Siemens PERFECT HARMONY GENIII/E Series User manual

Manual Number: A1A19000405A
Version 1.3
June 2009
Siemens Energy & Automation, Inc.
Large Drives A
500 Hunt Valley Road, New Kensington, PA, USA, 15068
Phone: [phone] Customer Support Phone: [phone] (24-hours)
Fax: [phone] Customer Support Web: www.siemens.com/automation/support-request
Web: www.siemens.com Customer Support E-mail: [email protected]
USER’SMANUAL
FOR
AIR COOLED
PERFECT HARMONY
GENIII/ESERIES
ADJUSTABLE SPEED AC MOTOR DRIVES
WITH NEXT GENERATION CONTROL
https://www.robiconperfectharmony.com/

For technical assistance and Field Service emergency support in the area nearest to you, please call the s
1.800.333.7421 toll-free number.
Version History
©2009 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of s LD A
Version 1.0 (original) August 2003
Version 1.1 October 2003
Version 1.2 (ECO - 79B92611) (ECR - 13140) September 2008
Version 1.3 (ECO - 79C18180) (ECR - 13710) June 2009

Perfect Harmony GENIII/e User’s Manual Table of Contents
Table of Contents
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Safety Precautions and Warnings...................................................................................iii
About This Manual ...........................................................................................................v
Separation of Manuals.............................................................................................v
Reference Tools.......................................................................................................v
Conventions Used in this Manual ..........................................................................vi
Chapter 1: Introduction.................................................................................................1-1
Introduction to the Perfect Harmony....................................................................1-1
Clean Power Input.........................................................................................1-1
High Power Factor and Nearly Perfect Sinusoidal Input Currents ...............1-2
Nearly Perfect Sinusoidal Output Voltages ..................................................1-2
Features Overview................................................................................................1-4
Specifications .......................................................................................................1-5
Chapter 2: Hardware Components ..............................................................................2-1
Hardware Configuration.......................................................................................2-1
Transformer Section......................................................................................2-3
Customer I/O Section....................................................................................2-7
Cell and Control Sections (GENIII Cell Specifications) ..............................2-8
Cell Bypass Option .....................................................................................2-16
The Cell Control System....................................................................................2-16
The Master Control System................................................................................2-16
The Power Circuit ..............................................................................................2-21
Monitoring of Input Power Quality.............................................................2-21
Chapter 3: The Keypad and Display Interface............................................................3-1
Introduction..........................................................................................................3-1
The Keypad ..........................................................................................................3-1
Fault Reset Key.............................................................................................3-2
Automatic Key..............................................................................................3-3
Manual Stop Key...........................................................................................3-3
Manual Start Key ..........................................................................................3-3
The 0-9 Key...................................................................................................3-4
The Enter/Cancel Key...................................................................................3-7
Shift Function Keys.......................................................................................3-7

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Arrow Keys...................................................................................................3-8
Diagnostic Indicators ..................................................................................3-12
The Display.................................................................................................3-13
Menu Descriptions .............................................................................................3-18
Motor Menu (1) Options.............................................................................3-22
Drive Menu (2) Options..............................................................................3-27
Stability Menu (3) Options..........................................................................3-36
Auto Menu (4) Options...............................................................................3-42
Main Menu (5) Options...............................................................................3-53
Log Control Menu (6) Options ...................................................................3-56
Protect Menu (7) Options............................................................................3-58
Meter Menu (8) Options..............................................................................3-61
Communications Menu (9) Options............................................................3-65
Menu Setup for Multiple Configuration Files (Slaves)...............................3-69
Appendix A: Glossary of Terms...................................................................................A-1
Appendix B: Commonly Used Abbreviations.............................................................B-1
Notes ...............................................................................................................................N-1
Reader Comments Form...............................................................................................R-1
Startup/Warranty Registration and Service Solutions.............................................W-1

