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UR11 Unit

UR11 G2

User's Manual WEG Equipamentos Elétricos S.A. Jaraguá do Sul - SC - Brazil Phone 55 (47) 3276-4000 - Fax 55 (47) 3276-4020 São Paulo - SP - Brazil Phone 55 (11) 5053-2300 - Fax 55 (11) 5052-4212 [email protected] www.weg.net 15484957 User’s Manual

Serie: UR11 G2

Language: English

Document: 10007640156 / 00

Models: 1414...1807 A/380...690 V

Publication Date: 06/2020 Summary of Revisions

The information below describes the revisions made to this manual.

Version Revision Description - R00 First edition Contents

1 SAFETY INSTRUCTIONS...... 1-1 1.1 SAFETY NOTICES IN THE MANUAL...... 1-1 1.2 SAFETY WARNINGS ON THE PRODUCT...... 1-1 1.3 PRELIMINARY RECOMMENDATIONS...... 1-2

2 GENERAL INFORMATION...... 2-1 2.1 ABOUT THE MANUAL...... 2-1 2.2 TERMS AND DEFINITIONS USED IN THE MANUAL...... 2-1 2.3 ABOUT THE UR11 G2...... 2-3 2.4 UR11 G2 IDENTIFICATION LABEL...... 2-5 2.5 HOW TO SPECIFY THE UR11 G2 MODEL (SMART CODE)...... 2-6 2.6 RECEIVING AND STORAGE...... 2-6

3 INSTALLATION AND CONNECTION...... 3-1 3.1 MECHANICAL INSTALLATION...... 3-1 3.1.1 Environment Conditions...... 3-1 3.1.2 List of Component...... 3-1 3.1.3 Positioning and Fixing...... 3-2 3.1.4 Hoisting...... 3-5 3.1.5 Panel Mounting...... 3-6 3.2 ELECTRICAL INSTALLATION...... 3-9 3.2.1 Identification of the Power and Grounding Connections...... 3-9 3.2.2 Input ...... 3-10 3.2.3 Line Reactor...... 3-10 3.2.4 Harmonics of the 6-Pulse Rectifier...... 3-12 3.2.5 Harmonics of the 12-Pulse Rectifier...... 3-13 3.2.6 Power Buses/Ground Wiring...... 3-14 3.2.7 Grounding Connections...... 3-15 3.2.8 Fuses...... 3-16 3.2.9 Power Connections...... 3-17 3.2.10 Input Connections...... 3-18 3.2.11 IT Networks...... 3-19 3.2.12 Control Connections ...... 3-20 3.2.13 Typical Connections...... 3-22 3.3 INSTALLATIONS ACCORDING TO THE EUROPEAN ELECTROMAGNETIC COMPATIBILITY DIRECTIVE...... 3-23 3.3.1 Conformal Installation...... 3-23 3.3.2 Definition of the Standards...... 3-23 3.3.3 Emission and Immunity Levels Met...... 3-24

4 FIRST TIME POWER-UP AND START-UP ...... 4-1 4.1 PREPARATION FOR START-UP...... 4-1 4.1.1 Precautions During Power-Up/Start-up...... 4-1 4.2 START-UP...... 4-1

5 TROUBLESHOOTING AND MAINTENANCE...... 5-1 5.1 OPERATION OF THE FAULTS...... 5-1 5.2 FAULTS, ALARMS AND POSSIBLE CAUSES...... 5-2 5.3 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS...... 5-3 5.4 INFORMATION TO CONTACT TECHNICAL SUPPORT...... 5-3 5.5 PREVENTIVE MAINTENANCE...... 5-3 5.5.1 Cleaning Instructions...... 5-4 Contents

6 TECHNICAL DATA...... 6-1 6.1 POWER DATA...... 6-1 6.2 ELECTRONICS/GENERAL DATA...... 6-2 6.2.1 Codes and Standards...... 6-2 6.3 MECHANICAL DATA...... 6-3

7 PROJECT EXAMPLE...... 7-1 Safety Instructions

1 SAFETY INSTRUCTIONS 1 This manual provides the necessary information for the proper use of the UR11 G2 Rectifier Unit, developed to power inverters of the CFW-11M G2 line.

It was developed to be used by people with proper technical qualification or training to operate this kind of equipment.

1.1 SAFETY NOTICES IN THE MANUAL

The following safety warnings are used in this manual:

DANGER! Failure to comply with the procedures recommended in this warning may lead to death, serious injuries and considerable material damages.

ATTENTION! Failure to comply with the procedures recommended in this warning may cause material damages.

NOTE! The text provides important information for the full understanding and proper operation of the product.

1.2 SAFETY WARNINGS ON THE PRODUCT

The following symbols are attached to the product as safety warnings:

High are present.

Components sensitive to electrostatic discharges. Do not touch them.

Mandatory connection to the protective ground (PE).

Connection of the shield to the ground.

Hot surface.

UR11 G2 | 1-1 Safety Instructions

1.3 PRELIMINARY RECOMMENDATIONS 1

DANGER! Only trained personnel, with proper qualification and familiar with the UR11 G2 rectifier and related equipment shall plan or perform the installation, start-up, operation and maintenance of this equipment. Such personnel must follow the safety instructions described in this manual and/or defined by local regulations. Failure to comply with the safety instructions may result in death, serious injury and/or equipment damage.

NOTE! For the purposes of this manual, qualified personnel are those trained and able to: 1. Install, ground, power up and operate the UR11 G2 in accordance with this manual and legal safety procedures in force. 2. Use the protective equipment according to the established regulations. 3. Provide first aid.

DANGER! Always turn off the main before touching any electrical component associated with the inverter. Several components may remain charged with high voltages and/or in movement (fans) even after the AC power supply has been disconnected or turned off. Wait for at least ten minutes to ensure the full discharge of the . Always connect the equipment frame to the protective ground (PE) at the proper terminal.

ATTENTION! Electronic boards have components sensitive to electrostatic discharges. Do not touch the components or connectors directly. If necessary, first touch the grounded metallic frame or wear a grounding strap.

Do not execute any withstand test on the inverter! If necessary, contact WEG.

NOTE! Frequency inverters may interfere in other electronic equipment. Observe the recommendations of Chapter 3 INSTALLATION AND CONNECTION on page 3-1 to minimize these effects.

NOTE! Read this entire manual before installing or operating this inverter.

ATTENTION! The operation of this equipment requires detailed installation and operation instructions provided in the User’s Manual and Manuals/Guides for Kits and Accessories. Only the User’s Manual is supplied in print. The other manuals can be obtained on WEG website - www.weg.net. A printed copy of this information may be requested through your local WEG representative.

1-2 | UR11 G2 General Information

2 GENERAL INFORMATION

2.1 ABOUT THE MANUAL

This manual contains the information for proper installation, main technical data and basic troubleshooting of the UR11 G2 .

2.2 TERMS AND DEFINITIONS USED IN THE MANUAL

Normal Duty Cycle (ND): inverter duty cycle that defines the maximum current operation current (Inom-ND) and the overload current (110 % for one minute). It is selected by programming P0298 (Application) = 0 –Normal Duty 2 Cycle (ND). It should be used for the operation of motors that are not subjected to high torques (with respect to the motor rated torque) when operating at permanent duty cycle, starting, accelerating or decelerating.

Inom-ND: inverter rated current for operation with normal duty cycle (ND). Overload: 1.1 x Inom-ND/ 1 minute.

Heavy Duty (HD) Cycle: inverter duty cycle that defines the maximum continuous operation current (Inom-HD) and the overload (150 % for one minute). It is selected by programming P0298 (Application) = 1 – Heavy Duty (HD) Cycle. It should be for the operation of motors that are subjected to high torques (with respect to the motor rated torque) when operating at constant speed, starting, accelerating or decelerating.

Inom-HD: inverter rated current for use with the heavy duty (HD) cycle. Overload: 1.5 x Inom-HD / 1 minute.

Rectifier: input circuit of inverters which transforms the AC input voltage into DC voltage. It is composed of thyristors or power diodes.

Pre-Charge Circuit: it loads the DC link capacitors with limited current, avoiding high current spikes at the inverter startup.

DC link: inverter intermediate circuit with DC voltage and current obtained from the rectification of the AC power supply, or from an external source; it supplies the output IGBT inverter bridge.

DC+: positive terminal of the DC Link.

DC-: negative terminal of the DC Link.

Diode: basic component of the input rectifier bridge. They work as an electronic switch (controlled by the voltage polarity between the anode and cathode terminals), in the following modes: conduction (closed switch, directly polarized terminals) and blocked (open switch, reversely polarized terminals).

