ME3 Manual - FindTheNeedle.co.uk
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1. 9 MIMICPANEE 2 1 9 PUSH BUTTONS UCM HL LLL LM ME CLA tL ee 10 necis uli nec a ae tcr E ADAE 12 Dial ABLOGDIDIBPEAY ceca ci otto 13 SELECTION OF 1 nana nana na nana nana 16 MODE cp ECTS 16 PARAEEELDIN 17 SZIN e THE OE O de Cou 18 19 19 SEC DIMENSIONES TINI item eM 19 INST ALP ATION oh i acetate LL m M M Lr 20 1 a e MN 24 M DL 25 VENTILATION AND AIR CONDITIONING rnt dtes tpi ete2. P S Use the latter indicating the number of days the SFC has been in use 16 SELECTION OF EQUIPMENT MODELS The range of SFC comes 8 different ratings as standard 10KW 15KW 20KW 30KW 40KW 50KW 60KW 80KW 100KW Single phase output units only go up to 50KW For different power ratings from the above you can consult us for advice The above power ratings are for loads of UNITY power factor These units can operate with loads of power factor ranging from 0 2 leading or lagging to unity due to the 4 quadrant operation of the Rectifier The standard models cater for input voltages of 400V 50Hz with output voltages 200V 60Hz 480V 60Hz 200V 400Hz On request we can supply machines with different input and or output voltages and frequencies 17 PARALLELING It is also important to note that the models can be paralleled redundant mode to increase reliability or to increase power capability The units to be paralleled must be of the same rating and no more than 4 in number PARALLEL OPERATION When two or more units are connected in Parallel Redundant mode their outputs are connected to a common point via a current equalizing saturable choke as in Figure 16 They also interface with each other via a CAN Field Bus so that the instructions and controls are synchronized Thus the parallel operation causes the following W
3. AVI AUAM FRONT SIDE SINE33 710 111 nnn ofc 20 SFC MODEL ENCLOSURE WIDTH LENGHT HEIGHT 10K 30K SINE33 NC 530 750 990 Cabinet The ME3 SFC due to its compact size and quietness of operation can operate in a computer room environment on a false floor or normal level floor INSTALLATION 10 15KW 10KW 30KW Units are shown above The units should be installed in a well ventilated area or room since in spite of very good efficiency heat is still generated INSTALLATION 40 100KW All units are front access which facilitates maintenance and saves space The units don t need back or side clearance but care must be taken not to block the top for proper ventilation The units should be installed in a well ventilated area or room since in spite of very good efficiency heat is still generated Users have access to the SFC Switch Gear Via the bottom door that has a Key Lock 21 The interior of the SFC should only be accessed by trained technical personnel after complete shut down and a waiting period of at least 10 min to allow the DC capacitors to discharge The sequence to open all the SFC panels is as follows 1 Open the bottom do
4. 25 ELECTRICAL ccccccscscsesescsceseseueseueuauesauauauasauauauasauaueucususususususususnen 26 ELECTRICAL CHARACTERISTICS pl ereitte nina kn hk 26 CABLES SELECTION 27 CABLES SELECTION 27 HARMONICS FROM RECTIFIER ccccccccccscececececesecesecesesesesescecececesecesececesecesesesesesesesesesesess 28 4 QUADRANT POWER FACTOR CORRECTED ACTIVE RECTIFIER 28 CONTENTS 4 EFFECTS OF HARMONICS ON OTHER EQUIPMENT in 29 2202 5 30 iii eset de 30 2 E E 31 MAINTENANCE AND BACKUP SERVICE 2 4 4 00 000 nennen 31 PRINCIPLES OF OPERATION INTRODUCTION three phase Static Frequency Converter SFC guarantees a supply free of disturbances and of high quality with maximum reliability The use of high frequency pulse width modulation PWM ensures exceptional performance a
