Electronic Load (EL DC)
Installation and operation manual
Tel: +49(0)7842-99722-00
Fax: +49(0)7842-99722-29
www.caltest.de
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D-77876 KAPPELRODECK
info@caltest.de
Caltest Instruments GmbH
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INDEX
1. INTRODUCTION ..................................................................................................................... 5
1.1. Symbols used ................................................................................................................. 5
1.2. Safety notes ................................................................................................................... 5
1.3. Quality and regulations ................................................................................................. 5
2. 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 .................................................................. 9
2.5. Functional diagram ........................................................................................................ 9
2.6. Principle of operation .................................................................................................. 10
3. INSTALLATION ..................................................................................................................... 16
3.1. Important safety instructions ...................................................................................... 16
3.2. Equipment views ......................................................................................................... 16
3.3. Equipment reception................................................................................................... 20
3.3.1. Unpacking and checking the content .................................................................. 20
3.3.2. Storage ................................................................................................................ 20
3.3.3. Transport to location ........................................................................................... 21
3.3.4. Location ............................................................................................................... 21
3.4. Connection .................................................................................................................. 23
3.4.1. Earth protection .................................................................................................. 23
3.4.2. Input connection, terminals (X1 to X5). .............................................................. 23
3.4.3. Output connection, terminals (X6 to X10) .......................................................... 23
3.4.3.1. DC unipolar mode............................................................................................ 23
3.4.3.2. DC bipolar mode .............................................................................................. 23
3.4.4. External Emergency Power Off connection (X12) ............................................... 23
3.4.5. Output signal of local Emergency Stop pushbutton (OPTIONAL) ....................... 25
3.4.6. Communications (Optional) ................................................................................ 26
3.4.7. Digital inputs and outputs ................................................................................... 26
3.4.8. Analog inputs and outputs (AIO Optional) .......................................................... 27
4. OPERATION ......................................................................................................................... 28
4.1. Safety ........................................................................................................................... 28
4.2. State Machine ............................................................................................................. 28
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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. Constant Current (CC) ......................................................................................... 31
4.3.3. Constant Power (CP) ........................................................................................... 32
4.3.4. Constant Voltage (CV) ......................................................................................... 32
4.4. Connection modes ...................................................................................................... 32
4.5. Working with the equipment ...................................................................................... 33
4.5.1. Start-up ................................................................................................................ 34
4.5.2. Stop ..................................................................................................................... 34
4.5.2.1. Full stop ........................................................................................................... 34
4.5.2.2. Standby stop .................................................................................................... 35
4.5.2.3. Ready ............................................................................................................... 35
4.5.3. Emergency stop ................................................................................................... 35
4.5.4. Accidental shut down .......................................................................................... 36
4.5.5. Alarms.................................................................................................................. 36
4.5.6. Alarms reset ........................................................................................................ 37
5. LOCAL TOUCHSCREEN CONTROL PANEL ............................................................................. 38
5.1. Basic functions............................................................................................................. 38
5.2. Menus and submenus ................................................................................................. 38
5.2.1. General ................................................................................................................ 38
5.2.2. Operational ......................................................................................................... 39
5.2.3. Supervision .......................................................................................................... 42
5.2.4. Configuration ....................................................................................................... 42
5.2.5. Alarms.................................................................................................................. 43
5.2.6. About EL .............................................................................................................. 44
6. REMOTE COMMUNICATIONS .............................................................................................. 44
6.1. IQ MANAGEMENT ....................................................................................................... 47
7. HUMAN MACHINE INTERFACE ............................................................................................ 49
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7.1. Operation .................................................................................................................... 49
7.1. Alarm ........................................................................................................................... 50
7.2. Supervision .................................................................................................................. 51
7.3. Unipolar/Bipolar connection ....................................................................................... 52
7.4. DC sequence ................................................................................................................ 53
8. WARRANTY AND MAINTENANCE ........................................................................................ 55
8.1. Replacing the input fuses ............................................................................................ 55
8.2. Fans ............................................................................................................................. 55
8.3. DC bus capacitors ........................................................................................................ 55
8.4. Warranty ..................................................................................................................... 55
8.5. Claim procedure .......................................................................................................... 56
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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.
This document is intended for appropriately qualified personnel. Only personnel with the
appropriate skills are allowed to perform the electrical connection and commissioning of the
equipment.
The information in this documentation is not binding. CINERGIA reserves the right to make
changes in part or in the whole at any time and without prior notice due to technical advance or
product improvement.
1.1. Symbols used
DANGER: Indicates a hazardous situation which can result in death or serious
injury and can cause important damage or destruction of the equipment or the
property.
WARNING: Indicates important information that must be taken into account to
operate the equipment. Take the appropriate prevention measures.
INFORMATION: Information that is important but is not safety-relevant.
1.2. Safety notes
Improper use of this equipment can cause both important personal injury and physical damage
to the electrical power grid and the loads connected to it. Read this document carefully and
follow all safety precautions at all times.
1.3. Quality and regulations
The equipment is based on a hardware designed, manufactured and commercialized in
accordance with the standard EN ISO 9001 of Quality Management Systems. The marking shows
conformity to the EEC Directive by means of application of the following standards:
• 2006/95/EC Low voltage directive.
• 2004/108/EC Electromagnetic Compatibility directive (EMC)
In accordance with the specifications of the harmonized standards:
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• 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).
• EN-IEC 62040-3. Uninterruptible power supply (UPS). Part 3: Methods of operation
specification and test requirements.
The manufacturer responsibility is excluded in the event of any modification or intervention in
the product by the customer’s side.
