Summary of Contents for Cinergia B2C10
- Page 1 Electronic Load (EL DC) Installation and operation manual 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...
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Page 2: Table Of Contents
INDEX INTRODUCTION ........................5 1.1. Symbols used ......................... 5 1.2. Safety notes ........................5 1.3. Quality and regulations ....................5 PRESENTATION ........................7 2.1. Introduction ........................7 2.2. Converter features ......................8 2.3. Operation and connection modes ................9 2.4. Configuration and control of the converter .............. - Page 3 EL DC Instalation and operation manual v13.docx 4.2.1. Initialization ......................29 4.2.2. Standby ........................ 29 4.2.3. Precharge ......................30 4.2.4. Ready ........................30 4.2.5. Run ........................30 4.2.6. Alarm ........................30 4.3. Operation modes ......................31 4.3.1. Constant Impedance (CI) ..................31 4.3.2.
- Page 4 7.1. Operation ........................49 7.1. Alarm ........................... 50 7.2. Supervision ........................51 7.3. Unipolar/Bipolar connection ..................52 7.4. DC sequence ........................ 53 WARRANTY AND MAINTENANCE ..................55 8.1. Replacing the input fuses .................... 55 8.2. Fans ..........................55 8.3. DC bus capacitors ......................55 8.4.
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Page 5: Introduction
EL DC Instalation and operation manual v13.docx 1. INTRODUCTION Dear customer, on behalf of CINERGIA team, thank you for the confidence placed in our company and for the purchase of this product. Please, read carefully this manual before using the equipment to get familiarized with it and to obtain the maximum performance from it. - Page 6 EL DC Instalation and operation manual v13.docx • EN-IEC 62040-1. Uninterruptible power supply (UPS). Part 1-1: General and safety requirements for UPS’s used in accessible areas by end users. • EN-IEC 60950-1. IT equipments. Safety. Part 1: General requirements. • EN-IEC 62040-2. Uninterruptible power supply (UPS). Part 2: Prescriptions for Electromagnetic compatibility (EMC).
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Page 7: Presentation
REFERENCE RATED POWER (25ºC) RATED CURRENT (25ºC) WEIGHT DIMENSIONS Independent Parallel Bipolar DxWxH (mm) 0-750V 0-750V -350 350V B2C7.5 6.75 ±10A ±30A ±10A 770x450x1100 B2C10 ±15A ±45A ±15A B2C15 13.5 ±20A ±60A ±20A B2C20 ±25A ±75A ±25A B2C30 ±30A ±90A ±30A... -
Page 8: Converter Features
EL DC Instalation and operation manual v13.docx 2.2. Converter features MAGNITUDE VALUE Power 7.5kVA-200kVA Input side (GRID side) AC Voltage Rated 3x400Vrms+Neutral+Earth Voltage range +15% / -20% Rated AC Current Depends on model (see table) 10-290Arms per phase Frequency 48-62Hz THDi (at rated power) <3%... -
Page 9: Operation And Connection Modes
Remote interface: an Ethernet communication interface with protocol MODBUS/TCP can be used to configure, monitor and operate the electronic load. By using HMI software application provided by CINERGIA, uploading of excel files is also possible. 2.5. Functional diagram The diagram below is the conceptual function block diagram of the converter:... -
Page 10: Principle Of Operation
EL DC Instalation and operation manual v13.docx The main components of the diagram are the following (from grid side to EUT side): Isolation transformer: a 50/60Hz isolation transformer can be provided optionally in order to isolate the output phases. In this case, an isolation monitor can be integrated in the converter to detect isolation faults also. - Page 11 (Please note that earth protection cable is only connected to the cabinet chassis). State-of-the-art digital control is used in all CINERGIA products. In the EL case, the control system algorithms are computed in two DSP based hardware, designed by CINERGIA, allowing a multitask execution of the regulation systems for the Active Rectifier and the Inverter output.
- Page 12 EL DC Instalation and operation manual v13.docx Setpoint Σ PR ω0 PWM x3 generator PR ω1 PR ω2 PR ω3 Feedback Therefore, the main characteristics of the Resonant Control applied are the ones listed below: Control loop rate of 15 kHz. 15 harmonics controlled*: 1 15 control loops executed per phase.
- Page 13 EL DC Instalation and operation manual v13.docx In this case, there is reactive power consumption from the EUT (PF = 0) and no power is injected into the grid. In this second picture, the EL is behaving like a single-phase rectifier. / 56...