Perfect Harmony GENIII/e User’s Manual Safety Precautions and Warnings
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Perfect Harmony drives are designed with considerable thought to personal safety. However, as with any piece of
high power equipment, there are numerous internal connections that present potentially lethal voltages. In addition,
some internal components are thermally hot to the touch. Follow the warnings below when working in or near the
Perfect Harmony system.
Safety Precautions and Warnings
Danger - Electrical Hazards!
•Always follow the proper lock-out/tag-out procedures before beginning any maintenance or trouble-
shooting work on the drive.
•Always follow standard safety precautions and local codes during installation of external wiring. Pro-
tective separation must be kept between extra low voltage (ELV) wiring and any other wiring as spec-
ified in IEC61800-5-1.
•Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses. Also,
always work with another person present.
•Always use extreme caution when handling or measuring components that are inside the enclosure. Be
careful to prevent meter leads from shorting together or from touching other terminals.
•Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements
(that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the
instrument).
•Never assume that switching off the input disconnect will remove all voltage from internal compo-
nents. Voltage is still present on the terminals of the input disconnect. Also, there may be voltages
present that are applied from other external sources.
•Never touch anything within the Perfect Harmony cabinets until verifying that it is neither thermally
hot nor electrically alive.
•Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points
beneath the shields.
•Never run the drive with cabinet doors open. The only exception is the control cabinet which contains
extra low voltages (ELV).
•Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the Perfect Harmony sys-
tem.
•Never connect or disconnect any meters, wiring, or printed circuit boards while the drive is energized.
•Never defeat the instrument’s grounding.
•Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A qualified
individual is “one familiar with the construction and operation of the equipment and the hazards
involved.”
•Hazardous voltages may still exist within the Perfect Harmony cabinets even when the disconnect
switch is open (off) and the supply power is shut off.

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Additional safety precautions and warnings appear throughout this manual. These important messages should be
followed to reduce the risk of personal injury or equipment damage.
∇∇∇
Warning!
•Always comply with local codes and requirements if disposal of failed components is
necessary (for example, CPU battery, capacitors, etc.).
•Always ensure the use of an even and flat truck bed to transport the Perfect Harmony drive system.
Before unloading, be sure that the concrete pad is level for storage and permanent positioning.
•Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the
drive system. Dropping the cabinet or lowering it too quickly could damage the unit.
•Never disconnect control power while medium voltage is energized. This could cause
severe system overheating and/or damage.
•Never store flammable material in, on, or near the drive enclosure. This includes
equipment drawings and manuals.
•Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure
that the fork truck tines fit the lifting tubes properly and are the appropriate length.
•During operation, the nominal weighted sound pressure level can possibly exceed 70 dB at a distance
of 1 meter from the drive.
ESD Sensitive Equipment!
•Always be aware of electrostatic discharge (ESD) when working near or touching components inside
the Perfect Harmony cabinet. The printed circuit boards contain components that are sensitive to
static electricity. Handling and servicing of components that are sensitive to ESD should be done only
by qualified personnel and only after reading and understanding proper ESD techniques. The follow-
ing ESD guidelines should be followed. Following these rules can greatly reduce the possibility of
ESD damage to PC board components.
•Always transport static sensitive equipment in antistatic bags.
•Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-style plunger
or copper braid when desoldering.
•Make certain that anyone handling the Perfect Harmony printed circuit boards is wearing a properly
grounded static strap. The wrist strap should be connected to ground through a 1 megohm resistor.
Grounding kits are available commercially through most electronic wholesalers.
•Static charge buildup can be removed from a conductive object by touching the object to a properly
grounded piece of metal.
•When handling a PC board, always hold the card by its edges.
•Do not slide printed circuit boards across any surface (e.g., a table or work bench). If possible, per-
form PCB maintenance at a workstation that has a conductive covering that is grounded through a 1
megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is
an excellent substitute.
•Avoid plastic, Styrofoam™, vinyl and other non-conductive materials. They are excellent static gen-
erators and do not give up their charge easily.
•When returning components to Siemens LD A, always use static-safe packing. This limits any fur-
ther component damage due to ESD.

