Operating Manual ALSPA MD2000 22 kVA ... 275 kVA

Operating Manual
ALSPA MD2000
22 kVA ... 275 kVA
Safety and Operating Instructions
for F req uency C onv erters
according to Low Voltage Directive 73/23/EEC
1. General
During op eration, f req uency converters can h ave live, rotating or
m oving p arts and th eir surf aces m ay b ecom e h ot, dep ending on
th e p rotection class involved.
T h ere is a risk of severe p h y sical inj ury or m aterial dam age if any
of th e covers are rem oved or th e unit is installed, used or
op erated incorrectly .
F urth er details are given in th e docum entation.
A ll sy stem design, transp ort, installation, com m issioning and
m aintenance work m ust b e carried out b y q ualif ied sp ecialist
p ersonnel ( according to I EC 6 0 36 4 , CEN ELEC H D 38 4 or DI N
VDE 0 1 0 0 and I EC 6 0 6 6 4 or DI N VDE 0 1 1 0 and national saf ety
regulations) .
Q ualif ied sp ecialist p ersonnel in th e sense of th ese saf ety
instructions are p ersons wh o are ex p erienced in th e sy stem
design, installation, erection, com m issioning and op eration of th e
p roduct and h ave th e q ualif ications req uired f or such work .
2 . C o rrec t u s e
Converters are intended f or installation in electrical p lant or
m ach inery .
W h en installed in m ach ines th e converter m ay not b e
com m issioned ( i. e. op eration of th e converter m ay not b e started)
until it is evident th at th e m ach ine com p lies with EC directive
9 8 /37/EC ( M ach ine Directive) ( f orm erly 8 9 /39 2/EEC) . A lso EN
6 0 20 4 m ust b e ob served.

Com m issioning ( i. e. op eration) is only p erm itted in com p liance
with th e EM C directive ( 8 9 /336 /EEC) .
O ur converters satisf y th e req uirem ents of low voltage directive
73/23/EEC. T h e standards of th e series EN 5 0 1 78 / DI N VDE
0 1 6 0 in conj unction with EN 6 0 4 39 - 1 / VDE 0 6 6 0 P art 5 0 0 and
EN 6 0 1 4 6 / VDE 0 5 5 8 are ap p licab le to drive converters.
T h e tech nical data and th e connection conditions are sh own on
th e rating p late and in th e docum entation. T h ey m ust b e
ob served.
3 . T rans p o rt and s t o rag e
T h e instructions f or transp ort, storage and correct h andling m ust
b e ob served.
Clim atic conditions are to b e m aintained according to
EN 5 0 1 78 .
4 . I ns t allat i o n
T h e installation and cooling m ust b e in accordance with th e
relevant docum entation.
A ll converters m ust b e p rotected against undue m ech anical
sh ock s or stress. I n p articular no com p onents m ay b e b ent
and/or no insulation sp acing m ay b e altered during transp ort
and h andling. Do not touch electronic com p onents or contacts.
Converters contain com p onents suscep tib le to electrostatic
disch arge ( ES D) wh ich are easily dam aged b y static electricity or
incorrect h andling. Do not dam age m ech anically or destroy
electrical com p onents ( h ealth h az ard p ossib le) .
5 . E lec t ri c al c o nnec t i o n
T h e ap p rop riate national saf ety regulations ( e. g. B G V A 2) m ust
b e ob served wh en work ing on converters wh ich are connected to
th e electricity sup p ly .
T h e electrical installation m ust b e ex ecuted in accordance with th e

relevant regulations ( e. g. cab le cross- sections, f uses, earth ing) .
A dditional instructions are given in th e docum entation.
I nstructions on EM C com p liant installation, such as screening,
earth ing, f ilters and cab le routing, are also given in th e
converters docum entation. T h ese also ap p ly to converters b earing
th e CE m ark . Com p liance with th e lim its sp ecif ied in EM C
legislation is th e resp onsib ility of th e p lant or th e m ach inery
m anuf acturer.
6 . O p erat i o n
I f necessary , p lant or m ach inery in wh ich converters are f itted
m ust b e eq uip p ed with additional m onitoring and saf ety f acilities
in accordance with th e relevant regulations, e. g. th e law on
tech nical eq uip m ent, th e ap p rop riate saf ety regulations etc.
Do not touch any p arts of th e eq uip m ent wh ich m ay b e live or
any p ower connections even af ter th e converter h as b een isolated
f rom th e electricity sup p ly , as cap acitors m ay rem ain ch arged.
F ollow th e instructions given on warning lab els.
A ll covers and doors m ust b e k ep t closed during op eration.
7 . S erv i c e and m ai nt enanc e
A ll instructions given in th e docum entation m ust b e ob served.
K E E P T H E S E S A F E T Y I N S T R U C T I O N S I N A S A F E P L A C E
Correction to Operating Manual
A L S P A MD 2 0 0 0 / 0 2 9 . 1 4 6 7 4 8 A E 0 1
Correction to Operating Manual
ALSPA MD2000 22 k V A . . . 27 5 k V A
Ord er N o. 0 2 9 . 1 4 6 7 4 8
!!! The mains chokes are not included in the ALSPA MD2000 scope of supply!!!
Page 6
2.2 Series of types
A L SP A M D 20 0 0 for 3 - ph a se A C c on n ec tion

