Submit Tal

SHOP DRAWING SUBMITTAL
For
FL Smidth Inc. – Cementos Argos
Specification #: 80009841 – General specification and requirements for medium

voltage AC variable frequency drive with dry type or drive isolation transformer
Sales Order #: 3001196416, 3001196287, 3001196302,

3001196303, 3001195583
Customer: Cementos Argos
Purchase Order #: 4-0720001-148703A, 4-0720001-148704A, 4-0720001-149934A,

4-0720001-149946A, 4-0720001-148702A
January 28, 2008
Originator: Matt Smochek

Title: Project Engineer
500 Hunt Valley Drive • New Kensington, Pennsylvania 15068 • Phone: (724) 339-9500 • Fax: (724) 339-9562
Project: FLS/Cementos Argos
Specification #: 80009841 Page
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 2
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 3
SUBMITTAL DOCUMENT SECTION INDEX

SECTION 1. SCOPE OF SUPPLY
SECTION 2. VFD DRAWINGS & MOTOR INFORMATION
SECTION 3. SUBMITTAL SPECIFICATION COMPLIANCE
SECTION 4. CLARIFICATIONS AND COMMENTS
SECTION 5. VFD SPECIFICATION INFORMATION
SECTION 6. VFD CATALOG INFORMATION
SECTION 7. EFFICIENCY & POWER FACTOR INFORMATION
SECTION 8. KEY COMPONENT DATA/VENDOR CUT SHEETS
SECTION 9. RECOMMENDED SPARE PARTS
SECTION 10. QUALITY CONTROL PLAN
SECTION 11. PRELIMINARY AIR COOLED TEST PLAN
SECTION 12. WARRANTY
SECTION 13. MANUALS

19000403, 19000404, 19000405 (USED FOR GENIIIE)
19001851, 19001591 (USED FOR GENIV, PHASE I)
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 4
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 5
SECTION 1. SCOPE OF SUPPLY
SO: 3001196416, PO: 4-0720001-148703A
Variable Frequency Drives
Order
Item Qty Part Number Description
102 1 A5E01585477 GenIIIe, 4000HP, 13.8KV, 4KV, 660A
202 1 A5E01585478 GenIV, PH2, 2000HP, 13.8KV, 4KV, 260A
Miscellaneous
Order Part
Item Qty Number Description
114 3 OM LDA O & M Manuals
Motors
Order
106 1 A5E01585480 4000HP Motor
205 1 A5E01616761 2000HP Motor
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 6
SO: 3001196287, PO: 4-0720001-148704A
Order
Miscellaneous
Order Part
Motors
Order
108 1 A5E01585472 900HP Motor
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 7
SO: 3001196302, PO: 4-0720001-149934A
Order
Miscellaneous
Order Part
Motors
Order
108 1 A5E01585474 1750HP Motor
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 8
SO: 3001196303, PO: 4-0720001-149946A
Order
Miscellaneous
Order Part
Motors
Order
108 1 A5E01585476 1750HP Motor
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 9
SO: 3001195583, PO: 4-0720001-148702A
Order
102 1 A5E01585468 GenIIIe, 6600HP, 13.8KV, 6KV, 660A
Miscellaneous
Order Part
Motors
Order
108 1 A5E01585470 6600HP Motor
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 10
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 11
SECTION 2. DRAWINGS
VFD DRAWINGS & MOTOR INFORMATION
SO: 3001196416, PO: 4-0720001-148703A

A5E01585477A – OUTLINES
4000HP, 13.8KVAC, 4KVAC, 660A – SHEET 1 thru 4
A5E01585477A – SCHEMATICS
A5E01585477B – SCHEMATICS
4000 HP MOTOR DATA, CURVES AND OUTLINES
2000HP MOTOR DATA, CURVES AND OUTLINES
SO: 3001196287, PO: 4-0720001-148704A

SO: 3001196302, PO: 4-0720001-149934A

Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 12
SO: 3001196303, PO: 4-0720001-149946A

SO: 3001195583, PO: 4-0720001-148702A

A5E01585468B – SCHEMATICS
6600HP MOTOR DATA, CURVES AND OUTLINES
Legend for machine dimension drawing
Type of construction IM B3
Degree of Protection IP55
Method of cooling IC 611
Total weight 198.2 kN
Dynamic Loading (maximum) 415 kN up, 640 kN down
The lifting lugs are designed to carry the weight of machine only.
No lifting of machine allowed together with base frame, adaptor plate
or sole plates!
Weight of rotor 47.9 kN
Rotor Inertia 426 kg-m2
DR = Direction of rotation (facing drive end DE) Counter Clockwise only
LE = Air inlet
LA = Air outlet
WA = Shaft extension DE
XA = Radius DE
Earthing connection
1 Terminal box for stator system connection

Type 1XD15---3AA
3 Terminal box for stator and bearing temperature protection

Type 1XB9014
5 Separate terminal box for anti-condensation heater

Type 1XB9014
10 Anti-friction bearing DE
Type NU1052+6052C3
11 Anti-friction bearing NDE

Type NU1052
40 Air Inlet RTD
41 Air Outlet RTD
42 Vibration Switch
Date 11.10.2007
Name Montgomery Details for machine
Checked. SWK dimension drawing
Type 1RQ6 710-8CS30-Z
A&D LD IO
Siemens AG Ident-No 3001064009/030-M002
Nbg Vo
Index Text Date Name WORD-Textgenerator V.1.0.0
Type 1XD15---3AA
Date 11.10.2007
A&D LD IO
Nbg Vo
Date 11.10.2007
A&D LD IO
Nbg Vo
3 Terminal box for auxiliary circuits
Type 1XB9014
Manufacturer BERNSTEIN
Material Aluminium-based alloy
Plate for cable entry (removable) not drilled
max. admissible conductor cross-section 4 mm2
Date 11.10.2007
A&D LD IO
Nbg Vo
Date 11.10.2007
A&D LD IO
Nbg Vo
Connections for:
● Bearing thermometer (double resistance thermometer Pt100; 100Ω at 0 °C)

Quantity per bearing 1
Guide values for adjustment of tripping temperature for bearing thermometers

Initial adjustment before starting for disconnection T0 = 110 °C
Adjustment acc. to measured values for warning T1 = T + 5 K ≤115 °C
for disconnection T2 = T + 10 K ≤120 °C
Advice: T = Temperature in condition of persistence (°C)
● Embedded winding thermometer (resistance thermometer Pt100; 100Ω at 0 °C)

Quantity 6
Thermometer with
connection-No. in phase
20:1R1 U
20:2R1 V
20:3R1 W
20:4R1 U
20:5R1 V
20:6R1 W
Guide values for adjustment of tripping temperature for Embedded winding thermometers
Date 11.10.2007
A&D LD IO
Nbg Vo
Type 1XB9014
Date 11.10.2007
A&D LD IO
Nbg Vo
Date 11.10.2007
A&D LD IO
Nbg Vo
General instructions
Recommendation for fixing the machine on a steel foundation

4 Fastening screws ISO 4017 / M42x120 - 8.8 - A3L
4 Washers DIN 125 / 45 - 100HV- A3L
4 Jacking screws ISO 4017 / M36x100 - 8.8 - A3L
Required tightening torque of the fastening screws MA = 1700 Nm (±15%)
Attention !
Limiting values for oscillations according to DIN ISO 10816-3
must not be exceeded!
Alignment accuracy for couplings:
Date 11.10.2007
A&D LD IO
Nbg Vo
Three-Phase-Inductionmotor with Squirrel Cage Rotor
Operationing and Installation Data:
Rated-
-power P N: 2983 kW Torque class : KL
-voltage U N: 4160 V Connection : Y
-frequency f N: 60 Hz Class of rating : S1
-current I N: 500 A Absolute altitude : <1000 m ab.s.l.
-speed n N: 896 1/min Coolant temperature : 45 °C
-torque M N: 31794 Nm
Power factor cosϕ : 0.85 Therm. class (design/util.) : 155 (F) / 130 (B)
Standard: NEMA MG-1

Tolerances: NEMA MG-1
Calculated Start-Up Data:
Motor voltage U/UN 1.00 0.9

Locked-rotor torque MA/MN 0.87 0.62
Pull-up torque MS/MN 0.87 0.62
Breakdown torque MK/MN 2.31 1.86
Locked-rotor current IA/IN 6.26 5.61
Calculated Partial Load Data: NEMA nominal efficiency
P/PN 1.25 1.00 0.75 0.50 0.25

cos ϕ 0.85 0.86 0.84 0.78 0.59
η [%] 96.5 96.5 96.3 95.2 92.4
Additional Technical Ratings and Information:
Rotor material:
Date 24.09.2007
Name BEATTY
Exam.
Electrical Data Sheet
Stnd.
A & D LD NOR Type 1RQ4 710-8
SIEMENS AG Order No. 3001064009 / 000030 - E
IND. Text Date Name
Rated-
Standard: NEMA MG-1

7
I(n) at UN
I/IN
I(n) at 90 % UN
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
n/nS
Date 24.09.2007
Name BEATTY
Exam.
Starting Data I=f(n)
Stnd.
IND. Text Date Name
Rated-
Standard: NEMA MG-1

for cold motor condition
for warm motor condition
100000
running motor
10000
allowable operating time [s]
1000
100
locked rotor
10
1
0 1 2 3 4 5 6 7 I/IN 8
Thermal copper time constant (short-term load variation): 20.0 min

Thermal time constant (long-term load variation): 65 min
Thermal time constant for cooling down (standstill): 260 min
Date 24.09.2007
Name BEATTY
Exam.
Thermal Limit Curve
Stnd.
IND. Text Date Name
Rated-
Standard: NEMA MG-1

3
M(n) at UN
M/MN
M(n) at 90 % UN
2.5
1.5
0.5
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
n/nS
Date 24.09.2007
Name BEATTY
Exam.
Starting Data M=f(n)
Stnd.
IND. Text Date Name
Rated-
Standard: NEMA MG-1

97.0 1.00
96.5 0.90
96.0 0.80
95.5 0.70
Efficiency [%]
Power factor
95.0 0.60
94.5 0.50
94.0 0.40
93.5 0.30
93.0 0.20
92.5 0.10
92.0 0.00
0 1000 2000 3000 4000 0 1000 2000 3000 4000
Power output [kW] Power output [kW]
700 899.5
899
600
898.5
500 898
Speed [1/min]
897.5
Current [A]
400 897
300 896.5
896
200 895.5
895
100
894.5
0 894
0 1000 2000 3000 4000 0 1000 2000 3000 4000
Date 24.09.2007
Name BEATTY
Exam.
Load Characteristics
Stnd.
IND. Text Date Name
Rated-
Standard: NEMA MG-1

Resistances, Reactances (Calculated Values per Phase)

Values (p.u.) refered to ZN ZN = UPH / IPH : 4.804 Ω
at slip : s=0 s=1

Stator-resistance R1 / ZN : 0.00517 0.00517
Stator-leakage reactance X1 / ZN : 0.19188 0.11304
Rotor-resistance R2' / ZN : 0.00448 0.01890
Rotor-leakage reactance X2' / ZN : 0.08558 0.05113
Magnetizing-reactance XH / ZN : 3.287 3.475
Ironloss-resistance RE / ZN : 111.83 111.83
The resistances apply to the warm machine.

The rotor-resistances / -reactances refer to the stator.
R1 X1 X2'
RE XH R2'
Time Constants, Currents

Magn. no load time constant : 2.00 s
No load-/rated current : 0.31
Power factor (s=1) : 0.14
Moment of inertia (motor) : kgm²
Date 24.09.2007
Name BEATTY
Exam.
Equivalent-Circuit Diagram
Stnd.
IND. Text Date Name
INDUCTION MOTOR DATA
Siemens Energy & Automation, Inc
Norwood, Ohio
Customer : SIEMENS LDA (ARGOS)

Order Number: 3001064009-000020
SPECIFIED REQUIREMENTS FRAME DATA
Horsepower : 2000 Frame : 8012S

Service Factor : 1.00 Type : CAZ
Voltage : 4160 Rotor Construction : Fabricated Copper Bar
Number of Phases : 3 Load Inertia (wk2), lb-ft2 :
Frequency, hertz : 48 Rotor Inertia (wk2), lb-ft2 : 4147
Ambient, deg C : 40 Rotor Weight, lbs : 6578
Enclosure : TEAAC Motor Weight, lbs : 27700
Synchronous Speed, RPM : 720
Percent Starting Voltage: 90
Elevation (ft): 3300
PERFORMANCE DATA
Full Load Speed, RPM : 715 Full Load Torque, lb-ft : 14691
Current, Amps : 250 Starting Torque, %FLT : 95
Locked Rotor Current, % FLA : 614 Breakdown Torque, %FLT : 218
KVA/Hp : 5.52
Code : F
0.50 0.75 Full No Locked

Load Load Load Load Rotor
Percent Efficiency : 96.1 96.2 95.9 N/A N/A
Percent Power Factor : 78.4 84.6 86.5 3.4 19.4
Current, Amps : 137.4 190.8 249.6 70.0 1532.7
100 90 % Voltage
Safe Stalled Time, Motor Hot : 27.0 37.0 Seconds
Safe Stalled Time, Motor Cold: 32.0 43.0 Seconds
Time Constants : 1.649 Seconds Open Circuit

0.075 Seconds Short Circuit (AC)
X/R Ratio : 16.124
Please Note:
1. All values are typical.
2. Guaranteed values are indicated in (GUAR)
Prepared by T.A. on 08/14/07

Siemens Energy & Automation, Inc.
Induction Motor
Percent Full Load Current and Torque vs. Percent Speed
250 700
600
200
500
Percent Full Load Torque (Solid)
Percent Rated Current (Dashed)

150
400
300
100
200
50
100
0 0
0 10 20 30 40 50 60 70 80 90 100
Percent Synchronous Speed
SO Number: 3001064009-000020
HP: 2000 HP
Rated Voltage: 4160 V
Rated Current: 249.6 A Curve groups from
Rated Speed: 715 RPM Top to Bottom are
Date: 8/14/2007 1.00, 0.90 Rated Voltage
Induction Motor
Calculated Time vs. Percent Full Load Current
1000
100 Running
Cold Stalled
Hot Stalled
Time in Seconds
10
0.1
0 100 200 300 400 500 600 700 800
Percent Full Load Current
SO Number: 3001064009-000020
HP: 2000 HP
Rated Current: 249.6 A
Rated Speed: 715 RPM
Date: 8/14/2007
Induction Motor
Calculated Eff, PF, & Amps vs. per unit Load
350
99
300
89
250
79
200
Eff & PF(%)
Eff
Amps
PF
Amps
150
69
100
59
50
49 0
0 0.2 0.4 0.6 0.8 1 1.2
Load(pu)
SO Number: 3001064009-000020
HP: 2000 HP
Date: 8/14/2007
Issue:01 MRS 08/24/07
Shaft Torsional Data

Yield Ultimate Rotor
Stiffness Core Bearing Shaft Modulus of Strength Strength Rotor WK2 Weight
Order # (in-lb/rad) Frame Type Poles Core Dia. Length Type Material Rigidity (PSI) (PSI) (PSI) (lb-ft2) (lbs)
3001064009-000020 4.49E+07 1126 CGGS 8 -26.97 -50.00 Anti-friction AISI 4140 11.8E+06 75,000 100,000 4147 6578
Inner Span Outer End of Shaft

Outer Keyway Inner Diameter Span Length Keyway
Span No. Diameter Length Tapered Span No. Diameter Tapered to Center of
Diameter (in) Width (in) (in) (in) Width (in)
(in) (in) Shaft? (in) Shaft? Core (in)
1 6.250 9.500 1.500 61.25
2 6.250 1.500
3 6.600 4.450
4 6.695 2.800
5 7.400 5.000
6 7.500 78.000 Total Length
7 7.400 5.000 of Shaft (in)
8 6.695 2.822 109.65
9 6.473 0.174
10 6.695 0.404
SHAFT MODEL
Drive End
20.0
15.0
10.0
DIAMETER
5.0
0.0
120.0 100.0 80.0 60.0 40.0 20.0 0.0
-5.0
-10.0
-15.0
-20.0
LENGTH
NOTE:
1. Torsional stiffness is calculated from the center of the core to the end of the shaft.
2. The span numbers begin at the first section of the drive end and move towards the last section of the opposite drive end.
3. This shaft includes spider arms. The torsional stiffness value above is calculated using only the solid shaft diameter. Due to manufacturing variances in rotor core fits and spider arm geometry,
the actual torsional stiffness may be +/- 15% from the calculated value. Contact the factory for more detailed shaft and spider dimensions.
ENG 024 7-00

Sheet
Norwood, Ohio
Customer : SIEMENS LDR (ARGOS)

Order Number: 3001064150-000010

Service Factor : 1.00 Type : CGZ
Number of Phases : 3 Rotor Inertia (wk2), lb-ft2 : 1333
Frequency, hertz : 60 Rotor Weight, lbs : 3530
Ambient, deg C : 45 Motor Weight, lbs : 13600
Enclosure : TEFC
PERFORMANCE DATA
KVA/Hp : 5.97
Code : G

Current, Amps : 77.3 99.5 125.5 51.9 745.3
100 90 % Voltage

X/R Ratio : 27.965
Prepared by DAVID BECKMAN on 08/14/07
Please Note:
3. Suitable for filtered VFD, VT, 293-880 speed range
Induction Motor
250 700
600
200
500

150
400
300
100
200
50
100
0 0
0 10 20 30 40 50 60 70 80 90 100
SO Number: 3001064150-000010
HP: 900 HP
Induction Motor
1000
100 Running
Cold Stalled
Hot Stalled
Time in Seconds
10
0.1
0 100 200 300 400 500 600 700 800
SO Number: 3001064150-000010
HP: 900 HP
Date: 8/14/2007
Induction Motor
180
160
91
140
81
120
71
Eff & PF(%)
100
Eff
Amps
PF
80 Amps
61
60
51
40
41
20
31 0
0 0.2 0.4 0.6 0.8 1 1.2
Load(pu)
SO Number: 3001064150-000010
HP: 900 HP
Date: 8/14/2007
Siemens Energy & Automation, Inc. Norwood, Ohio
Induction Motor Data
Customer SIEMENS LDR (ARGOS)

Serial Number 3001064150-000010
Customer Order LOI 1487404
Equivalent Circuit Parameters

for Polyphase Induction Motors
Rated RPM Stalled
R1 0.10661 0.10661
X1 2.54372 2.54372
R2 0.14676 0.49419
X2 2.75137 1.2876
XM 43.7141
Rre 2351.24
Note : Equivalent circuit parameters based on equivalent wye circuit.
Date: 8/15/2007
Issue:01 DB 08/31/07

Order # (in-lb/rad) Frame Type Poles Core Dia. Length Type Material Rigidity (PSI) (PSI) (PSI) (lb-ft2) (lbs)
3001064150-000010 4.00E+07 788 CGZ 8 -20.70 -32.00 Anti-friction AISI 1045 11.5E+06 39,000 75,000 1333 3530

1 5.000 7.500 1.253 16 5.250 2.450 44.20
2 5.000 1.500 17 4.900 3.250
3 5.250 2.600 18 3.750 1.500
4 5.513 1.600 19 3.000 0.400
5 6.600 3.500 20 3.000 3.400 0.377
6 9.000 9.750 21 2.933 1.000 0.377 Total Length
7 9.400 1.000 of Shaft (in)
8 9.007 33.270 0.377 89.25
9 7.500 0.300
10 7.847 1.200
11 7.507 1.000
12 7.400 3.580
13 6.939 2.000
14 6.600 6.250
15 5.513 2.200
SHAFT MODEL
Drive End
15.0
10.0
5.0
DIAMETER
0.0
100.0 90.0 80.0 70.0 60.0 50.0 40.0 30.0 20.0 10.0 0.0
-5.0
-10.0
-15.0
LENGTH
NOTE:
ENG 024 7-00

Norwood, Ohio

Order Number: 3001064062-000010

PERFORMANCE DATA
KVA/Hp : 5.48
Code : F

Current, Amps : 119.8 166.6 218.2 60.3 1331.0
100 90 % Voltage

X/R Ratio : 18.422
Please Note:

Induction Motor
250 700
600
200
500

150
400
300
100
200
50
100
0 0
0 10 20 30 40 50 60 70 80 90 100
SO Number: 3001064062-000010
HP: 1750 HP
Induction Motor
1000
100 Running
Cold Stalled
Hot Stalled
Time in Seconds
10
0.1
0 100 200 300 400 500 600 700 800
SO Number: 3001064062-000010
HP: 1750 HP
Date: 8/15/2007
Induction Motor
300
99
250
89
200
79
Eff & PF(%)
Eff
Amps
150 PF
Amps
69
100
59
50
49 0
0 0.2 0.4 0.6 0.8 1 1.2
Load(pu)
SO Number: 3001064062-000010
HP: 1750 HP
Date: 8/15/2007
Issue:01 TA 09/18/07
2
Order # (in-lb/rad) Frame Type Poles Core Dia. Length Type Material Rigidity (PSI) (PSI) (PSI) (lb-ft ) (lbs)
3001064062-10 5.81E+07 8010 CAZ 8 -26.90 -38.00 Anti-friction AISI 1045 11.5E+06 39,000 75,000 3155 4781

1 6.250 9.500 53.75
2 6.250 1.500
3 6.250 4.650
4 6.300 2.600
5 7.400 5.000
7 7.400 5.000 of Shaft (in)
8 6.300 3.250 113.21
9 6.250 3.900
10 6.000 8.120
11 3.000 2.410
12 2.437 3.400
13 2.240 0.880
SHAFT MODEL
Drive End
20.0
15.0
10.0
DIAMETER
5.0
0.0
120.0 100.0 80.0 60.0 40.0 20.0 0.0 -5.0
-10.0
-15.0
-20.0
LENGTH
NOTE:
ENG 024 7-00

Sheet
Norwood, Ohio

Order Number: 3001064105-000010

PERFORMANCE DATA
KVA/Hp : 5.48
Code : F

Current, Amps : 119.8 166.6 218.2 60.3 1331.0
100 90 % Voltage

X/R Ratio : 18.422
Please Note:

Induction Motor
250 700
600
200
500

150
400
300
100
200
50
100
0 0
0 10 20 30 40 50 60 70 80 90 100
SO Number: 3001064105-000010
HP: 1750 HP
Induction Motor
1000
100 Running
Cold Stalled
Hot Stalled
Time in Seconds
10
0.1
0 100 200 300 400 500 600 700 800
SO Number: 3001064105-000010
HP: 1750 HP
Date: 8/15/2007
Induction Motor
300
99
250
89
200
79
Eff & PF(%)
Eff
Amps
150 PF
Amps
69
100
59
50
49 0
0 0.2 0.4 0.6 0.8 1 1.2
Load(pu)
SO Number: 3001064105-000010
HP: 1750 HP
Date: 8/15/2007
Issue:01 TA 09/18/07
2
Order # (in-lb/rad) Frame Type Poles Core Dia. Length Type Material Rigidity (PSI) (PSI) (PSI) (lb-ft ) (lbs)
3001064105-000010 5.81E+07 8010 CAZ 8 -26.90 -38.00 Anti-friction AISI 1045 11.5E+06 39,000 75,000 3155 4781

1 6.250 9.500 53.75
2 6.250 1.500
3 6.250 4.650
4 6.300 2.600
5 7.400 5.000
7 7.400 5.000 of Shaft (in)
8 6.300 3.250 113.21
9 6.250 3.900
10 6.000 8.120
11 3.000 2.410
12 2.437 3.400
13 2.240 0.880
SHAFT MODEL
Drive End
20.0
15.0
10.0
DIAMETER
5.0
0.0
120.0 100.0 80.0 60.0 40.0 20.0 0.0 -5.0
-10.0
-15.0
-20.0
LENGTH
NOTE:
ENG 024 7-00

Legend for machine dimension drawing
Type of construction IM B3
Degree of Protection IP55
Method of cooling IC 611
Total weight 221.7 kN
Dynamic Loading (Maximum) 530 kN up, 780 kN down
The lifting lugs are designed to carry the weight of machine only.
No lifting of machine allowed together with base frame, adaptor plate
or sole plates!
Weight of rotor 58.0 kN
Rotor Inertia 542 kg-m2
DR = Direction of rotation (facing drive end DE) Clockwise only
LE = Air inlet
LA = Air outlet
WA = Shaft extension DE
XA = Radius DE
Earthing connection

Type 1XD15---3AA
3 Terminal box for stator and bearing temperature protection

Type 1XB9014

Type 1XB9014
10 Anti-friction bearing DE
Type NU1052+6052C3
11 Anti-friction bearing NDE

Type NU1052
40 Air Inlet RTD
41 Air Outlet RTD
42 Vibration Switch
Date 11.10.2007
A&D LD IO
Nbg Vo
Type 1XD15---3AA
Date 11.10.2007
A&D LD IO
Nbg Vo
Date 11.10.2007
A&D LD IO
Nbg Vo
3 Terminal box for auxiliary circuits
Type 1XB9014
Date 11.10.2007
A&D LD IO
Nbg Vo
Date 11.10.2007
A&D LD IO
Nbg Vo
Connections for:
● Bearing thermometer (double resistance thermometer Pt100; 100Ω at 0 °C)

Quantity per bearing 1
Guide values for adjustment of tripping temperature for bearing thermometers

● Embedded winding thermometer (resistance thermometer Pt100; 100Ω at 0 °C)

Quantity 6
Thermometer with
connection-No. in phase
20:1R1 U
20:2R1 V
20:3R1 W
20:4R1 U
20:5R1 V
20:6R1 W
Guide values for adjustment of tripping temperature for Embedded winding thermometers
Date 11.10.2007
A&D LD IO
Nbg Vo
Type 1XB9014
Date 11.10.2007
A&D LD IO
Nbg Vo
Date 11.10.2007
A&D LD IO
Nbg Vo
General instructions
Recommendation for fixing the machine on a steel foundation

4 Fastening screws ISO 4017 / M42x120 - 8.8 - A3L
4 Washers DIN 125 / 45 - 100HV- A3L
4 Jacking screws ISO 4017 / M36x100 - 8.8 - A3L
Required tightening torque of the fastening screws MA = 1700 Nm (±15%)
Attention !
Limiting values for oscillations according to DIN ISO 10816-3
must not be exceeded!
Alignment accuracy for couplings:
Date 11.10.2007
A&D LD IO
Nbg Vo
Rated-
Power factor cosϕ : .839 Therm. class (design/util.) : 155 (F) / 130 (B)
Standard: NEMA MG-1

Calculated Start-Up Data:
Motor voltage U/UN 1.00 0.9

Locked-rotor torque MA/MN 0.69 0.56
Pull-up torque MS/MN 0.69 0.56
Breakdown torque MK/MN 2.00 1.62
Locked-rotor current IA/IN 5.63 5.11
Calculated Partial Load Data: NEMA nominal efficiency
P/PN 1.25 1.00 0.75 0.50 0.25

cos ϕ 0.85 0.86 0.85 0.79 0.61
η [%] 97.0 97.2 97.2 96.7 94.5
Additional Technical Ratings and Information:
Rotor material:
Date 14.09.2007
Name BEATTY
Exam.
Electrical Data Sheet
Stnd.
AC 19.09.2007 BEATTY SIEMENS AG Order No. 3001063855 / 000020 - E

IND. Text Date Name BA148542
Rated-
Standard: NEMA MG-1

3
M(n) at UN
M/MN
M(n) at 90 % UN
2.5
1.5
0.5
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
n/nS
Date 14.09.2007
Name BEATTY
Exam.
Starting Data M=f(n)
Stnd.

Rated-
Standard: NEMA MG-1

6
I(n) at UN
I/IN
I(n) at 90 % UN
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
n/nS
Date 14.09.2007
Name BEATTY
Exam.
Starting Data I=f(n)
Stnd.

Rated-
Standard: NEMA MG-1

for cold motor condition
for warm motor condition
1000000
running motor
100000
allowable operating time [s]
10000
1000
100
locked rotor
10
1
0 1 2 3 4 5 6 I/IN 7
Thermal copper time constant (short-term load variation): 15.0 min

Thermal time constant (long-term load variation): 65 min
Thermal time constant for cooling down (standstill): 260 min
Date 14.09.2007
Name BEATTY
Exam.
Thermal Limit Curve
Stnd.

Rated-
Standard: NEMA MG-1

97.5 1.00
0.90
97.0
0.80
96.5 0.70
Efficiency [%]
Power factor
96.0 0.60
0.50
95.5 0.40
95.0 0.30
0.20
94.5
0.10
94.0 0.00
0 2000 4000 6000 8000 0 2000 4000 6000 8000
800 900
700 899
600 898
Speed [1/min]
Current [A]
500
897
400
896
300
200 895
100 894
0 893
0 2000 4000 6000 8000 0 2000 4000 6000 8000
Date 14.09.2007
Name BEATTY
Exam.
Load Characteristics
Stnd.

Rated-
Standard: NEMA MG-1

Resistances, Reactances (Calculated Values per Phase)

Values (p.u.) refered to ZN ZN = UPH / IPH : 6.131 Ω
at slip : s=0 s=1

Stator-resistance R1 / ZN : 0.00515 0.00515
Stator-leakage reactance X1 / ZN : 0.18704 0.11707
Rotor-resistance R2' / ZN : 0.00475 0.02075
Rotor-leakage reactance X2' / ZN : 0.10357 0.06553
Magnetizing-reactance XH / ZN : 3.575 3.906
Ironloss-resistance RE / ZN : 127.25 127.25
The resistances apply to the warm machine.

The rotor-resistances / -reactances refer to the stator.
R1 X1 X2'
RE XH R2'
Time Constants, Currents

Magn. no load time constant : 2.06 s
No load-/rated current : 0.29
Power factor (s=1) : 0.14
Moment of inertia (motor) : kgm²
Date 14.09.2007
Name BEATTY
Exam.
Equivalent-Circuit Diagram
Stnd.

Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 13
SECTION 3. SUBMITTAL SPECIFICATION COMPLIANCE
7.0 Documentation
7.1) Test Certificates showing results of standard tests for transformer, motor and drive.
Response: All certificates will be sent upon completion of testing.
7.2) Outline drawing for motor showing overall dimensions, weight, accessories, motor
connection diagram and rating, schematic diagrams for any auxiliary systems furnished
with motor.
Response: See Section 2 “VFD Drawings & Motor Information” of this submittal.
7.3) Motor data sheet including performance data (efficiencies, power factor and currents
at no load, ½, ¾, full load and service factor), rotor inertia, permissible stall times, noise
level.
7.5) Outline drawing showing dimensions and weight, nameplate drawing, connection
and schematic diagrams for transformer and accessories.
7.6) Installation, operation and maintenance manual for transformer, drive and motor and
any accessories.
Response: See Section 13 “Manuals”.
7.7) Spare parts lists for transformer, drive and motor.

Response: See Section 9 “Recommended Spare Parts” of this submittal. Motor spare parts
list will be provided once processed through engineering and a BOM has been created.
7.8) Shaft sketch and data for torsional analysis, when specified.
Response: Torsional analysis will be completed once motors are approved and final design
is released.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 14
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 15
SECTION 4. CLARIFICATIONS AND COMMENTS
A. Applicable Specifications
Siemens LDA Robicon Perfect Harmony, Gen IIIe, Gen IV – NXG Control Drives
Since Siemens LDA Robicon Perfect Harmony, Gen IIIe, Gen IV – NXG Control has a
power factor of .95 throughout the operating speed range; external power factor
correction equipment is not required.
Since the Siemens LDA Robicon Perfect Harmony, Gen IIIe, Gen IV – NXG Control
VFD inherently fulfills the requirements of the IEEE 519 1992 for both current and
voltage distortion on any power system, harmonic filters are not required.
Because of the motor-friendly, sinusoidal output, the Robicon Perfect Harmony, Gen IIIe,
Gen IV – NXG Control VFD does not require output filter capacitors and/or transformers
for operation.
Specifications for FLS/Holcim, Section 80009841 is the only specifications which shall
apply to this proposal, either directly or by reference. Any specifications that is not
explicitly included as part of this proposal is excluded from this offering.
General Comments
We propose to supply the Siemens LDA standard Robicon Perfect Harmony, Gen III,
Gen IIIe, Gen IV – NXG Control Drive design with features indicated in the proposal.
Siemens LDA is acting as an equipment supplier only, not as a contractor, or sub-

contractor. The listed specifications, (see Applicable Specifications, in this submittal)
are applicable only to the extent of the Siemens LDA “Equipment Provider” scope of
supply as described.
Specifically not included in this proposal is: Special crating, delivery to or offloading at
job-site, storage, installation and testing equipment, foundations, anchor bolts, templates,
system controls, external wiring, field testing, independent analysis, seismic calculations
and video taping of seminars.
NOTE: These items are the sole responsibility of the purchaser.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 16
Technical Comments
VFD requires a separate source of 460VAC, 3 phase, 60Hz power for auxiliary cooling
motors and control logic.
Power source for space heaters is by customer.
Incoming power and motor cable termination lugs are the responsibility of the purchaser.
Anchor bolts are the responsibility of the purchaser.
1 set of paper O&M Manuals will be shipped with each drive ordered. Additional
manuals will be supplied on CD.
Specifics
See As-Sold Proposal P000015700 Rev 2 for additional Comments to VFD

Specifications.
Page 1/Section 2.0 – Voltage variation is +10%, -5% from nominal 3-phase at rated
output.
Page 2/Section 3.1.4.2 – The input transformer is provided with ± 5% taps.
Page 2/Section 3.1.5.3 – Epoxy resin varnish is provided in lieu of VPI transformer.
Page 2/Section 3.1.6.5 – 13.8kV Primary will have a 75kV BIL rating along with
distribution class arrestors. 4.16kV Primary will have a 40kV BIL rating along with
distribution class arrestors.
Page3/Section 3.1.7 – Thermal switches are used for monitoring the temperature of the
transformer.
Page 3/Section 3.1.9 – VFD noise level is 75dB at 3 feet.
Page 5/Section 4.4 – A tachometer or encoder is typically not required for the Perfect
Harmony VFD, therefore not included.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 17
SECTION 5. VFD SPECIFICATION INFORMATION

ROBICON PERFECT HARMONY, GEN III/E, GEN IV – NXG CONTROL VFD STANDARD
COMPONENTS AND FEATURES
The Perfect Harmony series systems contain additional options, performance

enhancements and technological innovations that make Harmony drives efficient, cost-
effective, and easy to use. Some of these features are listed below.
• Ventilated NEMA 1 enclosure with gasket doors and filter media mounted to the air
inlets
• Input Air Cooled isolation transformer
• Distribution class surge arrestors
• Modular, trouble-free power cell design
• Door mounted customer interface keypad/display
• Sleeve type wire marker tags will be applied to power and control wiring
• Input isolation 4-20 mA speed follower
• Short circuit and ground fault protection
• User selectable automatic restart capability
• Catch spinning load restart capability
• Critical speed avoidance circuitry (3 programmable skip speeds)
• User configurable Digital Meters for indication of speed, amps, volts, kw, kw hours
and elapsed run time
• Report trending of parameters
• Fault log with first out indication and time/date stamp
• Diagnostic log pinpointing problem area and recourse
• Output frequency 0-60 HZ (constant torque), 61-120 Hz (constant horsepower)
• Accel/Decel .5-3200 seconds (load dependent)
• Cells receive commands and return status information via fiber optic cables
• Motor friendly PWM output eliminates VFD induced torque pulsations and
associated torsional analysis
• Sinusoidal output eliminates harmonic motor heating and can be used with a standard
AC induction motor without derating
• Electronic motor and VFD overload protection
• Common mode voltage protection, allows the use of a standard motor eliminating the
need for special high voltage insulation
• Motor is inherently protected from high voltage dV/dT stress, independent of cable
length to motor
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 18
Variable Speed Drive Data Sheet

Gen IIIe (6600HP)
Description Unit Specification
Robicon Perfect Harmony, Gen IIIe -
Model
NXG Control
Item 001
Dimensions (HxWxD) w/out
inches 308”W x 99.5”H x 54”D
blowers
Weight lbs 37900
Technology Voltage Source
Microprocessor-based Multilevel
Multi-Level PWM
Switching
Supply Voltage V 13,800
Tolerance % +10%, -5%
Supply Frequency Hz 60
Number of Phases 3
Rectifier Device Diode/IGBT
Inverter Device IGBT
Cell Voltage V 690
Number of Cells 12
Number of Pulses 24
Control Voltage V 460
120 VAC by Siemens Large Drives
Low Voltage Control V
Robicon
DC Link Capacitor Yes
Input Power Factor(30% - 100%
Cos f 95
speed)
Voltage Cut Ride Through Duration 5 Cycles
Volt Dip (w/ cont operation) 30%
VFD Output Voltage V 4160
Speed Control Hz .1 Hz
Overload Capability % 110% for 60s every 10m
Torque Pulsations Across Speed
% Maximum of .01 of 1%
Range
Quadrant Of Operation w/ Vector
2
Control
Cooling Air
Enclosure Protection Rating NEMA 1
Ambient Temperature Max Deg C 40
Humidity (non-condensing) % 95
Altitude ft 3300
Manuals Provided In Language English
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 19

Gen IIIe (4000HP)
Robicon Perfect Harmony, Gen IIIe -
Model
NXG Control
Item 001
Dimensions (HxWxD) w/out
inches 244”W x 91.5”H x 50”D
blowers
Weight lbs 29800
Multi-Level PWM
Switching
Number of Phases 3
Cell Voltage V 690
Number of Cells 12
Number of Pulses 24
Robicon
Cos f 95
speed)
Range
2
Control
Cooling Air
Altitude ft 3300
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 20

Gen IV, Phase 1 (900HP)
Perfect Harmony, Gen IV - NXG
Model
Control
Item 001
Dimensions (HxWxD)w/ Trans.
inches 78”W x 85.88”H x 42”D
Cab, w/out blowers
Weight lbs 7467
Multi-Level PWM
Switching
Number of Phases 3
Cell Voltage V 750
Number of Cells 9
Number of Pulses 18
Robicon
Cos f 95
speed)
Range
2
Control
Cooling Air
Altitude ft 3300
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 21

Gen IV, Phase 2 (1750HP, 2000HP)
Perfect Harmony, Gen IV - NXG
Model
Control
Item 001
Dimensions (HxWxD)w/ Trans.
inches 94”W x 86”H x 45”D
Cab, w/out blowers
Weight lbs 9061
Multi-Level PWM
Switching
Supply Voltage V 4160/13,800
Number of Phases 3
Cell Voltage V 750
Number of Cells 9
Number of Pulses 18
Robicon
Cos f 95
speed)
Range
2
Control
Cooling Air
Altitude ft 3300
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 22
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 23
SECTION 6. VFD CATALOG INFORMATION
The following pages are catalog information data sheets for the Perfect Harmony product
being used for this project.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 24
Perfect Harmony Series
ID-PWM AC Medium Voltage Variable Frequency Drives
400 HP-30000 HP 2300 VAC-13800 VAC
The only AC VFD system solution

designed to solve all power quality issues for
induction, synchronous and wound rotor motors.
It provides clean power input,
high power factor, trip-free operation
and near perfect sinusoidal output.
©ROBICON 1994
51
Power Quality Input
Clean Power Input
The Perfect Harmony series meets the most stringent IEEE 519 1992 requirements for voltage and current harmonic
distortion, even if the source is only large enough to operate the load. Although a 12-pulse inverter is better than previous
6-pulse designs, it still cannot meet the most rigorous recommendations of IEEE 519 1992 for many power systems. This is
why Robicon’s minimum design is an 18-pulse input AC to DC converter.
• Protects other on-line equipment from harmonic disturbance (computers, telephones, lighting ballast)
• Prevents “cross-talk” with other variable speed drives
• Eliminates need for time consuming harmonic analysis
• Avoids costly harmonic filters and associated resonance problems
Harmonic Comparison of Typical 1,000 HP

12-Pulse IGCT-PWM Inverter vs. Perfect Harmony Series Operating from
1,100 KVA, 5.75% Impedance Source
Typical PWM 12-Pulse Inverter Perfect Harmony Series, 24 Pulse
Source Current Source Current
Source Voltage Source Voltage
12-PULSE HARMONIC WAVEFORM PERFECT HARMONY SERIES WAVEFORM

Total Harmonic Distortion (CURRENT) 8.8% — Total Harmonic Distortion (CURRENT) 0.8% —
Total Harmonic Distortion (VOLTAGE) 5.9% — Total Harmonic Distortion (VOLTAGE) 1.2% —
HARMONY VS. CSI PWM

High Power Factor (CENTRIFUGAL LOAD)
Exceeds .95 power factor at normal operating speeds without external 1
Measured Power Factor
power factor correction capacitors. 0.9
• Eliminates utility penalties for poor power factor 0.8
• Avoids overloading feeders, breakers and transformers Perfect Harmony

Input Power Factor
0.7 Phase Controlled SCR Drive
with reactive power 0.6
• Improves voltage regulation 0.5
• Ideal for low synchronous speed induction motor 0.4
applications. A high and stable power factor is maintained 0.3
throughout entire speed range using standard induction motors 0.2
0.1
0
25 50 75 100
Motor Speed %
High Efficiency
Perfect Harmony provides higher than 98% converter efficiency,
96%-97% total VFD system efficiency, including input transformer, Typical System Efficiency
100
harmonic filter, power factor correction capacitors and output filters. 98
This far exceeds others when the transformer, power factor 96

Perfect Harmony
and harmonic filter losses are included in the total VFD system
94
Efficiency (%)
92
efficiency calculation. 90
88
86
84
82
80
10 20 30 40 50 60 70 80 90 100
Percent Load
System efficiency includes isolation transformer, harmonic filter, power factor correction and drive
52
Smart Electronics
The Perfect Harmony utilizes smart electronics with IGBTs to deliver power quality waveforms without extra, large, costly,
loss-adding filters. IGBTs are high volume, low-cost, robust devices with more than ten years of proven track record and
availability from a number of suppliers. IGBTs utilize simple, low-power gate drivers compared to IGCTs, making them more
reliable and easier to control. Unlike an IGCT, an IGBT will not be destoyed by any gate driver malfunction.
Power Quality Output

The Perfect Harmony’s unique multi-level PWM design inherently provides a sinusoidal output without the use of complex,
external output filters. There is no degradation to waveform at lower speeds, unlike loss producing traditional designs
which may be sinusoidal only at 60 Hz.
PERFECT HARMONY AT 100% SPEED PERFECT HARMONY AT 50% SPEED PERFECT HARMONY AT 25% SPEED
• Provides multi-level PWM output waveform

with no appreciable audible motor noise
• Requires no motor derating — can be applied Torque Pulsations
to new or existing 1.0 service factor motor and Robicon "Perfect Harmony" Series @ 30 Hertz, Full Load
unity power factor synchronous motors. 100
Percent of Rated Torque
Can be applied with motors from any

manufacturer without special design
10
considerations
• Eliminates harmful VFD-induced current
harmonics which cause motor heating 1
Rated
• Inherently protects motor against common Torque
mode voltage and dV/dT stress, regardless of (%)
0.1
cable length
• Eliminates VFD-induced torque pulsations,
even at low speeds, so there is minimal stress 0.01
to mechanical equipment
• Allows standard motor and cable insulation.
0.001
• Special insulation for DV/DT for common 0 100 200 300 400 500
mode voltage is not required Pulsation Frequency in Hz
Torque Pulsations at 30 Hertz, Full Load 900 HP, Four-Pole Motor on

Robicon Perfect Harmony Variable Frequency Drive
Output Torque Spectrum
Low output motor torque harmonics reduce
torsional stress on equipment (motor coupling,
gearbox, driven load, etc.).
Soft Start Protection

Prevents power-line dips due to motor inrush
currents and extends motor and equipment life.
53
Motor Cable Lengths
The Perfect Harmony drive system owns world records in terms of
electrical transmission distance for electrical submersible pumps.
Perfect Harmony systems are operating in three oil production fields
globally and have been field tested at 5km, 10km, 15km and 20km
cable lengths. Perfect Harmony needs no site-specific dedicated
filters to control harmonics so there is no retuning for power system
changes. Also, users can change cable lengths and pump sizes
within the horsepower range without redesigning an output filter.
Current harmonics are minimized. And with virtually no output
harmonics, there are no problems with motor, cables, or torque
pulsations. Even at long cable lengths, there are no problems with
cable over-voltage. Excerpts from published technical papers follow:
“Theoretical analysis, supported by field trials, has demonstrated

the very low harmonic content of this drive/cable/motor combi-
nation. The field trials, using redundant downhole cable, have
been carried out at 5, 10, 15 and 20 km cable length by Reda
Pumps in Inverurie.”
(Gannet E: The World’s Longest Subsea ESP, SPE 38534, 1998
Offshore Europe Conference)
“A final test was held in order to determine if the motor iron would
saturate and overheat for an over-voltage of 10% and to determine
if the motor would overheat or stall for an under-voltage of 5% with
full load shaft. Conclusion of the tests was that motor temperature
will not be a concern for terminal voltage within the tested range.”
(Gannet E Subsea ESP: The Application of Technology in Practice, SPE 50596, European Petroleum Conference 10/98)
“Low harmonic VFDs currently installed and operating at Canõ Limon have increased potential oil production an
average of 50,000 barrels per year per well. The energy consumed per barrel lifted is lower. Annual energy bill is
lowered around US $10,000 per year per well.”
(Medium Voltage Variable Frequency Drives with Low Harmonic Distortion, 1998 Electric Submersible Pump Workshop)
Reliability and Performance

MTBF
With more than 700 units sold and operating worldwide, Perfect Harmony has a “field proven” mean-time-before-failure of
51,000 hours, based on actual operating experience. When equipped with complete and redundancy options, the MTBF is
approximately 100,000 hours.
Parts Count Reduction

The evolution of the Perfect Harmony design has led to a 20% parts reduction while maintaining its industry-leading power
quality characteristics without output filters, common mode reactors, and other items or power devices needed for protection.
Testing
All Robicon drives with corresponding isolation transformers are shipped full-load tested to the customer site. With an
integral isolation transformer, Perfect Harmony is a “plug-n-play” drive system. A complete factory load test assures custom-
ers that their VFD with transformer isn’t being tested for the first time at their site.
Reliability
Proven, transistorized PWM design assures maximum reliability.
Fiber Optic Control Circuitry

Noise-free two-way optical link employs precise, high-speed digital communication. And it ensures high voltage isolation
between low voltage control and high voltage power section.
54
Air or Liquid Cooling Systems
Available with either forced air cooling or self-contained, closed loop liquid cooling. (Liquid-to-Liquid or Liquid-to-Air heat
exchangers available.) Redundant pumps are standard on liquid-cooled units. Redundant blower available for air-cooled units.
Multi-Motor Operation
Drive can easily accommodate multiple motor applications.
Integral Isolation Transformer

The Perfect Harmony solution utilizes an integral isolation transformer, which is factory mounted and pre-wired to the VFD.
This eliminates the cost of external customer remote mounting of the transformer with the field wiring and cost of conduit or
cable trays. In order to achieve maximum reliability of each Perfect Harmony system all transformers are shipped from our
transformer suppliers to Robicon’s facility for complete full load string testing of the transformer with each VFD. This insures
that any problems or defects are found on Robicon’s factory floor and not at the customer’s site at time of startup. The Perfect
Harmony transformer utilizes the best available insulation system rated for 220°C. Most VFD suppliers utilize oil-filled
transformers which require expensive environmental safeguards or less expensive dry-type transformers, which operate at
150°C rise that reduce system efficiency and transformer life. However, Robicon operates the Perfect Harmony dry type air-
cooled transformers at 115°C rise (just 80°C rise on larger liquid-cooled units) yielding higher efficiencies and longer
equipment life.
Sensorless Vector Control

This option raises the level of performance for constant torque general purpose motoring drive applications. Vector control
provides improved control for high starting torque and high-torque/low-speed. Hall effect sensors and vector control
software algorithms provide constant torque adjustable voltage and adjustable frequency control that is quiet, responsive,
precise and simple. Drives with this option offer full rated torque across the full range and a controlled speed range of 50:1
or better. The vector control option is available in the full family of Perfect Harmony drives including all power ranges,
voltage levels and line converter configurations.
Maximized Up-Time Perfect Harmony

5 Cycle Power Loss Ride-Through
The Perfect Harmony Series will keep your system up and running @ 100% Load
through most common failures. That means no loss of production and Drive Output Voltage
an improved bottom line.
Trip-Free Operation
Can ride though a 30% voltage dip, or loss of power for 5 cycles.
Thermal Ride-Through
Drive will stay on-line at reduced capacity instead of tripping on Drive Input Voltage
excessive ambient temperature.
Spinning Load Restart

In the event of more serious interruptions, the drive can be restarted into a motor that is still spinning and resume operation.
Modular Construction
Power cells are identical to one another and are mounted on a rack-out assembly for easy removal and on-site repair.
Modular construction offers a mean time to repair of approximately 15 minutes. Cells are easily replaced by disconnecting
5 leads and 1 fiber optic cable.
ProToPS™
Process Tolerant Protection Strategy is a standard implementation of the VFD SOP (System Operating Program) designed
to provide the operator with indication of a change in the state of the VFD. These annunciations identify changes that can
impact the ability of the VFD to meet process demands or provide advanced indication of a pending VFD trip. ProToPS™
allows the process operator to make process corrections to the VFD in use or adjust the process to address a pending
VFD trip.
55
Redundancy Options
Cell Bypass Option
This feature improves VFD availability by shunting a faulted power cell and resuming operation at reduced capacity with
remaining cells. This allows the process to continue and maintenance to be postponed until a convenient time.
CELL A-4 BYPASSED
Power Cell Diagnostics and Repair

Unlike high voltage SCRs, GTOs, IGCTs and SGCTs, Perfect
Harmony power cells can be repaired in the event of failure.
There are no special or matched components. Harmony cells
use standard low voltage components and give users the
safety and convenience of low voltage, stand-alone diagnostics
and troubleshooting. Shown is an optional power cell bench
tester kit.
Reports and Diagnostics

The Perfect Harmony Series drive offers user-programmable diagnostic tools. Advanced multi-channel fiber optic communi-
cation diagnostics provide for the most comprehensive evaluation available.
On-Line Tuning and Diagnostics

System can be reviewed and adjustments made while drive is operating. Allows operator to adjust tuning parameters while
drive is running.
RAMP SETUP
→ FWD ACCEL 2.0 SEC
Power Cell Check

Upon initialization, the drive verifies the integrity of each power cell, even to the power transistor level. Thereafter, the drive
monitors the status of each power cell and all of the associated components.
INITIAL STATUS CHECK

ALL POWER CELLS OK
Reports
Reports are stored in nonvolatile memory and
contain valuable operating information and *******************
PARAMETER SETTINGS
diagnostic data. The following reports can easily *******************
: Min : Max : :
be retrieved via printer or CRT: Parameter : Limit : Limit : Level :
************************************************
Motor Freq 60 Hz : 50 : 60 : 1 :
No of Poles 4 : 2 : 12 : 1 :
• diagnostic log FL Speed 1800 RPM : 475 : 3780 : 1 :
Motor Volts 460 V : 300 : 750 : 1 :
• historic log Motor FLC
Motor kWs
500 A :
209 kWs :
0 : 1000 :
15 : 1000 :
1 :
1 :
• cell fault log I min
I max
109 A :
500 A :
0 : 500 :
0 : 1000 :
1 :
1 :
500 A : 0 : 1000 : 1 :
• parameter log I drive
Acn. time 15.0 sec : 2.0 : 300.0 : 1 :
Dcn. time 20.0 sec : 2.0 : 300.0 : 1 :
• fault log I init
Flux Pause
40 A : 0 : 1000 :
3.0 sec ; 1.0 ; 30.0 ;
1 :
1 ;
• cell status V Min
V Max
0 V :
460 V : 300 :
0 : 50 :
750 :
1 :
1 :
56
Microprocessor Standard Features
Keypad/Display Module
Provides precise and repeatable parameter settings and adjustments. All
values are entered via the keypad in decimal digits. The keypad entry
process eliminates potentiometers and select resistors, and is common to
all Robicon drives. MODE DEMD FREQ RPM OAMP
AUTO 100 60 1780 112
Digital Display
The keypad/display is conveniently located for easy one-touch operation
and provides a programmable digital display of amps, frequency, kW,
rpm, % speed or voltage. kW-Hour and Elapsed Time Meter displays are
accessible through the keypad.
Advanced Diagnostics
Diagnostic routines are built into the control circuits. Separate personal
computers and auxiliary equipment are not required for diagnostics.
Provides continual, comprehensive monitoring of drive’s control functions
and a display of all system faults on the keypad/display module. Provides
easy and extensive troubleshooting with drive door closed.
Energy Saver
This feature sets the inverter output voltage as a function of the motor Motor
load, providing maximum motor efficiency over a wide range of load Voltage
100%
and duty cycles. This parameter specifies a minimum output motor
voltage. A value of 50% represents a maximum energy savings poten-
tial, while a value of 100% represents no energy savings potential. 50%
User Friendly Messages

Avoids codes and translating. All fault messages and operating condi- 0%
torque
tions are in text. 0% 10% 90% 100%

Energy Saver
Pre-Engineered Options
Robicon has developed standard “pre-engineered” options in response to feedback from the Perfect Harmony user base
and field service data. Advantages include standardization, proven design, quick delivery and cost savings. Some options
are mutually exclusive, contingent upon other options and may affect dimensions.
Power Options Metering Options

• Fused disconnect switch • Power Meter
• Power cell bypass • 3Ø input ammeter and voltmeter
• Constant speed/full voltage bypass • Multilin 269+™ motor relays
• Constant speed/reduced voltage bypass • Multilin SR469™ motor relays
• Keyed interlocks • 8 channel motor RTD monitor
• High voltage input to 34.5 kV • Multilin Power Quality Meter (PQM™)
• 50 Hz or 60 Hz input
• Copper-wound main transformer Custom Options
• Synchronous transfer (consult factory) • Control house
• Input surge arrestors • Redundant ventilation blower
• Output contactor
Control Options • Report printer
• Redundant control power feed • Touch screen display
• 120 V UPS for control power
• Control power transformer
• Modular I/O expansion
• High performance vector control
• Serial communications
57
Robicon Perfect Harmony
Compared to the Perfect Harmony approach, a low voltage solution with step up and step down transformers is less efficient,
provides lower starting torque, has higher installation cost and generates more heat load to the motor control room.
TYPICAL LOW VOLTAGE CONFIGURATION PERFECT HARMONY
Input
Input
Step Down
Transformer
Medium Voltage
Low Voltage VFD VFD
Step Up
Transformer
Motor
Motor
3Ø connection to motor
3Ø connection to utility
Perfect Harmony
The closest thing to plug-n-play.
Simple 3Ø power in/out One integral solution
connections with no site (Offers efficiency improvements
interconnection wiring. of 3-4%, more starting torque,
less heat load to motor control
room, lower install cost)
Medium Voltage Input

and Output Section
(Allows both top
and bottom entry/exit)
Power Cell Section
Input Isolation Transformer

Input Load Break
(Factory pre-wired for easy, Customer Control Section Rack Out Design
Disconnect Switch
low cost field installation) (Allows both top and bottom (Less mean time
(Optional)
58 entry/exit) to repair)
Communication and I/O Capabilities
Input/Output Options
The Perfect Harmony Series offers I/O capabilities in both digital and analog.
• Two isolated analog inputs individually software configurable as either 4-20 mA, 0-20 mA or 0-10 V.
• Up to three programmable isolated analog outputs 4-20 mA such as speed, voltage and current.
• Seven programmable, digital inputs, 120 VAC isolated.
• One system E-stop digital input, 120 VAC isolated.
• Three programmable from C relay digital outputs (dry contact).
• One programmable, 0-10 V non-isolated potentiometer input.
Industry Standard Communications

The Perfect Harmony has a microprocessor-based digital controller which offers more communication capability than any
other drive of its kind.
The Perfect Harmony Series can directly interface with industry-standard communications systems, energy management
systems and other digital control schemes including the following networks:
• Modicon Modbus™ or Modbus-Plus™ • GE Genius™
• Allen Bradley DH™, DH+™ • Ethernet™
• DeviceNet™
• Reliance AutoMAX™, AutoMATE™
• Siemens SIMATIC/TI505™
• GE GENIUS I-O™
• PROFIBUS DP™
• Other Programmable Logic Controller and serial interfaces available on request
Standard Cable Connections

A standard DB25 cable enables connections with PCs and printers.
These cables are available at most computer retailers.
59
Perfect Harmony Footprint Comparison
The Perfect Harmony is an integrated drive system. It includes the isolation transformer and arrives at
the customer site fully integrated, wired and full-load tested. Some suppliers only discuss inverter
dimensions and usually don’t provide details of integration and the transformer. With available space
in motor control rooms at a premium, users must consider the complete drive system lineup in their
evaluations.
Drive vs. Drives Systems

The illustrations below compare a 1,000 Hp, 4160 VAC Perfect Harmony to competing systems with and without required
isolation transformers. All three alternative drives require integration of the drive and transformer at the customer site,
including wiring and testing.
IGCT Neutral Point Clamp Inverter

and complete drive system
vs. Perfect Harmony.
3-Level, High Voltage, Voltage Source

PWM Inverter and drive system
vs. Perfect Harmony.
Current Source PWM inverter

and drive system vs. Perfect Harmony.
Note: Inverter dimensions come from published sales materials. Transformer dimensions are an approximate based on the
dimensions at one particular supplier.
60
Service and Support
Sales & Application Engineers
Robicon has been manufacturing variable frequency drives for more than 30 years. Our engineers have many years of
application-specific experience in industrial, municipal and HVAC markets and are strategically located at headquarters
and regional offices. Assistance is also available through our network of manufacturer’s representatives. Our representa-
tives are the first step in developing a drives system solution that saves time and money.
Technical Support Center

Associates at our 24-hour help line (724-339-9501) provide immediate telephone assistance for customers needing help
with troubleshooting, programming, installation or startup. Our contact management computer system enables our
associates to assure continuity of your dialogue and provide fast and accurate solutions.
Field Service Representatives

Field service representatives provide 24-hour emergency response around the world from 50 locations in addition to
Robicon’s factory. Our field service representatives are specifically trained to handle every phase of installation, startup,
maintenance and troubleshooting of Robicon drives and to take full advantage of Robicon’s extensive technical and
operational resources.
Commitment Management
Robicon’s process-based order fulfillment places sales and project engineers on the same team to ensure all aspects of our
commitment and diligent follow-through on your order.
Factory Repair, Parts, Exchanges

Associates provide turnaround on repairs for most items in 24 hours. Exchanges are available to maximize uptime. Spare
parts are held in strategic locations to provide same-day delivery and spare part kits are available to ensure critical
applications.
Warranty
Unlike many drives manufacturers, Robicon’s warranty covers all on-site and in-house repairs, labor, materials and
expenses.
Technical Training
User Training Programs teach customers how to operate and maintain Robicon drives. These programs are conducted at
customer sites and at Robicon’s factory training center. Classes cover every drive configuration with basic and advanced
courses for design, operation and maintenance personnel.
61
500 H
P PER
Technical Specifications
FECT
HP RANGE: 400 HP - 30000 HP
2300 VAC - 13800 VACHARM
DESIGN: Multi-Level PWM
ONY A
INPUT:
OUTPUT:
INPUT POWER FACTOR: .
+10%/-5% at full power, +10%/-30% at reduced power
SINUSOIDAL; 0-7200 VAC
.95 from 20% to 100% load
T 100
INPUT POWER: Non Phase Sequence Sensitive
FREQUENCY DRIFT: ± 0.5% from all factors
SPEED RANGE: 0-100% continuous (application dependent)
CURRENT RATING: 100% continuous; 150% for 1 minute (optional)
ACCELERATION RATE: 0.1 - 3200 sec. adjustable (load dependent)
DECELERATION RATE: 0.1 - 3200 sec. adjustable (load dependent)
OUTPUT FREQUENCY: 0 - 50/60 Hz; customer selectable up to 250 Hz
ENCLOSURE: NEMA-1 Ventilated air-cooled, NEMA-12 liquid cooled, IP21, IP52
AMBIENT TEMPERATURE: 0 - 40°C; higher available
HUMIDITY: 95% non-condensing
ALTITUDE: Maximum 3300 feet above MSL; higher available
MOTOR TYPES: Induction, Synchronous, Wound Rotor
APPLICATIONS: All constant and variable torque
QUALITY ASSURANCE: ISO 9001 Registered
10M - 4/00
62
Introducing the The Robicon MicroHarmony is
the latest innovation in Siemens
medium-voltage variable
Robicon MicroHarmony frequency drives (VFDs). Also
known as the Perfect Harmony
Medium-Voltage VFD Generation IV, the MicroHarmony
is designed to provide maximum
versatility, efficiency and
process availability.
A technical evolution of the

proven and well-established
Perfect Harmony Gen III, the
MicroHarmony maintains the
same core characteristics and
familiar competitive advantages–
such as high-power quality input
Features and Benefits

and output, along with high
availability–while capitalizing
on more recent technologies.
Specifically, the MicroHarmony
has 15 percent fewer parts than
previous Perfect Harmony designs,
a smaller drive footprint and an
overall more cost-effective design.
The MicroHarmony is engineered

for those applications where a
small footprint is paramount.
Measuring just 66" wide by 42"
deep by 110" high (168 cm wide
by 107 cm deep by 280 cm high),
it's the smallest medium-voltage
VFD in the world.
A fully integrated VFD system in a

single lineup, the MicroHarmony
includes the isolation transformer,
power electronics, and control
and cooling systems. There's no
customer site cabling required to
connect the assembled sections,
and access to all components is
easy. The control panel swings
out for access to power and
robicon
motor connections, and cells
can be pulled out easily when
maintenance is required.
s
Features and Benefits
The MicroHarmony at a Glance Advanced Cell Bypass ProToPS™ Process-First Mentality

쮿 Small overall footprint The Advanced Cell Bypass feature Robicon Perfect Harmony's Process
including transformer enables the MicroHarmony to remain Tolerant Protection Strategy (ProToPS)
쮿 High efficiency with operational in the event of a cell failure provides a hierarchical system of
high-performance IGBTs by bypassing a faulted cell. Depending warnings that keep the MicroHarmony
쮿 Reliable air-cooled design on the process requirement and the on line and in control of your process.
쮿 Clean power input (meets IEEE-519) VFD configuration, a cell fault could Drive trips and process interruptions
쮿 0.95 power factor throughout have minimal or no impact on the only occur in extreme circumstances.
speed range process; the motor output power ProToPS allows time for the operator
쮿 Near perfect sinusoidal output allows quality remains within to evaluate a VFD disturbance and
retrofit to existing motors NEMA-defined guidelines. respond appropriately to avoid
쮿 Multi-level PWM technology means system shutdown.
no special motor is required
쮿 Can be applied to induction,
synchronous and wound rotor motors
쮿 Control drive tool
(Windows interface)
쮿 Proven Perfect Harmony topology
쮿 Option for advanced cell bypass
(ProToPS™)
쮿 Option for redundant blowers
MicroHarmony Ratings
and Dimensions
Horsepower range
170 - 1100 HP (127 kW - 820 kW)
Output voltage range

0 - 4.2 kV
Input voltage range

2.4 kV - 13.8 kV (50 Hz - 60 Hz)
Overall dimensions
66" W x 42" D x 110" H with blower
168 cm W x 107 cm D x 280 cm H

Ideal for applications that
with blower require a small drive footprint.
Cells can be pulled out easily when maintenance is required. Control panel swings out for easy access to
power and motor connections.
Siemens Energy & Automation, Inc. automation.usa.siemens.com/drives

3333 Old Milton Parkway
쏘2006 Siemens Energy & Automation, Inc. All Rights Reserved.
Alpharetta, GA 30005
Siemens is a registered trademark of Siemens AG. Product names mentioned may be trademarks or registered
trademarks of their respective companies. Specifications are subject to change without notice.
1-800-964-4114
LRFL-00100-0406 New .50406 .5M0406 Printed in USA
info.sea@siemens.com
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 25
SECTION 7. EFFICIENCY & POWER FACTOR

High Efficiency
Perfect Harmony provides 98% converter efficiency, 96%-97% total VFD system
efficiency.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 26
High Power Factor
Exceeds .95 power factor at normal operating speeds without external power factor
correction capacitors.
• Eliminates utility penalties for poor power factor.
• Avoids overloading feeders, breakers and transformers with reactive power.
• Improves voltage regulation.
• Ideal for low synchronous speed induction motor applications. A high and stable
power factor is maintained throughout entire speed range using standard induction
motors.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 27
SECTION 8. KEY COMPONENT DATA/VENDOR CUT SHEETS
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 28
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 29
Gen IIIe
Description Manufacturer Manufacturer's P/N
Control Disconnect - CDS1 ABB OT30E3
T1-H1/H2/H3 - Arrestors COOPER 235-37
CB1 - 25A adj. SIEMENS 3RV1031-4EA10
CB2 - 20A SIEMENS BQ2B020QLD
F6 ATQR2
F7 GOULD SHAWMUT ATQR10
F8 ATQR12
Xfmr Blower EBM RH71-6/205304
Xfmr Blower Motor Starter ABB A9S-84M
Blower Motor Starter Fuses GOULD SHAWMUT AJT8/AJT10
Cell Blower EBM RH63M-6/130157
Cell Blower Motor Starter ABB A9S-84L
Blower Motor Starter Fuses GOULD SHAWMUT AJT8
Terminal Blocks WEIDMULLER 102000
Analog Input WAGO 750-452
Analog Output WAGO 750-554
Digital Input WAGO 750-406
Digital Output WAGO 750-517
INSTRUMENT
CT1/CT2 300 SERIES
TRANSFORMERS
HEB/HEC LEM LT-2005-S
PB4 ALLEN-BRADLEY 800T-FX6A5/800T-N151
SW1 ABB CBG-M3MK01
TS1/TS2/TS3 DAYTON 2E 206
HTR CHROMALOX SN-910/OT-702
CR1 SIEMENS 3TX7121-5DF13
Latch Fault Relay IDEC RR2KP-U-AC120V
LFR/CR1 Suppressor OKAYA XA1201
Tech System/Converter TECSYSTEM NT-538/ NT-CONV/420/8A
K1 Key Interlock SUPERIOR Type 4003 - S105810Y
Disconnect switches
Product index
SwitchLine, Non-fusible.......................... 17.1 - 17.74
Dimensions..........................................17.54 - 17.74
General information .................................17.1 - 17.7
Kits...........................................................17.8 - 17.9
Maintenance bypass switches.............17.37 - 17.38
Motor operators ...............................................17.39
Other configurations ............................17.35 - 17.36
Technical data .....................................17.40 - 17.53
Type OETL, 200A - 3150A...................17.23 - 17.34
Type OT, 16A - 125A ...........................17.10 - 17.22
PowerLine, Fusible.............................. 17.75 - 17.124
Dimensions......................................17.115 - 17.124
Fuse monitors................................................17.104
General information ..............................17.75 17.81-
Kits...................................................................17.82
Motor operators .............................................17.105
Other configurations ..........................17.96 - 17.103
Technical data .................................17.107 - 17.114
Type OESA, 200A - 800A ....................17.91 - 17.95
Type OS, 30A - 100A...........................17.83 - 17.90
SafeLine, Enclosed ........................... 17.125 - 17.152
Dimensions, fusible .........................17.150 - 17.151

Dimensions, non-fusible ..................17.141 - 17.142 17
Enclosed, fusible .............................17.140 - 17.145
Enclosed, non-fusible ......................17.130 - 17.130
General information .........................17.125 - 17.129
Technical data, fusible ...................................17.149
Technical data, non-fusible ............................17.140
Low Voltage Products & Systems 17.A

ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03
ct
17 n ne s Kits
o e
sc h le 16A – 3150A, 600V, 3 pole1
Di witc usib
s n-f
No
handle
Each kit includes: shaft2
1 three pole1 switch
1 handle switch
1 shaft
terminal lug kit3
1 terminal lug kit Kit
Kits with base & DIN rail mounted switches and selector handles
UL IEC Maximum horsepower rating Kit
general purpose AC21 Single phase Three phase catalog List
amp rating amp rating number price
120V 240V 200V – 208V 240V 480V 600V
16 16 1 2 3 5 10 10 OT16B2A1-180 $ 100
25 25 1.5 3 7.5 7.5 15 20 OT25B2A1-180 106
UL 508
40 40 2 5 10 10 20 25 OT32B2A1-180 110
60 63 2 5 15 15 30 30 OT45B2A1-180 134
80 80 2 5 20 20 40 40 OT63B2A1-180 154
30 40 2 5 10 10 20 30 OT30B2A1-180 184
UL 98
60 63 3 7.5 20 20 40 40 OT60B2A1-180 209

100 115 5 15 25 30 50 50 OT100B2A1-180 234
Kits with base and/or DIN rail mounted switches and pistol handles
120V 240V 200V – 208V 240V 480V 600V
16 16 1 2 3 5 10 10 OT16B6-170 $ 162
25 25 1.5 3 7.5 7.5 15 20 OT25B6-170 168
UL 508
40 40 2 5 10 10 20 25 OT32B6-170 172
60 63 2 5 15 15 30 30 OT45B6-170 196
80 80 2 5 20 20 40 40 OT63B6-170 216
30 40 2 5 10 10 20 30 OT30B6-170 246
60 63 3 7.5 20 20 40 40 OT60B6-170 271
100 115 5 15 25 30 50 50 OT100B6-170 296
125 160 7.5 20 30 40 75 100 OT160B6-210 516
UL 98
200 250 — — 60 75 150 200 OT200B8-240 804

400 630 — — 100 125 250 350 OT400B4-280 1736
600 800 — — 150 200 400 500 OT600B4-280 2706
800 1250 — — 200 250 500 600 OT800B4-280 5066
1200 1600 — — — — — — OT1200B4-280 7926
1600 2500 — — — — — — OT1600M8-325 17,630
2000 2500 — — — — — — OT2000M8-325 19,430
— 3150 — — — — — — OT3150M8-325 21,130
17
Kits with door mounted switches
120V 240V 200V – 208V 240V 480V 600V
16 16 1 2 3 5 10 10 OT16ET3S $ 98
25 25 1.5 3 7.5 7.5 15 20 OT25ET3S 104
UL 508
40 40 2 5 10 10 20 25 OT32ET3S 108
60 63 2 5 15 15 30 30 OT45ET3S 132
80 80 2 5 20 20 40 40 OT63ET3S 152
30 40 2 5 10 10 20 30 OT30ET3S 182
60 63 3 7.5 20 20 40 40 OT60ET3S 207
100 115 5 15 25 30 50 50 OT100ET3S 232
UL 98
30 40 2 5 10 10 20 30 OT30ET3P 254
60 63 3 7.5 20 20 40 40 OT60ET3P 279
100 115 5 15 25 30 50 50 OT100ET3P 304
125 160 7.5 20 30 40 75 100 OT160ET3P 640
1 Four poles are available — please reference accessories pages 17.12 & 17.21.
2 Shaft is not required with door mounted switch, except OT160ET3.
3 16A – 125A switches include standard integral terminal lugs.
4 Available as a kit using the standard base mount switch and a door mount bracket.
Discount schedule H1: NF, 16A – 100A

17.8 Low Voltage Products & Systems
AC 1000 - 11/03 Discount schedule H3: NF, 1200A – 3150A ABB Inc. • 888-385-1221 • www.abb-control.com
Di
s
Kit components
16A – 3150A, 600V, 3 pole1
17 sw con
No itc ne
n- he ct
fus s
ibl
e
handle
Each kit includes:
1 three pole 1 switch shaft 2
1 handle switch
1 shaft
1 terminal lug kit terminal lug kit 3
Kit
Kit components 2 for base & DIN rail mounted switches with selector handles
Switch Handle 4 Shaft Terminal lugs
Kit De- Mounting
catalog Catalog NEMA Marking feat- Catalog depth5 Length Catalog Wire Wire Catalog
number number type able number (inches) (inches/mm) number size type number
OT16B2A1-180 OT16E3 1,3R,12 O/I & Off/On — OHB2AJ1 7.4 – 8.1 7.1/180 OXS5X180 #18 – 8 Cu Integral
OT100B2A1-180 OT100E3 1,3R,12 O/I & Off/On — OHB2AJ1 7.6 – 8.6 7.1/180 OXS5X180 #8 – 1/0 Cu Integral
Kit components 2 for base and/or DIN rail mounted switches with pistol handles
Kit De- Mounting
catalog Catalog NEMA Marking feat- Catalog depth5 Length Catalog Wire Wire Catalog
OT16B6-170 OT16E3 1,3R,12 O/I & Off/On Yes OHB65J5 7.0 – 7.5 6.7/170 OXP5X170 #18 – 8 Cu Integral
OT100B6-170 OT100E3 1,3R,12 O/I & Off/On Yes OHB65J5 7.2 – 8.2 6.7/170 OXP5X170 #8 – 1/0 Cu Integral
OT160B6-210 OT160E3 1,3R,12 O/I & Off/On Yes OHB65J6 7.3 – 8.5 8.3/210 OXP6X210 #8 – 1/0 Cu Integral
OT200B8-240 OETL-NF200ASW 1,3R,12 O/I & Off/On Yes OHB80J8 8.7 – 12.6 9.5/240 OXP8X240 #6 – 300 kcmil Cu/Al OZXA-25
OT400B4-280 OETL-NF400SW 1,3R,12 O/I & Off/On Yes OHB145J12 10.2 – 14.5 11.0/280 OXP12X280 #2 – 600 kcmil Cu/Al OZXA-26
OT600B4-280 OETL-NF600ASW 1,3R,12 O/I & Off/On Yes OHB145J12 10.2 – 14.5 11.0/280 OXP12X280 (2)#2 – 600 kcmil Cu/Al OZXA-27
OT800B4-280 OETL-NF800ASW 1,3R,12 O/I & Off/On Yes OHB145J12 11.6 – 15.3 11.0/280 OXP12X280 (2)#2 – 600 kcmil Cu/Al OZXA-30
OT1200B4-280 OETL-NF1200SW 1,3R,12 O/I & Off/On Yes OHB145J12 11.6 – 15.3 11.0/280 OXP12X280 (4)#2 – 600 kcmil Cu/Al OZXA-28
OT1600M8-325 OETL-NF1600SW 1,3R,4,4X,12 Off/On — YASDA-8 13.4 – 23.1 12.8/325 OXP12X325 (4)#2 – 600 kcmil Cu/Al OZXA-28
OT2000M8-325 OETL-NF2000SW 1,3R,4,4X,12 Off/On — YASDA-8 13.4 – 23.1 12.8/325 OXP12X325 (8)#2 – 600 kcmil Cu/Al OZXA-28/2
OT3150M8-325 OETL-NF3150SW 1,3R,4,4X,12 Off/On — YASDA-8 13.4 – 23.1 12.8/325 OXP12X325 (8)#2 – 600 kcmil Cu/Al OZXA-28/2
17
Kit components 2 for door mounted switches
Kit De- Mounting
catalog Catalog NEMA Marking feat- Catalog depth Length Catalog Wire Wire Catalog
OT16ET3S OT16ET3 1,3R,12 O/I & Off/On — OHB2PJ No shaft required #18 – 8 Cu Integral
OT45ET3S OT45ET3 1,3R,12 O/I & Off/On — OHB2RJ No shaft required #14 – 1 Cu Integral
OT100ET3S OT100ET3 1,3R,12 O/I & Off/On — OHB2RJ No shaft required #8 – 1/0 Cu Integral
OT30ET3P OT30ET3 1,3R,12 O/I & Off/On — OHB65J5 Includes OHZX6 adapter #14 – 4 Cu Integral
OT60ET3P OT60ET3 1,3R,12 O/I & Off/On — OHB65J5 Includes OHZX6 adapter #14 – 4 Cu Integral
OT100ET3P OT100ET3 1,3R,12 O/I & Off/On — OHB65J5 Includes OHZX6 adapter #8 – 1/0 Cu Integral
OT160ET3P OT160ET3 1,3R,12 Off/On — OHB65J6 — 5.2/130 OXP6X130 #8 – 1/0 Cu Integral
If other handles or shafts are desired, please order from the individual component pages 17.10, 17.11, 17.20, 17.23, 17.27 and 17.31.
1 Other pole configurations available; please see individual components.
2 For more information please see individual components. 5 Mounting depth is the distance from the outside of door to the disconnect switch mounting
3 16A – 125A switches include standard integral terminal lugs. plate. Shaft can be cut to desired length.
4 Handles are black and accept three padlocks. For other handles see individual components. 6 Consists of standard base mounted switch with door mount conversion bracket.
Low Voltage Products & Systems Discount schedule H1: NF, 16A – 100A 17.9
ABB Inc. • 888-385-1221 • www.abb-control.com Discount schedule H3: NF, 1200A – 3150A AC 1000 - 11/03
ct
17 n ne s 16A – 100A, Base & DIN rail mounted

o e
sc h le
Di witc usib
s n-f
No
For a complete assembly,

please select one of each:
1 switch
1 handle
1 shaft
OT63E3 + OXS5X180 + OHB2AJ1
16 – 100 Amp switches, 600V, 3 pole1

UL IEC
general AC21 Maximum horsepower rating Terminal lugs
purpose amp Single phase Three phase Catalog List
amp rating rating 120V 240V 200V 240V 480V 600V Wire size Wire type number price
16 16 1 2 3 5 10 10 #18 – 8 Cu OT16E3 $ 66
25 25 1.5 3 7.5 7.5 15 20 #18 – 8 Cu OT25E3 72
UL 508
OT16E3 40 40 2 5 10 10 20 25 #18 – 8 Cu OT32E3 76

OT25E3
OT32E3 60 63 2 5 15 15 30 30 #14 – 1 Cu OT45E3 100
80 80 2 5 20 20 40 40 #14 – 1 Cu OT63E3 120
30 40 2 5 10 10 20 30 #14 – 4 Cu OT30E3 150
UL 98
60 63 3 7.5 20 20 40 40 #14 – 4 Cu OT60E3 175

100 115 5 15 25 30 50 50 #8 – 1/0 Cu OT100E3 200
Selector handles — for use with shafts .20 x .20" ( 5x5mm)

UL/NEMA IEC Defeat- Padlock- Weight Catalog List
Color
type type able able (lbs) number price
All marked both O/I & Off/On
1 IP54 Black — — 0.09 OHB1AH12 $ 22
1 IP54 Red/Yel — — 0.09 OHY1AH12 22
OT30E3
OT60E3 1 IP54 Black — Yes 0.12 OHB3AH12 24
OT100E3 1 IP54 Red/Yel — Yes 0.12 OHY3AH12 24
1,3R,12 IP65 Black — Yes 0.16 OHB2AJ1 28
1,3R,12 IP65 Red/Yel — Yes 0.16 OHY2AJ1 28
1,3R,12 IP65 Black Yes Yes 0.16 OHB2AJ 30
1,3R,12 IP65 Red/Yel Yes Yes 0.16 OHY2AJ 30
Shafts — for use with OH selector handles .20 x .20" ( 5x5mm)
OHB1AH1
Mounting depth3 in inches
OT16E3 OT30E3
OT45E3
Shaft OT25E3 OT60E3 Weight Catalog List
OT63E3
I ON length OT32E3 OT100E3 (lbs) number price
17 inches/mm OH_1_ &

OH_2_
OH_1_ &
OH_2_ OH_2_
O OFF
OH_3_ OH_3_
3.3/85 4.2 – 5.0 3.6 – 4.3 4.9 – 5.6 4.4 – 5.0 3.9 – 4.9 0.04 OXS5X85 $4
4.1/105 5.0 – 5.8 4.4 – 5.1 5.7 – 6.4 5.1 – 5.8 4.7 – 5.7 0.04 OXS5X105 4
4.7/120 5.6 – 6.4 5.0 – 5.8 6.3 – 7.0 5.7 – 6.4 5.3 – 6.3 0.05 OXS5X120 4
OHB3AH1 5.1/130 6.0 – 6.7 5.4 – 6.1 6.7 – 7.4 6.1 – 6.8 5.6 – 6.7 0.05 OXS5X130 6
7.1/180 7.1 – 8.7 7.4 – 8.1 8.6 – 9.4 8.1 – 8.7 7.6 – 8.6 0.08 OXS5X180 6
9.8/250 10.7 – 11.5 10.1 – 10.8 11.4 – 12.1 10.9 – 11.5 10.4 – 11.4 0.10 OXS5X250 12
13/330 13.8 – 14.6 13.3 – 14.0 14.6 – 15.3 14.0 – 14.7 13.5 – 14.5 0.14 OXS5X330 20
OHY2AJ
1 A snap on fourth pole may be added — please reference accessories pg 17.12.

2 Not suitable for use with OT30E3, OT60E3, OT100E3.
OXS5X__ 3 Mounting depth is the distance from the outside of door to the disconnect switch mounting plate. Shaft can be cut to desired length.
17.10 Discount schedule H1: NF, 16A – 100A Low Voltage Products & Systems
AC 1000 - 11/03 Discount schedule H6: Handles, shafts and accessories ABB Inc. • 888-385-1221 • www.abb-control.com
Di
s
16A – 100A, Base & DIN rail mounted
Handles & shafts
Pistol handles — for use with shafts .20 x .20" ( 5 x 5 mm)

17 sw con
No itc ne
n- he ct
fus s
ibl
e
Length
UL/NEMA IEC Color Marking inches/ Defeatable Padlockable Weight Catalog List
type type mm (lbs.) number price
1,3R,12 IP65 Black O/I & Off/On 1.8/45 Yes Yes 0.28 OHB45J5 $ 70
1,3R,12 IP65 Red/Yel O/I & Off/On 1.8/45 Yes Yes 0.28 OHY45J5 70
OHB__J5
1,3R,12 IP65 Black O/I & Off/On 2.6/65 Yes Yes 0.29 OHB65J5 80
OHB__L5 1,3R,12 IP65 Red/Yel O/I & Off/On 2.6/65 Yes Yes 0.29 OHY65J5 80
1,3R,12,4,4X IP66 Black O/I & Off/On 2.6/65 Yes Yes 0.29 OHB65L5 120
1,3R,12,4,4X IP66 Red/Yel O/I & Off/On 2.6/65 Yes Yes 0.29 OHY65L5 120
Shafts — for use with pistol handles .20 x .20" ( 5 x 5 mm)
Mounting depth1 (inches)

OHY__J5
OHY__L5 Shaft OT16E3 OT30E3
length OT25E3 OT45E3 OT60E3 Weight Catalog List
(inches/mm) OT32E3 OT63E3 OT100E3 (lbs.) number price
5.9/150 6.2 – 6.7 6.9 – 7.4 6.4 – 7.4 0.07 OXP5X150 $ 14

6.7/170 7.0 – 7.5 7.7 – 8.1 7.2 – 8.1 0.08 OXP5X170 16
10.4/265 10.7 – 11.3 11.4 – 11.9 10.9 – 11.9 0.12 OXP5X265 18
15.8/400 16.0 – 16.6 16.8 – 17.2 16.2 – 17.2 0.18 OXP5X400 30
OXP5X__ 19.7/500 20.0 – 20.5 20.7 – 21.1 20.1 – 21.1 0.23 OXP5X500 42
Twisted shafts — Rotates handle 45° .20 x .20" ( 5 x 5 mm)

Shaft OT16E3 OT30E3
length OT25E3 OT45E3 OT60E3 Weight Catalog List
OXP5X__/45 (inches/mm) OT32E3 OT63E3 OT100E3 (lbs.) number price
5.9/150 6.2 – 6.7 6.9 – 7.4 6.4 – 7.4 0.07 OXP5X150-45 $ 14
6.7/170 7.0 – 7.5 7.7 – 8.1 7.2 – 8.1 0.08 OXP5X170-45 16
10.4/265 10.7 – 11.3 11.4 – 11.9 10.9 – 11.9 0.12 OXP5X265-45 18
15.8/400 16.0 – 16.6 16.8 – 17.2 16.2 – 17.2 0.18 OXP5X400-45 30
19.7/500 20.0 – 20.5 20.7 – 21.1 20.1 – 21.1 0.23 OXP5X500-45 42
CXBY68135
Replacement knob — mounts directly to switch; no shaft necessary
UL/NEMA Color For use Length Catalog List
Padlockable
Type on: (inches) number price
1 Red OT16, OT25, OT32 1.0 — CXBY68135 $8
1 Red OT30, OT45 – OT100 1.4 — CXBY68306 12
CXBY68306 1 Red OT30, OT45 – OT100 1.6 Yes 2 CXBY68419/1 14
Metal collar OT16 – OT100 — — OTZS1 13
Set screw OT16 – OT100 — — FLSWM5X8AY 23
Modular adapter cover — for OT16, OT25, OT32

Length Padlockable Catalog List
17
CXBY68419/1 Item For use on: (inches) number price
Adapter cover OT16, OT25 OT32 — Yes OHY7 $ 28
A padlock can be used with the adapter cover.
OTZS1
1 Mounting depth is the distance from the outside of door to the disconnect switch mounting plate. Shaft can be cut to desired length.
OHY7 2 .1875" (3/16") diameter shackle required.
3 Set screw FLSWM5X8AY needed with replacement knobs CXBY__.
Low Voltage Products & Systems Discount schedule H6: Handles, shafts and accessories 17.11
ct

o e
sc h le Accessories
Di witc usib
s n-f
No
(N)7
L4 N N N PE
(N)8 N N N PE
OT16E
3
I
ON T4
O
OFF
Max. two contacts on each side of switch
Auxiliary contacts 1 — snap-on mounting

AC AC
Description For use on: Weight thermal rated Catalog List
(lbs.) amp rating voltage number price
1 N.O.
mounts on right OT16 – OT100 0.07 10 600 OA1G10 $ 20
side of switch only
OA1G__ 1 N.O.
mounts on left OT16E3C – OT100E3C 0.07 10 600 OA7G10 20
side of switch only
1 N.C.
mounts on left OT16 – OT100 0.07 10 600 OA1G01 20
side of switch only
1 N.C.
mounts on right OT16E3C – OT100E3C 0.07 10 600 OA3G01 20
side of switch only
1 N.O. & 1 N.C.
mounts on left or right OT16 – OT100 0.07 10 600 OA2G11 40
side of switch
OTP_32EP
Power poles
• Only one power pole per switch
• Mounts on left or right side of switch
AC AC
OT16, OT25, OT32 0.07 40 600 OTPS32EP $ 36

Fourth pole 2 OT45, OT63 0.13 80 600 OTPS63EP 44
OT30, OT60 0.31 60 600 OTPS60EP 54
OT100 0.31 100 600 OTPS125EP 54
OTP_63EP
17 OT16, OT25, OT32 0.07 40 600 OTPL32EP 36
Late-break/early-make 2 OT45, OT63 0.13 80 600 OTPL63EP 44
OT30, OT60, OT100 0.31 100 600 OTPL125EP 54
Terminal poles
• Switch accepts one terminal pole per side
AC AC
OT16, OT25, OT32 0.07 40 600 OTPN32EP $ 20

Solid neutral 2 OT45, OT63 0.13 80 600 OTPN63EP 36
OTP_125EP OT30, OT60, OT100 0.31 100 600 OTPN125EP 50
OT16, OT25, OT32 0.07 40 600 OTPD32EP 28

Detachable neutral 2 OT45, OT63 0.13 80 600 OTPD63EP 36
OT30, OT60 0.31 60 600 OTPD60EP 50
OT100 0.31 100 600 OTPD125EP 54
OT16, OT25, OT32 0.07 40 600 OTPE32EP 20

Ground terminal 2 OT45, OT63 0.13 80 600 OTPE63EP 36
OT30, OT60, OT100 0.31 100 600 OTPE125EP 50
1 UL File # E83510
2 Switch accepts one power pole or one terminal pole per side. Only one power pole per switch.
17.12 Discount schedule H6: Handles, shafts and accessories Low Voltage Products & Systems
AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com
Di
s
17 sw con
16A – 100A, Base & DIN rail mounted
No itc ne
6 Pole switches n- he ct
fus s
ibl
e

1 switch
1 handle
1 shaft
OT45E6 + OXS5X180 + OHY_J6
16 – 100 Amp switches, 600V, 6 pole 1

UL IEC Maximum horsepower ratings
general AC21 Terminal lugs Shaft
purpose amp Single phase Three phase size Catalog List
amp rating rating (mm) number price
120V 240V 200V 240V 480V 600V Wire size Wire type
16 16 1 2 3 5 10 10 OT16E6 $ 192
25 25 1.5 3 7.5 7.5 15 20 #18 – 8 Cu 5 OT25E6 204
UL 508
40 40 2 5 10 10 20 25 OT32E6 212
60 63 2 5 15 15 30 30 OT45E6 260
#14 – 1 Cu 6
80 80 2 5 20 20 40 40 OT63E6 300
30 40 2 5 10 10 20 30 #14 – 4 OT30E6 360
UL 98
OT45E6
60 63 3 7.5 20 20 40 40 #14 – 4 Cu 6 OT60E6 410
100 115 5 15 25 30 50 50 #8 – 1/0 OT100E6 460
Pistol handles — 5 & 6mm, for use with 6-pole switches

UL/NEMA IEC Length Defeat- Padlock- Weight Shaft Catalog List
Color Marking
type type in/mm able able (lbs) size (mm) number price
5mm— for use with OT16, OT25 & OT32
Black OHB65J5
1, 3R, 12 IP65 2.6/65 O/I & Off/On Yes Yes 0.29 5 $ 80
OHB__J6 Red/Yel OHY65J5
Black OHB65L5
1, 3R, 4, 4X, 12 IP66 2.6/65 O/I & Off/On Yes Yes 0.29 5 120
Red/Yel OHY65L5
6mm— for use with OT45, OT63, OT30E6, OT60E6 & OT100E6
Black 2.6/65 0.29 OHB65J6 80
Red/Yel 2.6/65 0.29 OHY65J6 80
1, 3R, 12 IP65 O/I & Off/On Yes Yes 6
Black 3.1/80 0.30 OHB80J6 90
Red/Yel 3.1/80 0.30 OHY80J6 90
Black OHB80L6
OHY__J6 1, 3R, 4, 4X, 12 IP66 3.1/80 O/I & Off/On Yes Yes 0.30 6 130
Red/Yel OHY80L6
Shafts —5 & 6mm, for use with 6 pole switches

Shaft OT16E6 OT45E6 OT30E6 Weight Shaft Catalog List
17
length OT25E6 OT63E6 OT60E6 (lbs) size number price
(inches/mm) OT32E6 OT100E6 (mm)
OXS5X__
5mm— for use with OT16, OT25 & OT32
5.9/160 7.2 — — 0.07 OXP5X150 $ 14
6.7/170 8.0 — — 0.08 OXP5X170 16
10.4/265 11.7 — — 0.12 5 OXP5X265 18
15.8/400 17.0 — — 0.18 OXP5X400 30
19.7/500 21.0 — — 0.23 OXP5X500 42
6mm— for use with OT45, OT63, OT30E6, OT60E6 & OT100E6
5.2/130 — 6.6 6.7 0.08 OXP6X130 12
5.9/150 — 7.4 7.5 0.09 OXP6X150 12
8.3/210 — 9.7 9.8 0.13 OXP6X210 16
6
11.4/290 — 12.9 13.0 0.18 OXP6X290 20
14.2/360 — 15.6 15.7 0.23 OXP6X360 24
16.9/430 — 18.4 18.5 0.27 OXP6X430 28
1 A snap-on power pole may be added to build a 7 or 8 pole switch; please reference accessories, page 17.12.
2 Mounting depth is the distance from the outside of door to the disconnect switch mounting surface. Shaft can be cut to desired length.
Low Voltage Products & Systems Discount schedule H1: NF, 16 – 100A 17.15
ABB Inc. • 888-385-1221 • www.abb-control.com Discount schedule H6: Handles, shafts and accessories AC 1000 - 11/03
ct

o e
sc h le
Di witc usib 3 Pole transfer switches
s n-f
No

1 switch
1 handle
1 shaft
OT45E3 + OXS5X180 + OHB_J5
16 – 100 Amp – 600V, 3 Pole transfer switches 1

UL IEC Maximum horsepower ratings
general AC21 Terminal lugs Shaft
purpose amp Single phase Three phase size Catalog List
amp rating rating (mm) number price
120V 240V 200V 240V 480V 600V Wire size Wire type
16 16 1 2 3 5 10 10 OT16E3C $ 258
25 25 1.5 3 7.5 7.5 15 20 #18 – 8 Cu 5 OT25E3C 270
UL 508
40 40 2 5 10 10 20 25 OT32E3C 288
60 63 2 5 15 15 30 30 OT45E3C 328
#14 – 1 Cu 5
80 80 2 5 20 20 40 40 OT63E3C 368
30 40 2 5 10 10 20 30 #14 – 4 OT30E3C 428
UL 98
OT45E3C
60 63 3 7.5 20 20 40 40 #14 – 4 Cu 5 OT60E3C 478
100 115 5 15 25 30 50 50 #8 – 1/0 OT100E3C 514
Selector handles — 5mm, for use with transfer switches; marked I/ON - O/OFF - II/ON
UL/NEMA IEC Color Defeatable Padlockable Weight Catalog List
type type (lbs.) number price
1, 3R, 12 IP65 Black OHB2AJE011

Yes Yes 0.16 $ 40
Red/Yel OHY2AJE011
Shafts for selector handles —5mm, for use with transfer switches
OHB2AJE011

Shaft OT16E3C OT45E3C OT30E3C Weight Shaft Catalog List
length OT25E3C OT63E3C OT60E3C (lbs) size number price
(inches/mm) OT32E3C OT100E3C (mm)
3.3/85 3.6 - 4.3 4.4 - 5.0 3.9 - 4.9 0.04 OXS5X85 $4
4.1/105 4.4 - 5.1 5.1 - 5.8 4.7 - 5.7 0.04 OXS5X105 4
4.7/120 5.0 - 5.8 5.7 - 6.4 5.3 - 6.3 0.05 OXS5X120 4
OHB__J5 5.1/150 5.4 - 6.1 6.1 - 6.8 5.6 - 6.7 0.05 5 OXS5X150 6
7.1/180 7.4 - 8.1 8.1 - 8.7 7.6 - 8.6 0.08 OXS5X180 6
9.8/250 10.1 - 10.8 10.9 - 11.5 10.4 - 11.4 0.1 OXS5X250 12
13/330 13.3 - 14.0 14.0 - 14.7 13.5 - 14.5 0.14 OXS5X330 20
Pistol handles — 5mm, for use with transfer switches; marked I/ON - O/OFF - II/ON
17 UL/NEMA IEC Color Length Marking Defeat- Padlock- Weight Shaft Catalog List
type type in/mm able able (lbs) size (mm) number price
OHY__J5 Black OHB65J5E011
1, 3R, 12 IP65 2.6/65 O/I & Off/On Yes Yes 0.29 5 $ 90
Red/Yel OHY65J5E011
Black OHB65L5E011
1, 3R, 4, 4X, 12 IP66 2.6/65 O/I & Off/On Yes Yes 0.29 5 130
Red/Yel OHY65L5E011
Shafts for pistol handles —5mm, for use with transfer switches
OXS5X__
Shaft OT16E3 OT45E3 OT30E3 Weight Shaft Catalog List
length OT25E3 OT63E3 OT60E3 (lbs) size number price
(inches/mm) OT32E3 OT100E3 (mm)
5.9/160 7.2 7.4 7.5 0.07 OXP5X150 $ 14
6.7/170 8.0 8.2 8.3 0.08 OXP5X170 16
10.4/265 11.7 11.9 12.0 0.12 5 OXP5X265 18
15.8/400 17.0 17.2 17.3 0.18 OXP5X400 30
19.7/500 21.0 21.2 21.3 0.23 OXP5X500 42
1 A snap on power pole may be added to build a 4 pole transfer switch; please reference accessories and auxiliary contact
information on page 17.12.
2 Mounting depth is the distance from the outside of door to the disconnect switch mounting plate. Shaft can be cut to desired length.
17.16 Discount schedule H1: NF, 16 – 100A Low Voltage Products & Systems
Di
s
16A – 100A, Door mounted
17sw con
No itc ne
n- he ct
fus s
ibl
e

please order one of each:
1 switch
1 handle
OT45ET3 OHB2RJ
16 – 100 Amp switches, 600V, 3 pole12

UL IEC Maximum horsepower rating Terminal lugs
general AC21
Single phase Three phase Catalog List
purpose amp
amp rating rating 120V 240V 200V 240V 480V 600V Wire size Wire type number price
16 16 1 2 3 5 10 10 #18 – 8 Cu OT16ET3 $ 70
25 25 1.5 3 7.5 7.5 15 20 #18 – 8 Cu OT25ET3 76
UL 508
40 40 2 5 10 10 20 25 #18 – 8 Cu OT32ET3 80
60 63 2 5 15 15 30 30 #14 – 1 Cu OT45ET3 104
80 80 2 5 20 20 40 40 #14 – 1 Cu OT63ET3 124
OT16ET3 30 40 2 5 10 10 20 30 #14 – 4 Cu OT30ET3 154
UL 98
OT25ET3 60 63 3 7.5 20 20 40 40 #14 – 4 Cu OT60ET3 179

OT32ET3 100 115 5 15 25 30 50 50 #8 – 1/0 Cu OT100ET3 204
Selector handles
UL/NEMA IEC Color Defeat- Padlock- Weight Catalog List
type type able able (lbs) number price
All marked both O/I & Off/On

Snap-on mounting — for use on OT16, 25, 32ET3
1 IP54 Black — — 0.10 OHB1PH $ 22
1 IP54 Red/Yel — — 0.10 OHY1PH 22
OHY1__ 1 IP54 Black — Yes 0.13 OHB3PH 24
1 IP54 Red/Yel — Yes 0.13 OHY3PH 24
1,3R,12 IP65 Black — Yes 0.17 OHB2PJ 28
1,3R,12 IP65 Red/Yel — Yes 0.17 OHY2PJ 28
I ON
Screw mounting — for use on OT16 – OT100. For OT30, OT60, OT100 use OH_2_ only
1 IP54 Black — — 0.11 OHB1RH 22
O OFF
1 IP54 Red/Yel — — 0.11 OHY1RH 22

1 IP54 Black — Yes 0.14 OHB3RH 24
1 IP54 Red/Yel — Yes 0.14 OHY3RH 24
1,3R,12 IP65 Black — Yes 0.18 OHB2RJ 28
OHB3__
1,3R,12 IP65 Red/Yel — Yes 0.18 OHY2RJ 28
Door mounted switches do not provide door interlock
Pistol grip handle adapter 17

Weight Catalog List
Description For use on:
(lbs) number price
Adapter piece
OT30, OT60, OT100 0.18 OHZX6 $ 20
for pistol grip handle
Includes hardware and a shaft. For pistol grip handles.
OHB2__
OHY2__
1 A snap on fourth pole may be added — please reference accessories pg 17.18.

2 Door mounted switches do not require shafts.
Low Voltage Products & Systems Discount schedule H1: NF, 16A – 100A 17.17
ABB Inc. • 888-385-1221 • www.abb-control.com Discount schedule H6: Handles, shafts and accessories AC 1000 - 11/03
ct
17 n ne s 16A – 100A, Door mounted

o e
sc h le Accessories
Di witc usib
s n-f
No
Door mounted switches
Auxiliary contacts 1 — snap-on mounting
Weight AC thermal AC rated Catalog List

Description For use on: (lbs) amp rating voltage number price
1 N.O.
mounts on righthand 0.07 10 600 OA1G10 $ 20
side of switch
OT16 – OT100
1 N.C.
OA1G__
mounts on lefthand 0.07 10 600 OA1G01 20
side of switch
Max. two contacts on each side of switch.
Power poles

OT16, OT25, OT32 0.07 40 600 OTPS32ED $ 36

OTP_32ED Fourth pole2 OT45, OT63 0.13 80 600 OTPS63ED 44
OT30, OT60, OT100 0.20 100 600 OTPS125ED 54
OT16, OT25, OT32 0.07 40 600 OTPL32ED 36

Late-break/early-make2 OT45, OT63 0.13 80 600 OTPL63ED 44
OT30, OT60, OT100 0.20 100 600 OTPL125ED 54
Terminal poles
17
OTP_63ED
OT16, OT25, OT32 0.07 40 600 OTPN32ED $ 20
Solid neutral 2 OT45, OT63 0.13 80 600 OTPN63ED 36
OT30, OT60, OT100 0.20 100 600 OTPN125ED 50
OT16, OT25, OT32 0.07 40 600 OTPD32ED 28

Detachable neutral 2 OT45, OT63 0.13 80 600 OTPD63ED 36
OT30, OT60, OT100 0.20 100 600 OTPD125ED 50
OT16, OT25, OT32 0.07 40 600 OTPE32ED 20

Ground terminal 2 OT45, OT63 0.13 80 600 OTPE63ED 36
OT30, OT60, OT100 0.20 100 600 OTPE125ED 50
1 UL File # E83510
2 Switch accepts one power pole or one terminal pole per side. Only one power pole per switch.
17.18 Discount schedule H6: Handles, shafts and accessories Low Voltage Products & Systems
AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com
ct
17 n ne s 125A
o e
sc h le
Di witc usib
s n-f
No

1 switch
1 handle
1 shaft
OT160E3 OXP6X210 OHB65J6
125 Amp Base & DIN rail mounted switches1, 600V

UL IEC Maximum horsepower rating
general AC21 Terminal lugs
purpose amp Three phase Catalog List
amp rating rating 200V 208V 240V 480V 600V Wire size Wire type number price
2 pole 2 pole
125 160 — — — — — #8 – 1/0 Cu OT160E2 $ 380
3 pole 3 pole
125 160 30 30 40 75 100 #8 – 1/0 Cu OT160E3 420
125 Amp Door mounted switch1, 600V, 3 pole

UL IEC Maximum horsepower rating
general AC21 Terminal lugs
purpose amp Three phase Catalog List
amp rating rating 200V 208V 240V 480V 600V Wire size Wire type number price
125 160 30 30 30 75 100 #8 – 1/0 Cu OT160ET3 $ 548
OT160ET3
Pistol handles — for use with .24 x .24" ( 6 x 6 mm)
UL/NEMA IEC Color Length Marking Defeat- Padlock- Weight Catalog List
type type in/mm able able (lbs) number price
1, 3R, 12 IP65 Black 2.6/65 O/I & Off/On Yes Yes 0.29 OHB65J6 $ 80
1, 3R, 12 IP65 Red/Yel 2.6/65 O/I & Off/On Yes Yes 0.29 OHY65J6 80
1, 3R, 12 IP65 Black 3.1/80 O/I & Off/On Yes Yes 0.30 OHB80J6 90
1, 3R, 12 IP65 Red/Yel 3.1/80 O/I & Off/On Yes Yes 0.30 OHY80J6 90
1, 3R, 4, 4X, 12 IP66 Black 3.1/80 O/I & Off/On Yes Yes 0.30 OHB80L6 130
1, 3R, 4, 4X, 12 IP66 Red/Yel 3.1/80 O/I & Off/On Yes Yes 0.30 OHY80L6 130
OHB__J6
Shafts — for use with pistol handles .24 x .24" ( 6 x 6 mm)

Shaft length Mounting depth 2 Weight Catalog List
inches/mm in inches (lbs) number price
5.2/130 4.3 – 6.0 0.08 OXP6X130 $ 12
5.9/150 5.0 – 6.7 0.09 OXP6X150 12
8.3/210 7.4 – 9.1 0.13 OXP6X210 16
11.4/290 10.5 – 12.2 0.18 OXP6X290 20
17 OHY__J6 14.2/360 13.3 – 15.0 0.23 OXP6X360 24
16.9/430 16.0 – 17.8 0.27 OXP6X430 28
Twisted shafts — Rotates handle 45° .24 x .24" ( 6 x 6 mm)

Shaft length Mounting depth 2 Weight Catalog List
inches/mm in inches (lbs) number price
5.2/130 4.3 – 6.0 0.08 OXP6X130-45 $ 12
8.3/210 7.4 – 9.1 0.13 OXP6X210-45 16
11.4/290 10.5 – 12.2 0.18 OXP6X290-45 20
OXP6X__ 14.2/360 13.3 – 15.0 0.23 OXP6X360-45 24
OXP6X__/45
1 A snap on fourth pole may be added – please reference accessories page 17.21.
2 Mounting depth is the distance from the outside of the door to the disconnect switch mounting plate. Shaft can be cut to desired length.
17.20 Discount schedule H2: NF, 125A – 800A Low Voltage Products & Systems
Di
s
125A
Accessories
Auxiliary contacts, top mounted

17sw con
No itc ne
n- he ct
fus s
ibl
e
• Accepts four contacts maximum, mounting base always required

Description For use with: (lbs) amp rating voltage number price
1 N.O. OEZNP1 0.07 10 600 OBEA-10 $ 28
1 N.C. OT160 10 600 OBEA-01 28
1 N.O. gold plated1 OEZNP1 0.07 10 600 OBEA-10AU 56
1 N.C. gold plated1 OT160 10 600 OBEA-01AU 56
OBEA-10 OBEA-01 Mounting base – required for OBEA_ OBEA__ 0.06 — — OEZNP1 20
Auxiliary contacts, side mounted

• Accepts four contacts maximum
1 N.O. & 1 N.C. OT160 0.07 10 600 OA2G11 $ 40
Mounting base – required for OA2G11 OT160 0.06 — — OAZX1 20
Max. two contacts on each side of switch. One mounting base required for each side of switch
Numbering stickers 2
OEZNP1
Catalog List
Description For use on: Package qty. number price
1 Pkg. of blank labels for
OT160 10 OBEA-ZX10 $ 32
OBEA-10, 1 N.O.
1 Pkg. of blank labels for
OT160 10 OBEA-ZX01 32
OBEA-01, 1 N.C.
Power pole — for use with base or door mounted switch

OAZX1 OA2G11 Fourth pole OT160 0.66 125 600 OTPS160EP $ 100
Terminal poles — for use with base or door mounted switch

Detachable neutral
mounts on side of OT160 0.66 125 600 OTPN160EP $ 100
switch or DIN rail
Ground terminal OT160 0.66 125 600 OTPE160EP 100
Locking accessories
OTP_160EP Weight Catalog List
(lbs) number price 17
Cam attachment for Kirk Key, Castell,
Lowe & Fletcher and Ronis interlock. 5, 6 & 8mm
For adapting to the interlock system shafts 0.29 OETL-ZW16 $ 190
The interlock is not included.
Handle support bracket

Weight Catalog List
(lbs) number price
Allows pistol handle to be
directly mounted to switch OT160 0.33 OHZX5 $ 24
behind the door
Shaft extension couplers

OETL-ZW16 Description For use on: Weight Catalog List
(lbs) number price
Joins two shafts together
for applications where for 6mm shafts 0.26 OESA-ZX167 $ 56
extended length is required for 12mm shafts 0.26 OETL-ZX95 100
1 Type _AU for low energy applications. The contacts are gold-plated. AC & DC ratings — Maximum: A600 & P600. Minimum: 12V, 1mA;
OETL-ZX167
5V, 2mA
OETL-ZX95
2 Required if several contact blocks are used in the same installation.
Low Voltage Products & Systems Discount schedule H6: Handles, shafts and accessories 17.21
Surge Arresters
UltraSIL™ Housed VariGAP® Surge Arresters: Electrical Apparatus
Normal Duty (5 kA), Heavy Duty (10 kA), and
Heavy Duty Riser Pole (10 kA) 235-37
GENERAL
Cooper Power Systems has set the
standard for design, manufacturing
and delivery of polymeric distribution
arresters with the UltraSIL housed
arrester family. The UltraSIL housed
surge arrester incorporates the industry
recognized superior polymer housing
material – silicone rubber.
Available in Normal Duty, Heavy Duty
and Heavy Duty Riser Pole designa-
tions, UltraSIL housed VariGAP
distribution class surge arresters
provide superior overvoltage protection
for any electric distribution system.
CONSTRUCTION
The VariGAP design is a combination
of both metal oxide and gapped
arrester technologies. Construction
consists of Metal Oxide Varistors
(MOVs) in series with a non-linear
gap structure. The mating of these two
service proven technologies results in
the gap structure and MOVs sharing
the system voltage during steady state
conditions. This sharing minimizes
voltage stress on each component.
This results in a significant improvement
in protective characteristics and 60 Hz
temporary overvoltage (TOV) Figure 1.
withstand. 10 kV UltraSIL housed VariGAP distribution class surge arrester.
The patented construction of VariGAP
UltraSIL housed arresters starts with
MOVs manufactured at our Olean, The UltraSIL housing is then surface tracking, performance in
NY facility. Manufacturing our own interference fit and bonded onto the contaminated environments, chemical
MOVs allows for strict quality control cured internal module to form a solid, inertness, temperature stability and
over all aspects of disk production. high-dielectric strength, insulation other important insulating properties.
Every MOV is subjected to a series of system. UltraSIL silicone rubber will not support
physical and electrical tests designed biological growth (algae and mildew),
Following assembly, each arrester is
to ensure that only disks meeting is non-flammable and will not support
subjected to a battery of electrical
strict quality standards are used in combustion.
tests to assure the highest quality and
UltraSIL arresters. The Cooper Power in-service field performance. An optional insulated mounting hanger
Systems MOV disk design has proven is available to allow connecting to a
its reliability and protective ability FEATURES wide variety of brackets. The insulated
through many years of field service. hanger, made of glass filled polyester,
The UltraSIL silicone rubber housing
The MOVs are placed in series with has undergone a wide range of design has been designed to provide needed
a gap assembly and aluminum end tests to determine the optimum shed mechanical strength for installation
electrodes to form a complete configuration. In addition, long term and severe loading conditions.
assembly. This assembly is coated with environmental testing has verified the A ground lead isolator is also
a fiberglass-reinforced epoxy collar lifetime superiority of silicone rubber available. The isolator removes the
using an automated fluidized bed when compared to other polymeric ground terminal from the arrester in
process. The collar is cured to form a insulating materials. the unlikely event of arrester failure,
solid, mechanically strong module thus preventing a permanent system
capable of withstanding extreme Independent laboratory tests have
verified the superiority of silicone rub- fault. An isolator that has operated
electrical, environmental, and gives visual indication of internal
cantilever loading conditions. ber in terms of non-wetting surfaces,
resistance to UV degradation and damage to the arrester and the need
for arrester replacement.
January 2000 • Supersedes 2/97 1

Printed in U.S.A.
UltraSIL™ Housed VariGAP® Surge Arresters
300 SERIES (CORROSION PROOF) PERMANENT STAMPED-IN

DESIGN TESTING
STAINLESS STEEL
LINE TERMINAL
NAMEPLATE INFORMATION The housing material, internals and
Standard connectors hardware work together as a system
STAINLESS STEEL
accommodate #6 solid TOP CAP
and must stand up to years of expo-
through 2/0 stranded sure to environmental extremes. To
leads. assure a superior level of performance,
both the components and assembled
ALUMINUM arrester units have been subjected to
ELECTRODE a program of testing that accurately
simulates years of exposure to actual
field conditions. Testing includes:
UltraSIL SILICONE ■ ANSI/IEEE C62.11 Testing – Full
RUBBER HOUSING
certification to performance
GAP ASSEMBLY requirements by an independent
Provides consistent low sparkover laboratory. A certified test report is
characteristics even for rapidly available under Bulletin Number
rising surge waves. 95061.
Additional design verification testing
METAL OXIDE VARISTOR of the UltraSIL housed distribution
BONDED SOLID
arrester includes:
INTERFACE ■ UV testing
■ Full dielectric testing
METAL OXIDE VARISTOR
■ Wet Arc Tracking Resistance
■ Thermal Shock test
GLASS REINFORCED ■ Multi-Stress Environmental test
EPOXY COLLAR
cycling
■ Tracking Wheel test
ALUMINUM ELECTRODE
■ Coefficients of expansion for
OPTIONAL materials compatibility
INSULATED ■ Cantilever test
HANGER ■ Terminal and Isolator Torque test
■ Hanger Mechanical Shock test
This is only a partial listing of design

tests performed on the UltraSIL
distribution arrester. For detailed test
reports and results please contact
your Cooper Power Systems sales
OPTIONAL representative.
kV RATING
ISOLATOR
GROUND LEAD 300 SERIES (Visible from ground) PRODUCTION TESTS
DISCONNECTOR STAINLESS STEEL A complete production test program
GROUND TERMINAL
Standard connectors accommodate
ensures a quality product. Each metal
#6 solid through 2/0 stranded leads. oxide varistor receives a series of
electrical tests. Quality is demonstrat-
Figure 2. ed by a series of destructive tests
Cutaway illustration of UltraSIL housed VariGAP distribution arrester. performed on every batch of varistors.
Listed are the production tests
performed on the varistors:
An optional universal wildlife protector by both the gap structure and MOVs. ■ 100% Physical Inspection
has two self-adjusting "valve" style When surges occur, the gaps spark ■ 100% Discharge Voltage test
openings which vary from 0 to 0.75" over, leaving only the MOVs in the ■ 100% V1mA/cm2
in diameter, thus allowing for a large circuit. The result is much lower dis- ■ 100% Leakage Current at 80% of
variety of conductor/insulation sizes charge voltages than are possible with
while providing optimum wildlife pro- gapless metal oxide arresters. The V1mA/cm2 Voltage
■ Batch High-current, Short-duration
tection. (See page 10, Figure 8 for a added gap assembly also increases
dimensional diagram.) the arrestor TOV withstand ability to test
■ Batch Thermal Stability test
levels up to 50% higher than compa- ■ Batch Aging test
OPERATION rable gapless MOV designs.
The operation of VariGAP arresters The superior protective characteristics
differs from conventional gapless of the VariGAP arresters provide
metal oxide arresters. During steady excellent protection for distribution
state conditions, line voltage is shared equipment with lower impulse with-
stand capabilities.
2
235-37
Each fully assembled VariGAP TABLE 1

arrester must pass the following Commonly Applied Voltage Ratings of VariGAP Arresters
production tests:
System Voltage Recommended Arrester Rating per IEEE C62.22
■ 100% Physical Inspection (kV rms) (kV rms)
■ 100% Leakage Current test
■ 100% Partial Discharge Inception Four-Wire Wye Three-Wire Wye Delta and
Multi-Grounded Solidly Grounded Ungrounded
Voltage test Nominal Maximum Neutral Neutral Wye
■ 100% 60 Hz Sparkover Level test
2.4 2.54 — — 3
GENERAL APPLICATION 4.16Y/2.4 4.4Y/2.54 3 6 6
RECOMMENDATIONS 4.16 4.4 — — 6
4.8 5.08 — — 6
The rating of an arrester is the maxi-
6.9 7.26 — — 9
mum power frequency line-to-ground
voltage at which the arrester is 8.32Y/4.8 8.8Y/5.08 6 9 —
designed to pass an operating 12.0Y/6.93 12.7Y/7.33 9 12 —
duty-cycle test. Table 1 provides a 12.47Y/7.2 13.2Y/7.62 9 15 —
general application guide for the 13.2Y/7.62 13.97Y/8.07 10 15 —
selection of the proper arrester rating 13.8Y/7.97 14.52Y/8.38 10 15 ––
for a given system voltage and system 13.8 14.52 — — 18
grounding configuration as outlined in 20.78Y/12.0 22Y/12.7 15 21 —
the IEEE C62.22 application guide. 22.86Y/13.2 24.2Y/13.87 18 24 —
Under fault conditions and other system 23 24.34 — — 30
anamolies, higher voltages can be 24.94Y/14.4 26.4Y/15.24 18 27 —
experienced by the arrester. To 27.6Y/15.93 29.3Y/16.89 21 30 —
ensure that the arrester ratings will not 34.5Y/19.92 36.5Y/21.08 27 36 —
be exceeded, Cooper Power Systems 46Y/26.6 48.3Y/28 36 — —
application engineers are available to
make recommendations. The following
information is normally required: Heavy Duty: 20 current surges of FAULT CURRENT
10 kA crest, 8/20 µs waveshape WITHSTAND TESTS
1. System maximum operating followed by 2 current surges of
voltage. 40 kA crest, 8/20 µs waveshape. Fault current withstand tests demon-
strate the ability to withstand fault
2. System grounding conditions. currents for specific durations without
■ High-Current, Short-Duration
A. For four-wire circuits, ground- Discharge: expelling any internal components.
ing conditions depend upon Normal Duty: 2 current surges of All UltraSIL housed distribution
whether the system is multi- 65 kA crest, 4/10 µs waveshape. arrester designs have been tested in
grounded, whether it has a Heavy Duty: 2 current surges of accordance with the requirements
neutral impedance and 100 kA crest, 4/10 µs waveshape. listed in ANSI/IEEE C62.11, and are
whether common primary non-fragmenting to the levels shown
and secondary neutrals are ■
in Table 2.
Low-Current, Long-Duration
used. Discharge:
B. For three-wire circuits, Normal Duty: 20 current surges of TABLE 2
grounding conditions depend 75 A crest 2000 µs duration Fault Current Withstand Tests
upon whether the system is rectangular wave.
solidly grounded at the Heavy Duty: 20 current surges of Fault Current Fault Current
Amplitude Duration
source, grounded through 250 A crest 2000 µs duration (kA rms) (cycles)
neutral impedance at the rectangular wave.
source transformers or 0.5 120
ungrounded. Following each of these tests, the 2.5 60
arresters remain thermally stable as 5.0 30
Consult your Cooper representative 10.0 10
to have your individual system verified by:
■ Continually decreasing power 20.0 10
application needs studied.
values during a thirty minute power
PERFORMANCE TEST monitoring period.
CHARACTERISTICS ■ No evidence of physical or
electrical deterioration.
UltraSIL housed VariGAP distribution ■ The 5 kA (normal duty) or 10 kA
class arresters withstand the (heavy duty) discharge voltages
following design tests as described by measured after each test changed
ANSI/IEEE C62.11: less then 10% from the initial values.
■ Duty Cycle:
Normal Duty: 22 current surges of In addition, full ANSI/IEEE C62.11
5 kA crest, 8/20 µs waveshape. certification has been completed and
verified.
3
DIMENSIONS AND
CLEARANCES
Outline drawings for several common
design options are shown in Figures
3-6. Dimensions for these designs
are listed in Table 3.
DIAMETER:
HEAVY DUTY = 3.70"
NORMAL DUTY = 3.40"
A
MOUNTING 1.25"
HOLE FOR B
1/2" HARDWARE
0.56"
D
1.25"
B FOR MORE DETAILS

ON BRACKET, SEE
FIGURES 11 & 13,
Figure 3. PAGE 11.
UltraSIL housed arrester with isolator and insulated
hanger.
Figure 5.
UltraSIL housed arrester with isolator, insulated hanger and
transformer mounting bracket.
0"-4"
4.12"-5.15"
C
A 2.56"
MOUNTING
HOLE FOR
1/2" HARDWARE
1.7"
1.25" 0.56"
B
Figure 4. Figure 6.
UltraSIL housed arrester with isolator, insulated hanger and UltraSIL housed arrester with insulated hanger without
NEMA cross-arm bracket. isolator.
4
235-37
TABLE 3
Dimensional Data – UltraSIL Housed VariGAP Arresters
Dimensions Minimum Recommended Clearances* (in.)
Standard Figures 3-5, page 4
Arrester Housing (Inches) Heavy Duty Normal Duty
Rating Code Phase-to- Phase-to- Phase-to- Phase-to-
A+ B C+ D
(kV rms) (Digits 6 & 7) Ground Phase Ground Phase
3 04 7.4 4.1 6.5 8.7 3.00 4.25 2.75 3.75

6 05 8.5 4.1 7.6 8.7 4.00 5.50 3.75 5.00
9 05 8.5 4.1 7.6 8.7 5.25 7.00 5.00 6.50
10 05 8.5 4.1 7.6 8.7 5.25 7.00 5.00 6.50
12 07 10.6 5.0 9.7 8.7 6.00 7.75 5.75 7.25
15 07 10.6 5.0 9.7 8.7 6.75 8.75 6.50 8.25
18 08 11.7 5.0 10.8 8.7 9.25 11.25 9.00 10.75
21 09 12.7 5.0 11.8 8.7 9.25 11.25 9.00 10.75
24 10 13.8 5.0 12.9 8.7 10.75 13.25 10.50 12.75
27 11 14.8 5.0 13.9 14.3 10.75 13.25 10.50 12.75
30 12 15.9 5.0 15.0 14.3 10.75 13.25 10.50 12.75
33 13 17.0 5.0 16.1 14.3 12.75 16.25 12.50 15.75
36 14 18.0 5.0 17.1 14.3 12.75 16.25 12.50 15.75
* All clearances are measured from centerline of arrester per IEEE C62.22.
+ With optional Wildlife Protector add 0.2 inches.
INSULATION
CHARACTERISTICS
The insulation characteristics of the
UltraSIL housed arrester family are
shown in Table 4.
TABLE 4
Housing Insulation Withstand Voltages of UltraSIL Housed VariGAP Arresters
Arrester
Mounting
Configuration
4.1" 5.0" 4.1" 5.0"
Arrester
Housing Creep Strike 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec.
Code Distance (in.) Impulse Dry Wet Impulse Dry Wet Impulse Dry Wet Impulse Dry Wet Impulse Dry Wet
(Digits 6 & 7) (in.) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms)
04 10.1 4.2 91 56 36 105 55 39 79 52 34 99 56 39 82 51 33

05 13.0 5.2 104 64 45 117 63 52 89 55 44 109 60 52 90 62 46
06 15.9 6.3 117 78 57 126 86 59 93 61 58 119 80 59 97 72 56
07 18.8 7.3 129 87 68 137 96 71 98 62 59 122 81 63 107 81 69
08 21.7 8.4 140 96 79 148 106 83 104 65 61 126 82 67 118 89 81
09 24.6 9.4 152 105 89 159 116 94 110 68 63 130 83 72 129 98 93
10 27.5 10.5 164 114 100 171 126 105 117 72 67 136 86 78 140 106 105
11 30.4 11.5 176 123 110 183 135 116 125 77 71 142 90 83 152 114 116
12 33.3 12.6 189 131 120 195 144 127 133 82 75 149 94 89 164 122 126
13 36.2 13.6 201 139 130 207 153 137 142 88 81 158 99 96 177 130 136
14 39.1 14.7 215 148 140 220 161 147 152 94 87 167 105 102 190 138 145
15 42.0 15.8 228 155 150 233 170 157 162 101 93 177 112 109 204 146 153
16 44.9 16.8 242 183 158 246 178 167 173 109 101 187 120 117 218 154 162
17 47.8 17.8 255 171 169 259 185 176 185 117 109 199 128 125 233 161 169
5
PROTECTIVE provide excellent overvoltage protec- characteristics of the UltraSIL housed

CHARACTERISTICS tion for electrical equipment throughout VariGAP arrester family are shown in
distribution systems. The protective Tables 5, 6 and 7.
VariGAP distribution class arresters
TABLE 5
Protective Characteristics – VariGAP Normal Duty (UNG)
Minimum Front-of-wave Maximum Discharge Voltage (kV crest)
Arrester 60 Hz Protective 8/20 µs Current Wave
Rating MCOV Sparkover Level*
(kV rms) (kV rms) (kV crest/√2) (kV crest) 1.5 kA 3 kA 5 kA 10 kA 20 kA 40 kA
3 2.55 7.00 19.5 8.80 9.50 10.2 11.1 12.7 14.8
6 5.10 14.0 25.0 17.6 19.0 20.4 22.3 25.5 29.6
9 7.65 15.3 31.0 19.2 20.8 22.3 24.4 27.9 32.4
10 8.40 16.8 33.0 20.1 21.7 23.3 25.5 29.1 33.8
12 10.2 20.4 37.0 27.9 30.1 32.3 35.4 40.4 46.9
15 12.7 25.4 43.0 30.5 33.0 35.4 38.7 44.2 51.4
18 15.3 30.6 48.5 37.1 40.2 43.1 47.1 53.8 62.6
21 17.0 34.0 54.5 39.4 42.6 45.8 50.0 57.1 66.4
24 19.5 39.0 60.0 49.3 53.3 57.2 62.5 71.4 83.0
27 22.0 44.0 66.0 55.7 60.3 64.7 70.7 80.7 93.9
30 24.4 48.8 71.5 59.1 63.9 68.6 75.0 85.6 99.6
33 27.0 54.0 77.5 65.0 70.4 75.5 82.5 94.2 110
36 29.0 58.0 83.0 69.0 74.6 80.1 87.8 99.9 116
*Larger of the Front-of-Wave (FOW) or Equivalent Front-of-Wave (EFOW) per ANSI/IEEE C62.11-1999. FOW - This is the value of the sparkover of the gap assembly
based on a wave rising 100 kV per µs per 12 kV of arrester rating. EFOW - Based on 5 kA current impulse that results in a discharge voltage cresting in 0.5 µs.
TABLE 6
Protective Characteristics – VariGAP Heavy Duty (UHG)
3 2.55 7.00 18.5 8.40 8.90 9.30 10.2 11.3 12.7
6 5.10 14.0 24.0 16.8 17.9 18.7 20.4 22.6 25.4
9 7.65 15.3 30.0 18.6 19.7 20.6 22.5 24.9 28.0
10 8.40 16.8 32.0 19.2 20.5 21.4 23.3 25.8 29.1
12 10.2 20.4 36.0 26.7 28.4 29.6 32.3 35.8 40.3
15 12.7 25.4 42.0 29.2 31.1 32.5 35.4 39.2 44.1
18 15.3 30.6 47.5 35.6 37.8 39.5 43.1 47.7 53.7
21 17.0 34.0 53.5 37.8 40.1 41.9 45.8 50.6 57.0
24 19.5 39.0 59.0 47.2 50.2 52.4 57.2 63.2 71.3
27 22.0 44.0 65.0 53.4 56.7 59.3 64.7 71.5 80.6
30 24.4 48.8 70.5 56.6 60.2 62.9 68.6 75.8 85.5
33 27.0 54.0 76.5 62.3 66.2 69.2 75.5 83.5 94.1
36 29.0 58.0 82.0 66.1 70.3 73.4 80.1 88.6 99.8
TABLE 7
Protective Characteristics – VariGAP Heavy Duty Riser Pole (URG)
3 2.55 7.00 17.5 7.60 8.10 8.40 9.20 10.2 11.5
6 5.10 14.0 23.0 15.2 16.1 16.9 18.4 20.4 22.9
9 7.65 15.3 29.0 16.8 17.9 18.7 20.4 22.6 25.4
10 8.40 16.8 31.0 17.5 18.6 19.4 21.2 23.4 26.4
12 10.2 20.4 35.0 24.3 25.8 26.9 29.4 32.5 36.6
15 12.7 25.4 41.0 26.6 28.2 29.5 32.2 35.6 40.1
18 15.3 30.6 46.5 32.4 34.4 35.9 39.2 43.3 48.8
21 17.0 34.0 52.5 34.3 36.5 38.1 41.6 46.0 51.8
24 19.5 39.0 58.0 42.9 45.6 47.7 52.0 57.5 64.8
27 22.0 44.0 64.0 48.5 51.6 53.9 58.8 65.0 73.2
30 24.4 48.8 69.5 51.5 54.7 57.2 62.4 69.0 77.7
33 27.0 54.0 75.5 56.6 60.2 62.9 68.6 75.8 85.5
36 29.0 58.0 81.0 60.1 63.9 66.7 72.8 80.5 90.7
6
235-37
TEMPORARY
2.1 OVERVOLTAGE (TOV)
CAPABILITY
2.0 2.00 2.00 2.00 The ability to withstand 60 Hz
overvoltage conditions [Temporary
1.9
Overvoltage (TOV)] is shown in
Figure 7 for all VariGAP distribution
arresters. The graph shows for a
Per Unit of MCOV
1.8 given voltage magnitude (on a Per

Unit of MCOV basis) the time an
arrester can survive a TOV condition
1.7 1.72 without going into thermal runaway.
ORDERING INFORMATION
1.6 Cooper Power Systems UltraSIL
housed distribution arresters are
supplied in a variety of customer
1.5 1.50
defined options. The catalog system
employed lets the number define the
features of the arrester. Table 8 shows
1.4 the catalog numbers for several of the
0.01 0.1 1 10 100 1000 10000 most common arrester styles. Table 9
Time Duration in seconds shows what each alpha-numeric
character in the catalog number
Figure 7. represents and lists several of the
Temporary overvoltage curve. No prior duty – 60° C ambient. available options defined by these
characters. A wide variety of options
are available, allowing users to
customize the arrester to their specific
needs. For further options contact
engineer.
TABLE 8
Catalog Numbers – VariGAP Distribution Class Surge Arresters
With Isolator, With Isolator,

Insulated Hanger Insulated Hanger
With Isolator and and NEMA and Transformer With Insulated Hanger
Arrester Insulated Hanger Cross-Arm Bracket Mounting Bracket Without Isolator
Rating (Figure 3) (Figure 4) (Figure 5) (Figure 6)
3 U✱G0304-0A1A-1A1A U✱G0304-0A1A-1B1A U✱G0304-0A1C-1C1C U✱G0304-0A0A-1A1A
27 U✱G2711-0A1A-1A1A U✱G2711-0A1A-1B1A U✱G2711-0A1C-1C1A U✱G2711-0A0A-1A1A
✱ Digit 2 Option: N = Normal Duty, H = Heavy Duty, R = Riser Pole.
Note: All catalog numbers listed above include a universal wildlife protector.
7
TABLE 9
UltraSIL™ Distribution Arrester UltraQUIK™ Catalog Numbering System
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
U G 1
Catalog Number Digits:
1 = “U”, UltraSIL Housed Arrester
2 = Arrester Class: N = Normal Duty H = Heavy Duty R = Riser Pole
3 = Arrester Type: G= VariGAP®
4 & 5 = Arrester Rating: 03 = 3 kV (2.55 kV) 12 = 12 kV (10.2 kV) 21 = 21 kV (17.0 kV) 30 = 30 kV (24.4 kV)
Duty Cycle (MCOV) 06 = 6 kV (5.1 kV) 15 = 15 kV (12.7 kV) 24 = 24 kV (19.5 kV) 33 = 33 kV (27.0 kV)
09 = 9 kV (7.65 kV) 18 = 18 kV (15.3 kV) 27 = 27 kV (22.0 kV) 36 = 36 kV (29.0 kV)
10 = 10 kV (8.4 kV)
6 & 7 = Housing Code: Select from Table below.

AVAILABLE HOUSINGS PER ARRESTER RATING
✽ = Standard Creepage Housing O = Optional Creepage Housings
Digits 6 & 7 04 05 06 07 08 09 10 11 12 13 14 15 16 17
Creep
Length
10.1" 13.0" 15.9" 18.8" 21.7" 24.6" 27.5" 30.4" 33.3" 36.2" 39.1" 42.0" 44.9" 47.8"
Arrester
Rating (kV rms)
3 ✱
6 ✱ O
9 ✱ O O O
10 ✱ O O O
12 ✱ O O O
15 ✱ O O O O
18 ✱ O O O O
21 ✱ O O O O
24 ✱ O O O O
27 ✱ O O O O
30 ✱ O O O O
33 ✱ O O O O
36 ✱ O O O
8 = Line Terminal Wire: 0 = No Line Terminal Wire
1 = 12", #6 AWG Insulated Wire, 4 = 18", #6 AWG Insulated Wire, 7 = 30", #6 AWG Insulated Wire,
Stripped 1.25" both ends Stripped 1.25" both ends Stripped 1.25" both ends
1 ring terminal /1 end stripped 1.25" 1 ring terminal /1 end stripped 1.25" 1 ring terminal /1 end stripped 1.25"
2 ring terminals 2 ring terminals 2 ring terminals
9 = Line Terminal Options
A = Silicon Bronze B = Silicon Bronze C = No Hardware D = Silicon Bronze E = Silicon Bronze K = Silicon Bronze
Nut, Stainless Steel Nut & Stainless Steel Nut, Lock Washer, Nut, Lock Washer, Nut, Stainless Steel
Wire Clamp & Universal Wire Clamp Flat Washer & & Flat Washer Wire Clamp, and
Wildlife Protector Universal Wildlife (For leads with ring Flipper Fuse Kit
Protector (For leads terminals) AM21A1 (See
with ring terminals) Page 10)
8
235-37
10 = Isolator
0 = No Isolator (3/8" Stainless 2 = Red Isolator with 3/8" 4 = Blue Isolator with 3/8" 6 = Orange Isolator with 3/8"
Steel Grounding Stud only) Stainless Steel Grounding Stud Stainless Steel Grounding Stud Stainless Steel Grounding Stud
1 = Black Isolator with 3/8" 3 = Yellow Isolator with 3/8" 5 = White Isolator with 3/8"
Stainless Steel Grounding Stud Stainless Steel Grounding Stud Stainless Steel Grounding Stud
11 = Ground Terminal Options
A = Stainless Steel Wire B = No Hardware C = Copper Transformer D = Stainless Steel

Clamp with Silicon (Shown with optional Grounding Strap with Washer, Lock Washer,
Bronze Nut (Shown with Isolator and Insulated Stainless Steel Lock Silicon Bronze Nut
optional Isolator and Hanger) Washer & Silicon Bronze
Insulated Hanger) Nut (Shown with optional
Isolator and Insulated
Hanger)
12 = Base Configuration Options
0 = Insulated Base 1 = Insulated Hanger 2 = Insulated Base With Conductive

(Base Mounted Arrester) (Shown with optional Isolator) Mounting Strap (Requires "D" in Digit 11)
13 = Mounting Bracket Options
A = Without an Additional B = NEMA Cross-Arm Bracket C = Transformer Bracket D = Option C plus

Mounting Bracket (Arrester Mounting Hardware Included) (Arrester Mounting Hardware Included) Transformer Mounting Hardware
(Requires "1" or "2" in Digit 12) (Requires "1" or "2" in Digit 12) (2 each – 1/2", 13-UNC x 3/4" Bolts,
Flat Washers, and Lock Washers)
(Requires "1" or "2" in Digit 12)
14 = Nameplate Information: 1 = ANSI/IEEE Standard C62.11 Required Data

15 = Packaging: A = Individual Carton (Assembled Terminal Hardware). Each arrester is shipped in an individual high strength cardboard
carton. The top and bottom terminal hardware is assembled to the arrester. Any optional brackets or hardware are
provided unassembled.
C = Bulk Packed (Assembled Terminal Hardware). Pallet sized bulk cardboard packaging for transformer mounting bracket
options (Digits 13 = C or D only). Each arrester is shipped fully assembled including transformer mounting bracket.
Available for 3-24 kV arresters only. Full pallet quantities only: 3-10 kV = 90, 12-18 kV = 72, 21-24 kV = 40.
9
AVAILABLE ACCESSORIES Open Link Flipper Fuse Kit

FOR THE UltraSIL ARRESTER Customers who need an open-link
flipper fuse kit without an arrester,
can order this assembly separately.
VALVE The kit includes the flipper arms (for
OPENING the transformer bushing and arrester
line terminal) and an optional bushing
VALVE
OPENING insulator cap. Table 10 lists the part
0.80" numbers to order the flipper fuse kit.
To order an UltraSIL arrester with
2.22" flipper fuse assembly AM21A1, insert
a “K” in digit 9 of the catalog number.
1.03" 152°
TABLE 10
Flipper Fuse Kit Catalog Numbers
VALVE Description Catalog Number

2.50" OPENING
Flipper Fuse Kit
SIDE VIEW TOP VIEW with Bushing AM21A1
Wildlife Protector
Figure 8.
Universal wildlife protector (catalog number AV346X1C). Flipper Fuse Kit
without Bushing AM21A2
Wildlife Protector
2.38"
1"
0"
TO
1.25" 4.00"
.344"
40°
6.75"
.438"
SQUARE 4.12"
TO
5.15" 11" .56 x 2.25"
4.50" MTG. SLOTS
(2 REQ'D)
.438" SQ. 2.56"
HOLE
7"
2.5"
.500"
1.50"
1.63"
0.5"
1.5"
Figure 9. Figure 10.

NEMA cross-arm bracket (catalog number AM35A1). Optional transformer mounting bracket
(catalog number AM36A1). Can be
specified with an “S” in Digit 13. (All
dimensions in inches.)
10
235-37
1.25" 3.00" 1.50"

.75" .75"
2.38"
.25" 1"
50° 45°
.56"
14.50"
8.70" 2.72"
2.25" 3.38"
5.70"
2.5"
2.12"
2.25"
1.63"
2.50"
2.12"
12.80"
Figure 11.
3.38"
Standard transformer mounting bracket for
3-24 kV arrester (part number AM36A2). Can be
specified with a “C” in Digit 13. (All dimensions
in inches.) 2.72"
1.82"
2.38"
Figure 13.
1" Standard transformer mounting bracket for 27-36 kV arrester
(part number AH46A2). Can be specified with a “C” in Digit 13.
(All dimensions in inches.)
40°
12.25" .56 x 2.25"

MTG. SLOTS
(2 REQ'D)
7"
2.5"
1.63"
0.5"
1.25"
Figure 12.
Optional transformer mounting bracket
(catalog number AM36A3), Can be
specified with an “N” in Digit 13. (All
11
©2000 Cooper Industries, Inc. P.O. Box 1640
UltraSIL™ is a trademark of Cooper Industries, Inc. Waukesha, WI 53187
VariSTAR® is a registered trademark of Cooper Industries, Inc. www.cooperpower.com
MI
Printed on Recycled Paper 1/00
AMP-TRAP 2000®
ATQR TIME DELAY / CLASS CC

TAKE CONTROL OF FAULT CURRENTS HEADED
FOR YOUR CONTROL TRANSFORMER
ATQR small-dimension fuses feature time delay
characteristics ideally suited for the high inrush
currents of control transformers, solenoids, and
similar inductive loads. The newest member of our
Amp-trap 2000® family of fuses - ATQR fuses provide
superior protection for the branch circuits of elec-
trical distribution systems.
Features/Benefits
➤ Time delay for control transformer inrush loads without

nuisance opening
➤ Highly current limiting for low peak let-thru current
➤ Rejection-style design prevents replacement errors
(when used with recommended fuse blocks)
➤ High-visibility orange label ensures instant recognition,
and simplifies replacement
➤ Metal-embossed date and catalog number
for traceability and lasting identification
➤ Fiberglass body provides dimensional stability in harsh
industrial settings
➤ High-grade silica filler ensures fast arc quenching and
high current limitation
HIGHLIGHTS: APPLICATIONS: Ratings Approvals
➤ Time Delay ➤ Control Transformers ➤ A C : 1/10 to 30A ➤ UL Listed to

600VAC, 200kA I.R. Standard 248-4
➤ Best Choice for Small ➤ Solenoids
➤ CSA Certified to
Transformer Protection ➤ Inductive Loads Standard C22.2
➤ Most Current-Limiting No. 248.4
➤ Lighting, Heating &
General-purpose Loads
A 16
AMP-TRAP 2000®
TIME DELAY / CLASS CC FUSES ATQR

Standard Fuse Ampere Ratings, Catalog Numbers
AMPERE CATALOG AMPERE CATALOG AMPERE CATALOG AMPERE CATALOG
RATING
1/10
NUMBER
ATQR1/10
RATING
8/10
NUMBER
ATQR8/10
RATING
2-8/10
NUMBER
ATQR2-8/10
RATING
7-1/2
NUMBER
ATQR7-1/2 A
1/8 ATQR1/8 1 ATQR1 3 ATQR3 8 ATQR8
15/100 ATQR15/100 1-1/8 ATQR1-1/8 3-2/10 ATQR3-2/10 9 ATQR9
2/10 ATQR2/10 1-4/10 ATQR1-4/10 4 ATQR4 12 ATQR12
3/10 ATQR3/10 1-6/10 ATQR1-6/10 5 ATQR5 17-1/2 ATQR17-1/2
1/2 ATQR1/2 2 ATQR2 6 ATQR6 25 ATQR25
3/4 ATQR3/4 2-1/2 ATQR2-1/2 7 ATQR7
Recommended ATQR Class CC Primary Fuses For Dimensions

Single Phase Control Transformers
TRANS PRIMARY ATQR TRANS PRIMARY ATQR
VA VOLTS FLA AMPS VA VOLTS FLA AMPS
600 0.04 1/10 600 0.50 1-1/8
480 0.05 1/10 480 0.63 1-1/2
25 240 0.10 2/10 300 240 1.25 2-1/2
208 0.12 1/4 208 1.44 3
120 0.21 4/10 120 2.5 5*
600 0.08 1/4 600 0.83 1-1/2
480 0.10 1/4 480 1.04 2
50 240 0.21 4/10 500 240 2.08 4*
208 0.24 1/2 208 2.40 6*
120 0.42 6/10 120 4.17 10*
600 0.13 1/4 600 1.25 2-1/2 Recommended Fuse Blocks for Class CC Fuses
480 0.16 3/10 480 1.56 3
75 240 0.31 1/2 750 240 3.13 7*
208 0.36 3/4 208 3.61 8* Number ULTRASAFE™ Screw Pressure Plate Copper
120 0.63 1 120 6.25 15* of Indicating with Double with Double Box
600 0.17 3/10 600 1.67 3 Poles Fuse Quick Quick Connector
480 0.21 4/10 480 2.08 4* Holder Connects Connects
100 240 0.42 6/10 1000 240 4.16 10*
208 0.48 1 208 4.81 12* ADDER 30310R 30320R 30350R
120 0.83 1-1/2 120 8.33 20* 1 USCC1I 30311R 30321R 30351R
600 0.25 1/2 600 2.50 5*
480 0.31 1/2 480 3.13 7* 2 USCC2I 30312R 30322R 30352R
150 240 0.63 1 1500 240 6.25 10 3 USCC3I 30313R 30323R 30353R
208 0.72 1-1/2 208 7.21 20*
120 1.25 2-1/2 120 12.5 25*
600 0.33 1/2 600 3.33 8*
480 0.42 6/10 2000 480 4.17 10* Primary fuses - If primary FLA is less than 2 amps, fuse may be 300%
200 240 0.83 1-1/2 240 8.33 20++* max. (500% for motor control). If primary FLA exceeds 2 amps but is
208 0.96 2 208 9.62 20++* less than 9 amps, fuse may not exceed 167% of primary FLA unless
120 1.67 3 600 5.00 12+* secondary protection is used, when it may be increased to 250%. Fuse
600 0.42 6/10 3000 480 6.25 15+* sizes shown are based on approx. 40 x FLA for .01 sec.
480 0.52 1-1/8 240 12.5 30++*
250 240 1.04 2 5000 600 8.33 20++* * Secondary protection is required for these ratings.
208 1.2 3 480 10.4 25+* + Fuse will withstand 30 x FLA for .01 second
120 2.08 4* ++ Fuse will withstand 25 x FLA for .01 second
A 17
AMP-TRAP 2000®
TIME DELAY / CLASS CC FUSES ATQR

ATQR1/8 to 30
Melting Time – Current Data, 600V Fuses
Current in Amperes
Time in Seconds
Peak Let-Thru Current Data – ATQR1/8 to 30, 600 Volts AC

Max. Instantaneous Peak Let-Thru Current
Available Current in RMS Sym. Amperes
A 18
Motorlüfterrad einflutig
Motorized impeller single inlet RH71M
Benennung Typ Artikel-Nr.

Product designation type article no.
Motorlüfterrad / Motorized impeller
mit seitlichem Anschlußkabel / RH71M-6DK.7M.1R 109 362

with cable side
mit Klemmenkasten / RH71M-6DK.7M.1R 121 882

with terminal box
RH71M-6DK.7M.1R 600
U I P1 n LWA
1 -1
V A W min dB
3~ 400 V ± 10% 50 Hz IP54 1 400 3,0 1250 940
Motor/Rad 165-90-6/250 500 2 400 4,0 2000 890 79
4
P1 2,0 kW 3 400 3,4 1600 920 85
I 4,0 A 400 4 230 2,9 960 830
7
n 890 min-1 5 230 4,1 1350 720 74
∆p fa in Pa
2
IA 16,5 A 6 230 3,6 1150 770 81
300 10 7 180 3,0 770 730
tR 40 °C 5 8 180 4,0 1000 600 70
200 9 180 3,6 900 670 78
Anschlußschaltbild 106XA 8
Connection diagram 10 140 2,9 570 620
11 11 140 3,7 670 480 66
100
55 kg 12 140 3,3 640 540 44
13 13 90 2,8 320 330
12 9 6 3
0
Vmax 16000 m3/h 0 5000 10000 15000 20000
pd2 1,55 · 10
-7
· V2 V in m /h 3
RH71M100 RH71M6DK7M1RV009
230 V1.0 Lufttechnik 2000 / Ventilation Technology 2000


mit seitlichem Anschlußkabel / RH71M-SDK.7M.1R 121 429

with cable side
mit Klemmenkasten / RH71M-SDK.7M.1R 107 701

with terminal box
RH71M-SDK.7M.1R 600
U I P1 n LWA
1 -1
V A W min dB
3~ 400 V ± 10% ∆/Y 50 Hz IP54 1 400 3,0 1250 940
500
Motor 165-90-6-6/250 2 ∆ 4,0 2000 890 79
P1 4
2,0/1,35 kW 3 3,4 1600 920 85
I 4,0/2,4 A 400 4 400 1,7 960 830
n 890/720 min-1 2 5 Y 2,4 1350 720 74
∆p fa in Pa
IA 16/5,3 A 6 2,1 1150 770 81

300
5
tR 40 °C
200
Anschlußschaltbild 108XA
Connection diagram
100
55 kg
6 3
0
Vmax 16000
3
m /h 0 5000 10000 15000 20000
pd2 1,55 · 10
-7
· V2 V in m3/h
RH71M101 RH71MSDK7M1RV009
V1.0 Lufttechnik 2000 / Ventilation Technology 2000 231


mit seitlichem Anschlußkabel / RH71M-8DK.6K.1R 121 392

with cable side
mit Klemmenkasten / RH71M-8DK.6K.1R 121 884

with terminal box
RH71M-8DK.6K.1R 350
U I P1 n LWA
-1
1 V A W min dB
3~ 400 V ± 10% 50 Hz IP54 1 400 1,45 590 700
300
Motor/Rad 137-76-8/250 2 400 1,9 960 650 71
P1 0,96 kW 3 400 1,6 740 680 77
250
I 1,9 A 4 2 4 230 1,45 440 580
n 650 min-1 5 230 1,95 580 440 63
∆p fa in Pa
200
IA 14 A 6 230 1,75 530 520 71
7 180 1,45 350 460
150 7
tR 40 °C 8 180 1,75 380 320 55
9 180 1,65 370 390 67
Anschlußschaltbild 106XA 100 5
Connection diagram 10
10 140 1,35 230 330
11 140 1,45 240 230 51
8
50 12 140 1,4 230 280 61
31 kg 11
13 12
9 6 3 13 90 0,97 98 150
0
Vmax 11900 m3/h 0 2000 4000 6000 8000 10000 12000
pd2 1,55 · 10-7 · V2 V in m3/h
RH71M102 RH71M8DK6K1RV801


mit seitlichem Anschlußkabel / RH71M-ADK.6K.1R 121 393

with cable side
mit Klemmenkasten / RH71M-ADK.6K.1R 107 703

with terminal box
RH71M-ADK.6K.1R 350
U I P1 n LWA
-1
1
V A W min dB
3~ 400 V ± 10% ∆/Y 50 Hz IP54 1 400 1,45 590 700
300
Motor/Rad 137-76-8-8/250 2 ∆ 1,9 960 650 71
P1 0,96/0,58 kW 3 1,6 740 680 77
250
I 1,9/1,15 A 4 400 0,84 440 580
2
n 650/440 min-1 4 5 Y 1,15 580 440 63
∆p fa in Pa
200
IA 14/4,7 A 6 1,0 530 520 71
150
tR 40 °C
Anschlußschaltbild 108XA 100 5

Connection diagram
50
31 kg 6 3
0
Vmax 11900 m3/h 0 2000 4000 6000 8000 10000 12000
pd2 1,55 · 10
-7
· V2 V in m /h
3
RH71M103 RH71MADK6K1RV801

AC Backward Curved
Motorized Impellers
Contact ebm Industries at 860-674-1515 • Fax: 860-674-8536 • E-mail: sales@ebm.com for Technical Assistance
© ebm Industries, Inc. 1995, 1996, 1997, 1999. ebm Industries, Inc. reserves the right to change any specifications or data without notice.
135
ebm's Backward Curved Motorized Impellers save
space and outperform conventional fans and blowers
These backward curved motorized

impellers provide efficient air
movement without compli-
cated, costly scroll housings.
Their space-saving design pro-
vides you with a completely
integrated, dynamically bal-
anced motor and impeller
to assure long-term, effi-
cient, maintenance-free,
trouble-free operation. The
impellers mount easily in any
orientation and are totally speed
controllable. You cannot select a
better product for air performance,
acoustic performance, compact size
and versatile installation ease.
Compact design, efficient operation
136 Contact ebm Industries at 860-674-1515 • Fax: 860-674-8536 • E-mail: sales@ebm.com for Technical Assistance
© ebm Industries, Inc. 1995, 1996, 1997, 1999. ebm Industries, Inc. reserves the right to change any specifications or data without notice.
ebm's Backward Curved Motorized Impellers
provide stable air movement, excellent space
utilization and improved noise characteristics
Backward Curved Motorized Impellers offer engineers the versatility, performance and efficiency required for
most air moving applications. ebm has pioneered the development and commercialization of external rotor
motors in motorized impellers for air moving applications. The excellent heat dissipation, large bearing system
and permanent attachment of the impeller to the motor assure trouble-free performance. ebm's state-of-the-art
quality control procedures assure reliable, long-life operation. Look at these important advantages:
• Reliable, long-life motors are assembled into integrated, • Motor cooled by passing air flow
dynamically balanced air moving products • 100% speed controllable
• Efficient air movement with flexible air flow patterns • Full range of voltages, accessories, options
• Excellent back pressure/static pressure characteristics to satisfy most application requirements:
• Simple enclosure and mounting requirements — 115v, 230v and 3 phase AC motors
• No extra mechanical parts (set screws or hubs) — Leads or wiring harnesses
• Safe operation in any orientation — Brushless DC motors
• Vibration-free, low noise performance — Speed Control
• UL, CSA and VDE agency approvals — Hall Effect monitoring
— IP54 Moisture & Dust protection
© ebm Industries, Inc. 1995, 1996, 1997, 1999. ebm Industries, Inc. reserves the right to change any specifications or data without notice. 137
Better commercial and industrial ducted air movement
ROOM CIRCULATION IN–LINE DUCT BOOSTERS
Impeller Impeller
Intake Exhaust
Intake to filter or plenum
ROOM AIR VENTILATORS & DIFFUSERS

Exhaust
IN–LINE DUCT
BOOSTERS
Fresh air can be supplied alone or can Impeller Intake

be mixed with recirculating ambient air
ROOM RECIRCULATION
IN–LINE DUCT
BOOSTERS
Impeller Intake Exhaust
Intake to filter
Easy installation and mounting
EXTERNAL ROTOR MOTOR

BACKWARD CURVED (Mounting holes, Wiring this surface) BACKWARD CURVED IMPELLER
IMPELLER (Permanently (Aerodynamic design for best
attached to motor rotor) performance with low noise)
AIR OUT – 360° AIR OUT – 360°
0.060" Ref.
INLET RING INCOMING AIR

(eliminates need for costly, (either evacuating
complicated housings) or pressurizing)
138 © ebm Industries, Inc. 1995, 1996, 1997, 1999. ebm Industries, Inc. reserves the right to change any specifications or data without notice.
Perfect for exhaust applications
ROOF EXHAUST WALL EXHAUST WALL EXHAUST
360° Discharge Bottom Discharge 360° Discharge
Impeller Intake Impeller Intake

(exhaust air) (exhaust air)
Impeller Intake
(exhaust air)
Exhaust
Exhaust Air
Exhaust
RANGE HOOD EXHAUST WALL EXHAUST RANGE HOOD ISLAND EXHAUST RANGE HOOD
Excellent for cabinets and enclosures
VERTICAL MOUNT
BOTTOM
BOTTOM TOP
CABINET
CABINET CABINET
(EVACUATING)
(PRESSURIZING) (EVACUATING)
CENTER
CABINET
High efficiency, long-life external rotor motor

Impeller is permanently
attached to motor housing
No adjustments, No maintenance
Excellent heat dissipation Broad Operating Temperature
improves reliability and Range – 22° to + 170° F
extends life (– 30° to + 75° C)
Rotating Rotor Permanent Stator Rugged

Maintenance-free Mechanical
Contact ebm Industries at 860-674-1515Ball• Fax: 860-674-8536 • E-mail:Construction
Bearings sales@ebm.com for Technical Assistance
© ebm Industries, Inc. 1995, 1996, 1997, 1999. ebm Industries, Inc. reserves the right to change any specifications or data without notice. 139
Across the line starters
Open & enclosed
A9 – A110
XL Starters
Description
A9 – A110 Overload relay protection
• Maximum UL/CSA horsepower ratings All starters, size A9 – A110, have Class 10
• NEMA sizes 00, 1, 2, 3 available adjustable overload relay protection as
• Compact space-saving design standard.
• Standard auxiliary contact configurations:
A9 – A40 1 N.O. or 1 N.C.
A50 – A110 1 N.O. & 1 N.C.
• Additional auxiliary contact blocks are
available
• D.C. ratings & D.C. control operation
available
• Fast, snap-on DIN rail mounting
• Double break contact design
• Snap-on front and side mounted
accessories include mechanical latch,
pneumatic timer and 1 & 4 pole auxiliary
contact blocks
• Easy coil change
• Captive terminal screws
• NEMA, UL, CSA, and most other
international standards
• Operates over an extended voltage range
of 85% to 110% of rated control voltage
• Screwdriver guide holes
• Rated for use with NEMA Design E Class
motors
Enclosure types
• NEMA 1 (Indoor metal)
• NEMA 3R (Outdoor metal)
Index
• NEMA 12 (Metal dusttight) Across the line starters
• NEMA 4X (Stainless steel) • Features ............................................ 1.1
• NEMA 4 (Water tight) • Starter selection by HP ........... 1.2 – 1.3
• NEMA 1, 3R, 4, 4X, & 12 (Plastic) • Non-reversing .......................... 1.4 – 1.7
• IP 65 plastic A9 – A16 starters • Reversing ................................ 1.8 – 1.9
• NEMA 7 & 9 • 2 Speed, 1 winding ............. 1.10 – 1.11
Class I, Group D, Div 1 & 2 • 2 Speed, 2 winding ............. 1.12 – 1.13
• Plastic enclosed starters ................. 1.14
AC 1000.2 – 9/99
Class II, Groups E, F, & G, Div 1 & 2

Class III, 4X • Technical data ..................... 1.15 – 1.16
• Approximate dimensions .... 1.17 – 1.23
• General wiring diagrams ................. 1.24
XL STARTERS: Selection: 1.2 – 1.14 Technical data: 1.15 – 1.16 Approximate dimension: 1.17 – 1.28 General wiring diagrams: 1.29 - 1.30
ABB Control Inc. 1.1

Starter selection by motor horsepower & voltage
Maximum UL/CSA ratings
Motor horsepower Complete starter Starter components

Contactors Overload relays
3-phase, 1800 RPM
Catalog List Catalog List Catalog List
200V 230V 460V 575V number price number price number price
– – – 1/4 A9S-84C A9-30-10-84 TA25DU0.4 (0.25 – .4)
– – 1/4,1/3 1/3 A9S-84D A9-30-10-84 TA25DU0.63 (0.4 – .63)
– – – 1/2 A9S-84E A9-30-10-84 TA25DU1.0 (0.63 – 1.0)
– – 1/2 3/4 A9S-84F A9-30-10-84 TA25DU1.4 (1.0 – 1.4)
– – 3/4 – A9S-84G A9-30-10-84 TA25DU1.6 (1.3 – 1.6)
– 1/2 1 1.5 A9S-84H A9-30-10-84 TA25DU2.4 (1.7 – 2.4)
$ 165 $ 78 $ 63
1/2 – 1.5 2 A9S-84J A9-30-10-84 TA25DU3.1 (2.2 – 3.1)
3/4 3/4 2 – A9S-84K A9-30-10-84 TA25DU4.0 (2.8 – 4.0)
– 1 – 3 A9S-84L A9-30-10-84 TA25DU5.0 (3.5 – 5.0)
1 1.5 3 5 A9S-84M A9-30-10-84 TA25DU6.5 (4.5 – 6.5)
2 2 5 – A9S-84N A9-30-10-84 TA25DU8.5 (6.0 – 8.5)
– – – 7.5 A9S-84P A9-30-10-84 TA25DU11 (7.5 – 11)
3 3 7.5 10 A12S-84Q 171 A12-30-10-84 84 TA25DU14 (10 – 14)
5 5 10 15 A16S-84R 200 A16-30-10-84 102 TA25DU19 (13 – 19)
– 7.5 15 20 A26S-84S 294 A26-30-10-84 183 TA25DU25 (18 – 25)
7.5 10 20 25 A26S-84T A26-30-10-84 TA25DU32 (24 – 32)
– – – 30 A30S-84B 365 A30-30-10-84 252 TA42DU32 (22 – 32) 78
10 15 30 40 A40S-84C 423 A40-30-10-84 297 TA42DU42 (29 – 42)
XL Starters
15 – 40 50 A50S-84D 458 A50-30-11-84 330 TA75DU52 (36 – 52)

– 20 – – A50S-84E A50-30-11-84 TA75DU63 (45 – 63)
20 – – – A63S-84F 522 A63-30-11-84 372 TA75DU80 (60 – 80) 102
– – 50 60 A63S-84F A63-30-11-84 TA75DU80 (60 – 80)
25 30 60 75 A75S-84F 563 A75-30-11-84 413 TA75DU80 (60 – 80)
30 – – – A95S-84A 735 A95-30-11-84 450 TA110DU90 (65 – 90) 165
– 40 75 100 A110S-84B 765 A110-30-11-84 480 TA110DU110 (80 – 110)
CAUTION: The above ratings are based on average motor FLA. Actual FLA Coil voltage selection
on the motor nameplate should be used for overload relay setting. All catalog numbers include a 120V coil. To select other coil voltages, substitute
the code from the coil voltage selection chart for the first digit after the dash in
the catalog number.
Coil voltage selection chart D.C. operated starters
Cntr Volts If DC operation is required, consult factory.
Hz
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600
60 A 81 83 84 84 34 75 80 42 86 86 51 53 55
50 A 81 83 84 80 85 86 55
AC 1000.2 – 9/99
1 For motors with RPM greater or less than 1800 RPM, check full load amp rating on motor nameplate to ensure proper overload protection.
1.2 ABB Control Inc.

NEMA sizes & ratings

3-phase, 1800 RPM
NEMA Catalog List Catalog List Catalog List
200V 230V 460V 575V
size number price number price number price
00 – – – 1/4 A9N00S-84C A9N00-30-10-84 TA25DU0.4 (0.25 – .4)
00 – – — 1/3 A9N00S-84D A9N00-30-10-84 TA25DU0.63 (0.4 – .63)
00 – – 1/4 1/2 A9N00S-84E A9N00-30-10-84 TA25DU1.0 (0.63 – 1.0)
00 – 1/4 1/3,1/2 — A9N00S-84F A9N00-30-10-84 TA25DU1.4 (1.0 – 1.4)
00 – 1/3 3/4 3/4 A9N00S-84G A9N00-30-10-84 TA25DU1.6 (1.3 – 1.6)
00 1/3,1/4 1/2 1 1,1.5 A9N00S-84H $ 165 A9N00-30-10-84 $ 78 TA25DU2.4 (1.7 – 2.4)
00 1/2 – 1.5 2 A9N00S-84J A9N00-30-10-84 TA25DU3.1 (2.2 – 3.1)
00 — 3/4,1 2 – A9N00S-84K A9N00-30-10-84 TA25DU4.0 (2.8 – 4.0)
00 3/4 – – – A9N00S-84L A9N00-30-10-84 TA25DU5.0 (3.5 – 5.0)
00 1 1.5 – – A9N00S-84M A9N00-30-10-84 TA25DU6.5 (4.5 – 6.5)
00 1.5 – – – A9N00S-84N A9N00-30-10-84 TA25DU8.5 (6.0 – 8.5) $ 63
0 – – 3 3 A16N0S-84L A16N0-30-10-84 TA25DU5.0 (3.5 – 5.0)
0 – – — 5 A16N0S-84M 200 A16N0-30-10-84 102 TA25DU6.5 (4.5 – 6.5)
0 2 2 5 – A16N0S-84N A16N0-30-10-84 TA25DU8.5 (6.0 – 8.5)
0 3 3 – – A16N0S-84P A16N0-30-10-84 TA25DU11 (7.5 – 11)
1 — – 7.5 7.5 A26N1S-84P A26N1-30-10-84 TA25DU11 (7.5 – 11)
1 — – 10 10 A26N1S-84Q 294 A26N1-30-10-84 183 TA25DU14 (10 – 14)
1 5 5 – – A26N1S-84R A26N1-30-10-84 TA25DU19 (13 – 19)
1 7.5 7.5 – – A26N1S-84S A26N1-30-10-84 TA25DU25 (18 – 25)
XL Starters
2 – – – 15 A50N2S-84R 458 A50N2-30-11-84 330 TA25DU19 (13 – 19)
2 – – 15 20 A50N2S-84A A50N2-30-11-84 TA75DU25 (18 – 25)
2 – 10 20 25 A50N2S-84B 458 A50N2-30-11-84 330 TA75DU32 (22 – 32)
2 10 15 25 — A50N2S-84C A50N2-30-11-84 TA75DU42 (29 – 42)
102
3 – – – 30 A75N3S-84C A75N3-30-11-84 TA75DU42 (29 – 42)
3 15 – 30 40 A75N3S-84D 563 A75N3-30-11-84 413 TA75DU52 (36 – 52)
3 20 20 40 50 A75N3S-84E A75N3-30-11-84 TA75DU63 (45 – 63)
3 25 25,30 50 – A75N3S-84F A75N3-30-11-84 TA75DU80 (60 – 80)
the catalog number.
Coil voltage selection chart
Cntr Volts
D.C. operated starters
Hz
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 If DC operation is required, consult factory.
60 A 81 83 84 84 34 75 80 42 86 86 51 53 55
50 A 81 83 84 80 85 86 55
AC 1000.2 – 9/99

Non-reversing
3 Pole, open & enclosed

Maximum ratings – UL Listed NEMA 1 NEMA 3R
Open type
UL (Indoor metal) ➀ (Outdoor metal)
Maximum motor horsepower ratings
motor
switching
current 208V 240V 480V 575/600V number price number price number price
UL rated
9 2 2 5 7.5 A9S-84★ $ 165 A9S1-84★ $ 255 A9S3-84★ $ 330
11 3 3 7.5 10 A12S-84★ 171 A12S1-84★ 285 A12S3-84★ 360
17 5 5 10 15 A16S-84★ 200 A16S1-84★ 300 A16S3-84★ 383
28 7.5 10 20 25 A26S-84★ 294 A26S1-84★ 405 A26S3-84★ 465
34 10 10 20 30 A30S-84★ 365 A30S1-84★ 473 A30S3-84★ 533
42 10 15 30 40 A40S-84★ 423 A40S1-84★ 525 A40S3-84★ 578
54 15 20 40 50 A50S-84★ 458 A50S1-84★ 600 A50S3-84★ 719
65 20 25 50 50 A63S-84★ 522 A63S1-84★ 713 A63S3-84★ 795
80 25 30 60 75 A75S-84★ 563 A75S1-84★ 975 A75S3-84★ 1058
95 30 30 60 75 A95S-84★ 735 A95S1-84★ 1140 A95S3-84★ 1485
110 30 40 75 100 A110S-84★ 765 A110S1-84★ 1170 A110S3-84★ 1515
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00S-84★ $ 165 A9NS1-84★ $ 255 A9NS3-84★ $ 330

0 18 3 3 5 5 A16N0S-84★ 200 A16NS1-84★ 300 A16NS3-84★ 383
1 27 7.5 7.5 10 10 A26N1S-84★ 294 A26NS1-84★ 405 A26NS3-84★ 465
2 45 10 15 25 25 A50N2S-84★ 458 A50NS1-84★ 600 A50NS3-84★ 719
3 90 25 30 50 50 A75N3S-84★ 563 A75NS1-84★ 975 A75NS3-84★ 1058
★ Overload relay suffix code. Select from the overload relay selection chart on page 1.14.
Coil voltage selection chart Coil voltage selection

Cntr Volts All catalog numbers include a 120V coil. To select other coil voltages, substitute
Hz
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 the code from the coil voltage selection chart for the first digit after the dash in
60 A 81 83 84 84 34 75 80 42 86 86 51 53 55 the catalog number.
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95-starter: A95S-80A
If DC operation is required, consult factory.
AC 1000.2 – 9/99
➀ A9 - A75 starters are mounted in a NEMA 1 lift-off cover enclosure.

Discount schedule AA - Open ABB Control Inc.

1.4 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
Non-reversing
NEMA 12 NEMA 4 NEMA 4X NEMA 1, 3R, 4, 4X & 12 NEMA 7 & 9 non-reversing

(Metal dustight) (Watertight) (Stainless steel) (Plastic) (Explosion proof)
Catalog List Catalog List Catalog List Catalog List Catalog List
number price number price number price number price number price
UL rated
A9S2-84★ $ 330 A9S4-84★ $ 495 A9SX-84★ $ 645 A9SP-84★ $ 315 A9S7-84★ $ 1500
A12S2-84★ 360 A12S4-84★ 540 A12SX-84★ 713 A12SP-84★ 345 A12S7-84★ 1560
A16S2-84★ 383 A16S4-84★ 570 A16SX-84★ 743 A16SP-84★ 360 A16S7-84★ 1590
A26S2-84★ 465 A26S4-84★ 630 A26SX-84★ 831 A26SP-84★ 443 A26S7-84★ 1680
A30S2-84★ 533 A30S4-84★ 690 A30SX-84★ 885 A30SP-84★ 510 A30S7-84★ 2040
A40S2-84★ 578 A40S4-84★ 1050 A40SX-84★ 1275 A40SP-84★ 555 A40S7-84★ 2410
A50S2-84★ 719 A50S4-84★ 1103 A50SX-84★ 1328 A50SP-84★ 698 A50S7-84★ 2600
A63S2-84★ 795 A63S4-84★ 1170 A63SX-84★ 1410 A63SP-84★ 773 A63S7-84★ 3350
A75S2-84★ 1058 A75S4-84★ 1425 A75SX-84★ 2010 A75SP-84★ 1035 A75S7-84★ 3900
A95S2-84★ 1485 A95S4-84★ 2070 A95SX-84★ 2783 A95SP-84★ 1410 A95S7-84★ 5510
A110S2-84★ 1515 A110S4-84★ 2100 A110SX-84★ 2813 A110SP-84★ 1440 A110S7-84★ 5550
NEMA rated
XL Starters
A9NS2-84★ $ 330 A9NS4-84★ $ 495 A9NSX-84★ $ 645 A9NSP-84★ $ 315 A9NS7-84★ $ 1500
A16NS2-84★ 383 A16NS4-84★ 570 A16NSX-84★ 743 A16NSP-84★ 360 A16NS7-84★ 1590
★ Overload relay suffix code. Select from the overload relay selection chart onpage 1.14.
Control transformer option Control transformer option (NEMA 7 & 9)

Contactor VA List price Contactor VA List price
size rating adder size rating adder
A9 – A40 45 1 $ 300 A9 – A16 50 $ 425

A9 – A40 50 360 A26 – A40 50 630
A50 – A75 75 435 A50 – A75 75 860
A95 – A110 100 560 A95 – A110 100 1035
A9 – A40 are provided with a 45VA transformer as standard. If 50VA is
required, add /50 to the end of the catalog number: Example: A9S2-8N/50
AC 1000.2 – 9/99
➀ No primary fusing provided.

Discount schedule AA - Open

ABB Control Inc. AAE - NEMA 1, 3R, 12, 4, 4X, 12
1.5
AXE - NEMA 7 & 9
Non-reversing, single phase
UL rated
Maximum ratings – UL Listed NEMA 1
Open type
UL (Indoor metal)
motor Maximum motor horsepower ratings
switching
current Catalog List Catalog List
120V 230V number price number price
9 .5 1 A9SS-84★ $ 165 A9SS1-84★ $ 255

11 .75 2 A12SS-84★ 171 A12SS1-84★ 285
17 1 3 A16SS-84★ 200 A16SS1-84★ 300
28 1.5 5 A26SS-84★ 294 A26SS1-84★ 405
34 2 7.5 A30SS-84★ 372 A30SS1-84★ 473
42 3 7.5 A40SS-84★ 423 A40SS1-84★ 525
54 3 7.5 A50SS-84★ 458 A50SS1-84★ 600
65 5 10 A63SS-84★ 522 A63SS1-84★ 713
80 7.5 15 A75SS-84★ 563 A75SS1-84★ 975
95 7.5 20 A95SS-84★ 735 A95SS1-84★ 1140
110 10 25 A110SS-84★ 765 A110SS1-84★ 1170

Hz the code from the coil voltage selection chart for the first digit after the dash in
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600
XL Starters

50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95-starter: A95SS-80A

DC ratings for switching motors
Maximum DC HP ratings (UL)
Frame Max
size current 125VDC 250VDC
A9 9.5 1 2
A12 13.2 1.5 3
A16 17 2 3
A26 25 3 5
A30 25 3 7.5
A40 40 5 10
A50 58 7.5 15
A63 76 10 20
A75 76 10 25
AC 1000.2 – 9/99

1.6 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
UL rated
NEMA 3R NEMA 12 NEMA 4 NEMA 4X NEMA 1, 3R, 4, 4X & 12

(Outdoor metal) (Metal dustight) (Watertight) (Stainless steel) (Plastic)
A9SS3-84★ $ 330 A9SS2-84★ $ 330 A9SS4-84★ $ 495 A9SSX-84★ $ 645 A9SSP-84★ $ 315
A12SS3-84★ 360 A12SS2-84★ 360 A12SS4-84★ 540 A12SSX-84★ 713 A12SSP-84★ 345
Control transformer option

Contactor VA List price
size rating adder
XL Starters
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9SS3-8N/50
AC 1000.2 – 9/99


1.7
AXE - NEMA 7 & 9
Reversing

Open type
(Indoor metal)
UL
motor Catalog List Catalog List
switching 208V 240V 480V 575/600V number price number price
current
UL rated
9 2 2 5 7.5 A9SR-84★ $ 342 A9SR1-84★ $ 510
11 3 3 7.5 10 A12SR-84★ 387 A12SR1-84★ 585
17 5 5 10 15 A16SR-84★ 443 A16SR1-84★ 630
28 7.5 10 20 25 A26SR-84★ 503 A26SR1-84★ 810
34 10 10 20 30 A30SR-84★ 675 A30SR1-84★ 953
42 10 15 30 40 A40SR-84★ 765 A40SR1-84★ 1080
54 15 20 40 50 A50SR-84★ 1152 A50SR1-84★ 1395
65 20 25 50 50 A63SR-84★ 1515 A63SR1-84★ 1560
80 25 30 60 75 A75SR-84★ 1620 A75SR1-84★ 1905
95 30 30 60 75 A95SR-84★ 1697 A95SR1-84★ 2767
110 30 40 75 100 A110SR-84★ 1800 A110SR1-84★ 2970
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00SR-84★ $ 342 A9NSR1-84★ $ 510

0 18 3 3 5 5 A16N0SR-84★ 443 A16NSR1-84★ 630
1 27 7.5 7.5 10 10 A26N1SR-84★ 503 A26NSR1-84★ 810
2 45 10 15 25 25 A50N2SR-84★ 1152 A50NSR1-84★ 1395
3 90 25 30 50 50 A75N3SR-84★ 1620 A75NSR1-84★ 1905

Hz
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95 reversing starter: A95SR-80B

AC 1000.2 – 9/99

1.8 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
Reversing

UL rated
A9SR3-84★ $ 630 A9SR2-84★ $ 630 A9SR4-84★ $ 810 A9SRX-84★ $ 1125 A9SRP-84★ $ 608
A12SR3-84★ 705 A12SR2-84★ 705 A12SR4-84★ 915 A12SRX-84★ 1230 A12SRP-84★ 683
NEMA rated
XL Starters
A9NSR3-84★ $ 630 A9NSR2-84★ $ 630 A9NSR4-84★ $ 810 A9NSRX-84★ $ 1125 A9NSRP-84★ $ 608
A16NSR3-84★ 750 A16NSR2-84★ 750 A16NSR4-84★ 990 A16NSRX-84★ 1313 A16NSRP-84★ 765

size rating adder
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9SR3-8N/50
AC 1000.2 – 9/99


1.9
AXE - NEMA 7 & 9
2 Speed, 1 winding

Open type
(Indoor metal)
UL
motor
switching Catalog List Catalog List
208V 240V 480V 575/600V
current number price number price
UL rated
9 2 2 5 7.5 A9ST-84★1★ $ 504 A9ST1-84★1★ $ 690
11 3 3 7.5 10 A12ST-84★1★ 525 A12ST1-84★1★ 771
17 5 5 10 15 A16ST-84★1★ 581 A16ST1-84★1★ 837
28 7.5 10 20 25 A26ST-84★1★ 752 A26ST1-84★1★ 1097
34 10 10 20 30 A30ST-84★1★ 1038 A30ST1-84★1★ 1316
42 10 15 30 40 A40ST-84★1★ 1259 A40ST1-84★1★ 1577
54 15 20 40 50 A50ST-84★1★ 1697 A50ST1-84★1★ 1940
65 20 25 50 50 A63ST-84★1★ 2150 A63ST1-84★1★ 2195
80 25 30 60 75 A75ST-84★1★ 2307 A75ST1-84★1★ 2592
95 30 30 60 75 A95ST-84★1★ 2495 A95ST1-84★1★ 2950
110 30 40 75 100 A110ST-84★1★ 2681 A110ST1-84★1★ 3851
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00ST-84★1★ $ 504 A9NST1-84★1★ $ 690

0 18 3 3 5 5 A16N0ST-84★1★ 581 A16NST1-84★1★ 837
1 27 7.5 7.5 10 10 A26N1ST-84★1★ 752 A26NST1-84★1★ 1097
2 45 10 15 25 25 A50N2ST-84★1★ 1697 A50NST1-84★1★ 1940
3 90 25 30 50 50 A75N3ST-84★1★ 2307 A75NST1-84★1★ 2589
1st ★ low speed, 2nd ★ high speed

Hz
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95-starter: A95ST-80A1B

AC 1000.2 – 9/99

1.10 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
2 Speed, 1 winding

UL rated
A9ST3-84★1★ $ 810 A9ST2-84★1★ $ 810 A9ST4-84★1★ $ 1020 A9STX-84★1★ $ 1305 A9STP-84★1★ $ 788
A12ST3-84★1★ 891 A12ST2-84★1★ 891 A12ST4-84★1★ 1095 A12STX-84★1★ 1416 A12STP-84★1★ 869
NEMA rated
XL Starters
A9NST3-84★1★ $ 810 A9NST2-84★1★ $ 810 A9NST4-84★1★ $ 1020 A9NSTX-84★1★ $ 1305 A9NSTP-84★1★ $ 788
A16NST3-84★1★ 957 A16NST2-84★1★ 957 A16NST4-84★1★ 1215 A16NSTX-84★1★ 1520 A16NSTP-84★1★ 972

size rating adder
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9ST-8A1A/50
AC 1000.2 – 9/99


1.11
AXE - NEMA 7 & 9
2 Speed, 2 winding

Open type
UL (Indoor metal)
motor
switching
208V 240V 480V 575/600V
number price number price
AC3 UL rated
9 2 2 5 7.5 A9ST-84★2★ $ 396 A9ST1-84★2★ $ 582
11 3 3 7.5 10 A12ST-84★2★ 426 A12ST1-84★2★ 657
17 5 5 10 15 A16ST-84★2★ 476 A16ST1-84★2★ 702
28 7.5 10 20 25 A26ST-84★2★ 552 A26ST1-84★2★ 882
34 10 10 20 30 A30ST-84★2★ 747 A30ST1-84★2★ 1025
42 10 15 30 40 A40ST-84★2★ 834 A40ST1-84★2★ 1152
54 15 20 40 50 A50ST-84★2★ 1224 A50ST1-84★2★ 1467
65 20 25 50 50 A63ST-84★2★ 1587 A63ST1-84★2★ 1632
80 25 30 60 75 A75ST-84★2★ 1692 A75ST1-84★2★ 1977
95 30 30 60 75 A95ST-84★2★ 1795 A95ST1-84★2★ 2450
110 30 40 75 100 A110ST-84★2★ 1872 A110ST1-84★2★ 3042
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00ST-84★2★ $ 396 A9NST1-84★2★ $ 582

0 18 3 3 5 5 A16N0ST-84★2★ 476 A16NST1-84★2★ 702
1 27 7.5 7.5 10 10 A26N1ST-84★2★ 552 A26NST1-84★2★ 882
2 45 10 15 25 25 A50N2ST-84★2★ 1224 A50NST1-84★2★ 1467
3 90 25 30 50 50 A75N3ST-84★2★ 1692 A75NST1-84★2★ 1977

Hz
Description D.C. operated starters

Motors that have separate windings for each speed provide more If DC operation is required, consult factory.
combinations of speed variations. Multi-speed starters from ABB Control are
available for constant horsepower, constant torque and variable torque
motors.
Constant horsepower
Motors that maintain the same horsepower regardless of speed are
called constant horsepower motors. These motors are used in
applications like metal working.
Constant torque
Motors that maintain constant torque at all speeds are called constant
torque motors. In applications like conveyors, horsepower varies directly
with speed.
Variable torque motors

Motors that produce a torque characteristic which varies as the square of
the speed are called variable torque motors and are used in applications
like blowers and fans.
AC 1000.2 – 9/99

1.12 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
2 Speed, 2 winding

Number Price Number Price Number Price Number Price Number Price
UL rated
NEMA rated
XL Starters

size rating adder
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9ST3-8A2A/50
AC 1000.2 – 9/99


1.13
AXE - NEMA 7 & 9
Plastic enclosed, IP65
3 pole, open & enclosed

Catalog Catalog List Catalog List
List
number number price number price
208V 240V 480V 575V/600V price
with blank cover with reset only with start & stop/reset
2 2 5 7.5 A9SD-84★ $ 233 A9SD-84★R $ 240 A9SD-84★A $ 278

3 3 7.5 10 A12SD-84★ 248 A12SD-84★R 255 A12SD-84★A 293
5 5 10 15 A16SD-84★ 278 A16SD-84★R 293 A16SD-84★A 330
★ Overload Relay suffix code. Select from the overload relay selection chart on back cover fold out page.
Overload relay selection chart

For Current Starter
Catalog
contactor range suffix
number
sizes (motor fla) code
0.1 – 0.16 TA25DU0.16 A

0.16 – 0.25 TA25DU0.25 B
0.25 – 0.4 TA25DU0.4 C
A9
0.4 – 0.63 TA25DU0.63 D

0.63 – 1.0 TA25DU1.0 E
1.0 – 1.4 TA25DU1.4 F
A12
1.4 – 1.8 TA25DU1.8 G

1.7 – 2.4 TA25DU2.4 H
A16
XL Starters
2.2 – 3.1 TA25DU3.1 J

2.8 – 4.0 TA25DU4.0 K
3.5 – 5.0 TA25DU5.0 L A9SD-84EA
4.5 – 6.5 TA25DU6.5 M
6.0 – 8.5 TA25DU8.5 N
7.5 – 11 TA25DU11 P
10 – 14 TA25DU14 Q
13 – 19 TA25DU19 R

Hz
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A9 starter: A9SD-80E

AC 1000.2 – 9/99
Enclosed
1.14 Discount schedule AAE ABB Control Inc.
UL & CSA Technical data
for AC operated A contactors
ABB contactor frame size A9 A12 A16 A26 A30 A40 A45 A50 A63 A75 A95 A110
NEMA size 00 — 0 1 1P — — 2 — 3 — —
Number of poles 3 or 4 3 3 or 4 3 or 4 3 3 4 3 or 4 3 3 or 4 3 3
A.C. rating information

NEMA cont. amp rating (thermal current) 9 — 18 27 36 — — 45 — 90 — —
NEMA maximum H.P ratings (1 phase)
115VAC 1/3 .75 1 2 3 — — 3 — — — —
230VAC 2 2 3 3 7.5 — — 10 — — — —
NEMA maximum H.P. ratings (3 phase)
200VAC 1.5 — 3 7.5 — — — 10 — 25 — —
230VAC 1.5 — 3 7.5 — — — 15 — 30 — —
460/575VAC 2 — 5 10 — — — 25 — 50 — —
U.L. general purpose current (40°C) A 21 25 30 40 50 60 65 80 90 105 125 140
U.L. max 3 Ph. switching motor loads A 9 11 17 28 34 42 — 54 65 80 95 110
U.L. maximum H.P. ratings (1 phase)
115 VAC 1/2 3/4 1 2 3 3 — 3 5 7.5 7.5 10
230 VAC 2 2 3 5 7.5 7.5 — 7.5 10 15 20 25
200 – 208 VAC 2 3 5 7.5 10 10 — 15 20 25 30 30
220 – 240 VAC 2 3 5 10 10 15 — 20 25 30 30 40
440 – 480 VAC 5 7.5 10 20 20 30 — 40 50 60 60 75
550 – 600 VAC 7.5 10 15 25 30 40 — 50 60 75 75 100
Lighting-ballast and incand., 600 VAC 15 15 20 35 50 60 65 65 85 105 — —
XL Starters
Resistive heating applications, 600 VAC 15 15 20 35 50 60 65 65 85 105 — —
Auxiliary contacts
NEMA rating, AC A600 A600 A600 A600 A600 A600 — A600 A600 A600 A600 A600
AC rated voltage, VAC 600 600 600 600 600 600 — 600 600 600 600 600
AC thermal rated current, A 10 10 10 10 10 10 — 10 10 10 10 10
AC maximum volt-ampere making, VA 7200 7200 7200 7200 7200 7200 — 7200 7200 7200 7200 7200
AC maximum volt-ampere breaking, VA 720 720 720 720 720 720 — 720 720 720 720 720
NEMA rating, DC P600 P600 P600 P300 P300 P300 — P300 P300 P300 P300 P300
DC rated voltage, VDC 600 600 600 600 600 600 — 600 600 600 600 600
DC thermal rated current A 5 5 5 5 5 5 — 5 5 5 5 5
DC maximum make-break A 0.2 0.2 0.2 0.2 0.2 0.2 — 0.2 0.2 0.2 0.2 0.2
Approximate weight
Contactor Lbs. 0.7 0.7 0.7 1.01 1.2 2.25 2.25 2.25 2.25 2.25 3.5 5
Starter Lbs. 1.04 1.04 1.04 1.35 1.54 3 — 3 3 3 6 7
Wire range AWG 18 – 10 18 – 10 18 – 10 12 – 8 8–4 8–4 8–1 8–1 8–1 8–1 6 – 2/0 6 – 2/0
Number of wires per phase 2 2 2 2 2 2 1 1 1 1 1 1
Tightening torque, lb. in. 9 9 9 15 20 20 40 40 40 40 50 50
Maximum short circuit ratings, UL/CSA
MCCB/MCP Amps/kA @ 480V 50/35 50/35 50/35 100/35 150/65 150/65 150/85 150/85 250/85 250/85 250/85 250/85
MCCB/MCP Amps/kA @ 600V 10/35 10/35 – 100/35 150/25 150/25 – – – – 250/35 250/35
Fuse Amps, Type/kA @ 600V 30J/200 30J/200 30J/200 60J/200 60J/200 100J/200 100J/200 100J/200 200J/200 200J/200 200J/200 200J/200
AC 1000.2 – 9/99

IEC Technical data
Type A9 A12 A16 A26 A30 A40 A45 A50 A63 A75 A95 A110
Insulation characteristics
Rated insulation voltage Ui
according to IEC947-4-1 and VDE0110 (Gr. C) V 1000
according to UL/ CSA V 600
Rated impulse withstand voltage Uimp. 8 kV
Main pole utilization characteristics

Rated operational voltage Ue V 690 690 1000 1000
Conventional free-air thermal current Ith
acc. to IEC947-4-1, open contactors θ ≤ 40°C A 26 28 30 45 65 65 100 100 125 125 145 160
2
with conductor cross-sectional area mm 4 4 4 6 16 16 35 35 50 50 50 70
Rated operational current I e /AC-1 for air temperature
close to contactor
with conductor cross sectional area

{ θ ≤ 40°C
θ ≤ 55°C
θ ≤ 70°C
A
A
A
mm2
25
22
18
2.5
27
25
20
4
30
27
21
4
45
40
32
6
55
55
39
10
60
60
42
16
70
60
50
25
100
85
70
35
115
95
80
50
125
105
85
50
145
135
115
50
160
145
130
70
Utilization category AC-3 for air temperature
close to contactor ≤ 55°C
Rated operational current Ie / AC-3 (1)
XL Starters
220-230-240 V A 9 12 17 26 33 40 40 53 65 75 96 110
380-400 V A 9 12 17 26 32 37 37 50 65 75 96 110
415 V A 9 12 17 26 32 37 37 50 65 72 96 110
3-phase Motors M 440 V A 9 12 16 26 32 37 37 45 65 70 93 100
3 500 V A 9 12 14 22 28 33 33 45 55 65 80 100
690 V A 7 9 10 17 21 25 25 35 43 46 65 82
1000 V A — — — — — — — 23 25 28 30 30
Rated operational power AC- 3 (1)
220-230-240 V kW 2.2 3 4 6.5 9 11 11 15 18.5 22 25 30
1500 r.p.m. - 50 Hz 380-400 V kW 4 5.5 7.5 11 15 18.5 18.5 22 30 37 45 55
1800 r.p.m. - 60 Hz 415 V kW 4 5.5 9 11 15 18.5 18.5 25 37 40 55 59
3-phase Motors M 440 V kW 4 5.5 9 15 18.5 22 22 25 37 40 55 59
500 V kW 5.5 7.5 9 15 18.5 22 22 30 37 45 55 59
3 690 V kW 5.5 7.5 9 15 18.5 22 22 30 37 40 55 75
1000 V kW — — — — — — — 30 33 37 40 40
Rated frequency limits Hz 25 – 400
Mechanical durability in millions of operating cycles 10 10
Max. mechanical switching frequency cycles/h 3600 3600
Max. electrical switching for AC-1 cycles/h 600 600 600 600 600 600 600 600 600 600 300 300
frequency for AC-3 cycles/h 1200 1200 1200 1200 1200 1200 600 600 600 600 300 300
for AC-2, AC-4 cycles/h 300 300 300 300 300 300 150 150 150 150 150 150
Rated making capacity AC- 3 according to IEC947-4-1 10 x Ie AC-3 12 x Ie AC-3
Rated breaking capacity AC- 3 according to IEC947-4-1 8 x Ie AC-3 8 x Ie AC-3
Max. breaking capacity cos ϕ = 0.45 at 440 V A 250 250 250 420 820 820 900 900 900 900 1160 1160
(cos ϕ = 0.35 for Ie > 100 A) at 690 V A 100 100 100 170 340 340 490 490 490 490 800 800
Short-circuit protection for contactors
without thermal O/L relays - Motor protection excluded1
Ue ≤ 500 V a.c. – gG (gl) type fuses A 25 32 32 50 63 63 80 100 125 160 160 200
Rated short-time withstand current Icw 1s A 250 280 300 400 600 600 1000 1000 1000 1000 1320 1320
at 40°C ambient temp., in free air, 10 s A 100 120 140 210 400 400 650 650 650 650 800 800
from a cold state 30 s A 60 70 80 110 225 225 370 370 370 370 500 500
1 min A 50 55 60 90 150 150 250 250 250 250 350 350
15 min A 26 28 30 45 65 65 100 100 100 100 160 175
Heat dissipation per pole Ie /AC-1 0.8 1 1.2 1.8 2.5 3 2.5 5 6.5 7 6.5 7.5
Ie /AC-3 W 0.1 0.2 0.35 0.6 0.9 1.3 0.65 1.3 1.5 2 2.7 3.6
AC 1000.2 – 9/99
1 Please consult us for the protection of motor starters against short circuits.

