Sag Simulator User Manual - the IGS Engineering services
Contents
1. jeyenu o Z l peo Aiddns uoyoauuo9 sele no aun SCHU ur eur ejeje JAR punog ep Ly yosun Bun vouwog Japanu Buyoog diq abeyon SH33NI9N3 DINOWLO313 o cSureis s Joyejnuis Bes abeyon a lt TE DOC FRITESU DEST LLBIBIUBPIDIHETSE ES As Ej Voltage Sag Simulator User Manual Mechanical Outline lt 311mm 12 24 SS 298mm 11 73 gt z switching i atan systems c Teen TE uka lt YV p Voltage Sag Simulator 120 e LO e E E g o e Common Line Line in Line out C Supply a Load off 11213 C C C ZU M6 SAG SIMULATOR MODEL VOLTS SERAL POWER DATE MFG HZ S W La 311mm 12 24 Fig 9 Dimensions of the Sag Simulator in mm inches Page 16 Voltage Sag Simulator User2. should there be a deviation from Vnom which is greater than the preset value the static switch is switched off and the inverter is activated The switch over is accomplished in less than 700us A 3 1 second timer adjustable in increments of 100ms starts timing the inverter out Should the input voltage recover within the set time the inverter supply is synchronized to the mains and the load is switched back to the supply the capacitors are recharged in less than one second and the inverter is ready to compensate forthe next voltage dip If the input voltage does not recover within the set time the load is switched back to the supply regardless of the voltage level Description Voltage Sag Simulator The Sag Simulator is intended to be used as a tool to evaluate the effects of momentary voltage sags and interruptions on industrial controls When used in conjunction with a Voltage Dip Proofing Inverter or a Voltage Dip Compensator and Bypass switch it may be used to prove the effectiveness of the DPI or VDC as a solution for these power quality problems The Simulator has two other useful functions that may be selected via the Function Select menu H J JJ CC Cc CC Page 4 Voltage Sag Simulator User Manual a Variac Output that enables direct output from the variac and a Soak Test function that may be used to perform repetitive testing The Sag Simulator is designed for 120 208 240Vac operation The main controls and their functions a
3. Gei SC Screws y Ng lt ji giele E 8 jq e Dr 88 El agas UL s e EE Se Se Line in Common Ling Line out bia A S Jm Load d UR ME _ Supply l a HUH PINA DEED 7S a CNET 2a 2 140 5 51 150 5 90 Re a a Ordering Stock No Description 5003 005 Housed By Pass Switch 10Amp 5003 007 Housed By Pass Switch 40Amp Voltage Sag Simulator Page 17 User Manual Voltage Sag Simulator For use with all DPI s 4 VDC s 120 208 240V 50 60Hz A typical DPI connection diagram IGS Engineering Company 1Gg Smart Engineering solutions Email info igs com sa gert igs com sa O 00966 346 2121 M 00966 55 614 0055
4. Manual Housed Bypass Switches Description Where no break maintenance is required a by pass switch must be installed It connects the supply directly to the load Bypass position and disconnects the power terminals of the inverter without interrupting the supply When in DPI position the load is connected to the supply via the inverter Specifications MODEL BPSW10A BPSW40A ELECTRICAL Maximum current 10A 40A Maximum input voltage 500Vac 500Vac TEMPERATURE Maximum working temperature 45 C 113 F 45 C 113 F HOUSING Construction Extruded Aluminum Height 182mm 7 17in 202mm 7 95in Width 150mm 5 9in 150mm 5 9in Depth 141mm 5 55in 141mm 5 55in Mass 0 72kg 1 58lbs 1kg 2 2lbs Mechanical outline d 1 1 1 1 1 i 1 1 1 1 1 1 1 l 1 l 1 1 1 1 1 1 1 i 1 rai Note 1 Note 2 Mounting holes 2 x 6 0 25 0 i Dimension units Without brackets mm i jS pem With brackets inches Si i ee DOOR a Topp i paa cs or VDE in out R mM MEN MEE a Linein Commonline Line out Z i Ground e EZ
5. OOO Sync pulse 4 x 20 Display A Amplitude 5V Duration Sag duration Line Program Switches Static Switch 1 3 Set sag level Supply Static Switch 2 Load Sag voltage Common Fig 6 Sag Simulator block diagram Controls amp indicators GG switching EP EL OT OETREM MEEN lt Y P Voltage Sag Simulator 0 Common Line Line in Line out upp Load D d i 11213 Fig 7 Controls amp indicators Page 14 Voltage Sag Simulator User Manual Typical test setup go DJ E eo DN kO PT uelis uelis dois g wes6elp uoipeuuoo Iojejnws bes 8 D Page 15 1S9 Jepun peo JO 84182 041u02 JOJO e o eui UOWWUOD Su UOWUOD peo1 Aove 802 A02 L Aiddns Qo eur u aun Ajddng o e e uop euuo z 585 237 o YMS ms ssed g FE EAT oE pesnoH UNO u J HAU o Sigil i m
