Manuale GI new - Caltest Instruments
Contents
1. 3 2 Inputs The AL 3000 power supplies are equipped with some inputs for the remote control function Description Emergency NC contact with no voltage its opening causes the immediate disengagement of the line breaker disconnecting the equipment from the mains on off NO contact with no voltage allows to start the power supply from a remote command Voltage command Analog input 0 10V remote command for the output voltage 0 100 Current command Analog input 0 10V remote command for the output current 0 100 3 3 Outputs The AL 3000 power supplies are equipped with some outputs for remote signaling function description Run stop PNP digital output signaling for output on off Max 30V 0 5A Alarm PNP digital output fault signaling Max 30V 0 5A 3 4 Communication port The power supply is equipped with a RS484 communication port which allows to connect a PC for some parameters setting and for the alarm register reading The Baud Rate is the transfer speed and is set at 9600 ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 15 of 41 rev xx November 2011 4 Power output 4 1 Command type selection The selection of the command type e Front panel e analog or digital inputs e serial port can be done via serial link by means of AL Manager software 4 2 Starting the output of power After the preliminary operations connecting the equipmen2. UMIS 0 Fixed value ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 39 of 41 rev xx November 2011 Request and sending Ramp mode Command Reply if IDX OK 0x12 R IDX Mode Reply if IDX not OK Command Reply 0x13 R IDX 0x13 R ESI IDX 0x81 Valore fisso Mode 0 No ramp 1 Linear ramp Commands for reading the actual values Reading the actual state Command Reply 0x14 E State ortestresult Test state o Halt 1 Running y Be 637 Aa 5 6 Fail failure or malfunction 7 Aa ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 40 of 41 rev xx November 2011 Reading the actual voltage Command Reply 0x14 M FA 0x14 M UMIS Actual value FA Necessary in the three phases devices Select the phase to read 1 2 3 if omitted it means 1 Millivolt Volt Reading the actual current Command Reply a ia hi S ps paee o FA Necessary in the three phases devices Select the phase to read 1 2 3 if omitted it means 1 Millivolt Milliampere Volt Ampere Reading the remote connection state Command Reply 0x14 L 0x14 L Connection state _ Connect
3. By means of the menu Set it s possible to select the parameters for the serial link PC port and baud rate In this case the baud rate must be 9600 FW Version 103 BL 14606 Board Status Q Reset 1004 Power supply measures AC voltage 385 Volt DC voltage 622 Volt Temperature 25 Degr oltage V 0 Current A 0 Max Gen Current Current A Max Abs Current Resistor Ohm PowerLimit kW Device Address 0 DSPAddress ii USB Serial Port COM 230400 b s O SSS oa eee Disconnect ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 32 of 41 rev xx November 2011 The PWMutil can work in two ways e directly on modulation board ZEL1004 e through digital card ZEL0901 10 2 Connection through digital card Enter the following parameters in position 2 e Device Address serial address of the power supply e DSP Address serial address of the power module if more power modules are present 1 for module 1 2 for module 2 etc in case of one module only enter 1 Once the parameters have been set up as shown above push the button Connect to start the connection In this situation the mask will appear as shown above and it s possible e display the machine state with the readings of Output voltage Output current AC mains voltage DC BUS voltage temperature of heat sink and the state of the alarms With the RESET but
4. Electromagnetic Compatibility Directive 2004 108 EEC EN 61000 6 1 CEI EN 61000 6 1 2 ed 2007 10 Electromagnetic compatibility EMC Part 6 1 Generic standards Immunity for residential commercial and light industrial environments EN 61000 6 3 CEI EN 61000 6 3 2 ed 2007 11 Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standard for residential commercial and light industrial environments EN 61326 1 2006 Electrical equipment for measurement control and laboratory use EMC requirements Part 1 General requirements Low Voltage Equipment Directive 2006 95 EEC and EN61010 1 Safety of Electrical Measuring Apparatus Mirabella 01 03 2011 Zenone Eletrronica S r l Luigi Zenone F Z Pr Copyright Acknowledgement EN publications are subject to the Copyright of IEC ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 8 of 41 rev xx November 2011 1 4 Identification label Each equipment is identified by the following label We invite you to consider the data shown in it as essential for product traceability and to communicate them for eventual request for assistance ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE Mogel Seria no Vin Pin Scale Firmware Po ver Seria address Ls date of calibrationdelivery es C mod INF 007 made in italy ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 9 of 41