Approximate dimensions
for 3 pole, AC operated A contactors & starters
00.00
00.00
Inches
Millimeters
A9 – A16
A9 – A16 + TA25 — Starter, 3 pole, AC operated
2.91
74
2.68
68
1.73 0.22 1.38

5.5 35
44
2.91 2.36 1.97

74 60 50
3.46
88
5.26
133.5
0.18
4.5
RESET
0.14
3.5
0.24
6
3.74
95
A9 – 16 + VM5 or VE5 + TA25 — Reversing starter, 3 pole, AC operated

2.91
XL Starters
74
5.50 2.68
139.7 68
4.06 0.22 1.38 2.32

103 5.5 35 59
2.91 2.36 1.97

74 60 50
3.46
88
5.26
133.5
0.18
4.5
RESET
0.14
3.5
0.24
6
3.74
95
A9 – 16 — 2 speed, 1 winding, 3 pole, AC operated
2.91
74
2.68
68
7.00 0.22
177.8 5.5
2.36 1.97
60 50
3.46
5.00 88
127.0
0.18
4.5
RESET RESET
0.24
6
0.14
3.74 3.5
95
AC 1000.2 – 9/99

A9-16 to A26 00.00
00.00
Inches
Millimeters
A9 – 16 — 2 speed, 2 winding
5.50
139.7
4.85 2.91 4.23
74 107.4
123.2
2.68
68
0.22
5.5
4.63
117.6
2.36 1.97
60 50
6.67 3.46
169.4 88
0.18
4.5
RESET RESET
0.24
6
3.74 0.14
3.5
95
XL Starters
A26 + TA25 — Starter
3.69
93.6
3.44
87.3
2.13 0.35 1.77
54 9 45
3.54 2.76 3.15

90 70 80
4.10
104.2
5.79
147
0.17
4.2
RESET
0.53
13.5
0.24
6
4.31
109.5
A26 + VM5 or VE5 + TA25 — Reversing starter

4.03
102
3.69
93.6
3.44 4.64
5.25 117.9
133.4 87.3
4.84 0.35 0.22
9 2.32 5.5
123.0 59
5.25
133.4
4.64
3.54 117.9 2.76 3.15
6.87 90 70 80
174.5 4.10
104.2
5.79
147
AC 1000.2 – 9/99
0.17
RESET 4.2
0.52
0.24 13.5
6
XL STARTERS: Selection: 1.2 – 1.14 4.31
Technical data: 1.15 – 1.16 1.77 – 1.28
Approximate dimension: 1.17 2.72 General wiring diagrams: 1.29 - 1.30
109.5 45 69

00.00
00.00
Inches
Millimeters
A26 to A30 & A40
A26 — 2 speed, 1 winding
4.03
102
3.69
93.6
3.44
7.87 87.3
200.0 0.35 3.94 0.22
9 100.0 5.5
4.64
6.87 3.54 117.9 2.76 3.15
174.5 90 70 80
4.10
104.2
5.79
147
0.17
RESET RESET 4.2
0.52
0.24 13.5
6
4.31 1.77 2.72
109.5 45 69
7.25
184.1
XL Starters
4.03
102
3.69
93.6
3.44 4.64
87.3 117.9
5.25
133.0 0.35 0.22
9 2.32 5.5
59
4.64
6.95 3.54 117.9 2.76 3.15
176.5 90 70 80
4.10
104.2
5.79
147
RESET 0.17 RESET

4.2
0.52
0.24 13.5
6
4.31 1.77 2.72
109.5 45 69
A30 & A40 + TA25 — Starter
4.26
108.3
4.02
102
2.13 0.35 1.77
54 9 45
3.54 2.76 3.15

90 70 80
4.20
106.7
5.87
6.44 149
163.5
TA25DU32 0.17
ONLY 4.2
RESET
0.35
8.8
AC 1000.2 – 9/99
0.24
6
4.08
104

for 3 pole, AC & DC operated A contactors & starters
A30 – A(E)40 00.00
00.00
Inches
Millimeters
A30 & A40 + TA42 — Starter, 3 pole, AC operated

4.26
108.3
4.02
102
2.13 0.35 1.77
54 9 45
3.54 2.76 3.15

90 70 80
4.09
104
6.08
154.5
0.17
4.2
RESET
0.33
8.3
0.24
6
4.43
112.5
A30 & A40 + VM5 or VE5 + TA25 — Reversing starter, 3 pole, AC operated
XL Starters
4.60
117 4.64
5.25 117.9
133.4 4.26
108.3
4.84 2.32 0.22
123.0
4.02 59 5.5
102
0.35
9
5.25
133.4 4.64
3.54 117.9 2.76 3.15 4.20
90 70 80 106.7
7.25
191 5.87
6.44 149
163.5
TA25DU32
ONLY
RESET 0.17
4.2
0.35
8.8
0.24
6
4.08 1.77 2.72
104 45 69
4.60
117 4.64
5.25 117.9
133.4 4.26
108.3
4.84 2.32 0.22
123 4.02 59 5.5
102
0.35
9
5.25 4.64
133.4 3.54 117.9 2.76 3.15 4.09
90 70 80 104
6.08
154.5
RESET 0.17
4.2
0.33
8.3
AC 1000.2 – 9/99
1.77 2.72
45 69

00.00
00.00
Inches
Millimeters
A(E)30 – A(E)40 to A50 – A75
A30 & A40 — 2 speed, 1 winding
4.60
117
4.26
7.87 108.3
3.94 0.22
200.0 4.02 100.0 5.5
102
0.35
9
5.25
133.4 4.64
3.54 117.9 2.76 3.15
90 70 80
4.10
104.2
7.25 5.87
191 6.44 149
163.5
TA25DU32
ONLY
0.17
RESET RESET 4.2
0.52
13.5
0.24 1.77 2.72

45 69
6
4.08 7.25
104 184.1
XL Starters
4.90
150
4.60
117 4.64
5.25 4.26 117.9
133.3 108.3 0.22

2.32
4.02 59 5.5
102
0.35
9
5.25
133.4 4.64
3.54 117.9 2.76 3.15 4.20
90 70 80 106.7
7.25 5.87
191 6.44 149
163.5
TA25DU32
ONLY
RESET RESET
0.17
4.2
0.35
8.8
0.24
6 1.77
4.08 2.72
45 69
104
A(E)50 – A(E)75 + TA75 — Starter, 3 pole, AC & DC operated
4.25
108
4.00
101.5
2.76 0.39 2.36

10
70 60
4.33 3.94 3.54 4.88

100 90
110 124
6.93
176
0.24
6.2
RESET
0.62
15.8
AC 1000.2 – 9/99
0.24
6
4.45
113

A(E)50 – A(E)75 00.00
00.00
Inches
Millimeters
A(E)50 – A(E)75 + VM5 or VE5 + TA75 — Reversing starter, 3 pole, AC & DC operated
4.54
115.3
6.62 4.25 6.00
168.2 152.5
108
6.10 4.00 3.00 0.22
155 101.5 5.5
76.3
0.39
10
3.54
6.50 90
165 4.33 5.87 3.94 4.88
110 149 100 124
8.25 6.93
209.5 176
RESET 0.24
6.2
0.24
XL Starters
6 0.62
15.8
4.45
113 2.36 3.35
60 85
A(E)50 – A(E)75 2 Speed, 1 winding

5.58
142.0
4.54
115.3
10.12 4.25
257.0 108
9.62 4.00 4.81 0.22
244.3 101.5 122.0 5.5
0.39
10
4.33 3.54
6.50 90
165 110 5.87 3.94 4.88
149 100 124
8.25 6.93
209.5 176
RESET RESET 0.24

6.2
0.24
6 0.62
15.8
4.45
113 2.36 3.35
60 85
9.00
228.6

4.54
115.3
6.82 6.00
4.25 152.5
173 108
6.62 4.00 3.00 0.22
168 101.5 76.3 5.5
0.39
10
4.33 3.54
6.50 90
165 110 5.87 3.94
149 100
8.25 6.93 4.88
124
209 176
AC 1000.2 – 9/99
RESET RESET
0.24 0.62
6 15.8
4.45
113 2.36 3.35 General wiring diagrams: 1.29 - 1.30
XL STARTERS: Selection: 1.2 – 1.14 Technical data: 1.15 – 1.16 Approximate dimension: 1.17 – 1.2860
85

00.00
00.00
Inches
Millimeters
A(E)95 & A(E)110
A(E)95 & A(E)110 + TA80 — Starter, 3 pole, AC & DC operated
4.86
123.5
4.61
117
3.54 0.39 3.07
90 10 78
5.35
136
4.96
126 6.38
162
8.43
214
0.24
6.2
RESET
1.00
25.4
0.24
6
4.49
114
XL Starters
4.86
123.5
4.61
117
3.54 0.39 3.07
90 10 78
5.35
136
4.96
126 6.93
176
10.16
258
0.24
6.2
RESET
0.98
25
0.24
6
5.16
131
A(E)95 & A(E)110 + VE5 + TA80 — Reversing starter, 3 pole, AC & DC operated
7.91
8.70 5.17 200.1
221 131 3.90
7.68 4.86 99 0.31
195 123.5 8
0.39
10
8.10 4.96
205.7 4.33 126
148 7.28 5.35
185 136
9.97 6.38
248 8.43 162
214
AC 1000.2 – 9/99
RESET 0.24
6.2
0.98
25
0.24
6
4.49 3.07 4.10
114 78 104
A(E)95 & A(E)110 00.00
00.00
Inches
Millimeters
8.70 5.17 7.91
221 131 200.1
7.68 4.86 0.31
3.90 8
195 123.5 99
0.39
10
8.10
205.7 4.96
4.33 126
148 7.28 5.35
185 136
6.93
11.45 176
290 10.16
258
0.24
RESET 6.2
0.98
25
0.24
6
5.16 3.07 4.13
131 78 105
XL Starters
A(E)95 & A(E)110 + TA80 — 2 Speed, 1 winding

5.17 12.06
12.85 306.3
326.3
131.3 0.31
7.8
4.86
123.5
8.10 7.28
205.7 185.0
9.79 3.70
248.6 94.0
0.33
8.3
RESET RESET
BUTTON BUTTON
0.24 4.13
6.0 105.0
2.38 4.40
60.4 111.7
12.06
12.85 5.17 306.3
326.3 131.3
0.31
7.8
4.86
123.5
8.10 7.28
205.7 185.0
11.45 4.13
290.8 105.0
0.83
21.0
RESET RESET
BUTTON BUTTON
0.24 4.73 0.07

AC 1000.2 – 9/99
2.38 4.40
6.0 120.1 1.7
60.4 111.7

00.00
00.00
Inches
Millimeters
A(E)95 & A(E)110
8.70 5.17 7.91

221.0 131.3 200.1 0.31
7.8
4.86
123.5
8.10
205.7 7.28
185.0
9.79 10.0
248.6 254.0
3.70
94.0
0.33
8.3
RESET RESET
BUTTON BUTTON
0.24 4.13 2.38 4.40
XL Starters
6.0 105.0 60.4 111.7
8.70 5.17 7.91

221.0 131.3 200.1
0.31
7.8
4.86
123.5
8.10
205.7 7.28
185.0
10.0
11.45 254.0
290.8
4.13
105.0
0.83
21.0
RESET RESET
BUTTON BUTTON
0.24 4.73 0.07

6.0 2.38 4.40
120.1 1.7 60.4 111.7
AC 1000.2 – 9/99

Enclosed devices, hinged cover
Full voltage, across the line & reversing 00.00
00.00
Inches
Millimeters
B C
A
XL Starters
Across the line Reversing

Enclosure type A B C Enclosure type A B C
A9 – A40 1 12 7 6 A9 – A40 1 12 10 6
3R 10 8 6 3R 12 10 6
4X Stainless 10 8 6 4X Stainless 12 10 6
4X Plastic 10 8 7 4X Plastic 12 10 6
12 10 8 6 12 14 12 8
A50 – A75 1 13 9 7 A50 – A75 1 14 12 8
3R 14 12 8 3R 14 12 8
12 14 12 8 12 14 12 8
A95 & A110 1 20 16 8 A95 & A110 1 20 16 8
3R 20 20 8 3R 20 20 8
12 20 16 8 12 20 16 8
AC 1000.2 – 9/99

00.00
00.00
Inches
Millimeters
Full voltage, multi-speed
B C
XL Starters
2 Speed, 1 winding w/CCT 2 Speed, 2 winding w/CCT
A9 – A40 1 14 12 8 A9 – A40 1 12 10 6
3R 14 12 8 3R 12 10 6
12 14 12 8 12 14 12 8
A50 – A75 1 20 16 8 A50 – A75 1 14 12 8
3R 20 16 8 3R 14 12 8
12 20 16 8 12 14 12 8
A95 & A110 1 20 16 8 A95 & A110 1 20 16 8
3R 20 20 8 3R 20 20 8
12 20 16 8 12 20 16 8
AC 1000.2 – 9/99

Wiring diagram
00.00 Inches
00.00 Millimeters
2X 0.25
2X M5
7.00
178.0
6.30
160.0
3.54 4.84 0.28

90.0 123.0 0.7
5.12
130.0
XL Starters

INCOMING LINES CONTROL OPTION 1, W/CCT
TO CONTACTOR
1
L1 L2
L1 L3
2
SHOP TO CONNECT PER
VOLTAGE SPECIFIED
CIRCUIT CHFU 1 CHFU 2
PROTECTIVE DEVICE H1 H2 H3 H4
(IF SPECIFIED) CHFU NOT REQUIRED
FOR 45VA CCT
CCT
CXFU
TO CONTROL XF
CIRCUIT OPTION 1
1 0R 2 AS SPECIFIED.
C OL
L1 L2 L3 C
13 14 A1 A2 95 96
C CONTROL OPTION 2, W/O CCT &

COIL VOLTAGE GREATER THAN 120V
TO CONTACTOR
L1 L3
OL
XF C OL
T1 T2 T3 C
13 14 A1 A2 95 96
CONNECTION MADE
ONLY WHEN PILOT
MOTOR DEVICES ARE SPECIFIED.
1PH
CONTROL OPTION 3, COIL VOLTAGE 120V OR LESS
CUSTOMER SUPPLIED
CONTROL VOLTAGE
XF C OL
C
13 14 A1 A2 95 96
NOTES
CCT- CONTROL CIRCUIT TRANSFORMER 1. COLOR OF CONTROL WIRE SHALL BE

PER VOLTAGE OF CONTACTOR COILS:
CHFU- CCT PRIMARY FUSE
CXFU- CCT SECONDARY FUSE RED - ALL AC VOLTAGES
WHITE MAY BE USED ON THE
XF- CONTROL POWER CONNECTON POINT GROUNDED SIDE OF THE AC
C- CONTACTOR CIRCUIT IF SPECIFIED.
CT- CURRENT TRANSFORMER BLUE - ALL DC VOLTAGES
OL- OVERLOAD RELAY
13- CONNECTION POINT ON DEVICE W/NUMBER 2. ALL DEVICES ARE SHOWN DE-ENERGIZED.
3. DO NOT USE SELECTOR SWITCHES WITH
AUTO-RESET OVERLOAD RELAYS
AC 1000.2 – 9/99

General wiring diagrams
Type A starters, non-reversing & reversing
00.00 Inches
00.00 Millimeters
Non-reversing, A9 – A110
Incoming Lines Connect per voltage specified

A B C
Connect if
CHFU CHFU CCT not specified
Circuit 1 and coil voltage
H1 H3 H2 H4
Protective Device CCT greater than
(if specified) (if specified) 120V.
CXFU X1 X2 Connect if
XF
1 CCT specified
White wire
L1 L2 L3 C OL if specified
13 14 A1
C A2 95 96
OL
Notes
T1 T2 T3
1. Color of 14 Ga. Control Wire shall
Legend be per Voltage of Contactor Coils:
XL Starters
RED - All AC Voltages
CCT- Control Circuit Transformer White may be used on the
Grounded Side of the AC
CHFU- CCT Primary Fuse Circuit if specified.
CXFU- CCT Secondary Fuse BLUE - All DC Voltages
CT- Current Transfer 2. All Devices are shown De-Energized.
XF- Control Power Connection Point 3. DO NOT Use Selector Switches with
Auto-Reset Overload Relays
C- Contactor
OL- Overload Relay
13- Connection Point on Device with Number

NON-REVERSING, A9 - A110
Reversing, A9 – A110
Connect per voltage specified

Incoming Lines
Connect If
A B C CHFU CHFU
CCT not specified
1 and coli voltage
H1 H3 H2 H4
Circuit CCT greater than
Protective Device (if specified)
(if specified) 120V.
CXFU OL
X1 X2
XF 96 95
1
F R
L1 L2 L3 L1 L2 L3 13 14 22 21 A1 F A2
(32) (31) B50-B75
A95-A110
F R R F
13 14 22 21 A1 R A2
(43) (44) B50-B75
T1 T2 T3 T1 T2 T3 A95-A110
OL Notes
T1 T2 T3 be per Voltage of Contactor Coils:
Legend RED - All AC Voltages
White may be used on the
CCT- Control Circuit Transformer Grounded Side of the AC
BLUE - All DC Voltages
CXFU- CCT Secondary Fuse
2. All Devices are shown De-Energized.
CT- Current Transfer
3. DO NOT Use Selector Switches with
AC 1000.2 – 9/99
XF- Control Power Connection Point Auto-Reset Overload Relays
C- Contactor
OL- Overload Relay
XL STARTERS: 13-
Selection: Connection
1.2 – 1.14 Point on Device with Number
Technical data: 1.15 – 1.16 Approximate dimension: 1.17 – REVERSING,
1.28 General wiring diagrams: 1.29 - 1.30
A9 - A110

00.00 Inches
00.00 Millimeters
2 Speed, one winding — constant or variable torque, selective control

A9 – A110

A B C If Deceleration Timing
Relay
( CR-TR) (TR) is Specified,
CHFU CHFU
Circuit Circuit
Add Timed Contact
Protective Device Protective Device H1 H3 1 H2 H4 in Series with 'S' Coil
(if specified) (if specified) CCT where shown.
(if specified)
CXFU FOL SOL
X1 X2
XF 96 95 96 95 TR
65 66
L1 L2 L3 L1 L2 L3 L1 L2 L3
S 1F
A1
S A2
13 14 21 22
2F S 1F (31) (32)
Mech. Intlk.
T1 T2 T3
A1
1F A2
FOL SOL
T1 T2 T3 T1 T2 T3 2F S 1F TR
A1
2F A2
13 14 21 22 13 14
(61) (62) (43) (44)
T6 T4 T5 T1 T2 T3
CR-TR
To 2-Speed,1-Winding Motor A1 A2
XL Starters
Legend
Notes CCT- Control Circuit Transformer
1. Color of 14 Ga. Control Wire shall CHFU- CCT Primary Fuse
be per Voltage of Contactor Coils: CXFU- CCT Secondary Fuse
RED - All AC Voltages CT- Current Transfer
White may be used on the XF- Control Power Connection Point
Grounded Side of the AC 1F- Shorting Contactor
Circuit if specified. 2F- Fast Speed Contactor
BLUE - All DC Voltages S- Slow Speed Contactor
FOL- Fast Speed Overload Relay
2. All Devices are shown De-Energized. SOL- Slow Speed Overload Relay
3. DO NOT Use Selector Switches with CR-TR- Optional Deceleration Timing Relay, Mtd on CR ( A95-A110; EH145-800 )
Auto-Reset Overload Relays TR- Optional Deceleration Timing Relay, Mtd on 2F ( B9-75 )
13- Connection point on device with number
2 Speed, two winding

A9 – A110

Relay
CHFU CHFU ( CR-TR) (TR) is Specified,
Circuit Circuit 1 Add Timed Contact
Protective Device Protective Device H1 H3 H2 H4
(if specified) (if specified) CCT in Series with 'S' Coil
(IF SPECIFIED)
where shown.
CXFU FOL SOL
X1 X2
XF 96 95 96 95 TR
65 66
L1 L2 L3 L1 L2 L3
S F
A1
S A2
13 14 21 22
S F
F S TR
FOL 13 14 21 22 A1 F A2
SOL T1 T2 T3 T1 T2 T3 CR-TR
A1 A2
T1 T2 T3 T11 T12 T13

Notes
To 2-Speed,2-Winding Motor
1. Color of 14 Ga. Control Wire shall Legend
be per Voltage of Contactor Coils:
RED - All AC Voltages CCT- Control Circuit Transformer
White may be used on the CHFU- CCT Primary Fuse
Grounded Side of the AC CXFU- CCT Secondary Fuse
Circuit if specified. CT- Current Transfer
BLUE - All DC Voltages XF- Control Power Connection Point
1F- Shorting Contactor
2. All Devices are shown De-Energized. 2F- Fast Speed Contactor
S- Slow Speed Contactor
3. DO NOT Use Selector Switches with FOL- Fast Speed Overload Relay
Auto-Reset Overload Relays SOL- Slow Speed Overload Relay
AC 1000.2 – 9/99
CR-TR- Optional Deceleration Timing Relay, Mtd on CR ( A95-A110; EH80-800 )

TR- Optional Deceleration Timing Relay, Mtd on 2F ( B9-75 )

SMARTSPOT INDICATOR AMP-TRAP 2000®
AJT TIME DELAY / CLASS J

SMARTSPOT™ WITH MAXIMUM CIRCUIT
PROTECTION
Amp-trap 2000® SmartSpot™ AJT fuses now
provide a visual open fuse indicator. With advanced
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line the AJT fuse provides IEC Type “2” (No Damage)
protection to main, feeder, and branch circuits, for all
types of loads — yet, they require only half the
mounting space needed for 600VAC Class RK fuses.
AJT’s time delay characteristics for handling harm-
less in-rush currents, its current limiting ability (the
most current limiting UL fuse class!), and wide range
of ratings (from 1 to 600 Amperes) — give excellent
protection for all your applications.
Features/Benefits
➤ Solid State SmartSpot Indicator
➤ Time delay for motor starting and transformer inrush
➤ 300kA interrupting rating - self-certified,
UL witnessed tests
➤ Extremely current limiting for low peak let-thru current
➤ Most current limiting UL class fuse
➤ Small footprint requires less mounting space and
allows smaller, more economical fuse blocks
➤ Easy 2-to-1 selectivity for prevention of nuisance
shutdowns
➤ Unique Class J dimensions prevent replacement errors
HIGHLIGHTS: APPLICATIONS: ➤ High-visibility orange label gives instant recognition
➤ Metal-embossed date and catalog number for
➤ Smart Spot Indicator ➤ Motor Circuits traceability and lasting identification
➤ Time Delay ➤ Mains ➤ Fiberglass body provides dimensional stability in harsh
➤ Feeders industrial settings
➤ Highly Current Limiting ➤ High-grade silica filler ensures fast arc quenching
➤ DC Ratings ➤ Branch Circuits ➤ Optional EI Indicator/Switch mount for AJT70 to
➤ Lighting, Heating 600 open fuse indication
➤ Optional Mechanical
& General Loads Ratings Approvals
Indicator
➤ Transformers
(70 to 600A fuses) ➤ AC: 1 to 600A AJT (1-600):
➤ Control Panels 600VAC, 200kA I.R. ➤ UL Listed to
(self certified for Standard 248-8
➤ Circuit Breaker Back-up 600VAC, 300kA I.R., ➤ DC Listed to UL
➤ Bus Duct UL witnessed) Standard 198L
➤ Load Centers DC: 1 to 600A Standard C22.2
500VDC, 100kA I.R. No. 248.8
➤ IEC 269-2-1
AJT (70-600) EI:
➤ UL Component
Recognized
➤ DC Tested to UL
Standard 198L
A2
TIME DELAY / CLASS J FUSES AJT

Recommended Fuse Blocks
With Box Connectors for
RATING NUMBER RATING NUMBER RATING NUMBER RATING NUMBER
Amp-trap® Class J Fuses
1
1-1/4
1-1/2
AJT1
AJT1-1/4
AJT1-1/2
4-1/2
5
5-6/10
AJT4-1/2
AJT5
AJT5-6/10
25
30
35
AJT25
AJT30
AJT35
125
150
175
AJT125
AJT150
AJT175
Fuse
Ampere
Catalog Number
600V OR LESS
A
1-6/10 AJT1-6/10 6 AJT6 40 AJT40 200 AJT200 Rating 1 Pole 3 pole
1-8/10 AJT1-8/10 6-1/4 AJT6-1/4 45 AJT45 225 AJT225 0-30 US3J1I US3J3I
2 AJT2 7 AJT7 50 AJT50 250 AJT250 31-60 US6J1I US6J3I
2-1/4 AJT2-1/4 8 AJT8 60 AJT60 300 AJT300 61-100 61036J 61038J
2-1/2 AJT2-1/2 9 AJT9 70 AJT70 350 AJT350 101-200 62001J 62003J
2-8/10 AJT2-8/10 10 AJT10 80 AJT80 400 AJT400 201-400 64031J 64033J
3 AJT3 12 AJT12 90 AJT90 450 AJT450 401-600 6631J 6633J
3-2/10 AJT3-2/10 15 AJT15 100 AJT100 500 AJT500
3-1/2 AJT3-1/2 17-1/2 AJT17-1/2 110 AJT110 600 AJT600 A variety of pole configurations and termination
provisions is available.
4 AJT4 20 AJT20
Note: Indicator Not availible (1-7a)
1-60A
70-600A
Dimensions
AMPERE A B C D E F G H
RATING In. mm In. mm In. mm In. mm In. mm In. mm In. mm In. mm
1-30 2-1/4 57 13/16 21 - - - - - - - - - - - -
31-60 2-3/8 60 1-1/16 27 - - - - - - - - - - - -
61-100 4-5/8 117 1-1/16 27 1/8 3.2 3/4 19 1 25 3-5/8 92 3/8 10 9/32 7
101-200 5-3/4 146 1-5/8 41 3/16 4.8 1-1/8 29 1-3/8 35 4-3/8 111 3/8 10 9/32 7
201-400 7-1/8 181 2-1/8 54 1/4 6.3 1-5/8 41 1-7/8 48 5-1/4 133 17/32 14 13/32 10
401-600 8 203 2-1/2 64 3/8 9.5 2 51 2-1/8 54 6 152 11/16 18 17/32 13
Optional Indicator/Microswitch Mount (EI) dimensions:
Note: Fuses with the EI option will receive

the AOS-S or AOS-Q Add-On-Switch CATALOG NUMBER A
2.80
AJT(70-100)-EI
(71.0)
3.22
AJT(110-200)-EI
(81.8)
3.24
AJT(225-400)-EI
(82.2)
3.61
AJT(450-600)-EI
(91.8)
A3

AJT1 to 600
Current in Amperes
Time in Seconds
Peak Let-Thru Current Data – AJT30 to 600, 600 Volts AC

Maximum Instantaneous Peak Let-Thru Amperes
Note: See Application Tables page L9

for Three Phase Class J AJT Fuses.
Available Current in RMS Symmetrical Amperes
A4

mit seitlichem Anschlußkabel / RH63M-4DK.7Q.1R 121 127

with cable side
mit Klemmenkasten / RH63M-4DK.7Q.1R 121 871

with terminal box
RH63M-4DK.7Q.1R 1200
U I P1 n LWA
-1
V A W min dB
3~ 400 V ± 10% 50 Hz IP54 1 1 400 4,6 2500 1430
Motor/Rad 165-120-4F/224 1000 2 400 6,8 4100 1380 88
P1 4,1 kW 4 3 400 5,9 3400 1400 93
I 6,8 A 800 4 230 5,6 2100 1300
2
n 1380 min-1 7 5 230 8,3 3100 1160 83
∆p fa in Pa
IA 29 A 6 230 7,2 2700 1220 90

600 5
7 180 6,2 1850 1190
10
tR 40 °C 8
8 180 8,3 2400 980 79
400 9 180 7,7 2200 1060 85
Connection diagram 11 10 140 6,1 1400 100
11 140 7,6 1600 780 72
200
50 kg 13 12 140 7,2 1550 850 80
12 9 6 3 13 90 5,6 700 500
0
Vmax 15600 m3/h 0 5000 10000 15000 20000
pd2 2,3 · 10-7 · V2 V in m /h 3
RH63M100 RH63M4DK7Q1RV801


mit seitlichem Anschlußkabel / RH63M-VDK.7Q.1R 121 390

with cable side
mit Klemmenkasten / RH63M-VDK.7Q.1R 121 878

with terminal box
RH63M-VDK.7Q.1R 900
U I P1 n LWA
1 V A W min-1 dB
3~ 400 V ± 10% ∆/Y 50 Hz IP54 800 1 400 4,6 2400 1330
Motor/Rad 165-120-4-4F/224 4 2 ∆ 6,8 3900 1340 87
700
P1 3,9/2,7 kW 2 3 5,9 3200 1360 92
I 6,8/4,7 A 600 4 400 3,3 1950 1240
-1 5 5
n 1340/1060 min Y 4,7 2700 1060 85
∆p fa in Pa
IA 27/9,1 A 500 6 4,2 2400 1130 86
400
tR 40 °C
300
50 kg 100
6 3
0
Vmax 15200
3
m /h 0 5000 10000 15000 20000
pd2 2,3 · 10-7 · V2 V in m3/h
RH63M101 RH63MVDK7Q1RV801


mit seitlichem Anschlußkabel / RH63M-6DK.6K.1R 109 363

with cable side
mit Klemmenkasten / RH63M-6DK.6K.1R 201 995

with terminal box
RH63M-6DK.6K.1R 500
U I P1 n LWA
-1
1 V A W min dB
3~ 400 V ± 10% 50 Hz IP54 450 1 400 2,2 750 940
Motor/Rad 137-76-6F/224 2 400 2,6 1200 900 76
400
P1 4
1,2 kW 3 400 2,4 880 930 80
350 4
I 2,6 A 230 1,8 580 850
7 2
n 900 min-1 300 5 230 2,5 850 760 72
∆p fa in Pa
IA 8 A 6 230 2,1 670 820 74

250
10 7 180 1,85 490 770
5
tR 50 °C 200 8 180 2,5 650 640 68
8
9 180 2,1 540 730 75
11 10 140 1,85 380 660
Connection diagram
100 11 140 2,2 450 530 63
13 12 140 2,0 410 620 71
34 kg 50
13 90 1,7 210 350
12 9 6 3
0
Vmax 10600 m3/h 0 2000 4000 6000 8000 10000 12000
pd2 2,5 · 10
-7
· V2 V in m3/h
RH63M102 RH63M6DK6K1RV002


mit seitlichem Anschlußkabel / RH63M-SDK.6K.1R 121 391

with cable side
mit Klemmenkasten / RH63M-SDK.6K.1R 107 697

with terminal box
RH63M-SDK.6K.1R 450
U I P1 n LWA
1 V A W min-1 dB
3~ 400 V ± 10% ∆/Y 50 Hz IP54 400 1 400 1,9 680 910
Motor/Rad 137-76-6-6F/224 2 ∆ 2,1 1050 850 74
350
P1 1,05/0,65 kW 2
3 2,0 800 890 79
4
I 2,1/1,15 A 300 4 400 0,88 490 770
n 850/640 min-1 5 Y 1,15 650 640 68
∆p fa in Pa
IA 5,4/1,8 A 250 6 0,95 540 730 75

5
200
tR 50 °C
150
31 kg 50
6 3
0
Vmax 10000
3
m /h 0 2000 4000 6000 8000 10000
pd2 2,5 · 10-7 · V2 V in m /h
3
RH63M103 RH63MSDK6K1RV801


mit seitlichem Anschlußkabel / RH63M-6EK.6N.1R 121 858

with cable side
mit Klemmenkasten / RH63M-6EK.6N.1R 121 873

with terminal box
RH63M-6EK.6N.1R 450
U I P1 n LWA
1 V A W min-1 dB
1~ 230 V ± 10% 50 Hz IP54 400 1 230 3,8 840 940
4
Motor/Rad 137-100-6/224 2 230 5,5 1200 870 75
350 2
P1 1,2 kW 3 230 4,4 960 910 80
7
I 5,5 A 300 4 160 4,0 650 860
-1 5
n 870 min 160 5,8 910 730 71
∆p fa in Pa
IA 12,5 A 250 5 6 160 4,8 760 820 77

C400V 25 µF 10 7 130 4,2 550 790
200
tR 40 °C 8 130 5,5 670 580 65
8
150 9 130 5,0 620 700 74
10 105 4,2 410 620
Connection diagram 100 11
11 105 4,8 470 450 59
12 105 4,6 450 550 68
36 kg 50 13
12 9 6 3 13 60 3,0 160 230
0
Vmax 10400 m3/h 0 2000 4000 6000 8000 10000 12000
pd2 2,3 · 10-7 · V2 V in m /h 3
RH63M106 RH63M6EK6N1RV001


mit seitlichem Anschlußkabel / RH63M-8DK.6C.1R 121 359

with cable side
mit Klemmenkasten / RH63M-8DK.6C.1R 121 875

with terminal box
RH63M-8DK.6C.1R 200
U I P1 n LWA
-1
1 V A W min dB
3~ 400 V ± 10% 50 Hz IP54 180 1 400 0,87 300 650
Motor/Rad 137-35-8/224 2 400 1,0 430 570 65
160
2
P1 0,43 kW 3 400 0,91 340 630 71
140
I 1,0 A 4 230 0,60 165 530
n 570 min-1 120 5 230 0,73 220 400 57
∆p fa in Pa
IA 1,9 A 4 6 230 0,66 190 480 65

100
7 180 0,55 125 440
tR 60 °C 80 5
8 180 0,63 140 320 53
7 9
180 0,58 130 400 61
Connection diagram 8 10 140 0,47 83 350
40 11
11 140 0,51 89 250
18 kg 12 140 0,49 86 310
20 9 6 3 13 90 0,27 50 170
0
Vmax 7850 m3/h 0 2000 4000 6000 8000
pd2 2,5 · 10-7 · V2 V in m /h
3
RH63M104 RH63M8DK6C1RV801


mit seitlichem Anschlußkabel / RH63M-ADK.6C.1R 121 360

with cable side
mit Klemmenkasten / RH63M-ADK.6C.1R 107 699

with terminal box
RH63M-ADK.6C.1R 250
U I P1 n LWA
-1
V A W min dB
3~ 400 V ± 10% ∆/Y 50Hz IP54 1 400 0,92 300 650
Motor/Rad 137-35-8-8/224 200 1 2 ∆ 1,15 460 590 66
P1 0,46/0,22 kW 3 0,96 340 630 71
I 1,15/0,46 A 2
4 400 0,38 165 530
n 590/400 min-1 150 5 Y 0,46 220 400 56
∆p fa in Pa
IA 2,1/0,7 A 4 6 0,42 190 480 65
tR 50 °C 100
5
Connection diagram
50
18 kg
6 3
0
Vmax 7850 m3/h 0 2000 4000 6000 8000
pd2 2,5 · 10-7 · V2 V in m /h
3
RH63M105 RH63MADK6C1RV801

Open & enclosed
A9 – A110
XL Starters
Description
A9 – A110 Overload relay protection
• Maximum UL/CSA horsepower ratings All starters, size A9 – A110, have Class 10
• NEMA sizes 00, 1, 2, 3 available adjustable overload relay protection as
• Compact space-saving design standard.
• Standard auxiliary contact configurations:
A9 – A40 1 N.O. or 1 N.C.
A50 – A110 1 N.O. & 1 N.C.
• Additional auxiliary contact blocks are
available
• D.C. ratings & D.C. control operation
available
• Fast, snap-on DIN rail mounting
• Double break contact design
• Snap-on front and side mounted
accessories include mechanical latch,
pneumatic timer and 1 & 4 pole auxiliary
contact blocks
• Easy coil change
• Captive terminal screws
• NEMA, UL, CSA, and most other
international standards
• Operates over an extended voltage range
of 85% to 110% of rated control voltage
• Screwdriver guide holes
• Rated for use with NEMA Design E Class
motors
Enclosure types
• NEMA 1 (Indoor metal)
• NEMA 3R (Outdoor metal)
Index
• NEMA 12 (Metal dusttight) Across the line starters
• NEMA 4X (Stainless steel) • Features ............................................ 1.1
• NEMA 4 (Water tight) • Starter selection by HP ........... 1.2 – 1.3
• NEMA 1, 3R, 4, 4X, & 12 (Plastic) • Non-reversing .......................... 1.4 – 1.7
• IP 65 plastic A9 – A16 starters • Reversing ................................ 1.8 – 1.9
• NEMA 7 & 9 • 2 Speed, 1 winding ............. 1.10 – 1.11
Class I, Group D, Div 1 & 2 • 2 Speed, 2 winding ............. 1.12 – 1.13
• Plastic enclosed starters ................. 1.14
AC 1000.2 – 9/99
Class II, Groups E, F, & G, Div 1 & 2

Class III, 4X • Technical data ..................... 1.15 – 1.16
• Approximate dimensions .... 1.17 – 1.23
• General wiring diagrams ................. 1.24

Maximum UL/CSA ratings

3-phase, 1800 RPM
200V 230V 460V 575V number price number price number price
– – – 1/4 A9S-84C A9-30-10-84 TA25DU0.4 (0.25 – .4)
– – 1/4,1/3 1/3 A9S-84D A9-30-10-84 TA25DU0.63 (0.4 – .63)
– – – 1/2 A9S-84E A9-30-10-84 TA25DU1.0 (0.63 – 1.0)
– – 1/2 3/4 A9S-84F A9-30-10-84 TA25DU1.4 (1.0 – 1.4)
– – 3/4 – A9S-84G A9-30-10-84 TA25DU1.6 (1.3 – 1.6)
– 1/2 1 1.5 A9S-84H A9-30-10-84 TA25DU2.4 (1.7 – 2.4)
$ 165 $ 78 $ 63
1/2 – 1.5 2 A9S-84J A9-30-10-84 TA25DU3.1 (2.2 – 3.1)
3/4 3/4 2 – A9S-84K A9-30-10-84 TA25DU4.0 (2.8 – 4.0)
– 1 – 3 A9S-84L A9-30-10-84 TA25DU5.0 (3.5 – 5.0)
1 1.5 3 5 A9S-84M A9-30-10-84 TA25DU6.5 (4.5 – 6.5)
2 2 5 – A9S-84N A9-30-10-84 TA25DU8.5 (6.0 – 8.5)
– – – 7.5 A9S-84P A9-30-10-84 TA25DU11 (7.5 – 11)
3 3 7.5 10 A12S-84Q 171 A12-30-10-84 84 TA25DU14 (10 – 14)
5 5 10 15 A16S-84R 200 A16-30-10-84 102 TA25DU19 (13 – 19)
– 7.5 15 20 A26S-84S 294 A26-30-10-84 183 TA25DU25 (18 – 25)
7.5 10 20 25 A26S-84T A26-30-10-84 TA25DU32 (24 – 32)
– – – 30 A30S-84B 365 A30-30-10-84 252 TA42DU32 (22 – 32) 78
10 15 30 40 A40S-84C 423 A40-30-10-84 297 TA42DU42 (29 – 42)
XL Starters
15 – 40 50 A50S-84D 458 A50-30-11-84 330 TA75DU52 (36 – 52)

– 20 – – A50S-84E A50-30-11-84 TA75DU63 (45 – 63)
20 – – – A63S-84F 522 A63-30-11-84 372 TA75DU80 (60 – 80) 102
– – 50 60 A63S-84F A63-30-11-84 TA75DU80 (60 – 80)
25 30 60 75 A75S-84F 563 A75-30-11-84 413 TA75DU80 (60 – 80)
30 – – – A95S-84A 735 A95-30-11-84 450 TA110DU90 (65 – 90) 165
– 40 75 100 A110S-84B 765 A110-30-11-84 480 TA110DU110 (80 – 110)
the catalog number.
Coil voltage selection chart D.C. operated starters
Cntr Volts If DC operation is required, consult factory.
Hz
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600
60 A 81 83 84 84 34 75 80 42 86 86 51 53 55
50 A 81 83 84 80 85 86 55
AC 1000.2 – 9/99

NEMA sizes & ratings

3-phase, 1800 RPM
NEMA Catalog List Catalog List Catalog List
200V 230V 460V 575V
size number price number price number price
00 – – – 1/4 A9N00S-84C A9N00-30-10-84 TA25DU0.4 (0.25 – .4)
00 – – — 1/3 A9N00S-84D A9N00-30-10-84 TA25DU0.63 (0.4 – .63)
00 – – 1/4 1/2 A9N00S-84E A9N00-30-10-84 TA25DU1.0 (0.63 – 1.0)
00 – 1/4 1/3,1/2 — A9N00S-84F A9N00-30-10-84 TA25DU1.4 (1.0 – 1.4)
00 – 1/3 3/4 3/4 A9N00S-84G A9N00-30-10-84 TA25DU1.6 (1.3 – 1.6)
00 1/3,1/4 1/2 1 1,1.5 A9N00S-84H $ 165 A9N00-30-10-84 $ 78 TA25DU2.4 (1.7 – 2.4)
00 1/2 – 1.5 2 A9N00S-84J A9N00-30-10-84 TA25DU3.1 (2.2 – 3.1)
00 — 3/4,1 2 – A9N00S-84K A9N00-30-10-84 TA25DU4.0 (2.8 – 4.0)
00 3/4 – – – A9N00S-84L A9N00-30-10-84 TA25DU5.0 (3.5 – 5.0)
00 1 1.5 – – A9N00S-84M A9N00-30-10-84 TA25DU6.5 (4.5 – 6.5)
00 1.5 – – – A9N00S-84N A9N00-30-10-84 TA25DU8.5 (6.0 – 8.5) $ 63
0 – – 3 3 A16N0S-84L A16N0-30-10-84 TA25DU5.0 (3.5 – 5.0)
0 – – — 5 A16N0S-84M 200 A16N0-30-10-84 102 TA25DU6.5 (4.5 – 6.5)
0 2 2 5 – A16N0S-84N A16N0-30-10-84 TA25DU8.5 (6.0 – 8.5)
0 3 3 – – A16N0S-84P A16N0-30-10-84 TA25DU11 (7.5 – 11)
1 — – 7.5 7.5 A26N1S-84P A26N1-30-10-84 TA25DU11 (7.5 – 11)
1 — – 10 10 A26N1S-84Q 294 A26N1-30-10-84 183 TA25DU14 (10 – 14)
1 5 5 – – A26N1S-84R A26N1-30-10-84 TA25DU19 (13 – 19)
1 7.5 7.5 – – A26N1S-84S A26N1-30-10-84 TA25DU25 (18 – 25)
XL Starters
2 – – – 15 A50N2S-84R 458 A50N2-30-11-84 330 TA25DU19 (13 – 19)
2 – – 15 20 A50N2S-84A A50N2-30-11-84 TA75DU25 (18 – 25)
2 – 10 20 25 A50N2S-84B 458 A50N2-30-11-84 330 TA75DU32 (22 – 32)
2 10 15 25 — A50N2S-84C A50N2-30-11-84 TA75DU42 (29 – 42)
102
3 – – – 30 A75N3S-84C A75N3-30-11-84 TA75DU42 (29 – 42)
3 15 – 30 40 A75N3S-84D 563 A75N3-30-11-84 413 TA75DU52 (36 – 52)
3 20 20 40 50 A75N3S-84E A75N3-30-11-84 TA75DU63 (45 – 63)
3 25 25,30 50 – A75N3S-84F A75N3-30-11-84 TA75DU80 (60 – 80)
the catalog number.
Coil voltage selection chart
Cntr Volts
Hz
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 If DC operation is required, consult factory.
60 A 81 83 84 84 34 75 80 42 86 86 51 53 55
50 A 81 83 84 80 85 86 55
AC 1000.2 – 9/99

Non-reversing

Maximum ratings – UL Listed NEMA 1 NEMA 3R
Open type
UL (Indoor metal) ➀ (Outdoor metal)
motor
switching
current 208V 240V 480V 575/600V number price number price number price
UL rated
9 2 2 5 7.5 A9S-84★ $ 165 A9S1-84★ $ 255 A9S3-84★ $ 330
11 3 3 7.5 10 A12S-84★ 171 A12S1-84★ 285 A12S3-84★ 360
17 5 5 10 15 A16S-84★ 200 A16S1-84★ 300 A16S3-84★ 383
28 7.5 10 20 25 A26S-84★ 294 A26S1-84★ 405 A26S3-84★ 465
34 10 10 20 30 A30S-84★ 365 A30S1-84★ 473 A30S3-84★ 533
42 10 15 30 40 A40S-84★ 423 A40S1-84★ 525 A40S3-84★ 578
54 15 20 40 50 A50S-84★ 458 A50S1-84★ 600 A50S3-84★ 719
65 20 25 50 50 A63S-84★ 522 A63S1-84★ 713 A63S3-84★ 795
80 25 30 60 75 A75S-84★ 563 A75S1-84★ 975 A75S3-84★ 1058
95 30 30 60 75 A95S-84★ 735 A95S1-84★ 1140 A95S3-84★ 1485
110 30 40 75 100 A110S-84★ 765 A110S1-84★ 1170 A110S3-84★ 1515
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00S-84★ $ 165 A9NS1-84★ $ 255 A9NS3-84★ $ 330

0 18 3 3 5 5 A16N0S-84★ 200 A16NS1-84★ 300 A16NS3-84★ 383
1 27 7.5 7.5 10 10 A26N1S-84★ 294 A26NS1-84★ 405 A26NS3-84★ 465
2 45 10 15 25 25 A50N2S-84★ 458 A50NS1-84★ 600 A50NS3-84★ 719
3 90 25 30 50 50 A75N3S-84★ 563 A75NS1-84★ 975 A75NS3-84★ 1058

Hz
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95-starter: A95S-80A
AC 1000.2 – 9/99
➀ A9 - A75 starters are mounted in a NEMA 1 lift-off cover enclosure.


1.4 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
Non-reversing
NEMA 12 NEMA 4 NEMA 4X NEMA 1, 3R, 4, 4X & 12 NEMA 7 & 9 non-reversing

(Metal dustight) (Watertight) (Stainless steel) (Plastic) (Explosion proof)
UL rated
A9S2-84★ $ 330 A9S4-84★ $ 495 A9SX-84★ $ 645 A9SP-84★ $ 315 A9S7-84★ $ 1500
A12S2-84★ 360 A12S4-84★ 540 A12SX-84★ 713 A12SP-84★ 345 A12S7-84★ 1560
A16S2-84★ 383 A16S4-84★ 570 A16SX-84★ 743 A16SP-84★ 360 A16S7-84★ 1590
A26S2-84★ 465 A26S4-84★ 630 A26SX-84★ 831 A26SP-84★ 443 A26S7-84★ 1680
A30S2-84★ 533 A30S4-84★ 690 A30SX-84★ 885 A30SP-84★ 510 A30S7-84★ 2040
A40S2-84★ 578 A40S4-84★ 1050 A40SX-84★ 1275 A40SP-84★ 555 A40S7-84★ 2410
A50S2-84★ 719 A50S4-84★ 1103 A50SX-84★ 1328 A50SP-84★ 698 A50S7-84★ 2600
A63S2-84★ 795 A63S4-84★ 1170 A63SX-84★ 1410 A63SP-84★ 773 A63S7-84★ 3350
A75S2-84★ 1058 A75S4-84★ 1425 A75SX-84★ 2010 A75SP-84★ 1035 A75S7-84★ 3900
A95S2-84★ 1485 A95S4-84★ 2070 A95SX-84★ 2783 A95SP-84★ 1410 A95S7-84★ 5510
A110S2-84★ 1515 A110S4-84★ 2100 A110SX-84★ 2813 A110SP-84★ 1440 A110S7-84★ 5550
NEMA rated
XL Starters
A9NS2-84★ $ 330 A9NS4-84★ $ 495 A9NSX-84★ $ 645 A9NSP-84★ $ 315 A9NS7-84★ $ 1500
★ Overload relay suffix code. Select from the overload relay selection chart onpage 1.14.
Control transformer option Control transformer option (NEMA 7 & 9)

Contactor VA List price Contactor VA List price
size rating adder size rating adder
A9 – A40 45 1 $ 300 A9 – A16 50 $ 425

A9 – A40 50 360 A26 – A40 50 630
A50 – A75 75 435 A50 – A75 75 860
A95 – A110 100 560 A95 – A110 100 1035
required, add /50 to the end of the catalog number: Example: A9S2-8N/50
AC 1000.2 – 9/99


1.5
AXE - NEMA 7 & 9
UL rated
Open type
UL (Indoor metal)
motor Maximum motor horsepower ratings
switching
120V 230V number price number price
9 .5 1 A9SS-84★ $ 165 A9SS1-84★ $ 255

11 .75 2 A12SS-84★ 171 A12SS1-84★ 285
17 1 3 A16SS-84★ 200 A16SS1-84★ 300
28 1.5 5 A26SS-84★ 294 A26SS1-84★ 405
34 2 7.5 A30SS-84★ 372 A30SS1-84★ 473
42 3 7.5 A40SS-84★ 423 A40SS1-84★ 525
54 3 7.5 A50SS-84★ 458 A50SS1-84★ 600
65 5 10 A63SS-84★ 522 A63SS1-84★ 713
80 7.5 15 A75SS-84★ 563 A75SS1-84★ 975
95 7.5 20 A95SS-84★ 735 A95SS1-84★ 1140
110 10 25 A110SS-84★ 765 A110SS1-84★ 1170

Hz the code from the coil voltage selection chart for the first digit after the dash in
type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600
XL Starters

50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95-starter: A95SS-80A

DC ratings for switching motors
Maximum DC HP ratings (UL)
Frame Max
size current 125VDC 250VDC
A9 9.5 1 2
A12 13.2 1.5 3
A16 17 2 3
A26 25 3 5
A30 25 3 7.5
A40 40 5 10
A50 58 7.5 15
A63 76 10 20
A75 76 10 25
AC 1000.2 – 9/99

1.6 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
UL rated

A9SS3-84★ $ 330 A9SS2-84★ $ 330 A9SS4-84★ $ 495 A9SSX-84★ $ 645 A9SSP-84★ $ 315

size rating adder
XL Starters
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9SS3-8N/50
AC 1000.2 – 9/99


1.7
AXE - NEMA 7 & 9
Reversing

Open type
(Indoor metal)
UL
motor Catalog List Catalog List
switching 208V 240V 480V 575/600V number price number price
current
UL rated
9 2 2 5 7.5 A9SR-84★ $ 342 A9SR1-84★ $ 510
11 3 3 7.5 10 A12SR-84★ 387 A12SR1-84★ 585
17 5 5 10 15 A16SR-84★ 443 A16SR1-84★ 630
28 7.5 10 20 25 A26SR-84★ 503 A26SR1-84★ 810
34 10 10 20 30 A30SR-84★ 675 A30SR1-84★ 953
42 10 15 30 40 A40SR-84★ 765 A40SR1-84★ 1080
54 15 20 40 50 A50SR-84★ 1152 A50SR1-84★ 1395
65 20 25 50 50 A63SR-84★ 1515 A63SR1-84★ 1560
80 25 30 60 75 A75SR-84★ 1620 A75SR1-84★ 1905
95 30 30 60 75 A95SR-84★ 1697 A95SR1-84★ 2767
110 30 40 75 100 A110SR-84★ 1800 A110SR1-84★ 2970
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00SR-84★ $ 342 A9NSR1-84★ $ 510

0 18 3 3 5 5 A16N0SR-84★ 443 A16NSR1-84★ 630
1 27 7.5 7.5 10 10 A26N1SR-84★ 503 A26NSR1-84★ 810
2 45 10 15 25 25 A50N2SR-84★ 1152 A50NSR1-84★ 1395
3 90 25 30 50 50 A75N3SR-84★ 1620 A75NSR1-84★ 1905

Hz
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A95 reversing starter: A95SR-80B

AC 1000.2 – 9/99

1.8 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
Reversing

UL rated
A9SR3-84★ $ 630 A9SR2-84★ $ 630 A9SR4-84★ $ 810 A9SRX-84★ $ 1125 A9SRP-84★ $ 608
NEMA rated
XL Starters
A9NSR3-84★ $ 630 A9NSR2-84★ $ 630 A9NSR4-84★ $ 810 A9NSRX-84★ $ 1125 A9NSRP-84★ $ 608

size rating adder
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9SR3-8N/50
AC 1000.2 – 9/99


1.9
AXE - NEMA 7 & 9
2 Speed, 1 winding

Open type
(Indoor metal)
UL
motor
switching Catalog List Catalog List
208V 240V 480V 575/600V
current number price number price
UL rated
9 2 2 5 7.5 A9ST-84★1★ $ 504 A9ST1-84★1★ $ 690
11 3 3 7.5 10 A12ST-84★1★ 525 A12ST1-84★1★ 771
17 5 5 10 15 A16ST-84★1★ 581 A16ST1-84★1★ 837
28 7.5 10 20 25 A26ST-84★1★ 752 A26ST1-84★1★ 1097
34 10 10 20 30 A30ST-84★1★ 1038 A30ST1-84★1★ 1316
42 10 15 30 40 A40ST-84★1★ 1259 A40ST1-84★1★ 1577
54 15 20 40 50 A50ST-84★1★ 1697 A50ST1-84★1★ 1940
65 20 25 50 50 A63ST-84★1★ 2150 A63ST1-84★1★ 2195
80 25 30 60 75 A75ST-84★1★ 2307 A75ST1-84★1★ 2592
95 30 30 60 75 A95ST-84★1★ 2495 A95ST1-84★1★ 2950
110 30 40 75 100 A110ST-84★1★ 2681 A110ST1-84★1★ 3851
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00ST-84★1★ $ 504 A9NST1-84★1★ $ 690

0 18 3 3 5 5 A16N0ST-84★1★ 581 A16NST1-84★1★ 837
1 27 7.5 7.5 10 10 A26N1ST-84★1★ 752 A26NST1-84★1★ 1097
2 45 10 15 25 25 A50N2ST-84★1★ 1697 A50NST1-84★1★ 1940
3 90 25 30 50 50 A75N3ST-84★1★ 2307 A75NST1-84★1★ 2589

Hz

AC 1000.2 – 9/99

1.10 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
2 Speed, 1 winding

UL rated
NEMA rated
XL Starters

size rating adder
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9ST-8A1A/50
AC 1000.2 – 9/99


1.11
AXE - NEMA 7 & 9
2 Speed, 2 winding

Open type
UL (Indoor metal)
motor
switching
208V 240V 480V 575/600V
AC3 UL rated
9 2 2 5 7.5 A9ST-84★2★ $ 396 A9ST1-84★2★ $ 582
11 3 3 7.5 10 A12ST-84★2★ 426 A12ST1-84★2★ 657
17 5 5 10 15 A16ST-84★2★ 476 A16ST1-84★2★ 702
28 7.5 10 20 25 A26ST-84★2★ 552 A26ST1-84★2★ 882
34 10 10 20 30 A30ST-84★2★ 747 A30ST1-84★2★ 1025
42 10 15 30 40 A40ST-84★2★ 834 A40ST1-84★2★ 1152
54 15 20 40 50 A50ST-84★2★ 1224 A50ST1-84★2★ 1467
65 20 25 50 50 A63ST-84★2★ 1587 A63ST1-84★2★ 1632
80 25 30 60 75 A75ST-84★2★ 1692 A75ST1-84★2★ 1977
95 30 30 60 75 A95ST-84★2★ 1795 A95ST1-84★2★ 2450
110 30 40 75 100 A110ST-84★2★ 1872 A110ST1-84★2★ 3042
NEMA rated
NEMA Continuous
size current
XL Starters
00 9 1.5 1.5 2 2 A9N00ST-84★2★ $ 396 A9NST1-84★2★ $ 582

0 18 3 3 5 5 A16N0ST-84★2★ 476 A16NST1-84★2★ 702
1 27 7.5 7.5 10 10 A26N1ST-84★2★ 552 A26NST1-84★2★ 882
2 45 10 15 25 25 A50N2ST-84★2★ 1224 A50NST1-84★2★ 1467
3 90 25 30 50 50 A75N3ST-84★2★ 1692 A75NST1-84★2★ 1977

Hz
Description D.C. operated starters

Motors that have separate windings for each speed provide more If DC operation is required, consult factory.
combinations of speed variations. Multi-speed starters from ABB Control are
available for constant horsepower, constant torque and variable torque
motors.
Constant horsepower
Motors that maintain the same horsepower regardless of speed are
called constant horsepower motors. These motors are used in
applications like metal working.
Constant torque
Motors that maintain constant torque at all speeds are called constant
torque motors. In applications like conveyors, horsepower varies directly
with speed.
Variable torque motors

Motors that produce a torque characteristic which varies as the square of
the speed are called variable torque motors and are used in applications
like blowers and fans.
AC 1000.2 – 9/99

1.12 AAE - NEMA 1, 3R, 12, 4, 4X, 12
AXE - NEMA 7 & 9
2 Speed, 2 winding

Number Price Number Price Number Price Number Price Number Price
UL rated
NEMA rated
XL Starters

size rating adder
A9 – A40 45 1 $ 300
A9 – A40 50 360
A50 – A75 75 435
A95 – A110 100 560
required, add /50 to the end of the catalog number: Example: A9ST3-8A2A/50
AC 1000.2 – 9/99


1.13
AXE - NEMA 7 & 9
3 pole, open & enclosed

Catalog Catalog List Catalog List
List
number number price number price
208V 240V 480V 575V/600V price
with blank cover with reset only with start & stop/reset
2 2 5 7.5 A9SD-84★ $ 233 A9SD-84★R $ 240 A9SD-84★A $ 278

3 3 7.5 10 A12SD-84★ 248 A12SD-84★R 255 A12SD-84★A 293
5 5 10 15 A16SD-84★ 278 A16SD-84★R 293 A16SD-84★A 330
★ Overload Relay suffix code. Select from the overload relay selection chart on back cover fold out page.
Overload relay selection chart

For Current Starter
Catalog
contactor range suffix
number
sizes (motor fla) code
0.1 – 0.16 TA25DU0.16 A

0.16 – 0.25 TA25DU0.25 B
0.25 – 0.4 TA25DU0.4 C
A9
0.4 – 0.63 TA25DU0.63 D

0.63 – 1.0 TA25DU1.0 E
1.0 – 1.4 TA25DU1.4 F
A12
1.4 – 1.8 TA25DU1.8 G

1.7 – 2.4 TA25DU2.4 H
A16
XL Starters
2.2 – 3.1 TA25DU3.1 J

2.8 – 4.0 TA25DU4.0 K
3.5 – 5.0 TA25DU5.0 L A9SD-84EA
4.5 – 6.5 TA25DU6.5 M
6.0 – 8.5 TA25DU8.5 N
7.5 – 11 TA25DU11 P
10 – 14 TA25DU14 Q
13 – 19 TA25DU19 R

Hz
50 A 81 83 84 80 85 86 55 Ex.: A 240V coil is required for an A9 starter: A9SD-80E

AC 1000.2 – 9/99
Enclosed
1.14 Discount schedule AAE ABB Control Inc.
UL & CSA Technical data
ABB contactor frame size A9 A12 A16 A26 A30 A40 A45 A50 A63 A75 A95 A110
NEMA size 00 — 0 1 1P — — 2 — 3 — —
A.C. rating information

NEMA cont. amp rating (thermal current) 9 — 18 27 36 — — 45 — 90 — —
NEMA maximum H.P ratings (1 phase)
115VAC 1/3 .75 1 2 3 — — 3 — — — —
230VAC 2 2 3 3 7.5 — — 10 — — — —
NEMA maximum H.P. ratings (3 phase)
200VAC 1.5 — 3 7.5 — — — 10 — 25 — —
230VAC 1.5 — 3 7.5 — — — 15 — 30 — —
460/575VAC 2 — 5 10 — — — 25 — 50 — —
U.L. general purpose current (40°C) A 21 25 30 40 50 60 65 80 90 105 125 140
U.L. max 3 Ph. switching motor loads A 9 11 17 28 34 42 — 54 65 80 95 110
115 VAC 1/2 3/4 1 2 3 3 — 3 5 7.5 7.5 10
230 VAC 2 2 3 5 7.5 7.5 — 7.5 10 15 20 25
200 – 208 VAC 2 3 5 7.5 10 10 — 15 20 25 30 30
220 – 240 VAC 2 3 5 10 10 15 — 20 25 30 30 40
440 – 480 VAC 5 7.5 10 20 20 30 — 40 50 60 60 75
550 – 600 VAC 7.5 10 15 25 30 40 — 50 60 75 75 100
Lighting-ballast and incand., 600 VAC 15 15 20 35 50 60 65 65 85 105 — —
XL Starters
Resistive heating applications, 600 VAC 15 15 20 35 50 60 65 65 85 105 — —
Auxiliary contacts
NEMA rating, AC A600 A600 A600 A600 A600 A600 — A600 A600 A600 A600 A600
AC rated voltage, VAC 600 600 600 600 600 600 — 600 600 600 600 600
AC thermal rated current, A 10 10 10 10 10 10 — 10 10 10 10 10
AC maximum volt-ampere making, VA 7200 7200 7200 7200 7200 7200 — 7200 7200 7200 7200 7200
AC maximum volt-ampere breaking, VA 720 720 720 720 720 720 — 720 720 720 720 720
NEMA rating, DC P600 P600 P600 P300 P300 P300 — P300 P300 P300 P300 P300
DC rated voltage, VDC 600 600 600 600 600 600 — 600 600 600 600 600
DC thermal rated current A 5 5 5 5 5 5 — 5 5 5 5 5
DC maximum make-break A 0.2 0.2 0.2 0.2 0.2 0.2 — 0.2 0.2 0.2 0.2 0.2
Approximate weight
Contactor Lbs. 0.7 0.7 0.7 1.01 1.2 2.25 2.25 2.25 2.25 2.25 3.5 5
Starter Lbs. 1.04 1.04 1.04 1.35 1.54 3 — 3 3 3 6 7
Wire range AWG 18 – 10 18 – 10 18 – 10 12 – 8 8–4 8–4 8–1 8–1 8–1 8–1 6 – 2/0 6 – 2/0
Number of wires per phase 2 2 2 2 2 2 1 1 1 1 1 1
Tightening torque, lb. in. 9 9 9 15 20 20 40 40 40 40 50 50
Maximum short circuit ratings, UL/CSA
MCCB/MCP Amps/kA @ 480V 50/35 50/35 50/35 100/35 150/65 150/65 150/85 150/85 250/85 250/85 250/85 250/85
MCCB/MCP Amps/kA @ 600V 10/35 10/35 – 100/35 150/25 150/25 – – – – 250/35 250/35
Fuse Amps, Type/kA @ 600V 30J/200 30J/200 30J/200 60J/200 60J/200 100J/200 100J/200 100J/200 200J/200 200J/200 200J/200 200J/200
AC 1000.2 – 9/99

IEC Technical data
Type A9 A12 A16 A26 A30 A40 A45 A50 A63 A75 A95 A110
Insulation characteristics
Rated insulation voltage Ui
according to IEC947-4-1 and VDE0110 (Gr. C) V 1000
according to UL/ CSA V 600
Rated impulse withstand voltage Uimp. 8 kV
Main pole utilization characteristics

Rated operational voltage Ue V 690 690 1000 1000
Conventional free-air thermal current Ith
acc. to IEC947-4-1, open contactors θ ≤ 40°C A 26 28 30 45 65 65 100 100 125 125 145 160
2
with conductor cross-sectional area mm 4 4 4 6 16 16 35 35 50 50 50 70
Rated operational current I e /AC-1 for air temperature
close to contactor
with conductor cross sectional area

{ θ ≤ 40°C
θ ≤ 55°C
θ ≤ 70°C
A
A
A
mm2
25
22
18
2.5
27
25
20
4
30
27
21
4
45
40
32
6
55
55
39
10
60
60
42
16
70
60
50
25
100
85
70
35
115
95
80
50
125
105
85
50
145
135
115
50
160
145
130
70
Utilization category AC-3 for air temperature
close to contactor ≤ 55°C
Rated operational current Ie / AC-3 (1)
XL Starters
220-230-240 V A 9 12 17 26 33 40 40 53 65 75 96 110
380-400 V A 9 12 17 26 32 37 37 50 65 75 96 110
415 V A 9 12 17 26 32 37 37 50 65 72 96 110
3-phase Motors M 440 V A 9 12 16 26 32 37 37 45 65 70 93 100
3 500 V A 9 12 14 22 28 33 33 45 55 65 80 100
690 V A 7 9 10 17 21 25 25 35 43 46 65 82
1000 V A — — — — — — — 23 25 28 30 30
Rated operational power AC- 3 (1)
220-230-240 V kW 2.2 3 4 6.5 9 11 11 15 18.5 22 25 30
1500 r.p.m. - 50 Hz 380-400 V kW 4 5.5 7.5 11 15 18.5 18.5 22 30 37 45 55
1800 r.p.m. - 60 Hz 415 V kW 4 5.5 9 11 15 18.5 18.5 25 37 40 55 59
3-phase Motors M 440 V kW 4 5.5 9 15 18.5 22 22 25 37 40 55 59
500 V kW 5.5 7.5 9 15 18.5 22 22 30 37 45 55 59
3 690 V kW 5.5 7.5 9 15 18.5 22 22 30 37 40 55 75
1000 V kW — — — — — — — 30 33 37 40 40
Rated frequency limits Hz 25 – 400
Mechanical durability in millions of operating cycles 10 10
Max. mechanical switching frequency cycles/h 3600 3600
Max. electrical switching for AC-1 cycles/h 600 600 600 600 600 600 600 600 600 600 300 300
frequency for AC-3 cycles/h 1200 1200 1200 1200 1200 1200 600 600 600 600 300 300
for AC-2, AC-4 cycles/h 300 300 300 300 300 300 150 150 150 150 150 150
Rated making capacity AC- 3 according to IEC947-4-1 10 x Ie AC-3 12 x Ie AC-3
Rated breaking capacity AC- 3 according to IEC947-4-1 8 x Ie AC-3 8 x Ie AC-3
Max. breaking capacity cos ϕ = 0.45 at 440 V A 250 250 250 420 820 820 900 900 900 900 1160 1160
(cos ϕ = 0.35 for Ie > 100 A) at 690 V A 100 100 100 170 340 340 490 490 490 490 800 800
Short-circuit protection for contactors
without thermal O/L relays - Motor protection excluded1
Ue ≤ 500 V a.c. – gG (gl) type fuses A 25 32 32 50 63 63 80 100 125 160 160 200
Rated short-time withstand current Icw 1s A 250 280 300 400 600 600 1000 1000 1000 1000 1320 1320
at 40°C ambient temp., in free air, 10 s A 100 120 140 210 400 400 650 650 650 650 800 800
from a cold state 30 s A 60 70 80 110 225 225 370 370 370 370 500 500
1 min A 50 55 60 90 150 150 250 250 250 250 350 350
15 min A 26 28 30 45 65 65 100 100 100 100 160 175
Heat dissipation per pole Ie /AC-1 0.8 1 1.2 1.8 2.5 3 2.5 5 6.5 7 6.5 7.5
Ie /AC-3 W 0.1 0.2 0.35 0.6 0.9 1.3 0.65 1.3 1.5 2 2.7 3.6
AC 1000.2 – 9/99
1 Please consult us for the protection of motor starters against short circuits.

00.00
00.00
Inches
Millimeters
A9 – A16
A9 – A16 + TA25 — Starter, 3 pole, AC operated
2.91
74
2.68
68
1.73 0.22 1.38

5.5 35
44
2.91 2.36 1.97

74 60 50
3.46
88
5.26
133.5
0.18
4.5
RESET
0.14
3.5
0.24
6
3.74
95
A9 – 16 + VM5 or VE5 + TA25 — Reversing starter, 3 pole, AC operated

2.91
XL Starters
74
5.50 2.68
139.7 68
4.06 0.22 1.38 2.32

103 5.5 35 59
2.91 2.36 1.97

74 60 50
3.46
88
5.26
133.5
0.18
4.5
RESET
0.14
3.5
0.24
6
3.74
95
A9 – 16 — 2 speed, 1 winding, 3 pole, AC operated
2.91
74
2.68
68
7.00 0.22
177.8 5.5
2.36 1.97
60 50
3.46
5.00 88
127.0
0.18
4.5
RESET RESET
0.24
6
0.14
3.74 3.5
95
AC 1000.2 – 9/99

A9-16 to A26 00.00
00.00
Inches
Millimeters
A9 – 16 — 2 speed, 2 winding
5.50
139.7
4.85 2.91 4.23
74 107.4
123.2
2.68
68
0.22
5.5
4.63
117.6
2.36 1.97
60 50
6.67 3.46
169.4 88
0.18
4.5
RESET RESET
0.24
6
3.74 0.14
3.5
95
XL Starters
A26 + TA25 — Starter
3.69
93.6
3.44
87.3
2.13 0.35 1.77
54 9 45
3.54 2.76 3.15

90 70 80
4.10
104.2
5.79
147
0.17
4.2
RESET
0.53
13.5
0.24
6
4.31
109.5
A26 + VM5 or VE5 + TA25 — Reversing starter

4.03
102
3.69
93.6
3.44 4.64
5.25 117.9
133.4 87.3
4.84 0.35 0.22
9 2.32 5.5
123.0 59
5.25
133.4
4.64
3.54 117.9 2.76 3.15
6.87 90 70 80
174.5 4.10
104.2
5.79
147
AC 1000.2 – 9/99
0.17
RESET 4.2
0.52
0.24 13.5
6
XL STARTERS: Selection: 1.2 – 1.14 4.31
Technical data: 1.15 – 1.16 1.77 – 1.28
Approximate dimension: 1.17 2.72 General wiring diagrams: 1.29 - 1.30
109.5 45 69

00.00
00.00
Inches
Millimeters
A26 to A30 & A40
4.03
102
3.69
93.6
3.44
7.87 87.3
200.0 0.35 3.94 0.22
9 100.0 5.5
4.64
6.87 3.54 117.9 2.76 3.15
174.5 90 70 80
4.10
104.2
5.79
147
0.17
RESET RESET 4.2
0.52
0.24 13.5
6
4.31 1.77 2.72
109.5 45 69
7.25
184.1
XL Starters
4.03
102
3.69
93.6
3.44 4.64
87.3 117.9
5.25
133.0 0.35 0.22
9 2.32 5.5
59
4.64
6.95 3.54 117.9 2.76 3.15
176.5 90 70 80
4.10
104.2
5.79
147
RESET 0.17 RESET

4.2
0.52
0.24 13.5
6
4.31 1.77 2.72
109.5 45 69
A30 & A40 + TA25 — Starter
4.26
108.3
4.02
102
2.13 0.35 1.77
54 9 45
3.54 2.76 3.15

90 70 80
4.20
106.7
5.87
6.44 149
163.5
TA25DU32 0.17
ONLY 4.2
RESET
0.35
8.8
AC 1000.2 – 9/99
0.24
6
4.08
104

A30 – A(E)40 00.00
00.00
Inches
Millimeters
A30 & A40 + TA42 — Starter, 3 pole, AC operated

4.26
108.3
4.02
102
2.13 0.35 1.77
54 9 45
3.54 2.76 3.15

90 70 80
4.09
104
6.08
154.5
0.17
4.2
RESET
0.33
8.3
0.24
6
4.43
112.5
XL Starters
4.60
117 4.64
5.25 117.9
133.4 4.26
108.3
4.84 2.32 0.22
123.0
4.02 59 5.5
102
0.35
9
5.25
133.4 4.64
3.54 117.9 2.76 3.15 4.20
90 70 80 106.7
7.25
191 5.87
6.44 149
163.5
TA25DU32
ONLY
RESET 0.17
4.2
0.35
8.8
0.24
6
4.08 1.77 2.72
104 45 69
4.60
117 4.64
5.25 117.9
133.4 4.26
108.3
4.84 2.32 0.22
123 4.02 59 5.5
102
0.35
9
5.25 4.64
133.4 3.54 117.9 2.76 3.15 4.09
90 70 80 104
6.08
154.5
RESET 0.17
4.2
0.33
8.3
AC 1000.2 – 9/99
1.77 2.72
45 69

00.00
00.00
Inches
Millimeters
A(E)30 – A(E)40 to A50 – A75
4.60
117
4.26
7.87 108.3
3.94 0.22
200.0 4.02 100.0 5.5
102
0.35
9
5.25
133.4 4.64
3.54 117.9 2.76 3.15
90 70 80
4.10
104.2
7.25 5.87
191 6.44 149
163.5
TA25DU32
ONLY
0.17
RESET RESET 4.2
0.52
13.5
0.24 1.77 2.72

45 69
6
4.08 7.25
104 184.1
XL Starters
4.90
150
4.60
117 4.64
5.25 4.26 117.9
133.3 108.3 0.22

2.32
4.02 59 5.5
102
0.35
9
5.25
133.4 4.64
3.54 117.9 2.76 3.15 4.20
90 70 80 106.7
7.25 5.87
191 6.44 149
163.5
TA25DU32
ONLY
RESET RESET
0.17
4.2
0.35
8.8
0.24
6 1.77
4.08 2.72
45 69
104
A(E)50 – A(E)75 + TA75 — Starter, 3 pole, AC & DC operated
4.25
108
4.00
101.5
2.76 0.39 2.36

10
70 60
4.33 3.94 3.54 4.88

100 90
110 124
6.93
176
0.24
6.2
RESET
0.62
15.8
AC 1000.2 – 9/99
0.24
6
4.45
113

A(E)50 – A(E)75 00.00
00.00
Inches
Millimeters
A(E)50 – A(E)75 + VM5 or VE5 + TA75 — Reversing starter, 3 pole, AC & DC operated
4.54
115.3
6.62 4.25 6.00
168.2 152.5
108
6.10 4.00 3.00 0.22
155 101.5 5.5
76.3
0.39
10
3.54
6.50 90
165 4.33 5.87 3.94 4.88
110 149 100 124
8.25 6.93
209.5 176
RESET 0.24
6.2
0.24
XL Starters
6 0.62
15.8
4.45
113 2.36 3.35
60 85

5.58
142.0
4.54
115.3
10.12 4.25
257.0 108
9.62 4.00 4.81 0.22
244.3 101.5 122.0 5.5
0.39
10
4.33 3.54
6.50 90
165 110 5.87 3.94 4.88
149 100 124
8.25 6.93
209.5 176
RESET RESET 0.24

6.2
0.24
6 0.62
15.8
4.45
113 2.36 3.35
60 85
9.00
228.6

4.54
115.3
6.82 6.00
4.25 152.5
173 108
6.62 4.00 3.00 0.22
168 101.5 76.3 5.5
0.39
10
4.33 3.54
6.50 90
165 110 5.87 3.94
149 100
8.25 6.93 4.88
124
209 176
AC 1000.2 – 9/99
RESET RESET
0.24 0.62
6 15.8
4.45
113 2.36 3.35 General wiring diagrams: 1.29 - 1.30
XL STARTERS: Selection: 1.2 – 1.14 Technical data: 1.15 – 1.16 Approximate dimension: 1.17 – 1.2860
85

00.00
00.00
Inches
Millimeters
A(E)95 & A(E)110
4.86
123.5
4.61
117
3.54 0.39 3.07
90 10 78
5.35
136
4.96
126 6.38
162
8.43
214
0.24
6.2
RESET
1.00
25.4
0.24
6
4.49
114
XL Starters
4.86
123.5
4.61
117
3.54 0.39 3.07
90 10 78
5.35
136
4.96
126 6.93
176
10.16
258
0.24
6.2
RESET
0.98
25
0.24
6
5.16
131
7.91
8.70 5.17 200.1
221 131 3.90
7.68 4.86 99 0.31
195 123.5 8
0.39
10
8.10 4.96
205.7 4.33 126
148 7.28 5.35
185 136
9.97 6.38
248 8.43 162
214
AC 1000.2 – 9/99
RESET 0.24
6.2
0.98
25
0.24
6
4.49 3.07 4.10
114 78 104
A(E)95 & A(E)110 00.00
00.00
Inches
Millimeters
8.70 5.17 7.91
221 131 200.1
7.68 4.86 0.31
3.90 8
195 123.5 99
0.39
10
8.10
205.7 4.96
4.33 126
148 7.28 5.35
185 136
6.93
11.45 176
290 10.16
258
0.24
RESET 6.2
0.98
25
0.24
6
5.16 3.07 4.13
131 78 105
XL Starters

5.17 12.06
12.85 306.3
326.3
131.3 0.31
7.8
4.86
123.5
8.10 7.28
205.7 185.0
9.79 3.70
248.6 94.0
0.33
8.3
RESET RESET
BUTTON BUTTON
0.24 4.13
6.0 105.0
2.38 4.40
60.4 111.7
12.06
12.85 5.17 306.3
326.3 131.3
0.31
7.8
4.86
123.5
8.10 7.28
205.7 185.0
11.45 4.13
290.8 105.0
0.83
21.0
RESET RESET
BUTTON BUTTON
0.24 4.73 0.07

AC 1000.2 – 9/99
2.38 4.40
6.0 120.1 1.7
60.4 111.7

00.00
00.00
Inches
Millimeters
A(E)95 & A(E)110
8.70 5.17 7.91

221.0 131.3 200.1 0.31
7.8
4.86
123.5
8.10
205.7 7.28
185.0
9.79 10.0
248.6 254.0
3.70
94.0
0.33
8.3
RESET RESET
BUTTON BUTTON
0.24 4.13 2.38 4.40
XL Starters
6.0 105.0 60.4 111.7
8.70 5.17 7.91

221.0 131.3 200.1
0.31
7.8
4.86
123.5
8.10
205.7 7.28
185.0
10.0
11.45 254.0
290.8
4.13
105.0
0.83
21.0
RESET RESET
BUTTON BUTTON
0.24 4.73 0.07

6.0 2.38 4.40
120.1 1.7 60.4 111.7
AC 1000.2 – 9/99

Full voltage, across the line & reversing 00.00
00.00
Inches
Millimeters
B C
A
XL Starters
Across the line Reversing

A9 – A40 1 12 7 6 A9 – A40 1 12 10 6
3R 10 8 6 3R 12 10 6
12 10 8 6 12 14 12 8
A50 – A75 1 13 9 7 A50 – A75 1 14 12 8
3R 14 12 8 3R 14 12 8
12 14 12 8 12 14 12 8
A95 & A110 1 20 16 8 A95 & A110 1 20 16 8
3R 20 20 8 3R 20 20 8
12 20 16 8 12 20 16 8
AC 1000.2 – 9/99

00.00
00.00
Inches
Millimeters
Full voltage, multi-speed
B C
XL Starters
2 Speed, 1 winding w/CCT 2 Speed, 2 winding w/CCT
A9 – A40 1 14 12 8 A9 – A40 1 12 10 6
3R 14 12 8 3R 12 10 6
12 14 12 8 12 14 12 8
A50 – A75 1 20 16 8 A50 – A75 1 14 12 8
3R 20 16 8 3R 14 12 8
12 20 16 8 12 14 12 8
A95 & A110 1 20 16 8 A95 & A110 1 20 16 8
3R 20 20 8 3R 20 20 8
12 20 16 8 12 20 16 8
AC 1000.2 – 9/99

Wiring diagram
00.00 Inches
00.00 Millimeters
2X 0.25
2X M5
7.00
178.0
6.30
160.0
3.54 4.84 0.28

90.0 123.0 0.7
5.12
130.0
XL Starters

INCOMING LINES CONTROL OPTION 1, W/CCT
TO CONTACTOR
1
L1 L2
L1 L3
2
SHOP TO CONNECT PER
VOLTAGE SPECIFIED
CIRCUIT CHFU 1 CHFU 2
PROTECTIVE DEVICE H1 H2 H3 H4
(IF SPECIFIED) CHFU NOT REQUIRED
FOR 45VA CCT
CCT
CXFU
TO CONTROL XF
CIRCUIT OPTION 1
1 0R 2 AS SPECIFIED.
C OL
L1 L2 L3 C
13 14 A1 A2 95 96
C CONTROL OPTION 2, W/O CCT &

COIL VOLTAGE GREATER THAN 120V
TO CONTACTOR
L1 L3
OL
XF C OL
T1 T2 T3 C
13 14 A1 A2 95 96
CONNECTION MADE
ONLY WHEN PILOT
MOTOR DEVICES ARE SPECIFIED.
1PH
CONTROL OPTION 3, COIL VOLTAGE 120V OR LESS
CUSTOMER SUPPLIED
CONTROL VOLTAGE
XF C OL
C
13 14 A1 A2 95 96
NOTES
CCT- CONTROL CIRCUIT TRANSFORMER 1. COLOR OF CONTROL WIRE SHALL BE

PER VOLTAGE OF CONTACTOR COILS:
CHFU- CCT PRIMARY FUSE
CXFU- CCT SECONDARY FUSE RED - ALL AC VOLTAGES
WHITE MAY BE USED ON THE
XF- CONTROL POWER CONNECTON POINT GROUNDED SIDE OF THE AC
C- CONTACTOR CIRCUIT IF SPECIFIED.
CT- CURRENT TRANSFORMER BLUE - ALL DC VOLTAGES
OL- OVERLOAD RELAY
13- CONNECTION POINT ON DEVICE W/NUMBER 2. ALL DEVICES ARE SHOWN DE-ENERGIZED.
3. DO NOT USE SELECTOR SWITCHES WITH
AUTO-RESET OVERLOAD RELAYS
AC 1000.2 – 9/99

00.00 Inches
00.00 Millimeters
Non-reversing, A9 – A110

A B C
Connect if
CHFU CHFU CCT not specified
Circuit 1 and coil voltage
H1 H3 H2 H4
Protective Device CCT greater than
(if specified) (if specified) 120V.
CXFU X1 X2 Connect if
XF
1 CCT specified
White wire
L1 L2 L3 C OL if specified
13 14 A1
C A2 95 96
OL
Notes
T1 T2 T3
Legend be per Voltage of Contactor Coils:
XL Starters
RED - All AC Voltages
CCT- Control Circuit Transformer White may be used on the
Grounded Side of the AC
CXFU- CCT Secondary Fuse BLUE - All DC Voltages
CT- Current Transfer 2. All Devices are shown De-Energized.
XF- Control Power Connection Point 3. DO NOT Use Selector Switches with
Auto-Reset Overload Relays
C- Contactor
OL- Overload Relay
13- Connection Point on Device with Number

NON-REVERSING, A9 - A110
Reversing, A9 – A110
Connect per voltage specified

Incoming Lines
Connect If
A B C CHFU CHFU
CCT not specified
1 and coli voltage
H1 H3 H2 H4
Circuit CCT greater than
Protective Device (if specified)
(if specified) 120V.
CXFU OL
X1 X2
XF 96 95
1
F R
L1 L2 L3 L1 L2 L3 13 14 22 21 A1 F A2
(32) (31) B50-B75
A95-A110
F R R F
13 14 22 21 A1 R A2
(43) (44) B50-B75
T1 T2 T3 T1 T2 T3 A95-A110
OL Notes
T1 T2 T3 be per Voltage of Contactor Coils:
Legend RED - All AC Voltages
White may be used on the
CCT- Control Circuit Transformer Grounded Side of the AC
BLUE - All DC Voltages
CXFU- CCT Secondary Fuse
2. All Devices are shown De-Energized.
CT- Current Transfer
3. DO NOT Use Selector Switches with
AC 1000.2 – 9/99
XF- Control Power Connection Point Auto-Reset Overload Relays
C- Contactor
OL- Overload Relay
XL STARTERS: 13-
Selection: Connection
1.2 – 1.14 Point on Device with Number
Technical data: 1.15 – 1.16 Approximate dimension: 1.17 – REVERSING,
1.28 General wiring diagrams: 1.29 - 1.30
A9 - A110

00.00 Inches
00.00 Millimeters
2 Speed, one winding — constant or variable torque, selective control

A9 – A110

Relay
( CR-TR) (TR) is Specified,
CHFU CHFU
Circuit Circuit
Add Timed Contact
Protective Device Protective Device H1 H3 1 H2 H4 in Series with 'S' Coil
(if specified) (if specified) CCT where shown.
(if specified)
CXFU FOL SOL
X1 X2
XF 96 95 96 95 TR
65 66
L1 L2 L3 L1 L2 L3 L1 L2 L3
S 1F
A1
S A2
13 14 21 22
2F S 1F (31) (32)
Mech. Intlk.
T1 T2 T3
A1
1F A2
FOL SOL
T1 T2 T3 T1 T2 T3 2F S 1F TR
A1
2F A2
13 14 21 22 13 14
(61) (62) (43) (44)
T6 T4 T5 T1 T2 T3
CR-TR
To 2-Speed,1-Winding Motor A1 A2
XL Starters
Legend
Notes CCT- Control Circuit Transformer
1. Color of 14 Ga. Control Wire shall CHFU- CCT Primary Fuse
be per Voltage of Contactor Coils: CXFU- CCT Secondary Fuse
RED - All AC Voltages CT- Current Transfer
White may be used on the XF- Control Power Connection Point
Grounded Side of the AC 1F- Shorting Contactor
Circuit if specified. 2F- Fast Speed Contactor
BLUE - All DC Voltages S- Slow Speed Contactor
FOL- Fast Speed Overload Relay
2. All Devices are shown De-Energized. SOL- Slow Speed Overload Relay
3. DO NOT Use Selector Switches with CR-TR- Optional Deceleration Timing Relay, Mtd on CR ( A95-A110; EH145-800 )
Auto-Reset Overload Relays TR- Optional Deceleration Timing Relay, Mtd on 2F ( B9-75 )
2 Speed, two winding

A9 – A110

Relay
CHFU CHFU ( CR-TR) (TR) is Specified,
Circuit Circuit 1 Add Timed Contact
Protective Device Protective Device H1 H3 H2 H4
(if specified) (if specified) CCT in Series with 'S' Coil
(IF SPECIFIED)
where shown.
CXFU FOL SOL
X1 X2
XF 96 95 96 95 TR
65 66
L1 L2 L3 L1 L2 L3
S F
A1
S A2
13 14 21 22
S F
F S TR
FOL 13 14 21 22 A1 F A2
SOL T1 T2 T3 T1 T2 T3 CR-TR
A1 A2
T1 T2 T3 T11 T12 T13

Notes
To 2-Speed,2-Winding Motor
1. Color of 14 Ga. Control Wire shall Legend
be per Voltage of Contactor Coils:
RED - All AC Voltages CCT- Control Circuit Transformer
White may be used on the CHFU- CCT Primary Fuse
Grounded Side of the AC CXFU- CCT Secondary Fuse
Circuit if specified. CT- Current Transfer
BLUE - All DC Voltages XF- Control Power Connection Point
1F- Shorting Contactor
2. All Devices are shown De-Energized. 2F- Fast Speed Contactor
S- Slow Speed Contactor
3. DO NOT Use Selector Switches with FOL- Fast Speed Overload Relay
Auto-Reset Overload Relays SOL- Slow Speed Overload Relay
AC 1000.2 – 9/99
CR-TR- Optional Deceleration Timing Relay, Mtd on CR ( A95-A110; EH80-800 )

TR- Optional Deceleration Timing Relay, Mtd on 2F ( B9-75 )


PROTECTION
Features/Benefits
UL witnessed tests
shutdowns
Indicator
➤ Transformers
500VDC, 100kA I.R. No. 248.8
➤ IEC 269-2-1
AJT (70-600) EI:
➤ UL Component
Recognized
➤ DC Tested to UL
Standard 198L
A2

1
1-1/4
1-1/2
AJT1
AJT1-1/4
AJT1-1/2
4-1/2
5
5-6/10
AJT4-1/2
AJT5
AJT5-6/10
25
30
35
AJT25
AJT30
AJT35
125
150
175
AJT125
AJT150
AJT175
Fuse
Ampere
Catalog Number
600V OR LESS
A
2-1/4 AJT2-1/4 8 AJT8 60 AJT60 300 AJT300 61-100 61036J 61038J
2-1/2 AJT2-1/2 9 AJT9 70 AJT70 350 AJT350 101-200 62001J 62003J
2-8/10 AJT2-8/10 10 AJT10 80 AJT80 400 AJT400 201-400 64031J 64033J
3 AJT3 12 AJT12 90 AJT90 450 AJT450 401-600 6631J 6633J
3-2/10 AJT3-2/10 15 AJT15 100 AJT100 500 AJT500
4 AJT4 20 AJT20
1-60A
70-600A
Dimensions
1-30 2-1/4 57 13/16 21 - - - - - - - - - - - -
31-60 2-3/8 60 1-1/16 27 - - - - - - - - - - - -
61-100 4-5/8 117 1-1/16 27 1/8 3.2 3/4 19 1 25 3-5/8 92 3/8 10 9/32 7
101-200 5-3/4 146 1-5/8 41 3/16 4.8 1-1/8 29 1-3/8 35 4-3/8 111 3/8 10 9/32 7
201-400 7-1/8 181 2-1/8 54 1/4 6.3 1-5/8 41 1-7/8 48 5-1/4 133 17/32 14 13/32 10
401-600 8 203 2-1/2 64 3/8 9.5 2 51 2-1/8 54 6 152 11/16 18 17/32 13

2.80
AJT(70-100)-EI
(71.0)
3.22
AJT(110-200)-EI
(81.8)
3.24
AJT(225-400)-EI
(82.2)
3.61
AJT(450-600)-EI
(91.8)
A3

AJT1 to 600
Current in Amperes
Time in Seconds


A4
Weidmuller Product Datasheet Page 1 of 2
Rail Mounted Terminal Blocks

1020000000
WDU 2.5
Representative Ph
Technical Information
Clamping Type Screw Clamp
Series W Series
Rail Type TS 35
Function Feed Through
Configuration Single Level
Wire Size #22...12 AWG
Current 25 A
Voltage 600 V
Color/Material Beige Wemid
Special Requirements Accepts WQV & ZQV jumpers
Technical Data
UL CSA VDE
Rated Voltage 600 V 600 V 800 V
Rated Current 25 A 20 A 24 A
Wire Size #22...12 AWG #26...12 AWG 2.5 mm²
Additional Data
Width/Length/Height mm (in.) 5/60/47 (.2"/2.36"/1.85")
Insulation Stripping Length mm (in.) 10 (.39")
Torque Nm (lb. in) 0.8 (7.1)
Clamping Screw M 2.5
Flammability Class UL 94 (V0)
Suggested Accessories
DIN-rail
End plate/partition (WAP/WTW)
Ferrules
Markers (SchT)
Marking pens
Marking system (WS/ZS)
Marking tags (DEK)
Mounting brackets
Test plugs/socket
Tools
http://catalog.weidmuller.com/asp/datasheet.asp?PN=1020000000&FAM=RMTB&P=38... 11/17/2003
WQB jumpers
WQV jumpers
ZQV jumpers
Product Liability The above information describes our products. It does not constitute guaranteed properties and is not intended to
the suitability of a product for a particular application. Regrettably, omissions and exceptions cannot be completely ruled out. Tech
data are always specified by their average values. Exact data and the tolerances which apply to our processes can be requested fro
Weidmüller - North America

United States 001 (800) 849-9343
Canada 001 (800) 268-4080
or
Weidmüller - Germany
Telephone operator 0049 (-5252) 960-0
2-Channel Analog Input Module 0/4-20 mA
differential inputs
13 14
A
Function AI 1 C Function AI 2
B
Error AI 1 D Error AI 2
+E1 +E2
Data contacts
+AI 1 +AI 2
—E1 —E2
–AI 1 –AI 2
M M
Common Common
Delivery without miniature WSB

(ground) (ground)
S S
Shield Shield
(screen) (screen)
750-452
Item-No. Pack.-unit
Description pcs
2AI 0 -20mA Diff. 750-452 10
2AI 4 -20mA Diff. 750-454 10
Technical Data
The analog input module receives signals with standardi- No. of inputs 2
zed values of 0-20 mA and 4-20 mA. Voltage supply via system voltage DC /DC
Current consumption typ. (internal) 70 mA
The input signal is electrically isolated and will be transmit- Common mode voltage max. 35 V
ted with a resolution of 12 bits. Signal current 0 mA ... 20 mA (750-452)
The internal system supply (via the data bus contacts) is 4 mA ... 20 mA (750-454)
used for the power supply of the module. Input resistance < 220 Ω at 20 mA
Resolution 12 bits
The input channels are differential inputs. The shield Measuring error 25°C < ± 0.2 % of the full scale value
(screen) is directly connected to the DIN rail. Temperature coefficient < ± 0.01 % /K of the full scale value
Isolation 500 V system /supply
Conversion time typ. 2 ms
Bit width 2 x 16 bits data
2 x 8 bits control /status (option)
Operating temperature 0 °C ... +55 °C
Wire connection CAGE CLAMP®
0.08 mm2 ... 2.5 mm2
AWG 28 ... 14
8 ... 9 mm /0.33 in stripped length
Dimensions (mm) W x H x L 12 x 64* x 100
* from upper edge of 35 DIN rail
Weight ca 55 g
Storage temperature -25 °C ... +85 °C
Relative air humidity 95 % no condensation
Vibration and acc. to IEC 60068-2-6
shock resistance acc. to IEC 60068-2-27
Degree of protection IP 20
EMC
Immunity to interference acc. to EN 50082-2 (96)
Emission of interference acc. to EN 50081-2 (94)
Subject to design changes WAGO Kontakttechnik GmbH Postfach 2880 • D-32385 Minden Tel.: 05 71 / 8 87-0 E-Mail: info@wago.com
08.10.2001 Hansastr. 27 • D-32423 Minden Fax.: 05 71 / 8 87-169 Web: http://www.wago.com
1 5
+AI 1 +AI 2 +AI
I A
Logic
D
2 6
–AI 1 –AI 2 –AI
Error
270pF 270pF Function
3 7
Common Common
(ground) (ground) 10nF
4 8
Shield Shield
(screen) (screen)
750-452
Item-No. Pack.-unit
Technical Data Variations pcs
2AI 0-20mA Diff./S 5 1) 750-452/000-200 1
2AI 4-20mA Diff./S 5 1) 750-454/000-200 1
1)
Data format for S5 control with FB 250.
Approvals
UL E175199, UL508
UL E198726, UL1604
Class I Div2 ABCD T4A
KEMA 01ATEX1024 X
EEx nA II T4
Conformity marking 1
Accessories
Miniature WSB quick marking system pages 1.166 /167
Subject to design changes

08.10.2001
2-Channel Analog Output Module 0/4-20 mA
13 14
Function Function
A
AO 1 C AO 2
B
D
A1 A2
Data contacts
AO 1 AO 2
+ +
24 V
0V 0V

0V
S S
Shield Shield
(screen) (screen)
750-552
Power jumper contacts
Item-No. Pack.-unit
Description pcs
2AO 0-20mA 750-552 10
2AO 4-20mA 750-554 10
Technical Data
The analog output module creates a standardized signal No. of outputs 2
of 0-20 mA or 4-20 mA. Current consumption max. (internal) 60 mA
Voltage supply DC 24 V via power jumper contacts
The output signal is electrically isolated and will be trans- (-15 % ... +20 %)
mitted with a resolution of 12 bits. Signal current 0 mA ... 20 mA (750-552)
“Current” analog output modules use power derived from 4 mA ... 20 mA (750-554)
the field side (loop powered). Load impedance < 500 Ω
Linearity ± 2 LSB
Resolution 12 bits
Conversion time ca 2 ms
Measuring error 25°C < ± 0.1 % of the full scale value
Temperature coefficient < ± 0.01 % /K of the full scale value (750-552)
< ± 0.015 % /K of the full scale value (750-554)
Isolation 500 V system /supply
Bit width 2 x 16 bits data
0.08 mm2 ... 2.5 mm2
AWG 28 ... 14
Weight ca 55 g
EMC
1 5
I A
AO 1 AO 2 AO Logic
U D
2 6 Function
24 V 24 V
270pF 10nF 10nF

3 7
0V 0V
10nF
4 8
Shield Shield
(screen) (screen)
750-552
Item-No. Pack.-unit
Technical Data Variations pcs
2AO 0-20mA S5 1) 750-552/000-200 1
2AO 4-20mA S5 1) 750-554/000-200 1
1)
Data format for S5 control with FB 251.
Approvals
UL E175199, UL508
UL E198726, UL1604
KEMA 01ATEX1024 X
EEx nA II T4
Accessories

08.10.2001
2-Channel Digital Input Module AC 120 V
2- to 4-conductor connection; high-side switching
13 14
Status Status
A
DI 1 C DI 2
B
D
13 14 Data contacts
DI 1 DI 2
L L
120 V
N N

N
750-406
Power jumper contacts
Item-No. Pack.-unit
Description pcs
2DI 120V AC 750-406 10
Technical Data
The digital input module receives control signals from digi- No. of inputs 2
tal field devices (sensors, etc.). Current consumption (internal) 2 mA
Nominal voltage AC 120 V (-15 % ... +10 %)
The module is a 2-channel, 4-conductor device and sen- Signal voltage (0) AC 0 V ... 20 V
sors with a ground (earth) wire may be directly connected Signal voltage (1) AC 79 V ... 1.1 UN
to the module. Switching time 10 ms
An optocoupler is used for electrical isolation between the Input current typ. 4.5 mA
Isolation 3.75 kV eff. system /supply
bus and the field side.
Internal bit width 2 bits
Attention: An additional supply module must be added Wire connection CAGE CLAMP®
for operation with AC 120 V! 0.08 mm2 ... 2.5 mm2
AWG 28 ... 14
Weight ca 50 g
EMC
1 5
DI 1 DI 2 DI
100nF
DI
2 6
120 V 120 V
U
3 7
N N
10nF
4 8
750-406
Technical Data
Approvals
UL E175199, UL508
UL E198726, UL1604
KEMA 01ATEX1024 X
EEx nA II T4
Accessories

08.10.2001
2-Channel Relay Output Module AC 230 V, DC 300 V
isolated outputs, 2 changeover contacts
K1 K2
Status Status
A
relay 1 C relay 2
B
D
14 24 Data contacts
DO 1 DO 2 N
11 21
L1 L2
12 22
_____ _____

DO 1 DO 2 N
750-517
Item-No. Pack.-unit
Description pcs
2DO 230V AC 1.0A/ Rel. 2CO/ Pot. Free 750-517 1
Technical Data
The connected load is switched via the digital output (relay No. of outputs 2 changeover contacts (SPDT)
contact) from the control system. The internal system volt- Current consumption max. (internal) 105 mA
Switching voltage max. AC 250 V/DC 300 V
age is used to trigger the relay.
Switching power max. 400 VA (module)
The SPDT contacts are electrically isolated. Switching current max. AC 1 A
The switched status of the relay is shown by a LED. DC 1 A at DC 40 V
DC 0.15 A at DC 300 V
Switching current min. AC /DC 10 mA at 5 V
Switching rate max. 6 /min
Contact material AgSnO2, gold-plated
Mechanical life min. 2 x107 switching operations
Electrical life min. 1 x106 switching operations (AC 1 A /250 V)
Isolation 2.5 kV system / supply**
**Rated voltage 230 V
Pollution degree 2
Overvoltage category II
Internal bit width 2 bits
0.08 mm2 ... 2.5 mm2
AWG 28 ... 14
Weight ca 55 g
EMC
1 5
14 24 DO
Status
2 6
11 21 L
3 7 ___
12 22 DO
4 8
750-517
Technical Data
Approvals
UL E175199, UL508
KEMA 01ATEX1024 X
EEx nC II C T4
Accessories

08.10.2001
Bulletin 800T
30.5 mm Push Buttons
Emergency Stop Operators — Type 4/13, Watertight/Oiltight
2-Position Push-Pull and Push-Pull/Twist Release, Non-Illuminated
Note: A jumbo or large legend plate is recommended, if space allows.
2-Position Push-Pull 2-Position Push-Pull/Twist

Cat. No. 800T-FX6D4 Cat. No. 800T-FXT6D4
Operator Position
Push-Pull/Twist
Contact Button Push-Pull
Release
Type Color
Maintained Maintained
Out In Cat. No. Cat. No.
N.C.L.B. ➊ X O Red 800T-FX6D4 800T-FXT6D4
N.O. - O X
Red 800T-FX6A1 800T-FXT6A1
N.C.L.B. ➊ X O
N.C.L.B. - X O
Red 800T-FX6A5 800T-FXT6A5
N.C.L.B. ➊ X O
S.M.C.B. ➊➋ X O Red 800TC-FX6D4S 800TC-FXT6D4S
N.O. - O X
Red 800TC-FX6A1S 800TC-FXT6A1S
S.M.C.B. ➊➋ X O
S.M.C.B. - X O
Red 800TC-FX6A5S 800TC-FXT6A5S
S.M.C.B. ➊➋ X O
Note: X = Closed/O = Open
Note: Emergency stop push buttons are compliant with EN-418 and IEC 60947-5-5 Standards when using N.C.L.B. contact blocks.
➊ Normally closed late break contact. When button is pushed from the OUT to IN position, the mechanical detent action of the operator occurs
before electrical contacts change state. When the button is pulled from the IN to the OUT position, the electrical contacts change state before
the mechanical detent occurs.
➋ The Self Monitoring Contact Block (S.M.C.B.) is composed of a N.C.L.B. contact wired in series with a N.O. monitoring contact. The N.O.
monitoring contact automatically closes when the S.M.C.B. is properly installed onto the E-stop operator. If the S.M.C.B. is separated from the
E-stop operator, the N.O. monitoring contact will automatically open.
Accessories — Page 49 Approximate Dimensions — Page 63

Legend Plates — Page 60
20
Bulletin 800T
Type 4/13, Watertight/Oiltight
2-Position Push-Pull and Push-Pull/Twist Release, Non-Illuminated
2-Position Push-Pull 2-Position Push-Pull/Twist

Cat. No. 800T-FX6D4 Cat. No. 800T-FXT6D4
Operator Position
Push-Pull/
Button Push-Pull
Contact Type Twist Release
Color
Maintained Maintained
Out In Cat. No. Cat. No.
N.C.L.B. X O 800T-FX6D4 ➋ 800T-FXT6D4 ➋
N.O. - O X
800T-FX6A1 ➋ 800T-FXT6A1 ➋
N.C.L.B. ➊ X O Red
N.C.L.B. - X O
800T-FX6A5 ➋ 800T-FXT6A5 ➋
N.C.L.B. ➊ X O
3-Position Push-Pull Units, Non-Illuminated

3-Position Push-Pull
Cat. No. 800T-FXM6A7
Operator Position
Button Push-Pull
Contact Type
Color
Momentary Maintained Maintained
Out Center In Cat. No.
N.C. - X O O
N.C.L.B. ➊ Red 800T-FXM6A7
X X O
Operator Position
Button Push-Pull
Contact Type
Color
Momentary Maintained Momentary
Out Center In Cat. No.
N.C. - X O O
N.C.L.B. ➊ Red 800T-FXN6A7
X X O
➊ Normally closed late break contact. When button is pushed from the OUT to IN position, the mechanical detent action of the operator occurs
before electrical contacts change state. When the button is pulled from the IN to the OUT position, the electrical contacts change state before
the mechanical detent occurs.
➋ Meets EN-418 and IEC 60947-5-5 standards for emergency stop applications.
Accessories — Page 49 Approximate Dimensions — Page 63
Legend Plates — Page 60
30
Bulletin 800T
Type 4/13, Watertight/Oiltight
General Accessories, Continued
Guards
Photo Description Type Cat. No.
1" Guard for
800T-N13
Non-Illuminated
1/2" Guard for
800T-N143
Non-Illuminated
Push Button Guards
1-1/2" Guard for
Momentary push button guards to reduce the risk 800T-N93
Illuminated
of accidental operation.
1-1/2" Guard for
Non-Illuminated
800T-N39
Push Button Unit with Cat. No. 800T-N13 with Locking
1" (25.4 mm) Extra Long Guard Attachment
Standard Guard 800T-N129

Mushroom Push Button Guards
Momentary mushroom guards for standard and Standard Guard
800T-N165
jumbo mushroom push buttons. Reduces the risk with Set Screw
Jumbo Size Guard 800T-N151
Momentary mushroom guards for standard and

Standard Mushroom Push Button Unit with Jumbo Size Guard
jumbo mushroom push buttons. Reduces the risk 800T-N154
Cat. No. 800T-N129 Guard with Set Screw
Photo Description Type of Finish Cat. No.
Protective Guard Stainless Steel 800T-N310

Protective ring for 800T 2-position push-pull
operators. Illuminated or non-illuminated. Often
used to avoid unintentional tripping of E-stop
operators. This guard is used with standard size
button (40 mm dia.). Black 800T-NX1320
Protective Ring for 2-Position Push-Pull
Cat. No. 800T-N310 and 800T-NX1320
Jumbo Protective Guard

Protective ring for 800T 2-position push-pull
operators. Illuminated or non-illuminated. Often
800T-N310J
used to avoid unintentional tripping of E-stop
operators. This guard is used with jumbo size
button (60 mm dia.).
Protective Ring for 2-Position Push-Pull
Cat. No. 800T-N310J
Ramp Guard
For Bulletin 800T/800H 2- and 3-position
800T-N339
illuminated and non-illuminated push-pull units.
Standard size button only (4 0mm dia.).
Ramp Guard
Cat. No. 800T-N339
58
Pilot devices
CBG 30mm
Description
Ratings Pilot devices
• Worldwide availability • Full voltage, resistor and transformer type
• UL Listed for Types 1, 3R, 4, 4X, 12 & 13 • LED bulbs available for illuminated
applications pushbuttons and pilot lights
• UL, CSA, NEMA, IEC and most international
standards Contact blocks
30 mm
• CE marking • CBK 22mm and CBG 30mm devices use the
• UL File # E57057 same contact blocks, lamp modules and
• CSA File # LR19700 transformers
• Quick-mount, quick-release contact block
General construction holder for fast, easy assembly
• Quick mounting feature reduces installation • N.O. & N.C. contact blocks are color coded for
time easy identification: Green, N.O./Red, N.C.
• Front ring options are chrome metal and black • Silver tipped contacts have wiping action for
plastic high reliability
• Contact block holder features rear mounting • Low energy gold plated contact blocks
with quick-release locking mechanism for high available
security • Base mounted contact blocks are available
• Knurled sleeve tightens against panel assuring and snap onto a 35mm DIN rail
secure mounting • 5 Contact block holder
• Buttons available in seven colors
• Engraved caps available
• Mounts in 30mm hole
• Anti-rotation
• Full line of accessories
Operators
• Mushroom operators in maintained, push-pull,
illuminated, twist release, momentary or key
operated designs
• Illuminated & non-illuminated push-push
operators with push-on & push-off designs
(maintained)
• Two-position toggle operators, maintained
• Three-position toggle operators, maintained or
momentary
• Key operated pushbuttons
• Potentiometers
• Selector switches, 2 or 3 position, illuminated,
maintained, momentary or key operated
• Available with or without contact blocks
ABB Control Inc. Discount schedule CC 2.1

AC 1400 – 2/00
Flush & extended pushbuttons
Non-illuminated
Momentary
Non-Illuminated, momentary
Black plastic ring Chrome metal ring
Type
Catalog number List price Catalog number List price
Flush button
Red CBG-KPR CBG-MPR
Green CBG-KPG CBG-MPG
Yellow CBG-KPY CBG-MPY
Blue CBG-KPL $ 17.00 CBG-MPL $ 17.00
Black CBG-KPB CBG-MPB
Clear1 CBG-KPC CBG-MPC
White CBG-KPW CBG-MPW
Extended button
Red CBG-KPER CBG-MPER
Green CBG-KPEG CBG-MPEG
CBG-MPR Yellow CBG-KPEY CBG-MPEY
Blue CBG-KPEL 17.00 CBG-MPEL 17.00
Black CBG-KPEB CBG-MPEB
Clear1 CBG-KPEC CBG-MPEC
White CBG-KPEW CBG-MPEW
Contact blocks (Maximum 6 per operator)

Separate contact blocks Included with List price
Item
catalog number operator suffix code adder
1 N.O. CBK-CB10 10 $ 8.00

1 N.C. CBK-CB01 01
1 N.O. & 1N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
2 N.C. CBK-CB01 + CBK-CB01 02
CBG-MPER Pushbuttons are complete except for contact blocks:

• To order a pushbutton operator complete with contact block, add the appropriate suffix code to the end of the catalog
number and add the list price adder to the operator list price. EX: CBG-KPR10, $ 25.00
• To order just the contact block, refer to "Separate Contact Blocks" column and indicate catalog number and quantity.
30 mm
EX: CBK-CB10, qty 1, $ 8.00
Example of individual component ordering
CBG-KPR CBK-CB10 = CBG-KPR10

+
$ 17.00 $ 8.00 $ 25.00
CBK-CB10 5 Contact block holders (Maximum 6 contact blocks)

• To order an assembled unit with a 5 contact block holder, add the digit "5" to the end of the catalog number and add
$ 4.00 to the list price. EX: CBG-KPR5, $ 21.00
5 contact block holder
1 To order a lens insert, refer to the lens inserts selection chart on pages 2.22 - 2.23 and place the appropriate suffix code at the end of the
catalog number (but before the contact block suffix code, if there is one) and add $.90 to the list price.
2.2 Discount schedule CC ABB Control Inc.

AC 1400 – 2/00
Flush & extended pushbuttons
Non-illuminated
Maintained
Non-Illuminated, maintained (push-push)
Type
Flush button
Red CBG-KPPR CBG-MPPR
Green CBG-KPPG CBG-MPPG
Yellow CBG-KPPY CBG-MPPY
Blue CBG-KPPL $ 34.20 CBG-MPPL $ 34.20
Black CBG-KPPB CBG-MPPB
Clear1 CBG-KPPC CBG-MPPC
White CBG-KPPW CBG-MPPW
Extended button
Red CBG-KPPER CBG-MPPER
Green CBG-KPPEG CBG-MPPEG
CBG-MPPR Yellow CBG-KPPEY CBG-MPPEY
Blue CBG-KPPEL 34.20 CBG-MPPEL 34.20
Black CBG-KPPEB CBG-MPPEB
Clear1 CBG-KPPEC CBG-MPPEC
White CBG-KPPEW CBG-MPPEW

Item
1 N.O. CBK-CB10 10
$ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
CBG-MPPER
Pushbuttons are complete except for contact blocks:
number and add the list price adder to the operator list price. EX: CBG-KPPR10, $ 42.20
30 mm
EX: CBK-CB10, qty 1, $ 8.00
CBG-KPPR CBK-CB10 = CBG-KPPR10

+
$ 34.20 $ 8.00 $ 42.20
CBK-CB10
5 Contact block holders (Maximum 6 contact blocks)
To order an assembled unit with a 5 contact block holder, add the digit "5" to the end of the catalog number and add
$ 4.00 to the list price. EX: CBG-KPPR5, $ 38.20
1 To order lens insert, refer to the lens inserts selection chart on pages 2.22 - 2.23 and place the appropriate suffix code at the end of the catalog
number (but before the contact block suffix code, if there is one) and add $.90 to the list price.

AC 1400 – 2/00
Extended pushbuttons
Illuminated
Momentary
Illuminated, momentary (extended button)
Type
Operator only1
CBG-KPI★ $ 17.00 CBG-MPI★ $ 17.00
Full voltage type
6V CBG-KPIF6★ CBG-MPIF6★
24V CBG-KPIF8★ 40.50 CBG-MPIF8★ 40.50
Resistor type
CBG-MPIF1R 120V/60V CBG-KPIR1★ 44.50 CBG-MPIR1★ 44.50
240V/120V CBG-KPIR2★ CBG-MPIR2★
Transformer type
120V/6V CBG-KPIT1★ CBG-MPIT1★
240V/6V CBG-KPIT2★ 75.50 CBG-MPIT2★ 75.50
★ Substitute the ★ for a suffix letter from the Illuminated buttons chart. Example: CBK-KPIF6R
NOTE: If a flush button is desired, add “F” suffix after the ★. Example: CBG-KPIF6RF.
Illuminated LED bulb, momentary (extended button)23

Type
CBG-KPIFL8R
Full voltage type
24V CBG-KPIFL8★ $ 49.50 CBG-MPIFL8★ $ 49.50
120V CBG-KPIFL1★ 49.50 CBG-MPIFL1★ 49.50
240V CBG-KPIFL2★ 55.50 CBG-MPIFL2★ 55.50
Transformer type
380V/24V CBG-KPITL3★ 84.50 CBG-MPITL3★ 84.50
480V/24V CBG-KPITL4★ CBG-MPITL4★
30 mm

Item
CBK-CB10 1 N.O. CBK-CB10 10 $ 8.00

1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00

number and add the list price adder to the operator list price.
EX: CBG-KPIF6R10, $ 48.50
• To order just the contact block, refer to "Separate contact blocks" column and indicate catalog number and quantity.
EX: CBK-CB10, qty 1, $ 8.00
CBG-KPIF6R CBK-CB10 = CBG-KPIF6R10
+
$ 40.50 $ 8.00 $ 48.50
$ 4.00 to the list price. EX: CBG-KPIF6R5, $ 44.50
★ Illuminated buttons
Button Suffix
color code
Red R
Green G
Yellow Y
Blue L
Illuminated button Clear 4 C
White W
1 Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21.
2 White LEDs use clear lenses.
3 For blue or white LED, add $ 3.00 to list price.
4 To order lens insert, refer to the lens inserts selection chart on pages 2.22 - 2.23 and place the appropriate suffix code at the
end of the catalog number (but before the contact block suffix code, if there is one) and add $.90 to the list price.

AC 1400 – 2/00
Extended pushbuttons
Illuminated
Maintained
Illuminated, maintained push-push (extended)
Type
Operator only1
CBG-KPPI★ $ 34.20 CBG-MPPI★ $ 34.20
Full voltage type
6V CBG-KPPIF6★ CBG-MPPIF6★
24V CBG-KPPIF8★ 57.70 CBG-MPPIF8★ 57.70
Resistor type
CBG-MPPIF1R
120V/60V CBG-KPPIR1★ 61.70 CBG-MPPIR1★ 61.70
240V/120V CBG-KPPIR2★ CBG-MPPIR2★
Transformer type
120V/6V CBG-KPPIT1★ CBG-MPPIT1★
240V/6V CBG-KPPIT2★ 92.70 CBG-MPPIT2★ 92.70
★ Substitute the ★ for a suffix letter from the Illuminated buttons chart. Example: CBG-KPPIF6R
NOTE: If a flush button is desired, add “F” suffix after the ★. Example: CBG-KPPIF6RF.
Illuminated LED bulb, maintained push-push (extended)23

Type
CBG-KPPIFL8R Full voltage type
24V CBG-KPPIFL8★ $ 66.70 CBG-MPPIFL8★ $ 66.70
120V CBG-KPPIFL1★ 66.70 CBG-MPPIFL1★ 66.70
240 CBG-KPPIFL2★ 72.70 CBG-MPPIFL2★ 72.70
Transformer type
380V/24V CBG-KPPITL3★ 101.70 CBG-MPPITL3★ 101.70
480V/24V CBG-KPPITL4★ CBG-MPPITL4★
30 mm
Item
1 N.O. CBK-CB10 10 $ 8.00
CBK-CB10 1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00

number and add the list price adder to the operator list price.
EX: CBG-KPPIF6R10, $ 65.70
EX: CBK-CB10, qty 1, $ 8.00

5 contact block holder Lamp module Lamp bulb
CBG-KPPIR + Transformer + CBK-LMF + CBK-LB6 + CBK-CB10 = CBG-KPPIF6R10
$ 34.20 (if required) $ 17.50 $ 6.00 $ 8.00 $ 65.70

$ 4.00 to the list price. EX: CBG-KPPIF6R5, $ 61.70
Button Suffix
color code
Red R
Green G
Yellow Y
Illuminated button Blue L
Clear 4 C
White W
1 Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21.
2 White LEDs use a clear lens.
3 For blue or white LEDs, add $ 3.00 to list price.
4 To order lens insert, refer to the lens inserts selection chart on pages 2.22 - 2.23 and place the appropriate suffix code at the end of the
catalog number (but before the contact block suffix code, if there is one) and add $.90 to the list price.

AC 1400 – 2/00
Mushroom pushbuttons, 30mm, 40mm & 60mm
Non-illuminated standard and lockable
Mushroom pushbuttons — standard

Type Color
30mm
Twist-release
Red CBG-PMT3R $ 49.00 CBG-MPMT3R $ 49.00
Black CBG-PMT3B CBG-MPMT3B
Push-pull
Red CBG-PMP3R CBG-MPMP3R
49.00 49.00
Black CBG-PMP3B CBG-MPMP3B
40mm
CBG-MPMP3R Momentary
Red CBG-KPM40R CBG-MPM40R
Yellow CBG-KPM40Y 35.00 CBG-MPM40Y 35.00
Black CBG-KPM40B CBG-MPM40B
Twist-release
Red CBG-PMT40R 53.00 CBG-MPMT40R 53.00
Black CBG-PMT40B CBG-MPMT40B
Push-pull
Red CBG-PMP40R 53.00 CBG-MPMP40R 53.00
Black CBG-PMP40B CBG-MPMP40B
60mm
Momentary
Red CBG-KPM6R CBG-MPM6R
CBG-MPMT40R Yellow CBG-KPM6Y 39.00 CBG-MPM6Y 39.00
Black CBG-KPM6B CBG-MPM6B
Mushroom pushbuttons — lockable plastic mushroom

Type Color
40mm
30 mm
Maintained, key release

Red CBG-KPMK40R $ 63.00 CBG-MPMK40R $ 63.00
Black CBG-KPMK40B CBG-MPMK40B

CBG-KPM6Y Separate contact blocks Included with List price
Item
1 N.O. CBK-CB10 10 $ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
Mushroom pushbuttons are complete except for contact blocks:

• To order a mushroom pushbutton operator complete with contact block, add the appropriate suffix code to the end of
the catalog number and add the list price adder to the operator list price. EX: CBG-PMT3R10, $ 57.00
CBG-MPMK40R EX: CBK-CB10, qty 1, $ 8.00
CBG-KPMT3R CBK-CB10 = CBG-KPMT3R10

+
$ 49.00 $ 8.00 $ 57.00
$ 4.00 to the list price. EX: CBG-KPMT3R5, $ 53.00
CBK-CB10

AC 1400 – 2/00
Mushroom pushbuttons, 40mm
Illuminated, momentary
Illuminated mushrooms, 40mm

Type
Operator only1
CBG-KPM40I★ $ 44.00 CBG-MPM40I★ $ 44.00
Full voltage type
6V CBG-KPM40IF6★ CBG-MPM40IF6★
24V CBG-KPM40IF8★ 67.50 CBG-MPM40IF8★ 67.50
CBG-MPM40IF1Y Resistor type
120V/60V CBG-KPM40IR1★ 71.50 CBG-MPM40IR1★ 71.50
240V/120V CBG-KPM40IR2★ CBG-MPM40IR2★
Transformer type
120V/6V CBG-KPM40IT1★ CBG-MPM40IT1★
240V/6V CBG-KPM40IT2★ 102.50 CBG-MPM40IT2★ 102.50
Illuminated mushrooms with LED bulbs, 40mm

Type
CBG-KPM40IFL1Y Full voltage type
24V CBG-KPM40IFL8★ $ 76.50 CBG-MPM40IFL8★ $ 76.50
120V CBG-KPM40IFL1★ 76.50 CBG-MPM40IFL1★ 76.50
Transformer type
380V/24V CBG-KPM40ITL3★ 111.50 CBG-MPM40ITL3★ 111.50
480V/24V CBG-KPM40ITL4★ CBG-MPM40ITL4★
30 mm
Button Suffix
color code
Red R
Yellow Y
Green G

Item
1 N.O. CBK-CB10 10 $ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
CBK-CB10 number and add the list price adder to the operator list price. EX: CBG-KPM40IF1R10, $ 75.50
EX: CBK-CB10, qty 1, $ 8.00
CBG-KPM40IF1R + CBK-CB10 = CBG-KPM40IF1R10

$ 67.50 $ 8.00 $ 75.50

To order an assembled unit with a 5 contact block holder, add the digit "5" to the end of the catalog number and add $ 4.00 to
the list price. EX: CBG-KPM40IF1R5, $ 71.50
➀ Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21.

AC 1400 – 2/00
Mushroom pushbuttons, 60mm
Illuminated, momentary
Illuminated mushrooms, 60mm

Type
1
Operator only1
CBG-KPM6I★ $ 48.00 CBG-MPM6I★ $ 48.00
Full voltage type
24V CBG-KPM6IF8★ 71.50 CBG-MPM6IF8★ 71.50
Resistor type
CBG-MPM6IF1R
120V/60V CBG-KPM6IR1★ 75.50 CBG-MPM6IR1★ 75.50
240V/120V CBG-KPM6IR2★ CBG-MPM6IR2★
Transformer type
106.50 106.50
Illuminated mushrooms with LED bulbs, 60mm

Type
Full voltage type
CBG-KPM6IFL1R
24V CBG-KPM6IFL8★ $ 80.50 CBG-MPM6IFL8★ $ 80.50
Transformer type
380V/24V CBG-KPM6ITL3★ 115.50 CBG-MPM6ITL3★ 115.50
480V/24V CBG-KPM6ITL4★ CBG-MPM6ITL4★
30 mm
Button Suffix
color code
Red R
Yellow Y
Green G

Item
1 N.O. CBK-CB10 10 $ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00

CBK-CB10
number and add the list price adder to the operator list price. EX: CBG-KPM6IF1R10, $ 79.50
EX: CBK-CB10, qty 1, $ 8.00

CBG-KPM6IF1R CBK-CB10 = CBG-KPM6IF1R10
+
$ 71.50 $ 8.00 $ 79.50
5 contact block holder 5 Contact block holders (Maximum 5 contact blocks)

$ 4.00 to the list price. EX: CBG-KPM6IF1R5, $ 75.50
➀ Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21

AC 1400 – 2/00
Press-to-test illuminated pushbuttons
Press-to-test
Voltage
Operator only1
CBG-KLPT★ $ 46.00 CBG-MLPT★ $ 46.00
Full voltage type
6V CBG-KLFPT6★ CBG-MLFPT6★
24V CBG-KLFPT8★ 69.50 CBG-MLFPT8★ 69.50
Resistor type
CBG-MLFPT1Y 120V CBG-KLRPT1★ 73.50 CBG-MLRPT1★ 73.50
240V CBG-KLRPT2★ CBG-MLRPT2★
Transformer type
120V/6V CBG-KLTPT1★ CBG-MLTPT1★
240V/6V CBG-KLTPT2★ 104.50 CBG-MLTPT2★ 107.00
★ Select the lens color from the Illuminated buttons & lenses selection chart and substitute the suffix code for the ★. The
lens and bulb are included in the price.
Press-to-test (LED bulb)2

Voltage
CBG-KLFPTL1Y Full voltage type

24V CBG-KLFPTL8★ $ 78.50 CBG-MLFPTL8★ $ 78.50
120V CBG-KLFPTL1★ CBG-MLFPTL1★
230V CBG-KLFPTL2★ 84.50 CBG-MLFPTL2★ 84.50
Transformer type
380V/24V CBG-KLTPTL3★ 113.50 CBG-MLTPTL3★ 116.00
480V/24V CBG-KLTPTL4★ CBG-MLTPTL4★
30 mm
★ Select the lens color from the Illuminated buttons & lenses selection chart and substitute the suffix code for the ★. The
lens and bulb are included in the price.
Button Suffix
color code
Red R
Green G
Yellow Y
Blue L
Illuminated button Clear C
White W
Schematic
L1 L2
CONTROL
VOLTAGE SOURCE
LIGHT COLOR
PER ORDER
★
X1 X2
CUSTOMER'S
CONTROL
CONTACT
21 22
WIRING
INCLUDED
13 14
1 1 N.O. & 1 N.C. contact block supplied; Lamp module and bulb must be ordered separately; see pages 2.20 – 2.21.
2 For blue or white LEDs, add $ 3.00 to list price.

AC 1400 – 2/00
Key operated pushbuttons
Key operated pushbuttons 1

Type
Maintained
Locks when depressed, can be released with the key only.
Key removable in locked and unlocked position.
Key code 1 CBG-PKM1 CBG-MPKM1
Momentary
CBG-PKM1 Can be operated without key when unlocked.
Key removeable in locked and unlocked position.
Key-lockable in non-depressed position.
Key code 1 CBG-PKS11 CBG-MPKS11
Key-lockable in depressed position.
Key-lockable in non-depressed and depressed position.
Key code 1 CBG-PKS31 $ 55.00 CBG-MPKS31 $ 55.00
Can be operated with the key only.
Key removeable in locked position(s).
Key-lockable in non-depressed position.
Key-lockable in depressed position.
30 mm

Key-lockable in non-depressed and depressed position.

Item
1 N.O. CBK-CB10 10
$ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
CBK-CB10 number and add the list price adder to the operator list price. EX: CBG-PKM110, $ 63.00
EX: CBK-CB10, qty 1, $ 8.00

CBG-PKM1 + CBK-CB10 = CBG-PKM110
$ 55.00 $ 8.00 $ 63.00

$ 4.00 to the list price. EX: CBG-PKM15, $ 59.00
1 See page 1.35 for key code details.

AC 1400 – 2/00
Toggle switches
Toggle switches
Type
Maintained, 2 position 2
A
CBG-TM $ 31.50 CBG-MTM $ 31.50

C
Maintained, 3 position 1
A
B CBG-TM3 31.50 CBG-MTM3 31.50

C
CBG-MTM
Momentary, 3 position 2
A
B CBG-TS 31.50 CBG-MTS 31.50

C
Toggle switch contacts and contact blocks

A
2 Position
As viewed from the front, the contacts are in the normal position with the switch handle in the
C "A" position. In the "C" position, the contact(s) change state.
CBG-MTS
A 3 Position Momentary
B
As viewed from the front, the contact(s) are in the normal position with the switch handle in the
"B" position. In the "A" position, the left contact(s) change state. In the "C" position, the right
C contact(s) change state.
A 3 Position Maintained
30 mm
B
As viewed from the front, the contact(s) are in the normal position with the switch handle in the
"B" position. In the "A" position, the left and center contacts change state. In the "C" position,
C the right and center contacts change state.

Item
1 N.O. CBK-CB10 10 $ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
Toggle switches are complete except for contact blocks.
• To order a toggle switch operator complete with contact block, add the appropriate suffix code to the end of the
catalog number and add the list price adder to the operator list price. EX: CBG-TM10, $ 39.50
CBK-CB10 • To order just the contact block, refer to "Separate contact blocks" column and indicate catalog number and quantity.
EX: CBK-CB10, qty 1, $ 8.00

CBG-TM CBK-CB10 = CBG-TM10
+
$ 31.50 $ 8.00 $ 39.50
$ 4.00 to the list price. EXAMPLE: CBG-MTS5, $ 35.50
Fig. 1 – Center position connection detail (CBG-TM & CBG-TS)

A B C
A B C
A
X
A 41 42
X
43 44
X
X 43 13 23 53 11 12 41 11 21 51
13 14
44 14 24 54 42 12 22 52
X
X 21 22
23 24
A A
X X
53 54 51 52
A Contacts may be N.O. or N.C. A Contacts may be N.O. or N.C.
1 Contact blocks can be used in the center position..
2 For center position operation, see Fig. 1. For B position, normally open function For B position, normally closed function

AC 1400 – 2/00
Selector switches
Non-illuminated
2 position
Knob operator — 2 position
Type Color
B C Maintained Black CBG-2BMK CBG-M2BMK
Red CBG-2BMKR $ 23.00 CBG-M2BMKR $ 23.00
Grey CBG-2BMKE CBG-M2BMKE
B Momentary Black CBG-2BSK CBG-M2BSK
C
Red CBG-2BSKR 35.00 CBG-M2BSKR 35.00
Grey CBG-2BSKE CBG-M2BSKE
A C Maintained Black CBG-2AMK CBG-M2AMK
Red CBG-2AMKR 23.00 CBG-M2AMKR 23.00
Grey CBG-2AMKE CBG-M2AMKE
CBG-M2BMK
Lever operator — 2 position
Type Color
B C Maintained Black CBG-2BML CBG-M2BML
Red CBG-2BMLR 23.00 CBG-M2BMLR 23.00
Grey CBG-2BMLE CBG-M2BMLE
B Momentary Black CBG-2BSL CBG-M2BSL
C
Red CBG-2BSLR 35.00 CBG-M2BSLR 35.00
Grey CBG-2BSLE CBG-M2BSLE
A C Maintained Black CBG-2AML CBG-M2AML
Red CBG-2AMLR 23.00 CBG-M2AMLR 23.00
Grey CBG-2AMLE CBG-M2AMLE
Selector switch contacts

2 Position
As viewed from the front, the contacts are in the normal position with the switch handle in either the "A" or "B" position. In
CBG-M2BML the "C" position, the contact(s) change state.

30 mm

Item
1 N.O. CBK-CB10 10 $ 8.00
1 N.C. CBK-CB01 01
1 N.O. & 1N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
Selector switches are complete except for contact blocks.
• To order a selector switch operator complete with contact block, add the appropriate suffix code to the end of the
catalog number and add the list price adder to the operator list price. EX: CBG-2BMK10, $ 31.00
CBK-CB10 • To order just the contact block, refer to "Separate contact blocks" column and indicate catalog number and quantity.
EX: CBK-CB10, qty 1, $ 8.00
CBG-2BMK + CBK-CB10 = CBG-2BMK10

$ 23.00 $ 8.00 $ 31.00

5 contact block holder $ 4.00 to the list price.
EX: CBG-2BMK5, $ 27.00

AC 1400 – 2/00
Selector switches
Non-illuminated
3 position
Knob operator — 3 position
Type Color
A BC Maintained Black CBG-3MK CBG-M3MK
Red CBG-3MKR $ 23.00 CBG-M3MKR $ 23.00
Grey CBG-3MKE CBG-M3MKE
B Momentary Black CBG-3SK CBG-M3SK
A C
return from Red CBG-3SKR 35.00 CBG-M3SKR 35.00
A & C position Grey CBG-3SKE CBG-M3SKE
B Momentary Black CBG-3SRK CBG-M3SRK
A C
return from Red CBG-3SRKR 35.00 CBG-M3SRKR 35.00
C position Grey CBG-3SRKE CBG-M3SRKE
CBG-M3MK B Momentary Black CBG-3SLK CBG-M3SLK
A C
return from Red CBG-3SLKR 35.00 CBG-M3SLKR 35.00
A position Grey CBG-3SLKE CBG-M3SLKE
Lever operator — 3 position

Type Color
A BC Maintained Black CBG-3ML CBG-M3ML

Red CBG-3MLR $ 23.00 CBG-M3MLR $ 23.00
Grey CBG-3MLE CBG-M3MLE
B Momentary Black CBG-3SL CBG-M3SL
A C
return from Red CBG-3SLR 35.00 CBG-M3SLR 35.00
A & C position Grey CBG-3SLE CBG-M3SLE
B Momentary Black CBG-3SRL CBG-M3SRL
A C return from Red CBG-3SRLR 35.00 CBG-M3SRLR 35.00
C position Grey CBG-3SRLE CBG-M3SRLE
B Momentary Black CBG-3SLL CBG-M3SLL
A C
return from Red CBG-3SLLR 35.00 CBG-M3SLLR 35.00
CBG-M3ML
A position Grey CBG-3SLLE CBG-M3SLLE
30 mm
Contact blocks (Maximum 4 per operator) Selector switch contacts
Separate contact blocks Assembled to List
3 Position
Type As viewed from the front, the contact(s) are in the normal position with the
switch handle in the "B" position. In the "A" position, the left contact(s) change
1 N.O. CBK-CB10 10 $ 8.00 state. In the "C" position, the right contact(s) change state.
1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11 5 Contact block holders (Maximum 4 contact blocks)
2 N.O. CBK-CB10 + CBK-CB10 20 16.00 To order an assembled unit with a 5 contact block holder, add the digit "5" to the
2 N.C. CBK-CB01 + CBK-CB01 02 end of the catalog number and add $ 4.00 to the list price.
EX: CBG-3MK5, $ 27.00
• To order a selector switch operator complete with contact block, add the Example of individual component ordering
appropriate suffix code to the end of the catalog number and add the list
price adder to the operator list price. CBG-3MK10
EX: CBG-3MK10, $ 31.00
CBG-3MK + CBK-CB10 =
• To order just the contact block, refer to "Separate contact blocks" column and $ 23.00 $ 8.00 $ 31.00
indicate catalog number and quantity.
EX: CBK-CB10, qty 1, $ 8.00
A B C A B C
A
A X
X 41 42
43 44
X 43 13 23 53 X
41 11 21 51
13 14 11 12
X 44 14 24 54 42 12 22 52
23 24 X
21 22
A
X
53 54 A
X
A Contacts may be N.O. or N.C. 51 52
A Contacts may be N.O. or N.C.
For B position, normally open function For B position, normally closed function

AC 1400 – 2/00
Selector switches
Illuminated
2 position
Knob operator — 2 position1
Type Color
Translucent knob operator
B C Maintained Clear CBG-2BMKIC CBG-M2BMKIC
Red CBG-2BMKIR CBG-M2BMKIR
Green CBG-2BMKIG $ 37.00 CBG-M2BMKIG $ 37.00
Yellow CBG-2BMKIY CBG-M2BMKIY
Blue CBG-2BMKIL CBG-M2BMKIL
Momentary Clear CBG-2BSKIC CBG-M2BSKIC
B Red CBG-2BSKIR CBG-M2BSKIR
C Green CBG-2BSKIG 49.00 CBG-M2BSKIG 49.00
CBG-M2BMKIY Yellow CBG-2BSKIY CBG-M2BSKIY
Blue CBG-2BSKIL CBG-M2BSKIL
Maintained Clear CBG-2AMKIC CBG-M2AMKIC
A C Red CBG-2AMKIR CBG-M2AMKIR
Green CBG-2AMKIG 37.00 CBG-M2AMKIG 37.00
Yellow CBG-2AMKIY CBG-M2AMKIY
Blue CBG-2AMKIL CBG-M2AMKIL
Lever operator — 2 position1

Type Color
B C Maintained Clear CBG-2BMLIC CBG-M2BMLIC
Red CBG-2BMLIR CBG-M2BMLIR
Green CBG-2BMLIG $ 37.00 CBG-M2BMLIG $ 37.00
Yellow CBG-2BMLIY CBG-M2BMLIY
Blue CBG-2BMLIL CBG-M2BML IL
Momentary Clear CBG-2BSLIC CBG-M2BSLIC
B Red CBG-2BSLIR CBG-M2BSLIR
C Green CBG-2BSLIG 49.00 CBG-M2BSLIG 49.00
30 mm
Yellow CBG-2BSLIY CBG-M2BSLIY

CBG-M2BMLIY Blue CBG-2BSLIL CBG-M2BSLIL
Maintained Clear CBG-2AMLIC CBG-M2AMLIC
A C Red CBG-2AMLIR CBG-M2AMLIR
Green CBG-2AMLIG 37.00 CBG-M2AMLIG 37.00
Yellow CBG-2AMLIY CBG-M2AMLIY
Blue CBG-2AMLIL CBG-M2AMLIL

Item
1 N.O. CBK-CB10 10 $ 8.00

1 N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00
Illuminated selector switches are complete except for lamp modules, lamp
CBK-CB10
bulbs, and contact blocks which should be ordered as separate components.
EX: To order a knob selector switch operator with a red 120V full voltage light
and 2 N.O. contact blocks:
• CBK-2BMKIR $ 37.00
• CBK-LMF 17.50
• CBK-LB1 6.00
• (2) CBK-CB10 16.00
TOTAL $ 76.50
To order an assembled unit with a 5 contact block holder, add the digit "5" to the
end of the catalog number and add $ 4.00 to the list price.
EX: CBG-2BMKIR5, $ 41.00
Selector switch contacts — 2 position
5 contact block holder As viewed from the front, the contacts are in the normal position with the switch
handle in either the "A" or "B" position. In the "C" position, the contact(s) change
state.
1 Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21

AC 1400 – 2/00
Selector switches
Illuminated
3 position
Knob operator — 3 position1
Type Color
Maintained Clear CBG-3MKIC CBG-M3MKIC
A BC Red CBG-3MKIR CBG-M3MKIR
Green CBG-3MKIG $ 37.00 CBG-M3MKIG $ 37.00
Yellow CBG-3MKIY CBG-M3MKIY
Blue CBG-3MKIL CBG-M3MKIL
Momentary Clear CBG-3SKIC CBG-M3SKIC
B return from Red CBG-3SKIR CBG-M3SKIR
CBG-M3MKIY A C A & C position Green CBG-3SKIG 49.00 CBG-M3SKIG 49.00
Yellow CBG-3SKIY CBG-M3SKIY
Blue CBG-3SKIL CBG-M3SKIL
Momentary Clear CBG-3SRKIC CBG-M3SRKIC
B return from Red CBG-3SRKIR CBG-M3SRKIR
A C C position Green CBG-3SRKIG 49.00 CBG-M3SRKIG 49.00
Yellow CBG-3SRKIY CBG-M3SRKIY
Blue CBG-3SRKIL CBG-M3SRKIL
B Momentary Clear CBG-3SLKIC CBG-M3SLKIC

A C return from Red CBG-3SLKIR CBG-M3SLKIR
A position Green CBG-3SLKIG 49.00 CBG-M3SLKIG 49.00
Yellow CBG-3SLKIY CBG-M3SLKIY
Blue CBG-3SLKIL CBG-M3SLKIL
Lever operator — 3 position1

Type Color
Maintained Clear CBG-3MLIC CBG-M3MLIC
A BC Red CBG-3MLIR CBG-M3MLIR
30 mm
Green CBG-3MLIG $ 37.00 CBG-M3MLIG $ 37.00
Yellow CBG-3MLIY CBG-M3MLIY
Blue CBG-3MLIL CBG-M3MLIL
CBG-M3MLIY Momentary Clear CBG-3SLIC CBG-M3SLIC
B return from Red CBG-3SLIR CBG-M3SLIR
A C A & C position Green CBG-3SLIG 49.00 CBG-M3SLIG 49.00
Yellow CBG-3SLIY CBG-M3SLIY
Blue CBG-3SLIL CBG-M3SLIL
Momentary Clear CBG-3SRLIC CBG-M3SRLIC
B return from Red CBG-3SRLIR CBG-M3SRLIR
A C C position Green CBG-3SRLIG 49.00 CBG-M3SRLIG 49.00
Yellow CBG-3SRLIY CBG-M3SRLIY
Blue CBG-3SRLIL CBG-M3SRLIL
Momentary Clear CBG-3SLLIC CBG-M3SLLIC
B return from Red CBG-3SLLIR CBG-M3SLLIR
A C A position Green CBG-3SLLIG 49.00 CBG-M3SLLIG 49.00
Yellow CBG-3SLLIY CBG-M3SLLIY
Blue CBG-3SLLIL CBG-M3SLLIL

Item Separate contact blocks Assembled to List 3 Position
catalog number operator suffix code adder As viewed from the front, the contact(s) are in the normal position with the
1N.O. CBK-CB10 10 switch handle in the "B" position. In the "A" position, the left contact(s) change
$ 8.00 state. In the "C" position, the right contact(s) change state.
1N.C. CBK-CB01 01
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11
2 N.O. CBK-CB10 + CBK-CB10 20 16.00 5 Contact block holders (Maximum 4 contact blocks)
2 N.C. CBK-CB01 + CBK-CB01 02 To order an assembled unit with a 5 contact block holder, add the digit "5" to the
Illuminated selector switches are complete except for lamp modules, lamp EX: CBG-3MKIR5, $ 41.00
bulbs, and contact blocks which should be ordered as separate components.
EX: To order a knob selector switch operator with a red 120V full voltage light
and 2 N.O. contact blocks:
• CBG-3MKIR $ 37.00
• CBK-LMF 17.50
• CBK-LB1 6.00
• (2) CBK-CB10 16.00
TOTAL $ 76.50
1 Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21

AC 1400 – 2/00
Selector switches
Illuminated
Components
Lamp modules — operator mounted Lamp bulbs
Catalog List Voltage Catalog List
Item Voltage Item
Filament Neon Filament
type type 6 VAC/DC CBK-LB6
Full voltage type CBK-LMF $ 17.50 12 VAC/DC CBK-LB12
24 VAC/DC CBK-LB24
Resistor type 30 VAC/DC CBK-LB30
120V/60V CBK-LMR1 48 VAC/DC CBK-LB48 $ 6.00
240V/120V CBK-LMR2 60 VAC/DC CBK-LB60
21.50
24V1 CBK-LMR24 130 VAC/DC CBK-LB1
CBK-LMF 120V/24V2 CBK-LMLED Neon3
110 VAC/DC CBK-LBN1
220 VAC CBK-LBN2
Transformer type 4 CBK-LB6 CBK-LBN1
220 VDC CBK-LBND2
120V/6V CBK-LT1
Color
240V/6V CBK-LT2 LED bulbs
380V/6V CBK-LT3 Standard
480V/6V CBK-LT4 35.00 Red 24 VAC/DC CBK-LBD8R 15.00
120V/24V CBK-LT124 120 VAC CBK-LBD1R 15.00
240V/24V CBK-LT224 230 VAC CBK-LBD2R 21.00
380V/24V CBK-LT324 Green 24 VAC/DC CBK-LBD8G 15.00
CBK-LT1 480V/24V CBK-LT424 120 VAC CBK-LBD1G 15.00
230 VAC CBK-LBD2G 21.00
NOTE: Illuminated selector switch operators are complete except for lamp
bulbs, lamp modules & contact blocks; these should be ordered separately from Yellow 24 VAC/DC CBK-LBD8Y 15.00
the above. 120 VAC CBK-LBD1Y 15.00
230 VAC CBK-LBD2Y 21.00
Blue 24 VAC/DC CBK-LBD8L 18.00
CBK-LBD1R 120 VAC CBK-LBD1L 18.00
230 VAC CBK-LBD2L 24.00
White 24 VAC/DC CBK-LBD8W 18.00
120 VAC CBK-LBD1W 18.00
Flashing
30 mm
Red 24 VDC CBK-LBDRF

Green 24 VDC CBK-LBDGF 20.00
Yellow 24 VDC CBK-LBDYF
1 Designed for electronic circuits. The resistor limits the making current and prevents disturbances in the circuit. 24V filament lamp bulb required.
2 Designed for LED 24V bulbs.
3 Use with red, yellow and clear lenses only.
4 Mounts onto CBK-LMF.

AC 1400 – 2/00
Key operated selector switches
Key operated
Description
Catalog number List price Catalog Number List price
B C
2 Position
Maintained
Key removal from all positions CBG-S2KM4 CBG-MS2KM4
B C
Maintained
Key removal from B position CBG-S2KM1 $ 60.00 CBG-MS2KM1 $ 60.00
B Momentary
C
Key removal from B position CBG-S2KS1 CBG-MS2KS1
CBG-MS2KM4
3 Position
A BC
Maintained
Key removal from all positions CBG-S3KM4 CBG-MS3KM4
B C
Maintained
Key removal from B position CBG-S3KM2 72.00 CBG-MS3KM2 72.00
B Momentary
A C
Key removal from B position, spring return
from A & C positions to B position CBG-S3KS2 CBG-MS3KS2
B Momentary
A C
Key removal from A position, spring return CBG-S3KSR1 CBG-MS3KSR1
CBG-MS3KM4 from C position to B position

Separate contact blocks Assembled to List 2 Position
Type As viewed from the front, the contacts are in the normal position with the switch
handle in the "B" position. In the "C" position, the contact(s) change state.
30 mm
1 N.O. CBK-CB10 10 $ 8.00 3 Position
1 N.C. CBK-CB01 01 As viewed from the front, the contact(s) are in the normal position with the
1 N.O. & 1 N.C. CBK-CB10 + CBK-CB01 11 switch handle in the "B" position. In the "A" position, the left contact(s) change
2 N.O. CBK-CB10 + CBK-CB10 20 16.00 state. In the "C" position, the right contact(s) change state.

• To order a selector switch operator complete with contact block, add the
appropriate suffix code to the end of the catalog number and add the list
price adder to the operator list price. EX: CBG-S2KM410, $ 68.00
• To order just the contact block, refer to "Separate contact blocks" column
and indicate catalog number and quantity. EX: CBK-CB10, qty 1, $ 8.00

To order an assembled unit with a 5 contact block holder, add the digit "5" to the
EX: CBG-S2KM45, $ 64.00

AC 1400 – 2/00
Standard pilot lights

Item
Operator only1
CBG-KLF★ $ 28.00 CBG-MLF★ $ 28.00
Full voltage type
6V CBG-KLF6★ CBG-MLF6★
24V CBG-KLF8★ 51.50 CBG-MLF8★ 51.50
Resistor type
120V/60V CBG-KLR1★ 55.50 CBG-MLR1★ 55.50
240V/120V CBG-KLR2★ CBG-MLR2★
CBG-MLF1G
Transformer type
120V/6V CBG-KLT1★ CBG-MLT1★
240V/6V CBG-KLT2★ 69.00 CBG-MLT2★ 69.00
LED bulb2
Full voltage
24V CBG-KLFL8★ 60.50 CBG-MLFL8★ 60.50
CBG-MLT1G
Transformer type
380V/24V CBG-KLTL3★ CBG-MLTL3★
78.00 78.00
480V/24V CBG-KLTL4★ CBG-MLTL4★
★ Select the lens color from the “Illuminated buttons & lenses” selection chart and substitute the suffix code for the ★. The
30 mm
lens and bulb are included in the price (except for operator-only devices).
Lamp bulbs
Voltage Catalog List
Item
number price
Filament Neon Filament
CBG-MLTL4Y type type 6 VAC/DC CBK-LB6
12 VAC/DC CBK-LB12
24 VAC/DC CBK-LB24
30 VAC/DC CBK-LB30
48 VAC/DC CBK-LB48 $ 6.00
60 VAC/DC CBK-LB60
130 VAC/DC CBK-LB1
Neon3
110 VAC/DC CBK-LBN1
220 VAC CBK-LBN2
CBK-LB6 CBK-LBN1
220 VDC CBK-LBND2
Color
Standard
LED bulbs
Red 24 VAC/DC CBK-LBD8R 15.00
120 VAC CBK-LBD1R 15.00
CBG-MLFL8G
Green 24 VAC/DC CBK-LBD8G 15.00
★ Illuminated buttons and lenses 120 VAC CBK-LBD1G 15.00
Suffix 230 VAC CBK-LBD2G 21.00
Color
code Yellow 24 VAC/DC CBK-LBD8Y 15.00
Red R 120 VAC CBK-LBD1Y 15.00
Green G 230 VAC CBK-LBD2Y 21.00
CBK-LBD1R
Yellow Y Blue 24 VAC/DC CBK-LBD8L 18.00
Blue L 120 VAC CBK-LBD1L 18.00
Clear 4 C 230 VAC CBK-LBD2L 24.00
White W White 24 VAC/DC CBK-LBD8W 18.00
NOTE: White LEDs come with clear lenses. 120 VAC CBK-LBD1W 18.00
1 Lamp module and bulb must be ordered separately; see pages 2.20 - 2.21 Flashing
2 For blue & white LEDs, add $ 3.00 to list price. Red 24 VDC CBK-LBDRF
3 Use with red, yellow and clear lenses only. Green 24 VDC CBK-LBDGF 20.00
4 To order a lens insert, refer to the lens insert selection chart on pages 2.22 - 2.23 and place Yellow 24 VDC CBK-LBDYF
the appropriate suffix code at the end of the catalog number (but before the contact block
suffix code, if there is one) and add $ .90 to the list price.

AC 1400 – 2/00
Components
Potentiometer, reset button
Potentiometer
Resistance
0 – 5 kilohm CBG-KSP5K CBG-MSP5K
$ 105.00 $ 105.00
0 – 10 kilohm CBG-KSP10K CBG-MSP10K
Note: Both trimmers have resistive elements made from cermet. These types of trimmers are excellent for commercial applications. The
cermet element provides a continuous contact surface for the wiper. A continuous contact surface allows the resistance value to be set closer
to the desired value than a typical wire-wound resistor.
Technical data1
Resistance range 0 to 5 kilohm for 5 kilohm potentiometer
CBG-KSP5K 0 to 10 kilohm for 10 kilohm potentiometer
Resistance tolerance +/- 10%
Power rating 2W
Reset actuator, UL Type 4X

Item
Black button with "RESET" engraved legend. CBG-RB $ 18.00 CBG-MRB $ 18.00
CBG-RB
30 mm
1 At room ambient: +25°C nominal and 50% relative humidity nominal

AC 1400 – 2/00
Components
Contact blocks & holders
Operator mounted contacts

All CBK contact blocks, lamp modules and
transformers can be used with CBK 22mm and
CBG 30mm operators.
Contact blocks are color coded to easily

identify the contact configuration:
• Green — Normally Open (N.O.) contacts
• Red — Normally Closed (N.C.) contacts
In addition, they snap-on to the operator for Operator mounted
time saving installation. contact block
Contact blocks – operator mounted

Contact Catalog List Operator with 5 contact block holder
Item
configuration number price
1 N.O. CBK-CB10 $ 8.00

1 N.C. CBK-CB01
Gold plated low energy contacts, 24VAC, 5mA

1 N.O. CBK-CB10G 16.00
CBK-CB10 1 N.C. CBK-CB01G
Dummy block CBK-XBB 2.00

CBK-XBB
30 mm
Contact block holders

Catalog List
Item
number price
5 block holder CBK-H5 4.00

includes two
CBK-AB bridges
CBK-H5
Bridges CBK-AB 2.00
CBK-AB

AC 1400 – 2/00
Components
Lamp modules & transformers
Lamp modules & transformers — operator mounted Lamp modules & transformers — base mounted
Catalog List Catalog List
Item Voltage Item Voltage
Lamp module
Full voltage type CBK-LMF $ 17.50 Full voltage type CBK-LMFB $ 17.50
Resistor type
Resistor type 120V/60V CBK-LMRB1
120V/60V CBK-LMR1 240V/120V CBK-LMRB2
21.50
240V/120V CBK-LMR2 21.50
24V1 CBK-LMR24
CBK-LMF 120V/24V2 CBK-LMLED
CBK-LMFB
Lamp module transformer
Lamp bulbs
120V/6V CBK-LMT1
240V/6V CBK-LMT2 Voltage Catalog List
Item
380V/6V CBK-LMT3 number price
480V/6V CBK-LMT4 35.00 Filament Neon Filament
120V/24V CBK-LMT124 type type 6 VAC/DC CBK-LB6
240V/24V CBK-LMT224 12 VAC/DC CBK-LB12
380V/24V CBK-LMT324 24 VAC/DC CBK-LB24
CBK-LMT1 480V/24V CBK-LMT424 30 VAC/DC CBK-LB30
48 VAC/DC CBK-LB48 $ 6.00
Illuminated pushbutton transformer 4 60 VAC/DC CBK-LB60
130 VAC/DC CBK-LB1
120V/6V CBK-LT1 Neon3
240V/6V CBK-LT2 110 VAC/DC CBK-LBN1
380V/6V CBK-LT3 220 VAC CBK-LBN2
CBK-LB6 CBK-LBN1
480V/6V CBK-LT4 35.00 220 VDC CBK-LBND2
120V/24V CBK-LT124 Color
240V/24V CBK-LT224
380V/24V CBK-LT324 Standard
CBK-LT1 LED Bulbs
480V/24V CBK-LT424 Red 24 VAC/DC CBK-LBD8R 15.00
30 mm
Diode block Green 24 VAC/DC CBK-LBD8G 15.00
Catalog List 120 VAC CBK-LBD1G 15.00
Item Voltage
number price 230 VAC CBK-LBD2G 21.00
Yellow 24 VAC/DC CBK-LBD8Y 15.00
Blue 24 VAC/DC CBK-LBD8L 18.00
250V, 1A CBK-CBD $ 14.00 CBK-LBD1R
White 24 VAC/DC CBK-LBD8W 18.00
CBK-CBD 230 VAC CBK-LBD2W 24.00
Flashing
Red 24 VDC CBK-LBDRF
Diagram for lamp test Green 24 VDC CBK-LBDGF 20.00
X1 X2 Yellow 24 VDC CBK-LBDYF
R
2 1
X1 X2
R
2 1
X1 X2
R
2 1
13 14
LAMP TEST DIODE PILOTLIGHTS
PUSHBUTTON UNITS
WHEN SEVERAL PILOT LIGHTS ARE CONNECTED

TO A COMMON LAMP TEST BUTTON, CONNECT A
DIODE TO EACH PUSHBUTTON AS SHOWN.
A SPECIAL DIODE BLOCK IS AVAILABLE FOR THIS
PURPOSE.
1 Designed for electronic circuits. The resistor limits the making current and prevents disturbances in the circuit. 24V filament bulb required.
2 Designed for LED 24V bulbs.
3 Use with red, yellow and clear lenses only.
4 Mounts on to CBK-LMF.

AC 1400 – 2/00
Components
Pushbutton and pilot light lens inserts1
Flush button Extended button Pilot light

Suffix2 List
Legend Cap color catalog catalog catalog
code price
number number number
White C21 CBK-KC21 CBK-KC21E CBK-KC21P

0 Red C22 CBK-KC22 CBK-KC22E —
Black C23 CBK-KC23 — —
I Red C25 CBK-KC25 — —
II Red C28 CBK-KC28 — —
III White C30 CBK-KC30 CBK-KC30E —

White C32 CBK-KC32 CBK-KC32E —
+ Red C33 CBK-KC33 — —
– Red C36 CBK-KC36 — —

30 mm

White C49 CBK-KC49 CBK-KC49E — $ .90
White C78 — — CBK-KC78P
White C79 — — CBK-KC79P
White C76 CBK-KC76 — —
1 Illuminated pushbuttons and pilot lights must use white insert.

2 For extended pushbuttons, insert “E” at the end of the catalog number. For pilot lights, insert “P” at end of the catalog number.

AC 1400 – 2/00
Components
Pushbutton and pilot light lens inserts1
Flush button Extended button Pilot light

Suffix List
Legend Cap color catalog catalog catalog
code2 price
number number number
Start White C67 CBK-KC67 CBK-KC67E CBK-KC67P
START Green C5 CBK-KC5 — —

On White C68 CBK-KC68 CBK-KC68E CBK-KC68P
White C69 CBK-KC69 — CBK-KC69P
ON Green C70 CBK-KC70 — —
Off White C71 CBK-KC71 CBK-KC71E CBK-KC71P
White C72 — CBK-KC72E —
OFF Red C73 — CBK-KC73E —
Black C2 CBK-KC2 CBK-KC2E —
Stop White C74 CBK-KC74 CBK-KC74E CBK-KC74P
STOP Red C4 CBK-KC4 CBK-KC4E —
$ .90
Reset White C75 CBK-KC75 CBK-KC75E CBK-KC75P
Blank White C15 CBK-KC15 CBK-KC15E CBK-KC15P

Green CG CBK-KCG CBK-KCEG —
UP Green C11 CBK-KC11 — —
DOWN Green C12 CBK-KC12 — —
OPEN White C16 CBK-KC16 — —

Green C19 CBK-KC19 — —
CLOSE White C17 CBK-KC17 — —

Green C20 CBK-KC20 — —
REV Green C6 CBK-KC6 — —
FWD Green C7 CBK-KC7 — —
30 mm
SLOW Green C8 CBK-KC8 — —
FAST Green C9 CBK-KC9 — —
JOG Green C10 CBK-KC10 — —
RESET Black C3 CBK-KC3 — —
LATCH White C18 CBK-KC18 — —
Flush Extended Pilot light Examples of inserts

pushbutton pushbutton 1 2 3
Insert assembly
1 Illuminated pushbuttons and pilot lights must use white insert.

2 For extended pushbuttons, insert “E” at the end of the catalog number. For pilot lights, insert “P” at end of the catalog number.

AC 1400 – 2/00
Components
Fixed nameplates
Fixed nameplates — Aluminum
Catalog List
Legend
number price
1 Position
CLOSE CBG-NPE1
DOWN CBG-NPE2
EMERGENCY STOP CBG-NPE3
FAST CBG-NPE4
CBG-NPE22 FORWARD CBG-NPE5
INCHING CBG-NPE6
IN CBG-NPE7
LEFT CBG-NPE8
LOWER CBG-NPE9
OFF CBG-NPE10
ON CBG-NPE11 $ 1.80
OPEN CBG-NPE12
RAISE CBG-NPE13
RESET CBG-NPE14
REVERSE CBG-NPE15
RUN CBG-NPE16
RIGHT CBG-NPE17
SLOW CBG-NPE18
CBG-NPE30 START CBG-NPE19
STOP CBG-NPE20
UP CBG-NPE21
2 Position (BC position)
HAND/AUTO CBG-NPE22
JOG/RUN CBG-NPE23
OFF/ON CBG-NPE24 1.80
STOP/START CBG-NPE25
FWD/REV CBG-NPE32
2 Position (AC position)
30 mm
HAND/AUTO CBG-NPE22AC
JOG/RUN CBG-NPE23AC
OFF/ON CBG-NPE24AC 1.80
STOP/START CBG-NPE25AC
FWD/REV CBG-NPE32AC
3 Position
HAND/O/AUTO CBG-NPE26
SLOW/OFF/FAST CBG-NPE27 1.80
LOW/OFF/HIGH CBG-NPE31
Blank
BLANK — Aluminum (1 – 2 line) CBG-NPE28
BLANK — Aluminum (2 – 3 line) CBG-NPE29 1.80
Custom engraving
NOTE: For custom engraving instructions, 5.20
please see “Ordering Instructions,” page 2.25.
Other
EMERGENCY STOP (70mm)1 CBG-NPE30 6.00
1 Nameplate is 70mm in diameter.

AC 1400 – 2/00
Components
Custom engraved nameplates
Fixed nameplates — aluminum 1

Maximum
Type letters Catalog List
per line number price
1
1 2 16 CBG-NPE28-01
2 3
1.75
1.54 44.50
36.00
1.18 1.18 16 CBG-NPE29-01

30.00 30.00
CBG-NPE28-01 Pushbuttons or pilot lights
1
General specifications 1 2 18 CBG-NPE28-02
1. All characters are 1/8" high, upper & lower case. Please specify if 2 3
all capital letters are desired. 1.54 1.75
44.50
39.00
2. All special engravings involve engraving the desired lettering into
the metal surface and then treating the engraved surfaces with 16 (line 1)
black ink. 1.18 1.18
8 (line 2) CBG-NPE29-02
30.00 30.00 8 (line 3)
Ordering custom engraved nameplates 2 Position selector switches
1. Select the desired legend plate.
2. Indicate the catalog number.
1 8 CBG-NPE28-03
3. Write the desired words to be engraved on each line. 1 2
2A 2B 3A 3B
EXAMPLE: CBG-NPE28-02 $ 5.20
1.54 1.75
Line 1: Pump No. 1 39.00 44.50
Line 2: Off
16 (line 1)
8 (line 2)
1.18 1.18 8 (line 3) CBG-NPE29-03
30.00 30.00 8 (line 3A)
30 mm
3 Position selector switches 8 (line 3B)
1.54
39.00
1
5 CBG-NPE28-04
1.18
30.00
1.18
30.00
2 6 CBG-NPE29-04
1.75
44.50
2 Position toggle switches
1.54
39.00
5 (line 1)
1
5 (line 1) CBG-NPE28-05
2 1.18 5 (line 1)
30.00
3
2 1.18 5 (line 1)
30.00
3 5 (line 1) CBG-NPE29-05
5 (line 1)
1.75
44.50
3 Position toggle switches
1 For drilling plans, see page 2.31.

AC 1400 – 2/00
UL & IEC enclosure standards comparison
Protection to Protection to UL 50
IEC definition UL 50 definition
IEC 144/BS5420 enclosure type
Protected against solid objects IP 20 1 (ventilated) General purpose

greater than 12mm
Protected against solid objects
IP 30 1 General purpose
greater than 2.5mm
Protected against solid objects IP 21 2 (ventilated) Drip proof
greater than 12mm and dripping water
Protected against solid objects IP 24 3R (ventilated) Rain proof, sleet (ice) resistant,
greater than 2.5mm and dripping water outdoor use
Protected against solid objects IP 34 3R Rain proof, sleet (ice) resistant,
greater than 2.5mm and dripping water outdoor use
Protected against dust & splashing liquid IP 54 — —
Dusttight, protected against waterjets IP 65 12 Industrial use, dusttight and driptight
Dusttight, protected against heavy seas IP 66 3S Dusttight, driptight
Dusttight, protected against heavy seas IP 66 4 Dusttight, watertight
Dusttight, watertight,
— — 4X
corrosion resistant
Submersible, watertight, dust-
Dusttight, protected against heavy submersion IP 68 6 tight, sleet (ice), resistant indoor
or outdoor
— — 13 Oiltight and dusttight
Protection against settling airborne dust,
Protected against dust & splashing liquid IP 54 5 falling dirt and dripping noncorrosive
liquids
30 mm

AC 1400 – 2/00
UL Technical data
General UL technical data Contacts — NEMA A600, 10A thermal

Contact blocks Voltage Inductive amps Maximum make Maximum break
Rated insulation voltage, UL 600V 120 VAC 6A
Minimum rating 24VDC, 5mA 240 VAC 3A
Mechanical life (millions of operations) 10 7200VA 720VA
480 VAC 1.5A
Temperature specifications 600 VAC 1.2A
Ambient temperature -30°C to +70°C
Exceptions:
Illuminated pushbutton (continuously lit) -30°C to +40°C Contacts — NEMA P600, 5A thermal
Pilot light (continuously lit) -30°C to +40°C
Maximum make Maximum make or
Storage temperature -30°C to +85°C
Voltage or break break volt-amps
Terminal connections Recommended current at 600V or less
Wire size
Contact blocks torque
125 VDC 1.1A 138VA
Minimum 20 AWG 250 VDC 0.55A 138VA
Maximum 2 x 12 AWG 301 – 600 VDC 0.22A 138VA
Lamp assemblies 7 lb. in.
Minimum 20 AWG
Maximum 2 x 14 AWG Low energy contacts — gold plated
Plus-minus pozidrive size 2 screws with DIN washer
Range Rating
Contact block terminal marking Maximum NEMA A600 & NEMA P600
Minimum 5VAC/DC, 2mA; 12VAC/DC, 1mA;
Type 1 N.O. 1 N.C. 24VAC/DC, 5mA
Catalog number CBK-CB10(G) CBK-CB01(G)
Schematic Lamp bulbs connected in common

diagram If several lamps are to be connected to a common lamp-test
13 14 21 22 pushbutton, a separate diode must be connected in series with each
respective lamp. A special block with a built-in diode (CBK-CBD) is
Approvals available for this purpose and can be securely snapped onto the lamp
CBK, 22mm block or placed at the side.
NEMA & UL Listed for Types 1, 3R, 4, 4X, 12 & 13 applications
CBG, 30mm
30 mm
NEMA & UL Listed for Types 1, 3R, 4, 4X, 12 & 13 applications
X1 X2
R
2 1
X1 X2
R
2 1
X1 X2
R
2 1
13 14
LAMP TEST DIODE PILOTLIGHTS
PUSHBUTTON UNITS

AC 1400 – 2/00
IEC Technical data
Mechanical life Lamp block

Operators Ratings as per IEC 947-5-1
Pushbuttons with flush or extended button, Rated insulation voltage 230V
momentary mushroom pushbutton 2 million operations Base BA 9s
Selector switch, maintained mushroom push-button, Max. permissible power 2W
key operated selector switch and double pushbutton 0.5 million operations Service life of filament bulb
Toggle switch 1 million operations Relative service life, luminous flux and power consumption at different
service voltages.
Lockable pushbuttons 0.3 million operations
It is generally true to say that bulbs for lower voltages give more light and
Temperature have better vibration-withstand capability than bulbs for higher voltages.
Ambient temperature during operation -25 to +70°C
Exception: All pilot devices with 2 W
continuously lit filament bulb -25 to +40°C Service life
Storage temperature -30 to +85°C
Terminals a = service life (H)
Plus-minus pozidrive size 2 screw with DIN-washer. b = luminous flux (lm)
Connectable area min. 1 x 0.5mm 2 c = power (W)
max. 2 x 2.5mm2 Ud = service voltage, V
Recommended torque 0.9 Nm Um= bulb voltage (V)
Contact blocks
Mechanical endurance 10 million operations
Self cleaning contacts of silver, N.C. contact has
forced breaking. Ud / Um
At voltages and currents below 24 V and 5.6 mA two
contact blocks in parallel are recommended. As an Lamp comparison
alternative, gold plated contacts are recommended.
Approx. Shock and High
Ratings as per UL/CSA, NEMA A 600, Q600 Bulb Low power
service vibration operating Brightness
Rated insulation voltage 600V type consumption
life (hours) immunity temperature
Rated thermal current 10A
Filament 5000–
Rated operational current at 120V 6A
10,000 + + + +++
240V 3A
480V 1.5A Neon 20,000 ++ +++ +++ +
600V 1.2A LED 25,000–
50,000 +++ ++ ++ ++
Ratings as per IEC 947-5-1
30 mm
Rated insulation voltage, Ui 690V Very good +++

Rated thermal current, Ith 10A Good ++
Rated operational current, Ie Less good +
utilization category AC 15, at 120V 8A
230V 6A Transformer block
400V 4A Suitable for bulb 6 or 24V and 1.2W and LED 24V.
690V 2A Rated power 1.5 W
Rated operational current, Ie Rated voltage Ratio, see page 2.21
utilization category DC 13, at 24V 5A Rated insulation voltage acc. to IEC
125V 1.1A
250V 0.55A 70°C (∆T) Class E
Contact resistance .025 ohms

Max. number of contact blocks per operator1 Bulbs
Pushbutton, toggle switch 6 Voltage Rated current, mA Rated output, W
Mushroom pushbutton 5
Double pushbutton, selector switch, key operated Filament type
selector switch and emergency stop pushbuttons 4 6VAC/DC 200 1.2
12VAC/DC 100 1.2
Short circuit protection 24VAC/DC 50 1.2
Max. fuse at 1 kA 16 A ordinary 30VAC/DC 40 1.2
10 A delayed 48VAC/DC 42 2
60VAC/DC 20 1.2
130VAC/DC 15 2
Neon type
110VAC/DC 0.8 0.10
220VAC 1.9 0.40
220VDC 0.9 0.20
LED type
24VAC/DC 20 .48
120VAC 5 .6
240VAC 4 .92
Flashing LED type
24VDC 25 .60
1 Contact blocks can be stacked maximum two deep.

AC 1400 – 2/00
00.00 Inches
00.00 Millimeters Approximate dimensions
Pushbutton and illuminated pushbutton Mushroom pushbutton — 40mm (Momentary)
1.61 0.06 - 0.24

41.0 1.5 - 6.1
0.06 - .236
R=1.14 ;;
;;
1.5 - 6.1
;;
29.0 R=1.14
29.0
1.69 1.14 0.92

42.9 29.0 23.4 1.69 1.57
42.9 40
;;
;;
1.18
30.0
;;
0.50 2.12 1.18 1.00 2.20
12.7
30 0
53.9
Illuminated pushbutton with transformer Mushroom pushbutton — 60mm
1.61 0.06 - 0.24 0.06 - .236

41.0 1.5 - 6.1 1.5 - 6.1
R=1.14 ;;
;;
R=1.14
29.0
;;
29.0
1.69 1.14 0.92 1.69 2.36

42.9 29.0 23.4 42.9 60
;;
;;
1.18
30.0 1.18 1.00 2.20
0.50 3.24 30.0 25.5 56
12.7
30 mm
82.3
Mushroom pushbutton — 30mm Mushroom pushbutton — 40mm lockable
1.61 0.06 - 0.24

41.0
1.5 - 6.1 1.61 0.06 - 0.236
;;
41.0 1.5 - 6.1
R=1.14
;; ;;
;;
29.0
R=1.14
29.0
1.69 1.24
;;
42.9 31.5 1.69 1.57
42.9 40.0
;;
;; ;;
1.18 1.18 1.96
1.25
31.7 ;; 2.12
30.0 30.0 49.8 53.9
1.30 2.12
33.0 53.9
Mushroom pushbutton — 40mm (Push-pull & twist release) Toggle switch
1.61 0.06 - 0.24

1.61 0.06 - 0.236 41.0 1.5 - 6.1
41.0 1.5 - 6.1
;; R=1.14
;;
R=1.14
29.0
;;
;;
29.0
1.00
25.4
1.69 1.57 1.69

40.0 42.9
42.9
;; ;;
1.18 1.29
;; 2.12 1.18
30.0 32.8 53.9 30.0
1.57 2.12
40.0 53.9

AC 1400 – 2/00
00.00 Inches
Approximate dimensions 00.00 Millimeters
Key operated pushbutton Pilot light
1.61 0.06 - 0.24 1.61 0.06 - 0.24

41.0 1.5 - 6.1
;;
41.0 1.5 - 6.1
R=1.14
;; ;;
;;
;;
29.0 R=1.14
;;
29.0
1.69 1.14
42.9 29.0
1.69 1.14
;; 42.9 29.0
;; ;;
1.18
30.0
1.0
25.4 ;;
;;
1.91 2.12 1.18
48.5 53.9 30.0
0.50 2.12
12.7 53.9
Selector switch — knob handle Pilot light with transformer
1.61 0.06 - .24

41.0 1.5 -6 .1
;;
1.61 0.06 - 0.24
41.0 1.5 - 6.1 R=1.14
;;
29.0
R=1.14
29.0
1.69 1.14
42.9 29.0
1.69 0.85
42.9 21.6
;; ;;
1.18 1.18 0.50
30.0 30.0 12.7
1.14 2.12 2.50
53.9
30 mm
29.0
63.5
Selector switch — lever handle Reset actuator
1.61 0.06 - 0.24

41.0
;; 1.5 - 6.1
;;
1.18 0.06 - 0.24
1.5 - 6.1
30.0
;;
R=1.14
29.0 ;; 1.61 1.14
41.0 29.0
1.69
42.9
;;
;; 0.75
1.18....7.87 19.0
;;
30.0....200.0
1.02 0.28
26.0 7.1
0.40
10.2
0.82 1.14 2.12

0.82 29.0 53.9
20.8 20.8
Selector switch — key operated Transformer block
1.61 0.06 - .24

41.0 1.5 - 6.1
;; 3.94
R=1.14
;;
100.0
;;
29.0
1.69 1.14 1.79

42.9 29.0 45.5
;;
;;
1.18
30.0
1.68
42.7
;; 2.12 0.20
5.1
1.12
28.4
53.9
1.12
28.5

AC 1400 – 2/00
00.00 Inches
00.00 Millimeters Approximate dimensions
Drilling plans
Potentiometer
2.38
60.0
SPEED 50
40 60
30 70
2.00
20 80 51.0
1.12
28.4
10 90
0 100
1.29 1.95
32.8 49.5
3.24
82.3
Drilling plans
1.20 Dia. 1.20 Dia.

30.5 30.5
1.20 Dia.
2.01 2.24 2.01
30.5
30 mm
51.1 56.9 51.1
1.65 1.65
41.91 1.65 41.9

AC 1400 – 2/00
Notes
30 mm

AC 1400 – 2/00
Components
OT
Strip and Ring

1-1/2" Wide Two Offset
Terminals, One End
• 7-1/2 - 47-1/2" Lengths

Dimensions
• 150 - 2,250 Watts A
B
• 120 and 240 Volt 5/16 x 1/2" Slot
1-1/2
• 6 - 27 W/In2
D
#10-32 Thd. 3/8
15/16
Applications
All Dimensions in Inches
Strip heaters are used for heat transfer by
conduction or convection to heat liquids, air,
gases and surfaces. See guidelines in the Strip
Heater Overview section.
Specifications and Ordering Information

Dimensions (In.) Rust-Resisting Iron Sheath Chrome Steel Sheath
120V 240V 120V 240V

Wt.
A B D Watts W/In2 Model Stock PCN Stock PCN Watts W/In2 Model Stock PCN Stock PCN (Lbs.)
7-1/2 6-1/2 6 150 11 OT-715 S 129314 S 129322 200 15 OT-702 S 129613 S 129621 0.5
8 7 6-1/2 150 10 OT-815 S 129330 S 129349 250 17 OT-802 S 129630 S 129648 0.56
8 7 6-1/2 175 12 OT-817 S 129357 S 129365 400 27 OT-804 S 129656 S 129664 0.56
10-1/2 9-1/2 9 250 10 OT-1025 S 129373 S 129381 350 15 OT-1003 S 129672 S 129680 0.75
10-1/2 9-1/2 9 — — — S — — — 400 17 OT-1004 S 129699 S 129701 0.88
12 11 10-1/2 250 8 OT-1225 S 129390 S 129402 250 8 OT-1202 S 129710 S 129728 0.88
12 11 10-1/2 — — — S — — — 350 14 OT-1203 S 129736 S 129744 0.88
12 11 10-1/2 — — — S — — — 500 17 OT-1205 S 129752 S 129760 0.88
14 13 12-1/2 300 8 OT-1430 S 129410 S 129429 500 14 OT-1405 S 129779 S 129787 1
15-1/4 14-1/4 13-3/4 325 8 OT-1532 S 129437 S 129445 500 12 OT-1505 S 129795 S 129808 1.13
17-7/8 16-7/8 16-3/8 350 6.5 OT-1835 S 129453 S 129461 500 10 OT-1805 S 129816 S 129824 1.38
17-7/8 16-7/8 16-3/8 375 7 OT-1837 S 129470 S 129488 750 15 OT-1807 S 129832 S 129840 1.38
17-7/8 16-7/8 16-3/8 500 10 OT-1850 S 129496 S 129509 1,000 19 OT-1801 S 129859 S 129867 1.38
19-1/2 18-1/2 18 350 6 OT-1935 S 129517 S 129525 500 9 OT-1905 S 129875 S 129883 1.5
19-1/2 18-1/2 18 500 8 OT-1950 S 129533 S 129541 750 13.5 OT-1907 S 129891 S 129904 1.5
19-1/2 18-1/2 18 — — — S — S — 1,000 18 OT-1901 S 129912 S 129920 1.5
21 20 19-1/2 500 8 OT-2150 S 129550 S 129568 750 12 OT-2107 S 129939 S 129947 1.63
23-3/4 22-3/4 22-1/4 500 7 OT-2450 S 129576 S 129584 500 7 OT-2405 S 129955 S 129963 1.81
23-3/4 22-3/4 22-1/4 750 10 OT-2475 S 129592 S 129605 750 10 OT-2407 S 129971 S 129980 1.81
23-3/4 22-3/4 22-1/4 — — — — — — — 1,000 14 OT-2401 S 129998 S 130008 1.81
23-3/4 22-3/4 22-1/4 — — — — — — — 1,500 19 OT-2415 S 129226 S 129234 1.81
25-1/2 24-1/2 24 500 6 OT-2550 S 121005 S 121013 750 9 OT-2507 S 121208 S 121216 2.06
25-1/2 24-1/2 24 750 9 OT-2575 S 121021 S 121030 1,000 13 OT-2501 S 121224 S 121232 2
26-3/4 25-3/4 25-1/4 700 8 OT-2670 S 121048 S 121056 1,000 12 OT-2601 S 121240 S 121259 2.19
26-3/4 25-3/4 25-1/4 750 9 OT-2675 NS 121064 S 121072 — — — — — — — 2.19
30-1/2 29-3/8 28 750 8 OT-3075 S 121080 S 121099 750 8 OT-3007 S 121267 S 121275 2.38
30-1/2 29-3/8 28 — — — — — — — 1,000 11 OT-3001 S 121283 S 121291 2.38
30-1/2 29-3/8 28 — — — — — — — 1,250 13 OT-3012 S — S 121304 2.38
33-1/2 32-3/8 31 750 7 OT-3375 S 121101 S 121110 750 7 OT-3307 S 121312 S 121320 2.69
35-7/8 34-3/4 33-1/2 1,000 9 OT-3610 S 121128 S 121136 1,500 13 OT-3601 S 121339 S 121347 2.88
38-1/2 37-1/2 36 800 6 OT-3880 S 121144 S 121152 1,000 8 OT-3801 S 121355 S 121363 3.19
38-1/2 37-1/2 36 1,000 8 OT-3810 S 121160 S 121179 1,500 12 OT-3815 S 121371 S 121380 3.19
42-1/2 41-3/8 40 1,250 9 OT-4312 S 121187 S 121195 1,500 11 OT-4315 S 121398 S 121400 3.38
47-7/8 46-3/4 45-3/8 — — — — — — — 1,350 9 OT-4813 S — S 121419 3.75
47-7/8 46-3/4 45-3/8 — — — — — — — 2,250 14 OT-4822 S — S 121427 3.75
Stock Status: S = stock AS = assembly stock NS = non-stock
To Order—Specify model, PCN, watts, volts and quantity.
www.chromalox.com 1-800-443-2640 A-61

Components
Strip & Ring Heaters
STRIP AND RING

Accessories
separately. Porcelain Hi-Temp Insulation
Shims Porcelain Hi-Temp Insulation —
• Protective Terminal Covers For insulating buss bars spec. 51 porcelain
Shims — Types OT, PT, S, SE and TH. Provide
insulators 1/2 L x 13/16" W with 1/8 x 9/16"
same advantage as flush-top construction and
• Shims slot. 95 pieces per lb.
can be used with stock heaters. Shims are
• Ceramic Post Terminal Shims

Insulators
• Porcelain Hi-Temp Insulation
Protective Terminal Covers — Types OT, PT, To Order — Specify pounds, PCN 269780 and
SE, WS and Seamless Types SSE, SSEM, porcelain insulators.
SSNH and SSNHM. Helps guard terminals
from spillovers, dripping. Removable sheet- For Insulating Bare Wires — Two types
metal cover, with Bx fitting, is shipped available:
Ceramic Post Terminal Insulaters
1. Porcelain Tubing — 3/8" O.D. x 1/8" I.D.
OT-AC-1 (PCN 129242) Ceramic Post Terminal Insulators — All types x 6" L (may be broken for shorter lengths).
except NS and SN. Use with insulated wire to Suitable for 10-gauge or smaller; 8-gauge
C help protect against electrical shock. Wires takes No. 6 porcelain bead.
B
can leave terminal at any angle.
To Order — Specify quantity and PCN 263863.
A
Ceramic Post Terminal Insulators Porcelain Tubing
PT-AC-1 (PCN 255724)

B
C
A 0.031" thick, 29/32" wide and lengths to fit

heater. 2. Porcelain Beads — Listed in table below.
Can be used when wiring does not permit
straight tubing.
PCN 259805 (Nickel plated steel hardware) Porcelain Beads
SE-AC-1 (PCN 256727)
PCN 255732 (Stainless steel hardware)
C B Cap
A A B
Wave Spring
Skirt
Protective Terminal Covers 3. When selecting porcelain beads for
stranded wire, use next larger gauge wire
Dimensions (In.)
and use bead for that size (i.e., 10 gauge
Model A B C stranded wire requires a No. 6 bead).
OT-AC-1 2 2-1/2 2-1/2
PT-AC-1 1-7/8 1-1/8 1-3/4 Porcelain Beads
SE-AC-11 2-1/16 1-1/2 2 Wire No. No.
Bead Dimensions (In.) Size Beads Beads
1. Used on type WS (mounted
sideways). Size A B C Solid Per Ft. Per Lb. PCN
2 0.17 0.068 0.17 14 B&S 88 4,535 263880
3 0.2 0.092 0.2 12 B&S 69 2,900 263900
4 0.26 0.156 0.26 8 B&S 51 1,500 263927
5 0.33 0.124 0.33 10 B&S 45 650 263943
6 0.4 0.156 0.4 8 B&S 38 360 263960
To Order—Specify PCN, number of pounds and quantity.
A-59
A-059.P65 73 9/18/02, 3:16 PM

Components

Wire & Accessories
(cont’d.)
High Temperature (Bare) Wire Buss Bar
• High Temperature (Bare) Wire Size Solid/S Amp- Nom. Manganese- DIM (In.) Amp-
AWG Strand/F acity1 O.D. Model PCN Nickel Width Thick acity1 PCN
• Insulated Wire 550°F Max. Wire Temp. 1100°F Max. Wire Temp.
Nickel-plated Copper, Uninsulated Solid 1/2 .032 26 263847
• Buss Bar 14 S 41 .064 CSB-14 263839 Perforated 1/2 .032 23 263855
10 S 70 .102 CSB-10 263812 To Order — Specify PCN and number
8 S 93 .128 CSB-8 263804 of feet.
• Silicone Boot Termination Kit 1000°F Max. Wire Temp.
Manganese-nickel, Uninsulated 1. These current values will cause the
14 F 12 .075 AFB-14 269317 conductor to operate at 100°F above
• Silicone Boot Termination Kit 14 S 12 .064 ASB-14 269309 surrounding ambient; values may
with Thermostat 12 F 15 .097 AFB-12 269296 also be used for bare wire with
12 S 15 .081 ASB-12 269288 porcelain tubes or bead insulation.
10 F 20 .12 AFB10 269270
10 S 20 .102 ASB-10 269261
Ambient Temperature Corrections for To Order — Specify PCN and quantity.
Insulated Wires — Multiply ampacity values,
in tables below, by the following correction
factors to determine current-carrying capacity Insulated Wire Silicone Boot Termination Kit
at higher ambient temperatures. Nom.
Size Solid/S Amp- O.D. SBK — The silicone boot termination kit
1
AWG Strand/F acity Insul In. Model PCN provides electrical insulation for strip heater
Nickel 392°F Max. Wire Temp. Type A Nickel Wire
Ambient Nickel-Plated MGS- terminals and leads with ring type insulated
Temp. Copper Teflon® Silicone Teflon® Mica Silicone Rubber Treated Glass Braid
Insulated 600V UL Listed connector on one end for bringing power to
°C °F Insulated Glass Glass Glass 16 F 27 .224 3-CFI-16 263759 the strip heaters.
30 86 — — — 1.36 16 S 27 .224 3-CSI-16 263740
50 122 0.98 0.97 0.98 — 14 F 36 .237 3-CFI-14 263732 Silicone Boot Termination Kit
60 140 0.95 0.94 0.95 — 14 S 36 .237 3-CSI-14 263724
70 158 0.93 0.9 0.93 — 12 F 45 .263 3-CFI-12 263716 with Thermostat
80 176 0.9 0.87 0.9 — 12 S 45 .263 3-CSI-12 263708
90 194 0.87 0.83 0.87 — 10 F 60 .29 3-CFI-10 263695 SBKT — The silicone boot termination kit with
100 212 0.85 0.79 0.85 1.22 10 S 60 .29 3-CSI-10 263687 thermostat used with strip heaters provides an
120 248 0.79 0.71 0.79 — 8 F 83 .31 3-CFI-8 263679
140 284 0.72 0.61 0.72 — inexpensive way to maintain temperature in
482°F Max. Wire Temp. Type TGT,
149 300 0.65 0.5 0.65 1.12 Nickel-plated Copper, Teflon® Impregnated control cabinets, panels and other small
177 350 0.58 0.35 0.58 — Glass Braid Insulated 600V UL Listed enclosures. In this application, strip heaters
204 400 0.49 — 0.49 1 are used to prevent freezing and corrosion,
232 450 0.35 — 0.35 — 14 F 39 .121 6-CFI-14 263791
260 500 — — — 0.87 14 S 39 .112 6-CSI-14 295398 and to control humidity in enclosures with
269 550 — — — — 12 F 54 .141 6-CFI-12 263783 humidity sensitive electronic components.
300 572 — — — 0.7 12 S 54 .13 6-CSI-12 295400
10 F 73 .17 6-CFI-10 263775
Note — After exposure to high tempera- 10 S 73 .156 6-CSI-10 295419
tures, all wire insulation becomes brittle Temperature (°F)
8 F 93 .212 6-CFI-8 263767
and will not withstand repeated flexing. Model PCN Closes Opens
482°F Max. Wire Temp. Teflon® Tape and
Silicone Impregnated Glass Braid SBKT-1 386011 38 53
Wire & Buss Bar Insulated 600V UL Listed SBKT-2 386020 60 75
14 F 39 .121 3-AFI-14 269253 SBKT-3 386038 105 120
High-temperature wire and buss bar are 12 F 54 .141 3-AFI-12 269237 SBK 121890 N/A N/A
recommended for connections to heater 10 F 73 .17 3-AFI-10 269210
terminals and for runs in heated zones. When 842°F Max. Wire Temp. Nickel-clad
ambient temperature exceeds maximum Copper, MGS-Mica Glass Insulated 600V SBKT
allowed for insulated wire, use bare wire or 16 F 331 .065 6-CFIM-16 295355
14 F 441 .102 6-CFIM-14 295363
buss bar with porcelain insulators. Current- 12 F 551 .118 6-CFIM-12 295371
carrying capacities should be carefully noted. To Order — Specify PCN and quantity.
Buss bar is solid or perforated to facilitate 1. See note 1 in Buss Bar Table.
wiring, especially when terminals are in line.
Perforated buss bar, has 11/32 x 7/32" slots
on 7/16" centers. When connecting elements
with buss bar, provide expansion loops
between elements. Buss bars may be used in
multiples for higher ampacity (approx.
33-1/2% per buss bar) than listed above,
center.
A-60
A-060.P65 1 10/7/02, 10:27 AM

Components
STRIP AND RING

Accessories (cont’d.)
Clamp 6933 — Use to clamp two strip heaters Clamping Bands (type SC)
• Element Clamps on 3" centers using 3/8" studs at 5" intervals
(PCN 263644).
• Clamping Bands
Clamp 6933
• Mounting Studs 2-1/4
3/8" Dia.
Stud Hole
4
Element Clamps
Cast-iron clamps, for use with Chromalox strip
3-3/8
and ring elements, retain their strength at 9/16
elevated temperatures to assure maximum 15/16
sheath-to-surface contact. Resulting uniform
5" Min. Rad.
efficient heat transfer from internal resistance Clamping Bands
wire to the heated material minimize hot spots Max. Pipe
Clamp 5970 — Use to clamp three strip
on the element, contributing to long service life. Dia. (In.) Model Stock PCN
heaters on 2" centers using 5/16" studs at 5"
6-1/8 SC-820-20 S 265340
Clamp 6018 — Usually used in sets of two or intervals (PCN 263652). 7-1/8 SC-820-22 S 265359
more to clamp ring elements to flat surfaces. 9-1/8 SC-820-26 S 265367
Clamp 5970 11-1/8 SC-820-30 S 265375
5/16" flathead machine screws are normally 14-1/8 SC-820-34 S 265383
used with head brazed or welded to work 5/16" Dia. Stud Hole 16-1/8 SC-820-36 S 265391
surface (PCN 263978). 20-1/8 SC-820-40 S 265404
26-1/8 SC-820-46 S 265412
1-1/2
To Order — Specify PCN and quantity.
Clamp 6018
2 5
5/16" Dia. Mounting Studs
Stud Hole
1-1/2
Mounting Studs — For use with Chromalox
clamps. For all clamps except No. 6933, studs
3/8
3 are 5/16 — 18 x 1-1/2" Monel® (PCN 127845),
3-1/2
5/8 steel washer (PCN 127853), Monel® nut (PCN
127861). For No. 6993 clamp; studs are 5/16"
5" Min. Rad. — 18 x 2" Monel® (PCN 127837).
Installation — Fasten studs to the work
Clamp 5971 — Use to clamp two strip heaters Clamping Bands surface by welding, brazing or threading. Use
on 2" centers using 5/16" studs spaced 5"
correct size stud to fit clamp. See Selection &
apart (PCN 263636). Type SC Clamping Bands — Provide
Installation Guidelines in the Components
permanently tight fit on cylinders, nozzles,
section. For temperatures over 750°F,
Clamp 5971 pipes and other round surfaces. Stainless steel
stainless steel studs are recommended.
5/16" Dia. Stud Hole band with alloy screw. For small pipe
diameters, strip elements should have cross- Note — When tightening nuts, torsion should
section curving (see Modifications in the not exceed 10 foot pounds maximum. Heaters
Components section). must be allowed to expand. One center clamp
3
should hold heater. Nuts on other clamps
For Most Satisfactory Results, bands should
should be backed off approximately 1/2 turn to
be spaced about 5 inches apart and should be
allow for heater expansion.
3 drawn up tight to assure good contact
between heater or thermostat bulb and
11/16
surface.
5" Min. Rad.
A-61
A-061.P65 73 9/18/02, 3:17 PM

SFCS-6002A-0502
May, 2002
Industrial Plug-In Relay

Catalog Supplement
Plug In Relay Line Overview
Siemens new general purpose plug in relay line is designed to meet your needs
We have updated our general purpose Throw, Three Pole/Double Throw or Four and come in many different styles and
plug in relay offering to better suit your Pole/Double Throw and are available in contact configurations.
needs. Plug in relays are easy to use most common coil voltages. Each relay Heavy Duty Power Relays
and install. The sockets can be either has Easy Grip covers, LED status indica-
panel mounted or DIN rail mounted. tor, mechanical indicator with push to For heavy duty applications we offer our
Since most of our relays have the indus- test button as well as an I.D. label. Our 3TX7130 series of power relays. These
try standard form, fit and funtion they new Premium Line offers premium bene- durable relays can handle currents up to
can typically fit right into your current fits at a reasonable price. 30A and come in various contact config-
application. urations.
Basic Line
Premium Line Our commitment to you
For simple applications that require a reli-
Our new durable Premium Line has able relay, we offer our standard Basic Our mission is to be your relay provider
many features and covers multiple con- Line. Our Basic Line can cover most any of choice by providing quick service and
tact configurations such as: Single relay need up to currents as high as 25A reliable relays at a reasonable price.
Pole/Double Throw, Double Pole/Double
IMPORTANT
This catalog supplement does not purport to cover all details or variations in equipment, nor to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further informa-
tion be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes,
the matter should be referred to the local Siemens sales office. The contents of this catalog supplement shall not
become part of or modify any prior or existing agreement, commitment or relationship. The sales contract contains
the entire obligation of Siemens. The warranty contained in the contract between the parties is the sole warranty
of Siemens. Any statements contained herein do not create new warranties or modify the existing warranty.
NOTE: For a current copy of all the pertinent instruction sheets, which contain important safety, application, and
installation information relating to this product, please see the Siemens Energy & Automation web site:
www.sea.siemens.com/controls. Downloading is highly recommended. Failure to review this information could
create a situation leading to death, serious injury, or property damage.
1
Siemens Energy & Aut omat ion, Inc. - Industrial Plug-In Relay Cat alog Supplement
General Relay Information
2
Table of Contents Contents
Contents Pages
Plug In Relay Line Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Relay Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
8 and 11 Pin Octal Base Relays

Premium Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Basic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Socket Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
General Purpose Square Base Relays

Premium Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Basic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-17
Magnetic Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
Socket Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21
Miniature Relays
Premium Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-29
Basic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-35
Heavy Duty Power Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42-45

Solid State Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46-47
Timing Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-51
Standard Terms and Conditions of Sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3
8 and 11 Pin Octal Base Relays - Premium Line
Features
Green LED status indicator - Allows worker to see the relay
status in dark conditions
Mechanical Indicator - Allows worker to see relay status under
normal light or bright conditions
Push to test button with pull-out locking tab-makes testing
and analyzing your circuit easier
Easy Grip cover - Adds to the ease of removing the relay from
the socket
Removable I.D. Label - Allows for easy identification
C US
Premium Line 12A, 8 PIN Octal Socket, DPDT UL Recognized
Catalog No. Coil Voltage List Price Socket File No: E14900
3TX7112-1LB13 12VAC $17.00 3TX7144-1E2
3TX7112-1LC13 24VAC $17.00 3TX7144-1E2
3TX7112-1LF13 120VAC $17.00 3TX7144-1E2
3TX7112-1LG13 220/230VAC $17.00 3TX7144-1E2
3TX7112-1LB03 12VDC $17.00 3TX7144-1E2 UL Contact Ratings Table
3TX7112-1LC03 24VDC $17.00 3TX7144-1E2 POLES 120 VAC 240 VAC 28 VDC
3TX7112-1LF03 110VDC $17.00 3TX7144-1E2 2&3 12 AMP 12 AMP
12 AMP
POLE 1/3 HP 1/2 HP
Premium Line 12A, 11 PIN Octal, 3PDT

3TX7112-1NB13 12VAC $17.50 3TX7144-1E3
3TX7112-1NC13 24VAC $17.50 3TX7144-1E3
3TX7112-1NF13 120VAC $17.50 3TX7144-1E3
3TX7112-1NG13 220/230VAC $17.50 3TX7144-1E3
3TX7112-1NB03 12VDC $17.50 3TX7144-1E3
3TX7112-1NC03 24VDC $17.50 3TX7144-1E3
3TX7112-1NF03 110VDC $17.50 3TX7144-1E3
Wiring Diagrams
Viewed from pin end
4
Outline Dimensions
Dimensions shown in Inches & (Millimeters)
Specifications
COIL Temperature
Pull-in voltage: 80% of nominal voltage or less for DC coils Ambient Temperature (Operating): -30IC to + 50IC (AC), -30IC to +65IC (DC)
85% of nominal voltage or less for AC coils Non operating storage: -30IC to +100IC
Drop-out voltage: ≥10% of nominal voltage. SHOCK RESISTANCE
Coil resistance: ± 10 % measured @ 25IC Operating: 5 G's
Minimum sensitivity: 125 milliwatts per pole Non-operating: 20 G's
Nominal power: 1.2 Watts for DC coils, 2 VA-2.75VA for AC coils Vibration Resistance
Insulation System: Class "B" (130IC per UL std. 1446) Operating: 5 G's, 10 Hz to 55 Hz
Duty: Continuous LIFE
CONTACTS Electrical: 200,000 Operations
Contact material: 3/16" silver cadmium oxide, gold flashed. Mechanical: 5,000,000 Operations
Contact resistance: 50 milliohms maximum @ 10A, 120VAC or 24 VDC MISCELLANEOUS
Contact conditioned for 50 make & break Insulation material: Molded plastic
Operations at 1 second "ON and 1 second "OFF". Operating Position: Any
Minimum Load: 12 V @ 100 Milliamps Terminals: 8 pin or 11 pin octal plug-in
TIMING Weight: 83 grams
Operate time: Max. 20 ms.
Release time: Max. 15 ms.
DIELECTRIC STRENGTH
Contacts to coil: 2500 V rms
Across open contacts: 1500 V rms
Pole to pole: 2500 V rms
Contacts to frame: 2500 V rms
Insulation resistance: 100 Megohms min. @ 500 VDC
5
12
Siemens
SiemensEnergy
Energy& &Aut
Automat
omation,
ion,Inc.
Inc.- Industrial
- IndustrialPlug-In
Plug-InRelay
RelayCat
Catalog
alogSupplement
Supplement
8 and 11 Pin Octal Base Relays - Basic Line
Features
Available in multiple coil voltages
Available with current ratings up to 10A
Economical
DPDT & 3PDT contact configurations
Uses industry standard socket
C US
UL Recognized LR 6535
Basic 10A, 8 PIN Octal DPDT File No: E14900
Catalog No. Coil Voltage List Price Socket
3TX7120-1DB13 12VAC $14.00 3TX7144-1E2
3TX7120-1DC13 24VAC $14.00 3TX7144-1E2
3TX7120-1DF13 120VAC $14.00 3TX7144-1E2
3TX7120-1DH13 240VAC $14.00 3TX7144-1E2
3TX7120-1DB03 12VDC $14.00 3TX7144-1E2
3TX7120-1DC03 24VDC $14.00 3TX7144-1E2
3TX7120-1DF03 110VDC $14.00 3TX7144-1E2
Basic 10A, 11 PIN Octal 3PDT UL Contact Ratings Table

3TX7120-1FB13 12VAC $14.50 3TX7144-1E3 POLES 120 VAC 240 VAC 28 VDC
3TX7120-1FC13 24VAC $14.50 3TX7144-1E3 12 AMP 10 AMP
DPDT 10 AMP
3TX7120-1FF13 120VAC $14.50 3TX7144-1E3 1/3 HP 1/2 HP
3TX7120-1FH13 240VAC $14.50 3TX7144-1E3 10 AMP 10 AMP
3PDT 10 AMP
1/3 HP 1/2 HP
3TX7120-1FB03 12VDC $14.50 3TX7144-1E3
3TX7120-1FC03 24VDC $14.50 3TX7144-1E3
3TX7120-1FF03 110VDC $14.50 3TX7144-1E3
Wiring Diagrams
Viewed from pin end
6
Outline Dimensions
Specifications
COIL DIELECTRIC STRENGTH
Pull-in voltage* 80% of nominal voltage or less for DC coils Contacts to coil: 1500 V rms
85% of nominal voltage or less for AC coils Across open contacts: 1000 V rms
Drop-out voltage: ≥10% of nominal voltage. Pole to pole: 1500 V rms
Coil resistance* ±10% Contacts to frame: 1500 V rms
Minimum sensitivity* 125 milliwatts per pole Insulation resistance: 1,000 Megohms min. @ 500 VDC
Nominal power* 1.2 Watts for DC coils, 2 VA-2.75VA for AC coils TEMPERATURE
Maximum coil dissipation* Capability of DC coils 3.0 Watts max. Operating: -10°C to +50°C (AC), -10°C to +60°C (DC)
Coil insulation System Class "B" coil insulation (130°C) per UL std. 1446 Storage: -30°C to +105°C
Duty: Continuous Shock Resistance
CONTACTS Operating: 5 G's,
Contact material 3/16" silver cadmium oxide, gold flashed Std. Non operating: 20 G's
Contact resistance: 50 milliohms maximum initial VIBRATION RESISTANCE
resistance at rated current Operating: 5 G's, 10 Hz to 55 Hz
Minimum Load: 12 V @ 100 Milliamps MISCELLANEOUS
TIMING Insulation material: Molded plastic
Operate time: Max. 25 ms. Operating Position: Any
Release time: Max. 20 ms. Terminals: 8 or 11 pin octal plug-in
*Measured at 25IC Weight: 3 1/2 ozs. 99.2 g approx.
7
8 and 11 Pin Octal Base Relays - Socket Selection
Sockets & Accessories

C US
Catalog No. Additional Description List Price
UL Recognized
3TX7144-1E2 8 pin octal, panel/DIN rail, screw term socket $4.75
File No: E196786
Specifications
Electrical Rating: 300 V, 15 AMPS / 600V, 10 AMPS
Voltage: 2000 V rms Min. between all electrical elements of opposite polarity including a metal mounting surface
CONSTRUCTION
Terminals: Clamping screws: M 3.5 x 0.6 yelow zinc plated with pressure clamp washers.Terminal connections are capable of accepting
two #12 AWG wires or smaller, one wire on each side of the clamping screw.
Molding: Break resistant high electrical grade thermoplastic
Internal electrical current carrying elements conform with UL requirements for relay sockets, including maximum
operating temperature rise limits and electrical spacing.
Grips: Fits 35mm wide DIN mounting track
Torque: Max. torque to clamping screws should not exceed 8-10 inch lbs.
8
Outline Dimensions
Wiring Diagram
Top View
9
Sockets & Accessories C US

Catalog No. Additional Description List Price UL Recognized
3TX7144-1E3 11pin octal, panel/DIN rail, screw term socket $10.00 File No: E196786
Specifications
Electrical Rating: 300V rms, 15 AMPS 600V rms 5 AMPS
Dielectric Withstanding
CONSTRUCTION
Terminals: Clamping screws: M 3.5 x 0.6 yellow zinc plated with pressure clamp washers.Terminal connections shall be capable of
accepting two #12 AWG wires or smaller, one wire on each side of the clamping screw.Terminal wire clamp must provide
equally good clamping when either one or two wire conductors are connected to a single terminal.
Internal electrical current carrying elements conform with UL and CSA requirements for relay sockets, including maximum
Grips: Fit 35mm wide DIN mounting track
10
Outline Dimensions
Wiring Diagram
Top View
11
General Purpose Square Base Relays - Premium Line
Features
the socket
Premium Line 12A, Square Base, DPDT

C US
Catalog No. Coil Voltage List Price Socket Style UL Recognized
3TX7115-5LC13 24VAC $17.00 3TX7144-1E4 File No: E14900
3TX7115-5LF13 120VAC $17.00 3TX7144-1E4
3TX7115-5LH13 240VAC $17.00 3TX7144-1E4
3TX7115-5LB03 12VDC $17.00 3TX7144-1E4
3TX7115-5LC03 24VDC $17.00 3TX7144-1E4
3TX7115-5LF03 110VDC $17.00 3TX7144-1E4 UL Contact Ratings Table
POLES 120 VAC 240 VAC 28 VDC
2&3 12 AMP 12 AMP
12 AMP
POLE 1/3 HP 1/2 HP
Premium Line 12A, Square Base, 3PDT
3TX7115-5NC13 24VAC $17.50 3TX7144-1E4
Typical Operating Characteristics
3TX7115-5NF13 120VAC $17.50 3TX7144-1E4
(For DC voltage types only @ 25°C)
3TX7115-5NH13 240VAC $17.50 3TX7144-1E4
3TX7115-5NB03 12VDC $17.50 3TX7144-1E4 POLES DPDT 3PDT
3TX7115-5NC03 24VDC $17.50 3TX7144-1E4 Min. Operate mW
250 375
3TX7115-5NF03 110VDC $17.50 3TX7144-1E4 Sensitivity
Operate Time
20.0 24.0
(Milliseconds maximum)
Release Time
28.0 26.0
Wiring Diagrams
Viewed from pin end
12
Outline Dimensions
Specifications
COIL TEMPERATURE
Pull-in voltage: 80% of nominal voltage or less. for DC coils Ambient Temperature (Operating): -30IC to + 50IC (AC), -30IC to +65IC (DC)
85% of nominal voltage or less for AC coils. Non operating storage: -30IC to +100IC
Coil resistance: ± 10 % measured @ 25IC Operating: 5 G’s,
Minimum sensitivity: 125 milliwatts per pole Non operating: 20 G’s
Nominal power: 1.2 Watts for DC coils, 2 VA-2.75VA for AC coils VIBRATION RESISTANCE
Maximum coil dissipation: Capability of DC coils 3.0 Watts max. Operating: 5 G’s, 10 Hz to 55 Hz
Insulation System Class “B” (130IC per UL std. 1446) LIFE
Duty: Continuous Electrical: 200,000 Operations
CONTACTS Mechanical: 5,000,000 Operations
Contact material: 3/16" silver cadmium oxide, gold flashed. MISCELLANEOUS
Contact resistance: 50 milliohms maximum @ 10A, 120VAC or 24 VDC Insulation material: Molded plastic
Contact conditioned for 50 make & break operations Operating Position: Any
at 1 second “ON and 1 second “OFF” Terminals: 3/16” x .020 Q.C. Solder/ plug-in
Minimum Load: 12 V @ 100 Milliamps Weight: 83 grams approx.
TIMING
Operate time: Max. 20 ms
Release time: Max. 15 ms
DIELECTRIC STRENGTH
13
General Purpose Square Base Relays - Basic Line
Features
Styles available with current ratings up to 16A and 25A
Economical
Push to test button - Makes testing and analyzing your
circuit easier
Various contact configurations: DPDT, 3PST and 3PDT
Both Socket Mount and Panel Flange Mount available
C US
UL Recognized
LR 6535
File No: E14900
16A, Square Base, DPDT

Catalog No. Coil Voltage List Price Socket Style
3TX7113-5DC13 24VAC $16.00 3TX7144-1E4
3TX7113-5DF13 120VAC $16.00 3TX7144-1E4 16A, Square Base, 3PDT
3TX7113-5DH13 240VAC $16.00 3TX7144-1E4 Catalog No. Coil Voltage List Price Socket Style
3TX7113-5DB03 12VDC $16.00 3TX7144-1E4 3TX7113-5FC13 24VAC $16.00 3TX7144-1E4
3TX7113-5DC03 24VDC $16.00 3TX7144-1E4 3TX7113-5FF13 120VAC $16.00 3TX7144-1E4
3TX7113-5FG13 220VAC $16.00 3TX7144-1E4
3TX7113-5FB03 12VDC $16.00 3TX7144-1E4
16A, Mounting Bracket, DPDT 3TX7113-5FC03 24VDC $16.00 3TX7144-1E4
3TX7113-6DC13 24VAC $16.00 Require .187 Quick Connect
3TX7113-6DF13 120VAC $16.00 Require .187 Quick Connect
16A, Mounting Bracket, 3PDT
3TX7113-6DH13 240VAC $16.00 Require .187 Quick Connect
3TX7113-6FC13 24VAC $16.00 Require .187 Quick Connect
3TX7113-6DB03 12VDC $16.00 Require .187 Quick Connect
3TX7113-6FF13 120VAC $16.00 Require .187 Quick Connect
3TX7113-6DC03 24VDC $16.00 Require .187 Quick Connect
3TX7113-6FH13 240VAC $16.00 Require .187 Quick Connect
3TX7113-6FC03 24VDC $16.00 Require .187 Quick Connect
25A, Mounting Bracket, DPDT
16A, Square Base, 3PST

3TX7113-5EC13 24VAC $16.00 3TX7144-1E4
3TX7113-5EF13 120VAC $16.00 3TX7144-1E4
3TX7113-5EH13 240VAC $16.00 3TX7144-1E4
3TX7113-5EC03 24VDC $16.00 3TX7144-1E4
12
14
Siemens
SiemensEnergy
Energy& &Aut
Automat
omation,
ion,Inc.
Inc.- Industrial
- IndustrialPlug-In
Plug-InRelay
RelayCat
Catalog
alogSupplement
Supplement
Outline Dimensions
Dimensions shown in Inch & (Millimeters)
Specifications
Pull-in voltage:* 80% of nominal voltage or less. for DC coils. Contacts to coil: 2000 V rms
85% of nominal voltage or less for AC coils. Across open contacts: 500 V rms
Coil resistance:* ± 10 % Contacts to frame: 2000 V rms
Coil insulation: Class “B” coil insulation system (130IC) per Insulation resistance: 1000 megohms min. @ 500 VDC.
UL Standard 1446 TEMPERATURE
COIL POWER Operating: -30IC to +50IC (AC), -30IC to +60IC (DC)
Maximum coil dissipation:* Capability of DC coils 2.5 Watts max. Storage: -30IC to 100IC
CONTACTS Electrical: 100,000 at rated load.
Contact material: 1/4" silver cadmium oxide, gold flashed Mechanical: 5 Million Operations no load
Contact gap: 0.015 min. is standard MISCELLANEOUS
Contact resistance: 50 Milliohms max. initial resist. at rated current Insulation material: Molded plastic
TIMING Terminals: .250 x 0.032 QC, .187 x 0.020 QC plug-in
Operate time, (exc. bounce): 20 ms typical at nominal voltage. Weight: 3.3 ozs. (94 grams) approx. with cover.
Release time, (exc. bounce): 20 ms typical at nominal voltage.
*Measured at 25IC
Wiring Diagrams
Viewed from pin end
NEMA Pilot Duty Contact Ratings

Rating Codes for AC control-circuit contacts at 50/60Hz
MAXIMUM CURRENT, AMPERES

NEMA THERMAL
CONTACT CONTINUOUS 120 VOLTS 240 VOLTS 480 VOLTS 600 VOLTS MAXIMUM
CODE TEST CURRENT 50/60Hz 50/60Hz 50/60Hz 50/60Hz VOLT-AMPERES
DESIGNATION AMPERES
Make Break Make Break Make Break Make Break Make Break
B300 5 30 3.00 15 1.50 - - - - 3600 360
B600 5 30 3.00 15 1.50 0.75 0.75 6 0.06 3600 360
15
Features
Available with current ratings up to 15A and 20A
Economical
DPDT and 3PDT contact configurations
C US
UL Recognized
LR 6535
File No: E14900
15A, Square Base, DPDT 15A, Mounting Bracket, DPDT

Catalog No. Coil Voltage List Price Socket Style Catalog No. Coil Voltage List Price Socket Style
3TX7121-5DB13 12VAC $13.50 3TX7144-1E4 3TX7121-6DC13 24VAC $14.00 Require .187 Quick Connect
3TX7121-5DC13 24VAC $13.50 3TX7144-1E4 3TX7121-6DF13 120VAC $14.00 Require .187 Quick Connect
3TX7121-5DF13 120VAC $13.50 3TX7144-1E4 3TX7121-6DB03 12VDC $14.00 Require .187 Quick Connect
3TX7121-5DH13 240VAC $13.50 3TX7144-1E4 3TX7121-6DC03 24VDC $14.00 Require .187 Quick Connect
3TX7121-5DB03 12VDC $13.50 3TX7144-1E4 3TX7121-6DF03 110VDC $14.00 Require .187 Quick Connect
3TX7121-5DC03 24VDC $13.50 3TX7144-1E4
3TX7121-5DF03 110VDC $13.50 3TX7144-1E4
15A, Square Base, 3PDT 3TX7121-6FF13 120VAC $14.50 Require .187 Quick Connect
3TX7121-5FB13 12VAC $14.50 3TX7144-1E4 3TX7121-6FH13 240VAC $14.50 Require .187 Quick Connect
3TX7121-5FC13 24VAC $14.50 3TX7144-1E4 3TX7121-6FB03 12VDC $14.50 Require .187 Quick Connect
3TX7121-5FF13 120VAC $14.50 3TX7144-1E4 3TX7121-6FC03 24VDC $14.50 Require .187 Quick Connect
3TX7121-5FH13 240VAC $14.50 3TX7144-1E4 3TX7121-6FF03 110VDC $14.50 Require .187 Quick Connect
3TX7121-5FB03 12VDC $14.50 3TX7144-1E4
3TX7121-5FC03 24VDC $14.50 3TX7144-1E4
3TX7121-5FF03 110VDC $14.50 3TX7144-1E4
UL Contact Ratings Table
20A, Square Base, DPDT 2&3 12 AMP 12 AMP
12 AMP
POLE 1/3 HP 1/2 HP
3TX7122-5DC13 24VAC $15.50 3TX7144-1E4
3TX7122-5DF13 120VAC $15.50 3TX7144-1E4
3TX7122-5DH13 240VAC $15.50 3TX7144-1E4 Typical Operating Characteristics
3TX7122-5DB03 12VDC $15.50 3TX7144-1E4
3TX7122-5DC03 24VDC $15.50 3TX7144-1E4
3TX7122-5DF03 110VDC $15.50 3TX7144-1E4 POLES DPDT 3PDT
Min. Operate mW
250 375
Sensitivity
Operate Time
20.0 24.0
Release Time
28.0 26.0
16
Outline Dimensions
Specifications
COIL TEMPERATURE
Pull-in voltage:* 80% of nominal voltage or less for DC coils Operating: -30IC to +50IC (AC), -30IC to +65IC (DC)
85% of nominal voltage or less for AC coils Storage: -30IC to 100IC
Drop-out voltage: ≥10% of nominal voltage. LIFE EXPECTANCY
Resistance:* ± 10 % Electrical: 100,000 Operations @ rated AC load
Coil power:* 1.2 Watts for DC coils, 2 VA to 2.75 VA for AC coils Mechanical: 5,000,000 Operations @ No load
Insulation System: Class “B” (130IC per UL std. 1446) MISCELLANEOUS
Maximum coil dissipation: Capability of DC coils 3.0 Watts max. Operating Position: Any
Duty: Continuous Insulation material: Molded plastic
CONTACTS Terminals: 3/16" (.187) solder/plug-in
Contact material: 3/16" silver cadmium oxide, gold flashed Weight: 3.1 oz. (88 g approx).
Contact resistance: 50 Milliohms maximum initial resistance
at rated current
DIELECTRIC STRENGTH
Pole to pole 2000 V rms
*Measured at 25IC
Wiring Diagrams
Viewed from pin end
17
Relays
Industrial Automation
Catalog Section - U906
Selection Guides
General Purpose Relays

• RU Series
• RR Series
For up-to-date information, or to

request a full copy of this catalog, contact
us at www.idec.com or 800-262-IDEC..
Due to continuous product improve-

ments, specifications are subject to change
wihtout notice.
Relays Selection Guide
Selection Guides

RU Series RR Series RH Series RM Series RY Series
Appearance
Page E-3 E-6 E-10 E-16 E-19

Contact Configuration 2, 4 Form C 1, 2, 3 Form C 1, 2, 3, 4 Form C 2 Form C 2, 4 Form C
DPDT: 10A, 30V DC 10A, 30V DC 10A, 30V DC DPDT: 3A, 30V DC;
Contact Rating 10A, 250V AC 10A, 120V, 240V AC 10A, 120V, 240V AC 5A, 30V DC 3A, 120V AC, 240V AC
(resistive) 4PDT: 6A, 30V DC 1/3HP, 240V AC 1/3HP, 240V AC 5A, 120V AC, 240V AC 4PDT: 5A, 30V DC;
6A, 250V AC 1/4HP, 120V AC 1/6HP, 120V AC 5A, 120V AC, 240V AC
AuSnOIn (silver tin
DPDT Standard Silver, gold-plated
oxide indium) Silver-cadmium
E Contact Material
4PDT AuAg/Ag (gold-
Silver oxide Silver
Bifurcated Silver-paladium
silver alloy on silver) alloy (Ag-PD Alloy)
General Purpose Latching Relays

RR2KP Series RH2L Series RY2KS Series RY2L Series
Appearance
Page E-23 E-26 E-29 E-32

Contact Configuration 2 Form C 2 Form C 2 Form C 2 Form C
Contact Rating 10A, 30V DC 3A, 30V DC

10A, 30V DC 3A, 30V DC
7.5A, 240V AC 3A, 120V AC
(resistive) 10A, 120V AC 3A, 120V AC
10A, 120V AC 3A, 240V AC
Contact Material Silver Silver-cadmium oxide Silver, gold-plated Silver, gold-flashed
Solid State Relays

RSS Series
Appearance
Page E-35
Contact Configuration 1 Form A (SPST-NO)
10, 25, 50, 75, 90A
Contact Rating 48V AC to 660V AC Output Ratings
Output Dual SCR (zero crossing)
E-2 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC
Relays RU Series
RU Series — General Purpose Relays
Key features of the RU series include:

• Non-polarized LED indicator
• Solder-free construction (lead-free)
• No internal wires
• Mechanical flag indicator
• Manual latching lever with color coding for AC or DC coil
• Snap-on marking plate
• Cadmium-free contacts
• Contact rating 6A: 4PDT
10A: DPDT
RU2 RU4
AuSnOIn (silver tin oxide AuAg/Ag (gold-silver alloy
Contact Material indium) on silver) UL Recognized
Contact Resistance 50 mΩ maximum File No. E66043
Minimum 24VDC, 5mA (reference
Applicable Load value) E
Operating Time 20 msec maximum
Release Time 20 msec maximum
Maximum
Continuous Applied
110%
Voltage
(AC/DC) at 20°C
Minimum
Operating Voltage 80%
(AC/DC) at 20°C
Drop-Out Voltage
30%
(AC) at 20°C
Drop-Out Voltage Ordering Information
10%
(DC) at 20°C
Order standard voltages for fastest delivery. Allow extra delivery time
Specifications
Power Consumption 1.1-1.4VA (AC); 0.9-1.0W (DC)

for non-standard voltages.
Between contact and coil: Between contact and coil:
2,500VAC, 1 minute 2,500VAC, 1 minute
Between poles: Between poles: Basic Part No. Coil Voltage:
Dielectric Strength 2,500VAC, 1 minute 2,000VAC, 1 minute
Between contacts of the Between contacts of the RU4S – A110
same pole: same pole:
Frequency Response 1,800 operations/hr
Operating extremes:
10 to 55Hz,
Vibration Resistance Amplitude 1.0 mm p-p
Damage limits: 10 to 55Hz,
Amplitude 1.0 mm p-p
Operating extremes:
150 m/s2 (15G)
Shock Resistance Damage limits:
1,000 m/s2 (100G)
Mechanical:
AC: 20,000,000 operations
minimum
Life Expectancy DC: 30,000,000 operations
minimum
Electrical:
see electrical life curve
Degreee of Protection IP40
Operating Temperature -55 to +70°C (no freezing)
Weight 35g
www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC E-3
Relays RU Series
Part Numbers
Part Numbers: RU Series with Options

Termination Contact Configuration Basic Part No.
DPDT RU2S
S: Solder/plugin
4PDT RU4S
Part Numbers: Sockets

Standard DIN Finger-Safe DIN Springs & Clips (optional)
Relays Panel Mount PC Mount
Rail Mount Rail Mount Part Number Use With
SY4S-02F1
SY4S-61
RU2 SM2S-05 SM2S-05C SY4S-51 SFA-101 use with SY4S-05, -05C & SM2S-05, -05C
SY4S-62 SFA-202
SFA-301
SY4S-61
RU4 SY4S-05 SY4S-05C SY4S-51 SFA-302 use with SY4S-51, -61
SY4S-62 SY4S-51F1
See Section F for details on sockets. All DIN rail mount
sockets shown above can be mounted using DIN rail BNDN1000.
E Ratings
Coil Ratings
Rated Current ±15% at 20°C Inductance
Rated Voltage Coil Resistance ±10% at 20°C Inrush Current
60Hz 50Hz Energizing De-Energizing
24V 37.5mA – 164 Ω 60mA 1.8H 0.96H
AC 110-120V 8.4mA – 4,550 Ω 14mA 36H 22H
220-240V 4.2mA – 18,230Ω 7mA 144H 87H
12V 83.3mA 160 Ω
DC 24V 41.7mA 605 Ω N/A
110V 9.1mA 12, 100 Ω
Contact Ratings
Voltage Resistive Inductive
DPDT 10A 5A
30V DC
4PDT 6A 3A
DPDT 0.6A 0.3A
110V DC
4PDT 0.4A 0.2A
DPDT 10A 5A
120V AC
4PDT 6A 3A
DPDT 10A 5A
240V AC
4PDT 6A 3A
Relays RU Series
Internal Circuit
RU2
RU4
Electrical Life Curves

E
Dimensions
Relays RR Series
RR Series — General Purpose Power Relays
Key features of the RR series include:

• High reliability and long service life
• Available in octal (8- and 11-pin) or square (11-blade) base
• Options include check button for test operation, indicator light, and
side flange
• DIN rail, surface and panel type sockets available for a wide range of
mounting applications
Contact Material Silver

Contact Resistance 30mΩ maximum (initial value)
Minimum 24V DC/10mA, 5V DC/20mA
Applicable Load (reference value)
Operating Time 25ms maximum
Release Time 25ms maximum UL Recognized
CSA Certified
File Nos. E67770 File No. LR35144
Maximum Continuous
E Applied Voltage (AC/
DC) at 20°C
110% of the rated voltage
*
Minimum Operating
Voltage (AC/DC) at 20°C File No. BL951113332319*
* Pin Style Only * Pin Style Only
Drop-Out Voltage (does not apply to blade style)
(AC) at 20°C
Drop-Out Voltage
(DC) at 20°C
AC: approximately 3VA (50Hz), 2.5VA (60Hz)
Power Consumption DC: approximately 1.5W
100MΩ minimum
Insulation Resistance
Specifications
(measured with 500V DC megger) Ordering Information

Pin (RR2P, RR3PA)
Between live and dead parts: Order standard voltages for fastest delivery. Allow extra delivery time for
1,500V AC, 1 minute non-standard voltages.
Between contact circuit and operating coil:
1,500V AC, 1 minute
Between contact circuits: 1,500V AC,
1 minute (1,000V AC between NO-NC contacts) Basic Part No. Coil Voltage:
Blade (RR1BA, RR2BA, RR3B) RR3PA-U – AC120V

Dielectric Strength
Between live and dead parts:
2,000V AC, 1 minute
2,000V AC, 1 minute
Between contact circuits:
2,000V AC, 1 minute
Between contacts of same polarity:
1,000V AC, 1 minute
Frequency Response 1,800 operations/hour
Coil: 85°C maximum
Temperature Rise Contact: 65°C maximum
Vibration Resistance 0 to 6G (55Hz maximum)
Shock Resistance 100N (approximately 10G)
Electrical: over 500,000 operations
Life Expectancy (120V, 50/60Hz, 10A)
Mechanical: over 10,000,000 operations
Operating Temperature –30 to +70°C
RR2P: 90g, RR3P/RR3PA: 96g (approximately)
Weight RR1BA/RR2BA/RR3B: 82g (approximately)
Relays RR Series
Part Numbers
Part Numbers: RR Series with Options

Termination Contact Configuration Basic Part No. Indicator Light Check Button Light and Check Button Side Flange
P, PA DPDT RR2P-U RR2P-UL RR2P-UC RR2P-ULC —
(pin) 3PDT RR3PA-U RR3PA-UL RR3PA-UC RR3PA-ULC —
SPDT RR1BA-U RR1BA-UL RR1BA-UC RR1BA-ULC RR1BA-US
B, BA DPDT RR2BA-U RR2BA-UL RR2BA-UC RR2BA-ULC RR2BA-US
(blade)
3PDT RR3B-U RR3B-UL RR3B-UC RR3B-ULC RR3B-US
1. RR1BA, RR2BA, and RR3PA are U.S. standard terminal arrangements.

