BENSHAW M2L 3000 User manual

BENSH®
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Use Guide
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M2L 3000 Series VFD
2

3
Important Reader Notice
Congratulations on the purchase of your new Benshaw M2L 3000 Medium Voltage Variable Frequency Drive, hereafter re-
ferred in this document as the “M2L 3000” or the “drive”.
This User Guide may not cover all of the applications for the M2L 3000, nor can it provide information on every possible contin-
gency concerning installation, programming, operation, or maintenance specific to M2L 3000 VFD systems.
The content of this manual will not modify any prior agreement, commitment or relationship between the customer and Ben-
shaw. The sales contract contains the entire obligation of Benshaw. The warranty enclosed within the contract between the
parties is the only warranty that Benshaw will recognize, and any statements contained herein do not create new warranties or
modify the existing warranty in any way.
Any electrical or mechanical modifications to Benshaw products without prior written consent of Benshaw will void all warran-
ties, and may also void any safety certifications; unauthorized modifications may also result in product damage, operation mal-
functions, or personal injury.
Incorrect handling of the drive may result in an unexpected fault or equipment damage. For best results when operating the
M2L 3000 drive, carefully read this manual and all warning labels attached to the system before installation and operation.
Keep this manual on hand for reference.
Do not attempt to install, operate, maintain or inspect the drive until you have thoroughly read this manual and related docu-
ments carefully, and can use the equipment correctly.
Do not use the drive until you have a full knowledge of the equipment, safety procedures and instructions.
Symbols This User Guide classifies safety, protection, and general information levels as Warning,
Caution, and Note.
WARNING: Warns of a physical safety condition or Electrical Hazard
which can cause personal injury or death
CAUTION: Warns of situations in which equipment damage may occur
NOTE: Indicates a specific piece of information applicable to the use or oper-
ation of the drive.

M2L 3000 Series VFD
4
WARNINGS HAZARDS OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH.
Failure to follow the instructions below may result in serious injury or death.
DANGER. This equipment does not provide isolation. Separate isolating
means required. Isolation devices can take several forms with the most
simple being an appropriately sized disconnect switch and contactor pair
utilizing the Inverter ‘Shunt Trip’ controls, or an appropriately sized and
protected vacuum circuit breaker also capable of remote operation from
the inverter ‘Shunt Trip’ controls. See page 32 for more information.
WARNING: At any time the system is energized with Medium Voltage
power, apply appropriate personal protective equipment (PPE) and follow
safe electrical work practices when operating or working near the system.
See NFPA 70E.
Cabinet Fault Limit: <10kA @ 10 Cycles
Min Arc Boundary: 40 Inches
Recommended Min. PPE: #1 at > 40 inches
WARNING: Branch circuit protection is required for the equipment. See
page 32 for more information.
WARNING: Only qualified personnel familiar with the use and hazards of
medium voltage equipment are to perform work described in this set of
instructions.
WARNING: Before performing visual inspections, tests, or maintenance
on the equipment, disconnect all sources of electric power. Assume that
circuits are live until completely de-energized, tested, and tagged.
Pay particular attention to the design of the power system. Consider all
sources of power, including the possibility of backfeeding.
Use a properly rated voltage sensing device to confirm that the power is
fully removed.
WARNING: Always perform applicable lock-out/tag-out procedures (ei-
ther general or site-specific) before performing any maintenance or trou-
bleshooting on the system.
WARNING: To avoid potentially lethal levels of both AC and DC voltages,
do not remove the cover to access the MV Input/Output section of the In-
verter while the Inverter is energized.
WARNING: Equipment may be supplied from multiple power sources.
Refer to drawings for more information.

