Eurotherm EPower User Manual

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Page 1

EPower™ Controller

User Guide

EPower™ Power management and control units Versions 3.05 and later

HA179769 issue 8 May 2011

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Declaration of Conformity

Manufacturer’s name: Eurotherm Automation SA

Manufacturer’s address: 6, chemin des Joncs

69574 Dardilly, France

Product type: Power Management and Control units

Models:

Safety specification: EN60947-4-3:2000

Including amendment A1

EMC emissions specification: EN60947-4-3:2000 Class A

EMC immunity specification: EN60947-4-3:2000

Eurotherm Automation SA hereby declares that the above products conform to the safety and EMC specifications listed. Eurotherm Automation SA further declares that the above products comply with the EMC directive 2004/108/EC, and also with the Low Voltage Directive 2006/95/EC.

Signed: Dated:

IA249986U740 Issue 6 Feb 10 (CN26093)

Including amendment A1

Signed for and on behalf of Eurotherm Automation

Kevin Shaw

(R&D Director)

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EPowerMC

ℶ❐

EPower

杔㻭柘 ⏼ↆ杻 ⮩䅃勣啾 ⮩䅃ℛ啾搩

洀┷⣷

┮䘖㲰⧦⸘⪈

┮䘖㲰⧦⸘⪈

┮䘖㲰⧦⸘⪈

┮䘖㲰⧦⸘⪈

┮䘖㲰⧦⸘⪈

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┮䘖㲰⧦⸘⪈

OOOOOO

歝⑆

㻃⑆

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┮䘖㲰⧦⸘⪈

Pb Hg Cd Cr(VI) PBB PBDE

Power Module 50A X X O O O O

Power Module 160A X X O O O O

Power Module 400A X X O O O O

Power Module 800A O O O O O O

Power Module 1300A O O O O O O

Power Module 2000A

(water cooled)

Power Module 4000A O O X X O O

Indicates that this toxic or hazardous substance contained in all of the homogeneous materials for

Restricted Materials Table

Restriction of Hazardous Substances (RoHS)

德㒥⏒侯

Product group

Table listing restricted substances

Chinese

XOXOOO XXOOOO XXOOOO XXOOOO XXOOOO

┮䘖㲰⧦⸘⪈

┮䘖㲰⧦⸘⪈

┮䘖㲰⧦⸘⪈

XXOOOO XXOOOO XXOOOO OOOOOO OOOOOO OOOOOO

OOOOOO

OOX XOO

OOX XOO OOX XOO

⴫␜年㦘㹡㦘⹂䓸德⦷年捷ↅ㓏㦘⧖德㧟㠨₼䤓⚺摞⧖⦷SJ/T11363-2006 㪖⑕屓⸩䤓棟摞尐 ᳞એޕ

⴫␜年㦘㹡㦘⹂䓸德咂⺠⦷年捷ↅ䤓㩟₏⧖德㧟㠨₼䤓⚺摞怔⒉SJ/T11363-2006 㪖⑕屓⸩䤓㒢㊂ⷐ᳞ޕ

Epower,

㒢೙૶↪᧚ᢱ৻屗嫷

᦭Ქ᦭ኂ‛

English

Product EPower

Driver

Power Module 100A X X OOOO

Power Module 250A X X OOOO

Power Module 500A X X OOOO Power Module 630A X X OOOO

Power Module 1000A OOOOOO

Power Module 1700A OOOOOO

(air cooled)

Power Module 3000A O O X X O O

Approval

Name: Position: Signature: Date:

Martin Greenhalgh Quality Manager

XOXOOO

OOOOOO

OOX XOO

!"

Indicates that this toxic or hazardous substance contained in at least one of the homogeneous



Toxic and hazardous substances and elements

IA029470U740 Issue 4 Dec 09 (CN25945)

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EPOWER CONTROLLER USER GUIDE

INSTALLATION AND OPERATION MANUAL

LIST OF SECTIONS

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 QUICKSTART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5 OPERATOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6 ENGINEER AND CONFIGURATION LEVEL MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7 USING ITOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

8 PARAMETER ADDRESSES (MODBUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

9 PREDICTIVE LOAD MANAGEMENT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

10 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

11 TECHNICAL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

12 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

APPENDIX A REMOTE DISPLAY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

APPENDIX B THREE PHASE FEEDBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

ASSOCIATED DOCUMENTS

HA179770 Communications Manual HA028838 iTools help manual

SOFTWARE EFFECTIVITY

This manual relates to units with software version 3.05

PATENTS

This product is covered by one or the more of the following patents:

France: FR 06/02582 (Published 2899038) Europe: 07104780.7 (Pending) US: 11/726,906 (Pending) China: 200710089399.5 (Pending)

HA179769 Contents Issue 8 May 11 Page i

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EPOWER CONTROLLER USER GUIDE

TABLE OF CONTENTS

Section Page

List of Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

ASSOCIATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

SOFTWARE EFFECTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

USER GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 UNPACKING THE UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Fixing details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.1 Driver Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SUPPLY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FAN SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ENABLE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SAFETY EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SIGNAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

WATCHDOG RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

RELAY 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

PREDICTIVE LOAD MANAGEMENT OPTION CONNECTOR . . . . . . . . . . . . . . . 14

CONFIGURATION PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

COMMUNICATIONS PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2.2 Power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

LINE/LOAD CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

RIBBON CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

EXTERNAL CURRENT FEEDBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

REMOTE VOLTAGE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

NEUTRAL/PHASE REFERENCE INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ACCESS TO LINE AND LOAD TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

THREE-PHASE STAR CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

THREE-PHASE DELTA CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

TWO-LEG CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

THREE PHASE CONFIGURATIONS WITH EXTERNAL FEEDBACK . . . . . . . . . . 29

3 OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2 PUSHBUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2.3 Menu item value selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.3 BEACONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4 FRONT PANEL MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4.1 Instrument events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4.2 Indication alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4.3 System alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4.4 Process alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4.5 Configuration errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4.6 Standby errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Contents HA179769 Page ii Issue 8 May 11

Page 7

EPOWER CONTROLLER USER GUIDE

TABLE OF CONTENTS (CONT.)

Section Page

3.4.7 Power module errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4.8 General errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4.9 Reset errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4.10 Fatal errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 QUICKSTART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.1 QUICKSTART MENU PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.2 SOME DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2.1 Firing modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

BURST FIXED FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

BURST VARIABLE FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

PHASE ANGLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

HALF CYCLE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.2.2 Feedback type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.2.3 Transfer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2.4 Limitation features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

FIRING ANGLE LIMITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

DUTY CYCLE LIMITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5 OPERATOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1 SUMMARY PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1.1 Single phase summary page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1.2 Two or three phase summary page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1.3 Two by two phase summary page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2 TOP LEVEL OPERATOR (USER) MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2.1 Alarm Summary pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2.2 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2.3 Strategy Standby mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6 ENGINEER AND CONFIGURATION LEVEL MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.1 ACCESS TO THE ENGINEER AND CONFIGURATION MENUS . . . . . . . . . . . . . . . . 44

6.1.1 Engineer level menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.1.2 Configuration level menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.2 TOP LEVEL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.3 ACCESS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.3.1 Engineer level menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.3.2 Configuration level access menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

GOTO MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

PASS CODE EDITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.4 ANALOGIP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.4.1 Analogue input parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.5 ANALOGOP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.5.1 Analogue output ‘Main’ submenu parameters . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.5.2 Analogue output ‘Alm’ parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.6 COMMS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.6.1 Communications User menu parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.6.2 COMMS REMOTE PANEL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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6.7 CONTROL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.7.1 Control Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.7.2 Control Main Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.7.3 Control Limit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.7.4 Control Diag parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6.7.5 Control Alarm disable parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.7.6 Control Alarm detection parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6.7.7 Control Alarm signalling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.7.8 Control Alarm Latch parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.7.9 Control Alarm Acknowledgement parameters . . . . . . . . . . . . . . . . . . . . . . . . 65

6.7.10 Control Alarm Stop parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.8 COUNTER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.8.1 Counter configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.8.2 Cascading counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.9 DIGITAL I/O MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.10 ENERGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.10.1 Energy counter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.10.2 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6.11 EVENT LOG MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6.12 FAULT DETECTION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.13 FIRING OUTPUT MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.14 INSTRUMENT MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.14.1 Instrument Display parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.14.2 Instrument Config parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.15 IP MONITOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.16 LGC2 (TWO INPUT LOGIC OPERATOR) MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6.16.1 Lgc2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6.17 LGC8 (EIGHT-INPUT LOGIC OPERATOR) MENU . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6.18 MATH2 MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.19 MODULATOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6.20 NETWORK MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

6.20.1 Meas submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

6.20.2 Network Setup Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

PARTIAL LOAD FAILURE CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

6.20.3 Network alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

NETWORK ALMDIS SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

NETWORK ALMDET SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

NETWORK ALMSIG SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

NETWORK ALMLAT SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

NETWORK ALMACK SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

NETWORK ALMSTOP SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

6.21 PLM (STATION AND NETWORK LM PARAMETERS) MENU . . . . . . . . . . . . . . . . . 94

6.21.1 Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

6.21.2 Predictive Load management ‘Station’ menu . . . . . . . . . . . . . . . . . . . . . . . . 96

6.21.3 Predictive Load Management ‘Network’ menu . . . . . . . . . . . . . . . . . . . . . . . 97

6.21.4 Predictive Load Management ‘Alarm’ menus . . . . . . . . . . . . . . . . . . . . . . . . 98

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6.22 PLMCHAN (LOAD MANAGEMENT OPTION INTERFACE) MENU . . . . . . . . . . . . 99

6.23 LOAD TAP CHANGER (LTC) OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

6.23.1 MainPrm parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.23.2 LTC Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.23.3 LTC Application wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

6.24 RELAY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6.24.1 Relay parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6.25 SETPROV MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6.25.1 Setpoint provider parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6.26 TIMER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

6.26.1 Timer configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

6.26.2 Timer examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6.27 TOTALISER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

6.28 USER VALUE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

7 USING ITOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

7.1 iTools CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

7.1.1 Serial communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

7.1.2 Ethernet (Modbus TCP) communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7.1.3 Direct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.2 SCANNING FOR INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

7.3 GRAPHICAL WIRING EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.3.1 Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

7.3.2 Wiring editor operating details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

COMPONENT SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

BLOCK EXECUTION ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

FUNCTION BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

WIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

THICK WIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

COMMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

MONITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

DOWNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

COLOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

DIAGRAM CONTEXT MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

COMPOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

TOOL TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

7.4 PARAMETER EXPLORER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

7.4.1 Parameter explorer detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

7.4.2 Explorer tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

7.5 FIELDBUS GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

EE CHECKSUM FAIL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.6 DEVICE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.7 WATCH/RECIPE EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

7.7.1 Creating a Watch List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

ADDING PARAMETERS TO THE WATCH LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

DATA SET CREATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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7.7.2 Watch Recipe toolbar icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.7.3 Watch/Recipe Context Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.8 USER PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

7.8.1 User Page creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

7.8.2 Style examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.8.3 User Pages Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8 PARAMETER ADDRESSES (MODBUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

8.2 PARAMETER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

8.3 PARAMETER SCALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

8.3.1 Conditional scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

8.4 PARAMETER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

9 PREDICTIVE LOAD MANAGEMENT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

9.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

9.1.1 Load Management layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

9.1.2 Power modulation and accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

9.2 LOAD SEQUENCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

9.2.1 Incremental control type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

9.2.2 Incremental control type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

9.2.3 Rotating Incremental control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

9.2.4 Distributed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

9.2.5 Incremental/Distributed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

9.2.6 Rotating Incremental Distributed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

9.3 LOAD SHARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

9.3.1 Total power demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

9.3.2 Sharing Efficiency Factor (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

9.3.3 Sharing algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

9.4 LOAD SHEDDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9.4.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9.4.2 Reduction of power demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

SHEDDING ABILITY FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

9.4.3 Load shedding comparisons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

WITHOUT LOAD SHARING, SYNCHRONISED . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

WITHOUT LOAD SHARING, SYNCHRONISED, REDUCTION FACTOR 50% . . 187

WITHOUT LOAD SHARING NOT SYNCHRONISED . . . . . . . . . . . . . . . . . . . . . . . 187

WITHOUT LOAD SHARING, NON-SYNCHRONISED, REDUCTION FACTOR 50% 188

WITH LOAD SHARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

WITH LOAD SHARING, REDUCTION FACTOR = 50% . . . . . . . . . . . . . . . . . . . . 189

9.5 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

9.5.1 iTools Graphical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

STANDARD POWER CONTROL LOOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

LOAD MANAGEMENT CHANNELS (LMCHAN 1 TO LMCHAN 4) . . . . . . . . . . . 190

GLOBAL LOAD MANAGEMENT CONTROL (LOADMNG) . . . . . . . . . . . . . . . . . 190

CALCULATION AND COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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9.5.2 Predictive Load Management function block details . . . . . . . . . . . . . . . . . . . 193

LM TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

SHEDFACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

PZMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

NUMCHAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

TOTALSTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

TOTALCHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

PMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

PR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

MASTER ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

9.6 MASTER ELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

9.6.1 Master Election triggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

9.7 ALARM INDICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

PROVERPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

9.8 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

9.8.1 Wrong Station status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

DUPLICATE LM ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

STATION STATUS PERMANENTLY ‘PENDING’ . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

STATION TYPE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

10 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1 SYSTEM ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.1 Missing mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.2 Thyristor short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.3 Thyristor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.4 Fuse blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.5 Over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.6 Network dips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.7 Mains frequency fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.1.8 Power board 24V fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.2 PROCESS ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.2.1 Total Load Failure (TLF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.2.2 Output short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.2.3 Chop Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.2.4 Mains Voltage Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.2.5 Temperature pre-Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.2.6 Partial Load Failure (PLF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.2.7 Partial Load Unbalance (PLU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

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EPOWER CONTROLLER USER GUIDE

TABLE OF CONTENTS (CONT.)

Section Page

10.3 INDICATION ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.3.1 Process Value Transfer active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.3.2 Limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.3.3 Load Over-Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

10.3.4 Over Load Shedding (Ps over Pr) alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

11 TECHNICAL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

12 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

12.1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

12.2 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

12.3 THYRISTOR PROTECTION FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

APPENDIX A REMOTE DISPLAY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

A1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

A1.1 SAFETY AND EMC INFORMATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

A2 MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

A3 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

A3.1 PINOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

A3.2 WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

SUPPLY VOLTAGE RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

ANALOGUE (MEASURING) INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

OUTPUT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

A3.3 OVER TEMPERATURE APPLICATION WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

A4 FIRST SWITCH ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

A5 OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

A5.1 FRONT PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

REM/MAN BEACONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

A5.2 LEVEL 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

A5.3 LEVEL 2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

A5.4 LEVEL 3 AND CONF LEVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

AUTO SCROLLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

A6 OTHER FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

A6.1 ALARMS AND ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

A6.2 RECIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

A6.3 EPOWER SETPROV CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

MULTIPLE SINGLE PHASE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

A6.4 PV RETRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

A6.5 DIGITAL ALARM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

A6.6 HOME PAGE TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

APPENDIX B THREE PHASE FEEDBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

B1 TRANSFORMER REPRESENTATION AND LABELLING . . . . . . . . . . . . . . . . . . . . . . . 235

B2 EXTERNAL FEEDBACK PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

B2.1 CURRENT TRANSFORMER CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

B2.2 FEEDBACK EXAMPLES FOR TYPICAL THREE PHASE NETWORKS . . . . . . . . . . . 237

B2.2.1 Two phase control with Delta-Star transformer and 3S load . . . . . . . . . . . . 237

B2.2.2 Two phase control with Delta-Star transformer and 3D load . . . . . . . . . . . 237

B2.2.3 Three phase control with Delta-Star transformer and 3S load . . . . . . . . . . 238

B2.2.4 Three phase control with Delta-Star transformer and 3D load . . . . . . . . . . 238

Contents HA179769 Page viii Issue 8 May 11

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EPOWER CONTROLLER USER GUIDE

TABLE OF CONTENTS (CONT.)

Section Page

B2.2.5 Three phase control with Star-Star transformer and 4S load . . . . . . . . . . . . 239

B2.2.6 Three phase control with Delta-Delta transformer and 3S load . . . . . . . . . 239

B2.2.7 Three phase control with 6D primary and 4S secondary with 4S load . . . 240

B2.2.8 Three phase control with 6D primary /secondary

with three independent loads . . 240

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

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This page is deliberately left blank

Contents HA179769 Page x Issue 8 May 11

Page 15

SAFETY NOTES

This product does not contain any branch-circuit protection or internal safety overload protection. It is the responsibility of the user to add branch-circuit protection upstream of the unit. It is also the responsibility of the user to provide external or remote safety overload protection to the end installation. Such branch-circuit and safety oveload protection must comply with applicable local regulations.

UL: The abovementioned branch-circuit protection is necessary for compliance with National Electric Code (NEC) requirements.

1. Any interruption of the protective conductor inside or outside the apparatus, or disconnection of the protective earth terminal is likely to make the apparatus dangerous under some fault conditions. Intentional interruption is prohibited.

2. Before carrying out any wiring to the unit it must be ensured that all relevant power and control cables, leads or harnesses are isolated from voltage sources. Wire conductor cross sections must comply with table 1 of EN60947-1 (or with table 2.2.2 of this manual).

3. This equipment is not suitable for isolation applications, within the meaning of EN60947-1.

4. Under some circumstances, the power module heatsink temperature may rise above 50 degrees Celsius. If operators are likely to come into contact with such heatsinks, adequate warnings and barriers must be put in place in order to prevent injury.

5. EPower alarms protect thyristors and loads against abnormal operation, and provide the user with valuable information regarding the type of fault. Under no circumstances should these alarms be regarded as a replacement for proper personnel protection. It is strongly recommended that the installing authority include independent, system-safety mechanisms to protect both personnel and equipment against injury or damage, and that such safety mechanisms be regularly inspected and maintained. Consult the EPower supplier for advice.

EPOWER CONTROLLER USER GUIDE

WARNING

BRANCH-CIRCUIT PROTECTION AND SAFETY OVERLOAD PROTECTION

WARNINGS

Note:

The instrument shall have one of the following as a disconnecting device, fitted within easy reach of the operator, and labelled as the disconnecting device. a. A switch or circuit breaker which complies with the requirements of IEC947-1 and IEC947-3 b. A separable coupler which can be disconnected without the use of a tool.

1. Before any other connection is made, the protective earth terminal shall be connected to a protective conductor.

2. The mains supply fuse within the Driver Module is not replaceable. If it is suspected that the fuse is faulty, the manufacturer’s local service centre should be contacted for advice.

3. Whenever it is likely that protection has been impaired, the unit shall be made inoperative, and secured against accidental operation. The manufacturer’s nearest service centre should be contacted for advice.

4. Any adjustment, maintenance and repair of the opened apparatus under voltage, is forbidden for safety reasons.

5. Units are designed to be installed in a cabinet connected to the protective earth according to IEC364 or applicable national standards. The cabinet must be closed under normal operating conditions. Adequate air conditioning/ filtering/ cooling equipment must be fitted to the cabinet in order to prevent the ingress of conductive pollution, the formation of condensation etc.

6. Units are designed to be mounted vertically. There must be no obstructions (above or below) which could reduce or hamper airflow. If more than one set of units is located in the same cabinet, they must be mounted in such a way that air from one unit is not drawn into another.

7. Signal and power voltage wiring must be kept separate from one another. Where this is impractical, shielded cables should be used for the signal wiring.

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EPOWER CONTROLLER USER GUIDE

SAFETY NOTES (Cont.)

8. If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment might be impaired.

9. In order to maintain protection against electrostatic discharge, any scratched or damaged intermodule ribbon cables must be replaced.

SELV

Safety Extra Low Voltage. This is defined (in EN60947-1) as an electrical circuit in which the voltage cannot exceed ‘ELV’ under normal conditions or under single fault conditions, including earth faults in other circuits. The definition of ELV is complex as it depends on environment, signal frequency etc. See IEC 61140 for further details.

SYMBOLS USED ON THE INSTRUMENT LABELLING

One or more of the symbols below may appear as a part of the instrument labelling.

Protective-conductor terminal Risk of electric shock

AC supply only

Underwriters laboratories listed mark, for Canada and the U.S.

Precautions against static electrical discharge must be taken when handling this unit.

Refer to the manual for instructions

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EPOWER CONTROLLER USER GUIDE

USER GUIDE

1 INTRODUCTION

This document describes the installation, operation and configuration of an EPower ‘station’ (Driver Module plus one or more Power Modules). The Driver Module comes in one version, but the Power Modules are available in a number of different power ratings, which are identical in operation and configuration, but which differ in physical size according to the number of phases being controlled and the maximum current being supplied. All but the 50 Amp and 100 Amp unit come with cooling fans attached.

The Driver Module includes the following analogue and digital inputs and outputs, fitted as standard: 10V supply Two analogue inputs One analogue output Two digital Inputs/Outputs. One change-over relay under software control, configurable by the user. Also fitted are a Watchdog relay, a configuration port and an isolated EIA485 port for attaching an optional Remote Display.

Three further (optional) I/O modules may be fitted, similar to the standard module but with the addition of an output change-over relay. Other options provide for external voltage and current feedback and for predictive load management.

Section two of this manual gives connector locations and pinouts. The operator interface consists of a display comprising four lines of 10-characters (where each character is

formed using a 5 x 7 LCD dot matrix) and four push buttons for navigation and data selection.

