WEG ECW500 User Manual

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Page 1

Motors I Automation I Energy I Transmission & Distribution I Coatings

Automatic Voltage Regulator

ECW500

Manual

Page 2

Page 3

Manual

Series: ECW500

Language: English

Document No: 10003224697 / 03

Software Version: 1.3X

Publication Date: 08/2018

Page 4

Summary of Reviews .

Revision

Description

Chapter

First edition

Detailing the MPFC and MRPC modes

Inclusion of new parameters created under version V1.10

Addition of the new parameters created in the version V1.20 to the Quick Reference guide.

Inclusion of a configuration and operation description for the Autotuning function

1 and 6

Inclusion of new parameters created on version V1.3X

Description of analog output operation

New network interfaces: Ethernet and Anybus

New protection against broken wire for the analog input (PLCI)

PxQ curve with new maximum and minimum limits

1, 2, 4, 6

and 12

Page 5

Summary

SUMMARY

1 QUICK PARAMETER REFERENCE ...................................................... 1

2 ERRORS, WARNINGS AND EVENTS ................................................. 12

2.1 ERRORS ............................................................................................................................................ 12

2.2 WARNINGS ....................................................................................................................................... 12

2.3 EVENTS ............................................................................................................................................. 13

3 SAFETY INSTRUCTIONS .................................................................... 14

3.1 SAFETY WARNINGS IN THE MANUAL........................................................................................... 14

3.2 SAFETY WARNINGS IN THE PRODUCT ........................................................................................ 14

3.3 PRELIMINARY RECOMMENDATIONS ........................................................................................... 15

4 ABOUT THE ECW500 .......................................................................... 16

4.1 ABOUT THE MANUAL ...................................................................................................................... 16

4.1.1 Symbols Used .................................................................................................................. 16

4.2 SOFTWARE VERSION ...................................................................................................................... 17

4.3 CHARACTERISTICS ......................................................................................................................... 18

4.4 LABEL INFORMATION ..................................................................................................................... 19

4.5 HUMAN MACHINE INTERFACE (HMI) ........................................................................................... 20

4.5.1 Keys ................................................................................................................................ 20

4.5.2 Installation ........................................................................................................................ 21

4.5.3 Battery ................................................................ ............................................................. 21

5 INSTALLATION AND CONNECTION .................................................. 22

5.1 RECEIVING AND STORAGE ............................................................................................................ 22

5.2 MECHANICAL INSTALLATION ....................................................................................................... 22

5.2.1 Environmental Conditions ................................................................................................. 22

5.2.2 Positioning and Mounting ................................................................................................. 22

5.3 ELECTRICAL INSTALLATION ......................................................................................................... 24

5.3.1 Power and Grounding Wiring ................................................................ ............................ 25

5.3.2 Protection Fuses .............................................................................................................. 26

5.3.3 Grounding Connection...................................................................................................... 27

5.3.4 Control Connections ......................................................................................................... 28

6 FUNCTIONAL DESCRIPTION ............................................................. 31

6.1 PARAMETER STRUCTURE IN HMI ................................................................................................ 31

6.1.1 Measurement Screens ...................................................................................................... 33

6.1.2 Edition Screens ................................................................................................................ 34

6.1.3 Event Screen .................................................................................................................... 34

6.1.4 Password Screen ............................................................................................................. 35

6.2 DIGITAL INPUTS............................................................................................................................... 36

6.2.1 ON Digital Input ................................ ................................................................................ 37

6.2.2 OFF Digital Input............................................................................................................... 37

6.2.3 MTVC Digital Input............................................................................................................ 37

6.2.4 MECC Digital Input ........................................................................................................... 37

6.2.5 ENABLE PARALLEL Digital Input ...................................................................................... 37

6.2.6 DISABLE PARALLEL Digital Input ..................................................................................... 37

6.2.7 ENABLE ONLINE Digital Input ........................................................................................... 38

6.2.8 DISABLE ONLINE Digital Input .......................................................................................... 38

6.2.9 INCREMENT Digital Input ................................................................................................. 38

6.2.10 DECREMENT Digital Input ............................................................................................. 38

6.2.11 ALARM RESET Digital Input .......................................................................................... 39

6.3 ANALOG INPUTS .............................................................................................................................. 39

6.4 ANALOG OUTPUT ............................................................................................................................ 41

6.5 OPERATION MODES ....................................................................................................................... 41

6.5.1 OFF .................................................................................................................................. 41

Page 6

Summary .

6.5.2 MTVC (Automatic) ................................................................................................ ............ 41

6.5.3 MECC (Manual) ................................................................................................................ 41

6.5.4 MTVC_DROOP ................................................................................................................ 42

6.5.5 MPFC (Power Factor Control) ........................................................................................... 43

6.5.6 MRPC (Var Control).......................................................................................................... 43

6.5.7 Switching Between Operating Modes ............................................................................... 43

6.6 LIMITERS.......................................................................................................................................... 45

6.6.1 Underfrequency Limiter (LUF) ........................................................................................... 45

6.6.2 Excitation Overcurrent Limiter (LEOC) ............................................................................... 47

6.6.3 Excitation Undercurrent Limiter (LEUC) ............................................................................. 48

6.6.4 Terminal Overcurrent Limiter (LTOC) ................................................................ ................. 49

6.7 PROTECTIONS ................................................................................................................................ 50

6.7.1 Feedback Loss Protection (PFL) ....................................................................................... 51

6.7.2 Excitation Overvoltage Protection (PEOV) ......................................................................... 51

6.7.3 Fault Protection in the Rotating Diodes (PED) ................................................................... 51

6.7.4 Excitation Loss Protection (PEL) ....................................................................................... 52

6.7.5 Terminal Overvoltage Protection (PTOV) ........................................................................... 52

6.7.6 Terminal Undervoltage Protection (PTUV) ......................................................................... 52

6.7.7 Power Module Overtemperature Protection ...................................................................... 52

6.7.8 Power Phase Loss Protection .......................................................................................... 52

6.7.9 Maximum/Minimum Protection Limits of the PWM ............................................................ 52

6.7.10 Analog Input in Current: Loss Protection (PLCI) ............................................................. 53

6.8 CRITICAL PROTECTION ................................................................................................................. 53

6.8.1 Underfrequency Protection............................................................................................... 53

6.8.2 Excitation Overcurrent Protection (PEOC) ......................................................................... 53

6.8.3 DC Link Overvoltage Protection........................................................................................ 53

6.8.4 Fault Protection on Triggers of the Power Switches .......................................................... 53

6.9 DIGITAL RELAY OUTPUT ............................................................................................................... 53

6.9.1 Status Relay .................................................................................................................... 53

6.9.2 General Fault Relay .......................................................................................................... 53

6.9.3 Configurable Relays 0, 1, 2 and 3 .................................................................................... 53

6.10 SOFT START................................................................................................................................. 54

6.11 AUTOMATIC TUNING (AUTOTUNING)....................................................................................... 54

6.11.1 Configuration Parameters ............................................................................................. 54

6.11.2 Commands .................................................................................................................. 56

6.11.3 Messages ..................................................................................................................... 57

6.11.4 Monitoring .................................................................................................................... 57

6.12 SPECIAL FUNCTIONS ................................................................................................................. 57

6.12.1 Self-Calibration of the Excitation Current Measurement ................................................. 57

6.12.2 Self-Calibration of the Analog Inputs ............................................................................. 58

7 MODBUS RTU COMMUNICATION..................................................... 59

7.1 STRUCTURE OF THE MESSAGES IN THE RTU MODE ............................................................... 59

7.2 MODBUS FUNCTIONS AVAILABLE ON THE ECW500 ................................................................. 59

7.2.1 Parameter Types of the ECW500 ..................................................................................... 59

7.3 SERIAL TRANSMISSION ................................................................................................................. 60

7.3.1 Time Between Messages ................................................................................................. 60

7.3.2 Physical Interface ............................................................................................................. 60

8 ETHERNET COMMUNICATION (MODBUS TCP) .............................. 62

9 ANYBUS COMMUNICATION .............................................................. 63

10 STARTUP ............................................................................................ 64

10.1 REQUIRED EQUIPMENT ............................................................................................................. 64

