19001914v1.0 vol. 1

8/18/2019 19001914V1.0 VOL. 1

1/531

ROBICON PERFECT HARMONY SERIES

ADJUSTABLE SPEED AC MOTOR DRIVE(AIR COOLED)

INSTRUCTION MANUAL

VOLUME 1 OF 2

Prepared for:

EMSBY PTY LTD

Customer/Customer Rep P.O. Number: 12343Siemens Energy & Automation, Inc. S.O. Number: HR9214394

Siemens Energy & Automation, Inc. O&M Number: 19001914V1.0Siemens Energy & Automation, Inc. Part Number: 31000856.00, .01

Project:

PALMAREJO

3500HP, 6600VAC, 315A, Next Gen Control Adjustable Speed AC Motor Drive

8/18/2019 19001914V1.0 VOL. 1

2/531

8/18/2019 19001914V1.0 VOL. 1

3/531

Table of Contents

500 Hunt Valley Road, New Kensington. PA 15068 Phone: (724) 339-9500 Fax: (724) 339-9562

http://automation.usa.siemens.com

Volume I

Table of Contents

Preface

Section 1. Equipment ListMaintenance Summary FormsMaintenance ProcedureField Service InformationStorage RequirementsWarranty InformationService Assistance Process

Section 2.

Robicon Air Cooled Perfect Harmony GEN III/E Series Installation Manual 190004Chapter 1 .......................................................... Introduction

Chapter 2 .......................................................... Hardware ComponentsChapter 3.......................................................... Installation and Setup

Appendix A ....................................................... Glossary of Terms Appendix B ....................................................... Commonly Used AbbreviationsIndexNotesReader Comments FormStart-up/Warranty Information Card

Section 3.

Robicon Air Cooled Perfect Harmony GEN III/E Series Startup Manual 19000404

Chapter 1 .......................................................... IntroductionChapter 2 .......................................................... Hardware ComponentsChapter 3 .......................................................... The Keypad and Display InterfaceChapter 4 .......................................................... Startup ProcedureChapter 5.......................................................... Application and Operation IssuesChapter 6 .......................................................... TheoryChapter 7 .......................................................... Troubleshooting and MaintenanceChapter 8 .......................................................... System Programming

Appendix A ....................................................... Glossary of Terms Appendix B ....................................................... Commonly Used Abbreviations Appendix C ....................................................... System Control Drawings

Appendix D ....................................................... Suggested Spare Parts ListIndexNotesReader Comments FormStart-up/Warranty Information Card

8/18/2019 19001914V1.0 VOL. 1

4/531

Table of Contents



Section 4.

Robicon Air Cooled Perfect Harmony GEN III/E Series User’s Manual 19000405Chapter 1 .......................................................... IntroductionChapter 2 .......................................................... Hardware ComponentsChapter 3 .......................................................... The Keypad and Display Interface

Appendix A ....................................................... Glossary of Terms Appendix B ....................................................... Commonly Used AbbreviationsIndexNotesReader Comments FormStart-up/Warranty Information Card

8/18/2019 19001914V1.0 VOL. 1

5/531

Table of Contents



Volume II

Table of Contents

Preface

Section 1.

NXG Communications Manual for Harmony Series 902399Chapter 1 .......................................................... Communications OverviewChapter 2 .......................................................... Modbus CommunicationsChapter 3 .......................................................... DeviceNetTM DPCommunicationsChapter 4.......................................................... Ethernet Modbus CommunicationsChapter 5.......................................................... Modbus Plus CommunicationsChapter 6 .......................................................... Profibus CommunicationsChapter 7.......................................................... Data Highway Plus CommunicationsChapter 8 .......................................................... ControlNet CommunicationsChapter 9 .......................................................... DeviceNetTM(Profile 12) Communications

Appendix A ....................................................... Parameter Read / Write Appendix B ....................................................... Output Data IDs Appendix C ....................................................... DeviceNetTM DP EDS File Appendix D ....................................................... Profibus GSD Datafile Appendix E ....................................................... ControlNet EDS File Appendix F........................................................ DeviceNetTM (Profile 12) EDS File Appendix G ....................................................... Network ImplementationIndexNotesReader Comments Form

Section 2. System Operating Program

Section 3. Blower and Blower Motor Instruction Manuals

Section 4. Control Power Disconnect Switch Technical Data

Section 5. Robicon Air Cooled Perfect Harmony System Drawings

System Outline ............................31000856C [Rev. C] sheets 1 through 7System Schematic .......................31000856S [Rev. C] sheets 1 through 5

Section 6. Southwest Electric Company Switchgear Drawings

Section 7. WAGO Technical Data

Section 8. Factory Acceptance Test Data

8/18/2019 19001914V1.0 VOL. 1

6/531

Table of Contents



8/18/2019 19001914V1.0 VOL. 1

7/531

Preface



This manual is organized into specific sections providing information on the key subsystems andcomponents within the drive. Refer to the following sections for specific information.

VOLUME I

SECTION 1: Equipment List, Maintenance Summary Forms, Maintenance Procedure, Field ServiceInformation, Storage Requirements, Warranty Information, and Service Assistance Process

The first section of this manual contains the list of Variable Frequency Drives for which this manualpertains. Also included, are maintenance instructions and field service rates for the listed drives.

SECTION 2: Robicon Air Cooled Perfect Harmony GEN III/E Series Installation Manual 19000403

The Installation Manual provides a brief overview of the product including a hardware overview andimportant safety issues. The steps leading up to and including the installation of the drive arediscussed in detail in this manual.

SECTION 3: Robicon Air Cooled Perfect Harmony GEN III/E Series Startup Manual 19000404

The Startup and Advanced Topics Manual is intended to address the more technical aspects of drivesetup, configuration and operation. This manual includes detailed descriptions of all parameters,functions and pick-list menu items. Software setup and startup procedures are also included.

Advanced topics such as the theory of operation, technical specifications, system programming,compiler and reverse compiler software operation, uploading and downloading functions, and otherapplication and operation issues are discussed.

SECTION 4: Robicon Air Cooled Perfect Harmony GEN III/E Series User’s Manual 19000405

The User’s Manual is for use by operators of the drive. The User’s Manual contains a brief overviewof the product including a hardware overview of the external components of the drive and basicsafety precautions. The keypad and display interface is explained in detail. A parameter listing isprovided for reference. A troubleshooting and maintenance section is also provided in this section tohelp the operator to diagnose and correct any potential problems that may occur, and reduce thepotential for future problems through inspections and regular maintenance.

8/18/2019 19001914V1.0 VOL. 1

8/531

Preface



VOLUME II

SECTION 1: NXG Communications Manual for Harmony Series 902399

This manual is for use by the operators of this drive. The manual contains an overview of theproduct, including a hardware overview of the components, settings, and protocol overview on thecontrol assembly.

SECTION 2: System Operating Program

Included in Section 2 is a listing of the System Operating Program. The Program is based onBoolean logic and is self-documenting. Reference the Perfect Harmony Startup and AdvancedTopics Manual [Volume I, Section 3, Chapter 8] for system programming guidelines.

SECTION 3: Blower and Blower Motor Technical Data

This system is provided with redundant blowers and associated motors. Failure of one of the

motors can result in the activation of the redundant blower allowing the VFD to continue to run.The operating and maintenance manuals are provided for troubleshooting and maintenanceinformation.

SECTION 4: Control Power Disconnect Switch

Technical Data

SECTION 5: Robicon Air Cooled Perfect Harmony System Drawings

System Outline..................................................31000856C [Rev. C] sheets 1 through 7

System Schematic.............................................31000856S [Rev. C] sheets 1 through 5

The complete set of the Robicon Air Cooled Perfect Harmony VFD as-built, including mechanical andelectrical drawings.