Thyristor (SCR): silicon-controlled rectifier; basic component of the input rectifier bridge. It works like the diode but requires a voltage pulse at the gate terminal to be able to get into the conduction mode (in addition to being directly polarized between the anode and cathode terminals), which allows the control of the starting conduction angle.

R, S and T Arm: it is a set of one diode and one thyristor of the R, S and T phases of the rectifier input.

U, V and W Arm: it is a set of two IGBTs of the U, V and W phases of the inverter output.

IGBT: insulated Gate Bipolar Transistor, basic component of the output inverters. They work as an electronic switch in the saturated (closed switch) and cut-off (open switch) modes.

Braking IGBT: it works as a switch for the activation of the braking resistors. It is controlled by the DC link level.

6-Pulse Rectifier: six-phase rectifier configuration, regularly available through a phase-shifting transformer with two secondaries, one of them connected in delta and the other connected in star, where each power diode operates for 120º and commutates every 30º, performing twelve commutations in one cycle of the power supply.

12-Pulse Rectifier: six-phase rectifier configuration, regularly available through a phase-shifting transformer with two secondaries, one of them connected in delta and the other connected in star, where each power diode operates for 120º and commutates every 30º, performing twelve commutations in one cycle of the power supply. UR11 G2 | 2-1 General Information

PTC: resistor whose resistance value in ohms increases proportionally to the temperature rise; used as temperature sensor on motors.

NTC: resistor whose resistance value in ohms decreases proportionally to the temperature drop; used as temperature sensor on power modules.

HMI: human-machine interface; device which allows controlling the motor, viewing and changing the inverter parameters. The HMI of the CFW11W G2 has motor control and navigation keys and a graphic LCD display.

FLASH Memory: nonvolatile memory that can be electrically written and erased. 2 RAM memory: random access volatile memory.

USB: universal serial bus; serial communication protocol conceived to operate according to the plug-and-play concept.

PE: protective earth.

RFI filter: Frequency Interference Filter; filter to reduce interference in the band.

PWM: pulse width modulation; pulsed voltage generated by the output inverter which feeds the motor.

Switching Frequency: switching frequency of the IGBTs of the inverter bridge, normally expressed in kHz.

Heatsink: metal part designed to dissipate the heat generated by power semiconductors.

PLC: programmable logic controller.

Amp, A: Ampere.

°C: degrees Celsius.

AC: alternating current.

DC: .

CFM: cubic feet per minute; a flow measurement unit.

cm: centimeter.

CV: Brazilian unit of power = 736 Watts; usually used to indicate mechanical power of electric motors.

ft: foot.

hp: horse power = 746 Watts; unit of power, usually used to indicate mechanical power of electric motors.

Hz: Hertz.

in: inch; length measurement unit.

kg: kilogram = 1000 grams.

kHz: Kilohertz = 1000 Hertz.

l/min: liters per minute.

lb: pound; mass measurement unit.

m: meter.

2-2 | UR11 G2 General Information mA: milliampere = 0.001 ampere. min: minute. mm: millimeter. ms: millisecond = 0.001 second.

Nm: newton meter; torque measurement unit. rms: root mean square; effective value. 2 rpm: revolutions per minute; unit of rotational speed. s: Second.

V: Volts.

Ω: Ohms.

2.3 ABOUT THE UR11 G2

The UR11 rectifier unit provides DC voltage to feed the CFW-11M line inverters. The UR11 can also be used to power other devices that require DC link voltage.

The DC link pre-charge is performed by the control of the thyristor firing angle through a microcontroller: the pre-charge provides a linear voltage ramp, avoiding high currents and eliminating the pre-charge circuit of the panels.

The UR11 G2 has an interface board powered by an external +24 Vdc source. This board features three relay outputs for fault and alarm signaling, and four LEDs to indicate faults and the rectifier bridge status. There are also two DIP switches to set the voltage of the UR11 G2 power supply, according to the model (refer to Item 3.2.12 Control Connections on page 3-20 for further information). This board also monitors the temperature of the heatsinks and controls the fans. Figure 2.1 on page 2-4 shows a simplified block diagram of the UR11.

UR11 G2 | 2-3 General Information

220 Vac external IUR11 G2 fan power supply

DC+ AC Power supply DC Output DC - RECTIFIER AC voltage Temperature DC voltage feedback feedback feedback 2 CPC11 Control Power supplies for electronics and thyristor power

IUR11

LEDs User Digital Outputs interface DO1 (RL1) to board DO3 (RL3) 24 Vdc External electronics power supply

Figure 2.1: Rectifier block diagram

Figure 2.2: Unidade Retificadora UR11 G2

NOTE! Several additional items are needed for the complete drive assembly, such as output inverters, AC power supply fuses, DC link fuses to protect the output power units, circuit breaker or switch- at the input.

2-4 | UR11 G2 General Information

2.4 UR11 G2 IDENTIFICATION LABEL

The identification label is located at the front of the UR11 G2.

Manufacturing date (48 corresponds UR11 G2 Model to the week and H to the year) WEG part number Serial number Maximum ambient temperature Rectifier net weight around the rectifier Rated input data (voltage, rated currents Rated output data (voltage, rated 2 for use with normal duty (ND) cycle and currents for normal duty (ND) heavy duty (HD) cycle, frequency) cycle and heavy duty (HD) cycle)

Current specifications for use with normal duty (ND) cycle

Current specifications for use with heavy duty (HD) cycle

Figure 2.3: UR11 G2 identification label

Identification label

Figure 2.4: Identification label location

UR11 G2 | 2-5 General Information

2.5 HOW TO SPECIFY THE UR11 G2 MODEL (SMART CODE)

In order to specify the UR11 G2 model, it is necessary to indicate, in the smart code, the desired voltage and current values in their respective fields for rated supply voltage and rated input current for normal duty cycle (ND), as shown in the example of Table 2.1 on page 2-6:

Table 2.1: Smart code Rectifier Model See the list of models in Chapter 6 TECHNICAL DATA on page 6-1, which also contains the technical data of the inverters Example BR UR11G2 1414 T 6 S Z 2 Field Market WEG Rectifier Rated current Number of Rated input Optional items Character that description identification Unit - 11 series for use with the input phases voltage identifies the (sets the normal duty code end language of the cycle (ND) manual and factory settings) Available 2 characters T = three- 4=380...480 V S = standard options phase 5=500...600 V product O = 6=660...690 V product with optional item

E.g.: UR11G21414T6SZ corresponds to a 1414 A three-phase UR11 rectifier, with 660 V to 690 V input voltage (input power supply). The options available for the rectifier rated input current under normal duty (ND) cycle are found in Table 2.2 on page 2-6, according to the rectifier rated input voltage, the corresponding output currents are found in Table 6.1 on page 6-1.

Table 2.2: Rated input currents under normal duty (ND) cycle 380-480 V 500-600 V 660-690 V 1807 = 1807 A 1414 = 1414 A 1414 = 1414 A

2.6 RECEIVING AND STORAGE

The UR11 G2 Rectifier Units are supplied in wooden boxes.

There is an identification label outside the package, identical to the one affixed to the inverter.

In order to open the package:

1. Remove the front cover of the package.

2. Damages occurred during transportation.

Check if:

1. The identification labels correspond to the models purchased.

2. Remove the styrofoam protection.

Report any problems immediately to the carrier.

If the products will not be installed immediately, store them in a clean and dry place (temperature between -25 ºC and 60 ºC) with a cover to prevent the ingress of dust.

2-6 | UR11 G2 Installation and Connection

3 INSTALLATION AND CONNECTION

This chapter describes the procedures for the electrical and mechanical installation of the UR11 G2. The instruction and guidelines listed in this document must be followed in order to ensure personal and equipment safety, as well as the proper operation of the inverter.

3.1 MECHANICAL INSTALLATION

The power units must be properly mounted on the drive panel, allowing easy removal and reinsertion in case of maintenance. The mounting must also be such to avoid damage during the panel transportation.

3.1.1 Environment Conditions

Avoid:

„ Direct exposure to sunlight, rain and high humidity.

„ Inflammable or corrosive liquids or gases.

„ Excessive vibration. 3 „ Dust, metallic particles and oil mist.

Environment conditions for operation:

„ Ambient temperature: 0 ºC to 45 ºC - nominal conditions (measured around the rectifier). From 45 ºC to 55 ºC - 2 % of current derating for each Celsius degree above 45 ºC.

„ Maximum altitude: up to 1000 m - nominal conditions.

„ From 1000 m to 4000 m - 1 % of current derating for each 100 m above 1000 m of altitude.