2. For diode option on DC coils please consult factory.
Ratings
Coil Ratings
6V 420mA 490mA 4.9Ω 720mA 0.04H 0.02H E
12V 210mA 245mA 18Ω 365mA 0.15H 0.08H
AC 24V 105mA 121mA 79Ω 182mA 0.57H 0.32H
120V 20.5mA 24mA 2100Ω 35mA 15H 8.2H
240V 10.5mA 12.1mA 8330Ω 18mA 57H 32H
6V 240mA 25Ω
12V 120mA 100Ω
DC 24V 60mA 400Ω N/A
48V 30mA 1600Ω
110V 13mA 8460Ω
Contact Ratings
Resistive Inductive Motor Load
Voltage Nominal UL CSA Nominal UL CSA UL
30V DC 10A 10A 10A 7.5A 7A 7.5A —
110V DC 0.5A — — 0.3A — 0.5A — Inductive load:
120V AC 10A 10A 10A 7.5A 7.5A 7.5A 1/4 hp cos ø = 0.3, L/R = 7ms.
240V AC 7.5A 10A 10A 5A 7A 7A 1/3 hp
Applicable Sockets

Relays Panel Mount
Rail Mount Rail Mount Part Numbers Use With
SR2P-05 SR2B-02F1 SR2P-05, -05C, -06
RR2P SR2P-05C SR2P-51
SR2P-06 SR3P-01F1 SR2P-51 See Section F for
details on sockets.
SR3P-05 SR3B-02F1 SR3P-05, -05C, -06
RR3PA SR3P-05C SR3P-51 All DIN rail mount
SR3P-06 SR3P-01F1 SR3P-51 sockets listed can be
RR1BA mounted using DIN
SR3B-05 rail BNDN1000.
RR2BA SR3B-05 — SR3B-51 SR3B-02F1 SR3B-51
RR3B
Relays RR Series
Internal Circuit
4 5 6
5 7
3 6 4 8
3 9
2 7
(-) (+) 2 10
(-) (+)
1 8 1 11
RR2P RR3PA
2 1 3 1 2 3
5 4 6 4 5 6
7 7 9 7 8 9
A B A B A B
(-) (+) (-) (+) (-) (+)
RR1BA RR2BA RR3B
E
AC 110V Resistive
DC 30V Resistive
1000 AC 220V Resistive 1000
Life (x 10,000) Operations
AC 110V Inductive DC 30V Inductive

500 500
AC 220V Inductive
100 100
50 DC 100V Resistive
50
DC 100V Inductive
10 10
0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10
Load Current (A) Load Current (A)
Relays RR Series
Dimensions
8-Pin 11-Pin
RR2P RR3PA
Total length from panel surface including socket: Total length from panel surface including socket:
SR2P-05: 3.33" (85.3mm) [3.44" (88.3mm) maximum] SR2P-05: 3.33" (85.3mm) [3.44" (88.3mm) maximum]
1.42" (36.4mm)
1.42" (36.4mm)
2.18" (56mm) or Less 1.14" (29.3mm) 2.18" (56mm) or Less 1.42" (36.4mm)
Blade Side Flange

RR1BA, RR2BA, RR3B RR1BA-US, RR2BA-US, RR3B-US
Total length from panel surface including socket: 2.94" (75.4mm)
(4.3mm)
SR3B-02: 2.87" (73.7mm) [3.0" (76.7mm) maximum] 0.187"
0.168"
1.09" (28mm) or less
0.64" (16.4mm)
SR3B-51: 2.21" (56.6mm) [2.36" (60.6mm) maximum] (4.8mm)
Ø 0.18" (4.6mm)
0.187" (4.8mm) 0.444"
(11.4mm)
2 Mounting Holes E
0.078" (2mm) x 0.117" (3mm) Ø 0.117" (3mm) 2.54" (65mm)
Terminal Hole 3 Terminal Holes
0.288" (7.4mm)
0.644" (16.5mm)
0.02" 2.54" (65mm)
1.42" (36.4mm)
(0.51mm)
0.02" (0.51mm)
1.44" (37mm)
0.288"
1.87" (48mm) or less (7.4mm) 1.42" (36.4mm)
Note: Dimensions in [ ] include hold-down spring.
1.44" (37mm)
UL-CSA VDE
SPARK QUENCHERS 125VAC, 250VAC
Fax Back Document #1202
Safety Agency : Standard File No.
XA SERIES
UL : UL-1414 E47474
O Small case size with superior CSA : CSA C22.2 No.0, No.1 LR37404/LR68886
performance VDE : VDE0565-1 10529-4670-1002
O PWB mounting
O Broad application in business XAB SERIES
equipment O Long insulated flexible wire leads
O ¼ watt non-inductive, high pulse O AC or DC applications
resistor O ¼ or ½ watt non-inductive, high pulse
resistor
ELECTRICAL SPECIFICATIONS Operating temp. range : -40 ~ + 85°C

Pulse condition (Max)
Peak Test
Safety Resistance Capacitance Peak to Pulse width (sec) Pulse voltage Insulation
Class Model No. Repetitive
Standard h ± 30% µF ± 20% Peak Pulse width x resistance
frequency Voltage JISC5102
(P-P) Frequency(Hz)
Line to Line to
120(60)Hz Line Line
XA120033 0.033 20msec.max 3(0.8)max 1200 Vrms 15,000Mh
max
50/60Hz min.
120(¼W)
700V 120(60)Hz 700V 2~5sec Line to
X2 XA1201 0.1 max 50msec.max max
3(0.8)max max Line to Case
Case 100,000Mh
XAB1201 0.1 50msec.max 120Hz max 3max 2000Vrms min.
50/60Hz (at 20°C
XAB1202 120(½W) 0.2 50msec.max 120Hz max 3max 60sec 500VDC)
2-14
MECHANICAL SPECIFICATIONS: XA Series
Case: Standoffs provided for improved cleanability
Case Material: Polybutylene Terephthalate (FR-PBT)
UL-94 Flame Class V-O
Potting Material: UL-94 Flame Class V-O
Leads: Tinned Copper Clad Steel,
Soldered Capacitor Element
Capacitor: Double Wound, Oil Impregnated,
Metallized Polyester Film
SPARK QUENCHERS
Add “C6” suffix to p/n for 6mm lead length.
Other lead lengths available—consult factory.
XAB Series
MECHANICAL SPECIFICATIONS:

Leads: Tinned Copper Copper Wire
Polyvinylchloride (PVC) Insulation
*Other lead lengths available—consult factory.
MECHANICAL DIMENSIONS
Dimensions
Safety Resistance Capacitance
Class Model No.
Standard h ± 30% µF ± 20% L H T F
XA120033 0.033 17.0 14.0 7.0 15.0

XA1201 120(¼W) 0.1 20.0 16.5 8.5 17.5
X2
XAB1201 0.1 18.0 23.5 8.5 15.0
XAB1202 120(½W) 0.2 19.0 25.0 8.5 15.0
2-15
“NT”
LA NUOVA SERIE
SISTEMI DI CONTROLLO DELLA TEMPERATURA DI MACCHINE ELETTRICHE

TEMPERATURE CONTROL SYSTEM FOR ELECTRIC UNITS
SISTEMI DI CONTROLLO DELLA TEMPERATURA
DI MACCHINE ELETTRICHE
Una nuova serie di apparecchiature dalle A new series of units with revolutionary
caratteristiche rivoluzionarie, per presta- technical characteristics thanks to the
zioni, affidabilità e completezza, per la performances, reliability and complete
protezione termica di macchine elettri- program for the thermal protection of
che. electric units such as cast resin transfor-
Non più apparecchiature elettroniche mers, motors and electric generators.
dedicate, con caratteristiche tecniche No more protection relay dedicated, with
prefissate e non variabili, ma una serie di technical characteristics pre-fixed, but the
apparecchiature che si possono man basic unit can be set simply adding a DIN
mano configurare secondo le esigenze di rail box with the required function, which
comunicazione e controllo a distanza, dif- is foreseen for the remote communica-
ferenti. tion and control.
I Mod. NT935 ed NT538 possono avere The basic units Mod.NT935 and NT538
configurazioni multiple, ovvero possono may have multiple configurations; they
abbinare contemporaneamente l’uscita may have at the same time, a digital out-
analogica ed una doppia uscita a relè put ModBus RTU, or an analog output 4-
(per ogni canale controllato) e l’uscita 20 mA
ModBus RTU. for each individual channel (RTD Pt100),
Ciò permette al tecnico progettista del- and two relays (ALL1 and ALL2) for each
l’impianto di controllo ed automazione di individual channel.
disporre di tutti gli elementi per perfezio- The exceptional flexibility of the system
nare il sistema di controllo e protezione. gives to the engineer the maximum aid for
Un protocollo residente TecsyBus fa flui- the solution of all the remote protection
re, dalla centralina a tutte le apprecchia- and monitoring of the status of the units.
ture esterne, le informazioni atte a A proprietary protocol (TecsyBus) gives
comandare i differenti convertitori. all the digital informations to the external
Le funzioni di comunicazione o di auto- modules.
mazione possono essere abbinate alla All the functions can be added in a
centralina, anche in seguito alla sua second time, after the main unit installa-
installazione. tion.
NT-538
CARATTERISTICHE TECNICHE TECHNICAL SPECIFICATIONS
Alimentazione: Power Supply:

• valori nominali 24-240 Vca-cc • rated voltage 24-240 Vac-dc
• massimi valori sopportabili 20-270 Vca-cc • maximum ratings 20-270 Vac-dc
• Vcc con polarità invertibili • Vdc with reversible polarities
Ingressi: Inputs:
• da 1 a 8 ingressi per sonde RTD tipo Pt100/Ni100/Ni120 a tre fili • 1 to 8 inputs from RTD Pt100/Ni100/Ni120 sensors - 3 wires
• collegamenti su morsettiere estraibili • removable rear terminals
• canali d'ingresso protetti contro i disturbi elettromagnetici • input channels protected against electromagnetic noises and spikes
• compensazione cavi per termoresistenze fino a 500 m (1 mm2) • sensors length cables compensation up to 500 m (1 mm2)
Uscite: Outputs:
• 2 relay di allarme (ALARM - TRIP) • 2 alarm relays (ALARM - TRIP)
• relay di guasto sonde o anomalia funzionamento (FAULT) • 1 alarm relay for sensor fault or working anomaly (FAULT)
• relay di uscita con contatti da 5A - 250 Vca res. • output contacts capacity: 5A - 250 Vac res.
• test dei relay di uscita • output relays test
• Contatto Aux (Fan) • auxiliary contact (Fan)
• programmazione di alarm e trip “fail safe” (N.C.) o no “fail safe” • fail-safe or non-fail-safe alarm and trip contacts programming
(N.O.)
Communication:
Comunicazione: • TecsyBus protocol for external modules
• protocollo TecsyBus per moduli esterni
Tests and Performances:
Test e Prestazioni: • assembling in accordance with CE rules - cURus - RINA
• costruzione in accordo alle normative CE - cURus - RINA • dielectric strength: 2500 Vac for 1 minute from relays to sensors,
• rigidità dielettrica: 2500 Vca per 1 minuto tra relay di uscita e sonde, relays to power supply, power supply to sensors
relay e alimentazione, alimentazione e sonde • accuracy: ± 1% full scale, ± 1 digit
• precisione: ± 1% fs, ± 1 digit • ambient operating temperature: -20 °C to 60 °C
• temperatura di lavoro: da -20 °C a 60 °C • humidity: 90% non condensing
• umidità ammessa: 90% senza condensa • ABS self-extinguishing housing - NORYL 94V0
• contenitore in ABS autoestinguente - NORYL 94V0 • frontal in polycarbonate - IP54
• frontale in policarbonato - IP65 • burden: 4 VA
• assorbimento: 4 VA • data storage: 10 years minimum
• memoria dati: 10 anni minimo • digital linearity of sensors signal
• linearizzazione digitale segnale sonde • self-diagnostic circuit
• circuito di autodiagnosi
Dimensions:
Dimensioni: • 96x96 mm - DIN43700 - 130 mm deep (with rear terminals)
• 96x96 mm - DIN43700 - prof. 130 mm (compreso morsettiera) • panel cutout 92x92 mm
• foro pannello 92x92 mm
Displaying and Data management:
Visualizzazione e Gestione dati: • number of channels programmable from 1 to 8
• programmazione input collegati da 1 a 8 • 1 display 13 mm high with 3 digits for displaying temperatures
• 1 display da 13 mm a 3 cifre per visualizzazione temperature • 8 LEDs for displaying reference channel
• 8 LEDS per visualizzare il canale di riferimento • 4 LEDs indicating alarm, trip, fan or fault
• 4 LEDS indicanti allarme, trip, fan o fault • temperature monitoring from 0 °C to 240 °C
• controllo della temperatura da 0 °C a 240 °C • 2 independent alarm thresholds for each input
• 2 soglie di allarme indipendenti per ogni ingresso • sensors diagnostic (Fcc - Foc - Fcd)
• diagnostica delle sonde (Fcc - Foc - Fcd) • entering the programming by frontal push button
• accesso alla programmazione tramite pulsante frontale • wrong programming automatic display
• segnalazione di errata programmazione • programmed data call out
• richiamo dati impostati in fase di programmazione • possibility of setting manual channel scanning or hottest channel or
• selezione tra scansione manuale o canale più caldo o scansione auto- automatic scanning
matica • maximum temperatures storage and alarms memory
• memoria delle massime temperature raggiunte dai canali e memoria • frontal push button for alarm reset
degli allarmi
• tasto frontale per reset allarmi
Collegamento in linea con i tre moduli
In line connection of the three modules
TecsyBus
Power Supply
Tx Rx
24 VAC/DC
Out
ModBus RTU
Out
4/20 mA x 8
Un doppino telefonico
collega tutte le unità
esterne di conversione.
Solo il modulo ModBus
RTU necessita di quat-
tro fili per la comunica-
zione Full-Duplex.
Only one twin cable for

the connection of all
the external conversion
units.
Only the ModBus RTU
module needs 4 wires
for the Full-Duplex
communication.
Out 16 relays
ALL 1 & ALL 2
Fault relay
NT-935

Ingressi: Inputs:
• 3 - 4 ingressi per sonde RTD Pt100/Ni100/Ni120 a tre fili • 3 - 4 inputs RTD Pt100/Ni1007Ni120 sensors - 3 wires
• canali d'ingresso protetti contro i disturbi elettromagnetici • input channels protected against electrical and magnetic noises and
• compensazione cavi per termoresistenze fino a 500 m (1 mm2) spikes
• sensors length cables compensation up to 500 m (1 mm2)
Uscite:
• 2 relay di allarme (ALARM - TRIP) Outputs:
• 2 relay di gestione ventilazione (FAN1 - FAN2) • 2 alarm relays (ALARM - TRIP)
• 1 relay di guasto sonde o anomalia funzionamento (FAULT) • 2 alarm relays for fan control (FAN1 - FAN2)
• relay di uscita con contatti da 5A - 250 Vca res. • 1 alarm relay for sensor fault or working anomaly (FAULT)
• test dei relay di uscita • analogue output 4-20 mA
• output contacts capacity: 5A - 250 Vac res.
Comunicazione: • output relays test
Communication:
Test e Prestazioni: • TecsyBus protocol for exsternal modules
• costruzione in accordo alle normative CE - cURus - RINA
• rigidità dielettrica: 2500 Vca per 1 minuto tra relay di uscita e sonde, Tests and Performances:
relay e alimentazione, alimentazione e sonde • assembling in accordance with CE rules - cURus - RINA
• precisione: ± 1% fs, ± 1 digit • dielectric strength: 2500 Vac for 1 minute from relays to sensors,
• temperatura di lavoro: da -20 °C a 60 °C relays to power supply, power supply to sensors
• umidità ammessa: 90% senza condensa • accuracy: ± 1% full scale, ± 1 digit
• contenitore in ABS autoestinguente - NORYL 94V0 • ambient operating temperature: -20°C to 60°C
• frontale in policarbonato - IP65 • humidity: 90% non condensing
• assorbimento: 4 VA • ABS self-extinguishing housing - NORYL 94V0
• memoria dati: 10 anni minimo • frontal in polycarbonate - IP65
• linearizzazione digitale segnale sonde • burden: 4 VA
• circuito di autodiagnosi • data storage: 10 years minimum
• digital linearity of sensors signal
• self-diagnostic circuit
Dimensioni:
• 96x96 mm - DIN43700 - prof. 130 mm (compreso morsettiera) Dimensions:
• foro pannello 92x92 mm • 96x96 mm - DIN43700 - 130 mm deep (with rear terminals)
• panel cutout 92x92 mm
Visualizzazione e Gestione dati:
• 1 display da 13 mm a 3 cifre per visualizzazione temperature Displaying and Data management:
• 4 LEDS per visualizzare il canale di riferimento • 1 display 13 mm high with 3 digits for displaying temperatures
• 4 LEDS indicanti allarme, trip, fan o fault • 4 LEDS for displaying reference channel
• controllo della temperatura da 0 °C a 240 °C • 4 LEDS indicating alarm, trip, fan or fault
• 2 soglie di allarme per Ch 1-2-3 e 2 per Ch 4 • temperature monitoring from 0 °C to 240 °C
• controllo ON-OFF ventilazione • 2 alarm thresholds for Ch 1-2-3 and 2 for Ch 4
• diagnostica delle sonde (Fcc - Foc - Fcd) • ON-OFF for fan control
• accesso alla programmazione tramite pulsante frontale • sensors diagnostic (Fcc - Foc - Fcd)
• segnalazione di errata programmazione • entering the programming by frontal push button
• richiamo dati impostati in fase di programmazione • wrong programming automatic display
• selezione tra scansione manuale o canale più caldo o scansione auto- • programmed data call out
matica • possibility of setting manual channel scanning or hottest channel or
• memoria delle massime temperature raggiunte dai canali e memoria automatic scanning
degli allarmi • maximum temperatures and alarms storage
• tasto frontale per il RESET degli allarmi • frontal alarm RESET push button
TecsyBus
Power Supply
Tx Rx
24 VAC/DC
Out
ModBus RTU
Out
4/20 mA x 4
esterne di conversio-
ne. Solo il modulo
ModBus RTU necessi-
ta di quattro fili per la
comunicazione Full-
Duplex.

the external conver-
sion units.
Only the ModBus RTU
for the Full-Duplex
communication.
Out 8 relays
ALL 1 & ALL 2
Fault relay
INTRODUZIONE - Introduction
Una nuova serie di apparecchiature dalle caratteristiche A new series of units with revolutionary technical charac-
rivoluzionarie, per prestazioni, affidabilità e completezza, teristics thanks to the performances, reliability and com-
per la protezione termica di macchine elettriche. plete program for the thermal protection of electric units
Non più apparecchiature elettroniche dedicate, con such as cast resin transformers, motors and electric
caratteristiche tecniche prefissate e non variabili, ma una generators.
No more protection relay dedicated, with technical cha-
serie di apparecchiature che si possono man mano con-
racteristics pre-fixed, but the basic unit can be set simply
figurare secondo le esigenze di comunicazione e control-
adding a DIN rail box with the required function, which is
lo a distanza, differenti. foreseen for the remote communication and control.
I Mod. NT935 ed NT538 possono avere configurazioni The basic units Mod.NT935 and NT538 may have multi-
multiple, ovvero possono abbinare contemporaneamente ple configurations; they may have at the same time, a
l’uscita analogica ed una doppia uscita a relè (per ogni digital output ModBus RTU, or an analog output 4-20 mA
canale controllato) e l’uscita ModBus RTU. for each individual channel (RTD Pt100), and two relays
Ciò permette al tecnico progettista dell’impianto di con- (ALL1 and ALL2) for each individual channel.
trollo ed automazione di disporre di tutti gli elementi per The exceptional flexibility of the system gives to the engi-
perfezionare il sistema di controllo e protezione. neer the maximum aid for the solution of all the remote
Un protocollo residente TecsyBus fa fluire, dalla centrali- protection and monitoring of the status of the units.
na a tutte le apprecchiature esterne, le informazioni atte A proprietary protocol (TecsyBus) gives all the digital
informations to the external modules.
a comandare i differenti convertitori.
All the functions can be added in a second time, after the
Le funzioni di comunicazione o di automazione possono
main unit installation.
essere abbinate alla centralina, anche in seguito alla sua
installazione.
CONVERTITORE DI SEGNALE ANALOGICO - Analog signal converter

Atto a fornire 4 uscite 4-20 mA (Mod.4A) oppure 8 uscite
4-20 mA (Mod.8A), funzione della temperatura rilevata
dalle sonde RTD.
Range 4-20 mA : da 0 a 240 °C (0-200 °C a richiesta)
Ingresso a due fili da NT935 e NT538
Alimentazione: 24 VCA-CC
Assorbimento: 3 W per Mod.4A - 5 W per Mod.8A
Montaggio su barra DIN 50022
Dimensioni: 106 x 90 x 58 mm
Materiale del contenitore: Noryl UL 94V-0
Colore: RAL 7035
4 outputs 4-20 mA (Mod.4A) or 8 outputs 4-20 mA (Mod.8A)

function of the temperature detected by the RTD sensors.
Range 4-20 mA: from 0 to 240°C (0 – 200°C on request)
Input: two wires from units NT935 or NT538
Power Supply: 24 VAC/DC
Burden: 3 W for Mod.4A - 5 W for Mod.8A
Mounting on DIN rail EN 50022
Dimensions: 106x90x58 mm
Box material: Noryl UL 94V-0
Color: RAL 7035
BUSMOD 8A
Convertitore di segnale digitale da protocollo TecsyBus a ModBus
RTU.
Alimentazione 24 VCA-CC
Consumo: 2 W
Dimensioni: 71x90x58 mm
Colore: RAL 7035
Digital signal converter from protocol TecsyBus to ModBus RTU.

Power supply: 24 VAC-DC
Burden: 2 W
Dimentions: 71x90x58 mm
Color: RAL 7035
UNITA’ PER ESTENSIONE DEI RELE’ DI SEGNALAZIONE - Multiple relay unit

Ingresso a due fili da NT935 o da NT538
4 Alarm + 4 Trip + 1 Fault (NT935)
Ogni ingresso sonda avrà due relè di segnalazione (ALL-TRIP)
Relè di Fault per la segnalazione di guasto (mancanza seriale- fault di alimentazione – guasto sonde)
Montaggio su barra DIN EN 50022
Consumo: 4 W (versione 4A) 7W (versione 8A)
Materiale del corpo: elementi laterali in poliammide UL 94V-0
Supporto profilato: PVC autoestinguente
Colore : verde
Input with two wires from NT935 and NT538

4 ALL1 and 4 ALL2 (NT935)
Each individual input shall have two alarm relays (ALL1 and
ALL2)
Fault relay for off-serial communication / off power supply / faulty
sensors
Dimensions: 182 x 127 x99 mm
Box material
Lateral Elements: Polyamides 6.6 UL94V0
Support section: PVC self-extinguishing
Color: green
http://www.tecsystem.it
Via C. Colombo, 5/C - 20094 CORSICO (MI) Italy - Tel. +39 / 02.45.81.861 (3 linee r.a.) - Fax +39 / 02.48.60.07.83
Page 1 of 1
http://www.superiorinterlock.com/products/4003ts.gif 11/17/2004
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 30
Gen IV (Phase 1 & Phase 2)

Description Manufacturer Manufacturer's P/N
Phase 1 - DS1 SIEMENS LBR3040
Auxiliary Contact - AUX2 SIEMENS LBRA1
Phase 2 - DS1 FERRAZ SHAWMUT LBSM16
T1-H1/H2/H3 - Arrestors COOPER 235-37
CB1 - 5A adj. SIEMENS 3RV1021-1GA10
CB2 - 20A SIEMENS BQ2B020QLD
Phase 1 – Blower R3G500-AG06-03
EBM
Phase 2 – Blower R3G630-AB01-05
Blower Motor Starter SIEMENS 3RT1023-1AK60
Starter Suppressor SIEMENS 3RT1926-1CD00
Starter Auxiliary Contact SIEMENS 3RT1921-1CA10
Blower Motor Starter Fuses GOULD SHAWMUT AJT8
Terminal Blocks WEIDMULLER 102000
CT1/CT2 INSTRUMENT TRANSFORMERS 300 SERIES
HEB/HEC LEM LT100-S
PB4 SIEMENS 52PA2W2A/52AAGM
SW1 SIEMENS 52SA2CABA2
TS1 DAYTON 2E 206
HTR1-2 CHROMALOX OT-1850
CR1 SIEMENS 3TX7121-5DF13
Latch Fault Relay IDEC RR2KP-U-AC120V
LFR/CR1 Suppressor OKAYA XA1201
Tec System/Converter TECSYSTEM NT-538/ NT-CONV/420/8A
Switches
Disconnect Switches
Compact Non-Fusible —
Selection
Rotary and Toggle
Features
▪ 25 -100 Ampere, to 50 hp 480V and 600V
▪ Rotary and Toggle actuation models
▪ LBR Type switches are UL & CUL listed
under File No. E191706 as manual motor
controllers per UL Standard UL508
▪ 3LD2 Type switches are UL listed under
File No. E47705 per UL508 and are CSA
certified under File No. 203576
▪ Base, DIN-rail and door mounting
▪ Multiple conductor, distribution terminal type
rating LBR & LBT Type (40A -100A only)
Type LBR Rotary Switches Type LBT Toggle Switches
▪ IEC 947-1 rated, CE marked
▪ Listed and marked “suitable as motor
disconnect” per NEC Section 430-109 Short Circuit Withstand Ratings
Switch Rating
Application & Type Max. Line Side Fuse Rating
Siemens Load Break Switches are listed 5kA with Line Side Class H, K, or
as manual motor controllers and are suitable RK5 Fuses
as motor disconnects. They are load break 25 & 32A 3LD2 80A Max. at 600V AC Max.
rated and act as enclosure disconnects when 63A 3LD2 175A Max. at 600V AC Max.
short circuit protection is provided upstream 3LD2254-0TK51
of the switch. If upstream over current protec- 10kA with Line Side Class H, K, or
tion is not provided, use a Siemens fusible RK5 Fuses
Type VBII, CFS or MCS Disconnect Switch. 25A LBR 30A Max. at 480V AC Max.
40A, 4P
Ordering Information LBR & LBT
60A Max. at 480V AC Max.
Door Mounted Switches (Rotary Base/DIN Rail Mounted Switches 40 & 60A, 3P
LBR & LBT
Type Only) — Order either complete (Rotary or Toggle Type) — Order
“3LD2” assemblies or individual “LBR” individual components as follows: 80 & 100A
LBR & LBT
components as follows: Toggle — Order the LBT switch required
Complete Assemblies include switch, and a toggle switch cover plate if 18kA with Line Side Class J, T, or
handle, and shaft. Certain 25 and 32A needed. CC Fuses
assemblies are also available with factory 40 –100A, 3P
Rotary, Base Mounted with Door LBR & LBT
installed neutral blocks and/or aux. Mounted Handle — Order “LBR”
contacts. These accessories can also switch + door mounted handle + shaft + Note: 3LD2 switches are also rated 5kA at 600V
be ordered as field installed kits. any accessories. AC Max. when protected by a 3RV motor starter
with a FLA rating equal to or less than the switch
Individual Components are ordered as Rotary, Base Mounted with Direct ampere rating.
follows: Mounted Handle — Order “LBR”
25A — LBR3025D switch + LBRH3 or 4 switch + direct mounted handle.
handle.
40 –100A — LBR switch + LBRH3 or 4
Door Mounted Complete Assemblies
handle + LBRD1. Operator, Shaft, & Switch) 600V AC Max.
Shaft Mounted 4 Hole Mounted AC Horsepower Ratings
Notes: (LBR Type switches only)
Catalog List Catalog List Number Ampere 120V 240V 480V 600V
1. Aux contacts are available as field Number Price $ Number Price $ of Poles Rating 1Ø 1Ø 3Ø 3Ø 3Ø
installed kits on 25A units only. 3LD2154-0TK_ _ 72.00 3LD2103-0TK_ _ 72.00 3
2. Lugs on 25A units face to the rear and 3LD2154-1TP_ _ 95.00 3LD2103-1TP_ _ 95.00 3
25 2 3 71/2 10 15
lugs on 40 –100A units face toward 3LD2154-1TL_ _ 90.00 3LD2103-1TL_ _ 90.00 3+N
3LD2154-2EP__ 110.00 3LD2103-2EP_ _ 110.00 3 + N
the front.
3LD2254-0TK_ _ 85.00 3LD2203-0TK_ _ 81.00 3
32 2 3 10 20 20
3LD2254-1TL_ _ 105.00 3LD2203-1TL_ _ 109.00 3+N
3LD2555-0TK_ _ 139.00 3LD2504-0TK_ _ 139.00 3 63 — 10 15 40 50
— — 3LD2704-0TK_ _ 210.00 3 100 — — 30 60 75
— — 3LD2804-0TK_ _ 269.00 3 125 — — 40 75 100
왎 Built to order. Allow 6–8 weeks for delivery. Add 51 for a black handle or 53 for a red & yellow handle
Includes auxiliary contacts (1 NO and 1 NC). to the end of the catalog number.
Handles are IP65 rated and are also UL listed for Type 1, 4X
and 12 applications.
18/16 Discount Code: Pilot Devices Siemens Energy & Automation, Inc.
Industrial Controls Catalog
Switches
Disconnect Switches
Rotary and
Selection
Toggle
Individual Components
Rotary and Toggle Switches
AC Horsepower Ratings
Max
Catalog Switch No. of Ampere AC 115V 240V 480V 600V List
Number Type Poles Rating Volt 1Ø 1Ø 3Ø 3Ø 3Ø Price $
3
LBR3025 Rotary 3 25 480 ⁄4 2 5 10 — 88.00
LBR3025D Rotary 3 25 480 3
⁄4 2 5 10 — 97.00
LBR3040 Rotary 3 40 600 2 3 71⁄2 20 25 105.00
LBR3060 Rotary 3 60 480 2 5 10 25 — 126.00
LBR3080 Rotary 3 80 600 3 10 20 40 50 151.00
LBR3100 Rotary 3 100 480 5 15 25 50 — 186.00
LBR4040 Rotary 4 40 480 2 3 71⁄2 20 — 164.00
1
LBT3040 Toggle 3 40 600 2 3 7 ⁄2 20 25 105.00
LBT3060 Toggle 3 60 480 2 5 10 25 — 126.00 Standard Duty Rotary Heavy Duty Rotary
LBT3080 Toggle 3 80 600 3 10 20 40 50 151.00
LBT3100 Toggle 3 100 480 5 15 25 50 — 186.00 Switch Door Handles Switch Door Handle
LBT4040 Toggle 4 40 480 2 3 71⁄2 20 — 164.00
LBR Type Handles
Cover
Catalog Used on NEMA Interlock List
Number Rotary Switches Type Mounting Marking Color Supplied Padlockable Price $
Standard Duty
LBRH2 All 1 Door ON/OFF Black No No 31.00
LBRH3 All 1, 3R, 12, 4X Door O/I, ON/OFF Black Yes Yes 45.50
LBRH4 All 1, 3R, 12, 4X Door O/I, ON/OFF Red/Yel Yes Yes 45.50
LBRH9 All (Pistol Grip Type) 1, 3R, 12, 4X Door O/I, ON/OFF Black Yes Yes 116.00
LBRH10 All (Pistol Grip Type) 1, 3R, 12, 4X Door O/I, ON/OFF Red/Yel Yes Yes 116.00
LBRH5 25 Amps 1 Direct Mount O/I Black — Yes 14.40
LBRH6 3-Pole, 40-60 Amps 1 Direct Mount O/I Black — Yes 18.60
Heavy Duty
CFSH10B12 All 1, 3R, 12 Door O/I, ON/OFF Black Yes Yes 122.00
CFSH10R12 All 1, 3R, 12 Door O/I, ON/OFF Red/Yel Yes Yes 122.00
LBR Type Rotary Shafts

Catalog No Length In. (mm) List Price $
For Standard Duty Handles
LBRS040 1.57 (40) 14.40
LBRS050 1.97 (50) 18.60
LBRS055 2.17 (55) 18.60
LBRS080 3.15 (80) 21.50
LBRS120 4.72 (120) 24.00
LBRS180 7.09 (180) 28.00
LBRS305 12.00 (305) 31.00
For Heavy Duty Handles
CFSS5200H 7.9 (200) 30.50
CFSS5400H 15.7 (400) 32.50 Rotary Shafts Rotary Switch Direct Toggle Switch Cover
Mount Handles Plates
25 Amp, 4th Pole
Used on Catalog No Catalog No List Price $ LBR Type Toggle Switch Cover Plate
LBR3025 LBRP25 61.00
LBR3025D LBRP25D 68.00 Used on List
3LD21 & 2 3LD9220-0B 25.50 Toggle Switches Catalog Number Price $
3LD25 3LD9250-0B 42.00 LBT3040, LBT3060 LBTCP1 23.00
LBT3080,LBT3100 LBTCP2 24.00
Auxiliary Switch Kits LBT4040 LBTCP3 27.00
Used on Catalog List LBR Type Rotary Switch Door Mounting Kit
Rotary Switch Number Contact Arrangement Price $ (For use with LBRH3 & LBRH4 only)
LBR3025 LBRA25 1 NO/1 NC 45.50 Used on List
LBR3025D LBRA25D 1 NO/1 NC 45.50 Rotary Switch Catalog Number Price $
LBR3040, 1 NO/1 NC
LBR3060 LBRA1 with common point 53.00
40-100 Amps LBRD1 53.00

LBR3080,
LBRA2
1 NO/1 NC Neutral Kit
LBR3100 with common point 58.00 Used with List

3LD9220-3B 1 NO 20.50 Catalog Number Catalog Number Price $
3LD21 & 22 3LD9220-5B 1 NO/1 NC 29.50 All HF63CX
3LD9250-3B 1 NO 20.50 3LD21 & 2 3LD9220-2B 20.50
3LD25 3LD9250-5B 1 NO/1 NC 29.50 3LD25 3LD9250-2B 28.50
No cover interlock defeat mechanism provided. To elimi- Auxiliary switch contacts break about 30 Ms before and Lug wire ranges:
nate cover interlock, order additional catalog number make about 3 Ms after main switch contacts. HF63CX —(1) #14-2 AWG 60/75°C Cu only
LBRDC1. Auxiliary switch contacts break about 3 Ms before and 3LD9220-2B—(1) #14-10 AWG 60/75°C Cu only
LBRH2 is IP54 rated. All others are IP65. make about 3 Ms after main switch contacts. 3LD9250-2B—(1) #14-6 AWG 60/75°C Cu only
Ratings Ratings Only door mountable and for use with LBRH3 &
15.1A resistive at 250V AC max. 10A at 120V AC 4 handles only.
.5A at 125V DC 6A at 240V AC For door mounting of 40–100A LBR switches use
.25A at 250V DC 1.4A at 480V AC door mounting kit LBRD1 & LBRH3 or 4 handle.
.5 HP at 250V AC max. Discount Schedule Pilot Devices
Siemens Energy & Automation, Inc. Discount Code: F 18/17

Switches
Disconnect Switches
Selection
Rotary and Toggle
Dimension Drawings and Wire Ranges
3.35 in.
3.15 in. (85 mm)
(80 mm) Minimum Depth 햲
2.92 in. 1.38 in. E A

1.77 in.
(74 mm) (35 mm) (45 mm) F D
0.16 in.
(4 mm) G
0.87 in. 0.20 in. 1.54 in. 0.71 in.

(22 mm) (5 mm) (39 mm) (18 mm) H
1.42 in. 2.24 in.
(36 mm) (57 mm)
0.31 in.
2.76 in. (8 mm)
(70 mm)
3.35 in.
(85 mm)
Minimum Depth 햲
LBR 3025 LBR & 3LD2 Rotary — 40-100 Amps
Wire Ranges 60/75°C Cu only

3.00 in.
(76 mm) (1) #14 - #10 AWG Solid
Minimum Depth 25 Amps LBR
(1) #14 - #8 AWG Stranded
C (1) #14 - #10 AWG Solid
E A (1) #14 - #4 AWG Stranded
UP to (4) #12 AWG Solid
F D 40 & 60 Amps
Up to (3) #12 AWG Stranded
LBR & LBT
with (1) #10 AWG Stranded
0.16 in.
(4 mm) G (1) #14 - #10 AWG Solid
Drilling
B Pattern (1) #14 - #1 AWG Stranded
.125 80 & 100 Amps (2) #6 AWG Stranded
(3.2) LBR & LBT Up to (3) #8 AWG Stranded
H Up to (6) #10 AWG Stranded
.95 Up to (6) #12 AWG Solid
(24.1)
25A, 3LD21 (1) #14-8 AWG
0.31 in.
(8 mm) .877 32A, 3LD22 (1) #14-8 AWG
(22.5) 63A, 3LD25 (1) #14-6 AWG
LBT Toggle — 40-100 Amps Shaft Mounted

3LD2 Handle Cutout
Switch Switch Dimensions Inches (mm)

Type Catalog Number A B C D E F G H
Rotary LBR3040 2.00 (51) 2.72 (69) 2.72 (69) 1.78 (45) 2.16 (55) 1.67 (42) 1.50 (38) 1.22 (31)
Rotary LBR3060 2.00 (51) 2.72 (69) 2.72 (69) 1.78 (45) 2.16 (55) 1.67 (42) 1.50 (38) 1.22 (31)
Rotary LBR3080 2.09 (53) 3.32 (84) 2.92 (74) 1.97 (50) 2.29 (58) 1.69 (42) 1.66 (42) 1.66 (42)
Rotary LBR3100 2.09 (53) 3.32 (84) 2.92 (74) 1.97 (50) 2.29 (58) 1.69 (42) 1.66 (42) 1.66 (42)
Rotary LBR4040 2.42 (61) 2.72 (69) 2.72 (69) 2.28 (58) 2.16 (55) 1.67 (42) 1.50 (38) 1.22 (31)
Rotary 3LD21 & 2 햳 1.81 (46) 2.17 (55) 2.88 (73) 햲 — — — — —
Rotary 3LD25 햳 2.36 (60) 2.52 (64) 3.25 (83)햲 — — — — —
Toggle LBT3040 2.00 (51) 2.72 (69) 2.75 (70) 1.78 (45) 2.16 (55) 1.67 (42) 1.50 (38) 1.22 (31)
Toggle LBT3060 2.00 (51) 2.72 (69) 2.75 (70) 1.78 (45) 2.16 (55) 1.67 (42) 1.50 (38) 1.22 (31)
Toggle LBT3080 2.09 (53) 3.32 (84) 2.90 (74) 1.97 (50) 2.29 (58) 1.69 (42) 1.66 (42) 1.66 (42)
Toggle LBT3100 2.09 (53) 3.32 (84) 2.90 (74) 1.97 (50) 2.29 (58) 1.69 (42) 1.66 (42) 1.66 (42)
Toggle LBT4040 2.42 (61) 2.72 (69) 2.75 (70) 2.28 (58) 2.16 (55) 1.67 (42) 1.50 (38) 1.22 (31)
햲 Depthfrom outside of cover to back of switch.
햳 Handlefront plate dimensions:
3LD21 & 2—2.64 inches square
3LD25—3.55 inches square
18/18 Siemens Energy & Automation, Inc.

SOCOMEC
LBS DISCONNECT SWITCHES

Ferraz Shawmut LBS load break disconnect switches
have been designed for today’s industrial control
systems. The LBS switches allow you to safely turn
power to your panel on and off or isolate a particular
circuit within the panel. These switches are compact
and offer a variety of mounting options like DIN rail
mounting, base mounting, or door mounting. A wide
assortment of handles, shafts and accessories exist to
provide you with the ultimate flexibility in the design of
your industrial control panels. Wiring terminations are
integral to the switch body and recessed to insure a
“finger safe” environment according to IEC standards to
an IP20 grade of protection.
HIGHLIGHTS: APPLICATIONS: Ratings Approvals

➤ Finger Safe ➤ On/Off switching and ➤ 600 VAC ➤ All LBS load break
➤ Compact footprint disconnect applications ➤ 16, 20, 25, 30, 40, disconnects meet
in circuits up to 600 60, 80, 100, and the requirements of
➤ DIN rail or base mount
volts, 125 amperes on 125 amperes UL 508
standard
the load side of branch ➤ UL Listed
➤ Door mounting optional Guide NLRV
circuit protection fusing.
➤ Choice of external File E196672
➤ Motor Controller
handles/shafts ➤ cUL Listed
➤ Motor Isolator
➤ Direct mount handle Guide NLRV7
➤ General Purpose
option File E196672
➤ IEC 947-3 as load
➤ Toggle handle option
break disconnector
K2
SOCOMEC

SELECT A SWITCH
LBS RANGE: Load Break Disconnect Switches from 16 to 125 Amperes
AMPERE RATING 16 20 25 30
CATALOG NUMBER LBSM16 LBSM20 LBSM25 LBSM30
SELECT A HANDLE
NEMA IEC
DEFEATABLE COLOR CATALOG NUMBER
TYPE TYPE
1,3R, 12, 4, 4X IP65 NO Black HMSB HMSB HMSB HMSB
1, 3R, 12, 4, 4X IP65 NO Red/Yellow HMSR HMSR HMSR HMSR
SHAFT LENGTH
SELECT A SHAFT CATALOG NUMBER
(inches/mm)
2.75 / 70 SM70-5L SM70-5L SM70-5L SM70-5L
4.72 / 120 SM120-5L SM120-5L SM120-5L SM120-5L
7.9 / 200 SM200-5L SM200-5L SM200-5L SM200-5L
12.0 / 305 SM300-5L SM300-5L SM300-5L SM300-5L
OR OR OR OR
NEMA IEC
SELECT A HANDLE DEFEATABLE COLOR CATALOG NUMBER
TYPE TYPE
1,3R, 12 IP54 YES Black HDPB HDPB HDPB HDPB
1, 3R, 12 IP54 YES Red/Yellow HDPR HDPR HDPR HDPR
1, 3R,12 IP54 NO Black HDPBND HDPBND HDPBND HDPBND
1, 3R, 12 IP54 NO Red/Yellow HDPRND HDPRND HDPRND HDPRND
SELECT A SHAFT SHAFT LENGTH
CATALOG NUMBER
(inches/mm)
4.72/120 SD120-5 SD120-5 SD120-5 SD120-5
7.9/200 SD200-5 SD200-5 SD200-5 SD200-5
12.6/320 SD320-5 SD320-5 SD320-5 SD320-5
OR OR OR OR
NEMA IEC
TYPE TYPE
1,3R, 12 IP54 YES Black HGPB HGPB HGPB HGPB
1, 3R, 12 IP54 YES Red/Yellow HGPR HGPR HGPR HGPR
1, 3R,12, 4, 4X IP65 YES Black HGPB4 HGPB4 HGPB4 HGPB4
1, 3R, 12, 4, 4X IP65 YES Red/Yellow HGPR4 HGPR4 HGPR4 HGPR4
CATALOG NUMBER
(inches/mm)
4.72/120 SG120-5 SG120-5 SG120-5 SG120-5
7.9/200 SG200-5 SG200-5 SG200-5 SG200-5
12.6/320 SG320-5 SG320-5 SG320-5 SG320-5
OPTIONS CATALOG NUMBER
Modular 4th power pole (rating same as switch) PPM16 PPM20 PPM25 PPM30
Neutral pole (feed through, not switched, rated 30A, 480VAC) NMM NMM NMM NMM
Ground pole (feed through, not switched, rated 30A, 480VAC) GMM GMM GMM GMM
(1) NO+NC, side mount, pre-break auxiliary contact, rated 15A @ 120 VAC ACMM ACMM ACMM ACMM
Terminal shroud (for 3 pole switch) TSLBSM TSLBSM TSLBSM TSLBSM
Terminal shroud for modular 4th pole or NMM or GMM TSLBSM4 TSLBSM4 TSLBSM4 TSLBSM4
Direct mounted handle (requires removing collar from switch) HAD60M HAD60M HAD60M HAD60M
OTHER VERSIONS AVAILABLE: Switch with Direct Mounted Handles AMPERE RATING
CATALOG NUMBER
16
LBSM16DH
20
LBSM20DH
25
LBSM25DH
30
LBSM30DH
K
Please consult factory for availability - special order parts
Door mounted switches AMPERE RATING 16 20 25 30
CATALOG NUMBER LBSDM16 LBSDM20 LBSDM25 LBSDM30
Options same as above
SELECT A HANDLE
NEMA IEC
TYPE TYPE
1,3R, 12, 4, 4X IP65 NO Black HMSB HMSB HMSB HMSB
1, 3R, 12, 4, 4X IP65 NO Red/Yellow HMSR HMSR HMSR HMSR
Modular 4th power pole (rating same as switch) PPDM16 PPDM20 PPDM25 PPDM30
Neutral pole (feed through, not switched, rated 30A, 480VAC) NDMM NDMM NDMM NDMM
Ground pole (feed through, not switched, rated 30A, 480VAC) GDMM GDMM GDMM GDMM
(1) NO+NC, side mount, pre-break auxiliary contact, rated 15A @ 120 VAC ACDMM ACDMM ACDMM ACDMM
Please consult factory for other shaft lengths or options.
K3
SOCOMEC

SELECT A SWITCH
AMPERE RATING 30 40 60 80 100 125

CATALOG NUMBER: 3 POLE LBSR30 LBSR40 LBSR60 LBSR80 LBSR100 LBSR125
CATALOG NUMBER: 4 POLE LBSR304 LBSR404
SELECT A HANDLE
NEMA IEC
TYPE TYPE
1,3R, 12, 4, 4X IP65 NO Black HMSB HMSB HMSB HMSB HMSB HMSB
1, 3R, 12, 4, 4X IP65 NO Red/Yellow HMSR HMSR HMSR HMSR HMSR HMSR
SHAFT LENGTH
SELECT A SHAFT CATALOG NUMBER
(inches/mm)
2.75 / 70 SM70-5L SM70-5L SM70-5L SM70-5L SM70-5L SM70-5L
OR OR OR OR OR OR
NEMA IEC
TYPE TYPE
1,3R, 12 IP54 YES Black HDPB HDPB HDPB HDPB HDPB HDPB
1, 3R, 12 IP54 YES Red/Yellow HDPR HDPR HDPR HDPR HDPR HDPR
1, 3R,12 IP54 NO Black HDPBND HDPBND HDPBND HDPBND HDPBND HDPBND
1, 3R, 12 IP54 NO Red/Yellow HDPRND HDPRND HDPRND HDPRND HDPRND HDPRND
CATALOG NUMBER
(inches/mm)
4.72/120 SD120-5 SD120-5 SD120-5 SD120-5 SD120-5 SD120-5
7.9/200 SD200-5 SD200-5 SD200-5 SD200-5 SD200-5 SD200-5
12.6/320 SD320-5 SD320-5 SD320-5 SD320-5 SD320-5 SD320-5
OR OR OR OR OR OR
NEMA IEC
TYPE TYPE
1,3R, 12 IP54 YES Black HGPB HGPB HGPB HGPB HGPB HGPB
1, 3R, 12 IP54 YES Red/Yellow HGPR HGPR HGPR HGPR HGPR HGPR
1, 3R,12, 4, 4X IP65 YES Black HGPB4 HGPB4 HGPB4 HGPB4 HGPB4 HGPB4
1, 3R, 12, 4, 4X IP65 YES Red/Yellow HGPR4 HGPR4 HGPR4 HGPR4 HGPR4 HGPR4
CATALOG NUMBER
(inches/mm)
4.72/120 SG120-5 SG120-5 SG120-5 SG120-5 SG120-5 SG120-5
7.9/200 SG200-5 SG200-5 SG200-5 SG200-5 SG200-5 SG200-5
12.6/320 SG320-5 SG320-5 SG320-5 SG320-5 SG320-5 SG320-5
(1) NO Auxiliary contact rated 10A, 600VAC AC11 AC11 AC11 AC11 AC11 AC11
(1) NC Auxiliary contact rated 10A, 600VAC AC12 AC12 AC12 AC12 AC12 AC12
Auxiliary contact holder: 3 pole ACHLBS1 ACHLBS1 ACHLBS2 ACHLBS2 ACHLBS2 ACHLBS2
4 pole ACHLBS14 ACHLBS14
Door mounting kit for LBSR switches DMKLBSR DMKLBSR DMKLBSR DMKLBSR DMKLBSR DMKLBSR
Direct mounted handle (requires removing collar from switch) HAD40R HAD40R HAD80R HAD80R HAD80R HAD80R
OTHER VERSIONS AVAILABLE:

Switch with Direct Mounted Handles (includes escutcheon plate for lockout capabilities)
AMPERE RATING 30 40 60 80 100 125
CATALOG NUMBER: 3 POLE LBSR30DH LBSR40DH LBSR60DH LBSR80DH LBSR100DH LBSR125DH
CATALOG NUMBER: 4 POLE LBSR304DH LBSR404DH
Please consult factory for availability of special order parts. Options same as above
Toggle style AMPERE RATING 30 40 60 80 100 125

CATALOG NUMBER: 3 POLE LBST30 LBST40 LBST60 LBST80 LBST100 LBST125
CATALOG NUMBER: 4 POLE LBST304 LBST404
Optional DIN escutcheon plate for lockout capabilities.
CATALOG NUMBER: 3 POLE CP40T CP40T CP80T CP80T CP80T CP80T
CATALOG NUMBER: 4 POLE CP40T4P CP40T4P
(No lockout capability for 4 pole)
Note: Please consult factory for other shaft lengths or options.
K4
SOCOMEC
LBS LOAD BREAK DISCONNECT SWITCHES FROM 16 TO 100 A
UL AND cUL TECHNICAL CHARACTERISTICS
LBS M LBS R
LBSM16 LBSM25 LBSR30 LBSR40 LBSR60 LBSR80 LBSR100
Rating (3 poles) 16 A 25 A 30 A 40 A 60 A 80 A 100 A
UL approval UL508/cUL UL508/cUL UL508/cUL UL508/cUL UL508/cUL UL508/cUL UL508/cUL
Short-circuit rating kA 5 5 10 10 10 10 10
- Fuse type RK5 RK5 RK5 RK5 RK5 RK5 RK5
- Fuse rating (A) 30 30 80 80 150 150 150
Maximum UL Horsepower 220-240 V AC 3 5 7.5 10 15 20 25
ratings (3-ph) 440-480 V AC 7.5 10 15 20 30 40 50
600 V AC 10 15 25 30 40 50 60
Maximum UL Horsepower 120 V AC 1 1.5 2 2 3 5 5
ratings (1-ph) 240 V AC 2 3 5 5 10 15 15
Electrical endurance (operation cycles) 6000 6000 6000 6000 6000 6000 6000
Mechanical endurance (operation cycles) 6000 6000 6000 6000 6000 6000 6000
Terminal lugs wire size #6-#10 #6-#10 #14-#8 #14-#8 #14-#3 #14-#3 #14-#3
wire type Cu Cu Cu Cu Cu Cu Cu
Weight (lb) 0.32 0.32 0.44 0.44 0.66 0.66 0.66
IEC TECHNICAL CHARACTERISTICS
LBS M LBS R
LBSM16 LBSM25 LBSR30 LBSR40 LBSR60 LBSR80 LBSR100
THERMAL CURRENT Ith (40 °C) 16 A 25 A 30 A 40 A 60 A 80 A 100 A
RATED INSULATION VOLTAGE Ui (V) 800 800 690 690 690 690 690
RATED IMPULSE WITHSTAND Uimp (kV) 8 8 8 8 8 8 8
OPERATIONAL CURRENT (A) 3 poles 3 poles 3 poles 3 poles 3 poles 3 poles 3 poles
400 V AC AC 22 A 16 25 32 40 63 80 80
AC 23 A 16 25 25 25 63 63 63
500 V AC AC 22 A 16 25 32 40 63 80 80
AC 23 A 16 20 25 25 45 45 45
690 V AC AC 22 A 16 25 32 40 63 80 80
AC 23 A 16 20 25 25 40 40 40
MOTOR POWER (KW)
400 V AC - AC 23 5.5 7.5 11 11 25 25 25
K
500 V AC - AC 23 7.5 9 15 15 25 25 25
690 V AC - AC 23 9 11 15 15 25 25 25
OVERLOAD CAPACITY
Short circuit current with fuses (kA rms) 50 50 50 50 50 50 50
Maximum rating for associated fuses gG (A) 16 25 32 40 63 80 80
Cut-off current (kA peak) 5.9 5.9 5 5 8 8 8
Short time withstand current Icw 1 s (kA) 1.2 1.2 1 1 1.5 1.5 1.5
WITHSTAND
Mechanical 100 000 100 000 20 000 20 000 20 000 20 000 20 000
Electrical 400 V AC 23 1 500 1 500 5 000 5 000 1 500 1 500 1 500
CONNECTION
Cu (mm2) 1.5 to 6 1.5 to 6 1.5 to 6 1.5 to 6 1.5 to 35 1.5 to 35 1.5 to 35
K5
Surge Arresters
UltraSIL™ Housed VariGAP® Surge Arresters: Electrical Apparatus
Normal Duty (5 kA), Heavy Duty (10 kA), and
Heavy Duty Riser Pole (10 kA) 235-37
GENERAL
Cooper Power Systems has set the
standard for design, manufacturing
and delivery of polymeric distribution
arresters with the UltraSIL housed
arrester family. The UltraSIL housed
surge arrester incorporates the industry
recognized superior polymer housing
material – silicone rubber.
Available in Normal Duty, Heavy Duty
and Heavy Duty Riser Pole designa-
tions, UltraSIL housed VariGAP
distribution class surge arresters
provide superior overvoltage protection
for any electric distribution system.
CONSTRUCTION
The VariGAP design is a combination
of both metal oxide and gapped
arrester technologies. Construction
consists of Metal Oxide Varistors
(MOVs) in series with a non-linear
gap structure. The mating of these two
service proven technologies results in
the gap structure and MOVs sharing
the system voltage during steady state
conditions. This sharing minimizes
voltage stress on each component.
This results in a significant improvement
in protective characteristics and 60 Hz
temporary overvoltage (TOV) Figure 1.
withstand. 10 kV UltraSIL housed VariGAP distribution class surge arrester.
The patented construction of VariGAP
UltraSIL housed arresters starts with
MOVs manufactured at our Olean, The UltraSIL housing is then surface tracking, performance in
NY facility. Manufacturing our own interference fit and bonded onto the contaminated environments, chemical
MOVs allows for strict quality control cured internal module to form a solid, inertness, temperature stability and
over all aspects of disk production. high-dielectric strength, insulation other important insulating properties.
Every MOV is subjected to a series of system. UltraSIL silicone rubber will not support
physical and electrical tests designed biological growth (algae and mildew),
Following assembly, each arrester is
to ensure that only disks meeting is non-flammable and will not support
subjected to a battery of electrical
strict quality standards are used in combustion.
tests to assure the highest quality and
UltraSIL arresters. The Cooper Power in-service field performance. An optional insulated mounting hanger
Systems MOV disk design has proven is available to allow connecting to a
its reliability and protective ability FEATURES wide variety of brackets. The insulated
through many years of field service. hanger, made of glass filled polyester,
The UltraSIL silicone rubber housing
The MOVs are placed in series with has undergone a wide range of design has been designed to provide needed
a gap assembly and aluminum end tests to determine the optimum shed mechanical strength for installation
electrodes to form a complete configuration. In addition, long term and severe loading conditions.
assembly. This assembly is coated with environmental testing has verified the A ground lead isolator is also
a fiberglass-reinforced epoxy collar lifetime superiority of silicone rubber available. The isolator removes the
using an automated fluidized bed when compared to other polymeric ground terminal from the arrester in
process. The collar is cured to form a insulating materials. the unlikely event of arrester failure,
solid, mechanically strong module thus preventing a permanent system
capable of withstanding extreme Independent laboratory tests have
verified the superiority of silicone rub- fault. An isolator that has operated
electrical, environmental, and gives visual indication of internal
cantilever loading conditions. ber in terms of non-wetting surfaces,
resistance to UV degradation and damage to the arrester and the need
for arrester replacement.
January 2000 • Supersedes 2/97 1

Printed in U.S.A.
300 SERIES (CORROSION PROOF) PERMANENT STAMPED-IN

DESIGN TESTING
STAINLESS STEEL
LINE TERMINAL
NAMEPLATE INFORMATION The housing material, internals and
Standard connectors hardware work together as a system
STAINLESS STEEL
accommodate #6 solid TOP CAP
and must stand up to years of expo-
through 2/0 stranded sure to environmental extremes. To
leads. assure a superior level of performance,
both the components and assembled
ALUMINUM arrester units have been subjected to
ELECTRODE a program of testing that accurately
simulates years of exposure to actual
field conditions. Testing includes:
UltraSIL SILICONE ■ ANSI/IEEE C62.11 Testing – Full
RUBBER HOUSING
certification to performance
GAP ASSEMBLY requirements by an independent
Provides consistent low sparkover laboratory. A certified test report is
characteristics even for rapidly available under Bulletin Number
rising surge waves. 95061.
Additional design verification testing
METAL OXIDE VARISTOR of the UltraSIL housed distribution
BONDED SOLID
arrester includes:
INTERFACE ■ UV testing
■ Full dielectric testing
METAL OXIDE VARISTOR
■ Wet Arc Tracking Resistance
■ Thermal Shock test
GLASS REINFORCED ■ Multi-Stress Environmental test
EPOXY COLLAR
cycling
■ Tracking Wheel test
ALUMINUM ELECTRODE
■ Coefficients of expansion for
OPTIONAL materials compatibility
INSULATED ■ Cantilever test
HANGER ■ Terminal and Isolator Torque test
■ Hanger Mechanical Shock test
This is only a partial listing of design

tests performed on the UltraSIL
distribution arrester. For detailed test
reports and results please contact
OPTIONAL representative.
kV RATING
ISOLATOR
GROUND LEAD 300 SERIES (Visible from ground) PRODUCTION TESTS
DISCONNECTOR STAINLESS STEEL A complete production test program
GROUND TERMINAL
Standard connectors accommodate
ensures a quality product. Each metal
#6 solid through 2/0 stranded leads. oxide varistor receives a series of
electrical tests. Quality is demonstrat-
Figure 2. ed by a series of destructive tests
Cutaway illustration of UltraSIL housed VariGAP distribution arrester. performed on every batch of varistors.
Listed are the production tests
performed on the varistors:
An optional universal wildlife protector by both the gap structure and MOVs. ■ 100% Physical Inspection
has two self-adjusting "valve" style When surges occur, the gaps spark ■ 100% Discharge Voltage test
openings which vary from 0 to 0.75" over, leaving only the MOVs in the ■ 100% V1mA/cm2
in diameter, thus allowing for a large circuit. The result is much lower dis- ■ 100% Leakage Current at 80% of
variety of conductor/insulation sizes charge voltages than are possible with
while providing optimum wildlife pro- gapless metal oxide arresters. The V1mA/cm2 Voltage
■ Batch High-current, Short-duration
tection. (See page 10, Figure 8 for a added gap assembly also increases
dimensional diagram.) the arrestor TOV withstand ability to test
■ Batch Thermal Stability test
levels up to 50% higher than compa- ■ Batch Aging test
OPERATION rable gapless MOV designs.
The operation of VariGAP arresters The superior protective characteristics
differs from conventional gapless of the VariGAP arresters provide
metal oxide arresters. During steady excellent protection for distribution
state conditions, line voltage is shared equipment with lower impulse with-
stand capabilities.
2
235-37
Each fully assembled VariGAP TABLE 1

arrester must pass the following Commonly Applied Voltage Ratings of VariGAP Arresters
production tests:
System Voltage Recommended Arrester Rating per IEEE C62.22
■ 100% Physical Inspection (kV rms) (kV rms)
■ 100% Leakage Current test
■ 100% Partial Discharge Inception Four-Wire Wye Three-Wire Wye Delta and
Multi-Grounded Solidly Grounded Ungrounded
Voltage test Nominal Maximum Neutral Neutral Wye
■ 100% 60 Hz Sparkover Level test
2.4 2.54 — — 3
GENERAL APPLICATION 4.16Y/2.4 4.4Y/2.54 3 6 6
RECOMMENDATIONS 4.16 4.4 — — 6
4.8 5.08 — — 6
The rating of an arrester is the maxi-
6.9 7.26 — — 9
mum power frequency line-to-ground
voltage at which the arrester is 8.32Y/4.8 8.8Y/5.08 6 9 —
designed to pass an operating 12.0Y/6.93 12.7Y/7.33 9 12 —
duty-cycle test. Table 1 provides a 12.47Y/7.2 13.2Y/7.62 9 15 —
general application guide for the 13.2Y/7.62 13.97Y/8.07 10 15 —
selection of the proper arrester rating 13.8Y/7.97 14.52Y/8.38 10 15 ––
for a given system voltage and system 13.8 14.52 — — 18
grounding configuration as outlined in 20.78Y/12.0 22Y/12.7 15 21 —
the IEEE C62.22 application guide. 22.86Y/13.2 24.2Y/13.87 18 24 —
Under fault conditions and other system 23 24.34 — — 30
anamolies, higher voltages can be 24.94Y/14.4 26.4Y/15.24 18 27 —
experienced by the arrester. To 27.6Y/15.93 29.3Y/16.89 21 30 —
ensure that the arrester ratings will not 34.5Y/19.92 36.5Y/21.08 27 36 —
be exceeded, Cooper Power Systems 46Y/26.6 48.3Y/28 36 — —
application engineers are available to
make recommendations. The following
information is normally required: Heavy Duty: 20 current surges of FAULT CURRENT
10 kA crest, 8/20 µs waveshape WITHSTAND TESTS
1. System maximum operating followed by 2 current surges of
voltage. 40 kA crest, 8/20 µs waveshape. Fault current withstand tests demon-
strate the ability to withstand fault
2. System grounding conditions. currents for specific durations without
■ High-Current, Short-Duration
A. For four-wire circuits, ground- Discharge: expelling any internal components.
ing conditions depend upon Normal Duty: 2 current surges of All UltraSIL housed distribution
whether the system is multi- 65 kA crest, 4/10 µs waveshape. arrester designs have been tested in
grounded, whether it has a Heavy Duty: 2 current surges of accordance with the requirements
neutral impedance and 100 kA crest, 4/10 µs waveshape. listed in ANSI/IEEE C62.11, and are
whether common primary non-fragmenting to the levels shown
and secondary neutrals are ■
in Table 2.
Low-Current, Long-Duration
used. Discharge:
B. For three-wire circuits, Normal Duty: 20 current surges of TABLE 2
grounding conditions depend 75 A crest 2000 µs duration Fault Current Withstand Tests
upon whether the system is rectangular wave.
solidly grounded at the Heavy Duty: 20 current surges of Fault Current Fault Current
Amplitude Duration
source, grounded through 250 A crest 2000 µs duration (kA rms) (cycles)
neutral impedance at the rectangular wave.
source transformers or 0.5 120
ungrounded. Following each of these tests, the 2.5 60
arresters remain thermally stable as 5.0 30
Consult your Cooper representative 10.0 10
to have your individual system verified by:
■ Continually decreasing power 20.0 10
application needs studied.
values during a thirty minute power
PERFORMANCE TEST monitoring period.
CHARACTERISTICS ■ No evidence of physical or
electrical deterioration.
UltraSIL housed VariGAP distribution ■ The 5 kA (normal duty) or 10 kA
class arresters withstand the (heavy duty) discharge voltages
following design tests as described by measured after each test changed
ANSI/IEEE C62.11: less then 10% from the initial values.
■ Duty Cycle:
Normal Duty: 22 current surges of In addition, full ANSI/IEEE C62.11
5 kA crest, 8/20 µs waveshape. certification has been completed and
verified.
3
DIMENSIONS AND
CLEARANCES
Outline drawings for several common
design options are shown in Figures
3-6. Dimensions for these designs
are listed in Table 3.
DIAMETER:
HEAVY DUTY = 3.70"
NORMAL DUTY = 3.40"
A
MOUNTING 1.25"
HOLE FOR B
1/2" HARDWARE
0.56"
D
1.25"
B FOR MORE DETAILS

ON BRACKET, SEE
FIGURES 11 & 13,
Figure 3. PAGE 11.
UltraSIL housed arrester with isolator and insulated
hanger.
Figure 5.
UltraSIL housed arrester with isolator, insulated hanger and
transformer mounting bracket.
0"-4"
4.12"-5.15"
C
A 2.56"
MOUNTING
HOLE FOR
1/2" HARDWARE
1.7"
1.25" 0.56"
B
Figure 4. Figure 6.
UltraSIL housed arrester with isolator, insulated hanger and UltraSIL housed arrester with insulated hanger without
NEMA cross-arm bracket. isolator.
4
235-37
TABLE 3
Dimensional Data – UltraSIL Housed VariGAP Arresters
Dimensions Minimum Recommended Clearances* (in.)
Standard Figures 3-5, page 4
Arrester Housing (Inches) Heavy Duty Normal Duty
Rating Code Phase-to- Phase-to- Phase-to- Phase-to-
A+ B C+ D
(kV rms) (Digits 6 & 7) Ground Phase Ground Phase
3 04 7.4 4.1 6.5 8.7 3.00 4.25 2.75 3.75

6 05 8.5 4.1 7.6 8.7 4.00 5.50 3.75 5.00
9 05 8.5 4.1 7.6 8.7 5.25 7.00 5.00 6.50
10 05 8.5 4.1 7.6 8.7 5.25 7.00 5.00 6.50
12 07 10.6 5.0 9.7 8.7 6.00 7.75 5.75 7.25
15 07 10.6 5.0 9.7 8.7 6.75 8.75 6.50 8.25
18 08 11.7 5.0 10.8 8.7 9.25 11.25 9.00 10.75
21 09 12.7 5.0 11.8 8.7 9.25 11.25 9.00 10.75
24 10 13.8 5.0 12.9 8.7 10.75 13.25 10.50 12.75
27 11 14.8 5.0 13.9 14.3 10.75 13.25 10.50 12.75
30 12 15.9 5.0 15.0 14.3 10.75 13.25 10.50 12.75
33 13 17.0 5.0 16.1 14.3 12.75 16.25 12.50 15.75
36 14 18.0 5.0 17.1 14.3 12.75 16.25 12.50 15.75
* All clearances are measured from centerline of arrester per IEEE C62.22.
+ With optional Wildlife Protector add 0.2 inches.
INSULATION
CHARACTERISTICS
The insulation characteristics of the
UltraSIL housed arrester family are
shown in Table 4.
TABLE 4
Housing Insulation Withstand Voltages of UltraSIL Housed VariGAP Arresters
Arrester
Mounting
Configuration
4.1" 5.0" 4.1" 5.0"
Arrester
Housing Creep Strike 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec. 1.2/50µs 1 min. 10 sec.
Code Distance (in.) Impulse Dry Wet Impulse Dry Wet Impulse Dry Wet Impulse Dry Wet Impulse Dry Wet
(Digits 6 & 7) (in.) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms) (kV crest) (kV rms) (kV rms)
04 10.1 4.2 91 56 36 105 55 39 79 52 34 99 56 39 82 51 33

05 13.0 5.2 104 64 45 117 63 52 89 55 44 109 60 52 90 62 46
06 15.9 6.3 117 78 57 126 86 59 93 61 58 119 80 59 97 72 56
07 18.8 7.3 129 87 68 137 96 71 98 62 59 122 81 63 107 81 69
08 21.7 8.4 140 96 79 148 106 83 104 65 61 126 82 67 118 89 81
09 24.6 9.4 152 105 89 159 116 94 110 68 63 130 83 72 129 98 93
10 27.5 10.5 164 114 100 171 126 105 117 72 67 136 86 78 140 106 105
11 30.4 11.5 176 123 110 183 135 116 125 77 71 142 90 83 152 114 116
12 33.3 12.6 189 131 120 195 144 127 133 82 75 149 94 89 164 122 126
13 36.2 13.6 201 139 130 207 153 137 142 88 81 158 99 96 177 130 136
14 39.1 14.7 215 148 140 220 161 147 152 94 87 167 105 102 190 138 145
15 42.0 15.8 228 155 150 233 170 157 162 101 93 177 112 109 204 146 153
16 44.9 16.8 242 183 158 246 178 167 173 109 101 187 120 117 218 154 162
17 47.8 17.8 255 171 169 259 185 176 185 117 109 199 128 125 233 161 169
5
PROTECTIVE provide excellent overvoltage protec- characteristics of the UltraSIL housed

CHARACTERISTICS tion for electrical equipment throughout VariGAP arrester family are shown in
distribution systems. The protective Tables 5, 6 and 7.
VariGAP distribution class arresters
TABLE 5
Protective Characteristics – VariGAP Normal Duty (UNG)
3 2.55 7.00 19.5 8.80 9.50 10.2 11.1 12.7 14.8
6 5.10 14.0 25.0 17.6 19.0 20.4 22.3 25.5 29.6
9 7.65 15.3 31.0 19.2 20.8 22.3 24.4 27.9 32.4
10 8.40 16.8 33.0 20.1 21.7 23.3 25.5 29.1 33.8
12 10.2 20.4 37.0 27.9 30.1 32.3 35.4 40.4 46.9
15 12.7 25.4 43.0 30.5 33.0 35.4 38.7 44.2 51.4
18 15.3 30.6 48.5 37.1 40.2 43.1 47.1 53.8 62.6
21 17.0 34.0 54.5 39.4 42.6 45.8 50.0 57.1 66.4
24 19.5 39.0 60.0 49.3 53.3 57.2 62.5 71.4 83.0
27 22.0 44.0 66.0 55.7 60.3 64.7 70.7 80.7 93.9
30 24.4 48.8 71.5 59.1 63.9 68.6 75.0 85.6 99.6
33 27.0 54.0 77.5 65.0 70.4 75.5 82.5 94.2 110
36 29.0 58.0 83.0 69.0 74.6 80.1 87.8 99.9 116
TABLE 6
Protective Characteristics – VariGAP Heavy Duty (UHG)
3 2.55 7.00 18.5 8.40 8.90 9.30 10.2 11.3 12.7
6 5.10 14.0 24.0 16.8 17.9 18.7 20.4 22.6 25.4
9 7.65 15.3 30.0 18.6 19.7 20.6 22.5 24.9 28.0
10 8.40 16.8 32.0 19.2 20.5 21.4 23.3 25.8 29.1
12 10.2 20.4 36.0 26.7 28.4 29.6 32.3 35.8 40.3
15 12.7 25.4 42.0 29.2 31.1 32.5 35.4 39.2 44.1
18 15.3 30.6 47.5 35.6 37.8 39.5 43.1 47.7 53.7
21 17.0 34.0 53.5 37.8 40.1 41.9 45.8 50.6 57.0
24 19.5 39.0 59.0 47.2 50.2 52.4 57.2 63.2 71.3
27 22.0 44.0 65.0 53.4 56.7 59.3 64.7 71.5 80.6
30 24.4 48.8 70.5 56.6 60.2 62.9 68.6 75.8 85.5
33 27.0 54.0 76.5 62.3 66.2 69.2 75.5 83.5 94.1
36 29.0 58.0 82.0 66.1 70.3 73.4 80.1 88.6 99.8
TABLE 7
Protective Characteristics – VariGAP Heavy Duty Riser Pole (URG)
3 2.55 7.00 17.5 7.60 8.10 8.40 9.20 10.2 11.5
6 5.10 14.0 23.0 15.2 16.1 16.9 18.4 20.4 22.9
9 7.65 15.3 29.0 16.8 17.9 18.7 20.4 22.6 25.4
10 8.40 16.8 31.0 17.5 18.6 19.4 21.2 23.4 26.4
12 10.2 20.4 35.0 24.3 25.8 26.9 29.4 32.5 36.6
15 12.7 25.4 41.0 26.6 28.2 29.5 32.2 35.6 40.1
18 15.3 30.6 46.5 32.4 34.4 35.9 39.2 43.3 48.8
21 17.0 34.0 52.5 34.3 36.5 38.1 41.6 46.0 51.8
24 19.5 39.0 58.0 42.9 45.6 47.7 52.0 57.5 64.8
27 22.0 44.0 64.0 48.5 51.6 53.9 58.8 65.0 73.2
30 24.4 48.8 69.5 51.5 54.7 57.2 62.4 69.0 77.7
33 27.0 54.0 75.5 56.6 60.2 62.9 68.6 75.8 85.5
36 29.0 58.0 81.0 60.1 63.9 66.7 72.8 80.5 90.7
6
235-37
TEMPORARY
2.1 OVERVOLTAGE (TOV)
CAPABILITY
2.0 2.00 2.00 2.00 The ability to withstand 60 Hz
overvoltage conditions [Temporary
1.9
Overvoltage (TOV)] is shown in
Figure 7 for all VariGAP distribution
arresters. The graph shows for a
Per Unit of MCOV
1.8 given voltage magnitude (on a Per

Unit of MCOV basis) the time an
arrester can survive a TOV condition
1.7 1.72 without going into thermal runaway.
ORDERING INFORMATION
1.6 Cooper Power Systems UltraSIL
housed distribution arresters are
supplied in a variety of customer
1.5 1.50
defined options. The catalog system
employed lets the number define the
features of the arrester. Table 8 shows
1.4 the catalog numbers for several of the
0.01 0.1 1 10 100 1000 10000 most common arrester styles. Table 9
Time Duration in seconds shows what each alpha-numeric
character in the catalog number
Figure 7. represents and lists several of the
Temporary overvoltage curve. No prior duty – 60° C ambient. available options defined by these
characters. A wide variety of options
are available, allowing users to
customize the arrester to their specific
needs. For further options contact
engineer.
TABLE 8
Catalog Numbers – VariGAP Distribution Class Surge Arresters
With Isolator, With Isolator,

Insulated Hanger Insulated Hanger
With Isolator and and NEMA and Transformer With Insulated Hanger
Arrester Insulated Hanger Cross-Arm Bracket Mounting Bracket Without Isolator
Rating (Figure 3) (Figure 4) (Figure 5) (Figure 6)
✱ Digit 2 Option: N = Normal Duty, H = Heavy Duty, R = Riser Pole.
Note: All catalog numbers listed above include a universal wildlife protector.
7
TABLE 9
UltraSIL™ Distribution Arrester UltraQUIK™ Catalog Numbering System
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
U G 1
Catalog Number Digits:
1 = “U”, UltraSIL Housed Arrester
2 = Arrester Class: N = Normal Duty H = Heavy Duty R = Riser Pole
3 = Arrester Type: G= VariGAP®
4 & 5 = Arrester Rating: 03 = 3 kV (2.55 kV) 12 = 12 kV (10.2 kV) 21 = 21 kV (17.0 kV) 30 = 30 kV (24.4 kV)
Duty Cycle (MCOV) 06 = 6 kV (5.1 kV) 15 = 15 kV (12.7 kV) 24 = 24 kV (19.5 kV) 33 = 33 kV (27.0 kV)
09 = 9 kV (7.65 kV) 18 = 18 kV (15.3 kV) 27 = 27 kV (22.0 kV) 36 = 36 kV (29.0 kV)
10 = 10 kV (8.4 kV)
6 & 7 = Housing Code: Select from Table below.

AVAILABLE HOUSINGS PER ARRESTER RATING
✽ = Standard Creepage Housing O = Optional Creepage Housings
Digits 6 & 7 04 05 06 07 08 09 10 11 12 13 14 15 16 17
Creep
Length
10.1" 13.0" 15.9" 18.8" 21.7" 24.6" 27.5" 30.4" 33.3" 36.2" 39.1" 42.0" 44.9" 47.8"
Arrester
Rating (kV rms)
3 ✱
6 ✱ O
9 ✱ O O O
10 ✱ O O O
12 ✱ O O O
15 ✱ O O O O
18 ✱ O O O O
21 ✱ O O O O
24 ✱ O O O O
27 ✱ O O O O
30 ✱ O O O O
33 ✱ O O O O
36 ✱ O O O
8 = Line Terminal Wire: 0 = No Line Terminal Wire
Stripped 1.25" both ends Stripped 1.25" both ends Stripped 1.25" both ends
1 ring terminal /1 end stripped 1.25" 1 ring terminal /1 end stripped 1.25" 1 ring terminal /1 end stripped 1.25"
2 ring terminals 2 ring terminals 2 ring terminals
9 = Line Terminal Options
A = Silicon Bronze B = Silicon Bronze C = No Hardware D = Silicon Bronze E = Silicon Bronze K = Silicon Bronze
Nut, Stainless Steel Nut & Stainless Steel Nut, Lock Washer, Nut, Lock Washer, Nut, Stainless Steel
Wire Clamp & Universal Wire Clamp Flat Washer & & Flat Washer Wire Clamp, and
Wildlife Protector Universal Wildlife (For leads with ring Flipper Fuse Kit
Protector (For leads terminals) AM21A1 (See
with ring terminals) Page 10)
8
235-37
10 = Isolator
0 = No Isolator (3/8" Stainless 2 = Red Isolator with 3/8" 4 = Blue Isolator with 3/8" 6 = Orange Isolator with 3/8"
Steel Grounding Stud only) Stainless Steel Grounding Stud Stainless Steel Grounding Stud Stainless Steel Grounding Stud
1 = Black Isolator with 3/8" 3 = Yellow Isolator with 3/8" 5 = White Isolator with 3/8"
Stainless Steel Grounding Stud Stainless Steel Grounding Stud Stainless Steel Grounding Stud
11 = Ground Terminal Options
A = Stainless Steel Wire B = No Hardware C = Copper Transformer D = Stainless Steel

Clamp with Silicon (Shown with optional Grounding Strap with Washer, Lock Washer,
Bronze Nut (Shown with Isolator and Insulated Stainless Steel Lock Silicon Bronze Nut
optional Isolator and Hanger) Washer & Silicon Bronze
Insulated Hanger) Nut (Shown with optional
Isolator and Insulated
Hanger)
12 = Base Configuration Options
0 = Insulated Base 1 = Insulated Hanger 2 = Insulated Base With Conductive

(Base Mounted Arrester) (Shown with optional Isolator) Mounting Strap (Requires "D" in Digit 11)
13 = Mounting Bracket Options
A = Without an Additional B = NEMA Cross-Arm Bracket C = Transformer Bracket D = Option C plus

Mounting Bracket (Arrester Mounting Hardware Included) (Arrester Mounting Hardware Included) Transformer Mounting Hardware
(Requires "1" or "2" in Digit 12) (Requires "1" or "2" in Digit 12) (2 each – 1/2", 13-UNC x 3/4" Bolts,
Flat Washers, and Lock Washers)
(Requires "1" or "2" in Digit 12)
14 = Nameplate Information: 1 = ANSI/IEEE Standard C62.11 Required Data

15 = Packaging: A = Individual Carton (Assembled Terminal Hardware). Each arrester is shipped in an individual high strength cardboard
carton. The top and bottom terminal hardware is assembled to the arrester. Any optional brackets or hardware are
provided unassembled.
C = Bulk Packed (Assembled Terminal Hardware). Pallet sized bulk cardboard packaging for transformer mounting bracket
options (Digits 13 = C or D only). Each arrester is shipped fully assembled including transformer mounting bracket.
Available for 3-24 kV arresters only. Full pallet quantities only: 3-10 kV = 90, 12-18 kV = 72, 21-24 kV = 40.
9
AVAILABLE ACCESSORIES Open Link Flipper Fuse Kit

FOR THE UltraSIL ARRESTER Customers who need an open-link
flipper fuse kit without an arrester,
can order this assembly separately.
VALVE The kit includes the flipper arms (for
OPENING the transformer bushing and arrester
line terminal) and an optional bushing
VALVE
OPENING insulator cap. Table 10 lists the part
0.80" numbers to order the flipper fuse kit.
To order an UltraSIL arrester with
2.22" flipper fuse assembly AM21A1, insert
a “K” in digit 9 of the catalog number.
1.03" 152°
TABLE 10
Flipper Fuse Kit Catalog Numbers
VALVE Description Catalog Number

2.50" OPENING
Flipper Fuse Kit
SIDE VIEW TOP VIEW with Bushing AM21A1
Wildlife Protector
Figure 8.
Universal wildlife protector (catalog number AV346X1C). Flipper Fuse Kit
without Bushing AM21A2
Wildlife Protector
2.38"
1"
0"
TO
1.25" 4.00"
.344"
40°
6.75"
.438"
SQUARE 4.12"
TO
5.15" 11" .56 x 2.25"
4.50" MTG. SLOTS
(2 REQ'D)
.438" SQ. 2.56"
HOLE
7"
2.5"
.500"
1.50"
1.63"
0.5"
1.5"
Figure 9. Figure 10.

NEMA cross-arm bracket (catalog number AM35A1). Optional transformer mounting bracket
(catalog number AM36A1). Can be
specified with an “S” in Digit 13. (All
10
235-37
1.25" 3.00" 1.50"

.75" .75"
2.38"
.25" 1"
50° 45°
.56"
14.50"
8.70" 2.72"
2.25" 3.38"
5.70"
2.5"
2.12"
2.25"
1.63"
2.50"
2.12"
12.80"
Figure 11.
3.38"
Standard transformer mounting bracket for
3-24 kV arrester (part number AM36A2). Can be
specified with a “C” in Digit 13. (All dimensions
in inches.) 2.72"
1.82"
2.38"
Figure 13.
1" Standard transformer mounting bracket for 27-36 kV arrester
(part number AH46A2). Can be specified with a “C” in Digit 13.
(All dimensions in inches.)
40°
12.25" .56 x 2.25"

MTG. SLOTS
(2 REQ'D)
7"
2.5"
1.63"
0.5"
1.25"
Figure 12.
Optional transformer mounting bracket
(catalog number AM36A3), Can be
specified with an “N” in Digit 13. (All
11
©2000 Cooper Industries, Inc. P.O. Box 1640
UltraSIL™ is a trademark of Cooper Industries, Inc. Waukesha, WI 53187
VariSTAR® is a registered trademark of Cooper Industries, Inc. www.cooperpower.com
MI
Printed on Recycled Paper 1/00
e-mail: sales@us.ebmpapst.com · TEL: 860-674-1515 · FAX: 860-674-8536
ebm-papst Inc., 100 Hyde Road, Farmington, CT 06034 USA
ebm-papst Inc., 2005 © ebm-papst Inc. reserves the right to change any specifications or data without notice
199
202
tL
[%]

201
202
Contactors and Contactor Assemblies
SIRIUS Contactors for Switching Motors
3RT10 contactors, 3-pole
Selection and ordering data

AC operation
3RT10 1 . -1A . . . 3RT10 1 . -2A . . . 3RT10 2 . -1A . 00 3RT10 2. -3A . 00
Horsepower ratings Auxiliary Rated control Screw connection Cage Clamp connection Weight
and utilization categories contacts supply voltage approx.
Us
AC-3 Horsepower ratings1) of AC-1 Ident. Design Order No. List Order No. List
Maximum three-phase motors Maximum no. Price $ Price $
inductive resistive
current current
Enclosed 200 230 460 575
Amp Ratings V V V V
AC3 UL HP HP HP HP Amps NO NC AC kg
For screwing and snapping onto 35 mm standard mounting rail
Size S00
Terminal designations according to EN 50 012
7 20 1.5 2 3 5 18 10 E 1 – 24 V, 50/60 Hz 3RT10 15-1AB01 55.00 3RT10 15-2AB01 60.00 0.19
120 V, 60 Hz 3RT10 15-1AK61 55.00 3RT10 15-2AK61 60.00
240 V, 60 Hz 3RT10 15-1AP61 55.00 3RT10 15-2AP61 60.00
01 – 1 24 V, 50/60 Hz 3RT10 15-1AB02 55.00 3RT10 15-2AB02 60.00 0.19
120 V, 60 Hz 3RT10 15-1AK62 55.00 3RT10 15-2AK62 60.00
240 V, 60 Hz 3RT10 15-1AP62 55.00 3RT10 15-2AP62 60.00
9 20 2 3 5 7.5 22 10 E 1 – 24 V, 50/60 Hz 3RT10 16-1AB01 72.00 3RT10 16-2AB01 77.00 0.19
120 V, 60 Hz 3RT10 16-1AK61 72.00 3RT10 16-2AK61 77.00
240 V, 60 Hz 3RT10 16-1AP61 72.00 3RT10 16-2AP61 77.00
01 – 1 24 V, 50/60 Hz 3RT10 16-1AB02 72.00 3RT10 16-2AB02 77.00 0.19
120 V, 60 Hz 3RT10 16-1AK62 72.00 3RT10 16-2AK62 77.00
240 V, 60 Hz 3RT10 16-1AP62 72.00 3RT10 16-2AP62 77.00
12 20 3 3 7.5 10 22 10 E 1 – 24 V, 50/60 Hz 3RT10 17-1AB01 89.00 3RT10 17-2AB01 94.00 0.19
120 V, 60 Hz 3RT10 17-1AK61 89.00 3RT10 17-2AK61 94.00
240 V, 60 Hz 3RT10 17-1AP61 89.00 3RT10 17-2AP61 94.00
01 – 1 24 V, 50/60 Hz 3RT10 17-1AB02 89.00 3RT10 17-2AB02 94.00 0.19
120 V, 60 Hz 3RT10 17-1AK62 89.00 3RT10 17-2AK62 94.00
240 V, 60 Hz 3RT10 17-1AP62 89.00 3RT10 17-2AP62 94.00
Size S0
9 35 2 3 5 7.5 40 – – – 24 V, 50/60 Hz 3RT10 23-1AC20 81.00 3RT10 23-3AC20 84.00 0.32
120 V, 60 Hz 3RT10 23-1AK60 81.00 3RT10 23-3AK60 84.00
240 V, 60 Hz 3RT10 23-1AP60 81.00 3RT10 23-3AP60 84.00
12 35 3 3 7.5 10 40 – – – 24 V, 50/60 Hz 3RT10 24-1AC20 105.00 3RT10 24-3AC20 108.00 0.32
120 V, 60 Hz 3RT10 24-1AK60 105.00 3RT10 24-3AK60 108.00
240 V, 60 Hz 3RT10 24-1AP60 105.00 3RT10 24-3AP60 108.00
17 35 5 5 10 15 40 – – – 24 V, 50/60 Hz 3RT10 25-1AC20 121.00 3RT10 25-3AC20 124.00 0.32
120 V, 60 Hz 3RT10 25-1AK60 121.00 3RT10 25-3AK60 124.00
240 V, 60 Hz 3RT10 25-1AP60 121.00 3RT10 25-3AP60 124.00
25 35 7.5 7.5 15 20 40 – – – 24 V, 50/60 Hz 3RT10 26-1AC20 136.00 3RT10 26-3AC20 139.00 0.32
120 V, 60 Hz 3RT10 26-1AK60 136.00 3RT10 26-3AK60 139.00
240 V, 60 Hz 3RT10 26-1AP60 136.00 3RT10 26-3AP60 139.00
AC Coil Selection for 3RT101

For further coil voltages, see page 2/35.
Coil Code B0 H0 F0 K6 P0 P6 U6 V6 T6 For auxiliaries and accessories,
50 Hz 24 V AC 48 V AC 110 V AC 110 V AC 230 V AC 220 V AC see page 2/41-52.
60 Hz 24 V AC 48 V AC 110 V AC 120 V AC 230 V AC 240 V AC 277 V AC 480 V AC 600 V AC For spare parts, see page 2/59.
For technical data, see page 2/94, 2/97-104
For description, see page 2/13.
For int. circuit diagrams, see page 2/149.
AC Coil Selection for 3RT102 through 3RT104
For dimension drawings, see page
Coil Code C2 H2 G2 K6 L2 P6 U6 V6 T6 2/177-178.
50 Hz 24 V AC 48 V AC 110 V AC 110 V AC 230 V AC 220 V AC
60 Hz 24 V AC 48 V AC 110 V AC 120 V AC 230 V AC 240 V AC 277 V AC 480 V AC 600 V AC 1) Complete HP ratings on page 2/94.
Siemens Energy & Automation, Inc. Discount Code: SIRIUS Contactors, OL’s, MSP’s 2/17
Contactors for Switching Motors SIRIUS
3RT10 contactors, 3-pole

AC operation
3RT10 3 . -1A . 00 3RT10 3 . -3A . 00 3RT10 4 . -1A . 00 3RT10 4 . -3A . 00
Horsepower ratings Auxiliary Rated control sup- Screw connection Cage Clamp connection Weight
and utilization categories contacts ply voltage Us for coil terminals approx.
AC-3 Horsepower ratings1) of AC-1 Ident. Design Order No. List Order No. List
Maximum three-phase motors Maximum no. Price $ Price $
inductive resistive
current
Enclosed 200 230 460 575
Amp Ratings V V V V
AC3 UL HP HP HP HP Amps NO NC AC kg
For screwing and snapping onto 35 mm standard mounting rail
Size S2
28 35 7.5 10 20 25 35 – – – 24 V, 50/60 Hz 3RT10 33-1A C20 156.00 3RT10 33-3AC2 0 159.00 0.78
120 V, 60 Hz 3RT10 33-1A K60 156.00 3RT10 33-3AK6 0 159.00
240 V, 60 Hz 3RT10 33-1A P6 0 156.00 3RT10 33-3AP6 0 159.00
32 45 10 10 25 30 50 – – – 24 V, 50/60 Hz 3RT10 34-1A C20 172.00 3RT10 34-3AC2 0 175.00 0.78
120 V, 60 Hz 3RT10 34-1A K60 172.00 3RT10 34-3AK6 0 175.00
240 V, 60 Hz 3RT10 34-1A P6 0 172.00 3RT10 34-3AP6 0 175.00
40 50 10 15 30 40 50 – – – 24 V, 50/60 Hz 3RT10 35-1A C20 191.00 3RT10 35-3AC2 0 194.00 0.78
120 V, 60 Hz 3RT10 35-1A K60 191.00 3RT10 35-3AK6 0 194.00
240 V, 60 Hz 3RT10 35-1A P6 0 191.00 3RT10 35-3AP6 0 194.00
50 50 15 15 40 50 60 – – – 24 V, 50/60 Hz 3RT10 36-1A C20 206.00 3RT10 36-3AC2 0 209.00 0.78
120 V, 60 Hz 3RT10 36-1A K60 206.00 3RT10 36-3AK6 0 209.00
240 V, 60 Hz 3RT10 36-1A P6 0 206.00 3RT10 36-3AP6 0 209.00
Size S3
65 90 20 25 50 60 100 – – – 24 V, 50/60 Hz 3RT10 44-1A C20 291.00 3RT10 44-3AC2 0 294.00 1.78
120 V, 60 Hz 3RT10 44-1A K60 291.00 3RT10 44-3AK6 0 294.00
240 V, 60 Hz 3RT10 44-1A P6 0 291.00 3RT10 44-3AP6 0 294.00
80 105 25 30 60 75 120 – – – 24 V, 50/60 Hz 3RT10 45-1A C20 331.00 3RT10 45-3AC2 0 334.00 1.78
120 V, 60 Hz 3RT10 45-1A K60 331.00 3RT10 45-3AK6 0 334.00
240 V, 60 Hz 3RT10 45-1A P6 0 331.00 3RT10 45-3AP6 0 334.00
95 105 30 30 75 100 120 – – – 24 V, 50/60 Hz 3RT10 46-1A C20 453.00 3RT10 46-3AC2 0 456.00 1.78
120 V, 60 Hz 3RT10 46-1A K60 453.00 3RT10 46-3AK6 0 456.00
240 V, 60 Hz 3RT10 46-1A P6 0 453.00 3RT10 46-3AP6 0 456.00
AC Coil Selection for 3RT102 through 3RT104

Coil Code C2 H2 G2 K6 L2 P6 U6 V6 T6
50 Hz 24 V AC 48 V AC 110 V AC 110 V AC 230 V AC 220 V AC
60 Hz 24 V AC 48 V AC 110 V AC 120 V AC 230 V AC 240 V AC 277 V AC 480 V AC 600 V AC
For further coil voltages, see page 2/35. 1) Complete horsepower ratings on
For auxiliaries and accessories, see page 2/41-52. page 2/94.
For spare parts, see page 2/59-63.
For technical data, see page 2/94, 2/105-112.
For description, see page 2/12-13.
For int. circuit diagrams, see page 2/149.
For dimension drawings, see page 2/178-182.
2/18 Discount Code: SIRIUS Contactors, OL’s, MSP’s Siemens Energy & Automation, Inc.
SIRIUS 3RT Contactors / 3RH Control Relays
Accessories for contactors and control relays
For Design Rated control supply Surge suppressor Weight

contactors voltage Us 1) approx.
Order No. List
Price $
Type kg
Surge suppressors without LED (also for Cage Clamp connection)

Size S00
For plugging onto the front of contactors
with or without an auxiliary switch block
3RT19 16-1DG00 3RT1 ., Varistor AC 24 V ... 48 V 3RT19 16-1BB00 10.00 0.01
3RH1 . DC 24 V ... 70 V
AC 48 V ... 127 V 3RT19 16-1BC00 10.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 16-1BD00 10.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 16-1BE00 10.00
AC 400 V ... 600 V 3RT19 16-1BF00 10.00
3RT1 ., RC element AC 24 V ... 48 V 3RT19 16-1CB00 10.00 0.01
3RH1 . DC 24 V ... 70 V
AC 48 V ... 127 V 3RT19 16-1CC00 10.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 16-1CD00 10.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 16-1CE00 10.00
AC 400 V ... 600 V 3RT19 16-1CF00 10.00
3RT1 ., Suppression diode DC 12 V ... 250 V 3RT19 16-1DG00 10.00 0.01
3RH1 .
3RT1 ., Diode assembly DC 12 V ... 250 V 3RT19 16-1EH00 12.00 0.01
3RH1 . (diode and Zener diode)
for DC operation
Size S0
For plugging onto coil terminals
on the top or bottom
3RT19 26-1B . 00 3RT1 . 2 Varistor AC 24 V ... 48 V 3RT19 26-1BB00 20.00 0.01
DC 24 V ... 70 V
AC 48 V ... 127 V 3RT19 26-1BC00 20.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 26-1BD00 20.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 26-1BE00 20.00
AC 400 V ... 600 V 3RT19 26-1BF00 20.00
3RT1 . 2 RC element AC 24 V ... 48 V 3RT19 26-1CB00 20.00 0.01
DC 24 V ... 70 V
AC 48 V ... 127 V 3RT19 26-1CC00 20.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 26-1CD00 20.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 26-1CE00 20.00
AC 400 V ... 600 V 3RT19 26-1CF00 20.00
3RT1 . 2 Diode assembly
for DC operation
for plugging onto top DC 24 V 3RT19 26-1ER00 20.00 0.01
(e. g. for contactors
with overload relay) DC 30 V ... 250 V 3RT19 26-1ES00 20.00
for plugging onto bottom DC 24 V 3RT19 26-1TR00 20.00
(e. g. for combination starters)
DC 30 V ... 250 V 3RT19 26-1TS00 20.00
1) Can be used for AC operation at 50/60 Hz.
3RT1 Contactors and 3RH1 Control Relays SIRIUS
For Design Rated control supply Surge suppressor Weight

contactors voltage Us 1) approx.
Order No. List
Price $
Type kg
Surge suppressors without LED (also for Cage Clamp connection)

Sizes S2 and S3
For plugging onto coil terminals on the top or bottom
3RT19 26-1B . 00 3RT1 . 3, Varistor AC 24 V ... 48 V 3RT19 26-1BB00 20.00 0.01
3RT1 . 4 DC 24 V ... 70 V
AC 48 V ... 127 V 3RT19 26-1BC00 20.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 26-1BD00 20.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 26-1BE00 20.00
AC 400 V ... 600 V 3RT19 26-1BF00 20.00
3RT19 36-1C . 00 3RT1 . 3, RC element AC 24 V ... 48 V 3RT19 36-1CB00 25.00 0.01

3RT1 . 4 DC 24 V ... 70 V
AC 48 V ... 127 V 3RT19 36-1CC00 25.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 36-1CD00 25.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 36-1CE00 25.00
AC 400 V ... 600 V 3RT19 36-1CF00 25.00
3RT1 . 3, Diode assembly

3RT1 . 4 for DC operation
for plugging onto top DC 24 V 3RT19 36-1ER00 25.00 0.01
(e. g. for contactors
with overload relay) DC 30 V ... 250 V 3RT19 36-1ES00 25.00
for plugging onto bottom DC 24 V 3RT19 36-1TR00 25.00

(e. g. for fuseless load
feeders) DC 30 V ... 250 V 3RT19 36-1TS00 25.00
Sizes S6 and S12
3RT19 56-1C . 00 For plugging into the withdrawable coil
for contactors with conventional operat. mechanism 3RT1...-.A...
solid-state operat. mechanism 3RT1...-.N...
3RT1 . 5, RC element AC 24 V ... 48 V 3RT19 56-1CB00 50.00 0.03
3RT1 . 6, DC 24 V ... 70 V
3RT1 . 7 AC 48 V ... 127 V 3RT19 56-1CC00 50.00
DC 70 V ... 150 V
AC 127 V ... 240 V 3RT19 56-1CD00 50.00
DC 150 V ... 250 V
AC 240 V ... 400 V 3RT19 56-1CE00 50.00
AC 400 V ... 600 V 3RT19 56-1CF00 50.00
For Design Rated control supply Power consump- Surge suppressor Weight
contactors voltage Us 1) tion of LED at Us approx.
Order No. 2) List
Price $
Type mW PG 101 1 unit kg
Surge suppressors with LED (also for Cage Clamp connection)
Size S00
For plugging onto the front of contactors with or without an auxiliary switch block
3RT19 16-1L . 00 3RT1, Varistor AC 24 V ... 48 V 10 ... 120 } 3RT19 16-1JJ00 12.00 0.01
3RH1 . DC 12 V ... 24 V
AC 48 V ... 127 V 20 ... 470 } 3RT19 16-1JK00 12.00
DC 24 V ... 70 V
AC 127 V ... 240 V 50 ... 700 } 3RT19 16-1JL00 12.00
DC 70 V ... 150 V
DC 150 V ... 250 V 160 ... 950 } 3RT19 16-1JP00 12.00
3RT1, Suppression DC 24 V ... 70 V 20 ... 470 } 3RT19 16-1LM00 12.00 0.01

3RH1 . diode
DC 50 V ... 150 V 50 ... 700 } 3RT19 16-1LN00 12.00
DC 150 V ... 250 V 160 ... 950 } 3RT19 16-1LP00 12.00
1) Can be used for AC operation at 50/60 Hz.
Accessories for contactors and
control relays with screw connections
For Design Order No. List Weight

contactors Price $ approx.
Type kg
EMC interference suppression module, 3-phase; ≤ 7.5 HP
Size S00 (for contactors with AC or DC operation)
3RT19 16-1PA . See also description on page 2/39
1 unit
3RT10 1 RC element up to 400 V 3RT19 16-1PA1 130.00
(3 x 220 Ω/0.22 µF) 575 V 3RT19 16-1PA2 130.00
690 V 3RT19 16-1PA3 130.00
3RT10 1 Varistor up to 400 V 3RT19 16-1PB1 130.00

575 V 3RT19 16-1PB2 130.00
690 V 3RT19 16-1PB3 130.00
Main conducting path surge suppression module for 3RT12 vacuum contactors
Sizes S10 and S12 1 unit
3RT12 Rated operational voltage Ue ≥ AC 500 V ... ≤ AC 690 V 3RT19 66-1PV3 125.00 0.18
Rated operational voltage Ue ≤ AC 1 000 V 3RT19 66-1PV4 180.00 0.36
For damping overvoltages and protecting the motor windings
against multiple reignition when switching off three-phase
motors.
For connection on the contactor feeder side (2-T1/4-T2/6-T3).
For separate installation.
Additional load module
Size S00 (also for Cage Clamp connection)
For plugging onto the front of contactors
3RT19 16-1GA00 with or without an auxiliary switch block
1 unit
3RT1 . 1, For increasing the permissible residual current and for limiting 3RT19 16-1GA00 10.00
3RH1 . the residual voltage. Ensures safe opening of contactors with
direct control via AC 230 V semiconductor outputs of SIMATIC
controls. Also performs the function of a surge damping circuit.
Rated voltage: AC 50/60 Hz, 180 V ... 255 V.
Coil voltage tolerance: 0.8 ... 1.1 x Us
Size S6
For contactors with
conventional operat. mechanism 3RT1.5.-.A...
solid-state operat. mechanism 3RT1.5.-.N...
For separate installation.
1 unit
3RT1 . 5 For control voltage Us (40 Hz ... 60 Hz) ≤ AC 277 V 3RT19 56-1GD00 56.00 0.03
> AC 277 V 3RT19 56-1GE00 56.00
Power consumption approx. 4.3 VA.
For reducing the interfering influence of the line capacitances of
long control leads (contactor does not switch off after OFF com-
mand) and extending the critical line length in AC lead lengths
to approx. 1000 m.
(Not necessary for contactors with solid-state operating
mechanism and operation via PLC/AS-Interface)
Accessories for contactors,
control relays and auxiliary contactors
3RH19 11-1HA . . 3RH19 11-2HA . . 3RH19 21-1HA . . 3RH19 21-2HA . . 3RH19 11-1AA . . 3RH19 11-1LA . .
-1FA . . -2FA . .
For Rated operational Auxiliary contacts Screw connection Cage Clamp connection Weight
contactors current 2) approx.
NEMA A600 / Q600 Ident. Design Order No. List Order No. List
no. Price $ Price $
Type NO NC NO NC kg
Auxiliary switch blocks for snapping onto the front
acc. to EN 50 012 1)
Size S00
For making contactors with 2, 4 or 5 auxiliary contacts
3RT10 1 . -1 . . . 1, 11 E – 1 – – 3RH19 11-1HA01 10.00 3RH19 11-2HA01 11.00 0.045
3RT10 1 . -2 . . . 1 22 E 1 2 – – 3RH19 11-1HA12 21.00 3RH19 11-2HA12 24.00
Ident. no. 10E 23 E 1 3 – – 3RH19 11-1HA13 28.00 3RH19 11-2HA13 32.00
32 E 2 2 – – 3RH19 11-1HA22 28.00 3RH19 11-2HA22 32.00
Sizes S0 to S12 1)
4-pole
3RT10 2, 31 3 1 – – 3RH19 21-1HA31 40.00 3RH19 21-2HA31 44.00 0.065
3RT1 . 3 to 22 2 2 – – 3RH19 21-1HA22 40.00 3RH19 21-2HA22 44.00
3RT1 . 7, 13 1 3 – – 3RH19 21-1HA13 40.00 3RH19 21-2HA13 44.00
3RT11
with location digits 22 2 2 – – 3RH19 21-1XA22-0MA0 44.00 3RH19 21-2XA22-0MA0 48.00
5, 6, 7, 8
acc. to EN 50 005 1)
Size S00
2 or 4-pole auxiliary switch blocks for making contactors with 3 or 5 auxiliary contacts
3RT1 . 1, 20 2 – – – 3RH19 11-1FA20 14.00 3RH19 11-2FA20 16.00 0.045
3RH11, 11 1 1 – – 3RH19 11-1FA11 14.00 3RH19 11-2FA11 16.00
3RH14 02 – 2 – – 3RH19 11-1FA02 14.00 3RH19 11-2FA02 16.00
11 U – – 1 1 3RH19 11-1FB11 14.00 3RH19 11-2FB11 30.00
40 4 – – – 3RH19 11-1FA40 28.00 3RH19 11-2FA40 32.00 0.045
31 3 1 – – 3RH19 11-1FA31 28.00 3RH19 11-2FA31 32.00
22 2 2 – – 3RH19 11-1FA22 28.00 3RH19 11-2FA22 32.00
22 U – – 2 2 3RH19 11-1FC22 42.00 3RH19 11-2FC22 46.00
11, 11 U 1 1 1 1 3RH19 11-1FB22 42.00 –
Single or 2-pole auxiliary switch blocks, cable entry from one side
Cable entry from above
– 1 – – – 3RH19 11-1AA10 10.00 – 0.015
– – 1 – – 3RH19 11-1AA01 10.00 –
– 1 1 – – 3RH19 11-1LA11 14.00 – 0.045
– 2 – – – 3RH19 11-1LA20 14.00 –
Cable entry from below
– 1 – – – 3RH19 11-1BA10 10.00 – 0.015
– – 1 – – 3RH19 11-1BA01 10.00 –
– 1 1 – – 3RH19 11-1MA11 14.00 – 0.045
– 2 – – – 3RH19 11-1MA20 14.00 –
EN50005 and EN50012 designate the markings 1) Exception: 3RT16 .

of the auxiliary terminal numbers. 2) UL ratings on page 19/18 in section 19.
For position of the terminals see pages 2/154-156.
For int. circuit diagrams see pages 2/150-151
3RT1 Contactors SIRIUS
Accessories for contactors
3RH19 21-1F . . . 3RH19 21-2F . . . 3RH19 21-1C . . . 3RH19 21-2C . . . 3RH19 21-1LA . . 3RH19 21-1MA..
For Rated operational Auxiliary contacts Screw connection Cage Clamp connection Weight Pack.
contactors current 2) approx.
NEMA A600 / Q600 Ident. Design Order No. List Order No. List
no. Price $ Price $
Type NO NC NO NC kg
acc. to EN 50 005
Sizes S0 to S12 1)
4-pole auxiliary switch blocks
3RT10 2, 40 4 – – – 3RH19 21-1FA40 40.00 3RH19 21-2FA40 44.00 0.065 1 unit
3RT1. 3 to 31 3 1 – – 3RH19 21-1FA31 40.00 3RH19 21-2FA31 44.00
3RT1. 7, 22 2 2 – – 3RH19 21-1FA22 40.00 3RH19 21-2FA22 44.00
3RT11 04 – 4 – – 3RH19 21-1FA04 40.00 3RH19 21-2FA04 44.00
22 U – – 2 2 3RH19 21-1FC22 54.00 3RH19 21-2FC22 58.00
Single-pole auxiliary switch blocks acc. to EN 50 005 and EN 50 012
3RT1. 2 to – 1 – – – 3RH19 21-1CA10 10.00 3RH19 21-2CA10 11.00 0.015 1 unit
3RT1. 7, – – 1 – – 3RH19 21-1CA01 10.00 3RH19 21-2CA01 11.00
3RT11 – – – 1 – 3RH19 21-1CD10 20.00 –
– – – – 1 3RH19 21-1CD01 20.00 –
2-pole auxiliary switch blocks with cable entry from one side
Cable entry from above
3RT10 2, – 1 1 – – 3RH19 21-1LA11 20.00 – 0.065 1 unit
3RT1. 3 to – 2 – – – 3RH19 21-1LA20 20.00 –
3RT1. 7, – – 2 – – 3RH19 21-1LA02 20.00 –
3RT11
Cable entry from below
– 1 1 – – 3RH19 21-1MA11 20.00 – 0.065 1 unit
– 2 – – – 3RH19 21-1MA20 20.00 –
– – 2 – – 3RH19 21-1MA02 20.00 –
EN50005 and EN50012 designate the markings 1) Exception: 3RT16 .

of the auxiliary terminal numbers. 2) UL ratings on page 19/18 in section 19.
For int. circuit diagrams see pages 2/149-151.
SIRIUS 3RT1 Contactors
Accessories for contactors
3RH19 21-1DA11 3RH19 21-2DA11 3RH19 21-1EA . . 3RH19 21-2EA . .

-1JA11 -2JA11 -1KA . . -2KA . .
For Rated operational current Auxiliary contacts Screw connection Cage Clamp connection Weight
contactors NEMA A300 / Q300 1) approx.
Design Order No. List Order No. List
Price $ Price $
Type NO NC kg
Laterally mountable auxiliary switch blocks acc. to EN 50 012
Sizes S0 to S12
First laterally mountable auxiliary switch block (right or left), 2-pole
3RT1 . 2 1 1 3RH19 21-1DA11 20.00 3RH19 21-2DA11 22.00 0.038
to
3RT1 . 7
Sizes S3 to S12
Second laterally mountable auxiliary switch block (right or left), 2-pole
3RT1 . 4 1 1 3RH19 21-1JA11 20.00 3RH19 21-2JA11 22.00 0.038
to
3RT1 . 7
Laterally mountable auxiliary switch blocks acc. to EN 50 005
Sizes S0 to S12
3RT1 . 2 2 – 3RH19 21-1EA20 20.00 3RH19 21-2EA20 22.00 0.038
to 1 1 3RH19 21-1EA11 20.00 –
3RT1 . 7 – 2 3RH19 21-1EA02 20.00 3RH19 21-2EA02 22.00
Sizes S3 to S12
3RT1 . 4 2 – 3RH19 21-1KA20 20.00 3RH19 21-2KA20 22.00 0.038
to 1 1 3RH19 21-1KA11 20.00 –
3RT1 . 7 – 2 3RH19 21-1KA02 20.00 3RH19 21-2KA02 22.00
EN50005 and EN50012 designate the markings 1) UL ratings on page 19/18 in section 19.
of the auxiliary terminal numbers.
3RT1 Contactors and 3RH1 Control Relays SIRIUS
3RH19 11-1NF . . 3RH19 11-2NF . . 3RH19 21-1FE22 3RH19 21-2FE22 3RH19 21-2DE11
-2JE11
For Design Contacts Screw connection Cage Clamp connection Weight
contactors / approx.
control relays
Design Order No. List Order No. List
Price $ Price $
Type NO N O NC NC kg
Solid-state compatible auxiliary switch blocks,
for snapping onto the front, acc. to EN 50 005
Size S00
3RT1 . 1, For use in dusty atmosphere and elec- 1 – – 1 3RH19 11-1NF11 63.00 3RH19 11-2NF11 65.00 0.045
3RH11, tronic circuits with rated operational 2 – – – 3RH19 11-1NF20 63.00 3RH19 11-2NF20 65.00
3RH14 currents from 1 mA to 300 mA – – – 2 3RH19 11-1NF02 63.00 3RH19 11-2NF02 65.00
at 3 V to 60 V.
Hard gold-plated contacts.No posi-
tively driven operation
Sizes S0 to S12
3RT1 . 2 1 NO + 1 NC solid-state compatible 1 1 1 1 3RH19 21-1FE22 79.00 3RH19 21-2FE22 79.00 0.065
to auxiliary switches:
3RT1 . 7 For use in dusty atmosphere and elec-
tronic circuits with rated operational
currents 1 mA to 300 mA at 3 V to 60 V.
Hard gold-plated contacts.
1 NO + 1 NC standard auxiliary
switches:
For technical data, see page 2/91.
Solid-state compatible auxiliary switch blocks,
laterally mountable, acc. to EN 50 012
Sizes S0 to S12
3RT1 . 2 1 NO + 1 NC solid-state compatible 1 – – 1 – 3RH19 21-2DE11 58.00 0.038
currents from 1 mA to 300 mA
at 3 V to 60 V.
Sizes S3 to S12
3RT1 . 4 1 NO + 1 NC solid-state compatible 1 – – 1 – 3RH19 21-2JE11 75.00 0.038
currents from 1 mA to 300 mA
at 3 V to 60 V.
EN50005 and EN50012 designate the markings of the auxiliary terminal numbers.

PROTECTION
Features/Benefits
UL witnessed tests
shutdowns
Indicator
➤ Transformers
500VDC, 100kA I.R. No. 248.8
➤ IEC 269-2-1
AJT (70-600) EI:
➤ UL Component
Recognized
➤ DC Tested to UL
Standard 198L
A2

1
1-1/4
1-1/2
AJT1
AJT1-1/4
AJT1-1/2
4-1/2
5
5-6/10
AJT4-1/2
AJT5
AJT5-6/10
25
30
35
AJT25
AJT30
AJT35
125
150
175
AJT125
AJT150
AJT175
Fuse
Ampere
Catalog Number
600V OR LESS
A
2-1/4 AJT2-1/4 8 AJT8 60 AJT60 300 AJT300 61-100 61036J 61038J
2-1/2 AJT2-1/2 9 AJT9 70 AJT70 350 AJT350 101-200 62001J 62003J
2-8/10 AJT2-8/10 10 AJT10 80 AJT80 400 AJT400 201-400 64031J 64033J
3 AJT3 12 AJT12 90 AJT90 450 AJT450 401-600 6631J 6633J
3-2/10 AJT3-2/10 15 AJT15 100 AJT100 500 AJT500
4 AJT4 20 AJT20
1-60A
70-600A
Dimensions
1-30 2-1/4 57 13/16 21 - - - - - - - - - - - -
31-60 2-3/8 60 1-1/16 27 - - - - - - - - - - - -
61-100 4-5/8 117 1-1/16 27 1/8 3.2 3/4 19 1 25 3-5/8 92 3/8 10 9/32 7
101-200 5-3/4 146 1-5/8 41 3/16 4.8 1-1/8 29 1-3/8 35 4-3/8 111 3/8 10 9/32 7
201-400 7-1/8 181 2-1/8 54 1/4 6.3 1-5/8 41 1-7/8 48 5-1/4 133 17/32 14 13/32 10
401-600 8 203 2-1/2 64 3/8 9.5 2 51 2-1/8 54 6 152 11/16 18 17/32 13

2.80
AJT(70-100)-EI
(71.0)
3.22
AJT(110-200)-EI
(81.8)
3.24
AJT(225-400)-EI
(82.2)
3.61
AJT(450-600)-EI
(91.8)
A3

AJT1 to 600
Current in Amperes
Time in Seconds


A4
Rail Mounted Terminal Blocks

1020000000
WDU 2.5
Representative Ph
Technical Information
Clamping Type Screw Clamp
Series W Series
Rail Type TS 35
Function Feed Through
Configuration Single Level
Wire Size #22...12 AWG
Current 25 A
Voltage 600 V
Color/Material Beige Wemid
Special Requirements Accepts WQV & ZQV jumpers
Technical Data
UL CSA VDE
Rated Voltage 600 V 600 V 800 V
Rated Current 25 A 20 A 24 A
Wire Size #22...12 AWG #26...12 AWG 2.5 mm²
Additional Data
Width/Length/Height mm (in.) 5/60/47 (.2"/2.36"/1.85")
Insulation Stripping Length mm (in.) 10 (.39")
Torque Nm (lb. in) 0.8 (7.1)
Clamping Screw M 2.5
Flammability Class UL 94 (V0)
Suggested Accessories
DIN-rail
End plate/partition (WAP/WTW)
Ferrules
Markers (SchT)
Marking pens
Marking system (WS/ZS)
Marking tags (DEK)
Mounting brackets
Test plugs/socket
Tools
WQB jumpers
WQV jumpers
ZQV jumpers
Product Liability The above information describes our products. It does not constitute guaranteed properties and is not intended to
the suitability of a product for a particular application. Regrettably, omissions and exceptions cannot be completely ruled out. Tech
data are always specified by their average values. Exact data and the tolerances which apply to our processes can be requested fro
Weidmüller - North America

United States 001 (800) 849-9343
Canada 001 (800) 268-4080
or
Weidmüller - Germany
Telephone operator 0049 (-5252) 960-0
Pushbutton Units and Indicator Lights
30 mm Heavy Duty, Watertight/Oiltight, Class 52
Pushbutton complete units
Version Color of Contact Flush cap Extended cap List Mushroom List Pack
actuator blocks order no. order no. Price head order no. Price
$ $ Unit
Pushbutton unit with black 1 NO 52PA8A1K 52PA8B1K 32.40 52PB9 1K 55.40 1
assembled contact blocks red 1 NO 52PA8A2K 52PA8B2K 32.40 52PB9 2K 55.40
green 1 NO 52PA8A3K 52PA8B3K 32.40 52PB9 3K 55.40
yellow 1 NO 52PA8A4K 52PA8B4K 32.40 52PB9 4K 55.40
Pushbutton with flush cap
blue 1 NO 52PA8A5K 52PA8B5K 32.40 52PB9 5K 55.40
gray 1 NO 52PA8A6K 52PA8B6K 32.40 52PB9 6K 55.40
orange 1 NO 52PA8A8K 52PA8B8K 32.40 52PB9 8K 55.40
black 1 NC 52PA8A1J 52PA8B1J 32.40 52PB9 1J 55.40 1

red 1 NC 52PA8A2J 52PA8B2J 32.40 52PB9 2J 55.40
green 1 NC 52PA8A3J 52PA8B3J 32.40 52PB9 3J 55.40
yellow 1 NC 52PA8A4J 52PA8B4J 32.40 52PB9 4J 55.40
blue 1 NC 52PA8A5J 52PA8B5J 32.40 52PB9 5J 55.40

Pushbutton with extended cap gray 1 NC 52PA8A6J 52PA8B6J 32.40 52PB9 6J 55.40
orange 1 NC 52PA8A8J 52PA8B8J 32.40 52PB9 8J 55.40
black 1 NO + 1 NC 52PA8A1A 52PA8B1A 44.00 52PB9 1A 67.00 1

red 1 NO + 1 NC 52PA8A2A 52PA8B2A 44.00 52PB9 2A 67.00
green 1 NO + 1 NC 52PA8A3A 52PA8B3A 44.00 52PB9 3A 67.00
yellow 1 NO + 1 NC 52PA8A4A 52PA8B4A 44.00 52PB9 4A 67.00
blue 1 NO + 1 NC 52PA8A5A 52PA8B5A 44.00 52PB9 5A 67.00

gray 1 NO + 1 NC 52PA8A6A 52PA8B6A 44.00 52PB9 6A 67.00
orange 1 NO + 1 NC 52PA8A8A 52PA8B8A 44.00 52PB9 8A 67.00
black 2 NO 52PA8A1F 52PA8B1F 44.00 52PB9 1F 67.00 1

red 2 NO 52PA8A2F 52PA8B2F 44.00 52PB9 2F 67.00
green 2 NO 52PA8A3F 52PA8B3F 44.00 52PB9 3F 67.00
yellow 2 NO 52PA8A4F 52PA8B4F 44.00 52PB9 4F 67.00
Pushbutton with 1 5/8" mushroom head
blue 2 NO 52PA8A5F 52PA8B5F 44.00 52PB9 5F 67.00
gray 2 NO 52PA8A6F 52PA8B6F 44.00 52PB9 6F 67.00
orange 2 NO 52PA8A8F 52PA8B8F 44.00 52PB9 8F 67.00
black 2 NC 52PA8A1G 52PA8B1G 44.00 52PB9 1G 67.00 1

red 2 NC 52PA8A2G 52PA8B2G 44.00 52PB9 2G 67.00
green 2 NC 52PA8A3G 52PA8B3G 44.00 52PB9 3G 67.00
yellow 2 NC 52PA8A4G 52PA8B4G 44.00 52PB9 4G 67.00
blue 2 NC 52PA8A5G 52PA8B5G 44.00 52PB9 5G 67.00

gray 2 NC 52PA8A6G 52PA8B6G 44.00 52PB9 6G 67.00
orange 2 NC 52PA8A8G 52PA8B8G 44.00 52PB9 8G 67.00
black 2 NO + 2 NC 52PA8A1B 52PA8B1B 67.20 52PB9 1B 90.20 1

red 2 NO + 2 NC 52PA8A2B 52PA8B2B 67.20 52PB9 2B 90.20
green 2 NO + 2 NC 52PA8A3B 52PA8B3B 67.20 52PB9 3B 90.20
yellow 2 NO + 2 NC 52PA8A4B 52PA8B4B 67.20 52PB9 4B 90.20
blue 2 NO + 2 NC 52PA8A5B 52PA8B5B 67.20 52PB9 5B 90.20

gray 2 NO + 2 NC 52PA8A6B 52PA8B6B 67.20 52PB9 6B 90.20
orange 2 NO + 2 NC 52PA8A8B 52PA8B8B 67.20 52PB9 8B 90.20
Order no. change
Small operating head - 1 5/8" (41.3 mm) D
E
Large operating head - 2.5" (63.5 mm)
Push pull operators

Version Color of actuator Contact Order no. List Order no. List Pack
blocks Price Price
$ $ Unit
2 Position Push Pull Maintained,
Non Illuminated
2 position push-pull
Metal Mushroom Head, red 1 NC + 1 NO 52PA2A2A 92.20 1
1 5/8" (41.3 mm) green 1 NC + 1 NO 52PA2A3A 92.20
chrome 1 NC + 1 NO 52PA2ACA 92.20
52PA2A2A Small Plastic Mushroom Head, black 1 NC + 1 NO 52PA2W1A 82.20

1 5/8" (41.3 mm) red 1 NC + 1 NO 52PA2W2A 82.20
green 1 NC + 1 NO 52PA2W3A 82.20
Large Plastic Mushroom Head, black 1 NC + 1 NO 52PA2V1A 99.90

52PA2ACA 2 1/4" (57.2 mm) red 1 NC + 1 NO 52PA2V2A 99.90
green 1 NC + 1 NO 52PA2V3A 99.90
3 Position Push Pull Momentary,

Non-Illuminated (Spring return to
52PA2V2A center-pull to start, push to stop)1)
Metal Mushroom Head, red 1 NC + 1 NO 52PA3A2U 90.20 1
1 5/8" (41.3 mm) green 1 NC + 1 NO 52PA3A3U 90.20
chrome 1 NC + 1 NO 52PA3ACU 90.20
52PA2W2A Small Plastic Mushroom Head, black 1 NC + 1 NO 52PA3W1U 90.20

1 5/8" (41.3 mm) red 1 NC + 1 NO 52PA3W2U 90.20
green 1 NC + 1 NO 52PA3W3U 90.20
Large Plastic Mushroom Head, black 1 NC + 1 NO 52PA3V1U 99.90

52PA3W2U 2 1/4" (57.2 mm) red 1 NC + 1 NO 52PA3V2U 99.90
green 1 NC + 1 NO 52PA3V3U 90.90
Operators Operators
2 position push pull with fully 2 Position Push Pull Maintained, with incan- with LED
Illuminated descent lamp lamp
illuminated mushroom head
24V Full Voltage less operating head 1 NC + 1 NO 52PA2DNA 112.10 *****2) ––––– 1
chrome red 1 NC + 1 NO 52PA2D2A 129.00 52PE2D2A 142.00
chrome green 1 NC + 1 NO 52PA2D3A 129.00 52PE2D3A 142.00
chrome amber 1 NC + 1 NO 52PA2D9A 129.00 52PE2D9A 142.00
full red 1 NC + 1 NO 52PA2DRA 129.00 52PE2DRA 142.00

52PA2D2A full green 1 NC + 1 NO 52PA2DSA 129.00 52PE2DSA 142.00
full amber 1 NC + 1 NO 52PA2DTA 129.00 52PE2DTA 142.00
120V transformer with 6V 755 type less operating head 1 NC + 1 NO 52PA2GNA 112.10 *****2) ––––– 1
lamp chrome red 1 NC + 1 NO 52PA2G2A 129.00 52PE2G2A 129.00
chrome green 1 NC + 1 NO 52PA2G3A 129.00 52PE2G3A 142.00
52PA2DRA chrome amber 1 NC + 1 NO 52PA2G9A 129.00 52PE2G9A 142.00
full red 1 NC + 1 NO 52PA2GRA 129.00 52PE2GRA 142.00

full green 1 NC + 1 NO 52PA2GSA 129.00 52PE2GSA 142.00
full amber 1 NC + 1 NO 52PA3GTA 129.00 52PE2GTA 142.00
240V transformer with 6V 755 type less operating head 1 NC + 1 NO 52PA2HNA 112.10 *****2) ––––– 1
lamp chrome red 1 NC + 1 NO 52PA2H2A 129.00 52PE2H2A 142.00
chrome green 1 NC + 1 NO 52PA2H3A 129.00 52PE2H3A 142.00
chrome amber 1 NC + 1 NO 52PA2H9A 129.00 52PE2H9A 142.00
480V transformer with 6V 755 type less operating head 1 NC + 1 NO 52PA2JNA 112.10 *****2) ––––– 1
lamp chrome red 1 NC + 1 NO 52PA2J2A 129.00 52PE2J2A 142.00
chrome green 1 NC + 1 NO 52PA2J3A 129.00 52PE2J3A 142.00
chrome amber 1 NC + 1 NO 52PA2J9A 129.00 52PE2J9A 142.00
600V transformer with 6V 755 type less operating head 1 NC + 1 NO 52PA2KNA 112.10 *****2) ––––– 1
lamp chrome red 1 NC + 1 NO 52PA2K2A 129.00 52PE2K2A 142.00
chrome green 1 NC + 1 NO 52PA2K3A 129.00 52PE2K3A 142.00
chrome amber 1 NC + 1 NO 52PA2K9A 129.00 52PE2K9A 142.00
1) Blocks cannot be interchanged (start-stop circuit). 2) LED color must match lens color.
Siemens Energy & Automation, Inc. Discount Code: Pilot Devices 10/133
Accessories and spare parts
Version Suitable for Lamp Color Order no. List
voltage Price
$
Flush actuator lens cap For flush type, black 52RA1A1 1.50
non-illuminated pushbuttons red 52RA1A2 1.50
green 52RA1A3 1.50
yellow 52RA1A4 1.50
blue 52RA1A5 1.50
gray 52RA1A6 1.50
orange 52RA1A8 1.50
kit- all colors 52RA1AN 10.50
Extended actuator lens cap For extended type, black 52RA1B1 1.50
non-illuminated pushbuttons red 52RA1B2 1.50
green 52RA1B3 1.50
yellow 52RA1B4 1.50
blue 52RA1B5 1.50
gray 52RA1B6 1.50
orange 52RA1B8 1.50
1 of each color cap 52RA1BN 10.50
Mushroom head cap - Plastic For small 1 5/8"(41.3mm) type, black 52RB3D1 7.70
non-illuminated mushroom pushbuttons red 52RB3D2 7.70
green 52RB3D3 7.70
yellow 52RB3D4 7.70
blue 52RB3D5 7.70
gray 52RB3D6 7.70
orange 52RB3D8 7.70
1 of each color cap 52RB3DN 61.60
Mushroom head cap - Metal For small 1 5/8"(41.3mm) type, chrome 52RB3FC 16.70
non-illuminated mushroom pushbuttons red 52RB3F2 16.70
green 52RB3F3 16.70
Mushroom head cap - Plastic For large 2 1/2"(63.5mm) type, black 52RB3E1 15.40
non-illuminated mushroom pushbuttons red 52RB3E2 15.40
green 52RB3E3 15.40
yellow 52RB3E4 15.40
blue 52RB3E5 15.40
gray 52RB3E6 15.40
orange 52RB3E8 15.40
1 kit of each color cap 52RB3EN 123.20
Illuminated mushroom head cap Illuminated Mushroom head red 52RB3H2 16.90
Illuminated metal pushbuttons green 52RB3H3 16.90
amber 52RB3H9 16.90
Illuminated plastic red 52RB3JR 16.90
Replacement Lens for Pilot Lights red 52RA4P2 5.40

Plastic lens green 52RA4P3 5.40
blue 52RA4P5 5.40
amber 52RA4P9 5.40
clear 52RA4PA 5.40
white 52RA4PB 5.40
Glass lens red 52RA4G2 21.00

green 52RA4G3 21.00
blue 52RA4G5 21.00
amber 52RA4G9 21.00
clear 52RA4GA 21.00
white 52RA4GB 21.00
Replacement Lens for Push to test/Illuminated pushbuttons red 52RA5P2 5.40

Plastic lens green 52RA5P3 5.40
blue 52RA5P5 5.40
amber 52RA5P9 5.40
clear 52RA5PA 5.40
white 52RA5PB 5.40

voltage Price
$
Replacement lens kit for red 52RA6P2 5.40
Illuminated selector switches green 52RA6P3 5.40
blue 52RA6P5 5.40
amber 52RA6P9 5.40
clear 52RA6PA 5.40
white 52RA6PB 5.40
Lever inserts red 52RA2A2 0.40

Short lever green 52RA2A3 0.40
blue 52RA2A4 0.40
amber 52RA2A5 0.40
gray 52RA2A6 0.40
orange 52RA2A8 0.40
white 52RA2AB 0.40
Long lever red 52RA2B2 0.40
green 52RA2B3 0.40
blue 52RA2B4 0.40
amber 52RA2B5 0.40
gray 52RA2B6 0.40
orange 52RA2B8 0.40
white 52RA2BB 0.40
Replacement lens for compact style pilot lights red 52RA7P2 5.40
Replacement lenses green 52RA7P3 5.40
blue 52RA7P5 5.40
amber 52RA7P9 5.40
clear 52RA7PA 5.40
white 52RA7PB 5.40
Clear protective boot Flush pushbutton operators 52AABA 15.40

Offers protection from ice and foreign
substances from interfering with button
operation
Pushbutton guard Non-Illuminated pushbuttons 52AAGP 7.70
Prevents accidental operation of the Black Max styles, non-Illuminated push- 52AXGP 7.70
pushbutton buttons
Lens guard Push to test pilot lights and indicator 52AAGL 7.70
lights
Black Max styles, push to test pilot lights 52AXGL 7.70
and indicator lights
Guard for mushroom head 1 5/8"(41.3mm) mushroom head pushbut- 52AAGM 31.00
Additional hole spacing is required on ton and push-pull operators
adjacent devices Black Max styles,1 5/8"(41.3mm) mush- 52AXGM 31.00
room head pushbutton and push-pull op-
erators
Pushbutton locknut Pushbutton and push-to-test device 52AANP 2.50
Replacement front ring Black Max styles, pushbutton and push- 52AXNP 2.50
to-test device
Push-pull/pilot light locknut Mushroom head and pilot light indicators 52AANL 2.50
Replacement front ring
Selector switch locknut Selector switch 52AANS 2.50
Replacement front ring Black Max styles, selector switch 52AXNS 2.50
Padlock attachments Flush pushbutton operators, extended 52AALA 23.00
operatotors1) 52AALB 23.00
Padlock cover Pushbuttons, selector switches, and non- 52AALS 46.00
illuminated mushroom heads
Can be used to lock devices in the off
position
Lock nut wrench All devices 52MAWB 23.00
Hole plugs Corrosion resistant 52AAH6 7.70
Steel, gray 52ABH6 7.70
Stainless steel 52ABHS 23.00
Spare keys 501CH (1 key) D28671015 5.30
Grounding kit All devices 52AL109145 3.90
Touchsafe shield Illuminated devices (Current revisions 52AASH 2.25
Pushbutton locknut Pushbutton and push-to-test device 52AANP 2.50
1) Must be used with step raised cap- 52PA8C2.

voltage Price
$
Lamps with screw connection, miniature bayonet (BA 9s style)
Incandescent lamps,
Flashing, type 267 lamp (replaces 755 lamp) 51, 52 6V 52AABNF 11.60
6V type 755 lamp 51, 52 6V 52AABN 7.70
12V type 756 51, 52 12 V 52AACN 7.70
24V type 757 51, 52 24 V 52AADN 7.00
120V, 2.5W, type #120MB 52 120 V 52AAENC1 7.70
Neon (uses resistors) type B2A (NE-51H) 52 120 V 52AAPN 15.90
Candelabra, 120 V, Full voltage type 3S6/5 1) 52 older revision styles 120 V 52AAENC 7.70
LED’s BA9s Style 52 6V red 52AEB2 21.00

52 6V green 52AEB3 21.00
52 6V yellow 52AEB4 21.00
52 6V white 52AEBB 21.00
52 6V blue 52AEB5 21.00
52 24 V red 52AED2 21.00

52 24 V green 52AED3 21.00
52 24 V yellow 52AED4 21.00
52 24 V white 52AEDB 21.00
52 24 V blue 52AED5 21.00
52 120 V red 52AEE2 21.00

52 120 V green 52AEE3 21.00
52 120 V yellow 52AEE4 21.00
52 120 V white 52AEEB 21.00
52 120 V blue 52AEE5 21.00
LED's, cluster type 52 6V red 52AEB27 26.50

For use with Class 52 pilot lights only 52 6V green 52AEB37 26.50
52 6V yellow 52AEB47 26.50
52 24 V red 52AED27 26.50

52 24 V green 52AED37 26.50
52 24 V yellow 52AED47 26.50
52 120 V red 52AEE27 26.50

52 120 V green 52AEE37 26.50
52 120 V yellow 52AEE47 26.50
Touchsafe contact blocks with gold flashing
1 NO 52BAK 11.60
52 BAJ 1 NC 52BAJ 11.60
1 NO - 1 NC 52BJK 23.20
1 NO early make closes before 52BAK 52BAH 11.60
1 NC late break opens after 52 BAJ 52BAE 11.60
52 BAK 1 NO - 1 NC Reed switch 52BAR2) 46.40
UL listed for class 1 division 2
.25A Max, 150V AC, 10 Watt max
.5A Max, 150V DC, 10 Watt max
1 NC extra late break 52BAU 11.60
52 BAR
1) Design change made in 2003 from candelabra to 2) Hermetically sealed.

BA 9s type bulbs. Contact technical support for
further information.
Selector switch complete units

Version Lever type Contact Cam1) Order no. List Pack
blocks Price
$ unit
Selector Switches with 2 switching positions
Maintained operation Short lever, non-Illuminated 1NO A 52SA2AABK1 40.10 1
Short lever, non-Illuminated 1NC A 52SA2AABJ1 40.10
Short lever assembled Short lever, non-Illuminated 1NO + 1NC A 52SA2AABA1 51.70
selector switch
Long lever, non-Illuminated 1NO A 52SB2AABK1 40.10
Long lever, non-Illuminated 1NC A 52SB2AABJ1 40.10
Long lever, non-Illuminated 1NO + NC A 52SB2AABA1 51.70
Spring return from right operation Short lever, non-Illuminated 1NO A 52SA2ACBK1 55.60 1
Short lever, non-Illuminated 1NC A 52SA2ACBJ1 55.60
Short lever, non-Illuminated 1NO + 1NC A 52SA2ACBA1 67.20
Long lever, non-Illuminated 1NO A 52SB2ACBK1 55.60
Long lever, non-Illuminated 1NC A 52SB2ACBJ1 55.60
Long lever, non-Illuminated 1NO + 1NC A 52SB2ACBA1 67.20
Selector Switches with 3 switching positions

Maintained operation Short lever, non-Illuminated 1NO + 1NC C 52SA2CABA1 51.70 1
Short lever, non-Illuminated 2NC + 1NO G 52SA2GABJ2K1 63.30
Long lever assembled Short lever, non-Illuminated 2NO + 2NC C 52SA2CABA2 74.90
selector switch
Long lever, non-Illuminated 1NO + 1NC C 52SB2CABA1 51.70
Long lever, non-Illuminated 2NC + 1NO G 52SB2GABJ2K1 63.30
Long lever, non-Illuminated 2NO + 2NC C 52SB2CABA2 74.90
Spring return from right Short lever, non-Illuminated 1NO + 1NC C 52SA2CCBA1 67.20 1
Short lever, non-Illuminated 2NC + 1NO G 52SA2GCBJ2K1 78.80
Short lever, non-Illuminated 2NO + 2NC C 52SA2CCBA2 90.40
Long lever, non-Illuminated 1NO + 1NC C 52SB2CCBA1 67.20
Long lever, non-Illuminated 2NC + 1NO G 52SB2GCBJ2K1 78.80
Long lever, non-Illuminated 2NO + 2NC C 52SB2CCBA2 90.40
Spring return from right & left operation Short lever, non-Illuminated 1NO + 1NC C 52SA2CDBA1 67.20 1
Short lever, non-Illuminated 2NC + 1NO G 52SA2GDBJ2K1 78.80
Short lever, non-Illuminated 2NO + 2NC C 52SA2CDBA2 90.40
Long lever, non-Illuminated 1NO + 1NC C 52SB2CDBA1 67.20
Long lever, non-Illuminated 2NC + 1NO G 52SB2GDBJ2K1 78.80
Long lever, non-Illuminated 2NO + 2NC C 52SB2CDBA2 90.40
Key-operated selector switches, 2 switching positions

Maintained operation Key removable in left positions 1NO A 52SC6AFK1 86.60 1
Assembled keyed Key removable in left positions 1NC A 52SC6AFJ1 86.60
selector switch
Key removable in left positions 1NO + 1NC A 52SC6AFA1 98.20
Spring return from right operation Key removable in left positions 1NO A 52SC6AXK1 101.60 1
Key removable in left positions 1NC A 52SC6AXJ1 101.60
Key removable in left positions 1NO + 1NC A 52SC6AXA1 113.20
Key-operated selector switches, 3 switching positions

Maintained operation Key removable in all positions 1NC + 1NO C 52SC6CEA1 98.20 1
Key removable in all positions 2NC + 1NO G 52SC6GEJ2K1 109.80
Key removable in all positions 2NO + 2NC C 52SC6CEA2 121.40
Spring return from right operation Key removable in all positions 1NO + 1NC C 52SC6CZA1 113.20 1
Key removable in all positions 2NC + 1NO G 52SC6GZJ2K1 124.80
Key removable in all positions 2NO + 2NC C 52SC6CZA2 136.40
Spring return from right & left operation Key removable in all positions 1NO + 1NC C 52SC6CVA1 113.20 1
Key removable in all positions 2NC + 1NO G 52SC6GVJ2K1 124.80
Key removable in all positions 2NO + 2NC C 52SC6CVA2 136.40
1) For contact operation, see cam selection table on page 10/151.
Components
OT
Strip and Ring

1-1/2" Wide Two Offset
Terminals, One End
• 7-1/2 - 47-1/2" Lengths

Dimensions
• 150 - 2,250 Watts A
B
• 120 and 240 Volt 5/16 x 1/2" Slot
1-1/2
• 6 - 27 W/In2
D
#10-32 Thd. 3/8
15/16
Applications
All Dimensions in Inches
Strip heaters are used for heat transfer by
conduction or convection to heat liquids, air,
gases and surfaces. See guidelines in the Strip
Heater Overview section.
Specifications and Ordering Information

Dimensions (In.) Rust-Resisting Iron Sheath Chrome Steel Sheath
120V 240V 120V 240V

Wt.
A B D Watts W/In2 Model Stock PCN Stock PCN Watts W/In2 Model Stock PCN Stock PCN (Lbs.)
7-1/2 6-1/2 6 150 11 OT-715 S 129314 S 129322 200 15 OT-702 S 129613 S 129621 0.5
8 7 6-1/2 150 10 OT-815 S 129330 S 129349 250 17 OT-802 S 129630 S 129648 0.56
8 7 6-1/2 175 12 OT-817 S 129357 S 129365 400 27 OT-804 S 129656 S 129664 0.56
10-1/2 9-1/2 9 250 10 OT-1025 S 129373 S 129381 350 15 OT-1003 S 129672 S 129680 0.75
10-1/2 9-1/2 9 — — — S — — — 400 17 OT-1004 S 129699 S 129701 0.88
12 11 10-1/2 250 8 OT-1225 S 129390 S 129402 250 8 OT-1202 S 129710 S 129728 0.88
12 11 10-1/2 — — — S — — — 350 14 OT-1203 S 129736 S 129744 0.88
12 11 10-1/2 — — — S — — — 500 17 OT-1205 S 129752 S 129760 0.88
14 13 12-1/2 300 8 OT-1430 S 129410 S 129429 500 14 OT-1405 S 129779 S 129787 1
15-1/4 14-1/4 13-3/4 325 8 OT-1532 S 129437 S 129445 500 12 OT-1505 S 129795 S 129808 1.13
17-7/8 16-7/8 16-3/8 350 6.5 OT-1835 S 129453 S 129461 500 10 OT-1805 S 129816 S 129824 1.38
17-7/8 16-7/8 16-3/8 375 7 OT-1837 S 129470 S 129488 750 15 OT-1807 S 129832 S 129840 1.38
17-7/8 16-7/8 16-3/8 500 10 OT-1850 S 129496 S 129509 1,000 19 OT-1801 S 129859 S 129867 1.38
19-1/2 18-1/2 18 350 6 OT-1935 S 129517 S 129525 500 9 OT-1905 S 129875 S 129883 1.5
19-1/2 18-1/2 18 500 8 OT-1950 S 129533 S 129541 750 13.5 OT-1907 S 129891 S 129904 1.5
19-1/2 18-1/2 18 — — — S — S — 1,000 18 OT-1901 S 129912 S 129920 1.5
21 20 19-1/2 500 8 OT-2150 S 129550 S 129568 750 12 OT-2107 S 129939 S 129947 1.63
23-3/4 22-3/4 22-1/4 500 7 OT-2450 S 129576 S 129584 500 7 OT-2405 S 129955 S 129963 1.81
23-3/4 22-3/4 22-1/4 750 10 OT-2475 S 129592 S 129605 750 10 OT-2407 S 129971 S 129980 1.81
23-3/4 22-3/4 22-1/4 — — — — — — — 1,000 14 OT-2401 S 129998 S 130008 1.81
23-3/4 22-3/4 22-1/4 — — — — — — — 1,500 19 OT-2415 S 129226 S 129234 1.81
25-1/2 24-1/2 24 500 6 OT-2550 S 121005 S 121013 750 9 OT-2507 S 121208 S 121216 2.06
25-1/2 24-1/2 24 750 9 OT-2575 S 121021 S 121030 1,000 13 OT-2501 S 121224 S 121232 2
26-3/4 25-3/4 25-1/4 700 8 OT-2670 S 121048 S 121056 1,000 12 OT-2601 S 121240 S 121259 2.19
26-3/4 25-3/4 25-1/4 750 9 OT-2675 NS 121064 S 121072 — — — — — — — 2.19
30-1/2 29-3/8 28 750 8 OT-3075 S 121080 S 121099 750 8 OT-3007 S 121267 S 121275 2.38
30-1/2 29-3/8 28 — — — — — — — 1,000 11 OT-3001 S 121283 S 121291 2.38
30-1/2 29-3/8 28 — — — — — — — 1,250 13 OT-3012 S — S 121304 2.38
33-1/2 32-3/8 31 750 7 OT-3375 S 121101 S 121110 750 7 OT-3307 S 121312 S 121320 2.69
35-7/8 34-3/4 33-1/2 1,000 9 OT-3610 S 121128 S 121136 1,500 13 OT-3601 S 121339 S 121347 2.88
38-1/2 37-1/2 36 800 6 OT-3880 S 121144 S 121152 1,000 8 OT-3801 S 121355 S 121363 3.19
38-1/2 37-1/2 36 1,000 8 OT-3810 S 121160 S 121179 1,500 12 OT-3815 S 121371 S 121380 3.19
42-1/2 41-3/8 40 1,250 9 OT-4312 S 121187 S 121195 1,500 11 OT-4315 S 121398 S 121400 3.38
47-7/8 46-3/4 45-3/8 — — — — — — — 1,350 9 OT-4813 S — S 121419 3.75
47-7/8 46-3/4 45-3/8 — — — — — — — 2,250 14 OT-4822 S — S 121427 3.75
Stock Status: S = stock AS = assembly stock NS = non-stock
To Order—Specify model, PCN, watts, volts and quantity.
www.chromalox.com 1-800-443-2640 A-61

Components
STRIP AND RING

Accessories
separately. Porcelain Hi-Temp Insulation
Shims Porcelain Hi-Temp Insulation —
• Protective Terminal Covers For insulating buss bars spec. 51 porcelain
Shims — Types OT, PT, S, SE and TH. Provide
insulators 1/2 L x 13/16" W with 1/8 x 9/16"
same advantage as flush-top construction and
• Shims slot. 95 pieces per lb.
can be used with stock heaters. Shims are
• Ceramic Post Terminal Shims

Insulators
• Porcelain Hi-Temp Insulation
Protective Terminal Covers — Types OT, PT, To Order — Specify pounds, PCN 269780 and
SE, WS and Seamless Types SSE, SSEM, porcelain insulators.
SSNH and SSNHM. Helps guard terminals
from spillovers, dripping. Removable sheet- For Insulating Bare Wires — Two types
metal cover, with Bx fitting, is shipped available:
Ceramic Post Terminal Insulaters
1. Porcelain Tubing — 3/8" O.D. x 1/8" I.D.
OT-AC-1 (PCN 129242) Ceramic Post Terminal Insulators — All types x 6" L (may be broken for shorter lengths).
except NS and SN. Use with insulated wire to Suitable for 10-gauge or smaller; 8-gauge
C help protect against electrical shock. Wires takes No. 6 porcelain bead.
B
can leave terminal at any angle.
To Order — Specify quantity and PCN 263863.
A
Ceramic Post Terminal Insulators Porcelain Tubing
PT-AC-1 (PCN 255724)

B
C
A 0.031" thick, 29/32" wide and lengths to fit

heater. 2. Porcelain Beads — Listed in table below.
Can be used when wiring does not permit
straight tubing.
PCN 259805 (Nickel plated steel hardware) Porcelain Beads
SE-AC-1 (PCN 256727)
PCN 255732 (Stainless steel hardware)
C B Cap
A A B
Wave Spring
Skirt
Protective Terminal Covers 3. When selecting porcelain beads for
stranded wire, use next larger gauge wire
Dimensions (In.)
and use bead for that size (i.e., 10 gauge
Model A B C stranded wire requires a No. 6 bead).
OT-AC-1 2 2-1/2 2-1/2
PT-AC-1 1-7/8 1-1/8 1-3/4 Porcelain Beads
SE-AC-11 2-1/16 1-1/2 2 Wire No. No.
Bead Dimensions (In.) Size Beads Beads
1. Used on type WS (mounted
sideways). Size A B C Solid Per Ft. Per Lb. PCN
2 0.17 0.068 0.17 14 B&S 88 4,535 263880
3 0.2 0.092 0.2 12 B&S 69 2,900 263900
4 0.26 0.156 0.26 8 B&S 51 1,500 263927
5 0.33 0.124 0.33 10 B&S 45 650 263943
6 0.4 0.156 0.4 8 B&S 38 360 263960
To Order—Specify PCN, number of pounds and quantity.
A-59
A-059.P65 73 9/18/02, 3:16 PM

Components

Wire & Accessories
(cont’d.)
High Temperature (Bare) Wire Buss Bar
• High Temperature (Bare) Wire Size Solid/S Amp- Nom. Manganese- DIM (In.) Amp-
AWG Strand/F acity1 O.D. Model PCN Nickel Width Thick acity1 PCN
• Insulated Wire 550°F Max. Wire Temp. 1100°F Max. Wire Temp.
Nickel-plated Copper, Uninsulated Solid 1/2 .032 26 263847
• Buss Bar 14 S 41 .064 CSB-14 263839 Perforated 1/2 .032 23 263855
10 S 70 .102 CSB-10 263812 To Order — Specify PCN and number
8 S 93 .128 CSB-8 263804 of feet.
• Silicone Boot Termination Kit 1000°F Max. Wire Temp.
Manganese-nickel, Uninsulated 1. These current values will cause the
14 F 12 .075 AFB-14 269317 conductor to operate at 100°F above
• Silicone Boot Termination Kit 14 S 12 .064 ASB-14 269309 surrounding ambient; values may
with Thermostat 12 F 15 .097 AFB-12 269296 also be used for bare wire with
12 S 15 .081 ASB-12 269288 porcelain tubes or bead insulation.
10 F 20 .12 AFB10 269270
10 S 20 .102 ASB-10 269261
Ambient Temperature Corrections for To Order — Specify PCN and quantity.
Insulated Wires — Multiply ampacity values,
in tables below, by the following correction
factors to determine current-carrying capacity Insulated Wire Silicone Boot Termination Kit
at higher ambient temperatures. Nom.
Size Solid/S Amp- O.D. SBK — The silicone boot termination kit
1
AWG Strand/F acity Insul In. Model PCN provides electrical insulation for strip heater
Nickel 392°F Max. Wire Temp. Type A Nickel Wire
Ambient Nickel-Plated MGS- terminals and leads with ring type insulated
Temp. Copper Teflon® Silicone Teflon® Mica Silicone Rubber Treated Glass Braid
Insulated 600V UL Listed connector on one end for bringing power to
°C °F Insulated Glass Glass Glass 16 F 27 .224 3-CFI-16 263759 the strip heaters.
30 86 — — — 1.36 16 S 27 .224 3-CSI-16 263740
50 122 0.98 0.97 0.98 — 14 F 36 .237 3-CFI-14 263732 Silicone Boot Termination Kit
60 140 0.95 0.94 0.95 — 14 S 36 .237 3-CSI-14 263724
70 158 0.93 0.9 0.93 — 12 F 45 .263 3-CFI-12 263716 with Thermostat
80 176 0.9 0.87 0.9 — 12 S 45 .263 3-CSI-12 263708
90 194 0.87 0.83 0.87 — 10 F 60 .29 3-CFI-10 263695 SBKT — The silicone boot termination kit with
100 212 0.85 0.79 0.85 1.22 10 S 60 .29 3-CSI-10 263687 thermostat used with strip heaters provides an
120 248 0.79 0.71 0.79 — 8 F 83 .31 3-CFI-8 263679
140 284 0.72 0.61 0.72 — inexpensive way to maintain temperature in
482°F Max. Wire Temp. Type TGT,
149 300 0.65 0.5 0.65 1.12 Nickel-plated Copper, Teflon® Impregnated control cabinets, panels and other small
177 350 0.58 0.35 0.58 — Glass Braid Insulated 600V UL Listed enclosures. In this application, strip heaters
204 400 0.49 — 0.49 1 are used to prevent freezing and corrosion,
232 450 0.35 — 0.35 — 14 F 39 .121 6-CFI-14 263791
260 500 — — — 0.87 14 S 39 .112 6-CSI-14 295398 and to control humidity in enclosures with
269 550 — — — — 12 F 54 .141 6-CFI-12 263783 humidity sensitive electronic components.
300 572 — — — 0.7 12 S 54 .13 6-CSI-12 295400
10 F 73 .17 6-CFI-10 263775
Note — After exposure to high tempera- 10 S 73 .156 6-CSI-10 295419
tures, all wire insulation becomes brittle Temperature (°F)
8 F 93 .212 6-CFI-8 263767
and will not withstand repeated flexing. Model PCN Closes Opens
482°F Max. Wire Temp. Teflon® Tape and
Silicone Impregnated Glass Braid SBKT-1 386011 38 53
Wire & Buss Bar Insulated 600V UL Listed SBKT-2 386020 60 75
14 F 39 .121 3-AFI-14 269253 SBKT-3 386038 105 120
High-temperature wire and buss bar are 12 F 54 .141 3-AFI-12 269237 SBK 121890 N/A N/A
recommended for connections to heater 10 F 73 .17 3-AFI-10 269210
terminals and for runs in heated zones. When 842°F Max. Wire Temp. Nickel-clad
ambient temperature exceeds maximum Copper, MGS-Mica Glass Insulated 600V SBKT
allowed for insulated wire, use bare wire or 16 F 331 .065 6-CFIM-16 295355
14 F 441 .102 6-CFIM-14 295363
buss bar with porcelain insulators. Current- 12 F 551 .118 6-CFIM-12 295371
carrying capacities should be carefully noted. To Order — Specify PCN and quantity.
Buss bar is solid or perforated to facilitate 1. See note 1 in Buss Bar Table.
wiring, especially when terminals are in line.
Perforated buss bar, has 11/32 x 7/32" slots
on 7/16" centers. When connecting elements
with buss bar, provide expansion loops
between elements. Buss bars may be used in
multiples for higher ampacity (approx.
33-1/2% per buss bar) than listed above,
center.
A-60
A-060.P65 1 10/7/02, 10:27 AM

Components
STRIP AND RING

Accessories (cont’d.)
Clamp 6933 — Use to clamp two strip heaters Clamping Bands (type SC)
• Element Clamps on 3" centers using 3/8" studs at 5" intervals
(PCN 263644).
• Clamping Bands
Clamp 6933
• Mounting Studs 2-1/4
3/8" Dia.
Stud Hole
4
Element Clamps
Cast-iron clamps, for use with Chromalox strip
3-3/8
and ring elements, retain their strength at 9/16
elevated temperatures to assure maximum 15/16
sheath-to-surface contact. Resulting uniform
5" Min. Rad.
efficient heat transfer from internal resistance Clamping Bands
wire to the heated material minimize hot spots Max. Pipe
Clamp 5970 — Use to clamp three strip
on the element, contributing to long service life. Dia. (In.) Model Stock PCN
heaters on 2" centers using 5/16" studs at 5"
6-1/8 SC-820-20 S 265340
Clamp 6018 — Usually used in sets of two or intervals (PCN 263652). 7-1/8 SC-820-22 S 265359
more to clamp ring elements to flat surfaces. 9-1/8 SC-820-26 S 265367
Clamp 5970 11-1/8 SC-820-30 S 265375
5/16" flathead machine screws are normally 14-1/8 SC-820-34 S 265383
used with head brazed or welded to work 5/16" Dia. Stud Hole 16-1/8 SC-820-36 S 265391
surface (PCN 263978). 20-1/8 SC-820-40 S 265404
26-1/8 SC-820-46 S 265412
1-1/2
To Order — Specify PCN and quantity.
Clamp 6018
2 5
5/16" Dia. Mounting Studs
Stud Hole
1-1/2
Mounting Studs — For use with Chromalox
clamps. For all clamps except No. 6933, studs
3/8
3 are 5/16 — 18 x 1-1/2" Monel® (PCN 127845),
3-1/2
5/8 steel washer (PCN 127853), Monel® nut (PCN
127861). For No. 6993 clamp; studs are 5/16"
5" Min. Rad. — 18 x 2" Monel® (PCN 127837).
Installation — Fasten studs to the work
Clamp 5971 — Use to clamp two strip heaters Clamping Bands surface by welding, brazing or threading. Use
on 2" centers using 5/16" studs spaced 5"
correct size stud to fit clamp. See Selection &
apart (PCN 263636). Type SC Clamping Bands — Provide
Installation Guidelines in the Components
permanently tight fit on cylinders, nozzles,
section. For temperatures over 750°F,
Clamp 5971 pipes and other round surfaces. Stainless steel
stainless steel studs are recommended.
5/16" Dia. Stud Hole band with alloy screw. For small pipe
diameters, strip elements should have cross- Note — When tightening nuts, torsion should
section curving (see Modifications in the not exceed 10 foot pounds maximum. Heaters
Components section). must be allowed to expand. One center clamp
3
should hold heater. Nuts on other clamps
For Most Satisfactory Results, bands should
should be backed off approximately 1/2 turn to
be spaced about 5 inches apart and should be
allow for heater expansion.
3 drawn up tight to assure good contact
between heater or thermostat bulb and
11/16
surface.
5" Min. Rad.
A-61
A-061.P65 73 9/18/02, 3:17 PM

SFCS-6002A-0502
May, 2002
Industrial Plug-In Relay

Catalog Supplement
Plug In Relay Line Overview
Siemens new general purpose plug in relay line is designed to meet your needs
We have updated our general purpose Throw, Three Pole/Double Throw or Four and come in many different styles and
plug in relay offering to better suit your Pole/Double Throw and are available in contact configurations.
needs. Plug in relays are easy to use most common coil voltages. Each relay Heavy Duty Power Relays
and install. The sockets can be either has Easy Grip covers, LED status indica-
panel mounted or DIN rail mounted. tor, mechanical indicator with push to For heavy duty applications we offer our
Since most of our relays have the indus- test button as well as an I.D. label. Our 3TX7130 series of power relays. These
try standard form, fit and funtion they new Premium Line offers premium bene- durable relays can handle currents up to
can typically fit right into your current fits at a reasonable price. 30A and come in various contact config-
application. urations.
Basic Line
Premium Line Our commitment to you
For simple applications that require a reli-
Our new durable Premium Line has able relay, we offer our standard Basic Our mission is to be your relay provider
many features and covers multiple con- Line. Our Basic Line can cover most any of choice by providing quick service and
tact configurations such as: Single relay need up to currents as high as 25A reliable relays at a reasonable price.
Pole/Double Throw, Double Pole/Double
IMPORTANT
This catalog supplement does not purport to cover all details or variations in equipment, nor to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further informa-
tion be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes,
the matter should be referred to the local Siemens sales office. The contents of this catalog supplement shall not
become part of or modify any prior or existing agreement, commitment or relationship. The sales contract contains
the entire obligation of Siemens. The warranty contained in the contract between the parties is the sole warranty
of Siemens. Any statements contained herein do not create new warranties or modify the existing warranty.
NOTE: For a current copy of all the pertinent instruction sheets, which contain important safety, application, and
installation information relating to this product, please see the Siemens Energy & Automation web site:
www.sea.siemens.com/controls. Downloading is highly recommended. Failure to review this information could
create a situation leading to death, serious injury, or property damage.
1
General Relay Information
2
Table of Contents Contents
Contents Pages
Plug In Relay Line Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Relay Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
8 and 11 Pin Octal Base Relays

Premium Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Basic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Socket Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
General Purpose Square Base Relays

Premium Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Basic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-17
Magnetic Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
Miniature Relays
Premium Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-29
Basic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-35
Heavy Duty Power Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42-45

Solid State Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46-47
Timing Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-51
Standard Terms and Conditions of Sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
3
Features
the socket
C US
Premium Line 12A, 8 PIN Octal Socket, DPDT UL Recognized
Catalog No. Coil Voltage List Price Socket File No: E14900
3TX7112-1LB13 12VAC $17.00 3TX7144-1E2
3TX7112-1LC13 24VAC $17.00 3TX7144-1E2
3TX7112-1LF13 120VAC $17.00 3TX7144-1E2
3TX7112-1LG13 220/230VAC $17.00 3TX7144-1E2
3TX7112-1LB03 12VDC $17.00 3TX7144-1E2 UL Contact Ratings Table
3TX7112-1LC03 24VDC $17.00 3TX7144-1E2 POLES 120 VAC 240 VAC 28 VDC
3TX7112-1LF03 110VDC $17.00 3TX7144-1E2 2&3 12 AMP 12 AMP
12 AMP
POLE 1/3 HP 1/2 HP
Premium Line 12A, 11 PIN Octal, 3PDT

3TX7112-1NB13 12VAC $17.50 3TX7144-1E3
3TX7112-1NC13 24VAC $17.50 3TX7144-1E3
3TX7112-1NF13 120VAC $17.50 3TX7144-1E3
3TX7112-1NG13 220/230VAC $17.50 3TX7144-1E3
3TX7112-1NB03 12VDC $17.50 3TX7144-1E3
3TX7112-1NC03 24VDC $17.50 3TX7144-1E3
3TX7112-1NF03 110VDC $17.50 3TX7144-1E3
Wiring Diagrams
Viewed from pin end
4
Outline Dimensions
Specifications
COIL Temperature
Pull-in voltage: 80% of nominal voltage or less for DC coils Ambient Temperature (Operating): -30IC to + 50IC (AC), -30IC to +65IC (DC)
85% of nominal voltage or less for AC coils Non operating storage: -30IC to +100IC
Coil resistance: ± 10 % measured @ 25IC Operating: 5 G's
Minimum sensitivity: 125 milliwatts per pole Non-operating: 20 G's
Nominal power: 1.2 Watts for DC coils, 2 VA-2.75VA for AC coils Vibration Resistance
Insulation System: Class "B" (130IC per UL std. 1446) Operating: 5 G's, 10 Hz to 55 Hz
CONTACTS Electrical: 200,000 Operations
Contact material: 3/16" silver cadmium oxide, gold flashed. Mechanical: 5,000,000 Operations
Contact resistance: 50 milliohms maximum @ 10A, 120VAC or 24 VDC MISCELLANEOUS
Contact conditioned for 50 make & break Insulation material: Molded plastic
Operations at 1 second "ON and 1 second "OFF". Operating Position: Any
Minimum Load: 12 V @ 100 Milliamps Terminals: 8 pin or 11 pin octal plug-in
TIMING Weight: 83 grams
Operate time: Max. 20 ms.
Release time: Max. 15 ms.
DIELECTRIC STRENGTH
5
12
Siemens
SiemensEnergy
Energy& &Aut
Automat
omation,
ion,Inc.
Inc.- Industrial
- IndustrialPlug-In
Plug-InRelay
RelayCat
Catalog
alogSupplement
Supplement
Features
Available with current ratings up to 10A
Economical
DPDT & 3PDT contact configurations
Uses industry standard socket
C US
UL Recognized LR 6535
Basic 10A, 8 PIN Octal DPDT File No: E14900
Catalog No. Coil Voltage List Price Socket
3TX7120-1DB13 12VAC $14.00 3TX7144-1E2
3TX7120-1DC13 24VAC $14.00 3TX7144-1E2
3TX7120-1DF13 120VAC $14.00 3TX7144-1E2
3TX7120-1DH13 240VAC $14.00 3TX7144-1E2
3TX7120-1DB03 12VDC $14.00 3TX7144-1E2
3TX7120-1DC03 24VDC $14.00 3TX7144-1E2
3TX7120-1DF03 110VDC $14.00 3TX7144-1E2
Basic 10A, 11 PIN Octal 3PDT UL Contact Ratings Table

3TX7120-1FB13 12VAC $14.50 3TX7144-1E3 POLES 120 VAC 240 VAC 28 VDC
3TX7120-1FC13 24VAC $14.50 3TX7144-1E3 12 AMP 10 AMP
DPDT 10 AMP
3TX7120-1FF13 120VAC $14.50 3TX7144-1E3 1/3 HP 1/2 HP
3TX7120-1FH13 240VAC $14.50 3TX7144-1E3 10 AMP 10 AMP
3PDT 10 AMP
1/3 HP 1/2 HP
3TX7120-1FB03 12VDC $14.50 3TX7144-1E3
3TX7120-1FC03 24VDC $14.50 3TX7144-1E3
3TX7120-1FF03 110VDC $14.50 3TX7144-1E3
Wiring Diagrams
Viewed from pin end
6
Outline Dimensions
Specifications
Pull-in voltage* 80% of nominal voltage or less for DC coils Contacts to coil: 1500 V rms
85% of nominal voltage or less for AC coils Across open contacts: 1000 V rms
Coil resistance* ±10% Contacts to frame: 1500 V rms
Minimum sensitivity* 125 milliwatts per pole Insulation resistance: 1,000 Megohms min. @ 500 VDC
Nominal power* 1.2 Watts for DC coils, 2 VA-2.75VA for AC coils TEMPERATURE
Maximum coil dissipation* Capability of DC coils 3.0 Watts max. Operating: -10°C to +50°C (AC), -10°C to +60°C (DC)
Coil insulation System Class "B" coil insulation (130°C) per UL std. 1446 Storage: -30°C to +105°C
Duty: Continuous Shock Resistance
CONTACTS Operating: 5 G's,
Contact material 3/16" silver cadmium oxide, gold flashed Std. Non operating: 20 G's
Contact resistance: 50 milliohms maximum initial VIBRATION RESISTANCE
resistance at rated current Operating: 5 G's, 10 Hz to 55 Hz
Minimum Load: 12 V @ 100 Milliamps MISCELLANEOUS
TIMING Insulation material: Molded plastic
Operate time: Max. 25 ms. Operating Position: Any
Release time: Max. 20 ms. Terminals: 8 or 11 pin octal plug-in
*Measured at 25IC Weight: 3 1/2 ozs. 99.2 g approx.
7
Sockets & Accessories

C US
Catalog No. Additional Description List Price
UL Recognized
3TX7144-1E2 8 pin octal, panel/DIN rail, screw term socket $4.75
File No: E196786
Specifications
Electrical Rating: 300 V, 15 AMPS / 600V, 10 AMPS
CONSTRUCTION
Terminals: Clamping screws: M 3.5 x 0.6 yelow zinc plated with pressure clamp washers.Terminal connections are capable of accepting
two #12 AWG wires or smaller, one wire on each side of the clamping screw.
Internal electrical current carrying elements conform with UL requirements for relay sockets, including maximum
Grips: Fits 35mm wide DIN mounting track
8
Outline Dimensions
Wiring Diagram
Top View
9
Sockets & Accessories C US

Catalog No. Additional Description List Price UL Recognized
3TX7144-1E3 11pin octal, panel/DIN rail, screw term socket $10.00 File No: E196786
Specifications
Electrical Rating: 300V rms, 15 AMPS 600V rms 5 AMPS
Dielectric Withstanding
CONSTRUCTION
Terminals: Clamping screws: M 3.5 x 0.6 yellow zinc plated with pressure clamp washers.Terminal connections shall be capable of
accepting two #12 AWG wires or smaller, one wire on each side of the clamping screw.Terminal wire clamp must provide
equally good clamping when either one or two wire conductors are connected to a single terminal.
Internal electrical current carrying elements conform with UL and CSA requirements for relay sockets, including maximum
Grips: Fit 35mm wide DIN mounting track
10
Outline Dimensions
Wiring Diagram
Top View
11
Features
the socket
Premium Line 12A, Square Base, DPDT

C US
Catalog No. Coil Voltage List Price Socket Style UL Recognized
3TX7115-5LC13 24VAC $17.00 3TX7144-1E4 File No: E14900
3TX7115-5LF13 120VAC $17.00 3TX7144-1E4
3TX7115-5LH13 240VAC $17.00 3TX7144-1E4
3TX7115-5LB03 12VDC $17.00 3TX7144-1E4
3TX7115-5LC03 24VDC $17.00 3TX7144-1E4
3TX7115-5LF03 110VDC $17.00 3TX7144-1E4 UL Contact Ratings Table
2&3 12 AMP 12 AMP
12 AMP
POLE 1/3 HP 1/2 HP
Premium Line 12A, Square Base, 3PDT
3TX7115-5NC13 24VAC $17.50 3TX7144-1E4
Typical Operating Characteristics
3TX7115-5NF13 120VAC $17.50 3TX7144-1E4
3TX7115-5NH13 240VAC $17.50 3TX7144-1E4
3TX7115-5NB03 12VDC $17.50 3TX7144-1E4 POLES DPDT 3PDT
3TX7115-5NC03 24VDC $17.50 3TX7144-1E4 Min. Operate mW
250 375
3TX7115-5NF03 110VDC $17.50 3TX7144-1E4 Sensitivity
Operate Time
20.0 24.0
Release Time
28.0 26.0
Wiring Diagrams
Viewed from pin end
12
Outline Dimensions
Specifications
COIL TEMPERATURE
Pull-in voltage: 80% of nominal voltage or less. for DC coils Ambient Temperature (Operating): -30IC to + 50IC (AC), -30IC to +65IC (DC)
85% of nominal voltage or less for AC coils. Non operating storage: -30IC to +100IC
Coil resistance: ± 10 % measured @ 25IC Operating: 5 G’s,
Minimum sensitivity: 125 milliwatts per pole Non operating: 20 G’s
Nominal power: 1.2 Watts for DC coils, 2 VA-2.75VA for AC coils VIBRATION RESISTANCE
Maximum coil dissipation: Capability of DC coils 3.0 Watts max. Operating: 5 G’s, 10 Hz to 55 Hz
Insulation System Class “B” (130IC per UL std. 1446) LIFE
Duty: Continuous Electrical: 200,000 Operations
CONTACTS Mechanical: 5,000,000 Operations
Contact material: 3/16" silver cadmium oxide, gold flashed. MISCELLANEOUS
Contact resistance: 50 milliohms maximum @ 10A, 120VAC or 24 VDC Insulation material: Molded plastic
Contact conditioned for 50 make & break operations Operating Position: Any
at 1 second “ON and 1 second “OFF” Terminals: 3/16” x .020 Q.C. Solder/ plug-in
Minimum Load: 12 V @ 100 Milliamps Weight: 83 grams approx.
TIMING
Operate time: Max. 20 ms
Release time: Max. 15 ms
DIELECTRIC STRENGTH
13
Features
Styles available with current ratings up to 16A and 25A
Economical
Push to test button - Makes testing and analyzing your
circuit easier
Various contact configurations: DPDT, 3PST and 3PDT
C US
UL Recognized
LR 6535
File No: E14900
16A, Square Base, DPDT

Catalog No. Coil Voltage List Price Socket Style
3TX7113-5DC13 24VAC $16.00 3TX7144-1E4
3TX7113-5DF13 120VAC $16.00 3TX7144-1E4 16A, Square Base, 3PDT
3TX7113-5DH13 240VAC $16.00 3TX7144-1E4 Catalog No. Coil Voltage List Price Socket Style
3TX7113-5DB03 12VDC $16.00 3TX7144-1E4 3TX7113-5FC13 24VAC $16.00 3TX7144-1E4
3TX7113-5DC03 24VDC $16.00 3TX7144-1E4 3TX7113-5FF13 120VAC $16.00 3TX7144-1E4
3TX7113-5FG13 220VAC $16.00 3TX7144-1E4
3TX7113-5FB03 12VDC $16.00 3TX7144-1E4
16A, Mounting Bracket, DPDT 3TX7113-5FC03 24VDC $16.00 3TX7144-1E4
3TX7113-6FH13 240VAC $16.00 Require .187 Quick Connect
3TX7113-6FC03 24VDC $16.00 Require .187 Quick Connect
25A, Mounting Bracket, DPDT
16A, Square Base, 3PST

3TX7113-5EC13 24VAC $16.00 3TX7144-1E4
3TX7113-5EF13 120VAC $16.00 3TX7144-1E4
3TX7113-5EH13 240VAC $16.00 3TX7144-1E4
3TX7113-5EC03 24VDC $16.00 3TX7144-1E4
12
14
Siemens
SiemensEnergy
Energy& &Aut
Automat
omation,
ion,Inc.
Inc.- Industrial
- IndustrialPlug-In
Plug-InRelay
RelayCat
Catalog
alogSupplement
Supplement
Outline Dimensions
Dimensions shown in Inch & (Millimeters)
Specifications
Pull-in voltage:* 80% of nominal voltage or less. for DC coils. Contacts to coil: 2000 V rms
85% of nominal voltage or less for AC coils. Across open contacts: 500 V rms
Coil resistance:* ± 10 % Contacts to frame: 2000 V rms
Coil insulation: Class “B” coil insulation system (130IC) per Insulation resistance: 1000 megohms min. @ 500 VDC.
UL Standard 1446 TEMPERATURE
COIL POWER Operating: -30IC to +50IC (AC), -30IC to +60IC (DC)
Maximum coil dissipation:* Capability of DC coils 2.5 Watts max. Storage: -30IC to 100IC
CONTACTS Electrical: 100,000 at rated load.
Contact material: 1/4" silver cadmium oxide, gold flashed Mechanical: 5 Million Operations no load
Contact gap: 0.015 min. is standard MISCELLANEOUS
Contact resistance: 50 Milliohms max. initial resist. at rated current Insulation material: Molded plastic
TIMING Terminals: .250 x 0.032 QC, .187 x 0.020 QC plug-in
Operate time, (exc. bounce): 20 ms typical at nominal voltage. Weight: 3.3 ozs. (94 grams) approx. with cover.
Release time, (exc. bounce): 20 ms typical at nominal voltage.
*Measured at 25IC
Wiring Diagrams
Viewed from pin end
NEMA Pilot Duty Contact Ratings

Rating Codes for AC control-circuit contacts at 50/60Hz
MAXIMUM CURRENT, AMPERES

NEMA THERMAL
CONTACT CONTINUOUS 120 VOLTS 240 VOLTS 480 VOLTS 600 VOLTS MAXIMUM
CODE TEST CURRENT 50/60Hz 50/60Hz 50/60Hz 50/60Hz VOLT-AMPERES
DESIGNATION AMPERES
Make Break Make Break Make Break Make Break Make Break
B300 5 30 3.00 15 1.50 - - - - 3600 360
B600 5 30 3.00 15 1.50 0.75 0.75 6 0.06 3600 360
15
Features
Available with current ratings up to 15A and 20A
Economical
DPDT and 3PDT contact configurations
C US
UL Recognized
LR 6535
File No: E14900
15A, Square Base, DPDT 15A, Mounting Bracket, DPDT

Catalog No. Coil Voltage List Price Socket Style Catalog No. Coil Voltage List Price Socket Style
3TX7121-5DB13 12VAC $13.50 3TX7144-1E4 3TX7121-6DC13 24VAC $14.00 Require .187 Quick Connect
3TX7121-5DC13 24VAC $13.50 3TX7144-1E4 3TX7121-6DF13 120VAC $14.00 Require .187 Quick Connect
3TX7121-5DF13 120VAC $13.50 3TX7144-1E4 3TX7121-6DB03 12VDC $14.00 Require .187 Quick Connect
3TX7121-5DH13 240VAC $13.50 3TX7144-1E4 3TX7121-6DC03 24VDC $14.00 Require .187 Quick Connect
3TX7121-5DB03 12VDC $13.50 3TX7144-1E4 3TX7121-6DF03 110VDC $14.00 Require .187 Quick Connect
3TX7121-5DC03 24VDC $13.50 3TX7144-1E4
3TX7121-5DF03 110VDC $13.50 3TX7144-1E4
15A, Square Base, 3PDT 3TX7121-6FF13 120VAC $14.50 Require .187 Quick Connect
3TX7121-5FB13 12VAC $14.50 3TX7144-1E4 3TX7121-6FH13 240VAC $14.50 Require .187 Quick Connect
3TX7121-5FC13 24VAC $14.50 3TX7144-1E4 3TX7121-6FB03 12VDC $14.50 Require .187 Quick Connect
3TX7121-5FF13 120VAC $14.50 3TX7144-1E4 3TX7121-6FC03 24VDC $14.50 Require .187 Quick Connect
3TX7121-5FH13 240VAC $14.50 3TX7144-1E4 3TX7121-6FF03 110VDC $14.50 Require .187 Quick Connect
3TX7121-5FB03 12VDC $14.50 3TX7144-1E4
3TX7121-5FC03 24VDC $14.50 3TX7144-1E4
3TX7121-5FF03 110VDC $14.50 3TX7144-1E4
UL Contact Ratings Table
20A, Square Base, DPDT 2&3 12 AMP 12 AMP
12 AMP
POLE 1/3 HP 1/2 HP
3TX7122-5DC13 24VAC $15.50 3TX7144-1E4
3TX7122-5DF13 120VAC $15.50 3TX7144-1E4
3TX7122-5DH13 240VAC $15.50 3TX7144-1E4 Typical Operating Characteristics
3TX7122-5DB03 12VDC $15.50 3TX7144-1E4
3TX7122-5DC03 24VDC $15.50 3TX7144-1E4
3TX7122-5DF03 110VDC $15.50 3TX7144-1E4 POLES DPDT 3PDT
Min. Operate mW
250 375
Sensitivity
Operate Time
20.0 24.0
Release Time
28.0 26.0
16
Outline Dimensions
Specifications
COIL TEMPERATURE
Pull-in voltage:* 80% of nominal voltage or less for DC coils Operating: -30IC to +50IC (AC), -30IC to +65IC (DC)
85% of nominal voltage or less for AC coils Storage: -30IC to 100IC
Drop-out voltage: ≥10% of nominal voltage. LIFE EXPECTANCY
Resistance:* ± 10 % Electrical: 100,000 Operations @ rated AC load
Coil power:* 1.2 Watts for DC coils, 2 VA to 2.75 VA for AC coils Mechanical: 5,000,000 Operations @ No load
Insulation System: Class “B” (130IC per UL std. 1446) MISCELLANEOUS
Maximum coil dissipation: Capability of DC coils 3.0 Watts max. Operating Position: Any
Duty: Continuous Insulation material: Molded plastic
CONTACTS Terminals: 3/16" (.187) solder/plug-in
Contact material: 3/16" silver cadmium oxide, gold flashed Weight: 3.1 oz. (88 g approx).
Contact resistance: 50 Milliohms maximum initial resistance
at rated current
DIELECTRIC STRENGTH
Pole to pole 2000 V rms
*Measured at 25IC
Wiring Diagrams
Viewed from pin end
17
Relays
Industrial Automation
Catalog Section - U906
Selection Guides

• RU Series
• RR Series
For up-to-date information, or to

request a full copy of this catalog, contact
us at www.idec.com or 800-262-IDEC..
Due to continuous product improve-

ments, specifications are subject to change
wihtout notice.
Relays Selection Guide
Selection Guides

RU Series RR Series RH Series RM Series RY Series
Appearance
Page E-3 E-6 E-10 E-16 E-19

Contact Configuration 2, 4 Form C 1, 2, 3 Form C 1, 2, 3, 4 Form C 2 Form C 2, 4 Form C
DPDT: 10A, 30V DC 10A, 30V DC 10A, 30V DC DPDT: 3A, 30V DC;
Contact Rating 10A, 250V AC 10A, 120V, 240V AC 10A, 120V, 240V AC 5A, 30V DC 3A, 120V AC, 240V AC
(resistive) 4PDT: 6A, 30V DC 1/3HP, 240V AC 1/3HP, 240V AC 5A, 120V AC, 240V AC 4PDT: 5A, 30V DC;
6A, 250V AC 1/4HP, 120V AC 1/6HP, 120V AC 5A, 120V AC, 240V AC
AuSnOIn (silver tin
DPDT Standard Silver, gold-plated
oxide indium) Silver-cadmium
E Contact Material
4PDT AuAg/Ag (gold-
Silver oxide Silver
Bifurcated Silver-paladium
silver alloy on silver) alloy (Ag-PD Alloy)
General Purpose Latching Relays

RR2KP Series RH2L Series RY2KS Series RY2L Series
Appearance
Page E-23 E-26 E-29 E-32

Contact Configuration 2 Form C 2 Form C 2 Form C 2 Form C
Contact Rating 10A, 30V DC 3A, 30V DC

10A, 30V DC 3A, 30V DC
7.5A, 240V AC 3A, 120V AC
(resistive) 10A, 120V AC 3A, 120V AC
10A, 120V AC 3A, 240V AC
Contact Material Silver Silver-cadmium oxide Silver, gold-plated Silver, gold-flashed
Solid State Relays

RSS Series
Appearance
Page E-35
Contact Configuration 1 Form A (SPST-NO)
10, 25, 50, 75, 90A
Contact Rating 48V AC to 660V AC Output Ratings
Output Dual SCR (zero crossing)
Relays RU Series
RU Series — General Purpose Relays
Key features of the RU series include:

• Non-polarized LED indicator
• Solder-free construction (lead-free)
• No internal wires
• Mechanical flag indicator
• Manual latching lever with color coding for AC or DC coil
• Snap-on marking plate
• Cadmium-free contacts
• Contact rating 6A: 4PDT
10A: DPDT
RU2 RU4
AuSnOIn (silver tin oxide AuAg/Ag (gold-silver alloy
Contact Material indium) on silver) UL Recognized
Contact Resistance 50 mΩ maximum File No. E66043
Minimum 24VDC, 5mA (reference
Applicable Load value) E
Operating Time 20 msec maximum
Release Time 20 msec maximum
Maximum
Continuous Applied
110%
Voltage
(AC/DC) at 20°C
Minimum
Operating Voltage 80%
(AC/DC) at 20°C
Drop-Out Voltage
30%
(AC) at 20°C
Drop-Out Voltage Ordering Information
10%
(DC) at 20°C
Order standard voltages for fastest delivery. Allow extra delivery time
Specifications
Power Consumption 1.1-1.4VA (AC); 0.9-1.0W (DC)

for non-standard voltages.
Between contact and coil: Between contact and coil:
Between poles: Between poles: Basic Part No. Coil Voltage:
Dielectric Strength 2,500VAC, 1 minute 2,000VAC, 1 minute
Between contacts of the Between contacts of the RU4S – A110
same pole: same pole:
Frequency Response 1,800 operations/hr
Operating extremes:
10 to 55Hz,
Vibration Resistance Amplitude 1.0 mm p-p
Damage limits: 10 to 55Hz,
Amplitude 1.0 mm p-p
Operating extremes:
150 m/s2 (15G)
Shock Resistance Damage limits:
1,000 m/s2 (100G)
Mechanical:
AC: 20,000,000 operations
minimum
Life Expectancy DC: 30,000,000 operations
minimum
Electrical:
see electrical life curve
Degreee of Protection IP40
Operating Temperature -55 to +70°C (no freezing)
Weight 35g
Relays RU Series
Part Numbers
Part Numbers: RU Series with Options

Termination Contact Configuration Basic Part No.
DPDT RU2S
S: Solder/plugin
4PDT RU4S

Relays Panel Mount PC Mount
Rail Mount Rail Mount Part Number Use With
SY4S-02F1
SY4S-61
RU2 SM2S-05 SM2S-05C SY4S-51 SFA-101 use with SY4S-05, -05C & SM2S-05, -05C
SY4S-62 SFA-202
SFA-301
SY4S-61
RU4 SY4S-05 SY4S-05C SY4S-51 SFA-302 use with SY4S-51, -61
SY4S-62 SY4S-51F1
See Section F for details on sockets. All DIN rail mount
sockets shown above can be mounted using DIN rail BNDN1000.
E Ratings
Coil Ratings
24V 37.5mA – 164 Ω 60mA 1.8H 0.96H
AC 110-120V 8.4mA – 4,550 Ω 14mA 36H 22H
220-240V 4.2mA – 18,230Ω 7mA 144H 87H
12V 83.3mA 160 Ω
DC 24V 41.7mA 605 Ω N/A
110V 9.1mA 12, 100 Ω
Contact Ratings
Voltage Resistive Inductive
DPDT 10A 5A
30V DC
4PDT 6A 3A
DPDT 0.6A 0.3A
110V DC
4PDT 0.4A 0.2A
DPDT 10A 5A
120V AC
4PDT 6A 3A
DPDT 10A 5A
240V AC
4PDT 6A 3A
Relays RU Series
Internal Circuit
RU2
RU4

E
Dimensions
Relays RR Series
RR Series — General Purpose Power Relays
Key features of the RR series include:

• High reliability and long service life
• Available in octal (8- and 11-pin) or square (11-blade) base
• Options include check button for test operation, indicator light, and
side flange
• DIN rail, surface and panel type sockets available for a wide range of
mounting applications
Contact Material Silver

Contact Resistance 30mΩ maximum (initial value)
Minimum 24V DC/10mA, 5V DC/20mA
Applicable Load (reference value)
Operating Time 25ms maximum
Release Time 25ms maximum UL Recognized
CSA Certified
File Nos. E67770 File No. LR35144
Maximum Continuous
E Applied Voltage (AC/
DC) at 20°C
*
Minimum Operating
Voltage (AC/DC) at 20°C File No. BL951113332319*
* Pin Style Only * Pin Style Only
Drop-Out Voltage (does not apply to blade style)
(AC) at 20°C
Drop-Out Voltage
(DC) at 20°C
AC: approximately 3VA (50Hz), 2.5VA (60Hz)
Power Consumption DC: approximately 1.5W
100MΩ minimum
Insulation Resistance
Specifications
(measured with 500V DC megger) Ordering Information

Pin (RR2P, RR3PA)
Between live and dead parts: Order standard voltages for fastest delivery. Allow extra delivery time for
1,500V AC, 1 minute non-standard voltages.
1,500V AC, 1 minute
Between contact circuits: 1,500V AC,
1 minute (1,000V AC between NO-NC contacts) Basic Part No. Coil Voltage:
Blade (RR1BA, RR2BA, RR3B) RR3PA-U – AC120V

Dielectric Strength
Between live and dead parts:
2,000V AC, 1 minute
2,000V AC, 1 minute
Between contact circuits:
2,000V AC, 1 minute
Between contacts of same polarity:
1,000V AC, 1 minute
Frequency Response 1,800 operations/hour
Coil: 85°C maximum
Temperature Rise Contact: 65°C maximum
Vibration Resistance 0 to 6G (55Hz maximum)
Shock Resistance 100N (approximately 10G)
Electrical: over 500,000 operations
Life Expectancy (120V, 50/60Hz, 10A)
Mechanical: over 10,000,000 operations
Operating Temperature –30 to +70°C
RR2P: 90g, RR3P/RR3PA: 96g (approximately)
Weight RR1BA/RR2BA/RR3B: 82g (approximately)
Relays RR Series
Part Numbers
Part Numbers: RR Series with Options

Termination Contact Configuration Basic Part No. Indicator Light Check Button Light and Check Button Side Flange
P, PA DPDT RR2P-U RR2P-UL RR2P-UC RR2P-ULC —
(pin) 3PDT RR3PA-U RR3PA-UL RR3PA-UC RR3PA-ULC —
SPDT RR1BA-U RR1BA-UL RR1BA-UC RR1BA-ULC RR1BA-US
B, BA DPDT RR2BA-U RR2BA-UL RR2BA-UC RR2BA-ULC RR2BA-US
(blade)
3PDT RR3B-U RR3B-UL RR3B-UC RR3B-ULC RR3B-US
1. RR1BA, RR2BA, and RR3PA are U.S. standard terminal arrangements.

