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Siemens Vendor Manual

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FOR INTERNAL COMPANY USE ONLY!!
Siemens Energy & Automation, Inc
Large Drives A
ROBICON
500 Hunt Valley Road, New Kensington, PA, USA, 15068
Phone:
724-339-9500
Fax:
724-339-9562
Web:
www.robiconperfectharmony.com
M
H
ICRO
ARMONY
S
40 - 260A
IZES
M
ANUAL
Manual Number: 19001467
Version 1.0
December 2006
Customer Support Phone:
Customer Support Fax:
Customer Support E-mail:
C
ELL
.
724-339-9501 (24-hours)
724-339-9507
documentcontrol@siemens.com

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  • Page 1 40 - 260A IZES ANUAL Manual Number: 19001467 Version 1.0 December 2006 FOR INTERNAL COMPANY USE ONLY!! Siemens Energy & Automation, Inc Large Drives A ROBICON 500 Hunt Valley Road, New Kensington, PA, USA, 15068 Phone: 724-339-9500 Customer Support Phone:...
  • Page 2 For the support representative nearest you, please call Siemens main office at 724.339.9500. Version History Version 1.0 (original) December 2006 © 2006 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of...

  • Page 3: Table Of Contents

    MicroHarmony Cell Sizes 40 - 260A Manual Table of Contents Table of Contents Safety Precautions and Warnings..................v Chapter 1: Cell Overview ....................1-1 Introduction ......................1-1 Features ........................1-3 Cell Racking System ..................1-3 Rear Blind-Mate Power Connections............1-3 Snubberless design ..................1-4 Fusing......................1-4 Cell Control Board ..................1-4 Gate Clamp Board..................1-4 Overload......................1-4 Heat Sink Design...................1-5...
  • Page 4 Table of Contents MicroHarmony Cell Sizes 40 - 260A Manual Chapter 3: Installation ....................3-1 Packaging Requirements..................3-1 Lifting Preferences....................3-1 System Installation and Removal ................ 3-2 System Requirements (40-140A)................. 3-3 Chapter 4: Electrical Description................4-1 Ratings and Performance ..................4-1 De-ratings......................
  • Page 5 MicroHarmony Cell Sizes 40 - 260A Manual Table of Contents In all cases the cell must pass all specified testing before re-using ....8-3 Chapter 9: Application Notes..................9-1 External Wiring....................9-1 Fusing........................9-1 Device Model Parameters ..................9-2 40-140A Rectifier Modules ................9-2 200-260A Rectifier Modules ................
  • Page 6 Table of Contents MicroHarmony Cell Sizes 40 - 260A Manual Parity ........................11-2 Cell Data ......................11-3 Mode 00 Data..................... 11-4 Modulator to CCB ..................11-4 CCB to Modulator ..................11-5 Mode 01 Data..................... 11-6 Modulator to CCB ..................11-6 CCB to Modulator ..................

  • Page 7: Safety Precautions And Warnings

    MicroHarmony Cell Sizes 40 - 260A Manual Safety Precautions and Warnings Safety Precautions and Warnings MicroHarmony Power Cells are designed with considerable thought to personal safety. However, as with any piece of high power equipment, there are numerous internal connections that present potentially lethal voltages. In addition, some internal components are thermally hot to the touch.
  • Page 8 Avoid plastic, Styrofoam™, vinyl and other non-conductive materials. They are excellent static gen- erators and do not give up their charge easily. • When returning components to Siemens LD A, always use static-safe packing. This limits any further component damage due to ESD. 19001467: Version 1.0...
  • Page 9 • Never substitute with non-approved components; never parallel or series non-identical manufac- turer's (or Siemens MDIT numbers) for IGBTs or capacitors in the same power cell. • Never use halogen type cleaning agents when cleaning a power cell. Use pressurized dry air, iso- propyl alcohol, or water based solvent cleaning agents.
  • Page 10 Safety Precautions and Warnings MicroHarmony Cell Sizes 40 - 260A Manual viii 19001467: Version 1.0...