Perfect Harmony GENIII/e User’s Manual About This Manual
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Separation of Manuals
This manual is one component of a series of manuals intended for use with the Perfect Harmony series of adjustable
speed AC motor drives. Each part in this series is for use by individuals having unique job functions and
qualifications. The manuals in this series are listed below:
• Perfect Harmony GENIII/e Installation Manual (A1A19000403A)
• Perfect Harmony GENIII/GENIII/e Startup and Advanced Topics Manual(A1A19000404A)
•Perfect Harmony GENIII/e User’s Manual (A1A19000405A)
The Installation Manual provides a brief overview of the product, including a hardware overview and important
safety issues. The steps leading up to and including the installation of the drive are discussed in detail in this manual.
The Startup and Advanced Topics Manual is intended to address the more technical aspects of drive setup,
configuration, and operation. This manual includes detailed descriptions of all parameters, functions, and pick list
menu items. Software setup and startup procedures are also included. Advanced topics such as the theory of
operation, technical specifications, system programming, compiler and reverse compiler software operation,
uploading and downloading functions, and other application and operation issues are discussed.
The User’s Manual is for use by operators of the drive. This manual contains a brief overview of the product,
including a hardware overview of the external components of the drive and basic safety precautions. The keypad and
display interface is explained in detail. A parameter listing is provided for reference. A troubleshooting and
maintenance section is also provided in this manual to help the operator diagnose and correct any potential problems
that may occur, and reduce the potential for future problems through inspections and regular maintenance.
All manuals in this series contain a glossary of terms, a list of commonly used abbreviations, and other reference
tools. In addition, a readers’ comments form is provided. Please complete these forms and return them to us.
Monitoring your feedback allows us to continue to exceed your expectations and provide complete, effective, easy to
use product documentation.
Reference Tools
Many steps have been taken to promote the use of this manual as a reference tool. Reference tools include the
following:
• A thorough table of contents for locating particular sections or subsections.
• Chapter number thumb nails in the outer margins for easy location of chapters.
•Special text styles are applied to easily differentiate between chapters, sections, subsections, regular text,
parameter names, software flags and variables, and test points.
•A comprehensive index.
• A glossary of terms and a list of commonly used abbreviations.
If you have any comments or suggestions to improve the organization or increase the usability of this manual, please
complete the Readers’ Comments Form located at the end of this manual and return it to Siemens LD A Document
Control.
About This Manual

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Conventions Used in this Manual
The following conventions are used throughout this manual:
• This manual is for use with the CE-marked Perfect Harmony product line.
• The terms “Perfect Harmony,” “VFD,” “variable frequency drive,” and “drive” are used interchangeably
throughout this manual.
• Chapter numbers are highlighted in the outer margins to facilitate referencing (see margin).
• Test points and terminal block designations are shown in uppercase, boldface, 8 pt. Arial fonts (e.g., TB1A).
• In the index, locator page numbers appear in regular type faces for standard index references (e.g., shown in
an italic type face (e.g., 6-24). For index references that correspond to items found in figures and
illustrations, the locator page numbers are shown in a boldface type face (e.g., 3-3). Illustrations that also
appear in tables have locator page numbers that are both boldface and italic (e.g., 6-16)
• The symbol “∇ ∇ ∇” is used to mark the end of the chapter.
∇ ∇ ∇
*Note: Hand icons in the left margin alert readers to important operational or application information that
may have special significance. The associated text is enclosed in a border for high visibility.
Attention! Attention icons in the left margin alert readers to important safety and operational
precautions. These notes warn readers of potential problems that could cause equipment damage or
personal injury. The associated text is enclosed in a border for high visibility.
Caution - Electrical Hazard! Electrical hazard icons in the outer margins alert readers to important
safety and operational precautions. These notes warn readers of dangerous voltages, potential safety
hazards, or shock risks that could be life threatening. The associated text is enclosed in a border for high
visibility.
ESD Warning! These icons in the left margin alert readers to static sensitive devices. Proper
electrostatic discharge precautions should be taken before proceeding or handling the equipment.

Perfect Harmony GENIII/e User’s Manual Introduction
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1.1 Introduction to the Perfect Harmony
The Perfect Harmony is a series of pulse-width modulated, variable frequency AC motor drives designed and
manufactured by Siemens LD A. The Perfect Harmony drive system addresses the following power quality issues:
• Providing clean power input
• Providing a high power factor
• Providing nearly perfect sinusoidal output.
1.1.1 Clean Power Input
The Perfect Harmony drive series meets the most stringent IEEE 519-1992 requirements for voltage and current
harmonic distortion, even if the source capacity is no larger than the drive rating. This series protects other on-line
equipment (such as computers, telephones, and lighting ballasts) from harmonic disturbances. Perfect Harmony also
prevents “cross talk” with other variable speed drives. Clean power input eliminates the need for time-consuming
harmonic/resonance analyses and costly harmonic filters. Figure 1-1 illustrates harmonic distortion waveforms for a
typical 6-pulse, a typical 12-pulse, and the Perfect Harmony series drive.
Figure 1-1: Harmonic Distortion Wave Form Comparisons (6-pulse, 12-pulse, and Perfect Harmony)
Total harmonic distortion of the source current is 25% for the 6-pulse, 8.8% for the 12-pulse, and 0.8% for the Perfect
Harmony. The corresponding voltage distortions with a typical source impedance are 10%, 5.9%, and 1.2%,
respectively.
CHAPTER
1Introduction
*Note: The above comparisons were done using a typical 1000 Hp current source drive (6-pulse
and 12-pulse modes), and a Perfect Harmony series drive operating from an 1100 kVA, 5.75%
impedance source.
Source Current Source Current Source Current
Source Voltage Source Voltage Source Voltage
Typical 6-pulse
Input Waveform Typical 12-pulse Input Waveform Perfect Harmony Series Input Waveform

