Product manual
Installation - Maintenance
PowerMASTER™
M-Frame
Application:
Motor/Generator Control
Active front end
Microgrid
Type:
Liquid cooled AC/DC-Inverter
Protection class:
IP 67
visedo.com
PowerMASTERTM AC/DC Inverter
PMA­M
Installation ­ Maintenance
Product Manual
Manual PN 000376 rev. 1 isedo Oy
V
Lentokentäntie 44
53600 Lappeenranta
Finland
http://www.visedo.com
Product Manual PMA­M
Table of contents
1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1. Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1.2. Intended use of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. Product naming convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5. Conformity according to standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7. Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
1.8. Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9. Responsibility of the manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1. General safety statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Safety message signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3. Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.4. Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5. Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6. Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. Intended use of the electric device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2. System introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3. Connections and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4. Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. Type code and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
3.6. Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Design principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1. System design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.1. Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1.1. Recommended coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2. Cabling and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1. Supporting structure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2. Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5. Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. Receiving and unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3. Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
5.4. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
6.1. Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2. Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1. Allowed mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.2. Mounting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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6.2.3. Cooling connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3. Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
6.3.1. Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.1.1. High voltage connections (power) . . . . . . . . . . . . . . . . . . . . . . .
40
. . . . . . . . . . . . . . . . . . . . . . .
6.3.1.2. Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.1.3. Cable gland assembly and power line
connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
6.3.1.4. Extended power connections . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2. Low voltage connections (control and monitoring signals) . . . . . . . . . . . . . 50
6.3.3. Grounding connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
6.3.4. Pre­charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
7.1. Operation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
7.2. Condition monitoring during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
8.1. Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
8.2. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3. Cooling system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9. Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Aftersales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
11.1. Service policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.2. Service parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
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1. General information
This manual is the installation and maintenance manual for the PowerMASTER™
heavy­duty inverter.
1.1. Copyright
©Visedo Oy. All rights reserved.
No parts of this manual may be reproduced or transmitted in any form or by any
means, electrical or mechanical including photocopying, recording or by an
information storage or retrieval system, without permission in writing from the
publisher.
All specifications and contents of this manual are subject to change without notice.
1.2. Intended use of the manual
This manual contains instructions necessary to safely and properly handle, install and
maintain the electronic device. They should be brought to the attention of anyone who
installs or maintains the device or associated equipment.
All of the safety warnings and instructions in this book must be followed to prevent
injury to personnel or damage to property. Only qualified and authorized personnel,
familiar with health and safety requirements and national legislation, shall be permitted
to handle, install and maintain the device.
This manual must be kept for future reference during installation, operation and
maintenance.
This manual uses illustrations as examples only. Illustrations in this manual may not
necessarily reflect all system features.
1.3. Product naming convention
In this manual, Visedo® PowerMASTER™ family heavy­duty inverter is referred as
the electric device.
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The PowerMASTER™ series electric device is abbreviated as PMA. The next letter
indicates the mechanical size of the electric device.
The following naming convention is used to refer to device frame model:
PMA­M
In addition, the basic model code includes markings of the nominal power and the
option of the system.
Example: Model code PMA­M­250­S indicates that mechanical size is M, device
nominal power is 250 kW and the system option is S (small). The exact model
code is indicated in the rating plate.
Table 1. Visedo® PowerMASTER™ heavy­duty inverter model options.
Model number
Mechanical size
PMA­M­100­
M
Nominal power (kW)
100
System option
X(*
PMA­M­150­
M
150
X(*
PMA­M­200­
M
200
X(*
PMA­M­250­
M
250
X(*
PMA­M­300­
M
300
X(*
X(* = Product and system specific, S (small) or L (large). See information from the
device rating plate.
Figure 1.Visedo® PowerMASTER™ heavy­duty inverter naming convention.
owerMASTER™ has option for small systems (S) and large systems (L). Small
P
system option is typical for vehicle applications and large system option is standard in
marine applications because of the marine regulations.
Complete system should be looked when choosing the option as for example vehicle
system with many devices could also need the L­option to keep the isolation
resistance or Y­capacitors at reasonable level. In large and small system options,
there are difference in the isolation measurement resistance, DC­link discharge
resistor and Y­capacitor values as shown in the figure 2. and table 2..
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Figure 2. PowerMASTER™ M­frame S­ and L­systems schematics.
Table 2. PowerMASTER™ M­frame S­ and L­system component values.
System option
Small (S)
Large (L)
Component
Resistors R1 and R2 (isolation measurement)
Resistor R3 (discharge)
Capacitors C1 and C2 (Y­capacitors)
Capacitor C3
Isolation resistance from DC­link to enclosure
Resistors R1 and R2 (isolation measurement)
Resistor R3 (discharge)
Capacitors C1 and C2 (Y­capacitors)
Capacitor, C3
Isolation resistance from DC­link to enclosure
Value
12 MΩ
3.9 kΩ
330 nF
1 mF
6 MΩ
240 MΩ
39 kΩ
3.3 nF
1 mF
120 MΩ
I ndividual model code of the device may include additional markings of the selected
options. All options are marked after the primary model code. The exact model code is
indicated in the rating plate. To see all options available, visit http://www.visedo.com.
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indicated in the rating plate. To see all options available, visit http://www.visedo.com.
1.4. Declaration of conformity
1.5. Conformity according to standards
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1.5. Conformity according to standards
Visedo PowerMASTER™ electric devices have been designed in accordance with
the essential parts of the following directives and meet the requirements of the
standards:
Table 3. Applicable Directives and standards
Directive /
Standard
Automotive
Directive
2004/104/EC
Explanation
European Automotive EMC directive 2004/104/EC, adapting to
technical progress Council Directive 72/245/EEC relating to the radio
interference (electromagnetic compatibility) of vehicles and amending
Directive 70/156/EEC on the approximation of the laws of the Member
States relating to the type­approval of motor vehicles and their trailers.
Low Voltage Electrical equipment means any equipment designed for use with a
Directive
voltage rating of between 50 and 1000 V for alternating current.
2014/35/EC PowerMASTER™ electric devices are subject to the Low Voltage
(from
Directive 2006/95/EC or 2014/35/EC.
20.4.2016
onwards)
ISO 7637­
Road vehicles ­ Part 2: Electrical disturbances from conduction and
2:2011
coupling
ISO 7637­
Road vehicles ­ Part 3: Electrical disturbances from conduction and
3:2011
coupling
ISO 11452­ Road vehicles ­ Part 2: Component test methods for electrical
2:2011
disturbances from narrowband radiated electromagnetic energy.
ISO 11452­ Road vehicles ­ Part 4: Component test methods for electrical
4:2011
disturbances from narrowband radiated electromagnetic energy.
ISO 7637­
Road vehicles ­ Part 2: Electrical disturbances from conduction and
2:2011
coupling.
ISO 10605: Road vehicles ­ Test methods for electrical disturbances from
2008
electrostatic discharge.
ISO 16750
Road vehicles ­ Environmental conditions and testing for electrical and
electronic equipment. (B­H)­N­K­D­(A;D)­IP6K7.
CISPR25
Vehicles, boats and internal combustion engines ­ Radio disturbance
characteristics ­ Limits and methods of measurement for the
protection of on­board receivers.
1.6. Warranty
Visedo Oy offers warranty against defects in workmanship and materials for its
products for a period of twelve (12) months from commissioning or eighteen months
(18) from delivery (Incoterms­EXW), whichever occurs first.
In order for the warranty to be valid, the customer must follow the requirements of this
and all related documents, especially those set out in the product installation and
maintenance documents, as well as the applicable standards and regulations in force
in each country.
Defects arising from the improper or negligent use, operation, and/or installation of the
equipment, non­execution of regular preventive maintenance, as well as defects
resulting from external factors or equipment and components not
supplied/recommended by Visedo, will not be covered by the warranty.
The warranty will not apply if the customer at its own discretion makes repairs and/or
modifications to the equipment without prior written consent from Visedo.
1.7. Terms and abbreviations
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1.7. Terms and abbreviations
Following symbols, terms and abbreviations may exist in this manual. See Table 4.
Symbols and Table 5. Terms and Abbreviations.
Table 4. Symbols
Symbol
Variable
Unit
UDC
Direct current (DC) link voltage
V
Uac
Alternating current output voltage
V
In
Rated current
Arms
Pn
Rated power
kW
fin/out
Input / Output frequency
Hz
fswitch
Switching frequency
kHz
IPEAK
Overcurrent limit
A
Qc
Rated coolant liquid flow
l/min
Tc
Rated coolant liquid input temperature
°C
Tamb
Rated ambient temperature
°C
GND
Ground in electrical connections
R
Resistance
Ω
Table 5. Terms and Abbreviations
Term/ Abbreviation
Explanation
AC
Alternating current
DC
Direct current
MCB
Miniature circuit breaker
EMC
Electromagnetic compatibility
EMI
Electromagnetic interference
1.8. Trademarks
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1.8. Trademarks
Listed below are Visedo Oy trademarks. All other product and company names
contained herein are the property of their respective owners.
VISEDO® is a trademark of Visedo Oy company.