„ From 2000 m to 4000 m - maximum voltage derating (690 V for models 500...690 V) of 1.1 % for each 100 m above 2000 m.

„ Maximum altitude of 4000 m.

„ Air relative humidity: 5 % to 95 % non-condensing.

„ Pollution degree: 2 (according to EN50178 and UL508C), with non-conductive pollution. Condensation must not cause conduction through the accumulated residues.

3.1.2 List of Component

The UR11 G2 rectifier was developed to power inverters of the CFW-11M G2 line. For drives that require currents above the rectifier unit rated current, rectifier modules can be added in parallel according to the drive current, as per information contained in Table 3.1 on page 3-1, Table 3.2 on page 3-2 and Table 3.3 on page 3-2.

Table 3.1: List of Components: Drives 380 - 480 V in the 6-pulse configuration Rated Current [A] Qty of Line Qty. UP11-02 G2 Qty. UR1111 G2 UR11 G2 Model ND HD Reactors 1 634 515 1 UR11G21807T4SZ 1 2 1205 979 1 UR11G21807T4SZ 1 3 1807 1468 1 UR11G21807T4SZ 1 4 2409 1957 2 UR11G21807T4SZ 2 5 3012 2446 2 UR11G21807T4SZ 2

UR11 G2 | 3-1 Installation and Connection

Table 3.2: List of Components: Drives 500 - 600 V in the 6-pulse configuration Rated Current [A] Qty of Line Qty. UP11-01 G2 Qty. UR1111 G2 UR11 G2 Model ND HD Reactors

1 496 380 1 UR11G21414T5SZ 1 2 942 722 1 UR11G21414T5SZ 1 3 1414 1083 1 UR11G21414T5SZ 1 4 1885 1444 2 UR11G21414T5SZ 2 5 2356 1805 2 UR11G21414T5SZ 2

Table 3.3: List of Components: Drives 660 - 690 V in the 6-pulse configuration Rated Current [A] Qty of Line Qty. UP11-01 G2 Qty. UR1111 G2 UR11 G2 Model ND HD Reactors

1 439 340 1 UR11G21414T6SZ 1 2 834 646 1 UR11G21414T6SZ 1 3 1251 969 1 UR11G21414T6SZ 1 4 1668 1292 2 UR11G21414T6SZ 2 5 2085 1615 2 UR11G21414T6SZ 2

The panel builder is responsible for the other drive components, such as AC power supply fuses, DC link fuses 3 to protect the output power units, input circuit breaker or switch-disconnector, phase-shifting transformer for six-phase power supply when using the 12-pulse configuration, power buses, panel fans, etc.

3.1.3 Positioning and Fixing

See the rectifier weight in Table 6.1 on page 6-1.

Install the rectifier in the upright position on a flat surface.

Position of the fixing holes according to Figure 3.1 on page 3-3. For further details, refer to Section 6.3 MECHANICAL DATA on page 6-3.

Mark the fixing points and drill the installation holes. Then, position the rectifier and firmly tighten all screws.

To allow the cooling air of the rectifier to circulate, it is necessary to leave at least the clearances specified in Figure 3.2 on page 3-4.

Do not install heat-sensitive components just above the rectifier.

ATTENTION! Provide independent conduits for the physical separation of , control and power cables (refer to Section 3.2 ELECTRICAL INSTALLATION on page 3-9).

3-2 | UR11 G2 Installation and Connection

650 [25.59] 300 [11.81] 150 [5.91]

Ø M10 3

Air flow

Figure 3.1: Mechanical installation data in mm [in]

UR11 G2 | 3-3 Installation and Connection 150 [5.91]

3 250 [9.84] 25 [1.00]

50 [2.00]

Figure 3.2: Ventilation clearances around the rectifier in mm [in]

3-4 | UR11 G2 Installation and Connection

3.1.4 Hoisting

Figure 3.3 on page 3-5 shows the position of the hoisting eyes.

3

Hoisting eyes Hoisting eyes

Figure 3.3: UR11 G2 hoisting eyes

Figure 3.4: Hoisting the rectifier through the side hoisting eyes

UR11 G2 | 3-5 Installation and Connection

Alternatively, the UR11 G2 can be lifted using a forklift, as shown in Figure 3.5 on page 3-6.

3

Figure 3.5: Lifting the UR11 G2 using a forklift

3.1.5 Panel Mounting

For mounting the rectifier on a panel, the following information must be considered:

„ Provide proper exhaustion so that the internal temperature of the panel will remain within the allowed range for the rectifier operating conditions.

„ The power dissipated by the rectifier at rated condition as specified in Table 6.1 on page 6-1.

„ The total air flow of the power unit fans is 740 m3/h (205 l/s; 435 CFM).

„ Position and diameter of the fixing holes according to Figure 3.1 on page 3-3.

The UR11 G2 must be mounted on a column at least 800 mm wide and 800 mm deep. The side tabs (Figure 3.6 on page 3-7) must be supported on the panel sides. An example of panel mounting (WEG standard) of the UR11 G2 is shown in Figure 3.7 on page 3-7.

3-6 | UR11 G2 Installation and Connection

Side tab Side tab

3

Figure 3.6: Side tabs of the UR11 G2

Rear mounting brackets

Supports for the UR11 G2 side tabs

Figure 3.7: UR11 G2 panel mounting

UR11 G2 | 3-7 Installation and Connection

Figure 3.8 on page 3-8 shows the procedure for inserting the UR11 G2 into a panel with the aid of a forklift and the side tabs.

3 (1) (2) (3)

(4) (5) (6) Figure 3.8: Step by step procedure to insert the UR11 G2 into a panel

NOTE! For more details on how to mount the UR11 G2 on a panel, contact WEG.

3-8 | UR11 G2 Installation and Connection

3.2 ELECTRICAL INSTALLATION

DANGER! The following information is merely a guide for proper installation. Comply with applicable regulations for electrical installations.

DANGER! Make sure the power supply is disconnected before starting the installation.

ATTENTION! The UR11 G2 can be connected to circuits with symmetrical short-circuit capacity up to 50,000 Arms.

ATTENTION! The short-circuit protection of the rectifier does not provide short-circuit protection for the feeder circuit. The short-circuit protection of the feeder circuit must be provided in accordance with the 3 applicable regulations.

3.2.1 Identification of the Power and Grounding Connections

R, S, T: AC power supply.

DC+: positive pole of the DC link output voltage.

DC-: negative pole of the DC link output voltage.

: grounding cable connection.

DC-

DC+

R

S

T Figure 3.9: Power and grounding connections

UR11 G2 | 3-9 Installation and Connection

3.2.2 Input Circuit Breaker

DANGER! Provide a device to disconnect the rectifier power supply. This device must disconnect the power supply to the rectifier whenever necessary (during maintenance jobs, for instance).

The main circuit breaker must be sized to withstand the drive rated current and its short-circuit interruption level must be compatible with the application. When the circuit breaker is closed, power is applied to the UR11 G2, starting the pre-charge of the DC link. In case an inverter fails, or if the local or remote emergency is activated, the circuit breaker may by switched off by the undervoltage release coil protection.

3.2.3 Line Reactor

The UR11 G2 Rectifier Unit with the bank of the UP11 G2 drains from the power supply line a current with non-sinusoidal wave shape, containing harmonics of the fundamental frequency. Those harmonic currents flowing on the power line impedances cause harmonic voltage drops, distorting the supply voltage of the inverter itself or of other consumers. As an effect of those current and voltage harmonic distortions, the electrical losses may increase on installations, overheating the components (cables, transformers, capacitor banks, motors, etc.) and resulting in a low power factor. 3 The input current harmonics depend on the values of the impedances present on the rectifier input/output circuit. The addition of a line reactor reduces the current harmonic content, providing the following advantages:

„ Increase of the power factor at the inverter input.

„ Reduction of the effective input current.

„ Reduction of the voltage distortion on the supply line.

„ Increase of the useful life of the DC link capacitors.

The following expression should be used to calculate the line reactor value necessary to obtain the desired percentage voltage drop:

Voltage Drop [%]. Line Voltage [V] Lrede = √3.2.π.Line Freq [Hz]. Inominal [A]. 100

ATTENTION! A line reactor of at least 3 % is recommended at the UR11 G2 input.

Table 3.4 on page 3-11, Table 3.5 on page 3-11 and Table 3.6 on page 3-11 contain basic specifications for the line reactors considering the CFW11M G2 drives with 3, 4 and 5 Power Units. Note that for drives with 4 and 5 Power Units, it is necessary to use rectifiers in parallel, as indicated in Table 3.1 on page 3-1, Table 3.2 on page 3-2 and Table 3.3 on page 3-2.

