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WCIII Operating Instructions

Manual

AAA5E32043214A

Introduction 1

Safety Notes 2

Description 3

Preparing for Use 4

Assembly 5

Electrical Connections 6

Commissioning 7

Operation 8

Maintenance 9

Spare parts 10

Disposal 11

Service and Support A

Technical Data B

Quality C

Abbreviations D

Legal informationWarning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGERindicates that death or severe personal injury will result if proper precautions are not taken.

WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.

CAUTIONindicates that minor personal injury can result if proper precautions are not taken.

NOTICEindicates that property damage can result if proper precautions are not taken.If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified PersonnelThe product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens productsNote the following:

WARNINGSiemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

TrademarksAll names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of LiabilityWe have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AGIndustry SectorPostfach 48 4890026 NRNBERGGERMANY

A5E32043214A 05/2013 Technical data subject to change

Copyright Siemens AG 2013.All rights reserved

Table of contents

1 Introduction...................................................................................................................................................92 Safety Notes...............................................................................................................................................11 2.1 General Safety Information..........................................................................................................11 2.2 Safety Concept............................................................................................................................12 2.3 Observing the Five Safety Rules.................................................................................................12 2.4 Safety Information and Warnings................................................................................................13 2.5 ESD-sensitive Components.........................................................................................................15 2.6 Electromagnetic Fields in Electrical Power Engineering Installations ........................................173 Description..................................................................................................................................................19 3.1 Key Interlocks..............................................................................................................................19 3.2 Supply Scope .............................................................................................................................19 3.3 WCIII Cabinet Details..................................................................................................................20 3.4 Input Power Cabinet....................................................................................................................21 3.5 Transformer Cabinet....................................................................................................................21 3.6 Fuse/Precharge/Control (FPC) Cabinet......................................................................................22 3.7 Cell Cabinet.................................................................................................................................24 3.8 Output Power Cabinet.................................................................................................................25 3.9 Coolant Cabinet...........................................................................................................................25 3.10 Output Reactor Cabinet...............................................................................................................25 3.11 Exciter Cabinet............................................................................................................................26 3.12 Coordinated Input Protection Scheme.........................................................................................264 Preparing for Use........................................................................................................................................29 4.1 Overview of Proper Installation Techniques ...............................................................................29 4.2 Safety Precautions for Transportation.........................................................................................29 4.3 Shipping Guidelines.....................................................................................................................30 4.4 Receiving.....................................................................................................................................32 4.5 Off-loading...................................................................................................................................32 4.6 Shipping Splits.............................................................................................................................32 4.7 Weight Estimates.........................................................................................................................32 4.8 Handling......................................................................................................................................32 4.8.1 Transportation with Crane...........................................................................................................33 4.8.1.1 Lifting Method for Standard Shipping Section 2 and 3................................................................34

WCIII Operating InstructionsManual, AA, A5E32043214A 3

4.8.1.2 Lifting Methods for Standard Shipping Section 1........................................................................37 4.8.2 Transportation with Roller Dollies................................................................................................38 4.8.3 Transportation with Pipe Rollers .................................................................................................40 4.9 Storage........................................................................................................................................41 4.10 Unpacking....................................................................................................................................42 4.11 Final Placement...........................................................................................................................435 Assembly....................................................................................................................................................45 5.1 Anchoring Cabinets to Floors and Walls.....................................................................................45 5.2 Securing the Cabinets Together..................................................................................................46 5.3 Protective Earthing Bars Connection...........................................................................................486 Electrical Connections................................................................................................................................49 6.1 Reconnecting Wiring and Plumbing............................................................................................49 6.2 Installation of I/O External Wiring................................................................................................50 6.3 Electrical Requirements...............................................................................................................51 6.4 EMC Installation Guidelines for Perfect Harmony ......................................................................53 6.5 Cable Gland Plates Removal and Installation Guidelines...........................................................56 6.6 Circuit Breaker (provided by the customer).................................................................................577 Commissioning...........................................................................................................................................59 7.1 Residual Current Device (RCD) Compatibility.............................................................................598 Operation....................................................................................................................................................619 Maintenance...............................................................................................................................................63 9.1 Door Access................................................................................................................................63 9.1.1 Mechanical Interlock System.......................................................................................................64 9.2 Preventive Maintenance..............................................................................................................64 9.2.1 Six Month Inspection...................................................................................................................64 9.2.2 Preventive Maintenance Checklist..............................................................................................66 9.3 Cleaning......................................................................................................................................66 9.3.1 Contact for Cleaning Measures...................................................................................................66 9.3.2 Removing Dust Deposits.............................................................................................................66 9.4 Repair and Replace.....................................................................................................................67 9.4.1 Safety-relevant Checks...............................................................................................................67 9.4.2 Maintenance and Earthing Procedure.........................................................................................68 9.4.3 Replacing Parts...........................................................................................................................70 9.4.4 Replacing the Door-mounted Keypad.........................................................................................71 9.4.5 Replacing the CompactFlash Card..............................................................................................72 9.4.6 Replacing Cell Input Power Fuses..............................................................................................73 9.4.7 Replacing Printed Circuit Boards (PCBs)....................................................................................74 9.5 Power Cell Removal....................................................................................................................80 9.5.1 Isolating and Positioning of Power Cell.......................................................................................80 9.5.2 Purging Power Cell......................................................................................................................82 9.5.3 Removing and Transporting Power Cell......................................................................................85

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WCIII Operating Instructions4 Manual, AA, A5E32043214A

9.5.4 Preparing Banding for Power Cell...............................................................................................87 9.5.5 Banding and Crating of Power Cell.............................................................................................91 9.6 Power Cell Installation.................................................................................................................93 9.6.1 Prerequisites for Installing Power Cell.........................................................................................94 9.6.2 Transporting Power Cell via Cell Lifter........................................................................................96 9.6.3 Transporting Power Cell via Transportation Device..................................................................100 9.6.4 Inserting Power Cell..................................................................................................................101 9.7 Cell Cabinet Construction and Maintenance.............................................................................11110 Spare parts...............................................................................................................................................119 10.1 NXGII Control............................................................................................................................120 10.2 Power Cell.................................................................................................................................121 10.3 Optional Components................................................................................................................12211 Disposal....................................................................................................................................................123 11.1 Disposing of Device Components.............................................................................................123 11.2 Disposing of Packaging.............................................................................................................123 11.3 Disposing of Old Services.........................................................................................................123A Service and Support.................................................................................................................................125B Technical Data..........................................................................................................................................127 B.1 WCIII System Technical Specifications.....................................................................................127 B.2 WCIII Storage, Transport and Operation Ambient Conditions...................................................129 B.3 WCIII Power Cell Specifications................................................................................................130 B.4 WCIII Current Parameters.........................................................................................................130 B.5 Power Cell Output Current Rating Deration Parameters ..........................................................131 B.6 Ingress Protection (IP) Ratings..................................................................................................132C Quality.......................................................................................................................................................135 C.1 CE Marking and Directives for Perfect Harmony Products........................................................135 C.2 CE Marking on Power Drive Systems (PDS).............................................................................136 C.3 Directives that apply to the Power Drive System (PDS)............................................................137 C.4 CE Marking................................................................................................................................138D Abbreviations............................................................................................................................................139

