Sinamics Perfect Harmony Gh180 Operating Instructions A5e32043214a Aa

Answers for industry.
Medium-Voltage Variable Frequency Drive

ROBlCON Perfect Harmony
WClll Operating lnstructions
Manual A5E32043214
ROBICON Perfect Harmony
05/2013 AA

WCIII Operating Instructions
Manual

AA
A5E32043214A
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 information
Warning 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.

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

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

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

NOTICE
indicates 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 Personnel
The 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 products
Note the following:

WARNING
Siemens 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.
Trademarks
All 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 Liability
We 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 AG
Industry Sector
Postfach 48 48
90026 NRNBERG
GERMANY
A5E32043214A
05/2013 Technical data subject to change
Copyright Siemens AG 2013.
All rights reserved
Table of contents
1 Introduction...................................................................................................................................................9
2 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 ........................................17
3 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.........................................................................................26
4 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
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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...........................................................................................................................43
5 Assembly....................................................................................................................................................45

5.1 Anchoring Cabinets to Floors and Walls.....................................................................................45

5.2 Securing the Cabinets Together..................................................................................................46

5.3 Protective Earthing Bars Connection...........................................................................................48
6 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).................................................................................57
7 Commissioning...........................................................................................................................................59

7.1 Residual Current Device (RCD) Compatibility.............................................................................59
8 Operation....................................................................................................................................................61
9 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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4 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.............................................................................111
10 Spare parts...............................................................................................................................................119

10.1 NXGII Control............................................................................................................................120

10.2 Power Cell.................................................................................................................................121

10.3 Optional Components................................................................................................................122
11 Disposal....................................................................................................................................................123

11.1 Disposing of Device Components.............................................................................................123

11.2 Disposing of Packaging.............................................................................................................123

11.3 Disposing of Old Services.........................................................................................................123
A Service and Support.................................................................................................................................125
B 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..................................................................................................132
C 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................................................................................................................................138
D Abbreviations............................................................................................................................................139
Glossary....................................................................................................................................................145
Index.........................................................................................................................................................157
Tables
Table 6-1 Torque Values for Electrical Connections (as per Regulation Document NKN-MF-0019)..........51
Table 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....................................................................................................52
Table 6-4 Conductor Dimensioning.............................................................................................................52
Table 10-1 NXGII Control Recommended Spare Parts...............................................................................120
Table 10-2 Power Cell Recommended Spare Parts....................................................................................121
Table 10-3 Optional Components Recommended Spare Parts (if furnished with drive).............................122
Table B-1 WCIII Parameters and Ratings..................................................................................................127
Table B-2 General Ambient Conditions......................................................................................................129
Table B-3 WCIII Power Cell Specifications................................................................................................130
Table B-4 WCIII 880 Amp Cell Type Specifications...................................................................................130
Table B-5 WCIII 1250 Amp Cell Type Specifications.................................................................................131
Table D-1 Commonly Used Abbreviations.................................................................................................139
Figures
Figure 2-1 ESD Protective Measures...........................................................................................................17
Figure 3-1 WCIII VFD...................................................................................................................................20
Figure 3-2 Standard TIMV Hardwired Control Signal Interface ...................................................................27
Figure 4-1 Displaced Center of Gravity.........................................................................................................30
Figure 4-2 Strap and Cradle Method of Lifting..............................................................................................34
Figure 4-3 Transportation with Crane using Single Spreader Bar................................................................35
Figure 4-4 Transportation with Crane using H-shaped Spreader Bar...........................................................36
Figure 4-5 Standard Lifting Method..............................................................................................................37
Figure 4-6 Optional Lifting Method................................................................................................................38
Figure 4-7 Proper Placement of Roller Dollies..............................................................................................39
Figure 4-8 Proper Use of Pipe Rollers in Handling Cabinets........................................................................41
Figure 5-1 Proper Anchoring Technique for Cabinets..................................................................................46
Figure 5-2 Connecting the Cabinets.............................................................................................................47
Figure 6-1 Perfect Harmony Drive System...................................................................................................53
Figure 6-2 Recommended Cable Segregation.............................................................................................55
Figure 9-1 Meter Connection on Cell DC Bus...............................................................................................69
Figure 9-2 Location of CompactFlash card on the NXGII Microprocessor Board.........................................72
Figure 9-3 Bussmann Blown Fuse Indicator.................................................................................................73
Figure 9-4 Ferraz Blown Fuse Indicator........................................................................................................73
Figure 9-5 NXGII Master Control Chassis....................................................................................................77
Figure 9-6 Power Cell pulled out to First Removal Position..........................................................................82
Figure 9-7 Cell Water Purge Kit....................................................................................................................83
Figure 9-8 Bucket positioned under Hose End to collect fluids.....................................................................84
Figure 9-9 Inserting Cell Water Purge Kit Hoses to Supply and Return Ports (Snap-on) to drain liquids.... 84
Figure 9-10 Power Cell Correct Position on Cell Lifter...................................................................................86
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Figure 9-11 Valox Insulation Locations...........................................................................................................86
Figure 9-12 Methods for Transporting Power Cell..........................................................................................87
Figure 9-13 Wooden Pallet.............................................................................................................................88
Figure 9-14 Covering Pallet with Cardboard...................................................................................................88
Figure 9-15 Preparing Power Cell for Lifting...................................................................................................89
Figure 9-16 Lacing Lifting Lanyards through Lifting Brackets.........................................................................89
Figure 9-17 Positioning Power Cell on Pallet..................................................................................................90
Figure 9-18 Styrofoam Spacer between Power Cells.....................................................................................91
Figure 9-19 Power Cells with Cardboard Corner Protectors...........................................................................91
Figure 9-20 Lacing the Banding Material........................................................................................................91
Figure 9-21 Typical Banding Tool...................................................................................................................92
Figure 9-22 Properly Banded Power Cells......................................................................................................92
Figure 9-23 Crate built to ship Power Cells....................................................................................................93
Figure 9-24 New Power Cells.........................................................................................................................94
Figure 9-25 Utility Cart with Plywood Boards placed on top...........................................................................95
Figure 9-26 Hydraulic Cell Lifter with Lifting Device.......................................................................................95
Figure 9-27 Rotating Power Cell Forward for Loading....................................................................................96
Figure 9-28 Cell Lifter Manual Brake in Locked Position................................................................................97
Figure 9-29 Cell Lifting Device Upper Roller Bar Installed with Locking Pins.................................................97
Figure 9-30 Slide Rail Positioned Away from Upper Roller Bar to Accommodate Power Cell.......................97
Figure 9-31 Power Cell Front Flange Positioned in Guides on Cell Lifter Slide Rail......................................98
Figure 9-32 Valox Insulation Locations...........................................................................................................98
Figure 9-33 Slide Rail Locking Pin Inserted....................................................................................................99
Figure 9-34 Power Cell Properly Positioned on Cell Lifter for Installation or Transport..................................99
Figure 9-35 Cell Lifter Manual Brake Release Position..................................................................................99
Figure 9-36 Power Cell Ready to Transport.................................................................................................101
Figure 9-37 Power Cell Aligned for insertion into Capacitor Bucket.............................................................102
Figure 9-38 Teflon Insulation Strip Locations on Top of Guide Rail in Capacitor Bucket.............................102
Figure 9-39 Slide Rail Locking Pin Inserted..................................................................................................103
Figure 9-40 Guide Pins.................................................................................................................................104
Figure 9-41 Power Cell Positioned Corectly prior to removing Cell Lifter.....................................................104
Figure 9-42 Power Cell stopped by Locking Tab..........................................................................................105
Figure 9-43 Hand Position for Cell Insertion.................................................................................................105
Figure 9-44 Power Cell Fully Inserted...........................................................................................................106
Figure 9-45 Capacitor Bank Connections with Proper Hardware Arrangement...........................................106
Figure 9-46 Capacitor Mounting Bolts..........................................................................................................107
Figure 9-47 Valox Insulation Locations.........................................................................................................108
Figure 9-48 Installing Capacitor Bank Cover Plate.......................................................................................108
Figure 9-49 Inserting Inlet and Outlet (Snap-on) Water Hoses.....................................................................109
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Figure 9-50 Fiber Optic Plug.........................................................................................................................110
Figure 9-51 Power Cell Ready for Operation................................................................................................110
Figure 9-52 9 Cell Cabinet............................................................................................................................112
Figure 9-53 9 Cell Cabinet with Front and Top Blower Covers Removed (for service)................................113
Figure 9-54 9 Cell Cabinet with Doors, Blowers and HEX Removed...........................................................114
Figure 9-55 9 Cell Cabinet with Cells, Majority of Capacitors and Capacitor Buckets Removed.................115
Figure 9-56 Bypass Contactor with T1-T2 Removed from Rear Panel.........................................................116
Figure 9-57 12 Cell Cabinet with Rear Panel Removed and Bus Exposed..................................................117
Figure 9-58 9 Cell Cabinet with Rear Panels Removed and only Verticals and Water Manifolds Installed. 118
Figure C-1 Power Drive System..................................................................................................................136
Figure C-2 Overview of PDS containing the Perfect Harmony BDM and CDM...........................................137
Figure C-3 CE Marking................................................................................................................................138
Table of contents
Introduction
1

About This Manual
This 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.

WARNING
Familiarity with the Product Documentation
Only 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
2
2.1 General Safety Information
Proper 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.

WARNING
Potential 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 Concept
The 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 Rules
There 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.

DANGER
Danger Due to High Voltages
High 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 Notes
2.3 Observing the Five Safety Rules
2.4 Safety Information and Warnings

DANGER
Hazardous 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 Notes
Additional safety precautions and warnings appear throughout this manual. These important
messages should be followed to reduce the risk of personal injury or equipment damage.

WARNING
Obey 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

WARNING
Ethylene 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 Notes
Propylene Glycol Safety Information and Warnings

WARNING
Propylene 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 Components
Guidelines for Handling Electrostatic Sensitive Devices (ESD)

NOTICE
ESD 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 Notes
Components that can be destroyed by electrostatic discharge (ESD)

NOTICE
Electrostatic discharge
Electronic 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 Notes
d
f f f f
b
e
a a a
c c c
e
b
f
d d
e
a
1 Sitting
2 Standing
3 Standing/sitting
a Conductive floor surface, only effective in conjunction with ESD shoes or ESD shoe grounding
strips
b ESD furniture
c ESD shoes or ESD shoe grounding strips are only effective in conjunction with conductive
flooring
d ESD clothing
e ESD wristband
f Cabinet ground connection
Figure 2-1 ESD Protective Measures
2.6 Electromagnetic Fields in Electrical Power Engineering Installations

WARNING
Electromagnetic 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 Notes
Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
Ensure personnel are wearing the appropriate protective gear.
Safety Notes
Description
3
3.1 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.

DANGER
The 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.

NOTICE
For 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 cabinet
Shipping 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 Details
The 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
Description
3.3 WCIII Cabinet Details
3.4 Input Power Cabinet
The 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 Cabinet
The 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.
Description
3.5 Transformer Cabinet
3.6 Fuse/Precharge/Control (FPC) Cabinet
The 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.

DANGER
Failure 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 PC
The 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:
Description
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.
Description
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 Cabinet
The 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.
Description
3.7 Cell Cabinet
See also
Technical Data (Page 127)
3.8 Output Power Cabinet
The 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.
3.9 Coolant Cabinet
The 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 Cabinet
The 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:
Description
3.10 Output Reactor Cabinet
3.11 Exciter Cabinet
The 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 Scheme
Drives 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.

DANGER
Secondary 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.

DANGER
Trip 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.

Description
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.
Trip Drive MV lnput Circuit Breaker
TlMV
Customer signal
terminal block
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
Description
Preparing for Use
4
4.1 Overview of Proper Installation Techniques

NOTICE
Read 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 wiring
Each 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.
See also
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.

WARNING
Transportation Not in Accordance with Proper Procedures
The 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.

WARNING
Improperly Placing / Setting Equipment
Serious 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 / Cabinet
Always take the center of gravity into account when lifting and installing the cabinet.
Front view
Side view
Figure 4-1 Displaced Center of Gravity
4.3 Shipping Guidelines
The 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 Use
Truck Transport
1. 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 Transport
1. 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 Load
Secure 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 Disclaimer
Failure 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 Use
4.4 Receiving
The 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-loading
Due 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 Unit
Verify 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 Splits
The 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 Estimates
The 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

Note
Siemens does not provide lifting and handling equipment.

Preparing for Use
4.8 Handling
The following sections describe the allowable methods for handling cabinets.

NOTICE
Transportation with Fork-lift
Lifting 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.

NOTICE
Final 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

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

Preparing for Use
4.8 Handling

Setup Procedure
1. 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 3
The 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

WARNING
Improper Use of Strap and Cradle
Ensure 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.

Preparing for Use
4.8 Handling

CAUTION
Potential Damage to Drive Cabinets
To 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 Procedure
1. 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 Bar
2
Centroid
3
Center of Gravity
Figure 4-3 Transportation with Crane using Single Spreader Bar
Preparing for Use
4.8 Handling
1
H-shaped Spreader Bar
2
Centroid
3
Center of Gravity
Figure 4-4 Transportation with Crane using H-shaped Spreader Bar

Note
Weight of Populated Drives
Exact 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.

WARNING
Center of Gravity Offset
Ensure 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.

Preparing for Use
4.8 Handling
4.8.1.2 Lifting Methods for Standard Shipping Section 1
Standard Lifting Method for Standard Shipping Section 1
The 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.

Figure 4-5 Standard Lifting Method

CAUTION
Damage to the Transformer
Allowing 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.

Preparing for Use
4.8 Handling
Optional Lifting Method for Standard Shipping Section 1
An 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

Note
The 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

WARNING
Improper Drive Foundation
Ensure 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.

Preparing for Use
4.8 Handling
Lifting Cabinet from Pallet
When space constraints prohibit using a crane, lift the cabinet from the pallet onto rollers.

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

Roller Dollies Procedure
1. 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
Preparing for Use
4.8 Handling
4.8.3 Transportation with Pipe Rollers
The use of pipe rollers is the least preferred method of transportation.

WARNING
Improper Drive Foundation
Ensure 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 Pallet
When 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 Rollers
Use 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 Procedure
1. 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.
Preparing for Use
4.8 Handling

Figure 4-8 Proper Use of Pipe Rollers in Handling Cabinets
4.9 Storage
The 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/s
2
(9-200 Hz)
and a shock response value of 40 m/s
2
.
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 Use
4.9 Storage

Note
Warranty Disclaimer
Failure 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

Note
Comply with All On-Site Requirements
Siemens 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 Shipment
If damage occurs during shipment, contact the shipping carrier to file a claim.

Preparing for Use
4.10 Unpacking
4.11 Final Placement
After 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.

NOTICE
Mounting Information
Mount 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 Specifications
The 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.

See also
Preparing for Use
4.11 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 Drive
Adhere 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 also
Safety Notes (Page 11)
5.1 Anchoring Cabinets to Floors and Walls
Holes 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.

0.81" diam.hole
Concrete
Side Wall
Concrete
Figure 5-1 Proper Anchoring Technique for Cabinets
5.2 Securing the Cabinets Together
Ensure 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

NOTICE
Before 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 Splits
Tie 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
back edge of each cabinet section.
Assembly
Bolts must be installed to secure the cabinets to each other: four bolts (top, two middle, and
bottom) in the front and four bolts in the back. The front connections can be made easily using
a 1/2-13 hex-head bolt with a lock washer for each of the four locations. The rear bolts can be
installed by removing the rear panels and installing the same hardware as in front.
The control wires are connected with plugs. These plugs are located in the front of the drive
near the control terminals located to the left of the control box.
Transformer Cabinet Cell Cabinet
Front of Cabinet
Back of Cabinet
Top View
Bolt and washer
Cell
Nuts (3)
Nuts (3)
Cell Cell
Figure 5-2 Connecting the Cabinets

Note
Before using hand tools, tie one end of a string to the tool and the other to your wrist. This
prevents loss of the hand tool if accidentally dropped into the drive.
If any hardware is accidentally dropped into the drive during reconnection, it must be removed
prior to application of control and medium voltage.

Assembly
5.3 Protective Earthing Bars Connection

DANGER
Grounding the Drive
The VFD must be grounded to allow safe operation.
If not sufficiently grounded during operation, the protection and monitoring functions can fail.
Death, serious injury, or material damage will result.
Always take the appropriate precautions and observe the five safety rules before carrying
out any work on the converter.
Follow these steps when grounding the machine:
Make the connections to the PE busbars within a cabinet.
Ensure that the connections to the PE busbars are made over several cabinets.
Set up the ground connection for the whole plant immediately.

Connecting the Protective Earthing (PE) Bars (for several cabinets)

Note
Each cabinet in the lineup is bonded together, generally via 1/0 cable.

Assembly
5.3 Protective Earthing Bars Connection
6

Prior to performing any type of electrical work on the equipment, be sure to read and
understand all vendor supplied information and all information presented in the Safety Notes
chapter of this manual.
See also
6.1 Reconnecting Wiring and Plumbing
Reconnect the power wiring, control wiring, and plumbing between the control/cell cabinet,
transformer cabinet, input-output cabinet, and pump cabinet. The cell input power cables in
the transformer cabinet connect to the cell input bus in the back of the cabinet. These can be
accessed by removing the cabinet rear panels.
The transformer power wire label must match the labels on the cell cabinet bus work. Power
wire must be firmly attached to the transformer supports that are located in the transformer
cabinet.
The transformer has a set of 5% voltage taps for compensating the primary voltage source.
The drive is shipped with the +5% taps connected, meaning that the VFD secondary cell
voltages are at the nominal 750 VAC (for example) for an input voltage of 5% above primary
nominal rating. Customer-supplied medium voltage (MV) power enters an access plate in the
top or bottom of the input section.
Customer-supplied AC power for both control and pumps enters an access plate in the top or
bottom of the control and liquid coolant cabinet section. Output connections for the motor exit
through an access plate in the top or bottom of the output section located to the right of the
power cells.