  • Page 11: Chapter 1: Cell Overview

    MicroHarmony Cell Sizes 40 - 260A Manual Cell Overview CHAPTER Cell Overview 1.1 Introduction The MicroHarmony series power cells are designed to replace GEN 3 (NBH) cell sizes 70-260A. Figure 1-1: MicroHarmony Cell The latest air cooled power cells are available in 6 frames: 40A, 70A, 100A, 140A, 200A, and 260A. All cells in the 40-140A frame have an identical footprint and internal design.
  • Page 12 Cell Overview MicroHarmony Cell Sizes 40 - 260A Manual Figure 1-3: 200-260A Cell Anatomy (*Top Lid not shown) 19001467: Version 1.0...

  • Page 13: Features

    MicroHarmony Cell Sizes 40 - 260A Manual Cell Overview 1.2 Features 1.2.1 Cell Racking System No hardware is required for mounting the cells in place within the drive. The MicroHarmony cell is designed to be mounted on polyethylene coated mounting rails. The cell is equipped with two locking latches on each side that latch into the mounting rail.

  • Page 14: Snubberless Design

    Cell Overview MicroHarmony Cell Sizes 40 - 260A Manual 1.2.3 Snubberless design A simple, low stray inductance bus, coupled with low self inductance capacitors and nomex insulation, eliminates the need for snubber capacitors at the IGBT power terminals. This reduces parts count, reduces complexity, and increases IGBT switching performance.

  • Page 15: Heat Sink Design

    MicroHarmony Cell Sizes 40 - 260A Manual Cell Overview 1.2.8 Heat Sink Design The heat sink assembly is designed for optimum IGBT cooling. The modules are arranged close together to reduce size. The IGBTs are separated for input/output bus locations and to increase thermal performance. The heat sink is a high performance, low pressure drop, light-weight aluminum design with a very thin base plate.
  • Page 16 Cell Overview MicroHarmony Cell Sizes 40 - 260A Manual 19001467: Version 1.0...

  • Page 17: Chapter 2: Physical Description

    MicroHarmony Cell Sizes 40 - 260A Manual Physical Description CHAPTER Physical Description 2.1 Mechanical Specifications Table 2-1: 40-140A Mechanical Specifications 10000424. 52Lbs 57.5Lbs 63Lbs 68.5Lbs Weight 23.58kg 26kg 28.6kg 31kg 3.714 stone 4.11 stone 4.5 stone 4.89 stone 13.496” W x 10.255” H x 22.086” D Envelope Dimensions (342.8 x 260.48 x 560.98 mm) 12.62”...

  • Page 18: Connections 40-260A

    Physical Description MicroHarmony Cell Sizes 40 - 260A Manual 2.2 Connections 40-260A Table 2-3: Connections 40-260A Bottom mount rails with polyethylene coated slider brackets. Front Mounting accessible self-locking latches. No hardware required. See Access/ Connections section for more details. Rear blind connection to nickel plated copper bus bars via cell Electrical mounted power plugs.
  • Page 19 MicroHarmony Cell Sizes 40 - 260A Manual Physical Description Air Flow vs Pressure Drop 1.00 40-140A 200-260A 0.90 R=8.1E-6 R=5.39E- 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 Air Flow , ft^3/m in 200- 40-140A 260A 0.02 0.01 0.05 0.03 0.08 0.05...

  • Page 20: 40-140A Outline

    Physical Description MicroHarmony Cell Sizes 40 - 260A Manual 2.4 40-140A Outline *Refer to Installation Section for mounting and bus connection information. Figure 2-1: 40-140A Outline 19001467: Version 1.0...

  • Page 21: 200-260A Outline

    MicroHarmony Cell Sizes 40 - 260A Manual Physical Description 2.5 200-260A Outline Figure 2-2: 200-260A Outline 19001467: Version 1.0...

