WEG CFW11W User manual

Brand: WEG

Model: CFW11W

Type: User manual

Motors I Automation I Energy I Transmission & Distribution I Coatings

Modular Drive

CFW-11W

Addendum of the Frequency Inverter

Series: CFW-11W

Language: English

Document Number: 10002796209 / 01

Models: 700...3325 A/380...480 V

640...3040 A/500...690 V

Publication Date: 05/2017

Contents

CONTENTS

1. GENERAL INFORMATION ..............................................................................1-1

1.1. ABOUT THE MANUAL ............................................................................................................. 1-1

1.2.

ABOUT THE CFW-11w ........................................................................................................... 1-1

1.3.

HOW TO SPECIFY THE MODEL .............................................................................................. 1-5

INSTALLATION AND CONNECTION ................................................................2-1

2.1.

ENVIRONMENTAL CONDITIONS ............................................................................................. 2-1

2.2.

COMPONENT LIST ................................................................................................................. 2-1

2.3.

MECHANICAL INSTALLATION ................................................................................................ 2-2

2.4.

COOLING SYSTEM ................................................................................................................. 2-6

2.4.1. Condensation ................................................................................................................. 2-7

2.5.

ELECTRICAL INSTALLATION .................................................................................................. 2-7

2.5.1. Input Rectifier .................................................................................................................. 2-8

2.5.2. Fuses .............................................................................................................................. 2-9

2.5.3. UP11 Connections .......................................................................................................... 2-9

2.6.

INSTALLATIONS ACCORDING TO THE EUROPEAN DIRECTIVE OF ELECTROMAGNETIC

COMPATIBILITY ........................................................................................................................... 2-12

2.6.1. Conformal Installation.................................................................................................... 2-12

2.6.2. Standard Definitions ...................................................................................................... 2-13

2.6.3. Emission and Immunity Levels ...................................................................................... 2-14

2.6.4. External RFI Filters ........................................................................................................ 2-14

TROUBLESHOOTING AND MAINTENANCE .....................................................3-1

3.1.

FAULTS, ALARMS AND POSSIBLE CAUSES ........................................................................... 3-1

3.2.

NECESSARY INFORMATION TO CONTACT TECHNICAL SUPPORT ........................................ 3-4

3.3.

PREVENTIVE MAINTENANCE.................................................................................................. 3-4

3.3.1. Cleaning Instructions....................................................................................................... 3-5

OPTIONAL KITS ............................................................................................4-1

4.1.

OptionAL Kits and AcCessories ............................................................................................... 4-1

TECHNICAL SPECIFICATIONS .......................................................................5-1

5.1.

POWER DATA ......................................................................................................................... 5-1

5.2.

ELECTRONICS/GENERAL DATA ............................................................................................. 5-5

5.2.1. Codes and Standards ..................................................................................................... 5-6

5.3.

MECHANICAL DATA ............................................................................................................... 5-7

5.4.

REGENERATIVE BRAKING OPERATION .................................................................................. 5-9

General Information

CFW11W | 1-1

1. GENERAL INFORMATION

ATTENTION

Strictly follow the safety instructions contained in this Addendum and in the CFW-11M user

manual

1.1.

ABOUT THE MANUAL

This manual provides information about the CFW-11W Modular Drive frequency inverter series. Refer to the

CFW-11M user manual and the CFW-11 programming manual.

1.2.

ABOUT THE CFW-11W

The inverters of CFW-11W series present a modular design, with configurations from one to five Power Units

(UP11), one Unit Control (UC11) and wiring cables. The modular assembly increases the reliability of the inverter

and simplifies its maintenance. A single control unit (UC11) can control up to 5 UP11s.

These inverters are water cooled, being more compact than other inverters. Moreover, the DC link features

plastic film capacitors, which reduce losses and increase maintenance intervals.

The UP11s are directly powered by the DC link and the UC11 is powered by an external +24 Vdc power supply.

Figure 1.1 shows the standard configuration with an input six pulses rectifier.

The power units are controlled by the UC11. The UC11 contains the control rack of CFW-11 series and the IPS

board. This board sends signals to all UP11s (PWM, control signals, etc.) and receives signals from them

(voltage feedback, current, etc.).