DANGER
Ensure that the entire system is earth grounded at its Protective Earth (PE) ground point.
Failure to do so will cause death and damage to the drive.
Ground bonding jumpers are factory-made. Reconnect ground bonding between cabinets at
shipping splits.


NOTICE
Do not bond the transformer primary winding neutral point to ground.
The transformer primary winding neutral point is designed to operate floating (ungrounded).
Failure to adhere to this instruction will cause large, unbalanced currents to circulate in the
ground/neutral path of the drives input source system during drive energization.

Note
EMC Compliance
To maintain EMC compliance, input medium voltage wiring must be installed in metallic
electrical conduit and routed through the approved access plates.
Customer supplied low voltage I/O cabling #12-#22 AWG must be routed separately from
power cables / medium voltage cables. Shielded low voltage cables shall maintain shield
integrity for the length of the cable including all inter-connections and the shield shall be
grounded only at the source.

NOTICE
Shielded Cable Requirement
If the output motor leads are shielded cable, the shields must be terminated at the drive end
only. Failure to do so will cause unwanted drive and system problems.

The input and output medium voltage terminals (L1, L2, L3 and T1, T2, T3) are offset from one
another and have two NEMA one-hole pattern configurations (vertical and horizontal) to
facilitate top or bottom cable termination. MV terminations are provided for 3/8" fasteners.
6.2 Installation of I/O External Wiring
Refer to the project drawing C set for the customer I/O connection interface (#12 - #22 AWG).
All hardwired I/O cabling should be routed and terminated prior to commissioning.

CAUTION
Electrical Hazard!
Standard safety precautions and local codes must be followed during installation of external
wiring.
Protection separation must be kept between extra low voltage (ELV) wiring and any other
wiring as specified in the CE safety standard IEC 61800-5-1.

6.2 Installation of I/O External Wiring
6.3 Electrical Requirements
Mechanical Connections
Unless otherwise specified on the drawing, Siemens standard is to use the American Institute
for Steel Construction (AISC)s definition of snug fit for all mechanical connections. Snug fit is
defined as the force exerted by a standard operator using ordinary hand tools. The spring
washer or locking mechanism should be fully engaged in the base metal to provide a solid
connection but not necessarily in continuous contact.
These connections do not require the use of a torque wrench and do not require a torque mark.
However, if a torque specification for a mechanical connection is called out in the assembly
drawings, then the assembler or technician will properly torque the fastener and mark the
connection with orange paint. Torque specifications for the Perfect Harmony drive are listed
in the following tables.
Table 6-1 Torque Values for Electrical Connections (as per Regulation Document NKN-MF-0019)
Fastener Size Tightening Torque Value
English Metric Newton-Meters (Nm) Ft-lb In-lb
2-56** M2 0.4 3.0
4-40** M3 0.7 6.0
6-32** M3.5 1.4 12.0
8-32** M4 2.5 22.0 (15.0)***
10-32 M5 4.0 36.0
1/4-20 M6 8.0 72.0
1/4-28 8.0 72.0
5/16-18 M8* 17.0 156.0
3/8-16 M10* 31.0 276.0
3/8-24 31.0 276.0
1/2-13 M12 76.0 56.0
5/8-11 153.0 112.0
3/4-10 270.0 198.0
1-8 600.0 480.0
* These values do not apply when this hardware is used on power modules (IGBT, diodes,
etc.)
For the required torque values in these instances refer to the drawings.
** These sizes are only torqued when used on ground wire.
*** #8 bolts used in secondary connections on CTs are torqued to 15 in-lbs.
Table 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)
Description Gasket Part Number Bolt Diameter Grade 5 bolt torque Grade 8 bolt torque
1/2 " 150# flange A1A0100925 1/2 19 ft-lb 25 ft-lb
3/4 " 150# flange A1A0100926 1/2 19 ft-lb 25 ft-lb
1 " 150# flange A1A0100927 1/2 20 ft-lb 25 ft-lb
Description Gasket Part Number Bolt Diameter Grade 5 bolt torque Grade 8 bolt torque
1.5 " 150# flange A1A0100928 1/2 20 ft-lb 26 ft-lb
2.5 " 150# flange A1A0100930 5/8 40 ft-lb 51 ft-lb
For Table Torque Values for Raised Face to Raised Face or Flat Face to Flat Face non-CPVC
Connections, the following assumptions apply to the calculations for the listed torque values:
Values are for ANSI Class 125 and 150 pound flanges.
Torque calculations are based on Grade 5 and Grade 8 bolts of listed size and using listed
gasket. Deviation from these components requires the torque value be recalculated.
A calibrated torque wrench is used and the proper tightening procedure is followed per
Siemens LD Document A5E02550752A.
Power Cabling Cross Sections
Table 6-3 Power Cabling Cross Sections
Motor
Voltage
Shaft Output Cable Cross Sections:
Line-side, max.
connectable per phase
with M10 screw
1

preliminary
Cable Cross Sections:
Motor-side, max.
connectable per phase
with M10 screw
1

preliminary
PE connection:
Max. connection cross
section at enclosure with
M12 screw
1
preliminary
kV hp kW AWG/MCM
(NEC, CEC)
mm
2
(DIN VDE)
AWG/MCM
(NEC, CEC)
mm
2
(DIN VDE)
AWG/MCM
(NEC, CEC)
mm
2
(DIN VDE)
3.3 4400
8133
2984
6067
2 x 1000
MCM
2 x 500 2 x 1000
MCM
2 x 500 1000 MCM 500
4.0 / 4.16 4500
8660
3357
7354
2 x 1000
MCM
2 x 500 2 x 1000
MCM
2 x 500 1000 MCM 500
4.6 / 4.8 4500
11830
3357
8825
2 x 1000
MCM
2 x 500 2 x 1000
MCM
2 x 500 1000 MCM 500
6.0 7000
14787
5222
11031
2 x 1000
MCM
2 x 500 2 x 1000
MCM
2 x 500 1000 MCM 500
6.6 8000
16266
5968
12134
2 x 1000
MCM
2 x 500 2 x 1000
MCM
2 x 500 1000 MCM 500
6.9 / 7.2 8000
17744
5968
13237
2 x 1000
MCM
2 x 500 2 x 1000
MCM
2 x 500 1000 MCM 500
1
Maximum installable size per phase
Table 6-4 Conductor Dimensioning
Object Length
Cable Length (motor side) No output filters are required up to 2.2 km (7500 ft).
Over 2.2 km (7500 ft) permissible only with output filters.
Cables must be shielded.

Note
Input Conductor Sizing
Conductor sizes for input medium voltage termination may vary based on the size of the drive
and dynamics of the system. The customized system schematic (included with your drive)
shows the conductor size used on the main transformer taps. The size of the input conductors
usually matches or exceeds this size.
Be sure to size the input conductors appropriately for your particular application, taking into
account the length of the input power feed and local standards and electrical codes. Labels
located near connections recommend the use of 75 C conductors.

6.4 EMC Installation Guidelines for Perfect Harmony
These guidelines cover the basic points to be considered when installing a Perfect Harmony
motor drive with minimum Radio Frequency Interference (RFI) impact on the surrounding
environment. A drive that limits RFI to within specified levels has achieved Electromagnetic
Compatibility (EMC). There are four key areas that need to be addressed to achieve EMC:
Earthing
Screening
Filtering
Wiring.
Motor
Motor
auxiliaries
Junction box
or isolator
(if fitted)
Rectifier lnverter
DC
Link
Control cables
Control
Factory Earth Ground
Transformer/
lnput Section
Cell / Output Section
Cells x n
Control Section
Ground
Ground
HMl
Figure 6-1 Perfect Harmony Drive System
Earthing
The Perfect Harmony drive has provisions for the customer to bond Protective Earth (PE)
to the drive cabinets. These connection points are identified with a symbol in the drive
assembly. The PE connections are provided adjacent to the L1/L2/L3 power input and T1/T2/
T3 power output terminals in the drive. All sections of the drive are internally PE bonded by
green/yellow conductor or black conductor with green and yellow tape. All customer PE
connections to the drive should be as short as physically possible and comply with all local
safety regulations regarding earthing. Siemens Industry, Inc recommends PE bonds be at only
one point on the drive to prevent circulating ground currents. All PE bonds should be checked
as part of routine drive maintenance.
Screening (Shielding)
The purpose of screening [shielding] is to prevent any unwanted radio frequency
electromagnetic radiation from escaping or entering a system. To accomplish this, the
screening must be part of the cabinets or enclosures as well as the connecting input and output
cables. The Perfect Harmony drive, with its switching elements and microprocessor
controllers, is a source of RFI. However, the enclosures of the Perfect Harmony drive have
been engineered and tested to provide an effective "Faraday Cage" that limits the amount of
RFI escaping from the drive. This cage also helps prevent unwanted RFI from entering the
drive. All cables in and out of the drive [power/mains and control/signal] must be shielded to
limit RFI emissions. The motor housing is typically an effective RFI screen. To achieve EMC,
the three screens cabinet, cable, motor housing must be bonded together to effectively
form one screen. No interruptions in the cable shielding are permitted. The connections in the
screening system must have a low impedance in the megaHertz (MHz) range. Special
connectors are designed for this purpose and recommended.
Filtering
An internal EMC line filter is installed in the Perfect Harmony drive on the customer control
power inputs. The customer's control power connections to the drive must be in metallic tubing
and must not be in close proximity with the internal EMC line filter.
Wiring
Control and Signal Cables
The control cabling is a part of the Faraday Cage as described in the screening section above.
Use shielded cables for all analog and digital control connections whenever possible.
Twisted pairs are an effective alternative to shielded cables.
If twisted pairs are used the twist should be carried as close as possible to the appropriate
terminals. If possible avoid the use of a common return for different analog signals.
Always separate digital and analog signals. Never mix 110 / 230 Volt signals in the same
cable as 24 Volt signals. A conventional screened or armored cable should be used for
110 / 230 V signals.
Double-shielded cables will give the best performance.
Control and signal cables must be separated from power cables.
Route control and signal cables in separate cable trunks at least 200 mm (8 in) away from
motor and power cables.
If control and signal cables must cross power cables, it must be at an angle as near to 90
degrees as possible. Refer to the following figure.
1
2
3
>

5
0
0
>

3
0
0
>

2
0
0
90
1
Motor cable
2
Mains cable
3
Signal/control cables
Figure 6-2 Recommended Cable Segregation
Power (Mains/Motor) Cables
Siemens Industry, Inc. recommends the input and output medium voltage power cable,
regardless of operating voltage, used for all Perfect Harmony drives be shielded to mitigate
RFI and achieve EMC. The cable shield should be electrically continuous for the entire cable
length and constructed of nonmagnetic metal, a tape shield is preferred. Cable armor and non-
tape shields, such as Unishield, also serve to limit RFI emissions. Both of these types of cable
have been successfully applied with Perfect Harmony drives, but they may not be as effective
as a tape shield in limiting RFI.
The cable manufacturers recommendations for maximum pulling tension and minimum
bend radius should always be followed when installing cable.
No other cable shields, power or control/signal, should be bonded to the motor cable shield.
Very high levels of electrical noise will be induced in such cables.
Siemens Industry, Inc. recommends all drive input [mains] and output [motor] power cable
shields be bonded to PE at one end only.
Whenever armored cables are used, they should be properly terminated with a gland, the
armor contacting the gland through all 360 degrees, and the gland circumferentially
grounded to the gland plate and bonded to PE.
Serial Communication Cables
The signal transmission standard (RS232, RS485, Ethernet, etc.) and protocol standard
(Profibus, ControlNet, Modbus, etc.) will recommend suitable cable types. Follow the
recommendations.
Encoder Cables
Pulse encoders may be galvanically connected to the motor rotor. It is important that any
bearing insulation not be bridged. The recommendations of the encoder supplier, such as cable
type, should always be strictly followed. The cable run from the encoder to the drive should
be a continuous length and not interrupted by screw terminals.

Note
Complete Guideline on EMC Installation
Go to the Gambica website at: http://www.gambica.org.uk/
Download the Variable Speed Drives and Motors - Installation Guidelines for power Drive
Systems - User Guide No. 3 from the publications link.

6.5 Cable Gland Plates Removal and Installation Guidelines
Removal of gland plates is necessary to complete output power cable installation. Gland plates
are attached to the drive enclosure and can be removed by unfastening the hardware.
Gland Plate Installation Preparation and Procedure:
1. Place the unfastened hardware in a safe place so that it may be easily located when re-
installing the gland plates.
2. Verify that the gland plates have a rubber gasket seal (prevents weather ingress) located
on the inside of the plate.
3. If cable size permits, make holes for drilling cable entries.
4. Do not drill the gland plate while it is still mounted to the enclosure.

NOTICE
Gland Plate Drilling
Do not drill the gland plate while it is mounted to the enclosure.
Drilling the plate while it is mounted leads to metal dust accumulation on sensitive electronics
that are located inside of the unit, which may cause loss of component integrity and possibly
affect system operability.

Gland Plate Drilling Guidelines
1. Take care not to damage the rubber gasket seal material during the drilling process.
2. Fit the cable entries with rubber gasket material to form a proper seal.
3. Ensure that gland plates are properly fastened to the drive with the original hardware.
4. Be sure to check the integrity of the rubber gasket seal prior to installing the gland plate.
6.5 Cable Gland Plates Removal and Installation Guidelines
6.6 Circuit Breaker (provided by the customer)
To ensure adequate protection for VFDs, the circuit breaker provided by the customer must
fulfill the following requirements:
The maximum time between when the circuit breaker trips, to when a no-current state (I=0)
is reached, is 100 ms.
The circuit breaker must be equipped with an undervoltage tripping function.
There must be a check-back signal for the circuit breaker states CLOSED and OPEN. The
check-back signals must not be delayed, i.e. they must not be carried via coupling relays.
The circuit breaker is activated and enabled by the VFD closed-loop controller. It must never
be switched on by electrical or external mechanical means without having been enabled.
An overcurrent protection device is provided to protect the VFD transformer.
6.6 Circuit Breaker (provided by the customer)
Commissioning
7

When commissioning the drive, be sure to read and understand all safety warnings as detailed
in the Safety Notes chapter. Obey all warnings and safety material presented in each chapter.

DANGER
Potential for Drive Damage, Serious Injury or Death
Improperly commissioning the drive can cause damage to property, serious injury, and
possible death.
Only qualified service personnel are permitted to commission a Perfect Harmony drive.

Refer to the WCIII Cooling System manual supplied along with this manual for cooling system
related commissioning information.
ln addition, refer to the WCIII Commissioning manual supplied at the conclusion of the
commissioning process.

Note
Contact Siemens customer service for commissioning documentation.

See also
7.1 Residual Current Device (RCD) Compatibility

CAUTION
RCD Incompatibility
Connecting this device to a power supply protected by a residual-current device can result
in damage to property and minor personal injury.
This product can produce a DC current in the grounding conductor.
When using a Residual Current Device (RCD) in cases where direct or indirect contact can
be made, only a Type-B RCD shall be permissible on the line side of this product. If this is
not possible, an alternative means of protection must be applied. Isolation from the
environment through double or reinforced insulation, or isolation from the power supply using
a transformer, is an example of alternative means of protection.


Note
The master mechanical interlock key must be coordinated with the input voltage switchgear.

Commissioning
7.1 Residual Current Device (RCD) Compatibility
Operation
8

When operating the drive, be sure to read and understand all safety warnings as detailed in
the Safety Notes chapter. Obey all warnings and safety material presented in each chapter.

DANGER
Improperly operating the drive can cause damage to property, serious injury, and possible
death.
Only qualified service personnel are permitted to operate a Perfect Harmony drive.

Refer to the NXG Control Operating manual supplied along with this manual for operating
information and a complete listing of faults and alarms and unexpected output conditions to
use in troubleshooting.
ln addition, refer to the WCIII Cooling System manual supplied along with this manual for
cooling system related operating, and alarm and fault information.
See also

Control power must always be applied prior to application of medium voltage.

CAUTION
Active Cooling System
NEVER energize the drive without an active and fully functional cooling system (cooling
pumps and external and internal heat exchanger fans).
The drive contains components that have losses in the idle state. Without air flow, these
losses may heat and eventually damage components. The damaged components over time,
may cause the drive to become damaged as well.
Applying medium voltage without air flow will result in a trip from the coordinated input
protection scheme.


NOTICE
Addressing Faults
Ensure that all faults are properly addressed prior to application of medium voltage. Doing
so helps to ensure the drive runs efficiently.
In addition, ensure that control power is not removed while MV is applied. Failure to comply
with this may result in cell damage.

Operation
Maintenance
9

The Perfect Harmony drive is designed, built, and tested to provide long, trouble-free
service. Keeping the drive working reliably, minimizing system down time, and maintaining
safety, requires periodic maintenance.
Prior to performing any type of maintenance, be sure to read all relevant safety and product
information. Perform procedures as indicated. Refer to the Safety Notes chapter in this manual.

