Siemens Robicon AIR COOLED PERFECT HARMONY GENIIIE SERIES VFD User Manual A1A19000405A
Siemens Robicon AIR COOLED PERFECT HARMONY GENIIIE SERIES VFD User Manual A1A19000405A
USER’S MANUAL
FOR
AIR COOLED
PERFECT HARMONY
GENIII/E SERIES
ADJUSTABLE SPEED AC MOTOR DRIVES
WITH NEXT GENERATION CONTROL
https://www.robiconperfectharmony.com/
For technical assistance and Field Service emergency support in the area nearest to you, please call the s
1.800.333.7421 toll-free number.
Version History
© 2009 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of s LD A
Version 1.0 (original) August 2003
Version 1.1 October 2003
Version 1.2 (ECO - 79B92611) (ECR - 13140) September 2008
Version 1.3 (ECO - 79C18180) (ECR - 13710) June 2009
Perfect Harmony GENIII/e User’s Manual Table of Contents
Table of Contents
A1A19000405A: Version 1.3 i
s
Safety Precautions and Warnings...................................................................................iii
About This Manual ........................................................................................................... v
Separation of Manuals............................................................................................. v
Reference Tools....................................................................................................... v
Conventions Used in this Manual ..........................................................................vi
Chapter 1: Introduction.................................................................................................1-1
Introduction to the Perfect Harmony....................................................................1-1
Clean Power Input.........................................................................................1-1
High Power Factor and Nearly Perfect Sinusoidal Input Currents ...............1-2
Nearly Perfect Sinusoidal Output Voltages ..................................................1-2
Features Overview................................................................................................1-4
Specifications .......................................................................................................1-5
Chapter 2: Hardware Components ..............................................................................2-1
Hardware Configuration.......................................................................................2-1
Transformer Section......................................................................................2-3
Customer I/O Section....................................................................................2-7
Cell and Control Sections (GENIII Cell Specifications) ..............................2-8
Cell Bypass Option .....................................................................................2-16
The Cell Control System ....................................................................................2-16
The Master Control System................................................................................2-16
The Power Circuit ..............................................................................................2-21
Monitoring of Input Power Quality.............................................................2-21
Chapter 3: The Keypad and Display Interface............................................................3-1
Introduction ..........................................................................................................3-1
The Keypad ..........................................................................................................3-1
Fault Reset Key .............................................................................................3-2
Automatic Key ..............................................................................................3-3
Manual Stop Key...........................................................................................3-3
Manual Start Key ..........................................................................................3-3
The 0-9 Key...................................................................................................3-4
The Enter/Cancel Key ...................................................................................3-7
Shift Function Keys.......................................................................................3-7
Perfect Harmony GENIII/e User’s Manual Table of Contents
Table of Contents
A1A19000405A: Version 1.3 ii
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Arrow Keys ...................................................................................................3-8
Diagnostic Indicators ..................................................................................3-12
The Display .................................................................................................3-13
Menu Descriptions .............................................................................................3-18
Motor Menu (1) Options .............................................................................3-22
Drive Menu (2) Options..............................................................................3-27
Stability Menu (3) Options..........................................................................3-36
Auto Menu (4) Options ...............................................................................3-42
Main Menu (5) Options...............................................................................3-53
Log Control Menu (6) Options ...................................................................3-56
Protect Menu (7) Options............................................................................3-58
Meter Menu (8) Options..............................................................................3-61
Communications Menu (9) Options............................................................3-65
Menu Setup for Multiple Configuration Files (Slaves)...............................3-69
Appendix A: Glossary of Terms...................................................................................A-1
Appendix B: Commonly Used Abbreviations............................................................. B-1
Notes ...............................................................................................................................N-1
Reader Comments Form...............................................................................................R-1
Startup/Warranty Registration and Service Solutions.............................................W-1
Perfect Harmony GENIII/e User’s Manual Safety Precautions and Warnings
A1A19000405A: Version 1.3 iii
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Perfect Harmony drives 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. Follow the warnings below when working in or near the
Perfect Harmony system.
Safety Precautions and Warnings
Danger - Electrical Hazards!
• Always follow the proper lock-out/tag-out procedures before beginning any maintenance or troubleshooting work on the drive.
• Always follow standard safety precautions and local codes during installation of external wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any other wiring as specified in IEC61800-5-1.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses. Also,
always work with another person present.
• Always use extreme caution when handling or measuring components that are inside the enclosure. Be
careful to prevent meter leads from shorting together or from touching other terminals.
• Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements
(that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the
instrument).
• Never assume that switching off the input disconnect will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnect. Also, there may be voltages
present that are applied from other external sources.
