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MarFlex Variable Speed Drive System

Author: Snijders Elektrotechniek B.V. MarFlex VDSV functional description.doc Page 1 of 67

User manualAnd

Functional Description

Disclaimer:Nothing of its contents may be published or distributed without the written approval of MarFlex BV

Rev Modification / Remarks Author Date

As build version L.Sonneveld 23-2-2011

2.0 Integration operating manual L.Sonneveld 24-3-2011

2.1 System design specifications L.Sonneveld 1-4-20112.2 Final changes L.Sonneveld 7-4-2011

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1 Table of contents

1 Table of contents...................................................................................................................2

2 Introduction ...........................................................................................................................5

3 List of abbreviations .............................................................................................................5

4 SYSTEM OVERVIEW .............................................................................................................6

4.1 General ..................................................................................................................................................... 6

4.2 Basic system overview......................................................................... ...................................................... 6

4.3 Power Conversion...................................................................................................................................... 7

4.4 Distribution Matrix ...................................................................................................................................... 7

5

SYSTEM FUNCTIONS...........................................................................................................8

5.1 Selection operation mode........................................................................................................................... 8

5.2 Emergency stop......................................................................................................................................... 8

5.3 Thermal motor protection ........................................................................................................................... 9

5.4 Motor heating.............................................................................................................................................9

5.5 Dry run ...................................................................................................................................................... 9 5.5.1 General................................................................................................................................................. 9 5.5.2 Ballast pumps ....................................................................................................................................... 9

5.6 Self Priming............................................................................................................................................. 10

5.7 Motor Data Sets....................................................................................................................................... 12

5.8 Discharge Pressure High ..................................................................... .................................................... 12 5.9 Inert Gas Low.......................................................................................................................................... 13

5.10 3rd

party cooling system failed .................................................................................................................. 13

5.11 Operating mode change failure................................................................................................................. 13

5.12 One or more Converters in operation........................................................................................................ 13

5.13 General alarm.......................................................................................................................................... 13

6 OPTIONAL FUNCTIONS ......................................................................................................14

6.1 Introduction.............................................................................................................................................. 14

6.2 Power Management System (PMS).......................................................................................................... 14

6.2.1 General description ............................................................................................................................. 14 6.2.2 PMS functionality for standard MarFlex configurations.......................................................................... 14

6.3 Water cooling........................................................................................................................................... 15

6.4 Cargo heating mode ................................................................................................................................ 15 6.4.1 General description ............................................................................................................................. 15 6.4.2 Cargo heating mode specifications....................................................................................................... 15

7 SYSTEM CONTROLS...........................................................................................................17

7.1 Introduction.............................................................................................................................................. 17

7.2 Local operation. ....................................................................................................................................... 17 7.2.1 General............................................................................................................................................... 17 7.2.2 The pump selection system ................................................................................................................. 17

7.2.3 The operation panels........................................................................................................................... 19

7.3 Remote modes ........................................................................................................................................ 28 7.3.1 Remote mode: Touch Panel ................................................................................................................ 28 7.3.2 Remote mode: Control Desk................................................................................................................ 28

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7.3.3 Remote mode: Cooperative with external systems................................................................................29

8 Remote Mode: TOUCH PANEL ...........................................................................................30

8.1 General ................................................................................................................................................... 30

8.2 Main Screens........................................................................................................................................... 31 8.2.1 Tree structure...................................................................................................................................... 31 8.2.2 Default screen..................................................................................................................................... 32 8.2.3 Overview screen ................................................................................................................................. 33 8.2.4 Pump control screens.......................................................................................................................... 34 8.2.5 Cargo heating mode screen................................................................................................................. 35 8.2.6 Cargo heating control screens ............................................................................................................. 36 8.2.7................................................................................................................................................................. 38 8.2.8 Pump screen....................................................................................................................................... 38 8.2.9 Converter screen................................................................................................................................. 39

8.3 Auxilliary screens..................................................................................................................................... 41 8.3.1 Tree structure...................................................................................................................................... 41 8.3.2 Communication fault screen................................................................................................................. 41 8.3.3 Fault screen ........................................................................................................................................ 42

8.3.4 Login screen ....................................................................................................................................... 43 8.3.5 Maintenance screen ............................................................................................................................ 44 8.3.6 Diagnosis screen................................................................................................................................. 45 8.3.7 Settings screen ................................................................................................................................... 46 8.3.8 Operating hours screen ....................................................................................................................... 47 8.3.9 Info screen.......................................................................................................................................... 48 8.3.10 Help screen .................................................................................................................................... 49

8.4 User management ................................................................................................................................... 50

9 Remote mode: CONTROL DESK........................................................................................51

9.1 Introduction.............................................................................................................................................. 51

9.2 General section ....................................................................................................................................... 52

9.2.1 Emergency stop button........................................................................................................................ 52 9.2.2 Emergency stop indication................................................................................................................... 52 9.2.3 Remote control indication .................................................................................................................... 52 9.2.4 External alarms ................................................................................................................................... 53 9.2.5 General alarm ..................................................................................................................................... 53 9.2.6 Buzzer ................................................................................................................................................ 53 9.2.7 Reset a converter-trip or emergency .................................................................................................... 53 9.2.8 Lamp test button ................................................................................................................................. 53

9.3 Converter sections................................................................................................................................... 55 9.3.1 Visualization....................................................................................................................................... 55 9.3.2 Speed / Power indication .................................................................................................................... 55 9.3.3 Start Pump.......................................................................................................................................... 55 9.3.4 Stop Pump.......................................................................................................................................... 56 9.3.5 Speed Change buttons........................................................................................................................ 56

9.4 Dry Run settings ...................................................................................................................................... 56

10 General Converter Functionalities .................................................................................58

10.1 Introduction.............................................................................................................................................. 58

10.2 Frequency converters in non-grounded systems....................................................................................... 58

10.3 Frequency converters as an electrical noise source .................................................................................. 59 10.3.1 High frequency harmonic distortion (load)........................................................................................ 59 10.3.2 Low frequency harmonic distortion (mains) ...................................................................................... 61

10.4 Frequency converters and earth fault detection......................................................................................... 62

10.5 Radio frequency interference suppression filters ....................................................................................... 62

11 Software design...............................................................................................................62

11.1 Standard control ...................................................................................................................................... 62

11.2 Dry run protection .................................................................................................................................... 63

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11.3 External interfaces................................................................................................................................... 63

12 VSDS system design specifications...............................................................................65

12.1 General ................................................................................................................................................... 65

12.2 Regulations ............................................................................................................................................. 65 12.3 Classification societies ............................................................................................................................. 65

12.4 Ambient conditions for panels............................................................... .................................................... 65

12.5 Power supply........................................................................................................................................... 65

12.6 Cable and cable entry specifications......................................................................................................... 66

12.7 Cooling water specifications ..................................................................................................................... 66 12.7.1 Sinamics converters........................................................................................................................ 66 12.7.2 Vacon converters............................................................................................................................ 66

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2 Introduction

This document describes the and functional specifications of the MarFlex Variable Speed Drive System(VSDS)which is required for Cargo handling with the MarFlex Deepwell pumps.

The MarFlex VSDS is an assembled system of electrical components, suitable to control the speed andtorque of MarFlex Deepwell pumps, complete with presentation of operational situations and alarms for automatic or human interventions.Frequency Converters are the main components of the system. By controlling the voltage and frequency of the electric motor, the speed of the motor can be adjusted. With parameter settings in the converter, themaximum current and frequency of the motor is limited. This means limitation of torque and speed of thepump.

Converters are assigned to electric pump motors by contactor matrices. Number of operational choicesdepends on the design of these matrices. In normal pump operation, only one pump is assigned to aconverter. In the optional VSDS function called Cargo Heating Mode, a maximum of 2 pumps can beassigned to one converter. Output power of the motor reduces likewise.Changes in operation situations are only possible when the converters are shut off.

Human control and operation takes place by means of Human Machine Interfaces (HMI). For emergencysituations the most direct way is local mode: simple manipulations on the converter cabinets with a paneland pushbuttons. For normal operation more sophisticated HMIs are possible, such as Touch Panels,Control desks and Cargo Computers. Flexibility of operation depends on the number of HMIs.Selection of the mode of operation and which HMI is active takes place with a selection switch.

All parts of the assembly are connected and controlled by a Programmable Logic Controller (PLC).

Due to the described layout of the MarFlex VSDS, the configuration can be easily expanded with severaloptions.

3 List of abbreviations

The abbreviations in the following list are used frequently in this document.

Abbreviation Meaning Description

AC Alternating Current 50 Hz or 60 Hz sinusoidal currentPLC Programmable Logic Controller Device for controlling processes using free programming

PTC element Positive TemperatureCoefficient element

Device for measuring temperature as resistance, alsocalled thermistor

TP Touch panel Device for operation and monitoring using a touchsensitive screen

VSDS Variable Speed Drive System Standard MarFlex system assembled as xx times 2-3frequency converters to drive 2-8 pumps simultaneously.