3-10 | UR11 G2 Installation and Connection

Table 3.4: Reactor specifications - drives with 3 CFW11M G2 Power Units Duty Cycle ND HD Rated Voltage 380 - 480 V 500 600 V 660 - 690 V 380 - 480 V 500 600 V 660 - 690 V Rated Current 1807 A 1414 A 1251 A 1468 A 1033 A 969 A Rated 14.6 µH 23.4 µH 30.4 µH 18.0 µH 30.5 µH 39.3 µH Inductance Tolerance ±10 % ±10 % ±10 % ±10 % ±10 % ±10 % Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz Number of Phases 3 3 3 3 3 3 Thermal Current 1988 A 1555 A 1376 A 1615 A 1191 A 1066 A Overload Current 2711 A 2121 A 1877 A 2202 A 1625 A 1454 A Overload Inductance ≥ 7.3 µH ≥ 11.7 µH ≥ 15.5 µH ≥ 9.0 µH ≥ 15.3 µH ≥ 19.6 µH Voltage Class 1 kV 1 kV 1 kV 1 kV 1 kV 1 kV Temperature Class F (155 °C) F (155 °C) F (155 °C) F (155 °C) F (155 °C) F (155 °C)

Table 3.5: Reactor specifications - drives with 4 CFW11M G2 Power Units Duty Cycle ND HD Rated Voltage 380 - 480 V 500 600 V 660 - 690 V 380 - 480 V 500 600 V 660 - 690 V Rated Current 1325 A 1037 A 917 A 1076 A 794 A 711 A Rated Inductance 22.0 µH 35.1 µH 45.6 µH 27.0 µ H 45.8 µH 58.9 µH Inductance Tolerance ±10 % ±10 % ±10 % ±10 % ±10 % ±10 % Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz Number of Phases 3 3 3 3 3 3 3 Thermal Current 1457 A 1140 1009 A 1184 A 874 A 782 A Overload Current 1987 A 1555 1376 A 1615 A 1191 A 1066 A Overload Inductance ≥ 11.0 µH ≥ 17.6 µH ≥ 22.8 µH ≥ 13.5 µH ≥ 22.9 µH ≥ 29.4 µH Voltage Class 1 kV 1 kV 1 kV 1 kV 1 kV 1 kV Temperature Class F (155 °C) F (155 °C) F (155 °C) F (155 °C) F (155 °C) F (155 °C)

Table 3.6: Reactor specifications - drives with 5 CFW11M G2 Power Units Duty Cycle ND HD Rated Voltage 380 - 480 V 500 600 V 660 - 690 V 380 - 480 V 500 600 V 660 - 690 V Rated Current 1657 A 1296 A 1147 A 1345 A 993 A 888 A Rated Inductance 17.6 µ H 28.1 µH 36.5 µH 21.6 µH 36.7 µH 47.1 µ H Inductance Tolerance ±10 % ±10 % ±10 % ±10 % ±10 % ±10% Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz Number of Phases 3 3 3 3 3 3 Thermal Current 1822 A 1425 A 1261 A 1480 A 1092 A 977 A Overload Current 2485 A 1994 A 1720 A 2018 A 1489 A 1332 A Overload Inductance ≥ 8.8 µH ≥ 14.0 µH ≥ 18.2 µH ≥ 10.8 µH ≥ 18.3 µH ≥ 23.6 µH Voltage Class 1 kV 1 kV 1 kV 1 kV 1 kV 1 kV Temperature Class F (155 °C) F (155 °C) F (155 °C) F (155 °C) F (155 °C) F (155 °C)

NOTE! Ideally, the line reactors should be sized according to the motor current of the application. For further details on sizing, contact WEG.

ATTENTION! In cases where rectifiers will be used in parallel, the line reactors must be sized considering a current imbalance of up to 10 %. That is, the reactors must be sized for a current 10 % higher.

UR11 G2 | 3-11 Installation and Connection

3.2.4 Harmonics of the 6-Pulse Rectifier

Table 3.7 on page 3-12, and Table 3.10 on page 3-15 and Figure 3.11 on page 3-12 show typical harmonic content values of the currents, Power Factor and THD(I) on the power supply line, considering the 6-pulse rectifier.

Table 3.7: Typical individual harmonics, Power Factor and THD(I) for rated load at the output. 6-pulse rectifier Harmonic Order I(%) PF THD(I) 1 100.0 % 5 38.7 % 7 14.1 % 11 6.7 % 0.89 42 % 13 3.3 % 17 2.9 % 19 1.9 % 23 1.4 %

40 %

35 %

3 30 %

25 % 5ª Harmonic 7ª Harmonic 20 % 11ª Harmonic 13ª Harmonic 15 % 17ª Harmonic 19ª Harmonic 23ª Harmonic 10 % Normalized Harmonic Harmonic Normalized

5 %

0 % 0 % 20 % 40 % 60 % 80 % 100 % 120 % Load percentage

Figure 3.10: Typical harmonic values of the input current with variation of the output power. Note: Amplitude of the normalized harmonics as a function of the fundamental with 100 % of load. 6-pulse rectifier

0.9 90 %

0.88 80 %

0.86 FP 70 % 0.84 THD

0.82 60 % THD

Power factor Power 0.8 50 % 0.78 40 % 0.76

0.74 30 % 0 % 20 % 40 % 60 % 80 % 100 % 120 % Load percentage

Figure 3.11: Power Factor (PF) and THD(I) with variation of the output power. 6-pulse rectifier

3-12 | UR11 G2 Installation and Connection

3.2.5 Harmonics of the 12-Pulse Rectifier

Table 3.8 on page 3-13, Figure 3.12 on page 3-13 and Figure 3.13 on page 3-13 show the typical values of the harmonic content of the currents, Power Factor and THD(I) on the power line, considering the 12-pulse rectifier.

Table 3.8: Typical individual harmonics, Power Factor and THD(I) for rated load at the output. 12-pulse rectifier Harmonic Order I(%) FP THD(I) 1 100,0 % 5 0,0 % 7 0,0 % 11 6,0 % 0,96 7,1 % 13 3,2 % 17 0,0 % 19 0,0 % 23 1,1 %

7 %

6 %

5 % 3

5ª Harmonic 4 % 7ª Harmonic 11ª Harmonic 13ª Harmonic 3 % 17ª Harmonic 19ª Harmonic 2 % 23ª Harmonic Normalized Harmonic Amplitude Harmonic Normalized

1 %

0 % 0 % 20 % 40 % 60 % 80 % 100 % 120 % Power factor

Figure 3.12: Typical harmonic values of the input current with variation of the output power. Note: Amplitude of the normalized harmonics as a function of the fundamental with 100 % of load. 12-pulse rectifier

0.97 12 %

0.968 11 %

FD 0.966 10 % THD

0.964 9 % THD Power factor 8 % 0.962

7 % 0.96

0.958 6 % 0 % 20 % 40 % 60 % 80 % 100 % 120 % Load percentage

Figure 3.13: Power Factor (PF) and THD(I) with variation of the output power. 12-pulse rectifier

UR11 G2 | 3-13 Installation and Connection

NOTE! The harmonics shown in Item 3.2.4 Harmonics of the 6-Pulse Rectifier on page 3-12 and Item 3.2.5 Harmonics of the 12-Pulse Rectifier on page 3-13 are typical values and may vary according to the application. The data shown are valid for the following condition: „ Short-circuit current of the transformer: 50,000 symmetric Arms. „ Line reactor of 3 %.

3.2.6 Power Buses/Ground Wiring

ATTENTION! Use proper terminals for the grounding cables.

ATTENTION! Sensitive equipment, such as PLCs, temperature controllers and thermocouple cables, should be at least 0.25 m away from the rectifiers, frequency inverters and cables connecting the inverter to the motor. 3 DANGER! Incorrect cable connection: - Check all the connections before energizing the inverter. - In case of replacing an existing rectifier with a UR11 G2, check that the installation and wiring complies with the instructions of this manual.

NOTE! The wire gauges listed in Table 3.9 on page 3-14 are just guiding values. To size wiring properly, take into account the installation conditions and the maximum permissible voltage drop.