• Never touch anything within the Perfect Harmony cabinets until verifying that it is neither thermally
hot nor electrically alive.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points
beneath the shields.
• Never run the drive with cabinet doors open. The only exception is the control cabinet which contains
extra low voltages (ELV).
• Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the Perfect Harmony system.
• Never connect or disconnect any meters, wiring, or printed circuit boards while the drive is energized.
• Never defeat the instrument’s grounding.
• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A qualified
individual is “one familiar with the construction and operation of the equipment and the hazards
involved.”
• Hazardous voltages may still exist within the Perfect Harmony cabinets even when the disconnect
switch is open (off) and the supply power is shut off.
Safety Precautions and Warnings Perfect Harmony GENIII/e User’s Manual
iv A1A19000405A: Version 1.3
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Additional safety precautions and warnings appear throughout this manual. These important messages should be
followed to reduce the risk of personal injury or equipment damage.
∇ ∇ ∇
Warning!
• Always comply with local codes and requirements if disposal of failed components is
necessary (for example, CPU battery, capacitors, etc.).
• Always ensure the use of an even and flat truck bed to transport the Perfect Harmony drive system.
Before unloading, be sure that the concrete pad is level for storage and permanent positioning.
• Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the
drive system. Dropping the cabinet or lowering it too quickly could damage the unit.
• Never disconnect control power while medium voltage is energized. This could cause
severe system overheating and/or damage.
• Never store flammable material in, on, or near the drive enclosure. This includes
equipment drawings and manuals.
• Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure
that the fork truck tines fit the lifting tubes properly and are the appropriate length.
• During operation, the nominal weighted sound pressure level can possibly exceed 70 dB at a distance
of 1 meter from the drive.
ESD Sensitive Equipment!
• Always be aware of electrostatic discharge (ESD) when working near or touching components inside
the Perfect Harmony cabinet. The printed circuit boards contain components that are sensitive to
static electricity. Handling and servicing of components that are sensitive to ESD should be done only
by qualified personnel and only after reading and understanding proper ESD techniques. The following ESD guidelines should be followed. Following these rules can greatly reduce the possibility of
ESD damage to PC board components.
• Always transport static sensitive equipment in antistatic bags.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style plunger
or copper braid when desoldering.
• Make certain that anyone handling the Perfect Harmony printed circuit boards is wearing a properly
grounded static strap. The wrist strap should be connected to ground through a 1 megohm resistor.
Grounding kits are available commercially through most electronic wholesalers.
• Static charge buildup can be removed from a conductive object by touching the object to a properly
grounded piece of metal.
• When handling a PC board, always hold the card by its edges.
• Do not slide printed circuit boards across any surface (e.g., a table or work bench). If possible, perform PCB maintenance at a workstation that has a conductive covering that is grounded through a 1
megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is
an excellent substitute.
• Avoid plastic, Styrofoam™, vinyl and other non-conductive materials. They are excellent static generators 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.
Perfect Harmony GENIII/e User’s Manual About This Manual
A1A19000405A: Version 1.3 v
sss
Separation of Manuals
This manual is one component of a series of manuals intended for use with the Perfect Harmony series of adjustable
speed AC motor drives. Each part in this series is for use by individuals having unique job functions and
qualifications. The manuals in this series are listed below:
• Perfect Harmony GENIII/e Installation Manual (A1A19000403A)
• Perfect Harmony GENIII/GENIII/e Startup and Advanced Topics Manual(A1A19000404A)
• Perfect Harmony GENIII/e User’s Manual (A1A19000405A)
The Installation Manual provides a brief overview of the product, including a hardware overview and important
safety issues. The steps leading up to and including the installation of the drive are discussed in detail in this manual.
The Startup and Advanced Topics Manual is intended to address the more technical aspects of drive setup,
configuration, and operation. This manual includes detailed descriptions of all parameters, functions, and pick list
menu items. Software setup and startup procedures are also included. Advanced topics such as the theory of
operation, technical specifications, system programming, compiler and reverse compiler software operation,
uploading and downloading functions, and other application and operation issues are discussed.
The User’s Manual is for use by operators of the drive. This manual contains a brief overview of the product,
including a hardware overview of the external components of the drive and basic safety precautions. The keypad and
display interface is explained in detail. A parameter listing is provided for reference. A troubleshooting and
maintenance section is also provided in this manual to help the operator diagnose and correct any potential problems
that may occur, and reduce the potential for future problems through inspections and regular maintenance.
All manuals in this series contain a glossary of terms, a list of commonly used abbreviations, and other reference
tools. In addition, a readers’ comments form is provided. Please complete these forms and return them to us.
