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1. 70 Amps AC 650 Vdc 40A The example shows that the system is running with a line current of 70 Amps The DC bus voltage is 650V and the reactive current reference is 40 Amps Operation and access to the Run Mode and Menu Mode is done with the console push buttons The action of each push button changes with the mode of operation and the state of the drive The following table describes how the console push buttons affect the drive control Console Push Button operations Console Mode System Running System Stopped Menu mode e Used for entering setup information Run Display mode system Page 12 Pressing STOP will stop the system Pressing A or Y will either select another menu item or adjust a setting Pressing will select the displayed menu item or accept the value being adjusted Pressing ESC will abort value adjustment or the current menu If the current menu is the top of the menu tree the console changes mode to the Run Display mode Pressing STOP will stop the Pressing A or Y will either increase or decrease the console reference value Pressing will have no effect Pressing ESC will abort the Run Display mode and the console changes to the Menu mode IM00097B Pressing STOP will not reset trip conditions to allow trip messages to be viewed after exiting menu mode Pressing A or V will either select another menu item or adjust a setting Pressing will select the
2. Protection Power stack IGBT protection is provided by the driver circuit electronics typically Semikron SKiiP modules and the trip status is displayed by Sine Saver Note that the line side converter topology used in a Sine Saver system requires semiconductor fuses to properly protect the diodes and other power components in the power stack It is essential that appropriately selected semiconductor fuses are used The Sine Saver Control Package Application Guide IM00096 contains details of the fuse selection criteria Page 27 Australian Manufacturers DELIVERY ADDRESS 366 Horsley Road MILPERRA NSW 2214 AUSTRALIA ZENER ELECTRIC PTY LIMITED ACN 001 595 428 POSTAL ADDRESS P O Box 4462 Tel 61 2 9795 3600 MILPERRA DC Fax 61 2 9795 3611 NSW 1891 Email zener zener net AUSTRALIA http www zener net O Zener Electric Pty Limited 2001 2002 IM00097B
3. SINE SAVER User s Manual SINE SAVER OPERATION General operation SINE SAVER has a structured arrangement of menus to allow custom setiings for your particular application SINE SAVER is supplied with a link between the En terminal and the 5V terminal which is all that is required to run SINE SAVER from the console A connection between these two terminals must always be made for the system to run Sine Saver ZENER ELECTRIC UP RUN DOWN ENTER EXIT STOP The five pushbuttons and display form a console through which drive features and settings are altered to suit the application When SINE SAVER is first powered up the start banner is displayed for approximately 2 seconds An example of the start banner is shown below It displays the product configuration identification and the software version While the banner is displayed the fan relay driver is switched on It will then be turned off unless heatsink temperatures are high enough to require fan operation This sequence will allow simple verification of fan operation Sine Saver R40 V1 02 IM00097B Page 11 SINE SAVER User s Manual SINE SAVER Run mode Once the start banner is finished Sine Saver is in the Run Mode The top line contains the run variable The second line contains the DC bus voltage and power factor reference values Trip error messages are also displayed on this line An example of the Run Mode display is shown below
4. or components at a hazardous voltage current connected to the AC line or DC link Class II circuit Wiring or components that are in a low voltage low energy circuit that meets certain requirements for voltage current levels and segregation from class I circuits Page 24 IM00097B SINE SAVER User s Manual SINE SAVER Trouble Shooting Guide LCD backlight does not Input power wiring not Check input power wiring refer to SINE SAVER illuminate connected properly Electrical Installation Diagram Input voltage not within Measure the input voltage at SINE SAVER input specification terminals Check with specifications No 24VDC supply Check output of SMPS No line current Enable signal is not Check that the EN terminal is connected to 5V active Check that the ENABLED message is displayed V LIMIT message Input voltage has See SINE SAVER General Specifications for input appears continuously exceeded maximum voltage ratings rating OPT SC message Hardware level Check power components appears protection in power stack activated OC Line current was Check system current ratings greater than SINE SAVER s maximum current OV Input voltage has See general specification and check the input is message appears exceeded maximum within ratings ratings Check input supply for voltage transients Fix the external source OT message Ventilation problem Ensure operating ambient
5. 7 Once satisfactory DC voltage control has been achieved other equipment may be connected to the DC terminals of SineSaver as required by the particular application 8 Ensure that the equipment connected to the DC side of Sine Saver includes an interlock so that it cannot run unless SineSaver is running Relay RL1 on the control board may be used for this purpose It should be configured for function O01 RUN factory default setting See page G04 RELAY1 on page 22 for additional information The maximum DC voltage is 400 800 or 1050 for L 240VAC R 480VAC and J 600VAC models respectively See specifications for additional detail IM00097B Page 9 SINE SAVER User s Manual Application specific settings This section provides some basic notes that may be helpful in setting up Sine Saver for particular applications Ultra low harmonic rectifier for AC motor inverters or similar equipment Line side converter for 4Q AC motor inverters Choose a fixed DC voltage reference this is the factory default setting Set DC voltage reference to be approximately 10 higher than the peak value of the highest expected AC line voltage Eg for a 460V AC supply with expected variation of 6 use a value of 460 X 1 06 X 1 414 X 1 1 758 V Note that typical AC drives that could be supplied with DC power by Sine Saver will have over voltage trip points around 800V so the DC voltage must be set sufficiently below this value to allow for mo