10.2 PREPARATION AND POWER-UP OF THE ELECTRONICS...................................................... 64

10.3 SYSTEM DATA ............................................................................................................................. 64

10.4 CONFIGURING THE ECW500 ..................................................................................................... 64

10.4.1 Rated Parameters ......................................................................................................... 64

10.4.2 Operating Modes and Limiters ...................................................................................... 65

10.4.3 Input and Output Configuration ..................................................................................... 65

Page 7

Summary

10.4.4 Control Configuration .................................................................................................... 66

10.4.5 Configuring the Protections ........................................................................................... 67

10.5 TESTS ON THE OFFLINE MODES ............................................................................................... 67

10.5.1 Turning On and Off the Regulator with Machine Spinning ............................................... 67

10.5.2 Test of the Excitation Current Limiter ............................................................................. 68

10.6 TESTS ON THE ONLINE MODES ................................................................................................ 69

11 MAINTENANCE .................................................................................. 71

11.1 DIAGNOSIS OF FAULTS, ERRORS AND MESSAGES ............................................................... 71

11.2 TECHNICAL ASSISTANCE ........................................................................................................... 71

11.3 PREVENTIVE MAINTENANCE ..................................................................................................... 71

11.4 INSTRUCTIONS TO CLEAN THE PRODUCT ............................................................................. 72

11.5 SOLVING THE MOST COMMOM PROBLEMS ........................................................................... 72

12 TECHNICAL SPECIFICATIONS ........................................................ 74

12.1 POWER DATA ............................................................................................................................... 74

12.2 ELETRONICS / GENERAL DATA ................................................................................................. 75

Page 8

Page 9

Quick Parameter Reference

ECW500 | 1

1 QUICK PARAMETER REFERENCE

Version: V1.3X Responsible: Date: / /

Modbus Address

Description

Adjustable Range

Factory

Setting

Proper

COMMANDS

Start excitation command

0 = Off, 1 = On

0 1 Stop excitation command

0 = Off, 1 = On

Automatic mode command

0 = Off, 1 = On

Manual mode command

0 = Off, 1 = On

0 6

Enable online command

0 = Off, 1 = On

0 7

Disable online command

0 = Off, 1 = On

0 8

Enable parallel command

0 = Off, 1 = On

Disable parallel command

0 = Off, 1 = On

Alarm reset command

0 = Off, 1 = On

Autotuning start command

0 = Off, 1 = On

F1 key command

0 = Off, 1 = On

F2 key command

0 = Off, 1 = On

0 STATUS

10000

ECW500 status

0 = Off, 1 = On

0 RO

10001

Running startup ramp

0 = Off, 1 = On

0 RO

10002

LUF Status

0 = Off, 1 = On

0 RO

10003

LEOC Status

0 = Off, 1 = On

0 RO

10004

LEUC Status

0 = Off, 1 = On

0 RO

10005

LTOC Status

0 = Off, 1 = On

0 RO

10006

DI Start status

0 = Off, 1 = On

0 RO

10007

DI Stop status

0 = Off, 1 = On

0 RO

10008

DI Increment status

0 = Off, 1 = On

0 RO

10009

DI Decrement status

0 = Off, 1 = On

0 RO

10010

DI MTVC status

0 = Off, 1 = On

0 RO

10011

DI MECC status

0 = Off, 1 = On

0 RO

10012

DI Enable Online status

0 = Off, 1 = On

0 RO

10013

DI Disable Online status

0 = Off, 1 = On

0 RO

10014

DI Enable Parallel status

0 = Off, 1 = On

0 RO

10015

DI Disable Parallel status

0 = Off, 1 = On

0 RO

10016

DI Pre-Position status

0 = Off, 1 = On

0 RO

10017

DI Reset Alarm status

0 = Off, 1 = On

0 RO

10018

DI Backup status

0 = Off, 1 = On

0 RO

COMMUNICATION

RS-485 / RS-422

30002

Serial port full duplex

0 = Disabled, 1 = Enabled

30006

Baud rate of the serial port

0 = 9600 bps

1 = 19200 bps

2 = 38400 bps

3 = 57600 bps

4 = 115200 bps

30008

Serial port parity

0 = None

1 = Odd

2 = Even

30010

Serial port stop bits

1 to 2 1

30012

Modbus ID

1 to 254 1

Page 10

Quick Parameter Reference .