1.1 UNPACKING THE UNITS

The units are despatched in a special pack, designed to give adequate protection during transit. If any of the outer boxes show signs of damage, they should be opened immediately, and the instrument examined. If there is evidence of damage, the instrument should not be operated and the local representative contacted for instructions.

After the instrument has been removed from its packing, the packing should be examined to ensure that all accessories and documentation have been removed. The packing should then be stored against future transport requirements.

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EPOWER CONTROLLER USER GUIDE

400A

250A

2 INSTALLATION

2.1 MECHANICAL INSTALLATION

2.1.1 Fixing details

Units are designed to operate at an operating temperature not exceeding 40°C (unless the modules are derated - see specification). Units must be installed in a fan-cooled cabinet (with fan failure detection or thermal safety cutout). Condensation and conductive pollution should be excluded to IEC 664 class 2. The cabinet must be closed and connected to the protective earth according to IEC 60634 or applicable national standard.

Units must be mounted with the heat sink vertical with no obstructions above or below which impede the airflow. Where more than one set of modules is enclosed in the same cabinet, they must be mounted such that air from one unit is not drawn in by another mounted above it. An air gap of at least 5 cm should be maintained between adjacent sets of modules.

The units are designed for fitting to the front face of a mounting panel using the fixings supplied. The thyristor power modules are heavy, so a Health and Safety risk assessment should be carried out before personnel attempt to lift the units. It should also be ensured, prior to fitting, that the mechanical strength of the panel is sufficient for the mechanical load being applied. Table 2.1.1 gives the weights of the various units.

GENERAL

Figure 2.1.1a, below, shows details of a generalised mechanical assembly for the top of the units. Assembly details for the bottom brackets is similar, except that there is no safety earth fixing. The power module shown is a 400 Amp unit for which the module is fixed to the support brackets using holes A and B. Lower current power modules use only one screw (C) to secure the module to the support bracket.

Weight (including 2 kg (4.4 lb) for driver module)

Current

50/100 A 6.5 14.3 11.0 24.3 15.5 34.2 20.0 44.1

160 A 6.9 15.2 11.8 26.0 16.7 36.8 21.6 47.6 250 A 7.8 17.2 13.6 30.0 19.4 42.8 25.2 55.6 400 A 11.8 26.0 21.6 47.6 31.4 69.2 41.2 90.8 500 A 14.0 30.9 26.0 57.3 38.0 83.8 50.0 110.2 630 A 14.5 32.0 27.0 59.5 39.5 87.1 52.0 114.6

1 phase 2 phases 3 phases 4 phases

kg lb kg lb kg lb kg lb

Table 2.1.1 Unit Weights

Weights ± 50gm (2 oz)

lb oz

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.6

3.2

4.8

6.4

8.0

9.6

11.2

12.8

14.4

Single-phase power module mounting shown. Multi-phase mountings similar

Safety Earth

See table 2.2.1 for Safety Earth details

500/630A Driver module bracket

Power unit

Driver module

Figure 2.1.1a Bracket fixing details

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EPOWER CONTROLLER USER GUIDE

2.1.1 FIXING DETAILS (Cont.)

Figures 2.1.1a to 2.1.1f show fixing centres and other mechanical details for the various modules.

Cable entry

Recommended fixing bolt size = M6

21.5 (0.85)

330 mm (12.99 in)

Door

317 mm (12.480 in)

(open)

Safety earth (M6)

Recommended tightening

torque = 5 Nm (3.7 ft lb)

Communications

Dimensions in millimetres (inches)

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

Front view

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

252.2 mm (9.93 in)

Cable exit/entry

194.4 mm (7.65 in)

Overall Widths (mm)

No of phases 1 2 3 4

Door closed 149.5 234.5 319.5 404.5

Door open 211.0 296.0 381.0 466.0

Overall Widths (inches) Upper bracket Lower bracket

No of phases 1 2 3 4 2-phase Use A and B Use E and F

Door closed 5.89 9.23 12.58 15.93 3-phase Use A, B and C Use E and G

Door open 8.31 11.65 15.00 18.35 4-phase Use A, B, C and D Use E, F, G and H

View on underside

Note: Units are shown with individual mounting brackets. Multi-phase units come supplied with two, three or four phase brackets as appropriate. See table below for details.

Figure 2.1.1b Fixing details (50 Amp and 100 Amp units)

HA179769 Issue 8 May 11 Page 5

Page 20

2.1.1 FIXING DETAILS (Cont.)

Insert 5mm screw-

driver here, and pull

down

to release door

85.0 (3.346)85.0 (3.346)85.0 (3.346)107.5 (4.232)61.4 (2.42)

42.0

(1.65)

6.5 (0.26)

NLE

EPOWER CONTROLLER USER GUIDE

Recommended fixing bolt size = M6

361 mm (14.21 in)

Door

348 mm (13.70 in)

(open)

Cable entry

21.5 (0.85)

Safety earth (M6)

Recommended tightening

torque = 5 Nm (3.7 ft lb)

(1/4 in) screwdriver here, and pull down to release

Insert uninsulated 5mm

door

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

Front view

Communications

Dimensions in millimetres (inches)

View on underside

252.2 mm (9.93 in)

Cable exit/entry

194.4 mm (7.65 in)

Overall Widths (mm)

No of phases 1 2 3 4

Door closed 149.5 234.5 319.5 404.5

Door open 211.0 296.0 381.0 466.0

Overall Widths (inches) Upper bracket Lower bracket

No of phases 1 2 3 4 2-phase Use A and B Use E and F

Door closed 5.89 9.23 12.58 15.93 3-phase Use A, B and C Use E, F and G

Door open 8.31 11.65 15.00 18.35 4-phase Use A, B, C and D Use E, F, G and H

Note: Units are shown with individual mounting brackets. Multi-phase units come supplied with two, three or four phase brackets as appropriate. See table below for details.

Figure 2.1.1c Fixing details (160 Amp unit)

HA179769

Page 6 Issue 8 May 11

Page 21

2.1.1 FIXING DETAILS (Cont.)

NLNLE

85.0 (3.346)85.0 (3.346)85.0 (3.346)107.5 (4.232)61.4 (2.42)

42.0

(1.65)

6.5 (0.26)

PWR LOC ALM

Recommended fixing bolt size = M6

EPOWER CONTROLLER USER GUIDE

Cable entry

21.5 (0.85)

401 mm (15.79 in)

388 mm (15.276 in)

Door

(open)

Safety earth (M8)

Recommended tightening

(1/4 in) screwdriver here, and pull down to release

torque = 12.5 Nm (9.2 ft lb)

Communications

Dimensions in millimetres (inches)

Insert uninsulated 5mm

door

Front view

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

Insert uninsulated 5mm (1/4 in) screwdriver here, and pull down to release

door

View on underside

252.2 mm (9.93 in)

Cable exit/entry

194.4 mm (7.65 in)

Overall Widths (mm)

No of phases 1 2 3 4

Door closed 149.5 234.5 319.5 404.5

Door open 211.0 296.0 381.0 466.0

Overall Widths (inches) Upper bracket Lower bracket

No of phases 1 2 3 4 2-phase Use A and B Use E and F

Door closed 5.89 9.23 12.58 15.93 3-phase Use A, B and C Use E, F and G

Door open 8.31 11.65 15.00 18.35 4-phase Use A, B, C and D Use E, F, G and H

Note: Units are shown with individual mounting brackets. Multi-phase units come supplied with two, three or four phase brackets as appropriate. See table below for details.

Figure 2.1.1d Fixing details (250 Amp unit)

HA179769 Issue 8 May 11 Page 7

Page 22

EPOWER CONTROLLER USER GUIDE

PWR LOC ALM

8.5 (0.33)

NLNLE

AB CD

EFGH

62 (2.44)

2.1.1 DIMENSIONAL DETAILS (Cont.)

Recommended fixing bolt size = M8

127.5mm (5.02in) 125mm (4.921in) 125mm (4.921in) 125mm (4.921in)

Safety earth (M10) Recommended tightening torque = 15 Nm (11.1 ft lb)

Line entry 25 (0.98)

Front view

Door

(open)

489.5 mm (19.28 in)

474.5 mm (18.681 in)

Communicatio

Dimensions in millimetres (inches)

Load entry 10mm (0.39in)

View on underside

252.2 mm (9.93 in) Cable exit/entry

208.4 mm (8.20 in)

Overall Widths (mm)

No of phases 1 2 3 4

Door closed 189.5 314.5 439.5 564.5

Door open 251.0 376.0 501.0 626.0

Overall Widths (inches) Upper bracket Lower bracket

No of phases 1 2 3 4 2-phase Use A and B Use E and F

Door closed 7.46 12.38 17.30 22.22 3-phase Use A, B and C Use E, F and G

Door open 9.88 14.80 19.72 24.65 4-phase Use A, B, C and D Use E, F, G and H

Note: Units are shown with individual mounting brackets. Multi-phase units come supplied with two, three or four phase brackets as appropriate. See table below for details.

Figure 2.1.1e Fixing details (400 Amp unit)

Page 8 Issue 8 May 11

HA179769

Page 23

EPOWER CONTROLLER USER GUIDE

Communications

PWR LOC ALM

8.5 (0.33)

62 (2.44)

NLNLE

AB CD

EFGH

63 (2.48)

(0.98)

(1.18)

68 (2.68)

2.1.1 DIMENSIONAL DETAILS (Cont.)

Recommended fixing bolt size = M8

127.5mm (5.02in) 125mm (4.921in) 125mm (4.921in) 125mm (4.921in)

Safety earth (M12) Recommended tightening torque = 25 Nm (18.4 ft lb)

Line cable entry

Front view

Door

(open)

489.5 mm (19.27 in)

474.5 mm (18.681 in)

Communicatio

Dimensions in millimetres (inches)

Load cable entry

View on underside

296 mm (11.65 in)

Cable exit/entry

212 mm (8.35 in)

Overall Widths (mm)

No of phases 1 2 3 4

Door closed 189.5 314.5 439.5 564.5

Door open 251.0 376.0 501.0 626.0

Overall Widths (inches) Upper bracket Lower bracket

No of phases 1 2 3 4 2-phase Use A and B Use E and F

Door closed 7.46 12.38 17.30 22.22 3-phase Use A, B and C Use E, F and G

Door open 9.88 14.80 19.72 24.65 4-phase Use A, B, C and D Use E, F, G and H

Note: Units are shown with individual mounting brackets. Multi-phase units come supplied with two, three or four phase brackets as appropriate. See table below for details.

Figure 2.1.1f Fixing details (500 Amp/630A units)

HA179769 Issue 8 May 11 Page 9

Page 24

EPOWER CONTROLLER USER GUIDE

2.2 ELECTRICAL INSTALLATION

2.2.1 Driver Module

SUPPLY VOLTAGE

The Line and neutral supply voltage connections are terminated using a 2-way connector (SK8), located on the underside of the unit, as shown in figure 2.2.1a, below. It is recommended that a 3 Amp slow-blow fuse be incorporated in order to protect the supply voltage wiring.

FAN SUPPLIES

CAUTION

The Driver Module power supply is capable of working from any supply voltage between 85V ac 265V ac. The fans (if fitted) on the power modules are specified for use at 115V ac or 230V ac, as defined at time of order. It must therefore be ensured that the fan voltage matches the supply voltage, or the fan will either fail within a short period, or it will be ineffective at cooling.

The three way connector (SK9) provides supply voltage for cooling fans which are fitted to all power modules except 50A and 100A modules. Suitable looms (harnesses) for the fans are supplied with the units. SK9 is not used for 50/100A modules, because there are no cooling fans.

Safety Earth

Supply

voltage

Enable

interlock

Fuse (3A)

Slow blow

Supply output socket

for power module fan(s)

View on underside

Supply in

Driver module Power module Power module Power module

SK1 (part of)

Internal

connection

SK9 not used with 50/100A

power modules

Internal

connection

To PSU

Internal connections

diagrammatic only

Integral with fanIntegral with fan Integral with fan

Fan cassette Fan cassette Fan cassette

Fan looms supplied with the

Figure 2.2.1a Driver module wiring

ENABLE INPUT

In order for the power module thyristors to operate, the Enable input to the driver module must be valid, In the default configuration, this is achieved by shorting pins 8 and 10 of SK1 (Digital input 1 - figure 2.2.1b), or by using a User Value block to apply a logic high to the enable input to the relevant firing block in iTools.

If required, DI1 can be reconfigured as a voltage input, and in this case it requires a high signal (figure 2.2.1c) to be applied to SK1 pin8 with the relevant zero voltage connected to pin 10.

HA179769

Page 10 Issue 8 May 11

Page 25

EPOWER CONTROLLER USER GUIDE

PWR LOC ALM

Com

14 11 12

04 01 02

2.2.1 Driver Module (Cont.)

SAFETY EARTH

The safety earth connection for the driver/power module set is made to the mounting bracket above the unit as shown in figures 2.1.1a to 2.1.1f, above. The connection must be made using the correct size of terminal and correct gauge of cable, as given in table 2.2.1 below.

Max. load

current

50/100A

160A 250A 400A 500A 630A

Minimum earth

cable cross-section.

25 mm

35 mm

70 mm 120 mm 150 mm 185 mm

Earth Terminal

Size

Tightening

torque M6 5 Nm (3.7 ft lb.) M6 5 Nm (3.7 ft lb) M8 12.5 Nm (9.2 ft lb)

M10 15 Nm (11.1ft lb) M12 25 Nm (18.4 ft lb) M12 25 Nm (18.4 ft lb)

Table 2.2.1 Safety Earth details

SIGNAL WIRING

Figure 2.2.1b shows the location of the various connectors; pinouts and typical wiring for SK1 (fitted as standard) are shown in figure 2.2.1c. Wiring for optional I/O units (SK 3 to SK5) is similar, except that they contain a relay in addition to the analog and digital circuits, and the digital circuits are inputs only.

Front

Configuration

port (EIA232)

Note: It is physically possible to insert an RJ11 plug into an RJ45 socket. Care must therefore be taken to ensure that the Configuration port cable is not mistakenly plugged into an RJ45 communications connector (if fitted) or the Remote display connector.

Load

management

View on

underside

Communications

Figure 2.2.1b Connector locations

Relay 1

Watchdog relay

Remote display (isolated EIA485)

HA179769 Issue 8 May 11 Page 11

Page 26

SK2

SK1

SK3

SK4

SK5

SK1

I/ O 1

I/ O 2

0 V

I/ O 1

I/ O 2

0 V

SK1

I/ O 1

I/ O 2

0 V

SK1

EPOWER CONTROLLER USER GUIDE

2.2.1 Driver Module (Cont.)

Predictive Load

Standard I/O

+10 Volts out Analogue i/p 1 + Analogue i/p 1 Analogue i/p 2 + Analogue i/p 2 -

Management

Terminator A Low Shield High

Terminator B Analogue o/p 1 + Analogue o/p 1 0V Digital i/o 1 + Digital i/o 2 + Digital i/o 0V

Mating

connector

(section)

= Polarising pin

Optional I/O 1 Optional I/O 2 Optional I/O 3

+10 Volts out

Polarising pins: Fixed connector: pins 1 and 2; Mating connector: pin 3

Analogue

input 1

Analogue

input 2

Analogue

output 1

Digital I/O

(Contact

Analogue i/p 3 + Analogue i/p 3 Analogue o/p 2 + Analogue o/p 2 0V Digital input 3 + Digital input 4 + Digital 0V Not used Relay 2 No (24) Relay 2 Com (21) Relay 2 NC (22)

+10V output

mA input (240R internal shunt)

mA or Voltage output

Polarising pins: Fixed connector: pins 2 and 3; Mating connector: pin 1

V input

+10 Volts out Analogue i/p 4 + Analogue i/p 4 Analogue o/p 3 + Analogue o/p 3 0V Digital input 5 + Digital input 6 + Digital 0V Not used Relay 3 No (34) Relay 3 Com (31) Relay 3 NC (32)

input 1

input 2

output 1

Analogue

Digital I/O

(logic input)

Relevant manual sections

Analogue I/P Section 6.4 Analogue O/P Section 6.5 Digital I/O Section 6.9 Relays Section

6.21

Polarising key (Position 3)

+10 Volts out Analogue i/p 5 + Analogue i/p 5 Analogue o/p 4 + Analogue o/p 4 0V Digital input 7 + Digital input 8 + Digital 0V Not used Relay 4 No (44) Relay 4 Com (41) Relay 4 NC (42)

Polarising pins: Fixed connector: pins 1 and 3; Mating connector: pin 2

+10V output

inputs

potentiometric

-30V < Vin < +2V = Low +4V < Vin < 30V = High

+2 < Vin < 4V = not defined

I/O 2 shown; I/O 1 similar

High (4 to 30 V)

Low (-30V to +2 V)

Digital I/O

(output)

Notes:

1. Analogue input type selected during configuration as one of: 0 to 5V, 0 to 10V, 1 to 5V, 2 to 10V, 0 to 20mA, 4 to 20 mA

2. Analogue output type selected during configuration as one of : 0 to 5V, 0 to 10V, 0 to 20mA, 4 to 20mA. Resolution 12 bits; accuracy ±1% scale.

3. Each analogue input -ve terminal is individually connected to 0V via a 150 Ohm resistor.

Figure 2.2.1c Drive unit connector pinouts

Page 12 Issue 8 May 11

15V 10mA current source I/O 2 shown; I/O 1 similar

HA179769

Page 27

EPOWER CONTROLLER USER GUIDE

2.2.1 Driver Module (Cont.)

WATCHDOG RELAY

The ‘watchdog’ relay is wired to a connector on the underside of the Driver Module (figure 2.2.1d).

= Polarising pin

Relay 1

14 11 12

Com NC

04 01 02

Com NC

Watchdog relay

Figure 2.2.1d Relay connector location and pinout.

Front

View on

underside

Relay 1

Watchdog relay

Mating connector polarising pin locations

Relay 1

Com

Relay not energised

(Com shorted to NC)

RELAY CONTACT DEFINITIONS

Relay energised

(Com shorted to NO)

Under normal operating conditions, the watchdog relay is energised (that is the common and normally open contacts are shorted). Should a system error (listed below) become active (or power to the Driver Module fail), the relay is de-energised (common and normally closed contacts shorted).

1. Missing mains. One or more Power Module supply voltage lines is missing.

2. Thyristor short circuit*

3. Thyristor open circuit*

4. Fuse Blown. Thyristor-protection fuse ruptured in one or more Power Modules.

5. Unit over temperature

6. Network dips. A reduction in supply voltage exceeding a configurable value (VdipsThreshold), causes firing to be inhibited until the supply voltage returns to a suitable value. VdipsThreshold represents a percentage change in supply voltage between successive half cycles, and can be defined by the user in the Network.Setup menu, as described in section 6.20.2.

7. Supply frequency fault. The supply frequency is checked every half cycle, and if the percentage change between successive 1/2 cycles exceeds a threshold value (max. 5%), a Mains Frequency System Alarm is generated. The threshold value (FreqDriftThold) is defined in the Network.Setup menu described in

section 6.20.2.

8. Power Module 24V Failure.

* Note: It is not possible to detect a thyristor short circuit when the unit is delivering 100% output power. Similarly, it is not possible to detect thyristor open circuit when the unit is delivering 0% output.

RELAY 1

This relay, supplied as standard, is located adjacent to the watchdog relay (figure 2.2.1d). The energisation/ de-energisation of the relay coil is under software control and is fully configurable by the user. The terms Normally open (NO) and Normally closed (NC) refer to the relay in its de-energised state. Up to three further relays are available if optional I/O Modules are fitted (see figure 2.2.1c).

HA179769 Issue 8 May 11 Page 13

Page 28

EPOWER CONTROLLER USER GUIDE

SK2

max

= 64

2.2.1 Driver Module (Cont.)

PREDICTIVE LOAD MANAGEMENT OPTION CONNECTOR

This option allows a number of systems to communicate with one another to allow load management techniques such as Load Sharing and Load Shedding to be implemented. The connector is located as shown in figure 2.2.1b.

Note: Connecting pins 1 and 5 together has the effect of introducing a terminating (120 Ohm) resistor across pins 2 and 4. It is recommended that this be done at each end of the transmission line.

Terminator A Signal Low Shield Signal High Terminator B

Signal low Shield Signal high

Station 1 Station 2 Station i Station n

Maximum Trunk line length = 100 metres (328 ft) Maximum individual drop length = 5 metres (16 ft) Maximum cumulative drop length = 30 metres (98 ft)

Conductor pair size = 24 gauge (0.25 mm

) Characteristic impedance at 500kHz = 120 Ohms 10% Nominal capacitance @ 800Hz = ≤40pF Unbalance capacitance = ≤4 10%pF/m Capacitance between conductors = 100pF/metre) Attenuation at 500kHz = 1.64dB/100 metres)

Note: The figures above are for a network of up to 100 metres with up to 64 units

connected. The actual network impedance is a function of cable type, cable length and the number of units connected. For futher details contact the manufacturer or local agent.

Figure 2.2.1e Predictive Load Management wiring

Load Sharing

In a system with several heating zones, this allows a strategy to be implemented which distributes power over time in such a way that the overall power consumption remains as steady as possible, thus reducing the peak power demand of the system.

Load Shedding

In a system with several heating zones, this allows a strategy to be implemented which limits the available load power at each heating zone and/or switches zones off according to a defined priority level, thus allowing the maximum running power consumption to be controlled. The total running power is the maximum power supplied to the loads, integrated over a 50 minute period.

See the Predictive Load Management option description (section 9), for more details.

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HA179769

Page 29

2.2.1 Driver Module (Cont.)

24 V dc

(N.C.)

(N.C)

DTR

DSR

RTS

CTS

(N.C)

+24 V

24 V dc

(N.C.)

CONFIGURATION PORT

This RJ11 connector located on the front of the Driver Module (figure 2.2.1b) is used for direct connection to a PC using EIA232C standard.