5
WARNING: Potentially hazardous voltages will remain in the cells until
the capacitors are able to de-energize. Wait at least 30 minutes after
main power is removed for the stored voltages to dissipate if removing
the Inverter Cell or Input/Output section covers. Do not rely solely on the
voltage values displayed on the HMI Meter Values screen to determine if
it is safe to remove the covers on the Inverter Cell and Input/Output sec-
tions.
WARNING: The Control section contains 240V control power when ac-
tive. The Control section does not contain medium voltage levels sup-
plied from the mains, and can be carefully accessed by qualified person-
nel while medium voltage from the AC mains is applied to the system.
WARNING: Replace all devices, doors, and covers before applying
power to this equipment.
WARNING: Do not attempt to lift and position either the Converter or In-
verter with a crane without the proper equipment or experience perform-
ing this type of operation. Benshaw can arrange the services of profes-
sional firms who routinely rig and lift heavy equipment.
CAUTIONS CAUTION: Special care must be taken with covers that have a ground
wire
attached to the inside that ties them to ground potential. It is im-
portant that the connection integrity of this wire be maintained to avoid
compromising the immunity of the Inverter to Electromagnetic Interfer-
ence (EMI) and safety.
CAUTION: Always be aware of electrostatic discharge (ESD) when work-
ing near or touching components inside the drive. Handling of compo-
nents sensitive to ESD should be done by qualified personnel only, famil-
iar with ESD mitigation techniques.
CAUTION: Parameter settings and adjustments should be performed by
those familiar with VFD and motor operation characteristics. It is not rec-
ommended for users unfamiliar with these concepts.

M2L 3000 Series VFD
6

7
Table of Contents
IMPORTANT READER NOTICE ....................................................................................................................................................................... 3
Symbols ............................................................................................................................................................................................. 3
1 - Introduction .............................................................................................................................................................................. 11
DOCUMENTATION ................................................................................................................................................................................... 11
ON-LINE DOCUMENTATION....................................................................................................................................................................... 11
REPLACEMENT PARTS ............................................................................................................................................................................... 11
PUBLICATION HISTORY ............................................................................................................................................................................. 11
WARRANTY ............................................................................................................................................................................................ 11
CONTACTING BENSHAW ........................................................................................................................................................................... 11
SYSTEM DESIGN FEATURES ........................................................................................................................................................................ 12
PART NUMBER DEFINITIONS ...................................................................................................................................................................... 14
2 - Specifications ............................................................................................................................................................................ 17
GENERAL SPECIFICATIONS ......................................................................................................................................................................... 17
CONVERTER INPUT: ................................................................................................................................................................................. 17
ENVIRONMENTAL .................................................................................................................................................................................... 17
CONDITIONS ........................................................................................................................................................................................... 17
COOLING SYSTEM .................................................................................................................................................................................... 18
CONSTRUCTION ...................................................................................................................................................................................... 18
LIFTING PROVISIONS ................................................................................................................................................................................ 18
MINIMUM CLEARANCE ............................................................................................................................................................................. 18
ELECTRICAL RATINGS – 300A UNIT ............................................................................................................................................................ 19
ELECTRICAL RATINGS – 260A UNIT ............................................................................................................................................................. 20
COMMON ELECTRICAL RATINGS – 260A AND 300A UNITS ............................................................................................................................. 21
3 – Installation ............................................................................................................................................................................... 25
EMC INSTALLATION GUIDELINES ................................................................................................................................................................ 25
WIRING CONSIDERATIONS ........................................................................................................................................................................ 26
WIRING SCHEMATICS ............................................................................................................................................................................... 27
POWER WIRING ...................................................................................................................................................................................... 30
Input Line Requirements ................................................................................................................................................................. 30
Recommended Wire Gauges .......................................................................................................................................................... 30
Power Wire Connections ................................................................................................................................................................. 30
Compression Lugs ........................................................................................................................................................................... 30
Motor Lead Length ......................................................................................................................................................................... 31
Input Line Requirements ................................................................................................................................................................. 31
DC Lead Length Between Converter and Inverter ........................................................................................................................... 31
4 - Theory of Operation ................................................................................................................................................................. 33
M2L 3000 OVERVIEW ............................................................................................................................................................................ 33
CONVERTER............................................................................................................................................................................................ 34
INVERTER ............................................................................................................................................................................................... 36
IGBT Cell .......................................................................................................................................................................................... 36
5 - Operation ................................................................................................................................................................................. 41
INTRODUCTION ....................................................................................................................................................................................... 41
HMI OVERVIEW ..................................................................................................................................................................................... 42
STATUS INDICATORS................................................................................................................................................................................. 43
GETTING THE DRIVE READY ....................................................................................................................................................................... 45
OPERATING THE DRIVE ............................................................................................................................................................................. 46