A L S PA M D 2 0 0 0 2 2 ... 2 7 5 k V A , 3 A C 3 8 0 ... 4 8 0 V
Pr o c es s o r - c o n t r o l l ed p u l s e i n v er t er w i t h f i el d - o r i en t at ed c o n t r o l c o n c ep t f o r c o n t i n u o u s
l o w - l o s s s p eed ad j u s t m en t o f s t an d ar d A C m o t o r s .
.
.
1 ) R at ed c u r r en t w i t h o v er l o ad c ap ac i t y 1 .2 x r at ed c u r r en t
2 ) B as i c l o ad c u r r en t w i t h o v er l o ad c ap ac i t y 1 .5 x b as i c l o ad c u r r en t
3 ) M ax . c u r r en t f o r m ax . 60 s o v er l o ad , c y c l e t i m e 60 0 s
4 ) M ai n s c o m m u t at i o n c h o k e n ot i n c l u d ed i n s c o p e o f s u p p l y . N o t i n s t al l ed i n t h e
A L S PA M D 2 0 0 0 . S u p p l i ed l o o s e f o r i n s t al l at i o n o u t s i d e t h e u n i t .
5 ) T h e d et ai l s f o r t h e m ai n s c u r r en t w i t h t h e s t an d ar d m ai n s c h o k e ar e b as ed o n a
m ai n s s h o r t c i r c u i t c ap ac i t y i n r el at i o n t o t h e i n v er t er p o w er o f 1 0 0 : 1 at u n i t o u t p u t
c u r r en t = r at ed c u r r en t
.
.
S c o p e o f s u p p l y : B u i l d - i n u n i t , I P2 0 ,
i n c l u d i n g m ai n s c o m m u t at i o n c h o k e s u p p l i ed l o o s e
Page 2 2
2.4 .1 .2 M a in s c h ok es ( 3 - ph a se c h ok es)
I f t h e A L S PA M D 2 0 0 0 i s c o n n ec t ed t o a 3 A C m ai n s s u p p l y a m ai n s c h o k e i s r eq u i r ed i n
t h e s u p p l y c ab l e t o r ed u c e t h e h ar m o n i c s an d l i m i t c o m m u t at i o n f ai l u r es . T h e m ai n s
c h o k es f o r t h e r el ev an t A L S PA M D 2 0 0 0 t y p es ar e l i s t ed i n t h e t ab l e b el o w .
M ai n s c h o k es ar e n ot i n c l u d ed i n t h e A L S PA M D 2 0 0 0 s c o p e o f s u p p l y f o r 3 A C m ai n s
c o n n ec t i o n . T h ey ar e s u p p l i ed l o o s e w i t h t h e A L S PA M D 2 0 0 0 an d ar e i n s t al l ed o u t s i d e
t h e A L S PA M D 2 0 0 0 i n t h e c u b i c l e.
.
.
Page 1 7 5
5 .3 M a in s a n d m otor c on n ec tion
Pl eas e r ef er t o t h e o p er at i n g m an u al " S o f t w ar e V 3 .0 " R ef . N o . 0 2 9 .2 0 8 8 8 9 f o r a

c o m p r eh en s i v e d es c r i p t i o n o f p ar am et er s an d d i s p l ay s .
.
.
T h e s em i c o n d u c t o r f u s es an d m ai n s c h o k es t o b e u s ed ar e l i s t ed i n s ec t i o n s 2 .4 .1 .1
an d 2 .4 .1 .2 . T h e m ai n s c h o k es ar e n ot i n c l u d ed i n t h e A L S PA M D 2 0 0 0 s c o p e o f s u p p l y
an d ar e s u p p l i ed l o o s e. T h e m ai n s c o n t ac t o r , m ai n s f i l t er , p o w er d u m p an d m o t o r d u / d t
f i l t er s ar e o p t i o n s an d ar e o n l y r eq u i r ed i f n ec es s ar y f o r t h e c o n n ec t i o n .
.
.
Contents


ALSPA MD2000
1 Brief description........................................................................................1

1.1 General ...........................................................................................................1

1.2 Basic operation...............................................................................................2

1.3 Main features...................................................................................................3

2 Technical Data...........................................................................................5

2.1 Key to types, rating plate ................................................................................5

2.2 Series of types.................................................................................................6

2.2.1 Technical data at rated current.......................................................................8

2.2.2 Technical data at basic load current...............................................................9

2.2.3 Power loss and cooling air volume................................................................10

2.3 System data ..................................................................................................11

2.3.1 Standards, operating conditions and certificates .........................................16

2.3.1.1 Standards applicable....................................................................................16

2.3.1.2 Certificate......................................................................................................17