DANGER
Electrical Hazard!
Handling the equipment with main input power connected will cause death or severe injuries.
Always switch off the main input power to the equipment before attempting inspection or
maintenance procedure.

WARNING
Only qualified service personnel are permitted to maintain Perfect Harmony equipment
and systems.
Failure to use qualified personnel may result in damage to property, serious injury, and
possible death.

Refer to Appendix Service and Support for customer service contact information.
See also
Service and Support (Page 125)
9.1 Door Access

The drive can be locked either mechanically or electromechanically.
Opening the Power Unit Doors
The doors must not be opened until the following statuses are present:
The DC link voltage has been de-energized:
DC bus voltage indicator LED, located on the front of each cell's cell control board, must
NOT be illuminated. An illuminated DC bus voltage indicator LED shows that more than
50 VDC

is present on the DC bus. This indicator light may not be visible until the cell
doors are opened.
Do not touch, remove or service the cell if the indicator is illuminated.
The EMERGENCY-OFF switch on the cabinet has been activated.
9.1.1 Mechanical Interlock System
The doors can also be protected using a key transfer system.
Once the primary-side (customer) circuit breaker has opened, a coded key for enabling the
key in the key transfer unit can be removed.
Operation
1. Switch off the primary-side (customer) circuit breaker.
2. The coded key for the key transfer unit, which is in the circuit breaker, can now be removed.
3. Use the key to unlock the keys in the key transfer unit.
4. Remove the keys and release the locks on the cabinet doors.

Note
Closing the Circuit Breaker
The circuit breaker cannot be closed again until the keys have been returned to the key
transfer unit, the key transfer unit has been locked, and the coded key is back in the circuit
breaker.

9.2 Preventive Maintenance

The purpose of an inspection is to ascertain and evaluate the current status of the equipment.
An inspection mainly comprises visual checks. Inspections should be carried out based on a
schedule that meets the needs of the special ambient conditions at the site of installation. The
following servicing and inspection instructions are used as the basis for regular inspection of
the equipment.
9.2.1 Six Month Inspection
Perform visual inspections as indicated for specific site installation requirements. Siemens
recommends doing so every six months.
Maintenance
The basic equipment required for a visual inspection is a mirror and a flashlight.
Inspect the following:
1. Check operation of fans in the top portion of the cell cabinet.
2. Check door filters on the control cabinet and the pump cabinet. Replace if necessary.
3. Inspect cooling system for leaks. Repair or replace components as necessary.
4. Use touch-up paint, as needed, on any rusty or exposed parts on the cabinet enclosure.
5. Test coolant for presence of required glycol concentration. Refer to Appendix Technical
Data of this manual.

Note
A minimum of 5% Glycol concentration by weight is recommended to control bacteria.

6. Check for contamination and dirt damage.

NOTICE
Contamination and dirt can damage the device.
For levels of contamination falling within the specifications specific to your site, perform
a visual inspection once a year, taking into account specified ambient conditions.
Depending on ambient conditions, visual inspections may need to be performed on a more
frequent basis.

Component Comments
Insulating clearances Slight, dry, non-conducting contamination is permitted.
Contamination caused by dust in conjunction with high relative humidity
must be removed. In particular the surfaces of the ceramic
semiconductors and the support insulators must be clean and dry.
Air filter Check the air filters in the cabinet doors for contamination.
7. Check electrical connections and fiber-optic connections
Component Comments
Contacts Carry out a visual inspection of the contacts to check that they are
seated correctly and not corroded.

Note
Fiber-Optic Conductors for Gating Boards
The fiber-optic conductors for the gating boards must be properly inserted in the
connectors.

Maintenance
9.2.2 Preventive Maintenance Checklist
Use the following table as a guide for performing preventive maintenance tasks.
Maintenance Frequency Comments
Clean the cabinet (exterior). As required Visual check, clean if required.
Clean the cabinet (interior). Annually Visual check, clean if required.
Check the electrical connections
(external power and test
connections) and check the cable/
screw terminals.
After 1 year
and then every 6 months or as needed
Check the cable and screw terminals
regularly to ensure that they are secure. If
they are not secure, tighten them according
to specifications.
Check the internal connections. After 1 year
and then every 6 months or as needed
Visual check, clean if required.
Carry out inspection and visual
check.
Annually See the specifications in the operating
manual.
Visually inspect the insulation. Annually
Cooling system related tasks. Refer to the WCIII Cooling System manual for cooling system related preventive
maintenance tasks.
9.3 Cleaning
9.3.1 Contact for Cleaning Measures
If contamination occurs, contact Siemens customer service. Refer to Appendix Service and
Support.

Note
Proper Cleaning Agents
Be sure to use cleaning agents that do not cause corrosion. Using cleaning agents that may
cause corrosion can produce unwanted equipment damage.

See also
9.3.2 Removing Dust Deposits
Dust Deposits
Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once a
year) by qualified personnel in line with the relevant safety regulations.
Maintenance
9.3 Cleaning
The unit must be cleaned using a brush and vacuum cleaner, and dry compressed air (max.
1 bar) for areas that cannot be easily reached.
Ventilation
The ventilation openings in the cabinet must never be obstructed. The fan must be checked
to make sure that it is functioning correctly.
Cable and Terminal-Screws
Check the cable and terminal-screws regularly to ensure that they are secure. Tighten them
if necessary.
Check the cabling for defects
Replace any defective parts immediately.

Note
The actual intervals at which maintenance procedures are to be performed depend on the
installation conditions (cabinet environment) and the operating conditions.
Siemens offers its customers support in the form of a service contract. For further details,
contact your regional office or sales office.

9.4 Repair and Replace
9.4.1 Safety-relevant Checks

WARNING
Visual Check of Cable Insulation
Improperly laid or damaged cables and incorrectly attached cable shieldings can heat up in
places and cause fires or short-circuits wherever they make contact.
Make sure that the cable shields are intact and insulate any that are damaged.
Make sure that a short-circuit cannot occur on the power cables due to failure of the
insulation as a result of incorrect cable installation.

Note
Component Replacement
Unless otherwise indicated by Siemens, always replace components with the same part
number and revision level.

Maintenance

Note
Drive Failure
When the power supply is switched off, data about error message statuses is lost.
Inadequate diagnostic and error rectification measures can result in damage to the Drive.
For additional technical support, please contact the Siemens Service Center.

Note
Door Interlock Failure
Please contact Siemens Service Center for technical support.

See also
9.4.2 Maintenance and Earthing Procedure

WARNING
Qualified Personnel Only
Due to the modularity of the Perfect Harmony VFD design, the maintenance and earthing
procedure does not cover all variations of equipment types or installations.
Siemens strongly recommends that only qualified personnel be allowed to perform
maintenance on Perfect Harmony Systems.

1. Stop drive operation, either through remote or local controls.
2. De-energize input voltage by opening incoming switchgear and locking to OPEN position
with mechanical interlock. Apply lock-out/tag-out principles as required by local code.
3. De-energize control voltages for synchronous motor field/exciter controls.
4. If applicable, close all make-proof grounding switches and lock into the CLOSE position. If
make-proof grounding is not available, check connection points with a non-contact voltage
probe and apply green/yellow insulated ground cables from L1/L2/L3 and T1/T2/T3 to
protective earth (PE).
Maintenance
5. Wait ten minutes to allow stored energy to dissipate from the drive.

WARNING
Discharging Resistors
The power cells include discharge resistors to dissipate stored energy after the input
voltage is removed. The power cell DC bus voltage decays to less than 50 VDC in less
than 10 minutes.
Ensure you follow all safety precautions to avoid risk of death, serious personal injury,
and equipment damage.

6. Use correct PPE, electrical safety (rubber) gloves/leathers must be worn.
7. Open the cell cabinet door and visually inspect several cells to confirm the charging light
is off.
If any lights are on wait until they have gone out.
8. Proceed to open the hinged cover on the front of the cell to access the capacitor connection
points.
9. Set voltmeter to DC setting to >1000 VDC scale.
10.Identify connection points on the cell (shown in the following figure), and working with one
hand only, connect leads.
Figure 9-1 Meter Connection on Cell DC Bus
11.Verify the capacitor banks are fully discharged.
12.Perform maintenance as required.
Maintenance
13.Remove the grounding device.
14.Close the doors in reverse sequence, and replace interlock key into input switchgear.
9.4.3 Replacing Parts
Replacement of component parts may be the best method of troubleshooting when spare parts
are available. When any sub-assembly is to be replaced, always check that the part number
of the new unit matches that of the old unit (including the revision letter).

NOTICE
Proper Disposal of Failed Components
The disposal of any failed components (capacitors, etc.) must be done in accordance with
local codes and requirements.

Failures traced to individual PC boards within the control cabinet are best serviced by
replacement of the entire board.
Failures traced to individual power cells are best serviced by replacement of the entire cell.
Report power cell failures to Siemens customer service.
Perform yearly inspection of hoses after seven years of service and/or during maintenance
outages. The service life of hoses varies based upon a variety of circumstances including
but not limited to:
Type of hose
Amount of electrical voltage across hose
Exposure to UV light or chemical contaminants
System pressure transients (pump switchovers, pressure testing, hours of operation,
etc.)
Mechanical stress (cable ties, clamps, walked on, vibration, etc.)
Exposure to high temperatures
Immediately address an indication of hose damage, such as cracking, bulging,
embrittlement or discoloration. Siemens recommends that all hoses within the drive be
replaced if any hose has indications of damage.
Deionizer Tank Replacement
The coolant conductivity High Alarm level is customer-programmable, with factory default at
1 microSiemens/cm. The coolant conductivity High-High Alarm level is fixed at 5 microSiemens/
cm.
Replace the deionizer tank with a new (fully charged) unit once conductivity exceeds
5 microSiemens/cm.
Refer to Section Deionizer Tank of the WCIII Cooling System manual for deionizer tank
description and the tank replacement procedure.
Maintenance
9.4.4 Replacing the Door-mounted Keypad
To replace the door-mounted keypad:
1. Switch off the main circuit breaker.
2. Open the cabinet.
3. Remove the Macrolon cover.
4. Disconnect the ribbon cable at J2 from the keypad.
5. Unscrew the four hexagon-head screws.
6. Pull the keypad out to the front.
7. Fit a new keypad.
8. Screw in the four hexagon-head screws.
9. Reconnect the ribbon cable at J2 on the keypad.
10.Reattach the Macrolon cover.
Maintenance
9.4.5 Replacing the CompactFlash Card
Copy the stored data of the old CompactFlash card to the new original Siemens card. Refer
to the following figure.
Flash Disk
Figure 9-2 Location of CompactFlash card on the NXGII Microprocessor Board
Perform the following steps to replace the CompactFlash card.
1. Remove the fiber-optic link from the fiber-optic control board.
2. Remove the enclosure cover from the NXGII card rack.
3. Remove the power cable and the SUB-D cable.
4. Loosen the fastener screw on the card.
5. Withdraw the card from the NXGII card rack.
6. Remove the old Compact Flash card.
7. Insert the new Siemens CompactFlash card.
8. Reinsert the card back into the NXGII card rack.
9. Retighten the fastener screw on the card.
10.Reconnect the power cable and the SUB-D cable.
Maintenance
11.Reattach the enclosure cover to the NXGII card rack.
12.Reconnect the fiber-optic link to the fiber-optic control board.
9.4.6 Replacing Cell Input Power Fuses
Currently, the approved fuse sources are Ferraz and Bussmann (additional vendors may be
added at a later date). Only two phases of each transformer secondary (power cell input) are
fused.
Blown Cell Input Power Fuse Indicator
Each fuse has visual blown indication, making it easy to diagnose a fuses condition. Refer to
the following figures for the locations of the fuse indicator for each manufacturer.
On the Bussmann fuse, the blown fuse indicator is located on the right side of the fuse
when viewed from the front of the cabinet.
Figure 9-3 Bussmann Blown Fuse Indicator
On the Ferraz Shawmut fuse, the blown fuse indicator is located on the top of the fuse as
installed.
Figure 9-4 Ferraz Blown Fuse Indicator
Maintenance
Cell Input Power Fuse Replacement Procedure
To replace an open cell input fuse:
1. Power down the system, following the standard shut-down procedure and obeying all
standard electrical and safety instructions. Refer to Section Maintenance and Earthing
Procedure in this chapter.
2. Open the doors to access the cell input fuse section.

Note
This section varies based on the drive output voltage and cell size. Reference the
customer specific documentation to locate the cell input fuse.

3. Use an appropriately sized AC voltage detector to ensure that the power is removed.

WARNING
Electrical Hazard
The secondary rating of a WCIII transformer to the input of the cell power fuse is 750 VAC.
Qualified personnel must obey all safety precautions.
Risk of death, serious personal injury, and equipment damage can occur.

4. Use the appropriate tools to remove the bolts holding the power bus.
5. Remove the open fuse and replace with a spare cell input power fuse.
6. Reconnect the bus and apply a new torque mark to the bolt.

Note
Torque the hardware per Section Electrical Requirements in Chapter Electrical
Connections of this manual.

See also
Maintenance and Earthing Procedure (Page 68)
Electrical Requirements (Page 51)
9.4.7 Replacing Printed Circuit Boards (PCBs)
Follow the procedures as indicated in the following sections when replacing PCB(s) on the:
Digital card rack
Signal conditioning board
I/O breakout board
Maintenance
Digital Card Rack
2. Use an appropriately sized AC voltage detector to ensure all power is removed to the NXG
Control.

Note
The drive can accommodate up to a 240 VAC power for the NXG Control.

3. Prior to servicing any printed circuit board (PCB), ensure proper ESD protection is followed.
All circuit boards shipped by Siemens are done so in an ESD protective bag. They must
stay inside this bag during transport and storage. They can only be removed after placing
the bag on a dissipative ESD workbench surface.
Before removal from the ESD protective bag, the personnel handling the PCB must be
properly grounded. Proper grounding is accomplished by using a heel grounder on a
dissipative floor surface or a wrist strap connected to a proper ground.

Note
ESD sensitive components can be identified by symbols being present on the
component or the component packaging.

Maintenance
4. The NXG Control has a digital card rack with 8 slots and is mounted within the respective
control tub. The following PCB locations, from right to left when facing the unit, are within
the digital card rack:
Slot 1: Keypad interface board
Slot 2: Single board computer (CPU) board
Slot 3: BGA digital modulator board
Slot 4: Fiber optic interface board (6600 V and 10000 V unit only)
Slot 5: DB37 connector
Slot 6: System I/O board
Slot 7: DB50 connector
Slot 8: Communication board with up to two Anybus modules.
Maintenance
BGA digital modulator board
To breakout board
To signal conditioning board
To breakout board
Communications board
System l/O board
Anybus
modules
Keypad adapter
board
Fiber optic interface
board
New microprocessor board
New power supply
Figure 9-5 NXGII Master Control Chassis
5. Identify which board requires service, and disconnect all connections to that specific board.
The board may include fiber optic cables, 50 pin connectors, 37 pin connectors, ribbon
cables, and a wire harness.
6. Use a Phillips-head screwdriver to remove the screws holding the PCB into the ISA bus on
the backplane. Remove the PCB.

Note
Slide the PCB slowly out of the DCR being sure not to bend the board.

Maintenance
7. Install the spare PCB.

Note
Slide PCB into slot and be sure it seeds in the backplane firmly being careful not to bend
the board.

8. Replace all of the removed screws, connectors, and cables.

Note
It is imperative that fiber optic connectors are installed back into their original location.
Failure to do so may lead to catastrophic damage. Validation can be performed using an
external light source and checking both ends of the fiber for transmission.
The system I/O Board has two 50 pin cables tied to it. Care needs to be taken to ensure
proper reconnection. Catastrophic damage may occur if improperly connected.

9. Place the removed PCB into the empty ESD protective bag if the PCB is being returned to
Siemens for analysis.
Signal Conditioning Board and I/O Breakout Board
2. Power down all low voltage feeds (24 V-690 V) to the drive.

Note
Low voltage feeds vary per customer design. Reference the customer specific
documentation to identify all low voltage feeds.

3. Use an appropriately sized AC voltage detector to ensure all power is removed to the NXG
Control.

Note
The drive can accommodate up to a 240 VAC power for the NXG Control.

Maintenance
4. Prior to servicing any printed circuit board (PCB), ensure proper ESD protection is followed.
All circuit boards shipped by Siemens are done so in an ESD protective bag. They must
stay inside this bag during transport and storage. They can only be removed after placing
the bag on a dissipative ESD workbench surface.
Before removal from the ESD protective bag, the personnel handling the PCB must be
properly grounded. Proper grounding is accomplished by using a heel grounder on a
dissipative floor surface or a wrist strap connected to a proper ground.

Note
ESD sensitive components can be identified by symbols being present on the
component or the component packaging.

5. The Signal Conditioning Board (SCB) and the I/O Breakout Board (IOB) are din-rail
mounted within the respective control tub.

Note
Reference the customer specific documentation to identify the location of the Signal
Conditioning Board (SCB) or the I/O Breakout Board (IOB).

6. Identify which board requires service and disconnect all connections to that specific board.
The board may include 50 pin connectors, 37 pin connectors, ribbon cables, a wire harness,
and single control wire connections.

Note
All control wire terminations require a flat-head screwdriver for removal.