SECTION 6: Southwest Electric Company Switchgear Drawings

3-Line Diagram and Outline Drawings

SECTION 7: WAGO Technical Data

Technical Data

SECTION 8: Factory Acceptance Test Data

Factory Acceptance Test Data for VFD No. 31000856.00, .01

8/18/2019 19001914V1.0 VOL. 1

9/531

SIEMENS CT No.:

APPROVAL\CHANGE TRANSMITTAL

FOR STANDARD AND O&M MANUALS

ECR \ITF #(if applicable)

Version Engineer Name Author Date Change/Comment

V1.0 Initial ReleaseN/A Jim Boronky WMM 04/17/07

0763

8/18/2019 19001914V1.0 VOL. 1

10/531

8/18/2019 19001914V1.0 VOL. 1

11/531

SECTION 1

8/18/2019 19001914V1.0 VOL. 1

12/531

8/18/2019 19001914V1.0 VOL. 1

13/531



Equipment List

Equipment Supplier: Siemens Energy & Automation, Inc.500 Hunt Valley DriveNew Kensington, PA 15068

Telephone: 724-339-9500Fax: 724-339-9562http://automation.usa.siemens.com

Qty. Part Number Description

1 31000856.00 3500HP, Harmony Drive, Nema1 Enclosure

Input: 13,800V, +10%, -5%, 3 Phase, 60Hz, 130A RMSOutput: 0-6600V, 3 Phase, 0-60Hz, 315A RMSControl: 460V, 3 Phase, 60Hz, 20A

P/N 12002079.00

1 31000856.01 3500HP, Harmony Drive, Nema1 Enclosure

Input: 13,800V, +10%, -5%, 3 Phase, 60Hz, 130A RMSOutput: 0-6600V, 3 Phase, 0-60Hz, 315A RMSControl: 460V, 3 Phase, 60Hz, 20AP/N 12002079.01

8/18/2019 19001914V1.0 VOL. 1

14/531



8/18/2019 19001914V1.0 VOL. 1

15/531

MAINTENANCE SUMMARY FORM

DCF-001 Rev C 5/11/06 Page 1 of 1

1. Equipment Item Variable Frequency Drive

2. Manufacturer Siemens Energy & Automation, Inc.

3. Equipment Identification Number(s) 31000856.00 (P/N 12002079.00)

4. Weight of Individual Components

(over 100 lbs.) Approx. 34,800 lbs.

5. Nameplate Data

(HP, voltage, speed, etc.) GEN3E, 3500HP, 6600V, 315A

6. Manufacturer’s Local Representative

Name Ian Lynch Telephone No. +61 (7) 3274-2566

Address Emsby Equipment Pty. Ltd., 27 Rodwell Street, Archerfield, QLD 4108 AUSTRALIA

7. Maintenance Operation Maintenance

Operation

Frequency Lubricant

(if applicable)

Comments

List briefly each maintenance

operation required and refer

to specific information in

Mfg.’s standard maintenance

manual, if applicable.

List Required frequency

of each maintenance

operation.

Refer by symbol to

lubricant required.

Clean Equipment Every six months N/A See Section 1 for procedure

Tighten Electrical

Connections

Every six months N/A See Section 1 for procedure

8. Lubricant List Reference Symbol Shell Std. Oil Gulf Arco Or Equal

List symbols used in item 7

above

List Equivalent lubricants, as distributed by each manufacturer for the specific use

recommended.

N/A N/A N/A N/A N/A N/A


9. Spare Parts (if applicable) See Section 1 - Supplied Spare Parts

8/18/2019 19001914V1.0 VOL. 1

16/531

MAINTENANCE SUMMARY FORM

DCF-001 Rev C 5/11/06 Page 1 of 1

1. Equipment Item Variable Frequency Drive

2. Manufacturer Siemens Energy & Automation, Inc.

3. Equipment Identification Number(s) 31000856.01 (P/N 12002079.01)

4. Weight of Individual Components

(over 100 lbs.) Approx. 34,800 lbs.

5. Nameplate Data

(HP, voltage, speed, etc.) GEN3E, 3500HP, 6600V, 315A

6. Manufacturer’s Local Representative

Name Ian Lynch Telephone No. +61 (7) 3274-2566

Address Emsby Equipment Pty. Ltd., 27 Rodwell Street, Archerfield, QLD 4108 AUSTRALIA

7. Maintenance Operation Maintenance

Operation

Frequency Lubricant

(if applicable)

Comments

List briefly each maintenance

operation required and refer

to specific information in

Mfg.’s standard maintenance

manual, if applicable.

List Required frequency

of each maintenance

operation.

Refer by symbol to

lubricant required.

Clean Equipment Every six months N/A See Section 1 for procedure

Tighten Electrical

Connections

Every six months N/A See Section 1 for procedure

8. Lubricant List Reference Symbol Shell Std. Oil Gulf Arco Or Equal

List symbols used in item 7

above

List Equivalent lubricants, as distributed by each manufacturer for the specific use

recommended.



9. Spare Parts (if applicable) See Section 1 - Supplied Spare Parts

8/18/2019 19001914V1.0 VOL. 1

17/531



Maintenance Procedure - Clean equipment

PROCEDURE: Clean equipmentFREQUENCY: Every six monthsEQUIPMENT REQUIRED: Vacuum Cleaner with soft bristle brush attachment

High Voltage Field Non-Contact Detector such as TIFbrand TIF300HV

1. De-energize power to the drive input and use local lock-out/tag-out procedures toinsure maintenance crew safety. CAUTION: MAKE SURE TO DE-ENERGIZE ALLPOWER AT THE DISCONNECTING MEANS SUPPLYING THE DRIVE - IF THEDRIVE INCLUDES A DISCONNECT SWITCH, DO NOT USE THE DISCONNECTSWITCH TO DE-ENERGIZE THE DRIVE. After removing power for the drive waitfive minutes to allow all capacitors in the drive to fully discharge.

NOTE: Power from outs ide sources such as 120 volts on control circuitswhich originates elsewhere may stil l be present even with the main power

disconnected. Proceed with CAUTION.

2. Open cabinet door.

3. Verify that power is de-energized by using the High Voltage Field Non-ContactDetector to determine the presence of an electrical field. The presence of an electricfield indicates that the power has not been removed for the drive.

DO NOT PROCEED UNTIL YOU ARE SURE POWER HAS BEEN REMOVED FORTHE EQUIPMENT.

4. Vacuum cabinet interior being careful to remove all loose dirt, dust and debris.Stained cabinet surfaces may be cleaned using any household spray cleaner.

5. After cleaning make sure all relays are firmly inserted in their relay sockets. Checkfor, and correct loose wiring or components.

6. Clean or replace cabinet air filters.

7. Close cabinet door.

8. Restore power being careful to follow local lock-out/tag-out procedures. Place unit

back in service.

8/18/2019 19001914V1.0 VOL. 1

18/531



Maintenance Procedure - Tighten electrical connections

PROCEDURE: Tighten electrical connectionsFREQUENCY: Every six monthsTOOLS/TEST EQUIPMENT: Vacuum Cleaner with soft bristle brush attachment

High Voltage Field Non-Contact Detector such as TIFbrand TIF300HV

1. De-energize power to the drive input and use local lock-out/tag-out procedures toinsure maintenance crew safety. CAUTION: MAKE SURE TO DE-ENERGIZE ALLPOWER AT THE DISCONNECTING MEANS SUPPLYING THE DRIVE - IF THEDRIVE INCLUDES A DISCONNECT SWITCH, DO NOT USE THE DISCONNECTSWITCH TO DE-ENERGIZE THE DRIVE. After removing power for the drive waitfive minutes to allow all capacitors in the drive to fully discharge.

NOTE: Power from outs ide sources such as 120 volts on control circuitswhich originates elsewhere may stil l be present even with the main power

disconnected. Proceed with CAUTION.

2. Open cabinet door.

3. Verify that power is de-energized by using the High Voltage Field Non-ContactDetector to determine the presence of an electrical field. The presence of an electricfield indicates that the power has not been removed for the drive.

DO NOT PROCEED UNTIL YOU ARE SURE POWER HAS BEEN REMOVED FORTHE EQUIPMENT.

4. Observe all power connections for discoloration. Discoloration indicates a looseconnect. Tighten as necessary

5. Check all that control connections are secure.

6. Close cabinet doors.

7. Restore power being careful to follow local lock-out/tag-out procedures. Place unitback in service.

8/18/2019 19001914V1.0 VOL. 1

19/531

TECHNICAL SERVICE & ASSISTANCE RATE SCHEDULE

CSF-028 Rev P 10/9/06 Page 1 of 4

Technical Support Communication Center Telephone: 01 (724) 339-9501

Fax: 01 (724) 339-9507


Prices are effective October 1, 2006 and supersede any previous Service Rate Schedules or Pricing Agreements

and are subject to changes without notice.

SIEMENS

SERVICE TYPE

STANDARD

RATE

OVERTIME

RATE

PREMIUM

RATE

DAY

RATE

Drives Specialist $165.00 / hr $247.00 / hr $330.00 / hr $1,650.00 / day

Power Conversion System

Up to 2 MWAbove 2 MW

$165.00 / hr$190.00 / hr

$247.00 / hr$286.00 / hr

$330.00 / hr$380.00 / hr

$1650.00 / day$1900.00 / day

Engineering ServicesDesign & Consulting

$190.00 / hr $286.00 / hr $380.00 / hr $1900.00 / day

Training Class PRE-SCHEDULED CLASS RATE CUSTOM CLASS RATE

(4-Day Class)

$2,000.00 / attendee

(3-Day Classes)

$1,500.00 / attendee

(Up to 5 Attendees)

$2,200.00 / day

(Additional attendees )

$500.00 / attendee

In House Repair STANDARD REPAIR RATE RUSH REPAIR RATE$120.00 / hr $180.00 / hr

Most current units have flat rate pricing. If these rates do not apply the parts will be at list price and labor will be billed as above.