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2. PRESENTATION
2.1. Introduction
As an electronic load, the EL is designed to test electric and electronic equipment in linear and
non-linear DC loading. It allows to verify the functionality of the Equipment Under Test (EUT) in
normal and fault operation.
The main functionalities of the EL are the following:
- 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 CI: Constant Impedance output
o CC: Constant Current output
o CP: Constant Power output
o CV: Constant Voltage output
- As a bidirectional converter, energy can flow from the grid to the EUT or viceversa. It
allows energy saving during the tests by returning energy to the power grid.
- The AC current consumed from the grid is sinusoidal (THD < 6%).
- The user can define the reactive power to be injected by the EL and also choose between
capacitive or inductive.
The power range covered by the EL electronic loads goes from 6.75 to 160kW. The parallelization
of ELs is also possible to increase power:
REFERENCE
RATED POWER (25ºC)
RATED CURRENT (25ºC)
WEIGHT
DIMENSIONS
kVA
kW
Independent
Parallel
Bipolar
kg
DxWxH (mm)
0-750V
0-750V
-350 to
350V
B2C7.5
7.5
6.75
±10A
±30A
±10A
150
770x450x1100
B2C10
10 9 ±15A
±45A
±15A
150
B2C15
15
13.5
±20A
±60A
±20A
150
B2C20
20
18
±25A
±75A
±25A
150
B2C30
30
27
±30A
±90A
±30A
150
B2C40
40
36
±38A
±115A
±38A
185
B2C50
50
45
±47A
±140A
±47A
185
B2C60
60
54
±57A
±180A
±57A
185
B2C80
80
72
±105A
±315A
±105A
265
880x590x1320
B2C100
100
90
±130A
±390A
±130A
290
B2C120
120
108
±130A
±390A
±130A
290
B2C160
160
128
±155A
±465A
±155A
540
850x900x2000
B2C200
200
160
±185A
±555A
±185A
550
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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%
Power Factor
Typical at rated power
≥0.99
Configurable by user
0-1 (capacitive/inductive)
Efficiency
(at rated power)
>92%
Overload
125% for 10 min /150% for 60 s
Output side (EUT side)
DC Voltage
Channel-Com_neg
Channel_Com_neg
Channel_com_neg
20 to 750V (≤60kVA)
40 to 750V (>60kVA)
-350 to 350V
Minimum voltage
At rated power
320V
DC Current
Parallel channels mode
Independent channels mode
Bipolar output
0 to ±555A global
0 to ±185A per channel
0 to ±185A per channel
DC Overcurrent
110% during 1min
Modes of operation
Range
Resolution
Ripple
Constant Current
0-±100%
<±0.1%
<1%
Constant Power
0-±100%
<±0.1%
<1%
Constant Resistance
min.-100%
<±0.1%
<1%
Constant Voltage
0-100%
<±0.1%
<1%
Response time
Rated resistance load
1-5ms (10-90%)
General
Measurements
Input Voltage (Vrms) and current (Irms)
Input and Output Power
Output voltage (Vrms) and current (Irms)
Temperatures
User interface
3.2’’ Touchscreen
Local Control port: 4 digital inputs, 3 relay outputs (Option for AIO)
Communication Port: Ethernet (Optionals: RS485, RS232, CAN)
Communication Protocol: Modbus/TCP
Humidity
10-90% (Absolute maximum, without condensation)
Temperature
5-35ºC (Absolute maximum)
Cooling
Forced air
Protections
Over Current, Over Voltage, Shortcircuit, Overtemperature
Standards
CE Marking
Safety
EN-62040-1-2,EN-60950-1
EMC
EMC: EN-62040-2
Please note that items marked as optional shall be requested specifically at additional cost.
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2.3. Operation and connection modes
The output of the power converter is formed by three phases referenced to the neutral point of
the system (N). Consequently, the user can choose between two possible connection modes for
the electronic load:
- Independent phases: each phase (U, V, W) is controlled independently. The current
setpoint can be different in angle and magnitude for each of the three phases.
- Parallel phases: It is exactly the same as the previous case, but in this case the user has
shorted the phases. In this case the total amount of current consumed will be the sum
of all three phases.
- Unipolar mode: Electronic Load behaves as 3 independent and positive DC power
supplies.
- Bipolar mode: Electronic Load behaves as 2 independent DC power supplies. One is
positive and the other negative.
Three operation modes are allowed:
- Constant Impedance (CI): the output impedance is controlled to the set point value. The
emulator will perform as a constant R.
- Constant Current (CC): the output current is controlled to the set point value.
- Constant Power (CP): the output active power is regulated to the set point value.
- Constant Voltage (CV): the output voltage is controlled to the set point value.
2.4. Configuration and control of the converter
The converter can be interfaced by three means:
- Local touchscreen: a 3.2” color local touchscreen panel can be used to configure,
monitor and operate the electronic load. See section Local Touchscreen Control Panel
for further information.
- Analog and digital inputs: the converter owns three isolated analog inputs (+/-10V) and
tow optocoupled digital inputs.
- 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:
AC
ACTIVE RECTIFIER
GRID
DC AC
DC
EUT
DC/AC
Input LCL
filter
Input EMI
filter
Protections Protections
Output EMI
filter
Output LCL
filter
OPTIONAL
ELECTRONIC LOAD
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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.
- Input protections: these protections include a thermal-magnetic circuit breaker and
fuses. The connection of the converter input with the grid is done by screw terminals.
Please follow the safety instructions in the Installation section to connect the electronic
load.