Glossary....................................................................................................................................................145 Index.........................................................................................................................................................157

TablesTable 6-1 Torque Values for Electrical Connections (as per Regulation Document NKN-MF-0019)..........51Table 6-2 Torque Values for Raised Face to Raised Face or Flat Face to Flat Face non-CPVC Connections (as per Regulation Document NKN-MF-0008)............................................................................51

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Table 6-3 Power Cabling Cross Sections....................................................................................................52Table 6-4 Conductor Dimensioning.............................................................................................................52Table 10-1 NXGII Control Recommended Spare Parts...............................................................................120Table 10-2 Power Cell Recommended Spare Parts....................................................................................121Table 10-3 Optional Components Recommended Spare Parts (if furnished with drive).............................122Table B-1 WCIII Parameters and Ratings..................................................................................................127Table B-2 General Ambient Conditions......................................................................................................129Table B-3 WCIII Power Cell Specifications................................................................................................130Table B-4 WCIII 880 Amp Cell Type Specifications...................................................................................130Table B-5 WCIII 1250 Amp Cell Type Specifications.................................................................................131Table D-1 Commonly Used Abbreviations.................................................................................................139

FiguresFigure 2-1 ESD Protective Measures...........................................................................................................17Figure 3-1 WCIII VFD...................................................................................................................................20Figure 3-2 Standard TIMV Hardwired Control Signal Interface ...................................................................27Figure 4-1 Displaced Center of Gravity.........................................................................................................30Figure 4-2 Strap and Cradle Method of Lifting..............................................................................................34Figure 4-3 Transportation with Crane using Single Spreader Bar................................................................35Figure 4-4 Transportation with Crane using H-shaped Spreader Bar...........................................................36Figure 4-5 Standard Lifting Method..............................................................................................................37Figure 4-6 Optional Lifting Method................................................................................................................38Figure 4-7 Proper Placement of Roller Dollies..............................................................................................39Figure 4-8 Proper Use of Pipe Rollers in Handling Cabinets........................................................................41Figure 5-1 Proper Anchoring Technique for Cabinets..................................................................................46Figure 5-2 Connecting the Cabinets.............................................................................................................47Figure 6-1 Perfect Harmony Drive System...................................................................................................53Figure 6-2 Recommended Cable Segregation.............................................................................................55Figure 9-1 Meter Connection on Cell DC Bus...............................................................................................69Figure 9-2 Location of CompactFlash card on the NXGII Microprocessor Board.........................................72Figure 9-3 Bussmann Blown Fuse Indicator.................................................................................................73Figure 9-4 Ferraz Blown Fuse Indicator........................................................................................................73Figure 9-5 NXGII Master Control Chassis....................................................................................................77Figure 9-6 Power Cell pulled out to First Removal Position..........................................................................82Figure 9-7 Cell Water Purge Kit....................................................................................................................83Figure 9-8 Bucket positioned under Hose End to collect fluids.....................................................................84Figure 9-9 Inserting Cell Water Purge Kit Hoses to Supply and Return Ports (Snap-on) to drain liquids.... 84Figure 9-10 Power Cell Correct Position on Cell Lifter...................................................................................86

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Figure 9-11 Valox Insulation Locations...........................................................................................................86Figure 9-12 Methods for Transporting Power Cell..........................................................................................87Figure 9-13 Wooden Pallet.............................................................................................................................88Figure 9-14 Covering Pallet with Cardboard...................................................................................................88Figure 9-15 Preparing Power Cell for Lifting...................................................................................................89Figure 9-16 Lacing Lifting Lanyards through Lifting Brackets.........................................................................89Figure 9-17 Positioning Power Cell on Pallet..................................................................................................90Figure 9-18 Styrofoam Spacer between Power Cells.....................................................................................91Figure 9-19 Power Cells with Cardboard Corner Protectors...........................................................................91Figure 9-20 Lacing the Banding Material........................................................................................................91Figure 9-21 Typical Banding Tool...................................................................................................................92Figure 9-22 Properly Banded Power Cells......................................................................................................92Figure 9-23 Crate built to ship Power Cells....................................................................................................93Figure 9-24 New Power Cells.........................................................................................................................94Figure 9-25 Utility Cart with Plywood Boards placed on top...........................................................................95Figure 9-26 Hydraulic Cell Lifter with Lifting Device.......................................................................................95Figure 9-27 Rotating Power Cell Forward for Loading....................................................................................96Figure 9-28 Cell Lifter Manual Brake in Locked Position................................................................................97Figure 9-29 Cell Lifting Device Upper Roller Bar Installed with Locking Pins.................................................97Figure 9-30 Slide Rail Positioned Away from Upper Roller Bar to Accommodate Power Cell.......................97Figure 9-31 Power Cell Front Flange Positioned in Guides on Cell Lifter Slide Rail......................................98Figure 9-32 Valox Insulation Locations...........................................................................................................98Figure 9-33 Slide Rail Locking Pin Inserted....................................................................................................99Figure 9-34 Power Cell Properly Positioned on Cell Lifter for Installation or Transport..................................99Figure 9-35 Cell Lifter Manual Brake Release Position..................................................................................99Figure 9-36 Power Cell Ready to Transport.................................................................................................101Figure 9-37 Power Cell Aligned for insertion into Capacitor Bucket.............................................................102Figure 9-38 Teflon Insulation Strip Locations on Top of Guide Rail in Capacitor Bucket.............................102Figure 9-39 Slide Rail Locking Pin Inserted..................................................................................................103Figure 9-40 Guide Pins.................................................................................................................................104Figure 9-41 Power Cell Positioned Corectly prior to removing Cell Lifter.....................................................104Figure 9-42 Power Cell stopped by Locking Tab..........................................................................................105Figure 9-43 Hand Position for Cell Insertion.................................................................................................105Figure 9-44 Power Cell Fully Inserted...........................................................................................................106Figure 9-45 Capacitor Bank Connections with Proper Hardware Arrangement...........................................106Figure 9-46 Capacitor Mounting Bolts..........................................................................................................107Figure 9-47 Valox Insulation Locations.........................................................................................................108Figure 9-48 Installing Capacitor Bank Cover Plate.......................................................................................108Figure 9-49 Inserting Inlet and Outlet (Snap-on) Water Hoses.....................................................................109

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Figure 9-50 Fiber Optic Plug.........................................................................................................................110Figure 9-51 Power Cell Ready for Operation................................................................................................110Figure 9-52 9 Cell Cabinet............................................................................................................................112Figure 9-53 9 Cell Cabinet with Front and Top Blower Covers Removed (for service)................................113Figure 9-54 9 Cell Cabinet with Doors, Blowers and HEX Removed...........................................................114Figure 9-55 9 Cell Cabinet with Cells, Majority of Capacitors and Capacitor Buckets Removed.................115Figure 9-56 Bypass Contactor with T1-T2 Removed from Rear Panel.........................................................116Figure 9-57 12 Cell Cabinet with Rear Panel Removed and Bus Exposed..................................................117Figure 9-58 9 Cell Cabinet with Rear Panels Removed and only Verticals and Water Manifolds Installed. 118Figure C-1 Power Drive System..................................................................................................................136Figure C-2 Overview of PDS containing the Perfect Harmony BDM and CDM...........................................137Figure C-3 CE Marking................................................................................................................................138

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Introduction 1

About This ManualThis manual provides customer documentation for the Perfect Harmony Water-Cooled III (WCIII) Variable Frequency Drive (VFD).The content of this manual provides WCIII VFD standard information including safety warnings and notes, preparation for use, assembly/installation, electrical, commissioning, operation, maintenance, spare parts, and disposal information. The latter pages of this manual contain appendices for specific technical documents, support services information and other relevant data.This manual is intended for use by trained personnel having unique job functions and qualifications since there are areas on the VFD that are hazardous and therefore may cause death or serious bodily harm to personnel and also cause serious damage to the drive.The manual is also intended for use by planners, project engineers, installation personnel, programmers, commissioning personnel, operators, service and maintenance personnel.