2. For diode option on DC coils please consult factory.
Ratings
Coil Ratings
6V 420mA 490mA 4.9Ω 720mA 0.04H 0.02H E
12V 210mA 245mA 18Ω 365mA 0.15H 0.08H
AC 24V 105mA 121mA 79Ω 182mA 0.57H 0.32H
120V 20.5mA 24mA 2100Ω 35mA 15H 8.2H
240V 10.5mA 12.1mA 8330Ω 18mA 57H 32H
6V 240mA 25Ω
12V 120mA 100Ω
DC 24V 60mA 400Ω N/A
48V 30mA 1600Ω
110V 13mA 8460Ω
Contact Ratings
Resistive Inductive Motor Load
Voltage Nominal UL CSA Nominal UL CSA UL
30V DC 10A 10A 10A 7.5A 7A 7.5A —
110V DC 0.5A — — 0.3A — 0.5A — Inductive load:
120V AC 10A 10A 10A 7.5A 7.5A 7.5A 1/4 hp cos ø = 0.3, L/R = 7ms.
240V AC 7.5A 10A 10A 5A 7A 7A 1/3 hp
Applicable Sockets

Relays Panel Mount
Rail Mount Rail Mount Part Numbers Use With
SR2P-05 SR2B-02F1 SR2P-05, -05C, -06
RR2P SR2P-05C SR2P-51
SR2P-06 SR3P-01F1 SR2P-51 See Section F for
details on sockets.
SR3P-05 SR3B-02F1 SR3P-05, -05C, -06
RR3PA SR3P-05C SR3P-51 All DIN rail mount
SR3P-06 SR3P-01F1 SR3P-51 sockets listed can be
RR1BA mounted using DIN
SR3B-05 rail BNDN1000.
RR2BA SR3B-05 — SR3B-51 SR3B-02F1 SR3B-51
RR3B
Relays RR Series
Internal Circuit
4 5 6
5 7
3 6 4 8
3 9
2 7
(-) (+) 2 10
(-) (+)
1 8 1 11
RR2P RR3PA
2 1 3 1 2 3
5 4 6 4 5 6
7 7 9 7 8 9
A B A B A B
(-) (+) (-) (+) (-) (+)
RR1BA RR2BA RR3B
E
AC 110V Resistive
DC 30V Resistive
1000 AC 220V Resistive 1000
AC 110V Inductive DC 30V Inductive

500 500
AC 220V Inductive
100 100
50 DC 100V Resistive
50
DC 100V Inductive
10 10
0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10
Load Current (A) Load Current (A)
Relays RR Series
Dimensions
8-Pin 11-Pin
RR2P RR3PA
Total length from panel surface including socket: Total length from panel surface including socket:
1.42" (36.4mm)
1.42" (36.4mm)
2.18" (56mm) or Less 1.14" (29.3mm) 2.18" (56mm) or Less 1.42" (36.4mm)
Blade Side Flange

RR1BA, RR2BA, RR3B RR1BA-US, RR2BA-US, RR3B-US
Total length from panel surface including socket: 2.94" (75.4mm)
(4.3mm)
SR3B-02: 2.87" (73.7mm) [3.0" (76.7mm) maximum] 0.187"
0.168"
1.09" (28mm) or less
0.64" (16.4mm)
SR3B-51: 2.21" (56.6mm) [2.36" (60.6mm) maximum] (4.8mm)
Ø 0.18" (4.6mm)
0.187" (4.8mm) 0.444"
(11.4mm)
2 Mounting Holes E
0.078" (2mm) x 0.117" (3mm) Ø 0.117" (3mm) 2.54" (65mm)
Terminal Hole 3 Terminal Holes
0.288" (7.4mm)
0.644" (16.5mm)
0.02" 2.54" (65mm)
1.42" (36.4mm)
(0.51mm)
0.02" (0.51mm)
1.44" (37mm)
0.288"
1.87" (48mm) or less (7.4mm) 1.42" (36.4mm)
Note: Dimensions in [ ] include hold-down spring.
1.44" (37mm)
UL-CSA VDE
SPARK QUENCHERS 125VAC, 250VAC
Fax Back Document #1202
Safety Agency : Standard File No.
XA SERIES
UL : UL-1414 E47474
O Small case size with superior CSA : CSA C22.2 No.0, No.1 LR37404/LR68886
performance VDE : VDE0565-1 10529-4670-1002
O PWB mounting
O Broad application in business XAB SERIES
equipment O Long insulated flexible wire leads
O ¼ watt non-inductive, high pulse O AC or DC applications
resistor O ¼ or ½ watt non-inductive, high pulse
resistor
ELECTRICAL SPECIFICATIONS Operating temp. range : -40 ~ + 85°C

Pulse condition (Max)
Peak Test
Safety Resistance Capacitance Peak to Pulse width (sec) Pulse voltage Insulation
Class Model No. Repetitive
Standard h ± 30% µF ± 20% Peak Pulse width x resistance
frequency Voltage JISC5102
(P-P) Frequency(Hz)
Line to Line to
120(60)Hz Line Line
XA120033 0.033 20msec.max 3(0.8)max 1200 Vrms 15,000Mh
max
50/60Hz min.
120(¼W)
700V 120(60)Hz 700V 2~5sec Line to
X2 XA1201 0.1 max 50msec.max max
3(0.8)max max Line to Case
Case 100,000Mh
XAB1201 0.1 50msec.max 120Hz max 3max 2000Vrms min.
50/60Hz (at 20°C
XAB1202 120(½W) 0.2 50msec.max 120Hz max 3max 60sec 500VDC)
2-14
MECHANICAL SPECIFICATIONS: XA Series
Case: Standoffs provided for improved cleanability
Leads: Tinned Copper Clad Steel,
SPARK QUENCHERS
Add “C6” suffix to p/n for 6mm lead length.
Other lead lengths available—consult factory.
XAB Series
MECHANICAL SPECIFICATIONS:

Leads: Tinned Copper Copper Wire
Polyvinylchloride (PVC) Insulation
*Other lead lengths available—consult factory.
MECHANICAL DIMENSIONS
Dimensions
Safety Resistance Capacitance
Class Model No.
Standard h ± 30% µF ± 20% L H T F
XA120033 0.033 17.0 14.0 7.0 15.0

XA1201 120(¼W) 0.1 20.0 16.5 8.5 17.5
X2
XAB1201 0.1 18.0 23.5 8.5 15.0
XAB1202 120(½W) 0.2 19.0 25.0 8.5 15.0
2-15
“NT”
LA NUOVA SERIE
SISTEMI DI CONTROLLO DELLA TEMPERATURA DI MACCHINE ELETTRICHE

SISTEMI DI CONTROLLO DELLA TEMPERATURA
DI MACCHINE ELETTRICHE
Una nuova serie di apparecchiature dalle A new series of units with revolutionary
caratteristiche rivoluzionarie, per presta- technical characteristics thanks to the
zioni, affidabilità e completezza, per la performances, reliability and complete
protezione termica di macchine elettri- program for the thermal protection of
che. electric units such as cast resin transfor-
Non più apparecchiature elettroniche mers, motors and electric generators.
dedicate, con caratteristiche tecniche No more protection relay dedicated, with
prefissate e non variabili, ma una serie di technical characteristics pre-fixed, but the
apparecchiature che si possono man basic unit can be set simply adding a DIN
mano configurare secondo le esigenze di rail box with the required function, which
comunicazione e controllo a distanza, dif- is foreseen for the remote communica-
ferenti. tion and control.
I Mod. NT935 ed NT538 possono avere The basic units Mod.NT935 and NT538
configurazioni multiple, ovvero possono may have multiple configurations; they
abbinare contemporaneamente l’uscita may have at the same time, a digital out-
analogica ed una doppia uscita a relè put ModBus RTU, or an analog output 4-
(per ogni canale controllato) e l’uscita 20 mA
ModBus RTU. for each individual channel (RTD Pt100),
Ciò permette al tecnico progettista del- and two relays (ALL1 and ALL2) for each
l’impianto di controllo ed automazione di individual channel.
disporre di tutti gli elementi per perfezio- The exceptional flexibility of the system
nare il sistema di controllo e protezione. gives to the engineer the maximum aid for
Un protocollo residente TecsyBus fa flui- the solution of all the remote protection
re, dalla centralina a tutte le apprecchia- and monitoring of the status of the units.
ture esterne, le informazioni atte a A proprietary protocol (TecsyBus) gives
comandare i differenti convertitori. all the digital informations to the external
Le funzioni di comunicazione o di auto- modules.
mazione possono essere abbinate alla All the functions can be added in a
centralina, anche in seguito alla sua second time, after the main unit installa-
installazione. tion.
NT-538

Ingressi: Inputs:
• da 1 a 8 ingressi per sonde RTD tipo Pt100/Ni100/Ni120 a tre fili • 1 to 8 inputs from RTD Pt100/Ni100/Ni120 sensors - 3 wires
• canali d'ingresso protetti contro i disturbi elettromagnetici • input channels protected against electromagnetic noises and spikes
• compensazione cavi per termoresistenze fino a 500 m (1 mm2) • sensors length cables compensation up to 500 m (1 mm2)
Uscite: Outputs:
• 2 relay di allarme (ALARM - TRIP) • 2 alarm relays (ALARM - TRIP)
• relay di guasto sonde o anomalia funzionamento (FAULT) • 1 alarm relay for sensor fault or working anomaly (FAULT)
• relay di uscita con contatti da 5A - 250 Vca res. • output contacts capacity: 5A - 250 Vac res.
• test dei relay di uscita • output relays test
• Contatto Aux (Fan) • auxiliary contact (Fan)
• programmazione di alarm e trip “fail safe” (N.C.) o no “fail safe” • fail-safe or non-fail-safe alarm and trip contacts programming
(N.O.)
Communication:
Comunicazione: • TecsyBus protocol for external modules
Tests and Performances:
Test e Prestazioni: • assembling in accordance with CE rules - cURus - RINA
• costruzione in accordo alle normative CE - cURus - RINA • dielectric strength: 2500 Vac for 1 minute from relays to sensors,
• rigidità dielettrica: 2500 Vca per 1 minuto tra relay di uscita e sonde, relays to power supply, power supply to sensors
relay e alimentazione, alimentazione e sonde • accuracy: ± 1% full scale, ± 1 digit
• precisione: ± 1% fs, ± 1 digit • ambient operating temperature: -20 °C to 60 °C
• temperatura di lavoro: da -20 °C a 60 °C • humidity: 90% non condensing
• umidità ammessa: 90% senza condensa • ABS self-extinguishing housing - NORYL 94V0
• contenitore in ABS autoestinguente - NORYL 94V0 • frontal in polycarbonate - IP54
• frontale in policarbonato - IP65 • burden: 4 VA
• assorbimento: 4 VA • data storage: 10 years minimum
• memoria dati: 10 anni minimo • digital linearity of sensors signal
• linearizzazione digitale segnale sonde • self-diagnostic circuit
• circuito di autodiagnosi
Dimensions:
Dimensioni: • 96x96 mm - DIN43700 - 130 mm deep (with rear terminals)
• 96x96 mm - DIN43700 - prof. 130 mm (compreso morsettiera) • panel cutout 92x92 mm
• foro pannello 92x92 mm
Displaying and Data management:
Visualizzazione e Gestione dati: • number of channels programmable from 1 to 8
• programmazione input collegati da 1 a 8 • 1 display 13 mm high with 3 digits for displaying temperatures
• 1 display da 13 mm a 3 cifre per visualizzazione temperature • 8 LEDs for displaying reference channel
• 8 LEDS per visualizzare il canale di riferimento • 4 LEDs indicating alarm, trip, fan or fault
• 4 LEDS indicanti allarme, trip, fan o fault • temperature monitoring from 0 °C to 240 °C
• controllo della temperatura da 0 °C a 240 °C • 2 independent alarm thresholds for each input
• 2 soglie di allarme indipendenti per ogni ingresso • sensors diagnostic (Fcc - Foc - Fcd)
• diagnostica delle sonde (Fcc - Foc - Fcd) • entering the programming by frontal push button
• accesso alla programmazione tramite pulsante frontale • wrong programming automatic display
• segnalazione di errata programmazione • programmed data call out
• richiamo dati impostati in fase di programmazione • possibility of setting manual channel scanning or hottest channel or
• selezione tra scansione manuale o canale più caldo o scansione auto- automatic scanning
matica • maximum temperatures storage and alarms memory
• memoria delle massime temperature raggiunte dai canali e memoria • frontal push button for alarm reset
degli allarmi
• tasto frontale per reset allarmi
TecsyBus
Power Supply
Tx Rx
24 VAC/DC
Out
ModBus RTU
Out
4/20 mA x 8
esterne di conversione.
Solo il modulo ModBus
RTU necessita di quat-
tro fili per la comunica-
zione Full-Duplex.

the external conversion
units.
Only the ModBus RTU
for the Full-Duplex
communication.
Out 16 relays
ALL 1 & ALL 2
Fault relay
NT-935

Ingressi: Inputs:
• 3 - 4 ingressi per sonde RTD Pt100/Ni100/Ni120 a tre fili • 3 - 4 inputs RTD Pt100/Ni1007Ni120 sensors - 3 wires
• canali d'ingresso protetti contro i disturbi elettromagnetici • input channels protected against electrical and magnetic noises and
• compensazione cavi per termoresistenze fino a 500 m (1 mm2) spikes
• sensors length cables compensation up to 500 m (1 mm2)
Uscite:
• 2 relay di allarme (ALARM - TRIP) Outputs:
• 2 relay di gestione ventilazione (FAN1 - FAN2) • 2 alarm relays (ALARM - TRIP)
• 1 relay di guasto sonde o anomalia funzionamento (FAULT) • 2 alarm relays for fan control (FAN1 - FAN2)
• relay di uscita con contatti da 5A - 250 Vca res. • 1 alarm relay for sensor fault or working anomaly (FAULT)
• test dei relay di uscita • analogue output 4-20 mA
• output contacts capacity: 5A - 250 Vac res.
Comunicazione: • output relays test
Communication:
Test e Prestazioni: • TecsyBus protocol for exsternal modules
• costruzione in accordo alle normative CE - cURus - RINA
• rigidità dielettrica: 2500 Vca per 1 minuto tra relay di uscita e sonde, Tests and Performances:
relay e alimentazione, alimentazione e sonde • assembling in accordance with CE rules - cURus - RINA
• precisione: ± 1% fs, ± 1 digit • dielectric strength: 2500 Vac for 1 minute from relays to sensors,
• temperatura di lavoro: da -20 °C a 60 °C relays to power supply, power supply to sensors
• umidità ammessa: 90% senza condensa • accuracy: ± 1% full scale, ± 1 digit
• contenitore in ABS autoestinguente - NORYL 94V0 • ambient operating temperature: -20°C to 60°C
• frontale in policarbonato - IP65 • humidity: 90% non condensing
• assorbimento: 4 VA • ABS self-extinguishing housing - NORYL 94V0
• memoria dati: 10 anni minimo • frontal in polycarbonate - IP65
• linearizzazione digitale segnale sonde • burden: 4 VA
• circuito di autodiagnosi • data storage: 10 years minimum
• digital linearity of sensors signal
• self-diagnostic circuit
Dimensioni:
• 96x96 mm - DIN43700 - prof. 130 mm (compreso morsettiera) Dimensions:
• foro pannello 92x92 mm • 96x96 mm - DIN43700 - 130 mm deep (with rear terminals)
• panel cutout 92x92 mm
Visualizzazione e Gestione dati:
• 1 display da 13 mm a 3 cifre per visualizzazione temperature Displaying and Data management:
• 4 LEDS per visualizzare il canale di riferimento • 1 display 13 mm high with 3 digits for displaying temperatures
• 4 LEDS indicanti allarme, trip, fan o fault • 4 LEDS for displaying reference channel
• controllo della temperatura da 0 °C a 240 °C • 4 LEDS indicating alarm, trip, fan or fault
• 2 soglie di allarme per Ch 1-2-3 e 2 per Ch 4 • temperature monitoring from 0 °C to 240 °C
• controllo ON-OFF ventilazione • 2 alarm thresholds for Ch 1-2-3 and 2 for Ch 4
• diagnostica delle sonde (Fcc - Foc - Fcd) • ON-OFF for fan control
• accesso alla programmazione tramite pulsante frontale • sensors diagnostic (Fcc - Foc - Fcd)
• segnalazione di errata programmazione • entering the programming by frontal push button
• richiamo dati impostati in fase di programmazione • wrong programming automatic display
• selezione tra scansione manuale o canale più caldo o scansione auto- • programmed data call out
matica • possibility of setting manual channel scanning or hottest channel or
• memoria delle massime temperature raggiunte dai canali e memoria automatic scanning
degli allarmi • maximum temperatures and alarms storage
• tasto frontale per il RESET degli allarmi • frontal alarm RESET push button
TecsyBus
Power Supply
Tx Rx
24 VAC/DC
Out
ModBus RTU
Out
4/20 mA x 4
esterne di conversio-
ne. Solo il modulo
ModBus RTU necessi-
ta di quattro fili per la
comunicazione Full-
Duplex.

the external conver-
sion units.
Only the ModBus RTU
for the Full-Duplex
communication.
Out 8 relays
ALL 1 & ALL 2
Fault relay
INTRODUZIONE - Introduction
Una nuova serie di apparecchiature dalle caratteristiche A new series of units with revolutionary technical charac-
rivoluzionarie, per prestazioni, affidabilità e completezza, teristics thanks to the performances, reliability and com-
per la protezione termica di macchine elettriche. plete program for the thermal protection of electric units
Non più apparecchiature elettroniche dedicate, con such as cast resin transformers, motors and electric
caratteristiche tecniche prefissate e non variabili, ma una generators.
No more protection relay dedicated, with technical cha-
serie di apparecchiature che si possono man mano con-
racteristics pre-fixed, but the basic unit can be set simply
figurare secondo le esigenze di comunicazione e control-
adding a DIN rail box with the required function, which is
lo a distanza, differenti. foreseen for the remote communication and control.
I Mod. NT935 ed NT538 possono avere configurazioni The basic units Mod.NT935 and NT538 may have multi-
multiple, ovvero possono abbinare contemporaneamente ple configurations; they may have at the same time, a
l’uscita analogica ed una doppia uscita a relè (per ogni digital output ModBus RTU, or an analog output 4-20 mA
canale controllato) e l’uscita ModBus RTU. for each individual channel (RTD Pt100), and two relays
Ciò permette al tecnico progettista dell’impianto di con- (ALL1 and ALL2) for each individual channel.
trollo ed automazione di disporre di tutti gli elementi per The exceptional flexibility of the system gives to the engi-
perfezionare il sistema di controllo e protezione. neer the maximum aid for the solution of all the remote
Un protocollo residente TecsyBus fa fluire, dalla centrali- protection and monitoring of the status of the units.
na a tutte le apprecchiature esterne, le informazioni atte A proprietary protocol (TecsyBus) gives all the digital
informations to the external modules.
a comandare i differenti convertitori.
All the functions can be added in a second time, after the
Le funzioni di comunicazione o di automazione possono
main unit installation.
essere abbinate alla centralina, anche in seguito alla sua
installazione.
CONVERTITORE DI SEGNALE ANALOGICO - Analog signal converter

Atto a fornire 4 uscite 4-20 mA (Mod.4A) oppure 8 uscite
4-20 mA (Mod.8A), funzione della temperatura rilevata
dalle sonde RTD.
Range 4-20 mA : da 0 a 240 °C (0-200 °C a richiesta)
Ingresso a due fili da NT935 e NT538
Assorbimento: 3 W per Mod.4A - 5 W per Mod.8A
Montaggio su barra DIN 50022
Colore: RAL 7035
4 outputs 4-20 mA (Mod.4A) or 8 outputs 4-20 mA (Mod.8A)

function of the temperature detected by the RTD sensors.
Range 4-20 mA: from 0 to 240°C (0 – 200°C on request)
Input: two wires from units NT935 or NT538
Dimensions: 106x90x58 mm
Color: RAL 7035
BUSMOD 8A
Convertitore di segnale digitale da protocollo TecsyBus a ModBus
RTU.
Alimentazione 24 VCA-CC
Consumo: 2 W
Dimensioni: 71x90x58 mm
Colore: RAL 7035
Digital signal converter from protocol TecsyBus to ModBus RTU.

Power supply: 24 VAC-DC
Burden: 2 W
Dimentions: 71x90x58 mm
Color: RAL 7035
UNITA’ PER ESTENSIONE DEI RELE’ DI SEGNALAZIONE - Multiple relay unit

Ingresso a due fili da NT935 o da NT538
Ogni ingresso sonda avrà due relè di segnalazione (ALL-TRIP)
Relè di Fault per la segnalazione di guasto (mancanza seriale- fault di alimentazione – guasto sonde)
Montaggio su barra DIN EN 50022
Consumo: 4 W (versione 4A) 7W (versione 8A)
Materiale del corpo: elementi laterali in poliammide UL 94V-0
Supporto profilato: PVC autoestinguente
Colore : verde
Input with two wires from NT935 and NT538

Each individual input shall have two alarm relays (ALL1 and
ALL2)
Fault relay for off-serial communication / off power supply / faulty
sensors
Dimensions: 182 x 127 x99 mm
Box material
Lateral Elements: Polyamides 6.6 UL94V0
Support section: PVC self-extinguishing
Color: green
http://www.tecsystem.it
Via C. Colombo, 5/C - 20094 CORSICO (MI) Italy - Tel. +39 / 02.45.81.861 (3 linee r.a.) - Fax +39 / 02.48.60.07.83
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 31
SECTION 9. RECOMMENDED SPARE PARTS
Recommended Spare Parts for 660A GenIIIe

Qty Description P/N
1 VFD Power Cell A1A31000082.660
15 Door Filter A1A094816
1 Pentium CPU board A1A363658.00M
1 Mother board A1A363628.00M
1 Analog I/O board board A1A10000423.00M
1 Signal conditioning board A1A10000403.01M
1 NXG Microprocessor Board A1A363818.00M
1 Modulator board A1A10000225.00M
1 Keypad A1A460A68.23
1 Power supply [DCR] A1A091652
1 Power supply [Wago] A1A090103
1 Power supply [Hall effects] A1A094888
1 Case for power supply A1A094889
1 Wago - Analog in A1A091113
1 Wago - Analog out A1A091539
1 Wago - Digital in A1A091537
1 Wago - Relay out A1A092363
1 Wago - Field bus coupler A1A091143
1 Fuse, 12A, 600V A1A095390
1 Fuse, 2A, 600V A1A090715
1 Fuse, 10A, 600V A1A084918
6 Fuse, 8A, 600V A1A089149
1 Blower, 28.1” AC Impeller A1A091386
1 Blower, 25 AC Impeller A1A095260
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 32
Recommended Spare Parts for 140A GenIV

Qty Description P/N
1 1000V, 1A Fuse A1A 092604
4 1000V, 250A Fuse A1A 099720
2 Door Filter A1A 097565
6 Door Filter A1A 099615
1 SBC & Keypad Adapter A1A 10000623.00M
1 System I/O Board A1A 10000423.00M
1 BGA Modulator A1A 10000350.00M
1 Comm. Board A1A 363818.00M
1 Signal Cond. Board A1A 10000403.01M
1 I/O Breakout Board A1A 10000126.00M
4 NXGII Power Supply A1A 14000461.00
2 Keypad A1A 460A68.23
1 Cell Lifter A1A 163496.08
1 Fuse, 8A, 600V A1A081100
4 Fuse, 8A, 600V (blowers) A1A 089149
2 Fuse, 6A, 600V A1A081099
4 Fuse, 3A, 600V A1A080752
1 Blower, 6,538 CFM A1A098200
1 Fiber Optic Link, 2.9M A1A 10000614.00
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 33
Recommended Spare Parts for 260A GenIV

Qty Description P/N
1 1000V, 1A Fuse A1A092604
4 1000V, 500A Fuse A1A0100505
3 Door Filter A1A11006180.01M
6 Door Filter A1A11006180.00M
1 SBC & Keypad Adapter A1A10000623.00M
1 System I/O Board A1A10000423.00M
1 BGA Modulator A1A10000350.00M
1 Comm. Board A1A363818.00M
1 Signal Cond. Board A1A10000403.01M
1 I/O Breakout Board A1A10000126.00M
4 NXGII Power Supply A1A14000461.00
2 Keypad A1A460A68.23
1 Fuse, 8A, 600V A1A081100
4 Fuse, 8A, 600V (blowers) A1A089149
2 Fuse, 6A, 600V A1A081099
4 Fuse, 3A, 600V A1A080752
1 Blower, 9,594 CFM A1A0100118
1 Fiber Optic Link, 2.9M A5E01437712
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 34
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 35
SECTION 10. QUALITY CONTROL PLAN
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 36
QUALITY CONTROL PLAN Template Revised 03/06/06
MV DRIVES Page 1 of 7
TITLE: ENTER PROJECT NAME DOCUMENT # SO # - QCP
PLANT: SIEMENS LD R – NEW KENSINGTON, PA U.S.A.
CLIENT: ENTER CUSTOMER NAME SALES ORDER: ENTER S/O #
CONTACTS:
PROJECT MANAGEMENT: Mr. / Ms. ENTER NAME

ENGINEERING: Mr. / Ms. ENTER NAME
SALES: Mr. / Ms. ENTER NAME
QUALITY: Mr. / Ms. ENTER NAME
DISTRIBUTION: ENTER NAME
REV. DESCRIPTION OF CHANGE ORIGINATOR DATE

00 Quality Control Plan ENTER NAME ENTER DATE
Template Revised 03/06/06
QUALITY CONTROL PLAN
MV DRIVES Sales Order: ENTER SO#
Revision : 00
SITE INSPECTION AUTHORITY Page 2 of 7

(A, S, O) DATE
ITEM ACTIVITY DOCUMENTS 1 2 3 4 APPROVED
RECORDS REMARKS
EVALUATION AND
PREPARATION TO MEET
CUSTOMER REQUIREMENTS.
1.0 Contract Review SAI-002 (*) A R SAF-004
SAI-003 (*)
CCI-003 (*)
2.0 Kick-off Meeting Organizational understanding of A R Meeting Minutes
Customer Requirements.
3.0 Drawing Review TSI-106 (*) A R Meeting Minutes
INSPECTION CODES
H – Mandatory Hold Point (production stopped W – Witness Test (proceed if witness not D Documentation Approval Required by
until requirements are met) present at designated time) Client (Production not stopped)
N – Notification Point to Client ( production will R – Internal Review of Documentation C Copy of Documentation Provided to
SITE
not be stopped) Client
INSPECTION AUTHORITY CODES A Siemens LD R (P)

2 TBD 4 TBD S Subcontractor
1 Siemens LD R (P) 3 TBD O Other Site(s), as required
Revision : 00

(A, S, O) DATE
RECORDS REMARKS
ACCEPTANCE TESTS OF MAIN

COMPONENTS AND SUB-
ASSEMBLIES
4.0 Incoming Inspection (Visual) QSI-001 (*). A Inspection
Database
4.1 • PCBA's QSI-001 (*) 4.6 “ A R Inspection
Supplier Inspection/Test Rept. Database
4.2 • Cabinets QSI-001 (*) 4.7 “ A R Inspection
Database
4.3 • Transformers QSI-001 (*) 4.8 “ A R Inspection
Supplier Inspection/Test Rept. Database
Applicable drawings & specs.
4.4 • Miscellaneous Parts QSI-001 (*) 4.9 “ A R Inspection
Database
5.0 Environmental Stress Screening of TSI-103 (*) ESS Database

PCBA’s.
5.1 • Elevated Temperature TSI-103 (*) 4.3 A R ESS Database
5.2 • Power cycling TSI-103 (*) 4.3 A R ESS Database
INSPECTION CODES
SITE

Revision : 00

(A, S, O) DATE
RECORDS REMARKS
6.0 Cell Test TSI-062 (*) A Cell Test Database

6.1 • Cell Inspection/Ohm Check TSI-062 (*) 5.5 A R Cell Test Database
6.2 • HiPot Test TSI-062 (*) 5.6 A R Cell Test Database
6.3 • Automated Tests TSI-062 (*) 5.7 A R Cell Test Database
6.4 • Rectifier Test TSI-062 (*) 5.7.2 A R Cell Test Database
6.5 • Preliminary Cell Test TSI-062 (*) 5.7.3 A R Cell Test Database
6.6 • Bypass Test TSI-062 (*) 5.7.4 A R Cell Test Database
6.7 • Thermister Burn-in Test TSI-062 (*) 5.7.5 A R Cell Test Database
6.8 • Start Burn-in Test TSI-062 (*) 5.7.6 A R Cell Test Database
6.9 • End Burn-in Test TSI-062 (*) 5.7.7 A R Cell Test Database
6.10 • Diagnostic Display TSI-062 (*) 5.7.8 A R Cell Test Database
INSPECTION CODES
SITE

Revision : 00

(A, S, O) DATE
RECORDS REMARKS
SYSTEM LEVEL VFD TEST AND Drawings:

INSPECTION ENTER DWG. #’s
7.0 Inspection & Test QSI-008 (*)
7.1 • Chassis, Panel & Cell Assembly QSI-008 (*) 4.5 A R TSF-051
Inspection
7.2 • System Assembly Self-Inspect QSI-008 (*) 4.7.1 A R TSF-051
7.3 • Final Systems Test QSI-008 (*) 4.8.1 A R Factory
TSI-061 Acceptance Test
Plan (FAT)
7.3.1 • Test Inspection TSI-061 (*) 4.3 A R FAT, TSF-055
7.3.1.1 • H/W torque/marks TSI-061 (*) 4.3.1 A R FAT, TSF-055
7.3.1.2 • Correct parts TSI-061 (*) 4.3.2 A R FAT, TSF-055
Per drawing
7.3.1.3 • Wire check Point–to-point TSI-061 (*) 4.3.3 A R FAT, TSF-055
Per drawing
7.3.1.4 • Fiber Optic Check TSI-061 (*) 4.3.4 A R FAT, TSF-055
7.3.1.5 • Check Grd. wires TSI-061 (*) 4.3.5 A R FAT, TSF-055
7.3.1.6 • Burden Resistor values TSI-061 (*) 4.3.6 A R FAT, TSF-055
7.3.2 • Program & Install Flash Memory TSI-061 (*) 4.4 A R
7.3.3 • Hi-pot Test TSI-061 (*) 4.5 A R FAT, TSF-055
QSF-033
7.3.4 • System Tests on Motor TSI-061 (*) 4.8 A R FAT, TSF-055
7.3.4.1 • Hall Effect Transducers TSI-061 (*) 4.8. A R FAT, TSF-055
7.3.4.2 • Output Filter, per FAT TSI-061 (*) 4.8 A R FAT, TSF-055
7.3.4.3 • Verify Open Loop Control, per TSI-061 (*) 4.8 A R FAT, TSF-055
FAT
INSPECTION CODES
SITE

Revision : 00

(A, S, O) DATE
RECORDS REMARKS
7.3.4.4 • Verify Pwr. Factor & Drive TSI-061 (*) 4.8 A R FAT, TSF-055
Efficiency
7.3.4.5 • Verify Fast Bypass, if required TSI-061 (*) 4.8 A R FAT, TSF-055
per FAT
7.3.4.6 • E-Stop , Local and Remote TSI-061 (*) 4.8 A R FAT, TSF-055
7.3.4.7 • Verify all door controls and TSI-061 (*) 4.8 A R FAT, TSF-055
indications.
7.3.4.8 • Verify blower operation TSI-061 (*) 4.8 A R FAT, TSF-055
7.3.4.9 • Verify drive starting per dwg. TSI-061 (*) 4.8 A R FAT, TSF-055
& SOP
7.3.4.10 • Verify Proper WAGO TSI-061 (*) 4.8 A R FAT, TSF-055
Function, per FAT
7.3.4.11 • Verify all other features and TSI-061 (*) 4.8 A R FAT, TSF-055
options not previously tested
7.3.4.12 • Perform Synchronous TSI-061 (*) 4.8 A R FAT, TSF-055
Transfer, per FAT TSI-060 (*)
7.3.4.13 • Verify & Name SOP TSI-061 (*) 4.8 A R FAT, TSF-055
7.3.5 • System Load Test TSI-061 (*) 4.8 A R FAT, TSF-055
TSI-060 (*)
7.3.6 • Synchronous Motor Testing, if TSI-061 (*) 4.10 A R FAT, TSF-055
required per FAT
7.3.6.1 • Tune 3PCI Regulator TSI-061 (*) 4.10 A R FAT, TSF-055
7.3.6.2 • Verify 3PCI Output Contactor TSI-061 (*) 4.10 A R FAT, TSF-055
7.3.6.3 • Verify WAGO – 3PCI TSI-061 (*) 4.10 A R FAT, TSF-055
Connection
7.3.6.4 • Enter Sync. Motor Parameters TSI-061 (*) 4.10 A R FAT, TSF-055
INSPECTION CODES
SITE

Revision : 00

(A, S, O) DATE
RECORDS REMARKS
7.3.6.5 • Load Test Drive on Sync. TSI-061 (*) 4.10 A R FAT, TSF-055
Motor
7.3.6.6 • Verify Fast Bypass Contactor, TSI-061 (*) 4.10 A R FAT, TSF-055
per FAT
7.3.7 Engineering and Tech Approval of FAT Factory Acceptance Test (FAT) Plan A R,H FAT
8.0 Witness Test TSI-055 (*) 4.1 A W Required = Yes / No ?
9.0 Final Inspection QSI-008 (*) 4.10.1 A H QSF-011, 3rd PART CERT
QSF-031 REQUIRED?
10.0 Packaging Appropriate SRI series packaging A R

instruction
Project Reference Documents:
Document Identification Number Document Title

Enter Document Identification or Spec. Number Enter Document Title or Name
INSPECTION CODES
SITE

Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 37
SECTION 11. PRELIMINARY AIR COOLED TEST PLAN
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 38
500 Hunt Valley Drive
New Kensington, PA 15068
FACTORY ACCEPTANCE TEST

MEDIUM VOLTAGE
AIR COOLED
FAT- GEN III/E
COMPANY NAME
APPLIED Engineering
DATE:
REVISION:
Template Revision K Page 1 of 7

Customer Name SO Eng Required to Fill In
P/N S/N SOP# Eng Required to Fill In
Agency Listing CSA UL CE No Listing
Agency Testing Required Yes No
HP Rating: XFMR KVA:

Input Voltage: Output Voltage:
Cell Size: Total # of Cells:
Table of Contents
I. Test Plan - Contains the actual test plan with reference to associated test procedures and forms for
data collection.
II. Completed Forms - Contains the forms used to collect associated test data using the procedures.
III. Analysis/Plots Data - If applicable, this section contains any analysis or additional test data supplied
with buy out items or data specific to a customer order and not specifically
required by the FAT.
Revision History
Revision Level Details Date

Siemens Energy & Automation, Inc. Air Cooled Test Plan
Customer Name
SO P/N S/N
Test Type Parameter Test Procedure Test Criteria (Eng) Test Data
Std. Visual Inspection Hardware Check Emp#:
Labels, Warnings and Safety aspects Emp#:
Pt. To Pt. Wire check Emp#:
Fiber optics Emp#:
Ground wires Emp#:
Burden Resistor Value (hall effect) Eng. Spec. Ω
Set Dip switch (FR) Pos. 2 only is “On”, all
others “Off” Emp#:
Set Dip switch (P) Pos. 4 & 5 only are
“On”, all others “Off” Emp#:
Set Address 1X 1X=1 Emp#:
Set Address 10X 10X=0 Emp#:
Std. Hipot TSI-061 Applied Voltage Record Leakage

Power circuit to GND Eng. Spec. Emp#:
L1, L2, L3, to GND Eng. Spec.
L1 with L2, L3, to GND Eng. Spec.
L2 with L1, L3 to GND Eng. Spec.
T1, T2, T3, to GND Eng. Spec.
T1 with T2, T3, to GND Eng. Spec.
T2 with T1, T3 to GND Eng. Spec.
Control Power to GND Eng. Spec. Emp#:
120 to GND Eng. Spec. Emp#:
Logic to GND Eng. Spec. Emp#:
Std. Initial Power Up Control Power Supply

V2 to COM +12Vdc (11.64 to 12.36Vdc) Vdc
V3 to COM –12Vdc (-11.64 to -12.36Vdc) Vdc
V1 to COM +5Vdc (4.90 to 5.10Vdc) Vdc
V4 to RET –5Vdc (-4.85 to –5.15Vdc) Vdc
T5 (Secondary) 110Vac to 130Vac Vac
Software Version # Eng. Spec. Emp#:
Establish Wago Communications Emp#:
Enter Input Attenuator Sum (3045) Emp#:
Enter Output Attenuator Sum (3455) Emp#:
Set correct # of
Analog Outputs (2810) Eng. Spec.
Analog Inputs (2820) Eng. Spec.
Digital Inputs (2830) Eng. Spec.
Digital Outputs (2840) Eng. Spec.
Set correct Drive Parameters Emp#:
Input Voltage (2010) Eng. Spec.
Input Current (2020) Eng. Spec.
Output Voltage (2030) Eng. Spec.
Output Current (2040) (Should be “Cell Rating”) Eng. Spec.
Control Loop Type (2050) OLTM
Spinning Load Mode (2430) Off
Installed Cells/Phase (2530) Eng. Spec.
Set Min Cells/Phase (2540) to match Installed Cells/Phase
Cell Voltage (2550) Eng. Spec.
Bypass Type (2590) Eng. Spec.
Neutral Connection (2630) Eng. Spec.
Input CT ratio (3035) Eng. Spec.
Low Freq WO (3070) (12.566 or 37.859) Eng. Spec.
Tap Setting (+5% typical) (7050) Eng. Spec.
Program Clock (8080) Emp#:
Program SO (8100) Eng. Spec. Emp#:
Program Drive Number (8110) Eng. Spec. Emp#:
Download SOP Eng. Spec. Emp#: PC#

Customer Name
SO P/N S/N
Initial Power Up Set correct Drive Parameters (con’t)
(con’t)
Set Speed Profile
Accel Time 1 (2270) 30 sec Emp#:
Decel Time 1 (2280) 30 sec Emp#:
Test Upload & Download thru RS232 port Emp#:
Ethernet Connection Verified Emp#:
Optional Electrical Door (“Test Criteria” Must be specified and filled in by the Eng. Spec. Emp#:
Interlocks Engineer)
Optional Space Heaters (“Test Criteria” Must be specified and filled in by the Eng. Spec. Emp#:
Engineer)
Std. Backfeed Modulation TSI-061
& Clipping Power Supply & Hall Effect Pwr Supply Fault Emp#:
Output Transorbs Approx. 56Vp-p Emp#:
Note: Backfeed Cell B1

Disconnect plug P10 from MV Bypass Control Board
Input Transorbs Approx. 56Vp-p Emp#:

Verify all Cells Primary V. ±10% of Variac
voltage Emp#:
Modulation of Cells (0 to 100% demand) Emp#:
MV Bypass Board Measure on plug pins 1 & 2 Approx. 36Vac± Emp#:
Power Supply Measure on plug pins 3 & 4 Approx. 76Vdc± Emp#:
Checks (P/N
363549.00)
Std. Medium Voltage With Cell Series Links Installed
Testing VMA, VMB, VMC = ½ * (Motor Voltage Emp#:
Rating/Drive Voltage
Rating) * 6.6v peak @
30Hz
VMA, VMB, VMC = (Motor Voltage Emp#:
60Hz
Set Control Loop Type OLVC
With Motor Connected to the Drive Output IMA Leads VMA by Emp#:
90°
IMB Leads VMB by Emp#:
90°
IMC Leads VMC by Emp#:
90°
Std. System Testing on

Motor
Check E-stop Logic Depress Local E-Stop
Verify VFD coasts to stop Emp#:
Measure on TB2-1 & 2 Open for E-stop Emp#:
Verify Fault contact on TB2-23 & 24 changes state Eng. Spec. for Fault Emp#:
Verify Run contact on TB2-15 & 16 changes state Eng. Spec. for Run Emp#:
Remove Jumper on TB2-9 & 10 – Remote E-Stop
Std. Transformer Remove alarm wire from Wago digital input O1G and Verify alarm Emp#:
Thermal Switches verify fault light blinks and keypad displays alarm message
message
Remove trip wire from Wago digital input O1H and verify Verify trip message Emp#:
VFD faults, VFD coasts to a stop and keypad displays Verify VFD Fault Emp#:
trip message

Customer Name
SO P/N S/N
Std. Remote Start/Stop Momentarily Close contact between TB2-3 & 4 & verify Drive is running Emp#:
VFD starts running
Momentarily Open contacts between TB2-5 & 6 Drive ramps to stop Emp#:
Std. Remote Fault Reset Cause system fault and check Drive Ready contact TB2- Eng. Spec. on Fault Emp#:
13 & 14 (changes state)
Momentarily close Remote Fault Reset contact on TB2-7 Drive should reset Emp#:
&8
Verify Drive Ready contact on TB2-13 & 14 changes Eng. Spec. for
Emp#:
state Ready
Std. Local Remote Place drive in local mode by turning switch to local
Select position
Verify speed demand and local at VFD on TB2-11 & 12 Eng. Spec. when
Emp#:
VFD runs
Std. 4 to 20mA Remote Place drive in remote mode and connect 4-20mA signal Verify system
Speed Command to TB2-ELV-59 & 60 speed change
Scale 4-20mA signal to be proportional to 0-100% speed 4ma=0% speed
20mA=100% speed Emp#:
Std. 4 to 20mA Spare Program Spare Input as Remote Speed command via 4ma=0% speed
Input Keypad menu and connect 4-20mA signal to TB2-ELV- 20mA=100% speed Emp#:
62 & 63
RE-PROGRAM REMOTE SPEED INPUT TO ANALOG1! Emp#:
Std. 4 to 20mA Motor Monitor current output on TB2-ELV-53 & 54 and Verify 4ma=0% speed
Speed Output output 20mA=100% speed Emp#:
4 to 20mA Spare Program analog output as Motor Speed and monitor 4ma=0% speed
Output output on TB2-ELV-56 & 57 20mA=100% speed Emp#:
Std. Blower 1 Operation With Blower running trip blower motor with TOL
Transformer Cabinet Verify VFD faults and display reads “Blower 1 Failed” VFD coasts to stop Emp#:
Blower 2 Operation With Blower running trip blower motor with TOL
Cell Cabinet Verify VFD faults and display reads “Blower 2 Failed” VFD coasts to stop Emp#:
Std. Spinning Load 1. Enable spinning load feature (Set Spinning Load
Mode true) via keypad
2. Run VFD at 100% speed
3. Trip VFD by pressing E-stop
4. Pull out E-stop
5. Push Fault Reset
6. Restart VFD
7. Verify VFD goes back to full speed Motor returns to full Emp#:
speed
Optional Cell Bypass Option

With Bypass 1. Enable Bypass operations by setting Bypass Enable
Enabled parameter to true
2. Remove Fiber Optic cable from Cell A1 from the DCR
3. Verify Bypass Contactor is Closed by measuring from T1 of <50mV Emp#:
previous cell to T1 of Cell A1
4. Remove Fiber Optic cable from Cell B1 from the DCR
previous cell to T1 of Cell B1
6. Remove Fiber Optic cable from Cell C1 from the DCR
previous cell to T1 of Cell C1
8. Reconnect all Fiber Optic Cables and enable “Reset
Bypass Cells”
9. Repeat steps 1-8 for remaining columns of cells All contactors <50mV Emp#:

Customer Name
SO P/N S/N
Std. MODBUS Connect computer to MODBUS port
Open MODBUS program and verify communication Receiving data from Emp#:
VFD
Std. Logic Check Complete Eng Initial & Date

SOP Changes After Sign Off Yes No (Circle One)
If Yes, Name & Date of New SOP
Retest Required Yes No (Circle One)
SOP Changes Approved Eng Initial & Date
Optional Precharge Test Verify Precharge circuit per TSI-061 (“Test Criteria” Must Eng. Spec. Emp#:
Procedure be specified and filled in by the Engineer)
Std. System Load Test Run Load Test using Dyno Load
(Only one test needs to Run at Eng. Spec. amps (full load input current) 4 hrs or Stabilize Emp#:
be performed, choose Run Load Test using Motorless Dyno Load
the appropriate one. Setup and run per TSI-122
Then delete this
statement as well as the
Run at Eng. Spec. amps (full load input current) 4 hrs or Stabilize Emp#:
redundant test)
Std. Motor Overload Adjust motor parameters [Menu 1000] and overload Emp#:
Protection settings [Menu 1120] to verify overload operates after
‘Constant’ 60 seconds.
Std. Non-latching Run 1. Remove Medium Voltage Power Eng. Spec. Emp#:
Request with No 2. Reboot NXG Control
Medium Voltage Input 3. Clear/Reset all faults on drive
4. Monitor SOP RunRequest flag via debugger
5. Verify that SOP RunRequest flag remains false
when all start inputs are set.
Cust. Special I/O Must be specified and filled in by the Engineer
Spec # “PLC Battery present as required.” Emp#:
Cust. Efficiency Testing Run VFD at following speed points:

Spec #
100 %Speed 100% Load Eng. Spec.% TSF-056
100 %Speed 50% Load Eng. Spec.% TSF-056
Cust. Harmonic Testing Run VFD at 100% speed and 100% load THD Eng. Spec.%
Spec # Voltage Emp#:
THD Eng. Spec.%
Current Emp#:
Optional Interlocks Record all Interlock model #’s and keycode #’s for the Eng. Spec. Emp#:
drive
Verify correct operation of Interlocks Emp#:
Ensure hardware and adapter plates are supplied Emp#:
(“Test Criteria” Must be specified and filled in by the Eng. Spec.
Engineer)
Std. Save Parameter, Save files under the Project Files Folder Parameter Upload Emp#:
Fault and Event Logs (Level 7)
Std. Flash Card Cleanup All Test versions of SOP & Hex files have been removed Emp#:
from Flash
No Wago SOP & Hex is on Flash Emp#:
Final SOP is on Flash and correct Hex file is selected Emp#:
Clear Fault and Event Logs Emp#:

Customer Name
SO P/N S/N
Record Hipoter Used

Model Manufacturer ID# Cal. By Cal. Due
Record Voltmeter Used

Oscilloscope

Clamp on C.T.
Tested By: Date:

Approved for Shipment: Date:

FACTORY ACCEPTANCE TEST

MEDIUM VOLTAGE
AIR COOLED
FAT- GEN IV
COMPANY NAME
APPLIED Engineering
DATE:
REVISION:
Template Revision C Page 1 of 8

Customer Name Eng Required to Fill In SO Eng Required to Fill In
P/N Base P/N - No Dash S/N SOP# Eng Required to Fill In
Agency Listing CSA UL CE No Listing
Agency Testing Required Yes No
HP Rating: XFMR KVA:

Input Voltage: Output Voltage:
Cell Size: Total # of Cells:
Table of Contents
I. Test Plan - Contains the actual test plan with reference to associated test procedures and forms for
data collection.
II. Completed Forms - Contains the forms used to collect associated test data using the procedures.
III. Analysis/Plots Data - If applicable, this section contains any analysis or additional test data supplied
with buy out items or data specific to a customer order and not specifically
required by the FAT.
Revision History
Revision Level Details Date

Customer Name
SO P/N S/N
Std. Visual Inspection Hardware Check Emp#:
Visual Inspection Labels, Warnings and Safety aspects Emp#:
Metering Pt. To Pt. Wire check Emp#:
Visual Fiber optics Emp#:
Visual Ground wires Emp#:
Metering Burden Resistor Value (hall effect – HEB1, HEC1) Eng. Spec.Ω Ω
Metering Input/Output attenuator resistor Value (IATTA-OATTC) Eng. Spec.Ω Ω
Optional (only with WAGO) Set Dip switch (FR) Pos. 2 only is “On”, all
others “Off” Emp#:
Optional (only with WAGO) Set Dip switch (P) Pos. 4 & 5 only are
“On”, all others “Off” Emp#:
Optional (only with WAGO) Set Address 1X 1X=1 Emp#:
Optional (only with WAGO) Set Address 10X 10X=0 Emp#:
Std. Hipot TSI-061 Applied Voltage Record Leakage

Power circuit to GND Emp#:
L1, L2, L3, to GND Eng. Spec.
L1 with L2, L3, to GND Eng. Spec.
T1, T2, T3, to GND Eng. Spec.
T1 with T2, T3, to GND Eng. Spec.
Eng. Spec.V Control Power to Eng. Spec. Emp#:
GND
120V Control Power to GND 1750 VDC Emp#:
Logic Circuits to GND 500 VDC Emp#:
Std. Control Power Control and Control Transformer Power Supplies

Metering CPS, +5 VDC (Slot 6 I/O Board Plug P6 Pin 1 to 4) +4.85 to +5.15 V Vdc
Metering CPS, +12 VDC (Slot 6 I/O Board Plug P6 Pin 2 to 4) +11.4 to +12.6V Vdc
Metering CPS, -12 VDC (Slot 6 I/O Board Plug P6 Pin 3 to 4) -11.4 to -12.6V Vdc
Metering CPS, +/- 15 VDC (at HEB1 + to – device terminals) 28.5 to 31.5 V diff Vdc
Metering CPS, +/- 15 VDC (at HEC1 + to – device terminals) 28.5 to 31.5 V diff Vdc
Metering CPS, + 24 VDC (IOB board J11-11 to J11-9) +21.6 to +26.4 Vdc
Logic CPS, Power Supply Fault Vdc
Metering X5 (Secondary) 110Vac to 130Vac Vac
Install, Visual Software Version # Eng. Spec. Emp#:
Optional Metering Encoder Pwr Supply, +15 VDC (IOB board J7-5 to J7-7) +14.25 to +15.75 Vdc
Std. End User Settings PARAMETER SETTINGS: Emp#:

Motor kW Rating (HP*0.7457) ID 1010 Eng. Spec.
Motor Frequency ID 1020 Eng. Spec.
Rated Input Voltage ID 2010 Eng. Spec.
Rated Input Current ID 2020 Eng. Spec.
Rated Output Voltage ID 2030 Eng. Spec.
Rated Output Current (should be cell rating) ID 2040 Eng. Spec.
Control Loop Type ID 2050 OLVC
Accel Time 1 ID 2270 60 sec
Decel Time 1 ID 2280 60 sec
Spinning Load Mode ID 2430 Eng. Spec.
Installed Cells Per Phase ID 2530 Eng. Spec.
Set Min cells/phase to match installed cells/phase ID 2540 Eng. Spec.
Cell Voltage ID 2550 750 µH
Bypass Type ID 2590 Eng. Spec.
Neutral Connection ID 2630 Eng. Spec.
External Analog Inputs ID 2810 Eng. Spec.
External Analog Outputs ID 2820 Eng. Spec.
External Digital Inputs ID 2830 Eng. Spec.
External Digital Outputs ID 2840 Eng. Spec.
Input Current Scaler ID 3030 1.0
Input CT Ratio ID 3035 Eng. Spec.
Input Voltage Scaler ID 3040 1.0

Customer Name
SO P/N S/N
Input Attenuator Sum ID 3045 Eng. Spec.Ω
Output Current Scaler ID 3440 1.0
Output Voltage Scaler ID 3450 1.0
Output Attenuator Sum ID 3455 Eng. Spec.Ω
Carrier Frequency ID 3580 600 Hz
Transformer Tap Setting (0% tap required) ID 7050 0%
Program Clock ID 8080
Customer Order ID 8100 Eng. Spec.
Customer Drive Number ID 8110 Eng. Spec.
Network 1 Type ID 9901 Eng. Spec.
MenuTimer1 ID 9112 30 sec
MenuTimer2 (Option: Redundant Blowers) ID 9113 Eng. Spec.
MenuTimer5 (Option: Redundant Blowers) ID 9116 Eng. Spec.
Select System Program (SOP) ID 4145 Eng. Spec.
PC#
Std. Initial Power Up Test Upload & Download thru RS232 port Verify Comm. Emp#:
Ethernet Connection Verified Verify Comm. Emp#:
Special Serial Comm. Eng. Spec.Connection Verified (RS-485) Verify Comm. Emp#:
Optional Electrical Door (“Test Criteria” Must be specified and filled in by the Eng. Spec. Emp#:
Interlocks Engineer)
Optional Space Heaters (“Test Criteria” Must be specified and filled in by the Eng. Spec. Emp#:
Engineer)
Std. Backfeed Modulation TSI-061
& Clipping Power Supply & Hall Effect Pwr Supply Fault Emp#:
Output Transorbs Clipping Approx. 56Vp-p Emp#:
Note: Backfeed Cell B1

Disconnect plug P10 from MV Bypass Control Board
Input Transorbs Clipping Approx. 56Vp-p Emp#:

Verify all Cells Input Voltages ±10% of Variac
voltage Emp#:
Modulation of Cells (0 to 100% demand) Emp#:
MV Bypass Board Measure on plug pins 1 & 2 Approx. 36Vac± Emp#:
Power Supply Measure on plug pins 3 & 4 Approx. 76Vdc± Emp#:
Checks (P/N
10000484.00)
Std. Medium Voltage With Cell Series Links Installed
Testing VMA, VMB, VMC = ½ * (Motor Voltage Emp#:
30Hz
VMA, VMB, VMC = (Motor Voltage Emp#:
60Hz
Set Control Loop Type (ID 2050) OLVC Emp#:
With Unloaded Motor connected to the Drive Output, IMA leads VMA by 90° Emp#:
monitor the interface board test points and verify. IMB leads VMB by 90° Emp#:
IMC leads VMC by 90° Emp#:
Std. System Testing on

Motor
Check E-stop Logic Depress Local E-Stop
Measure on TB2-3 & 4 Open for E-stop Emp#:
Verify Fault contact on TB2-43 & 44 changes state Eng. Spec. for Fault Emp#:
Customer Name
SO P/N S/N
Verify Run contact on TB2-39 & 40 changes state Eng. Spec. for Run Emp#:
Remove Jumper on TB2-1 & 2 – Remote E-Stop
Std. Transformer Thermal Remove 170deg C wire from IOB J10-4 and verify fault Verify alarm Emp#:
Switches light blinks and keypad displays alarm message message
Remove 190deg C wire from IOB J21-1 and verify fault Verify trip message Emp#:
occurs 30 seconds later. Verify alarm/fault message. Verify VFD Fault Emp#:
Std. REMOTE LOGIC While SW1 in Remote position, momentarily Close Drive is running Emp#:
[Remote Start/Stop] contact between TB2-7 & 8 & verify VFD starts running
per Remote Analog Input #1 4-20mA control.
Momentarily Open contacts between TB2-9 & 10 Drive ramps to stop Emp#:
Open contacts between TB2-5 & 6 (Remote Inhibit) Drive will not run Emp#:
Cause system fault and check Drive Ready contact TB2- Eng. Spec. on Fault Emp#:
[Remote Fault Reset] 37 & 38 (changes state)
Momentarily close Remote Fault Reset contact on TB2- Drive Fault resets Emp#:
11 & 12
Verify Drive Ready contact on TB2-37 & 38 changes Eng. Spec. for
Emp#:
state Ready
Std. LOCAL LOGIC Place drive in local mode by turning switch to local Drive is running
[Local Remote Select] position. Press Keypad Manual Start pushbutton. Speed
demand follows the keypad speed control arrow keys
proportionally.
Verify speed demand and local mode at VFD on TB2-35 Eng. Spec. when
Emp#:
& 36 VFD in local mode
Press Keypad Manual Stop Pushbutton Drive ramps to Stop Emp#:
Keypad Manual Fault Reset Pushbutton acknowledges Verify
Emp#:
alarms and resets faults.
Std. 4 to 20mA Place drive in remote mode and connect 4-20mA signal Verify system
Remote Speed to TB2-ELV-7 & 8 speed change
Command Scale 4-20mA signal to be proportional to 0-100% speed 4ma=0% speed
20mA=100% speed Emp#:
Std. 4 to 20mA Program Spare Input as Remote Speed command via 4ma=0% speed
Spare Input Keypad menu and connect 4-20mA signal to TB2-ELV- 20mA=100% speed Emp#:
10 & 11
Std. 4 to 20mA Program Spare Input as Remote Speed command via 4ma=0% speed
Spare Input Keypad menu and connect 4-20mA signal to TB2-ELV- 20mA=100% speed Emp#:
13 & 14
Std. 4 to 20mA Monitor Motor Speed output on TB2-ELV-1 & 2 and 4ma=0% speed
Motor Speed Output Verify output 20mA=100% speed Emp#:
Std. 4 to 20mA Monitor Motor Torque output on TB2-ELV-4 & 5 and 4ma=0% speed
Motor Torque Verify output 20mA=100% speed Emp#:
Std. Blower #1 With Blower running remove alarm feedback (IOB J21-2)
Gen4 Cabinet Verify VFD faults, the starter opens, and display reads VFD coasts to stop Emp#:
“All Blowers Lost”
Replace alarm feedback , wait 30 seconds, reset fault Blower starts and Emp#:
runs automatically
Optional Redundant Blower #1 With Blower running remove alarm wire IOB-J21-2
Gen 4 Cabinet Verify VFD alarm condition and display reads “BLW 1 Verify VFD alarm Emp#:
Alarm” displayed and
Blower 2 turns on
Redundant Blower #2 With Blower running remove alarm wire IOB J21-3
Customer Name
SO P/N S/N
Gen 4 Cabinet Verify VFD alarm condition and display reads “BLW 2 Verify VFD alarm Emp#:
Alarm” displayed and
Blower 1 turns on
Blower Cycling Verify blowers cycle properly, adjust timer accordingly Emp#:
Trip blower motors 1&2 by removing alarm wires from
IOB
Verify VFD fault condition and display reads “BOTH Verify VFD fault Emp#:
BLOWERS FAILED” displayed and VFD
coasts to stop
Std. Spinning Load 1. Enable spinning load feature (ID 2430 = FWD)
2. Run VFD at 100% speed
3. Trip VFD by pressing E-stop
4. Pull out E-stop
5. Push Fault Reset
6. Restart VFD
7. Verify VFD catches a spinning load Returns to setpoint Emp#:
Std. MV Input Breaker Change the input CT ratio parameter (ID 3035) to cause Open on trip Emp#:
Enable the drive to trip on “Excessive Drive Losses” and verify
MV input Breaker Enable on TB2 59&60 changes state.
Verify Latch Fault Relay contact on pins 1&5 changes Opens on trip Emp#:
state
Enter the correct input CT ratio parameter (ID 3035) Eng. Spec. Emp#:
Use Switch Reset (SW2) to reset fault and verify drive is Verify fault is reset Emp#:
ready to run on TB2 37&38 and drive is ready
to run
Optional Cell Bypass Option
With Bypass 1. Enable Bypass operations by setting Bypass Enable
Enabled parameter to true
2. Remove Fiber Optic cable from Cell A1 from the DCR
previous cell to T1 of Cell A1
4. Remove Fiber Optic cable from Cell B1 from the DCR
previous cell to T1 of Cell B1
6. Remove Fiber Optic cable from Cell C1 from the DCR
previous cell to T1 of Cell C1
8. Reconnect all Fiber Optic Cables and enable “Reset
Bypass Cells”
9. Repeat steps 1-8 for remaining columns of cells All contactors <50mV Emp#:
Std. MODBUS Connect computer to MODBUS port

Open MODBUS program and verify communication Receiving data from Emp#:
VFD
Std. Logic Check Complete Eng Initial & Date

SOP Changes After Sign Off Yes No (Circle One)
If Yes, Name & Date of New SOP
Retest Required Yes No (Circle One)
SOP Changes Approved Eng Initial & Date
Std. System Load Test Run Load Test using Motor Dyno Load Debug Screen
Run at Eng. Spec. amps (full load input current) 4 hrs Emp#:
Record Input kW and Input Current _____kW _____A Emp#:
Record Output kW and Output Current _____kW _____A Emp#:
Std. Motor Overload Adjust motor parameters [Menu 1000] and overload Operate at 105% Emp#:
Protection settings [Menu 1120] to verify overload operates after user output motor
‘Constant’ 60 seconds. current
Std. Non-latching Run 1. Remove Medium Voltage With MV available Emp#:
Request with No 2. Reboot NXG Control and DriveReady

Customer Name
SO P/N S/N
Medium Voltage Input 3. With no MV applied, Clear/Reset all faults on drive both low, the
4. Monitor SOP RunRequest flag via debugger RunRequest cannot
5. Verify that SOP RunRequest flag remains false go high
when all start inputs are set.
Cust. Special I/O Must be specified and filled in by the Engineer
Spec # “PLC Battery present as required.” Emp#:
Cust. Special Testing

Spec # Customer Thermal Run at Eng. Spec. amps (full load input current) for Eng. TSF-053
Load Testing Spec. hrs
XFMR Core <180°C Emp#:
Coil Surface < 90°C Emp#:
Output Wire bundle <120°C Emp#:
Cust. Efficiency Testing Run VFD at following speed points:

Spec # Eng. Spec. %Speed Eng. Spec.% Load Eng. Spec.% TSF-056
Eng. Spec. %Speed Eng. Spec.% Load Eng. Spec.% TSF-056
Cust. Power Factor Run VFD at following speed points:

Spec # Testing Eng. Spec. %Speed Eng. Spec.% Load Eng. Spec.PF TSF-006
Eng. Spec. %Speed Eng. Spec.% Load Eng. Spec.PF TSF-006
Cust. Harmonic Testing Run VFD at 100% speed and 100% load THD Eng. Spec.%
Spec # Voltage Emp#:
THD Eng. Spec.%
Current Emp#:
Cust. Motor Data Enter Customer Supplier Motor Data From E-file under Emp#:
Spec # Project Engineering
/ Motor Data and
Drawings
Optional Interlocks Record all Interlock model #’s and keycode #’s for the Emp#:
drive
Verify correct operation of Interlocks K1:_____________ Emp#:
Ensure hardware and adapter plates are supplied Emp#:
(“Test Criteria” Must be specified and filled in by the
Engineer)
Std. Save Parameter, Save files under the Project Files Folder Parameter Upload Emp#:
Fault and Event Logs SOP, HEX, and Config Files (Level 7)
Std. Flash Card Cleanup All Test versions of SOP & Hex files have been removed Emp#:
from Flash
No Wago SOP & Hex is on Flash Emp#:
Final SOP is on Flash and correct Hex file is selected Emp#:
Clear Fault and Event Logs Emp#:

Customer Name
SO P/N S/N
Record Hipoter Used


Oscilloscope

Clamp on C.T.
Tested By: Date:

Approved for Shipment: Date:

Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 39
SECTION 12. WARRANTY
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 40
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 41
VFD WARRANTY
Extended warranty is twenty four months from date of startup, not to exceed thirty six
months after date of shipment, and covers defects in workmanship and materials only.
Warranty is limited to the value of the Siemens supplied equipment. The standard
Siemens terms and conditions of sale are attached herewith and will apply to any
purchase order resulting form this proposal unless other terms and conditions are
specifically negotiated in written form and signed as acceptable by Siemens. IN NO
EVENT WILL CONSEQUENTIAL AND/OR LIQUIDATED DAMAGES BE
ACCEPTABLE BY SIEMENS.
MOTOR WARRANTY
Siemens Energy & Automation, Inc. (“Company”) warrants that on the date of shipment,
the goods are of the kind and quality described herein and are free of nonconformities in
workmanship and material.
Purchaser's exclusive remedy for a nonconformity in any item of the goods shall
be the repair or the replacement (at Company's option) of the item and any
affected part of the goods. Company’s obligation to repair or replace shall be in
effect for a period of one (1) year from initial operation of the goods but not more
than eighteen (18) months from Company’s shipment of the goods, provided
Purchaser has sent written notice within that period of time to the Company that
the goods do not conform to the above warranty. Repaired and replacement parts
shall be warranted for the remainder of the original period of notification set forth
above, but in no event less than 12 months from repair or replacement. At its
expense, Purchaser shall remove and ship to Company any such nonconforming
items and shall reinstall the repaired or replaced parts. Purchaser shall grant
Company access to the goods at all reasonable times in order for Company to
determine any nonconformity in the goods. Company shall have the right of
disposal of items replaced by it. If Company is unable or unwilling to repair or
replace, or if repair or replacement does not remedy the nonconformity, Company
and Purchaser shall negotiate an equitable adjustment in the contract price which
may include a full refund of the contract price.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 42
Company’s warranty does not apply to any item of the goods delivered by Company but
manufactured by others. Such items shall be covered only by the express warranty, if
any, of the manufacturer thereof. The Company and its suppliers shall also have no
responsibility if the goods have been improperly stored, handled, or installed, if the goods
have not been operated or maintained according to their ratings or according to
instructions in Company or supplier-furnished manuals, or if unauthorized repairs or
modifications have been made to the goods.
COMPANY HEREBY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS

OR IMPLIED, EXCEPT THAT OF TITLE. SPECIFICALLY, IT DISCLAIMS
THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR
PARTICULAR PURPOSE, COURSE OF DEALING, AND USAGE OF
TRADE.
Purchaser and successors of Purchaser are limited to the remedies specified in this
article and shall have no others for a nonconformity in the goods. Purchaser
agrees that these remedies provide Purchaser and its successors with a minimum
adequate remedy and are their exclusive remedies, whether the Purchaser's or
successors’ remedies are based on contract, warranty, tort (including negligence),
strict liability, indemnity, or any other legal theory, and whether arising out of
warranties, representations, instructions, installations, or nonconformities from
any cause.
Optional Warranties: The following Optional Warranties (individually or in

combination) are available to Purchaser pursuant to the terms and conditions specified.
A. Deferred Warranty: The Standard Warranty terms and conditions shall apply
subject to the following modification:
Company’s total warranty period shall be a period of “X” months from the date of initial
operation but not more than “Y” months from Company’s shipment of the goods (where
“X” and “Y” are as set forth in Table 1 below).
For the Deferred Warranty period desired, make the percentage addition from Table 1
below to the net price of each unit.
Table 1 – Deferred Warranty Period

“X” Months “Y” Months
from Initial Operation From Shipment % Addition
12 19-30 1%
12 31-36 2%
12 37-42 3%
12 43-48 4%
12 49-54 5%
12 55-60 6%
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 43
The Deferred Warranty shall be valid only if Purchaser complies with each and every one
of the following conditions:
1. Within thirty (30) days prior to initial operation, Purchaser shall hire a
Company Service Engineer (at Company’s standard rates) to thoroughly
inspect the apparatus to ascertain that said apparatus is in “as shipped”
condition. This inspection (the “Deferred Warranty Inspection”) will include,
but not be limited to, the following:
(a) Megger test of winding insulation;
(b) Internal inspection to determine that the winding has not been damaged
and that the apparatus is clean and dry;
(c) Inspection of the bearings to determine that they have not been damaged
by moisture in the oil reservoirs or bearing cavities;
(d) External inspection to determine that no damage has been done; and
(e) Review of the motor storage and maintenance records to ensure
compliance with Company’s requirements as stated in the applicable
motor instruction, operation, and maintenance manual.
2. Purchaser shall make any and all corrections which the Deferred Warranty
Inspection reveals to be needed because the apparatus has been in storage or
standing idle. Any and all corrections which are required because of storage
conditions shall be made at Purchaser’s sole cost and expense.
3. Adjustable Frequency Drive Applications: Any application utilizing a motor

operated by an adjustable frequency drive shall be reviewed and approved by
Company prior to start-up. Failure to submit said application for Company’s
review and approval shall void the applicable Deferred Warranty.
B. Extended Operational Warranty: The Standard Warranty terms and conditions

shall apply subject to the following modification:
Company’s total warranty period shall be a period of “X” months from the date of initial
operation but not more than “Y” months from Company’s shipment of the goods (where
“X” and “Y” are as set forth in Table 2 below).
For the Extended Operational Warranty period desired, make the percentage addition
from Table 2 below to the net price of each unit.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 44
Table 2 – Extended Operational Warranty Period
“X” Months “Y” Months

From Initial Operation From Shipment % Addition
24 30 4%
36 42 6%
The Extended Operational Warranty shall be valid only if Purchaser complies with each
and every one of the following conditions:
1. Within thirty (30) days prior to initial operation, and again during the 13th and
25th month of operation (if motor is still within the extended operating
warranty period), Purchaser shall hire a Company Service Engineer (at
Company’s standard rates) to thoroughly inspect the apparatus to ascertain
that said apparatus is in “as shipped” condition. This inspection (the
“Extended Warranty Inspection”) will include, but not be limited to, the
following:
(a) Megger test of winding insulation;
(b) Internal inspection to determine that the winding has not been damaged
and that the apparatus is clean and dry;
(c) Inspection of the bearings to determine that they have not been damaged
by moisture in the oil reservoirs or bearing cavities;
(d) External inspection to determine that no damage has been done; and
(e) Review of the motor storage and maintenance records to ensure
compliance with Company’s requirements as stated in the applicable
motor instruction, operation, and maintenance manual.
Purchaser shall also be obligated to hire a Company Service Engineer to

perform an Extended Warranty Inspection during the 19th and 31st months of
storage if the motor has yet to be put into service at that time and if the motor
is still within the extended operating warranty period.
2. Purchaser shall make any and all corrections which the Extended Warranty
Inspection reveals to be needed because the apparatus has been in storage or
standing idle. Any and all corrections that are required because of storage
conditions shall be made at Purchaser’s sole cost and expense.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 45
3. Adjustable Frequency Drive Applications: Any application utilizing a motor

operated by an adjustable frequency drive shall be reviewed and approved by
Company prior to start-up. Failure to submit said application for Company’s
review and approval shall void the applicable Extended Warranty.
Operational Warranties longer than those listed in Table 2 are available, but must be
negotiated with Company.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 46
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 47
SECTION 13. MANUALS
MANUALS FOR GENIIIE VFD (4000HP & 6600HP)
19000403 INSTALLATION MANUAL
19000404 STARTUP & ADVANCE MANUAL
19000405 USER’S MANUAL
MANUALS FOR GENIV, PH1 VFD (900HP)
19001851 INSTALLATION MANUAL
19001591 USER’S MANUAL
MANUALS FOR GENIV, PH2 VFD (2000HP & 1750HP)
THESE MANUALS ARE IN THE PROCESS OF BEING UPDATED. ONCE

COMPLETE THEY WILL BE SENT TO FLS.
Sales Order: 3001196416, 3001196287, 3001196302, 3001196303, 3001195583 48
INSTALLATION MANUAL
FOR
AIR COOLED
PERFECT HARMONY
GENIII/E SERIES
Adjustable Speed AC Motor Drives with
Next Generation Control
Manual Number: 19000403

Version 1.1
OCTOBER 2003
A Subsidiary of High Voltage Engineering Corporation
500 Hunt Valley Road, New Kensington, PA, USA, 15068

Phone: 724-339-9500 Customer Support Phone: 724-339-9501 (24-hours)
Fax: 724-339-9562 Customer Support Fax: 724-339-9507
Web: www.us.asirobicon.com Customer Support E-mail: support@us.asirobicon.com
DECLARATION OF CONFORMITY
Manufacturer’s Name: ASIRobicon Corporation
Manufacturer’s Address: 500 Hunt Valley Road
USA
declares that the product:
Product Name: AC Variable Frequency Drives, Perfect Harmony Series
GEN II, GEN III, and GEN3E Air Cooled and Liquid Cooled
(Product models (459XXX.XX & 3100XXXX.XX))
Product Description: 50Hz/60Hz, 200 HP to 20,000HP, 2.4 kV to
13.8 kV input, 2.4 kV to 7.2 kV output
Product Options: This declaration covers all options of the product described.
Supplementary Information:
The products herewith comply with the requirements of the Low Voltage Directive 73/23/EEC (as amended) and the EMC
Directive 89/336/EEC (as amended).
LVD Safety Directive: The products listed above conform to IEC Standard EN50178.
EMC Directive: ASIRobicon certifies that the apparatus (both air and liquid cooled) to which this Declaration of Conformity
relates conforms to the protection requirements of Council Directive 89/336/EEC on the approximation of the Laws of the
Member States relating to electromagnetic compatibility. Testing performed under generic standards EN50081-2, EN50082-2,
and EN61000-4-2 – ESD, EN61000-4-3 Radiated Immunity; EN61000-4-4 – EFT, EN61000-4-6, Conducted RF Immunity and
EN61000-4-5 – Surge Immunity.
Competent Body Assessment for EMC by York Services, Ltd. EMC Test Centre, Fleming Building, Donibristle Industrial Park,
Dalgerty Bay, Dunfermline, FIFE KY119HZ.
Competent Body Certificate and Report No. 1084-2/CBC/CBR dated August 6, 2001.
Name: Tom Bierman, Director of Quality Technical documentation holder:
Signature: Ray Tomer, Staff Compliance Engineer
Perfect Harmony is a trademark of ASIRobicon . Date of issue: September 18, 2003

ASIRobicon Corporation: Phone: 724-339-9500 Customer Support Phone: 724-339-9501 (24-hours)
ASIRobicon Website: www.asirobiocn.com
This manual applies to all air-cooled Perfect Harmony adjustable-speed AC motor drives including GEN III (GEN3) (200 hp through 10,000 hp)
having the following cell sizes:
00A through 5C (460 V cells)
70, 100, 140, 200, and 260 (630 V cells)
360H, 315H, 375H, 500H, and 660H (690 V cells).
For the support representative nearest you, please call ASIRobicon’s main office at (724)-339-9500.
Perfect Harmony, GEN III (GEN3) and GEN IIIe (GEN3e) are product lines of AC motor drives from ASIRobicon.
PLC is a trademark of Allen-Bradley Company, Inc.
Copyright 2001 – ASIRobicon
Installation Manual for Perfect Harmony Series (p/n 19000403)
Version History:
Version 1.0 August 2003
Version 1.1 October 2003
 2001 by ASIRobicon. No portion of this document may be reproduced either mechanically or electronically without the prior consent of ASIRobicon.
Perfect Harmony GENIII/e Installation Manual Table of Contents
TABLE OF CONTENTS
Table of Contents ......................................................................................................................................... iii

Safety Precautions and Warnings ................................................................................................................ ix
About This Manual..................................................................................................................................... 1-xi
CHAPTER 1: Introduction ..........................................................................................................................1-1
1.1. Introduction to the Perfect Harmony....................................................................................1-1
1.1.1. Clean Power Input ..................................................................................................1-1
1.1.2. High Power Factor and Nearly Perfect Sinusoidal Input Currents .........................1-1
1.1.3. Nearly Perfect Sinusoidal Output Voltages ............................................................1-2
1.2. Hardware Overview .............................................................................................................1-2
1.3. Features Overview ..............................................................................................................1-4
1.4. Specifications ......................................................................................................................1-5
CHAPTER 2: Hardware Components..............................................................................................2-1
2.1. Hardware Configuration ......................................................................................................2-1
2.1.1. Transformer Section ...............................................................................................2-3
2.1.2. Customer I/O Section..............................................................................................2-6
2.1.3. Cell and Control Sections (GEN III Cell Specifications) .........................................2-7
2.1.4. Cell Bypass Option ...............................................................................................2-13
2.2. The Cell Control System....................................................................................................2-13
2.3. The Master Control System...............................................................................................2-13
2.4. The Power Circuit ..............................................................................................................2-18
2.4.1. Monitoring of Input Power Quality ...........................................................................2-18
CHAPTER 3: Installation and Set-up .........................................................................................................3-1
3.1. Introduction..........................................................................................................................3-1
3.2. Receiving .............................................................................................................................3-1
3.3. Shipping Splits.....................................................................................................................3-1
3.4. Weight Estimates.................................................................................................................3-1
3.5. Handling ..............................................................................................................................3-1
3.5.1. Overhead Crane Lifting Using Slings......................................................................3-2
3.5.2. Using a Fork Lift Truck............................................................................................3-2
3.5.3. Using Roller Dollies.................................................................................................3-3
3.5.4. Using Pipe Rollers ..................................................................................................3-3
3.6. Location ...............................................................................................................................3-4
3.7. Anchoring Cabinets to Floors and Walls .............................................................................3-5
3. 8. Transformer Cabinet Wiring ................................................................................................3-5
3.9. External Wiring ....................................................................................................................3-6
3.9.1. Input Power Wiring..................................................................................................3-6
3.9.2. Input Primary Power Interruption ............................................................................3-7
3.9.3. Grounding ...............................................................................................................3-8
3.9.4. Drive Inhibit and Emergency Stop Wiring ...............................................................3-9
3.10. Torque Specifications ..........................................................................................................3-9
3.11. Insulation Resistances.......................................................................................................3-10
3.12. Cell Capacitor Reforming ..................................................................................................3-11
APPENDIX A: Glossary of Terms ............................................................................................................ A-1
APPENDIX B: Commonly Used Abbreviations ........................................................................................ B-1
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
Readers’ Comments Form ......................................................................................................................... r-1
Startup/Warranty Registration and Service Solutions................................................................................ vii
Version 1.1 (19000403) ASIRobicon iii

Table of Contents Perfect Harmony GENIII/e Installation Manual
∇ ∇ ∇
iv ASIRobicon Version 1.1 (19000403)

Perfect Harmony GENIII/e Installation Manual List of Figures
LIST OF FIGURES
List of Figures .............................................................................................................................................. vii

Figure 1-1. Harmonic Distortion Wave Form Comparisons (6-pulse, 12-pulse and Perfect Harmony)1-1
Figure 1-2. Comparison of Perfect Harmony and a Typical Phase-controlled SCR Drive....................1-2
Figure 1-3. Nearly Sinusoidal Wave Form of the Output Current from a Perfect Harmony Drive ........1-2
Figure 1-4. Typical 4,160V (Left) and 6,600V (Right) GEN III Perfect Harmony VFDs .........................1-3
Figure 1-5. Typical 4,160V (Left) and 6,600V (Right) GENIIIe Perfect Harmony VFDs ........................1-3
Figure 2-1. Typical GEN III-style VFDs ..................................................................................................2-2
Figure 2-2. Typical GEN IIIe-style VFDs ................................................................................................2-3
Figure 2-4. Field Connections and Major Components in the GEN III Transformer Section ................2-5
Figure 2-5. Field Connections and Major Components in the GEN IIIe Transformer Section (left) and
Cell Section (right) ..................................................................................................................................2-6
Figure 2-6. Customer I/O Section (Typical) of a GEN III-style Perfect Harmony Drive.........................2-7
Figure 2-7. Typical GEN III Cell .............................................................................................................2-8
Figure 2-8. Typical GENIIIe Cell ............................................................................................................2-9
Figure 2-9. Details of GENIIIe Terminals and Indicators.......................................................................2-9
Figure 2-10. Cell Section (Typical) of a GEN III-style Perfect Harmony Drive ....................................2-10
Figure 2-11. Typical Connection Diagram for an 18 Cell 6.6 KV System ...........................................2-13
Figure 2-12. Master Control System.....................................................................................................2-15
Figure 2-13. Location of Flash Disk on Microprocessor Board ...........................................................2-16
Figure 2-14. Typical Perfect Harmony Power Circuit ...........................................................................2-17
Figure 2-15. Typical Power Cell Schematic.........................................................................................2-19
Figure 3-1. Proper Handling Using the Sling Lifting Technique and an Overhead Crane ....................3-2
Figure 3-2. Proper Fork Lift Handling and Dimensions .........................................................................3-3
Figure 3-3. Proper Placement of Roller Dollies .....................................................................................3-3
Figure 3-4. Proper Use of Pipe Rollers in Handling Perfect Harmony Cabinets...................................3-4
Figure 3-5. Proper Anchoring Techniques for Perfect Harmony Cabinets............................................3-5
Figure 3-6. Transformer Cabinet Detail Showing Typical Tap Connections .........................................3-6
Figure 3-7. Typical GEN III VFD .............................................................................................................3-7
Figure 3-8. Typical GEN IIIe VFD ...........................................................................................................3-8
Figure 3-9. The Drive Inhibit/Emergency Stop of the Perfect Harmony ................................................3-9
Version 1.1 (19000403) ASIRobicon vii

List of Figures Perfect Harmony GENIII/e Installation Manual

INDEX............................................................................................................................................................. i
Notes ..........................................................................................................................................................n-1
∇ ∇ ∇
viii ASIRobicon Version 1.1 (19000403)

Perfect Harmony GENIII/e Installation Manual List of Tables
LIST OF TABLES
List of Tables ................................................................................................................................................ xi

Table 1-1. Common Specifications for Standard Perfect Harmony Systems........................................1-5
Table 2-1. Field Connections and Major Components in the Transformer Section ..............................2-4
Table 2-2. GENIII Cell Specification Details ..........................................................................................2-7
Table 2-3. GENIIIe Cell Specification Details ........................................................................................2-8
Table 2-4. 3,300 VAC GENIII Cell Specifications: 9 Cells Total, 3 (630 VAC) Cells in Series ...........2-10
Table 2-5. 4,160 VAC GENIII Cell Specifications: 12 Cells Total, 4 (630 VAC) Cells in Series .........2-11
Table 2-7. 2,300 VAC GENIIIe Cell Specifications: 6 Cells Total, 2 (690 VAC) Cells in Series .........2-11
Table 2-9. 4,160 VAC GENIIIe Cell Specifications: 12 Cells Total, 4 (690 VAC) Cells in Series .......2-12
Table 2-10. 6,000 VAC GENIIIe Cell Specifications: 15 Cells Total, 5 (690 VAC) Cells in Series .....2-12
Table 3-1. Grounding Conductor Sizes .................................................................................................3-9
Table 3-2. Torque Specifications for the Perfect Harmony .................................................................3-10
Table 3-3. Minimum Values of Insulation Resistances........................................................................3-10
Table B-1. Commonly Used Abbreviations........................................................................................... B-1
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
Version 1.1 (19000403) ASIRobicon xi

List of Tables Perfect Harmony GENIII/e Installation Manual
∇ ∇ ∇
xii ASIRobicon Version 1.1 (19000403)

Perfect Harmony GENIII/e Installation Manual SAFETY PRECAUTIONS AND WARNINGS
SAFETY PRECAUTIONS AND WARNINGS

Perfect Harmony drives are designed with considerable thought to personal safety. However, as with any
piece of high power equipment, there are numerous internal connections that present potentially lethal
voltages. In addition, some internal components are thermally hot to the touch. Follow the warnings
below when working in or near the Perfect Harmony system.
Danger - Electrical Hazards!
• Always follow the proper lock-out/tag-out procedures before beginning any
maintenance or troubleshooting work on the drive.
• Never touch anything within the Perfect Harmony cabinets (other than the control
cabinet) until verifying that it is neither thermally hot nor electrically alive.
• Always follow standard safety precautions and local codes during installation of
external wiring. Protective separation must be kept between extra low voltage
(ELV) wiring and any other wiring as specified in the CE safety standard.
• Never assume that switching off the input disconnect will remove all voltage from
internal components. Voltage is still present on the terminals of the input disconnect.
Also, there may be voltages present that are applied from other external sources.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety
glasses. Also, always work with another person present.
• Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage
measurements (that is, isolation is provided inside the instrument, not provided by
isolating the chassis ground of the instrument). Never defeat the instrument’s
grounding.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to
measure points beneath the shields.
• Always use extreme caution when handling or measuring components that are inside
the enclosure. Be careful to prevent meter leads from shorting together or from
touching other terminals.
• Hazardous voltages may still exist within the Perfect Harmony cabinets even when
the disconnect switch is open (off) and the supply power is shut off.
• Never run the drive with cabinet doors open. The only exception is the control cabinet,
which contains extra low voltages (ELV).
• Only qualified individuals should install, operate, troubleshoot, and maintain this
drive. A qualified individual is “one familiar with the construction and operation
of the equipment and the hazards involved.”
Warning!
• Never disconnect control power while medium voltage is energized. This could cause
severe system overheating and/or cell damage.
• Never store flammable material in, on or near the drive enclosure. This includes
equipment drawings and manuals.
• Always ensure the use of an even and flat truck bed to transport the Perfect Harmony
drive system. Before unloading, be sure that the concrete pad is level for storage and
permanent positioning.
• Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the
drive system. Dropping the cabinet or lowering it too quickly could damage the unit.
• Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure
that the fork truck tines fit the lifting tubes properly and are the appropriate length.
• Always comply with local codes and requirements if disposal of failed components is
necessary (for example, CPU battery, capacitors, etc.).
• During operation, the nominal weighted sound pressure level may exceed 70 dB
at a distance of 1 meter from the drive.
Version 1.1 (19000403) ASIRobicon ix

SAFETY PRECAUTIONS AND WARNINGS Perfect Harmony GENIII/e Installation Manual
ESD Sensitive Equipment!

Always be aware of electrostatic discharge (ESD) when working near or touching components
inside the Perfect Harmony cabinet. The printed circuit boards contain components that are
sensitive to static electricity. Handling and servicing of components that are sensitive to ESD
should be done only by qualified personnel and only after reading and understanding proper ESD
techniques. The following ESD guidelines should be followed. Following these rules can greatly
reduce the possibility of ESD damage to PC board components.
• Make certain that anyone handling the Perfect Harmony printed circuit boards is
wearing a properly grounded static strap. The wrist strap should be connected to ground
through a 1 megaohm resistor. Grounding kits are available commercially through most
electronic wholesalers.
• Static charge buildup can be removed from a conductive object by touching the object to
a properly grounded piece of metal.
• Always transport static sensitive equipment in antistatic bags.
• When handling a PC board, always hold the card by its edges.
• Do not slide printed circuit boards across any surface (e.g., a table or work bench). If
possible, perform PCB maintenance at a workstation that has a conductive covering which is
grounded through a 1 megaohm resistor. If a conductive tabletop cover is unavailable, a
clean steel or aluminum tabletop is an excellent substitute.
• Avoid plastic, Styrofoam, vinyl and other non-conductive materials. They are excellent
static generators and do not give up their charge easily.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic
vacuum-style plunger or copper braid when desoldering.
• When returning components to ROBICON, always use static-safe packing. This limits
any further component damage due to ESD.
Additional safety precautions and warnings appear throughout this manual. These important messages
should be followed to reduce the risk of personal injury or equipment damage.
∇ ∇ ∇
x ASIRobicon Version 1.1 (19000403)

Perfect Harmony GENIII/e Installation Manual ABOUT THIS MANUAL
ABOUT THIS MANUAL
Separation of Manuals
This manual is one component of a three-part series of manuals intended for use with the Perfect
Harmony series of adjustable speed AC motor drives. Each part in this series is for use by individuals
having unique job functions and qualifications. The manuals in this series are listed below:
Installation Manual (this manual) (manual number 19000403)
User’s Manual (manual number 19000405)
Startup and Advanced Topics Manual (manual number 19000404)
The Installation Manual provides a brief overview of the product including a hardware overview and
important safety issues. The steps leading up to and including the installation of the drive are discussed
in detail in this manual.
The User’s Manual is for use by operators of the drive. The User’s Manual contains a brief overview of
the product including a hardware overview of the external components of the drive and basic safety
precautions. The keypad and display interface is explained in detail. A parameter listing is provided for
reference. A troubleshooting and maintenance section is also provided in this section to help the
operator to diagnose and correct any potential problems that may occur, and reduce the potential for
future problems through inspections and regular maintenance.
The Startup and Advanced Topics Manual is intended to address the more technical aspects of drive
setup, configuration and operation. This manual includes detailed descriptions of all parameters,
functions, and picklist menu items. Software setup and startup procedures are also included. Advanced
topics such as the theory of operation, technical specifications, system programming, compiler and
reverse compiler software operation, uploading and downloading functions, and other application and
operation issues are discussed.
All manuals in this series contain a glossary of terms, a list of commonly used abbreviations, and other
reference tools. In addition, a readers’ comments form is provided. Please complete these forms and
return them to us. Monitoring your feedback allows us to continue to exceed your expectations and
provide complete, effective, easy-to-use product documentation.
Reference Tools
Many steps have been taken to promote the use of this manual as a reference tool. Reference tools
include the following:
• a thorough table of contents for locating particular sections or subsections
• a list of all figures and their associated captions as they appear in the manual
• a list of all tables and their associated titles as they appear in the manual
• chapter number thumb nails in the outer margins for easy location of chapters
• special text styles are applied to easily differentiate between chapters, sections, subsections, regular
text, parameter names, software flags and variables, and test points.
• a comprehensive index with special locator references for illustrations and tables.
If you have any comments or suggestions to improve the organization or increase the usability of this
manual, please complete the Readers’ Comments Form located at the end of this manual and return it to
ASIROBICON.

ABOUT THIS MANUAL Perfect Harmony GENIII/e Installation Manual
Conventions Used in this Manual

The following conventions are used throughout this manual.
• This manual for use with the CE Mark Perfect Harmony product line.
• The terms “Perfect Harmony”, “VFD”, “variable frequency drive” and “drive” are used interchangeably
throughout this manual.
*
Note icons in the outer margins alert readers of important operational or application information
that may have extra special significance. The associated text is enclosed in a border for high
visibility.
Attention! Attention icons in the outer margins alert readers of important safety and operational
precautions. These notes warn readers of potential problems that could cause equipment
damage or personal injury. The associated text is enclosed in a border for high visibility.
Caution - Electrical Hazard! Electrical hazard icons in the outer margins alert readers of
important safety and operational precautions. These notes warn readers of dangerous
voltages, potential safety hazards or shock risks that could be life threatening. The associated
text is enclosed in a border for high visibility.
ESD Warning! These icons in the outer margins alert readers of static sensitive devices.
Proper electrostatic discharge precautions should be taken before proceeding or handling the
equipment.
• Chapter numbers are highlighted in the outer margins to facilitate referencing (see margin).
• Test points and terminal block designations are shown in uppercase, boldface, 8 pt Arial fonts (e.g.,
TB1A).
• In the index, locator page numbers appear in regular type faces for standard index references (e.g.,
7-10). For index references that correspond to items found in tables, the locator page numbers are
shown in an italic type face (e.g., 6-24). For index references that correspond to items found in
figures and illustrations, the locator page numbers are shown in a boldface type face (e.g., 3-3).
Illustrations that also appear in tables have locator page numbers that are both boldface and italic
(e.g., 6-16).
• The symbol “ ∇ ∇ ∇ ” is used to mark the end of each section.
∇ ∇ ∇

Perfect Harmony GENIII/e Installation Manual INTRODUCTION
CHAPTER 1: INTRODUCTION 1
1.1. Introduction to the Perfect Harmony

Perfect Harmony is a series of pulse-width modulated, variable frequency AC motor drives designed and
manufactured by ASI Robicon. The Perfect Harmony drive system addresses the following power quality
issues: providing clean power input, providing a high power factor, and providing nearly perfect sinusoidal
output.
1.1.1. Clean Power Input

The Perfect Harmony drive series meets the most stringent IEEE 519 1992 requirements for voltage and
current harmonic distortion, even if the source capacity is no larger than the drive rating. This series of
drives protects other on-line equipment (such as computers, telephones, and lighting ballasts) from
harmonic disturbances. Perfect Harmony also prevents “cross talk” with other variable speed drives.
Clean power input eliminates the need for time-consuming harmonic/resonance analyses and costly
harmonic filters. Figure 1-1 illustrates input wave forms for typical 6-pulse, 12-pulse and Perfect
Harmony series drives.

Source Current
Source Voltage
Typical 6-pulse Typical 12-pulse Perfect Harmony Series

Input Wave Form Input Wave Form Input Wave Form
Figure 1-1. Harmonic Distortion Wave Form Comparisons

(6-pulse, 12-pulse and Perfect Harmony)
Total harmonic distortion of the source current is 25% for the 6-pulse, 8.8% for the 12-pulse, and 0.8% for
the Perfect Harmony series drive. The corresponding voltage distortions with a typical source impedance
are 10%, 5.9% and 1.2%, respectively.
*
The above comparisons were done using a typical 1,000 hp current source drive (6-pulse and 12-
pulse modes) and a Perfect Harmony series drive operating from a 1100 kVA, 5.75% impedance
source.
1.1.2. High Power Factor and Nearly Perfect Sinusoidal Input Currents
Power factor is a measure of the fraction of current that produces real power to the load. Typically, power
factor is given as a percentage. A high power factor VFD (e.g., 95%) makes much better use of its input
line current demand in producing real power to the motor than a VFD operating at a low power factor
(e.g., 30%). VFDs having low operating power factor often generate square-wave shaped line currents.
This can lead to harmonics and other associated resonance problems.
The Perfect Harmony series draws nearly perfect sinusoidal input currents having a power factor that
exceeds 95% throughout the entire speed range without the use of external power factor correction
capacitors. This eliminates utility penalties for power factor and demand charges, and improves voltage
regulation. In addition, feeders, breakers and transformers are not overloaded with reactive power. Low
speed applications specifically benefit from the Perfect Harmony series because a high and stable power
Version 1.1 (19000403) ASIRobicon 1-1

INTRODUCTION Perfect Harmony GENIII/e Installation Manual
factor is maintained throughout the entire speed range using standard induction motors. Figure 1-2
1 compares graphs of power factor versus percent speed for the Perfect Harmony series and a typical
phase-controlled SCR drive.
100
90
80 Perfect Harmony
Series Drive
70
60
50
40 Phase-controlled
SCR Drive
30
20
10 Percent Speed
20 27 33 40 47 53 60 67 73 80 87 93 100
Figure 1-2. Comparison of Perfect Harmony and a Typical Phase-controlled SCR Drive
1.1.3. Nearly Perfect Sinusoidal Output Voltages

The design of the Perfect Harmony series of variable frequency drives inherently provides a sinusoidal
output without the use of external output filters. This means that the drive provides a low distortion output
voltage wave form that generates no appreciable audible motor noise. In addition, there is no need to
derate motors (the drive can be applied to new or existing 1.0 service factor motors). In fact, Perfect
Harmony drives eliminate harmful VFD-induced harmonics which cause motor heating. Similarly, VFD-
induced torque pulsations are eliminated (even at low speeds), thereby reducing the stress on
mechanical equipment. Common mode voltage stress and dV/dt stress are also minimized. A typical
graph of the output current from a Perfect Harmony drive is illustrated in Figure 1-3.
Typical Phase
Output Current
Time
Figure 1-3. Nearly Sinusoidal Wave Form of the Output Current from a Perfect Harmony Drive
1.2. Hardware Overview

The cabinet configurations of Perfect Harmony drives vary based on the horsepower of the drive, the
number and type of cells, and other factors. However, cabinet configurations can generally be divided
into two broad categories:
• GEN III style (shown in Figure 1-4)
• GEN IIIe style (shown in Figure 1-5)
1-2 ASIRobicon Version 1.1 (19000403)

Figure 1-4. Typical 4,160V (Left) and 6,600V (Right) GEN III Perfect Harmony VFDs
This style is discussed in Chapter 2: Hardware Components.
Figure 1-5. Typical 4,160V (Left) and 6,600V (Right) GENIIIe Perfect Harmony VFDs

1
1.3. Features Overview
Additional features of the Perfect Harmony drive include the following:
• redundant cooling blowers • cell back-up
• high efficiency • serial port
• reliability • reports capabilities
• modular construction • micro PLC capabilities
• surge arrestors • keypad and English message display
• fiber optic control circuitry • on-line diagnostics
• soft start protection • digital display module
• multi-motor operation • advanced diagnostics
• trip-free operation • on-line operation while tuning
• dual performance operation modes • industry standard communications
• undervoltage ride-through • dual frequency braking
• spinning load restart • auto tuning
• transparent cell bypass • input monitoring
• PC tool interface
• power cell check

1
1.4. Specifications
Table 1-1 lists common electrical and mechanical specifications for all standard Perfect Harmony
systems. Note that Perfect Harmony specifications may be changed without notice.
Table 1-1. Common Specifications for Standard Perfect Harmony Systems
Item Description
hp range GEN III: Up to 3,000 hp at 6,300V
GEN IIIe: Up to 8000hp at 6,600V
Input line voltages 2.2 kV, 3.0 kV, 3.3 kV, 4.1 kV, 4.8 kV, 6.0 kV, 6.6 kV, 6.9 kV, 7.2 kV, 8.4 kV,
10.0 kV, 11.0 kV, 12.0 kV, 12.5 kV, 13.2 kV, and 13.8 kV.
Input voltage tolerance +10%, -5% from nominal 3-phase at rated output
Input power factor 0.95 above 10% load
Output line voltages 2.4 kV, 3.3 kV, 4.16 kV, 4.8 kV, 6.0 kV, 6.6 kV, 6.9 kV, and 7.2 kV.
Output frequency drift ±0.5%
Speed range 0.5-330 Hz (motor dependent)
Overload capability A function of the installed type of cell.
Accel/decel time range 0.5-3,200 sec (load dependent)
Output torque 15-139 Hz rated torque; 3-14 Hz and 140-330 Hz derated torque
Enclosure NEMA 1 ventilated, IP31
Ambient temperature 0-40°C
Storage Temperature -40 to 70°C
(System w/o Cells)
(Cells*)
Humidity 95% non-condensing
Altitude Up to 3,300 feet. Above 3,300 feet require derating.
Dust contamination <100 micron @ 6.5 mg/cu. ft.
Gas contamination <4 PPB reactive halides and sulfides
*Non-energized cells should not be stored at more than 45°C to preserve reliability of Filter Capacitors.
Non-energized cells stored for more than two (2) years should be reformed per procedure indicated in
Section 3-12 of this manual.

∇∇∇

Perfect Harmony GENIII/e Installation Manual HARDWARE COMPONENTS
CHAPTER 2: HARDWARE COMPONENTS

2.1. Hardware Configuration
Figure 2-1 depicts a typical GEN III style configuration in which each VFD normally consists of a single
cabinet with multiple sections. These sections, described below, are:
• the transformer section 2
• the customer I/O section
• the control section
• the cell section
Depending on the HP and voltage ratings, some GENIII systems may be shipped as a single unit in which
the Transformer and Cell Cabinet are integrated into one unit. Larger GENIII systems may be shipped so
that the Transformer and Cell Cabinets are split due to size and weight restrictions. In all GENIII
systems, the input and output connections are located in the Transformer Cabinet. The control section is
a swinging panel that resides in the left side of the cell cabinet.
Figure 2-2 depicts a typical GEN IIIe style configuration in which each VFD of a Cell/Control cabinet
connects to a Transformer Cabinet. These sections, described below, are:
GENIIIe (which are higher current versions of GENIII systems) is always shipped so that the Transformer
and Cell Cabinets are separated. In these systems, the Output section is always on the left side of the
cell cabinet (behind the control panel) and the Input section is always in the Transformer Cabinet. The
control section is a swinging panel that resides in the left side of the cell cabinet.

HARDWARE COMPONENTS Perfect Harmony GENIII/e Installation Manual
Blowers
Air Intakes
Single Point (Do Not Block)
Cooling for
Small Units
Transformer
Section
Customer Control
Wiring and
Control Power
Section
Control Section
and Access to
Cell Cabinet
Split Cooling for

Longer Lineup
Transformer
Section
Control
Customer Control Section and
Wiring and Control Access to Cell
Power Section Section
Figure 2-1. Typical GEN III-style VFDs

SHIPPING SPLIT
AIR EXHAUST
DO NOT BLOCK
AIR EXHAUST
DO NOT BLOCK
2
TRANSFORMER AIR INTAKE (TYP) AIR INTAKE (TYP)
DO NOT BLOCK DO NOT BLOCK
AIR INTAKE (TYP) AIR INTAKE (TYP) AIR INTAKE (TYP)
DO NOT BLOCK DO NOT BLOCK DO NOT BLOCK
K1 K1
K1 K1
Customer
Control
Wiring and
Control
Section
INPUT/TRANSFORMER
CELL/OUTPUT
CABINET
FRONT VIEW CABINET
Figure 2-2. Typical GEN IIIe-style VFDs
2.1.1. Transformer Section

The transformer section of the Perfect Harmony drive contains the input power transformer. Input power
wires enter the drive through this section and output wires to the motor exit the drive through this section.
The input and output power wiring can enter and exit the drive from either the top or bottom of this
section. In addition to the main multi-secondary phase-shifting power transformer, the transformer
section contains either one or more blowers (at the top of the cabinet) used to cool the drive. Refer to
Figure 2-3. Major components of the transformer section are illustrated in Figure 2-3 and described in
Table 2-1.
*
Input and output wiring enters the cabinet from the top or bottom of the transformer section.

Blower
Figure 2-3. Power Section (Typical) of a GEN III-style Perfect Harmony Drive
Table 2-1. Field Connections and Major Components in the Transformer Section
Item Description
L1, L2, L3 Input power terminals
T1, T2, T3 Output power terminals
Transformer
T1 Multi-secondary, phase-shifting power transformer
T5 Control power transformer
F24-F35 Control fuses
F21, F22 Blower fuses
F4, F5 Fuses
BM1-BM5 Blower motor starters
CDS1 Control power disconnect switch
RA1-RA4, RB1-RB4, RC1-RC4 Input and output voltage feedback resistors
CT4, CT5 Output current transformers
TB-120-CUS Customer wiring terminal strip
METERING Metering terminal strip
TB-ELV Low voltage terminal strip (4-20 mA signals, etc.)

Figure 2-4. Field Connections and Major Components in the GEN III Transformer Section

Rear Bus Connections

between Cell and
Transformer are made
here
2
L1
L2
L3
T1, T2, T3
Figure 2-5. Field Connections and Major Components in the GEN IIIe Transformer Section (left)
and Cell Section (right)
2.1.2. Customer I/O Section

The customer I/O section of the drive contains terminal blocks for customer control wiring connections,
control power connections, and the blower control panel. Optional motor monitors and power quality
meters (PQMs) are mounted in this section if they are ordered with the drive. Refer to Figure 2-6.
*Refer to the “as built” system drawings that are shipped with the drive for information on specific
customer I/O connections.
*
Note: The rear bus connections need to be made prior to startup. It is recommended, but not
necessary, to have a minimum of two feet between the rear of the VFD and any wall or structure.
This is to allow easier connection of the rear bus between the transformer and the cell cabinets.
The VFD can be moved against the wall once the connections are made and the rear panel re-
installed.If space behind the VFD cannot be provided, the connections are made by removing the
hall affect CT’s and the panels between the fuse group. These are located behind the control box.

Blower
Customer
I/O
Section
Figure 2-6. Customer I/O Section (Typical) of a GEN III-style Perfect Harmony Drive
2.1.3. Cell and Control Sections (GEN III Cell Specifications)

The control section is a hinged section that swings out to provide access to the cell section. The control
section contains master control components. The cell section contains power cells and up to three
blowers mounted on top of the cabinet.
The AC drive system is offered in 5 basic cell sizes (current ratings), grouped to provide output operating
voltages of 3300 VAC (3 cells in series), 4160 VAC (4 cells in series), 4800 VAC (5 cells in series), and
6600 VAC (6 cells in series). Table 2-2 provides the basic specifications associated with all cell
combinations for the drives.
*
Note: Output current ratings are a function of the selected cell size. Input current ratings are a
function of the transformer size associated with each hp rating. All specifications are subject to
change without notice.
Table 2-2. GENIII Cell Specification Details
Output Line-to-line Cells in Drive hp Range Available Cell Sizes

Cells Per Voltages (VAC) (Without Spares)
Phase
3 3,300 9 up to 1500 70A, 100A, 140A, 200A, 260A
4 4,160 12 up to 2000 70A, 100A, 140A, 200A, 260A
6 6,600 18 up to 3000 70A, 100A, 140A, 200A, 260A

Table 2-3. GENIIIe Cell Specification Details

Phase
2 2 2,300 6 up to 3000 315A, 375A, 500A, 660A

3 3,300 9 up to 4000 315A, 375A, 500A, 660A
4 4,160/4,800 12 up to 6000 315A, 375A, 500A, 660A
5 6,000 15 up to 8000 315A, 375A, 500A, 660A
6 6,600 18 up to 0000 315A, 375A, 500A, 660A
The individual output cells are located in the Cell Section. All cells are electrically and mechanically
identical, so that they may be interchanged. Each cell contains its own control boards, which
communicate with the system through a fiber optic link. This link is the only connection between the cells
and the master control located in the Control Section, thus each cell is isolated from the main control.
Refer to Figure 2-7 for GENIII type cell. Refer to Figure 2-8and Figure 2-9 for GENIIIe type cells.
Figure 2-7. Typical GEN III Cell

Figure 2-8. Typical GENIIIe Cell
Figure 2-9. Details of GENIIIe Terminals and Indicators

Blower
Control
Cell Section
Section (Back)
2
Figure 2-10. Cell Section (Typical) of a GEN III-style Perfect Harmony Drive
A switch mode power supply located on the Cell Control/Gate Driver Board allows the control power to be
derived from the individual 3-phase secondary connections of the transformer.
The Control Section contains PC boards which provide central control of the Perfect Harmony drive
system. The Control Section is physically and electrically isolated from all medium voltage for safety.
Control for each of the output cells is provided via a fiber optic communications link between the Master
Control System and the Cell Control/Gate Driver Board located within each output cell.
The following tables give length and weight information for many common configurations of sectional
Perfect Harmony drives, based on 60 Hz input power at the voltages listed. If applications require inputs
at 50 Hz or HP not listed, sizes and weights will increase. GenIIIe weights and ventilation are estimated.
*
Note: The ventilation information (in CFM) and losses information (in BTUs) given in the following
tables represent worst case conditions. Actual values may vary based on load, blower size, cell
size and transformer size.
Table 2-4. 3,300 VAC GENIII Cell Specifications: 9 Cells Total, 3 (630 VAC) Cells in Series
Hp1 Amps In2 Amps Out3 Losses4 Ventilation5 Length6 Weight7 Size8
200 33 70 20,000 4,400 100 4,800 70
300 49 70 30,000 4,400 100 4,800 70
400 64 70 40,000 4,400 100 5,600 70
500 80 100 50,000 4,400 100 6,200 100
600 96 100 60,000 4,400 100 6,200 100
700 112 140 70,000 4,400 100 7,500 140
800 128 140 80,000 4,400 100 7,500 140
900 145 200 90,000 8,800 123 7,500 200
1000 162 200 100,000 8,800 123 8,000 200
1250 202 260 125,000 8,800 137 8,500 260
1500 242 260 150,000 8,800 137 9,000 260

300 38 70 30,000 4,400 100 5,100 70
400 51 70 40,000 4,400 100 5,100 70
500 63 70 50,000 4,400 100 5,800 70
600 75 100 60,000 4,400 100 6,600 100 2
700 89 100 70,000 4,400 100 6,600 100
800 101 140 80,000 4,400 100 7,700 140
900 114 140 90,000 4,400 100 7,700 140
1000 126 140 100,000 4,400 100 7,700 140
1250 160 200 125,000 8,800 137 9,500 200
1500 192 200 150,000 8,800 137 9,500 200
1750 224 260 175,000 8,800 137 10,000 260
2000 256 260 200,000 8,800 137 11,000 260
600 48 70 60,000 8,800 137 7,700 70
700 56 70 70,000 8,800 137 9,000 70
800 64 70 80,000 8,800 137 9,000 70
900 72 100 90,000 8,800 137 9,000 100
1000 80 100 100,000 8,800 137 10,400 100
1250 100 100 125,000 8,800 137 10,400 100
1500 120 140 150,000 8,800 137 12,300 140
1750 140 140 175,000 8,800 137 12,300 140
1750 141 200 175,000 13,200 172 12,500 200
2000 162 200 200,000 13,200 192 13,000 200
2250 182 200 225,000 13,200 192 13,000 200
2500 202 260 250,000 13,200 192 13,500 260
2750 222 260 275,000 13,200 192 14,000 260
3000 242 260 300,000 13,200 192 14,000 260
Table 2-7. 2,300 VAC GENIIIe Cell Specifications: 6 Cells Total, 2 (690 VAC) Cells in Series
1500 324 375 114,000 8,800 172 7,450 375H
1750 378 375 133,000 8,800 172 8,200 375H
2000 432 500 152,000 8,800 172 8,800 500H
2250 486 500 171,000 8,800 172 9,500 500H
2500 540 660 190,000 8,800 172 10,200 660H
3000 648 660 228,000 8,800 188 11,500 660H
1750 264 315 133,000 15,000 172 9,700 315H
2000 301 315 152,000 15,000 172 11,200 315H
2250 339 375 171,000 15,000 172 11,200 375H

2500 377 375 190,000 15,000 172 12,000 375H
3000 452 500 228,000 15,000 188 13,400 500H
3500 527 660 266,000 15,000 188 14,900 660H
4000 603 660 304,000 15,000 188 16,400 660H
2 Table 2-9. 4,160 VAC GENIIIe Cell Specifications: 12 Cells Total, 4 (690 VAC) Cells in Series
2250 269 315 171,000 18,000 192 13,800 315H
2500 299 315 190,000 18,000 192 14,600 315H
3000 359 375 228,000 18,000 208 16,200 375H
3500 418 500 266,000 18,000 208 17,900 500H
4000 487 500 304,000 18,000 208 19,100 500H
5000 598 660 380,000 18,000 232 22,800 660H
3500 290 315 266,000 25,000 248 20,100 315H
4000 331 375 304,000 25,000 272 21,900 375H
5000 414 500 380,000 25,000 272 25,500 500H
6000 497 500 450,000 25,000 272 29,100 500H
7000 580 660 532,000 25,000 272 32,700 660H
3500 264 315 266,000 28,000 248 21,900 315H
4000 301 315 304,000 28,000 272 23,800 315H
5000 377 375 380,000 28,000 272 27,700 375H
6000 452 500 450,000 28,000 272 31,600 500H
7000 527 660 532,000 28,000 272 35,500 660H
8000 603 660 608,000 28,000 272 39,400 660H
1
Motor nameplate hp may not exceed the drive rated hp.
2
Drive rated input current (in Amps) is the transformer rated current.
3
Drive rated output current (in Amps) is the maximum cell current.
4
Losses are given in BTU/hr and are based on a loss of 3 kW per 100 hp.
5
Minimum ventilation requirements are given in CFM (lps in parentheses)
6
Represents lineup minimum length in inches (centimeters in parentheses), subject to change.
7
Represents estimated minimum weight of lineup in pounds (kg in parentheses), subject to change.
8
Cell sizes for each hp are based on motors with ≥ 95% efficiency and ≥ 85% power factor.
The basic electrical diagrams for all Perfect Harmony systems are similar. Depending on the operating
voltages, different numbers of output cells are operated in series to develop the required output operating
voltage (refer to the previous tables).

2.1.4. Cell Bypass Option

As an option, each cell in the system can be equipped with a bypass contactor. This contactor will be
automatically energized by the VFD master control if the associated cell malfunctions. Once the
contactor is energized, the damaged cell is no longer electrically part of the system, which allows the VFD
to resume operation.
Anytime a cell malfunctions and is bypassed, the control automatically compensates (shifts the neutral
point) so that the motor voltage stays balanced. To compensate for the loss in voltage, systems with up 2
to 5 cells per phase can be equipped (as an option) with an extra cell per phase. The 3 spare cells would
then compensate for the loss in voltage. If spare cells are not installed, then the VFD will operate at a
slightly lower voltage, but will still provide full rated current.
The cell bypass system includes a bypass contactor per cell, a contactor control board (installed inside
the cell cabinet) and a fiber optic link between the master control system and the contactor control board.
2.2. The Cell Control System

All Perfect Harmony cells are controlled in the same manner. The Cell Control/Gate Driver Boards reside
within the output cell and accept all communication from the Digital Modulator in the Control Cabinet via
fiber-optic links.
Control power for all cell boards is supplied from a switch mode power supply resident on the Cell
Control/Gate Driver Board.
9 Cells 12 Cells 15 Cells 18 Cells
Cell Cell Cell Cell Cell Cell

A1 A2 A3 A4 A5 A6

B1 B2 B3 B4 B5 B6

C1 C2 C3 C4 C5 C6
Future Expansion
A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4
A5 B5 C5 A6 B6 C6
Fiber Optic Interface Board
Fiber Optic Interface Boards in Control Chassis
Figure 2-11. Typical Connection Diagram for an 18 Cell 6.6 KV System
2.3. The Master Control System

The Master Control located within the Control Cabinet consists of a chassis and several control boards
refer to Figure 2-12. The chassis is supplied power by a standalone power supply. The heart of the
control is the Microprocessor board. This board is the master of the backplane bus and controls the
operation of each board in the system.
Contained on the Microprocessor Board is Flash Disk, which may be removed from the Microprocessor
Board if, for any reason, the microprocessor board would need to be replaced. The Flash Disk contains

all the specific parameter information and system program for the VFD and therefore, allows the
Microprocessor Board to be replaced without the need to re-program the VFD.
*
NOTE! If the Microprocessor Board is replaced, the Flash Disk should be moved to the new board.
See Figure 2-13.
2 The System Interface board collects the drive input and output feedback signals and sends them to the
Analog to Digital board. The Analog to Digital board executes the conversion at specified intervals and
sends digital representations of the feedback signals to the Microprocessor board. The Microprocessor
board then computes the next set of values to be sent to the Digital Modulator and sends them. The
Digital Modulator then determines the switching commands for each cell and compiles a message with
this command for each cell. These messages are then sent through the Fiber Optic Interface boards.
Refer to Figure 2-12.
Note that the number of Fiber Optic Interface Boards and the number of fiber optic channels varies
depending on the number of cells in the drive.
Also shown in Figure 2-12 is a communications board. This board provides a direct interface to a
Modbus network and allows network adapter boards for several other industrial networks to be connected
to the drive control. A typical schematic of the master control is shown in Figure 2-14.

Fiber Optic Cable Modulator board

to By-pass board
Fiber Optic Interface boards
Communications board
System Interface board
Analog to Digital board 2

Microprocessor board
Fiber Optic Cables to Cells
Power
Supply
connection
Figure 2-12. Master Control System

Flash Disk
Figure 2-13. Location of Flash Disk on Microprocessor Board

T1 Cell
Special Transformer
with 18 Isolated A1
Secondaries
(9 for 3300 VAC) Cell
B1 Keypad
Cell
C1 2
Cell
A2
Cell Fiber
B2 Optic
Input Power Interface
3-phase AC Board
Cell
C2
Cell
A3
See 2.4.1.
Cell
B3 Microprocessor
Board
Cell
C3
Cell
A4
Cell
B4
Cell Digital WAGO

C4 Modulator I/O
Input Voltage and Board
Current Feedback
Cell
A5
Cell
B5
Analog to
Fiber Digital Board
Cell Optic
C5 &
Interface
Cell Board System
A6 Interface
Board
Cell
B6
Cell
C6 Conditioning
Circuits
Voltage
Attenuator
Induction
Motor
Figure 2-14. Typical Perfect Harmony Power Circuit

2.4. The Power Circuit

The basic power schematic for an 18 cell (4160 VAC) system is shown in Figure 2-14. Besides the direct
operating information received from each cell by the Fiber Optic System, input voltage, output voltage,
and current are also directly monitored. Input and output voltage information is supplied to the control
boards by an attenuator system consisting of a voltage divider and voltage clamps.
Two Hall Effect sensors placed on output phases B and C sense output motor current. Two CTs placed
2 on input phase B and C sense drive input current. Polarity and burden resistor values must always be
maintained.
Each secondary of the power transformer T1 serves one cell only. Each cell receives modulation
information through the Fiber Optic System in a way that develops the required output voltage and
frequency demanded by the load. Unlike standard PWM systems, the voltage applied to the motor leads
is developed in many small steps instead of through a few large steps. This provides two distinct
advantages: the voltage stress on the motor insulation is dramatically reduced, and the quality of the
motor currents is dramatically increased.
DANGER—Electrical Hazard! Even though each cell by itself develops no more than 690
VAC, the voltage to ground can increase to the rated drive output.
Since each cell is fed from transformer T1 with varying degrees of phase shift (see Figure 2-14), the input
VFD current distortion is dramatically reduced. Input power factor is always maintained greater than 0.94
lagging.
Each VFD cell within a specific system is identical (refer to Figure 2-15). Larger and smaller versions of
power cells differ in the size or quantity of input diodes, filter capacitors and IGBTs.
At a minimum, each cell contains a Cell Control Board and an IGBT Gate Driver Board. The Cell Control
Board performs all communication and control for each cell.
2.4.1. Monitoring of Input Power Quality

Input currents and voltages to the drive input T1 transformer are also measured and processed
continuously by the control system. Information such as efficiency, power factor, and harmonics are
available to the user. The input monitoring also protects against T1 transformer secondary side faults that
cannot be seen by typical primary protection relaying. Thus it is very important that the drive input
medium switchgear, if not supplied as standard, is interlocked to the control system so that input medium
voltage can be interrupted upon the rare event of such a fault.
A Form C 250VAC/300VDC rated contact output is supplied standard with each drive to trip the drive
input medium voltage circuit breaker or contactor. This contact is designated "TRIP INPUT MEDIUM
VOLTAGE" and changes state whenever the drive input power and power factor are outside hardcoded
normal operating conditions. This contact must be integrated with input switchgear to deactivate drive
input medium voltage in the rare event of a T1 transformer secondary circuit fault.
DANGER! This contact must be integrated with input switch-gear to deactivate the drive input
medium voltage upon the rare event of a secondary circuit fault.

Input fuses for

GENIIIe are not
located in Cell
Figure 2-15. Typical Power Cell Schematic

∇ ∇ ∇

Perfect Harmony GENIII/e Installation Manual INSTALLATION AND SET-UP
CHAPTER 3: INSTALLATION AND SET-UP
3.1. Introduction
Be sure to read and understand this procedure before installing the Perfect Harmony drive. Installation is
divided into the following sections:
• receiving • re-connecting shipping splits

• shipping splits • anchoring cabinets to floors and walls
• weight estimates • re-connecting internal wiring
• handling • external wiring
• location • torque specifications and insulation resistances. 3
Each of these installation components are discussed in the sections that follow.
3.2. Receiving
The proper receiving procedure consists of the following steps:
• Verify that the proper items have been shipped
• Inspect shipments for damage that may have occurred in transit
• File a claim with the shipping carrier if any damage is present.
3.3. Shipping Splits
The GEN III unit is self contained and shipped as one unit (see Figure 3-7). The GENIIIe units,
depending on size, may be in shipped self-contained or in two sections only (Transformer/Input section
and Cell-Control/Output section)
3.4. Weight Estimates

Because the Perfect Harmony drive system is a customizable system, exact weights of systems will vary
based on the ratings of the drive and included options. However, approximate dimensions and weight
estimates for Perfect Harmony drives are given in tables in Chapter 2.
3.5. Handling
Due to the size and weight of Perfect Harmony components, it is important to carefully plan all handling
operations. Off-loading from the truck is often the most critical operation because of the limited access.
Advanced planning and coordination between the manufacturer, the carrier, the installation contractor,
and the owner are vital.
Danger! Never attempt to support the Transformer Cabinet using only the upper cabinet
structure. Never use eye bolts for lifting any of the Perfect Harmony cabinets. Eye bolts are
used at the beginning of the manufacturing process when the cabinets weigh much less. Drives
may be shipped with the eye bolts removed from certain cabinets (for example, the Transformer
Cabinet).
Perfect Harmony enclosures are provided with heavy duty base structures that contain transverse tubes
to accept fork-lift tines. There are four possible methods of handling cabinets:
• overhead crane lifting using slings (cabinet must have base tubes)
• fork lift truck lifting (cabinet must have base tubes)
• roller dollies

INSTALLATION AND SET-UP Perfect Harmony GENIII/e Installation Manual
• pipe rollers.
These methods are summarized in the sections that follow.
3.5.1. Overhead Crane Lifting Using Slings

If an overhead crane is available, the best method is to pass fabric slings through the base tubes and lift
as shown in Figure 3-1. The slings must be long enough that the crane hook is at least 4 feet above the
top of the enclosure to prevent buckling of the drive cabinet. If this distance cannot be maintained,
spreader bars of appropriate strength must be used. The strength of the slings must be adequate for the
weight given on the drawings (or estimated in Chapter 2).
Attention! Be sure to use slings that are strong enough to support the weight of the drive and
long enough to prevent the cabinet from buckling. Refer to Figure 3-1.
3
Use spreader Without

bar if < 4 ft. spreader bar
4 ft. min.
< 4 ft.. < 4 ft.
Front Side Front Side Front Side
Figure 3-1. Proper Handling Using the Sling Lifting Technique and an Overhead Crane
3.5.2. Using a Fork Lift Truck

A second handling method is to use a suitable fork lift truck. The tines of the truck must be at least 40″
long, and no greater than 10″ wide or 2.5″ thick. Transformer cabinets will accept tines that are up to
2.75″ thick. The tine spacing must be adjustable from 30″ to 50″.
Warning!
Be sure that the fork truck is appropriately rated for the weight being lifted.
Be careful that the fork lift does not damage the front surface of the enclosure. It is a good idea
to place a wooden stop block in the corner of the tines as shown in Figure 3-2. The center of
gravity of the Perfect Harmony enclosure is approximately midway between the front and back
surfaces.

Side
Tine spacing must adjust

Fork
from 30″ to 50″ Wooden
Truck C.G.
Block
Tine width is 10″ (maximum) Side

Tine height is 2.5″ (maximum)
3
Fork
Truck C.G.
Tine length must be

at least 40″ long
Figure 3-2. Proper Fork Lift Handling and Dimensions
3.5.3. Using Roller Dollies

If roller dollies are used on the GenIII enclosures, they should be placed under the front and rear
channels of the base, just outside the fork tubes as shown in Figure 3-3. An additional roller may be
needed under the middle transformer support on the GenIIIe units. If this is not feasible, the rollers must
be placed under the transformer support structure.
Figure 3-3. Proper Placement of Roller Dollies
Warning! Be sure that the roller dollies are appropriately rated for the weight being supported.
3.5.4. Using Pipe Rollers

This is the least preferred method of handling. It is possible to set the enclosure on many parallel pipe
sections placed on the floor and move it by rolling.

Warning! If pipe rollers are used, the pipes must be no less than 2″ in diameter and at least 48″
in length for GenIII units and 50” to 54” for the GenIIIe units depending on the cabinet depth.
The pipes must be spaced no more than 18″ apart. Refer to Figure 3-4.
3 18” max.
Figure 3-4. Proper Use of Pipe Rollers in Handling Perfect Harmony Cabinets
3.6. Location
When choosing the location for the Perfect Harmony drive be sure the area is clean, flat, dry, and the
front of the drive is easily accessible with the drive doors open.
When installing the GenIIIe cabinets, it is recommended, but not necessary, to leave approximately two
feet between the rear of the unit and any wall or structure. This is done to allow easy access to the
electrical and mechanical connections between the transformer and cell sections. Once the connections
are made, the unit may be moved flush with the wall.
Warning! If the mounting surface is not flat, the metal cabinets of the drive may buckle, causing
the cabinet doors to be misaligned. If this happens, the cabinet doors may not open and close
properly.
All cooling air for both the Cell and Transformer Cabinets is drawn through the front doors and ejected
through the roof. The final placement of the drive should permit appropriate air circulation. Refer to the
tables in Chapter 2 for rated losses and ventilation requirements for various drive sizes.

Caution!
The performance of the centrifugal blower is strongly affected by output plenum pressure and air
resistance.
Indoor equipment is not weatherproof and must be protected. If it is necessary to temporarily
store the drive or its components in an outdoor area, heaters should be used in the equipment to
prevent moisture accumulation. A protective cover such as plastic or a tarp should be placed over
the drive to eliminate exposure to the outside elements. This is especially important if the storage
is for more than a few days.
In GEN II drives, verify that all rear cabinet plenum connections between Transformer and Cell.
Blower Cabinets must be securely connected so that all gaps are less than 1/8″. Larger gaps may
significantly reduce the cooling airflow that passes across the cells and transformer.
3
3.7. Anchoring Cabinets to Floors and Walls

Holes for anchor bolts are located on the base-mounting channel for each cabinet section (see
Figure 3-5). When anchoring the unit to the floor, the installer should use cemented J-bars on all
corners. Holes in the base of the drive cabinets are 0.81″ in diameter and easily accept 0.5″ threaded J-
bars. If the drive is mounted against a wall, top angles may be used to secure the drive to the back wall
in lieu of the rear J-bar connections to the floor. Refer to Figure 3-5. Exact dimensions are given in the
system drawings supplied with the drive.
0.81” diam. Wall

hole Side
Concrete
Concrete
Figure 3-5. Proper Anchoring Techniques for Perfect Harmony Cabinets
3. 8. Transformer Cabinet Wiring

Located at the bottom of the transformer is a set of ±5% voltage taps for compensating the primary
voltage source (see Figure 3-6). The VFD is shipped with the +5% taps connected. This means that the
VFD secondary cell voltages are at the nominal 460 VAC or 690VAC (for example) for an input voltage of
5% above primary nominal rating.

Taps Taps Taps

-5% 0 +5% -5% 0 +5% -5% 0 +5%
Taps Taps Taps
3
-5% 0 +5% -5% 0 +5% -5% 0 +5%
Figure 3-6. Transformer Cabinet Detail Showing Typical Tap Connections
Attention! Do not change the transformer tap connections unless operating experience
requires it.
Attention! The transformer primary winding neutral point is designed to operate floating
(ungrounded). Do not bond the transformer primary winding neutral point to ground. Failure to
adhere to this instruction will cause large, unbalanced currents to circulate in the ground/neutral
path of the drive’s input source system during drive energization.
3.9. External Wiring

External wiring diagrams are provided with the drawing package that is shipped with the Perfect Harmony
system. Follow the instructions on the drawings provided with your system.
Caution – Electrical Hazard!

Standard safety precautions and local codes must be followed during installation of external
wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any other
wiring as specified in the CE safety standard.
Warning!
For proper cooling, always maintain the control power when medium voltage is applied to the
VFD.
To maintain EMC compliance, be sure to use shielded cables as described on the drawings
shipped with the Perfect Harmony system.
3.9.1. Input Power Wiring
Attention!
In order to maintain EMC compliance, input power wiring must be installed in metallic electrical
conduit and routed through the approved wire ways. Improper phasing of the AC Control Power
will cause the blower motor(s) to run in reverse. Be sure to verify proper phasing to avoid
overheating the drive. GEN III AC power input must be routed through input CTs.
Customer-supplied AC power for both control and blowers enters an access plate in the top or bottom of
the Control Cabinet. Customer-supplied medium voltage power enters an access plate in the top or

bottom of the Power Input Cabinet. Figure 3-7 shows the location of these access plates on a typical
Perfect Harmony VFD Lineup.
3.9.2. Input Primary Power Interruption
3
VOLTAGE" and changes state whenever the drive input power and power factor are outside hard-coded
Danger! This contact must be integrated with input switch-gear to deactivate the drive input
Motor MV
Cables Entry
Input MV
Cables Entry
Input Control Power Cables and

User Control Signals Entry
Figure 3-7. Typical GEN III VFD

Transformer and Cell Output MV & Control Cables

Cabinet separate here. – top and bottom
Input MV
Cables –
top and
bottom
Figure 3-8. Typical GEN IIIe VFD
*
Note: Harmony drives are wired to have correct blower rotation for R-S-T phase sequencing.
Wire all phases according to standard codes (wire the phases from left to right [T1-T2-T3 or R-
S-T] for proper operation). Check blower rotation at start-up. With blowers running and doors
closed, make sure air flows into air filters and comes out the top of the cabinet by using a piece
of paper.
Conductor sizes for input power may vary based on the size of the drive and the dynamics of the system.
The customized system power schematic (included with your drive) shows the conductor size used on
the main transformer taps. The size of the input power conductors will usually match this size, however,
be sure to size the input conductors appropriately for your particular application, taking into account the
length of the input power feed and your local standards and electrical codes. Torque specifications are
given in Section 3.10.
3.9.3. Grounding
Danger - Electrical Hazard! Ground bonding cables are factory made. Re-connect ground
bonding between cabinets at shipping split(s). A fixed ground connection is also required.
Ensure that the entire system is earth grounded at one of its grounding points. Grounding
points are located inside the cabinet and are labeled with the protective earth symbol .

The cross sectional area of the grounding conductors relates to the cross sectional area of the service
conductors as shown in Table 3-1.
Table 3-1. Grounding Conductor Sizes
Cross Sectional Area of Minimum Cross Sectional Area of the Corresponding

Phase Conductors S (in mm2) Protective Conductor Sp (in mm2)
S ≤ 16 S
16 < S ≤ 35 16
S > 35 S/2
3.9.4. Drive Inhibit and Emergency Stop Wiring

3
The Perfect Harmony system provides an option for an emergency stop (or E-stop) “mushroom” push
button that performs two distinct functions (see Figure 3-9):
1. It issues an internal stop command causing all IGBTs to stop firing. (Drive Inhibit)
2. If installed properly, it deactivates a customer-supplied electromechanical contactor that removes
VFD power. (E-stop)
Normally-closed push button provides
coordinated access to an E-stop
function and an inhibit function.
(1)
To CR3
(2) When activated, this inhibits the VFD control, commanding it to
stop firing all IGBTs.
To the Customer’s Control I/O Termination Block

This electrically isolated contact (which is accessible from the
Control I/O Termination Block) can be used to provide additional
safety by deactivating an electromechanical contactor to
completely remove electrical power from the VFD. This E-stop
branch is made accessible to the customer for additional
protection.
Figure 3-9. The Drive Inhibit/Emergency Stop of the Perfect Harmony
3.10. Torque Specifications

Connections made during the installation of the Perfect Harmony drive must be torqued to the appropriate
values. Torque specifications for the Perfect Harmony drive are listed below.

Table 3-2. Torque Specifications for the Perfect Harmony
Standard Torque Chart Deviations to Standard Torque Specifications

Fastener Size Tightening Perfect Harmony Tightening
English (Metric) Torque Connectors Torque
2-56 (M2) 3.0 in-lb all green connectors 6.0 in-lb
4-40 (M3) 6.0 in-lb receptacle GRND 36.0 in-lb
6-32 (M3.5) 12.0 in-lb panel GRND 22.0 in-lb
8-32 (M4) 22.0 in-lb F4, F5, F21, F22 22.0 in-lb
3 10-32 (M5) 36.0 in-lb F23, F24, F25 36.0 in-lb
1/4-20 (M6) 70.0 in-lb 3MI 9.0 in-lb
1/4-20 (M6) elec 100.0 in-lb TB2, TBAMA, B, C, metal cover 12.0 in-lb
1/4-28 70.0 in-lb T6, relays, receptacle wiring 12.0 in-lb
5/16-18 155.0 in-lb transformer GND (T5) 70.0 in-lb
(M8) 80.0 in-lb PB and light switches (door) 9.0 in-lb
3/8-16, 3/8-24 275.0 in-lb RTM 4.0 in-lb
(M10) 180.0 in-lb keypad 6.0 in-lb
1/2-13 (M12) 672.0 in-lb breaker (wiring) lugs 36.0 in-lb
5/8-11 112.0 ft-lb CTB and CTC terminals 12.0 in-lb
3/4-10 198.0 ft-lb
1 500.0 ft-lb
3.11. Insulation Resistances

After all necessary wiring is reconnected, insulation resistance of interconnecting conductors must be
measured and verified against the values in Table 3-3.
Table 3-3. Minimum Values of Insulation Resistances
Nominal Circuit Voltage Test Insulation

Voltage Resistance
Extremely low voltages (ELVs)1 (≤ 50 VAC and ≤ 120 VDC) 250 VDC ≥ 0.25 MΩ
Up to and including 500 V, with the exception of the above cases 500 VDC ≥ 0.5 MΩ
Above 500 V 1000 VDC ≥ 1.0 MΩ
1 - This includes protective ELV (PELV), safety ELV (SELV) and functional ELV (FELV) when the circuit is supplied from a safety
transformer (IEC 364-4-411.1.2.1) and also fulfills the requirements of IEC 364-4-411.1.3.3.

3.12. Cell Capacitor Reforming

The electrolytic capacitors used in the filter section of each power cell should be re-formed to replenish
lost oxide prior to full power primary energization if one or both of the following conditions are noted:
• Cell have been stored voltage free for more than 2 years at between the storage temperature of -
55oC and 45oC
• Cells have been stored voltage free above 45oC for more than 1 month.
Reformation requires operation from a variable voltage source of at least 1KVA rating for up to 1.5hrs.
This can be accomplished by using a single or 3 phase variable voltage source (variac ) capable of 0-
760vac. (Consult ASIRobicon service support for more information). The procedure is as follows:
3
• Connect variac to input terminals L1-L2-L3
• Raise voltage to 25% increments of the rated cell voltage for 15 minutes at a time (about 125vac for
460vac rated cells and about 200vac for 690vac cells) until the 10% High line rating of the cell is
achieved (500vac for 460vac cells or 760vac for 690vac cells)
• Maintain 10% High line rated voltage for an additional 1.5 hours.

∇ ∇ ∇

Perfect Harmony GENIII/e Installation Manual GLOSSARY OF TERMS
APPENDIX A: GLOSSARY OF TERMS A

This appendix contains definitions of terms and abbreviations used throughout the Perfect Harmony
series manuals.
AND - AND is a logical Boolean function whose output is true if all of the inputs are true. In SOP
notation, AND is represented as “•” (e.g., C=A•B), although sometimes it may be omitted between
operands with the AND operation being implied (e.g., C=AB).
ASCII - ASCII is an acronym for American Standard Code for Information Interchange, an set of 8-bit
computer codes used for the representation of text.
automatic bypass operation - Automatic bypass operation is the same as bypass operation, but it
occurs automatically if a drive fault occurs and a pre-defined time has elapsed after the fault.
automatic mode - Automatic mode is a control scheme in which the operator selects an input to be used
as the desired velocity input. Speed profiling is used in automatic mode to allow the operator to scale the
output based on a programmable input range.
baud rate - Baud rate is a measure of the switching speed of a line representing the number of changes
of state of the line per second. Note that that this term commonly (and erroneously) is used to specify a
“bits per second” value for any modem speed. The baud rate of the serial port of the Perfect Harmony is
selected through the Baud Rate parameter in the Communications Menu [9].
bit - Bit is an acronym for BInary digiT. Typically, bits are used to indicate either a true (1) or false (0)
state within the drive’s programming.
Boolean algebra - A form of mathematical rules developed by the mathematician George Boole used in
the design of digital and logic systems.
bypass option - Bypass is an option that can be selected to customize a drive to provide optional line
operation of the motor.
carrier frequency - Carrier frequency is a unique frequency that is used to “carry” data within its
boundaries. The carrier frequency is measured in cycles per second (Hz).
“catch a spinning load” feature - Catch a spinning load is a feature that can be used with high-inertia
loads (e.g., fans) in which the drive may attempt to turn on while the motor is already turning. This
feature can be enabled using the Spinning Load Select parameter in the Drive Parameter Menu [14]. Also
reference the Spinning Load Threshold parameter in the Standard Control Submenu [24].
comparator - A comparator is a device that compares two quantities and determines their equality. The
Perfect Harmony contains 16 software equivalents located in submenus 121 through 136. These
comparator submenus allow the programmer to specify two variables to be compared. The results of the
16 custom comparison operations can be used in the system program.
converter - The converter is the component of the drive that changes AC voltage to DC voltage.
critical speed avoidance - Critical speed avoidance is a feature that allows the operator to program up
to 3 mechanical system frequencies that the drive will “skip over” during its operation.
DC link - The DC link is a large inductor between the converter and inverter section of the drive. The DC
link, along with the converter, establish the current source for the inverter.
De Morgan’s Theorem - The duality principal of Boolean algebra. Refer to the system program section
for more information.
downloading - Downloading is a process by which information is transmitted from a remote device (such
as a PC) to the drive. The term downloading implies the transmission of an entire file of information (e.g.,
the system program) rather than continued interactive communications between the two devices. The
use of a PC for downloading requires special serial communications software to be available on the PC.
DRCTRY - Directory file which contains system tokens and internal addresses.
Version 1.1 (19000403) ASIRobicon A-1

GLOSSARY OF TERMS Perfect Harmony GENIII/e Installation Manual
drive - The term “drive” refers to the controlled source for both power and control of a motor (i.e., the
A Perfect Harmony system).
EEPROM - EEPROM is an acronym for electrically erasable programmable read-only memory. An
EEPROM is a memory chip that holds its contents without power. Parameter values such as setpoints
are stored in EEPROM.
ELV - ELV is an acronym for extra low voltage and represents any voltage not exceeding a limit which is
generally accepted to be 50 VAC and 120 VDC (ripple free).
EMC - EMC is an acronym for electromagnetic compatibility–the ability of equipment to function
satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic
disturbances to anything in that environment.
EPROM - EPROM is an acronym for erasable programmable read-only memory. An EPROM is used to
hold the program code that runs the drive.
ESD - ESD is an acronym for electrostatic discharge. ESD is an undesirable electrical side effect that
occurs when static charges build up on a surface and are discharged to another. When printed circuit
boards are involved, impaired operation and component damage are possible side effects due to the
static sensitive nature of the PC board components. These side effects may manifest themselves as
intermittent problems or total component failures. It is important to recognize that these effects are
cumulative and may not be obvious.
fault log - Fault messages are saved to memory so that the operator may view them at a later time. This
memory location is called the fault log. The fault log lists fault messages, the date and time that they
occurred. The Fault Log Menu [33] contains functions that are used to display and upload the fault log.
faults - Faults are error conditions that have occurred in the Perfect Harmony system. The severity of
faults vary. Likewise, the treatment or corrective action for faults may vary from changing a parameter
value to replacing a hardware component such as a fuse.
function - A function is one of four components found in the Perfect Harmony menu system. Functions
are built-in programs that perform specific tasks. Examples of functions include System Program
Upload/Download and Display System Program Name.
GAL - GAL is an acronym for Generic Array Logic - a device similar to a PAL (programmable array logic)
that is electrically erasable and programmable like an EEPROM.
harmonics - Harmonics are undesirable AC currents or voltages at integer multiples of the fundamental
frequency. The fundamental frequency is the lowest frequency in the wave form (generally the repetition
frequency). Harmonics are present in any non-sinusoidal wave form and they cannot transfer power on
average.
Harmonics arise from non-linear loads in which current is not strictly proportional to voltage. Linear loads
like resistors, capacitors and inductors do not produce harmonics. However, non-linear devices such as
diodes and SCRs do generate harmonic currents. Harmonics are also found in uninterruptable power
supplies (UPSs), rectifiers, transformers, ballasts, welders, arc furnaces and personal computers.
hexadecimal digits - Hexadecimal (or “hex”) digits are the “numerals” used to represent numbers in the
base 16 (hex) number system. Unlike the more familiar decimal system which uses the numerals 0
through 9 to make numbers in powers of 10, the base 16 number system uses the numerals 0, 1, 2, 3, 4,
5, 6, 7, 8, 9, A, B, C, D, E, and F to make numbers in powers of 16. Hex numbers A through F are rarely
used in the Perfect Harmony, but can be entered from the keypad using the [Shift] plus the number keys
[1] through [6].
historic log - The historic log is a troubleshooting/diagnostic tool of the Perfect Harmony. The historic
log continuously logs 78 entries, each containing the drive state, two fault words and 10 user-selectable
variables. This information is sampled every 1 ms (1,000 times per second). When a fault condition
occurs, the previous 58 samples are recorded along with the next 20 samples (for a total of 78 samples)
and stored in backed-up NVRAM. This information stays in NVRAM until the next fault occurs, at which
A-2 ASIRobicon Version 1.1 (19000403)

time the old information is overwritten. The information in NVRAM is stored in ASCII hex format and can
be uploaded via the drive’s serial port to a PC for troubleshooting analysis. A
hmpd - The term “hmpd” refers to a set of four security fields associated with each parameter of the
system. These fields allow the operator to individually customize specific security features for each menu
option (submenu, parameter, pick list and function). These fields are shown in parameter dumps and
have the following meanings. Setting H=1 hides the menu option from view until the appropriate access
level has been activated. Setting M=1 blocks submenus from printing when a parameter dump is
performed. Setting P=1 locks out the menu option during parameter dump printouts. Setting D=1 hides
the menu option only when the drive is running.
I/O - I/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a
computer system. Both inputs and outputs can be classified as analog (e.g., input power, drive output,
meter outputs, etc.) or digital (e.g., contact closures or switch inputs, relay outputs, etc.).
IGBT - IGBT is an acronym for Insulated Gate Bipolar Transistors. IGBTs are semiconductors that are
used in the Perfect Harmony drives to provide reliable, high-speed switching, high-power capabilities,
improved control accuracy and reduced motor noise.
induction motor - An induction motor is an AC motor that produces torque by the reaction between a
varying magnetic field (generated in the stator) and the current induced in the coils of the rotor.
Intel hex - Intel hex refers to a file format in which records consist of ASCII format hexadecimal (base 16)
numbers with load address information and error checking embedded.
inverter - The inverter is a portion of the drive that changes DC voltage into AC voltage. The term
“inverter” is sometimes used mistakenly to refer to the entire drive (the converter, DC link and inverter
sections).
jerk rate - Jerk rate is the time it takes for the drive to go from one acceleration rate to another. The jerk
rateis a programmable parameter used to limit the rate of change of the acceleration. Jerk rate has no
effect if acceleration is constant. Jerk rate helps to prevent small overshoots and provides the “S-curve”
(time/speed plot) characteristic as the speed setpoint is reached.
jog mode - Jog mode is an operational mode that uses a pre-programmed jog speed when a digital input
(programmed as the jog mode input) is closed.
jumpers - Jumper blocks are groups of pins that can control functions of the system based on the state
of the jumpers. Jumpers (small, removable connectors) are either installed (on) or not installed (off) to
provide a hardware switch.
ladder logic - (Also Ladder Diagram) A graphical representation of logic in which two vertical lines
representing power flow from the source on the left and the sink on the right with logic branches running
between and resembling rungs of a ladder. Each branch consists of various labeled contacts placed in
series and connected to a single relay coil (or function block) on the right.
LCD - liquid crystal display. On the Perfect Harmony, a 2-line by 24-character back-lit display interface
located on the front panel of the system.
LED - LED is an acronym for light emitting diode. The Perfect Harmony uses three LEDs as diagnostic
indicators on the keypad/display assembly.
loss of signal feature - The loss of signal feature is a control scheme (in automatic mode) that gives the
operator the ability to select one of 3 possible actions in the event that an external sensor is configured to
specify the speed demand and the signal from that sensor is lost. Under this condition, the operator may
program the drive (through the system program) to (1) revert to a fixed, pre-programmed speed, (2)
maintain the current speed, or (3) perform a controlled (ramped) stop of the drive. By default, current
speed is maintained.
manual mode - Manual mode is a control scheme of the Perfect Harmony in which the desired velocity of
the drive is set manually by the operator. In local manual mode, the desired velocity is set using the up

and down arrow keys on the front keypad of the drive. In remote manual mode, the desired velocity is set
A using a potentiometer input (located remotely from the drive) that is wired to the drive.
memory - Memory is the working storage area for the Perfect Harmony drive that is a collection of RAM
chips.
microprocessor - A microprocessor is a central processing unit (CPU) that exists on a single silicon
chip. The microprocessor board is the printed circuit board on which the microprocessor is mounted.
NEMA 1 and NEMA 12 - NEMA 1 is an enclosure rating in which no openings allow penetration of a 0.25-
inch diameter rod. NEMA 1 enclosures are intended for indoor use only. NEMA 12 is a more stringent
NEMA rating in which the cabinet is said to be “dust tight” (although it is still not advisable to use NEMA
12 in conductive dust atmospheres).
Normally closed (NC) - Normally closed refers to the contact of a relay that is closed when the coil is de-
energized.
Normally open (NO) - Normally open refers to the contact of a relay that is open when the coil is de-
energized.
NVRAM - An acronym for non-volatile random access memory, NVRAM is an area of memory that is
backed-up by battery. In other words, information stored in NVRAM is maintained if power to the drive is
lost (however backup power in the form of a battery, for example, must be maintained or the contents are
lost).
OOS - OOS is an abbreviation for out of saturation - a type of fault condition in which a voltage drop is
detected across one branch/phase of the IGBT during conduction. This can indicate that the motor is
drawing current too rapidly.
OR - OR is a logical Boolean function whose output is true if any of the inputs is true. In SOP notation,
OR is represented as “+”.
parameter - A parameter is one of four items found in the Perfect Harmony menu system. Parameters
are system attributes which have corresponding values that can be monitored or, in some cases,
changed by the user.
pick list - A pick list is one of four items found in the Perfect Harmony menu system. Pick lists are
parameters that have a finite list of pre-defined “values” from which to choose, rather than a value ranged
used by parameters.
PID - PID is an acronym for proportional + integral + derivative, a control scheme used to control
modulating equipment in such a way that the control output is based on (1) a proportional amount of the
error between the desired setpoint and the actual feedback value, (2) the summation of this error over
time, and (3) the change in error over time. Output contributions from each of these three components
are combined to create a single output response. The amount of contribution from each component is
programmable through gain parameters. By optimizing these gain parameters, the operator can “tune”
the PID control loop for maximum efficiency, minimal overshoot, quick response time and minimal cycling.
qualified user - A qualified user is an individual who is familiar with the construction and operation of the
equipment and the hazards involved.
quick menu - Quick menu is a feature of the menu system that allows the operator to directly access one
of the nine top level menus (1-9) rather than scrolling through the Main Menu [5] to the appropriate menu.
This feature uses the [Shift] button in conjunction with the numerical buttons 1-9. The corresponding
menus are listed in green text above the numbers on the keypad buttons. Note that the Security Edit
Menu [0] is not available through the quick menu feature. It is available only through the Main Menu [5].
RAM - RAM is an acronym for random access memory, a temporary storage area for drive information.
The information in RAM is lost when power is no longer supplied to it. Therefore, it is referred to as
volatile memory. Compare RAM with NVRAM (non-volatile RAM) which is electrically backed-up memory
that does not lose its contents when the drive is shut off.

regeneration - Regeneration is the characteristic of an AC motor to act as a generator when the rotor’s
synchronous frequency is greater than the applied frequency. A
relay - A relay is an electrically controlled device that causes electrical contacts to change their status.
Open contacts will close and closed contacts will open when rated voltage is applied to the coil of a relay.
resonance avoidance - Resonance avoidance is a feature that allows the operator to program up to 3
mechanical system frequencies that the drive will “skip over” during its operation.
RS232C - RS232C is a serial communications standard of the Electronics Industries Association (EIA).
The RS232C interface is a DB25 serial port located on the front of the drive or on DB9 of the
microprocessor board. This interface is used to connect the drive to a printer, dumb terminal or PC to
allow parameter listing, system program downloading (after off-line editing), and uploading of historical
and diagnostic log files.
serial port - Serial port refers to the external connector on the Perfect Harmony that is used to connect to
a serial device such as a PC, serial printer, or serial network. The serial port transmits information one bit
(1 or 0) at a time sequentially, as compared to parallel transmission which transmits 8 or 16 bits (for
example) at a time.
setpoint - Setpoint is the desired or optimal speed of the VFD to maintain process levels. (Speed
command).
slip - Slip is the difference between the stator frequency of the motor and the rotor frequency of the
motor, normalized to the stator frequency as shown in the following equation.
Slip = ω S - ω R
ωS
Slip is the force that produces torque in an induction motor. Slip can also be defined as the shaft power
of the motor divided by the stator input power.
slip compensation - Slip compensation is a method of increasing the speed reference to the speed
regulator circuit (based on the motor torque) to maintain motor speed as the load on the motor changes.
The slip compensation circuit increases the frequency at which the inverter section is fired to compensate
for decreased speed. For example, a motor with a speed of 1760 rpm has a slip of 40 rpm. The no load
rpm would be 1800 rpm. If the motor name plate current is 100 A, the drive is sending a 60 Hz wave form
to the motor, and the motor is fully loaded, then the slip compensation circuit would fire the inverter
1.33 Hz faster to allow the motor to run at 1800 rpm.
SOP - SOP is an acronym for “sum of products”. The term “sum-of-products” comes from the application
of Boolean algebraic rules to produce a set of terms or conditions that are grouped in a fashion that
represents parallel paths (ORing) of required conditions that all must be met (ANDing). This would be
equivalent to branches of connected contacts on a relay logic ladder that connect to a common relay coil.
In fact the notation can be used as a shortcut to describe the ladder logic.
standard control - Standard control is one of two available application modes of the Perfect Harmony
drive. Standard control mode means that the control algorithm of the drive consists of an open loop
speed control component with closed loop voltage and current control. In standard control applications,
the drive compensates for the load by using the current and voltage loops. Encoders and magnetic
pickups are not needed in standard control applications. Typical standard control applications include
centrifugal loads such as fans and pumps. Compare with vector control.
stop mode - Stop mode is used to shut down the drive in a controlled manner, regardless of its current
state. To enter this mode, the operator must either press the [Manual Stop] button on the system keypad
or press a user-supplied, digital input switch that is programmed as a manual stop input.
submenus - A submenu is one of four components found in the Perfect Harmony menu system.
Submenus are nested menus (i.e., menus within other menus). Submenus are used to logically group
menu items based on similar functionality or use.
synchronous speed - Synchronous speed refers to the speed of an AC induction motor’s rotating
magnetic field. It is determined by the frequency applied to the stator and the number of magnetic poles

present in each phase of the stator windings. Synchronous Speed equals 120 times the applied
A Frequency (in Hz) divided by the number of poles per phase.
system program - The functions of the programmable inputs and outputs are determined by the default
system program. These functions can be changed by modifying the appropriate setup menus from the
front keypad and display. I/O assignments can also be changed by editing the system program (an ASCII
text file with the extension .SOP), compiling it using the compiler program (CMP.EXE), and then
downloading it to the controller through its serial port.
torque - The force that produces (or attempts to produce) rotation as in the case of a motor.
uploading - Uploading is a process by which information is transmitted from the drive to a remote device
such as a PC. The term uploading implies the transmission of an entire file of information (e.g., the
system program) rather than continued interactive communications between the two devices. The use of
a PC for uploading requires special serial communications software to be available on the PC.
variable frequency drive (VFD) - A VFD is a device that takes a fixed voltage and fixed frequency AC
input source and converts it to a fixed voltage, variable frequency output that can be used to control the
speed of an AC motor.
vector control - Vector control is one of two available application modes of the Perfect Harmony drive.
Vector control mode means that the control algorithm of the drive consists of a closed loop speed control
component and a closed loop torque control component. Since vector control applications require (a)
precisely controlled starting torques (±0.1%), (b) precisely controlled speeds (±0.1%), and/or (c) fast
response, such applications use either an encoder or a magnetic pickup for direct speed control
feedback. Typical vector control applications include centrifuges, extruders and test stands. Compare
with standard control.
∇ ∇ ∇

Perfect Harmony GENIII/e Installation Manual COMMONLY USED ABBREVIATIONS
APPENDIX B: COMMONLY USED ABBREVIATIONS

This appendix contains a list of symbols and abbreviations commonly used throughout the Perfect Harmony series
of manuals.
Table B-1. Commonly Used Abbreviations
Abbreviation Meaning Abbreviation Meaning

B
• Boolean AND function div division
+ addition or Boolean OR dmd demand
≥ greater than or equal to e error
≤ less than or equal to EEPROM electrically erasable
programmable read-only
° degrees memory
″ inches ELV extra low voltage
Σ summation EMC electromagnetic compatibility
τ torque EMF electromotive force
AC alternating current EPROM erasable programmable read-
accel acceleration only memory
ack acknowledge ESD electrostatic discharge
AI analog input ESTOP, e-stop emergency stop
alg analog fb, fdbk feedback
avail available ffwd feed forward
BTU British thermal units FLC full load current
cap capacitor FOHB Fiber Optic Hub Board
ccw counter clockwise freq frequency
cmd command ft, ′ feet
com common fwd forward

conn connector GAL generic array logic
CT current transformer gnd ground
CTS clear to send H height
cu cubic hex hexadecimal
curr current hist historic
cw clockwise hp horsepower
D derivative (PID), depth hr hour
D/A digital-to-analog (converter) Hz Hertz
DC direct current I current, integral (PID)
DCL drive communications link I/O input(s)/output(s)
decel deceleration ID identification
deg degrees IGBT insulated gate bipolar transistor
Version 1.1 (19000403) ASIRobicon B-1

COMMONLY USED ABBREVIATIONS Perfect Harmony GENIII/e Installation Manual

in input PID proportional integral derivative
in, ″ inches PLC programmable logic controller
info information pot potentiometer
B INH inhibit pp peak-to-peak

K 1,000 (e.g., Kohm) ppb parts per billion
LAN local area network PPR pulses per revolution
lbs pounds (weight) PQM power quality meter
LCD liquid crystal display PSDBP power spectral density break
point
ld load
psi pounds per square inch
LED light-emitting diode
pt point
lim limit
PT potential transformer
LOS loss of signal
PWM pulse width modulation
lps liters per second
rad radians
mA milliamperes
RAM random access memory
mag magnetizing
ref reference
max maximum
rev reverse, revolution(s)
MCC motor control center
RFI radio frequency interference
mg milligram
RLBK rollback
min minimum, minute
rms root-mean-squared
msec millisecond(s)
RPM revolutions per minute
msl mean sea level
RTS request to send
mvlt motor voltage
RTU remote terminal unit
NEMA National Electrical
Manufacturer’s Association RX receive
no. number s second(s)
NMI non-maskable interrupt sec second(s)
NVRAM non-volatile random access ser serial
memory SOP sum of products
oamp output current spd speed
OOS out of saturation stab stability
overld overload std standard
P proportional (PID) sw switch
Pa Pascals TB terminal block
pb push button TOL thermal overload
PC personal computer TP test point
PIB Power Interface Board
trq, τ torque
B-2 ASIRobicon Version 1.0 (19000403)

Perfect Harmony GENIII/e Installation Manual COMMONLY USED ABBREVIATIONS
Abbreviation Meaning
TX transmit
UPS uninterruptable power supply
um user module
V voltage, volts
B
VAC volts AC
var variable
VDC volts DC
vel velocity
VFD variable frequency drive
vlts voltage(s), volts
W width, watts
XCL external communications link
xformer transformer

COMMONLY USED ABBREVIATIONS Perfect Harmony GENIII/e Installation Manual
∇ ∇ ∇

Perfect Harmony GENIII/e Installation Manual INDEX
INDEX
ambient temperature, 1-5

analog to digital board, 2-15
—±— anchor bolts, 3-5
±5% voltage taps, 3-5 anchoring cabinets, 3-5
anchoring cabinets to floors and walls, 3-1, 3-5
AND, A-5
—0— attenuator, 2-17
0.5” threaded J-bars, 3-5 attenuator system, 2-18
audible motor noise, 1-2
auto tuning, 1-4
—1—
12-pulse wave form, 1-1 —B—
18 cell 6.6 KV system, 2-13
base structures, 3-1
base tubes, 3-1, 3-2
—2— basic power schematic, 2-18
blower, 3-5
2400 VAC system, 2-17 blower cabinet, 1-3, 3-5
blower fuses, 2-4
—3— blower motor, 3-6
blower motor running in reverse, 3-6
3300 VAC system, 2-17 blower motor starters, 2-4
3-phase input, 2-17 blower power, 3-6
3-phase secondary connections, 2-10 blower rotation, 3-8
blowers, 2-3, 2-7
—4— Boolean algebra, A-5
BTU/hr losses, 2-12
4160 VAC, 2-18 buckling of cabinets, 3-2
4160 VAC system, 2-17 burden resistor values, 2-18
4800 VAC system, 2-17 bypass, 2-13
bypass circuit, 2-19
—5—
50 Hz, 2-10
—C—
cabinet, ix
line-up, 2-1
—6— cabinet illustration, 3-7
6-pulse wave form, 1-1 cabinets, 1-3
cabinets, 1-3
anchoring, 3-5
—A— buckling, 3-2
abbreviations, B-1 center of gravity, 3-3
AC power for both control and blowers, 3-7 cell back-up, 1-4
acceleration cell boards
time range, 1-5 control power, 2-13
advanced diagnostics, 1-4 cell bypass option, 2-13
air circulation, 3-4 cell cabinet, 1-3, 3-4, 3-5
air duct covers, 1-3 cell control board, 2-18
air flow, 3-5 cell control system, 2-13
air intakes, 3-7 cell control/gate driver board, 2-10, 2-19
altitude, 1-5 switch mode power supply, 2-13
Version 1.1 (19000403) ASIRobicon i

INDEX Perfect Harmony GENIII/e Installation Manual
cell current, 2-12 —D—

cell malfunctions, 2-13
cell section, 2-1, 2-10 damage, 3-1
cell specifications, 2-10, 2-11, 2-12 damage during shipping, 3-1
cells deceleration
configurations, 2-17 time range, 1-5
control, 2-10 derating motors, 1-2
control boards, 2-8 diagnostics, 1-4
damage due to overheating, ix digital display module, 1-4
fiber optic control link, 2-10 dimensions, 3-1, 3-5
galvanic isolation, 2-8 disconnect switch, ix
illustration, 2-8 disconnect switch for control power, 2-4
mechanical and electrical comparisons of sizes, 2-8 distortion wave form comparisons, 1-1
number of in a series, 2-7 dual frequency braking, 1-4
output, 2-8 dual performance operation modes, 1-4
output cells per phase, 2-7, 2-8 dust contamination, 1-5
output current as a function of size, 2-7 dV/dt stress, 1-2
size 2, 2-18
sizes for GEN III, 2-7
specification details, 2-7, 2-8
—E—
center of gravity, 3-2, 3-3 efficiency, 1-4, 2-12
centrifugal blower, 3-5 electrical components, 2-12
CFM requirements, 3-4 electrical hazards, ix
clean power input, 1-1 electrical specifications, 1-5
coffin, 2-7, 2-10 electrostatic discharge precautions, x
common mode voltage stress, 1-2 eliminating exposure to outside elements, 3-5
communications board, 2-15 ELV, ix, 3-10
compensating the primary voltage source, 3-5, 3-6 EMC compliance, 3-6
conductor sizes, 3-8 emergency stop, 3-9
conductor sizes for grounding, 3-9 emergency stop wiring, 3-9
connection diagram for an 18 cell 6.6 KV system, 2-13 enclosure
connection gaps, 3-5 specifications, 1-5
control “coffin”, 2-7 enclosures, 3-1
control boards, 2-8 e-stop, 3-9
control cabinet, 1-3, 2-13 e-stop functions, 3-9
access plates, 3-7 exposed connections, ix
control fuses, 2-4 external power factor correction capacitors, 1-1
control panel, 2-10 external wiring, 3-1, 3-6
control power, 2-10, 2-13 extra low voltage, ix
warning on disconnecting, ix eye bolts, 3-1
control power connections, 2-6
control power disconnect switch, 2-4
control section, 2-1, 2-8, 2-10 —F—
isolation from medium voltage, 2-10 fabric slings, 3-2
control system, 2-10 features, 1-4
control transformer, 2-4, 2-17 feedback resistors, 2-4
cooling, 3-4, 3-6 fiber optic cable to bypass board, 2-15
reduction in, 3-5 fiber optic cables to cells, 2-15
cooling air, 3-4, 3-5 fiber optic communications link, 2-10
cooling considerations, 3-6 fiber optic control circuitry, 1-4
CR3, 3-9 fiber optic data link, 2-19
crane lifting, 3-2 fiber optic hub board, 2-13
cross talk, preventing, 1-1 connectors, 2-17
current, 2-18 fiber optic interface boards, 2-15
current distortion, 2-18 fiber optic link, 2-8
current harmonic distortion, 1-1 fiber optic links, 2-13
current transformers, 2-4 fiber optic system, 2-18
customer I/O section, 2-1, 2-6 filter capacitors, 2-18
customer wiring terminal strip, 2-4 flash disk, 2-16
flash memory card, 2-16
fork lift truck, 3-2
ii ASIRobicon Version 1.1 (19000403)

adjustability of tines, 3-3 IEEE 519 1992 requirements, 1-1

dimensions of tines, 3-2, 3-3 IGBT gate driver board, 2-18, 2-19
weight rating, 3-2 IGBTs, A-3
fork lift truck lifting, 3-1 induction motors, 1-2
fork lift tubes, 3-1, 3-2 industry standard communication, 1-4
fork truck tines, ix input current, 2-12
fork-lift tines, 3-1 input current ratings, 2-7
front doors of the cabinet, 3-4 input diodes, 2-18
fuse, 2-17 input frequency specifications, 2-10
fuses, 2-4 input line voltages, 1-5
input monitoring, 1-4
input motor currents, 2-18
—G— input power, 2-17, 2-19
galvanic isolation of cells, 2-8 conductor sizes, 3-8
gaps between cabinets, 3-5 input power factor, 1-5
gas contamination, 1-5 Input power factor, 2-18
GEN III, 2-1, 2-2, 3-7 input power feed length, 3-8
cells, 2-8 input power specifications, 2-10
hardware overview, 1-2 input power terminals, 2-4
lineup, 1-3 input power wiring, 3-7
power section, 2-4 input voltage, 2-18
transformer section, 2-4 tolerance, 1-5
GEN IIIe, 2-3, 2-6 installation, 3-1
GENIIIe, 3-1 installation contractor, 3-1
GENIIIe Perfect Harmony VFDs, 1-3 insulation resistance, 3-1
glossary of terms, A-1 insulation resistances, 3-10
ground bonding cables, 3-8 internal wiring, 3-1
ground connection, 3-8 introduction, 1-1
grounding, 3-8 isolated secondaries on transformer, 2-17
conductor sizes, 3-9 isolation
grounding conductors, 3-9 between control and medium voltage sections, 2-10
grounding points, 3-8 isolation of cells, 2-8
—H— —J—
handling, 3-1, 3-2, 3-3, 3-4 J-bars, 3-5
roller dollies, 3-3 J-bars used for anchoring, 3-5
using a fork lift truck, 3-3
handling operations, 3-1 —K—
hardware overview, 1-2
harmonic distortion, 1-1 keypad, 1-4, 2-17, 3-7
sources, 1-1
harmonic distortion wave forms, 1-1 —L—
harmonic filters, 1-1
harmonics, 1-1, 1-2 length, 2-12
hazardous voltages, ix length specifications, 2-10
hazards lethal voltages, ix
electrical, ix lifting precautions, ix
mechanical, ix lifting tubes, 1-3, 3-1, 3-2
heating of motor, 1-2 list of symbols, B-1
high efficiency, 1-4 location, 3-1
horsepower specifications, 2-10 location of drive, 3-4
hp range, 1-5 environment, 3-4
humidity, 1-5 lock-out/tag-out procedures, ix
losses, 3-4
low speed applications, 1-1
—I— low voltage terminal strip, 2-4
I/O section, 2-6 low-voltage power cell, 2-19
I/O termination board, 3-9
IEC 364-4-411.1.2.1, 3-10
IEC 364-4-411.1.3.3, 3-10

—M— output voltage, 2-18

overhead crane, 3-2
main transformer taps, 3-8 overhead crane lifting, 3-1, 3-2
maintainance overheating, ix
qualified individuals, ix overheating the drive, 3-6
maintenance, ix overload capability, 1-5
master control, 2-8
system module, 2-13
master control components, 2-7
—P—
master control system, 2-10 parameters
maximum cell current, 2-12 storage in system module, 2-14
mechanical specifications, 1-5 PB4, 3-7
medium voltage, 3-6, 3-7 PC tool interface, 1-4
isolation from control section, 2-10 phase shift from transformer T1, 2-18
warning about control power, ix phase shifting transformer, 2-10
metering terminal strip, 2-4 phase-shifting power transformer, 2-3
microprocessor board, 2-13, 2-15, 2-17 phasing
replacing without reprogramming parameters or verifying, 3-6
system program, 2-14 pipe rollers, 3-2, 3-3, 3-4
misalignment of cabinets, 3-4 dimensions, 3-4
modular construction, 1-4 proper placement, 3-4
modulator board, 2-15 placement of drive, 3-4
moisture accumulation, preventing, 3-5 environment, 3-4
motor heating, 1-2 PLC capabilities, 1-4
motor monitors, 2-6 plenum, 3-5
motor nameplate, 2-12 connections, 3-5
motor noise, 1-2 polarity, 2-18
multi-motor operation, 1-4 power cell check, 1-4
multi-secondary phase-shifting power transformer, 2-3 power cell with optional bypass, 2-19
mushroom push button, 3-9 power circuit, 2-17
power factor, 1-1, 1-2, 2-12
—N— definition, 1-1
units, 1-1
NEMA 1 power input cabinet, 1-3, 2-1, 3-7
enclosure specifications, 1-5 power interface board, 2-17
power quality meters, 2-6
power schematic, 3-8
—O— power supply connection, 2-15
off-loading, 3-1 power transformer, 2-4
on-line diagnostics, 1-4 power wires, 2-3
on-line operation while tuning, 1-4 power wiring, 2-3
operating voltages, 2-12, 2-17 pressure and air resistance in the output plenum, 3-5
operation while tuning, 1-4 primary voltage source, 3-5
OR, A-5 printed circuit (PC) boards, 2-10
outdoor storage requirements, 3-5 proper handling using the sling lifting technique, 3-2
output bypass circuit, 2-19 protective earth symbol, 3-8
output cell, 2-13
output cells, 2-8, 2-12, 2-17
output current, 2-12
—Q—
output current ratings, 2-7 qualified individual (for troubleshooting and
output current wave form, 1-2 maintenance), ix
output frequency drift, 1-5
output line voltages, 1-5
output motor current, 2-18 —R—
output operating voltage, 2-12 rated hp, 2-12
output operating voltages, 2-7 rated losses, 3-4
output phases, 2-18 reactive halide contamination, 1-5
output plenum, 3-5 receiving, 3-1
output power cabinet, 1-3 re-connecting internal wiring, 3-1
output power terminals, 2-4 re-connecting shipping splits, 3-1
output torque, 1-5 redundant cell operation, 2-17

reliability, 1-4 terminal strip for low voltage, 2-4

reports capabilities, 1-4 terminal strip for metering, 2-4
resonance avoidance, A-5 thermally hot components, ix
resonance avoidance feature, A-5 tine spacing, 3-2
resonance problems, 1-1 tines
reverse operation of blower motor, 3-6 adjustability, 3-3
roller dollies, 3-1, 3-3 dimensions, 3-3
weight ratings, 3-3 top angles, 3-5
RS232 connector, 3-7 torque pulsations (VFD-induced), 1-2
R-S-T phase sequencing, 3-8 torque specifications, 3-1, 3-8, 3-9, 3-10
total harmonic distortion of the source current, 1-1
transformer, 2-4, 2-10, 2-12, 2-17, 3-5
—S— isolated secondaries, 2-17
safety, ix sizing and CFM/BTU effects, 2-10
safety precautions, ix transformer cabinet, 1-3, 3-1, 3-2, 3-4, 3-5, 3-6
SCRs, 1-2 lifting tubes, 3-2
secondary cell voltages, 3-5 supporting, 3-1
secondary of the power transformer, 2-18 wiring, 3-5
serial port, 1-4 transformer section, 2-3
set-up, 3-1 major components, 2-4
shielded cables, 3-6 transformer size, 2-7
shipping carrier, 3-1 transformer T1, 2-18
shipping split, 3-8 taps, 3-8
shipping splits, 1-3, 3-1 voltage taps (±5%), 3-5, 3-6
sinusoidal input currents, 1-1 transformer tap connections, 3-6
sinusoidal output, 1-1, 1-2 transparent cell bypass, 1-4
sinusoidal output voltages, 1-2 transporting precautions, ix
sling lifting, 3-2 transverse tubes, 3-1
slings, 3-2 trip-free operation, 1-4
length, 3-2 troubleshooting, ix
strength, 3-2 qualified individuals, ix
slings used to lift the cabinet, 3-1, 3-2
soft start protection, 1-4
sound pressure, 1-2
—U—
source impedances, 1-1 undervoltage ride-through, 1-4
specifications, 1-5 using slings to lift the cabinet, 3-1, 3-2
speed range, 1-5
spinning load restart, 1-4
spreader bar, 3-2 —V—
spreader bars, 3-2 ventilation requirements, 3-4
starters for blower motors, 2-4 voltage attenuator, 2-17
stop command, 3-9 voltage clamps, 2-18
storage, 3-5 voltage divider, 2-18
safety precautions, ix voltage harmonic distortion, 1-1
sulfide contamination, 1-5 voltage regulation
surge arrestors, 1-4 improved, 1-1
switch mode power supply, 2-10, 2-13 voltage stress, 2-18
symbols, B-1 voltage taps, 3-5, 3-6
system interface board, 2-15
system module, 2-13
system program, 2-14 —W—
storage in the system module, 2-14
warnings, ix
wave form of output current, 1-2
—T— wave forms
distortion comparisons, 1-1
T1, 2-18 weight estimates, 3-1
T1-T2-T3 or R-S-T phase wiring, 3-8 weight of lineup, 2-12
tap connections, 3-6 weight specifications, 2-10
terminal blocks, 2-6 wooden stop block, 3-2, 3-3
terminal strip for customer wiring, 2-4
Version 1.1 (19000403) ASIRobicon v

∇ ∇ ∇

Perfect Harmony GENIII/e Installation Manual NOTES
NOTES
Version 1.1 (19000403) ASIRobicon N-1

NOTES Perfect Harmony GENIII/e Installation Manual
N-2 ASIRobicon Version 1.1 (19000403)

Perfect Harmony GENIII/e Installation Manual NOTES

NOTES Perfect Harmony GENIII/e Installation Manual

Perfect Harmony GENIII/e Installation Manual READERS’ COMMENT FORM
READERS’ COMMENTS FORM

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Version 1.1 (19000403) ASIRobicon R-1

READERS’ COMMENT FORM Perfect Harmony GENIII/e Installation Manual
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∇ ∇ ∇
R-2 ASIRobicon Version 1.1 (19000403)

STARTUP/WARRANTY REGISTRATION
AND SERVICE SOLUTIONS
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be completed by the end user or equipment owner. For information on ASIRobicon post sale service solutions,
please check the appropriate boxes below before returning this form to ASIRobicon.
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Part Number (P/N) (see system door or system
panel)
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system panel)
Start-up Date
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A Subsidiary of High Voltage Engineering

STARTUP AND ADVANCED
TOPICS MANUAL
FOR
GENIII/GENIIIE SERIES
ADJUSTABLE SPEED AC MOTOR DRIVES
WITH NEXT GENERATION CONTROL

Version 1.1
OCTOBER 2003

USA

70, 100, 140, 200, and 260 (630 V cells)
0I, 1I, 2I, 3I, 4I, 315H, 375H, 500H, and 660H (690 V cells).
For the support representative nearest you, please call ASI Robicon’s main office at (724)-339-9500.
Perfect Harmony, GENIII (GEN3) and GENIIIe (GEN3e) are product lines of AC motor drives from ASIRobicon.
Startup and Advanced Topics Manual for Perfect Harmony Series (p/n 902232)
Version History:
Perfect Harmony GENIII/e Startup and Advanced Topics Table of Contents
TABLE OF CONTENTS

1.1.
Introduction to the Perfect Harmony....................................................................................1-1
1.4. Specifications ......................................................................................................................1-5
2.1.
Hardware Configuration ......................................................................................................2-1
CHAPTER 3: The Keypad and Display Interface.......................................................................................3-1
3.1. Introduction..........................................................................................................................3-1
3.2. The Keypad .........................................................................................................................3-1
3.2.1. Fault Reset Key ......................................................................................................3-2
3.2.2. Automatic Key .........................................................................................................3-3
3.2.3. Manual Stop Key.....................................................................................................3-3
3.2.4. Manual Start Key ....................................................................................................3-3
3.2.5. The 0-9 Key.............................................................................................................3-4
3.2.6. The Enter/Cancel Key.............................................................................................3-6
3.2.7. Shift Function Keys .................................................................................................3-6
3.2.8. Arrow Keys..............................................................................................................3-7
3.2.9. Diagnostic Indicators.............................................................................................3-10
3.2.10. The Display...........................................................................................................3-10
3.3. Menu Descriptions.............................................................................................................3-14
3.3.1. Motor Menu (1) Options ........................................................................................3-17
3.3.2 Drive Menu (2) Options..........................................................................................3-21
3.3.3. Stability Menu (3) Options.....................................................................................3-28
3.3.4. Auto Menu (4) Options..........................................................................................3-33
3.3.5. Main Menu (5) Options .........................................................................................3-42
3.3.6. Log Control Menu (6) Options ..............................................................................3-45
3.3.7 Protect Menu (7) Options.......................................................................................3-47
3.3.8. Meter Menu (8) Options ........................................................................................3-49

Table of Contents Perfect Harmony GENIII/e Startup and Advanced Topics
3.3.9. Communications Menu (9) Options ......................................................................3-53

3.3.10 Menu Setup for Multiple Configuration Files (Slaves) ..........................................3-56
CHAPTER 4: Startup Procedure ................................................................................................................4-1
4.1. Introduction............................................................................................................................4-1
4.2. Pre-power Visual Inspection .................................................................................................4-2
4.3. Power Circuit, Modulation and Bypass Contactor Test..........................................................4-4
4.4. Drive Test in Open Loop Test Mode without Motor ...............................................................4-5
4.5. Drive Test in Open Loop Test Mode with Motor Connected .................................................4-8
4.6. Drive Test in Open Loop Vector Control Mode with Motor Connected...............................4-10
4.7. Drive Test in Synchronous Motor Control Mode .................................................................4-17
4.7.1.Tuning the 3PCI (SCR Regulator)............................................................................4-18
4.7.2. Testing 3PCI Connection to the VFD ......................................................................4-19
4.7.3. Drive Test with Synchronous Motor ........................................................................4-20
4.8. Drive Tuning ........................................................................................................................4-22
4.8.1 Auto-Tuning ..............................................................................................................4-23
4.8.2. Spinning Load........................................................................................................4-24
4.8.3. Application Menus ..................................................................................................4-25
4.9. Synchronous Transfer Procedure (if applicable).................................................................4-25
4.10. Output Filter Setup (if applicable)......................................................................................4-26
4.10.1. Adjusting Current Regulator Gains with Output Filters ........................................4-28
4.10.2. Verification of Filter CT wiring ..............................................................................4-28
4.10.3. Determining Stator Resistance in Long Cable Application ..................................4-28
4.11. Encoder Setup (if applicable) ............................................................................................4-29
4.11.1. Verification of encoder operation .........................................................................4-29
4.12. Verification of Input Monitoring..........................................................................................4-29
CHAPTER 5: Application and Operation Issues ........................................................................................5-1
5.1. Introduction............................................................................................................................5-1
5.2. Synchronous Transfer Operation ..........................................................................................5-1
5.2.1. Introduction...............................................................................................................5-1
5.2.2. Transfer Setup and Faults........................................................................................5-1
5.2.3. Up Transfer................................................................................................................5-1
5.2.4. Down Transfer ...........................................................................................................5-3
5.2.5. Reservoir Example - Synchronous Transfer with Multiple Motors and a PLC .........5-4
5.2.6. The PLC Interface ....................................................................................................5-6
5.2.7. “Up” Transfer (from VFD to Line Control)..................................................................5-7
5.2.8. “Down” Transfer (from Line to VFD Control) .............................................................5-8
5.2.9. Required Signals ......................................................................................................5-9
5.2.10. Additional Parameter Description.........................................................................5-10
5.3. Spinning Load Operation.....................................................................................................5-11
5.3.1. Spinning Load Menu (2420) ....................................................................................5-11
5.4. User I/O ...............................................................................................................................5-12
5.4.1. Introduction.............................................................................................................5-12
5.4.2. Wago Modbus Coupler Settings ............................................................................5-13
5.4.3. External I/O Menu (2800) .......................................................................................5-15
5.4.4. Digital I/O................................................................................................................5-15
5.4.5. Analog Output Menu (4660) ...................................................................................5-15
5.4.6. Analog Input Menu (4100)......................................................................................5-16

5.5. Signal Frame of Reference for Motor Control .....................................................................5-16

5.5.1. Frame of Reference ...............................................................................................5-16
5.5.2. Signal Polarities......................................................................................................5-18
5.6. Mechanical Bypass .............................................................................................................5-18
5.7. Fast Bypass..........................................................................................................................5-19
5.8. Neutral Point Shift During Bypass........................................................................................5-20
5.9. Power Monitoring ................................................................................................................5-25
5.10. Dual Frequency Braking....................................................................................................5-25
5.10.1. Introduction to Dual Frequency Braking................................................................5-25
5.10.2. Operation..............................................................................................................5-26
5.10.3. Setting parameters for Dual-Frequency Braking..................................................5-28
5.10.4. Limitations ............................................................................................................5-28
5.11. Energy Saver.....................................................................................................................5-29
5.12. Motor Thermal Overload Protection ..................................................................................5-29
5.13. Process Availability - The Perfect Harmony Advantage ...................................................5-31
5.13.1. What is ProToPS? ................................................................................................5-31
5.13.2. How Does ProToPS Work?..................................................................................5-31
5.13.3. ProToPS Implementation .....................................................................................5-32
5.13.4. The ProToPS Advantage .....................................................................................5-32
5.14. PID Controller ....................................................................................................................5-32
CHAPTER 6: Theory .................................................................................................................................5-1
6.1. Introduction............................................................................................................................6-1
6.2. The Power Circuitry .............................................................................................................6-2
6.3. The Control System.............................................................................................................6-9
6.4. The Control Modes..............................................................................................................6-12
6.4.1. Open Loop Vector Control (OLVC) .........................................................................6-13
6.4.2. Open Loop Test Mode (OLTM) ..............................................................................6-14
6.4.3. Synchronous Motor Control (SMC) .........................................................................6-14
6.4.4. Volts/Hertz Control (V/Hz) .......................................................................................6-15
6.4.5. Closed Loop Control (CLVC or CSMC)...................................................................6-15
6.5. Input Side Monitoring and Protection ..................................................................................6-16
6.6. Drive Output Torque Limiting ..............................................................................................6-17
6.6.1. Input Under-Voltage Rollback ................................................................................6-18
6.6.2. Input Single-Phase Rollback ..................................................................................6-18
6.6.3. Transformer Thermal Rollback...............................................................................6-19
6.6.4. Menu Torque Limit..................................................................................................6-19
6.6.5. Regeneration ..........................................................................................................6-19
6.6.6. Field-Weakening Limit............................................................................................6-19
6.6.7. Cell Current Overload.............................................................................................6-19
CHAPTER 7: Troubleshooting and Maintenance ......................................................................................7-1
7.1. Introduction..........................................................................................................................7-1
7.2. Faults and Alarms................................................................................................................7-1
7.3. Drive Faults and Alarms ......................................................................................................7-2
7.4. Cell Faults/Alarms .............................................................................................................7-16
7.4.1. Troubleshooting General Cell and Power Circuitry Faults ...................................7-24
7.4.2. Troubleshooting Cell Over Temperature Faults ...................................................7-24
7.4.3. Troubleshooting Overvoltage Faults.....................................................................7-25
7.4.4. Troubleshooting Cell Communications and Link Faults .....................................7-25

7.4.5. Status Indicator Summaries for MV Mechanical Bypass Boards .........................7-25

7.5.
User Faults ........................................................................................................................7-26
7.6.
Unexpected Output Conditions .........................................................................................7-26
7.6.1. Output Speed Limit ...............................................................................................7-27
7.7. Drive Input Protection..........................................................................................................7-27
7.7.1. One Cycle Protection (or Excessive Input Reactive Current Detection)................7-27
7.7.2. Excessive Drive Losses .........................................................................................7-27
7.7.3. Transformer Over-Temperature and Loss of Cooling ............................................7-28
7.8. Portable Harmony Cell Tester ...........................................................................................7-28
7.9. Removing Power Cells .........................................................................................................7-30
7.10. Six Month Inspection .......................................................................................................7-32
7.11. Replacement of Parts ........................................................................................................7-32
CHAPTER 8: System Programming...........................................................................................................8-1
8.1.
Introduction............................................................................................................................8-1
8.2.
System Program Terminology...............................................................................................8-1
8.3.
Overview of the Compile Process .........................................................................................8-2
8.4.
Software Tools ......................................................................................................................8-3
8.5.
Input Source File ...................................................................................................................8-3
8.5.1. System Type Identification .......................................................................................8-4
8.5.2. Operators and Precedence ......................................................................................8-6
8.5.3. Statement (SOP) Format..........................................................................................8-8
8.5.4. Input Flags..............................................................................................................8-10
8.5.5. Output Flags ...........................................................................................................8-10
8.5.6. SOP Interpretation..................................................................................................8-12
8.5.7. SOP Timing ............................................................................................................8-12
8.5.8. Ladder Logic Translation........................................................................................8-12
8.5.9. Comparators...........................................................................................................8-14
8.5.10. Analog Inputs........................................................................................................8-14
8.6. Compiler Invocation.............................................................................................................8-15
8.6.1. Windows-based SOP Utilities.................................................................................8-15
8.6.2. DOS-based Compiler and Reverse Compiler ........................................................8-16
8.7. Compiler Operation .............................................................................................................8-16
8.8. Output Hex File....................................................................................................................8-17
8.9. Downloading a System Program (Hex File) ........................................................................8-17
8.9.1. ASI Robicon SOP Upload/Download Utility Method ..............................................8-18
8.9.2. Terminal Emulation Method ...................................................................................8-19
8.9.3. Termination.............................................................................................................8-20
8.10. Uploading a System Program (Hex File)...........................................................................8-21
8.11. Reverse Compiler..............................................................................................................8-22
8.11.1. Windows-based “Integrated” Reverse Compiler ..................................................8-22
8.11.2. DOS-based Reverse Compiler Software .............................................................8-23
APPENDIX B: Commonly Used Abbreviations ......................................................................................... B-1
APPENDIX C: SYSTEM control drawings ................................................................................................ C-1
Appendix D: Suggested Spare Parts List.................................................................................................. D-1
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
vi ASIRobicon Version 1.1 (19000404)



∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics List of Figures
LIST OF FIGURES

Figure 3-1. The Keypad and Display Interface of the Perfect Harmony Series ....................................3-2
Figure 3-2. Comparison of the two Manual Control Modes...................................................................3-4
Figure 3-3. Anatomy of a Numeric Keypad Key ....................................................................................3-5
Figure 3-4. Accessing Items Using ID Numbers ...................................................................................3-6
Figure 3-5. Location of Shift Mode Indicator on the Perfect Harmony Display .....................................3-7
Figure 3-6. Using the Up and Down Arrow Keys to Control Velocity Demand .....................................3-9
Figure 3-7. Security Level Cleared Message on the Perfect Harmony Display ....................................3-9
Figure 3-8. The Identification/Version Screen and Meter Displays .....................................................3-10

List of Figures Perfect Harmony GENIII/e Startup and Advanced Topics
Figure 3-9. Dynamic Programmable Meter Display ............................................................................3-11

Figure 3-10. Dynamic Programmable Meter Display in Rollback Mode..............................................3-11
Figure 3-11. Dynamic Programmable Meter Display in Regeneration Mode......................................3-11
Figure 3-12. Status Display After [SHIFT] [ENTER] ([CANCEL]) Key Sequence ...............................3-11
Figure 3-13. Status Display After [SHIFT]+[2] Key Sequence ............................................................3-12
Figure 3-14. Status Display After [Ø] [Ø] Key Sequence ....................................................................3-12
Figure 3-15. Status Display After [Ö] ..................................................................................................3-12
Figure 3-16. Status Display After [Ø] Key Sequences .......................................................................3-12
Figure 3-17. Status Display After [ENTER] Key to Change a Parameter ...........................................3-12
Figure 3-18. Status Display Upon Entering a Value In the Range of the System ...............................3-12
Figure 3-19. Status Display After [SHIFT] [Ö] and the Parameter ID 1020 is entered .......................3-13
Figure 3-20. Status Display After [ENTER] [ENTER] ..........................................................................3-13
Figure 3-21. Status Display Upon Entering a Value Beyond the Range of the System......................3-13
Figure 3-22. Critical Speed (Resonance Avoidance) Parameters ......................................................3-24
Figure 3-23. Advantages of Using Speed Profiling Control.................................................................3-35
Figure 3-24. Dynamic Programmable Meter Display ..........................................................................3-51
Figure 4-1. Sample System Nameplate.................................................................................................4-2
Figure 4-2. Transformer Cabinet Detail Showing Typical Tap Connections .........................................4-2
Figure 4-3. AC input voltages at test-points VIA, VIB and VIC on system interface card .....................4-6
Figure 4-4. AC output voltages at test-points VMA and VMB at 15Hz in Open Loop Test Mode .........4-7
Figure 4-5. AC output voltages at test-points VMA and VMB at 60Hz in Open Loop Test Mode .........4-8
Figure 4-6. Open Loop Test Mode operation at 10% speed with an unloaded motor. .......................4-10
Figure 4-7. AC motor voltage and motor current at test-points VMA and IMA at 10% speed in Open
Loop Vector Control..............................................................................................................................4-16
Figure 4-8. AC motor voltage and motor current at test-points VMA and IMA at 100% speed in Open
Loop Vector Control..............................................................................................................................4-17
Figure 4-9. AC motor voltage and motor current at test-points VMA and IMA at 10% speed with
Synchronous Motor Control. .................................................................................................................4-21
Figure 4-10. AC motor voltage and motor current at test-points VMA and IMA at 100% speed with
Synchronous Motor Control. .................................................................................................................4-22
Figure 4.11. Drive output voltage and filter capacitor current on test-points VMA and IFA, respectively,
to determine if filter CT wiring is correct. ..............................................................................................4-28
Figure 5-1. Synchronous Transfer State Diagram for “Up Transfer”.....................................................5-2
Figure 5-2. Synchronous Transfer State Diagram for “Down Transfer” ................................................5-3
Figure 5-3. Overview of a Sample Transfer Application........................................................................5-5
Figure 5-4. Graphical Representation of a Sample “Up Transfer” with Continued Demand.................5-5
Figure 5-5. Graphical Representation of a Sample “Down Transfer” with No Demand ........................5-6

Perfect Harmony GENIII/e Startup and Advanced Topics List of Figures
Figure 5-6. Communications Outline Drawing using a Modbus Network Configuration .......................5-7
Figure 5-7. State changes during Up Transfer Sequence.....................................................................5-8
Figure 5-8. State changed during Down Transfer Sequence................................................................5-9
Figure 5-9. Wago I/O System Photo....................................................................................................5-12
Figure 5-10. Wago MODBUS Coupler Bottom ....................................................................................5-13
Figure 5-11. Wago MODBUS Coupler with Cover lifted......................................................................5-13
Figure 5-12. Wago MODBUS Coupler DIP switch settings.................................................................5-14
Figure 5-13. Wago MODBUS Coupler DIP switch settings label ........................................................5-14
Figure 5-14. Four Quadrant Operation of a Motor...............................................................................5-17
Figure 5-15. Typical Cell with Bypass Contactor.................................................................................5-19
Figure 5-16. A Simplified diagram of a 15 Cell Drive ...........................................................................5-20
Figure 5-17. Drive output with 2 Cells Bypassed .................................................................................5-20
Figure 5-18. Drive output re-balanced by Bypassing Functional Cells. ...............................................5-21
Figure 5-19. Drive output re-balanced by Adjusting Phase Angles (Neutral-Shift) ..............................5-21
Figure 5-20. Drive output after loss of 3 Cells ......................................................................................5-22
Figure 5-21. Drive output after loss of 5 Cells ......................................................................................5-22
Figure 5-22. Available Voltage after First Failure .................................................................................5-23
Figure 5-23. Block diagram showing Dual Frequency voltages being added together with the normal
three-phase voltages. ...........................................................................................................................5-27
Figure 5-24. Scope picture showing Dual Frequency Braking waveform ...........................................5-27
Figure 5-25. Best case braking torque with Dual Frequency Braking for a typical motor. ..................5-29
Figure 5-26. Block diagram of motor thermal model. ...........................................................................5-30
Figure 5-28. PID Controller..................................................................................................................5-33
CHAPTER 6: Theory .................................................................................................................................5-1
Figure 6-1. Topology of Perfect Harmony VFD (3 Cells, 2400 or 3300 VAC).......................................6-4
Figure 6-2. Schematic of a Typical Power Cell......................................................................................6-5
Figure 6-3. Waveforms for Phase A ......................................................................................................6-5
Figure 6-4. Wave Forms for Phase B ....................................................................................................6-6
Figure 6-5. Wave Forms for Line-to-line Voltage ..................................................................................6-6
Figure 6-7. Harmony Input Wave Forms for a 2400 Volt Drive at Full Load .........................................6-7
Figure 6-8. Motor A-B Voltage and Current in Phase C at Full Load for a 4160 Volt Harmony Drive ..6-8
Figure 6-9. Input A-B Voltage and Current in Phase C at Full Load for a 4160 Volt Harmony Drive ...6-8
Figure 6-10. Block Diagram of Harmony Control Structure for 6000 V Drive......................................6-11
Figure 6-11. Block diagram of vector control algorithms for induction and synchronous motor control.
(Numbers within square brackets indicate the parameter IDs that affect the corresponding functions)6-12
Figure 6-12. Harmony drive arrangement for brushless synchronous motor (with no bypass). .........6-15
Figure 6-13. Block diagram of input-side monitoring. (Numbers within square brackets indicate the
parameter IDs that affect the corresponding functions.) ......................................................................6-17

List of Figures Perfect Harmony GENIII/e Startup and Advanced Topics
Figure 6-14. Drive power (Pmax) as a function of input voltage magnitude (Ed)...................................6-18
Figure 6-15. Drive power (Pmax) as a function of input unbalance voltage (Eunbalance). ........................6-18
Figure 7-1. Connections and Test Points on the System Interface Board ..........................................7-16
Figure 7-2. Connectors and Diagnostic Components of a Model 430 Cell Control Board..................7-17
Figure 7-3. Typical Power Cell with Optional Mechanical Bypass ......................................................7-22
Figure 7-4. Typical Power Cell Schematic (GEN III and GENIIIe Design) ..........................................7-23
Figure 7-5. Typical Fiber Optic Interface Boards Connection Diagram...............................................7-24
Figure 7-6. Excessive Drive Loss Protection.......................................................................................7-28
Figure 7-7. Protecting an Open Cell Connector Using Plastic and a Wire Tie....................................7-30
Figure 7-8. Installation/Removal of a Cell Using a Fork-style Lifting Device.......................................7-31
Figure 7-9. Front View of a Cell in Cabinet..........................................................................................7-31
Figure 8-1. Block Diagram of the Compile Process ..............................................................................8-3
Figure 8-2. Windows-based Compiler Showing Product Types (Dimmed)...........................................8-5
Figure 8-3. Ladder Logic Representation of a Boolean Expression - Example 1 ...............................8-13
Figure 8-4. Ladder Logic Representation of a Boolean Expression - Example 2 ...............................8-13
Figure 8-5. ASI Robicon SOP Utilities Icon and Pop-up Box ...............................................................8-15
Figure 8-6. Compiler Help Screen .......................................................................................................8-15
Figure 8-7. Selecting the .SOP File Using the Browse Button ............................................................8-16
Figure 8-8. Upload/Download SOP Utility Screen ...............................................................................8-18
Figure 8-9. Reverse Compiler Options Window ..................................................................................8-22
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics List of Tables
LIST OF TABLES
List of Tables ................................................................................................................................................ xi

Table 3-1. Hexadecimal Digit Assignments on the Perfect Harmony Keypad ......................................3-5
Table 3-2. Summary of Common [SHIFT] Key Sequences...................................................................3-8
Table 3-3. Summary of Common Arrow Key Sequences....................................................................3-10
Table 3-4. Summary of Operation Mode Displays: Line 1 of Mode Display........................................3-13
Table 3-6. Perfect Harmony Menu and Submenu Summary ..............................................................3-15
Table 3-7. Motor Parameter Menu (1000) ...........................................................................................3-17
Table 3-8. Limits Menu (1120).............................................................................................................3-18
Table 3-9. Speed Derate Curve Menu (1151) .....................................................................................3-20
Table 3-10. Autotune Menu (1250)......................................................................................................3-20
Table 3-11. Encoder Menu (1280) (Closed Loop Vector Control Only) ..............................................3-21
Table 3-12. Drive Parameter Menu (2000)..........................................................................................3-21
Table 3-13. Speed Setup Menu (2060) ...............................................................................................3-22
Table 3-14. Speed Ramp Setup Menu (2260).....................................................................................3-23
Table 3-15. Critical Frequency Menu (2340) ........................................................................................3-23
Table 3-16. Spinning Load Menu (2420) ..............................................................................................3-25
Table 3-17. Conditional Timer Setup Menu (2490) ..............................................................................3-25

List of Tables Perfect Harmony GENIII/e Startup and Advanced Topics
Table 3-18. Cell Menu (2520) ..............................................................................................................3-26

Table 3-19. Sync Transfer Menu (2700)..............................................................................................3-27
Table 3-20. External I/O Menu (2800) .................................................................................................3-27
Table 3-21. Output Connection Menu (2900) ......................................................................................3-28
Table 3-22. Stability Menu (3) (Parameters) .......................................................................................3-28
Table 3-23. Input Processing Menu (3000) .........................................................................................3-29
Table 3-24. Output Processing Menu (3050) ......................................................................................3-30
Table 3-25. Low Frequency Compensation Menu (3060) ...................................................................3-31
Table 3-26. Flux Control Menu (3100).................................................................................................3-31
Table 3-27. Speed Loop Menu (3200).................................................................................................3-32
Table 3-28. Current Loop Menu (3250) ...............................................................................................3-32
Table 3-29. Stator Resistance Estimator Menu (3300) .......................................................................3-32
Table 3-30. Braking Menu (3350)........................................................................................................3-33
Table 3-31. Control Loop Test Menu (3460) .......................................................................................3-33
Table 3-32. Speed Profile Menu (4000) ..............................................................................................3-34
Table 3-33. Analog Input Menu (4090)................................................................................................3-35
Table 3-34. Analog Input #1 Menu (4100)...........................................................................................3-35
Table 3-35. Analog Input #2 Menu (4170)............................................................................................3-36
Table 3-37. Auxiliary Input #1 Menu (4500) ........................................................................................3-37
Table 3-39. Analog Outputs Menu (4660) ...........................................................................................3-38
Table 3-40. Pick list for Analog Variable parameters (all units are %) ................................................3-38
Table 3-41. Speed Setpoint Menu (4240) ...........................................................................................3-39
Table 3-42. Incremental Speed Setup Menu (4970) ...........................................................................3-39
Table 3-43. PID Select Menu (4350) ...................................................................................................3-40
Table 3-44. Comparator Setup Menu (4800).......................................................................................3-40
Table 3-45. Compare 1-32 Setup Menu Parameter Descriptions .......................................................3-41
Table 3-46. Variable Pick List for Comparator Setup Submenus........................................................3-41
Table 3-47. Main Menu (5) Options.....................................................................................................3-42
Table 3-48. Security Edit Functions Menu (5000) ...............................................................................3-43
Table 3-49. Security Edit Menu Function Descriptions (5010, 5020)..................................................3-44
Table 3-50. Default Security Access Levels and Access Codes.........................................................3-44
Table 3-51. Event Log Menu (6180)....................................................................................................3-45
Table 3-52. Alarm/Fault Log Menu (6210)...........................................................................................3-45
Table 3-53. Historic Log Menu (6250) ..................................................................................................3-45
Table 3-54. Pick List Variables for Historic Log (all units are %) ........................................................3-46

Table 3-55. Drive Protect Menu (7) Parameters .................................................................................3-47

Table 3-56. Input Protect Menu (7000)................................................................................................3-47
Table 3-57. Single Phasing Menu (7010) ............................................................................................3-48
Table 3-58. Meter (8) General Drive Parameters................................................................................3-49
Table 3-59. Display Parameters Menu (8000) ....................................................................................3-49
Table 3-60. Pick List Variables for the Front Display ..........................................................................3-51
Table 3-61. Hour Meter Setup (8010)..................................................................................................3-52
Table 3-62. Input Harmonics Menu (8140)..........................................................................................3-52
Table 3-63. Communications Menu (9) Parameters ...........................................................................3-53
Table 3-64. Serial Port Setup Menu (9010).........................................................................................3-54
Table 3-65. Serial Functions Menu (9110) ..........................................................................................3-55
Table 3-66. TCP/IP Setup Menu (9300) ..............................................................................................3-55
Table 3-67. Slave Parameter...............................................................................................................3-57
Table 3-68. Parameter Menu - Slave ..................................................................................................3-57
Table 4-1. Pre-power Visual Inspection..................................................................................................4-2
Table 4-2. Power Circuit, Modulation, and Bypass Contactor Test........................................................4-4
Table 4-3. Drive Test in Open Loop Test Mode without Motor..............................................................4-5
Table 4-4. Drive Test in Open Loop Test Mode with Motor Connected .................................................4-8
Table 4-5. Drive Test in Open Loop Vector Control Mode with Motor Connected...............................4-10
Table 4-7. Scaling of drive input and output voltages and currents on Signal Conditioning Board. ....4-15
Table 4-8. Tuning the 3PCI (SCR Regulator).......................................................................................4-18
Table 4-9. Testing 3PCI Connection to the VFD ..................................................................................4-19
Table 4-10. Drive test with Synchronous Motor....................................................................................4-20
Table 4-11. Tuning the Scan Mode of Spinning Load .........................................................................4-24
Table 4-12. Drive Control Setup for Synchronous Transfer .................................................................4-25
Table 4-13. Synchronous Transfer Check List .....................................................................................4-26
Table 4-14. Output Connection Menu (2900) .......................................................................................4-27
Table 4-15. Recommended value of carrier frequency as a function of cell stages in the drive..........4-27
Table 5-1. Control States of Motors in a Sample “Up Transfer” ............................................................5-6
Table 5-2. Control States of Motors in a Sample “Down Transfer” .......................................................5-6
Table 5-3. Required Signals and Descriptions ....................................................................................5-10
Table 5-4. Sync Transfer Menu (2700).................................................................................................5-10
Table 5-5. Spinning Load Menu (2420) ................................................................................................5-11
Table 5-6. Wago I/O Module Color Codes ...........................................................................................5-12
Table 5-7. External I/O Menu (2800) ...................................................................................................5-15
Version 1.1 (19000404) ASIRobicon xiii

Table 5-8. Analog Output #1 (4661) ....................................................................................................5-16

Table 5-9. Analog Input #1 Menu (4100).............................................................................................5-16
Table 5-10. Signal Polarities................................................................................................................5-18
Table 5-11. Input Table 5-12. Output..............................................................................................5-25
Table 5-13. Description of parameters for Dual-Frequency Braking (DFB). ........................................5-28
Table 5-14 . Parameters for Motor Thermal Overload protection. ......................................................5-29
CHAPTER 6: Theory .................................................................................................................................5-1
Table 6-1. List of symbols used in Figure 6-11....................................................................................6-13
Table 6-2. Description of parameters in Encoder Menu (1280) and recommended values. ...............6-16
Table 6-3. List of symbols used in Figure 6-13....................................................................................6-17
Table 6-4. Example of overload current capability versus time of a cell with 120% overload..............6-20
Table 7-1. Fault/Alarm Type and Drive Responses ..............................................................................7-1
Table 7-2. Auto Re-settable faults .........................................................................................................7-2
Table 7-3. Drive Faults ..........................................................................................................................7-3
Table 7-4. Cell Faults............................................................................................................................7-18
Table 7-5. Diagnostic Cell Faults..........................................................................................................7-20
Table 7-6. LED Status Indicators for MV Mechanical Bypass Boards ................................................7-25
Table 7-7. Summary of Operation Mode Displays ..............................................................................7-26
Table 7-8. Load Reactor Information...................................................................................................7-28
Table 8-1. System Program Terminology..............................................................................................8-1
Table 8-2. Product Types Recognized by the System Program Compiler............................................8-5
Table 8-3. Compiler Invocation Options for the /t:n Switch (DOS Version Only) ..................................8-6
Table 8-4. Directory Filename Associations ..........................................................................................8-6
Table 8-5. Boolean Truth Table for the NOT, AND and OR Functions .................................................8-7
Table 8-6. Precedence of Operations....................................................................................................8-7
Table 8-7. Syntax Examples..................................................................................................................8-7
Table 8-8. Boolean Laws .......................................................................................................................8-8
Table 8-9. General Rules of Boolean Math ...........................................................................................8-9
Table 8-10. SOP Text File Format.........................................................................................................8-9
Table 8-11. Types of Output Flags ......................................................................................................8-10
Table 8-12. Error Messages ................................................................................................................8-20
xiv ASIRobicon Version 1.1 (19000404)


Table D-1. Spare Parts List for 800 hp Perfect Harmony Drive ........................................................... D-1
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
Version 1.1 (19000404) ASIRobicon xv

∇ ∇ ∇
xvi ASIRobicon Version 1.1 (19000404)

Perfect Harmony GENIII/e Startup and Advanced Topics SAFETY PRECAUTIONS AND WARNINGS


• Always follow the proper lock-out/tag-out procedures before beginning any maintenance or
troubleshooting work on the drive.
• Never touch anything within the Perfect Harmony cabinets (other than the control cabinet)
until verifying that it is neither thermally hot nor electrically alive.
• Always follow standard safety precautions and local codes during installation of external
wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any
other wiring as specified in the CE safety standard.
• Never assume that switching off the input disconnect will remove all voltage from internal
components. Voltage is still present on the terminals of the input disconnect. Also, there may
be voltages present that are applied from other external sources.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses.
Also, always work with another person present.
isolating the chassis ground of the instrument). Never defeat the instrument’s grounding.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure
points beneath the shields.
• Always use extreme caution when handling or measuring components that are inside the
enclosure. Be careful to prevent meter leads from shorting together or from touching other
terminals.
• Hazardous voltages may still exist within the Perfect Harmony cabinets even when the
disconnect switch is open (off) and the supply power is shut off.
• Never run the drive with cabinet doors open. The only exception is the control cabinet, which
contains extra low voltages (ELV).
• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A
qualified individual is “one familiar with the construction and operation of the equipment and
the hazards involved.”

SAFETY PRECAUTIONS AND WARNINGS Perfect Harmony GENIII/e Startup and Advanced Topics
Warning!
• Never store flammable material in, on or near the drive enclosure. This includes equipment
drawings and manuals.
• Always ensure the use of an even and flat truck bed to transport the Perfect Harmony drive
system. Before unloading, be sure that the concrete pad is level for storage and permanent
positioning.
• Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the drive
system. Dropping the cabinet or lowering it too quickly could damage the unit.
• Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure that the
fork truck tines fit the lifting tubes properly and are the appropriate length.
• During operation, the nominal weighted sound pressure level may exceed 70 dB at a
distance of 1 meter from the drive.

• Static charge buildup can be removed from a conductive object by touching the object to a
properly grounded piece of metal.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style
plunger or copper braid when desoldering.
• When returning components to ROBICON, always use static-safe packing. This limits any
further component damage due to ESD.
should be strictly adhered to in order to reduce the risk of personal injury or equipment damage.
∇ ∇ ∇
x ASIRobicon Version 1.1(19000404)

Perfect Harmony GENIII/e Startup and Advanced Topics ABOUT THIS MANUAL
ABOUT THIS MANUAL
functions and picklist menu items. Software setup and startup procedures are also included. Advanced
Reference Tools
ASIRobicon.

ABOUT THIS MANUAL Perfect Harmony GENIII/e Startup and Advanced Topics

*
Note: icons in the outer margins alert readers of important operational or application
information that may have extra special significance. The associated text is enclosed in a
border for high visibility.
equipment.
TB1A).
(e.g., 6-16).
∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics INTRODUCTION

output.


Source Current
Source Voltage


*
source.

INTRODUCTION Perfect Harmony GENIII/e Startup and Advanced Topics
100
90
80 Perfect Harmony
Series Drive
70
60
50
40 Phase-controlled
SCR Drive
30
20
10 Percent Speed
20 27 33 40 47 53 60 67 73 80 87 93 100

Typical Phase
Output Current
Time



1

1
1.4. Specifications
Item Description
(System w/o Cells)
(Cells*)

∇∇∇

Perfect Harmony GENIII/e Startup and Advanced Topics HARDWARE COMPONENTS


HARDWARE COMPONENTS Perfect Harmony GENIII/e Startup and Advanced Topics
Blowers
Air Intakes
Cooling for
Small Units
Transformer
Section
Customer Control
Wiring and
Control Power
Section
Control Section
and Access to
Cell Cabinet
Split Cooling for

Longer Lineup
Transformer
Section
Control

SHIPPING SPLIT
AIR EXHAUST
DO NOT BLOCK
AIR EXHAUST
DO NOT BLOCK
2
K1 K1
K1 K1
Customer
Control
Wiring and
Control
Section
INPUT/TRANSFORMER
CELL/OUTPUT
CABINET
FRONT VIEW CABINET

Table 2-1.
*

Blower
Item Description
Transformer
F4, F5 Fuses



between Cell and
here
2
L1
L2
L3
T1, T2, T3

*

Blower
Customer
I/O
Section

*

Phase
3 3,300 9 up to 1500 70A, 100A, 140A, 200A, 260A
4 4,160 12 up to 2000 70A, 100A, 140A, 200A, 260A
6 6,600 18 up to 3000 70A, 100A, 140A, 200A, 260A


Phase
2 2 2,300 6 up to 3000 315A, 375A, 500A, 660A

3 3,300 9 up to 4000 315A, 375A, 500A, 660A
4 4,160/4,800 12 up to 6000 315A, 375A, 500A, 660A
5 6,000 15 up to 8000 315A, 375A, 500A, 660A
6 6,600 18 up to 0000 315A, 375A, 500A, 660A


Blower
Control
Cell Section
Section (Back)
2
*
200 33 70 20,000 4,400 100 4,800 70
300 49 70 30,000 4,400 100 4,800 70
400 64 70 40,000 4,400 100 5,600 70
500 80 100 50,000 4,400 100 6,200 100
600 96 100 60,000 4,400 100 6,200 100
700 112 140 70,000 4,400 100 7,500 140
800 128 140 80,000 4,400 100 7,500 140
900 145 200 90,000 8,800 123 7,500 200
1000 162 200 100,000 8,800 123 8,000 200
1250 202 260 125,000 8,800 137 8,500 260
1500 242 260 150,000 8,800 137 9,000 260

300 38 70 30,000 4,400 100 5,100 70
400 51 70 40,000 4,400 100 5,100 70
500 63 70 50,000 4,400 100 5,800 70
600 75 100 60,000 4,400 100 6,600 100 2
700 89 100 70,000 4,400 100 6,600 100
800 101 140 80,000 4,400 100 7,700 140
900 114 140 90,000 4,400 100 7,700 140
1000 126 140 100,000 4,400 100 7,700 140
1250 160 200 125,000 8,800 137 9,500 200
1500 192 200 150,000 8,800 137 9,500 200
1750 224 260 175,000 8,800 137 10,000 260
2000 256 260 200,000 8,800 137 11,000 260
600 48 70 60,000 8,800 137 7,700 70
700 56 70 70,000 8,800 137 9,000 70
800 64 70 80,000 8,800 137 9,000 70
900 72 100 90,000 8,800 137 9,000 100
1000 80 100 100,000 8,800 137 10,400 100
1250 100 100 125,000 8,800 137 10,400 100
1500 120 140 150,000 8,800 137 12,300 140
1750 140 140 175,000 8,800 137 12,300 140
1750 141 200 175,000 13,200 172 12,500 200
2000 162 200 200,000 13,200 192 13,000 200
2250 182 200 225,000 13,200 192 13,000 200
2500 202 260 250,000 13,200 192 13,500 260
2750 222 260 275,000 13,200 192 14,000 260
3000 242 260 300,000 13,200 192 14,000 260
1500 324 375 114,000 8,800 172 7,450 375H
1750 378 375 133,000 8,800 172 8,200 375H
2000 432 500 152,000 8,800 172 8,800 500H
2250 486 500 171,000 8,800 172 9,500 500H
2500 540 660 190,000 8,800 172 10,200 660H
3000 648 660 228,000 8,800 188 11,500 660H
1750 264 315 133,000 15,000 172 9,700 315H
2000 301 315 152,000 15,000 172 11,200 315H
2250 339 375 171,000 15,000 172 11,200 375H

2500 377 375 190,000 15,000 172 12,000 375H
3000 452 500 228,000 15,000 188 13,400 500H
3500 527 660 266,000 15,000 188 14,900 660H
4000 603 660 304,000 15,000 188 16,400 660H
2250 269 315 171,000 18,000 192 13,800 315H
2500 299 315 190,000 18,000 192 14,600 315H
3000 359 375 228,000 18,000 208 16,200 375H
3500 418 500 266,000 18,000 208 17,900 500H
4000 487 500 304,000 18,000 208 19,100 500H
5000 598 660 380,000 18,000 232 22,800 660H
3500 290 315 266,000 25,000 248 20,100 315H
4000 331 375 304,000 25,000 272 21,900 375H
5000 414 500 380,000 25,000 272 25,500 500H
6000 497 500 450,000 25,000 272 29,100 500H
7000 580 660 532,000 25,000 272 32,700 660H
3500 264 315 266,000 28,000 248 21,900 315H
4000 301 315 304,000 28,000 272 23,800 315H
5000 377 375 380,000 28,000 272 27,700 375H
6000 452 500 450,000 28,000 272 31,600 500H
7000 527 660 532,000 28,000 272 35,500 660H
8000 603 660 608,000 28,000 272 39,400 660H
1
2
3
4
5
6
7
8



fiber-optic links.

