Three-phase Converter FVC series User's manual
Contents
1. 24V Max current sink from each Max current for each input 4mA 24Vdc output 500mA MUGL Page 14 of 38 rev 18 November 2009 24V 20 30V l O section The I O section of the interface connector is made of 2 outputs PNP type at 24V Pin 11 and 12 1 Emergency input pin 3 1 24V supply output limited at 100 mA max 2 Pins assigned for a 24V supply 4 GND e 10 VCC ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 15 of 38 rev 18 November 2009 The inputs have the following function e Input 1 Allows to START and to STOP 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 2 DB15 RS485 connection 5V DB15 Pinout RS485 section 1K A B GND 1K 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 resistances of 1Kohm connected as in the diagram ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 16 of 38 rev 18 November 2009 6 3 DB15 analog connections DB15 Pinout Analog section ANALOG section The Analog section o2. To REF1 fro modulator outer loop oS eee Se ee ee oe i i a t ia a m ae ai D m a a a 10 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 32000pS 0 integral disabled It s the integration time of the regulation 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 the offset Td range dt 32000uS 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 can not be modified Positive integral limitation range 0 100 It s the maximum value the integral variable can take Negative integral limitation range 0 100 It s the minimum value the integral variable can take ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 22 of 38 rev 18 November 2009 Positive derivative limitation range 0 100 It s the maximum value the derivative variable can take Negative derivative limitation range 0 100 It s the minimum value the derivative variable can take Z T R block The Z T R block ensure the correc
3. la 67 5 4 J 250 J 50 sos 4 samt igo sam Tensione Frequenza Scola 11 Legoif seii Stato Halt a Scrittura Automatica 754 E 55 Jn a E 52 50 72 5 50 75 257 7225 b 47 5 725 4 N Fi 0 250 5 80 Comunicazione i Above right it is possible to set the command sources Sorgente riferimento source reference e da pannello front panel potentiometer e analogico analog input 1 0 10V e seriale serial interface Sorgente Start Start source e pannello seriale front panel serial interface e ingresso digitale digital input EA Note In order to control the converters with the software you need to set Sorgente riferimento seriale serial interface Sorgente Start pannello seriale bottom left you can set the FVC voltage and frequency outputs e With digital potentiometer e By entering the number expressed in in the box under the potentiometer e Using increment and decrement arrows keys placed under the potentiometer Once the value is set click on the button scrivi to transfer it to the converter If the box Scrittura Automatica is selected each modification of the reference will be automatically written in the converter With the Start and Stop buttons it s possible start and or stop the supply of energy ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 31 of 38 rev 18 November 2009 Under the voltage c
4. on front panel jacks or bars rack version on terminal blocks inside the cabinet metal cabinet version on front panel on front panel ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 3 of 38 rev 18 November 2009 Front panel example Emergency Voltage Frequency Mains line breaker setting setting Multifunction connector 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 This 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 AUTOMAZIO
5. 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 s 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 X D ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 7 of 38 rev 18 November 2009 1 3 Compliance declaration C MANUFACTURER DECLARATION OF CONFORMITY The Zenone Elettronica Converter FVC 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 Electromagnetic Compatibility Directive 2004 108 EEC EN 61000 6 1 CEI EN 61000 6 1 2 ed 2007 10 Electromagnetic compatibility EMO Part 6 1 Generic standards Immunity for residential commercial and light industrial environments EN 61000 6 3 CEI EN 61000 6 3
6. for this specific converter 11 1 Connecting the equipment to the PC The converter 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 GesPWM is executed the following mask will appear _ Gestione PWM amp Controlli ii Versione FW MISURE By means of the menu Set it s possible to TOMATE voit select the parameters for the serial link UR a vor m PC port and baud rate Temperatura 9000 Gradi In this case the baud rate must be 9600 STATO ENABLE PWM ACLine E p BYPASS Autoripristinanti SHUT DOWN O Limite Corrente O SovraTensione o NON Ripristinanti SottoTensione FAULT Q Temperatura Q Precarica O Errore NTC Q RESET ndirizzo EN Indirizzo DSP 1 Macchina Disconnetti In position 2 must be set ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 27 of 38 rev 18 November 2009 e Indirizzo Macchina machine address Equipment serial address DEFAULT case 1 e Indirizzo DSP DSP address indirizzo seriale del modulo di potenza in this case 1 Once the parameters have been set up as shown above push the button 3 to start the connection In this situation the mask will appear as shown above and it s possible e By means of the button 4 to display the machine state with the readings of AC mains voltage DC BUS voltage temperature of heat sink and the state of the al
