Summary of Contents for Caltest CINERGIA
- Page 1 DC Programmable Power Supply (DCPS) Installation and operation manual Caltest Instruments GmbH Tel: +49(0)7842-99722-00 Kohlmattstrasse 7 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. Power supply features....................8 2.3. Operation and connection modes ................9 2.4. Limits .......................... - Page 3 4.2.3. Precharge ......................23 4.2.4. Ready ........................23 4.2.5. Run ........................23 4.2.6. Alarm ........................24 4.3. Operation modes ......................24 4.3.1. Current mode ...................... 24 4.3.2. Voltage mode ...................... 25 4.3.3. Power mode ......................26 4.3.4. Programmable limits ................... 27 4.4.
- Page 4 WARRANTY AND MAINTENANCE ..................54 8.1. Replacing the output fuses..................54 8.2. Fans ..........................54 8.3. DC bus capacitors ......................54 8.4. Warranty ........................54 8.5. Claim procedure ......................55 Page / 55...
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Page 5: Introduction
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 to obtain the maximum performance from it. - Page 6 • 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
2. PRESENTATION 2.1. Introduction The DCPS is a DC Programmable Power Supply, a power electronics equipment with the following main functionalities: It converts the AC input, of the main grid, in a controlled DC output by using an IGBT- based switching topology and DSP-based state-of-the-art digital control. It can be operated as: o Constant voltage output o Constant current output... -
Page 8: Power Supply Features
2.2. Power supply features Magnitude Value Power 6.75kW-160kW Input AC Voltage Rated 3x400V+Neutral+Earth +15% / -20 % Voltage range AC Current 2Arms -290Arms Frequency 50/60Hz Power Factor Controllable -1/1 (capacitive/inductive) >92% Efficiency at full load Overload 125% for 10 min / 150% for 60 s DC Outputs DC Current 3 independent channels... -
Page 9: Operation And Connection Modes
2.3. Operation and connection modes The output of the power supply is formed by three channels referenced to a common negative channel. The power supply can be used in two different connection modes: Independent channel: each channel (U,V,W) is controlled independently. The setpoint and also the operation mode can be different for each channel. -
Page 10: Configuration And Control Of The Power Supply
Remote interface: an Ethernet communication interface with protocol MODBUS/TCP can be used to configure, monitor and operate the power supply. By using HMI software application provided by CINERGIA, downloading of excel files is also possible. 2.6. Functional diagram The diagram below is the conceptual functions blocks diagram of the power supply:... -
Page 11: Principle Of Operation
The active rectifier has bidirectional power flow capability and the injected reactive power (grid side) can be defined by the customer. DC/DC output converter: a three-branch IGBT converter allows three buck-boost DC- DC conversions from the DC bus to each of the output channels. Each channel can be controlled independently or, by software, the three channels will share the same operation mode and setpoints. - Page 12 State-of-the art digital control is used in all CINERGIA products. In the DCPS case, the control system algorithms are computed in a dual core DSP-based hardware, designed by CINERGIA, allowing a multitask execution of the regulation systems for the Active Rectifier and the DC/DC output.
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Page 13: Installation
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 DCPS input. All the electrical connections, including those for control (interface, remote control…etc.), shall be done with the switches in OFF position and with the mains supply disconnected (thermal- magnetic circuit breaker in OFF position too... - Page 14 Front view (with the door open): Detailed view of the signal connectors: / 55...
- Page 15 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. Connection elements (X*): (X1) Phase input terminal R. ...
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Page 16: Equipment Reception
On receiving the device, make sure that the power supply 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 17: Location
It is also important to consider the most suitable means to place the power supply in its final location (floor, hoist, lift, stairs, …etc). 3.3.4. Location It is necessary to leave a minimum of 25 cm in the contour of the equipment for its ventilation. If possible, as shown in following figures, it is recommended to leave additional 75 cm to facilitate the operations of maintenance of the equipment or the interventions of the technical service in case of breakdown. - Page 18 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 power supply 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 19: Connection
3.4. Connection 3.4.1. Earth protection 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 DCPS input. On the other hand, connect the protection earth wire to the terminal (X10) before connecting the load to the DCPS output. -
Page 20: Communications
3.4.5. Communications There are several connectors dedicated to communications, which are listed below: Connector for RS485 communications (X11): DB9 connector to be used when Modbus RS485 option is chosen. Connectors for CAN communications (X13, X14): DB9 connectors to be used when parallelization of DCPSs is needed (X13 works as input and X14 works as output). -
Page 21: Analog Inputs And Outputs
3.4.7. Analog inputs and outputs Analog inputs and outputs are gathered in X17. The analog inputs of DCPS are isolated and accept a voltage range from -10 to 10V. There are 3 analog inputs and, depending on the connection mode, there are two possible configurations for them: Parallel channels: the analog input Analog_In_1 is the reactive power command and the Analog_In_2 depends on the power supply operation mode. -
Page 22: Operation
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 power supply start-up. -
Page 23: Initialization