PowerDRUM™ is the trademark of the Visedo electric machine.
PowerDISK™ is the trademark of the Visedo electric machine.
PowerMASTER™ is the trademark of the Visedo heavy duty inverter.
Power CAP™ is the trademark of the Visedo energy storage module.
PowerBOOST™ is the trademark of Visedo DC/DC converter.
PowerUSER™ is the trademark of Visedo application for monitoring, diagnostics
and setting up the Visedo products.
1.9. Responsibility of the manufacturer
Visedo is responsible for the safety, reliability and performance of the device only if:
Handling, mounting, installation, operation and maintenance are carried out by
qualified and authorized service personnel.
The installation of the system complies with the requirements of the appropriate
regulations.
The device is used in accordance with the instructions in this manual.
The device is installed, maintained and serviced in accordance with the
instructions in this manual.
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2. Safety information
2.1. General safety statement
The device is intended for use as a component for industrial and commercial
installations. The end product containing the device must conform with all related
regulations.
The use of the device is prohibited in hazardous areas unless it is expressly designed
for such use.
The device is intended for installation, use and maintenance by qualified personnel,
familiar with health and safety requirements and national legislation. Ignoring these
instructions may invalidate all applicable warranties.
These instructions must be followed to ensure safe and proper installation, operation
and maintenance of the device. They should be brought to the attention of anyone
who installs, operates or maintains the device or associated equipment.
High voltage and rotating parts can cause serious or fatal injuries. For device covered
by this manual, it is important to observe safety precautions to protect personnel from
possible injury.
2.2. Safety message signal words
Safety message signal words indicate the severity of a potential hazard.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. CAUTION may also alert against unsafe practices.
NOTICE Indicates a potentially hazardous situation which, if not avoided, could result
in property damage.
2.3. Safety symbols
The following safety and information related symbols may exist in this manual and on
the device.
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Danger
This symbol is is identified by a yellow background, red
octagonal band and a black STOP text. It indicates a
hazardous situation that causes severe injury or death. Action
indicated by this symbol may not be executed.
General warning
This symbol is identified by a yellow background, black
triangular band, and a black exclamation point symbol. It
indicates a general potentially hazardous situation.
Electric shock warning
The symbol is identified by a yellow background, black
triangular band, and a black arrowhead symbol. It indicates
dangerous electric voltage that could cause an electric shock
to a person.
Burn warning
The symbol is identified by a yellow background, black
triangular band, and a black wavy lines­ symbol. It indicates a
hot device that could cause burns to a person.
Magnet warning
The symbol is identified by a yellow background, black
triangular band, and a black magnet symbol. It indicates
strong magnetic field that could cause harm to a person or
property.
Electric shock warning ­ Read the instructions in the manual.
General Information.
Read the instructions in the manual.
2.4. Personal protective equipment
Personal protective equipment shall be used when necessary during handling,
installation and maintenance of the electric device to avoid injury.
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Use eye protective equipment like safety goggles or mask when working
with the device! Permanent damage to the eye could be caused if hot
water, glycol or other fluids splash.
Use hearing protective equipment when working on the device in noisy
environment! Hearing injuries could be caused by too loud noise (noise in
excess of 85 dBA).
Use head protective equipment like helmet when mounting or dismounting
the device! Head injuries could be caused by object impact.
Use cut resistant gloves when handling and maintaining the device! There
is a risk of cut injuries.
Use protective footwear when lifting or moving the device! Foot injuries
could be caused if lifting system or lifting brackets fail.
2.5. Safety features
Visedo PowerMASTER™ electric devices are equipped with following electrical
protection features:
Table 6. Protection features.
Protection type
Overcurrent
Overvoltage
Short circuit
Overspeed
Overheat (device internal
temperature)
Emergency stop
Built­
Information
in
Yes
750 APEAK
Yes
1050 V DC
Yes
­
Yes
Adjustable according to controlled motor
Yes
Sophisticated thermal model that can lower the
current if needed
Yes
Hardware secured device switch OFF feature
In addition to the electrical protection features, the device is equipped with mechanical
safety feature, a connector shield, which prevents direct entry to the power terminals,
when the device is powered ON. The connector shield is a sheet metal component,
which secures the power terminal cover and it is not possible to release without
disconnecting the control signal connector (X1­connector) first. When X1­connector is
disconnected, it shuts down the device and starts electrical energy discharging
process.
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Figure 3. Connector shield (mechanical safety feature).
2.6. Electromagnetic compatibility (EMC)
EMC stands for Electromagnetic compatibility. It is the ability of electric equipment to
operate without problems within an electromagnetic environment. Likewise, the
equipment must not disturb or interfere with any other product or system within its
locality. This is a legal requirement for all equipment taken into service within the
European Economic Area (EEA).
All PowerMASTER™ products are designed with high standards of EMC in mind.
Connect the power lines and groundings along the instructions in this manual to
achieve the required level of EMC protection.
It is the responsibility of the installer to ensure that the equipment or system into which
the product is incorporated complies with the EMC legislation of the country of use.
Within the European Union, equipment into which this product is incorporated must
comply with the EMC Directive 2004/108/EC.
All PowerMASTER™ inverters are equipped with an internal EMC filter. This filter is
designed to reduce the conducted emissions back into the supply via the power
cables for compliance with the above harmonised European standards. When using
the product with an internal or optional external filter, compliance with the following
EMC Categories, as defined by EN61800‐3:2004 can be achieved:
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Drive
Type /
Rating
3
Phase,
500
Volt
Input
EMC Category
Category C1
Category C2
Category C3
External filter required
No additional filtering required
Shielded motor cables required
If the cable length is over 15 m, an output du/dt filter must be used for
shielded motor cables. Contact Visedo representative to select the right
du/dt filter. Compliance with EMC directives is achieved with the factory
default parameter settings.
Notice! When interfacing other equipment, connect only equipment that are
specified as part of the system and as compatible.
Warning! Magnetic and electromagnetic fields generated near current­carrying
conductors and permanent magnets in electric devices represent a health
danger to persons with heart pacemakers, metal implants and hearing aids.
Persons with a heart pacemaker, metal implants or hearing aids must consult a doctor
before they enter the following areas:
areas in which electric equipment and parts are operated
areas in which electric equipment with permanent magnets are stored, mounted,
operated or repaired
If necessary, perform a special electromagnetic compatibility (EMC) test on the
installation.
3. Product overview
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3. Product overview
The PowerMASTER™ heavy­duty inverter series is designed especially for electric or
hybrid electric drive trains for mobile work machines, marine vessels and
transportation applications.
Typical applications are:
Controlling the speed and torque of electric motors.
Converting alternating current (AC) from electric generator to direct current (DC)
for energy storage.
Active Front End for connecting to AC grid with regenerative power and low
harmonic content.
Creating standalone three phase microgrid.
The advantages and features of the electric device:
Extremely compact structure. Up to 300 kW, weight only 15 kg.
Robust design withstanding high levels of mechanical vibrations and shocks.
High protection class IP67 ensuring operation in extreme conditions.
Wide ambient temperature range from ­40 ºC to +105 ºC.
Liquid cooling.
Wide allowed coolant temperature range.
Multiple mounting possibilities.
Designed especially for highly cyclical loads typical in heavy mobile work
machines.
Controls both induction and permanent magnet motors with or without sensor.
Speed and torque reference motor control.
Generator control mode for DC­link voltage control.
Flexible control interface –CAN, resolver, analog, digital inputs/outputs.
Visedo PowerUSER™ PC­program for commissioning available.
Various communication protocols e.g. CANopen, SAE J­1939.
Possibility to create customer specific applications with CODESYS (IEC61131­3)
software tool.
High performance vector control.
Wide selection of protective safety functions.
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Wide selection of protective safety functions.
Table 7. Motor control characteristics
Controllable
motor types
Control
principle
Reference
types
Field
weakening
control
Working
point
optimization
Synchronous permanent magnet motors
Asynchronous induction motors
Special features to control Visedo synchronous reluctance
assisted permanent magnet motors.
Rotor flux oriented current vector control
Torque reference motor control
Speed reference motor control
Generator control mode for regulating the DC­link voltage
Maximizes the field weakening performance by optimizing the
use of inverter current and torque production capability of the
motor.
Maximum torque per ampere working point optimization is used
to improve efficiency of the motor.
For product specific and up to date information see product data sheets,
http://www.visedo.com.
The PowerMASTER™ inverters have several model options, offering a wide range to
select an optimal solution for different applications.
See detailed product and option information from product data sheets,
http://www.visedo.com.
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3.1. Intended use of the electric device
Intended use of the PowerMASTER™ electric devices
PowerMASTER™ heavy­duty inverters are solely intended for professional use.
Installation, operation and maintenance of the devices are permitted only for the
trained personnel and professionals.
Typical applications for Visedo® PowerMASTER™ electric devices are:
system component, functioning as a speed and torque controller for electric motors
system component, functioning as a current converter, converting alternating
current (AC) from electric generator to direct current (DC) for energy storage.
Device is intended to a fixed installation, as a part of complete power generation
equipment or system.
