Operating manual - triolcorp.com · Operating manual АТ27 – 6 kV block-box version. ... per GOST 14254-96, featuring a block-box design, and to be used in conjunction with motors

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Operating manual

АТ27 – 6 kV block-box version

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Dear Customer!

We are grateful to You for purchasing the equipment produced by Triol Corporation. We are sure that our АТ27 variable-frequency drive will be run by You effectively and will make a profit for You.

We also want to remind You that the variable-frequency drive purchased by You is a complex electrical device , improper operation of which may lead to its failure. So we recommend study-ing this Manual carefully before proceeding to operation of this variable-frequency drive paying particular attention to the notes and warnings specified herein.

The present «Operating Manual» is intended for examination of technical data, design, ser-vice, rules of operation and maintenance of the variable-frequency drive produced by Triol Cor-poration.

Information contained herein is reviewed on a regular basis and is amended if required in subsequent editions. Any improving proposals relating to the contents of this document will be accepted with great pleasure and appreciation.

АТ.654226.843 OM

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Table of Contents1. Safety recommendations ........................................................................................................................... 6

1.1. Application of safety signs used in the Manual ...................................................................................... 6

1.2. General warnings ......................................................................................................................................... 7

2. Introduction .................................................................................................................................................. 8

2.1. Compatibility of this Manual ...................................................................................................................... 8

2.2. Users of this Manual .................................................................................................................................... 8

2.3. Abbreviations and definitions .................................................................................................................... 9

2.4. Installation and commissioning block diagram ....................................................................................10

3. General information of the Triol AT27 medium-voltage multilevel variable-frequency drive ....11

3.1. Intended use, capabilities and features .................................................................................................11

3.2. Principle of Triol АТ27 operation .............................................................................................................14

3.3. Triol АТ27 VFD basic technical specifications ........................................................................................16

3.4. Triol АТ27 embodiments ...........................................................................................................................19

3.5. Intended use of elements included into a block-box version of

AT27 variable-frequency drive ........................................................................................................................21

3.5.1. Operator’s compartment control cabinet ......................................................................................21

3.5.2. Power switching compartment ........................................................................................................22

3.5.3. Transformer compartment ...............................................................................................................23

3.5.4. Power cells compartment .................................................................................................................24

3.5.5. Ventilation compartment ..................................................................................................................28

3.5.6. Snow-and-moisture trap compartment .........................................................................................29

3.6. Ventilation and heating system inside block-box version

of the Triol AT27 variable-frequency drive ....................................................................................................30

4. Triol АТ27 variable-frequency drive service conditions ......................................................................32

5. Electromagnetic compatibility of Triol AT27 variable-frequency drive

with electrical grid and motor .....................................................................................................................33

6. Triol АТ27 drive principle of operation ...................................................................................................34

6.1. General description of AT27 drive functioning .....................................................................................34

6.2. Description functioning power cells .......................................................................................................37

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6.3. Control system description ......................................................................................................................38

7. Transportation and storage .....................................................................................................................40

7.1. Transportation of Triol АТ27 variable-frequency drive .......................................................................40

7.2. Unloading of Triol АТ27 variable-frequency drive ................................................................................42

7.3. Product unpacking .....................................................................................................................................46

7.4. Triol АТ27 drive storage conditions ........................................................................................................46

8. Safety precautions .....................................................................................................................................47

9. Installation of Triol АТ27 variable-frequency drive .............................................................................49

9.1. Checking for complete set of supply and visual examination ...........................................................49

9.2. Checking internal elements .....................................................................................................................49

9.3. Product marking .........................................................................................................................................50

9.4. Designation of Triol АТ27 configuration ................................................................................................50

9.5. Installation of Triol АТ27 variable-frequency drive ..............................................................................52

10. Electrical installation (external connections) of Triol AT27 variable-frequency drive ................53

10.1. Overview of wiring installation ..............................................................................................................54

10.2. Wiring of power circuits (6 kW) ..............................................................................................................55

10.3. Wiring of 0.4kV circuits ............................................................................................................................56

10.4. Wiring of control circuits .........................................................................................................................57

10.5. Triol АТ27 installation check ..................................................................................................................58

11. Commissioning .........................................................................................................................................59

11.1. Switching АТ27 variable-frequency drive for the first time ..............................................................59

11.2. Preparation of AT27 to startup and its startup in idle mode ...........................................................59

11.3. Preparation of AT27 to startup and its startup using motor with no load on the shaft .............62

11.3.1. Asynchronous machine startup ....................................................................................................64

11.3.2. Synchronous machine startup without excitation ....................................................................64

11.3.3. Synchronous machine startup with excitation ...........................................................................64

11.4. Motor startup with a load on the shaft ................................................................................................65

11.4.1. Asynchronous/synchronous machine startup ............................................................................67

11.5. The list of possible faults and their solutions .....................................................................................67

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12. Maintenance and repair .........................................................................................................................71

12.1. Periodic maintenance .............................................................................................................................72

12.2. I/O compartment servicing ....................................................................................................................72

12.3. CC servicing ...............................................................................................................................................72

12.4. Power cell replacement procedure ......................................................................................................73

13. Warranty and services ............................................................................................................................74

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1. Safety recommendations

1. Safety recommendationsThis Section contains safety instructions to be followed during installation, operation and

maintenance of the variable-frequency drive. Non-compliance with the rules specified below may result in the personnel injury and damage of the variable-frequency drive, motor and all the connected equipment. Carefully read the safety instructions before starting the VFD opera-tion.

1.1. Application of safety signs used in the ManualThis Manual uses two types of safety guidelines requiring attention when performing any

operations with electric drive:

• Warnings indicate conditions that may result in serious injuries or even death and/or may lead to the equipment damage. They also contain information how to avoid a danger;

• Notes serve to draw attention to certain conditions or facts, or contain additional informa-tion regarding an issue under consideration.

Warnings depending on their content are also symbolized as follows:

Electrical hazard sign — if recommendations specified in warnings denoted by this symbol are not followed there is a hazard of electrical shock for the operating personnel and/or a risk of the equipment damage.

!General warning sign — if recommendations specified in warnings denoted by this symbol

are not followed a hazard may occur that is not associated with electrical factors.

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1.2. General warningsWarnings, instructions and guidelines specified below are intended to provide user safety as

well as to prevent any damages of the product.Special warnings, instructions and guidelines pertaining to certain kinds of work are given at

the beginning of a relevant section as well as in particularly important locations within the sec-tions.

Please, carefully read these instructions as this will assure both your personal safety and long service life of the variable-frequency drive.

Neglecting warnings specified in this Manual may result in a hazard to life, serious injuries or extensive material damage.

WARNING! Variable-frequency drive is connected to a hazardous high-voltage source, and it operates mechanisms with rotating parts which are also sources of danger. Therefore ONLY highly qualified electricians are authorized to perform any electric installation work and maintenance of the Triol AT27 variable-frequency drive.

WARNING! Access of children or any unauthorized persons to the variable-frequen-cy drive shall be excluded!

WARNING! Any operations with power cables and control cables when the VFD power source is connected are prohibited. Hazardous voltage (from external sourc-es) may exist across relay-controlled outputs even if a supply voltage is not applied to the VFD input terminals.

WARNING! Exclude operation of the variable-frequency drive with any parts of its housing removed or unfixed as otherwise there is a hazard of electric shock and/or damage of the equipment.

WARNING! To assure the personnel safety as well as to reduce the level of elec-tromagnetic radiation and to enhance the interference resistance make sure to reliably ground the housing of variable-frequency drive, and casings of motor and all connected equipment. To connect grounding conductors the electric drive is

equipped with grounding bolts denoted by the «Ground» sign.

WARNING! Variable-frequency drive may be used only for the purposes specified by the manufacturer. Unauthorized changes and usage of spare parts and fixtures not manufactured or not recommended by the VFD manufacturer may result in a fire, electric shock or injuries.

WARNING! PC boards contain elements sensitive to static electricity. When working with PC boards it is mandatory to wear grounding straps. Do not touch PC boards unless necessary.

WARNING! Variable-frequency drive shall be repaired only in service centers of Tri-ol Corporation or by its qualified personnel at the site.

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2. Introduction

2. IntroductionThis section contains some information pertaining to the compatibility of this Manual, re-

quired level of the user qualification and the abbreviations used.

2.1. Compatibility of this ManualThis section contains some information corresponding to the Triol AT27 medium-voltage vari-

able-frequency drive with a multilevel sine pulse-width modulation (hereinafter referred to as «Drive», «AT27» or «VFD») produced by Triol Corporation, having IP43 degree of protection as per GOST 14254-96, featuring a block-box design, and to be used in conjunction with motors and electric installations for voltage of 6kV.

Depending on their power variable-frequency drives may be divided into the following models:

• АТ27-М20;

• АТ27-М25;

• АТ27-М32;

• АТ27-М40;

• АТ27-М50;

• АТ27-М63;

• АТ27-М80;

• АТ27-1М0;

• АТ27-1М2;

• АТ27-1М4;

• АТ27-1М6;

• АТ27-2М0;

2.2. Users of this ManualThis Manual is meant for the personnel performing installation, setting-up, operation, repair

and disposal of the variable-frequency drive. Carefully read this Manual before proceeding to any of the aforesaid operations. In development of this Manual we have assumed that a user is familiar with the basics of electrical engineering, installation rules, electric components and electrical schematic symbols.

• АТ27-2М5;

• АТ27-3М0;

• АТ27-3М5;

• АТ27-4М0;

• АТ27-4М5;

• АТ27-5М0;

• АТ27-5М5;

• АТ27-6М3;

• АТ27-8М0;

• АТ27-9М3;

• АТ27-10М;

• АТ27-12М5.

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2.3. Abbreviations and definitionsThe АТ27 medium-voltage multilevel variable-frequency drive may be hereinafter referred to

as AT27 VFD or AT27.

The following abbreviations and designations are used throughout this document:

VFD (АТ27, variable-frequency drive, АТ27 variable-frequency drive) means «Triol AT27 medium-voltage variable-frequency drive with multilevel sine pulse-width modulation».

FRS — frequency regulation system;

VFD — variable-frequency drive;

PC — power cell;

PCC — power cells compartment;

IOC — I/O compartment;

PSC — power switching compartment;

TC — transformer compartment;

CC — control cabinet;

AR — automatic restart;

PACS — process automated control system;

IM — Installation Manual;

BB — block-box;

CIO — cabinet I/O;

CD — compartment demister;

HVSC — high-voltage switching compartment;

ACS — automatic control system;

КВТв — type vacuum contactor;

THD — total harmonic destruction.

List of accompanying manuals for Triol AT27 variable-frequency drive

«Programming Manual»

Here the VFD functions and parameters as well as the UMKA-27 controller usage are de-scribed; issues of programming and real-time control are also reviewed here in detail.

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2. Introduction

2.4. Installation and commissioning block diagramA block diagram presenting brief description of the installation procedures for the variable-

frequency drive variable (a more detailed list of operations is given in Design Manual for this product) is given below.

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3. General information of the Triol AT27 medium-voltage multilevel variable-frequency drive

3.1. Intended use, capabilities and featuresАТ27 medium-voltage multilevel frequency converter (MMFC) is designed to perform fre-

quency control of the speed in cage asynchronous motors as well as in synchronous motors with rated voltage of 6000 V and rated power from 200 kW to 6300 kW.