  • Page 22: Access And Connections

    Physical Description MicroHarmony Cell Sizes 40 - 260A Manual 2.6 Access and Connections The figures below illustrate all power input/output terminals and fiber optic control terminals. Power connections are made via power plugs; no hardware is required. Fiber optic control connections are made at the front of the cell directly to the cell control board.

  • Page 23: Indicators And Labels

    MicroHarmony Cell Sizes 40 - 260A Manual Physical Description 2.7 Indicators and Labels The figure below illustrates the indicator functions and labels of the MicroHarmony Cell. Particular attention should be paid to the DC bus illumination LED that indicates that more than 50VDC is present on the DC bus. The cell should not be touched, removed, or serviced if the indicator is illuminated.

  • Page 24: Key Components

    Physical Description MicroHarmony Cell Sizes 40 - 260A Manual 2.8 Key Components The table below lists all the key components found within a MicroHarmony power cell as a reference. Always refer to the latest revision BOM. 10000424. Eupec Eupec Eupec Eupec BSM100GB170DLC BSM100GB170DLC...
  • Page 25 MicroHarmony Cell Sizes 40 - 260A Manual Physical Description 10000424. Western Electronic Company WPP4001-24 QTY 1 Thermodisc 100 ohm at 25°C, 250 ohm at 80°C P/N 094595 P/N 099416 QTY 5 Power Plugs Tyco: 538-17-00100 Anderson Power: PCL01 10000494. Eupec FF200R17KE3 x 2P Eupec FF300R17KE3 x 2P 1700V 300A 1700V 300A...
  • Page 26 Physical Description MicroHarmony Cell Sizes 40 - 260A Manual 10000494. P/N 11004896.00 QTY 1 135in wide x 8in deep 0.31" base plate, 3.41" fins Heat Sink R-Theta: 11004896.00 ERM: 11004896.00 Western Electronic Company WPP4001-24 QTY 1 Thermodisc 100 ohm at 25°C, 250 ohm at 80°C P/N 094595 P/N 099416 QTY 5 Power Plugs...

  • Page 27: Bill Of Material Structure

    Common parts (used on all cells regardless of current rating: input rectifier modules, heat sink, wire harnesses, power plugs, thermodisc, and handles) Hardware kit (screws, washers, thermal compound, bushings, etc.) IGBT kits Reference drawings 10000424.140 Capacitor Vendor #1 Capacitor Vendor #2 Capacitor Vendor #3 Capacitor Mounting Tray Common Parts Kit Chassis/Bus Kit...
  • Page 28 Note that the IGBT kit includes the gate clamp board, cell control board, IGBT module, and label. The gate resistors change from one vendor to the next, which requires the correct board-IGBT combinations. A label is placed on the cell chassis to identify what components are installed for replacement purposes.

  • Page 29: Assembly Notes

    MicroHarmony Cell Sizes 40 - 260A Manual Physical Description 2.10 Assembly Notes 2.10.1 Heat Sink Thermal Compound For proper thermal performance, the specified thermal compound and application procedure must be followed. Failure to do so may result in excessive heating and catastrophic cell damage. The assembly drawing identifies the approved compound and application procedure, which is shown below for the 40-140A cells.

  • Page 30: Semiconductor Torque Specifications

    Physical Description MicroHarmony Cell Sizes 40 - 260A Manual 2.10.2 Semiconductor Torque Specifications Proper heat sink mounting connections are just as important as proper thermal compound application. An insufficient tightening torque may cause the contact thermal resistance at the base plate to increase or the screws to come loose during shipping or operation.

  • Page 31: Capacitors

    MicroHarmony Cell Sizes 40 - 260A Manual Physical Description 2.10.3 Capacitors Electrolytic capacitors are polarized. Check the polarity of the capacitor before energizing. Reverse voltage results in capacitor destruction! Do not over tighten the mounting bolts. Excessive torque will strip the threads. Should this occur, the capacitor should not be used.

  • Page 32: Multiple Sources

    Mixing capacitors can cause voltage imbalance and damage the cell. IGBTs must be from the same vendor with identical MDIT and manufacturer's part numbers. Make sure to use the correct IGBT kit label on the outside of the cell chassis. Always use the correct gate clamp and cell control board.