Evaluation Fee STANDARD EVALUATION RATE RUSH EVALUATION RATE

$120.00 / hr $240.00 / hr

Only applies on units not repaired or replaced

Standard Rate applies to 8 hours ofservice work and travel time during anormal weekday, 4 hour minimum charge.The normal weekday is defined as anyconsecutive 8 hour day, Monday throughFriday inclusive, excluding Holidays.

Overtime Rate applies to all servicework and travel time in excess of 8 hours per day or after 5:00pm on normalweekdays and up to 8 hours on Saturday.

Premium Rate applies to all service workand travel time on Saturdays beyond 8hours per day and all hours on Sundaysand Holidays.

International & Offshore Rates areinvoiced at an additional 5% premium.

Day Rates are prearranged agreements providing for up to 10 hours per dayregardless of the day or time worked(excluding travel time). All hours worked

in excess of 10 hours and on Holidayswill be invoiced at the applicable overtimeor premium rate for the time and day ofthe services.

Travel Time applies to all round triptransit time from point of dispatchorigination to the job site including travelto and from local living accommodations.

Standby, On-Call and Holdover Time provided at the customers request or dueto circumstances beyond SIEMENS’control, and invoiced as work time per theapplicable rate schedule for the time andday of the service.

Travel & Living Expenses are notincluded in service work rates. Livingexpenses include but are not limited tolodging, meals, air and groundtransportation, permits, customs fees,mileage, parking fees and tolls.Per Diem Rates are used for all lodging &meals within the travel expenses. Thedaily per diem amounts are based on theIRS defined per diem rates.IRS Standard Cost Location per diem rateis $93.00 Lodging, $36.00 meals.IRS High Cost Location per diem rate is$158.00 Lodging, $46.00 meals.Personal vehicle mileage is invoiced at arate of $0.75 per mile.

Other Charges include:Administrative Fee of (15%) on allinvoiced travel & living expenses.Environmental Safety & HealthRegulation Fee of (3%) on all invoicedservice and travel time charges.Documentation Fee of (25%) surcharge oftravel & living expense totals for anyrequest for copies of employee expensereports and expense receipts.

Dispatch of Technician requires one ofthe following:U.S. location, a hard copy Purchase Order(PO) for the estimated dollar amount forservice hours, travel time, and travel &living expenses.Emergency & After-hours service, a

Temporary PO Approval Form faxed to724-339-9507 at the Pittsburgh servicedepartment in the estimated dollar amounfor service hours, travel time, and travel &living expenses.International location, a Wire Transfer ofFunds in the estimated dollar amount priorto scheduling travel.

Training Class services are offered onSIEMENS equipment to operation &maintenance personnel.Pre-Scheduled Classes are periodicallyheld at our facility in Pittsburgh.Custom Classes are specifically developedfor a customer and held at your facility orat SIEMENS facility in PittsburghTravel time and travel & living expenseswill be billed for classes held at customerfacility.

PM Agreements are available for alSIEMENS equipment at your site. This pre-paid preventive maintenance serviceis quoted for a yearly term.Additional benefit during the term of thePM Agreement is a price reduction on alltechnical service rates.

8/18/2019 19001914V1.0 VOL. 1

20/531


CSF-028 Rev P 10/9/06 Page 2 of 4

Commissioning Services

(1) Terms and Conditions of SaleSIEMENS hereby gives notice to its objectionto any different or additional terms andconditions except for any such terms andconditions as may be expressly accepted byit in writing.Unless different or additional terms andconditions are stated or referred to in anyproposal which is attached hereto (the“Proposal”), in which event such different or

additional terms and conditions shall beexclusive as to the particular subject covered,the terms and conditions stated below apply,and such terms and conditions supersedeany prior or contemporaneous agreements orcorrespondence between the parties.

(2) ExpirationThis quotation or Proposal (and anyquotations contained therein) will expire 30days from its date unless otherwise stated inthe quotation or extended in writing bySIEMENS.

(3) Price Polic y(3A) For Services:Prices quoted are firm for ninety days fromthe date of order. If shipment of repairedequipment or completion of service extendsbeyond ninety days from the date of order,

the prices will be adjusted to those in effect atthe time of such shipment or completion;however, increases will not exceed 1% of theunpaid balance per month from the date ofthe order.

(4) PricesPrices are net to all purchasers.

(5) TaxesThe price does not include any federal, state,or local property, license, privilege, sales,use, excise, gross receipts, value added orother like taxes which may now or hereafterbe applicable to, measured by, or imposedupon, or with respect to the Project, anyproperty or material required to perform theProject, its sale, its value, or its use, or anyservices performed in connection therewith.

Such taxes are for the account of thePurchaser and the Purchaser agrees to payor reimburse any such taxes, whichSIEMENS or its contractors or suppliers are,required to pay.

(6) Terms of PaymentPayment is due upon receipt of invoice fororders amounting to less than $50,000.00.Terms of payment for orders exceeding$50,000.00 shall be made according to thefollowing:1. Twenty percent (20%) of order value

with purchase order payable uponpresentation of invoice.

2. Eighty percent (80%) of order value inequal monthly payments over theperformance period payable uponpresentation of invoice.

Except for work performed (i) under a firmfixed price basis or (ii) pursuant to terms of apreviously priced existing contract betweenSIEMENS and Purchaser, invoices for workperformed by SIEMENS shall have addedand noted on each invoice a charge of 3%(over and above the price of the work) whichis related to SIEMENS compliance withpresent and proposed environmental, health,and safety regulations associated withprescribed requirements covering hazardousmaterials management and employeetraining, communications, personal protectiveequipment, documentation and recordkeeping associated therewith.

(7) Delayed PaymentsIf payments are not made in accordance withthese terms, a service charge will, withoutprejudice to the right of Siemens Energy & Automation Inc. to immediate payment, beadded to the account of the Purchaser in anamount equal to the lower of 1 1/2% permonth or fraction thereof or the highest legalrate on the unpaid balance.

(8) Payments

SIEMENS shall have the right to require fullor partial payment in advance at any time, ifin its opinion, the financial condition of thePurchaser does not justify the terms ofpayment specified.Should the Purchaser be adjudged bankruptor insolvent in any legal proceeding,SIEMENS shall have the right, at its electionand throughout the period allowed in suchproceeding for filing claims against thepurchaser’s estate, to cancel the order and torecover its proper cancellation charges fromthe Purchaser’s estate.Whenever, in SIEMENS’ judgment, thereexists reasonable grounds to questionwhether Purchaser is willing or able to fullyperform its obligations hereunder or to makepayments as required, SIEMENS may require

Purchaser to provide such assurances of dueperformance and/or payment as SIEMENSshall deem proper, and SIEMENS maysuspend its performance hereunder untilsuch assurances are provided. SIEMENSmay terminate any order or contracthereunder if Purchaser fails to provide suchassurances within a reasonable time.If the work is delayed by the Purchaser,SIEMENS may require payment for allmaterials accumulated and work performedunder the order.

(9) Delivery - Risk of Loss All transportation costs shall be for theaccount of the Purchaser and shall be addedto the invoice. Any equipment sent toSIEMENS for repair shall be delivered byPurchaser F.O.B. SIEMENS plant.

Repaired equipment and other equipment ormaterials furnished by SIEMENS shall bedelivered to the Purchaser F.O.B. SIEMENSplant. Title to and risk of loss of or damage toany material or equipment furnished bySIEMENS under the contract shall pass tothe Purchaser F.O.B. SIEMENS plant. Riskof loss or damage to the purchaser’s materialor equipment shall be with the Purchaser atall times.

(9A) Upgrades/Acceptance of PartsWhenever possible, SIEMENS will ship spareparts or replacement parts in advance ofscheduled work. Purchaser shallacknowledge legal possession of spare orreplacement parts and will safeguard parts ina secure, environmentally controlled locationuntil scheduled installation.

(10) Shipping and Completion DatesQuoted shipping and completion dates areapproximate and are based on prompt receiptof all necessary information and approvalsfrom the Purchaser and access as requiredby SIEMENS and its contractors orsubcontractors (if any) to the site and to theequipment which is the subject of theProposal. Unless Purchaser stipulates inwriting in the purchase order that an earliershipment or completion is not permissible,SIEMENS reserves the right to ship orcomplete prior to any dates set forth herein.Orders requiring special handling orpackaging will be invoiced additionally plus

shipping. Standard orders will be invoiced a15% of freight charges or a $5.00 minimumplus shipping.