WARNINGFamiliarity with the Product DocumentationOnly the complete product documentation will allow you to assemble and install the equipment, to put it into operation and to maintain it correctly and safely.Incorrect work on the equipment can result in death, severe injury or material damage.Always refer to the Operating Instructions manual when working on the equipment. Find the Operating Instructions manual, and other necessary equipment information about your product, on the CD supplied with the drive.

Refer to the NXG Control Operating manual for information relating to the NXG Control System and the related hardware and user interfaces.Refer to the WCIII Cooling System manual for coolant cabinet specific information.

Variable Frequency Drive Overview A variable frequency drive (VFD) system controls the rotational speed and torque of an alternating current (AC) electric motor by adjusting the frequency and voltage of the electrical power supplied to the motor. In an AC motor, frequency determines the motor speed.


Safety Notes 22.1 General Safety InformationProper Use

Perfect Harmony Medium Voltage Drives must always be installed in closed electrical operating areas. The Drive is connected to the industrial network via a circuit-breaker. The specific transport conditions must be observed when the equipment is transported. The equipment shall be assembled/installed and the separate cabinet units connected properly by cable and/or busbar in accordance with the assembly/installation instructions. The relevant instructions regarding correct storage, EMC-compliant installation, cabling, shielding and grounding and an adequate auxiliary power supply must be strictly observed. Fault-free operation is also dependent on careful operation and maintenance. Refer to the Drive's Operating Instructions Manual, Section EMC Installation Guidelines for Perfect Harmony.

WARNINGPotential Arc Hazard Arcing can result in damage to property, serious injury and even death. The equipment has not been tested for resistance to internal arcing. Avoiding arc hazard risks is dependent upon proper installation and maintenance. Incorrectly applied equipment, incorrectly selected, connected or unconnected cables, or

the presence of foreign materials can cause arcing in the equipment. Follow all precautionary rules and guidelines as used in working with Medium Voltage

switchgear. The equipment may be used only:

for the applications defined as suitable in the technical description. in combination with equipment and components supplied by other manufacturers

which have been approved and recommended by Siemens.

The power sections are designed for variable-speed drives use with synchronous and asynchronous motors. Operating modes, overload conditions, load cycles, and ambient conditions different to those described in this document are allowed only by special arrangement with the manufacturer. Commissioning may only be carried out by trained service personnel in accordance with the commissioning instructions. System components such as circuit-breaker, transformer, cables, cooling unit, motor, speed sensors, etc., must be matched to VFD operation. System configuration may only be carried out by an experienced system integrator.


2.2 Safety ConceptThe medium-voltage variable frequency drive (VFD) and its components are subject to a comprehensive safety concept which, when properly implemented, ensures safe installation, operation, servicing, and maintenance. The safety concept encompasses safety components and functions to protect the device and operators.The VFD is also equipped with monitoring functions to protect external components.The VFD operates safely when the interlock and protection systems are functioning properly. Nevertheless, there are areas on the medium-voltage drive that are hazardous for personnel and that can cause material damage if the safety instructions described in this section and throughout the product documentation are not strictly observed.

2.3 Observing the Five Safety RulesThere are five safety rules that must always be observed to assure not only personal safety, but to prevent material damage as well. Always obey safety-related labels located on the product itself and always read and understand each safety precaution prior to operating or working on the drive.The five safety rules: 1. Disconnect the system.2. Protect against reconnection.3. Make sure that the equipment is de-energized.4. Apply grounding means.5. Cover or enclose adjacent components that are still live.

DANGERDanger Due to High VoltagesHigh voltages cause death or serious injury if the safety instructions are not observed or if the equipment is handled incorrectly.Potentially fatal voltages occur when this equipment is in operation which can remain present even after the VFD is switched off.Ensure that only qualified and trained personnel carry out work on the equipment.Follow the five safety rules during each stage of the work.

Safety Notes2.3 Observing the Five Safety Rules


2.4 Safety Information and Warnings

DANGERHazardous Voltage! Always follow the proper lock-out/tag-out procedures before beginning any maintenance

or troubleshooting work on the VFD. Always follow standard safety precautions and local codes during installation of external

wiring. The installation must follow wiring practices and insulation systems as specified in IEC 61800-5-1.

Always work with one hand, wear electrical safety gloves, wear insulated electrical hazard rated safety shoes, and safety goggles. 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 disconnector will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnector. Also, there may be voltages present that are applied from other external sources.

Never touch anything within the VFD 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 operate the VFD 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 system. Never connect or disconnect any meters, wiring, or printed circuit boards while the VFD

is energized. Never defeat the instruments grounding. Only qualified individuals should install, operate, troubleshoot, and maintain this VFD. A

qualified individual is "a person, who is familiar with the construction and operation of the equipment and the hazards involved."

Hazardous voltages may still exist within the VFD cabinets even when the disconnect switch is open (off) and the supply power is shut off.

When a system is configured with VFD bypass switchgear (e.g. contactors between line and motor, and VFD and motor), these switches should be interlocked so that the line voltage is never applied to the VFD output if the medium input voltage is removed from the VFD.

Safety Notes2.4 Safety Information and Warnings


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.

WARNINGObey Rules to Avoid Risk of Death 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 VFD 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 VFD

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.

Ethylene Glycol Safety Information and Warnings

WARNINGEthylene glycol must be treated as a hazardous waste material.Ethylene glycol is: Harmful if swallowed. A skin and respiratory irritant. Severe eye irritant. Reproductive toxin. Always wash hands after handling ethylene glycol. Always consult the Material Safety Data Sheet (MSDS) for complete information regarding

safety and handling of ethylene glycol. Always clean up spills promptly. Ethylene glycol is a sweet tasting liquid that can kill pets

if ingested.

Safety Notes2.4 Safety Information and Warnings


Propylene Glycol Safety Information and Warnings

WARNINGPropylene glycol is: Slight eye irritant. Mist may cause respiratory irritation. Wash hands after handling propylene glycol. Always consult the Material Safety Data Sheet (MSDS) for complete information regarding

safety and handling of propylene glycol. Always clean up spills promptly.

2.5 ESD-sensitive ComponentsGuidelines for Handling Electrostatic Sensitive Devices (ESD)

NOTICEESD Sensitive Equipment Always be aware of electrostatic discharge (ESD) when working near or touching

components inside the VFD cabinet. The printed circuit boards contain components that are sensitive to electrostatic discharge. 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 observed. Following these rules can greatly reduce the possibility of ESD damage to printed circuit (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. Ensure that anyone handling the 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 build-up can be removed from a conductive object by touching the object with a properly grounded piece of metal.