  • Page 33: Chapter 3: Installation

    MicroHarmony Cell Sizes 40 - 260A Manual Installation CHAPTER Installation 3.1 Packaging Requirements The 40-260A MicroHarmony cells are designed to be shipped within the drive. For spare parts shipment, the cell should be packaged as shown below: Fill bottom of box with Place cell into box on top of Fill sides and top with Instapak Instapak sealed air foam in...

  • Page 34: System Installation And Removal

    Installation MicroHarmony Cell Sizes 40 - 260A Manual 3.3 System Installation and Removal A DC bus indicator light is located at the front of the cell on the cell control board and will stay lit at bus voltages greater than 50VDC. The cell should not be touched, removed, or serviced if the indicator is illuminated. Remember that the cell chassis is not grounded and when energized can float to lethal voltages.

  • Page 35: System Requirements (40-140A)

    MicroHarmony Cell Sizes 40 - 260A Manual Installation 3.4 System Requirements (40-140A) For reference only; always refer to latest core design. Figure 3-2: System Dimensions ∇ ∇ ∇ 19001467: Version 1.0...
  • Page 36 Installation MicroHarmony Cell Sizes 40 - 260A Manual 19001467: Version 1.0...

  • Page 37: Chapter 4: Electrical Description

    MicroHarmony Cell Sizes 40 - 260A Manual Electrical Description CHAPTER Electrical Description 4.1 Ratings and Performance All ratings at Tamb ≤40 °C at 180CFM, 0.95 output power factor for the 40-140A cells. All ratings at Tamb ≤40 °C at 300CFM, 0.95 output power factor for the 200-260A cells. 10000494 10000492 10000424.
  • Page 38 Electrical Description MicroHarmony Cell Sizes 40 - 260A Manual Base volt-ampere output rating of the cell. With 5% over modulation, maximum output voltage of cell is 750 x 1.78 x 1.05 / sqrt(3) = 809Vrms. VA = rated output current rating x 809Vrms Amount of no load and load losses of the cell at rated output power.

  • Page 39: Ratings

    MicroHarmony Cell Sizes 40 - 260A Manual Electrical Description 4.2 De-ratings In some cases the cell maximum output current capability must be de-rated in order to keep the maximum junction temperature below the manufacturer's maximum rating. The following general de-ratings should be applied to all cells sizes: Fo >...

  • Page 40: Schematic- 40-140A Cells (10000424S)

    Electrical Description MicroHarmony Cell Sizes 40 - 260A Manual 4.3 Schematic- 40-140A cells (10000424S) 19001467: Version 1.0...

  • Page 41: Schematic- 200-260A Cells (10000494S)

    MicroHarmony Cell Sizes 40 - 260A Manual Electrical Description 4.4 Schematic- 200-260A cells (10000494S) ∇ ∇ ∇ 19001467: Version 1.0...
  • Page 42 Electrical Description MicroHarmony Cell Sizes 40 - 260A Manual 19001467: Version 1.0...

  • Page 43: Chapter 5: Cell Control Board - 10000432

    MicroHarmony Cell Sizes 40 - 260A Manual Cell Control Board - 10000432 CHAPTER Cell Control Board - 10000432 5.1 New Features A new cell control board has been developed that is backwards compatible with the previous 10000092, 461E90, and 10000311 boards. New features include: Up to 1200VDC input operation 630, 690, 750V jumpers for high bus voltage fault.

  • Page 44: Power Supply

    Cell Control Board - 10000432 MicroHarmony Cell Sizes 40 - 260A Manual Mating Connector Function Pins Connector Q4 gate drive 5 (3 used, remainder removed) 089398 Q3 gate drive 5 (3 used, remainder removed) 089398 Q2 gate drive 5 (3 used, remainder removed) 089398 Q1 gate drive 5 (3 used, remainder removed)

  • Page 45: Gate Drive

    MicroHarmony Cell Sizes 40 - 260A Manual Cell Control Board - 10000432 5.4 Gate Drive Four independent and optically isolated gate drive circuits provide the proper IGBT gate drive and out of saturation feedback between the control and IGBTs. 5.4.1 Typical Gate Drive Circuit P1, C1, and E1 connects to a blocking test circuit used for verifying IGBT operation at start up.