Table 3.9: /Wiring recommended for the standard models - use only copper wiring (75 °C) and busbars Power Connections Busbars [mm] Maximum Cables Quantity of Thickness Model Duty Cycle Terminals Screw Torque Nm [mm2] Buses by x (lbf.in) Terminal Width 60 HD - 1 10 x 60 R, S, T 2 x M12 (531.00) ND - 1 10 x 60 60 HD - 1 10 x 100 UR11 G2 1807 T4 DC+, DC- 3 x M12 (531.00) ND - 1 10 x 100 60 HD 150 - - Ground M12 (531.00) ND 185 - - 60 HD - 1 10 x 60 R, S, T 2 x M12 (531.00) ND - 1 10 x 60 60 HD - 1 10 x 100 UR11 G2 1414 T5 DC+, DC- 3 x M12 (531.00) ND - 1 10 x 100 60 HD 150 - - Ground M12 (531.00) ND 185 - - 60 HD - 1 10 x 60 R, S, T 2 x M12 (531.00) ND - 1 10 x 60 60 HD - 1 10 x 100 UR11 G2 1414 T6 DC+, DC- 3 x M12 (531.00) ND - 1 10 x 100 60 HD 150 - - Ground M12 (531.00) ND 185 - -

3-14 | UR11 G2 Installation and Connection

Table 3.10: Recommended terminals for power connections with gauge in mm2 Cable Gauge Number of Screw Manufacturer Lug Terminal, Code Crimping Tool, Code [mm2] Crimps Hollingsworth RM150-12 Hydraulic tool H6-500 1 150 M12 Tool without die: Y644 or Y81 Burndy (FCI) YA30L Tool+die: Y35 or Y750 / 1 U30RT Hollingsworth RM185-12 Hydraulic tool H6-500 1 185 M12 Tool without die: Y644 or Y81 Burndy (FCI) YA31L Tool+die: Y35 or Y750 / 1 U31RT

Table 3.11: Recommended terminals for power connections with gauges in kcmil Cable Gauge Number of Screw Manufacturer Lug Terminal, Code Crimping Tool, Code [mm2] Crimps Hollingsworth R 30012 Hydraulic tool H6-500 1 300 M12 Tool without die: Y644 or Y81 Burndy (FCI) YA30L Tool+die: Y35 or Y750 / 1 U30RT Hollingsworth R 35012 Hydraulic tool H6-500 1 350 M12 Tool without die: Y644 or Y81 Burndy (FCI) YA31L Tool+die: Y35 or Y750 / 1 U31RT 3

3.2.7 Grounding Connections

DANGER! Do not share the grounding wiring with other equipment that operate with high currents (e.g., high power motors, welding machines, etc.). When several rectifiers are used, follow the procedure shown in Figure 3.14 on page 3-16 for the grounding connection.

ATTENTION! The neutral conductor of the line that powers the rectifier must be solidly grounded; however, this conductor must not be used to ground the rectifier.

DANGER! The rectifier must be connected to a protective ground (PE). Observe the following: - Use a ground wiring gauge at least equal to that recommended in Table 3.9 on page 3-14. if local standards require different gauges, they must be observed. - Connect the grounding points of the rectifier to a specific grounding rod, or specific grounding point or to the general grounding point (resistance ≤ 10 Ω).

UR11 G2 | 3-15 Installation and Connection

Grounding bar inside the panel

3

Figure 3.14: Grounding connections with multiple rectifiers

3.2.8 Fuses

The to be used at the input must be of the UR (Ultra-Fast) type with I2t equal to or lower than that indicated in Table 3.12 on page 3-16. The current extinction value (not the melting value) must be taken into account to protect the input rectifier diodes of the inverter and wiring.

Table 3.12: Recommended fuses I2t of the Recommended Fuses WEG FNHFE aR Flush End Fuse @ Number of Model 25 °C Parallel Fuses In [A] Model Frame [A2s] per Phase UR11 G2 1807 T4 3300000 2 1100 FNH3FEM-1100Y-A 3 UR11 G2 1414 T5 3300000 2 900 FNH3FEM-900Y-A 3 UR11 G2 1414 T6 3300000 2 900 FNH3FEM-900Y-A 3

3-16 | UR11 G2 Installation and Connection

3.2.9 Power Connections

CF W11M G2 Fuses

R S T

Fuses

Line reactor

Switch- 3 disconnector

R S T U V W

AC Power supply PE U V W U V W U V W

PE

Figure 3.15: Power and grounding connections in the 6-pulse configuration

CF W11M G2 Fuses

R S T R S T

Fuses

Line reactor

U V W

Circuit PE U V W U V W U V W R S T PE AC Power supply

Figure 3.16: Power and grounding connections in the parallel configuration

UR11 G2 | 3-17 Installation and Connection

CF W11M G2 Fuses

R S T R S T

Fuses

Line reactor

U V W

PE U V W U V W U V W Transformer 3 PE

Circuit

R S T AC Power supply Figure 3.17: Power and grounding connections in the 12-pulse configuration

ATTENTION! Use line reactors according to Item 3.2.3 Line Reactor on page 3-10 Line reactor when the rectifier is configured in 12 pulses.

3.2.10 Input Connections

DANGER! Provide a device to disconnect the rectifier power supply. This device must cut off the rectifier power supply whenever necessary (during maintenance jobs, for instance).

ATTENTION! A contactor or another device that frequently disconnects the rectifier power must not exceed the limit of one operation per minute, or the rectifier may be damaged.

ATTENTION! The rectifier power supply must have the neutral solidly grounded. In case of IT networks, follow the instructions described in Item 3.2.11 IT Networks on page 3-19.

NOTE! The input power supply voltage must be compatible with the rectifier rated voltage.

NOTE! Power factor correction capacitors are not necessary at the input (R, S, T).

3-18 | UR11 G2 Installation and Connection

Power supply capacity:

The UR11 G2 is suitable for use in a circuit capable of supplying no more than 50.000 symmetrical arms, when protected by class J fuses or special fuses.

3.2.11 IT Networks

ATTENTION! To use the UR11 G2 rectifier in IT networks (neutral conductor not grounded or grounded by a high ohmic resistor) or in delta corner earthed networks, it is necessary to remove the grounding cable located on the PRT2 board, as shown in Figure 3.18 on page 3-19 and Figure 3.19 on page 3-19. That is necessary to avoid damages when operating with a line input with ground fault.

3

Remove the grounding cable

Figure 3.18: Grounding connections – location and procedure for adaptation to IT or delta earthed networks

Figure 3.19: Cable removed from the PRT2 board

UR11 G2 | 3-19 Installation and Connection

3.2.12 Control Connections

S1: DIP switch input voltage selection XC1: 24 Vdc control power XC2: relay outputs Indication LEDs

3

Figure 3.20: Control connections

The UR11 G2 control is powered by the XC1 connector, located on the IUR11 board, which is described in Table 3.13 on page 3-20.

Table 3.13: Description of connector XC1 XC1 Standard Function Specifications Positive pole of the +24 Vdc 1 +24 V power supply 24 Vdc (±10 %) power 2 - Not connected supply Reference of the +24 Vdc Consumption: 400 mA 3 0 V power supply

The digital relay outputs RL1, RL2 and RL3 located on the IUR11 board, connector XC2 - Table 3.14 on page 3-20, monitor the UR11 G2 operating status and the alarm and temperature fault condition. With the NO contact closed (NC open), the UR11 G2 is in normal operation, and when the NO contact is open (NC closed), a fault is present. See Section 5.2 FAULTS, ALARMS AND POSSIBLE CAUSES on page 5-2 for further details.

Table 3.14: Description of connector XC2 XC2 Standard Function Specifications 1 NO1 Digital output RL1 with DC Link function OK 2 C1 (UDC1 & UDC2 OK). - UDC1: DC link of the rectifier bridge 1 3 NC1 - UDC2: DC link of the rectifier bridge 2 Capacity of the contacts: 1 A 4 NO2 Maximum voltage: 240 Vac Digital Output RL2 with "Without Temperature Alarm" 5 C2 NA - Normally open function C - Common 6 NC2 NC - Normally closed 7 NC3 Digital Output RL3 with "Without Temperature Fault" 8 C3 function 9 NC3

The IUR11 board sets the rated operating voltage of the UR11 G2 through DIP Switch S1. A model of the 400 V line (UR11 G2 1807 T4 SZ) can be adjusted for four different voltage ranges: 380 V, 400 V / 415 V, 440 V / 460 V and 480 V, according to Table 3.15 on page 3-21.

3-20 | UR11 G2 Installation and Connection

Table 3.15: DIP Switch S1 Setting DIP Switch Rated Voltage S1:1 S1:2 UR11 G2 1807 T4 UR11 G2 1414 T5 UR11 G2 1414 T6 OFF OFF 480 V 600 V OFF* ON* 440V / 460 V* 550 V / 575 V* 660 V / 690 V* ON OFF 400 V / 415 V 500 V / 525 V ON ON 380 V * Default factory setting.