Not allowed use of the PowerMASTER™ electric devices
It is forbidden to use, handle, maintain and storage the device in following ways
(including but not limited to):
Using the devices for other purposes than defined in the manual.
Disregarding the obligation to comply with the manual, safety signs and rating
plate of the devices.
Using the devices, making adjustments and maintenance without first reading the
manual.
Exceeding the designed limits during the operation.
Using non­original service parts of wrong material causing corrosion problems and
mechanical failures in time.
Operating and performing maintenance for the devices without appropriate
personal protective equipment.
Using the devices for supporting other structures or indirect movements.
Causing any kind of impact forces to the device (e.g. hitting or hammering or
dropping objects).
Operating the devices with electric connections other than defined in the manual.
Operating the devices with insufficiently tightened connections or cable glands.
Operating the devices with power cables routed against the instructions.
Operating the devices without properly dimensioned and operating cooling system.
Accessing the connection box(es) of the devices, performing maintenance or
adjustment operations without securing that the electricity is disconnected and
device is discharged as defined in the manual.
Lifting additional load with the devices.
Using the devices in potentially explosive environment.
Allowing dirt or liquid to enter into the device or connection box.
Using cables that can't withstand the device's maximum currents.
Using dirty cable lugs or broken tools.
Connecting power cables that there is less than 10 mm air gap between the cable
lug and other metallic structure (including the braid of the cable).
Storing the devices contrary to the guidelines presented in this manual e.g.
outdoors in wet or dusty conditions.
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outdoors in wet or dusty conditions.
Storing the devices without proper support to prevent overturning or dropping of
the devices.
For product specific and up to date information see product data sheets,
http://www.visedo.com.
3.2. System introduction
Visedo® provides electric drivetrains for applications in heavy mobile work machines,
marine vessels and transportation vehicles. The drivetrains include all essential
components from converting from traditional to hybrid electric (HEV) or electric vehicle
(EV) solutions. Visedo technology saves fuel and lowers emission and noise levels.
The PowerMASTER™ heavy­duty inverters are essential part of the electric drivetrain
system. Typically these inverters are used as a speed and torque controller for electric
motors and as a current converter, converting alternating current (AC) from electric
generator to direct current (DC) for energy storage.
The PowerMASTER™ heavy­duty inverters are capable for supplying three­phase
alternating current, powering and controlling electric machines e.g. Visedo®
PowerDRUM™ product family electric machines.
If the drivetrain system is equipped with Visedo® smart energy storage PowerCAP™,
it can be charged by using PowerMASTER™ inverter between the electric machine
and energy storage. System may include also Visedo® DC/DC converter,
PowerBOOST™.
Figure 4. Overview of the Visedo® drivetrain system (for reference only).
For product specific and up to date information see product data sheets,
http://www.visedo.com.
3.3. Connections and interfaces
This chapter contains information about the mechanical and electrical connections and
interfaces of the PowerMASTER™ electric device.
Mechanical connections and interfaces
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Mechanical connections and interfaces
Figure 5. Mechanical connection interfaces.
Item
20
Description
Amount
(pcs)
Air vents
Mounting threads. Bottom side of the device, Connection
box lid side (M8 x 20 mm).
Mounting threads. Long sides of the device (M8 x 22 mm).
Mounting threads. Long sides of the device (M8 x 19 mm).
Mounting threads. Short, back side of the device (M6 x 22
mm).
2
6
X(* See detailed dimension information from the product
dimension drawings, http://www.visedo.com.
X(*
Connection box lid (power terminal cover).
1
Liquid cooling, Out­connection (for 3/4" diameter hose).
1
Connector shield (mechanical safety feature).
1
Liquid cooling, In­connection (for 3/4" diameter hose).
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3. Product overview
2 x 5
2 x 1
4
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Electrical connections and interfaces
Figure 6. Electrical connections and interfaces.
Item
Description
Low voltage control signal connection, X1­connector (35­pin
system connector).
Maintenance connection (PC/USB­interface for
PowerUSERTM application).
Positive ( + ) DC connection through the frame's M25
threaded hole to the power terminal (inlet Ø = 23 mm).
Negative ( ­ ) DC connection through the frame's M25
threaded hole to the power terminal (inlet Ø = 23 mm).
Grounding connection, protective earth (thread M8,
through).
Auxiliary negative ( ­ ) DC connection through the frame's
M25 threaded hole to the power terminal (inlet Ø = 23 mm).
Auxiliary positive ( + ) DC connection through the frame's
M25 threaded hole to the power terminal (inlet Ø = 23 mm).
AC­L3 connection through the frame's M25 threaded hole
to the power terminal (inlet Ø = 23 mm).
AC­L2 connection through the frame's M25 threaded hole
to the power terminal (inlet Ø = 23 mm).
AC­L1 connection through the frame's M25 threaded hole
to the power terminal (inlet Ø = 23 mm).
Amount
(pcs)
1
1
1
1
2
1
1
1
1
1
For detailed and up to date alignment and dimensioning information, see product data
sheets, http://www.visedo.com.
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3.4. Rating plate
Each electric device has a rating plate which can be found on top of the device. The
rating plate contains device rating and identification details. Figure 7. shows the
location of the rating plate in the electric device. Figure 8. shows an example of a
rating plate. Explanation to the fields in rating plate are shown in the table 8.
The rating values in the figure are illustrations only. For the exact information, see the
rating plate on the device and product data sheets, http://www.visedo.com.
Figure 7. Location of the PowerMASTER™ electric device rating plate.
Figure 8. PowerMASTER™ rating plate.
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Table 8. Rating plate fields.
Field
Explanation
Unit
Type
Electric device type code and options
Serial No
Serial number
Manuf.
Manufacturing year
UDC
Direct current ­link voltage
V Uac
Alternating current output voltage
V fin/out
Input / output frequency
Hz
In
Rated current
ARMS
Pn
Rated power
kW
Operating temperature
Operating temperature range (ambient)
°C
Coolant temperature
Coolant temperature range
°C
IP rating
Enclosure class according to IEC60034­5
3.5. Type code and serial number
Every electric device that is manufactured by Visedo® has a type code and serial
number, which are permanently marked on the devices rating plate, see Figure 9. The
unit can be identified by them. The serial number of the Visedo® electric device is a
consecutively running number. The type code includes the information of the basic
product and all included options. See Figure 10. for explanation of the type code.
Please provide the type code and the serial number when requested.
Figure 9. Type code and serial number in the rating plate.
Figure 10. Type code explanation.
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Figure 10. Type code explanation.
Product Manual PMA­M
3.6. Tightening torques
For proper and safe operation, it is essential to use specified tightening torques for the
electric device screws. Tightening torques (screw preloads) used in
PowerMASTER™ electric devices are shown in the table 9.
Table 9. Tightening torques.
Connection
Device mounting screws, M8
Device mounting screws, M6
Connection box lid (power terminal cover) mounting screws
Cable lug mounting screws, M8
Grounding cable mounting screws, M8
Cable gland (tighten from the cap of the gland)
Torque
20 Nm
10 Nm
4 Nm
15 Nm
15 Nm
15 Nm
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4. Design principles
This chapter describes design principles that must be taken into account when
designing the system using the PowerMASTER™ electric device.
4.1. System design
4.1.1. Cooling
PowerMASTER™ electric devices are liquid cooled. The coolant connections (Inlet /
Outlet) are suitable for a hose with internal diameter of 19 mm (e.g. from company
Telle ET CORD ¾” further details at http://www.telle.de). It is recommended to mount
the hose on the coolant connection with a hose clamp or a hose clip after the
protection cap has been removed. For cooling a water/glycol mix or pure water with
corrosion inhibitor should be used.
Properly operating cooling system requires, that the device is installed correctly. When
connecting the cooling system, it must be ensured that appropriate cooling liquid runs
freely in and out from the electric device with the coolant flow equal or higher than
specified. It must be ensured that the coolant temperature at the inlet of the device is
below the maximum specified temperature. WARNING! Do not operate the device
without properly dimensioned and operating cooling system.
WARNING! Ensure that the cooling system is in use when the DC­link is
powered.
Table 10. Cooling system requirements.
Cooling system properties
Cooling type
Coolant type
Coolant temperature
Coolant flow
Maximum operating pressure
Pressure drop
Specification
Liquid cooling
Water or water glycol mixture (glycol max. 50 %)
­40º…+65 ºC
10 l/min
2 bar
100 mbar with 10 l/min (+25 °C coolant)
See detailed information and specifications from the product data sheets,
http://www.visedo.com. Rated values can be found from the device rating plate.
4.1.1.1. Recommended coolants
PowerMASTER™ electric devices are designed to work properly with water based
coolant. Plain water with appropriate corrosive inhibitor is acceptable, eg. water with
max. 50% glycol coolant.
Ethylene glycol based Glysantin® G48® (includes also corrosion inhibitors) or similar
can be used. WARNING! Ethylene glycol is a toxic compound. Avoid exposure
to the coolant. Handle with care.