5. rev xx November 2011 2 Preliminary operations 2 1 Working environment The Power Supply is designed for indoor use aK 5 C HE 40 Place the device on a suitable support or on a plane surface for good stability Be sure that proper ventilation is allowed and no objects obstruct the ventilation openings 2 2 Precautions A Q A A Operate the equipment at its rated mains voltage on earthed outlet only Fasten suitable cables or bars of adequate section on the output bolts calculated on the bases of equipment functional characteristics WARNING Power connections can generate high temperature spots that could cause burnings WARNING All standard power supplies are delivered with output FLOATING not connected to any potential unless otherwise specified at the moment of installation MUST BE CONNECTED TO GND OR TO ANY OTHER POTENTIAL Maximum allowed voltage on the output bolts when not connected to earth is 300VAC If necessary connect eventual protection devices differential relay isolation control relay etc WARNING This equipment puts energy into the mains net if power to the equipment is supplied from an external source batteries independent generator etc make sure to have adequate protection elements complying with local actual regulations and eventual authorizations from the energy supplier agency ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 10 of 41 rev xx Novemb
6. ELETTRONICA ZENONE Elettronica S r l Via Nazionale Pianopantano AUTOMAZIONE 83036 Mirabella Eclano AV STRUMENTAZIONE J P1 02407830641 Tel 0825449171 Fax 0825407907 ZENONE DC Power Supplies AL3000 series User s manual Release xx November 2011 Firmware version VXXx DSP version VXXx This manual is integrant and essential to the product Read carefully and completely the instructions and the warnings herein they will provide important information regarding safety of operation and maintenance This equipment must be used only for the purpose for which has been designed Any other utilization is improper and therefore potentially dangerous The manufacturer is not responsible for possible damages caused by improper incorrect and unreasonable utilization of this equipment Any intervention on the equipment that would cause a change in the structure or in the cycle of operation must be performed or authorized by the technical department of Zenone Elettronica ZENONE Elettronica S r l Via Nazionale Pianopantano 83036 Mirabella Eclano AV Tel 0825449171 Fax 0825407907 www zenoneelettronica it info zenoneelettronica it Attention This manual provides all the necessary information regarding the mode of operation of AL3000 and AL3000R power supplies series For the correct use of this specific equipment it is recommended to refer to the characteristics data sheet of the power supply which is an integral part of this m
7. G section The Analog section of the interface connector is made of pin e AIN1_P and AIN1_N of the Analog input 1 Pin 14 and 7 e AIN2_P and AIN2_N of the Analog input 2 Pin 15 and 8 e Reference ground GND Pin 6 They are two balanced inputs that can take a maximum voltage of 10V with respect to GND Their function when enabled by appropriate command via RS485 is to set the Voltage Input 1 and the Current Input 2 ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 22 of 41 rev xx November 2011 7 Error and faults signals The converters are equipped with self diagnosis routine in case of anomalous event they stop the power output and show an error message Signal Cause Remedy DSP X FAIL Communication error between Shut off and turn on the equipment if the the central processor and the error remains contact the assistance DSP shown by nr X FAIL XX Generic error See the display on cards or connect a PC to the equipment and by means of the software PWMutil check the table below signal Type error Remedy 1 DC overvoltage Check the mains voltage the presence of all three phases and that the regenerator works properly 2 DC undervoltage Check the mains voltage the presence of all three phases and that the regenerator works properly 3 Over temperature Shut off the equipment and wait a few minutes If the phenomenon repeats chec
8. KS error AC overvoltage AC undervoltage HI frequency LOW frequency ZC missing Feedback error olm OIA wl gt l wo Co NW OT A WN a Slave T OUT ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 12 of 41 rev xx November 2011 2 7 Regenerator serial port The regenerator is equipped with standard RS485 serial port communication with rate fixed at 9600 DB9 Pinout RS485 2 8 Regenerator functional diagram only AL3000R models Line Input precharge DC out PWM Modulator RS485 comm serial Control unit ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 13 of 41 rev xx November 2011 3 Inputs Auxiliary outputs 3 1 sensing output sensing Main power Internal Sensing input Power output measurement A sensing output Sensing circuit diagram The sensing circuit has internally resistors that link the senses to the main output in order to prevent the AL3000 to go to its maximal voltage when the sense line is broken or accidentally removed The resistors are sized that If the sense is broken or removed the output voltage result Set output voltage X 1 1 circa BA 4 If the sensing is reversed the AL3000 will not started and can break the sense circuit ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 14 of 41 rev xx November 2011