EPOWER CONTROLLER USER GUIDE

Optional jack plug integral with Dtype

(6-way RJ11 Male to

Processor module)

Note: Jack plug option available from the epower manufacturer

REAR VIEW

9-way D-type socket (To PC EIA232 port)

HA179769 Issue 8 May 11 Page 15

(6-way RJ11 Male to

Processor module)

REAR VIEW

Figure 2.2.1f Configuration port wiring details

25-way D-type socket

(To PC EIA232 port)

Page 30

EPOWER CONTROLLER USER GUIDE

2.2.1 Driver Module (Cont.)

COMMUNICATIONS PINOUTS

Serial communications is discussed in the Communications Manual HA179770. Pinouts for the relevant protocols are given here for convenience.

Green

Yellow

Connectors

PinSignal

(EIA485)

Reserved

N/C

Isolated 0V

MODBUS / RTU

Internal connections: Pin 1 to 5V via 100k Pin 2 to 0V via 100k

LEDs: Green = Tx activity Yellow = Rx activity

in parallel

Network status LED Indication

LED state Interpretation

Off Steady green Flashing green Steady red Flashing red

Off-line or no power On-line to 1 or more units On-line - no connections Critical link failure 1 or more connections timed out

Module status LED Indication

LED state Interpretation

Off Steady green Flashing green Steady red Flashing red

No power Operating normally Missing or incomplete configuration Unrecoverable fault(s) Recoverable fault(s)

Pin Function

Yellow

MODBUS / TCP

Green

Figure 2.2.1h Modbus TCP (Ethernet 10baseT) pinout Figure 2.2.1g Modbus RTU pinout

Network Status

Module

Status

Pin Function

V- (negative bus supply voltage)

CAN_L

Cable shield

CAN_H

V+ (positive bus supply voltage).

Notes:

1. See DeviceNet specification for power supply specification

2. During startup, an LED test is performed, satisfying the DeviceNet standard.

N/C

Rx-

N/C

Rx+

Tx-

Tx+

LEDs: Green = Tx activity Yellow =

Network activity

Figure 2.2.1i DeviceNet® connector pinout

OPERATION MODE LED INDICATION

LED state Interpretation

Off Steady green Flashing green Red single flash Red double flash

Off line or no power On-line, data exchange On-line, clear Parametrisation error PROFIBUS configuration error

STATUS LED INDICATION

LED state Interpretation

Off Steady green Flashing green Steady red

No power or not initialised Initialised Diagnostic event present Exception error

Figure 2.2.1j Profibus connector pinout

Mode

PROFIBUS / DP

Status

Pin Function Pin Function

N/C

A (RxD -/TxD -)

N/C

+5 V (See note 1)

Notes:

1. Isolated 5 Volts for termination purposes. Any current drawn from this terminal affects the total power consumtion.

2. The cable screen should be terminated to the connector housing.

Isolated ground

RTS

B (RxD+ / TxD+)

N/C

HA179769

Page 16 Issue 8 May 11

Page 31

EPOWER CONTROLLER USER GUIDE

PROFINET IO

LINK

2.2.1 Driver Module (Cont.)

COMMUNICATIONS PINOUTS (Cont.)

‘RUN’ LED Indication

LED state Interpretation

Off Green Red

LED state Interpretation

Off Steady red Flickering red Flashing red

Off-line or no power Normal operation Major fault (fatal error)

‘ERR’ LED Indication

No error or no power Exception or fatal event CRC Error Station number or Baud rate has changed since startup.

LED state Interpretation

Off Steady green Flashing green Steady red Flashing red

Figure 2.2.1k CC-Link connector pinout

NS (Network status) LED

No power or no IP address On-line; one or more connections established (CIP class 1 or 3) On-line, no connections enabled Duplicate IP address (‘fatal’ error) One or more connections timed out (CIP class 1 or 3)

Pin Function

RUN

ERR

DA (Rx+/Tx+)

DB (Rx-/Tx-)

DG (Signal ground)

SLD (Cable shield)

FG (Protective earth)

Notes:

1. A 110 Ohm (±5% 1/2 watt) terminating resistor should be connected across pins 1 and 2 of the connectors at each end of the transmision line.

2. The cable shield should be connected to pin 4 of each CC-Link connector.

3. The shield and Protective earth terminals (pins 4 and 5) are internally connected.

110R, 1/2W, 5% across pins 1 and 2 of first and last connec-

SLD and FG connected internally

LINK

ETHERNET/IP

LED state Interpretation

Off Steady green Flashing green Steady red Flashing red

No power Controlled by a scanner in Run state Not configured or scanner in Idle state Major fault (Exception state, fatal error etc.) Recoverable fault

Figure 2.2.1l Ethernet I/P connector pinout

NS (Network status) LED

LED state Interpretation

MS (Module status) LED

Off

Steady Green

Flashing

Green

No power or no connection On-line (RUN); connection with I/O controller established. Controller in ‘Run’ state

On-line (STOP); connection with IO controller established. Controller in ‘Stop’ state.

MS (Module status) LED

LED state Interpretation

Off Green steady Green 1 flash Green 2 flash Red steady Red1 flash Red 2 flash Red 3 flash Red 4 flash

Not initialised Normal operation Diagnostic event Blink Exception error Configuration error IP address error Station Name error Internal error

No power, or the module is in ‘SETUP’ or ‘NW_INIT’ state. The module has shifted from the ‘NW_INIT’ state. One or more Diagnostic Event present. Used by engineering tools to identify the node on the network. The module is in the ‘EXCEPTION’ state. The Expected Identification differs from the Real Identification. The IP address is not set. The Station name is not set. The module has encountered a major internal fault.

LINK LED

LED state Interpretation

Off Steady green Flickering green

No link; no activity Link established Activity in progress

LINK LED

Off

Steady Green

Flashing Green

No link; no activity Link established; no activity

Activity in progress

InterpretationLED state

Figure 2.2.1m Profinet IO connector pinout

HA179769 Issue 8 May 11 Page 17

Page 32

EPOWER CONTROLLER USER GUIDE

2.2.1 Driver Module (Cont.)

REMOTE PANEL CONNECTOR

Located on the underside of the driver module (figure 2.2.1b) this RJ45 connector supplies isolated 3-wire EIA485 outputs for an optional remote panel display unit. Figure 2.2.1n gives the pinout. See section 6.6.2 for configuration details. Parity is set to ‘None’. See also Appendix A for details of a suitable remote panel unit.

Pin Definition

Reserved

Figure 2.2.1n Remote panel connector

N/C

Isolated 0V

Internal connections: Pin 1 to 5V via 100k Pin 2 to 0V via 100k

HA179769

Page 18 Issue 8 May 11

Page 33

EPOWER CONTROLLER USER GUIDE

V1&V2

I1&I2

I1& I2I1

V1 V2 V1 V2 V1 V2 V1 V2

2.2.2 Power modules

LINE/LOAD CABLES

Line power is routed through the top of the unit and load power emerges from the bottom of the unit. Details of recommended cable sizes etc. are given in table 2.2.2, below. Safety earth wiring is discussed in section

2.2.1, above. Figures 2.2.2c to 2.2.2f show typical connection details.

Max. load

current

50/100A M8

160A M8 250A M10 400A M12 500A 2 x M12 630A 2 x M12

RIBBON CABLE

The ribbon cable is daisy-chained from the Driver Module to the power modules.

Note: In order to maintain protection against damage due to electrostatic discharge, any ribbon cable which is chafed, scratched or otherwise damaged must be replaced.

Terminal

size

Minimum cable

cross-section.

2 x 150 mm 2 x 185 mm

35 mm

70 mm 120 mm 240 mm

Recommended

torque setting

12.5 Nm (9.2 ft lb)

12.5 Nm (9.2 ft lb) 25 Nm (18.4 ft lb)

28.8 Nm (21.2 ft lb) 30 Nm (22.1 ft lb) 30 Nm (22.1 ft lb)

Table 2.2.2 Line/Load termination details

EXTERNAL CURRENT FEEDBACK

If the option is fitted, a two-pin connector on the underside of the unit allows the connection of an external current transformer to measure the load current. The option also includes the Remote Voltage sensing input, described below. Both connectors must have polarising devices fitted, by the user, to prevent misconnection.

The currrent transformer ratio must be such that its full scale output is 5 Amps. For example when measuring up to 400 Amps, a 400:5 ratio transformer should be chosen.

CAUTION

External feedback connections must be correctly phased (figure 2.2.2b) or the unit might switch to full conduction at start-up. See also Appendix B for more details about external feedback.

Load cable exit

Voltage feedback connector

None

Underneath view

Module 1 Module 2 Module 3

None

Module 4

Load

External feedback

Load voltage

Neutral / phase reference (Either pin)

Figure 2.2.2a External feedback, and neutral/phase reference connectors

HA179769 Issue 8 May 11 Page 19

Current feedback connector

Polarising details for external feedback connectors.

(Polarising pins to be fitted by the user according to

power module number.)

Page 34

EPOWER CONTROLLER USER GUIDE

2.2.2 POWER MODULES (Cont.)

REMOTE VOLTAGE INPUT

WARNING

It must be ensured that the remote voltage sensing inputs (if fitted) are correctly fused. Otherwise, under certain fault conditions the cables could attempt to carry the full load current, leading to overheating and potentially to a fire hazard.

If the option is fitted, the two end pins of a four-pin connector (figure 2.2.2a) are used for terminating remote voltage sensing cable. It is recommended that each input be fitted with slow-blow fuse (figure 2.2.2b) of a lower current rating than that of the sensing cable harness. If the option is fitted, the Current Transformer input, described above, is also fitted.

Single phase shown; multiple phases similar

Supply

Isolating device

Phase/neutral

reference

Use either

terminal

Power

Module

Supply

Isolating device

Phase/neutral

reference

Use either

terminal

Power

Module

Current

transformer

Secondary

Detail

Primary

Fuses

Fuse

Return

Isolating device

Internal feedback connections (Standard)

Load

Figure 2.2.2b Fusing for remote voltage sensing input and neutral reference inputs

NEUTRAL/PHASE REFERENCE INPUT

For 4S, 6D and two-leg configurations the reference input described below is connected to neutral or to a phase supply as appropriate (figure 2.2.2g). For these configurations a fuse must be fitted in the reference input circuit or, under certain fault conditions, the reference input cable could attempt to carry the full load current, leading to overheating and potentially to a fire hazard. The current rating of the fuse must be lower than the current rating of the reference input cable.

1. For ‘4S’ and single phase configurations, loss of the neutral supply causes the reference to be lost as well. For ‘6D’ and ‘two-leg’ configurations, loss of the relevant phase supply also causes the loss of the reference.

2. The reference connection must be made before power is applied, and not disconnected until after power has been switched off.

Return

Isolating device

Fuse

External feedback connections (Option)

Load

WARNING

CAUTION

In order to ensure correct firing for 4S, 6D and two-leg configurations, a connection to neutral or to the relevant phase must be made using the relevant two-pin connector on the underside of the unit (figure

2.2.2a). (Both pins are connected together internally, so either may be used.) This supplies a reference for voltage measurements within the unit. It is recommended that such inputs be fitted with a suitable slow-blow fuse, as shown in figure 2.2.2b above and figure 2.2.2g, below). The reference inputs for other configurations are not connected directly to the supply, and fusing is therefore not required.

The unit has been designed to detect the loss of any of the reference signals and to suspend firing should any of them ‘fail’. Firing may not be correct during the detection period. As shown in the various figures, the reference connection is taken ‘down-line’ of any isolating device, so that should this device (e.g. contactor) ‘trip out’, then the controller will be able to detect the loss of reference signal and shut down appropriately.

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2.2.2 POWER MODULES (Cont.)

NEUTRAL/PHASE REFERENCE INPUT (Cont.)

Polarising pins are fitted to the connectors as shown in the figure below.

Load cable exit

Module 1

Underneath view

Module 2 Module 3 Module 4

Neutral/phase reference connector

Neutral/phase reference connector polarising pins

ACCESS TO LINE AND LOAD TERMINATIONS

WARNING

LETHAL VOLTAGES of up to 690 V ac appear at large areas of exposed metal when the doors to the power modules are open. It must be ensured by the user that the units are isolated from all hazardous voltages, and secured against accidental application of power, before the doors are opened. It is recommended that voltage checks are carried out within the unit (if wired), or at the supply and load cables before any work is started.

For 50A, 100A, 160A and 250A units, to remove the doors, insert a non-insulated screwdriver with a 5 mm flat blade into the slot near the top of the door, and gently lever downwards to disengage the catch, and pull the top of the door away from the unit. Once free, the door can be lifted off its pivots which are located at the bottom of the case.

For the 400A unit, the door is released by undoing the two fasteners near the top of the door and then pulling the top of the door away from the unit. Once free, the door can be lifted off its pivots which are located at the bottom of the case.

The 500A/630Amp module door is similar to the 400Amp module, but once released, the bottom of the door is pulled downwards to disengage it from its securing lugs, not lifted off, as described for the 400A module.

Door removal (500/630A units)

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2.2.2 POWER MODULES (Cont.)

EPOWER CONTROLLER USER GUIDE

Supply

voltage

termination

Fuse

Nut

Spring washer

Washer

Crimp tag

Termination detail

Ribbon

cable

(in)

Cable termination recommended torque: 50A/100A/160A = 12.5Nm 250A = 25Nm

Load

termination

Figure 2.2.2c Line and load termination (50A, 100A and 160A units) (250A units similar)

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2.2.2 POWER MODULES (Cont.)

EPOWER CONTROLLER USER GUIDE

Ribbon

cable (in)

Fuse

Supply

voltage

termination

‘Serrated’ washer

Flat washer

Ring terminal

Copper busbar

Recommended torque = 28.8 Nm

Bolt (M12 x 25)

Termination detail

Load

termination

Figure 2.2.2d Line and Load termination (400A units)

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2.2.2 POWER MODULES (Cont.)

EPOWER CONTROLLER USER GUIDE

Supply voltage

termination

Fuse

Recommended torque = 30 Nm

M12 Nut

(19mm A/F)

Spring washer

Flat washer

Ring terminal

Copper busbar

Termination detail

Ribbon

cable (in)

Load

termination

Figure 2.2.2e Line and Load termination (500A units) (630A units similar)

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2.2.2 POWER MODULES (Cont.)

EPOWER CONTROLLER USER GUIDE

Supply

voltage

termination

Fuse

Recommended torque = 30 Nm

M12 Nut

(19mm A/F)

Spring washer

Flat washer

Ring terminal

Copper busbar

Termination detail

Ribbon

cable (in)

Load

termination

Figure 2.2.2f Line and Load termination (630A units)

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EPOWER CONTROLLER USER GUIDE

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1

3/L2

5/L3

2/T1

4/T2

6/T3

1/L1

3/L2

5/L3

2/T1

4/T2

6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

2.2.2 POWER MODULES (Cont.)

The illustrations which make up figure 2.2.2g, below, show schematic and practical wiring arrangements for a number of common three-phase configurations. Earthing and driver module wiring are omitted for the sake of clarity. Fuses (where fitted) should have values compatible with the current carrying capacity of the associated wiring. Appendix B contains a discussion of external feedback.

CAUTION

1. Neutral/phase reference connections (if applicable) must be located between any isolating device and the relevant Power Module.

2. For single phase configurations, all Neutral reference connections must be individually fused.

Note: The figures below are intended only as theoretical examples. In order to comply with NEC requirements, branch circuit protection must be incorporated by the user, upstream of the equipment. Such protection is not shown in the figures below, for the sake of clarity. The installation, in its entirety, must comply with all applicable local safety and emissions regulations.

THREE-PHASE STAR CONFIGURATIONS

Fuse rating must be lower than cable current rating

Phase

Neutral

Vline2

Phase

Vline3

Phase

Vline

Vline3

EPower 1

Vline

EPower 2

EPower 3

EPower 1

EPower 2

EPower 3

Load 2 (Z2)

Phase 1 Phase 2 Phase 3

Neutral

Load 1 (Z)

Load 3 (Z3)

Star with neutral (4S)

Load 1 (Z)

Load 3 (Z3)

Isolating

device

Fused

Neutral

reference

Phase 1 Phase 2 Phase 3

Reference inputs

Isolating

device

connected

together

EPower 1

Load 1

EPower 1

EPower 2

Load 1

Load 2

EPower 2

EPower 3

Load 2

Load 3

EPower 3

Load 3

Star without neutral (3S)

Figure 2.2.2g Typical wiring schemes (Star)

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EPOWER CONTROLLER USER GUIDE

φ1 φ2 φ3

φ2

φ3 φ1

1/L1

3/L2

5/L3

2/T1

4/T2

6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1

3/L2

5/L3

2/T1

4/T2

6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

2.2.2 POWER MODULES (Cont.)

THREE-PHASE DELTA CONFIGURATIONS

Phase

Vline3

Phase

Vline

EPower 1

Vline

EPower 2

EPower 3

Vline2

oad 1

EPower 1

Load 3

Load 2

Closed Delta (3D)

Load 3

EPower 3

Phase 1 Phase 2 Phase 3

Reference inputs

connected together

Phase 1 Phase 2 Phase 3

Isolating

device

All reference

inputs fused

Isolating

device

EPower 1

EPower 2

Load 1

Load 2

EPower 1

EPower 2

EPower 3

Load 3

EPower 3

Phase

EPower 2 Load 2

Load 1

Load 2

Load 3

Phase

Open Delta (6D)

Fuse rating must be lower than cable current rating

Figure 2.2.2g (Cont.) Typical wiring schemes (Delta)

CAUTION

Neutral/phase reference connections (if applicable) must be located between any isolating device

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2.2.2 POWER MODULES (Cont.)

1/L1 3/L2

2/T1 4/T2

1/L1

3/L2

2/T1

4/T2

1/L1 3/L2

2/T1 4/T2

1/L1

3/L2

2/T1

4/T2

TWO-LEG CONFIGURATIONS

EPOWER CONTROLLER USER GUIDE

Phase

Vline3

Phase

Vline3

EPower 1

Vline

EPower 2

Vline2

Vline

EPower 1

Load 2

oad 1

Load 1

Load 3

Star (3S)

Load 3

Phase 1 Phase 2 Phase 3

connected together

Phase 1 Phase 2 Phase 3

Isolating

device

Fuse

Reference inputs

to phase 3.

Isolating

device

Fuse

EPower 1

EPower 2

Load 1

Load 2

Load 3

Fuse rating must be lower than cable current rating

EPower

Reference inputs

Phase

EPower 2

Load 2

connected together to

phase 3.

Load 1

Load 2

Load 3

Phase

Delta (3D)

Figure 2.2.2g (Cont.) Typical wiring schemes (2-leg)

CAUTION

Neutral/phase reference connections (if applicable) must be located between any isolating device and the relevant Power Module.

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S1 S2

I1I2

V1V2

V1V2 I1I2

I1I2V1V2

2.2.2 POWER MODULES (Cont.)

THREE PHASE CONFIGURATIONS WITH EXTERNAL FEEDBACK

See for a discussion about external feedback, including more examples.

Note: The current transformer should be chosen such that its full-scale output is 5 amps.

Phase 1

Phase 2

Phase 3

Phase 1

EPower 1

EPower 2

Phase

Reference

Star without neutral (3S)

2 phase reference

Load 2

Phase

Reference

Load 1

EPower 3

Load 3

Fuse rating must be lower than cable current rating

Load 3

V2V1

I2I1

S1S2

Load 2

Phase 2

Phase 3

3 phase

reference

EPower 1

EPower 2

V2 V1

EPower 3

I2 I1

I2I1

1 phase reference

Load 2

Open Delta (6D)

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Figure 2.2.2g (cont.) Typical 3-phase external feedback wiring

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EPOWER CONTROLLER USER GUIDE

2.2.2 POWER MODULES (Cont.)

THREE PHASE CONFIGURATIONS WITH EXTERNAL FEEDBACK (Cont.)

Phase

Reference

Phase 3

Phase 1

Phase

EPower 1

I1I2 V1V2

S1S2

Load 1

EPower 2

I1I2 V1V2

Load 3

Load 2

2-leg Delta (3D)

Phase Reference

EPower 1

I1I2V1V2

Phase

Reference

Phase 2

Phase 3

S1S2

Load 1

Load 3

EPower 2

V1V2

Figure 2.2.2g (cont.) Typical 3-phase external feedback wiring

I1I2

Load 2

Phase

Reference

Closed Delta (3D)

V1V2 I1I2

EPower 3

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PWR

3 OPERATOR INTERFACE

Located at the front of the Driver Module, the operator interface consists of a display, featuring four lines of up to 10 characters each, four push-button switches and three LED ‘beacons’.

Beacons

Figure 3 Operator interface

3.1 DISPLAY

As mentioned above, the display consists of four lines of characters, these characters being formed using a seven-high, by five-wide dot matrix. This display, together with the four pushbuttons allows full operation and configuration of the unit.

3.2 PUSHBUTTONS

The functions of the four pushbuttons below the display depend on whether the unit is in configuration mode or in operating mode:

Return Scroll

Down

3.2.1 Configuration

Return Generally, this button reverses the last operation of the ‘Enter’ button Scroll down/up Allows the user to scroll through the available menu items or values. The up/down

Enter Goes to next menu item.

3.2.2 Operation

In operation, two pushbuttons may be operated simultaneously to carry out the following functions:

Scroll up + Scroll down Acknowledge alarms Scroll up + Enter Toggle between ‘Local’ and ‘Remote’ operation. Scroll down + Enter PLF adjustment request

3.2.3 Menu item value selection

Menu items are scrolled through using the enter key. Editing of the item’s value is carried out by scrolling through the available choices, using the up and down scroll keys. Once the desired value is displayed, it will become the selected value approximately two seconds after the final scroll key operation, this selection being indicated by a single off/on flash of the desired value.