Propylene glycol based coolants, like Splash® RV&Marine antifreeze, can also be
used. Propylene glycol is relatively safe compound for humans and the environment.
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used. Propylene glycol is relatively safe compound for humans and the environment.
NOTICE! Make sure that sufficient personal protective equipment is used when
handling the coolant.
4.1.2. Cabling and wiring
PowerMASTER™ electric device must be installed and connected according to
instructions. Ensure that all system included applications e.g. motors are connected to
the device according to the instructions presented in this manual and the product
specific guidelines.
Cabling
For the power cables, it's recommended to use Radox Elastomer S, screened
automotive cable or equivalent cable with similar specifications.
Cable cross section can be 35 mm2, 50 mm2, or max. 70 mm2, depending on the
maximum needed current.
To ensure the proper operation of the device and to minimize the radiated emissions,
the power cabling must be EMC­shielded. Cable shields must be connected to the
device ground at both ends of the cable. All Visedo® products use EMC­shielded
cable glands for power connections.
Every device must be grounded the best possible way. The best grounding level is
achieved, if the frame of each device is connected directly to the ground. Ensure that
grounding surfaces and contacts are clean and free from paint. Additional grounding
cables connected to the grouding points of the device should be used to ensure good
grounding.
Wiring
To ensure proper and steady operation, it is recommended to use EMC­shielded
cables for the device's control signals. Cable shields must be connected to the device
ground at both ends of the cable.
Table 11. Recommendations for control signal cables.
Cable
Cable type and properties
Resolver cabling
shielded cable (twisted pair)
CAN cabling
shielded cable (twisted pair)
SYNC signals (for parallel or dual motor connection) shielded cable (twisted pair)
Other signals
multistrand wire (0.5­1.5 mm2)
For more detailed information, see appropriate chapters in this manual and product
data sheets http://www.visedo.com.
CAUTION! Ensure, that power cables are routed as far from the control signal
wires that is possible to arrange in practice. Minimum separating distance is
100 mm. The crossings must be arranged to be at 90º. Power cables and control
wires should be routed near the frame of the application e.g. vehicle. Ensure that all
terminal connections are tightened according to instructions.
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4.2. Mounting
4.2.1. Supporting structure requirements
The mountings of the electric device must be secure and sufficiently rigid to prevent
vibrations and mechanical failures. Necessary actions should be taken to avoid
corrosion e.g. on the mounting bracket.
WARNING! Do not install the electric device near or in direct contact with
easily flammable materials. The surface of the device will heat and may become
hot during operation.
The supporting structure e.g. bracket for the electric device must be designed
according to device's allowed mounting positions, see chapter Allowed mounting
positions.
The space for the mounting must be adequate for the device itself and for the possible
auxiliary components. Main dimensions of the device are shown in the figure 11. The
figure shows the main dimensions only and it is for reference use.
Figure 11. Main dimensions of the device.
For detailed information see product data sheets and dimension drawing,
http://www.visedo.com.
4.2.2. Grounding
WARNING! For proper and safe operation, it is important to ensure proper
grounding (earthing) of the device and follow installation instructions and
guidelines for component selection presented in this manual. Don’t operate the
device without correctly attached protective earth conductor. The grounding cable
must be sufficient to carry the maximum supply fault current which normally will be
limited by the fuses or Miniature Circuit Breaker (MCB). Suitably rated fuses or MCB
should be fitted in the mains supply to the inverter, according to local legislation and
recommendations.
Generic grounding guidelines
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Generic grounding guidelines
The ground terminal of each unit should be individually connected directly to the site
ground bus bar (through the filter if installed). The ground connections should not loop
from one unit to another, or to, or from any other equipment. Ground loop impedance
must be compliant with local industrial safety regulations.
The protective ground of the unit must be connected to the system ground. Ground
impedance must meet with the requirements of national and local industrial safety
regulations and electrical requirements. The condition of the grounding connections
must be checked periodically.
Ensure that all grounding surfaces are clean and possible paint is removed from the
contact areas.
For detailed information, see appropriate chapters in this manual and product data
sheets, http://www.visedo.com.
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5. Transportation and storage
5.1. Transportation
All Visedo® electric devices are shipped in first class condition. Products have been
inspected and packed properly to prevent damage from ordinary handling during
shipment. Transport conditions shall be in accordance with the product specification,
any kind of shocks must be avoided.
Plug and seal the cabling and cooling connections for transportation.
WARNING! Heavy electric equipment. Handle with care during transportation.
See the weight of the electric device from the product data sheets,
http://www.visedo.com.
5.2. Receiving and unpacking
The electric device and the package must be inspected immediately upon arrival.
Check that the rating plate data in the cover letter complies with the purchase order.
All external damage (e.g. in the package or in the device itself) must be photographed
and reported immediately.
5.3. Handling
Although the PowerMASTER™ heavy­duty inverter is designed to operate in harsh
and demanding environment, any misuse or improper handling of the device is
prohibited to avoid malfunctions later and after installation.
CAUTION! To avoid injuries, use of personal protective equipment is
recommended during handling, installation and maintenance of the electric device.
WARNING! Heavy electric device, handle with care. Use proper, adequately
dimensioned equipment for lifting and supporting the device during handling. Check
the condition of the equipment before attempting to start any work. Weight information
can be found from the device rating plate and product data sheets. Do not apply any
excess weight on the device when lifting.
5.4. Storage
Store the electric device always indoors having the storage temperature preferably
above ­20 ºC and the relative humidity less than 60 %. Storage conditions should be
dry, dust free and vibration free.
WARNING! Heavy equipment. Store on appropriate base. Support the device
to prevent accidental turning and falling.
Ensure that the cabling and cooling connections are plugged and sealed before
storage.
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storage.
The device must not be subjected to any external vibrations during storage to avoid
possible hidden structural damages.
6. Installation
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6. Installation
WARNING! Only trained and qualified personnel familiar with the relevant
safety requirements are allowed to install the electric device. If the device is
installed incorrectly it may lead to safety hazard.
WARNING! This electric device is intended for professional use as complete
equipment or system and as part of a fixed installation. The electric device uses
high voltages and currents, contains large amounts of stored electrical energy,
and can be used to control mechanical equipment that may cause injury. Close
attention is required to system design and electrical installation to avoid hazards in
either normal operation or in the event of equipment malfunction.
WARNING! Do not perform any flash test or voltage withstand test on the
electric device. If electrical tests or measurements are required, the tests must be
carried out with the device disconnected and stored energy discharged.
WARNING! Risk of electric shock! Disconnect and isolate the electric device
before attempting any work on it. High voltages are present at the terminals and
within the inverter. Passive discharging of the DC­link capacitor is performed by the
bleeder­resistor. Discharging below 50 Volts will be performed within 8 minutes after
the power is disconnected. Always ensure, that voltage is not present on any inverter
power terminals prior to start any work on it.
WARNING! Ensure correct grounding connections. Don’t run the device without
correctly attached protective earth conductor. The grounding cable must be sufficient
to carry the maximum supply fault current which normally will be limited by the fuses
or Miniature Circuit Breaker (MCB). Suitably rated fuses or MCB should be fitted in
the mains supply to the inverter, according to local legislation and recommendations.
WARNING! Ensure that correct type and value of protective fuses are used on high
voltage DC­system.
WARNING! Do not carry out any work on the electric device control cables when the
power is applied to the inverter or to the external control circuits.
WARNING! The control input functions of the electric device – e.g. stop/start,
forward/reverse and maximum speed must be secured using independent channel
protection in safety critical applications. All applications where malfunction could
cause injury or loss of life must be subject to a risk assessment and improve control
signal protection if needed.
WARNING! The motor connected to the inverter can start at power up if the start­
input signal is present.
WARNING! The STOP function does not remove potentially lethal high voltages.
Isolate the device and wait 8 minutes before starting any work on it. Never carry out
any work on the inverter, connected motor or motor cable whilst the input power is still
applied.
WARNING! Do not activate the automatic fault reset function on any system, where
this may cause a potentially dangerous situation.
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WARNING! The electric device can be programmed to drive connected electric
machine at speeds above or below compared to the speeds achieved with direct
power supply connection. Ensure from the manufacturer data sheets, that the driven
electric machine is capable to operate over the intended speed range during start up.
WARNING! Ensure that the supply voltage corresponds to the specification of the
electric device.
WARNING! Do not attempt to carry out any repair of the electric device. In the case
of suspected fault or malfunction, contact Visedo or Visedo authorized service center
for further assistance.
WARNING! When installing the device, ensure that cooling system and used coolant
are according to manufacturer specification. Ensure that the cooling system is in
use when the DC­link is powered.
CAUTION! If the control cabling is installed close with the power cabling, ensure that
minimum separation distance is 100 mm and crossings at 90 degrees. Ensure that all
terminal connections are tightened according to instructions.
CAUTION! Product must not be opened (excluding the connection box lid). Any
attempt causes loss of warranty.
CAUTION! Within the European Union, all machinery in which this product is used
must comply with Directive 98/37/EC, Safety of Machinery. In particular, the machine
manufacturer is responsible for providing a main switch and ensuring the electrical
equipment complies with EN60204­1.