2.3.1.3 CE Certificate................................................................................................17

2.3.2 CE mark ........................................................................................................18

2.4 Supply components ......................................................................................20

2.4.1 Components for 3AC supply.........................................................................20

2.4.1.1 Fuses for 3AC mains connection ..................................................................20

2.4.1.2 Mains chokes (3-phase chokes)...................................................................22

2.4.1.3 Line fuses for

operation class gL and

cable cross-sections.........................26

2.4.1.4 Fuse circuit breakers.....................................................................................27

2.4.1.5 Mains contactor.............................................................................................28

2.4.2 DC supply .....................................................................................................29

2.5 Options..........................................................................................................30

2.5.1 Control unit (BDE) .........................................................................................30

2.5.2 Brake chopper and braking resistors............................................................32

2.5.2.1 Brake chopper option E31 ............................................................................33

2.5.2.2 Braking resistors ...........................................................................................34

2.5.2.3 Thermal overcurrent relay .............................................................................36

2.5.2.4 Overload relay for braking resistors ..............................................................37

2.5.3 Mains filters and push-pull chokes................................................................38

2.5.4 Motor filters and output chokes.....................................................................39

2.5.4.1 Motor du/dt filters ..........................................................................................39

2.5.4.2 Output choke.................................................................................................42

2.5.5 Optional assemblies for A10 Control board ..................................................44

2.5.5.1 Relay outputs 220 V Option E81 ...................................................................44

2.5.5.2 Optocoupler, Option E80 ..............................................................................46

2.5.6 Option boards for ALSPA MD2000 ...............................................................48

2.5.6.1 Encoder interface Option E83.......................................................................53

2.5.6.2 I/O Interface Option E24 ...............................................................................60

2.5.6.3 Field bus coupler Modnet 1/SFB (Bitbus) Option E11 ..................................67

2.5.6.4 Field bus coupler Modnet 1/P (PROFIBUS) Option E11 ...............................69

2.5.6.5 Field bus coupler Modnet 1/MB+ (Modbus Plus) Option E11 ......................72

2.5.6.6 Field bus coupler Modnet1/SN1 (SNET) Option E11 ....................................75

2.5.6.7 Technology coprozessor...............................................................................78

2.5.6.8 Additional power supply NG3.......................................................................79

2.5.6.9 Connection kit ...............................................................................................81

2.5.6.10 Connection kit Technology coprocessor.......................................................82

2.5.6.11 Electronics auxiliary supply...........................................................................83

2.5.6.12 Analog isolation module................................................................................84

2.5.6.13 Function low voltage .....................................................................................85

2.5.6.14 Through-mounting.........................................................................................86

2.5.6.15 Operation on a mains supply with no earth...................................................88

2.5.7 PC Handling and Operating Software...........................................................89

2.5.7.1 ALSPA PCS ...................................................................................................89

2.5.7.2 Unit-specific files...........................................................................................90

2.5.7.3 RS232 PC connection (V.24).........................................................................91

2.5.7.4 RS422 connection for the PC........................................................................93
Contents
ALSPA MD2000
2.6 Summary circuit diagrams ........................................................................... 95

2.6.1 Summary circuit diagram, ALSPA MD2000 with 3AC supply....................... 95

2.6.2 Summary circuit diagram, ALSPA MD2000 with DC supply ........................ 96

2.7 Connection, terminal wiring.......................................................................... 97

2.7.1 Power stack.................................................................................................. 97

2.7.1.1 3AC supply................................................................................................... 97

2.7.1.2 DC supply .................................................................................................. 100

2.7.2 Electronics section, A10 control board :X15 .............................................. 103

2.7.2.1 Terminal strip wiring :X15 and signal functions.......................................... 104

2.7.2.2 Description of terminal strip inputs / outputs.............................................. 109

2.8 Dimensions, Installation drawing, weights ................................................. 113

2.8.1 Alspa MD2000 build-in units ...................................................................... 113

2.8.2 Mains chokes for ALSPA MD2000 ............................................................. 115

2.8.3 Installation drawing for ALSPA MD2000 control unit BDE.......................... 117

2.8.4 Dimensions and installation dimensions Base
for semiconductor fuses of operating class gR with 110 mm length.......... 119

2.8.5 Dimensions and installation dimensions Fuse isolator
for semiconductor fuses with 110 mm length (DIN 43653) ........................ 120

2.8.6 Dimensions and installation dimensions Fuse isolator
for encapsulated fuses 27.60..................................................................... 121

2.8.7 Dimensions and installation dimensions Braking resistors......................... 122

2.8.8 Dimensions and installation dimensions, motor du/dt filters ...................... 123

2.8.9 Dimensions and weights ............................................................................ 125

2.8.10 Output choke.............................................................................................. 126

2.8.11 Dimensions and weights ............................................................................ 127

2.8.11.1 Connection and Installation dimensions, Mains filter ................................. 128

2.8.11.2 Connection and installation dimensions, Matching chokes ....................... 132

2.8.12 Electronics auxiliary supply........................................................................ 134

2.8.13 Dimensions and connection Thermal overcurrent release......................... 135

3 Transport, Installation and Connection........................................ 137

3.1 Safety instructions ...................................................................................... 137

3.2 Storage....................................................................................................... 138

3.3 Transport.................................................................................................... 138

3.4 Installation .................................................................................................. 138

3.5 Connection and wiring ............................................................................... 139

3.5.1 Potential separation.................................................................................... 146

3.6 Installation and connection instructions for EMC ....................................... 148

3.7 Specific measures for ensuring electromagnetic compatibility (EMC)....... 159

4 Operation and Software..................................................................... 161

4.1 Unit operation............................................................................................. 161

4.1.1 Software structure ...................................................................................... 162

4.1.2 Control philosophy ..................................................................................... 163

4.2 Parameter adjustment................................................................................ 164

4.3 Menu .......................................................................................................... 166

4.4 Description of parameters and displays .................................................... 171

5 Commissioning...................................................................................... 173

5.1 Safety instructions for commissioning........................................................ 173

5.2 General....................................................................................................... 175

5.3 Mains and motor connection...................................................................... 175

5.4 Sequence diagram..................................................................................... 176
5.5 Commissioning report ................................................................................ 180

Contents

ALSPA MD2000
6 Help in the event of errors .................................................................189

6.1 First value log for error messages...............................................................189

6.2 Switching sequence on errors.....................................................................189

6.3 Event log .....................................................................................................189

6.4 Events .........................................................................................................189

6.5 Error log ......................................................................................................192

6.6 Errors...........................................................................................................192

7 Maintenance...........................................................................................197

7.1 Battery for RAM and clock ..........................................................................197

7.1.1 Battery change............................................................................................197

7.1.2 Technical data of battery ............................................................................197

7.2 Fans ............................................................................................................197

7.3 Power connections......................................................................................197

7.4 Reforming the link capacitors .....................................................................198

8 Spare Parts .............................................................................................201

9 Appendix..................................................................................................205

EU – Declaration of Conformity........................................................................233

List of diagrams ....................................................................................................235

List of Tables .........................................................................................................237

Comments from users .........................................................................................239


c 06-1/01

Comments

ALSPA MD2000
Expressions used

Note:
::
:



Notes separate important information from the text and give additional information.



Important!
!!
!

Important means that the relevant instruction must be followed exactly to avoid
damage.

Warning!

Warning means that the operator may be injured if the instructions are
not followed.


Limitation of liability Unless anything to the contrary is contractually agreed, the "General Delivery Terms
for Products and Services of the Electrical Industry" ["Allgemeine Lieferbedingungen
für Erzeugnisse und Leistungen der Elektroindustrie"] as amended from time to time
shall apply.

Data, illustrations and descriptions contained in this manual shall not entitle any
customer, user or any third party to request any modification whatsoever of equipment
previously supplied.
In the event of any software modifications and updates, we are not obliged to make
such modifications and updates available to customers on a retroactive basis.

The contents of this manual were developed and revised with utmost care. However,
ALSTOM does not accept any liability for any damage or loss whatsoever which might
result from any defects in such documentation.

