56161791 SAMI STAR Optional Equipment

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SAMI STAR Frequency Converters

Optional Equipment

Code:

3AFE56161791

Revision:

D

Language:

EN

This document describes the optional equipment for SAMISTAR frequency converters.

If there is a need for optional equipment that is notmentioned in this paper, please contact ABB Industry Oy/Power Electronics/Sales Department.


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3AFE56161791 Optional Equipment

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Issued by: FIIND/EILDate: 1994-07-13File: Optional.DOCCreated with: WinWord 2.0a

Designer 3.02Microsoft DrawExcel 3.0

Table of Revisions:

Date: Code: Rev.: Remark:

1992-04-10 3AFE56161791 A First issue1992-09-15 3AFE56161791 B Corrections1993-12-08 3AFE56161791 C New options1993-05-20 3AFE56161791 D New options

Table of references:

For Information on: See:


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CONTENTS Page

MECHANICS ......................................................................................... 5

Bottom plates........................................................................................ 5Fire-resisting top plate (additional cabinet) .......................................... 6Top entry input and output terminals (additional cabinet) .................... 6Top entry input terminals (no additional cabinet) ................................. 7 Air filters................................................................................................ 7Insect screen ........................................................................................ 8Door lock .............................................................................................. 8IP 41 ..................................................................................................... 8IP 54 by connection to ventilation system............................................ 9Vibration dampers .............................................................................. 10

WIRING ........................................................................................ 11Marking of conductors........................................................................ 11

Standard marking..................................................................... 11Special marking........................................................................ 12

Customer terminal block..................................................................... 12

CONTROL ........................................................................................ 13Main contactor control switch............................................................. 13Emergency-stop switch ...................................................................... 13Potentiometer ..................................................................................... 14Keylock switch.................................................................................... 14Galvanic Isolator................................................................................. 15Galvanically isolated converter .......................................................... 15Operating-hour counter ...................................................................... 15Mains voltage measurement .............................................................. 16Output for a separately ventilated motor............................................ 16

1 motor by-pass.................................................................................. 17Restart after power failure in the supply net....................................... 18External auxiliary supply voltage 220 VAC ........................................ 18Start via closing the main contactor ................................................... 19

PROTECTION ..................................................................................... 20Thermistor relay motor protection ...................................................... 20"Pt-100" motor protection ................................................................... 20Earth-fault protection.......................................................................... 21

System-earthed network ............................................................. 21Network disconnected from earth ............................................... 23Monitoring of insulation resistance in the unearthed network..... 24Monitoring of insulation resistance in the 12-pulse system......... 2412-pulse system with neutral earthing reactor ............................ 25

Protection of electrical parts, IP20 doors open .................................. 26ENVIRONMENT .................................................................................. 27

Anticondensation heater of cabinet.................................................... 27Varnishing of the control cards........................................................... 27The output for anticondensation heater of motor ............................... 27

SAMINODE (ABB MASTER INTERFACE) ......................................... 28DMS (DRIVE MAINTENANCE SYSTEM)............................................ 29PACKING ........................................................................................ 30


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MECHANICS

BOTTOM PLATES

A bottom plate and gland plate are used when:- a fire-resistant cabinet structure is required,- there are filters in the air inlet,- a customer wants to support the cables by using cable

glands.

Gland plate and bottom plate are made from 1,5 mm thick steelplate. They are galvanized and their type is St37. The gland platecan also be made of brass (does not include ready holes for thecables). The bottom plate is attached to the frame of the cabinetby means of screws. The bottom plate should be grounded to aPE bus.

Warming up of the bottom plate which is caused by eddy currentscan be prevented by cutting openings between cable holes or byusing a three-phase cable.

1 2 1 3 2

4

4

2

31

Figure 1. Installation of a bottom plate and a fire-resistingbottom plate (5616 2615).


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FIRE-RESISTING TOP PLATE (ADDITIONAL CABINET)

Fire-resisting top plate is used, when the input and (or) output

terminals enter the cabinet through the top.