5. DIG SIGNALS 11101111 Two events are shown Both happened at the date 19 10 04 The first one at 6 30 and the fault belongs to group 4 Load on Bypass The second one happened at 6 20 and the fault belongs to group 1 Bat Undervolt The zeros indicate the faults that triggered the event The next table helps to identify the protections that triggered the events from the information above Position 1 Least Significant Bit The left hand side scroll buttons will scroll the logger lines one by one and the right hand side buttons will scroll 5 lines at a time It must be noted that the same information in a more user friendly format is also available using our Windows based software or a Netagent connection NEZ 61 62 64 65 CHARGER INVERTER SAT 1 ON LINE OVERVOLT PROT LOAD ON BYPASS BUTTON ON EMERG POWER INVERTER 2 OFF CHARGER FAULT OVERCURRENT MANUAL BYPASS BUTTON OFF INVERTER 3 MAINS LOW CHARGER BOOST UNDERVOLT OUT OF SYNC REMOTE OFF INVERTER 4 MAINS HIGH BAT DISCHARGING OVERVOLT FUSE FAILURE REMOTE ON 5 BAT UNDERVOLT RECT OVERVOLT OVERLOAD INV DC OFFSET BATTERY TEST OVERTEMPERATUR DC OUT OF 6 BAT HALF RECT FAULT E BALANCE MICRO RESET BAT EARTH 7 BAT LOW INVERTER OFF SHORT CIRCUIT LEAKAGE CHARGER OFF UNVERTER FAULT PHASE ROTATION OUTPUT ISOLATED 13 DIGITAL LCD DISPLAY METER DISPLAY The first two lines of the LCD are used for the Meter functions They can be scrol
6. any one time By pressing this button the meter readings will scroll up When there are no more readings above the 0 symbol will show next to the last meter reading If there are more readings above an arrow will be seen To scroll 5 items at a time press this button and while maintaining it depressed press the METER SCROLL DOWN also 11 4 5 6 7 3 4 5 METER SCROLL DOWN ALL SCROLL BUTTONS MICRO RESET RESET FLAG SCROLL LOGGER The same as for the Meter Scroll Up but in the downwards direction To scroll 5 items at a time press this button and while maintaining it depressed press the METER SCROLL UP also Pressing all scroll buttons simultaneously will reset the Micro After reset all LEDs will light up momentarily allowing to check faulty ones By pressing the Reset Button and any of the Flag Scroll buttons simultaneously the display will enter the Logger In this mode buttons 4 and 5 will provide a normal scroll while buttons 6 and 7 will provide a 5 item scroll LOGGER DISPLAY To check the history of the information from the previous section the Display Logger can be activated by pressing simultaneously the Reset button and any of the Digital Scroll Buttons left hand side ones To exit the Logger mode the Reset button must be pressed The Display Logger uses all 4 lines of the LCD An example 19 10 04 6 30 G4 FE DIG SIGNALS 11111110 19 10 05 6 20 G1 EF
7. push button pressed The SFC Inverter is off If there is no other fault indication the Inverter was switched off manually When the load current exceeds aproximately 10 times the nominal full load value the Inverter is switched off No SFC output will be available At this stage this indication and the audible alarm are active Before trying to reset the SFC make sure that the short circuit on the load is removed When the load current exceeds 105 this indication will be triggered The Inverter will try to cope with the overload being protected by an inverse time protection i e the larger the overload the shorter the time the Inverter will take to switch off Typically 1min for a 120 overload and 5 seconds for 15096 15 Mains High The mains input is out of parameters greater than 110 The Power Factor Correction function of the Rectifier is inhibited The SFC should not be operated in this conditions for a long period of time since it exceeds its design parameters 0 Phase Rotation If the input phase rotation is not correct R Y B the indication will be ON This happens when one of the phases is swapped around or failed The Rectifier will not start Normally this type of problem only arises in the initial installation of the machine and is easily rectified by swapping around two of the input phases for the Rectifier Input Rectifier Off Rect The following conditions c
8. walk in 2 second to maximum Overall Current 11596 Short Circuit Proof iet cec eee ets Standard INVERTER Static regulation 0 100 0 5 Dynamic regulation 100 load application removal Transient 5 recovering to 1 a within 5 millisecond Total harmonic distortion Better than 3 Linear load Overload capacity 120 Limited to 1 Min Frequency stability 50 0 Hz 0196 crystal controlled Load power factor 0 2 1 Efflcleney ine tn cer tees 9396 9596 Short circuit proof by electric current limiting and shutdown COMMUNICATIONS RS232 RS4685 seen Standard with Windows Software Ethernet 2 Standard with Netagent CAN With Remote Optional ENVIRONMENTAL CONDITIONS Temperature range 0 40 degrees Celsius At sea level full load be cunt eM Seb een 90 Celsius at 2000m full load Humidity Recommended 40 to 60 Extreme 096 to 90 Noise level below 55 dBA at 1 meter Altitude rine Up to 2500m Other Voltages and Frequencies available on request 31 GUARANTEE All Magnus Power equipment is guaranteed against faults attributable to fau