The user shall be solely responsible for the proper and correct use of the
ALSPA MD2000 frequency inverter. ALSTOM disclaims any liability whatsoever for
improper or incorrect installation or use.

Process information and circuit details contained in this manual shall be deemed as

being suggestions only, which shall be subject to verification with regard to their
suitability for any given application. ALSTOM disclaims any warranty or liability for the
suitability of such process information and circuit suggestions with regard to any given
application.




Data, illustrations, modifications Data and illustrations shall not be deemed as being warranted properties in the legal
meaning.
Modifications in the interest of technical progress are reserved.
Please let us know if you have any suggestions for improvement or modification.
A model form can be found on the last pages of this publication.


Training ALSTOM offers training programs for additional and supplementary system knowledge



Without our prior approval, this document shall not be copied or disclosed to any third party in any manner whatsoever. The
recipient hereof or any third party shall not use this document for any improper purpose whatsoever. Translation to any foreign
language is not permitted. Any data, dimensions, weights, illustrations and other technical information shall be subject to change
without notice, particularly in the interest of further perfecting our equipment. The data and specifications agreed to in the event of
an order shall be generally deemed as being the binding basis.

© 2001 ALSTOM Power Conversion GmbH



1 Brief description

ALSPA MD2000 1
1.1 General ALSPA MD2000 units are processor-controlled pulse inverters with a field-orientated
control concept for continuous low-loss speed adjustment of AC motors.

The power stack consists of a diode rectifier in a 3-phase bridge circuit on the mains
side and an IGBT inverter on the motor side.

The basic inverter models are designed for standard applications. Through suitable
options (eg. bus couplers, encoder interface) the units can be integrated into
automation systems and can also fulfil highly dynamic requirements.

Operation of all units is identical throughout the entire type range. Easy familiarisation
and operation as well as maximum flexibility were the prime objectives during
development.

The inverters are operated and parameters adjusted by means of a optional
removable control unit (BDE) or using a PC and an PC software package.

Connection to automation systems is possible through conventional bus systems (see
field bus coupler options).

With a mains voltage range from 380 to 480 V build-in units cover the power range
from 22 kVA to 330 kVA.

In conjunction with standard asynchronous motors the drive capacities provided are
therefore as follows:

- At unit rated current
18.5 kW to 200 kW, 400 V
21 kW to 230 kW, 480 V

- At unit basic load current
15 kW to 160 kW, 400 V
17 kW to 184 kW, 480 V


Note:

This operating manual applies to the following units:

ALSPA MD2000 22/27-400 ... 225/275-400

Software version: V3.0

Ref. No.: 029.152 730











Important!

ALSPA MD2000 units are designed as standard for operating on earthed networks.

1 Brief

description
2 ALSPA MD2000
1.2 Basic operation The link voltage is generated from the mains supply through the mains rectifier. A 3-
phase choke connected to the mains supply reduces harmonic currents and serves to
decouple the unit from other converters (consumers) on the same supply network.
ALSPA MD2000 units are connected as standard to an earthed network.
The link voltage is smoothed by high quality electrolytic capacitors. With the motor
converter these provide the magnetising reactive power required by the motor and
decouple the converter on the mains side from the inverter on the motor side.

Through optimised pulse width modulation the motor converter generates from the link
voltage a sinusoidal 3-phase system with variable frequency and voltage.

A power dump (option) in conjunction with a braking resistor allows braking energy to
be used in regenerative operation.

Control and regulation of the ALSPA MD2000 are fully digital. Different control
structures such as, frequency control, speed control with or without encoder and
torque control with or without encoder can be selected, depending on the application
requirements. The field-orientated control concept provides control dynamics directly
comparable to those of a DC drive.

In addition, various inputs and outputs can be connected individually according to the
task involved. Thus the drive system can very easily be customised for the
requirements of the specific application.

RS 422/485
A

D
I/O
CPU Controller
SAB 80C 187
Options
Encoder
Interface
Bus
Central Control PLC
R
B
*)
Powerboard
*)
*)
*)
*)
M
3~
+
-
Start
Stop
Motor
Parameter
menu enter
quit
error
ready
run

PC
*) Option

Fig. 1: Summary circuit diagram, basic layout, operation
Brief

description 1
ALSPA MD2000 3
1.3 Main features • Consistent range of Types for drives from 15 kW to 250 kW with
IGBT inverters

• Supply voltage ranges:

- 3AC 380 V ... 460 V +10 %/ -15 % ... 480 V +6 %/ -15 %

• Standard design for connection to earthed networks

• Output frequency range: 0 ... 300 Hz

• 120 % overload capacity for 60 s based on unit rated current
(Unit rated current = 1.25 ∗ unit basic load current)

• 150 % overload capacity for 60 s based on unit basic load current

• Standard asynchronous motors can be used without power reduction

• High dynamics: Torque rise time: t
an
= 2 to 8 ms

• ALSPA MD2000 units are resistant to idling, short circuit and earth fault

• DC system bus supply for several ALSPA MD2000 through
DC link connection (option)

• 4Q operation (option) through power dump with braking resistor or mains
feedback unit (option)

• Cooling airflow Power stack cooling air circuit can be remote (optional through-
mounting facility)
The cooling system can be installed outside the switchgear cubicle

• Mains supply power connections at top and motor connections at foot

• Motor temperature monitoring by thermistor processing electronics (PTC)

• Easy, user-friendly system structure

• Consistent and easily learned operation via control unit (option) with plain
text display (various languages available)

• Extensive additional operating facilities via PC, for example menu control,
user-controlled commissioning, oscilloscope function

• RS 422 serial interface as standard

• Consistent operation through control systems (option)

• Connection to automation system through field buses (option):
Bitbus, Profibus, Modbus Plus, SNET

• Control structures available:
- Frequency control
- Speed control with or without incremental rotation encoder
- Torque control with or without incremental rotation encoder