Figure 2. Top entry fire-resisting input and output terminalsinstalled in the same cabinet. (5616 2640)

TOP ENTRY INPUT AND OUTPUT TERMINALS (ADDITIONAL CABINET)

Additional cabinets should be used in the following SAMI STARsizes:- 200 F 380 and higher power ranges- 250 F 500 and higher power ranges- 200 F 660 and higher power ranges

Depending on a drive, input and output terminals can be installedin the same additional cabinet or in separate additional cabinets.


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TOP ENTRY INPUT TERMINALS (NO ADDITIONAL CABINET)

No additional cabinet is used, when the input terminals enter the

cabinet through the top of a MD-cabinet for:SAMI STAR 25 - 100 F 380

25 - 100 F 41532 - 125 F 500

AIR FILTERS

Air filters are mounted in front of the air inlet or on the side of thecabinet. A bottom plate and special sealing are always used withthe air filter.

Type: Pliotron CRDimensions: (245 * 245 * 24)mm for 400 mm wide cabinets

(245 * 500 * 24)mm for 600 and 800 mm widecabinets

The frames of the filters can be the same colour as the cabinet.

Figure 3. Location of air filters. (5616 2658)


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INSECT SCREEN

Insect screen (1mm * 1mm) is used inside the air inlet and air

outlet to protect the SAMI STAR from insects around. A bottomplate and special sealing are always used with the insect screen.

DOOR LOCK

The cylinder lock type C101 with lever is used to lock cabinetdoor. It replaces standard triangle axle lock, when special lockingis required. It can also be easily mounted afterwards. Also padlock can be used. The padlock is chosen by the customer.

Figure 4. Cylinder lock with lever

IP 41

Normal enclosure class of SAMI STAR is IP 21 (door closed).It is possible to have a SAMI STAR which meets the requirementsof protection provided by enclosure IP 41. The enclosure class

IP41 requires an insect screen (1mm * 1mm) inside the air inlet,an insect screen inside the air outlet, a bottom plate, and specialsealing.

IP 20 DOORS OPEN -see part Protection, page 26.


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IP 54 BY CONNECTION TO VENTILATION SYSTEM

The cooling of the SAMI STAR by connection to ventilation system

gives excellent protection against dust and water. The MD cubicleis sealed to fulfill the IP54 protection class requirements, accordingto the IEC 529 standard. The cabinets are equipped with plaindoors without lattices on door or backplate. The top plate coversthe length of a transportation unit, and includes only collars forconnection to ventilation system as shown in figure 5.The protection class for complete drive system will be IP54,provided connection to ventilation system and the cable lead-throughs are carried out properly. The hole for intake air ininverter cabinet must be the size of the hole for exhaust air plusthe total size (mm2) of cables. The holes for intake air in other

cabinets must be 250∗500mm as minimum.The required cooling air volume is mentioned in User's Manual.It is recommended that intake air had overpressure, because therequired air flow is difficult to achieve, especially in large SAFUIunits. The cable lead-through in the floor must be done such thatno dust or rubbish can flow into SAMI with the intake air flow.The collars in exhaust air are equipped with a net with 10 * 10mmholes to prevent foreign bodies from dropping into SAMI.

COLLAR FOR JOINING

TO VENTILATION SYSTEM

VENTILATION SYSTEM

VENTILATION SYSTEM

AIR OUTLET

600mm

MD CABINET

800mm 400mm

inputcables

outputcables

AIR INLET

Figure 5. The connections to ventilation system (61048286)

If it is not possible to connect air outlet to ventilation system, thecooling can be arranged by means of a heat exhanger system.The best possible solution to carry out construction varies

depending on the SAMI size. Before selling this kind of a system,please contact our sales to get heat exhanger cabinets situatedright.


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VIBRATION DAMPERS

Vibration dampers are recommended, if a SAMI STAR is installedin a place where vibration can occur. The vibration dampers areassembled under and above the cabinet.

The vibration dampers are delivered unattached but the positionsof the vibration dampers are checked in the factory. Installationplaces are marked with numbers both on the SAMI STAR cabinetand on the vibration dampers.

Minimum weight of a cabinet is 360 kg and maximum load for onedamper is from 90 to 100 kg.

Figure 6. Positions of the vibration dampers (6100 1441).


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WIRING

MARKING OF CONDUCTORS

STANDARD MARKING

The ribbon cables and connection busbars are always marked inthe standard SAMI STAR frequency converters.