It is designed to work with the following processing machinery:

• fans;• vacuum cleaners;• smoke exhausters;• water supply pumps;• circulating pumps;• feed pumps;• vacuum and pressure pumps;• oil pumps;• compressors;• mills;• crushers and other processing machinery.

VFD may be used at thermal power plants, enterprises of oil and chemical industries, water-supply facilities and iron-and-steel and mining plants.

Application of the AT27 MMFC allows to:

• reduce power consumption;

• start up high-starting-torque motors;

• increase performance reliability and prolong service life of motors as well as of machinery driven by them;

• exclude water hammers in a piping system;

• decrease the equipment failure rate as well as to reduce costs associated with repairs and maintenance;

• integrate the АТ27 MMFC control into the process control system of an enterprise.

АТ27 MMFC has the following features and advantages:

• auxiliary power supply is performed from two independent power sources increasing the overall operational reliability of AT27 MMFC;

• under rated operating conditions an overall performance of the system is not less than 97 %, and that of the converting part – not less than 98 %;

• Power cells are repairable and interchangeable;

• АТ27 MMFC features the motor startup current limitation function;

• output voltage is adjusted automatically;

• АТ27 MMFC has the function of automatic restart if a short-term power failure takes place;

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3. General information of the Triol AT27 variable-frequency drive

• АТ27 MMFC features a power cell bypassing system ensuring the FC continuous operation if a single power cell in each output phase is failed;

• power cells are controlled by means of fiber-optic cables. Thus high resistance to electro-magnetic interference is achieved;

• separate RS485 interface ensures data exchange with upper-level ACS using the MODBUS protocol;

• АТ27 MMFC ensures the motor overload and overcurrent protection;

• АТ27 MMFC has a diagnostic system that ensures timely alerting, protection, recording and storage of the fault information;

• ensures the motor hot start-up;

• makes it possible to perform automatic switching at the motor starting up in the coasting mode;

• has a function of assigning the motor speed static deviation (in the mode of closed-loop control system);

• ensures fast transmission of resonant frequencies (using this function there may be achieved a transmission of resonant frequencies in the drive at a much quicker rate);

• makes it possible to automatically control the acceleration and braking values with a pre-set accuracy (in the mode of closed-loop control system);

• ensures low level of noise both at the input and output, occurring during the VFD opera-tion and THD not exceeding 5%;

• provides for the function of the energy-consumption optimization under stationary oper-ating conditions;

• may be readily incorporated into control processes due to availability of advanced control algorithms and functions such as:

• Triol «Cascade» automatic control system (next, in the test ACS);

• motor pickup;

• operation by calendar;

• built-in PID-controller;

• automatic restart (AR).

• may be operated outdoors, designed УХЛ (for areas with temperate and cold climate), placement category 1 according to GOST 15150;

• may be operated over wide range of working temperatures from – 60 to + 50°С;

• has high overload capability — 120% within 60 sec;

• features high inverter efficiency, not lower than 98%, with the transformer efficiency not lower than 98% as well. In winter thermal losses are used to heat the block-box thereby increasing the system efficiency and maintaining such temperature in a room that is com-fortable for the attending personnel;

• remains functional if a supply voltage drops down to – 30%;

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• has a function of entering records of the VFD operation into the logs as well as analyzing emergencies and optimizing manufacturing processes;

• makes it possible to start up the motor with high starting torque;

• increases the motor operational life;

• ensures electromagnetic compatibility with the motor and power supply system;

• features optimum weight-and-size characteristics that makes it possible to convey the equipment by any mode of transport;

• ensures arrangement of the connection diagram with a required number of power inputs and outputs to meet to the Customer’s requirements;

• readily integrated into the PACS;

• ensures maximum functionality according to users’ needs;

• has a function of automatic maintenance of a preset value of the technological parameter;

• supplied assembled that makes it possible to perform quick installation of the product;

• different models may be supplied with the power varying within the range from 200 to 12 500 kW; any equipment for the power exceeding 5MW is designed in accordance with the customized technical requirements agreed upon with the Customer.

A block-box version of the Triol АТ27 6kV electric drive incorporates the up-to-date techni-cal solutions and optimized operating algorithms. The form factor of this product significantly simplifies its installation, commissioning and maintenance of high-voltage drives, wherein no additional construction documents and expert examinations for their installation at the site are required.

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3.2. Principle of Triol АТ27 operationAT27 medium-voltage multilevel frequency converter performs a conversion of the three-

phase voltage with constant frequency and amplitude into the three-phase voltage with vari-able frequency and amplitude.

The AC/DC/AC principle of conversion with a single input power transformer has been real-ized in the AT27 frequency converter. Conversion from DC into AC is executed in IGBT power cells (cells).

Functional diagram of the AT27 medium-voltage multilevel frequency converter is given in Fig. 3.1.

Fig. 3.1 — Functional diagram of the VFD power circuit with motor power supply

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Primary winding of the input transformer (star connection) is connected to the 6kV three-phase mains. The dry-type transformer features the inboard forced air cooling. Secondary wind-ings are delta auto-connected; each group of secondary windings is distinguished by phase dis-placement of the voltage transformed. Such technical solution makes it possible to decrease the influence of the frequency converter on the mains.

Series connection of power cells allows a user to arrange the AT27 MMFC operation in the mode of multilevel conversion with pulse width modulation (hereinafter referred to as «PWM-conversion»). Such a mode makes it possible to lower the amplitude of output ripple propor-tional to the number of phase units (cells) applied.

Diagram of the power cell (cell) is shown in Fig.3.2. Input circuits A, B and C are connected to a three-phase voltage of the transformer secondary winding. Voltage from the transformer charg-es capacitors through a three-phase diode rectifier. Electric energy accumulated in capacitors is consumed by a single-phase bridge inverter consisting of IGBT transistors Q1 — Q4 to generate a PWM voltage across inputs L1 and L2.

Fig. 3.2 – Schematic diagram of power cells

Power cells have a «bypass» function. In case a power cell is faulty making it impossible for the MMFC to further operate using this cell, such a bypass is enabled automatically so that to provide its continuous availability.

Control system consists of an industrial controller of UMKA-27 type, motor-operated control-ler, discrete and analog I/O expansion units, power supply units.

Motor-operated controller controls the operation of power cells by fiber optic lines; receives and processes data on the state and actual parameters of power cells.

User interface unit collects signals from process variable sensors, receives/transmits signals with the help of analog and discrete inputs/outputs, processes them and communicates with the UMKA-27 controller.

UMKA-27 industrial controller processes the information on the frequency converter opera-tion, generates control signals using its own discrete and analog inputs/outputs as well as with the help of expansion units.

АТ27 MMFC may be controlled both in manual and automatic modes (PID-control). Besides, there is an option to control the ACS computer or to enter the enterprise control network.

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3.3. Triol АТ27 VFD basic technical specificationsAT27 VFD basic technical specifications are given in Table 3.1.

Table 3.1 — AT27 VFD basic technical specifications

Parameter Value

Rated input voltage, kV 6 kV, ± 15%

Nominal input frequency, Hz 50 ± 10%

The number of phases at the inlet piece 3

Auxiliary rated input voltage, V 380

Rated frequency of auxiliary input voltage, Hz 50 ± 5%

Number of phases at auxiliary output, pcs 3

Output (linear) voltage range, V 50…6000

Output frequency range, Hz 1...80 ± 0,1

Frequency tolerance, % ± 0,1

Number of phases at output, pcs 3

Rated output current, A see table 1.2

Rated output active power, kW see table 1.2

Overload capacity

120 % of Ir within 1 min.150 % of Ir within 3 s200 % of Ir within 10 ms.

Power factor under design conditions, not less than 0,97

Driving part efficiency, not less than 0,98

Mean time between failures, hours, not less than 20000

Type of cooling forced air

Operating mode continuous

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Rated currents of primary power circuit for variable-frequency drives of different power are given in Table 3.2.

Table 3.2 — Rated currents of primary power circuit for variable-frequency drives of differ-ent power

VFDtype Rated voltage, V Rated active

power, kWRated current,

ANumber of

power cells per phase

АТ27-М20 6000 200 25 6

АТ27-М25 6000 250 30 6

АТ27-М32 6000 320 40 6

АТ27-М40 6000 400 50 6

АТ27-М50 6000 500 60 6

АТ27-М63 6000 630 75 6

АТ27-М80 6000 800 95 6

АТ27-1М0 6000 1000 125 6

АТ27-1М2 6000 1200 145 6

АТ27-1М4 6000 1400 170 6

АТ27-1М6 6000 1600 195 6

АТ27-2М0 6000 2000 245 6

АТ27-2М5 6000 2500 305 6

АТ27-3М0 6000 3000 375 6

АТ27-3М5 6000 3500 440 6

АТ27-4М0 6000 4000 500 6

АТ27-4М5 6000 4500 565 6

АТ27-5М0 6000 5000 625 6

АТ27-5М5 6000 5500 690 6

АТ27-6М3 6000 6300 790 6

АТ27-8М0 6000 8000 1015 6

АТ27-9М3 6000 9300 1180 6

АТ27-10М 6000 10500 1330 6

АТ27-12М5 6000 12500 1585 6

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АТ27 MMFC operation and control modes as well as frequency setting modes are given in Table 3.3.

Table 3.3 — AT27 MMFC operation and control modes as well as frequency setting modes

Characteristic Value

Motor control mode Scalar Control by U/F Characteristics; Flux Vector Speed and Torque control

Number of U/f character-istic points to be set, pcs 8

Motor shaft speed control modes

Direct frequency control

PID-control

АТ27-1М6 MMFCoperation modes

Manual control mode (by operator’s commands from local op-erator’s panel)Mode of automatic control by preset algorithm allowing for defined events («scheduled» operation)Automatic control mode allowing for the state of «dry contact» discrete inputs (control from external contact-relay equipment)Mode of automatic control by the state of analog inputs of «0...10 V», «0...20 mA» and «4…20 mA» types (control from PACS)External control mode using control devices through RS-485 (ModBus-RTU. PROFIBUS)

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3.4. Triol АТ27 embodimentsАТ27 variable-frequency drive is made as a block box.

Number and models of devices included into the complete set of supply may vary depending on the Customer’s requirements.

VFD includes:

• Power transformer compartment (TC);• Power cells compartment (herein after referred to as PCC);• High-voltage switching compartment (herein after referred to as HVSC).

Optionally the АТ27 VFD may include the following component parts:

• through-type high-voltage compartment;• compartment for HVSC 2-2 high-voltage contactors;• compartment for HVSC 3-3 high-voltage contactors.

Overall dimensions and power values are given in Table 3.4.

Table 3.4 — VFD overall dimensions

Model Triol AT27 Power, kW Width,mm

Height, mm X (length), mm

АТ27 VFD (6 kV, 6 cells in a phase with bypass, length of 6/9 m) 1 section of

АТ27-ххх-6/6-1хС64х-К6(К9)-14200 – 630

2400 26008000

800 – 2000 100002500 – 4000 10000+3000

АТ27 VFD (6 kV, 6 cells in a phase with bypass, length of 9/12 m) 2 sections of

АТ27-ххх-6/6-2хС64х-К9(К12)-14200 – 630

2400 260010000

800 – 2000 120002500 – 4000 10000+5000

АТ27 VFD (6 kV, 6 cells in a phase with bypass, length of 9/12 m) 3 sections of

АТ27-ххх-6/6-0хС64х-К6(К9,К12)-14200 – 630

2400 260010000

800 – 2000 120002500 – 4000 10000+5000

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Fig. 3.3. — Overall dimensions VFD

The АТ27 consists of the VFD working compartments (power cells and transformer compart-ments) as well as operator’s compartment (ensures access to the control cabinet and drives of power circuit disconnect switches).

