SAMI STAR Functional Description

SAMI STAR
Frequency Converters
Functional Description
Code:
3AFE 53515487
Revision:
Language:
EN
3AFE 53515487
Issued by:
FIDRI/EIB
Date:
1994-01-03
File:
SFUNCDEC.DOC
Created with:Word for Windows 2.0
Designer 3.1
Excel 3.0
Table of Revisions:
Date:
Code:
1992-11-04 3AFE 53515487
1994-01-03 3AFE 53515487
Rev.:
E
F
Table of references:
For information on:
See:
Remark:
New issue, corrections
3AFE 53515487
CONTENTS
Page
1. INTRODUCTION ..............................................................................5
2. FUNDAMENTAL FEATURES...........................................................6
2.1 PWM techniques .........................................................................6
2.2 Gate-commutated semiconductor................................................8
2.2.1 Power transistor (GTR = Giant Transistor) ........................9
2.2.2 Gate Turn Off (GTO) thyristor............................................10
2.3 Star modulation ...........................................................................11
2.4 Additional motor losses ...............................................................13
2.5 Switching frequency ....................................................................14
2.6 Full digital control.........................................................................15
2.7 Serial data communication techniques ........................................16
2.8 Scalar control - vector control ......................................................17
2.8.1 Scalar control ....................................................................17
2.8.2 Vector control ....................................................................23
3. SAMI STAR FREQUENCY CONVERTER........................................26
3.1 Mechanical design of the Frequency Converter ..........................26
4. MODULES OF THE SAMI STAR FREQUENCY CONVERTER.......28
4.1 Contactor Unit SAFUL .................................................................28
4.2 Line Converter Unit SAFUC.........................................................30
4.2.1 6-pulse diode rectifier ........................................................30
4.2.2 12-pulse diode rectifier ......................................................31
4.2.3 24-pulse diode rectifier ......................................................32
4.3 Line Generating Unit SAFUG ......................................................33
4.3.1 Line Filter Unit SAFUF.......................................................35
4.4 Thyristor Braking Unit SAFUX .....................................................36
4.5 Capacitor Bank Unit SAFUB........................................................38
4.6 Inverter Unit SAFUI .....................................................................40
4.6.1 Optional cards ...................................................................43
4.6.2 GTR inverter......................................................................44
4.6.3 GTO inverter......................................................................45
4.6.4 Parallel-connected inverter units .......................................47
4.7 Braking Chopper SAFUK.............................................................49
5. CONTROL PANEL SAFP 11 PAN (Control Panel 1 ^ CP1) .............50
6. CONTROL PANEL SAFP 21 PAN (Control Panel ^ CP2) ................53
6.1 Single-drive control......................................................................54
6.2 Common DC-bus drive and sectional drive control......................56
7. DRIVE APPLICATIONS....................................................................57
7.1 Single drive..................................................................................57
7.2 Common DC-bus drive ................................................................58
7.2.1 DC bus ..............................................................................59
7.3 Sectional drive .............................................................................60
3AFE 53515487
3AFE 53515487
1.
INTRODUCTION
The SAMI STAR frequency converters manufactured by ABB Industry are
efficient, economical devices designed for controlling the speed of squirrelcage induction motors. The design of SAMI STAR, which is based on the vast
experience ABB Industry has gained with earlier SAMI types, includes the
features that have made the earlier SAMI types so popular. In addition, the
rapid progress in the power semiconductor and microprocessor technology
has made it possible to develop new features that will further expand the
application range of the SAMI frequency converters.
The operation of the SAMI STAR frequency converters is based on
-
PWM techniques,
gate-commutated semiconductors
o
power transistors (GTR),
o
gate turn-off thyristors (GTO),
electrolytic capacitors in the capacitor bank unit,
common DC bus (in common DC-bus drives),
full digital control and microprocessor techniques,
serial data communication techniques,
star modulation,
scalar control and, if necessary, vector control,
microprocessor techniques also when implementing the drive applications.
The SAMI STAR application range is very extensive. In addition to the single
drives, SAMI STAR can be used to replace e.g. the DC-motor drives in
sectional drive applications.
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2.
FUNDAMENTAL FEATURES
2.1
PWM techniques
In most cases, frequency converters which include an intermediate DC circuit
are used in the speed controlled AC induction motor drives. Figure 2.1 shows
the block diagram of such a frequency converter.
CONTROL UNIT
M
3~
MAINS
INVERTER UNIT
D.C. INTERMEDIATE CIRCUIT
LINE CONVERTER UNIT
Figure 2.1.
Block diagram of a frequency converter. (EN 5709 7094)
At the input side of the frequency converter there is a line converter unit
(rectifier-diode bridge). The pulsating DC voltage from the line converter unit is
filtered on the DC bus through an LC low pass filter. At the output side there is
an inverter unit which forms an AC voltage of the desired frequency from the
DC voltage. The control unit supervises the operation of the frequency
converter.
The voltage to be supplied to the cage induction motor must be controlled in
an appropriate proportion to the frequency. Frequency converters in which the
r.m.s. value of the output voltage is varied by altering the output voltage pulse
pattern are called PWM (Pulse Width Modulation) frequency converters.
-
In the PWM frequency converters the control rate is high, because the
voltage is adjusted by means of the inverter unit.
Thanks to the diode bridge, the power taken by the PWM frequency
converter from the mains is almost entirely active power and thus the
power factor of the frequency converter is approximately 1 in regard to the
mains.
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In the PWM frequency converters the intermediate circuit voltage is constant.

From this DC voltage the inverter unit forms a symmetrical three-phase
voltage of controlled frequency and magnitude. Figure 2.2 shows the output
voltage of a PWM frequency converter when the pulse number per half cycle
is one and three.
a)
b)
Figure 2.2.
The output voltage between two phases of a PWM frequency

converter when the pulse number is one (a) and three (b).
(5709 7108)
2.2
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Gate-commutated semiconductor
Gate-commutated semiconductors are used in the inverter unit of the SAMI
STAR frequency converter. There are two types of semiconductors: the power
transistor (GTR) and the gate turn-off thyristor (GTO). Their use in the inverter
unit offers the following benefits:
-
A simplified inverter construction, as the forced commutated circuits are

not needed and the number of components as well as the size and weight
of the inverter are thus reduced.
The switching frequency of the inverter is 780 Hz. The high switching
frequency reduces heating of the motor and gives good modulation
properties.
The frequency converter losses are extremely low, as there are no

commutation losses.
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2.2.1 Power transistor (GTR = Giant Transistor)

The power transistors have earlier been limited to a low voltage range, but
components that are also applicable to higher mains voltages are now
available.
The transistors used in SAMI STAR are bipolar, triple-diffused Darlingtons.
Mechanically, they are insulated modules containing either all power
semiconductors (2 transistors + 2 free-wheeling diodes, figure 2.3) of one
phase or, at high currents, the power semiconductors (1 transistor + 1 freewheeling diode) of one leg.
C1
E2
B1
Figure 2.3.
E1/C2
B2
Connection of the transistor module
The benefits offered by power transistors compared to those offered by GTO

thyristors:
-
The rate of rise of the voltage need not be limited while turning off the
transistor, i.e. snubber capacitors are not needed.
The output terminals of the inverter can be made to withstand short-circuit

without the need of additional components in the main circuit.
A GTR is easier to manufacture than a GTO thyristor.
On the other hand, a GTR requires approximately 2 to 3 times more silicon

surface area than a GTO does at the same electrical values. The GTR is thus
used at the power ratings of up to 125 kVA, while the GTOs are used for
higher power ratings.
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2.2.2 Gate Turn Off (GTO) thyristor