7. Use a flat-head screwdriver to depress the two tabs on the board for removal of the PCB
from the din-rail.
8. Install the spare PCB on the din-rail.
9. Replace all of the removed connectors, ribbon cables, and wire harnesses.
10.Place the removed PCB into the empty ESD protective bag if the PCB is being returned to
Siemens for analysis.
See also
Maintenance
9.5 Power Cell Removal

This section provides the instructions to remove a power cell from the cell cabinet for
troubleshooting, maintenance, or return for repair, in the following subsections:
Isolating and positioning of power cell
Purging power cell
Removing and transporting power cell
Preparing banding for power cell
Banding and crating of power cell

CAUTION
Avoid personal injury
Workers must always wear proper Personal Protective Equipment (PPE) electrical safety
gloves, safety shoes (composite or steel toe with an electrical hazard rating), and safety
glasses whenever performing the procedures in this chapter.

9.5.1 Isolating and Positioning of Power Cell

DANGER
Lethal Voltages
Possible death, serious injury to personnel and damage to equipment is possible.
Ensure the system is electrically isolated and no hazardous voltages are present before
proceeding. This applies only to power cells still located in the drive unit compartment.

To remove a WCIII power cell from the cell cabinet, the cell chassis must be disconnected
from its integral capacitor bank located below the cell chassis. The power cell has a three-
phase nominal 750 VAC input which produces a nominal DC bus voltage, (+) to (-) across the
capacitor bank, of 1,060 VDC.
Even after waiting ten minutes and observing that the DC bus voltage-indicator LED on the
front of the power cell is extinguished, never assume that the capacitor bank is completely
Maintenance
discharged. A residual charge may still be present on the DC bus (across the capacitor bank).
To prevent a shock hazard take a reading to assure not residual charge is present.

DANGER
Lethal Voltages
The cell should not be touched, removed, or serviced if the indicator is illuminated.
The cell chassis is not grounded and when energized can float to lethal voltages. Touching
the ungrounded chassis will result in death and damage to equipment.

WARNING
Existing Voltage May Still Be Present
A DC bus voltage-indicator LED on the front of the power cell that is not extinguished indicates
that power is present.
Even if the LED is extinguished, voltage may still be present and must be checked with an
appropriately sized multimeter.
The power cells include discharge resistors to dissipate stored energy after the input voltage
is removed. The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes
Connecting a temporary grounding cable to the exterior metal case of the power cell that still
has voltage present, can cause personal injury and damage to the equipment.

1. Power down the WCIII System, obeying all standard electrical and safety instructions. Refer
to the Section Maintenance and Earthing Procedure located in this chapter of the manual.
2. Open the doors to access the power cells.
3. Make sure that the DC bus LED is unlit.
4. Be sure to wear Cat 1 gloves.
5. Open the access panel and verify with a multimeter that the DC bus is less than 10 VDC
before removing capacitor bolts.
6. Remove all of the DC bus capacitor bolts.

CAUTION
Stop both pumps before removing the power cell hose!
Lines are pressurized.

7. When the power cell is fully de-energized and all electrical hazards have been isolated,
disconnect the hose connections from the supply and return ports of the power cell.
8. Remove the fiber optic communications cable to the power cell control board. Ensure the
fiber optic communications cable is secured away from the path of the cell to be removed
to avoid the possibility of damage to the fiber.
Maintenance
9. Next, pull the power cell out to the first removal position in the drive unit compartment (refer
to below figure). This is done by pulling the right and left side edge of the power cell, while
lifting the cell out of the locking tabs and pulling until the cell is disengaged from the rear
power stab connections.

NOTICE
While sliding the power cell forward on the guide rail, use extra caution to avoid damage
to the DC bus insulation along the bottom edge of the cell frame.
After the cells have been removed, visually inspect the DC Bus insulation to ensure there
has been no damage.

1
Danger DC Bus light
2
DC Bus measurement: Place meter leads of a properly rated and scaled voltmeter between
the top plate and the center terminal, being careful not to inadvertently short the center
terminal to the top plate, with the meter leads.
3
Label: DANGER! High Energy Filter. Do not disconnect bolts until DC Voltage is less than
10 V.
Figure 9-6 Power Cell pulled out to First Removal Position
10.Proceed to the Purging Power Cell Section.
See also
9.5.2 Purging Power Cell

NOTICE
All coolant must be purged from power cell prior to shipping.

Materials Required
Prior to purging coolant from the power cell, obtain the following items:
Maintenance
Cell Water Purge Kit P/n A5E02240940 containing two 3-foot lengths of silicone hose with
a colder coupling receptacle installed on one end of each hose. One hose has a hose clamp
on the opposite end of the hose, to be used for attaching the low pressure air source. Refer
to Figure Cell Water Purge Kit.
1
One hose clamp to connect low pressure air source.
2
Colder coupling receptacles at one end of each hose.
Figure 9-7 Cell Water Purge Kit
One large bucket or retainer is needed to collect the coolant. Refer to Figure Bucket
Positioned Under Hose End to Collect Fluids.
Material Safety Data Sheet (MSDS) for glycol prior to connecting hoses and draining liquids.
Safety Data for Polypropylene and Ethyl Glycol*
Toxicology Harmful if swallowed. May be harmful by inhalation or in contact with the skin.
May act as skin and respiratory irritant. Severe eye irritant. Reproductive
hazard.
Transport Information Non-hazardous for air, sea and road freight.
Personal Protection Safety glasses, rubber gloves, adequate ventilation
This information is provided to help you work safely, but is not intended to be used in place of a full
MSDS. Obtain the proper MSDS from site safety or download it from the internet.
Procedure
With the power cell de-energized and pulled out to the first removal position, drain the power
cell by completing the following steps:
Maintenance
1. Place bucket under hose prior to connecting to supply/return port.

CAUTION
Avoid Spillage
Place bucket under hose prior to connecting to supply/return port to avoid spillage.
Some drainage may occur due to gravitational flow.

Figure 9-8 Bucket positioned under Hose End to collect fluids
2. Connect one cell water purge kit hose to either the supply or return port while keeping the
bucket positioned under the hose end. When the power cell has been disconnected, either
the supply or return port can be used for the pressure input and/or drainage.

CAUTION
Glycol must be treated as a hazardous waste material.
Do not discard glycol into waste drains or on the ground.
For power cells containing any form of glycol, ALWAYS follow site safety and applicable
MSDS requirements for proper handling and disposal of these liquids.

1
Return
2
Supply
3
Press and push
Figure 9-9 Inserting Cell Water Purge Kit Hoses to Supply and Return Ports (Snap-on) to drain
liquids
3. Locate a low pressure ( 20 psi recommended) air source (instrument air, nitrogen) to be
used to purge fluids from the power cell.
4. Secure the low pressure air source to the remaining cell water purge kit hose, using hose
clamp for connection (refer to insert in Figure Cell Water Purge Kit).
Maintenance
5. Connect the second silicone hose from the kit with the low pressure air source, to remaining
supply/return port.

CAUTION
Avoid Splashing
Slowly apply low pressure air to avoid splashing of liquid while discharging fluids into
bucket.

6. Proceed until discharge flow of liquid is no longer visible.

NOTICE
Do not reuse contaminated fluids.
Discard per MSDS requirements.

7. Remove and bag the cell water purge kit hoses.
8. Proceed to the Removing and Transporting Power Cell Section.
9.5.3 Removing and Transporting Power Cell
1. Place cell lifter in front of power cell to be removed.
2. Raise up the cell lifter until the rollers touch the bottom of the power cell.

CAUTION
Avoid Personal Injury
Serious injury to personnel and damage to equipment is possible.
Prior to placing the power cell on the cell lifter the following safety precautions must be
observed:
Ensure that cell lifter manual parking brake is in the locked position.
Ensure cell lifting device upper roller bar is installed with locking pins inserted.
Verify that lower slide rail is extended away from upper roller bar.

3. Raise the power cell approximately 1/8 inches so that the cell lifter is supporting the weight
of the front of the cell.
Maintenance
4. Slide the power cell completely out of the cabinet and onto the cell lifter (refer to the following
figure).
Figure 9-10 Power Cell Correct Position on Cell Lifter

NOTICE
Avoid Damage to Insulation Material
When handling or removing the power cell, take care not to damage the Valox FR-1
thermoplastic dielectric insulation material located as shown in the below figure. The Valox
film provides an insulation barrier between the dielectric material between the plates on
the capacitor bus.
The thin membrane of the material must not come into contact with the transport device,
cell lifter, pallet, or technicians hands.
Preventing damage to this material reduces replacement cost and repair time. If the
insulation becomes damaged the power cell should be returned to Siemens for
replacement.

1
Valox insulation material located around DC Bus capacitor bolts.
2
Valox insulation material located at bottom of power cell.
Figure 9-11 Valox Insulation Locations
5. Secure power cell onto the cell lifter using the front and rear locking pins.
Maintenance
6. Transport the power cell to the staging area for banding and crating using the cell lifter or
move the power cell from the cell lifter to an appropriate transportation device, such as
utility cart as shown below.

1
Power cell on cell lifter.
2
Power cell on utility cart.
Figure 9-12 Methods for Transporting Power Cell
7. Proceed to the Preparing Banding for Power Cell Section.
9.5.4 Preparing Banding for Power Cell
Materials Required
Large pallet (wood, plastic, fiberglass, etc.), large enough to accommodate two power cells.
Refer to Figure Wooden Pallet.
Cardboard. Refer to Figure Covering Pallet with Cardboard.
Crane or other lifting device (optional)
Lifting hooks and lanyards/straps (optional)
Banding tool and banding material. Refer to Figure Typical Banding Tool in next section.

NOTICE
Do not use steel banding.
Steel bands can deform the exterior casing of the power cell.

Maintenance
Power Cell Lifting and Positioning Procedure
1. Ensure that area is clear of any debris or obstructions to avoid tripping.
2. Place pallet on a level surface as shown in the following figure.
Figure 9-13 Wooden Pallet
3. Cover pallet with cardboard to protect painted surface of power cell as shown in the
following figure.
Figure 9-14 Covering Pallet with Cardboard

CAUTION
Exercise Caution Lifting Power Cell
A power cell transported by either a cell lifter or transportation device must be rotated 180
degrees, with the bottom (metallic side) facing up for shipment.
Two technicians are required to rotate the power cell by hand (refer to Figure Preparing
Power Cell for Lifting).
The unit is extremely heavy and must be lifted using extreme caution to avoid damage or
injury.

4. Each technician should stand at opposite ends of the power cell as shown in following figure.
Maintenance
5. In unison, slowly roll the power cell 180 degrees until fully resting on top (painted surface)
using caution not to damage the Valox insulation material or dent/scratch the outside panel.
Turn power cell
1
4 3
2
Figure 9-15 Preparing Power Cell for Lifting
6. Place lifting lanyards through the lifting brackets located on the bottom side of the power
cell as shown in following figure.
1
Lifting bracket locations
Figure 9-16 Lacing Lifting Lanyards through Lifting Brackets
Power Cell is ready to be lifted.
Maintenance
7. Slowly and carefully lift, move, and lower the power cell onto the pallet as shown in following
figure.
Figure 9-17 Positioning Power Cell on Pallet
8. Remove the lifting lanyards once the power cell is placed into position.

Note
Repeat all previous sections/steps for the second power cell, prior to banding/crating.
Only two power cells can be crated on one pallet.

9. Proceed to the Banding and Crating of Power Cell Section.
Maintenance
9.5.5 Banding and Crating of Power Cell
1. Prior to placing a second power cell beside the first power cell, ensure a Styrofoam spacer
and cardboard corner protectors are placed along the outer edge of both power cells. Refer
to the following figures.

NOTICE
Do not exceed number of power cells on pallet.
Limit of two power cells per pallet only.

1
Styrofoam spacer location
Figure 9-18 Styrofoam Spacer between Power Cells
Figure 9-19 Power Cells with Cardboard Corner Protectors
2. Lace the banding material through the pallet and back through the lifting brackets of both
power cells as shown in the following figure.

1
Lacing banding material through wooden pallet.
2
Lacing banding material through lifting brackets.
Figure 9-20 Lacing the Banding Material
Maintenance
3. Continue banding power cells to pallet using the instructions provided with the type of
banding tool and material used. A typical banding tool is shown in the following figure.
Figure 9-21 Typical Banding Tool
4. After completing Step 2 and Step 3, continue with application of the second band.
5. Lace the second band through the pallet as done with the first band, then bring the band
around the power cell just in front of lifting brackets. Final installation of both bands should
look like the power cells shown in the following figure.

1
Styrofoam insulation between cells.
2
Cardboard corner protectors placed under bands.
3
First band placed in front of lifting brackets.
4
Second band placed in front of lifting brackets.
Figure 9-22 Properly Banded Power Cells
6. Power cells are ready for crating.
Maintenance
7. Build a sturdy crate around the power cells, using wooden boards (2 x 4 or 1 x 3) and
cardboard sheets as shown in the following figure.
Figure 9-23 Crate built to ship Power Cells
8. The power cell(s) is ready for return to Siemens.
9.6 Power Cell Installation

This section provides the instructions to install a power cell, in the following subsections:
Prerequisites for installing power cell
Transporting power cell via cell lifter
Transporting power cell via transportation device
Inserting power cell

CAUTION
Workers must always wear proper Personal Protective Equipment (PPE) electrical safety
gloves, safety shoes (composite or steel toe with an electrical hazard rating), and safety
glasses whenever performing the procedures in this chapter.

Maintenance
9.6.1 Prerequisites for Installing Power Cell
Prior to installing a power cell, perform the following steps:
1. Remove power cells from shipping crate. Carefully remove crating material and all packing
materials. Using caution cut and remove banding material around power cells using the
proper cutting tool. Refer to the following figure.

CAUTION
Wear proper work gloves and safety glasses when cutting and removing banding material
from around power cells.

1
Banding to be removed
Figure 9-24 New Power Cells
2. Visually inspect the new power cells for any damage that may have occurred during
shipment.

Note
Record any damage found in writing and with photos.

Maintenance
3. Prior to placing the power cell on a transportation device such as a utility cart, place pre-
cut 2 x 4 plywood boards on top of the utility cart to prevent damage to insulation material
on the bottom of the power cell, as shown in the following figure.
Figure 9-25 Utility Cart with Plywood Boards placed on top
4. The power cell is ready to be placed on the transportation device or a cell lifter.
1
Cell lifting device
Figure 9-26 Hydraulic Cell Lifter with Lifting Device
Maintenance
5. The power cell is shipped with the top of the cell resting on a wooden pallet, as shown in
the following figure. When lifting the power cell for transport, the power cell must be rotated
180 degrees forward (bottom of cell to be facing floor).
Rotate power cell
forward 180 degrees
Figure 9-27 Rotating Power Cell Forward for Loading
6. Proceed to Transporting Power Cell via Cell Lifter Section to transport cell via cell lifter.
Proceed to Transporting Power Cell via Transportation Device Section to transport cell via
transportation device.
See also
Transporting Power Cell via Cell Lifter (Page 96)
Transporting Power Cell via Transportation Device (Page 100)
9.6.2 Transporting Power Cell via Cell Lifter
The following procedure is to load a power cell onto a cell lifter in the side-lift position only. A
power cell can also be transported in the front-lift position.

CAUTION
Avoid Personal Injury
Serious injury to personnel and damage to equipment is possible.
Prior to placing the power cell on the cell lifter the following safety precautions must be
observed, as shown in the figures that follow:
Ensure that cell lifter manual parking brake is in the locked position.
Ensure cell lifting device upper roller bar is installed with locking pins inserted.
Verify that lower slide rail is extended away from upper roller bar.

Maintenance
Press pedal to
lock brake
Figure 9-28 Cell Lifter Manual Brake in Locked Position
1
Locations to insert locking pins
Figure 9-29 Cell Lifting Device Upper Roller Bar Installed with Locking Pins
1
Slide lower rail to forward position
Figure 9-30 Slide Rail Positioned Away from Upper Roller Bar to Accommodate Power Cell
Maintenance
1. Place power cell onto cell lifter by placing front flange of power cell in slide rail guides while
gently setting the rear of power cell on the upper roller bar rollers. Refer to the following
figure.
Figure 9-31 Power Cell Front Flange Positioned in Guides on Cell Lifter Slide Rail

NOTICE
When handling or removing the power cell, take care not to damage the Valox FR-1
the capacitor bus.
replacement.

1
Valox insulation material locations
2. Position the slide rail forward until the rail comes in contact with the front stops. Insert locking
pin for safe transport, as shown in the following figure.
Maintenance
Figure 9-33 Slide Rail Locking Pin Inserted
3. The power cell is ready for transport. Refer to the following figure.

1
Rear
2
Front
3
Upper roller rail
4
Lower slide rail
Figure 9-34 Power Cell Properly Positioned on Cell Lifter for Installation or Transport
4. Release the cell lifter manual brake to transport the power cell as shown in the following
figure.

NOTICE
Prevent Damage to Power Cell
When transporting power cell via cell lifter, always keep one hand on the component to
prevent it from tipping or falling off the lifter.

1
Press release lever to release manual brake.
Figure 9-35 Cell Lifter Manual Brake Release Position
5. Proceed to Inserting Power Cell Section.
Maintenance
9.6.3 Transporting Power Cell via Transportation Device
The following procedure is to load a power cell onto a transportation device.

NOTICE
Prior to placing the power cell on a transportation device, place pre-cut 2 x 4 plywood boards
on top of the utility cart to prevent damage to insulation on the bottom of the power cell as
shown in Figure Utility Cart with Plywood Boards placed on top.

CAUTION
Exercise Caution Lifting Power Cell
Two technicians are required to lift and place power cell onto the transportation device due
to the weight and size of the component.
The unit is extremely heavy and must be lifted using extreme caution to avoid damage or
injury.
Observe safety rules for bending and lifting heavy objects. Always avoid pinch points.