When handling a PC board, always hold the card by its edges. Do not slide printed circuit boards (PCBs) 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 Industry, Inc. always use static-safe packing. This limits any further component damage due to ESD.

Safety Notes2.5 ESD-sensitive Components


Components that can be destroyed by electrostatic discharge (ESD)

NOTICEElectrostatic dischargeElectronic components can be destroyed in the event of improper handling, transporting, storage, and shipping.Pack the electronic components in appropriate ESD packaging; e.g. ESD foam, ESD packaging bags and ESD transport containers.To protect your equipment against damage, follow the instructions given below.

Avoid physical contact with electronic components. If you need to perform absolutely essential work on these components, then you must wear one of the following protective gear: Grounded ESD wrist strap ESD shoes or ESD shoe grounding strips if there is also an ESD floor.

Do not place electronic components close to data terminals, monitors or televisions. Maintain a minimum clearance to the screen (> 10 cm).

Electronic components should not be brought into contact with electrically insulating materials such as plastic foil, plastic parts, insulating table supports or clothing made of synthetic fibers.

Place components in contact with ESD-suited materials e.g. ESD tables, ESD surfaces, ESD packaging.

Measure on the components only if one of the following conditions is met: The measuring device is grounded with a protective conductor, for example. The measuring head of a floating measuring device has been discharged directly before

the measurement.The necessary ESD protective measures for the entire working range for electrostatically sensitive devices are illustrated once again in the following drawings. Precise instructions for ESD protective measures are specified in the standard DIN EN 61340-5-1.

Safety Notes2.5 ESD-sensitive Components


d

f f f f

b

e

a a ac c c

e

b

f

d d

e

a

1 Sitting2 Standing3 Standing/sittinga Conductive floor surface, only effective in conjunction with ESD shoes or ESD shoe grounding

stripsb ESD furniturec ESD shoes or ESD shoe grounding strips are only effective in conjunction with conductive

flooringd ESD clothinge ESD wristbandf Cabinet ground connection

Figure 2-1 ESD Protective Measures

2.6 Electromagnetic Fields in Electrical Power Engineering Installations

WARNINGElectromagnetic fields "electro smog" when operating electrical power engineering installations Electromagnetic fields are generated during operation of electrical power engineering installations.Electromagnetic fields can interfere with electronic devices, which could cause them to malfunction. For example, the operation of heart pacemakers can be impaired, potentially leading to damage to a person's health or even death. It is therefore forbidden for persons with heart pacemakers to enter these areas.The plant operator is responsible for taking appropriate measures (labels and hazard warnings) to adequately protect operating personnel and others against any possible risk.

Observe the relevant nationally applicable health and safety regulations. For example, in Germany, "electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance institution.

Display adequate hazard warning notices on the installation. Place barriers around hazardous areas.

Safety Notes2.6 Electromagnetic Fields in Electrical Power Engineering Installations


Take measures, e.g. using shields, to reduce electromagnetic fields at their source. Ensure personnel are wearing the appropriate protective gear.

Safety Notes2.6 Electromagnetic Fields in Electrical Power Engineering Installations


Description 33.1 Key Interlocks

As a standard all high voltage access points require a special tool to gain access. Key and/or mechanical interlocks are available as an additional protection to access various compartments in the VFD. Key interlocks are intended to interlock the VFD high voltage sections with the customer input circuit breaker when needed to perform maintenance.

Note

A door is defined as a hinged panel, as opposed to a bolt-on panel.

DANGERThe Perfect Harmony drive as standard does not provide isolation from MV power. Separate, user supplied isolating methods are required. Consult the key interlocking schematic diagram furnished with each drives factory production drawing set to determine the interlocking supplied with the drive.

NOTICEFor a CSA or UL listed Perfect Harmony drive, the listing is void if the drives MV sections are not mechanically interlocked with the main upstream disconnecting means.

3.2 Supply Scope The WCIII Perfect Harmony series of MV Pulse Width Modulated (PWM) VFDs incorporate the patented Perfect Harmony power topology in concert with NXGII hardware and Eagle software. WCIII drives are used to power both induction and synchronous motors. The WCIII design is the third generation of Siemens LD Perfect Harmony water cooled MV drive. The NXGII hardware is the second generation of the Siemens LD NeXtGeneration control platform for Perfect Harmony. NXGII hardware operates with embedded Eagle software.A liquid coolant (deionized water and glycol mix) removes rejected heat from the WCIII drive. The coolant path in the system is closed loop and pressurized, powered by fixed speed or variable speed pumps. Rejected heat is typically removed from the coolant through a forced air finned tube (liquid-to-air) or plate and frame (liquid-to-liquid) heat exchanger. Typically, this heat exchanger is furnished by Siemens with the drive.The standard WCIII drive consists of three shipping sections comprised of the following cabinets:


Shipping Section 1: Input power and transformer cabinets Shipping Section 2: Fuse/precharge/control (FPC), cell, and output power cabinets Shipping Section 3: Coolant cabinetShipping Section 3 can also contain one or both of the following optional cabinets: Output Reactor Cabinet: Furnished when drive operates in parallel with other WCIII units,

or performs closed synchronous transfer. This cabinet inserts in the standard WCIII lineup between the output power and coolant cabinets.

Exciter Cabinet: Furnished when the drive powers a synchronous motor. This cabinet inserts at the end of the standard WCIII lineup to the right of the coolant cabinet.

The standard WCIII drive outline dimensions vary depending upon the size of the coolant cabinet, input line voltage and frequency, motor type, motor nameplate ratings, motor overload requirements, and whether or not parallel operation or closed synchronous transfer is required. Reference the connection and lifting diagrams furnished with your particular drive for outline dimension, electrical and piping connection gland plate, weight, and center of gravity details.

3.3 WCIII Cabinet DetailsThe components furnished in a WCIII drive vary, depending upon individual customer requirements. Reference the Schematic S and Wiring W diagrams furnished with your particular drive assembly.

Figure 3-1 WCIII VFD

Description3.3 WCIII Cabinet Details


3.4 Input Power CabinetThe standard WCIII input power cabinet is a IP 53 (NEMA 12) painted steel enclosure with a hinged three-point latching door. The door has provision for key interlocking, and mounting of an optional input power quality meter.The following optional component may be mounted on the door: Siemens 9510 or GE Multilin PQMII power quality meter.The input power cabinet houses the following standard components: Customer input MV line terminals L1/L2/L3. Stainless steel ground pads, which are welded to the cabinet and provide a means to bond

the drive lineup to the customers plant grounding grid. Input line current transformers, which provide scaled analog current signals to NXGII control

and optional input power quality meter. Input line voltage attenuator resistors, which provide scaled analog voltage signals to NXGII

control. Input line surge arresters. Cooper Power Systems UltraSIL heavy duty distribution class

are standard.The input power cabinet houses the following optional components: Input line voltage transformer, which provides scaled analog voltage signals to:

optional input power quality meter. optional sync-check and phase rotation relays for type 6 pre-charge.

Fixed point medium voltage protective earthing.