9. 29 30 Brunel Road Churchfields Industrial Estate St Leonards on Sea MAGNUS POWER East Sussex TN38 9RT United Kingdom Global Power Supply Specialists Sales amp Service 01424 853 013 All Other Departments 01424 853 464 Fax 01424 852 268 magnuspower sales akersolutions com magnuspower service akersolutions com Magnus Power ME3 Three Phase Frequency Converter Manual ME3 Three Phase Frequency Converter Operation and Maintenence Magnus Power 29 30 Brunel Road St Leonards on Sea East Sussex TN38 ORT United Kingdom Telephone 44 0 1424 853 013 Sales amp Service 44 0 1424 853 464 all other Enquires Fax 44 0 1424 853 2 268 www magnuspower co uk magnuspower sales akersolutions com magnuspower service akersolutions com ME3 Manual Rev 1 CONTENTS MAGNUS POWER SFC STATIC FREQUENCY CONVERTER USER MANUAL CONTENTS CONTENTS 3 CONTENTS CONTENTS niiina aat EL 3 PRINCIPLES OF OPERATION canaaa na ana an a aaa an a ana aa nya wy RYR ya a a Da YR Tad n DA ca Gk 04 Cd n 5 INTRODUG TION 5 START UP AND SHUT 21 rene natnra 6 BEGTIEIEBR suena tte it c 7 INVERTER eM 8 MICRO PROCESSOR DISPLAY AND FAULT
10. RTER OFF 10 PUSH BUTTONS DISPLAY PUSH BUTTON NAME POSITION 1 INVERTER ON green 2 INVERTER OFF red 3 INDICATION RESET R 4 FLAG SCROLL UP 5 FLAG SCROLL DOWN 6 METER SCROLL UP PUSH BUTTON FUNCTION It will turn the UPS Inverter ON if no fault is present To switch the UPS Inverter OFF and transfer the load to Static Bypass both red buttons must be pressed simultaneously This pushbutton performs the following functions simultaneously when pressed a Some fault indications in the Digital Display will latch when triggered This push button will Reset these indications if the respective fault has cleared b It Resets the audible alarm c It will reset and restart the Rectifier only after a Rectifier trip d It will exit the Logger display if in this mode If more than two Status flags are present in the Digital Display by pressing this button the flags will scroll up When there are no more flags above the O symbol will show next to the flag If there are more flags above an arrow will be seen next to the flag To scroll 5 items at a time press this button and while maintaining it depressed press the FLAG SCROLL DOWN also The same as for the Flag Scroll Up but in the downwards direction To scroll 5 items at a time press this button and while maintaining it depressed press the FLAG SCROLL UP also Only two readings from the Meter will be shown at
11. an cause these indications Overvolt Rectifier Fault to be on DC Offset DC Out of 1 Mains failure Balance 2 Mains input breaker in the SFC or Mains feeding breaker in the distribution box tripped 3 Phase rotation on mains input incorrect 4 Rectifier fault DC over voltage or control voltage failure 5 Inverter control failure causing DC Offset The above anomalies should be corrected as soon as possible by calling the SFC supplier Fuse Fail When available this flag indicates one of the SFC main fuses has failed Other indications such as Mains Failure should give an idea of which fuse has failed Otherwise a physical observation is necessary to discover the faulty fuse This is better left done by the Maintenance personnel The above fault finding information should be enough to solve any problem that might arise and should give enough information about the status of the SFC at any moment A remote alarm panel is available with most of the diagnosis information of the SFC display panel with exception of the digital meter Also available are a relay interface card with the same characteristics and a network connection with SNMP protocol via Netagent for easier access to all the SFC information CONCLUSION For the SFC to be in perfect working order no red indication should be present on the display panel The Status Digital Display should have only the flags Power System OK and