Figure 1.1:

Example of configuration with 5 UP11s and 6-pulse rectifiers

General Information

CFW11W | 1-2

Figure 1.2:

Block Diagram of the CFW-11W

General Information

CFW11W | 1-3

Figure 1.3:

UC 11 Main parts

Figure 1.4:

UP 11 Main parts

General Information

CFW11W | 1-4

Figure 1.5:

UP11 connections between the IPS1 interface board and CIM1

Figure 1.6:

UP11 – connections between the CIM1 interface board and the PSB1 power supply board

Figure 1.7:

UP11 - connections between the CIM1 interface board, the gate driver boards, module and sensors for output voltage and

current condition

General Information

CFW11W | 1-5

NOTE

In order to assemble the complete drive, several additional items are needed, such as: input

rectifier, fuses on the DC power supply for each UP11, external pre-charge circuit and input

reactance with minimum input impedance of 3% when it is a 6-pulse rectifier.

NOTE

It is not necessary to add the ground fault CT to the drive, since the UP11s have their own

protection.

1.3.

HOW TO SPECIFY THE MODEL

In order to specify the model of the CFW-11W, replace the smart code values with the desired rated supply

voltage and rated output current in the respective fields, for operation under normal duty cycle (ND), as shown in

the example:

Table 1.1:

Smart Code

Inverter Model

Option Items Available

Refer to the model list of the CFW

11W

series in chapter 5, which

also contains

the technical specifications of the

inverters.

Refer to chapter 7 of the CFW11M user manual

for further details on the option items.

Example BR CFW11W

0640 T

(*)

S _ _ _ _ _ _ _ _ Z

Field

description

Identification

of the market

(defines the

manual

language and

factory

settings)

WEG

frequency

inverter

series 11

Rated

output

current

for

use

with

the

Normal

Duty

(ND)

cycle

Number

of output

phases

Rated

output

voltage

Option kit

Braking

Safety

stop

Special

hardware

Special

software

Character

that

identifies

the code

end

Options

available

2 characters

T=Three-

Phase

4=380..

.480 V

6=500..

.690 V

S=Standard

product

O=Product

with option

items

Blank=

standard

RB=

Regenerative

braking

Blank=

Standard

(without

safety

stop)

Y=with

safety stop

function as

per EN

954

-1

category 3

Blank=

Standard

H1=

Special

hardware

# 1

Blank=

Standard

S1=

Special

software #

(*)

This field (voltage) represents the three-phase input voltage on the rectifier that feeds DC voltage to the CFW-11W. The rectifier is not part

of the CFW11W.

NOTE

For the other fields of the code, refer to the CFW-11M user manual.

E.g.: CFW11W0640T6SZ corresponds to a standard CFW-11W inverter with 640-A three-phase output and

input supply voltage of 500 - 690 V. The options for the inverter rated current under normal duty (ND) cycle are

available in Table 1.2 below:

General Information

CFW11W | 1-6

Table 1.2:

Rated currents under normal duty cycle

380-480 V

500-690 V

0700 = 700 A

0640 = 640 A

1330 = 1330 A

1216 = 1216 A

1995 = 1995 A

1824 = 1824 A

2660 = 2660 A

2432 = 2432 A

3325 = 3325 A

040 A

Installation and Connection

CFW11W | 2-1

2. INSTALLATION AND CONNECTION

This chapter describes the procedures for the electrical and mechanical installation of the CFW-11W Modular

Drive. The directions and suggestions must be observed so as to ensure the safety of people and equipment,

and the proper operation of the inverter.

2.1.

ENVIRONMENTAL CONDITIONS

Avoid installing the CFW-11W in areas with:

Direct exposure to sunlight, rain and high humidity

Inflammable or corrosive gases or liquids

Excessive vibration

Dust, metallic particles and oil mist.

Environment conditions for the operation of the inverter:

Ambient temperature: 0 °C to 40 °C (32 °F to 104 °F) – nominal conditions (measured around the

inverter). 40 °C to 45 °C (104 °F to 113 °F) – current derating of 2 % for each 1 °C (1.8 °F) above 40 °C

(104 °F).

Coolant input temperature: 0 ºC to 40 ºC (32°F to 104°F) according to the coolant used. 40 ºC to 45 ºC

(104 °F to 113 °F) – current derating of 3 % for each 1 °C (1.8 °F) above 40 ºC (104 °F)

Coolant flow: 20 l/min.

Air relative humidity: 5 % to 90 % non-condensing.

Maximum altitude: up to 1000 m (3,300 ft) – nominal conditions. 1000 m to 4000 m (3,300 ft to 13,200

ft) – current derating of 1 % for each 100 m (or 0.3 % each 100 ft) above 1000 m (3,300 ft). 2000 m to

4000 m (6,600 ft to 13,200 ft) – maximum voltage derating of 1.1 % for each 100 m (or 0.33 % each

100 ft) above 2000 m (6,600 ft). Maximum altitude up to 4000 m (13,200 ft).

Pollution degree: 2 (according to EN50178 and UL508C), with non-conductive pollution. Condensation

shall not originate conduction through the accumulated residues.