Access to working compartments (where power cells and transformer are located) is blocked when the frequency converter is in operation.

Arrangement of compartments within the АТ27-1М6 MMFC is given in Fig.3.4.

E B G

A C D F

A – operator’s compartment; B – power switching compartment; C – transformer compartment; D – power cell compartment; Е – operator’s compartment control cabinet, F – ventilation and moisture trap compartment и, G –

transformer ventilation compartment

Fig. 3.4 — Arrangement of compartments within AT27-1M6 MMFC

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3.5. Intended use of elements included into a block-box ver-sion of AT27 variable-frequency drive

3.5.1. Operator’s compartment control cabinetOperator’s compartment is a room in the block box where all the controls and monitoring de-

vices of the АТ27 VFD are located. This is the only compartment within the frequency converter where people may stay during its operation.

Operator’s compartment is shown on the diagram where general arrangement of compart-ments inside the block box is represented, Fig. 3.4.

This compartment includes the АТ27 VFD operator’s compartment control cabinet, power switching compartment, fire-warning panel as well as the operator’s compartment heating sys-tem.

Operator’s compartment control cabinet consists of the following components:

• industrial controller of UMKA-27 with graphic display and control buttons. This controller provides an access to programmable parameters for users of the AT27 MMFC. Besides its menu makes it possible to display actual values and operating conditions of the frequency converter. The UMKA-27 controller allows users to automatize the process (PID-control of parameters using sensors, etc.);

• microprocessor-based system to control the cabinet with cells;

• uninterruptible power supply system for control units enabled when the auxiliary voltage (380 V) is lost;

• power cell filters precharge system;

• block-box ventilation, cooling and heating control system;

• container ventilation capacity automatic control system;

• climate control system (to maintain comfortable tem-perature for personnel in the Operator’s compartment and in those designed for equipment – in power cells and transformer compartments);

• automatic container ventilation control system;

• peripherals expansion units – discrete inputs/outputs, analog inputs/outputs, RS-485 digital interfaces.

• user terminal blocks to connect the upper-level con-trol circuits.

General view of the control cabinet is given in Fig. 3.5.

Fig. 3.5 — General view of the operator’s compartment control

cabinet

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3.5.2. Power switching compartmentPower switching of motors and switchgear working cells is performed inside the power switch-

ing compartment. This compartment is designed for selecting a section of power buses within the АТ27 frequency converter as well as for selecting a motor to be connected to the VFD and its bypass.

A cascade circuit scheme can be realized in the frequency converter. This system enables starting up to 5 motors from a single AT27 VFD. In this system the AT27 variable-frequency drive may bring any motor out of the grid or hook it up that makes the control process more dynamic and environmentally friendly for the motor.

Power switching compartment is equipped with high-voltage vacuum contactors (HVVC) and disconnectors. General view of the power switching compartment is given in Fig. 3.6.

Fig. 3.6 — General view of power switching compartment

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3.5.3. Transformer compartmentInside the transformer compartment a dry-type power transformer of appropriate power is

installed. Six pressurization fans for cooling the transformer are located at the bottom (under the windings). On the front panel covering the transformer there is a thermal switch to monitor and adjust the transformer winding temperature.

General view of the transformer compartment is given in Fig. 3.7.

Fig. 3.7 — General view of transformer compartment

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3.5.4. Power cells compartmentPower cell compartment is designed to accommodate power cells (hereinafter referred to as

a «cell» or «PC») inside the AT27 VFD. PCs are arranged in three tiers, six pieces in each. On each tier PCs are connected in series, thus constituting one output phase of the frequency converter. Right output terminals of the rightmost cells on each tier are connected electrically creating a star. Left output terminals of the leftmost cells on each tier are connected to output terminals of the AT27 VFD. Power cells are fixed in place with the help of guides and bolts. The cells have the same overall dimensions and electrical specifications; they are interchangeable. They are numbered from left to right, from top to bottom.

When the frequency converter is running, power cells evolve some amount of heat. This heat is removed by pumping air through air ducts of the cells where cooling fins of power IGBT tran-sistors and the PC DC-link capacitors are located. Air intake is performed from the front. Air heated by cells goes into the air manifold located at the rear of the power cell compartment from where it is drawn off into atmosphere by fans.

General view of the power cell compartment is given in Fig. 3.8.

Fig. 3.8 — General view of АТ27 power cell compartment

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Three-phase power is supplied from the power transformer secondary windings to power cells by high-voltage cables. Input circuits of power cells are provided with protective fuses. Each PC has a separate control unit and drivers of power IGBT transistors. Communication with power cells is performed using fiber optic cables thereby minimizing the influence of electromagnetic interference on the control circuits.

Overall view of the 320…630 kW VFD power cell is shown in Fig. 3.9.

Fig. 3.9 — Overall view of 320…630 kW VFD power cell

Overall view of the 800…1600 kW VFD power cell is shown in Fig. 3.10.

Fig. 3.10 — Overall view of 800…1600 kW VFD power cell

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Power cells designed for the same output current are interchangeable.

A power cell converts a three-phase AC voltage in the secondary winding into a DC one using a diode-type bridge and then converts this DC voltage into a single-phase AC voltage using a sin-gle-phase voltage inverter on IGBT-transistors. A power cell is controlled by the drive’s controller over optical fiber link. Such a cell contains the cell‘s controller unit which enables the following:

• IGBT-transistors connection as per signals received from the drive’s controller;

• Diagnostics of the cell state and transmission of the diagnostics information to the drive’s controller;

• Protection of the cell’s power transistors, their automatic disabling in emergencies as well as activation of bypass circuit so that to provide a continuous-duty operation of the drive in case of the cell failure.

The cell’s controller unit is shown in Fig. 3.11.

Fig. 3.11 — Overall view of cell’s controller unit

Terminals and connectors for power and signaling cables are located on the power cell’s front panel:

• terminals for connection of the cell’s power supply from the power transformer’s second-ary winding;

• cell’s output terminals (connected in series with other cells in a phase);

• connectors for optic fiber control and diagnostics cable;

• connectors for the cell’s backup power supply.

Arrangement of terminals and connectors on the 320…630 kW VFD power cell’s front panel is given in Fig. 3.12.

27

Fig. 3.12 — Arrangement of power cell’s terminals and connections

Optic fiber link providing communication between cells and the drive’s controller makes it possible to ensure electrical isolation between a power cell and the drive-controlling electronics.

Front and back panels of each power cell has vent ports.

A cell is inserted into the PCC using special guides located on the cell’s bottom. Power input of a cell is protected by fuses located in the cell.

Access to the fuses, power cells and electronics in a cell for their repair or replacement is pro-vided when the cell’s side wall is removed.

28


3.5.5. Ventilation compartmentVentilation system includes three centrifugal induced-draft fans of R3G500- AQ33-001 type

ensuring air exchange between the outdoor environment and the VFD container. Operating modes are controlled with the help of «Germic-С» and «Regular» wire-guided vent dampers. External dampers are equipped with heating system preventing their icing.

Dampers are installed in three ventilation compartments. Mixing and moisture trap chamber through which the air intake is performed is located at the end face of the frequency converter. The moisture trap chamber prevents water ingress into the product.

To prevent dust and dirt getting into the container a system of air mesh filters of ФВС-3.5 type is used. These filters serve also as additional protection against snow and rain preventing moisture ingress into the VFD container.

The block box is heated by electric heaters of Master B 15 EPB type. Ventilation and heating compartments of the АТ27-1М6 VFD block box are shown in Fig. 3.13.

и

А1, А2 —heated dampers of КВУ type; А3, А4 —dampers of ЗВУ type; А5, А6 — electric heaters of Master B 15 type EPB; М1...М5 — exhaust fans of EBM R3G500-AQ33-001 type

Fig. 3.13 — Arrangement of components of the block-box ventilation and heating system

29

3.5.6. Snow-and-moisture trap compartmentMixing and moisture-trap chamber through which the air is trapped is located on the face end

of the variable-frequency drive (Fig. 3.14). Snow-and-moisture trap is designed for preventing ingress of precipitations inside the product.

Fig. 3.14 — Snow-and-moisture trap compartment

30


3.6. Ventilation and heating system inside block-box version of the Triol AT27 variable-frequency drive

It is designed to perform hearting and ventilation by forced supply of atmospheric air masses. The system has a function of both decreasing and increasing the overall temperature of oper-ating elements depending on the vector of deviation of their temperature from the allowable values within the preset range.

Ventilation schematic diagram is shown in Fig. 3.15, where blue color indicates the flow path of air masses with ambient temperature and red color indicates warm air heated by operating elements.

Fig. 3.15 — Ventilation schematic diagram

Air mass flow pattern reveals its distinguishing features when the АТ27 variable-frequency drive operates with open dampers and the ventilation system is supplied with the ambient in-take air (Fig. 3.16).

Fig. 3.16 — Air flow diagram (external dampers are open)

Operation with closed dampers when the ventilation system cycle has become closed and the system starts functioning independent of the ambient air as shown in Fig. 3.17.

31

Fig. 3.17 — Air flow diagram (external dampers are closed)

32

4. Triol АТ27 variable-frequency drive service conditions

4. Triol АТ27 variable-frequency drive service conditionsVFD is designed for outdoor installation. Values of climatic factors for УХЛ climatic version, 1st

category of location as per GOST 15150-69 and GOST 15543.1-89 with the following distinctive parameters are given in Table 4.1.

Table 4.1 — Service conditions of VFD АТ27

Parameter Condition Limits ofmeasurement

Type of protection

Unexplosive, not containing corrosive gases and vapors in concentrations

that may cause a destruction of met-als and insulation; not saturated with current-conducting dust and vapors

content of corrosion-active agents, mg/m2 per day

sulphur dioxide 20…250chlorides less than 0.3

Ambient temperature, °С from - 60 to + 40 °С*

Relative humidity, % 100 % at + 25 °С

Elevation above sea level, m not exceeding 1000

Values of climatic factorsfor УХЛ climatic version, 1st category of location as per GOST 15150-69 and

GOST 15543.1-89Degree of protection as per GOST 14254-80 IP43

(*) Note: When the temperature reaches its upper limit within the preset range the automatic overheat protection system operates and the drive automatically decreases its output power.

АТ27 VFD shall be connected to the 6 kV supply line through stationary or self-contained units complete with controls and protective devices.

Working position of VFD АТ27 is vertical, allowable deviation from the vertical to any direction shall not exceed 5°.

This VFD shall be operated by personnel with electrical safety qualification level not low-er than the 3rd one , authorized to operate electrical installations rated for 1000 V and higher and instructed in operational aspects of this variable-frequency drive.

33

5. Electromagnetic compatibility of Triol AT27 variable-frequency drive with electrical grid and motor

АТ27 medium-voltage multilevel frequency converter provides electromagnetic compatibility with a motor and power-supply system. Level of voltage and current fluctuations in the supply line caused by the frequency converter meets the requirements of applicable CIS standards and IEEE Std 519-1992.