6. User Manual Voltage Sag Simulator For use with all DPI s amp VDC s 120 208 240V 50 60Hz Se aa Voltage Sag 7h Simulator Pn IGS Engineering Company IGS smart Engineering solutions Ke Email info igs com sa gert igs com sa O 00966 346 2121 M 00966 55 614 0055 User Manual Contents Introduction to the DPl 3 Theory of DPI operation 3 Description Voltage Sag Simulator 4 Operation masm ador catur bt AE E te 5 Sag Simulation 5 E eh eu e in eani ERR ai ex GUY Er apu Aa 8 SOAK TES ida 8 Simulated Sag Profile 000manannnnannnannnnannnannna 12 Sag Simulator Specifications 13 Sag Simulator block diagram 14 Controls Lee E 14 Typical test setup 15 Mechanical Outline 16 PC CC SSON CS Mt 17 bird E 19 e__ _ _ ____ _ lt lt Page 2 Voltage Sag Simulator User Manual 1 Introduction The reliability of electrical power to industry is in general very high nevertheless brown outs and short power interruptions or voltage dips occur These instabilities are caused by short circuits li
7. ag Simulator User Manual Sag Simulator Specifications AC INPUT SUPPLY Supply voltage Maximum input voltage Full load current VARIAC CONTROL Variac range Maximum power Maximum continuous current Maximum short term current for 3 seconds Overload amp short circuit protection DIRECT VARIAC OUTPUT Variac range Maximum power Maximum continuous current Overload amp short circuit protection SAG DELAY TIMER Range Setting SAG DURATION TIMER Range Setting CONTROLS amp INDICATORS Programming Menu parameter indication SYNC PULSE OUTPUT Amplitude Polarity Electrically isolated output Duration TEMPERATURE Maximum ambient working temperature HOUSING Construction Height Width Depth Mass 15kg 33lb 120 208 240Vac 50 60Hz 10 20A 0 240Vac RMS 1200VA 120V 2400VA 240V 10A 20A Yes 0 240Vac RMS 1200VA 120V 2400VA 240V 10A Yes 0 00 to 20 00 ms 0 01 ms steps 0 010 to 9 999 seconds 0 001 second steps Four push switches 4 x 20 LCD display 5V Positive Yes Equal to sag duration 45 C 113 F Extruded aluminium 390mm 15 35in 311mm 12 24in 162mm 6 38in n M Voltage Sag Simulator Page 13 User Manual Sag Simulator block diagram 5 LEELEEELEELELELELLTSSTH H S CLOUD LLELLELEELEEEELLLETTT Controls O OOOO O
8. e VOLTAGE DIP PROOFING INVERTER is designed to be maintenance free and highly reliable It consists of a static switch in series with and an inverter parallel to the load Energy is stored in a capacitor bank the inverter block diagram is shown in Fig 1 Static Switch Inverter Supply Load Storage Capacitor Fig 1 Inverter Block Diagram Voltage Sag Simulator Page 3 User Manual The STATIC SWITCH is robust and can withstand large current surges It is ideally suited for contactor operation where high peak currents of short duration occur during energizing The INVERTER is configured as a full bridge with overcurrent and short circuit protection The output waveform is a square wave where the RMS and the peak voltage are the same as for a sine wave as shown in Fig 2 V Fig 2 Inverter stepped square wave output waveform This is important for circuits where magnetic devices such as transformers and contactors RMS voltage are in circuit with electronic relays that derive their DC voltage from capacitor input filters peak voltage The computer grade CAPACITOR BANK operates under ideal conditions being charged to working voltage but carrying no ripple current most of the time During stand by operation the static switch supplies power directly to the load the inverter is switched off and the capacitors are charged to the full operating voltage The supply voltage is constantly monitored for deviations