2 | ECW500

Modbus Address

Description

Adjustable Range

Factory

Setting

Proper

30014

Modbus timeout

100 to 9950 ms

500 ms

Anybus

31114

Reset Anybus Module

0 = Disable, 1 = enable

31124

Anybus Ethernet IP Field 1

0 a 255

192

31126

Anybus Ethernet IP Field 2

0 a 255

168

31128

Anybus Ethernet IP Field 3

0 a 255

31130

Anybus Ethernet IP Field 4

0 a 255

31132

Anybus Ethernet Mask Field 1

0 a 255

255

31134

Anybus Ethernet Mask Field 2

0 a 255

255

31136

Anybus Ethernet Mask Field 3

0 a 255

255

31138

Anybus Ethernet Mask Field 4

0 a 255

31140

Anybus Ethernet Gateway Field 1

0 a 255

192

31142

Anybus Ethernet Gateway Field 2

0 a 255

168

31144

Anybus Ethernet Gateway Field 3

0 a 255

31146

Anybus Ethernet Gateway Field 4

0 a 255

31148

Anybus DHCP Configuration

0 = Disable, 1 = Enable

31150

Anybus Mapped Reading Address 0

30002 a 49998

39998

31152

Anybus Mapped Reading Address 1

30002 a 49998

39998

31154

Anybus Mapped Reading Address 2

30002 a 49998

39998

31156

Anybus Mapped Reading Address 3

30002 a 49998

39998

31158

Anybus Mapped Reading Address 4

30002 a 49998

39998

31160

Anybus Mapped Reading Address 5

30002 a 49998

39998

31162

Anybus Mapped Reading Address 6

30002 a 49998

39998

31164

Anybus Mapped Reading Address 7

30002 a 49998

39998

31166

Anybus Mapped Reading Address 8

30002 a 49998

39998

31168

Anybus Mapped Reading Address 9

30002 a 49998

39998

31170

Anybus Mapped Reading Address 10

30002 a 49998

39998

31172

Anybus Mapped Reading Address 11

30002 a 49998

39998

31174

Anybus Mapped Writing Address 0

30000 a 39998

30000

31176

Anybus Mapped Writing Address 1

30000 a 39998

30000

31178

Anybus Mapped Writing Address 2

30000 a 39998

30000

31180

Anybus Mapped Writing Address 3

30000 a 39998

30000

31182

Anybus Mapped Writing Address 4

30000 a 39998

30000

31184

Anybus Mapped Writing Address 5

30000 a 39998

30000

31186

Anybus Mapped Writing Address 6

30000 a 39998

30000

31188

Anybus Mapped Writing Address 7

30000 a 39998

30000

31190

Anybus Mapped Writing Address 8

30000 a 39998

30000

31192

Anybus Mapped Writing Address 9

30000 a 39998

30000

31194

Anybus Mapped Writing Address 10

30000 a 39998

30000

31196

Anybus Mapped Writing Address 11

30000 a 39998

30000

31198

Anybus device node ID

0 a 255

31200

Anybus baud rate

0 = 125 kbps

1 = 250 kbps

2 = 500 kbps

3 = auto

31202

Anybus Modbus timeout

100 a 9990 ms

500 ms

31204

Enable DCP

0 = Disable, 1 = Enable

31214

Status Word

0 a 127

31216

Command Word

0 a 32767

Ethernet

30258

Ethernet IP Field 1

0 a 255

192

30260

Ethernet IP Field 2

0 a 255

168

30262

Ethernet IP Field 3

0 a 255

Page 11

Quick Parameter Reference

ECW500 | 3

Modbus

Address

Description

Adjustable Range

Factory

Setting

Proper

30264

Ethernet IP Field 4

0 a 255

30266

Ethernet Mask Field 1

0 a 255

255

30268

Ethernet Mask Field 2

0 a 255

255

30270

Ethernet Mask Field 3

0 a 255

255

30272

Ethernet Mask Field 4

0 a 255

30274

Ethernet Gateway Field 1

0 a 255

192

30276

Ethernet Gateway Field 2

0 a 255

168

30278

Ethernet Gateway Field 3

0 a 255

30280

Ethernet Gateway Field 4

0 a 255

31218

Ethernet Modbus TCP connection port

0 a 65535

502

31220

Ethernet Modbus Device ID

0 a 255

31222

Ethernet Modbus TCP timeout

5 a 99999 s

10 s

31224

Active Modbus TCP Connections

0 a 8

31226

Ethernet Link speed

0 = No Link

1 = 10 Mb/s Half Duplex

2 = 10 Mb/s Full Duplex

3 = 100 Mb/s Half Duplex

4 = 100 Mb/s Full Duplex

31228

Transmitted Modbus Telegrams

0 a 65535

31230

Received Modbus Telegrams

0 a 65535

31232

Ethernet DHCP Configuration

0 = Disable, 1 = Enable

31234

Ethernet Modbus IP Field 1

0 a 255

31236

Ethernet Modbus IP Field 2

0 a 255

31238

Ethernet Modbus IP Field 3

0 a 255

31240

Ethernet Modbus IP Field 4

0 a 255

31242

Ethernet Modbus Mask Field 1

0 a 255

31244

Ethernet Modbus Mask Field 2

0 a 255

31246

Ethernet Modbus Mask Field 3

0 a 255

31248

Ethernet Modbus Mask Field 4

0 a 255

31250

Ethernet Modbus Gateway Field 1

0 a 255

31252

Ethernet Modbus Gateway Field 2

0 a 255

31254

Ethernet Modbus Gateway Field 3

0 a 255

31256

Ethernet Modbus Gateway Field 4

0 a 255

MACHINE RATED VALUES

30058

Machine nominal voltage

85 V to 30 kV

380 V

30060

Machine nominal current

10 A to 60 kA

22.7 A

30062

Machine nominal frequency

30 to 180 Hz

60 Hz

30064

Nominal excitation voltage

0 to 180 V

32.0 V

30066

Nominal excitation current

0 to 20.00 A

1.00 A

30068

Nominal power

0.85 kVA to 1750 MVA

22.8 kVA

FEEDBACK

30070

Potential transformer primary

85 V to 30 kV

380 V

30072

Potential transformer secondary

85 V to 600 V

115 V

30074

Current transformer primary

1 A to 60 kA

1 A

30076

Current transformer secondary

1 A or 5A

5 A

31032

Potential transformer configuration

0 = Single phase

1 = Three phase

OPERATION MODES

30206

Mode selection MTVC/MECC 0 = MECC

1 = MTVC

30208

Online mode selection

0 = Off

1 = MPFC Mode

2 = MRPC Mode

Page 12

Quick Parameter Reference .

4 | ECW500

Modbus Address

Description

Adjustable Range

Factory

Setting

Proper

30210

Parallel mode selection 0 = Off

1 = Droop

31028

External Power Module

0 = OFF, 1 = ON

31032

Transition time between modes

0 to 10000 s

10 s

SETPOINTS

30212

MTVC Setpoint

0.0 x V

nom

to 1.5 x V

nom

380 V

30214

MECC Setpoint

0.00 x Iexc

nom

a 1.50 x Iexc

nom

1.00 A

30216

DROOP Setpoint

-30.0 to 30.0 %

5.0 %

30218

MRPC Setpoint

-1.2 x P

nom

to 1.2 x P

nom

0 Var

30220

MPFC Setpoint

-0.01 a 0.01

1.00

30222

Minimum MTVC Setpoint

0.00 x V

nom

to 1.00 x V

nom

0.70 x V

nom

30224

Maximum MTVC Setpoint

1.00 x V

nom

to 1.50 x V

nom

1.20 x V

nom

30226

Minimum MECC Setpoint

0.00 x Iexc

nom

to 1.00 x Iexc

nom

0.00 x Iexc

nom

30228

Maximum MECC Setpoint

0.00 x Iexc

nom

to 1.20 x Iexc

nom

1.20 x Iexc

nom

30230

Minimum MRPC Setpoint

-1.20 x P

nom

to 1.20 x P

nom

-1.00 x P

nom

30232

Maximum MRPC Setpoint

-1.20 x P

nom

to 1.20 x P

nom

1.00 x P

nom

30234

Maximum MPFC Lag

1.00 a 0.01

0.50

30236

Minimum MPFC Lead

-1.00 a -0.01

-0.50

30238

Setpoint MTVC Preposition

0.00 x V

nom

a 1.50 x V

nom

380 V

30240

Setpoint MECC Preposition

0 a 1.5 x Iexc

nom

0.50 A

30242

Setpoint MRPC Preposition

-1.2 x P

nom

a 1.2 x P

nom

0 Var

30244

Setpoint MPFC Preposition

-0.01 a 0.01

1.00

30246

Enable MECC reference tracking

0 = False, 1 = True

31016

Enable DI for Inc/Dec of reference

0 = Disabled, 1 = Enabled

31036

Enable MTVC reference tracking

0 = False, 1 = True

31038

Enable MRPC reference tracking

0 = False, 1 = True

31040

Enable MPFC reference tracking

0 = False, 1 = True

31042

Enable Follower on MTVC

0 = False, 1 = True

31044

Enable MRPC Follower

0 = False, 1 = True

31046

Enable MRPC Follower

0 = False, 1 = True

31048

Source for Setpoint

0 = Parameter

1 = Analog Input

2 = Parameter + Analog Input

REGULATORS

30016

Proportional gain MTVC

0.0 to 99.999

0.150

30018

Integral gain MTVC

0.0 to 99.999

0.250

30020

MTVC Derivative gain Kd

0.0 to 9.999

0.020

30022

MECC Proportional gain

0.0 to 99.999

0.250

30024

MECC Integral gain

0.0 to 99.999

0.500

30028

Proportional gain MRPC

0.0 to 99.999

0.100

30030

Integral gain MRPC

0.0 to 99.999

0.200

30034

Proportional gain MPFC

0.0 to 99.999

0.010

30036

Integral gain MPFC

0.0 to 99.999

0.020

LIMITERS

Excitation Overcurrent (LEOC)

30132

LEOC High level

0 to 2000.0 A

1.0 A

30134

LEOC Time

0 to 60 s

10 s

30140

LEOC Low level

0.1 a 2000.0 A

0.5 A

30142

LEOC enable

0 = False, 1 = True

30040

LEOC Proportional gain Kp

0.0 to 99.999

0.250

30042

LEOC Integral gain Ki

0.0 to 99.999

0.500

Terminal Overcurrent (LTOC)

30124

LTOC Enable

0 = False, 1 = True

Page 13

Quick Parameter Reference

ECW500 | 5

Modbus

Address

Description

Adjustable Range

Factory

Setting

Proper

30126

LTOC High level

1 A to 66 kA

200 A

30128

LTOC Time

0 to 60 s

15 s

30130

LTOC Low level

1 A to 60 kA

100 A

30046

LTOC Proportional gain Kp

0.0 to 99.999

0.150

30048

LTOC Integral gain Ki

0.0 to 99.999

0.250

31330

LTOC Always Active

0 = False, 1 = True

Excitation Undercurrent (LEUC)

30146

LEUC multiplier

0 = 0.1 k 0 1 = 1 k

2 = 10 k

3 = 100 k

4 = 1000 k

30148

Enables LEUC

0 = False, 1 = True

30150

LEUC Active Power Point 1

0 to 2000 MW

30152

LEUC Active Power Point 2

0 to 2000 MW

30154

LEUC Active Power Point 3

0 to 2000 MW

30156

LEUC Active Power Point 4

0 to 2000 MW

30158

LEUC Active Power Point 5

0 to 2000 MW

30160

LEUC Reactive power point 1

- 2000 MVar to 0

30162

LEUC Reactive power point 2

- 2000 MVar to 0

30164

LEUC Reactive power point 3

- 2000 MVar to 0

30166

LEUC Reactive power point 4

- 2000 MVar to 0

30168

LEUC Reactive power point 5

- 2000 MVar to 0

30170

Maximum reactive LEUC adjust

- 2000 MVar to 0

30172

Minimum reactive LEUC adjust

- 2000 MVar to 0

-4.5 MVar

30174

Maximum active LEUC adjust

0 to 2000 MW

4.5 MW

30176

Minimum active LEUC adjust

0 to 2000 MW

30052

LEUC Proportional gain Kp

0.0 to 99.999

0.100

30054

LEUC Integral gain Ki

0.0 to 99.999

0.200

Underfrequency (LUF)