The difference between a GTO thyristor and a conventional high-speed
thyristor is that the GTO thyristor can be turned off by applying a negative
current pulse to the gate. The peak value of the required current pulse is
approx. 25 % of the anode current to be turned off and the pulse duration is 10
to 20 s. The GTO has characteristics of both a thyristor and a power
transistor.
The GTO gives best results when applied in the high-current and high-voltage
ranges. The GTOs used in SAMI STAR are of the presspack-type (figure 2.4)
Anode
Gate
Cathod
Figure 2.4.
A GTO thyristor and its connection.
The rate of rise of the voltage must be limited while turning off the thyristor by
connecting a snubber capacitor across the GTO. Correspondingly, while the
GTO is turned on, the rate of rise of the current must be limited by means of a
di/dt choke.
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2.3
Star modulation
The modulator is a program segment which controls the power
semiconductors so that AC power of the desired frequency, phase and voltage
is generated. The modulator of SAMI STAR is optimized to minimize distortion
in accordance with the star modulation theory.
The star modulation method was developed for full digital control. It was
developed considering the special requirements set for the modulator by
vector control. The special requirements are:
-
zero frequency,
zero voltage,
reversing at zero frequency,
voltage controllable regardless of frequency,
voltage controllable over the entire frequency range.
The modulator uses two modulation methods:

- asynchronous: the number of times the switch is turned in a given time
unit remains constant. This makes zero frequency and smooth reversing
possible. In addition, the distortion of current remains small.
- synchronous: the number of the mains voltage pulses per half cycle
remains constant. This makes smooth running at high frequencies
possible. The pulse numbers are so selected that the distortion of current
remains as small as possible.
Figure 2.5.
Switching frequency fk as a function of output frequency f of the

inverter unit when the field weakening point is at 50 Hz.
(EN 5709 7116)
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The asynchronous (ASYN) modulation is used in the range 0 to 20 Hz, the

synchronous (SYN) modulation between 20 and 200 Hz. Six different pulse
numbers are used for synchronous modulation:
-
27
19
11
7
5
3
20 to 26 Hz
26 to 37 Hz
37 to 65 Hz
65 to 100 Hz
100 to 150 Hz
150 to 200 Hz
In practice, when the field weakening point is at 50 Hz, a transfer is made to

pulse number 3 at approx. 50 Hz. Pulse numbers 5 and 7 are used if the field
weakening point is at a frequency above 65 Hz.
When the star modulation is used the switching operations made between
different modulation methods and pulse numbers are smooth.
With respect to the heating of the motor, the star modulation gives, depending
on the frequency, a result which is as good as or better than that given by the
sine-triangle comparison at the same switching frequency.
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2.4
Additional motor losses

The frequency converter supply causes additional losses in the cage induction
motor because the motor currents are not completely sinusoidal but contain
harmonics. The harmonic content of the current is depicted by the ratio k of
the fundamental wave and r.m.s. value of the motor current, i.e. the
fundamental-wave portion of the motor current, in such a way that the motor
loadability at the frequency converter supply is approximately proportional to k.
In figure 2.6 the values of k are compared in certain variable AC-motor drives.
The superiority of the new technique in its softness on the motor is apparent,
in particular at fractional speeds, which is important for self-ventilated motors.
Figure 2.6.
The fundamental-wave portion of the motor current in certain ACmotor frequency converters. (EN 5709 7123)
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2.5
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Switching frequency
The switching frequency means the number of times a single switch (GTR,
GTO) is turned to and fro in a given time unit. A switching cycle consists of
one turn-on and one turn-off operation.
As the switching frequency increases, the additional motor losses caused by
the distortion of current are halved every time the switching frequency is
doubled. The switching frequency for the SAMI STAR frequency converter
series is 780 Hz.
Figure 2.7.
The heating of a squirrel-cage induction motor as a function of

the switching frequency of an inverter (measured on motor
HXUR 188 A2, 1.5 kW, 1500 rpm) a) at normal mains supply,
b) at frequency converter supply.
(5709 7132)
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2.6
Full digital control

The following benefits are achieved by means of full digital control:
-
definition of the set points as numerical values,

ideal repeatability of set points and parameters,
high accuracy,
standardized hardware, application-specific software,
reduced number of components and cards, high reliability,
serial data communication and thus reduced need for cabling.
The SAMI STAR control circuits are composed of a protection logic and an
INTEL 80186 processor and its peripheral circuits.
A separate protection logic guarantees fast and reliable protection functions.
The processor and its peripheral circuits are used to execute the output-stagespecific programs and to perform the operations required by the programs.
The programs are:
-
diagnostics,
modulator,
vector/scalar control,
data communications.
The diagnostics programs monitor the condition of semiconductors and current

transducers, detect faults in the tachometer signals and serial data
communications, and give reports on the operation of the protection logic.
The modulation program controls the switching functions of the inverter.
The vector/scalar control programs perform the motor drive control functions.
The data communication programs transfer data to the external control.
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2.7
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Serial data communication techniques

The use of serial data communication means:
-
reduced cabling costs,

flexible connection to various data processing equipment,
unlimited number of transferred variables,
improved noise tolerance.
SAMI STAR is connected to external control through a serial data bus.

Connection to the SAMI STAR serial channel can be made through a control
panel, a terminal, a PC, etc. The channel is implemented by means of a 20
mA optocoupled current loop. The baud rate is 4800 or 9600 Bd.
The serial channel is used for all communications between external control
and SAMI. The main operations are:
-
start/stop,
set-point setting,
reading of actual values,
setting of parameters for the controllers,
transfer of diagnostics messages.
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2.8
Scalar control - vector control

An electric drive is designed to transmit mechanical power to a driven machine
to establish a desired operating condition, normally a certain speed or torque.
2.8.1 Scalar control

In scalar control, the speed of the motor is set by adjusting the supply
frequency. The amount by which the speed remains below the synchronous
speed that corresponds to the supply frequency is dependent on the slip. The
slip settles to a value at which the driven machine will have the power it
requires.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
AC MOTOR
INVERTER
MODULATOR
UREF CALCULATION
CALCULATION OF ACTUAL VALUES
FORMATION OF FREQUENCY REFERENCE
REFERENCE-VALUE INTEGRATOR
TORQUE CONTROLLER
TORQUE-LIMIT CONTROLLER
UC-LIMIT CONTROLLER
CONTROL-MODE SELECTOR
SPEED CONTROLLER (REQUIRES A TACHOMETER SIGNAL)
Figure 2.8.
Block diagram of scalar control. (EN 5709 7639)
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Scalar control includes the following standard functions:

1.
2.
3.
4.
5.
6.
Standard program + blocks freely programmable

IR compensation
Slip compensation
S-curve of the reference value integrator
Trend buffers
SAFT 154 DAC D/A-converter connection facility
Standard program + blocks