2.2.

COMPONENT LIST

The kit for panel mounting is composed of the control set and the UP11 power units, whose number varies

according to the current. The control set contains the UC11 control unit, the cable sets required for wiring the

IPS board to the power units and the ribbon cable that connects the IPS board to the CC11 control board.

Table 2.1:

Currents and settings at 390-490 V

Rated Current (A)

Number of UP11-04

power units

ND HD

700 515 1

1330

979

1995

1468

2660 1957 4

3325

2446

Installation and Connection

CFW11W | 2-2

Table 2.2:

Currents and settings at 500-690V

Rated Current (A)

Number of UP11-05

power units

640

477

1216

906

1824 1359 3

2432

1812

3040 2265 5

For other components, such as cable set and fiber optic cables, refer to item 3.2 – Component List of the

CFW11M user manual.

2.3.

MECHANICAL INSTALLATION

The power units must be installed on the drive panel appropriately, allowing easy extraction and reassembly in

case of maintenance. The fastening must be such to avoid damage during panel transportation.

Figure 2.1:

UP11 hosting eyes

Figure 2.2:

Mounting of the UP11 side by side without lateral gap

Installation and Connection

CFW11W | 2-3

The UP11 has wheels to help insert and remove the panel (Figure 2.3 and Figure 2.4).

Figure 2.3:

UP11 bottom view [mm(in)]

Figure 2.4:

UP11 bottom view highlighting the wheels

Installation and Connection

CFW11W | 2-4

The base where the UP11s are installed has rails for proper positioning (Figure 2.5).

Figure 2.5:

Rails on the mounting base

In order to insert the UP11 in the panel, it is necessary to remove the lower bracket that comes installed on the

power unit (Figure 2.6).

Figure 2.6:

UP11 lower bracket

Installation and Connection

CFW11W | 2-5

Figure 2.7:

Fastening holes for the power unit

Besides the lower bracket, there are holes for fastening the upper part of the power unit (Figure 2.8).

Figure 2.8:

Upper fixation bracket [mm(in)]

For further information about the mechanical installation, refer to item 3.3 - Mechanical Installation of the CFW11

M user manual.

Installation and Connection

CFW11W | 2-6

2.4.

COOLING SYSTEM

Figure 2.8 shows the main components and scheme of the cooling system.

Figure 2.9:

Coolant circulation scheme

The valve located in the upper part of the UP11 drains possible accumulations of air pockets. This valve is

connected to the discharge tube located in the lower part of the UP11.

Figure 2.10:

Detail of the coolant input and output

Installation and Connection

CFW11W | 2-7

2.4.1.

Condensation

The condensation occurs when the incoming water temperature is excessively below the ambient temperature.

To avoid condensation the water temperature varies according to the relative humidity and ambient

temperature. The temperature at which the water vapor in the air turns into liquid as droplets is known as "dew

point".

The Table 2.3 and Table 2.4 show the dew point in relation to the air relative humidity and the ambient

temperature for an atmosphere pressure of 1 atm. If the water temperature is lower than the presented value,

condensation may occur.

Table 2.3:

Dew point in relation to the air relative humidity and the ambient temperature in ºC.

Air Relative Humidity [%]

5 10 20 30 40 50 60 70 80 90

Ambient

Temperature [°C]

0.1

2.6

4.8

6.7

8.4

1.9

6.0

9.3

12.0

14.4

16.4

18.3

25 <0 <0 0.5 6.2 10.5 13.8 16.7 19.1 21.3 23.2

4.6

10.5

14.9

18.4

21.4

23.9

26.2

28.2

8.7

14.8

19.4

23.0

26.1

28.7

31.0

33.1

40 <0 2.6 12.7 19.1 23.8 27.6 30.7 33.5 35.9 38.0

6.3

16.8

23.4

28.2

32.1

35.4

38.2

40.7

43.0

Table 2.4:

Dew point in relation to the air relative humidity and the ambient temperature in ºF

Air Relative Humidity [%]

5 10 20 30 40 50 60 70 80 90

Ambient Temperature

[°F]

50 <0 <0 <0 <0 <0 32,18 36,68 40,64 44,06 47,12

68 <0 <0 <0 35,42 42,8 48,74 53,6 57,92 61,52 64,94

77 <0 <0 32,9 43,16 50,9 56,84 62,06 66,38 70,34 73,76

86 <0 <0 40,28 50,9 58,82 65,12 70,52 75,02 79,16 82,76

95 <0 <0 47,66 58,64 66,92 73,4 78,98 83,66 87,8 91,58

104 <0 36,68 54,86 66,38 74,84 81,68 87,26 92,3 96,62 100,4

113 <0 43,34 62,24 74,12 82,76 89,78 95,72 100,8 105,3 109,4

ATTENTION

The water temperature must always be higher or equal to the dew point.