30118

U/F Corner frequency

15 to 150.0 Hz

57.0 Hz

30120

U/F Curve slope

0 to 150.0 V/Hz

3.0 V/Hz

30122

U/F or V/Hz mode selection

0 = UF, 1 = V/Hz

ANALOG INPUT

30110

Calibrate voltage AI

0 = Off, 1 = On

30248

AI gain to MTVC

-9.99 to 9.99

1.00

30250

AI gain to MECC

-9.99 to 9.99

1.00

30252

AI gain to MRPC

-9.99 to 9.99

1.00

30254

AI gain to MPFC

-9.99 to 9.99

1.00

30256

Full Scale for Excitation Current

0 to 2000 A

100 A

31054

Function of Analog Input 1 (0 to 10V)

0 = Setpoint

1 = Feedback I

exc

31056

Function of Analog Input 2 (4 to 20mA)

0 = Setpoint

1 = Feedback I

exc

31068

AI Offset for MTVC

-30 kV to 30 kV

ANALOG OUTPUT

31058

Analog Output Gain

0 to 99.99

1.00

31060

Analog Output Signal 0 = 0 to 10 V

1 = 4 to 20 mA

31062

Analog Output Function

0 = Control Output

1 = Terminal Voltage

2 = Terminal Current

3 = Power Factor

Page 14

Quick Parameter Reference .

6 | ECW500

Modbus Address

Description

Adjustable Range

Factory

Setting

Proper

4 = Active Power

5 = Excitation Current

6 = Reactive Power

DIGITAL INPUTS

30178

Start digital input type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30180

Stop digital input type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30182

Increment digital input

0 = Button Released

1 = Button Pressed

2 = Button Hold

30184

Decrement digital input

0 = Button Released

1 = Button Pressed

2 = Button Hold

30186

Automatic digital input

0 = Button Released

1 = Button Pressed

2 = Button Hold

30188

Manual digital input type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30190

Enable online DI type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30192

Disable online DI type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30194

Enable parallel DI type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30196

Disable parallel DI type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30198

Alarm reset DI type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30200

Preposition DI type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30202

Backup Di type

0 = Button Released

1 = Button Pressed

2 = Button Hold

30204

DI increment multiplier

1 to 200 1

DIGITAL OUTPUTS

30298

Status Relay NC (Normally Closed)

0 = False, 1 = True

30300

Failure Relay NC

0 = False, 1 = True

30302

RL0 Relay NC

0 = False, 1 = True

30304

RL1 Relay NC

0 = False, 1 = True

30306

RL2 Relay NC

0 = False, 1 = True

30308

RL3 Relay NC

0 = False, 1 = True

30310

RL0 annunciation type

0 = Momentary

Page 15

Quick Parameter Reference

ECW500 | 7

Modbus

Address

Description

Adjustable Range

Factory

Setting

Proper

1 = Maintain

2 = Latched

30312

RL1 annunciation type

0 = Momentary

1 = Maintain

2 = Latched

30314

RL2 annunciation type

0 = Momentary

1 = Maintain

2 = Latched

30316

RL3 annunciation type

0 = Momentary

1 = Maintain

2 = Latched

0.1 to 5.0 s

30318

RL0 time

0.1 to 5.0 s

0.2 s

30320

RL1 time

0.1 to 5.0 s

0.2 s

30322

RL2 time

0.1 to 5.0 s

0.2 s

30324

RL3 time

0.1 to 5.0 s

0.2 s

30326

RL0 field overvoltage

0 = False, 1 = True

30328

RL1 field overvoltage

0 = False, 1 = True

30330

RL2 field overvoltage

0 = False, 1 = True

30332

RL3 field overvoltage

0 = False, 1 = True

30334

RL0 machine overvoltage

0 = False, 1 = True

30336

RL1 machine overvoltage

0 = False, 1 = True

30338

RL2 machine overvoltage

0 = False, 1 = True

30340

RL3 machine overvoltage

0 = False, 1 = True

30342

RL0 machine undervoltage

0 = False, 1 = True

30344

RL1 machine undervoltage

0 = False, 1 = True

30346

RL2 machine undervoltage

0 = False, 1 = True

30348

RL3 machine undervoltage

0 = False, 1 = True

30350

RL0 underfrequency

0 = False, 1 = True

30352

RL1 underfrequency

0 = False, 1 = True

30354

RL2 underfrequency

0 = False, 1 = True

30356

RL3 underfrequency

0 = False, 1 = True

30358

RL0 overexcitation

0 = False, 1 = True

30360

RL1 overexcitation

0 = False, 1 = True

30362

RL2 overexcitation

0 = False, 1 = True

30364

RL3 overexcitation

0 = False, 1 = True

30366

RL0 underexcitation

0 = False, 1 = True

30368

RL1 underexcitation

0 = False, 1 = True

30370

RL2 underexcitation

0 = False, 1 = True

30372

RL3 underexcitation

0 = False, 1 = True

30374

RL0 to MECC mode

0 = False, 1 = True

30376

RL1 to MECC mode

0 = False, 1 = True

30378

RL2 to MECC mode

0 = False, 1 = True

30380

RL3 to MECC mode

0 = False, 1 = True

30382

RL0 feedback loss

0 = False, 1 = True

30384

RL1 feedback loss

0 = False, 1 = True

30386

RL2 feedback loss

0 = False, 1 = True

30388

RL3 feedback loss

0 = False, 1 = True

30390

RL0 excitation diode failure

0 = False, 1 = True

30392

RL1 excitation diode failure

0 = False, 1 = True

30394

RL2 excitation diode failure

0 = False, 1 = True

30396

RL3 excitation diode failure

0 = False, 1 = True

Page 16

Quick Parameter Reference .

8 | ECW500

Modbus Address

Description

Adjustable Range

Factory

Setting

Proper

30398

RL0 LEOC acting

0 = False, 1 = True

30400

RL1 LEOC acting

0 = False, 1 = True

30402

RL2 LEOC acting

0 = False, 1 = True

30404

RL3 LEOC acting

0 = False, 1 = True

30406

RL0 LTOC acting

0 = False, 1 = True

30408

RL1 LTOC acting

0 = False, 1 = True

30410

RL2 LTOC acting

0 = False, 1 = True

30412

RL3 LTOC acting

0 = False, 1 = True

30414

RL0 U/F acting

0 = False, 1 = True

30416

RL1 U/F acting

0 = False, 1 = True

30418

RL2 U/F acting

0 = False, 1 = True

30420

RL3 U/F acting

0 = False, 1 = True

31206

RL0 Anybus Offline

0 = False, 1 = True

31208

RL1 Anybus Offline

0 = False, 1 = True

31210

RL2 Anybus Offline

0 = False, 1 = True

31212

RL3 Anybus Offline

0 = False, 1 = True

31332

RL0 Power Failure Phase

0 = False, 1 = True

31334

RL1 Power Failure Phase

0 = False, 1 = True

31336

RL2 Power Failure Phase

0 = False, 1 = True

31338

RL3 Power Failure Phase

0 = False, 1 = True

31340

RL0 Loss of Excitement

0 = False, 1 = True

31342

RL1 Loss of Excitement

0 = False, 1 = True

31344

RL2 Loss of Excitement

0 = False, 1 = True

31346

RL3 Loss of Excitement

0 = False, 1 = True

PROTECTIONS

Feedback Loss (PFL)

30286

Enable PFL

0 = Disabled, 1 = Enabled

30288

Enable PFL to MECC

0 = Disabled, 1 = Enabled

30290

PFL delay

0.0 to 30.0 s

0.2 s

30292

PFL balanced level

0.0 to 100.0 %

15.0 %

30294

PFL unbalanced level

0.0 to 100.0 %

15.0 %

Excitation Loss (PEL)