All application functional blocks are available as standard in the scalar control
standard program.
IR compensation
At the low frequencies (up to 10 Hz) a significant voltage drop is produced by
the stator resistance of the motor. The drop is compensated by boosting the
output voltage of the frequency converter so that the proper magnetization is
always achieved. This so-called IR compensation is needed e.g. in constanttorque drives that require a high starting torque and in drives that require a
high release torque.
Slip compensation
Slip compensation is used when constant speed is required irrespective of
changes occurring in the load torque. The compensation effect can be
adjusted in proportion to the slip of the driven motor. The slip compensation
does not operate at frequencies below 10 Hz.
S curve of the reference value integrator
The operation of the reference value integrator is normally softened at the
bend points by means of a so-called S curve. If the integration time required
by the drive is short (< 3 s), the softening function begins to increase the
integration times significantly. In that case the S curve can be eliminated.
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Trend buffer
The inverter software contains 8 sampling buffers with 100 samples capacity.
The measuring point number can be set to the trend control address which is
to be used. A trend triggering occurs every time the inverter detects a fault. A
triggering can also be initiated manually (during operation) or it can be made
to occur when a deviation of two successive samples of a measuring point
monitored by the first trend buffer is detected.
The shortest sampling interval is 3 ms.
Trends can be examined in analog form by connecting the trend to a printer
(printing speed 100 samples/21 s) via the A/D converter of the inverter or by
reading trend numeric values on the control panel or via DMS on the screen of
your PC.
The SAFT 154 DAC D/A converter available as optional extra can be
connected to the inverter control card for a printer or an oscilloscope.
Scalar control also includes the following additional functions:
1.
2.
3.
4.
5.
6.
7.
Stall protection
Running start
Power loss control
Torque control
Speed measurement by means of a tachometer
Speed control by means of a tachometer
DC Braking
An additional function can be selected provided it has been activated in the

program at the factory.
Stall protection
The stall protection stops the inverter when the motor is in apparent danger of
overheating. The rotor is either mechanically stalled or the load is otherwise
continuously too high.
Running start
The running start program facilitates starting of the inverter to a running motor
without braking of the motor first. The inverter searches for a frequency that
corresponds to the shaft speed of the rotating motor and is synchronized to it.
A search can also be made when the shaft rotates in the direction opposite to
the frequency reference.
Large fan drives and centrifuge drives are good examples of suitable running
start drive applications.
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Power loss control

The power loss control circuit holds the inverter in operating condition during
short (approx. 0.5 s) power failures. The energy required for operation is then
taken from the kinetic energy available on the drive shaft. If a power failure
lasts longer than one second, the main contactor control logic will not be able
to close the contactor any more even if the kinetic energy is sufficient. In that
case a backed-up auxiliary voltage should be used for the relay block.
Torque control (> 5 Hz)
When torque control is selected for operation, the frequency converter is
controlled by means of the torque reference. The PI controller tries to keep the
drive torque at the set point by varying the frequency reference.
At frequencies below 5 Hz, torque control is automatically switched to
frequency control.
If torque control is required at frequencies below 5 Hz, the vector control
program must be used.
Speed measurement by means of a tachometer
If accurate information about the rotational speed of the motor is required, the
motor can be equipped with a tachometer which is connected to the inverter.
The speed is then available as a digital readout on the inverter control panel or
it can be obtained as an analog message.
Speed control by means of a tachometer
If the motor is equipped with a tachometer, speed control can be used. The
speed controller uses a tachometer signal to eliminate the error caused in the
shaft speed by the slip of the cage induction motor. The slip is dependent on
the load of the motor. The normal speed control operating range is 5 to 200
Hz. At frequencies below 5 Hz, speed control operates but its control
characteristics are slow. The rise time for a step response is 100 ms at
frequencies above 5 Hz.
When more demanding control dynamics are required, vector control must be
used.
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DC Braking
DC braking provides a stabile method of braking the motor by injection a DC
current into the stator winding of the machine. With DC braking the kinetic
energy stored in the rotating masses of the drive is dissipated in the motor.
Application Blocks
The following functions can be implemented by means of the application
blocks:
1.
2.
3.
4.
5.
6.
7.
Process control
PFC automatic system
Proportional control
Limiting control
Critical frequency protection
Flux optimization
Motor overload supervision
Combinations of the above mentioned functions are possible. The functions

can also be tailored for specific needs by means of the application functional
blocks. A total of approx. 250 functional blocks are available.
Process control
The process control function is used when it is advantageous to have the
process controller in the frequency converter. Pump and fan drives with
pressure, level or flow control are the most common application examples.
The process controller is a PI controller.
PFC automatic system
The PFC automatic system (automatic Pump, Fan and Compressor control
system) is used e.g. in drives which have several parallel-connected pumps.
The speed of one pump is controlled by a frequency converter while the other
pumps are connected direct on line as required. The PFC automatic system
facilitates stepless control of the entire volume to be moved.
A total of 5 pumps at a time can be started.
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Proportional control
The proportional control program is suitable for control applications in which
the basic drive speed reference is corrected by an additional reference
supplied from another source. An application example is the headbox fan
pump control of a paper machine. The proportional effect of the additional
reference on the basic reference is set through a program and is normally a
few percent of the basic reference.
Limiting control
The limiting control program is applicable e.g. in a gang mill feeding roll control
or in a pulp mill feeding chain control. The frequency converter is used to
control the speed of the feeding motor.
If the main motor (sawing or grinding motor) tends to be overloaded, the
program automatically reduces the speed reference.
Critical frequency protection
The frequency converter can be programmed so that running at critical speeds
is disabled. A total of 5 frequency ranges can be programmed into the
memory.
Flux optimization
When the flux optimization is used the motor can be driven with a reduced flux
at frequencies between 10 and 50 Hz, for example. The flux optimization
function is designed for pump and fan drives in which the load torque
increases quadratically in proportion to the speed. The noise level of the
motor can be reduced by means of the flux optimization.
Motor overload supervision
The motor overload supervision function includes a simple overload protection
for the motor in transient overload conditions. The loadability curve of the
motor is programmed into the memory (loadability at 0 Hz and at the field
weakening point). If an overshoot of the curve lasts longer than a preset
overshoot time, an overload alarm or tripping occurs.
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2.8.2 Vector control

The torque of an electrical motor is proportional to the current and the flux.
We get the fastest torque response from an asynchronous motor if we keep
the flux constant and only vary the current. To keep the flux of an
asynchronous motor also during transients constant we must employ a control
scheme called vector control. With vector control the stator current is
seperated into two components. One component, called id, is in the direction
of the flux vector. The other component, called iq, makes angle of 90 degrees
with the flux vector. By keeping id constant we are able to keep the flux
constant. We then control the torque by controlling iq.
To be able to seperate the stator current into id and iq, we must know the
position of the flux, which is rotating. In SAMI STAR the position of the flux is
found in the following way. We measure the motor currents and the rotor
speed. These signals are fed to a model of the machine that is stored in the
memory of the frequency converter. The SAMI STAR then calculates the
position of the flux. This calculation must be made in real time and we
therefore need a fast microprocessor. Once we know the flux position,
indicated by in Figure 2.9, the stator current can be seperated in the fluxoriented components.
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9
id ref
ref
id act
Tref
11
+
-
Flux
Control
iq ref
nref
+ n
PI
14
iq act
13
+
-
s +
Torque
Control
10
8
AM
act
-
Machine
Model
Parameter
Identification
12
Figure 2.9.
Block diagram of vector control. (5709 7141)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
Rectifier
DC-Bus
Inverter
AC-Machine
Pulse Generator
Modulator
Motor Model
Coordinate Changer
Saturation curve
Torque Control
Flux Control
Rotor Time Constant Identification
Torque reference selector
PI-controller (speed)
The parameters for the motor model are determined during commissioning of
the drive. The parameter identification is automated making the
commissioning easy. Saturation and changes of the rotor temperature are
fully taken into account. In fact, the control of SAMI STAR compensates for
changes in the rotor temperature while the drive is operating. This form of
adaptive control is indicated by block 12 in Figure 2.9.
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Vector control can operate in either torque control or speed control mode This
is indicated by the switch 13 in Figure 2.9. In torque control mode the torque
reference is directly applied to the torque controller. In speed control mode an
outer speed control loop is activated. The speed of the motor is controlled to
the desired value by means of a speed controller. The speed controller output
functions as the torque reference of the torque controller.
The static speed measurement accuracy is 0.01 % of the nominal speed when
a tachometer is used giving 1000 pulses per revolution. 10 to 20 ms torque
step responses can be achieved by using the torque controller.
Vector control is suitable for applications demanding good dynamic
characteristics and/or accurate speed control. The use of vector control gives
a squirrel-cage induction motor control characteristics equivalent to those of a
DC drive.
Vector control can, for example, be used to prevent flux weakening when the
load increases instantaneously and the whole current is needed in the rotor to
increase the torque. In practice, the flux and the torque are controlled by
varying the output voltage and frequency of the frequency converter.
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3.
SAMI STAR FREQUENCY CONVERTER
3.1
Mechanical design of the Frequency Converter

