WEG CFW-11M RB User manual

Frequency Inverter
CF W-11M RB
Motors | Automation | Energy | Transmission & Distribution | Coatings
User's Manual

Series: CFW-11M RB
Language: English
Document: 10000874747 / 02
Models: 600...2850 A / 380...480 V
470...2232 A / 500...600 V
427...2028 A / 660...690 V
REGENERATIVE
FREQUENCY
CONVERTER MANUAL
04/2019

Indice
Summary of Revisions
The information below describes the reviews made in this manual.
Versión Revision Description
- R00 First edition
- R01 Updating of the tables, notes and general revision
- R02 General revision

Index
1 SAFETY INSTRUCTIONS.............................................................. 1-1
1.1 SAFETY WARNINGS IN THE MANUAL .................................................... 1-1
1.2 SAFETY WARNINGS IN THE PRODUCT................................................... 1-1
1.3 PRELIMINARY RECOMMENDATIONS ...................................................... 1-2
2 GENERAL INSTRUCTIONS .......................................................... 2-1
2.1 ABOUT THE MANUAL ............................................................................ 2-1
2.2 TERMS AND DEFINITIONS ..................................................................... 2-1
2.3 ABOUT THE CFW-11M RB ...................................................................... 2-4
2.4 IDENTIFICATION LABELS FOR THE UC11 ............................................... 2-8
2.5 IDENTIFICATION LABELS FOR THE UP11 ............................................... 2-9
2.6 CFW-11M RB MODEL SPECIFICATION (SMART CODE) ........................... 2-9
2.7 RECEIVING AND STORAGE.................................................................. 2-10
3 INSTALLATION AND CONNECTION........................................... 3-1
3.1 INSTALLATION ENVIRONMENT ............................................................. 3-1
3.2 LIST OF COMPONENTS.......................................................................... 3-1
3.3 MECHANICAL INSTALLATION ................................................................ 3-3
3.3.1 Keypad Installation at the Cabinet Door or Command Panel
(Remote keypad) .................................................................................... 3-8
3.4 ELECTRICAL INSTALLATION ................................................................... 3-8
3.4.1 Pre-charge Circuit ........................................................................ 3-8
3.4.2 Bus Bars ...................................................................................... 3-10
3.4.3 DC Link Fuses.............................................................................. 3-10
3.4.4 General Connection Diagram and Layout ................................... 3-11
3.4.5 UP11 Connections....................................................................... 3-19
3.4.6 UC11 Connections ...................................................................... 3-23
3.4.7 Input Filter .................................................................................. 3-25
3.4.7.1 Basic Definitions.............................................................. 3-25
3.4.7.2 Type of Filters.................................................................. 3-26
3.4.7.3 Filter 1 ............................................................................ 3-26
3.4.7.4 Filter 2 ............................................................................ 3-27
3.4.7.5 Filter Type Selection ........................................................ 3-29
3.4.7.6 Filter Components........................................................... 3-30
3.4.8 Synchronism................................................................................ 3-34
3.4.9 Control Connections.................................................................... 3-36
3.4.10 Typical Control Connection........................................................ 3-40
3.5 INSTALLATION ACCORDING TO THE EUROPEAN DIRECTIVE OF
ELECTROMAGNETIC COMPATIBILITY ........................................................ 3-41
3.5.1 Conformal Installation ................................................................ 3-41
3.5.2 Standard Definitions ................................................................... 3-42
3.5.3 Emission and Immunity Levels..................................................... 3-43
3.5.4 External RFI Filters ...................................................................... 3-43
4 KEYPAD AND DISPLAY................................................................ 4-1
4.1 INTEGRAL KEYPAD - HMI - CFW11 ........................................................ 4-1
4.2 PARAMETERS ORGANIZATION............................................................... 4-3

