
37
45
55
0,935
0,943
0,946
0,947
0,951
0,955
0,958
0,96
75
90
110
132
160
200
250
315
355
400
0,963
0,963
0,965
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 (ηMot
the “typical” inverter efficiency is considered equal to 0.97 (ηI)
)
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
IDCL = PMot / (hMot x hI x ULN x 1.35)
where for column „Current Dclink IDCL Overload class 2“ it is obtained multiplying by 1.36.
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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
S2.1-3
S3.1-4
S4 - S5
CV
Selection of the delay for thyristor disabling during mains dip.
Selection of the undervoltage threshold.
Selection of the capacitors precharge time
Selection of the AC mains frequency: 50 or 60 Hz
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
L = 0.14 mH
V = 70V
C = 3760 mF
e = 2.718
16
——————— INSTRUCTION MANUAL ————————
CS300
1)
2
1
R
ω
=
-
(
)
L* C
2* 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 =
2* L
from which:
3)
α = 357.14
π
2* ω
=
tM
from which:
tM = 0.00117 s
( tM states the time needed by the current to reach its maximum value )
4)
the peak current can be calculated with the following formula:
V
α *
tM
=(
)*
IP
e
ω * L
from which :
IP = 572.3A
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.
17
——————— Half controlled power supply for inverter DC-Link ————————
GEH-6639
S1.1
ON
S1.2
OFF
ON
S1.3
OFF
ON
S1.4
OFF
OFF
ON
Delay in the thyristor disabling
1.1mS +/- 10%
2.2mS +/- 10%
3.3mS +/- 10%
4.4mS +/- 10%
5.5mS +/- 10%
6.6mS +/- 10%
7.7mS +/- 10%
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
OFF
OFF
ON
OFF
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 off 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
460V -10%÷480V+10% (Default)
400V +/-15%
S2.1
ON
S2.2
OFF
ON
S2.3
OFF
OFF
ON
Threshold of the PS drop
370 Vdc
OFF
OFF
300 Vdc
( 230 +10/-10% )
OFF
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)
18 S +/-15%
S3.1
OFF
OFF
ON
S3.2
OFF
OFF
OFF
ON
S3.3
OFF
ON
S3.4
OFF
OFF
OFF
OFF
ON
11 S +/-15% (Default)
7 S +/-15%
OFF
OFF
OFF
4 S +/-15%
OFF
OFF
2 S +/-15%
OFF
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
50 Hz (Default)
60 Hz
S4
S5
OFF
ON
OFF
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.
19
——————— Half controlled power supply for inverter DC-Link ————————
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
C
E
F
D
B
Form 1
A
E
C
F
B
Form 2
D
A
F
A
B
C
D
E
Weight
Converter
Form
inch [mm]
inch [mm]
inch [mm]
inch [mm]
inch [mm]
Ø
lbs [kg]
6KCS3185-480
6KCS3280-480
6KCS3420-480
6KCS3650-480
6KCS310H-480
6KCS315H-480
12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 36.6 [18]
12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 57.3 [26]
12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 66.1 [30]
12.22 [311] 15.25 [388] 10.61 [270] 14.73 [375] 10.70 [275] M6 68.3 [31]
1
2
20.63 [525] 21.77 [554] 13.48 [343]
21.65 [551] 26.96 [686] 14.93 [380]
7.86 [200]
7.86 [200]
19.65 [500] M6 138.8 [63]
20.67 [526] M8 187.3 [85]
cs120
21
——————— Half controlled power supply for inverter DC-Link ————————
GEH-6639
Chapter 6 - CONVERTER OPERATION
6.1 EXAMPLE OF TERMINAL STRIP CONNECTION
L1
L2
L3
N
PE
F1
K1M
F2
1
2
3
4
5
6
Note !
3
4
5
6
1
2
Q2
Fan with external supply
only from 1050A size
and higher
PRECHARGE
COMMAND
L1
23
33
PE
U3
V3
52
37
34
35
U V W
Digital
output
From 1050
size
OK Relay
70 72
C
D
PE
32
36
PE
D
C
22
——————— INSTRUCTION MANUAL ————————
CS300
6.2 SIGNAL DIAGRAM
AC CONTACTOR U.V.W
PRECHARGE ENABLE
DC-LINK VOLTAGE
PRECHARGE TIME
OK RELAY
Figure A
AC POWER
SUPPLY.
MLP signal
TYRISTOR FIRING
PRECHARGE
ML signal " CV ON "
ML signal "CV OFF "
150 ms MIN
Figure B
23
——————— Half controlled power supply for inverter DC-Link ————————
GEH-6639
6.3 COMMON BUS MULTI-INVERTER SYSTEM
_
+
DC BUS
External
fuses
*
*
C
D
C
D
C
D
C
D
C
D
Braking
unit
AC
Drive
AC
Drive
AC
Drive
CS300
External
braking
resistor
“Rbr”
AC mains
choke
M
E
M
M
E
AC mains
contactor
OPTION
External
fuses
AC MAINS
INPUT
* : Fuses for cables protection.