When designing the SAMI STAR series of frequency converters, ABB Industry
has utilized the experience gained with the earlier models. One important
design objective was the frequency converter's good adaptability to various
drives and applications. The construction of the SAMI STAR frequency
converter is based on the advanced module technology. A frequency
converter application is composed of modules which are assembled and
tested as separate units and which are easy to install in a cabinet.
Modules of SAMI STAR are:
-
Line Supply Unit SAFUS,

Contactor Unit SAFUL,
Line Rectifier Unit SAFUD,
Line Converter Unit SAFUC,
Line Generating Unit SAFUG, (Not in the scope of module deliveries)
Line Filter Unit SAFUF,
(Not in the scope of module deliveries)
Thyristor Braking Unit SAFUX,
Capacitor Bank Unit SAFUB,
Braking Chopper SAFUK,
Inverter Unit SAFUI,
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Figure 3.1.
The modules of the SAMI STAR frequency converter in a single

drive. (EN 5709 7159)
The modules are placed in the cabinet one beside the other. The space in the
cabinet is efficiently used as the modules are narrow, relatively deep and high.
The depth of the modules is, however, so selected that all modules will fit in a
600 mm deep cabinet. In single drives, the height of the cabinets is 2200 mm.
Modules weighing more than 50 kg are equipped with rollers.
The SAMI STAR modules are designed to be independent of the cabinet
construction as far as possible. The modules are suitable for the ABB MD
cabinets, but they can also be installed in cabinets of other manufacturers.
27
4.
3AFE 53515487
MODULES OF THE SAMI STAR FREQUENCY CONVERTER

The Line Supply Unit SAFUS includes connection devices, a diode bridge, a
DC choke and a capacitor bank. In the SAMI STAR frequency converters with
a power rating higher than 200 kVA, the SAFUS is divided into three separate
units:
- Contactor Unit SAFUL,
- Line Converter Unit SAFUC,
- Capacitor Bank Unit SAFUB.
The Line Rectifier Unit SAFUD includes a diode bridge, a DC choke and a
capacitor bank at the ratings 250 kVA, 400 kVA/380 V/415 V, 315 kVA/500 V,
and 250 kVA/660 V.
4.1
Contactor Unit SAFUL

The frequency converter is connected to the distributing mains via a
disconnector and a contactor. The main contactor is used to disconnect the
frequency converter from the mains also in case of a line converter unit failure
and in case of an emergency. Possible line converter unit failures are uneven
voltage division in the capacitors of the capacitor bank unit or overtemperature
in the line converter unit.
The main fuses of the contactor unit provide short-circuit protection for the
frequency converter.
CTU
U> O>
SAFT 136 CTS
0.5s
3~
IN
3~
OUT
220V
Figure 4.1.
24V
Block diagram of Contactor Unit SAFUL. (5709 7621)
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The SAFUB is charged through the charging resistors prior to the closing of
the main contactor. After termination of the 0.5 s charging period the auxiliary
contactor opens the charging circuit and the main contactor closes. The
operation is controlled by the Contactor Unit control and supervision card,
which also trips the main contactor in certain fault situations. External
interlock signals are also directly connected to the control and supervision
card.
The auxiliary voltage transformer of the SAFUL supplies 220 V to the
contactors of the unit and to the fans of the other modules. In sectional drives,
the auxiliary voltage transformer supplies power to all fans of the inverter units.
The SAFUL devices form a separate unit. Power to the contactor unit is
supplied either through the bottom of the cabinet or through the top. The
SAFUL is connected to the adjacent line converter unit by means of
connection busbars.
The Terminal Block Card (SAFT 174 TBC) to which the customer signals are
connected is located in the SAFUL unit or in the SAFUS unit at power ratings
less than or equal to 200 kVA. The application-specific devices, such as
earth-fault control, overvoltage protection and radio interference protection
devices, are located in the contactor unit when needed.
The SAFUL contactor units are built for the ratings 250 to 2500 kVA.
29
4.2
3AFE 53515487
Line Converter Unit SAFUC

The line converter units used in SAMI STAR are either 6- or 12-pulse diode
bridges.
4.2.1 6-pulse diode rectifier

The diode bridge and the electrical mains form the DC source of the frequency
converter. The DC source is connected to the SAFUB capacitor bank unit of
the intermediate circuit through a DC choke. The diode bridge is implemented
for different ratings as follows:
- diode modules for 40 to 125 kVA ratings,
- single-side cooled press-pack diode for 160 to 400 kVA ratings,
- double-side cooled press-pack diode for 630 to 2500 kVA ratings.
The RC snubber connected across the diode bridge eliminates short-time
overvoltages.
V51
V52
V53
C51
U1
R51
V1
W1
V54
V55
V56
PE
R52
A
L-
S51
X51
X52
V57
F51
~
N
Figure 4.2.
M51
M
1~
Circuit diagram of the 6-pulse line converter unit. (5741 8958)
30
3AFE 53515487

The 12-pulse diode rectifier is composed of two 6-pulse bridges with a 30
phase difference at the input generated by means of a transformer.
SAFUL 1.
SAFUC 1.
SAFUL 2.
SAFUC 2.
DC - bus
Figure 4.3.
The 12-pulse line converter unit in the SAMI STAR frequency

converter. (5779 6529)
Benefits of a 12-pulse line converter unit compared to a 6-pulse line converter

unit:
-
reduced harmonics, e.g. the fifth and seventh harmonics are not present.
Compared to the 6-pulse bridge, the power output is doubled by using the
same diodes in a 12-pulse connection.
31
3AFE 53515487

The 24-pulse diode rectifier is composed of four 6-pulse bridges with a 15
phase difference at the input generated by means of phase shifting
transformers.
SAFUL 1
SAFUL 2
SAFUC 1
SAFUC 2
SAFUC 3
SAFUC 4
SAFUL 3
SAFUL 4
DC-BUS
Figure 4.4.
The 24-pulse line converter unit in the SAMI STAR frequency

converter. (Example of a possible transformer connection)
The benefits of a 24-pulse supply compared with a 12-pulse one consist in a

further reduction of line harmonics. In order to fully benefit from this feature, a
very good symmetry of the phase shifting transformers is vital.
32
3AFE 53515487
4.3
Line Generating Unit SAFUG

The line generating unit is a normal SAMI STAR inverter unit (SAFUI) whose
terminal block card and control unit program are modified for regenerative
braking operation. This unit is not in the scope of module deliveries.
LGU
CONTROL CIRCUIT
U-SYNC.
UC
IR,IS,IT
+
LFU
I
MAINS
UC
~
220V
50Hz N
Figure 4.5.
M
1~
Block diagram of the line generating unit. (EN 5709 7175)
33
3AFE 53515487
The mains voltage is measured and on the basis of the measured value the
line generating unit is then synchronized to the mains.
The line reactor operates as a filtering choke which helps to reduce the line
current distortion to a sufficiently low level.
The current transducer provides overload protection for the line generating
unit.
A line filter unit SAFUF, which includes a choke, is always used in connection
with the line generating unit.
The intermediate circuit voltage (Uc) can be raised above the value which is
attainable by means of an ordinary diode bridge. This is done by controlling
the voltage and frequency of the inverter unit. The benefits offered by a line
generating unit compared to an ordinary diode bridge are:
-
DC-line reactive power compensation is possible when the Uc voltage is