Index
5 FIRST TIME POWER-UP AND START-UP ....................................... 5-1
5.1 PREPARATIONS FOR THE START-UP........................................................ 5-1
5.1.1 Procedures for the First Time Power-up/Start-up ........................... 5-1
5.2 START-UP ............................................................................................... 5-2
5.2.1 Password Setting in P0000 ............................................................ 5-3
5.2.2 Oriented Start-Up.......................................................................... 5-3
5.3 SETTING DATE AND TIME ...................................................................... 5-5
5.4 BLOCKING PARAMETERS MODIFICATION.............................................. 5-5
5.5 HOW TO CONNECT TO A PC ................................................................ 5-6
5.6 FLASH MEMORY MODULE...................................................................... 5-6
6 TROUBLESHOOTING AND MAINTENANCE ................................ 6-1
6.1 OPERATION OF THE FAULTS AND ALARMS............................................ 6-1
6.2 FAULTS, ALARMS, AND POSSIBLE CAUSES............................................. 6-2
6.3 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS .............................. 6-7
6.4 INFORMATION FOR CONTACTING TECHNICAL SUPPORT..................... 6-7
6.5 PREVENTIVE MAINTENANCE ................................................................. 6-8
6.5.1 Cleaning Instructions .................................................................. 6-10
7 ACCESSORIES............................................................................. 7-1
7.1 ACCESSORIES ........................................................................................ 7-1
8 TECHNICAL SPECIFICATIONS..................................................... 8-1
8.1 POWER DATA ......................................................................................... 8-1
8.2 ELECTRICAL / GENERAL SPECIFICATIONS.............................................. 8-4
8.2.1 Codes and Standards .................................................................... 8-4
8.3 MECHANICAL DATA............................................................................... 8-5

C F W -11M R B |1-1
1
Safety Instructions
1 SAFETY INSTRUCTIONS
This manual provides information for the proper installation and operation
of the regenerative frequency converter CFW-11M RB.
Only trained and qualified personnel should attempt to install, start-up,
and troubleshoot this type of equipment.
1.1 SAFETY WARNINGS IN THE MANUAL
The following safety warnings are used in this manual:
DANGER!
The procedures recommended in this warning have the purpose of protecting the user against dead,
serious injuries and considerable material damage.
ATTENTION!
The procedures recommended in this warning have the purpose of avoiding material damage.
NOTE!
The text intents to supply important information for the correct understanding and good operation
of the product.
1.2 SAFETY WARNINGS IN THE PRODUCT
The following symbols are attached to the product and require special attention:
Indicates a high voltage warning.
Electrostatic discharge sensitive components.
Do not touch them.
Indicates that a ground (PE) must be connected securely.
Indicates that the cable shield must be grounded.
Indicates a hot surface warning.

1-2 | CFW-11M RB
1
Safety Instructions
1.3 PRELIMINARY RECOMMENDATIONS
DANGER!
Only qualified personnel familiar with the CFW-11M RB regenerative frequency converter and
associated equipment should plan or implement the installation, start-up and subsequent maintenance
of this equipment.
These personnel must follow all the safety instructions included in this Manual and/or defined by
local regulations.
Failure to comply with these instructions may result in death, serious injury, and equipment damage.
NOTE!
For the purposes of this manual, qualified personnel are those trained and able to:
1. Install, ground, power-up and operate the CFW-11M RB according to this manual and the effective
legal safety procedures.
2. Use protection equipment according to the established regulations.
3. Provide first aid.
DANGER!
Always disconnect the main power supply before touching any electrical component associated to
the converter.
Several components can remain charged with high voltages and/or in movement (fans) even after
the AC power supply is disconnected or switched off.
Wait at least 10 minutes to assure a total discharge of the capacitors.
Always connect the equipment frame to the protection earth (PE) at the suitable connection point.
ATTENTION!
Electronic boards have components sensitive to electrostatic discharges. Do not touch directly
on components or connectors. If necessary, touch the grounded metallic frame before or use an
adequate grounded wrist strap.
Do not perform any withstand voltage test!
If necessary, consult WEG.
NOTE!
Regenerative frequency converter may interfere with other electronic equipment. In order to reduce
these effects, take the precautions recommended in the chapter 3 - Installation and Connection.
NOTE!
Read this manual completely before installing or operating the converter.