A1 A2 A3 A4 A5 A6

B1 B2 B3 B4 B5 B6

C1 C2 C3 C4 C5 C6
Future Expansion
A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4
A5 B5 C5 A6 B6 C6


*
See Figure 2-13.


to By-pass board

Power
Supply
connection

Flash Disk

T1 Cell
Special Transformer
with 18 Isolated A1
Secondaries
B1 Keypad
Cell
C1 2
Cell
A2
Cell Fiber
B2 Optic
3-phase AC Board
Cell
C2
Cell
A3
See 2.4.1.
Cell
B3 Microprocessor
Board
Cell
C3
Cell
A4
Cell
B4
Cell Digital WAGO

C4 Modulator I/O
Current Feedback
Cell
A5
Cell
B5
Analog to
Fiber Digital Board
Cell Optic
C5 &
Interface
Cell Board System
A6 Interface
Board
Cell
B6
Cell
C6 Conditioning
Circuits
Voltage
Attenuator
Induction
Motor


maintained.
lagging.


Input fuses for

GENIIIe are not
located in Cell

∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics THE KEYPAD AND DISPLAY INTERFACE
CHAPTER 3: THE KEYPAD AND DISPLAY INTERFACE
3.1. Introduction
The menu system is the software program that allows operators to navigate through hierarchical
structures (menus) which contain related menu items. Menu items include parameters, pick lists,
functions and submenus (“nested” menus). These menu items allow the operator to configure a drive to
his particular needs.
It is important to understand the mechanism through which the menu system operates. This mechanism
is the front panel keypad and display interface. The display interface is a 24-by-2 character back-lit LCD.
The keypad provides numerical keys for entering data and arrow keys for scrolling through the menu
structure of the Perfect Harmony drive. 3
The keypad has built-in keys for fault reset, auto mode, manual start, and manual stop functions. Three
diagnostic LEDs (power on, fault status, alarm status, and run) are built in to the standard keypad.
Normally, the keypad and display interface is mounted permanently to the drive. However, the
keypad/display module need not be mounted for normal operation. It can be plugged in as an external
module for set-up and diagnostic purposes only. Thus, one may use it to provide extra parameter
security.
The Perfect Harmony system provides a fully programmable, multi-level security system that assures
menu access and modification capabilities by only authorized personnel.
3.2. The Keypad
Warning: Do not remove or attach the keypad while the drive is powered.
The Perfect Harmony series contains a user-friendly keypad and display interface. This keypad/display
interface is located on the front of the Perfect Harmony Drive Control Cabinet. The Keypad and Display
Interface is illustrated in Figure 3-1.
The Keypad and Display Interface is used to access the control parameters and functions of the Perfect
Harmony drive. Parameters are organized into logical groups using a menu structure
. To view or edit parameters, the operator must maneuver through the menu structure to the desired
parameters. This is accomplished using special key sequences. A summary of these key sequences is
given later in this chapter.
The [SHIFT] key (which is used in conjunction with the 10 numeric keys and the [ENTER] key) is provided
to access 9 common system menus, a help display function and a [CANCEL] key. The keypad is used to
navigate through the menu system, activate control functions, reset the system after faults have occurred,
edit parameter values, enter security access codes, and place the system in either automatic, manual or
stop (auto/hand/off) mode.

THE KEYPAD AND DISPLAY INTERFACE Perfect Harmony GENIII/e Startup and Advanced Topics
On (Red) when On (Red) when On (Red)

control power is faulted, blinks (Red) when drive is
supplied when alarm exists running
Status
Indicators
(Red LEDs)
ROBICON Harmony
Version #.## Date
Display (2×24
Characters)
3
Modes of Operation:
• Automatic Keypad
• Manual Start
• Manual Stop
Figure 3-1. The Keypad and Display Interface of the Perfect Harmony Series
*
Note: Parameter values are stored in a Flash Disk - a non-volatile memory area. When a
parameter value is changed, the new value is saved internally. Even after a power failure, the value
remains intact and can be recalled.
The Perfect Harmony keypad contains 20 keys. Each of these keys has at least one function associated
with it. Some keys are used for 2 or more functions. The following sections give descriptions and uses
for each of the keys on the keypad, as well as the diagnostic LEDs and the built-in display.
3.2.1. Fault Reset Key
The [FAULT RESET] key is located in the top left corner of the keypad and is used for two functions.
Function one is to clear fault conditions that may occur in the Perfect Harmony system. Function two is to
acknowledge alarm conditions that may occur in the Perfect Harmony system. Faults refer to fatal errors
that have been detected by both the hardware and software and prevent the drive from running. Alarms
refer to nonfatal errors that have been detected by both the hardware and software and, as such, do not
prevent the drive from running. However, alarm conditions which are ignored may ultimately lead to a
fatal fault. The current alarm/fault status of the drive is displayed by the Fault indicator located above the
keypad and display (refer to Figure 3-1).
When a fault condition occurs, the fault indicator glows red continuously. To reset the system (that is,
acknowledge fault conditions), the operator must:
• Determine the cause of the fault (see the display or check the alarm/fault logger table)
• Correct conditions that may have caused the fault, if appropriate
• Reset the system by pressing the [FAULT RESET] key on the keypad.
When there are no fault conditions and an alarm condition occurs, the fault indicator flashes red. To
acknowledge the alarm conditions, the operator should:

• Determine the cause of the alarm (see the display or check the alarm/fault logger table).
• Correct conditions that may have caused the alarm, if appropriate.
• Acknowledge the alarm by pressing the [FAULT RESET] key on the keypad. Acknowledging an
alarm will cause that alarm to be no longer displayed on the keypad display, however, as long as any
alarm condition exists the fault indicator LED will flash red.
*
Note: An alarm condition will be reset automatically once it no longer exists. If an alarm is not
acknowledged, that alarm’s LCD text message may still appear. However, the red “FAULT” LED
will turn off once the condition that triggered the alarm is resolved.
3.2.2. Automatic Key

The [AUTOMATIC] key is located below the [FAULT RESET] key on the keypad and is used to put the
Perfect Harmony drive into automatic mode. In automatic mode, the standard speed setting for the drive 3
is obtained from the 4-20 mA input and through speed profile parameters located in the Speed Profile
Menu (4000).
*
Note: Automatic mode can be customized to suit particular application needs by modifying the
appropriate I/O parameters from the keypad and display interface. Modification of the standard
system program of the Perfect Harmony is also a viable option, although it requires an
understanding of the system program format, the compilation process and downloading
techniques.
3.2.3. Manual Stop Key

The [MANUAL STOP] key is used to place the Perfect Harmony into stop mode. Stop mode shuts down
the drive in a controlled manner, regardless of its current state (manual, remote or automatic).
*
Note: Modification of the standard system program of the Perfect Harmony requires an
techniques.
3.2.4. Manual Start Key

The [MANUAL START] key is located below the [AUTOMATIC] key on the left side of the keypad.
[MANUAL START] is used to put the Perfect Harmony system into manual control mode.
There are two varieties of manual mode: local and remote. These varieties are distinguished by the
sources of the velocity demand. In local manual mode, the desired velocity is selected manually using
the up and down arrow keys ([×] and [Ø]) on the system keypad. In remote manual mode, the desired
velocity is selected manually using a user-supplied potentiometer connected to the system. Remote
manual mode is activated by pressing the momentary digital input assigned to manual start mode. A
simplified flow diagram of manual mode is illustrated in Figure 3-2.

Local manual mode is activated by pressing

Perfect Harmony Keypad the Manual Start key on the keypad and
setting the velocity demand using the up
Velocity and down arrow keys.
MANUAL Demand Set
START Manually from
Arrow Keys
Drive
Momentary Remote Digital Input Output to
(120 VAC Logic) Motor
Perfect
3 Dedicated Harmony
Pot Input Drive
Remote manual mode is activated by
pressing the momentary input and
setting the velocity demand using the
remote potentiometer.
Velocity Demand Set Manually from a
programmable Remote Pot
Figure 3-2. Comparison of the two Manual Control Modes
3.2.5. The 0-9 Key
Numeric keys are centrally located on the keypad of the Perfect Harmony system. These 10 keys
(labeled 0 through 9) provide the following functions:
• entry of security access codes
• speed menu (direct access to 10 basic menus according to assigned menu names [in green text
above each numeric key])
• Direct access to all menus, submenus, parameters and pick lists (with proper security) based on ID
number.
• Ability to change the values of parameters.
One function of the numeric keys of the Perfect Harmony keypad is to enter a 4-digit security access
code. The security code consists of any combination of digits 0 through 9 and hexadecimal digits “A”
through “F”.
*
Note: Hexadecimal (or hex) is a method of representing numbers using base 16 (digits 0-9, A, B,
C, D, E and F) rather than the more common base 10 (digits 0-9). Hex digits “A” through “F” can be
entered from the keypad by pressing the [SHIFT] key followed by the numbers [1] through [6],
respectively. The keystrokes required to enter hex values “A” through “F” are listed in Table 3-1.
Decimal equivalents are also listed.
Another function of the numeric keys is the speed menu feature. Speed menu allows the operator to
access 10 common menus within the system using the pre-programmed numeric keys. Each of the
numeric keys has an associated menu name printed in green (on top of each numeric key). To access
one of these 10 menus, the operator uses the [SHIFT] key followed by the appropriate numeric key (e.g.,
[SHIFT]+[1] to access the Motor menu, [SHIFT]+[2] to access the Drive menu, etc.). Refer to Figure 3.3..

Table 3-1. Hexadecimal Digit Assignments on the Perfect Harmony Keypad
Key Combination Hex Value Decimal Equivalent
MOTOR
A 10
SHIFT
1
SHIFT DRIVE
B 11
2
C 12
SHIFT STAB
3
D 13
3
SHIFT AUTO
4
MAIN
E 14
SHIFT
5
SHIFT LOGS
F 15
6
Number for Entering Speed Menu Name (Use with Shift

Parameter Values, Security MOTOR Key from the Default Meter Display)
Codes or Menu Numbers 1
Figure 3-3. Anatomy of a Numeric Keypad Key
In addition to the speed menu feature, a second menu access feature is available for all remaining menus
in the Perfect Harmony system. The speed menu feature is available only from the main meter display on
the LCD. The hexadecimal entry feature is available only during security code entry. Therefore, the
results of [SHIFT]+[1] through [SHIFT]+[6] key combinations depends on the context in which they are
used. This second access feature cannot only be used on menus, but can also be used to go directly to
a particular parameter, or pick list. While this second method requires more keystrokes to access target
menus, parameters or pick lists, the operator can gain access to all security approved items rather than
just the 10 most common menus. Accessing items in this manner requires that the operator know the
item ID number. This item number will be a four digit number. This number is listed on the display each
time the item is displayed and is also listed in the menu reference charts later in this chapter. To access
an item using its ID number, press the [SHIFT] key followed by the right arrow key [Ö]. The display
prompts the operator for the desired ID number. Using the numeric keys on the keypad, the operator
enters the desired ID number then presses the [ENTER] key. If the number was a valid ID number, and
the current security level permits access to that item, then the desired item will be displayed. Refer to
Figure 3-4.
Note:
• Any menu, parameter, or pick list can be accessed by ID. To do this press [SHIFT]+ [Ö]. The
display will read “Enter Param ID:”. Simply enter the ID number of the item you want to go to
and hit [ENTER].
*
• The menu, parameter and pick list ID can be found in the menu tables later in this chapter or is
listed on the display in () when the item is displayed.
If the operator requests access to a menu number that is assigned a higher security level than the current
security level, the drive will prompt the operator for the appropriate security level code.
Finally, the numeric keys on the keypad can also be used to change the value of system parameters.
Once a parameter is selected for modification, the leftmost digit of the parameter value is underlined and
is called the active digit. The active digit can be changed by pressing a numeric key. This method

automatically advances the underline to the next digit to the right. The operator continues pressing
numeric keys until the desired value is displayed. The [ENTER] key is used to accept the new value.
*
Note: When editing parameter values be sure to pad significant digit fields with zeroes where
appropriate. For example to change the value of a 4-digit parameter from 1234 to 975 the operator
must enter 0975.
First, press the Shift key

SHIFT
Ö then the right arrow key. Finally, press the Enter key.
If the ID was valid and the
“Enter Param ID:” is
MOTOR DRIVE STAB
displayed. 1 2 3
security access level is set
appropriately, the selected item
3 Speed Parameter AUTO MAIN LOGS
name will be displayed (with the
corresponding menu number in
4 5 6
Enter Param ID: parentheses).
DRV PRO METER COMM.

Next, enter the ID number of the 7 8 9 CANCE
L
item to be accessed using the ENTER
numeric keys on the keypad. HELP
0
Figure 3-4. Accessing Items Using ID Numbers
Note: In the case of signed parameters (parameter values that can be either positive or negative),
the first active digit is actually the sign of the value. The sign is changed by using the up [×] and
down [Ø] arrow keys when the leftmost (sign) position of the value is underlined (i.e., it is the active
* “digit”). Either a “+” or a “-” will be displayed during the editing process. After the new value is
accepted (using the [ENTER] key), positive values are displayed without the “+” sign. Negative
values always show the “-” sign unless the negative sign is implied in the parameter name itself.
3.2.6. The Enter/Cancel Key

The [ENTER] key is located below the up and down arrow keys on the right side of the keypad. This key
is similar to the Return or Enter key on a standard PC keyboard. It is used to choose/accept a selection
or confirm an operation. For example, after locating and displaying a parameter within the Perfect
Harmony menu structure, the operator may use the [ENTER] key to edit the parameter’s value. Common
functions of the [ENTER] key include:
• Selecting a submenu
• Enter edit mode for a selected parameter value
• Accept a new parameter value after editing.
By using the [SHIFT] key, the [ENTER] key can be used as a cancel function. The [CANCEL] function is
used to abort the current operation or return to the previous menu display. Common functions of the
[CANCEL] key include:
• Returning out of the menu system
• Rejecting any modifications to a parameter value in edit mode.
3.2.7. Shift Function Keys
The [SHIFT] key is located in the bottom right corner of the keypad on the Perfect Harmony system. This
key is used to access a second set of functions using existing keys on the keypad. Keypad keys that can
be used with the [SHIFT] key have two labels (one on top and one on the bottom of the key). The
standard (un-shifted) function of the key is listed on the bottom half of the key and has a white
background. The shifted function of the key is shown on the top of the key and has a green background
(matching the green background of the [SHIFT] key to identify that they are used together).

When the Perfect Harmony prompts the operator for a numerical value (e.g., during entry of the security
access code, parameter modification, etc.), the [SHIFT] function of numerical keys 1 through 6 changes
from quick menus to hexadecimal numbers “A” through “F” respectively. Refer to Table 3-1 on page 3-5
Note: It is not necessary to simultaneously press the [SHIFT] key and the desired function key.
The operator must press the [SHIFT] key first, release it, and then press the desired function key.
When the [SHIFT] key is pressed, the word “SHIFT” appears in the lower right corner of the
interface display (indicating that the Perfect Harmony is waiting for the second key to be pressed).
*
After a key is pressed, the word SHIFT is removed from the LCD. Refer to Figure 3-5.
SHIFT
3
Figure 3-5. Location of Shift Mode Indicator on the Perfect Harmony Display
Common functions of the [SHIFT] key include:

• Entering “speed menus” ([SHIFT] plus appropriate “speed menu” key from main meter display)
• Using the [CANCEL] function ([SHIFT] + [ENTER] sequence)
• Entering hex values “A” through “F” ([SHIFT] + [1] through [SHIFT] + [6] when editing values or
entering security code)
• Accessing menus, parameters or pick lists based on menu numbers ([SHIFT] + [Ö])
• Returning to the top of the current menu/submenu ([SHIFT] + [×])
• Going to the bottom of the menu or submenu ([SHIFT] + [Ø])
• Resetting the current security level to 0 ([SHIFT] + [Õ] + [SHIFT] + [Õ] + [SHIFT] + [Õ] from the main
meter display).
• Setting a parameter value back to its factory default ([SHIFT] + [Õ]).
A summary of [SHIFT] key key sequences is listed in Table 3-2.

3.2.8. Arrow Keys
There are four yellow arrow keys on the Perfect Harmony keypad. The up and down arrow keys ([×] and
[Ø]) are located in the upper right corner of the keypad. The left and right arrow keys ([Õ] and [Ö]) are
located on the lower row of the keypad. Common uses of the arrow keys include:
• Navigating through the menu structure
• Scrolling through lists of parameters
• Incrementing/decrementing parameter values (when in edit mode)
• Manually advancing to the next digit (when in edit mode)
• Increasing (up arrow [×]) and decreasing (down arrow [Ø]) the desired velocity demand of the drive
(when in local manual mode)
• Clearing security level (press [SHIFT] + [Õ] 3 times from the default meter display)
• Entering menu access mode ([SHIFT] + [Ö]).
The left and right arrow keys ([Õ] and [Ö]) can be used to navigate through the menu structure of the
Perfect Harmony system. In general, the right arrow [Ö] is used to penetrate deeper into the menu
structure and the left arrow [Õ] is used to back out of the menu structure. For example, from the main
display, the operator can press the right arrow key [Ö] to access the Main menu.
The up and down arrow keys ([×] and [Ø]) can be used to scroll through lists of items. For example, after
using the right arrow key [Ö] to reach the Main menu, the operator may select the down arrow key [Ø] to
scroll through the list of options within the Main menu. These options may be parameters, pick lists, or
submenus. Refer to the next section for information about the structure of the menu system.

The up and down arrows ([×] and [Ø]) can be used to increment or decrement the desired velocity
demand when the system is in local manual mode (refer to Section 3.2.4 on page 3-3). As the up and
down arrow keys are pressed, the changes in desired velocity demand can be viewed from the main
display on the LCD. Refer to Figure 3-6.
*
Note: The velocity demand field (DEMD) on the front panel display is assigned by default. This
display assignment (and the other three) can be changed from the menu system.
Table 3-2. Summary of Common [SHIFT] Key Sequences
Key Combination Description
SHIFT MOTOR
Speed menu to the Motor menu (from the default meter display)
1
Enters hexadecimal “A” (from value edit and security prompts)
3 DRIVE Speed menu to the Drive menu (from the default meter display)
SHIFT
2
Enters hexadecimal “B” (from value edit and security prompts)
SHIFT STAB Speed menu to the Stability menu (from the default meter display)
3
Enters hexadecimal “C” (from value edit and security prompts)
SHIFT AUTO Speed menu to the Auto menu (from the default meter display)
4
Enters hexadecimal “D” (from value edit and security prompts)
SHIFT MAIN Speed menu to the Main menu (from the default meter display)
5
Enters hexadecimal “E” (from value edit and security prompts)
SHIFT LOGS
6
Speed menu to the Logs menu (from the default meter display)
Enters hexadecimal “F” (from value edit and security prompts)
SHIFT DRV PRO

Speed menu to the Drive Protect menu (from the default meter display)
7
SHIFT METER Speed menu to the Meter menu (from the default meter display)
8
SHIFT COMM. Speed menu to the Communications menu (from the default meter display)
9
SHIFT HELP Speed menu to a context sensitive Help menu (from anywhere except the
0
default meter display)
SHIFT CANCEL Cancels/aborts the current action/keystroke or exits menu system
ENTER
Enters “numerical menu access mode”. The operator is then prompted to

SHIFT
Ö enter the 1, 2 or 3 digit number for the associated menu.
Returns to the top of the current menu or submenu.
SHIFT
×
Restores the security level back to 0. The [SHIFT] + [Õ] key sequence must
SHIFT
Õ be entered three times in succession from the default meter display to restore
SHIFT
Õ the security level back to 0.
SHIFT
Õ
Going to the bottom of the menu or submenu.
SHIFT
Ø
When editing a value that has been changed from its factory default, this key
SHIFT
Õ sequence will return the value to its factory default.

Next, use the up and down arrow keys to The velocity demand is displayed
increase and decrease the velocity demand. dynamically on the front LCD
panel of the Perfect Harmony.
First, place the drive in
local Manual mode
MANUAL MODE DEMD FREQ RPM ITOT

START
OFF 50 30 890 40
Figure 3-6. Using the Up and Down Arrow Keys to Control Velocity Demand
Another feature of the arrow keys is that they can be used to edit the values of parameters. To edit a
parameter value, the operator must first navigate through the menu structure (using the arrow keys) and
locate the parameter to be changed. With the parameter displayed on the LCD, the operator must press
3
the [ENTER] key. This places the selected parameter into edit mode. Once in edit mode, an underscore
is displayed beneath the first (i.e., the most significant) position of the parameter value. Changing the
value of that position can be accomplished by pressing the desired numeric key or by using the up and
down arrow keys ([×] and [Ø]) to scroll (and wrap around) through the numbers 0 through 9 for that
position. When the up and down arrow keys are used, the operator must press the right and left arrow
keys ([Õ] and [Ö]) to move to the next (or previous) position in the number to be edited (unlike using the
number keys which automatically shift the underscore to the next digit in the number). The operator must
press the [ENTER] key to accept the new value or press the [SHIFT] + [ENTER] (i.e., [CANCEL]) to abort
the change.
A feature unique to the left arrow key (with the [SHIFT] key) is its ability to cancel the current security
mode and return to level 0. An operator can increase the security access level (by entering the
appropriate security codes), but cannot lower the security access level using the standard “Change
Security Code” option of the Main menu. If an experienced user enters level 7 (or any other security
level) then wishes to return to level 0 when he is finished (for security reasons), he may reset the drive by
toggling power to the drive or using the [SHIFT] + [Õ] sequence three times from the main display (i.e.,
[SHIFT] + [Õ] + [SHIFT] + [Õ] + [SHIFT] + [Õ] ). The latter method is a convenient way to reset the
security level to 0 without interrupting the operation of the drive. When the security level is reset, the
display shows a “Security Level Cleared” message. Refer to Figure 3-7.
MODE DEMD FREQ RPM ITOT

Security Level Cleared.
Figure 3-7. Security Level Cleared Message on the Perfect Harmony Display
Note:
• Security will return automatically to level 0 after 15 minutes of inactivity.
• The [SHIFT] + [Õ] + [SHIFT] + [Õ] + [SHIFT] + [Õ] key sequence is valid only when performed *
from the default meter display.
The right arrow key [Ö] is also used in conjunction with the [SHIFT] key to provide a menu, parameter, or
pick list access feature. The operator can gain access to all security approved menus parameters, or
pick lists. Accessing items in this manner requires that the operator know the ID number associated with
the target item. This ID number can be a one, two, three or four digit number. To access an item using
its ID number, press the [SHIFT] key followed by the right arrow key [Ö]. The display prompts the
operator for the desired ID number. Using the numeric keys on the keypad, the operator enters the
desired ID number then presses the [ENTER] key. If the number was a valid ID number and the current
security level permits access to that item, then the desired item will be displayed. Refer to Figure 3-4 on
page 3-6. Some common arrow key sequences are listed in Table 3-3.

Table 3-3. Summary of Common Arrow Key Sequences

Used individually to navigate through the menu structure. Also used to
Õ orÖ change the active digit of a parameter value (when in edit mode).
Used individually to scroll through lists of menu options, lists and
× or Ø parameters. Used to change velocity demand (from default meter display).
Increments/decrements parameter values (when in edit mode).
Enters “numerical item access mode”. The operator is then prompted to
SHIFT
Ö enter the 1 or 4 digit ID number for the associated item.
3 Jumps to the top menu item of the currently selected menu or submenu.
SHIFT
× Hitting an additional up arrow will take you out of the current menu or
submenu to the previous menu.
Restores the security level back to 0. The [SHIFT]+[Õ] (left arrow) key
SHIFT
Õ sequence must be entered three times in succession from the default
meter display to restore the security level back to 0.
SHIFT
Õ
SHIFT
Õ
SHIFT
Ø Jumps to the bottom menu item of the currently selected menu or
submenu.
When editing a value that has been changed from its factory default, this
SHIFT
Õ key sequence will return the value to its factory default.
3.2.9. Diagnostic Indicators

The standard keypad and display interface also contains 3 diagnostic LED indicators that are located
above the display: Power On, Fault and Run. The Power On indicator is lit when control power is
supplied to the system. The Run indicator is illuminated when the drive is running. The Fault indicator is
lit when one or more system errors have occurred (e.g., boot-up test failure, overvoltage fault, etc.). The
Fault indicator blinks when one or more alarms are active. The [FAULT RESET] key must be pressed to
clear any existing fault conditions and restore the system to normal operation. Refer to Figure 3-1 for the
location of the 3 diagnostic indicators.
3.2.10. The Display
After power up or reset, the ASI Robicon identification and software version number is displayed for 2-3
seconds. Afterwards, the meter display is shown on the LCD by default. The meter display is the starting
point of the menuing system. This display remains on the LCD until keys are pressed.
ASIRobicon Harmony MODE DEMD FREQ RPM ITOT

VERSION #.## DATE HAND 70 70 1260 40
Figure 3-8. The Identification/Version Screen and Meter Displays
The meter display screen contains five fields that are monitored and updated dynamically. These fields
are the MODE (the operational mode), DEMD (the velocity demand), RPM (calculated revolutions per
minute), VLTS (motor voltage) and ITOT (total output current) fields. The value (or state) of each field is

shown dynamically on the second line of the display. Refer to Figure 3-9. The MODE field is fixed. The
last 4 fields on the display contain parameter values that can be defined by the operator.
Fixed display User-defined
field display fields
Top row of display shows
field names. MODE is MODE DEMD RPM VLTS ITOT
displayed when not in KYPD 80 0 0 0 Bottom row of display
RGEN or RLBK mode. shows dynamic values
Figure 3-9. Dynamic Programmable Meter Display
The MODE field displays the current operational mode of the Harmony system. This field can have any
one of the displays summarized in Table 3-4 depending on the current operational mode or the current
state of the drive. 3


RLBK for rollback mode. RLBK DEMD RPM VLTS ITOT
KYPD in row 2 indicates KYPD 80 0 0 0 Bottom row of display
manual (local) mode also. shows dynamic values
Figure 3-10. Dynamic Programmable Meter Display in Rollback Mode


RGEN for regen mode. RGEN DEMD RPM VLTS ITOT
Figure 3-11. Dynamic Programmable Meter Display in Regeneration Mode
The following illustrations depict the 2-line, 24-character display in various modes of access as the
operator attempts to locate and change the Ratio Control and Motor Frequency parameters.
Figure 3-12 depicts the display immediately following power up or system reset. Note that the first three
variable displays (from the right) can be selected from a pick list using the Display Parameters (8000).
SHIFT CANCEL
ENTER
MODE DEMD
Æ FREQ RPM ITOT
HAND 70 70 1260 40
Figure 3-12. Status Display After [SHIFT] [ENTER] ([CANCEL]) Key Sequence
The DEMD display (refer to Figure 3-12) shows the “commanded speed reference” in percent.
Figure 3-13 depicts the display following a [SHIFT]+[2] ([DRIVE]) key combination. From this point the
nine standard menus listed in Table 3-2 can then be selected using the up/down arrow keys ([×] and
[Ø]). Depicts the display after the down arrow key ([Ø]) is pressed twice and prior to the selection of the
Speed Setup Menu (2060). If the [ENTER] or right arrow key ([Ö]) is pressed at this display, the Speed
Setup Menu (2060) will be entered Figure 3-15. Figure 3-16. Figure 3-16 depicts the display following a
down arrow keystroke to the Ratio Control Parameter (2070). The down arrow key ([Ø]) was pressed
once to obtain this display. depicts the display once the Ratio control parameter in the Speed Setup
Menu (2060) is entered for edit. Note the word edit appears in the display when a parameter is in the edit
mode. The left/right arrow keys ([Õ] and [Ö]) can be used to position the cursor under the desired digit

(or sign) to be changed. The digit can be set by either using the number keys, or it may be
incremented/decremented using the up/down arrow keys ([×] and [Ø]). The sign can be changed using
the up/down arrow keys. The parameter is selected into memory once the [ENTER] or right arrow key
([Ö]) is pressed. Figure 3-19 Depicts the display when a number in range is entered.
*
Note: An asterisk (*) is used to denote when a parameter is changed from its current default value.
This allows the user to quickly see which parameters have been changed. To return a parameter to
its factory default value, press [SHIFT] + [Õ] while in edit mode.
SHIFT DRIVE Drive (2)

(Arrow Æ
2
keys select)
3 Figure 3-13. Status Display After [SHIFT]+[2] Key Sequence
Ø Ø Speed setup
(2060)
Æ
(submenu)
Figure 3-14. Status Display After [Ø] [Ø] Key Sequence
SpeedÆsetup (2060)
Ö (Arrow keys select)
Figure 3-15. Status Display After [Ö]
Ratio control
Æ
Ø (2070) 1.0
Figure 3-16. Status Display After [Ø] Key Sequences
Ratio control
CANCEL
ENTER Æ
(edit) ±001.0
Figure 3-17. Status Display After [ENTER] Key to Change a Parameter
Ratio control
*(edit) -03.0
Figure 3-18. Status Display Upon Entering a Value In the Range of the System

In the following example a [SHIFT] [Ö] to get to the Parameter ID display. The parameter ID for Motor
Frequency (1020) is entered. See Figure 3-19. The [ENTER] key is then pressed once to show the Motor
Frequency display and then [ENTER] is pressed again to edit its value. See Figure 3-21 depicts the
display if 010 is attempted to be entered for the Motor Frequency. Since the range of the variable is 15 to
330, an error message will be displayed.
Speed Parameter
SHIFT
Ö Æ Enter Param ID:1020
Figure 3-19. Status Display After [SHIFT] [Ö] and the Parameter ID 1020 is entered
3
Motor Frequency
Æ
CANCEL CANCEL
ENTER ENTER
(edit) 010
Figure 3-20. Status Display After [ENTER] [ENTER]
Motor Frequency
OUT OF RANGE
Figure 3-21. Status Display Upon Entering a Value Beyond the Range of the System
Table 3-4. Summary of Operation Mode Displays: Line 1 of Mode Display
Code Meaning Description

FRST Fault reset Displayed after the [FAULT RESET] button is pressed.
Note: This may not be visible because of the speed of
response to a Fault Reset.
TLIM Menu setting rollback Drive is being limited by a menu setting. Refer to torque
limits settings in Table 3-8.
SPHS Single phasing rollback A Single phasing condition of the input line is limiting drive
torque.
UVLT Under voltage rollback A Under Voltage condition of the input line is limiting the
drive torque.
T OL Thermal overload rollback The drive has limited the amount of torque produced to
prevent thermal overload of the input transformer.
F WK Field weakening rollback This condition exists when the motor flux is low and the
application requires high torque. This prevents “motor pull-
out”, an unstable operating condition of the motor.
C OL Cell overload rollback A Cell current overload model has calculated a thermal
overload condition of the drive cells and the drive has
limited the amount of torque produced.
RGEN Regeneration During normal deceleration, this message will be displayed
because the drive is preventing the motor from
regenerating power back into the drive.
BRKG Dual Frequency Braking Appears while drive is decelerating with dual frequency
braking enabled.
RLBK Roll back Appears during acceleration if drive has reached its torque


limit setting.
BYPS Cell Bypassed Indicates that one or more cells is in bypass
OLTM Open Loop Test Mode Appears if drive control algorithm is set to Open Loop Test
Mode
NET1 Network 1 limit Torque limited by network 1 setting
ALIM Analog Torque Limit Torque limited by analog input
MODE Normal mode display This is the typical display message during normal
operation.
3 Table 3-5. Summary of Operation Mode Displays: Line 2 of Mode Display

NOMV No medium voltage No input line voltage detected.
INH CR3 inhibit The CR3 or “Drive inhibit” input is asserted.
OFF Idle state The drive is ready to run but is in an idle state.
MAGN Magnetizing motor state The drive is magnetizing the motor.
The drive is trying to detect the speed of the motor in order
SPIN Spinning load state
to synchronize the drive frequency.
The drive is in the “Up Transfer State” preparing to transfer
UXFR Up transfer state
the motor to the input line.
The drive is in the “Down Transfer State” preparing to
DXFR Down transfer state
transfer the motor from the input line to the drive.
KYPD Keypad speed demand The drive speed demand source is the keypad.
TEST Speed/Torque test The drive is in a Speed or Torque test mode.
The drive 4-20mA analog input signal has dropped below
a predefined setting. See
LOS Loss of Signal
Table 3-34, Table 3-35, Table 3-37, and
Table 3-38.
The SOP flag AutoDisplayMode_O is set true usually to
indicate drive is receiving its speed demand from a source
AUTO Automatic mode
other than the keypad or network. Typically used with a
analog input speed source.
NET1 Network 1 Indicates drive is being controlled from Network 1
DECL Decelerating (no braking) The drive is decelerating normally.
BRAK Dynamic Braking Indicates that dynamic braking is enabled
The drive is not controlling the motor and it is coasting to a
COAS Coasting to stop
stop due only to friction.
The drive is in a “Auto Tuning” mode used to determine
TUNE Auto Tuning
motor characteristics.
HAND Hand mode Appears if the drive is running under normal conditions
3.3. Menu Descriptions

The following sections contain a condensed description of all parameter items available in the Perfect
Harmony menu structure.
Table 3-6 depicts main menus and submenus of the system. Each menu and submenu is associated
with an ID shown in the ID column. The key sequence [SHIFT]+[Ö] ([SHIFT] plus the right arrow key)

and up/down arrow keys ([×] and [Ø]) as described above can be used to directly access each menu
item.
Note:
• A help feature for all parameter settings is available by pressing the [SHIFT] + [0]
([HELP]) key sequence on the keypad. This feature provides a text description of the
desired selection, plus the parameters minimum and maximum value if applicable. If
more that 2 lines of help text are available, the operator may use the up and down arrow
keys ([×] and [Ø]) to scroll through the entire help message.
• Parameters are always hidden in the menu display when there is insufficient security to
edit the parameter.
• Menu items may be hidden if they do not apply to the current drive configuration.
Example if Spinning load mode (ID 2430) is set to off IDS 2440 through 2480 (spinning
load parameters) are not displayed.
* 3
• Table 3-6 lists menus and submenu name only. Parameters and functions found in
these menus are described in the sections that follow. Use the associated table and
page number from Table 3-6 to quickly locate the section of the chapter that explains all
of the associated items.
• Note that menu items change with new releases of software. Hence the menu system
described here may be slightly different than the menu system on your drive. Your drive
has help functions for every parameter and these can be used if the function is not
described here.
Table 3-6. Perfect Harmony Menu and Submenu Summary
Menu ID Submenu Names ID Table Page Description

Motor 1 Motor Parameter 1000 Table 3-7 17 Used to enter motor-
Menu specific data
Limits 1120 Table 3-8 18
Autotune 1250 Table 3-10 20
Encoder 1280 Table 3-11 21
Drive 2 Drive Parameter 2000 Table 3-12 21 Used to configure the
Menu VFD for various load
Speed Setup 2060 Table 3-13 22 conditions and drive
Speed Ramp Setup 2260 Table 3-14 23 applications.
Critical Frequency 2340 Table 3-15 23

Spinning Load 2420 Table 3-16 23
Conditional Time 2490 Table 3-17 25
Setup
Cells 2520 Table 3-18 26
Sync Transfer 2700 Table 3-19 27
External I/O 2800 Table 3-20 27
Output Connection 2900 Table 3-21 28


Stability 3 Input Processing 3000 Table 3-23 29 Used to adjust the
Menu VFD’s various control
Output Processing 3050 Table 3-24 29 loop gains, including
Control Loop Test 3460 Table 3-31 32 current and speed
regulator gains.
Auto 4 Speed Profile 4000 Table 3-32 33 Used to configure
Menu various speed
Analog Inputs 4090 Table 3-33 35 setpoint, profile, and
Analog Outputs 4660 Table 3-39 38 critical speed
avoidance and
Speed Setpoints 4240 Table 3-41 39 comparator
3 Incremental Speed 4970 Table 3-42 39
parameters.
Setup
PID Select 4350 Table 3-43 40 PID Select Menu
contains PID setup
parameters
Comparator Setup 4800 Table 3-44 40 Used to configure the
analog comparators
controlled through
the SOP.
Main Menu 5 Motor 1 see above
Drive 2 see above
Stability 3 Table 3-22 28
Auto 4 see above
Logs 6 see below
Drive Protect 7 Table 3-55 47
Meter 8 Table 3-58 49
Communications 9 Table 3-63 53
Security Edit 5000 Table 3-48 43 Configures security
Functions features.
Logs Menu 6 Event Log 6180 Table 3-51 45 Used to configure
and inspect the
Alarm/Fault Log 6210 Table 3-52 45 event, alarm/fault,
Historic Log 6250 Table 3-53 45 and historic logs of
the VFD.
Drive 7 Input Protection 7000 Table 3-56 47 Adjusts setpoint
Protect limits for critical VFD
Menu variables.
Meter 8 Display Parameters 8000 Table 3-59 49 Set up Variables for
Menu display to LCD
Hour Meter Setup 8010 Table 3-61 52
Input Harmonics 8140 Table 3-62 52
Fault display override 8200 Table 3-57 50
Commun- 9 Serial Port Setup 9010 Table 3-64 54 Used for configuring
ications the various


ications Network Control 9943 Please refer to the various
Menu Communications Communications
Network 1 Configure 9900 manual (number features of the VFD.
Network 2 Configure 9914 902399)
Display Network 9950 Table 3-62 55

Monitor
Serial echo back test 9180 Please refer to
Communication
s manual
(number 902399)
Sop & serial 9110 Table 3-65 55 3
functions
TCP/IP Setup 9300 Table 3-66 55
3.3.1. Motor Menu (1) Options

The Motor Menu (1) consists of the following menu options:
• Motor Parameter Menu (1000)
• Sync Motor Menu (1100)
• Limit Protection Menu (1120)
• Autotune Menu (1250)
• Encoder Menu (1280)
The contents of these menus are explained in tables that follow.
Table 3-7. Motor Parameter Menu (1000)
Parameter ID Units Default Min Max Description
Motor frequency 1020 Hz 60 15 330 Enter the rated or base frequency

of the motor from the nameplate.
Full load speed 1030 RPM 1780 1 19800 Enter the full load speed of the
motor from the nameplate.
Motor voltage 1040 V 4160 380 13800 Enter the rated voltage for the
Full load current 1050 A 125.0 12.0 1500.0 Enter the rated nameplate full load
current of the motor.
No load current 1060 % 25.0 0.0 1000.0 Enter the no load current of the
motor, if it is provided, or use the
Autotune function.
Motor kW rating 1010 kW 746.0 120.0 20000.0 Enter the motor kW (0.746Hp) from
the nameplate.
Leakage 1070 % 16.0 0.0 30.0 Enter the leakage inductance of the
inductance motor if it is provided, or use the
Autotune function.

Stator resistance 1080 % 0.10 0.00 25.00 Enter the stator resistance of the
motor if it is provided. To convert
from ohms to % use the formula:
[%Rs = 100 * √3 * Rs(in ohms) *
Motor Current/Motor Voltage], or
use the Autotune function.
Inertia 1090 Kgm2 30.0 0.0 100000.0 Enter the rotor inertia of the motor if
known (1Kgm2 = 23.24 lbft2), or use
the Autotune function.
3
Table 3-8. Limits Menu (1120)

Overload select 1130 Constant Selects the type of motor thermal
overload protection from:
• Constant (fixed current based): Use

when only current limit based alarm
is required.
• Straight Inverse Time (motor model

used to estimate temperature):
Motor model assumes the allowable
motor load to be 100% for the entire
speed range.
• Inverse Time with thresholds
(motor model used to estimate
temperature): Motor model uses
allowable load data from the
speed derate curve.
Overload pending 1139 % 100.0 10.0 210.0 Sets the overload level (in % of
rated) at which an alarm is
generated. The pending level
corresponds to a current level with
Constant method and to a motor
temperature level with the other two
TOL methods.
Overload 1140 % 120.0 20.0 210.0 Sets the overload level (in % of
rated) at which a fault is generated.
The overload level corresponds to a
current level with Constant method
and to a motor temperature level with
the other two TOL methods.
Overload timeout 1150 sec 60.0 0.0 300.0 When output of the TOL model
exceeds the overload level for the
timeout period, a fault is generated.


Speed Derate 1151 Submenu This menu sets allowable motor load
Curve as a function of speed. See
Table 3-9.
Motor trip volts 1160 V 4800 5 9999 Sets the motor over-voltage trip
point.
Maximum Load 1159 Kgm2 0.0 0.0 500000.0 Sets the maximum load inertia that
Inertia the motor can line start without
exceeding maximum temperature.
Set this parameter only if the motor
does not conform to NEMA MG-1,
Part 20, Table 20-1. 3
Overspeed 1170 % 120.0 0.0 250.0 Sets the motor overspeed trip level
as a percentage of rated speed.
Underload enable 1180 Disable Enables or disables underload
protection.
I underload 1182 % 1.0 1.0 80.0 Sets the current underload level
based on the rated motor current.
Underload timeout 1186 sec 10.0 0.0 300.0 Sets the time for underload trip.
Motor torque limit 1190 % 100.0 0.0 300.0 Sets the motoring torque limit as a
1 function of the rated motor current.
Regen torque limit 1200 % -0.3 - 0.0 Sets the regenerative torque limit as
1 300.0 a function of rated motor current at
full speed. The limit is allowed to
increase inversely with speed.
2 function of the available motor
current.
current.
Phase Imbalance 1244 % 40.0 0.0 100.0 Sets the current threshold level for
Limit the output phase current imbalance
Ground Fault Limit 1245 % 5.0 0.0 100.0 alarmthe threshold of voltage for the
Sets
output ground fault alarm.
Ground Fault Time 1246 sec 0.017 0.001 2.000 Sets the filter time constant for
Const averaging the ground voltage and
delaying the response of the ground
fault detection.

Table 3-9. Speed Derate Curve Menu (1151)

0 Percent Break Point 1152 % 0.0 0.0 200.0 Sets the maximum motor load at
0% speed.
10% speed.
17% speed.
25% speed.
3
50% speed.
100% speed.
Table 3-10. Autotune Menu (1250)
Parameter ID Type Description

Autotune stage 1 1260 Function This function determines the stator resistance and
leakage inductance of the motor. The motor does not
rotate during this stage. If this function is not used the
menu entered values are used.
Autotune stage 2 1270 Function This function determines the no-load current & rotor
inertia of the motor. The motor rotates during this stage.
If this function is not used the menu entered values are
used.
Auto Tuning provides motor information that optimizes the Output Processing Control. Both stages of
Auto Tuning are optional. The user can enter the motor information if available (see Table 3-10). The
process is performed in two stages.

Table 3-11. Encoder Menu (1280) (Closed Loop Vector Control Only)

Encoder 1 PPR 1290 720 1 4000 Enter the number of pulses per
revolution delivered by the encoder.
Encoder filter gain 1300 0.0 0.0 0.999 Sets the gain of the filter for encoder
feedback. This parameter can have
a value between 0.0 (no filtering)
and 0.999 (maximum filtering).
Encoder loss 1310 % 0.0 0.0 75.0 Sets the level for the error between
threshold encoder output and calculated motor
speed to determine encoder loss. 3
Encoder loss 1320 Open Sets the drive response to a loss of
response Loop encoder.
• Stop (on Fault)
• Open Loop
3.3.2 Drive Menu (2) Options

The Drive Menu (2) consists of the following submenus:
• (2000) Drive Parameter Menu • (2420) Spinning Load Menu
• (2060) Speed Setup Menu • (2490) Conditional Timer Menu
• (2210) Torque Reference Menu • (2520) Cell Menu
• (2260) Speed Ramp Setup Menu • (2700) Sync Transfer Menu
• (2340) Critical Frequency Menu • (2800) External I/O Menu
Contents of these menus are explained in the tables that follow.
Table 3-12. Drive Parameter Menu (2000)

Rated input voltage 2010 V 4160 200 23000 Rated RMS input voltage of the drive.
Rated input current 2020 A 100.0 12.0 1500.0 Rated RMS input current of the drive.
Rated output voltage 2030 V 4160 200 23000 Rated drive output voltage RMS
Rated output current 2040 A 100.0 12.0 1500.0 Rated drive output current RMS
Control loop type 2050 OLTM Control loop algorithm type
selection.
• Volts per Hertz (V/Hz) for
parallel motors
• Open Loop Vector Control
(OLVC) for single induction
motors
• Closed Loop Vector Control


(CLVC) for single induction
motors with speed sensor(s)
• Open Loop Test Mode
(OLTM) for determining
modulation with Hall-effect
transducer testing
• Synchronous Motor Control
(SMC) without speed sensor
• Closed Loop Synchronous
Motor Control (CSMC) with
3 speed sensor
Table 3-13. Speed Setup Menu (2060)

Ratio control 2070 1.0 -125.0 125.0 Used to adjust the scaling of the
speed reference value.
Speed fwd max limit 2080 % 100.0 0.0 200.0 The forward max speed reference limit
1 1.
Speed fwd min limit 1 2090 % 0.0 0.0 200.0 The forward min speed reference limit
1.
2 2.
2.
3 3.
3.
Speed rev max limit 1 2140 % -100.0 -200.0 0.0 The reverse max speed reference limit
1.
Speed rev min limit 1 2150 % 0.0 -200.0 0.0 The reverse min speed reference limit
1.
2.
2.
3.
3.
Zero speed 2200 % 0.0 0.0 100.0 The zero speed threshold value.

Table 3-14. Speed Ramp Setup Menu (2260)

Accel time 1 2270 sec 5.0 0.0 3200.0 Acceleration time 1 in seconds.
Decel time 1 2280 sec 5.0 0.0 3200.0 Deceleration time 1 in seconds.
Jerk rate 2330 0.1 0.0 3200.0 Jerk rate in time to reach an acceleration rate
that will achieve rated velocity in 1 sec. 3
Table 3-15. Critical Frequency Menu (2340)

Skip center freq 1 2350 Hz 15.0 0.0 360.0 Enter the center of the first critical
frequency band to be avoided.
Skip center freq 2 2360 Hz 30.0 0.0 360.0 Enter the center of the second critical
Skip center freq 3 2370 Hz 45.0 0.0 360.0 Enter the center of the third critical
Skip bandwidth 1 2380 Hz 0.0 0.0 6.0 Enter the bandwidth of the first critical
Skip bandwidth 2 2390 Hz 0.0 0.0 6.0 Enter the bandwidth of the second critical
Skip bandwidth 3 2400 Hz 0.0 0.0 6.0 Enter the bandwidth of the third critical
Freq avoid accel 2410 sec 5.0 0.0 180.0 The accelerate used to pass through
time critical speed bands.

The critical frequency feature (sometimes called resonance avoidance) is accomplished using skip
frequencies and skip bands as defined in . This is illustrated in Figure 3-22.
Drive Speed (RPM)
RPM = 120 x Freq / # of Poles

Max
Freq = RPM x (# of Poles) / 120
Skip Freq 3
Skip Band 3
Skip Freq 2
Skip Band 2
3
Skip Freq 1
Skip Band 1
Controller
Min
Output
0% 100% (% Demand)
Figure 3-22. Critical Speed (Resonance Avoidance) Parameters

Table 3-16. Spinning Load Menu (2420)

Spinning 2430 Off Enable/Disable Spinning Load and set
load mode the direction of frequency scans:
• Off
• Forward
• Reverse
• Both
Enable Spinning Load if the drive is
required to detect the speed of an
already spinning motor. Spinning Load
should be Enabled for Fast Bypass or 3
Synchronous Motor, and should be
disabled for OLTM.
Scan end 2440 % 20.0 1.0 50.0 Point where scan ends if motor flux is
threshold above this level (as a percentage of
motor rated flux).
Current 2450 % 15.0 1.0 50.0 Sets the drive current level (as a
Level percentage of motor rated current)
Setpoint used during scanning.
Current ramp 2460 sec 0.01 0.00 5.00 Time to ramp drive current to Current
Level Setpoint.
Max current 2470 % 50.0 1.0 50.0 Sets the current trip level (as a
percentage of motor rated current) for
scanning. Use the default value of
50%.
Frequency 2480 sec 3.00 0.00 5.00 Sets the time taken to scan from rated
scan rate speed to zero. The default value of
3.00sec should be satisfactory for
most cases.
Table 3-17. Conditional Timer Setup Menu (2490)

Cond stop 2500 sec 0.8 0.0 999.9 Dwell time after stop is invoked. User
timer function defined.
Cond run 2510 sec 0.8 0.0 999.9 Dwell time after start is invoked. User

Table 3-18. Cell Menu (2520)

Installed cells/phase 2530 6 1 8 Installed cells per phase in the drive.
Min cells/phase count 2540 1 1 8 Minimum cells per phase count
(n/3)
Cell voltage 2550 Vrms 630 Rated cell voltage:
• 460V
• 630V
• 690V
Thermistor warn level 2560 % 70.0 5.0 70.0 Sets the level at which a temperature
3 alarm is generated.
Contactor settling time 2570 msec 200.0 0.0 1000.0 Time taken by bypass contactors to
change state. Use 100ms for small
contactors and 250ms for larger ones.
Max back EMF decay 2580 sec 7.0 0.0 10.0 Sets the maximum time that the
time control waits for the motor voltage to
decay while attempting a fast bypass.
Once cell fault(s) occurs, the drive
may not be able to support actual
motor voltage. If the motor voltage
does not decay below the max drive
voltage (with the faulted cell(s)) within
the time set by this parameter, the
drive issues a fault.
Bypass Type 2590 Mech Designates the type of bypass in the
drive:
• Mechanical
• None
Fast bypass 2600 Enable This parameter enables or disables
fast cell bypass. Disabling fast
bypass with mechanical contactors
will still provide manual bypass.
Display Cell Status 2610 Function Displays cell status:
A = active,
B = bypassed,
F = faulted.
Display Bypass Status 2620 Function Displays bypass status:
A = available,
B = active,
U = unavailable.
Reset Bypassed Cells 2640 Function Allows bypassed cells to be reset
when the drive is in an idle state.
Use the reset function only after
verifying that the problems with the
faulted cell(s) have been resolved.
Neutral Connection 2630 T2 Select from terminal T1 or T2,
depending on the terminal of cells A1,
B1 d C1 th t i d t f th


B1 and C1 that is used to form the
drive star-point.
Table 3-19. Sync Transfer Menu (2700)

Phase I gain 2710 2.0 0.0 15.0 Integral gain of the phase loop used
during Up Transfer.
Phase P gain 2720 4.0 1.0 12.0 Proportional gain of the phase loop
used during Up Transfer. 3
Phase offset 2730 deg 0.0 -90.0 90.0 Phase offset provided at the input of the
phase loop to adjust phase errors due
to sampling. The typical value is 2
degrees.
Phase error 2740 deg 1.5 0.0 5.0 Phase error level that is used to
threshold determine if phase lock has been
achieved during Up Transfer.
Frequency 2750 % 0.0 -10.0 10.0 Frequency offset provided at the input
Offset of the speed loop to force the drive to
torque limit during Down Transfer.
Up Transfer 2760 sec 0.0 0.0 600.0 If the time taken for Up Transfer
Timeout exceeds this value then an Up
Transfer Timeout Fault is generated.
Down 2770 Sec 0.0 0.0 600.0 If the time taken for Down Transfer
Transfer exceeds this value then a Down
Timeout Transfer Timeout Fault is generated.
Table 3-20. External I/O Menu (2800)

Analog Inputs 2810 0 0 24 Sets the quantity of analog inputs in the
attached external I/O.
Analog 2820 0 0 16 Sets the quantity of analog outputs in

Outputs the attached external I/O.
Digital Inputs 2830 0 0 96 Sets the quantity of digital inputs in the

Digital 2840 0 0 64 Sets the quantity of digital outputs in

Wago 2850 sec 0 0 600 Sets the Wago watchdog timeout

timeout period.

Table 3-21. Output Connection Menu (2900)

Filter CT 2910 0 0 250 Secondary side turns (assuming
Secondary primary turns = 5) of the CTs used to
Turns measure filter capacitor currents.
Filter 2920 % 0.0 0.0 20.0 Sets the output filter inductor
Inductance (impedance) value as a ratio of the
base output impedance of the drive
(typically 5%).
Filter 2930 % 0.0 0.0 20.0 Sets the output filter capacitor
3 Capacitance (admittance) value as a ratio of the
base output admittance of the drive
(typically 10%).
Cable 2940 % 0.0 0.0 50.0 Output cable resistance value as a ratio
Resistance of the base output impedance of the
drive.
Filter 2950 0.50 -5.00 5.00 Controls the gain for damping
damping gain oscillations due to output filter. Use a
positive constant (typically 0.5) with
short cable lengths (< 30,000 feet) and
a negative constant (typically -0.5) for
long cable lengths.
3.3.3. Stability Menu (3) Options

The Stability Menu (3) consists of the following menu options:
• Input Processing Menu (3000)
• Output Processing Menu (3050)
• Control Loop Test Menu (3460)
The Stability Menu also contains some parameters. These menus and parameters are explained in tables
that follow.
Table 3-22. Stability Menu (3) (Parameters)

Input 3000 Submenu Contains all of the sub menus related
Processing to drive line side processing.
Menu See Table 3-23
Output 3050 Submenu Contains all of the sub menus related
Processing to drive motor side processing.
Menu
See Table 3-24
Control Loop 3460 Submenu Contains all of the sub menus related
Test Menu to speed and torque loop testing.
See Table 3-31
Slip constant 3545 4.3 0.0 10.0 Gain for slip compensation. This
value is calculated by the control


software and cannot be changed.
Dead time 3550 µsec 16.0 0.0 50.0 Sets the dead time (or firing delay
comp time) of the IGBTs for software
compensation.
Feed forward 3560 0.0 0.0 1.0 Sets the gain for voltage feed forward.
constant This is used to improve the torque
current regulator response.
Carrier 3580 Hz 601.3 100.0 1500.0 IGBT switching frequency. The control
frequency adjusts the entered value according to
available resolution. 3
Table 3-23. Input Processing Menu (3000)

PLL prop 3010 70.0 0.0 200.0 Proportional gain of input phase
gain locked loop (PLL).
PLL integral 3020 3840.0 0.0 12000.0 Integral gain of input PLL.
gain
Input 3030 1.0 0.0 2.0 Sets the scaling for input current
current feedback.
scaler
CT Turns 3035 200 50 2000 Secondary side turns for input
current CT (with primary turns equal
to 5).
Input 3040 1.8 0.0 2.0 Sets the scaling for input line voltage
voltage feedback.
scaler
*
Note: Many of the parameters in the Output Processing section are automatically set up during
autotuning. They are presented here so the user can do additional fine-tuning of the drive.
Additional fine-tuning is not generally required but may be needed in special circumstances.
Table 3-24. Output Processing Menu (3050)

Low freq 3060 Submenu Menu contains parameters that
comp effect motor flux calculation. See
Table 3-25.
Flux control 3100 Submenu This menu contains the flux control
parameters. See Table 3-26.
Speed loop 3200 Submenu This menu contains the speed loop
Current loop 3250 Submenu This menu contains the current
loop parameters. See Table 3-28.


Stator resis 3300 Submenu This menu contains the stator
est resistance estimator parameters.
See Table 3-29.
Braking 3350 Submenu This menu contains the dual
frequency braking parameters.
See Table 3-30.
PLL prop 3420 188.0 1.0 500.0 Proportional gain of output phase-
gain locked loop.
PLL integral 3430 3683.81 0.0 12000.0 Integral gain of output phase-locked
gain loop. This value is updated only by
the control.
3
Output 3440 1.0 0.0 2.0 Scaling for output current
current feedbacks.
scaler
Output 3450 1.0 0.0 2.0 Scaling for output voltage
voltage feedbacks.
scaler
Table 3-25. Low Frequency Compensation Menu (3060)

Low Freq Wo 3070 Rad 12.6 0.0 20.0 Pole of hardware RC integrator
Low freq com gain 3080 1.0 1.0 50.0 Low Frequency compensation gain for
scaling estimated flux.
S/W compensator 3090 2.0 0.5 12.6 Pole of software integrator used for
pole flux estimation.
Table 3-26. Flux Control Menu (3100)

Flux reg 3110 1.7 0.0 5.0 Flux PI regulator proportional gain
prop gain term
Flux reg 3120 1.0 0.0 1200.0 Flux PI regulator integral gain term
integral gain
Flux Filter 3130 sec 0.0667 0.0 10.0 Time constant of the low pass filter
Time Const used on the flux error.
Flux demand 3150 per unit 1.0 0.0 10.0 Sets the flux demand (or desired
Volts-per-Hertz ratio) in per unit.
Flux ramp 3160 sec 0.5 0.0 5.0 Sets the ramp time to go from zero to
rate rated flux. This time establishes the
time to magnetize the motor.
Energy 3170 100.0 10.0 125.0 This parameter sets the lowest value
saver min of flux (as a percentage of Rated
flux Motor Flux) that the drive will apply to
an unloaded motor. Energy Saver is
enabled if a value that is less than the


Flux Demand is entered. The control
establishes the amount of flux (or
motor voltage) that minimizes the
losses in the motor.
Ids DC 3190 % 10.0 1.0 25.0 DC current level used when stator
resistance estimator is enabled.
Table 3-27. Speed Loop Menu (3200)

Speed reg prop 3210 0.02 0.0 1.0 Speed PI regulator proportional gain 3
gain term. Automatically calculated after
Auto Tuning stage 2.
Speed reg integral 3220 0.046 0.0 1200.0 Speed PI regulator integral gain
Speed reg Kf gain 3230 0.6 0.1 1.0 Allows a smooth variation of the
speed regulator from a simple PI (Kf
=1.0) to a double speed loop
(Kf=0.5).
Speed filter time 3240 0.0488 0.0 10.0 Time constant of the low pass filter
const used on the speed error.
Automatically calculated after Auto
Tuning stage 2.
Table 3-28. Current Loop Menu (3250)

Current reg prop gain 3260 0.5 0.0 5.0 Current PI regulator proportional
gain term.*
Current reg integ gain 3270 25.0 0.0 6000.0 Current PI regulator integral gain
term.*
Prop gain during brake 3280 0.16 0.0 5.0 Current PI regulator proportional
during dual frequency braking.*
Integ gain during brake 3290 9.6 0.0 6000.0 Current PI regulator integral gain
term during dual frequency
braking.*
* All values in this table are automatically updated after AutoTuning stage 1.
Table 3-29. Stator Resistance Estimator Menu (3300)

Stator resistance 3310 Off This parameter enables or disables
est the stator resistance estimator
function.


• Off
• On
Stator resis filter 3320 0.0 0.0 1.0 Stator resistance estimator filter gain
gain
Stator resis integ 3330 0.002 0.0 1.0 Stator resistance estimator integral
gain gain
Table 3-30. Braking Menu (3350)
3 Parameter ID Units Default Min Max Description

Enable 3360 Off Enable or disable dual frequency
braking braking (DFB). User must be aware of
torque pulsations and motor heating
produced with this method.
Pulsation 3370 Hz 277.5 100.0 5000.0 Torque pulsation frequency when
frequency dual-frequency braking is enabled.
Adjust for a different torque pulsation
frequency. The control always
recalculates the desired value due to
limited resolution.
Brake power 3390 % 0.3 0.0 50.0 Amount of high frequency losses at
loss the onset of braking.
VD Loss Max 3400 0.25 0.0 0.5 Max amplitude of the loss inducing
voltage. Use this to adjust the braking
torque.
Braking 3410 1.05 0.0 10.0 Ratio of high frequency losses to
constant power absorbed from load. This
parameter should always be set to a
value greater than 1.0.
The need for braking capacity is addressed through a feature known as dual frequency braking. This
feature essentially creates a braking function by means of injecting a counter-rotating flux vector at well
beyond the slip of the machine. This generates additional losses in the motor. The injection frequency is
adjustable via a menu setting to allow critical frequencies (i.e. mechanical resonances) to be avoided.
Table 3-31. Control Loop Test Menu (3460)

Test type 3470 Speed This pick list selects the type of loop
test desired (speed or torque).
• Speed
• Torque
Test positive 3480 % 30.0 -200.0 200.0 Positive going limit of the test
waveform.
Test negative 3490 % -30.0 -200.0 200.0 Negative going limit of the test
waveform


waveform.
Test time 3500 sec 30.1 0.0 500.0 Sets the time for the drive to spend in
either the positive or negative test
setting.
Begin test 3510 Function This Function starts the speed or
torque loop test.
Stop test 3520 Function This function stops the speed or
torque loop test.
3
3.3.4. Auto Menu (4) Options
The Auto Menu (4) consists of the following menu options:
• Speed Profile Menu (4000)
• Analog Input Menu (4090)
• Analog Outputs Menu (4660)
• Speed Setpoint Menu (4240)
• PID Select Menu (4350)
• Comparator Setup Menu (4800)
These menus are explained in the tables that follow.
Table 3-32. Speed Profile Menu (4000)

Entry point 4010 % 0.0 0.0 150.0 Sets the % of speed cmd at which the
drive begins following the speed cmd.
Exit point 4020 % 150.0 0.0 150.0 Sets the % of speed cmd at which the
drive stops following the speed cmd.
Entry speed 4030 % 0.0 0.0 150.0 Sets the speed that the drive
accelerates to when given a start
command when the speed profile
function is enabled.
Exit speed 4040 % 150.0 0.0 150.0 Sets the speed that the drive reaches
at the exit point.
Auto off 4050 % 0.0 0.0 100.0 Sets the level of cmd at which the
drive turns off.
Delay off 4060 sec 0.5 0.5 100.0 Sets a time delay between the time
the cmd reaches the Auto Off point
and the time the drive shuts off.
Auto on 4070 % 0.0 0.0 100.0 Sets the level of cmd at which the
drive turns on.


Delay on 4080 sec 0.5 0.5 100.0 Sets a time delay between the time
the cmd reaches the Auto On point
and the time the drive starts.

Figure 3-23 illustrates the advantages of using speed profiling control. This method of
control provides an increased “usable control range” for the motor. Ultimately, the speed
of the motor can be adjusted in much finer increments when speed profiling is used.
Speed No Action Until Speed Speed
Reaches 75% of Rated Motor Using Speed
100% Exit Speed 100%
75% Entry 75%
“Usable” Control “Usable” Control
0% Input Input
0%
4 mA 20 mA
Signal
4 mA 8 mA 20 mA
Signal 3
No Speed Profiling Entry Exit
Point Point
Figure 3-23. Advantages of Using Speed Profiling Control
Table 3-33. Analog Input Menu (4090)

Analog input #1 4100 Submenu Menu for Analog input #1. See
Table 3-34.
Analog input #2 4170 Submenu Menu for Analog input #2. See Table 3-35.
Auxiliary input #1 4500 Submenu Menu for Auxiliary input #1. See Table 3-37.
Auxiliary input #2 4580 Submenu Menu for Auxiliary input #2. See
Table 3-38.
Table 3-34. Analog Input #1 Menu (4100)

Source 4105 Off This parameter sets the input source
for analog input #1.
• Off
• Ext 1-24
Type 4110 4– This parameter sets the operational
20mA mode for analog input 1.
• 0 - 20mA
• 4 - 20mA
• 0 - 10V
Min input 4120 % 0.0 0.0 200.0 Minimum Analog input
Max input 4130 % 100.0 0.0 200.0 Maximum Analog input
Loss point threshold 4140 % 15.0 0.0 100.0 Threshold where loss of signal action
is activated.


Loss of signal action 4150 Preset Select loss of signal action.
• Preset
• Maintain
• Stop
Loss of signal setpoint 4160 % 20.0 0.0 200.0 Loss of signal preset speed.

3 Source 4175 Off This parameter sets the input source
• Off
• Ext 1-3
Type 4180 4 – 20mA This parameter sets the operational
mode for analog input 2.
• 0 – 20mA
• 4 – 20mA
• 0 – 10V
Loss point 4210 % 15.0 0.0 100.0 Threshold where loss of signal action
threshold is activated.
Loss of 4220 Preset Select loss of signal action.
signal action
• Preset
• Maintain
• Stop
Loss of 4230 % 20.0 0.0 200.0 Loss of signal preset speed.
signal
setpoint

• Off
• Ext 1-24
• 0 - 20mA
• 4 - 20mA
0 - 10V


signal action
• Preset
• Maintain
Stop 3
signal
setpoint
Table 3-37. Auxiliary Input #1 Menu (4500)

Source 4510 Off Auxiliary input source
• Off
• Ext 1-3
mode for auxiliary input 1.
• 0 - 20mA
• 4 - 20mA
• 0 - 10V
Min input 4530 % 0.0 0.0 200.0 Minimum auxiliary input.
Max input 4540 % 100.0 0.0 200.0 Maximum auxiliary input.
signal action
• Preset
• Maintain
• Stop
signal
setpoint


• Off
• Ext 1-3

3 Max input 4620 % 100.0 0.0 200.0 Maximum auxiliary input.

is activated.
• Preset
• Maintain
• Stop
Table 3-39. Analog Outputs Menu (4660)

Analog 4660+4(n-1)+1 Submenu ID of submenu for Analog
Output #n Output #n (n=1-16).
Analog 4660+4(n-1)+2 Total This variable sets the input
variable Current source for analog output #n.
See Table 3-40
Output 4660+4(n-1)+3 Unip Sets the output type for the
module type module.
• Unip
• Bip
Full range 4660+4(n-1)+4 % 0.0 0.0 300.0 Scales the output range of the
variable selected.
Table 3-40. Pick list for Analog Variable parameters (all units are %)
Motor Voltage Total Current Average Power Analog Input #1

Motor Speed Speed Demand Speed Reference Analog Input #2
Raw Flux Demand Flux Reference Current (RMS) Analog Input #3
Zero Sequence Av Neg Sequence D Neg Sequence Q Analog Input #4
Input Frequency Input Power Avg Input Pwr Factor Analog Input #5
Ah Harmonic Bh Harmonic Total Harmonics Analog Input #6

Xfmr Therm Level 1 Cycle Protect Single Phase Cur Analog Input #7
Under Volt Limit Out Neutral Volts Synch Motor Field Analog Input #8
Motor Torque Encoder Speed
Table 3-41. Speed Setpoint Menu (4240)

Speed setpoint 1 4250 rpm 186 -18000 18000 Programmable speed setpoint that
can be selected through an external
contact and the system program.
3
Jog speed 4330 rpm 0 -18000 18000 This parameter sets the drive jog
speed.
Safety setpoint 4340 rpm 0 -18000 18000 Safety Override preset speed.
Table 3-42. Incremental Speed Setup Menu (4970)

Speed increment 4971 % 1.0 0.0 200.0 When selected through the SOP it
1 will increase the speed demand by
the program amount.
Speed decrement 4972 % 1.0 0.0 200.0 When selected through the SOP it
1 will decrease the speed demand by
the program amount.


the program amount.
the program amount.
the program amount.
3 3 will decrease the speed demand by
the program amount.
Table 3-43. PID Select Menu (4350)

Prop gain 4360 0.4 0.0 99.0 Sets the PID loop Proportional (P) gain.
Integral gain 4370 0.4 0.0 99.0 Sets the PID loop Integral (I) gain.
Diff gain 4380 0.0 0.0 99.0 Sets the PID loop Derivative (D) gain.
Min clamp 4390 % 0.0 -200.0 200.0 Sets the minimum value for the PID loop
integrator.
Max clamp 4400 % 100.0 -200.0 200.0 Sets the maximum value for the PID
loop integrator.
Setpoint 4410 % 0.0 -200.0 200.0 Sets a value to be used as the reference
setpoint for the external PID loop. The
value is set as a percent of full scale.
Table 3-44. Comparator Setup Menu (4800)
Submenu Description
Comparator n Setup Submenus that contain 32 sets of comparators for custom use in the
system program. Each comparator set (Compare 1 through Compare 32)
consists of three parameters that are located in the comparator setup
menus. Comparators are system program flags (Comparator1_I through
Comparator32_I ) which can be used anywhere within the system program
environment to control software switches. Refer to Table 3-45

Table 3-45. Compare 1-32 Setup Menu Parameter Descriptions
Menu Item DefaultValue Description

Comp n A in Manual value “Comp n A” and “Comp n B” inputs can be selected from
variable select (list) the list in Table 3-46
(n=1-32)
Comp n B in Manual value The comparator flag compar_n_f (where n=1-16) in the
variable select (list) system program is set true if “Comp n A in” > “Comp n B in”.
(n=1-32)
Comp n manual 0.0% Min: -10,000% Max: 10,000%
value
Compare n type ‘Mag’ if n=1; “Compare n” can be set to the following: 3
(list) (n=1-32) ‘Off’ if n>1 signed (e.g., 10 > -50)
magnitude (e.g., -50 > 10)
disabled (no compare is done).
Table 3-46. Variable Pick List for Comparator Setup Submenus
Analog Input 1 Analog Input 13 Motor speed

Analog Input 2 Analog Input 14 Motor current
Analog Input 3 Analog Input 15 Enter Manual Value
Analog Input 4 Analog Input 16 Manual ID
Analog Input 5 Analog Input 17 Max Avail Out Vol
Analog Input 6 Analog Input 18

3.3.5. Main Menu (5) Options

The Main Menu (5) consists of the following menu options:
• Motor Menu (1)
• Drive Menu (2)
• Stability Menu (3)
• Auto Menu (4)
• Log Control Menu (6)
3 • Drive Protect Menu (7)
• Meter Menu (8)
• Communications Menu (9)
• Security Edit Functions Menu (5000)
• Parameter Default/File Functions
• Language and Security Functions
The contents of submenus 1-4 have already been explained earlier in this chapter. The contents of
submenus 6-9 are explained later in this chapter. All of these submenus can be accessed directly using
the keypad or from the Main Menu (5). Refer to the appropriate sections elsewhere in this chapter for
descriptions of menu options within these submenus.
Main Menu (5) functions and submenus are explained in the tables that follow.
Table 3-47. Main Menu (5) Options
Parameter (ID) ID Type Description

Motor Menu 1 submenu Provides access to the Motor Menu. See
page 3-17.
Drive Menu 2 submenu Provides access to the Drive Menu. See
page 3-21.
Stability Menu 3 submenu Provides access to the Stability Menu.
See page 3-28.
Auto Menu 4 submenu Provides access to the Auto Menu. See
page 3-20.
Log Control 6 submenu Provides access to the Log Control Menu.
See page 3-45.
Drive Protect Menu 7 submenu Provides access to the Drive Protect
Menu. See page 3-48.
Meter Menu 8 submenu Provides access to the Meter Menu. See
page 3-49.
Communications Menu 9 submenu Provides access to the Communications
Security Edit Functions Menu 5000 submenu This menu contains functions which are
used to edit a menu item’s security codes.


See table Table 3-48.
Set Defaults to Current 5045 function Used to set all default parameters to the
current parameter settings.
Reset to Defaults 5050 function Used to reset all parameters to their

factory defaults.
Select Language 5080 pick list Sets language for keypad.

• English (default)
• French
• German
• Spanish 3
Change Security Codes 5090 function Used to change the security codes for the
various security levels used by the drive.
Default codes are shown in Table 3-50.
Enter Security Code 5500 function Used to enter the security code to set the
clearance level for access.
An electronic security code is provided to limit unauthorized access to various parameters within the drive
equipment. The default factory settings for parameter security codes is as follows:
Table 3-48. Security Edit Functions Menu (5000)

Change 5010 Function This function is used to change a menu item’s security level.
security level When active an “x” will appear as the first character on the
second line of the display. Please scroll past Main(5) into
another menu. The current security level will appear as the
last character on the second line of the display. Press
[ENTER] to edit the security level for the ID that is shown.
Choose among levels 0, 5, 7, or 8. See Table 3-49.
Drive running 5020 Function This function is used to change a menu item’s run inhibit.
inhibit When active an “x” will appear as the first character on the
second line of the display. The current run inhibit state will
appear as the last character on the second line of the
display. See Table 3-49.

Table 3-49. Security Edit Menu Function Descriptions (5010, 5020)
ID Name Description
5010 Change “Change security level” prohibits access to menu or menu items
Security Level until “enter security level” is set to that level or higher.
Level = 0,5,7,8 Sets the level of security on that particular menu item.
5020 Drive Running Prohibits certain parameters from being changed when drive is
Inhibit in the Run State (D).
1 = enable Drive running lockout will not allow the parameter to be
0 = disable changed while the drive is running. “0” indicates that a
parameter may be changed while the drive is running. “1”
3 indicates that a parameter may not be changed while the drive
is running.
Caution!−Do not change the Drive Running Inhibit (5020) setting of any parameter unless you
are completely certain that the change is safe. Changes may result in massive environmental
and property destruction, injuries, and/or loss of life.
Upon selecting either of these functions, an “Enter Menu ID” prompt is displayed. If the menu number is
known, it may be entered at this point. If the menu number is not known, press the [ENTER] key and the
display will default to the top of the Main Menu (5), allowing the user to scroll to the menu item to be
changed.
When the operator reaches the menu item to be changed, he must press the [ENTER] key followed by
either a [0] to disable or a [1] to enable the selected edit feature. An asterisk character (*) appears on the
left of the display to indicate that the menu or submenu is in the security edit mode, and not in normal
mode. Press the [Cancel] key to exit security edit mode.
Table 3-50. Default Security Access Levels and Access Codes
Access Level Default Access Code Level of Security

0 None Minimum Access
5 5555 Startup Access for Service and/or Startup
7 7777 Advanced Access for Troubleshooting
8 Proprietary Factory Use Only
Note that menu options above security level 5 are more technical in nature and are typically used by ASI
Robicon personnel during commissioning or servicing.
The Security Edit Menu (5000) can be accessed to change the factory default security settings. When the
Harmony is configured for security level 7 access, the Security Edit Menu (5000) is visible from the Main
Menu (5). Functions within this menu are used to set the security levels for menu items, to “hide” menu
items, and to prevent changes to specific parameters. The Security Edit Functions Menu (5000) contains
security functions described in Table 3-48.

3.3.6. Log Control Menu (6) Options

The Log Control Menu (6) consists of the following menu options:
• Event Log Menu (6180)
• Alarm/Fault Log Menu (6210)
• Historic Log Menu (6250)
The contents of these menus are explained in the tables that follow.
Table 3-51. Event Log Menu (6180)

The event log is stored in a file on the CompactFLASH. The maximum file size is 65Kbytes. The file is
overwritten once the maximum size is reached.
Parameter ID Units Default Min Max Description 3

Upload event log 6190 Function Upload the event log via the RS232
serial port.
Clear event log 6200 Function Used to clear the event log.
Table 3-52. Alarm/Fault Log Menu (6210)

Alarm/Fault 6220 Function Used to display the fault log.
log display
Alarm/Fault 6230 Function Upload the fault log via the RS232 serial
log upload port.
Alarm/Fault 6240 Function Used to clear the fault log.
log clear
Table 3-53. Historic Log Menu (6250)

The event log is stored in non-volatile battery backed up RAM. Seventy-eight events are recorded 58
before a fault occurs and 20 after. If the “Store in event log” is “On”, several historical logs can be stored.
The maximum number is limited by the event log size (65Kbytes).
Parameter ID Default Description
Store in event log 6255 On When selected the Historical log is stored in the
event log
Historic log variable 1 6260 Spd Ref Select the 1st variable for the historic log. See
Table 3-54 for pick list variables.
Historic log variable 2 6270 Trq I Cmd Select the 2nd variable for the historic log. See
Historic log variable 3 6280 Mtr Flux Select the 3rd variable for the historic log. See
Historic log variable 4 6290 Pwr Out Select the 4th variable for the historic log. See
Historic log variable 5 6300 I Total Out Select the 5th variable for the historic log. See


Historic log variable 6 6310 Mag I Fdbk Select the 6th variable for the historic log. See
Historic log variable 7 6320 Mtr Flux Select the 7th variable for the historic log. See
Historic log upload 6330 Upload Historic log to serial port
Table 3-54. Pick List Variables for Historic Log (all units are %)
3
Abbreviation Description
Mtr Spd Motor speed
Spd Ref Speed reference
Spd Dmd Raw Speed Demand
Trq I Cmd Torque Current Command
Trq I Fdbk Torque Current Feedback
Mag I Cmd Magnetizing Current Command
Mag I Fdbk Magnetizing Current Feedback
I Total Out Total Motor Current
Mtr Volt Motor Voltage
Mtr Flux Motor Flux
V Avail Line Voltage Available
V Avail RMS Line Voltage RMS
Pwr Out Output Power
V Neutral Output Neutral Volts
I Total In Total Input Current
Pwr In Input Power
Freq In Input Frequency
*
See Appendix D for Historical Log Fault word decoder.

3.3.7 Protect Menu (7) Options

The Drive Protect Menu (7) consists of the following menu options:
• Input Protect Menu (7000)
• Single Phasing Menu (7010)
These menus are explained in tables that follow.
Table 3-55. Drive Protect Menu (7) Parameters

Input Protection 7000 Submenu Input protection parameters.
See Table 3-56 3
Drive IOC Setpoint 7110 % 150.0 50.0 200.0 Drive instantaneous
overcurrent setpoint (as a
percentage of drive output
rating).
Cell Overload Level 7112 % 100.0 100.0 150.0 Cell current overload (as a
rating) allowed for 1 minute out
of every 10 minutes.
Auto Reset Enable 7120 No Enables the reset of the Drive
after a fault.
Auto Reset Time 7130 sec 1 1 120 Adjusts the time between the
fault and its automatic reset.
Auto Reset Attempts 7140 5 1 10 The number of attempts a
drive will be reset before a
permanent shutdown.
Auto Reset Memory Time 7150 sec 501 1 1000 The amount of time between
faults that will clear the
attempts counter.
Fault Reset 7160 function Issues a Drive fault reset when
selected
Table 3-56. Input Protect Menu (7000)

Single phasing 7010 Submenu Single phasing protection
parameters. See Table 3-57
Undervoltage prop gain 7060 0.0 0.0 10.0 Under voltage PI regulator
proportional gain term.*
Undervoltage integ gain 7070 0.001 0.0 1.0 Undervoltage PI regulator integral
gain term.*


1 Cyc Protect integ gain 7080 0.0025 0.0 1.0 Gain of integral regulator for
detecting excessive input reactive
current. Output of this regulator is
used to fault the drive in case high
reactive currents flow in the input
(other than the instant when MV is
applied to the drive). Adjust the
gain to change the response to
high reactive currents.**
1 Cycle Protect Limit 7081 % 50.0 0.0 100.0 Integrator output level at which
drive issues a 1 Cycle Protect
3 Fault.
Xformer tap setting 7050 % 0 Choose from the
{-5,0,+5%} settings to match
transformer tap setting.
Xformer thermal gain 7090 0.0133 0.0 1.0 Gain of integral regulator to limit
input current to 105% of its rated
value.
Xformer protection const 7100 0.375 0.0 10.0 Gain to adjust model of input
transformer. Use the default
value of 0.375.
Phase Imbalance Limit 7105 % 40.0 0.0 100.0 Input current level (as a percent of
Rated Input Current) above which
Input Phase Imbalance Alarm is
issued.
Ground Fault Limit 7106 % 40.0 0.0 100.0 Level above which drive issues an
Input Ground Fault Alarm.
Ground Fault Time Const 7107 sec 0.2 0.001 2.0 Time constant of filter used for
averaging input neutral voltage.
Table 3-57. Single Phasing Menu (7010)

SPD prop gain 7020 0.0 0.0 10.0 Single phase detector PI regulator
proportional gain term.
SPD integral 7030 0.001 0.0 1.0 Single phase detector PI regulator
gain integral gain term.
SPD threshold 7040 % 50.0 0.0 100.0 Regulator output level below which
an alarm is generated

3.3.8. Meter Menu (8) Options

The Meter Menu (8) consists of the following menu options:
• Display Parameters Menu (8000)
• Hour Meter Setup Menu (8010)
• General Drive Parameters Menu (Set Time, Software Version, Language, Output Units)
• Input Harmonics Menu (8140)
Table 3-58. Meter (8) General Drive Parameters

3
Display 8000 Submenu This menu contains display
Parameters parameters. See Table 3-59
Hour Meter Setup 8010 Submenu This menu contains hour meter
setup. See Table 3-61
Input Harmonics 8140 Submenu This menu contains input
harmonics. See Table 3-62
Fault Display 8200 Off Enables or disables the display of
Override Fault/Alarm messages on the
keypad.
Set the clock time 8080 Function Used to change the time and date
of the real-time clock chip.
Display version 8090 Function Displays the installed version of
number firmware.
Customer order 8100 0 0 999999 Customer order number
Customer drive 8110 1 0 20 Customer drive number
Table 3-59. Display Parameters Menu (8000)

Status variable 1 8001 DEMD Select variable 1 to be displayed on the LCD
display. Pick List – See Table 3-60
Status variable 2 8002 %SPD Select variable 2 to be displayed on the LCD
display. Pick List − See Table 3-60
Status variable 3 8003 VLTS Select variable 3 to be displayed on the LCD
Status variable 4 8004 RPM Select variable 4 to be displayed on the LCD
This menu contains the pick lists to select the variables to be displayed on the front panel default display.

Note: Table 3-60 contains name, abbreviation, display and variable columns of standard pick list
variables (used in the Historic Log Menu, the Display Variable Menu, etc.. The name column
contains the name of the display variable. This is what is displayed as the user scrolls through the
list of available display variables. The abbreviation column contains an abbreviation that is
displayed after a variable is selected from the list. The display column contains an even more
abbreviated form of the variable name. This final abbreviation (between 2 and 5 characters in
*
length is what the Perfect Harmony displays on the front panel of the drive. The variable column
shows the associated system program variable for reference.
User-defined Display User-defined Display User-defined Display

Variable #1 Variable #2 Variable #3 User-defined Display
Variable #4
3
Top row of display shows MODE DEMD RPM MVLT OAMP
field names Bottom row of display
OFF 80 0 0 0
shows dynamic values
Table 3-60. Pick List Variables for the Front Display
Abbreviation Description & Units Abbreviation Description & Units

IMRF Magnetizing current ref (A) VAIN Phase A input voltage (V)
ITRF Torque current ref (A) VBIN Phase B input voltage (V)
FLDS Flux DS (%) VCIN Phase C input voltage (V)
FLQS Flux QS (%) VZSQ Zero sequence voltage (V)
VDRF Vds reference (%) VNSD Negative sequence D voltage (V)
VQRF Vqs reference (%) VNSQ Negative sequence Q voltage (V)
SLIP Slip frequency (%) VDIN Input D voltage (V)
%SPD Motor speed (%) VQIN Input Q voltage (V)
FREQ Motor speed (Hz) VAVI Input voltage (V)
RPM Motor speed (RPM) FRIN Input frequency (Hz)
VLTS Motor voltage (V) KWIN Input power average (kW)
IMAG Magnetizing current filtered (A) PFIN Input power factor (%)
ITRQ Torque current filtered (A) HRCA Ah harmonic coefficient (%)
ITOT Motor current (A) HRCB Bh harmonic coefficient (%)
%TRQ Torque out (%) HARM Total A, B harmonics (%)
KWO Output power (kW) XTHL Transformer thermal level (%)
RESS Stator resistance 1CRI One cycle reactive current level (%)
DEMD Speed demand (%) SPHI Single phasing current level (%)
SREF Speed reference (%) UNVL Under Voltage level (%)
FDMD Raw flux demand (%) EFF Efficiency (%)
FXRF Flux reference (%) THD Total Harmonic Distortion (%)
IDIN Id input current (A) VNGV Output Neutral Voltage (V)
IQIN Iq input current (A) %VNG Output Neutral Voltage (%)
IAIN Phase A input current (A) SMFC Synch Motor Field Current (A)
IBIN Phase B input current (A) %ESP Encoder Speed (%)
ICIN Phase C input current (A) ERPM Encoder Speed (RPM)
IAVI Total input current (A)

Table 3-61. Hour Meter Setup (8010)

Display hour meter 8020 Function Used to display the amount of time that
the drive has been operational since it
was commissioned.
Preset hour meter 8030 Function Used to preset the hour meter to the
accumulated time that the drive has been
operational since it was commissioned
(in the event that a micro board has been
replaced on an existing drive).
3 Reset hour meter 8040 Function Used to reset the hour meter when the
drive is commissioned.
Display Output kWH 8050 Function Displays the total output kW hours that
meter have been accumulated since the drive
was commissioned.
Preset output kWH 8060 Function Presets the output kW hour counter to a
meter previous value (when the microboard is
replaced).
Reset output kWH 8070 Function Resets the output kW hour counter to
meter zero.
Display input kWH 8072 Function Displays the total input kW hours that
was commissioned.
Preset input kWH 8074 Function Presets the input kW hour counter to a
replaced).
Reset input kWH 8076 Function Resets the input kW hour counter to
meter zero.
Table 3-62. Input Harmonics Menu (8140)

Selection for HA 8150 IA Selection for harmonic Analysis
• IA
• IB
• IC
• VA
• VB
• VC
Harmonics order 8160 1.0 0.0 30.0 Harmonic Order
Harmonics integral 8170 0.001 0.0 1.0 Harmonics regulator integral gain term
gain

3.3.9. Communications Menu (9) Options

The Communications Menu (9) consists of the following menu options:
• Serial Port Setup Menu (9010)
• Network Control (9943)
• Network 1 Configure (9900)
• Serial Functions (9110)
• TCP/IP Setup (9300)
These menu items are explained in tables that follow.

Table 3-63. Communications Menu (9) Parameters 3
Serial port setup 9010 Submenu This menu contains all serial port setup
parameters.
See Table 3-64
Network Control 9943 Submenu Please refer to Communications manual
(number 902399)
Network 1 9900 Submenu

Configure

Configure
Display Network 9950 Function

Monitor
Serial echo 9180 Function

back test
Sop & serial 9110 Submenu This menu contains functions that utilize
Functions the local serial port.
See Table 3-65
TCP/IP Setup 9300 Submenu This menu contains functions which set
the parameters for TCP/IP.
See Table 3-66

Table 3-64. Serial Port Setup Menu (9010)

Serial port use 9020 Local Designates the usage of the on board
serial port.
• Local
• Tool
Flow Control 9030 Xon/ Designates the type of flow control used
by the serial port.
3 Xoff
• None
• Xon/Xoff
Baud rate 9040 19200 Designates the baud rate of the on board
serial port
• 9600
• 19200
• 38400
• 57600
• 115200

Table 3-65. Serial Functions Menu (9110)

System program 9120 Function Used to transfer the system
download program to a remote system.
System program upload 9130 Function Used to transfer the system

program from a remote system.
Display sys prog name 9140 Function Displays the current system
program name. 3
Display drectry version 9147 Function Displays current directory file
version.
Select system program 9145 none Displays the list of system

program files.
Multiple config files 9185 Off Enables multiple configuration

files.
Parameter data upload 9150 Function Used to transfer the current

configuration file to a remote
system.
Parameter data download 9160 Function Used to transfer the current
configuration file from a remote
system.
Parameter dump 9170 Function Used to get a print out of the
current configuration data.
Parameter upload functions are used to transmit data from the drive to a printer or computer. Parameter
download functions are used to transmit data to the drive. A terminal emulator such as Smart Term’s
“ST220.EXE” or Procomm’s “PCPLUS” is required to upload, download, and echo files. Windows
“Terminal” protocol settings for the RS232 port are 9600 baud, no parity, and one stop bit.
Note that all parameters are printed on the parameter dump.
Table 3-66. TCP/IP Setup Menu (9300)

IP 9310 172.16.106.16 0.0.0.0 255.255.255.255 Used to enter the
address system IP address in
dotted decimal.
Subnet 9320 255.255.0.0 0.0.0.0 255.255.255.255 Used to enter the
mask system subnet mask in
dotted decimal.


Gateway 9330 172.16.1.1 0.0.0.0 255.255.255.255 Used to enter the
address system gateway
address in dotted
decimal.
3.3.10 Menu Setup for Multiple Configuration Files (Slaves)

The NXG drive is designed to operate with multiple motors that may or may not be of the same size. This
is accomplished by using multiple parameter configuration files. There is one master configuration file
that is always named current.cfg. The slave files are stored in a sub directory of CfgFiles named SubCfgs
and can have any legal name conforming to the eight dot three file convention.
3 NOTE: All slave configuration files have the ‘.sfg’ extension. This is not changeable through the menus.
The configuration files can be created at runtime in the drive’s memory and then stored to a flash disk.
The slave files are created via the keypad menus by setting the slave parameters as desired and writing
them to a flash disk.
There are eight SOP flags that can be set to point to a configuration file. The menus are used to map
each SOP flag to a corresponding configuration file. Once mapped, the SOP flags are used to activate
the SOP for a particular motor.
Menu item descriptions
Multiple config files This pick list enables the switching of the slave configuration files. If set to OFF, no
other multiple configuration file menus will be displayed. Once enabled, if any one
of SOP flags is set to true, the corresponding configuration file will become active.
Show active config Function to display the current active configuration file. If correct configuration file is
file not displayed, the SOP file should be checked for accuracy. Check the ‘Setup SOP
configuration flags menu to be sure the correct file is mapped to the SOP flag.
Set active config This pick list sets the displayed file to be the active configuration file. This function
file overrides what is set in the SOP program. Any change in the SOP program is
checked against the file set in this function. Once a change in the SOP is detected,
that file will then be the active file. The keypad menu setting is now ignored. This
insures no unintentional toggling of the configuration files. To switch back to the
keypad file set it by this menu. If no change in the SOP program occurs, the keypad
set configuration file will remain in memory.
Create new config This function allows you to save slave parameters to a file name you specify. The
file name is entered using the drive keypad. To get to the alphanumeric characters, you
must first press a number key. The table below shows all possible combinations of
letters, numbers and symbols.
Set This function allows you to map the name of the flag in the SOP file,
SOPConfigFileX_ SOPConfigFileX_O, where X = 1 to 8, to a name of a slave configuration file. Then,
O (X = 1 to 8) when the SOP program is running, and this flag is set to ‘true’, the configuration file
will be switched into memory. This is a method of switching among multiple motors
using one drive. The file names are selected from a pick list. New files can be
created using the method described previously.
NOTE: You do not need to add the file extension. The file extension is always .’sfg’. Press the ‘enter’ key
to save the parameter(s) as they exist in memory to a new configuration file name. This file will be stored
to the flash disk in the ‘SubCfgs’ subdirectory. This function does NOT make this configuration file the
active configuration file. It uses the current data in memory to create a new slave configuration file. Any
parameter that is saved to a slave configuration file is easily identifiable by the small ‘s’ adjacent to the
parameter ID number if it has not changed from the default setting, or a ‘$’ if it has been changed from its
default setting, i.e. (s9586) or ($9586).

Table 3-67. Slave Parameter

Multiple config files 9185 OFF Enable multiple config file
operation
Show active config 9195 Display current active config file
file
Set active config 9196 Defaults.sfg Set the displayed file to be the
file active config file
Setup SOP config 9186 Sub menu Sub-menu for SOP flag
flags configuration 3
Create new config 9197 Create new config file using
file numeric keypad.
Set 9187 Defaults.sfg Set name of config file #1 that
SOPConfigFile1_O corresponds to the SOP flag #1.
Table 3-68. Parameter Menu - Slave
Parameter ID Parameter ID
Motor Menu
Motor kW rating 1010 50 Percent Break Point 1156
Motor frequency 1020 100 Percent Break Point 1157
Full load speed 1030 Maximum Load Inertia 1159
Motor voltage 1040 Motor trip volts 1160
Full load current 1050 Overspeed 1170
No load current 1060 Underload enable 1180
Leakage inductance 1070 I underload 1182
Stator resistance 1080 Underload timeout 1186
Inertia 1090 Motor torque limit 1 1190
Overload select 1130 Regen torque limit 1 1200
Overload pending 1139 Motor torque limit 2 1210
Overload 1140 Regen torque limit 2 1220
Overload timeout 1150 Motor torque limit 3 1230
0 Percent Break Point 1152 Regen torque limit 3 1240
10 Percent Break Point 1153 Phase Imbalance Limit 1244

17 Percent Break Point 1154 Ground Fault Limit 1245
25 Percent Break Point 1155 Ground Fault Time Const 1246
Drive Menu
Control loop type 2050 Skip center freq 3 2370
Ratio control 2070 Skip bandwidth 1 2380
Speed fwd max limit 1 2080 Skip bandwidth 2 2390
Speed fwd min limit 1 2090 Skip bandwidth 3 2400
Speed fwd max limit 2 2100 Freq avoid accel time 2410
Speed fwd min limit 2 2110 Spinning load mode 2430
Speed fwd max limit 3 2120 Scan end threshold 2440
Speed fwd min limit 3 2130 Current Level Setpoint 2450
Speed rev max limit 1 2410 Current ramp 2460
3 Speed rev min limit 1 2150 Max current 2470
Speed rev max limit 2 2160 Frequency scan rate 2480
Speed rev min limit 2 2170 Cond stop timer 2500
Speed rev max limit 3 2180 Cond run timer 2510
Speed rev min limit 3 2190 Min cells/phase count (n/3) 2540
Accel time 1 2270 Fast bypass 2600
Decel time 1 2280 Phase I gain 2710
Accel time 2 2290 Phase P gain 2720
Decel time 2 2300 Phase offset 2730
Accel time 3 2310 Phase error threshold 2740
Decel time 3 2320 Frequency Offset 2750
Jerk rate 2330 Up Transfer Timeout 2760
Skip center freq 1 2350 Down Transfer Timeout 2770
Skip center freq 2 2360 Cable Resistance 2940
Stability Menu
Flux reg prop gain 3110 Integ gain during brake 3290
Flux reg integral gain 3120 Enable braking 3360
Flux Filter Time Const 3130 Pulsation frequency 3370
Flux demand 3150 Brake power loss 3390
Flux ramp rate 3160 VD Loss Max 3400
Energy saver min flux 3170 Braking constant 3410
Speed reg prop gain 3210 Test Type 3470
Speed reg integral gain 3220 Test positive 3480
Speed reg Kf gain 3230 Test negative 3490
Speed filter time const 3240 Test time 3500
Current reg prop gain 3260 Slip constant 3545
Current reg integ gain 3270 Feed forward constant 3560
Prop gain during brake 3280
Auto Menu
Entry point 4010 Delay on 4080
Exit point 4020 Prop gain 4360
Entry speed 4030 Integral gain 4370
Exit speed 4040 Diff gain 4380
Auto off 4050 Min clamp 4390
Delay off 4060 Max clamp 4400
Auto on 4070 Setpoint 4410
Logs Menu
Historic log variable 1 6260 Historic log variable 5 6300

Historic log variable 4 6290
Drive Protection Menu
Auto reset Enable 7120 Auto Reset Attempts 7140
Auto Reset Time 7130 Auto Reset Memory Time 7150
Display Configuration Data Menu
Status variable 1 8001 8005
Status variable 4 8004
Meters Menu
Customer Order 8100 Harmonics order 8160
Customer Drive 8110 Harmonics integral gain 8170
Selection for HA 8150 Fault Display Override 8200
3

∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics STARTUP PROCEDURE
CHAPTER 4: STARTUP PROCEDURE

4.1. Introduction
This chapter outlines the necessary steps that are required to successfully startup a Perfect Harmony
drive from a pre-power visual inspection to a complete medium voltage motor test. These checks are
discussed individually within the separate sections of this procedure. Following any introductory text and
precautions, each section contains a series of individual steps. Tables may be included in some
sections. Some tables are used to record parameter settings, test point data, and any errors or
deviations from expectations.
DANGER—Electrical Hazard! The steps outlined in the following procedure could cause
serious injury or death if the drive has not been properly installed and checked. Before
proceeding, be sure to remove power from the drive and follow proper lock out and tag out
procedures.
DANGER—Electrical Hazard! Hazardous voltages may still exist within the Perfect Harmony
cabinets even when the medium voltage disconnect switch is open (off) and the control power
switch is shut off (for example, internally stored energy found in cells).
Warning! Never disconnect control power while medium voltage is energized. This
will disable the cooling system and potentially cause severe overheating of the system
and possibly cause damage to the cells.
Note: Proper drive setup will require the use of a DC voltmeter an AC voltmeter and a dual- 4
trace oscilloscope for testing purposes. In addition a 3-phase 460 volt source is required. With
55 A fuses a fixed three-phase voltage source can also be used with a voltage of 270 V for 460 *
V cells or 390 V for 690 V cells.

STARTUP PROCEDURE Perfect Harmony GENIII/e Startup and Advanced Topics
4.2. Pre-power Visual Inspection

Before power is applied to the drive, pre-power visual inspections must be conducted. Verify the system
specifications as detailed below.
Table 4-1. Pre-power Visual Inspection
Step Description
Verify the source voltage to the drive matches the drive specification. The drive’s intended
1 input voltage is specified on the foil label located inside the control panel door. See
Figure 4-1. (Note: This foil label may be located in the customer connection cabinet.)
The drive’s maximum output voltage as stated on the foil label should match the motor’s
2
voltage rating as stated on the motor nameplate. See Figure 4-1.
The control voltage (low voltage) must match the drive’s control voltage ratings as stated on
3
the foil label. See Figure 4-1.
The motor nameplate power
rating must match the drive’s
power rating. Refer to
Figure 4-1. PAT. 5625545
HARMONY DRIVE 1750HP, 1306KW
SYSTEM P/N 459xxx.xx S/N 12345
4 INPUT: 4160VAC, 3PH, 60HZ, 216A
OUTPUT: 0-4160VAC, 3PH, 0-60HZ, 220A
4 CONTROL VOLTAGE: 460VAC, 60HZ, 3PH, 25A
S.O. 12 34567
DATE CODE: xxxxxxxx ENG: xxxxxx
Figure 4-1. Sample System Nameplate

Verify that the two tap cables for the medium voltage input are securely connected to the
three transformer taps. These connections should be made to the +5% taps on each of the
three coils of the transformer. The other taps are used only when the power requirements
of the system (or the voltage source) are not sufficient for system operation. In low line
voltage situations, moving to the “O” taps will increase voltage by 5%. Refer to Figure 4-2.
Medium Voltage
Tap Cables
5 Taps Taps Taps

-5% 0 +5% -5% 0 +5% -5% 0 +5%
Taps Taps Taps
-5% 0 +5% -5% 0 +5% -5% 0 +5%
Figure 4-2. Transformer Cabinet Detail Showing Typical Tap Connections

Verify that all wiring between the transformer and cell cabinet shipping splits has been
6
properly and securely re-connected.

Step Description
Inspect all connections and wiring ensuring that they are connected appropriately and
securely. Verify all torque markings are properly aligned on all electrical connections
7
including power connections. Tighten any incorrect connections in accordance with the
torque specifications listed in the Installation Manual.
Ensure that all electrical connections are tight and that all torque markings are intact. Verify
8 that no sheet metal damage nor excessive coating damage has occurred. If found, verify the
integrity of the components, cables or other materials behind or below the damage.
Check all cabling for splitting and/or cracking. Check to ensure no conductors are exposed
9
due to chafing or other shipping abuse.
If applicable, ensure that all stress cones are adequately connected to ground and installed
10
properly on the cables.
Verify the presence of markings or labels on all terminal strips, mounted components, cells,
11
and other sub-assemblies. Notify the factory of any discrepancies.
12 Verify the presence and proper installation of all protective covers.
13 Verify the installation of the fan hood. Verify that the fan rotates freely while mounted.
Ensure that control and main power are installed and connected properly and in accordance
14
with local regulations.
15 Verify all customer connections for tightness and accuracy.
Standard safety precautions and local codes must be followed during installation of external
16 wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any
4
To maintain EMC compliance, be sure to use shielded cables as described on the drawings
17
shipped with the Perfect Harmony system.
Control wiring for GEN II and GEN III Perfect Harmony Drives must be routed down the
wireway where the EMI filter is located. (typically the left side), then to the disconnect switch.
18
These wires must be kept away from the output (filtered side) of the EMI Filter. Use of
metallic electrical conduit is required to maintain EMC Compliance.
Verify that all system grounds are connected between shipping splits. Verify that the system
ground is connected to a suitable site ground in accordance with local regulations. Ensure
19 that the entire system is earth grounded at one of its grounding points. Grounding points are
located inside the cabinet and are labeled with the protective earth symbol .
*
Note: If any of the previous checks yield inconsistent or unusual results cancel the startup
procedure and notify the factory.

4.3. Power Circuit, Modulation and Bypass Contactor Test

This test can be performed with a single 55A, 3-phase, 460VAC variac and an optional PC/Laptop with
Robicon’s Tool Suite. Full voltage can be supplied to all cells.
Table 4-2. Power Circuit, Modulation, and Bypass Contactor Test
Step Description
To connect the PC/Laptop to the Pentium control processor, use an Ethernet cable with a RJ-
1
45 standard jack along with a crossover cable.
Disconnect the series connection between T1 and T2 of all adjacent cells. Disconnect the
2 motor leads or open the motor contactor. Connect a 3-phase variac to the input of cell B1, in
addition to the existing cables from the transformer.
Connect an AC voltmeter to the input of any cell. Turn on the control power to the Control
3
Cabinet and verify that the control properly initializes.
Make sure the Drive Parameters (2000) match the rated values for the Drive. Set the Control
4
Loop Type (2050) to Open Loop Test Mode.
Verify that the Input Voltage (3030) and Input Current (3040) Scalers (Stability -> Input
5
Processing) are set to the default values of 1.0.
Select the correct Transformer Tap Setting using Drive Protect -> Input Protect -> Xformer
6
4 Tap Setting (7050).
Turn on the variac and slowly increase the variac’s output voltage to about 75V.
• Measure all cell input voltages to make sure they are all receiving approximately the
same voltage. The “Not Safe” neon light should be lit on each Cell Control Board.
• If all cell voltages are OK, continue increasing the variac to 230VAC and make sure
all of the switch-mode power supplies are working (the Lnk ON and cell fault LEDs on
7 the cell control boards should be ON).
• Continue increasing the voltage to 460VAC. Push the Fault Reset Button on the
Keypad. All power cell faults should be reset and the normal keypad display should
appear.
The previous steps verify that the main power transformer is OK and the Attenuator Module
in the Transformer Cabinet is properly connected.
Check the modulation at the outputs of all cells by placing the VFD in the run mode.
8
• Verify that the 4 LED’s (Q1 – Q4) on each Cell Control Board should illuminate.

Step Description
Perform this test only if the Drive is equipped with Mechanical Bypass Contactors.
• Stop the drive by giving a STOP command.
• Once the drive is in the OFF or IDLE state, change the Control Mode (2050) to Open
Loop Vector Control
• ENABLE Fast (cell) Bypass (2600). Access this parameter through Drive -> Cells ->
Fast Bypass. Also make sure that in the Cells submenu, the Min. Cells/Phase Count
(2540) is set to be one less than the installed rank of cells.
• On the keypad, select Bypass Status (2620). The display should show all “A”
(available) characters. The order displayed is A-phase (1 through n), B-phase (1
through n), and C-phase (1 through n), where n represents the number of cells per
phase.
9
A. Pull a fiber-optic link for an A-phase cell (e.g., A1) out of the fiber-optic interface
board.
B. Check Bypass Status (2620). It will now display a “B” (bypassed) character in the
location for the cell that the fiber was removed from.
C. Repeat steps A and B for a cell from each of the other two phases (e.g., B1 and
C1). 4
D. Re-connect all fiber-optic links to their corresponding cells and reset their bypass
status using Reset Bypassed Cells (2640).
E. Repeat steps A through C until all bypass contactors have been verified. Make
sure all fiber-optic links are connected back in the correct order before moving to
the next step.
10 Shut down the AC supply to the control and the variac. Disconnect the variac.
4.4. Drive Test in Open Loop Test Mode without Motor
The following steps verify operation of the drive (without a motor) in Open Loop Test Mode.
Table 4-3. Drive Test in Open Loop Test Mode without Motor
Step Description
Reconnect the series connections between T1 and T2 of all adjacent cells, plus the neutral
1
connection between cells A1, B1 and C1.
2 Secure all doors to the Cell and Transformer Cabinets.
3 Enable the blower motor and remove any interlock jumpers.
4 Re-energize the AC control power. Energize the medium voltage feeder.

Step Description
5 Change the Control Loop Type (2050) back to Open Loop Test Mode.
DISABLE Spinning Load using Drive (2) -> Spinning Load (2420) -> Spinning Load Mode
6
(2430).
Make sure that Fast bypass (2600) is DISABLED. Access this parameter through Drive ->
7
Cells -> Fast Bypass.
Configure the Keypad to display input voltage (VDIN), input frequency (FRIN) and motor
8
voltage (VLTS).
Set the Motor Rated Voltage (1040) parameter (access it through Motor -> Motor
9 Parameters) to be equal to the Drive Rated Output Voltage and the Motor Frequency (1020)
equal to 60Hz.
Verify that the Keypad displays the correct value of input voltage and frequency. At rated
primary voltage, the AC input voltage feedback on test points VIA, VIB and VIC should be
10.80Vpp or 3.82Vrms. See Figure 4-3. These test points are on the system interface
card. Perform the following corrective step if the input (or line) voltage is too high or too
low.
V IB V IC V IA
4
10
Figure 4-3. AC input voltages at test-points VIA, VIB and VIC on system interface card
• If the input voltage to the drive is too high, then this needs to be corrected. Harmony
Drives are shipped with the transformer tap set to + 5% which reduces the voltage by
that percentage on the secondary side of the transformer.
• If the voltage is low (5% less than rated) then change the tap on the transformer to the
neutral (“O”) or the –5 % tap.
If the input frequency is displayed as a negative number then one pair of input phases has
to be switched.

Step Description
Enter a speed demand of 25% and give the RUN command. The AC output voltage on test-
points VMA, VMB and VMC should be 2.70Vpp +/-0.27V (measure the average peak-to-
peak voltage using cursors as shown in Figure 4) or 0.96Vrms +/-0.20V. See Figure 4-4 for
signals on test-points VMA and VMB at 25% speed (15Hz).
VM A VM B
11
Figure 4-4. AC output voltages at test-points VMA and VMB at 15Hz in Open Loop Test 4
Mode

Step Description
Increase the speed demand to 50%. The output feedback signals should increase in
proportion.
• Note that in Open Loop Test Mode the flux regulator is not perfect and hence the output
voltage will read higher or lower than the calculated value corresponding to 50% of
rated voltage. Adjust the Flux Demand parameter (3150) such that the motor voltage
(on the Keypad or Tool) is approximately equal to 50% of rated voltage.
• Further increase the speed demand to 100%. The AC output voltage on test-points
VMA, VMB and VMC should be 10.80Vpp +/-0.27Vor 3.82Vrms +/-0.20V. The Motor
Voltage on the Keypad should read the rated value of output voltage +/-5%. See
Figure 4-5 for the AC output voltage waveforms VMA and VMB at 60Hz.
12
VM A VM B
Figure 4-5. AC output voltages at test-points VMA and VMB at 60Hz in Open Loop Test
Mode
4.5. Drive Test in Open Loop Test Mode with Motor Connected
The following steps verify operation of the drive (with a motor connected at its output) in Open Loop Test
Mode. This test is required only when the operation of the output Hall Effect Transducers requires to be
verified . During this test the motor should be unloaded. If this test is not required then proceed to the
next test.
Table 4-4. Drive Test in Open Loop Test Mode with Motor Connected
Step Description
Disconnect control voltage and medium voltage sources. Reconnect motor leads or enable
1
motor contactor.
2 Energize the control circuit breaker. Energize input voltage.
3 Set the Motor Rated Voltage (1040) and Frequency (1020) parameters (access it through

Step Description
Motor -> Motor Parameters) to be equal to the motor nameplate values.
4 Make sure that Spinning Load Mode (2430) and Fast Bypass (2600) are DISABLED.
Increase the Speed Ramp parameters in order to slow down drive acceleration and
deceleration.
5 Speed ramp setup (2260)

Accel time 1(2270) 60.0 sec or greater
Decel time 1(2280) 60.0 sec or greater
Reduce the Flux Demand parameter to 0.5.
Stability(3)
6 Output Processing (3050)
Flux Control(3100)
Flux demand(3150) 0.5
Energize the medium voltage feed to the VFD. Push the Fault Reset Button on the Keypad to
reset faults and push the Button a second time to acknowledge any alarms.
7 If the Mode on the Keypad display reads RLBK, then change the Control Loop Type (2050) to 4
Open Loop Vector Control and exit out of the menu entry. This should force the RLBK on the
Keypad to change back to Mode. Then change the Control Loop Type (2050) back to Open
Loop Test Mode.
Configure the Keypad to display motor magnetizing current, motor torque current and motor
8
voltage.
9 Spin the motor at 1% speed and observe proper rotation.
Operate the drive with a Speed Demand of 10%. Observe the AC output voltage feedback
and motor current for phase A on test-points VMA and IMA using an oscilloscope.
• Since the motor is unloaded the current waveform should lead the voltage waveform by
almost 90° (see Figure 4-6). The Hall Effect Current Transducers introduce a negative
sign since they are configured to measure the incoming current. Check test-points
VMB, IMB and VMC, IMC for similar waveforms.
10
• The Keypad display should read a positive average value for Ids (magnetizing current)
and a small value for Iqs (the torque current). Note that the Keypad displays of Ids and
Iqs will not show constant values. This is because in the Open loop Test Mode, the
drive does not have good control of the currents. The average value of Ids should be
equal to half the no-load current of the motor while the average value of Iqs should be
nearly zero.

Step Description
IM A
VM A
Figure 4-6. Open Loop Test Mode operation at 10% speed with an unloaded motor.
AC motor voltage and motor current at test-points VMA and IMA are shown.
4.6. Drive Test in Open Loop Vector Control Mode with Motor Connected
4 At this point the VFD is ready for actual (induction) motor operation. The following steps verify operation
of the drive and the load induction motor in Open Loop Vector Control Mode. If the drive is connected to a
synchronous motor then use the steps in the following section.
Table 4-5. Drive Test in Open Loop Vector Control Mode with Motor Connected
Step Description
1 Reconnect motor leads or enable motor contactor, if required.
2 Energize the control circuit breaker.
3 Change the drive Control Loop Type (2050) to Open Loop Vector Control.
DISABLE Spinning Load
Drive (2)
4
Spinning Load (2420)
Spinning Load Mode (2430) Disabled [Enable]

Step Description
Setup the Speed Ramp parameters according to the following recommendation:
The acceleration and deceleration rate for a fan should be set to around 60 seconds and for
a pump around 30 seconds.
5
Speed ramp setup (2260)
Accel time 1 (2270) 30.0 sec
Decel time 1 (2280) 60.0 sec
Verify that Fast (cell) bypass is disabled at this time if you have that option
6
Fast bypass (2600) Disabled
Setup the following motor parameters according to the nameplate values.
Motor parameter (1000)

Motor frequency (1020) Hz
7 Full load speed (1030) rpm
Motor voltage (1040) V
Full load current (1050) A
Motor kW Rating (1010) kW 4

Use default values for the other motor parameters as shown below. For this test set the
Stator Resistance to 0.1%. The entry within square braces refers to the no-load field current
setting for Synchronous Motor Control.
Leakage inductance (1070) 16.0 %
8
Stator resistance (1080) 0.1 %
No load current (1060) 25.0 % [No load Field Current = 15.0%]
Inertia (1090) 30.0 Kgm2

Step Description
Setup the Motor Overload and Torque Limits as shown below. Set the Motor Trip Volts to be
equal to 120% of the Motor Rated Voltage or to the value required by the customer. Set the
Overspeed parameter to be 120% or to the value required by the customer.
Limits (1120)
Overload select (1130) Constant
I overload Pending (1139) 100.0 %
9
I overload (1140) 110.0 %
Overload timeout (1150) 60.0 sec
Motor Trip Volts (1160) 4800 V or value required by customer
Overspeed (1170) 120 % or value required by customer
Motor torque limit 1 (1190) 100.0 %
Regen torque limit 1 (1200) -0.25 %

Step Description
Verify that the control loop gains are at their default values as shown below. Entries within
square braces refer to settings for Synchronous Motor Control.
Stability (3)
Output Processing (3050)
Flux Control (3100)
Flux reg prop gain (3110) 1.72 [0.50]
Flux reg integral gain (3120) 1.00 [0.50]
Flux filter time const (3130) 0.0667 sec [0.022 sec]
Flux demand (3150) 1.0
Flux ramp rate (3160) 0.5 sec
Energy saver min flux (3170) 100 %
Speed Loop (3200)
Speed reg prop gain (3210) 0.02
Speed reg integral gain (3220) 0.046
Speed reg Kf gain (3230) 0.60
Speed filter time const (3240) 0.0488 sec
Current Loop (3250) 4
Current reg prop gain (3260) 0.50
Current reg integral gain (3270) 25.0
10
Braking (3350)
Enable braking (3360) Disable
Pulsation frequency (3370) 275.0 Hz
Output Processing (3050)
Output current scaler (3440) 1.0
Output voltage scaler (3450) 1.0
Stability (3)
Dead time comp (3550) 12.0 usec
Feed forward constant (3560) 0.0
Carrier frequency (3570) 600.0 Hz
Note:
• Auto-Tuning modifies the italicized menu items in the above list.
• For synchronous motors make sure that the WAGO Analog Output module providing
the command for the Field Supply is correctly selected. Select the appropriate Analog
Module # within the Analog Outputs sub-menu (4660).
For this analog module select:
Synch Motor Field as the Analog Variable,
Unipolar as the Module Type, and
100% for the Full Range.

Step Description
11 Verify the System Operational Program and Customer Interface.
Energize the medium voltage feed to the VFD. Push the Fault Reset Button on the Keypad
12 to reset faults and push the Button a second time to acknowledge any alarms. Spin the
motor at 1% speed and observe proper rotation, if this was not verified in the previous test.
Configure the Keypad to display motor magnetizing current, motor torque current, and motor
13
voltage
Operate the drive with a Speed Demand of 10%. Observe the AC output voltage feedback
and motor current for phase A on test-points VMA and IMA using an oscilloscope.
• If the motor is unloaded, then the current waveform should lead the voltage waveform
by almost 90° (see Figure 4-7 [top frame]). The Hall Effect Current Transducers
introduce a negative sign since they are configured to measure the incoming current.
The Keypad display should read a positive value of Ids (magnetizing current) equal to
the no-load current of the motor and Iqs (the torque current) should read a small value
14
(typically 1-3% of rated current).
• If the motor is loaded then the current waveform will lead the motor voltage by an
angle smaller than 90° (see Figure 4-7 [bottom frame]). Ids would still read a positive
value that is larger than the no-load current while Iqs would read a value larger than
zero. The sign of Iqs directly depends on the direction of rotation.
4
• The motor voltage should be 10% of the motor rated voltage.
Increase the Speed Demand while monitoring the motor voltage. The motor voltage should
read according to the following table. See Figure 4-8 for waveforms at 100% speed (60Hz).
Table 4-6 shows the drive voltage scaling for signals on test-points VMA, VMB and VMC as
15 a function of speed. Table 4-7 lists the scaling for the currents and voltage feedback signals
available on the Signal Conditioning Board at the rated operating point of the drive.
Table 4-6. Scaling of drive output voltage as a function of speed

Speed Command Motor Speed Motor Voltage Motor Voltage
(%) (Hz) Feedback (V, pp) Feedback (V, rms)
10 6 1.08 0.38
25 15 2.70 0.96
50 30 5.40 1.91
75 45 8.10 2.87
100 60 10.80 3.82

Table 4-7. Scaling of drive input and output voltages and currents on Signal Conditioning Board.
Variable Rated value (rms) at drive terminals Feedback value Feedback value
under rated under rated
conditions (Vpeak) conditions (Vrms)
Input Current Primary Current Rating of Input CT 5.0 3.54
Input Voltage (Rated Input Voltage L-L) / 1.732 5.4 3.82
Output Current Output Current Rating (≡ Cell Rating) 5.0 3.54
Output Voltage (Rated Output Voltage L-L) / 1.732 5.4 3.82
Examples - Output Current Scaling: Cell current rating ≡ 3.54 Vrms
Output Voltage Scaling: [(Rated output voltage L-L) / 1.732] * 1.414 ≡ 5.4 Vpeak

IM A
VM A
IM A
VM A
Figure 4-7. AC motor voltage and motor current at test-points VMA and IMA at 10% speed
in Open Loop Vector Control.
(a) Unloaded Operation and (b) Full Load Operation.

VM A
IM A
VM A
IM A
Figure 4-8. AC motor voltage and motor current at test-points VMA and IMA at 100%
speed in Open Loop Vector Control.
(a) Unloaded Operation and (b) Full Load Operation.
4.7. Drive Test in Synchronous Motor Control Mode

This section tests the operation of the VFD with a synchronous motor. A 3PCI regulator is typically used
for the exciter supply. The following items are required for tuning the 3PCI regulator:
• 4-20mA current output box.
• If the drive is not equipped with meters for displaying output voltage and output current, then DVMs
are needed for observing the voltage and current (in one of the phases) at the output of the 3PCI
regulator.

• Values of (a) rated output current of 3PCI, (b) maximum field current for the synchronous motor field,
and (c) rated synch motor field current.
• Drawing #479150 (3PCI control schematics) and the drawing (shipped with drive) that shows
connections to the 3PCI regulator will be helpful during setup.
Warning! Field current should not be applied for more than a few minutes at a time to prevent
damage to the field current windings.
DANGER! During the following tests, high voltages may be present on the stator side of the
motor.
4.7.1.Tuning the 3PCI (SCR Regulator)

Perform the following set-up changes and tests to tune the 3PCI. The following should be performed with
a stationery motor. For these tests MV is not required on the drive. Make sure that the input voltage
sequence to the 3PCI is correct.
Table 4-8. Tuning the 3PCI (SCR Regulator)
Step Description
Jumper and Potentiometer Settings. Ensure that the jumper and potentiometer setting
4 are set as follows:
Jumper:
J1 Should be OPEN, i.e. not connected to any other terminal (for NO ramp)
J2 Position A (for Standard Integrator)
J3, J4 Position B (for Current Regulation)
J5 Position B (for Current Regulation)
Potentiometer: Set all pots as stated below, and then adjust them as described in Step 3
1 . These are 10-20 turn pots except for P3 (single turn pot):
P100 Full CCW
P1 This is the bias pot and is required to be adjusted with zero command so that
the SCRs are barely (but not) phased-on
P2 This adjusts the gain for current feedback scaling. Set to full CW.
P3 This adjusts the max current limit for the 3PCI. Viper of P3 (at Pt. C, block
D8, sheet 2, drawing #479150) should be connected to Pt. C1. This should
be first set to Full CW.
P4 Full CCW
Point A (block J8, sheet 2 of drawing #479150) should not be connected to either Pt. A1 or
2
Pt. A2.

Step Description
Make sure that the output contactor of the 3PCI is closed. Apply 480V power to the field
supply and make the following adjustments as required:
(1) Adjustment of the bias pot – P1.

a. Check the type of WAGO module that is used to provide the field exciter
current command. It should be an Analog Output module with either a 0-20 mA
or a 4-20mA output.
b. If the module is a 4-20mA type, then connect a 4-20mA box between terminals
7 and 1 on TB1 (refer to block A8, sheet 1 of drawing #479150). Set the output
for 4mA.
c. If the module has a 0-20mA output, then do not connect any device to the
reference inputs on TB1.
d. Adjust pot P1 until the SCRs just begin to be gated-on, i.e. the output voltage
meter will begin to show output volts.
3 (2) Adjustment of the gain adjust pot – P2.
a. Connect the 4-20mA current output box to terminals 7 and TB1, if not already
done. Increase the command slowly towards 20mA while monitoring the
current as the output of the field exciter. At 20mA, the output of the 3PCI
should be equal to its rated output (which 60A in this case). Adjust P3 to make
sure that the rated current is observed with a 20mA command.
b. If the winding resistance is such that the rated current cannot be achieved
(because the 3PCI regulator runs out of voltage capability), then adjust 20mA
to be equal to the max expected field current (50A in this case) which should be
smaller than the PCI current rating. If such an adjustment is made, then skip
4
the adjustment for P3 and leave pot P3 in the Full CW position.
(3) Adjustment of max current limit pot – P3.
a. With the command adjusted for 20mA, adjust P3 until the output current of the
3PCI is reduced to the max field current required for the application (which is
50A in this case).
4.7.2. Testing 3PCI Connection to the VFD

The following tests verify the WAGO connection of the VFD to the 3PCI Regulator.
Table 4-9. Testing 3PCI Connection to the VFD
Change the variable selection for the Analog Output (that is being used for 3PCI control)
1 from Synch Motor Field I to Speed Demand. This will allow for control of the 3PCI current
from the drive Keypad.
Make sure that the output contactor of the 3PCI is closed. With zero Speed Demand, the
2
3PCI should put out zero voltage.
Increase the Speed Demand 10%. Verify that the 3PCI output is 10% of the (3PCI) Full-
3
Scale setting.
Further increase the Speed Demand to 50%. Verify that the 3PCI output is 50% of the
4
(3PCI) Full-Scale setting.

4.7.3. Drive Test with Synchronous Motor

The following procedure verifies operation of drive with a synchronous motor in Synchronous Motor
Control Mode.
Table 4-10. Drive test with Synchronous Motor
Connect the synchronous motor to the drive. Enter motor parameters and use default gains
except for the following parameters:
(1) Enter Synch Motor Field no-load current as the No-load Current setting (1060). This
parameter should be calculated (in %) on the basis of the actual no-load field current
and the maximum capability of the 3PCI regulator.
Example: Drive with a synchronous motor that requires 24A of no-load field current
and a 3PCI that is tuned such that 75A is the maximum output (at 20mA command
input), then the No-Load Current Parameter should be set to:
No-Load Current setting = 100% *24/75A = 32.0%
1 (2) Enable Spinning Load (2420).

(3) Change the drive control loop type (2050) to Synchronous Motor Control.
(4) Use default control loop gains except for the flux loop gains that should be changed as
follows:
Flux reg prop gain (3110) 0.50
4 Flux reg integral gain (3120) 0.50
Flux filter time coast (3130) 0.22 sec
(5) The SOP should have been modified to include the logic for controlling the 3PCI output
contactor. The contactor should be ON as soon as the Start command to the drive is
given and should be turned OFF immediately when the drive trips on a Fault or when
the drive goes to Coast State (while stopping).
2 Energize medium voltage to the drive. Run the drive with a speed demand of 10%.
Verify that after Start command is given, the 3PCI (field supply) first starts by applying
3
current and building motor flux. During this time Ids and Iqs should be zero.
After a time period equal to the Flux Ramp Rate parameter (3160), the drive starts by
4
increasing the Speed Reference to the Speed Demand.
With Synchronous Motors, the drive current is always in phase with the voltage, i.e., Ids ≈ 0
5 under steady-state conditions. At no-load, there is very little current supplied from the drive
(on the Keypad, motor current display, ITOT ≈0).
Run the drive to 10% speed. Verify that the no-load and full load (if possible) current
6
waveforms along with the drive voltage waveforms as shown in Figure 4-9.

Run the drive to 100% speed. Verity that the no-load and full-load (if possible) current
waveforms along with the drive voltage waveforms are as shown in Figure 4-10. Note that
the drive output currents at 100% speeds are distorted. This is due to the shape of the
7 poles in the synchronous motor. At low speeds the current regulator bandwidth is sufficient
to correct for the distortion introduced by the motor poles as shown in the second figure of
Figure 4-9. However, at high speeds, the current regulator gains are insufficient to
maintain sinusoidal output currents when the distortion is due to motor pole construction.
VMA
IM A
IM A
VM A
Figure 4-9. AC motor voltage and motor current at test-points VMA and IMA
at 10% speed with Synchronous Motor Control.
(a) Unloaded and (b) 75% torque operation.

VM A
IM A
VM A
IM A
Figure 4-10. AC motor voltage and motor current at test-points VMA and
IMA at 100% speed with Synchronous Motor Control.
(a) Unloaded and (b) 75% torque operation.
4.8. Drive Tuning

Use the following sections to complete the startup of the drive. The first section describes Auto-Tuning
and its use in determining motor and control parameters. The second section describes the setup of the
Spinning Load Menu. This feature is used by the drive control to detect motor speed by scanning the
output frequency over the operating range of the application. The last section lists the other menus that
may need adjustment for completing the drive setup.

4.8.1 Auto-Tuning
The basic motor parameters can be divided into two categories - nameplate data and equivalent
circuit data. Nameplate data, as the name suggests, is readily available (such as Motor Rated
Voltage, Full Load Current, etc.). However, equivalent circuit data (such as Stator Resistance,
No-load Current, etc.) is available only from the motor manufacturer. The correct equivalent
circuit data is required only when good control performance, such as high starting torque or very
low speed operation, is desired.
When operating an induction motor, the drive control has the capability to perform Auto-Tuning.
This feature allows the drive to estimate parameters of the motor equivalent circuit. Auto Tuning
is optional, but is recommended for applications in which high performance, as stated above, is
required. There are two stages of auto-tuning; each stage being selected individually. Apart from
measuring the motor equivalent circuit parameters during auto-tuning, the control uses the
measured motor parameters to adjust the control loops for best possible control bandwidth (the
bandwidth for each control loop is fixed internally in software) and hence provides good
performance in demanding applications.
Such a feature provides drive tuning without the need for an extensive adjustment procedure.
Although, the auto-tuning feature can be used with all induction motors, there are some
limitations. Both stages of auto-tuning can be performed with induction motors (OLVC or CLVC).
However, only Stage 1 should be performed with Synchronous Motors (SMC or CSMC) or when
Output Filters are connected.
*
Note: In most general-purpose applications (such as pumps and fans) default data for the motor
equivalent circuit is sufficient and auto-tuning is not necessary.
• Autotune Stage 1 (1260) 4

Stage 1 determines the Stator Resistance and Leakage Inductance. This stage of auto tuning does
not require the motor to be de-coupled from the load. The motor does not rotate during this Stage.
The data obtained from stage 1 are used to tune the inner regulators that control motor current. The
current loop gains are automatically calculated and saved by the control.
DANGERLETHAL VOLTAGES!! Lethal voltages will appear on the drive outputs during both
stages (1 and 2) of Auto Tuning.
• Autotune Stage 2 (1270)

Stage 2 determines the no-load motor current and the motor inertia. The motor rotates at 30% of
rated speed during this stage. Generally, this stage of auto tuning requires the motor to be de-
coupled from the load. Make sure that it is ok (to spin the motor) with the customer before this test is
enabled. Data obtained in stage 2 are used to optimize the operation of the outer loops that control
motor speed and motor flux. The speed and flux loop gains are automatically calculated and saved by
the control.
DANGER!! The motor will spin during stage 2 of Auto Tuning.
*
Note: Quadratic loads, such as pumps and fans, do not require the motor to be de-coupled.
The control is designed to minimize the errors introduced by such loads.

4.8.2. Spinning Load

Spinning Load should be enabled if one or more of the following operating modes/features are
selected:
1. Fast Bypass,
2. Auto-Restart,
3. Synchronous Motor Control (SMC and CSMC), or
4. Closed Loop Vector Control (CLVC)
*
Note: Spinning Load does not provide instantaneous restart with V/Hz control.
*
Note: With synchronous motors, spinning load is always instantaneous, i.e. the drive will never go
into a scan mode.
Perform the following steps to tune the scan mode of Spinning Load. Use the Tool Suite to monitor Motor
Flux (FluxDS), Motor Speed and Speed Reference.
Table 4-11. Tuning the Scan Mode of Spinning Load

4
Step Description
1 Enable Spinning Load and make sure the following parameters are set to the values shown.
Spinning Load (2420)

Spinning Load Mode (2430) Forward or Reverse whichever is
appropriate
Scan end threshold (%) (2440) 20 %
2 Current level set point (%) (2450) 25 % [or equal to the No-load
load current setting]
Current ramp (s) (2460) 0.01 s
Max current (%) (2470) 50 %
Scan time (s) (2480) 3.0 s
3 Operate the drive with a demand of 30%.
4 Trip the drive by using ESTOP.
Wait for the motor flux to decay below 4%. This can take more than a few seconds for large
5
horse-power or high efficiency motors.
6 Reset ESTOP (and hit Fault Reset if required) and give a RUN command.

Step Description
On the Tool Suite monitor the speed reference and motor speed at the moment the drive
‘catches’ the motor.
• If the speed reference is higher than the motor speed, then the drive has ‘caught’ the
7
motor too soon. In this case, increase the Scan End Threshold parameter (2440).
• If the speed reference is lower than the motor speed, then the drive has ‘missed’ the
motor. In this case, reduce the Scan End Threshold parameter (2440).
Repeat steps 3 through 7 until the speed reference and motor speed (at the moment the
8
drive ‘catches’ the motor) are within a few percent of each other.
4.8.3. Application Menus

Setup the following Menus according to user/application requirements:
• Motor Limits (1120) including Phase Imbalance (1244) and Ground Fault (1245)
• Bypass Type (2590) and Fast Bypass (2600)
• Critical Frequency Menu (2340)
4
• Drive Protection Menu (7)
4.9. Synchronous Transfer Procedure (if applicable)

This section of the startup procedure involves optional synchronous transfer checks. The Perfect
Harmony may be configured for optional synchronous transfer operation in which the drive can be used to
control multiple motors (for example) one motor at a time. If such a configuration is not defined for the
application, then this section may be skipped. For additional information on signals, flags, transfer steps
and sample application refer to Section 9.2 describing Synchronous Transfer Operation in Chapter 9.
The following steps should be used to set up the drive control for Synchronous Transfer:
Table 4-12. Drive Control Setup for Synchronous Transfer
Step Description
Configure Synchronous Transfer Menu parameters as shown below.

Synchronous Transfer (2700)
• Phase I gain (2710) 2
1
• Phase P shift (2720) 4
• Phase offset (2730) 2 deg
• Phase error threshold (2740) 1.5 deg

Step Description
• Frequency Offset (2750) 0.5 %
• Up Transfer Timeout (2760) 0 sec
• Down Transfer Timeout (2770) 0 sec
2 ENABLE Spinning Load by setting Spinning Load Mode (2430) to Forward.
3 Set the Speed Fwd Max Limit1 (2080) to 105%.
Go through the following checklist to complete the set up for Synchronous Transfer:
Table 4-13. Synchronous Transfer Check List
Step Description
1 Configure the drive control as described above.
2 Ensure that PLC related hardware is properly connected (for information, see the respective
PLC communications network manuals supplied by the vendor) to the WAGO I/O modules.
3 Verify wiring of all VFD control and line control electrical contactors.
4 Ensure that the system operating program for the “up transfer” and “down transfer” process
4 logic is as described in the Application and Operations chapter.
5 The state machines for up and down transfers reside in the Perfect Harmony’s control
program. These interface with the control system integrator’s PLC network via the VFD
system operating program to handle handshaking between each motor control center (MCC)
and the VFD. All controls for the VFD and line reactors are controlled from the system
integrator’s PLC. Verify that these controls are operational.
6 Verify all communications flags.
4.10. Output Filter Setup (if applicable)

An output filter is typically used to prevent the output cable dynamics from interfering with the drive
output. The Output Connection submenu (2900) should be used when an output filter is connected at the
drive output (refer to Table 4.14).
The Filter CT secondary turns parameter (2910) represents the secondary side turns on the filter CT
assuming primary turns are 5. The percent filter inductance (2920) and capacitance (2930) can be
calculated from the inductor value (in Henries) and capacitor value (in Farads), respectively, using the
following formula. Typical values for the filter inductance and capacitance are 5.0% and 10.0%,
respectively. The cable resistance (in ohms) can be estimated from the total cable length and the cable
resistance per foot. For this parameter entry (2940), an estimate is good enough. Use the last formula to
convert from ohms to percent of drive output impedance.
Drive_base_impedance [in ohms] = Drive_output_rated_voltage / (1.732 * Drive_output_rated_current)

%Filter_inductance = 100.0 * 377.0 * Filter_inductance [in Henries] / Drive_base_impedance [in ohms]
%Filter_capacitance = 100.0 * 377.0 * Filter_capacitance [in Farads] * Drive_base_impedance [in ohms]
% Cable_resstance = 100.0 * Cable_resistance [ in ohms] / Drive_base_impedance [ in ohms]

Note: Entries in the Output Connection submenu are related to the drive and not to the motor. Hence
changes in motor parameters do not affect the parameters in this submenu.

secondary turn primary turns = 5) of the CTs used to
measure filter capacitor currents.
Filter inductance 2920 % 0 0 16 Sets the output filter inductor value
(impedance) as a ratio of the base
output impedance of the drive
(typically 5%)
Filter capacitance 2930 % 0 0 96 Sets the output capacitor value
(admittance) as a ratio of the base
output admittance of the drive
(typically 10%)
Cable resistance 2940 % 0 0 64 Sets the output calble resistance
value as a ratio of the base output
impedance of the drive.
Filter damping 2950 p.u. 0 -5.0 5.0 Adjusts the active damping gain.
gain
4
A new parameter called Filter Damping Gain (2950) in the Output Connection submenu is available in
versions 2.20 and higher. This allows an adjustment of the damping gain that is used by the control to
damp the output frequencies amplified by the filter. For long cables (length > ~ 30000 feet) the damping
gain is required to be a negative number, normally between –1.0 and 0.0. For shorter cable lengths, the
gain should be in the range of 0.0 and +1.0.
For versions 2.02 and 2.11, there is no direct parameter that can be adjusted to control damping. An
indirect way of adjusting the internal damping gain is to change the Motor Leakage Inductance
parameter. The internal damping gain is directly proportional to the square root of the motor leakage
inductance.
For active damping, the sample rate should be above the 4.0 – 4.5 kHz range. Depending on the number
of ranks in the drive, use the following table to adjust the carrier frequency (3580).
Table 4-15. Recommended value of carrier frequency as a function of cell stages in the drive.
Number of Ranks Carrier Frequency (Hz)

3 800
4 600
5 600
6 500

4.10.1. Adjusting Current Regulator Gains with Output Filters

When output filters are used, the current loop gains (3260 and 3270) should be below 0.30 (for
proportional gain) and 30.00 (for integral gain), respectively.
If the drive repeatedly trips on IOC when the start command is given, then the wiring of the filter CTs must
be checked for correct connections using the procedure described in the following subsection. After the
connections are verified, both visually and by operating in OLTM, then the next step is to reduce current
loop gains. Reduction of the current loop gains (in steps on 0.05 and 5.00, respectively) must be
performed until IOC-free operation is obtained. The Filter damping gain should then be adjusted to
reduce the high frequency oscillations in the drive output current waveforms. A good value of Filter
damping gain will allow an increase in current loop gains towards 0.30 and 30.00.
4.10.2. Verification of Filter CT wiring

Three CTs are used for measuring the filter capacitor currents, one CT for each phase. The CTs are
placed on the star-point (or Y-point) of the capacitors so that the CTs are not subject to high common-
mode voltages. For each CT, two wires, one from each secondary, go back to the control section. This
results in a total of six wires going from the CTs to the control section. Perform a visual inspection of the
filter cabinet (with Medium Voltage off) to verify CT placement and connections.
The capacitor current feedback signals are available on test-points IFA, IFB, and IFC, located on the
System Interface Board. In order to check the CT connections, the drive should be operated without the
4 motor in Open Loop Test Mode. Run the drive to at least 50% speed and observe the drive output
voltage, VMA and filter capacitor current, and IFA on a scope. The filter capacitor current should lead the
drive voltage as shown in the following figure, where the waveforms were measured at 100% speed.
VMA
IFA
Figure 4.11. Drive output voltage and filter capacitor current on test-points VMA and IFA,
respectively, to determine if filter CT wiring is correct.
4.10.3. Determining Stator Resistance in Long Cable Application

If cable resistance data is not available then an alternate way of determining cable and motor resistance
(total resistance in series with the drive) is to use Auto-Tuning Stage 1. Use this feature only when the
motor current rating is at least 50% of the drive current rating. If cable resistance (2940) has already
been entered as a value less than the actual resistance value, then the drive will subtract the entered

cable resistance value from the estimated (total) stator resistance and save the difference as the motor
stator resistance (1080). If cable resistance is entered as 0.0, then the drive will assign the total
(measured) resistance as the stator resistance parameter.
*
Note: Stator resistance is with respect to motor base impedance, while cable resistance is with
respect to drive output base impedance. The drive does the conversion only after Auto-Tuning
Stage 1.
*
Note: After Auto-Tuning Stage 1, the current loop gains have to be manually adjusted such that
they are below 0.30 and 30.0, respectively.
4.11. Encoder Setup (if applicable)

An encoder is used in applications that require very tight speed control, especially at low speeds. Use the
following steps to set the drive that is equipped with an encoder.
1. Set the drive Control Loop Type (2050) to CLVC (for Closed Loop Vector Control). Choose CSMC
(Closed Loop Synchronous Motor Control) if the motor is of synchronous type.
2. Enable Spinning Load by choosing the appropriate direction in menu 2430.
3. Enter the parameters in the Encoder Menu (1280) as shown.
Encoder PPR 1290 Enter PPR value from encoder
Encoder filter gain 1300 0.75
Encoder loss threshold 1310 5.0%
4
Encoder loss response 1320 Open loop
4.11.1. Verification of encoder operation

Use the following steps to determine if the encoder is operating correctly.
1. Run the drive in Open Loop Vector Control.
2. Compare the (estimated) motor speed with the encoder speed (measured) value for different speed
demands. They should track each other very closely. If tracking is greater than the rated slip of the
motor, then check the Encoder PPR parameter to see if it is correct. To change the polarity of the
encoder feedback, switch the pair A, A′ with B, B′.
4.12. Verification of Input Monitoring

This section provides steps to verify the monitoring capabilities of the drive. The following steps should
be performed after drive operation in one of the (motor) control modes has been verified.
1. Run the drive to a speed at which output power is greater than 20 – 25% of rated drive power.
2. Check if the calculated values of input and output power are reasonably close, in other words, the
drive efficiency should read 95% or higher. If this is not the case, then an adjustment of voltage
and/or current scalers (input or output) may be required.
Determination of the voltage/current scaling requires independent means of measuring these quantities.
In some drives, PQMs are already installed. PQM readings can be compared with the calculated values
from the drive control to determine the actual scaler setting (default setting is 1.0). If a PQM is not
available, then a PT/CT can be used to make the independent measurement.

Table 4.7. provides values of voltage/current signals on the test points at rated conditions. For each
signal, note the drive display reading, the reading from the independent measurement and the value
measured at the test point. Compare these three readings to determine the cause of the error. A (drive)
scaler adjustment should be made until the measurements are within 1% of each other.
*
Note: Increasing the scaler value (for voltage or current) increases the value of the measured
quantity in the control.
∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics APPLICATION AND OPERATION ISSUES
CHAPTER 5: APPLICATION AND OPERATION ISSUES

5.1. Introduction
This chapter provides an overview of some of the more complex application and operation issues
surrounding the Perfect Harmony VFD.
5.2. Synchronous Transfer Operation
5.2.1. Introduction
The term “up transfer” is used to transfer a motor running from a variable frequency drive (VFD) to the
line and then decouple the motor from the drive. “Down transfer” is used to match the drive with a motor
running off the line and decouple the motor from the line and transfer the motor to the VFD.
5.2.2. Transfer Setup and Faults

Before attempting synchronous transfer, the command generator options selected during pre-
synchronous transfer should be examined. It is important to disable command generator functions that
may cause the transfer to fail. Verify that the speed profile, polarity change function, and speed limits do
not modify the input frequency when a synch transfer is requested. The input frequency is treated much
the same way as any other raw speed demand into the drive. Refer to the Command Generator diagram
(459713).
During synchronous transfer there are three alarm/fault conditions that can occur:
1. Up Transfer timeout: Meaning that the transfer has taken longer than allocated in the “Up transfer
timeout” menu (ID = 2760). 5
2. Down Transfer timeout: Meaning that the transfer has taken longer than allocated in the “Up
transfer timeout” menu (ID = 2770).
3. Phase Sequence: Indicating that the Drive input phase sequence or direction is different than the
Drive output.
The timeout faults may indicate that other conditions maybe causing the transfer to fail. An example
would be that there might not be enough active cells left in the drive to support the line voltage during
down transfer. In this case, the drive sets the SOP flag InsufficientOutputVolts_I high.
5.2.3. Up Transfer
Up transfers are accomplished by taking the motor up to speed on the VFD to match the frequency of the
line. This is accomplished by using the line frequency as a velocity reference. Once the frequency is
matched the phase also needs to be matched with a predetermined phase difference to prevent
transients and to start with the power being provided by the VFD while the line contactor is closed. This
step is done by enabling a phase lock loop using the line frequency and phase information and the output
phase information to determine a vernier adjustment to the frequency that is added to the velocity
command. The load is then transferred to the line by adjusting the VFD frequency to decrease the
current from the drive while the current from the line increases. When the drive current is minimized, the
drive contactor is opened and the drive coast stopped to end the transition. The sequence of control logic
is as follows.
1. Start the VFD as a normal running drive with proper speed command. The drive must be in the
“RUN” state in order to initiate transfer.
2. Initiate the transfer with the transfer request system flag (UpTransferRequest_O) when a transfer is
desired. Also a system program timer is enabled for transfer time-out (a transfer fault). If no transfer
fault exists, the drive enters “UP_TRANSFER” state and transfer state “TRANSFER_INIT” (A). If the
drive output voltage capability, due to cell bypass is less than the line voltage (see Section on

APPLICATION AND OPERATION ISSUES Perfect Harmony GENIII/e Startup and Advanced Topics
Neutral Point Shift during Cell Bypass in this chapter), the control will prevent the Drive from
entering the “DOWN_TRANSFER” state, and set the InsufficientOutputVolts_I flag high.
3. From this point the transfer is controlled through the transfer state machine from within the
“UP_TRANSFER” Drive State. With the entry into this state the velocity regulator demand generator
is forced to accept the reference from the line frequency measurement.
4. In Transfer State “TRANSFER_INIT”(A), the new velocity reference represents input line frequency
as described above with no vernier for phase offset correction. The drive will stay in this state until
the frequency error is reduced to less than 0.5 Hz. At this point the Transfer State is advanced to
“WAITING_FOR_FREQUENCY_ LOCK”(B).
E to A (VFD contactor open;

drive leaves transfer state) A A to B (frequency error < 0.5 Hz)
E B
D to E (line contactor acknowledge) B to C (frequency error < 0.5 Hz for 1 second)

D C
C to D
(phase error < setting for 3 seconds)
Figure 5-1. Synchronous Transfer State Diagram for “Up Transfer”
5. In transfer state “WAITING_FOR_FREQUENCY_LOCK”(B) the drive maintains frequency lock for 1

5 second before advancing to the next Transfer State “WAITING_FOR_PHASE_ LOCK”(C).
6. In transfer state “WAITING_FOR_PHASE_LOCK”(C) the drive uses the phase lock loop phase error
in a P+I loop to calculate a phase correction velocity reference vernier adjustment that is added to the
line frequency reference as the input demand to the velocity regulator. This correction is continued
until the phase error is less than a user entered value for a period of 3 seconds. An optional offset to
the error programmable through a menu entry in degrees of phase shift may be added as well. When
the minimized phase error has been maintained for the proper time, the state machine sets a system
program flag “UpTransferPermit_I” to enable the line contactor and advance to the next transfer state.
This flag must be used by the system program to enable the line contactor.
7. In transfer state “WAITING_FOR_CONTACTOR_CLOSURE”(D) the drive maintains the phase lock
loop and waits for the acknowledgment of the line contactor pickup. When the contactor closed is
sensed via the system program flag “LineContactorAcknowledge_O”, the drive sets the
“UpTransferComplete_I” and advances to the final Transfer State “TRANSFER_COMPLETE”.
8. In transfer state “TRANSFER_COMPLETE”(E) the drive is waiting until the Drive Run request is
removed. The system program must then drop out the VFD contactor while maintaining the line
contactor.
9. Once the drive enters the drive state “UP_TRANSFER”, the only way out is through the normal
completion of the transfer, or if a transfer time-out failure, or if a drive fault or E-stop occurs. A
transfer timeout failure occurs if the system is unsuccessful at completing a transfer before the end of
the timeout period. If a timeout occurs before reaching the “TRANSFER_COMPLETE” (E) State the
drive returns to drive state “RUN” state and presets the Transfer State back to “TRANSFER_INIT”(A).
The drive issues a Transfer Failure Warning and waits for a reset before attempting a new Up
Transfer. If the drive makes it to the “TRANSFER_COMPLETE” (E) State the drive will not issue a
timeout.
A Drive Fault causes the drive to go into “Coast Stop”. A Fault Reset is required to put the drive into
“IDLE” State. A drive restart is required as in Step # 1 to begin a new Up Transfer Sequence. The drive
responds to a CR3 or drive-inhibit in the same way as a Fault.

5.2.4. Down Transfer

“Down transfer” is used to transfer a motor from the line to the Drive. With NXG control, the drive
compares input line voltage with the output voltage before locking-in to the line frequency. For the drive to
perform such a comparison, the VFD contactor is required to be closed at the beginning of the Down
Transfer sequence. The drive is capable of locking-in within a few milliseconds. The drive then raises the
output torque current before indicating that it is ready to accept the motor (or open the line contactor).
The sequence for down transfer is as follows:
E to A (VFD contactor open;

drive leaves transfer state) A A to B (frequency error < 0.5 Hz)
E B
D to E (line contactor acknowledge) B to C (frequency error < 0.5 Hz for 1 second)

D C
C to D
when torque current > 75% of rated
Figure 5-2. Synchronous Transfer State Diagram for “Down Transfer”
1. NXG Control requires Spinning Load to be enabled, and that the Drive is in the “IDLE” state prior to
down transfer. To start, assume that the motor is running from the line, the line contactor is closed
and a contactor acknowledge is provided to the drive.
2. The down transfer request system program flag (DownTransferRequest_O) is set. 5
3. A “run request” is issued to the drive.
4. The drive issues a permit (DownTransferPermit_I) which is used to close the VFD Output Contactor.
The Drive will begin to sense the voltage from the drive output. During this time the drive remains in
“IDLE” State. Once the drive output frequency is within ½ hertz of the input frequency, the drive will
advance to the "“DOWN_TRANSFER” state. If the drive output voltage capability, due to cell
bypass is less than the line voltage (see Section on Neutral Point Shift during Cell Bypass in
this chapter), the control will prevent the Drive from entering the “DOWN_TRANSFER” state,
and set the InsufficientOutputVolts_I flag high.
5. Within the “DOWN_TRANSFER” state are five transfer states (refer to Figure 5-2
5-2).
TRANSFER_INIT(A),
WAITING_FOR_FREQUENCY_LOCK(B),
WAITING_FOR_TORQUE_TO_REACH_75_PERCENT(C),
WAITING_FOR_CONTACTOR_OPENING(D), and
TRANSFER_COMPLETE(E).
After entering “DOWN_TRANSFER” state the drive is initially in the transfer state
“TRANSFER_INIT(A),” and will quickly transition to transfer state “WAITING_FOR_
FREQUENCY_LOCK(B)”. Transition from B to C requires that the drive output frequency and the line
frequency be within ½ hertz for 1 second.
6. Now that the drive has matched the line frequency, it will begin to raise the amount of torque
producing current to the motor in preparation for the transfer of motor control from the line to the
drive. Transition form C to D occurs when the torque producing current is greater than or equal to
75% of the maximum permissible current (Iqs max). The drive issues a signal (sets it True) to unlatch
the line contactor (LineContactorUnlatch_I).

7. Once the PLC opens the line contactor and provides the line contactor acknowledge
(LineContactorAcknowledge_O) that is False, the state machine transitions to the
“TRANSFER_COMPLETE(E)” state.
8. The drive issues a down transfer complete signal (DownTransferComplete_I) after which the down
transfer request (DownTransferRequest_O) can be removed.
9. The drive returns to the speed setpoint set by the customer.
10. If a Transfer Time-out occurs when the drive is within the “DOWN_TRANSFER” state, then the drive
goes back to the state “TRANSFER_INIT(A)”. The drive issues a Transfer Failure Warning and waits
for a reset before attempting a new Down Transfer.
To Stop the Drive while it is connected to the line, give a Stop Request should be issues. This will disable
the Drive output immediately. Then remove the VFD Contactor Acknowledge, open the VFD Contactor
and remove the Down Transfer Request.
A Drive Fault causes the drive to go into “Coast Stop”. A Fault Reset is required to put the drive into
“IDLE” State. To reset the Fault remove the VFD Contactor Acknowledge, open the VFD Contactor and
remove the Down Transfer Request. Follow the sequence listed from Step # 1 for a new Down Transfer
sequence. The drive responds to a CR3 or drive-inhibit in the same way as a Fault.
5.2.5. Reservoir Example - Synchronous Transfer with Multiple Motors and a PLC
Perfect Harmony drives can be used to control multiple motors using synchronous transfer methodology.
Such applications are used to proportionally control a series of motors one motor at a time. Consider the
following example. A reservoir is being filled with liquid at an unknown, variable rate. Up to three pumps
5 can be used to remove the liquid to keep the reservoir level at a certain setpoint (this is the external
process). As the external system error (i.e., the positive or negative deviation from the setpoint)
continues for an external process (e.g., the feedback value rises above a setpoint value), the first motor
(a pump, for example) is controlled by the drive to attempt to correct the error and bring the reservoir level
back to its setpoint level. If the error from the external process continues (i.e., the reservoir level remains
above its setpoint value), the first pump may be unable to reach or maintain the level setpoint - even at
100% speed. If this occurs, the first pump is smoothly transferred to line voltage (at 100% speed), and
the drive begins to control a second pump. If the error of the external process remains, the second pump
can then be operated in addition to the first pump (at 100%) using straight line voltage, while a third motor
is brought on line and controlled by the drive. This transfer of drive control from one motor to the next
can occur with a single Perfect Harmony drive and any number of motors.
Figure 5-3. shows a reservoir being emptied by pumps 1, 2 and 3 (which use induction motors M1, M2
and M3, respectively). As the tank fills past the setpoint level (monitored by an external feedback signal),
the drive controls motor M1 (via motor control center MCC1) to maintain the level. As the tank level
continues to increase, the motor on pump 1 will eventually reach 100% speed. If the tank level continues
to increase, the Perfect Harmony initiates an “up transfer“. This process involves electronically switching
control of motor M1 to line control (rather than VFD control). This process is done smoothly using a serial
communications network (MODBUS protocol, for example) and a pair of electronically controlled
contactors (L1 for line control and V1 for VFD control). With motor M1 running at 100% (line voltage),
motor M2 (on pump 2) is switched from an idle state into VFD control using PLC commands and
contactor V2. This process continues with additional motors until the external process feedback indicates
that the tank level is at its setpoint. This entire process works in the reverse order (called a “down
transfer“) when a negative error occurs (i.e., the feedback signal shows that the measured value is below
the setpoint value). An “up transfer” process is illustrated graphically in Figure 5-4
5-4.. A “down transfer”
process is illustrated graphically in Figure 5-55-5.. These graphs show motor output percentages as
functions of time with either continued demand (positive error) for “up” transfers or no demand (negative
error) for “down” transfers.
Note that the graphs in Figure 5-4. and Figure 5-5. show very “clean” proportional ramps. These ramps
are for illustration purposes only and do not include any integral or derivative control action. A continued

demand throughout time period t4 is assumed in Figure 5-4 5-4.. and no demand is assumed throughout time
period t9 in Figure 5-5. An overview of the control states of the motors used in example Figure 5-4
5-4.. is
given in Table 5-1. A similar overview for Figure 5-5. is given in Table 5-2.
*
Note: The state machines for up and down transfers reside in the Perfect Harmony’s control
program. These interface with the control system integrator’s PLC network via the VFD system
operating program to handle handshaking between each motor control center (MCC and the VFD.
All controls for the VFD and line reactors are controlled from the system integrator’s PLC.
Pump 1
M1
Pump 2 To An External
M2
Process
Pump 3
M3
Perfect Harmony
VFD
Main
PLC
Controller
MCC1 MCC2 MCC3
Current PLC
Level Reservoir Interface
L1 V1 L2 V2 L3 V3 Card
Line
Voltage
VFD
Output
5
Motor Control Centers
Process Feedback Signal
Figure 5-3. Overview of a Sample Transfer Application
100%
M1 is switched to line control (100%). VFD
M1 control is transferred from M1 to M2 at time
period t2 as demand continues.
0%
100%
M2 is switched to line control (100%). VFD
M2 control is transferred from M2 to M3 at time
period t3 as demand continues.
0%
100%
M3
0%
t0 t1 t2 t3 t4
Figure 5-4. Graphical Representation of a Sample “Up Transfer” with Continued Demand

Table 5-1. Control States of Motors in a Sample “Up Transfer”
Time M1 M2 M3
t0 VFD (0-100%) Off (0%) Off (0%)
t1 VFD (0-100%) Off (0%) Off (0%)
t2 Line (100%) VFD (0-100%) Off (0%)
t3 Line (100%) Line (100%) VFD (0-100%)
t4 Line (100%) Line (100%) VFD (100%)
100%
M1
0%
100% M2 is switched to idle control (0%). VFD

control is transferred from M2 to M1 at time
period t8 as demand stays low. At this time,
M2 M1 control goes from Line to VFD.
0%
100% M3 is switched to idle control (0%). VFD control is

transferred from M3 to M2 at time period t7 as demand stays
5 M3
low. At this time, M2 control goes from Line to VFD.
0%
t5 t6 t7 t8 t9
Figure 5-5. Graphical Representation of a Sample “Down Transfer” with No Demand
Table 5-2. Control States of Motors in a Sample “Down Transfer”
Time M1 M2 M3
t5 Line (100%) Line (100%) VFD (100%)
t6 Line (100%) Line (100%) VFD (100-0%)
t7 Line (100%) VFD (100-0%) Off (0%)
t8 VFD (100-0%) Off (0%) Off (0%)
t9 VFD (100-0%) Off (0%) Off (0%)
5.2.6. The PLC Interface

All VFD control is accomplished over a RS485 serial communications network using a supported
communications protocol (e.g., Modicon Corporation’s MODBUS communications protocol). For
example, a Modicon-compatible PLC interface is located at each motor control center. These PLCs are
networked to a main MODBUS controller (e.g., a PC) and the communications board on the Perfect
Harmony drive. Refer to Figure 5-6.

*
Note: PLC interface refers to Modicon’s MODBUS Serial interface only.
MODBUS Plus Network

MCC1 MCC2
Main
Communication Board PLC PLC
MODBUS
Controller
V1 V2
Perfect Harmony VFD

L1 L2
L0
M1 M2
Line
Voltage
Figure 5-6. Communications Outline Drawing using a Modbus Network Configuration
5.2.7. “Up” Transfer (from VFD to Line Control)

This section provides the necessary steps to be followed for Up Transfer. The state transitions that occur 5
during these sequences are graphically shown in Figure 5-75-7. If the drive is not already running, the PLC
should begin by closing the VFD Output Contactor.
1. The PLC issues an “up transfer request” [UpTransferRequest_O].

2. If the drive is not already running, the PLC issues a “run request” [RunRequest_O].
3. The PLC provides the VFD with the output contactor acknowledge
[VFDContactorAcknowledge_O].
4. The VFD ramps to line frequency and phase-locks to the line for 3 seconds.
5. The VFD issues a “Up Transfer Permit ” command [UpTransferPermit_I] to the PLC.
6. The line contactor (e.g., L1) is closed by the PLC.
7. The PLC signals the VFD that the line contactor (e.g., L1) is closed.
8. The VFD receives the “line contactor closed acknowledge” signal
[LineContactorAcknowledge_O] and signals the PLC “up transfer complete”
[UpTransferComplete_I].
9. The PLC stops the VFD through the serial interface by removing the “run request”
[RunRequest_O].
10. The PLC removes the “up transfer request” [UpTransferRequest_O].
11. The VFD contactor (e.g., V1) is opened by the PLC.
12. The PLC removes the “line contactor closed” [LineContactorAcknowledge_O] signal to the
VFD.
13. New motor parameters are loaded through the serial interface for use in the next operation
(or the VFD stays idle). This step is possible in version 2.3 or higher of NXG software.

Run Request
(Input Flag)
VFD Contactor
(State: HI=ON/LO=OFF)
VFD Contactor Acknowledge

(Input Flag)
Up Transfer Request
(Input Flag)
Up Transfer Permit
(Output Flag)
Line Contactor
(State: HI=ON/ LO=OFF)
Line Contactor Acknowledge

(Input Flag)
5 Up Transfer Complete
(Output Flag)
Run State
VFD Ramp Up & Motor Operating
Synchronization on Utility
Figure 5-7. State changes during Up Transfer Sequence.

(The ↓↑ arrows indicate transitions that are used by the customer interface (for e.g. a PLC) to
control the process.)
5.2.8. “Down” Transfer (from Line to VFD Control)
The Down Transfer process (refer to Figure 5-8.5-8.)consists of the following steps. The line contactor is
assumed to be closed at the beginning of this procedure.
1. The PLC loads the correct motor parameters into the VFD through the serial interface.
(This step is possible in version 2.3 or higher of NXG software.)
2. The PLC issues a “down transfer request” [DownTransferRequest_O].
3. The PLC issues a “run request” [RunRequest_O] to the drive.
4. The PLC provides the VFD with the acknowledge from the line contactor
[LineContactorAcknowledge_O].
5. The VFD issues a “do down transfer” command [DownTransferPermit_I] to the PLC.
6. The PLC closes the VFD contactor and sends a signal to the VFD indicating the VFD
contactor (e.g., V1) is closed [VFDContactorAcknowledge_O].

7. The VFD locks-in to the line frequency and issues the “line contactor unlatch” signal
[LineContactorUnlatch_I] to the PLC.
8. The PLC verifies that the VFD has not faulted.
9. The line contactor (e.g., L1) is opened by the PLC and the signal
[LineContactorAcknowledge_O] is cleared.
10. The VFD signals the PLC “down transfer complete” [DownTransferComplete_I].
11. The PLC removes the “down transfer request” [DownTransferRequest_O].
12. The VFD follows the process setpoint from the PLC.
Run Request
(Input Flag)
VFD Contactor
VFD Contactor Acknowledge

(Input Flag)
Line Contactor Unlatch

(Output Flag)
Line Contactor
5
Line Contactor Acknowledge

(Input Flag)
Down Transfer Request

(Input Flag)
Down Transfer Permit

(Output Flag)
Down Transfer Complete

(Output Flag)
Motor Motor
Operating VFD Operating
on Utility Synchronization on VFD
to Utility
Figure 5-8. State changed during Down Transfer Sequence.

(The ↓↑ arrows indicate transitions that are used by the customer interface (for e.g. a PLC) to
control the process.)
5.2.9. Required Signals

Table 5-3 lists descriptions of signals that are required for synchronous transfer operation.

Table 5-3. Required Signals and Descriptions
Signal Description
UpTransferRequest_O Input signal from PLC used to request transfer from VFD to Line.
DownTransferRequest_O Input signal from PLC used to request transfer from Line to VFD.
VFDContactorAcknowledge_O Input from PLC to indicate the VFD output contactor status.
LineContactorAcknowledge_O Input from PLC to indicate the Line contactor status.
UpTransferPermit_I Permit to close the Line contactor during an Up Transfer.
UpTransferComplete_I Signal indicating successful synchronization of the drive to the
line, after receiving which the PLC can remove the run request
and up transfer request.
LineContactorUnlatch_I Signal to open the Line contactor during Down Transfer.
DownTransferPermit_I Permit to close the VFD output contactor during Down Transfer.
DownTransferComplete_I Signal indicating a successful Down Transfer, after receiving
which the PLC can remove the down transfer request.
5.2.10. Additional Parameter Description

Sync Transfer Menu (2700) is used exclusively for synchronous transfer applications. The menu items
and descriptions for this menu are listed in Table 5-4. This information is also available in Chapter 3 of
this manual.
5 Table 5-4. Sync Transfer Menu (2700)

Phase I gain 2610 2 0 15 Phase integrator gain
Phase P gain 2620 4 1 12 Phase proportional gain
Phase offset 2630 Degrees 0 0 180 Specifies the phase angle setpoint
used during Up Transfer. This is
expressed in degrees leading.
Phase error 2640 Degrees 1.5 0 5 Specifies the phase synchronization
threshold error during Up transfer. This
parameter adjusts the amount of error
allowed during phase-locking and is
expressed in degrees.
Frequency 2750 % 0 -10 10 Frequency offset used during Down
Offset transfer

5.3. Spinning Load Operation

The Spinning Load feature allows the drive to determine the speed of an already rotating motor. The
Drive is thus able to apply output voltages at the same frequency as the rotating motor and minimize any
chance of a speed transient. The Spinning Load feature in NXG Control is divided into two stages. During
the first stage Spinning Load operates automatically when enabled, and requires no user adjustments.
The drive control monitors motor flux and is able to provide an instantaneous restart. This stage is valid
as long as there is detectable flux in the motor. Typically the drive is capable of restarting instantaneously
if the time duration between drive disable and re-start is within 3 to 4 motor time constants.
The second stage consists of a scan feature during which a fixed level of current (set by the Current
Level Set Point parameter) of varying frequency is applied to the motor. The control monitors the
measured motor flux, and when the motor flux exceeds a flux threshold (set by the Scan End Threshold
parameter) the control assumes that the applied frequency is equal to the rotating speed of the motor.
This stage requires parameters to be tuned in order for the Scan to function properly.
5.3.1. Spinning Load Menu (2420)

Spinning 2430 Off This parameter sets the spinning load
load mode functional mode.
• Off
• Forward 5
• Reverse
• Both
Scan end 2440 % 20 1 50 While scanning, if the measured motor
threshold flux increases beyond this set point
then the drive assumes the present
output frequency to be the motor speed.
This threshold is normally set to 20%.
For motors with high magnetizing
current, this number should be reduced,
and vice versa.
Current 2450 % 20 1 50 This sets the amplitude of current that is
Level forced into the motor (by the drive)
setpoint while scanning for motor speed. This is
usually set to 20% or equal to the motor
no-load current setting.
Current ramp 2460 sec 0.01 0 5 This sets the time taken by the control
to establish the current level prior to
scanning. Default value is 0.01s.
Max current 2470 % 50 1 50 This sets the maximum value of current
during scanning. The drive trips/fails to
scan if the actual current exceeds this
value. Default value is 50%.
Frequency 2480 sec 3 0 5 This sets the time to scan from rated
scan rate speed to zero.
Note: Spinning load should always be enabled for Cell Bypass.

5.4. User I/O
5.4.1. Introduction
The I/O modules (Digital In/Out, Analog In/Out) allow user customization of the system for the application
requirements. The Next Gen control uses the Wago© I/O system. This system consists of DIN rail
mounted modules that can be easily expanded by simply attaching modules to the existing modules (see
photo below). The Configuration of the I/O is handled through the External I/O Menu (2800) see Table 5-
7. External I/O Menu (2800).
Modbus Coupler
End Terminator
Digital Input
Analog Inputs
Digital Outputs
5
Figure 5-9. Wago I/O System Photo
Table 5-6. Wago I/O Module Color Codes
Module Function Color

Digital Outputs Red
Digital Input Yellow
Analog Input Green
Analog Output Blue
Special Modules Colorless

5.4.2. Wago Modbus Coupler Settings

This section covers the settings of the MODBUS coupler used for communications between the NXG
control and the Wago I/O system. Normally this coupler is configured at the factory and there is no need
to make changes.
Figure 5-10. Wago MODBUS Coupler Bottom
This figure shows the bottom of the WAGO Fieldbus coupler case. To access the DIP switches you have
to remove the cover. To do so, you must pry with just a little pressure the sides on the bottom of the unit
5
where there are little “bump” on either side. You can the start applying pressure from the top where the
DB9 connector is, pushing down.
Figure 5-11. Wago MODBUS Coupler with Cover lifted
This picture shows how the cover should lift off of the WAGO Fieldbus Coupler to give access to the
DIPswitches.

Figure 5-12. Wago MODBUS Coupler DIP switch settings
This figure shows the actual DIP switches in the WAGO Fieldbus Coupler. The first three switches of the
top DIP switches, labeled FR on the cover plate, are to set the baudrate. Switch 1 is off, switch 2 is on,
and switch 3 is off. The correct settings are shown here and on the picture that displays the outside
5 cover that is removed to access the DIP switches.
Figure 5-13. Wago MODBUS Coupler DIP switch settings label

5.4.3. External I/O Menu (2800)

The External I/O is configured from the External I/O Menu (2800). The user must define the total number
of I/O’s per the Table below for each type of I/O (Analog I/O and Digital I/O). If the I/O count is incorrect
the Drive will indicate a “Wago Configuration Fault”. Once the correct number of I/O is entered, the fault
can be cleared by a Fault Reset.




5.4.4. Digital I/O

The Digital I/O data is only available and useable within the System Program. The System Program has
predefined variable names for External Digital Inputs and Outputs. The user has the choice of writing a
system program and making use of these I/O for whatever functionality or logic is required. The I/O is 5
assigned system program variable names based on the location or order that the module is inserted into
the Wago I/O system. For example, if a single Digital input module and a single Digital Output module
are inserted into the Wago system the system program would define them as follows:
Digital Input Module #1: (assuming the module is a 4 input module)
ExternalDigitalInput01a_I through ExternalDigitalInput01d_I
Digital Output Module #1: (assuming the module is a 2-output module)
ExternalDigitalOutput01a_I through ExternalDigitalOutput01b_I
If there are additional modules added they would be defined as follows:
Digital Input Module #2: (assuming the module is a 4 input module)
ExternalDigitalInput01e_I through ExternalDigitalInput01h_I
Digital Output Module #2: (assuming the module is a 2-output module)
ExternalDigitalOutput01c_I through ExternalDigitalOutput01d_I
5.4.5. Analog Output Menu (4660)

The analog outputs are set up via the pick list parameters in the Analog Output menus (4661 through
4721). First a pick list is presented to allow selection of the variable to be output to the Analog Output
module. To complete the setup the type of output, bipolar, unipolar and the percent of the value to
provide full scale analog output to determine the scaling for the variable.

Table 5-8. Analog Output #1 (4661)

Analog 4662 This variable sets the input source for
variable analog output #1.
Output 4663 Sets the output type for the module
module type (Unipolar or Bipolar).
Full range 4664 % 0 0 300 Scales the output range of the variable
selected.
5.4.6. Analog Input Menu (4100)

The analog inputs are set up to receive the converted data from the user modules selected as either 0 -
20mA, 4 - 20mA, 0 - 10V. The user defines the minimum and maximum values for scaling as well as the
Loss of Signal (LOS) threshold and action. All Analog inputs are available to be used by the Comparator
for additional control functionality (refer to the Comparator Setup Menu (4800) in Chapter 3).

Source 4105 This parameter sets the input source
for analog input #1. Can be anyone of
24 External Analog Inputs.
5
Type 4110 0 - 20ma This parameter sets the operational
• 0 - 20mA
• 4 - 20mA
• 0 - 10V
Min input 4120 Minimum Analog input
Max input 4130 Maximum Analog input
Loss point threshold 4140 Threshold where loss of signal action
is activated.
• Preset
• Maintain
• Stop
Loss of signal setpoint 4160 Loss of signal preset speed.
5.5. Signal Frame of Reference for Motor Control

The control signals used for controlling the motor must be assigned a polarity for use over four quadrants
of control to maintain consistency of the algorithms. This section clarifies what they are and what their
polarities mean in the various quadrants.
5.5.1. Frame of Reference

The four-quadrant frame of reference is defined as the four quadrants of operation of a motor. They are
divided left to right by the direction of rotation and from top to bottom by the torque in the machine.

Energy flow from the drive into the machine is called motoring and out of the machine and into the drive is
called regeneration or braking. The diagram is shown in Figure 5-14
Figure 5-14 shows the relationship between the polarities of the signals. For example, starting at rest (in
the ordinances of the two axes), if a positive torque is applied to the motor, the acceleration is positive
and the resultant speed increases in the forward direction. This is governed by the following equations:
T
α= ω = ∫ αdt
J
where:
α = acceleration T = torque
J = inertia (an unsigned magnitude) ω = rotational speed.
+slip
−P Braking +T Motoring +P
+α +α
−V II I +V
−ω +ω
Reverse Forward
III IV
−α −α
5
+P Motoring Braking −P
−T
−slip
Figure 5-14. Four Quadrant Operation of a Motor
This then carries over into quadrant IV showing that a negative torque produces negative acceleration
(deceleration) stopping the motor. If however, the same torque is applied continuously, the speed of the
motor will decrease to zero and begin to accelerate in the opposite direction producing a negative
rotational speed (ω) in what is now quadrant III. Now if a positive torque is applied, the motor enters
quadrant II and begins to decelerate. Since the rotational speed is negative and begins to diminish and
approaches a positive value, the acceleration must be positive to conform to the above equations. Again,
if the torque is held constant, the motor will slow to zero and then accelerate in the forward direction
passing back into quadrant I.
The injection frequency must always be opposing the direction of rotation and is only used in the case of
braking or negative energy flow. Therefore it is zero in the motoring quadrants (I and III) and is the
inverse polarity of the electrical frequency in the braking quadrants (II and IV).

5.5.2. Signal Polarities
Table 5-10. Signal Polarities
Signals Quadrant 1 Quadrant 2 Quadrant 3 Quadrant 4

Rotation speed (ωr) + - - +
Electrical frequency (ωs) + - - +
Slip (ωslip) + + - -
Torque + + - -
Current (Iq) + + - -
Voltage (vqs) + + - -
Acceleration + + - -
Injection Frequency (ωinj) 0 + 0 -
Power (flow) + - + -
Mag Current (Id) + + + +
Voltage (vds) + + + +
5 * Note: For the electrical frequency (ωs) in the braking quadrants (II and IV) where the slip opposes
the rotational speed, when the speed magnitude approaches the slip magnitude, the electrical
polarity is uncertain (when the slip magnitude is greater than the rotor speed, the sign will match
that of the slip rather than the sign of the rotor speed). This is due to the relationship
ω s = ω r ± ω slip .
5.6. Mechanical Bypass

When the Perfect Harmony was first introduced, its most salient attributes were improved power quality at
the utility interface, and at the motor interface. A third attribute is now becoming recognized, which offers
extremely high reliability by utilizing the inherent redundancy of these drives. Mechanical Cell Bypass is
the feature that allows this third attribute to be realized.
The Mechanical Cell Bypass option is implemented by adding a contactor to the output of each cell as
shown in Figure 5-15. Now when the control detects that a cell has failed, a command can be sent to
close the appropriate contactor. This simultaneously disconnects the cell output from the circuit and
connects the two adjacent cells together, effectively taking the failed cell out of the circuit. The drive can
then be restarted and operation can continue at reduced capacity.
It does not matter which of the components has failed within the cell, as long as the failure can be
detected. In fact, even a failure in the fiber optic link that communicates to the cell can be detected and
bypassed. Therefore, this approach protects against the failure of any component in the power circuits or
in the communications circuits, rather than protecting the drive against power semiconductor failure only.
The amount of reduction in capacity that can be tolerated will depend on the application, but in most
cases a reduction in capacity is preferable to a complete shutdown. Neutral Point Shift is a feature that
was developed to minimize the reduction in capacity after a bypass. Neutral Point Shift is discussed in
Section 5.8. Another related feature is Fast Bypass. This feature is designed to quickly bypass a cell and
get the drive running again in less than ½ second. Fast Bypass is discussed in Section 5.7.

BYPASS
CONTACTOR
Q1 Q3 COIL
FROM OUTPUT
Q2 Q4
DEDICATED OF POWER
SECONDARY MODULE
OF INPUT
TRANSFORMER FIBER OPTIC
LOCAL CONTROL CIRCUITS SIGNALS TO & FROM
MASTER CONTROL
Figure 5-15. Typical Cell with Bypass Contactor
5.7. Fast Bypass

Up time is an important factor in many processes. A Medium Voltage drive is often a critical part of the
process and even small interruptions in output torque of a Medium Voltage drive can cause the process
to stop. This can result in lost material and production time.
Fortunately, in general, a process can ride through an interruption of ½ second or less. The NXG control
has a feature that is designed to limit the interruption of torque to the process to less than ½ second if a
cell failure is detected. This feature is called Fast Bypass. The conditions as to when the drive can meet
this ½ second maximum interruption are described below. 5
All cell failures are detected in hardware. This hardware is designed to quickly shut down the drive so that
additional damage will not occur. Once this happens the control is notified. The control can then quickly
determine which cell failed and the bypass process can be started.
When the drive trips and stops delivering torque to the motor, the motor acts like a generator and
produces a voltage on the drive output terminals. This voltage decays over time, but can be near the
drive rated output voltage for a few seconds. If a cell is bypassed the remaining cells may not be able to
support this voltage and damage can occur.
To prevent this damage, a check is done in the control to verify if the motor output voltage can be
supported before a cell is bypassed and the drive is restarted. If this check passes when it is first done
the cell can be bypassed and torque can be delivered to the drive in under ½ second from the time the
fault occurred. If the motor voltage is too high, an additional delay may be needed to allow the voltage to
decay.
To guarantee that the drive will bypass a cell fault in under ½ second the drive needs to be running at an
output voltage that can be supported by one less than the existing number of cells per phase. One way is
for the drive to be sized so that it has more than the minimum number of cells required to provide the
voltage needed. Another way is to limit the maximum speed. These issues will have been studied and
resolved before the drive is installed.
*
Note: In a drive with an additional cell per phase, bypass in under ½ second will happen only on
the first cell failure per phase. If a second cell in a phase fails the control needs to wait for the
motor voltage to decay, hence the bypass time may exceed ½ second.
*
Note: In Fast Bypass the drive will start to deliver torque to the motor in ½ second after a fault
occurs. It may take longer for the drive to get back up to the set-point speed.

5.8. Neutral Point Shift During Bypass

Since the cells in each phase of a Perfect Harmony Drive are in series, bypassing a failed cell has no
effect on the current capability of the drive, but the voltage capability will be reduced. Usually the required
motor voltage is roughly proportional to speed, so that the maximum speed at which the drive can fulfill
the application requirements will also be reduced. Therefore it is important to maximize the motor voltage
available after one or more cells have failed.
Figure 5-16 through Figure 5-17 illustrate the voltage available from a Harmony drive, where the cells,
represented by circles, are shown as simple voltage sources. Figure 5-16 shows a 15 cell drive in which
no cells are bypassed. With 100% of the cells in use, 100% of the original voltage is available. The
voltage commands to the three phase groups of cells will have phase A displaced from phase B by 120°,
and from phase C by 120°.
A
15 Module Drive 100% of the Modules
A5
with no Modules are in use. 100% of
Bypassed. full voltage is
A4 available.
A3
A2
VAC VBA
A1
120 o
5
TYP.
C1 N B1
C2 B2
C3 B3
C4 B4
C C5 B5 B
VCB
Figure 5-16. A Simplified diagram of a 15 Cell Drive
When cells are bypassed in one of the drive phases, the output voltage will tend to become unbalanced,
as illustrated in Figure 5-17. One possible remedy is to bypass an equal number of cells in all three
phases, even though some may not have failed. Figure 5-18 illustrates this approach. Obviously, this
method prevents unbalance but sacrifices possible voltage capability. In Figure 5-18, 87% of the cells
are functional, but only 60% are in use, and only 60% voltage is available.
15 Module Drive A 87% of the Modules

after Bypass A3 are in use, but the
of 2 Modules output voltage is
in Phase C. A2
imbalanced.
A1
120 o
VAC TYP. VBA
C1 N B1
C2 B2
C3 B3
C4 B4
C C5 B5 B
VCB
Figure 5-17. Drive output with 2 Cells Bypassed

15 Module Drive after A 87% of the Modules

Bypass of 2 Modules in are OK, but only
A3
all Phases. Balance 60% are in use.
is restored. 60% of full volt-
A2
age is available.
A1
VAC 120 o VBA
TYP
C1 N B1
C2 B2
C C3 B3 B
VCB
Figure 5-18. Drive output re-balanced by Bypassing Functional Cells.
A better approach is illustrated in Figure 5-19. This method takes advantage of the fact that the star-point
of the cells is floating, and is not connected to the neutral of the motor. Therefore the star-point can be
shifted away from the motor neutral, and the phase angles of the cell voltages can be adjusted, so that a
balanced set of motor voltages is obtained even though the cell group voltages are not balanced.
ASI Robicon calls this approach Neutral-Shift, and has a US Patent (5,986,909) that covers it. This
approach is equivalent to introducing a zero-sequence component into the voltage command vectors for
the cells. In Figure 5-19 the full remaining 87% of functional cells are in use, and 80% of the original
voltage is available. The phase angles of the cell voltages have been adjusted so that phase A is 5
displaced from phase B and from phase C by 132.5°, instead of the normal 120°.

Bypass of 2 Modules A3
are in use. 80% of
in Phase A only, full voltage is
and Adjustment available.
A2
of phase Angles.
A1
VAC VBA
o
132.5 132.5 o
C1 B1
C2 95o B2
C3 B3
C4 B4
C5 B5 B
C
VCB
Figure 5-19. Drive output re-balanced by Adjusting Phase Angles (Neutral-Shift)
The same neutral-shift approach can be applied to more extreme situations, as is illustrated by
Figure 5-20 and Figure 5-21. Figure 5-20 shows a drive which originally had five cells per phase, or a
total of 15 cells. All five cells remain in phase A, but one cell has failed in phase B and two cells have
failed in phase C. Without neutral-shift, all phases would need to be reduced to match the cell count of
phase C in order to maintain balanced motor voltages. One functional cell would be bypassed in phase B,
and two functional cells would be bypassed in phase A. Only 60% of the original cells would remain in
use, and only 60% of the original voltage would be available.

However, with the neutral-shift approach shown in Figure 5-20, only the failed cells are bypassed. The
phase angles of the cell voltages have been adjusted so that phase A is displaced from phase B by 96.9°
and from phase C by 113.1°, instead of the normal 120°. The star point of the cells no longer coincides
with the neutral of the motor voltages, but the motor voltage is still balanced. The neutral-shift keeps 80%
of the original cells in use, and 70% of the original voltage is available.
A
15 Module Drive after 80% of the Modules
Bypass of 1 Module are in use. 70% of
in Phase B, and 2 A5 full voltage is
Modules in available.
Phase C. A4
VAC A3 VBC
A2
113.1 A1 96.9
C1 B1
C2 B2
C B3 B4 B
C3
VCB
Figure 5-20. Drive output after loss of 3 Cells
As another example, Figure 5-21 shows the same 15-cell drive. All five cells remain in phase A, but two
5 cells have failed in phase B and three cells have failed in phase C. Without neutral-shift, one functional
cell would be bypassed in phase B, and three functional cells would be bypassed in phase A. Only 40%
of the original cells would remain in use, and only 40% of the original voltage would be available.
However, in Figure 5-21 only the failed cells are bypassed. The phase angles of the cell voltages have
been adjusted so that phase A is displaced from phase B by 61.1° and from phase C by 61.6°. The star
point of the cells is far removed from the neutral of the motor voltages, but the motor voltage is still
balanced. The neutral-shift keeps 67% of the original cells in use, and 50% of the original voltage is
available.

Bypass of 2 Modules are in use. 50% of
in Phase B, and 3 full voltage is
Modules in A5 available.
Phase C.
A4
VAC VBA
A3
A2
C VCB B
C2
61.6
A1 61.1 B3
B2
C1 B1
Figure 5-21. Drive output after loss of 5 Cells
Figure 5-22 compares the available voltage after one failure with and without using neutral-shift. In many
cases, the extra voltage available with neutral-shift will determine whether or not a cell failure can be

tolerated. The voltage capability of a drive after cell bypass can be calculated by using the following
procedure.
If X is the largest number of cells in bypass in two of the phases, then the maximum voltage at
the drive output will be:
Vout_bypass = Vout * (2*N - X) / (2*N),
where, Vout is maximum output voltage that the drive can deliver (Vout = 1.78*N*Vcell), N is the
number of ranks (or the total number of cells = 3*N), and Vcell is the cell voltage rating.
Example: Consider a drive with 18 cells each rated for 690V. The maximum output voltage that
this drive can deliver is (with N = 6 and Vcell = 690),
Vout = 1.78 * 6 * 690 = 7.37 kV.
Now, if after cell bypass, the drive has 6 cells operational in phase A, 5 cells in phase B
and 4 cells in phase C, then the maximum voltage that the drive can produce with
neutral shift from the above formula is (with X = 1 + 2 = 3, because 2 cells in phase C
and 1 cell in phase B are bypassed),
Vout_bypass = 7370 * (2 * 6 - 3) / (2 * 6) = 5.53 kV
The ratio (Vout_bypass / Vout) is available as the Max. Available Drive Voltage (%MAV) for display on the
Keypad and for use in the Comparator and Analog Output Menus.
100
With Neutral-Shift
Available after One Failure
Percent of Original Voltage
90
5
80 Without Neutral-Shift
70
60
3 4 5 6 7 8
Original Number of Modules per Phase
Figure 5-22. Available Voltage after First Failure
The drive control uses the information of faulted cells to automatically calculate the phase angles of cell
voltages to maintain balanced motor voltages. During neutral-shift, each phase of the drive operates with
a different power factor. Under lightly loaded conditions it is possible that one or more phases is
absorbing real power while the other phase(s) are delivering power to the motor. In order to prevent the
cell dc-voltage (corresponding to cells that are absorbing real power) from increasing (and subsequently
causing a drive trip condition) the control automatically enables the “Energy Saver” function. Under light
loads the energy saver function reduces motor flux sufficiently so that the motor operates with 70% power
factor. At this operating point the magnetizing and torque components of motor current are equal and all
cells deliver real power to the motor. As motor load is increased, the motor flux level is automatically
increased to maintain 70% power factor until rated flux (or maximum possible flux) is achieved. This
function ensures that the cells are delivering real power under all operating conditions.

*
Note: In Cell Bypass the drive will invoke Energy Saver under light loads to prevent certain cells
from charging-up.

5.9. Power Monitoring

Many Harmony Drives that ASI Robicon builds have requirements for optional Power Quality Meters
(PQM). Adding PQMs can be an expensive option. NXG control builds this functionality into the drive.
NXG control does processing on the input waveforms to aid in control of the drive. Because of this the
drive can determine and display information about the drive input. Likewise, since the control is
continuously sampling the drive output, the drive output information can also be displayed. Table 5-11
5-11and
Table 5-12 list the parameters that can currently be displayed. More parameters will be added in the
future. See Meter Menu (8) for details on displaying this information.
Table 5-11. Input Table 5-12. Output
Input Display Parameters Output Display Parameters
Phase A Input Current Motor Current
Phase B Input Current Motor Voltage
Phase C Input Current Magnetizing Current
Phase A Input Voltage Torque Current
Phase B Input Voltage Motor Speed
Phase C Input Voltage Output Torque 5

Input Frequency Motor Flux
Average Input Power Motor Slip

(kilowatts)
Input Power Factor Output Power
Average Input Current THD Output KWHrs
Efficiency
Input KWHrs
Input Reactive Power (kVAr)
5.10. Dual Frequency Braking
5.10.1. Introduction to Dual Frequency Braking

There are many applications for VFDs that need occasional negative torque for braking. Unfortunately, at
present the most popular static converters used for VFDs are not capable of returning energy to the
utility. Such applications therefore require additional circuits to regenerate the braking energy into the AC
mains, or to dissipate the braking energy in a resistor. Both of these solutions add cost to the VFD, and
are especially undesirable for large modular medium-voltage VFDs.
Additional power devices can be avoided by using the existing circuits to inject DC current into the motor
windings. This method dissipates the braking energy in the motor, and adds little cost to the VFD.

However, DC injection braking is not very effective unless the available current is several times rated,
especially for large motors. Another drawback is that estimation of motor speed is very difficult during DC
injection braking.
Dual Frequency Braking is another method in which braking energy can be dissipated in the motor. Dual
Frequency Braking provides much higher torque per ampere than DC injection braking, and permits
continuous estimation of motor speed. Like DC injection braking, this approach is implemented in
software and requires no additional hardware that can reduce the reliability of the drive.
ASI Robicon has a patent on Dual Frequency Braking (US 6,417,644).
5.10.2. Operation
Dual Frequency Braking causes extra losses to be induced in the motor, by applying a second set of
three-phase voltage vectors to the motor; in addition to the normal set of voltage vectors used for speed
control. These extra losses are used to absorb the kinetic energy released during braking.
There are two side effects of Dual Frequency Braking (DFB) that are protected against as follows.
1) Torque pulsations: The motor can be subjected to as much as 70% torque pulsation at the pulsation
frequency with DFB. However, the customer can select the torque pulsation frequency via the menu
entry for Pulsation Frequency to avoid any mechanical resonance frequencies.
2) Motor heating: The losses generated during DFB cause motor heating and limit the number of
deceleration ramps (from full speed to zero) that can be performed repetitively. Motor heating due to
the additional losses is designed to be no worse than a line start. The software motor thermal model
in NXG monitors motor heating due to these losses and can provide an alarm and/or a trip to indicate
excessive heating. (Refer to the Motor Thermal Overload Protection section in this chapter for
5 information on the thermal model.) Since the motor heating is no worse than that for a line start, MG-
1 Part 20.43 can be used as a guide to determine the frequency of stops with DFB. MG-1
recommends two starts in succession with the motor initially at ambient temperature or one start with
the motor at a temperature not exceeding its rated operating temperature. This recommendation
applies when the load inertia and load torque are those for which the motor is designed. With lower
values of load inertia and/or smaller speed reductions, DFB can be used more frequently.
The second set of voltage vectors creates a counter-rotating flux vector that produces high slip in the
machine and generates these additional losses in the motor. The pulsation frequency is adjustable via a
menu setting to allow critical frequencies (i.e. mechanical resonances) to be avoided. The injection
frequency is always in opposite rotation to the applied motor electrical frequency (speed and direction of
the machine). Figure 5-23 is a block diagram showing how the two voltage vectors (normal VA1 and loss-
inducing VA2) are added together to produce the braking function. Figure 5-24 is a scope picture of the
two voltage vectors added together. The higher frequency voltage waveform VA2 is riding on the lower
frequency waveform VA1.
*
Note: The pulsation frequency is an input from the menu system (Parameter ID 3370) that is
selectable by the end user. It provides the reference to produce the desired additional braking for
the system and is adjustable in order to avoid resonance in the system.

FLOW OF BRAKING POWER VIA DC LINK
VA1 VA2 IA1+IA2

ZERO-
SEQUENCE
VOLTAGE
IB1+IB2 AC
INDUCTION
VZS VB1 VB2
MOTOR
VC1 VC2 IC1+IC2
NORMAL LOSS-INDUCING
THREE-PHASE THREE-PHASE
VOLTAGES VOLTAGES
EQUIVALENT CIRCUIT TO OUTPUT OF DRIVE
Figure 5-23. Block diagram showing Dual Frequency voltages being added together with the normal three-
phase voltages.
Va,ref
(50%/div.)
ωs
(50%/div.)
Ia
(150%/div.)
Figure 5-24. Scope picture showing Dual Frequency Braking waveform
In this method the first vector set controls the torque and flux in the motor, and is nearly synchronous.
The second vector set induces losses in the motor, to absorb the braking power returned by the first
vector set. The amplitudes of the two vector sets are coordinated to best utilize the current and voltage
limitations of the converter. The frequency of the loss-inducing vector set is chosen with the goal of
maximizing losses per ampere. This automatically minimizes the torque pulsations by minimizing the
loss-inducing current.
The dominant losses in a motor are conduction losses, proportional to I2R. Maximum losses per ampere
require a large value of R. The nominal resistance of the motor windings is fixed by the design.
Fortunately, the effective resistance depends on the frequency. The rotor windings are deliberately
designed to exhibit a strong “deep-bar” effect, so that their resistance (above a low threshold) increases
roughly proportional to frequency.
In principle the frequency of the loss-inducing vector set should be as high as possible, for maximum
effective resistance. Since this high loss-inducing frequency produces negative slip, it will have negative
sequence. The maximum applied frequency is limited by the control bandwidth of the converter, and also

by the available voltage. However, because the loss-inducing vector set is negative sequence, the rotor
frequency will be higher than the stator frequency due to the rotational speed.
5.10.3. Setting parameters for Dual-Frequency Braking

The table below provides a description of parameters in the Braking Menu (ID 3350). The Pulsation
Frequency should be chosen such that it avoids the (mechanical) resonant frequencies of the system
(motor, shaft and load). A study of the mechanical system is required to determine these resonant
frequencies. The Brake Power Loss parameter sets the initial value of motor losses; the default value is
satisfactory for most cases. The maximum voltage that is applied at the second (loss inducing) frequency
is set by VD loss. This parameter cannot be set to a value higher than 0.5p.u. Adjustment of this
parameter will have a direct effect on the achievable braking torque. Braking Constant sets the ratio of
the power losses created in the motor to the power absorbed by the drive during braking. Using the
default value gives sufficient margin and prevents the cell dc-bus voltages from increasing to trip levels.
Table 5-13. Description of parameters for Dual-Frequency Braking (DFB).
Parameter Name Units ID # Description Usage / Help

Enable 3360 Enable or disable dual frequency User must be aware of torque
braking (DFB). pulsations and motor heating
generated with DFB.
Pulsation Hz 3370 Torque pulsation frequency when Adjust for a different torque pulsation
Frequency DFB is enabled. frequency. The control always
limited resolution.
5 Brake Power Loss % 3390 Amount of high frequency losses at Use default value of 0.25%.
the on-set of DFB.
VD loss p.u. 3400 Max amplitude of the loss inducing Lower the entered value for reduced
voltage. braking. Max. value is 0.5 p.u.
Braking Constant p.u. 3410 Ratio of motor (induced) losses to Adjust to higher value if dc-bus over-
power absorbed from load. voltage trip occurs during
deceleration with DFB.
5.10.4. Limitations
The drive output current plus the braking current must not exceed the current capability of the cells in the
drive. Hence the braking torque is limited in the drive and is greatest at slow speed and smallest at high
speed. Figure 5-25 shows the typical braking torque that can be expected with Dual Frequency Braking.

70
60
Percent of Rated Torque

50
(Imax = 100%)
40
30
20
10
100
13
20
27
33
40
47
53
60
67
74
80
87
94
0
Percent of Rated Speed
Figure 5-25. Best case braking torque with Dual Frequency Braking for a typical motor.
5.11. Energy Saver

Energy saver control allows the reduction of motor losses (and improves overall efficiency) when the
demanded motor load is low. To activate the energy saver control, adjust the Energy Saver Min Flux
Demand (parameter ID 3170) in the Flux Control Menu (3100) to a value that is less than the Flux
Demand (ID 3150, which is typically set to 1.0). Depending on the motor load, the control will reduce 5
motor flux to a level between the Energy Saver Min Flux Demand and Flux Demand. As motor load
increases, the control will increase motor flux until the value set by Flux Demand is achieved. Note that
the response of the drive to sudden load changes is reduced with lower flux demand.
Energy saver is automatically invoked when an unbalanced set of cells is present after fast bypass.
Under light loads, it is possible for one or more phases to be absorbing power from the motor. To prevent
the cell DC bus from charging up to a trip level, the control reduces motor flux to improve power factor,
which allows all three phases to provide power to the motor, and prevents the cells from charging up.
5.12. Motor Thermal Overload Protection
Table 5-14 . Parameters for Motor Thermal Overload protection.
Parameter ID Description Default

Overload select 1130 Selects the overload trip algorithm. Inv time w/
• Constant (fixed current-based TOL) speed derating
• Straight inverse time (motor temperature based TOL)
• Inv time w/ speed derating (motor temperature based TOL)
Overload 1139 Sets the thermal overload level at which a warning is issued. 100.0
pending
Overload 1140 Sets the motor thermal overload trip level at which the timeout 120.0
counter is started.
Overload 1150 Sets the time for the overload trip. 60.0
timeout
Speed Derate 1151 This menu sets allowable motor load as a function of speed. Sub-menu’s
Curve

Parameter ID Description Default

Maximum Load 1159 Sets the maximum load inertia that the motor can line start 0.0
Inertia without exceeding maximum temperature.
NXG Harmony control provides Motor Thermal Overload (TOL) protection to prevent the motor from
being subjected to excessive temperatures. TOL protection of the motor can be set up using the menus
shown in Table 5-14 . The “overload select” parameter allows one of three options to be selected for
motor protection. The first model, which is called “constant,” is based on the current flowing into the
motor. A Motor Thermal Overload Alarm 1 is issued as a warning to the user (of an impending overload
fault) when the motor current exceeds the “overload pending” parameter. When the drive current exceeds
the “overload” setting, Motor Thermal Overload Alarm 2 is issued and a thermal trip timer is started. If this
condition is present for a period greater than the time set in the “overload timeout” parameter, the drive
will trip and annunciate the event as Motor Thermal Overload Fault. It should be noted that both the
Alarms – 1 and 2 – have to be enabled through the SOP for the drive to display those conditions.
The second and third thermal models, which are called “straight inverse time” and “inverse time with
thresholds,” use a software motor thermal model to determine motor temperature. For these options, the
“overload pending” and “overload” settings represent the motor temperature limits (in percent of rated
motor temperature) at which the overload warning and trip are generated. A brief description of the
thermal model follows.
Motor
Motor loss + 1 temperature
Motor voltages,
currents calculation
Σ M TH
-
5
Motor
parameters Motor cooling
model
Speed derate
curve
Figure 5-26. Block diagram of motor thermal model.

The motor model estimates motor temperature based on the net heat generated in the motor and its
thermal mass. A block diagram of the implementation is shown in Figure 5-26 The heat generated in the
motor is estimated from the stator voltages, currents and motor parameters, while an estimate of the heat
transferred from the motor (due to motor cooling) is made from the allowable motor current (more on this
in the following paragraph). The motor loss calculation also includes the losses generated with Dual-
Frequency Braking. The thermal mass (shown as MTH) of the motor (or its heat capacity) is determined
from the maximum load inertia listed in Table 20-1 of NEMA Standard MG-1 1993 Part 20.42. The user
has the option of entering a known value of max load inertia as well (which can be obtained from the
manufacturer).
If “straight inverse time” protection is chosen, then it is assumed that the motor has an allowable current
level of 100% (for example, when the motor is equipped with a constant-speed cooling fan). With “inverse
time with speed-derating,” the allowable current level is determined from the speed-derating curve
entered through the keypad. This curve requires the user to enter allowable motor load for various speed
breakpoints. The default-derating curve provides breakpoints for a quadratic cooling curve (and is shown
in Figure 5-27). The motor manufacturer normally provides data for this curve. The control software uses
the allowable current level to determine the cooling capability of the motor.

If the user’s preference is to enter a fixed value of an allowable current level other than 100% (as with the
“straight inverse time” option), the speed-derating curve can be modified to have the same desired level
for all the breakpoints.
Figure 5-27. Default speed-derating curve showing maximum motor load as a function of speed.
5.13. Process Availability - The Perfect Harmony Advantage
Process availability is the primary prerequisite for applying a Medium Voltage VFD system in a process
critical application. By combining the capabilities of Perfect Harmony’s unique distributed power
architecture, with the power of the NXG control, and the patented advanced power cell bypass feature, it
is possible to deliver unparalleled opportunities for improved process availability. It is also essential that
the process operator receive complete and accurate information on VFD status, to allow for process 5
adjustments that can preclude process trips and disruptions in process capability.
5.13.1. What is ProToPS?

ProToPS is an acronym that stands for "Process Tolerant Protection Strategy". ProToPS is a standard
implementation of the VFD SOP (System Operating Program). The ProToPS goal is simply to put the
process operator in control of the process. ProToPS is a system program implemented from a customer
process perspective.
ProToPS provides the operator with indication of a change in state in the VFD. These annunciation's
identify changes that can impact the ability of the VFD to meet process demands, or to provide advance
indication of a pending VFD trip. ProToPS allows the process operator to make process corrections to
maintain the VFD in use in service, or adjust the process to address a pending VFD trip.
With ProToPS the process operator not only knows the general status of the VFDs, but also understands
the VFD condition that has caused the general alarm to exist.
5.13.2. How Does ProToPS Work?