20 % higher than the voltage supplied by an ordinary diode bridge.
There is no need to overdimension the inverter unit of the frequency
converter because of the line undervoltage as the Uc voltage is
independent of the line undervoltage.
Flow of active power in both directions (regenerative braking).
Almost sinusoidal line current.
The line generating units are built for the 160 kVA to 1000 kVA power ratings.
34
3AFE 53515487
4.3.1 Line Filter Unit SAFUF

The line filter unit is connected between the line generating unit and the 3phase mains. The SAFUF is designed to reduce harmonics in the output
current of the line generating unit. The nominal power range of the line filter
unit is 160 to 1000 kVA. This unit is not in the scope of module deliveries.
X71 1
F71
L71
U1
V1
W1
U2
V2
W2
PE
S71
X72
3
4
13
X72
1
1
1 0
~ 2
14
F72
2
~
N
M71
M
1~
Figure 4.6.
Circuit diagram of the line filter unit. (5742 4796)
35
4.4
3AFE 53515487
Thyristor Braking Unit SAFUX

The SAFUX thyristor braking unit includes an antiparallel connected thyristor
bridge with its control circuits and a DC choke. The thyristor braking unit is
used to implement regenerative braking and it then replaces the line converter
unit SAFUC.
The SAFUX is independent in operation. The operation is based on
supervision of the DC voltage and the line current. The power units have
presspack-type thyristors.
SAFUX units are built into three mechanical designs:
1.
2.
3.
SAFUX 315 F 500 (250 F 415) and 400 F 660

SAFUX 500 to 800 F 500 (400 to 630 F 415) and 630 to 1000 F 660
SAFUX 1250 to 2000 F 500 (1000 to 1600 F 415) and 1600 to
2500 F 660
The control techniques are based on the SAMI BG cards and software:
*
*
*
*
*
*
*
Power Supply Card

Thyristor Bridge Control Card
Interface Card
Interface Card
Motherboard
Pulse Amplifier Card
Voltage Measuring Card
SAMC 11 POW
SAMC 15 TBC
SAMC 19 INF
SAFT 181 INF
SAFT 182 MOB
SAMT 11
SAFT 183 VMC
36
3AFE 53515487
The voltage-specific matchings are made on the voltage measuring card (Udc)
and the pulse amplifier card (mains voltage). The inverter unit STOP signal
can be wired to the SAFUX. The STOP signal prevents unnecessary
generator mode control operations. In the event of a fault the SAFUX supplies
a potential-free output contact signal.
When the SAFUX thyristor braking unit is used, the following additional
components are required in the contactor unit:
o Synchronizing transformer
o 48 V DC generating circuits
SAFUX
M
1~
FG
CONTROL
Figure 4.7.
Circuit diagram of the thyristor braking unit (5709 9453)
37
4.5
3AFE 53515487
Capacitor Bank Unit SAFUB

The capacitor bank unit is needed in the intermediate circuit, because the
power taken from the intermediate DC circuit by the inverter unit (SAFUI) and
the power supplied to the intermediate DC circuit by the diode bridge both
contain ripple current. The SAFUB is a DC capacitor bank.
A1
X3
L+
C1.1
C1.n
X6
1
X1
1
X6
2
X1
2
R1
X2
PE
C2.1
C2.n
R2
X1
LS1
X1
3
1 0
~ 2
X2
1
M1
M
1~
Figure 4.8.
Circuit diagram of the capacitor bank unit. (5741 5703)
Gate-commutated semiconductors are used in the SAMI STAR inverter unit.

Since no commutation circuits are needed, the ripple currents of the DC
capacitor bank are reduced to approximately a third when compared to an
inverter unit implemented by means of high-speed thyristors. Thanks to the
small amount of ripple currents electrolytic capacitors can be used instead of
paper capacitors. Capacitors are connected in parallel and in series depending
on the power rating and voltage of the capacitor bank.
The compensating resistors distribute voltage evenly among the seriesconnected capacitors.
A fuse is connected in series with each capacitor in the SAFUBs with power
ratings equal to or higher than 400 kVA.
38
3AFE 53515487
When a fuse is blown, it disconnects the defective capacitor from the capacitor
bank while the rest of the bank continues to operate normally. The capacitor
bank unit supervision card gives an alarm of a blown fuse or of uneven voltage
distribution.
When the SAFUB is disconnected from the voltage supply, the capacitors are
discharged each through its own discharge resistor.
The design of the capacitor bank units is such that the units are suitable both
for single drive and for common DC-bus drive applications.
The nominal power range of the capacitor bank unit is 160 kVA to 630 kVA.
39
4.6
3AFE 53515487
Inverter Unit SAFUI

The inverter unit forms a three-phase voltage for the motor from the DC
intermediate circuit voltage. The power semiconductors used in the inverter
unit are either power transistors (GTR) or GTO thyristors, depending on the
power rating of the unit. There are therefore certain differences in the main
circuits of the unit.
The following standard cards control the inverter unit:
-
Power Supply Card,

Pulse Amplifier Card,
Chopper Control Card in the GTO inverter,
Control Card,
Interface Card,
Terminal Block Card.
Current Measurement Card in the inverter units with In = 1200 A.
The signals are galvanically isolated by means of fibre optic links.

See figure 4.9.
INU
+
V1
V2
V3
U2
I/U
Uc
V2
1)
I/U
M
3~
W2
I/U
V4
V5
M
1~
V6
V1
V6
CP1
4
P
I/O
CP2
Figure 4.9.
Hz
Block diagram of the inverter unit and its peripheral circuits.

(5709 5199)
40
3AFE 53515487
1
Power Supply Card (SAFT ___ POW). In GTR inverters, the card's power
is supplied direct from the intermediate DC circuit; in GTO inverters, the
power is supplied from the intermediate DC circuit through a power
connection card SAFT 190 APC. The SAFT 190 APC card is the power
connection part of the power supply card.
The power supply card supplies stabilized and filtered +14 V, +5 V to the
control card of the unit and an AC voltage of 42 V, 80 kHz for the pulse
amplifiers. In GTO inverters, the power supply card supplies 42 V AC, 80
kHz also to the SAFT 190 APC card, which produces +24 V and +13 V
from the 42 V for the interface card SAFT 188 IOC.
In GTR inverters, the SAFT 190 APC function circuits are contained on the
power supply card.
The power supply card is at the main circuit potential. The circuits needed
for Uc measurements (see figure 4.8) are also contained on this card.
Pulse Amplifier Card (SAFT ___ PAC, in the inverter units with In = 1200 A
SNAT 634 PAC) gives the turn-on and turn-off pulses (GTO) to the power
semiconductors in the order determined by the control card. The GTO
inverter units contain one pulse amplifier card per phase. In addition, a
separate pulse amplifier and control card is needed to control the DC
chopper.
The pulse amplifiers of the GTR inverter unit are all contained on one card.
The pulse amplifier cards include a separate power supply which provides
the supply power for the card from the 42 V, 80 kHz input voltage.
The pulse amplifier cards are at the main circuit potential. All pulse
amplifier cards also include logic that monitors the condition of the power
semiconductors and inhibits shoot-through control even if the control card
gave false control signals.
Control Card (SAFT 187 CON) is microprocessor controlled and its

operation is fully digital. In addition to monitoring its own operation the
card monitors the operation of the whole frequency converter and gives
report on the following failures:
overcurrent,
overvoltage in the intermediate circuit,
undervoltage in the intermediate circuit,
DC-chopper overvoltage or undervoltage (in GTO inverters only),
short-circuit,
serial data communications fault,
overtemperature in the power unit.
After a failure, a report is given on the first six failures.
41
3AFE 53515487
The main function of the card is to control the power semiconductors of