6. R09 SELECTOR This feature allows the actual reference used to be selected from one of eight possible sources according digital inputs on the terminal strip It is a convenient way to allow external digital signals to determine the source of the reference to be used The references available depend on whether the selector is used for the DC link voltage or the reactive current reference Selector used for the DC link voltage reference Reference Terminal D2 Terminal D3 Terminal D4 R01 V PRESET 1 Low Low Low R02 V PRESET 2 Low Low High RO3 V PRESET 3 Low High Low R04 V PRESET 4 Low High High RO5 V PRESET 5 High Low Low RO6 LVC PRESET 1 High Low High R07 LVC PRESET 2 High High Low R08 LVC PRESET 3 High High High Selector used for the reactive current reference Reference Terminal D2 Terminal D3 Terminal D4 R10 Li PRESET 1 Low Low Low R11 Li PRESET 2 Low Low High R12 Li PRESET 3 Low High Low R13 Li PRESET 4 Low High High R14 PF PRESET High Low Low R15 ZERO High Low High R16 AN1 High High Low R17 CONSOLE High High High 2 R14 is reserved for future use as PF PRESET It has no function in the current software version IM00097B Page 21 SINE SAVER User s Manual G00 INPUT OUTPUT G01 RUN COMMAND Available choices G02 ENABLE G03 CONSOLE PB default This selection allows source of the run command to be selected Selecting G
7. RO5 V PRESET 5 R06 LVC PRESET 1 R07 LVC PRESET 2 R08 LVC PRESET 3 R09 SELECTOR IM00097B Page 17 SINE SAVER User s Manual This reference is the set point used by the DC bus voltage control function of Sine Saver The DC bus voltage control is active whenever Sine Saver is running F02 REACTIVE CUR Available Choices R09 SELECTOR R10 Li PRESET 1 R11 Li PRESET 2 R12 Li PRESET 3 R13 Li PRESET 4 R14 Reserved for future use as PF PRESET R15 ZERO default R16 AN1 R17 CONSOLE The reference source selected here determines how the reactive component of the line current is controlled In many applications the reactive current is undesirable and the default choice of Zero is used Use the A and Y push buttons to select a reference and press Enter to accept the selection or ESC to abandon Reference list ROO AN1 When the Analog Input is selected as a reference for any of the different operating modes two parameters need to be checked SINE SAVER will let you do this every time the analog input is selected as a reference They are RO1 REF AT 0 and R02 REF AT 100 Use the up or down buttons to change the values if required Press enter to accept the value or ESC to abort R18 INPUT CONFIG R18 INPUT CONFIG Available choices R19 0 10V 00 R20 0 5V 01 default R21 4 20mA 11 This selection allows different signal ranges to be accommodated The values in brackets eg 00 serve a reminder to set the switch
8. Range 48 to 62 Hz Use the up or down push buttons to adjust this setting to the line frequency Press Enter when finished and the frequency is displayed or ESC to abort the adjustment Page 14 IM00097B SINE SAVER User s Manual B04 IMPEDANCE Default value 15 Range 2 25 Use the up or down push buttons to adjust this setting to the line inductor impedance Press Enter when finished or ESC to abort the adjustment impedance is defined as the percentage of the system phase voltage ie phase to neutral voltage that is dropped across the line inductor at the system nominal line current C00 PERFORMANCE This section allows you to set the system performance characteristics C01 CARRIER FREQ Available Choices C02 4kHz default c03 8kHz This value sets the switching frequency that the system uses to control the line currents This frequency is noticeable as a ripple on the line current waveform and also an audible sound from the line inductor Higher settings reduce the ripple on the line current waveform resulting in a lower level of distortion Semiconductor switching losses will increase with switching frequency For most efficient operation select 4 kHz Press Enter then use the up or down buttons to choose the CARRIER FREQ Press Enter when finished to accept the choice or ESC to abort C04 BUS P I D C05 BUS PB Default value 15 Range 10 to 1000 C06 BUS Ti sec r Default value 0 10 Range 0 t
9. Type 1 coordination requires that under short circuit conditions the contactor or starter shall cause no danger to persons or installation and may not be suitable for further service without repair and replacement of parts Type 2 coordination requires that under short circuit conditions the contactor or starter shall cause no danger to persons or installation and shall be suitable for further use SKiiP Semikron Integrated Intelligent Power Module see www semikrom com for further information Power stack An assembly of power semiconductors typically IGBTs diodes together with heatsinks DC link capacitors etc Switchgear A general term covering power switches contactors fuse circuit breakers etc Usually applied to power components rather than control circuit elements PU A measurement system in which all values are stated in terms of their magnitude relative to the nominal value of the quantity PU impedance base The nominal impedance value used for PU impedances Generally nominal phase voltage rated current Line reactor An inductor connected in series with the AC line for the purposes of increasing the AC line impedance seen by the equipment SMPS Switch Model power Supply It A protection function that simulates the heating effect of current in a conductor Class circuit Any wiring or components that are not in a class II circuit Typically this will be wiring