4.2.1. Initialization During the initialization, the power supply control system checks the presence of all internal components, the embedded PC loads the operating system and the isolation detector runs a self-test. No voltage is present at the DC bus and the IGBTs PWMs are completely stopped. The transition from Initialization state brings the power supply to the Standby state as long as the emergency stop is deactivated (equipment armed) and the isolation detector performs a complete self-test successfully. -
Page 24: Alarm
stabilizes the DC link voltage. After that, the output side will measure the actual output state (voltage levels) and will start the control algorithms and PWM. This state can evolve to Standby state when a Not enable signal is received, to Ready state when a Not run signal is received or to Alarm state if an error condition is detected. -
Page 25: Voltage Mode
The user can configure: Amplitude: desired output current value. Sign: a positive sign represents a current sourced from the power supply. A negative sign represents a current sunk by the power supply. Setpoint limitation: this limitation can be lower than the maximum power supply output current. -
Page 26: Power Mode
The user can configure: Amplitude: desired output voltage value. Sign: the output voltage between channels U,V,W is always positive with respect to N. No negative voltages can be set. Setpoint limitation: the maximum current may be controlled in this operation mode. The maximum available voltage will affect to the limit of the voltage setpoint given, but it will not be controlled. -
Page 27: Programmable Limits
When the power supply reaches the configured value, the output current will be regulated to the limit defined. This limitation can be useful to protect a load with a maximum allowable current below the maximum current of CINERGIA power supply. For instance, to protect a battery against excessive discharge in constant current mode. -
Page 28: Working With The Equipment
(keep it in mind). In order to operate the output phases, Cinergia recommends a start-up voltage of 200V for each connected phase. From this initial voltage, sum the desired setpoint divided by 2 to one phase and subtract the same value to the other phase. -
Page 29: Start-Up
The grid side of the power supply is protected by a thermal-magnetic circuit breaker. Be sure that this breaker is switched off: Check that all wires are connected and secured before proceeding to the power supply start-up. If these steps are validated the power supply is ready to be started. 4.5.1. -
Page 30: Stop
other voltage sources at the output. If the power supply is operated as a current source, please do not connect any other current sources at the output. 4.5.2. Stop Once the equipment is running (Run state) it may be stopped in three ways: 4.5.2.1. -
Page 31: Emergency Stop
EPO wire button or reconnect the EPO in no longer connected. wire. Drivers IGBTs saturation protection Contact Cinergia for technical has been activated. This support if this alarm persists. alarm is triggered when Check the equipment under test / 55... - Page 32 Internal error caused by a Check the grid voltage. timeout low voltage in mains. Overload in Internal alarm caused by a Contact Cinergia for technical precharge shortcircuit. support. Overvoltage in The DC link voltage has Reduce the DC output step...
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Page 33: Alarms Reset
Communication cable Contact Cinergia in order to No Heart Beat broken or control board isolate the problem. without response. PLL error The frequency of the grid is Check the grid frequency. too high or low. There is no voltage on the Mains lost Check the grid voltage. -
Page 34: Local Touchscreen Control Panel
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 converters. Besides, the touchscreen allows the user to interact with the mother board and control multiple variables in regard to the DC power output of the power converters. -
Page 35: Operational
5.2.2. Operational The main purpose of the Operational menu is, in case the LCD Control is activated, to allow the user to manage the power converters State Machine and to introduce current, voltage and both active and reactive power setpoints. The user gets to read the following information as well: ... - Page 36 Commands The button COMMANDS allows the user to introduce different setpoints: Voltage setpoints Current setpoints Active power setpoints Once again, this function is only permitted when the Control variable is set to LCD. Information about the different kinds of setpoints that the user can introduce through the touchscreen can be found below.
- Page 37 In case the user wants to set a negative setpoint, this can be made by pressing the button +/-. The Cancel button (green one) can be pressed anytime to return to the Operational menu without sending any setpoint. / 55...
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Page 38: Configuration
Voltage setpoint The user can introduce an independent voltage setpoint per every channel. Current setpoint The user can introduce an independent current setpoint per every channel. Active power setpoint The user can introduce an independent power setpoint per every channel. SET REACTIVE The SET REACTIVE button allows the user to introduce a global reactive power setpoint. - Page 39 In case the Control variable is set to LCD, the user may change the current connection mode. Two types are available for the user to choose: Independent Parallel Pressing the BACK button the user can return to the main Configuration window. Mode The following screen appears when the user presses the Mode button: In case the Control variable is set to LCD, the user may change the current mode.
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Page 40: Alarms
Control The following screen appears when the user presses the Control button: In case the Control variable is set to LCD, the user may change the current control mode. Three types of control mode are available for the user to choose: ... -
Page 41: Remote Communications
6. REMOTE COMMUNICATIONS CINERGIA’s power supplies 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 42 Variable MODBUS Address Size ACCESS TYPE DESCRIPTION (dec) AR_VRS IQ21 _IQ(440.0) // Voltage PhR-PhS AR_VST IQ21 _IQ(440.0) // Voltage PhS-PhT AR_VTR IQ21 _IQ(440.0) // Voltage PhT-PhR AR_VRN IQ21 _IQ(440.0) // Voltage PhR-N AR_VSN IQ21 _IQ(440.0) // Voltage PhS-N AR_VTN IQ21 _IQ(440.0) // Voltage PhT-N AR_IR...
