CF series water cooled

Transcription

1 Sheet 1 Job SP02U Inverter for stirrer application, Brochure 01 C Water quality data Carnevale Quintiliani Pietrantonio 00 C Issue Carnevale Quintiliani Pietrantonio Rev. File Date Revision description Drawn Checked Approved This document is property of Sistem Power Srl company. Duplication and reproduction are forbidden without specific written authorization of Sistem Power Srl Management. Contents of the present documentation refers to products described in it. All technical data contained in the document may be modified without prior notice.

2 Sheet 2 PRODUCT DESCRIPTION The CF inverters water cooled series are removable AC/AC converter for convert the input three phase alternate voltage of fixed voltage and frequency into a variable alternate voltage of amplitude and frequency coming from reference input. The CF series inverter consists of 3 parts: 1. the AC/DC converter (for the conversion from AC to DC voltage), 2. the DC/AC converter (for the conversion from DC to AC voltage), 3. the control board. This 3 parts are assembled in the same devices, for this reason the inverter is an AC/AC converter. The water-cooled power modules in the CF drive range have the same functional and performance features, electronics hardware, and control options as the air-cooled modules. The water cooled components are also mechanically compatible with the air cooled components. Using the water-cooled power modules of the CF Drive Modules provides the following advantages: The power semiconductors are insulated from the cooling elements thus allowing use of fresh cooling water instead of special non conducting coolant Reduced need of cleaning and better serviceability compared to air cooled units Lower audible noise compared to air-cooled units High protection (IP) degree Liquid cooling guarantees more stable conditions Enclosure temperature level can be high without risk of overheating Using a switchboard with an air-water (or air-air) heat exchanger with a cooling power dimensioned only for the power loss in the air of the drives, an high degree of protection (IP54 or higher) can easily be achieved with these drives, they can be installed almost anywhere in the production area. This also reduces the load on the airconditioning system in the electrical rooms in many retrofit applications this is an important consideration. As the liquid cooled drives do not require large cooling fans, they are also quiet. The output load of the inverter is a three phase reactor like stirrer; modifying the current and the frequency in the stirrer with the inverter, a magnetic field with a different rotation speed and strength will be generated; in this way is possible to apply this force to the steel during the casting phase; the stirring force applied to the steel will give a better quality to the final product. The internal control of the inverter can work normally with the current feedback, taking this information from the 3 current sensor inside the inverter and comparing this with the reference current from 0 to Inom (nominal current of the inverter): the error current is given to a current regulator that rise or lower the output voltage of the inverter in way of applying an output current equal to the current reference. The internal vector current control performs a high precision in the current regulator with a excellent stability. The internal parameter of the inverter can be modified with the inverter operator panel PU400. The inverter can work with 3 different operating mode: Service Digital Fieldbus (The command and reference are given from the internal operator panel PU400, this working mode is reserved to SISTEM POWER personnel), (The command and reference are given from the digital and analog input), (The command and reference are given from the Main PLC by the HMI supervisor directly to the fieldbus board present in the control board). The inverter can supply a three phase voltage with a variable frequency from fmin to fmax Hz and a variable current from 0 to Inom (A) for the stirrer, the fmin, fmax, The nominal current of the inverter depends from the CF inverter order code.