- Page 14 EL DC Instalation and operation manual v13.docx In this last case, the EL is behaving like a three-phase rectifier. PID control The EUT side control algorithm is based on a traditional current PID controller. In case controlling power, or even the impedance, both magnitudes are decoupled and translated to current set points on each control loop.
- Page 15 EL DC Instalation and operation manual v13.docx Parameter Description Default maxIout Maximum limitation of positive output current: Maximum current maximum current the equipment is able to inject limitation 110% Irated minIout Maximum limitation of negative output current: Maximum current maximum current the equipment is able to drain limitation 110% Irated maxVout...
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Page 16: Installation
EL DC Instalation and operation manual v13.docx 3. INSTALLATION 3.1. Important safety instructions As a device with class l protection against electric shocks, it is essential to install a protective earth wire (connect earth ). Connect the protection earth wire to the terminal (X5) before connecting the grid to the electronic load input. - Page 17 EL DC Instalation and operation manual v13.docx Local front panel: Front view (with the door open): / 56...
- Page 18 EL DC Instalation and operation manual v13.docx Detailed view of the front protections and switches: Detailed view of the signal connectors: 18 / 56...
- Page 19 EL DC Instalation and operation manual v13.docx General view (with the front door closed): Protection elements (Q*): (Q1a) Input thermal-magnetic circuit breaker or disconnector according to power of the equipment (Q2) Output disconnector (Q3) Output fuses (Q5) Parallel connection switch ...
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Page 20: Equipment Reception
On receiving the device, make sure that the converter has not suffered any damage during the transportation. Otherwise, make all pertinent claims to the supplier or to CINERGIA. The packing of the device consists of a wooden palette, a cardboard or wooden packaging (depending on the case), expanded polystyrene corner pieces, a polyethylene sleeve and bands;... -
Page 21: Transport To Location
EL DC Instalation and operation manual v13.docx 3.3.3. Transport to location The equipment includes castors to facilitate its transport to its final location. It is important to check previously if the weight of the converter is appropriate for the site where it will be located. - Page 22 EL DC Instalation and operation manual v13.docx Recommendable minimum distance, 1 m. Recommendable minimum distance, 1 m. The equipment may be installed in any place as long as the safety and ventilation requirements are fulfilled. The converter includes 2 levelling elements located near the front castors, which serve to immobilize the unit once it is in place.
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Page 23: Connection
Negative power supply: between X8 and X7 3.4.4. External Emergency Power Off connection (X12) CINERGIA units are equipped with a local Emergency Stop pushbutton at the front panel. When this local pushbutton is pressed, the unit will be completely switched off by disconnecting the main contactors at the input and at the output. - Page 24 EL DC Instalation and operation manual v13.docx In addition, CINERGIA units also integrate two terminals dedicated to an external Emergency Power Off (EPO). When these terminals are used, the unit will have two Emergency Pushbuttons active: the local pushbutton and the external-remote pushbutton. This document describes the connection of the external-remote pushbutton (hereafter EPO).
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Page 25: Output Signal Of Local Emergency Stop Pushbutton (Optional)
NC contact is wired to the lower front of the equipment, along with the connection power terminals. The additional contact could be used by the customer to integrate CINERGIA equipment into the Emergency Power Off sequence of the installation. -
Page 26: Communications (Optional)
EL DC Instalation and operation manual v13.docx 3.4.6. Communications (Optional) There are several connectors dedicated to communications, which are listed below: (Optional) Connector for RS485 communications (X11): DB9 connector to be used when Modbus RS485 option is chosen. (Optional) Connectors for CAN communications (X13, X14): DB9 connectors to be used when parallelization of electronic loads is needed (X13 works as input and X14 works as output). -
Page 27: Analog Inputs And Outputs (Aio Optional)
EL DC Instalation and operation manual v13.docx The list of each digital functionality is the following (Note that those are default functionalities). (The maximum admitted input voltage is 10V and 12 output voltage) DIG_IN_1: Enable console mode DIG_IN_2: Run equipment DIG_IN_3: Emergency stop DIG_IN_4: Rearme (used in combination: Rearme+Stop=Reset / Rearme+Run=Enable) DIG_IN_5: Single push: Ready. -
Page 28: Operation