- Page 43 AR_READQT IQ10 _IQ10(-2000000) _IQ10(2000000) // Reactive Power T AR_SETQ0 IQ10 _IQ10(-2000000) _IQ10(2000000) // Reactive Power (Set-Point) DCDC_VAB IQ21 _IQ(440.0) // Voltage PhA-PhB DCDC_VBC IQ21 _IQ(440.0) // Voltage PhB-PhC DCDC_VCA IQ21 _IQ(440.0) // Voltage PhC-PhA DCDC_VAN IQ21 _IQ(440.0) // Voltage PhA-NEG DCDC_VBN IQ21 _IQ(440.0)
- Page 44 DCDC_READPC IQ10 _IQ10(-2000000) _IQ10(2000000) // Active Power C DCDC_SETP0 IQ10 _IQ10(-2000000) _IQ10(2000000) // Active Power global (Set-Point) DCDC_SETPA IQ10 _IQ10(-2000000) _IQ10(2000000) // Active Power A (Set-Point) DCDC_SETPB IQ10 _IQ10(-2000000) _IQ10(2000000) // Active Power B (Set-Point) DCDC_SETPC IQ10 _IQ10(-2000000) _IQ10(2000000) // Active Power C (Set-Point) DCDC_BATSTATUSWORDGL UINT32 0X7FFFFFFF...
- Page 45 DCDC_SETCHIA IQ21 0X7FFFFFFF // Recommended charging current A DCDC_SETCHVA IQ21 0X7FFFFFFF // Equalization battery voltage A DCDC_FLOATINGVA IQ21 0X7FFFFFFF // Floating voltage A DCDC_SETCHPA IQ10 0X7FFFFFFF // Battery capacity A DCDC_BATSOCA UINT32 0X7FFFFFFF // Battery State of Charge A DCDC_BATVDCA UINT32 0X7FFFFFFF // Battery DC voltage measured A...
- Page 46 DCDC_ALARMBATLC IQ21 0X7FFFFFFF // Battery Low Voltage Alarm C DCDC_ALARMBATMAXCHC IQ21 0X7FFFFFFF // Battery Max Charging Current Alarm C DCDC_ALARMBATMINCHC IQ21 0X7FFFFFFF // Battery Max Discharging Current Alarm C DCDC_SETCHIC IQ21 0X7FFFFFFF // Recommended charging current C DCDC_SETCHVC IQ21 0X7FFFFFFF // Equalization battery voltage C DCDC_FLOATINGVC IQ21...
- Page 47 DCDC_MAXVPHC IQ21 0X7FFFFFFF // Phase C maximum allowable voltage DCDC_MINVGLOBAL IQ21 0X7FFFFFFF // Global DC minimum allowable voltage DCDC_MINVPHA IQ21 0X7FFFFFFF // Phase A minimum allowable voltage DCDC_MINVPHB IQ21 0X7FFFFFFF // Phase B minimum allowable voltage DCDC_MINVPHC IQ21 0X7FFFFFFF // Phase C minimum allowable voltage The Bit Coded Variables descriptions are: CONTROL WORD bits...
- Page 48 ERRORS bits Definition Phase Undervoltage in Overvoltage in Precharge Precharge time Drivers EMCY Watchdog overvoltage the DC link the DC link overload sequence Overvoltage in The DC link is The DC link is Overload in Internal error, Internal error Emergency Digital processor is phase discharged...
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Page 49: Iq Management
6.1. IQ MANAGEMENT Many of the parameters of this equipment are defined as IQ numbers (Texas Instruments nomenclature). An IQ number refers to a 32 bit signed fixed point number where the number of fractional bits is specified. For instance, IQ21 means that the number has 21 fractional bits, 10 integer bits and 1 bit is for the sign. - Page 50 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 51: Human Machine Interface
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. This application is based on Windows 7/Windows XP. The software can be installed by executing Setup.exe file in Administrator Mode and following the instructions of the application. -
Page 52: Supervision Tab
C- Connection parameters for the communications: IP of the equipment (192.168.55.204), port (502). This equipment has a fixed IP. Pooling time [ms] is the time to refresh all parameters. The minimum value recommended is 500 ms. Connect / Disconnect / Pause buttons D- Information about the State Machine of the two converters of the equipment (Active Rectifier and DC/DC Output). -
Page 53: Alarm Tab
7.3. Alarm tab In this tab, the alarm status of each converter is shown. 7.4. I, V, P configuration tab A- Information and setpoints for the electrical parameters associated to the Current, Voltage and Power operating modes. By using the Send button the data is downloaded to the equipment. -
Page 54: 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 55: Claim Procedure
• If the claim is covered by the warranty terms, CINERGIA shall provide on-site technical assistance or, alternatively, can request the shipping of the defective product and/or component to have it repaired at CINERGIA premises. At last, CINERGIA shall decide to send a replacement product and/or component. The faulty product and/or component shall be returned to CINERGIA.