Monitoring your feedback allows us to continue to exceed your expectations and provide complete, effective, easy to
use product documentation.
Reference Tools
Many steps have been taken to promote the use of this manual as a reference tool. Reference tools include the
following:
• A thorough table of contents for locating particular sections or subsections.
• Chapter number thumb nails in the outer margins for easy location of chapters.
• Special text styles are applied to easily differentiate between chapters, sections, subsections, regular text,
parameter names, software flags and variables, and test points.
• A comprehensive index.
• A glossary of terms and a list of commonly used abbreviations.
If you have any comments or suggestions to improve the organization or increase the usability of this manual, please
complete the Readers’ Comments Form located at the end of this manual and return it to Siemens LD A Document
Control.
About This Manual
About This Manual Perfect Harmony GENIII/e User’s Manual
vi A1A19000405A: Version 1.3
ss
Conventions Used in this Manual
The following conventions are used throughout this manual:
• This manual is for use with the CE-marked Perfect Harmony product line.
• The terms “Perfect Harmony,” “VFD,” “variable frequency drive,” and “drive” are used interchangeably
throughout this manual.
• Chapter numbers are highlighted in the outer margins to facilitate referencing (see margin).
• Test points and terminal block designations are shown in uppercase, boldface, 8 pt. Arial fonts (e.g., TB1A).
• In the index, locator page numbers appear in regular type faces for standard index references (e.g., shown in
an italic type face (e.g., 6-24). For index references that correspond to items found in figures and
illustrations, the locator page numbers are shown in a boldface type face (e.g., 3-3). Illustrations that also
appear in tables have locator page numbers that are both boldface and italic (e.g., 6-16)
• The symbol “∇ ∇ ∇” is used to mark the end of the chapter.
∇ ∇ ∇
* Note: Hand icons in the left margin alert readers to important operational or application information that
may have special significance. The associated text is enclosed in a border for high visibility.
Attention! Attention icons in the left margin alert readers to important safety and operational
precautions. These notes warn readers of potential problems that could cause equipment damage or
personal injury. The associated text is enclosed in a border for high visibility.
Caution - Electrical Hazard! Electrical hazard icons in the outer margins alert readers to important
safety and operational precautions. These notes warn readers of dangerous voltages, potential safety
hazards, or shock risks that could be life threatening. The associated text is enclosed in a border for high
visibility.
ESD Warning! These icons in the left margin alert readers to static sensitive devices. Proper
electrostatic discharge precautions should be taken before proceeding or handling the equipment.
Perfect Harmony GENIII/e User’s Manual Introduction
A1A19000405A: Version 1.3 1-1
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1.1 Introduction to the Perfect Harmony
The Perfect Harmony is a series of pulse-width modulated, variable frequency AC motor drives designed and
manufactured by Siemens LD A. The Perfect Harmony drive system addresses the following power quality issues:
• Providing clean power input
• Providing a high power factor
• Providing nearly perfect sinusoidal output.
1.1.1 Clean Power Input
The Perfect Harmony drive series meets the most stringent IEEE 519-1992 requirements for voltage and current
harmonic distortion, even if the source capacity is no larger than the drive rating. This series protects other on-line
equipment (such as computers, telephones, and lighting ballasts) from harmonic disturbances. Perfect Harmony also
prevents “cross talk” with other variable speed drives. Clean power input eliminates the need for time-consuming
harmonic/resonance analyses and costly harmonic filters. Figure 1-1 illustrates harmonic distortion waveforms for a
typical 6-pulse, a typical 12-pulse, and the Perfect Harmony series drive.
Figure 1-1: Harmonic Distortion Wave Form Comparisons (6-pulse, 12-pulse, and Perfect Harmony)
Total harmonic distortion of the source current is 25% for the 6-pulse, 8.8% for the 12-pulse, and 0.8% for the Perfect
Harmony. The corresponding voltage distortions with a typical source impedance are 10%, 5.9%, and 1.2%,
respectively.
CHAPTER
1 Introduction
* Note: The above comparisons were done using a typical 1000 Hp current source drive (6-pulse
and 12-pulse modes), and a Perfect Harmony series drive operating from an 1100 kVA, 5.75%
impedance source.
Source Current Source Current Source Current
Source Voltage Source Voltage Source Voltage
Typical 6-pulse
Input Waveform
Typical 12-pulse
Input Waveform
Perfect Harmony Series
Input Waveform
Introduction Perfect Harmony GENIII/e User’s Manual
1-2 A1A19000405A: Version 1.3
ss 1 1.1.2 High Power Factor and Nearly Perfect Sinusoidal Input Currents
Power factor is a measure of the fraction of current that produces real power to the load. Typically, power factor is
given as a percentage. A high power factor VFD (e.g., 95%) makes much better use of its input line current demand
in producing real power to the motor than a VFD operating at a low power factor (e.g., 30%). VFDs having a low
operating power factor often generate square-wave-shaped line currents. This can lead to harmonics and other
associated resonance problems.