Recommendations on ensuring electromagnetic compatibility and reducing the noise level:

1. Make sure that all compartments and supporting structure of the AT27 VFD are grounded in proper way.

2. It is advisable to ground shields of power cables only on one side.

3. Ground shields of power cable entering and leaving the AT27 compartments to the ground-ing terminals located inside the I/O compartment.

4. Make sure to ground shields of control cables entering the control cabinet.

5. It is advisable to lay cables with analog and digital signals in different cable trays.

6. It is prohibited to use the same cable for transmitting 110/220V signals and 24V signals. All the user-available signals of the AT27 variable-frequency are those rated for 24V.

7. Signaling and control cable shall be separated from the power cables.

Control and signaling cables shall be laid separately. If control and signaling cables are laid in the same cable conduit they shall be arranged in separate cable trays or be separated by con-ductive grounded strip. Recommended distance between control and signaling cable shall be at least 200 mm.

8. At the points of intersection between control and signaling cables an angle between them shall be as close to 90° as possible.

34

6. Triol АТ27 drive principle of operation

6. Triol АТ27 drive principle of operation6.1. General description of AT27 drive functioning

The АТ27 variable-frequency drive has implemented an advanced multilevel PWM (pulse-width modulation) formation technology which implies converting a three-phase voltage with constant frequency and amplitude into a three-phase voltage with alternating frequency and amplitude, and formation of output voltage by summing voltages from separate power cells connected in series. A cell is characterized by «three-phase uncontrolled rectifier — single-phase inverter» structure, wherein the VFD output voltage waveform approaches to sine wave. The PCC inverter is based on IGBT-transistors.

Functional diagram of the AT27 medium-voltage multilevel frequency converter is given in Fig. 6.1.

Fig. 6.1 – АТ27 VFD functional diagram

Primary winding of the input transformer (star connection) is connected to the 6kV three-phase mains. The dry-type transformer features the inboard forced air cooling. Secondary wind-ings are delta auto-connected; each group of secondary windings is distinguished by phase dis-placement of the voltage transformed. Such technical solution makes it possible to decrease the influence of the frequency converter on the mains.

35

Series connection of power cells allows a user to arrange the AT27 MMFC operation in the mode of multilevel conversion with pulse width modulation (hereinafter referred to as «PWM-conversion»). Such a mode makes it possible to lower the amplitude of output ripple propor-tional to the number of phase units (cells) applied.

Voltage phase shift on the secondary winding subsequent group with respect to the voltage phase on the secondary winding preceding group is 10 electric degrees. Such technical solution makes it possible to decrease the influence of VFD on the power supply mains as the 36-pulse AC current-rectification circuit forms a smoothed characteristic of the current consumed from the mains.

A diagram of PCC voltage combining into a phase-to-neutral voltage and 6kV linear voltage at the VFD output is shown in Fig. 6.2.

Fig. 6.2 — Diagram of PCC voltage combining into a phase-to-neutral voltage and 6kV linear voltage

Application of 6 cells per a phase in VFD makes it possible to obtain +6…0…–6, i.e. 13 levels of the PWM output voltage that completely excludes a devastating impact of voltage fluctuations and dU/dt effect on the motor insulation. Such number of the PWM voltage levels has enabled to significantly enhance the VFD output characteristics, wherein the output voltage and current waveforms are close to a sine.

Curves of PCC output voltages, formed phase-to-neutral voltage and output linear voltage in VFD are shown in Fig. 6.3, 6.4 and 6.5, respectively.

36

6. Triol АТ27 drive principle of operation2000

0

-2000

2000

0

-2000

2

0

-2

2000

0

-2000

2000

0

-2000

2000

0

-2000

2000

0

-2000

2000

0

-2000

х104

0 0,01 0,02 0,03 0,04 0,05 0,06 0,07 0,08 0,09 0,1

Fig. 6.3 — Curves of PCC output voltages and formed phase-to-neutral voltage in VFDInput A32,000

24,000

16,000

8,000

0,000 V

-8,000

-16,000

-24,000

-32,0007 ms/Div-9,60 ms

Fig. 6.4 — VFD output linear voltage curve

400,00

300,00

200,00

100,00

0,00 А

-100,00

-200,00

-300,00

-400,00

Input A

5 ms/Div-9,60 ms

Fig. 6.5 — VFD output current curve (as exemplified by АТ27-2М0-6)

37

6.2. Description functioning power cellsDiagram of the power cell (cell) is shown in Fig.4.2. Input circuits A, B and C are connected to a

three-phase voltage of the transformer secondary winding. Voltage from the transformer charg-es capacitors through a three-phase diode rectifier. Electric energy accumulated in capacitors is consumed by a single-phase bridge inverter consisting of IGBT transistors Q1 — Q4 to generate a PWM voltage across inputs L1 and L2.

A

B

C

L1

Q1

Q3

Q2

Q4

L2

Fig. 6.6 — Schematic diagram of power cells

Power cells have a «bypass» function. In case a power cell is faulty making it impossible for the VFD to further operate using this cell, such a bypass is enabled automatically so that to pro-vide its continuous availability.

Control system consists of an industrial controller of UMKA-27 type, motor-operated control-ler, discrete and analog I/O expansion units, power supply units.

Motor-operated controller controls the operation of power cells by fiber optic lines; receives and processes data on the state and actual parameters of power cells.

User interface unit collects signals from process variable sensors, receives/transmits signals with the help of analog and discrete inputs/outputs, processes them and communicates with the UMKA-27 controller.

UMKA-27 industrial controller processes the information on the frequency converter opera-tion, generates control signals using its own discrete and analog inputs/outputs as well as with the help of expansion units.

АТ27 VFD may be controlled both in manual and automatic modes (PID-control). Besides, there is an option to control the ACS computer or to enter the enterprise control network.

38

6. Triol АТ27 drive principle of operation

6.3. Control system descriptionControl system controls the variable-frequency drive according to the assignment (manual,

automatic or remote), ensures the motor overload and overcurrent protection, and applies commands to actuate a corresponding alarm.

For the sake of visualization and to simplify the process of monitoring of the VFD operation the control system has a function of displaying the data and graphs for an operator on the UMKA-27 controller’s graphic panel.

The АТ27 variable-frequency drive control system block diagram is shown in Fig. 6.7.

Powertransformer

Powercells

OpticOptic UMKA-27

controller

US

B

RS

-485

RS

-485

Control unit Discrete andanalog inputs/

outputs

to PACStransducers

and actuators

to PACS

Voltagemeasuring

unit

М6 kV

Currenttransducer

MVT

Input~ 6kV

to control unit

A1

A2

A3

A4

A5

A6

B1

B2

B3

B4

B5

B6

C1

C2

C3

C4

C5

C6

Fig. 6.7 — АТ27 VFD control system structure flow chart

Control system includes:

• VFD control unit with fiber optic multiplexer;

• control unit add-on module;

• UMKA-27 controller with operator’s interface;

• interface converter («USB — RS-485»);

• discrete and analog inputs/outputs to connect transducers of process parameters;

• link of communication with the enterprise’s PACS.

39

Variable-frequency drive control unit with a fiber optic multiplexer receives instructions from UMKA-27 controller, makes all necessary calculations and controls the state of power cells (PWM parameters, operating mode) via fiber optic lines. Having received a data batch the power cell forms a required state of the output, wherein power cells direct data with the PC actual state and the failure code into the fiber optic multiplexer.

Add-on module collects data of output voltages and currents as well as internal data required to ensure the VFD control and protection. Based on the data collected the VFD control unit forms the PWM. This data is also transmitted to UMKA-27.

The UMKA-27 controller is designed to set up a human-machine interface, makes it possible to adjust and control the variable-frequency drive (in manual and automatic modes), to collect and process data associated with its operation.

Discrete and analog inputs/outputs collect signals from transducers of process parameters, receive and transmit signals via analog and discrete inputs/outputs, process them and commu-nicate with the UMKA-27 controller.

40

7. Transportation and storage

7. Transportation and storage7.1. Transportation of Triol АТ27 variable-frequency drive

Frequency converters may be transported by any kind of roofed transport in accordance with laws and regulations being valid at this kind of transport.

Transportation conditions for АТ27 VFD shall correspond to Group «Л» as per requirements of GOST 23216-78 as it pertains to mechanical impacts:

• transportation by rail with no transshipments;

• transportation by road with no transshipments:

• by asphalt and concrete roads;

• by cobblestone and dirt roads with a speed of up to 40 km/h.

• combined transportation: air or rail transportation in combination with the road one where the total number of transshipments does not exceed 2.

The АТ27 VFD of УХЛ1 type is delivered wrapped in inner packaging. Such packaging implies protection against ingress of water splashes and solar ultraviolet radiation, and limits the in-gress of dust and sand. During transportation and storage all parts with no corrosion-resistant coating shall be temporarily protected against corrosion by corrosion-preventive grease or any other equivalent means as per GOST 9.014-78.

Circuit breakers shall be set to OFF position for the period of transportation and storage.

Operational documentation shall be packed in a sealed polyethylene bag and put into inside pocket on the CC door.

Packing is marked to meet the requirements of GOST 14192-96.

The following handling marks are stamped on a packing:

• «Handle with care»;• «This side up»;• «Keep dry»;• «Cargo not stackable»;• «Center of gravity».

The following informative lettering is printed on a packing:

• Net and gross weight of a package;• Overall dimensions of a package.

To fix onto the platform there shall be used four anchor brackets located on side surfaces at the bottom of the container. Upon completion of transportation and prior to putting the equip-ment in storage check air-tightness of locations with lifting brackets, cover slinging points with a protective film.

Component parts of АТ27 VFD shall be transported packed. Depending on the means of trans-portation a frequency converter of АТ27 type may be transported either completely assembled or partially disassembled.

41

In case any АТ27 VFD shall be transported disassembled, it shall be divided into the following component parts:

1. Block-box with equipment (framework clad with sandwich panels, power cell compart-ment, transformer compartment, power switching compartment, operator’s compart-ment control cabinet, ventilation and heating system);

2. Ladder;

3. Platform;

4. Power cells (may be transported separately in unit container or mounted in the power cell compartment);

5. Set of external components.

!Arrangement and fixing of the FC component parts in a vehicle shall ensure their stable position excluding displacements and impacts against each other and against the vehicle walls.

Keep the frequency converter assemblies upright, do not jerk and tilt them (tilt angle shall not exceed 5°) when transporting, loading-unloading and handling. The equipment shall be hoisted and moved smoothly with no jerks and swinging.

Hoisting, handling or lowering of the equipment is prohibited if there are people under it. The equipment shall be lowered only to the intended place where drops, overturning or sliding down are excluded.

Component parts of the frequency converter shall be hoisted and handled only in original packing with due regard to the hoisting machine load-carrying capacity.

Storage conditions for the FC component parts shall correspond to Group I (Л) as per require-ments of GOST 15150-69:

• Ambient temperature from - 60 °С to + 50 °С;• Relative humidity 100 % at + 25 °С;• Content of corrosion-active agents – Class II atmosphere as per GOST 15150-69.

Environment is non-explosive, not containing corrosive gases and vapors in such concentrations that may cause destruction of metals and insulation, not saturated with current-conducting dust.

42


7.2. Unloading of Triol АТ27 variable-frequency drive

!When inloading the AT27 variable-grequency the interindustry labor safety rules at cargo handling operations and disposition shall be strictly followed.