By default, DIP Switch S1:1 is set to OFF and DIP Switch S1:2 is set to ON.

3

Fan power supply

Figure 3.21: Terminals to power the fans

Table 3.16: Specification of the power supply of the fans Voltage Frequency Current 220 Vca 50 / 60 Hz 700 mAca

For the correct wiring of the control, use:

1. Cable gauges: 0.5 mm² (20 AWG) to 1.5 mm² (14 AWG).

2. Maximum torque: 0.5 N.m (4.50 lbf.in).

3. Relays, contactors, solenoids or electromechanical brake coils installed close to the output inverters may occasionally generate interference in the control circuit. To eliminate this effect, RC suppressors must be connected in parallel to the coils of those devices in case of AC power supply and freewheel diodes in case of DC power supply.

UR11 G2 | 3-21 Installation and Connection

3.2.13 Typical Connections In order to use the UR11 G2 Rectifier Unit feeding the CFW-11M G2 inverters, it is recommended to interconnect the fault and/or alarm , available at the UR11 G2 relay outputs, with the CFW-11M G2 digital inputs DIM1 and DIM2, located on the ICUP board of the Control Unit (UC11 G2), allowing the rectifier to be monitored by the inverter.

UR11 G2 CFW11M G2 XC2 XC5 NO1 1 1 DIM1 DO1 C1 2 2 DIM2 (RL1) NC1 3 3 COM NO2 4 4 +24 V DO2 C2 5 5 GND_24 V (RL2) NC2 6 NC3 7 DO3 C3 8 (RL3) NC3 9

Figure 3.22: Application example with active high signal at the DIs of the CFW-11M G2

UR11 G2 CFW11M G2 3 XC2 XC5 NO1 1 1 DIM1 DO1 C1 2 2 DIM2 (RL1) NC1 3 3 COM NO2 4 4 +24 V DO2 C2 5 5 GND_24 V (RL2) NC2 6 NC3 7 DO3 C3 8 (RL3) NC3 9

Figure 3.23: Application example with active low signal at the DIs of the CFW-11M G2

In both examples (Figure 3.22 on page 3-22 and Figure 3.23 on page 3-22), digital inputs DIM1 and DIM2 are set respectively with the function "Without External Rectifier Fault" (P0832 = 6) and "Without Rectifier Overtemperature Fault" (P0833 = 4). On both examples, the CFW-11M G2 will show F414 ("External Rectifier Fault") if the 24 V signal is interrupted at input DIM1 (due to the opening of relay RL1 - "UCD_OK - of UR11 G2) when the voltage on the DC link is greater than the undervoltage level and the PWM of the CFW-11M G2 inverter is enabled; or else it will indicate F412 ("External Rectifier Overtemperature") if the 24 V signal is interrupted at input DIM2 (due to the opening of relay RL3 - "Without Temperature Fault " - of UR11 G2). At Figure 3.24 on page 3-22, digital inputs DIM1 and DIM2 are programmed respectively with the function "Without External Rectifier Temperature Alarm" (P0832 = 5) and "Without External Rectifier Overtemperature Fault" (P0833 = 4). In this case, the CFW-11M G2 will indicate A415 ("External Rectifier High Temperature Alarm") if the 24V signal is interrupted at DIM1 (due to the opening of relay RL2 - "Without Temperature Alarm" - of UR11 G2), and it will indicate F412 ("External Rectifier Overtemperature") if the 24 V signal is interrupted at input DIM2 (as a result of the opening of relay RL3 - "Without Temperature Fault" - of UR11 G2).

UR11 G2 CFW11M G2 XC2 XC5 NO1 1 1 DIM1 DO1 C1 2 2 DIM2 (RL1) NC1 3 3 COM NO2 4 4 +24 V DO2 C2 5 5 GND_24 V (RL2) NC2 6 NC3 7 DO3 C3 8 (RL3) NC3 9

Figure 3.24: Application example with active high signal at the DIs of the CFW-11M G2

3-22 | UR11 G2 Installation and Connection

3.3 INSTALLATIONS ACCORDING TO THE EUROPEAN ELECTROMAGNETIC COMPATIBILITY DIRECTIVE

The UR11 G2 rectifiers, when correctly installed, meet the requirements of the electromagnetic compatibility directive "EMC Directive 2014/30/EU".

The UR11 G2 rectifiers were developed for professional applications only. Therefore, the limits for emission of harmonic currents established by the IEC/EN 61000-3-2 and IEC/EN 61000-3-12 are not applicable.

3.3.1 Conformal Installation

For conformal installation, use:

„ Standard UR11 G2 rectifier for emission levels according to IEC/EN61800-3 Adjustable Speed Electrical Power Drive Systems, category C3.

„ Grounding of the rectifier according to instructions of the Item 3.2.7 Grounding Connections on page 3-15 Grounding Connections.

3.3.2 Definition of the Standards 3 IEC/EN 61800-3: "Adjustable Speed Electrical Power Drives Systems"

Environments:

First Environment: environments that include domestic premises; it also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for domestic purposes.

Example: houses, apartments, commercial premises or offices located in residential buildings.

Second Environment: environments that include all establishments other than those directly connected to the low voltage power supply network which supplies buildings used for domestic purposes.

Example: industrial areas, technical areas of any building fed from a dedicated transformer.

Categories:

Category C1: inverters of rated voltage less than 1000 V, intended for use in the First Environment.

Category C2: inverters with rated voltage less than 1000, which is neither a plug in device nor a movable device, and, when used in the First Environment, is intended to be installed and commissioned by a professional.

Note: a professional is a person or organization having necessary skills in installing and/or commissioning power drive systems, including their EMC aspects.

Category C3: inverters of rated voltage less than 1000 V intended for use in the Second Environment and not intended for use in the First Environment.

Category C4: inverters with rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the Second Environment.

UR11 G2 | 3-23 Installation and Connection

3.3.3 Emission and Immunity Levels Met

Table 3.17: Emission and immunity levels met EMC Phenomenon Basic Standard Level Emission Mains Terminal Disturbance Voltage Frequency Range: 150 kHz to 30 MHz) It depends on the inverter model and motor cable IEC/EN61800-3 Electromagnetic Radiation Disturbance length. See Table 3.18 on page 3-24 Frequency Range: Immunity: Electrostatic Discharge (ESD) IEC/EN61000-4-2 4 kV for contact discharge and 8 kV for air discharge 2 kV/5 kHz (coupling capacitor) input cables Fast Transient-Burst IEC/EN61000-4-4 1 kV/5 kHz control cables 2 kV/5 kHz (coupling capacitor) motor cables 0.15 to 80 Mhz; 10 V; 80 % AM (1 kHz) Conducted Radio-Frequency Common Mode IEC/EN61000-4-6 Motor and control cables 1.2/50 µs, 8/20 µs Surges IEC/EN61000-4-5 1 kV line-to-line coupling 2 kV line-to-ground coupling 80 to 1000 MHz Radio-Frequency Electromagnetic Field IEC/EN61000-4-3 10 V/m 80 % AM (1 kHz) 3 Table 3.18: Mains terminal disturbance voltage and electromagnetic radiation disturbance levels Mains Terminal Disturbance Voltage - Electromagnetic Radiation Rectifier Model Maximum Length Disturbance of the Motor Cable Category C3 Category UR11 G2 1807 T4 SZ 100 m C3 UR11 G2 1414 T5 SZ 100 m C3 UR11 G2 1414 T6 SZ 100 m C3 (1) Information valid for power supply networks with a solidly grounded neutral.

3-24 | UR11 G2 First Time Power-Up and Start-Up

4 FIRST TIME POWER-UP AND START-UP

This chapter describes how to:

„ Check and prepare the rectifier before power-up.

„ Power-up the rectifier and check the result.

„ Set the rectifier for operation with the power supply chosen for the application.

4.1 PREPARATION FOR START-UP

The inverter must have already been installed according to the recommendations listed in Chapter 3 INSTALLATION AND CONNECTION on page 3-1. The following recommendations are applicable even if the application design is different from the suggested control connections.

DANGER! Always disconnect the main power supply before performing any connections.

4.1.1 Precautions During Power-Up/Start-up

1. Verify all the connections of the panel.

2. Search for short-circuits at the input, DC link, etc.

3. Verify the condition of all fuses.

4. Verify all grounding connections (panel, doors, etc.). 4

5. Remove all the remaining extra materials from the rectifier or drive interior.

6. Close the rectifier or drive covers.

4.2 START-UP

1. Set the power supply voltage according to the rectifier model, as shown in Table 3.15 on page 3-21, through DIP switches S1.