Scroll

Enter

arrow symbol appears against menu items that can be edited.

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3.3 BEACONS

There are three LED illuminated ‘beacons’ between the display area and the pushbuttons. For clarity, figure 3, above, shows the locations of these beacons in an enhanced way; on the real instrument, they are ‘invisible’ unless illuminated.

PWR

PWR ‘Power’. Illuminated green whilst power is applied to the unit. The Beacon flashes if any of

the associated power modules is not firing, or if the unit is in Standby (for any reason other than that the unit is in ‘config’ mode).

LOC ‘Local’. Illuminated orange when setpoints are to be read from the operator interface or

from PC/iTools.

ALM ‘Alarm’. Illuminated red when one or more enabled alarms is active.

3.4 FRONT PANEL MESSAGES

A number of messages can appear at the display panel. These messages and their interpretations are listed below. See section 10 for a more detailed description of some of these alarms.

3.4.1 Instrument events

Cold Start The instrument has been cold-started. Conf Entry The instrument has been placed in configuration mode. Conf Exit The instrument has been taken out of configuration mode. GlobalAck A global acknowledgement of all safe latched alarms has been performed. Power down The instrument has restarted after a power down. QS Entry The Quick Start menu has been re-entered. QS Exit The Quick Start menu has been left.

3.4.2 Indication alarms

LimitAct One or more limits are active in the control block LoadOverI An over current alarm has become active in one or more Network blocks. LMoverSch (Predictive Load Management over schedule). The actual power (Pr) is greater than the

requested shed power value (Ps) (detected in the PLM block).

PrcValTfr Process value transfer is active in one or more control blocks,

3.4.3 System alarms

FuseBlown One or more thyristor protection fuses is ruptured. MainsFreq Mains Frequency is outside the acceptable range. Missmains One or more supply phases is missing. NetwDip One or more ‘network dip’ alarms has been detected. OverTemp One or more ‘over temperature’ alarms has been detected. PMod24V A power supply problem has been detected on the Driver Unit power board.

3.4.4 Process alarms

ChopOff One or more ‘Chop-off’ alarm has been detected. ClosedLp One or more Control block ‘Closed Loop’ alarm has been detected. InputBrk An ‘Input Break’ alarm has been detected in one or more Analogue input blocks. MainVFault One or more ‘Mains Voltage Fault’ (over or under) has been detected. OutFault An ‘Output short Circuit’ alarm has been detected in one or more Analogue output

blocks. PLF One or more ‘Partial Load Failure’ alarm has been detected. PLU One or more ‘Partial Load Unbalance’ alarm has been detected. TLF One or more ‘Total Load failure’ alarm has been detected.

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3.4.5 Configuration errors

InvPAdata (Invalid parameter database). The non-volatile parameter database has become

corrupt and should not be relied upon. InvWires (Invalid wiring table). The non-volatile storage of user (soft) wiring has become corrupt

and should not be relied upon.

3.4.6 Standby errors

PwrModRev (Power Module revision). One or more power units has an invalid revision number, or

its revision level is not compatible with the firmware version of the driver module. HWDiffers The fitted hardware does not match the instrument configuration. ErrDSP Error(s) reported by the Digital Signal Processor, during the instrument’s start-up self

test procedure. Pwr1Ribbon A fault was detected in the power module 1 ribbon cable during the instrument’s start-

up self test procedure. Pwr2(3)(4)Ribbon As above but for power module 2, 3 or 4.

3.4.7 Power module errors

Ph1(2)(3)(4)ComErr The phase 1, 2, 3 or 4 power module has attempted to communicate with the driver

module, and either the driver module or the power module (or both) has failed to

‘understand’ the communication commands/responses. Ph1ComTout (Comms timeout). The phase 1, 2, 3 or 4 power module indicated that it wished to

report a fault to the driver module but the communications transaction was not

completed. Ph2(3)(4)ComTout As for phase 1, above but for phase 2, 3 or 4. Pwr1EEProm Header information in power module 1 non-volatile memory was found to be invalid at

the instrument’s start-up self test procedure. Pwr2(3)(4)EEProm As for power module 1, above but for power module 2, 3 or 4. Ph1(2)(3)(4)Wdog The phase 1, 2, 3 or 4 power module microprocessor has detected that its watchdog

timer has timed out. A reset has been performed and this has caused the power

module to report the fault.

3.4.8 General errors

Watchdog The driver module’s microprocessor has detected that its watchdog timer has timed

out, and has therefore performed a reset, causing the instrument to restart. LogFault The event log could not be restored at start-up. PWR1(2)(3)(4)cal The calibration data stored in the non-volatile memory of power module 1, 2, 3 or 4 is

invalid, and the default calibration will be used instead.

3.4.9 Reset errors

InvRamCsum (Invalid RAM checksum). Internal fault DSPnoRSP (DSP no response). Internal fault. DSP Wdog (DSP task watchdog). Internal fault.

3.4.10 Fatal errors

FuseConfig The driver module’s internal fuses are incorrectly configured. ErrRestart An error has occurred that requires the instrument to be restarted.

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4 QUICKSTART

At first switch-on, the Driver Module enters the ‘QuickStart’ menu which allows the user to configure the major parameters without having to enter the full configuration menu structure of the unit. Figure 4 shows an overview of a typical Quickstart menu. The actual displayed menu items will vary according to the number of options fitted.

Select Language

Power Modules

Nominal Current

Nominal Voltage

Network Type

Load Coupling

Load Type

Firing Mode

Feedback

Transfer Mode

Use up/down scroll to select: English, French, German, Italian

Use up/down scroll to select 0, 1, 2, 3 or 4 Change confirmation is required, as shown.

Use up/down scroll to select nominal current. Maximum value = Current rating of power modules

Use up/down scroll to select nominal voltage (see text for more details)

Use up/down scroll to select 1, 2, 3 or 4 phase. Available values depend on the number of power modules selected.

Use up/down scroll to select: 3Star, 3Delta, 4Star, 6Delta

Use up/down scroll to select: Resistive or Txformer (i.e. Transformer)

Use up/down scroll to select: None, Logic, Burst Var, Burst fix, Half cycle, Ph. Angle

Use up/down scroll to select: Open loop, V

Appears only if Feedback is not ‘Open Loop’ Use up/down scroll to select: None, I

, I2, Power, V

rms

, I

rms

or I

rms

PWR

Note: Confirmation is required if the number of power modules is edited

Analog OP 1 Func

Analog OP 1 Type

Digital IP 2 func

Use up/down scroll to select: Unused, Power, Current, Voltage, Impedance

Appears only if OP Func is not ‘Unused’ Use up/down scroll to select: 0-10V, 1-5V, 2-10V, 0-5V, 0-20mA, 4-20mA

Use up/down scroll to select: Unused, RemSP Sel, Alarm Ack

Analog IP 1 Func

Analog IP 1 Type

Analog IP 2 Func

Analog IP 2 Type

Use up/down scroll to select: Unused, Setpoint, SP limit, I limit, V limit, P limit, Transfer

Appears only if IP Func is not ‘Unused’ Use up/down scroll to select: 0-10V, 1-5V, 2-10V, 0-5V, 0-20mA, 4-20mA

Use up/down scroll to select: Unused, Setpoint, SP limit, I limit, V limit, P limit, Transfer

Appears only if IP Func is not ‘Unused’ Use up/down scroll to select: 0-10V, 1-5V, 2-10V, 0-5V, 0-20mA, 4-20mA

Figure 4 Typical Quickstart menu

Relay 1 func

Energy

Load Man Type

fitted

Load Man Addr

Appear only if ‘Load

Management’ option

Finish

No Yes

Finish Yes?

Cancel OK

Use up/down scroll to select: Unused, Any Alarm, NetwAlarm, Fuse Blown

Appears only if Energy Counter option enabled. Use up/down keys to select Energy Counter on or off

Use up/down keys to select Load Management type (see text)

Use up/down keys to set Load Management address.

Use up/down scroll to select: No, Yes

Confirm

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4 QUICKSTART MENU (Cont.)

Notes:

1. If the unit has been fully configured at the factory, the Quickstart menu will be skipped, and the unit will go into operation mode at first switch on.

2. Once quit, the Quickstart menu can be returned to at any time from the Engineer or Configuration menus (described later in this document) by holding the ‘Return’ key operated for approximately two seconds. If values have been changed ‘outside’ the Quickstart menu, these values are displayed as ‘---’ on re-entry to the Quickstart menu.

4.1 QUICKSTART MENU PARAMETERS

Language Initially, English, French, German and Italian may be selected. Other languages may be

added during the lifetime of this issue of the manual. Once confirmed (single blink after approximately two seconds), then all further displays appear in the selected language.

Power Modules Select the number of power modules between 0 and 4 that the driver module is to

control. The number of phases offered (in Network type, below) depends on this value. Editing this value causes a confirmation screen to appear. ‘OK’ confirms the change.

Nominal Current A value, normally between the maximum current the Power Modules are each able

safely to sustain and a quarter of this value. Thus, for a 400 Amp unit, any nominal current value between 100 and 400 may be selected. (Lower values are not recommended as in such cases, the resulting accuracy and linearity are not guaranteed to be within specification.)

Nominal Voltage A value between the maximum permanent supply voltage (+10%) to the modules, and

a quarter of this value. Available values are 100, 110, 115, 120, 127, 200, 208, 220, 230, 240, 277, 380, 400, 415, 440, 460, 480, 500, 575 and 600.

Network Type Allows the user to select 1, 2 or 3 phases depending on the

selection made in ‘Power Modules’, above. The table shows the choices.

Load Coupling For Network Type entries other than single phase:

2 phase: allows 3 Star or 3 Delta to be selected 3 phase: allows 3 Star, 3 Delta, 4 Star or 6 Delta to be selected.

Load Type Allows ‘Resistive’ or ‘Txformer’ (transformer) to be selected as the type of load. If

Txformer is selected, this modifies the start up procedure to limit the inrush current. Firing Mode Select from ‘Logic’, ‘BurstVar’, ‘BurstFix’, ‘HalfCycle’ or ‘Ph.Angle’. Feedback Transfer Mode

Allows the user to choose open Loop, V2, I2, Power, Vrms or Irms.

If Feedback is set to any value other than ‘Open Loop’, ‘None’, ‘I2’ or ‘Irms’ can be

selected as transfer mode. If Feedback is set to ‘Open Loop’, the Transfer Mode page

does not appear. Analog IP1 Func Selects the Analogue input 1 function as ‘Unused’, ‘Setpoint’, ‘SP limit’, ‘I limit’, ‘V limit’,

‘P limit’ (power limit) or ‘Transfer’. Allows (for example) a potentiometer to be

connected to Analogue input 1, so that setpoint can be dynamically varied. Analog IP 1 Type Allows the user to select the analogue input type as 0 to 10V, 1 to 5V, 2 to 10V, 0 to 5V,

0 to 20mA, 4 to 20mA. This menu item does not appear if ‘Unused’ is selected in IP1

Func (above). Analog IP 2 Func As for Analog IP 1 Func, except ‘Setpoint’ does not appear if it has already been

selected as Analog IP 1 type Analog IP 2 Type As for Analog IP 1 type Analog OP 1

Func Analog OP 1

Type

Allows the user to select ‘Unused’. ‘Power’, ‘Current’, ‘Voltage’ or ‘Impedance’ to be

selected as output type.

Allows the user to select the analogue output type as 0 to 10V, 1 to 5V, 2 to 10V, 0 to 5V,

0 to 20mA, 4 to 20mA. This menu item does not appear if ‘Unused’ is selected in OP1

Func (above). Digital IP2 Func Select Digital input 2 function as ‘Unused’, ‘RemSP Sel’ (Remote setpoint select) or

‘Alarm Ack’ Relay 1 Func Allows the function of Relay 1 to be set as ’Unused’, ‘Any Alarm’, ‘NetwAlarm’, or ‘Fuse

Blown’.

Power Modules Network Type

0 0 11 2 1 or 2 3 1 or 3 4 1 or 2

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4.1 QUICKSTART PARAMETERS (Cont.)

Relay 1 Func Allows the function of Relay 1 to be set as ’Unused’, ‘Any Alarm’, ‘NetwAlarm’, or ‘Fuse

Blown’.

Energy Appears only if one or more Energy counter blocks (section 6.10) are included in the

configuration. Allows energy counters to be enabled and disabled.

Load Man Type Appears only if the Predictive Load Management option is fitted. Allows the user to

select one of LMNo (disabled), Sharing, IncrT1, IncrT2, RotIncr, Distrib, DistIncr, RotDisInc. See section 9 for more details.

Load Man Address Appears only if the Predictive Load Management option is fitted. Allows the user to

enter a Predictive Load Management address.

Finish Select ‘No’ to return to the top of the Quickstart menu, or ‘Yes’ to enter the User

menu, after confirmation. (See also note below.)

Note: The ‘Finish’ item might not appear if an inconsistent or incomplete configuration is entered. In such a case, the ‘Language’ selection page at the top of the menu re-appears.

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4.2 SOME DEFINITIONS

4.2.1 Firing modes

LOGIC

Power switches on, two or three zero crossings of the supply voltage after the logic input switches on. Power switches off wo or three zero crossings of current after the logic input switches off. For resistive loads, voltage and current cross zero simultaneously. With inductive loads, a phase difference exists between the voltage and current, meaning that they cross zero at different times. The size of the phase difference increases with increasing inductance.

Power on-off delay = two or three mains

periods depending on where in the mains

cycle the logic output changes state.

Logic output from controller

Power applied

Figure 4.2.1a Logic firing mode

BURST FIXED FIRING

This means that there is a fixed ‘cycle time’ equal to an integer number of supply voltage cycles as set up in the Modulator menu. Power is controlled by varying the ratio between the on period and the off period within this cycle time (figure 4.2.1b).

Tcyc

Power applied

Ton Toff Ton

Tcyc = Ton + Toff

Figure 4.2.1b Burst Fixed mode

Power applied

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4.2.1 FIRING MODES (Cont.)

BURST VARIABLE FIRING

Burst Firing Variable is the preferred mode for temperature control. Between 0 and 50% of setpoint, the on time is the ‘Min on’ time set in the modulator menu and the off time is varied to achieve control. Between 50% and 100%, the off time is the value set for ‘Min on’ and power is controlled by varying the number of on cycles.

Power applied

Ton

Min off

Toff

Power applied

Ton

Power

applied

Min offMin on Min on

Power

applied

ToffTon Ton

Toff = 1/2 Min on = 66.7% duty cycle

Min On = Min Off = 2 for these examples

Power applied

Min on

ToffTon Ton

Toff = 2 x Min on = 33.3% duty cycle

Toff = Min on = 50% duty cycle

Power applied

Figure 4.2.1c Burst variable firing

PHASE ANGLE CONTROL

This mode of firing controls power by varying the amount of each cycle which is applied to the load, by switching the controlling thyristor on part-way through the cycle. Figure 4.2.1d shows an example for 50% power.

On On On On On On On

50% shown. Power is proportional to area under curve

Figure 4.2.1d Phase angle mode

HALF CYCLE MODE

Burst mode firing with a single firing (or non-firing) cycle is known as ‘Single cycle’ mode. In order to reduce power fluctuations during firing time, Intelligent half-cycle mode uses half cycles as firing/non-firing periods. Positive and negative going cycles are evened out, to ensure that no dc component arises. The following examples describe half-cycle mode for 50%, 33% and 66% duty cycles.

50% DUTY CYCLE The firing and non-firing time corresponds to a single supply cycle (figure 4.2.1e).

Ton Toff

For 50% duty cycle Tn = Toff = 2 half cycles

Figure 4.2.1e Half cycle mode: 50% duty cycle

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4.2.1 FIRING MODES (Cont.)

33% DUTY CYCLE

For duty cycles less than 50%, the firing time is one half-cycle. For a 33% duty cycle, firing time is one half cycle; the non-firing time is two half-cycles (figure 4.2.1f).

Ton TonToff Toff

For 33% duty cycle

Ton = 1 half cycle; Toff = 2 half cycles

Figure 4.2.1f Half cycle mode: 33% duty cycle

66% DUTY CYCLE

For duty cycles of greater than 50%, the non-firing time is one half-cycle. For 66% duty cycle, the firing time is two half cycles; the non-firing time is one half cycle (figure 4.2.1g).

Ton TonToff

Ton = 2 half cycles; Toff = 1 half cycle

Figure 4.2.1g Half cycle mode: 66% duty cycle

Toff

For 66% duty cycle

4.2.2 Feedback type

All feedback types (except ‘Open Loop’) are based on real-time measurement of electrical parameters that are normalised to their equivalent Nominal values. Thus V normalised to the square of Nominal Voltage and ‘P’ is normalised to the product of Nominal Voltage and Nominal Current.

Feedback is directly proportional to the square of the RMS voltage measured across

the load. For two- or three-phase systems, feedback is proportional to the average of

the squares of the individual phase-to-phase or phase-to-Neutral RMS voltage across

each load. Power Feedback is directly proportional to the total true power delivered to the load network.

Feedback is directly proportional to the square of the RMS current through the load.

For two- or three-phase systems, feedback is proportional to the average of the

squares of the individual RMS load currents. V

rms

Feedback is directly proportional to the RMS voltage measured across the load or, for

multi-phase systems, to the average of the individual phase-to-phase or phase-to-

neutral RMS load voltages. I

Feedback is directly proportional to the RMS current through the load or, for multi-

rms

phase systems, to the average of the individual RMS load currents. Open loop No measurement feedback. The thyristor firing angle in Phase angle mode, or the duty

cycle in burst-firing mode, are proportional to the setpoint.

is normalised to Nominal Voltage; V2 is

RMS

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4.2.3 Transfer Mode

The control system can use automatic transfer of certain feedback parameters. For example with loads with very low cold resistance, I2 feedback should be used to limit inrush current, but once the load has started to warm up, Power feedback should be used; the control program can be configured to change feedback mode automatically.

The Transfer mode can be selected as I2 to P or I

to P as appropriate to the type of load being controlled

rms

None No feedback parameter transfer to the control program I2 Selects transfer mode: I2 to the selected Feedback Mode (above). I

rms

Selects transfer mode: I

to the selected Feedback Mode (above).

RMS

4.2.4 Limitation features

In order, for example, to prevent potentially damaging inrush currents, it is possible to set a value for power or Current squared which is not to be exceeded. This limiting is implemented using phase angle reduction, duty cycle reduction or ‘chop off’, depending on the type of control (e.g. phase angle, burst firing). For loads exhibiting a low impedance at low temperatures but a higher impedance at working temperature, the current drawn reduces as the load warms, and limiting gradually becomes unnecessary.

Section 6.7.3 describes the configuration parameters which allow the user to enter a Process Variable (PV)

and a setpoint (SP) for each phase, where the PV is the value to be limited (e.g. I2) and the SP is the value that the PV must not exceed.

FIRING ANGLE LIMITING

For phase angle control, limiting is achieved by reducing the firing

(gradually reducing)

Limiting

Target phase angle

angle on each half mains cycle such that the limit value of the relevant parameter is not exceeded. As limiting is reduced so the phase angle tends to its target value.

DUTY CYCLE LIMITING

For Burst Firing only, limiting reduces the ‘On’ state of the burst firing driving the load. Load current, voltage and active power are calculated over the period of each (Ton + Toff) period.

CAUTION

When applied to load current, duty cycle limiting does not limit the peak current value, and under some circumstances this may allow an overheating hazard in the load and/or Power Module to develop.

CHOP OFF

This is a limiting technique which detects an over-current alarm state and stops further thyristor firing for the duration of that alarm state. All the relevant parameters are to be found in the Network Setup menu (section 6.20.2). There are two alarms which may trigger Chop Off, as follows:

1. The alarm is active when ChopOff1Threshold is exceeded for more than five seconds. This threshold can be set to any value between 100% and 150% inclusive, of the unit’s nominal current (INominal).

2. The alarm is active if ChopOff2Threshold is exceeded more than a specified number of times (Number Chop Off)) within a specified time period (Window Chop Off). ChopOff2Threshold is adjustable between 100% and 350% inclusive, of Inominal; Number Chop Off can be selected to any value between 1 and 16 inclusive; Window Chop Off can be set to any value between 1 and 65535 seconds (approximately 18 hours 12 mins.). Each time the threshold is exceeded, the unit stops firing, raises a chop off condition alarm, then after 100ms, restarts using an up-going safety ramp. The condition alarm is cleared if the unit successfully restarts. If the alarm is raised more than the specified number of times within the specified window, then the Chop Off alarm is set and the unit stops firing. Firing is not resumed until the operator acknowledges the Chop Off alarm.

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5 OPERATOR MENU

At power up or after quitting the Quickstart menu, the unit initialises itself (figure 5) and then enters the first summary page of the Operator menu (figure 5.2).

EN.NN = software revision level

Enter keyReturn key

Figure 5 Initialisation screens

Note: If any faults are detected during initialisation (e.g. supply voltage missing), then error messages appear on the display screen. The up and down arrow keys must be operated simultaneously to acknowledge each alarm in turn, before any further operations can take place.

5.1 SUMMARY PAGES

Each summary page displays the voltage, current and power status described below calculated over the mains period when in Phase Angle mode or over the Modulation Period when in Burst Mode. The user may also edit the local setpoint from the summary pages. Where more than one, single phase unit is being driven, the parameter names have a numeric suffix (e.g. V2) to indicate which phase is being displayed. The enter key can be used to scroll through the available phases.