(10A) Export Compliance ClausePurchaser acknowledges that SIEMENS isrequired to comply with applicable exporlaws and regulations relating to the saleexportation, transfer, assignment, disposaand usage of the Equipment/Servicesprovided under the Contract, including any

export license requirements. Purchaseagrees that such Equipment/Services shalnot at any time directly or indirectly be usedexported, sold, transferred, assigned ootherwise disposed of in a manner which wilresult in non-compliance with such applicableexport laws and regulations. It shall be acondition of the continuing performance bySIEMENS of its obligations hereunder thacompliance with such export laws andregulations be maintained at all times.Purchaser agrees to indemnify and holdSIEMENS harmless from any and all cos tsliabilities, penalties, sanctions and finesrelated to non-compliance with applicableexport laws and regulations.

(11) Force MajeureSIEMENS shall not be liable for failure to

perform or for delay in performance due tofire, flood, strike or other labor difficulty, act oGod, act of any governmental authority or othe Purchaser, riot, wrecks or delay intransportation, inability to obtain necessarymaterials or services (including but not limitedto the loss of license, permit or approval byany transportation, storage or disposafacility) from usual sources, lack of access tothe site or to the equipment which is thesubject of the proposal, interruption oelectrical service to SIEMENS suppliedequipment, or due to any cause beyond itsreasonable control.In the event of delay in performance due toany such cause, the date of delivery or timefor completion will be extended by a period otime reasonably necessary to overcome the

effect of such delay.(12) WarrantySIEMENS warrants, to the extent to whichany of the same may be applicable, that (a)any replacement or other parts furnished by ior any work done by it on the Purchaser’sequipment or both shall be free of defects inworkmanship and materials, (b) anyspecialized tools, equipment and instrumentsfor the use of which a charge is made to thePurchaser shall be adequate for the work tobe performed and (c) the engineeringservices performed by it will be performed inaccordance with generally acceptedprofessional standards.SIEMENS shall correct any failure to conformto any of the applicable foregoing warrantiesof which it is notified in writing within a period

of one (1) year after completion of the workor shipment of the part, requiring correctionunder this warranty. Such correction may, inthe case of item (a) above and at the electionof SIEMENS shall be limited to the repair orreplacement F.O.B. SIEMENS plant, of thedefective part or parts furnished by it. In thecase of any other breach of the foregoingwarranty, SIEMENS shall furnish engineeringservices or specialized tools, equipment andinstruments, to the same extent as on theoriginal work. It is understood and agreedthat, unless otherwise agreed to in writing bySIEMENS; SIEMENS assumes noresponsibility with respect to the suitability othe purchaser’s equipment or with respect to

8/18/2019 19001914V1.0 VOL. 1

21/531


CSF-028 Rev P 10/9/06 Page 3 of 4

any latent defects in the same. In no eventshall SIEMENS be responsible for providingworking access to the defect, including theremoval, disassembly, replacement orreinstallation of any equipment, materials orstructures to the extent necessary to permitSIEMENS to perform its warranty obligations,or transportation costs to and from theSIEMENS factory or repair facility, or fordamage to equipment components or partsresulting in whole or in part from impropermaintenance or operation or from theirdeteriorated condition. The condition of anytests shall be mutually agreed upon andSIEMENS shall be notified of, and may bepresent at, all tests that may be made.The above warranties do not apply toproducts which have a life, under normal use,inherently shorter than the one-year periodindicated above. SIEMENS, on products notmanufactured by SIEMENS, limits itself toextending the same warranty it receives fromthe supplier.SIEMENS warrants that any engineeringstudies performed by it will conform togenerally accepted professional standards. Any portion of the study which does not soconform shall be corrected by SIEMENSupon notification in writing by the Purchaserwithin six months after completion of thestudy. All warranty work shall be performedin a single shift straight time basis Monday

through Friday. In the event that the productrequires correction of warranty items on anovertime schedule, the premium portion ofsuch overtime shall be for the Purchaser’saccount.THE FOREGOING WARRANTIES AREEXCLUSIVE AND IN LIEU OF ALL OTHERWARRANTIES WHETHER STATUTORY,EXPRESS OR IMPLIED (INCLUDING ALLWARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULARPURPOSE AND ALL WARRANTIES ARISING FROM COURSE OF DEALING ORUSAGE OF TRADE), EXCEPT OF TITLE AND AGAINST PATENT INFRINGEMENT.The remedies provided above are thePurchaser’s sole remedies for any failure ofSIEMENS to comply with its obligations.Correction of any nonconformity in themanner and for the period of time providedabove shall constitute complete fulfillment ofall the liabilities of SIEMENS whether theclaims of the Purchaser are based incontract, in tort (including negligence) orotherwise with respect to or arising out of thework performed hereunder.Note: This Warranty does not apply to anysoftware which may be furnished bySiemens. In such cases, the attachedSoftware License Addendum applies

(13) Limitation of LiabilityNeither SIEMENS, nor its suppliers shall beliable, whether in contract, warranty, failure ofa remedy to achieve its intended or essentialpurposes tort (including negligence), strictliability, indemnity or any other legal theory,

for loss of use, revenue or profit, or for costsof capital or of substitute use or performance,or for indirect, special, liquidated, incidentalor consequential damages, or for any otherloss or cost of a similar type, or for claims byPurchaser for damages of Purchaser'scustomers. SIEMENS’ maximum liabilityunder this contract shall not exceed 5% ofthe contract price. Purchaser and SIEMENSagree that the exclusions and limitations setforth in this article are separate andindependent from any other remedies, whichPurchaser may have.

(14) Intellect ual Property

Subject to the following provisions, SIEMENSshall at its own expense, defend or at itsoption settle any claim, suit, or proceedingbrought against the Purchaser, and/or itsvendors, mediate and immediate, so far asbased on an allegation that any goods,material, equipment, device or article(hereinafter referred to as product) or anypart thereof furnished hereunder constitutes adirect or a contributory infringement of anyclaim of any patent, copyright or trade secretof the United States. This obligation shall beeffective only if Purchaser shall have madeall payments then due hereunder and ifSIEMENS is notified promptly in writing andgiven authority, information and assistancefor the defense of said claim, suit orproceeding. SIEMENS shall pay all damagesand costs awarded in such suit orproceedings so defended. In case theproduct or any part thereof furnishedhereunder becomes the subject of any claim,suit or proceeding for infringement of anyUnited States patent, copyright or tradesecret, or in the event of any adjudication thatsuch product or part infringes any UnitedStates patent, copyright or trade secret,SIEMENS will, at its option and its ownexpense, either:a) procure for the Purchaser the right to

continue using said product or partthereof; or

b) replace it with a noninfringing product; orc) modify it so it becomes non-infringing; ord) as a last resort remove it and refund the

purchase price and the transportationand installation costs thereof.

The foregoing indemnity does not apply to thefollowing:1) Patented processes performed by the

product, or another product producedthereby.

2) Products supplied according to a designother than that of SIEMENS and whichis required by the Purchaser.

3) Combination of the product with anotherproduct not furnished hereunder unlessSIEMENS is a contributory infringer.

4) Any settlements of a suit or proceedingmade without SIEMENS’ writtenconsent.

The foregoing states the entire liability ofSIEMENS with respect to patent infringementby said product or any part thereof.If a suit or proceeding is brought againstSIEMENS solely on account of activitiesenumerated in paragraphs 1, 2, or 3, above,the Purchaser agrees to indemnify SIEMENSin the manner and to the extent SIEMENSindemnified Purchaser in the first paragraphof this provision insofar as the terms thereofare appropriate.

(15) IndemnificationSIEMENS shall, subject to paragraph 13titled Limitation of Liability, indemnify andsave the Purchaser harmless from, but onlyfrom, claims of third parties for physicaldamage to tangible property and personal

injury, including death, occurring during theperformance of the work hereunder on thepremises of the Purchaser and resultingdirectly and solely from the negligence of theemployees of SIEMENS while engaged insuch work, except where such damage orinjury arises out of or results from a “nuclearincident” (as defined in the Atomic Energy Actof 1954, as amended). SIEMENS shall, withrespect to such work, comply with theprovisions of the applicable workmen’s(worker’s) compensation act.

(16) Termination Any order or contract may be terminated bythe Purchaser only upon written notice to

SIEMENS and upon payment of reasonableand proper termination charges.

(17) Minimum Billi ngThe minimum billing for any service performed on a single order will be equivalent tofour (4) times the current hourly rate oservice engineers.