7. 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 10 2009 Zenone Eletrronica S r l Luigi Zenone A nim FX Copyright Acknowledgement EN publications are subject to the Copyright of IEC c ELETTRONICA AUTOMAZIONE STRUMENTAZIONE ZENONE MUGL Page 8 of 38 rev 18 November 2009 1 4 Identification label Each equipment is identified by the following label We invite you to consider the data shown in it as indispensable for the product traceability and to communicate them for eventual request for support ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE Model ver Serial no Vin Pin Scale Firmware Lo ve Serial address O date of calibrationdelivery Lo C mod INF 007 made in italy ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 9 of 38 rev 18 November 2009 2 Preliminary operations 2 1 Working environment The converter is designed for indoor use BE esc ME 40 Place the device on a suitable support or on a plane surface for good stability Be sure that proper ventilation is
8. Command mask eostce sees etui ev stes see vae s ya vn ut ur Ou Wess tiles andes sieves tileven se goed ede SR E anes 29 13 Communication protocol V1 1 acies e etae nina ea aas aa paa E a Ua XE A Aor P ERES 32 ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 5 of 38 rev 18 November 2009 1 Preface 1 4 How to use and understand the instructions provided in this manual 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 Do not expose the Equipment 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 38 rev 18 November 2009 Attention
9. 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 ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 38 of 38 rev 18 November 2009 Test start Command Reply Note It s possible to start the test only if in remote mode and the 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 Test stop Command Reply Note It s possible to stop the test 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 IND
10. Supply voltage to high gt 460V Check the mains voltage Current limit Maximum allowed current Check the load or the parameters settings exceeded NTC error Fault in the temperature Contact the assistance measurement circuit Fault IGBT failure Contact the assistance Precharge Malfunction of the precharge Check the precharge relay capacitors circuit If the fault persists contact the assistance ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 18 of 38 rev 18 November 2009 8 Converter diagram Mains Input Output PWM modulator Serial comm Command O Control unit FVC basic diagram ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 19 of 38 rev 18 November 2009 9 Control scheme The FVC converter has two control units one for regulation and one for central management both are externally accessible and modifiable through the appropriate programs e Control and regulation unit by means of GesPWM software e Central management unit by means of FVC Manager software 10 Control and regulation unit The converter 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 Inner loop with feedback current taken at the output Outer loop with feedback voltag
11. AZIONE ZENONE MUGL Page 33 of 38 rev 18 November 2009 General information commands and device options Device serial number request Command epl 0x10 S Serial number Device firmware version request Command Repl x10 F Firmware version Device name request Command Repl 0x10 N Devicenam sd Request and setting device setup mode ommand Reply 0x10 M Setupmode Command 0x11 M Setup mode setting 0 Setup and start from panel 1 2 9 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 ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 34 of 38 rev 18 November 2009 Commands for test main setup Request and sending voltage value Command Reply if IDX ok oxi2 M IDX x12 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 sending frequency value Command Reply 0x12 F 0x12 F Frequency in hundredths of Hz Command Reply 0x13 F Frequency in hundredths of Hz 0x13 F ESI ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 35 of 38 rev 18 November 2009 Request and s
12. ELETTRONICA ZENONE Elettronica S r l Via Nazionale Pianopantano AUTOMAZIONE 83036 Mirabella Eclano AV STRUMENTAZIONE J p i 02407830641 Tel 0825449171 Fax 0825407907 ZENONE Three phase Converter FVC series User s manual Release 18 November 2009 Firmware version V1 01 This manual is an integral and essential part of the product Read carefully and completely the warnings herein contained 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 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 FVC series converters For the correct use of this specific equipment it is recommended to refer to the characteristics data sheet of the converter which is an integral part of this manual CALTEST Instruments GmbH Caltest Instruments GmbH Kohl
13. ENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 13 of 38 rev 18 November 2009 4 4 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 communication by means of FVC Manager software look at paragraph 12 4 5 Measurements display While the output is on the converter shows on the displays the concatenated output voltage between the phases L1 L2 and the current on phase L1 Pressing F1 it s possible to visualize in sequence e FREQ output frequency F1V voltage L1 L2 F1 A current L1 F2 V voltage L2 L3 F2 A current L2 F3 V voltage L3 L1 e F3A current L3 If no keys are pressed within 3 seconds the displays will show the initial condition 4 5 change of scale The FVC converters can have two voltage scales this allows to supply the maximum of energy even with lower output voltages The change of scale is done with appropriate selector on the front panel and has effect only with the equipment in stand by 5 Maintenance instructions e Check periodically the air vents clean them or change the filter if present e Check and tighten periodically the bolts of the connections between the power outputs and the external circuit under test in case of high currents ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE 6 External connections 6 1 DB15 I O connections DB15 Pin Out I O section Vout 24Vcc max 100mA
14. NE STRUMENTAZIONE MUGL Page 4 of 38 rev 18 November 2009 Summary LN uris 5 1 1 How to use and understand the instructions provided in this manual 5 1 2 Safety instructions eiie recen esee anoo exeo nre anre E Reo tss si ee 4o vago Ee ox eo s KESKE KESSENS aee 5 1 3 Compliance declaration iere eene ean nnne EN ne Seer eno Eee aeo eh aeg stss uo eda ere ee era dS 7 1 4 Identification label ecce ee ettet n nie nao EN esteros Toss eee aeo sare eee uo ape ENEEK Eata 8 2 Preliminary operations iaesscdirrxedenen edad Nose dip dix d E neia a DIL as do uad i up dade d add 9 2 1 Working environment eee eee eee ova R Res gua eva v deser Det ee e sU E Dee SU DP e eT PEE 9 2 2 UI spo m nesiete E EE E EE E E EE 9 2 3 Equipment operation ooo iec eo eon Ere ox HERR Rd Re E AAE eO pee d Sense des SE e E Oeo edau iaa 10 3 Ausxihary Inputs 7 OUEDDES i eswaxi pad RENE RER RR SK CERCURARUATRKE ERU P a renant ie nendi UR 11 3 1 1 ID DCN ME M 11 3 1 2 UIDI AM enm 11 3 2 COMMUNICATION Port sensen coe eee eben Rex ERAN E sS queo yog ETE vase ques ee ERU ERTERVPSEE EAT QAS 11 4 Converter operati ioiacessaa Ve ad rex a eR RAE teast Enets Si ENEE EE EEEE I GU 12 4 1 Starting the output of DOWET ceecec cee ececenceceecec ences eme seme se ense enses sense eee 12 4 2 S
15. allowed and no objects obstruct the ventilation openings 2 2 Precautions 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 the equipment functional characteristics could cause burnings WARNING All standard converters 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 WARNING Power connections can generate high temperature spots that ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 10 of 38 rev 18 November 2009 2 3 Equipment operation Connect the equipment 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 which 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 a self diagnostic routine tests the most important equipment functionalities and detects eventual faults In case
16. arms With the RESET button it s possible to reset some stored alarms e By means of the button Parametri PWM to step into the next mask where the PWM parameters are shown and could eventually be changed Parametri PWM Parametri Funzionali Scala 1 WTd KP v Denvata ERR 7 Lim Slope 0 PID Esterno Ti usec 0 Td usec 0 MIN 100 MAX 190 MIN 100 MAX 100 Offset PID 100 PID Interno Corr Diretta 1 Corr Filtrata 0 Ti Td KP v Derivata ERR v Ti usec EJ Td usec 0 KP 8 MIN 100 MAX 100 MIN 100 MAX 100 ZTRAMP o REFRESH The regulation parameters for this type of equipment are those shown with 1 the others must not be changed The sampling timing dt is shown at point 2 In order to change any parameter just overwrite it and push ENTER on the keyboard The button REFRESH provides an over reading of the parameters stored in the memory module ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 28 of 38 rev 18 November 2009 12 FVC Manager software The FVC Manager software allows full control of FVC series voltage sources The FVC Manager can manage up to 32 FVC generators 12 1 Software installation The FVC manager software it s compatible with windows XP and supplied in a compressed package For the installation just click over the proper icon and a