- Input EMI filter: an electromagnetic filter is integrated to fulfil electromagnetic
compatibility regulations. The structure of the filter is the same as the one of the output
EMI filter.
- Input LCL filter: the purpose of this filter is to reduce the current distortion at
frequencies equal to or higher than switching frequency and reduce THD.
- Active Rectifier: a three-branch IGBT active front end is integrated in the equipment to
consume/inject a sinusoidal current from/into the grid.
The DC link voltage is set to 800V providing a regulation margin for fast transients at the
output of the electronic load.
The active rectifier has bidirectional power flow capability and the injected reactive
power (grid side) can be defined by the customer.
- DC/AC output converter: it is a three-branch IGBT converter. Its topology is the three
phase inverter and allows the conversion from the DC bus to each of the output AC
phases.
The user can choose between having each phase controlled independently or having the
three of them controlled as a unique phase (sharing the same operation mode and
setpoints).
- Output LCL filter: analogously to the input LCL filter, the filter reduces the current
distortion (caused by switching) at the output of the electronic load.
- Output EMI filter: a high frequency common mode LC filter is used to reduce the
electromagnetic disturbances at the output of the electronic load.
- Output protections: a disconnector is provided to isolate the output from the EUT. Screw
terminals are also integrated to connect the EUT. Please, follow safety instructions in
Installation section to connect them.
2.6. Principle of operation
Below, a technical diagram of the converter is shown:
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Drivers x6 Drivers x6
Current
sensor x3
Voltage
sensor x2
Voltage
sensor x3
Current
sensor x3
Voltage
sensor x3
PE
-U
-U
PE
PE
EMC
filter
EMC
filter
AC output
PE
EL
U
DSP
board
DSP
board
CAN/
Ethernet
board
CAN
MODBUS/TCP
ETHERNET
V
W
N
PE
R
S
T
N
PE
(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.
This produces a fast transient response and a high performance against EUT changes. A 12 bits
analog to digital conversion, with digital processing, allows a high resolution output up to 0.1%.
Resonant control (only AC)
Control algorithms based on Resonant controllers are used in both AC sides; i.e. Resonant
Control is always used in grid side but it is used in EUT side only when AC output option is chosen
for the electronic load.
The algorithms regulation is structured in blocks resonating at a given frequency. Within the
resonant frequency each block allows the suppression of gain and phase errors of the current.
Thanks to this, each harmonic can be controlled independently and thus it can be generated or
suppressed, as needed.
The following diagram illustrates how the mentioned algorithms operate:
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PR ω0
PWM x3
Σ
PR ω1
PR ω2
PR ω3
...
Feedback
+
-
KR
KFF
Setpoint
generator
Therefore, the main characteristics of the Resonant Control applied are the ones listed below:
- Control loop rate of 15 kHz.
- 15 harmonics controlled*: 1
st
-15th
- 15 control loops executed per phase.
- 45 control loops executed in total (for the 3 phases).
- Each control loop controls independently magnitude and angle of one harmonic.
- Any kind of load can be implemented in the EUT side.
- All harmonics can be suppressed in the grid side.
* It should be noted that the equipment bandwidth is 800 Hz. Therefore, the harmonic content
will be determined by the bandwidth as well as by the fundamental frequency specified by the
user.
Finally, the following pictures are some examples of how the EL Resonant Control can work. It is
important to take into account that, in these three pictures:
- Yellow waveform: input U
phase-N
- Green waveform: input I
phase-N
- Pink waveform: output U
phase-N
- Blue waveform: output I
phase-N
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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.
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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.
The following diagram illustrates how the algorithms operate:
Both in voltage mode and current mode, the equipment is regulated for the limits imposed by
the interface: maxIout, minIout, maxVout and minVout. In case that those limits are not
configured, the equipment is protected by the natural limits (110% of the nominal current).
The following table explains how those limits work.
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Parameter
Description
Default
maxIout
Maximum limitation of positive output current:
maximum current the equipment is able to inject
Maximum current
limitation
110% Irated
minIout
Maximum limitation of negative output current:
maximum current the equipment is able to drain
Maximum current
limitation
110% Irated
maxVout
Maximum limitation of voltage the equipment is
able to put in the output
750V
Range: 0V-750V
minVout
Minimum limitation of voltage the equipment is able
to put in the output
30V
Range: 0V-750V
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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.
All the electrical connections, including those for control (interface, remote control…etc.), shall
be done with all the switches in OFF position and with the mains supply disconnected (thermalmagnetic circuit breaker in OFF position too).
It must never be forgotten that the EL is a power converter, so users must take all
necessary precautions against direct or indirect contact.
Warning labels should be placed on all primary power switches installed in places far from the
device to alert the electrical maintenance personnel of the presence of a voltage in the circuit
up to 10 minutes after stopping the device.
In devices without isolation transformer, precautions must be taken as they are not
isolated from the alternating input line, and there might be dangerous voltage
between the output phases and the ground.
3.2. Equipment views
Electrical connections:
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Local front panel:
Front view (with the door open):
LCD
EPO
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Detailed view of the front protections and switches:
Detailed view of the signal connectors:
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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
(Q7) Isolation detector (which is inside the cabinet and it is optional)
(Q8) Bipolar/unipolar switch
Connection elements (X*):
(X1) Phase input terminal R.
(X2) Phase input terminal S.
(X3) Phase input terminal T.
(X4) Neutral input terminal N.
(X5) Earth connection terminal for main supply input ( ).
(X6) Phase output terminal U.
(X7) Phase output terminal V.
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(X8) Phase output terminal W.
(X9) Neutral output terminal N.
(X20) Negative output terminal U.