The Perfect Harmony series draws nearly perfect sinusoidal input currents having a power factor that exceeds 95%
throughout the entire speed range without the use of external power factor correction capacitors. This eliminates
utility penalties for power factor and demand charges, and improves voltage regulation. In addition, feeders, breakers,
and transformers are not overloaded with reactive power. Low speed applications specifically benefit from the
Perfect Harmony series because a high and stable power factor is maintained throughout the entire speed range using
standard induction motors. Figure 1-2 compares graphs of power factor versus percent speed for the Perfect Harmony
series and a typical phase-controlled SCR drive.
Figure 1-2: Comparison of Perfect Harmony and a Typical Phase-Controlled SCR Drive
1.1.3 Nearly Perfect Sinusoidal Output Voltages
The design of the Perfect Harmony series of variable frequency drives inherently provides a sinusoidal output without
the use of external output filters. This means that the drive provides a low-distortion output voltage waveform that
generates no appreciable audible motor noise. In addition, there is no need to derate motors (the drive can be applied
to new or existing 1.0 service factor motors). In fact, Perfect Harmony drives eliminate harmful VFD-induced
harmonics that cause motor heating. Similarly, VFD-induced torque pulsations are eliminated (even at low speeds),
thereby reducing the stress on mechanical equipment. Common mode voltage stress and dV/dt stress are also
minimized. A typical graph of the output current from a Perfect Harmony drive is illustrated in Figure 1-3.
Figure 1-3: Nearly Sinusoidal Wave Form of the Output Current from a Perfect Harmony Drive
100
80
90
70
60
50
40
30
20
10 Percent Speed
Phase - controlled
SCR Drive
Perfect Harmony
Series Drive
20 27 33 40 47 53 60 67 73 80 87 93 100
rotcaFrewoPtnecreP
Perfect Harmony GENIII/e User’s Manual Introduction
A1A19000405A: Version 1.3 1-3
sss 1 The cabinet configurations of Perfect Harmony drives vary based on the horsepower of the drive, the number and
type of cells, and other factors. However, cabinet configurations can generally be divided into two broad categories:
• GEN III style (shown in Figure 1-4)
• GEN III/e style (shown in Figure 1-5)
Figure 1-4: Typical 4160V (Left) and 6600V (Right) Gen III Perfect Harmony VFDs
Figure 1-5: Typical 4160V (Left) and 6600V (Right) Gen III/e Perfect Harmony VFDs
These two styles are discussed in Chapter 2: Hardware Components.
Introduction Perfect Harmony GENIII/e User’s Manual
1-4 A1A19000405A: Version 1.3
ss 1 1.2 Features Overview
Additional features of the Perfect Harmony drive include the following:
• Redundant cooling blowers
• High efficiency
• Reliability
• Modular construction
• Surge arrestors
• Fiber optic control circuitry
• Soft start protection
• Multi-motor operation
• Trip-free operation
• Dual performance operation modes
• Undervoltage ride-through
• Spinning load restart
• Transparent cell bypass
• PC tool interface
• Power cell check
• Cell back-up
• Serial port
• Reports capabilities
• Micro PLC capabilities
• Keypad and English message display
• On-line diagnostics
• Digital display module
• Advanced diagnostics
• On-line operation while tuning
• Industry standard communications
• Dual frequency braking
• Auto-tuning
• Input monitoring
Perfect Harmony GENIII/e User’s Manual Introduction
A1A19000405A: Version 1.3 1-5
sss 1 1.3 Specifications
Table 1-1 lists common electrical and mechanical specifications for all standard Perfect Harmony systems. Note that
Perfect Harmony specifications may be changed without notice.
Table 1-1: Common Specifications for Standard Perfect Harmony Systems
∇ ∇ ∇
Item Description
hp range GEN III: Up to 3,000 Hp at 6,300V
GEN III/e: Up to 8,000 Hp at 6,600V
Input line voltages
2.2 kV, 3.0 kV, 3.3 kV, 4.1 kV, 4.8 kV, 6.0 kV, 6.6 kV,6.9 kV,
7.2 kV, 8.4 kV, 10.0 kV, 11.0 kV, 12.0 kV, 12.5 kV, 13.2 kV,
and 13.8 kV.