Make sure that sufficient personal protective equipment is used when operating near
the electric device.
Read the instructions in the manual before installing the electric device.
6.1. Required tools
Following tools are required to install the electric device:
Ratchet torque wrench.
Hex head wrench kit with different metric sizes.
Socket wrench kit with different metric sizes.
Cable gland tightening tool. Size according to cable glands.
Cable skinning knife.
Crimping tool for cable lugs.
For more detailed information, see appropriate chapters in this manual and product
data sheets, http://www.visedo.com.
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WARNING! Risk of electric shock when performing electrical installations. Use
insulated tools.
6.2. Mechanical installation
6.2.1. Allowed mounting position
The electric device must be mounted on a flat, heat­ and flame­resistant mounting
place e.g. bracket. Device grounding must be ensured connecting the chassis of the
device direcly to the ground or by using the grounding cable. Paint must be removed
from the grounding points!
The device can be mounted in any direction, in all operating conditions according to
product specification. Install the device permanently by using the device mounting
points.
In order to fullfill mechanical and environmental standards e.g. vibration and shock, it
is recommended to mount the device from the bottom side, by using at least 6 pcs of
M8 screws. Primary mounting points are shown in the view A.
Mounting can be secured from the additional mounting points shown in the views B
and C. Tighten the screws according to recommended torques. Ensure dimensions
for the mounting from the product data sheets and dimension drawings,
http://www.visedo.com.
Figure 12. Location of the fixing points for mounting.
Selected mounting position must allow the cooling system work properly. During
installation, the air must be bled away from the cooling channels to prevent air
pockets.
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pockets.
Ensure that the air vents (2 pcs) are clean and the selected installation place and
mounting direction do not allow water, dust or dirt block the air vents.
Figure 13. Location of the air vents.
Ensure mounting dimensions from the product data sheets and dimension drawings,
http://www.visedo.com.
6.2.2. Mounting the device
Read the instructions in the manual before mounting the electric device.
Ensure that sufficient personal protective equipment are used when operating near
the electric device.
Before mounting the device, ensure that the chosen installation place fulfills the
environmental requirements specified for the product.
If the conditions require, the operating environment of the product must be
designed to protect the device against ingress of corrosive gases or liquids,
conductive contaminants (such as condensation, carbon dust, and metallic
particles) and sprays or splashing water from all directions.
Protect the electric device in high humidity, salty or chemical content environments
with suitable additional enclosure.
The mounting place and mounting interfaces should be sufficient to carry the
weight of the product.
Mount the electric device according to appropriate supporting structure e.g.
bracket.
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bracket.
Do not install the device without sufficient mounting and operating clearances for
the maintenance.
Installation order may vary from the mounting procedure shown in this manual. All
steps must be included in the procedure, although the order may be different.
Mounting procedure
1. Prepare the installation place and ensure that it meets the requirements for the
product. Confirm product and mounting dimensions from the data sheets,
http://www.visedo.com.
2. Connect the cooling system inlet and outlet channels. Ensure that there is no air
pockets in the channels and coolant runs freely in and out. Check that cooling system
operates according to instructions.
3. Ensure that the device will be grouded according to instructions (direct contact from
the frame and / or from the protective earth contacts).
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WARNING! For proper and safe operation, it is important to ensure effective
grounding (earthing) of the device and follow installation instructions and
guidelines for component selection presented in this manual and product data
sheets. Don’t operate the device without correctly attached protective earth
conductor. The grounding cable must be sufficient to carry the maximum supply fault
current which normally will be limited by the fuses or MCB. Suitably rated fuses or
MCB should be fitted in the mains supply to the inverter, according to local legislation
and recommendations.
4. Check existing potentials of the connected system devices. If needed, pre­charge
according to instructions, see chapter Pre­charging. The voltage difference
between two potentials should be 5­10 volts, until the potentials are safe to
connect.
WARNING! If pre­charging is not performed or is performed incompletely,
the high inrush current may break device external electrical components!
5. Uninstall the connector shield (mechanical safety component, sheet metal part).
6. Dismount the connection box lid (power terminal cover).
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WARNING! Risk of electric shock when the connection box lid is open. Ensure
that the device is discharged, safe voltage level must be ensured with
measurements. Discharge below 50 Volts will be performed within 8 minutes.
7. Connect the power cabling according to instructions. See chapter Electrical
installation.
8. Install the connection box lid.
9. Install the connector shield.
10. Lift and support the device for the mounting.
WARNING! Heavy electric device. Handle with care. Handle the device with care
when installing it to the correct mounting position. See chapter Handling. Use proper,
adequate lifting equipment and personal protective equipment during operation.
11. Install all appropriate mounting screws, do not tighten the screws until all screws
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11. Install all appropriate mounting screws, do not tighten the screws until all screws
are aligned and pre­installed. In order to fullfill mechanical and environmental
standards e.g. vibration and shock, it is recommended to mount the device from the
bottom side, by using at least 6 pcs of M8 screws. Primary mounting points are shown
in the view A.
Mounting can be secured from the additional mounting points shown in the views B
and C. Tighten the screws according to recommended torques. Ensure dimensions
for the mounting from the product data sheets and dimension drawings,
http://www.visedo.com.
12. Connect the X1­connector (control signal connector).
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12. Connect the X1­connector (control signal connector).
CAUTION! Do not use excessive force when installing and handling the X1­
connector, the plastic housing of the connector may get broken! When
disconnecting the connector, retaining clip of the connector must be released
first.
13. The electric device is now mounted and prepared for the trial run.
WARNING! Do not touch the electric device during operation. The device
warms up and may be hot.
6.2.3. Cooling connections
Connect the electric device directly to the cooling circuit. Ensure that the coolant flow
is equal or higher than rated and the coolant temperature at the inlet of the device is
lower or equal to the rated temperature. For more information, see Chapter
Recommended coolants and product data sheets. Rated values can be found in the
device rating plate.
The coolant connections (Inlet / Outlet) are suitable for a hose with internal diameter
of 19 mm (e.g. from company Telle ET CORD ¾” further details at
http://www.telle.de). It is recommended to fix the hose on the coolant connection with
a hose clamp or a hose clip after the protection cap has been removed. For cooling a
water/glycol mix or pure water with corrosion inhibitor should be used.
WARNING! Ensure that cooling liquid runs freely in and out from the device.
Do not operate the device without properly dimensioned and operating
cooling system.
WARNING! Ensure the the cooling system is in use when the device DC­link is
powered.
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PowerMASTER™ inverter can monitor and control the temperatures of the Visedo®
PDR family electric machines by connecting the temperature signal to the inverter's
temperature monitoring pin and ensuring that the temperature protection feature is
activated. For further information, see produt data sheets, http://www.visedo.com.
6.3. Electrical installation
6.3.1. Power connections
6.3.1.1. High voltage connections (power)
The electric device must be installed and connected according to the instructions.
Ensure that all connected applications e.g. motors are connected to the device
according to the product specific operating voltage.
PowerMASTER™ electric devices are delivered with the power terminal cover
mounted. To access the power connections, the mechanical safety feature and the
connection box lid needs to be dismounted.
WARNING! Risk of electric shock when power terminal cover is open. When
working with the power connections make sure that electricity has been
disconnected and the device has discharged! The level of the remaining
voltage must be measured before touching the power terminal lines.
Figure 14. Connector shield and connection box lid dismounted, access to power
terminals.
Connection specifications DC link
DC link voltage range
0­850 VDC
DC link nominal voltage
750 VDC
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AC connection
AC output voltage
0­560 VEFF (UDC = 800VDC)
Output frequency
Switching frequency
Maximum power
0...580 Hz. Up to 1000 Hz as option.
8 kHz
300 kW
For more information, see appropriate chapters in this manual and product data
sheets, http://www.visedo.com.
6.3.1.2. Connection diagram
PowerMASTER™ power connection diagram is shown in the figure 15..
Figure 15. Schematic of the electric device power stage.
6.3.1.3. Cable gland assembly and power line connection
All electrical connections must be done according to instructions. It is essential to
ensure that all terminal connections are installed properly and the connected
application e.g. electric motor is using the correct operating voltage.
WARNING! Risk of electric shock when connection box lid is dismounted.
When working with the power connections make sure that electricity has been
disconnected and the device has discharged! The level of the remaining voltage
must be measured before touching the power terminal lines.
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The high current and high voltage cable harness for AC and DC connections needs to
be terminated with cable lugs and cable glands. It is recommended to use IP67/68
rated, 360º shielded cable glands and single core automotive rated screened cable.
The cross section area of the copper cable must be 70 mm2 or smaller, depending on
the needed maximum current.
The cable gland has three functions, it works as a stress relief, it seals the connection
against water and dirt and provides appropriate EMI shielding. Advanced cable glands
could achieve high EMI attenuation over a wide frequency range.
The cable lug and cable gland must be assembled according to instructions. For
correct assembly of the cable gland, it is recommended to use a torque key with a
turnkey head and a key to adapt the cable gland. The cable lug is connected to
terminal with a M8 screw. Shielding of the power cable must be connected to the
electric device body by the cable gland. Recommendations for the tightening torques
must be followed.