(X21) Negative output terminal V.
(X22) Negative output terminal W.
(X10) Earth connection terminal for EUT ( ).
(X11) DB9 connector for RS485 communications.
(X12) Terminals for external Emergency Power Off (EPO) button.
(X13) DB9 connector for CAN communications (input).
(X14) DB9 connector for CAN communications (output).
(X15) RJ45 connector for MODBUS interface.
(X16) DE15 connector for digital inputs and outputs.
(X17) DE15 connector for analogic inputs and outputs.
3.3. Equipment reception
3.3.1. Unpacking and checking the content
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;
all recyclable materials. Therefore, they should be disposed of according to current regulations.
We recommend to keep the packaging in case its use is necessary in the future.
In order to unpack, cut the bands and remove the cardboard packaging with a vertical
movement. In case of wooden packaging, remove it with the appropriate tools. Afterwards,
remove the corner pieces and the plastic sleeve. At this point the equipment will be unpacked
on the pallet. Please, use suitable tools to lower the converter from the pallet.
After unpacking the equipment, check that the data in the nameplate (stuck on the inner part
of the front door) correspond to those specified in the purchase order. Contact the supplier or
CINERGIA in case of disconformity.
Keep the equipment in the original package if it will not be used in order to protect it from any
possible mechanical damages, dust, dirt, etc…
3.3.2. Storage
The equipment shall be stored in a dry, ventilated place and protected against rain, water jets
or chemical agents. It is advisable to keep the converter into its original package, which has been
designed to assure the maximum protection during the transport and storage.
Do not store the unit where the ambient temperature exceeds 40ºC or falls
below -20ºC
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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.
It is also important to consider the most suitable means to place the converter 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.
Front view:
Recommendable minimum
distance, 1 m.
Recommendable minimum distance
, 1 m.
Recommendable minimum distance
, 1 m.
Top view:
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Recommendable minimum
distance, 1 m.
Recommendable minimum distance
, 1 m.
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.
To adjust the level, open the front door of the cabinet and proceed as follows:
By hand, loosen the levelling elements by turning them anticlockwise until they touch
the floor, and then, using a spanner, continue loosening until the castors are raised off
the floor 0.5 cm maximum.
Close the door once more.
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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 electronic load input.
On the other hand, connect the protection earth wire to the terminal (X10) before connecting
the EUT to the electronic load output.
3.4.2. Input connection, terminals (X1 to X5).
Connect the grid cables R, S, T and N to the terminals (X1), (X2), (X3) and (X4) respectively. This
connection must always be done according to the label placed under the input screw terminals.
In case of discrepancies between labelling and this manual instructions, the label information
will always prevail.
3.4.3. Output connection, terminals (X6 to X10)
3.4.3.1. DC unipolar mode
The equipment behaves as 3 independent (or parallel) positive power supplies. Each one is
referenced to its common (negative) point.
- First power supply: between X6 and X20
- Second power supply: between X7 and X21
- Third power supply: between X8 and X22
It is important not to use X9 terminal.
3.4.3.2. DC bipolar mode
The equipment behaves as 2 independent power supplies. One is always positive, the other
always negative and both are referenced at the same point X7.
- Positive power supply: between X6 and X7
- 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. For safety reasons, the operation is done by
hardware.
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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).
WARNING: the internal circuitry will be damaged if an external power supply is
connected to X12 (J15) EPO terminals. Do not connect an external power supply or
active signal. Only Normally Closed dry contact is allowed.
Figure 1: internal circuitry of EPO connection (J15 is X12 in above schematic)
There are three alternatives for connection:
a) Connecting an external Emergency pushbutton to X12 (NC contact, without potential)
b) Installing a cable bridge/shunt to close the circuit in terminal X12 (in case an external
EPO is not used)
c) Using the X12 terminals to serialize an external Emergency Power Off sequence (Figure
3)
The figures below describe the connection of the EPO.
X12
EPO
(Emergency
Power Off)
Figure 2: An External Emergency pushbutton (option a) or Cable bridge/shunt (option b) is
required
X12
External EPO
X12
Without EPO
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Figure 3: connection to serialize the Emergency Power Off sequence (option c)
3.4.5. Output signal of local Emergency Stop pushbutton (OPTIONAL)
In the standard units, there is no readback signal of the position of the local Emergency Stop
pushbutton located in the front panel. On request (OPTION), it is possible to add a Normally
Closed output contact of the front panel Emergency pushbutton.
In this case, the Emergency Stop pushbutton installed on the front panel of equipment has two
normally closed (NC) output contacts: one NC contact is used for the internal emergency
sequence of the equipment; and the second 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.
EPO - NC contact
X12
NO Relay
contact
External EPO 1
External EPO 2
External EPO N
External Relay
Vexternal
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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).
- Connector for MODBUS interface (X15): RJ45 connector A standard Ethernet cable must
be connected between X15 and PC to communicate a remote PC with the Electronic
Load. Alternatively, a standard Ethernet cable can be connected between X15 and a Hub
or a Router to communicate a remote PC with the Electronic Load.
- (Optional) Connector for RS232 communications (X11): DB9 connector to be used
when RS232 communication option is chosen.
3.4.7. Digital inputs and outputs
Digital inputs and outputs are gathered in X16. All of them are isolated and configurable.
Specifically, there are 5 digital inputs which operate at 24 V and 3 relay digital outputs.
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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. Long push: disable
Relay normally open output contact (3A, 250VAC / 3A, 30VDC)
- DIG_OUT_1_NO: Run (signal in run, ready and initialization)
- DIG_OUT_2_NO: Alarm (signal in alarm and initialization)
- DIG_OUT_3_NO: Ready (signal in ready, initialization and blinking during precharge)
In standby, none of the digital output is activated.