Before proceeding to unloading and installation of the variable-frequency drive be sure to carefully read these safety rules and installation guidelines. In case of improper installation the VFD operation with open door may cause major injuries to the service personnel and damage to the equipment and property. Additionally, it should be noted that variable-frequency drives op-erate rotating parts of the mechanical equipment that bears some extra risks. So guidelines set forth in this Manual shall be followed. In these rules a qualified personnel shall be understood to mean some persons possessing required skills to perform installation, set-up, operation and maintenance of variable-frequency drives, as well as those who have appropriate qualification to execute such kinds of work.

Access of unauthorized persons to the variable-frequency drive shall be prohibited.

The housing of variable-frequency drive and casings of the motor and all the equipment con-nected to them as well as shields of power and control cables shall be reliably grounded to en-sure the personnel security.

To fix a VFD onto the platform there shall be used four anchor brackets located on side sur-faces at the bottom of the VFD container. Slinging operations with a VFD shall be conducted us-ing 4 lugs located at the upper part of the block box (Fig. 7.1).

Fig. 7.1 – Lugs for slinging АТ27

Slinging devices of 4СК1-20,0 type or their equivalents able to hold up the hoisted cargo are recommended for lifting. A slinging device of 4СК1 type is shown in Fig. 7.2.

43

Fig. 7.2 — Slinging device of 4СК1 type

During loading/unloading of the АТ27 frequency converter an angle between sling arms shall not exceed 90° (Fig. 7.3).

Fig. 7.3 – During slinging operations an angle between sling arms shall not exceed 90 °

Hooks of К and К1 types equipped with preventers (locks) shall be used as gripping devices in slings (Fig. 7.4).

Fig. 7.4 – Hook of К type with lock: 1 – hoist hook; 2 – lock

44


Correct position of the hook in a lug is shown below (Fig. 7.5).

Fig. 7.5 — Incorrect (a) and correct (b) position of the hook in a lug

!Arrangement and fixing of the FC component parts in a vehicle shall ensure their stable position excluding displacements and impacts against each other and against the vehicle walls.

Keep the frequency converter assemblies upright, do not jerk and tilt them (tilt angle shall not exceed 5°) when transporting, loading-unloading and handling. The equipment shall be hoisted and moved smoothly with no jerks and swinging.

! Hoisting, handling or lowering of the equipment is prohibited if there are people under it.

The equipment shall be lowered only to the intended place where drops, overturning or slid-ing down are excluded.

Component parts of the variable-frequency drive shall be lifted and conveyed only packed in standard containers according to the machine load-carrying capacity, table of allowable loads on the lifter slings and/or the lift-truck forks depending on the center-of-gravity position.

Unloading process is illustrated in Fig. 7.6 – 7.8.

45

Fig. 7.6 — Container with AT27 packed

Remove the canopy from the truck, and remove a bracket over the truck gate (Fig. 7.7).

Fig. 7.7 — Unpacking after transportation

Remove the container transportation belts. Container shall be unloaded through the truck gates as shown in Fig. 7.8).

46


Fig. 7.8 — Unloading container from a vehicle

7.3. Product unpackingUnpacking process involves dismantling of OSB-panels and removal of protective film. These

materials ensure protection against mechanical impacts during loading, transportation and un-loading, and prevent influence of precipitations.

Dismantling of packaging shall begin with removal of the roof protection film. Then proceed to dismantling of the OSB wall panels.

!WARNING! Damaged paintwork on protective elements of the structure results in corrosion spots which fact significantly shortens service life of such elements and deteriorates the marketable appearance of the product.

7.4. Triol АТ27 drive storage conditionsАТ27 variable-frequency drive shall be stored assembled.

Storage conditions for the FC component parts shall correspond to Group I (Л) as per require-ments of GOST 15150-69:

• Ambient temperature from - 60 °С to + 50 °С;• Relative humidity 100 % at + 25 °С;• Content of corrosion-active agents – Class II atmosphere as per GOST 15150-69.

Environment is non-explosive, not containing corrosive gases and vapors in such concentrations that may cause destruction of metals and insulation, not saturated with current-conducting dust.

Allowable storage time for packed and preserved equipment before commissioning is 1 year.

47

8. Safety precautions

Any work associated with electrical installation of variable-frequency drive shall be done only by qualified personnel having appropriate authorization.

It should be especially noted that this variable-frequency drive is designed for operation in 6kV high-voltage grids so all high-voltage safety precautions shall be taken dur-ing installation work.

Any work associated with installation and maintenance of the drive, motor or motor cable is prohibited if the supply voltage is connected. Before proceeding to work, check for the lack of voltage using a corresponding probe for 6kV.

The AТ27 VFD contains dangerous high-voltage electrical circuits and elements. A voltage of 6000V is available in power switching compartment, transformer com-partment and power cells compartment. A voltage of 380/230V is available in the operator compartment’s control cabinet as well as in ventilation, heating, lighting

and fire detection systems.

Only specially trained and highly qualified personnel of appropriate electrical safety quali-fication level is authorized to mount and service any AT27 VFD. All maintenance work shall be conducted according to the requirements of this Operating manual.

To avoid accidents in the process of operation of any АТ27 frequency converter, strictly adhere to the requirement of the following documents and observe the following rules:

• Electrical Installations Code (EIC);

• Rules for Operation of Customers’ Electrical Installations (RO);

• Safety Rules for Operation of Customers’ Electrical Installations (SR);

• This Operating Manual;

• Regulations of an enterprise (organization) where a frequency converter of AT27 type is operated;

• АТ27 VFD as well as all its units and assemblies shall be reliably grounded;

• exclude operation of VFD with removed or loose parts (covers, panels, etc.) of the FC sections and power cells;

• it is prohibited to enter the transformer and power cell compartments as well as to remove panels of power switching cabinets or to open the control cabinet door when the AT27 VFD is in operation. If any of the above-listed actions is taken, an emergency stop of the frequency converter will take place;

• it is prohibited to connect and disconnect detachable contact joints in AT27 if there is a line voltage across its terminals;

• to urgently stop the АТ27 frequency converter use the «EMERGENCY STOP» remote button;

• maintenance of a frequency converter shall be conducted with a supply-line discon-nected and no voltage across all circuit elements.

48

8. Safety precautions

Capacitors in power cells keep a charge dangerous to life within 5 minutes after the AT27 VFD has been stopped and power supply of 6000 V has been disconnected! Be-fore conducting any operations inside the power cell compartment or transformer compartment make sure that no voltage is available across power cells.

Electronic control units of any AT27 frequency converter contain MOS-technology-based ele-ments for which static electricity is potentially dangerous. If you have to touch any MOS-element use a grounding wrist strap and ground the tool used. When working with units place them on conductive gaskets.

Periodically check the state of bolted connections and plug-and-socket connectors in the fre-quency converter circuits. Breaks in connections may lead to their overheating, ignition of con-ductors and assembly components as well as to failures of the system as a whole.

АТ27 VFD provides for the automatic restart mode enabled after disconnections associated with the loss of mains voltage or with operation of external interlocks. In this mode of operation a safety of the personnel shall be assured.To enable or disable the VFD specified in Sec. 12.3 and 12.4.

Safety and operating reliability of any frequency converter depends on strict ad-herence to all rules and requirements specified in this manual!

The variable-speed drive meets the safety requirements of GOST 12.2.007.0 and GOST 12.2.007.11-75 as well as the requirements of Rules for Operation of Customers’ Electrical Instal-lations, Safety Rules for Operation of Customers’ Electrical Installations, Rules for Safety in the Oil and Gas Industry and Interindustry Rules on Labor Safety for Operation of Electrical Installa-tions.

All the activities on installation, mounting, dismantling, operation and mainte-nance of a variable-speed drive shall be carried out in conformity with effective Electri-cal Installations Code (EIC), Rules for Operation of Customers’ Electrical Installations (RO-CEI), Safety Rules for Operation of Customers’ Electrical Installations (SROCEI), Rules for Safety in the Oil and Gas Industry (RSOGI), Interindustry Rules on Labor Safety for Operation of Electrical Installations (IRLS), instructions of an enterprise (organization) that operates a variable-speed drive as well as this Operating Manual.

Before proceeding to any operation with VFD the personnel shall:

• receive special training and pass the knowledge test regarding the AT27 drive operation and labor safety;

• be medically examined preliminarily (when entering employment) and periodically (in the course of working life);

• have an electrical safety qualification level not lower than the 3rd one;• be briefed on labor safety issues.

Before connecting the variable-frequency drive check the integrity and insulation resistance of the feeding cell and lead-in cable as well as of the lead-out cable and motor.

Immediately after the VFD tripping the capacitors in power cells are discharged au-tomatically. Before executing any work inside the power cells compartment make sure that no voltage is across the cells using a voltage tester. The HL1 lamps lo-cated on the PC front panels serve as supplementary indicators.

WARNING! A socket in the control cabinet shall be used ONLY to connect 220V set-

up instruments with the total power NOT EXCEEDING 2 kW!

49

9. Installation of Triol АТ27 variable-frequency drive9.1. Checking for complete set of supply and visual examination

When unpacking the variable-frequency drive its complete set of supply shall be verified. The AT27 compete set of supply is specified in the technical certificate fro the product.

After the variable-frequency drive has been unpacked perform some checks to meet the fol-lowing criteria:

• check with identification marks of the VFD cabinets according to your purchase order; marking is made on the nameplate located on the front of each cabinet;

• visually examine the variable-frequency drive for any scratches or other shipping dam-ages;

• check for any fasteners fell out of their places as well as for loosened external parts of the VFD housing.

If any of the aforesaid criteria is not met, report of the same to Triol Corporation.

9.2. Checking internal elementsCheck the AT27 drive for internal elements listed in Table 9.1.

Table 9.1 — АТ27 VFD component partsSection No. in this Operating

Manual Name Q-ty

3 АТ27 VFD (comprising): 1

3.5.1 Control cabinet 1

3.5.2 Power switching compartment 1

3.5.4 Power cells compartment 1

3.5.3 Transformer compartment 1

Power cells 18

Different complete sets of supply specified in the product certificate may be provided for dif-ferent types of AT27 VFD and depending on the particular order. One backup power cell is sup-plied with the variable-frequency drive.

50

9. Installation of Triol АТ27 variable-frequency drive

9.3. Product markingАТ27 VFD as well as all its cabinets and component parts are provided with nameplates con-

taining the information as required by GOST 12969:

• product name and designation;• spec No;• supply-line rated frequency;• rated voltage in kilovolts;• rated active power in kilowatts;• degree of protection;• supplementary data;• date of manufacture;• product weight.

These nameplates are fixed on the front face of VFD cabinets and on the inner door in such a place that ensures convenient reading. At the bottom of all АТ27 VFD components there is an earth sign close to the grounding device.

9.4. Designation of Triol АТ27 configurationDesignation structure of variable-frequency drives has been developed as per spec 3416-017-

82539763-2011, and is as follows:

1. Model — AT27.2. Motor Power, shown in Table 3.2.3. Input voltage, kV — 3,3; 4,2; 6; 10. Another power upon Customer confirmation.4. Output voltage, kV — 3,3; 4,2; 6; 10. Another power upon Customer confirmation.5. Input/output cabinets:

• 0Х — special design of input cabinet;• 1Х — one input cabinet;• 2Х — one input cabinet;• 3Х — one input cabinet with bypass;• 4Х — two input cabinets with bypass;• 5Х …9Х — reserve;• Х0 — no bypass;• Х1 — with bypass.