The Return key can be operated briefly to access the top level operator menu, which contains all summary pages and Alarm and Event Log entries. (Operation of the Return key for an extended interval calls the Access page - see section 6.3)

Notes:

1. A suffix ‘n’ below represents the number of the network currently being displayed.

2. ‘LSP’ is replaced in the display by ‘RSP’ for remote working.

5.1.1 Single phase summary page

Vn The RMS load voltage measurement for network ‘n’. In The RMS load current measurement for network ‘n’. Pn The true power delivered to network ‘n’. LSPn The local setpoint value for network ‘n’ - see also Note 2 above.

5.1.2 Two or three phase summary page

Vavg The average RMS load voltage over all three loads. Iavg The average RMS load current over all three loads. P The true power delivered to the load network. LSP The local setpoint value - see also Note 2 above.

5.1.3 Two by two phase summary page

This is a mode of operation whereby a single four-power-module unit can control two independent, threephase networks.

Vavn The RMS load voltage averaged over all three loads for network ‘n’. Iavn The RMS load current averaged over all three loads for network ‘n’. Pn The true power delivered to load network ‘n’. LSPn The local setpoint value for network ‘n’ - see also Note 2 above.

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5.2 TOP LEVEL OPERATOR (USER) MENU

1st Summary page appears:

1. After quitting the Quickstart menu.

2. On power up if the unit was left in Access level 1 (operator) or 2 (Engineer) at power down. (If powered off in Config mode, it restarts in Config mode.)

Summary Page 1

Summary Page 2

Summary Page 3

Summary Page 4

Hold operated for 2 secs min.

USER Menu

Alarms

Vn 248.9V In 120.3A Pn 29943W LSPn 55%

Enter Return

Alm summry Miss Mains

Please wait

Use the ‘Enter’ key to scroll through summary pages. The number of summary pages depends on the number (n) of separate power networks in the system. n = 1, 2, 3 or 4 according to which Summary page is being displayed. n is not present if there is only one summary page.

Hold the Enter key continuously operated to return to the summary pages. Hold the Return key continuously operated to call the Access (Goto) page.

Use the Enter key to scroll through alarms, acknowledging them as required. Hold the Enter key continuously operated to return to the summary pages. Hold the Return key continuously operated to call the Access (Goto) page.

USER Menu

EventLog

Event Log Event 1 ErrStandby HwDiffers

Use the Enter or up/down keys to scroll through the event log. Hold the Enter key continuously operated to return to the summary pages. Hold the Return key continuously operated to call the Access (Goto) page.

Figure 5.2 User menu overview

Note: The summary page is displayed at switch on only if the unit has been configured, either via the

Quickstart menu, or at the factory. Otherwise, at first switch on, the Quickstart menu is entered.

Summary pages are discussed in section 5.1, above.

5.2.1 Alarm Summary pages

This page contains a list of currently active alarms, together with a group of four flashing bell symbols if the alarm is unacknowledged. The ‘Enter’ key is used to scroll through the list, and the up/down arrow keys are operated, simultaneously, to acknowledge each alarm, as required.

5.2.2 Event Log

This is a list of up to 40 event items where Event 1 is the latest. As shown in the figure below, Event number, Event Type and Actual Event (known as ‘Event ID’) appear on the screen.

Event Types and Event IDs are given in table 5.2.2.

EventLog EventNN Event Type Event ID

General

EventLog Event30 Instrument

Conf Exit

Typical example

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5.2.2 EVENT LOG (Cont.)

Event Type Event ID

Config error DSP Error Fatal error General error Indication Alarm Network ‘n’ Active Indication Alarm Network ‘n’ Inactive Indication Alarm Network ‘n’ Acknowledged Instrument event Network ‘n’ error Power Module ‘n’ error Process Alarm External ‘n’ Active Process Alarm External ‘n’ Inactive Process Alarm External ‘n’ Acknowledged Process Alarm Network ‘n’ Active Process Alarm Network ‘n’ Inactive Process Alarm Network ‘n’ Acknowledged Restart Error Standby Error System Alarm Network ‘n’ Active System Alarm Network ‘n’ Inactive System Alarm Network ‘n’ Acknowledged

‘n’ = 1, 2, 3 or 4

EPOWER CONTROLLER USER GUIDE

EXTERNAL PROCESS ALARMS

Deviation Band Deviation High Deviation Low High Low

ATAL ERRORS

Internal Fuse configuration Restart Failure

ONFIG ERRORS

Invalid parameter database Invalid wiring table

NDICATION ALARMS

Limit active Load over current Load Management over schedule Process Value transfer

ENERAL ERRORS

Processor watchdog Event Log fault Power Module ‘n’ Calibration

INSTRUMENT EVENTS

Cold start Config entry Config exit Global Acknowledge Power down Quickstart entry Quickstart exit

NETWORK ERRORS

Phase ‘n’ power module Comms err Phase ‘n’ power module Timeout Phase ‘n’ power module watchdog

OWER MODULE POST ERRORS

Comms error Comms timeout Fuse blown Power rail fail Watchdog

ROCESS ALARMS

Chop Off Closed loop Main voltage fault Output short circuit Partial load fault Partial load unbalance Temperature pre-alarm Total Load Failure

ESET ERRORS

Invalid RAM checksum DSP no response DSP task Watchdog

STANDBY ERRORS

Invalid Power Module Revision Hardware mismatch Power Module ‘n’ Ribbon Fault

SYSTEM ALARMS

Fuse Blown Mains Frequency Fault Missing mains NetworkDip Over Temperature Power Module 24V fault Thyristor Open circuit Thyristor Short circuit

Table 5.2.2 Event types and IDs

Notes:

1. Event ID ‘Fuse blown’ may appear in association with either Event Type ‘System Alarm Network ‘n’’ or Event Type ‘Power module ‘n’ Error’.

2. Event ID ‘Watchdog’ appears in association with Event Type ‘General error’ and indicates that the microprocessor in the Driver Module has performed a watchdog reset.

3. Event ID ‘Watchdog fault’ appears with Event Type ‘Power Module ‘n’ Error’ and indicates that the relevant Power Module PIC microprocessor has performed a watchdog reset.

5.2.3 Strategy Standby mode

For SCADA systems, in order to determine Standby mode, the user should use bit 8 of the Faultdet.Strategy-

Status parameter, not the Instrument.Mode parameter.

This is because Instrument Mode reflects user selection, not error states such as Hardware Mismatch.

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6 ENGINEER AND CONFIGURATION LEVEL MENUS

These two menu sets are mostly identical, displaying the unit’s parameters in a number of sub-menus. As the Engineer level menu is accessible whilst the Driver Module is on-line to the power module(s), the majority of the displayed items are Read Only (i.e. they can be viewed, but not edited), although some non-critical items can be changed.

Full configuration may be carried out from the Configuration level menus, which (apart from the access menu) contain the same parameters as the equivalent Engineering level menus. It is normally recommended, however, that configuration be carried out from a pc running iTools configuration software. In either case, the unit goes off-line as soon as Configuration mode is entered.

6.1 ACCESS TO THE ENGINEER AND CONFIGURATION MENUS

6.1.1 Engineer level menu

The Engineer level menu is entered as follows (figure 6.1.1):

1. Operate the return key repeatedly, until no further changes occur, then hold the Return key continuously operated until the ‘Access’ ‘Goto’ display appears.

2. Use the up or down arrow key until ‘Engineer’ appears.

3. Either wait for a few seconds or operate the Enter key.

4. Use the up or down arrow key to change the code to the Engineer level code (factory default = 2, but reconfigurable in the CONFIG level menu)

5. Either wait for a few seconds or operate the Enter key to display the first Summary Page. Press and hold the Enter key until the first page of the top level Engineer menu appears.

Enter key

Return key

Note: when entering from configuration level no password is required. Once Engineer level has been selected, the unit restarts in the Engineer top level menu

Any Menu

Hold 4 to 5 secs

Access Goto

Operator

Access Goto

Engineer

Wait or

Access Pass code

Code =1 Code =2

Wait or

V1 248.9 I1 120.3A P1 29943w LSP1 55%

ENG

Access AnalogIP AnalogOP

Operate ‘Return’ [rtn key] repeatedly until no further changes occur, then hold continuously operated until the access page appears.

Display depends on existing access level.

Use up/down arrow key to select Engineer. Once selected, wait a few seconds or operate the ‘Enter’ key for pass code page.

Default code = 2, but this may be edited in the Configuration menu

Summary page

Hold ‘Enter’ operated until first engineer level menu page appears

Figure 6.1.1 Access to the Engineer level menu

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6.1.2 Configuration level menu

The Configuration level menu is entered as follows (figure 6.1.2):

1. Operate the return key repeatedly, until no further changes occur, then hold the Return key continuously operated until the ‘Access’ ‘Goto’ display appears.

2. Use the up or down arrow key until ‘Configuration’ appears.

3. Either wait for a few seconds or operate the Enter key.

4. Use the up or down arrow key to change the code to the Engineer level code (factory default = 3, but reconfigurable in the CONFIG level Access menu)

5. Either wait for a few seconds or operate the Enter key to display the first page of the top level Configuration menu.

Any Menu

Hold 4 to 5 secs

Access Goto

Operator

Access Goto

Engineer

Access Goto

Config

Wait or

Access Pass code

Code =1

Code =2

Code =3

Wait or

Top level

Config menu

Operate ‘Return’ [rtn key] repeatedly until no further changes occur, then hold continuously operated until the access page appears.

Use up arrow key twice to select Config

Once selected, wait a few seconds or operate ‘Enter’ key for Pass code page.

Use up arrow key to enter the Config Pass code

Default code = 3, but this may be edited as described in section 6.3.2

Figure 6.1.2 Access to the Configuration level menu

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6.2 TOP LEVEL MENU

Figure 6.2 shows the top level menu for Configuration level. Engineer top level menu similar (Default code = 2).

Submenus are discussed in the following sections:

Note: Section 6 contains descriptions of all the menus which can appear. If an option or a feature is not fitted and/or enabled, then it does not appear in the top level menu.

Access . . . . . . . . . . . . . . . . . . . Section 6.3

Analogue I/P . . . . . . . . . . . . . . Section 6.4

Analogue O/P . . . . . . . . . . . . . Section 6.5

Comms . . . . . . . . . . . . . . . . . . . Section 6.6

Control . . . . . . . . . . . . . . . . . . . Section 6.7

Counter. . . . . . . . . . . . . . . . . . . Section 6.8

Digital I/O. . . . . . . . . . . . . . . . . Section 6.9

Energy. . . . . . . . . . . . . . . . . . . . Section 6.10

Event Log . . . . . . . . . . . . . . . . . Section 6.11

Fault Detection . . . . . . . . . . . . Section 6.12

Firing O/P. . . . . . . . . . . . . . . . . Section 6.13

Instrument . . . . . . . . . . . . . . . . Section 6.14

IP Monitor. . . . . . . . . . . . . . . . . Section 6.15

Pass code = 3

CONF

Access

CONF

AnalogIP

CONF

AnalogOP

Section 6.3

Section 6.4

Section 6.5

Use the up/down arrows to select the required configuration area, then use the enter key to access

CONF

Faultdet

CONF

FiringOP

CONF

Instr

Lgc2 logic operator. . . . . . . . Section 6.16

Lgc8 logic operator. . . . . . . . Section 6.17

Math2. . . . . . . . . . . . . . . . . . . . Section 6.18

Modulator . . . . . . . . . . . . . . . . Section 6.19

Network. . . . . . . . . . . . . . . . . . Section 6.20

Predictive Load Management Section 6.21

PLM Channels. . . . . . . . . . . . . Section 6.22

Load tap changer. . . . . . . . . . Section 6.23

Relay . . . . . . . . . . . . . . . . . . . . Section 6.24

Setpoint provider. . . . . . . . . . Section 6.25

Timer . . . . . . . . . . . . . . . . . . . . Section 6.26

Totaliser. . . . . . . . . . . . . . . . . . Section 6.27

User value . . . . . . . . . . . . . . . . Section 6.28

Section 6.12

Section 6.13

Section 6.14

CONF

PLM

CONF

PLMChan

CONF

PLMChan

Section 6.21

Section 6.22

Section 6.23

CONF

Comms

CONF

Control

CONF

Count

CONF

Digital

CONF

Energy

CONF

EventLog

Section 6.6

Section 6.7

Section 6.8

Section 6.9

Section 6.10

Section 6.11

CONF

IPMon

CONF

Lgc2

CONF

Lgc8

CONF

Math2

CONF

Modultr

CONF

Network

Section 6.15

Section 6.16

Section 6.17

Section 6.18

Section 6.19

Section 6.20

CONF

Relay

CONF

SetProv

CONF

Timer

CONF

Totaliser

CONF

UsrVal

Section 6.24

Section 6.25

Section 6.26

Section 6.27

Section 6.28

Figure 6.2 Top level menu

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6.3 ACCESS MENU

6.3.1 Engineer level menu

Entered from the Engineer top level menu, this allows the user to go to any other menu for which the access code is known. The default access codes are Operator = 1; Engineer = 2, Config = 3, Quickstart = 4.

Figure 6.3.1 below, shows details.

ENG

Access

Goto

Access Goto

Engineer

Access Goto

Config

Access Goto

Quick

Access Goto

Operator

Wait or

Operator Menu

Wait or

Access Pass Code

Default codes

Config = 3 Quick = 4

Figure 6.3.1 Engineer level Access menu

Use up/down arrows to enter code for required level, then wait or use ‘Enter’ key

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6.3.2 Configuration level access menu

This menu allows:

1. The user to quit the Configuration level menu and ‘Goto’ a different access level. Operator and Engineer level menus require no Pass code as they are considered to be at a lower security level than Configuration. (Figure 6.3.2a shows the menu layout.)

2. The user to edit the current Pass codes for Engineer, Configuration and Quickstart menus (figure

6.3.2b),

3. Access to the Operator Interface push-buttons to be restricted in Operator and Engineer Level menus (figure 6.3.2b).

GOTO MENU

ENG

Access

Goto

Access Goto

Config

Access Goto

Engineer

Access Goto

Operator

Access Goto

See figure 6.3.2b for other Access menu items

Use up/down arrows to select required level, then wait or use ‘Enter’ key

Quick

Access Pass Code

Engineer Menu

Operator Menu

Use up/down arrows to select pass code (default = 4) then wait or use ‘Enter’ key

Quick Start Menu

Figure 6.3.2a GoTo menu

To change access level, the ‘Enter’ key is operated once to select ‘Goto’, then for a second time to enter the Goto selection page.

The up/down keys are used to select the required access level. After a few seconds, or after a further entry of the ‘Enter’ key, the unit restarts in the selected level (except for ‘Quick Start’ which requires the relevant Pass Code (default = 4) to be entered).

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6.3.3 CONFIGURATION LEVEL ACCESS MENU (Cont.)

PASS CODE EDITING

CONF

Access

Goto

Access

Engineer...

Access

Config C...

Access

Quick Co...

Access

Keylock

Access Goto Config

(If access level left unchanged)

Access Engineer Code

Access Config Code

Access Quick Code

Access Keylock

See figure 6.3.2a for GoTo menu items

Use up/down arrows to set new pass code (default = 2)

Use up/down arrows to set new pass code (default = 3)

Use up/down arrows to set new pass code (default = 4)

Use up/down arrows to set user interface access for

None

Operator/Engineer levels

Back to ‘Goto’

Figure 6.3.2b Access configuration

Code As depicted above, the ‘Enter’ key is used to select ‘GoTo’, then the up/down keys are

used to select the required access level’s Pass code for editing. Once the required level is selected (e.g. Engineer), the ‘Enter’ key is used once more, to enter the edit page, where the current Pass Code is displayed (e.g. 2). The up/down keys can now be used to enter a new value of between 0 and 9999. If 0 is selected, then the relevant menu will no longer be pass code protected. After a few seconds, the new value blinks once to confirm that it has been written into the configuration.

KeyLock None: No restriction. All parameters at the current access level may be viewed and

edited.

All: All editing and navigation is prevented. All keys are locked so it is not

possible to ‘undo’ this action from the Operator interface. Once ‘All’ is selected, the keyboard can be released only via iTools.

Edit: Parameter editing is possible only in Configuration level; parameters are

Read Only in other levels. In the Operator or Engineer level menus, the ‘Back’ key is still active allowing access to the ‘Goto’ menu so that the access level may be changed if the relevant Pass code is known.

Note: Keylock is available only from the user interface (i.e. it cannot be accessed from iTools or over a communications link.)

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6.4 ANALOGIP MENU

This menu item appears only if one or more analogue inputs have been configured as anything but ‘Off’ in Quickstart, or if one or more analogue inputs has been enabled using iTools.

CONF

AnalogIP

AnalogIP 1

Type

AnalogIP 2

Type

AnalogIP 2

RangeHigh

AnalogIP 2

RangeLow

AnalogIP 2

MaesVal

Use up/down arrows to select AnalogIP, then ‘Enter’

Use up/down arrows to select the required Analogue input (2 in this example), then ‘Enter’ Use the up/down arrows to select the parameter to be edited

Type

RangeHigh

RangeLow

MaesVal

Use the up/down arrows to select: 0 to 10V, 1 to 5V, 2 to 10V,

0-10V

0 to 5V, 0 to 20mA or 4 to 20mA

Use the up/down arrows to set Range High

10.0

Use the up/down arrows to set Range Low

0.0

The input in process units, clipped by Range High/Low if input is over/under range.

1.0

The input value in electrical units.

0.0

Back to’ Type’.

Figure 6.4 Analogue input menu

6.4.1 Analogue input parameters

Type Allows the type of input to be set as one of: 0 to 10V, 1 to 5V, 2 to 10V, 0 to 5V, 0 to

20mA, 4 to 20mA.

RangeHigh High range of input for scaling from measurement units to process units. PV is

clipped to range high if input goes over range.

RangeLow Low range of input for scaling from measurement units to process units. PV is

clipped to range low if input goes under range.

PV The scaled value in process units. Clipped to the Range High or Range Low value if

the signal goes over range or under range respectively.

MeasVal The value at the instrument terminals in electrical units.

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6.5 ANALOGOP MENU

This menu item appears only if one or more analogue outputs have been configured as anything but ‘Off’ in Quickstart, or if one or more analogue outputs has been enabled using iTools.

This provides a current or voltage output scaled from a Process Variable (PV) using Range High and Range Low. Figure 6.5.1 shows the ‘Main’ configuration submenu; figure 6.5.2 shows the alarm parameters.

6.5.1 Analogue output ‘Main’ submenu parameters

CONF

AnalogOP

AnalogOP 1

Type

Main

Type

Main

RangeHigh

Main

RangeLow

Main

MeasVal

Use up/down arrows to select AnalogOP, then ‘Enter’ Use up/down arrows to select the required Analogue output, then ‘Enter’ Use up/down arrows to select parameter to edit

See figure 6.5.2 for Alarm parameters

Type

RangeHigh

RangeLow

MeasVal

Use the up/down arrows to select: 0 to 10V, 1 to 5V, 2 to 10V, 0 to 5V,

0-10V

0 to 20mA or 4 to 20mA.

Use the up/down arrows to set Range High

100.0

Use the up/down arrows to set Range Low

0.0

Input value for retransmission

0.0

Output value (PV scaled to Range low and Range high values)

0.0

Back to’ Type’.

Figure 6.5.1 Analogue output ‘Main’ menu

Type Allows the output type to be set as one of: 0 to 10V, 1 to 5 V, 2 to 10V, 0 to 5V, 0 to

20mA, 4 to 20mA. RangeHigh Used to scale the Process Variable (PV) from Process units to electrical units. RangeLow Used to scale the PV from Process units to electrical units. PV The value to be output by the analogue output. MeasVal The electrical output value derived by mapping the input PV via input range to

output range.

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6.5.2 Analogue output ‘Alm’ parameters

CONF

AnalogOP

AnalogOP 1

Main

AnalogOP 1

AlmDis

AnalogOP 1

AlmDet

AnalogOP 1

AlmSig

AnalogOP 1

AlmLat

AnalogOP 1

AlmAck

AnalogOP 1

AlmStop

Use up/down arrows to select AnalogOP, then ‘Enter’ Use up/down arrows to select the required Analogue output, then ‘Enter’ Use up/down arrows to select parameter to edit

See figure 6.5.1 for ‘Main’ menu

AlmDis

Output Fault

Output F...

AlmDet

Output F...

AlmSig

Output F...

AlmLat

Output Fault

Output F...

AlmAck

Output Fault

Output F...

AlmStop

Output Fault

Output F...

Key is yellow outline Key is solid yellow

= Alarm enabled; = Alarm disabled

= Alarm not detected; = Alarm detected

= Alarm not latched; = Alarm latched

= Alarm not acknowledged; = Alarm acknowledged

= output enabled; = output stopped on alarm

Figure 6.5.2 Analogue output alarm parameter access

AlmDis Allows the user to view the current disable status of the output Fault alarm. AlmDet Indicates whether the alarm has been detected and is active. AlmSig Signals that the alarm has occurred and whether it is latched. To assign the alarm to a

relay (for example), it is the AlmSig parameter that should be wired. AlmLat Allows the user to set the alarm as latching or non-latching. AlmAck Allows the user to view the current acknowledgement status of the output Fault

alarm. AlmStop Allows the user to set up the alarm to disable Power Module firing whilst active.

Note: Output fault may be triggered by either short circuit or open circuit.

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6.6 COMMS MENU

CONF

Comms

User

EPOWER CONTROLLER USER GUIDE

See fig 6.6.2

Comms

RmtPanel

User

Subnet4...

Enter fourth Byte of Subnet Mask address.

User

Ident

User

Protocol

User

Baud Rate

User

Address

User

Occupied...

User

Parity

User

Comms De...

User

Unit IDe...

User

DHCP ena...