M2L 3000 Series VFD
8
SELECTABLE VIEW OPTIONS ....................................................................................................................................................................... 47
6 - Parameter List .......................................................................................................................................................................... 57
DRIVE GROUP PARAMETER LIST ................................................................................................................................................................ 57
FUNCTION GROUP PARAMETER LIST ........................................................................................................................................................ 58
AFN (ADVANCED FUNCTION) GROUP PARAMETER LIST .................................................................................................................................. 61
I/O (INPUT/OUTPUT) GROUP PARAMETER LIST ............................................................................................................................................ 62
7 - Parameter Descriptions ............................................................................................................................................................ 73
DRIVE GROUP PARAMETERS ...................................................................................................................................................................... 73
FUNCTION GROUP PARAMETERS ................................................................................................................................................................ 77
AFN (ADVANCED FUNCTION) GROUP PARAMETERS ...................................................................................................................................... 83
I/O (INPUT/OUTPUT) GROUP PARAMETERS ................................................................................................................................................. 85
Digital Input Options ....................................................................................................................................................................... 85
Digital Output Options .................................................................................................................................................................... 87
Analog Input Options ...................................................................................................................................................................... 88
Low/High Parameters Process and Input Value ............................................................................................................................. 89
INVERTER ANALOG OUTPUT FUNCTIONS (I/O-72 THROUGH I/O-79) ............................................................................................................... 90
Analog Output Options ................................................................................................................................................................... 90
ANALOG OUTPUT PARAMETERS (I/O-80 THROUGH I/O-223) ........................................................................................................................ 92
Analog Output Type ........................................................................................................................................................................ 92
Process and Output Value Low/High .............................................................................................................................................. 92
CCI I/O PARAMETERS .............................................................................................................................................................................. 92
8 – Fault Conditions ....................................................................................................................................................................... 93
TABLE KEY ............................................................................................................................................................................................. 93
9 – Spare Parts ............................................................................................................................................................................. 125
SPARE PARTS LIST .................................................................................................................................................................................. 125
References ................................................................................................................................................................................... 127
Appendix A: Profibus-DP Modbus ................................................................................................................................................ 129
PROFIBUS-DP CONNECTION .................................................................................................................................................................... 129
PROFIBUS-DP INPUT DATA ..................................................................................................................................................................... 129
PROFIBUS-DP OUTPUT DATA .................................................................................................................................................................. 131
Glossary ....................................................................................................................................................................................... 133
COMPONENTS ...................................................................................................................................................................................... 133
18-Pulse Transformer ................................................................................................................................................................... 133
2-Position DC Landing Pad ............................................................................................................................................................ 133
3-Position AC Landing Pad ............................................................................................................................................................ 133
Card Cage ..................................................................................................................................................................................... 133
Computer Card .............................................................................................................................................................................. 133
Control Power Transformer .......................................................................................................................................................... 133
Converter ...................................................................................................................................................................................... 133
DC Bus Bar .................................................................................................................................................................................... 134
Disconnect Switch ......................................................................................................................................................................... 134
Dual Diode Module ....................................................................................................................................................................... 134
Ethernet Switch ............................................................................................................................................................................. 134
FOB ............................................................................................................................................................................................... 134
HMI ............................................................................................................................................................................................... 134
IGBT .............................................................................................................................................................................................. 134