3 Sheet 3 Inside the inverter is present a Stirrer insulation measuring system (from 50 kohm to 100 Ohm) for prevent dangerous working condition and for monitoring the Stirrer damaging during the time. This monitoring system can stop the inverter or only warn the supervisor system when a low stirrer insulation condition is detected. The commands that is possible to apply to the inverter are: PRECHARGE ON, PRECHARGE OFF command, START, STOP command, RESET command. When a PRECHARGE ON command is performed, the internal control of the inverter will close the external main contactor, then when the input ac voltage is applied to the inverter, the internal AC/DC conversion is performed with internal thyristors, after few second the DC link precharge procedure is performed and the inverter is considered in READY status. When the inverter is in READY status, then is possible to START it giving the START command, in this way the control will enable the output pulse, giving a correct output voltage for having the required output current using the Space Vector modulator, in this way is possible to obtain in the inverter output a voltage up to 96% of the incoming line voltage When the inverter is in START condition, will be possible to STOP it giving the STOP command, in this case the inverter will perform the ramp down voltage and after will disable the output power to the stirrer. When the inverter is in READY status, the is possible to put the inverter in NOT READY status giving the PRECHARGE OFF command, in this way the main and precharge contactor will be opened. The PRECHARGE ON procedure will be enabled only when the inverter is without fault, From the START condition the inverter will switch in STOP status when a fault condition occurs. The fault are resumed below: Driver fault of phase U, V, W (or short-circuit) Overcurrent of phase U, V, W, Overvoltage of DC link, Under voltage of DC link, Inverter overtemperature, Unbalance fault, External fault from digital input (coming from the inverter connector X27:1 14), External fault from analog input (coming from the inverter connector X18:1,2, X18:4,5, X22:1,2, X22:3,4, X20:1,2). For protect the Stirrer an insulation earth leakage monitor is present; this control (if present and enabled) perform the earth leakage measure of the output load (stirrer), this function can be performed: Never, Each time the inverter switch from Preset ON status to Start Status, When the earth leakage is less than a minimum value, a warning will be generated. Also is present an unbalance current monitoring, in this way if the real current is different from the setpoint current for more than a specified level (default value 30 A) for 15 seconds, a warning will be generated. if the real current is different from the setpoint current for more than a specified level (default value 50 A) for 20 seconds, a fault will be generated. In this way is possible to monitor if the stirrer or the cable has some problems. Another function present in the inverter is the alternate cycle, in this mode the output current is not equal to the reference current, but is given from a positive cycle (the output magnetic field is clockwise, with a selected period) followed by a negative cycle (the output magnetic field is counter-clockwise, with a selected period). This alternate mode can be performed by a specified command.

4 Sheet 4 Instead of using air for cooling, CF-W inverter drives are cooled with liquid. The liquid circulation of the drive is usually connected to a heat-exchanger (liquid-liquid) for cools down the liquid circulating in the internal heatsinks of the drive. The heat exchanging equipment can be located outside the electrical switchboard of the drives. We recommend that a regulating valve equipped with a measuring point is mounted. In order to prevent dir particles from accumulating in the connections and thus gradually weakening the cooling effect, installation of filter is also recommended. The highest point of the piping must be equipped with either an automatic or a manual venting devices. The material o the piping must comply with at least AISI 304 (AISI 316 is recommended). To facilitate the cleaning and venting of the cooling water, we recommend to install a bypass valve in the main line and valves at each drives converter inlet and water outlet. Below is possible to see a simplified example of the cooling system with the connection between the drives and the cooling system. Because the cooling elements are made of aluminum and the cooling liquid isn t in direct contact with the power semiconductors, is possible to use demineralized water, drinking water or a mixture of water and glycol. The nominal conductivity of cooling water has to be less than 100 us/cm, an external conductivity meter has to be installed for continuously monitor the electrical conductivity of the water, when the water conductivity exceeds the level of 300 us/cm an external fault has to be stop the drives. Below is possible to see the requirements on the cooling water quality circulating in the CF_W drives Water Quality ph value Chloride < 50 mg/l Sulfate < 100 mg/l Total dissolved solids < 250 mg/l, no deposits are allowed Total hardness as CaCO3 < 250 mg/l Conductivity < 300 us/cm The water must be clean of solid matter A water cooling system used for CF-W inverter drives has to be an hydraulic system of closed type, the piping has to be air-tight and pipes has to be made of metal, or specific plastic. An external heat exchanger has to be of stainless steel material (no brass or copper elements has to be used in the liquid circulation of the drive). The design temperature of the cooling agent entering the drive modules is 40 C. During circulation of liquid inside the hydraulic system of the drive, the liquid remove the heat produced in the power semiconductors. The typical

5 Sheet 5 temperature rise of the water cooling system is less than 6 C at nominal output power. Typically 90% o f power losses is dissipated in the liquid, the other power losses (10%), generated from capacitors and from the others components inside the drive, are removed with internal cooling fans. Below is possible to see a typical water cooling system used for 3 inverter of CF types. Each switchboard contain an inverter module and an air-water (or air-air) heat exchanger. Each inverter module contain both ½ male and female water plug profiles conform to ISO Standard series B. Below is possible to see the CF inverter dimension:

