Frequency Converter Manual

30kVA 3x200V 400Hz

Technical data described in this manual belong to ELIT Srl and they cannot be reproduced without
any written license.

1
WARRANTY

The apparatus is guaranteed from defect of materials and defect in workmanships

within bounds of right working.

If within the warranty period, the apparatus was defective, ELIT would repair or
substitute, free of charge, the damage part, ex our works.

The warranty will be not applied in the following situations:

- Without a proper installation (inadequate air conditioning, high
temperatures, dusty and corrosive ambient);
- If a whatever part of the apparatus has repaired or manipulated by not
qualified ELIT personnel;
- If it turns out that the cause of the fault is due to negligence of not qualified
personnel or to bad working of other apparatus (conditioners, fans..);
- If it turns out that the cause of the fault is due to events as: thunderbolts,
fires, earthquakes, inundations or other disasters;

REMARK: Ordinary maintenance, if it is not provided in the purchase contract, is

charged to customer even during warranty period.
The apparatus has to maintain clean observing the safety instructions described
in the chapter “MAINTENANCE”.

INTRODUCTION

This technical manual contains all the necessary information for the correct use of
the apparatus. If a fault or a bad working happens, our Customer Service will
provide authorized electricians or qualified internal personnel to perform the
necessary operations. In case of conflict between this manual and drawings or
purchase orders, the manual NOT has priority. If errors would be notified upon
the content of this manual, these ones had to be communicated to Engineering
Department in order to substitute the relative part.

2
DANGER OF ELECTROCUTION

Inside the apparatus there are some voltage potentials which are dangerous for health
bodily.
We exhort to allow the admittance at the apparatus only to expert personnel. Before
starting any maintenance operations it is necessary wait for the discharge of electrolytic
capacitors and IT IS NECESSARY MEASURE THEIR VOLTAGE BEFORE TOUCH THEM.

TABLE OF CONTENTS

Product introduction
Installation
Start up procedure
Shutdown procedure
Frequency converter maintenance
Troubleshooting
Adjustments
Schematics
Mechanical assembly
Control Logic
CE declaration
Test report

PRODUCT INTRODUCTION

The diodes rectifier converts the input AC voltage into a DC voltage. Therefore the IGBT
three phase bridge, reconverts the DC voltage into a AC voltage with PWM technology.
The output bridge voltage, is applied to the transformer in order to have a galvanic
insulation between input and output and in the meantime to adapt the output voltage
from the bridge to the user voltage requested. The filter, placed downstream of
transformer, gives the output voltage sinusoidal with a low harmonic content.
The electronic circuits whom provide to the stabilization, with an answer time lower than
a semi cycle, and to all protection and control functions, are realized with high immunity
components.

3
INSTALLATION

Upon receiving the frequency converter, carefully examine the packing container
for any sign of physical damage.
Place the converter in a room with an enough aeration, and verify that the
dissipation power can be evacuated by the foreseen devices in the room.
Not place the apparatus where some dripping of water or of other fluid can be
occurred.
Generally:
- If the air change has got with a forced ventilation, calculate the air-flow
taking care also of the input latent heat (other apparatus, sun exposure –
1kW/m2), and avoid zones with heat stagnations. The cooling system have to
be redundant in order to avoid critical situation for any fan faults.
- If you use air-conditioners, take care that, even in fault condition, the
temperature room doesn’t overcome the admitted values.
- If the converter is made for external use, it is important foreseeing a lean-to.
Take care that the air feed opening are always without any obstructions.
Connect the Input/Output Terminal Board. If not request in explicit form, the output
neutral is NOT grounded.

START UP PROCEDURE

1. Check that input breaker SI is in OFF position.

2. Feed the mains to the input converter.
3. Close SI.
4. Push INPUT green button. Immediately K2 is excited. Green RUNNING lamp
and red ALARM lamp are lighted.
After 10 seconds K1 is closed.
After 7 seconds the converter is in function and red ALARM lamp come off:
the converter is OK.
5. When converter is OK, VOLTAGE IS PRESENT AT OUTPUT.