12. e taken in providing the correct ventilation or air conditioning for the room where the SFC is going to be installed The following table provides information about the heat losses of the various models for 100 load at 1 power factor UNIT POWER HEAT LOSSES 100 Load 10KW 1 1KW 26 ELECTRICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS The following table gives the electrical characteristics of the SFC for an input voltage of 400V output voltage of 200V and full load at 1 power factor ME3 MODEL MAX INPUT OUTPUT 3 phase CURRENT CURRENT 27 CABLES SELECTION CABLES SELECTION ARMORED CABLE FREE UNARMORED CABLE AIR WIRED FREE AIR WIRED Suggested maximum currents 28 HARMONICS FROM RECTIFIER SFC uses 4 Quadrant Active Power Factor Control rectifier charger with unity power factor correction and sinusoidal input current to minimize the effect of harmonics upstream of the SFC installation Input RFI filters are also fitted as a standard in every model to comply with EN50091 2 1995 AND IEC61000 3 4 1998 Harmonics 4 QUADRANT POWER FACTOR CORRECTED ACTIVE RECTIFIER DC TO INVERTER MAINS INPUT BATTERY 4 QUAD CONVERTER The 4 Quadrant capability of the ME3 Rectifier allows the SFC to handle a larger range of difficult loads such as induction motors in regeneration mode and high capacitive circulating currents which could cause
13. es e RFI Filter Input triple pole circuit breaker for protection against faults MOV input protection against over voltage transients LC filter 4Quadrant PF Correction IGBT Bridge The Rectifier supplies the Inverter with a constant DC voltage The Power Factor Correction IGBT Bridge 4 Quad Converter guaranties input unity power factor and sinusoidal current with low Harmonic content as well as 4 quadrant operation INVERTER The basic principle of operation of the Inverter is achieved by having a voltage loop control followed by a current loop control which maintains the output voltage and wave shape constant and with no DC offset To create the sinusoidal wave shape the DC supply is switched on and off with varying pulse length pulse width modulation These pulses are then filtered by a LC filter producing a low distortion sine wave in the output DC FROM RECT TRANSFORMER OUTPUT INVERTER The Inverter consists of 3 Phase IGBT Bridge e LC Filter Inverter transformer Control circuitry MICRO PROCESSOR DISPLAY AND FAULT FINDING The display panel consists of a digital display a mimic display a diagnosis display an audible alarm and push buttons MIMIC PANEL MIMIC INDICATION FLAG IN THE DIGITAL DISPLAY POSITION 1 INPUT FAILURE RECTIFIER OFF 2 INVERTER OFF INVE
14. hen the ON button is pressed in one SFC the Inverters of all SFC will turn ON with no faults present If one SFC is switched OFF manually or by a failure the others will carry on supplying the load while the former will be isolated from the load by its own Static Isolator Besides the above the operation of the Individual SFC is identical to a single SFC SFC 1 MAINS INPUT 1 OUTPUT SFC 2 18 To size the SFC in a safe way the following points should be taken in to account All the peak loads must be added The sum of the peak loads must be divided by 1 5 and if the result is equal or larger than the sum of the steady loads times 1 2 this result must be used in the selection Example _ 5KW S3KW Peak 12KW SFC 1 c 15KW Peak 30KW 6KW Steady state load 5KW 3KW 15KW 6KW 29KW Peak load 5KW 12KW 30KW 6KW 53KW 53KW 1 5 35 3KW Larger than 29KVA x 1 2 Since the next model is a 40KW this model should be selected This will allow for start up and peak currents and will provide a power margin of 20 19 INSTALLATION INSTALATION DATA SFC DIMENSIONS mm SFC MODEL ENCLOSURE WIDTH DEPTH HEIGHT 40K 50 SINE33 710 710 800 1400 60K 100K SINE33 1400 1400 800 1400 SINE33 1400 CAMA AIO TVA