In the ProToPS SOP all of the automatic roll-back flags are turned off, and both cell bypass and auto-
restart are implemented as standard. The need to roll-back is now provided, but the process operator is
now able to implement a roll-back as part of a process correction, as opposed to having the VFD roll-back
either dictating, or in worse case upsetting, the process.
ProToPS takes the standard fault indications available in the VFD and categorizes them into four basic
major categories as follows:
1. Alarm
An alarm is an indication that a VFD parameter limit has been reached, or that a VFD system
condition is present. An alarm provides the operator with awareness of the condition, but

demands no immediate action. Examples of alarms include: over-voltage, under-voltage, and

ground fault.
2. Process Alarm
A process alarm is an indication that a VFD parameter limit has been exceeded and that the
process either should be limited, or that the VFD capacity to meet the process demand is limited.
Examples of process alarms include thermal limits above the rated limit and the condition of a cell
having been bypassed.
3. Trip Alarm
A trip alarm provides a clear indication that a VFD high parameter limit has been reached. A trip
alarm is a indication that a VFD trip is pending. The operator receives a message that that unless
the alarm can be cleared by a process change the VFD will trip.
4. Trip
Certain VFD faults cannot be provided with advance warning. This limited number of faults will
result in a VFD trip. A trip message is also annunciated when a trip alarm time limit has been
exceeded. The number of mandated trips is considerably reduced with the implementation of
GEN III cell bypass.
With ProToPS the (VFD Run) signal is maintained as "true" and the (VFD Trip) signal is
maintained as "faults" for all alarm states.
5.13.3. ProToPS Implementation

With ProToPS the four main protection indication categories are provided as separate digital output
5 signals. The concept is to provide the operator, or the process program, with a clear message to indicate
a status change in the VFD. These five digital outputs are delivered from the Wago I/O system. The
location of the five outputs is maintained as a standard set of TB2 terminations.
The specific information on the VFD parameter change is indicated (along with the general category
information) as a serial address across a serial communications interface. Any serial communications
protocol supported by the VFD product can be supported in the ProToPS implementation.
If other specific digital output information is required for a specific customer project that information must
be mapped to a new digital output point on an additional digital output module. The four basic category
outputs must be present as digital outputs, at the standard designated TB2 terminal point
locations, to validate the ProToPS implementation.
5.13.4. The ProToPS Advantage

With advanced contactor cell bypass there are virtually no cell faults or cell communication faults that are
non-bypassable. With NXG control the need for the designation "Transient Alarm" has disappeared as all
bypassable faults become process transparent.
With ProToPS and the NXG control, combined with the unique benefits of the Perfect Harmony cell based
distributed power technology, process availability can be considerably enhanced and, the process
operator can truly control the process.
5.14. PID Controller
The NXG Control has a built-in PID controller available for use as a process control input of the NXG
Command Generator. The PID is depicted in the figure below and also in the Command Generator Diagram
drawing number 459713 located in Appendix C. The PID output is selected as the Speed Demand for the
system by setting the System Program flag “RawDemandPid_0” to true. The PID command feedback source

is fixed from Analog Input #2. This Analog input can be any of the available Analog inputs within the system,
but must be designated as Analog input #2 in the setup menu (refer to section “Analog Input #2 Menu (4170)”
in Chapter 3). The PID command has two possible sources: Analog input #1 or the PID set point menu item
(ID 4410). The source for the PID command is controlled by the state of the system program flag
“PidMenu_0”. Setting this flag to true selects the PID set point menu as the source. Setting this flag to false
selects Analog Input #1. Analog input #1 source is configured from the “Analog input #1 menu (4100)” in
chapter 3. Refer to “PID Select Menu (4350)” chapter 3 for details regarding the PID parameters.
PidMenu_0 = true
PID SETPOINT
Analog Input #1 RawDemandPid_0 = true

PID
PidMenu_0 = false
CONTROLLER
Analog Input #2
Figure 5-28. PID Controller

∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics THEORY
CHAPTER 6: THEORY
6.1. Introduction
The Harmony series of drives from ASI Robicon is intended for use with standard medium-voltage three-
phase AC induction and synchronous motors. The induction motor is widely used due to its robust and
simple construction, its tolerance for bad environments, and its low cost. On the other hand, a
synchronous motor is used in applications where very high efficiency or high torque is required. When
either of these types of motors is connected to a utility supply at a fixed frequency (60 or 50 Hz),
operation at a single fixed speed is obtained. The Harmony series drives allow variable speed operation,
without sacrificing any of the desirable properties of the induction motor.
The Harmony series drives provide variable speed operation by converting utility power at fixed frequency
and fixed voltage to variable frequency, variable voltage power. This conversion is done electronically,
without moving parts. Unlike older drive types, the Harmony series does not force the user to accept
unpleasant by-products of this conversion process. Specifically:
• The Perfect Harmony series drives do not inject significant harmonic distortion into the plant’s
distribution system. No power filters are required. No interference to sensitive equipment or
resonance problems with power factor capacitors will occur.
• The Perfect Harmony series drives present a high power factor to the utility, typically 95% or better
throughout the speed range. No power factor correction is required.
• The Perfect Harmony series drives do not require any derating of the motor due to output harmonics.
No additional motor heating is produced versus operation directly from the utility.
• The Perfect Harmony series drives do not produce torque pulsations, which can excite mechanical
resonance.
• The Perfect Harmony series drives cause no noticeable increase in acoustic noise from the motor,
versus operation directly from the utility.
• The Perfect Harmony series drives cause no appreciable additional stress to the motor insulation,
versus operation directly from the utility.
• The Perfect Harmony series drives allow unrestricted use of rated motor torque throughout the speed
range, subject only to the thermal limitations of the motor.
6
• The Perfect Harmony series drives are virtually silent in operation if liquid-cooled, so that normal
conversation is possible next to drives running at full power.
• The Perfect Harmony series drives are completely modular in construction, so that if necessary, a
defective module can be replaced in minutes. Sophisticated microprocessor-based diagnostics
pinpoint the location of any defects.

THEORY Perfect Harmony GENIII/e Startup and Advanced Topics
6.2. The Power Circuitry
* Note: The examples used in this section refer to drives having low-voltage cells. High-Voltage cell
systems will have different values.
The Harmony series drives achieve this uncompromised performance by employing well-proven
technology in a new configuration. Medium voltage levels are obtained by adding together the outputs of
multiple low-voltage power cells. The low-voltage power cells are simplified variations of standard PWM
motor drives for low-voltage service, which have been built in high volume for many years.
Figure 6-1 shows a typical power circuit topology for a 2400 or 3300 volt Perfect Harmony series drive,
using 690 VAC cells. Each motor phase is driven by 3 power cells connected in series. The groups of
power cells are wye connected with a floating neutral. Each cell is powered by an isolated secondary
winding of an integral isolation transformer. The nine secondaries are each rated for 690 VAC at one
ninth of the total power. The power cells and their secondaries are insulated from each other and from
ground for 7.2 kV class service.
For a 4160 or 4800 volt drive, Figure 6-1 would be extended to have 4 power cells in series in each
phase, with 12 secondaries on the integral isolation transformer. For a 6000 volt drive, there would be
5 power cells in series in each phase, with 15 secondaries on the integral transformer. For a 6600 to
7200 volt drive, there would be 6 power cells in series in each phase, with 18 secondaries on the integral
transformer.
Each cell is a static power converter. It is capable of receiving input power at 690 VAC 3-phase, 50/60
Hz and delivering that power to a single-phase load at any voltage up to 690 VAC and at any frequency
up to 330 Hz. Note: for output frequencies greater than 180 hertz the VFD power cell current output will
be de-rated. Consult the factory for information applicable to the specific application requirements
With three 690 VAC power cells in series per phase, a Perfect Harmony series drive can produce as
much as 2080 VAC line-to-neutral, or a maximum V-available of 3600 volts. With four 690 VAC power
cells in series per phase, a Perfect Harmony series drive can produce as much as 2780 VAC
line-to-neutral, or a maximum V-available of 4800 volts. With five 690 VAC power cells in series per
6 phase, a Perfect Harmony series drive can produce as much as 3470 VAC line-to-neutral, or a maximum
V-available of 6000 volts. With six 690 VAC power cells in series per phase, a Perfect Harmony series
drive can produce as much as 4160 VAC line-to-neutral, or a maximum V-available of 7200 volts.
It should be noted that it is possible to connect as many as eight power cells in series using the Harmony
control. V-available determines the maximum voltage that can be delivered from the VFD output. The
actual voltage delivered is fully adjustable. As the Harmony VFD topology is based on multi-level output
capabilities the result is true adjusted voltage. The advantages of utilizing the V-available capability of
the VFD become apparent when the patented advanced cell bypass option is applied.
Other cell voltages are available, which will change the number of cells needed for a given output voltage.
However, the basic principle is unchanged.
The power cells all receive commands from one central controller. These commands are passed to the
cells over fiber optic cables in order to maintain the 7kV class isolation.
The transformer secondaries that supply the power cells in each output phase are wound to obtain a
small difference in phase angle between them. This cancels most of the harmonic currents drawn by the
individual power cells, so that the primary currents are nearly sinusoidal. The power factor is always high
- typically 95% at full load.
The schematic of a typical power cell is shown Figure 6-2. In this example, a 3-phase diode rectifier, fed
by the 690 VAC secondary, charges a DC capacitor bank to about 860 VDC. The DC voltage feeds a
single-phase H-bridge of IGBTs.

At any instant of time, each cell has only three possible output voltages. If Q1 and Q4 are on, the output
will be +600 volts from T1 to T2. If Q2 and Q3 are on, the output will be -600 volts. Finally, if either Q1 and
Q3 or Q2 and Q4 are on, the output will be 0 volts.
With 3 power cells per phase, the circuit of Figure 6-1 can produce 7 distinct line-to-neutral voltage levels
(±2570, ±1720, ±860, or 0 volts). With 5 cells per phase, 11 distinct voltage levels are available. With 6
cells per phase, 13 distinct voltage levels are available. The ability to generate many different voltage
levels allows the Harmony series drives to produce a very accurate approximation to a sinusoidal output
wave for.
Figure 6-3 shows how these wave forms are generated for the case of 3 cells per phase. First, a
reference signal is created for each phase. These signals are digital replicas of the ideal wave form to be
approximated. In Figure 6-3, RA illustrates the reference signal for phase A. This reference signal is
then compared with 3 triangular carrier signals. Figure 6-3 shows conditions when the output frequency
is 60 Hz and the carrier frequency is 600Hz, so that there are exactly 10 carrier cycles per reference
cycle. The 3 carriers are identical except for successive phase shifts of 60 degrees (based on the carrier
frequency). Phase shift between carriers in each phase is computed based on the following equation.
180degrees
Carrier Phase Shift (same phase) =
# of cells/phase

Special Transformer with Power

9 Isolated Secondaries Cell
(12 for 4,160 VAC) A1
Power
Cell
B1
Power
Cell
C1
Power
Cell
Input Power A2
3-phase AC
Power
Cell
B2
Power
Cell
C2
Power
Cell
A3
Power
Cell
B3
Power
Cell
C3
6
2400 VAC
Induction
Motor
Figure 6-1. Topology of Perfect Harmony VFD (3 Cells, 2400 or 3300 VAC)
Whenever the reference is greater than the first (unshifted) carrier, the signal L1 is high; otherwise L1 is
low. L1 is used to control the pair of transistors Q1 and Q2 in cell A1 (see the left pair of transistors in
Figure 6-2). Whenever the reference is greater than the inverse of the first carrier, the signal R1 is low;
otherwise R1 is high. R1 is used to control the pair of transistors Q3 and Q4 in cell A1 (see the right pair of
transistors in Figure 6-2).
The difference between L1 and R1 gives the output wave form of cell A1, shown in Figure 6-3 for Phase A
as A1.
In a similar manner, the reference signal is compared with the second carrier (shifted 60 degrees) and its
inverse to generate control signals L2 and R2 for the transistors in cell A2. The output waveform of cell A2
is shown as A2.

Dedicated 690 VAC

Winding on Power Q1 Q3
Transformer IGBTs Q1-Q4
+
1
T2
Power Output
2 of Cell
+
Q2 Q4 T1
3
Fuses on
GENIIIe
cells are
mounted
external to
cell
Local Fiber Optic Signals
Control Local Control Circuits
to and from
Power Master Control
Figure 6-2. Schematic of a Typical Power Cell
Finally, the reference signal is compared with the third carrier (shifted 240 degrees) and its inverse to
generate control signals L3 and R3 for the transistors in cell A3. The output waveform of cell A3 is shown
as A3.
RA
L1
R1 6
A1
L2
R2
A2
L3
R3
A3
AN
Figure 6-3. Waveforms for Phase A
The sum of the output voltages from cells A1, A2 and A3 produces the A-to-neutral output voltage of the
drive, shown in Figure 6-3 as AN. There are 7 distinct voltage levels. Note that this voltage is defined
between terminal A and the floating neutral inside the drive, not the motor neutral.

RB
L1
R1
B1
L2
R2
B2
L3
R3
B3
BN
Figure 6-4. Wave Forms for Phase B
Figure 6-4 shows the same signals for Phase B. The 3 carriers are identical to Figure 6-3 except each is
shifted by 20 degrees from its Phase A equivalent (see note below). The reference RB is also identical to
Figure 6-3, except that it is delayed by 120 degrees (at the reference frequency).
The sum of the output voltages from cells B1, B2 and B3 produces the B-to-neutral output voltage of the
drive, shown in Figure 6-4 as BN.
Figure 6-5 repeats the two line-to-neutral voltages AN and BN. The numerical difference between AN and
BN forms the line-to-line voltage impressed on the motor, and is shown in Figure 6-3 as AB.
AN
BN
AB
Figure 6-5. Wave Forms for Line-to-line Voltage
Note: The phase shift of the carrier signals between phases is determined by the number of cells in the
system. The equation being Phase shift = 180 degrees / total number of cells. In this case (3 ranks or 9
cells) the carrier signal phase shift phase to phase is (180 / 9) = 20 degrees. This shift of the carriers
between phases reduces the number of devices that are switching at one time. The above is true if no
cells are in bypass. If one or more cells are in bypass the carrier signals are offset by 180 degrees / total
remaining cells.

1,000 HP, 2,400 VAC Motor at Full Speed, Full Load
Motor Line-to-neutral Voltage, Peak = 2,000 Volts

Motor Phase A Current, Peak = 348.9841 Amps
Figure 6-6. Harmony Output Wave Form, 2400 Volt Drive at Full Load
Figure 6-6 shows motor voltage and current waveforms for a 2400 VAC Harmony drive rated at 1000 hp.
The voltage shown is between phase A and the motor neutral (not the same as the drive neutral). The
motor current is in phase A during full-load operation. Anyone familiar with such waveforms for other
types of static drives will appreciate how accurately they approximate true sine waves. A quantitative
measure of the wave form quality is its Total Harmonic Distortion, or THD. The THD of the motor
currents with a Harmony series drive is always less than 5 percent.
Figure 6-7 shows the input voltage and current waveforms for the same drive as in Figure 6-6, under the
same conditions. The perfect sine wave in Figure 6-7 is the voltage into the special input transformer,
measured between phase A and the neutral of the wye-connected primary. The other waveform is the
current into phase A of the same winding.
6
The currents drawn from the power source by Harmony series drives are also good approximations to
true sine waves, due to the harmonic cancellation obtained with the phase-shifted secondary windings of
the transformer. The THD of the input currents with a Harmony series drive is also always less than 5
percent.
Input Voltage
Input Current
Figure 6-7. Harmony Input Wave Forms for a 2400 Volt Drive at Full Load
Note in Figure 6-7 that the input current lags behind the input voltage by less than 15 degrees at full load.
This represents a power factor better than 96 percent. Harmony series drives always maintain a high
power factor, typically better than 95 percent throughout the speed and load range.

*
Note: The wave forms shown in Figure 6-2 through Figure 6-7 represent the worst case for a
Harmony series drive when there are only 3 cells per phase. When the number of cells increases,
as in 12 or 15 cell drives, the wave forms become considerably better.
Figure 6-8 shows the motor voltage and current for a 15 cell Harmony drive at full power, while
Figure 6-9 shows the input voltage and current for the same drive and load.
Figure 6-8. Motor A-B Voltage and Current in Phase C at Full Load for a 4160 Volt
Harmony Drive
Figure 6-9. Input A-B Voltage and Current in Phase C at Full Load for a 4160 Volt Harmony
Drive

6.3. The Control System
The block diagram in Figure 6-10 shows the implementation of the Harmony Control System. The
Control System consists of Signal Interface and Conditioning Boards, an A/D Converter Board, a Pentium
Processor Board, a Digital Modulator Board, and one or two Fiber Optic Interface Boards.
The Signal Interface Board processes the feedback signals collected from the drive. The circuits on this
board scale and filter the feedback signals before passing them along to the A/D Converter Board over a
50pin cable. This board also contains connections for an analog input signal and a relay contact. The
contact is typically used for ESTOP.
The function of the A/D Converter Board is to sample the input and output currents and voltages, and
convert them to digital signals for the Pentium processor. The sample rate varies from 3kHz to 6KHz and
is a function of the carrier frequency (which is also the IGBT switching frequency) and the number of
‘available’ cells in the system. The Digital Modulator Board generates the signal for the A/D converters to
start sampling. Once the A/D converters finish sampling, they provide an interrupt to the processor to
begin its calculation cycle.
The Pentium processor performs all the functions for motor control and generates three-phase voltage
commands for the digital modulator. In addition, it monitors the input voltages and currents to provide
metering functions (such as power factor, input power and harmonic calculation), input protection (from
over-current, excessive reactive current, under-voltage and single-phasing), and input voltage magnitude,
frequency and phase angle for Synchronous Transfer.
The Digital Modulator comprises of four modulator EPLDs (Erasable Programmable Logic Devices), one
master and three slaves, each running the same code. Each EPLD provides communications for six
Harmony cells. The master EPLD contains registers that are used for communication with the Processor.
For each phase voltage command, the processor writes to the EPLDs, two values, the first for the present
time instant and the second for a time instant that is half-a-sampling period away. A voltage increment,
corresponding to these values, is also written to the EPLDs. These phase commands are written to the
EPLDs once every sampling period.
6
The master EPLD creates a set of timing signals that causes the control software to sample the feedback
signals and run the control, monitoring algorithms. These timing signals cause all of the EPLDs to
transmit information to the cells simultaneously, once every 9 to 11 microseconds. This time (is
determined by the processor and) is based on the drive configuration and is fixed for a particular
configuration. In between every transmission period, each EPLD performs interpolation, phase-shifted
carrier generation, pulse-width modulation (PWM), and cell communication. The resulting PWM
commands for each cell along with the mode of operation is assembled as an 8-bit packet (at a rate of 5
Megabaud) that is transmitted to the cells through the Fiber Optic Interface. In response to the
transmitted data, the modulators receive a similar 8-bit packet from each of the cells. The return message
from the cells contains status bits that are decoded by the EPLDs and conveyed to the processor. In case
of a fault other EPLDs are also affected. The portion of code that is associated with sending and receiving
messages from the cells is called FOLA (for Fiber Optic Link Adapter).
In addition to the tasks listed above, the master EPLD communicates with the bypass controller and
monitors hardware faults such as IOC, ESTOP and power supply faults. The Bypass Controller is
implemented in a separate EPLD that is configured to control the cell bypass (mechanical) contactors.
This device resides along with the modulator EPLDs on the Modulator Board. After detection of a cell
fault the processor communicates with the Bypass Controller to bypass the faulted cells. In addition to
bypassing cells, the Bypass Controller constantly checks the status of the contactors to verify if they are
in their requested states.
The Fiber Optic Interface transfers data between the modulator EPLDs and the cells over fiber optic
channels. Each Fiber Optic Interface Board can communicate with up to 12 cells. Up to two Fiber Optic

Interface Boards can be put in the system. Each cell receives its firing commands and status signals from
the Interface Board through a dual fiber optic channel.
Every transmission is checked for completeness and parity. If an error is detected a link fault is
generated. The 8-bit packet sent to the power cells provides operational mode and switching information.
The local communication circuits in each power cell operate as slaves to the EPLDs on the Modulator
Board. The local control circuits on each power cell convert the information received to IGBT firing pulses.

Special Transformer Cell

with 15 Isolated A1
Secondaries
B1
Keypad
Cell
C1
Cell
A2
Cell Fiber
B2 Optic
Interface
Cell Board
C2
Cell
Input Power A3
3-phase AC
Cell
B3 Microprocessor
Board
Cell
C3
Cell
A4
Cell
B4
Cell Digital
C4 Modulator
Board
Cell
A5
Cell 6
B5
Analog to
Fiber Digital Board
Cell Optic
C5 &
Interface
Board System
Interface
Board
Conditioning
Circuits
Voltage
Attenuator
6000 VAC
Induction Input Voltage and Current Feedback
Motor
Figure 6-10. Block Diagram of Harmony Control Structure for 6000 V Drive

6.4. The Control Modes

Harmony drives use vector control to control induction and synchronous motors. Vector control provides
a framework that is simple to implement, but performs nearly as well as a DC motor. Figure 6-11 shows
a simplified representation of the vector control algorithm implemented in Harmony drives. The basic
components of vector control are:
1. Motor model: determines motor flux and speed.
2. Current regulators: these regulators are referred to as the inner loops.
3. Flux and speed regulators: these regulators are referred to as the outer loops.
4. Feed-forward (FF) compensation: improves the transient response of torque loop and flux loop.
FluxDS Ids
Magnetizing
Flux Current Regulator Dual
- Regulator - Frequency
Ids,ref +
Flux Ref Σ PI Braking [3350]
+ Σ PI + LPF
+ 3
Voltage
commands to
[3250]
[3100] Modulator
Vds,ref Dead-Time
Field current D-Q Compensation
command (only for
SMC and CSMC)
Flux FF To Σ & Peak
[1060-70]
Vqs,ref 3∅ Reduction
Speed Torque Current [3550]
Regulator Regulator
Speed Ref + + + θs
Σ PI + LPF Σ PI Σ
Iqs,ref
- [3200] - [3250] +
Motor
ωr Iqs ωs
Speed
OLVC, SMC, FluxDS
Iq FF [3560]
+ V/Hz
Σ ωs Ids
- ωencoder 3∅ Ia Current
CLVC, CSMC
CLVC, CSMC, Iqs To Ib Feedback
SMC, V/Hz OLVC DQ Ic [3440]
6 ωslip
θs
FluxDS
Slip calculation [3545] ya
Low Freq.
[3420-30] Comp. & yb Integrated-voltage
ωs Feedback
Ids, ref Iqs, ref FluxDS PLL 3∅ to DQ yc
[3450]
FluxQS
[3060]
Motor θs θs [1080]
Model
Figure 6-11. Block diagram of vector control algorithms for induction and synchronous motor
control. (Numbers within square brackets indicate the parameter IDs that affect the corresponding
functions)
The motor model uses measured motor voltage and estimated stator resistance voltage drop to
determine stator flux amplitude, motor speed and flux angle. This allows stator resistance compensation
to be automatic. A simplification of motor equations is obtained by transforming the 3-phase AC
quantities (which are referred to being in a stationary reference frame) to DC quantities (that are in a
synchronously rotating or DQ reference frame). A phase-locked loop (PLL) within the motor model tracks
the (stator) frequency and angle of the flux vector.
Motor flux amplitude is controlled by the flux regulator; its output forms the command for the magnetizing
(or flux producing) component. Motor speed is determined from stator frequency, and is controlled by the
speed regulator. Its output is the command for the torque (producing) current regulator.

The flux angle is used to decompose the measured motor currents into magnetizing and torque producing
components. It is this decomposition that allows independent control of flux and torque, similar to DC
motor control. These current components are regulated to their commanded values by the current
regulators. Outputs of the current regulators are combined to produce three-phase voltage commands
that get modified with signals from various control routines before being passed on to the modulator.
These control routines include: (1) dead-time compensation (to compensate for dead-time in the
switching of the upper and lower IGBTS of each pole in a power cell), (2) peak reduction for third-
harmonic injection (to maximize drive output voltage, and for drive neutral-shift [during transparent cell-
bypass]), and (3) voltage commands to produce losses for dual-frequency braking. Transient response
of the flux and torque regulators is improved with the use of feed-forward compensation (FF) as shown in
Figure 6-11. The following table describes the symbols used to represent various quantities in the
control diagram.
Table 6-1. List of symbols used in Figure 6-11.
Symbol Description
FluxDS D-component of motor flux; also equal to the motor flux, since Q-component is zero. Motor Flux is
defined as: Motor_Voltage / Stator_Frequency (rad/s). Flux (which has units of Volt-seconds) is
also equivalent (but not equal) to Volts-per-Hertz ratio.
r For an induction motor: Motor_Speed = Stator_Frequency / Pole_Pairs – Slip_Speed

For a synchronous motor: Motor _Speed = Stator_Frequency / Pole_Pairs
Ids Magnetizing component of motor current
Iqs Torque component of motor current
Vds,ref Output of magnetizing current regulator
Vqs,ref Output of torque current regulator
s Stator frequency or output frequency of the drive
s Flux angle
6
Ia Ib , Ic Motor phase currents
Motor torque (in Newton-meters) and shaft power can be calculated as,
Torque (Nm) = 3* Pole_Pairs * Flux (Vs)* Iqs (A)
≈ 3* Pole_Pairs * Motor_Voltage (V) * Iqs (A) / (2π * Frequency (Hz)),
Shaft Power (W) = Torque (Nm) * Speed (rad/s) = Torque (Nm) * Speed (rpm) / 9.55
6.4.1. Open Loop Vector Control (OLVC)
This control mode should be used for most applications with single induction motors. In this method the
control estimates motor slip as a function of load torque and provides a performance that matches a
vector controlled drive (with speed sensor/transducer) above a certain minimum speed. With the correct
motor parameters the control can provide good performance even at 1% of rated speed.
Speed feedback is synthesized from the stator frequency and the estimated motor slip, as shown in
Figure 6-11. With this control method, slip compensation is automatic.
In this control mode, the drive begins by scanning the frequency range to detect the speed of the rotating
motor if Spinning Load is selected (please refer to Chapter 5 for a description of Spinning Load
Operation). Once the drive has completed the scan or if the feature is disabled, the drive goes into
Magnetizing State. During this state the drive ramps the motor flux to its commanded value at the

specified Flux Ramp Rate (parameter ID 3160). Only when the flux feedback is within 90% of the
commanded flux, the drive changes to the Run State. Once in Run State, the drive increases the speed
to the desired value. All motor and drive parameters as described in Chapter 3 are required for this
mode of operation. Default values for the control loop gains (in the Stability Menu) are sufficient for most
applications.
6.4.2. Open Loop Test Mode (OLTM)
In this control method the motor current feedback signals are ignored. This control mode should be used
during drive set-up, when the modulation on the cells is to be verified or when testing the drive without a
load. It can also be used when the motor is first connected to the drive to make sure that the Hall Effect
Transducers are working correctly and are providing the correct feedback signals. This method should
not be used to adjust scale factors for input and output, voltages and currents.
In this mode, the drive goes through the Magnetizing State to the Run State without looking at the motor
flux. Only motor nameplate values and some drive related parameters as described in Chapter 3 are
required for this mode. Special attention should be given to the following parameters:
1. Spinning Load and Fast Bypass should be disabled.
2. Acceleration and deceleration times (in the Speed Ramp Menu) should be increased.
3. Flux Demand should be reduced.
6.4.3. Synchronous Motor Control (SMC)

For synchronous motor control (SMC), the drive is equipped with a field exciter that consists of a SCR
based current regulator; a 3PCI controller is typically used for the exciter. The field exciter operates to
maintain a field current level that is commanded by the flux regulator. An example application for a
brushless synchronous motor is shown in Figure 6-12. For brushless motors, the diagram assumes that
the exciter stator is wound for 3 phase AC in the range of 350 to 400 volts. If that is not the case, a
transformer will be necessary between the auxiliary power and the 3PCI. The circuit wheel needs only a
rectifier. For the brushless case without bypass, the motor does not require any protection other than that
included in the drive. Next Gen Control will trip the drive on a loss of field fault, if the motor draws
6 excessive reactive current, which will occur when the exciter fails full on or off. Please refer to Chapter 7
for further discussion of this fault.
The overall control strategy is similar to Open Loop Vector Control, except for the flux regulator
implementation as shown in Figure 6-11. For synchronous motors, the flux regulator provides two
current commands, one for the field exciter current, and another for the magnetizing component of stator
current.
With synchronous motor control, scanning the motor frequency to determine motor speed is completely
avoided. The control uses information from the rotor induced speed voltages on the stator to determine
rotor speed before applying torque to the motor. When starting the motor, the drive begins (in the
Magnetizing State) by giving a field current command, which is equal to the no-load field current setting,
to the exciter. This lasts for a time equal to the flux ramp time that is entered through the keypad
(parameter ID 3160).
After this period of time, the drive goes into the run state. In most cases, the regulator in the field exciter
is slow, and the drive applies magnetizing current (through the stator windings) to assist the exciter in
establishing rated flux on the motor. At the same time, the speed regulator commands a torque
producing current to accelerate the motor to the demanded speed. Once the field exciter establishes the
required field current to maintain flux in the motor, the magnetizing component of stator current reduces
to zero. From this point onward, the drive provides torque-producing current (for acceleration or
deceleration) that is in-phase with the drive output voltage. In other words, under steady state conditions,
unity power factor condition is automatically maintained at the drive output.
The field current command is provided to the field exciter with the use of an analog output module from
WAGO. Other differences between SMC and OLVC are summarized below.

1. The motor no-load current parameter represents the Field no-load current value in SMC.
2. With SMC the flux loop gains are slightly lower than with OLVC.
3. Spinning Load should always be enabled with SMC.
4. The drive magnetizing current regulator uses only the proportional gain of the flux exciter.
5. Only Auto-Tuning Stage 1 can be used with synchronous motors.
Harmony Drive
Input Synchronous
Inverter
MV Motor
Control Circuit wheel

(on Motor)
Field current
command
480 V
Aux
Power
3-phase wound
Induction exciter
3PCI - Field Exciter ~ 460 VAC
Figure 6-12. Harmony drive arrangement for brushless synchronous motor (with no bypass).
6
6.4.4. Volts/Hertz Control (V/Hz)

This control mode should be used when the drive is connected to multiple motors in parallel. The control
algorithm is similar to that of Open Loop Vector Control (OLVC), but it does not use some of the motor
parameters in its control algorithm that OLVC does. Also, many of the features available with OLVC,
such as fast bypass, spinning load and slip compensation, are not available with this method.
6.4.5. Closed Loop Control (CLVC or CSMC)

In some applications, when stable (very) low speed operation under high torque conditions is required, an
encoder may be used to provide speed feedback. The drive uses an ‘off-the-shelf’ carrier board to
interface with industry standard encoders.
The control diagram of Figure 6-11 remains the same except for the slip calculation block which is
disabled, so that encoder speed feedback is directly used as an input to the speed regulator.
When an encoder is used with the drive, the control loop type is required to be set to CLVC (for closed
loop vector control with an induction motor) or to CSMC (for closed loop vector control with a
synchronous motor). The encoder menu (ID 1280) contains parameters required for encoder operation.
The table below describes the menu entries and provides typical values. Spinning load should be enabled
when this control mode is enabled.

Table 6-2. Description of parameters in Encoder Menu (1280) and recommended values.
Parameter name ID Description Value

Encoder PPR 1290 Pulse-per-revolution of the encoder. From
encoder
Encoder filter gain 1300 Sets the gain of the filter for encoder feedback. This parameter can 0.75
have a value between 0.0 (no filtering) and 0.999 (maximum
filtering).
Encoder loss 1310 When the difference between the encoder feedback and the 5.0%
threshold estimated speed is greater than this level, an encoder loss
alarm/fault is generated.
Encoder loss 1320 This sets the response of the drive when encoder loss occurs. In Open
response the event of an encoder loss, selection of ‘Stop (fault)’ will cause loop
the drive to trip, while ‘Open loop’ will cause the control to switch to
Open Loop Vector Control.
6.5. Input Side Monitoring and Protection

The NXG Control monitors input side voltages and currents, as well as those on the ouput side. This
allows the control to monitor and respond to events on the input side of the drive. RMS values of the
input currents and voltages are available, along with input power, kVA, energy and power factor. Figure
6-13 shows a simplified view of the functions implemented for input side monitoring. Other quantities
such as drive efficiency, average input current THD, and individual harmonic component (in input
voltages/currents) are also calculated. All variables have an accuracy of ± 1%, except for efficiency (< ±
2%) and input current THD (± 1% above ~ 60% of rated power). A list of symbols used in Figure 6-13
and a description of the parameters they represent are given in Table 6-3. Note that the definition of Id
and Iq components of the input current is different from the output side quantities.
6 Input side monitoring allows the drive to protect the secondary side of the transformer from abnormal
conditions. Two faults, excessive drive losses and one cycle protection, are generated under such
conditions. Please refer to Chapter 7 for further discussion of these two faults. Input side control also
provides torque current limiting for line under-voltage, single-phasing and transformer overload
conditions. These are described below. Please note that these three rollback sources can be disabled
using the SOP.

Ea,b,c Input
Input
3 Power Excessive Drive
Ia,b,c Power Drive Losses Alarm
Voltage 3
Calc. Losses
Output
Calc. Erms Under
Feedback Power Voltage Under Voltage Limit
[3040]
Eau Input Power Ride
Ea
Va Zero Ebu Unbalance Through [7060-70]
Eb RMS Eunbalance
Vb Seq. Ecu Voltage
Ec Calc.
Vc Comp. Erms Calc.
Single Single Phasing Limit
E0 Phasing
Input Power
Ea Detect
3∅ Tap Setting Ed [7020-40]
Eb To Eq ωu
Ec DQ PLL
[3010-20] One One Cycle Protection Limit
Cycle
θa + θu
Protect
θa Σ [7080-81]
[7100]
-
Id π/2
Ia 3∅ Power Input Power Factor
Ib To Iq Factor
Ic DQ Calc.
Current
Feedback
[3030] Iau
[3035] Ia Max Xfrmr Thermal Overload Limit
RMS Ibu
Ib RMS Thermal
Calc. Icu Ovld.
Ic Calc. [7090]
Irms
Figure 6-13. Block diagram of input-side monitoring. (Numbers within square brackets indicate
the parameter IDs that affect the corresponding functions.)
Table 6-3. List of symbols used in Figure 6-13. 6
Name Description
Erms Average rms voltage (of all 3 phases)
Ed Amplitude of voltage taking the transformer tap setting into account. This
represents the actual voltage being provided to the cells. If the tap setting is
+5%, Ed will be 5% smaller than Erms, and vice versa.
u Input frequency
u Angle of input-side flux
Irms Average rms current (in all 3 phases)
Id Real component of input current.
Iq Reactive component of input current.
Iq Reactive component of input current.
6.6. Drive Output Torque Limiting

The drive uses measured voltages and currents to implement rollback conditions. Under one or more of
these conditions, the drive will continue to operate, but at a lower output torque (or current) level. An
output torque limit will force the motor (and the drive) to go into speed rollback, during which speed is

reduced until the torque demanded by the load falls below the torque limit. Rollbacks which are triggered
by various conditions are described below.
6.6.1. Input Under-Voltage Rollback

When the input line voltage drops below 90% of its rated value, the drive limits the amount of power (and
the hence the torque) that can be delivered to the load. The maximum allowable drive power as a
function of line voltage is shown in Figure 6-14. At 63% input voltage, the maximum drive power is
limited to 50%, and is quickly reduced to a slightly negative value (Limit) at 58%. This limit forces the
drive to absorb power from the motor and maintain the (cell) DC-bus voltages in case the input voltage
recovers. The limit is implemented as an inverse function of speed in order to maintain constant power
flow to the (cell) DC-bus.
A regulator is implemented to match the maximum drive power (PMAX) to the actual power flowing into the
drive. The output of this regulator sets the output torque limit. Keypad parameters 7060 and 7070 (in the
Drive Protect Menu, under Input Protection) represent the proportional and integral gains of this regulator.
Typical values of the proportional and integral gains are 0.0 and 0.001. An under voltage rollback
condition is annunciated by the drive as UVLT on the keypad and in the Tool Suite.
Pmax (%)
100
50
0 58
Limit 63 90 Erms (%)
Figure 6-14. Drive power (Pmax) as a function of input voltage magnitude (Ed).
6
6.6.2. Input Single-Phase Rollback
With Next Gen Control, input voltage unbalance (Eunbalance) is used for rolling back the drive output torque.
Figure 6-15 shows the reduction in drive power as a function of the unbalance voltage. When the
unbalance is less than 10% the drive operates without any output limitation. There is a linear reduction
as the unbalance voltage increases from 10% to 33%, at which point the input has a single-phase
condition. When the input line voltage drops below 90% of its rated value, the drive limits the amount of
output power that can be delivered to the load.
Pmax (%)
100
40
0
10 33 Eunbalance (%)
Figure 6-15. Drive power (Pmax) as a function of input unbalance voltage (Eunbalance).

A regulator is implemented to match the maximum drive power (PMAX) with the actual power flowing into
the drive. The output of this regulator sets the output torque limit. Keypad parameters 7020 and 7030 (in
the Drive Protect Menu, under Input Protection, Single Phasing) represent the proportional and integral
gains of this regulator. Typical values of the proportional and integral gains are 0.0 and 0.001. A single-
phasing alarm is generated when the output level of this regulator goes below the level set by the SPD
threshold parameter (ID 7040). The drive’s keypad displays SPHS instead of MODE, and the Tool Suite
displays SPHS when a rollback occurs because of this condition.
6.6.3. Transformer Thermal Rollback

The input currents to the drive are monitored continuously. The largest among the three input phase
currents is limited to be at or below 105% of the nominal rating of the transformer. Drive output torque is
reduced when this current level is exceeded.
An integral regulator is implemented to limit the maximum input current to 105%. The output of this
regulator sets the output torque limit. The Xformer thermal gain parameter (ID 7090, in the Drive Protect
Menu, under Input Protection) represents the integral gain of this regulator. A typical value of the integral
gain is 0.0133. During transformer thermal rollback, the drive displays T OL on the keypad and in the
ToolSuite.
6.6.4. Menu Torque Limit

When the output torque current exceeds the max torque limit setting (parameter ID 1190, 1210 or 1230),
the drive will limit output current. When this happens, the drive displays TLIM on the keypad and in the
Tool Suite.
6.6.5. Regeneration
An inverse speed function based on the Regen torque limit setting (parameter ID 1200, 1220 or 1240) is
used during drive deceleration. This forces the drive to absorb a constant amount of power from the load.
When this happens, the drive displays TLIM on the keypad and in the Tool Suite.
6.6.6. Field-Weakening Limit 6

The field-weakening limit is a torque limit that is based on the motor flux and motor leakage inductance.
This limit prevents the motor slip from exceeding pullout torque slip. Thus, it prevents unstable operation
of the motor. This limit normally occurs when motor flux is reduced significantly during energy saver
operation or when operating beyond the base speed of the motor. Under such conditions, a large step
(increase) in load will force the output to be limited, resulting in a loss of speed rather than motor pullout.
When this happens, the drive displays F WK on the keypad and in the Tool Suite.
6.6.7. Cell Current Overload

The cell (current) overload setting is given by the keypad parameter ID 7112 in the Drive Protect Menu
(7). A cell can operate at this overload value for 1 minute out of every 10 minutes. When the current is
between the cell rating and the overload rating, then the time spent at that level is inversely proportional
to the overload current. An example of the time versus current overload capability with a cell that has
120% overload capacity is shown in Table 6-4.

Table 6-4. Example of overload current capability versus time of a cell with 120% overload.
Drive current (%) Allowed operating time (out of every 10 minutes)

120 1 minute
110 2 minutes
105 4 minutes
100 Continuous
If the motor current rating is smaller than the drive rating, then the rollback is annunciated on the keypad
and in the Tool Suite as TLIM for Torque Limit. However, when the drive current rating is smaller than
the motor rating, C OL (for Cell Overload) is displayed.
Note that some cells like the 360H and the GENIIIe 315-660H, have 1-minute overload ratings based on
reduced continuous current ratings. For these applications, the system should be full scale rated for this
reduced continuous ratings.
*
Note: The power cells used in Harmony drives do not have a fixed overload capability. Please
consult the factory to determine the level of overload capability for a particular type of cell.
∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics TROUBLESHOOTING AND MAINTENANCE
CHAPTER 7: TROUBLESHOOTING AND MAINTENANCE
7.1. Introduction
We have designed, built and tested the Perfect Harmony variable speed drive for long, trouble-free
service. However, periodic maintenance is required to keep the drive working reliably, to minimize
system down time, and to maintain safety.
DANGER—Electrical Hazard! Always switch off the main input power to the equipment before
attempting inspection or maintenance procedure.
Warning: Only qualified service personnel should maintain Perfect Harmony equipment and
systems.
This chapter is contains information that can be categorized as:

• Fault and Error troubleshooting (beginning)
• Supporting (technical) information (middle)
• Maintenance information (end).
The sections at the beginning of this chapter explain faults, how they are annunciated, fault messages,
fault logging, and troubleshooting techniques. The sections in the middle of this chapter provide
supporting information such as technical data, test point locations, and internal operations. Finally, the
sections at the end of this chapter provide maintenance information such as inspections, replacement
parts, etc. Review the section titles shown in the “In This Section” table above, then proceed to the
appropriate section to troubleshoot or maintain your drive as appropriate.
*
Note: Refer to Chapter 2: Hardware Components for locations and details of major hardware
components of the Perfect Harmony system.
7.2. Faults and Alarms

If a fault or alarm condition exists, it will be annunciated on the keypad. The Master Control software and
hardware sense faults and alarms and stored them within the fault logger. Faults are either detected via
direct hardware sensing or by software algorithm.
Cell faults are sensed by the cell control system logic located on the Cell Control Board (see Figure 7-2)
in each output power cell. Each power cell has its own sense circuitry (Refer to Chapter 6: Theory).
The Master Control software interprets the cell faults and displays them and logs them based on the 7
faulted cell and the specific fault within the cell.
Generally, all faults will immediately remove power from the motor and inhibit the drive from running.
Some faults that are user defined can be control the drive response via the system program. Alarms are
annunciated and logged but usually do not inhibit the drive from operation.
Refer to Table 7-1 for a determination of the drive response for the various fault and alarm conditions.
Table 7-1. Fault/Alarm Type and Drive Responses
Type Drive Responses

Fault All IGBT gate drives are inhibited.
Motor coasts to stop.
The fault is logged. Refer to the Fault Log Menu (6210).
The fault is displayed on the front panel.
The Keypad Fault LED is ON.

TROUBLESHOOTING AND MAINTENANCE Perfect Harmony GENIII/e Startup and Advanced Topics
Type Drive Responses

User Faults The motor either ramp stops or coast stops depending on the content of the System
Program.
The fault is logged. Refer to the Fault Log Menu (6210).
The fault is displayed on the front panel.
The Keypad Fault LED is ON.
Alarm Drive does not necessarily revert to the idle state via a coast or ramp stop unless
specifically required to by the system program.
The alarm is logged. Refer to the Fault Log Menu (6210).
The alarm is displayed on the front panel.
The Keypad Fault LED flashes.
The [FAULT RESET] key on the Keypad can be used to manually reset a fault. The drive must be
returned to the run condition by manual start or by forcing the RunRequest_I equal to “true” (refer to
Chapter 8: System Programming).
A fault can be reset automatically if enabled by the corresponding auto fault reset enable flag for the
specific fault, refer to Table 7-2. for a list of auto re-settable faults. If reset is successful, then drive will
return to the run state automatically only if the RunRequest_I is maintained at the value “true” (refer to
Chapter 8: System Programming). The [FAULT RESET] key of the Keypad can acknowledge alarms.
Table 7-2. Auto Re-settable faults
Back EMF Timeout Over speed fault

Encoder Loss Under load fault
Failed to magnetize Down transfer
IOC Up transfer
Keypad communication Loss of Signal 1-24
Line over voltage
Medium voltage low
7 Menu initialization
Motor over voltage
Output ground fault
Network 1 communication fault
Network 2 communication fault
7.3. Drive Faults and Alarms

The master control senses all drive faults and alarms, either from direct hardware or via software
algorithms. Use Table 7-3 to quickly locate major causes of fault conditions. The table also lists the type
of drive response, if it is a fault (F), alarm (A), or both (F/A), and whether it can be enabled or disabled
using the SOP program (SOP), or if it is permanently enabled (Fixed in software).

Table 7-3. Drive Faults
Fault Display Type Enable Potential Causes and Possible Corrective Actions
Input Line Disturbance
Cause
Loss of input phase.
Action
Input Phase Loss A Fixed Check the input fuses and connection to verify
that the input phases are connected properly.
Using an Oscilloscope verify the presence of all
3 input voltages on test points VIA/TP1, VIB/TP2, VIC/TP3
of the System Interface board.
Cause
Estimated input ground voltage is greater than limit
set by the Ground Fault Limit (in the Drive Protection
Menu).
Input Ground A Fixed
Action
Using an Oscilloscope verify the symmetry of the 3
input voltages on test points (VIA/TP1, VIB/TP2,
VIC/TP3) of the System Interface board.
Cause
The drive-input RMS voltage is greater than 110% of
the drive rated input voltage.
Action
Using a voltmeter verify the input voltages on test
Line Over Voltage 1 A SOP points (VIA/TP1, VIB/TP2, VIC/TP3) of the System
Interface board are ~3.8V RMS. This is the expected
value for rated input voltage. Values greater than
~4.2v RMS will trigger over voltage conditions. Note:
This alarm can be caused by a transient condition,
and may not be present when the making the
measurements.
Cause
The drive-input RMS voltage is greater than 115% of 7
Line over voltage 2 A SOP the drive rated input voltage.
Action
Refer to Line over voltage 1 section above.
Cause
The drive-input RMS voltage is greater than 120% of
Line over voltage fault F Fixed the drive rated input voltage.
Action
Refer to Line over voltage 1 section above.

Cause
The drive-input RMS voltage is less than 90% of the
drive rated input voltage.
Action
Using a voltmeter verify the input voltages on test
Medium voltage low 1 A SOP points (VIA/TP1, VIB/TP2, VIC/TP3) of the System
Interface board are ~3.8V RMS. This is the expected
value for rated input voltage. Values less than ~3.4v
RMS (90% of rated) will trigger Medium voltage low
conditions. Note: This alarm can be caused by a
transient condition, and may not be present when
making the measurements.
Cause
Medium voltage low 2 A Fixed drive rated input voltage.
Action
Refer to Medium voltage low 1 section above.
Cause
Medium voltage low Flt F Fixed drive rated input voltage.
Action
Refer to Medium voltage low 1 section above.
Cause
(1) Possible fault on the secondary side of the
transformer, or (2) inrush current is too high and
creating a nuisance fault.
Input One Cycle (or
excessive input reactive F/A Fixed Action
current) (1) Remove medium voltage and visually inspect all
the cells and their connections to the transformer
secondary; contact ASI Robicon for field support, (2)
Reduce the 1 Cyc Protect integ gain (7080) and the 1
Cycle Protect Limit (7081) to avoid nuisance trips.
7 Cause
Drive input (line) current imbalance is greater than the
setting in the Phase Imbalance Limit parameter (in
Drive Protection Menu).
Input Phase Imbal SOP Fixed
Action
Verify proper symmetry of the input voltages and
currents on test points VIA/TP1, VIB/TP2, VIC/TP3, IIB/TP12
and IIC/TP13.
Motor/Output Related

Cause
The motor speed is greater than 95% of the
Overspeed parameter setting (1170) in the Limits
Menu (1120). An improperly set-up or mistuned drive
usually causes this fault.
Over Speed Alarm A SOP
Action
Verify that the motor and drive nameplate settings
match the corresponding parameters in Motor
Parameter Menu (1000) and Drive Parameter Menu
(2000).
Cause
The motor speed exceeds the Overspeed setting
(1170) parameter in the Limits Menu (1120). An
improperly set-up or mistuned drive usually causes
this fault.
Action
Over Speed Fault F Fixed Verify that the motor and drive nameplate settings
match the corresponding parameters in Motor
(2000).
Cause
This fault is caused (due to an output ground fault
condition) when the estimated ground voltage
exceeds the Ground Fault Limit parameter (1245) in
the Motor Limits Menu.
Action
Output Ground Fault A Fixed Verify proper symmetry of voltages on test points
VMA/TP5, VMB/TP6, and VMC/TP7.
If voltages are not a problem, check the divider

resistors in the Motor Sense Unit or replace the 7
System Interface Board.
Disconnect the motor from the VFD. Use a Meger to
verify motor and cable insulation.

Cause
The software has detected an encoder signal loss
due to a faulty encoder or faulty encoder interface.
Action
Verify that the information in the Encoder menu
(1280) is correct for the encoder being used. Run the
Encoder loss Menu Menu drive in Open Loop Vector Control mode (select
OLVC in the Control loop type, ID 2050) of the Drive
parameter menu (2000). Go to Meter Menu (8); select
Display Parameters Menu (8000) and set one of the
display parameters (8001-8004) to ERPM or %ESP
and observe if ERPM follows motor speed (also refer
to Section 5.*).
Cause
Motor temperature (or motor current, depending on
choice of overload method) above Overload pending
setting.
Mtr Therm Over Load 1 A SOP Action
Verify if the Overload pending parameter (1139) is set
correctly. Check load conditions and, if applicable,
verify that the speed derate curve (submenu 1151)
matches the load conditions
Cause
choice of overload method) above Overload setting.
Mtr Therm Over Load 2 A SOP Action
Check if the Overload parameter (1140) is set
correctly. Refer to Mtr Therm Over Load 1 section
above.
Cause
choice of overload method) has exceeded the
Overload setting for the time specified by the
Mtr Therm Over Ld Fault F Fixed Overload timeout parameter.
7 Action
Check if the Overload timeout parameter (1150) is set
correctly. Refer to Mtr Therm Over Load 1 section
above.
Cause
If motor voltage exceeds 90% of the Motor over
voltage limit in the Motor limit menu
Motor Over Volt Alarm A SOP
Action
Check menu settings for correct motor rating, and
limit setting.

Cause
The measured motor voltage exceeds the threshold
set by the Motor trip volts (1160) parameter in the
Limits Menu (1120). An improperly set-up or tuned
drive usually causes this fault.
Actions
Verify that the motor and drive nameplate settings
Motor Over Volt Fault F Fixed match the corresponding parameters in Motor
(2000).
Verify that the signals on the VMA/TP5, VMB/TP6, and
VMC/TP7 test points on the System Interface Board are
operating properly with in +/-6V. If an incorrect
voltage is noted, check the voltage divider in the
Motor Sense Unit or replace the System Interface
Board.
Cause
Drive instantaneous over-current (IOC) faults usually
result when the signal from test point IOC on the System
Interface Board exceeds the level set by the Drive IOC
setpoint (7110) parameter in the Input Protect
Menu (7000).
Actions
Verify that the motor current rating (1050)is below the
IOC F Fixed
Drive IOC setpoint (7110) in the Drive Protect Menu
(7). Check if the output current scaler (3440) is set to
a number that is close to 1.0.
Verify that the signals on test points IMB and IMC on
the System Interface Board match the percentage of
full-scale signals.
Perform the tests listed in Section 5.5 to verify the
operation of hall effect transducers.
Cause
The torque producing current of the drive has 7
dropped below a preset value set by the user.
Under Load Alarm A SOP Actions
This alarm usually indicates a loss of load condition.
If this not the case verify the settings in I underload
menu (1182) within the Limits menu (1120).
Cause
This fault usually indicates a loss of load condition
when the torque producing current of the drive has
dropped below a preset value set by the user for the
specified amount of time.
Under Load Fault F Menu
Actions
If this not an unexpected condition then verify the
setting of the I underload (1182) and the Under Load
Timeout (1186) parameters within the Limits Menu
(1120).

Cause
The software has detected an imbalance in the motor
currents.
Action
Output Phase Imbal A Fixed Verify proper symmetry of the motor currents on test
points VMA/TP5, VMB/TP6, VMC/TP7, IMA/TP21, IMB/TP22,
and IMC/TP23. If the currents are unsymmetrical, verify
if the burden resistors for the Hall Effect Transducers
are connected correctly on the Signal Conditioning
board.
Cause
The software has detected an open phase condition
at the drive output to the motor.
Output Phase Open A SOP Action
Verify all connections to the motor are secure.
Verify the presence of motor voltages and currents on
test points VMA/TP5, VMB/TP6, VMC/TP7, IMA/TP21,
IMB/TP22, and IMC/TP23 during drive operation.
Cause
This alarm is issued when the drive is in speed
rollback (due to a torque limit condition) for more than
In Torque Limit A SOP one minute.
Action
Check load conditions. Check proper settings for
drive and motor ratings.
Cause
This fault or alarm (depending on the SOP program)
is issued when the drive is in speed rollback (due to a
torque limit condition) for more than thirty minutes.
In Torq Limit Rollback SOP SOP Action
Check load conditions. Check proper settings for
drive and motor ratings.
7
Cause
Motor speed is below the Zero speed setting (2200).
This is either due to a motor stall condition (if speed
demand is higher than the Zero speed setting) or a
low speed demand condition (where speed demand is
Minimum Speed Trip F/A SOP lower than the Zero speed setting).
Action
Increase motor torque limit (ID 1190, 1210 or 1230) if
it is a stall condition or adjust the Zero speed setting
to avoid the desired low speed operating region.

Cause
This occurs only with synchronous motor control due
to field exciter failure or loss of power to the exciter.
Action
Loss of Field Current F/A SOP Check if the power supply to the exciter is energized
To determine if the field exciter is operating correctly,
reduce Flux demand (3150) to 0.40, increase Accel
time 1 (2260) to a larger value and run the motor with
5% speed demand. If the drive magnetizing current
reference (Idsref) does not go to zero, then the field
exciter is not working (or is not adjusted) properly.
Cause
This occurs only with induction motors due to high
magnetizing current (or poor power factor).
Action
Failed to magnetize F/A SOP
Increase the flux ramp time to give more time for
magnetizing current to settle down at startup. Verify if
motor stator resistance parameter (1060) is not set
too high for the application; reduce it if continuous
operation at very low speed is not desired.
System Related
Cause
Estimated drive losses are too high, due to (1) internal
problem in the cells, or (2) scaling error in voltage and
current measurement on input and output side.
Action
Excessive Drive Losses SOP Fixed Remove medium voltage and visually inspect all
the cells and their connections to the transformer
secondary. Contact ASI Robicon for support.
With the drive operating above 25% power, verify
if estimated drive efficiency is above 95%. If this is not
the case, then voltage and current scaling needs to
be checked.
7
Cause
The software detected a menu entry for Carrier
Frequency Menu (3580) was below the lowest
possible setting based on the system information.
Action
Carrier Frq Set Too Low A Fixed
Change the value enter in Carrier Frequency
Menu (3580).
Check the value of the Installed Cells/phase
Menu (2530).
Consult factory.

Cause
The software detected an error in the system program
file.
System Program F Fixed
Actions
• Reload system program.
• Consult factory.
Cause
The software detected an error in one of the files
Menu Initialization F Fixed stored on the CPU board Compact FLASH disk.
Action
Consult factory.
Occurs if system not able to write a master or slave
Config File Write Alarm A Fixed
config file.
Occurs if system not able to read data from a master
Config File Read Error F Fixed
of slave config file.
Cause
CPU Temperature is > 70 C.
CPU Temperature Alarm A Fixes Action
• Check air flow and chassis fans.
• Check CPU heatsink.
Cause
CPU Temperature is > 85 C.
CPU Temperature Fault F SOP Action
• Check air flow and chassis fans.
• Check CPU heatsink.
Cause
A/D board indicated a hardware error
A/D Hardware Alarm A Fixed
Action
Replace A/D board
Cause
A/D board hardware error persists for more than 10
A/D Hardware Fault F Fixed samples.
Action
Replace A/D board
Modulator related
7 Cause
Modulator Configuration F Fixed The software detected a problem when attempting to
initialize the Modulator.
Action Replace Modulator board.
Cause
The software detected a Modulator board fault.
Modulator Board Fault F Fixed
Action
Replace Modulator board.
Cause
Cell Fault/Modulator F Fixed Modulator has an undefined fault from a cell.
Action
Check cell, modulator board

Cause
Cell data packet mode bits incorrect.
Bad Cell Data F Fixed
Action
Check cell control board
Cause
Modulator Cell configuration does not agree with
Menu setting of Installed cells.
Cell Config. Fault F Fixed
Action
Insure correct number of cells are entered into menu
setting. Check modulator board
Cause
Modulator detected that the CPU stop communicating
Modulator Watchdog Flt F Fixed with it.
Action
Reset drive control power
Cause
Modulator detected loss of drive enable.
Loss of Drive Enable F SOP
Action
Reset drive control power.
Cause
The software detected a weak battery on the
Modulator board. This battery is used to power the
Weak Battery A Fixed memory for the fault and historical logger.
Actions
• Replace battery on Modulator board.
• Replace Modulator board.
Low Voltage Power Supply Related
Cause
One or both of the supplies that power the Hall Effects
on the drive output has failed.
Actions
Verify +/-15V on the Hall Effect Power supplies.
Hall Effect Pwr Supply F Fixed Verify +/-15V on the System Interface Board
Connector P4 pins 31 and 32. If +/-15V is not present,
check wiring from Hall Effect Power Supplies to the
System Interface Board.
7
If these signals are incorrect, replace the System
Interface Board.
Cause
The chassis power supply has indicated a loss of
power. This can either be due to loss of AC or a failed
Power Supply F Fixed power supply.
Action
Verify control power outputs
System I/O Related

Cause
The software detected a Loss of Signal on one of the
0-20mA inputs (1 through 24).
Menu/ Actions
Loss of Signal (1-24) A
SOP Check connection to the Wago 0-20mA input
corresponding to the Loss of signal message.
Replace effected Wago module.
Consult factory.
Cause
The software was unable to establish or maintain
communication with the Wago I/O system. The fault
is triggered when the lack of communication exceeds
timeout.
Actions
Wago Communication Alarm A Fixed
• Verify that the cable between the CPU board and
Wago Communication Alarm module is connected
properly.
• Replace Wago Communication Alarm module.
• Replace the CPU board.
Cause
The software was unable to establish or maintain
communication with the Wago I/O system. The fault
is triggered when the lack of communication exceeds
timeout.
Actions
Wago Communication Fault F SOP
• Verify that the cable between the CPU board and
Wago Communication alarm module is connected
properly.
• Replace Wago Communication Alarm module.
• Replace the CPU board.
Cause
Number of Wago modules does not equal number set
in menu
7 Wago configuration F Fixed
Action
Insure correct number of Wago modules are set in the
menu. Check Wago modules.
External Serial Communications Related
Cause
Tool is not communicating to drive
Tool communication SOP SOP Action
Check PC connecting cable, CPU BIOS settings, and
correct TCP/IP address agrees in Tool and Drive.
Cause
Keypad is not communicating to drive
Keypad Communication SOP SOP
Action
Check keypad cable, connections.

Cause
The drive is not communicating with the active
external network.
Actions
• Verify all network connections are secure.
Network 1 Communication SOP SOP
• Verify that the UCS board #1 and
Communications board are properly seated. If the
source of the problem is not found, then replace
the UCS board #1 and then the Communications
board.
Cause
The drive is not communicating with the active
external network.
Actions
Network 2 Communication SOP SOP • Verify all network connections are secure.
• Verify that the UCS board #2 and
Communications board are properly seated. If the
source of the problem is not found, then replace
the UCS board #2 and then the Communications
board.
Synch Transfer Related
Cause
Time-out has occurred from request to up synch
transfer.
Up Transfer Failed A SOP
Action
Increase menu setting, or set to zero to disable time
out.
Cause
Time-out has occurred from request to down synch
transfer.
Down Transfer Failed A SOP
Action
Increase menu setting, or set to zero to disable time
out.
Cause
Sign of input frequency and operating frequency are
Phase Sequence SOP SOP
opposite. 7
Action
Swap one pair of motor leads and change sign of
speed command
User Defined Faults
Cause
The UserFault_1 through UserFault_64 flags in the
system program have been set to the value “true”.
User Defined Fault (64) SOP SOP
Refer to Chapter 8: System Programming.
Action
Refer to the section on User Faults (on page 7-26).
Cooling Related
One Blower Not Avail A SOP See description for system program user faults above
All Blowers Not Avail F/A SOP See description for system program user faults above.
Clogged Filters SOP SOP See description for system program user faults above
One Pump Not Available A SOP See description for system program user faults above

Both Pumps Not Available F/A SOP See description for system program user faults above
Coolant Cond > 3 uS A SOP See description for system program user faults above
Coolant Cond > 5 uS F/A SOP See description for system program user faults above
Coolant Inlet Temp > 60° C SOP SOP See description for system program user faults above
Coolant Inlet Temp < 22° C SOP SOP See description for system program user faults above
Cell Water Temp High SOP SOP See description for system program user faults above
Coolant Tank Level < 30° C A SOP See description for system program user faults above
Coolant Tank Level < 20° C F/A SOP See description for system program user faults above
Low Coolant Flow < 60% A SOP See description for system program user faults above
Low Coolant Flow < 20% F SOP See description for system program user faults above
Loss One HEX Fan A SOP See description for system program user faults above
Loss All HEX Fans SOP SOP See description for system program user faults above
All HEX Fans On A SOP See description for system program user faults above
Input Transformer Temperature Related
Xformer OT Alarm A SOP See description for system program user faults above
Xformer OT Trip Alarm A SOP See description for system program user faults above
Xformer OT Fault F/A SOP See description for system program user faults above
Xfrm Cool OT Trip Alarm SOP SOP See description for system program user faults above
Input Reactor Temperature Related
Cause
Programmable via the System Program
Reactor OT Alarm A SOP
Action
Check output current waveform for sinusoidal shape.
Cause
Reactor OT Trip Alarm A SOP
Action
Cause
Reactor OT Fault F/A SOP
Action
Cell Bypass Related
Cause
7 The Master Control system is not communicating with
the MV Bypass board.
Action
Cell Bypass Com Fail F Fixed
Verify the Fiber Optic connection between the
Modulator board and MV Bypass board is intact.
Replace Modulator board.
Replace MV Bypass board.
Cause
The Master Control issued a command to bypass a
cell, but the MV bypass board did not return an
Cell Bypass Acknowledge F Fixed acknowledgement.
Action
Verify that the bypass contactor is working properly.
Check wiring between MV bypass board an contactor.
Replace MV bypass board or Contactor.

Cause
The Master Control system is not
communicating with the MV Bypass board.
Cell Bypass Link F Fixed
Action
Refer to “Cell Bypass COM Fail” above.
Cause
The Master Control system is not communicating with
Cell Bypass COM Alarm A Fixed the MV Bypass board, but the bypass system is not in
use.
Action
Cause
Cell Bypass Link Alarm A Fixed the MV Bypass board, but the bypass system is not in
use.
Action
Cause
Cell Bypass Fault F Fixed the MV Bypass board.
Action
Cause
xx Bypass Verify Failed F Fixed Bypass contactor closure verify failed
xx=cell that is faulted
Action
Check bypass system
Cause
xx Bypass Ack Failed Bypass contactor closure acknowledge failed
F Fixed
xx=cell that is faulted Action
Check bypass system
Cause
Cell level bypass available alarm. Only if
xx Bypass Avail Warning
A Fixed bypass is not used 7
Action
Check bypass system
Cell Related
Cause
The software detected a difference in the number
of cells detected versus the Installed Cells/phase
Menu (2530).
Action
Cell Count Mismatch F Fixed • Verify that the Installed Cells/phase Menu (2530)
matches the actual number of cells in the system.
• Verify all fiber optic cable connections are correct.
• Replace Modulator board.
• Replace Fiber Optic board(s).

The software timed out waiting for the Motor Back
Back EMF Timeout F Fixed EMF Voltage to decay to a safe level for cell device
testing.
VI VI VI A V V V V A AI A IIB IIC A IF IF IF A IO A IM IM IM A
A B C G M M M O G G G A B C G C G A B C G
N A B C N N N N N N N
7 15-pin Ribbon 37 Pin D-shell

to Modulator 50-pin Ribbon
to A/D Board to External
Board Conditioning
Board
Figure 7-1. Connections and Test Points on the System Interface Board
7.4. Cell Faults/Alarms

Cell faults/alarms are logged by the Microprocessor Board following a power cell fault indication. These
faults are available for inspection through the keypad display or can be uploaded to a PC via the serial
port. All active cell faults/Alarms are displayed on the keypad display. Use the arrow keys to scroll up and
down through the faults. The Alarm/Fault log upload function (Parameter ID 6230) in the Alarm/Fault Log
Menu (6210) can be used to upload the log to a PC for analysis and for sending to the appropriate ASI
Robicon or plant personnel.
All cell faults are generated by circuitry located on the Cell Control Board (CCB) of each power cell and
are received by the Microprocessor Board through circuitry on the Digital Modulator Board. Table 7-4

can be used as a quick troubleshooting guide to locate the cause of the fault condition. This table lists
faults that may occur in multiple-cabinet and GEN III and GENIIIe styles of Perfect Harmony drives unless
otherwise noted. All cell faults are initiated by the Cell Control Board or CCB (see Figure 7-2) located in
each power cell.
Not Safe
PL1-4 PL1-7 PL1-5 PL1-2
PL1-8 PL1-6 PL1-3 PL1-1
PL1
VAVAIL
VT1
XMTR1
VT2 RCVR1
VAUX VDC V- V+
PL1-12 LNKON
+10VREF / Q1
+5V
PL1-11 / Q2
-15V
+15V / Q3
+24V / Q4
IC27 / BYP
COM1
COM1 FLT
PL2 PL3
Figure 7-2. Connectors and Diagnostic Components of a Model 430 Cell Control Board
Note:
• Model 430 Cell Control Boards are only used in the multiple-cabinet versions of Perfect Harmony
drives (not GEN III or GENIIIe). Cell Control Boards for GEN III and GENIIIe drives use a single
board which contains all control, power supplies and gate drive and is different from the board
depicted in Figure 7-2.
*
• If a spare Cell Control Board is ordered for a drive that contains a model 430 board, a model N15
board will be shipped with an adapter harness for proper connection.

Table 7-4. Cell Faults
Cause
One or more of the input power fuses to a cell are
open.
Power Fuse Blown F Fixed
Action
Determine the reason for the fuse failure then repair
(if required) and replace the fuse.
Cause
Cell temperature above fault limit (fixed)
xx Over Temp Warning
F SOP Action
Check condition of the cooling system. Check motor
load conditions.
Cause
Each cell sends a PWM signal to the Modulator
Board. This signal represents the heat sink
Over Temperature temperature.
F Fixed
Action
Check the condition of the cooling system.
Refer to Section 7.4.1:on page 7-24.
Cause
One or more of the local power supplies (+24, +15,
+5, or -5 VDC) on a Cell Control Board (see
Figure 7-2) has been detected to be out of
Control Power F Fixed specification.
Action
If this occurs, the Cell Control Board should be
repaired or replaced. Refer to Section 7.4.1 on page
7 7-24.
Cause
Each Gate Driver Board includes circuits which verify
that each IGBT has fully turned on. This fault may
indicate a shorted IGBT, an open IGBT, or a failure in
the detection circuitry (i.e., logic low signals on
IGBT OOS n opto-couplers IC12, IC22, IC32, and IC42 pin 7 on Gate
F Fixed Drive Board usually as a result of a Q1, Q2, Q3, or Q4
(n=1,2,3,4)
collector-to-emitter short in the cell’s power bridge).
The cell’s power components and Gate Driver Board
should be checked.
Action
Refer to Section 7.4.1 on page 7-24.

Cause
A capacitor share fault usually indicates that the
voltage shared by the two DC link capacitors is not
being shared equally (i.e., the voltage on an individual
Cap Share F Fixed capacitor in a cell has been detected over 425 VDC).
This can be caused by a broken bleeder resistor (or
wire) or a failed DC link capacitor (C1 and/or C2).
Action
Cause
xx Link Cell communication link failure
F Fixed
Check fiber optic cable. Cell may need serviced.
Cause
An error in the optical communications was detected
by a cell (i.e., a logic low signal is detected on pin 13
of IC37). This is usually a parity error caused by
Communication F Fixed noise, but can also be a time-out error caused by a
faulty communications channel on the Cell Control
Board (see Figure 7-2).
Action
Refer to Section 7.4.4: on page 7-25.
Cause
xx Control Fuse Blown Cell control power fuse blown
F Fixed
Check cell fuses, replace if necessary.
xx DC Bus Low Warning Cause
xx=cell that is faulted Cell DC bus below alarm level
A Fixed Action
Check for single phase input, low input line
7
conditions, blown input fuses.
Cause
Cell DC bus below fault level
Cell DC Bus Low F Fixed Action
Check for single phase input, low input line
conditions, blown input fuses.

Cause
The bus voltage in a cell has been detected over
800 VDC (for 460VAC cells) or 1200VDC (for
690VAC cells) (i.e., the signal on the VDC test point is
DC Bus Over Volt F Fixed >8.0 VDC). This is usually caused by a regeneration
limit that is too high, or improper tuning of the drive.
Action
Refer to Section 7.4.3: on page 7-25.
Cause
The DC bus voltage detected in a cell is abnormally
low (the signal on test point VDC on the Cell Control
Board is <3.5 VDC). Refer to Figure 7-2. If this
DC Bus Under Volt F Fixed symptom is reported by more than one cell, it is
usually caused by a low primary voltage on the main
transformer T1.
Action
*
Note: Fault class designations in the previous table are shown in parentheses and are explained
in Figure 7-2 on page 7-17.
The following cell faults will occur only during the cell diagnostic mode (immediately following initialization
or reset). All IGBTs in each cell are sequentially gated and checked for proper operation (blocking/not
blocking). See Table 7-5.
Table 7-5. Diagnostic Cell Faults
Cause
During cell diagnostic mode, the Perfect Harmony
checks the voltage across each IGBT under “gate off”
conditions. A blocking failure is reported if insufficient
voltage is detected, i.e., voltages on test points VT1
7 Blocking Qn
F Fixed and VT2 on the Cell Control Board (see Figure 7-2)
(n = 1,2,3,4) are < ±0.5 VDC when power transistors Q1-Q4 are
gated. This may indicate a damaged IGBT, or a
malfunctioning gate driver board or cell control board.
Action

Cause
During cell diagnostic mode, the Perfect Harmony
turns each IGBT on one-by-one, and verifies the
collapse of voltage across the devices. A switching
failure is reported if a device is supporting voltage
Switching Qn while it is gated on (i.e., voltages on test points VT1
F Fixed and VT2 on the Cell Control Board are > ±0.5 VDC
(n = 1,2,3,4)
when power transistors Q1-Q4 are gated). Usually,
this fault is caused by a malfunctioning gate driver
board, IGBT, or cell control board.
Action
xx Blocking Timeout Cause
xx=cell that is faulted Blocking Test timeout
F Fixed
Action
Check cell, or back EMF too high
xx Switching Timeout Cause
xx=cell that is faulted Switching Test timeout
F Fixed
Action
Check cell, or back EMF too high
*
Note: Fault class designations in the previous table are shown in parentheses and are explained in
Figure 7-2 on page 7-17.

Output
To Power
Bypass
Board
T2’ T1’
NOTE: Each semiconductor is

Optional Bypass shown as one device for
Contactor simplicity, but may actually be
several parallel devices.
T2 T1
Q3
Q4
Ribbon Cable
PL1 PL2
Q1 F10 Q2
Fiber Optic
Data Link
IGBT Gate
Driver
Cell Control
Board
S2
TAS2B
TAS2A
7 PL1
C1 C2
3
DDC 12
11
DDB 2
10
1
DDA 8
4
F12 F13
F11 F3
7
F2 6
Input Power 5
from T1 F1
Figure 7-3. Typical Power Cell with Optional Mechanical Bypass

Fuses mounted
external to cell
on GENIIIe Cells
Figure 7-4. Typical Power Cell Schematic (GEN III and GENIIIe Design)


A1 A2 A3 A4 A5 A6

B1 B2 B3 B4 B5 B6

C1 C2 C3 C4 C5 C6
Future Expansion
A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4
A5 B5 C5 A6 B6 C6
Figure 7-5. Typical Fiber Optic Interface Boards Connection Diagram
7.4.1. Troubleshooting General Cell and Power Circuitry Faults

The types of faults addressed in this section include the following:
• AC fuse(s) blown faults
• control power faults
• device out of saturation (OOS) faults
• capacitor sharing faults
• Q1-Q4 OOS faults
• bypass failed faults
• VDC undervoltage faults
• blocking failure faults
• switching failure faults.
7.4.2. Troubleshooting Cell Over Temperature Faults

Water Cooled
7 Cell Over Temperature faults are typically caused by problems in the cooling system. Use the following
steps to troubleshoot this type of fault:
• Check the cooling system for proper flows and temperatures.
• Inspect cell cooling paths for kinked hoses or major leaks.
• Be sure all Cell Cabinet manifold valves are fully open.

7.4.3. Troubleshooting Overvoltage Faults

This fault is usually caused by an improperly set-up or tuned drive. Use the following steps to
troubleshoot this type of fault.
• Verify that the motor and drive nameplate settings match parameters in the Motor Parameter Menu
(1000) and Drive Parameter Menu (2000).
• Reduce the regen torque limit parameters (1200, 1220, 1240) in the Limits Menu (1120).
• Reduce Flux Regulator Proportional Gain (3110) and Flux Regulator Integral Gain (3120) parameters
in the Flux Control Menu (3100).
• If the failure is occurring in bypass mode, increase the Energy Saver Minimum Flux (3170) parameter
in the Flux Control Menu (3100) to at least 50%.
• If the measured signals (from the previous section) seem to be correct, change the Modulator board.
7.4.4. Troubleshooting Cell Communications and Link Faults
Faults of this variety can be the result of circuit failures on either the Digital Modulator Board or Cell
Control Board (see Figure 7-2).
• If the fault indication persists after replacing the Digital Modulator Board, see Section 7.4.1 above.
7.4.5. Status Indicator Summaries for MV Mechanical Bypass Boards
The MV Mechanical Bypass Board includes 3 LEDs that provide complete status of the MV board. These
LEDs are summarized in the following table.
Table 7-6. LED Status Indicators for MV Mechanical Bypass Boards
LED Function Color Description

CommOK green Indicates active communication link established with LV board.
Fault red Indicates that a bypass fault is active.
PwrOK green This LED is hardware controlled and indicates that the 5/15VDC
supplies are in tolerance.

7.5. User Faults
*
Attention! User faults are closely tied to the system program configuration. Refer to
Chapter 8: System Programming for more information.
User faults occur due to conditions defined in the system program. User faults are displayed on the
keypad in the form of user defined fault #n, where n equals 1 to 64. The faults can also be displayed
through user defined text strings. Most user-defined faults are written to respond to various signals from
the Wago I/O such as the analog input modules (through the use of comparators) as well as the digital
input modules.
A copy of the system program is required to specifically define the origin of the fault. In the example
program found in the Chapter 8: System Programming, the UserFault_1 flag is used to display the
event of a blower fault. Note that the UserText1 string pointer is used to display the specific fault
message. If this string pointer is not used, then the fault displayed would be “user defined fault #1”.
7.6. Unexpected Output Conditions
In some cases, the Perfect Harmony VFD will revert to operating conditions which limit the amount of
output current, output speed, or output voltage, but with no apparent fault condition displayed. The most
usual causes of these conditions are described in the subsections that follow.
The mode display shown in Table 7-7 can sometimes be used to troubleshoot the cause of the output
limitation. The first column of the table lists the abbreviated message that is shown on the display of the
drive. The second column lists the meaning of the abbreviated message. The third column lists
descriptions of the operating modes. Further descriptions of possible limit situations and troubleshooting
tips are listed in the subsections that follow.
Table 7-7. Summary of Operation Mode Displays
Display Meaning Description

CR3 CR3 Relay CR3 relay is not picked. The drive is inhibited (cr2_picked is not “true”).
Rgen Regeneration VFD is decreasing output speed due to a change in the speed
command.
Rlbk Rollback VFD is attempting to limit output speed due to torque output limitations.
Off Off Indicates that the VFD is in idle state A.
7 Hand Hand Normal operating mode while drive is running motor. Usually indicates
that operation is controlled from the front cabinet.

7.6.1. Output Speed Limit

If the mode display shows Rlbk (rollback mode), then the Perfect Harmony VFD is attempting to reduce
the output speed due to a torque limit condition. Use the following steps to troubleshoot this type of fault.
• Check the motor torque limit (1190, 1210, 1230) parameters in the Limits Menu (1120).
• Check all motor and drive nameplate ratings against parameters set in the Motor Parameter Menu
(1000) and the Drive Parameter Menu (2000).
*
Note: Spare parts are available through our Customer Service Center by calling (724)-339-9501.
7.7. Drive Input Protection

This section describes the routines used to detect abnormal conditions due to an internal drive failure and
thus provide protection to the drive. The faults generated by the routines may be used with suitable
interlocking, via a relay output and/or serial communication, to disconnect medium voltage from the drive
input.
7.7.1. One Cycle Protection (or Excessive Input Reactive Current Detection)
NXG Control utilizes input reactive current to determine whether a ‘hard’ fault on the secondary side of
the transformer has occurred. For example, a short-circuit in one of the secondary windings will result in
poor power factor on the high-voltage side of the transformer. A model of the transformer based on the
power factor at rated load (typically 0.95) is implemented in the control processor. The drive input
reactive current is continuously checked with the predicted value from the model. An alarm/trip is
generated if the actual reactive current exceeds the prediction by more than 10%. This check is avoided
during the first 0.25 seconds after medium voltage power-up to avoid the inrush current from causing
nuisance trips.
7.7.2. Excessive Drive Losses
The Excessive Drive Loss protection guards against low-level fault currents. Drive losses are calculated
as the difference between the measured input and output powers, and compared against reference
losses. For Liquid Cooled Drives, the reference losses are fixed at 3.5% during “Idle” State and at 5.5%
during “Run” State, while they are fixed at 5.0% and 7.0%, respectively, for Air Cooled Drives. When the
calculated losses exceed the reference losses, a drive trip is issued and this condition is annunciated as
an “Excessive Drive Loss Alarm”. In addition to this response, a digital output is set low in the System
Operating Program (SOP), which in the default drive configuration is used to open the input disconnect
device. The fixed reference limit is low enough to detect a fault in one set of transformer windings, and at
the same time is large enough to avoid nuisance trips. When the drive is not supplying power to the
motor, the losses in the system are primarily due to the transformer; the fixed limit is then lowered to 7
increase the sensitivity of the protection routine.
In earlier software versions up to version 2.22, the protection was such that when the calculated losses
exceeded the reference losses for more than one second, a trip was generated. For software versions
2.30 and higher, an inverse power loss function is implemented for Excessive Drive Loss protection. The
plots in Figure 7.6 show the time to trip as a function of calculated losses for Liquid and Air Cooled
Drives. Each plot contains two curves, one of which is used when the Drive is in “Idle” State (i.e. medium
voltage is applied, but the motor is not being operated) while the second curve (slightly longer time to trip)
is used during the “Run” State.

Run State
Run State
Idle State
Idle State
Figure 7-6. Excessive Drive Loss Protection
7.7.3. Transformer Over-Temperature and Loss of Cooling

The temperatures of all the secondary windings are monitored using two (series-connected) sets of
(normally closed) thermal switches. The first set opens when the temperature exceeds 150°F (or 65°C)
while and the second set opens above 180°F (or 82°C). Two outputs, one output corresponding to each
set, are read through the WAGO by the control logic. A Xfrmr Temperature Alarm 1 is issued when one
or more 150°F switches open, and a Xfrmr Temperature Alarm 2 is issued when one or more 180°F
switches open. When both these conditions exist for 30 seconds, a Xfrmr Over Temp Fault is generated
that causes the drive to trip.
A vortex flow sensor monitors liquid coolant flow through the drive. This sensor is connected to a display
unit on the door of the Coolant Section, which displays flow rate, among other parameters, and outputs a
4-20 mA signal to the WAGO. A software comparator, interacting with the control logic, monitors this 4-
20 mA signal. As a standard default, the alarm "Loss of Coolant Flow" is issued whenever the detected
flow rate is below 40 percent of rated for 7 seconds.
The SOP program can be used to trip the input Medium Voltage Breaker when the conditions of Xfrmr
Temperature Alarm 1, Xfrmr Temperature Alarm 2, and Loss of Coolant Flow exist simultaneously.
7 7.8. Portable Harmony Cell Tester

ASI Robicon can supply the necessary equipment to perform on-site cell testing at a customer’s site.
This test is essentially a duplication of the cell test done at the factory prior to installation into the Cell
Cabinet. Since each cell operates independently within the Perfect Harmony system, it is possible to fully
test the performance of each cell and thus verify the proper performance of the cell system without having
to actually apply rated voltage to the motor.
The following equipment is required for on-site cell testing:
• Portable Harmony Cell Tester (PCT) (P/N 469939.00)
• IBM compatible computer (286 or greater with Centronics port and EGA capability)
• 480 VAC, 30 A variable auto transformer variable voltage source (STACO type 6020-3 or
equivalent)
• Load reactor (refer to Table 7-8).
• DVM capable of measuring 500 VAC (Beckman 3030A or equal).
• Clamp on ammeter (Beckman CT-232 or equal).

Table 7-8. Load Reactor Information
Cell Size Reactor P/N Reactor Configuration

NBH 70 161661.13 1 Unit with Series windings L=8mH
NBH100 161661.13 1 Unit with Series windings L=8mH
NBH 140 161661.13 1 Unit with Series windings L=8mH
NBH 200 161661.13 1 Unit with single windings L=4mH
NBH 260 161661.13* 1 Unit with parallel windings L=2mH
3I 161661.13* 1 Unit with single winding L=4mH
360H 161661.13* 1 Unit with parallel windings L=2mH
4I (300H) 161661.13* 1 Unit with parallel windings L =2mH
4B 161661.13* 1 Unit with parallel windings L=2mH
5C 161661.13* 1 Unit with parallel windings L=2mH
5B 161661.13* 2 Units in parallel with series windings L= 1mH
500H 161661.13* 2 Units in parallel with series windings L= 1mH
660H 161661.13* 2 Units in parallel with series windings L= 1mH
* Requires small cooling fans that are not included.
The portable cell tester (PCT) comes equipped with cables and software required to interface the PCT
with the cell’s optical communications port and the PC. The individual tests are menu driven with go and
no go features.
The load reactors will allow each cell to attain full rated current with a minimal input service requirement
to the variable voltage source.
The clamp-on ammeters and voltmeters will allow evaluation of the proper output voltages and cell
currents during the test.
The procedure for testing an installed cell is listed below.
• If possible, switch off the source of the medium voltage power at the switchgear. Make sure the
drive's medium voltage input switch is open, and lock it out. Rack out any output contactors in the
system and lock them out. Take any other necessary steps to release the interlock key that allows
access to the cell cabinet. Keep the transformer cabinet and power input cabinet closed and locked.
Be sure the cooling system pump is operational.
• Isolate the cell to be tested by removing the series links from the output at T1 and T2.
• Unplug the fiber optic cable from this cell at the Fiber Optic Interface Board and plug it into the PCT.
Connect the PCT to the parallel printer port of the computer. Turn on the power to the portable cell
tester.
• Disconnect the 3-phase input from the cell and connect the 3-phase output of the variable voltage
source to the input of the cell. Connect the input of the variable voltage source to the load side of the
7
460 VAC control breaker (CB1).
• Execute the 1CELL.EXE program on the computer. From the Main Menu (5) choose #1. The
preliminary test will go through a step-by-step go/no go procedure. This will verify that the
communications are working and the transistors are blocking (not shorted).
Attention! At this point of the test, the functionality of the IGBTs has been determined. When
prompted to use a resistor, the operator should cancel the program by following the instructions
on the screen.
• Turn off the variable voltage source. Connect the load reactor to output connections T1 and T2 of the
cell. If the cell is operated externally from the cabinet, a separate water supply is required.
• From the Main Menu [5] choose #2 Burn-in Test Menu. Make sure that the pot on the tester is turned
fully in the counter-clockwise direction. From the Burn-in Test Menu start the burn-in. The bottom of
the screen will indicate that the cell is running. LED’s Q1-Q4 on the cell should be illuminated. This
verifies that all four transistors are firing. Connect an ammeter to T1 or T2. Turn the pot on the tester
clockwise and note that the output current increases. Continue until output current reaches the rated

current of the cell. Run the cell for 1 hour. Turn the pot fully in the counter-clockwise direction. Stop
the burn-in test and exit to the Main Menu.
• If faults occur while the cell is running, the PC will display all faults detected.
• Install the cell in the Cell Cabinet and reconnect all power cables, hoses and fiber optic cables.
7.9. Removing Power Cells

Lethal Voltages--DANGER!! Verify that the input power is fully locked in the off position
and that the bus LED on each cell is off.
If it is necessary to remove a single power cell from a drive that is filled with coolant, follow the procedure
below:
1. Disconnect input and control power to the drive. Allow the cell capacitor bank to bleed down. This
usually takes 5 to 10 minutes after removal of input power.
2. Close valves BV4A and BV4B AND 16A to isolate the cell cooling liquid from the rest of the system.
Disconnect the fiber optic cable from the cell.
3. Using two temporary clamps (ASI Robicon P/N 088145.00), clamp off the two hoses to the cell to
minimize spillage when the hose quick disconnect fittings are uncoupled.
4. Disconnect the two cooling liquid lines from the cell using the quick disconnects. The fittings are
disconnected by pushing the hose side of the fitting inward and pulling the ring around the cell side
fitting from the hose side. When the ring is moved, the hose side of the fitting can be pulled out.
5. Protect the two open hose connectors and the two open cell connectors to prevent entry of dirt or
debris. Dummy connectors or a plastic sheet and tape can be used. See Figure Figure 7-7.
6. Disconnect the three phase input connections by removing the links at the bottom of the cell power
fuses F11, F12 and F13 (shown in Figure 7-9). Disconnect the output link to each adjacent cell.
7. Position the cell lift device (e.g., a fork lift truck or ASI Robicon P/N163469.01) in front of the cell
with the lifting rails aligned both horizontally and vertically with the cell mounting frame rails. Lock
the cell lift device in position on the floor.
8. Remove the cell retaining angle brackets at the front bottom of the cell (see Figure 7-9). Roll the
cell onto the lift device rails and lock it in place prior to moving the lifting device. Refer to Figure 7-
8.)
Figure 7-7. Protecting an Open Cell Connector Using Plastic and a Wire Tie

Figure 7-8. Installation/Removal of a Cell Using a Fork-style Lifting Device
Cell Coolant Outlet to

Next Cell Cell Coolant Inlet
Cell Output T2 Cell Output T1
Power fuses (3)
Input Connection
Links
Retaining Angle Cell Input

Connectors
7
Bracket Retaining Angle
Bracket not
Installed Yet
Figure 7-9. Front View of a Cell in Cabinet
Attention! When placing power cells into service which have been stored for more than two (2)
years without application of rated input voltage, it is advisable to use the following procedure to
reform the cell’s electrolytic capacitor bank: follow the procedure in section 7.8, and apply rated
voltage from the variable 690VAC voltage source for at least one hour prior to installation of the
cell into the cell cabinet.

7.10. Six Month Inspection

• Check operation of fans in the top rear portion of the Cell Cabinet. Clean or replace them if
necessary.
• Inspect cooling system for leaks. Repair or replace components as necessary.
• Use touch-up paint as required on any rusty or exposed parts.
• Test coolant for presence of required glycol concentration. Reference Table 9-4 in Section 9.12 of
this manual. Note: a minimum of 5% concentration by weight is recommended to control bacteria.
7.11. Replacement of Parts

Replacement of component parts may be the best method of troubleshooting when spare parts are
available. Use troubleshooting guidelines found elsewhere in this chapter when attempting to locate a
failed sub-assembly. When any sub-assembly is to be replaced, always check that the part number of
the new unit matches that of the old unit (including the dash number).
• Failures traced to individual PC boards within the Control Cabinet are best serviced by replacement
of the entire board.
• Failures traced to individual power cells are best serviced by replacement of the entire cell.
*
Note: For spare parts lists for customized drives, refer to the custom documentation package
shipped with the drive or call ASIRobicon Customer Service Department at (724) 339-9501.
When calling for spare parts information, please have your sales order number.
Attention! The disposal of any failed components (for example, CPU battery, capacitors, etc.)
must be done in accordance with local codes and requirements.
∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics SYSTEM PROGRAMMING
CHAPTER 8: SYSTEM PROGRAMMING
8.1. Introduction
ASI Robicon’s ID Series of digital drives contain customized programmable logic functions that define
many features and capabilities of the drives. These logic functions are combined into a system program
that can be edited either at the factory or in the field. Examples of logic functions include start/stop
control logic, input and output control logic (e.g., annunciators, interlocks, etc.), drive-to-machinery
coordination and more). The system program is stored in a non-volatile portion of memory on the drive
and is executed continuously by the drive’s run-time software in a repetitive fashion causing the intended
logic statements to perform their functionality.
To fully understand the system program operation it is necessary to look at how data is structured, how
the compiler puts the data together, how the drive’s software performs its evaluation, and timing related
issues. To begin, an understanding of system program terminology is required.
8.2. System Program Terminology
To understand system programs, it is helpful to understand the process by which these programs are
created, edited, translated, and transferred to the drive. These processes use certain terms which are
summarized in Table 8-1.
Table 8-1. System Program Terminology
Name Function
PC All of the software programs (the ASCII text editor, compiler program,
decompiler program, communications software package, etc.) are found on the
PC. The PC is also used to send/receive the compiled system program (the
hex file) to/from the drive (via the communications cable).
Source File The source file is an ASCII text file containing simple Boolean statements and
operators. This is the “human” version of the system program. The source file
is edited on a PC using any standard ASCII text editor. This file is used as the
input to the compiler program and is unreadable by the drive. The source file
uses the .SOP file extension.
Hex File The hex file is a compiled version of the source file (in an Intel hex format).
This is the “machine” version of the system program. The hex file is a result (or
output) of the compile process. This file is the compiled version of the system
program source file that is used by the drive. It is sent from the PC to the drive
over the communications cable using communications software located in the
PC and software functions chosen from the drive menus. The hex file is
unreadable by the user. It must be reverse compiled in order to be viewed by
the user.
ASCII Text Editor The ASCII text editor is a software program used on the PC to edit the source
file of the system program.
Compiler Program The compiler program is an off-line (i.e., separate from the drive) software
program that resides and runs on an IBM-compatible PC. It is used to translate
8
the ASCII text source file (.SOP) into the hex version system program file
(.HEX). This program reads the input source file (.SOP), validates the
statements for proper syntax and symbolic content, generates primitive logic
functions that implement the higher level logic statements, and stores this
information into an output file using Intel hex file format. The resulting .HEX file
can be downloaded to the drive.
Reverse Compiler The reverse compiler program does the opposite of the compiler program. It
Program uses the compiled hex file (with a .HEX extension) as the input and produces
an ASCII text output file (with a .DIS [for disassembly] extension) that can be

SYSTEM PROGRAMMING Perfect Harmony GENIII/e Startup and Advanced Topics
Name Function
read by the user via any standard text editor software. This program is useful if
the original source file is lost, damaged or unavailable. Note that any
comments in the original source file will not be reverse compiled since they are
ignored by the compiler program when the hex file is created.
Communications The communications software is used to send the compiled version of the
Software system program from the PC to the drive. The communications software must
be configured for proper communications to occur (i.e., baud rate, number of
data bits, number of stop bits, and parity settings). ASI Robicon recommends
using the ASI Robicon SOP Utilities program (requires Windows 95 or
Windows NT), however an appropriate third-party serial communications
program is acceptable, as long as it was designed for the platform on which it
is run. (It is not recommended to run DOS-based programs from Windows
95 or Windows NT.)
Communications This is a serial communications cable over which data (e.g., the system
Cable program) is transmitted between the drive and the PC. The exact
specifications of this cable vary based on the drive being used and the type of
connector available on the serial communications port of the PC.
Drive The drive is an ASI Robicon ID-Series motor drive. It contains a system
program that is stored in a non-volatile portion of memory on the drive and is
executed continuously by the drive in a repetitive fashion causing intended
logic statements to perform their functionality. Within its menu structure, the
drive contains software functions used to enable uploading and downloading
between the drive and the PC. The settings of communications parameters in
the drive must match the settings in the communications software on the PC
for proper communications during system program transfers.
*
Note: Intel hex format is an ASCII representation of binary data. The hex file mentioned in the
previous table uses various record types to set the download location and for error detection.
8.3. Overview of the Compile Process

To be practical, the “logic” that is represented by the system program must be understood by both man
and machine. For the system program to be an effective mechanism through which human operators
define (and even change) the logic functions of the drive (in the field, especially), the representation of the
logic functions in the system program must be easily understood by the operator. However, the defined
logic functions ultimately must be interpreted by the drive itself. In ID Series drives, a compiler is used to
convert user-friendly logic statements (in English text) into a downloadable, ASCII representative format
of binary data which is run (interpreted) by the drive (increasing its flexibility of configuration and system
integration). The logic statements can be written directly from a ladder logic representation of the system
logic.
The compile process is accomplished off-line on a PC. The term off-line means that the process is
8 separate from the drive and does not require a physical or electrical connection to the PC. The chief
advantage of off-line editing is that the source code of the system program can be changed anywhere
(not just near the drive) using any standard ASCII text editor on any IBM compatible PC. With the system
program compiler software installed on the PC, the source code can even be remotely compiled into its
machine-friendly hex format. Then, all that remains is to serially connect the PC and the drive and
download the hex file to the non-volatile RAM portion of the drive. The run-time software of the drive then
executes the system program logic statements sequentially and repetitively, causing the drive to function
as intended.
The compiler reads the source input file, validates the statements for proper syntax and symbolic content,
generates primitive logic functions and stores this information into an output file using the Intel hex file
format. Refer to Figure 8-1.

Note:
• After off-line creation and compilation, the system program (in hex file format) can be
downloaded to the ID Series drive. The downloading process requires a PC, a communications
cable (appropriate for the PC and the drive) and either (1) appropriately configured
communications software in the PC, or (2) the upload/download component of the ASI Robicon
*
SOP Utilities software (requires Windows 95 or Windows NT).
• In this context, the term “operator” refers to the individual in charge of customizing the system
program, and not necessarily any user of the drive.
Symbol
ASCII text file Directory
File
ASCII text file Intel Hex file
Input System Output

Source Program ASCII
File Compiler File
Figure 8-1. Block Diagram of the Compile Process
*
Note:
It is a good programming practice to save an electronic copy of the original SOP file before making
any changes. This gives you the opportunity to refer back to the original SOP if the need ever
arises.
A copy of the symbol directory file (e.g., DRCTRY.NGN) must exist within the same directory as the
compiler and reverse compiler.
8.4. Software Tools

ASI Robicon offers a Windows-based program that contains an integrated compiler, reverse compiler
and upload/download utility. The program is compatible with Windows 95 and Windows NT (and
newer releases). DOS versions of the compiler and reverse compiler are also available for older
versions of Windows. For additional information, contact the ASI Robicon Customer Service Center at
(724) 339-9501.
8.5. Input Source File
The input source file is the ASCII text version of the system program that is edited by the user. Editing
can be performed using any standard ASCII text editor on an IBM (or compatible) PC. The file can
contain both logic statements and explanatory comments to aid in documenting the content and intent of
the logic statements. With the exception of simple true and false logic assignments, the order of the
statements in the source file is the order that the statements will be executed by the drive’s run time 8
software.
*
Note: In the case of logic assignments where the source state is a simple “true” or “false”, the
assignment is made only once at runtime software initiation. False assignments are optional as the
default state of any system flag is “false”.
The execution flow of the run time software is as follows:

1. Comparator evaluations are performed and the resulting system flags are updated
2. Input flags are scanned and their present state(s) are recorded
3. logic equations are executed based on the recorded input states

4. the results of the logic statement(s) are output.

A sample input source file is illustrated at the end of this section. Although this sample source file may
appear to be very complex, it contains only two basic types of statements:
• source lines
• comment lines.
Comment lines are distinguished by a semi-colon (;) followed by descriptive text for the rest of the line.
All lines that begin with text instead of a semi-colon are program source lines. Program source lines may
continue to other lines and are finally terminated with a semi-colon.
Comment lines provide additional information to the reader. This information includes the program name,
the date it was written, the author’s name, an edit history, etc. Comments can also be placed
strategically throughout the code to separate source lines into logical groups and to improve readability.
In addition, comment lines can be used to explain the functionality of complex program statements. It is
good programming practice to use comments to thoroughly document source code, especially if more
than one person may be editing or reviewing it. Note, however, that comments should add useful
information to the source code (e.g., make the code more readable, describe the purpose of a particular
logic statement, define the goal of the program segment, etc.) and not just restate the obvious.
Note:
• All source code comment lines are ignored by the system program compiler. Only the program
statements (with any optional comment suffixes omitted) are compiled into the binary (hex
* formatted) system program that is downloaded to the drive. For this reason, the process of
reverse compiling the system program yields source code without comments. For more
information on the process of reverse compilation, refer to section 8.11 on page 8-22.
• Comment text can be included in source lines if it appears after the program statement (i.e.,
after the statement terminator [;]). Never embed a comment within a program statement. For
examples, Refer to the sample input source file that follows.
Source lines contain logic statements that define inputs, outputs, control logic and operations of the drive.
Logic statements contain statements, flags and operators that must follow precise spelling and syntax
rules in order for them to be interpreted correctly by the compiler. An example of one such syntax rule is
the fact that all program statements within a system program are terminated with a semi-colon character.
Program statements may, however, continue on multiple lines to aid in readability. Syntax rules for all
source code components are discussed later in this chapter.
Note:
• Single source lines of code must not exceed 132 characters in length.
* • The name and source file date/time stamp of the system program can be recalled and displayed
in the keypad display using the Display System Program Name function. This can be useful in
determining the exact system program that is being executed in the drive.
8.5.1. System Type Identification

Because the compiler and reverse compiler support a number of different end products, the compiler
8 needs to know what the target system is so that it can generate the proper code for that target system.
There are two methods that can be used to inform the compiler what the target is.
• Use the #system_type; identification command on line #1 (recommended)
• Specify the system type on invocation of the compiler (DOS version only).
Method 1: The first method is to include the system type identifier command as the first line in the
system program SOP file. The syntax of this command is shown below.
#system_type; (begins with “#” in column 1, ends with “;”)
The statement must be on the first line of the file, the “#” character must appear in column 1, and the
program line must end with a semicolon. For Perfect Harmony drives, the proper format of this command
is shown below.
#NEXTGEN;

*
Note: A comment can follow the semicolon with the system type identification command.
The compiler also recognizes other system types. These are listed in Table 8-2 and shown in
Figure 8-2.
Table 8-2. Product Types Recognized by the System Program Compiler
Target Product Type Identification Command

Perfect Harmony #HARMONY;
454 GT #ID_454GT;
ID-CSI #ID_CSI;
DC Harmony #HARMONY_DC;
ID-2010 #ID_2010;
NextGen Control #NEXTGEN
Figure 8-2. Windows-based Compiler Showing Product Types (Dimmed)
*
Note: If you use the ASI Robicon SOP Utilities program to compile an SOP file that does not
include the #system_type; identifier, then the Product Type radio buttons (see Figure 8-2) will
become enabled and the user must select the appropriate product type. 8
Method 2: The second method (and least preferred) is to define the system type on the invocation
command line (available only with the DOS version of the compiler) using the /t:n switch. In the case of
the Perfect Harmony, n has a value of 1. Other target devices are shown with their respective n values in
Table 8-3. If the command line switch is not used and a drive type is not present in the source file, the
user will be prompted to select the type. The compilation process cannot complete without a valid drive
type.

Table 8-3. Compiler Invocation Options for the /t:n Switch (DOS Version Only)
Target System Type Value for n Invocation Switch

Perfect Harmony 1 /t:1
454 GT 2 /t:2
ID-CSI 3 /t:3
DC Harmony (e.g., torch supply) 4 /t:4
ID-2010 5 /t:5
Based on the system type, the compiler will search for a unique directory file. Because each system type
uses its own directory file, it is convenient for the compiler (and reverse compiler) to automatically use the
correct file. The directory file that the compiler uses is based on the target system type. These are
summarized in Table 8-4.
Table 8-4. Directory Filename Associations
Target System Type Directory File Name

Perfect Harmony DRCTRY.PWM
454 GT DRCTRY.IGB
ID-CSI DRCTRY.CSI
DC Harmony (e.g., torch supply) DRCTRY.HDC
ID-2010 DRCTRY.DC
8.5.2. Operators and Precedence

There are two forms of operators that can be used in a source line of the system program. These forms
are unary operators (requiring only a single operand) and binary operators.
There is a single unary operator–the negate operator. This operator takes the form of a slash character
(“/”) which precedes a single input symbol. This operator forms the inverse logic equivalent of the symbol
immediately following it for incorporation into the statement evaluation. It has higher precedence than the
binary operators, which means it is evaluated before the evaluation of any binary operations.
*
Note: The “/” symbol must be followed by an input symbol.
For example, the expression

/Zero_O
equates to
NOT Zero_O.
8 If the input variable “Zero_O” were FALSE, then “/Zero_O” would equate to TRUE.
There are two binary operators–AND and OR. These operators take the form of an asterisk (“*”) and a
plus sign (“+”), respectively. These operators correspond to the Boolean AND and OR functions. Unlike
the unary NOT operator (which requires only a single variable), each of these operators requires two
variables which surround the operator.
The binary operators “+” and “*” serve to form the simple Boolean combination of the combined
expression preceding the operator and the symbol (possibly negated) immediately following the operator.
Parentheses are not allowed to force expression evaluation. The expression must be formed with left to
right precedence and must be expanded to simple form.
Refer to the Boolean truth tables in Table 8-5 for functional descriptions of the operators. Table 8-6
shows the precedence of operations. Table 8-7 shows syntax examples.

Table 8-5. Boolean Truth Table for the NOT, AND and OR Functions
NOT Function AND Function OR Function

A /A A B A*B A B A+B
False True False False False False False False
True False False True False False True True
True False False True False True
True True True True True True
Table 8-6. Precedence of Operations
Type of Operation Symbol Meaning Precedence

Unary Operation / Not High (performed first)
Binary Operation * And :
Binary Operation + Or Low (performed last)
Table 8-7. Syntax Examples
Example Description
C = A + B; Correct, C equals A OR B
C = A * B + D; Correct, C equals (A AND B) OR D
C = A + B * D; Correct, C equals A OR (B AND D)
C = A * B + A * D; Correct, C equals (A AND B) OR (A AND D)
C = A * (B + D); Incorrect, parentheses not allowed.
C = A + /B; Correct, C equals A OR (NOT B)
/C = A * B; Incorrect, negation not permitted on output side

8.5.3. Statement (SOP) Format

The format for a system program source statement is as follows:
output_symbol = {unary_operator} input_symbol { [ binary_operator input_symbol ] ... };
where:
output_symbol represents an output symbol defined in the symbol directory file
= the assignment operator (only one per source statement)
input_symbol represents an input symbol defined in the symbol directory file
unary_operator Boolean NOT operator (/ character)
binary_operator Boolean operators OR and AND (+ and *, respectively)
{ } represents optional syntax
[ ] represents required syntax
... the previous operation may be repeated
; statement terminator
The statement can span multiple lines and can contain spaces as needed for readability. The
output_symbol is a required field and can be any symbol that would be valid as an output variable. The
output_symbol is followed by one or more optional spaces and then the required assignment operator “=”.
A source statement can contain only a single assignment operator.
*
Note: Program statements may span multiple lines by breaking the line at a convenient operator.
Examples are shown in Table 8-1. The single line length of 132 characters should not be exceeded.
The input side of the equation must equate to a simple Boolean form (either true or false) after evaluation.
It is formed from either a simple input symbol (possibly negated with a NOT unary operator) or a
combination of input symbols operated on with binary operators.
Input symbols and binary operators are evaluated left to right by the run time software. The precedence
of operations is summarized in the next section.
Note:
* • Each statement must be terminated with a semicolon.

• Symbol names are case insensitive to the compiler. The symbols symbol_1, Symbol_1 and
SYMBOL_1 are all treated identically.
The term “sum-of-products” comes from the application of Boolean algebraic rules to produce a set of
terms or conditions that are grouped in a fashion that represents parallel paths (ORing) of required
conditions that all must be met (ANDing). This would be equivalent to branches of connected contacts on
a relay logic ladder that connect to a common relay coil. In fact the notation can be used as a shortcut to
describe the ladder logic.
First let us examine the rules of Boolean algebra. The set of rules that apply in this logical math are
broken into 3 sets of laws: commutative, associative, and distributive. The operators are “AND”
(abbreviated with the “x” character [or “*” character from a keyboard]), “OR” (abbreviated with the “+”

character) and “NOT” (abbreviated with a line above the operand, e.g., A [or a preceding “/” character
from a keyboard]). The commutative, associative, and distributive rules are shown as follows.
8 Table 8-8. Boolean Laws
Commutative1 Associative1 Distributive1

A+B=B+A A+(B+C)=(A+B)+C A ( B + C ) = AB + AC
AB = BA A ( BC ) = ( AB ) C
1 - The syntax “AB” implies (AxB).

Table 8-9. General Rules of Boolean Math
General Rules General Rules General Rules1
Ax0=0 A+0=A A + AB = A
Ax1=A A+1=1 A(A+B)=A
AxA=A A+A=A ( A + B ) ( A + C ) = A + BC
  
Ax A =0 A+ A =1 A+ AB=A+B
=
A=A
1 - The syntax “AB” implies (AxB).
Add to this DeMorgan’s Theorem which states “the complement of the intersection (AND) of any number
of sets equals the union (OR) of their complements” which, simply stated, means that if you invert a
grouping of elements, you invert the individual elements and also change the logical relationship between
them. So you can change from an OR to an AND function, for example
  
( A+B ) = ( A x B )
or from an AND to an OR function, for example
  
(A x B) = ( A + B ).
By using these rules, any logical statement can be reduced to the sum (+) of products ( x ) or the ORing of
ANDed terms as illustrated in the following example.
 
O = AB + B C D + CD F ;
The SOP file, as mentioned above is written with a text editor or a word processor set for pure ASCII text
(having a .TXT file extension) with no control or formatting codes with the exception of horizontal tabs
(ASCII code 09h) and carriage returns (0Dh). Only printable characters and spaces (20h) can be used.
The file consists of the following format:
Table 8-10. SOP Text File Format
Item Description
Drive type specifier This must reside on the first line of the file prefixed with the pound sign
(#) and followed with the name of the drive (in the case of Perfect
Harmony this would be #Harmony;).
Header A comment field containing the following information:
Title - ASI Robicon Perfect Harmony drive
Program part number
Customer name
Sales order number and ASI Robicon drive part number
Drive description
Original SOP date
File name
Engineer name (Originator)
Revision history (date and change description).
8
Note: A comment is any text within the file that is used exclusively for
informational purposes and is ignored by the compiler.
Operators Comment field containing operators and symbols

Item Description
I/O specifier Comment field describing the system input and output flags as they relate
to the external system. This would include any user faults and notes on
menu settings, such as Comparator setups and XCL settings, as they
apply to the system program (more on this later). These can (and
should) be grouped logically to allow easy access to information and to
make the SOP more understandable.
User fault messages Assigns the text to be displayed when this particular user fault is
activated.
Main logic section All the equations and assignments for the configuration, annunciation,
and operation of the drive. These should be logically arranged with
careful consideration given to the order of evaluation of the equations.
8.5.4. Input Flags

Input flags are identified by variable_I. Input flags are symbols that are encountered on the right hand
side of a source statement (to the right of the equals sign) that express the state of an input to the
system. They may reflect the state of a digital input (e.g., ExternalDigitalInput01a_O,
ExternalDigitalInput01b_O) or switch (e.g., KeypadManualStart_O), the state of a system process (e.g.,
Cells_I, OverloadFault_I, OutputPhaseOpen_I), internal variable, Comparator flag (e.g., Comparator_1),
or a simple literal (TRUE, FALSE). These input flags are combined using the unary and binary operators
to form logic expressions.
Digital input flags generally represent the state of a discrete digital input signal into the system. These
may be a 24-volt logic input, a key switch or push-button in the system or some form of a binary input.
The inputs are scanned at the beginning of each execution cycle, but may reflect older information in
some cases.
System constants TRUE and FALSE are predefined and can be used as input terms to an expression.
Note:
• Note that any expression that uses a TRUE or FALSE constant by the compiler will be placed in
a section of run time system program statements that are executed only once during system
* program initialization. The one time execution of invariant expressions improves the execution
speed of the remaining conditional expressions.
• Constant expressions are not updated at the completion of each system program execution
loop. They are only set during system program initiation.
There exists the capability to compare at the value of certain system variables against preset thresholds
in real time and then use the results of the comparisons (TRUE or FALSE) in the system program to
control actions on the drive. The variable(s) to be compared and the thresholds are entered into the
system using the keypad. The output of the comparisons (Comparator1_I ... Comparator16_I) are
available for use in the system program as input symbols.
8.5.5. Output Flags
8 The output flags all have “_O”, tagged onto the end of the variable name (variable_O). The output flags
(the symbol placed on the left-hand side of the assignment “=” operator) direct the result of the input
expression towards an output purpose. Output flags represent items such as digital outputs and system
control switches.
Table 8-11. Types of Output Flags
Types Examples
digital outputs ExternalDigitalOuptput01a_O, ExernalDigitalOutput01b_O, …
system control switches AutoDisplayMode_O, RampStop_O, , RunRequest_O

Digital output flags generally represent some form of discrete digital output bit(s) from the system. These
may be a relay coil driving contacts (NO or NC), direct digital outputs or lamp controls. The digital output
signals are updated at the completion of each system program execution loop.
The Perfect Harmony series of drives (as well as all other ID series drives) has a set of pre-defined
symbols that describe control outputs or “switches” that can be controlled by the system program. These
switches can control functions such as the source of the speed reference, a selection for the system
acceleration rate and a multitude of others. In most cases, to cause the system to perform in the
intended manner, the proper control switches must be set (and others cleared) by the system program.
The default state for all control switches is FALSE. Unless the system program sets the switch to TRUE,
it will be inactive (FALSE).
*
Note: No variable_I, Input variable can appear on the left side of the “=” sign. Both variable_I and
variable_O can appear on the right side of the “=” sign.
*
Note: Only one switch should be set at any one time from any group.
There is a set of Boolean temporary flags available to hold temporary or common expressions in the
system program. By using these temporary flags to hold common expressions, system program
execution times can be improved. The system program compiler does not perform any optimization, it
generates code closely matching the equations as written. If there are expressions that are repeatedly
evaluated, set a temporary flag to the intermediate results and then use the flag instead of the longer
expression.
For example:
ExternalDigitalOutput01a_O = ExternalDigitalInput01_a + ExternalDigitalInput01_b + RunRequest_O;
SetPoint1_O = ExternalDigitalInput01_a + ExternalDigitalInput01_b + RunRequest_O;
SetPoint2_O = ExternalDigitalInput01_a + ExternalDigitalInput01_b + RunRequest_O ;
could be replaced with:
TempFlag01 = ExternalDigitalInput01_a + ExternalDigitalInput01_b + RunRequest_O;
ExternalDigitalOutput01a_O = TempFlag01;
SetPoint1_O = TempFlag01;
SetPoint2_O = TempFlag01;
A time-out function may be implemented with system program timers. These timers are enabled using
logic statements and the output (based on the timer expiring) is available as an input to logic statements.
The time period is set in seconds with the resolution. The unit specified in the logic statement is seconds
(with a decimal fraction rounded to the nearest internal resolution). Time intervals are up to 16,383.5
seconds for the Next Gen version of Perfect Harmony.
The statement
Timer01(20.0) = symbol_a;
enables timer 1 if symbol_a is true. The statement 8
output_1 = Timer01;
sets the symbol output_1 true if the timer has expired (timed out). In the example above, if symbol_a is
false, output_1 will be false. If symbol_a is set true, then 20 seconds later, output_1 will be set true
(assuming symbol_a remains true).
Once the enabling logic goes FALSE, the entire time-out period must pass before the timer will time-out.
Should it go FALSE before the time-out period, the timer count is reset to zero and the timer must go the
entire period before timing out.
Counters in a system program can be used to count the number of FALSE to TRUE transitions of the
counter input. A corresponding counter reset input is used to reset the counter value to zero. For
example:

Counter01(13) = input_a;
CounterReset01 = input_b;
output_a = Counter01;
If input_b is set TRUE, Counter01 is set and held to zero. If input_b is FALSE, after 13 FALSE to TRUE
transitions of input_a, the symbol Counter01 (and output_a) will be set TRUE. After 13 transitions,
Counter01 will remain TRUE until Counter01 is cleared by CounterReset01. The maximum count value
is 32767. The count value must be an integer.
8.5.6. SOP Interpretation

System configuration and operational logic is depicted in the command generator diagram (ASI Robicon
drawing 459713) which displays (in a diagram format) the various input options, parameter sets, and
modes of operation of the drive. All logic flags controlling the configuration and control flags used in the
state transitions are shown along with many internal variable names.
The system program consists of the hex program output file (created with an external compiler, the
source ASCII text sum-of-products [SOP] file, and the DRCTRY.xxx directory file [used for mapping flag
names to internal variable addresses]) and the system interpreter in the drive itself.
The SOP file is written by application engineering (and can be modified by field service personnel),
compiled to a tokenized, Intel hex formatted file, and then downloaded via an RS-232-C serial channel to
the drive. The drive initializes the file and then begins to interpret the token codes and data structures.
This is detailed in the next section.
8.5.7. SOP Timing
The scan time for running the compiled program is dependent on the length and complexity of the
program and the available time left over from the control software. The control software timing includes
any features that are running (based on the configuration information flags in the system program itself).
The typical scan time is between 20 and 50 msec, but can become longer for a synchronous transfer
program.
8.5.8. Ladder Logic Translation
It was mentioned above that the sum-of-products notation can represent ladder logic. In actuality, it is
very easy to directly translate between the two. For example, consider the equation or statement
 
Z = A BC + D E F + FGH;
Translated into the notation of the limited ASCII characters available in a common text editor, the
statement would read as follows (note that the components are separated at “ORs” and stacked for
clarity).
Z = /A*B*C
+ D*/E*F
+ F*G*H;
This statement can be pictorially represented by breaking each statement down in the following manner.
1. First, the output variable (in this case Z) is represented by a coil to the right of the ladder.
2. Second, each product term (the variables separated by the asterisk) is represented by a single line of
contacts connecting to the coil.
3. All the product terms that are summed (separated by the plus sign) are represented by parallel paths
to the same coil.
4. All non-inverted contacts are represented by normally open (NO) contacts while the inverted terms
8 are represented by normally closed (NC) contacts.
The resulting ladder logic is illustrated in Figure 8-3.

A B C Z
D E F
F G H
Z = /A*B*C + D*/E*F + F*G*H;
Figure 8-3. Ladder Logic Representation of a Boolean Expression - Example 1
Conversely, if the ladder logic shown in Figure 8-4 was desired, it could be converted into a sum-of-
products statement. The procedure would be the inverse of the previous and is enumerated below.
1. First place the label of the output relay coil to the left, with an equals sign following.
2. Next, start in each path from left to the connection to the coil on the right, writing the label for each
contact with the asterisk representing the AND or product operator in between.
3. In front of each NC contact, place a forward slash representing the inversion or NOT operator (shown
in the equations as a bar over the variable name).
4. Repeat this for each parallel path using the OR (sum) operator (+) in between each grouping of
product terms.
5. Finally the statement is terminated by a semicolon to represent the end of the statement.
R G N J
A C F
P Q M
J = /R*G*N + A*C*/F + /P*/Q*M;
Figure 8-4. Ladder Logic Representation of a Boolean Expression - Example 2
The resultant statement written for the ladder logic in Figure 8-4 is shown below.
J = /R*G*N
+ A*C*/F
+ /P*/Q*M;
*
Note: For all program statements that span multiple lines, only the last line has the semi-colon end-
of-line character (;).

8.5.9. Comparators
Sometimes a simple digital input is not enough to adequately control a system function or establish a
warning or protection scheme. Analog signals from various transducers may need to be monitored and
compared to set thresholds to allow conditions to change. This is the purpose of the comparator
functions. Any signal fed into the drive through an analog input externally or internally can be mapped to
a system flag to use in any logic statement.
These comparators exist in Comparator n Setup Submenus (4810-4965) under the Comparator Setup
Submenu (4800) in the Auto Menu (4). There are 16 comparators with individual setup menus. Each
comparator has an ‘A’ and a ‘B’ input and a control setting. These are set up by selecting from a pick list
- a scrollable listing that allows the selection of predetermined variables, or entry of variable addresses
(only in RAM) or a fixed percentage of rated value or a fixed number entered in hexadecimal (the base 16
numbering system as opposed to decimal which is base 10).
The comparators have a system program flag associated with each (Comparator01_I through
Comparator16_I) that are controlled by the comparator functions. In essence, the logical state of the
comparator flags (TRUE or FALSE) is determined by the equation: Comparatorxx_I = (A > B), which
means that if input A is greater than input B, the flag is set true, and if A is less than or equal to B the flag
is set false.
The rest of the setup is accomplished by setting the control variable. This also is a pick list but consists
of the selections: signed, magnitude, and off or disabled. When the comparator is switched off, no further
processing is done and the system flag retains its last value indefinitely. The flags (as are all system
flags) are initialized to false on power-up, system program re-initialization, or hard reset.
8.5.10. Analog Inputs
Sometimes you may want to use an external analog signal as an input to a comparator. This can be
accomplished by selecting an analog input source in the pick list. However, the analog input needs to be
setup properly before it has any meaning to the system program comparator functions.
When the system program scans the comparators, the last analog sample is used. The analog inputs
have a 12 bit resolution, which means that 12 bits are used to determine the sign and magnitude of the
signal. Therefore the voltage resolution for each step is approximately 5 mV.
When the analog user modules are enabled (when their type is set to something other than off or
disabled) they are only read at the system program scan rate. They are, however, converted constantly
inside the external module itself so that the drive processor does not have to interface to an analog signal
or spend time converting it to a digital number.
To use the external or internal analog input modules as a reference to the drive they need to be set up
using the Analog inputs menu (4090). The sequential number used in Analog input #1 source (4105), or
Analog input #2 source (4175) menu of the external analog inputs is determined by left to right orientation
arrangement of the modules as they are placed on the DIN rail. The leftmost analog input module is the
first input. It contains two ports so analog inputs one and two are within this module. Reading left to right
the second module contains the next two analog inputs. This module also contains two ports so they are
numbered three and four and so on. The remaining menus are filled in as required.

8.6. Compiler Invocation

8.6.1. Windows-based SOP Utilities
Note: The Windows-based utilities

Windows NT, and newer versions.
program is compatible with Windows 95,
*
To invoke the Windows-based SOP utilities program, double click on the COMPILER.EXE icon. This
causes the ASI Robicon SOP Utilities pop-up to be displayed.
Figure 8-5. ASI Robicon SOP Utilities Icon and Pop-up Box
Figure 8-6. Compiler Help Screen

8

8.6.2. DOS-based Compiler and Reverse Compiler
*
Note: The DOS-based compiler and reverse compiler programs can be used by computers that run
versions of Windows prior to Windows 95 or Windows NT.
The MS-DOS compiler application is invoked with or without command line fields and options. If the
compiler is invoked without command line fields, the compiler will prompt for required fields (but will
default non-required fields). The syntax for the command line is:
CMP <inputfile> <dirfile> </t:nn> </h> </s>
where: <inputfile> is the input source system program file. (required)
<dirfile> is the name of the directory file (optional)
</t:nn> defines a system type to the compiler (optional)
</h> requests help text (optional)
</s> requests file size info to be printed (optional).
The input filename follows standard DOS filename format restrictions. If no extension is given, .SOP will
be used as a default. If a <dirfile> is not specified, the file “DRCTRY.NGN” in the current directory will be
assumed (if Harmony is the drive type). If it is not found, an error message will be given.
8.7. Compiler Operation
As discussed earlier in this chapter, three files are accessed during the compilation process: the source
(or SOP) file, the DRCTRY.NGN (directory) file, and the output hex file. When the compiler is invoked, it
first opens the SOP file to determine if it contains a system_id definition line as the first line in the file.
This line defines to the compiler the target system type. If the necessary files are not found in the default
directory, the user may search elsewhere using the standard Browse button.
Figure 8-7. Selecting the .SOP File Using the Browse Button
8

The system type information is used to search for a proper directory file to use during compilation. The
type information is placed into the hex file so that the system program cannot be used in the wrong type
of system (e.g., loading a Harmony system program into a 454 GT drive).
*
Note: If you use the ASI Robicon SOP Utilities program to compile an SOP file that does not
include the #system_type; identifier, then the Product Type radio buttons (see Figure 8-7) will
become enabled, and you must select the appropriate product type.
The compiler searches for the directory file in the current directory first. If it is not found there, the
compiler looks in the directory "C:\CMP" for the files. In all cases, the full search path of the “found” file is
displayed so the operator can verify that the intended file was used.
If the system type line is not found, the DOS-based compiler looks in the current directory for the
existence of the DRCTRY.NGN file. If the directory file cannot be found using the DOS-based compiler, it
will abort with an error. The SOP utilities program will wait for the user to browse to find the appropriate
file.
*
Note: The DRCTRY.NGN file must adhere to certain syntax and format rules. Refer to Appendix
D: DRCTRY.NGN File for more information.
After loading the token directory, the DOS-based compiler prompts for a source sum-of-products file (if
one is not specified in the command line). If the file exists the compilation process begins. The
Windows-based program contains a “Compile” button that remains dimmed until the user provides all of
the necessary files. Only then can the user press the “Compile” button to start the compile process.
*
Note: A copy of the symbol directory file (e.g., DRCTRY.NGN) must exist within the same
directory as the DOS-based compiler and reverse compiler programs or in the directory of the
executable files.
8.8. Output Hex File

Any inconsistencies that occur during the compilation process are flagged and error messages are
printed to the screen. These error messages indicate the problem and lead the user towards problem
resolution. Error messages are listed in Table 8-12.
After successful processing, the third and final file is created. This is the hex file and it is named the
same as the source file with the extension changed to “.HEX”. The entire compiled system program is
summed up in a modulo 256 result that is inverted and placed in the header of the compiled system
program. This is the system program checksum. The output is formatted in Intel 8086/8088 record
format with a starting load offset of 0000. Each record consists of 16 bytes of data. Zeroes are
appended to the final record for padding.
When interpreted as an Intel hex file by the drive during the download process, a binary image of the
logic functions results. These logic functions are stored and later executed by the drive. Each line of the
hex file contains its own checksum. In addition, the compiler generates an overall system program
checksum. All of these checksums are validated during system program downloading and restart to
ensure correctness prior to storing the statements inside the drive.
When downloaded into the drive, the system program is structured into sections. The first section is 8
called the header and contains system program location pointers as well as the version number and the
system program checksum.
8.9. Downloading a System Program (Hex File)
Once the text for a system program has been created, and the text file has been compiled into a hex file
using the system program compiler, the resulting hex file must be downloaded into the drive to become
functional. Software embedded in the drive can be invoked to accept the properly formatted hex file into
the drive using the RS-232 serial port as the transfer medium. The program can be downloaded in one of
two methods:
1. Using the Upload/Download component of the ASI Robicon SOP Utilities software. This method can
be used by PCs that have at least Windows 95 or NT installed.

2. Using a terminal emulation program on the PC set up in ASCII file mode. This method can be used
by PCs that do not run Windows or have a Windows version before Windows 95 or Windows NT
(using a DOS window).
8.9.1. ASI Robicon SOP Upload/Download Utility Method
The .HEX file must be downloaded using the Upload/Download component of the ASI Robicon SOP
Utilities program.
Figure 8-8. Upload/Download SOP Utility Screen
1. Invoke the ASI Robicon SOP Utilities program.

2. Select the Upload/Download tab.
3. Enter the HEX file to be downloaded.
4. Select the Download radio button.
5. Set the baud rate from the drop down box to 9600 baud.
6. Connect the appropriate serial port of the host PC to the DB9 port of the drive using an appropriate
serial cable (9-pin with appropriate connectors).
7. Select the “System Program Download” function menu (9120) of the drive. The drive will display
download status information on the front panel (e.g., “Downloading from RS232”). The drive will
indicate when it starts to receive data.
At the end of each hex line received, the drive will cause a bar in the last column of the keypad display to
rotate to indicate that data is being received. Each data record that follows is then checked against its
own checksum and loaded at the appropriate address in RAM. Errors in a data record result in a
8 displayed error message and termination of the download process.
Note: The drive’s software checks the downloaded system program file for the proper version
number. If the user tries to download a system program that was compiled with the wrong
DRCTRY.NGN file (for example, an obsolete DRCTRY.DAT file), an error message will be
* displayed and the downloaded system program will not be transferred to FLASH. Further, the
system will not run a motor if, on power-up, the software detects a system program checksum error
or an out of range system program version stored in the FLASH. In order to use an older system
program in a drive with newer software, the system program must be recompiled with the newer
DRCTRY.NGN file before it is downloaded.

8.9.2. Terminal Emulation Method

The .HEX file must be downloaded with a terminal emulation program on the PC set up in ASCII file
mode.
1. Set the baud rate (the same as drive’s baud rate parameter), parity (none), data bits (8) and stop
bits (1) of the communications software on the host PC, notebook or laptop computer.
2. Connect the appropriate serial port of the host PC to the DB9 port of the drive using an appropriate
serial cable (9-pin with appropriate connectors).
3. “Enable” the communications software (i.e., prepare the software to either send information to the
drive or receive information from the drive). This basically puts the PC and communications software
into a ready state. Typical communications software packages include Microsoft Windows Terminal
and Procomm-Plus (only Windows 95-compatible if running this operating system).
4. Use the “System Program Upload” or “System Program Download” function from the Serial
Functions Menu (9110) of the drive to perform the desired function. The drive will display download
status information on the front panel (e.g., “Downloading from RS232”).
The drive will indicate when it starts to receive data. At the end of each hex line received, the drive will
cause a bar in the last column of the keypad display to rotate to indicate that data is being received.
Each data record that follows is then checked against its own checksum and loaded at the appropriate
address in RAM. Errors in a data record result in a displayed error message and termination of the
download process.
Note: The drive’s software checks the downloaded system program file for the proper version
number. If the user tries to download a system program which was compiled with the wrong
DRCTRY.NGN file (for example, an obsolete DRCTRY.DAT file), an error message will be
displayed and the downloaded system program will not be transferred to FLASH. Further, the *
system will not run a motor if, on power-up, the software detects a system program checksum error
or an out of range (wrong) system program version stored in the FLASH.

8.9.3. Termination
Termination occurs when a valid “End Record” is received. If any error in transmission occurs, or if the
user manually “CANCELs” the transmission, the original system program will be copied back down from
FLASH. If the new program is accepted and reaches normal termination, it is then transferred from
temporary RAM into non-volatile FLASH storage, overwriting the original. The system program is then re-
initialized with the new information, and the system program is restarted, executing the new statements.
Note:
During the system program download process, if it is desired to cancel the download process, a
* [SHIFT]+[CANCEL] key sequence can be entered from the drive’s keypad to terminate the
download process and restore the system to its original state.
Since the system program execution must be stopped while downloading a new system program,
the drive cannot be running during the download process.
Table 8-12. Error Messages
Error Message Description

ERROR!! file %s cannot be opened DOS error (file corrupted or not found).
%s is the directory file.
WARNING...DRCTRY.DAT overflows Too many flags (>5000) are in the directory file.
internal storage
ERROR!! a filename must be entered No source filename was given either on the command
line or prompt.
ERROR!! file << %s >> cannot be DOS error (file corrupted or not found). %s is the
opened" (prompted) source file.
ERROR!! file %s cannot be opened DOS error (file corrupted or not found). %s is the
(command line) source file.
ERROR!! opcode >>%s<< not supported Either not in directory or not a legal opcode (+ * ;).
ERROR!! input >>%s<< is not an input The 4th field of flag token in directory must be (1, 2, 3,
type 4, 5, 6, 8, 9).
ERROR!! input >>%s<< not in directory Cannot find flag name (%s) in the directory file.
ERROR!! Expecting = got >>%s<< Was expecting an equal sign “=” after an output flag
name or compiler could be out of sync with source.
ERROR!! output >>%s<< is not an output The 4th field of flag token in directory must be (1, 2, 3,
type 4, 5, 6, 8).
ERROR!! output name >>%s<< not in Cannot find flag name (%s) in the directory file.
8 directory
ERROR! no timer/counter defined Timers and counters must be defined as outputs before
they can be used as an input.
ERROR!! input scan table is full Only a maximum of 800 input flags can be used
(although each can be used more than once).
ERROR!! Reset used without a defined Counters must be defined as outputs before their
counter associated reset flags can be defined.
ERROR!! output scan table is full Only a maximum of 800 output flags can be used. (An
output can only be defined once.)

Error Message Description

ERROR!! logic table is full A maximum of 5,000 entries can exist in the logic table -
this roughly evaluates to the total number of flags that
are used counting a flag for each use in an expression.
ERROR!! Expecting ( got >>%s<< Enclosing parentheses not used or number format not
proper for a counter or timer.
ERROR!! Expecting ) got >>%s<< Enclosing parentheses not used or number format not
proper for a counter or timer.
ERROR!! data overflows FLASH The entire system file will occupy more space than is
available on the FLASH.
8.10. Uploading a System Program (Hex File)

In a manner similar to downloading a system program, the drive’s current system program can be
uploaded from the drive to a receiving computer (binary format in the drive, hex format from the drive or
compiler). This can permit archival of a functioning system program. Also, the text statements in a
system program can be re-created (by using the system program’s reverse compiler) so that the program
can be examined or modified as needed.
Using a similar method as described in the download section, invoke the serial communications upload
function on the drive. If using the DOS-based upload utility, invoke the data capture process of the
communications software prior to starting the data upload function in the drive. If using the Windows-
based SOP Utilities program, press the “Start” button prior to starting the data upload function in the
drive.
From the drive keypad, enter the “System Program Upload” function menu (9130). Once this function
has been invoked, the keypad will indicate that the drive is uploading data. Most serial communications
packages will display the ASCII hex data while it is being uploaded so that the upload process can be
monitored. Once complete, the drive will indicate that it has finished and will return to the System
program upload menu (9130). At this point, the data capture process in the PC is stopped and the
resulting file is saved.
*
Note: As with the download, the upload process can be terminated from the drive side by entering
a [SHIFT]+[CANCEL] key sequence.

8.11. Reverse Compiler

Because the system program embedded in the drive is in a non-readable form, a program to reverse
compile the hex records of a system program back into readable statements was created. A reverse
compiled program can be examined for logic functions and even edited, recompiled, and re-downloaded
into the drive to alter the system program functionality as needed. Since the embedded hex file does not
contain any symbolic information, a directory file within range is needed during the reverse compile
process to convert from the binary address information back into symbolic readable form.
The reverse compilation process can be accomplished in one of two ways:
1. Using the Reverse Compiler component of the ASI Robicon SOP Utilities software. This method can
be used by PCs that have at least Windows 95 or NT installed.
2. Using the DOS-based reverse compiler program. This method can be used by PCs that do not run
Windows or have a Windows version before Windows 95 or Windows NT (using a DOS window).
8.11.1. Windows-based “Integrated” Reverse Compiler
The ASI Robicon SOP Utilities program contains an integrated Reverse Compiler program. This
component is similar to the compile component. A HEX file and DRCTRY file must be specified. If they
do not exist in the default directory, the user must use the “Browse” buttons to locate the necessary files.
When the appropriate files are specified, the “Rev Compile” button is pressed to perform the reverse
compilation. See the window below.
Figure 8-9. Reverse Compiler Options Window

8.11.2. DOS-based Reverse Compiler Software

The reverse compiler command line has the following format:
revcmp <hexfile> </d:direcfile> </o:outfile> </h> </s>
where:
hexfile name of the system program hex file (required except if /h)
/d:directfile dirfile = name of the directory file, optional
/o:outfile outfile = name for the output file, optional
/h causes help text to be displayed, use by itself
The name of the input hexfile is required. An extension of “.HEX” will be assumed if one is not given.
The switch /d:dirfile can be used to specify the name of the directory file to be used for symbol lookup. If a
dirfile name is not given, the system will search the current directory and then the directory of the
executable file for the file name DRCTRY.NGN. The switch /o:outfile can be used to enter the desired
name for the output source file if desired. If an outfile name is not given, a file with the same name as the
hexfile, but with the extension “.DIS” will be created.
The command switch “/h” will cause a help text message to be given. This is useful in situations where
the command line format needs to be displayed.
The output file will contain a source statement for each original statement in the system program. The
statements will be ordered with the invariant statements first, followed by the dependent statements. All
of the statements in a section will be in the same order as the original file, with the exception of any
true/false type statements which are moved to the front of the file.
Note:
• Comments from the original source file are not reverse compiled.
• A copy of the symbol directory file (e.g., DRCTRY.NGN) must exist within the same directory as *
the compiler and reverse compiler, or in the directory of the invoked executable program.

∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics GLOSSARY OF TERMS

series manuals.

GLOSSARY OF TERMS Perfect Harmony GENIII/e Startup and Advanced Topics
A
Perfect Harmony system).
average.
[1] through [6].

time the old information is overwritten. The information in NVRAM is stored in ASCII hex format and can A
be uploaded via the drive’s serial port to a PC for troubleshooting analysis.
sections).

chips.
energized.
energized.
lost).
used by parameters.

example) at a time.
command).
Slip = ω S - ω R
ωS

∇ ∇ ∇

Perfect Harmony GENIII/e Startup and Advanced Topics : COMMONLY USED Abbreviations

This appendix contains a list of symbols and abbreviations commonly used throughout the Perfect
Harmony series of manuals.

B
° degrees memory
AC alternating current EPROM erasable programmable
accel acceleration read-only memory
deg degrees IGBT insulated gate bipolar

transistor

: COMMONLY USED Abbreviations Perfect Harmony GENIII/e Startup and Advanced Topics

in input derivative
in, ″ inches PLC programmable logic

controller
info information
pot potentiometer
INH inhibit
B pp peak-to-peak
K 1,000 (e.g., Kohm)
ppb parts per billion
LAN local area network
PPR pulses per revolution
lbs pounds (weight)
PQM power quality meter
LCD liquid crystal display
PSDBP power spectral density break
ld load point
LED light-emitting diode psi pounds per square inch
lim limit pt point
LOS loss of signal PT potential transformer
lps liters per second PWM pulse width modulation
mA milliamperes rad radians
mag magnetizing RAM random access memory
max maximum ref reference
MCC motor control center rev reverse, revolution(s)
mg milligram RFI radio frequency interference
min minimum, minute RLBK rollback
msec millisecond(s) rms root-mean-squared
msl mean sea level RPM revolutions per minute
mvlt motor voltage RTS request to send
NEMA National Electrical RTU remote terminal unit
Manufacturer’s Association
RX receive
no. number
s second(s)
NMI non-maskable interrupt
sec second(s)
NVRAM non-volatile random access
memory ser serial
oamp output current SOP sum of products
OOS out of saturation spd speed
overld overload stab stability
P proportional (PID) std standard
Pa Pascals sw switch
pb push button TB terminal block
PC personal computer TOL thermal overload
PIB Power Interface Board TP test point
PID proportional integral trq, τ torque

Perfect Harmony Startup and Advanced Topics : COMMONLY USED Abbreviations
TX transmit
um user module
V voltage, volts
B
VAC volts AC
var variable
VDC volts DC
vel velocity
W width, watts
xformer transformer
∇ ∇ ∇

: COMMONLY USED Abbreviations Perfect Harmony GENIII/e Startup and Advanced Topics

Perfect Harmony GENIII/e Startup and Advanced Topics SYSTEM CONTROL DRAWINGS
APPENDIX C: SYSTEM CONTROL DRAWINGS

This appendix contains the system control diagrams for a Perfect Harmony drive with Next Gen Control.
• Harmony Control Diagram drawing number 459712
• Command Generator Diagram drawing number 459713
• Input/Output Process Diagram drawing number 459717
Version 1.1 (19000404) ASIRobicon C-1

SYSTEM CONTROL DRAWINGS Perfect Harmony GENIII/e Startup and Advanced Topics
C-2 ASIRobicon Version 1.1 (19000404)

Perfect Harmony GENIII/e Startup and Advanced Topics SUGGESTED SPARE PARTS LIST
APPENDIX D: SUGGESTED SPARE PARTS LIST
This appendix contains a sample spare parts list for Perfect Harmony drives (200-2000 hp). The quantity
and part number “dash numbers” in Table D-1 are typical for 800 hp Perfect Harmony drives (part
number 459384.SPK). Perfect Harmony drives may have different quantities and “dash numbers” based
on the horsepower of the drive. Some drives may have spare parts lists that differ slightly from the list in
Table D-1.
The lists are arranged in sections based on drive voltages. Within each section, the lists are arranged
based on horsepower and part number. A base part number is given for each table. The part number for
each associated spare parts kit is the base part number with the .SPK extension.
*
Note: The spare parts list in this appendix is for an 800 hp Perfect Harmony drive only. Parts lists
for customized drives and other standard drives may vary. Call the ASIRobicon Customer Service
Department at (724) 339-9501 for more information. Spare parts lists are subject to change without
notice.
Table D-1. Spare Parts List for 800 hp Perfect Harmony Drive
Cabinet Qty Description P/N D

VFD Cell Cabinet 1 VFD Power Cell 4608C0.140
1 Cell Control/Gate Board 461E90.07
3 Fuse, 100A, 690V (F11-F13) 090391
3 Dual Rectifier Module 089706
2 IGBT Module 088794
Control and Output 1 Pentium CPU kit 363658.00
Cabinet
1 Mother board 363628.00
1 Analog I/O board kit 363629.00
1 Signal conditioning board 363633.00
1 Modulator board 363644.00
1 Fiber optic link board 461D85.00
1 Serial communication board 461F11.00
1 System interface board 461F53.00
1 Keypad 460A68.23
1 Power supply [DCR] 091652

1 Power supply [Hall effects] 091293
1 Power supply [Wago] 090103
1 Wago – Field bus coupler 091143
Wago – 0-20mADC Analog in ♦ 091113
Wago – 4-20mADC Analog out ♦ 091539
Wago – 24VDC Digital in ♦ 090789
Wago – 120VAC Digital in ♦ 091537
Version 1.1 (19000404) ASIRobicon D-1

SUGGESTED SPARE PARTS LIST Perfect Harmony GENIII/e Startup and Advanced Topics
Cabinet Qty Description P/N

Wago – 250VAC/30VDC Relay out ♦ 090790
1 Wago – 250VAC/300VDC Relay out ♦ 092363
1 MV Bypass board ♦ 363662.00
♦ - Use of these modules is application dependent. Some may not be required.
∇ ∇ ∇
D-2 ASIRobicon Version 1.1 (19000404)

Perfect Harmony GENIII/e Startup and Advanced Topics INDEX
INDEX
—— —2—
- sign, 3-6 2,080 VAC line-to-neutral, 6-2
implied, 3-6 2,400 or 3,300 volt Harmony series drive, 6-2
- VCN test point, 7-5, 7-7 2,780 VAC line-to-neutral, 6-2
2400 VAC system, 2-17
286 PC
—)— use with cell tester, 7-28
semi-colon (, 8-4
—3—
—.— 3 cells in series, 7-24
.HEX file, 8-17 3,470 VAC line-to-neutral, 6-2
3PCI controller, 6-14
—[— 3-phase diode rectifier, 6-2
, 3-4 3-phase input, 2-17, 7-29
, 3-3 3-phase input connections
[CANCEL] function, 3-6, 3-7 disconnecting, 7-30
[CANCEL] key, 3-1 3-phase output, 7-29
common functions, 3-6 3-phase secondary connections, 2-10
[ENTER] key, 3-1, 3-5, 3-6, 3-9, 3-11, 3-13
changing security features, 3-44 —4—
, 3-2, 3-3, 3-10
[HELP] key, 3-15 4 cells in series, 7-24
, 3-3, 3-4 4,160 VAC line-to-neutral, 6-2
, 3-3 4160 VAC, 2-18
[SHIFT] [2] ([DRIVE]) key combination, 3-11 4160 VAC system, 2-17
[SHIFT] key, 3-1, 3-4, 3-5, 3-6, 3-7, 3-9 4-20 mA input
common functions, 3-7 speed setting source, 3-3
[SHIFT] key sequences, summary of, 3-8 460 VAC, 7-29
[SHIFT]+[0] key sequence, 3-15 480 VAC, 7-28
4-digit security access code, 3-4
—+—
+ sign, 3-6 —5—
+5% taps, 4-2
5 KV class service, 6-2
50 Hz, 2-10
—1—
12-pulse wave form, 1-1 —6—
18 cell 6.6 KV system, 2-13
1CELL.EXE program, 7-29 6 cells in series, 7-24
6-pulse wave form, 1-1

INDEX Perfect Harmony GENIII/e Startup and Advanced Topics
—9— asterisk character (*)

security edit mode indicator, 3-44
9 common system menus, 3-1 attenuator, 2-17
attenuator system, 2-18
audible motor noise, 1-2
—A— Auto Menu (4), 3-8, 3-16, 3-33, 3-42, 8-14
A/D Converter Board, 6-9 auto mode, 3-1
abbreviations, B-1 auto tuning, 1-4, 3-14, 4-23
AC induction motors, 6-1 auto/hand/off mode, 3-1
AC voltmeter, 4-1 automatic mode, 3-1, 3-3
acceleration customizing, 3-3
time range, 1-5 Autotune Menu (1250), 3-15, 3-17, 3-20
acceleration rate, 8-11 Auxiliary Input #1 Menu (4500), 3-37
accepting new parameter values, 3-6 Auxiliary Input #2 Menu (4580), 3-38
access code, 3-4, 3-7
access codes, 3-1 —B—
proprietary, 3-44
accessing menus, 3-10 back EMF timeout fault, 7-16
accessing menus by menu number, 3-8 bad cell data fault, 7-11
, 3-6 base 10 format of numbers, 3-4
acknowledging fault conditions, 3-2 base 16 format of numbers, 3-4
acoustic noise, 6-1 basic power schematic, 2-18
active digit, 3-5, 3-6, 3-10 baud rate, 8-2, 8-19
advanced diagnostics, 1-4 Beckman 3030A, 7-28
, 3-35 Beckman CT-232, 7-28
air duct covers, 1-3 binary operators, 8-6, 8-8, 8-10
alarm/fault log, 3-16 blocking failure faults, 7-24
Alarm/Fault Log Menu (6210), 3-16, 3-45 blocking Qn fault, 7-20
all blowers lost fault, 7-13 blocking timeout fault, 7-21
all HEX fans on alarm, 7-14 blower, 7-26, 7-29
all pumps failed fault, 7-14 blower cabinet, 1-3
altitude, 1-5 blower fault, 7-26
ambient temperature, 1-5 blower fuses, 2-4
ammeter, 7-29 blower motor starters, 2-4
ammeters, 7-29 blowers, 2-3, 2-7
Analog Input #1 Menu (4100), 3-35, 5-16 Boolean algebra, 8-8, A-5
Analog Input #2 Menu (4170), 3-36 Boolean AND and OR functions, 8-6
Analog Input #3 Menu (4232), 3-36 Boolean laws, 8-8, 8-9
Analog Input Menu (4090), 3-16, 3-33, 3-35 Boolean operators, 8-8
Analog Input Module, 7-26 Boolean statements, 8-1
analog input setup, 5-16 Boolean syntax examples, 8-7
analog inputs, 8-14 Boolean Truth Table for the NOT, AND and OR
dedicated POT input, 3-3 Functions, 8-7
pot input, 3-3 Boolean truth tables, 8-6
analog output setup, 5-15 boot-up test failure, 3-10
Analog Outputs Menu (4660), 3-16, 3-33, 3-38 Braking Menu (3350), 3-32
analog to digital board, 2-15 BTU/hr losses, 2-12
AND, 8-8, 8-9, 8-13, A-5 burden resistor values, 2-18
AND (*) operator, 8-6 burn-in test menu, 7-29
application issues, 5-1 Burn-In Test Menu, 7-29
arrow key sequences, summary of, 3-10 bus LED, 7-30
arrow keys, 3-1, 3-4, 3-6, 3-7, 3-8, 3-9, 3-11 bypass, 2-13, 7-22
common uses, 3-7 bypass ack failed fault, 7-15
right and left, 3-7 bypass avail warning alarm, 7-15
selecting desired velocity, 3-3 bypass circuit, 2-19
summary of key sequences, 3-10 bypass failed faults, 7-24
up and down, 3-3 bypass mode, 7-25
up and down, 3-7 bypass verify failed fault, 7-15
ASCII text, 8-1, 8-2, 8-3 by-products of the conversion process, 6-1
ASCII text editor, 8-1, 8-2, 8-3
assignment operator, 8-8

—C— 3-phase input, 7-29

bus LEDs, 7-30
cabinet, ix communications port, 7-29
line-up, 2-1 configurations, 2-17
cabinets, 1-3 control, 2-10
cabinets, 1-3 control boards, 2-8
cables currents, 7-29
used with Harmony cell tester, 7-29 damage due to overheating, x
cancel key evaluation of, 7-29
exiting security edit mode, 3-44 faults, 7-16
canceling/aborting the current action, 3-8 fiber optic control link, 2-10
cap share fault, 7-19 galvanic isolation, 2-8
capacitor bank, 6-2 illustration, 2-8
capacitor share faults, 7-24 mechanical and electrical comparisons of sizes, 2-8
carrier frq set too low alarm, 7-9 number of in a series, 2-7
carrier signals, 6-3 optical communications port, 7-29
CCB, 7-16, 7-20 output, 2-8
cell A1, 6-4 output cells per phase, 2-7, 2-8
cell back-up, 1-4 output current as a function of size, 2-7
cell boards overload capability, 6-20
control power, 2-13 retaining clips, 7-30
cell bus, 6-18 size 2, 2-18
cell bypass acknowledge fault, 7-14 sizes for GEN III, 2-7
cell bypass COM alarm, 7-15 specification details, 2-7, 2-8
cell bypass COM fail fault, 7-14 stored energy, 4-1
cell bypass fault, 7-15 central controller, 6-2
cell bypass link alarm, 7-15 Centronics port, 7-28
cell bypass link fault, 7-15 change security code, 3-9
cell bypass option, 2-13 Change Security Codes Function, 3-43
cell cabinet, 1-3, 7-28, 7-29, 7-30 change security level function, 3-44
Cell Cabinet, 7-24 changing a parameter, 3-12
cell communication faults, 7-25 changing the velocity demand, 3-7
cell config fault, 7-11 checksum, 8-17, 8-18, 8-19
cell control board, 2-18, 7-18, 7-20, 7-21, 7-25 circuit failures, 7-25
model 430, 7-17 clamp on ammeter, 7-28
model N15, 7-17 clamp-on ammeters, 7-29
spare, 7-17 clean power input, 1-1
Cell Control Board, 7-1, 7-16, 7-17, 7-18, 7-19 clearing fault conditions, 3-10
cell control system, 2-13 clogged filters alarm, 7-13
cell control/gate driver board, 2-10, 2-19 clogged filters fault, 7-13
switch mode power supply, 2-13 closed transfer, 5-1
cell cooling liquid, 7-30 synchronous transfer state diagram, 5-2, 5-3
cell count mismatch fault, 7-15 coast stop, 7-2
cell current, 2-12 coast stops, 7-2
cell DC bus low fault, 7-19 coasting, 3-14
cell diagnostic mode, 7-20, 7-21 coasts to stop, 7-1
cell fault/modulator, 7-10 coffin, 2-7, 2-10
cell faults, 7-1, 7-16, 7-20 commanded speed reference, 3-11
cell lift device, 7-30 comment lines, 8-4
cell malfunctions, 2-13 comments, 8-3, 8-4
Cell Menu (2520), 3-15, 3-21, 3-26 common functions of the Shift key, 3-7
cell overload rollback, 3-13 common mode voltage stress, 1-2
cell overtemperature faults, 7-24, 7-25 common uses of the arrow keys, 3-7
cell power fuses, 7-30 communication circuits, 6-10
cell retaining clips, 7-30 communication fault, 7-19
cell section, 2-1, 2-10 communications
cell sense circuitry, 7-1 outline drawing, 5-7
cell specifications, 2-10, 2-11, 2-12 RS485 network, 5-6
cell test, 7-28 communications board, 2-15
cell water temp high alarm, 7-14 communications cable, 8-1, 8-2, 8-3
cell water temp high fault, 7-14 communications flags, 4-26
cells Communications Menu (9), 3-8, 3-16, 3-42, 3-53, 8-21

communications port control power faults, 7-24

use with cell tester, 7-29 control range, 3-35
communications software, 8-1, 8-2, 8-3, 8-21 control section, 2-1, 2-8, 2-10
communications software package, 8-1 isolation from medium voltage, 2-10
compar_b_f flag, 3-41 control states, 5-6
comparator control structure, 6-11
A variable, 3-41 control switches, 8-10, 8-11
B variable, 3-41 default state, 8-11
comparison types, 3-41 control system, 2-10, 6-9
comparator flag, 3-41 control transformer, 2-4, 2-17
Comparator n Setup Submenus (4810-4965), 8-14 controlled stop, 3-3
Comparator Setup Menu (4800), 3-16, 3-33, 3-40 coolant cond high alarm, 7-14
Comparator Setup Submenu (4800), 8-14 coolant cond high fault, 7-14
comparators, 3-40, 7-26, 8-14 cooling, 7-29
compare n setup N, 3-40 cooling fans, 7-29
compare n type, 3-41 cooling liquid
, 3-4 isolating, 7-30
comparisons, 8-10 cooling liquid lines, 7-30
compilation process, 3-3 cooling system, 7-24, 7-29
compile process, 8-1, 8-2, 8-3, 8-22 counters, 8-11, 8-20
compiler, 8-1, 8-2, 8-3, 8-4, 8-5, 8-6, 8-9, 8-11, 8-12, cr2_picked flag, 7-26
8-16, 8-17, 8-20, 8-21, 8-22, 8-23 CR3 display, 7-26
error messages, 8-20 CR3 relay, 7-26
invocation, 8-15 CR3 relay mode, 7-26
operation, 8-16 cr3_f, 8-10
product types, 8-5 Critical Frequency Menu (2340), 3-23
true and false constants, 8-10 Critical Frequency Menu (2340), 3-15, 3-21
compiler and reverse compiler, 8-15, 8-16 critical speed, 3-16, 3-24
compiler invocation options, 8-6 critical speed parameters, 3-24
compiler program, 8-1 cross talk, preventing, 1-1
COMPILER.EXE, 8-15 crystal oscillator, 6-9
computer, 3-55, 7-29 current, 2-18
use with cell tester, 7-28 current distortion, 2-18
conditional expressions, 8-10 current harmonic distortion, 1-1
Conditional Time Setup Menu (2490), 3-15 Current Loop Menu (3250), 3-31
Conditional Timer Menu (2490), 3-21 current transformers, 2-4
Conditional Timer Setup Menu (2490), 3-25 cursor, 3-11
configuring the I/O interfaces, 3-16 customer connection cabinet, 4-2
connection diagram, 7-24 customer I/O section, 2-1, 2-6
connection diagram for an 18 cell 6.6 KV system, 2-13 Customer Service Department, 7-32
connectors customer wiring terminal strip, 2-4
T1 and T2, 7-22 customized programmable logic functions, 8-1
constants, 8-10
context sensitive Help menu, 3-8
context-sensitive help, 3-15
—D—
control “coffin”, 2-7 data bits, 8-2, 8-19
control boards, 2-8 data capture process, 8-21
control breaker CB1, 7-29 DC bus low warning alarm, 7-19
control cabinet, 1-3, 2-13, 3-1, 7-32 DC bus over volt fault, 7-20
control diagram, 8-12 DC bus under volt fault, 7-20
control fuse blown fault, 7-19 DC capacitor bank, 6-2
control fuses, 2-4 DC link capacitors C1 and C2, 7-19
control logic, 7-1 DC voltmeter, 4-1
Control Loop Test Menu (3460), 3-16, 3-28, 3-32 decelerating, 3-14
, 3-4, 6-12 deceleration, 3-13
control outputs, 8-11 time range, 1-5
control panel, 2-10 decompiler, 8-1
control power, 2-10, 2-13, 4-1 , 3-4
warning on disconnecting, x default access codes
control power connections, 2-6 proprietary, 3-44
control power disconnect switch, 2-4 default, factory, 3-10
control power fault, 7-18 , 3-9

DEMD, 3-10, 3-11 drive fault status, 3-2

display, 3-11 drive faults, 7-1, 7-2
field, 3-8 Drive IOC Setpt, 7-7
DEMD field, 3-10, 3-11 drive is inhibited, 7-26
DeMorgan’s theorem, 8-9 Drive Menu (2), 3-4, 3-8, 3-15, 3-17, 3-21, 3-42
derating motors, 1-2 drive nameplate settings, 7-5, 7-7, 7-25
derating of the motor, 6-1 Drive Parameter Menu (2000), 7-7
desired velocity, 3-7, 3-8 Drive Parameter Menu (2000), 3-15, 3-21, 7-5, 7-25,
selecting in manual mode, 3-3 7-27
device out of saturation (OOS) faults, 7-24 Drive Protect Menu (7), 3-8, 3-16, 3-42, 3-47
, 3-10 drive run state, 7-5
diagnostics, 1-4, 6-1, 6-9 drive running inhibit function, 3-44
digit, changing values of, 3-11 drive state “A”, 5-3
digital display module, 1-4 drive state “U”, 5-1, 5-2
digital input drive test
, 3-4 open loop test mode with motor, 4-8
remote manual mode, 3-3 open loop test mode without motor, 4-5
digital input module, 7-26 open loop vector control mode with motor
digital meters pick list variables, 3-46 connected, 4-10
Digital Modulator, 6-9 synchronous motor control mode, 4-17
digital output signals, 8-11 drive tuning
, 8-10, 8-11 auto tuning, 4-23
auto function, 3-8 spinning load, 4-24
fault function, 3-10 drive type specifier, 8-9
, 3-4 dual frequency braking, 1-4, 5-25
power on function, 3-10 limitations, 5-28
run function, 3-10 operation, 5-26
directory file, 8-6, 8-8, 8-16, 8-17, 8-20, 8-22, 8-23 dual performance operation modes, 1-4
directory filename associations, 8-6 dual-trace oscilloscope, 4-1
disconnect switch, ix, 4-1 dust contamination, 1-5
disconnect switch for control power, 2-4 dV/dt stress, 1-2
display, 3-2, 3-3, 3-10, 3-11 DVM, 7-28
DEMD field, 3-11 dynamic programmable meter display, 3-11
description, 3-11
display interface, 3-1, 3-3, 3-10
use with menu system, 3-1
—E—
Display Parameters Menu (8000), 3-16, 3-49 Eb* and -VBN test points at 30 Hz, 7-3
Display System Program Name function, 8-4 echo files, 3-55
Display Variable Menu edit mode, 3-6, 3-7, 3-9, 3-10
pick list variables, 3-51 editing a parameter value, 3-9
distortion wave form comparisons, 1-1 editing parameters, 3-1
divider resistors, 7-5 EEPROM
do_up_xfer_f flag, 5-10 storage of parameter values, 3-2
DOS-based compiler and reverse compiler, 8-16 efficiency, 1-4, 2-12
down arrow key, 3-7, 3-8, 3-10, 3-11 EGA capability, 7-28
pressed three times, 3-11 electrical components, 2-12
down arrow keystrokes, 3-11 electrical connections, 4-3
down transfer, 4-26, 5-1, 5-3, 5-4, 5-6, 5-8, 5-9 electrical hazards, ix
synchronous transfer state diagram, 5-3 electrical specifications, 1-5
down transfer fault, 7-13 electronic power conversion, 6-1
download, 8-2, 8-17, 8-18, 8-19, 8-20, 8-21 electrostatic discharge precautions, x
download files, 3-55 ELV, ix
downloading, 8-2, 8-3, 8-17, 8-20 EMC compliance, 4-3
sections, 8-17 emergency stop, 8-11
downloading hex files, 8-17 enclosure
downloading the system program, 3-3 specifications, 1-5
DRCTRY.DAT, 8-20 encoder loss, 7-6
DRCTRY.DAT file, 8-18, 8-19 Encoder Menu (1280), 3-17
DRCTRY.IGB, 8-3, 8-6, 8-17, 8-18, 8-23 Encoder Menu (1280), 3-15, 3-21
DRCTRY.IGB file, 8-16, 8-17, 8-18, 8-19 energy saver parameter, 7-25
DRCTRY.PWM, 8-6, 8-17 Enter Fixed Value, 3-41
DRCTRY.xxx directory file, 8-12 enter key

common functions, 3-6 features, 1-4

default access of Main Menu (5), 3-44 feedback resistors, 2-4
enter menu ID prompt, 3-44 FHOB, 7-16
, 3-6 fiber optic cable, 7-29
Enter Security Code Function, 3-43 disconnecting, 7-30
enter security level, 3-44 fiber optic cable to bypass board, 2-15
, 3-6 fiber optic cables, 6-2
entering a value beyond the range of the system, 3- 5 Megabaud communication, 6-10
12, 3-13 fiber optic cables to cells, 2-15
entering data fiber optic communications link, 2-10
using numerical keys, 3-1 fiber optic control circuitry, 1-4
Erasable Programmable Logic Devices, 6-9 fiber optic data link, 2-19, 7-22, 7-23
error, 8-16, 8-18, 8-19, 8-20 fiber optic hub board, 2-13, 7-24
compiler, 8-17 connectors, 2-17
error message Fiber Optic Interface Board, 6-9
out of range, 3-13 fiber optic interface boards, 2-15
range error, 3-13 fiber optic link, 2-8
error messages, 8-20 fiber optic links, 2-13
errors fiber optic system, 2-18
link faults, 6-10 field exciter, 6-14
event log, 3-16 field weakening rollback, 3-13
Event Log Menu (6180), 3-16, 3-45 filter capacitors, 2-18
excessive drive losses, 7-9 flags, 8-3, 8-4, 8-10, 8-11, 8-20, 8-21
execution flow of the run time software, 8-3 flash disk, 2-16
execution speed, 8-10 flash memory card, 2-16
exposed connections, ix floating neutral, 6-2, 6-5
expression evaluation, 8-6 flow of the run time software, 8-3
External I/O Menu (2800), 3-15, 3-21, 3-27 Flux Control Menu (3100), 7-25
external power factor correction capacitors, 1-1 Flux Control Menu (3100), 3-30
extra low voltage, ix flux regulator, 6-12
forcing the run_req_f flag to true, 7-2
—F— fork lift, 7-30
formulas
failed to magnetize fault, 7-9 frequency, 3-24
fan, 7-29 RPM, 3-24
fan hood, 4-3 four quadrant operation of a motor, 5-17
fault, 7-1, 7-2, 7-5, 7-7, 7-16, 7-17, 7-25, 7-26 frequency, 6-1, 6-2, 6-3, 6-6
fault condition, 3-2 , 3-9
fault indicator, 3-2, 3-3 front panel, 7-2, 8-18, 8-19
fault LED, 3-2, 3-10 front panel display, 3-8
fault log, 7-2 front panel display of fault logs, 7-1
Fault Log Menu (6210), 7-1, 7-2 front panel keypad, 3-1
fault logger table, 3-2, 3-3 full load, 6-2, 6-7
fault messages, 7-1 full rated current, 7-29
fault reset, 3-13 full scale signals, 7-7
fault reset push-button, 7-2 full-load operation, 6-7
fault reset,, 3-1 functions
faults, 7-1, 7-24 manual start, 3-1
AC fuse(s) blown, 7-24 manual stop, 3-1
blocking failure, 7-24 fuse, 2-17
bypass failed, 7-24 fuses, 2-4, 7-23
capacitor share, 7-24 AC fuse(s) blown fault, 7-24
clearing, 3-2 F1, F2 and F3, 7-22
device out of saturation (OOS), 7-24 F11, F12 and F13, 7-22
hardware, 3-2 Fuses
overvoltage, 3-10 F10, 7-22
Q1-Q4 OOS, 7-24
resetting system after, 3-1
software, 3-2 —G—
status, 3-2
galvanic isolation of cells, 2-8
switching failure, 7-24
gas contamination, 1-5
VDC undervoltage, 7-24

gate drive board, 7-18 historic log pick list variables, 3-46
gate driver board, 7-20, 7-21 horsepower specifications, 2-10
GEN II Hour Meter Setup Menu (8010), 3-16, 3-49, 3-52
lineup, 1-3 hp range, 1-5
GEN III, 2-1, 2-2, 7-17, 7-23 hub board, 7-24
cells, 2-8 humidity, 1-5
hardware overview, 1-2
power cell schematic, 7-23
power section, 2-4
—I—
transformer section, 2-4 I/O section, 2-6
GEN IIIe, 2-3, 2-6 I/O specifier, 8-10
general cell faults, 7-24 IbFDBK test point, 7-7
general rules of Boolean math, 8-9 IBM compatible computer
Generation 4 control, 5-25 use with cell tester, 7-28
GENIIIe Perfect Harmony VFDs, 1-3 IBM-compatible PC, 8-1
glossary of terms, A-1 IC37, 7-19
green keys, 3-6 IcFDBK test point, 7-7
ground fault, 7-5 #system_type, 8-4
grounding, 4-3 identification screen, 3-10
grounding points, 4-3 idle state, 5-4, 7-2
grounds, 4-3 idle state A, 7-26
IEEE 519 1992 requirements, 1-1
IGBT gate driver, 7-22
—H— IGBT gate driver board, 2-18, 2-19
Hall effect pwr supply fault, 7-11 IGBT gate drives, 7-1
Hand display, 7-26 IGBT out of saturation fault, 7-18
hand mode, 7-26 IGBTs, 6-2, 7-20, 7-29, A-3
hardware faults, 3-2 improperly addressed node, 7-13
hardware overview, 1-2 in torq limit rollback, 7-8
harmonic cancellation, 6-7 in torque limit alarm, 7-8
harmonic currents, 6-2 , 3-10
harmonic distortion, 1-1, 6-1 induction motors, 1-2, 6-1
sources, 1-1 industry standard communication, 1-4
harmonic distortion wave forms, 1-1 Inhibit, 3-44
harmonic filters, 1-1 initialization, 7-20
harmonics, 1-1, 1-2 inlet water temp high alarm, 7-14
hazardous voltages, ix, 4-1 inlet water temp high fault, 7-14
hazards inlet water temp low alarm, 7-14
electrical, ix inlet water temp low fault, 7-14
mechanical, x input
header, 8-9 remote manual mode, 3-3
heating of motor, 1-2 input and output control logic, 8-1
help display function, 3-1 input connections
help feature, 3-15 disconnecting, 7-30
hex file, 8-1, 8-2, 8-3, 8-16, 8-17, 8-21, 8-22, 8-23 input current, 2-12, 6-7
hex files input current ratings, 2-7
downloading, 8-17 input diodes, 2-18
uploading, 8-21 input flags, 8-3, 8-10, 8-20
hex format, 8-2 input frequency specifications, 2-10
hexadecimal digit assignments on the keypad, 3-5 input ground alarm, 7-3
hexadecimal digits Input Harmonics Menu (8140), 3-49
use in security code, 3-4 Input Harmonics Menu (8140), 3-16, 3-52
hexadecimal digits A-F, 3-4 input line voltages, 1-5
hexadecimal format of numbers, 3-4 input monitoring, 1-4
hexadecimal number system, 3-5 input motor currents, 2-18
hiding menu items, 3-44 input one cycle fault, 7-4
high efficiency, 1-4 input phase imbalance, 7-4
historic log, 3-16 input phase loss alarm, 7-3
Historic Log Menu input power, 2-17, 2-19, 7-1, 7-22
pick list variables, 3-51 locking off, 7-30
Historic Log Menu (6250), 3-16, 3-45 input power factor, 1-5
Input power factor, 2-18

input power specifications, 2-10 numeric keys, 3-1, 3-6

input power terminals, 2-4 numeric keys, 3-4, 3-5
Input Processing Menu (3000), 3-16, 3-28, 3-29 parameter modification, 3-3
Input Protect Menu (7000), 3-47, 7-7 shift key, 3-6
Input Protection Menu (7000), 3-16 standard, 3-1
input source file, 8-3 use with menu system, 3-1
input switch, 7-29 keypad and display interface, 3-1, 3-2
input switch cabinet, 7-29 keypad communication alarm, 7-12
input transformer, 6-7 keypad communication fault, 7-12
input voltage, 2-18, 4-2, 6-7, 6-8 , 3-5
tolerance, 1-5 keypad/display interface, 3-1
input voltage unbalance, 6-18 keypad/display module, 3-1
input waveforms, 6-7 , 3-5
inputs, 3-41
pot input, 3-3
inspection procedure —L—
warnings, 7-1 ladder logic representation of a Boolean expression,
installation, 7-28 8-13
integral isolation transformer, 6-2 ladder logic translation, 8-12
Intel 8086/8088 record format, 8-17 LCD, 3-1, 3-5, 3-7, 3-8
Intel hex file format, 8-1, 8-2 changing variable assignments, 3-8
Intel hex format, 8-1, 8-2 parameters displayed on, 3-9
Intel hex formatted file, 8-12 , 3-10
interlock key, 7-29 , 3-9
internal drive failure, 7-27 LCD interface, 3-1
interpreting keypad display fault messages, 7-1 LED status indicators, 7-25
introduction, 1-1 LEDs, 3-10, 7-29
invariant expressions, 8-10 fault, 3-2
invocation command line, 8-5 transistors Q1-Q4, 7-29
invocation options for the compiler, 8-6 left arrow key, 3-7, 3-9, 3-10, 3-11
IOC fault, 7-7 length, 2-12
isolated secondaries on transformer, 2-17 length specifications, 2-10
isolation lethal voltages, ix, 7-30
between control and medium voltage sections, 2-10 level A faults, 7-1
isolation of cells, 2-8 level B faults, 7-2
isolation transformer, 6-2 level C faults, 7-2
, 3-10, 3-11 lifting precautions, x
, 3-9 lifting tubes, 1-3
field, 3-10 Limit Protection Menu (1120), 3-17
ITOT field, 3-11 limiting output speed, 7-26
limits, 3-16
—K— Limits Menu (1120), 7-5, 7-27
Limits Menu (1120), 3-15, 3-18, 7-7, 7-25
key sequences, 3-1 line frequency, 5-1, 5-2, 5-7, 5-9
keypad, 1-4, 2-17, 3-1, 3-3, 3-4, 3-5, 3-6, 3-9, 3-10 line over voltage 1 alarm, 7-3
, 3-4 line over voltage 2 alarm, 7-3
arrow keys, 3-7 line over voltage fault, 7-3
automatic key, 3-3 line reactors, 4-26, 5-5
cancel key, 3-44 line voltage, 5-5
display of user faults, 7-26 line-to-neutral voltage levels, 6-3
enter key, 3-6 link fault, 6-10, 7-19
changing security features, 3-44 link faults, 7-25
fault reset key, 3-2 liquid-cooled, 6-1
faults displayed on, 7-1 list of symbols, B-1
functions, 3-1 load conditions, 3-15
green keys, 3-4 load reactor, 7-28, 7-29
green text, 3-4 load reactors, 7-29
hexadecimal digit assignments, 3-5 local manual mode, 3-3, 3-4, 3-7, 3-8
, 3-5 lock out and tag out procedures, 4-1
key functions, 3-2 lock-out/tag-out procedures, ix
, 3-4 Log Control Menu (6), 3-16, 3-42, 3-45

log variable pick list, 3-46 mechanical specifications, 1-5

logic assignments, 8-3 medium voltage
logic equations, 8-3 isolation from control section, 2-10
logic functions, 8-1, 8-2, 8-17, 8-22 warning about control power, x
logic section, 8-10 medium voltage input, 4-2
logic statements, 8-1, 8-2, 8-3, 8-4, 8-11 medium voltage input switch, 7-29
Logs Menu (6), 3-8 medium voltage low 1 alarm, 7-4
loss all HEX fans alarm, 7-14 medium voltage low 2 alarm, 7-4
loss all HEX fans fault, 7-14 medium voltage low Flt, 7-4
loss of drive enable fault, 7-11 medium voltage motor test, 4-1
loss of field fault, 6-14, 7-9 medium voltage tap cables, 4-2
loss of signal (1-24) alarm, 7-12 medium voltage tap connections, 4-2
loss one HEX fan alarm, 7-14 medium-voltage power, 7-29
Low Frequency Compensation Menu (3060), 3-30 menu
low motor speed fault, 7-8 going to bottom, 3-10
low speed applications, 1-1 returning to the top, 3-10
low voltage terminal strip, 2-4 menu access, 3-7, 3-8, 3-10
low water flow alarm, 7-14 numeric, 3-5
low water flow fault, 7-14 security, 3-1
low water level alarm, 7-14 menu access feature, 3-9
low water level fault, 7-14 menu and submenu summary, 3-15
low-voltage power cell, 2-19 menu descriptions, 3-14
menu initialization fault, 7-10
menu items
—M— hiding, 3-44
main display, 3-7, 3-8, 3-9 prohibiting access to, 3-44
availablility of speed menu feature, 3-5 prohibiting changes, 3-44
main menu, 7-29 menu number, 3-5, 3-9
Main Menu (5), 3-7, 3-8, 3-9, 3-16, 3-42 menu numbers, 3-4, 3-5, 3-6, 3-7
default access to, 3-44 menu setting rollback, 3-13
Main Menu (5) Options, 3-42 menu structure, 3-1, 3-7, 3-10
main meter display navigating through, 3-7, 3-9
availability of speed menu feature, 3-5 menu system, 3-1, 3-7, 3-8
main transformer, 7-20 changing variable assignments on LCD, 3-8
maintainance navigation through, 3-1
qualified individuals, ix menuing system, 3-10
maintenance, ix, 7-1 menus
maintenance procedure accessing, 3-8, 3-10
warnings, 7-1 accessing based on menu numbers, 3-4
maneuvering between menus, 3-10 accessing using numeric menu codes, 3-5
manifold valves, 7-24 accessing using speed menu, 3-4
manual control mode, 3-3 maneuvering in, 3-10
, 3-4 navigating to the bottom, 3-8
manual mode, 3-1 navigating to the top, 3-8
flow diagram, 3-3 Meter (8) General Drive Parameters, 3-49
local, 3-8 meter display, 3-7, 3-8, 3-9, 3-10, 3-11
manual start, 3-1, 7-2 meter display sceen, 3-10
, 3-4, 3-9 meter display screen, 3-10
manual start mode, 3-3 DEMD field, 3-10, 3-11
manual stop, 3-1 ITOT field, 3-10, 3-11
master control, 2-8 MODE field, 3-10, 3-11
system module, 2-13 RPM field, 3-10, 3-11
master control components, 2-7 VLTS field, 3-10, 3-11
master control system, 2-10 Meter Menu (8), 3-8, 3-16, 3-42, 3-47, 3-49
master EPLD, 6-9 metering terminal strip, 2-4
master link board, 7-24, 7-25 microprocessor, 6-1, 6-9
replacing, 7-25 microprocessor board, 2-13, 2-15, 2-17, 7-13, 7-16
spare, 7-24 logging cell faults, 7-16
Master Link Board, 7-29 replacing without reprogramming parameters or
maximum cell current, 2-12 system program, 2-14
mechanical bypass boards Modbus RTU Setup Menu (9050), 3-17, 3-53
status indicators, 7-25 Mode, 7-27

, 3-9, 3-11, 7-26 network 2 communication fault, 7-13

mode displays summary, 3-13 neutral, 6-2, 6-3, 6-5, 6-6, 6-7
MODE field, 3-10, 3-11 non-volatile, 8-2, 8-20
, 3-4 non-volatile memory, 8-1
modification capabilities, 3-1 non-volatile memory area, 3-2
modular construction, 1-4, 6-1 non-volatile RAM, 8-2
modulator board, 2-15 normal mode, 3-44
modulator board fault, 7-10 normal operating mode, 7-26
modulator configuration fault, 7-10 normal operation, 3-1, 3-10
modulator watchdog flt, 7-11 NOT, 8-8, 8-13
momentary digital input, 3-3 NOT operator, 8-6, 8-8
motor number systems, 3-4
four quadrant operation, 5-17 numeric keys, 3-1, 3-4, 3-5, 3-9
signal polarities, 5-18 numeric menu access, 3-5
motor control center, 4-26 numerical keys
motor control centers, 5-5 functions, 3-1
motor heating, 1-2, 6-1 numerical menu access, 3-8
motor insulation, 6-1 numerical menu access mode, 3-10
motor losses
reduction, 5-29 —O—
Motor Menu (1), 3-4, 3-8, 3-15, 3-17, 3-42
Motor Menu (1000), 7-5 Off display, 7-26
motor monitors, 2-6 off mode, 7-26
motor nameplate, 2-12 off-line editing, 8-2
motor neutral, 6-5, 6-7 one blower lost alarm, 7-13
motor noise, 1-2 one pump failure alarm, 7-13
motor over volt fault, 7-7 on-line diagnostics, 1-4
motor over voltage alarm, 7-6 on-line operation while tuning, 1-4
Motor Parameter Menu (1000), 7-5, 7-7 on-site cell testing, 7-28
Motor Parameter Menu (1000), 3-15, 3-17, 3-57, 7-25, open cell connectors
7-27 protecting after disconnetcs, 7-30
motor phase, 6-2 open hose connectors
motor sense unit, 7-7 protecting after disconnects, 7-30
Motor Sense Unit, 7-5 open loop test mode, 6-14
motor speed open loop vector control, 6-13
adjusting, 3-35 operating voltages, 2-12, 2-17
motor speed in RPM, 3-10, 3-11 operation issues, 5-1
motor test, 4-1 operation mode displays, 3-13
motor torque limit parameter, 7-27 , 3-4
Motor Trip volts, 7-7 operation while tuning, 1-4
motor voltage and current waveforms, 6-7 operators, 8-6, 8-9
mtr therm over ld fault, 7-6 optional syntax, 8-8
mtr therm over load 1 alarm, 7-6 opto-couplers, 7-18
mtr therm over load 2 alarm, 7-6 OR, 8-8, 8-9, 8-12, 8-13, A-5
multi-motor operation, 1-4 OR (+) operator, 8-6
multiple motors oscilloscope, 4-1
controlling, 4-25, 5-4 output bypass circuit, 2-19, 7-22
multi-secondary phase-shifting power transformer, 2-3 output cell, 2-13
MV mechanical bypass board, 7-25 output cells, 2-8, 2-12, 2-17
Output Connection Menu (2900), 3-28
output connections, 7-29
—N— output contactor, 7-5
nameplate ratings, 7-27 output contactors, 7-29
nameplate settings, 7-5, 7-7, 7-25 output current, 2-12, 3-10, 3-11, 7-29
navigating through the menu structure, 3-7 output current ratings, 2-7
negate operator, 8-6 output current wave form, 1-2
NEMA 1 output current, limiting, 7-26
enclosure specifications, 1-5 output file, 8-1, 8-2, 8-23
network 1 communication alarm, 7-13 output flags, 8-10
network 1 communication fault, 7-13 output frequency drift, 1-5
network 2 communication alarm, 7-13 output ground fault, 7-5
output harmonics, 6-1

output hex file, 8-17 outputs, 3-3

output limitations, 7-26 padding with zeroes, 3-6
output line voltages, 1-5 preventing changes to, 3-44
output motor current, 2-18 prohibiting changes to, 3-44
output operating voltage, 2-12 rejecting modifications, 3-6
output operating voltages, 2-7 storage in system module, 2-14
output phase, 6-2 viewing and editing, 3-1
small difference in phase angle, 6-2 parity, 6-10, 8-2, 8-19
output phase imbal alarm, 7-8 PC
output phase open alarm, 7-8 editing the system program, 8-1
output phases, 2-18 PC boards, 7-32
output power, 7-22 PC tool interface, 1-4
output power cabinet, 1-3 PCplus, 3-55
output power cell, 7-1 PCT, 7-29
output power terminals, 2-4 Pentium processor, 6-9
Output Processing Menu (3050), 3-28 Perfect Harmony menu structure, 3-14
Output Processing Menu (3050), 3-16, 3-29 periodic maintenance, 7-1
output speed phase angle, 6-2
decreasing, 7-26 phase angle setpoint, 5-10
output speed phase error, 5-2
limiting, 7-26 phase error threshold, 4-25
output speed limit, 7-27 phase lock loop, 5-1, 5-2
output speed, limiting, 7-26 phase offset, 4-25
output terminals T1 and T2, 7-23 phase sequence alarm, 7-13
output torque, 1-5 phase sequence fault, 7-13
output voltage, 2-18, 7-26 phase shift from transformer T1, 2-18
output voltage, limiting, 7-26 phase shifting transformer, 2-10
output voltages, 6-3, 6-5, 6-6 phase-shifting power transformer, 2-3
evaluation of, 7-29 PIB, 8-14
output waveform, 6-4, 6-5 pick list, 3-11
over speed alarm, 7-5 pick list variables, 3-46, 3-51
over speed fault, 7-5 pick lists, 3-1, 3-7
over temp warning fault, 7-18 PID Select Menu (4350), 3-16, 3-33, 3-40
over temperature fault, 7-18 PL1, 7-22
overheating, x PL2, 7-22
overload capability, 1-5 PLC
Overspeed setting, 7-5 communications, 4-26
overvoltage faults, 3-10, 7-25 hardware, 4-26
PLC capabilities, 1-4
PLC interface, 5-6
—P— polarity, 2-18
P/N 469939.00, 7-28 portable cell tester, 7-29
padding zeroes in parameter values, 3-6 portable Harmony cell tester, 7-28
parallel printer port, 7-29 position the cursor, 3-11
parameter is selected into memory, 3-12 pot, 7-29
parameter security, 3-1 selecting desired velocity using, 3-3
parameters , 3-4
accepting new values, 3-6 potentiometer
accessing, 3-1 selecting desired velocity using, 3-3
changing values, 3-4 power cell, 6-2, 6-10, 7-1, 7-16, 7-17, 7-22
changing values of, 3-5 schematic, 7-23
edit mode, 3-6, 3-10 power cell check, 1-4
edit mode, 3-7 power cell fault, 7-16
editing, 3-9 power cell with optional bypass, 2-19
editing process, 3-6 power cells, 6-2, 6-3, 6-10, 7-32
editing values, 3-1 power circuit, 2-17
entering a value beyond the range of the system, 3- power circuit topology, 6-2
12, 3-13 power circuit, modulation, and bypass contactor test,
entering hex values, 3-4 4-4
incrementing/decrementing values of, 3-7 power circuitry faults, 7-24
inputs, 3-3 power circuitry theory, 6-2
organization, 3-1 power factor, 1-1, 1-2, 2-12, 6-1, 6-2, 6-7

definition, 1-1 rated current, 7-29, 7-30

units, 1-1 rated hp, 2-12
power factor capacitors, 6-1 rated voltage, 7-28
power factor correction, 6-1 reactive halide contamination, 1-5
power failure, 3-2 reactor temperature 1 alarm, 7-14
power filters, 6-1 reactor temperature 2 alarm, 7-14
power fuse blown fault, 7-18 reactor temperature flt, 7-14
power fuses, 7-30 redundant cell operation, 2-17
power input cabinet, 1-3, 2-1 reference signal, 6-3, 6-4, 6-5
power interface board, 2-17 regen torque limit parameter, 7-25
Power Interface Board, 7-3, 7-5, 7-6, 7-7 regeneration, 3-13
replacing, 7-5 regeneration mode, 7-26
power monitoring, 5-25 rejecting modifications, 3-6
power on indicator, 3-10 reliability, 1-4
power quality meters, 2-6, 5-25 remote manual mode, 3-3, 3-4
power supply connection, 2-15 activation, 3-3
power supply fault, 7-11 replacement of component parts, 7-32
power transformer, 2-4 reports capabilities, 1-4
power transistors Q1-Q4, 7-20, 7-21 required syntax, 8-8
power up, 3-11 reset, 3-2, 3-11, 7-2, 7-20
power up display, 3-10 resetting of faults automatically, 7-2
power wires, 2-3 resetting the current security level to 0, 3-9
power wiring, 2-3 resetting the system, 3-1
PQM, 4-29 resonance, 6-1
precedence, 8-6 resonance avoidance, A-5
precedence of operations, 8-7 resonance avoidance feature, A-5
pre-power visual inspection, 4-1, 4-2 resonance avoidance parameters, 3-24
primary currents, 6-2 resonance problems, 1-1
primitive logic functions, 8-1, 8-2 restore default value, 3-10
printed circuit (PC) boards, 2-10 restore factory default, 3-10
printer, 3-55 restore the security level back to 0, 3-10
Procomm, 3-55 retaining clips, 7-30
profile, 3-16 returning to the previous menu, 3-6, 3-8
program lines spanning multiple lines, 8-8 reverse compiler, 8-1, 8-3, 8-4, 8-6, 8-16, 8-17, 8-21,
program statement format, 8-8 8-22, 8-23
program statements that span multiple lines, 8-13 DOS based, 8-23
programmable meter display, 3-11 error messages, 8-20
prohibiting changes to parameters, 3-44 reverse compiler program, 8-1
proprietary security code levels, 3-44 Rgen display, 7-26
protective covers, 4-3 ribbon cable, 7-22
protective earth symbol, 4-3 right arrow key, 3-5, 3-6, 3-7, 3-9, 3-10, 3-11
pulsations, 6-1 Rlbk (Rollback Mode), 7-27
Rlbk display, 7-26
rollback conditions, 6-17
—Q— rollback mode, 7-26
Q1, 6-3, 6-4 RPM, 3-10, 3-11
Q1-Q4 OOS faults, 7-24 , 3-9
Q2, 6-3, 6-4 RS232 download functions, 3-55
Q3, 6-3, 6-4 RS232 port, 3-55
Q4, 6-3, 6-4 baud rate setting, 3-55
qualified individual (for troubleshooting and parity setting, 3-55
maintenance), ix stop bit setting, 3-55
qualified service personnel, 7-1 RS-232 serial port, 8-17
quick disconnect fittings, 7-30 RS232 upload functions, 3-55
RS485 serial communications network, 5-6
rstop_f, 8-10
—R— run condition, 7-2
ramp stop, 7-2 run indicator, 3-10
ramp stops, 7-2 run state, 7-2, 7-5
range run state (D)
errors, 3-13 prohibiting parameter changes during, 3-44
run state “D”, 5-2

run time software, 8-3, 8-8 , 3-6

run time system program, 8-10 , 3-7
run_req_f, 8-10, 8-11 shipping splits, 1-3
run_req_f flag, 7-2 sign, changing value of, 3-11
run-time software, 8-1, 8-2 signal frame of reference for motor control, 5-16
Signal Interface Board, 6-9
sine wave, 6-7
—S— single induction motors, 6-13
safety, ix Single Phasing Menu (7010), 3-47, 3-48
safety precautions, ix single phasing rollback, 3-13
scaler adjustments, 4-30 single-phase H-bridge of IGBTs, 6-2
schematic of a typical power cell, 6-2, 6-5 sinusoidal, 6-2, 6-3
scrolling, 3-7 sinusoidal input currents, 1-1
using arrow keys, 3-1 sinusoidal output, 1-1, 1-2
scrolling through parameter lists, 3-15 sinusoidal output voltages, 1-2
SCRs, 1-2 six month inspection, 7-32
secondary of the power transformer, 2-18 slash character, 8-6
secondary winding, isolated, 6-2 slaves, 6-10
security, 3-1, 3-4, 3-5, 3-7, 3-8, 3-9 slip, 5-18
approved menus, 3-9 Smart Term, 3-55
entering access codes, 3-1 soft start protection, 1-4
pluggable keypad/display module, 3-1 software faults, 3-2
security access code, 3-4, 3-7 software switches
security access codes, 3-1, 3-4 closing and opening, 3-40
security access levels and default codes, 3-44 software tools, 8-3
proprietary, 3-44 software version number, 3-10
security code, 3-4, 3-5 SOP file, 8-9, 8-12
changing, 3-9 SOP interpretation, 8-12
prompting user after menu requests, 3-5 SOP text file format, 8-9
security codes, 3-44 SOP timing, 8-12
prompts for new level, 3-5 SOP utilities, 8-5
proprietary, 3-44 SOP utilities program, 8-17, 8-18
Security Edit Functions Menu (5000), 3-42, 3-43, 3-44 SOP Utilities program, 8-2, 8-5, 8-17, 8-18, 8-21, 8-22
Security Edit Menu (5000), 3-16 sound pressure, 1-2
security edit mode source code, 8-2, 8-4
asterisk character (*), 3-44 source file, 8-1, 8-3, 8-4, 8-16, 8-17, 8-20, 8-23
exiting, 3-44 source impedances, 1-1
security features, 3-16 source lines, 8-4
security level, 3-10 spanning multiple lines, 8-13
changing, 3-44 spare parts, 7-32
clearing, 3-7
restoring back to zero, 3-10
SPARE PARTS LISTS, D-1
spd fwd lim parameter, 3-13
restoring to zero, 3-8
specifications, 1-5
security level cleared message, 3-9
, 3-35
, 3-9
changes affecting output speed, 7-26
security level, resetting to 0, 3-9
changes in, 7-26
security levels, 3-44
speed demand, 3-10, 3-11
setting, 3-44
Speed Derate Curve Menu (1151), 3-20
Select Language Function, 3-43
speed forward limit parameter, 3-13
selecting a submenu, 3-6
Speed Loop Menu (3200), 3-31
semi-colon end-of-line character, 8-13
speed menu, 3-4, 3-8
sense circuitry of cells, 7-1
speed menu feature, 3-4, 3-5
serial communications, 5-4
speed menus, 3-7
serial communications port, 8-2
Speed Profile Menu (4000), 3-3, 3-16, 3-33
Serial Functions Menu (9110), 3-55, 3-57
speed profiling, 3-3
Serial Functions Menu (9110), 3-17, 8-19
serial port, 1-4 speed profiling control, 3-35
Serial Port Setup Menu (9010), 3-16, 3-53, 3-54 using, 3-35
series links, 7-29 Speed Ramp Setup Menu (2260), 3-15, 3-21, 3-23
setpoint, 3-16 speed range, 1-5
setpoint limits, 3-16 speed reference source, 8-11
shielded cables, 4-3 speed regulator, 6-12

Speed Setpoint Menu (4240), 3-33 synchronous transfer procedure, 4-25

Speed Setpoint Menu (4240), 3-16, 3-39 synchronous transfer state diagram for closed “down
speed setting transfer”, 5-3
source in auto mode, 3-3 synchronous transfer state diagram for closed “up
Speed Setup Menu (2060), 3-11, 3-15, 3-21, 3-22 transfer”, 5-2
spinning load, 4-24 syntax, 8-1, 8-2, 8-4, 8-6, 8-8, 8-16, 8-17
Spinning Load Menu (2420), 3-25 system constants, 8-10
Spinning Load Menu (2420), 3-15, 3-21, 5-11 system control switches, 8-10
spinning load restart, 1-4 system errors, 3-10
ST220.EXE, 3-55 system faults, 7-1
Stability Menu (3), 3-8, 3-16, 3-28, 3-42 system ground, 4-3
standard menus, 3-11 system interface board, 2-15
standard PWM motor drives, 6-2 system menus, 3-1
start/stop control logic, 8-1 system module, 2-13
starters for blower motors, 2-4 system program, 2-14, 3-3, 3-40, 3-41, 3-51, 7-2, 7-
startup procedure, 4-1 13, 7-26, 8-1
state A, 7-26 closing and opening software switches, 3-40
state machine, 8-12 comments, 8-1
state machine diagram, 8-12 compar_b_f flag, 3-41
statement format, 8-8 comparators, 3-40
statement terminator, 8-4, 8-8 compilation process, 3-3
static drives, 6-7 do_up_xfer_f flag, 5-10
static power converter, 6-2 downloading, 3-3
Stator Resistance Estimator Menu (3300), 3-31 editing, 8-1
, 3-12 modification, 3-3
, 3-11 modifications, 3-3
status indicators, 7-25 statement format, 8-8
stop, 3-55 storage, 8-1
stop bits, 8-19 storage in the system module, 2-14
stop bits, 8-2 terminology, 8-1
stop mode, 3-1 types of statements, 8-4
effects of, 3-3 use of spaces, 8-8
storage system program compiler invocation options, 8-6
safety precautions, x System Program Download Function (9120), 8-18
stored energy found in cells, 4-1 system program fault, 7-10
string pointer, 7-26 system program initiation, 8-10
submenu system program transfers, 8-2
going to bottom, 3-10 system program upload function, 8-21
returning to the top, 3-10 System Program Upload Function (9130), 8-21
submenus, 3-1, 3-4, 3-7, 3-21, 3-42 system programming, 8-1
sulfide contamination, 1-5 system reset, 3-1, 3-11
summary of operation mode displays, 3-13 system type identification, 8-4
sum-of-products, 8-8, 8-12, 8-13, 8-17 system types recognized by the system program
sum-of-products (SOP) file, 8-12 compiler, 8-5
surge arrestors, 1-4
switch mode power supply, 2-10, 2-13
switchgear, 7-29 —T—
switching failure faults, 7-24 T1, 2-18, 6-3, 7-29
switching Qn fault, 7-21 T1 output, 7-29
switching timeout fault, 7-21 T2, 6-3, 7-29
symbol, 8-6, 8-8, 8-10, 8-11, 8-12, 8-23 T2 output, 7-29
symbolic content, 8-1, 8-2 tap cables, 4-2
symbols, B-1 tap connections, 4-2
symmetry of voltages, 7-5 TAS2A, 7-22
Sync Motor Menu (1100), 3-17 TAS2B, 7-22
Sync Transfer Menu (2700), 3-15, 3-21, 3-27, 5-10 TCP/IP Setup Menu (9300), 3-17, 3-55
, 6-14 temporary flags, 8-11
synchronous transfer, 8-12 terminal blocks, 2-6
example, 5-4 terminal emulation program, 8-18, 8-19
multiple motors and a PLC, 5-4 terminal emulator, 3-55
Synchronous Transfer Menu (2700), 4-25 terminal protocol settings for the RS232 port, 3-55
synchronous transfer operation, 5-1, 5-9 terminal strip for customer wiring, 2-4
xiv ASIRobicon Version 1.1 (19000404)

terminal strip for low voltage, 2-4 TRUE and FALSE, 8-10
terminal strip for metering, 2-4 true and false logic assignments, 8-3
test points - VCN, -VBN, and -VAN, 7-5 TRUE or FALSE, 8-10
THD, 6-7
THEORY OF OPERATION, 6-1
thermal limitations of the motor, 6-1
—U—
thermal overload, 3-13 unary operators, 8-6
thermal overload rollback, 3-13 under load alarm, 7-7
thermally hot components, ix under load fault, 7-7
three phase input connections under voltage rollback, 3-13
disconnecting, 7-30 underscore, 3-9
three possible output voltages, 6-3 undervoltage ride-through, 1-4
time-out fault, 5-2 up and down arrow keys, 3-6, 3-9
timers, 8-11 scrolling through parameter lists, 3-15
toggling power to the drive, 3-9 up arrow key, 3-7, 3-8, 3-10, 3-11
token, 8-12, 8-17, 8-20 up transfer, 4-26, 5-1, 5-4, 5-5, 5-6, 5-7
token directory, 8-17 synchronous transfer state diagram, 5-2
tool communication alarm, 7-12 up transfer fault, 7-13
tool communication fault, 7-12 up/down arrow keys, 3-12
topology of Perfect Harmony VFD, 6-4 upload files, 3-55
torque, 4-3, 5-16, 5-17 upload/download utility, 8-3
torque and velocity loop gains, 3-16 uploading, 8-2, 8-21
torque limit, 7-25, 7-27 uploading a system program, 8-21
torque limit condition, 7-27 uploading hex files, 8-21
torque markings, 4-3 , 3-35
torque output limitations, 7-26 user defined fault, 7-13
torque pulsations, 6-1 user defined fault #n, 7-26
torque pulsations (VFD-induced), 1-2 User defined text strings, 7-26
Torque Reference Menu (2210), 3-21 user fault messages, 8-10
total harmonic distortion, 6-7 user faults, 7-26
total harmonic distortion of the source current, 1-1 user modules, 5-12, 5-16
touch-up paint, 7-32 user_fault1 flag, 7-26
transfer application, 5-5 user_fault1 through user fault16, 7-13
transfer fault, 5-1 user_text_1 string pointer, 7-26
transfer of drive control, 5-4
transfer state “A”, 5-1, 5-2
transfer state “B”, 5-2 —V—
transfer state “C”, 5-2
values beyond the range of the system, entering, 3-
transfer state “D”, 5-2
12, 3-13
transfer state “E”, 5-2
valve BV21, 7-30
transformer, 2-4, 2-10, 2-12, 2-17
valve BV7, 7-30
isolated secondaries, 2-17
-VAN test point, 7-5
secondary windings, 7-28
variable, 3-11
sizing and CFM/BTU effects, 2-10
variable displays, 3-11
transformer cabinet, 1-3, 7-29 variable pick list for Compare Setup Submenus (4810-
transformer secondaries, 6-2 4960), 3-41
transformer section, 2-3 variable speed operation, 6-1
major components, 2-4 variable voltage source, 7-28, 7-29
transformer size, 2-7 variables, 8-6, 8-10
transformer T1, 2-18 various speed, 3-16
transformer taps, 4-2 -VBN test point, 7-5, 7-7
transistors are firing, 7-29 VDC test point, 7-20
transmit data, 3-55 VDC undervoltage faults, 7-24
transparent cell bypass, 1-4 vector control, 3-21, 6-12
transporting precautions, x
current regulators, 6-12
trip-free operation, 1-4
dead-time compensation, 6-13
troubleshooting, ix, 7-1, 7-17
feed-forward compensation, 6-12
cell communication and link faults, 7-25
flux angle, 6-13
general cell and power circuitry faults, 7-24
flux regulators, 6-12
overvoltage faults, 7-25
motor model, 6-12
qualified individuals, ix
peak reduction, 6-13
troubleshooting cell overtemperature faults, 7-24, 7-25
Version 1.1 (19000404) ASIRobicon xv

speed regulators, 6-12 wave form of output current, 1-2

velocity and torque loop gains, 3-16 wave forms
velocity demand, 3-4, 3-7, 3-8, 3-9, 3-10, 3-11 distortion comparisons, 1-1
changing, 3-7 waveforms for line-to-line voltage, 6-6
changing, 3-10 waveforms for phase B, 6-6
, 3-9 weak battery alarm, 7-11
sources for manual modes, 3-3 weight of lineup, 2-12
velocity demand field, 3-8 weight specifications, 2-10
velocity reference, 5-1, 5-2 Windows 95, 8-2, 8-3, 8-15, 8-16, 8-17, 8-18, 8-19, 8-
version number, 3-10 22
version screen, 3-10 Windows NT, 8-3
VFD output, 5-5 Windows-based SOP utilities program, 8-15
viewing parameters, 3-1 Windows-based utilities program, 8-15
visual inspection, 4-1 wiring, 4-26
VLTS, 3-10, 3-11 wye connected power cells, 6-2
voltage attenuator, 2-17 wye-connected primary, 6-7
voltage clamps, 2-18
voltage divider, 2-18
voltage harmonic distortion, 1-1
—X—
voltage regulation Xformer temperature 1 alarm, 7-14
improved, 1-1 Xformer temperature 2 alarm, 7-14
voltage stress, 2-18 Xformer temperature flt, 7-14
voltmeter, 7-29 Xformer water temp high alarm, 7-14
volts/hertz control mode, 6-15 Xformer water temp high fault, 7-14
vortex flow sensor, 7-28 Xfrmr Temperature Alarm 1, 7-28
VT1 and VT2 test points, 7-20, 7-21 Xfrmr Temperature Alarm 2, 7-28
—W— —Z—
Wago communication alarm, 7-12 zero security level, 3-10
Wago communication fault, 7-12 zeroes
Wago configuration fault, 7-12 padding during parameter editing, 3-6
WAGO I/O module color codes, 5-12
warnings, ix
∇ ∇ ∇
xvi ASIRobicon Version 1.1 (19000404)

Perfect Harmony GENIII/e Startup and Advanced Topics NOTES
NOTES

NOTES Perfect Harmony GENIII/e Startup and Advanced Topics

Perfect Harmony GENIII/e Startup and Advanced Topics NOTES

NOTES Perfect Harmony GENIII/e Startup and Advanced Topics

Perfect Harmony GENIII/e Startup and Advanced Topics READERS’ COMMENTS FORM



READERS’ COMMENTS FORM Perfect Harmony GENIII/e Startup and Advanced Topics
Additional Comments

ASIRobicon
USA
∇ ∇ ∇

To assure timely technical updates on your equipment, please complete and return this form. This
information is to be completed by the end user or equipment owner. For information on ASIRobicon post
sale service solutions, please check the appropriate boxes below before returning this form to
ASIRobicon.
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panel)
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For additional information by phone, please complete the table above and check the appropriate items
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USER’S MANUAL
FOR
AIR COOLED
PERFECT HARMONY
GENIII/E SERIES
ADJUSTABLE SPEED AC MOTOR DRIVES
WITH NEXT GENERATION CONTROL

Version 1.1
October 2003

USA

70, 100, 140, 200, and 260 (630 V cells)
0I, 1I, 2I, 3I, 4I, 315H, 375H, 500H, and 660H (690 V cells).
For the support representative nearest you, please call ASIRobicon’s main office at (724)-339-9500.
Perfect Harmony, GEN III (GEN3) and GEN IIIe (GEN3e) are product lines of AC motor drives from ASIRobicon.
User’s Manual for Air Cooled Perfect Harmony Series (p/n 19000405)
Version History:
Perfect Harmony GENIII/e User’s Manual Table of Contents
TABLE OF CONTENTS

1.1.
Introduction to the Perfect Harmony....................................................................................1-1
1.4. Specifications ......................................................................................................................1-5
CHAPTER 2: Hardware Components .....................................................................................................2-1
2.1.
Hardware Configuration ......................................................................................................2-1
3.1. Introduction..........................................................................................................................3-1
3.2. The Keypad .........................................................................................................................3-1
3.2.1. Fault Reset Key ......................................................................................................3-2
3.2.2. Automatic Key .........................................................................................................3-3
3.2.3. Manual Stop Key.....................................................................................................3-3
3.2.4. Manual Start Key ....................................................................................................3-3
3.2.5. The 0-9 Key.............................................................................................................3-4
3.2.6. The Enter/Cancel Key.............................................................................................3-6
3.2.7. Shift Function Keys .................................................................................................3-6
3.2.8. Arrow Keys .............................................................................................................3-7
3.2.9. Diagnostic Indicators.............................................................................................3-10
3.2.10. The Display...........................................................................................................3-11
3.3. Menu Descriptions.............................................................................................................3-15
3.3.1. Motor Menu (1) Options ........................................................................................3-18
3.3.2 Drive Menu (2) Options..........................................................................................3-22
3.3.3. Stability Menu (3) Options.....................................................................................3-29
3.3.4. Auto Menu (4) Options..........................................................................................3-35
3.3.5. Main Menu (5) Options .........................................................................................3-44
3.3.6. Log Control Menu (6) Options ..............................................................................3-47
3.3.7 Protect Menu (7) Options.......................................................................................3-50
3.3.8. Meter Menu (8) Options ........................................................................................3-52

Table of Contents Perfect Harmony GENIII/e User’s Manual
3.3.9. Communications Menu (9) Options ......................................................................3-57

3.3.10 Menu Setup for Multiple Configuration Files (Slaves) ..........................................3-60
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual List of Figures
LIST OF FIGURES

CHAPTER 2: Hardware Components .......................................................................................................2-1
Figure 3-1. The Keypad and Display Interface of the Perfect Harmony Series ....................................3-2
Figure 3-2. Comparison of the two Manual Control Modes...................................................................3-4
Figure 3-3. Anatomy of a Numeric Keypad Key ....................................................................................3-5
Figure 3-4. Accessing Items Using ID Numbers ...................................................................................3-6
Figure 3-5. Location of Shift Mode Indicator on the Perfect Harmony Display .....................................3-7
Figure 3-6. Using the Up and Down Arrow Keys to Control Velocity Demand .....................................3-9
Figure 3-7. Security Level Cleared Message on the Perfect Harmony Display ....................................3-9
Figure 3-8. The Identification/Version Screen and Meter Displays .....................................................3-10
Figure 3-9. Dynamic Programmable Meter Display ............................................................................3-11

List of Figures Perfect Harmony GENIII/e User’s Manual
Figure 3-10. Dynamic Programmable Meter Display in Rollback Mode..............................................3-11

Figure 3-11. Dynamic Programmable Meter Display in Regeneration Mode......................................3-11
Figure 3-12. Status Display After [SHIFT] [ENTER] ([CANCEL]) Key Sequence ...............................3-11
Figure 3-13. Status Display After [SHIFT]+[2] Key Sequence ............................................................3-12
Figure 3-14. Status Display After [Ø] [Ø] Key Sequence ....................................................................3-12
Figure 3-15. Status Display After [Ö] ..................................................................................................3-12
Figure 3-16. Status Display After [Ø] Key Sequences .......................................................................3-12
Figure 3-17. Status Display After [ENTER] Key to Change a Parameter ...........................................3-12
Figure 3-18. Status Display Upon Entering a Value In the Range of the System ...............................3-12
Figure 3-19. Status Display After [SHIFT] [Ö] and the Parameter ID 1020 is entered .......................3-13
Figure 3-20. Status Display After [ENTER] [ENTER] ..........................................................................3-13
Figure 3-21. Status Display Upon Entering a Value Beyond the Range of the System......................3-13
Figure 3-22. Critical Speed (Resonance Avoidance) Parameters ......................................................3-24
Figure 3-23. Advantages of Using Speed Profiling Control.................................................................3-35
Figure 3-24. Dynamic Programmable Meter Display ..........................................................................3-51
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1
∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual List of Tables
LIST OF TABLES
List of Tables ................................................................................................................................................ xi

CHAPTER 2: Hardware Components ........................................................................................................2-1
Table 3-1. Hexadecimal Digit Assignments on the Perfect Harmony Keypad ......................................3-5
Table 3-2. Summary of Common [SHIFT] Key Sequences...................................................................3-8
Table 3-3. Summary of Common Arrow Key Sequences....................................................................3-10
Table 3-6. Perfect Harmony Menu and Submenu Summary ..............................................................3-15
Table 3-7. Motor Parameter Menu (1000) ...........................................................................................3-17
Table 3-8. Limits Menu (1120).............................................................................................................3-18
Table 3-9. Speed Derate Curve Menu (1151) .....................................................................................3-20
Table 3-10. Autotune Menu (1250)......................................................................................................3-20
Table 3-11. Encoder Menu (1280) (Closed Loop Vector Control Only) ..............................................3-21
Table 3-12. Drive Parameter Menu (2000)..........................................................................................3-21
Table 3-13. Speed Setup Menu (2060) ...............................................................................................3-22
Table 3-14. Speed Ramp Setup Menu (2260).....................................................................................3-23
Table 3-15. Critical Frequency Menu (2340) ........................................................................................3-23
Table 3-16. Spinning Load Menu (2420) ..............................................................................................3-25
Table 3-17. Conditional Timer Setup Menu (2490) ..............................................................................3-25

List of Tables Perfect Harmony GENIII/e User’s Manual
Table 3-18. Cell Menu (2520) ..............................................................................................................3-26

Table 3-19. Sync Transfer Menu (2700)..............................................................................................3-27
Table 3-20. External I/O Menu (2800) .................................................................................................3-27
Table 3-21. Output Connection Menu (2900) ......................................................................................3-28
Table 3-22. Stability Menu (3) (Parameters) .......................................................................................3-28
Table 3-23. Input Processing Menu (3000) .........................................................................................3-29
Table 3-24. Output Processing Menu (3050) ......................................................................................3-29
Table 3-25. Low Frequency Compensation Menu (3060) ...................................................................3-30
Table 3-26. Flux Control Menu (3100).................................................................................................3-30
Table 3-27. Speed Loop Menu (3200).................................................................................................3-31
Table 3-28. Current Loop Menu (3250) ...............................................................................................3-31
Table 3-29. Stator Resistance Estimator Menu (3300) .......................................................................3-31
Table 3-30. Braking Menu (3350)........................................................................................................3-32
Table 3-31. Control Loop Test Menu (3460) .......................................................................................3-32
Table 3-32. Speed Profile Menu (4000) ..............................................................................................3-33
Table 3-33. Analog Input Menu (4090)................................................................................................3-35
Table 3-34. Analog Input #1 Menu (4100)...........................................................................................3-35
Table 3-39. Analog Outputs Menu (4660) ...........................................................................................3-38
Table 3-40. Pick list for Analog Variable parameters (all units are %) ................................................3-38
Table 3-41. Speed Setpoint Menu (4240) ...........................................................................................3-39
Table 3-42. Incremental Speed Setup Menu (4970) ...........................................................................3-39
Table 3-43. PID Select Menu (4350) ...................................................................................................3-40
Table 3-44. Comparator Setup Menu (4800).......................................................................................3-40
Table 3-45. Compare 1-32 Setup Menu Parameter Descriptions .......................................................3-41
Table 3-46. Variable Pick List for Comparator Setup Submenus........................................................3-41
Table 3-47. Main Menu (5) Options.....................................................................................................3-42
Table 3-48. Security Edit Functions Menu (5000) ...............................................................................3-43
Table 3-49. Security Edit Menu Function Descriptions (5010, 5020)..................................................3-44
Table 3-50. Default Security Access Levels and Access Codes.........................................................3-44
Table 3-51. Event Log Menu (6180)....................................................................................................3-45
Table 3-52. Alarm/Fault Log Menu (6210)...........................................................................................3-45
Table 3-53. Historic Log Menu (6250) ..................................................................................................3-45
Table 3-54. Pick List Variables for Historic Log (all units are %) ........................................................3-46
xii ASIRobicon Version 1.0 (19000405

Perfect Harmony GENIII/e User’s Manual List of Tables
Table 3-55. Drive Protect Menu (7) Parameters .................................................................................3-47

Table 3-56. Input Protect Menu (7000)................................................................................................3-47
Table 3-57. Single Phasing Menu (7010) ............................................................................................3-48
Table 3-58. Meter (8) General Drive Parameters................................................................................3-49
Table 3-59. Display Parameters Menu (8000) ....................................................................................3-49
Table 3-60. Pick List Variables for the Front Display ..........................................................................3-51
Table 3-61. Hour Meter Setup (8010)..................................................................................................3-52
Table 3-62. Input Harmonics Menu (8140)..........................................................................................3-52
Table 3-63. Communications Menu (9) Parameters ...........................................................................3-53
Table 3-64. Serial Port Setup Menu (9010).........................................................................................3-54
Table 3-65. Serial Functions Menu (9110) ..........................................................................................3-55
Table 3-66. TCP/IP Setup Menu (9300) ..............................................................................................3-55
Table 3-67. Slave Parameter...............................................................................................................3-57
Table 3-68. Parameter Menu - Slave ..................................................................................................3-57
INDEX............................................................................................................................................................. i
notes ...........................................................................................................................................................n-1

List of Tables Perfect Harmony GENIII/e User’s Manual
∇ ∇ ∇
xiv ASIRobicon Version 1.0 (19000405

Perfect Harmony GENIII/e Startup and Advanced Topics SAFETY PRECAUTIONS AND WARNINGS


• Always follow the proper lock-out/tag-out procedures before beginning any maintenance or
troubleshooting work on the drive.
• Never touch anything within the Perfect Harmony cabinets (other than the control cabinet)
until verifying that it is neither thermally hot nor electrically alive.
• Always follow standard safety precautions and local codes during installation of external
wiring. Protective separation must be kept between extra low voltage (ELV) wiring and any
• Never assume that switching off the input disconnect will remove all voltage from internal
components. Voltage is still present on the terminals of the input disconnect. Also, there may
be voltages present that are applied from other external sources.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses.
Also, always work with another person present.
isolating the chassis ground of the instrument). Never defeat the instrument’s grounding.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure
points beneath the shields.
• Always use extreme caution when handling or measuring components that are inside the
enclosure. Be careful to prevent meter leads from shorting together or from touching other
terminals.
• Hazardous voltages may still exist within the Perfect Harmony cabinets even when the
disconnect switch is open (off) and the supply power is shut off.
• Never run the drive with cabinet doors open. The only exception is the control cabinet, which
contains extra low voltages (ELV).
• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A
qualified individual is “one familiar with the construction and operation of the equipment and
the hazards involved.”