9. anual 07 i i a Instruments GmbH Caltest Instruments GmbH Kohlmattstrasse 7 Tel 49 0 7842 99722 00 D 77876 KAPPELRODECK Fax 49 0 7842 99722 29 info caltest de www caltest de ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 2 of 41 rev xx November 2011 Regenerative bidirectional Power Supply AL 3000R series The power supplies AL3000 and AL3000R series are fast AC DC static converters with double conversion and IGBT technology under microprocessor control They supply the load with voltage or current at the value that has been set regardless of the inpedance value and the mains fluctuations they can also draw in energy from the load and put it on the mains net They are particularly suited to users with high dynamic needs The information about voltage and current supplied is shown by means of 7 segments displays They can be controlled by external signals They are equipped with RS485 serial interface for diagnostics and parameters setting 1 R model 2 in current control mode Product presentation According to the output power the equipment can be assembled in table rack recessed rack metal cabinet Control interface commands and connections voltage setting command and visualization on front panel current setting command and visualization on front panel logical command for output on on front panel selection local remote commands from serial interface line breaker on fro
10. compressed package For the installation just click over the proper icon and accept the license agreement terms The AL Manager program is supplied with free license for the ZENONE ELETTRONICA equipments users and its disclosure it s forbidden Note ZENONE ELETTRONICA disclaims any liability for incompatibilities or conflicts with other software and operating systems ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 34 of 41 rev xx November 2011 12 Communication protocol VXX Communication protocol It s possible to communicate with the device send commands and get replies by means of the RS485 serial interface according to a half duplex communication protocol The settings of the communication port is Device address from 1 to 32 assigned with appropriate software Baud rate 9600 b s Number of bits 8 Stop bit 1 Parity None Each command and each reply are preceded by a start STX and the address IND of the device we intend to communicate with followed by a stop ETX and a checksum CKSUM for the data correctness verification STX Start character Hexadecimal value 0x02 IND Device address added to the hexadecimal value 0x80 ex Address 1 character 0x81 ETX Stop character Hexadecimal value 0x03 CKSUM Control checksum it s a character sum of all characters of the command Inclusive of STX and ETX characters module 256 Each command that carries a parameter receiv
11. egulation loop in microseconds can be applied directly or multiplied by the parameter Kp causes the output to change with a speed proportional to the error sets the regulation point canceling out the offset Td range dt 32000pS 0 derivative disabled It s the derivative time of the regulation loop in microseconds can be applied directly or multiplied by the parameter Kp causes the output to change proportionally to the rate of change of the input reduces the system response time dt machine cycle time not changeable Positive integral limitation range 0 100 It s the maximum value the variable integral can take Negative integral limitation range 0 100 It s the minimum value the variable integral can take ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 27 of 41 rev xx November 2011 Positive derivative limitation range 0 100 It s the maximum value the variable derivative can take Negative derivative limitation range 0 100 It s the minimum value the variable derivative can take F F Feed forward range 0 20 It s the anticipation value on the current output is used to speed the voltage recovery during the load variations 9 4 Fine tuning procedure for the control system Note To change the control parameters it s necessary to have a PC connected to the serial port of the console and the software program PWMutil Look at paragraph PWMutil software The follow
12. er 2011 2 3 Emergency circuit The AL3000 series is equipped with an emergency circuit that provides to opening the main breaker The opening condition are e Pressing the emergency button e Opening of doors e Main power failure e Opening external circuit ae The emergency circuit is always powered even when the main breaker is off 2 4 Switching the equipment on Connect the power supply to the power mains it is recommended to follow the instructions given on the equipment or in the attached sheet regarding voltage frequency and earth connection then turn on the power switch that could be located on the back panel or by the cabinet side depending on the type of equipment In some models the power on command can be part of an external power supply frame In some cases the integrated console keyboard display can be connected to the cabinet by means of an external cable At system power on an self diagnostic routine tests the most important equipment functionalities and detects eventual faults the information are visible with the proper software In case of failure or malfunctions we must be informed in advance before sending the equipment to our laboratories 2 5 Regeneration only AL3000R models The AL3000R power supply series are bidirectional devices as a matter of fact they can either supply energy to the load or absorb energy from it the energy is taken from or is put on the power mains This function is accomplished