User

IP1 Addr...

User

IP2 Addr

User

IP3 Addr

User

IP4 Addr

User

Subnet1...

User

Subnet2...

User

Subnet3...

Displays type of communications fitted

Displays the protocol for the type of communications fitted

Allows Baud Rate to be selected for relevant protocols. Selectable values depend on communications type

Allows the unit address to be set. Each instrument on the link must have a unique address.

Displays the number of addresses occupied by this EPower unit (See text for details).

Allows ‘Odd’, ‘Even’ or ‘None’ to be selected for relevant protocols.

Select Comms delay on or off for relevant protocols.

Allows Unit ID checking ensble to be set up.

Choose ‘Fixed’ or ‘Dynamic’.

Enter first Byte of IP address.

111.222.333.444

E.G.

Enter second Byte of IP address. E.G. 111.222.333.444

Enter third Byte of IP address. E.G. 111.222.

Enter fourth Byte of IP address. E.G. 111.222.333.444

Enter first Byte of Subnet Mask address. E.G.

Enter second Byte of Subnet Mask address. E.G. 111.

Enter third Byte of Subnet Mask address. E.G. 111.222.333.444

333.444

111.222.333.444

222.333.444

User

Gateway1

User

Gateway2

User

DefGate3

User

DefGate4

User

IP1 Pref...

User

IP2 Pref...

User

IP3 Pref...

User

IP4 Pref...

User

Show MAC

User

MAC1

User

MAC2

User

MAC3

User

MAC4

User

MAC5

User

MAC6

User

Network

Enter first Byte of Gateway address. E.G. 111.222.333.444

Enter second Byte of Gateway address. E.G. 111.

222.333.444

Enter third Byte of Gateway address. E.G. 111.222.

Enter fourth Byte of Gateway address. E.G. 111.222.333.

Enter first Byte of Preferred Master address. E.G.

Enter second Byte of Preferred Master address.

Enter third Byte of Preferred Master address. E.G. 111.222.333.444

Enter fourth Byte of Preferred Master address.

Select ‘Yes’ to view MAC address or ‘No’ to hide MAC

First Byte of MAC address E.G. (Appears only if ‘Show MAC’ = ‘Yes’.

Second Byte of MAC address E.G. 11.22.33.44.55.66 (Appears only if ‘Show MAC’ = ‘Yes’.

Third Byte of MAC address E.G. 11.22.33.44.55.66 (Appears only if ‘Show MAC’ = ‘Yes’.

Fourth Byte of MAC address E.G. 11.22.33. (Appears only if ‘Show MAC’ = ‘Yes’.

Fifth Byte of MAC address E.G. 11.22.33.44. (Appears only if ‘Show MAC’ = ‘Yes’.

Sixth Byte of MAC address E.G. 11.22.33.44.55. (Appears only if ‘Show MAC’ = ‘Yes’.

Shows status of Ethernet network

333.444

444

111.222.333.444

11.22.33.44.55.66

44.55.66

55.66

Figure 6.6 Communications User menu

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EPOWER CONTROLLER USER GUIDE

6.6 COMMS MENU (Cont.)

This menu allows the user to view, and in some cases, to edit communications parameters associated with the communications option. The user may also view the Address and Baud Rate parameters associated with the Remote Panel option.

6.6.1 Communications User menu parameters

The following parameter list includes all parameters which can appear. Only those parameters which are relevant to the fitted communications option appear in the menu list.

ID Displays the type of communications board fitted: RS-485 (EIA 485), Ethernet, or a

Network comms board such as Profibus or DeviceNet. (These options are fully

discussed in the Communications manual, HA179770.) ID is not user editable. Protocol Read only. Displays the current transmission protocol: Modbus, Modbus TCP,

Network, Profibus, DeviceNet, CANopen, CC-Link, EtherNet/IP. Baud Allows the Baud rate setting for the unit to be set. Available values vary according to

the type of communications board fitted. Address Allows the instrument address to be set up. Each instrument in a communications

link must have a unique address allocated to it. The available address ranges vary

according to link protocol. Occupied Stations Appearing for CC-Link protocol only, this read-only value shows the number of

addresses occupied by the unit, according to the number of input and output

definitions are set up (in iTools Fieldbus I/O Gateway) , and as shown in the table

below. For example, if the address of this unit is 4, and the number of occupied

stations is 3, then the next available address is 7.

Number of

occupied stations

1 3 4 278 3 11 12 41516

Maximum No. of

input definitions

Maximum No. of

output definitions

Input definition: 2-byte word parameter to be read by the master. Output definition: 2-byte word parameter to be written by master.

Parity Allows the parity setting to be selected as None, odd or Even. None is often used

because there are other corruption detection methods (e.g. CRC) in use, and

selecting ‘Odd’ or ‘Even’ increases the number of bits transmitted, thus reducing

throughput. Delay Selects Transmission Delay ‘On’ or ‘Off’. ‘On’ inserts a guaranteed 10 millisecond

delay between reception and response. This is needed by some converter boxes in

order to switch driver direction. Unit ident Enables/disables the checking of the Modbus TCP Unit Identity field.

Strict: The Modbus TCP Unit Identity Field (UIF) does not have to match the

instrument address. The instrument responds only to Hex value FF in the UIF.

Loose: The Modbus TCP Unit Identity Field (UIF) does not have to match the

instrument address. The instrument responds any value in the UIF.

Instr: The Modbus TCP Unit Identity Field (UIF) must match the instrument address

or no response will be made to messages. A value of 0 in the UIF is treated as a ‘Broadcast Message’.

DHCP Enable Allows the user to choose whether the IP address and subnet mask are fixed or to be

supplied by a DHCP Ethernet server. IP1 Address The first byte of the IP address. (If the IP address were to be 111.222.333.444, then

the first byte would be 111; the second byte 222, and so on). IP2 to IP4 Address As IP address 1, but for the remaining three Bytes. Subnet1 to Subnet4 Mask

As IP Address 1 to 4, but for the Subnet Mask Gateway1 to 4 As IP Address 1 to 4, but for the Default Gateway. IP1 Pref Master to IP4 Pref Master

As for IP Address 1 to 4, but for the Preferred Master.

Local network information (IP address, subnet mask address etc.) is normally supplied by the user’s IT department.

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EPOWER CONTROLLER USER GUIDE

6.6.1 COMMUNICATIONS USER MENU PARAMETERS (Cont.)

Show MAC Allows the user to choose whether the unit’s MAC address may be shown (Yes), or

not (No). MAC1 Appears only if Show MAC (above) is set to ‘Yes’. This is the first byte of the non-

editable MAC address. (If the MAC address were to be 11.22.33.44.55.66 then the

first byte would be 11; the second byte 22, and so on). MAC2 to MAC6 As for MAC1, but for bytes two to six respectively Network Read Only. Also known as ‘Ethernet Status’. Shows the status of the communictions

link, as follows:

Running:

Init:

Ready:

Offline:

Bad: NetStatus Read Only. Appears to ‘Fieldbus’ protocols only. Shows the status of the

communications network, as follows:

Setup:

Init:

Ready:

Idle:

Active:

Error:

Fault:

Link connected and running Communications initialising Network ready to accept connection Network offline Network Status Bad GSD (Profibus only)

Anybus module set-up in progress Anybus module is initialising network-specific functionality Process Data channel ready but inactive Interface is inactive Process Data channel is active and error free One or more errors have been detected Host fault detected.

6.6.2 COMMS REMOTE PANEL PARAMETERS

CONF

Comms

See fig 6.6

Comms

RmtPanel

Rmt Panel

Address

Rmt Panel

Baud

Figure 6.6.2 Communications remote panel menu

Address Each instrument on the link must be given a unique address between 1 and 254

inclusive.

This may be the same or different from the address set in the CONF ‘User’ Menu

(section 6.6.1). Baud Displays the Baud rate for the Remote panel communications. Either 9600 or 19200.

This may be the same or different from the Baud rate set in the CONF ‘User’ Menu

(section 6.6.1).

Note: Remote Panel parity setting should be set to ‘No parity’ or ‘None’.

Comms

User

Address

Baud

Set a unique address between 1 and 254 inclusive for each instrument

Use the up/down arrows to select 9600 or 19200 as Baud rate for the

9600

remote panel network

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6.7 CONTROL MENU

The control menu provides the control algorithm to perform power control and transfer, threshold limiting and phase angle reduction (in the case of burst firing). Figure 6.7, below, gives an overview of the menu, which is described in the following sections:

6.7.1

6.7.2

6.7.3

6.7.4

6.7.5

6.7.6

6.7.7

6.7.8

6.7.9

6.7.10

CONF

Comms

Control N

Section 6.7.1

Control

Setup

Standby

Setup

NominalPV

Setup

Limit En...

Setup

Trans En...

Setup

FF Type

Setup

FF Gain

Setup

FF Offset

Setup Main Limit Diag (Diagnostics) AlmDis (Alarm disable) AlmDet (Alarm detection) AlmSig (Alarm signalling) AlmLat (Alarm latch) AlmAck (Alarm Acknowledge) AlmStop (Stop firing on alarm)

Use up/down arrows, to select the required control algorithm, then Enter. Use return key one or more times from within menu to return to this page

Section 6.7.2

Control

Main

Trans PV

Main

Trans SP...

Main

Section 6.7.3

Control

Limit

PV1

Limit

PV2

Limit

PV3

Limit

SP1

Limit

SP2

Limit

SP3

Limit

Section 6.7.4

Control

Diag

Status

Diag

Output

Diag

PA Limit

Section 6.7.5

Control

AlmDis

ClosedLo...

AlmDis

PVTransf...

AlmDis

Limitati...

Section 6.7.6

Control

AlmDet

ClosedLo...

AlmDet

PVTransf...

AlmDet

Limitati...

Section 6.7.7

Control

AlmSig

ClosedLo...

AlmSig

PVTransf...

AlmSig

Limitati...

Section 6.7.8

Control

AlmLat

ClosedLo...

AlmLat

PVTransf...

AlmLat

Limitati...

Section 6.7.9

Control

AlmAck

ClosedLo...

AlmAck

PVTransf...

AlmAck

Limitati...

Section 6.7.10

Control

AlmStop

ClosedLo...

AlmStop

PVTransf...

AlmStop

Limitati...

Figure 6.7 Control menu

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6.7.1 Control Setup Parameters

This contains parameters for setting the type of control to be performed.

CONF

Control

Control N

Setup

Control

Setup

Standby

Setup

NominalPV

Setup

Limit En...

Setup

Trans En...

Setup

FF Type

Setup

FF Gain

Setup

FF Offset

Use up/down arrows, to select the required control loop, then Enter. Use [rtn return key one or more times from within menu to return to this page

Standby

Nominal PV

Limit Enable

Trans Enable

FF Type

FF Gain

FF Offset

Use up/down arrows to set the unit to standby (Yes) or not (No).

Enter Nominal PV value (see text for more details)

57500

Enables threshold limit feature

Enable Transfer (Proportional limit)

Select the type of Feed Forward to be used.

Tri

Enter Feed Forward gain value to be applied.

0

Enter Feed Forward offset value to be applied.

0.0

Back to Standby

Figure 6.7.1 Control setup menu

Standby If Yes, the controller enters Standby mode and zero % power is demanded. When

removed from Standby the unit returns to operating mode in a controlled manner. Nominal PV Normally the nominal value for each control type. For example, for feedback mode =

V2, Vsq should be wired to the Main PV, and Nominal PV set to the nominal value

expected for V2 (usually VLoadNominal2). Limit Enable Used to enable/disable threshold limit. Trans Enable Select Transfer Enable (Proportional limit) as ‘Yes’ (enabled) or ‘No’ (not enabled). FFType Feedforward Type.

Off: Feedforward is disabled

Trim:

FFonly:

Feedforward value is the dominant element of the output. Trimmed by the control loop based on the Main PV and setpoint.

The feedforward value is the output from the controller. Open loop control may be configured by this means.

Feedforward is for use only with the main control elements, and the limit loop will

override feedforward. FFGain The entered gain value is applied to the Feedforward input. FFOffset The entered value is applied to the Feedforward input after the Gain value has been

applied to it.

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6.7.2 Control Main Parameters

This menu contains all the parameters associated with the Main control loop.

CONF

Control

Control N

Setup

Control

Main

Trans PV

Main

Trans Sp...

Main

Use up/down arrows, to select the required control loop, then Enter. Use [rtn return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘Main’, then Enter.

Trans PV

Trans Span

Use up/down arrows to set the value of the Main PV of the controller

Use the up/down arrows to set the main Setpoint

0.0

(% of Nominal PV).

The PV measurement for transfer.

Use the up/down arrows to define the span of operation for transfer.

Use the up/down arrows to define the integration time of the main PI loop

Back to PV

Figure 6.7.2 Control Main parameters

PV Displays the main Controller Process Variable (PV). Wired to the measurement which

it is to be controlled. For example, to perform V2 control. Vsq should be wired to this

(PV) parameter and Nominal PV configured appropriately (section 6.7.1). SP The Setpoint to control at, as a percentage of Nominal PV (the upper range of the

loop in engineering units). For example, if NominalPV = 500V RMS, and SP is set to

20%, the controller attempts to regulate at 500 x 20/100 = 100V RMS. If Transfer or

Limit is enabled, these will override SP. Trans PV

Transfer PV. This is the PV measurement for transfer. For example, if a V2 to I2 transfer

is required, the Vsq should be wired to MainPV and Isq to TransferPV. Appears only if

Trans Enable (section 6.7.1) is set to ‘Yes’ (via iTools). Transfer Span The span of operation for transfer. Appears only if Trans Enable (section 6.7.1) is set

to ‘Yes’ (via iTools). TI Allows the user to define an integral time for the main PI control loop.

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6.7.3 Control Limit parameters

Parameters relating to the limit control loop.

CONF

Control

Control N

Setup

Control

Limit

PV1

Limit

PV2

Limit

PV3

Limit

SP1

Limit

SP2

Limit

SP3

Use up/down arrows, to select the required control loop, then Enter. Use [rtn ke return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘Limit’, then Enter.

PV1

PV2

PV3

SP1

SP2

SP3

The Process Variable value which is to perform first threshold limit

control

The Process Variable value which is to perform second threshold

limit control

The Process Variable value which is to perform third threshold limit

control

The setpoint for PV1

The setpoint for PV2

The setpoint for PV3

Limit

Use the up/down arrows to define the integral time for the limit control loop

Back to PV1

Figure 6.7.3 Control Limit menu

PV1 to PV3 Threshold value for limit loops 1 to 3 respectively. This is the value to perform

threshold limit control. ‘Limit Enable’ must be set to ‘Yes’ in the Setup menu (section

6.7.1).

SP1 to SP3 The setpoint for limit loops 1 to 3 respectively. TI The integration time for the limit PI control loop.

Example: If I2 threshold limiting is required, Isq is wired to PV1, and the required threshold value is entered at SP1. In

phase angle configuration, the phase angle is reduced to achieve the limit setpoint; in burst firing, the unit continues to fire in bursts, but these bursts are of phase angle in order to achieve the limit setpoint. The modulation continues to attempt to reach the main setpoint.

Also known as phase angle reduction burst firing.

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6.7.4 Control Diag parameters

This menu contains diagnostic parameters related to Control.

CONF

Control

Control N

Setup

Control

Diag

Status

Diag

Output

Diag

PA Limit

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘Diag’, then Enter.

Status

Main PV

Output

PA Limit

Displays the current operating state of the controller.

Displays the output demand of the controller, in %

0.0

Phase angle output for Phase Angle reduction in burst firing

100

Back to status

Figure 6.7.4 Control Diag menu

Status Indicates the current operating state of the controller:

Main PV: The control strategy is using Main PV as the control input Transfer function

active:

Limit 1(2)(3) active:

The transfer input us being used as the input to the control strategy.

Control limiting is currently active using limit PV1(2)(3) and limit SP 1(2)(3).

Output The current output demand in percent. Normally wired to Modulator.In or

FiringOP.In

PA Limit Applies only to Burst Firing control modes. If this parameter is wired to

FiringOP.PALimit, the power module will deliver bursts of phase angle firing depending both on the Main Setpoint and on the Limit Setpoint.

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6.7.5 Control Alarm disable parameters

Allows each alarm of the control block to be disabled, individually. May be wired.

CONF

Control

Control N

Setup

Control

AlmDis

ClosedLo...

AlmDis

PVTransf...

AlmDis

Limitati...

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘AlmDis’, then Enter.

ClosedLoop

PVTransfer

Limitation

Used to disable the ‘Loop Break’ alarm Solid yellow = Alarm disabled

Used to disable the ‘Transfer Active’ alarm Solid yellow = Alarm disabled

Used to disable the ‘Control Limit Active’ alarm Solid yellow = Alarm disabled

Back to Closed Loop

Figure 6.7.5 Control Alarm disable menu

Closed Loop The ‘piano key’ in the bottom right corner of the display indicates the current enable

status of the closed loop alarm. The up and down arrows are used to enable/disable the alarm. An ‘empty’ key indicates that the alarm is enabled; a solid yellow key

means that the alarm is disabled. PV Transfer As for Closed Loop, but for the ‘Transfer Active’ alarm. Limitation As for Closed Loop, but for the ‘Control limit active’ alarm.

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6.7.6 Control Alarm detection parameters

Indicates whether each alarm has been detected and whether or not it is currently active.

CONF

Control

Control N

Standby

Control

AlmDet

ClosedLo...

AlmDet

PVTransf...

AlmDet

Limitati...

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select AlmDet, then Enter.

ClosedLoop

PVTransfer

Limitation

Solid yellow = Closed loop alarm is active.

Solid yellow = Transfer is currently active

Solid yellow = Limitation control loop is active

Back to ClosedLoop

Figure 6.7.6 Control Alarm detection menu

Closed Loop The ‘piano key’ in the bottom right corner of the display shows whether or not the

closed loop alarm is currently active. An ‘empty’ key indicates that the alarm is

inactive; a solid yellow key means that the alarm is active. PV Transfer As for Closed Loop, but for the ‘Transfer Active’ alarm. Limitation As for Closed Loop, but for the ‘Control limit active’ alarm.

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6.7.7 Control Alarm signalling parameters

Signals that an alarm has occurred and has been latched (if so configured in ‘Alarm Latch’ (section 6.7.8)). If it is required that an alarm is to be assigned to a relay (for example), then the appropriate alarm signalling parameter should be used.

CONF

Control

Control N

Setup

Control

AlmSig

ClosedLo...

AlmSig

PVTransf...

AlmSig

Limitati...

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘AlmSig’, then ‘Enter’.

ClosedLoop

PVTransfer

Limitation

Back to ClosedLoop

Solid yellow = Indicates that the loop alarm has occurred.

Solid yellow = Signals that the transfer alarm has occurred.

Figure 6.7.7 Control Alarm Signalling menu

Closed Loop The ‘piano key’ in the bottom right corner of the display indicates whether the closed

loop break alarm is currently active. An ‘empty’ key indicates that the alarm is

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6.7.8 Control Alarm Latch parameters

Allows each alarm to be configured as latching or not latching. The latched status is shown in the Network AlmSig submenu (ref section 6.20.3).

CONF

Control

Control N

Setup

Control

AlmLat

ClosedLo...

AlmLat

PVTransf...

AlmLat

Limitati...

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘AlmLat’, then Enter.

ClosedLoop

PVTransfer

Limitation

Solid yellow = Indicates that the loop alarm is configured as a latching alarm.

Solid yellow = Signals that the transfer alarm is configured as a latching alarm.

Solid yellow = Signals that the limitation alarm is configured as a latching alarm.

Back to ClosedLoop

Figure 6.7.8 Control Alarm latching menu

Closed Loop Use the up/down arrows to change the latching status of the alarm. The ‘piano key’ in

the bottom right corner of the display indicates whether the closed loop alarm is

latching (solid yellow) or non-latching (‘empty’). PV Transfer As for Closed Loop, but for the ‘Transfer Active’ alarm. Limitation As for Closed Loop, but for the ‘Control limit active’ alarm.

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6.7.9 Control Alarm Acknowledgement parameters

This menu allows individual alarms to be acknowledged. On acknowledgement, the related Signalling parameter is cleared. The Acknowledge parameters automatically clear after being written.

If the alarm is still active (as shown by the Alarm Detection display) it may not be acknowledged.

CONF

Control

Control N

Control

AlmAck

ClosedLo...

AlmAck

PVTransf...

AlmAck

Limitati...

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘AlmAck’, then ‘Enter’.

ClosedLoop

PVTransfer

Limitation

Solid yellow = the closed loop alarm has not been acknowledged.

Solid yellow = the transfer alarm has not been acknowledged.

Solid yellow = the limitation alarm has not been acknowledged.

Back to ClosedLoop

Figure 6.7.9 Control Alarm Acknowledge menu

Closed Loop The ‘piano key’ in the bottom right corner of the display shows whether the closed

loop alarm has been acknowledged or not. An ‘empty’ key indicates that the alarm is

acknowledged; a solid yellow key indicates that the alarm is unacknowledged. The

up/down arrow keys are used to acknowledge. PV Transfer As for Closed Loop, but for the ‘Transfer Active’ alarm. Limitation As for Closed Loop, but for the ‘Control limit active’ alarm.

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6.7.10 Control Alarm Stop parameters

Allows individual channels to be configured such that it will stop the associated power channel from firing whilst the alarm is active. This feature is activated by the signalling parameters, so the alarm stop may be latching.

CONF

Control

Control N

Setup

Control

AlmStop

ClosedLo...

AlmStop

PVTransf...

AlmStop

Limitati...

Use up/down arrows, to select the required control loop, then Enter. Use return key one or more times from within menu to return to this page

Use up/down arrows, to select ‘AlmStop’, then Enter.