EL DC Instalation and operation manual v13.docx 4. OPERATION 4.1. Safety Before operating the equipment, check that the Protective Earth is properly connected. Check out the electrical installation in both sides (input and output) of the cabinet. All wires shall be connected and secured before proceeding to the converter start- 4.2. -
Page 29: Initialization
EL DC Instalation and operation manual v13.docx From any Initialization Error EMCY Reset? sequence? Standby Enable? Precharge Ready Run? Enable? Run? Enable? 4.2.1. Initialization During the initialization, the converter control system checks the presence of all internal components and the embedded PC loads the operating system. No voltage is present at the DC link and the IGBTs PWMs are completely stopped. -
Page 30: Precharge
EL DC Instalation and operation manual v13.docx this means that there is no voltage in the DC link and no voltage/current is applied to the output of the converter. The transition from the Standby state is the Enable signal or, in case of errors, a Fault signal. The Enable signal will bring the State Machine to Precharge and eventually to the Ready state. -
Page 31: Operation Modes
EL DC Instalation and operation manual v13.docx The only possible transition from Alarm state is to Initialization state. Once in Alarm state a Reset signal is required from the customer after clearing the fault condition. If the fault condition has not been cleared the converter state will be kept in Alarm (for example, when heatsink overheating has occurred and the temperature is still high). -
Page 32: Constant Power (Cp)
EL DC Instalation and operation manual v13.docx Analog inputs The RMS magnitude set point will come from the (X17) connector (1 input for all three phases). 10V (input) 20Arms (output) (EL15 case) 4.3.3. Constant Power (CP) This mode allows the user to define the active power consumption per output phase. Parameters and limits In CP mode, the user may modify the value of the following parameters, as long as they are within the specified range:... -
Page 33: Working With The Equipment
EL DC Instalation and operation manual v13.docx 4.5. Working with the equipment Before powering the cabinet check step by step the following items: The converter output must be disconnected: The grid side of the converter is protected by a thermal-magnetic circuit breaker. Be sure that this breaker is switched off: / 56... -
Page 34: Start-Up
EL DC Instalation and operation manual v13.docx Check that all wires are connected and secured before proceeding to the converter start- If these steps are validated the converter is ready to be started. 4.5.1. Start-up Switch on the thermal-magnetic circuit breaker of the grid side of the converter. After switching it on, the converter will initiate the start-up sequence. -
Page 35: Standby Stop
EL DC Instalation and operation manual v13.docx 1. Send the Not enable signal to the converter (Run Ready Standby). 2. Press the emergency stop button (Standby Alarm). 3. Disconnect the output disconnector. 4. Wait at least 60 seconds (time to get discharged the internal DC link capacitors). 5. -
Page 36: Accidental Shut Down
Overvoltage in the The DC link voltage has Reduce the output step transition DC link exceeded its maximum value. time. Contact Cinergia for technical support if this alarm persists. Undervoltage in the Undervoltage in the DC link Reduce the output step transition... -
Page 37: Alarms Reset
3. Send a Not enable and Not run signals (note: this step is done automatically when the user is interfacing the converter by the LCD or by the software provided by Cinergia). 4. Proceed as a standard start-up process by deactivating the emergency stop (pull out the button). -
Page 38: Local Touchscreen Control Panel
EL DC Instalation and operation manual v13.docx 5. LOCAL TOUCHSCREEN CONTROL PANEL 5.1. Basic functions The LCD touchscreen main purpose is to provide the user with the necessary information about the power supply principal variables. Besides, the touchscreen allows the user to interact with the power converter and control some of these variables. -
Page 39: Operational
EL DC Instalation and operation manual v13.docx 5.2.2. Operational The main purpose of the Operational menu is allowing the user to introduce set-points as well as manage the power supply State Machine (as long as the Local control is activated). The user gets to read the following information as well: ... - Page 40 EL DC Instalation and operation manual v13.docx Commands The button Set Point allows the user to introduce different set points: Being in the Current mode the user can introduce the current set points. In the Power mode the user can also introduce active and reactive set points. ...
- Page 41 EL DC Instalation and operation manual v13.docx In order to change the sign of the set point the +/- button is used. First enter the value of the setpoint and then click the +/- button (if +/- button is pressed before entering the setpoint value, it does not work).