SAFETY PRECAUTIONS AND WARNINGS Perfect Harmony GENIII/e Startup and Advanced Topics
Warning!
• Never store flammable material in, on or near the drive enclosure. This includes equipment
drawings and manuals.
• Always ensure the use of an even and flat truck bed to transport the Perfect Harmony drive
system. Before unloading, be sure that the concrete pad is level for storage and permanent
positioning.
• Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the drive
system. Dropping the cabinet or lowering it too quickly could damage the unit.
• Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure that the
fork truck tines fit the lifting tubes properly and are the appropriate length.
• During operation, the nominal weighted sound pressure level may exceed 70 dB at a
distance of 1 meter from the drive.

• Static charge buildup can be removed from a conductive object by touching the object to a
properly grounded piece of metal.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style
plunger or copper braid when desoldering.
• When returning components to ROBICON, always use static-safe packing. This limits any
further component damage due to ESD.
should be strictly adhered to in order to reduce the risk of personal injury or equipment damage.
∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual ABOUT THIS MANUAL
ABOUT THIS MANUAL
functions and picklist menu items. Software setup and startup procedures are also included. Advanced
Reference Tools
ASIRobicon.

ABOUT THIS MANUAL Perfect Harmony GENIII/e User’s Manual

*
Note: icons in the outer margins alert readers of important operational or application
information that may have extra special significance. The associated text is enclosed in a
border for high visibility.
equipment.
TB1A).
(e.g., 6-16).
∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual INTRODUCTION

output.


Source Current
Source Voltage


*
source.

INTRODUCTION Perfect Harmony GENIII/e User’s Manual
100
90
80 Perfect Harmony
Series Drive
70
60
50
40 Phase-controlled
SCR Drive
30
20
10 Percent Speed
20 27 33 40 47 53 60 67 73 80 87 93 100

Typical Phase
Output Current
Time



1

1
1.4. Specifications
Item Description
(System w/o Cells)
(Cells*)

∇∇∇

Perfect Harmony GENIII/e User’s Manual HARDWARE COMPONENTS


HARDWARE COMPONENTS Perfect Harmony GENIII/e User’s Manual
Blowers
Air Intakes
Cooling for
Small Units
Transformer
Section
Customer Control
Wiring and
Control Power
Section
Control Section
and Access to
Cell Cabinet
Split Cooling for

Longer Lineup
Transformer
Section
Control

SHIPPING SPLIT
AIR EXHAUST
DO NOT BLOCK
AIR EXHAUST
DO NOT BLOCK
2
K1 K1
K1 K1
Customer
Control
Wiring and
Control
Section
INPUT/TRANSFORMER
CELL/OUTPUT
CABINET
FRONT VIEW CABINET

Table 2-1.
*

Blower
Item Description
Transformer
F4, F5 Fuses



between Cell and
here
2
L1
L2
L3
T1, T2, T3

*

Blower
Customer
I/O
Section

*

Phase
3 3,300 9 up to 1500 70A, 100A, 140A, 200A, 260A
4 4,160 12 up to 2000 70A, 100A, 140A, 200A, 260A
6 6,600 18 up to 3000 70A, 100A, 140A, 200A, 260A


Phase
2 2 2,300 6 up to 3000 315A, 375A, 500A, 660A

3 3,300 9 up to 4000 315A, 375A, 500A, 660A
4 4,160/4,800 12 up to 6000 315A, 375A, 500A, 660A
5 6,000 15 up to 8000 315A, 375A, 500A, 660A
6 6,600 18 up to 0000 315A, 375A, 500A, 660A


Blower
Control
Cell Section
Section (Back)
2
*
200 33 70 20,000 4,400 100 4,800 70
300 49 70 30,000 4,400 100 4,800 70
400 64 70 40,000 4,400 100 5,600 70
500 80 100 50,000 4,400 100 6,200 100
600 96 100 60,000 4,400 100 6,200 100
700 112 140 70,000 4,400 100 7,500 140
800 128 140 80,000 4,400 100 7,500 140
900 145 200 90,000 8,800 123 7,500 200
1000 162 200 100,000 8,800 123 8,000 200
1250 202 260 125,000 8,800 137 8,500 260
1500 242 260 150,000 8,800 137 9,000 260

300 38 70 30,000 4,400 100 5,100 70
400 51 70 40,000 4,400 100 5,100 70
500 63 70 50,000 4,400 100 5,800 70
600 75 100 60,000 4,400 100 6,600 100 2
700 89 100 70,000 4,400 100 6,600 100
800 101 140 80,000 4,400 100 7,700 140
900 114 140 90,000 4,400 100 7,700 140
1000 126 140 100,000 4,400 100 7,700 140
1250 160 200 125,000 8,800 137 9,500 200
1500 192 200 150,000 8,800 137 9,500 200
1750 224 260 175,000 8,800 137 10,000 260
2000 256 260 200,000 8,800 137 11,000 260
600 48 70 60,000 8,800 137 7,700 70
700 56 70 70,000 8,800 137 9,000 70
800 64 70 80,000 8,800 137 9,000 70
900 72 100 90,000 8,800 137 9,000 100
1000 80 100 100,000 8,800 137 10,400 100
1250 100 100 125,000 8,800 137 10,400 100
1500 120 140 150,000 8,800 137 12,300 140
1750 140 140 175,000 8,800 137 12,300 140
1750 141 200 175,000 13,200 172 12,500 200
2000 162 200 200,000 13,200 192 13,000 200
2250 182 200 225,000 13,200 192 13,000 200
2500 202 260 250,000 13,200 192 13,500 260
2750 222 260 275,000 13,200 192 14,000 260
3000 242 260 300,000 13,200 192 14,000 260
1500 324 375 114,000 8,800 172 7,450 375H
1750 378 375 133,000 8,800 172 8,200 375H
2000 432 500 152,000 8,800 172 8,800 500H
2250 486 500 171,000 8,800 172 9,500 500H
2500 540 660 190,000 8,800 172 10,200 660H
3000 648 660 228,000 8,800 188 11,500 660H
1750 264 315 133,000 15,000 172 9,700 315H
2000 301 315 152,000 15,000 172 11,200 315H
2250 339 375 171,000 15,000 172 11,200 375H

2500 377 375 190,000 15,000 172 12,000 375H
3000 452 500 228,000 15,000 188 13,400 500H
3500 527 660 266,000 15,000 188 14,900 660H
4000 603 660 304,000 15,000 188 16,400 660H
2250 269 315 171,000 18,000 192 13,800 315H
2500 299 315 190,000 18,000 192 14,600 315H
3000 359 375 228,000 18,000 208 16,200 375H
3500 418 500 266,000 18,000 208 17,900 500H
4000 487 500 304,000 18,000 208 19,100 500H
5000 598 660 380,000 18,000 232 22,800 660H
3500 290 315 266,000 25,000 248 20,100 315H
4000 331 375 304,000 25,000 272 21,900 375H
5000 414 500 380,000 25,000 272 25,500 500H
6000 497 500 450,000 25,000 272 29,100 500H
7000 580 660 532,000 25,000 272 32,700 660H
3500 264 315 266,000 28,000 248 21,900 315H
4000 301 315 304,000 28,000 272 23,800 315H
5000 377 375 380,000 28,000 272 27,700 375H
6000 452 500 450,000 28,000 272 31,600 500H
7000 527 660 532,000 28,000 272 35,500 660H
8000 603 660 608,000 28,000 272 39,400 660H
1
2
3
4
5
6
7
8



fiber-optic links.

A1 A2 A3 A4 A5 A6

B1 B2 B3 B4 B5 B6

C1 C2 C3 C4 C5 C6
Future Expansion
A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4
A5 B5 C5 A6 B6 C6


*
See Figure 2-13.


to By-pass board

Power
Supply
connection

Flash Disk

T1 Cell
Special Transformer
with 18 Isolated A1
Secondaries
B1 Keypad
Cell
C1 2
Cell
A2
Cell Fiber
B2 Optic
3-phase AC Board
Cell
C2
Cell
A3
See 2.4.1.
Cell
B3 Microprocessor
Board
Cell
C3
Cell
A4
Cell
B4
Cell Digital WAGO

C4 Modulator I/O
Current Feedback
Cell
A5
Cell
B5
Analog to
Fiber Digital Board
Cell Optic
C5 &
Interface
Cell Board System
A6 Interface
Board
Cell
B6
Cell
C6 Conditioning
Circuits
Voltage
Attenuator
Induction
Motor


maintained.
lagging.


Input fuses for

GENIIIe are not
located in Cell

∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual THE KEYPAD AND DISPLAY INTERFACE
CHAPTER 3: THE KEYPAD AND DISPLAY INTERFACE
3.1. Introduction
The menu system is the software program that allows operators to navigate through hierarchical
structures (menus) which contain related menu items. Menu items include parameters, pick lists,
functions and submenus (“nested” menus). These menu items allow the operator to configure a drive to
his particular needs.
It is important to understand the mechanism through which the menu system operates. This mechanism
is the front panel keypad and display interface. The display interface is a 24-by-2 character back-lit LCD.
The keypad provides numerical keys for entering data and arrow keys for scrolling through the menu
structure of the Perfect Harmony drive. 3
The keypad has built-in keys for fault reset, auto mode, manual start, and manual stop functions. Three
diagnostic LEDs (power on, fault status, alarm status, and run) are built in to the standard keypad.
Normally, the keypad and display interface is mounted permanently to the drive. However, the
keypad/display module need not be mounted for normal operation. It can be plugged in as an external
module for set-up and diagnostic purposes only. Thus, one may use it to provide extra parameter
security.
The Perfect Harmony system provides a fully programmable, multi-level security system that assures
menu access and modification capabilities by only authorized personnel.
3.2. The Keypad
Warning: Do not remove or attach the keypad while the drive is powered.
The Perfect Harmony series contains a user-friendly keypad and display interface. This keypad/display
interface is located on the front of the Perfect Harmony Drive Control Cabinet. The Keypad and Display
Interface is illustrated in Figure 3-1.
The Keypad and Display Interface is used to access the control parameters and functions of the Perfect
Harmony drive. Parameters are organized into logical groups using a menu structure
. To view or edit parameters, the operator must maneuver through the menu structure to the desired
parameters. This is accomplished using special key sequences. A summary of these key sequences is
given later in this chapter.
The [SHIFT] key (which is used in conjunction with the 10 numeric keys and the [ENTER] key) is provided
to access 9 common system menus, a help display function and a [CANCEL] key. The keypad is used to
navigate through the menu system, activate control functions, reset the system after faults have occurred,
edit parameter values, enter security access codes, and place the system in either automatic, manual or
stop (auto/hand/off) mode.

THE KEYPAD AND DISPLAY INTERFACE Perfect Harmony GENIII/e User’s Manual
On (Red) when On (Red) when On (Red)

control power is faulted, blinks (Red) when drive is
supplied when alarm exists running
Status
Indicators
(Red LEDs)
ROBICON Harmony
Version #.## Date
Display (2×24
Characters)
3
Modes of Operation:
• Automatic Keypad
• Manual Start
• Manual Stop
Figure 3-1. The Keypad and Display Interface of the Perfect Harmony Series
*
Note: Parameter values are stored in a Flash Disk - a non-volatile memory area. When a
parameter value is changed, the new value is saved internally. Even after a power failure, the value
remains intact and can be recalled.
The Perfect Harmony keypad contains 20 keys. Each of these keys has at least one function associated
with it. Some keys are used for 2 or more functions. The following sections give descriptions and uses
for each of the keys on the keypad, as well as the diagnostic LEDs and the built-in display.
3.2.1. Fault Reset Key
The [FAULT RESET] key is located in the top left corner of the keypad and is used for two functions.
Function one is to clear fault conditions that may occur in the Perfect Harmony system. Function two is to
acknowledge alarm conditions that may occur in the Perfect Harmony system. Faults refer to fatal errors
that have been detected by both the hardware and software and prevent the drive from running. Alarms
refer to nonfatal errors that have been detected by both the hardware and software and, as such, do not
prevent the drive from running. However, alarm conditions which are ignored may ultimately lead to a
fatal fault. The current alarm/fault status of the drive is displayed by the Fault indicator located above the
keypad and display (refer to Figure 3-1).
When a fault condition occurs, the fault indicator glows red continuously. To reset the system (that is,
acknowledge fault conditions), the operator must:
• Determine the cause of the fault (see the display or check the alarm/fault logger table)
• Correct conditions that may have caused the fault, if appropriate
• Reset the system by pressing the [FAULT RESET] key on the keypad.
When there are no fault conditions and an alarm condition occurs, the fault indicator flashes red. To
acknowledge the alarm conditions, the operator should:

• Determine the cause of the alarm (see the display or check the alarm/fault logger table).
• Correct conditions that may have caused the alarm, if appropriate.
• Acknowledge the alarm by pressing the [FAULT RESET] key on the keypad. Acknowledging an
alarm will cause that alarm to be no longer displayed on the keypad display, however, as long as any
alarm condition exists the fault indicator LED will flash red.
*
Note: An alarm condition will be reset automatically once it no longer exists. If an alarm is not
acknowledged, that alarm’s LCD text message may still appear. However, the red “FAULT” LED
will turn off once the condition that triggered the alarm is resolved.
3.2.2. Automatic Key

The [AUTOMATIC] key is located below the [FAULT RESET] key on the keypad and is used to put the
Perfect Harmony drive into automatic mode. In automatic mode, the standard speed setting for the drive 3
is obtained from the 4-20 mA input and through speed profile parameters located in the Speed Profile
Menu (4000).
*
Note: Automatic mode can be customized to suit particular application needs by modifying the
appropriate I/O parameters from the keypad and display interface. Modification of the standard
system program of the Perfect Harmony is also a viable option, although it requires an
techniques.
3.2.3. Manual Stop Key

The [MANUAL STOP] key is used to place the Perfect Harmony into stop mode. Stop mode shuts down
the drive in a controlled manner, regardless of its current state (manual, remote or automatic).
*
Note: Modification of the standard system program of the Perfect Harmony requires an
techniques.
3.2.4. Manual Start Key

The [MANUAL START] key is located below the [AUTOMATIC] key on the left side of the keypad.
[MANUAL START] is used to put the Perfect Harmony system into manual control mode.
There are two varieties of manual mode: local and remote. These varieties are distinguished by the
sources of the velocity demand. In local manual mode, the desired velocity is selected manually using
the up and down arrow keys ([×] and [Ø]) on the system keypad. In remote manual mode, the desired
velocity is selected manually using a user-supplied potentiometer connected to the system. Remote
manual mode is activated by pressing the momentary digital input assigned to manual start mode. A
simplified flow diagram of manual mode is illustrated in Figure 3-2.

Local manual mode is activated by pressing

Perfect Harmony Keypad the Manual Start key on the keypad and
setting the velocity demand using the up
Velocity and down arrow keys.
MANUAL Demand Set
START Manually from
Arrow Keys
Drive
Momentary Remote Digital Input Output to
(120 VAC Logic) Motor
Perfect
3 Dedicated Harmony
Pot Input Drive
Remote manual mode is activated by
pressing the momentary input and
setting the velocity demand using the
remote potentiometer.
Velocity Demand Set Manually from a
programmable Remote Pot
Figure 3-2. Comparison of the two Manual Control Modes
3.2.5. The 0-9 Key
Numeric keys are centrally located on the keypad of the Perfect Harmony system. These 10 keys
(labeled 0 through 9) provide the following functions:
• entry of security access codes
• speed menu (direct access to 10 basic menus according to assigned menu names [in green text
above each numeric key])
• Direct access to all menus, submenus, parameters and pick lists (with proper security) based on ID
number.
• Ability to change the values of parameters.
One function of the numeric keys of the Perfect Harmony keypad is to enter a 4-digit security access
code. The security code consists of any combination of digits 0 through 9 and hexadecimal digits “A”
through “F”.
*
Note: Hexadecimal (or hex) is a method of representing numbers using base 16 (digits 0-9, A, B,
C, D, E and F) rather than the more common base 10 (digits 0-9). Hex digits “A” through “F” can be
entered from the keypad by pressing the [SHIFT] key followed by the numbers [1] through [6],
respectively. The keystrokes required to enter hex values “A” through “F” are listed in Table 3-1.
Decimal equivalents are also listed.
Another function of the numeric keys is the speed menu feature. Speed menu allows the operator to
access 10 common menus within the system using the pre-programmed numeric keys. Each of the
numeric keys has an associated menu name printed in green (on top of each numeric key). To access
one of these 10 menus, the operator uses the [SHIFT] key followed by the appropriate numeric key (e.g.,
[SHIFT]+[1] to access the Motor menu, [SHIFT]+[2] to access the Drive menu, etc.). Refer to Figure 3.3..

Table 3-1. Hexadecimal Digit Assignments on the Perfect Harmony Keypad
Key Combination Hex Value Decimal Equivalent
MOTOR
A 10
SHIFT
1
SHIFT DRIVE
B 11
2
C 12
SHIFT STAB
3
D 13
3
SHIFT AUTO
4
MAIN
E 14
SHIFT
5
SHIFT LOGS
F 15
6
Number for Entering Speed Menu Name (Use with Shift

Parameter Values, Security MOTOR Key from the Default Meter Display)
Codes or Menu Numbers 1
Figure 3-3. Anatomy of a Numeric Keypad Key
In addition to the speed menu feature, a second menu access feature is available for all remaining menus
in the Perfect Harmony system. The speed menu feature is available only from the main meter display on
the LCD. The hexadecimal entry feature is available only during security code entry. Therefore, the
results of [SHIFT]+[1] through [SHIFT]+[6] key combinations depends on the context in which they are
used. This second access feature cannot only be used on menus, but can also be used to go directly to
a particular parameter, or pick list. While this second method requires more keystrokes to access target
menus, parameters or pick lists, the operator can gain access to all security approved items rather than
just the 10 most common menus. Accessing items in this manner requires that the operator know the
item ID number. This item number will be a four digit number. This number is listed on the display each
time the item is displayed and is also listed in the menu reference charts later in this chapter. To access
an item using its ID number, press the [SHIFT] key followed by the right arrow key [Ö]. The display
prompts the operator for the desired ID number. Using the numeric keys on the keypad, the operator
enters the desired ID number then presses the [ENTER] key. If the number was a valid ID number, and
the current security level permits access to that item, then the desired item will be displayed. Refer to
Figure 3-4.
Note:
• Any menu, parameter, or pick list can be accessed by ID. To do this press [SHIFT]+ [Ö]. The
display will read “Enter Param ID:”. Simply enter the ID number of the item you want to go to
and hit [ENTER].
*
• The menu, parameter and pick list ID can be found in the menu tables later in this chapter or is
listed on the display in () when the item is displayed.
If the operator requests access to a menu number that is assigned a higher security level than the current
security level, the drive will prompt the operator for the appropriate security level code.
Finally, the numeric keys on the keypad can also be used to change the value of system parameters.
Once a parameter is selected for modification, the leftmost digit of the parameter value is underlined and
is called the active digit. The active digit can be changed by pressing a numeric key. This method

automatically advances the underline to the next digit to the right. The operator continues pressing
numeric keys until the desired value is displayed. The [ENTER] key is used to accept the new value.
*
Note: When editing parameter values be sure to pad significant digit fields with zeroes where
appropriate. For example to change the value of a 4-digit parameter from 1234 to 975 the operator
must enter 0975.
First, press the Shift key

SHIFT
Ö then the right arrow key. Finally, press the Enter key.
If the ID was valid and the
“Enter Param ID:” is
MOTOR DRIVE STAB
displayed. 1 2 3
security access level is set
appropriately, the selected item
3 Speed Parameter AUTO MAIN LOGS
name will be displayed (with the
corresponding menu number in
4 5 6
Enter Param ID: parentheses).
DRV PRO METER COMM.

Next, enter the ID number of the 7 8 9 CANCE
L
item to be accessed using the ENTER
numeric keys on the keypad. HELP
0
Figure 3-4. Accessing Items Using ID Numbers
Note: In the case of signed parameters (parameter values that can be either positive or negative),
the first active digit is actually the sign of the value. The sign is changed by using the up [×] and
down [Ø] arrow keys when the leftmost (sign) position of the value is underlined (i.e., it is the active
* “digit”). Either a “+” or a “-” will be displayed during the editing process. After the new value is
accepted (using the [ENTER] key), positive values are displayed without the “+” sign. Negative
values always show the “-” sign unless the negative sign is implied in the parameter name itself.
3.2.6. The Enter/Cancel Key

The [ENTER] key is located below the up and down arrow keys on the right side of the keypad. This key
is similar to the Return or Enter key on a standard PC keyboard. It is used to choose/accept a selection
or confirm an operation. For example, after locating and displaying a parameter within the Perfect
Harmony menu structure, the operator may use the [ENTER] key to edit the parameter’s value. Common
functions of the [ENTER] key include:
• Selecting a submenu
• Enter edit mode for a selected parameter value
• Accept a new parameter value after editing.
By using the [SHIFT] key, the [ENTER] key can be used as a cancel function. The [CANCEL] function is
used to abort the current operation or return to the previous menu display. Common functions of the
[CANCEL] key include:
• Returning out of the menu system
• Rejecting any modifications to a parameter value in edit mode.
3.2.7. Shift Function Keys
The [SHIFT] key is located in the bottom right corner of the keypad on the Perfect Harmony system. This
key is used to access a second set of functions using existing keys on the keypad. Keypad keys that can
be used with the [SHIFT] key have two labels (one on top and one on the bottom of the key). The
standard (un-shifted) function of the key is listed on the bottom half of the key and has a white
background. The shifted function of the key is shown on the top of the key and has a green background
(matching the green background of the [SHIFT] key to identify that they are used together).

When the Perfect Harmony prompts the operator for a numerical value (e.g., during entry of the security
access code, parameter modification, etc.), the [SHIFT] function of numerical keys 1 through 6 changes
from quick menus to hexadecimal numbers “A” through “F” respectively. Refer to Table 3-1 on page 3-5
Note: It is not necessary to simultaneously press the [SHIFT] key and the desired function key.
The operator must press the [SHIFT] key first, release it, and then press the desired function key.
When the [SHIFT] key is pressed, the word “SHIFT” appears in the lower right corner of the
interface display (indicating that the Perfect Harmony is waiting for the second key to be pressed).
*
After a key is pressed, the word SHIFT is removed from the LCD. Refer to Figure 3-5.
SHIFT
3
Figure 3-5. Location of Shift Mode Indicator on the Perfect Harmony Display
Common functions of the [SHIFT] key include:

• Entering “speed menus” ([SHIFT] plus appropriate “speed menu” key from main meter display)
• Using the [CANCEL] function ([SHIFT] + [ENTER] sequence)
• Entering hex values “A” through “F” ([SHIFT] + [1] through [SHIFT] + [6] when editing values or
entering security code)
• Accessing menus, parameters or pick lists based on menu numbers ([SHIFT] + [Ö])
• Returning to the top of the current menu/submenu ([SHIFT] + [×])
• Going to the bottom of the menu or submenu ([SHIFT] + [Ø])
• Resetting the current security level to 0 ([SHIFT] + [Õ] + [SHIFT] + [Õ] + [SHIFT] + [Õ] from the main
meter display).
• Setting a parameter value back to its factory default ([SHIFT] + [Õ]).
A summary of [SHIFT] key key sequences is listed in Table 3-2.

3.2.8. Arrow Keys
There are four yellow arrow keys on the Perfect Harmony keypad. The up and down arrow keys ([×] and
[Ø]) are located in the upper right corner of the keypad. The left and right arrow keys ([Õ] and [Ö]) are
located on the lower row of the keypad. Common uses of the arrow keys include:
• Navigating through the menu structure
• Scrolling through lists of parameters
• Incrementing/decrementing parameter values (when in edit mode)
• Manually advancing to the next digit (when in edit mode)
• Increasing (up arrow [×]) and decreasing (down arrow [Ø]) the desired velocity demand of the drive
(when in local manual mode)
• Clearing security level (press [SHIFT] + [Õ] 3 times from the default meter display)
• Entering menu access mode ([SHIFT] + [Ö]).
The left and right arrow keys ([Õ] and [Ö]) can be used to navigate through the menu structure of the
Perfect Harmony system. In general, the right arrow [Ö] is used to penetrate deeper into the menu
structure and the left arrow [Õ] is used to back out of the menu structure. For example, from the main
display, the operator can press the right arrow key [Ö] to access the Main menu.
The up and down arrow keys ([×] and [Ø]) can be used to scroll through lists of items. For example, after
using the right arrow key [Ö] to reach the Main menu, the operator may select the down arrow key [Ø] to
scroll through the list of options within the Main menu. These options may be parameters, pick lists, or
submenus. Refer to the next section for information about the structure of the menu system.

The up and down arrows ([×] and [Ø]) can be used to increment or decrement the desired velocity
demand when the system is in local manual mode (refer to Section 3.2.4 on page 3-3). As the up and
down arrow keys are pressed, the changes in desired velocity demand can be viewed from the main
display on the LCD. Refer to Figure 3-6.
*
Note: The velocity demand field (DEMD) on the front panel display is assigned by default. This
display assignment (and the other three) can be changed from the menu system.
Table 3-2. Summary of Common [SHIFT] Key Sequences
SHIFT MOTOR
Speed menu to the Motor menu (from the default meter display)
1
Enters hexadecimal “A” (from value edit and security prompts)
3 DRIVE Speed menu to the Drive menu (from the default meter display)
SHIFT
2
Enters hexadecimal “B” (from value edit and security prompts)
SHIFT STAB Speed menu to the Stability menu (from the default meter display)
3
Enters hexadecimal “C” (from value edit and security prompts)
SHIFT AUTO Speed menu to the Auto menu (from the default meter display)
4
Enters hexadecimal “D” (from value edit and security prompts)
SHIFT MAIN Speed menu to the Main menu (from the default meter display)
5
Enters hexadecimal “E” (from value edit and security prompts)
SHIFT LOGS
6
Speed menu to the Logs menu (from the default meter display)
Enters hexadecimal “F” (from value edit and security prompts)
SHIFT DRV PRO

Speed menu to the Drive Protect menu (from the default meter display)
7
SHIFT METER Speed menu to the Meter menu (from the default meter display)
8
SHIFT COMM. Speed menu to the Communications menu (from the default meter display)
9
SHIFT HELP Speed menu to a context sensitive Help menu (from anywhere except the
0
default meter display)
SHIFT CANCEL Cancels/aborts the current action/keystroke or exits menu system
ENTER
Enters “numerical menu access mode”. The operator is then prompted to

SHIFT
Ö enter the 1, 2 or 3 digit number for the associated menu.
Returns to the top of the current menu or submenu.
SHIFT
×
Restores the security level back to 0. The [SHIFT] + [Õ] key sequence must
SHIFT
Õ be entered three times in succession from the default meter display to restore
SHIFT
Õ the security level back to 0.
SHIFT
Õ
Going to the bottom of the menu or submenu.
SHIFT
Ø
When editing a value that has been changed from its factory default, this key
SHIFT
Õ sequence will return the value to its factory default.

Next, use the up and down arrow keys to The velocity demand is displayed
increase and decrease the velocity demand. dynamically on the front LCD
panel of the Perfect Harmony.
First, place the drive in
local Manual mode
MANUAL MODE DEMD FREQ RPM ITOT

START
OFF 50 30 890 40
Figure 3-6. Using the Up and Down Arrow Keys to Control Velocity Demand
Another feature of the arrow keys is that they can be used to edit the values of parameters. To edit a
parameter value, the operator must first navigate through the menu structure (using the arrow keys) and
locate the parameter to be changed. With the parameter displayed on the LCD, the operator must press
3
the [ENTER] key. This places the selected parameter into edit mode. Once in edit mode, an underscore
is displayed beneath the first (i.e., the most significant) position of the parameter value. Changing the
value of that position can be accomplished by pressing the desired numeric key or by using the up and
down arrow keys ([×] and [Ø]) to scroll (and wrap around) through the numbers 0 through 9 for that
position. When the up and down arrow keys are used, the operator must press the right and left arrow
keys ([Õ] and [Ö]) to move to the next (or previous) position in the number to be edited (unlike using the
number keys which automatically shift the underscore to the next digit in the number). The operator must
press the [ENTER] key to accept the new value or press the [SHIFT] + [ENTER] (i.e., [CANCEL]) to abort
the change.
A feature unique to the left arrow key (with the [SHIFT] key) is its ability to cancel the current security
mode and return to level 0. An operator can increase the security access level (by entering the
appropriate security codes), but cannot lower the security access level using the standard “Change
Security Code” option of the Main menu. If an experienced user enters level 7 (or any other security
level) then wishes to return to level 0 when he is finished (for security reasons), he may reset the drive by
toggling power to the drive or using the [SHIFT] + [Õ] sequence three times from the main display (i.e.,
[SHIFT] + [Õ] + [SHIFT] + [Õ] + [SHIFT] + [Õ] ). The latter method is a convenient way to reset the
security level to 0 without interrupting the operation of the drive. When the security level is reset, the
display shows a “Security Level Cleared” message. Refer to Figure 3-7.
MODE DEMD FREQ RPM ITOT

Security Level Cleared.
Figure 3-7. Security Level Cleared Message on the Perfect Harmony Display
Note:
• Security will return automatically to level 0 after 15 minutes of inactivity.
• The [SHIFT] + [Õ] + [SHIFT] + [Õ] + [SHIFT] + [Õ] key sequence is valid only when performed *
from the default meter display.
The right arrow key [Ö] is also used in conjunction with the [SHIFT] key to provide a menu, parameter, or
pick list access feature. The operator can gain access to all security approved menus parameters, or
pick lists. Accessing items in this manner requires that the operator know the ID number associated with
the target item. This ID number can be a one, two, three or four digit number. To access an item using
its ID number, press the [SHIFT] key followed by the right arrow key [Ö]. The display prompts the
operator for the desired ID number. Using the numeric keys on the keypad, the operator enters the
desired ID number then presses the [ENTER] key. If the number was a valid ID number and the current
security level permits access to that item, then the desired item will be displayed. Refer to Figure 3-4 on
page 3-6. Some common arrow key sequences are listed in Table 3-3.

Table 3-3. Summary of Common Arrow Key Sequences

Used individually to navigate through the menu structure. Also used to
Õ orÖ change the active digit of a parameter value (when in edit mode).
Used individually to scroll through lists of menu options, lists and
× or Ø parameters. Used to change velocity demand (from default meter display).
Increments/decrements parameter values (when in edit mode).
Enters “numerical item access mode”. The operator is then prompted to
SHIFT
Ö enter the 1 or 4 digit ID number for the associated item.
3 Jumps to the top menu item of the currently selected menu or submenu.
SHIFT
× Hitting an additional up arrow will take you out of the current menu or
submenu to the previous menu.
Restores the security level back to 0. The [SHIFT]+[Õ] (left arrow) key
SHIFT
Õ sequence must be entered three times in succession from the default
meter display to restore the security level back to 0.
SHIFT
Õ
SHIFT
Õ
SHIFT
Ø Jumps to the bottom menu item of the currently selected menu or
submenu.
When editing a value that has been changed from its factory default, this
SHIFT
Õ key sequence will return the value to its factory default.
3.2.9. Diagnostic Indicators

The standard keypad and display interface also contains 3 diagnostic LED indicators that are located
above the display: Power On, Fault and Run. The Power On indicator is lit when control power is
supplied to the system. The Run indicator is illuminated when the drive is running. The Fault indicator is
lit when one or more system errors have occurred (e.g., boot-up test failure, overvoltage fault, etc.). The
Fault indicator blinks when one or more alarms are active. The [FAULT RESET] key must be pressed to
clear any existing fault conditions and restore the system to normal operation. Refer to Figure 3-1 for the
location of the 3 diagnostic indicators.
3.2.10. The Display
After power up or reset, the ASI Robicon identification and software version number is displayed for 2-3
seconds. Afterwards, the meter display is shown on the LCD by default. The meter display is the starting
point of the menuing system. This display remains on the LCD until keys are pressed.
ASIRobicon Harmony MODE DEMD FREQ RPM ITOT

VERSION #.## DATE HAND 70 70 1260 40
Figure 3-8. The Identification/Version Screen and Meter Displays
The meter display screen contains five fields that are monitored and updated dynamically. These fields
are the MODE (the operational mode), DEMD (the velocity demand), RPM (calculated revolutions per
minute), VLTS (motor voltage) and ITOT (total output current) fields. The value (or state) of each field is

shown dynamically on the second line of the display. Refer to Figure 3-9. The MODE field is fixed. The
last 4 fields on the display contain parameter values that can be defined by the operator.
field names. MODE is MODE DEMD RPM VLTS ITOT
displayed when not in KYPD 80 0 0 0 Bottom row of display
RGEN or RLBK mode. shows dynamic values
The MODE field displays the current operational mode of the Harmony system. This field can have any
one of the displays summarized in Table 3-4 depending on the current operational mode or the current
state of the drive. 3


RLBK for rollback mode. RLBK DEMD RPM VLTS ITOT
Figure 3-10. Dynamic Programmable Meter Display in Rollback Mode


RGEN for regen mode. RGEN DEMD RPM VLTS ITOT
Figure 3-11. Dynamic Programmable Meter Display in Regeneration Mode
The following illustrations depict the 2-line, 24-character display in various modes of access as the
operator attempts to locate and change the Ratio Control and Motor Frequency parameters.
Figure 3-12 depicts the display immediately following power up or system reset. Note that the first three
variable displays (from the right) can be selected from a pick list using the Display Parameters (8000).
SHIFT CANCEL
ENTER
MODE DEMD
Æ FREQ RPM ITOT
HAND 70 70 1260 40
Figure 3-12. Status Display After [SHIFT] [ENTER] ([CANCEL]) Key Sequence
The DEMD display (refer to Figure 3-12) shows the “commanded speed reference” in percent.
Figure 3-13 depicts the display following a [SHIFT]+[2] ([DRIVE]) key combination. From this point the
nine standard menus listed in Table 3-2 can then be selected using the up/down arrow keys ([×] and
[Ø]). Depicts the display after the down arrow key ([Ø]) is pressed twice and prior to the selection of the
Speed Setup Menu (2060). If the [ENTER] or right arrow key ([Ö]) is pressed at this display, the Speed
Setup Menu (2060) will be entered Figure 3-15. Figure 3-16. Figure 3-16 depicts the display following a
down arrow keystroke to the Ratio Control Parameter (2070). The down arrow key ([Ø]) was pressed
once to obtain this display. depicts the display once the Ratio control parameter in the Speed Setup
Menu (2060) is entered for edit. Note the word edit appears in the display when a parameter is in the edit
mode. The left/right arrow keys ([Õ] and [Ö]) can be used to position the cursor under the desired digit

(or sign) to be changed. The digit can be set by either using the number keys, or it may be
incremented/decremented using the up/down arrow keys ([×] and [Ø]). The sign can be changed using
the up/down arrow keys. The parameter is selected into memory once the [ENTER] or right arrow key
([Ö]) is pressed. Figure 3-19 Depicts the display when a number in range is entered.
*
Note: An asterisk (*) is used to denote when a parameter is changed from its current default value.
This allows the user to quickly see which parameters have been changed. To return a parameter to
its factory default value, press [SHIFT] + [Õ] while in edit mode.
SHIFT DRIVE Drive (2)

(Arrow Æ
2
keys select)
3 Figure 3-13. Status Display After [SHIFT]+[2] Key Sequence
Ø Ø Speed setup
(2060)
Æ
(submenu)
Figure 3-14. Status Display After [Ø] [Ø] Key Sequence
SpeedÆsetup (2060)
Ö (Arrow keys select)
Figure 3-15. Status Display After [Ö]
Ratio control
Æ
Ø (2070) 1.0
Figure 3-16. Status Display After [Ø] Key Sequences
Ratio control
CANCEL
ENTER Æ
(edit) ±001.0
Figure 3-17. Status Display After [ENTER] Key to Change a Parameter
Ratio control
*(edit) -03.0
Figure 3-18. Status Display Upon Entering a Value In the Range of the System

In the following example a [SHIFT] [Ö] to get to the Parameter ID display. The parameter ID for Motor
Frequency (1020) is entered. See Figure 3-19. The [ENTER] key is then pressed once to show the Motor
Frequency display and then [ENTER] is pressed again to edit its value. See Figure 3-21 depicts the
display if 010 is attempted to be entered for the Motor Frequency. Since the range of the variable is 15 to
330, an error message will be displayed.
Speed Parameter
SHIFT
Ö Æ Enter Param ID:1020
Figure 3-19. Status Display After [SHIFT] [Ö] and the Parameter ID 1020 is entered
3
Motor Frequency
Æ
CANCEL CANCEL
ENTER ENTER
(edit) 010
Figure 3-20. Status Display After [ENTER] [ENTER]
Motor Frequency
OUT OF RANGE
Figure 3-21. Status Display Upon Entering a Value Beyond the Range of the System
Table 3-4. Summary of Operation Mode Displays: Line 1 of Mode Display

FRST Fault reset Displayed after the [FAULT RESET] button is pressed.
Note: This may not be visible because of the speed of
response to a Fault Reset.
TLIM Menu setting rollback Drive is being limited by a menu setting. Refer to torque
limits settings in Table 3-8.
SPHS Single phasing rollback A Single phasing condition of the input line is limiting drive
torque.
UVLT Under voltage rollback A Under Voltage condition of the input line is limiting the
drive torque.
T OL Thermal overload rollback The drive has limited the amount of torque produced to
prevent thermal overload of the input transformer.
F WK Field weakening rollback This condition exists when the motor flux is low and the
application requires high torque. This prevents “motor pull-
out”, an unstable operating condition of the motor.
C OL Cell overload rollback A Cell current overload model has calculated a thermal
overload condition of the drive cells and the drive has
limited the amount of torque produced.
RGEN Regeneration During normal deceleration, this message will be displayed
because the drive is preventing the motor from
regenerating power back into the drive.
BRKG Dual Frequency Braking Appears while drive is decelerating with dual frequency
braking enabled.
RLBK Roll back Appears during acceleration if drive has reached its torque


limit setting.
BYPS Cell Bypassed Indicates that one or more cells is in bypass
OLTM Open Loop Test Mode Appears if drive control algorithm is set to Open Loop Test
Mode
ALIM Analog Torque Limit Torque limited by analog input
MODE Normal mode display This is the typical display message during normal
operation.
3 Table 3-5. Summary of Operation Mode Displays: Line 2 of Mode Display

NOMV No medium voltage No input line voltage detected.
INH CR3 inhibit The CR3 or “Drive inhibit” input is asserted.
OFF Idle state The drive is ready to run but is in an idle state.
MAGN Magnetizing motor state The drive is magnetizing the motor.
The drive is trying to detect the speed of the motor in order
SPIN Spinning load state
to synchronize the drive frequency.
The drive is in the “Up Transfer State” preparing to transfer
UXFR Up transfer state
the motor to the input line.
The drive is in the “Down Transfer State” preparing to
DXFR Down transfer state
transfer the motor from the input line to the drive.
KYPD Keypad speed demand The drive speed demand source is the keypad.
TEST Speed/Torque test The drive is in a Speed or Torque test mode.
The drive 4-20mA analog input signal has dropped below
a predefined setting. See
LOS Loss of Signal
Table 3-34, Table 3-35, Table 3-37, and
Table 3-38.
The SOP flag AutoDisplayMode_O is set true usually to
indicate drive is receiving its speed demand from a source
AUTO Automatic mode
other than the keypad or network. Typically used with a
analog input speed source.
DECL Decelerating (no braking) The drive is decelerating normally.
BRAK Dynamic Braking Indicates that dynamic braking is enabled
The drive is not controlling the motor and it is coasting to a
COAS Coasting to stop
stop due only to friction.
The drive is in a “Auto Tuning” mode used to determine
TUNE Auto Tuning
motor characteristics.
HAND Hand mode Appears if the drive is running under normal conditions
3.3. Menu Descriptions

The following sections contain a condensed description of all parameter items available in the Perfect
Harmony menu structure.
Table 3-6 depicts main menus and submenus of the system. Each menu and submenu is associated
with an ID shown in the ID column. The key sequence [SHIFT]+[Ö] ([SHIFT] plus the right arrow key)

and up/down arrow keys ([×] and [Ø]) as described above can be used to directly access each menu
item.
Note:
• A help feature for all parameter settings is available by pressing the [SHIFT] + [0]
([HELP]) key sequence on the keypad. This feature provides a text description of the
desired selection, plus the parameters minimum and maximum value if applicable. If
more that 2 lines of help text are available, the operator may use the up and down arrow
keys ([×] and [Ø]) to scroll through the entire help message.
• Parameters are always hidden in the menu display when there is insufficient security to
edit the parameter.
• Menu items may be hidden if they do not apply to the current drive configuration.
Example if Spinning load mode (ID 2430) is set to off IDS 2440 through 2480 (spinning
load parameters) are not displayed.
* 3
• Table 3-6 lists menus and submenu name only. Parameters and functions found in
these menus are described in the sections that follow. Use the associated table and
page number from Table 3-6 to quickly locate the section of the chapter that explains all
of the associated items.
• Note that menu items change with new releases of software. Hence the menu system
described here may be slightly different than the menu system on your drive. Your drive
has help functions for every parameter and these can be used if the function is not
described here.
Table 3-6. Perfect Harmony Menu and Submenu Summary

Motor 1 Motor Parameter 1000 Table 3-7 17 Used to enter motor-
Menu specific data
Limits 1120 Table 3-8 18
Autotune 1250 Table 3-10 20
Encoder 1280 Table 3-11 21
Drive 2 Drive Parameter 2000 Table 3-12 21 Used to configure the
Menu VFD for various load
Speed Setup 2060 Table 3-13 22 conditions and drive
Speed Ramp Setup 2260 Table 3-14 23 applications.
Critical Frequency 2340 Table 3-15 23

Spinning Load 2420 Table 3-16 23
Conditional Time 2490 Table 3-17 25
Setup
Cells 2520 Table 3-18 26
Sync Transfer 2700 Table 3-19 27
External I/O 2800 Table 3-20 27
Output Connection 2900 Table 3-21 28


Stability 3 Input Processing 3000 Table 3-23 29 Used to adjust the
Menu VFD’s various control
Output Processing 3050 Table 3-24 29 loop gains, including
Control Loop Test 3460 Table 3-31 32 current and speed
regulator gains.
Auto 4 Speed Profile 4000 Table 3-32 33 Used to configure
Menu various speed
Analog Inputs 4090 Table 3-33 35 setpoint, profile, and
Analog Outputs 4660 Table 3-39 38 critical speed
avoidance and
Speed Setpoints 4240 Table 3-41 39 comparator
3 Incremental Speed 4970 Table 3-42 39
parameters.
Setup
PID Select 4350 Table 3-43 40 PID Select Menu
contains PID setup
parameters
Comparator Setup 4800 Table 3-44 40 Used to configure the
analog comparators
controlled through
the SOP.
Main Menu 5 Motor 1 see above
Drive 2 see above
Stability 3 Table 3-22 28
Auto 4 see above
Logs 6 see below
Drive Protect 7 Table 3-55 47
Meter 8 Table 3-58 49
Communications 9 Table 3-63 53
Security Edit 5000 Table 3-48 43 Configures security
Functions features.
Logs Menu 6 Event Log 6180 Table 3-51 45 Used to configure
and inspect the
Alarm/Fault Log 6210 Table 3-52 45 event, alarm/fault,
Historic Log 6250 Table 3-53 45 and historic logs of
the VFD.
Drive 7 Input Protection 7000 Table 3-56 47 Adjusts setpoint
Protect limits for critical VFD
Menu variables.
Meter 8 Display Parameters 8000 Table 3-59 49 Set up Variables for
Menu display to LCD
Hour Meter Setup 8010 Table 3-61 52
Input Harmonics 8140 Table 3-62 52
Fault display override 8200 Table 3-57 50
Commun- 9 Serial Port Setup 9010 Table 3-64 54 Used for configuring
ications the various


ications Network Control 9943 Please refer to the various
Menu Communications Communications
Network 1 Configure 9900 manual (number features of the VFD.
Network 2 Configure 9914 902399)
Display Network 9950 Table 3-62 55

Monitor
Serial echo back test 9180 Please refer to
Communication
s manual
(number 902399)
Sop & serial 9110 Table 3-65 55 3
functions
TCP/IP Setup 9300 Table 3-66 55
3.3.1. Motor Menu (1) Options

The Motor Menu (1) consists of the following menu options:
• Motor Parameter Menu (1000)
• Sync Motor Menu (1100)
• Limit Protection Menu (1120)
• Autotune Menu (1250)
• Encoder Menu (1280)
The contents of these menus are explained in tables that follow.
Table 3-7. Motor Parameter Menu (1000)
Motor frequency 1020 Hz 60 15 330 Enter the rated or base frequency

of the motor from the nameplate.
Full load speed 1030 RPM 1780 1 19800 Enter the full load speed of the
Motor voltage 1040 V 4160 380 13800 Enter the rated voltage for the
Full load current 1050 A 125.0 12.0 1500.0 Enter the rated nameplate full load
current of the motor.
No load current 1060 % 25.0 0.0 1000.0 Enter the no load current of the
motor, if it is provided, or use the
Autotune function.
Motor kW rating 1010 kW 746.0 120.0 20000.0 Enter the motor kW (0.746Hp) from
the nameplate.
Leakage 1070 % 16.0 0.0 30.0 Enter the leakage inductance of the
inductance motor if it is provided, or use the
Autotune function.

Stator resistance 1080 % 0.10 0.00 25.00 Enter the stator resistance of the
motor if it is provided. To convert
from ohms to % use the formula:
[%Rs = 100 * √3 * Rs(in ohms) *
Motor Current/Motor Voltage], or
use the Autotune function.
Inertia 1090 Kgm2 30.0 0.0 100000.0 Enter the rotor inertia of the motor if
known (1Kgm2 = 23.24 lbft2), or use
the Autotune function.
3
Table 3-8. Limits Menu (1120)

Overload select 1130 Constant Selects the type of motor thermal
overload protection from:
• Constant (fixed current based): Use

when only current limit based alarm
is required.
• Straight Inverse Time (motor model

used to estimate temperature):
Motor model assumes the allowable
motor load to be 100% for the entire
speed range.
• Inverse Time with thresholds
(motor model used to estimate
temperature): Motor model uses
allowable load data from the
speed derate curve.
Overload pending 1139 % 100.0 10.0 210.0 Sets the overload level (in % of
rated) at which an alarm is
generated. The pending level
corresponds to a current level with
Constant method and to a motor
temperature level with the other two
TOL methods.
Overload 1140 % 120.0 20.0 210.0 Sets the overload level (in % of
rated) at which a fault is generated.
The overload level corresponds to a
current level with Constant method
and to a motor temperature level with
the other two TOL methods.
Overload timeout 1150 sec 60.0 0.0 300.0 When output of the TOL model
exceeds the overload level for the
timeout period, a fault is generated.


Speed Derate 1151 Submenu This menu sets allowable motor load
Curve as a function of speed. See
Table 3-9.
Motor trip volts 1160 V 4800 5 9999 Sets the motor over-voltage trip
point.
Maximum Load 1159 Kgm2 0.0 0.0 500000.0 Sets the maximum load inertia that
Inertia the motor can line start without
exceeding maximum temperature.
Set this parameter only if the motor
does not conform to NEMA MG-1,
Part 20, Table 20-1. 3
Overspeed 1170 % 120.0 0.0 250.0 Sets the motor overspeed trip level
as a percentage of rated speed.
Underload enable 1180 Disable Enables or disables underload
protection.
I underload 1182 % 1.0 1.0 80.0 Sets the current underload level
based on the rated motor current.
Underload timeout 1186 sec 10.0 0.0 300.0 Sets the time for underload trip.
1 function of the rated motor current.
current.
current.
Phase Imbalance 1244 % 40.0 0.0 100.0 Sets the current threshold level for
Limit the output phase current imbalance
Ground Fault Limit 1245 % 5.0 0.0 100.0 alarmthe threshold of voltage for the
Sets
output ground fault alarm.
Ground Fault Time 1246 sec 0.017 0.001 2.000 Sets the filter time constant for
Const averaging the ground voltage and
delaying the response of the ground
fault detection.

Table 3-9. Speed Derate Curve Menu (1151)

0% speed.
10% speed.
17% speed.
25% speed.
3
50% speed.
100% speed.
Table 3-10. Autotune Menu (1250)

Autotune stage 1 1260 Function This function determines the stator resistance and
leakage inductance of the motor. The motor does not
rotate during this stage. If this function is not used the
menu entered values are used.
Autotune stage 2 1270 Function This function determines the no-load current & rotor
inertia of the motor. The motor rotates during this stage.
If this function is not used the menu entered values are
used.
Auto Tuning provides motor information that optimizes the Output Processing Control. Both stages of
Auto Tuning are optional. The user can enter the motor information if available (see Table 3-10). The
process is performed in two stages.

Table 3-11. Encoder Menu (1280) (Closed Loop Vector Control Only)

Encoder 1 PPR 1290 720 1 4000 Enter the number of pulses per
revolution delivered by the encoder.
Encoder filter gain 1300 0.0 0.0 0.999 Sets the gain of the filter for encoder
feedback. This parameter can have
a value between 0.0 (no filtering)
and 0.999 (maximum filtering).
Encoder loss 1310 % 0.0 0.0 75.0 Sets the level for the error between
threshold encoder output and calculated motor
speed to determine encoder loss. 3
Encoder loss 1320 Open Sets the drive response to a loss of
response Loop encoder.
• Stop (on Fault)
• Open Loop
3.3.2 Drive Menu (2) Options

The Drive Menu (2) consists of the following submenus:
• (2000) Drive Parameter Menu • (2420) Spinning Load Menu
• (2060) Speed Setup Menu • (2490) Conditional Timer Menu
• (2210) Torque Reference Menu • (2520) Cell Menu
• (2260) Speed Ramp Setup Menu • (2700) Sync Transfer Menu
• (2340) Critical Frequency Menu • (2800) External I/O Menu
Contents of these menus are explained in the tables that follow.
Table 3-12. Drive Parameter Menu (2000)

Rated input voltage 2010 V 4160 200 23000 Rated RMS input voltage of the drive.
Rated input current 2020 A 100.0 12.0 1500.0 Rated RMS input current of the drive.
Rated output voltage 2030 V 4160 200 23000 Rated drive output voltage RMS
Rated output current 2040 A 100.0 12.0 1500.0 Rated drive output current RMS
Control loop type 2050 OLTM Control loop algorithm type
selection.
• Volts per Hertz (V/Hz) for
parallel motors
• Open Loop Vector Control
(OLVC) for single induction
motors
• Closed Loop Vector Control


(CLVC) for single induction
motors with speed sensor(s)
• Open Loop Test Mode
(OLTM) for determining
modulation with Hall-effect
transducer testing
• Synchronous Motor Control
(SMC) without speed sensor
• Closed Loop Synchronous
Motor Control (CSMC) with
3 speed sensor
Table 3-13. Speed Setup Menu (2060)

Ratio control 2070 1.0 -125.0 125.0 Used to adjust the scaling of the
speed reference value.
1 1.
1.
2 2.
2.
3 3.
3.
1.
1.
2.
2.
3.
3.
Zero speed 2200 % 0.0 0.0 100.0 The zero speed threshold value.

Table 3-14. Speed Ramp Setup Menu (2260)

Jerk rate 2330 0.1 0.0 3200.0 Jerk rate in time to reach an acceleration rate
that will achieve rated velocity in 1 sec. 3
Table 3-15. Critical Frequency Menu (2340)

Skip center freq 1 2350 Hz 15.0 0.0 360.0 Enter the center of the first critical
Skip center freq 2 2360 Hz 30.0 0.0 360.0 Enter the center of the second critical
Skip center freq 3 2370 Hz 45.0 0.0 360.0 Enter the center of the third critical
Skip bandwidth 1 2380 Hz 0.0 0.0 6.0 Enter the bandwidth of the first critical
Skip bandwidth 2 2390 Hz 0.0 0.0 6.0 Enter the bandwidth of the second critical
Skip bandwidth 3 2400 Hz 0.0 0.0 6.0 Enter the bandwidth of the third critical
Freq avoid accel 2410 sec 5.0 0.0 180.0 The accelerate used to pass through
time critical speed bands.

The critical frequency feature (sometimes called resonance avoidance) is accomplished using skip
frequencies and skip bands as defined in . This is illustrated in Figure 3-22.
Drive Speed (RPM)
RPM = 120 x Freq / # of Poles

Max
Freq = RPM x (# of Poles) / 120
Skip Freq 3
Skip Band 3
Skip Freq 2
Skip Band 2
3
Skip Freq 1
Skip Band 1
Controller
Min
Output
0% 100% (% Demand)
Figure 3-22. Critical Speed (Resonance Avoidance) Parameters


Spinning 2430 Off Enable/Disable Spinning Load and set
load mode the direction of frequency scans:
• Off
• Forward
• Reverse
• Both
Enable Spinning Load if the drive is
required to detect the speed of an
already spinning motor. Spinning Load
should be Enabled for Fast Bypass or 3
Synchronous Motor, and should be
disabled for OLTM.
Scan end 2440 % 20.0 1.0 50.0 Point where scan ends if motor flux is
threshold above this level (as a percentage of
motor rated flux).
Current 2450 % 15.0 1.0 50.0 Sets the drive current level (as a
Level percentage of motor rated current)
Setpoint used during scanning.
Current ramp 2460 sec 0.01 0.00 5.00 Time to ramp drive current to Current
Level Setpoint.
Max current 2470 % 50.0 1.0 50.0 Sets the current trip level (as a
percentage of motor rated current) for
scanning. Use the default value of
50%.
Frequency 2480 sec 3.00 0.00 5.00 Sets the time taken to scan from rated
scan rate speed to zero. The default value of
3.00sec should be satisfactory for
most cases.
Table 3-17. Conditional Timer Setup Menu (2490)

Cond stop 2500 sec 0.8 0.0 999.9 Dwell time after stop is invoked. User
Cond run 2510 sec 0.8 0.0 999.9 Dwell time after start is invoked. User

Table 3-18. Cell Menu (2520)

Installed cells/phase 2530 6 1 8 Installed cells per phase in the drive.
Min cells/phase count 2540 1 1 8 Minimum cells per phase count
(n/3)
Cell voltage 2550 Vrms 630 Rated cell voltage:
• 460V
• 630V
• 690V
Thermistor warn level 2560 % 70.0 5.0 70.0 Sets the level at which a temperature
3 alarm is generated.
Contactor settling time 2570 msec 200.0 0.0 1000.0 Time taken by bypass contactors to
change state. Use 100ms for small
contactors and 250ms for larger ones.
Max back EMF decay 2580 sec 7.0 0.0 10.0 Sets the maximum time that the
time control waits for the motor voltage to
decay while attempting a fast bypass.
Once cell fault(s) occurs, the drive
may not be able to support actual
motor voltage. If the motor voltage
does not decay below the max drive
voltage (with the faulted cell(s)) within
the time set by this parameter, the
drive issues a fault.
Bypass Type 2590 Mech Designates the type of bypass in the
drive:
• Mechanical
• None
Fast bypass 2600 Enable This parameter enables or disables
fast cell bypass. Disabling fast
bypass with mechanical contactors
will still provide manual bypass.
Display Cell Status 2610 Function Displays cell status:
A = active,
B = bypassed,
F = faulted.
Display Bypass Status 2620 Function Displays bypass status:
A = available,
B = active,
U = unavailable.
Reset Bypassed Cells 2640 Function Allows bypassed cells to be reset
when the drive is in an idle state.
Use the reset function only after
verifying that the problems with the
faulted cell(s) have been resolved.
Neutral Connection 2630 T2 Select from terminal T1 or T2,
depending on the terminal of cells A1,
B1 d C1 th t i d t f th


B1 and C1 that is used to form the
drive star-point.
Table 3-19. Sync Transfer Menu (2700)

Phase I gain 2710 2.0 0.0 15.0 Integral gain of the phase loop used
during Up Transfer.
Phase P gain 2720 4.0 1.0 12.0 Proportional gain of the phase loop
used during Up Transfer. 3
Phase offset 2730 deg 0.0 -90.0 90.0 Phase offset provided at the input of the
phase loop to adjust phase errors due
to sampling. The typical value is 2
degrees.
Phase error 2740 deg 1.5 0.0 5.0 Phase error level that is used to
threshold determine if phase lock has been
achieved during Up Transfer.
Frequency 2750 % 0.0 -10.0 10.0 Frequency offset provided at the input
Offset of the speed loop to force the drive to
torque limit during Down Transfer.
Up Transfer 2760 sec 0.0 0.0 600.0 If the time taken for Up Transfer
Timeout exceeds this value then an Up
Transfer Timeout Fault is generated.
Down 2770 Sec 0.0 0.0 600.0 If the time taken for Down Transfer
Transfer exceeds this value then a Down
Timeout Transfer Timeout Fault is generated.




Wago 2850 sec 0 0 600 Sets the Wago watchdog timeout

timeout period.


Secondary primary turns = 5) of the CTs used to
Turns measure filter capacitor currents.
Filter 2920 % 0.0 0.0 20.0 Sets the output filter inductor
Inductance (impedance) value as a ratio of the
base output impedance of the drive
(typically 5%).
Filter 2930 % 0.0 0.0 20.0 Sets the output filter capacitor
3 Capacitance (admittance) value as a ratio of the
base output admittance of the drive
(typically 10%).
Cable 2940 % 0.0 0.0 50.0 Output cable resistance value as a ratio
Resistance of the base output impedance of the
drive.
Filter 2950 0.50 -5.00 5.00 Controls the gain for damping
damping gain oscillations due to output filter. Use a
positive constant (typically 0.5) with
short cable lengths (< 30,000 feet) and
a negative constant (typically -0.5) for
long cable lengths.
3.3.3. Stability Menu (3) Options

The Stability Menu (3) consists of the following menu options:
• Input Processing Menu (3000)
• Output Processing Menu (3050)
• Control Loop Test Menu (3460)
The Stability Menu also contains some parameters. These menus and parameters are explained in tables
that follow.
Table 3-22. Stability Menu (3) (Parameters)

Input 3000 Submenu Contains all of the sub menus related
Processing to drive line side processing.
Menu See Table 3-23
Output 3050 Submenu Contains all of the sub menus related
Processing to drive motor side processing.
Menu
See Table 3-24
Control Loop 3460 Submenu Contains all of the sub menus related
Test Menu to speed and torque loop testing.
See Table 3-31
Slip constant 3545 4.3 0.0 10.0 Gain for slip compensation. This


software and cannot be changed.
Dead time 3550 µsec 16.0 0.0 50.0 Sets the dead time (or firing delay
comp time) of the IGBTs for software
compensation.
Feed forward 3560 0.0 0.0 1.0 Sets the gain for voltage feed forward.
constant This is used to improve the torque
current regulator response.
Carrier 3580 Hz 601.3 100.0 1500.0 IGBT switching frequency. The control
frequency adjusts the entered value according to
available resolution. 3
Table 3-23. Input Processing Menu (3000)

PLL prop 3010 70.0 0.0 200.0 Proportional gain of input phase
gain locked loop (PLL).
PLL integral 3020 3840.0 0.0 12000.0 Integral gain of input PLL.
gain
Input 3030 1.0 0.0 2.0 Sets the scaling for input current
current feedback.
scaler
CT Turns 3035 200 50 2000 Secondary side turns for input
current CT (with primary turns equal
to 5).
Input 3040 1.8 0.0 2.0 Sets the scaling for input line voltage
voltage feedback.
scaler
*
Note: Many of the parameters in the Output Processing section are automatically set up during
autotuning. They are presented here so the user can do additional fine-tuning of the drive.
Additional fine-tuning is not generally required but may be needed in special circumstances.
Table 3-24. Output Processing Menu (3050)

Low freq 3060 Submenu Menu contains parameters that
comp effect motor flux calculation. See
Table 3-25.
Flux control 3100 Submenu This menu contains the flux control
Speed loop 3200 Submenu This menu contains the speed loop
Current loop 3250 Submenu This menu contains the current
loop parameters. See Table 3-28.


Stator resis 3300 Submenu This menu contains the stator
est resistance estimator parameters.
See Table 3-29.
Braking 3350 Submenu This menu contains the dual
frequency braking parameters.
See Table 3-30.
PLL prop 3420 188.0 1.0 500.0 Proportional gain of output phase-
gain locked loop.
PLL integral 3430 3683.81 0.0 12000.0 Integral gain of output phase-locked
gain loop. This value is updated only by
the control.
3
Output 3440 1.0 0.0 2.0 Scaling for output current
current feedbacks.
scaler
Output 3450 1.0 0.0 2.0 Scaling for output voltage
voltage feedbacks.
scaler
Table 3-25. Low Frequency Compensation Menu (3060)

Low Freq Wo 3070 Rad 12.6 0.0 20.0 Pole of hardware RC integrator
Low freq com gain 3080 1.0 1.0 50.0 Low Frequency compensation gain for
scaling estimated flux.
S/W compensator 3090 2.0 0.5 12.6 Pole of software integrator used for
pole flux estimation.
Table 3-26. Flux Control Menu (3100)

Flux reg 3110 1.7 0.0 5.0 Flux PI regulator proportional gain
prop gain term
Flux reg 3120 1.0 0.0 1200.0 Flux PI regulator integral gain term
integral gain
Flux Filter 3130 sec 0.0667 0.0 10.0 Time constant of the low pass filter
Time Const used on the flux error.
Flux demand 3150 per unit 1.0 0.0 10.0 Sets the flux demand (or desired
Volts-per-Hertz ratio) in per unit.
Flux ramp 3160 sec 0.5 0.0 5.0 Sets the ramp time to go from zero to
rate rated flux. This time establishes the
time to magnetize the motor.
Energy 3170 100.0 10.0 125.0 This parameter sets the lowest value
saver min of flux (as a percentage of Rated
flux Motor Flux) that the drive will apply to
an unloaded motor. Energy Saver is
enabled if a value that is less than the


Flux Demand is entered. The control
establishes the amount of flux (or
motor voltage) that minimizes the
losses in the motor.
Ids DC 3190 % 10.0 1.0 25.0 DC current level used when stator
resistance estimator is enabled.
Table 3-27. Speed Loop Menu (3200)

Speed reg prop 3210 0.02 0.0 1.0 Speed PI regulator proportional gain 3
Speed reg integral 3220 0.046 0.0 1200.0 Speed PI regulator integral gain
Speed reg Kf gain 3230 0.6 0.1 1.0 Allows a smooth variation of the
speed regulator from a simple PI (Kf
=1.0) to a double speed loop
(Kf=0.5).
Speed filter time 3240 0.0488 0.0 10.0 Time constant of the low pass filter
const used on the speed error.
Automatically calculated after Auto
Tuning stage 2.
Table 3-28. Current Loop Menu (3250)

Current reg prop gain 3260 0.5 0.0 5.0 Current PI regulator proportional
gain term.*
Current reg integ gain 3270 25.0 0.0 6000.0 Current PI regulator integral gain
term.*
Prop gain during brake 3280 0.16 0.0 5.0 Current PI regulator proportional
during dual frequency braking.*
Integ gain during brake 3290 9.6 0.0 6000.0 Current PI regulator integral gain
term during dual frequency
braking.*
* All values in this table are automatically updated after AutoTuning stage 1.
Table 3-29. Stator Resistance Estimator Menu (3300)

Stator resistance 3310 Off This parameter enables or disables
est the stator resistance estimator
function.


• Off
• On
Stator resis filter 3320 0.0 0.0 1.0 Stator resistance estimator filter gain
gain
Stator resis integ 3330 0.002 0.0 1.0 Stator resistance estimator integral
gain gain
Table 3-30. Braking Menu (3350)
3 Parameter ID Units Default Min Max Description

Enable 3360 Off Enable or disable dual frequency
braking braking (DFB). User must be aware of
torque pulsations and motor heating
produced with this method.
Pulsation 3370 Hz 277.5 100.0 5000.0 Torque pulsation frequency when
frequency dual-frequency braking is enabled.
Adjust for a different torque pulsation
frequency. The control always
limited resolution.
Brake power 3390 % 0.3 0.0 50.0 Amount of high frequency losses at
loss the onset of braking.
VD Loss Max 3400 0.25 0.0 0.5 Max amplitude of the loss inducing
voltage. Use this to adjust the braking
torque.
Braking 3410 1.05 0.0 10.0 Ratio of high frequency losses to
constant power absorbed from load. This
parameter should always be set to a
value greater than 1.0.
The need for braking capacity is addressed through a feature known as dual frequency braking. This
feature essentially creates a braking function by means of injecting a counter-rotating flux vector at well
beyond the slip of the machine. This generates additional losses in the motor. The injection frequency is
adjustable via a menu setting to allow critical frequencies (i.e. mechanical resonances) to be avoided.
Table 3-31. Control Loop Test Menu (3460)

Test type 3470 Speed This pick list selects the type of loop
test desired (speed or torque).
• Speed
• Torque
Test positive 3480 % 30.0 -200.0 200.0 Positive going limit of the test
waveform.
Test negative 3490 % -30.0 -200.0 200.0 Negative going limit of the test
waveform


waveform.
Test time 3500 sec 30.1 0.0 500.0 Sets the time for the drive to spend in
either the positive or negative test
setting.
Begin test 3510 Function This Function starts the speed or
torque loop test.
Stop test 3520 Function This function stops the speed or
torque loop test.
3
3.3.4. Auto Menu (4) Options
The Auto Menu (4) consists of the following menu options:
• Analog Input Menu (4090)
• Analog Outputs Menu (4660)
• Speed Setpoint Menu (4240)
• PID Select Menu (4350)
• Comparator Setup Menu (4800)
These menus are explained in the tables that follow.
Table 3-32. Speed Profile Menu (4000)

Entry point 4010 % 0.0 0.0 150.0 Sets the % of speed cmd at which the
drive begins following the speed cmd.
Exit point 4020 % 150.0 0.0 150.0 Sets the % of speed cmd at which the
drive stops following the speed cmd.
Entry speed 4030 % 0.0 0.0 150.0 Sets the speed that the drive
accelerates to when given a start
command when the speed profile
function is enabled.
Exit speed 4040 % 150.0 0.0 150.0 Sets the speed that the drive reaches
at the exit point.
Auto off 4050 % 0.0 0.0 100.0 Sets the level of cmd at which the
drive turns off.
Delay off 4060 sec 0.5 0.5 100.0 Sets a time delay between the time
the cmd reaches the Auto Off point
and the time the drive shuts off.
Auto on 4070 % 0.0 0.0 100.0 Sets the level of cmd at which the
drive turns on.


Delay on 4080 sec 0.5 0.5 100.0 Sets a time delay between the time
the cmd reaches the Auto On point
and the time the drive starts.

Figure 3-23 illustrates the advantages of using speed profiling control. This method of
control provides an increased “usable control range” for the motor. Ultimately, the speed
of the motor can be adjusted in much finer increments when speed profiling is used.
Speed No Action Until Speed Speed
Reaches 75% of Rated Motor Using Speed
100% Exit Speed 100%
75% Entry 75%
“Usable” Control “Usable” Control
0% Input Input
0%
4 mA 20 mA
Signal
4 mA 8 mA 20 mA
Signal 3
No Speed Profiling Entry Exit
Point Point
Figure 3-23. Advantages of Using Speed Profiling Control
Table 3-33. Analog Input Menu (4090)

Analog input #1 4100 Submenu Menu for Analog input #1. See
Table 3-34.
Analog input #2 4170 Submenu Menu for Analog input #2. See Table 3-35.
Auxiliary input #1 4500 Submenu Menu for Auxiliary input #1. See Table 3-37.
Auxiliary input #2 4580 Submenu Menu for Auxiliary input #2. See
Table 3-38.

• Off
• Ext 1-24
• 0 - 20mA
• 4 - 20mA
• 0 - 10V
is activated.


• Preset
• Maintain
• Stop

3 Source 4175 Off This parameter sets the input source
• Off
• Ext 1-3
• 0 – 20mA
• 4 – 20mA
• 0 – 10V
signal action
• Preset
• Maintain
• Stop
signal
setpoint

• Off
• Ext 1-24
• 0 - 20mA
• 4 - 20mA
0 - 10V


signal action
• Preset
• Maintain
Stop 3
signal
setpoint

• Off
• Ext 1-3
mode for auxiliary input 1.
• 0 - 20mA
• 4 - 20mA
• 0 - 10V
Max input 4540 % 100.0 0.0 200.0 Maximum auxiliary input.
signal action
• Preset
• Maintain
• Stop
signal
setpoint


• Off
• Ext 1-3

3 Max input 4620 % 100.0 0.0 200.0 Maximum auxiliary input.

is activated.
• Preset
• Maintain
• Stop
Table 3-39. Analog Outputs Menu (4660)

Analog 4660+4(n-1)+1 Submenu ID of submenu for Analog
Output #n Output #n (n=1-16).
Analog 4660+4(n-1)+2 Total This variable sets the input
variable Current source for analog output #n.
See Table 3-40
Output 4660+4(n-1)+3 Unip Sets the output type for the
module type module.
• Unip
• Bip
Full range 4660+4(n-1)+4 % 0.0 0.0 300.0 Scales the output range of the
variable selected.
Table 3-40. Pick list for Analog Variable parameters (all units are %)
Motor Voltage Total Current Average Power Analog Input #1

Motor Speed Speed Demand Speed Reference Analog Input #2
Raw Flux Demand Flux Reference Current (RMS) Analog Input #3
Zero Sequence Av Neg Sequence D Neg Sequence Q Analog Input #4
Input Frequency Input Power Avg Input Pwr Factor Analog Input #5
Ah Harmonic Bh Harmonic Total Harmonics Analog Input #6

Xfmr Therm Level 1 Cycle Protect Single Phase Cur Analog Input #7
Under Volt Limit Out Neutral Volts Synch Motor Field Analog Input #8
Motor Torque Encoder Speed
Table 3-41. Speed Setpoint Menu (4240)

3
Jog speed 4330 rpm 0 -18000 18000 This parameter sets the drive jog
speed.
Safety setpoint 4340 rpm 0 -18000 18000 Safety Override preset speed.
Table 3-42. Incremental Speed Setup Menu (4970)

the program amount.
the program amount.


the program amount.
the program amount.
the program amount.
3 3 will decrease the speed demand by
the program amount.
Table 3-43. PID Select Menu (4350)

Prop gain 4360 0.4 0.0 99.0 Sets the PID loop Proportional (P) gain.
Integral gain 4370 0.4 0.0 99.0 Sets the PID loop Integral (I) gain.
Diff gain 4380 0.0 0.0 99.0 Sets the PID loop Derivative (D) gain.
Min clamp 4390 % 0.0 -200.0 200.0 Sets the minimum value for the PID loop
integrator.
Max clamp 4400 % 100.0 -200.0 200.0 Sets the maximum value for the PID
loop integrator.
Setpoint 4410 % 0.0 -200.0 200.0 Sets a value to be used as the reference
setpoint for the external PID loop. The
value is set as a percent of full scale.
Table 3-44. Comparator Setup Menu (4800)
Submenu Description
Comparator n Setup Submenus that contain 32 sets of comparators for custom use in the
system program. Each comparator set (Compare 1 through Compare 32)
consists of three parameters that are located in the comparator setup
menus. Comparators are system program flags (Comparator1_I through
Comparator32_I ) which can be used anywhere within the system program
environment to control software switches. Refer to Table 3-45

Table 3-45. Compare 1-32 Setup Menu Parameter Descriptions
Menu Item DefaultValue Description

Comp n A in Manual value “Comp n A” and “Comp n B” inputs can be selected from
variable select (list) the list in Table 3-46
(n=1-32)
Comp n B in Manual value The comparator flag compar_n_f (where n=1-16) in the
variable select (list) system program is set true if “Comp n A in” > “Comp n B in”.
(n=1-32)
Comp n manual 0.0% Min: -10,000% Max: 10,000%
value
Compare n type ‘Mag’ if n=1; “Compare n” can be set to the following: 3
(list) (n=1-32) ‘Off’ if n>1 signed (e.g., 10 > -50)
magnitude (e.g., -50 > 10)
disabled (no compare is done).
Table 3-46. Variable Pick List for Comparator Setup Submenus
Analog Input 1 Analog Input 13 Motor speed

Analog Input 2 Analog Input 14 Motor current
Analog Input 3 Analog Input 15 Enter Manual Value
Analog Input 4 Analog Input 16 Manual ID
Analog Input 5 Analog Input 17 Max Avail Out Vol

3.3.5. Main Menu (5) Options

The Main Menu (5) consists of the following menu options:
• Motor Menu (1)
• Drive Menu (2)
• Stability Menu (3)
• Auto Menu (4)
• Log Control Menu (6)
3 • Drive Protect Menu (7)
• Meter Menu (8)
• Communications Menu (9)
• Security Edit Functions Menu (5000)
• Parameter Default/File Functions
• Language and Security Functions
The contents of submenus 1-4 have already been explained earlier in this chapter. The contents of
submenus 6-9 are explained later in this chapter. All of these submenus can be accessed directly using
the keypad or from the Main Menu (5). Refer to the appropriate sections elsewhere in this chapter for
descriptions of menu options within these submenus.
Main Menu (5) functions and submenus are explained in the tables that follow.
Table 3-47. Main Menu (5) Options

Motor Menu 1 submenu Provides access to the Motor Menu. See
page 3-17.
Drive Menu 2 submenu Provides access to the Drive Menu. See
page 3-21.
Stability Menu 3 submenu Provides access to the Stability Menu.
See page 3-28.
Auto Menu 4 submenu Provides access to the Auto Menu. See
page 3-20.
Log Control 6 submenu Provides access to the Log Control Menu.
See page 3-45.
Drive Protect Menu 7 submenu Provides access to the Drive Protect
Meter Menu 8 submenu Provides access to the Meter Menu. See
page 3-49.
Communications Menu 9 submenu Provides access to the Communications
Security Edit Functions Menu 5000 submenu This menu contains functions which are
used to edit a menu item’s security codes.


See table Table 3-48.
Set Defaults to Current 5045 function Used to set all default parameters to the
current parameter settings.
Reset to Defaults 5050 function Used to reset all parameters to their

factory defaults.
Select Language 5080 pick list Sets language for keypad.

• English (default)
• French
• German
• Spanish 3
Change Security Codes 5090 function Used to change the security codes for the
various security levels used by the drive.
Default codes are shown in Table 3-50.
Enter Security Code 5500 function Used to enter the security code to set the
clearance level for access.
An electronic security code is provided to limit unauthorized access to various parameters within the drive
equipment. The default factory settings for parameter security codes is as follows:
Table 3-48. Security Edit Functions Menu (5000)

Change 5010 Function This function is used to change a menu item’s security level.
security level When active an “x” will appear as the first character on the
second line of the display. Please scroll past Main(5) into
another menu. The current security level will appear as the
last character on the second line of the display. Press
[ENTER] to edit the security level for the ID that is shown.
Choose among levels 0, 5, 7, or 8. See Table 3-49.
Drive running 5020 Function This function is used to change a menu item’s run inhibit.
inhibit When active an “x” will appear as the first character on the
second line of the display. The current run inhibit state will
appear as the last character on the second line of the
display. See Table 3-49.

Table 3-49. Security Edit Menu Function Descriptions (5010, 5020)
ID Name Description
5010 Change “Change security level” prohibits access to menu or menu items
Security Level until “enter security level” is set to that level or higher.
Level = 0,5,7,8 Sets the level of security on that particular menu item.
5020 Drive Running Prohibits certain parameters from being changed when drive is
Inhibit in the Run State (D).
1 = enable Drive running lockout will not allow the parameter to be
0 = disable changed while the drive is running. “0” indicates that a
parameter may be changed while the drive is running. “1”
3 indicates that a parameter may not be changed while the drive
is running.
Caution!−Do not change the Drive Running Inhibit (5020) setting of any parameter unless you
are completely certain that the change is safe. Changes may result in massive environmental
and property destruction, injuries, and/or loss of life.
Upon selecting either of these functions, an “Enter Menu ID” prompt is displayed. If the menu number is
known, it may be entered at this point. If the menu number is not known, press the [ENTER] key and the
display will default to the top of the Main Menu (5), allowing the user to scroll to the menu item to be
changed.
When the operator reaches the menu item to be changed, he must press the [ENTER] key followed by
either a [0] to disable or a [1] to enable the selected edit feature. An asterisk character (*) appears on the
left of the display to indicate that the menu or submenu is in the security edit mode, and not in normal
mode. Press the [Cancel] key to exit security edit mode.
Table 3-50. Default Security Access Levels and Access Codes
Access Level Default Access Code Level of Security

0 None Minimum Access
5 5555 Startup Access for Service and/or Startup
7 7777 Advanced Access for Troubleshooting
8 Proprietary Factory Use Only
Note that menu options above security level 5 are more technical in nature and are typically used by ASI
Robicon personnel during commissioning or servicing.
The Security Edit Menu (5000) can be accessed to change the factory default security settings. When the
Harmony is configured for security level 7 access, the Security Edit Menu (5000) is visible from the Main
Menu (5). Functions within this menu are used to set the security levels for menu items, to “hide” menu
items, and to prevent changes to specific parameters. The Security Edit Functions Menu (5000) contains
security functions described in Table 3-48.

3.3.6. Log Control Menu (6) Options

The Log Control Menu (6) consists of the following menu options:
• Event Log Menu (6180)
• Alarm/Fault Log Menu (6210)
• Historic Log Menu (6250)
The contents of these menus are explained in the tables that follow.
Table 3-51. Event Log Menu (6180)

The event log is stored in a file on the CompactFLASH. The maximum file size is 65Kbytes. The file is
overwritten once the maximum size is reached.
Parameter ID Units Default Min Max Description 3

Upload event log 6190 Function Upload the event log via the RS232
serial port.
Clear event log 6200 Function Used to clear the event log.
Table 3-52. Alarm/Fault Log Menu (6210)

Alarm/Fault 6220 Function Used to display the fault log.
log display
Alarm/Fault 6230 Function Upload the fault log via the RS232 serial
log upload port.
Alarm/Fault 6240 Function Used to clear the fault log.
log clear
Table 3-53. Historic Log Menu (6250)

The event log is stored in non-volatile battery backed up RAM. Seventy-eight events are recorded 58
before a fault occurs and 20 after. If the “Store in event log” is “On”, several historical logs can be stored.
The maximum number is limited by the event log size (65Kbytes).
Store in event log 6255 On When selected the Historical log is stored in the
event log
Historic log variable 1 6260 Spd Ref Select the 1st variable for the historic log. See
Historic log variable 2 6270 Trq I Cmd Select the 2nd variable for the historic log. See
Historic log variable 3 6280 Mtr Flux Select the 3rd variable for the historic log. See
Historic log variable 4 6290 Pwr Out Select the 4th variable for the historic log. See
Historic log variable 5 6300 I Total Out Select the 5th variable for the historic log. See


Historic log variable 6 6310 Mag I Fdbk Select the 6th variable for the historic log. See
Historic log variable 7 6320 Mtr Flux Select the 7th variable for the historic log. See
Historic log upload 6330 Upload Historic log to serial port
Table 3-54. Pick List Variables for Historic Log (all units are %)
3
Abbreviation Description
Mtr Spd Motor speed
Spd Ref Speed reference
Spd Dmd Raw Speed Demand
Trq I Cmd Torque Current Command
Trq I Fdbk Torque Current Feedback
Mag I Cmd Magnetizing Current Command
Mag I Fdbk Magnetizing Current Feedback
I Total Out Total Motor Current
Mtr Volt Motor Voltage
Mtr Flux Motor Flux
V Avail Line Voltage Available
V Avail RMS Line Voltage RMS
Pwr Out Output Power
V Neutral Output Neutral Volts
I Total In Total Input Current
Pwr In Input Power
Freq In Input Frequency
*
See Appendix D for Historical Log Fault word decoder.

3.3.7 Protect Menu (7) Options

The Drive Protect Menu (7) consists of the following menu options:
• Input Protect Menu (7000)
• Single Phasing Menu (7010)
Table 3-55. Drive Protect Menu (7) Parameters

Input Protection 7000 Submenu Input protection parameters.
See Table 3-56 3
Drive IOC Setpoint 7110 % 150.0 50.0 200.0 Drive instantaneous
overcurrent setpoint (as a
rating).
Cell Overload Level 7112 % 100.0 100.0 150.0 Cell current overload (as a
rating) allowed for 1 minute out
of every 10 minutes.
Auto Reset Enable 7120 No Enables the reset of the Drive
after a fault.
Auto Reset Time 7130 sec 1 1 120 Adjusts the time between the
fault and its automatic reset.
Auto Reset Attempts 7140 5 1 10 The number of attempts a
drive will be reset before a
permanent shutdown.
Auto Reset Memory Time 7150 sec 501 1 1000 The amount of time between
faults that will clear the
attempts counter.
Fault Reset 7160 function Issues a Drive fault reset when
selected
Table 3-56. Input Protect Menu (7000)

Single phasing 7010 Submenu Single phasing protection
parameters. See Table 3-57
Undervoltage prop gain 7060 0.0 0.0 10.0 Under voltage PI regulator
proportional gain term.*
Undervoltage integ gain 7070 0.001 0.0 1.0 Undervoltage PI regulator integral
gain term.*


1 Cyc Protect integ gain 7080 0.0025 0.0 1.0 Gain of integral regulator for
detecting excessive input reactive
current. Output of this regulator is
used to fault the drive in case high
reactive currents flow in the input
(other than the instant when MV is
applied to the drive). Adjust the
gain to change the response to
high reactive currents.**
1 Cycle Protect Limit 7081 % 50.0 0.0 100.0 Integrator output level at which
drive issues a 1 Cycle Protect
3 Fault.
Xformer tap setting 7050 % 0 Choose from the
{-5,0,+5%} settings to match
transformer tap setting.
Xformer thermal gain 7090 0.0133 0.0 1.0 Gain of integral regulator to limit
input current to 105% of its rated
value.
Xformer protection const 7100 0.375 0.0 10.0 Gain to adjust model of input
transformer. Use the default
value of 0.375.
Phase Imbalance Limit 7105 % 40.0 0.0 100.0 Input current level (as a percent of
Rated Input Current) above which
Input Phase Imbalance Alarm is
issued.
Ground Fault Limit 7106 % 40.0 0.0 100.0 Level above which drive issues an
Input Ground Fault Alarm.
Ground Fault Time Const 7107 sec 0.2 0.001 2.0 Time constant of filter used for
averaging input neutral voltage.
Table 3-57. Single Phasing Menu (7010)

SPD prop gain 7020 0.0 0.0 10.0 Single phase detector PI regulator
proportional gain term.
SPD integral 7030 0.001 0.0 1.0 Single phase detector PI regulator
gain integral gain term.
SPD threshold 7040 % 50.0 0.0 100.0 Regulator output level below which
an alarm is generated

3.3.8. Meter Menu (8) Options

The Meter Menu (8) consists of the following menu options:
• Hour Meter Setup Menu (8010)
• General Drive Parameters Menu (Set Time, Software Version, Language, Output Units)
• Input Harmonics Menu (8140)
Table 3-58. Meter (8) General Drive Parameters

3
Display 8000 Submenu This menu contains display
Parameters parameters. See Table 3-59
Hour Meter Setup 8010 Submenu This menu contains hour meter
setup. See Table 3-61
Input Harmonics 8140 Submenu This menu contains input
harmonics. See Table 3-62
Fault Display 8200 Off Enables or disables the display of
Override Fault/Alarm messages on the
keypad.
Set the clock time 8080 Function Used to change the time and date
of the real-time clock chip.
Display version 8090 Function Displays the installed version of
number firmware.
Customer order 8100 0 0 999999 Customer order number
Customer drive 8110 1 0 20 Customer drive number
Table 3-59. Display Parameters Menu (8000)

Status variable 1 8001 DEMD Select variable 1 to be displayed on the LCD
display. Pick List – See Table 3-60
Status variable 2 8002 %SPD Select variable 2 to be displayed on the LCD
Status variable 3 8003 VLTS Select variable 3 to be displayed on the LCD
Status variable 4 8004 RPM Select variable 4 to be displayed on the LCD
This menu contains the pick lists to select the variables to be displayed on the front panel default display.

Note: Table 3-60 contains name, abbreviation, display and variable columns of standard pick list
variables (used in the Historic Log Menu, the Display Variable Menu, etc.. The name column
contains the name of the display variable. This is what is displayed as the user scrolls through the
list of available display variables. The abbreviation column contains an abbreviation that is
displayed after a variable is selected from the list. The display column contains an even more
abbreviated form of the variable name. This final abbreviation (between 2 and 5 characters in
*
length is what the Perfect Harmony displays on the front panel of the drive. The variable column
shows the associated system program variable for reference.
User-defined Display User-defined Display User-defined Display

Variable #1 Variable #2 Variable #3 User-defined Display
Variable #4
3
Top row of display shows MODE DEMD RPM MVLT OAMP
field names Bottom row of display
OFF 80 0 0 0
shows dynamic values
Table 3-60. Pick List Variables for the Front Display
Abbreviation Description & Units Abbreviation Description & Units

IMRF Magnetizing current ref (A) VAIN Phase A input voltage (V)
ITRF Torque current ref (A) VBIN Phase B input voltage (V)
FLDS Flux DS (%) VCIN Phase C input voltage (V)
FLQS Flux QS (%) VZSQ Zero sequence voltage (V)
VDRF Vds reference (%) VNSD Negative sequence D voltage (V)
VQRF Vqs reference (%) VNSQ Negative sequence Q voltage (V)
SLIP Slip frequency (%) VDIN Input D voltage (V)
%SPD Motor speed (%) VQIN Input Q voltage (V)
FREQ Motor speed (Hz) VAVI Input voltage (V)
RPM Motor speed (RPM) FRIN Input frequency (Hz)
VLTS Motor voltage (V) KWIN Input power average (kW)
IMAG Magnetizing current filtered (A) PFIN Input power factor (%)
ITRQ Torque current filtered (A) HRCA Ah harmonic coefficient (%)
ITOT Motor current (A) HRCB Bh harmonic coefficient (%)
%TRQ Torque out (%) HARM Total A, B harmonics (%)
KWO Output power (kW) XTHL Transformer thermal level (%)
RESS Stator resistance 1CRI One cycle reactive current level (%)
DEMD Speed demand (%) SPHI Single phasing current level (%)
SREF Speed reference (%) UNVL Under Voltage level (%)
FDMD Raw flux demand (%) EFF Efficiency (%)
FXRF Flux reference (%) THD Total Harmonic Distortion (%)
IDIN Id input current (A) VNGV Output Neutral Voltage (V)
IQIN Iq input current (A) %VNG Output Neutral Voltage (%)
IAIN Phase A input current (A) SMFC Synch Motor Field Current (A)
IBIN Phase B input current (A) %ESP Encoder Speed (%)
ICIN Phase C input current (A) ERPM Encoder Speed (RPM)
IAVI Total input current (A)

Table 3-61. Hour Meter Setup (8010)

Display hour meter 8020 Function Used to display the amount of time that
the drive has been operational since it
was commissioned.
Preset hour meter 8030 Function Used to preset the hour meter to the
accumulated time that the drive has been
operational since it was commissioned
(in the event that a micro board has been
replaced on an existing drive).
3 Reset hour meter 8040 Function Used to reset the hour meter when the
drive is commissioned.
Display Output kWH 8050 Function Displays the total output kW hours that
was commissioned.
Preset output kWH 8060 Function Presets the output kW hour counter to a
replaced).
Reset output kWH 8070 Function Resets the output kW hour counter to
meter zero.
Display input kWH 8072 Function Displays the total input kW hours that
was commissioned.
Preset input kWH 8074 Function Presets the input kW hour counter to a
replaced).
Reset input kWH 8076 Function Resets the input kW hour counter to
meter zero.
Table 3-62. Input Harmonics Menu (8140)

Selection for HA 8150 IA Selection for harmonic Analysis
• IA
• IB
• IC
• VA
• VB
• VC
Harmonics order 8160 1.0 0.0 30.0 Harmonic Order
Harmonics integral 8170 0.001 0.0 1.0 Harmonics regulator integral gain term
gain

3.3.9. Communications Menu (9) Options

The Communications Menu (9) consists of the following menu options:
• Serial Port Setup Menu (9010)
• Network Control (9943)
• Serial Functions (9110)
• TCP/IP Setup (9300)
These menu items are explained in tables that follow.

Table 3-63. Communications Menu (9) Parameters 3
Serial port setup 9010 Submenu This menu contains all serial port setup
parameters.
See Table 3-64
Network Control 9943 Submenu Please refer to Communications manual
(number 902399)

Configure

Configure
Display Network 9950 Function

Monitor
Serial echo 9180 Function

back test
Sop & serial 9110 Submenu This menu contains functions that utilize
Functions the local serial port.
See Table 3-65
TCP/IP Setup 9300 Submenu This menu contains functions which set
the parameters for TCP/IP.
See Table 3-66

Table 3-64. Serial Port Setup Menu (9010)

Serial port use 9020 Local Designates the usage of the on board
serial port.
• Local
• Tool
Flow Control 9030 Xon/ Designates the type of flow control used
by the serial port.
3 Xoff
• None
• Xon/Xoff
Baud rate 9040 19200 Designates the baud rate of the on board
serial port
• 9600
• 19200
• 38400
• 57600
• 115200

Table 3-65. Serial Functions Menu (9110)

System program 9120 Function Used to transfer the system
download program to a remote system.
System program upload 9130 Function Used to transfer the system

program from a remote system.
Display sys prog name 9140 Function Displays the current system
program name. 3
Display drectry version 9147 Function Displays current directory file
version.
Select system program 9145 none Displays the list of system

program files.
Multiple config files 9185 Off Enables multiple configuration

files.
Parameter data upload 9150 Function Used to transfer the current

configuration file to a remote
system.
Parameter data download 9160 Function Used to transfer the current
configuration file from a remote
system.
Parameter dump 9170 Function Used to get a print out of the
current configuration data.
Parameter upload functions are used to transmit data from the drive to a printer or computer. Parameter
download functions are used to transmit data to the drive. A terminal emulator such as Smart Term’s
“ST220.EXE” or Procomm’s “PCPLUS” is required to upload, download, and echo files. Windows
“Terminal” protocol settings for the RS232 port are 9600 baud, no parity, and one stop bit.
Note that all parameters are printed on the parameter dump.
Table 3-66. TCP/IP Setup Menu (9300)

IP 9310 172.16.106.16 0.0.0.0 255.255.255.255 Used to enter the
address system IP address in
dotted decimal.
Subnet 9320 255.255.0.0 0.0.0.0 255.255.255.255 Used to enter the
mask system subnet mask in
dotted decimal.


Gateway 9330 172.16.1.1 0.0.0.0 255.255.255.255 Used to enter the
address system gateway
address in dotted
decimal.
3.3.10 Menu Setup for Multiple Configuration Files (Slaves)

The NXG drive is designed to operate with multiple motors that may or may not be of the same size. This
is accomplished by using multiple parameter configuration files. There is one master configuration file
that is always named current.cfg. The slave files are stored in a sub directory of CfgFiles named SubCfgs
and can have any legal name conforming to the eight dot three file convention.
3 NOTE: All slave configuration files have the ‘.sfg’ extension. This is not changeable through the menus.
The configuration files can be created at runtime in the drive’s memory and then stored to a flash disk.
The slave files are created via the keypad menus by setting the slave parameters as desired and writing
them to a flash disk.
There are eight SOP flags that can be set to point to a configuration file. The menus are used to map
each SOP flag to a corresponding configuration file. Once mapped, the SOP flags are used to activate
the SOP for a particular motor.
Menu item descriptions
Multiple config files This pick list enables the switching of the slave configuration files. If set to OFF, no
other multiple configuration file menus will be displayed. Once enabled, if any one
of SOP flags is set to true, the corresponding configuration file will become active.
Show active config Function to display the current active configuration file. If correct configuration file is
file not displayed, the SOP file should be checked for accuracy. Check the ‘Setup SOP
configuration flags menu to be sure the correct file is mapped to the SOP flag.
Set active config This pick list sets the displayed file to be the active configuration file. This function
file overrides what is set in the SOP program. Any change in the SOP program is
checked against the file set in this function. Once a change in the SOP is detected,
that file will then be the active file. The keypad menu setting is now ignored. This
insures no unintentional toggling of the configuration files. To switch back to the
keypad file set it by this menu. If no change in the SOP program occurs, the keypad
set configuration file will remain in memory.
Create new config This function allows you to save slave parameters to a file name you specify. The
file name is entered using the drive keypad. To get to the alphanumeric characters, you
must first press a number key. The table below shows all possible combinations of
letters, numbers and symbols.
Set This function allows you to map the name of the flag in the SOP file,
SOPConfigFileX_ SOPConfigFileX_O, where X = 1 to 8, to a name of a slave configuration file. Then,
O (X = 1 to 8) when the SOP program is running, and this flag is set to ‘true’, the configuration file
will be switched into memory. This is a method of switching among multiple motors
using one drive. The file names are selected from a pick list. New files can be
created using the method described previously.
NOTE: You do not need to add the file extension. The file extension is always .’sfg’. Press the ‘enter’ key
to save the parameter(s) as they exist in memory to a new configuration file name. This file will be stored
to the flash disk in the ‘SubCfgs’ subdirectory. This function does NOT make this configuration file the
active configuration file. It uses the current data in memory to create a new slave configuration file. Any
parameter that is saved to a slave configuration file is easily identifiable by the small ‘s’ adjacent to the
parameter ID number if it has not changed from the default setting, or a ‘$’ if it has been changed from its
default setting, i.e. (s9586) or ($9586).

Table 3-67. Slave Parameter

Multiple config files 9185 OFF Enable multiple config file
operation
Show active config 9195 Display current active config file
file
Set active config 9196 Defaults.sfg Set the displayed file to be the
file active config file
Setup SOP config 9186 Sub menu Sub-menu for SOP flag
flags configuration 3
Create new config 9197 Create new config file using
file numeric keypad.
Table 3-68. Parameter Menu - Slave
Motor Menu
Motor kW rating 1010 50 Percent Break Point 1156
Motor frequency 1020 100 Percent Break Point 1157
Full load speed 1030 Maximum Load Inertia 1159
Motor voltage 1040 Motor trip volts 1160
Full load current 1050 Overspeed 1170
No load current 1060 Underload enable 1180
Leakage inductance 1070 I underload 1182
Stator resistance 1080 Underload timeout 1186
Inertia 1090 Motor torque limit 1 1190
Overload select 1130 Regen torque limit 1 1200
Overload pending 1139 Motor torque limit 2 1210
Overload 1140 Regen torque limit 2 1220
Overload timeout 1150 Motor torque limit 3 1230
0 Percent Break Point 1152 Regen torque limit 3 1240
10 Percent Break Point 1153 Phase Imbalance Limit 1244

17 Percent Break Point 1154 Ground Fault Limit 1245
25 Percent Break Point 1155 Ground Fault Time Const 1246
Drive Menu
Control loop type 2050 Skip center freq 3 2370
Ratio control 2070 Skip bandwidth 1 2380
Speed fwd max limit 1 2080 Skip bandwidth 2 2390
Speed fwd min limit 1 2090 Skip bandwidth 3 2400
Speed fwd max limit 2 2100 Freq avoid accel time 2410
Speed fwd min limit 2 2110 Spinning load mode 2430
Speed fwd max limit 3 2120 Scan end threshold 2440
Speed fwd min limit 3 2130 Current Level Setpoint 2450
Speed rev max limit 1 2410 Current ramp 2460
3 Speed rev min limit 1 2150 Max current 2470
Speed rev max limit 2 2160 Frequency scan rate 2480
Speed rev min limit 2 2170 Cond stop timer 2500
Speed rev max limit 3 2180 Cond run timer 2510
Speed rev min limit 3 2190 Min cells/phase count (n/3) 2540
Accel time 1 2270 Fast bypass 2600
Decel time 1 2280 Phase I gain 2710
Accel time 2 2290 Phase P gain 2720
Decel time 2 2300 Phase offset 2730
Accel time 3 2310 Phase error threshold 2740
Decel time 3 2320 Frequency Offset 2750
Jerk rate 2330 Up Transfer Timeout 2760
Skip center freq 1 2350 Down Transfer Timeout 2770
Skip center freq 2 2360 Cable Resistance 2940
Stability Menu
Flux reg prop gain 3110 Integ gain during brake 3290
Flux reg integral gain 3120 Enable braking 3360
Flux Filter Time Const 3130 Pulsation frequency 3370
Flux demand 3150 Brake power loss 3390
Flux ramp rate 3160 VD Loss Max 3400
Energy saver min flux 3170 Braking constant 3410
Speed reg prop gain 3210 Test Type 3470
Speed reg integral gain 3220 Test positive 3480
Speed reg Kf gain 3230 Test negative 3490
Speed filter time const 3240 Test time 3500
Current reg prop gain 3260 Slip constant 3545
Current reg integ gain 3270 Feed forward constant 3560
Prop gain during brake 3280
Auto Menu
Entry point 4010 Delay on 4080
Exit point 4020 Prop gain 4360
Entry speed 4030 Integral gain 4370
Exit speed 4040 Diff gain 4380
Auto off 4050 Min clamp 4390
Delay off 4060 Max clamp 4400
Auto on 4070 Setpoint 4410
Logs Menu

Historic log variable 4 6290
Drive Protection Menu
Auto reset Enable 7120 Auto Reset Attempts 7140
Auto Reset Time 7130 Auto Reset Memory Time 7150
Display Configuration Data Menu
Status variable 4 8004
Meters Menu
Customer Order 8100 Harmonics order 8160
Customer Drive 8110 Harmonics integral gain 8170
Selection for HA 8150 Fault Display Override 8200
3

∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual GLOSSARY OF TERMS

series manuals.

GLOSSARY OF TERMS Perfect Harmony GENIII/e User’s Manual
A
Perfect Harmony system).
average.
[1] through [6].

time the old information is overwritten. The information in NVRAM is stored in ASCII hex format and can A
be uploaded via the drive’s serial port to a PC for troubleshooting analysis.
sections).

chips.
energized.
energized.
lost).
used by parameters.

example) at a time.
command).
Slip = ω S - ω R
ωS

∇ ∇ ∇

Perfect Harmony GENIII/e Uers’s Manual : COMMONLY USED Abbreviations

This appendix contains a list of symbols and abbreviations commonly used throughout the Perfect
Harmony series of manuals.

B
° degrees memory
AC alternating current EPROM erasable programmable
accel acceleration read-only memory
deg degrees IGBT insulated gate bipolar

transistor

: COMMONLY USED Abbreviations Perfect Harmony GENIII/e User’s Manual

in input derivative
in, ″ inches PLC programmable logic

controller
info information
pot potentiometer
INH inhibit
B pp peak-to-peak
K 1,000 (e.g., Kohm)
ppb parts per billion
LAN local area network
PPR pulses per revolution
lbs pounds (weight)
PQM power quality meter
LCD liquid crystal display
PSDBP power spectral density break
ld load point
LED light-emitting diode psi pounds per square inch
lim limit pt point
LOS loss of signal PT potential transformer
lps liters per second PWM pulse width modulation
mA milliamperes rad radians
mag magnetizing RAM random access memory
max maximum ref reference
MCC motor control center rev reverse, revolution(s)
mg milligram RFI radio frequency interference
min minimum, minute RLBK rollback
msec millisecond(s) rms root-mean-squared
msl mean sea level RPM revolutions per minute
mvlt motor voltage RTS request to send
NEMA National Electrical RTU remote terminal unit
Manufacturer’s Association
RX receive
no. number
s second(s)
NMI non-maskable interrupt
sec second(s)
NVRAM non-volatile random access
memory ser serial
oamp output current SOP sum of products
OOS out of saturation spd speed
overld overload stab stability
P proportional (PID) std standard
Pa Pascals sw switch
pb push button TB terminal block
PC personal computer TOL thermal overload
PIB Power Interface Board TP test point
PID proportional integral trq, τ torque

Perfect Harmony GENIII/e User’s Manual : COMMONLY USED Abbreviations
TX transmit
um user module
V voltage, volts
B
VAC volts AC
var variable
VDC volts DC
vel velocity
W width, watts
xformer transformer
∇ ∇ ∇

: COMMONLY USED Abbreviations Perfect Harmony GENIII/e User’s Manual

Perfect Harmony GENIII/e User’s Manual Index
INDEX
speed setting source, 3-3

—— 4-digit security access code, 3-4
- sign, 3-6
implied, 3-6 —5—
50 Hz, 2-10
—[—
, 3-4 —6—
, 3-3
[CANCEL] function, 3-6, 3-7 6-pulse wave form, 1-1
[CANCEL] key, 3-1
common functions, 3-6
[ENTER] key, 3-1, 3-5, 3-6, 3-9, 3-11, 3-13
—9—
changing security features, 3-44 9 common system menus, 3-1
, 3-2, 3-3, 3-10
[HELP] key, 3-15
, 3-3, 3-4 —A—
, 3-3 abbreviations, B-1
[SHIFT] [2] ([DRIVE]) key combination, 3-11 acceleration
[SHIFT] key, 3-1, 3-4, 3-5, 3-6, 3-7, 3-9 time range, 1-5
common functions, 3-7 accepting new parameter values, 3-6
[SHIFT] key sequences, summary of, 3-8 access code, 3-4, 3-7
[SHIFT]+[0] key sequence, 3-15 access codes, 3-1
proprietary, 3-44
—+— accessing menus, 3-10
accessing menus by menu number, 3-8
+ sign, 3-6 , 3-6
acknowledging fault conditions, 3-2
—1— active digit, 3-5, 3-6, 3-10
advanced diagnostics, 1-4
12-pulse wave form, 1-1 , 3-35
18 cell 6.6 KV system, 2-13 air duct covers, 1-3
alarm/fault log, 3-16
Alarm/Fault Log Menu (6210), 3-16, 3-45
—2— altitude, 1-5
2400 VAC system, 2-17 ambient temperature, 1-5
Analog Input #1 Menu (4100), 3-35
Analog Input #2 Menu (4170), 3-36
—3— Analog Input #3 Menu (4232), 3-36
3300 VAC system, 2-17 Analog Input Menu (4090), 3-16, 3-33, 3-35
3-phase input, 2-17 analog inputs
3-phase secondary connections, 2-10 dedicated POT input, 3-3
pot input, 3-3
Analog Outputs Menu (4660), 3-16, 3-33, 3-38
—4— analog to digital board, 2-15
AND, A-5
4160 VAC, 2-18
arrow key sequences, summary of, 3-10
arrow keys, 3-1, 3-4, 3-6, 3-7, 3-8, 3-9, 3-11
4-20 mA input
common uses, 3-7

Index Perfect Harmony GENIII/e User’s Manual
right and left, 3-7 cell specifications, 2-10, 2-11, 2-12

selecting desired velocity, 3-3 cells
summary of key sequences, 3-10 configurations, 2-17
up and down, 3-3 control, 2-10
up and down, 3-7 control boards, 2-8
asterisk character (*) damage due to overheating, ix
security edit mode indicator, 3-44 fiber optic control link, 2-10
attenuator, 2-17 galvanic isolation, 2-8
attenuator system, 2-18 illustration, 2-8
audible motor noise, 1-2 mechanical and electrical comparisons of sizes, 2-8
Auto Menu (4), 3-8, 3-15, 3-33, 3-42 number of in a series, 2-7
auto mode, 3-1 output, 2-8
auto tuning, 1-4, 3-14 output cells per phase, 2-7, 2-8
auto/hand/off mode, 3-1 output current as a function of size, 2-7
automatic mode, 3-1, 3-3 size 2, 2-18
customizing, 3-3 sizes for GEN III, 2-7
Autotune Menu (1250), 3-15, 3-17, 3-20 specification details, 2-7, 2-8
Auxiliary Input #1 Menu (4500), 3-37 change security code, 3-9
Auxiliary Input #2 Menu (4580), 3-38 Change Security Codes Function, 3-43
change security level function, 3-44
changing a parameter, 3-12
—B— changing the velocity demand, 3-7
base 10 format of numbers, 3-4 clean power input, 1-1
base 16 format of numbers, 3-4 clearing fault conditions, 3-10
basic power schematic, 2-18 coasting, 3-14
blower cabinet, 1-3 coffin, 2-7, 2-10
blower fuses, 2-4 commanded speed reference, 3-11
blower motor starters, 2-4 common functions of the Shift key, 3-7
blowers, 2-3, 2-7 common mode voltage stress, 1-2
Boolean algebra, A-5 common uses of the arrow keys, 3-7
boot-up test failure, 3-10 communications board, 2-15
Braking Menu (3350), 3-32 Communications Menu (9), 3-8, 3-16, 3-42, 3-53
BTU/hr losses, 2-12 compar_b_f flag, 3-41
burden resistor values, 2-18 comparator
bypass, 2-13 A variable, 3-41
bypass circuit, 2-19 B variable, 3-41
comparison types, 3-41
comparator flag, 3-41
—C— Comparator Setup Menu (4800), 3-16, 3-33, 3-40
cabinet, ix comparators, 3-40
line-up, 2-1 compare n setup N, 3-40
cabinets, 1-3 compare n type, 3-41
cabinets, 1-3 , 3-4
cancel key compilation process, 3-3
exiting security edit mode, 3-44 computer, 3-55
canceling/aborting the current action, 3-8 Conditional Time Setup Menu (2490), 3-15
cell back-up, 1-4 Conditional Timer Menu (2490), 3-21
cell boards Conditional Timer Setup Menu (2490), 3-25
control power, 2-13 configuring the I/O interfaces, 3-16
cell bypass option, 2-13 connection diagram for an 18 cell 6.6 KV system, 2-13
cell cabinet, 1-3 context sensitive Help menu, 3-8
cell control board, 2-18 context-sensitive help, 3-15
cell control system, 2-13 control “coffin”, 2-7
cell control/gate driver board, 2-10, 2-19 control boards, 2-8
switch mode power supply, 2-13 control cabinet, 1-3, 2-13, 3-1
cell current, 2-12 control fuses, 2-4
cell malfunctions, 2-13 Control Loop Test Menu (3460), 3-15, 3-28, 3-32
Cell Menu (2520), 3-15, 3-21, 3-26 , 3-4
cell overload rollback, 3-13 control panel, 2-10
cell section, 2-1, 2-10 control power, 2-10, 2-13
warning on disconnecting, ix

control power connections, 2-6 Display Variable Menu

control power disconnect switch, 2-4 pick list variables, 3-51
control range, 3-35 distortion wave form comparisons, 1-1
control section, 2-1, 2-8, 2-10 down arrow key, 3-7, 3-8, 3-10, 3-11
isolation from medium voltage, 2-10 pressed three times, 3-11
control system, 2-10 down arrow keystrokes, 3-11
control transformer, 2-4, 2-17 download files, 3-55
controlled stop, 3-3 downloading the system program, 3-3
Critical Frequency Menu (2340), 3-23 drive fault status, 3-2
Critical Frequency Menu (2340), 3-15, 3-21 Drive Menu (2), 3-4, 3-8, 3-15, 3-17, 3-21, 3-42
critical speed, 3-15, 3-24 Drive Parameter Menu (2000), 3-15, 3-21
critical speed parameters, 3-24 Drive Protect Menu (7), 3-8, 3-16, 3-42, 3-47
cross talk, preventing, 1-1 drive running inhibit function, 3-44
current, 2-18 dual frequency braking, 1-4
current distortion, 2-18 dual performance operation modes, 1-4
current harmonic distortion, 1-1 dust contamination, 1-5
Current Loop Menu (3250), 3-31 dV/dt stress, 1-2
current transformers, 2-4 dynamic programmable meter display, 3-11
cursor, 3-11
customer I/O section, 2-1, 2-6
customer wiring terminal strip, 2-4
—E—
echo files, 3-55
—D— edit mode, 3-6, 3-7, 3-9, 3-10
editing a parameter value, 3-9
decelerating, 3-14 editing parameters, 3-1
deceleration, 3-13 EEPROM
time range, 1-5 storage of parameter values, 3-2
, 3-4 efficiency, 1-4, 2-12
default access codes electrical components, 2-12
proprietary, 3-44 electrical hazards, ix
default, factory, 3-10 electrical specifications, 1-5
, 3-9 electrostatic discharge precautions, x
DEMD, 3-10, 3-11 ELV, ix
display, 3-11 enclosure
field, 3-8 specifications, 1-5
DEMD field, 3-10, 3-11 Encoder Menu (1280), 3-17
derating motors, 1-2 Encoder Menu (1280), 3-15, 3-20
desired velocity, 3-7, 3-8 Enter Fixed Value, 3-41
selecting in manual mode, 3-3 enter key
, 3-10 common functions, 3-6
diagnostics, 1-4 default access of Main Menu (5), 3-44
digit, changing values of, 3-11 enter menu ID prompt, 3-44
digital display module, 1-4 , 3-6
digital input Enter Security Code Function, 3-43
, 3-4 enter security level, 3-44
remote manual mode, 3-3 , 3-6
digital meters pick list variables, 3-46 entering a value beyond the range of the system, 3-12, 3-13
entering data
auto function, 3-8 using numerical keys, 3-1
fault function, 3-10 error message
, 3-4 out of range, 3-13
power on function, 3-10 range error, 3-13
run function, 3-10 event log, 3-16
disconnect switch, ix Event Log Menu (6180), 3-16, 3-45
disconnect switch for control power, 2-4 exposed connections, ix
display, 3-2, 3-3, 3-10, 3-11 External I/O Menu (2800), 3-15, 3-21, 3-27
DEMD field, 3-11 external power factor correction capacitors, 1-1
description, 3-11 extra low voltage, ix
display interface, 3-1, 3-3, 3-10
use with menu system, 3-1
Display Parameters Menu (8000), 3-16, 3-49

—F— —H—
fault condition, 3-2 hardware faults, 3-2
fault indicator, 3-2, 3-3 hardware overview, 1-2
fault LED, 3-2, 3-10 harmonic distortion, 1-1
fault logger table, 3-2 sources, 1-1
fault reset, 3-13 harmonic distortion wave forms, 1-1
fault reset,, 3-1 harmonic filters, 1-1
faults harmonics, 1-1, 1-2
clearing, 3-2 hazardous voltages, ix
hardware, 3-2 hazards
overvoltage, 3-10 electrical, ix
resetting system after, 3-1 mechanical, ix
software, 3-2 heating of motor, 1-2
status, 3-2 help display function, 3-1
features, 1-4 help feature, 3-15
feedback resistors, 2-4 hexadecimal digit assignments on the keypad, 3-5
fiber optic cable to bypass board, 2-15 hexadecimal digits
fiber optic cables to cells, 2-15 use in security code, 3-4
fiber optic communications link, 2-10 hexadecimal digits A-F, 3-4
fiber optic control circuitry, 1-4 hexadecimal format of numbers, 3-4
fiber optic data link, 2-19 hexadecimal number system, 3-5
fiber optic hub board, 2-13 hiding menu items, 3-44
connectors, 2-17 high efficiency, 1-4
fiber optic interface boards, 2-15 historic log, 3-16
fiber optic link, 2-8 Historic Log Menu
fiber optic links, 2-13 pick list variables, 3-51
fiber optic system, 2-18 Historic Log Menu (6250), 3-16, 3-45
field weakening rollback, 3-13 historic log pick list variables, 3-46
filter capacitors, 2-18 horsepower specifications, 2-10
flash disk, 2-16 Hour Meter Setup Menu (8010), 3-16, 3-49, 3-52
flash memory card, 2-16 hp range, 1-5
Flux Control Menu (3100), 3-30 humidity, 1-5
fork truck tines, ix
formulas —I—
frequency, 3-24
RPM, 3-24 I/O section, 2-6
, 3-9 identification screen, 3-10
front panel display, 3-8 IEEE 519 1992 requirements, 1-1
front panel keypad, 3-1 IGBT gate driver board, 2-18, 2-19
functions IGBTs, A-3
manual start, 3-1 , 3-10
manual stop, 3-1 induction motors, 1-2
fuse, 2-17 industry standard communication, 1-4
fuses, 2-4 Inhibit, 3-44
input
remote manual mode, 3-3
—G— input current, 2-12
galvanic isolation of cells, 2-8 input current ratings, 2-7
gas contamination, 1-5 input diodes, 2-18
GEN III, 2-1, 2-2 input frequency specifications, 2-10
cells, 2-8 Input Harmonics Menu (8140), 3-49
hardware overview, 1-2 Input Harmonics Menu (8140), 3-16, 3-52
power section, 2-4 input line voltages, 1-5
transformer section, 2-4 input monitoring, 1-4
GEN IIIe, 2-3, 2-6 input motor currents, 2-18
GENIIIe Perfect Harmony VFDs, 1-3 input power, 2-17, 2-19
glossary of terms, A-1 input power factor, 1-5
green keys, 3-6 Input power factor, 2-18
input power specifications, 2-10
input power terminals, 2-4

Input Processing Menu (3000), 3-15, 3-28, 3-29 lethal voltages, ix

Input Protect Menu (7000), 3-47 lifting precautions, ix
Input Protection Menu (7000), 3-16 lifting tubes, 1-3
input voltage, 2-18 Limit Protection Menu (1120), 3-17
tolerance, 1-5 limits, 3-16
inputs, 3-41 Limits Menu (1120), 3-15, 3-18
pot input, 3-3 list of symbols, B-1
introduction, 1-1 load conditions, 3-15
isolated secondaries on transformer, 2-17 local manual mode, 3-3, 3-4, 3-7, 3-8
isolation lock-out/tag-out procedures, ix
between control and medium voltage sections, 2-10 Log Control Menu (6), 3-16, 3-42, 3-45
isolation of cells, 2-8 log variable pick list, 3-46
, 3-10, 3-11 Logs Menu (6), 3-8
, 3-9 Low Frequency Compensation Menu (3060), 3-30
field, 3-10 low speed applications, 1-1
ITOT field, 3-11 low voltage terminal strip, 2-4
low-voltage power cell, 2-19
—K—
—M—
key sequences, 3-1
keypad, 1-4, 2-17, 3-1, 3-3, 3-4, 3-5, 3-6, 3-9, 3-10 main display, 3-7, 3-8, 3-9
, 3-4 availablility of speed menu feature, 3-5
arrow keys, 3-7 Main Menu (5), 3-7, 3-8, 3-9, 3-16, 3-42
automatic key, 3-3 default access to, 3-44
cancel key, 3-44 Main Menu (5) Options, 3-42
enter key, 3-6 main meter display
changing security features, 3-44 availability of speed menu feature, 3-5
fault reset key, 3-2 maintainance
functions, 3-1 qualified individuals, ix
green keys, 3-4 maintenance, ix
green text, 3-4 maneuvering between menus, 3-10
hexadecimal digit assignments, 3-5 manual control mode, 3-3
, 3-5 , 3-4
key functions, 3-2 manual mode, 3-1
, 3-4 flow diagram, 3-3
numeric keys, 3-1, 3-6 local, 3-8
numeric keys, 3-4, 3-5 manual start, 3-1
parameter modification, 3-3 , 3-4, 3-9
shift key, 3-6 manual start mode, 3-3
standard, 3-1 manual stop, 3-1
use with menu system, 3-1 master control, 2-8
keypad and display interface, 3-1, 3-2 system module, 2-13
, 3-5 master control components, 2-7
keypad/display interface, 3-1 master control system, 2-10
keypad/display module, 3-1 maximum cell current, 2-12
, 3-5 mechanical specifications, 1-5
medium voltage
isolation from control section, 2-10
—L— warning about control power, ix
LCD, 3-1, 3-5, 3-7, 3-8 menu
changing variable assignments, 3-8 going to bottom, 3-10
parameters displayed on, 3-9 returning to the top, 3-10
, 3-10 menu access, 3-7, 3-8, 3-10
, 3-9 numeric, 3-5
LCD interface, 3-1 security, 3-1
LEDs, 3-10 menu access feature, 3-9
fault, 3-2 menu and submenu summary, 3-15
left arrow key, 3-7, 3-9, 3-10, 3-11 menu descriptions, 3-14
length, 2-12 menu items
length specifications, 2-10 hiding, 3-44
prohibiting access to, 3-44

prohibiting changes, 3-44 normal operation, 3-1, 3-10

menu number, 3-5, 3-9 number systems, 3-4
menu numbers, 3-4, 3-5, 3-6, 3-7 numeric keys, 3-1, 3-4, 3-5, 3-9
menu setting rollback, 3-13 numeric menu access, 3-5
menu structure, 3-1, 3-7, 3-10 numerical keys
navigating through, 3-7, 3-9 functions, 3-1
menu system, 3-1, 3-7, 3-8 numerical menu access, 3-8
changing variable assignments on LCD, 3-8 numerical menu access mode, 3-10
navigation through, 3-1
menuing system, 3-10
menus
—O—
accessing, 3-8, 3-10 on-line diagnostics, 1-4
accessing based on menu numbers, 3-4 on-line operation while tuning, 1-4
accessing using numeric menu codes, 3-5 operating voltages, 2-12, 2-17
accessing using speed menu, 3-4 operation mode displays, 3-13
maneuvering in, 3-10 , 3-4
navigating to the bottom, 3-8 operation while tuning, 1-4
navigating to the top, 3-8 OR, A-5
Meter (8) General Drive Parameters, 3-49 output bypass circuit, 2-19
meter display, 3-7, 3-8, 3-9, 3-10, 3-11 output cell, 2-13
meter display sceen, 3-10 output cells, 2-8, 2-12, 2-17
meter display screen, 3-10 Output Connection Menu (2900), 3-28
DEMD field, 3-10, 3-11 output current, 2-12, 3-10, 3-11
ITOT field, 3-10, 3-11 output current ratings, 2-7
MODE field, 3-10, 3-11 output current wave form, 1-2
RPM field, 3-10, 3-11 output frequency drift, 1-5
VLTS field, 3-10, 3-11 output line voltages, 1-5
Meter Menu (8), 3-8, 3-16, 3-42, 3-47, 3-49 output motor current, 2-18
metering terminal strip, 2-4 output operating voltage, 2-12
microprocessor board, 2-13, 2-15, 2-17 output operating voltages, 2-7
replacing without reprogramming parameters or system output phases, 2-18
program, 2-13 output power cabinet, 1-3
Modbus RTU Setup Menu (9050), 3-16, 3-53 output power terminals, 2-4
, 3-9, 3-11 Output Processing Menu (3050), 3-28
mode displays summary, 3-13 Output Processing Menu (3050), 3-15, 3-29
MODE field, 3-10, 3-11 output torque, 1-5
, 3-4 output voltage, 2-18
modification capabilities, 3-1 overheating, ix
modular construction, 1-4 overload capability, 1-5
modulator board, 2-15 overvoltage faults, 3-10
momentary digital input, 3-3
motor heating, 1-2
Motor Menu (1), 3-4, 3-8, 3-15, 3-17, 3-42
—P—
motor monitors, 2-6 padding zeroes in parameter values, 3-6
motor nameplate, 2-12 parameter is selected into memory, 3-12
motor noise, 1-2 parameter security, 3-1
Motor Parameter Menu (1000), 3-15, 3-17, 3-57 parameters
motor speed accepting new values, 3-6
adjusting, 3-35 accessing, 3-1
motor speed in RPM, 3-10, 3-11 changing values, 3-4
multi-motor operation, 1-4 changing values of, 3-5
multi-secondary phase-shifting power transformer, 2-3 edit mode, 3-6, 3-10
edit mode, 3-7
—N— editing, 3-9
editing process, 3-6
navigating through the menu structure, 3-7 editing values, 3-1
NEMA 1 entering a value beyond the range of the system, 3-12, 3-
enclosure specifications, 1-5 13
non-volatile memory area, 3-2 entering hex values, 3-4
normal mode, 3-44 incrementing/decrementing values of, 3-7

inputs, 3-3 errors, 3-13

organization, 3-1 rated hp, 2-12
outputs, 3-3 reactive halide contamination, 1-5
padding with zeroes, 3-6 redundant cell operation, 2-17
preventing changes to, 3-44 regeneration, 3-13
prohibiting changes to, 3-44 rejecting modifications, 3-6
rejecting modifications, 3-6 reliability, 1-4
storage in system module, 2-13 remote manual mode, 3-3, 3-4
viewing and editing, 3-1 activation, 3-3
PC tool interface, 1-4 reports capabilities, 1-4
PCplus, 3-55 reset, 3-2, 3-11
Perfect Harmony menu structure, 3-14 resetting the current security level to 0, 3-9
phase shift from transformer T1, 2-18 resetting the system, 3-1
phase shifting transformer, 2-10 resonance avoidance, A-5
phase-shifting power transformer, 2-3 resonance avoidance feature, A-5
pick list, 3-11 resonance avoidance parameters, 3-24
pick list variables, 3-46, 3-51 resonance problems, 1-1
pick lists, 3-1, 3-7 restore default value, 3-10
PID Select Menu (4350), 3-16, 3-33, 3-40 restore factory default, 3-10
PLC capabilities, 1-4 restore the security level back to 0, 3-10
polarity, 2-18 returning to the previous menu, 3-6, 3-8
position the cursor, 3-11 right arrow key, 3-5, 3-6, 3-7, 3-9, 3-10, 3-11
pot RPM, 3-10, 3-11
selecting desired velocity using, 3-3 , 3-9
, 3-4 RS232 download functions, 3-55
potentiometer RS232 port, 3-55
selecting desired velocity using, 3-3 baud rate setting, 3-55
power cell check, 1-4 parity setting, 3-55
power cell with optional bypass, 2-19 stop bit setting, 3-55
power circuit, 2-17 RS232 upload functions, 3-55
power factor, 1-1, 1-2, 2-12 run indicator, 3-10
definition, 1-1 run state (D)
units, 1-1 prohibiting parameter changes during, 3-44
power failure, 3-2
power input cabinet, 1-3, 2-1
power interface board, 2-17
—S—
power on indicator, 3-10 safety, ix
power quality meters, 2-6 safety precautions, ix
power supply connection, 2-15 scrolling, 3-7
power transformer, 2-4 using arrow keys, 3-1
power up, 3-11 scrolling through parameter lists, 3-15
power up display, 3-10 SCRs, 1-2
power wires, 2-3 secondary of the power transformer, 2-18
power wiring, 2-3 security, 3-1, 3-4, 3-5, 3-7, 3-8, 3-9
printed circuit (PC) boards, 2-10 approved menus, 3-9
printer, 3-55 entering access codes, 3-1
Procomm, 3-55 pluggable keypad/display module, 3-1
profile, 3-15 security access code, 3-4, 3-7
programmable meter display, 3-11 security access codes, 3-1, 3-4
prohibiting changes to parameters, 3-44 security access levels and default codes, 3-44
proprietary security code levels, 3-44 proprietary, 3-44
security code, 3-4, 3-5
—Q— changing, 3-9
prompting user after menu requests, 3-5
qualified individual (for troubleshooting and maintenance), security codes, 3-44
ix prompts for new level, 3-5
proprietary, 3-44
Security Edit Functions Menu (5000), 3-42, 3-43, 3-44
—R— Security Edit Menu (5000), 3-16
range security edit mode
asterisk character (*), 3-44

exiting, 3-44 ST220.EXE, 3-55

security features, 3-16 Stability Menu (3), 3-8, 3-15, 3-28, 3-42
security level, 3-10 standard menus, 3-11
changing, 3-44 starters for blower motors, 2-4
clearing, 3-7 Stator Resistance Estimator Menu (3300), 3-31
restoring back to zero, 3-10 , 3-12
restoring to zero, 3-8 , 3-11
security level cleared message, 3-9 stop, 3-55
, 3-9 stop mode, 3-1
security level, resetting to 0, 3-9 effects of, 3-3
security levels, 3-44 storage
setting, 3-44 safety precautions, ix
Select Language Function, 3-43 submenu
selecting a submenu, 3-6 going to bottom, 3-10
Serial Functions Menu (9110), 3-55, 3-57 returning to the top, 3-10
Serial Functions Menu (9110), 3-17 submenus, 3-1, 3-4, 3-7, 3-21, 3-42
serial port, 1-4 sulfide contamination, 1-5
Serial Port Setup Menu (9010), 3-16, 3-53, 3-54 summary of operation mode displays, 3-13
setpoint, 3-15 surge arrestors, 1-4
setpoint limits, 3-16 switch mode power supply, 2-10, 2-13
, 3-6 symbols, B-1
, 3-7 Sync Motor Menu (1100), 3-17
shipping splits, 1-3 Sync Transfer Menu (2700), 3-15, 3-21, 3-27
sign, changing value of, 3-11 system errors, 3-10
Single Phasing Menu (7010), 3-47, 3-48 system interface board, 2-15
single phasing rollback, 3-13 system menus, 3-1
sinusoidal input currents, 1-1 system module, 2-13
sinusoidal output, 1-1, 1-2 system program, 2-13, 3-3, 3-40, 3-41, 3-51
sinusoidal output voltages, 1-2 closing and opening software switches, 3-40
Smart Term, 3-55 compar_b_f flag, 3-41
soft start protection, 1-4 comparators, 3-40
software faults, 3-2 compilation process, 3-3
software switches downloading, 3-3
closing and opening, 3-40 modification, 3-3
software version number, 3-10 modifications, 3-3
sound pressure, 1-2 storage in the system module, 2-13
source impedances, 1-1 system reset, 3-1, 3-11
spd fwd lim parameter, 3-13
specifications, 1-5
, 3-35
—T—
speed demand, 3-10, 3-11 T1, 2-18
Speed Derate Curve Menu (1151), 3-19 TCP/IP Setup Menu (9300), 3-17, 3-55
speed forward limit parameter, 3-13 terminal blocks, 2-6
Speed Loop Menu (3200), 3-31 terminal emulator, 3-55
speed menu, 3-4, 3-8 terminal protocol settings for the RS232 port, 3-55
speed menu feature, 3-4, 3-5 terminal strip for customer wiring, 2-4
speed menus, 3-7 terminal strip for low voltage, 2-4
Speed Profile Menu (4000), 3-3, 3-15, 3-33 terminal strip for metering, 2-4
speed profiling, 3-3 thermal overload, 3-13
speed profiling control, 3-35 thermal overload rollback, 3-13
using, 3-35 thermally hot components, ix
Speed Ramp Setup Menu (2260), 3-15, 3-21, 3-23 toggling power to the drive, 3-9
speed range, 1-5 torque and velocity loop gains, 3-15
Speed Setpoint Menu (4240), 3-33 torque pulsations (VFD-induced), 1-2
Speed Setpoint Menu (4240), 3-16, 3-39 Torque Reference Menu (2210), 3-21
speed setting total harmonic distortion of the source current, 1-1
source in auto mode, 3-3 transformer, 2-4, 2-10, 2-12, 2-17
Speed Setup Menu (2060), 3-11, 3-15, 3-21, 3-22 isolated secondaries, 2-17
Spinning Load Menu (2420), 3-25 sizing and CFM/BTU effects, 2-10
Spinning Load Menu (2420), 3-15, 3-21 transformer cabinet, 1-3
spinning load restart, 1-4 transformer section, 2-3

major components, 2-4 changing, 3-7

transformer size, 2-7 changing, 3-10
transformer T1, 2-18 , 3-9
transmit data, 3-55 sources for manual modes, 3-3
transparent cell bypass, 1-4 velocity demand field, 3-8
transporting precautions, ix version number, 3-10
trip-free operation, 1-4 version screen, 3-10
troubleshooting, ix viewing parameters, 3-1
qualified individuals, ix VLTS, 3-10, 3-11
voltage attenuator, 2-17
voltage clamps, 2-18
—U— voltage divider, 2-18
under voltage rollback, 3-13 voltage harmonic distortion, 1-1
underscore, 3-9 voltage regulation
undervoltage ride-through, 1-4 improved, 1-1
up and down arrow keys, 3-6, 3-9 voltage stress, 2-18
scrolling through parameter lists, 3-15
up arrow key, 3-7, 3-8, 3-10, 3-11 —W—
up/down arrow keys, 3-12
upload files, 3-55 warnings, ix
, 3-35 wave form of output current, 1-2
wave forms
distortion comparisons, 1-1
—V— weight of lineup, 2-12
values beyond the range of the system, entering, 3-12, 3-13 weight specifications, 2-10
variable, 3-11
variable displays, 3-11 —Z—
variable pick list for Compare Setup Submenus (4810-
4960), 3-41 zero security level, 3-10
various speed, 3-15 zeroes
vector control, 3-20 padding during parameter editing, 3-6
velocity and torque loop gains, 3-15
velocity demand, 3-4, 3-7, 3-8, 3-9, 3-10, 3-11

∇ ∇ ∇

Perfect Harmony GENIII/e User’s Manual NOTES
NOTES

NOTES Perfect Harmony GENIII/e User’s Manual

Perfect Harmony GENIII/e User’s Manual NOTES

NOTES Perfect Harmony GENIII/e User’s Manual

Perfect Harmony GENIII/e User’s Manual READERS’ COMMENTS FORM



READERS’ COMMENTS FORM Perfect Harmony GENIII/e User’s Manual
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Sales Order Number (SO #) (see system door
or system panel)
Start-up Date
For additional information by phone, please complete the table above and check the appropriate items
below:
Extended Warranty
In-house Training at ASI Robicon
Spare Parts Kits.
Return this information to ASIRobicon at the address below, e-mail it to support@us.asirobicon.com, fax
it to (724) 339-9562, or call the Technical Support Department at (724) 339-9501. Please visit our web
site at www.robicon.com.
ASIRobicon
USA

GENIV
INSTALLATION,
COMMISSIONING,
AND MAINTENANCE
MANUAL

Version 1.0
March 2007

Large Drives A

Web: www.siemens.com Customer Support E-mail: customerservice@siemens.com
For the support representative nearest you, please call Siemens main office at 724.339.9500.
Version History
Version 1.0 (original) March 2007
© 2007 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of s LD A
GenIV Installation, Commissioning, and Maintenance Manual Table of Contents
Table of Contents
Safety Precautions and Warnings...................................................................................iii
About This Manual ........................................................................................................... v
Separation of Manuals............................................................................................. v
Reference Tools....................................................................................................... v
Conventions Used in this Manual .......................................................................... vi
Chapter 1: Introduction.................................................................................................1-1
Purpose .................................................................................................................1-1
Perfect Harmony...................................................................................................1-1
GenIV ...................................................................................................................1-2
Cabinet Details ..............................................................................................1-2
Maintenance Earthing Procedure .........................................................................1-2
Chapter 2: Installation...................................................................................................2-1
Installation ............................................................................................................2-1
Receiving..............................................................................................................2-1
Shipping Splits .....................................................................................................2-1
Off-loading ...........................................................................................................2-2
Weight Estimates..................................................................................................2-2
Handling ...............................................................................................................2-3
Strap and Cradle Method of Lifting ..............................................................2-4
Forklift Truck ...............................................................................................2-5
Pipe Rollers ..................................................................................................2-5
Roller Dollies ...............................................................................................2-6
Placement Location and Storage ..........................................................................2-6
Anchoring Cabinets to Floors and Walls .............................................................2-7
External Wiring ....................................................................................................2-7
Protection Circuits.........................................................................................2-9
I/O External Wiring.......................................................................................2-9
Chapter 3: Commissioning ............................................................................................3-1
Pre-Commissioning ..............................................................................................3-1
Description ....................................................................................................3-1
Process...........................................................................................................3-1
Start Up (Commissioning)....................................................................................3-3
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Table of Contents GenIV Installation, Commissioning, and Maintenance Manual
Nomenclature ID .......................................................................................... 3-4

Chapter 4: Maintenance................................................................................................ 4-1
General Maintenance ........................................................................................... 4-1
Six Month Inspection........................................................................................... 4-1
Replacement of Parts ........................................................................................... 4-4
Spare Parts List ............................................................................................. 4-4
Basic Rules for Repairing Harmony Cells........................................................... 4-6
How to Remove Harmony Power Cells........................................................ 4-7
How to Return the Power Cell to Siemens ................................................... 4-9
How to Install Harmony Power Cells........................................................... 4-9
General Repair Hints and Procedures ................................................................ 4-11
NOTES ........................................................................................................................... N-1
Reader Comments Form .............................................................................................. R-1
Startup/Warranty Registration
and Service Solutions.................................................................................................. W-1
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ii 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Safety Precautions and Warnings
Safety Precautions and Warnings

The GenIV is designed with considerable thought to personal safety. However, as with any piece of high power
equipment, there are numerous internal connections that present potentially lethal voltages. In addition, some internal
components are thermally hot to the touch. Follow the warnings below when working in or near the GenIV System.

• Always follow the proper lock-out/tag-out procedures before beginning any maintenance or trouble-
shooting work on the drive.
• Always follow standard safety precautions and local codes during installation of external wiring. Pro-
tective separation must be kept between extra low voltage (ELV) wiring and any other wiring as spec-
ified in IEC61800-5-1.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses. Also,
always work with another person present.
• Always use extreme caution when handling or measuring components that are inside the enclosure. Be
careful to prevent meter leads from shorting together or from touching other terminals.
• Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements
(that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the
instrument).
• Never assume that switching off the input disconnect will remove all voltage from internal compo-
nents. Voltage is still present on the terminals of the input disconnect. Also, there may be voltages
present that are applied from other external sources.
• Never touch anything within the GenIV cabinets until verifying that it is neither thermally hot nor
electrically alive.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points
beneath the shields.
• Never run the drive with cabinet doors open. The only exception is the control cabinet which contains
extra low voltages (ELV).
• Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the GenIV system.
• Never connect or disconnect any meters, wiring, or printed circuit boards while the drive is energized.
• Never defeat the instrument’s grounding.
• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A qualified
individual is “one familiar with the construction and operation of the equipment and the hazards
involved.”
• Hazardous voltages may still exist within the GenIV cabinets even when the disconnect switch is
open (off) and the supply power is shut off.
• When a system is configured with drive bypass switchgear (e.g., contactors between line and motor,
and drive and motor), these switches should be interlocked so that the line voltage is never applied to
the drive output if the medium input voltage is removed from the drive.
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19001851: Version 1.0 iii
Safety Precautions and Warnings GenIV Installation, Commissioning, and Maintenance Manual
Warning!
• Always ensure the use of an even and flat truck bed to transport the GenIV drive system. Before
unloading, be sure that the concrete pad is level for storage and permanent positioning.
severe system overheating and/or damage.
• Never store flammable material in, on, or near the drive enclosure. This includes

• Always be aware of electrostatic discharge (ESD) when working near or touching components inside
the GenIV cabinet. The printed circuit boards contain components that are sensitive to static electric-
ity. Handling and servicing of components that are sensitive to ESD should be done only by qualified
personnel and only after reading and understanding proper ESD techniques. The following ESD
guidelines should be followed. Following these rules can greatly reduce the possibility of ESD dam-
age to PC board components.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style plunger
or copper braid when desoldering.
• Make certain that anyone handling the GenIV printed circuit boards is wearing a properly grounded
static strap. The wrist strap should be connected to ground through a 1 megohm resistor. Grounding
kits are available commercially through most electronic wholesalers.
• Static charge buildup can be removed from a conductive object by touching the object to a properly
grounded piece of metal.
• Do not slide printed circuit boards across any surface (e.g., a table or work bench). If possible, per-
form PCB maintenance at a workstation that has a conductive covering that is grounded through a 1
megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is
an excellent substitute.
• Avoid plastic, Styrofoam™, vinyl and other non-conductive materials. They are excellent static
generators and do not give up their charge easily.
• When returning components to Siemens LD A, always use static-safe packing. This limits any further
component damage due to ESD.
Additional safety precautions and warnings appear throughout this manual. These important messages should be
followed to reduce the risk of personal injury or equipment damage.
∇ ∇ ∇
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iv 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual About This Manual
About This Manual

This manual is one component of a series of manuals intended for use with the Robicon Perfect Harmony series of
Medium Voltage (MV) Pulse Width Modulated (PWM) Variable Frequency Drives (VFD). Each part in this series is
for use by individuals having unique job functions and qualifications. The manuals in this series are listed below:
• The GenIV Product User Manual (19001591)
• GenIV Installation, Commissioning, and Maintenance Manual (19001851)
• NXG ToolSuite Software User Manual (902291)
• NXG Communications Manual (902399)
• NXG Control Manual (19001588)
The GenIV Product User Manual (19001591) defines the configuration and capabilities of the Perfect Harmony
family of Medium Voltage Variable Frequency Drives and specifically addresses the GenIV configuration.
The GenIV Installation, Commissioning, and Maintenance Manual (19001851) provides a detailed description of
how the system is transported, installed, and maintained at the customer’s site.
The NXG ToolSuite Software User Manual (902291) provides a detailed description of ToolSuite, a PC-based
application that integrates various software tools used for NXG-based Drives. The NXG ToolSuite is a high-level
GUI that runs on a PC that is equipped with the Microsoft Windows operating system. The NXG control and the PC
running the NXG ToolSuite communicate using Ethernet and TCP/IP protocol.
The NXG Communications Manual (902399) describes the NXG control communication board, which enables
network communication via a variety of protocols and enables modem connection.
The NXG Control Manual (19001588) describes the NXG control system. The Harmony family of drives is a
collection of MV drives with different power topologies and cooling methods. The unifying factor with the drives is
the NXG control system - a second generation control for the Harmony line.
All manuals contain a readers’ comments form. Please complete these forms and return them to us. Monitoring your
feedback allows us to continue to exceed your expectations and provide complete, effective, easy-to-use product
documentation.
Reference Tools
Many steps have been taken to promote the use of this manual as a reference tool. Reference tools include the
following:
• A thorough table of contents for locating particular sections or subsections
• Chapter number thumb nails in the outer margins for easy location of chapters
• Special text styles are applied to easily differentiate between chapters, sections, subsections, regular text,
parameter names, software flags and variables, and test points
• A comprehensive index
If you have any comments or suggestions to improve the organization or increase the usability of this manual, please
complete the Readers’ Comments Form located at the end of this manual and return it to Siemens LD A Document
Control.
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19001851: Version 1.0 v
About This Manual GenIV Installation, Commissioning, and Maintenance Manual

The following conventions are used throughout this manual:
• The terms “Perfect Harmony,” “VFD,” “variable frequency drive,” and “drive” are used interchangeably
* Note: Hand icons in the left margin alert readers to important operational or application information that
may have special significance. The associated text is enclosed in a border for high visibility.
Attention! Attention icons in the left margin alert readers to important safety and operational
precautions. These notes warn readers of potential problems that could cause equipment damage or
personal injury. The associated text is enclosed in a border for high visibility.
Caution - Electrical Hazard! Electrical hazard icons in the outer margins alert readers to important
safety and operational precautions. These notes warn readers of dangerous voltages, potential safety
hazards, or shock risks that could be life threatening. The associated text is enclosed in a border for high
visibility.
ESD Warning! These icons in the left margin alert readers to static sensitive devices. Proper
electrostatic discharge precautions should be taken before proceeding or handling the equipment.
• Chapter numbers are highlighted in the outer margins to facilitate referencing (see margin)
∇ ∇ ∇
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vi 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Introduction
CHAPTER 1
1 Introduction
The Robicon Perfect Harmony series of Medium Voltage (MV) Pulse Width Modulated (PWM), Variable Frequency
Motor Drives (VFD) are designed and manufactured by Siemens LD A, New Kensington, PA, USA with additional
manufacturing facilities in Europe, Asia, and South America. The Harmony VFD is intended for use with standard
medium-voltage three-phase AC induction, synchronous, wound rotor, permanent magnet, or super conducting
motors. When any of these types of motor is connected to a utility supply at a fixed frequency (i.e., 60 or 50 Hz), the
motor runs at a single speed. The Harmony series of drives allows variable speed motor operation without sacrificing
any of the desirable properties of the motor.
1.1 Purpose
This manual defines the commissioning and maintenance of the Perfect Harmony family of Medium Voltage
Variable Frequency Drives and specifically addresses the GenIV configuration. Detailed descriptions of the common
features of the Harmony drive family are defined in the following manuals:
Companion Manuals:
• GenIV Product User Manual (19001591)
1.2 Perfect Harmony

The Perfect Harmony VFD is based on a patented (U.S. patent #5,625,545) multi-level output topology. Medium
voltage levels are obtained by adding together the outputs of multiple low-voltage power cells. The low-voltage
power cells are simplified variations of standard PWM motor drives for low-voltage service, which have been built in
high volume for many years.
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Introduction GenIV Installation, Commissioning, and Maintenance Manual
1.3 GenIV
1 Refer to companion manual GenIV Product User Manual (19001591), Chapters 3 and 4, for an overview of the
GenIV technology and specifications.
1.3.1 Cabinet Details

The GenIV core enclosure is Nema 1 Ventilated (IP 31 degree of protection) and is provided with top and bottom
cable access plates (see Figure 1-1). The doors are hinged and mechanical key interlock provisions are provided.
Figure 1-1: GenIV Enclosure (4160V Output, 200-1100 Hp)
1.4 Maintenance Earthing Procedure
Note: The Perfect Harmony is a modular system that can be marketed into highly integrated applications.
* Therefore, these instructions do not cover all variations of equipment types or installations. Only qualified
personnel should perform maintenance on these systems.
1. De-energize input voltage by opening incoming switchgear and locking to OPEN position with mechanical
interlock. Apply lock-out/tag-out principles as required by local code.
2. De-energize auxiliary control voltages and synchronous motor field/exciter controls.
3. Wait ten minutes to allow stored energy to dissipate from the Perfect Harmony drive.
4. Observe the cell control board voltage LEDs by removing the interlock key from the input switchgear and
opening the Perfect Harmony cell sections door(s).
5. The LEDs are an indication of stored energy within the power cell capacitors (see Figure 1-2). If all cell
LEDs are not lit, remove polyglass plates located behind the swing-out control box. Where available, use
ancillary AC voltage sensing devices to confirm the drive is de-energized.
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GenIV Installation, Commissioning, and Maintenance Manual Introduction
6. Apply GREEN/YELLOW insulated ground cables from L1/L2/L3 and T1/T2/T3 to protective earth, P.E.,
7.
with captive fasteners.
Perform maintenance as required.
1
8. Remove GREEN/YELLOW insulated ground cables from L1/L2/L3 and T1/T2/T3 to protective earth, P.E.
9. Close Perfect Harmony doors in reverse sequence, and replace interlock key into input switchgear.
OOOOOO
Fiber DC Bus Voltage Indicator

Q4
Q3
Q2
Q1
FAULT
LINK ON
Optic (>50VDC)
Figure 1-2: Indicators and Labels
Warning! The power cells include discharge resistors to dissipate stored energy after the input voltage is
removed. The power cell DC bus voltage decays to less than 50 VDC in less than 5 minutes.
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Introduction GenIV Installation, Commissioning, and Maintenance Manual
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GenIV Installation, Commissioning, and Maintenance Manual Installation
CHAPTER
2 Installation
2
Important!
Before installing the Perfect Harmony drive, be sure to read and understand the Installation as described
in this chapter.
2.1 Installation
When installing Perfect Harmony drives, it is essential to understand the proper techniques associated with the
following procedures:
• Receiving
• Shipping splits
• Off-loading
• Weight estimates
• Handling
• Placement and storage
• Anchoring
• Reconnecting wiring
Each of these procedures is discussed in the sections and subsections that follow.
2.2 Receiving
The proper receiving procedure consists of the following steps:
• Verify that the proper items have been shipped.
• Inspect all items for damage that may have occurred during shipping.
• File a claim with the shipping carrier if any damage is present.
2.3 Shipping Splits

The cabinet configurations of the GenIV Perfect Harmony drives vary, depending upon the project requirements for
input and output voltage, and output power and amperage. The GenIV, in its core configuration, consists of a single
cabinet with multiple sections. The GenIV system is shipped in two parts:
• The blower assembly, which is shipped on a pallet, includes eyebolts for lifting and installation.
• The GenIV drive (refer to Figure 1-1)
* Note: Cells may be shipped separately in some instances.
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Installation GenIV Installation, Commissioning, and Maintenance Manual
2.4 Off-loading
Due to the size and weight of Perfect Harmony components, it is important to carefully plan all handling operations.
Off-loading from the truck is often the most critical operation because of the limited access. Advance planning and
coordination among the manufacturer, the carrier, the installation contractor, and the owner are vital. Prior
2 considerations should be made for ceiling heights, door widths, and ease of installation.
Danger!
Never use eye bolts for lifting any of the Perfect Harmony cabinets. Eye bolts are used at the
beginning of the manufacturing process when the cabinets weigh much less. Drives may be shipped
with the eye bolts removed from certain cabinets.
Prior to moving the unit, ensure that:

• The unit doors are closed
• The unit is in an upright position
• The unit is stabilized to prevent tilting
• Each cell’s locking latches are tie-wrapped in an upright position
2.5 Weight Estimates

Because the Perfect Harmony drive system is a customizable system, exact weights of systems will vary based on the
ratings of the drive and included options. The approximate weights of the GenIV core configuration are:
Table 2-1: Weight Estimates
Hp1 Weight (lbs)2

200 4352
300 4890
400 5438
450 5674
500 5900
600 6374
700 6760
800 7108
900 7467
1000 7739
1100 7973
1. Drive Rated Hp
2. For redundant blower, add 160 lbs.
For cell bypass, add 75 lbs.
* Note: For customized drives that include switchgear or transition cabinets, refer to the project drawings
for weight estimates.
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2.6 Handling
There are four possible methods of handling cabinets:
• Strap and Cradle
• Fork Lift Truck Lifting 2
• Pipe Rollers
• Roller Dollies
These methods are summarized in this section.
Important!
• Though lifting options are presented, the final lifting is the liability of those lifting the struc-
tures. Care and attention should be used while lifting to monitor the condition of the lift at all
times. Low lifting heights and slow movements should be made where possible.
• The actual lifting process must be monitored continuously. Also, the equipment used must be
sized appropriately according to forces to which they will be subjected. This analysis has
been prepared without knowing any of the equipment available on site, so tailored lifting
descriptions cannot be made.
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19001851: Version 1.0 2-3
2.6.1 Strap and Cradle Method of Lifting

Fabric slings may be used to lift the cabinets, which is the strap and cradle method. The length and strength of the
slings are very important. In order to prevent buckling of the drive cabinets, the slings must be long enough for the
crane hook to be at least 4 feet above the top of the enclosure, as shown in Figure 2-1. If this minimum distance
2 cannot be maintained, spreader bars of appropriate strength must be used. The strength of the slings must be adequate
for the weight given in the drawings.
Figure 2-1: Strap and Cradle Method of Lifting
Lifting Unit Containing Louvers

When lifting a unit that contains louvers, such as shown in the following photo, the louvers must be protected by
placing blocks of wood between the unit and the straps. Two 2-by-4 pieces of wood, encased in bubble wrap, should
be wedged between the bottom of the unit and the straps, and two 2-by-4 pieces of wood, encased in bubble wrap,
should be placed at the top of the unit, above the louvers, between the unit and the straps.
Wood Block Placement
Figure 2-2: Lifting Unit containing Louvers
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2-4 19001851: Version 1.0
2.6.2 Forklift Truck

A properly sized forklift truck may be used to lift the drive. These enclosures have heavy duty base structures that
will accept forklift tines. Be careful that the forklift does not damage the surface of the enclosure. It is a good idea to
place a wooden stop block in the corner of the tines as shown in Figure 2-3.
2
Side
Side
Wooden
Block C.G.
Fork Fork
C.G.
Truck Truck
Figure 2-3: Proper Handling of GenIV Enclosure Using a Fork Lift Truck
(Rear Insertion is Recommended)
2.6.3 Pipe Rollers

The use of pipe rollers is the least preferred method of handling. However, it is possible to set the enclosure on many
parallel pipe sections placed on the floor and move it by rolling. The pipes must be no less than 2” in diameter and at
least 6” longer than the width of the cabinet (3” on each side). The pipes must be spaced no more than 18” apart.
Figure 2-4: Proper Use of Pipe Rollers in Handling Perfect Harmony Cabinets
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19001851: Version 1.0 2-5
2.6.4 Roller Dollies

If roller dollies are used, they should be placed under the front and rear channels of the base, just outside the fork
tubes (as shown in Figure 2-5).
Figure 2-5: Proper Placement of Roller Dollies
2.7 Placement Location and Storage
Note:
• Intake cooling air enters the drive through front-mounted ventilation grilles, and is
* exhausted through the cage mounted on top of the enclosure. Do not place the drive
where the intake/exhaust paths could be blocked.
• Place the drive in a location where the removable access plates interface adequately with
the cable termination to the drive.
After final inspection, move the drive promptly to its final position or dry indoor storage area. When choosing the
location for the Perfect Harmony drive, be sure the area is clean, flat, dry, and the front of the drive is easily
accessible even when the drive doors are open. Shims may be necessary to level the cabinet on uneven floors.
Avoid extreme temperatures, such as below 0°C or above 55°C; avoid conditions as noted on the shipping labels. If it
is necessary to temporarily store the drive in an outdoor area, heaters may be placed in the drive and operated to
prevent moisture accumulation. A protective cover such as plastic or a tarp should be placed over the drive to reduce
any problems due to the outside elements. This is especially important if the storage is for more than a few days.
Warning!
If the mounting surface is not flat, the metal cabinets of the Perfect Harmony drive may buckle,
causing the cabinet doors to be misaligned and/or not open and close properly. Shims may be
necessary to level the drive for proper door operation.
Warning!
If a drive is de-energized (or in storage) for 6 months or more, the Harmony cell electrolytic
capacitors will need to be reformed. Contact Siemens about reforming procedures for the GenIV.
Failure to follow reforming procedures and guidelines may result in cell or system damage.
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2-6 19001851: Version 1.0
2.8 Anchoring Cabinets to Floors and Walls

Holes for anchor bolts are located on the base mounting channel typically 1” from front and back edges, and 4” from
the sides. Refer to supplied drawings for mounting details.
When anchoring the cabinets to the floor, we recommend that the installer use cemented J-bars on all corners. Holes
in the base of the drive cabinets are 0.81” in diameter and easily accept 0.5” threaded J-bars. If the drive is mounted 2
against a wall, top angles may be used to secure the drive to the back wall in lieu of the rear J-bar connections to the
floor. Refer to Figure 2-6 for an overview. Exact dimensions are given in the drawings supplied with the drive.
* Note: Refer to system drawings for the type of base structure used with the cabinet as well as the exact
connection locations.
0.81” diam. Wall

hole Side
Concrete
Concrete
Figure 2-6: Proper Anchoring Technique for Cabinets
* Note: Given the location of the right blower assembly, wall anchoring may require enclosure drilling
modifications.
2.9 External Wiring

The transformer has a set of +5%, nominal, -5% voltage taps for compensating the primary voltage source. The
GenIV VFD (Variable Frequency Drive) is shipped with the nominal taps connected. This means that the VFD
secondary cell voltages are at the nominal 750 VAC (for example) for rated primary input voltage. Customer-
supplied medium voltage cables enter an access plate in the top (input/output section) or bottom (transformer
section). See Figure 1-1 or project drawings for exact locations.
Customer-supplied low-voltage cables (#8 - #22 AWG) for the control enter an access plate in the top (input/output
section) or bottom (transformer section). See Figure 1-1 or project drawings for exact locations.
Danger!
Ensure that the entire system is earth grounded at its P.E. ground point.
Attention!
The transformer primary winding neutral point is designed to operate floating (ungrounded). Do not
bond the transformer primary winding neutral point to ground. Failure to adhere to this instruction will
cause large, unbalanced currents to circulate in the ground/neutral path of the drive’s input source
system during drive energization.
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19001851: Version 1.0 2-7
* Note: Torque specifications for the Perfect Harmony drive are listed in Table 2-2.
Note: Conductor sizes for input medium voltage termination may vary based on the size of the drive and
2 the dynamics of the system. The customized system schematic (included with your drive) shows the
* conductor size used on the main transformer taps. The size of the input conductors will usually match or
exceed this size. However, be sure to size the input conductors appropriately for your particular
application, taking into account the length of the input power feed and your local standards and electrical
codes. Labels are applied near the connects recommending the use of 75 °C conductors.
Attention!
To maintain EMC compliance, input medium voltage wiring must be installed in metallic electrical
conduit and routed through the approved access plates.
The input and output medium voltage terminals (L1, L2, L3 and T1, T2, T3) are offset from one another and have two
NEMA one-hole pattern configurations (vertical and horizontal) to facilitate top or bottom cable termination. MV
terminations are provided for 3/8” fasteners.
* Note: The GenIV design is best accommodated for single-conductor single-core medium voltage
cables. Three-conductor single-core cables are not recommended and may require special attention.
* Note: Customer should not terminate MV cables at drive output until start of commissioning cycle.
Wire bending space has been allocated for 150 mm2 (350 mcm) cable (one per terminal) for the MV input/output
connections from the top entry.
If the output cable length approaches 7500 feet in length, the drive may require an output filter as described in
Chapter 4 of the GenIV Product User Manual (19001591). When output filters are required, the drive voltage is
limited as described in Chapter 4 of the GenIV Product User Manual (19001591).
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2-8 19001851: Version 1.0
Table 2-2: Torque Specifications for the Perfect Harmony
Standard Torque Chart

Fastener Size Tightening
English (Metric) Torque
2-56 (M2) 3.0 in-lb 2
4-40 (M3) 6.0 in-lb
6-32 (M3.5) 12.0 in-lb
8-32 (M4) 22.0 in-lb
10-32 (M5) 36.0 in-lb
1/4-20 (M6) 70.0 in-lb
1/4-20 (M6) elec 100.0 in-lb
1/4-28 70.0 in-lb
5/16-18 155.0 in-lb
(M8) 80.0 in-lb
3/8-16, 3/8-24 275.0 in-lb
(M10) 180.0 in-lb
1/2-13 (M12) 672.0 in-lb
5/8-11 112.0 ft-lb
3/4-10 198.0 ft-lb
1 500.0 ft-lb
2.9.1 Protection Circuits

The input protection and E-Stop circuits described in the GenIV Product User Manual (19001591), Section 4.3.4,
should be integrated to the external wire scheme prior to Siemens start-up (commissioning).
2.9.2 I/O External Wiring

Refer to the project drawing C set for the customer I/O connection interface (#12 - #22 AWG). All hardwired I/O
cabling should be routed and terminated prior to commissioning.
Caution - Electrical Hazard!
Standard safety precautions and local codes must be followed during installation of external wiring.
Protection separation must be kept between extra low voltage (ELV) wiring and any other wiring as
specified in the CE safety standard IEC61800-5-1.
∇ ∇ ∇
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GenIV Installation, Commissioning, and Maintenance Manual Commissioning
CHAPTER
3 Commissioning
3.1 Pre-Commissioning
3.1.1 Description 3
Instructions for receiving, off-loading, handling, placement, anchoring, and external wiring, are defined by this
manual. Customer or Customer’s Agent is responsible for these tasks.
After the location of the drive has been determined and the drive is in the installed location (including bolting and
anchoring of the drive), Siemens can arrive at the site to commence the pre-commissioning process.
3.1.2 Process
1. Obtain site equipment information and verify it matches factory information.
2. Install lockouts and de-energize equipment (see Section 1.4).
3. Torque check the cabinet connections. Inspect the entire drive for shipping and/or installation damage, and
verify each cell is properly engaged to its rear bus connectors.
4. Ensure that the enclosure is earth grounded at the P.E. point of the drive. Confirm what type of cable the
customer is using for the motor connections. If it is a shielded cable, only one end of the shield can be
grounded. It must be grounded at the drive. Inspect MV input cabling and hardwired I/O control wiring.
5. Check and note if the drive integral isolation transformer neutral is grounded. Is transformer neutral
grounded? Note “yes” or “no” on form. Ohm check all secondary transformer connections to the chassis
cabinet to ensure no damage has occurred during shipment.
* Note: Siemens strongly recommends no ground on transformer neutral conductor. However, the
transformer iron core is routinely chassis-grounded to the enclosure by Siemens.
6. Inspect customer load.

7. Inspect internal routing of the fiber optic connections and their integrity.
8. Obtain permission to energize.
9. At this time, it is necessary to have an auxiliary control voltage source connected per the VFD schematics to
allow the pre-commissioning process to continue. A temporary source can be utilized.
10. Remove lockouts and energize LV controls.
11. Power is required to test the cooling system and control. Energize auxiliary 120 VAC and 3-phase power to
the blowers to verify the rotation and phase sequencing of the cooling fans.
12. Confirm input and output voltage attenuator resistors and output Hall Effect current sensor burden resistors
according to project drawings.
Note:
• The motor leads should not be connected to the drive when performing the following OLTM
* check.
• The input MV switchgear should be locked and tagged out prior to OLTM checks in the next
step.
13. In OLTM, backfeed the drive with a variac connected to one of the Harmony transformer secondary
windings. Verify all cell and the drive input line voltages are correct.
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19001851: Version 1.0 3-1
Commissioning GenIV Installation, Commissioning, and Maintenance Manual
14. If the VFD has cell bypass, verify contactor operation by removing cell fiber optics at the NXG DCR.
15. De-energize and apply lockouts until start up and commissioning is performed.
16. At the end of the pre-commissioning, a copy of the pre-commissioning report should be left with the
responsible site manager.
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3-2 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Commissioning
3.2 Start Up (Commissioning)

1. Initial inspection:
o Obtain phase sequence of motor
o Remove lockouts
o Verify customer has not operated, altered, or energized equipment since pre-commissioning was done
by Siemens
o Verify hardwired I/O per system drawings
3
o Ensure blower is running prior to applying input MV
2. Energize MV input with motor disconnected. Leave the power on the drive for at least 1 hour; if possible
leave the power on over night.
3. Verify control is working in OLTM as per Table 6-2 in the NXG Control Manual (19001588).
4. Where applicable, verify cell bypass on each cell:
o Remove fiber optic link. Contactor will close.
o Very all cells bypass correctly.
5. De-energize and apply lockouts. See Section 1.4.
6. Connect motor to VFD output (T1, T2, T3) with proper phase sequence.
7. Remove lockouts and energize VFD.
8. Bump motor and inspect proper rotor rotation.
9. Run motor uncoupled from load, and verify speed ranges and feedbacks per Section 6.3, Table 6-3, of the
NXG Control Manual (19001588).
10. Couple motor and operate according to Section 6.4, Table 6-4, of the NXG Control Manual (19001588).
* Note: If motor parameters are loaded in parameter list, do not use auto-tune feature. Otherwise,
reference Section 6.6.1 of the NXG Control Manual (19001588).
11. Complete speed loop and spinning load tuning. See Section 6.6.2 of the NXG Control Manual (19001588).
12. Verify DCS address across serial link, and verify DCS operation where applicable.
13. Establish application manual parameters with customer. See Section 6.7 of the NXG Control Manual
(19001588).
14. Once system has reached the process design operating condition, utilize Siemens ToolSuite to record the
following VFD data:
o Plant Load At Test Point
o Voltage VFD Input
o Current VFD Input
o Power Factor VFD Input
o Voltage VFD Output
o Current VFD Output
o Speed Demand
o Motor Speed (RPM)
o VFD Efficiency
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19001851: Version 1.0 3-3
Commissioning GenIV Installation, Commissioning, and Maintenance Manual
* Note: If plant is operated across a load range, take load data at incremental load points to obtain a profile
of the VFD operation as part of the process.
15. Complete the cell identification page (Table 3-1) before leaving site.
16. Test spares where applicable
3 17. Review six-month maintenance procedures with end user, as described in Section 4.2.
18. The commissioning process is now complete. Acquiring customer's signature provides acceptance of the
Siemens equipment.
o Customer's signature (required)
o Print name
o Title
o Company
o Phone number
o E-mail address
* Note: For output filters, encoders, synchronous motors, synchronous transfer applications, and start-up
criteria, refer to Chapter 6 of the NXG Control Manual (19001588).
3.2.1 Nomenclature ID
Please record the following information at the end of the commissioning process.
Table 3-1: Customer Drive Nomenclature ID
A3 A2 A1
Serial Number Serial Number Serial Number
Goes Here Goes Here Goes Here
______________ ______________ ______________
B3 B2 B1
______________ _____________ ______________
C3 C2 C1
______________ ______________ ______________
∇ ∇ ∇
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3-4 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Maintenance
CHAPTER
4 Maintenance
4.1 General Maintenance
Siemens has designed, built and tested the Perfect Harmony variable speed drive for long, trouble-free service.
However, periodic maintenance is required to keep the drive working reliably, to minimize system down time, and to
maintain safety.
4
DANGER-ELECTRICAL HAZARD!
Always switch off the main input power to the equipment before attempting inspection or maintenance
procedure. See Section 1.4 of this manual.
Warning:
Only qualified service personnel should maintain Perfect Harmony equipment and systems.
4.2 Six Month Inspection

1. Check operation of fans in the blower assembly:
o While in operation, listen for audible noises that may indicate that impeller imbalance may be present.
o De-energize the MV input to the drive (see Section 1.4) and low voltage to the blower.
o Wipe off any accumulated dust.
o Verify mounting bolt torque (M10).
o Inspect electrical connections for stray wire strands or insulation failures.
o Check that the impeller rotates freely without obstruction.
o Record any ALARMS issued by the drive. If these alarms are persistent, a Siemens field service
engineer can analyze the blowers with OEM software.
2. Use touch-up paint as required on any rusty or exposed parts on the enclosure exterior.
3. For drive internal inspection, contact Siemens about a preventative maintenance service agreement.
4. Verify replacement part stock and contact Siemens for additional spares.
5. Replace door filters on the enclosure (reference Table 4-1 for P/Ns) as described next.
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19001851: Version 1.0 4-1
Maintenance GenIV Installation, Commissioning, and Maintenance Manual
The front view of the cell door filter during normal operation is as shown in the following photograph:
A. To remove the filter, lift up on the filter retainer until its bottom is free from the door:
B. Pull out the bottom of the filter retainer, which will release it from the door:
4-2
s 19001851: Version 1.0
C. Remove the filter and replace it with a spare.
* Note: If the filter is removed but not replaced, make sure to use the same orientation upon reinsertion.
DANGER-ELECTRICAL HAZARD!
The cell door includes partially expanded metal, which holds the filter captive and provides protection
against accidental contact with the electrical components.
D. Reverse Steps A and B to reinstall the filter retainer.
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19001851: Version 1.0 4-3
4.3 Replacement of Parts

Replacement of component parts may be the best method of troubleshooting when spare parts are available. When
any sub-assembly is to be replaced, always check that the part number of the new unit matches that of the old unit
(including the revision letter).
* Note: Companion manual NXG Control Manual (19001588) includes a Troubleshooting section in
Chapter 7.
• Failures traced to individual PC boards within the Control Cabinet are best serviced by replacement of the
entire board.
4 • Failures traced to individual power cells are best serviced by replacement of the entire cell.
Attention!
The disposal of any failed components (capacitors, etc.) must be done in accordance with local codes and
requirements.
4.3.1 Spare Parts List

The following spare parts list is shown for reference and is subject to change without notice. Always contact Siemens
about the latest information regarding spare parts.
* Note: For spare parts lists for customized drives, refer to the custom documentation package shipped
with the drive or call Siemens LD A Customer Service Department at (724) 339-9501. When calling for
spare parts information, please have your sales order number and drive part number readily available.
4-4
s 19001851: Version 1.0
Table 4-1: Spare Parts, 200 - 1100 Hp (4160V Output)
Item
Spare Part
Part Number
40A Cell 70A Cell 100A Cell 140A Cell

Power Cell*
10000424.040 10000424.070 10000424.100 10000424.140
1000V, 1A Fuse
Cell CCB Fuse
092604
Cell Input Fuses
Transformer Air
Refer to chart in Section 4.4
Door Filter
4
Filters 097565
Door Filter
Cell Air Filters
099615
SBC & Keypad System I/O Communications

BGA Modulator
Adapter Board Board
10000350.00
10000623.000 10000423.00 363818.00
NXG
I/O Breakout NXGII Power
Signal Control Board Keypad
Board Supply
10000403.01 460A68.23
10000126.00 14000461.00
8A, 600V AJT

Blower Fuses
089149
Secondary 6A, 600V
Control
081099
Transformer Fuse
Control Primary 3A, 600V Primary 3.5A, 600V

Transformer Fuse 080752 (480V) 089205 (400V)
Fiber Optic Link, 2.9M

Fiber Optic
10000614.00
EC Blower
Blower
098200 (EBM)
Bypass Contactor Fuse 2A 1200V PCA Bypass Control Power Supply

Cell Bypass
10000539.00 089592 363662.01 10000484.00
Devicenet
Profibus DP Modbus Ethernet Control Net
Profile12
Communications 252241.155 252241.157 252241.158
252241.156
Network
Modbus + Modbus
252241.159 252241.160
* Customer may request IGBTs, diode rectifiers, and Cell Control Boards rather than a complete spare cell. Contact
Siemens for further information regarding individual cell P/Ns.
* Note: Unless notified differently by Siemens, always replace components with the same P/N and revision
level.
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19001851: Version 1.0 4-5
4.4 Basic Rules for Repairing Harmony Cells

Cell failures or component failures should be reported to both the Quality Group and Product Development at
Siemens.
Always refer to the latest BOM and Assembly Drawings for approved component Part Numbers and procedures
when repairing any cell. Failure to use components other than those listed in the BOM may result in poor cell
performance or further failures.
Warning! It is imperative to follow these rules for repairing Harmony Cells.
4 1. Never parallel or series non-identical manufactures part numbers (or Siemens LD A MDIT Numbers) for
IGBTs or Electrolytic Capacitors in the same power cell.
2. Never substitute a non-specified CCB/GCB/SMPS board (or any specified component or subassembly)
without formal approval from the Product Development Group.
3. Never change an input power fuse(s) without first determining the root cause for the fuse operation. Fuses
are not designed to protect components in the Power cell against overload. If a fuse(s) is open, there is
usually a component failure within the cell. Re-application of rated power may cause catastrophic damage.
Always inspect the related transformer winding and cell before replacing fuses.
Note: In cases where the latest BOM specifies obsolete components and the substitution of an
* alternative is not available, contact the Siemens LD A Product Development Group for assistance. In
such events, Product Development may suggest alternative components, only after sufficient technical
review and verification.
The following fuses are approved for GenIV use:
Power Cell Cell Amps
10000424. 040 070 100 140

P/N099725 P/N 099726 P/N 099727 P/N 099728
Bussman 170M4810 170M4812 170M4813 170M4814
1000V 100A 1000V 160A 1000V 200A 1000V 250A
P/N 099717
P/N 099718 P/N 099719 P/N 099720
1021CPURB27.60Q100D
Ferraz 1000C4URC160LD80 1000C4URC200LD80 1000C4URC250LD80
80
1000V 160A 1000V 200A 1000V 250A
1000V 100A
P/N 099721 P/N 099722 P/N 099723 P/N 099724

Siba 2056020.125 2056020.200 2056020.225 2056020.280
1000V 125A 1000V 200A 1000V 225A 1000V 280A
4-6
s 19001851: Version 1.0
4.4.1 How to Remove Harmony Power Cells

To Remove the Power Cell:
1. Power down the GenIV System, following the standard shut-down procedure shown in Section 1.4.
2. Open the doors to access the power cells.
3. Make sure that the DC bus LED (labeled “Charge LED” - see Section 1.4), located on the Cell Control
Board (CCB), is off. Then wait an extra minute before proceeding.
4. Remove the fiber optic from the CCB as shown below.
5. Grab the two locking latches and pull down to a horizontal position to release the power cell.
* Note: When the latches are pulled down to a horizontal position, the power cell will move forward
approximately 1/2 inch.
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19001851: Version 1.0 4-7
6. Still holding onto the latches, pull the power cell approximately one-third of the way out of its slot as shown
next. Do not lift up or pull down on the cell, but rather let it slide on the polyethylene-coated mounting rails:
7. Using the Siemens cell lifter (Siemens P/N 163496.08), slide the cell completely out of its slot and onto the
lifter, as shown below:
* Note: It is good practice to not run the system with one of the cells removed.
4-8
s 19001851: Version 1.0
4.4.2 How to Return the Power Cell to Siemens

To ship the cell back to the factory, it should be packaged as shown below:
4
Fill bottom of box with Place cell into box on top of Fill sides and top with Instapak
Instapak sealed air foam in foam. Be sure that the sealed air foam packaging
bag packaging material. locking latches are pointed material. Before cooling, close
up. box lid to form top. Check for air
pockets and fill as needed.
Seal box and ship.
4.4.3 How to Install Harmony Power Cells

To Install the Power Cell:
1. Using the Siemens cell lifter (P/N 163496.08), line up the power cell with its slot.
2. Push the cell into its slot. Do not lift up on the cell, but instead let it slide in on the polyethylene-coated
mounting rails.
3. Make make sure that the cell latches are above the ledge of the cell rail, and align the locking latches with
the corresponding rail notches, as shown below:
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19001851: Version 1.0 4-9
4. Push up on the latches until they are vertical:
5. Reinstall the Fiber Optic:
4-10
s 19001851: Version 1.0
4.5 General Repair Hints and Procedures

1. Input fuse(s) or control fuse(s) opening is almost always an indication of component failure in a cell.
2. Damage to the cell chassis ground wire is always an indication of an insulation failure internal to the power
circuit or its components, or the result of arcing between the power circuit and chassis. Always perform the
appropriate HIPOT test or look for arc damage before re-using the subject cell.
3. An electrolytic capacitor failure that results in venting, bulging, or header expulsion, is usually caused by
sustained over-voltage of 15 to 20% above its operating voltage rating.
4. If one or more electrolytic capacitors have failed, but only in a particular parallel group, and there this no
indication of other component damage, look for a shorted or high leakage capacitor in the other parallel
groups. 4
5. If capacitor damage is apparent in all parallel groups and if there is damage to the IGBTs or CCB, the cell
was most likely exposed to over-voltage. Furthermore, failed input fuses may indicate that an over-voltage
was generated from the transformer secondary.
6. An IGBT failure is usually a result of an over-voltage because the cell has system level over-current
protection.
In non-catastrophic IGBT failures (those which do not result in case rupture), the root cause can often be
found by Product Development or the device manufacturer if the devices are returned for analysis. In most
of these cases, the GCG and CCB are left unaffected and can be presumed functional.
In catastrophic IGBT failures (those which result in case rupture), the root cause is more difficult to deter-
mine. Failures of this type usually result in collateral damage to adjacent IGBTs, especially those IGBTs in
the same pole (for instance Q1/Q2 or Q3/Q4). These failures almost always cause damage to any connected
GCB and CCB.
7. The following tests can be performed by qualified personnel to verify an IGBT’s condition after a cell
failure:
G-E Check
Short the collector to the emitter. Ohm check gate to emitter. Resistance should be 10M to infinite. A low
resistance indicates device destruction. Device must be replaced.
C-E Check
Short the gate to the emitter. Ohm check collector to emitter. Resistance should be 10M to infinite. A low
resistance indicates device destruction. Device must be replaced.
A-K Check
Use a diode checker to verify a small positive voltage drop (<1V) from emitter to collector (anode to cathode
of the FWD) and blocking from collector to emitter (cathode to anode of the FWD). If a short, or if >1V is
measured, the device must be replaced.
∇ ∇ ∇
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19001851: Version 1.0 4-11
4-12
s 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Index
Index
A Manuals v
About This Manual v Misalignment of cabinets 2-6
AC power 2-7 N
Access plate 2-7 Nomenclature ID 3-4
Anchoring Cabinets 2-7 O
B Off-loading 2-2
Blower inspection 4-1 P
C Parts 4-4
Carrier 2-1, 2-2 Pipe rollers 2-5
Companion Manuals 1-1 Placement 2-6
Compensating the primary voltage source 2-7 Pre-Commissioning 2-9
Control power 2-7 Primary voltage source 2-7
Conventions Used in this Manual vi Purpose 1-1
Customer Service Department 4-4 R
D Reader Comments Form R-1
Damage Receiving 2-1
from shipping 2-1 Reference Tools v
preventing 2-5 Remove Harmony Power Cells 4-7
Dimensions 2-7 Repair 4-11
E Repairing Harmony Cells 4-6
Electrostatic discharge iv Replacement of Parts 4-4
F Roller dollies 2-6
Fan Inspection 4-1 S
Filter replacement 4-1, 4-2, 4-3 Safety precautions and warnings iii, iv
Forklift Truck 2-5 Secondary cell voltages 2-7
G Shipping splits 2-1
General Maintenance 4-1 Six Month Inspection 4-1
Sling lifting 2-4
H
Storage 2-6
Hand tools 2-7
Strap and Cradle 2-4
Handling 2-3
Handling operations 2-2 T
Hanlin casters 2-6 Top angles 2-7
Torque Specifications 2-8
I
Torque specifications 2-9
Install Harmony Power Cells 4-9
Transformer 2-7
Installation 2-1
Transformer cabinet 2-4
Installation contractor 2-2
supporting 2-4
Installation practices 2-1
Introduction 1-1 U
Using any hand tools 2-7
J
J bars 2-7 V
Voltage taps 2-7
L
Lifting 2-4 W
Location 2-6 Warnings iii
Lock-out/tag-out Weight estimates 2-2
procedures iii Wooden stop block 2-5
M
Maintenance 4-1 ∇ ∇ ∇
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19001851: Version 1.0 I-1
Index GenIV Installation, Commissioning, and Maintenance Manual
s
I-2 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual NOTES
NOTES
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NOTES GenIV Installation, Commissioning, and Maintenance Manual
s
N-2 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual NOTES
s
19001851: Version 1.0 N-3
NOTES GenIV Installation, Commissioning, and Maintenance Manual
∇ ∇ ∇
s
N-4 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Reader Comments Form
Reader Comments Form

To provide quality documentation that meets the needs of its customers, Siemens LD A invites comments
and criticisms of this manual. Please complete the attached form and provide your comments on this
manual. After completing this form, please remove this page from the manual (or photocopy it) and either
mail, E-mail or fax it back to the Documentation Department at Siemens LD A. These are mechanisms
through which you can positively effect the documentation that you receive from Siemens. Thank you for
your feedback. It is always valued and appreciated.
Did you find the manual well organized? { Yes { No

Was the information presented clearly? { Yes { No
Was the manual sufficiently illustrated? { Yes { No
Did you find the material adequate? { Yes { No
Would you prefer a more technical or less technical approach? { More { Less
What improvements would you like to see? (Please be specific and cite examples, if possible.)
Did you find any technical inaccuracies or mistakes? If so, please indicate page number(s) and information
that needs to be corrected.
What feature of the manual did you find the most useful? The least useful?
s
19001851: Version 1.0 R-1
Reader Comments Form GenIV Installation, Commissioning, and Maintenance Manual
Additional Comments
Attention: Documentation Control

Siemens LD A
USA
Phone: (724) 339-9500 Fax: (724) 339-9562 E-mail: DocumentControl@siemens.com
∇ ∇ ∇
s
R-2 19001851: Version 1.0
GenIV Installation, Commissioning, and Maintenance Manual Startup/Warranty Registration and Service Solutions
and Service Solutions
To assure timely technical updates on your equipment, please complete and return this form. This information is to be
completed by the end user or equipment owner. For information on post sale service solutions, please check the
appropriate boxes below before returning this form to Siemens Energy & Automation,Inc.
Company Name
Contact Name
Company Address
Phone
Fax
E-mail
Part Number (P/N) (see system door or system panel)
system panel)
Start-up Date
• Extended Warranty
• Full Service Agreement
• Preventative Maintenance Agreement
• In-House Training at Siemens
• On-Site Training at your Location
• Spare Parts Kits
Return this information to Siemens at the address below, or fax it to (724) 339-9562, or call the Technical Support
Department at (724) 339-9501. Please visit our web site at www.siemens.com.
Attention: Customer Service Operations
Siemens LD A
USA
s
19001851: Version 1.0 W-1
Startup/Warranty Registration and Service Solutions GenIV Installation, Commissioning, and Maintenance Manual
s
W-2 19001851: Version 1.0
GENIV PRODUCT
USER MANUAL

Version 1.0
January 2007

Large Drives A

Web: www.siemens.com Customer Support E-mail: customerservice@siemens.com
For the support representative nearest you, please call Siemens main office at 724.339.9500.
Version History
Version 1.0 (original) January 2007
© 2007 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of s LD A
GenIV Product User Manual Table of Contents
Table of Contents
Safety Precautions and Warnings.................................................................................... v
About This Manual .........................................................................................................vii
Separation of Manuals...........................................................................................vii
Reference Tools.....................................................................................................vii
Conventions Used in this Manual ........................................................................viii
Chapter 1: Overview ......................................................................................................1-1
Purpose .................................................................................................................1-1
Introduction ..........................................................................................................1-1
Clean Power ..................................................................................................1-2
High Power Factor ........................................................................................1-3
Nearly Perfect Sinusoidal Output Voltages ..................................................1-4
Perfect Harmony Features ....................................................................................1-4
Harmony VFD Family Features....................................................................1-5
VFD Scalability.............................................................................................1-6
VFD Output Ratings .....................................................................................1-6
Rectifier Configuration .................................................................................1-7
Power Cell Bypass Option ............................................................................1-7
Transformer Winding Configuration ............................................................1-7
Control Overview..........................................................................................1-8
Applications..........................................................................................................1-8
Evolution ..............................................................................................................1-9
Intellectual Property .............................................................................................1-9
Chapter 2: Theory ..........................................................................................................2-1
Introduction ..........................................................................................................2-1
The Power Circuitry .............................................................................................2-1
The Control System..............................................................................................2-8
Chapter 3: GenIV Specifications ..................................................................................3-1
System Specifications...........................................................................................3-1
Power Cell Specifications ....................................................................................3-2
Chapter 4: Product Description....................................................................................4-1
Drive Family Description.....................................................................................4-1
Cabinet Outlines ...................................................................................................4-2
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19001591: Version 1.0 i
Table of Contents GenIV Product User Manual
9 cell, 4160V Output, 200-1100 Hp ............................................................. 4-3

Cabinet Details..................................................................................................... 4-6
Input/Output Section..................................................................................... 4-7
Transformer Section ................................................................................... 4-10
Cell Section................................................................................................. 4-12
Control Section ........................................................................................... 4-21
Control Wire Way Section.......................................................................... 4-28
Cooling ....................................................................................................... 4-29
Long Cable Filters ............................................................................................. 4-31
Reactors and Capacitors ............................................................................. 4-31
Synchronous Transfer Reactors ......................................................................... 4-32
Motor Compatibility .......................................................................................... 4-33
IEEE 519 Conformance ..................................................................................... 4-34
Ride Through ..................................................................................................... 4-35
Chapter 5: Application and Operation ........................................................................ 5-1
Signal Frame of Reference for Motor Control..................................................... 5-1
Frame of Reference....................................................................................... 5-1
Signal Polarities ............................................................................................ 5-2
The Control Modes .............................................................................................. 5-2
Open Loop Vector Control (OLVC)............................................................. 5-4
Open Loop Test Mode (OLTM) ................................................................... 5-4
Synchronous Motor Control (SMC) ............................................................. 5-5
Volts/Hertz Control (V/Hz) .......................................................................... 5-6
Closed Loop Control (CLVC or CSMC)...................................................... 5-6
Slip Compensation........................................................................................ 5-6
Frequency Regulator..................................................................................... 5-8
Torque Current Regulator............................................................................. 5-8
Magnetizing Current Regulator .................................................................... 5-8
Flux Regulator .............................................................................................. 5-8
Phase Lock Loop .......................................................................................... 5-8
High Performance Control................................................................................... 5-8
High Starting Torque .................................................................................... 5-8
Low Speed Operation ................................................................................. 5-10
System Program (SOP) ...................................................................................... 5-10
Command Generator.......................................................................................... 5-11
Raw Speed Reference ................................................................................. 5-11
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ii 19001591: Version 1.0
GenIV Product User Manual Table of Contents
Speed Profile............................................................................................... 5-12

Critical Speed Avoidance ........................................................................... 5-12
Polarity Control........................................................................................... 5-12
Speed Ramp ................................................................................................ 5-12
Speed Limit................................................................................................. 5-12
Energy Saver ...................................................................................................... 5-12
Drive Output Torque Limiting ........................................................................... 5-12
Torque/Regeneration Limit......................................................................... 5-13
Input Under-Voltage Rollback.................................................................... 5-13
Input Single-Phase Rollback....................................................................... 5-13
Transformer Thermal Rollback................................................................... 5-14
Field-Weakening Limit............................................................................... 5-14
Cell Current Overload................................................................................. 5-14
Drive Tuning ...................................................................................................... 5-15
Auto Tuning ................................................................................................ 5-15
Spinning Load............................................................................................. 5-16
User IO ............................................................................................................... 5-17
Data Logs ........................................................................................................... 5-17
Fault Log..................................................................................................... 5-17
Historic Log ................................................................................................ 5-17
Event Log.................................................................................................... 5-18
Faults and Alarms .............................................................................................. 5-18
Motor Overload.................................................................................................. 5-18
Input Side Monitoring and Protection................................................................ 5-20
One Cycle Protection .................................................................................. 5-21
Excessive Drive Losses............................................................................... 5-23
Cell Bypass......................................................................................................... 5-25
Fast Bypass ................................................................................................. 5-25
Fast Bypass Process .................................................................................... 5-26
Neutral Point Shift During Bypass ............................................................. 5-26
Tool Suite ........................................................................................................... 5-30
Drive Host................................................................................................... 5-31
NXG Debug Utility..................................................................................... 5-32
Serial Port........................................................................................................... 5-32
Dual Frequency Braking .................................................................................... 5-32
Introduction to Dual Frequency Braking .................................................... 5-32
19001591: Version 1.0

s iii
Table of Contents GenIV Product User Manual
Operation .................................................................................................... 5-32

Limitations.................................................................................................. 5-35
Debug Functionality .......................................................................................... 5-36
Chapter 6: Application Specific Features.................................................................... 6-1
Control Mode Summary ...................................................................................... 6-1
Control Loops ...................................................................................................... 6-1
Current Loop................................................................................................. 6-1
Speed Loop ................................................................................................... 6-2
Flux Loop ..................................................................................................... 6-2
System Program ................................................................................................... 6-2
Speed Droop ........................................................................................................ 6-2
Long Cable Applications ..................................................................................... 6-2
Output Filters ....................................................................................................... 6-3
Synchronous Transfer .......................................................................................... 6-4
Introduction................................................................................................... 6-4
VFD Synchronous Transfer Implementation................................................ 6-4
Input/Output Signals for Sync Transfer........................................................ 6-5
Up Transfer Implementation......................................................................... 6-6
Down Transfer Implementation.................................................................... 6-7
Parallel Control .................................................................................................... 6-8
Communication Interfaces ................................................................................... 6-8
Available Networks ...................................................................................... 6-8
Multiple Networks ........................................................................................ 6-8
Process Availability - The Perfect Harmony Advantage..................................... 6-8
What is ProToPSTM?................................................................................... 6-9
How Does ProToPSTM Work? .................................................................... 6-9
ProToPSTM Implementation ....................................................................... 6-9
The ProToPSTM Advantage ...................................................................... 6-10
Glossary ......................................................................................................................... A-1
Abbreviations .................................................................................................................B-1
NOTES ........................................................................................................................... N-1
Reader Comments Form .............................................................................................. R-1
and Service Solutions.................................................................................................. W-1
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iv 19001591: Version 1.0
GenIV Product User Manual Safety Precautions and Warnings
Safety Precautions and Warnings

The GenIV is designed with considerable thought to personal safety. However, as with any piece of high power
equipment, there are numerous internal connections that present potentially lethal voltages. In addition, some internal
components are thermally hot to the touch. Follow the warnings below when working in or near the GenIV System.