9
Inner Air Filter ............................................................................................................................................................................... 134
Inverter ......................................................................................................................................................................................... 134
Inverter IO ..................................................................................................................................................................................... 134
Isolating CT ................................................................................................................................................................................... 135
Loop Power Supply Reactor .......................................................................................................................................................... 135
Loop Power Supply Transformer ................................................................................................................................................... 135
Main Contactor ............................................................................................................................................................................. 135
Main Contactor Relay ................................................................................................................................................................... 135
Modular Fan Assembly ................................................................................................................................................................. 135
Outer Air Filter .............................................................................................................................................................................. 135
Pole Filter ...................................................................................................................................................................................... 135
Power Cell ..................................................................................................................................................................................... 135
Power Cell Back Panel ................................................................................................................................................................... 136
Power FOB .................................................................................................................................................................................... 136
Precharge Board ........................................................................................................................................................................... 136
Precharge Board Cover ................................................................................................................................................................. 136
Precharge Resistor ........................................................................................................................................................................ 136
Rectifier Module ........................................................................................................................................................................... 136
SD Card ......................................................................................................................................................................................... 136
Shunt Trip Relay ............................................................................................................................................................................ 136
Snubber Assembly ......................................................................................................................................................................... 136
Surge Arrestor ............................................................................................................................................................................... 136
Thermal Switch Isolation Receiver Board ..................................................................................................................................... 137
Thermal Switch Isolation Transmitter Board ................................................................................................................................ 137
CONCEPTS............................................................................................................................................................................................ 137
Arm ............................................................................................................................................................................................... 137
ATL ................................................................................................................................................................................................ 137
Control Power ............................................................................................................................................................................... 137
Front End ...................................................................................................................................................................................... 137
Ground Fault ................................................................................................................................................................................. 137
Look Ahead ................................................................................................................................................................................... 138
Loop Power Supply........................................................................................................................................................................ 138
Low Voltage .................................................................................................................................................................................. 138
Medium Voltage ........................................................................................................................................................................... 138
Precharge ...................................................................................................................................................................................... 138
VFD ............................................................................................................................................................................................... 138
Revision History ........................................................................................................................................................................... 140

M2L 3000 Series VFD
10

1 - Introduction
11
1 - Introduction
Benshaw personnel are available to answer all inquiries including information regarding start-up services and on-site train-
ing. Refer to the following pages for contact information.
Documentation Benshaw can provide all customers with:
 User Guides
 Drawings / Wiring Diagrams
Drawings are available on CD / DVD or via e-mail by contacting Benshaw Customer
Service.
On-Line Documenta-
tion
All MVVFD documentation is available on-line at www.benshaw.com.
Replacement Parts Spare and replacement parts can be purchased from Benshaw Technical Support.
Publication History Refer to the inside back cover.
Warranty Benshaw provides a standard 5 Year factory warranty on the M2L 3000 MVVFD Sys-
tem.
Contacting Benshaw Information about all Benshaw products and services is available on the internet at
www.benshaw.com, or by contacting Benshaw at one of the following offices:
Benshaw Corporate Headquarters Benshaw Canada
615 Alpha Drive
Pittsburgh, PA 15238
550 Bright Street East
Listowel, Ontario N4W 3W3
Phone: [phone]
Tech Support: 1-800-203-2416
Fax: [phone]
Phone: [phone]
Tech Support: 1-877-291-5112
Fax: [phone]
Technical support is available by contacting Benshaw Customer Service at any of the
above telephone numbers. A service technician is available Monday through Friday from
8:00 a.m. to 5:00 p.m. EST.
NOTE: An on-call technician is available after normal business hours and on week-
ends. Call Benshaw and follow the recorded instructions.
To help assure prompt and accurate service, please have the following information
available when contacting Benshaw:
 Name of Company
 Telephone number where the caller can be contacted
 Fax number of caller
 Benshaw product name
 Benshaw model number
 Benshaw serial number
 Name of product distributor
 Approximate date of purchase