3.4.8. Analog inputs and outputs (AIO Optional)
Analog inputs and outputs are gathered in X17.
The analog input of EL is isolated and accept a voltage range from ‐10 to 10V. There is only one
analog input and it corresponds to the current setpoint for all three phases. If the analog input
is set to zero volts, that corresponds to 0A. In this way, by setting 10V, the EL will supply or sink
(depending on the sign) the rated current specified in the datasheet.
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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 startup.
4.2. State Machine
The operation of the converter is based on 6 different states (rectangles) and 6 transitions
(rhombs). Each state defines the behavior and possible actions of the converter:
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Initialization
EMCY
sequence?
Standby
Yes
No
Enable?
Precharge
Yes
Ready
Run? Enable?
No
Run
Yes
Yes
Run? Enable?
Yes
No
Yes
Error
From any
Reset?
Yes No
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.
The transition from Initialization state brings the converter to the Standby state as long as the
emergency stop is deactivated (equipment armed).
4.2.2. Standby
The Standby state keeps the converter in low power mode until an Enable signal is received.
While the converter is in standby only the internal power supplies are energized. In particular,
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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. If an
error is detected the converter will go into Alarm state.
4.2.3. Precharge
The Precharge is an internal transition state between Standby and Ready. During this state the
DC link is gradually charged through resistors until the rated DC link voltage is reached. The
transition will finish successfully as long as, in less than 10 seconds of precharge, the DC link has
reached the specified voltage. Otherwise, the next state will be Alarm.
The Precharge state is only applicable to the grid side converter.
4.2.4. Ready
In the Ready state the converter is ready to operate but no PWM signal is sent to IGBTs. The DC
link is charged to the rectified voltage and there is no voltage/current applied to the outputs.
The transition from Ready state can be the Run signal, the Not enable signal or, in case of errors,
a Fault signal. When a Run signal is received the State Machine will evolve to the Run state.
When a Not enable signal is received the State Machine puts the converter on standby, thus
discharging the DC link capacitors. If a fault is detected the converter goes to Alarm state.
Only on the Ready state the user can change the operation mode between (CC, CI, CP or CV).
4.2.5. Run
In this state, the converter is completely operational. Due to the converter architecture, the grid
side converter (Active Rectifier) will make the transition first while stabilizes the DC link voltage.
After that, the three-phase inverter of the EL will measure the actual EUT voltage levels and will
synchronize with them. Finally, the inverter 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.
Please, note that, while the EL is in Run state, it is not possible to change the working mode. For
doing this change the state machine to the corresponding mode.
4.2.6. Alarm
In this state, the converter is stopped and kept in a safe condition: the DC link is discharged and
the PWM signals are stopped.
The Alarm state can be reached by any fault detected during the normal operation of the
converter, for instance, an emergency stop activation (see Alarms chapter for further detail).
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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).
4.3. Operation modes
The EL has three operation modes available:
- Constant Impedance (CI): the output resistance is controlled to the setpoint value.
- Constant Current (CC): the output current is controlled to the setpoint value.
- Constant Power (CP): the output active power is regulated to the given setpoint value.
- Constant Voltage (CV): the output voltage is controlled to the set point value.
- Battery Mode (BM): B2C charge and discharge batteries within, if required, a cycling
mode.
4.3.1. Constant Impedance (CI)
This mode allows the user to define the resistance for each output phase.
Parameters and limits
In CI mode, the user may modify the value of the following parameter as long as they are within
the allowed range:
Parameter
Allowed range of values
Resistance
1000 – 0.8 Ohm
The allowed range for each of these parameter depends on the equipment’s rated power.
4.3.2. Constant Current (CC)
This mode allows the user to define the current shape for each output.
Parameters and limits
In CC mode, the user may modify the values of the following parameters as long as they are
within the specified range:
Parameter
Allowed range of values
Current (Unipolar mode)
Depending on catalogue
Current (Bipolar mode)
Depending on catalogue
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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:
Parameter
Allowed range of values
Active power (P)
[0 , +Maximum permitted depending on catalogue]
4.3.4. Constant Voltage (CV)
In CV mode, B2C works as a DC power supply.
Parameter
Allowed range of values
Unipolar voltage
[0 , +750]
Bipolar voltage
[-350 , +350]
4.4. Connection modes
As it has been previously mentioned, for the EL there are two possible connection modes:
- Independent phases: each phase (U,V,W) is controlled independently.
- Parallel phases: It is exactly the same as the previous case, but in this case the user has
shorted the phases. In this case the total amount of current consumed will be the sum
of all three phases.
- Unipolar mode: Electronic Load behaves as 3 independent and positive DC power
supplies.
- Bipolar mode: Electronic Load behaves as 2 independent DC power supplies. One is
positive and the other negative.
Please remember to disconnect the equipment before modifying the connection
mode.
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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:
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Check that all wires are connected and secured before proceeding to the converter start-
up.
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. This sequence will activate the cabinet
fans for one second.
At this point the converter will start the initialization process, as described previously. During
this time the embedded PC will load the operating system and the communications program.
The converter will ignore any command during this process.
The Initialization state can last up to 15 seconds. If every step is completed successfully the
converter will move automatically to Standby state.
Summarizing, to put the equipment in Run state the user should follow step by step the next
checklist:
1. Connect the mains.
2. Turn on the thermal-magnetic circuit breaker.
3. Activate the cabinet output by switching the disconnector.
4. Deactivate the emergency stop (pull out the button). (Initialization
Standby).