WCU Water Cooling Unit External unit to cool Frequency Converters with water

HMI Human Machine Interface Part of VSDS which converts human commands intoautomatic actions

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4 SYSTEM OVERVIEW

4.1 General

The MarFlex Cargo Handling System consists of pumps which are used to discharge cargo and slop tanks.The pumps are driven by AC motors which are speed controlled by the MarFlex Variable Speed DriveSystem.Sometimes discharge of Ballast tanks is as well part of the MarFlex System. Also these pumps can becontrolled by the VSDS.Next to the tank pumps, some auxiliary pumps can be driven by the VSDS, such as residual, tank cleaning,skimming and bilge water pumps. In case variable speed is not requested, these pumps will be driven by softstarters.

4.2 Basic system overview

The configuration of the system is shown in figure below.

The basic configuration consist of a PLC, connected to the frequency converters by a Profibus-DP field bus.The PLC (Programmable Logic Controller) is the master controller of the system. The field bus carries out allinterfacing between the PLC, frequency converters and HMIs. The PLC can be connected to the cargocomputer, hard wired or by a field bus. A PLC is a Programmable Logic Controller which contains software. The operating system of the PLC is S7.This is highly stable industrial software, it can not be compared to PC operating systems like Windows.Windows only acts on events and actions from the outside, S7 is a real time operating system. This meansthat in cycles of milliseconds standard internal actions take place. For example: scanning inputs and storingmeasured values, scanning internal memory and activating outputs. The programmer decides with theproject related software which specific actions are necessary.

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4.3 Power Conversion

To control pumps at variable speed, the electric power delivered by the generator, must be converted to a

variable frequency (speed) and current (power) level. These frequency converters are placed in converter cabinets, together with basic local safety and control components, such as:- main power circuit breaker - local control paneland external hard wired safety signals such as:- emergency stop - overheating signal electromotor

Variable speed control is standard supplied for cargo and slop pumps. For other pumps it is optional.Basic supply for ballast pumps as well as auxiliary pumps is control by soft starter.

MarFlex advises against the use of Star-Delta starters, both for technical and commercial reasons.

During cargo handling a converter is connected to one pump (single drive configuration). The number of converters, together with the capacity of the pumps, determines the total cargo discharge capacity and

discharge time.

4.4 Distr ibu tion Matrix

To make efficient use of materials, the number of converters used for the pumps are as small as possible. All pumps can be connected dynamical to each CONVERTER by using contactors.This way of energy distribution is called a matrix.In local control the matrix is controlled by hardwired logic, in remote control the matrix is controlled by thePLC.

The way of distribution determines the flexibility of the discharge operations and the time loss in case a

converter is out of order. Classification rules state that each cargo, slop or ballast pump must be at leastconnectable to two converters. This is stated to be certain that, in case of malfunction of a converter, a tankcan always be discharged.

MarFlex advises to distribute in a way that always more then one converter can take over. Most practicaldistribution configuration for both construction and operation is at least three converters to all pumps on oneside of the vessel. This configuration is called the portside-starboard-matrix.

The energy distribution is as follows:1 time 3on6 matrix 2 times 2on4 matrix

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5 SYSTEM FUNCTIONS

5.1 Selection op eration mod e.

One VSDS cabinet, the first matrix cabinet or the PLC cabinet, has a switch to select thecontrol operation of the system. Several options are possible. Always present is:

- LOCAL = Local operationOne or more of the following options are present:

- CARGO = Remote operation with the cargo computer - TOUCH = Remote operation with the touch panel- DESK = Remote operation with the control desk

In local control the pumps are controlled using only an converter. The PLC is not essential in this mode. Allnecessary functionalities are built in the converter and therefore limited.

By using the pushbuttons on the cabinet, a pump can be allocated to theconverter. The pump can be operated on the keypad of the converter cabinet.Local control is only used in emergency situations, such as PLC failure.During local control without defects in the remote control, information is still presented to the operator as inremote mode. Remote operation is not possible.

Only one mode is valid at a certain moment. When one converter is switched to local mode the completesystem is in local mode. All pumps running during the transition are normally stopped.

In remote control the pumps are controlled using the PLC which increases the functionality and thereforeflexibility. Operation can take place in different ways depending on the customers wish.Remote control only becomes active again when all converters are switched back to remote control and allpumps are stopped. Remote control is the preferred and default way of operating the pumps.

When the operating mode is changed from a remote mode to a other mode,with one or more drives running,a “Operating mode change failure” is generated, and the running drives will be stopped by a “General stop”.Changing the operating mode from local mode to another operating mode, with one or more drives running,only the “Operating mode change failure” is generated. In this situation the drives will stay running.The operating mode change will only take effect when all drives are stopped, and the “Operating changefailure” has been reset.

5.2 Emergency stop .

The system is provided with an emergency stop safety relay which is situated in the

PLC cabinet. All emergency stop buttons are connected to this relay. By activating anemergency stop button all pumps, except for ballast pumps, will be switched off immediately. Emergency stops are handled this way in both local and remoteoperating modes.

The converter receives a hard wired signal to stop, which results in an OFF2 stop.With the OFF2 stop the converter stops pulsing, and the motor will coast down. The local control padpresents the emergency stop as an external fault. For extra safety the power supply of the contactors isswitched off by hard wiring.

To restart the system after an emergency stop, a reset command must be given. Thereset button is mounted on the PLC cabinet door.

At least one emergency stop push button is present in the system. It is located on the PLC cabinet door.Inside terminal strokes are present to connect 3 extra pushbuttons and one is provided separately. 4terminals are provided in the PLC cabinet for extending the number of emergency push buttons.Two Ex-barriers are in line (one per channel) with the safety circuit of all emergency stop push buttons.

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8 terminals are provided to connect emergency stop buttons in the Ex-zone on deck.

5.3 Thermal moto r protectio n

All motors are equipped with one or more PTC-resistors for thermal protection. The motor PTC-elements areconnected to a PTC-relay with one fault contact. In case of overheating the motor, the PTC-relay generatesa failure. The fault contact of the relay is hard wired connected to the converter.The actions of the system are:

- OFF2 stop (coasting down) of the motor connected.- Temperature fault displayed on the remote mode control panels- External fault message on the local display, in local and remote mode.- Activation PLC output General Alarm

A thermal fault can only be cleared once the PTC-relay has been reset manually in the cabinet.

5.4 Motor heating

When a pump motor is not running and disconnected from a converter, the motor is heated by stand stillheating. This heating prevents condensation in the motor. Activation of the motor heaters is hard wired. Therefore this function is also present in local mode.

Note: optional it is possible to signal the operation of the standstill heating with a blue signal lamp on thecontactor cabinets

5.5 Dry run

5.5.1 General

In normal operation the selected pump is pumping fluid, which results in a motor load. The motor load isrepresented in the converter by motor current, dependent on the speed of the pump (more speed meansmore flow, means more load). MarFlex pumps needs fluid to cool the pump seals. Running a pump withoutfluid will damage the pump and should be prevented. This is called dry run.

To prevent a dry run situation, the converters are equipped with a safety function.If a pump is running above 50% of its maximum speed and the motor current drops below 30% of thenominal motor current, the dry run function is activated. If the value of the current does not rise within 30seconds, the system will generate a dry run alarm signal.If the value of the current does not rise within 180 seconds, the system will generate a dry run trip, whichresults in a normal motor stop in local and remote mode.

Dry run function is available in local and remote control. Alarm and trip situations are signalled on the remote control panels and on the local control screen.Local control alarm is presented as an external fault.

Dryrun parameters can only be changed by authorised MarFlex engineers, and are therefore protected witha password.

Since Simocode motor switches run at a fixed speed, dry run is detected when the motor current dropsbelow 30% of the nominal motor current, independent of the motor speed.

5.5.2

Ballast pumps

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For ballast pumps running on a converter (Not on a Simocode) there is a different dryrun detection system.The dryrun-current is dependent on the actual speed. This dependency is set by 4 parameters: S1 , S2 , I1and I2. The following diagram shows the calculation of the dryrun current:

The dry-run current (Idr) at speed (Sact) is calculated with the following formula:

Dry run detection for ballast pumps running on a Simocode is the same as dry run detection for normalpumps, as described in par. 5.5.1.

5.6 Self Priming

The MarFlex pumps are of the centrifugal type, a type of pump type which is not capable of self aspiration.Self priming is a function for non-self priming pumps, which are not always surrounded by fluid. In this case itis only applied to the ballast pumps. Non-self priming pumps need fluid in the pump before the pump isstarted to create a start flow. When a start flow is created, the flow will continue as long as the pump keepsrunning and fluid is available at the pump suction side.To create a start flow, the housing of the pump is filled with fluid by activating a fluid injector. This activationis called here the “self priming” function of the VSDS.

After a start of a ballast pump, the priming valve is opened, and the motor current is monitored. If the currentremains below a preset value ( Idr) of its nominal value for 30 seconds, it means that the start flow in thepump has been insufficient to create a continuous flow. A dry-run warning is generated. On this dry-runwarning the pumpspeed will be set to zero.