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1.1.2 High Power Factor and Nearly Perfect Sinusoidal Input Currents
Power factor is a measure of the fraction of current that produces real power to the load. Typically, power factor is
given as a percentage. A high power factor VFD (e.g., 95%) makes much better use of its input line current demand
in producing real power to the motor than a VFD operating at a low power factor (e.g., 30%). VFDs having a low
operating power factor often generate square-wave-shaped line currents. This can lead to harmonics and other
associated resonance problems.
The Perfect Harmony series draws nearly perfect sinusoidal input currents having a power factor that exceeds 95%
throughout the entire speed range without the use of external power factor correction capacitors. This eliminates
utility penalties for power factor and demand charges, and improves voltage regulation. In addition, feeders, breakers,
and transformers are not overloaded with reactive power. Low speed applications specifically benefit from the
Perfect Harmony series because a high and stable power factor is maintained throughout the entire speed range using
standard induction motors. Figure 1-2 compares graphs of power factor versus percent speed for the Perfect Harmony
series and a typical phase-controlled SCR drive.
Figure 1-2: Comparison of Perfect Harmony and a Typical Phase-Controlled SCR Drive
1.1.3 Nearly Perfect Sinusoidal Output Voltages
The design of the Perfect Harmony series of variable frequency drives inherently provides a sinusoidal output without
the use of external output filters. This means that the drive provides a low-distortion output voltage waveform that
generates no appreciable audible motor noise. In addition, there is no need to derate motors (the drive can be applied
to new or existing 1.0 service factor motors). In fact, Perfect Harmony drives eliminate harmful VFD-induced
harmonics that cause motor heating. Similarly, VFD-induced torque pulsations are eliminated (even at low speeds),
thereby reducing the stress on mechanical equipment. Common mode voltage stress and dV/dt stress are also
minimized. A typical graph of the output current from a Perfect Harmony drive is illustrated in Figure 1-3.
Figure 1-3: Nearly Sinusoidal Wave Form of the Output Current from a Perfect Harmony Drive
100
80
90
70
60
50
40
30
20
10
Percent Speed
Phase -
controlled
SCR Drive
Perfect Harmony
Series Drive
20 27 33 40 47 53 60 67 73 80 87 93 100
PercentPow
erFactor

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The cabinet configurations of Perfect Harmony drives vary based on the horsepower of the drive, the number and
type of cells, and other factors. However, cabinet configurations can generally be divided into two broad categories:
• GEN III style (shown in Figure 1-4)
• GEN III/e style (shown in Figure 1-5)
Figure 1-4: Typical 4160V (Left) and 6600V (Right) Gen III Perfect Harmony VFDs
Figure 1-5: Typical 4160V (Left) and 6600V (Right) Gen III/e Perfect Harmony VFDs
These two styles are discussed in Chapter 2: Hardware Components.

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1.2 Features Overview
Additional features of the Perfect Harmony drive include the following:
• Redundant cooling blowers
• High efficiency
• Reliability
• Modular construction
• Surge arrestors
• Fiber optic control circuitry
• Soft start protection
• Multi-motor operation
• Trip-free operation
• Dual performance operation modes
• Undervoltage ride-through
• Spinning load restart
• Transparent cell bypass
• PC tool interface
• Power cell check
• Cell back-up
• Serial port
• Reports capabilities
• Micro PLC capabilities
• Keypad and English message display
• On-line diagnostics
• Digital display module
• Advanced diagnostics
• On-line operation while tuning
• Industry standard communications
• Dual frequency braking
• Auto-tuning
• Input monitoring