15. led by the two right hand side buttons The following functions are available METER FUNCTION DESCRIPTION Inv Volt PH A Phase A Inverter voltage V Inv Volt PH B Phase B Inverter voltage V Inv Volt PH C Phase C Inverter voltage V Op Curr PH A Phase A Output Current Op Curr PH B Phase B Output Current Op Curr PH C Phase C Output Current Input Volt PH A Phase A Input voltage V Input Volt PH B Phase B Input voltage V Input Volt PH C Phase C Input voltage V Input Curr PH A Phase A Input Current Input Curr PH B Phase B Input Current Input Curr PH C Phase C Input Current Pk Op Curr PH A Phase A Peak Output Current Pk Op Curr PH B Phase B Peak Output Current Pk Op Curr PH C Phase Peak Output Current DC Link Volt DC Link Voltage V DC Link Curr DC Link Current Input Freq Mains Input Frequency Hz Invert Freq Inverter Frequency Hz Temperature Cabinet Interior Temperaure Every single one of these measurements can be eliminated from the display in the Display Configuration Program 14 STATUS FLAG DISPLAY FAULT FINDING The Status Flag display 39 and fourth row provides enough information for the SFC user to know the operational statu
16. lty design components and workmanship whilst operating under normal conditions for a period of 12 months from date of delivery During this period all faulty components will be replaced free of charge Accommodation and traveling costs involved therein shall be for the customer account All call outs which cannot be attributed to faults or malfunctions on our equipment shall be charged at our standard service rates and be for your account Our liability under our guarantee is limited to the above and we do not accept any responsibility for any consequential loss MAINTENANCE AND BACKUP SERVICE All spares are available locally and we guarantee stock for ten years The combination of spares availability and factory trained service personnel should ensure that no unit is out of order for more than 48 hours after receipt of report of malfunction failure At the expiry of the guarantee period we can service the unit on a continuous base but this would necessitate the negotiation of a separate agreement MAGNUS POWER bu Power Supply Specialists 29 30 Brunel Road St Leonards on Sea East Sussex TN38 9RT United Kingdom Sales 01424 853013 All Other Departments 01424 853464 Fax 01424 852268 Registered in England Registered office Unit 12 Clivemont Road Cornwallis Ind Est Maidenhead SL6 7BZ Registration No 4977339 VAT Registration No GB 829 4203 28
17. nd extremely quiet operation A 4 quadrant Power Factor Corrected RECTIFIER guarantees lower input currents reduced harmonics THD lt 5 and the capability to handle any type of load including regenerative ones The advantages of this technology are Fast response to load changes Quiet operation Reduction in size and weight 9 High efficiency low heat losses Short circuit protection If your load is sensitive to mains supply such as computer Systems process electronics emergency equipment etc then the SINE33 is the answer The SFC comprises the following e Rectifier Inverter MAINS 7 7 SFC INPUT DC AC OUTPUT RECTIFIER INVERTER START UP AND SHUT DOWN POWER UP SEQUENCE Switch on AUX SUP SWITCH Electronics should start up Switch on INPUT MCB Switch on OUTPUT ISOLATOR Switch Inverter on by pressing the Green button POWER DOWN SEQUENCE Switch Inverter off by pressing both Red Buttons simultaneously Switch off OUTPUT ISOLATOR Switch off INPUT MCB Switch off AUX SUP SWITCH Be gt Any other sequence will not cause any harm to the SFC Make sure that the Auxiliary Supply Switch is always ON when operating the SFC This will allow the SFC to operate correctly in the event of Mains Supply dips RECTIFIER DC TO INVERTER MAINS INPUT 4 QUAD CONVERTER The rectifier charger compris
18. or and unscrew the top door bottom left hand side 2 Open the top door and will have access to all the SFC components that may need maintenance 3 Unscrew the top panel front via the round apertures at the inner protection plate and remove it pulling upwards and to the 4 With the top removed the magnetics cooling fans are accessible 22 5 Unscrew the side and back panels top and remove them by pulling towards you and lifting them They are secured to the uprights by wedges The panels have inside handles to help remove and replace them Units with external batteries can have remote temperature compensation optional The standard external battery cabinets open in a similar way as the UPS except that they have a single door in the front and don t have a top inner protection plate 23 POWER TERMINALS The power terminals are accessed via the bottom front door that has a key lock With units up to 50KW SINE33 710 cabinets another protection plate at the MCB assembly must be removed The Input amp Output cables are fed to the SFC via the bottom gland plate that is placed next to the Power Terminals Care must be taken to terminate the cables correctly to avoid damage to the SFC Mistakes like connecting the Input cables to the Output Terminals can damage the SFC in spite of its protections Units with Top Cable Entry optional will have the Power Terminals on the top inner protection