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The injector will inject liquid into the housing of the pump and after 30 seconds the pump will speedup to theprevious setpoint automatically. If the current again remains below Idr for another 30 seconds thepumpspeed will be set to zero again. This sequence will be repeated until there is enough liquid in the pumpto create a continuous flow, 4 times maximum.The priming valve remains active until one of the following events occur:

1. The pomp is stopped. ( By the operator or by a system-stop )2. There has not been a dry-run warning for more than 40 seconds.

If a dry-run warning occurs after 4 restarts, the system will generate the “dry run” failure.

The following diagrams show the different self-priming sequences:

1. Self-priming sequence, dry-run fault after 4 priming cycles

2. Self-priming sequence, no dryrun after second priming cycle

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5.7 Moto r Data Sets

One converter can select different motors with different specifications. The specifications (protection) of 4individual motors can be stored in the converter Motor Data Sets.The Motor Data Sets are:

1. Cargo pump.2. Slop pump.3. 2 Cargo pumps in heating mode. (*1) 4. Ballast pump.

Data Sets are introduced and checked by MarFlex.

They may not be altered during operation. Only after installation of a new motor or pump with other specifications, data sets may be changed by specialists.

(*1) If in heating mode two different types of pumps are selected (e.g. cargo and slop), the motor data set for cargo pumps is selected. In this situation no guaranty is provided for each pump running at the correct speed!

5.8 Discharge Pressure High

MarFlex VSDS is equipped with the possibility to react on high pressure situations in the cargo dischargepiping. Information of a pressure limit switch is necessary, connected with a potential free contact.When the potential free contact opens, all cargo and slop pumps will stop by an OFF2 stop, and an alarm ispresented to the operator. Ballast pumps are not affected with this alarm.

The discharge pressure high function is present only in remote modes.In local mode, the pumps will not stop.

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When an “Discharge pressure high” failure appears in local mode, the 3rd

party will have to present anaudible signal, in order to warn the operator for the situation.

In case pressure switch information is not available, this function is deactivated

5.9 Inert Gas Low

MarFlex VSDS is equipped with the possibility to react on inert gas low situations in the cargo and sloptanks. Information of a pressure limit switch or gas analysis system is necessary, connected with a potentialfree contact.When the potential free contact opens, all cargo and slop pumps will stop by an OFF2 stop, and an alarm ispresented to the operator. Ballast pumps are not affected with this alarm.

The inert gas low function is present only in remote modes.In local mode, the pumps will not stop.When an “Inert gas low” failure appears in local mode, the 3

rdparty will have to present an audible signal, in

order to warn the operator for the situation.In case pressure switch information is not available, this function is deactivated

5.10 3 rd party cool ing system fai led

If applied, the MarFlex VSDS system can detect a 3rd

party cooling system failure. This detection is through adigital input of the PLC. When “3

rdparty cooling system failed” is detected, in remote operation all pumps will

stop. In local mode the pumps will not stop.

5.11 Operating mod e chang e failure

When the operating mode is attempted to be changed from one remote mode to another mode, and one or more pumps are running, an “Operating mode change failure” is generated, and presented on the remotecontrol. When the “Operating mode change failure” occurs, all pumps will stop.When the operating mode is attempted to be changed from local mode to another mode, the pumps will keeprunning, and an “Operating mode change failure” is presented on the remote display.

5.12 One or more Converters in operation

There may be circumstances on board that it is necessary to warn other systems that the MarFlex VSDS isactive. For this the VSDS is equipped with an output signal containing that information.This signal is provided by the PLC to indicate that at least one CONVERTER is in operation. The signal ispresent for external use as a potential free contact. It is only available in remote control.

5.13 General alarm

General alarm is provided by the PLC to indicate that there is a pending alarm. The alarm is presented aslight indication on the contactor cabinet and on all remote control panels.The signal is present for external use as a potential free contact. It is only available in remote control.

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6 OPTIONAL FUNCTIONS

6.1 Introduction

The MarFlex VSDS can be equipped with several fully integrated optional functions. Functions can be addedin the following ways:

- Extra internal VSDS-function: extension of local or remote control application- Import or export of hard wired signals: the imported signals are potential free normally closed

contacts. They are used to generate a normal or quick stop, or used only for signalling purposes. Actions can be done per pump or for the whole VSDS.

- Import and export of information with data communication lines. In this way the amount of communicated information is unlimited. Also actions can be numerous. Extra thorough specificationsare needed to execute the right actions.

Extra functional specifications are needed to execute the wished actions in particular operation situations.Some common known optional functions are specified in the paragraphs hereafter.

6.2 Power Management System (PMS)

6.2.1 General description

To prevent that the electrical grid will vary in voltage and frequency due to the start of too many consumers,a power management system decides if an electrical consumer may be started.

When the operator chooses a pump to start, the VSDS generates a “start request” signal for this pump. Thesignal will be sent to the power management system, which checks if enough electrical power is available tostart this pump. When there is enough power available the VSDS will receive a “start permit” signal (eachpump needs a start permit signal). When the pump finally runs, the VSDS will activate a “Pump Running”signal.This function is managed by the PLC, therefore it only operates in remote mode.The VSDS is designed for standard MarFlex PMS systems.

6.2.2 PMS functionality for standard MarFlex configurations

- For standard MarFlex VSDS systems the PMS system has the following specifications: PMS is only

functional for cargo and slop pumps.- PMS is not functional in “cargo heating mode”.- There is one “PMS Request to Start Pump” signal, a plc-output.- There is one “PMS Start Pump Permitted” signal, a plc-input.- For each pump [x] there is a “Pump [x] running” signal, a plc-output.- .Only one “PMS Request to Start Pump” can be executed, other pumps have to wait until the request

sequence for the active pump has finished.

- The sequence for starting a pump is:

1. A pump start request is generated by one of the operating systems (Touch panel (TP), control

desk (CD) or cargo computer).

2. If there is no other PMS request pending, the “PMS Request to Start Pump” signal is set to “1”.

3. On the operating system (TP or CD) a signal “PMS start request pending” is presented.

4. If the PMS responds with the signal “PMS Start Pump Permitted”, the pump will be started, and

the “PMS Request to Start Pump” signal is set to “0”.

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5. When the pump is running, for each pump the signal “Pump [x] running” ( where x is the name of

the pump ) will be set to “1”.

6. When the pump is stopped, for each pump the signal “Pump [x] running” ( where x is the name

of the pump ) will be set to “0”.

7. If the PMS does not respond with the signal “PMS Start Pump Permitted” within 90 seconds, thefault message “PMS start prohibited” is presented in the operating system (TP or CD). The

signal “PMS start request” will be set to “0”.

On the touch panel the PMS status is presented in the following way:“PMS start pending” : blinking green led in pump section of matrix screen.“PMS start permitted” : green led in pump section of matrix screen.“PMS start prohibited” : red led in pump section of matrix screen.“Other PMS request pending” : blinking red led in pump section of matrix screen.

On the control desk the PMS status is presented in the following way:

“PMS start pending” : blinking 1 Hz green led in the pump start button.

“PMS start permitted” : green led in the pump start button.“PMS start prohibited” : blinking 5 Hz green led in the pump start button, and general

failure lamp on.“Other PMS request pending” : not presented on control desk.

If a “PMS start prohibited” occurs, a fault message is generated, and presented in the fault screen of thetouch panel.

6.3 Water cool ing

Water is a better cooling medium than air. Normally the MarFlex VSDS is supplied with air cooledconverters. High power systems can be delivered with water cooled converters.

The heat loss of the converters must be removed by an external water cooling system.To guarantee the minimum water quality specifications MarFlex advises to use a separate cooling unit for theMarFlex VSDS. This unit is not standard included in the package of the MarFlex VSDS.The cooling unit has to comply to the specifications as described in chap Fout! Verwijzingsbron nietgevonden..

6.4 Cargo heat ing mode

6.4.1 General description

Cargo heating mode is a optional function that provides a flow of cargo while keeping it at certain

temperature by leading the cargo through heaters.In cargo heating mode it is possible to connect a maximum of two pumps to one converter. The maximumspeed of the pumps is limited by the maximum power of the converters.The heaters are not controlled by the VSDS.

Cargo Heating Mode is only possible when a touch panel is present as remote control unit.

6.4.2 Cargo heating mode specifications

Cargo heating mode has the following specifications:1. A maximum of 2 pumps can be connected to one converter in cargo heating mode.2. The maximum pump speed in cargo heating mode is 50%.

3. There is no guaranty that both pumps in cargo heating mode operate at the same speed. If for example one pump is in a less viscous media then the other pump, the first pump can still be at thecorrect speed, while the other pump runs at speed zero.

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4. If two pumps with different specifications (e.g. a cargo and a slop pump) are connected to oneconverter, there is no guaranty that both pumps will operate at the same speed.

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7 SYSTEM CONTROLS

7.1 Introduction

The MarFlex VSDS can be operated in several ways. For normal operation there are more remote modespossible. In emergency situations local mode is always present.Only one mode of operation can be active at one time. The choice between the different modes isdetermined by using the selector switch on the PLC cabinet.