  • Page 46: Oos Detection/Latch

    Cell Control Board - 10000432 MicroHarmony Cell Sizes 40 - 260A Manual 5.4.3 OOS Detection/Latch Out of Saturation is detected by monitoring Vce of the IGBT. Each fault feedback from the gate drive channels goes through a two-shot circuit that verifies that two consecutive OOS (Out-of SAT) faults occur before the drive trips. This provides extra immunity from false OOS faults.

  • Page 47: Protection Features

    MicroHarmony Cell Sizes 40 - 260A Manual Cell Control Board - 10000432 5.5 Protection Features The Cell Control Board (CCB) contains circuitry and firmware that protects the cell from various abnormal operating conditions. A description of these protection functions as well as the resulting cell response and the detection thresholds are described below: CCB Board Cell Protection...

  • Page 48: Communication

    Cell Control Board - 10000432 MicroHarmony Cell Sizes 40 - 260A Manual CCB Board Cell Protection Description and Thresholds Ref. Signal This is complimentary meaning of LINK ON, which is displayed on CCB Communication by means of LED lamp. Therefore, if LINK ON is off then CMFLT is CMFLT active.

  • Page 49: Chapter 6: Gate Clamp Board

    MicroHarmony Cell Sizes 40 - 260A Manual Gate Clamp Board CHAPTER Gate Clamp Board The gate clamp board protects the IGBT from over voltage transients. “Personality” gate resistors and capacitors are installed on this board as well; they are specific to the IGBT used. The board also acts as a terminal block for paralleling IGBT modules with a common gate drive.
  • Page 50 Gate Clamp Board MicroHarmony Cell Sizes 40 - 260A Manual The gate resistor is connected in series with the cell control board's turn on resistor during turn on, and connected in series with the cell control board's turn off resistor during turn off. The effective RgON is the sum of the cell control board RgON and the gate clamp board resistor.

  • Page 51: Chapter 7: Testing

    • QSI-013, section 4.3.4 includes instructions for product identification and traceability. 7.2 Testing Equipment MicroHarmony cells can be tested on Siemens Automated Cell Tester or manually. If tested manually, the following equipment is required. Cell Tester P/N 469939.00. Load inductors P/N 161661.13 (2mH in parallel, 8mH in series) or a suitable equivalent with required minimum inductance and current specification (see following table).
  • Page 52 Testing MicroHarmony Cell Sizes 40 - 260A Manual Table 7-1: Test Parameters for MicroHarmony Cells 10000494 10000494 10000424. .200 .260 Minimum Load Inductance 16mH 34Arms 58Arms 84Arms 117Arms 265Arms 265Arms 3 Minute Input Rectifier Test 10 sec nuisance Out of 125Arms 125Arms 180Arms...

  • Page 53: Chapter 8: Repair Hints

    8.3 Basic Rules Never parallel or series non-identical manufacturer's part numbers (or Siemens MDIT numbers) for IGBTs or electrolytic capacitors in the same power cell, even if these part numbers are approved as 1 , or 3 sources on the BOM.

  • Page 54: Component Re-Use

    Repair Hints MicroHarmony Cell Sizes 40 - 260A Manual An IGBT failure is usually also a result of an over voltage. Failures due to over current are rare since the cell and system is much more capable of protecting itself from this condition. There are two types of IGBT failures, catastrophic and non-catastrophic.

  • Page 55: Electrolytic Capacitors

    1 year of service (operating or non-operating), they may be re-used and supplemented with the approved capacitor of the same manufacturer's part number or Siemens MDIT number, if: The re-used capacitors are evenly re-distributed between parallel capacitor groups so that each group has the same number of re-used capacitors and have no more than 2 years of operation life on them.
  • Page 56 Repair Hints MicroHarmony Cell Sizes 40 - 260A Manual 19001467: Version 1.0...