13. es a reply with a result character ESI that can have the following values 0 Command executed 1 Command not executed ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 35 of 41 rev xx November 2011 General information commands and device options Device serial number request Command Reply 0x10 S Serial number Device firmware version request O S 5 fed J 42 rs oO 3 Be Firmware version Device name request O S 5 ed J za v5 oO 3 Be N Device name Request and setting device setup mode Reply 0x10 M Setupmode Command 0x11 M Setup mode setting 0 Setup and start from panel 4 ou 3 4 Setup and external start Note In case of remote mode look at appropriate command 0x15 M this command has effect only for the start ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 36 of 41 rev xx November 2011 Commands for test main setup Request and setting voltage value Command Reply if IDX ok 0x12 M IDX 0x12 M IDX UMIS Voltage value Reply if IDX not ok Command 0x13 M IDX UMIS Voltage value 0x81 Fixed value 1 Fixed value For the allowed ranges refer to equipment specifications Request and setting current value Reply if DX OK VE IDX UMIS Current value Reply if IDX not OK Co
14. essed in OHM with respect to the maximum value and has a 1MOHM resolution It can be done through the analog input if selected or through a serial string If resistance is selected on analog input is possible to set the maximum value corresponding at 10V by software GESMD Note with simulated resistance and some types of reactive loads a instabilities might be triggered 4 5 Maximum power limitation The power supply can work with constant power operation To use this function first adjust voltage and current limits within which you want to work then set the value of maximum power output In these conditions when the load will require more power than that set the voltage will be automatically decreased so that the P out lt P set In the case of regeneration the voltage is increased The setting of power is expressed in W with respect to the value of the specification sheet and has a resolution of 1W It can be done through analog input if selected or through serial string 4 5 1 Ramps up and down Ramps up and down allow a sweet start of the output voltage avoiding overshoot Ramps can be set at 0 or from 100mS up to 10S Ramps have effect only during the transition OFF ON The setting of ramps can be done through serial interface 4 5 2 Separate control of the current limits supply absorption You can independently set the maximum limits of positive and negative current In this way the power supply wil
15. ing paragraph provides only a guide for the fine tuning of the PID regulation loops since in many cases a unique rule it s not applicable and regulations are made on the bases of personal experience Note Eventual parameters modifications must be done by specialized personnel only because these modifications could cause malfunctions and or generator damages we Note Before making any change to the regulation parameters it s fe advisable to take note of the existing parameters so to restore the initial setup In most cases in particular when the equipment must be adapted to the load it s sufficient to make slight changes to some parameters following simple rules In case of sever capacitive load lower the Kp coefficients and increase the integration time Ti In case of sever inductive load increase the Kp coefficients and lower the integration time Ti ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 28 of 41 rev xx November 2011 9 5 Technique for fine tuning the loops The fine tuning of the PID loops must be done in two phases first the internal one and then the external In order to fine tune and verify the dynamic performances of the generator it s better to set the references with an external generator connected to the proper input using a square waveform with the following parameters Frequency gt 0 lt 50Hz Amplitude 0 V lt 5V or have an external dynamic load Under these conditio
16. ion state E Not ACTIVE R Active ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 41 of 41 rev xx November 2011 Test Start and Stop commands Enables remote mode Command 0x15 M Mode Remote mode L Not active R Active In Remote mode the output values are defined via SERIAL link The start can be given from SERIAL link or from PANEL EXTERNAL according to the appropriate command 0x11 M Supply start Command Reply Note It s possible to start the supply only if in remote mode and start from selected PANEL EXTERNAL The positive result of the command means that it was accepted but in order to be sure the start has taken place it s necessary to read the device state Command 14E Supply stop Command Reply Note It s possible to stop the supply only if in remote mode and stop from selected PANEL EXTERNAL The positive result of the command means that it was accepted but in order to be sure the stop has taken place it s necessary to read the device state Command 14E Address assignment Command 0x15 A ND