Figure 16. Cable harness connection with the cable lug and the cable gland (for
illustration only).
It is essential to select a cable gland with a thread M25 x 1.5 (maximum wrench size
of 30 mm) otherwise the cable gland cannot be installed! Ensure that the cable lug
can enter through the M25 threaded hole, Ø 23 mm!
The information below describes how to assemble screened power cables to Visedo®
electric devices. Visedo recommends to use Pflitsch BlueGlobe­series cable glands
and H+S Radox Elastomer S automotive cables. Cable gland assembly instruction
can also be found from Pflitsch gland catalogue available from http://www.pflitsch.de.
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can also be found from Pflitsch gland catalogue available from http://www.pflitsch.de.
Correct cable gland type for 35 mm2, 50 mm2, and 70 mm2 cross section cables is
bg225mstri.
Cable lug and cable gland assembly steps
1. Remove the small hexagonal piece from the BlueGlobe­sealing insert as shown in
Figure 17. BlueGlobe­sealing
Figure 17. BlueGlobe­sealing
. Cut the cable sheath at the distance A from the end of the cable, see Figure 18.
2
Cut lenght of the cable sheath. Pull the cut part of the sheath partly (length B is from
10 to 15 mm) off the cable as shown in the figure. The distance A depends on the
product where the cable gland is used, and is given below.
NOTICE! Do not remove the cable sheath completely at this point and do not
cut the braid screen of the cable!
Figure 18. Cut lenght of the cable sheath
For PowerMASTER™ electric devices, the cable sheath cut distance A is 60 mm.
3. Insert the cable to the cable gland with slight turning motion. This helps the cable
go through the spring inside the cable gland. Push the cable gland against the sheath
of the cable as shown in Figure 19. Cable to the gland assembly.
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of the cable as shown in Figure 19. Cable to the gland assembly.
Figure 19. Cable to the gland assembly
4. After the cable gland is in place remove the length A piece of the sheath and cut
the braid screen (cover) from 10 mm (distance C) from the gland bottom as shown in
Figure 20. Cut the braid screen.
NOTICE! Ensure that the cable gland spring is against the cable sheath before
cutting the braid screen
'
Figure 20. Cut the braid screen
5. Cut a piece of length D of the inner sheath shown in Figure 21. Cutting the inner
sheath. The length D must equal to the length of the cable lug body.
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sheath. The length D must equal to the length of the cable lug body.
Figure 21. Cutting the inner sheath
. Place the cable inside the cable lug body, and crimp the cable lug twice in different
6
places. See Figure 22. Connecting cable lug.
Figure 22. Connecting cable lug
. Cut piece of shrink tube and shrink it over the cable lug and braid screen as shown
7
in Figure 23. Shrink tube. This is done to keep the braid screen in place and for extra
insulation.
NOTICE! The shrink tube must be specified for operating temperature range
from ­40 ºC to 150 ºC. Self gluing shrink tube is recommended.
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Figure 23. Shrink tube
8. Insert the cable through the corresponding M25 hole in the device frame and
connect the cable lug to the correct power terminal with M8 screw. Use spring washer
between the cable lug and the connection screw or nut. Do not tighten the cable lug
screw at this point to ensure fitting of the cable gland.
WARNING! Ensure that there is at least 10 mm air gap beetween the cable lug
and other metallic structures including the braid of the cable. If the air gap is
smaller, use extra insulation shrink tube to cover the lug.
. Screw the cable gland to the device power terminals according to instructions.
9
Tighten the cable gland with the specified torque.
NOTICE! Do not turn the body of the gland! By tightening from the cap of the
gland, the cable is sealed to the cable gland. At the same time, the cable gland
is tightened to the terminal frame with correct torque.
10. Tighten the cable lug using the specified torque.
11. Repeat the procedure to the other cables and connections.
12. Check that the phase connections order in the power terminal is correct, ie.
corresponding phases between the inverter and the machine are connected (U, V, W
corresponds to the L1, L2, L3 phases).
13. Close the power terminal cover and install the connector shield.
14. Ensure that the power cable shields are grounded properly.
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Figure 24. Cable lug and cable gland assembly cross­ section.
Table 12. Individual tightening torques
Part
Cable lug screws (M8)
Cable gland
Connection box lid screws
Tightening torque [Nm]
15
15
4
Table 13. Example of the equipment needed for the assembly.
Assemply
equipment
(example)
Description
Torque key and
turnkey head
Key
Assembly
example for a
70 mm2 cable
Cable with
nominal cross­
section of 70
mm2
Cable lug
Cable gland
Screw
Assembly
example for a
50 mm2 cable
Cable gland
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http://www.pflitsch.de
http://www.pflitsch.de
http://www.hubersuhner.com
http://www.druseidt.de
http://www.pflitsch.de
http://www.wuerth.com
Cable with
nominal cross­
section of 50
mm2
C able lug
Screw
Manufacturer's homepage
http://www.hubersuhner.com
http://www.druseidt.de
http://www.pflitsch.de
http://www.wuerth.com
6. Installation
Art.No./Part No.
730N710­50
SE30
Radox Elastomer
S
10872
Bg225mstri
DIN 7984 M8 12
mm
Radox Elastomer
S
10862
Bg225mstri
DIN 7984 M8 12
mm
47
Product Manual PMA­M
6.3.1.4. Extended power connections
The device can be equipped with extension options, +DCE and +CEB. Extension
options can be used if there is a need to divide the DC­link connection or if stronger
cables are needed to carry higher currents. In practice, the extension options will
double the selected cable connections e.g. from 1 x 70 mm2 to 2 x 70 mm2.
Extended DC­connections (+DCE option)
DC­connections can be extended by using the Spacer sleeve kit, which includes all
needed parts to double DC­connections. Also if system requires to connect two or
more inverters in chain, +DCE option can be utilized for the connections.
Figure 25. Extended DC­connections (+DCE) option.
Item
Quantity
1
1
1
Description
Item/
order
number
Spacer sleeve kit (includes 2 pcs of cable glands,
2 pcs spacers and necessary screws and
13231
washers) for double DC­link connection.
Auxiliary positive ( + ) DC connection through the
frame's M25 threaded hole to the power terminal N/A
(inlet Ø = 23 mm). Plugged.
Auxiliary negative ( ­ ) DC connection through the
frame's M25 threaded hole to the power terminal N/A
(inlet Ø = 23 mm). Plugged.
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WARNING! The spacing sleeve carries all current present on the DC­link and must
be dimensioned according to the system requirements.
Connection extension box (+CEB option)
Optional connection extension box (+CEB) enables to extend all power connections
(AC and DC). +CEB option and connection interfaces are shown in the figure 26.
Figure 26. Connection extension box (+CEB) option.
Item
Quantity
Item/ order
number
Description
1
Connection Extension Box (CEB).
13159
1
Auxiliary AC­L1 connection.
N/A
1
Auxiliary AC­L2 connection.
N/A
1
Auxiliary AC­L3 connection.
N/A
1
1
Auxiliary positive ( + ) DC
connection.
Auxiliary negative ( ­ ) DC
connection.
N/A
N/A
More information about the options see product data sheets, http://www.visedo.com.
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More information about the options see product data sheets, http://www.visedo.com.
6.3.2. Low voltage connections (control and monitoring signals)
Control signals
Basic device supports following CAN­protocols:
CANopen
SAE J­1939
CAN­protocols are alternatives and the choice should be made when placing an
order.
The control signals of the electric device are operated via X1­connector.
Figure 27. X1­connector, low voltage control signal connection.
Low voltage control signal connection includes following functions:
powers the device control system
power On/Off
communication channels (CAN)
digital In/Out
analog In
emergency stop (according to automotive standards)
external temperature monitoring PT100 and PT1000
To ensure control signal prompt and constant operation, it is essential to use
compatible connector interface (male/female) and appropriate shielded wiring.
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Table 14. Control signal connector information.
Description
X1­Control signal connector
(in the chassis)
Part number
1­776163­1
Supplier example
http://www.te.com/usa­
en/product­1­776163­1.html
Tyco
Electronics/AMPSEAL, 35­
pin (male)
X1­Cable connector
(mating connector)
Case:776164­1
http://www.te.com/usa­
en/product­776164­1.html
Tyco
Pins: 770854­3 (wire
Electronics/AMPSEAL, 35­ 0.5­1.25mm2)
pin (female)
http://www.te.com/usa­
en/product­770854­3.html
Table15. Tools and accessories.
Description
Part
number
Crimping Tool 58529­1
Assembly
58529­1 with
Die Assembly
58529­2
Connector
770678­
seal plug (for 1
storage and
transportation)
35­position
776463­
wire relief
1
Supplier example
http://fi.mouser.com/ProductDetail/TE­Connectivity/58529­
1/?
qs=Xf%252b3Aw93yEM%2FQReWIgzu%252bw%3D%3D
http://www.te.com/usa­en/product­770678­1.html
http://www.te.com/usa­en/product­776463­1.html
Detailed and up to date information can be found at manufactures's web­pages.