17. ccept the license agreement terms The FVC 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 12 2 Presentation When opened the program shows the following mask Ei FYC Manager f CE ills ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 29 of 38 rev 18 November 2009 12 3 Preliminary operations The first things to do in the initial mask is to enter the COM number on which the converter or the converters are connected Click on porta COM and select the appropriate address if not present click on refresh The Baud Rate for this equipment must be 9600 The Timeout is the maximum waiting time for the acknowledgment by the load that a program command has been accepted After which a serial communication error is generated Once these operations are finished the serial communication can be activated pressing the proper button the green light means activation ok eventual communication errors can be reset with the appropriate button 12 4 identification of FVC connected A this point the program must identify the converters Write in the window at the bottom left the starting address for the search and click on Cerca In this way the program will begin the id
18. e taken at the output The following figure shows the principle of operation 10 1 Control system block diagram Outer loop Inner loop Voltage reference Output Output voltage current The control loops are pre adjusted in production to have a good compromise between speed and stability over most loads in some cases it is necessary to change 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 20 of 38 rev 18 November 2009 10 2 Control system description The control system is based on two PID loops in sequence named Inner loop and Outer loop The inner loop is the fastest and will adjust the current in the load It takes as input the reference of the outer loop The outer loop regulates the output voltage reacts more slowly and it provides the value of current to the inner loop It takes as input the main reference and the feedback comes from the output voltage of the converter Outer loop Integral limitation REF from REF1 to inner potentiometer or loop from input p M ELETTRONICA ZENONE AUTOMAZIONE STRUMENTAZIONE MUGL Page 21 of 38 rev 18 November 2009 Inner loop Integral limitation
19. ending scales Command Repl 0x12 w Scae o Command Repl 0x13 w Scale o Scala Can take values 1 or 2 ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 36 of 38 rev 18 November 2009 Commands for reading the running test values Reading the converter state Command Reply 0x14 E State orresultofconverter Test state o Halt 4 Running Fail failure or malfunction Reading the actual main value Command Repl 0x14 M FA 0x14 M UMIS Actualvalue i FA Necessary in the three phases devices Select the phase to read 1 2 3 if omitted it means 1 Mmillivolt Volt ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 37 of 38 rev 18 November 2009 Reading the actual secondary value Command Reply Ox14 S FA 0x14 S UMIS Actualvalue FA Necessary in the three phases devices Select the phase to read 1 2 3 if omitted it means 1 Milliampere Ampere Reading the remote connection state Command Repl 0x14 L 0x14 L Connection state sid Connection state L Not ACTIVE R Active Test Start and Stop commands Enables remote mode Command Repl 0x15 M Mode 0x15 PM EST Remote mode
20. entification of all converters connected and list them in the window Once all converters are recognized it s possible to stop the search with the button Stop otherwise automatically goes up to 32 12 5 Address change In the section at the top right it s possible to change the address to the single converter selecting it in the window assign the new address and click on applica Warning do not assign the same address to more equipments The acquisition of the new address will take place immediately after sending the command for which the identification of the converters must be repeated 12 6 Test applications The program can run 32 applications of command To run a command application select the converter in the appropriate window and click on lancia 12 7 Command mask After selecting the converter it s possible to run the application command The program first reads the settings of the selected converter and then displays the mask shown below the top row shows the name of the converter the serial number and his serial address ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 30 of 38 rev 18 November 2009 Ei Utenza Connessa FYC 990 1 info utenza collegatal ELETTRONICA FVC Trifase ZENONE AUTOMAZIONE STRUMENTAZIONE Tensione Corrente Sorgente riferimento Sericie a m Sorgente Start Pannello Seriale Opzioni Mostra indicatori di Lettura Scrittura riuscita 12 62 5 20 P ae Sr ie 3