C F W -11M R B |1-3
1
Safety Instructions
ATTENTION!
When in operation, electric energy systems – such as transformers, converters, motors and
cables – generate electromagnetic fields (EMF), posing a risk to people with pacemakers or implants
who stay in close proximity to them. Therefore, those people must stay at least 2 meters away from
such equipment.

1-4 | CFW-11M RB
1
Safety Instructions

2
C F W -11M R B |2-1
General Instructions
2 GENERAL INSTRUCTIONS
2.1 ABOUT THE MANUAL
This manual presents how to install, to start-up, the main characteristics
and shows how to troubleshoot the most common problems of the
CFW-11M RB converter series.
For information on other functions, accessories and operation conditions
please refer to the following manuals:
ATTENTION!
The operation of this equipment requires installation instructions and detailed operation provided
in the user manual, programming manual and manuals/guides for kits and accessories. The
user manual and the parameters quick reference are supplied in a hard copy together with
the converter. The other manuals are available at www.weg.net. A printed copy of the files
available on WEG’s website can be requested at your local WEG dealer.
;Programming Manual, with a detailed description of the parameters and advanced functions of the
C F W -11M R B .
;I/O Expansion Module Manual.
2.2 TERMS AND DEFINITIONS
Regenerative Frequency Converter: three-phase switching frequency converter “boost type” (amplifier)
that converts the AC voltage from the power supply to a DC voltage (DC Link). It has the capability of
absorbing the energy of the power supply (AC) or to recover the energy back to the power supply, being
used as a DC voltage source to supply voltage to several output inverter.
Output inverter: frequency inverter fed by the DC link bus bar supplied by the regenerative converter. It
is responsible for the motor control.
Normal Duty Cycle (ND): converter duty cycle that defines the maximum continuous operation current
(Inom-ND) and overload current conditions (110 % for 1 minute). The ND cycle is selected by setting P0298
(Application) = 0 (Normal Duty (ND)). The inverter overload conditions are reflected in the regenerative
converter.
Inom-ND:converter rated current for use with the normal duty (ND) cycle.
Overload: 1.1 x Inom-ND / 1 minute.
Heavy Duty Cycle (HD): converter duty cycle that defines the maximum continuous operation current
(Inom-HD) and overload current conditions (150 % for 1 minute). The HD cycle is selected by setting P0298
(Application) = 1 (Heavy Duty (HD)). The inverter overload conditions are reflected in the regenerative
converter.
Inom-HD:converter rated current for use with the heavy duty (HD) cycle.
Overload: 1.5 x Inom-HD / 1 minute.

2
2-2 | CFW-11M RB
General Instructions
Current Imbalance (%):
Imbalance of power unit X - phase Y = IYX - IYAVG x 100
IYAVG
IYAVG = IY1 + IY2 + ... + IYN
N
Where:
N = number of power units.
IYN = phase current Y (U, V or W) of the N power unit (P0815 to P0829).
IYAVG = average current of phase Y.
Pre-charge Circuit: charges the DC bus capacitors with limited current, which avoids higher peak currents
at the converter power-up.
DC Bus: converter intermediate circuit; DC voltage obtained from the AC input voltage rectification or
from an external power supply; feeds the output IGBTs converter bridge.
Power modules U, V, and W: set of two IGBTs of the regenerative converter input phases R, S, and T.
IGBT: Insulated Gate Bipolar Transistor; basic component of the power modules U, V and W. The IGBT
works as an electronic switch in the saturated (closed switch) and cut-off (open switch) modes.
NTC: resistor which resistance value in ohms decreases proportionally to the temperature increase; used
as a temperature sensor in power modules.
HMI: Human Machine Interface: it is a device that allows the visualization and modification of the converter
parameters. The CFW-11 HMI presents keys for the regenerative converter control, navigation keys and a
graphic LCD display.
FLASH Memory: non-volatile memory that can be electronically written and erased.
RAM Memory: Random Access Memory (volatile).
USB: Universal Serial Bus; is a serial bus standard that allows devices to be connected using the ”Plug
and Play” concept.
PE: Protective Earth.
RFI Filter: Radio-Frequency Interference Filter for interference reduction in the Radio-Frequency range.
PWM: Pulse Width Modulation; pulsed voltage at the input of the regenerative converter.
Switching Frequency: frequency of the IGBTs switching, normally expressed in kHz.
General Enable: when activated, the converter controls the voltage at the DC bus. When deactivated,
this function immediately blocks the PWM pulses. The General Enable function may be controlled through
a digital input set to this function.
Heatsink: metal device designed to dissipate the heat generated by the power semiconductors.