7.2 Lo cal operation .

7.2.1 General

In emergency situations or when the PLC is stopped (due to a failure), the converters can be operated inlocal mode. This mode is automatically active in case the PLC detects a data communication failure.

To provide starting and stopping in local mode the converters are equipped with a pump selection system,and with an operation panel. For each brand of converter, a different type of operation panel is used. Thepump selection system is the same for each brand of converter.

7.2.2 The pump selection system

To select a pump on a converter a number of illuminated pushbuttons are available on the converter cabinet. A pump can be selected by pushing the corresponding button. A red pushbutton is available to undo theselection. On a converter only one pump can be selected. The following drawing shows an example for thepump selection buttons :

Pump 1p Pump 2p Pump 3p

Deselect

Before a pump can be started by the operation panel on a converter, the following conditions have to bepresent:

.The operating mode switch has to be in the position “Local mode”. The converter has to be available ( No other pump selected on this converter ). The converter has to be ready ( No faults )

A pump can be selected in the following way:

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On the converter cabinet the pushbutton corresponding with the desired pump is pressed.

The light in the pushbutton will be lit. Now the pump can be controlled via the converter panel.

After the selected pump has come to a complete standstill, and the operating panel has given up control, thepump can be deselected by pressing the red deselect pushbutton. The light in the green pushbutton will beoff.

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7.2.3 The operation panels

7.2.3.1 The operation panel for Sinamics converters

Each Sinamics converter has an AOP30 (Advanced Operator Panel) mounted on the door which isconnected to the corresponding converter. Using this panel a motor can be started and stopped.With this panel it is possible to increase or decrease the speed of the motor connected. On the display of thepanel the motor speed and motor current is presented, as well as the actual status of the converter.

If the key switch on the PLC cabinet is set in mode “LOCAL”, all running converters will be stoppedautomatically.

AOP30 Layout

Before a pump can be started, the pump has to be selected ( par 7.2.2 ).First action to operate with the AOP30 panel is to place it into the local mode by pushing the Master ControlSelector. The selector reacts with highlighting a yellow LED in the button, meaning that the converter is

ready to operate in local mode. After the pump has come to a complete stop, the control can be given up bypushing the Master Control Selector. After that the yellow LED in the button will be off.Because remote control is deactivated, all AOP30 panels must be placed in local mode to make fulloperation possible.The following functions are available on the AOP30 panel:- Start pump: Choose pump with selection switch on front door and press the green ON key.- Stop pump: Press the red OFF key.- Increase pump speed: Press the Increase key until setpoint speed is reached.- Decrease pump speed: Press the Decrease key until setpoint speed is reached.- Change visualization LCD screen: Navigation with MENU, F2 ▲, F3▼ and F5 OK

Status information is displayed by three LEDs:- green flashing: converter is “READY FOR OPERATION”

- green continuously: converter is “RUNNING”.- yellow continuously: an alarm is active.- red continuously: a fault is active

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After a pump is started, the pushbuttons on the matrix cabinet are de-activated.

An important visualization to control the pumps is the status display of the AOP30 panel.

The following information is displayed:- Status of converter:

• Ready: Converter stand by, no fault present, ready to switch on.• Operation: Converter is active.

• Fault: Converter has an actual fault. Reset with function key F5.- Operating direction: direction of the pump.

• ►: operation clockwise (not possible for MarFlex systems)

• ◄: operating counter clockwise.- Operation time: System time.- NSET = Desired speed: Desired pump speed. (rpm)- 24001 = Actual speed. (%)- N_ACT = Actual speed. (rpm)- PACTV = Actual power consumption: Output power converter = Input power E-motor connected.(kW)- I_ACT = Actual current. (Aeff)- 24002 = Actual current. (%)- V_DC = Actual bus voltage: Voltage of the internal DC bus of the converter.(V)- V_OUT = Output voltage. (Veff)- M_ACT = Actual torque: Output torque of the E-motor connected.(Nm)- F_ACT = Actual frequency. (Hz)

- Text line: Line of comment to be used for

• Functional description of the F-key’s.

• Actual fault message.

• Actual alarm message.

Information about faults and alarms can be found on the “Active Alarms” and “Active Faults” displays and inmanual Sinamics S120 AOP30 2006-03 eng.pdf.

Parameterization of dry run parameters for cargo, slop and residual pumps:25000 – threshold for start detection below the value, in rpms. Default value 50%25001 – threshold for decision dry run in Amps as percentage of the nominal value. Default value 30%

Parameterization of dry run parameters for ballast pumps:24525 - dry run speed limit 1, default value 50%24526 - dry run current limit 1, default value 35%24527 - dry run speed limit 2, default value 100%24528 - dry run current limit 2, default value 67%

7.2.3.2 The operation panel for Vacon converters

Each Vacon converter has an Vacon Operator Panel mounted on the door which is connected to thecorresponding converter. Using this panel a motor can be started and stopped.

Desired speed

Actual speed

Actual current

Actual bus volt.

Actual power

Actual frequency

Actual voltage

Status of drive Operating direction Operation time

Text line

Actual torque

Actual speed %

Actual current %

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With this panel it is possible to increase or decrease the speed of the motor connected. On the display of thepanel the motor speed and motor current is presented, as well as the actual status of the converter.

If the key switch on the PLC cabinet is set in mode “LOCAL”, all running converters will be stoppedautomatically.

VACON Local Panel

On the panel the following buttons have the following meaning:

Start button: When the converter is ready this button is used to start the pump

Stop button: When the converter is running this button is used to stop the pump

Up button: This button is used to increase the selected parameter or setpointand to display the next menu

Down button: This button is used to decrease the selected parameter or setpoint and to

display the previous menu

Right button: This button is used to display the first submenu or parameter of the currentmenu or to start editing the current parameter

Left button: This button is used to display the previous submenu or parameter

Select button: This button is used to toggle between the setpoint menu or other menu’s

Reset button: This button is used to reset converter faults during local mode

START

STOP

select

reset

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Enter button: This button is used to accept a changed parameter

The following LEDs have the following meaning:

Ready LED: When this LED lights green the converter is ready for operation

Run LED: When this LED light green the converter (and the pump) is running

Fault LED: When this LED lights red the converter has a fault

The following display indicators have the following meaning:

Run indicator: This indicator indicates the convertor (and the pump) is running

Stop indicator: This indicator indicates the converter (and the pump) is stopped

Ready indicator: This indicator indicates the converter is ready for operation

Alarm indicator: This indicator indicates that an alarm is present

Fault indicator: This indicator indicates that a fault is present

Forward indicator: This indicator indicates the forward direction of the pump

Reverse indicator: This indicator indicates the reverse direction of the pump (n/a)

I/O indicator: This indicator indicates the converter is controlled via the I/Oterminal (n/a)

Keypad indicator: This indicator indicates the converter is controlled via the display(local mode)

Bus/Comm indicator: This indicator indicates the converter is controlled via the profibus

(remote mode)

Parameter number: This text shows the number of the current parameter or menu

Parameter name: This text shows the name of the current parameter or menu

Parameter value: This text shows the value and unit of the current parameter or value

Before a pump can be started, the pump has to be selected ( par 7.2.2 ).

The Ready LED on the panel lights and on the display the Keypad indicator and the Ready indicator will be

visible.

enter

ready

run

fault

RUN

STOP

READY

ALARM

FAULT

I/O term

Bus/Comm

keypad

V 1.5.5

Actual speed

89 %

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reset

select enter

START

STOP

ready runfault

READYSTOP

V 1.5.8 keypad

MarFlex VSDS

After pressing the Start button the converter will start. The Run LED lights and the Run indicator becomesvisible in the display.

reset

select enter

START

STOP

ready run fault

READYRUN

R 1.5.4 keypad

Speed setpoint0 %

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The panel automatically selects reference parameter R 1.5.4 which is the speed setpoint. The Up and Downbuttons can be used to increase and decrease the speed setpoint.

reset

select enter

START

STOP

ready runfault

READYRUN

R 1.5.4 keypad

Speed setpoint

54 %

To view other menu’s or parameters while the pump runs the Select button can be pressed. After acceptingthe setpoint value with the Enter button, the Up, Down, Left and Right buttons can be used to navigatethrough the menu’s and parameters.

reset

select enter

START

STOP

ready runfault

READYRUN

V 1.5.5 keypad

Actual current

36 %

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When the select button is pressed again the display will return to the setpoint reference which can beadapted immediately using the Up and Down buttons.

reset

select enter

START

STOP

ready runfault

READYRUN

R 1.5.4 keypad

Speed setpoint

54 %

To stop the pump the Stop button can be used. The Run LED will start blinking to indicate the down rampingof the speed.

reset

select enter

START

STOP

ready runfault

READYRUN

R 1.5.4 keypad

Speed setpoint

0 %

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When the converter has stopped the pump the display remains in the setpoint menu for a period of fiveminutes. After these five minutes the display returns to the default menu.

reset

select enter

START

STOP

ready runfault

READYSTOP

V 1.5.8 keypad

MarFlex VSDS

When a fault occurs the pump will be stopped by the converter and display will show the fault text. The FaultLED will be lit and the Fault indicator will be shown. The Reset button can be used to reset the converter.