10. not for use in life support appliances devices or systems where malfunction of the components can reasonably be expected to result in personal injury or death Customers using or selling Zener products for use in such applications do so at their own risk and agree to indemnify Zener for any damage resulting from improper use or sale THE CONTENT OF THIS MANUAL IS SUBJECT TO CHANGE WITHOUT NOTICE SINE SAVER User s Manual WARNING Sees WANNA 5 RECEIVING us Ned orc an DA See a te PIN a Meee ty MU OM tae 5 SOFTWARE ies dst E A EE ES 5 INTRODUCTION A E TE 6 N ONE T EEE A T E IAA 6 OPERATING MODES an 6 DC LINK VOLTAGE REGULATOR AC LINE DC LINK ooocicccccccccccnccccccnnnnnnnono nono nono nono no conoci 6 REACTIVE POWER COMPENSATOR AC LINE eee 6 ENERGY RECOVERY CONVERTER DC LINK gt AC LINE oocicicccccccococnccnncnnncnnnnnnno nono no nono no nono nocacicnin 6 PRINCIPLE OF OPERATION nas 7 HOW DOES SIMESAVER WORK ocn as 7 SINE SAVER INITIAL START UP as 9 APPLICATION SPECIFIC SETTINGS ocn nana 10 SINE SAVER OPERATION rms 11 GENERAL OPERATION ci enema 11 SINE SAVER RUN MODE as 12 CONSOLE PUSH BUTTON OPERATIONS ceccssosescecescsseccececeececeecacecsecaceesaceecateceasatsevatercatetestanereatenes 12 SINE SAVER MENU MODE mas 13 CONTROL CONSOLE MENU 2 te o ane a loa Lar 13 AOO DISPLAY ee 0 PSE er wano osy rozlew reece ee NT 13 A01 RUN VARIABLE 0 emma 13 A02 MENU PROTECT cuclillas 14 AOS SET DERAUI E ie lao atar te
11. R 808VDC J 1050VDC 400VDC Environmental Storage Temperature 20 to 70 C 4 to 158 F Operating Temperature 0 to 50 C 32 to 122 C Relative Humidity 5 to 95 Non condensing Altitude 0 to 1000m 0 to 3281 feet User Parameters Standards Compliance Segregation between Class and Class II circuits and clearance creepage distances designed to meet the requirements of UL 508C Local Controls Up Run Down Enter Exit Stop Terminal Strip Digital Inputs 5V and DIG COM 5Vdc supply 40mA max current D1 to D4 and EN Digital Inputs Logic High 3 to 5Vdc Logic Low 0 to 2Vdc Analog Input Vref and AN COM 5Vdc Supply 5mA max current IN and IN Differential Input 0 to 5V range 0 to 10V range 0 to 20mA range 4 to 20mA range Common mode range 25Vdc to AN COM Relay Outputs 2 Form C Outputs Single pole change over contacts Contact Rating Resistive load 5A 250Vac 5A 30Vdc Contact Rating Inductive load 2A 250Vac 2A030Vdc IM00097B Switching 4 or 8kHz user selectable Frequency Current Limit 20 to 100 of max overload current Pi 20 to 110 of max cont current Auto Restart Number of restarts 0 to 20 Reset time 0 1 to 20 minutes References Analog Input Console Reference Presets Line compensated presets Digitally controlled reference selector The following functions can be enabled or disabled Menu Protect Reset by Power Failure Automatic Restart
12. angle is between the line voltage and the inductor current which is the line current is zero ie exactly in line the power factor is 1 power factor COS 0 1 The control system in SineSaver can manipulate the inverter output voltage to be anywhere in the circled area This means that the AC line current can be controlled to be any required magnitude and angle so operation at any power factor is possible This allows the line current to be reversed to provide IM00097B Page 7 SINE SAVER User s Manual regenerative operation or set at 90 to the line voltage to give only reactive current SineSaver can also do both of these at the same time by automatically choosing a magnitude and angle for V inverter that results in the required level of energy transfer in mathematical terms the real current and also the necessary reactive imaginary current to achieve the desired power factor In normal operation ine aver adjusts the real component of line current to always keep the DC bus voltage at a preset level by means of an inbuilt PID controller The reactive current can be independently set by the user to the required value In applications that just involve real power transfer between the AC and DC sides in either direction a unity power factor is desirable so the reactive current reference is set to zero Page 8 IM00097B SINE SAVER User s Manual SINE SAVER Initial Start up This procedure assumes that you have already in
13. displayed menu item or accept the value being adjusted Pressing ESC will abort value adjustment or the current menu If the current menu is the top of the menu tree the console changes mode to the Run Display mode Pressing STOP will reset any trip condition Pressing A or Y will either increase or decrease the console reference value Pressing will have no effect Pressing ESC will abort the Run Display mode and the console changes to the Menu mode SINE SAVER User s Manual Sine Saver Menu mode The Menu mode is entered from the Run mode by pressing the ESC push button pressing ESC again will return to Run mode Use the A and W push buttons to display each menu item To enter the menu press the J push button This action will either display another menu or display a setting ready for adjustment Control Console Menu A00 DISPLAY This menu allows selection of run variables It also provides a restore factory defaults function A01 RUN VARIABLE A single run variable is selected from this menu for display on the run screen VO1 Amps V02 Amps Real V03 Amps Imag Line current magnitude Line current in phase real component Line current reactive imaginary component V04 Vac Line Line voltage V05 Vdc Bus DC link voltage V06 Vac Choke Line inductor voltage VO7 kw Line side power real V08 kVAR Line side reactive kVA V09 kWh In Line side total energy consumed from