1. If available engage the manual brake to lock the wheels of the transportation device prior
to loading the power cell.
2. If a manual brake is not available, two technicians must carefully walk the power cell into
position on the transportation device/utility cart. Carefully place the unit face down onto the
2 x 4 boards as shown in the following figure.
3. Ensure that power cell is securely resting on the transportation device to prevent damage
due to tipping. If the power cell is to be stored on the cart for any duration, secure the power
cell to the transportation device with banding material.
Maintenance
100 Manual, AA, A5E32043214A
4. The power cell is ready for transporting with the transportation device as shown in the
following figure.

NOTICE
Prevent Damage to Power Cell
When transporting a power cell with a transportation device (utility cart), always keep one
hand on the component to prevent it from tipping or falling off the cart.
For best transport practice, secure the power cell to the cart with banding material before
moving it to the installation location.

Figure 9-36 Power Cell Ready to Transport
5. Proceed to Inserting Power Cell Section.
9.6.4 Inserting Power Cell

DANGER
Lethal Voltages
Possible death, serious injury to personnel and damage to equipment is possible.
Ensure the system is electrically isolated and no hazardous voltages are present before
proceeding. Ensure electrical power has been removed and the power cell has been isolated
per Section Isolating and Positioning of Power Cell.
Allow 15 minutes for the cell capacitor bank to bleed down after removal of input power.

1. If the power cell is located on a transportation device, transfer the unit to a cell lifter using
the procedure in Section Transporting Power Cell via Cell Lifter. Once the power cell is
secured on the cell lifter and VFD power has been electrically isolated you can proceed
with positioning the power cell for insertion into the capacitor bucket.
2. Verify location of capacitor bucket where power cell is to be inserted: Section A (Top),
Section B (Center), or Section C (Bottom).
3. Visually inspect the capacitor bucket for any loose parts (e.g. guide rails), bent bus stabs,
cables or water lines and debris that may impede installation.
Maintenance
Manual, AA, A5E32043214A 101
4. Push the cell lifter to the front of the capacitor bucket with the rear of the power cell facing
the capacitor bucket, then raise the cell lifter to the approximate height of the opening as
shown in the following figure.
Figure 9-37 Power Cell Aligned for insertion into Capacitor Bucket

NOTICE
To prevent damage to the Teflon insulation strips on top of the capacitor bucket guide
rails, position the power cell on the upper roller bar of the cell lifter device so that the
bottom of the power cell clears the Teflon insulation strips, as shown in the following figure.

1
Teflon insulation locations
Figure 9-38 Teflon Insulation Strip Locations on Top of Guide Rail in Capacitor Bucket
Maintenance
102 Manual, AA, A5E32043214A
5. Remove the cell lifter slide rail locking pin shown in the following figure.
Figure 9-39 Slide Rail Locking Pin Inserted
Maintenance
Manual, AA, A5E32043214A 103
6. Paying close attention to the alignment of the rear guide pins and capacitor bucket guide
rail, and side-to-side clearance, slowly push the power cell inward until the cell lifter slide
rail is aligned with the upper roller bar and power cell is in the correct position. Refer to the
following figures.

NOTICE
When inserting the power cell, verify the rear guide pins (on both sides of cell) are aligned
below the capacitor bucket guide rails, while ensuring the bottom of the cell does not make
contact with the Teflon insulation strips.

1
Guide pin locations
Figure 9-40 Guide Pins
Figure 9-41 Power Cell Positioned Corectly prior to removing Cell Lifter
Maintenance
104 Manual, AA, A5E32043214A
7. Remove cell lifter. Assure the power cell is locked in place on the guide rail with the guide
pins and slowly lower the cell lifter.

Note
If the power cell lowers with the cell lifter, raise the cell lifter and verify that the guide pins
are positioned properly.
Slowly lower the cell lifter until upper roller bar clears power cell, while verifying the power
cell remains stationary.

If the power cell is inserted in Section C (bottom) of enclosure, the upper roller bar must
first be removed from the cell lifter by pulling the locking pins and sliding out the upper roller
bar to allow for removal of cell lifter.
8. Once the cell lifter has been removed, slide the power cell into the capacitor bucket, while
verifying that the front guide pins on the bottom of the power cell are properly aligned below
the capacitor bucket guide rails flange.
9. Slowly push the power cell until the locking tabs prevent the power cell from moving farther
as shown in the following figure.
1
Locking tab (both sides) stops further insertion
2
Slot in bucket that accepts the locking tab (both sides)
Figure 9-42 Power Cell stopped by Locking Tab
10.Once the power cell is aligned correctly, it can be fully inserted by placing hands at the right
and left upper corners of the power cell as shown in the following figure.
Figure 9-43 Hand Position for Cell Insertion
Maintenance
Manual, AA, A5E32043214A 105
11.Firmly and simultaneously push up and in until the cell tabs on both sides are fully inserted
in the slots as shown in the following figure. If the cell tabs do not drop into position as
shown, stop and pull the power cell back out, and recheck the front and back guide pins
as shown in Step 8.

NOTICE
Avoid Damage to Components
If the power cell stops before both tabs (one on either side of cell) come into contact with
the guide rails on the capacitor bucket, this indicates the cell is not properly aligned or the
rear power bus stabs are bent or misaligned.
DO NOT FORCE the power cell into the capacitor bucket.
Pull the power cell back out to mid position and inspect for a problem, then attempt to
reinsert.

Left side of power cell Right side of power cell
1
1
1
Bottom tab is correctly inserted in slot (both sides)
Figure 9-44 Power Cell Fully Inserted
12.Once the power cell is fully inserted into the capacitor bucket, insert bolts with washers into
the tapped holes in the capacitor bank as shown in the following figure (eight bolts are used
for a 880A cell).
1
5/16" oversize flat washer
2
M8 x 14 mm bolt
3
5/16" split lock washer
Figure 9-45 Capacitor Bank Connections with Proper Hardware Arrangement
Maintenance
106 Manual, AA, A5E32043214A
13.Torque each capacitor connection as designated below:
P/N A1A099563 Capacitor (AVX): 75.6 in-lbs (8.5 N-m)
P/N A1A0100622 Capacitor (EPCOS): 88.8 in-lbs (10 N-m)
P/N A1A099181 Capacitor (NWL): 52.8 in-lbs (6 N-m).
If holes on the power cell do not align with the capacitor holes, loosen the capacitor
mounting bolts (see following figure) so that the holes can be aligned. Insert and torque all
connection bolts. After torquing connections, retighten capacitor mounting bolts.
1
Capacitor mounting bolt locations
Figure 9-46 Capacitor Mounting Bolts
Maintenance
Manual, AA, A5E32043214A 107
14.Perform visual inspection to verify that no tears, folds, or contamination has occurred to
the Valox insulation. Inspect the Valox insulation at the bottom edge of the capacitor bus
for damage. Refer to the following figures.

NOTICE
When handling or installing the power cell, take care not to damage the Valox FR-1
the capacitor bus.
replacement.

1
Valox insulation material located around DC Bus capacitor bolts.
2
Valox insulation material located at bottom of power cell.
15.Install capacitor bank cover plate as shown in the following figure.
Figure 9-48 Installing Capacitor Bank Cover Plate
Maintenance
108 Manual, AA, A5E32043214A
16.Install inlet and outlet (snap-on) water hoses to ports on the front of the power cell as shown
in the following figure.

1
Press and push
2
Outlet side
3
Inlet side
Figure 9-49 Inserting Inlet and Outlet (Snap-on) Water Hoses
Maintenance
Manual, AA, A5E32043214A 109
17.Connect the fiber optic plug-in connection to the link port on the front of the power cell as
shown in the following figure.
Figure 9-50 Fiber Optic Plug
18.The power cell is ready for operation.
Figure 9-51 Power Cell Ready for Operation
See also
Isolating and Positioning of Power Cell (Page 80)
Transporting Power Cell via Cell Lifter (Page 96)
Maintenance
110 Manual, AA, A5E32043214A
9.7 Cell Cabinet Construction and Maintenance
Silicone Hose and Clamps Maintenance
The WCIII system uses a Thermopol Type THH or Parker Type 6723 single ply silicone heater
hose.

NOTICE
Avoid Coolant Leakage
Coolant hoses are fastened to the power cell heat-sinks using a constant tension type hose
clamp. The clamps are torqued and marked at 27 in-lbs at the Siemens factory and require
no additional adjustment.
Tightening beyond the factory setting may result in coolant leakage.

Sub-Assemblies
The cell cabinet system consists of the following basic sub-assemblies:
Top hat air-to-water heat exchange system, as shown in Figure 9 Cell Cabinet with Front
and Top Blower Covers Removed (for service) and Figure 9 Cell Cabinet with Doors,
Blowers and HEX Removed.
Power cells, as shown in Figure 9 Cell Cabinet with Cells, Majority of Capacitors and
Capacitor Buckets Removed.
Rear panel assembly, as shown in Figure Bypass Contactor with T1-T2 Removed from
Rear Panel.
Bypass contactor assembly, as shown in Figure Bypass Contactor with T1-T2 Removed
from Rear Panel and Figure 12 Cell Cabinet with Rear Panel Removed and Bus Exposed.
Rear supply and return manifold sections, as shown in Figure 9 Cell Cabinet with Rear
Panels Removed and only the Verticals and Water Manifolds Installed.
Cell Cabinet Maintenance Sequence
Access components in the cell cabinet in the opposite sequence from which it is built.
This sequence is as follows:
Maintenance
Manual, AA, A5E32043214A 111
1. The top hat air-to-water heat exchange system is a complete subassembly. It can be
unbolted from the top of the cabinet by removing bolts in each corner, which are accessible
when the front and rear panels are removed. Refer to the following figures.
1
Front covers
2
Rear cover
Note: Remove the front and rear covers of the blower section to gain access to the bolts that hold
the top hat blower rear covers.
Figure 9-52 9 Cell Cabinet
Maintenance
112 Manual, AA, A5E32043214A
1
Access the bolts holding the fan power terminal strip and quick connect water connection in
this section.
2
Blower is attached to housing by top mounting screws and bottom mounting flanges.
Figure 9-53 9 Cell Cabinet with Front and Top Blower Covers Removed (for service)
2. When the cell cabinet doors are open, the water supplies to the air-water heat exchangers
can be disconnected by the self-sealing hose fitting just below the assembly.
Maintenance
Manual, AA, A5E32043214A 113
At these disconnection points the total system water section can be air purged during
the coolant water filling procedure.
A terminal strip supplying power to the fans is accessible when the front cover of the
assembly is open.
Access the air-to-water heat exchangers by first removing the fan mounting bracket and
then the front metal plenum in which it is mounted, as shown in the following figure.
Figure 9-54 9 Cell Cabinet with Doors, Blowers and HEX Removed
3. The power cells are removed or installed from the capacitor bucket by using the insertion
truck.
4. The capacitor bucket can be removed after the cell and capacitors are removed. Tabs at
rear of capacitors slide into rear slots of the bucket, while two bolts hold the capacitor in
place at the bottom flange of bucket.

Note
It is recommended, when installing or changing capacitors, that these bolts are left loose
until the cell is fully engaged and connected to aid in capacitor-to-cell alignment. The bolts
may then be tightened.

Maintenance
114 Manual, AA, A5E32043214A
5. The capacitor bucket is inserted by hooks that engage the rear glastic panel and 8 bolts
that engage the front vertical channels. Refer to the following figure.
1
Buckets hook into these slots.
2
Buckets are secured to the front verticals with 8 bolts.
3
Slots in rear of bracket provide access to lock the back of the capacitors.
4
Mounting bolts for capacitors.
Figure 9-55 9 Cell Cabinet with Cells, Majority of Capacitors and Capacitor Buckets Removed
6. The pigtail hose sub-assemblies connect to the rear supply and return manifolds (refer to
Figure 9 Cell Cabinet with Rear Panels Removed and only the Verticals and Water
Manifolds Installed).
Maintenance
Manual, AA, A5E32043214A 115
7. Before removing the inch glastic rear panels:
Disconnect the cell input bus at the front L1, L2, and L3 connections on the panel.
Disconnect the output bus section from the bypass subassembly (refer to the following
figure).
1
Leave this rear bus connected to contactor; connectors and panel to be removed.
2
Disconnect right rear bus of contactor to left of panel to be removed.
3
Panels behind cells can be removed completely with connectors and bypass attached
once the rear bus on the right side of contactor is disconnected on both the panel to be
removed and also on the panel to the left of the panel to be removed.
4
Disconnect L1, L2 and L3 rear bus at these points.
Figure 9-56 Bypass Contactor with T1-T2 Removed from Rear Panel
Maintenance
116 Manual, AA, A5E32043214A
8. The rear bus system is built in layers starting with bottom C row (C1 through C6) and
finishing with top A row (A1 through A6). Bus mounts into horizontal supports, which insert
in slots between rear vertical support and rear mullion of cell cabinet. As cell row is built up
left to right (from front), a layered bus clamp system that holds the bus together is also built
and finally clamped when the cell row is completed. Refer to the following figure.
1
Rear bus comb clamps
2
Rear bus supports
3
Insulating plates between FPC and cell bus
Figure 9-57 12 Cell Cabinet with Rear Panel Removed and Bus Exposed
Maintenance
Manual, AA, A5E32043214A 117
9. Hose connections between the cell return and the rear supply and return manifolds are
mounted along supports shown in the following figure. These supports are designed to
maintain at least one inch clearance between the hose OD and metal cabinet/supports.
Figure 9-58 9 Cell Cabinet with Rear Panels Removed and only Verticals and Water Manifolds
Installed
10.The bypass twisted pair must also not directly touch the metal cabinet and bus work. Three
bypass panduit systems are mounted on rear vertical support for this purpose.
11.Mounted on top of these panduit systems are three small panduits that contain the output
voltage lead that connects to the output attenuator in the FPC cabinet.
12.The cell cabinet assemblies just described are all mounted on a series of front and rear
vertical insulating support structures.
Maintenance
118 Manual, AA, A5E32043214A
Spare parts
10

Serviceable Parts
The customer serviceable spares are listed below. For additional information about how to
service these parts, refer to the chapter of this manual titled Maintenance.
Door Filters
Power Cells
Cell Input Fuses
Control Fuses (includes Blower Fuses)
Printed Circuit Boards
Non Customer Serviceable Parts
All other spare parts are NOT customer serviceable. However, they may be serviced by
qualified Siemens personnel. These include, but are not limited to the following:
Fiber-Optic connections
Blower(s)
Bypass Contactor(s)
Bypass Control Board
Bypass Power Supply
Input Current Transformers
Input/Output Voltage Attenuators
Hall Effect Current Transducers
NXG Power Supply
Refer to the System Outline and System Schematic Drawings, Series A and B respectively for
your specific drive. These drawings are contained in the O&M package supplied with the drive.

Note
Spare Parts for Customized Drives
For spare parts lists for customized drives, refer to the custom documentation package
shipped with the drive or contact the Siemens Industry, Inc. Customer Service Department.
When calling for spare parts information, please have your sales order number and drive part
number readily available.

Manual, AA, A5E32043214A 119

Note
Component Replacement
Unless notified differently by Siemens, always replace components with the same P/N and
revision level.

See also
Maintenance (Page 63)
10.1 NXGII Control
Table 10-1 NXGII Control Recommended Spare Parts
Quantity LD P/N Description
1 each A1A098194 PCA, ISA Backplane
1 each A1A10000623.00M PCA, Single Board Computer + Keypad Adapter
1 each A1A10000423.00M PCA, System I/O Board
1 each A1A461D85.00M
1
PCA, Fiber Optic, 12-channel
1 each A1A10000350.00M PCA, Modulator
1 each A5E03407403 PCA, Communications Board
1 each A5E02363383 or
A5E02624585 or
A5E02669557 or
A5E02669580 or
A5E02669582
2
Keypad, Siemens, English
Keypad, Siemens, Chinese
Keypad, Siemens, Portuguese
Keypad, Siemens, Russian
Keypad, Siemens, German
1 each A5E01649325 PCA, System I/O Breakout Board: 120 VAC DIG IN
1 each A5E01708486 PCA, Signal Conditioning Board
2 each A5E02381532 Fan, Axial, 24 VDC
1 each A1A0100275 Power supply, 700 W
1 each A1A094519 or
A1A094518
2
Relay, latching (LFR): 120 VAC coil
Relay, latching (LFR): 24 VDC coil
1
Recommended spare for systems with 15 or more power cells.
2
Verify which P/N is used on the Production Bill of Materials (PBOM) and furnish that one as a spare.
Spare parts
10.1 NXGII Control
120 Manual, AA, A5E32043214A
10.2 Power Cell
Table 10-2 Power Cell Recommended Spare Parts
Cell Rating Quantity LD P/N Description
880 Amp 2 Quadrant 1 each A5E02248613 Cell, 880 A, 2 Quadrant
2 per cell A1A099563 or
A1A099181 or
A1A0100622 or
A5E01521969
1
Film Capacitor, 13500 F, 1300 V
A1A0100665
2
Fuse, 700 A, 1000 V
880 Amp 4 Quadrant

1 each A5E02248617 Cell, 880 A, 4 Quadrant
A1A099181 or
A1A0100622 or
A5E01521969
1
A1A0100665
2
Fuse, 700 A, 1000 V
1250 Amp 2 Quadrant

1 each A5E02251463 Cell, 1250 A, 2 Quadrant
A1A099181 or
A1A0100622 or
A5E01521969
1
A1A0100664
2
Fuse, 1000 A, 1000 V
1250 Amp 4 Quadrant 1 each A5E02200053 Cell, 1250 A, 4 Quadrant
A1A099181 or
A1A0100622 or
A5E01521969
1
A1A0100664
2
Fuse, 1000 A, 1000 V
1
Verify which P/N is used on the Production Bill of Materials (PBOM) and furnish that one as a spare.
Capacitors listed above are form and fit equivalent, not functionally equivalent.
Different manufacturer's capacitors must not be mixed on the same cell.
2
Fuses listed above of the same ampacity rating (880 or 1250 Amps RMS) are form, fit and function equivalent.
Spare parts
10.2 Power Cell
Manual, AA, A5E32043214A 121
10.3 Optional Components
Table 10-3 Optional Components Recommended Spare Parts (if furnished with drive)
Quantity LD P/N Description
1 each A5E03036273 PCA, Bypass Control Board (Cell Bypass)
1 each A5E03448019 Power Supply, 750 V (Cell Bypass)
1 each A5E31704948 Contactor Assembly, Cell Bypass
1 each A1A099201 Anybus, Profibus-DP module (serial communication)
1 each A1A098628 Anybus, DeviceNet module (serial communication)
1 each A1A099202
1
Anybus, Ethernet Modbus module (serial communication)
1 each A1A099203 Anybus, ControlNet module (serial communication)
1 each A1A10000441.00
2
PCA, Modbus module (serial communication)
1
Only furnished with drive if dual Ethernet Modbus interface is required.
2
Only furnished with drive if dual Modbus interface is required.