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1.3 Specifications
Table 1-1 lists common electrical and mechanical specifications for all standard Perfect Harmony systems. Note that
Perfect Harmony specifications may be changed without notice.
Table 1-1: Common Specifications for Standard Perfect Harmony Systems
∇∇∇
Item Description
hp range GEN III: Up to 3,000 Hp at 6,300V
GEN III/e: Up to 8,000 Hp at 6,600V
Input line voltages 2.2 kV, 3.0 kV, 3.3 kV, 4.1 kV, 4.8 kV, 6.0 kV, 6.6 kV,6.9 kV,
7.2 kV, 8.4 kV, 10.0 kV, 11.0 kV, 12.0 kV, 12.5 kV, 13.2 kV,
and 13.8 kV.
Input voltage tolerance +10%, -5% from nominal 3-phase at rated output
Input power factor 0.95 above 10% load
Output line voltages 2.4 kV, 3.3 kV, 4.16 kV, 4.8 kV, 6.0 kV, 6.6 kV,6.9 kV, and
7.2 kV
Output frequency drift ±0.5%
Speed range 0.5 - 330 Hz (motor dependent)
Overload capability A function of the installed type of cell
Accel/decel time range 0.5 - 3200 sec (load dependent)
Output torque 15 - 139 Hz rated torque; 3 - 14 Hz and 140 - 330 Hz der-
ated torque
Enclosure NEMA 1 ventilated, IP31
Ambient temperature 0 - 40°C
Storage temperature
(System w/o Cells) - 40 to 70°C
Storage temperature
(Cells*) -55 to 45°C
Humidity 95% non-condensing
Altitude Up to 3300 feet. Above 3300 feet require derating.
Dust contamination <100 micron 2 6.5 mg/cu. ft.
Gas contamination <4 PPB reactive halides and sulfides
*Note: * Non-energized cells should not be stored at more than 45°C to preserve reliability of
Filter Capacitors. Non-energized cells stored for more than two (2) years should be reformed per
procedure indicated in Section 3-12 of this manual.

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Perfect Harmony GENIII/e User’s Manual Hardware Components
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2.1 Hardware Configuration
Figure 2-1 depicts a typical GEN III style line-up in which each VFD normally consists of a single cabinet with
multiple sections. These sections, described below, are:
• The transformer section
• The custom I/O section
• The control section
• The cell section
Depending on the HP and voltage ratings, some GENIII systems may be shipped as a single unit in which the
Transformer and Cell Cabinet are integrated into on unit. Larger GENIII systems may be shipped so that the
Transformer and Cell Cabinet are split due to size and weight restrictions. In all GENIII systems, the input and output
connections are located in the Transformer Cabinet. The control section is a swinging panel that resides in the left
side of the cell cabinet.
Figure 2-2 depicts a typical GENIII/e style configuration in which each VFD of a Cell/Control cabinet connects to a
Transformer Cabinet. These sections, described below, are:
GENIII/e (which are higher current versions of GENIII systems) is always shipped so that the Transformer and Cell
Cabinets are separated. In these systems, the Output section is always on the left side of the cell cabinet (behind the
control panel) and the Input section is always in the Transformer Cabinet. The control section is a swinging panel that
resides in the left side of the Cell Cabinet.
CHAPTER
2Hardware Components

Hardware Components Perfect Harmony GENIII/e User’s Manual
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Figure 2-1: Typical GEN III-style VFDs
Transformer
Section
Single Point
Cooling for
Small Units
Transformer
Section
Customer Control Wiring
And Control Power Section
Control Section and
Access to Cell Cabinet
Blowers Air Intakes
(Do Not Block)
Customer Control
Wiring and Control
Power Section
Control
Section
and Access
to Cell
Section
Split Cooling for
Longer Lineup

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Figure 2-2: Typical GENIII/e style VFDs
2.1.1 Transformer Section
The Transformer Section of the Perfect Harmony drive contains the input power transformer. Input power wires enter
the drive through this section and output wires to the motor exit the drive through this section. The input and output
power wiring can enter and exit the drive from either the top or bottom of this section. In addition to the main multi-
secondary phase-shifting power transformer, the transformer section contains either one or more blowers (at the top
of the cabinet) used to cool the drive. Refer to Figure 2-3. Major components of the Transformer Section are
illustrated in Figure 2-3 and described in Table 2-1.
*Note: Input and output wiring enters the cabinet from the top or bottom of the transformer section.

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Figure 2-3: Typical Power Input Cabinet (Front, Door Removed, and Side Views)
Transformer
Section
Blower
Transformer

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Table 2-1: Field Connections and Major Components in the Transformer Section
Item Description
L1, L2, L3 Input power terminals
T1, T2, T3 Output power terminals
TI Multi-secondary, phase-shifting power transformer
T5 Control power transformer
F24 - F35 Control fuses
F21, F22 Blower fuses
F4, F5 Fuses
BM1 - BM5 Blower motor starters
CDS1 Control power disconnect switch
RA1 - RA4, RB1 - RB4, RC1 - RC4 Input and output voltage feedback resistors
CT4, CT5 Output current transformers
TB-120-CUS Customer wiring terminal strip
METERING Metering terminal strip
TB-ELV Low voltage terminal strip (4 - 20 mA signals, etc.)

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Figure 2-4: Field Connections and Major Components in the GEN III Transformer Section