2
C F W -11M R B |2-3
General Instructions
Amp, A: ampères.
°C: Celsius degree.
°F: Fahrenheit degree.
AC: alternated current.
DC: direct current.
CFM: Cubic Feet per Minute; unit of flow.
cm: centimeter.
ft: foot.
hp: horse power = 746 Watts; unit of power, used to indicate the mechanical power of electrical motors.
Hz: hertz.
in: inch.
kg: kilogram = 1000 grams.
kHz: kilohertz = 1000 Hertz.
l/s: liters per second.
lb: pound.
m: meter.
mA: miliampère = 0.001 Ampère.
min: minute.
mm: millimeter.
ms: millisecond = 0.001 seconds.
N.m.: newton meter; unit of torque.
rms: root mean square; effective value.
rpm: revolutions per minute; unit of speed.
s: second.
V: volts.
Ω: ohms.

2
2-4 | CFW-11M RB
General Instructions
2.3 ABOUT THE CFW-11M RB
The regenerative frequency converter is a bidirectional three-phase boost type AC/DC converter that
generates higher DC voltage than the line peak voltage. These converter are commonly known as AFE
(Active Front End) drives. The CFW-11M RB line utilizes the “RB” sulfix which states for Regenerative Braking
because it has the natural capacity of allowing the energy to flow from the converter to the power supply
when the motor is braking. The DC voltage generated by the regenerative converter is used to feed other
inverter power units that are controlling three-phase motors.
The CFW-11M RB regenerative converter is a high performance product that allows three-phase power
supply rectification with the following advantages:
;Low input current harmonic distortion.
;Capacity of recovering energy back to the power supply (regeneration) allowing high braking torque levels.
The CFW-11M RB line presents a modular structure with the possibility of assembling up to five power units
(UP11 - Books), one control unit (UC11) and interconnection cables. The control unit (UC11) is able to
control up to 5 (five) UP11’s.
The UP11 are directly feed via DC link bus bar and the UC11 is fed via the +24 Vdc power supply. Figure
2.1 shows an application sample.
The UP11 power units control is done by the UC11 control unit. The control unit is composed by the CFW-11M
RB control rack line, the IPS1 board and the CSR11 synchronism board. The IPS1 board exchange signals
with all UP11 units. The CSR11 synchronism board supervises the power supply, measuring the voltage values
and synchronizing the control.
U P11
Output
inverter
Filter
U P11
U P11
U C11 R B
C C11 R BC S R11 IPS1
Motor
Figure 2.1 - Configuration sample with 3 UP11