Spare parts
10.3 Optional Components
122 Manual, AA, A5E32043214A
Disposal
11
11.1 Disposing of Device Components
Before dismantling the Drive, ensure that it is brought to a standstill and grounded.
If disposed of properly, none of the material listed below will pose any threat to the environment.
Take particular care when disposing of and recycling the following components:
Batteries
Capacitors
PCBs
Electronic components
Be sure to dispose of or recycle in accordance with the applicable country-specific guidelines
and regulations.
11.2 Disposing of Packaging
The packing is designed in such a way as to pose the minimum risk to the environment. Some
of the packaging can be recycled.
The disposal of packaging is controlled by country-specific laws. If in doubt, ask local disposal
specialists or contact the local authorities.
List of Packing Waste Materials
Wooden frames
Wooden pallets
Polyethylene foil
Plywood
Plastic
Silica gel
11.3 Disposing of Old Services
Observance of Applicable National Regulations
Dispose of the device in accordance with the applicable national regulations.
Manual, AA, A5E32043214A 123
Service and Support
A

Siemens can provide trained and certified field service representatives to provide technical
guidance and assistance for the installation, startup/commissioning, repair and maintenance
of Siemens Perfect Harmony VFD equipment and systems. Contact your regional service
call center or sales office for details.
Siemens service call centers can be reached at the regional locations listed below.

DANGER
Incorrectly Performed Work
Certain components described in this documentation may be replaced or repaired only by
personnel trained by Siemens.
Work incorrectly performed on the drive can result in damage to the equipment, degrade VFD
operational integrity, and possibly cause physical injury to personnel or even death.
Ensure that only personnel trained by Siemens work on the equipment. Siemens accepts no
liability for any damage that occurs because these instructions have not been observed e.g.
if an untrained person carries out a repair or replaces components.

Technical Support (Hotline)
America time zone:
Johnson City, TN, USA 800 333 7421 +1 423 262 5711
Asia and Australia time zone:
Shanghai, China +86 1064 719 990
Europe and Africa time zone:
Nuremberg, Germany +49 911 895 7222 +49 180 5050 222
To find country-specific phone numbers, please visit our internet page:
http://support.automation.siemens.com/WW/view/en/16604318
Technical Support (Internet)
Send your inquiries directly via the internet to a specialist in technical support:
www.siemens.com/automation/supportrequest
Technical support is available round the clock 365 days a year.
Your inquiries are delivered directly to the responsible specialist.
Have all relevant data available and technical support can respond to your inquiry as quickly
as possible.
Send records, screen shots and photos to the specialists to support fault analysis.
Manual, AA, A5E32043214A 125
Contacts may change. Please find current contact partners in the Siemens AG A&D service
catalog: www.automation.siemens.com/partner
Service and Support
126 Manual, AA, A5E32043214A
Technical Data
B
B.1 WCIII System Technical Specifications
The specifications shown in the following tables apply to the standard open loop or closed loop
vector control system performance for induction or synchronous motors.
Table B-1 WCIII Parameters and Ratings
Parameter Rating
Input Voltage 2400 to 13800 V / +10%, -5%
Input Frequency 50 or 60 Hz / +10%, -5% input voltage worst case
Input Power Factor 0.95 or better with motor speed 25% rated or higher (not valid for unloaded motor)
Input Current Harmonics Meets most stringent TDD requirements from IEEE 519
Transformer Windings Copper
Output Power 4000 Hp / 2984 kW to 19000 Hp / 14169 kW single inverter
Output Voltage 2.3 kV to 8.0 kV
Output HVF < 0.03
Output dV/dt < 1000 V/uS
Output Frequency and Drift 0.5 330 Hz, +/- 0.5%
Harmonic Voltage Factor Less than 0.03 per NEMA MG-1
Motor Speed Range f
0
= 0.5 to 166 Hz (motor dependent); 300 Hz f
c
600 Hz SWF
Motor Speed Range f
0
= 167 to 330 Hz (motor dependent); 1200 Hz f
c
(3.6 x f
0
) Hz SWF
Output Torque
1
2 or 4 Quadrant
f
0
= 0.5 to 10 Hz derated torque
f
0
= 10 to 167 Hz full rated torque
f
0
= 167 to 330 Hz derated torque
Auxiliary Voltage
( 10% auxiliary voltage tolerance,
per IEC 61800-4. For more
information, refer to standard.)
208 V, 60 Hz, 3-phase
230 V, 60 Hz, 3-phase
380 V 400 V 415 V, 50 / 60 Hz, 3-phase
460 V 480 V, 60 Hz, 3-phase
575 V, 60 Hz, 3-phase
690 V, 50 Hz, 3-phase
If exciter is needed, a separate auxiliary voltage supply is needed.
Acceleration/Deceleration Time 0.5 to 3200 seconds (load dependent)
Cell Frame Sizes 880 Amp and 1250 Amp
Overload Capacity Refer to WCIII Current Parameters Section.
Efficiency
Motor load PF = 1.0
Cells at 100% continuous rating
Total System 96.5% / Transformer 97.5% + Cells 99.0% (cell redundancy = N+0)
Enclosure Type MV Power Sections: IP 53 (NEMA 12)
LV Control Sections: IP 21 (NEMA 1)
Manual, AA, A5E32043214A 127
Altitude No de-rating up to 3300 feet / 1006 meters above Mean Sea Level.
Above 3300 feet / 1006 meters, refer to Cell Output Deration Formulas.
Above 6562 feet / 2000 meters, consult Siemens customer service.
Sound level
2
Less than 76 dB at 3 feet (~ 1 meter) from cabinet.
Control Power
3
One: single phase, 120 VAC RMS 10%, 50 / 60 Hz
Three: three phase, 380 VAC RMS 10% / 50 Hz or 460 VAC RMS 10% / 60 Hz
Control NXGII hardware + Eagle software
Cooling De-ionized water and glycol mix
Design Life 20 years
Accessibility Rear access is required for maintenance and installation. For details, contact Siemens
customer service.
1
Refer to deration formulas in Power Cell SpecificationsSection.
2
The WCIII drive generates acoustic noise levels above 70 dB. Hearing protection is not required.
3
Control Power is sourced by the customer in the standard configuration. A fourth three-phase feed ( 10% continuous RMS
voltage tolerance) is required if a forced air type drive main heat exchanger is used.

Note
Synchronous motor operates at fixed 1.0 (Unity) Power Factor.

Technical Data
B.1 WCIII System Technical Specifications
128 Manual, AA, A5E32043214A
B.2 WCIII Storage, Transport and Operation Ambient Conditions
Refer to the following table to view the ambient conditions of the Perfect Harmony WCIII
drives. These conditions meet the IEC 60721 and 61800 applicable standards.
Table B-2 General Ambient Conditions
Storage Transport Operating
CLIMATIC AMBIENT CONDITIONS
Ambient temperature 41 F / +5 C to 104 F / +40 C
(no cooling water in the
system)
25 C to +60 C
(no cooling water in the
system)
Minimum 32 F / 0 C ambient air
temperature with minimum inlet
water temperature 41 F / 5 C.
Recommend inlet water
temperature be maintained
minimum 4 F / 2 C above cabinet
internal air dew point.
Maximum concurrent temperature
conditions listed below. Use linear
interpolation for intermediate
conditions.
Condition 1: Maximum 104 F /
40 C drive ambient air
temperature with maximum
117 F / 47 C drive inlet water
temperature concurrent.
Condition 2: Maximum 122 F /
50 C drive ambient air
temperature with maximum
108 F / 42 C drive inlet water
temperature concurrent.
Relative air humidity < 95 %
(VFD must be completely
dry before commissioning)
< 95 %
(VFD must be completely
dry before commissioning)
< 95 %
(condensation not permitted)
Other climatic
conditions in
accordance with class
1K3, 1Z2
in accordance with
IEC 60721-3-1
2K2
in accordance with
IEC 60721-3-2
3K3
in accordance with
IEC 60721-3-3
Degree of pollution 2
without conductive pollution
in accordance with
IEC 61800-5
2
in accordance with
IEC 61800-5
2
in accordance with
IEC 61800-5
MECHANICAL AMBIENT CONDITIONS
STATIONARY VIBRATION, SINUSOIDAL
Displacement 1.5 mm (2 to 9 Hz) 3.5 mm (2 to 9 Hz) 0.3 mm (2 to 9 Hz)
Acceleration 5 m/s
2
(9 to 200 Hz) 10 m/s
2
(9 to 200 Hz)
15 m/s
2
(200 to 500 Hz)
1 m/s
2
(9 to 200 Hz)
Other mechanical
conditions in
1M2
in accordance with
IEC 60721-3-1
2M1
in accordance with
IEC 60721-3-2
3M1
in accordance with
IEC 60721-3-3
OTHER AMBIENT CONDITIONS
Biological ambient
conditions in
1B1
in accordance with
IEC 60721-3-1
2B1
in accordance with
IEC 60721-3-2
3B1
in accordance with
IEC 60721-3-3
Technical Data
B.2 WCIII Storage, Transport and Operation Ambient Conditions
Manual, AA, A5E32043214A 129
Storage Transport Operating
Chemical active
substances in
1C1
in accordance with
IEC 60721-3-1
2C1
in accordance with
IEC 60721-3-2
3C1
in accordance with
IEC 60721-3-3
Mechanical active
substances in
1S1
in accordance with
IEC 60721-3-1
2S1
in accordance with
IEC 60721-3-2
3S1
in accordance with
IEC 60721-3-3

(standard)
3S3
in accordance with
IEC 60721-3-3 (in liquid-cooled
systems with IP 53 (NEMA 12) MV
enclosures)
B.3 WCIII Power Cell Specifications
The following tables contains the parameters for each WCIII power cell type.
Table B-3 WCIII Power Cell Specifications
Power Cell Type 880A2 880A4 1250A2 1250A4
Power cell height 24.75 in / 628.7 cm
Power cell width 22.25 in / 565.2 cm
Power cell depth 32.75 in / 831.9 cm
Power cell weight Power chassis = 155 pounds / 70.3 kilograms
Capacitors = 2 x 130 = 260 pounds / 118 kilograms Capacitors =3 x 130 = 390 pounds / 177 kilograms
Electrical connections Rear access blind connection via power plugs
Cooling flow 4 GPM / 15.1 LPM
Cold-plate pressure drop 6 PSIG / 41.3 kPa
Storage temperature -13 F / -25 C to 140 F / 60 C
Ambient humidity No condensation formation
B.4 WCIII Current Parameters

Table B-4 WCIII 880 Amp Cell Type Specifications
Cell Type 880A2 880A4
Output Current Rating (I
o
) No overload required 880 Amps RMS Continuous
110% overload for 1 min / 10 min (CL-1) 880 Amps RMS Continuous
968 Amps RMS Overload
Nominal Input Current (Cell Input PF = 1.0) 590 Amps RMS Continuous
Technical Data
B.4 WCIII Current Parameters
130 Manual, AA, A5E32043214A
Nominal Three-Phase Line-to-Line Input Voltage 750 Volts RMS +10 / -5% at 50 or 60 Hz
Cell Efficiency at 100% Continuous Rated Output Current with Motor Load PF
= 1.0
99.0% (no redundant cells)
98.7% (1 rank of redundant cells)

Table B-5 WCIII 1250 Amp Cell Type Specifications
Output Current Rating (I
o
) No overload required 1250 Amps RMS Continuous
Nominal Input Current (Cell Input PF = 1.0) 838 Amps RMS Continuous
Nominal Three-Phase Line-to-Line Input Voltage 750 Volts RMS +10 / -5% at 50 or 60 Hz
Cell Efficiency at 100% Continuous Rated Output Current with Motor Load
PF = 1.0
99.0% (no redundant cells)
98.7% (1 rank of redundant cells)
B.5 Power Cell Output Current Rating Deration Parameters
Power Cell Output Current Rating Deration for Drive Maximum Output Frequency [f
o
]
If 330 f
o
10 Hz Cell Output Current Rating = I
o
(from Cell Type Specifications Tables)
If 0.5 f
o
< 10 Hz Cell Output Current Rating = I
o
x [0.5 + (f
o
/ 20)]
Power Cell Output Current Rating Deration for Cell Carrier Frequency [f
c
]
f
c
can be assigned any value from 300 to 1200 Hz provided f
c
(3.6 x f
o
) Hz
For f
o
< 167 Hz, the default value f
c
= 600 Hz is typically adequate.
A smaller value of f
c
can be chosen provided 300 Hz f
c
(3.6 x f
o
) Hz
For f
o
= 167 330 Hz, select carrier using 1200 Hz f
c
(3.6 x f
o
) Hz
If 300 f
c
o
(from Cell Type Specifications Tables)
If 600 < f
c
o
x {1 - { [ (f
c
- 600) / 600 ] x 0.20}}
Power Cell Output Current Rating Deration for Drive Altitude Above Mean Sea Level
If Altitude 3300 feet (1006 meters) Cell Output Current Rating = I
o
(from Cell Type
Specifications Tables)
If 3300 feet (1006 meters) < Altitude 20000 feet (6096 meters)
Cell Output Current Rating = I
o
x { 1 - { [ 0.5 x ( Alt - 3300 )] / 16700 }} - Altitude in feet
Cell Output Current Rating = I
o
x { 1 - { [ 0.5 x ( Alt - 1006 )] / 5090 }} - Altitude in meters

Technical Data
B.5 Power Cell Output Current Rating Deration Parameters
Manual, AA, A5E32043214A 131
B.6 Ingress Protection (IP) Ratings
IP ratings are developed by the European Committee for Electro Technical Standardization
(CENELEC) (NEMA IEC 60529 Degrees of Protection Provided by Enclosures - IP Code),
specifying the environmental protection the enclosure provides.
The IP rating normally has two (or three) numbers:
Protection from solid objects or materials
Protection from liquids (water)
Protection against mechanical impacts (commonly omitted, the third number is not a part
of IEC 60529).
Refer to the following table using the example shown to help in understanding the IP rating as
it applies to your equipment.
Example - IP Rating
With the IP rating IP 54, 5 describes the level of protection from solid objects and 4 describes
the level of protection from liquids.
An "X" can be used for one of the digits if there is only one class of protection (e.g.,IPX1,
which, addresses protection against vertically falling drops of water such as condensation).
IP First Number: Protection against solid objects
0 No special protection.
1 Protected against solid objects over 50 mm e.g. accidental touch by person's hands.
2 Protected against solid objects over 12 mm e.g. person's fingers.
3 Protected against solid objects over 2.5 mm (tools and wires).
4 Protected against solid objects over 1 mm (tools, wires and small wires).
5 Protected against dust limited ingress (no harmful deposit).
6 Totally protected against dust.
IP Second Number: Protection against liquids
0 No protection.
1 Protected against vertically falling drops of water e.g. condensation.
2 Protected against direct sprays of water up to 15 from the vertical.
3 Protected against direct sprays of water up to 60 from the vertical.
4 Protected against water sprayed from all directions - limited ingress permitted.
5 Protected against low pressure jets of water from all directions - limited ingress.
6 Protected against temporary flooding of water e.g. for use on ship decks - limited ingress permitted.
7 Protected against the effect of immersion between 15 cm and 1 m.
8 Protected against long periods of immersion under pressure.
IP Third Number: Protection against mechanical impacts
0 No protection.
1 Protected against impact of 0.225 joule (e.g. 150 g weight falling from 15 cm height).
Technical Data
132 Manual, AA, A5E32043214A
IP Third Number: Protection against mechanical impacts
5 Protected against impact of 6.0 joule (e.g. 1.5 kg weight falling from 40 cm height).
6 Protected against impact of 20.0 joule (e.g. 5 kg weight falling from 40 cm height).
To comply with the stringent requirements for CE marking machine makers today fit their
machines with parts certified according to European Union and international standards.
Technical Data
Manual, AA, A5E32043214A 133
Quality
C
C.1 CE Marking and Directives for Perfect Harmony Products
The CE marking identifies products that are in compliance with the appropriate EU directives.
The CE marking is not a seal of quality. It was created to guarantee end users safe products
in the free flow of goods within the European Economic Community (EEC) and the European
Community (EC). By applying the CE marking the manufacturer acknowledges the product is
in conformance with the applicable EU Directives and the product complies with the essential
requirements defined in these directives. Based on the Gambica CE Marking and Technical
Standardization Guidelines, Edition 3.0, compliance to EN 61800-5-1 is a harmonized standard
and confers a presumption of conformity with the essentials of the Low Voltage Directive (LVD).
Manual, AA, A5E32043214A 135
C.2 CE Marking on Power Drive Systems (PDS)
To form a basic understanding of the PDS, refer to the following figure.
lnstallation or part of installation
Feeding section &
auxiliaries
Basic Drive Module (BDM)
Control & Converter
System control &
sequencing
Driven Equipment
Complete Drive Module (CDM)
Motor & Sensors
Power Drive System (PDS)
BDM Basic drive module consisting of power input, control, and power output sections.
CDM Complete drive module consisting of BDM and auxiliary sections, including devices such as
incoming switches, input and output transformers and filters, etc., but excluding the motor,
cables, and motor-coupled sensors.
PDS Power drive system consisting of CDM, motor and sensors, excluding the driven equipment and
sensors.
Figure C-1 Power Drive System
The terminology used throughout IEC and EN standards relating to electrical VFDs is contained
in the IEC 61800 series of standards. The IEC 61800 series of standards references other
components of the PDS, with respect to the VFD, but those components are covered by
different IEC product relevant standards.
Siemens Industry, Inc. I DT LD Perfect Harmony designs always include the Basic Drive
Module (BDM) consisting of a Perfect Harmony transformer, converter/inverter (power cell)
section, and control section. Depending on the Siemens Industry, Inc. I DT LD scope of supply,
the Perfect Harmony Complete Drive Module (CDM) may include optional components, such
as a motor excitation unit, output line filter, output line reactor, or earthing switches. Refer to
the following figure for further detail on this concept.
Quality
C.2 CE Marking on Power Drive Systems (PDS)
136 Manual, AA, A5E32043214A
LV
power
LV control
power
* Drive bypass
Circuit breaker contactor
Load-break switch
* Drive input
Load-break switch
Earth switch
3 phase
MV power
50 / 60 Hz
Harmony
transformer
PDS
Perfect
Harmony
TM