1 Brief

description
4 ALSPA MD2000
• Kinetic support on mains failure
supports operation of the control electronics using the kinetic energy in the drive
systems at speeds close to zero, also suitable for flow machines
• Capture without torque surge
(the inverter is applied to the de-excited motor while the motor is running)

• Automatic restart facility after mains failure
(Parameter-adjustable up to 15 s as standard)

• Conventional drive through standard terminal strip

- 12 digital potential-separated inputs for control signals (eg. Start, Stop etc.),
of which 3 inputs are parameter-adjustable through selection list

- 4 digital potential-free outputs for messages (On, Ready, Error, free
output parameter-adjustable through selection list, 1 output
"Ready” can be re-assigned via technology)

- 2 free adjustable and scaleable analog outputs

- 2 scaleable analog demand inputs

- 2 parameter sets switchable via control unit or terminal strip

• Expansion of standard terminal strip (I/O interface option)

- 20 configurable digital inputs with separate potential
- 8 configurable digital outputs with separate potential
- 2 configurable analog demand inputs
- 2 configurable analog outputs

• Comprehensive testing and diagnostics facilities:

- Self-test on control electronics and hardware

- Event memory with timings of all binary events with first
value error message and documentation

- Error log with timing details

- Protocol log for documenting all parameter changes

- Oscilloscope function (history log) with 4 analog and 8 digital
channels, can be processed with the Windows PC Handling
Program ALSPA PCS. Trigger signal is safe against mains failure.

• Comprehensive protection and monitoring facilities.

• Co-processor (option), can be customised for user-specific solutions

2 Technical Data
ALSPA MD2000 5
2.1 Key to types, The type data includes the following information. An example:
rating plate



ALSPA MD2000 225 / 275 - 400

Supply voltage 3AC 380 ... 480 V
Unit apparent power in kVA
*)
at rated current
Overload capacity: 1.2 ∗ Rated current
Unit apparent power in kVA
*)
at basic load current
Overload capacity: 1.5 ∗ basic load current
Series

*)
Based on 3AC 400 V supply voltage


Fig. 2: ALSPA MD2000 rating plate

The following details are required for identifying the unit:

- Type No :

- Serial No :
- Project No :
- Option No :
2 Technical data
6 ALSPA MD2000
2.2 Series of types ALSPA MD2000 for 3-phase AC connection

ALSPA MD2000 22 ... 275 kVA, 3AC 380 ... 480 V
Processor-controlled pulse inverter with field-orientated control concept for continuous
low-loss speed adjustment of standard AC motors.


ALSPA
MD2000 type
Frame
size
Unit input
current,
Unit output current ALSPA MD2000 for
3AC supply
4)


mains current
5)
Rated
current
1)

Basic load

current
2)

Max. current
60 s
3)

Ref. No. Supply voltage

eff [A]

[A]

[A]

[A]




22/27-400 1 43 40 32 48 029.146 624
27/33-400 1 51 48 40 60 029.146 625
33/43-400 1 65 62 48 72 029.146 626 3 AC 50/60Hz
43/54-400 1 82 78 62 93 029.146 627 380 ... 460 V
54/62-400 2 95 90 78 117 029.146 628 +10/-15 %
62/78-400 2 119 113 90 135 029.146 629
78/102-400 2 154 147 113 170 029.146 630
102/122-400 2 184 176 147 221 029.146 631 ...480 V
122/150-400 3 226 216 176 264 029.146 632 +6/-15 %
150/178-400 3 268 257 216 324 029.146 633

178/225-400 4 340 325 257 386 029.146 634
225/275-400 4 415 396 325 488 029.146 635

Table 1: ALSPA MD2000 series


1)
Rated current with overload capacity 1.2 x rated current
2)
Basic load current with overload capacity 1.5 x basic load current
3)
Max. current for max. 60 s overload, cycle time 600 s
4)
Mains commutation choke included in scope of supply. Not installed in the
ALSPA MD2000. Supplied loose for installation outside the unit.
5)
The details for the mains current with the standard mains choke are based on a
mains short circuit capacity in relation to the inverter power of 100 : 1 at unit output
current = rated current





Frame size Dimensions Weight
H x W x D [mm] ca. [kg]


1 591 x 345 x 383 35

2 824 x 495 x 419 70

3 1049 x 495 x 419 90

4 1499 x 495 x 419 140

Table 2: ALSPA MD2000 frame sizes, AC supply

Scope of supply: Build-in unit, IP20,
including mains commutation choke supplied loose

Technical data 2
ALSPA MD2000 7
ALSPA MD2000 for DC

supply

ALSPA MD2000 22 ... 275 kVA, DC 500 ... 630 V

Processor-controlled pulse inverter with field-orientated control concept for continuous
low-loss speed adjustment of standard AC motors.


ALSPA MD2000 type Frame size Unit output current ALSPA MD2000 for DC
supply

Rated
current
1)

Basic load
current
2)

Max. current
60 s
3)

Ref. No. Supply voltage

[A]

[A]

[A]




22/27-400 1 40 32 48 029.146 637
27/33-400 1 48 40 60 029.146 638
33/43-400 1 62 48 72 029.146 639 DC
43/54-400 1 78 62 93 029.146 640 500 ... 605 V
54/62-400 2 90 78 117 029.146 641 +10/-15 %
62/78-400 2 113 90 135 029.146 642
78/102-400 2 147 113 170 029.146 643
102/122-400 2 176 147 221 029.146 644 ... 630 V
122/150-400 3 216 176 264 029.146 645 +6/-15 %
150/178-400 3 257 216 324 029.146 646
178/225-400 4 325 257 386 029.146 647

225/275-400 4 396 325 488 029.146 648

Table 3: ALSPA MD2000 series for DC system bus connection
1)
Rated current with overload capacity 1.2 x rated current

2)
Basic load current with overload capacity 1.5 x basic load current
3)
Max. current for max. 60 s overload, cycle time 600 s



Frame size Dimensions Weight
H x W x D [mm] ca. [kg]


1 591 x 345 x 383 35

2 824 x 495 x 419 70

3 1049 x 495 x 419 90

4 1499 x 495 x 419 140

Table 4: ALSPA MD2000 frame sizes. DC supply

Scope of supply: Build-in unit, IP 20

Important!