6. Transformer:

• А — аluminum transformer;• C — сopper transformer.

7. Power cells cabinet:

• 4 — four power cells in each phase;• 5 — five power cells in each phase;• 6 — six power cells in each phase;• 9 — nine power cells in each phase;• 1 — ten power cells in eachphase;• F (active front end) — regenerative cells.

51

8. Control Cabinet:

• 0 — special requirements for control cabinet;• 1 — option №1 (one motor with bypass);• 2 — option №2 (two motors with bypass);• 3 — option №3 (3 motors with bypass and sensors);• 4 — control cabinet for block-box (container) with bypass and safety system + Сascade.

9. Exchange protocol:

• M — modbus RTU;• P — profibus;• C — CAN Open;• E — industrial Ethernet.

10. Enclosure type:

• C — cabinet;• K6 — six meter container;• K9 — nine meter container;• K12 — twelve meter container;• В — module construction (several boxes in parralel;• S — special enclosure.

11. Climate conditinos according to Russian GOST standards:

• 0 — special requirements;• 1 — УХЛ1 (outdoor cold climate);• 4 — УХЛ4 (indoor);

12. Enclosure protection:

• 0 — special requirement;• 3 — IP30;• 4 — IP43;• 5 — IP54;• N — Nema 3R.

52

9. Installation of Triol АТ27 variable-frequency drive

9.5. Installation of Triol АТ27 variable-frequency driveАТ27 МАВ is designed for use under the following conditions:

• Еnvironment is unexplosive, not containing corrosive gases and vapors in concentrations that may cause a destruction of metals and insulation; not saturated with current-conduct-ing dust and vapors;

• Elevation above sea level not exceeding 1000 m.

Values of climatic factors for УХЛ climatic version, 1st category of location as per GOST 15150-69 and GOST 15543.1-89, featured by the following:

• Ambient temperature from - 60 to + 40 °С;• Relative humidity 100 % at + 25 °С;• Class II as referred to the content of corrosion-active agents in atmosphere:

• sulphur dioxide — from 20 to 250 mg/m2 per day (from 0.025 to 0.31 mg/m3);• chlorides — less than 0.3 mg/m2 per day.

Degree of protection – IP30, 43, 54, as per GOST 14254-80.

АТ27 VFD shall be connected to the 6 kV supply line through stationary or self-contained units complete with controls and protective devices.

Working position of VFD АТ27 is vertical, allowable deviation from the vertical to any direction shall not exceed 5°.

53

10. Electrical installation (external connections) of Triol AT27 variable-frequency drive

General recommendations on power cable termination and installation:

• 6 kV power cables in points of their connection to AT27 shall be terminated with coupling sleeves;

• cable termination and installation of coupling sleeves shall be performed out of the cabi-net stretching the cable so that not to damage the cabinet electrical equipment when heating the coupling sleeve;

• cable shall be fixed by a clamp;

• lead of the cable shield, if any, shall be attached to the grounding stud at the bottom of a cabinet, in which the connection is being made;

• prior to connection all cables shall be tested for insulation resistance and electrical strength as per the voltage rating;

• laying of power and control cables in the same tray is prohibited;

• transmission of both discrete and analog signals by a single auxiliary supply voltage cable is prohibited;

• shields of all cables, both power and control ones, shall be grounded;

• avoid intersections between power and control cables; but if any, an angle between them shall be as close to 90° as possible.

54

10. Electrical installation (external connections) of Triol AT27 VFD

10.1. Overview of wiring installationThe variable-speed drive meets the safety requirements of GOST 12.2.007.0 and GOST

12.2.007.11-75 as well as the requirements of Rules for Operation of Customers’ Electrical Instal-lations, Safety Rules for Operation of Customers’ Electrical Installations, Rules for Safety in the Oil and Gas Industry and Interindustry Rules on Labor Safety for Operation of Electrical Installa-tions.

All the activities on installation, mounting, dismantling, operation and maintenance of a variable-speed drive shall be carried out in conformity with effective Electrical In-stallations Code (EIC), Rules for Operation of Customers’ Electrical Installations (RO-CEI), Safety Rules for Operation of Customers’ Electrical Installations (SROCEI), Rules

for Safety in the Oil and Gas Industry (RSOGI), Interindustry Rules on Labor Safety for Opera-tion of Electrical Installations (IRLS), instructions of an enterprise (organization) that operates a variable-speed drive as well as this Operating Manual.

Before proceeding to any operation with VFD the personnel shall:

• receive special training and pass the knowledge test regarding the AT27 drive operation and labor safety;

• be medically examined preliminarily (when entering employment) and periodically (in the course of working life);

• have an electrical safety qualification level not lower than the 3rd one;• be briefed on labor safety issues.

Before connecting the variable-frequency drive check the integrity and insulation resistance of the feeding cell and lead-in cable as well as of the lead-out cable and motor.

Electronic control units of any AT27 frequency converter contain MOS-technology-based ele-ments for which static electricity is potentially dangerous. If you have to touch any MOS-element use a grounding wrist strap and ground the tool used. When working with units place them on conductive gaskets.

55

10.2. Wiring of power circuits (6 kW)All 6kV power connections are made in the power switching compartment as per the diagram

of external connections shown in Fig. 10.1.

7

4

8

3

1

2

ADC

31

98

56

1

32

432

9

7

43

5

12

21

23

1

3

12

32

3

1

11

6

1

Input 1 - 6 kV

80

77

74

71

68

54

51

48

45

42

39

36

22

19

16

13

10

7

4

1

2

22

19

16

13

10

M5

M2

Input 3 - 6 kV

Input 2 - 6 kV

81

7576

7069

67

61

636465

62

575859

5556

5253

4950

4647

4344

41

38

40

37

3132333435

26272829

25

2120

23

1415

89

6

321

321

23

1

3

TV

Reserve

30

32

29

252627

2324

2120

1718

1514

1211

XT33

XT24

M

M

M

M

M

M4

M3

M1

7879

7273

66

60

1718

30

24

12

5

XT23

PC

28

DIN_COM (FA) Common Din

Dout 15 (NO)Mtr.3 oper fr. mains

RS485A ACS

CTS ACS

0v ACS

Reserve Аin 2 (5v)

Reserve Аin 1 (5v)

Аout 1 GNDAssignment Excit.2G

Reserve Dout 13 (NO)

O�. CE3 Dout 10 (НО)



Din 21Current overload CE2

Condition CE2 (NC) Din 18

Condition CE1 (NO) Din 15

Condition IC2 (NО) Din 12

Condition IC1 (NO) Din 9

Reserve Din 7

STOP Mtr.2. Din 4

Input 2 phase А

Input 1 phase В

Dout 23

Dout 20 Motor 1 stop

O�. IC2Dout17 (NC)

Common 29...31 Common Din

Din 29

Din 27

Din 25

CAN_H

Net

Fire Din 17

0v ACSMtr.3 oper fr. VFD Dout 14 (NO)

RTS ACSTXD ACS

Encoder 5v

Encoder nB Encoder СEncoder nC

Encoder nA Encoder B

ReserveReserveReserve

Reserve

Аin 3 (5v)Аin 3 (0V)Аin 3 GND

Аin 2 (0V)Reserve Аin 2 GND

Reserve Аin 1 (0V)Аin 1 GND

Аout 2Аout 2 GND

Assignment Excit. 1АAssignment Excit.1G

ReserveАout 1

ReserveReserve

Dout 11 (NO)Dout 12 (NO)

Assignment Excit.2АCommon Dout11...13

Common CE2

On. CE3Common CE3

Dout 9 (M)

Dout 10 (NC)Dout 10 (M)

On. CE2 Dout 9 (NC)

Common IC1O�. IC1

On. CE1Common CE1

Dout 7 (M)Dout 7 (НО)Dout 8 (NC)Dout 8 (M)

On. IC1 Dout 7 (NC)

Fail. Mtr.1Fail. Mtr.2Fail. VFD

Dout 3 (NO)Dout 4 (NO)Dout 5 (NO)Dout 6 (NO)

Dout 2 (NO)Freq.Start Excit.3Freq.Start Excit.2

ReserveCondition CE2 (NО)

Common Din

Din 19Din 20

Common

ReserveCondition CE1 (NC)

Din 13Din 14

Common DinCondition IC1 (NC)

STOP Mtr.3.

CommonDin 8

Din 6

STOP Mtr.1.START Mtr.2.

Net

Din 2Din 3

START Mtr.1. Din 1

Input 3 phase СInput 3 phase ВInput 3 phase А

Net

Input 2 phase ВInput 2 phase С

Net

Input 1 phase А

Input 1 phase С

Net

Аout 3Аout 3 GND

Reserve

O� IC3Dout 25 (NC)

Common DoutDout 24 (M)ReserveOn. IC3

Dout 24 (NC)Dout 25 (NO)

Common 18...23 Common DinFail. Mtr 3Dout 24 (NO)

Dout 21Dout 22

Dout 18Dout 19

Common IC2On. IC2

Dout 17 (M)Dout 17 (NO)

Din 30Din 31 Reserve

Common DinDin 28

Common 26...28

Din 26Common DinCommon 22...25

Din 22

Din 24 ReserveDin 23

Circuit

XT6XT7XT8

CAN_0V

CAN_L

Circuit

0V_UC2

Net

Net

Net

Net

Stop Mtr.3Common Dout

RXD ACSRS485B ACS

Encoder 5v

Dout 16 (NO)

Encoder А

Reserve

Common Dout1...6

Dout 1 (NO)

Din 16Din 17

Common Dout (M)

Freq.Start Excit.1

Current.overload CE1

ReserveCondition IC2 (NC)

START Mtr.3.

Din 10Din 11

Din 5

Common IC3Dout 25 (M)

0V_UC6

XT5

Net

Motor 2 stop

Condition IC3 (NC)

Fail. Excit. 2

Current overload CE3

Output 5 phase_W

Output 2 phase U

Output 1 phase V

Assignment Excit. 3Assignment Excit. G

Mtr. 2 oper fr. VFDMtr. 2 oper fr.mains

Mtr.1 oper fr. VFDMtr.1 oper fr.mains

Condition IC3 (NO)

Fail. Excit. 3

Fail. Excit. 1

Condition CE3 (NC)Condition CE3 (NO)

~380 V -A ~380 V - B~380 V - C

RS485B_UC6RS485A_UC6

RS485B_UC2RS485A_UC2

Output 5 phase_VOutput 5 phase_U

Output 4 phase VOutput 4 phase W

Output 4 phase U

Output 3 phase W

Output 3 phase UOutput 3 phase V

Output 2 phase WOutput 2 phase V

Output 1 phase W

Output 1 phase U

АТ27 variable-frequency

drive

Common Dout 14...16

~380 V -N

Reserve

Fig. 10.1 — Diagram of external connections

56


Motor connection is also produced high voltage copper cable.

Cable cross-section is defined by the formula (1):

S = Ir / 2,7 (1)

, where

S – cable cross-section area,

Ir – VFD rated input/output current,

2,7 – constant, current density.

Connection of power cables to the I/O terminals in the power switching compartment is shown in Fig. 10.2.