The ribbon cables are marked with plastic tape on which the PC-board and connector symbols are marked with waterproof blackink - see figure 7. The busbars in the SAMI STAR frequency

converters are marked with labels. Adhesion of the labels is fastand reliable - see figure 8.

In the Contactor Unit CTU (< 1000 kVA) the wires (Nokia MJEMT)are marked with an imprint on the insulation material, except forshort obvious connections. The imprint consists of the apparatussymbol and the terminal number.

Figure 7. Marking a ribbon cable with marking tape.(5709 7710)

Figure 8. Marking a busbar with an adhesive aluminium label.

(5709 7710)


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SPECIAL MARKING

The wires are marked with SES PLIOTEX PT-V rings (figures 9and 11) and/or with imprint on isolation material (figure 10).

The main circuit wires are not marked. The marking is dividedinto 3 classes:

CLASS A: The wires between and outside modules are markedwith terminal numbers. Also the conductors led to the terminalblocks are marked. Short, obvious links are not marked.

Figure 9. Marking the conductors with the PT-V rings. (57097710)

CLASS B: All wires, including internal wires of modules aremarked with terminal numbers. Also short, obvious links aremarked.Note! The terminal numbers are not marked with PT-V-rings inthe modules where both apparatus identification and terminalnumber are marked with an imprint on the insulation material ofwire.

T3/S

Figure 10. Marking the conductors with imprint on the insulationmaterial of wire. (5709 7710 )

CLASS C: All the wires both inside and outside of modules aremarked with apparatus identification and terminal numbers usingPT-V-rings.

K 1 1 2 4

Figure 11. Marking the conductors with PT-V ring for apparatusidentification and terminal number. (5709 7710 )

Note! The marking class A is used if the class is not specified.

CUSTOMER TERMINAL BLOCK

A customer terminal block is a block with 1 to 10 (1 to 20 or 1 to 30)

terminals in which all the control signals that a customer wants tocontrol are collected. The customer terminal block is usuallyinstalled in the supply unit.


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CONTROL

MAIN CONTACTOR CONTROL SWITCH

A main contactor control switch is used to control the maincontactor of the line supply unit or the contactor unit of the SAMISTAR frequency converters. Main contactor control switch ismounted on the cabinet door and used in a standard delivery.

0

I

S

Figure 12. Main contactor control switch. (5616 2666)

EMERGENCY-STOP SWITCH

The emergency-stop pushbutton is locked when depressed and

released when turned in the direction indicated by the arrows. Thepushbutton is red, the arrows are white. The emergency-stopswitch is mounted on the cabinet door and used in a standarddelivery.

EMERGENCY STOP

Figure 13. Emergency-stop switch. (5616 2674)


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POTENTIOMETER

The frequency reference of the SAMI STAR frequency converter

can be adjusted by a manual potentiometer mounted on thecabinet door. In manual control, the frequency can be controlledfor example by a potentiometer at 0.5V. The frequency referenceis normally set from the digital control panel.

Figure 14. Potentiometer. (5616 2682)

KEYLOCK SWITCH

Unauthorized access to the SAMI parameter mode can beprevented on the digital control panel by means of a keylock

switch mounted on the door of the SAMI STAR cabinet. Thekeylock switch has two positions, one normally-closed and onenormally-open contact. The keylock switch is connected to theSAMI STAR terminal block card.

Figure 15. Keylock switch.. (5616 2691)


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GALVANIC ISOLATOR

The galvanic isolation unit type Camille Bauer 84-2I1 can be usedfor analog input INPUT1 in signal levels 0...5mA, 0...20mA or

4...20mA and analog outputs OUTPUT0 and OUTPUT1 in signallevel 0...1mA. The output of isolation unit equal to input i.e. theratio of transformation is 1:1. In addition it can be used for outputsOUTPUT2 and OUTPUT3 to separate them in cases when thecommon zero for outputs is not acceptable.

GALVANICALLY ISOLATED CONVERTER

The galvanically isolated converter type PR Electronics 2284/x/2can be used in inputs and outputs of SAMI to provide desiredsignal level.The converter is programmed for signal level 0...1mA / 4...20mAas standard.