5. Send the Enable signal. (Standby
Precharge Ready).
6. Select the connection mode between Independent or Parallel phases. This option
cannot be done while the converter is running.
7. Select the operation mode. Please keep in mind that not all EUTs are compatible with
all operation modes. For example, if the converter is acting like a current source, do not
connect any other current sources at the output. The connection mode cannot be
changed during Run operation.
8. Send the Run signal. (Ready
Run).
Please keep in mind that not all EUTs are compatible with all operation modes. If
the converter 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. Full stop
This type of stop is recommended if the electrical connections are to be modified or the
converter will be stopped for a long time.
When the converter is running, special care must be taken. It is strongly recommended to follow
the next steps:
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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. Disconnect the input thermal-magnetic circuit breaker.
Before manipulating the cables in the cabinet terminals, please check the
voltages with a voltmeter to assure no voltage is present. The grid cable and the
EUT must be completely unpowered before connecting or disconnecting the
cables. The user must be sure that the input and output switches are both in
OFF position.
4.5.2.2. Standby stop
This type of stop is recommended if the converter will be stopped during some hours. The DC
link is discharged and therefore aging of the DC bus capacitors is prevented.
Send the Not enable signal to the converter. If the user wants to lock the converter in order to
avoid an accidental start-up, press the emergency stop button, and keep it pressed.
For restarting operation, release the emergency stop button and send the Reset signal. After
doing this, proceed as a standard start-up sending the Enable signal.
NEVER connect or disconnect the cables while the converter is in this state.
4.5.2.3. Ready
This type of stop is recommended if the converter will be stopped for a short time. The DC link
is kept charged and the converter is ready to run.
When the converter is running, the user may send the Not run signal at any time. This will stop
the IGBT PWM signals but all internal parts will be kept powered. To restart operation, send the
Run signal.
NEVER connect or disconnect the cables while the converter is in this state.
4.5.3. Emergency stop
The emergency stop button may be pressed at any time bringing the converter to the Alarm
state. The emergency stop shall be only used when an emergency is detected. Please, avoid to
stop the equipment with the emergency button as a “normal practice” since it will contribute to
premature component aging. To lock the converter and bring it to the Alarm state, follow the
Full stop procedure.
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The emergency stop unpowers all the electromechanical devices in the cabinet so the converter
is stopped by hardware assuring a full stop. The internal contactors will be open so no power
will be present at the DC link or at the output of the converter. Only the control boards, the
embedded PC and the local touchscreen remain powered.
4.5.4. Accidental shut down
When the converter is suddenly disconnected from the mains special care must be taken for
restarting it. When the converter is shut down with a charged DC link, some thermal protections
of the internal power supplies will prevent its start-up.
When an accidental shutdown happens disconnect the mains and wait for at least 2 minutes for
powering the cabinet again.
4.5.5. Alarms
There are different sources of alarm in the converter. The following table describes them and
offers possible causes and solutions to the user.
Code
Name
Cause
Solution
0
Watchdog
Internal microcontroller error.
If this alarm persists and is the only
alarm triggered, contact Cinergia’s
technical support.
1
Emergency
sequence
The emergency stop button is
activated or the EPO wire is no
longer connected.
Unpress the emergency stop
button or reconnect the EPO wire.
2
Drivers
IGBTs saturation protection
has been activated. This alarm
is triggered when there is a
sudden overcurrent in the
power supply output.
Contact Cinergia for technical
support if this alarm persists. Check
the equipment under test before
restarting the power supply.
3
Precharge timeout
Internal error caused by a low
voltage in mains.
Check the grid voltage.
4
Overload in
precharge
Internal alarm caused by a
shortcircuit. It may also be
triggered if there is not enough
time between the EPO release
and the enable signal.
Repeat the Enable action 5 seconds
after the EPO release.
Contact Cinergia for technical
support if this alarm persists.
5
Overvoltage in the
DC link
The DC link voltage has
exceeded its maximum value.
Reduce the output step transition
time. Contact Cinergia for technical
support if this alarm persists.
6
Undervoltage in the
DC link
Undervoltage in the DC link
caused by a fast output
transient.
Reduce the output step transition
time. Contact Cinergia for technical
support if this alarm persists.
7
AC overvoltage
The voltage in the emulated
grid is too high. Also in DC
indicates overvoltage.
Check the emulated grid voltage. It
can be triggered due to
connection/disconnection load
transition.
8
AC overcurrent
The output current has
exceeded the configured
limitation.
Check the output load.
9
Heatsink
overtemperature
Overtemperature in the
heatsink.
Check if there is enough space
between the power supply and the
wall. There is insufficient air flow
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inside the power supply. Check if
the fans are working correctly.
13
Alarm in node
One of the two control boards
has an alarm.
Reset alarms.
14
Node without
Heart Beat
Communications cable is
broken or there is a control
board without response.
Contact Cinergia in order to isolate
the problem.
16
CAN bus
error/Node SDO
Communications cable is
broken or one connector is
failing.
Contact Cinergia in order to isolate
the problem.
17
PLL error
The frequency of the grid is too
high or too low.
Check the grid frequency.
19
Mains lost
There has been an interruption
in the mains.
Check the mains and the grid
impedance
20
Isolation
The isolation detector detects
less than 10kOhm between
any phases and ground
Check the output and input
electrical connections. Check the
EUT to isolator faults.
21
Overload
The output power exceeds
150% during 60s or 120%
during 10 minutes.
Reduce de EUT power.
19
Output Shortcircuit
The power supply has
detected a shortcircuit in the
equipment under test.
