ZENONE FVC Series, User Manual

Page 1: ...mended to refer to the characteristics data sheet of the converter which is an integral part of this manual 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 othe...

Page 2: ...ifferent 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 on front panel frequency setting command and visualization on front panel logical command for output on on front panel selection for local remote commands from RS485 seri...

Page 3: ...ons 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 s...

Page 4: ...y 13 4 5 change of scale 13 5 Maintenance instructions 13 6 External connections 14 6 1 DB15 I O connections 14 6 2 DB15 RS485 connection 15 6 3 DB15 analog connections 16 7 Error and faults signaling 17 8 Converter diagram 18 9 Control scheme 19 10 Control and regulation unit 19 10 1 Control system block diagram 19 10 2 Control system description 20 10 3 Parameters definition and function 21 10 4...

Page 5: ...s 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 ...

Page 6: ...tional 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 instruct...

Page 7: ...ember States relating to Electromagnetic Compatibility Directive 2004 108 EEC CEI EN 61000 6 1 2 ed 2007 10 Electromagnetic compatibility 1 Generic standards Immunity for residential commercial and industrial environments CEI EN 61000 6 3 2 ed 2007 11 Electromagnetic compatibility EMC Part 6 3 Generic standards standard for residential commercial and light industrial environments Electrical equipm...

Page 8: ...r 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 ...

Page 9: ...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 WARNING Power connections can generate high temperature spots that could cause burnings WARNING All standard converters are delivered with output FLOATING not connected to any potential unless otherwise specified at th...

Page 10: ... 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 ...

Page 11: ...te 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...

Page 12: ...t 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 by means of the potentiometers on the front panel by means of analog signal 0 10V 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 diffe...

Page 13: ...e L1 L2 F1 A current L1 F2 V voltage L2 L3 F2 A current L2 F3 V voltage L3 L1 F3 A 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 h...

Page 14: ... type at 24V Pin 1 and 2 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 DB15 Pin Out I O section 9 1 4 24V 20 30V Vout 24Vcc max 100mA 24V Out 1 0V in1 in2 Emergency 12 Out 2 11 10 2 3 Max current for each output 500mA Max current sink from each input 4mA 24Vdc ...

Page 15: ...uts have the following function Output 1 Active when the power output is on Output 2 Active in case of fault 6 2 DB15 RS485 connection 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 a...

Page 16: ... input 1 Pin 14 and 7 AIN2_P and AIN2_N of the Analog input 2 Pin 15 and 8 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 7 AIN1_P AIN1_N GND 14 6 8 AIN2_N 15 AIN2_P DB15 Pinout Analog section ...

Page 17: ... 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 Supply voltage to high 460V Check the mains vol...

Page 18: ...MUGL Page 18 of 38 rev 18 November 2009 8 Converter diagram Mains Input FVC basic diagram Output Bridge PWM modulator µ P Control unit Serial comm Command I O ...

Page 19: ...dless 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 voltage taken at the output The following figure shows the principle of operation 10 1 Control system block diagram The control loops are pre adjusted in production to have a good compromise between speed and sta...

Page 20: ...rrent 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 Output voltage REF from potentiometer or from input REF1 to inner loop 1 1 Derivative limitation Integ...

Page 21: ...g the offset Td range dt 32000µS 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 dt dt dt machine cycle time can not be modified Positive integral limitation range 0 100 It s the maximum val...

Page 22: ...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 dam...

Page 23: ... 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 Kp Ti Kp Ti Kp Ti and Td Td Td Td parameters until the maximum performances are obtained Once the inner loop has been adjusted the parameters Kp Ti Kp Ti Kp Ti Kp Ti and Td Td Td Td of the external loop can be adjusted so to optimize the gl...

Page 24: ...MUGL Page 24 of 38 rev 18 November 2009 Step function response varying Kp with Ti constant Step function response varying Ti with Kp constant ...

Page 25: ...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 ...

Page 26: ...e it s possible that are displayed some parameters that have no function 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 By means of the menu Set it s possible to selec...

Page 27: ... the readings of AC mains voltage DC BUS voltage temperature of heat sink and the state of the alarms With the RESET button it s possible to reset some stored alarms By means of the button Parametri PWM to step into the next mask where the PWM parameters are shown and could eventually be changed The regulation parameters for this type of equipment are those shown with 1 the others must not be chan...

Page 28: ... windows XP and supplied in a compressed package For the installation just click over the proper icon and accept 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...

Page 29: ...n Cerca In this way the program will begin the identification 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 a...

Page 30: ...et Sorgente riferimento seriale serial interface Sorgente Start pannello seriale bottom left you can set the FVC voltage and frequency outputs With digital potentiometer By entering the number expressed in in the box under the potentiometer 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 th...

Page 31: ...ember 2009 Under the voltage command 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 ...

Page 32: ...a start STX and the address IND of the device we intend to communicate with followed by a stop ETX and a checksum CKSUM for the data correctness verification STX IND Command or reply ETX CKSUM STX Start character Hexadecimal value 0x02 IND Device address added to the hexadecimal value 0x80 ex Address 1 character 0x81 ETX Stop character Hexadecimal value 0x03 CKSUM Control checksum it s a character...

Page 33: ...and Reply 0x10 F 0x10 F Firmware version Device name request Command Reply 0x10 N 0x10 N Device name Request and setting device setup mode Command Reply 0x10 M 0x10 M Setup mode Command Reply 0x11 M Setup mode setting 0x11 M ESI 0 Setup and start from panel 1 2 3 4 Setup and external start Note In case of remote mode look at appropriate command 0x15 M this command has effect only for the start ...

Page 34: ...S Voltage value Reply if IDX not ok 0x12 M ESI Command Reply 0x13 M IDX UMIS Voltage value 0x13 M ESI IDX 0x81 Fixed value UMIS 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 ...

Page 35: ...MUGL Page 35 of 38 rev 18 November 2009 Request and sending scales Command Reply 0x12 W 0x12 W Scale Command Reply 0x13 W Scale 0x13 W ESI Scala Can take values 1 or 2 ...

Page 36: ...nd Reply 0x14 E 0x14 E State or result of converter Test state 0 Halt 1 Running 2 3 4 5 6 Fail failure or malfunction 7 A Reading the actual main value Command Reply 0x14 M FA 0x14 M UMIS Actual value FA Necessary in the three phases devices Select the phase to read 1 2 3 if omitted it means 1 UMIS 0 Mmillivolt 1 Volt ...

Page 37: ...illiampere 1 Ampere Reading the remote connection state Command Reply 0x14 L 0x14 L Connection state Connection state L Not ACTIVE R Active Test Start and Stop commands Enables remote mode Command Reply 0x15 M Mode 0x15 M ESI Remote mode L Not active R Active In Remote mode the output values are defined via SERIAL link The start can be given from SERIAL link or from PANEL EXTERNAL according to the...

Page 38: ...in order to be sure the start has taken place it s necessary to read the device state Command 14E Test stop Command Reply 0x15 S 0x15 S ESI 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 ...