9. ghtning strikes on overhead power lines and heavy load switching The duration of such faults is generally shorter than one second Most plant can ride through such voltage dips by virtue of their mechanical and electrical inertia However this is not the case with electrically held in contactors and relays that control the machinery Contactors typically drop out from 5ms to 20ms after power is removed Each short voltage dip now becomes a power failure and the plant must be restarted This can be complicated time consuming and costly SWITCHING SYSTEMS VOLTAGE DIP PROOFING INVERTERS are designed to maintain the switchgear control voltage during voltage dips effectively keeping the plant connected The stored electrical and magnetic energy is allowed to flow supporting the mechanical inertia of the machinery When the power is restored after a short voltage dip the plant is still running at near synchronous speed the inrush currents will be small and the stress to the system minimal Historically this problem has been addressed by using DC contactors latched contac tors and intelligent controls such as PLC s These systems are complex and expensive and do not provide a solution for equipment already in existence The current approach to this problem has been to employ intelligent control systems which provide a curative solution In contrast the Voltage Dip Proofing Inverter provides a preventative solution 2 Theory of operation Th
10. isolated 000808080800 o ______________AAAAAAAAAAAA lt gt gt Page 6 Voltage Sag Simulator ieuoMoj nuau JOJejNWIS bes ejqe uorounj Kex BuiuuieiDOJ4 E D ubip jueure10eq UM 9AOqe 116 p 1ueuie1ou Bon SS Ha yo o i Bip snorejg ER kan gt Du and W I 1X N a EN 4 anjea jas diem kan Bes jo uoneanp 10 sKejdsig Jas 10J sKeJdsig HB S uo JAMO as 10J shejdsiq Page 7 Voltage Sag Simulator User Manual Variac Output 1 Oulput direct from variac At times it is convenient to have a variable AC supply available The Sag Simulator can be programed to connect the variac output to terminal 3 In this mode the output voltage is set by the variac and is available continuously the set value is indicated on the display The output is overload and short circuit protected To enable direct variac output navigate to the Function Select Menu Select Variac Output and press the key The display will show 2 To exit Variac Output mode first set the variac output to zero and disconnect the load Then switch the Sag Simulator off and then on to reset to normal operation Soak Test Follow the steps outlined below to set up and operate the Soak Tester Refer to Fig 4 on page 11 for information on menu layout and programming key functions 1 Connect the supply Voltage Dip Proofing Inverter or Voltage Dip Compensator Bypass Switch and load to the Sag Sim
11. ment the digit to the desired value Set Sag Depth The Set Sag Depth is set from the Start Soak Test Menu Set Voltage will flash and the current sag level voltage will be displayed Adjust the variac to the desired Sag Depth value The value may be adjusted at any time during testing an EE Voltage Sag Simulator Page 9 User Manual 10 11 Start Test When the parameters have been set navigate back to the Soak Test menu by pressing the 4 key Press the key to reach the Start Soak Test menu Set Voltage will flash use the variac to adjust the Sag Depth voltage see 8 5 above Start the Soak Test by pressing the key The display will show Stop or interrupt the test by pressing the key The display will show Press the gt key to stop the test and return to the Soak Test Menu If no action is taken testing will resume in 30 seconds When the test is complete the total number of dips are displayed Press the key to return to the Soak Test Menu Start up error conditions 1 Error conditions The simulator will perform a power on test to check the supply frequency and the load current If the supply frequency is not 50 or 60Hz or if there is an overload then one of the error messages below will be displayed Or Whenan error condition is detected the simulator will shut down automatically and the error message will remain on the display Check the test setup for the source ofthe problem To rese