SHUTDOWN PROCEDURE

1. Push OFF button (local or remote) to SHUT-OFF OUTPUT VOLTAGE.

4
FREQUENCY CONVERTER MAINTENANCE

After having started up the apparatus in the right way, it doesn't need any particular
care: however it is necessary that the ambient, where the frequency converter is placed,
must be airy and without dust. It is important after the first six months to carry out a
check of the apparatus to verify its cleanness; if the accumulated dust on radiators is
excessive, it is necessary to remove this one with dry low compressed air. For normal
environment, it had better clean the apparatus al least yearly.
SCHEDULED OPERATION
- Replacement of the fans after 20.000 working hours;
- Replacement of the electrolytic capacitors after 80.000 working hours;
- Replacement of the filter capacitors after 100.000 working hours;
The above schedules refer to an apparatus that works on average of 25°C. For higher
temperatures, consider that for every 10°C more, there is a cutting in a half of above
indicated periods.

TROUBLESHOOTING

- Closing Q1 the fans don’t start. Check

- the fuse of auxiliary transformer,10x38 6A;
- the circuit breaker of fan: Q1.
- Closing Q1 the P1 meter doesn’t light up. Check the fuse of protection of measure
instrument: 10x38 1A.
- Pressing the INPUT green push button, the K2 contactor is not energized. Check
the fuse of protection of input auxiliary circuits: 10x38 4A.
- Thermostats of each heat sink.
- Thermostats of each magnetic components (when mounted)
- Emergency push button must be taken out.
1. In spite of being energized K2, K1 is not energized after 10-12 seconds.
Check:
- that K3 is energized, and V56 on AICO is lighted. The pilot lamps of START and
ALARM on the control panel are lighted.
- KT timer: is set on 12 seconds. When k3 is energized the green led have to be
lighted. When the yellow led lights K1 has to be energized.
If V56 and the pilot lamps doesn’t light, switch off the converter, check F7 (10x38
1 A). If it is in fault, change it with an other one. Repeat the forward trasition. If
the fuse is yet in fault, call the technical service. The fault regards the ALUP
(power supply).
2. K1 is energized, but inverter do not start. When K1 energizes, V57 on AICO has to
be lighted.
Check
- CORE must have yellow LED and 2 green LED lighted. If not control the fuse of
ALUP (F4).

5
- After 7 seconds that V57 lights on AICO, V96 has to be lighted on CORE (V94 had
to be already lighted).After 1-2 seconds V95 has to be lighted.
- If is not happened, call the technical service.
3. The faults, while the converter is running or starting, are signalled on CORE by
LEDs.
- V95: the led doesn’t light. The converter can be in overload.
- V97. the led lights (yellow) . the converter is in overvoltage and it locks.
- V98. the led lights (red). The right leg of IGBT bridge has a problem: the problem
can depend on by an IGBT, by driver board (PGBT) or by section 41-60, (red wire)
of CORE flat cable.
- V99. the led lights (red). The central leg of IGBT bridge has a problem: the
problem can depend on by an IGBT, by driver board (PGBT) or by section 21-40
of CORE flat cable.
- V100. the led lights (red). The left leg of IGBT bridge has a problem: the
problem can depend on by an IGBT, by driver board (PGBT) or by section 01-20 of
CORE flat cable.
4. For a fast diagnosis, in order to check the fault causes, after have switched off
the converter and after have waited for the discharge of the capacitors, you can do
the following test. This test can be done only by technical staff and with the agree
of technical ELIT office.
This test consists in changing the wrong leg connector with one of the others two
ones: for example, if the led V100 is lighted, it means that the fault is in the
section 01-20 of flat cable. If you change this connector with that relative to the
part of flat cable 21-40 and remake the starting, it can happen two cases: 1) the
led V100 is off, but V99 lights. 2) the led V100 goes on lighting.
In case 1) the fault can regards the IGBTs of the left leg or its driver board. The
wrong of a IGBT can be checked by a tester.
In case 2) the fault regards the CORE board.

ADJUSTMENTS

The possible regulations can be done on the CORE board.

- % of droop line compensation (If requested).

- RV3: block of the converter for breakdown output voltage
- RV4: alarm for minimum output voltage ( the converter doesn’t block and,
ceased the overload, it restarts to supply the voltage output rating.
- RV5: reserved to technical services.
- RV6: the setting of current limit ( to set only with the authorization of technical
service)
- RV8: overload signal.
- RV9: reserved to technical assistance
- RV11: setting of voltage output rating.