After the selected pump has come to a complete standstill the pump can be deselected, as described in par 7.2.2.

After deselecting the pump the Ready LED will go off and the pump can no longer be started. Depending onthe state of other converters and the selection switch on the PLC cabinet, the system remains local or transits to remote mode.

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reset

select enter

START

STOP

ready runfault

STOP

V 1.5.8 keypad

MarFlex VSDS

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7.3 Remote mod es

If the key switch on the PLC cabinet is set from local mode to a remote mode the system can be controlledby one of the remote operating options.To activate the remote control chosen, all converters have to be stopped on the converter cabinets and AOP30 panels. After the last converter is stopped, the remote indicator light on the PLC cabinet indicatesremote operation.

If the key-switch on the PLC cabinet is set from remote mode to another remote mode or local mode, whilethere are still converters running, all converters stop automatically, and a general fault is generated. After the last converter is stopped, and the general fault is reset, the operating mode change will take effect.

For remote control the following modes are possible:- Touch panel- Control Desk

- Cooperation with external systems

In case of remote mode with a touch panel or an external system, the operator starts and stops pumps.Which converter will be used is determined by the PLC. If more than one converter is available, the PLCchooses the one with the smallest amount of operation hours.In case of remote mode with a control desk, the operator starts and stops pumps, connected to a specificconverter.

7.3.1 Remote mode: Touch Panel

The MP377 touch panel is a 15” TFT panel with a Windows CEoperating system.

It is a most flexible for operation and very easy to understandHuman Machine Interface (HMI).

The panel has a Profibus-DP interface to communicate withthe PLC. The panel will report if the communication to the PLC islost or the PLC has stopped.

Detailed information about this panel together with the operatorsand maintenance application in chapter 8.

7.3.2 Remote mode: Control Desk

A more conventional HMI, but not less adequateto use, is the control desk.Operation takes place with switches, buttons,lamp and meter indications.

With a control desk the function “cargo heating

mode” is not possible.

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A control desk consist of a number of operating devices such as switches, pushbuttons and visualizationdevices such as lamps and meters.

A pump can be started by pushing a start button. The PLC allocates the pump to a converter and the pump

can be operated using pushbuttons to alter the speed or to stop the pump. Indication lamps inform theoperator about faults and statuses. Meters inform the operator about motor speed and currents.

Detailed information about the operation with the desk in chapter 9.

7.3.3 Remote mode: Cooperative with external systems

With interconnection of more than oneintelligent system present on the vessel, it ispossible to create a centralized operation

station. For example the cooperation of theoperation stations of the MarFlex VSDS andthe Cargo Computer.

Cooperation takes place through datacommunication.For this the standard used protocol isMODbus.

Communication during engineering takes place with common data tables. Standard the VSDS is designed towork with the standard MarFlex data model.

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8 Remote Mode: TOUCH PANEL

8.1 General

This chapter describes the functional design of the touch panel (TP) which is used for operation of the VSDSduring remote control.

The following screens are present:- Default screen·························Screensaver with picture, any touch will open the Overview screen- Overview screen ·····················Overview of the system including pump control- Pump control screen ···············Pump control and status, 1 screen per distribution matrix- Cargo heating mode screen ····Similar as the Pump Control screen of activating cargo heating mode- Pump screen···························Pump status- Converter screen ····················Converter status

- Fault screen····························Fault message table including reset and accept possibilities- Login screen ···························For access to Maintenance and System screen by changing the user - Maintenance screen················To adapt date and time, calibration of touch screen (accessible for client’s

technician).- System screen ························Reset operation times, view logs and exit the runtime environment

(necessary to load new software, accessible for MarFlex technician)- Information screen ··················MarFlex contact information, with software version and project number - Communication fault screen····Appears when the connection with the PLC is lost- Help screen per screen ··········· Information on the use of the screen including explanation of colors

Every screen has the standard view configuration:

The following items are visible on each screen:- Name of the screen with pump or converter identification where applicable- Current date and time

- Status of operation mode (local or remote),- Current user Touch: navigate to login screen- Help area Touch: navigate to help screen- Current, most recent faults, maximum of five Touch: navigate to fault screen

General information line

Command buttons

Screen hierarchy

creenavigationuttons

Active alarms

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- Current position in the screen hierarchy. Touch: navigate to overview screen- Logo of MarFlex Touch: navigate to MarFlex contact information

8.2 Main Screens

8.2.1 Tree structure

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8.2.2 Default screen

This screen is shown when the touch panel (TP) is (re)started. It shows a representative picture or animation

and facultative information.

The following interaction with other screens is present:

Origin Action Destination Operating system TP Restart of Touch Panel

Overview screen No touch activity for 8 hours and no converter active

Cargo heating screen No touch activity for 8 hours and no converter active

Any touch Overview screen

Fault occurs Overview screen

Communication fault occurs Communication fault screen

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8.2.3 Overview screen

This screen shows all tanks with MarFlex pumps in the shape of the vessel. It contains the followinginformation:

- operation status (running, standby, not active, warning, fault) using tank colours- actual speed pumps in operation, using bargraphs and numerical visualization outside vessel

contours.The screen has no control functions, it is only meant as general status overview.

Navigation links with other screens:

Origin Action Destination

Default screen Any touchPump Control screen Navigation tree touched

Cargo heating mode screen Overview button touched

No touch activity for 8 hours Default screen

Navigation tree touched Default screen

Tank button touched Pump Control screen (default) or CargoHeating Mode screen, depending onprevious chosen way of operation.

Fault area touched Fault screen

User area touched Login screen

MarFlex logo touched Info screen


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8.2.4 Pump control screens

The screen shows all pumps and converters in a distribution matrix with following information:

- Pump and converter connection status.(using colours: green=running, red=fault, grey=connected,yellow=dry run)

- Actual speed (%)- Actual current (%)- Pump operation status (using colours: green=running, red=fault, white=not active, yellow=dry run)- Converter operation status(using colours: green=running, red=fault , grey/white text=not active,

grey/green text= first drive to start)

- Cargo heating mode status (if applicable)- PMS status (if applicable)- Motor temperature fault status- Speed deviation warning status- Dry run warning and fault status- Converter fault status- Actual speed setpoint (%)

The following functions will be activated by touching:- a pump: selects the pump for operation and navigation- a converter: selects the converter for navigation- Start / stop button: starts or stops the selected pump- Speed up / down button: raises / lowers the setpoint of the selected pump


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Origin Action Destination Overview screen Tank touch

No touch activity for 5 minutes Overview screen

Navigation tree touched Overview screen

Pump status button touched Pump screen

Converter status button touched Converter screenFault area touched Fault screen




8.2.5 Cargo heating mode screen

This screen shows all tanks with MarFlex pumps in the shape of the vessel. It contains the followinginformation:

- operation status (running, standby, not active, warning, fault) using tank colours- actual speed pumps in operation, using bargraphs and numerical visualization outside vessel

contours.The screen has no control functions, it is only meant as general status overview.

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Origin Action Destination Default screen Any touch

Pump Control screen Navigation tree touched

Cargo heating mode screen Overview button touched

No touch activity for 8 hours Default screen

Navigation tree touched Default screenTank button touched Pump Control screen (default) or Cargo

Heating Mode screen, depending onprevious chosen way of operation.





Cargo Heating Mode contains also control screens, 1 per distribution matrix:

8.2.6

Cargo heating control screens

These screen are similar to the pump control screens, with the exception that a maximum of 2 pumps can beselected for operation. A Clear selection button clears the selection of the pumps.Starting a pump will start it in cargo heating mode. Only pumps in cargo heating mode can be stopped.The cargo heating control screen shows the following information:

- Pump and converter connection status.(using colours: orange=running, red=fault, grey=connected,yellow=dry run)

- Actual speed (%)- Actual current (%)

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Author: Snijders Elektrotechniek B.V. MarFlex VDSV User Manual Concept.doc Page 37 of 67

- Pump operation status (using colours: orange=running, red=fault, white=notactive, yellow=dry run)

- Converter operation status(using colours: orange=running, red=fault , grey/white text=not active,grey/green text= first drive to start)

- Cargo heating mode status (if applicable)

- Motor temperature fault status- Speed deviation warning status- Dry run warning and fault status- Converter fault status- Actual speed setpoint (%)

The following functions will be activated by touching:- a pump: selects the pump for operation and navigation- a converter: selects the converter for navigation- Start / stop button: starts or stops the selected pump(s)- Speed up / down button: raises / lowers the setpoint of the selected pump(s)


Origin Action Destination Overview screen Tank touch

No touch activity for 5 minutes Overview screen


Pump control screen button touched Pump control screen

Pump status button touched Pump screen last selected pump

Converter status button touched Converter screen





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Author: Snijders Elektrotechniek B.V. MarFlex VDSV User Manual Concept.doc Page 38 of 67

8.2.7

8.2.8 Pump screen

This screen shows the status of the selected pump:- Actual speed (%)- Actual current (%)- Dry run speed limit (%)- Dry run current limit (%)

- Operating hours (h)- Connected converter - Cargo heating mode status (if applicable)- PMS status (if applicable)- Motor temperature fault status- Speed deviation warning status- Dry run warning and fault status- Converter fault status- Actual speed setpoint (%)

The following functions functions will be activated by touching :- Start/ stop button: starts or stops the selected pump- Speed up / down button: raises / lowers the setpoint of the selected pump(s)

The following navigation links with other screens exist:

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Author : L.Sonneveld Functional Description rev22 2011-04-11.doc Page 39 of 67


Pump control screen Pump status button touched

No touch activity for 5 minutes or Navigation tree touched

Pump control screen or Cargo heating mode screen


User area touched Login screenMarFlex logo touched Info screen


8.2.9 Converter screen

This screen shows the status of the selected frequency converter:- Operation status (running, standby, not active, fault)- Actual selected parameter set- Operation time of the converter - Speed deviation warning status- Converter fault status and converter fault number - Connected pump- Actual speed (%)- Actual current (%)- Cargo heating mode status (if applicable)- Actual setpoint (%)

No control functions present.