The programmable ranges are as follows:INPUT: 0...1mA, 0...5mA, 0...10mA, 0...20mA, 0...33mA,0...50mA, 0...100mA, 0...250mA, 0...500mA, 0...1V, 0...2,5V,0...5V, 0...10V and 0...100V. A 20% offset for each range is also available.

OUTPUT: 0...5mA, 0...20mA, 0...250mV, 0...1V, 0...2,5V and0...10V, with 20% offset. The programming instructions are givenon the enclosed data sheet. The auxiliary voltage +24V isobtained from SAMI.

OPERATING-HOUR COUNTER

An operating-hour counter is used to follow the running time of a

motor e.g. in connection with regular maintenance of the motor.The hours run meter is mounted on the SAMI STAR cabinet door.The hours run meter is in action when the frequency converter isdriven to run state by giving a RUN signal through the STARTpushbutton of the control panel or the Terminal Block Card SAFT174 TBC. A 24 V relay (220 V/50 Hz) is always used with thecounter.


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MAINS VOLTAGE MEASUREMENT

The purpose of mains voltage measurement is to confirm:- if all phases of supply are live- if phases are symmetrical- the supply voltage value

In mains voltage measurement, the main-circuit voltage ismeasured between each two phases. The supply voltage ismeasured using a voltmeter and a special changeover switch.The voltmeter and the changeover switch are mounted on theSAMI STAR cabinet door. The voltmeter is connected to the

supply cables from behind the fuses or a circuit breaker.

OUTPUT FOR A SEPARATELY VENTILATED MOTOR

A separately ventilated motor is used to produce a sufficientcooling effect at low speeds. The fan motor is connected directlyto the mains and it runs at a constant speed.

A therminal relay or a motor overcurrent switch and connectors

are always needed in the output connection. A combination whichcontains a fuse, a motor overcurrent switch and a contactor canalways be used.

When ordering this option please mention the current and voltageof the ventilation motor.


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1 MOTOR BY-PASS

A frequency converter can be equipped with a motor by-passwhen:

- a service is wanted for the SAMI STAR while the drive is in operation- reliability of a drive is to be optimized- different kind of connection combinations are needed for

motor or motors (for example in automatic pump controlsystem)

Standard by-pass equipment is installed stationary in the SAMISTAR (extra field in the MD-cabinet). The by-pass equipment isdimensioned according to the maximum motor size of thefrequency converter. See figure 16 for connections.

Note! The power loss control and auto-restart used in scalarcontrol are not available with a standard by-pass.

Figure 16. Connection of the 1 motor by-pass. (5780 2502)


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START VIA CLOSING THE MAIN CONTACTOR

Normally the main contactor of the SAMI STAR is closed

manually and after that the start command is led to the inverterunit.

When starting through closing the main contactor, the startcommand which is led to the inverter unit first closes the maincontactor via a digital output and then an auxiliary contact of themain contactor gives a start command to the inverter unit. This isused for example in unmanned stations.

When the SAMI STAR is stopped, it first decelerates down andthen the main contactor will open.


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PROTECTION

THERMISTOR RELAY MOTOR PROTECTION

Thermistor relay motor protection consists of one thermistor relay(GHC 106) and three series-connected thermistors embedded inthe stator windings. The thermistors have a positive temperaturecoefficient, i.e. their resistance value increases sharply at certaintemperature.

In normal state the relay is energized and it continuously monitorsthe condition of the thermistor circuit. As the resistance value ofthe thermistor increases, the current supplied to the relay coil is

reduced and the relay is de-energized at the operatingtemperature of the thermistor (the main contactor will open).

The thermistor relay can be reset by means of the reset button orexternally. The thermistor relay cannot be reset until the motortemperature has decreased below a preset value.

"PT-100" MOTOR PROTECTION

"PT-100" motor protection consists of three relays (ST 199 724)and three temperature sensors embedded in the stator windings.The resistance value of the temperature sensors increaseslinearily.

The operating temperature of the relays 0 - 900°C is set by thecustomer.

The relay releases (the main contactor will open) when the actualtemperature reaches the set value and operates when thetemperature drops below the hysteresis fixed by selection of therelated resistor.