Input voltage tolerance +10%, -5% from nominal 3-phase at rated output
Input power factor 0.95 above 10% load
Output line voltages 2.4 kV, 3.3 kV, 4.16 kV, 4.8 kV, 6.0 kV, 6.6 kV,6.9 kV, and
7.2 kV
Output frequency drift ± 0.5%
Speed range 0.5 - 330 Hz (motor dependent)
Overload capability A function of the installed type of cell
Accel/decel time range 0.5 - 3200 sec (load dependent)
Output torque 15 - 139 Hz rated torque; 3 - 14 Hz and 140 - 330 Hz derated torque
Enclosure NEMA 1 ventilated, IP31
Ambient temperature 0 - 40°C
Storage temperature
(System w/o Cells) - 40 to 70°C
Storage temperature
(Cells*) - 55 to 45°C
Humidity 95% non-condensing
Altitude Up to 3300 feet. Above 3300 feet require derating.
Dust contamination <100 micron 2 6.5 mg/cu. ft.
Gas contamination <4 PPB reactive halides and sulfides
* Note: * Non-energized cells should not be stored at more than 45°C to preserve reliability of
Filter Capacitors. Non-energized cells stored for more than two (2) years should be reformed per
procedure indicated in Section 3-12 of this manual.
Introduction Perfect Harmony GENIII/e User’s Manual
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Perfect Harmony GENIII/e User’s Manual Hardware Components
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2.1 Hardware Configuration
Figure 2-1 depicts a typical GEN III style line-up in which each VFD normally consists of a single cabinet with
multiple sections. These sections, described below, are:
• The transformer section
• The custom I/O section
• The control section
• The cell section
Depending on the HP and voltage ratings, some GENIII systems may be shipped as a single unit in which the
Transformer and Cell Cabinet are integrated into on unit. Larger GENIII systems may be shipped so that the
Transformer and Cell Cabinet are split due to size and weight restrictions. In all GENIII systems, the input and output
connections are located in the Transformer Cabinet. The control section is a swinging panel that resides in the left
side of the cell cabinet.
Figure 2-2 depicts a typical GENIII/e style configuration in which each VFD of a Cell/Control cabinet connects to a
Transformer Cabinet. These sections, described below, are:
GENIII/e (which are higher current versions of GENIII systems) is always shipped so that the Transformer and Cell
Cabinets are separated. In these systems, the Output section is always on the left side of the cell cabinet (behind the
control panel) and the Input section is always in the Transformer Cabinet. The control section is a swinging panel that
resides in the left side of the Cell Cabinet.
CHAPTER
2 Hardware Components
Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-1: Typical GEN III-style VFDs
Transformer
Section
Single Point
Cooling for
Small Units
Transformer
Section
Customer Control Wiring
And Control Power Section
Control Section and
Access to Cell Cabinet
Blowers
Air Intakes
(Do Not Block)
Customer Control
Wiring and Control
Power Section
Control
Section
and Access
to Cell
Section
Split Cooling for
Longer Lineup
Perfect Harmony GENIII/e User’s Manual Hardware Components
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Figure 2-2: Typical GENIII/e style VFDs
2.1.1 Transformer Section
The Transformer Section of the Perfect Harmony drive contains the input power transformer. Input power wires enter
the drive through this section and output wires to the motor exit the drive through this section. The input and output
power wiring can enter and exit the drive from either the top or bottom of this section. In addition to the main multisecondary phase-shifting power transformer, the transformer section contains either one or more blowers (at the top
of the cabinet) used to cool the drive. Refer to Figure 2-3. Major components of the Transformer Section are
illustrated in Figure 2-3 and described in Table 2-1. * Note: Input and output wiring enters the cabinet from the top or bottom of the transformer section.
Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-3: Typical Power Input Cabinet (Front, Door Removed, and Side Views)
Transformer
Section
Blower
Transformer
Perfect Harmony GENIII/e User’s Manual Hardware Components
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Table 2-1: Field Connections and Major Components in the Transformer Section
Item Description
L1, L2, L3 Input power terminals
T1, T2, T3 Output power terminals
TI Multi-secondary, phase-shifting power transformer
T5 Control power transformer
F24 - F35 Control fuses
F21, F22 Blower fuses
F4, F5 Fuses
BM1 - BM5 Blower motor starters
CDS1 Control power disconnect switch
RA1 - RA4, RB1 - RB4, RC1 - RC4 Input and output voltage feedback resistors
CT4, CT5 Output current transformers
TB-120-CUS Customer wiring terminal strip
METERING Metering terminal strip
TB-ELV Low voltage terminal strip (4 - 20 mA signals, etc.)
Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-4: Field Connections and Major Components in the GEN III Transformer Section
Perfect Harmony GENIII/e User’s Manual Hardware Components
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Figure 2-5: Field Connections and Major Components in the GENIII/e Transformer Section (left)
and Cell Section (right)
2.1.2 Customer I/O Section
The customer I/O section of the GEN III-style Perfect Harmony drive contains terminal blocks for customer control
wiring connections, control power connections, and the blower control panel. Optional motor monitors and power
quality meters (PQMs) are mounted in this section if they are ordered with the drive. Refer to Figure 2-5. * Note: Refer to the “as built” system drawings that are shipped with the drive for information on
specific customer I/O connections.
*
Note: The rear bus connections need to be made prior to startup. It is recommended, but not
necessary, to have a minimum of two feet between the rear of the VFD and any wall or structure.
This is to allow easier connection of the rear bus between the transformer and the cell cabinets.
The VFD can be moved against the wall once the connections are made and the rear panel
reinstalled. If space behind the VFD cannot be provided, the connections are made by removing
the hall affect CT’s and the panels between the fuse group. These are located behind the control
box.
Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-6: Customer I/O Section (Typical) of a GEN III-Style Perfect Harmony Drive
2.1.3 Cell and Control Sections (GENIII Cell Specifications)
The Control Section is a hinged section that swings out to provide access to the cell section. The control section
contains master control components. The cell contains power cells and up to three blowers mounted on top of the
cabinet.
Siemens’GEN III AC drive system is offered in 5 basic cell sizes (current ratings), grouped to provide output
operating voltages of 3300 VAC (3 cells in series), 4160 VAC (4 cells in series), 4800 VAC (5 cells in series), and
6600 VAC (6 cells in series). Table 2-2 provides the basic specifications associated with all cell combinations for
GEN III Perfect Harmony drives.
* Note: Output current ratings are a function of the selected cell size. Input current ratings are a
function of the transformer size associated with each hp rating. All specifications are subject to
change without notice.
Perfect Harmony GENIII/e User’s Manual Hardware Components
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Table 2-2: GENIII Cell Specification Details
Table 2-3: GENIII/e Cell Specification Details
The individual output cells are located in the Cell Section. All cells are electrically and mechanically identical, so that
they may be interchanged. Each cell contains its own control boards, which communicate with the system through a
fiber optic link. This link is the only connection between the cells and the master control located in the Control
Section, thus each cell is isolated from the main control. Refer to Figure 2-7 for GENIII type cell. Refer to Figure 2-8
and Figure 2-9 for GENIII/e type cells.
Figure 2-7: Typical GEN III Cell
Output
Cells Per
Phase
Line-to-Line
Voltages(VAC)
Cells in Drive
(Without
Spares)
hp Range Available Cell Sizes
3 3,300 9 up to 1500 70A, 100A, 140A,200A, 260A
4 4,160 12 up to 2000 70A, 100A, 140A,200A, 260A
6 6,600 18 up to 3000 70A, 100A, 140A,200A, 260A
Output
Cells per
Phase
Line-to-Line
Voltages (VAC)
Cells in Drive
(without spares) Hp Range Available Cell Sizes
2 2,300 6 up to 3000 315A, 375A, 500A, 660A
3 3,300 9 up to 4000 315A, 375A, 500A, 660A
4 4,160 12 up to 6000 315A, 375A, 500A, 660A
5 6,000 15 up to 8000 315A, 375A, 500A, 660A
6 6,600 18 up to 0000 315A, 375A, 500A, 660A
Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-8: Typical GENIII/e Cell
Figure 2-9: Details of GENIII/e Terminals and Indicators
Perfect Harmony GENIII/e User’s Manual Hardware Components
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sss 2
Figure 2-10: Cell Section (Typical) of a GENIII style Perfect Harmony Drive
A switch mode power supply located on the Cell Control/Gate Driver Board allows the control power to be derived
from the individual 3-phase secondary connections of the transformer.
The Control Section contains PC boards, which provide central control of the Perfect Harmony drive system. The
Control Section is physically and electrically isolated from all medium voltage for safety.
Control for each of the output cells is provided via a fiber optic communications link between the Master Control
System and the Cell Control/Gate Driver Board located within each output cell.
The following tables give length and weight information for many common configurations of sectional Perfect
Harmony drives, based on 60 Hz input power at the voltages listed. If applications require inputs at 50 Hz or
horsepowers not listed, sizes and weights will increase.
* Note: The ventilation information (in CFM) and losses information (in BTUs) given in the
following tables represent worst case conditions. Actual values may vary based on load, blower
size, cell size and transformer size.