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Origin Action DestinationPump control screenCargo heating mode screen

Converter status button touched

No touch activity for 5 minutesNavigation tree touched

Pump control screenCargo heating mode screen

Pump status button touched Pump status screenFault area touched Fault screen




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8.3 Au xil l iary screens

8.3.1

Tree structure

8.3.2 Communication fault screen

This screen appears when there is no connection with the PLC. No operation or navigation is possible. Whenthe connection is (re)established an accept button appears to acknowledge the fault.

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8.3.3 Fault screen

The screen shows all current faults and warnings.The colors represent the following fault status:Yellow : WarningRed/Blinking : Fault active and not acceptedRed : Fault activeBlue : Fault not active and not accepted

The following control functions will be activated by touching :- Reset button: resets all faults and accept all faults and warnings- Accept button: accepts all visible faults and warnings



Any screen Fault area touchedNo touch activity for 5 minutesNavigation tree touched

Previous screen



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8.3.4 Login screen

In this screen the user can log in as dedicated user, which changes the presentation and control possibilitiesaccording the authorisations granted to this user.

The following control functions are present:- Log in with a code by choice of code en acknowledgement with the Enter button.


Origin Action Destination Any screen User area touched


Overview Screen



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8.3.5 Maintenance screen

The following control functions will be activated by touching :- Change of the current date and time, by choice of time zone with acknowledgement of the

choice by touching the Set button.- Calibration the touch screen, by touching precisely the symbols which are visualized one by one.- Temporarily deactivation of the screen for cleaning purpose

The following navigation links with other screens are present:

Origin Action DestinationLogin screen User area touched


No touch activity for 5 minutes Overview screen with deactivation user code



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8.3.6 Diagnosis screen

In this screen the user can scoll through the fault history where up to 500 previous faults are stored.In the logging part of the screen, changes to important parameters like dry run settings are stored.In the bottom part of the screen, below Profibus slaves, the active profibus stations are shown.


Origin Action Destination Login screen User area touched


No touch activity for 5 minutes Overview screen with deactivation user codeFault area touched Fault screen


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8.3.7 Settings screen

The Settings screen is only accessible in engineer mode. In this screen dry run settings for each pump canbe adjusted.The following engineer functions are available :

- Initialize all plc data- Erase all diagnosis data- Exit runtime ( to operating system)- Alter contactor switch off delay- Adjust the engineer logout time


Origin Action Destination Login screen User area touched





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8.3.8

Operating hours screen

This screen shows the operating hours for all pumps and converters.By pressing the reset button, the operating hours of a pump/converter are being reset.


Origin Action Destination Login screen Operating hours button touched





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8.3.9 Info screen

This screen shows general information of MarFlex and the Variable Speed Drive System.


Origin Action Destination Any main screen MarFlex logo touched


Previous screen



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8.3.10 Help screen

Every screen has a separate help screen, which displays information on the functions and indications on thepresent screen.


Origin Action Destination Any screen Question mark area touched


Previous screen

Fault area touched Fault screenCommunication fault occurs Communication fault screen

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8.4 User manag ement

To manage the accessibility of screens or functions three different user levels are present:

- Operator

Granted to all functions except the Maintenance screen and Settings screen- MaintenanceGranted to all functions except for Settings screen.

- Engineer (available for MarFlex engineers only)Granted to all functions

Passwords consist of 4 decimal digits which can be selected with a numeric key pad:

User Operator has no password.User Maintenance has a password which is provided to the client, e.g. 1397 (square on the panel)User Engineer has a password which is provided to MarFlex engineers only.

Passwords or other special application changes can only be changed by MarFlex. One of these changes isfor example management of dry run parameters.

The system automatically deactivates the user Maintenance or Engineer after 5 minutes of no touch activity.

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9 Remote mode: CONTROL DESK

9.1 Introduction

The control desk displays the pump-controls divided into several vertical sections:- per converter one section- a general section at the right side of the desk.

The control desk is actived for operation by switching the key switch on the PLC cabinet to remote mode – control desk. In all other cases, the desk only presents the results of other operation equipment if possible.

The control desk is connected to the VSDS through data communication, protocol Profibus-DP.

In case of data communication error, all signalisations on the desk will be off, read outs will be zero.Emergency stop remains active in all cases, established by its hard wired connections.

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9.2 General section

For common use several buttons and indications are available at the right side of the desk,

From the top to bottom side:

- Emergency stop-button- Emergency stop indication- Remote-control indication- Inert gas indication- High pressure indication- General failure indication- Buzzer - Buzzer reset-button- Lamp test-button

9.2.1 Emergency stop button

On top of the desk at the right side, the emergency stop button is situated.This button is active in all operation situation.

After activation, no motors can be started and all motors in operation are switched-off immediately (motor-contactors are powered down).

To reset the emergency situation, first the push button activated must be released by tearing it upwards, thenthe reset button must be pushed to acknowledge the safe situation

9.2.2 Emergency stop indication

The emergency stop indication is available for displaying the status of the emergency stop relay in the PLCcabinet of the VSDS.

9.2.3 Remote control indication

With the key switch on the PLC cabinet, the operation mode is selected: local or remote.

In case of the choice remote mode control desk, the green signalization on the desk will beactive.

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9.2.4 External alarms

It is possible to show external alarms on the control desk.

Standard MarFlex supply is the signalisation of the external alarms “Inert gas pressure levelto low” and “high pressure alarm at the output side of the MarFlex pumps”. and possibility tostop the VSDS for external reasons. are the

9.2.5 General alarm

When there is a general alarm in the system, a signalisation is present at the control desk toindicate there is a general failure. This indication only works if the control desk operation isselected.

9.2.6 Buzzer

The buzzer on the control desk is used to indicate an error or emergency situation. After detecting an error or emergency, the sound of this buzzer can be switched off by pressingthe reset button. The sound will be activated again, when a new error or emergency isdetected.

9.2.7 Reset a converter-trip or emergency

To de-activate the buzzer, push the reset buzzer button.

The buzzer reset button is also used to reset any emergency, alarm or converter tripsituation.

9.2.8 Lamp test button

Lamp test button is used for checking the LEDs, buzzer and analogue panel-meters on thecontrol desk.

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After pressing this button at first, all analogue signals are activated to the full-scale (20mA). After a fewseconds, the analogue-signals are changed to 4mA and all digital signals are on for one second (theLEDs and the buzzer on the control desk).

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9.3 Con verter sections

Each converter has its own section on the desk, all sections are identical.

For each panel the following controls are available for running the connected pumps:

- Selection indication/start-buttons for the pumps- Dry-run indication/stop-button for the pumps- Panel meter for RPM- Panel meter for current- Error indication- Power indication- Run indication/motor-pot buttons

9.3.1 Visualization

The following indications are present on each converter section:Stand by – Converter is powered on, no faults are present and it is ready

for use.In operation – Converter in operation in cooperation with the pump of which

the visualization is active.Motor fail – Converter stopped, due to external motor failure, mostly

thermal alarm.Dry Run – Dry Run alarm. Blinking in warning phase, continuous at motor

stop.Trip – Converter stopped, due to internal malfunction. Detailed information on the local control panel

on the converter cabinet.

9.3.2 Speed / Power indication

Two panel-meters are used for the motor-speed and motor-currentindication. The meters are displaying the actual measured process-value, read from the converter.

The signals from PLC to the meters are 4-20mA values and correspond

to the full-range of the meter.

The 20mA signal corresponds to the maximum speed setting from the parameters in the converter.

9.3.3 Start Pump

Pumps can be started by pressing the push button concerning. After activation of the pump (motor), the signalization in the button will beactivated continuous during pump operation.

If pump start does not succeed, it is possible that this pump alreadyoperates with another converter.

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9.3.4 Stop Pump

To stop a pump, the stop button must be pressed.

