SINAMICS PERFECT HARMONY GH180 GenI/GenII/GenIII/GenIV/6SR5, Power cell 260 A Debug Tools v 5.4.0.1-
SINAMICS PERFECT HARMONY GH180 SINAMICS PERFECT HARMONY GH180 GenI/GenII/GenIII/GenIV/6SR5, Power cell 260 A Debug Tools v 5.4.0.1
Dear All,
Kindly note that we have Siemens Perfect Harmony Drive Gen IV . Input 11KV , Output 6.6KV
The drive was out of service and de-energized for more than 6 months.
According to the manual , the Harmony cell electrolytic capacitors will need to be reformed.
It is recommended to contact Siemens for the reforming procedure.
Please advice for the reforming procedure before Energizing the drive.
This procedure is to be followed for reforming electrolytic capacitors on Gen IV Perfect Harmony Drives. Reforming is necessary on Gen IV cell capacitors if the cells have not been energised in the last 6 months.
1 Equipment Required:
Variac – (variable auto transformer) variable voltage source.
Rating 0 - 750 Vac - 30Amps. (0 to 415/440 Vac ok if 0 – 750 Vac not available, note this will only partially reform the capacitors).
Safety: All Safety procedures must be followed. Required PPE must be worn.
Isolation procedure,
Personal Protective Equipment
2 Reforming Power Cells
Method with power cells in the VFD. This is the preferred procedure when this can be done. This provides a higher level of personal safety protection as well as cooling protection for the power cells.
Insure the input interrupting device is open, Locked out and Tagged out. This is the Input Medium Voltage.
Connect the variac
To power cell C1 or any secondary winding connection.
Verify variac input operating voltage and input breaker voltage.
Connect the input of the variac to the input breaker of the VFD or other source if required.
When applying power and bringing the variac up protect yourself by standing behind the doors of the Cell cabinets with correct PPE on.
Turn the variac on and bring up the input cell voltages slowly to 30% of its rating. This is because you are magnetizing the transformer and all the additional cell caps.
At 30% input voltage check the voltage across ½ of the 480 Vac circuit and 1/3 of the 690 Vac power cell. If the voltage is balanced then continue increasing the voltage in 10% steps until rated input voltage of the cell is reached.
Once full voltage is reached, maintain 100% voltage for 10 minutes.
Once this process is complete, decrease voltage source to zero. Let capacitors discharge for ≈ ten minutes. Ensure that the “Safe LED” on the Cell Control Board has gone out.
Disconnect variable voltage from cell.
Reforming a Power Cell out of the VFD. This is not the preferred method of reforming power cells. In particular cases this may be required to be done because the VFD cannot be shut down and the power cell has not been installed for a couple of years.
1. (One point of the capacitors is referenced to the chassis of the cell) The power cell must be isolated from earth ground.
2. The power cell must be separated by means of a shielding it behind a wall – protective device.
3. For air cooled and liquid cooled power cells a fan must be directed across the bleeder resistors. This must be done to protect the bleeder resistors.
Failure to do this could result in overheating and failure of the bleeder resistors in the cell.
4. Connect the Variac to the cell 3 phase input
5. Verify variac input operating voltage and input breaker voltage.
6. Connect the input of the variac to the input breaker of the VFD or other source if required.
7. Turn the variac on and bring up the input cell voltage slowly to 30% of its rating. This is because you are magnetizing the transformer and all the additional cell caps.
8. At 30% input voltage checks the voltage across ½ of the 480 Vac circuit and 1/3 of the 690 Vac power cell. If the voltage is balanced then continue increasing the voltage in 10% steps until rate input voltage of the cell is reached.
9. Once full voltage is reached, maintain 100% voltage for 10 minutes.
10. Once this process is complete, decrease voltage source to zero. Let capacitors discharge for ≈ ten minutes. Ensure that the “Safe LED” on the Cell Control Board has gone out.
11. Disconnect variable voltage from cell.
Once the drive has been in continuous service reforming of the drive’s cells should not be necessary. However the spare cell(s) may need to be re-formed if they are not cycled through the drive on a regular basis.