6 Sheet 6 Below is possible to see the inverter external layout

7 Sheet 7 Below is possible to see the inverter connection diagram:

8 Sheet 8 TECHNICAL FEATURES AC/AC INVERTER Here below is possible to see electrical output data of the AC/AC inverter when the maximum load power factor is 0.2. CF CODE Output Phase Number Dimension * LxHxD mm AC Input voltage AC Input current NOMINAL OUTPUT CURRENT (Arms) INPUT FUSE SIZE (Arms) EARTH (PE) CABLE SIZE mm 2 250/40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x Here below is possible to see electrical output data of the AC/AC inverter when the maximum load power factor is 0.3. (Note: for the model 800/40.INV-3 the data is at a maximum load power factor of 0.27). CF CODE Output Phase Number Dimension * LxHxD Mm AC Input voltage AC Input current NOMINAL OUTPUT CURRENT (Arms) INPUT FUSE SIZE (Arms) EARTH (PE) CABLE SIZE mm 2 250/40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x Here below is possible to see electrical output data of the AC/AC inverter when the maximum load power factor is CF CODE Output Phase Number Dimension * LxHxD Mm AC Input voltage AC Input current NOMINAL OUTPUT CURRENT (Arms) INPUT FUSE SIZE (Arms) EARTH (PE) CABLE SIZE mm 2 250/40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x /40.INV-3W 1 245x1400x * dimension with AC input bars

9 Sheet 9 400V VOLTAGE RANGE INVERTER DATA Model Model Model Model ORDER CODE No. CF.. 250/40.INV-3W 400/40.INV-3W 600/40.INV-3W 800/40.INV-3W Nominal voltage Vac Vac Vac Vac Input Vin (ac input) 3AC 3AC 3AC 3AC Output Vout *Vin *Vin *Vin *Vin Input fuses External (3) 170M3816D External (3) 170M3817D External (3) 170M3819D External (3) 170M3819D Filterless Yes Yes Yes Yes DC link soft charge Yes Yes Yes Yes Removable Yes Yes Yes Yes Output phases Output nominal current [A] Nominal output power [kva] [kw] Maximum load power factor Input nominal current [A] Internal DC link Capacitor [uf] Input power factor Cooling type Water cooled Water cooled Water cooled Water cooled tot [W] * in water [W] * in air [W] * tot [W] ** in water[w] ** in air [W] ** Nominal water flow [l/min] Maximum water input temperature [ C] System max working pressure 6 bar 6 bar 6 bar 6 bar Water plug connection ½ male and female ½ male and female ½ male and female ½ male and female Conductivity of liquid cooling 100 / 250 / / 250 / / 250 / / 250 /300 [us/cm] (nominal/alarm/trip) External flow switch trip level 20 l/min 20 l/min 30 l/min 30 l/min Maximum pressure drop [bar] 2,0 2,0 3,0 3,0 at nominal water flow Internal air flow [mc/h] Sound pressure level [db (A)] Dimension [mm] Lenght Height Depth Weight [Kg] Ambient temperature ( C) 0 to 50 0 to 50 0 to 50 0 to 50 Without derating Ambient temperature ( C) With derating until 70% of Pnom 50 to to to to 60 Conformity CE, UL (pending) CE, UL (pending) CE, UL (pending) CE, UL (pending) IP protection IP20 IP20 IP20 IP20 * With switching frequency of 1.5 khz, ** with switching frequency of 0,5kHz

10 Sheet V VOLTAGE RANGE INVERTER POWER LOSS DATA (switching frequency 0,5 khz, Vdc=700V, fout max=10 Hz, THD I < 4% with L load > 10 mh) Model Model Model Model ORDER CODE No. CF.. 250/40.INV-3W 400/40.INV-3W 600/40.INV-3W 800/40.INV-3W 65 A 100 A 150 A 200 A 320W / 270W 430W / 370W 600W / 510W 800W / 700W / 50W / 60W / 90W / 110W 125 A 640W / 540W / 100W 188 A 950W / 800W / 150W 250 A 1530W/ 1300W / 230W 200 A 880W / 750W / 130W 300 A 1440W/ 1220W / 220W 400 A 2040W/ 1740W / 300W 300 A 1300W/ 1100W / 200W 450 A 75% 2200W/1870W /330W 600 A 3100W/2640W / 460W 400 A 1700W/1450W / 250W 600 A 2800W/ 2400W / 400W 800 A 4050W/3450W /600 W 400V VOLTAGE RANGE INVERTER POWER LOSS DATA (switching frequency 1 khz, Vdc=700V, fout max=25 Hz, THD I < 4% with L load > 10 mh) Model Model Model Model ORDER CODE No. CF.. 250/40.INV-3W 400/40.INV-3W 600/40.INV-3W 800/40.INV-3W 65 A 100 A 150 A 200 A 350W/ 300W / 520W / 440W 720W / 610W 900W / 760W 50W / 80W / 110W / 140W 125 A 700W / 600W / 100W 188 A 1140W / 970W / 170W 250 A 1660W/ 1400W / 260W 200 A 1020W / 870W / 150W 300 A 1620W/ 1370W / 250W 400 A 2250W/ 1900W / 350W 300 A 1490W/ 1230W / 220W 450 A 2440W/2080W / 360W 600 A 3440W/2920W / 520W 400 A 1990W/ 1690W / 300W 600 A 3180W/ 2700W / 480W 800 A 4550W/3850W / 700W