12. re listed below refer to Fig 7 page 14 for their locations 1 A variac that is used to set the depth of an under voltage sag condition 2 The sag level set by the variac is indicated on the LCD display 3 A variable interrupt timer that is used to set the duration of the voltage sag and the point in the cycle at which it begins Both variables are set using the programming keys and are indicated on the LCD display Refer to the menu flow chart and programming key function table in Fig 3 p7 for Sag Simulation page 8 for Variac Output and Fig 4 p11 for Soak Test Operation Sag Simulation Follow the steps outlined below to set up and operate the Sag Simulator Refer to Fig 3 on page 7 for information on menu layout and programming key functions 1 Connect the supply Voltage Dip Proofing Inverter or Voltage Dip Compensator Bypass Switch and load to the Sag Simulator as shown in Fig 8 page 15 2 Set the variac to zero output and the Bypass Switch to nverter Bypassed 3 Switch on the power to the Sag Simulator the display will show Note If an error message is displayed and the Simulator shuts down please refer to Error conditions at the end of this section on page 10 4 Press the key to reach the Sag Simulator menu the display will show an EE Voltage Sag Simulator Page 5 User Manual 6 The Sag Depth may be adjusted using the Variac prior to performing the test The value is shown on the Voltage readou
13. t In this case preset values are used for Sag Delay 5ms amp Sag Duration 100ms The simulator will store the values used for the last test and use them as the defaults for the next test 7 Press the key to Start Test or press the 4 key to return to the Sag Simulator menu 8 To set the Sag Parameters to values different to the defaults navigate to the Sag Simulator menu press the v key to select Set Parameters then press the gt key to reach the adjustment menus The Sag Depth is set using the variac and then the interrupt timer should be programmed to set the position and duration of the voltage sag to be generated The three parameters are adjusted as follows 8 1 Set Sag Depth At the Set Sag Depth Menu press the gt key to reach the Adjust Variac menu Adjust the variac until desired voltage is indicated on the display 8 2 Set Sag Delay position after a positive zero crossing At the Adjust Variac menu press the key to select the Set Sag Delay menu Press the key to program the Sag Delay value Use the and 4 keys to select the digit to adjust The active digit will flash Use the a keys to increment or decrement the digit to the desired value 8 3 Set Sag Duration From the Set Sag Delay menu press key to select the Set Sag Duration menu Press the key to program the Sag Duration value Use the and keys to select the digit to adjust The active digit will flash Use the v keys to increment or decrement
14. t the simulator switch the power off and then back on again E Page 10 Voltage Sag Simulator User Manual 9AO0qe 1161p 1ueuie49U nuewixen W EI ubip snomeid nue ion P Bu 1151p 1X N Qm 9n 8A Jas T SOE 10 s ejdsig H8u2 0JJ 19189 YEOS y ejqe uo dun Kex BuiuwueiDO44d t D 34818 UO 19 0gd 998 g 10J sKejdsig es 10J shejdsiq Page 11 Voltage Sag Simulator User Manual Simulated Sag Profile ETA KE E T T T D T T T T T T E 3 LO T T T T T I T T T T T T Y 4 EE F T T L Sag Duration 60ms 54300 Positive zero E 4 2 crossing Sag Depth E D 200 50 a Sag a Voltage T 110Vrms 100 J O Maa Mid Nep EE dr d nr E 100 200 Sag Delay 5ms 300 a Supply voltage 220V 50Hz Sag Simulator output i qc eL AA oro loo cy Doe accu Tod 1r p Loi ror o e d s noa 0 10 20 30 40 50 60 70 80 90 100 ei Time ms C T T T T T T TT T T alike T T T T T T T DE T T T T T T T T T T Sync pulse output Terminals 4 A 5 d G t fe gt Z 0 CNN ulbuet Amplitude 5V Duration 60mS Sag Duration 5 Lor ls ci oi i d i K i i o 4 uda Li roo la e Lupo po lah p ay 0 10 20 30 40 50 60 70 80 90 100 Time ms Fig 5 Profile of simulated sag output amp sync pulse from simulator E Page 12 Voltage S