ALSPA MD2000 drives with a DC system bus connection must be designed
accordingly. Special matching chokes and semiconductor fuses will be required
according to the system configuration.

2 Technical data
8 ALSPA MD2000
2.2.1 Technical data Overload capacity 1.2 x rated current

The technical data shown in Table 5 applies at a pulse frequency of f
p
= 3 kHz,
as supplied ex works, and a maximum air supply temperature up to 40 °C.


ALSPA MD2000
type
Rated current Max. current
1)
for max. 60 s
Unit rated current [kVA]
at rated current
motor rating
2)
[kW]

[A] [A] 400 V 415 V 460 V 480 V 400 ... 415 V 460 ... 480 V

22/27-400 40 48 27 29 32 33 18,5 21
27/33-400 48 60 33 35 38 40 22 25
33/43-400 62 72 43 45 49 52 30 34
43/54-400 78 93 54 56 62 65 37 42
54/62-400 90 117 62 65 72 75 45 51
62/78-400 113 135 78 81 90 94 55 63
78/102-400 147 170 102 106 117 122 75 86
102/122-400 176 221 122 127 140 146 90 103
122/150-400 216 264 150 155 172 180 110 126
150/178-400 257 324 178 185 205 214 132 151
178/225-400 325 386 225 234 259 270 160 184
225/275-400 396 488 275 285 316 330 200 230

Table 5: Technical data at rated current with overload capacity 1.2 x rated current

1)
120 % overload for total max. 60 s on a load cycle of 1 : 10 / cycle time 600 s
2)
motor rating based on standard 2, 4 and 6 pole motors at
400 ... 415 V or 460 ... 480 V rated voltage.

Rated current
Max. current
600600
t [sec]
Output current

Fig. 3: ALSPA MD2000 Overload capacity 1.2 x rated current

Technical data 2

ALSPA MD2000 9
2.2.2 Technical data Overload capacity 1.5 x basic load current
at basic load current
The technical data shown in Table 6 applies at a pulse frequency of f
p
= 3 kHz
as set ex works, and a maximum air supply temperature up to 50 °C.


ALSPA MD2000
type
Basic load
current
Max. current
1)
for
max. 60 s
Unit apparent power [kVA]
at basic load current
motor rating
2)
[kW]

[A] [A] 400 V 415 V 460 V 480 V 400 ... 415 V 460 ... 480 V


22/27-400 32 48 22 23 25 27 15 17
27/33-400 40 60 27 29 32 33 18,5 21
33/43-400 48 72 33 35 38 40 22 25
43/54-400 62 93 43 45 49 52 30 34

54/62-400 78 117 54 56 62 65 37 42
62/78-400 90 135 62 65 72 75 45 51
78/102-400 113 170 78 81 90 94 55 63
102/122-400 147 221 102 106 117 122 75 86
122/150-400 176 264 122 127 140 146 90 103
150/178-400 216 324 150 155 172 180 110 126
178/225-400 257 386 178 185 205 214 132 151
225/275-400 325 488 225 234 259 270 160 184

Table 6: Technical data at rated current with overload capacity 1.5 x basic load current

1)
150 % overload for total max. 60 s on a load cycle of 1 : 10 / cycle time 600 s
2)
motor rating based on standard 2, 4 and 6 pole motors at
400 ... 415 V or 460 ... 480 V rated voltage.


Basic load current
Max. current
600600
t [sec]
Output current

Fig. 4: ALSPA MD2000 Overload capacity 1.5 x basic load current

2 Technical data
10 ALSPA MD2000
2.2.3 Power loss and

The rise in temperature of the cooling air at rated current is ∆υ ≤ 16 °C for the
cooling air volume

cooling air volume stated and when the installation clearances are maintained.




ALSPA MD2000 type Frame size Cooling air
volume
2)

Rated current Power loss
1)
[kW] at rated current und
3AC supply voltage
[m³/h] [A] 400 V 460 V 480 V


22/27-400 1 260 40 0,62 0,64 0,64
27/33-400 1 260 48 0,74 0,76 0,77
33/43-400 1 260 62 0,92 0,95 0,96
43/54-400 1 260 78 1,17 1,21 1,23
54/62-400 2 390 90 1,26 1,30 1,32
62/78-400 2 390 113 1,50 1,56 1,57
78/102-400 2 390 147 2,04 2,11 2,13
102/122-400 2 390 176 2,40 2,49 2,52
122/150-400 3 580 216 3,07 3,16 3,19
150/178-400 3 580 257 3,73 3,84 3,88
178/225-400 4 950 325 4,78 4,98 5,05

225/275-400 4 950 396 5,55 5,80 5,88


Table 7: Power loss and cooling air volume at rated current

1)
The values stated apply to a pulse frequency of fp = 3 kHz

2)
The values apply to a static pressure increase of ∆p ≈ 32 Pa between cooling air
inlet and outlet.



ALSPA MD2000 type Frame size Cooling air
volume
Basic load
current
Power loss
1)
[kW] at basic load current und
3AC supply voltage
[m³/h] [A] 400 V 460 V 480 V


22/27-400 1 300 32 0,50 0,52 0,53
27/33-400 1 300 40 0,61 0,63 0,63
33/43-400 1 300 48 0,70 0,72 0,73
43/54-400 1 300 62 0,93 0,96 0,97
54/62-400 2 500 78 1,09 1,13 1,14

62/78-400 2 500 90 1,19 1,23 1,25
78/102-400 2 500 113 1,56 1,62 1,64
102/122-400 2 500 147 2,0 2,07 2,09
122/150-400 3 700 176 2,5 2,57 2,61
150/178-400 3 700 216 3,14 3,22 3,24
178/225-400 4 1000 257 3,78 3,94 4,00
225/275-400 4 1000 325 4,54 4,74 4,83