11 Sheet V VOLTAGE RANGE INVERTER POWER LOSS DATA (switching frequency 1.5 khz, Vdc=700V, fout max=50 Hz, THD I < 5% with L load > 10 mh) Model Model Model Model ORDER CODE No. CF.. 250/40.INV-3W 400/40.INV-3W 600/40.INV-3W 800/40.INV-3W 65 A 100 A 150 A 200 A 380W/ 320W / 610W / 520W 840W / 710W 1000W/ 850W 50W / 90W / 130W / 150W 125 A 760W / 640W / 120W 188 A 1230W/ 1040W / 190W 250 A 1800W/ 1520W / 280W 200 A 1160W / 990W / 170W 300 A 1800W/ 1530W / 270W 400 A 2460W/ 2100W / 360W 300 A 1680W/ 1430W / 250W 450 A 2680W/ 2280W / 400W 600 A 3880W/3300W / 580W 400 A 2290W/ 1940W / 350W 600 A 3570W/ 3020W / 550W 800 A 5100W/4300W / 800W

12 Sheet 12 Common electrical data Auxiliary voltage [V] 1AC, Vac, 50-60Hz 1.5A Electronic supply External power supply for digital input 24V=, 1.5A IGBT Switching frequency [khz] 0.5, 0.75, 1, 1.25, 1.5 Modulation type 2 level Space Vector Control algorithm Vector current controlled or V/Hz scalar Loop algorithm cycle [us] 200 Output frequency [Hz] Frequency error < 0.1% Function Source command Local HMI operator panel PC (remote) parameter programming capable Fieldbus isolated available interface (option) Fieldbus interchange word number Profibus network speed (Mbit/sec) DeviceNet network speed (kbit/sec) CANopen network speed (kbit/sec) Ethernet IP network speed (Mbit/sec) 10 / 100 Profinet network speed (Mbit/sec) 10 / 100 Alternating stirring mode 3 (local, digital/analog input, fieldbus) Yes, graphic type Yes, by USB or RS485 communication link Profibus DP slave, DeviceNet, CANopen, Ethernet IP, Profinet 16 IN, 16 OUT External optoisolated programmable digital input for fixed function External relay output for fixed function External programmable 5 analog input for external programmable protection (stirrer water flow, (4..20mA or 0..10V) stirrer water temperature, resolution 12 bit water pressure, water conductivity, water inlet temperature) External analog output (0..10V) resolution 10 bit 4 Internal Earth insulation monitor YES Earth insulation measuring range (Ohm) 100 Ohm to 50 kohm Internal protection 2 redundant inverter over temperature protection, AC input under voltage / overvoltage, DC under voltage / overvoltage, DC link shortcircuit, Output overcurrent, Output shortcircuit, Load unbalance and load open circuit, Communication error, 14 external configurable trip One of this digital input has to be reserved to external flow switch (the flow switch closes if the water flow exceeds 20 l/min or 30 l/min depending on drive type) Historic fault YES Buffer of historic fault 312 fault or alarm event

13 Sheet 13 SISTEM POWER S.r.l. Registered office: Via Galileo Galilei, Pescara (PE) Head office: Strada Vicinale Stradone, snc Cepagatti (PE) INVERTER FOR STIRRER APPLICATION CF SERIES WATER COOLED BROCHURE R01 JUNE 2016 ACCORDING TO LAW SISTEM POWER SRL CONSIDERS THIS DOCUMENT TO BE A COMPANY SECRET AND THEREFORE PROHIBITS ANY PERSON TO REPRODUCE OR DISCLOSE IT IN WHOLE OR PART TO THIRD PARTIES, WITHOUT SPECIFIC WRITTEN AUTHORIZATION OF SISTEM POWER SRL MANAGEMENT