30296

PEL delay

1 to 100 s

5 s

30436

PEL enable

0 = Disabled, 1 = Enabled

Excitation Overvoltage (PEOV)

30422

Enable PEOV

0 = False, 1 = True

30424

PEOV level

1 to 325 Vcc

32 Vcc

30426

PEOV delay

0.2 to 30.0 s

0.2 s

Power Module

30428

Power temperature level

0 to 130 °C

125 °C

30430

Power temperature delay

0 to 30 s

2 s

30432

Power temperature turn off ECW

0 = False, 1 = True

30434

Enable phase loss at power

0 = Off, 1 = On

30438

Maximum PWM

0.00 to 100.00 %

100.00 %

30440

Minimum PWM

-100.00 to 0.00 %

-100.00 %

30472

Phase loss protection delay

0 a 60 s

3 s

30474

DC link overvoltage delay

0.0 a 10.0

2 s

Terminal Overvoltage (PTOV)

30442

PTOV enable

0 = False, 1 = True

30444

PTOV delay

0.5 to 60.0 s

1.0 s

30446

PTOV level

100 to 200 % (V

nom

)

130 %

Terminal Undervoltage (PTUV)

30448

PTUV enable

0 = False, 1 = True

Page 17

Quick Parameter Reference

ECW500 | 9

Modbus

Address

Description

Adjustable Range

Factory

Setting

Proper

30450

PTUV delay

0.5 to 60.0 s

20.0 s

30452

PTUV level

40 to 100 % (V

nom

)

40 %

Excitation Overcurrent (PEOC)

30454

PEOC enable

0 = False, 1 = True

30456

PEOC level

0.1 to 30.0 A

30 A

30458

PEOC delay

0.1 to 30.0 s

1.0 s

Rotating Diodes (PED)

30460

Limit 1st Harmonic PED

0.1 to 100.0 %

60.0 %

30462

Limit 2st Harmonic PED

0.1 to 100.0 %

60.0 %

30464

Ripple Maximum PED

0.1 to 100.0 %

60.0 %

30466

Enable PED

0 = False, 1 = True

30468

Delay PED

5 to 60 s

60 s

30470

PED Turn Off ECW500

0 = False, 1 = True

Loss of Analog Current Input (PLCI)

31024

PLCI Enable

0 = False, 1 = True

31026

PLCI Delay

0 to 5 s

1 s

HMI

30078

Password

1 to 999

30080

New password

0 to 999

30082

Time to show message on HMI

0 to 9000 ms

500 ms

30084

Time to hide message on HMI

0 to 9000 ms

8000 ms

30086

Fast key multiplier

0 to 300

30088

Super fast key multiplier

0 to 3000

30090

Ultra fast key multiplier

0 to 3000

30092

LCD Contrast

0 to 31

30094

Calendar Month

1 to 12

30096

Calendar Day

1 to 31

30098

Calendar Year

2000 to 2200

2010

30100

Calendar Week day

0 = Sunday

1 = Monday

2 = Tuesday

3 = Wednesday

4 = Thursday

5 = Friday

6 = Saturday

30102

Time - Hours

0 to 23

30104

Time - Minutes

0 to 59

30106

Time - Seconds

0 to 59

30114

HMI language

0 = English

1 = Portuguese

2 = NA

3 = NA

30116

Enable HMI on/off buttons

0 = Off, 1 = On

31320

Button F1 function

0 = Disabled

1 = Reference increment

2 = Reference decrement

31322

Button F2 function

0 = Disabled

1 = Reference increment

2 = Reference decrement

31324

Increment / Decrement Button F1

0 a 100 %

0 %

31326

Increment / Decrement Button F2

0 to 100 %

0 %

START-UP RAMP / CALIBRATION

Page 18

Quick Parameter Reference .

10 | ECW500

Modbus Address

Description

Adjustable Range

Factory

Setting

Proper

30108

Calibrate Excitation Current

0 = Off, 1 = On

30282

Soft Start Level

0 to 100 %

5 %

30284

Soft Start Time

1 to 7200 s

5 s

AUTOTUNING

31070

Level for output variation

0 to 50 %

5 %

31072

Hysteresis level

0 to 20 %

0.5 %

31074

Convergence tolerance

0.1 to 20 %

2.5 %

31076

Timeout for autotuning execution

1 to 120 s

15 s

31078

Autotuning: proportional gain (Kp)

0 to 99.999

31080

Autotuning: integral gain (Ki)

0 to 99.999

31082

Autotuning: derivative gain (Kd)

0 to 99.999

31084

Controller configuration for autotuning

0 = PI

1 = PID

0 31108

Copy gains to current mode

0 = Disabled, 1 = Enabled

31100

Upper level for feedback during autotuning

0 to 100 %

20 %

31112

Lower level for feedback during autotuning

0 to 100 %

20 %

MONITORING

40000

Terminal voltage AB

0 to 40 kV

40002

Terminal voltage BC

0 to 40 kV

40004

Terminal voltage CA

0 t 40 kV

40006

Terminal mean voltage

0 to 40 kV

40008

Terminal current

0 to 65 kA

40010

Frequency

0 to 200 Hz

40012

Power factor

-1.000 to 1.000

40014

Active power per phase

0 to 2100 MW

40016

Reactive power per phase

-2100 MVar to 2100 MVar

40018

Apparent power per phase

0 to 2100 MVA

40020

Three-phase active power

0 to 2100 MW

40022

Three-phase reactive power

-2100 MVar to 2100 MVar

40024

Three-phase apparent power

0 to 2100 MVA

40026

4 to 20 mA Analog input measurement

0 to 25 mA

40028

10 Vcc Analog input measurement

0 to 12 Vcc

40030

Excitation current

0 to 35 A

40034

Operating mode

0 = MECC

1 = MTVC

2 = DROOP

3 = MRPC

4 = MPFC

40038

Power voltage AC

0 to 275 Vac

40040

Power voltage BC

0 to 275 Vac

40042

Power voltage AB

0 to 275 Vac

40044

Power DC bar voltage

0 to 450 Vcc

40046

Excitation voltage

-350 to 350 Vcc

40048

Power temperature

0 to 200 °C

40050

Result setpoint

-2100 M to 2100 M

40052

Analog input setpoint

-100 to 100 % (Ref.)

40054

Digital input setpoint

-100 to 100 % (Ref.)

40056

Droop setpoint

-10 kV to 10 kV

40060

Soft-start input setpoint

0 to 100 % (Ref. MECC/MTVC)

40062

Duty cycle

-100 to 100 %

40064

Maximum excitation current

0 to 30 A

40066

Minimum excitation current

0 to 30 A

40068

U/F reference part

-100 to 0 % (Ref. MTVC)

Page 19

Quick Parameter Reference

ECW500 | 11

Modbus

Address

Description

Adjustable Range

Factory

Setting

Proper

40070

ECW500 CPU usage

0 to 100 %

40072

ECW500 CPU stack size

0 to 16383 bytes

40074

ECW500 CPU stack usage

0 to 16383 bytes

40076

Fundamental frequency of I

exc

0 to 500 Hz

40078

1st harmonic frequency of I

exc

0 to 500 Hz

40080

2nd harmonic frequency of I

exc

0 to 500 Hz

40084

Fundamental amplitude of I

exc

0 to 35 A

40086

1st harmonic amplitude of I

exc

0 to 500 % (fn)

40088

2nd harmonic amplitude of I

exc

0 to 500 % (fn)

40092

Excitation current (I

exc

) ripple

0 to 500 %

40112

Firmware version

0.00 to 99.99

40114

Analog Output Value

0.00 to 100.00 %

40116

MAC address byte 0 (MSB)

0 to 255

40118

MAC address byte 1

0 to 255

40120

MAC address byte 2

0 to 255

40122

MAC address byte 3

0 to 255

40124

MAC address byte 4

0 to 255

40126

MAC address byte 5

0 to 255

40128

Status relay condition

0 = Disabled, 1 = Enabled

40130

Fault relay condition

0 = Disabled, 1 = Enabled

40132

Condition of Relay 0

0 = Disabled, 1 = Enabled

40134

Condition of Relay 1

0 = Disabled, 1 = Enabled

40136

Condition of Relay 2

0 = Disabled, 1 = Enabled

40138

Condition of Relay 3

0 = Disabled, 1 = Enabled

40140

Serial Number

0 a 4294967295

Note: RO = Read only parameter

Page 20

Errors, Warnings and Events .