3.5 Transformer CabinetThe standard WCIII transformer cabinet is a IP 53 (NEMA 12) painted steel enclosure with bolt-on access panels.The transformer cabinet houses the following standard components: Perfect Harmony multi-winding power transformer. The transformer primary and

secondary windings are built with copper tubing for the drive coolant flow (liquid inner-cooled electrical windings). The transformer assembly includes 80C and 90C thermal switches to monitor individual transformer winding coolant discharge temperatures and may also include a coolant diverter valve to regulate coolant flow through the transformer. The ratings of this transformer vary, based upon individual customer input supply frequency and voltage, drive power cell redundancy requirements, and motor requirements.

Five finned tube forced air heat exchangers to remove transformer and associated power cable rejected heat from the cabinet. Each heat exchanger has two fans (total of ten fans). The loss of any one fan out of ten does not result in a loss of required heat transfer capability.

70C and 75C thermal switches to monitor ambient air temperature within the cabinet.

Description3.5 Transformer Cabinet


3.6 Fuse/Precharge/Control (FPC) CabinetThe standard WCIII FPC cabinet is a IP 21 (NEMA 1) painted steel enclosure with hinged overlapping opposed front doors secured by a three point latch. An inner low voltage control panel swings out through these doors to provide access to the MV compartment behind. Quarter-turn fasteners secure this inner panel. The inner panel has provision for key interlocking.

DANGERFailure to follow standard safety precautions can result in severe injury or death.When their primary circuits are energized the PT and CT secondary circuits are capable of generating lethal voltages and currents. Follow standard safety precautions while performing any installation or service work (removing PT fuses, shorting secondaries, etc.).

The following components may be mounted on the left front door: Standard drive HMI keypad Optional drive HMI touch screen panel PCThe following standard components are mounted on the right front door: Emergency Stop (E-Stop) pushbutton Speed Demand Mode selector switch (Local-Remote or Off-Local-Remote) RJ45 ethernet port (temporary connection for walk-up communication with drive via

ethernet Modbus or Siemens LD ToolSuite)The low voltage (front) compartment of the FPC cabinet houses the following standard components:

Description3.6 Fuse/Precharge/Control (FPC) Cabinet


Circuit breaker CB1, which sources customer-supplied single phase 120 VAC control power Customer control signal terminal strips TB2 and TB2ELV Key-interlockable NXGII control panel with the following items:

NXGII Digital Card Rack (DCR) with Modbus RTU interface via DB9 connector NXGII Control Power Supply (CPS) NXGII Signal Conditioning Board (SCB) NXGII I/O Breakout Board, which provides interface for critical customer remote

hardwired analog and digital control signals via terminal strips TB2 and TB2ELV (refer to Figure Standard TIMV Hardwired Control Signal Interface in this chapter).

Drive HMI keypad (unless mounted on front door) Latch Fault relay (LFR) to lock-out drive in IDLE state if a medium voltage power circuit

fault occurs within the drive. Key Reset (KR) switch resets drive to resume operation after fault has been cleared.

Contactors CIMV (Close Input MV) and TIMV (Trip Input MV). These contactors provide a CLOSE and TRIP hardwired signal interface to the drive input line circuit breaker.

Ethernet switch with ST fiber optic and RJ45 interfaces for customer interface (permanent connection for remote communication with drive via ethernet Modbus and/or Siemens LD ToolSuite).

The low voltage (front) compartment of the FPC cabinet houses an optional Wago 750 Series Fieldbus. This provides interface for non-critical customer remote hardwired analog and digital control signals via terminal strips TB2 and TB2ELV.The MV (rear) compartment of the FPC cabinet houses the following standard components: Power cell input line fuses One finned tube forced air heat exchanger to remove heat rejected within the compartment

by bus and fuses. This heat exchanger has two fans. The loss of one fan does not result in a loss of required heat transfer capability.

Output line Hall Effect current sensors, which provide scaled analog current signals to NXGII control

Output line voltage attenuator resistors, which provide scaled analog voltage signals to NXGII control

Circuit breaker CB2, which sources customer-supplied three-phase AC power for power cell precharge, transformer cabinet heat exchanger fans, cell cabinet cooling blowers, and optional drive cabinet space heaters. This circuit breaker can be key interlocked.

Description3.6 Fuse/Precharge/Control (FPC) Cabinet


Power cell pre-charge circuit series capacitors C1/ C2/ C3/ C4/ C5/ C6, series resistors R1/ R2/ R3, and capacitor discharge resistors PCR1/ PCR2/ PCR3/ PCR4/ PCR5/ PCR6

Power Distribution Panel with the following items: Contactors M2, M3, and M4 for power cell pre-charge Circuit breakers CBA/ CBB/ CBC/ CBD/ CBE/ CBH and contactors CBM1/ CBM2/

CBM3/ CBM4 to source cell cabinet cooling blowers BLWR1/ BLWR2/ BLWR3/ BLWR4. The total number of these circuit breakers and contactors varies, based on the total number of power cells.

Control relays CBM1/ CBM2/ CBM3/ CBM4 for cell cooling blower thermal overload status. The total number of these relays varies, based on the total number of power cells.

Circuit breaker CBD and Control Power Transformer CPT to source transformer cabinet heat exchanger fans.

The MV (rear) compartment of the FPC cabinet houses the following optional components: Control board (BCC) and power supply (BPPS), providing control interface for optional

power cell bypass Circuit breaker CBH, contactor CB7, and Control Power Transformer CPT2 (mounted on

Power Distribution Panel) to source optional drive cabinet space heaters

3.7 Cell CabinetThe standard WCIII cell cabinet is a IP 53 (NEMA 12) painted steel enclosure with hinged three point latching doors. The doors have provision for key interlocking.The cell cabinet houses the following standard components: Power cells A1/ B1/ C1 A6/ B6/ C6. The total number of power cells varies based upon

individual customer cell redundancy and motor requirements. Each power cell is comprised of a power chassis (containing power electronic devices and associated control) and a set of integral cell DC bus filter capacitors.

Cell cabinet cooling blowers and accompanying finned tube heat exchangers. The blowers are configured as follows: 9 power cells: Two blowers (BLWR1 and BLWR2). The loss of one blower does not

result in a loss of required heat transfer capability. 12 power cells: Three blowers (BLWR1, BLWR2, and BLWR3). The loss of one blower

does not result in a loss of required heat transfer capability. 15 power cells: Three blowers (BLWR1, BLWR2, and BLWR3). The loss of one blower

does not result in a loss of required heat transfer capability. 18 power cells: Four blowers (BLWR1, BLWR2, BLWR3, and BLWR4). The loss of one

blower does not result in a loss of required heat transfer capability.Reference Appendix Technical Data for a complete listing of the types and ratings of standard WCIII power cells.The cell cabinet houses optional power cell bypass contactors BPKA1/ BPKB1/ BPKC1 BPKA6/ BPKB6/ BPKC6. There is one bypass contactor for each power cell.

Description3.7 Cell Cabinet


See alsoTechnical Data (Page 127)

3.8 Output Power CabinetThe standard WCIII output power cabinet is a IP 53 (NEMA 12) painted steel enclosure with a hinged three point latching door. The door has provision for key interlocking and mounting of an optional motor protection relay.An optional Siemens 7UM61/ 7UM62 or GE Multilin 369/ 469 relay may be mounted on the door.The output power cabinet houses the following standard components: Customer output medium voltage line terminals T1/T2/T3 Stainless steel ground pads. These pads are welded to the cabinet and provide a means

to bond the drive lineup to the customers plant grounding grid.The output power cabinet houses the following optional components: Output line current transformers. Provide scaled analog current signals to optional motor

protection relay. Output line voltage transformer. Provides scaled analog voltage signals to optional motor

protection relay. Fixed point medium voltage protective earthing.