the inverter unit so that correct frequency and voltage is always supplied
to the cage induction motor under various operating conditions.
The control card is programmed either for scalar control, vector control or
for line generating unit control, depending on the application. Various
process application programs are also programmed into the control card
memory.
The control card contains a SAMI-type specific signal matching card (e.g.
SAFT 25 F 380).
The control card is at the main circuit potential.
4
Interface Card (SAFT 188 IOC) connects the inverter control unit to the
control panel. The connection between the interface card and the control
card is arranged through fibre optics, which gives an effective galvanic
isolation and a signal channel which is insensitive to disturbances coming
from external sources. The +24 V and +13 V supply voltages for the
interface card come direct from the power supply card.
The interface card is connected with ribbon cable to the SAFT 174 TBC
terminal block card which is located in the line supply unit or in the
contactor unit. The customer signals will be wired to the TBC card.
Terminal Block Card (SAFT 174 TBC) is used to connect the SAMI cards
SAFT 188 IOC and SAFT 164 AIO to external devices. The connection
between the TBC card and the IOC and AIO cards is arranged through 40and 10-pole ribbon cables.
The card includes serial channels for control panel CP2.
All customer signals except the maintenance panel and the associated
serial link are connected direct through the TBC card. The TBC card is
located in the line supply unit or, at power ratings higher than 200 kVA, in
the contactor unit.
42
3AFE 53515487
4.6.1 Optional cards

The following optional cards are available for the SAMI STAR frequency
converter:
- Relay Digital Output Card SAFT 175 RDO,
- Analog Input/Output Card SAFT 164 AIO,
- Analog Input/Output Card SAFT 186 AIO,
- Input Card SAFT 162 INP.
The relay digital output card is used when potential-free contact signals are
needed from the digital outputs of the SAMI. The card includes four output
channels.
The analog input/output card is used in process applications that require a
galvanic isolation of input signals, or in which two concurrent analog signals
are needed to control the SAMI. The card includes two galvanically isolated
analog input channels and two output channels. The card is applicable to
input signals 0...10 V, -10...+10 V, 0...20 mA and 4...20 mA.
Correspondingly, the output signal is a voltage signal 0...10 V, -10...+10 V or a
current signal 0...20 mA, 4...20 mA.
The Analog Input/Output card SAFT 186 AIO includes only one analog input
channel, which is not galvanically isolated.
The SAFT 162 INP card is a stripped-down version of the SAFT 164 AIO card.
The INP card includes only one analog input channel.
43
3AFE 53515487
4.6.2 GTR inverter

This power-transistor-based SAMI STAR inverter is used at low power ratings
up to 125 kVA.
CONTROL
PANEL
INTERFACE CARD (I/O)

6
CONTROL CARD ( )
POWER
SUPPLY
PULSE AMPLIFIERS
L1
R1
UDC
C11
C1
C12
C13
Figure 4.10. Block diagram of the GTR inverter. (EN 5709 7256)
The power semiconductors of the inverter unit are placed in insulated
modules, which contain either two transistors and two free-wheeling diodes or
one transistor and one free-wheeling diode depending on the power rating.
The power semiconductors do not require du/dt protection. The di/dt protection
is arranged through choke L1. After commutation, the excess energy stored in
the choke and the capacitors C11 to C13 is transferred through snubber
diodes to the clamping capacitor C1 which is discharged to the capacitor bank
via resistor R1.
The control card as well as the power supply and the pulse amplifier card are
at the minus potential of the main circuit voltage.
44
3AFE 53515487
Optocouplers are used to transmit the control signals of the power transistors.
The motor current is measured at two phases by means of Hall-effect current
transducers.
The self-diagnostics (control card) of the unit checks the condition of power
semiconductors, measuring transducers, pulse amplifiers and control logic
after the switching-on of the supply voltage. If a fault is detected, a fault report
is transmitted to the control panel.
4.6.3 GTO inverter
n
CONTROL
PANEL
INTERFACE CARD (I/O)

6
CONTROL CARD ( )
POWER
SUPPLY
CH
+
PULSE AMPLIFIERS
C9
L1
C1
C2
C3
UDC
Figure 4.11. Block diagram of the GTO inverter. (EN 5709 7264)
In principle, the connection of the GTO inverter is similar to the connection of
the GTR inverter except that GTO thyristors are used instead of transistors. In
addition, a DC chopper (CH) is used to feed the energies of the di/dt and du/dt
protection circuits back to the intermediate DC circuit.
The semiconductors of the inverter unit are presspack-type GTO thyristors.
Choke L1 is used as a di/dt protection and capacitors C1 to C3 as du/dt
protections for the GTO thyristors.
45
3AFE 53515487
The energy stored in the protection circuits is fed to capacitor C9 and from
there back to the intermediate DC circuit via the DC chopper (CH). This has
resulted in extremely low switching losses. A separate pulse amplifier and
control card control the DC chopper.
The motor current is measured at each phase by means of Hall-effect
measuring transducers.
After switching-on of the power, the self-diagnostics of the unit checks the
condition of each power semiconductor, the current measuring transducers,
the DC chopper, the pulse amplifiers, and the control logic. If a fault is
detected, starting is inhibited and a fault signal is transmitted to the control
panel.
For the unit the worst fault situations are a short-circuit in the output terminals,
an earth fault or a shoot-through in the power unit. In these cases, the
protective measures consist of turning off of the GTO thyristors and stopping
of the frequency converter.
46
3AFE 53515487
4.6.4 Parallel-connected inverter units

Control of the parallel-connected inverter units is based on master/slave
principle. The operation of the standard control cards which are contained in
the master inverter unit is the same as that of the control cards of smaller
frequency converters. The parallel connection cards collect and process data
on the operation of both frequency converters for the standard control cards
and transmit the control signals of the thyristors to the pulse amplifiers.
The parallel-connected construction is possible only in the following power
ratings:
1100 kVA 380/400/415 V
1500 kVA 380 V
1400 kVA 500 V
1600 kVA 400 V
1800 kVA 660/690 V
1650 kVA 415 V
2000 kVA 500 V
2500 kVA 660/690 V.
SAFUL
SAFUC
SAFUI
(MASTER)
SAFUI
(SLAVE)
f1
SAFUB
SAFUB
f1
f2
f2
M
3~
Figure 4.12. Block diagram of parallel-connected inverter units.

The interface card and the control card are contained in the master unit. The
external control connections are the same as those in a standard SAMI. In
addition, the drive requires the following four parallel connection cards:
- SAFT 176 MAC
- SAFT 177 SAC
- SAFT 180 PCC
- SAFT matching card.
N.B. The balancing choke shown in the figures on this and on the next
page is available only for the inverter types listed above on the
left side. The inverter types listed above on the right side can only
feed a motor with a double stator winding.
The choke is not needed with any parallel-connected inverter if the motor fed
by the inverter is equipped with a double stator winding.
47
3AFE 53515487
DC
busbar
Slave
-
Master
-
+
SAFT
188
IOC
Communication
interface
SAFT
187
CON
SAFT 180 PCC

SAFT 176 MAC
SAFT 177 SAC
SAFT 1100 F 380

1800 F 660
SAFT 630 F 380

1000 F 660
U2
V2 W2
U2
W1
W2
V1
V2
U1
U2
V2 W2
To motor
Figure 4.13. Parallel-connected inverter units.

The drive normally requires an output current unbalance limiting reactor.
However, if the motor has two separated identical stator windings with a
double set of connection terminals then the output reactor is not necessary.
48
3AFE 53515487
4.7
Braking Chopper SAFUK

In a SAMI STAR with no line generating unit, braking of the motor drive is
normally possible only by utilizing the SAMI and motor losses. The SAMI's
output frequency is lowered at a rate determined by the decrease of the motor
speed.
The braking power available from SAMI STAR can be increased by means of
a braking chopper.
BRC
BRR
CONTROL LOGIC
Uc
V2
&
V1
PULSE AMPLIFIER
Figure 4.14. Block diagram of a braking unit. (EN 5709 7124)