A brief description of the application

M2L 3000 Series VFD
12
System Design Features
Compact Modular Design  Simplistic component arrangement with minimal total part count compared to
competitive offerings
 Unique modular power inverter
o Voltage requirements met by configuring standard IGBT cells
o Self-healing film capacitors that do not need reforming, superior to
common electrolytics
o Field maintenance and repair using pre-assembled, pre-tested power
cells
o Internal communication through high-speed fiber optics using Ethernet
protocol for high noise immunity and high bandwidth
Installation Flexibility  Patented topology that enables extended separation of converter and inverter
sections
 Uses a standard input transformer in the converter that can accommodate a
wide range of input voltages (480 - 13.8 kV)
 Interconnection using standard high-voltage cable
 Reduced heat load and space requirements in environmentally-conditioned
equipment rooms with a remotely located converter
 Customer sourcing of the transformer (per Benshaw’s specification)
 Operation directly from customer DC bus (per Benshaw’s specification)
 Remote or direct mounted HMI and optional controls
Robust Control Architecture  Modern Control Platform
 Distributed control with intelligent power cells
 Ultra-fast dual core processor for high-speed processing and expansion capa-
bility
 Industry-standard card cage
o Front access for easy removal and replacement
o Low Voltage Differential Signaling backplane - EMI resistant
 Industry standard field buses and communication protocols
 Profibus DP, Modbus TCP/IP, http, Ethernet IP, DeviceNet, via built in compo-
nents or industrial gateways
 Benshaw Connect for monitoring, parameter setting, and review of event logs
at the drive or over the internet via optional modem
Arc Flash Resistant Design  Arc flash footprint inherently lower
o Utilizes distributed energy storage
o No centralized bulk storage capacitors
o Optical arc flash detection in each power cell
o Offending cell is immediately reported to the control system
 Fault currents greatly reduced compared to other VFDs
o Converter will not feed energy into faults
 Increased user safety work envelope
o Remote control via HMI, industrial gateway, digital and analog I/o, or
Benshaw Connect PC tool

1 - Introduction
13
User Interface  Intuitive, user-friendly touch screen
 No need to remember multi-use key assignments used on other low-end user
interfaces
 Benshaw Connect Tool Suite
o Application allows for seamless connectivity between a PC and the drive
o Easy to use configuration and diagnostic tool
o Windows-based tool for use on Windows XP, Windows 7 and Windows 10
Energy Efficiency  Unique modular inverter design has improved efficiency over Cascaded H-
Bridge and Neutral Point Clamped (NPC) inverter designs.
 Uses the latest in efficient IGBT designs for minimum losses and maximum
performance.
 Inverter efficiency >99% over a wide speed range and wide load range
 Modular inverter design allowing the input converter to operate more effi-
ciently than other inverter designs reducing losses
 No efficiency reducing output transformers or output filters are required
 Input power supply power factor of ≥0.95 minimizes losses in the power sup-
ply and input wiring
Energy Savings  Shaft power of motor driven equipment (fans, pumps, blower) is proportional
to the cube of the rotational speed
 By design, VFDs improve efficiency at low speeds
 Considerable energy savings can be achieved by outfitting motors with VFDs,
as the speed can be adjusted to match the required load

M2L 3000 Series VFD
14
Part Number Definitions
UL Applicable Base Part Numbers:

1 - Introduction
15
 NOTE: Only the 260A and 300A models are presently available as UL listed models.

M2L 3000 Series VFD
16

2 - Specifications
17
2 - Specifications
General Specifications
Inverter Output –
Variable Torque:
Rated Output Power Up to 9 MW
Output Voltage 0 – 7200 Volts
Output Frequency (Min/Max) 0.1 – 300 Hz
Rated Output Currents Available 130A, 260A, 300A, 440A, 550A, 660A, 770A
Required Auxiliary Supply 230 VAC (-0%/+10%), 60 Hz
Converter Input: Rated Supply Voltage 480 – 13.8 kV
Rated System Frequency 50 – 66 Hz
Input Distortion Meets IEEE 519 when using 18-pulse or
greater rectifier system
Voltage Variations Steady State: +/- 10%
Transient State: +10%, -30% for 30 Line Cycles
Frequency Variations Steady State: 95 - 105%
Transient State: +/-5% / sec
Environmental
Conditions
Ambient Temperature Min. 0
o
C (no frost), Max. 40
o
C
Humidity 95%, no condensation
Air Quality No corrosive gasses or semi-conductive dust
Pollution IEC 61010-1 and UL 840 Degree 2
IEC 60664-3 (Optional)
Seismic IBC-2006 (3G on stiff soil)
Altitude 1,000 meters
4,000 meters derated operation