12 | ECW500

2 ERRORS, WARNINGS AND EVENTS

2.1 ERRORS

In order to avoid dangerous situations and damages to the synchronous machine, the regulator and other materials, the protections of the ECW500 may actuate to that certain physical limits will not be exceeded.

In this regard, an error is an improper condition of some signal or internal functionality that will be signalized in the general fault relay, so that the operator must take some action. When an error occurs, the ECW500 cannot be turned on until an alarm reset occurs. The most serious errors, as link overvoltage and fault on power switches, will shut down the ECW500.

The actuation of the errors occurs as follows:

■ the regulator is disabled by removing the firing signals from de power module;

■ the HMI (keypad) signalizes that there is an error present, and its code is registered on the events list;

■ the fault relay actuates (connectors 33 and 34).

In order to enable the ECW500 again and operate it normally, it is necessary to reset it, which can be done the following ways:

■ switching off the electronic power supply (connectors 37, 38 or 39, 40) and switching it back on (power-on

reset);

■ pressing the key on the HMI;

■ sending the command reset by the Modbus communication (address 11);

■ via specific connectors 64 and 65).

Table 2.1 Error list

ER000

Overvoltage in the power DC link

ER001

Fault on power switch S1

ER002

Fault on power switch S2

ER003

It was not possible to reset the power drive

ER004

Fault in the automatic calibration

ER005

Problem on the communication with the power board

ER006

Problem to initialize the parameters on the EEPROM

ER007

Problem to read the factory default from the EEPROM

ER008

Watchdog fault

2.2 WARNINGS

Warning messages indicate a condition occurred and that can lead to a dangerous situation. They do not stop the regulator, but it is necessary to correct the operation.

Page 21

Errors, Warnings and Events

ECW500 | 13

Table 2.2 Warning list

WR000

Digital input did not receive complementary command

WR001

Problem on the configuration of the digital inputs

WR002

Incorrect command of the parallel or online digital inputs

WR003

Parallel command received with the ECW500 off

WR004

No online mode configured, but online command received

WR005

Increment and decrement digital inputs simultaneously triggered

WR006

Calibration executed with the ECW500 on

WR007

Excitation disconnected

WR008

Phase loss at the power terminals

WR009

Internal overheating

WR010

Terminal overvoltage

WR011

Terminal undervoltage

WR012

Excitation overvoltage

WR013

Excitation overcurrent

WR014

Underfrequency

WR015

Received command to reset parameters with the ECW500 enabled

WR016

Alarm reset is missing to execute the command

WR017

Analog input cable 4 to 20 mA broken

WR018

Autotuning execution fail

WR019

MAC address problem

WR020 WR034

Reserved

WR035

Feedback loss

WR036

Rotating diodes fault

WR037

PxQ curve configuration problem

WR038

Anybus offline

WR039

Anybus fault

2.3 EVENTS

Events, on the other hand, are normal occurrences and not harmful to the system operation, as a mode transition, a received command and others.

Events are not indicated on the HMI, and only recorded in the event list.

Table 2.3 Event list

EV000

Excitation OFF

EV001

Excitation ON

EV002

Calibration of the analog input of +/-10 Vdc executed

EV003

Command of alarm reset received

EV004

Changed to MECC mode

EV005

LEOC limiter actuating

EV006

LEOC limiter stopped actuating

EV007

LUF limiter actuating

EV008

LUF limiter stopped actuating

EV009

Received command for resetting parameters to factory default

EV010

Calibration of the measurement of the excitation current executed

EV011

LTOC limiter actuating

EV012

LTOC limiter stopped actuating

EV013

Changed to MTVC mode

EV014

LEUC limiter actuating

EV015

LEUC limiter stopped actuating

EV016

Changed to online mode

EV017

Changed to parallel mode

EV018

Autotuning started

EV019

Autotuning finished with successful

EV020

Autotuning canceled by the user

EV021

Autotuning timeout

NOTE!

When a warning or error occurs, the HMI will periodically display the message "There are some warnings or errors" until an alarm reset is executed.

You can set how long this message appears and how long it is hidden in the HMI Configuration screen.

Page 22

Safety Instructions .

14 | ECW500

3 SAFETY INSTRUCTIONS

This manual contains information necessary for the proper use of the voltage regulator ECW500. It has been written to be used by qualified personnel with suitable training or technical qualification for operating

this type of equipment.

3.1 SAFETY WARNINGS IN THE MANUAL

The following safety notices are used in the manual:

DANGER!

The procedures recommended in this warning have the purpose of protecting the user against death, serious injuries and considerable material damage.

ATTENTION!

The procedures recommended in this warning have the purpose of avoiding material damage.

NOTE!

The information mentioned in this warning is important for the proper understanding and correct operation of the product.

3.2 SAFETY WARNINGS IN THE PRODUCT

The following symbols are attached to the product, serving as safety notices:

High voltages are present.

Components sensitive to electrostatic discharge. Do not touch them.

Mandatory connection to the ground (PE conductor).

Page 23

Safety Instructions

ECW500 | 15

3.3 PRELIMINARY RECOMMENDATIONS

DANGER!

Only qualified personnel familiar with the ECW500 and associated equipment should plan or implement the installation, start-up and subsequent maintenance of this equipment. These personnel must follow all the safety instructions included in this manual and/or defined by local regulations. Failure to comply with these instructions may result in life threatening and/or equipment damage.

NOTES!

For the purposes of this manual, qualified personnel are those trained to be able to:

1. Install, ground, energize and operate the ECW500 according to this manual and the effective legal safety procedures.

2. Use protective equipment according to the established standards.

3. Give first aid services.

DANGER!

Always disconnect the main power supply before touching any electrical device associated with the ECW500. Several components may remain charged with high voltage, even after the AC/DC power input is disconnected or turned off. Wait at least 20 minutes to guarantee the fully discharge of capacitors. Always connect the equipment frame to the grounding installation (PE) in the appropriate place for this purpose.

ATTENTION!

Electronic boards have components sensitive to electrostatic discharges. Do not touch directly on components or connectors. If necessary, touch the grounded metallic frame before or use an adequate grounded wrist strap.

NOTE!

Follow the installation guidelines described in chapter 5.

NOTE!

Chapter 10 contains a list with the procedure suggested to put the ECW500 into operation.

NOTE!

Read this manual thoroughly before installing or operating the ECW500.

Page 24

About the ECW500 .

16 | ECW500

4 ABOUT THE ECW500

4.1 ABOUT THE MANUAL

This manual contains information for the operation, configuration and start-up of the product ECW500 applicable to both synchronous machine operating as a motor (synchronous compensator) and as a generator. The main electrical features, standard functions and application of the ECW500 will be presented.

Due to the wide range of functions of this product, it may be used in applications different from those presented hereby. Neither does this manual aim at presenting all the possible applications of the ECW500, nor can the manufacturer take any liability for the use of the converter which is not based on this manual.

This manual can also be downloaded at WEG website www.weg.net.

4.1.1 Symbols Used

This section presents the definition of the symbols used in this manual to identify features of the ECW500.

Digital Input ON

Digital Input OFF

Digital Input Enable Parallel Operation

Digital Input Disable Parallel Operation

Digital Input Enable Online Operation

Digital Input Disable Online Operation

INC

Digital Input Increase Active Reference

DEC

Digital Input Decrease Active Reference

RST

Digital Input Reset Alarms

G/M

Generator/Motor

Not connected

Rectifier: Input circuit of the inverters which converts the AC input voltage into DC. It is formed by power diodes.

DC link: Intermediate circuit of the ECW500; continuous voltage obtained by rectifying the alternate power supply or through external source; supplies the IGBTs switches used to control the excitation of the synchronous machine.