Table 8: Power loss and cooling air volume at basic load current
1)
The values stated apply to a pulse frequency of fp = 3 kHz

2)
The values apply to a static pressure increase of ∆p ≈ 32 Pa between cooling air
inlet and outlet.
Technical data 2
ALSPA MD2000 11
2.3 System data • Mains supply voltage 3AC 400 ... 460 V; +10/-15 % ... 480 V; +6/-15 %

• Mains frequency 50 ... 60 Hz ±5 %

• Power factor
- Mains base frequency cos ϕ
1
> 0.97
- Total at rated current
depending on mains
impedance λ
N

≈ 0,88 ind - 0,93 ind

• DC supply voltage DC 500 ... 605 V; +10/-15 %

• Output voltage 3AC 0 ... U
mains
for DC supply 3AC 0 ... U
DC
∗ 0.71

• Approvals prEN50178:1994/VDE0160
CE mark according to low voltage directive
• Efficiency
at rated power ≥0.97 on 3-phase supply
≥0.98 on DC supply (inverter component)

• Overload factor 1.2 for max. 60 s at rated current Cycle time
1.5 for max. 60 s at basic load current ≥10 min

• Min. operating frequency
With encoder 0 Hz
Without encoder Motor: 1 Hz
Regenerative: 2.5 Hz

• Max. operating frequency 300 Hz

• Speed adjustment range For speed control
without encoder With encoder
1:50
1)

>1:1000


1)
The adjustment range is 1:20 in regenerative
operation using the control structure “Speed
control without encoder”

• Speed accuracy For speed control
Without encoder With encoder
with digital demand preset
0.5 % 0.05 %

• Torque rise times For speed control
With or without encoder
2 ... 8 ms

• Frequency resolution 10 mHz standard
Adjustable with parameter f
100

• Frequency stability for
frequency control <0.01 % standard
<0.001 % option, on application



2 Technical data
12 ALSPA MD2000
• Frequency accuracy for

frequency control <0.01 %

• Temperature response
of analog demand <0.01 %/°C

• Speed encoder Incremental encoder
See encoder interface option

• Noise A-weighted sound pressure level
Frame sizes 1 and 2 <66 dB(A)
Frame size 3 <70 dB(A)
Frame size 4 <72 dB(A)

• Overtemperature shutdown Frame size 1 and 2 at >90 °C
Frame size 3 at >95 °C
Frame size 4 at >105 °C

• Ambient temperature
Operation 0 ... +55 °C
1)

Storage -25 °C ... +65 °C

• Cooling Forced air cooling
See section 2.2.3 for cooling air volumes

• Coolant temperature 0 ... 40 °C at rated current, overload factor 1.2
for 60 s every 10 minutes
up to max. 55 °C with power reduction 2 % per 1 °K

0 ... 50 °C at basic load current, overload factor 1.5
for 60 s every 10 minutes
up to max. 55 °C with power reduction 2 % per 1 °K

• Installation altitude ≤1000 m above MSL, up to max. 2200 m with
power reduction 1.2 % per 100 m

• Protection classes
Build-in units IP20

Cubicle-mounted units IP21 Standard
IP31, IP43, IP54 Option

• Environment class DIN EN 60721 Part 3-3
3K3 / 3M2 / 3C2
2)
/ 2K2

- Max. relative humidity 85 % at 28 °C, condensation not permitted

- Insulation Contamination Class II to DIN VDE 0110

• Permitted switching Precharging circuit duty cycle = 2 %/180 s,
frequency max. 20 per hour

• Power loss of control ca. 80 W (Frame size 1) ... ca. 130 W (frame size 4)
electronics with control board, no additional options


Technical data 2

ALSPA MD2000 13
• Mechanical use prEN50178:1994/IPA90 DIN IEC86 T.2-6 10 ... 150 Hz
(Vibration)

• Electromagnetic
compatibility:

Interference resistance To IEC1800-3 (IEC22G/21/CDV), EN50082-2,
suitable for use in an industrial environment

Radiated interference To IEC1800-3 (IEC22G/21/CDV)
- industrial mains supply AC mains choke
4)

- public supply network Additional mains filter
4)



EN50081-2, limit to EN55011 Group 1 Class A:
DS-Drossel and mains filter
4)

EN50081-1, limit to EN55011 Group 1 Class B:
DS-Drossel, mains filter und pus-pull chokes
4)



1)

Adequate convection cooling must be provided for the ALSPA MD2000 control
electronics. No heat build up inside the ALSPA MD2000.
2)
No salt spray mist.
3)
Connection to earthed network
4)
see section 3.7 for optional measures

• Vector frequency adjustable
Standard 3 kHz

Maximum Up to 12 kHz

At a vector frequency of f
V
= 12 kHz a power reduction is done depending on the type
of unit.

• Servicing Data memory battery replacement required,
see section 7.1
Fan replacement recommended, see section 7.2
Check power connection screws, see section 7.3
2 Technical data
14 ALSPA MD2000
Power reduction curves


70
80

86
90
100
0 500 1000 1500 2000
2200
2500
Installation altitude above msl in m
Rated current in %


40
50
60
80
100
90
70
0369
Pulse frequency in kHz
Current rating in %
Frame size 1;
400 V, 460 V
Frame size 2;
400 V
Frame size 4; 460 V
Frame size 2; 460 V
Frame size 3; 400 V, 460 V
Frame size 4; 400 V

60
100
70
80
90
10 6050403020
Coolant temperature in C°
Current rating in %
Rated current (3kHz)
Basic load current (3kHz)

Fig. 5: Power reduction curves (Derating) ALSPA MD2000 22 ... 275-400
Technical data 2
ALSPA MD2000 15

Efficiency curves

75
10 20 30 40 50 60
80
85
90
95
100
Frequency in Hz
M=konst.
Mn»
2
Efficiency
in %

h

Fig. 6: ALSPA MD2000 Efficiency curves 22 ... 275-400

The curves in Fig. 6 apply to pulse frequency 3 at a 400 ... 460 V supply voltage.
2 Technical data
16 ALSPA MD2000
2.3.1
2.3.1 2.3.1
2.3.1 Standards, operating conditions and certificates