24
——————— INSTRUCTION MANUAL ————————
CS300
Chapter 7 - REPLACEMENT PARTS
Converter power & quantity per product
CODE
Rating
Catalog No.
185
280
420
650
1050
1500
Regulation card
R-SM3L
6KS5V99
6KS5V98
1
1
1
1
1
R-SM3-LM
1
Filter cards
6KS5N14
SN5-31
1
1
1
1
1
1
1
1
Filter link
6KS5V97
6KS5N15
V-SM3
FL-31
1
3
1
SCR MODULE
6KS776F
6KS781F
6KS79F4
6KS79F6
6KS79F5
6KS714F
SCR MODULE
116A 1K6V
130A 1K6V
210A 1K6V
320A 1K6V
500A 1K6V
3
SCR MODULE
3
SCR MODULE
3
SCR MODULE
3
SCR MODULE
SCR AT 1007 S16
Diode
3
3
6KS8T79
DIODES AR1104 S16
Fans
6KS7G76
6KS7G71
6KS7G78
6KS7G17
FAN A 024 DC-62/72-B-20/+60
FAN A 024 DC-170-B-20/+75
FAN 024 DC-345-B-15/+60
FAN A 230V AC 50HZ
Thermistors
2
2
2
2
2
2
2
3
3
3
6KS7G33
6KS7G29
6KS7G30
BIM. THERM.85°C EC
BIM. THERM.80°C EV
BIM. THERM.90°C EC
BIM. THERM.90°C EC
SCR filters
3
3
6KS7S58
6KS8S61
RC SCR FILTER
RC SCR FILTER
Internal fuses
18ohm50W
1mF 850Vac
3
3
6KS8B28
6KS8B19
6KS8B30
6KS820B
6KS821B
6KS827B
6KF4G76
6KS827B
6KF4G76
FUSES 5X20 T20
FUSES 6,3X32
FUSES 6,3X32
FAST FUSES 6,3X32
FAST FUSES 6,3X32
1A 250V
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4A 500V
1,6A 500V
16A 500V
25A 500V
3
3
3
3
3
3
3
6
6
FUS. PWR GOULD (for Europe only) 1000A 660V
G3MUEF1 JM (for Europe only)
FUS. PWR GOULD (for USA only)
G3MUEF1 JM (for USA only)
1000A 660V
1000A 660V
1000A 660V
3
External fuses (Europe)
S00UF1/80/200A/660V
S2UF2/110/315A/660V
S2UF1/110/500A/660V
S2UF1/110/630A/660V
MK MICROSWITCH FUS. JM
6KFAG23
6KF4G30
6KF4E30
6KF4E31
6KF4C10
3
3
3
3
3
3
3
3
6
6
External fuses (USA)
PDFP7V200ABLADE FAST FUSE CSA 200A 700V
PDFP7V350ABLADE FAST FUSE CSA 350A 700V
PDFP7V500ABLADE FAST FUSE CSA 500A 700V
PDFP7V600ABLADE FAST FUSE CSA 600A 700V
6KF4C10
MK MICROSWITCH FUS. JM
25
——————— Half controlled power supply for inverter DC-Link ————————
GEH-6639
Chapter 8 - WARRANTY PARTS AND SERVICE
The purpose of this section is to provide specific in- WARRANTY COVERAGE
structions to the user of the standard drive referenced
The warranty covers all major parts of the drive such
in this book regarding warranty administration and how
to obtain assistance on both in-warranty and out-of-
warranty equipment.
as the main printed circuit boards, transistor modules,
etc. The warranty does not cover replacement of fuses
or of the entire drive.
If assistance is required to determine warranty status,
identify defective parts, or obtain the name of your
local distributor, call:
“Warranty period is 12 months after installation or 18
months after shipment from the Company, whichever
occurs first”.
GE Industrial Systems
Product Service Engineering
1501 Roanoke Blvd.
However, the guarantee will not apply in the following
cases, even if the guarantee term has not expired:
Salem, VA 24153-6492 USA
1. Damage was caused by incorrect use or inappro-
priate repair or modification.
Phone:
+ 1 800 533 5885 (United States)
+ 1 540 378 3280 (International)
+ 1 540 387 8606 (All)
2. The product was used in an environment outside
the standard specified range.
Fax:
3. Damage was caused by dropping the product after
purchase or occurred during transportation.
(“+” indicates the international access code required
when calling from outside of the USA.)
4. Damage was caused by an earthquake, fire, flood-
ing, lightning, abnormal voltage, or other natural
calamities and secondary disasters.
Before calling the number at left to determine war-
ranty 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 gener-
ally handled by GE Authorized Electric Motor
Servicenters or GE Apparatus Service Shops. For spe-
cific instructions on your motor, call the distributor
from which it was purchased and be prepared to furnish
complete nameplate data.
26
——————— INSTRUCTION MANUAL ————————
CS300
Notes:
27
——————— Half controlled power supply for inverter DC-Link ————————
GE Industrial Systems
General Electric Company
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
GEH-6639 (Draft)
010119
+ 1 540 387 7000
SIEI
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