21. etting voltage and frequency cscessssessssesesseeeee eese hene meme sese sese semen ree 12 4 3 SCal SCLECEION MEE 12 4 3 Display of set VQlUCS 22000 oii sees eee eee seed nese soo ER En tans vn eo She whee vais ve ean sni ennes oe ne sie wh oad 12 4 4 Command type selection ise ees eee oven ere re Eve ux ewes sone poU Vn EV vase ence VA VEU EY CER Ea reu ex 13 4 5 Measurements display recorrer oa OR nd dec eons donstseedess cess bese oes deen NEN 13 4 5 change Of scale eoe rra Asn ES AEE AAE E SEE EE SENE ceed ANA E ANA EEEE TANA 13 5 Maintenance INSEPUCHONS 6ic5iccssnrsnnnsenansne bnnsonadeidaivcsassebucneesddusbarsunsaeees 13 6 External connections a cccccsevancescanceacyasceaaawaguontantanansassanneinenameareunennouanty 14 6 1 DB15 WO connections sssssssssississssssvsssss ss ee enean aeo Eno Ree a Pa an ae ER o queue ECESE SSES Ere seus 14 6 2 DB15 RS485 connection eee eene eee ahhh Eno aeu ape aao erg ee queue ee ee ao aera go orans 15 6 3 JDB15 analog connectioils e xS E Ent Ven SERES EXUERi re ux ue Rx n DIEN EE 16 Z Error and faults signaling iaoxsereseusiexe xo cymd ba ueaaddncd d tassas UE DUO EK hd Cox lx da 17 8 Converter diagralibssosogxaaxecoN A a ECHU EepIA eb RAN CUERDGDCMANS CEU MAREC MM be A Md 18 9 Control scheme eco ea ES E SEERERREE VAM QE EXE RO VpERQEE VENE REF ERA TERKC VU EVE Ta eR a DEA 19 10 Control and regulation unit ssces sa c
22. f 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 frequency Input 2 ELETTRONICA AUTOMAZIONE STRUMENTAZIONE ZENONE 7 Error and faults signaling MUGL Page 17 of 38 rev 18 November 2009 The converters are equipped with self diagnosis routine in case of anomalous event the power output is stopped and an error message is displayed Signal Cause Remedy DSP X FAIL Communication error between the central processor and the DSP shown by nr X Shut off and turn on the equipment if the error remains contact the assistance FAIL Generic error Connect a PC to the equipment and by means of the software GesPWM check the table below By means of the software GesPWM it s possible to visualize the following table Signal Cause Remedy Temperature Very high temperature of the heath sink Shut off the equipment and wait a few minutes If the phenomenon repeats check the air vents and make sure the fans work properly Under voltage Supply voltage to low 350V Check the mains and the presence of all three phases Over voltage
23. hnique for adjusting the loops The adjusting of PID loops must be done in two phases first the inner one and then the external one In order to adjust and verify the dynamic performances it s better to have a dynamic load at the output so to visualize the voltage variations with respect to the load variations Under these conditions adjust first the inner loop Kp Ti and Td parameters until the maximum performances are obtained Once the inner loop has been adjusted the parameters Kp Ti and Td of the external loop can be adjusted so to optimize the global performance Ideal system response to a step function ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 24 of 38 rev 18 November 2009 Step function response varying Ti with Kp constant ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 25 of 38 rev 18 November 2009 Step function response with Kp too high Step function response with Kp and Ti too smal ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 26 of 38 rev 18 November 2009 11 GesPWM software The GesPWM software is compatible with WINDOWS XP systems and allows to set up some important parameters of the converter 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
24. ia inia 5 Qu ARE RR RA WE NEAR eA REA RR ERAAR QE EA REA TA cRAN 19 10 1 Control system block diagram ecessssesssseeseseee eee 19 10 2 Control system description i eec cesi eese oet ea eo Va Fo ua go ee To ze ETE Ce Euge aV Dev eg iUe duo 20 10 3 Parameters definition and function ccecccncccnceenceeaeeeeceeaeeeaeeeaseeaseeasesaseeasesanes 21 10 4 Procedure for adjusting the control system ccesessesseeeeee eene hehehe hene tenue 22 10 5 Technique for adjusting the loops cecessssseeseeeeee eene hehehe hehe tee tenter 23 11 GesPWM software 1i icxd ek E RERUAEARETRE EAR A MERECE CAUSA ERREOREVERARCRUE NOE CAES REA ERE 26 11 1 Connecting the equipment to the PC essssessssessssessese essen enne 26 12 FVC Manager software iisaseevsa veau ena aa b aa SPRRRE OR ERE ERROR ROREM Ra NbOqE NC ea Vas 28 12 1 Software installation 5 a occ secs ree eere ne E DLEE n Ree Sore ge Ese S re eroi E SERRE S 28 12 2 da Xii m MME 28 12 3 Preliminary operations cessseseeeeeeeeee eene ehe hehehe thee ehe hs there rere terne een 29 12 4 identification of FVC connected ccesessessesseeeeeeeee eee hehe hehe tete terreas 29 12 5 Address change 32 3 eR SIME dae ahaa aR OE es a D PEE PONES 29 12 6 Test applicatiolis ecetceeseus cs tates ae eo xt aks Rey Reo gules o Ure boe an sd RXE FEIER RENET E KEY NUTS EERENS 29 12 7
25. mattstrasse 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 38 rev 18 November 2009 Converter series FVC The converter FVC series are static AC AC three phase devices with double conversion and IGBT technology under microprocessor control They supply the load with variable voltage and frequency at the set value regardless of impedance value and mains fluctuations 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 They can have two output scales so to supply the maximum power at two different full scales 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 frequency setting command and visualization logical command for output on selection for local remote commands line breaker RS485 serial interface mains supply outputs emergency input auxiliary inputs outputs on front panel on front panel on front panel from RS485 serial interface on front panel on front panel from cable on the back side rack version on terminal blocks inside the cabinet metal cabinet version