6
TECHNICAL SPECIFICATION FREQUENCY CONVERTER
30kVA – 3x200V - 400Hz

1. INPUT DATA
- Rated voltage: : 3 x 400V +-15%
- Frequency: : 50/60Hz +-5%
- Input current at full load : 50 A

- Power factor (full load) : 0.94

- Total Current Harmonic Distortion : 25%
- Inrush current : absent

2. OUTPUT DATA
- Rated power (cosphì=0,8) : 30kVA
- Rated voltage : 200/115V 4w
- Frequency : 400Hz ±0,01%
- Power factor : ind./cap.
- Waveform : sinusoidal
- Total Harmonic Distortion (linear load) : 3%
- Voltage regulation :  1%
- Voltage transient (for load step 0-100%
and back): :  8%
- Recovery time : 2 msec.
- Overload 10 minutes : 1.25 of full load
- Overload 1 minute : 1.5 of full load
- Voltage symmetry with balanced load :  1%
- Voltage symmetry with 30% unbalanced load : ± 2%

3. SYSTEM PARAMETERS
- Dimensions ( Width x Depth x Height mm) : 600x800x1200
- Weight (kg) : 350
- Efficiency : >88%
- Audible noise : 65dBA
- Operating temperature : –25°C to +50°C
- Relative humidity ( non-condensing) : 0 to 95%
- Altitude without derating :1000m msl
- Enclosure: : IP 20
- Cooling: : forced air

1
 4. STANDARDS
CE compliant.
ISO 6858: Ground support electrical supplies
EN 2282: Characteristics of aircraft electrical supplies – General requirements
MIL-STD-704E
EN50091-1
EN 61000-6-2: Electromagnetic compatibility. Emission
EN 61000-6-4: Electromagnetic compatibility. Immunity.

5. BREAKERS, OPERATOR CONTROLS, MEASURES, INDICATORS

- Input switch
- Output switch
- ON/OFF push buttons
- Measures: : output voltage
: output current
: output frequency
-Indicators: : frequency converter running
: frequency converter alarm/start up
- Remote Power Off.

ELIT Srl reserves his right to do modifications to his products without notice.

2
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 BOLLETTINO COLLAUDO CONVERTITORE FREQUENZA n.s. 1849
TEST REPORT FREQUENCY CONVERTER s.n. 1849

BOLLETTINO DI COLLAUDO
CONVERTITORE DI FREQUENZA
TEST REPORT FREQUENCY CONVERTER

CONVERTITORE DI FREQUENZA 30kVA

FREQUENCY CONVERTER
POTENZA NOMINALE : 30kVA
RATED POWER
INGRESSO : 400V 3 Ph, 50/60Hz
INPUT
USCITA : 200V 3 Ph + N, 400Hz
OUTPUT 87A cosphì= 0,8 ; 70A cosphì= 1

MATRICOLA : 1849
S/N
CODICE APPARATO : 140444
DWG
CLIENTE : SIMAV
CUSTOMER

1
 BOLLETTINO COLLAUDO CONVERTITORE FREQUENZA n.s. 1849
TEST REPORT FREQUENCY CONVERTER s.n. 1849

Piacenza 10-12-11
Operatore/Op2rator : MD
Controllore/Control: FD

Prova di Isolamento pag.3

Insulation Test
Ingresso/Input
Uscita /Output

Rigidità dielettrica
Dieletric Strength Test pag.4
Ingresso/Input
Uscita/Output

Verifiche meccaniche: pag.5

Mechanical Inspection
- Peso/weigth
- Dimensioni/dimentions
- Verniciatura/painting

Controllo tarature e circuiti ausiliari: pag.5

Calibrations and auxiliary circuits

Prove Funzionali 400Hz : pag.6

Funtional tests
- Prova a vuoto/no load test:
- Prova a carico nominale/rated load test:
- Misura frequenza/frequency test:
- Misura distorsione/Total Harmonic Distorsion test:
- Prova sovraccarico/overload test:
- Prova compensazione cdt/Drop Line Compensation test:

Strumentazione: pag.8
Meters

2
 BOLLETTINO COLLAUDO CONVERTITORE FREQUENZA n.s. 1849
TEST REPORT FREQUENCY CONVERTER s.n. 1849

PROVA ISOLAMENTO
INSULATION TEST

Il convertitore è isolato dalla rete. I morsetti di ingresso U,V,W sono cortocircuitati.

I morsetti di uscita A,B,C sono cortocircuitati. Il generatore è impostato a 500Vcc.
Input: U,V,W short-circuited
Output: A,B,C,N short-circuited
Test Voltage: 500Vdc

Condizioni atmosferiche/Enviromental condition :

- Temperatura ambiente/Ambient temperature: 15°C< T amb.<35°C
- Umidità relativa/Relative humidity : 25%< UR < 95%
- Pressione atmosferica/Atmospheric Pressure : 860mb < PA < 1060mb

Generatore tra massa ed ingresso/Ground-Input : 50Mohm

Generatore tra massa ed uscita/Ground_Output : 50Mohm

PROVA RIGIDITA’ DIELETTRICA

DIELECTRIC STRENGTH TEST

Il convertitore è isolato dalla rete. I morsetti di ingresso U,V,W sono cortocircuitati.