The motor is decelerated to 0 RPM after which it’s contactor is switched off and thefrequency-converter is stopped.

9.3.5 Speed Change buttons

To change the speed of the selected motor, two buttons are used on the lower part of the controls-section.

At start 0 RPM is send to the converter for speed-reference.Changing the speed reference from 0 to 100% is possible by pressing the “up”and “down“ buttons.

Pressing the “UP” button will increase the speed, pressing “DOWN” will decrease the motor speed.Change of the speed can be verified at the analogue speed indications.

9.4 Dry Run settings

The settings for the dry run protection can be changed individually for each pump on the control desk. This

function is only available when the control desk is the only available remote control (when no touch panel isavailable ).The analogue panel meters are used to display the settings for the maximum speed and the minimumcurrent at dry run protection.

Warning:The dry-run settings should only be changed by MarFlex-personal and is accessible when all motors areswitched off and remote control is selected on the control desk with the key switch.

+

Conditions for entering set-up-mode:Before the dry-run parameters on the control desk arechanged, make sure that all pumps are off and remotecontrol on the control desk is selected.

20sec.

To enter dry run set up mode:To prevent accidental changes of the dry-run settings, you can onlyenter the set-up-mode after pressing the reset-button for more than20 sec. As soon as the reset-button is released the set-up-mode is closedand the system is ready for running a pump.

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+

Dry-run selection is active:

Keeping the reset button pressed will provide the option of changingthe minimum speed-, or the maximum current-settings for the dry rundetection on all pumps individually.The setup mode is displayed in the control desk by blinking motor

start buttons. When all pump start buttons are blinking, a pumpselection can be made.

+

Pump selection for dry run:Keeping the reset button pressed simultaneously with a pump startbutton, the dry run settings for the selected pump are activated. All other pump-indications in this section will stop blinking exept for the selected one.

+

Changing the dry-run settings:

At first the setting for the minimum speed is set displayed on the RPMpanel-meter.Dry run is detected when the measured speed is higher than thevalue, now displayed on the panel meter.

+ +

Increase the minimum speed setting:The minimum speed setting is increased in steps after pressing the “up” on the speed reference buttons, whilethe reset button is still pressed.

+ +

Decrease the minimum speed setting:The minimum speed setting will be decreased in stepsafter pressing the “down“ on the speed reference buttons,while the reset-button is still pressed.

+ +

Switch between speed and current setting:Switching between the selection for the minimum speed

or the maximum current setting for dry-run detection isdone by pressing the stop-button, while the reset-buttonis still pressed.

The maximum current setting can be changed the same wayas the minimum speed settingby reading the current valueand also increasing and decreasing with the UP and DOWNbuttons. Allways with the Buzzer button pressed down

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10 General Converter Functionalities

10.1 Introduction

This chapter is a brief overview of frequency converter systems with respect to the following subjects:- Frequency converters in non-grounded systems- Frequency converters as a electrical noise source- Frequency converters and the earth fault detection system- Radio interference suppression filters

10.2 Frequency conv erters in non -ground ed systems

In many industrial sectors, non-grounded supplies (IT supplies) are used to increase the availability of theplant/installation. In the event of a ground fault, no fault current flows, and the plant remains in operation andtherewith in production.

Earthed (TN) system Unearthed (IT) system

When an earth fault occurs in an earthed system, a high current via this earth fault will flow back to theenergy source, here a transformer. Because of this, the over current protection (and directly the differentialprotection) will respond.

In an unearthed system there is just a small capacitive coupling between the system and earth. This iscaused by cabling. The cable lengths and the cable quality determine the size of the couplings. According toEMC-directives, these couplings must be as small as possible.

Small capacitive currents can and may be neglected by insulation monitor devices (IMD).

When an earth fault occurs in an unearthed system, the short circuit current from the earth point back to theenergy source will be small. Over current protection will not respond, situation remains safe.Only the IMD detects the earth fault and warns the environment that the system is earthed.

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Unearthed system, Second earth fault

Only when a second earth fault occurs, in an unearthed system, a fault current, causing a danger to bothman and installation, can flow (see figure 9.3).

A phase-to-phase fault will always result in a current flow and will always activate the protective systems.

Therefore, correctly configured and maintained, non-grounded systems offer a reduced danger for both manand installation and also provide a higher reliability and availability because protection systems do not switchoff the power in case of an earth fault.To maintain this unearthed, safe, situation, the resistance value between the system and earth has to bemonitored continuously with an insulation-monitoring relay.The unearthed, IT-system provides the following advantages in comparison with earthed systems (TT, TN):- High continuity of the system (no switching off)- Higher level of electrical protection for man

- Better protection against damage when earth faults emerge- Higher level of fire protection

10.3 Frequency converters as an electrical noise sou rce

10.3.1 High frequency harmonic distortion (load)

Sinamics frequency converters operate with a voltage-source DC link.

Built-up frequency converter

In order to keep the power losses as low as possible, the inverter switches the DC link voltage to the motor winding in the form of voltage blocks. The properties of the electric circuit at the output side of the converter change the voltage block commands into an almost sinusoidal current, which flows through the motor.

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Block diagram output voltage (V) and motor current (I) of a converter

This mode of operation, in conjunction with high-performance semiconductor switching elements, have madeit possible to develop compact frequency drives which now play a vital role in drive technology.

As well as having many advantages, the fast semiconductor switches also have one disadvantage. A pulse-type noise current flows to ground through parasitic capacitances CP at each switching edge.Parasitic capacitances exist between the motor cable and ground, and also within the motor.

Block diagram output voltage (V) and fault current

The source of the noise current IS of the inverter and therefore the noise current must also flow back to theinverter. Impedance ZN and ground impedance ZE act in the return flow path of the noise current. ImpedanceZN is from parasitic capacitances between the supply cable and ground in parallel with the impedance

(between phase and ground) of the supply transformer. The noise current itself and the voltage drops acrossZN and ZE caused by the noise current, can also affect other electrical units.The high-frequency noise emission can only be reduced if the generated noise current is correctly routed.Using non-shielded motor cables, the noise current flows in an undefined fashion back to the frequency

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drive, e.g. via foundation, base frame grounders, cable ducts, cabinet frames. These current paths have avery low resistance for currents with a frequency of 50 or 60 Hz. However, the noise current induces a high-frequency component, which can result in problematical voltage drops.

A shielded motor cable is absolutely essential to enable the noise current to flow back to the frequency

drive in a defined fashion. The shield must be connected to the housing of the frequency drive and to themotor housing through a large surface area. The shield now forms the easiest path for the noise current totake when returning to the frequency converter.

Flow of the noise current with shielded motor cable

A shielded motor cable with a shield connected at both sides causes the noise current to

flow back to the frequency converter through the shield. Although (almost) no voltage drop arises across impedance ZE for shielded motor cables, thevoltage drop across impedance ZN can affect other electrical units. For detailed information, see theSinamics drives manual Sinamics Engineering Manual V3.1 eng.pdf

10.3.2 Low frequency harmonic distortion (mains)

Besides the high-frequency noise currents generated by frequency drives, as previously described, low-frequency harmonics should also be taken into account. As a result of rectification of the line supply, a non-sinusoidal line current is drawn, which causes a distortion of the line supply voltage.

Power Systems have been designed to generate, transform, transport and distribute power at a frequency 50or 60 Hertz. The presence of voltages and/or currents at any other frequencies can cause problems.

Traditionally, typical loads consisted of lights, motors, heaters etc., are based on inductive, capacitive andresistive elements. All of which are linear in nature. This means that when fed with a sinusoidal voltage theywill create a sinusoidal current of the same frequency. Since the development of rectifiers and power semiconductor technology, the term "typical loads" has broadened to include personal computers, faxmachines, photocopiers, variable speed drives, etc. This new generation of power consumers is based onvery sophisticated electronics that create power in a nonlinear fashion. In other words, when powered by asinusoidal voltage they do not create a sinusoidal current.

The degree by which this current deviates from a perfect sine wave is known as Harmonic Current Distortion.By the same token the degree by which a voltage deviates from a perfect sine wave is referred to asHarmonic Voltage Distortion. Although there is no such thing as a perfect voltage or current, there aremaximum distortion limits deemed as acceptable. When the harmonic distortion exceeds these limits,

problems can be expected.

Traditional analysis no longer applies to systems with harmonic problems. It is important to approach themwith the right tools and philosophy in order to obtain meaningful results.

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Many articles and papers have been written regarding harmonics in power systems. They explain thephenomenon as the result of nonlinear loads drawing non sinusoidal currents.Terms such as Total Harmonic Distortion, Zero sequence harmonics, etc. are often utilized to further definetheir behaviour. Although these explanations are accurate in every respect, often, some of the terms used,

end up being confusing rather than informative.

Harmonic oscillations are not a recent discovery. Physicists and mathematicians identified them quite a longtime ago. They postulated the laws that explain the movement of pendulums, springs, the planets, and other oscillatory phenomena including alternating currents. In fact, the very foundation of Power Systems Analysisrevolves around harmonic theory.