(18) Scrap Material All scrap materials become the property oSIEMENS

(19) Containers An extra charge will be made for returnable

containers and special devices, but refundwill be made if returned in good condition tothe factory or other point designated bySIEMENS within 90 days from the date ooriginal shipment, charges prepaid.

(20) Nuclear ApplicationIn the event that the Purchaser or thirdparties use services, product, or any parthereof, in connection with any activity oprocess involving nuclear fission or fusion oany use or handling of any source, specianuclear or by-product material as thosematerials are defined in the U.S. AtomicEnergy Act of 1954 (as amended).Purchaser shall immediately notify SIEMENSof such nuclear application so that nuclearegulations and insurance provisioncontained in those terms and conditions can

be complied with. Such notification shall bein writing by certified mail to SIEMENS.

(21) Projects(21A) Additional Work Any additional work performed by SIEMENSfor Purchaser, beyond the scope of theProposal, shall be performed in accordancewith these general terms and conditions, andPurchaser shall pay SIEMENS for same aSIEMENS’ then current rates for suchservices, or as may be otherwise negotiatedby the parties.(21B) Purchaser WarrantiesThe Purchaser warrants and represents toSIEMENS that:(a) Purchaser will comply with and fulfill its

obligations as set forth herein; and(b) Purchaser has the sole title and

possession of equipment servicedhereunder and this title shall remain withPurchaser subject to any applicable lienrights of SIEMENS.

(21C) Purchaser’s NotificationPurchaser acknowledges the importance oresponding promptly to any PCB relatedproblem or condition at the site. AccordinglyPurchaser hereby agrees to notify SIEMENSwithin forty-eight (48) hours after discoveryor the time when such reasonably should bediscovered, of any PCB related problem ocondition created solely by SIEMENS aPurchaser’s site.

(22) AsbestosFederal Law requires that building or facilityowners identify the presence, location andquantity of asbestos containing materials

(hereinafter "ACM") at work sites. SIEMENSis not licensed to abate ACM. Accordingly,prior to (i) commencement of work at any Siteunder a specific Purchase Order, or (ii) achange in the work scope of any PurchaseOrder, the Purchaser will certify that the workarea associated with the SIEMENS scope ofwork under said Purchase Order, ChangeOrder, or either of them, is free of ACM.

(23) Governing Law and AssignmentThe laws of the State of Georgia shall governthe validity, interpretation and enforcement ofthis contract, without regard to its conflicts oflaw principles. Assignment may be madeonly with written consent of both parties.

8/18/2019 19001914V1.0 VOL. 1

22/531


CSF-028 Rev P 10/9/06 Page 4 of 4

(24) Attorney FeesPurchaser shall be liable to SIEMENS for anyattorney fees and costs incurred bySIEMENS in enforcing any of its rightshereunder.

(25) Disputes Either party may give the other party writtennotice of any dispute arising out of or relating

to this contract and not resolved in thenormal course of business. The parties shallattempt in good faith to resolve such disputepromptly by negotiations between executiveswho have authority to settle the dispute. Ifthe matter has not been resolved within 60days of the notice, either party may initiatenon-binding mediation of the dispute.

(26) Statute of Limitations To the extent permitted by applicable lawany lawsuit for breach of contract, includingbreach of warranty, arising out of thetransactions covered by this contract, musbe commenced not later than twelve (12)months from the date the cause of actionaccrued.

Service assistance may be obtained by contacting

Siemens Energy & Automation, Inc. Technical Support Communication Center500 Hunt Valley Drive, New Kensington PA 15068

Phone #: (724) 339-9501Fax #: (724) 339-9507

Please contact us regarding our many customer services, including: customer training, preventive maintenance and service contract

programs, renewal parts, harmonic and power testing, equipment upgrades and refurbishments.

8/18/2019 19001914V1.0 VOL. 1

23/531



Siemens Energy & Automation, Inc.

500 Hunt Valley Drive New Kensington. PA 15088Phone: (724) 339-9500Fax: (724) 339-9562

Siemens Energy & Automation, Inc. Variable Frequency Drive Storage Requirements

Storage

After the initial inspection, the equipment should be promptly moved to the final position or to a dry indoor storage

area. This equipment is not weatherproof and must be protected from outdoors environmental conditions at all

times. Every reasonable effort should be made to store the VFD equipment indoors in an environmentallycontrolled area.

If it is necessary to temporarily store the VFD equipment in an outdoor area the following precautions must be

observed. Heaters should be placed in the equipment and operated to prevent moisture accumulation. One hundred-

watt light bulbs are adequate to serve as temporary heaters. One heater should be placed in each VFD compartment.

Care should be taken to insure heaters do not come in contact with sensitive parts. High quality tarps should coverthe entire equipment to protect it from driven rain. VFD equipment should never be placed on undeveloped areas

such as grass, sand or dirt. Outdoor storage should be considered temporary and not exceed 3 days. VFDequipment should never be subjected to extreme temperatures. Avoid temperatures below 32 degrees F and avoid

storage in direct sunlight.

Environmental Issues

Although each Robicon VFD is extremely well protected against ambient and atmospheric conditions, there aresome environmental settings that may be detrimental to its operation and life expectancy. The operator should

consult the factory regarding any questionable issues that may exist at his particular site.

Indoor equipment is not weatherproof and should never be stored in an outdoor area for extended periods of time.

Problematic Environments for Storage and Operation

1. Avoid exposure to corrosive gases (particularly, but not exclusively, hydrogen sulfide and chlorine). Consultfactory for acceptable levels.

2. Avoid exposure to excessive moisture (i.e., relative humidity greater than 95%), dripping water, steam,and condensation. Excessive humidity causes moisture to condense on the sheet metal of the Perfect

Harmony drive. Moisture from any source can cause permanent damage to the equipment (e.g., the inverter

power circuits) and possible injury to the operator.

3. Avoid exposure to conductive dust such as coal dust. In general, however, "non-conductive" dust should not

be a problem.

4. Avoid exposure to abrasive dust, oil vapor, explosive mixtures, explosive gases, and salt air. Although totalsystem failure may not result, exposure to such elements may result in reduced life expectancy of the

equipment.

5. Avoid exposure to vibration, shocks, or tilting. All Robicon drives have been designed to withstand theshocks of truck transit, normal bumps and jolts during installation. Continuous mechanical shock may result

in early failure of components.

6. Avoid exposure to strong magnetic fields, nuclear radiation and high levels of RFI from communicationtransmitters.

Failure to follow these guidelines could jeopardize your Siemens Energy & Automation, Inc.

warranty coverage.

8/18/2019 19001914V1.0 VOL. 1

24/531



8/18/2019 19001914V1.0 VOL. 1

25/531

WARRANTY

Siemens LD A warranty is 12 months from date of startup, not to exceed 24

months after date of shipment, and covers defects in workmanship and materials

only. Siemens warranty liability is limited to the value of the Siemens LD A

supplied equipment. The standard Siemens LD A terms and conditions of sale

will apply to any purchase order unless other terms and conditions are specifically

negotiated in written form and signed as acceptable by Siemens LD A.

8/18/2019 19001914V1.0 VOL. 1

26/531

8/18/2019 19001914V1.0 VOL. 1

27/531


500 Hunt Valley Road Tel: (724) 339-9500 Service Assistance Process 05-07-22New Kensington, PA 15068 Fax: (724) 339-9562 Page 1 of 5

Customer Service

Service Assistance Process

Enclosed you will find information on the customer support services provided and how you canobtain service support from Siemens Energy & Automation, Inc., Large Drives-R, Robicon

Business Unit. Included in this document is a list of support programs offered, a list of products

supported and key contact names and numbers responsible for assisting in each of the servicesupport areas.

Contact the Customer Service Department for service call requests, quotations, and other service

related information through either our email address [email protected] or forUS customers, contact us from a touch tone phone by dialing 800-334-4689 or 724-339-9501; for

Canadian customers, contact us from a touch tone phone by dialing 877-414-6095 or 780-414-6095.

US customers will have five options to choose from to route your call to the service group that yourequire for support; or, you can remain on the line to speak with a service call operator:

Press Key 1 - Field Service Call Scheduling / Dispatching

Press Key 2 - Technical Assistance

Press Key 3 - Spare PartsPress Key 4 - Repairs

Press Key 5 - Product Training, Preventive Maintenance, Upgrades & Special Services

If no one is currently available for the specific service group selected, the phone will be transferred

to the Service Call Operator who will assist you. The following is a brief description of each

available service option.