17. is technical document version voids and replaces all previous versions The products cited in this document could be trademarks and or registered mark of respective manufactures ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 4 of 41 rev xx November 2011 Summary l PrefaC rrisni nnnop rarasan NAE E UNEA 1 1 How to use and understand the instructions provided in this manual cccsceseeeeeeeeeeees 5 1 3 Compliance declaration ccccccccccccceceeceuaeeaeeceeeeeeecaeceeeeeeeeaeeaeeaeegeuaeuasvaesaeeeuaaegaeangs 7 1 4 Identification label siinne aa aaa N Ea E 8 2 Preliminary operations 05 Perr rr ec rer rie eer 2 1 Working environment cccccccccecceesceeseecaeeeeeeeeee sees sees aa n a oaii aE 9 2 2 PFECAUTIONS iiniiviuiiccccnedwarcndcredtinncdnesnasanneaecerneuaadieaansaanecuanendunndeintisacs seemmnnenennacunns 9 2 3 Emergency CIFCUIE i iiisicieccnsstettnnccnnesendsancencentinwnsi a a aa EEE 10 2 4 Switching the equipment OM ccccccscecececseeceeeeeeeeeeceeeeeeeeaeeneeeeeeeeeeeeeeeaeeaaeeaaeaaeeaggy 10 2 5 Regeneration only AL3000R models sssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 10 2 6 Regenerator error conditios sccccscccscecceeeaeeeeeeeeeceeeeeeeeaeenaeeeeeeeeeeaeteaeegaeeaueaaeeaggs 11 2 7 Regenerator serial PON i ciiiirresiica tie ssacsecscveenindvensvieasssceneans dened enaa nna 12 2 8 Regenerator functional diagram only AL3000R models ssssssssssssnnnnnnnn
18. k the air vents and the operation of the fans 4 IGBT Error FAULT Contact the assistance 5 Precharge error Check the precharge relay 6 Current limitat Check the load or the parameters settings 7 NTC error Contact the assistance 8 CKS error 9 A B C D E Feedback error 0 Slave T OUT If the fault remains contact the assistance ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE 8 Converter diagram BUS DC Input a i PWM Modulator Serial Command I O Control Unit Functional diagram Power supply load section MUGL Page 23 of 41 rev xx November 2011 Output ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 24 of 41 rev xx November 2011 9 Control system The power supply is equipped with a sophisticated digital control system which has to keep the voltage and or the current output constant regardless of load change and mains variations The regulation is based on two PID algorithms in sequence and named Internal with feedback from internal current External with feedback from the output voltage The following figure shows the principle of operation 9 1 Control system block diagram Output current Power limitation Current reaulation Voltage reference Output Internal current vollage Internal Loop The control loops are pre adjusted in production to achieve a good compromise between speed and stability for most loads in some case
19. l follow the current limitation set by the potentiometer or other input up to the maximum limit set for this polarity for any other value over the limit the current will be cut to the limit This function is used to set profiles of current asymmetrical between supply and absorption The two parameters are settable by serial link ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 17 of 41 rev xx November 2011 4 6 Visualization of values entered In stand by it s possible to visualize on the displays the voltage and current values simply pressing the F1 push button F1 pressed visualization of voltage and current entered F1 released off 4 7 Visualization of measurements While the output is on the power supply shows on the displays the voltage and current outputs Pressing F1 it s possible to visualize voltage and current setting 5 Maintenance instructions e Check periodically the air vents clean them or change the filter e Check the fans efficiency e Check periodically the bolts of the connections between the power outputs and the external circuit under test ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 18 of 41 rev xx November 2011 6 External connections 6 1 MAIN connections Line input DB15 o o CJ ERREGER HREP EARTH bar Output 6 2 DB15 I O connections DB15 Pin Out 1 O section Vout 24Vcc max 100mA 24V 20 30V Max c
20. mmand 0x13 E IDX UMIS Current value 0x81 Fixed value 1 fixed value Ampere For the allowed ranges refer to equipment specifications ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 37 of 41 rev xx November 2011 Request and setting maximum power value Command Reply 0x12 x2 Power Command Reply 0x13 X2 Power_ Power is in Watt from 0 to f s Request and setting internal resistance Command Reply 0x12 X1 Resistor Command Reply 0x13 X1 Resistor Resistor is in Ohm from 0 001 to 1000 ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 38 of 41 rev xx November 2011 Request and setting reference sources 0x20 C RIF SRC Reply if RIF not OK cC Command 0x21 C _ RIF__ SRC Reference values and associated source ae e Aa RESISTANCE reference Fixed 0 ohm Input IN1 From serial 5 POWER LIMITATION reference Fixed MAX Input AN2 Nota This command ESI can take also value 2 In this case means that SRC you want to use is already used by the reference RIF2 Request end sending RAMP timing Command Reply if IDX OK 0x12 T IDX 0x12 T _ IDX__ UMIS RAMP timing ms Reply if IDX not OK 0x12 T JESI Command Reply 0x13 T IDX UMIS RAMP timing milliseconds 0x13 T JESI IDX 0x81 Fixed value