The values presented in Table 2.3 are based on the August-Roche-Magnus approximations, which are valid for:

Ambient temperature 0 °C to 60 °C (32 °F to 140 °F)

Air relative humidity 1 % to 100 %

Dew point 0 °C to 50 °C (32 °F to 122 ºF)

2.5.

ELECTRICAL INSTALLATION

ATTENTION

The water temperature must always be higher or equal to the dew point.

Installation and Connection

CFW11W | 2-8

DANGER!

The water temperature must always be higher or equal to the dew point.

DANGER!

Vérifiez que l'alimentation secteur est débranchée avant de commencer l'installation..

ATTENTION

The CFW-11W can be connected to circuits with short-circuit capacity of up to 150000

symmetric Arms (maximum 480 V/690 V).

ATTENTION

The short-circuit protection of the inverter does not provide short-circuit protection for the

power supply circuit. The short-circuit protection of the power supply circuit must be provided

in accordance with applicable local standards.

2.5.1.

Input Rectifier

The main rectifier bridge is selected to comply with the nominal power of the drive. The heat dissipation caused

by losses at the rectifier bridge should be taken into account for the sizing of the heatsink, as well as in the

heating up of the panel internal air.

The resistors of the pre-charge circuit must be dimensioned according to the following criteria:

Maximum voltage

Maximum energy

Power overload capacity of the resistors during the pre-charge period (energy dissipation capacity)

Table 2.5:

Dimensioning of the pre-charge

Peak current during pre-charge (A) 0.82 (Vline/R)

Energy stored in the capacitor bank (J)

Line 400 V N∙0.008∙Vline

Line 600 V

N∙0.004∙Vline

Duration of the pre-charge (s)

Line 400 V

0.02∙N∙R.

Line 600 V 0.01∙N∙R.

Where R is the ohmic value of the resistor used in each phase and N is the number of power units. Example:

In a drive composed of three power units, whose line voltage at the rectifier input is 380 Vrms (Line 400 V), the

obtained values would be:

Energy stored in the capacitor bank: 3∙0.008∙380

= 3466 J.

Using 3 resistors of 10 Ω (one per phase), each resistor must withstand 1155 J.

The manufacturer of the resistor informs the energy the component withstands.

The peak current during pre-charge would be 31 A and the duration of the pre-charge would be 0.6 s.

Installation and Connection

CFW11W | 2-9

2.5.2.

Fuses

It is recommended the use of fuses suitable for operation with direct current at the UP11 DC supply. The

maximum bus voltage at the 400 V line is 800 Vdc, at the other lines it is 1200 Vdc (IGBT overvoltage trip level).

Fuses used in AC lines can be used; however, a derating in the AC voltage must be applied. Consult the fuse

manufacturer in order to obtain the derating factor.

Fuses examples:

Line 400 V 10URD73TTF1000 (FERRAZ)

Line 600 V 12URD73TTF900 (FERRAZ)

2.5.3.

UP11 Connections

The installation of the input connections of the UP11 is done with 4 screws M12X25 (recommended torque: 60

Nm); see Figure 2.11.

Figure 2.11:

Input links of the UP11; DC input connection [mm(in)]

The output connections in the internal reactance are done by means of 6 screws M12X30 (recommended

torque: 60 N.m); 2 screws are used for each phase. The links are 40X10 mm and the fastening is done through

nut M12 inserted in the link, refer to Figure 2.1.

Installation and Connection

CFW11W | 2-10

Figure 2.12:

Output links of the UP11; output connections to the motor [mm(in)]

Use two cables in parallel, with the recommended gauge indicated in the, for connecting the UP11 output

reactor to the output bus bar (motor connection).

Table 2.6:

Output cables

Current (A) Voltage (V) Duty

Minimum Cables

Cross-Section (mm

)

700

380-480

ND (2x) 240

515

(2x) 150

640

500-690

(2x) 240

477

(2x) 150

The screw used to fasten the grounding cable of the UP11 is M12X30 (recommended torque: 60 N∙m), refer to

Figure 2.13.

Installation and Connection

CFW11W | 2-11

Figure 2.13:

Grounding points of the UP11

Use the cables with the gauge indicated in Table 2.6 to ground the UP11 power units.

Table 2.7:

Grounding cables

Current (A) Voltage (V) Duty

Minimum Cross-

Section of

the Grounding Cable (mm

)

700

380-480

240

515

150

640

500-690

240

477

150

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WEG CFW11W User manual

WEG CFW11W User manual

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