CDM
Perfect
Harmony
TM

BDM
Pre-
charge
Fiber optic
intercon-
nection
LV
power
* Drive output
Reactor
Low-pass filter
* Drive output
Load-break switch
Earth switch
lnduction or
synchronous
motor
Control
* Static exciter
Power
section
* Optional Components in Perfect Harmony CDM:
May not be in Siemens scope of supply.
May be housed separately in stand-alone enclosure.
Figure C-2 Overview of PDS containing the Perfect Harmony BDM and CDM
As referenced in Figure Power Drive System, the installation, parts of the installation, the motor
or any machinery, including gearboxes and the driven equipment, are outside of the scope of
Siemens LD's responsibility.
C.3 Directives that apply to the Power Drive System (PDS)
LVD: Low Voltage Directive 2006/95/EEC (formerly 72/23/EEC). Siemens Industry, Inc.
I DT LD Perfect Harmony designs comply with IEC 61800-5-1 (2007) Adjustable Speed
Electrical Power Drive Systems, Part 5-1 Safety Requirements Electrical, Thermal and
Energy.
EMC: EMC Directive - 2004/108/EEC (formerly 89/36/EEC). Siemens Industry, Inc. I DT
LD Perfect Harmony designs comply with IEC 61800-3 (2004) Adjustable Speed
Electrical Power Drive Systems, Part 3 EMC Requirements and specific test methods.
Reference Section EMC Installation Guidelines for Perfect Harmony in Siemens
Industry, Inc. I DT LD document A5E03091809 (this document).
The Perfect Harmony VFD is verified compliant to IEC 61800-3 through type testing
of the BDM/CDM itself. Compliance with IEC 61800-3 is a requirement of the EMC
Directive; however, the Perfect Harmony VFD cannot directly state compliance to the
EMC Directive because the directive requires type testing of the complete PDS as it is
installed at the customer site.
Quality
C.3 Directives that apply to the Power Drive System (PDS)
Manual, AA, A5E32043214A 137
MD: Machinery Directive 98/37/EEC until 29 Dec. 2009, then 2006/42/EEC becomes
effective.
Although the Machinery Directive is a recognized directive associated with a PDS, the
Perfect Harmony VFD cannot directly state compliance to the Machinery Directive.
The Machinery Directive provides clear definition for a machine and a partially
completed machine. The Perfect Harmony VFD does not meet these definitions. This
is defined in Section CE Marking.
PED: Pressure Equipment Directive 97/23EC. Liquid cooled Siemens Industry, Inc. I DT
LD Perfect Harmony designs are exempt since they operate at pressures less than ten
bars.
ATEX: Explosive Atmospheres 94/9/EC. Siemens Industry, Inc. I DT LD does not
authorize the use of Perfect Harmony designs in an explosive atmosphere.

C.4 CE Marking
Applying the CE marking confers the presumption of conformity to the EU directive(s).
The CE marking is required for all products which fall in the scope of a European Directive
(which foresees the CE marking for those products) which are placed on the market in the
European Economic Area.
Figure C-3 CE Marking

Note
Access "CE Marking and Technical Standardization - Guidelines for Application to Electrical
Power Drive Systems", Edition 3.0, at http://www.gambica.org.uk/

Access EU Directives and Norms at the following link:
http://ec.europa.eu/enterprise/policies/european-standards/documents/harmonised-
standards-legislation/list-references/
This site provides access to all European Directives and the appropriate standards according
to each manufacturers specific products.
Quality
C.4 CE Marking
138 Manual, AA, A5E32043214A
Abbreviations
D