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Page 42: Supervision
EL DC Instalation and operation manual v13.docx 5.2.3. Supervision The Supervision window is exclusively informative. It shows the main variables of the inverter. 5.2.4. Configuration The Config. window abbreviation of Configuration window is used to set the configuration mode of the converter. 42 / 56... -
Page 43: Alarms
EL DC Instalation and operation manual v13.docx Using this menu, the user can choose: Select Master. The supervision master is the device which controls the converter. Choosing the LCD, the converter is controlled by the touchscreen, on the other hand if the user chooses the Modbus master, the converter will be controlled by the HMI interface. -
Page 44: About El
This window shows the basic hardware and software information of the converter. 6. REMOTE COMMUNICATIONS CINERGIA’s power converters can be operated and supervised remotely through an Ethernet communications bus. An internal embedded PC, with CINERGIA’s proprietary software, allows the exchange of information between the internal CAN bus and the external Modbus TCP/IP (Ethernet). - Page 45 EL DC Instalation and operation manual v13.docx A: Actual IP is shown. B: Write the new IP below and send it. After around 30 seconds, the interface will turn blue, which means that is disconnected from the old IP. Connect with the equipment again (Operation tab) with the new IP.
- Page 46 EL DC Instalation and operation manual v13.docx Property Implementation Function Codes: 0x03: READ_HOLDING_REGISTER 0x10: WRITE_MULTIPLE_REGISTER Server port: 502 (decimal) Modbus node ID: 10 (decimal) Not used. Relayed on the TCP stack. Multiple connections Only one master at one time allowed. Additional connection requests might be delayed or even rejected.
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Page 47: Iq Management
EL DC Instalation and operation manual v13.docx 6.1. IQ MANAGEMENT Many of the parameters of this equipment are defined as IQ (Texas Instruments nomenclature). An IQ number refers to a 32 bit signed integer and in its name it is specified in which bit the decimal number begins. - Page 48 IQ21 functions: public double IQ21toFloat(double Var) if (Var > 2147483648) //if the value is bigger than 2^31 (positive) Var = Var - 4294967296; // Var - 2^32 Var = Var / (2097152); // Var / (2^21) else Var = Var / (2097152); //Var/(2^21) return Var;...
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Page 49: Human Machine Interface
EL DC Instalation and operation manual v13.docx 7. HUMAN MACHINE INTERFACE CINERGIA delivers, within the scope of the supply, a Human Machine Interface software that communicates with the equipment using MODBUS protocol. The software is based on a Tab Dialog, in which each tab has one of the following purposes:... -
Page 50: Alarm
Remote: using Modbus Ethernet (IP) or serial port. Console: analogue control. F: In some scenarios, the control system interacts with the active harmonic compensation of the equipment under test. When that happens, the control system can be unstable. Due to the converter’s design, limiting the bandwidth of the control algorithm can help to stabilize the plant and move forward with the tests. -
Page 51: Supervision
EL DC Instalation and operation manual v13.docx 7.2. Supervision A: Information about the electrical parameters of both converters: Voltage Current Frequency Temperatures Active power Reactive power Voltage DC link B: Current trend plots: Three variable per plot are allowed at the same time. Due to a long refreshing time, it is not possible to detect fast current transients of the variables. -
Page 52: Unipolar/Bipolar Connection
7.3. Unipolar/Bipolar connection EL DC behaves as a DC voltage power supply. Unipolar A: Current mode is selected in the case of the image above. To change the mode, EL does not have to be in RUN state. B: It is illuminated the part of the selected mode. In parallel case, Global option will be the one for the setpoint. -
Page 53: Dc Sequence
EL DC Instalation and operation manual v13.docx EL bipolar mode tab is very similar than unipolar tab. It is important to make sure that the cables are properly connected and remember than EL in bipolar mode behaves as 2 DC power supplies: one is positive (between X6 and X7) and the other one is negative (between X8 and X7). - Page 54 First column is for the time that the status is going to last. Control mode refers to CV, CC, CP and CI (Battery mode is only available for B2C equipment of CINERGIA). The last four columns are the setpoints. Working in parallel, the global is the control, whereas working in independent mode, the last three columns are each phase U, V and W.
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Page 55: Warranty And Maintenance
(1) year from the Ex Works delivery date. If a purchased CINERGIA product becomes defective because of a faulty component or manufacturing, at any time during its standard warranty period, CINERGIA shall provide one of the following solutions: •... -
Page 56: Claim Procedure
If defect of malfunction is detected, please proceed as follows: • Immediately notify in writing CINERGIA by submitting a brief report describing the type of fault detected and all the data contained in the product data plate, attaching a copy of the purchase invoice/receipt.
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