3.9 Coolant CabinetThe standard WCIII coolant cabinet is a IP 21 (NEMA 1) painted steel enclosure with overlapping opposed front doors secured by a three point latch.Reference Siemens WCIII Cooling System manual for a complete description of the components housed in the coolant cabinet.

3.10 Output Reactor CabinetThe optional WCIII output reactor cabinet is a IP 53 (NEMA 12) painted steel enclosure with a hinged three point latching door. The door has provision for key interlocking.The output reactor cabinet houses the following standard components: Three single-phase iron core reactors (inductors) with copper windings inner-cooled by

drive coolant. When an output reactor cabinet is furnished, the customer output medium voltage line

terminals T1/ T2/ T3 move from the output power cabinet to the output reactor cabinet.The output reactor cabinet houses the following optional component:

Description3.10 Output Reactor Cabinet


Fixed point medium voltage protective earthing.

3.11 Exciter CabinetThe optional WCIII exciter cabinet is a IP 21 (NEMA 1) painted steel enclosure with a hinged three point latching door. The components furnished in this cabinet vary depending upon individual customer requirements.

3.12 Coordinated Input Protection SchemeDrives require an appropriate input current interrupting device (typically a circuit breaker) installed upstream of the drive. This device must be connected between the power source (input line) and the drive input connections (L1, L2, and L3). The input current interrupting device is considered an integral part of the drive safety and pre-charge systems. It is required that the input current interrupting device be interlocked to the control system so that input medium voltage can be interrupted upon the rare event of a transformer secondary side fault.

DANGERSecondary Circuit Fault It is required that the drive medium voltage switchgear be interlocked to the control system so that the input medium voltage can be interrupted upon the rare event of such a fault.Failure to integrate a medium voltage circuit breaking device, or contactor, may cause death, serious personal injury, and damage to the drive.

The control of the input current interrupting devices also ensures that input power is applied only after pre-charging the cell DC links. The "close input MV" contact (CIMV), when closed, allows the application of medium voltage power to the drive. A separate check-back signal (dry contact) must be provided from the input current interrupting device to confirm that the device is closed. Check-back signal delay must not exceed 500 milliseconds.A dry contact "trip input MV" (TIMV) output is supplied standard with each drive to trip open the input current interrupting device. This contact changes status whenever a drive input protection occurs. The TIMV contact should act immediately and directly, without any coupling relays involved. Additional delays tripping the input current interrupting device must be avoided. The input protection is defined in the NXG Control Operating manual.

DANGERTrip Input Medium Voltage (TIMV) The TIMV contact must be integrated with input current interrupting device to deactivate the drive input medium voltage upon the rare event of a secondary circuit fault.Failure to integrate this contact as specified may cause death, serious personal injury and damage to the drive.

Description3.12 Coordinated Input Protection Scheme


When a drive input protection occurs a dedicated NXGII I/O digital output (IDO-15) is closed as a one-shot pulse latches the LFR coil. This causes the 'Normally Closed' (N.C.) LFR contact to open, and the NXGII I/O digital output IDO-14 to open. This logic results in the operation of relay contact "trip input MV" (TIMV) at the customer control signal interface within the drive. Refer to the following figure.

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Notes: Contact rating 125 VDC 20 A This signal MUST be integrated into the drive main input line circuit breaker. Dashed line = wiring by customer

Figure 3-2 Standard TIMV Hardwired Control Signal Interface

Description3.12 Coordinated Input Protection Scheme


Preparing for Use 44.1 Overview of Proper Installation Techniques

NOTICERead this chapter prior to installing the Perfect Harmony VFD. Be sure to follow the procedures as indicated.

When installing Perfect Harmony drives, it is essential to understand the proper techniques associated with the following: Transport / shipping Receiving Off-loading Shipping splits Weight estimates Handling Storage Unpacking Final placement Anchoring and securing Reconnecting wiringEach of these topics is discussed, respectively, in the following chapters: Preparing for Use, Assembly and Electrical Connections.Refer to Appendix Technical Data for further information relating to transport and storage requirements.


4.2 Safety Precautions for Transportation Be sure to read all safety-related instructions provided. Perform procedures as instructed. Comply with all transportation and handling procedures to help ensure that no components

are bent and/or no alterations were made to the isolating distances, all doors/panels are closed or installed and the unit is stablized to prevent tilting.


WARNINGTransportation Not in Accordance with Proper ProceduresThe transportation unit/cabinet is heavy. The equipment may tip over if it is not transported correctly or if an unpermitted means of transport is used.Death, serious injury, or material damage can result.Ensure that the transportation unit/cabinet is transported by trained personnel only. Only use permitted means of transport and lifting equipment. Always position the cabinet in the proper upright position. Never tip the cabinet.

WARNINGImproperly Placing / Setting EquipmentSerious mechanical shocks during transportation or when placing/setting can damage the equipment and destroy the internal insulation material. This can result in insufficient insulation with respect to ground leading to a ground flashover.Death, serious injury, or material damage can result.Avoid mechanical shocks and impacts when placing the equipment.

Center of Gravity of the Transportation Unit / CabinetAlways take the center of gravity into account when lifting and installing the cabinet.

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Figure 4-1 Displaced Center of Gravity

4.3 Shipping GuidelinesThe guidelines shown below are based on a maximum transit time of eight weeks.1. Siemens references IEC 607213-2 2M1 standards. The WCIII drive is designed for truck

and ocean transport. It meets all 2M2 conditions with the exceptions of free fall, and pitch and roll.

2. Climatic conditions for transport follow IEC 60721-3-2 2K2. Low air temperature is -25 C and high temperature is +60 C.

3. Ensure precautions are made to minimize the risk of exposure of embedded and other sensitive electronics to water and chemicals.

Preparing for Use4.3 Shipping Guidelines


Truck Transport1. Use air ride trailers when they are available.2. Completely cover uncrated cabinets in plastic (minimum 4 mil) and stretch wrap seal around

the cabinet sides.3. Use full length tarps to completely cover the load (crated or uncrated).4. If securing over the top of uncrated cabinets, position the straps toward the four corners of

the shipping split to prevent bending.5. If using chains through the fork pockets, use chain protectors to minimize damage to the

finish/paint.

Ocean Transport1. Obey the guidelines as specified in the preceding section Truck Transport when

transporting to and from the port.2. Do NOT stack large crates.3. Stow cargo shipping via open top container, flat rack, mafi, or breakbulk below deck.4. Do NOT breach or alter crates while securing.

Rail Transport Ensure that crates in transit are fully covered by tarp. Ensure that Siemens is notified prior to the design phase when transport by rail is to be

used for transport.

Securing the LoadSecure the load in the following ways: Use retaining straps. Use positive locking on the loading surface, e.g., by wedging the transportation unit/cabinet

on the truck loading surface. Properly fit spacers.

Note

Warranty DisclaimerFailure to follow these guidelines will void your Siemens Industry, Inc. warranty coverage.If you are unsure of your specific warranty requirements, contact Siemens Industry, Inc.