M2L 3000 Series VFD
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Cooling System Cooling Method
 Inverter/Converter
 Fans Designed for N-1
Redundancy
Forced Air
Fans Designed for N-1 Redundancy
Heat Loss at Full Load (max)
 Inverter
 Converter
<1% Full Load kW
<2% Full Load kW
Construction Power Connection Entry Bottom or Top
Power Connection Type
 Inverter
 Converter
Cables
Cables
Auxiliary Cable Entry Bottom or Top
Lifting Provisions Integral channel slots in bottom cabinet frames
Minimum Clearance
(Front x Back x Sides x Above) 36 x 0 x 0 x 36 inches

2 - Specifications
19
Electrical Ratings – 300A Unit
Terminal Points and Functions
Table 1: Converter Power Wiring Terminals
Function Terminal Description
AC Line Power Input H1 (L1/R) 3 Phase AC Line Power to Con-
verter (Transformer Terminals)
4160VAC 260A 50/60Hz.
H2 (L2/S)
H3 (L3/T)
Chassis Ground CG Ground Input
DC Power Output DC (+) DC Power to Inverter
6300VDC 292A
DC (-)
AC Control Power Input FU10 (L) Single Phase AC Control Power
from Inverter (for Fans)
230VAC 20A 50/60Hz.
FU11 (N)
Table 2: Converter Control Wiring Terminals
Function Terminal Description
Control Wiring to / from Converter TB1-6 (relay common) 115VAC from Inverter
TB1-6TW (relay NC contact) 3A 125VAC
TB1-6TF (relay NC contact)
TB1-6CW (relay NC contact)
TB1-6CF (relay NC contact)
Table 3: Inverter Power Wiring Terminals
Function Terminal Description
DC Bus Power Input DC (+) DC Bus Power from Converter
6300VDC 292A
DC (-)
Ground CG Chassis Ground
AC Motor Power Output T1 3 Phase AC Power to Motor
0 to 4160VAC 300A
0 to 60Hz. PWM
T2
T3
AC Control Power Input TB1-4 (L) Single Phase AC Control Power to
Inverter
230VAC 40A 50/60Hz.
TB1-5 (N)
TB1-GND
AC Control Power Output TB2-4D
TB2-5D
Single Phase AC Control Power to
Converter (for Fans)
230VAC 20A 50/60Hz.

M2L 3000 Series VFD
20
Electrical Ratings – 260A unit
Terminal Points and Functions
Table 4: Converter Power Wiring Terminals
Function Terminal Description
AC Line Power Input H1 (L1/R) 3 Phase AC Line Power to Con-
verter (Transformer Terminals)
4160VAC 230A 50/60Hz.
H2 (L2/S)
H3 (L3/T)
Chassis Ground CG Ground Input
DC Power Output DC (+) DC Power to Inverter
6300VDC 259A
DC (-)
AC Control Power Input FU10 (L) Single Phase AC Control Power
from Inverter (for Fans)
230VAC 20A 50/60Hz.
FU11 (N)
Table 5: Converter Control Wiring Terminals
Function Terminal Description
Control Wiring to / from Converter TB1-6 (relay common) 115VAC from Inverter
TB1-6TW (relay NC contact) 3A 125VAC
TB1-6TF (relay NC contact)
TB1-6CW (relay NC contact)
TB1-6CF (relay NC contact)
Table 6: Inverter Power Wiring Terminals
Function Terminal Description
DC Bus Power Input DC (+) DC Bus Power from Converter
6300VDC 259A
DC (-)
Ground CG Chassis Ground
AC Motor Power Output T1 3 Phase AC Power to Motor
0 to 4160VAC 260A
0 to 60Hz. PWM
T2
T3
AC Control Power Input TB1-4 (L) Single Phase AC Control Power to
Inverter
230VAC 40A 50/60Hz.
TB1-5 (N)
TB1-GND
AC Control Power Output TB2-4D
TB2-5D
Single Phase AC Control Power to
Converter (for Fans)
230VAC 20A 50/60Hz.