2. Measure the line voltage and make sure it is within the acceptable range.

3. Energize the control (+24 Vdc power supply). The LED +12 V ON LED must light. The remaining LEDs must be off.

4. Command the main circuit breaker/contactor and wait for the complete pre-charge. The UDC OK ON must light.

5. Verify the proper operation of the fans. They will remain on for approximately one minute.

6. Observe the existence of faults/alarms at the relay outputs and LEDs. In case of any fault or alarm, verify the possible causes and solve the problem.

7. De-energize the drive. Then connect the inverters of the application without connecting the motor. Inspect the inverter connections and check that the voltage and current are according to the UR11 G2.

8. Command the main circuit breaker/contactor and wait for the complete pre-charge.

UR11 G2 | 4-1 First Time Power-Up and Start-Up

4

4-2 | UR11 G2 Troubleshooting and Maintenance

5 TROUBLESHOOTING AND MAINTENANCE

This chapter:

„ Lists all faults and alarms that may occur.

„ Indicates the possible causes of each fault and alarm.

„ Lists the most frequent problems and corrective actions.

„ Presents instructions for periodical inspections and preventive maintenance in que equipment.

5.1 OPERATION OF THE FAULTS

When the high temperature alarm is detected:

„ The "TEMP ALARM" LED (yellow) lights.

„ There is no blocking of the thyristor gate pulses; the rectifier remains in operation.

When a fault is detected:

„ Blocking of the thyristor gate pulses.

„ The UDC OK LED turns of.

„ The RL1 relay output opens.

„ In case of overtemperature (heatsink temperature above 75 ºC), the TEMP FAULT LED (red) lights. In this case: ­ - ­The RL3 relay output opens simultaneously to RL1. ­ - ­The TEMP ALARM LED must be lit previously indicating an alarm, and the RL2 output must be open.

„ In case of undertemperature (heatsink temperature below -9 ºC) or rupture of NTC cables, the TEMP FAULT LED (red) lights. In this case: ­ - ­The RL3 relay output opens simultaneously to RL1.

The rectifier will be back to normal operation after the fault is solved in case it is properly connected to the power 5 supply.

UR11 G2 | 5-1 Troubleshooting and Maintenance

5.2 FAULTS, ALARMS AND POSSIBLE CAUSES

Table 5.1 on page 5-2 summarizes the inputs, outputs and indications via LED of the UR11 G2.

The monitoring signals that can indicate fault/alarm and the status outputs are presented in Table 5.2 on page 5-2.

Table 5.1: Description of inputs, outputs and LED indications Name Description +24 Vdc +24 Vdc power supply R, S, T R, S and T input power connections Inputs Pre-Charge Pre-Charge Status: "Not Performed", "In Progress" or "Completed" Temperature UR11 G2 heatsink temperature measured via NTCs RL1 Relay output with the pre-charge status indication function. It closes when the UR11 G2 completes the pre-charge RL RL2 Relay output with the "Without Temperature Alarm" function. It opens with alarm outputs RL3 Relay output with the "Without Temperature Fault" function. It opens with fault +12V ON Green LED with +12 V ON power supply indication, generated at the CIR11 from the +24 Vdc Green LED with status indication function of the UR11 G2 pre-charge – it lights when the pre-charge has UDC OK LEDs been completed TEMP ALARM Yellow LED that lights in case the UR11 G2 temperature is too high (alarm) TEMP FAULT Red LED that lights under overtemperature or undertemperature fault condition

Table 5.2: Faults, alarms and possible causes Inputs RL Outputs LEDs +24 +12 V UDC Temp Temp Possible Causes R, S, T Pre-charge Temperature RL1 RL2 RL3 Vdc ON OK Alarm Fault „ + 24 Vdc applied to the control circuit (CIR11) and the main

OK OFF OFF TMIN ≤ T ≤ TAL OFF ON ON ON OFF OFF OFF power supply (R, S and T) is missing. Ready for power energization „ Power supply connected, pre- OK OK In Progress (1) T ≤ T ≤ T OFF ON ON ON OFF OFF OFF MIN AL charge in progress

OK OK Completed. TMIN ≤ T ≤ TAL ON ON ON ON ON OFF OFF „ Regular operation „ Phase fault or undervoltage at Phase fault the input power OK OFF T ≤ T ≤ T OFF ON ON ON OFF OFF OFF undervoltage MIN AL „ Open fuse „ Open input circuit breaker

OK OK OFF TMIN ≤ T ≤ TAL OFF ON ON ON OFF OFF OFF „ Defective UR11 G2 „ High heatsink temperature OK OK Completed. T (2) < T ON OFF ON ON ON ON OFF AL above 65 ºC (alarm temperature) „ Heatsink overtemperature, OK OK OFF T (2) < T OFF OFF OFF ON OFF ON ON FAULT above 75 ºC (fault temperature) 5 „ Control without +24 Vdc power OFF (3) (3) (3) OFF OFF OFF OFF OFF OFF OFF supply „ Heatsink undertemperature,

OK OK OFF T < TMIN OFF ON OFF ON OFF OFF ON below -9 ºC „ Defective or open NTC Note: (1) Temporary operating condition. (2) The monitoring temperatures are: a. High temperature alarm: active with TAL ≅ 89 ºC (TEMP ALARM). b. Overtemperature fault: active with TFAULT ≅ 94 ºC (TEMP FAULT). c. Undertemperature fault: active with TMIN ≅ -9 ºC (TEMP FAULT). (3) The input state is not decisive for the output state.

5-2 | UR11 G2 Troubleshooting and Maintenance

5.3 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS

Table 5.3: Solutions for the most frequent problems Problem Point to Be Verified Corrective Action +12 V ON LED does not light, +12 Vdc +24 Vdc supply cable connection inverted, 1. Connect the +24 Vdc power supply cabling power supply does not start wiring disconnected with the proper polarity to the XC1 connector Rectifier does not start Power supply connections (R, S, T), +24 Vdc 1. Provide the control with +24 power supply Vdc connections, input fuses, input circuit breaker, 2. Provide R, S and T with proper voltage DIP Switch S1 configuration 3. Set the DIP Switch S1 according to the input power supply Phase loss or undervoltage at the input Input power supply, fuses, circuit breaker 1. Replace blown fuses power and connections 2. Check main circuit breaker switching 3. Provide R, S and T with proper voltage High temperature alarm in the heatsink Fans of the UR11 G2. Phase current 1. Provide proper voltage to the fans (temperature above 65 ºC) balance of the UR11 input 2. Replace the fans Heatsink overtemperature (temperature Check if the current waveform is typical to 3. Replace the defective UR11 above 75 ºC) a 6-pulse rectifier, if all pulses are present in the current waveform at all the input phases (R, S, T) Heatsink undertemperature (below -9 ºC) IUR11 XC5, XC6 and XC7 board 1. Tighten the connections of the CIR11 board Defective or open NTC connections 2. Replace the defective UR11

5.4 INFORMATION TO CONTACT TECHNICAL SUPPORT

NOTE! For technical support or servicing, it is important to have the following information at hand: „ Rectifier model. „ Serial number, manufacturing date and hardware revision listed on the product nameplate (see Chapter 2 GENERAL INFORMATION on page 2-1). „ Application data and rectifier setting.

5.5 PREVENTIVE MAINTENANCE

DANGER! „ Always turn off the main power supply before touching any electrical component associated with the rectifier. „ High voltages may still be present even after disconnecting the power supply. „ Wait at least 10 minutes for the complete discharge of the power capacitors. „ Always connect the equipment frame to the protective ground (PE) at the proper terminal. 5 ATTENTION! Electronic boards have electrostatic discharges sensitive components. Do not touch the components or connectors directly. If necessary, first touch the grounded metallic frame or wear a grounding strap.

Do not perform any withstand voltage test on the rectifier! If necessary, contact WEG.

When properly installed and operated, the rectifiers require low maintenance.

For the UR11 G2, it is recommended to replace the fans after 50,000 hours of operation. Figure 5.1 on page 5-4 shows the replacement procedure.

Table 5.4 on page 5-4 contains the recommended inspections to be performed every 6 months after the start-up.

