Motors I Automation I Energy I Transmission & Distribution I Coatings
Modular Drive
CFW-11W
Addendum of the Frequency Inverter
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
2.
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
3.
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
4.
OPTIONAL KITS ............................................................................................4-1
4.1.
OptionAL Kits and AcCessories ............................................................................................... 4-1
5.
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
6
(*)
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 #
1
(*)
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
2
1995
1468
3
2660 1957 4
3325
2446
5
Installation and Connection
CFW11W | 2-2
Table 2.2:
Currents and settings at 500-690V
Rated Current (A)
Number of UP11-05
power units
ND
HD
640
477
1
1216
906
2
1824 1359 3
2432
1812
4
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 | 2-4
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]
10
<0
<0
<0
<0
<0
0.1
2.6
4.8
6.7
8.4
20
<0
<0
<0
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
30
<0
<0
4.6
10.5
14.9
18.4
21.4
23.9
26.2
28.2
35
<0
<0
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
45
<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
2
Line 600 V
N∙0.004∙Vline
2
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
2
= 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
2
)
700
380-480
ND (2x) 240
515
HD
(2x) 150
640
500-690
ND
(2x) 240
477
HD
(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
2
)
700
380-480
ND
240
515
HD
150
640
500-690
ND
240
477
HD
150
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