2
C F W -11M R B |2-5
General Instructions
The CFW-11M RB can be provided as a complete panel (AFW-11M RB) or as a panel mounting kit for
local assembly in a panel. The output inverter stage (CFW-11M) is needed for the mounting kit assembly.
The panel mounting kit is composed by the control unit set and the power units (UP11), which quantity
varies according to the CFW-11M RB model. The control unit set is composed by the control unit (UC11),
the cable set needed for the connection between the IPS1 board and the power units and the ribbon cable
to connect the IPS1 board to the CC11 RB board.
U P11
U P11
Capac.
Bank
Capac.
Bank
DC Bus Bar
Feedback
- voltage
- current
Pre-
Charge
Input
filter
Supply
220 V Ext.
Power section
PE
+
-
FLASH
memory
module
(Slot 5)
Digital
inputs
(DI1 to DI6)
IPS1 Electronics power supplies and
interface between power and control
USB
CSR
Control UC11
HMI
C C11R B
Control
board
with
CPU
32 bit
"RISC"
Analog outputs
(AO1 and AO2)
Digital outputs
DO1 (RL1) to
DO3 (RL3)
HMI (remote)
Accessories
I/O expansion
(Slot 1 - white)
Figure 2.2 - CFW-11M RB block diagram

2
2-6 | CFW-11M RB
General Instructions
NOTE!
Additional itens are need for the assembly of the complete unit, such as output inverter, DC fuses
in the DC link bus bar connection, external pre-charge circuit and filter.
NOTE!
It is not necessary to add a current transformer (CT) for output short circuit protection to the ground
since each UP11 module has its own internal protection.
Keypad
Front cover
Control rack
IPS1 shield
IPS1 shield base
IPS1 board - interface
between power and
control
Figure 2.3 - UC11 main components
DC Bus capacitors
IGBTs module
decoupling capacitors
Set of IGBTs modules
gate resistor board
gate driver board
DC Bus
Hall effect CT
Fan
Output reactor
PSB1 board – switched
mode power supply
CIM1 board – Interface
with the control
Figure 2.4 - UP11 main components

2
C F W -11M R B |2-7
General Instructions
U C11
U P11
UP
UN
VP
VN
WP
WN
N1
N2
N3
N4
N5
N6
C C11 R B
XC60
Keypad XC60
IPS1
XC40 XC40 CIM1
XC9
Power supply
24 Vdc(*)
External
supply
(*) Tolerance: ±10 %.
Current: 4 A.
Figure 2.5 - UP11: Connections between the IPS1 and the CIM1 interface boards
+UD
- UD
XP
XN
XC3 XC5
XC5
XC3
+ 15 V
+ 5 V
+ 20 V
PSB1
CIM1
XP
XN
+UD
- UD
Figure 2.6 - UP11: Connections between the CIM1 interface board and the PSB1 power supply board
CIM1
XC4A XC4AB
XC16BXC16A
XC33
Ext. 220 V
V5V4
Power Section Fans
Figure 2.7 - UP11: Connections between the CIM1 interface board and the fans

2
2-8 | CFW-11M RB
General Instructions
GDB5
XC4
XC1 XC2
CRG9
XC14
-UD +UD
TCU U
+UD
-UD
TCV V
XC2
CRG9
XC14
GDB5
XC4
XC1
GDB5
XC4XC1 XC2
CRG9
XC14
+UD
-UD
TCW W
XW
XC64W
XC14W
XC1W
XV
XC64V
XC14V
XC1V
CIM1
XU
XC64U
XC14U
XC1U
L1
(0,5 %) UOUT
VOUT
WOUT
1 2 3 4 5 8
10
11
11
11
10
10
10
11
11
11
10
10
1
1
2
2
3
3
4
4
5
5
8
8
10
11
11
11
10
10
Figure 2.8 - UP11: Connections between the CIM1 interface board, gate driver boards, modules and sensors for the output voltage and
output current
NOTE!
The synchronism connection diagram is presented at figure 3.46.
2.4 IDENTIFICATION LABELS FOR THE UC11
The UC11 identification label is located on the control rack.
WEG part number
Serial number
Manufacturig date
U C11 m o d e l
Figure 2.9 - UC11 identification label
Identification label
Figure 2.10 - Location of the identification label