14. link voltage regulator AC line 3 DC link Ultra low harmonic rectifier for AC motor inverters or similar equipment 4Q AC motor control inverters for elevators hoists high inertia industrial applications centrifuge etc Reactive power compensator AC line Reactive power compensator power factor COS correction AC line voltage regulation can be used to stabilise the voltage of weak electricity distribution lines in rural areas at a much lower cost and better performance than re building the distribution line Energy recovery converter DC link gt AC line Alternative energy systems Energy recovery from DC systems railways Applications with multiple AC motor drives on a common DC link Surplus capacity can be used for power factor correction in any mode Note Regulation of the DC link voltage is an essential part of all operating modes and is always active Page 6 IM00097B SINE SAVER User s Manual Principle of Operation How does SineSaver work Fundamentally SineSaver is a solid state inverter that generates an AC voltage from a DC source using pulse width modulation PWM techniques The AC line connection to SineSaver is always 3 phase This line voltage can be represented as a voltage vector meaning that it has both a magnitude and an angle The concept of a magnitude is clear enough but what about the angle The simplest approach to this is to say we have no control over the line volta
15. temperature is within specification Check fans are rotating freely and there is no build up of dust or debris in blades Visually examine the heatsink fins for build up of dust and debris System is constantly Check SINE SAVER continuous current and overloaded ambient temperature rating IM00097B Page 25 SINE SAVER User s Manual Your SINE SAVER Setup Notes Photocopy this page or complete in pencil User Parameters Date sn 2 1 A00 DISPLAY __ User Default ROO AN1 User _ Default A01 RUN VARIABLE _ vot Amps RI8INPUTGONFIG R2005v o A02 MENU Disabled R22 AMPS LO IN PROTECT BOOACLINE RZ8BAMPSCOHIN Bo LINEVOLTS mestomeurw R25HlINPUTW R26LOINPUTMA coo 4KHz C11 React Td secs 300 R06 LVC PRESET 1 R07 LVC PRESET 2 0 00 _ RO8LVC PRESET 3 DO2 Ft E02 A Rs ALLOWED RHILIPRESET2 RI2LIPRESET3 RI8LIPRESET4 CT RIP PRESET G00 INPUT OUTPUT ee COMMAND GosRevays 606RELAY2 FOO REFERENCES R01 V F02 REACTIVE CUR RiszERO C12 Delay too RHOLIPRESETA Page 26 IM00097B SINE SAVER User s Manual SINE SAVER Specifications AC Line Voltage R 380 to 480Vac 30 J 440 to 600Vac 30 L 208 to 240Vac 30 All these voltages have a tolerance of 15 to 10 Line Frequency 48 to 62Hz DC Over Voltage Trip
16. 02 ENABLE will cause SINE SAVER to run whenever the enable terminal is connected to 5V The UP RUN and STOP console buttons will be ignored G03 CONSOLE PB will only allow SINE SAVER to run if enable terminal is connected to 5V and the UP RUN console button is pressed Pressing the STOP console button or removing 5V from the enable terminal will cause the system to stop G02 is the usual selection for a normal installation G03 CONSOLE PB may be convenient for commissioning and adjusting the system G04 RELAY1 G05 RELAY2 These two menu items permit an individual function assignment to each relay output Pressing enter on these menu items presents a list of output functions with the currently assigned function being presented first Some relay functions require a value to be set When these functions are selected the chance to set the value will follow with the current value displayed first Use the A and Y push buttons to move through the list press Enter to select the new function or Esc to abort Relay Output Functions 004 OFF Relay is de energised OO5 A R FAIL Indicates that the drive could not auto restart as all restarts have been exhausted none 006 I2t TRIP Indicates that the l t overload feature has activated 007 OVER TEMP Indicates that power components are too hot for safe operation Page 22 IM00097B KENA Display Messages SINE SAVER displays a variety of messages on the second line of its
17. 03 SET DEFAULTS This menu allows the factory default parameters to be reinstalled SINE SAVER must be disabled before you can restore the defaults Pressing the Enter button will cause the message A04 CONTINUE to be displayed This is intended as a warning and an opportunity to confirm that you want the factory default parameters installed Pressing the ENTER button again will cause the defaults to be loaded BOO AC LINE This menu allows you to enter line inductor information Press the Enter button to view and modify rated current and inductor value information B01 LINE VOLTS Default value system nominal line voltage Range 380 to 480 Volts AC same as hardware voltage range Use the up or down push buttons to adjust this setting to nominal AC line voltage of the system Press Enter when finished and the voltage is displayed or ESC to abort the adjustment B02 RATED AMPS Default value system nominal line current Range 25 to 150 of system nominal line current Use the up or down push buttons to adjust this setting to the line inductor continuous rated current in amps Press Enter when finished and the current is displayed or ESC to abort the adjustment Entering the rated current of your line inductor determines the operation points for the It feature This setting is not used to limit the output current of Sine Saver Refer to D01 CURRENT LIMIT for that particular feature B03 RATED FREQ Default value 50Hz
18. 22 GOT RUN COMMAND nade acia o ee ol a o Boga ad LG Bat Kaan 22 COREA ea 22 GOD RELAN 2 ui a IO B 22 RELAY OUTPUT FUNCTIONS gs c ye Eo e ea 22 DISPLAY MESSAGES icc uses eee AREA ARRAS ey ae ele Osad 23 DEFINITIONS zezna alone 24 SINE SAVER TROUBLE SHOOTING GUIDE 0 ee ee eee eee ee ree eee tenner ono n cnn nnnnn nn cnn once cane n cnn nine nnnn nine 25 YOUR SINE SAVER SETUP NOTES uuu ge er eer ener ee et AC AE 26 SINE SAVER SPECIFICATIONS uuu eee aaa aaa aaa aaa aaa aaa 27 Page 4 IM00097B SINE SAVER User s Manual Warning SINE SAVER must be applied installed and operated in a safe manner in accordance with all local rules and regulations In particular it is the system builders responsibility to address electrical safety machinery safety and electromagnetic compatibility issues The system may also contain high energy circuits that may be hazardous A typical SINE SAVER system will include capacitors that take greater than one minute to discharge below 50Vdc Ensure that all power sources are isolated and all capacitors discharged to a safe voltage before working on any part of a the system Receiving Inspect SINE SAVER for any shipping damage If any damage is found report it to the carrier immediately Access the inside of the controller and visually check for any damage Do not attempt to operate SINE SAVER if any damage is apparent After the initial inspection SINE SAVE