The braking unit is composed of a braking chopper and a separate braking
resistor. The braking chopper (SAFUK) is a separate unit which is directly
connected to the intermediate DC circuit of the frequency converter. When the
intermediate circuit voltage increases above the allowed limit during braking,
the braking chopper begins to operate and feeds the power supplied to the
intermediate circuit from the motor to the braking resistor R (SAFUR). The
chopper control logic controls the power fed to the braking resistor by
adjusting the conducting times of the GTO thyristor V1. The free-wheeling
diode V2 protects the GTO thyristor against peak overvoltages in turn-off
conditions.
Braking choppers are built for 63 kVA to 250 kVA power ratings.
49
5.
3AFE 53515487
CONTROL PANEL SAFP 11 PAN (Control Panel 1 ^ CP1)

The control panel CP1 is used to control the SAMI STAR frequency converter
in single drive applications.
The CP1 is installed in the door of the frequency converter cabinet and it
cannot be used for remote control. The panel contains 9 pushbuttons and a
digital display. The panel is connected to the terminal block card of the
inverter unit through a ribbon cable.
DP
PAR
0
1
S
Figure 5.1.
LOC
REM
RESET
FL 01CHOP UNDERVOLT (GTO)

FL 02 CHOP OVERVOLT (GTO)
FL 03 AUX.VOLTS FAULT
FL 04 OVERTEMPERATURE
FL 05OVERCURRENT
FL 06 DC-OVERVOLT
FL07 DC-UNDERVOLT
FL 09 SEMICON. FAULT U+
FL 10SEMICON. FAULT UFL 11 SEMICON. FAULT V+
FL 12 SEMICON. FAULT VFL 13SEMICON. FAULT W+
FL 14SEMICON. FAULT WFL 15 OUTPUT FAULT
FL 17 COMMUNICATION FAULT
FL 18 TACHO LOSS
FL 19 CURRENT MEAS. FAULT
FL 20 MOTOR STALLED
FL 21 MATCH CARD FAULT
FL 22 MODULATOR FAULT
FL 25 EXTERNAL FAULT
FL 28 SAMINODE FAULT
SA 50 NEW EEPROM
SA 51 STORED TO MEMORY
SA 52 MEMORY STORAGE FAILS
SA 53 PARAMETER TOO SMALL
SA 54 PARAMETER TOO LARGE
SA 55 ILLEGAL PARAMETER
SA 56 NO BATTERY BACKUP
SA 57 LOW AC/DC VOLT
SA 58 START INHIBIT
SA 59 SYSTEM RESET
Control panel CP1. (5709 7396)
The panel has the following functions:

-
operation commands to the drive (start/stop, frequency reference, etc.),

monitoring the operation (indication of frequency or load),
diagnostics,
drive-specific parameter settings.
50
3AFE 53515487
The digital display contained in the panel gives the following failure indications:
-
overcurrent,
undervoltage,
overvoltage,
overtemperature,
semiconductor fault,
processor fault,
line supply unit fault (digital input),
external interlock (digital input).
The control panel can be used to set parameters, e.g. the following:
-
integration time for the frequency reference,

minimum and maximum frequency,
torque limit,
field-weakening point,
starting torque maximizing,
crawl speed.
CTU
3~
AC IN
LCU
CBU
INU
CP1
M
3~
Figure 5.2.
Control panel CP1 in a single drive.(5709 7418)
51
3AFE 53515487
DP
PAR
0
1
S
Figure 5.3.
LOC
REM
10
RESET
FL 01CHOP UNDERVOLT (GTO)

FL 02 CHOP OVERVOLT (GTO)
FL 03 AUX.VOLTS FAULT
FL 04 OVERTEMPERATURE
FL 05OVERCURRENT
FL 06 DC-OVERVOLT
FL07 DC-UNDERVOLT
FL 09 SEMICON. FAULT U+
FL 10SEMICON. FAULT UFL 11 SEMICON. FAULT V+
FL 12 SEMICON. FAULT VFL 13SEMICON. FAULT W+
FL 14SEMICON. FAULT WFL 15 OUTPUT FAULT
FL 17 COMMUNICATION FAULT
FL 18 TACHO LOSS
FL 19 CURRENT MEAS. FAULT
FL 20 MOTOR STALLED
FL 21 MATCH CARD FAULT
FL 22 MODULATOR FAULT
FL 28 SAMINODE FAULT
SA 50 NEW EEPROM
SA 51 STORED TO MEMORY
SA 52 MEMORY STORAGE FAILS
SA 53 PARAMETER TOO SMALL
SA 54 PARAMETER TOO LARGE
SA 55 ILLEGAL PARAMETER
SA 56 NO BATTERY BACKUP
SA 57 LOW AC/DC VOLT
SA 58 START INHIBIT
SA 59 SYSTEM RESET
Operations on the control panel CP1.(5709 7396)
1. Six-digit display
2. Display selection: frequency reference, actual value of frequency or
current.
Selection of parameter value.
3. Starting the inverter
4. Stopping the inverter
5. Frequency reference increases, the parameter number or value increases
6. Frequency reference decreases, the parameter number or value
decreases
7. Selection of parameter number
8. Selection of local or remote control
9. Fault reset or storing of parameter value
10. Programmable key (reversing)
52
3AFE 53515487
6.
CONTROL PANEL SAFP 21 PAN (Control Panel ^ CP2)

The SAMI STAR control panel SAFP 21 PAN (figure 6.1) is designed for
controlling ABB Industry AC and DC drives. The panel contains 12
pushbuttons, a 16-character alphanumeric fluorescence display and a
microprocessor-controlled control unit.
The control panel enclosure is made of plastic and aluminium and its
enclosure class is IP55. The control panel can be installed in the door of an
AC or DC drive cabinet, in the control room desk or as a separate unit it can
even be placed close to the driven machine.
+125.6
F0
+125.5
+
START
STOP
Figure 6.1.
38.5
F1
PAR
F2
CTRL
F3
RESET
Control panel CP2. (5709 7442)
The control panel has the following functions:

-
operation commands to the motor drive

o
start/stop
o
frequency setting
o
direction of rotation
indications of the operating conditions of the motor drive

o
ready to start
o
current
o
frequency
o
process value
fault indications from the SAMI's diagnostics

o
overcurrent
o
semiconductor fault
o
tachometer fault, etc.
53
6.1
3AFE 53515487
indication of the test-point values

o
flux angle
o
intermediate circuit voltage, etc.
setting of process reference in single drives

o
level control
o
speed control
o
limit control, etc.
setting of parameters
o
tachometer matching
o
frequency limits
o
control gains, etc.
Single-drive control
The control panel can be used as an independent unit to control a separate
SAMI STAR drive. Figure 6.2 shows the block diagram of the control principle.
CTU
LCU
3~
AC IN
CBU
INU
CP2
M
3~
Figure 6.2.
Block diagram of a single drive. (5709 7451)
If the frequency control alone is sufficient for the application, the basic
operations of the control panel can be used (figure 6.3).
54
3AFE 53515487
+ 46,22 + 46,22 + 1,7

F0
START
STOP
Figure 6.3.
F1
PAR
F2
CTRL
F3
RESET
Operations on control panel CP2. (5709 7442)
1. 16-character alphanumeric display, indicating

frequency reference/actual value/motor current
texts: status and fault
parameter number and value
2. Starting of inverter
3. Stopping of inverter
4. Frequency reference increases, the parameter number or value increases
5. Rapid increase or decrease
6. Frequency reference decreases, the parameter number or value
decreases
7. Programmable key
8. Selection of parameter number
9. Selection of parameter value
10. Fault reset or storing of parameter value
If process control is needed, the control application is constructed by softwiring
the functional blocks stored in the memory of the inverter control card and by
setting the parameters. This can be done by means of the control panel
pushbuttons.
55
6.2
3AFE 53515487
Common DC-bus drive and sectional drive control

The control panel may also be connected to a more extensive computercontrolled system. Figure 6.4 shows the block diagram of such a system.
CONTROL PANEL
F0
START
STOP
F1
PAR
F2
CTRL
F3
RESET
DRIVE
No1
~
M
3~
DRIVE
No2
DRIVE
No3
Figure 6.4.
Block diagram of a common DC-bus drive or a sectional drive.