Fig. 10.2 — Power connections to АТ27 MMFC

10.3. Wiring of 0.4kV circuitsTo ensure the FRS serviceability, connection of the auxiliary power supply mains (380V, 50Hz)

is provided.

Connection of the 380V grid lead-in cables is performed in the control cabinet. Use cables with a cross-section area of not less than 25 mm2. To that end the control cabinet provides for X5 (N neutral), ХТ6 (А phase), ХТ7 (В phase) and ХТ8 (С phase) terminals as shown in Fig. 10.1.

Consumed power of the auxiliary power-supply circuits is up to 30kW.

57

10.4. Wiring of control circuitsTo connect the AT27 external control signals the control cabinet provides for ХТ23 and XT24

terminal blocks (ХТ33 terminal block as an option). Fig. 10.1 illustrates ХТ23, XT24 and ХТ33 ter-minal blocks, and Table 10.1 – their intended use.

Table 10.1 — Intended use of VFD user terminal blocksDescription Terminal

«System start» and «System stop» discrete signals to start and stop the drive in the process algorithm mode of operation (e.g. «Cascade»; for more details of process algorithms and their setup refer to Programming Manual)

XT23

Emergency stop discrete signal (normally closed) XT23Telemechanics discrete outputs of «dry contact» type such as «Ready», «Op-eration», «Fault» (normally open) as well as switch to the grid operation (only for drives supporting the function of the motor switch to the grid operation)

XT23

Exciter controlling signals:• operation in the variable-frequency control mode;• operation in the direct startup mode;• 4-20 mA excitation setting output;• exciter alarm input.

XT23

Motor cubicle controlling and monitoring signals:• switching-on;• switching-off;• status checking (NO+NC);• ready check (NO).

XT33

VFD incoming cubicle controlling and monitoring signals:• switching-on;• switching-off;• status checking (NO+NC);• ready check (NO).

XT23, XT33

Analog inputs for connection of process transducers XT23

RS-485 link for connection to the Customer’s ACS XT23

RS-485/RS-232 redundant channel XT23Backup discrete outputs(normally open and normally closed)

XT23, XT33

Number of user terminal blocks and their intended use depend on the configuration to meet the Customer’s needs. Basic set of user terminal blocks includes «Start» and «Stop» discrete signals for a single motor (XT23).

58


10.5. Triol АТ27 installation checkBefore applying voltage and prior to the VFD connection the following checks shall be per-

formed:

• if doors of the VFD cabinets are closed tight;

• if 6 kV power cables and 380 V auxiliary cables are connected properly;

• if power cells are connected properly to the power transformer;

• for visible mechanical damages in conductors and cables;

• for a fault to earth and short circuits between isolated conductors;

• if distances between conductive parts and grounded elements of the structure meet the requirements.

59

11. CommissioningThis section contains instructions on safe commissioning of the variable-frequency drive. Be-

fore proceeding to fulfillment of the below instructions all the installation operations and relevant checks such as those for electrical strength and insulation resistance of power cir-cuits shall be completed!

11.1. Switching АТ27 variable-frequency drive for the first timeBefore applying voltage to the AT27 drive, set SA1 and SA2 switches in the control cabinet to

«Auto» position. Enable all circuit breakers located inside the control cabinet. To that end open the CC door (use a special key to open the lock, which is included into complete set of supply). Then close the CC door!

Apply 380V voltage to the CC input «auxiliary power supply» and enable the following circuit breakers: QF2, QF5, QF6, QF14, QF15, QF25, QF26 QF20, QF30 and QF27. If a temperature in the block-box exceeds 10°С, the uninterruptible power-supply unit and CC electronics modules shall be activated within one minute. If a temperature in the block-box is lower than 10°С, the CC heating system will be activated.

WARNING! Control cabinet door shall be closed!

Depending on the temperature inside the block-box the CC heating may take from half an hour to 4 hours.

After the UMKA-27 controller has been switched on, enable all the remaining circuit breakers. Open the «Actual Faults» option in the UMKA-27 controller’s menu. In case some actual faults are listed there, they shall be corrected (refer to «AT27 diagnostics» paragraph).

11.2. Preparation of AT27 to startup and its startup in idle modeBefore starting the AT27 variable-frequency drive, the main circuit in the high-voltage switch-

ing compartment shall be assembled in such a way that its input is enabled and the output is disabled.

WARNING! Grounding switches for the input and output shall be in OFF state!

Set parameters of UMKA-27 as per Table 11.1.

Fig. 11.1

Group Name Factory values Unit of measure-ment

09 Start frequency 2,5 Hz09 Speedup time 40 s09 Braking time 40 s09 Braking type Frequency –09 Run-down time 40 s09 Fmin 16 Hz

60

11. Commissioning


09 Fmax 50 Hz11 U1 U/F 750 V11 U2 U/F 1500 V11 U3 U/F 2250 V

11 U4 U/F 3000 V

11 U5 U/F 3750 V

11 U6 U/F 4500 V11 U7 U/F 5250 V

11 U8 U/F 6000 V

11 F1 U/F 6.2 Hz11 F2 U/F 12.5 Hz11 F3 U/F 18.7 Hz11 F4 U/F 25 Hz11 F5 U/F 31.2 Hz11 F6 U/F 37.5 Hz11 F7 U/F 43 Hz11 F8 U/F 50 Hz

12 FonInhibit Off –

15 ВВ min voltage 5100 V

15 ВВ max voltage 6900 V

15 ВВ dU set value 20 %

15 ВВ1 UovervoltProt On –

15 ВВ1 UundervoltProt On –

15 ВВ1 UvoltUnbalProt On –15 ВВ2 UovervoltProt On –15 ВВ2 UundervoltProt On –15 ВВ2 UvoltUnbalProt On –15 ВВ3 UovervoltProt On –15 ВВ3 UundervoltProt On –15 ВВ3 UvoltUnbalProt On –16 НВ min voltage 323 V16 НВ max voltage 437 V16 UivervolProt On –

The continuation of Table 11.1

61


16 НВ UundervoltProt On –

16 НВ UunbalProt On –

16 UdChrgdlProt On –

16 НВ ImaxProt On –

18 OutCurUnbalProt Off –

18 dIout set value 20 %

18 OutCurUnbal 20 %

18 dIout time 1 s

19 OCP set value 90 А

19 Max charge time 50 s

19 Start algorithm Scalar –

19 Charge end Voltage-responsive –

19 Start w/o GCC On –

49 Control link Local panel –

51 Setting link Local panel –

57 Log record Always –

57 Period 1 20 s57 Period 2 20 s

65 OperSupAlgON On –

65 MaxOperTemp 20 °С

65 MinOperTemp 15 °С

163 FireOutOper Fire alarm system failure Startup

Select an appropriate motor to start (refer to Programming Manual) and press START button. Upon expiry of one minute the input contactor will be switched on, and in a second – the output one (or incoming cubicle and outcoming cubicle respectively, depending on the VFD configura-tion). In 40 seconds the variable-frequency drive will reach the frequency of 50Hz.

WARNING! If variable-frequency drive fails to start or is tripped as a result of any fault, contact the service center!


62

11. Commissioning

11.3. Preparation of AT27 to startup and its startup using motor with no load on the shaft

Before starting the AT27 variable-frequency drive, the main circuit in the high-voltage switch-ing compartment shall be assembled in such a way that both its input and output are enabled.

WARNING!Grounding switches for the input and output shall be in OFF state!

Adjust the settings UMKA-27 as shown in Table 11.2.

Fig. 11.2


09 Start frequency 2,5 Hz09 Speedup time 20 s09 Braking time 40 s09 Braking type Coast –09 Run-down time 40 s09 Fmin 16 Hz09 Fmax 50 Hz11 U1 U/F 750 V11 U2 U/F 1500 V11 U3 U/F 2250 V

11 U4 U/F 3000 V

11 U5 U/F 3750 V

11 U6 U/F 4500 V11 U7 U/F 5250 V

11 U8 U/F 6000 V




63




15 ВВ1 UovervolProt On –

15 ВВ1 UundervolProt On –

15 ВВ1 UvoltUnbalProt On –15 ВВ2 UovervolProt On –15 ВВ2 UundervolProt On –15 ВВ2 UvoltUnbalProt On –15 ВВ3 UovervolProt On –15 ВВ3 UundervolProt On –15 ВВ3 UvoltUnbalProt On –16 НВ min voltage 323 V16 НВ max voltage 437 V16 UovervoltProt On –

16 НВ UundervolProt On –

16 НВ U unbalProt On –



18 OutCurUnbalProt On –


18 OutCurUnbal 20 %

18 dIout time 1 s

19 OCP set value Ir*1.2 engine А



19 Charge end Voltage-responsive –

19 Start w/o GCA On –





64

11. Commissioning






11.3.1. Asynchronous machine startup

Select an appropriate motor to start (refer to Programming Manual) and press START button. Upon expiry of one minute the input contactor will be switched on, and in a second – the output one (or incoming cubicle and outcoming cubicle respectively, depending on the VFD configura-tion). In 20 seconds the variable-frequency drive will reach the frequency of 50Hz. Motor shaft shall rotate with rated speed.


11.3.2. Synchronous machine startup without excitation

Disconnect the exciter control circuit from АТ27 (analog output is designed for controlling exci-tation, and discrete output – for setting the mode of operation). Power on the exciter.

WARNING! Before performing any further operations disconnect the load from asynchronous machine!

Select an appropriate motor to start in UKMA-27 (refer to Programming Manual) and press START button. Upon expiry of one minute the input contactor will be switched on, and in a sec-ond – the output one (or incoming cubicle and outcoming cubicle respectively, depending on the VFD configuration). In 20 seconds the variable-frequency drive will reach the frequency of 50Hz. Motor shaft shall rotate with rated speed.

11.3.3. Synchronous machine startup with excitation

Restore the exciter control circuit. Power on the exciter.


Select an appropriate motor to start in UMKA-27(refer to Programming Manual), set the out-put frequency to 25Hz and press START button. Upon expiry of one minute the input contactor will be switched on, and in a second – the output one (or incoming cubicle and outcoming cubicle respectively, depending on the VFD configuration). In 20 seconds the variable-frequency drive will reach the frequency of 25Hz.

Motor shaft shall rotate with a preset speed. Set output frequency to 50Hz, and in 20 seconds the motor will pick up the rated speed of rotation.


65

11.4. Motor startup with a load on the shaftConnect a load to the motor.

Before starting the AT27 variable-frequency drive, the main circuit in the high-voltage switch-ing compartment shall be assembled in such a way that both its input and output are enabled.


Adjust the settings UMKA-27 as shown in Table 11.3.