Option #1 Field Service Call Scheduling / Dispatching – Please select this option if you need to

schedule a field service technician to visit your site. We will ask you to provide the following

information when we receive your call in order to facilitate your service visit:

1. Company Name and Bill-to-Address 5. Equipment Part Number2. Site location 6. Your Company’s Purchase Order Number3. Site Contact Name and Phone Number 7. Description of Problem or Service Required4. Equipment Original Sales Order No. 8. Date that you require Service

The key individual to assist you with field service scheduling / dispatching is:

Patrick Meehan Phone: 724-334-6228

Senior Technical Support Engineer Fax to Office: 724-339-9507Email: [email protected] Fax to Email: 724-339-9562

8/18/2019 19001914V1.0 VOL. 1

28/531



Option #2 Technical Assistance – Please select this option for any technical assistance that you

may need on your equipment. Typical questions that you may be asked during your call willdepend on your particular situation and may include the following:

1. Company Name and Address 5. Contact Name and Phone Number2. Equipment Part Number 6. Equipment Original Sales Order Number3. Horsepower, Voltage, Application4. Description of the problem you are experiencing with the equipment

The key individuals to assist you for technical assistance are:

Rick Baur Dave OrmesherSr. Technical Support Technician Sr. Technical Support Engineer

Phone: 724-339-8379 Phone: 724-339-9552

Fax to Office: 724-339-9507 Fax to Office: 724-339-9507

Fax to Email: 724-339-9562 Fax to Email: 724-339-9562Email: [email protected] Email: [email protected]

Matt Sowinski Harry Losier

Sr. Technical Support Technician Sr. Technical Support Technician

Phone: 724-339-9217 Phone: 724-339-8340Fax to Office: 724-339-9507 Fax to Office: 724-339-9507

Fax to Email: 724-339-9562 Fax to Email: 724-339-9562

Email: [email protected] Email: [email protected]

Option #3 Spare Parts – Please select this option if you need to purchase spare parts. The main

contacts for spare parts will be:

Wendy Butcher

Sales Support SpecialistPhone: 724-339-8171

Fax to Office: 724-339-9507

Fax to Email: 724-339-9562

Email: [email protected]

We will need the following information from you when placing your request for parts:

1. Equipment Sales Order Number(to verify Parts, Warranty Status, and Discounts)

2. Equipment Part Number or Manufacturer’s Part Number

The current price and delivery will be determined and provided to you via phone, if available,followed by a formal quotation document by fax or email.

8/18/2019 19001914V1.0 VOL. 1

29/531



Option #4 Repairs – Please select this option to return a part for repair or to check on the repair

status of a part. Please call prior to sending in a part for repair to be assigned a Return MerchandiseAuthorization (RMA#) number. We will send you the RMA# form, either by mail of Fax, which

will also provide you with the shipping information where to return the part. Please include a copy

of the RMA# form when returning parts, the RMA# will facilitate the tracking of the part. The keyindividuals to assist you for repairs are:

Wendy Urick Bob Carothers

Sales Support Specialist Assistant Team Leader Repair TechnicianPhone: 724-339-9307 Phone: 724-339-9395



Option #5 Product Training, Preventive Maintenance, Upgrade & Special Services – Pleaseselect this option if you require a quote or other information on training classes, preventivemaintenance programs, equipment updates & upgrades, extended warranty, full service agreements

or other special services.

The key individual to assist you with training services is:

William (Bill) Long

Senior Technical TrainerPhone: 724-339-8176

Fax to Office: 724-334-6252

Fax to Email: 724-339-9562Email: [email protected]

The key individuals to assist you with preventive maintenance programs, equipment updates &upgrades, extended warranty, full service agreements or other special services are:

David Goga Marilyn Wills

Proposal Specialist Sales Support SpecialistPhone: 724-339-8147 Phone: 724-339-9457




8/18/2019 19001914V1.0 VOL. 1

30/531



For training, preventive maintenance, equipment updates & upgrades, extended warranties, full

service agreements or other special services, you will be asked to provide some or all of thefollowing information when calling about pricing for one of these services:

1. Company Name and Address 8. Site Address2. Contact Name and Phone Number 9. Equipment to be Trained On3. Company Billing to Address 10. Training Location4. Equipment Original Sales Order Number 11. Training Dates5. Equipment Part Numbers 12.Any Special Training Requirements6. Quantities of Equipment 13. Number of Attendees and Names

Siemens Robicon Business Unit offers training classes on the operation, maintenance, service and

interfacing of the equipment.

Under the PM agreement service, a Field Service Representative (FSR) will visit your facility on a periodic schedule to provide a visual inspection, cleaning, connection check, power-up checkout,and performance tuning during a scheduled shutdown.

Updates and Upgrades available on your equipment will provide you with the latest improvement in

technology or replace aging components with items to extend the overall life cycle of yourequipment.

Extended Warranties and Full Service Agreements limit the overall expenses associated with longterm equipment maintenance. Equipment evaluation may be required on your equipment prior to

warranty approval. Based on the equipment age and condition, repairs or upgrades may be required

to bring your equipment to a factory acceptable state for the extended warranty agreement.

Some of the special services offered to our customers include:

• Electrical Testing of Support Equipment including:o Switchgearo Transformerso Motors

• Electrical and Mechanical Analysis including:o Drive Performanceo System Efficiencyo Power Factoro Network Harmonicso Motor Vibration

8/18/2019 19001914V1.0 VOL. 1

31/531



Service Support on the following Products:

• Robicon, Ansaldo Ross Hill Products

• Variable Frequency Drives (Current Source and PWM)

• DC Drives

• AC & DC Power Supplies / Power Systems

• AC & DC Motors

Service Support Programs:

• Commissioning Assistance

• Preventive & Predictive Maintenance

• Extended Warranty

• Full Service Agreements – Preventive Maintenance + Extended Warranty

• Customer Training Programs• Renewal Parts Support

• Emergency Repair Services

• Circuit Board & Assembly Exchange Programs

• Equipment Refurbishment & Rebuild Programs

• Equipment Update & Upgrade Programs

• Remote Diagnostic / Monitoring

For additional assistance, please contact any of the individuals below:

Jay Lavrinc John H. Steele

Technical Services Manager Technical Services ManagerPhone: 724-334-5691 Phone: 724-334-1153



Fraser Cameron Ron Squires

Field Service Manager, Canada After-Market Service SalesPhone: 780-414-6095 Phone: 774-334-6237




8/18/2019 19001914V1.0 VOL. 1

32/531

8/18/2019 19001914V1.0 VOL. 1

33/531

SECTION 2

8/18/2019 19001914V1.0 VOL. 1

34/531

8/18/2019 19001914V1.0 VOL. 1

35/531



ROBICON (AIR-COOLED) PERFECT HARMONY GEN III/E MANUALMANUAL NO. 19000403 INSTALLATION

EMSBY PTY LTD, Project Name: PALMAREJO

Robicon ( Air Cooled) Perfect Harmony Series, Adjustable Speed, AC Motor DriveEMSBY PTY LTD, Customers P.O.: 12343 HR9214394, System Part Nos.: 31000856.00, .01

Siemens Energy & Automation, Inc. regrets that because of product liability issues,edited, incomplete manuals may not be furnished. Once the equipment is shippedfrom Siemens Energy & Automation, Inc., its ultimate application is outside of SiemensEnergy & Automation, Inc. control, and allowance must be made for the possibility thatthe VFDs may be applied in ways that are not currently part of this contract. (Forexample, the Owner at some later date would decide to remove a VFD from service

then sell it with its documentation.) To guard against the possibility of misapplication ormisuse (and any possible attendant risk of injury) in the future, Siemens Energy &

Automation, Inc. requires that “complete” User/Operation and Maintenance Manuals“must” be provided.

8/18/2019 19001914V1.0 VOL. 1

36/531



8/18/2019 19001914V1.0 VOL. 1

37/531

INSTALLATION MANUAL FOR

AIR COOLED

PERFECT HARMONY

GENIII/E SERIES Adjustable Speed AC Motor Drives with

Next Generation Control

Manual Number: 19000403

Version 1.1

OCTOBER 2003

A Subsidiary of High Voltage Engineering Corporation

500 Hunt Valley Road, New Kensington, PA, USA, 15068

Phone: 724-339-9500 Customer Support Phone: 724-339-9501 (24-hours)

Fax: 724-339-9562 Customer Support Fax: 724-339-9507

Web: www.us.asirobicon.com Customer Support E-mail: [email protected]

mailto:[email protected]:[email protected]

8/18/2019 19001914V1.0 VOL. 1

38/531

DECLARATION OF CONFORMITY

Manufacturer’s Name: ASIRobicon Corporation

Manufacturer’s Address: 500 Hunt Valley RoadNew Kensington, PA 15068USA

declares that the product:Product Name: AC Variable Frequency Drives, Perfect Harmony SeriesGEN II, GEN III, and GEN3E Air Cooled and Liquid Cooled(Product models (459XXX.XX & 3100XXXX.XX))

Product Description: 50Hz/60Hz, 200 HP to 20,000HP, 2.4 kV to13.8 kV input, 2.4 kV to 7.2 kV output

Product Options: This declaration covers all options of the product described.