UR11 G2 | 5-3 Troubleshooting and Maintenance

Table 5.4: Periodic inspections – every six months Component Problem Corrective Action Loose screws Terminals, connectors Tighten Loose connectors Dirty fans Clean Abnormal acoustic noise Replace fan; see Figure 5.1 on page 5-4. Fans/Cooling system Blocked fan Check the fan connections Abnormal vibration Dust in the panel air filters Clean or replace Accumulation of dust, oil, humidity, etc Clean Printed circuit boards Odor Replace Accumulation of dust, oil, humidity, etc Clean Power module/Power connections Loose connection screws Tighten Dust accumulation Heatsink Clean Dirt

Fan fixing screws and nuts

Bracket fixing screws and fan guard

Fan guard Fan bracket 5 Figure 5.1: Fan replacement 5.5.1 Cleaning Instructions

When it becomes necessary to clean the inverter, follow the instructions below:

Electronic boards:

1. Cut off the inverter power supply and wait for 10 minutes.

2. Remove the dust accumulated on the boards using an anti-static brush or ion compressed air gun (E.g.: Charges Burtes Ion Gun (non-nuclear) reference A6030-6DESCO).

3. If necessary, remove the boards from the inverter.

4. Always wear a grounding strap.

5-4 | UR11 G2 Technical Data

6 TECHNICAL DATA

This chapter contains the technical data (electrical and mechanical) of the UR11 G2 Rectifier Unit.

6.1 POWER DATA

Power supply:

„ Maximum rated input voltage: 480 V for 380...480 V models, 600 V for 500...600 V models and 690 V for models 660...690 V models, up to 2000 m altitude. The voltage derating for higher altitudes is 1.1 % for each 100 m above 2000 m - maximum altitude: 4000 m.

„ Tolerance: - 15 % to + 10 %.

„ Frequency: 50/60 Hz (48 Hz to 62 Hz).

„ Phase imbalance: ≤ 3 % of the rated phase-phase input voltage.

„ Overvoltages according to Category III (EN 61010/UL 508C).

„ Transient voltages according to Category III.

„ Maximum of 60 connections per hour (1 every minute).

„ Typical efficiency: ≥ 98 %.

Table 6.1: UR11 G2 technical specifications Model UR11 G2 1807 T4 UR11 G2 1414 T5 UR11 G2 1414 T6 Power Supply (Vac) 380...480 500...600 660...690 Output Voltage (Vdc) 513...648 675...810 891...932 Rated Input Current [Arms] 1807 1414 1414 Overload Current 1 min 1988 1555 1555 ND Overload [Arms] 3 s 2711 2121 2121 Rated Output Current (1) [Adc] 2168 1697 1697 Dissipated Power (2) [kW] 5.4 5.0 5.0 Rated Input Current [Arms] 1468 1083 1083 Overload Current 1 min 2202 1625 1625 HD Overload [Arms] 3 s 2936 2166 2166 Rated Output Current (1) [Adc] 1762 1300 1300 Dissipated Power (2) [kW] 4.2 3.8 3.8 Ambient Temperature [°C] 45 45 45 Weight [kg] 160 160 160 Protection Rating IP00 IP00 IP00 Note: (1) Steady state rated current in the following conditions: - Temperature­ around the rectifier: 0 °C to 45 °C. The rectifier is able to operate in environments with temperatures up to 55 °C if a 2 % derating is applied to the output current for each Celsius degree above 45 °C. - ­Air relative humidity: 5 % to 90 % non-condensing. - ­Altitude: 1000 m. Above 1000 m up to 4000 m; the output current must be derated by 1 % for each 100 m above 1000 m. ­ - ­Environment with pollution degree 2 (as per EN50178 and UL508C). (2) The specified losses are valid for rated operating conditions, that is, for rated output current. 6

UR11 G2 | 6-1 Technical Data

6.2 ELECTRONICS/GENERAL DATA

Table 6.2: General data regarding the inverter control and electronics Electronics Power Supply External „ +24 Vdc / 400 mA ±10 % power supply Outputs (IUR11 Board) Relay „ 3 relays with NO/NC contacts, 240 Vac, 1 A „ Power under/overvoltage Safety Protection „ Overtemperature Protection Rating IP00

6.2.1 Codes and Standards

„ UL 61800-5-1 – Adjustable Speed Electrical Power Drive Systems – Part 5-1: Safety Requirements – Electrical, Thermal and Energy Safety Standards „ IEC/EN 61800-5-1 - Adjustable Speed Electrical Power Drive Systems – Part 5-1: Safety Requirements – Electrical, Thermal and Energy „ IEC/EN 61800-3 - Adjustable speed electrical power drive systems - Part 3: EMC product standard including specific test methods „ IEC/EN 61000-4-2 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques - Section 2: Electrostatic discharge immunity test „ IEC/EN 61000-4-3 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques Electromagnetic - Section 3: Radiated, radio-frequency, electromagnetic field immunity test Compatibility Standards „ IEC/EN 61000-4-4 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques (EMC) - Section 4: Electrical fast transient/burst immunity test „ IEC/EN 61000-4-5 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques - Section 5: Surge immunity test „ IEC/EN 61000-4-6 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques - Section 6: Immunity to conducted disturbances, induced by radio-frequency fields „ IEC/EN 60529 - Degrees of protection provided by enclosures (IP code) Mechanical Standards „ UL 50 - Enclosures for electrical equipment

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6-2 | UR11 G2 Technical Data

6.3 MECHANICAL DATA

The dimensions of the UR11 G2 are shown in Figure 6.1 on page 6-3. 421.9 [16.61]

[27.559] [16.61] 700 421.9 [27.921] [12.598] 709.2 320 [ 7.874] 200 50

17.5 [0.787] [1.969] [0.689] 20 612.2 [24.102] 612.2 82.5 43 [24.102] [3.248] [0.669] [1.693] 17 Detalhe B

[1.693] 17

43 [0.669] Detalhe A

[6.567] 166.8 [13.811] 350.8 [21.055] 534.8 [27.559] 700 [27.559] 700 200 [ 7.874] 320 [12.598] 421.9 [16.61]

Figure 6.1: Mechanical dimensions of the UR11 G2 in mm [in] 6

UR11 G2 | 6-3 Technical Data 567 [22.323] 612.2 527.5 [24.102] [20.768] 77.5 [3.051] 277.5 [8.957] 2.5

[0.098] [0.984] 25 [26.575] 675 [27.559] 700 Figure 6.2: Rear view of the UR11 G2; dimensions in mm [in]

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6-4 | UR11 G2 Project Example

7 PROJECT EXAMPLE One-line Diagram One-line

Fiber optic Fiber Digital Digital Analog Analog outputs outputs CC11 controle Cartão de HMI inputs inputs inputs Digital Digital Digital Digital Analog Analog Command Panel exhaustion Panel Power supply

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UR11 G2 | 7-1 Project Example 01/ 06 Electrical Diagram Electrical Rectifier unit Rectifier Main control power supply power control Main Power supply Main power supply

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7-2 | UR11 G2 Project Example 02/06 Electrical Diagram Electrical Panel exhausters Panel Power units

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UR11 G2 | 7-3 Project Example 03/06 Diagrama Elétrico Diagrama Without Without temperature Cooling – XC33 Rectifier unit – UR11 G2 UR11 – unit Rectifier Electronics/cooling power supply power Electronics/cooling Without Without temperature Digital outputs - XC2 Bar.CC ok Bar.CC Power supply – XC1 Cooling – XC33 Power supply – XC6 Cooling – XC33 Power units G2 – UP11 Electronics/cooling power supply power Electronics/cooling Power supply – XC6 Cooling – XC33 Power supply – XC6

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7-4 | UR11 G2 Project Example 04/06 Electrical Diagram Electrical Opening Opening Closing coil Closing Motor Input breaker control Input breaker control Emergency

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UR11 G2 | 7-5 Project Example 05/06 Electrical Diagram Electrical ON indication ON Panel exhaustion Panel Defect indication Defect ON/OFF Indication Blown fuse detection fuse Blown

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7-6 | UR11 G2 Project Example 06/06 Not used Not Electrical Diagram Electrical Not used Not Pre-charge ok Without Not used Not

Shield Not used Not Output current Output Output current signal current Output Shield Without external Without Run/stop Effective speed Effective Effective speed signal speed Effective Shield Common DIs Common Not used Not Available

Shield 24 Vdc power24 Common DIs Common Speed Speed reference reference Digital and analog inputs/outputs analog and Digital Reference 0 Vdc 0 Vdc Reference power 24 Vdc 24 Comm Comm Without Without temp. fault temp. Auxiliary power supply – XC9 Without Without +24 Vdc retif. fault retif.

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UR11 G2 | 7-7 Project Example Mechanical layout Mechanical UP11 G2 UP11 G2 UP11 G2 UR11 G2

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7-8 | UR11 G2