19. 6 LO INPUT mA Default value Range This value specifies the minimum value of the input signal range to be used with the analog input terminals For example if the signal range is 8 to 20 mA select the 4 20 mA range R18 INPUT CONFIG R21 4 20mA and then set R26 LO INPUT mA to 8 mA This adjustment is only used when the analog input 4 20 mA range is selected Use R24 LO INPUT V for the voltage ranges R27 HI INPUT mA Default value Range This value specifies the maximum value of the input signal range to be used with the analog input terminals For example if the signal range is 4 to 12 mA select the 4 20 mA range R18 INPUT CONFIG R21 4 20mA and then set R26 HI INPUT mA to 12 mA This adjustment is only used when the analog input 4 20 mA range is selected Use R25 HI INPUT V for the voltage ranges R17 CONSOLE When this is selected the reference is set from the console using the A and W arrows when SINE SAVER is in the run mode IM00097B Page 19 SINE SAVER User s Manual R01 V PRESET 1 R02 V PRESET 2 R03 V PRESET 3 R04 V PRESET 4 RO5 V PRESET 5 Default values 155 0 0 0 0 respectively Range 0 to 200 These presets provide extra reference values for the DC link When a preset is selected it is adjusted using the console A and W push buttons Presets 2 3 4 and 5 are used in conjunction with the reference selector R06 LVC PRESET 1 R07 LVC PRESET 2 R08 LVC PRESET 3 Default value 109 Ran
20. AC line V10 kWh Out Line side total energy returned to AC line V11 Amps Ft Thermal overload level V12 deg C T1 Power circuit temperature 1 C V13 deg C T2 Power circuit temperature 2 C V14 deg C T3 Power circuit temperature 3 C V15 deg C T4 Power circuit temperature 4 C V16 deg C T5 Power circuit temperature 5 C V17 deg C T6 Power circuit temperature 6 C V18 deg C T7 Power circuit temperature 7 C V19 deg C T8 Power circuit temperature 8 C V20 deg C HS Temperature of the hottest power circuit temperature sensor that is included in the semiconductor virtual junction temperature C V21 deg C Tj Semiconductor virtual junction temperature C V22 line Hz Line frequency Hz V23 pf Line side power factor COS IM00097B Page 13 SINE SAVER User s Manual A02 Menu Protect The feature protects the entire menu mode with a code so that settings and configurations are protected from unauthorised changes After you enable this feature return to the Run Screen The next time anyone presses ESC to enter the Menu mode the following message will appear A02 Enter Code 0 Use the A and Y buttons to adjust the code value to the number 1470 Press Enter to accept If entered correctly the familiar menu mode will be displayed If the correct code is not entered you are returned back to the run screen Note that protection code cannot be changed so you can always gain access to the menus by reference to this manual A
21. R can be repacked and stored in a clean dry location until it is required for use DO NOT store this equipment in an area where the ambient temperature will fall below 20 C 4 F or rise above 70 C 158 F DO NOT store this equipment in areas of high condensation or corrosive atmosphere Proper storage is necessary to ensure satisfactory controller start up and performance Software This manual applies to SINE SAVER software revision 1 02 The software revision is displayed briefly at power up IM00097B Page 5 SINE SAVER User s Manual Introduction SINE SAVER is a regenerative converter active rectifier Sine Saver may be used alone as a high quality reactive power compensator or in conjunction with other equipment to transfer power between AC and DC systems in both directions at any desired power factor on the AC side The AC side line currents are near perfect sine waves Applications Typical Sine Saver applications include Ultra low harmonic rectifier for AC motor inverters or similar equipment Line side converter for 4Q AC motor inverters Alternative energy systems Energy recovery from DC systems eg railways Reactive power compensation power factor COS correction Line voltage stabilization for weak distribution lines eg rural areas Operating modes In order to accommodate a wide range of applications Sine Saver can be programmed to achieve the following DC
22. Sine Saver User s Manual SINE SAVER User s Manual ZENER TECHNOLOGY AND QUALITY ASSURANCE Since 1978 Zener Electric has supplied many thousands of AC drives to industry These drives have been installed into numerous applications resulting in a wealth of in house experience The Zener SINE SAVER controller is the culmination of this experience modern technology and industrial application requirements The Zener Quality Assurance program ensures that every SINE SAVER manufactured has proven to operate correctly in the production test bay before dispatch SINE SAVER PRODUCT WARRANTY Zener Electric warrants SINE SAVER against defective workmanship and materials for a period of 12 months from the date of dispatch Such defects will be rectified free of charge for both labour and material at Zener Electric s premises subject to di Zener Electric s customer raising an order upon Zener for service and or repairs subject to a warranty claim The order is to state particulars of the model and serial number the date of original purchase and invoice delivery docket number 2 All damage resulting from incorrect installation or use other than in accordance with the instruction manuals issued by Zener Electric is excluded from this warranty 3 The Warranty being rendered invalid if the product is misused or if any unauthorised alteration modification or substitution of any part of the product be made or the serial number of the product is de