Page 25

About the ECW500

ECW500 | 17

IGBT: Insulated Gate Bipolar Transistor; basic component of the output inverter bridge. Functions as electronic switches in saturated (switch closed) and cut off (open switch) modes.

HMI: human-machine interface; device that allows configuring, viewing and changing parameters of the ECW500; features command keys, navigation keys and graphic LCD display.

USB -andconcept.

PE: Protective Earth. PWM: Pulse Width Modulation; modulation by pulse width, pulsed tension that provides excitation for the

synchronous machine through the field output terminals.

Switching Frequency: switching frequency of the IGBTs, usually given in kHz. Heatsink: piece of metal designed to dissipate heat generated by power semiconductors. Amp, A: Amps. °C: degrees Celsius. AC: alternate current. DC: direct current. Hz: hertz. min: minute. rms: root mean square; effective value. rpm: revolutions per minute; unit of speed. s: second. V: volts.

: ohms.

IT: inverse time; term used to indicate the actuation time of the current limiters based on the inverse time characteristic (Ixt); the higher the current that exceeds the limit set, the lower the actuation time of the relevant limiter.

NO: Normally Open NC: Normally closed Numerical multipliers

■ k (quilo): x1.000 (x10

)

■ M (mega): x1.000.000 (x10

)

■ G (giga): x1.000.000.000 (x10

)

■ m (mili): ÷1.000 (x10

-3

)

■ (micro): ÷1.000.000 (x10

-6

)

■ n (nano): ÷1.000.000.000 (x10

-9

)

4.2 SOFTWARE VERSION

The software version used on the ECW500 defines the functions and programming parameters, and it can be updated during the product lifecycle.

Page 26

About the ECW500 .

18 | ECW500

This manual refers to the software version as indicated on the back cover. For instance, the version 1.0X means

are that do not affect the content of this manual.

The version installed on the ECW500 can be checked on the HMI in the path "Menu -> Measures -> OS/FW Information" or by the Modbus 40112 address.

4.3 CHARACTERISTICS

The Voltage Regulator ECW500 is a high performance product intended to drive synchronous machines with brushless excitation, for variation and control of its terminal voltage, excitation current, reactive power or power factor.

Among its main characteristics, we may point out:

■ Keypad with 2.

■ Five control modes

- MTVC Terminal Voltage Control Mode

- MECC Excitation Current Control Mode

- MTVC_DROOP Voltage Control Mode with Reactive Droop

- MPFC Power Factor Control Mode

- MRPC Reactive Power Control Mode

■ Start ramp for MTVC and MECC modes

■ )

■ Limiter LUF to compensate underfrequency operating on modes MTVC and MTVC_DROOP

■ Other 3 limiters operating in all control modes (except in the MECC mode)

- LEOC Excitation Over Current Limiter

- LEUC Excitation Under Current Limiter

- LTOC Terminal Over Current Limiter

■ PID stability sets for MTVC mode and PI for the other modes

■ Protections that can turn the unit off or switch to MECC mode according to configuration:

- Underfrequency protection

- PFL Protection Feedback Loss

- PED Protection Excitation Diodes

- Protection against overtemperature in the power module

- PEOC Protection Excitation Over Current

■ Protections that can be warned on the relays:

- PTOV Protection Terminal Over Voltage

- PTUV Protection Terminal Under Voltage

- PEL Protection Excitation Loss

- PEOV Protection Excitation Over Voltage

■ Datalog of up to 128 events, warnings and errors with date and time log

■ An analog input +/-10 Vdc or 4 to 20 mA to actuate in reference of all operating modes with adjustable gain

The block diagram below provides a general view of the ECW500 set:

Page 27

About the ECW500

ECW500 | 19

Figure 4.1 Simplified block diagram of the ECW500

4.4 LABEL INFORMATION

The identification label of the product, located on the side of the regulator, contains important information about its model, such as voltage and current ranges allowed for operation.

Page 28

About the ECW500 .

20 | ECW500

Figure 4.2 Identification label

4.5 HUMAN MACHINE INTERFACE (HMI)

Through the HMI of the product is possible to perform the command and configuration of the regulator, since this interface gives access to all parameters. It has intuitive form of navigation, with the option of parameter access via menus.

Figure 4.3 Description of the buttons

4.5.1 Keys

The navigation keys include the navigation buttons ▲ / ▼ and the left and right menu buttons. The ▲ e ▼ navigation buttons are used for both navigating through the menus and increasing and decreasing the values of variables. The functions of the left and right menu vary according to the indication made on the LCD.

The buttons Turn on and Turn off can be configured to not operate, if is desired that operation be performed only by external controls.

The alarm reset button (RST) is always available.

Date code

Serial number

Operating temperature

Electronics Power Supply

Output Power

Power Supply

Voltage Feedback

Current Feedback

Output Relays

Digital Inputs

Product Certifications

Page 29

About the ECW500

ECW500 | 21

4.5.2 Installation

The keypad (HMI) can be installed or removed with the regulator powered up or down. It can also be used for remote control of the product through specific cable.

For this connection mode, use:

■ cable with D-Sub9 (DB9) male and female connectors with pin to pin connection (mouse extension or Null-

Modem type, market standard);

■ maximum length of 10 meters.

4.5.3 Battery

In order to keep the operation of the internal clock while the regulator is powered down, the keypad (HMI) of the ECW500 has a battery.

If the battery is low or if it is not installed on the HMI, the clock time will be invalid. In this case, replace the battery for a new one of the same model (CR2032), according to the procedure

presented in Figure 4.4.

Figure 4.4 HMI battery replacement

NOTE!

The life expectation of the battery is of approximately 10 years. At the end of the useful life, do not dispose of the battery in common garbage, but in a proper place for batteries.

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Installation and Connection .

22 | ECW500

5 INSTALLATION AND CONNECTION

5.1 RECEIVING AND STORAGE

On the outside of the ECW500 package there is a label similar to the label that is affixed on the side of the product.

Make sure the ECW500 identification label corresponds to the model purchased or if there were any damages during transport. If any problem is detected, contact the carrier immediately.

If the ECW500 is not installed soon, store it in a clean and dry location (temperature between -40 F and 185 F), with a cover to prevent dust accumulation inside it.

5.2 MECHANICAL INSTALLATION

5.2.1 Environmental Conditions

The location of the voltage regulator is determinant for its proper operation and normal useful life of its parts. Thus, it is recommended to avoid installing it in the following conditions:

■ direct exposure to sunlight, rain, high humidity or sea-air;

■ explosive or corrosive liquids or gases;

■ excessive vibration;

■ dust, metallic particles or oil mist.

Accepted operating and environmental conditions:

■

Temperature:

- -40 °C to 50 °C (-40 F to 122 F) rated conditions;

- 50 ºC to 60 ºC (122 F to 140 F) 2 % of current derating for each Celsius degree above 50 ºC;

■ Air relative humidity: 10 % to 90 % non-condensing;

■

Altitude:

- 0 to 1000 m rated conditions;

- 1000 m to 4000 m 1 % current derating for each 100 m above 1000 m;

■

Pollution degree:

2 (according to EN50178 and UL508C), with non-conductive pollution. Condensation must

not originate conduction through accumulated residues.

5.2.2 Positioning and Mounting

The ECW500 should be mounted inside electrical panels and can be positioned both horizontally and vertically. Furthermore, we recommend following the instructions below:

■ keep a minimum clearance of 60 mm on all sides of the regulator in relation to the walls of the panel;

■ do not put sensitive component parts right above the regulator;

■ if mounting a regulator next to another, use the minimum distance of 120 mm;

■ if mounting a regulator above another, use the minimum distance of 120 mm and deflect the hot air coming

from the lower regulator;

■ drill the mounting holes according to Figure 5.1;

■ provide independent conduits or gutters for physical separation of the signal, control and power conductors

(refer to section 5.3 Electrical Installation), also separating the machine cables from the other cables.

NOTE!

For regulators installed inside cabinets or metal boxes, provide proper exhaustion, so that the temperature remains within the allowed range.

Page 31

Installation and Connection

ECW500 | 23

Figure 5.1 Front and back view with dimensions

Figure 5.2 Left and right side views of ECW500

Page 32

Installation and Connection .