19. plate with the cable glands installed at the back of the SFC This type of unit must be ordered from factory as Top Entry 24 LTDB MAINS INPUT LOAD A low tension distribution board must be provided by the customer to feed the SFC and the user s load The input circuit breaker feeding the SFC should be of at least the same rating and of the same type as the RECTIFIER MCB breaker in the SFC For the output circuit breakers the ratings are dependent on the specific load each of the breakers is feeding The SFC will be able to clear a B type MCB of at least 3396 of the Full Load Current without tripping the Inverter The diagram illustrates an installation with separate supplies in the input section LTDB 54 OUTPUT ISOLATOR SFC With larger units where considerable currents flow in the input and output cables these must be carefully laid so that the magnetic field they produce does not interfere with other equipment such as screens magnetic card readers etc 25 ACOUSTICAL NOISE range of SFC is extremely quiet making it ideal for use in the office or computer room The emitted noise is less than 55 dBA VENTILATION AND AIR CONDITIONING The range of SFC is designed to operate at an ambient temperature of up to 40 C at sea level For 2000m altitude the operating ambient temperature should not exceed 30 C Since there are heat losses in the SFC care must b
20. s of the SFC as well as in the case of a fault if a technician should be contacted If no flags are active the third row will show Power System If any flag is active the flags messages will appear in the third and fourth rows of the LCD The left hand side buttons will scroll the flags The following indications are available Mains Low Inverter Fault Inverter Sat Prot Inverter Overcurr Inverter Undervolt Inverter Overvolt Overtemperature Inverter Off Short Circuit Over Load Mains are absent or bellow limits 20 of nominal These indications indicate that the Inverter has been subjected to high stress such as excessive current flown through the IGBT s causing the Inverter to trip These indication are self latching To clear them the INDICATION RESET push button must be pressed If after restarting the Inverter any of these indications persist there is a fault in the Inverter and the SFC supplier should be contacted No further attempts at restarting the Inverter should be made The SFC heat sinks temperature has exceeded 80 C Check if there is any obstruction to the ventilation inlets or outlets of the SFC and remove it If that is not the problem it is likely that one of the fans has gone faulty Contact the SFC supplier This indication is self latching To reset it the fault must be cleared and the INDICATION RESET
21. serious problems with standard SFC By using this topology not only the input Power Factor is corrected to very close to unity improving the energy bills but the current harmonics are greatly reduced THD lt 5 at full Load 29 EFFECTS OF HARMONICS ON OTHER EQUIPMENT The presence of current harmonics in the Mains can disrupt the operation of equipment connected to it affect the sizing of generating sets feeding the SFC Increases the losses in transformers motors and other inductive equipment Increases currents through power factor correction equipment Interfaces with measuring instruments telephone circuits and sensitive equipment The with its built in power factor correction minimizes the above mentioned problems 30 SFC SPECIFICATIONS SFC SPECIFICATIONS INPUT 4 Wire 3 Wire optional 3 Phase 400V 415V 20 10 0 0 2 5 Input Current lt 5 at Full Load Sinusoidal OUTPUT Phase200V 400V 415V AC 60 0 HZ 400Hz 190 1 Phase115V 230V 240V 60 0 2 400 2 190 Overall 8590 9090 Max Crest 3 1 RECTIFIER 4 Quadrant Operation 93 95 Input Frequency Deviation esee 5 Overload Capacity 120 Continuous Current
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