  • Page 57: Chapter 9: Application Notes

    1100V 500A Note: Approved fuses have similar fuse curves. Although not recommended, non-identical manufacturer's and Siemens part numbers may be used with a cell and/or within a system. However, this may cause confusion with the customer and should be avoided.

  • Page 58: Device Model Parameters

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual 9.3 Device Model Parameters 9.3.1 40-140A Rectifier Modules Vendor Eupec Semikron Vendor P/N: DD106N1800 SKKD100/18 Siemens P/N 099414 0100375 Package Dual 92 x 25 Dual 93 x 20 Vrrm 1800 1800 Ifavm A at Tc=100°C...

  • Page 59: 200-260A Rectifier Modules

    MicroHarmony Cell Sizes 40 - 260A Manual Application Notes 9.3.2 200-260A Rectifier Modules Vendor Eupec Semikron Vendor P/N: DD171N1800 SKKD162/18 Siemens P/N 088173 0100787 Package Dual 94 x 34 Dual 94 x 34 Vrrm 1800 1800 Ifavm A at Tc=100°C Tjmax °C...

  • Page 60: Igbt Modules - Primary Sources

    040,070 10000494.200 10000494.260 Vendor Eupec Eupec Eupec Eupec Eupec BSM100GB170 BSM150GB170 FF200R17KE3 FF300R17KE3 Vendor P/N: FF200R17KE3 Siemens P/N 097065 097066 097067 097067 x 2 097068 X 2 Package 106 x 62 106 x 62 106 x 62 106 x 62...

  • Page 61: General Information

    MicroHarmony Cell Sizes 40 - 260A Manual Application Notes 9.4 General Information 10000424. 10000494.200 10000494.260 229nH 91nH 73nH 63nH 126nH 127nH Bus Inductance Power Plug maximum current 300Arms at 55 °C plug ambient, 25CFM Mechanical life test at 250 insertions/extractions with no significant change in Power Plug useful life resistance 1 Measured at nominal dc bus voltage, rated output current.

  • Page 62: Cell Loss Calculations

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual 9.5 Cell Loss Calculations The most accurate and quickest way to calculate cell losses is to use Drive Calc Express. However, losses can be estimated using the tables, equations, and plots below. Cell losses consist of the following: rectifier, capacitor, bleeder resistor, IGBT, FWD, control, bus work, and power plugs.

  • Page 63: Total Igbt/Fwd Cell Losses Vs Output Current

    MicroHarmony Cell Sizes 40 - 260A Manual Application Notes 9.5.2 Total IGBT/FWD Cell Losses vs Output Current The table and charts below can be used for estimating IGBT losses as a function of cell output current. Primary source values are used. Losses include conduction and switching losses for both the IGBT and FWD. Losses shown are per cell.

  • Page 64: Individual Igbt Losses Vs Output Current

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual 9.5.3 Individual IGBT Losses vs Output Current The table and charts below can be used for estimating individual IGBT losses as a function of cell output current. Primary source values are used. Losses include conduction and switching losses for a single IGBT only. FWD losses are neglected.

  • Page 65: Capacitor Losses Vs Output Current

    MicroHarmony Cell Sizes 40 - 260A Manual Application Notes 9.5.4 Capacitor Losses vs Output Current Capacitor losses are based on I^2 x R losses using ESR at 120Hz. This is a conservative approach to estimating capacitor losses. Furthermore, a conservative ESR of 9 mohms is used for the 40-140A capacitors, and 17 mohms for the 200-260A cells.

  • Page 66: Total Cell Losses

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual 9.5.5 Total Cell Losses The table below lists the no load losses (constant regardless of output) and load losses at maximum output power using primary source components, at rated 750Vrms input. The values shown are the cell TOTAL losses versus output current.