I morsetti di uscita 1 A,B,C,N sono cortocircuitati. I morsetti di uscita 2 sono
cortocircuitati
Input short-circuited; Output 1 short-circuited; Output 2 short-circuited

Condizioni atmosferiche/Enviromental conditions:

- Temperatura ambiente/Ambient Temperature: 15°C< T amb.<35°C
- Umidità relativa/ Relative Umidity : 25%< UR < 95%
- Pressione atmosferica/Atmospheric Pressure : 860mb < PA < 1060mb

Generatore impostato a 3000V 50Hz per 1 min. tra massa ed ingresso : ok

Input-Ground 3000V, 50Hz, 60seconds
Generatore impostato a 2000V 50Hz per 1 min. tra massa ed uscita 1 : ok
Output 1-Ground 2000V, 50Hz, 60seconds
Generatore impostato a 2000V 50Hz per 1 min. tra massa ed uscita 2 : ok
Output 2 – Ground 2000V, 50Hz, 60sec.

3
 BOLLETTINO COLLAUDO CONVERTITORE FREQUENZA n.s. 1849
TEST REPORT FREQUENCY CONVERTER s.n. 1849

VERIFICHE MECCANICHE
MECHANICAL INSPECTION

- Peso/weigth : 350kg (presumed)

- Dimensioni/Dimentions ( LxPxH) : 600x800x1200
- Verniciatura/Painting : RAL 7035

CONTROLLO TARATURE e VERIFICA CIRCUITI AUSILIARI

CALIBRATIONS AND AUXILIARY CIRCUITS

- Controllo funzionamento circuiti desaturazione : ok

Short-circuit protection
- Soglia minima tensione uscita Fase-Neutro : 100V
Minimum voltage L-N
- Soglia massima tensione uscita Fase-Neutro : 140V
Maximum Voltage L-L
- Allarme sovracorrente (carico resistivo) : 70A
Overload alarm (resistive load)
- Limitazione corrente (carico resistivo) : 105A
Current Limit
- Verifica senso ciclico, uscita 1 : ok
ABC phase sequence check, output 1

4
 BOLLETTINO COLLAUDO CONVERTITORE FREQUENZA n.s. 1849
TEST REPORT FREQUENCY CONVERTER s.n. 1849

PROVE FUNZIONALI a 400Hz

FUNTIONAL TESTS
USCITA 1
PROVA A VUOTO, (Tensione fase-neutro),.
NO LOAD TEST, (line-neutral voltage).
- Tensione A-N /A-N Voltage : 115,4V (116.7)
- Tensione B-N/B-N Voltage : 116,3V (116.8)
- Tensione C-N/C-N Voltage : 115,9V (116.8)
- Frequenza/Frequency : 400.2Hz
- Distorsione/THD : 3%
PROVA A CARICO, Compensazione minima ( Tensione fase-neutro)
LOAD TEST, Minimum Drop Line Compensation (line-neutral voltage)
Condizioni: Carico resistivo (Resistive load)
- Tensione A-N/A-N voltage : 117.5V
- Corrente linea A/A line current : 70A
- Tensione B-N/B-N voltage : 118,7V
- Corrente Linea B/B line current : 70A
- Tensione C-N/C-N voltage : 117V
- Tensione Linea C/C line current : 70A
- Frequenza/Frequency : 400.2Hz
- Distorsione/THD : 2%
SOVRECCARICO 125% 87A per 10 minuti (carico resistivo)
125% overload (resistive), 10 min
SOVRACCARICO 150% : 105A per 1 minuto (carico resistivo)
150% overload (resistive), 1 min

STRUMENTAZIONE
METERS
- Misuratore Isolamento : Hioki 3454-1 s.n.040416444
Insulation tester
- Misuratore Rigidità : Elektrotechishes Laboratorium
Dielectric strength tester UH28CS/12kV 200477020008
- Oscilloscopio : Tektronix TDS s.n.B052819
Scope
- Analizzatore Rete : Hioki 3190 s.n.040543418
Mains analyzer
- Tester / Tester : Fluke 179 s.n.86520631
- Pinza Amperometrica : Fluke 337 s.n.594040195
Amperometric clamp
- Carico resistivo portabile : Cannon 120kW a 200V 400Hz a
Resistive load
5