Supplementary Information:

The products herewith comply with the requirements of the Low Voltage Directive 73/23/EEC (as amended) and the EMC

Directive 89/336/EEC (as amended).

LVD Safety Directive: The products listed above conform to IEC Standard EN50178.

EMC Directive: ASIRobicon certifies that the apparatus (both air and liquid cooled) to which this Declaration of Conformityrelates conforms to the protection requirements of Council Directive 89/336/EEC on the approximation of the Laws of theMember States relating to electromagnetic compatibility. Testing performed under generic standards EN50081-2, EN50082-2,and EN61000-4-2 – ESD, EN61000-4-3 Radiated Immunity; EN61000-4-4 – EFT, EN61000-4-6, Conducted RF Immunity and

EN61000-4-5 – Surge Immunity.

Competent Body Assessment for EMC by York Services, Ltd. EMC Test Centre, Fleming Building, Donibristle Industrial Park,Dalgerty Bay, Dunfermline, FIFE KY119HZ.

Competent Body Certificate and Report No. 1084-2/CBC/CBR dated August 6, 2001.

Name: Tom Bierman, Director of Quality Technical documentation holder:Signature: Ray Tomer, Staff Compliance Engineer

Perfect Harmony is a trademark of ASIRobicon . Date of issue: September 18, 2003

ASIRobicon Corporation: Phone: 724-339-9500 Customer Support Phone: 724-339-9501 (24-hours)

Fax: 724-339-8100 Customer Support Fax: 724-339-9507

ASIRobicon Website: www.asirobiocn.com

This manual applies to all air-cooled Perfect Harmony adjustable-speed AC motor drives including GEN III (GEN3) (200 hp through 10,000 hp)

having the following cell sizes:

00A through 5C (460 V cells)

70, 100, 140, 200, and 260 (630 V cells)

360H, 315H, 375H, 500H, and 660H (690 V cells).

For the support representative nearest you, please call ASIRobicon’s main office at (724)-339-9500.

Perfect Harmony, GEN III (GEN3) and GEN IIIe (GEN3e) are product lines of AC motor drives from ASIRobicon.

PLC is a trademark of Allen-Bradley Company, Inc.

Copyright 2001 – ASIRobicon

Installation Manual for Perfect Harmony Series (p/n 19000403)

Version History:

Version 1.0 August 2003

Version 1.1 October 2003

2001 by ASIRobicon. No portion of this document may be reproduced either mechanically or electronically without the prior consent of ASIRobicon.

http://www.asirobiocn.com/http://www.asirobiocn.com/http://www.asirobiocn.com/

8/18/2019 19001914V1.0 VOL. 1

39/531

Perfect Harmony GENIII/e Installation Manual Table of Contents

TABLE OF CONTENTS

Table of Contents ......................................................................................................................................... iiiSafety Precautions and Warnings................................................................................................................ ix

About This Manual.....................................................................................................................................1-xiCHAPTER 1: Introduction ..........................................................................................................................1-1

1.1. Introduction to the Perfect Harmony....................................................................................1-1

1.1.1. Clean Power Input ..................................................................................................1-1

1.1.2. High Power Factor and Nearly Perfect Sinusoidal Input Currents .........................1-1

1.1.3. Nearly Perfect Sinusoidal Output Voltages ............................................................1-21.2. Hardware Overview .............................................................................................................1-21.3. Features Overview ..............................................................................................................1-41.4. Specifications ......................................................................................................................1-5

CHAPTER 2: Hardware Components..............................................................................................2-12.1. Hardware Configuration ......................................................................................................2-1

2.1.1. Transformer Section ...............................................................................................2-3

2.1.2. Customer I/O Section..............................................................................................2-6

2.1.3. Cell and Control Sections (GEN III Cell Specifications) .........................................2-7

2.1.4. Cell Bypass Option ...............................................................................................2-132.2. The Cell Control System....................................................................................................2-132.3. The Master Control System...............................................................................................2-132.4. The Power Circuit ..............................................................................................................2-18

2.4.1. Monitoring of Input Power Quality ...........................................................................2-18CHAPTER 3: Installation and Set-up .........................................................................................................3-1

3.1. Introduction..........................................................................................................................3-13.2. Receiving.............................................................................................................................3-13.3. Shipping Splits .....................................................................................................................3-13.4. Weight Estimates.................................................................................................................3-13.5. Handling ..............................................................................................................................3-1

3.5.1. Overhead Crane Lifting Using Slings......................................................................3-2

3.5.2. Using a Fork Lift Truck............................................................................................3-23.5.3. Using Roller Dollies.................................................................................................3-3

3.5.4. Using Pipe Rollers ..................................................................................................3-33.6. Location ...............................................................................................................................3-43.7. Anchoring Cabinets to Floors and Walls .............................................................................3-53. 8. Transformer Cabinet Wiring ................................................................................................3-53.9. External Wiring ....................................................................................................................3-6

3.9.1. Input Power Wiring..................................................................................................3-6

3.9.2. Input Primary Power Interruption ............................................................................3-7

3.9.3. Grounding ...............................................................................................................3-8

3.9.4. Drive Inhibit and Emergency Stop Wiring...............................................................3-93.10. Torque Specifications..........................................................................................................3-93.11. Insulation Resistances.......................................................................................................3-103.12. Cell Capacitor Reforming ..................................................................................................3-11

APPENDIX A: Glossary of Terms ............................................................................................................ A-1 APPENDIX B: Commonly Used Abbreviations ........................................................................................B-1INDEX............................................................................................................................................................. inotes...........................................................................................................................................................n-1Readers’ Comments Form ......................................................................................................................... r-1Startup/Warranty Registration and Service Solutions................................................................................ vii

Version 1.1 (19000403) ASI Robicon iii

8/18/2019 19001914V1.0 VOL. 1

40/531

Table of Contents Perfect Harmony GENIII/e Installation Manual

iv ASI Robicon Version 1.1 (19000403)

8/18/2019 19001914V1.0 VOL. 1

41/531

Perfect Harmony GENIII/e Installation Manual List of Figures

LIST OF FIGURES

List of Figures.............................................................................................................................................. vii

Safety Precautions and Warnings................................................................................................................ ix

About This Manual.....................................................................................................................................1-xi

CHAPTER 1: Introduction ..........................................................................................................................1-1

Figure 1-1. Harmonic Distortion Wave Form Comparisons (6-pulse, 12-pulse and Perfect Harmony)1-1

Figure 1-2. Comparison of Perfect Harmony and a Typical Phase-controlled SCR Drive....................1-2

Figure 1-3. Nearly Sinusoidal Wave Form of the Output Current from a Perfect Harmony Drive ........1-2

Figure 1-4. Typical 4,160V (Left) and 6,600V (Right) GEN III Perfect Harmony VFDs .........................1-3

Figure 1-5. Typical 4,160V (Left) and 6,600V (Right) GENIIIe Perfect Harmony VFDs ........................1-3

CHAPTER 2: Hardware Components..............................................................................................2-1

Figure 2-1. Typical GEN III-style VFDs ..................................................................................................2-2

Figure 2-2. Typical GEN IIIe-style VFDs ................................................................................................2-3

Figure 2-4. Field Connections and Major Components in the GEN III Transformer Section................2-5

Figure 2-5. Field Connections and Major Components in the GEN IIIe Transformer Section (left) andCell Section (right) ..................................................................................................................................2-6

Figure 2-6. Customer I/O Section (Typical) of a GEN III-style Perfect Harmony Drive.........................2-7

Figure 2-7. Typical GEN III Cell .............................................................................................................2-8

Figure 2-8. Typical GENIIIe Cell ............................................................................................................2-9

Figure 2-9. Details of GENIIIe Terminals and Indicators.......................................................................2-9

Figure 2-10. Cell Section (Typical) of a GEN III-style Perfect Harmony Drive....................................2-10

Figure 2-11. Typical Connection Diagram for an 18 Cell 6.6 KV System ...........................................2-13

Figure 2-12. Master Control System.....................................................................................................2-15

Figure 2-13. Location of Flash Disk on Microprocessor Board ...........................................................2-16

Figure 2-14. Typical Perfect Harmony Power Circuit ...........................................................................2-17

Figure 2-15. Typical Power Cell Schematic.........................................................................................2-19

CHAPTER 3: Installation and Set-up .........................................................................................................3-1

Figure 3-1. Proper Handling Using the Sling Lifting Technique and an Overhead Crane ....................3-2

Figure 3-2. Proper Fork Lift Handling and Dimensions .........................................................................3-3