21. nnnnnnnnnnnnnnnnnn 12 3 Inputs Auxiliary OUCPUtS division L3 ZL SeNS NQisna cna aaa a aa aaa aa a adai iaa 13 e r INDUS E E vette seni reesereenn ewwtien ean Pewee ed ered Nae CaN Ni NNO DUNNETT NEES 14 3 3 OMG DUS iaiiiidensiiiciee nine aa Neate alee ween de a Drewes dead ene R a 14 3 4 COMMUNICATION POF acces sercictiasnssacessaceaeeenmesansaneases sient narimtausTFiensaeeseeaientnientiaces 14 4 Power Output ccccceeesseceeeeeens edena aiana ee ee re A 4 1 Command type selection ccccccceccecceceeceeceeeeeeeeeecaeceeeeeeeeaeeaesaeeceuaeuaeuaegaeaeeeeuaguags 15 4 2 Starting the output Of POWES ccccccccceescesceeceeeseeeeeeeeeeeeeeee seas a a 15 4 3 Setting the voltage and current values ssssssssssssnssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 15 4 4 Setting the simulated resistance ssssssssasssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 16 4 5 Maximum power limitation cccccccccscceccesceeceeeseeeeeeeeeeeeeeeeeeaeenaeeeeeeeeeeaeenaeenaeeaeeaee 16 4 5 1 Ramps Up ANd GOWN cceccecccece eee eceeeeeee eee cee eee eee cena seas ease ceeeenaenaesaeeeeeenaanaaeangs 16 4 5 2 Separate control of the current limits supply absorption cccceeeeeeceeeeeeeees 16 4 6 Visualization of values entered ssssssssasssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 17 4 7 Visualization of measurementS ssssssssunssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 17 5 Maintenance instruc
22. nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 32 11 AL Manager SOftWare ssssssnnnnnnnnnnnnnnnnnnnnnnnunnunnnnnnnnnnnnnnnnnnnnnnnnnnnn OO 11 1 Software installation si ssssicreverassecscscevasceresindenaarnssacansentaged iW tisnseerdesdcer iiaiai 33 12 Communication protocol VXX sssssssssssssusssunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna SF ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 5 of 41 rev xx November 2011 1 Preface 1 1 How to use and understand the instructions provided in this manual In this manual have been used conventional keys to simplify and standardize the utilization and the control of our generators In this manual you can find also functions that might not be present on the equipment you have purchased nevertheless proper information will tell you about eventual limitations This solution has been chosen for clarity and to better evaluate the functional characteristics available on all our products 1 2 Safety instructions The following notes or graphic symbols list a series of instructions essential for the correct use of the equipments Such information could be found in graphic form also on the equipment or used in the manual to focus the attention on the specific issue It is highly recommended to read such instructions carefully before equipment installation Do not install the equipment in environments with temperatures different aK from those allowed 7 Do not expose the equi
23. ns freeze the external loop and adjust the parameters Kp Ti and Td of the internal loop to get maximum performance Once the internal loop has been fine tuned the parameters Kp Ti and Td of the external loop can be adjusted so to optimize the global performance 3 Ideal system response to a step function ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 29 of 41 rev xx November 2011 Ti 0 333 Step function response varying Ti with Kp constant ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 30 of 41 rev xx November 2011 Step function response with Kp too high Step function response with Kp and Ti too small ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 31 of 41 rev xx November 2011 10 Software PWMutil The PWMutil software is compatible with WINDOWS XP systems and allows to set up some important parameters of the power supply it must be installed on a suitable PC and executed Such software is designed to set up the parameters of different equipment types we produce therefore it s possible that are displayed some parameters that have no function for this specific power supply 10 1 Connection to a PC The equipment must be connected to the PC trough the serial port of the console by means of the specific cable After the connection has been done and the program PWMutil is executed the following mask will appear 3 PWM control panel