Fig. 11.3


09 Start frequency 2,5 Hz09 Speedup time 40 s09 Braking time 40 s09 Braking type Frequency –09 Run-down time 40 s09 Fmin 16 Hz09 Fmax 50 Hz11 U1 U/F 750 V11 U2 U/F 1500 V11 U3 U/F 2250 V

11 U4 U/F 3000 V

11 U5 U/F 3750 V

11 U6 U/F 4500 V11 U7 U/F 5250 V

11 U8 U/F 6000 V




66

11. Commissioning




15 ВВ1 UovervoltProt On –

15 ВВ1 UundervolProt On –

15 ВВ1 UvoltUnbalProt On –15 ВВ2 UovervoltProt On –15 ВВ2 UundervolProt On –15 ВВ2 UvoltUnbalProt On –15 ВВ3 UovervoltProt On –15 ВВ3 UundervolProt On –15 ВВ3 UvoltUnbalProt On –16 НВ min voltage 323 V16 НВ max voltage 437 V16 UovervoltProt On –

16 НВ UundervolProt On –

16 НВ UunbalProt On –



18 OutCurUnbalProt On –


18 OutCurUnbal 20 %

18 dIout time 1 s

19 OCP set value In*2.2 А



19 Discharge end Voltage-responsive –

19 Start w/o GCA On –





67






11.4.1. Asynchronous/synchronous machine startup

Select an appropriate motor to start (refer to Programming Manual) and press START button. Upon expiry of one minute the input contactor will be switched on, and in a second – the output one (or incoming cubicle and outcoming cubicle respectively, depending on the VFD configura-tion). In 40 seconds the variable-frequency drive will reach the frequency of 50Hz. Motor shaft shall rotate with rated speed.


11.5. The list of possible faults and their solutionsAll the VFD malfunctions may be divided into the following groups:

• faults not requiring the VFD immediate tripping allow the variable-frequency drive to start up (if in STOP mode) with a subsequent troubleshooting;

• faults requiring the VFD immediate tripping prevent the variable-frequency drive from starting until such a fault (defect) is corrected.

Table 11.4 — The list of possible faults and their solutions

Failure description Possible cause Action to be taken by personnel

UMKA-27 control-ler’s screen is not illuminated after АТ27 MMFC is switched on

No power supply to control cir-cuits (380 V)

Check up and supply power of 380 V

QF2 circuit breaker is disabled Enable QF2 circuit breaker

UPS unit cannot be switched on Check if QF5 circuit breaker is switched on; if not, switch it on.

If the ambient temperature is low-er than +1°С, control cabinet is be-ing warmed up. The CC warmup time depends on the ambient temperature and is from 20 min(-1…0°С) up to 4 hours (-50°С).

Wait until the CC warmup is com-pleted


68

11. Commissioning


No charging of cells after pressing START button

QF3 circuit breaker for discharging is disabled Check QF3 state, enable it

380V incoming grid voltage fell be-yond the range of ±15 %, or there is voltage unbalance in phases

Check incoming grid voltage

Incorrect phase sequence Interchange the position of any two phases at the 380V CC power supply input

Lack of one of phases in 380V pow-er-supply line

Check for the 380V grid power supply across three phases

Upon completion of charging the drive fails to start

«Input contactor ON error» alarm actuation Report to service center

«Output contactor ON error» alarm actuation Report to service center

Minimum permissible voltage of the incoming grid on the high side No.1 (No.2)

Check up the incoming grid; try to attain rated capacity of the elec-tric grid.

Maximum permissible voltage of the incoming grid on the high side No.1 (No.2)Voltage unbalance of the incoming grid on the high side No.1 (No.2)Incorrect sequence of the incom-ing grid phases on the high side No.1 (No.2)

Interchange the position of any two phases at the VFD input; high side

No incoming high-voltage grid Check for and apply power supply; check the state of QS1 and QS2 circuit breakers in HVSC.

«DC-link low voltage at starting» alarm actuation

1. Charge the drive once again.2. Report to service center.


69


АТ27 VFD is switched off when in operation

«Output current unbalance» alarm actuation

1. Check for connection of the motor.

2. Check the connection to HVSC.3. Report to service center.

«Maximum current underload reached» alarm actuation

Check the process«Maximum overload exceeded» alarm actuation

«DC-link maximum overvoltage exceeded» alarm actuation

1. Check up the incoming grid voltage; it shall correspond to the drive rated voltage.

2. In case this failure occurs dur-ing frequency braking, “Brak-ing time” set value shall be in-creased.

The following alarms are active:«U phase overcurrent»,«V phase overcurrent»,«W phase overcurrent».

1. Check up the motor connec-tion; the VFD output may be short-circuited.

2. Increase “Speeding-up time” set value.

3. Report to service center.The following alarms are active:«Cell fault in U phase»,«Cell fault in V phase»,«Cell fault in W phase».

1. Replace corresponding cell.2. Report to service center.

«GSA unit failure» alarm actua-tion

Enable starting w/o GSA unit (to be set in UMKA-27 menu).2. Report to service center.

«Lost communication with МК-27» alarm actuation

Restart the control cabinet (dis-able QF3 circuit breaker, switch off the uninterruptible power-supply unit, and then make a restart).

«380V auxiliary power-supply con-tactor connection error» alarm actuation

Report to service center«380V transformer power-supply contactor connection error» alarm actuation«Faulty exciter (one fault per each exciter)» alarm actuation

1. Correct the exciter fault.2. Report to service center.


70

11. Commissioning


(АТ27 VFD is switched off when in operation)

«Bypass contactor connection er-ror» alarm actuation

Report to service center

«Block-box temperature mini-mum permissible value» alarm actuation«No communication with TC ther-mal relay» alarm actuation«No communication with Din16D-out8, AOUT8 and ADC8_2Mode add-on modules» alarm actuation

«Transformer temperature maxi-mum permissible value exceed-ed» alarm actuation

1. In case the ambient tempera-ture exceeds allowable level, output voltage shall be re-duced.

2. If the ambient temperature does not exceed allowable level or in case of overreads, report to service center.

«Control cabinet door open» alarm actuation

If the door is closed, report to ser-vice center.

«Cells compartment door open» alarm actuation«Panel in high-voltage switching compartment removed» alarm actuation

If panel is installed, report to ser-vice center.

«Fire» alarm actuation In case this alarm is a false on, re-port to service center.

«Faulty fire alarm system» alarm actuation

Check the state of QF25 circuit breaker, it shall be enabled.

«Earth fault protection (EFE)» alarm actuation

Check insulation resistance and electrical strength of the high-voltage cable to be connected to VFD.


71

12. Maintenance and repairThis variable-frequency drive does not require continuous presence of attending personnel

in the process of operation.

Maintenance and repair shall be performed only by specially trained and highly qualified per-sonnel to meet the requirements of this Manual and instructions applicable at the site.

The АТ27 drive has been designed to comply with all the requirements of regulatory docu-ments on labor safety during operation and maintenance. Since AT27 is a medium-voltage drive, the requirements set forth in Section 8 «Safety precautions» shall be met.

In view of higher risks in the process of VFD operation and servicing, the following safety mea-sures shall be taken:

• It is prohibited to switch off the VFD auxiliary power supply in the course of operation un-less it is done to protect the VFD and motor;

• It is prohibited to connect or disconnect transducers, cables or fiber optic cables under voltage;

• Before proceeding to operations inside the compartments, the variable-frequency drive shall be switched off;

• All operations shall be conducted to meet the requirements specified in Section 8 «Safety precautions».

!Maintenance, diagnostics and repair of the АТ27 variable-frequency drive may be performed only by specialists of Triol Corporation or properly qualified personnel specially trained at the premises of Triol Corporation.

Technical inspection and servicing of АТ27 VFD shall be performed at least once a year so that to ensure its reliable operation as well as to exclude any malfunctions of the frequency converter.

АТ27 VFD features a self-diagnostics system designed to detect failures (malfunctions) of fre-quency converters.

In case of any uncritical failure (associated with the drive) the VFD controller informs of the same; the frequency converter keeps on running at that. Data on the failure are displayed on the UMKA-27 controller’s or enterprise ACS screen (if available).

If a protection operates or a critical failure (associated with the motor or drive) takes place, an emergency stop of the frequency converter (motor) is performed with appropriate alerting.

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12. Maintenance and repair

12.1. Periodic maintenancePeriodic maintenance of the variable-frequency drive shall be performed once a year. In case

of the VFD operation in excessively dusty conditions, periodic maintenance of the variable-fre-quency drive shall be performed each half year.

Safety requirements shall be met during operation (refer to Section 8 “Safety precautions”). List of tools and instruments required for VFD servicing is given in Table 12.1.

Table 12.1 — Tools and instruments for VFD servicingTool or instrument Q-ty

Set of wrenches (10,13,17 and 19) 1 set

Set of slot head/crosshead screwdrivers

(corresponding to the fasteners used)1 set

Set of fasteners 1 set

Multiple-purpose meter (1000V, 10A) 1 pc

Megohmmeter (2500 V) 1 pc

Clip-on ammeter (1000A) 1 pc

Devices for crimping cable ends 1 pc

Ladder 1 pc

Vacuum cleaner or compressor 1 pc

12.2. I/O compartment servicingClean the cabinet using a vacuum cleaner. Then purge the IOC with compressed air under the

pressure of 4…6 kg/cm2.

Input power contactor located inside the HVSC compartment shall be serviced as per «Vacu-um Contactor of КВТ-10 type. Technical Specification and Operating Manual. КУЮЖ.674273.001 ТО» document.

Check up if the HVSC bolt and screw connections are properly tightened; tighten them up, if necessary.

The rest of the equipment and circuits shall be serviced according to provisions of MRO and other applicable regulatory documents.

12.3. CC servicingCleaning the cabinet to produce a vacuum cleaner. Then purged with dry compressed air at

a pressure of 4 ... 6 kg / cm2. Special attention shall be paid to the cooler (may be observed from the cabinet’s rear side).

Check the tightness of all the available bolt and screw connections CC, if necessary - tighten.Check up the state and locking of plug-and-socket connections in electronics modules.

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12.4. Power cell replacement procedurePower cells in the PCC compartment are perfectly identical and interchangeable. If any power

cell fails, it may be replaced according to the procedure as follows:

3. Stop the motor, switch off the variable-frequency drive.

4. De-energize the variable-frequency drive (both 6000V and 380V).

5. Open the power cabinet door. Using a voltage tester make sure that no dangerous voltage is available. Make sure that PC power capacitors are discharged as shown by indicators. If indicators glow, wait until all of them go out.

6. Disconnect fiber optic cables outgoing from XV1 and XV2 terminals, from the faulty power cell. Disconnect a cable from the ХТ1 terminal.

7. Disconnect А, В, С, АС1 and АС2 input and output cable (buses).

8. Unscrew the cell fastening (locking) bolts.

9. Remove PC from the guides in a smooth flowing manner.

10. Install spare PC, and perform aforesaid steps in the reverse order.

11. Apply voltage to VFD and switch it on.

12. Draw up a report with a detailed description of the fault revealed, and inform the manu-facturer’s service department of the same.

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13. Warranty and services

13. Warranty and servicesManufacturer guarantees a compliance of the drive with the specification requirements pro-

vided that operation, transportation and storage regulations are observed by the end user.

Warranty period is 2 (two) months from the moment of commissioning (by persons or orga-nizations authorized by the manufacturer), but not more than 24 months since the date of ship-ping from the manufacturing facility.

The warranty period is specified individually for each product and recorded in the certificate for a particular AT27 VFD.

Service centers

AlmetyevskBuzulukNefteyuganskMoscow IzhevskNizhnevartovskNoyabrsk

Triol Corporation

Scientific Production Association«Vertikal» Co Ltd

10-K, Frunze avenue, Kharkov, Ukraine, postal code: 61007.

Tel: +3-8-(057)-766-08-57.

Fax: +3-8-(057)-703-32-52.

Documents

Operating manual - triolcorp.com · Operating manual АТ27 – 6 kV block-box version. ... per GOST 14254-96, featuring a block-box design, and to be used in conjunction with motors