Reason for Forming in Electrolytic Capacitors
Aluminium Electrolytic Capacitors suffer gradual deterioration of the oxide dielectric during storage. The result is increased leakage current when they are put back in service, until the oxide can re-form itself. If the leakage is too great, the power dissipation may cause venting if full voltage is applied abruptly. The solution is to build up the voltage gradually, limiting the leakage current until the oxide has re-formed.
The length of storage time after which re-forming is necessary depends on the storage temperature, the manufacturer and the length of time voltage has been applied during the original forming in process.
Re-forming is never harmful. To be safe, capacitors should be re-formed if the ambient storage temperature is 40 degrees C or higher and/or the cell(s) has not had full voltage applied for 6 months.
Thank you Mr.Will4 for the reply ,
kindly clarify step no. 5 in first method.
and what is meant by 1/2 of the 480 Vac circuit , 1/3 of the 690 Vac power cell
You are looking for the capacitors to be balanced in terms of voltage accross them. Each individual capacitor should have the same voltage accross it as the others ie they should be sharing the voltage. If you measure the capacitor bank in two halfs then boths halfs should give the same voltage reading. More often than not this step is actually skipped as it is difficult to access the capacitors.
Hi Experts,
If I have spare brand new power cells kept in ware house @less than 50 deg C, and wish to replace within 6 months of manufacturing date. From the VFD I will remove two healthy cells to keep in ckt these new cells. Shall the next period for using these old cells w/o reforming also holds good @ 6 months or not ?
Regards,
Vijay
Dear Expert / will4,
Power cell is similar to AC Drive principle.
From the transformer secondary will give input to power cell.
Power cell input voltage will rectifier pass through pre-charge contactor, then it will charge DC capacitor.
Capacitor charging voltage will be : Input * 1.25
Example: 415(input) * 1.25 = 518.75VDC
As you mentioned previously regarding transformer specification.
“ 0 to 415/440 Vac ok if 0 – 750 Vac not available”
750*1.25: 937.5VDC
Do you recommend 0-937 VDC to do forming function?
If yes; Please let me the forming function linear data sheet Voltage vs time for both 415VAC/750VAC ?
Note : We are using , Medium voltage drive : 6600V / 100AMPs POWER CELL
Regards,
Sivaji Manigandan
Hi Sivaji,
The best way to confirm the exact forming requirements of the specific capacitors you have inside your power cells is as follows.
Isolate drive and wait for capacitors to discharge,
Remove a power cell from drive,
Open and inspect capacitors,
Note capacitor manufacturer and part number,
Contact capacitor manufacturer directly and confirm recommended forming details.
Procedure listed in above post is generic and covers all the bases. Additional information is best obtained from capacitor manufacturer as different brands/type are used across drives.
Thank you for the well explained procedure. Few points need elaboration:
1. The variac used for reforming with cells installed in VFD, apparently you are using an MV variac because you are connecting it to transformer primary.
2. What if you have an LV variac, say 400V or 690V.
3. What would be the minimum current rating of required variac in both the cases?
4. For 10% step increment, what should be waiting time for each step?
Hi Z0021JNX,
The procedure uses a 415 VAC variac. If you are using the method with the cells in the drive then the size of the variac depends on the drive size and transformer construction. As an example for a 1250kW drive with a Copper wound transformer you can use a 30 amp variac. If you have a Aluminium wound transformer you will need a larger variac for the same rating of transformer. If you are reforming the cell capacitors one cell at a time outside of the drive you can use a much smaller variac. We use the following variac https://au.rs-online.com/web/p/variacs/8902856/ with a step up transformer 415 to 1500VAC in our power cell bench testing facility.
Regards,
will4
Local/manual frequency changes 0.1Hz
Hi everyone
I would like to know if it is possible to increase/decrease frequency from the Keypad (up/down keys) with increments of 0.1 Hz--->0.166% in demand.
The actual VDF increments with the keypad is 0.5%--->0.3Hz. So, It must be done with the "entry manual speed" function in the PC. I want to avoid that.
Thanks in advace
Joan
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