24. nt panel RS485 serial interface on front panel mains supply from cable on the back side rack version on terminal blocks inside the cabinet heavy duty cabinet version outputs on front panel jacks or bars rack version on terminal blocks inside the cabinet metal cabinet version ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 3 of 41 rev xx November 2011 emergency input on front panel auxiliary inputs outputs on front panel Front panel 88838 8888 O Emergency V A Voltage Current Mains line setting setting breaker Q O Output jacks Introduction Thank you for choosing our product We invite you to read this manual thoroughly because here you can find the technical characteristics and all the necessary information for using this equipment correctly The information contained in this document is subject to change without notice and it is expected to be updated exclusively for the product for which is provided ZENONE ELETTRONICA is not liable for technical error printing error or omissions that might be encountered in this manual neither is responsible for accidental or consequential damages caused by the use of its product This guide provides specific information related only to the mentioned products No part of this manual may be reproduced in any form or by any means without our written consent The software herein described is provided with end user license unless otherwise specified Th
25. pment to direct sun light Do not pour any kind of liquids on the Equipment In case of fire use foam CO2 or dry chemicals fire extinguishers ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 6 of 41 rev xx November 2011 Attention The lightning symbol within a triangle is a warning symbol that indicates the presence of dangerous voltages inside the equipment with risk of electric shock The exclamation mark within a triangle is a caution symbol that indicates the presence of important additional information for the correct use of the equipment The empty triangle it is a caution symbol that indicates a danger of equipment damage if improperly used The text that follows this symbol gives information recommendations or other particular instructions for the correct operation of the equipment The text that follows this symbol gives information recommendations or other particular instructions in order to avoid danger and or injury to personnel A proper disposal of the shipment packing is recommended o a gt gt D ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 7 of 41 rev xx November 2011 1 3 Compliance declaration MANUFACTURER DECLARATION OF CONFORMITY The Zenone Elettronica Power Supplies AL3000 and AL3000R are herewith confirmed to comply with the requirements set out in the Council Directive on the Approximation of the Law of Member States relating to
26. s it is necessary to modify some parameters for the following reasons e Oscillations due to a load too reactive e To enhance the generator dynamic performance e To adapt the generator to the load ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 25 of 41 rev xx November 2011 9 2 Control system description The control system is based on two PID loops in sequence named Internal and External The internal loop is the fastest and regulates the current in the load It takes input the external loop reference properly adapted by the current regulation The external loop regulates the output voltage reacts more slowly and provides the value of current to the internal loop It takes at the input the main reference and the feedback comes from the output voltage of the power supply External loop Integral limitation REF REF1 to internal loop ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 26 of 41 rev xx November 2011 Internal loop Offset Current limiter Integral limitation REF1 from external loop To modulator lt gt gt 3 2 g a D Internal current From voltage control 9 3 Parameters definition and function Kp range 0 10000 It s the proportional gain of the regulation loop it causes the output to change according to the input error Ti range dt 32000uS 0 integral disabled It s the integration time of the r
27. t to the mains and to an eventual load have been done it s possible to turn on the power supply acting on the main switch Note the main switch will not activate if the emergency circuit is open or ee the emergency push button is pressed Once the equipment is turned on it s possible to start the output of power in following ways e With local command acting on the on off push button e With remote command activating the proper input e With command from serial port entering the appropriate string Under these conditions the power supply will take immediately the voltage and current values set 4 3 Setting the voltage and current values The setting of voltage and current output can be done e With local command by means of the potentiometers on the front panel e With remote command by means of analog signal 0 10V e With command from serial port by means of appropriate strings aA N Note some particular settings are possible only by means of command from serial port ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 16 of 41 rev xx November 2011 4 4 Setting the simulated resistance The power supply can simulate a resistance in the output such that given a set voltage V The output voltage is dynamically reduced by the value R set x I circulating in case of power output is dynamically increased by the value R set x I circulating in case of absorption The resistance setting is expr