23. board or the power interface board as a invalid type The following messages indicate the current operating condition of SINE SAVER Run Message Meaning 5 535 CHARGING SINE SAVER is waiting for the DC Bus capacitors to be fully charged CURRENT LIMIT The line current is at the maximum overload point NOT ENABLED SINE SAVER is ON but has no enable signal RUNNING SINE SAVER is operating normally IM00097B Page 23 SINE SAVER User s Manual Definitions Term Definition Line voltage The voltage between two phase conductors in a 3 phase system Phase voltage The voltage between one phase conductor and the neutral conductor even if the neutral conductor does not physically exist Nominal line voltage The value of AC line voltage used for design purposes Rated current The maximum value of current that can be sustained indefinitely Overload A current value exceeding the rated current Only permitted for a limited time current Line voltage A reference value that automatically follows the ratio Actual AC line voltage compensated Nominal AC line voltage LVC An uncontrolled 3 phase rectifier configuration defined in IEC 60146 B6U AC B6U According to IEC 60947 4 1 also AS NZS 3947 4 1 2001 Low voltage switchgear Type and controlgear Contactors and motor starters Electromechanical contactors and coordination Type II coordination motor starters
24. display to indicate the drive status These messages may be divided into two types trip messages and run messages SINE SAVER will protect the power components under a variety of fault conditions When one of these conditions is experienced SINE SAVER will trip shut down the line current output and display one of the following messages The message will be displayed until the fault is cleared and a reset signal is applied The reset signal may take the form of a 5V pulse applied to the control board reset terminal D1 pressing the stop button manually or operation of the power fail reset or auto restart functions TripMessage Meaning OUTPUT SHORT The power semiconductor proteciion has stopped the system HOT DEVICES The calculated virtual junction temperature of a power semiconductor has exceeded the maximum permitted temperature CHARGE RLY OPEN There is no feedback signal to confirm that the slow charge contactor is closed OVER VOLTAGE The DC Bus voltage has exceeded its maximum value OVER CURRENT SINE SAVER control system has detected an excessive line current value LOW BUS VOLTS The DC Bus voltage has fallen below its minimum threshold POWER FAILURE All input phases on the input power supply are either low or missing HOT HEATSINK One or more temperature sensors in the power semiconductor seciion is too hot I2T TRIP An t trip has occurred UNKNOWN PWR BRD The SineSaver software does not recognise the power
25. es on the control board to appropriate positions R22 AMPS O LO IN Default value 0 Range 100 to 100 This value specifies the reactive current reference value when the minimum input signal is present at the analog input terminals See R25 and R27 to set the maximum value of input signal to be used R23 AMPS O HI IN Default value 0 Range 0 to 100 Page 18 IM00097B SINE SAVER User s Manual This value specifies the reactive current reference value when the maximum input signal is present at the analog input terminals See R24 and R26 to set the minimum value of input signal to be used R24 LO INPUT V Default value Range This value specifies the minimum value of the input signal range to be used with the analog input terminals For example if the signal range is 3 to 10 volts select the 0 10V range R18 INPUT CONFIG R19 0 10V and then set R24 LO INPUT V to 3 volts This adjustment is only used when an analog input voltage range is selected Use R26 LO INPUT mA for the 4 20mA input range R25 HI INPUT V Default value Range This value specifies the maximum value of the input signal range to be used with the analog input terminals For example if the signal range is 0 to 9 volts select the 0 10V range R18 INPUT CONFIG R19 0 10V and then set R25 HI INPUT V to 9 volts This adjustment is only used when an analog input voltage range is selected Use R27 HI INPUT mA for the 4 20mA input range R2
26. estarts This number indicates how many times SINE SAVER will attempt to restart after a trip For the system to run after the trip is cleared the drive must be given a valid run command Select 0 restarts in order to de activate Auto Restart Use the up or down buttons to adjust A Rs ALLOWED Press Enter to accept the adjustment or ESC to abort E03 A R CLR TIME Default value 20 min Range 0 1 to 20 min If SINE SAVER operates for the A R CLR TIME without any trips occurring the number of restarts is reset to the value of A Rs ALLOWED Set the A R CLR TIME to 0 1min for infinite auto restarts Use the up or down buttons to adjust A R CLR TIME Press Enter to accept the adjustment or ESC to abort E04 Reset by PF Available Choices H00 ENABLE H01 DISABLE default Enabling this facility allows SINE SAVER to reset all trips when a momentary power failure occurs This feature is useful in power up start applications because trips may be cleared without any extra switch logic by turning the power off and straight back on again without waiting for the system to completely power down Use the up or down buttons to select either Enable or Disable Press Enter to accept the selection or ESC to abort FOO REFERENCES This lets you set the voltage and current references for the different SINE SAVER operating modes F01 BUS LEVEL Available Choices R01 V PRESET 1 default R02 V PRESET 2 RO3 V PRESET 3 R04 V PRESET 4
27. faced or altered 4 The cost of transportation both ways is to be met by the owner if it s necessary to return the product or any part of it to Zener Electric s premises 5 A charge being accepted by the owner for traveling time and expenses incurred in connection with warranty service at the user s site as requested by the owner 6 If the product was not purchased from Zener Electric directly then a warranty claim must be lodged with the original supplier in the first instance Repairs will not be effected by Zener Electric unless approved by the original supplier Goods not of our own manufacture incorporated in our supply or sold by us carry their maker s warranty only 7 Goods returned for claim under warranty will be accepted on the condition that should the claim be rejected then all costs including inspection will be charged to the customer s account 8 Zener Electric is not liable for any consequential loss SAFETY Your SINE SAVER must be applied installed and operated in a safe manner It is the responsibility of the system builder and user to ensure compliance with all regulations and practices covering the installation and wiring of your SINE SAVER The instruction manual should be completely read and understood before attempting to connect or operate SINE SAVER Only skilled personnel should install this equipment This equipment contains a number of components that are designated by their various manufacturers as