Blower
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Table 2-4: 3,300 VAC GENIII Cell Specifications: 9 Cells Total, 3 (630 VAC) Cells in Series
Table 2-5: 4,160 VAC GENIII Cell Specifications: 12 Cells Total, 4 (630 VAC) Cells in Series
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
200 33 70 20,000 4,400 100 4,800 70
300 49 70 30,000 4,400 100 4,800 70
400 64 70 40,000 4,400 100 5,600 70
500 80 100 50,000 4,400 100 6,200 100
600 96 100 60,000 4,400 100 6,200 100
700 112 140 70,000 4,400 100 7,500 140
800 128 140 80,000 4,400 100 7,500 140
900 145 200 90,000 8,800 123 7,500 200
1000 162 200 100,000 8,800 123 8,000 200
1250 202 260 125,000 8,800 137 8,500 260
1500 242 260 150,000 8,800 137 9,000 260
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
300 38 70 30,000 4,400 100 5,100 70
400 51 70 40,000 4,400 100 5,100 70
500 63 70 50,000 4,400 100 5,800 70
600 75 100 60,000 4,400 100 6,600 100
700 89 100 70,000 4,400 100 6,600 100
800 101 140 80,000 4,400 100 7,700 140
900 114 140 90,000 4,400 100 7,700 140
1000 126 140 100,000 4,400 100 7,700 140
1250 160 200 125,000 8,800 137 9,500 200
1500 192 200 150,000 8,800 137 9,500 200
1750 224 260 175,000 8,800 137 10,000 260
2000 256 260 200,000 8,800 137 11,000 260
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Table 2-6: 6,600 VAC GENIII Cell Specifications: 18 Cells Total, 6 (630 VAC) Cells in Series
Table 2-7: 2,300 VAC GENIII/e Cell Specifications: 6 Cells Total, 2 (690 VAC) Cells in Series
Table 2-8: 3,300 VAC GENIII/e Cell Specifications: 9 Cells Total, 3 (690 VAC) Cells in Series
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
600 48 70 60,000 8,800 137 7,700 70
700 56 70 70,000 8,800 137 9,000 70
800 64 70 80,000 8,800 137 9,000 70
900 72 100 90,000 8,800 137 9,000 100
1000 80 100 100,000 8,800 137 10,400 100
1250 100 100 125,000 8,800 137 10,400 100
1500 120 140 150,000 8,800 137 12,300 140
1750 140 140 175,000 8,800 137 12,300 140
1750 141 200 175,000 13,200 192 12,500 200
2000 162 200 200,000 13,200 192 13,000 200
2250 182 200 225,000 13,200 192 13,000 200
2500 202 260 250,000 13,200 192 13,500 260
2750 222 260 275,000 13,200 192 14,000 260
3000 242 260 300,000 13,200 192 14,000 260
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
1500 324 375 114,000 8,800 172 7,450 375H
1750 378 375 133,000 8,800 172 8,200 375H
2000 432 500 152,000 8,800 172 8,800 500H
2250 486 500 171,000 8,800 172 9,500 500H
2500 540 660 190,000 8,800 172 10,200 660H
3000 648 660 228,000 8,800 172 11,500 660H
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
1750 264 315 133,000 15,000 172 9,700 315H
2000 301 315 152,000 15,000 172 11,200 315H
2250 339 375 171,000 15,000 172 11,200 375H
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Table 2-9: 4,160 VAC GENIII/e Cell Specifications: 12 Cells Total, 4 (690 VAC) Cells in Series
Table 2-10: 6,000 VAC GENIII/e Cell Specifications: 15 Cells Total, 5 (690 VAC) Cells in Series
2500 377 375 190,000 15,000 172 12,000 375H
3000 452 500 228,000 15,000 188 13,400 500H
3500 527 660 266,000 15,000 188 14,900 660H
4000 603 660 304,000 15,000 188 16,400 660H
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
2250 269 315 171,000 18,000 192 13,800 315H
2500 299 315 190,000 18,000 192 14,600 315H
3000 359 375 228,000 18,000 208 16,200 375H
3500 418 500 266,000 18,000 208 17,900 500H
4000 487 500 304,000 18,000 208 19,100 660H
5000 598 660 380,000 18,000 232 22,800 660H
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
3500 290 315 266,000 25,000 248 20,100 315H
4000 331 375 304,000 25,000 272 21,900 375H
5000 414 500 380,000 25,000 272 25,500 500H
6000 497 500 450,000 25,000 272 29,100 500H
7000 580 660 532,000 25,000 272 32,700 660H
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
Perfect Harmony GENIII/e User’s Manual Hardware Components
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Table 2-11: 6,600 VAC GENIII/e Cell Specifications: 18 Cells Total, 6 (690 VAC) Cells in Series
The basic electrical diagrams for all Perfect Harmony systems are similar. Depending on the operating voltages,
different numbers of output cells are operated in series to develop the required output operating voltage (refer to the
previous tables).