Check the equipment under test
impedance.
20
Connection
mode/Wrong
Connection
The independent/parallel
switch has been switched
during the converter
operation
Do not operate the
independent/parallel switch
while the converter is running
21
Overvoltage
The Output voltage has
exceeded its maximum value.
Check the equipment under test
voltage.
22
Undervoltage
The Output voltage has
exceeded its minimum value.
Check the equipment under test
voltage.
23
Overcurrent
The output current has
exceeded the configured
limitation.
Check the output load.
24
Node Reset
Request
Communications cable is
broken or one connector is
failing.
Contact Cinergia in order to isolate
the problem.
4.5.6. Alarms reset
The user shall follow the next steps for resetting the alarms:
1. Press the emergency stop button.
2. Send a Reset signal to the converter.
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).
A Reset will be performed only in the case that the alarm source has been cleared. If the problem
persists after resetting the converter, a new alarm will be triggered.
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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.
By means of the black bar in the upper side of the touchscreen, the user is constantly aware of
the following variables:
- Mode (LCD/Remote/Console)
- Control (Current/Power/Impedance/Voltage)
- State of the power supply (Init/Standby/Precharge/Ready/Run/Alarm)
The rest of information can be found throughout the menus and submenus.
5.2. Menus and submenus
5.2.1. General
There are five main menus: Operational, Supervision, Config., Alarms, About. A description of
each one can be found in the following points.
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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:
Output voltage
Output current
The output current has a resolution until the second decimal, while the output voltage is
truncated on the units.
State Machine
By means of the ENABLE/DISABLE and RUN/READY buttons the user can manage the
power converters State Machine as long as the Control variable is set to LCD.
ENABLE/DISABLE: the function of this button depends on the power converters state:
o Standby State: the ENABLE/DISEABLE button is released. By pressing the
ENABLE/DISEABLE button the user orders the system to move to the Ready
state.
o Ready & Run States: the ENABLE/DISEABLE button is pressed. By pressing the
ENABLE/DISEABLE button the user orders the system to disable the power
converters.
The ENABLE/DISEABLE button has no effect in every other state.
RUN/READY: the function of this button depends on the power converters state:
o Ready State: the RUN/READY button is released. By pressing the RUN button
the user orders the system to move to Run State.
o Run State: the RUN/READY button is pressed. By pressing the RUN button the
user orders the system to return to Ready State.
The RUN/READY button has no effect in every other state.
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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.
Working in Impedance mode resistor set point, capacitor set point and inductor set
point could be introduced.
In the Voltage mode the user can introduce the DC setpoint voltage.
The power supply State Machine must be in either READY or RUN for the user to introduce these
set-points.
When the Set Point button is pressed, the following keyboard will appear.
The procedure to send a set point consists of the following steps:
1. Press Set Point button.
2. Introduce the first set point and press Enter.
3. Introduce the second set point and press Enter.
4. Introduce the third set point and press Enter.
5. Press SEND button.
If the user needs to erase the current set point being edited, the Cancel button (grey one) sets
it to zero. As it is shown in the next figure:
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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). It is shown in the next figure:
The Cancel button (green one) can be pressed anytime to return to the Operational menu
without sending any set point.
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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.
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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.
Operation Mode. The user can choose between the Current mode, Power Mode and
Impedance Mode.
5.2.5. Alarms
The Alarms window displays information about the power supply alarms. Any existing
alarm will appear in this window. In case the user is willing to reset the system, the RESET button
permits him to do so.
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5.2.6. 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). In this way, the customer can build specific HMI client software application while
CINERGIA’s power converter acts as a Modbus TCP/IP server.
Change IP
To change the IP of the EL DC and connect the equipment in the required net, the user can
change the IP through the interface:
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- 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. If necessary, look at the LCD local screen in order
to make sure that the new IP is correct.
Drivers x6 Drivers x6
Current
sensor x3
Voltage
sensor x2
Voltage
sensor x3
Current
sensor x3
Voltage
sensor x3
PE
-U
-U
PE
PE
EMC
filter
EMC
filter
AC output
PE
EL
U
DSP
board
DSP
board
CAN/
Ethernet
board
CAN
MODBUS/TCP
ETHERNET
V
W
N
PE
R
S
T
N
PE
This Modbus TCP slave has the following properties:
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It is important to read the document Modbus Data Table.
Property
Implementation
Function Codes:
0x03: READ_HOLDING_REGISTER
0x10: WRITE_MULTIPLE_REGISTER
Server port:
502 (decimal)
Modbus node ID:
10 (decimal)
CRC
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.
Idle connections
Idle connections might be closed by the slave.
Anyway, the listen socket will force the master to keep the connection
active, even when there is no active connection at all.
Other
All variables are 32-bit length. This is 2 Modbus base register addresses.
And so all Read operations must begin at the beginning of one variable,
and be Even.
For Write operations, ONLY 2 REGISTER WRITE OPERATIONS ARE
ALLOWED, i.e. only one variable (32 bits long) at one time.
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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. As an example, IQ21 means that the decimal part has 21 bits, the integer
part 10 and the first one is for the sign.