(EN 5709 7469)
In sectional drives or in common DC-bus drives, the control panel keys may be
used by a separate computer. The computer then operates on a higher
hierarchical level than the control panel. This reduces cabling costs and the
functions of the control panel keys are easy to change during commissioning
by modifying the master computer program.
56
3AFE 53515487
7.
DRIVE APPLICATIONS
The modules of the SAMI STAR frequency converter are used to implement
various drive applications. The three most common of these applications are
described below.
7.1
Single drive
The single drive is the most common of the frequency converter applications.
A frequency converter drive is called a single drive when it consists of a
separate power supply and one inverter unit which supplies one motor or
several motors.
Figure 7.1 shows the block diagram of a single drive, including contactor unit
SAFUL, line converter unit SAFUC, capacitor bank unit SAFUB, and inverter
unit SAFUI. The drive is controlled by means of SAMI STAR control panel
SAFP 11 PAN.
SAFUL
V1
U1
3~
IN
SAFUI
SAFUB
SAFUC
V2
V3
U2
I/U
V1
V2
W1
I/U
W2
I/U
V4
V5
V6
V1
V6
CP1
P
I/O
CP2
Figure 7.1.
Block diagram of a single drive. (5709 5199)
57
Hz
M
3~
7.2
3AFE 53515487
Common DC-bus drive

A common DC-bus drive is a combination of several single drives, with a
shared contactor unit, line converter unit and capacitor bank unit.
CP1
Dc Bus
(L+, L-)
CTU
3~
AC IN
CP1
LCU
INU
CBU
M
3~
supply section
Figure 7.2.
CP1
INU
M
3~
INU
M
3~
drive
section
Block diagram of a common DC-bus drive. (EN 5709 7426)
The inverter units of a common DC-bus drive are connected to the capacitor
bank unit through fuse switches and the DC bus. The control principle is the
same as in single drives.
Figure 7.3.
Block diagram of the inverter unit (SAFUI) of a common DC-bus

drive. (5709 7400)
58
3AFE 53515487
7.2.1 DC bus
Figure 7.2 shows that when several frequency converters are placed in the
same electrical equipment room, only the SAFUIs are needed as separate
units for each frequency converter, while the SAFUL, the SAFUC and the
SAFUB may be shared by all frequency converters of the drive.
A feature fundamental to the design of the SAMI STAR frequency converter is
the common DC bus, which brings the following benefits:
-
braking power is freely conducted from one inverter to another via the DC
bus,
total number of components is reduced,
load current on the DC capacitor bank is reduced,
costs are reduced,
suppression of interferences to and from the AC mains is easier.
Since the inductance of the DC bus must be an order smaller than the
inductance of the di/dt choke of the inverter units, the normal AC busbars
cannot be used. The required small leakage inductance is achieved when
thin, broad busbars are used pressed against each other and plastic insulation
is inserted between the busbars.
The DC bus is located in the upper part of the cabinets and the inverter is
connected to the bus through a disconnector.
A common DC bus can naturally be used for the supply of different sections of
one machine (paper machine, winder, barking line, bandsaw line). It is also
applicable when several frequency converters are placed in the same
electrical equipment room.
59
7.3
3AFE 53515487
Sectional drive
In a sectional drive (e.g. a paper machine), each section has its own inverter
unit SAFUI, while the SAFUL, the SAFUC and the SAFUB are shared by the
whole line.
CP2
CP2
CP2
SELMA 2
Dc Bus
(L+, L-)
CTU
3~
AC IN
LCU
CBU
INU
M
3~
supply section
Figure 7.4.
INU
INU
M
3~
M
3~
drive
section
Block diagram of a sectional drive. (EN 5709 7434)
Each SAFUI is connected to the DC bus through a fuse isolator (see figure
7.3). The emergency-stop command of the drive controls the main contactor
of the contactor unit. A motor-specific safety switch, if required, may be fitted
between the motor and the inverter unit.
The whole sectional drive is controlled by a computer (e.g. SELMA 2) with a
duplex, point-to-point serial communication link to the control panel of each
section. The control panel CP2 (SAFP 21 PAN) is the operating and display
station of the section concerned.
60

SAMI STAR Functional Description

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SAMI STAR

Block diagram of a frequency converter. (EN 5709 7094)

In the PWM frequency converters the intermediate circuit voltage is constant.

The output voltage between two phases of a PWM frequency

A simplified inverter construction, as the forced commutated circuits are

The frequency converter losses are extremely low, as there are no

2.2.1 Power transistor (GTR = Giant Transistor)

Connection of the transistor module

The benefits offered by power transistors compared to those offered by GTO

The output terminals of the inverter can be made to withstand short-circuit

A GTR is easier to manufacture than a GTO thyristor.

On the other hand, a GTR requires approximately 2 to 3 times more silicon

2.2.2 Gate Turn Off (GTO) thyristor

A GTO thyristor and its connection.

The modulator uses two modulation methods:

Switching frequency fk as a function of output frequency f of the

The asynchronous (ASYN) modulation is used in the range 0 to 20 Hz, the

In practice, when the field weakening point is at 50 Hz, a transfer is made to

Additional motor losses

The heating of a squirrel-cage induction motor as a function of

Full digital control

definition of the set points as numerical values,

The diagnostics programs monitor the condition of semiconductors and current

Serial data communication techniques

reduced cabling costs,

SAMI STAR is connected to external control through a serial data bus.

Scalar control - vector control

2.8.1 Scalar control

Block diagram of scalar control. (EN 5709 7639)

Scalar control includes the following standard functions:

Standard program + blocks freely programmable

Standard program + blocks

An additional function can be selected provided it has been activated in the

Power loss control

Combinations of the above mentioned functions are possible. The functions

2.8.2 Vector control

Block diagram of vector control. (5709 7141)

SAMI STAR FREQUENCY CONVERTER

Mechanical design of the Frequency Converter

Line Supply Unit SAFUS,

The modules of the SAMI STAR frequency converter in a single

MODULES OF THE SAMI STAR FREQUENCY CONVERTER

Contactor Unit SAFUL

SAFT 136 CTS

Block diagram of Contactor Unit SAFUL. (5709 7621)

Line Converter Unit SAFUC

4.2.1 6-pulse diode rectifier

Circuit diagram of the 6-pulse line converter unit. (5741 8958)

4.2.2 12-pulse diode rectifier

The 12-pulse line converter unit in the SAMI STAR frequency

Benefits of a 12-pulse line converter unit compared to a 6-pulse line converter

4.2.3 24-pulse diode rectifier

The 24-pulse line converter unit in the SAMI STAR frequency

The benefits of a 24-pulse supply compared with a 12-pulse one consist in a

Line Generating Unit SAFUG

Block diagram of the line generating unit. (EN 5709 7175)

DC-line reactive power compensation is possible when the Uc voltage is

4.3.1 Line Filter Unit SAFUF

Circuit diagram of the line filter unit. (5742 4796)

Thyristor Braking Unit SAFUX

SAFUX 315 F 500 (250 F 415) and 400 F 660

Power Supply Card

Circuit diagram of the thyristor braking unit (5709 9453)