• Always follow the proper lock-out/tag-out procedures before beginning any maintenance or trouble-
shooting work on the drive.
• Always follow standard safety precautions and local codes during installation of external wiring. Pro-
tective separation must be kept between extra low voltage (ELV) wiring and any other wiring as spec-
ified in IEC61800-5-1.
• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses. Also,
always work with another person present.
• Always use extreme caution when handling or measuring components that are inside the enclosure. Be
careful to prevent meter leads from shorting together or from touching other terminals.
• Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements
(that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the
instrument).
• Never assume that switching off the input disconnect will remove all voltage from internal compo-
nents. Voltage is still present on the terminals of the input disconnect. Also, there may be voltages
present that are applied from other external sources.
• Never touch anything within the GenIV cabinets until verifying that it is neither thermally hot nor
electrically alive.
• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points
beneath the shields.
• Never run the drive with cabinet doors open. The only exception is the control cabinet which contains
extra low voltages (ELV).
• Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the GenIV system.
• Never connect or disconnect any meters, wiring, or printed circuit boards while the drive is energized.
• Never defeat the instrument’s grounding.
• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A qualified
individual is “one familiar with the construction and operation of the equipment and the hazards
involved.”
• Hazardous voltages may still exist within the GenIV cabinets even when the disconnect switch is
open (off) and the supply power is shut off.
• When a system is configured with drive bypass switchgear (e.g., contactors between line and motor,
and drive and motor), these switches should be interlocked so that the line voltage is never applied to
the drive output if the medium input voltage is removed from the drive.
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19001591: Version 1.0 v
Safety Precautions and Warnings GenIV Product User Manual
Warning!
• Always ensure the use of an even and flat truck bed to transport the GenIV drive system. Before
unloading, be sure that the concrete pad is level for storage and permanent positioning.
severe system overheating and/or damage.
• Never store flammable material in, on, or near the drive enclosure. This includes

• Always be aware of electrostatic discharge (ESD) when working near or touching components inside
the GenIV cabinet. The printed circuit boards contain components that are sensitive to static electric-
ity. Handling and servicing of components that are sensitive to ESD should be done only by qualified
personnel and only after reading and understanding proper ESD techniques. The following ESD
guidelines should be followed. Following these rules can greatly reduce the possibility of ESD dam-
age to PC board components.
• Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style plunger
or copper braid when desoldering.
• Make certain that anyone handling the GenIV printed circuit boards is wearing a properly grounded
static strap. The wrist strap should be connected to ground through a 1 megohm resistor. Grounding
kits are available commercially through most electronic wholesalers.
• Static charge buildup can be removed from a conductive object by touching the object to a properly
grounded piece of metal.
• Do not slide printed circuit boards across any surface (e.g., a table or work bench). If possible, per-
form PCB maintenance at a workstation that has a conductive covering that is grounded through a 1
megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is
an excellent substitute.
• Avoid plastic, Styrofoam™, vinyl and other non-conductive materials. They are excellent static gen-
erators and do not give up their charge easily.
• When returning components to Siemens LD A, always use static-safe packing. This limits any further
component damage due to ESD.
Additional safety precautions and warnings appear throughout this manual. These important messages should be
followed to reduce the risk of personal injury or equipment damage.
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vi 19001591: Version 1.0
GenIV Product User Manual About This Manual
About This Manual

This manual is one component of a series of manuals intended for use with the Robicon Perfect Harmony series of
Medium Voltage (MV) Pulse Width Modulated (PWM) Variable Frequency Drives (VFD). Each part in this series is
for use by individuals having unique job functions and qualifications. The manuals in this series are listed below:
• The GenIV Product User Manual (19001591)
• GenIV Commissioning and Maintenance Manual (19001851)
The GenIV Product User Manual (19001591) defines the configuration and capabilities of the Perfect Harmony
family of Medium Voltage Variable Frequency Drives and specifically addresses the GenIV configuration.
The GenIV Commissioning and Maintenance Manual (19001851) provides a detailed description of how the system
is transported, installed, and maintained at the customer’s site.
The NXG ToolSuite Software User Manual (902291) provides a detailed description of ToolSuite, a PC-based
application that integrates various software tools used for NXG based Drives. The NXG ToolSuite is a high-level
GUI that runs on a PC that is equipped with the Microsoft Windows operating system. The NXG control and the PC
running the NXG ToolSuite communicate using Ethernet and TCP/IP protocol.
The NXG Communications Manual (902399) describes the NXG control communication board, which enables
network communication via a variety of protocols and enables modem connection.
The NXG Control Manual (19001588) describes the NXG control system. The Harmony family of drives is a
collection of MV drives with different power topologies and cooling methods. The unifying factor with the drives is
the NXG control system - a second generation control for the Harmony line.
All manuals contain a readers’ comments form. Please complete these forms and return them to us. Monitoring your
feedback allows us to continue to exceed your expectations and provide complete, effective, easy-to-use product
documentation.
Reference Tools
Many steps have been taken to promote the use of this manual as a reference tool. Reference tools include the
following:
• A thorough table of contents for locating particular sections or subsections
• Chapter number thumb nails in the outer margins for easy location of chapters
• Special text styles are applied to easily differentiate between chapters, sections, subsections, regular text,
parameter names, software flags and variables, and test points
• A comprehensive index
If you have any comments or suggestions to improve the organization or increase the usability of this manual, please
complete the Readers’ Comments Form located at the end of this manual and return it to Siemens LD A Document
Control.
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19001591: Version 1.0 vii
About This Manual GenIV Product User Manual

The following conventions are used throughout this manual:
• The terms “Perfect Harmony,” “VFD,” “variable frequency drive,” and “drive” are used interchangeably
* Note: Hand icons in the left margin alert readers to important operational or application information that
may have special significance. The associated text is enclosed in a border for high visibility.
Attention! Attention icons in the left margin alert readers to important safety and operational
precautions. These notes warn readers of potential problems that could cause equipment damage or
personal injury. The associated text is enclosed in a border for high visibility.
Caution - Electrical Hazard! Electrical hazard icons in the outer margins alert readers to important
safety and operational precautions. These notes warn readers of dangerous voltages, potential safety
hazards, or shock risks that could be life threatening. The associated text is enclosed in a border for high
visibility.
ESD Warning! These icons in the left margin alert readers to static sensitive devices. Proper
electrostatic discharge precautions should be taken before proceeding or handling the equipment.
• Chapter numbers are highlighted in the outer margins to facilitate referencing (see margin)
• Test points and terminal block designations are shown in uppercase, boldface (e.g., TB1A)
∇ ∇ ∇
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viii 19001591: Version 1.0
GenIV Product User Manual Overview
CHAPTER 1
1 Overview
The Robicon Perfect Harmony series of Medium Voltage (MV) Pulse Width Modulated (PWM), Variable Frequency
Motor Drives (VFD) are designed and manufactured by Siemens LD A, New Kensington, PA, USA with additional
manufacturing facilities in Europe, Asia, and South America. The Harmony VFD is intended for use with standard
medium-voltage three-phase AC induction, synchronous, wound rotor, permanent magnet, or super conducting
motors. When any of these types of motor is connected to a utility supply at a fixed frequency (i.e., 60 or 50 Hz), the
motor runs at a single speed. The Harmony series of drives allows variable speed motor operation without sacrificing
any of the desirable properties of the motor.
1.1 Purpose
This manual defines the configuration and capabilities of the Perfect Harmony family of Medium Voltage Variable
Frequency Drives and specifically addresses the GenIV configuration. Detailed descriptions of the common features
of the Harmony drive family are defined in the following manuals:
Companion Manuals:
• GenIV Commissioning and Maintenance Manual (19001851)
1.2 Introduction
The Perfect Harmony VFD is based on a patented (U.S. patent #5,625,545) multi-level output topology. Medium
voltage levels are obtained by adding together the outputs of multiple low-voltage power cells. The low-voltage
power cells are simplified variations of standard PWM motor drives for low-voltage service, which have been built in
high volume for many years.
The Harmony series drives achieve this uncompromised performance by employing time-proven technology in a
simple configuration. Figure 1-1 shows a typical power circuit topology for a 4160 Volt Perfect Harmony series
drive, using 750 VAC power cells. In this configuration, each motor phase is driven by 3 power cells connected in
series. The groups of power cells are wye connected with a floating neutral. Each cell is powered by an isolated
secondary winding of an integral isolation transformer. The nine secondaries are each rated for 750 VAC at one ninth
of the total power. The power cells and their associated transformer secondaries are insulated from each other and
from ground for 5 kV class service or “according to the output voltage rating of the drive.”
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19001591: Version 1.0 1-1
Overview GenIV Product User Manual
Figure 1-1: Harmony Topology
For higher output voltage capabilities, Figure 1-1 would be extended to have up to 8 power cells in series in each
phase, with additional secondary windings (number of secondaries equals number of power cells) on the integral
isolation transformer.
Each power cell is simply a static power converter. It is capable of receiving input power at 750 VAC, 3-phase, 50/60
Hz and delivering that power to a single-phase load at a variable frequency from 0.1 to the maximum rated output
frequency of the drive.
1.2.1 Clean Power

Prior to the introduction of the Perfect Harmony Drive, other solutions with variable frequency output power
conversion created unwanted line disturbance (refer to Figure 1-2, six-pulse and twelve-pulse input waveforms).
The Perfect Harmony drive system mitigates power quality issues by:
• Providing clean power input (low values of flicker, TIF, harmonic current distortion)
• Providing a high power factor
• Providing a nearly perfect sinusoidal output
The Perfect Harmony drive series meets the most stringent IEEE 519-1992 requirements for voltage and current
harmonic distortion, even if the source capacity is no larger than the drive rating. This series protects other on-line
equipment (such as computers, telephones, and lighting ballasts) from harmonic disturbances. Perfect Harmony also
prevents “cross talk” with other variable speed drives. Clean power input eliminates the need for time-consuming
harmonic/resonance analyses and costly harmonic filters. Figure 1-2 illustrates harmonic distortion waveforms for a
typical 6-pulse, a typical 12-pulse, and the Perfect Harmony series drive.
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1-2 19001591: Version 1.0
1
Source Current Source Current Source Current
Source Voltage Source Voltage Source Voltage

Input Waveform Input Waveform Input Waveform
Figure 1-2: Harmonic Distortion Wave Form Comparisons (6-pulse, 12-pulse, and Perfect Harmony)
Total harmonic distortion of the source current is 25% for the 6-pulse, 8.8% for the 12-pulse, and 0.8% for the Perfect
Harmony. The corresponding voltage distortions with a typical source impedance are 10%, 5.9%, and 1.2%,
respectively.
Note: The above comparisons were done using a typical 1000 Hp current source drive (6-pulse
* and 12-pulse modes), and a Perfect Harmony series drive operating from an 1100 kVA, 5.75%
impedance source.
1.2.2 High Power Factor

Power factor is a measure of the fraction of current that produces real power to the load. Typically, power factor is
given as a percentage. A high power factor VFD (e.g., 94%) makes much better use of its input line current demand
in producing real power to the motor than a VFD operating at a low power factor (e.g., 30%). VFDs having a low
operating power factor often generate square-wave-shaped line currents. This can lead to harmonics and other
associated resonance problems.
The Perfect Harmony series draws nearly perfect sinusoidal input currents having a power factor that exceeds 94%
throughout the entire output frequency range without the use of external power factor correction capacitors. This
eliminates utility penalties for power factor and demand charges, and improves voltage regulation. In addition,
feeders, breakers, and transformers are not overloaded with reactive power. Low speed applications specifically
benefit from the Perfect Harmony series, since a high and stable power factor is maintained throughout the entire
output range using standard induction motors. Figure 1-3 compares graphs of power factor versus percent speed for
the Perfect Harmony series and a typical phase-controlled SCR drive.
100
90
Perfect Harmony
Percent Power Factor
80
Series Drive
70
60
50
40 Phase -controlled
SCR Drive
30
20
10 Percent Speed
20 27 33 40 47 53 60 67 73 80 87 93 100
Figure 1-3: Comparison of Perfect Harmony and a Typical Phase-Controlled SCR Drive
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19001591: Version 1.0 1-3
1.2.3 Nearly Perfect Sinusoidal Output Voltages

1 The design of the Perfect Harmony series of variable frequency drives inherently provides a sinusoidal output without
the use of external output filters. This means that the drive provides a low-distortion output voltage waveform that
generates no appreciable audible motor noise. In addition, there is no need to derate motors (the drive can be applied
to new or existing 1.0 service factor motors). In fact, Perfect Harmony drives eliminate harmful VFD-induced
harmonics that cause motor heating. Similarly, VFD-induced torque pulsations are eliminated (even at low speeds),
thereby reducing the stress on mechanical equipment. Common mode voltage stress and dv/dt stress are also
minimized. A typical graph of the output current from a Perfect Harmony drive is illustrated in Figure 1-4.
Phase C
Output Current Time
Figure 1-4: Nearly Sinusoidal Wave Form of the Output Current from a Perfect Harmony Drive
Unlike standard PWM Systems, the voltage applied to the motor leads is developed in many small steps instead of a
few large steps. This provides two distinct advantages: the voltage stress on the motor leads is dramatically reduced,
and the quality of the motor currents is dramatically increased.
The staircase multilevel Perfect Harmony inverter output can produce 2N+1 voltages (where N= # cells per phase)
from line to neutral. The ability to generate many different voltage levels allows the Perfect Harmony to synthesize
an accurate approximation of a sinusoidal output waveform.
1.3 Perfect Harmony Features

The features of the Perfect Harmony family of Medium Voltage drives are summarized as follows:
• Truly Scalable Technology with modular construction
o Air Cooled: GenIV, GenIIIe, GenIII NBH
o Liquid Cooled: WCIII, HV
• 200 to 40000 Hp (150 kW to 30 MW)
• Wide range of Motor Voltages Supported
o 2300 VAC through 13800 VAC
• Low Harmonic Input
• High Efficiency and Power Factor
• Line Disturbance Immune
• Compatible with new or existing motors
• Power Cell Bypass with floating neutral point control
• Negligible Torsion
• Wide Range of Connectivity to industrial PLC Networks
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1-4 19001591: Version 1.0
• Parallel drive control

• Multi-motor control 1
• Long cable compatible
• Synchronous line/load transfer capability
• Inherent input/output metering
• Coordinated input protection scheme
• Dual frequency braking
• ProToPSTM
• Partial or fully regenerative (4Q)
1.3.1 Harmony VFD Family Features

The Harmony VFD families consist of four core design configurations, where they are functionally identical and
share a common controller. These four design configurations are targeted at distinct output power configurations with
little overlap between the frame sizes. These drive families are summarized as follows:
* Note: The following ratings are subject to change.
GenIV:
(Refer to Table 4-1 for full GenIV product range)
• 200 to 1100 Hp (150 - 825 kW)
• 2.3 to 4.2 kV Output
• 2.4 to 13.8 kVAC 50/60 Hz Input
• Air Cooled
• Power Cell Ratings:
o 750 Volts
o 40, 70, 100, or 140 Arms
GenIIIe:
• 3000 to 9000 Hp (2.25 - 6.75 MW)
• 2.3 to 7.2 KV Output
• 2.4 to 13.8 kVAC 50/60 Hz Input
• Air Cooled
• Power Cell Ratings:
o 690 Volts
o 315, 375, 500, or 660 Arms
WCIII:
• 4000 to 10000 Hp (3 MW - 14.2 MW)
• 2.4 to 13.8 kVAC 50/60 Hz Input
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19001591: Version 1.0 1-5
• Water Cooled
1 • Power Cell Ratings
o 750 Volts
o 880 or 1250 Arms
HV:
• 10000 to 40000 Hp (7.5 MW to 30 MW)
• 2.4 to 13.8 kVAC 50/60 Hz Input
• Water Cooled
• Power Cells
o 1375 Volts
o 500, 800, or 1400 Arms
1.3.2 VFD Scalability

The Perfect Harmony Power cells provide truly scalable technology that is provided by the wide range of output
power configurations offered by the power cells, and the ability to connect up to 8 cells in series for each output
phase. When connected in series, the current rating for each phase is simply equal to the output current rating of the
cells; the output voltage rating is simply the sum of the output voltage ratings of the cells.
* Note: Cells of different power ratings should not be intermixed.
The Control system for the Harmony is identical regardless of the output ratings of the VFD, where the only
configuration differences are the feedback sensor configurations and the number of cell communication channels
required. The Control is based on a per unit implementation, where the user simply enters the nameplate ratings for
the Motor and VFD. The controller automatically scales itself, based on these ratings. This results in a common
control implementation and “touch and feel” for all drives, regardless of the power ratings.
1.3.3 VFD Output Ratings

Using the cell output voltage rating, the output capability of the VFD can be calculated based on the number of power
cells connected in series in each of the 3 output phases, which establishes the Available System Output Capability,
also known as “VAVAILABLE.” This is also the maximum voltage that can be supported on the output terminals of
the drive when energized.
The rated output voltage of the drive is then calculated as follows:
VAVAILABLE (Volts) = 1.78 * #Cells * CellV * Vin / Vrated * TransformerTapSetting
Where: #Cells = Number series power cells per phase
Vin = Measured Line Input voltage (rms)
Vrated = Rated VFD Input Voltage (rms)
TransformerTapSetting: use 0.95 when +5% tap on input transformer is used
1.00 when 0% tap is used
1.05 when -5% tap is used
* Note: Overmodulation (O-M) is used for GenIV and WCIII product families to achieve output
voltages that are slightly above the calculated VAVAILABLE.
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1-6 19001591: Version 1.0
The VFD Rating is then calculated using VAVAILABLE and the rated cell current.
VFD Rating (KVA) = 1.732 * VAVAILABLE * Power Cell Continuous Current Rating. 1
Note: The VFD integral isolation transformer and cell frame are chosen in agreement with the
* load ratings, i.e., site conditions, cable length, and motor nameplate data (power factor efficiency,
frequency, and service factor).
1.3.4 Rectifier Configuration

Each Power Cell Input is configured as a 6-Pulse uncontrolled diode rectifier. The Input transformer includes a
dedicated secondary winding for each power cell, where the transformer secondaries are arranged in a delta and
extended delta configuration with varying degrees of phase shift. Typical Perfect Harmony VFD configurations
consist of a minimum of 3 to a maximum of 8 series power cells per output phase.
Effective Rectifier Configuration is:
• 3 Cells/Phase = 18 Pulse
1.3.5 Power Cell Bypass Option

As an option, each power cell in the drive can be equipped with a bypass contactor. This contactor will be
automatically energized by the VFD master control if the associated power cell malfunctions. Once the contactor is
energized, the damaged cell is no longer electrically part of the inverter system, which allows the VFD to resume
operation.
Since the cells in each phase of a Perfect Harmony Drive are in series, bypassing a cell has no effect on the current
capability of the drive, but the output voltage capability will be reduced. Usually the required motor voltage is
roughly proportional to speed, so that the maximum speed at which the drive can fulfill the application requirements
will also be reduced. Therefore it is important to maximize the motor voltage available after one or more cells have
been bypassed. The Harmony control system maximizes output voltage capability using a patented technique (US
Patent 5,986,909) defined as “Neutral Point Shift,” which is described in Section 5.13.1 of this document.
1.3.6 Transformer Winding Configuration

Each transformer secondary winding sees typical 6-Pulse Harmonics. The transformer secondaries are wound with
varying phase angles, resulting in a multi-pulse reaction. The input transformer primary winding and the line sees
between 18 to 48 Pulse Harmonics, as defined by the power cell configuration. This patented topology results in
nearly sinusoidal current and a high, stable input power factor across the entire load range.
• Secondary Windings see Higher Harmonics
o Plurality of phase staggered delta or extended delta reduces current
• Primary Winding sees Low Harmonics
o Harmonics reflect multi-pulse secondary configuration
The Perfect Harmony transformers are applied to motor drives using the rule of 1 kVA per Hp (see below), resulting
in a transformer utilization factor of 89%. The transformer is unusual in that the secondary windings carry six pulse
currents, while the primary carries nearly perfect sine waves. The total VA of the secondary windings is greater than
the VA of the primary windings.
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19001591: Version 1.0 1-7
1
Rated Input Current (Amps) = [(kVA rating) x 802] ÷ [√3 x Rated Primary voltage x 0.96 x 0.94]
With following assumptions used for sizing purpose:
Motor efficiency = 93%
VFD efficiency at full load = 96%
Input power factor = 94%
Output power per Hp at shaft = 746 / 0.93 = 802
Reducing this equation results in:
Rated Input Current (Amps) = [(kVA rating) ÷ (Rated primary voltage)] x 513.11
1.3.7 Control Overview

Perfect Harmony is a simple “synchronous” control. Basic operation is summarized as follows:
• Control sends message to each power cell control via dedicated fiber links
• Cell executes request by firing one switch pair:
o Plus DC voltage
o Minus DC voltage
o Zero voltage
• Cell control confirms switch pair fired
• Control confirms firing from:
o Output voltage divider
o Output Hall Effect current transducer
• No two cells ever switch at the same time
• Cell switching rate is low compared to effective switching frequency of VFD:
o Typically 600 Hz carrier frequency per pole, results in 1200 Hz switching frequency per cell
• VFD effective switching frequency is simply the cell switching frequency times the number of cells per
phase
• Switching rate is constant over the entire output frequency range
• Default control is an open flux vector control:
o V/Hz and closed loop (i.e., encoder) control modes also available
1.4 Applications
• Oil and gas (including long cables)
• Municipal water
• Power Generation
• HVAC
• Cement
• Chemicals
• Research
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1-8 19001591: Version 1.0
1.5 Evolution
1
Historic Milestones:
1994: World’s 1st fully integrated voltage source inverter (VSI) medium voltage motor drive using IGBTs that
meet IEEE 519 for input current distortion and NEMA/IEC for motor HVF (without using output step-up
transformers or line/load filters).
1995: 1st IGBT-based 6.6 kV drive without an output transformer.
1996: 1st IGBT-based drive above 10000 Hp (7500 kW).
1998: Introduction of ProToPSTM and 500th Perfect Harmony drive installed.

1999: Introduction of process-transparent cell bypass (“fast bypass”) capability and neutral point shift.
2000: 1st VSI drive to operate a medium voltage synchronous motor.
2001: 1000th Perfect harmony drive installed.
2002: 1500th Perfect Harmony drive installed.
2003: 1st High Voltage 13.8 kV drive capable of operating motors from 4000 to 90000 Hp connected directly to
13.8 kV source.
2004: Built largest PWM drive, 80000 Hp.
2006: Introduction of smallest footprint medium voltage VFD, GenIV “MicroHarmony.”
1.6 Intellectual Property

The Perfect Harmony topology and features are protected by the following patents:
5,625,545 6,222,284 6,313,600
5,986,909 6,236,580 6,411,530
6,014,323 6,262,555 6,417,644
6,166,513 6,301,130 6,762,947
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19001591: Version 1.0 1-9
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1-10 19001591: Version 1.0
GenIV Product User Manual Theory
CHAPTER
2 Theory
2
2.1 Introduction
The Harmony series drives provide variable speed operation by converting utility power at fixed frequency and fixed
voltage to variable frequency, variable voltage power. This conversion is done electronically, without moving parts.
Unlike older drive types, the Harmony series does not force the user to accept unpleasant by-products of this
conversion process. Specifically:
• The Perfect Harmony series drives do not inject significant harmonic distortion into the plant’s distribution
system. No power filters are required. No interference to sensitive equipment or resonance problems with
power factor capacitors will occur.
• The Perfect Harmony series drives present a high power factor to the utility, typically 95% or better
throughout the speed range. No power factor correction is required.
• The Perfect Harmony series drives do not require any derating of the motor due to output harmonics. No
additional motor heating is produced, versus operation directly from the utility.
• The Perfect Harmony series drives, when set up properly, do not produce torque pulsations, which can
excite mechanical resonance.
• The Perfect Harmony series drives cause no noticeable increase in acoustic noise from the motor, versus
operation directly from the utility.
• The Perfect Harmony series drives cause no appreciable additional stress to the motor insulation, versus
operation directly from the utility.
• The Perfect Harmony series drives allow unrestricted use of rated motor torque throughout the speed range,
subject only to the thermal limitations of the motor.
• The Perfect Harmony series drives are virtually silent in operation, if liquid-cooled, so that normal
conversation is possible next to drives running at full power.
• The Perfect Harmony series drives are completely modular in construction, so that if necessary, a defective
module can be replaced in minutes. Sophisticated microprocessor-based diagnostics pinpoint the location of
any defects.
2.2 The Power Circuitry
* Note: The examples used in this section refer to drives having 750V cells. High-Voltage cell systems
(1375V) and GenIIIe (690V) will have different values.
The Harmony series drives achieve this uncompromising performance by employing well-proven technology in a
modular configuration. Medium voltage levels are obtained by adding together the outputs of multiple low-voltage
power cells. The low voltage power cells are simplified variations of standard PWM motor drives for low-voltage
service, which have been built in high volume for many years.
Figure 2-1 shows a typical power circuit topology for a 4160 Volt Perfect Harmony series drive, using 750 VAC
cells. Each motor phase is driven by 3 power cells connected in series. The groups of power cells are wye connected
with a floating neutral. Each cell is powered by an isolated secondary winding of an integral isolation transformer.
The nine secondaries are each rated for 750 VAC at one ninth of the total power. The power cells and their
secondaries are insulated from each other and from ground for full output voltage rating.
For higher output voltages, additional power cells and isolated transformer secondaries would be added as required.
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19001591: Version 1.0 2-1
Theory GenIV Product User Manual
Each cell is a static power converter. It is capable of receiving input power at 750 VAC 3-phase, 50/60 Hz and
delivering that power to a single-phase load at any voltage up to 750 VAC and at any frequency up to the rated
maximum frequency defined in Chapter 3.
2 * Note: For output frequencies greater than 167 Hz, the VFD power cell current output may be de-rated due to
switching losses. Consult the factory for information applicable to the specific application requirements.
With three 750 VAC power cells in series per phase, a Perfect Harmony series drive can produce as much as 2425
VAC line-to-neutral, or a maximum VAVAILABLE of 4200 Volts.
* Note: Over-modulation is used to allow 750 Volt cells to achieve nominal motor ratings (e.g., 4,160V with 9
cells).
It should be noted that it is possible to connect as many as eight power cells in series using the Harmony control.
VAVAILABLE determines the maximum voltage that can be delivered from the VFD output. The actual voltage
delivered is fully adjustable. As the Harmony VFD topology is based on multi-level output capabilities, the result is
true adjusted voltage. The advantages of utilizing the VAVAILABLE capability of the VFD become apparent when
the patented advanced cell bypass option is applied for high availability or redundant applications.
Other cell voltages are available, which will change the number of cells needed for a given output voltage. However,
the basic principle is unchanged.
The power cells all receive commands from one central controller. These commands are passed to the cells over fiber
optic cables to maintain electrical isolation.
The transformer secondaries that supply the power cells in each output phase are wound to obtain a small difference
in phase angle between them. This cancels most of the harmonic currents drawn by the individual power cells, so that
the primary currents are nearly sinusoidal. The power factor is always high - typically 95% at full load.
The schematic of a typical power cell is shown in Figure 2-2. In this example, a 3-phase diode rectifier, fed by the 750
VAC secondary, charges a DC capacitor bank to about 1012 VDC. The DC voltage feeds a single-phase H-bridge of
IGBTs.
At any instant of time, each cell has only three possible output voltages. If Q1 and Q4 are on, the output will be +DC
bus volts from T1 to T2. If Q2 and Q3 are on, the output will be –DC bus volts. Finally, if either Q1 and Q3 or Q2 and
Q4 are on, the output will be 0 volts.
With 3 power cells per phase, the circuit can produce 7 distinct line-to-neutral voltage levels (±3036, ±2024, ±1012,
or 0 volts). With N cells per phase, (N*2)+1 distinct voltage levels are available, where N is a maximum of 8. The
ability to generate many different voltage levels allows the Harmony series drives to produce a very accurate
approximation to a sinusoidal output waveform.
Figure 2-3 shows how these waveforms are generated for the case of 3 cells per phase. First, a reference signal is
created for each phase. These signals are digital replicas of the ideal waveform to be approximated. In Figure 2-3, RA
illustrates the reference signal for phase A. This reference signal is then compared with 3 triangular carrier signals.
Figure 2-3 shows conditions when the output frequency is 60 Hz and the carrier frequency is 600 Hz, so that there are
exactly 10 carrier cycles per reference cycle. The 3 carriers are identical except for successive phase shifts of 60
degrees (based on the number of cells per phase). Phase shift between carriers in each phase is computed based on the
following equation:
Carrier Phase Shift (same phase) = 180 degrees / # Cells per Phase
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Motor
Figure 2-1: Topology of Perfect Harmony VFD (3 Cells)
Whenever the reference is greater than the first (unshifted) carrier, the signal L1 is high; otherwise L1 is low. L1 is
used to control the pair of transistors Q1 and Q2 in cell A1 (see the left pair of transistors in Figure 2-2). Whenever the
reference is greater than the inverse of the first carrier, the signal R1 is low; otherwise R1 is high. R1 is used to control
the pair of transistors Q3 and Q4 in cell A1 (see the right pair of transistors in Figure 2-2).
The difference between L1 and R1 gives the output waveform of cell A1, shown in Figure 2-3 for Phase A as A1.
In a similar manner, the reference signal is compared with the second carrier (shifted 120 degrees) and its inverse to
generate control signals L2 and R2 for the transistors in cell A2. The output waveform of cell A2 is shown as A2.
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19001591: Version 1.0 2-3
IGBTs Q1-Q4
Q1 Q3
2 Dedicated Winding
on Power
Transformer
+
1 T2
Power Output
2 of Cell
T1
3 +
Q2 Q4
Local Fiber Optic Signals

Local Control to and from
Control
Power Circuits Master Control
Figure 2-2: Schematic of a Typical Power Cell
Finally, the reference signal is compared with the third carrier (shifted 240 degrees) and its inverse to generate control
signals L3 and R3 for the transistors in cell A3. The output waveform of cell A3 is shown as A3.
RA
L1
R1
A1
L2
R2
A2
L3
R3
A3
AN
Figure 2-3: Waveforms for Phase A
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The sum of the output voltages from cells A1, A2 and A3 produces the A-to-neutral output voltage of the drive, shown
in Figure 2-3 as AN. There are 7 distinct voltage levels. Note that this voltage is defined between terminal A and the
floating neutral inside the drive, not the motor neutral.
Figure 2-4: Waveforms for Phase B
Figure 2-4 shows the same signals for Phase B. The 3 carriers are identical to Figure 2-3, except each is shifted by 20
degrees from its Phase A equivalent (see following note). The reference RB is also identical to Figure 2-3, except that
it is delayed by 120 degrees (at the reference frequency).
The sum of the output voltages from cells B1, B2 and B3 produces the B-to-neutral output voltage of the drive, shown
in Figure 2-4 as BN.
Figure 2-5 repeats the two line-to-neutral voltages AN and BN. The numerical difference between AN and BN forms the
line-to-line voltage impressed on the motor, and is shown in Figure 2-5 as AB.
AN
BN
AB
Figure 2-5: Waveforms for Line-to-Line Voltage
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19001591: Version 1.0 2-5
Note: The phase shift of the carrier signals between phases is determined by the number of cells in the
system, the equation being Phase shift = 180 degrees / total number of cells. In this case (3 per phase or 9
2 * cells total), the carrier signal phase shift phase to phase is (180 / 9) = 20 degrees. This shift of the carriers
between phases reduces the number of devices that are switching at one time. The above is true if no cells are
in bypass. If one or more cells are in bypass, the carrier signals are offset by 180 degrees / total remaining
cells.
Figure 2-6: Harmony Output Waveforms, 2400 Volt Drive at Full Load
Figure 2-6 shows motor voltage and current waveforms for a 2400 VAC Harmony drive rated at 1000 Hp. The
voltage shown is between phase A and the motor neutral (not the same as the drive neutral). The motor current is in
phase A during full-load operation. Anyone familiar with such waveforms for other types of static drives will
appreciate how accurately they approximate true sine waves. A quantitative measure of the waveform quality is its
Total Harmonic Distortion, or THD. The THD of the motor currents with a Harmony series drive is typically less than
5 percent.
Figure 2-7 shows the input voltage and current waveforms for the same drive as shown in Figure 2-6, under the same
conditions. The perfect sine wave in Figure 2-7 is the voltage into the special input transformer, measured between
phase A and the neutral of the wye-connected primary. The other waveform is the current into phase A of the same
winding.
The currents drawn from the power source by Harmony series drives are also good approximations to true sine
waves, due to the harmonic cancellation obtained with the phase-shifted secondary windings of the transformer. The
THD of the input currents with a Harmony series drive is typically less than 5 percent.
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2-6 19001591: Version 1.0
Figure 2-7: Harmony Input Waveforms for a Drive at Full Load
Note in Figure 2-7 that the input current lags behind the input voltage by less than 15 degrees at full load. This
represents a power factor better than 96 percent. Harmony series drives always maintain a high power factor,
typically better than 95 percent throughout the speed and load range.
* Note: The waveforms shown represent the worst case for a Harmony series drive when there are only 3 cells
per phase. When the number of cells increases, as in 12 or 15 cell drives, the waveforms improve
considerably.
Figure 2-8 shows the motor voltage and current for a 15 cell Harmony drive at full power, while Figure 2-9 shows the
input voltage and current for the same drive and load.
Figure 2-8: Motor A-B Voltage and Current in Phase C at Full Load for a Harmony Drive
Figure 2-9: Input A-B Voltage and Current in Phase C at Full Load for a Harmony Drive
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19001591: Version 1.0 2-7
2.3 The Control System

The block diagram in Figure 2-10 shows the implementation of the Harmony Control System. The Control System
consists of the following functional blocks: Signal Interface and Conditioning, an A/D Converter, a Processor, a
Digital Modulator, and Fiber Optic Interfaces.
2 The Signal Interface processes the feedback signals collected from the drive. These circuits scale and filter the
feedback signals before passing them along to the A/D Converter. Provisions are included to interface to an ESTOP
signal.
The function of the A/D Converter is to sample the input and output currents and voltages, and convert them to digital
signals for the processor. The sample rate varies from 3 kHz to 6 kHz and is a function of the carrier frequency
(which is also the IGBT switching frequency), and the number of “available” cells in the system. The Digital
Modulator generates the signal for the A/D converters to start sampling. Once the A/D converters finish sampling,
they provide an interrupt to the processor to begin its calculation cycle.
* Note: The A/D converter function includes provisions for encoder feedback monitoring.
The processor performs all of the functions for motor control and generates three-phase voltage commands for the
digital modulator. In addition, it monitors the input voltages and currents to provide metering functions (such as
power factor, input power, and harmonic calculation), input protection (excessive losses, excessive reactive current,
under-voltage, and single-phasing), and input voltage magnitude, frequency, and phase angle for Synchronous
Transfer.
The Digital Modulator contains registers that are used for communication with the Processor. For each phase voltage
command, the processor writes two values to the modulator. The first for the present time instant and the second for a
time instant that is extrapolated for half a sampling period. A voltage increment, or step corresponding to these
values, and the direct number of steps between values, is also written to the modulator. These phase commands are
written by the processor once every sampling period.
The modulator creates a set of timing signals that cause the control software to sample the feedback signals and run
the control and monitoring algorithms. These timing signals are used to transmit information to the cells
simultaneously, once every 9 to 11 microseconds. This time (is determined by the processor and) is based on the drive
configuration, and is fixed for a particular configuration. In between every transmission period, the modulator
performs interpolation, phase-shifted carrier generation, pulse-width modulation (PWM), and cell communication.
The resulting PWM commands for each cell, along with the mode of operation, is assembled as a data packet that is
transmitted to each cell through dedicated Fiber Optic Interfaces. In response to the transmitted data, the modulators
receive a similar data packet from each of the cells. The return message from the cells contains status bits that are
decoded by the modulator and conveyed to the processor.
Every transmission is checked for completeness and parity. If an error is detected, a link fault is generated. The data
packet sent to the power cells provides operational mode and switching information. The local communication
circuits in each power cell operate as slaves to the Modulator. The local control circuits on each power cell convert
the information received to IGBT firing pulses.
The return packet echos the operational mode and cell status. Should an individual cell be bypassed, the modulator
commands all power cells to disable their outputs with the next message to the cells. The worst case shut down of all
power cells requires 2 transmission cycles or 22 µsec. maximum.
When advanced cell bypass is included with a drive, the modulator communicates with the bypass controller and
monitors hardware faults such as IOC, ESTOP, and power supply faults. The Bypass Controller is configured to
control the cell bypass (mechanical) contactors. After detection of a cell fault, the processor communicates with the
Bypass Controller to bypass the faulted cells. In addition to bypassing cells, the Bypass Controller constantly checks
the status of the contactors to verify if they are in their requested states.
The Fiber Optic Interface transfers data between the modulator and the cells over dedicated fiber optic channels. Each
cell receives its firing commands and status signals through a full duplex fiber optic channel.
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Analog to
Digital
Convertor
and
System
Interface
Output
Current Sensors
Motor
Figure 2-10: Block Diagram of Harmony Control Structure
∇ ∇ ∇
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19001591: Version 1.0 2-9
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GenIV Product User Manual GenIV Specifications
CHAPTER
3 GenIV Specifications
3.1 System Specifications
Parameter Rating 3
2.4, 3.0, 3.3, 4.16, 4.8, 6.0, 6.3, 6.6, 6.9, 7.2, 8.4, 10, 11, 12, 12.47, 13.2, or
Input Line Voltage
13.8kV; 3 phase; ±10%
Input Frequency 50 or 60Hz ±5%
Input Power Factor > 0.95 above 10% load, 0.97 typical
Input Harmonics <= 5% TDD with ambient THDv <= 2%
Efficiency 98% Transformer, 99% Converter, 97% Total VFD
Output Horsepower,
200, 300, 400, 450, 500, 600, 700, 800, 900, 1000, 1100
Frame Sizes
Output Voltage 0 - 4160V
Output HVF < 0.03
Output dv/dt < 3000 V/µS
Output Current 40, 70, 100, 140A Cell Frame Sizes
Overload Capacity 150% 1 minute / 10 minute (Ambient temperature < 40°C)
Output Frequency & Drift1 0.5 - 330 Hz, ± 0.5%
Output Torque 10 - 167 Hz rated torque (2 Quadrant)
Design Life 20 years
Auxiliary Voltage 380 - 400 - 415V, 50 Hz; 460 - 480V, 60 Hz; 3 phase
Enclosure Type NEMA 1 Ventilated
Degree of Protection IP 31
Ambient Temperature 0 - 40 °C (max. 45 °C with useful life derate2)
Altitude 0 - 3300 ft. without derating
Audible Noise ≤ 75db at 3 ft. from cabinet
Dust contamination < 100 micron @ 6.5 mg/cu. ft.
Gas contamination < 4 PPM reactive halides and sulfides
Cooling Ventilated, forced air-cooled with integrated fans
1. For high speed projects (> 300 Hz), consult Siemens concerning trade sanctions.
2. Consult engineering for reduced life expectancy calculation.
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GenIV Specifications GenIV Product User Manual
3.2 Power Cell Specifications
Cell Frame 040 070 100 140

Output Nameplate Current 40A 70A 100A 140A
Input Voltage 750V ± 10%, 3 phase, 50/60 Hz

3 Input Current 32.5A 57A 81A 114A
CL-1: 110% of nameplate 1 minute/10 minutes

Overload Capacity (see Note)
CL-2: 150% of nameplate 1 minute/10 minutes
(* Ambient < 40°C)
CL-3: 200% of nameplate 3 seconds/10 minutes
Losses % 1.3 1.2 1.1 1.0
Discharge to 50 VDC, minutes. 0.84 1.68 2.53 3.37
Electrical Connections Rear access blind connection via power plugs

Weight (lbs.) 52 57.5 63 68.5
Envelope Width 13.42”
Envelope Depth 21.83”
Envelope Height 9.67”

Forced Air Cooling > 180 CFM (225-250 typical)
* Note: At ambient temperatures ranging from 40 to 45°C, the 140A cell frame is limited to 150%
1 minute/10 minutes overload with a 130 Amp continuous rating.
∇ ∇ ∇
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GenIV Product User Manual Product Description
CHAPTER
4 Product Description
4.1 Drive Family Description
GenIV is the fourth generation of forced air-cooled medium voltage, voltage source inverter drives offered in the
patented Robicon Perfect Harmony topology. GenIV differentiates itself from prior generations in that:
•
•
The 200 - 1100 Hp, 4160V frame uses a single enclosure (no shipping splits)
At its inception, the 200-1100 Hp, 4160V drive is the smallest footprint MV AC drive in the world
4
• Nine Cell configuration for 4160V output (750V cell input, and O-M techniques)
• Transformer and cell sections have independent intake air cooling paths
• Electronically commutated (EC) brushless DC motor cooling blower
• NXGII control with integral I/O system and Eagle software
• Power cell connections are made with blind mate power plugs and locking latches (no fasteners)
The GenIV is a series of adjustable speed AC motor drives presently available in 4160V outputs, and loads ranging
from 200 - 1100 Hp. Four power cell amperage types are available: 40, 70, 100, and 140. Drives in this product series
provide an efficient, cost effective, and reliable method of adjusting the speed of an AC motor. The core unit contains
a wide range of expandable features, enabling it to meet the demands of many types of industrial applications.
Siemens GenIV (also known as MicroHarmony) may be purchased in one of three configurations.
• Core: These units contain a wide range of components that achieve common requirements for Medium
Voltage drive performance:
o Integral isolation transformer
o NEMA 1 ventilated (IP31) enclosure
o Multiple power and amperage frame sizes
o Multiple input voltages and frequencies
o ASA 61 gray enclosure paint
o Keypad, E-Stop
o Electronically commutated (EC) cooling blower
o NEMA hole pattern medium voltage connections
• Pre-Engineered: These option packages allow customers to specify a variety of add-ons to the flexible Core
unit without an increase in footprint (see list below):
o Electrostatic transformer shield
o Distribution class surge arresters
o Mechanical cell bypass
o Redundant blower (or N+1)
o Blower cage with duct interface
o Encoder power supply for CLVC
o EMC auxiliary voltage filter
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19001591: Version 1.0 4-1
Product Description GenIV Product User Manual
o Mechanical door key interlocks

o Auxiliary voltage isolation transformers
o Industry standard communications (single or dual networks)
o Agency approval
• Custom: These selections are not readily available as pre-engineered options for the GenIV; however, our
Siemens engineering staff has experience in designing these configurations in transition cabinets as an add-
on to the drive line-up (see list below):
o Synchronous transfer output reactors
4 o Synchronous motor exciters and field supplies
o RTD scanners
o Motor encoders
o Switchgear and full/reduced voltage motor starters
o Power quality and motor relay, metering and equipment
o Long cable filters
o Control power transformers
o Anti-condensation heaters
o Off-voltage auxiliary voltage transformers
o IP42 and NEMA 3R enclosures
o Customer specified enclosure paint colors
o Marine duty packages
o Expansion I/O and PLC capabilities
o Control houses
o Heat exchanger systems
4.2 Cabinet Outlines

The cabinet configurations of the GenIV Perfect Harmony drives vary, depending upon the project requirements for
input and output voltage, and output power and amperage. The GenIV, in its core configuration, consists of a single
cabinet with multiple sections. Single cabinet units are shipped with their blower cage(s) removed. The various
sections are described below:
• Transformer section
• Cell section
• Input/output section
• Control section
• Control wire way
• Blower #1 (and #2 with redundant option)
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4-2 19001591: Version 1.0
GenIV is offered in various core configurations, dependent upon the number of cells and power cell type amperage.
Table 4-1 lists the core configurations:
Table 4-1: GenIV Core Configurations
Output Voltage Power Cell Types

Cells in Drive
Available L-L Hp Range (Continuous Current
(without Redundancy)
(with O-M) Rating)
9 4160V 200-1100 40, 70, 100, 140
9* 4160V 1250-2250 200*, 260*

4
15* 6900V TBD TBD
24* 11000V TBD TBD
* Not Released for Production

4.2.1 9 cell, 4160V Output, 200-1100 Hp
Figure 4-1 details the GenIV 4160V output 200-1100 Hp drive, and Figure 4-2 points out each core section. The
default color of the enclosure is ASA 61 Gray.
Figure 4-1: GenIV 4160V Output 200-1100 Hp General Arrangement
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19001591: Version 1.0 4-3
Figure 4-2: GenIV 4160V Output 200-1100hp, Sectional View

(Redundant Blower #2 not shown)
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4-4 19001591: Version 1.0
Table 4-2 gives detailed mechanical and electrical information for the core configuration. (Note the assumptions.)
Table 4-2: Nine Cell 4160V Output GenIV, 200-1100 Hp
Hp1 Losses (kW)2 Ventilation3 Footprint4 Weight (lbs)5

200 5.25 4352
300 8.00 4250 CFM @ 66” Wide, 4890
1.3” H2O 42” Deep,
400 10.50 5438
110” High
450 11.75 5674
4
500 13.00 5900
600 15.75 6374
Note: For duct
700 18.25 interface projects, 6760
800 20.75 the added pressure Note: Shipping 7108
drop cannot exceed height is 86” when
900 23.50 7467
1.8” H2O at 4000 blower cage is
1000 26.00 ACFM. removed. 7739
1100 28.50 7973
1. Drive Rated Hp
2. Losses are shown as 2.59 kW per 100 Hp, rounded up to the nearest ¼ value
3. EC Blower operates at 80% speed typically (100% speed with Duct Interface)
4. Subject to change without notice
5. For Redundant blower, add 160 lbs. For cell bypass, add 75 lbs.
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19001591: Version 1.0 4-5
4.3 Cabinet Details

The GenIV core enclosure is Nema 1 Ventilated (IP 31 degree of protection) and is provided with top and bottom
cable access plates (see Figure 4-3). The doors are hinged and mechanical key interlock provisions are provided.
Figure 4-3: GenIV Enclosure (4160V Output, 200-1100hp)
* Note: The following drive “Section” details include components by label and description as found on the
core configuration. These labels are also found on customer outline “C” and wire diagram “W” drawing sets.
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4-6 19001591: Version 1.0
4.3.1 Input/Output Section

The Input/Output section is located behind the control section as shown in Figure 4-4.
Table 4-3: Input/Output Section Components
Component Label1 Part Description

L1, L2, L3 Medium Voltage Input Connections
T1, T2, T3 Medium Voltage Output Connections
CT1, CT2 Input B and C Phase Current Transformers
IATTA, IATTB, IATTC Input Medium Voltage Attenuator Resistors
OATTA, OATTB, OATTC
HEB1, HEC1
Output Medium Voltage Attenuator Resistors
Output B and C Phase Hall Effect Current Transducers
4
X5 Auxiliary Voltage Control Transformer
BPPS Bypass Power Supply (Optional)
BCC Bypass Control Circuit (Optional)
TB1, TB2, TB2ELV, TB4 Terminal Blocks
GND2, GND3, GND7 Grounding Pads (GND7 is a Ground Lug)
PE Protective Earth
1. Refer to customer drawing “C” set and wiring diagram “W” set for references.
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19001591: Version 1.0 4-7
Figure 4-4: I/O Section
All medium voltage terminations and control terminal blocks are accessible from the front of the drive when the
control section panel is in the open position. Side and rear access is not required for field installation; however, a left
side removable panel is provided for use with transition cabinets and can be used for greater access where applicable.
Top and bottom access plates are provided for aiding installation. Swinging the control tub out is possible while the
medium voltage input is energized; however, only the terminal blocks are accessible because two polyglass barriers
(not shown) are installed on all units to the left of the terminal blocks. Qualified personnel can remove these
polyglass barriers to access the bypass control circuit, bypass power supply, auxiliary voltage control transformer,
and input/output medium voltage terminals.
The input and output medium voltage terminals (L1, L2, L3 and T1, T2, T3) are offset from one another and have two
NEMA one-hole pattern configurations (vertical and horizontal) to facilitate top or bottom cable termination (see
Figure 4-5).
* Note: The GenIV design is best accommodated for single conductor single core medium voltage cables.
Three conductor single core cables are not recommended and may require special attention.
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4-8 19001591: Version 1.0
Figure 4-5: Medium Voltage Terminations (L1, L2, L3, or T1, T2, T3)
The input current transformers, output Hall Effect current transducers, and input/output voltage attenuators are pre-
engineered according to each project's requirements. The metallic chassis, housing the hall effect current transducers
and low voltage portion of the medium voltage attenuating resistors, are grounded at point GND3. The secondary of
CT1 and CT2 are also grounded to point GND3. The bypass power supply and bypass control circuit are used when
Mechanical Cell Bypass is selected as an option. The auxiliary voltage transformer steps customer-supplied three
phase low voltage down to single phase 120V for use with the NXG II controller. This 500 VA transformer is
protected by three control fuses (2 primary, 1 secondary) that are located in the Control Wire Way section.
Figure 4-6: Output Hall Effect Current Transducers (HEB1, HEC1)
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19001591: Version 1.0 4-9
4.3.2 Transformer Section

The Transformer section is located in the bottom half of the GenIV enclosure and contains the following components:
Table 4-4: Transformer Section Components
Component Label Part Description
X1 Integral Isolation Transformer
FA1A, FA1C, FB1A, FB1C, FC1A, FC1C,
4
FA2A, FA2C, FB2A, FB2C, FC2A, FC2C, Power Cell A and C Phase Input Fuses
FA3A, FA3C, FB3A, FB3C, FC3A, FC3C
GND6 Grounding Pad
The transformer enclosure section primarily houses the transformer, polyglass air baffling, and the secondary fuse
block containing each power cell’s A and C phase input fuses. The left front side of this section also serves as the
access point for input/output medium voltage cabling. The transformer core is grounded to the enclosure at GND6.
Transformer
The GenIV uses an isolating multi-winding nine secondary phase shifting transformer (see Figure 4-7). It is
configured for an 18-pulse power quality reaction to the utility by using +20o, 0o, and -20o extended delta 750V
secondary windings with reference to the wye primary. The transformer impedance is 6 - 7%. The transformer is a
dry type forced air cooled unit, and polyglass air baffles are used to direct air movement across the coils. Some
transformers are equipped with secondary winding coolers for improved thermal performance. The transformer is
wound with 220oC winding insulation and the BIL level depends on the input voltage rating. During Siemens'
assembly, the transformer and polyglass baffling are installed through the top of the transformer section enclosure.
Adequate ventilation is provided by the centralized blower to maintain less than a 15o C rise across the unit. A
conservative winding design rise is used to ensure a 20-year life expectancy given the non-linear secondary loading.
All connections to and from the transformer are made with insulated wire. Two sets of normally closed thermal
protectors are imbedded into the transformer primary windings and are continuously monitored by NXG Control
(typically 170o C and 190 o C temperatures are used). The transformer is equipped with off-line taps to accommodate
utility line variations, +5%, 0%, and -5% are supplied on typical units (at shipment, the units are placed on the 0%
tap).
The default winding conductor is aluminum; however, some cases will require the use of a copper winding, which is
dependent upon the apparent power (kVA) size, input voltage, frequency, and user preference. The transformer is
optionally available with an electrostatic shield and/or primary distribution class surge arresters. Several line
voltages, apparent powers (kVA), and frequencies are provided as customer options (see Chapter 3 for applicable
ranges and frames). Values outside these boundaries will be considered CUSTOM and will be subject to engineering
evaluation.
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4-10 19001591: Version 1.0
Figure 4-7: GenIV Transformer
* Note: In the unlikely event of a transformer failure requiring replacement, the drive must be disassembled,
allowing for top removal from the transformer section.
The transformers are sized on a 1000 VA per Hp basis (as shown in Chapter 1, and further shown below); however,
other factors must be considered, such as motor lead length, motor service factor, environment ambient and altitude,
and power cell redundancy (N+1 3300V project). These factors may increase the kVA size of the Perfect Harmony
transformer as follows:
1. Transformer initial sizing is based upon 1000 VA per Hp (including motor service factor):
kVA1 = Hp * Service Factor
2. If ambient temperature exceeds 45 °C, then transformer size is increased by:
kVA2 = kVA1 * [175/(220-AMB)]^0.5
3. If altitude exceeds 3300 feet above sea level, then transformer size is increased by:
kVA3 = kVA2 * [1+0.00003*(ALT-3300)]
4. If Redundant N+1 operation is required (3300V projects), then the transformer size is increased by:
kVA4 = kVA3 * 1.125
5. Choose the smallest rating greater than or equal to kVA4 from the applicable frame size list shown in
Chapter 3.
Figure 4-8: GenIV Transformer Sizing and Derating Factors1,2
1. Excludes long cable provisions

2. Maximum ambient of 60 oC and maximum altitude of 6562 feet
Note: At elevations above 6562 feet, a dielectric strength derate is required. Consult engineering.
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19001591: Version 1.0 4-11
Fuses
The secondary fuse block is conveniently located at the front of the transformer section. There are three approved
fuse sources (Ferraz, Bussmann, and Siba). A label is located on the left side of the fuse block that shows all
approved replacements. Only two phases of each transformer secondary (power cell input) are fused. Each fuse has
visual blown indication, making it easy to diagnose a fuse’s condition. Fuses are forced air cooled for longer life and
less thermal stress.
Figure 4-9: Cut-Out View of Fuse Assembly
The GenIV fuses are mounted external to the cell. This not only reduces the size of the cell, but also allows for the
fuses to be located in one central accessible location. They primarily provide secondary short circuit protection and
are sized to accommodate power cell charging currents upon initial energizing.
Note: A mixture of the three fuse vendors are permitted in terms of fuse replacement as long as any two
* fuses protecting the secondary windings are matched (i.e., FA1A and FA1C should be from the same
vendor).
Note: The GenIV core drive does not include primary fuses. When E-rated fuses are required, choose the
* smallest rating greater than or equal to the transformer’s primary nameplate current value
(e.g., 1000 KVA / (1.732 * 4160V) = 139A, use 150E fuses).
4.3.3 Cell Section

The Cell Section is located in the upper right hand portion of the GenIV drive enclosure. The basic electrical
diagrams for all Perfect Harmony systems are similar. One of the most critical components of all Perfect Harmony
drives is the power cell (see Table 4-5). Depending on the operating load voltage, in GenIV either 9, 15, or 24 cells
are used to develop the multi-level PWM output waveform. The following table lists the components found in the
Cell section.
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4-12 19001591: Version 1.0
Table 4-5: Cell Section Components
A1, A2, A3, B1, B2,

GenIV Power Cells (40, 70, 100, or 140 Amp types)
B3, C1, C2, C3
BPKA1, BPKA2,
BPKA3, BPKB1,
BPKB2, BPKB3, Mechanical Cell Bypass Contactors (Optional)
BPKC1, BPKC2,
BPKC3 4
K2 Mechanical Key Interlock (Optional)
* Note: The core GenIV drive does not include medium voltage input switchgear. The K2 mechanical
interlock key must be coordinated with the input voltage switchgear.
Figure 4-10: GenIV 40-140A Power Cell Frame
The Cell Section portion of the enclosure includes two hinged doors. The left door is master door of the GenIV
system and has provisions for a K2 mechanical key interlock. A system requiring agency approval will require
mechanical key interlocks. This K2 key should be interlocked with a keyed lock located in the incoming switchgear
(coordinated with the Siemens project engineer). Only when the incoming switchgear is mechanically and electrically
opened should the K2 key be released for use at the GenIV drive. The GenIV doors are coordinated mechanically to
minimize the amount of keyed locks.
* Note: The Control Door, Control Section, and I/O Section are accessible without a K2 key. However, the
medium voltage components located in the I/O section are separated by fixed polyglass barriers.
The cells are installed in the enclosure by sliding them on the polyethylene coated mounting rails. The cell’s locking
latches are then rotated into the mounting rail slots, aligning and locking the cell into place. High-temperature foam
provides for an air-tight seal between the cell chassis and the backplane. Power Cell line and load connections are
made via blind mate power plugs located at the rear of the cell. The plugs accept a special sized nickel plated copper
chamfered power bus. No hardware is required to make the power connections or to physically mount the cell,
making installation, replacement, and maintenance simple. See Figure 4-11 for a depiction of the cell racking system.
* Note: The blind mate power plugs have been factory tested at 250 insertions/extractions with no significant
change in contact resistance.
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19001591: Version 1.0 4-13
Figure 4-11: Cell Installation and Latching System
The cell mounting infrastructure consists of a polyglass backplane, cell mounting rails, and horizontal polyglass
supports. Each of the nine Power Cell’s three-phase AC input connections exit at the top right of the Transformer
Section, and are routed to the cell via three large adalets (right enclosure wall) and two lexan wire trays. These trays
are located underneath the cells. The Power Cell’s single phase PWM AC output connections are made in the rear air
plenum via bus connections. Projects requiring Cell Bypass will use an additional bus network scheme to connect
and physically mount the bypass contactors (BPKA1 through BPKC3). Contactors can be changed in the field
through the front of the enclosure by removing a Power Cell, disconnecting the subject contactor, and pulling it
through the polyglass back plane (only qualified personnel should access the contactors). The contactors and bus
connections are forced air cooled (see Figures 4-12 and 4-13). Projects that do not require Cell Bypass use an
alternative bus connection made between the power cells’ T2 and T1 terminals.
* Note: A cell lifter, P/N 163496.08, may be required to install or remove power cells from the GenIV System.
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4-14 19001591: Version 1.0
Figure 4-12: Nine Cell 40-140 Amp Mounting Structure
Figure 4-13: Bypass Contactors and Bus Connections
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19001591: Version 1.0 4-15
Cell Construction
All GenIV MicroHarmony 750V Cells frames (40, 70, 100, and 140 Amp) have an identical footprint, see Figure 4-
14 (dimensions and mass are detailed further in Chapter 3 of this manual). The cells in any given drive are
mechanically and electrically identical, so that they may be interchanged. Each cell contains its own Cell Control
Board (CCB), which communicates to the centralized controller (NXG II) via a fiber optic link. This link is the only
connection between the Power Cells and the controller, thus each cell is galvanically isolated from the main control.
A switch mode power supply located on the CCB allows the control power to be derived from the individual 3-phase
secondary connections of the transformer feeding the power cell line inputs. This power supply is operational at a
fraction of the rated voltage of the cell input voltage. The Perfect Harmony controller, known as NXG II, provides
central control and interrogation of the nine cells, as detailed in previous chapters of this manual.
4 The following figures illustrate all power input/output terminals and fiber optic control terminals. Power connections
are made via power plugs; no hardware is required. Fiber optic control connections are made at the front of the cell
directly to the cell control board. The cell control board and power electronics can be accessed and tested at the same
time by rotating the cell 90o as shown (only qualified technicians should examine the Power cells), removing the
chassis top cover, and opening the CCB access plate (see Figure 4-14). The + and - DC bus can be accessed by
removing the top lid (not shown). Threaded studs are located on the bus for test connections.
Figure 4-14: GenIV Power Cell with Board Shown
The 40, 70, 100, and 140 Amp power cells are only differentiated by the number of electrolytic capacitors that are
installed and the semiconductor devices (diode rectifiers, IGBTs) on the heat sink.
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4-16 19001591: Version 1.0
Figure 4-15: GenIV Cell, 40-140Amp, Anatomy

* Shown with full population of electrolytic capacitors
The GenIV cells use an uncontrolled diode rectifier to convert the three-phase secondary voltage to DC. Since power
can only flow from the transformer to the cells, the converter is considered a two quadrant type (2Q).
Figure 4-16: GenIV Cell, 40-140Amp, Heat Sink
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19001591: Version 1.0 4-17
Cell Data
Switching Frequency
Cells are typically switched at 600 Hz per pole, with an output switching frequency of 1200 Hz per cell. The total
effective drive output switching frequency with 9 cells is 3600 Hz. At this switching frequency, the output (motor)
frequency can increase to 167 Hz. At motor frequencies beyond 167 Hz, its recommended to switch the cells faster.
The cells can switch (with current de-rating) as high as 1200 Hz per pole, which allows a maximum output (motor)
frequency of 330 Hz.
Communications
4
The Cell Control Board (CCB) communicates with the NXG Controller via a duplex fiber optic cable using a
proprietary protocol.
Protection Features
The Cell Control Board (CCB) contains circuitry and firmware that protects the cell from the following abnormal
operating conditions:
• DC Bus Over-Voltage
• DC Bus Under-Voltage
• Control Power Loss
• Capacitor Voltage Sharing
• IGBT Out of Saturation
• Cell Over-Temperature
• IGBT Device Failure
• AC Bus Under-Voltage
• Communication Fault
These conditions are interrogated by the main NXG Controller and may result in a Cell Fault, which inhibits the
power cell output.
Indicators and Labels
Figure 4-17 illustrates the indicator functions and labels of the Power Cell. Particular attention should be paid to the
DC bus voltage-indicator LED that shows that more than 50 VDC is present on the DC bus. This indicator light is
located on the front of each cell’s Cell Control Board (and may not be visible until the cell doors are opened). The cell
should not be touched, removed, or serviced if the indicator is illuminated.
Danger! Remember that the cell chassis is not grounded and when energized can float to lethal voltages.
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4-18 19001591: Version 1.0
OOOOOO
Fiber DC Bus Voltage Indicator

Q4
Q3
Q2
Q1
FAULT
LINK ON
Optic (>50VDC)
Figure 4-17: Indicators and Labels
Warning! The power cells include discharge resistors to dissipate stored energy after the input voltage is
removed. The power cell DC bus voltage decays to less than 50 VDC in less than 5 minutes.
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19001591: Version 1.0 4-19
Cell De-rating
In some cases, a cell’s continuous output current rating is de-rated due to site conditions and abnormal applications.
(Refer to Figure 4-18.)
1. Power Cell initial sizing is based upon the motor parameters,

(including motor service factor):
IMTR = Hp * SF * 746 / (VMTR * 1.732 * PF * EFF)
4 2. If motor nameplate frequency exceeds 167Hz, the FCAR = 3.6 * FOUT

[Hz], and when FCAR exceeds 600 Hz de-rate cell current as:
IBASE 1 = (1-[(FCAR-600)/600]*0.2)
3. If FOUT is operated continuously below 10 Hz, de-rate cell current as:

IBASE 2 = (0.5 + FOUT / 20)
4. If altitude exceeds 3300 FASL, then de-rate cell current as:
IBASE 3 = (1-0.00003*[ALT-3300])
5. If ambient temperature exceeds 45 °C, then de-rate cell current as:

IBASE 4 = ([60 - TAMB]/15)^0.67
6. Use only the smallest de-rate factor from IBASE 1, IBASE 2, IBASE 3, and
IBASE 4 to size the cell (de-rates are not compounded). Select the smallest
cell frame size equal or greater than IMTR / IBASE (1,2,3, or 4)
Figure 4-18: GenIV Cell Current De-Rate Factors 1, 2
1. Excludes long cable provisions

2. Maximum ambient of 60 °C and maximum altitude of 6562 feet
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4-20 19001591: Version 1.0
Cell Bypass
As an option, the core GenIV drive can be equipped with Cell Bypass. Each cell output is fitted with a single pole
double throw electromechanical contactor (as shown in Figure 4-19 below).
Figure 4-19: Electromechanical Contactor (Single Pole, Double Throw)
The bypass contactors are mounted behind the cell in the air plenum. All connections are made with insulated wire
and bus connections. The Bypass Power Supply (BPPS) and Bypass Control Circuit (BCC) are located in the I/O
Section. The BCC connects to the NXG controller via a fiber optic link and contactor controls are wired to the BCC.
The BPPS is energized from one of the transformer secondary windings and is referenced to the VFD output neutral.
Refer to Sections 1.3.5 and 5.13.1 for further details concerning power Cell Bypass.
Figure 4-20: Cell Bypass Operation
4.3.4 Control Section

The Control Section is located in front of the I/O Section and contains the NXG II Controller, low voltage apparatus,
and the auxiliary voltage disconnect switch; the Control Door is considered part of this section in reference to the “C”
and “W” drawings. The door in the control section is hinged so that it can swing open 150 degrees to allow access to
the input/output section for purposes such as terminating medium voltage cables. Upon opening the control door, two
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19001591: Version 1.0 4-21
polyglass barriers are encountered as describe previously. In addition, the terminal blocks are accessible with the door
in the open position. See Table 4-6 for the components found in this section.
Table 4-6: Control Section Components

SCB NXGII: Signal Conditioning Board
SW2 Latch Fault Relay Reset
DCR NXGII, Digital Card Rack
Slot 1: Keypad Interface Board
4 Slot 2: Single Board Computer
Slot 3: BGA Modulator with 12 Fiber Optic Ports
Slot 4: Reserved
Slot 5: Analog I/O Cable Assembly
Slot 6: System I/O Board
Slot 7: Digital I/O Cable Assembly
Slot 8: Communications Board
CPS Control Power Supply
DS1, AUX2 Auxiliary Voltage Disconnect and Position Switch
LFR Latch Fault Relay
EPS Encoder Power Supply (optional)
IOB NXGII, Input/Output Breakout
GND1 Grounding Pad
PB4 Emergency Stop Pushbutton
KP1 Keypad
RS232 RS232 Port and Ethernet Port
SW1 Mode Selector Switch
ANYBUS1, ANYBUS21 Network 1 and Network 2 communication cards (optional)
1. These expansion boards plug into the communications board in slot 8 of the
DCR
Control Tub
The control tub contains all the components shown in Figure 4-21.
* Note: Encoder Power Supply option not shown; it mounts to the din rail beside DS1.
The auxiliary voltage for control is switched on with the disconnect, DS1. The encoder power supply, EPS, is a 120V
powered +15 VDC output that is used in CLVC applications and is available as an option. GND1 is connected to
GND2, located in the I/O section using a flexible ground conductor; several points within the Control Tub are
grounded to GND1.
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4-22 19001591: Version 1.0
Figure 4-21: GenIV Control Tub
NXG II
The four components comprising NXG II Control are SCB, DCR, CPS, and IOB. The components are fully detailed
in the companion manual, NXG Control Manual 19001588.
Analog and Digital Input/Output
The input/output breakout (IOB) contains a finite amount of hard-wired I/O. Some of these signals are dedicated for
use within the drive (refer to Table 4-7). The remaining SPARE I/O can be used in agreement with the Siemens
project engineer for customer related signalization using the SOP.
Signal Type Quantity Core Configuration Custom Options
a) Customer powered2
Digital Inputs 20 1
120 VAC b) 24 VDC, drive powered3
c) Other than Table 4-7
Dry N.O. Contacts, a) Dry N.C. Contacts

Digital Outputs 16
rated 250 VAC @ 6A b) Other than Table 4-7
a) (2) 0-10 VDC inputs

Analog Inputs 3 4-20 mADC
b) Other than Table 4-7
Analog Outputs 2 4-20 mADC a) Other than Table 4-7
1. Drive Powered Digital Inputs

2. Subject to Custom Engineering Requirements
3. Requires Custom Engineering
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19001591: Version 1.0 4-23
Note: Network communications have provisions for I/O signalization as described in the NXG Control
* Manual 19001588 and NXG Communications Manual 902399. For GenIV expansion, hardwired I/O must be
treated as Custom engineering and requires the use of a Transition cabinet due to the limited space available
within the core drive.
Table 4-7: Nine Cell, GenIV, Core Hardwired I/O Assignments
(Subject to Change. Always refer to the project “C” and “W” for I/O assignments)
Signal Type Signal Name Function
Digital Input IDI-0A Remote Inhibit
4 Digital Input IDI-1A Remote Start
Digital Input IDI-2A Remote Stop
Digital Input IDI-3A Remote Fault Reset
Digital Input IDI-0B SW1-Off

Digital Input IDI-1B SW1-Remote/Auto
Digital Input IDI-2B Output Reactor Winding Temperature, High (Else SPARE)
Digital Input IDI-3B Output Reactor Winding Temperature, High-High (Else SPARE)
Digital Input IDI-0C SPARE
Digital Input IDI-3C Transformer Winding Temperature, High

Digital Input IDI-0D Transformer Winding Temperature, High-High
Digital Input IDI-1D Cooling Blower 1 O.K.
Digital Input IDI-2D Redundant Cooling Blower 2 O.K. (Optional)

Digital Input IDI-3D SPARE
Digital Input IDI-0E SPARE

Digital Input IDI-3E Latch Fault Relay (LFR) Feedback
Digital Output IDO-0 Speed Demand in Local at VFD
Digital Output IDO-1 Drive Ready to Run
Digital Output IDO-2 Drive Running
Digital Output IDO-3 Drive Alarm

Digital Output IDO-4 Drive Fault
Digital Output IDO-5 ProToPS, Process Alarm (Else SPARE)
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4-24 19001591: Version 1.0
Signal Type Signal Name Function
Digital Output IDO-6 ProToPS, Process Trip Alarm (Else SPARE)
Digital Output IDO-7 SPARE
Digital Output IDO-8 Cooling Blower 1 Starter
Digital Output IDO-9 Redundant Cooling Blower 2 Starter (Optional)

4
Digital Output IDO-14 Coordinated Input Protection Scheme
Digital Output IDO-15 Latch Fault Relay (LFR), Set Pulse
Analog Input IAI-1 Remote Speed Demand, 4-20 mADC
Analog Input IAI-2 SPARE
Analog Input IAI-3 SPARE
Analog Output IAO-A Motor Speed, 4-20 mADC
Analog Output IAO-2 Motor Torque, 4-20 mADC
Coordinated Input Protection Scheme
Input currents and voltages to the drive input transformer are measured and processed continuously by the control
system. Information such as efficiency, power factor, and harmonics are available to the user. The input monitoring
also protects against transformer secondary side faults that cannot be seen by typical primary protection relaying.
Thus it is very important that the drive input medium switchgear, if not supplied as standard, is interlocked to the
control system so that input medium voltage can be interrupted upon the rare event of such a fault.
A dry contact output is supplied standard with each drive to trip the drive input medium voltage circuit breaker or
contactor. This contact changes state whenever the drive input power and power factor are outside hardcoded normal
operating conditions.
Danger! This contact must be integrated with input switchgear to deactivate the drive input medium
voltage upon the rare event of a secondary circuit fault.
This scheme is active on all GenIV drives. Therefore, a medium voltage input circuit breaking device is required. As
shown in Figure 4-22 below, the latch fault relay, LFR, and its reset switch, SW2, make a portion of the coordinated
input protection scheme. The drive control continuously meters the input power, and if the drive exhibits excessive
losses or reactive power, then a dedicated NXG II I/O digital output (IDO-15) is closed as a one-shot pulse latches the
LFR coil. This causes the N.C. LFR contact to OPEN, and the NXG II I/O digital output IDO-14 also opens. As
shown in the following figure, if the contacts looking into the drive are closed, the user is permitted to close the
incoming breaker, hence the signal name “MV IP Breaker Enable”. However, if the contacts are open, then the input
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19001591: Version 1.0 4-25
breaker must also be immediately opened. In addition to the Input Protection scheme controlled by the NXG II
Controller, GenIV also series connects one deck of the E-Stop (PB4) in series with the Coordinated Input Protection
Scheme. Therefore, if the E-Stop located at the drive is operated, the contacts at TB2 will also open (this is only a
portion of the protection scheme that is subject to change, based upon user preference). To reset the protection
scheme, the LFR must be reset using SW2 (located in the Control Tub), which immediately recloses the LFR N.C.
contacts, and then a Drive Fault Reset must be initiated (NXG Control will not re-close IDO-14 if the FAULT
conditions still exist).
Figure 4-22: Input Protection Interface for Trip Contact

* This circuit is repeated in the “C” set of drawings. Contact ratings are shown for resistive switching.
* Note: Given the amperage rating of the components used in the Coordinated Input Protection Scheme, an
additional customer pilot relay may be required.
Terminal Blocks
The core drive uses 8mm 600V terminal blocks for the auxiliary input three-phase voltage (TB4). These terminals
accept #8 - #22 AWG wire.
The control terminal blocks (TB1, TB2, TB2 ELV) accept #12 - #22 AWG wire.
* Note: Only a small amount of spare terminals are available for custom engineering use.
Control Door
The Control Section includes the components mounted on the control door (see Figure 4-24). The operation of the
keypad, KP1, is described in the NXG Control Manual 19001588 (see Figure 4-25 for a view of the keypad operator).
The RS232 communications port is located on the front of the Control Door and is used for Serial communications
for debugging and uploading/downloading information to the NXG II controller. An Ethernet port is included on the
front door. Ethernet Modbus is available on the SBC, depending on what communications networks are selected for
Network 1 and 2 (see NXG Communications Manual, 902399).
SW1 is a Mode Select switch that is optionally selected as Off-Local-Remote or Off-Hand-Auto (SW1 can also be
keyed). The functionality is the same. If SW1 is in the OFF position, the inverter output will be inhibited. If SW1 is in
the Remote/Auto position, the control will use either a Remote 4-20 mADC speed demand or Network demand,
depending on how the project SOP is written. If SW1 is not in OFF or Remote/Auto, the speed demand is set by the
Keypad operator (this is considered the Local/Hand operation).
PB4, is a red mushroom-head maintained N.C. multi-deck operator that is used for emergency stops (E-Stop). One
deck of the PB4 operator is drive power 120V powered, and is used in series with the CR3 function of the drive. In
addition, this set of contacts is series connected to the terminal blocks, where the customer can wire in a N.C. set of
E-Stop wires (reference the “C” set of drawings) (see Figure 4-23). The YELLOW jumper must be removed from the
terminal blocks located in the I/O Section to allow proper operation of the remote E-Stop wiring. When activated, the
inverter output will be inhibited immediately and the connected load will coast. A second deck of the N.C. PB4
operator is connected to the terminal block section for use by the customer and is a dry set of contacts. A third deck of
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4-26 19001591: Version 1.0
the PB4 operator is connected in series with the Coordinated Input Protection Scheme. Therefore, in this scenario,
when PB4 is activated at the drive, the “MV IP Breaker Enable” signal will open (some customers may prefer
Custom engineering to alter the logic of this third deck).
Figure 4-23: E-Stop Circuits (Deck 1 and Deck 2) 4
Figure 4-24: Control Door
Figure 4-25: Keypad
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19001591: Version 1.0 4-27
4.3.5 Control Wire Way Section

The Control Wire Way Section is located within the enclosure and above the Cell Section. Two hinged door plates
are provided so that this section can be accessed with ¼ turn cams even while the drive’s medium voltage and
auxiliary power are energized.
* Note: Only qualified personnel should access this section at any time.
Following is a list of components found in this section (see Figure 4-26) for a view of the Control Wireway section
4 with all options selected).
F4, F21, F22 Control Power Fuses
F24, F25, F26 Blower 1 Line Fuses
F27, F28, F29 Blower 2 Line Fuses (Optional)
Motor Starter for Blower 1, auxiliary contact, and AC

STR21, AUX21, SUPP21
coil suppressor
Motor Starter for Blower 2, auxiliary contact, and AC

STR22, AUX22, SUPP22
coil suppressor (Optional)
X2 2.5% Line Reactor for EC Blower 1
X3 2.5% Line Reactor for EC Blower 2 (Optional)
FLTR1 EMC Filter for Auxiliary Control Voltage (Optional)
PL2, PL3 Blower Control Disconnect Harnesses
GND4, GND5 Grounding Pads
The auxiliary voltage control transformer, X5, is protected by three fuses, which are located in this section. F21 and
F22 are located on the primary of the auxiliary control voltage transformer, and F4 is located on the secondary of the
transformer. These fuses are CC time delay 600V rated.
The EMC filter is typically used on agency projects requiring CE certification. FLTR1 is a two-stage zero sequence
filter rated at 7A, and when used, is applied between the disconnect switch (DS1 in the Control Section) and the EC
Blowers’ motor starter.
Figure 4-26: Control Wire Way Section (with all options)
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4-28 19001591: Version 1.0
Cooling System Control

The cooling system control consists of several parts other than the EC blower and Zener command circuit described
in the next section. In addition to those components, each blower has three 600V Class J time delay fuses (F24, F25,
F26 and optionally F27, F28, F29) that feed 2.5% line reactors (X2 and optionally X3). The line reactors are then
connected to motor starters (STR21 and optionally STR22) that are controlled through the SOP of the NXG II
Controller. The output of the motor starters connect to quick disconnect plugs (PL2 and optionally PL3) that are
connected to the EC blowers. Fault logic is fed back from the blower through the plugs into the I/O system of the
NXG controller.
The default SOP logic is such that upon energizing the control power, Blower # 1 is operated immediately. The fault
4
logic is ignored for a short duration to allow the blower to soft start up to 80% speed. After this duration, if the SOP
logic controller detects a FAULT feedback, the redundant blower is started, or else the drive trips on a ALL
BLOWERS LOST fault, and the drive must be manually reset. The starter voltage is automatically removed for a
brief duration to allow the EC blower to reset its state. If redundant blowers are equipped on the drive, the blowers are
cycled on a periodic basis (typically every 7 days). The 2.5% line reactors (X2 and X3) are used to decouple the EC
blower from brief line disturbances; in addition, the reactors filter the current draw from the blower and make it more
sinusoidal.
4.3.6 Cooling
An extremely important part of the installation process is making provisions for exhausting the heat that is generated
by the operation of the drive. Although the GenIV drive is highly efficient, there may be as much as a 3.0% energy
loss emitted in the form of heat from inside the system cabinetry. This heat must be transmitted to the outdoor air or
into the structure of the building at a rate fast enough to prevent the ambient temperature from rising above the rated
conditions stated in Chapter 3.
Blowers # 1 and #2
The GenIV blower cages are located on the roof of the enclosure. Only one blower is required to operate the drive.
The cage assemblies are typically removed and packaged separately for shipment. All electrical connections between
the drive and blower are made via a quick disconnect harness for ease of installation. The GenIV blower cage uses a
rear tongue and groove lip and two front flange-mounted fasteners so that it is easily front-access-maintainable
following installation. Components in these sections include:
BLW1 Solid state (inverter) Blower #1
RBLW1*, DBLW1* Blower command; resistor and zener diode
BLW2 Solid state (inverter) Blower #2 (optional)
RBLW2*, DBLW2* Blower command; resistor and zener diode (optional)
*
Resistor and Zener diode form a clamp circuit to command the blowers to an 80% speed demand. However, if a
Duct Interface is required, these components are removed and the command jumpers directly to the +10VDC for a
100% speed demand.
The GenIV drive is a parallel path forced air cooled system using one electronically commutated blower; each of the
cells and the transformer are cooled in parallel by one centralized exhaust blower. Parallel air cooling allows each
component to have the same inlet air temperature (close to the drive’s ambient temperature) independent of the other
components. The cell section has six air inlet paths, each air inlet feeds 1½ cells. The transformer section has two air
inlet paths, each supplying ½ the transformer air. The transformer is baffled to force air up through the secondary
coils and around the windings.
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19001591: Version 1.0 4-29
The cell section and transformer section exhaust air into a common rear air duct. Each cell’s input and output power
connections are made via blind mate power plugs at the rear of the cell. The male connecting bus is located in line
with the exhaust air of the cell. For systems with mechanical cell bypass, the contactors are mounted on an additional
bus, located in the rear common exhaust air plenum. All of the bus and the contactors are therefore forced-air cooled,
but at an elevated ambient due to cell and transformer losses. Two phases of each cell’s inputs are fused. A common
fuse block is located at the front of the transformer section. The fuse ambient is the same as the drive’s ambient air
temperature.
The blower cage is a modular design; if redundant blowers are required, a cover plate is removed from the top of the
enclosure and an additional blower cage assembly is installed. A damper is installed at the base of each blower cage
to prevent reverse air flow. The dampers are opened by air pressure differential and closed by springs. The blower
4 cage assembly design consists of a steel frame with expanded metal mesh on three sides (duct interface jobs require
alternative pre-engineered blower cage). Air is exhausted out of the front and sides of the cage. Air is not exhausted
towards the back or top of the drive. A small portion of the blower’s exhaust air crosses the EC blower’s heat sink,
allowing high exhaust air ambient temperatures. The GenIV 4160V output 200-1100 Hp drive uses a 500mm EC
blower with inherent protection features (soft-start, under-voltage, phase failure, current limit, over temperature,
locked rotor protection, and short circuit protection). A fault contact is wired into the NXG II control I/O. If a
redundant blower is selected, the control cycles the blower periodically, and toggles them upon receiving a FAULT
feedback from the blower.
Note: The control removes power via a starter for a brief time following a FAULT signalization, according
* to the blower manufacturer’s recommendation. See Figure 4-27 for a view of the blower cage and EC
blower.
Figure 4-27: GenIV 500mm EC Blower and Cage Cutaway
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4-30 19001591: Version 1.0
Figure 4-28: GenIV 500mm Blower Cage Assembly
Note: Never energize the drive without operational blowers providing air flow. The drive contains
* components that have losses in the IDLE state. Without air flow, these losses may heat up components and
eventually damage the drive over time.
4.4 Long Cable Filters

For GenIV, output filters are typically required when cable lengths on the output of the drive exceed 7500 feet. At this
distance and beyond, the effective switching frequency harmonics and sidebands may excite a cable resonance,
resulting in transmission line over-voltages at the motor terminals. The output L-C filter decouples the drive output
from the cable/motor dynamics. NXG II control supports output filters for all control modes; however, torque
responses and high starting torque capabilities are somewhat diminished due to the added components. The filter
capacitor currents are monitored by NXG II control through the SCB, and active damping is provided in lieu of
additional hardware resistors.
* Note: GenIV drives should not operate into the O-M region when output filters are required. Therefore, the
nine cell system is limited to an output voltage of 4005V.
4.4.1 Reactors and Capacitors

When the GenIV requires an OUTPUT FILTER, the drive output is equipped with an output inductor and capacitor
filter. These components cannot be packaged into the core configuration due to space limitations; therefore, they are
housed in transition cabinets. Tables 4-8 and 4-9 list the required inductance and capacitance for GenIV output L-C
filters.
The reactors are typically custom engineered, and may include an overload rating that matches the cell type and two
sets of thermal protectors embedded into the windings.
The capacitors are heavy duty IEEE Standard 18 rated. Most commonly, available off-the-shelf capacitors are rated
for 60 Hz.
The filter connects to the output of the motor drive’s T1, T2, and T3 connections. The long cable load is then
connected to the load side of the filter reactors. The filter may include a customer-supplied down hole monitoring
system (DHMS). Special attention is required and small resistors may need to be placed in series with the DHMS to
prevent fuse failures during motor starting. The filter components are sized, based upon the continuous current rating
of the power cells and maximum voltage available (without O-M) of the drive.
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19001591: Version 1.0 4-31
Table 4-8: Nine Cell Output Filter, Capacitance
Q, Reactive
C, Capacitance C% C%
Cell Size ZFL @ 4005V @ 60Hz,
@ 60Hz @ 50 Hz @ 60 Hz
4160V, 3Ph
40 A 57.81 Ohms 25 kVAr 3.83 μF 6.95 8.35
70 A 33.03 Ohms 50 kVAr 7.66 μF 7.95 9.54
100 A 23.12 Ohms 75 kVAr 11.5 μF 8.35 10.00
4 140 A 16.52 Ohms 100 kVAr 15.32 μF 7.95 9.54
The filter reactor is sized to create a resonant frequency near 710 Hz. This results in the following inductance values.
Table 4-9: Nine Cell Output Filter, Inductance
Cell Size L, Inductance L % @ 50Hz L % @ 60Hz CT Ratio (# of turns)

40 A 13.5 mH 7.33 8.8 20A:5 (2T)
70 A 6.8 mH 6.46 7.76 30A:5 (2T)
100 A 4.8 mH 6.52 7.83 20A:5 (1T)

140 A 3.4 mH 6.46 7.76 30A:5 (1T)
* Note: Actual project L and C values are subject to change.
4.5 Synchronous Transfer Reactors

When the GenIV requires the SYNCH TRANSFER feature, the output of the drive is equipped with a reactor and
switchgear (contactors). These reactors cannot be packaged into the core configuration due to space limitations;
therefore, they are housed in transition cabinets. These reactors limit the rate of rise of current during transfers if the
line voltage and drive output voltage amplitude, frequency, and phase angle do not exactly match. Table 4-10 lists the
required inductance for GenIV synchronous transfer reactors. These reactors are typically custom engineered, and
may include an overload rating that matches the cell type and two sets of thermal protectors embedded into the
windings. They are sized, based upon the continuous current rating of the power cells and maximum voltage available
of the drive.
Table 4-10: Nine Cell Output Transfer Inductance
Cell Size ZFL @ 4160V L, Inductor L % @ 50Hz L % @ 60Hz
40 A 60.04 Ohms 13.5 mH 7.06 8.47
70 A 34.31 Ohms 6.8 mH 6.22 7.47
100 A 24.02 Ohms 4.8 mH 6.28 7.53
140 A 17.16 Ohms 3.4 mH 6.22 7.47
* Note: Actual project L values are subject to change.
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4-32 19001591: Version 1.0
4.6 Motor Compatibility

Although the Perfect Harmony topology output voltage contains a high THDv%, the drive was shown to have
low harmonic content between the fundamental and 25th. The nine cell GenIV drive was factory tested at Siemens
and was found to meet NEMA MG-1 for Harmonic Voltage Factor (HVF) < 0.03 and, therefore, motors do not need
to be derated.
Figure 4-29: HVF for Nine Cell GenIV

* Results are shown for a 1100 Hp 4160V nine cell drive loaded at 505kW, 86A, and 4230 voltage output
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19001591: Version 1.0 4-33
4.7 IEEE 519 Conformance

The eighteen-pulse nine cell GenIV drive was factory tested at SIEMENS and was found to meet IEEE 519 for the
most stringent TDD limits. The pre-existing voltage distortion was less than 2% and the primary current contained a
K-factor of less than 2.
Figure 4-30: Nine Cell, Harmonic Current Distortion (TDD < 5%)
* Results shown for a 4160V input 1100 Hp drive.
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4-34 19001591: Version 1.0
4.8 Ride Through

For NXG control, “Ride Through” occurs when the medium voltage input to the drive decreases below ~65% of
nominal. During this condition, the control forces the drive to go into regeneration, thereby absorbing power from the
rotating motor and maintaining the power cell stored energy. Such operation is maintained as long as medium voltage
is absent (or below 65%) and all cells are functioning. Typically, with very large inertia loads such as fans, operation
with no medium voltage is achievable for periods in excess of 5 cycles. If a cell reports a fault when the drive is
operating in “Ride Through,” the drive will trip on a “No Medium Voltage Fault.”
The eighteen-pulse nine cell GenIV drive was factory-tested at SIEMENS for input line voltage immunity. The drive
was shown to have a ride through capability of 5 cycles or more (line voltage was removed and then re-applied 7.5
cycles later).
4
Figure 4-31: Five Cycle Ride Through Capability

* Results shown for a 4160V input 1100 Hp drive loaded at 515 kW output prior to the input medium voltage
removal.
* Note: Depending upon motor inertia, ride through in excess of 5 cycles is possible with the addition of a
UPS for the auxiliary controls.
∇ ∇ ∇
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19001591: Version 1.0 4-35
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4-36 19001591: Version 1.0
GenIV Product User Manual Application and Operation
CHAPTER
5 Application and Operation

This chapter provides an overview of some of the features, applications, and operating issues of the Siemens LD-A
Perfect Harmony VFD. Detailed descriptions and setup of many of these features are provided in the NXG Control
Manual, 19001588.
5.1 Signal Frame of Reference for Motor Control

The control signals used for controlling the motor must be assigned a polarity for use over four quadrants of control
to maintain consistency of the algorithms. This section clarifies what they are and what their polarities mean in the
various quadrants.
5.1.1 Frame of Reference

5
The four-quadrant frame of reference is defined as the four quadrants of operation of a motor. They are divided left to
right by the direction of rotation and from top to bottom by the polarity of the torque in the machine. Energy flow
from the drive into the machine is called motoring. Energy flow out of the machine and into the drive is called
regeneration or braking.
Figure 5-1 shows the relationship between the polarities of the signals. For example, starting at rest (in the ordinances
of the two axes), if a positive torque is applied to the motor, the acceleration is positive and the resultant speed
increases in the forward direction. This is governed by the following equations:
+slip
+T
-P Braking Motoring +P
+α +α
-V II I
+V
−ω +ω
Reverse Forward
III IV
−α −α
+P Motoring Braking -P
-T
-slip
Figure 5-1: Four Quadrant Operation of a Motor
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19001591: Version 1.0 5-1
Application and Operation GenIV Product User Manual
This then carries over into quadrant IV, showing that a negative torque produces negative acceleration (deceleration),
stopping the motor. If, however, the same torque is applied continuously, the speed of the motor will decrease to zero
and begin to accelerate in the opposite direction producing a negative rotational speed (ω) in what is now quadrant
III. Now if a positive torque is applied, the motor enters quadrant II and begins to decelerate. Since the rotational
speed is negative, and begins to diminish and approach a positive value, the acceleration must be positive to conform
to the above equations. Again, if the torque is held constant, the motor will slow to zero and then accelerate in the
forward direction, passing back into quadrant I.
The injection frequency must always be opposing the direction of rotation and is only used in the case of braking or
negative energy flow. Therefore, it is zero in the motoring quadrants (I and III) and is the inverse polarity of the
electrical frequency in the braking quadrants (II and IV).
5.1.2 Signal Polarities
Table 5-1: Signal Polarities

5 Signals Quadrant 1 Quadrant 2 Quadrant 3 Quadrant 4
Rotation speed (ωr) + - - +
Electrical frequency (ωs) + - - +
Slip (ωslip) + + - -
Torque + + - -
Current (Iq) + + - -
Voltage (vqs) + + - -
Acceleration + + - -
Injection Frequency (ωinj) 0 + 0 -
Power (flow) + - + -
Mag Current (Id) + + + +
Voltage (vds) + + + +
Note: For the electrical frequency (ωs) in the braking quadrants (II and IV) where the slip opposes the
* rotational speed, when the speed magnitude approaches the slip magnitude, the electrical polarity is
uncertain (when the slip magnitude is greater than the rotor speed, the sign will match that of the slip
rather than the sign of the rotor speed).
5.2 The Control Modes

Harmony drives use vector control to control induction and synchronous motors. Vector control provides a
framework that is simple to implement, but performs nearly as well as a DC motor. Figure 5-2 shows a simplified
representation of the vector control algorithm implemented in Harmony drives. The basic components of vector
control are:
1. Motor model: determines motor flux and speed.
2. Current regulators: these regulators are referred to as the inner loops.
3. Flux and speed regulators: these regulators are referred to as the outer loops.
4. Feed-forward (FF) compensation: improves the transient response of torque loop and flux loop.
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5-2 19001591: Version 1.0
Figure 5-2: Block Diagram of Vector Control Algorithms for Induction and Synchronous Motor Control
The motor model uses measured motor voltage and estimated stator resistance voltage drop to determine stator flux
amplitude, motor speed, and flux angle. This allows stator resistance compensation to be automatic. A simplification
of motor equations is obtained by transforming the 3-phase AC quantities (which are referred to as being in a
stationary reference frame) to DC quantities (that are in a synchronously rotating or DQ reference frame). A phase-
locked loop (PLL) within the motor model tracks the (stator) frequency and angle of the flux vector.
Motor flux amplitude is controlled by the flux regulator; its output forms the command for the magnetizing (or flux
producing) component. Motor speed is determined from stator frequency, and is controlled by the speed regulator. Its
output is the command for the torque (producing) current regulator.
The flux angle is used to decompose the measured motor currents into magnetizing and torque producing
components. It is this decomposition that allows independent control of flux and torque, similar to DC motor control.
These current components are regulated to their commanded values by the current regulators. Outputs of the current
regulators are combined to produce three-phase voltage commands that get modified with signals from various other
control routines before being passed on to the modulator. These control routines include: (1) dead-time compensation
(to compensate for dead-time in the switching of the upper and lower IGBTS of each pole in a power cell), (2) peak
reduction for third-harmonic injection (to maximize drive output voltage, and for drive neutral-shift (during
transparent cell-bypass), and (3) voltage commands to produce losses for dual-frequency braking. Transient response
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19001591: Version 1.0 5-3
of the flux and torque regulators is improved with the use of feed-forward compensation (FF) as shown in Figure 5-2.
The following table describes the symbols used to represent various quantities in the control diagram.
Table 5-2: List of Symbols Used in Figure 5-2
Symbol Description
D-component of motor flux; also equal to the motor flux, since Q-component is zero. Motor Flux is defined as:
FluxDS Motor_Voltage / Stator_Frequency (rad/s). Flux (which has units of Volt-seconds) is also proportional (but not
equal) to Volts-per-Hertz ratio.
For an induction motor: Motor_Speed = Stator_Frequency / Pole_Pairs – Slip_Speed
r This is the rotor (mechanical) frequency, which is equivalent to the motor speed.
For a synchronous motor: Motor _Speed = Stator_Frequency / Pole_Pairs
Ids Magnetizing component of motor current
5
Iqs Torque component of motor current
Vds,ref Output of magnetizing current regulator used in the D-Q transformation to produce 3-phase voltages
Vqs,ref Output of torque current regulator used in the inverse D-Q transformation to produce 3-phase voltages
s Stator frequency or output frequency of the drive. This is motorspeed (r) + Slip.
s Flux angle. This is the instantaneous position of the rotating Slip vector.
Ia Ib, Ic Motor phase currents.
Motor torque (in Newton-meters) and shaft power can be calculated as:
Torque (Nm)= 3* Pole_Pairs * Flux (Vs)* Iqs (A)
≈ 3* Pole_Pairs * Motor_Voltage (V) * Iqs (A) / (2π * Frequency (Hz)),
Shaft Power (W) = Torque (Nm) * Speed (rad/s) = Torque (Nm) * Speed (rpm) / 9.55
5.2.1 Open Loop Vector Control (OLVC)
This control mode should be used for most applications with single induction motors. In this method, the control
estimates motor slip as a function of load torque, and provides a performance that matches a vector controlled drive
(with speed sensor/transducer) above a certain minimum speed. With the correct motor parameters, the control can
provide good performance even at 1% of rated speed.
Speed feedback is synthesized from the stator frequency and the estimated motor slip, as shown in Figure 5-2. With
this control method, slip compensation is automatic.
In this control mode, if Spinning Load is selected, the drive begins by scanning the frequency range to detect the
speed of the rotating motor (please refer to Section 5.8.2) for a description of Spinning Load Operation). Once the
drive has completed the scan or if the feature is disabled, the drive goes into Magnetizing State. During this state, the
drive ramps the motor flux to its commanded value at the specified Flux Ramp Rate. Only when the flux feedback is
within 90% of the commanded flux, the drive changes to the Run State. Once in Run State, the drive increases the
speed to the desired value. All motor and drive parameters as described in the NXG Control Manual (19001588) are
required for this mode of operation. Default values for the control loop gains are sufficient for most applications.
5.2.2 Open Loop Test Mode (OLTM)
In this control method, the motor current feedback signals are ignored. This control mode should be used during drive
set-up, when the modulation on the cells is to be verified, or when testing the drive without a load. It can also be used
when the motor is first connected to the drive to make sure that the Hall Effect Transducers are working correctly and
are providing the correct feedback signals. This method should not be used to adjust scale factors for input and
output, voltages and currents.
In this mode, the drive goes through the Magnetizing State to the Run State without looking at the motor flux. Only
motor nameplate values and some drive related parameters are required for this mode. Special attention should be
given to the following parameters:
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5-4 19001591: Version 1.0
1. Spinning Load and Fast Bypass should be disabled.

2. Acceleration and deceleration times (in the Speed Ramp Menu) should be increased.
3. Flux Demand should be reduced.
5.2.3 Synchronous Motor Control (SMC)

For synchronous motor control (SMC), the drive is equipped with a field exciter that usually consists of a SCR based
current regulator. The field exciter operates to maintain a field current level that is commanded by the flux regulator.
An example application for a brushless synchronous motor is shown in Figure 5-3. For brushless motors, the diagram
assumes that the exciter stator is wound for 3 phase AC in the range of 350 to 400 volts. If that is not the case, a
transformer will be necessary between the auxiliary power and the field exciter. The circuit wheel needs only a
rectifier. For the brushless case without bypass, the motor does not require any protection other than that included in
the drive. Next Gen Control will trip the drive on a loss of field fault if the motor draws excessive reactive current,
which will occur when the exciter fails full on or off.
The overall control strategy is similar to Open Loop Vector Control, except for the flux regulator implementation as
5
shown in Figure 5-2. For synchronous motors, the flux regulator provides two current commands, one for the field
exciter current, and another for the magnetizing component of stator current.
With synchronous motor control, scanning the motor frequency to determine motor speed is completely avoided. The
control uses information from the rotor-induced speed voltages on the stator to determine rotor speed. The drive
begins (in the Magnetizing State) by giving a field current command, which is equal to the no-load field current
setting to the exciter. This lasts for a time equal to the programmable flux ramp time that is entered through the menu
system.
After this period of time, the drive goes into the run state. In most cases, the regulator in the field exciter is slow, and
the drive applies magnetizing current (through the stator windings) to assist the exciter in establishing rated flux on
the motor. At the same time, the speed regulator commands a torque-producing current to accelerate the motor to the
demanded speed. Once the field exciter establishes the required field current to maintain flux in the motor, the
magnetizing component of stator current reduces to zero. From this point onward, the drive provides torque-
producing current (for acceleration or deceleration) that is in-phase with the drive output voltage. In other words,
under steady state conditions, unity power factor condition is automatically maintained at the drive output. The field
current command is provided to the field exciter with the use of an analog output signal. Other differences between
SMC and OLVC are summarized below.
• The motor no-load current parameter represents the Field no-load current value in SMC.
• With SMC, the flux loop gains are slightly lower than with OLVC.
• Spinning Load should always be enabled with SMC.
• The drive magnetizing current regulator uses only the proportional gain for the flux exciter.
• Only Stage 1 Auto-Tuning can be used with synchronous motors.
• When you are performing Stage 1 Auto-Tuning, you must short the field winding to get a proper setup of the
stator resistance.
Attention! Never use Stage 2 Auto-tuning with synchronous motors.
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19001591: Version 1.0 5-5
Figure 5-3: Harmony Drive Arrangement for Brushless Synchronous Motor (with no bypass)
5.2.4 Volts/Hertz Control (V/Hz)

This control mode should be used when the drive is connected to multiple motors in parallel. The control algorithm is
similar to that of Open Loop Vector Control (OLVC), but it does not use some of the motor parameters in its control
algorithm that OLVC does.
* Note: Many of the features available with OLVC, such as fast bypass, spinning load, and slip compensation,
are not available with this method, as individual feedback and control of each motor is not possible.
5.2.5 Closed Loop Control (CLVC or CSMC)

In some applications, when stable, low speed (below 1 Hz) operation under high torque conditions is required, an
encoder may be used to provide speed feedback.
The control diagram of Figure 5-2 remains the same, except for the slip calculation block, which is disabled so that
encoder speed feedback is directly used as an input to the speed regulator.
When an encoder is used with the drive, the control loop type is required to be set to CLVC (for closed loop vector
control with an induction motor) or to CSMC (for closed loop vector control with a synchronous motor). Spinning
load should be enabled when this control mode is enabled.
5.2.6 Slip Compensation

NEMA B induction motors require slip of the rotor speed (RPM) relative to the stator speed (frequency) to develop
torque. The amount of slip is directly affected by the loading of the machine. For induction motors, the control
provides Slip Compensation to the speed reference to allow the motor to run at a constant speed, regardless of the
torque output required.
Slip Compensation operates as an open loop speed regulator that increases the electrical output frequency of the drive
as the load increases, or decreases the frequency as the load drops.
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5-6 19001591: Version 1.0
Effect of Slip Compensation on Motor Speed with NXG Control

With Slip Compensation, the electrical frequency is always greater than the desired shaft speed (mechanical
frequency) for all non-zero loads. Therefore, at 100% speed demand, the NXG OLVC will maintain the shaft speed at
the rated synchronous speed of the motor, not full load speed.
Example: A 6-pole motor rated for 60 Hz has a synchronous speed of 1200 rpm. The Full Load speed from the motor
nameplate is 1192 rpm. Sending a speed demand of 100% will produce a mechanical (shaft) speed of 1200 rpm with
slip compensation. This will result in a higher output (electrical) frequency to the motor, to provide the necessary
torque to achieve the desired speed. The slip frequency is directly proportional to the required torque, up to the rated
torque current.
Theory: Sending the drive a speed demand of 100% means that Synchronous or Rated Speed is desired. This is
calculated by equation 1 below.
5
Synchronous Speed, Ns, is defined by the formula:
1. NS = 120 * fRATED / # of poles
Slip is defined as a percentage (at rated torque) of the difference between synchronous and full-load speed (NFL)
divided by the synchronous speed:
2. Slip (%) = 100 * (NS - NFL) / NS
With slip compensation, the slip frequency is subtracted from the output frequency (fOUT) to ensure that the
mechanical speed matches the desired speed. In simple terms, this is done by taking the per unit (PU) Torque (TPU)
times the slip and subtracting it from the speed feedback (in frequency), effectively adding it to the speed reference:
3. SMOT = fOUT - (Slip * TPU)
4. SERR = SDMD - SMOT
In equation 4, SERR represents the error signal processed by the speed regulator. The implication for this is that for a
speed command of 100%, based on the synchronous speed, the applied electrical frequency will be higher than rated
frequency due to the increase created by the slip compensation (equation 3 and 4). This will result in the motor
running at true requested mechanical speed with the electrical frequency adjusted to provide the torque necessary to
produce that speed.
Limiting Frequency by Disabling Slip Compensation
If the motor is to be limited to a specific frequency, then the slip compensation can be disabled. In the same example,
the Full Load speed must be set to 1200 rpm. This effectively disables the slip compensation by reducing equation 2
to produce a slip of zero. Then equation 3 and 4 reduce to:
1. Slip = (1200 - 1200) / 1200 = 0
2. SMOT = fOUT - 0 = fOUT
The end result will be that the drive will regulate to the output frequency rather than the motor shaft speed
(mechanical speed). No compensation for slip is done.
Conclusion
With Slip compensation:
• Output shaft speed will equal the percentage of synchronous speed requested
• The frequency will vary depending on load, but the speed will be fixed
• Motor Speed in rpm should be monitored
Without Slip Compensation:
• The Output Frequency will equal the speed demand percentage of rated frequency
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19001591: Version 1.0 5-7
• The mechanical (shaft) speed will vary with load, but the frequency will be fixed
• Motor Frequency in Hz should be monitored
5.2.7 Frequency Regulator

A Frequency Regulator generates the motor’s torque-producing current reference. The Stator Frequency Reference
(Ws_ref) is generated from the output of the Slip Compensator. The Stator Frequency (Wout) comes from Phase
Lock Loop (an estimate of the actual stator frequency). The Frequency Regulator is evaluated at 1/5th of the inner
current loop update rate.
5.2.8 Torque Current Regulator

The Torque Current Regulator generates the motor’s Q-axis motor voltage. The Torque Producing Motor Current
Reference (Iqs_ref) is generated from the output of the Frequency Regulator. The Torque Producing Current
5
Feedback (Iqs) comes from Motor Current D-Q converter. The Torque Current Regulator is evaluated at the inner
current loop update rate. This regulator is the innermost (i.e., fastest) control loop in the NXG Control operating at
the sampling rate of the system (typically 3 to 6 KHz).
5.2.9 Magnetizing Current Regulator

The Magnetizing Current Regulator generates the D-axis motor voltage reference. The Magnetizing Motor Current
Reference (Ids_ref) is generated from the output of the Flux Regulator. The Magnetizing Producing Current
Feedback (Ids) comes from Motor Current D-Q converter. The Torque Current Regulator is evaluated at the inner
current loop update rate. This regulator is the innermost (i.e., fastest) control loop in the NXG Control operating at
the sampling rate of the system (typically 3 to 6 KHz).
5.2.10 Flux Regulator

The Flux Regulator generates the magnetizing motor current reference. The Flux Reference (λds_ref) is generated
from the control’s flux ramp. The Flux Feedback (λds) comes from Motor Voltage D-Q converter. The Flux
Regulator is evaluated at 1/5th of the inner current loop update rate.
5.2.11 Phase Lock Loop
The Phase Lock Loop module generates the Flux Angle (θ) and Stator Frequency (ωout). The Flux Q-axis term is
generated by the motor voltage D-Q transformation (λqs). The Phase Lock Loop module is evaluated at 1/5th of the
inner current loop update rate.
5.3 High Performance Control

When applying the Harmony drives, applications requiring high starting torque or low speed operation are considered
as “High performance” control.
5.3.1 High Starting Torque

When OLVC or CLVC control is used, the harmony VFD can deliver approximately 85-90% torque with 100% rated
motor current. The V/Hz control mode can provide 95-100% torque at 100% motor rated current.
This control mode is useful for obtaining high starting torque in applications with high series resistance (> 10%). To
enable this mode of operation, the following conditions should be satisfied:
• Drive control loop type should be set to V/HZ
• Rated slip should be non-zero
• Minimum speed limit should be greater than rated slip
For long cable applications, the minimum speed limit should be set to be the same as the percentage value of the total
resistance in series with the motor. For example, if the total series resistance (motor + cable) is about 30% of the
motor base impedance (this is a very long cable!), a minimum speed limit of 30% should be set.
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5-8 19001591: Version 1.0
The magnetization time or the Flux Ramp Rate should be set to at least twice the rotor time constant of the motor.
Drive Operation in High Starting Torque Mode
Once the drive start is issued, the drive goes through the following stages to the minimum speed setting, irrespective
of the speed demand. (Refer to Figure 5-4.) During the initial stages after the drive start is given, the drive operates in
an open loop mode (i.e., both speed and flux loops are initially disabled).
During the magnetization stage, the drive applies a magnetizing component equal to the no-load current parameter.
The drive then ramps up to rated slip speed while increasing the torque component (Iqs) of current to its rated value.
The drive maintains rated current for a time duration equal to the magnetization time. During this time, the motor
should produce rated torque under locked rotor (or high stiction) conditions.
The control then ramps the output from rated slip to the minimum speed limit while maintaining rated current. At
minimum speed, the control holds the speed ramp for one second at this value, reduces the torque current (Iqs), and
5
enables the speed loop. One second later, the flux loop is enabled and the drive resumes acceleration to the desired
speed demand. After the flux loop has been enabled, if the drive senses that the motor flux is low (or Ids is too high),
then the drive trips on Fail to Magnetize Fault within the time set by the Flux Ramp Time. Note that a “bump” in
output voltage may be noticed when the flux loop is enabled, since the control transitions from an open loop control
to closed loop using measured voltages and current.
When a stop command is issued, the drive ramps down normally from the operating speed to the minimum speed
settings, and then transitions to a coast stop (i.e., drive output is disabled).
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19001591: Version 1.0 5-9
FluxDS
FluxDS
Flux FLUX LOOP
Flux Reference CLOSED
No-load OPEN LOOP CONTROL

MAG Current - current
Ids
5 Motor
Minimum
speed Speed
Demand
Minimum
speed
Rated slip SPEED LOOP
Speed
CLOSED
Max TRQ
TRQ current - current
Iqs
Idle Magnetizing Run State Coast Idle

State State State State
RUN STOP
Command Command
Figure 5-4: Drive Operation in High Starting Torque Mode
5.3.2 Low Speed Operation

In some applications, when stable, low speed (below 1 Hz) operation under high torque conditions is required, an
encoder may be used to provide speed feedback. Use of a shaft encoder is recommended where the control’s slip
calculation block is disabled so that encoder speed feedback is directly used as an input to the speed regulator.
When an encoder is used with the drive, the control loop type is required to be set to CLVC (for closed loop vector
control with an induction motor) or to CSMC (for closed loop vector control with a synchronous motor). The VFD’s
Spinning load function should be enabled when this control mode is enabled.
5.4 System Program (SOP)

The Harmony Series of digital drives contain customized programmable logic functions that define many features
and capabilities of the drives. These logic functions are combined into a system program (SOP) that can be edited
either at the factory or in the field. Examples of logic functions include start/stop control logic, reference signal
handling, input/output control logic (e.g., annunciators, interlocks, etc.), drive-to-machinery coordination and more.
The system program is stored on the drive’s flash disk. Upon power-up, it is executed continuously by the drive’s
run-time software in a repetitive fashion, causing the intended logic statements to perform their functionality
depending on system operating conditions.
The SOP is developed and compiled off-line and can be downloaded to the drive’s flash disk via either serial or
Ethernet ports. Note that while the drive flash disk can hold multiple system programs, only one SOP can be active at
any time, and the VFD output must be idle to change the active SOP.
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5-10 19001591: Version 1.0
5.5 Command Generator

This section defines the Command generator functional blocks shown in Figure 5-5.
Analog Input
Sources
Ratio
Control
Critical Polarity Speed
Speed Speed
Speed Control Limits
Profile Ramp
Avoidance
PID
Controller
Reference
5
Set point
Sources
Figure 5-5: Command Generator
5.5.1 Raw Speed Reference

The NXG Control includes provisions for output speed demand entry as required for a specific application. The
active reference source is configured per specific system requirements and can be dynamically changed. This is
implemented via the drive’s “System Program” as defined in Section 5.4. An overview of each of the major
functional blocks is defined next, and a detailed description is provided in the NXG Control Manual, 19001588.
Analog Input Sources
The NXG control provides a means to provide multiple analog input sources that can be selected as demand inputs to
the system. The control scales these analog values into internal units, and monitors the levels for possible loss of
signal conditions. The control includes provisions for predetermination of VFD action upon loss of signal conditions,
including maintain speed, transition to preset speed, or trip VFD.
Ratio Control
The Ratio control is simply a fractional scaling unit available for the analog reference signals. This feature allows
multiple drives to share the same reference signal with rescaled output signal levels.
PID Controller
The PID loop is programmable from User Interface. The PID Command set point can be either an external Analog
Input or an internal set point. The PID Feedback is always from an Analog Input. The Proportional, Integral, and
Derivative gains, as well PID output limits, are programmable.
Set Point Sources
Set Points are internal menu entries that are static values based on user entry, keypad settings, or remote demand from
a network communication interface. There are a total of eight inputs that are menu entries from remote
communications. There are two special additional entries that are reserved for safety override and jog level set
points.
• Keypad
o Front panel keypad (or ToolSuite computer) used to set speed demand
• Increment/Decrement (Sample and Hold)
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19001591: Version 1.0 5-11
o Digital inputs (x2) that increase/decrease raw speed demand at the active acceleration/deceleration
rate, while input is maintained
• Increment/Decrement Step
o Digital Inputs (x6) that provide programmable step change to output demand each time input
transitions from Low to High state
• Preset levels
o Multiple user-defined preset values via menu system
• Jog
o Set to maximum active speed limit, intended for test purposes to “bump” motor
• Communication Network
5 o Digital Value as set per external communication interface to a PLC/DCS
5.5.2 Speed Profile

The Speed Profile uses the velocity demand signal as input, and generates a modified Best Fit Straight Line (BFSL)
velocity demand output.
5.5.3 Critical Speed Avoidance

Critical speed avoidance is used to prohibit the drive from operating in frequency ranges that may cause resonant
frequencies in mechanical systems. The NXG control provides three independent avoidance bands.
5.5.4 Polarity Control

Polarity control is simply an inverter. The output of the polarity block is the opposite polarity of the input. The
selection of this feature is based solely on the system program logic.
5.5.5 Speed Ramp

The Speed ramp is a functional block that takes an input demand and generates an output with a controlled rate of
change, based on the acceleration and deceleration limits established by the end user. Provisions are included for
multiple sets of acceleration and deceleration settings. The control provides a means to use any one of three separate
menu-defined acceleration/deceleration sets, or PLC network control as selected by the SOP.
5.5.6 Speed Limit

The Speed Limit simply limits the final output of the demand shaping chain to within preset operating limits defined
by the user. Provisions are included for multiple sets of forward rotation maximum/minimum limits, and reverse
rotation maximum/minimum limits. The control provides a means to use any one of three separate menu-defined
speed limit sets, or PLC network control as selected by the SOP.
5.6 Energy Saver

The VFD automatically implements an energy-saver function that adjusts the motor voltage as a function of torque,
and speed based on available voltage.
5.7 Drive Output Torque Limiting

The drive uses measured voltages and currents to implement torque-limit (rollback) conditions. Under one or more of
these conditions, the drive will continue to operate, but at a lower output torque (or current) level. An output torque
limit will force the motor (and the drive) to go into speed rollback, during which speed is reduced until the torque
demanded by the load falls below the torque limit. Rollbacks, which are triggered by various conditions, are
described in the following sections. The control will limit output current based on the lowest value determined.
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5-12 19001591: Version 1.0
5.7.1 Torque/Regeneration Limit

When the VFD output current exceeds the maximum torque-limit setting for the motor, the drive will limit output
current.
An inverse speed function based on the Regeneration limit setting is used during drive deceleration. This forces the
drive to absorb a constant amount of power from the load.
Provisions are included for multiple menu settings of torque/regeneration limits. The control provides a means to use
any one of three separate menu-defined torque/regeneration limits, PLC network control, or analog signal as selected
by the SOP.
5.7.2 Input Under-Voltage Rollback

When the input line voltage drops below 90% of its rated value, the drive limits the amount of power (and hence the
torque) that can be delivered to the load. The maximum allowable drive power as a function of line voltage is shown
in Figure 5-6. At 66% input voltage, the maximum drive power is limited to 50%, and is quickly reduced to a slightly
negative value at 65%. This limit forces the drive to absorb power from the motor and maintain the (cell) DC-bus
5
voltages, in case the input voltage recovers during MV ride-through. The limit is implemented as an inverse function
of speed to maintain constant power flow to the (cell) DC-bus.
A regulator is implemented to match the maximum drive power (PMAX) to the actual power flowing into the drive.
The output of this regulator sets the output torque limit. The NXG control provides menu settings for the proportional
and integral gains of this regulator.
Figure 5-6: Drive Power (Pmax) as Function of Input Voltage Magnitude (Ed)
5.7.3 Input Single-Phase Rollback

With Next Gen Control, input voltage unbalance (Eunbalance) is used for rolling back the drive output torque. Figure
5-7 shows the reduction in drive power as a function of the unbalance voltage. When the unbalance is less than 10%,
the drive operates without any output limitation. There is a linear reduction as the unbalance voltage increases from
10% to 30%, at which point the input has a single-phase condition. When the input line voltage unbalance increases
above 30%, the drive limits the amount of output power that can be delivered to the load to 40% of rated.
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19001591: Version 1.0 5-13
Figure 5-7: Drive Power (Pmax) as Function of Input Unbalance Voltage (Eunbalance)
A regulator is implemented to match the maximum drive power (PMAX) with the actual power flowing from the
drive. The output of this regulator sets the output torque limit. The NXG control provides menu settings for the
proportional and integral gains of this regulator, as well as an alarm setting for single-phase input detection.
5.7.4 Transformer Thermal Rollback

The input currents to the drive are monitored continuously. The largest among the three input phase currents is
limited to be at or below 105% of the nominal rating of the transformer. Drive output torque is reduced when this
current level is exceeded.
An integral regulator is implemented to limit the maximum input current to 105%. The output of this regulator sets
the output torque limit. The NXG Control provides a thermal gain parameter to represent the integral gain of this
regulator.
5.7.5 Field-Weakening Limit

The field-weakening limit is a torque limit that is based on the motor flux and motor leakage inductance. This limit
prevents the motor slip from exceeding pullout torque slip. Thus, it prevents unstable operation of the motor. This
limit normally occurs when motor flux is reduced significantly during energy-saver operation, or when operating
beyond the base speed of the motor. Under such conditions, a large step (increase) in load will force the output to be
limited, resulting in a loss of speed rather than motor pullout.
5.7.6 Cell Current Overload

The NXG Control provides a power cell (current) overload setting. A cell can operate at this overload value for 1
minute out of every 10 minutes. When the current is between the cell rating and the overload rating, the time spent at
that level is inversely proportional to the overload current setting. Table 5-3 provides an example of the time versus
current overload capability with a cell that has 120% overload capacity.
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5-14 19001591: Version 1.0
Table 5-3: Example of Overload Current Capability versus Time of Cell with 120% Overload
Allowed operating time (out of

Drive current (%)
every 10 minutes)
120 1 minute
110 2 minutes
105 4 minutes
100 Continuous
Note: The power cells used in Harmony drives do not have a fixed overload capability. Please refer to the 5
* cell’s overload rating as shown in Chapter 3 of this document to determine the overload capability for a
specific power cell.
5.8 Drive Tuning

Section 5.8.1 describes the Auto Tuning feature provided by the NXG control and its use in determining motor and
control parameters. Section 5.8.2 describes the setup of the Spinning Load function. This feature is used by the drive
control to detect motor speed by scanning the output frequency over the operating range of the application.
5.8.1 Auto Tuning

The basic motor parameters can be divided into two categories: nameplate data and equivalent circuit data.
Nameplate data, as the name suggests, is readily available (such as Motor Rated Voltage, Full Load Current, etc.).
However, equivalent circuit data (such as Stator Resistance, No-load Current, etc.) is available only from the motor
manufacturer. If this data is available, it can be entered into the NXG menu system. If this data is not available, either
default settings or Auto-tuning functions can be used.
Note 1: Auto Tuning is optional, but as stated above, it is recommended for applications in which high
* performance is required.
Note 2: The correct equivalent circuit data is required only when good control performance, such as high
starting torque or very low speed operation, is desired.
When operating an induction motor, the drive control is capable of performing Auto-Tuning. This feature allows the
drive to estimate parameters of the motor equivalent circuit. There are two stages of auto-tuning, each stage being
selected individually. Apart from measuring the motor equivalent circuit parameters during auto-tuning, the control
uses the measured motor parameters to adjust the control loops for the best possible control bandwidth (the
bandwidth for each control loop is fixed internally in software), and hence provides good performance in demanding
applications.
Such a feature provides drive tuning without the need for an extensive adjustment procedure. Although the auto-
tuning feature can be used with all induction motors, there are some limitations. Both stages of auto-tuning can be
performed with induction motors (OLVC or CLVC).
Warning! Only Stage 1 should be performed with Synchronous Motors (SMC or CSMC) or when Output
Filters are connected.
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19001591: Version 1.0 5-15
* Note: In most general-purpose applications (such as pumps and fans), default data for the motor
equivalent circuit is sufficient and auto-tuning is not necessary.
DANGER! LETHAL VOLTAGES!

Lethal voltages will appear on the drive outputs during both stages (1 and 2) of Auto Tuning.
Auto Tune Stage 1

Stage 1 determines the Stator Resistance and Leakage Inductance. This stage of auto tuning does not require the
motor to be de-coupled from the load. The motor does not rotate during this Stage. The data obtained from Stage 1 is
used to tune the inner regulators that control motor current. The current loop gains are automatically calculated and
5 saved by the control.
Auto Tune Stage 2
Stage 2 determines the no-load motor current and the motor inertia. The motor rotates at 30% of rated speed during
this stage. Generally, this stage of auto tuning requires the motor to be de-coupled from the load. Ensure that it is
acceptable to spin the motor before this test is enabled. Data obtained in Stage 2 is used to optimize the operation of
the outer loops that control motor speed and motor flux. The speed and flux loop gains are automatically calculated
and saved by the control.
DANGER! The motor will spin during Stage 2 of Auto Tuning.
* Note: Quadratic loads, such as pumps and fans, do not require the motor to be de-coupled for Stage 2 auto
tuning. The control is designed to minimize the errors introduced by such loads.
5.8.2 Spinning Load

The Spinning Load feature allows the drive to determine the speed of a motor that is already rotating. The drive is
thus able to apply output voltages at the same frequency as the rotating motor, and minimize any chance of a speed
transient. The Spinning Load feature in NXG Control is divided into two stages. During the first stage, Spinning Load
operates automatically when enabled, and requires no user adjustments. The drive control monitors motor flux, and is
able to provide an instantaneous restart. This stage is valid as long as there is detectable flux in the motor. Typically,
the drive is capable of restarting instantaneously if the time duration between drive disable and re-start is within 3 to
4 motor time constants.
The second stage consists of a scan feature during which a preset level of current of varying frequency is applied to
the motor. The control monitors the measured motor flux, and when the motor flux exceeds a programmable flux
threshold, the control assumes that the applied frequency is equal to the rotating speed of the motor.
Spinning Load should be enabled if any of the following operating modes or features is selected:
• Fast Bypass
• VFD Startup while motor is spinning (forward or reverse)
o Note that the ability to catch and decelerate a motor spinning in the reverse direction is determined by
the drive’s regenerative current capabilities
• Synchronous Motor Control (SMC and CSMC)
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5-16 19001591: Version 1.0
• Close Loop Vector Control (CLVC)
* Note: Spinning Load does not provide instantaneous restart with V/Hz control. With synchronous motors,
spinning load is always instantaneous, i.e., the drive will never go into a scan mode.
5.9 User IO
The VFD provides terminal strips as required for end-user connection of isolated analog and digital input/output
signals to the drive. Specific I/O implementation is customized for each drive where the end user must refer to
drawings provided with the drive. The NXG control interfaces each of these IO points via either built-in or expansion
IO modules. The built-in IO is dedicated to IO points critical to drive operation. The expansion IO connections, as
required, are intended for system IO that is for typical drive operation or non-critical for protection.
The system includes provisions for the following types of IO where specific configuration is as shown with the
drive’s drawing set. Note that the SOP determines the routing of each of these IO points, while the NXG Control
provides a means to define the type and scaling of the analog signals. 5
• Analog Inputs/Outputs
o 0-20 mA
o 4-20 mA
o 0 ±10V
• Digital Inputs - low side switching
o 24VDC
o 120VAC
• Digital (Relay) outputs
o Normally open or normally closed contacts available
o Refer to system drawings for contact ratings
5.10 Data Logs

The NXG control includes 3 separate data loggers to record events detected by the software. Each of these logs are
stored in non-volatile memory and can be captured by the user via the VFD’s serial debug port or the Ethernet Port.
The debug port is a standard RS232 interface. Data file access via the Ethernet port requires the user to connect a PC
running the NXG Tool Suite software (as described in Section 5.15) to the drive, and uploading the files to the PC’s
hard drive or display.
5.10.1 Fault Log

The Fault Log consists of a circular buffer that records up to 256 faults or alarms. This log allows the user to access
the 256 most recent faults and/or alarms that have been detected. The faults/alarms are time stamped to a resolution of
1 second, and also include a time stamp showing when the fault/alarm was reset/cleared.
5.10.2 Historic Log

The Historic Log records operating data of the drive and is frozen upon detection of a fault. The data recorded
consists of both fixed and programmable data points, which are sampled at the slow loop rate (typically 300-600 Hz).
Upon detection of a drive fault by the NXG software, the fault is recorded at time =0 and the drive continues to record
data for a brief period after the fault. This allows recovery of data just prior to and after any fault so that operational
data prior to and after the fault can be reviewed. Note that a new fault will overwrite the recorded Historic Log. The
Event log includes provisions to copy/record the historic log so that all fault events are recorded.
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19001591: Version 1.0 5-17
5.10.3 Event Log

The Event Log is a very large circular file that is used to record time stamped (1 second resolution) significant drive
events that are encountered. Data in the log includes:
• All Faults/Alarms (essentially Fault Log data)
• Historic Log, if enabled
• Significant Events, including:
o CPU Bootup
o Medium Voltage status
o Drive operating state changes (e.g., idle, magnetize, run, stop, etc.)
o Fault reset requests from user
5 o Menu entries
5.11 Faults and Alarms

If a fault or alarm condition exists, it will be annunciated on the keypad and recorded in both the Fault and Event
Logs. External hardwire indicators are also set as defined in the System Program. PLC access is available for all
faults/alarms.
All faults will immediately remove power from the motor and inhibit the drive from running, resulting in the motor
coasting to rest. Some faults that are user-defined can control the drive response via the system program. Alarms are
annunciated and logged, but usually do not inhibit the drive from operation. Faults are either detected via direct
hardware sensing or by software algorithm.
The NXG control includes both internal faults and alarms and the ability to define “User Faults” via the SOP, which
can be set as either faults or alarms.
Regardless of the source, all faults are user-friendly messages displayed in plain text where no fault “code” numbers
are used. User Fault/Alarm messages allow the SOP writer to define the fault as desired, with a 24-character limit.
5.12 Motor Overload

NXG Perfect Harmony control provides Motor Thermal Overload (TOL) protection to prevent the motor from being
subjected to excessive temperatures. TOL protection of the motor can be set up using the NXG control menu system.
The “overload select” parameter allows one of three options to be selected for motor protection. The first model,
which is called “constant,” is based on the current flowing into the motor. A Motor Thermal Overload Alarm 1 is
issued as a warning to the user (of an impending overload fault) when the motor current exceeds the “overload
pending” parameter. When the drive current exceeds the “overload” setting, Motor Thermal Overload Alarm 2 is
issued and a thermal trip timer is started. If this condition is present for a period greater than the time set in the
“overload timeout” parameter, the drive will trip and annunciate the event as Motor Thermal Overload Fault. It
should be noted that both the Alarms 1 and 2 have to be enabled through the SOP for the drive to display these
conditions.
The second and third thermal models, which are called “straight inverse time” and “inverse time with thresholds,” use
a software motor thermal model to determine motor temperature (see Figure 5-8). For these options, the “overload
pending” and “overload” settings represent the motor temperature limits (in percent of rated motor temperature) at
which the overload warning and trip are generated. A brief description of the thermal model follows.
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5-18 19001591: Version 1.0
Motor
Motor loss + 1 temperature
Motor voltages,
currents calculation
Σ M TH
-
Motor
parameters Motor cooling
model
Speed derate
curve 5
Figure 5-8: Block Diagram of Motor Thermal Model
The motor model estimates motor temperature based on the net heat generated in the motor and its thermal mass. A
block diagram of the implementation is shown in Figure 5-8. The heat generated in the motor is estimated from the
stator voltages, currents, and motor parameters, while an estimate of the heat transferred from the motor (due to
motor cooling) is made from the allowable motor current (explained in the following paragraph). The motor loss
calculation also includes the losses generated with Dual-Frequency Braking. The thermal mass (shown as MTH) of
the motor (or its heat capacity) is determined from the maximum load inertia listed in Table 20-1 of NEMA Standard
MG-1 1993 Part 20.42. The user has the option of entering a known value of max load inertia as well (which can be
obtained from the manufacturer).
If “straight inverse time” protection is chosen, then it is assumed that the motor has an allowable current level of
100% (for example, when the motor is equipped with a constant-speed cooling fan). With “inverse time with speed-
derating,” the allowable current level is determined from the speed-derating curve entered through the keypad. This
curve requires the user to enter allowable motor load for various speed breakpoints. The default-derating curve
provides breakpoints for a quadratic cooling curve (and is shown in Figure 5-9). The motor manufacturer normally
provides data for this curve. The control software uses the allowable current level to determine the cooling capability
of the motor.
If the user’s preference is to enter a fixed value of an allowable current level other than 100% (as with the “straight
inverse time” option), the speed-derating curve can be modified to have the same desired level for all breakpoints.
Figure 5-9: Default Speed-Derating Curve Showing Maximum Motor Load as Function of Speed
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19001591: Version 1.0 5-19
The plot in Figure 5-10 shows results from an experimental evaluation of the software thermal model with the
“straight inverse time” option (100% “overload” setting) for various levels of drive current. A 4kV, 300 Hp motor
was used for this test. The experimental data shows the time taken for the estimated motor temperature to go from
rated temperature to 120% of rated. This curve is quite conservative as compared to a Class 10 TOL that trips at
280sec with 150% current and at 630sec with 125% current.
Figure 5-10: Drive Current (in percent of motor rated current) vs. Time taken for Motor Temperature to rise
from Rated Temperature to 120% of rated *
* The data was measured with the “straight inverse time” option.
5.13 Input Side Monitoring and Protection

The NXG Control monitors input side voltages and currents, as well as those on the output side. This allows the
control to monitor and respond to events on the input side of the drive. RMS values of the input currents and voltages
are available, along with input power, kVA, energy, and power factor. Figure 5-11 shows a simplified view of the
functions implemented for input side monitoring. Other quantities, such as drive efficiency, average input current
THD, and individual harmonic component (in input voltages/currents), are also calculated. All variables have an
accuracy of ± 1%, except for efficiency (< ± 2%) and input current THD (± 1% above ~ 60% of rated power). A list
of symbols used in Figure 5-11 and a description of the parameters they represent are given in Table 5-4. Note that
the definitions of Id and Iq components of the input current are different from the output side quantities.
Input side monitoring allows the drive to protect the secondary side of the transformer from abnormal conditions.
Two faults, excessive drive losses, and one-cycle protection are generated under such conditions. Input side control
also provides torque current limiting for line under-voltage, single-phasing, and transformer overload conditions.
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5-20 19001591: Version 1.0
Figure 5-11: Block Diagram of Input-Side Monitoring
Table 5-4: List of Symbols Used in Figure 5-11
Name Description
Erms Average rms voltage (of all 3 phases)
Amplitude of voltage taking the transformer tap setting into account. This represents the actual voltage
Ed
being provided to the cells. If the tap setting is +5%, Ed will be 5% smaller than Erms, and vice versa.
Ea,b,c Zero sequence (DC offset) corrected input phase voltages
u Input frequency
u Angle of input-side flux
Irms Average rms current (in all 3 phases)
Id Real component of input current
Iq Reactive component of input current
Ia,b,c Single-phase components of input current
5.13.1 One Cycle Protection

NXG Control utilizes input reactive current to determine whether a “hard” fault on the secondary side of the
transformer has occurred. For example, a short-circuit in one of the secondary windings will result in poor power
factor on the high-voltage side of the transformer. A model of the transformer, based on the power factor at rated
load, is implemented in the control processor. The drive input reactive current is continuously checked with the
predicted value from the model. An alarm/trip is generated if the actual reactive current exceeds the prediction by
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19001591: Version 1.0 5-21
more than 10%. This check is avoided during medium voltage power-up to avoid the inrush current from causing
nuisance trips.
Implementation
Figure 5-12 shows the implementation of One Cycle Protection.
Figure 5-12: Implementation of One Cycle Protection
Transformer Model
The Transformer Model block in Figure 5-12 provides the maximum value of the input reactive current for a given
value of transformer constant, Ktr, as given below:
IReactive,Max = 1.10 * (0.05 + Ktr * IReal2)

Figure 5-13 shows a plot of the Max Reactive Current versus Real Current with a transformer constant of 0.5.
0.7
0.6
M ax R eactive current(p.u.)
0.5
0.4
0.3
0.2
0.1
0
0 0.2 0.4 0.6 0.8 1
Real current (p.u.)
Figure 5-13: Plot of Max Reactive Current Versus Real Current with a Transformer Constant of 0.5
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5-22 19001591: Version 1.0
Integral Timer
The integral timer gain can be calculated based on the desired response time (Ttrip) as shown below:
Igain = Ttrip / (Error * Slow_loop_sample_rate)
Where:
• Error is the maximum error (in per unit) that can be tolerated between IReactive,Max and actual reactive
current Ireactive
• Slow_loop_sample_rate is the sample frequency of the slow loop (typically 450 – 600 Hz).
5.13.2 Excessive Drive Losses

NXG control utilizes input power and output power calculations to determine whether an internal fault has occurred.
5
Drive Power Loss is estimated as the difference between input power and output power. This quantity is continuously
checked with a pre-defined threshold that is inverse time-based, i.e., if the threshold is exceeded by a large margin,
then the trip occurs a short time after the event, and vice-versa.
Implementation
Figure 5-14 shows the implementation of the Drive Loss fault circuit.
Figure 5-14: Implementation of the Drive Loss Fault Circuit
Inverse Time Curve

Figure 5-15 shows the inverse time-to-trip curves as a function of Drive Losses. Each plot shows two curves – one for
Idle State and the other for Run State (slightly longer time to trip). For software versions 2.22 and lower, a fixed trip
time of one second was used instead of the curves shown next.
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19001591: Version 1.0 5-23
- Idle
5
Figure 5-15: Inverse Time-To-Trip Curves Left – Idle State, Right – Run State
Internal Threshold
The internal threshold is a function of the rated drive input power. For example, in Run State, the internal threshold is
given as:
Internal Threshold (Watts)= 0.07 * rated Drive Input Poser
= 0.07 * √3 * Rated Input Voltage * Rated Input Current
* Note: The excessive losses threshold is programmable via the NXG menu system. This value is preset and
should not be changed without consulting the factory.
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5-24 19001591: Version 1.0
5.14 Cell Bypass

When the Perfect Harmony was first introduced, its most salient attributes were improved power quality at both the
utility interface and the motor interface. A third attribute is now recognized, which offers extremely high reliability
by utilizing the inherent redundancy of these drives. Cell Bypass is the feature that allows this third attribute to be
realized.
The Cell Bypass option is implemented by adding a contactor to the output of each cell as shown in Figure 5-16.
When NXG control interrogates the cells and detects that a cell has faulted, a command is sent to close the
appropriate contactor. This disconnects the cell output from the circuit. The drive can then be restarted and operation
can continue at reduced capacity. The amount of reduction in capacity that can be tolerated will depend on the
application, but in most cases a reduction in capacity is preferable to a complete shutdown. Neutral Point Shift is a
feature that was developed to minimize the reduction in capacity after a bypass. Another related feature is Fast
Bypass. This feature is designed to quickly bypass a cell and get the drive running again in less than ½ second.
Neutral Point Shift and Fast Bypass are discussed in the following sections.
5
Figure 5-16: Typical Power Cell with Bypass Contactor
5.14.1 Fast Bypass

Up time is an important factor in many processes. A Medium Voltage drive is often a critical part of the process and
even small interruptions in output torque of a Medium Voltage drive can cause the process to stop. This can result in
lost material and production time. Fortunately, in general, a process can ride through an interruption of ½ second or
less. The NXG control has a feature that is designed to limit the interruption of torque to the process by less than ½
second if a cell fault is detected. This feature is called Fast Bypass, which utilizes the capabilities of the NXG Control
system and the cell bypass functionality. The conditions that must exist for the drive to meet this ½ second maximum
interruption are described below.
Possible abnormal operating conditions are detected in cell control board hardware. This hardware is designed to
quickly shut down the drive to minimize damage. Once this happens, NXG control is then signaled. The control can
then quickly determine which cell faulted and the bypass process can be started. When the drive trips and stops
delivering torque to the motor, the motor acts like a generator and produces a voltage on the drive output terminals.
This voltage decays over time, but can be near the drive rated output voltage for a few seconds. If a cell is bypassed,
the remaining cells may not be able to support this voltage and damage can occur. To prevent this damage, a check is
done in the control to verify that the motor output voltage can be supported before a cell is bypassed. If sufficient
output voltage is available, the cell can be bypassed and torque can be delivered to the motor in under ½ second from
the time the cell fault occurred. If the motor voltage is too high, the control will delay the bypass process to allow the
back EMF voltage to decay. To guarantee that the drive will bypass a cell fault in under ½ second, the drive needs to
be operating at an output voltage that N-1 cells can supply. One way is for the drive to be sized so that it has more
than the minimum number of cells required to provide the voltage needed, defined as N+X redundancy (where X is
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19001591: Version 1.0 5-25
typically 1 or 3), following cell bypass. Another solution is to limit the maximum speed following cell bypass. These
issues must be studied and resolved before the drive is installed.
* Note: Fast bypass is dependent upon the available output voltage.
* Note: Acceleration following cell bypass is dependent upon parameter ramp rates and available torque
current.
5.14.2 Fast Bypass Process

The Fast Bypass process is summarized as follows, where control mode must be OLVC, CLVC, SMC or CSMC, and
Fast Bypass must be enabled.
1. VFD output enabled, output phase locked loop valid
5 2. Any cell fault occurs, output phase lock loop continues to track motor
3. VFD output disabled (all power cells disabled by NXG hardware)
4. NXG control detects cell fault(s)
5. NXG control monitors motor back EMF until it is within “safe” voltage
6. Control issues commands to bypass faulted cell(s)
7. Brief delay to allow mechanical contactors to fully close
8. Spinning load algorithm is performed (OLVC, CLVC) to detect motor voltage/frequency/phase
9. VFD output is enabled, synchronized to detected motor position/speed
10. VFD output ramps back to motor speed prior to cell fault
* Note: Maximum speed is a function of remaining VFD output voltage capability.
5.14.3 Neutral Point Shift During Bypass

Since the cells in each phase of a Perfect Harmony Drive are in series, bypassing a cell has no effect on the current
capability of the drive, but the voltage capability will be reduced. Usually the required motor voltage is roughly
proportional to speed, so that the maximum speed at which the drive can fulfill the application requirements will also
be reduced. Therefore, it is important to maximize the motor voltage available after one or more cells have been
bypassed. Figures 5-17 through 5-21 illustrate the voltage available from a Perfect Harmony drive, where the cells,
represented by circles, are shown as simple voltage sources. Figure 5-21 shows a 15-cell drive in which no cells are
bypassed. With 100% of the cells in use, 100% of the original voltage is available. The voltage commands to the three
phase groups of cells will have phase A displaced from phase B by 120°, and from phase C by 120°.
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5-26 19001591: Version 1.0
A
15 Module Drive 100% of the Modules
A5
with no Modules are in use. 100% of
Bypassed. full voltage is
A4
available.
A3
A2
VAC VBA
A1
120 o
TYP.
C1 N B1
C2 B2
C4
C3 B3
B4 5
C C5 B5 B
VCB
Figure 5-17: A Simplified Diagram of a 15 Cell Drive
When cells are bypassed in one of the drive phases, the output voltage will tend to become unbalanced, as illustrated
in Figure 5-18. One possible remedy is to bypass an equal number of cells in all three phases, even though some may
not have faulted. Figure 5-19 illustrates this approach. Obviously, this method prevents unbalance but sacrifices
possible voltage capability. In Figure 5-19, 87% of the cells are functional, but only 60% are in use, and only 60%
voltage is available.
15 Module Drive A 87% of the Modules

after Bypass are in use, but the
A3
of 2 Modules output voltage is
in Phase C. imbalanced.
A2
A1 120 o
VAC TYP. VBA
C1 N B1
C2 B2
C3 B3
C4 B4
C C5 B5 B
VCB
Figure 5-18: Drive Output with 2 Cells Bypassed
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19001591: Version 1.0 5-27

Bypass of 2 Modules in are OK, but only
A3
all Phases. Balance 60% are in use.
is restored. 60% of full volt-
A2 age is available.
A1 120o
VAC VBA
TYP
C1 N B1
C2 B2
C C3 VCB B3 B
5 Figure 5-19: Drive Output Re-Balanced by Bypassing Functional Cells
A better approach is illustrated in Figure 5-20. This method takes advantage of the fact that the star-point of the cells
is floating, and is not connected to the neutral of the motor. Therefore the star-point can be shifted away from the
motor neutral, and the phase angles of the cell voltages can be adjusted, so that a balanced set of motor voltages is
obtained even though the cell group voltages are not balanced.
Siemens calls this approach Neutral-Shift, and has a US Patent (5,986,909) that covers it. This approach is equivalent
to introducing a zero-sequence component into the voltage command vectors for the cells. In Figure 5-20, the full
remaining 87% of functional cells are in use, and 80% of the original voltage is available. The phase angles of the cell
voltages have been adjusted so that phase A is displaced from phase B and from phase C by 132.5°, instead of the
normal 120°.

Bypass of 2 Modules A3
are in use. 80% of
in Phase A only, full voltage is
and Adjustment available.
A2
of phase Angles.
A1
VAC VBA
132.5 o 132.5 o
C1 B1
C2 95o B2
C3 B3
C4 B4
C C5 B5 B
VCB
Figure 5-20: Drive Output Re-Balanced by Adjusting Phase Angles (Neutral-Shift)
The same neutral-shift approach can be applied to more extreme situations, as is illustrated by Figures 5-21 and 5-22.
Figure 5-21 shows a drive which originally had five cells per phase, or a total of 15 cells. All five cells remain in
phase A, but one cell has faulted in phase B and two cells have faulted in phase C. Without neutral-shift, all phases
would need to be reduced to match the cell count of phase C to maintain balanced motor voltages. One functional cell
would be bypassed in phase B, and two functional cells would be bypassed in phase A. Only 60% of the original cells
would remain in use, and only 60% of the original voltage would be available.
However, with the neutral-shift approach shown in Figure 5-21, only the faulted cells are bypassed. The phase angles
of the cell voltages have been adjusted so that phase A is displaced from phase B by 96.9° and from phase C by
113.1°, instead of the normal 120°. The star point of the cells no longer coincides with the neutral of the motor
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5-28 19001591: Version 1.0
voltages, but the motor voltage is still balanced. The neutral-shift keeps 80% of the original cells in use, and 70% of
the original voltage is available.
Figure 5-21: Drive Output after Loss of 3 Cells
As another example, Figure 5-22 shows the same 15-cell drive. All five cells remain in phase A, but two cells have
faulted in phase B and three cells have faulted in phase C. Without neutral-shift, one functional cell would be
bypassed in phase B, and three functional cells would be bypassed in phase A. Only 40% of the original cells would
remain in use, and only 40% of the original voltage would be available. However, in Figure 5-22, only the faulted
cells are bypassed. The phase angles of the cell voltages have been adjusted so that phase A is displaced from phase B
by 61.1° and from phase C by 61.6°. The star point of the cells is far removed from the neutral of the motor voltages,
but the motor voltage is still balanced. The neutral-shift keeps 67% of the original cells in use, and 50% of the
original voltage is available.

Bypass of 2 Modules are in use. 50% of
in Phase B, and 3 full voltage is
Modules in A5 available.
Phase C.
A4
VAC VBA
A3
A2
C VCB B
C2
61.6
A1 61.1 B3
B2
C1 B1
Figure 5-22: Drive Output after Loss of 5 Cells
Figure 5-23 compares the available voltage after one cell is bypassed with and without using neutral-shift. In many
cases, the extra voltage available with neutral-shift will determine whether or not a cell fault can be tolerated. The
voltage capability of a drive after cell bypass can be calculated by using the following procedure.
If X is the largest number of cells in bypass in two of the phases, then the maximum voltage at the drive output will
be:
Vout_bypass = Vout * (2*N - X) / (2*N)
where: Vout is maximum output voltage that the drive can deliver (Vout = 1.78*N*Vcell)
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19001591: Version 1.0 5-29
N is the number of ranks (i.e., number of installed cells per phase)

Vcell is the cell voltage rating.
Example: Consider a drive with 18 cells, each rated for 750V. The maximum output voltage that this drive can
deliver is (with N = 6 and Vcell = 750, and without O-M):
Vout = 1.78 * 6 * 750 = 8.01 kV
If after cell bypass, the drive has 6 cells operational in phase A, 5 cells in phase B, and 4 cells in phase C, then the
maximum voltage that the drive can produce with neutral shift from the above formula is (with X = 1 + 2 = 3, because
2 cells in phase C and 1 cell in phase B are bypassed):
Vout_bypass = 8010 * (2 * 6 - 3) / (2 * 6) = 6 kV
5 100
With Neutral-Shift
Available after One Failure
Percent of Original Voltage
90
80 Without Neutral-Shift
70
60
3 4 5 6 7 8
Original Number of Modules per Phase
Figure 5-23: Available Voltage after One Cell Bypass
The drive control uses the information of faulted cells to automatically calculate the phase angles of cell voltages to
maintain balanced motor voltages. During neutral-shift, each phase of the drive operates with a different power
factor. Under lightly loaded conditions, it is possible that one or more phases are absorbing real power while the other
phase(s) are delivering power to the motor. To prevent the cell dc-voltage (corresponding to cells that are absorbing
real power) from increasing (and subsequently causing a drive trip condition), the control automatically enables the
“Energy Saver” function. Under light loads, the energy saver function reduces motor flux sufficiently so that the
motor operates with 70% power factor. At this operating point, the magnetizing and torque components of motor
current are equal, and all cells deliver real power to the motor. As motor load is increased, the motor flux level is
automatically increased to maintain 70% power factor until rated flux (or maximum possible flux) is achieved. This
function ensures that the cells are delivering real power under all operating conditions.
* Note: In Cell Bypass, the drive will invoke Energy Saver under light loads to prevent certain cells from
charging-up.
5.15 Tool Suite

The NXG Tool Suite is a PC-based application software package that includes the Drive Host, Debug Utility, System
Program Compiler, and Configuration tools for the NXG control. Note that the Drive Host and Debug utility
communicate with an NXG drive via an Ethernet link. The System Program compiler and Configuration Update
Tools are PC applications. Please refer to NXG ToolSuite Software User Manual 902291 for a complete description
of the Tool Suite software package.
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5-30 19001591: Version 1.0
5.15.1 Drive Host

The NXG Drive Host is a PC-based application software package that provides a remote graphical user interface for
Medium Voltage Perfect Harmony NXG series drives. With the Drive Host tool, the user can navigate through a
drive’s features using a PC and a mouse, allowing monitoring and control of the drive’s functions quickly and easily.
This makes the Drive Host Suite more convenient to use than the keypad on the front of the drive. The NXG Drive
Host is a high-level GUI that runs on a PC equipped with the Microsoft Windows operating system. The NXG Drive
software and the PC running the NXG Drive Host interface using Ethernet and TCP/IP protocols.
Configuration
• Multilevel password to limit access
o Passwords same as used in drive
• Folders for each drive configuration category (i.e., VFD Menu system)
o Icon colors to indicate default and modified parameter values 5
o On screen parameter identifier (matches keypad IDs for speed menus)
o Parameter editing assisted by minimum/maximum limits and defaults
• Ability to upload logs, parameters, system program
• Ability to download system program and/or configuration data files
Graphing
• Adjustable Time Scale
• Predefined variable list to select variable to be graphed
• Graph up to 10 variables
• Individual variable offsets
• Individual variable scaling
• Customizable Graphics - Fonts, Color, Styles
• Freeze Graphics
• Freeze graph on fault
• Freeze on selectable trigger
• Zoom graph
• Printable Graphics
• Exportable Graphics
Status
• Programmable display variables
o Pick list selectable variables, same as drive keypad display list
o First 4 synchronized to keypad display
• Fault and Alarm indicators (traffic lights: red = fault, yellow = alarm, green = none)
Control (** only if enabled by SOP)
• Manual Start Button
• Stop Button
• Fault Reset Button
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19001591: Version 1.0 5-31
5.15.2 NXG Debug Utility

The NXG Control provides a built in debug function that provides real time status of various parameters, measured
values, and calculations. This function is wholly contained in the NXG control, and user access is available from
three separate ports:
• NXG CPU Video port using a standard VGA monitor with a standard PC keypad connected to the CPU card
for navigating displays
• Ethernet port using the Debug Utility provided by the NXG Tool Suite
• RS232 Serial Port
The debug utility is intended for use during test, commissioning, and troubleshooting of the drive.
5.16 Serial Port

5 The NXG Control includes an RS232 serial port that can be used for downloading system program data from a PC, as
well as for uploading parameter dumps, event logs, and historic data logs directly to a PC. Note that no automatic
SOP downloads can be performed through this port; download activities must be initiated via the NXG Keypad.
Upload functions in the default operating mode must also be initiated via the Drive keypad.
5.17 Dual Frequency Braking

5.17.1 Introduction to Dual Frequency Braking
There are many applications for VFDs that need occasional negative torque for braking. Unfortunately, at present the
most popular static converters used for VFDs are not capable of returning energy to the utility. Such applications
therefore require additional circuits to regenerate the braking energy into the AC mains, or to dissipate the braking
energy in a resistor. Both of these solutions add cost to the VFD, and are especially undesirable for large modular
medium-voltage VFDs.
Additional power devices can be avoided by using the existing circuits to inject DC current into the motor windings.
This method dissipates the braking energy in the motor, and adds little cost to the VFD. However, DC injection
braking is not very effective unless the available current is several times rated, especially for large motors. Another
drawback is that estimation of motor speed is very difficult during DC injection braking.
Dual Frequency Braking (DFB) is another method in which braking energy can be dissipated in the motor. Dual
Frequency Braking provides much higher torque per ampere than DC injection braking, and permits continuous
estimation of motor speed. Like DC injection braking, this approach is implemented in software and requires no
additional hardware that can reduce the reliability of the drive.
Siemens has a patent on Dual Frequency Braking (US 6,417,644).
5.17.2 Operation
Dual Frequency Braking causes extra losses to be induced in the motor by applying a second set of three-phase
voltage vectors to the motor, in addition to the normal set of voltage vectors used for speed control. These extra losses
are used to absorb the kinetic energy released during braking.
There are two side effects of Dual Frequency Braking (DFB) against which protection is applied as follows:
1. Torque pulsations: The motor can be subjected to as much as 1 per-unit torque pulsation at the pulsation
frequency with DFB. However, the customer can select the torque pulsation frequency via the menu entry
for Pulsation Frequency to avoid any mechanical resonance frequencies.
2. Motor heating: The losses generated during DFB cause motor heating and limit the number of deceleration
ramps (from full speed to zero) that can be performed repetitively. Motor heating due to the additional losses
is designed to be no worse than a line start. The software motor thermal model in NXG monitors motor
heating due to these losses, and can provide an alarm and/or a trip to indicate excessive heating. The number
of repetitive deceleration ramps (from full speed to zero) is limited to 2-per-hour (based on MG-1, Part 20,
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5-32 19001591: Version 1.0
which assumes that the motor has cooled down to its rated temperature before the second ramp down). This
recommendation applies when the load inertia and load torque are those for which the motor is designed.
With lower values of load inertia and/or smaller speed reductions, DFB can be used more frequently.
The second set of voltage vectors creates a counter-rotating flux vector that produces high slip in the machine and
generates these additional losses in the motor. The injection frequency is always in opposite rotation to the applied
motor electrical frequency (speed and direction of the machine).
Figure 5-24 is a block diagram showing how the two voltage vectors (normal VA1 and loss-inducing VA2) are added
together to produce the braking function. Figure 5-25 is a scope picture of the two voltage vectors added together.
The higher frequency voltage waveform VA2 is riding on the lower frequency waveform VA1.
Note: The pulsation frequency is programmable via the NXG Control, which is selectable by the end user.
* It provides the reference to produce the desired additional braking for the system and is adjustable to avoid
resonance in the system.
5
Figure 5-24: Dual Frequency Voltages Being Added Together with the Normal Three-Phase Voltages
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19001591: Version 1.0 5-33
Figure 5-25: Scope Picture Showing Dual Frequency Braking Waveform
Using this method, the first vector set controls the torque and flux in the motor, and is nearly synchronous. The
second vector set induces losses in the motor to absorb the braking power returned by the first vector set. The
amplitudes of the two vector sets are coordinated to best utilize the current and voltage limitations of the converter.
The frequency of the loss-inducing vector set is chosen with the goal of maximizing losses per ampere. This
automatically minimizes the torque pulsations by minimizing the loss-inducing current.
The dominant losses in a motor are conduction losses, proportional to I2R. Maximum losses per ampere require a
large value of R. The nominal resistance of the motor windings is fixed by the design. Fortunately, the effective
resistance depends on the frequency. The rotor windings are deliberately designed to exhibit a strong “deep-bar”
effect, so that their resistance (above a low threshold) increases roughly proportional to frequency.
In principle, the frequency of the loss-inducing vector set should be as high as possible for maximum effective
resistance. Since this high loss-inducing frequency produces negative slip, it will have negative sequence. The
maximum applied frequency is limited by the control bandwidth of the converter, and also by the available voltage.
However, because the loss-inducing vector set is negative sequence, the rotor frequency will be higher than the stator
frequency due to the rotational speed.
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5-34 19001591: Version 1.0
5.17.3 Limitations
The drive output current plus the braking current must not exceed the current capability of the cells in the drive.
Hence the braking torque is limited in the drive and is greatest at slow speed and smallest at high speed. Figure 5-26
shows the typical braking torque that can be expected with Dual Frequency Braking.
Figure 5-26: Typical Braking Torque with Dual Frequency Braking
With high efficiency motors and inverter duty motors, the braking torque that can be achieved with DFB is lower than
the values shown in Figure 5-26. Contact Siemens Engineering with the following motor-related data to determine
the braking torque capability with a higher efficiency motor:
• Rated HP
• Rated Voltage
• Rated Frequency
• Full/Half load speed
• Full/Half load efficiency
• Locked Rotor Torque and Current
• Pull out torque
• Critical frequencies of the mechanical system
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19001591: Version 1.0 5-35
5.18 Debug Functionality

The Serial Debug function of the NXG control serves as a means for the user to connect to an interactive menu that
allows a user to capture VFD run-time data, including debug data described in Section 5.15.2. This port does not
permit any data to be downloaded to the drive. It is provided as a means to extract human readable VFD status and
logs from the NXG Control.
The port is configured as a standard RS-232 serial interface where no hardware handshake is required. The NXG
control includes provisions to allow a serial modem to be connected so that drive status can be remotely accessed via
telephone. When a modem is connected, it can be configured as an auto-answer device, or the NXG control is capable
of configuring compatible modems to automatically answer.
* Note: Any RS232 compatible device can be connected to this port. The only requirement is that the user
must initiate desired output data via single character inputs to the port.
5 Diagnostic data available via this port includes:

• Parameter Dump
• Fault/Event/Historic Log
• Drive Status/Id
• Debug Functions (as defined in Section 5.15.2)
∇ ∇ ∇
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5-36 19001591: Version 1.0
GenIV Product User Manual Application Specific Features
CHAPTER
6 Application Specific Features

6.1 Control Mode Summary
The NXG Control provides six control modes for the Perfect Harmony drive family. These modes are described as
follows:
• CLVC - Closed Loop Vector Control
CLVC provides flux vector control for an induction machine utilizing an encoder for speed feedback.
• CSMC - Closed Loop Synchronous Machine Control
CSMC is a flux vector control for a synchronous machine utilizing an encoder for speed feedback and
providing a field excitation command for use by an external field exciter.
• OLTM - Open Loop Test Mode
OLTM is intended for running the drive with no load attached to permit verifying the output voltage 6
waveforms.
* Note: OLTM is intended for test purposes only and should not be used to control a motor.
• OLVC - Open Loop Vector Control, also known as Encoderless Vector Control
OLVC is a flux vector control for induction machines that computes the rotational speed of the rotor based
on measured output currents from the drive, and uses this computed speed as the speed feedback.
• SMC - Synchronous Motor Control
SMC computes the rotational speed similarly to open-loop vector control, and controls the field reference or
the synchronous motor as in closed-loop synchronous motor control. The field reference is controlled to
achieve unity power factor.
• VHZ - Volts per Hertz control
V/Hz is intended to be used when multiple induction motors are connected in parallel to the output of the
drive. V/Hz operates similarly to open-loop vector control with de-tuned current regulators.
* Note: Spinning Load and Fast Bypass are not available in V/Hz control mode.
6.2 Control Loops

The NXG Control includes three main control loops that are defined in the following sections.
6.2.1 Current Loop

The current loops form the innermost loop of the NXG control system. It is essential that these loops are stable. When
the current loop gains are very low, then the drive output currents do not have a sinusoidal waveshape, i.e., dead-
bands can be seen around the zero-crossings, and the peaks are not smooth but appear flat. On the other hand, when
current loop gains are too high, then a high frequency ringing appears on the sinusoidal current waveform. IOC trips
can also occur if this is the case.
Default values of the current loop gains are sufficient for most applications. Tuning may be required for high
performance applications and when output filters are used.
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19001591: Version 1.0 6-1
Application Specific Features GenIV Product User Manual
6.2.2 Speed Loop

Control of motor speed is accomplished with the speed regulator. The output of the speed loop forms the torque
current command. The default speed loop gains work well when the inertia of the motor and the load are reasonable,
i.e., motor and load have similar inertia. Examples of applications where this is not the case are given below. Speed
loop gains require tuning when its output shows significant oscillations during small changes in speed command.
ESP applications have motors with very low inertia. In such applications, the speed loop gains can be safely reduced
by a factor of 5 or more from their default settings.
Fan applications have motors with very high inertia. In such applications, the speed loop gains are typically reduced
(by a factor of 2 to 5 from their defaults). These applications, in general, do not require fast/sudden response, and a
reduction in speed loop gains prevents large/sudden changes in the torque current command.
6.2.3 Flux Loop

Regulation of motor flux is accomplished with the flux control loop. The output of the flux loop forms the
magnetizing current command. The default flux loop gains work well for most induction motor applications. With
synchronous motors, lower gains should be used. Flux loop gains will require tuning when the regulator output shows
6 significant oscillations during steady state operation.
6.3 System Program

The System Program, as described in Section 5.4, is developed for each drive application to configure the VFD to
function as desired by the end user. The System Program allows the end user to define the drive operation, where
possible, so that system response and I/O configuration is configured for the application. The system program is used
to define reference sources, select a subset of operating parameters, configure all I/O, and to define alarms/fault
conditions as desired by the end user.
* Note: Internal drive-generated faults defined for drive protection cannot be modified by the SOP.
The System Program is downloaded onto the NXG drive in non-volatile memory, and can be field-modified for
changing requirements. Note that the drive must be in an idle state (i.e., output disabled) for a new SOP to be utilized.
6.4 Speed Droop

Speed Droop is the decrease in the speed of a motor with a constant voltage and frequency when the motor is under
load. The difference between the synchronous (unloaded) speed of the motor and the full load speed is known as slip.
Normally, slip compensation increases the output frequency of the VFD as the motor speed attempts to decrease. This
compensation maintains a constant motor speed by minimizing droop.
However, in some applications, droop is needed. For example, in a multiple motor application, such as two motors
mechanically connected to a common load, there are inherent differences between the motors. In the case of a torque
current increase, these differences may allow one motor to attempt to run faster, causing that motor to bear a greater
portion of the load.
By adding droop to the more heavily loaded motor, its speed reference will proportionally decrease (based on load),
shifting some of the load to the less loaded motor. The less loaded motor speed reference is not affected as much
(because the current is lower) and will therefore start to pick up more of the load. As the loaded motor’s speed
reference is decreased, it begins to shed load until an equilibrium is reached, and each motor is bearing its share of the
load.
6.5 Long Cable Applications

When a step of voltage from a drive is applied to one end of a transmission line, it causes a traveling wave to be
propagated toward the opposite (or motor) end of the transmission line. When the traveling wave reaches the motor
end of the cable, the motor leakage reactance is so high that the line behaves as if it were open-circuited. A reflection
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6-2 19001591: Version 1.0
wave begins to travel back toward the drive end. The total voltage at any point is the sum of all waves present, in this
case the forward wave and the reflected wave. The reflection at an open circuit is such that the reflected voltage wave
has the same polarity as the forward voltage wave. At the motor end, the reflected wave appears at the same instant as
the forward wave arrives, so that the effective voltage step is doubled. At other points, there is a delay from the time
that the forward wave passes until the reflected wave passes, so that two separate steps appear, each equal to the
original.
When the reflected wave reaches the drive end of the cable, the drive impedance is so low that the line behaves as if it
were short-circuited. A second reflection wave begins to travel back toward the motor end. The reflection at a short-
circuit is such that the second reflected voltage wave has the opposite polarity as the first reflected voltage wave.
If the drive output remains static long enough after each step, then these reflected waves will bounce back and forth,
losing energy at each reflection, until the voltage stabilizes. In this case, the worst step size imposed on the motor will
be almost twice the step size from the drive, while the number of steps per second will be multiplied by the number of
significant reflections per step.
However, a much worse scenario can occur if the drive produces another step before the waves from the previous step
have decayed. The absolute worst case occurs when the next step from the drive coincides with the arrival of the first
reflection back at the drive, and when the next step has the opposite polarity to the previous step. This happens most
often when the propagation delay of the cable is equal to ¼ cycle at the effective switching frequency, which Siemens
6
LD A defines as the critical length. In this case, the reflected waves from successive steps reinforce each other, and
the worst step size on the motor can become many times higher than the step size from the drive.
The same effect will occur when the cable length is an odd multiple of the critical length, but it is less severe because
the waves are reflected several times before they are reinforced.
For a Perfect Harmony Drive, the critical length is a function of the number of power cells per phase and the effective
switching frequency of the drive. If the cable length exceeds a critical length (refer to Section 4.4), an output filter is
included with the drive.
6.6 Output Filters

Output filters are required for down-hole pumping with long cables and also must be considered when shielded
output cables are used. When required, the filter completely avoids any problem with cable reflections. NXG control
supports output filters for all control modes. The output filter consists of an LC filter used to prevent the output cable
dynamics from interfering with the drive output. An output filter might also be used to address EMI or DV/DT
requirements. With the capacitors omitted, the filter can function as output reactors for Synchronous Transfer used to
limit the current that can circulate while the VFD output is connected to the Medium Voltage input.
The output filter is designed to effectively remove all high frequency components in the drive output voltage.
Because Perfect Harmony is already free of low-order output harmonics, the result is a nearly perfect sinusoidal
output waveform.
Note that the filter adds losses proportional to the square of the RMS output current. The filter inductance is in series
with the VFD output and motor load and can reduce the output voltage capability, depending on the load power
factor. The filter also introduces an amplifying resonance, which could limit the closed-loop gain for high-
performance applications. The filter consists of series inductors in each phase connected between the drive outputs
and the load (motor) terminals. Shunt capacitors in each phase connect between the load terminals and are arranged in
a floating wye configuration (capacitors are omitted for Closed Synchronous Transfer applications). Refer to Chapter
4 for output filter values.
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19001591: Version 1.0 6-3
6.7 Synchronous Transfer

6.7.1 Introduction
The synchronous transfer feature is used to avoid line start mechanical/electrical strain in constant-speed
applications. The VFD soft starts the motor(s), and then NXG control matches line/load electrical characteristics,
allowing “bumpless” synchronous transfer.
* Note: Beyond the core drive, synchronous transfer requires additional hardware: output reactor and
switchgear. A PLC is recommended in multi-motor applications.
• “Up Transfer” - The process of transferring a VFD-controlled motor to the line, and then decoupling the
motor from the drive.
• “Down transfer” - The process of transferring a line-energized motor to VFD control, and then decoupling
the motor from the line.
To achieve successful up/down transfers, the output voltage of the VFD must match or exceed the amplitude of the
line. If the line is unstable with frequency and/or voltage variations, the VFD may not be able to synchronize, and
6 therefore transfer is inhibited.
* Note: In transfer applications, where a synchronous motor is used, the VFD must have control of the field
supply.
* Note: Synchronous Up/Down transfer is not available in V/HZ or OLTM control modes.
WARNING!
• Improper phase sequence may result in a synchronous transfer related VFD fault.
6.7.2 VFD Synchronous Transfer Implementation

Synchronous transfer is inherent to NXG control. To optimize this feature, Siemens engineering should always be
involved (regardless of scope of supply) in the switchgear configuration and logic sequencing for both equipment and
personnel safety. Siemens engineering can supply switchgear and reactors as part of the drive, or provide
recommendations as needed.
VFD Transfer Permissive
WARNING!
• The VFD output contactor and motor line contactors should never be simultaneously closed if the
digital output signal “VFD Transfer Permissive” is low, or when the VFD input is not energized.
Failure to ensure that this condition does not occur could result in severe damage to the VFD power
cells.
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6-4 19001591: Version 1.0
CB1
L1
L2 V1 L3 V2
VFD 6
M1 M2
PLC
Figure 6-1: Multi-Motor, Synchronous Transfer
Figure 6-1 provides a block diagram showing the VFD configuration for synchronous transfer for a two motor
implementation.
* Note: A PLC is recommended for multi-motor synchronous transfer applications. This PLC and its logic
can be supplied by Siemens engineering to coordinate the transfer sequence and also control the
switchgear. In addition, motor protection relays are recommended since the VFD cannot protect a motor
operating from the line.
* Note: It is not required that all motors connected to a drive configured for synchronous transfer have
matching ratings. If mis-matched motors are implemented, the drive must be sized for the worst case
load. “Smaller” motor loads can be mechanized via parameter read/write functionality or the NXG
Control Multiple Configuration file capability, as described in NXG Communications Manual (902399)
and NXG Control Manual (19001588), respectively. As a rule, the smallest motor rating should be greater
than 50% of the ratings of the largest motor to ensure feedback signal integrity. When mis-matched
motors are used, the proper configuration file should be active for the subject motor.
Controller Implementation
Refer to the NXG Control Manual, 19001588, for a detailed description of NXG control configuration required for
synchronous transfer.
6.7.3 Input/Output Signals for Sync Transfer

Excluding standard run, stop, and speed reference inputs, synchronous transfer requires four dedicated input signals
and six dedicated output signals to be implemented. These signals can either be hardwired or implemented as digital
control bits over one of the NXG-supported PLC communication links.
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Input Signals to the VFD:

• Up Transfer Request
• Down Transfer Request
• VFD Output Contactor Status
• Motor Line Contactor Status
Output Signals from the VFD:
• VFD Transfer Permissive
• Up Transfer Permit
• Up Transfer Complete
• Down Transfer Permissive
• Down Transfer Complete
6 • Open Motor Line Contactor
6.7.4 Up Transfer Implementation

Up transfers are accomplished by transferring the motor from the VFD directly to the line. Up Transfer requires that
the VFD synchronize its output to match the voltage, phase angle, and frequency of the line. This is accomplished by
using the drive input line frequency as a velocity reference and adjusting the VFD output voltage to match the line.
Both functions are automatically implemented by the NXG control when an “Up Request” is received. The active
acceleration ramps and torque limits set in the control are used during this period.
* Note: Mismatched line/motor voltages are permitted when careful consideration is given to the
configuration of the VFD (including step up/down transformers between the line and the motor).
Once the VFD output frequency is matched to the line, the output phase also needs to be matched with a pre-
determined leading phase to ensure the power flow is out of the VFD when both the VFD output and motor line
contactors are closed (both must be closed at one time to ensure bumpless transfer). When the synchronization is
complete, the motor line contactor remains closed (i.e., motor connected to the line), the VFD output is disabled, and
the drive output contactor is then opened to end the transfer.
A typical Up Transfer sequence is summarized as follows:
1. Start the VFD as a normal running drive with desired speed command. The drive must be in the “RUN” state
to initiate transfer, and the “VFD Transfer Permissive” signal must be set true. In addition, the digital input
flag “VFD Output Contactor Status” must be set true.
2. Initiate the transfer with the “Up Transfer” request digital input when an up transfer is desired. A timer
should be used to establish a maximum time period for the transfer to complete. Transfer timeouts are rarely
encountered and are usually due to an unstable source, a varying load, or improperly tuned drive.
* Note: The VFD will attempt to perform the Up Transfer as long as the “Up Transfer Request” signal is
set or until a VFD stop command is issued. If a VFD fault occurs at any time prior to closing the Motor
Line Contactor, the external controller must reset its Up Transfer state machine and clear all Transfer
related digital inputs sent to the VFD. As a rule, an Up Transfer typically will be completed within 10-20
seconds after the VFD output reaches the rated line frequency. Should a timeout occur, the transfer
should be terminated and the NXG control will revert to its previous state, using the speed reference that
was active prior to initiating the Up Transfer sequence.
3. The VFD will ramp the output to match the measured line frequency.
* Note: The VFD will automatically ramp the output to rated frequency upon initiating the Up Transfer
Sequence. There is no need to change the speed reference prior to issuing an “Up Transfer request.”
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4. The VFD ramps to line frequency and phase-locks for a minimum a 5 seconds. Note that the NXG control
includes provisions for offsetting the phase should a configuration exist where the VFD Medium Voltage
input is not the same phase as the line voltage to be used at the motor.
5. Once synchronized, the VFD issues a permit signal, “Up Transfer Permit”, indicating that the Motor Line
Contactor can be closed (VFD Output contactor also remains closed during this stage).
6. Once the Motor Line Contactor is closed and acknowledged at the VFD, the VFD will disable its output.
7. Once the VFD Output is disabled, the run request should be removed and the VFD output contactor must be
opened. This completes the Up Transfer process, and the Up Transfer Request digital input can be removed.
6.7.5 Down Transfer Implementation

Down transfers are accomplished by transferring a motor from the line to VFD control. This is accomplished by using
the voltage/frequency present at the motor terminals as a velocity reference, which is automatically implemented by
the NXG control when a “Down Request” is received. Once the VFD output frequency is matched to the motor, the
VFD output phase also needs to be matched with a predetermined leading phase to ensure the power flow is out of the
VFD when both the VFD output and the motor line contactors are closed (both must be closed at one time to ensure
bumpless transfer). When the de-synchronization is complete, the VFD output contactor remains closed (i.e., motor
connected to the VFD), and the motor line contactor is then opened to end the transition. At this point, the VFD
6
controls the motor.
A typical Down Transfer sequence is summarized as follows:
1. The motor is running directly from the line, VFD is idle, the VFD output contactor must be open, and the
external speed reference must be set to the speed desired upon completion of the down transfer (remember to
account for motor slip if bumpless down transfer is desired).
2. If the VFD indicates that it is capable of performing a down transfer (i.e., sufficient output voltage available,
drive energized, and ready to run), the down transfer request is issued to the VFD.
3. Once the drive acknowledges the down request, the VFD output contactor is closed, and the VFD run
request must be set.
* Note: The VFD output is not actually enabled at this time. The run request enables the VFD output phase
locked loop (PLL) to monitor and lock to the line voltage/frequency. Since the VFD output contactor is
closed while the motor is connected to the line, the line voltage and frequency are available via the
drive’s output sensors.
4. Once the VFD PLL maintains phase/frequency and voltage lock (typically 5-10 seconds), the VFD output is
automatically enabled with a small frequency offset to ensure that current flows from the VFD to the line/
motor.
5. Once the output current from the VFD reaches a predetermined level, the VFD signals that the line contactor
can be opened. The output current will be limited to the maximum torque limit set in the NXG control.
* Note: The VFD will remain in the Down Transfer state as long as the “Down Transfer Request” signal is
set or until a VFD stop command is issued. If a VFD fault occurs at any time prior to opening the Line
Contactor, the motor should remain connected to the line and all input flags to the VFD should be cleared.
As a rule of thumb, a Down Transfer typically will be complete within 30-60 seconds. There is no defined
maximum or minimum time period required for opening the line contactor after the VFD issues the status
flag to allow the Line Contactor to be opened.
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6. Once the line contactor is opened, the Down Transfer Request must be removed and the VFD will control
the motor as commanded. The run request must be maintained, and desired speed reference should be
present to ensure a bumpless transition.
* Note: For induction machines: to maintain bumpless down transfer, the speed reference source to be used
upon completion of down transfer should preset the speed reference to the mechanical shaft speed of the
motor at rated line frequency (i.e., externally compensate for slip, where the speed reference should be set
to 100% - RatedSlip).
6.8 Parallel Control

The Perfect Harmony drive family design includes the ability to combine multiple drives in parallel to provide a
higher power output than is available from a single drive.
6.9 Communication Interfaces

The NXG control provides a means for the Harmony series of drives to be directly connected to several industry
6 standard PLC communication networks, which provides the capability to control and/or monitor the VFD over these
networks. A detailed description of the network capabilities is defined in the NXG Control Manual, 19001588, and
the NXG Communication Manual, 902399. A brief summary of the networks and their associated capabilities are
provided in the following subsections.
6.9.1 Available Networks

At present, the NXG control supports the following industry standard PLC networks:
• Modbus RTU
• Modbus Ethernet
• Profibus DP
• ControlNet
• DeviceNet
• Modbus Plus
* Note: Modbus RTU or Modbus Ethernet is available as Network 1 without additional hardware. Other
Network 1 communication protocols require an additional printed circuit board to be attached to the
communications card within the NXG digital card rack.
6.9.2 Multiple Networks

The NXG controller allows the user to operate two independent network interfaces at one time, where both can
monitor the drive, but only one can control the drive. The networks do not need to be identical, and each can map data
separately. The second network, Network 2, is obtained by placing an additional printed circuit board to the
communications card within the NXG digital card rack.
* Note: The ability to provide two networks is not implemented as a redundant or dual interface. The
Harmony VFD simply provides a means to provide two separate ports where the user can define which of
the ports may be used to control the VFD. Switchover from one network port to the other is implemented
via the SOP.
6.10 Process Availability - The Perfect Harmony Advantage

Process availability is the primary prerequisite for applying a Medium Voltage VFD system in a process critical
application. By combining the capabilities of Perfect Harmony’s unique distributed power architecture with the
power of the NXG control and the patented power cell bypass feature, it is possible to deliver unparalleled
opportunities for improved process availability. It is also essential that the process operator receive complete and
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accurate information on VFD status, to allow for process adjustments that can preclude process trips and disruptions
in process capability.
6.10.1 What is ProToPSTM?

ProToPSTM is an acronym that stands for “Process Tolerant Protection Strategy.” ProToPSTM is a standard
implementation of the VFD SOP (System Operating Program). The ProToPS goal is simply to put the process
operator in control of the process. ProToPSTM is a system program implemented from a customer process
perspective.
ProToPSTM provides the operator with indication of a change in state in the VFD. These annunciations identify
changes that can impact the ability of the VFD to meet process demands, or to provide advance indication of a
pending VFD trip. ProToPSTM allows the process operator to make process corrections to maintain the VFD in
service, or adjust the process to address a pending VFD trip.
With ProToPSTM, the process operator not only knows the general status of the VFDs, but also understands the VFD
condition that has caused the general alarm to exist.
6.10.2 How Does ProToPSTM Work? 6

ProToPSTM takes the standard fault indications available in the VFD and categorizes them into four basic major
categories as follows:
1. Alarm - An alarm is an indication that a VFD parameter limit has been reached, or that a VFD system
condition is present. An alarm provides the operator with awareness of the condition, but demands no
immediate action. Examples of alarms include: over-voltage, under-voltage, and ground fault.
2. Process Alarm - A process alarm is an indication that a VFD parameter limit has been exceeded and that the
process either should be limited, or that the VFD capacity to meet the process demand is limited. Examples
of process alarms include thermal limits above the rated limit, and the condition of a cell having been
bypassed.
3. Trip Alarm - A trip alarm provides a clear indication that a VFD high parameter limit has been reached. A
trip alarm is an indication that a VFD trip is pending. The operator receives a message that, unless the alarm
can be cleared by a process change, the VFD will trip.
4. Trip - Certain VFD faults cannot be provided with advance warning. This limited number of faults will
result in a VFD trip. A trip message is also annunciated when a trip alarm time limit has been exceeded. The
number of mandated trips is considerably reduced with the implementation of GENIV cell bypass.
With ProToPS the (VFD Run) signal is maintained as “true” and the (VFD Trip) signal is maintained as “false” for all
alarm states.
6.10.3 ProToPSTM Implementation

With ProToPSTM, the four indication categories are provided as separate digital output signals (Alarm, Process
Alarm, Trip Alarm, Trip). The concept is to provide the operator, or the process program, with a clear message to
indicate a status change in the VFD.
The specific information on the VFD parameter change is indicated (along with the general category information)
across a serial communications interface. Any serial communications protocol supported by the VFD product can be
supported in the ProToPSTM implementation.
If other specific digital output information is required for a specific customer project, that information must be
mapped to a new digital output point on an additional digital output module. The four defined outputs must be present
as digital outputs to validate the ProToPSTM implementation.
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6.10.4 The ProToPSTM Advantage

With cell bypass, there are virtually no cell faults that are non-bypassable. With NXG control, the need for the
designation “Transient Alarm” has disappeared as all bypassable faults become process transparent.
With ProToPSTM and the NXG control, combined with the unique benefits of the Perfect Harmony cell based
distributed power technology, process availability can be considerably enhanced and the process operator can truly
control the process.
∇ ∇ ∇
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GenIV Product User Manual Glossary
CHAPTER
A Glossary
This appendix contains definitions of terms and abbreviations used throughout the Perfect Harmony series manuals.
AND - AND is a logical Boolean function whose output is true if all of the inputs are true in SOP notation, AND is
represented as “∗” (e.g., C=A∗B), although sometimes it may be omitted between operands with the AND operation
being implied (e.g., C=AB).
ASCII - ASCII is an acronym for American Standard Code for Information Interchange, a set of 8-bit computer
codes used for the representation of text.
Baud rate - Baud rate is a measure of the switching speed of a line, representing the number of changes of state of the
line per second. The baud rate of the serial port of the Perfect Harmony is selected through the Baud Rate parameter
in the Communications Menu [9].
Bit - Bit is an acronym for BInary digiT. Typically, bits are used to indicate either a true (1) or false (0) state within
the drive’s programming.
Boolean algebra - A form of mathematical rules developed by the mathematician George Boole used in the design of A
digital and logic systems.
Carrier frequency - Carrier frequency is the set switching frequency of the power devices (IGBTs) in the power
section of each cell. The carrier frequency is measured in cycles per second (Hz).
“Catch a spinning load” feature - “Catch a spinning load” is a feature that can be used with high-inertia loads (e.g.,
fans), in which the drive may attempt to turn on while the motor is already turning. This feature can be enabled via
the NXG menu system.
CLVC - An acronym for Closed Loop Vector Control - which is one of six control modes in the NXG drive. This is
flux vector control for an induction machine (IM), utilizing an encoder for speed feedback.
CMP - Refer to the glossary term SOP.
Comparator - A comparator is a device that compares two quantities and determines their equality. The comparator
submenus allow the programmer to specify two variables to be compared. The results of the custom comparison
operations can be used in the system program.
Configuration Update - see Tool Suite definition.
Converter - The converter is the component of the drive that changes AC voltage to DC voltage.
Critical speed avoidance - Critical speed avoidance is a feature that allows the operator to program up to 3
CSMC - An acronym for Closed Loop Synchronous Machine (SM) Control. One of six control modes of the NXG
drive. This is a flux vector control for a synchronous machine, utilizing an encoder for speed feedback and providing
a field excitation command for use by an external field exciter.
Debug Tool - see Tool Suite definition.
DC link - The DC link is a large capacitor bank between the converter and inverter section of the drive. The DC
link, along with the converter, establishes the voltage source for the inverter.
De Morgan’s Theorem - The duality principal of Boolean algebra used to convert system logic equations into sum-
of-products notation.
Downloading - Downloading is a process by which information is transmitted from a remote device (such as a PC) to
the drive. The term “downloading” implies the transmission of an entire file of information (e.g., the system program)
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Glossary GenIV Product User Manual
rather than continued interactive communications between the two devices. The use of a PC for downloading
requires special serial communications software to be available on the PC, which may link to the drive via RS232 or
through the Host Simulator via an ethernet connection.
DRCTRY - Directory file for system tokens and flags used in the compilation of system programs. It provides a
direct lookup table of ASCII names to internal ID numbers. It also identifies whether the flag is a word or bit-field,
and also whether it can be used as an input or output only, or can be used for both.
Drive - The term “drive” refers to the power conversion equipment that converts utility power into power for a motor
in a controlled manner.
ELV - ELV is an acronym for extra low voltage, and represents any voltage not exceeding a limit that is generally
accepted to be 50 VAC and 120 VDC (ripple free).
EMC - EMC is an acronym for electromagnetic compatibility–the ability of equipment to function satisfactorily in its
electromagnetic environment without introducing intolerable electromagnetic disturbances to anything in that
environment.
ESD - ESD is an acronym for electrostatic discharge. ESD is an undesirable electrical side effect that occurs when
static charges build up on a surface and are discharged to another. When printed circuit boards are involved, impaired
operation and component damage are possible side effects due to the static-sensitive nature of the PC board
components. These side effects may manifest themselves as intermittent problems or total component failures. It is
A important to recognize that these effects are cumulative and may not be obvious.
Fault log - Fault messages are saved to memory so that the operator may view them at a later time. This memory
location is called the fault log. The fault log lists both fault and alarm messages, the date and time that they occurred,
and the time and date that they are reset.
Faults - Faults are error conditions that have occurred in the Perfect Harmony system. The severity of faults vary.
Likewise, the treatment or corrective action for a fault may vary from changing a parameter value to replacing a
hardware component such as a fuse.
Flash Card - Non-volatile memory storage device for the NXG control. It stores the drive program, system program,
logs, parameters, and other related drive files.
FPGA - Field Programmable Gate Array. An FPGA is an integrated circuit that contains thousands of logic gates.
Function - A function is one of four components found in the Perfect Harmony menu system. Functions are built-in
programs that perform specific tasks. Examples of functions include System Program Upload/Download and Display
System Program Name.
Harmonics - Harmonics are undesirable AC currents or voltages at integer multiples of the fundamental frequency.
The fundamental frequency is the lowest frequency in the wave form (generally the repetition frequency). Harmonics
are present in any non-sinusoidal wave form and cannot transfer power on average.
Harmonics arise from non-linear loads in which current is not strictly proportional to voltage. Linear loads like
resistors, capacitors, and inductors do not produce harmonics. However, non-linear devices such as diodes and silicon
controlled rectifiers (SCRs) do generate harmonic currents. Harmonics are also found in uninterruptable power
supplies (UPSs), rectifiers, transformers, ballasts, welders, arc furnaces, and personal computers.
Hexadecimal digits - Hexadecimal (or “hex”) digits are the “numerals” used to represent numbers in the base 16
(hex) number system. Unlike the more familiar decimal system, which uses the numerals 0 through 9 to make
numbers in powers of 10, the base 16 number system uses the numerals 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, and F
to make numbers in powers of 16.
Historic log - The historic log is a troubleshooting/diagnostic tool of the Perfect Harmony NXG control. The historic
log continuously logs drive status, including the drive state, internal fault words, and multiple user-selectable
variables. This information is sampled every slow loop cycle of the NXG control (typically 450 to 900 times per
second). If a fault occurs, the log is frozen a predefined number of samples after the fault event, and data samples
prior to and after the fault condition are recorded to allow post-fault analysis. The number of samples recorded are
user-selectable via the NXG control, as well as the option to record the historic log within the VFD event log.
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Host Simulator - see Tool Suite definition.

I/O - I/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a computer system.
Both inputs and outputs can be classified as analog (e.g., input power, drive output, meter outputs, etc.) or digital
(e.g., contact closures or switch inputs, relay outputs, etc.).
IGBT - IGBT is an acronym for Insulated Gate Bipolar Transistors. IGBTs are semiconductors that are used in the
Perfect Harmony drives to provide reliable, high-speed switching, high-power capabilities, improved control
accuracy, and reduced motor noise.
Induction motor - An induction motor is an AC motor that produces torque by the reaction between a varying
magnetic field (generated in the stator) and the current induced in the coils of the rotor.
Intel hex - Intel hex refers to a file format in which records consist of ASCII format hexadecimal (base 16) numbers
with load address information and error checking embedded.
Inverter - The inverter is a portion of the drive that changes DC voltage into AC voltage. The term “inverter” is
sometimes used mistakenly to refer to the entire drive (the converter, DC link, and inverter sections).
Jog mode - Jog mode is an operational mode that uses a pre-programmed jog speed when a digital input
Jumpers - Jumper blocks are groups of pins that can control functions of the system, based on the state of the
jumpers. Jumpers (small, removable connectors) are either installed (on) or not installed (off) to provide a hardware
switch.
A
Ladder logic - (Also Ladder Diagram) A graphical representation of logic in which two vertical lines, representing
power, flow from the source on the left and the sink on the right, with logic branches running between, resembling
rungs of a ladder. Each branch consists of various labeled contacts placed in series and connected to a single relay
coil (or function block) on the right.
Loss of signal feature - The loss of signal feature is a control scheme that gives the operator the ability to select one
of three possible actions in the event that the signal from an external sensor, configured to specify the speed demand,
is lost. Under this condition, the operator may program the drive (through the system program) to (1) revert to a fixed,
pre-programmed speed, (2) maintain the current speed, or (3) perform a controlled (ramped) stop of the drive. By
default, current speed is maintained.
LVD - LVD is an acronym for Low Voltage Directive, a safety directive in the EU.
Lvl RH - This term refers the two security fields associated with each parameter of the system. These fields allow the
operator to individually customize specific security features for each menu option (submenu, parameter, pick list, and
function). These fields are shown in parameter dumps and have the following meanings. Lvl is the term for the
security level. Setting R=1 blocks parameter change, and setting H=1 hides the menu option from view until the
appropriate access level has been activated.
Memory - Memory is the working storage area for the Perfect Harmony drive that is a collection of RAM chips.
Microprocessor - A microprocessor is a central processing unit (CPU) that exists on a single silicon chip. The
microprocessor board is the printed circuit board on which the microprocessor is mounted. The NXG drive employs
a single-board computer with a Pentium® microprocessor.
NEMA 1 and NEMA 12 - NEMA 1 is an enclosure rating in which no openings allow penetration of a 0.25-inch
diameter rod. NEMA 1 enclosures are intended for indoor use only. NEMA 12 is a more stringent NEMA rating in
which the cabinet is said to be “dust tight” (although it is still not advisable to use NEMA 12 in conductive dust
atmospheres). The approximate equivalent IEC rating is IP52.
Normally closed (NC) - Normally closed refers to the contact of a relay that is closed when the coil is de-energized.
Normally open (NO) - Normally open refers to the contact of a relay that is open when the coil is de-energized.
OLTM - An acronym for Open Loop Test Mode - One of six control modes of the NXG drive.
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OLVC - An acronym for Open Loop Vector Control, also known as Encoderless Vector Control. OLVC is a flux
vector control that is one of six control modes of the NXG drive. The drive computes the rotational speed of the rotor
and uses it for speed feedback.
OOS - OOS is an abbreviation for out of saturation - a type of fault condition in which a voltage drop is detected
across one of the IGBTs during conduction. This can indicate that the motor is drawing current too rapidly or in
excess.
OR - OR is a logical Boolean function whose output is true if any of the inputs is true. In SOP notation, OR is
represented as “+”.
Parameter - A parameter is one of four items found in the Perfect Harmony menu system. Parameters are system
attributes that have corresponding values that can be monitored or, in some cases, changed by the user.
PED - PED is an acronym for pressure equipment directive, a directive of the EU relating to pressure vessels.
Pick list - A pick list is one of four items found in the Perfect Harmony menu system. Pick lists are parameters that
have a finite list of pre-defined “values” from which to choose, rather than a value range used by parameters.
PID - PID is an acronym for proportional + integral + derivative, a control scheme used to control modulating
equipment in such a way that the control output is based on (1) a proportional amount of the error between the desired
setpoint and the actual feedback value, (2) the summation of this error over time, and (3) the change in error over
A
time. Output contributions from each of these three components are combined to create a single output response. The
amount of contribution from each component is programmable through gain parameters. By optimizing these gain
parameters, the operator can “tune” the PID control loop for maximum efficiency, minimal overshoot, quick response
time, and minimal cycling.
Qualified user - A qualified user is a properly trained individual who is familiar with the construction and operation
of the equipment and the hazards involved.
Quick menu - Quick menu is a feature of the menu system that allows the operator to directly access any of the
menus or parameters, rather than scrolling through menus to the appropriate item. This feature uses the [Shift] button
in conjunction with the right arrow. The user is prompted to enter the four digit ID number associated with the desired
menu or parameter.
RAM - RAM is an acronym for Random Access Memory, a temporary storage area for drive information. The
information in RAM is lost when power is no longer supplied to it. Therefore, it is referred to as volatile memory.
Regeneration - Regeneration is the characteristic of an AC motor to act as a generator when the rotor’s mechanical
frequency is greater than the applied electrical frequency.
Relay - A relay is an electrically controlled device that causes electrical contacts to change their status. Open contacts
will close and closed contacts will open when rated voltage is applied to the coil of a relay.
Setpoint - Setpoint is the desired or optimal speed of the VFD to maintain process levels (speed command).
Slip - Slip is the difference between the stator electrical frequency of the motor and the rotor mechanical frequency of
the motor, normalized to the stator frequency as shown in the following equation.:
Slip =ω S - ω R
ωS
Slip is the force that produces torque in an induction motor. Slip can also be defined as the shaft power of the motor
divided by the stator input power.
Slip compensation - Slip compensation is a method of increasing the speed reference to the speed regulator circuit
(based on the motor torque) to maintain motor speed as the load on the motor changes. The slip compensation circuit
increases the frequency at which the inverter section is controlled to compensate for decreased speed due to load
droop. For example, a motor with a full load speed of 1760 rpm has a slip of 40 rpm. The no load rpm would be 1800
rpm. If the motor nameplate current is 100 A, the drive is sending a 60 Hz wave form to the motor (fully loaded); then
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the slip compensation circuit would cause the inverter to run 1.33 Hz faster to allow the motor to operate at 1800 rpm,
which is the synchronous speed of the motor.
SMC - Is an acronym for Synchronous Motor Control - which is one of six control modes in the NXG drive.This
mode computes the rotational speed similarly to open-loop vector control, and controls the field reference or the
synchronous motor as in closed-loop synchronous motor control.
SOP - (1) SOP is an acronym for Sum Of Products. The term “sum-of-products” comes from the application of
Boolean algebraic rules to produce a set of terms or conditions that are grouped in a fashion that represents parallel
paths (ORing) of required conditions that all must be met (ANDing). This would be equivalent to branches of
connected contacts on a relay logic ladder that connect to a common relay coil. In fact, the notation can be used as a
shortcut to describe the ladder logic. (2) SOP, when used as a filename extension, refers to System Operating
Program.
SOP Utilities - The program within the Siemens LD A Tool suite used for converting between text and machine
loadable code. It can also be used for uploading and downloading files over the RS232 connection.
Stop mode - Stop mode is used to shut down the drive in a controlled manner, regardless of its current state.
Submenus - A submenu is one of four components found in the Perfect Harmony menu system. Submenus are nested
menus (i.e., menus within other menus). Submenus are used to logically group menu items based on similar
functionality or use.
Synchronous speed - Synchronous speed refers to the speed of an AC induction motor’s rotating magnetic field. It is
determined by the frequency applied to the stator and the number of magnetic poles present in each phase of the stator
A
windings. Synchronous Speed equals 120 times the applied Frequency (in Hz) divided by the number of poles per
phase.
System Operating Program - The functions of the programmable inputs and outputs are determined by the default
system program. These functions can be changed by modifying the appropriate setup menus from the front keypad
and display. I/O assignments can also be changed by editing the system program (an ASCII text file with the
extension .SOP), compiling it using the compiler program, and then downloading it to the controller through its serial
port, all by utilizing the SOP Utility Program with the Siemens LD A Tool Suite.
SOP Utilities - see Tool Suite definition.
Tool Suite - Is the suite of programs developed by Siemens that allows easier access to the NXG drive for
programming and monitoring. It is comprised of the following components:
• Tool Suite Launcher - also referred to as Tool Suite; used for coordinating other tools.
• SOP Utilities - used to launch an editor that compiles or reverse compiles a System Program. It also allows
for serial connection to the drive for uploading and downloading System Programs.
• Configuration Update - allows for backing-up, updating, and cloning drives via direct access to the Flash
Disk.
• Host Simulator - used for monitoring, programming, and controlling a drive remotely from a PC over the
built-in ethernet port of the drive. Parameter changes, status display, and graphing of internal variables are
its main functions.
• Debug Tool - this tool is used to display the diagnostic screens of the drive for diagnosing drive problems
or improving performance via the built-in ethernet port of the drive.
Tool Suite Launcher - see Tool Suite definition.
Torque - The force that produces (or attempts to produce) rotation, as in the case of a motor.
Uploading - Uploading is a process by which information is transmitted from the drive to a remote device such as a
PC. The term uploading implies the transmission of an entire file of information (e.g., the system program) rather
than continued interactive communications between the two devices. The use of a PC for uploading requires
communications software to be available on the PC.
s
19001591: Version 1.0 A-5
Variable frequency drive (VFD) - A VFD is a device that takes a fixed voltage and fixed frequency AC input source
and converts it to a variable voltage, variable frequency output that can control the speed of an AC motor.
VHZ - Is an acronym for Volts per Hertz control, one of six control modes in the NXG drive. This mode is intended
for multiple motors connected in parallel. Therefore, it disables spinning load and fast bypass. This is essentially
open-loop vector control with de-tuned (smaller bandwidth obtained by reducing the gain) current regulators.
∇ ∇ ∇
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A-6 19001591: Version 1.0
GenIV Product User Manual Abbreviations
CHAPTER
B Abbreviations
This appendix contains a list of symbols and abbreviations commonly used throughout this manual group.
Commonly Used Abbreviations
• Boolean AND function
+ Addition or Boolean OR
Σ Summation
µ Microsecond
A Amp, Ampere
AC Alternating Current
accel Acceleration
A/D Analog to Digital Converter
ADC Analog to Digital Converter
AI
alg
Analog Input
Analog
B
avail Available
BIL Basic Impulse Level
BTU British thermal units
C Centigrade or Capacitor
cap Capacitor
CCB Cell Control Board
ccw Counter clockwise
CE Formerly European Conformity, now true definition
CFM Cubic feet per minute
CLVC Closed Loop Vector Control
cmd Command
com Common
conn Connector
CPS Control Power Supply
CPU Central Processing Unit
CSMC Closed Loop Synchronous Motor Control
CT Current Transformer
cu Cubic
curr, I Current
cw Clockwise
D Derivative (PID), depth
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19001591: Version 1.0 B-1
Abbreviations GenIV Product User Manual
D/A Digital-to-analog (converter)

db Decibel
DC Direct Current
DCR Digital Control Rack
DCS Distributed Control System
decel Deceleration
deg, ° Degrees
DHMS Down hole monitoring system
div Division
dmd Demand
e Error
EC Electrically Commutated
ELV Extra Low Voltage
EMC Electromagnetic Compatibility
EMF Electromotive Force
EMI Electromagnetic Interference
EPS Encoder Power Supply
B ESD Electrostatic Discharge
ESP Electrical Submersible Pump
ESTOP, e-stop Emergency Stop
fb, fdbk Feedback
ffwd Feed Forward
FLC Full Load Current
freq Frequency
ft, ' Feet
fwd Forward
GenIIIe Generation IIIe
GenIV Generation IV
gnd Ground
GUI Graphical User Interface
H Height
H 2O Water
hex Hexadecimal
hist Historic
hp Horsepower
hr Hour
HV High Voltage
HVAC Heating, Ventilation, Air Conditioning
HVF Harmonic Voltage Factor
Hz Hertz
s
B-2 19001591: Version 1.0
I Integral (PID)
ID Identification
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronic Engineers
IGBT Insulated Gate Bipolar Transistor
in Input
in, “ Inches
INH Inhibit
I/O Input(s)/Output(s)
IOB I/O Breakout Board
IOC Instantaneous Overcurrent
IP Input Protection
k 1,000 (e.g., Kohm)
kHz KiloHertz
kV Kilo Volts
kVA One Thousand Volt Amps
kW Kilowatt
L Inductor B
LAN Local Area Network
lbs Pounds (weight)
LCD Liquid Crystal Display
ld Load
LED Light-emitting Diode
LFR Latch Fault Relay
lim Limit
LOS Loss Of Signal
lps Liters Per Second
mA Milliamperes
mag Magnetizing
max Maximum
MCC Motor Control Center
mg Milligram
min Minimum, Minute
msec Millisecond(S)
msl Mean Sea Level
MV Medium Voltage
mvlt Motor Voltage
MW Megawatt
NC Normally Closed
NEMA National Electrical Manufacturer’s Association
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19001591: Version 1.0 B-3
NMI Non-Maskable Interrupt

No Normally Open
NVRAM Non-Volatile Random Access Memory
NXG Next Generation Control
NXG II Next Generation Control II
oamp Output Current
OLVC Open Loop Vector Control
O-M Overmodulation
OOS Out of Saturation (IGBT)
overld Overload
P Proportional (PID)
Pa Pascals
pb Push Button
PC Personal Computer or Printed Circuit
PCB Printed Circuit Board
PID Proportional Integral Derivative
PLC Programmable Logic Controller
B PLL Phase Locked Loop
pot Potentiometer
pp Peak-to-peak
ppm Parts per Million
PPR Pulses per Revolution
PQM Power Quality Meter
ProToPS TM
Process Tolerant Protection Strategy
PSDBP Power Spectral Density Break Point
psi Pounds Per Square Inch
pt Point
PT Potential Transformer
PWM Pulse Width Modulation
Q1,Q2,Q3,Q4 Output Transistor Designations
rad Radians
RAM Random Access Memory
ref Reference
rev Reverse, Revolution(S)
RFI Radio Frequency Interference
RLBK Rollback
rms Root-mean-squared
RPM Revolutions Per Minute
RTD Resistance Temperature Detector
RTU Remote Terminal Unit
s
B-4 19001591: Version 1.0
RX Receive (RS232 Communications)

s Second(s)
SCB Signal Conditioning Board
SCR Silicon Controlled Rectifier
sec Second(s)
ser Serial
SMC Synchronous Motor Control
SOP Sum of Products; System Operating Program
spd Speed
stab Stability
std Standard
sw Switch
T1, T2 Output Terminals TI and T2
TB Terminal Block
TBD To Be Determined
TCP/IP Transmission Control Protocol/Internet Protocol
THD Total Harmonic Distortion
TOL Thermal Overload B
TP Test Point
trq, τ Torque
TX Transmit (RS232 Communications)
UPS Uninterruptable Power Supply
V Voltage, Volts
VA Volt-Amperes
VAC Volts AC
var Variable
VDC Volts DC
vel Velocity
VFD Variable Frequency Drive
V/Hz Volts per Hertz
vlts Voltage(s), Volts
VSI Voltage Source Inverter
W Width, Watts
WAGO Expansion I/O System
WCIII Water Cooled III
xfmr, xformer Transformer
∇ ∇ ∇
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19001591: Version 1.0 B-5
s
B-6 19001591: Version 1.0
GenIV Product User Manual Index
Index
Limitations 5-35
A Operation 5-32
A/D Converter Board 2-8 E
Abbreviations B-1 Electrostatic discharge iv
abbreviations B-1 EMC A-2
About This Manual vii Errors
Application Specific Features 6-1 link faults 2-8
Applications 1-8 Evolution 1-9
Available Networks 6-8 Excessive Drive Losses 5-23
B Excessive drive losses 5-23
Blowers # 1 and #2 4-29 implementation 5-23
C internal threshold 5-24
Cabinet Details 4-6 inverse time curve 5-23
Cabinet Outlines 4-2 F
Cell A1 2-3 Fast Bypass 5-25
Cell Bypass 4-21, 5-25 Fast Bypass Process 5-26
Cell Construction 4-16 fiber optic cables
Cell Current Overload 5-14 5 Megabaud communication 2-8
Cell Data 4-18 Fiber Optic Interface Board 2-8
Cell De-rating 4-20 field exciter 5-5
Cell Frame 3-2 Field-Weakening Limit 5-14
Clean Power 1-2 floating neutral 2-5
CMP A-1 Flux Loop 6-2
Communication circuits 2-8 Frequency 2-5
Communication Interfaces 6-8 Full load 2-7
Communications 4-18 Fullload operation 2-6
Companion Manuals 1-1 Fuses 4-12
Compiler A-1 G
Control Door 4-26 GenIV Core Configurations 4-3
Control Loops 6-1 GenIV Specifications 3-1
Control Mode Summary 6-1 Glossary A-1
Control Overview 1-8 Glossary of terms A-1
Control Section 4-21 Graphing 5-31
Control Section Components 4-22 H
Control Tub 4-22 Harmonic cancellation 2-6
Control Wire Way Section 4-28 Harmony VFD Family Features 1-5
Controller Implementation 6-5 High Power Factor 1-3
Conventions Used in this Manual viii I
Cooling 4-29 IEEE 519 Conformance 4-34
Cooling System Control 4-29 Indicators and Labels 4-18
Crystal oscillator 2-8 Input current 2-7
Current Loop 6-1 Input Protection Scheme 4-25
D Input transformer 2-6
Debug Functionality 5-36 Input voltage 2-6, 2-7
Diagnostics 2-8 Input/Output Section 4-7
Drive Family Description 4-1 Integral Timer 5-23
Drive Tuning 5-15 Integral timer 5-23
Dual Frequency Braking 5-32 Intellectual Property 1-9
s
19001591: Version 1.0 I-1
Index GenIV Product User Manual
Internal Threshold 5-24 Power factor 2-7

Internal threshold 5-24 Product Description 4-1
Introduction 1-1 Protection Features 4-18
Inverse Time Curve 5-23 ProToPSTM 6-9
inverse time curve 5-23 ProToPSTM Advantage 6-10
L ProToPSTM Implementation 6-9
Link fault 2-8 Purpose 1-1
List of symbols B-1 Q
Lock-out/tag-out Q1 2-3
procedures 2-iii Q2 2-3
Long Cable Applications 6-2 Q3 2-3
Long Cable Filters 4-31 Q4 2-3
Loss of field fault 5-5 R
LVD A-3 Reactors and Capacitors 4-31
M Reader Comments Form R-1
Manuals 3-vii Rectifier 1-7
Master EPLD 2-8 Reference signal 2-3, 2-4
Microprocessor 2-8 Reference Tools 3-vii
Motor Ride Through 4-35
signal polarities 5-2 S
Motor Compatibility 4-33 Safety Precautions 2-iii
Motor neutral 2-5, 2-6 Safety precautions 2-iii
Motor voltage and current waveforms 2-6 Safety precautions and warnings 2-iv
Multiple Networks 6-8 Schematic of a Typical Power Cell 2-4
N Schematic of a typical power cell 2-4
Neutral 2-5, 2-6 Serial Port 5-32
Neutral Point Shift During Bypass 5-26 Signal Interface Board 2-8
NXG control configuration 6-5 Sine wave 2-6
NXG Debug Utility 5-32 Single induction motors 5-4
O Sinusoidal Output Voltages 1-4
One cycle protection 5-21 Slaves 2-8
integral timer 5-23 Slip 5-2
transformer model 5-22 Speed Droop 5-26
Open loop test mode 5-4 Speed Loop 6-2
Open loop vector control 5-4 Static drives 2-6
Output Filters 6-3 Switching Frequency 4-18
Output voltages 2-5 Symbols B-1
Output waveform 2-3, 2-4 Sync Transfer
Overload Current Capability versus Time of Cell 5-15 Input/Output Signals 6-5
Overview 1-1 Synchronous Transfer 6-4
P Down Transfer Implementation 6-7
Parallel Control 6-8 Input/Output Signals 6-5
Parameters 3-1 Up Transfer Implementation 6-6
Parity 2-8 Synchronous Transfer Reactors 4-32
PED A-4 System Program 6-2
Pentium processor 2-8 System Specifications 3-1
Perfect Harmony Advantage 6-8 T
Perfect Harmony Features 1-4 Terminal Blocks 4-26
power cell 2-8 THD 2-6
Power Cell Bypass Option 1-7 Theory 2-1
Power Cell Specifications 3-2 Tool Suite 5-30
Power cells 2-8 ToolSuite
Power Circuitry 2-1 Configuration 5-31
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I-2 19001591: Version 1.0
GenIV Product User Manual Index
Control 5-31
Drive Host 5-31
Graphing 5-31
NXG Debug Utility 5-32
Status 5-31
Topology of Perfect Harmony VFD 2-3
Total harmonic distortion 2-6
Transformer 5-22
Transformer model
one cycle protection 5-22
Transformer Section 4-10
Transformer Thermal Rollback 5-14
Transformer Winding Configuration 1-7
U
Up Transfer Implementation 6-6
V
Vector control 5-2
current regulators 5-2
dead-time compensation 5-3
feed-forward compensation 5-2
flux angle 5-3
flux regulators 5-2
motor model 5-2, 5-3
peak reduction 5-3
speed regulators 5-2
VFD Output Ratings 1-6
VFD Scalability 1-6
VFD Synchronous Transfer Implementation 6-4
W
Warnings iii
Warnings iii
Waveforms 2-4
wyeconnected primary 2-6
∇ ∇ ∇
s
19001591: Version 1.0 I-3
Index GenIV Product User Manual
s
I-4 19001591: Version 1.0
GenIV Product User Manual NOTES
NOTES
s
19001591: Version 1.0 N-1
NOTES GenIV Product User Manual
s
N-2 19001591: Version 1.0
GenIV Product User Manual NOTES
s
19001591: Version 1.0 N-3
NOTES GenIV Product User Manual
∇ ∇ ∇
s
N-4 19001591: Version 1.0
GenIV Product User Manual Reader Comments Form
Reader Comments Form

To provide quality documentation that meets the needs of its customers, Siemens LD A invites comments
and criticisms of this manual. Please complete the attached form and provide your comments on this
manual. After completing this form, please remove this page from the manual (or photocopy it) and either
mail, E-mail or fax it back to the Documentation Department at Siemens LD A. These are mechanisms
through which you can positively effect the documentation that you receive from Siemens. Thank you for
your feedback. It is always valued and appreciated.
Did you find the manual well organized? { Yes { No

Was the information presented clearly? { Yes { No
Was the manual sufficiently illustrated? { Yes { No
Did you find the material adequate? { Yes { No
Would you prefer a more technical or less technical approach? { More { Less
What improvements would you like to see? (Please be specific and cite examples, if possible.)
Did you find any technical inaccuracies or mistakes? If so, please indicate page number(s) and information
that needs to be corrected.
What feature of the manual did you find the most useful? The least useful?
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19001591: Version 1.0 R-1
Reader Comments Form GenIV Product User Manual
Additional Comments
Attention: Documentation Control

Siemens LD A
USA
Phone: (724) 339-9500 Fax: (724) 339-9562 E-mail: DocumentControl@siemens.com
∇ ∇ ∇
s
R-2 19001591: Version 1.0
GenIV Product User Manual Startup/Warranty Registration and Service Solutions
and Service Solutions
To assure timely technical updates on your equipment, please complete and return this form. This information is to be
completed by the end user or equipment owner. For information on post sale service solutions, please check the
appropriate boxes below before returning this form to Siemens Energy & Automation,Inc.
Company Name
Contact Name
Company Address
Phone
Fax
E-mail
Part Number (P/N) (see system door or system panel)
system panel)
Start-up Date
• Extended Warranty
• Full Service Agreement
• Preventative Maintenance Agreement
• In-House Training at Siemens
• On-Site Training at your Location
• Spare Parts Kits
Return this information to Siemens at the address below, or fax it to (724) 339-9562, or call the Technical Support
Department at (724) 339-9501. Please visit our web site at www.siemens.com.
Attention: Customer Service Operations
Siemens LD A
USA
s
19001591: Version 1.0 W-1
Startup/Warranty Registration and Service Solutions GenIV Product User Manual
s
W-2 19001591: Version 1.0

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SHOP DRAWING SUBMITTAL

Specification #: 80009841 – General specification and requirements for medium

Sales Order #: 3001196416, 3001196287, 3001196302,

Customer: Cementos Argos

Purchase Order #: 4-0720001-148703A, 4-0720001-148704A, 4-0720001-149934A,

January 28, 2008

Originator: Matt Smochek

SUBMITTAL DOCUMENT SECTION INDEX

SECTION 2. VFD DRAWINGS & MOTOR INFORMATION

SECTION 3. SUBMITTAL SPECIFICATION COMPLIANCE

SECTION 4. CLARIFICATIONS AND COMMENTS

SECTION 5. VFD SPECIFICATION INFORMATION

SECTION 6. VFD CATALOG INFORMATION

SECTION 7. EFFICIENCY & POWER FACTOR INFORMATION

SECTION 8. KEY COMPONENT DATA/VENDOR CUT SHEETS

SECTION 9. RECOMMENDED SPARE PARTS

SECTION 10. QUALITY CONTROL PLAN

SECTION 11. PRELIMINARY AIR COOLED TEST PLAN

SECTION 12. WARRANTY

SECTION 13. MANUALS

SECTION 1. SCOPE OF SUPPLY

SO: 3001196416, PO: 4-0720001-148703A

Variable Frequency Drives

SO: 3001196287, PO: 4-0720001-148704A

Variable Frequency Drives

SO: 3001196302, PO: 4-0720001-149934A

Variable Frequency Drives

SO: 3001196303, PO: 4-0720001-149946A

Variable Frequency Drives

SO: 3001195583, PO: 4-0720001-148702A

Variable Frequency Drives

VFD DRAWINGS & MOTOR INFORMATION

SO: 3001196416, PO: 4-0720001-148703A

4000 HP MOTOR DATA, CURVES AND OUTLINES

2000HP MOTOR DATA, CURVES AND OUTLINES

SO: 3001196287, PO: 4-0720001-148704A

900 HP MOTOR DATA, CURVES AND OUTLINES

SO: 3001196302, PO: 4-0720001-149934A

1750 HP MOTOR DATA, CURVES AND OUTLINES

SO: 3001196303, PO: 4-0720001-149946A

1750 HP MOTOR DATA, CURVES AND OUTLINES

SO: 3001195583, PO: 4-0720001-148702A

6600HP MOTOR DATA, CURVES AND OUTLINES

Degree of Protection IP55

Method of cooling IC 611

Total weight 198.2 kN

Dynamic Loading (maximum) 415 kN up, 640 kN down

Weight of rotor 47.9 kN

Rotor Inertia 426 kg-m2

DR = Direction of rotation (facing drive end DE) Counter Clockwise only

1 Terminal box for stator system connection

3 Terminal box for stator and bearing temperature protection

5 Separate terminal box for anti-condensation heater

11 Anti-friction bearing NDE

40 Air Inlet RTD

41 Air Outlet RTD

● Bearing thermometer (double resistance thermometer Pt100; 100Ω at 0 °C)

Guide values for adjustment of tripping temperature for bearing thermometers

● Embedded winding thermometer (resistance thermometer Pt100; 100Ω at 0 °C)

Recommendation for fixing the machine on a steel foundation

Alignment accuracy for couplings:

Standard: NEMA MG-1

Calculated Start-Up Data:

Motor voltage U/UN 1.00 0.9