Preparing for Use4.3 Shipping Guidelines


4.4 ReceivingThe proper receiving procedure consists of the following steps: 1. Verify that the proper items have been shipped.2. Inspect all items for damage that may have occurred during shipping. 3. File a claim with the shipping carrier if any damage is present.

4.5 Off-loadingDue to the size and weight of the components, it is important to carefully plan all handling operations when off-loading. Siemens recommends that prior considerations be made for ceiling heights, door widths, and ease of installation.Off-loading from the truck is often the most critical operation because of the limited access. Advance planning and coordination among the manufacturer, the carrier, the installation contractor, and the owner are vital.Precautions Prior to Moving the UnitVerify the following prior to moving the unit: The unit doors are closed. The unit is in an upright position. The unit is stabilized to prevent tilting.

4.6 Shipping SplitsThe Perfect Harmony drive system is a customized product, therefore shipping split configurations vary from system to system. Refer to the lifting diagrams provided with your system to determine the shipping split configuration for your particular system.

4.7 Weight EstimatesThe Perfect Harmony drive system is a customized product, therefore exact weights of systems vary. Refer to the lifting diagrams provided with your system regarding estimated weight and center of gravity for your particular system.

4.8 Handling

NoteSiemens does not provide lifting and handling equipment.

Preparing for Use4.8 Handling


The following sections describe the allowable methods for handling cabinets.

NOTICETransportation with Fork-liftLifting with a fork-lift is not recommended due to size and weight distribution of the equipment.If the tines are too short, the transportation unit/cabinet may tip over resulting in death, serious injury, or damage to the cabinet.The customer assumes all responsibility for any damage incurred if a fork-lift is used to lift the unit.

NOTICEFinal Lifting Liability The final lifting is the liability of personnel lifting the structures. Siemens provides general

descriptions for each permissible handling method and does not provide custom handling descriptions.

The lifting analysis presented in this manual was prepared without knowing the specific equipment to be used on site, therefore tailored lifting descriptions cannot be made.

To help assure proper lifting of cabinets, Siemens suggests the following actions: Verify that the equipment used is sized appropriately according to forces to which they will

be subjected. Continuously monitor the actual lifting process. Use slow movements and low lifting heights where possible.

Note

The drive contains many cable entry and exit locations. For complete details, refer to the system drawings supplied with the drive.

4.8.1 Transportation with Crane

WARNINGFailure to Transport in Accordance with Proper ProceduresIf not properly transported with crane, the transportation unit/cabinet may tip over or fall. This may result in death, serious injury, or equipment damage.



Setup Procedure1. Read all available safety information about crane transportation before using a crane for

transporting units/cabinets.2. Ensure that the lifting equipment is undamaged.3. Do not exceed the permissible transportation weight of crane.4. Locate the center of gravity for the transportation unit/cabinet and lift using a spreader bar

(refer to figures in the following section). In most cases, the center of gravity will be off-center and this must be taken into account before lifting.

5. Adjust sling length to compensate for a displaced center of gravity.

4.8.1.1 Lifting Method for Standard Shipping Section 2 and 3The recommended lifting method for standard Shipping Section 2 and Section 3 is the strap and cradle method. The strap and cradle method of transportation employs the use of fabric slings through the lifting openings in the cabinet base to lift cabinets. Refer to the following figure. The length and tensile strength of the slings are crucial to this method of lifting.

Figure 4-2 Strap and Cradle Method of Lifting

WARNINGImproper Use of Strap and CradleEnsure that the load carrying capacity of the hoisting equipment is adequate for the weight specified in the order specific lifting diagram furnished by Siemens. Death, serious injury, or damage to the cabinet/unit may result if the load carrying capacity of the equipment is inadequate.



CAUTIONPotential Damage to Drive CabinetsTo prevent buckling of the drive cabinets, the slings must be of adequate length and spreader bars of appropriate strength must be used.

Strap and Cradle Procedure1. Ensure that slings are at least 1.3 m (51 ") above the top of the enclosure.2. Use spreader bars (single or H-shaped depending on cabinet size) to prevent damage to

the cabinet/unit.3. Ensure that the strength of the sling is adequate for the weight specified in the dimension

drawings.4. Lift the transportation unit/cabinet using the sling.5. Avoid distorting cabinet or displacing the center of gravity.6. Ensure that cabinet/unit is parallel to the ground.

1 Single Spreader Bar2 Centroid3 Center of Gravity

Figure 4-3 Transportation with Crane using Single Spreader Bar



1 H-shaped Spreader Bar2 Centroid3 Center of Gravity

Figure 4-4 Transportation with Crane using H-shaped Spreader Bar

NoteWeight of Populated DrivesExact weights of systems vary based on the ratings of the drive and the included options. For customized drives having switchgear or transitions cabinets, refer to the project drawings supplied with the drive.Approximate weights of the WCIII core configuration are shown in Appendix Technical Data.

WARNINGCenter of Gravity OffsetEnsure great care is taken when determining the length and positions of the lifting straps.Death, serious injury, or damage to the cabinet/unit may result if determinations for strap length and position are not correctly determined.



4.8.1.2 Lifting Methods for Standard Shipping Section 1

Standard Lifting Method for Standard Shipping Section 1The standard lifting method for standard Shipping Section 1 is shown in the following figure. The lift points with this method are located on the transformer frame.

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Figure 4-5 Standard Lifting Method

CAUTIONDamage to the TransformerAllowing water or debris to enter the transformer cabinet can result in damage to the transformer.Ensure care is taken to prevent water and debris from entering the cabinet and causing damage to the Perfect Harmony transformer.Where possible, remove the lifting access panels on the roof of the transformer cabinet when the cabinet is indoors in a clean, dry location.



Optional Lifting Method for Standard Shipping Section 1An optional lifting method for standard Shipping Section 1 is shown in the following figure. The lift points with this method are located on the transformer cabinet roof. These lift points are sealed to prevent dust and water from entering the cabinet.

Figure 4-6 Optional Lifting Method

NoteThe optional lifting method for standard Shipping Section 1 must be specified at the time the drive is purchased.

4.8.2 Transportation with Roller Dollies

WARNINGImproper Drive FoundationEnsure that the ground is stable and the foundation for the drive is level and flat. Any sloping can produce uncontrolled drive movement.If the ground is soft and unlevel, lay a "trackway" by using rails, bars, or boards.If the foundation is unstable or unlevel, death, serious injury, or damage to the cabinet/unit may result.



Lifting Cabinet from PalletWhen space constraints prohibit using a crane, lift the cabinet from the pallet onto rollers.

Note

Weight RatingBe sure that the weight rating on the roller dolly complies with the dimension drawings shipped with the drive.

Roller Dollies Procedure1. Place roller dollies under the front and rear channels of the base, just outside the fork tubes

as shown in the following figure.2. Raise the transportation unit/cabinet and then place the lifting wheels under it.3. Push the angle plates of the lifting wheels from both sides into the position of the center of

gravity of the load.4. Roll the transportation unit/cabinet to the installation location. Take into account safety

information, precautions, and warnings.