Connector assembly according to connector manufacturer instructions (e.g. contact
crimping).
The durability of the X1­connector is limited to 10 mating cycles by the
connector manufacturer.
Minimum wiring and connections needed for powering the device are shown below. If
any of these signals is not connected, the device will not be switched on or it will be in
tripped state and will not work.
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Figure 28. Low voltage signals. Minimum connections needed for powering the
device.
Table 16. Minimum wiring and connections.
Pin
Pin name
number
13
VIN_N
1
VIN_P
2
24
3
Description
Power supply negative
Power supply positive (continuous). Typically 12­24 V, see
data sheets http://www.visedo.com.
POWER_ON Power supply positive (from on/off key). Typically the same
voltage as VIN_P.
STOP_1
Stop input 1. Needs to be pulled up (same range as VIN_P)
for the converter to run. Disconnecting the STOP input or
pulling it low externally causes the power semiconductor
switch drivers to be disabled, which makes the converter a
diode bridge. Stopping the converter with one of the STOP
inputs causes also a fault, which needs to be cleared before
continuing operation.
STOP_2
Stop input 2. Identical to stop input 1. Both need to be pulled
up in order to be able to run.
A minimal wiring scheme is shown in the figure 29. The main point is that the
POWER_ON input is the one that should be used to turn the converters ON or OFF.
In particular, shutting the converter down by disconnection VIN_N or VIN_P may in
some circumstances result in the corruption of the converter parameters or other data.
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Figure 29. Example of the minimum connections.
The switch (SW1) is used to turn the converter on and off. VIN_P and VIN_N are
continuously connected to the power supply. There is an internal pull­down in the
POWER_ON input.
Use appropriate fuse (F1) for protection. See values and information for fuse selection
from the product data sheets http://www.visedo.com.
WARNING! When powering OFF any of the Visedo devices, use the POWER_ON
input. The power supply (VIN_N and/or VIN_P) can be disconnected, if desired, after
time tmin has elapsed from the deactivation of POWER_ON (see the following figure).
A safe value for tmin is 5 seconds.
Figure 30. Disconnecting the power supply.
Sufficient time should elapse between bringing the POWER_ON voltage down and
bringing VIN_P down.
Use of the grounding pins
In addition to the aforementioned signals, there are various ground (GND) pins in the
signal connector. CAN and I/O features use separate GND pins. The difference
between unisolated GND pins and VIN_N is that VIN_N/VIN_P go through a
common mode choke for the filtering of conducted emissions. Connecting GND and
VIN_N together effectively disables the common mode choke.
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VIN_N together effectively disables the common mode choke.
POWER_ON and STOP signals use GND as their reference. If, externally, they are
produced with respect to VIN_N, a high level of common mode disturbance may
throw POWER_ON and STOPs out of their operating range and cause the converter
to stop or reboot. This can be fixed by connecting VIN_N and GND, but this comes at
the cost of increased EMI. Finally, there is an enclosure ground pin, which is
connected to the enclosure (frame) of the converter and can be used to connect cable
shields.
General information
Connect VIN_P to the positive power supply and VIN_N to the negative power
supply. POWER_ON and STOP_1/STOP_2 are usually connected to positive power
supply. If STOP signals are used connect the emergency stop switch between the
STOP and positive power supply.
STOP signal should go high at the same time or before the power supply is connected
to VIN_P and VIN_N. If STOP signals are connected after VIN_P and VIN_N the
inverter will most likely register the STOP as active and be in emergency stop trip
state. If this happens the wiring can be changed connecting the power supply to
VIN_P and VIN_N at same time or before the STOP signals. The emergency state
trip can also be cleared after every startup of the device.
Resolver and CAN­network should be done using twisted pair shielded cable to
minimize the EMC­disturbances for both resolver and CAN signals.
If PT100/1000 temperature inputs are used, use signal ground as the ground
connection for the sensor.
Ensure correct signal connections and product specific pin­layout from
product data sheets, http://www.visedo.com.
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Signals for monitoring, diagnostics and set­up
he device can be connected to the PC's USB­port by using maintenance connector
T
interface (USB to RS485). Maintenance connector enables monitoring, diagnostics
and setting up the electric device. By using the PowerUSER™ application, it enables
these functions via remote access e.g. in the case of problem solving.
Reliable connection between the PC and the device can be ensured by using Visedo
Power Series Service Cable (PSSC). The PSSC is isolated RS485 and shielded
cable, designed for demanding environments. The cable is available in 3 meter
(PSSC­3M) and 10 meter version (PSSC­10M). Same cable can be used with all
Visedo products that have service connector.
The service cable is ordered separately, see table 20. in this manual for ordering
details.
PowerUSER™ application can be downloaded for free from Visedo website ⇒
Products­menu http://www.visedo.com/en/products.
Figure 31. Maintenance connector.
6.3.3. Grounding connections
Main frame
The best grounding level is achieved, if the main frame of each eletric device is
directly connected to the ground. If this is not possible to arrange, the device must
be grounded at least from one of the safety grounding points with a appropriate
grounding cable. Grounding points are marked to the device.
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Safety grounding points and protective earth conductor
One of the safety grounding points must be connected to adjacent building steel
(girder, joist), a floor ground rod, or bus bar. Grounding points must comply with
national and local industrial safety regulations and/or electrical codes. The cross
sectional area of the protective earth conductor must be at least equal to that of the
incoming supply conductor.
All grounding surfaces and contact areas must be clean, the paint must be
removed!
Cabling and wiring
To ensure device steady operation and to minimize the radiated emissions, all
connected cables and wires must be EMC­shielded. Shieldings must be connected to
the ground at both ends of the cable or wire. All power connections must be secured
with cable lugs and cable glands. EMC­shielded cable glands are used in all Visedo®
products for the power connections. Ensure that the low voltage cable (control signal
cable) shield is also grounded.
Follow the manufacturer's recommendations when selecting components to
the system. Ensure that installation is done according to instructions.
Electric motor ground
The electric motor ground must be connected to the PowerMASTER™ ground
terminal.
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Shield termination (cable screen)
The safety ground terminal provides a grounding point for the motor cable shield. The
motor cable shield connected to this terminal (unit end) should also be connected to
the motor frame (motor end). Use a shield terminating or EMI clamp to connect the
shield to the safety ground terminal.
6.3.4. Pre­charging
Devices with DC­link capacitance should be pre­charged before connecting them to
battery, supercapacitor or charged DC­link. Pre­charging is needed to limit the inrush
current that would happen, if the capacitors are not pre­charged. Pre­charging can be
done by using pre­charge resistor and contactor before the DC­link is connected to
battery, supercapacitor or to another DC­link that has different voltage. After pre­
charging, the voltage difference between two potentials should be 5­10 volts,
until the potentials are safe to connect.
PowerMASTER™ M­ frame DC­link capacitance is 1 mF.
WARNING! If pre­charging is not performed or is performed incompletely,
the high inrush current may break device external electrical components!
7. Operation
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7. Operation
7.1. Operation conditions
The electric device should be used for its intended purpose only and within limits
specified by the manufacturer, concerning:
loading
cooling
speed range
service interval
ambient conditions such as temperature and moisture
The devices are designed for the following conditions:
Ambient temperature limits are from ­40 °C to +105 °C.
Maximum altitude 2000 m above sea level.
Maximum coolant liquid temperature at the inlet of the coolant circuit, see product
data sheets.
Coolant liquid must be water­glycol mixture with maximum of 50 % glycol content.
See Chapter Recommended coolants.
The device may only be used in applications it is intended for. The rated nominal
values and operational conditions are shown in the rating plate. WARNING! Do not
use the device without properly dimensioned and operating cooling system.
Maximum operation temperature must not be exceeded to avoid permanent
damage to the device. In addition, all requirements of this manual and other related
instructions and standards must be followed.
WARNING! Do not touch the device during operation. The surface of the device
might be hot.
WARNING! Ensure that the cooling system is in use when the DC­link is
powered.
If the operation limits are exceeded and the device is damaged, please contact local
Visedo representative.
More detailed and up to date information can be found from product data sheets,
http://www.visedo.com.
7.2. Condition monitoring during operation
The electric device should be monitored regularly during operation. This will ensure
reliable operation, foresee possible upcoming failures and help to reach designed
lifetime of the product.
WARNING! Permanent damage to the electric device can be caused if it is
used against specified ambient conditions or against defined technical
guidelines (e.g. overheating, improper cooling system).
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NOTICE! If any deviations from expected normal operation are noticed, e.g.
abnormal high temperatures or noise, the device should not be operated.
Reason for such abnormal behavior must be inspected to determine necessary
actions for returning the functionality of the device.
8. Maintenance
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8. Maintenance
This chapter contains necessary information for the qualified and trained personnel to
carry out regular maintenance work.
WARNING! Do not disassemble the electric device. Only procedures
described in this manual may be performed. For further information contact
Visedo local representative.
WARNING! Only trained and qualified personnel familiar with the relevant
safety requirements are allowed to perform any maintenance to the electric
device.