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EARTH-FAULT PROTECTION

The earth-fault protection is used when the SAMI STAR is to be

stopped and disconnected from the mains for reasons of safetyand process reliability whenever there is an earth fault in theSAMI or the circuits after it.

SYSTEM-EARTHED NETWORK

In a system-earthed network the neutral point of the distributiontransformer is earthed solidly. The current transformer isconnected to the network side and an overcurrent relay to thesecondary of the current transformer - see figure 17.

The earth-fault protection circuit includes a current transformerT6, a SAFT 158 EFS supervision card and the necessarymechanics. The circuit measures the sum of the inverter supplycurrent flowing through the current transformer, which is normallyzero. The circuit is activated if the sum current differs from zero. An earth leakage current exceeding the preset alarm limit causesan alarm which is given as a relay signal. This contact signal canbe used to trip the SAMI or merely to give an alarm.

∑

Figure 17. System-earthed network. (5707 1508)


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In a system-earthed network with large supply busbars one currenttransformer cannot be installed around three phases. In thosecases three current transformers are used to measure the sum of

inverter supply current as shown in figure 18. The operation issame as in one transformer system -see figure 17.

∑

Figure 18. System-earthed network with large supply busbars.


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NETWORK DISCONNECTED FROM EARTH

In a network disconnected from earth the neutral point of the

transformer secondary is unearthed, or connected to earththrough a high-ohmic resistor. An overvoltage relay is used todetect an earth current through a resistance that is connectedbetween the neutral point and the earth - see figure 19.

Figure 19. A network disconnected from earth. (5707 1516)

If the neutral point of a transformer is not available the super-vision of the earth fault is implemented by means of an artificialneutral point. This is also used in the parallel connected SAMIsand normally when large supply busbars are used - see figure 20.

Figure 20. A network disconnected from earth with an artificialneutral point (5616 3158)


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MONITORING INSULATION RESISTANCE IN AN UNEARTHED NETWORK

The insulation monitoring device, type Bender IRDH265, is used

to measure insulation resistance between unearthed network andequipotential bonding (PE) as shown in figure 21.

The resistance to be measured is between 10 to 900 kΩ.The measuring values and alarms are indicated on an LCD display.The device is mounted on DIN-rail inside the cabinet.The Operator's Manual (issued by Bender) gives a more detaileddescription of the device.

IRDH265

PE

Figure 21. Monitoring insulation resistance in an unearthednetwork with large supply busbars.

MONITORING INSULATION RESISTANCE IN THE 12-PULSE SYSTEM

Only one insulation monitor, type Bender IRDH265, is used ineach interconnected system. In the drives with12-pulse supply thedevice is connected to one 6-pulse supply to measure insulationresistance between unearthed network and equipotential bonding

- see figure 22.The earth fault in any part of the circuit is supervised. The sensitivityof the alarms and trips is not equal in both 6-pulse supplies.

IRDH265

Figure 22. Monitoring insulation resistance in the 12-pulse system.


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12-PULSE SYSTEM WITH A NEUTRAL EARTHING REACTOR

In 12-pulse systems with 2 supply transformers the trans-former neutrals may not be connected directly to earth.If the connection is made high circulating currents will flowbetween supplies with a frequency of 150 Hz. It is, however,sometimes required that supply transformers be earthed solidly.

As an alternative to the high resistance earthing ABB StrömbergPower has constructed a neutral earthing reactor that has verylittle effect on earth fault current and protection, but limits thecirculation current. It has two windings in series for the 150 Hzcirculating current as shown in figure 23. The earth-fault

protection can be done with a ring-type CT around thetransformer neutrals. The reactor is of dry type and enclosed foroutdoor installation. It can be placed nereby the transformer andboth transformer neutrals are connected insulated from eachother to the reactor terminals.

Figure 23. Earth -fault protection of a 12-pulse diode rectifiersystem. (5616 2704)


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PROTECTION OF ELECTRICAL PARTS, IP20 DOORS OPEN

Additional plexiglass (polycarbonate) and steel net with 10 sq.mm

holes are used when the electrical parts are to be protected tofulfil protection class IP20 when doors are open, according to IEC529 standard.