This appendix contains a list of symbols and abbreviations commonly used throughout this
manual group.
Table D-1 Commonly Used Abbreviations
Abbreviation Meaning
Boolean AND function
+ Addition or Boolean OR
Summation
Microsecond
A Amp, Ampere
AC Alternating Current
ACFM Actual Cubic Feet per Minute
accel Acceleration
A/D Analog to Digital Converter
ADC Analog to Digital Converter
AI Analog Input
Alg Analog
avail Available
BIL Basic Impulse Level
BTU British thermal units
C Centigrade or Capacitor
cap Capacitor
CCB Cell Control Board
ccw Counter clockwise
CE Formerly European Conformity, now true definition
CFM Cubic Feet per Minute
CLVC Closed Loop Vector Control
cmd Command
com Common
conn Connector
CPS Control Power Supply
CPU Central Processing Unit
CSMC Closed Loop Synchronous Motor Control
CT Current Transformer
cu Cubic
curr, I Current
cw Clockwise
D Derivative (PID), depth
Manual, AA, A5E32043214A 139
D/A Digital-to-analog (converter)
db Decibel
DC Direct Current
DCR Digital Control Rack
DCS Distributed Control System
decel Deceleration
deg, Degrees
DHMS Down hole monitoring system
Div Division
dmd Demand
e Error
EC Electrically Commutated
ELV Extra Low Voltage
EMC Electromagnetic Compatibility
EMF Electromotive Force
EMI Electromagnetic Interference
EPS Encoder Power Supply
ESD Electrostatic Discharge
ESP Electrical Submersible Pump
ESTOP, e-stop Emergency Stop
fb, fdbk Feedback
ffwd Feed Forward
FLC Full Load Current
freq Frequency
ft, ' Feet
fwd Forward
GenIIIe Generation IIIe
GenIV Generation IV
gnd Ground
GUI Graphical User Interface
H Height
H2O Water
hex Hexadecimal
hist Historic
Hp Horsepower
hr Hour
HV High Voltage
HVAC Heating, Ventilation, Air Conditioning
HVF Harmonic Voltage Factor
Hz Hertz
I Integral (PID)
ID Identification
IEC International Electrotechnical Commission
Abbreviations
140 Manual, AA, A5E32043214A
IEEE Institute of Electrical and Electronic Engineers
IGBT Insulated Gate Bipolar Transistor
In Input
In, " Inches
INH Inhibit
I/O Input(s)/Output(s)
IOB I/O Breakout Board
IOC Instantaneous Overcurrent
IP Input Protection
k 1,000 (e.g., Kohm)
kHz KiloHertz
kV Kilo Volts
kVA One Thousand Volt Amps
kW Kilowatt
L Inductor
LAN Local Area Network
Lbs Pounds (weight)
LCD Liquid Crystal Display
ld Load
LED Light-emitting Diode
LFR Latch Fault Relay
Lim Limit
LOS Loss Of Signal
lps Liters Per Second
mA Milliamperes
mag Magnetizing
max Maximum
MCC Motor Control Center
Mg Milligram
Min Minimum, Minute
msec Millisecond(S)
Msl Mean Sea Level
MV Medium Voltage
mvlt Motor Voltage
MW Megawatt
NC Normally Closed
NEMA National Electrical Manufacturers Association
NMI Non-Maskable Interrupt
No Normally Open
NVRAM Non-Volatile Random Access Memory
NXG Next Generation Control
NXG II Next Generation Control II
oamp Output Current
Abbreviations
Manual, AA, A5E32043214A 141
OLVC Open Loop Vector Control
O-M Overmodulation
OOS Out of Saturation (IGBT)
overld Overload
P Proportional (PID)
Pa Pascals
pb Push Button
PC Personal Computer or Printed Circuit
PCB Printed Circuit Board
PID Proportional Integral Derivative
PLC Programmable Logic Controller
PLL Phase Locked Loop
pot Potentiometer
pp Peak-to-peak
ppm Parts per Million
PPR Pulses per Revolution
PQM Power Quality Meter
ProToPSTM Process Tolerant Protection Strategy
PSDBP Power Spectral Density Break Point
psi Pounds Per Square Inch
pt Point
PT Potential Transformer
PWM Pulse Width Modulation
Q1,Q2,Q3,Q4 Output Transistor Designations
rad Radians
RAM Random Access Memory
ref Reference
rev Reverse, Revolution(S)
RFI Radio Frequency Interference
RLBK Rollback
rms Root-mean-squared
RPM Revolutions Per Minute
RTD Resistance Temperature Detector
RTU Remote Terminal Unit
RX Receive (RS232 Communications)
s Second(s)
SCB Signal Conditioning Board
SCR Silicon Controlled Rectifier
sec Second(s)
ser Serial
SMC Synchronous Motor Control
SOP Sum of Products; System Operating Program
spd Speed
Abbreviations
142 Manual, AA, A5E32043214A
stab Stability
std Standard
sw Switch
T1, T2 Output Terminals TI and T2
TB Terminal Block
TBD To Be Determined
TCP/IP Transmission Control Protocol/Internet Protocol
THD Total Harmonic Distortion
TOL Thermal Overload
TP Test Point
trq, Torque
TX Transmit (RS232 Communications)
UPS Uninterruptable Power Supply
V Voltage, Volts
VA Volt-Amperes
VAC Volts AC
var Variable
VDC Volts DC
vel Velocity
VFD Variable Frequency Drive
V/Hz Volts per Hertz
vlts Voltage(s), Volts
VSI Voltage Source Inverter
W Width, Watts
WAGO Expansion I/O System
WCIII Water Cooled III
xfmr, xformer Transformer
Abbreviations
Manual, AA, A5E32043214A 143
Glossary
AND
AND is a logical Boolean function whose output is true if all of the inputs are true in SOP
notation, AND is represented as "" (e.g., C=AB), although sometimes it may be omitted
between operands with the AND operation being implied (e.g., C=AB).
ASCII
ASCII is an acronym for American Standard Code for Information Interchange, a set of 8-bit
computer codes used for the representation of text.
Baud rate
Baud rate is a measure of the switching speed of a line, representing the number of changes
of state of the line per second. The baud rate of the serial port of the Perfect Harmony is
selected through the Baud Rate parameter in the Communications Menu [9].
Bit
Bit is an acronym for BInary digiT. Typically, bits are used to indicate either a true (1) or false
(0) state within the drives programming.
Boolean algebra
A form of mathematical rules developed by the mathematician George Boole used in the design
of digital and logic systems.
Carrier frequency
Carrier frequency is the set switching frequency of the power devices (IGBTs) in the power
section of each cell. The carrier frequency is measured in cycles per second (Hz).
Catch a spinning load
"Catch a spinning load" is a feature that can be used with high-inertia loads (e.g., fans), in
which the drive may attempt to turn on while the motor is already turning. This feature can be
enabled via the NXG menu system.
CLVC
An acronym for Closed Loop Vector Control, one of the control modes in the drive. This is flux
vector control for an induction machine (IM), utilizing an encoder for speed feedback.
Manual, AA, A5E32043214A 145
CMP
Refer to the glossary term SOP.
Comparator
A comparator is a device that compares 2 quantities and determines their equality. The
comparator submenus allow the programmer to specify two variables to be compared. The
results of the custom comparison operations can be used in the system program.
Configuration Update
see Tool Suite definition.
Converter
The converter is the component of the drive that changes AC voltage to DC voltage.
Critical speed avoidance
Critical speed avoidance is a feature that allows the operator to program up to 3 mechanical
system frequencies that the drive will "skip over" during its operation.
CSMC
An acronym for Closed Loop Synchronous Machine (SM) Control, one of the control modes
of the drive. This is a flux vector control for a synchronous machine, utilizing an encoder for
speed feedback and providing a field excitation command for use by an external field exciter.
DC link
The DC link is a large capacitor bank between the converter and inverter section of the drive.
The DC link, along with the converter, establishes the voltage source for the inverter.
De Morgans Theorem
The duality principal of Boolean algebra used to convert system logic equations into sum-of-
products notation.
Debug Tool
Downloading
Downloading is a process by which information is transmitted from a remote device (such as
a PC) to the drive. The term "downloading" implies the transmission of an entire file of
information (e.g., the system program) rather than continued interactive communications
Glossary
146 Manual, AA, A5E32043214A
between the two devices. The use of a PC for downloading requires special serial
communications software to be available on the PC, which may link to the drive via RS232 or
through the Host Simulator via an ethernet connection.
DRCTRY
Directory file for system tokens and flags used in the compilation of system programs. It
provides a direct lookup table of ASCII names to internal ID numbers. It also identifies whether
the flag is a word or bit-field, and also whether it can be used as an input or output only, or can
be used for both.
Drive
The term "drive" refers to the power conversion equipment that converts utility power into power
for a motor in a controlled manner.
ELV
ELV is an acronym for extra low voltage, and represents any voltage not exceeding a limit that
is generally accepted to be 50 VAC and 120 VDC (ripple free).
EMC
EMC is an acronym for electromagnetic compatibilitythe ability of equipment to function
satisfactorily in its electromagnetic environment without introducing intolerable
electromagnetic disturbances to anything in that environment.
ESD
ESD is an acronym for ElectroStatic Discharge. ESD is an undesirable electrical side effect
that occurs when static charges build up on a surface and are discharged to another. When
printed circuit boards are involved, impaired operation and component damage are possible
side effects due to the static-sensitive nature of the PC board components. These side effects
may manifest themselves as intermittent problems or total component failures. It is important
to recognize that these effects are cumulative and may not be obvious.
Fault log
Fault messages are saved to memory so that the operator may view them at a later time. This
memory location is called the fault log. The fault log lists both fault and alarm messages, the
date and time that they occurred, and the time and date that they are reset.
Faults
Faults are error conditions that have occurred in the Perfect Harmony system. The severity of
faults vary. Likewise, the treatment or corrective action for a fault may vary from changing a
parameter value to replacing a hardware component such as a fuse.
Glossary
Manual, AA, A5E32043214A 147
Flash Card
Non-volatile memory storage device for the NXG control. It stores the drive program, system
program, logs, parameters, and other related drive files.
FPGA
Field Programmable Gate Array. An FPGA is an integrated circuit that contains thousands of
logic gates.
Function
A function is one of four components found in the Perfect Harmony menu system. Functions
are built-in programs that perform specific tasks. Examples of functions include System
Program Upload/Download and Display System Program Name.
Harmonics
Harmonics are undesirable AC currents or voltages at integer multiples of the fundamental
frequency. The fundamental frequency is the lowest frequency in the wave form (generally the
repetition frequency). Harmonics are present in any non-sinusoidal wave form and cannot
transfer power on average.
Harmonics arise from non-linear loads in which current is not strictly proportional to voltage.
Linear loads like resistors, capacitors, and inductors do not produce harmonics. However, non-
linear devices such as diodes and silicon controlled rectifiers (SCRs) do generate harmonic
currents. Harmonics are also found in uninterruptable power supplies (UPSs), rectifiers,
transformers, ballasts, welders, arc furnaces, and personal computers.
Hexadecimal digits
Hexadecimal (or "hex") digits are the "numerals" used to represent numbers in the base 16
(hex) number system. Unlike the more familiar decimal system, which uses the numerals 0
through 9 to make numbers in powers of 10, the base 16 number system uses the numerals
0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, and F to make numbers in powers of 16.
Historic log
The historic log is a troubleshooting/diagnostic tool of the Perfect Harmony NXG control. The
historic log continuously logs drive status, including the drive state, internal fault words, and
multiple user-selectable variables. This information is sampled every slow loop cycle of the
NXG control (typically 450 to 900 times per second). If a fault occurs, the log is frozen a
predefined number of samples after the fault event, and data samples prior to and after the
fault condition are recorded to allow post-fault analysis. The number of samples recorded are
user-selectable via the NXG control, as well as the option to record the historic log within the
VFD event log.
Host Simulator
Glossary
148 Manual, AA, A5E32043214A
I/O
I/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a
computer system. Both inputs and outputs can be classified as analog (e.g., input power, drive
output, meter outputs, etc.) or digital (e.g., contact closures or switch inputs, relay outputs,
etc.).
IGBT
IGBT is an acronym for Insulated Gate Bipolar Transistors. IGBTs are semiconductors that
are used in the Perfect Harmony drives to provide reliable, high-speed switching, high-power
capabilities, improved control accuracy, and reduced motor noise.
Induction motor
An induction motor is an AC motor that produces torque by the reaction between a varying
magnetic field (generated in the stator) and the current induced in the coils of the rotor.
Intel hex
Intel hex refers to a file format in which records consist of ASCII format hexadecimal (base 16)
numbers with load address information and error checking embedded.
Inverter
The inverter is a portion of the drive that changes DC voltage into AC voltage. The term
"inverter" is sometimes used mistakenly to refer to the entire drive (the converter, DC link, and
inverter sections).
Jog mode
Jog mode is an operational mode that uses a pre-programmed jog speed when a digital input
(programmed as the jog mode input) is closed.
Jumpers
Jumper blocks are groups of pins that can control functions of the system, based on the state
of the jumpers. Jumpers (small, removable connectors) are either installed (on) or not installed
(off) to provide a hardware switch.
Ladder logic (Also Ladder Diagram)
A graphical representation of logic in which two vertical lines, representing power, flow from
the source on the left and the sink on the right, with logic branches running between, resembling
rungs of a ladder. Each branch consists of various labeled contacts placed in series and
connected to a single relay coil (or function block) on the right.
Glossary
Manual, AA, A5E32043214A 149
Loss of signal feature
The loss of signal feature is a control scheme that gives the operator the ability to select one
of three possible actions in the event that the signal from an external sensor, configured to
specify the speed demand, is lost. Under this condition, the operator may program the drive
(through the system program) to (1) revert to a fixed, pre-programmed speed, (2) maintain the
current speed, or (3) perform a controlled (ramped) stop of the drive. By default, current speed
is maintained.
LVD
LVD is an acronym for Low Voltage Directive, a safety directive in the EU.
Lvl RH
This term refers the two security fields associated with each parameter of the system. These
fields allow the operator to individually customize specific security features for each menu
option (submenu, parameter, pick list, and function). These fields are shown in parameter
dumps and have the following meanings. Lvl is the term for the security level. Setting R=1
blocks parameter change, and setting H=1 hides the menu option from view until the
appropriate access level has been activated.
Memory
Memory is the working storage area for the Perfect Harmony drive that is a collection of RAM
chips.
Microprocessor
A microprocessor is a central processing unit (CPU) that exists on a single silicon chip. The
microprocessor board is the printed circuit board on which the microprocessor is mounted.
The drive employs a single-board computer with a Pentium microprocessor.
NEMA 1 and NEMA 12
NEMA 1 is an enclosure rating in which no openings allow penetration of a 0.25-inch diameter
rod. NEMA 1 enclosures are intended for indoor use only. NEMA 12 is a more stringent NEMA
rating in which the cabinet is said to be "dust tight" (although it is still not advisable to use
NEMA 12 in conductive dust atmospheres). The approximate equivalent IEC rating is IP52.
Normally closed (NC)
Normally closed refers to the contact of a relay that is closed when the coil is de-energized.
Normally open (NO)
Normally open refers to the contact of a relay that is open when the coil is de-energized.
Glossary
150 Manual, AA, A5E32043214A
OLTM
An acronym for Open Loop Test Mode, one of the control modes of the drive.
OLVC
An acronym for Open Loop Vector Control, also known as Encoderless Vector Control. OLVC
is a flux vector control that is one of the control modes of the drive. The drive computes the
rotational speed of the rotor and uses it for speed feedback.
OOS
OOS is an abbreviation for out of saturation - a type of fault condition in which a voltage drop
is detected across one of the IGBTs during conduction. This can indicate that the motor is
drawing current too rapidly or in excess.
OR
OR is a logical Boolean function whose output is true if any of the inputs is true. In SOP notation,
OR is represented as "+".
Parameter
A parameter is one of four items found in the Perfect Harmony menu system. Parameters are
system attributes that have corresponding values that can be monitored or, in some cases,
changed by the user.
PED
PED is an acronym for pressure equipment directive, a directive of the EU relating to pressure
vessels.
Pick list
A pick list is one of four items found in the Perfect Harmony menu system. Pick lists are
parameters that have a finite list of pre-defined "values" from which to choose, rather than a
value range used by parameters.
PID
PID is an acronym for proportional + integral + derivative, a control scheme used to control
modulating equipment in such a way that the control output is based on (1) a proportional
amount of the error between the desired setpoint and the actual feedback value, (2) the
summation of this error over time, and (3) the change in error over time. Output contributions
from each of these three components are combined to create a single output response. The
amount of contribution from each component is programmable through gain parameters. By
optimizing these gain parameters, the operator can "tune" the PID control loop for maximum
efficiency, minimal overshoot, quick response time, and minimal cycling.
Glossary
Manual, AA, A5E32043214A 151
Qualified user
A qualified user is a properly trained individual who is familiar with the construction and
operation of the equipment and the hazards involved.
RAM
RAM is an acronym for Random Access Memory, a temporary storage area for drive
information. The information in RAM is lost when power is no longer supplied to it. Therefore,
it is referred to as volatile memory.
Regeneration
Regeneration is the characteristic of an AC motor to act as a generator when the rotors
mechanical frequency is greater than the applied electrical frequency.
Relay
A relay is an electrically controlled device that causes electrical contacts to change their status.
Open contacts will close and closed contacts will open when rated voltage is applied to the
coil of a relay.
RS232C
RS232C is a serial communications standard of the Electronics Industries Association (EIA).
Set point
Set point is the desired or optimal speed of the VFD to maintain process levels (speed
command).
Slip
Slip is the difference between the stator electrical frequency of the motor and the rotor
mechanical frequency of the motor, normalized to the stator frequency as shown in the
following equation:
Slip = S - R S
Slip compensation
Slip compensation is a method of increasing the speed reference to the speed regulator circuit
(based on the motor torque) to maintain motor speed as the load on the motor changes. The
slip compensation circuit increases the frequency at which the inverter section is controlled to
compensate for decreased speed due to load droop. For example, a motor with a full load
speed of 1760 rpm has a slip of 40 rpm. The no load rpm would be 1800 rpm. If the motor
nameplate current is 100 A, the drive is sending a 60 Hz wave form to the motor (fully loaded);
then the slip compensation circuit would cause the inverter to run 1.33 Hz faster to allow the
motor to operate at 1800 rpm, which is the synchronous speed of the motor.
Glossary
152 Manual, AA, A5E32043214A
SMC
Is an acronym for Synchronous Motor Control, one of the control modes of the drive. This mode
computes the rotational speed similarly to open-loop vector control, and controls the field
reference or the synchronous motor as in closed-loop synchronous motor control.
SOP - (1)
SOP is an acronym for Sum Of Products. The term "sum-of-products" comes from the
application of Boolean algebraic rules to produce a set of terms or conditions that are grouped
in a fashion that represents parallel paths (ORing) of required conditions that all must be met
(ANDing). This would be equivalent to branches of connected contacts on a relay logic ladder
that connect to a common relay coil. In fact, the notation can be used as a shortcut to describe
the ladder logic. (2) SOP, when used as a filename extension, refers to System Operating
Program.
SOP Utilities
The program within the Siemens LD A Tool suite used for converting between text and machine
loadable code. It can also be used for uploading and downloading files over the RS232
connection.
See Tool Suite definition.
Speed Menu function
Speed menu is a feature of the menu system that allows the operator to directly access any
of the menus or parameters, rather than scrolling through menus to the appropriate item. This
feature uses the [Shift] button in conjunction with the right arrow. The user is prompted to enter
the four digit ID number associated with the desired menu or parameter.
Stop mode
Stop mode is used to shut down the drive in a controlled manner, regardless of its current
state.
Submenus
A submenu is one of four components found in the Perfect Harmony menu system. Submenus
are nested menus (i.e., menus within other menus). Submenus are used to logically group
menu items based on similar functionality or use.
Synchronous speed
Synchronous speed refers to the speed of an AC induction motors rotating magnetic field. It
is determined by the frequency applied to the stator and the number of magnetic poles present
in each phase of the stator windings. Synchronous Speed equals 120 times the applied
Frequency (in Hz) divided by the number of poles per phase.
Glossary
Manual, AA, A5E32043214A 153
System Operating Program
The functions of the programmable inputs and outputs are determined by the default system
program. These functions can be changed by modifying the appropriate setup menus from the
front keypad and display. I/O assignments can also be changed by editing the system program
(an ASCII text file with the extension .SOP), compiling it using the compiler program, and then
downloading it to the controller through its serial port, all by utilizing the SOP Utility Program
with the Siemens LD A Tool Suite.
Tool Suite
Is the suite of programs developed by Siemens that allows easier access to the drive for
programming and monitoring. It is comprised of the following components:
Tool Suite Launcher - also referred to as Tool Suite; used for coordinating other tools.
SOP Utilities - used to launch an editor that compiles or reverse compiles a System
Program. It also allows for serial connection to the drive for uploading and downloading
System Programs.
Configuration Update - allows for backing-up, updating, and cloning drives via direct access
to the Flash Disk.
Host Simulator - used for monitoring, programming, and controlling a drive remotely from
a PC over the built-in ethernet port of the drive. Parameter changes, status display, and
graphing of internal variables are its main functions.
Debug Tool - this tool is used to display the diagnostic screens of the drive for diagnosing
drive problems or improving performance via the built-in ethernet port of the drive.
Tool Suite Launcher
Torque
The force that produces (or attempts to produce) rotation, as in the case of a motor.
Uploading
Uploading is a process by which information is transmitted from the drive to a remote device
such as a PC. The term uploading implies the transmission of an entire file of information (e.g.,
the system program) rather than continued interactive communications between the two
devices. The use of a PC for uploading requires communications software to be available on
the PC.
Variable frequency drive (VFD)
A VFD is a device that takes a fixed voltage and fixed frequency AC input source and converts
it to a variable voltage, variable frequency output that can control the speed of a motor.
Glossary
154 Manual, AA, A5E32043214A
VHZ
Is an acronym for Volts per Hertz control, one of the control modes in the drive. This mode is
intended for multiple motors connected in parallel. Therefore, it disables spinning load and fast
bypass. This is essentially open-loop vector control with de-tuned (smaller bandwidth obtained
by reducing the gain) current regulators.
Glossary
Manual, AA, A5E32043214A 155
Index
A
abbreviations, 139
AC power, 49
access plate, 49
alarms, 61
anchor bolts
holes, 45
anchoring cabinet, 45
Arcing, 11
assembly
drive, 45
Asynchronous motors, 11
Auxiliary power supply, 11
B
basic drive module, 136
bolts, 46
bypass contactor, 24
C
cabinet
cell, 24
coolant, 25
exciter, 26
FPC, 22
input power, 21
output power, 25
output reactor, 25
transformer, 21
cable, 48
control, 54
encoder, 55
power, 55
serial communication, 55
signal, 54
Cable and screw terminals, 67
cable entry
location, 33
Cabling, 11
capacitor
bucket, 106, 114
mounting bolts, 107
capacitor bank
connections, 106
cover plate, 108
CE marking, 135, 138
Gambica guidelines, 135
on Power Drive Systems, 136
cell cabinet, 24
12 cell, 117
9 cell, 112
bypass contactor assembly, 116
construction, 111
maintenance, 111
power cells, 114
rear panel assembly, 116
rear supply and return manifold, 118
sub-assemblies, 111
top hat air-to-water heat exchange system, 112
cell input power fuse
fuse replacement, fuse indicator, Bussmann,
Ferraz, 73
circuit breaker, 23, 26
customer, 57
cleaning
contamination, 66
close input MV contact, 26
commissioning
safety, 59
trained personnel, 59
Commissioning, 11
compensating the primary voltage source, 49
components
WCIII drive, 20
contact
hotline, 125
website, 125
control power, 49, 61
coolant cabinet, 25
cooling blower, 24
cooling system, 61
D
derating, 131
dimensions, 45
Disposal of
old device, 123
packing waste materials, 123
drive, 9
grounding, 48
Dust deposits, 66
Manual, AA, A5E32043214A 157
E
electrical
connections, 49
safety, 49
electromagnetic compatibility, 53
earthing, 53
filtering, 54
guideline, 56
shielding, 54
wiring, 54
Electromagnetic fields, 17
electro smog, 17
Electrostatic discharge, 15
Electrostatic Protective Measures, 17
EMC Directive, 137
EMC-compliant installation, 11
emergency stop pushbutton
E-Stop, 22
EN standards, 136
ESD guidelines, 15
ethylene glycol
safety information, 14
warnings, 14
EU directives, 135, 138
exciter cabinet, 20, 26
F
faults, 61, 62
Five safety rules, 12
FPC cabinet, 22
fuse sources
blown cell input fuse, 73
G
gasket
damage, 46
sealing strip, 46
gland plate, 56
drilling, 56
install, 56
removal, 46, 56
Grounding, 11, 48
H
Hall Effect current sensors, 23
handling, 32
crane, 34
final lifting liability, 33
fork-lift, 33
strap and cradle method, 34
hazardous waste, 14
heat exchanger, 21, 23, 24
HMI, 22
hose, 111
I
IEC standards, 136
Industrial network, 11
ingress protection ratings, 132
input conductor
sizing guidelines, 53
input current interrupting device, 26
input line current transformer, 21
input line surge arrester, 21
input line voltage attenuator resistor, 21
input MV line terminals
L1/L2/L3, 21
input power cabinet, 21
input protection, 26
inspection, 64
checklist, 66
contamination, 65
damage, 65
visual, 65
installation
electrical, 49
mechanical, 45
Installation, 11
installing the VFD, 29
J
J-bar, 45
K
key interlocks, 19, 60, 63, 64
electrical, 19
mechanical, 19
unlocking, 63
L
lifting, 32
Index
158 Manual, AA, A5E32043214A
Lock-out / Tag-out procedure, 13
Low Voltage Directive, 135, 137
M
Machinery Directive, 138
maintenance
safety, 63
maintenance and earthing
procedure, 68
manual
description, 9
medium voltage, 61
N
NXGII control panel, 23
O
off-loading, 32
operating
safety, 61
operating conditions, 129
outline dimensions, 20
output line voltage attenuator resistor, 23
output medium voltage line terminals
T1/T2/T3, 25
output power cabinet, 25
output reactor cabinet, 20, 25
P
placement, 43
conditions, 43
mounting, 43
requirements, 43
power cell, 24
banding, 87, 91
banding tool, 87
capacitor discharge resistors, 24
cell lifter, 95, 96, 103
crating, 91
damage, 100, 102, 106, 108
deration parameters, 131
inserting, 101
inspection, 94, 108
installation, 93, 94
isolating, 80, 101
lethal voltages, 80, 101
lifting, 88
pallet, 88
positioning, 80
pre-charge circuit series capacitors, 24
purging, 82
removal, 80, 85
safety, 80, 93, 96, 100
transporting, 85, 96, 100
utility cart, 95, 101
power distribution panel, 24
power quality meter, 21
Pressure Equipment Directive, 138
primary voltage source, 49
propylene glycol
safety information, 15
protective earthing, 48
R
receiving procedure
carrier, 32
damage, 32
inspection, 32
replacement of parts, 70
CompactFlash card, 72
deionizer tank, 70
residual current device, 59
RJ45 ethernet port, 22
S
safety
glycol, 14
safety precautions
handling, 29
moving the unit, 32
transportation, 29
secondary cell voltages, 49
secondary circuit fault
coordinated input protection scheme, 26
Shielding, 11
shipping
by ocean, 31
by rail, 31
by truck, 31
conditions, 30
guidelines, 30
secure load, 31
standards, 30
Index
Manual, AA, A5E32043214A 159
shipping sections, 19
shipping section 1, 20
shipping splits, 32
reconnecting, 46
spare parts
NXGII control, 120
optional components, 122
power cell, 121
specifications, 127, 129
speed demand mode selector switch, 22
storage, 41
conditions, 41
indoor, 41
inspection, 41
requirements, 41
symbols, 139
Synchronous motors, 11
T
technical support
hotline, 125
website, 125
thermal switch, 21
TIMV contact, 26
top angles, 45
torque specifications, 51
transformer, 21, 49
transformer cabinet, 21
Transport, 11
transportation
center of gravity, 30, 36
crane, 34
pipe rollers, 40
roller dollies, 39
standard lifting method, 37
strap and cradle method, 34
trip input medium voltage, 26
U
unpacking, 42
damage, 42
inspection, 42
V
variable frequency drive, 9
Variable-Speed Drives, 11
Ventilation, 67
VFD, 9, 19
voltage taps, 49
W
Wago 750 Series Fieldbus, 23
WCIII drive
1250 amp cell type, 131
880 amp cell type, 130
operating conditions, 129
power cell specifications, 130
specifications, 127
storage condiitons, 129
transport condiitons, 129
weight
system, 32
Index
160 Manual, AA, A5E32043214A

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Sinamics Perfect Harmony Gh180 Operating Instructions A5e32043214a Aa

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