2.3.1.1 Standards applicable As per

06.1996

VDE 0100-540 Installation of heavy current systems with rated voltages up to 1000 V; selection and
installation in electrical equipment, earthing, protective conductor, potential
compensation conductor

VDE 0106-100 Protection against electric shock; configuration of actuator components close to parts
which are dangerous to touch

VDE 0110 Insulation coordination for electrical equipment in low voltage systems.
Rating of air gaps and creepage distances

VDE 0160/pr EN50178 Installing electronic equipment on heavy current systems

DIN EN 60146-1-1 (IEC 146-1-1) Semiconductor converters; general requirements and mains-fed converters;
basic requirements (DIN VDE 0558 Part 11: 1994-03)

DIN EN 60146-1-3 (IEC 146-1-3) General requirements and mains-fed converters,
transformers and choke coils (DIN VDE 0558 Part 8: 1994-03)

IEC 1000-4-2 Resistance to electrostatic discharge,
requirements and test methods (conversion IEC 801-2)

IEC 1000-4-3 Resistance to electromagnetic HF fields,
requirements and test methods

IEC 1000-4-4 Resistance to fast electrical transients and bursts (conversion IEC 801-4)

IEC 801-5 Resistance to surge voltages on mains supply cables (surge pulses)

IEC 1000-4-5 Resistance to voltage peaks

DIN EN 55011 Radio interference suppression of electrical plant and equipment;
(VDE 0875 Part 11), limits and test methods for radio interference suppression of
industrial, scientific and medical high frequency equipment

DIN EN 55022 Electromagnetic compatibility of equipment in information processing and
telecommunications technology (VDE 0878 Part 3), limits and test methods for radio
interference suppression on technical information equipment

IEC1800-3/prEN61800-3:1995 EMC product standard for variable speed drives
(IEC22G/21/CDV) EMC interference resistance and radiated interference Anforderungen und
Meßverfahren

DIN EN 50081-1 Electromagnetic compatibility (EMC); specialist basic standard for radiated
interference;
Part 1: Residential, business and light industry

DIN EN 50081-2 Electromagnetic compatibility (EMC); specialist basic standard, radiated interference;
Part 2: Industrial

DIN EN 50082-1 Electromagnetic compatibility (EMC); specialist basic standard, interference
resistance;
Part 1: Residential, business and light industry

DIN EN 50082-2 Electromagnetic compatibility (EMC); specialist basic standard, interference
resistance,
Part 2: Industrial (VDE 0839 Part 82-2)

Technical data 2
ALSPA MD2000 17
DIN EN 60204-1 (IEC 204-1) Machine safety; electrical equipment on machines;
Part 1: General requirements (VDE0113 Part 1: 1993-06)

DIN EN 60249-2 Basic materials for printed circuits;
Part 2: Individual conditions

DIN EN 60529 Protection classes by enclosure (IP Code)
DIN EN 60721-3 classification of environmental conditions
- Classes of environmental influences and limits

IEC 68-2 Electrical technology; basic environmental test methods; tests

IEC 364-5-54 DIN VDE 0110 TS10: 1995-12

DIN EN 60439-1:1994 Low voltage switchgear combinations
VDE 0660 Part 500 1994-04


2.3.1.2 Certificate

DIN EN ISO 9001 Model for quality assurance in development, design, production, assembly, testing,
sales and maintenance.
TÜV-Südwest Audit QM-M-96/732
Certificate Registration No. 70 100 M732
Certificate obtainable from ALSTOM Power Conversion GmbH.

UL/CSA Certification in preparation


2.3.1.3 CE Certificate

CE mark CE mark to low voltage directive 73/23 EC 1995
See appendix for EC Certificate of Conformity.

VDE0160/prEN50178 Fitting heavy current systems with electronic equipment

2 Technical data
18 ALSPA MD2000
2.3.2 CE mark The ALSPA MD2000 frequency inverter carries the CE mark. This confirms for
monitoring authorities responsible in the European Union (EU) that the unit complies
with the low voltage guideline 73/23 EC and the CE mark guideline 93/68/EC.
The certificate of conformity with the low voltage guideline is available on request.

The ALSPA MD2000 frequency inverter is completed into a drive system by the
connection of an AC motor and electrical components, safety equipment and external
radio interference suppression components. Installation must be carried out by
experienced personnel in compliance with the relevant rules and regulations.

No certificate of conformity is required for the ALSPA MD2000 as an “independently
operated unit” in the sense of EMC Directive 89/336/EC. The ALSPA MD2000 is
classified according to CEMEP2 for use and supply through the industry, trade and
other users experienced in the field of electromagnetic compatibility (EMC).

Type tests on electromagnetic compatibility (EMC) were carried out to demonstrate
compliance with the documented EMC-relevant IEC standards, DIN EN standards,
EMC installation guidelines and specified combinations with optional radio
interference suppression components in this operating manual when connected to an
earthed mains supply. Compliance with the EMC installation instructions in section 3.6
is essential.
Section 3.7 provides optional measures for guaranteeing EMC.

IEC 22G/21/CDV
EMC product standard including specific test methods for
power drive systems;
EMC product standard for drive converters;
EMC radiated interference and interference resistance.

DIN EN 50082
Electromagnetic compatibility (EMC)
Specialist basic standard, interference resistance
Part 1: Residential, business and light industry connected to
the public electricity supply network

(VDE 0839 Part 82-1)
Part 2: Industrial 1) VDE 0839 Part 82-2).

DIN EN 50081
Electromagnetic compatibility (EMC)
Specialist basic standard, radiated interference
Part 1: Residential, business and industrial connected to
the public electricity supply network

(VDE 0839 Part 81-1). Limit to EN 55011 Group 1 Class B
Part 2: Industrial
1)
(VDE 0839 Part 81-2). Limit to EN 55011 Group 1 Class A


1)
Compare ESD, burst and surge limits on the following page