2
C F W -11M R B |2-9
General Instructions
2.5 IDENTIFICATION LABELS FOR THE UP11
There are two identification labels, one located at the converter front cover and another inside the UP11, close
to the fans.
Rated input data (voltage, rated currents
for use with Normal Duty (ND) and Heavy
Duty (HD) cycles, frequency)
Current specifications for use with the
Heavy Duty (HD) cycle
Available certifications
Current specifications for use with the
Normal Duty (ND) cycle
U P11 M o d e l
Rated output data (voltage, number of
power phases, rated currents for use with
Normal Duty (ND) and Heavy Duty (HD)
cycles, overload currents for 1 min and 3 s,
and frequency range)
Maximum surrounding air
temperature
Manufacturing date
(24 corresponds to
week and I to year)
Serial number
WEG part number
Converter net weight
Figure 2.11 - UP11 identification label
Figure 2.12 - Location of the identification labels
2.6 CFW-11M RB MODEL SPECIFICATION (SMART CODE)
In order to specify the CFW-11M RB it is necessary to, fill in the desired voltage and current values in the
respective fields for the nominal supply voltage and the rated input current for normal duty (ND) cycle in
the smart code according to the example of the table 2.1.

2
2-10 | CFW-11M RB
General Instructions
Table 2.1 - Smart code
Converter Model Available Option Kits
Refer to Chapter 8 for the CFW-11M RB list
of models and for the complete technical
specifications
Refer to the chapter 7 for more
details on the options.
Example BR CFW11M 0470 T 5 O RB _ _ _ _ Z
Field
description
Market
identification
(defines
the manual
language and
the factory
settings)
WEG
CFW-11M
frequency
converter
series
Rated
current
for
Normal
Duty
(ND)
cycle
Number
of output
phases
Nominal voltage Option kit Braking Special
hardware
Special
software
Character
that
identifies
the end of
the code
Available
options
2 characters T =
three-
phase
4 = 380...480 V
5 = 500...600 V
6 = 660...690 V
O =
product
with
option kit
RB =
Regenerative
Braking
Blank =
standard
H1=
special
hardware
n°1
Blank =
standard
S1=
special
software
n°1
Ex.: CFW11M0470T5ORBZ corresponds to a CFW-11M RB regenerative braking converter, 470 A three-
phase, with power supply voltage from 500 V to 600 V. An converter for 380 / 480 V would be specified
as CFW11MXXXXT4ORBZ and for 660 / 690 V voltage it would be specified as CFW11MXXXXT6ORBZ
(where XXXX is replaced by the converter current). The possible options for the converter nominal current
in normal duty (ND) cycle are showed in the table 2.2, according to the rated input voltage.
Table 2.2 - Nominal currents at normal duty cycle (ND)
380 / 480 V 500 / 600 V 660 / 690 V
0600 = 600 A
1140 = 1140 A
1710 = 1710 A
2280 = 2280 A
2850 = 2850 A
0470 = 470 A
0893 = 893 A
1340 = 1340 A
1786 = 1786 A
2232 = 2232 A
0427 = 427 A
0811 = 811 A
1217 = 1217 A
1622 = 1622 A
2028 = 2028 A
2.7 RECEIVING AND STORAGE
The CFW-11M RB power units, as well as the control sets, are supplied packed in wooden boxes (refer to
the figure 2.14).
Figure 2.13 - Power unit packing
There are identification labels outside these boxes, the same as the ones fixed on the respective products.

2
C F W -11M R B |2-11
General Instructions
In order to open the box:
1. Put the control set box on a table with the help of two people; for the power units put the box on the
floor.
2. Open the wood crate.
3. Remove all the packing material (the cardboard or styrofoam protection) before removing the converter.
Check the following items once the converter is delivered:
;Verify that the product identification label corresponds to the model number on your purchase order.
;Inspect the product for external damage during transportation.
In case of any damage, immediately report it to the carrier responsible for delivering your product.
If the products are not installed immediately, store them in a clean and dry place (temperature between
-25 °C (-13 °F) and 60 °C (140 °F)) with a cover to prevent the contamination with dust.
ATTENTION!
Capacitor reforming is required if the converter or power units are stored for long periods of time
without power. Refer to the procedures in item 6.5 - table 6.3.
Figure 2.14 - Do not tilt the power units