Figure 4-7 Proper Placement of Roller Dollies



4.8.3 Transportation with Pipe Rollers The use of pipe rollers is the least preferred method of transportation.

WARNINGImproper Drive FoundationEnsure that the ground is stable and the foundation for the drive is level and flat. Any sloping can produce uncontrolled drive movement.If the ground is soft and unlevel, lay a "trackway" by using rails, bars, or boards.If the foundation is unstable or unlevel, death, serious injury, or damage to the cabinet/unit may result.

Lifting Cabinet from PalletWhen space constraints prohibit using a crane, lift the cabinet from the pallet onto rollers.It is possible to set the enclosure on many parallel pipe sections placed on the floor and then move it by rolling.

Note

Pipe RollersUse thick-walled steel pipes. Other suitable pipes are round steel, round timber, or concrete-lined pipes.Ensure pipes are at least 6 cm (2.36 ") thick and are at least one fifth longer than the depth of the transportation unit/cabinet.The pipes must be spaced no more than 45.72 cm (18 ") apart.Attach equipment only in places that have load-bearing capability in the direction of tension, such as on the transport rails.

Pipe Rollers Procedure1. Raise the transportation unit/cabinet.2. Place pipes under the unit/cabinet.3. Roll the unit/cabinet to the installation location. Take into account safety information,

precautions, and warnings.4. Raise the unit/cabinet slightly and remove the pipes.



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Figure 4-8 Proper Use of Pipe Rollers in Handling Cabinets

4.9 StorageThe following section provides information for storage of the drive after completion of the inspection.Indoor Storage Choose an indoor storage location that is clean, flat, and dry. Store the drive in an ambient air temperature range of +5 C to +40 C.Storage Requirements

Note

Siemens may require periodic inspection of equipment in storage.

Ensure that climatic conditions for storage comply with IEC 60721-3-1 1K3. Low air temperature is +5 C and high temperature is +40 C.

Avoid exposure to corrosive gasses particularly, but not exclusively, hydrogen sulfide and chlorine.

Avoid exposure to excessive moisture, such as relative humidity greater than 95% steam and condensation.

Avoid exposure to conductive dust such as coal dust, metal dust, etc. Avoid exposure to abrasive dust, oil vapors, explosive mixtures, explosive gases and salt

air. Avoid exposure to vibration, shocks, or tilting as it may result in the early failure of Siemens

components. Perfect Harmony drives are designed to withstand shocks/vibrations to a displacement amplitude of 1.5 mm (2-9 Hz), an acceleration amplitude of 5 m/s2 (9-200 Hz) and a shock response value of 40 m/s2.

Avoid exposure to magnetic fields, nuclear radiation and high levels of radio frequency interference (RFI) from communication transmitters.

Ensure that drives are completely clean and dry before beginning the commissioning process.

Preparing for Use4.9 Storage


Note

Warranty DisclaimerFailure to follow these guidelines will void your Siemens Industry, Inc. warranty coverage.If you are unsure of your specific warranty requirements, contact Siemens Industry, Inc.

4.10 Unpacking

NoteComply with All On-Site RequirementsSiemens recommends that the operating areas be dry and free of dust. The air supplied should not contain any electrically conductive gas, vapors, or dust, which could impair operation.

Upon receipt of the drives:1. Perform a visual inspection to assure shipment is undamaged.2. Verify that all items are received. 3. Perform the following steps to ensure that no damage occurs to open mounting parts.4. If applicable, carefully remove the foil and load securing devices.5. If applicable, remove the packaging immediately prior to installation. 6. If applicable, discard the packaging material in accordance with the applicable country-

specific guidelines and rules. 7. Protect the cabinets against dust by covering the ventilation opening and keeping the doors

closed, until commissioning is realized.8. Do not remove crane instructions from the cabinet(s).

Note

Damage During ShipmentIf damage occurs during shipment, contact the shipping carrier to file a claim.

Preparing for Use4.10 Unpacking


4.11 Final PlacementAfter final inspection, promptly move the drive to its final position or dry indoor storage area. Comply with the steps indicated below:1. Place the equipment in a clean, dry, and level place.2. Allow enough clearance to easily access the front of the drive with doors open. Allow at

least 36 " (915 mm) of clearance in front of the unit for intake cooling air that enters the drive through front-mounted ventilation grilles and is exhausted through the crate mount on top of the enclosure. Do not place the drive where the intake/exhaust paths could be blocked.

3. Ensure stored equipment is protected from dirt and ambient influences. This rule is essential for long periods of storage time. Refer to Appendix Technical Data for additional storage data.

NOTICEMounting InformationMount the drive on a flat surface. Use shims to level the cabinet to assure proper door operation.Mounting to an uneven surface may cause the drive cabinets to buckle, causing the cabinet doors to be misaligned and/or to not open and close properly.

Note

Mounting SpecificationsThe drive mounting surface must satisfy a floor flatness number (Ff) of 38 (min. local, 32) and a floor levelness number (Fl) of 25 (min. local, 20) per ACI 117-90, Section 4.5.6.1 (as measured in accordance with ASTM E 1155-87). Adjacent mounting surfaces must qualify as Class A per ACI 117-90, Section 4.5.4. Comparable values from comparable standards, such as DIN 18202-Table 3, CSN EN 15620, or appropriate non-concrete substrate standards, will suffice.


Preparing for Use4.11 Final Placement


Assembly 5

Prior to performing any type of work on the equipment, be sure to read and understand all information presented in the Safety Notes chapter of this manual.

Assembly of the Perfect Harmony DriveAdhere to the following general information with respect to installation: The cabinets must be installed (and cooled) in accordance with the guidelines in this manual. Protect the VFD against excessive stress and loading.

See alsoSafety Notes (Page 11)

5.1 Anchoring Cabinets to Floors and WallsHoles for anchor bolts are located on the base mounting channel typically 0.75 " from the front and back edges, and 3 " from the sides. Refer to supplied drawings for mounting details.When anchoring the cabinets to the floor, Siemens recommends that the installer use cemented J-bars on all corners. Holes in the base of the drive cabinets are 0.81 " in diameter and easily accept 0.5 " threaded J-bars. If the drive is mounted against a wall, top angles may be used to secure the drive to the back wall in lieu of the rear J-bar connections to the floor. Refer to Figure Proper Anchoring Technique for Cabinets for an overview. Exact dimensions are given in the drawings supplied with the drive.

Note

Refer to the system drawings provided with the drive for the type of base structure used with each cabinet as well as the exact connection locations.


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Figure 5-1 Proper Anchoring Technique for Cabinets

5.2 Securing the Cabinets TogetherEnsure that access to the holes on the bottom of the cabinets is unobstructed. Remove the gland plates.Be sure the materials listed below are located in the shipment: Sealing strips, self-adhesive Hexagon-head bolts Hexagon nuts Snap rings Washers Contact washers

NOTICEBefore operating the drive, verify cabinets are sealed together using supplied gaskets. Do not operate the drive if the gaskets are damaged or absent.If a gap exists or gaskets are damaged or absent, use 100% silicone caulking to completely seal the gaps between cabinets.Failure to seal all gaps between cabinets will inhibit the drive's cooling system and/or cause internal contamination.

Reconnecting the Shipping SplitsTie bolts are used to connect the individual cabinets to each other, such as the transformer cabinet and the control cabinet. Each section should be bolted to the next using the gasket sealing strips to prevent creating air gaps. Holes for tie bolts are located along the front and bac

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