28. through an extra converter called REGENERATOR In fact it will adjust the DC voltage on an intermediate bus taking it or putting it back into the network providing also to put in phase the absorption and the regeneration so to guaranty a PF gt 0 95 at Pn According to the model the regenerator block can be either internal to the equipment or external in a separate unit The regenerator block in normal mains network condition does not need any setting or adjusting because it works autonomously controlling the BUS voltage in some special cases it might be necessary to touch up some control parameters using the software PWMutil The power that the equipment is capable to draw from the load is the same that is capable to supply The regenerator has its own electronics with microprocessor that provides the energy management and the monitoring of all alarms and system parameters ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 11 of 41 rev xx November 2011 2 6 Regenerator error conditions Under error conditions the regenerator stops the operation and signals the failure by display on the cards The cause of the fault can be visualized by error code or means of the PWMutil program connecting it to the appropriate serial port on the regenerator signal Type error Remedy DC overvoltage DC undervoltage Over temperature IGBT Error FAULT Precharge error Current limitat NTC error C
29. tions cccesseeseeeeeeeees eee er ee a La 6 External connectionS 00088 ee re cre rece eer ree sitcom 18 6 1 MAIN CONNECCONS viwiisceiieieriicne nnna cana dbasenaeinsi aati a a 18 6 2 DBL5 I O connections siiticvericcertsnsedsesnadersctnaneewessie cease daacensevindiaaen a mentee swans 18 6 3 DB15 RS485 connection cccccecccecececeuceeeucececaeceueuceeecaeceuauseeeeaecauaegeueeaesavaeueuanaeass 20 6 4 DB15 analog CONNECTIONS cccccccecccsceeceeeceeeeeeeeeeeeeeeeeeae seas EEEa 21 7 Error and faults Signals ccscceesseeeeeeeeeeees re er ere ee rere es 4 8 Converter diagramM s s sssssssssssunusnnnns T E a E 9 Control system T aiid stieareaaaipinta tenia anaemia Diea DE nanii 2A 9 1 Control system block diagram cccccsccccceecceecceeceeeeeeeeeeaeeeaeeeee seer sees Cees eee naeeneeeeeenes 24 9 2 Control system AeSCriptiOn ccccccceeceeceeeeceeceeceeeeuaeeaeeceeceeaeuaeeaseaeeeunaeuaecaeaeeaeuaguags 25 9 3 Parameters definition and function sssssssssnssnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnannnnnnnnnnnnn 26 9 4 Fine tuning procedure for the control SysStemM sssssssssssnnunnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnn 27 9 5 Technique for fine tuning the lOOPS cccccscccccesceeeeecseeceeeeaeeeeeeeeeeeeeeeeeeaeenaeeneeeneeaes 28 10 Software PWMutil cccccseeeeeeeeees ee Tee AT eer A Te Al 10 1 C nnection toa PC ssisirisoseean a E E 31 10 2 Connection through digital card s sssssssssssssnnnsnnnsn
30. ton it s possible to reset some stored alarms e In quadrant 1 appear the box Enabe control panel if checked is possible to set parameter in the appropriate boxes This if the power supply is in off state this function excludes all other controls front panel analog input ecc e By means of the button PIDs parameter to step into the next mask where the PWM parameters are shown and could eventually be changed PIDs Parameter External PID Tiffd KP r Derivative ERR T Ti usec Td usec KP 50 MIN 100 MAX 100 MIN hoo MAX 100 Internal PID Tif Td KP r Derivative ERR P Ti usec Td usec KP 50 MIN 100 MAX MIN 100 MAX FeedForw 0 REFRESH ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 33 of 41 rev xx November 2011 The sampling timing dt is shown at point 1 In order to change any parameter just overwrite it and press ENTER on the keyboard The button REFRESH provides an over reading of the parameters stored in the memory module Warning in case of more power modules the regulation parameters must be the same for each module 11 AL Manager software The AL Manager software allows the total control of the power supplies AL2000M and AL2000BX series AL Manager software can handle up to 32 power supplies AL2000 series 11 1 Software installation The AL Manager software is compatible with Windows XP and is supplied in a
31. urrent sink from each Max current for each input 4mA 24Vdc output 500mA ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 19 of 41 rev xx November 2011 1 0 section The I O section of the interface connector is made of 2 Inputs PNP type at 24V Pin 1 and 2 2 outputs PNP type at 24V Pin 11 and 12 1 24V supply output limited at 100 mA max 2 Pins assigned for a 24V supply 4 GND e 10 VCC ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 20 of 41 rev xx November 2011 The inputs have the following function e Input 1 Allows to START the output supply e Input 2 Not used e Input Emergency normally closed to the common of 24V When opened causes the disengagement of the line breaker The outputs have the following function e Output 1 Active when the power output is on e Output 2 Active in case of fault 6 3 DB15 RS485 connection 5V DB15 Pin out RS485 section GND RS485 section The RS485 section of the interface connector is made up of pin A and B of the RS485 interface and of a Ground pin For a proper functioning of the serial communication it s suggested to insert in a point of the line two resistance of 1K ohm connected as in the diagram ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 21 of 41 rev xx November 2011 6 4 DB15 analog connections DB15 Pin out Analog section AIN1_N AIN2_N ANALO
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