Low-frequency harmonics are reduced using line reactors, such as coils, sinusoidal filters or transformers.

10.4 Frequency converters and earth fault detection.

The SINAMICS S120 converter features electronic voltage sensing using high value resistors to provide anelectrical connection between the power unit and the grounded converter electronics.This circuit design provides for a certain inevitable insulation resistance.The insulation resistance of a SINAMICS S120 is approx. 800 Mega Ohm.

If a large number of electronic devices with lower insulation resistances operate together parallel in one ITsupply system, the insulation value to earth of the supply system can drop to a low value.

If classification or other involved survey and inspection societies subscribe a minimum insulation value of anIT supply-system in operation, the supply system must be monitored continuously.

Siemens recommends the use of an earth fault protection device / insulation monitor with two fault contacts.Each contact should react to a different insulation level. Low level when the drives are not ‘switched on ’ and

high level when the drives are ‘switched off’.The insulation monitoring device made by BENDER, type IRDH 275 for example, is an established and safesolution for monitoring for insulation faults and has the two level contacts. The frequency converters for theSiemens-MarFlex installations are equipped as standard with a connection for the insulation monitoringdevice.

10.5 Radio frequency interference sup pression fi lters

RFI filters are not used in Siemens-MarFlex installations.

A radio interference suppression filter needs grounding to earth. When a radio interference

suppression filter is used in an unearthed system, a fault current will flow when a ground faultoccurs. This earth fault may cause shutdown of the drives or even the destruction of theradio interference suppression filter.

Radio interference suppression filters additionally affect the concept of non-grounded supply networks andcan result in a safety risk when used with these networks (see Product Standard EN 61800-3: 1996).

11 Software design

11.1 Standard con trol

The Converter is controlled in speed control without feedback (steering).

The direction of the motor is fixed, the reverse signal of the converter is not used.

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Two ways of stopping exist:- OFF2 stop (coasting down)- Normal stop

A OFF2 stop is engaged in fault situations:

- An emergency stop button is pressed- Converter fault- motor temperature fault- dry run fault- communication fault

A OFF2 stop is a direct disconnection of the motor with the converter, followed by a free coast down. Coastdown time depends on physical specifications at the driven pump. A normal stop is engaged when the operator issues the stop command. A normal stop results in a fixedramping down the speed, following the preset ramp down time.The ramp up and ramp down time for a normal stop are fixed values, default 30 seconds.

11.2 Dry run pro tection

When the motor speed is above a preset value and the motor current is below a certain a preset value thepump is probably running dry. An output signal of the converter called Dry Run is set.

Dry Run function

11.3 Extern al int erfaces

The PLC software design consists of a number of control classes and interfaces:

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An interface is an implementation of signal enhancement. One side of the interface provides and acceptsstandard signals, the other side expects signals implementing functionality that can be converted into thestandard signals. Interfaces are non-standard implementations, but provide and accept standard signals toand from control classes.

For VSDS operation with human machine Interfaces connected through Profibus-DP, the operation interfaceprovides and accepts standard signals necessary to operate the VSDS.

Per pump and per converter an interface like table 11-1 is necessary to communicate with the HMIs.Standard HMIs like touch screens are internal MarFlex supply. Creation of the interface on both PLC andHMI side is done under responsibility of MarFlex. In case an external HMI is used, creation of these tablesmust be done in cooperation with the supplier of the HMI.

Table 11-2: Example of an external operation interface

Signal name Description Type Range

StartRequest Request to start the converter Logical [0-1]ResetRequest Request to reset the converter Logical [0-1]HeatingMode Combine more than one pump on a converter Logical [0-1]Setpoint Setpoint to the converter Numerical [0-100%]

P r o v i d e s

Ready The connected converter is ready Logical [0-1]Running The connected converter is running Logical [0-1]SpeedDeviationWarning Actual speed is deviating from setpoint Logical [0-1]DryRunWarning Dry run warning Logical [0-1]DryRunFault Dry run fault Logical [0-1]MotorTemperatureFault Motor temperature is high Logical [0-1]DriveFault Number of the pending converter fault Numerical [0-9999] ActualSpeed The speed of the connected converter Numerical [0-100%]

ActualCurrent The current of the connected converter Numerical [0-100%]DriveNr The number of the connected converter Numerical [0-99]

A c c e p t s

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12 VSDS system design specifications

12.1 General

The MarFlex VSDS systems are designed to operate under the specifications as described in the followingparagraphs of this chapter.

12.2 Regulations

The MarFlex VSDS systems are designed and manufactured according to the following regulations:

- Standards for low voltage directive : NEN-EN-60439-1- Standards for the machinery directive : NEN-EN-IEC-60204-1

- Standards for the safety of machinery : NEN-EN-954-1- Standards for the electromagnetic : EN-50081,EN-50082 and EN-61800-3

compatibility directive (EMC)- Standards for equipment intended for : ATEX95

use in potentially explosive atmospheres(only for connections to field equipment where needed)

- Standards for symbols in electric documents :IEC 60617, symbols related to IEC 60617

12.3 Classif ication societies

MarFlex VSDS systems are designed and manufactured according to the regulations of the followingclassification societies:

- ABS (American Bureau of Shipping)- Bureau Veritas- CCS (China Classification Society)- DNV ( Det Norske Veritas)- Lloyd’s Register - RMRS (Russian Maritime Register of Shipping)

12.4 Amb ient condit ions for panels

Ambient conditions for the panels have to comply with the following specifications:- Location : Indoors- Panels should be mounted in a conditioned area, free of dust and dirt

- The mounting base should be stable- There must be free area around opened doors (escape route), according to classification rules- Altitude : < 1000m- Temperature : 0-40˚C- Relative humidity (min-max) : 30-95% (without condensation)- Mechanical forces/impact :

1. Vibration frequency range 5 to 50 Hz with vibration velocity amplitude 20 mm/s2. Peak accelerations ±0.6 g for vessels of length exceeding 90 m (duration 5 to 10 s) or ± 1 g for

vessels of length less than 90 m (duration 5 to 10 s)

12.5 Power supp ly

The MarFlex VSDS systems are designed to operate with main switch board power supply complying withthe following specifications:

- Mains configuration : IT with insulation protection in switch board (provided by others)- Line voltage main supply : Steady +/- 2,5% and transient +20%/-15%, 400-690VAC

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- Number of supplies (cables) : Each converter or each matrix- Nominal Current (per supply) : 435A- Frequency : 50/60Hz +/-5%- Max. short-circuit strength : 50kA

- Auxiliary voltage supply : 230VAC +/-10%- Number of supplies (cables) : Each converter or each matrix- Nominal current (per supply) : 4A- Frequency : 50/60Hz +/-5%- Max. short-circuit strength : 10kA

- Simultaneous power : 1994kVA

12.6 Cable and cable entry specif ication s

Cables and cable entries have to comply with the following specifications:

- Cables must enter the panels from the bottom side- Cables must be tightened on the pull relief - Cable shields must be connected to the EMC screen rail properly

12.7 Coolin g water specif ication s

12.7.1 Sinamics converters

The cooling system for Sinamics water cooled converters has to comply with the following specifications:- Coolant : Filtered drinking water with specifications as follows:

- Chloride : <200 mg/l- Sulfate Ions : <240 mg/l- Nitrate Ions : <50 mg/l- pH value : 6,5-9,0- Conductivity : <2000 μS/cm- Total hardness : <1,7 mmol/l- Dissolved solids : <340 mg/l- Size of entrained particles : <100 μm- Max. system pressure : 6 bar - Max. differential pressure : 2 bar - Max. coolant temperature : 38˚C- Rated volumetric flow for water : 12 l/min

At 7 kPa pressure drop- Power loss max. : on request (depending on converter)- Closed cooling circuit is the recommended standard solution- Connection flange : Only for stainless steel heat sink (Frame size FL/GL)

Note : Drinking water may contain more than 200 mg/l chloride. Values higher than 200 mg/l may damagethe heat sinks if no inhibitors are added.

12.7.2 Vacon converters

The cooling system for Vacon water cooled converters has to comply with the following specifications:- Coolant : Filtered drinking water with specifications as follows:- Non corrosive

- Cortec corrosion inhibitor is required- Chloride : <200 mg/l- Sulfate Ions : <240 mg/l- Nitrate Ions : <50 mg/l

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- pH value : 6,5-9,0- Conductivity : <2000 μS/cm- Total hardness : <1,7 mmol/l- Dissolved solids : <340 mg/l- Size of entrained particles : <100 μm

- Max. system pressure : 6 bar - Recomm. system pressure : 1,5 bar - Max. differential pressure : 2 bar - Max. coolant temperature : 38-40˚C- Rated volumetric flow for water : 12 l/min

At 7 kPa pressure drop- Power loss max. : on request (depending on converter)- Closed cooling circuit is the recommended standard solution- Connection flange : Only for stainless steel heat sink (Frame size FL/GL)

Note : Drinking water may contain more than 200 mg/l chloride. Values higher than 200 mg/l may damagethe heat sinks if no inhibitors are added.

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