15. the digit to the desired value 9 Start Test When the Sag Voltage Delay and Durationhave been set navigate back to the Sag Simulator menu by pressing the key Pressthe keyto reachthe Start Test menu At this point the variac may be used to readjust the sag voltage The voltage setting will be indicated on the display The supply voltage can be interrupted by pressing the gt key The effect of the programmed sag can be seen on the unprotected load one or more contactors or relays will drop out The sag profile can be observed using a power monitor or an oscilloscope if these are available The simulation can be tried with various settings sag depth delay and duration as often as desired to pinpoint sensitive components in the control system 10 Test with DPI or VDC in circuit The Bypass Switch should now be set to Inverter in Circuit and the sag simulations repeated to evaluate the effectiveness of using the Voltage Dip Proofing Inverter or Voltage Dip Compensator to harden the controls against momentary sags and interruptions 11 Sync pulse output A synchronization pulse is available at terminals 4 amp 5 This pulse may be used to trigger an oscilloscope in order to display the sag profile The output remains at zero volts until a sag is initiated at which time the output rises to 5 volts and remains at this level until the end of the sag duration period The output then returns to zero volts The sync pulse output is electrically
16. to return to the Soak Test menu To set the Soak Test Parameters to values different to the defaults navigate to the Soak Test menu press the v key to select Set Parameters then press the key to reach the adjustment menus Five parameters may be adjusted as follows Set Dip Interval At the Set Dip Interval menu press the key to program the Dip Interval value Use the gt and 4 keys to select the digit to adjust The active digit will flash Use the a keys to increment or decrement the digit to the desired value Set Start Dip Length t Start At the Set Dip Interval menu press the key to select the Start Dip Length menu Press the key to program the Start Dip length value Use the gt and 4 keys to select the digit to adjust The active digit will flash Use the v keys to increment or decrement the digit to the desired value Set End Dip Length t End From the Set Start Dip Length menu press key to selectthe Set End Dip Length menu Press the gt key to program the End Dip Length value Use the and keys to select the digit to adjust The active digit will flash Use the keys to increment or decrement the digit to the desired value Set Number of Steps From the Set End Dip Length menu press v key to select the Set Number of Steps menu Pressthe key to program the Number of Steps value Use the and keys to select the digit to adjust The active digit will flash Use the v keys to increment or decre
17. ulator as shown in Fig 8 page 15 2 Set the variac to zero output and the Bypass Switch to Inverter in circuit 3 Switch on the power to the Sag Simulator the display will show Note If an error message is displayed and the Simulator shuts down please refer to Error conditions at the end of this section on page 10 4 Press the w key twice to select Soak Test then Press the gt key to reach the Soak Test menu the display will show Page 8 Voltage Sag Simulator User Manual 6 5 8 1 8 2 8 3 8 4 8 5 The Sag Depth may be adjusted using the Variac prior to performing the test The value is shown on the Voltage readout Stored values are used for INT Interval between consecutive dips initial default 10 seconds SDUR Duration of the first test dip initial default 100ms EDUR Duration of the last test dip initial default 1000ms STEPS Number of steps between first dip amp last dip initial default 200 Each step consist of a series of 20 dips The first dip starts at zero crossing the next dip is delayed by the period of the supply frequency divided by 20 Subsequent dips sweep through a complete cycle with increasing delays after zero crossing Note that the values shown above are factory settings for first use When parameters are set up for a test the new values are stored and will become the default values for the next test Press the key to Start Test or press the lt key
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