For the representation of the negative numbers:
And for the positive numbers:
As an example, 1.4142 in IQ10 representation:
Below there is a C# sample code for the representation:
IQ10 functions:
public double IQ10toFloat(double Var)
{
if (Var > 2147483648) //if the value is bigger than 2^31 (positive)
{
Var = Var - 4294967296; // Var - 2^32
Var = Var / (1024); // Var/(2^10)
}
else
{
Var = Var / (1024);
}
return Var;
}
public UInt32 FloatToIQ10(double Var)
{
UInt32 Retorn=0;
if (Var <0 ) // if negative
{
Var = (1024*Var) + 4294967296; // x*2^10 + 2^32
}
else
{
Var = Var * (1024);
}
Retorn = Convert.ToUInt32(Var);
return Retorn;
}
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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;
}
public UInt32 FloatToIQ21(double Var)
{
UInt32 Retorn = 0;
if (Var < 0) // if negative
{
Var = (2097152 * Var) + 4294967296; // Var*2^21 + 2^32
}
else
{
Var = Var * (2097152); // Var*2^21
}
Retorn = Convert.ToUInt32(Var);
return Retorn;
}
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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:
- OPERATION
- ALARM
- SUPERVISION
- UNIPOLAR (CURRENT, POWER, IMPEDANCE, VOLTAGE)
- BIPOLAR (CURRENT, POWER, IMPEDANCE, VOLTAGE)
- DC SEQUENCE
Further information of each kind of tab can be found in the following sections.
7.1. Operation
- A: Information about the status of the equipment and buttons to control it:
- Enable / Disable: the corresponding led shows whether the equipment is
enabled or disabled.
- Run / Ready: the corresponding led shows whether the equipment is running or
is ready for operation.
- Reset: it allows the user to reset all the alarms that have occurred and that have
been previously announced.
- B: Information about of Active Rectifier and Inverter status.
- C: Connection mode. Informs about the connection:
- DC independent/parallel unipolar
- DC independent bipolar (note that parallel bipolar is not allowed)
- D: Choose the control mode (CI, CC, CP or CV) in any state instead of RUN.
- E: Informs about which is the equipment’s control:
- Local: control from LCD screen.
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- 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. Another
option is to limit the speed of the application of the load. In the ramp section, a ramp
can be programmed from 0.001 to 100 Units per millisecond.
- G: Connection settings.
7.1. Alarm
In this tab, the alarm status of each converter is shown. When there is an alarm, the light turns
to red.
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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.
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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. When all the values are ready, send setpoints.
- C: Limits allow the equipment to be more protected. Choose the proper limits and send
them. It is important not to work very close from the limits.
Bipolar
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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).
Select the control mode (CI, CC, CP or CV) in some state different than RUN, then enter the
setpoints and send them.
7.4. DC sequence
EL gives the opportunity to create a DC sequence using Current mode, Power mode, Impedance
mode and Voltage mode.
- A: Information about actual values of current, voltage and power.
- B: During the sequential DC test, the plots are being drawn. User can adjust the scale.
- C: .csv files can be created, opened and modified if necessary in the interface. Example
of .csv file:
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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.
- D: Once everything is ready, send button starts the sequence, stop one makes it to finish.
Repeat sequence allows the sequence to restart when finished.
- E: .csv file is showed in this window when it is opened.
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8. WARRANTY AND MAINTENANCE
Fans and capacitors must be replaced at the end of their useful lifetime.
Inside the equipment there are dangerous voltages and metallic parts at high
temperatures even when the equipment is stopped. The direct contact can cause
electrocutions and burns. All the operations must be done by authorized
technical staff.
8.1. Replacing the input fuses
This operation must be performed by personnel experienced with electrical
systems. The direct contact can cause electrocutions and burns.
In order to replace the input fuses follow procedure below:
1. Stop the converter following the instructions of FULL STOP
2. Turn the output switch-disconnector (Q2) to the OFF position
3. Open the fuse holder and replace the fuses
These fuses can only be replaced by new ones of exactly the same model.
8.2. Fans
The useful lifetime of the fans used to cool the power circuits depends on the use and
environment conditions. It is recommended their preventive replacement by authorized
technical staff.
8.3. DC bus capacitors
The useful lifetime of the DC bus capacitors and those ones used in the input and output filtering
depends on the use and the environment conditions. It is recommended their preventive
replacement by authorized technical staff.
8.4. Warranty
CINERGIA warrants that the delivered equipment is free from any defect affecting the
functioning thereof for a time period not exceeding one (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:
• On-site technical assistance
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• Product or component repair at CINERGIA’s premises
• Replacement of the defective product or component
The decision whether to perform the assistance on-site, to repair or replace the faulty product
and/or component shall be taken in any case exclusively by CINERGIA.
8.5. Claim procedure
The warranty rights can be exercised during the validity of the warranty period and immediately
upon detecting any abnormalities, except in the case of visible defects, in which case the claim
shall be submitted within a maximum time of 7 days from the date of receipt of the equipment
and always prior to its installation.
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. Such documentation shall be sent to the email address of the Sales Team
(comercial@cinergia.coop).
• Upon receiving the documentation, CINERGIA will analyse it to decide whether the
intervention required is covered by the warranty terms described herein.
• 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. Any shipping damages attributable to improper packaging shall not be covered by
warranty. The faulty product should be shipped back in upright position over a pallet and
properly covered and protected.
• Failure to return the replaced equipment within 10 (ten) standard days shall authorize
CINERGIA to invoice the equipment supplied as replacement.
• In case the defect of the returned equipment is deemed not to be covered by the warranty,
CINERGIA shall issue an invoice to the purchaser for the repair activity.
• If on arrival at CINERGIA’s premises the returned equipment is deemed to be in perfect
operating conditions, CINERGIA shall be authorized to issue an invoice for all the costs resulting
from its replacement (analysis and testing of the equipment and shipping costs).
• CINERGIA reserves the right to provide a different model of product and/or component to
process the claims covered by the warranty terms, in case the original model and/or component
is out of production.
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