ClosedLoop

PVTransfer

Limitation

Back to ClosedLoop

Solid yellow = the closed loop alarm prevents firing when active.

Solid yellow = the transfer alarm prevents firing when active.

Solid yellow = the limitation alarm prevents firing when active.

Figure 6.7.10 Control Alarm Stop menu

Closed Loop The ‘piano key’ in the bottom right corner of the display shows whether the closed

loop alarm has been configured to disable firing or not. An ‘empty’ key indicates that

the firing is enabled; a solid yellow key indicates that the firing is disabled. PV Transfer As for Closed Loop, but for the ‘Transfer Active’ alarm. Limitation As for Closed Loop, but for the ‘Control limit active’ alarm.

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6.8 COUNTER MENU

The counter output is a 32-bit integer the value of which is recalculated every sample period. When a clock state change from 0 (false) to 1 (true) is detected the counter value is incremented if the count direction is ‘up’ or decremented if the direction is ‘down’.

At reset, the counter value is set to 0 for count up counters or to the ‘Target’ value for count down counters.

6.8.1 Counter configuration menu

CONF

Count

Count N

Enable

Count N

Enable

Count N

Direction

Count N

Ripple C...

Count N

Overflow

Count N

Clock

Count N

Target

Count N

Count

Count N

Reset

Use up/down arrows to select Counter number, then Enter. Use return key one or more times from within menu to return to this page

Enable

Direction

Ripple Carry

Overflow

Clock

Target

Count

Reset

Use up/down arrows to enable or disable the selected counter

Use up/down arrows to set count direction as ‘Up’ or ‘Down’.

Shows whether ripple carry is active (On) or not (Off).

‘Yes’ if up counter has exceeded target. OR if down counter has reached zero. Otherwise ‘No’.

Use up/down arrows to change state of clock. (Counter increments or decre-

ments on 0 to 1 Clock transition)

Target value for count-up counters, or starting value for count-down counters.

9999

The current value of the counter.

Use up/down arrows to select ‘Yes’ to carry out counter reset.

Count N

Clear Ov...

Clear Overflow

Use up/down arrows to clear the overflow ‘flag’.

Back to ‘Enable’

Figure 6.8.1 Counter menu

Enable The counter responds to clock transitions when enabled; the count is frozen when

disabled. Direction Select up or down as the direction of count. Up counters start at (and are reset to)

zero; down counters start from (and are reset to) the Target value (below) Ripple Carry The Ripple carry output of one counter can act as the enabling input for the next

counter in a cascade. Ripple carry is set ‘true’ when the counter is enabled and its

value is either zero (for count down timers) or equal to the Target value (count up

counters). Overflow Overflow becomes ‘true’ when the value of the counter is either zero (for count down

timers) or equal to the Target value (count up counters). Clock The counter increments or decrements on a positive going edge (0 to 1; False to

true).

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6.8 COUNTER MENU (Cont.)

Target Up counters: Start at zero and count towards the Target value. When this value is

reached, Overflow and Ripple-carry are set true (value = 1).

Down counters: Start at the Target value and count towards zero. When zero is

reached, Overflow and Ripple-carry are set true (value = 1). Count The current value of the counter. This is a 32-bit integer which accumulates clock

transitions. Minimum value is zero. Reset Resets up-counters to zero or down-counters to the Target value. Reset also sets

Overflow to False (i.e. Overflow = 0) Clear Overflow Sets Overflow to False (i.e. Overflow = 0)

6.8.2 Cascading counters

As implied above, it is possible to ‘wire’ counters in cascade mode. Details for an ‘up’ counter are shown in figure 6.8.2, below. Down counter configuration is similar.

Clock

Enable

(high= enabled)

Direction

Target

Reset

(high= reset values)

Clear overflow

Counts clock rising edges

Count 1

Ripple/carry 1

Counter 1

(High = Clear overflow flag)

Overflow 1

Clear overflow

Clock

Enable

Direction

Target

Reset

Counts the number of times Counter 1 target is exceeded

Count 2

Ripple/carry

Counter 2

Overflow

Clear overflow

To further counters

123 456789101112

Count 1

(Target = 4)

Ripple/Carry 1

Overflow 1

Count 2

Clock

Count 2

0 1

2 3 4 5 6 7 8 9

11 12

Count 1

0 0 0 0 0 1 1 1 1 1 2 2 2

Figure 6.8.2 Cascading up counters

Note: Counter 2 above counts the number of times that Counter 1 target is exceeded. By permanently enabling counter 2, and wiring counter 1 ‘Ripple Carry’ output to counter 2 ‘Clock’ input (replacing the connection to the clock pulse stream), counter 2 will indicate the number of times counter 1 target is reached, rather than exceeded.

0 1 2 3 4 0 1 2 3 4 0 1 2

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6.9 DIGITAL I/O MENU

Digital I/O configuration.

CONF

Control

EPOWER CONTROLLER USER GUIDE

Digital N

Type

Digital N

Invert

Digital N

Meas Val

Use up/down arrows to select Digital I/O number, then Enter. Use return [rtn key one or more times from within menu to return to this page

Type

IPContac

Invert

Meas Val

Use up/down arrows to select IP Contact, IPVolts (Input volts) or OP (Digital

Use up/down arrows to select Yes or No (to invert the signal or not,

respectively).

Desired output value, or the state of the input (see text for further details).

Sense of the output (0 or 1), or the electrical input at the terminals (see

text for further details).

Back to ‘Type’

Figure 6.9 Digital I/O menu

Type Selects I/O type: Logic Input, IPContact or digital output. For pinout details, see

figure 2.2.1c.

Invert Sets the inversion status to ‘No’ or ‘Yes’. For inputs, Yes inverts the input; for outputs,

Yes inverts the output measured value with respect to the input PV. MeasVal For inputs, this shows the value measured at the instrument terminals, in electrical

units. For outputs, this shows 1 or 0 according as the output is high or low. PV For inputs, this is the current state of the input, after any inversion has been applied.

For outputs, this is the desired output value (before any inversion is applied).

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6.10 ENERGY

Provides a number of energy counters to totalise consumed energy. The value(s) can be displayed at the driver module front panel (using iTools User Pages), and at the remote panel, if fitted. The power consumed can be displayed in one of number of units, ranging from W to GW. Figure 6.10 shows the menu.

CONF

Energy

Energy N

Input

Energy N

Input

Energy N

Reset

Energy N

Hold

Energy N

UsrEnergy

Energy N

TotEnergy

Energy N

Pulse

Energy N

UsrUnit

Energy N

TotUnit

Use up/down arrows to select energy number, then Enter. Use return key one or more times from within menu to return to this page

Input

Reset

Hold

UsrEnergy

TotEnergy

Pulse

UsrUnit

TotUnit

Shows the instantaneous measured power. Normally wired to Network Meas.P parameter.

Does not appear for the Global Energy Counter.

1 = Output fleetingly reset to zero; 0 = Output totalises. (Resetting the global counter resets all Energy counters.)

1 = Output frozen at current value 0 = Output totalises.

(Holding the global counter holds all Energy counters.)

Energy consumed by this network since reset

0.0

Global energy consumption (this network). The parameter value is not resettable

0.0

0 = No pulse output

1 = Pulse output enabled

Units scaling for this Network. Select ‘1Wh’, ‘10Wh’, ‘100Wh’, ‘1kWh’, ‘10kWh’,

1Wh

‘100kWh’, ‘1MWh’, ‘10MWh’, ‘100MWh’, ‘1GWh’

As above, but for Global consumption value

1Wh

Energy N

PulseSca...

Energy N

PulseLen

Energy N

IsGlobal

Energy N

AutoScale

PulseScale

PulseLen

IsGlobal

AutoScale

Pulse length scaling. Select ‘Disable’, ‘1Wh’, ‘10Wh’, ‘100Wh’, ‘1kWh’, ‘10kWh’, ‘100kWh’, ‘1MWh’

1Wh

Minimum pulse length in ms Valid entries 0 to 32000 inclusive

‘Global’ = This is the global counter ‘No’ = This is a network counter

‘No’ = use power scaling configured in UsrUnit (or TotUnit). ‘Yes’ = Autoscale the power display

Back to ‘Input’ (or to ‘Reset’ for Global Counter)

Figure 6.10 Energy counter menu

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6.10.1 Energy counter parameters

Input Shows the instantaneous power input from the measuring source. Normally wired to

the Meas.P output of a Network block. Does not appear for the Global Energy

Counter (see ‘IsGlobal’, below). Reset 1 = Energy counter output goes to zero and immediately starts accumulating.

0 = Energy counter not reset.

If the Global Energy counter is reset, it resets all other Energy counters (see

‘IsGlobal’, below). Hold 1 = Hold output value. This freezes the output value for the block at the current value.

The input continues to be totalised, so when the Hold input returns to 0, the output

value is instantaneously updated to the new current value.

0 = output value is not held, and represents the current accumulated Energy value.

If the Global Energy counter is held, all other Energy counters are held as well (see

‘IsGlobal’, below). UsrEnergy Shows the current value for the selected Energy Counter block. If this is the global

counter, this value is the sum of the energy values of all those networks being

totalised. TotEnergy Shows the total energy value for the relevant network. Not reset by ‘Reset’ above. Pulse This enables a pulse output which causes a pulse to be generated at a specified

number of watt-hours (1, 10, 100kW-h or 1MW-h). The length of the pulse and a

scaling factor can be entered, as described below. UsrUnit Allows a scaling units value to be entered for the energy display. Selectable as ‘1Wh’,

‘10Wh’, ‘100Wh’, ‘1kWh’, ‘10kWh’, ‘100kWh’, ‘1MWh’, ‘10MWh’, ‘100MWh’ or ‘1GWh’. TotUnit As ‘UsrUnit’, above, but for the total energy counter. PulseScale One pulse is generated every ‘n’ Watt-hours, where ‘n’ can be selected as 1, 10, 100,

1k, 10k, 100k, 1M Watt-hours. This value, and that of Pulse Len(gth) must be chosen

to suit the application, such that the next pulse is not requested before the previous

one is finished. (In such a case, the PulseScale factor is automatically increased.) PulseLen* Select pulse length between 0 and 32000 ms. The actual pulse length is rounded to

the next longest multiple of 1/2 the supply frequency. Thus, for a 50Hz system

(multiple = 10ms) pulse length entries of 1 to 10 will result in a pulse length of 10ms.

For entries of 11 to 20 the pulse length will be 20ms, and so on. This value, and that

of Pulse Scale must be chosen to suit the application, such that the next pulse is not

requested before the previous one is finished. (In such a case, the PulseScale factor is

automatically increased.) IsGlobal One (only) of the Energy blocks can be defined as being ‘Global’. This means that it

sums the values of all the other Energy counters. The block ‘input’ is disabled. The

‘IsGlobal’ parameter becomes non-editable (set to ‘No’) for all other Energy counter

blocks. If the Global energy Counter is held or reset, all other counters are held and

reset as well.

‘No’ = This counter is not the Global counter.

‘Global’ = this counter is the Global counter. Autoscale No = Use UsrUnit and TotUnit settings.

Yes = Autoscale power value display. Table 6.10.1 shows the breakpoints.

* Note: due to the computing time required, the pulse-length may vary according to circumstance. For example, if a 20ms pulse is selected, the actual pulse length may be a mixture of 20ms and 30 ms pulses.

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6.10.1 ENERGY COUNTER PARAMETERS (Cont.)

Power Range (Watt-hours) Scaler value

0 65,535 65,535,000 655,350,000 6,553,500,000 65,535,000,000 655,350,000,000 6,553,500,000,000

Table 6.10.1 Autoscale breakpoints

to 65,535 to 65,535,000 to 655,350,000 to 6,553,500,000 to 65,535,000,000 to 655,350,000,000 to 6,553,500,000,000 upwards

1 1k 10k 100k 1M 10M 100M 1G

6.10.2 Resolution

The resolution of the stored energy value varies according to the totalised value, as shown in table 6.10.2 below. For example, for stored values between 33,554,432 watt-hours and 67,108,863 watt-hours, the value increases in 4 watt-hour increments.

Power Range (Watt-hours)

0 16,777,216 33,554,432 67,108,864 134,217,728 268,435,456 536,870,912 1,073,741,824 2,147,483,648 4,294,967,296 8,589,934,592

to 16,777,215 to 33,554,431 to 67,108,863 to 134,217,727 to 268,435,455 to 536,870,911 to 1,073,741,824 to 2,147,483,647 to 4,294,967,295 to 8,589,934,591 to 17,179,869,183

Resolutio

n (W-h)

1 2 4

8 16 32 64

128 256 512

1,024

Table 6.10.2 Energy counter resolution

17,179,869,184 34,359,738,368 68,719,476,736 137,438,953,472 274,877,906,944 549,755,813,888 1,099,511,627,776 2,199,023,255,552 4,398,046,511,104 8,796,093,022,208

Power Range (Watt-hours)

to 34,359,738,367 to 68,719,476,735 to 137,438,953,471 to 274,877,906,943 to 549,755,813,887 to 1,099,511,627,775 to 2,199,023,255,551 to 4,398,046,511,103 to 8,796,093,022,207 to 17,592,186,044,415

6.11 EVENT LOG MENU

This topic is identical with the Event log in the User/Operator menu, and is described in section 5.2.2.

Resolution

(W-h)

2,048 4,096

8,192 16,384 32,768 65,536

131,072 262,144

524.288

1,048,576

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6.12 FAULT DETECTION MENU

This manages Alarm logging and provides an interface for the General Alarm Acknowledgement

CONF

Faultdet

Global A...

Faultdet

Any Alarm

Faultdet

Network...

Faultdet

Fuse Ala...

Faultdet

Global D...

Faultdet

Strat St...

Faultdet

Watchdog...

Faultdet

Alarm St...

Faultdet

Alm St...

Global Ack

Any Alarm

Network Alarm

Inactive

Fuse Alarm

Inactive

Global Disable

Strat Status

Watchdog...

Alarm Status 1

Alarm Status 2

Active

259

Active

8209

256

Back to Global Ack

Bit Value Description

0 1 Network 1 not firing

2 4 Network 2 not firing

4 16 Network 3 not firing

532

6 64 Network 4 not firing

7 128

8 256 Strategy in standby mode

9 512 Strategy in Telemetry mode 10 1024 Reserved 11 2048 Reserved 12 4096 Reserved 13 8192 Reserved 14 16384 Reserved

Bit Value Description

0 1 Missing Mains 1 2 Thyristor short circuit 2 4 Open Thyristor

See text for details

3 8 Fuse blown 4 16 Over temp 5 32 Network Dips 6 64 Frequency fault 7 128 PB24V fault 8 256 Total Load Failure

9 512 Chop Off 10 1024 Partial Load Failure 11 2048 Partial Load Unbalance 12 4096 Volt fault 13 8192 Pre Temp 14 16384 Over current 15 32768 Power Module wdog fault

Table 6.12b

Alarm Status 1 word

Network 1 not synchronized

Network 2 not synchronized

Network 3 not synchronized

Network 4 not synchronized

Bit Value Description

0 1

2 4 Closed Loop 3 8 Transfer active 4 16 Limit active 5 32 PLM Pr over Ps fault 6 64 Output fault 7 128 LTC Fuse 8 256 LTC Temp

9 512 Reserved 10 1024 Reserved 11 2048 Reserved 12 4096 Reserved 13 8192 Reserved 14 16384 Reserved 15 32768 Reserved

Alarm Status 2 word

Power Module Comms error

Pwr Module Comms timeout

Table 6.12c

Figure 6.12 Fault detect menu

Global Ack Performs a global acknowledgement of alarms. Latched alarms are cleared if their

trigger sources are no longer in an alarm state.

Any Alarm ‘Active’ indicates that there is one or more System, Process or ‘Chop Off’ alarm active.

If the relevant alarms are enabled, System alarms and Chop Off alarms always cause the power module to stop firing. Process alarms can also be configured to prevent

firing in ‘Alarm stop’. Network Alarm Indicates that a process alarm has occurred in one or more Power Modules. Fuse Alarm Indicates that a fuse has blown in one or more Network blocks. Global Disable Allows the user to disable/enable all alarms. StratStatus A coded status word giving strategy information as shown in table 6.12a. Watchdog Watchdog relay status (Active or Inactive). The watchdog relay is active (non-

energised) under fault conditions. Alarm Status 1/2 Two 16-bit words containing alarm status information as shown in tables 6.12b and

6.12c respectively.

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6.13 FIRING OUTPUT MENU

This forms the link between the control strategy and the physical load. Configuration includes Firing mode, Network Type and the type of Load coupling. This block also supplies Phase-Angle Ramp (Soft start) and Safety Ramp.

In Engineer level, these items are mostly Read only (i.e. their values cannot be edited).

CONF

Firing OP

= wired input

Firing OP N

Mode

Firing OP N

Mode

Firing OP N

Load Type

Firing OP N

Safety R...

Firing OP N

Soft Sta...

Firing OP N

Soft Stop

Firing OP N

Delayed...

Firing OP N

Enable

Use up/down arrows to select Firing op number, then Enter. Use return key one or more times from within menu to return to this page

Mode

Load Type

Resistive

Safety Ramp

Soft Start

Soft Stop

Delayed Trigger

Enable

Displays the active firing mode of the control strategy as one of: IHC, Burst, PA or No Mode.

Logic

Select ‘Resistive’ or TxFormer’ (transformer).

Safety Ramp duration, applied at startup, in mains periods, from 0 to 255. The ramp is from 0 to the target

phase angle, or from 0 to 100% for burst firing.

Use up/down arrows to select soft-start duration in mains 1/2 cycles.

Off

Use up/down arrows to select soft-stop duration in mains 1/2 cycles.

For transformer loads, use the up/down arrows to select delayed trigger phase angle between

0 to 90 degrees

Enable/disable the Firing output block. Enable value must be non-zero.

Firing OP N

PA Limit

Firing OP N

Ramp Sta...

PA Limit

Ramp Status

Ramping

Displays the input power demand value that the firing must deliver.

Displays the phase angle reduction factor, in %, used in Burst Firing. If this value is below 100, the unit delivers a burst of phase angle. Can be used to perform

100

threshold current limting in burst firing.

Displays the safety ramp status

Back to Mode

Figure 6.13a Configuration firing Output

Mode Displays the current firing mode as Intelligent half cycle (IHC), Burst firing, Phase

angle firing or no mode. Configured in the ‘Modultr’, menu described below. Load Type Allows the load type to be selected as ‘Resistive’ or ‘Transformer’. For Load type =

Resistive, the load must be connected directly to the power module and only

resistive loads may be so connected. For Load Type = Transformer, the load is

connected to the power module via a transformer, and may be resistive or reactive.

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6.13 FIRING OUTPUT (Cont.)

Safety Ramp Displays the safety ramp duration, in supply voltage cycles (0 to 255), to be applied

at startup. The ramp is either a phase angle ramp from zero to the requested target

phase angle or, for Burst Firing, from 0 to 100%. See figure 6.13b. Safety Ramp is not

applicable to Half cycle Mode. Soft Start For Burst Firing only, this is the soft start duration, in supply voltage 1/2 cycles,

applying a phase angle ramp at the beginning of each on period. (Figure 6.13c). Soft Stop In Burst Firing, the soft stop duration, in supply voltage 1/2 cycles, applying a phase

angle ramp at the end of each on period. Delayed Trigger Appears only if Mode = Burst, Soft Start = Off, and Load Type = TxFormer. Delayed

Trigger specifies the triggering delay, in phase angle, when delivering power into a

transformer load. Used to ensure that the thyristor is fired when the current is zero.

Configurable between 0 and 90 degrees inclusive. See figure 6.13d. Enable Enables/disables firing. Must be wired to a non-zero value to enable firing (typically a

digital input). In Displays the input power demand value that the power module is to deliver. PA Limit Phase angle limit. This is a phase angle reduction factor used in Burst Firing. If lower

than 100% the power module will deliver a burst of phase angle firing. Used,

typically, to perform threshold current limiting in Burst Firing. Ramp Status Displays the safety ramp status as ‘Ramping’ or ‘Finished’.

Output voltage

Line supply

Safety Ramp (10 cycles)

Resistive load

Output voltage

Figure 6.13b Safety ramp (burst firing) examples

Soft start = 2

Line supply

Figure 6.13c Soft start example

High current transient

Load voltage

Load current

Safety (Magnetisation) Ramp

(4 cycles)

Output voltage

Line supply

Inductive load

Load voltage

Load current

Delayed trigger angle

0 0

Switch at zero volts

Switch at zero current

= Delayed Trigger angle

Figure 6.13d Delayed trigger definition

Note: Waveforms have been idealised for clarity

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6.14 INSTRUMENT MENU

Allows the user to select the display language, and to view the unit’s Serial number and the current Network configuration.

CONF

Instr

Display

Instr

Config

See figure 6.14.1

See figure 6.14.2

Figure 6.14 Instrument menu

6.14.1 Instrument Display parameters

Allows the user to select display language and to view the unit’s serial number.

CONF

Instr

Display

Select L...

Display

Serial N...

Instr

Config

Select Language

English

Serial Num

See figure 6.14.2 for Config menu

Use up/down arrows to select display language

Displays unit’s serial number (read only)

Back to ‘Select Language’

Figure 6.14.1 Instrument Display submenu

Serial Num Read only. Displays the factory-set Serial number of the unit. Select Language The up and down arrow keys are used to select the required language from English,

French, German or Italian. (Correct at time of writing - further languages may be

added during the life of this manual.)

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6.14.2 Instrument Config parameters

Allows the user access to the current power network configuration.

CONF

Instr

Display

Instr

Config

Power Mo...

Config

IO Modul...

Config

Network...