Hp1
1. Motor nameplate Hp may not exceed the drive rated Hp.
Amps In2
2. Drive rated input current (in Amps) is the transformer rated current.
Amps Out3
3. Drive rated output current (in Amps) is the maximum cell current.
Losses4
4. Losses are given in BTU/hr and are based on a loss of 3 kW per 100 Hp.
Ventilation5
5. Minimum ventilation requirements are given in CFM (lps in parentheses).
Length6
6. Represents lineup minimum length in inches (centimeters in parentheses), subject to change.
Weight7
7. Represents estimated minimum weight of lineup in pounds (kg in parentheses), subject to change.
Size8
8. Cell sizes for each Hp are based on motors with ≥ 95% efficiency and ≥ 85% power factor.
3500 264 315 266,000 28,000 248 21,900 315H
4000 301 315 304,000 28,000 272 23,800 315H
5000 377 375 380,000 28,000 272 27,700 375H
6000 452 500 450,000 28,000 272 31,600 500H
7000 527 660 532,000 28,000 272 35,500 660H
8000 603 660 608,000 28,000 272 39,400 660H
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2.1.4 Cell Bypass Option
As an option, each cell in the system can be equipped with a bypass contactor. This contactor will be automatically
energized by the VFD master control if the associated cell malfunctions. Once the contactor is energized, the
damaged cell is no longer electrically part of the system, which allows the VFD to resume operation.
Any time a cell malfunctions and is bypassed, the control automatically compensates (shifts the neutral point) so that
the motor voltage stays balanced. To compensate for the loss in voltage, systems with up to 5 cells per phase can be
equipped (as an option) with an extra cell per phase. The 3 spare cells would then compensate for the loss in voltage.
If spare cells are not installed, then the VFD will operate at a slightly lower voltage, but will still provide full rated
current.
The cell bypass system includes a bypass contactor per cell, a contactor control board (installed inside the cell
cabinet), and a fiber optic link between the master control system and the contactor control board.
2.2 The Cell Control System
All Perfect Harmony cells are controlled in the same manner. The Cell Control/Gate Driver Boards reside within the
output cell and accept all communication from the Digital Modulator in the Control Cabinet via fiber-optic links.
Control power for all cell boards is supplied from a switch mode power supply that is resident on the Cell Control/
Gate Driver Board.
Figure 2-11: Typical Connection Diagram for an 18 Cell 6.6 kV System
2.3 The Master Control System
The Master Control located within the Control Cabinet consists of a chassis and several control boards refer to Figure
2-12. The chassis is supplied power by a stand alone power supply. The heart of the control is the Microprocessor
board. This board is the master of the backplane bus, and controls the operation of each board in the system.
Contained on the Microprocessor Board is Flash Disk, which may be removed from the Microprocessor Board if, for
any reason, the Microprocessor Board would need to be replaced. The Flash Disk contains all the specific parameter
Perfect Harmony GENIII/e User’s Manual Hardware Components
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information and system program for the VFD, and therefore allows the Microprocessor Board to be replaced without
the need to re-program the VFD.
The System Interface board collects the drive input and output feedback signals and sends them to the Analog to
Digital board. The Analog to Digital board executes the conversion at specified intervals and sends digital
representations of the feedback signals to the Microprocessor board. The Microprocessor board then computes the
next set of values to be sent to the Digital Modulator and sends them. The Digital Modulator then determines the
switching commands for each cell and compiles a message with this command for each cell. These messages are then
sent through the Fiber Optic Interface boards. Refer to Figure 2-12.
Note that the number of Fiber Optic Interface Boards and the number of fiber optic channels varies, depending on the
number of cells in the drive.
Also shown in Figure 2-12 is a communications board. This board provides a direct interface to a Modbus network
and allows network adapter boards for several other industrial networks to be connected to the drive control. A
typical schematic of the master control is shown in Figure 2-12. * Note: If the Microprocessor Board is replaced, the Flash Disk should be moved to the new board.
See Figure 2-13.
Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-12: Master Control System
Fiber Optic Cable
To By-pass Board
Modulator board
Fiber Optic Interface boards
Communications board
Analog to Digital board
System Interface board
Power
Supply
connection
Microprocessor board
Fiber Optic Cables to Cells
Perfect Harmony GENIII/e User’s Manual Hardware Components
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