  • Page 67: Heat Sink Temperature Monitor

    Application Notes 9.6 Heat Sink Temperature Monitor Siemens P/N 094595 A PTC over temperature protector is installed on the heat sink at the rear of the cell (hottest cell temperature) next to the Q1/Q2 IGBT module. Positive Temperature Coefficient (PTC) thermistors are thermally sensitive semiconductor resistors which exhibit an increase in resistance at a specified temperature.
  • Page 68 Application Notes MicroHarmony Cell Sizes 40 - 260A Manual The following circuitry resides on the cell control board, and handles the heat sink temperature monitoring. Sync signal from EPLD resets and synchronizes the 600Hz ramp generator U100 circuit. Ramp at TP34 starts at 4.88V and ramps up linearly to 8.8Vpk.
  • Page 69 MicroHarmony Cell Sizes 40 - 260A Manual Application Notes Figure 9-2: Resistance vs Temperature Figure 9-3: Temperature vs Duty Cycle The control trips the cell when the thermodisc temperature reaches approximately 80°C. 19001467: Version 1.0 9-13...

  • Page 70: Exiting Air Temperature

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual 9.7 Exiting Air Temperature A simple formula can be used to predict the exiting air temperature of the cell: Tair,out = Tair,in + 1.75 x Watts / CFM For example, consider the 140A cell operating at rated current with a 45°C ambient: Tair,in = 45 °C (given) CFM = 180 (minimum allowable air flow) Watts = 1160 (from losses chart)

  • Page 71: Failure Modes

    The inevitable death of an aluminum electrolytic capacitor is defined differently from one vendor to the next, and formulas for forecasting end of life differ as well. United-Chemi Con's life model has been proven to be effective in forecasting the useful life of their capacitor. UCC defines end of life as a 20% capacitance loss, 2 times the initial ESR specification and initial DC leakage current specification.

  • Page 72: Disposal

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual (ΔTx - ΔTo) / k (Tx - To) / 10 LX = LR x 2 x (Vo/Vx) LX: Expected Life (Hrs) 5600μF (40-140A) 10,000μF (200-260A) LR: Endurance Test Life (Hrs) = 5000 = 10000 TX: Maximum Rated Ambient (°C) = 85...

  • Page 73: Output Voltage Capability After Bypass

    MicroHarmony Cell Sizes 40 - 260A Manual Application Notes where, N = number of ranks in the drive (or the total number of cells = 3*N), Vcell = 750, Tap = 1.00 (for 0% tap), 0.95 (for +5% tap) or 1.05 (for -5% tap) Vin = actual input line voltage, Vin,rated = rated drive input voltage M = 1.00 min (unity) to 1.08 max (over modulation)

  • Page 74: Microharmony Volt Map

    Application Notes MicroHarmony Cell Sizes 40 - 260A Manual 9.12 MicroHarmony Volt Map Note: 1PU = maximum cell DC bus voltage (MicroHarmony = 1200Vpk). For RMS, divide by 1.414. Internal Cell Components Between cell chassis and output terminals (For 4,5,6,7, or 8 series cells, continue the counting) Any transformer secondary to ground- 4 pu /3 typical, 2Npu worst case (GF)

  • Page 75: Chapter 10: Drive Calc Express

    MicroHarmony Cell Sizes 40 - 260A Manual Drive Calc Express CHAPTER Drive Calc Express Drive Calc Express is an excel spreadsheet tool that can be used to estimate the performance of a MicroHarmony Drive. With easy to use scroll bars and drop down menus with error messages, many of the rather tedious calculations previously shown can be performed in a few short steps.
  • Page 76 Drive Calc Express MicroHarmony Cell Sizes 40 - 260A Manual 10-2 19001467: Version 1.0...

  • Page 77: Chapter 11: Communication Protocol

    CHAPTER Communication Protocol This section summarizes the Siemens Harmony VFD message protocol and data handling between the Host and Cell Control Boards (CCB). The scope of this document includes a detailed description of the actual message contents and the CCB's implementation.