Config

Load Cou...

Config

Load 2 C...

Config

PwrMod1R...

Config

PwrMod2R...

See figure 6.14.1 for Display menu

Power Modules

IO Modules

Network Type

2Phase

Load Coupling

3Star

Load 2 Coupling

3Star

PwrMod1Rev

VN.N

PwrMod2Rev

VN.N

Use up/down arrows to enter the number of power modules fitted.

(Confirmation required)

Use up/down arrows to enter number of I/O mod-

ules fitted (if any).

Use up/down arrows to select power network type

Use up/down arrows to select coupling type

For 2 x 2-leg systems, use up/down arrows to select coupling type for second load.

Displays revision level of power module 1

Displays revision level of power module 2

Config

PwrMod3R...

Config

PwrMod4R...

PwrMod3Rev

PwrMod4Rev

Displays revision level of power module 3

VN.N

Displays revision level of power module 4

VN.N

Back to ‘Power Modules’

Figure 6.14.2 Instrument Config submenu

Power Modules Configures the number of power modules fitted. If left at zero, the system

automatically determines the number of modules fitted and sets the parameter

accordingly. IO Modules Specifies the number of optional I/O modules fitted. If left at zero, the system

automatically determines the number of modules fitted and sets the parameter

accordingly. Network Type Selects the type of network to be used, from 3 Phase, Single Phase or 2 Phase. Load Coupling For a three-phase system this allows the user to select the wiring configuration from

3Star, 3Delta, 4Star or 6Delta. For a two-phase system, only 3Delta or 3Star is

selectable. Load 2 Coupling As Load Coupling, above, but for the second load in 2 x 2-leg systems. PwrMod1Rev Shows the revision level of power module ‘1’. PwrMod2Rev Shows the revision level of power module ‘2’. PwrMod3Rev Shows the revision level of power module ‘3’. PwrMod4Rev Shows the revision level of power module ‘4’.

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0.0

00:00.0

6.15 IP MONITOR MENU

This monitors a wired parameter and records its maximum value, minimum value and the cumulative time that its value spends above a configurable threshold. An alarm can be set up to become active when the time-over-threshold exceeds a further threshold.

CONF

IPMon

IPMon N

Max

IPMon N

Min

IPMon N

Threshold

IPMon N

Days Abo...

IPMon N

Time Abo...

IPMon N

Alarm Da...

IPMon N

Alarm Ti...

IPMon N

Alarm Out

IPMon N

Reset

IPMon N

Status

Use up/down arrows to select input monitor number, then Enter. Use return key one or more times from within menu to return to this page

Max

Min

Threshold

The parameter being monitored. Normally wired to a parameter using iTools.

The maximum value reached by the parameter since last reset

The minimum value reached by the parameter since last reset

The trigger value for accumulating ‘Time Above’ values

Days Above

The total time (since last reset) that the parameter value has spent above the threshold value, in

Time Above

whole days plus hours and minutes

Alarm Days

The total time that the parameter value may spend above the threshold value before triggering ‘Alarm out’.

Alarm Time

Alarm Out

Alarm out goes ‘True’ (on) if the Days above + Time Above exceeds Alarm days + Alarm Time

Off

Reset

Sets Max and Min values to zero. Sets ‘Days Above’ and ‘Time Above’ values to zero.

Status

Good

The status of the parameter input (Good or Bad).

Back to ‘In’

Figure 6.15 IP Monitor menu

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6.15 IP MONITOR MENU (Cont.)

In The parameter to be monitored. Normally wired (using iTools) to a parameter, but a

numeric entry can be made for testing purposes. Max The maximum value reached by the parameter since last reset. Min The minimum value reached by the parameter since last reset Threshold This value acts as a trigger for the ‘Time Above’ measurement. Days above Shows how many complete days the parameter value has spent above the Threshold

value (continuously or intermittently) since last reset. The ‘Time Above’ value should

be added to ‘Days Above’ in order to find the total time. Time Above Shows how many hours, minutes and tenths of minutes that the parameter value has

spent above the threshold value (continuously or intermittently) since last reset, or

since the last complete day. (once the value exceeds 23:59.9, it increments the ‘Days

Above’ value and resets itself to 00:00.0.) The ‘Time Above’ value should be added

to ‘Days Above’ in order to find the total time. Alarm Days Together with ‘Alarm Time’ this defines a ‘total time above threshold’ value, which,

when exceeded, sets the Alarm out parameter ‘On’. Alarm Time See ‘Alarm Days’ above. Reset Resetting causes the Max. and Min. values to be set to the current value, sets the

‘Days Above’ value to zero, and the ‘Time Above’ value to 00:00.0. Status Shows the status of the input parameter as either ‘Good’ or ‘Bad’.

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6.16 LGC2 (TWO INPUT LOGIC OPERATOR) MENU

This logic operator block provides a number of two-input logic operations. The output is always a ‘Boolean’ (logic 0 or 1) no matter whether the inputs are analogue or digital. For analogue inputs, any value below 0.5 is deemed to be logic 0 (off). A value equal to or greater than 0.5 is treated as a logic 1 (on).

Either input can be ‘inverted’ as a part of the configuration (that is, a high input is treated as a low input and vice-versa.)

Figure 6.16 shows the LGC2 menu.

CONF

Lgc2

= wired input

Lgc2

Oper

Lgc2 N

Oper

Lgc2 N

Input1

Lgc2 N

Input2

Lgc2 N

Fall Type

Lgc2 N

Invert

Lgc2 N

Output

Lgc2 N

Status

Lgc2 N

Hyst

Use up/down arrows to select Lgc2 number, then Enter. Use return key [rtn ke one or more times from within menu to return to this page

Oper

Input1

Input2

Fall Type

Invert

Output

Status

Hyst

FalseBad

Select operator as: ’OFF’, ‘AND’, ‘OR’, ‘XOR’, ‘LATCH’,

OFF

‘==’, ‘<>’, <,>’, ‘>=’, ‘<=’

Shows current value of input 1. If not wired, allows a value to be entered.

Shows current value of input 2. If not wired, allows a value to be entered.

0.4900

Select ‘FalseBad’, ‘TrueBad’, ‘FalseGood’ or ‘TrueGood’ as fallback type.

Select ‘None’, ‘Input1’, ‘Input2’ or ‘Both’ for input inversion

None

Shows current value of the output

Off

Shows current status of the output

Good

Back to ‘Oper’

Figure 6.16 LGC2 menu

6.16.1 Lgc2 Parameters

Oper Allows the user to select a logic operation for the block. The descriptions below

assume neither input is inverted. High = 1 or on; Low = 0 or off. Off No logic operation selected. AND Output high if both inputs high, otherwise output is low. OR Output high if either or both inputs high, otherwise output low. XOR Output high if either (but not both) inputs high. Low if neither or both inputs high. LATCH If i/p2 low, output latches next transition of i/p1. Value remains latched until i/p2

goes low, when output = i/p1 (see figure 6.16.1). == Output high if both inputs are equal, otherwise output is low. <> Output high if inputs are unequal. Output is low if both inputs are equal. > Output high if i/p1 value greater than i/p2 value, otherwise output is low. < Output high if i/p1 value less than i/p2 value, otherwise output is low. >= Output high if i/p1 value is equal to or greater than i/p2 value, otherwise output is

low. <= Output high if i/p1 value is less than or equal to i/p2 value, otherwise output is low.

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I/P2

I/P1

O/P

I/P1 > (I/P2-H) I/P1 > (I/P2-H)

X XX

6.16.1 LGC2 PARAMETERS (Cont.)

Input 1 If wired, shows the value of input 1; if not, allows the user to enter a value. Input 2 If wired, shows the value of input 1; if not, allows the user to enter a value. Fall type Allows a fallback type to be selected. This defines the output value and status

displays if the status of one or both inputs is ‘bad’.

FalseGood Output value displays ‘False’ ; Status displays ‘Good’ FalseBad Output value displays ‘False’ ; Status displays ‘Bad’ TrueGood Output value displays ‘True’ ; Status displays ‘Good’

TrueBad Output value displays ‘True’ ; Status displays ‘Bad’ Invert Allows none, either or both inputs to be inverted. Output Shows the current output value Status Shows the status of the output (‘Good’ or ‘Bad’). Hysteresis For comparison operators only (e.g. >) this

allows a hysteresis value to be entered. For example, if the operator is ‘>’ and hysteresis is H, then the output goes high when input 1 exceeds input 2, and remains high until input 1 falls to a value less than (Input 2 - H). Not applicable to the ‘==’ (equals) function.

Hysteresis

i/p 1

i/p 2

o/p

o/p latches first

transition of i/p1

When i/p2 goes low, o/p follows the next positive or negative transition of i/p 1 (points ‘X’) and latches at this value until i/p2 goes high. When i/p2 is high, o/p follows i/p1.

o/p follows

i/p1

o/p latches first

transition of i/p1

o/p follows

i/p1

Figure 6.16.1 Latch operation

o/p latches first

transition of i/p1

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6.17 LGC8 (EIGHT-INPUT LOGIC OPERATOR) MENU

This allows between 2 and 8 inputs to be combined using an AND, OR or Exclusive OR (EXOR) logic function. The inputs may be individually inverted, and the output can also be inverted, thus allowing the full range of logic functions to be implemented.

CONF

Lgc8

Lgc8 N

Operation

Lgc8 N

Operation

Lgc8 N

Number o...

Lgc8 N

Invert

Lgc8 N

Out Inve...

Lgc8 N

In1

Lgc8 N

In8

Lgc8 N

Out

Use up/down arrows to select Logic number, then Enter. Use return key [rtn

key] one or more times from within menu to return to this page

Operation

Number of

Invert

Out Invert

In1

In8

Out

Select AND, OR, Exclusive OR or OFF.

AND

Select number of inputs from two to eight.

Use Enter key to move from input to input (current selection flashes). Use up/down key to select

invert (solid yellow) or not for the current selection. Final Enter quits Invert configuration.

No = Output not inverted Yes = Output inverted

Off

Input states 1 to N, where N is the number of inputs selected (two to eight inclusive).

Off

The output status of the selected logic function.

Off

Back to ‘Operation’

Figure 6.17 Lgc8 Menu

Operation Allows selection of AND, OR or Exclusive OR functions (or OFF).

AND = output is high only if all inputs are high OR = output is high if any or all inputs are high XOR = output is high if an odd number of inputs are high, and low if an even number of inputs are high. Logically, a cascaded XOR function: (((((((In1  In 2)  In 3)  In

4)....  In 8)

Number of inputs Set the number of inputs to between two and eight inclusive. This number defines

how many invert keys appear in ‘Invert’, and how many Input value pages appear.

Invert Between two and eight piano keys appear (according to the number of inputs

selected) at the bottom line of the display, with the left-most one (input 1) flashing. The up or down arrow can be used to select ‘invert’ for this input (key goes solid yellow), and/or the ‘Enter’ key can be used to move to the next input. Once all the inputs have been accessed, the final operation of the Enter key quits the Invert configuration, and ‘output invert’ is entered.

Out Invert No = normal output; ‘Yes’ means that the output is inverted, allowing NAND and

NOR functions to be implemented. In1 The state (on or off) of the first input In2 onwards The state of the remaining inputs Out The Output value of the function (i.e. On or Off)

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6.18 MATH2 MENU

This feature allows a range of two-input mathematical functions to be performed. The available functions are listed below.

CONF

Math2

Math2 N

Operation

Math2 N

Operation

Math2 N

Input1 S...

Math2 N

Input2 S...

Math2 N

Out Units

Math2 N

Out Reso...

Math2 N

Low Limit

Math2 N

High Lim...

Math2 N

Fallback

Use up/down arrows to select Math2 number, then Enter. Use return key [rtn key] one or more times from within menu to return to this page

Operation

Input1 Scale

Input2 Scale

Out Units

Out Resolution



Low Limit

-99999

High Limit

99999

Fallback

Clip bad

Use the up/down keys to select required maths function (see text for details).

Off

Use the up/down keys to enter the scaling factor to be applied to input 1

1.0

Use the up/down keys to enter the scaling factor to be applied to input 2

1.0

Use the up/down arrows to select output units (see text for details)

None

Use the up/down arrows to select the number of decimal places for the output value

Use the up/down arrow keys to enter the output low limit

Use the up/down arrow keys to enter the output high limit

The state to which the output and status parameters are forced under fault conditions. See text for details.

Math2 N

Fallback...

Math2 N

In1

Math2 N

In2

Math2 N

Out

Math2 N

Status

Fallback Value

In1

In2

Out

Status

Specifies the value which the output takes under fault conditions.

Input 1, normally wired to an input source.

Input 2, normally wired to an input source.

Displays the current output value

Displays ‘Good’ or ‘Bad’.

Good

Back to ‘Operation’

Figure 6.18 Analogue maths functions menu

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EPOWER CONTROLLER USER GUIDE

6.18 MATH2 MENU (Cont.)

Note: For the sake of this description, ‘High’, ‘1’ and ‘True’ are synonymous, as are ‘Low’, ‘0’ and ‘False’.

Operation Defines the mathematical function to be applied to the inputs:

None No operation. Add Adds input one to input two. Sub Subtracts input two from input one. Mul Multiplies inputs one and two together. Div Divides input one by input two. AbsDif The difference in value between inputs one and two, ignoring sign. SelMax Output = the higher of inputs one and two. SelMin Output = the lower of inputs one and two. HotSwp Input one appears as the output for as long as input one is ‘good’. If input one

status is bad, input two appears as the output instead.

SmpHld Sample and Hold. The output follows input one, for as long as input two is high

(sample). When input two goes low (hold), the output is held, at the value current when the output went low, until input two goes high again. Input two is normally a digital value (low = 0 or high =1); when it is an analogue value, then any positive non-zero value is interpreted as a high.

Power

Output = Input one raised to the power of input two (In1

one has the value 4.2, and the value of input two is 3, then output = 4.23 = 74.09. Sqrt The output is the square root of input one. Input two is not used. Log Output = Log10 (input one). (Log base 10). Input two is not used. Ln Output = Logn (input one). (Log base e). Input two is not used. Exp 10 x

Output = e

Output = 10

(input one)

. Input two is not used.

Select If the Select input is high, input two appears at the output; if the Select input is

low, input one appears at the output.

Input1 Scale The scaling factor to be applied to input one. Input2 Scale The scaling factor to be applied to input two. Out Units Allows the user to choose units for the output. Out

Resolution

Use the up and down arrows to position the decimal point as required.

Low Limit The low limit for all inputs to the function and for the fallback value. High Limit The high limit for all inputs to the function and for the fallback value. Fallback The fallback strategy comes into play if the status of the input value is ‘Bad’, or if its value lies

outside the range (High limit- Low limit). Fall Good: The output is set to the fallback value (below); output status is set to ‘Good’. Fall Bad: The output is set to the fallback value (below); output status is set to ‘Bad’. Clip Good: The output is set to the high or low limit as appropriate; output status is set to

‘Good’. Clip bad: The output is set to the high or low limit as appropriate; output status is set to

‘Bad’. DownScale: The output is set to the low limit and Status is set to ‘Bad’. Upscale: The output is set to the high limit and Status is set to ‘Bad’.

Fallback value

Allows the user to enter the value to which the output is set for Fallback = Fall Good, or Fall Bad.

Select Appears only if Operation = Select. Allows input one or input two to be selected for output. In1 Input one value (normally wired to an input source). In2 Input two value (normally wired to an input source). Out The output value resulting from the configured mathematical operation. If either input is ‘Bad’,

or if the result is out of range, the fallback strategy is adopted.

Status Indicates the status of the operation as ‘Good’ or ‘Bad’. Used to flag error conditions and can

be used as an interlock for other operations.

In2

). For example if input

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6.19 MODULATOR MENU

This function implements the modulation type firing modes such as fixed and variable period modulation.

CONF

Modultr

Modultr N

Mode

Modultr N

Mode

Modultr N

Input

Modultr N

Output

Modultr N

Min On

Modultr N

Cycle Ti...

Mutually exclusive

Modultr N

Logic Mo...

Modultr N

LMIn

Use up/down arrows to select modulator number, then Enter. Use return key [rtn key] one or more times from within menu to return to this page

Mode

Input

Output

Min On time

Cycle Time

Logic Mode

Full cycle

LMIn

Allows modulation firing mode to be selected from: ‘Logic’, ‘PA’ (phase angle), ‘Half Cycle’, ‘BurstVar’ or

Logic

‘BurstFix’

Input signal representing the required power output

0.0

Modulator logical output for controlling the power module(s). If mode = PA, this is a phase angle demand.

0.0

Appears only for Mode = BurstVar.

Appears only for Mode = BurstFix

For Mode = Logic only, defines when the output from the modulator block is to be stopped. Half Cycle = stops on next zero crossing Full Cycle = stops at next full cycle zero crossing

Use up/down arrows to select the load management interface input.

Modultr N

InFiltTi...

Modultr N

Switch PA

InFiltTime

Switch PA

Input fillter time in modulation periods. 0 = Filter disabled

Use up/down arrows to select: Burst or Phase Angle

Burst

Figure 6.19 Modulator menu

Mode Select the required firing mode from “Logic’, ‘PA’ (Phase angle) ‘Half cycle’, ‘BurstVar’

(Burst firing - minimum on time) or ‘BurstFix’ (Burst firing - cycle time). Input This is the value that the modulator is required to deliver. Output The output logic signal controlling the power module on and off times, normally wired

to the input of the firing block. For Mode = Phase angle, this is a phase angle demand. Min on Time For Variable Period Modulation, this sets the minimum on time in supply voltage

periods. At 50% demand from the modulator, Ton = Toff = Minimum on time, and Cycle

time is 2 x Minimum on time = Modulation period. The minimum off time is equal to

‘Min on time’. Cycle Time For Fixed Period Modulation, this is the cycle time in supply voltage periods. Logic Mode For Logic Firing Modulation, Half cycle sets firing stop to the next zero crossing; Full

cycle sets firing stop at the zero crossing of the next full cycle. LMIn Load Management Interface input. Defines a connection from the modulator to a load

management channel (if fitted). InFiltTime Modulator input filter time as a number of modulation periods. When set to zero, filter is

disabled. Switch PA Allows the user to impose Phase Angle firing, overriding the configured Burst Mode as

displayed in ‘Mode’, above.

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6.20 NETWORK MENU

This identifies the type of electrical network to be controlled, and this, in turn defines how the network’s electrical measurements are presented. The configuration is related to a power channel, not necessarily the Power Module number. For a network of four single-phase units, four network blocks are required; for two leg control of a three-phase network, two network blocks are used; for three-phase control of a single network, one Network block is required.

CONF

Network

Network N

Meas

Network N

Meas

Network N

Setup

Network N

AlmDis

Network N

AlmDet

Network N

AlmSig

Network N

AlmLat

Network N

AlmAck

Use up/down arrows to select network number, then Enter. Use return key one or more times from within menu to return to this page

Figure 6.20.1

Figure 6.20.2

Figure 6.20.3

Network N

AlmStop

Figure 6.20 Network menu

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Eurotherm EPower User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF SECTIONS

ASSOCIATED DOCUMENTS

SOFTWARE EFFECTIVITY

PATENTS

SAFETY NOTES

SYMBOLS USED ON THE INSTRUMENT LABELLING

1 INTRODUCTION

1.1 UNPACKING THE UNITS

2 INSTALLATION

2.1 MECHANICAL INSTALLATION

2.1.1 Fixing details

GENERAL

2.2 ELECTRICAL INSTALLATION

2.2.1 Driver Module

SUPPLY VOLTAGE

FAN SUPPLIES

ENABLE INPUT

SAFETY EARTH

SIGNAL WIRING

WATCHDOG RELAY

Relay 1

PREDICTIVE LOAD MANAGEMENT OPTION CONNECTOR

CONFIGURATION PORT

COMMUNICATIONS PINOUTS

2.2.2 Power modules

LINE/LOAD CABLES

RIBBON CABLE

EXTERNAL CURRENT FEEDBACK

REMOTE VOLTAGE INPUT

NEUTRAL/PHASE REFERENCE INPUT

ACCESS TO LINE AND LOAD TERMINATIONS

THREE-PHASE STAR CONFIGURATIONS

THREE-PHASE DELTA CONFIGURATIONS

TWO-LEG CONFIGURATIONS

THREE PHASE CONFIGURATIONS WITH EXTERNAL FEEDBACK

3 OPERATOR INTERFACE

3.1 DISPLAY

3.2 PUSHBUTTONS

3.2.1 Configuration

3.2.2 Operation

3.2.3 Menu item value selection

3.3 BEACONS

3.4 FRONT PANEL MESSAGES

3.4.1 Instrument events

3.4.2 Indication alarms

3.4.3 System alarms

3.4.4 Process alarms

3.4.5 Configuration errors

3.4.6 Standby errors

3.4.7 Power module errors

3.4.8 General errors

3.4.9 Reset errors

3.4.10 Fatal errors

4 QUICKSTART

4.1 QUICKSTART MENU PARAMETERS

4.2 SOME DEFINITIONS

4.2.1 Firing modes

LOGIC

BURST FIXED FIRING

BURST VARIABLE FIRING

PHASE ANGLE CONTROL

HALF CYCLE MODE

4.2.2 Feedback type

4.2.3 Transfer Mode

4.2.4 Limitation features

FIRING ANGLE LIMITING

DUTY CYCLE LIMITING

5 OPERATOR MENU

5.1 SUMMARY PAGES

5.1.1 Single phase summary page

5.1.2 Two or three phase summary page

5.1.3 Two by two phase summary page

5.2 TOP LEVEL OPERATOR (USER) MENU

5.2.1 Alarm Summary pages

5.2.2 Event Log

5.2.3 Strategy Standby mode