Figure 24. Protections of electrical parts to fulfil protection classIP 20 , when doors are open, according to IEC 529standard. (5616 2712)


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ENVIRONMENT

ANTICONDENSATION HEATER OF CABINET

A self-adjusting heating resistor (SR 50) can be used to preventwater condensation inside the SAMI STAR when the frequencyconverter is not in operation. One heating resistor is used percubicle and the resistor size is 50W/220V. The heating resistor isconnected to the 220V auxiliary voltage of a supply unit.

VARNISHING OF THE CONTROL CARDS

Varnishing of the control card is used to protect a card from dustand humidity. The whole card is varnished, except connectors, ICsockets, pushbuttons, switches, fibre optic links, fuses, fuseholders and adjustable capacitors. Varnishing is done twice with aspray. The type of the lacquer is HYSOL 28, PolyurethaneLacquer.

Note! Varnishing of the cards does not provideprotection against corrosion of connectorsand IC sockets!

• Varnished cards are not available from stock!

• Reparing the cards is very difficult!

The corrosion severity level of SAMI STAR is specified so that thecorrosion severity of the cooling air supplied to SAMI STAR shallnot exceed level G1 according to standard ISA-S71.04.

THE OUTPUT FOR ANTICONDENSATION HEATER OF MOTOR

A heater is meant to work when the main contactor of SAMI isopen. The heating resistor is connected to the 220V auxiliaryvoltage of a supply unit via normally closed contact of maincontactor and it is equipped with circuit breaker. It has also theterminal blocks for external 220V supply for cases when mainssupply to SAMI is disconnected .

When ordering this option please mention the power of theheating resistor.


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SAMINODE (ABB MASTER INTERFACE)

Interface between ABB Master Automation System and SAMI

STAR frequency converter requires a protocol converter unitbetween Master Fieldbus and Samiprotocol. This unit is calledSAMINode.

SAMINode consists of three circuit boards: a modem board YPC104 (standard), a modified YPK 107A microprocessor board anda current loop / auxiliary power board SAFT 184 MIF designedspecially for this purpose.

In single drives, SAMINode is installed into a specific closed metalbox (IP 21) that can be attached outside the cabinet with four

screws.

In sectional drives, all SAMINodes can be installed into a commoncubicle and they have each only open protecting box aroundthem. Protecting box is also attached with four screws.

The distance between the SamiNode and ABB Master AutomationSystem can be maximum 750 m long.

The document 'ABB MasterFieldbus Interface for SAMI STARusing SAMINode adapter' (code 5812 4664) gives a more detailed

description of the SAMINode.


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DMS (DRIVE MAINTENANCE SYSTEM)

DMS is a software and hardware package including an RS-232

communications port for direct programming of the SAMI STARfrom a personal computer (IBM or IBM compatible).

The DMS is used for remote control, maintenance, fault tracingand commissioning of the SAMI STAR. Up to eight SAMIs can beconnected to the DMS.

The document "Drive Maintenance System User's Manual 1.71"(code EN 5805 7169) gives a more detailed description of theDMS.


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PACKING

An antistatic solid cell polyethene mat or clear polyethene film isused for basic protection. The goods are wrapped and taped

against dust and splashed water.

SAMI STAR is always packed in a crate.

Crate: See figure 25.Maximum weight of goods 10000 kg,maximum height 2500 mm.Storage outdoors is not allowed.

Seaworthy export package, ordinary:See figure 25.Maximum weight of goods 10000 kg,maximum height 2500 mm.Period of storage less than six months.

Seaworthy export package, period of storage more than six months:The package is the same as the ordinaryseaworthy export package, but the basicprotection is made from aluminium foil.The welding seams of foil are made hermetic(air-tight).

Storage outdoors under shelter is allowed for the seaworthy exportpackages only if direct contact with rain is prevented.

The document "Packing methods" (code: 53517056) gives a moredetailed description of the packing.

Figure 25. Seaworthy export package and crate (5616 2721)


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ABB Industry OyPower ElectronicsP.O.Box 184

00381 HELSINKIFINLANDTelephone + 358-0-5641

56161791 SAMI STAR Optional Equipment

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Transcript of 56161791 SAMI STAR Optional Equipment