28. ge 105 to 137 These presets are DC link voltage reference values with the special property that they are compensated with respect to line voltage at the time of use The effective value of line voltage compensated LVC presets is Set value X measured RMS line voltage X 1 414 LVC presets are intended to be used as DC bus level reference values in applications where it is desirable that the DC bus voltage reference tracks the line voltage in order to avoid circulation of energy when uncontrolled rectifiers feed the same DC bus When an LVC preset is selected it is adjusted using the console A and Y push buttons LVC presets 2 and 3 are used in conjunction with the reference selector R10 Li PRESET 1 R11 Li PRESET 2 R12 Li PRESET 3 R13 Li PRESET 4 Default values 155 0 0 0 0 respectively Range 0 to 200 These presets provide extra reference values for reactive current When a preset is selected it is adjusted using the console A and W push buttons These presets can also be used in conjunction with the selector R14 Reserved for future use Page 20 IM00097B SINE SAVER User s Manual R15 ZERO Default value 0 Range Not adjustable This is simply the value 0 Typically it will be used as the reactive current reference in applications that do not involve reactive current control Note It is also possible to generate zero from the reference selector both methods produce the same result SELECTOR
29. ge so we will just consider it to be zero degrees and measure everything else relative to this In the diagram below the line voltage is represented by the horizontal line angle 0 marked as Line voltage Line current Line voltage Line frequency Inverter voltage Now the line voltage vector is really rotating at line frequency that is it goes through a complete 360 rotation either 50 or 60 times per second depending on the local line frequency Drawing the line voltage vector as a stationary line is convenient and can if necessary be shown to be appropriate in mathematical terms In the diagram above the inverter output voltage inverter voltage is also a 3 phase voltage advanced in phase by around 207 relative to the line voltage vector V line You can see that it has a slightly larger magnitude the line is longer as well In a SineSaver system there is an inductor connected between the line voltage and the inverter output voltage This is the line reactor In the diagram the voltage across the line inductor is simply the difference between V line and V inverter This has been drawn in as the vertical line and for the conditions shown just happens to be at 90 to the line voltage vector Now it just so happens that the current in an inductor in an AC circuit always lags the applied voltage by 90 so this means that they current in the inductor will flow back in line with the AC line voltage Since the
30. got o iaa dc i 18 R2Z3 AMRSG FHEINI to a o a a ad NM LAG e NAWA 18 RILLO INPUT V i aa eye zara acan Geert ani Swe dowi da Et owa eae Odlot ratte acs dun lt a aoe 19 POS WISIN PU ME A a AC PONY e aa A PY z anh zad E 19 R26 LO INPUT MA dd 19 R2 HIINPUT MAGZ w oc se taa M R odd dy O A ca ice da EE Ns kapa daty At 19 RIZ CONSOLE saa aa a o R a Re cee Mag oz ani aid A Mai 19 ROT PRESEA o turk atthe gh Ada 20 RO2 VPRESET Zain Rear wood a ect relatan aio Sevi crono cido a ie E act NE 20 ROS ViPRESETD cinta a e ii Roe a ah 20 ROAM PRESET Aden fa tte ee ances Sage EO ani Sue dwie dl ob Mane is ces Ha e tt RO 20 ROD PRESEA rta a al 20 POGHWG PRESET tic esc cece a adi favs oh eee desd dio a ed sed thee ydy 20 ROZEVG PRESET A ii a AE NONE 20 ROS VW CIPRESE TS 6 aa it tt a dt a a lt ut E Wdy caldo niet td eens 20 RIO EUPRESET e thre eaten eae en A ner at ae ate Sa AOL nas 20 RU PRESET DO ete sets on at Kont Aude ce aty fe cl osi ae th rat ocali fai Y ecu Avid NY 20 RIZ LIPRESETS named arta M ALA A O Aa AW ONET SPAM arca Ts oy OAZIE ATE SNOW LA O 20 IM00097B Page 3 SINE SAVER User s Manual RES LTPRESET4 ia se e SOS Oh I Te Ele 20 R14 RESERVED FOR FUTURE USE e uee eee aaa aaa aaa aaa aaa aetna eee aaa aata 20 PUD ZERO to o iR KKA DYNAMO RER ADA NENA NA SKORE ACE Loga 21 SELECTOR a da lies 21 ROS SELECTOR 2 28 58 eit ll dol o add dl Eda ka Met 21 GOO INPUNT OUTPU a oo a o or a art semen Bact e eee
31. h m dak 14 BOOAGIEINE oo So e rito soto e col e pario ente di ed nor dle eto el ed od 14 BOTIEINE VOLTS Cita oy repre arcano i carter e LND ette e tano ara 14 BO2 RATED AMPS a icon ea Owy stato Obama sa ill del asa dla bobas da cil esa acidos 14 BO3iRATED FREQ adne ooo ON az ean ac hod tar 14 B04 IMPEDANGE a yo dac de ai wo A az o ele e o edo yk 15 COO PERFORMANCE eee eee aaa 15 C07 GARRIER FREQ zaw ada oai oai dany daje Pa tho wt lady dawn d tau dla oot E E 15 COA BUS PA Diner na Ac Ao wad Ya EEE at aaa dt ob Retin a2 CLAN A Akagi 15 COBIREACTWE PID parn a Nd r o s dadza do dy ee tly et due diy EA 15 DOO PROTECTION e 0 a e d Re E dan a wad a toy szy ara 16 DOT GURRENTHLIM 2 eee cn ato Z a ani a lok ot da GODY owi urna et 16 DA aa za A Po oo sat YO aan ZN dd LS a E oz SAM 16 DOZI A ERO OCR NARNIA ROSEN 16 E00 STOP RUN Mt ut M Wea e ld NE 17 EOI AUTO RESTART enone o z we dawaj Magen dla i tae teat AR cid 17 E02 A RS ALLOWED e e e al al 17 EOS V2 Bd Fa Lae Reset tyz da Bua wz a ee cr oai yty A 17 E04 RESET BY PRoto a tie Aer nest a Sa pada dra it w fw Aa 17 FOO REFERENCES ec tecetecnt A yt aw dt aa Yon TE etn 17 FOMBUS LEVEL cert ee ao etarra cine 17 FOZ REACTIVE CUR oa ecc rca ttn o adn i race eae o ito o e a ait 18 REFERENCE LS Tr e el od big ica OS 18 ROO AN aa rd de te dt ecos E e ones ae action 18 RI8INPUTRCONFIGN own e e eto do arios nO Ages 18 R22 AMPS OO Naa ats rienda di ido deci not dn roi sia Devi ar