26. of failures or malfunctions we must be informed in advance before sending the equipment to our laboratories ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 11 of 38 rev 18 November 2009 3 Auxiliary Inputs Outputs 3 1 1 Inputs The FVC converters have some inputs for remote control function Description Emergency Voltage free NC contact its opening causes the immediate disengagement of the line breaker disconnecting the equipment from the mains on off Voltage free NO contact allows to start the converter from remote control Voltage command Analog input 0 10V remote command for the output voltage 0 100 Frequency command Analog input 0 10V remote command for the output frequency 0 100 3 1 2 Outputs The FVC converters have some outputs for remote signaling function description Converter running PNP digital output it signals that the converter is running Max 30V 0 5A Alarm PNP digital output it signals a fault Max 30V 0 5A 3 2 Communication port The converter is equipped with a RS484 communication port which allows to connect a PC or other system for parameters setting for the alarm register reading and for remote control The Baud Rate is the transfer speed and is set at 9600 ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 12 of 38 rev 18 November 2009 4 Converter operation 4 1 Starting
27. ommand Tensione it s possible to change the output scale in the appropriate box and confirming it with the command srivi The displays in the top left show RMS voltages and currents on the three phases ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 32 of 38 rev 18 November 2009 13 Communication protocol V1 1 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 Command or reply STX Start character Hexadecimal value 0x02 IND Device address added to the hexadecimal value 0x80 ex Address 1 character 0x81 Stop character Hexadecimal value 0x03 Control checksum it s a character sum of all characters of the command Inclusive of STX and ETX characters module 256 ETX CKSUM Each command that carries a parameter receives a reply with a result character ESI that can have the following values 0 Command executed 1 Command not executed ELETTRONICA AUTOMAZIONE STRUMENT
28. the output of power After the preliminary operations connecting the equipment to the mains and to an eventual load are done it s possible to turn on the converter acting on the main switch Note the main switch will not activate if the emergency circuit is open or e the emergency push button is pressed Once the equipment is turned on it s possible to start the output of power in the following ways e Pressing the on off push button on the front panel e With command from serial port entering the appropriate string e Activating the appropriate digital input Under these conditions the converter will take immediately the voltage and frequency set 4 2 Setting voltage and frequency The setting of voltage and frequency output can be done e by means of the potentiometers on the front panel e by means of analog signal 0 10V e from serial port 4 3 Scale selection The FVC converters can have one or two output scales in order to supply the maximum power with different full scales The scale selection must be done with the appropriate selector in stand by mode An eventual change of scale while the output is on will take place only after o the converter is switched off 4 3 Display of set values In stand by it s possible to visualize on the displays the voltage and frequency values simply pressing the F1 push button F1 pressed visualization of voltage and frequency entered F1 released off Z
29. tion of the waveform during the crossing of the zero correction of dead time by adding an additional gain when the current crosses zero The adjusting of this block is made with sine wave or triangular wave Z T R gain range 0 100 Represents the additional gain during the zero crossing by the current Z T R amplitude range 0 100 Represents the maximum correction value previously calculated that can applied to the modulator 10 4 Procedure for adjusting the control system The following section provides only a guideline for adjusting the PID regulation loops as in many cases does not apply a clear rule and adjustments are made based on personal experiences Note Eventual parameters modifications must be done by specialized personnel only because these modifications could cause malfunctions and or converter damages t Note Before making any change to the regulation parameters it s f 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 reduce the Kp coefficients and increase the integration time Ti In case of sever inductive load increase the Kp coefficients and reduce the integration time Ti ZENONE ELETTRONICA AUTOMAZIONE STRUMENTAZIONE MUGL Page 23 of 38 rev 18 November 2009 10 5 Tec
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