Figure 3-3. Proper Placement of Roller Dollies .....................................................................................3-3

Figure 3-4. Proper Use of Pipe Rollers in Handling Perfect Harmony Cabinets...................................3-4

Figure 3-5. Proper Anchoring Techniques for Perfect Harmony Cabinets............................................3-5

Figure 3-6. Transformer Cabinet Detail Showing Typical Tap Connections.........................................3-6

Figure 3-7. Typical GEN III VFD.............................................................................................................3-7

Figure 3-8. Typical GEN IIIe VFD...........................................................................................................3-8

Figure 3-9. The Drive Inhibit/Emergency Stop of the Perfect Harmony................................................3-9

Version 1.1 (19000403) ASI Robicon vii

8/18/2019 19001914V1.0 VOL. 1

42/531

List of Figures Perfect Harmony GENIII/e Installation Manual

viii ASI Robicon Version 1.1 (19000403)

APPENDIX A: Glossary of Terms ............................................................................................................A-1

APPENDIX B: Commonly Used Abbreviations ........................................................................................B-1

INDEX............................................................................................................................................................. i

Notes ..........................................................................................................................................................n-1

Readers’ Comments Form ......................................................................................................................... r-1Startup/Warranty Registration and Service Solutions................................................................................ vii

8/18/2019 19001914V1.0 VOL. 1

43/531

Perfect Harmony GENIII/e Installation Manual List of Tables

LIST OF TABLES

List of Tables ................................................................................................................................................ xi

Safety Precautions and Warnings................................................................................................................ ix

About This Manual.....................................................................................................................................1-xi

CHAPTER 1: Introduction ..........................................................................................................................1-1

Table 1-1. Common Specifications for Standard Perfect Harmony Systems........................................1-5

CHAPTER 2: Hardware Components..............................................................................................2-1

Table 2-1. Field Connections and Major Components in the Transformer Section ..............................2-4

Table 2-2. GENIII Cell Specification Details..........................................................................................2-7

Table 2-3. GENIIIe Cell Specification Details ........................................................................................2-8

Table 2-4. 3,300 VAC GENIII Cell Specifications: 9 Cells Total, 3 (630 VAC) Cells in Series ...........2-10

Table 2-5. 4,160 VAC GENIII Cell Specifications: 12 Cells Total, 4 (630 VAC) Cells in Series .........2-11

Table 2-6. 6,600 VAC GENIII Cell Specifications: 18 Cells Total, 6 (630 VAC) Cells in Series .........2-11

Table 2-7. 2,300 VAC GENIIIe Cell Specifications: 6 Cells Total, 2 (690 VAC) Cells in Series .........2-11

Table 2-8. 3,300 VAC GENIIIe Cell Specifications: 9 Cells Total, 3 (690 VAC) Cells in Series .........2-11

Table 2-9. 4,160 VAC GENIIIe Cell Specifications: 12 Cells Total, 4 (690 VAC) Cells in Series .......2-12

Table 2-10. 6,000 VAC GENIIIe Cell Specifications: 15 Cells Total, 5 (690 VAC) Cells in Series .....2-12

Table 2-11. 6,600 VAC GENIIIe Cell Specifications: 18 Cells Total, 6 (690 VAC) Cells in Series .....2-12

CHAPTER 3: Installation and Set-up .........................................................................................................3-1

Table 3-1. Grounding Conductor Sizes .................................................................................................3-9

Table 3-2. Torque Specifications for the Perfect Harmony .................................................................3-10

Table 3-3. Minimum Values of Insulation Resistances........................................................................3-10

APPENDIX A: Glossary of Terms ............................................................................................................A-1

APPENDIX B: Commonly Used Abbreviations ........................................................................................B-1

Table B-1. Commonly Used Abbreviations........................................................................................... B-1

INDEX............................................................................................................................................................. i

notes...........................................................................................................................................................n-1

Readers’ Comments Form ......................................................................................................................... r-1

Startup/Warranty Registration and Service Solutions................................................................................ vii

Version 1.1 (19000403) ASI Robicon xi

8/18/2019 19001914V1.0 VOL. 1

44/531

List of Tables Perfect Harmony GENIII/e Installation Manual

xii ASI Robicon Version 1.1 (19000403)

8/18/2019 19001914V1.0 VOL. 1

45/531

Perfect Harmony GENIII/e Installation Manual SAFETY PRECAUTIONS AND WARNINGS

SAFETY PRECAUTIONS AND WARNINGS

Perfect Harmony drives are designed with considerable thought to personal safety. However, as with anypiece of high power equipment, there are numerous internal connections that present potentially lethalvoltages. In addition, some internal components are thermally hot to the touch. Follow the warningsbelow when working in or near the Perfect Harmony system.

Danger - Electrical Hazards!• Always follow the proper lock-out/tag-out procedures before beginning any

maintenance or troubleshooting work on the drive.

• Never touch anything within the Perfect Harmony cabinets (other than the control cabinet) until verifying that it is neither thermally hot nor electrically alive.

• Always follow standard safety precautions and local codes during installation ofexternal wiring. Protective separation must be kept between extra low voltage

(ELV) wiring and any other wiring as specified in the CE safety standard.

• Never assume that switching off the input disconnect will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnect.

Also, there may be voltages present that are applied from other external sources.

• Always work with one hand, wear insulated or rubber safety shoes, and wear safety glasses. Also, always work with another person present.

• Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements (that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the instrument). Never defeat the instrument’s grounding.

• Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points beneath the shields.

• Always use extreme caution when handling or measuring components that are inside the enclosure. Be careful to prevent meter leads from shorting together or from touching other terminals.

• Hazardous voltages may still exist within the Perfect Harmony cabinets even when the disconnect switch is open (off) and the supply power is shut off.

• Never run the drive with cabinet doors open. The only exception is the control cabinet, which contains extra low voltages (ELV).

• Only qualified individuals should install, operate, troubleshoot, and maintain this drive. A qualified individual is “one familiar with the construction and operation of the equipment and the hazards involved.”

Warning!

• Never disconnect control power while medium voltage is energized. This could cause severe system overheating and/or cell damage.

• Never store flammable material in, on or near the drive enclosure. This includes equipment drawings and manuals.

• Always ensure the use of an even and flat truck bed to transport the Perfect Harmony drive system. Before unloading, be sure that the concrete pad is level for storage and permanent positioning.

• Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the drive system. Dropping the cabinet or lowering it too quickly could damage the unit.

• Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure that the fork truck tines fit the lifting tubes properly and are the appropriate length.

• Always comply with local codes and requirements if disposal of failed components is necessary (for example, CPU battery, capacitors, etc.).

• During operation, the nominal weighted sound pressure level may exceed 70 dBat a distance of 1 meter from the drive.

Version 1.1 (19000403) ASI Robicon ix

8/18/2019 19001914V1.0 VOL. 1

46/531

SAFETY PRECAUTIONS AND WARNINGS Perfect Harmony GENIII/e Installation Manual

x ASI Robicon Version 1.1 (19000403)

ESD Sensitive Equipment!

Always be aware of electrostatic discharge (ESD) when working near or touching componentsinside the Perfect Harmony cabinet. The printed circuit boards contain components that aresensitive to static electricity. Handling and servicing of components that are sensitive to ESDshould be done only by qualified personnel and only after reading and understanding proper ESDtechniques. The following ESD guidelines should be followed. Following these rules can greatly

reduce the possibility of ESD damage to PC board components.

• Make certain that anyone handling the Perfect Harmony printed circuit boards iswearing a properly grounded static strap. The wrist strap should be connected to groundthrough a 1 megaohm resistor. Grounding kits are available commercially through mostelectronic wholesalers.

• Static charge buildup can be removed from a conductive object by touching the object toa properly grounded piece of metal.

• Always transport static sensitive equipment in antistatic bags.

• When handling a PC board, always hold the card by its edges.

• Do not slide printed circuit boards across any surface (e.g., a table or work bench). If

possible, perform PCB maintenance at a workstation that has a conductive covering which isgrounded through a 1 megaohm resistor. If a conductive tabletop cover is unavailable, aclean steel or aluminum tabletop is an excellent substitute.

• Avoid plastic, Styrofoam, vinyl and other non-conductive materials. They are excellentstatic generators and do not give up their charge easily.

• Always use a soldering iron that has a grounded tip. Also, use either a metallicvacuum-style plunger or copper braid when desoldering.

• When returning components to ROBICON, always use static-safe packing. This limitsany further component damage due to ESD.

Additional safety precautions and warnings appear throughout this manual. These important messagesshould be followed to reduce the risk of personal injury or equipment damage.

8/18/2019 19001914V1.0 VOL. 1

19001914v1.0 vol. 1

Documents