WARNING! Risk of electric shock when the connection box lid is dismounted.
NOTICE! Ensure that sufficient personal protective equipment is used when
operating near the electric device. Read the instructions in the manual before installing the electric device. To
ensure safe and reliable operation of the device, maintenance instructions should be
followed carefully.
8.1. Regular maintenance
Proper supervision and maintenance of the electric device will ensure reliable
operation and designed lifetime.
NOTICE! Inspect the device at regular intervals. Use regular maintenance
checklists in the inspections.
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Table 17. Maintenance intervals
Object
General
Operation
construction
Mounting
Enclosure
and
connected
parts
Electrical
system
Cooling
system
Check/Task
Weekly Monthly Yearly
Abnormal phenomenon e.g.
X
noise or heating. If clearly
increased, contact local Visedo
representative.
Tightness of the screws.
X
Tighten to proper value if
necessary. Applies to screws
that are presented in this
manual. See chapter
Tightening torques.
Check cleanliness. Clean if
X
necessary. See chapter
Cleaning.
Cables
Visual check e.g. wear.
Replace if necessary.
Electrical
Check connections. Ensure
connections that sufficient tightening torque
is applied to cable glands. See
chapter Tightening torques.
Groundings Check groundings (earthings). (earthings) Ensure that the connection
resistance is valid. Re­connect
if necessary.
Operation
Functioning. Cooling system
functions as specified.
Tubing and No visible leakage. If leaking,
connection tighten connections
tightness
appropriately, or replace parts.
Ventilation Cleanliness. Clean if
plug
necessary. See chapter
Cleaning.
Coolant
Use the coolant as specified
quality
(proper glycol and water/glycol
mixture appropriate). Refill if
necessary. See Chapter
Cooling system maintenance.
X
X
X
X
X
X
X
NOTICE! Do not attempt to tighten or release any screws, nuts or joints which
are not presented in this manual and needed for normal installation and
maintenance procedures.
8.2. Cleaning
Keep the electric device clean. For cleaning, use non­abrasive and non­corrosive
cleaning products. Make sure that the detergent may be used for aluminum.
When cleaning the air vents, do not open / remove the vents. Clean the vents from
the dirt outside.
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WARNING! Do not use pressure washer for cleaning! High water pressure may
damage the gaskets allowing water ingress in to the electric device.
WARNING! Risk of electric shock if the device is cleaned against instructions
allowing water ingress in to the device.
8.3. Cooling system maintenance
The PowerMASTER™ electric device cooling system requires certain regular
observation and maintenance activities.
Observe weekly that the cooling system operates properly and check monthly that
there is no leakages in the cooling system.
The quality of the coolant must be checked yearly. The mixture of water and glycol as
well as the type of the glycol used must be as specified. See Chapter Recommended
coolants.
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9. Dismounting
Read the instructions in the manual before dismounting the electric device.
Ensure that sufficient personal protective equipment are used when operating near
the electric device.
For dismounting the electric device, follow the steps below and read the chapter
Mounting the device for additional information.
Dismounting procedure
1. Switch off the device.
2. Ensure that the cooling system remains operational.
3. Release retaining clip of the X1­connector (control signal connector, low voltage,
35­pin) and disconnect the connector.
CAUTION! Do not use do not use excessive force when disconnecting the
connector, the plastic housing of the connector may get broken! Connector
retaining clip must be released before disconnecting the connector.
4. Wait until the device has discharged the storaged energy. Discharge below 50 Volts
will be performed within 8 minutes. Always ensure by using a suitable multimeter that
no voltage is present on any inverter power terminals prior to commencing any work.
5. Wait until the temperature of the device and cooling liquid is decreased below +40
oC.
WARNING! Do not touch the device or continue working until the temperature
of the device has decreased!
6. Release the mounting screws and dismount the device from the mounting base.
7. Dismount the connector shield (mechanical safety component).
8. Dismount the connection box lid (power terminal cover)
WARNING! Risk of electric shock if dismounting steps are continued before
the device is discharged and safe voltage level has been ensured with
measurements.
9. Disconnect the power terminal cabling.
10. Disconnect grounding cables (protective earth).
11. Disconnect the liquid cooling system.
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11. Disconnect the liquid cooling system.
Product Manual PMA­M
12. Release the mounting screws and dismount the device from the mounting base.
13. Re­ install connection box lid and connector shield and plug all electrical and
cooling connections for longer storage.
14. Place and support the device according to handling instructions.
CAUTION! Support the device during dismounting, handle with care!
10. Troubleshooting
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10. Troubleshooting
Some unexpected situations may occur while operating the electric device. Some of
the possible causes and actions are given in Table 18.Troubleshooting chart. If the
situation occurs, it should be corrected as soon as possible.
These instructions do not cover all details or variations in the equipment nor provide
information for every possible condition to be met in connection with installation,
operation or maintenance. If additional information is needed, please contact local
Visedo representative.
For the reason of general safety and correct operative actions, read the
instructions carefully before starting any analyses or working with the
device. Especially see chapters installation and dismounting of the electric device.
Ensure that sufficient personal protective equipment are used when operating
near the electric device.
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Table 18. Troubleshooting chart
Fault
description
Device
overheating
Significant
coolant leak
Electric device
does not work
properly or the
performance is
poor
Possible
cause
Cooling
system
failure.
Leakage in
the cooling
system.
Rigid particle
inside the
device's
cooling
channel.
Loosen
cooling
system
connections.
Broken
cooling
hose.
Poor
powerline
contacts
(highvoltage)
Poor control
signal
contacts
(low voltage)
Action
Check cooling system operation and functionality,
especially possible leaks, flow rate and fluid
temperature.
Change cooling flow direction to flush the cooling
system from sediment possibly accumulated. Risk
of burns! For safety operation, see the chapters
installation and dismounting the device.
Check cooling system cirquit and connections.
Try pulsating coolant to open the channels. Contact
local Visedo representative.
Check, clean and tighten the connections. Replace
if neccessary. Risk of burns! For safety
operation, see the chapters installation and
dismounting the device.
Replace the hose.
Check, clean and tighten the contacts. Risk of
electric shock! For safety operation, see the
chapters installation and dismounting.
Check X1­connector mounting (35­pin system
connector).
Fault history and fault reset
When an unusual operating condition is detected by the PowerMASTER™ control
diagnostics, the device will give a notification.The notifications varies depending on the
consequence and required action:
Fault­ type of notification stops (power off) the unit and requires reset.
Warning­ type of notification informs of unusual operating conditions, but the unit
stays operative (power on).
When a fault appears and stops the unit, the root cause of the fault must be defined
before any further actions. All faults are stored in to Fault history­ menu.
After the root cause is defined and the device is inspected and recovered according to
instructions, the fault can be reset. Fault resetting can be done with the reset signal
through the fieldbus or by using maintenance connection and PowerUSER™
application.
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WARNING! Do not attempt to carry out any repair of the electric device. In the case
of suspected fault or malfunction, contact Visedo or Visedo authorized service centre
for further assistance.
WARNING! Do not activate the automatic fault reset function on any system, where
this may cause a potentially dangerous situation.
More information about the fault history and fault reset see product data sheets,
http://www.visedo.com or take a contact to Visedo representatives.
11. Aftersales
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11. Aftersales
11.1. Service policy
Maintenance and service of the electric device is limited to the procedures described
in this manual. See chapter Service parts (tables 19. and 20.) for available service
and accessory parts. For further information, contact local Visedo representative,
[email protected] or see http://www.visedo.com/
11.2. Service parts
The recommended service parts are listed in the table below. Contact local Visedo
representative for more information and purchasing.
Table 19. PowerMASTER™ M­frame spare parts.
Item / Quantity
Description
order
number
10756 1
Connector shield. Mechanical safety feature,
which prevents opening the connection box if
the signal connector is not disconnected.
10348 5
Cable glands
13231 1
Spacer sleeve kit (includes 2 pcs of cable
glands, 2pcs spacers and necessary screws and
washers) for double DC­link connection.
10988 1
Service connector cap.
Type
­
bg225mstri
­
X(*
1
Connection box lid (power terminal cover).
Binder series:
713, P/N
082616000000
­
X(*
11780
1
Connection box lid screw kit (10 screws).
­
1
Signal connector wire harness 3m (all pins
connected).
­
X(* = Use description for ordering
Table 20. PowerMASTER™ accessory spare parts.
Item / order Quantity
Description
number
11131
1
Connection cable between PC and PMA (USB to
RS485), 3 meter serial cable.
11132
1
Connection cable between PC and PMA (USB to
RS485), 10 meter serial cable.
Type
PSSC­
3M
PSSC­
10M
Needed PC­ application, PowerUSER™ program can be downloaded from Visedo
homepage, http://www.visedo.com.
12. Disposal
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12. Disposal
The disposal of the electric device and any of its parts must be performed using
appropriate means in accordance with local laws and regulations.
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Headquarters and factory
VISEDO Oy
Lentokentäntie 44
53600 Lappeenranta
FINLAND
Phone: +358 40 450 4464
Email: info @visedo.com
http://www.visedo.com