32. ill take approximately two minutes The time to trip will shorten the further the line current exceeds the I t value If power is removed from the drive after an Ft trip the system should be allowed to cool down before it is restarted Direct sensing devices such as microtherms or thermistors may be fitted to the line inductor or other power components eg transformers for additional protection D02 Ft Default value system nominal current Range 25 to 100 of system Overload Current listed entered in amps This sets the upper limit of Ft and is entered in amps This is equivalent to the usual Ft setting Use the A and Y push buttons to adjust the D02 I2t value and press Enter to accept the value or ESC to abandon changes Page 16 IM00097B SINE SAVER User s Manual E00 STOP RUN This section sets the system stopping and starting modes E01 AUTO RESTART Auto Restart allows Sine Saver to automatically attempt to restart after a trip occurs If Sine Saver trips it will wait 10 seconds then attempt to clear the fault If it is unsuccessful it will keep trying every ten seconds It will do this the number of times specified in A Rs ALLOWED If the fault is cleared and the drive runs without tripping for the A R CLR TIME the number of auto restarts attempted will start counting from 1 again If the trip is cleared by any other means the fault count will start from 1 again E02 A Rs ALLOWED Default value 0 Range 0 to 15 r
33. mentary DC bus voltage excursions caused by sudden load and or speed changes on the AC drive Alternative energy systems Energy recovery from DC systems eg railways The considerations here are generally similar to those discussed above for 4 quadrant drive applications There are additional issues to be considered in energy recovery systems where there may more than one source of DC supplied to the system sometimes over a wide geographic area In some instances a transformer may be required in the AC supply to Sine Saver depending on the grounding arrangements on the DC system The Line Voltage Compensated LVC references available in Sine Saver may be useful in overcoming recirculating energy problems in these systems Reactive power compensation power factor COS O correction Choose fixed DC bus reference at around 10 above the AC supply peak value see 4 quadrant drive notes above Selecting a DC voltage that is too low will degrade the AC line waveform quality Set for external reactive current reference input choose input type and apply a suitable signal from an external reactive current measurement controller device Line voltage stabilization for weak distribution lines eg rural areas The same considerations as for reactive power compensation discussed above apply The external reactive current reference should come from a controller that implements the user s chosen strategy for line voltage control Page 10 IM00097B
34. o 20 0 C07 BUS Td secs Default value 2 00 Range 0 to4 C08 Reactive P I D C09 React PB Default value 300 Range 10 to 1000 C10 React Ti sec r Default value 2 00 Range 0 to 20 0 C11 BUS Td secs Default value 0 00 IM00097B Page 15 SINE SAVER User s Manual Range 0 to4 C12 Delay Default value 1 00 Range 0 to3 C4 11 set the tuning parameters of the internal PID controllers that regulate the DC link voltage and the reactive current C12 Delay provides a means of compensating for small phase shifts in the AC line voltage reference that may occur for example if a potential transformer is used C12 is in milliseconds Use the A and Y push buttons to adjust the value and press Enter to accept the value or ESC to abandon changes Do not adjust these parameters without prior consultation with the factory DOO PROTECTION This section lets you set the system thermal protection features D01 CURRENT LIM Default value System overload current Range 25 to 100 of System Overload Current This sets the maximum line current of Sine Saver Press Enter then use the up or down buttons to adjust the CURRENT LIM Press Enter when finished to accept the adjustment or ESC to abort D02 I t The l feature estimates the heating of the line inductor according to the line current When the estimated heating exceeds 1 setting the drive will trip on Ft For a system running at 110 of its I t current this w
35. stalled and wired according to the instructions in the Sine Saver Application Guide IM00096 and that the various user adjustments are in the factory default state See the Sine Saver Operation section of this manual for information on restoring factory default settings Read the Sine Saver Operation section of this manual to become familiar with the way that various settings can be customized before you attempt to start up Sine Saver WARNING Hazardous voltages will be present during this procedure This equipment must only be installed or adjusted by skilled personnel 1 Temporarily disconnect any wiring to the DC terminals of Sine Saver 2 Connect a voltmeter capable of safely reading the maximum DC voltage to the DC terminals of Sine Saver 3 Apply AC line power to Sine Saver and observe that the DC output voltage rises to approximately AC line voltage X 1 4 4 Start SineSaver by pressing the UP RUN button Observe that the DC voltage rises by about 10 The exact value depends on the setting of the DC bus voltage 5 Set the DC voltage to the required value The default value will be suitable for the majority of applications In the factory default state Sine Saver uses RO1 V PRESET 1 to determine the DC bus level Edit this setting to change the DC bus voltage 6 Other adjustments may be made according to the application See application specific settings section below for suggested settings for various applications

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