  • Page 78: Error Handling

    Communication Protocol MicroHarmony Cell Sizes 40 - 260A Manual 11.4 Error Handling Several levels of error handling are implemented on the CCB in order to validate each message. The IMS C011 Transceiver provides the following inputs/outputs that are implemented as follows on the CCB: Table 11-2: IMS C011 Status Indicators Indicates that data on pins Q0-7 is valid (data from Master Link) Input for CCB 'ACTIVITY' circuit that verifies message activity from Master Link...

  • Page 79: Cell Data

    MicroHarmony Cell Sizes 40 - 260A Manual Communication Protocol 11.6 Cell Data The following tables define the Perfect Harmony Modulator/CCB communication data bytes where bit 0 is the least significant bit (LSB). Table A-3 shows the information that flows from the Modulator card to the CCB. Table A-4 shows the CCB response message for each of the 4 data modes.

  • Page 80: Mode 00 Data

    Communication Protocol MicroHarmony Cell Sizes 40 - 260A Manual 11.7 Mode 00 Data 11.7.1 Modulator to CCB Mode ‘00’ is the default communication mode, which has the capability of enabling the cell output, commanding the left or right poles, or in the case of electronic bypass, requesting that cell bypass be enabled. Note that this method of handling bypass (electronic or SCR) is no longer used (this function is maintained for compatibility).

  • Page 81: Ccb To Modulator

    MicroHarmony Cell Sizes 40 - 260A Manual Communication Protocol 11.7.2 CCB to Modulator The CCB Mode 00 response data to the Modulator is shown below, where the Hub/Modulator boards monitor response bit 2 to determine the operational integrity of each power cell. The CCB indicates a cell fault condition by setting the Fault flag (bit 2) in the Mode “00”...

  • Page 82: Mode 01 Data

    Communication Protocol MicroHarmony Cell Sizes 40 - 260A Manual 11.8 Mode 01 Data 11.8.1 Modulator to CCB Mode 01 is dedicated for collecting diagnostic information from the CCB and is also used for issuing ‘Cell Fault Reset’ commands by setting bit 2 high (‘1’). Table 11-7: Mode 01 Modulator to CCB Data Description 1 ->...

  • Page 83: Mode 10 Data

    MicroHarmony Cell Sizes 40 - 260A Manual Communication Protocol 11.9 Mode 10 Data 11.9.1 Modulator to CCB Mode 10 is dedicated to collecting diagnostic information from the CCB and is also used for issuing ‘Cell Fault Reset’ commands by setting bit 2 high (‘1’). Table 11-9: Mode 10 Modulator to CCB Data Description 0 ->...

  • Page 84: Mode 11 Data

    Communication Protocol MicroHarmony Cell Sizes 40 - 260A Manual 11.10 Mode 11 Data 11.10.1 Modulator to CCB Mode 11 is dedicated, for the purpose of diagnostics, to provide a means to test device status. It also provides an indication if the Cell bypass option is available. Table 11-11: Mode 11 Modulator to CCB Data Description 1 ->...

  • Page 85: Ccb To Modulator

    MicroHarmony Cell Sizes 40 - 260A Manual Communication Protocol 11.11.2 CCB to Modulator The response data for Mode 11 data from the cell provides discrete indicators that show whether voltage is present at the output terminal of each of the power cell switching devices. Also included is a Bypass Available status bit that the Host can query to determine if the Cell Bypass option is available on the cell.
  • Page 86 Communication Protocol MicroHarmony Cell Sizes 40 - 260A Manual 11-10 19001467: Version 1.0...

  • Page 87: Notes

    MicroHarmony Cell Sizes 40 - 260A Manual NOTES NOTES 19001467: Version 1.0...
  • Page 88 NOTES MicroHarmony Cell Sizes 40 - 260A Manual 19001467: Version 1.0...
  • Page 89 MicroHarmony Cell Sizes 40 - 260A Manual NOTES 19001467: Version 1.0...
  • Page 90 NOTES MicroHarmony Cell Sizes 40 - 260A Manual ∇ ∇ ∇ 19001467: Version 1.0...

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