24 | ECW500

5.3 ELECTRICAL INSTALLATION

DANGER!

A device must be provided to disconnect the power supply from the regulator, and it must be opened before beginning any connections.

DANGER!

The ECW500 must not be used as an emergency stop device.

ATTENTION!

The following information is merely a guide for proper installation. Comply with applicable local regulations for electrical installations.

ATTENTION!

For technical information of the ECW500, refer to chapter 12.

Page 33

Installation and Connection

ECW500 | 25

Figure 5.3 Typical connections of the ECW500.

5.3.1 Power and Grounding Wiring

The use of wiring with gauges suitable for the regulator is essential to prevent damages to the installation and equipment.

Thus, the following Table 5.1 presents the minimum recommended values for cables to connect the power circuit and also for the protection conductor (PE), based on NBR 5410 standard.

ATTENTION!

When flexible cables are used for the power and grounding connections, proper terminals must be used.

Page 34

Installation and Connection .

26 | ECW500

ATTENTION!

Sensitive equipment, such as PLCs, temperature controllers and thermocouple cables must be placed at least 25 cm away from the cables between the regulator and the machine.

Table 5.1 Recommended Wiring for Power and Grounding Connection, as per NBR 5410

Input Cables

(P-A / P-B / P-C)

Output Cables

(F+ / F-)

Grounding Wiring

(PE)

4 mm2

4 mm2 (terminal 48)

1,5 mm2 (terminal 19)

NOTE!

The values of Table 5.1 are only valid in the following conditions:

■ copper cables with PVC 70°C (158 F) insulation;

■ maximum ambient temperature of 50°C (122 F);

■ installation in vertical or horizontal perforated channels;

■ arrangement of the cables in a single layer.

For installation in other conditions, refer to NBR 5410.

NOTE!

The output wiring of the regulator (F+ / F-) must be installed separately from the input power wiring (P-A/P-B/P-C), as well as from the control and signal wiring.

5.3.2 Protection Fuses

In order to protect the product against short circuit, ultra fast fuses must be used at the regulator input, dimensioned according to the current and to the maximum of the power I2t semiconductors.

Figure 5.4 Configuration of the elements for the protection of the input circuit of the ECW500.

Table 5.2 Recommended Fuses for the Protection of the Input Circuit of ECW500 (AC side)

Fuse

Rated

Current

[A]

Maximum I2t

[A2s]

WEG Model

Part-number

Code

1.200

FNH00-20K-A

10687494

ATTENTION!

Fuses must not be used at the output circuit of ECW500 (F+ / F-).

ECW500

fuses

P-A

P-B

P-C

F-

F+

Page 35

Installation and Connection

ECW500 | 27

5.3.3 Grounding Connection

The ECW500 must be connected to a protection grounding (PE). In order to do so, observe the following:

■ use a minimum wire gauge equal to the indicated in Table 5.1. If local standards require different gauges,

they must be observed;

■ connect the regulator grounding point to a specific ground rod, or to the exclusive or general grounding point

The supply lines allowed for use with the ECW500 are those of the TN or TT (IEC) type. The connection of lines of the IT type is also possible, since it is grounded via impedance.

ATTENTION!

The neutral conductor of the line that feeds the regulator must be solidly grounded; however, it must not be used to ground the product.

DANGER!

Do not share the grounding wiring with other equipment that operate at high currents (e.g., high power motors, welding machines, etc.). When several regulators are used, follow the procedure shown in Figure 5.5 for the grounding connection.

NOTE!

The frame of the synchronous machine driven by the ECW500 must always be grounded. The machine must be grounded in the panel where the regulator is installed, or on the regulator itself.

NOTE!

When the electromagnetic interference generated by the regulator is an issue for the other equipment, use shielded wires or wires protected by metal conduit for the output connection of the product (F+/F-), connecting the shield at each end to the grounding point of the regulator and to the synchronous machine frame.

Page 36

Installation and Connection .

28 | ECW500

Figure 5.5 Grounding connection for more than one ECW500

5.3.4 Control Connections

The control connections of the ECW500 (analog inputs/output, digital inputs/outputs) are made at terminals 1 to 36 and 52 to 75, located at the side of the product.

The typical control functions and connections are shown in Figure 5.6.

Grounding bar inside the

panel

Page 37

Installation and Connection

ECW500 | 29

Terminal

Function

Specifications

Not used

GND

Reference 0V for the serial port RS485/422

Communication serial port RS 485 / 422 Full duplex / half duplex 9600 bps to 115200 bps, 8 bits Modbus RTU

TxB

Transmission and reception signals for the communication in full duplex mode

TxA 5 RxB

Transmission and reception signals for the communication in half duplex mode

RxA

Digital input Turn On Excitation

Isolated Digital Inputs High Level:  8Vdc Low Level:  3Vdc Maximum input voltage: 30Vdc Input current: 11mA @ 24Vdc

Digital input Turn Off Excitation

AO+

Analog output

Isolated analog output Resolution: 14 bits Signal: 0 to +10V (RL  10k) 4 to 20mA (RL  500)

AO-

MTVC

Digital input MTVC Mode

Isolated Digital Inputs High Level:  8Vdc Low Level:  3Vdc Maximum input voltage: 30Vdc Input current: 11mA @ 24Vdc

MECC

Digital input MECC Mode

I+

Analog input (current)

4 to 20 mA (RIN = 249) Resolution: 12 bits

I-

19 Protective earth (PE)

Conectado diretamente à carcaça do produto

V-

Analog input (voltage)

Differential measurement from 0 to ± 10V (RIN = 200k) Resolution: 11 bits + signal

V+

E3/C

Input for measurement of phase voltage C

Rated voltage for measurement: 600 Vac Maximum voltage for measurement: 660 Vac

E2/B

Input for measurement of phase voltage B

E1/A

Input for measurement of phase voltage A

RL03

Digital output 3 (RL03) Programable

6 relay outputs Rated voltage of contacts: 250Vac Maximum voltage for commutation: 400Vac Rated current: 8 A

Maximum capacity for commutation: 35 Vdc 8 A

48 Vdc 1,2 A 125 Vdc 0,3 A

RL02

Digital output 2 (RL02) Programable

RL01

Digital output 1 (RL01) Programable

RL00

Digital output 0 (RL00) Programable

RL FL

Digital output General Fault

RL ST

Digital output Status ECW500

Digital input Disable Parallel Operation

Isolated Digital Inputs High Level:  8V Low Level:  3V Maximum input voltage: 30V Input current: 11mA @ 24Vdc

Digital input Disable Online Operation

HB Rx

Signals for the backup channel function (function not available on this version)

HB Tx

+Vcc

12Vdc power supply

12 Vdc Power Supply, ±10% Capacity: 200mA

GND

Reference 0V to the 12 Vdc power supply

TxA

Signals of the serial communication for the backup channel function (function not available on this version)

TxB

RxA

RxB

RST

Digital input Reset

Isolated Digital Inputs High Level:  8V Low Level:  3V Maximum input voltage: 30V Input current: 11mA @ 24Vcc

INC

Digital input Increase

DEC

Digital input Decrease

Digital input Enable Online Operation

Digital input Enable Parallel Operation

PRE

Digital input Pre-position

Figure 5.6 Control connections for the ECW500

Page 38

Installation and Connection .

30 | ECW500

For the correct installation of the control wiring, use:

■ cables from 0.5 mm

(20 AWG) to 1.5 mm2 (14 AWG);

■ maximum torque of 0.5 N.m (4.50 lbf.in);

■ shielded cables separate from the other wiring (power, control in 110Vac/220Vac, etc.) according to Table

5.3. If the crossing of those cables cannot be avoided, it must be done perpendicularly between them, keeping the minimum separation distance of 5 cm at the crossing point.

The shield connection of the cables must also observe the form presented in Figure 5.7.

Table 5.3 Separation distances between control wiring and other wiring

Wiring Length

Minimum Separation

Distance

 30 m

10 cm

> 30 m

25 cm

Figure 5.7 Correct form of connection of the control cable shield

NOTE!

Relays, contactors, solenoids or coils of electromechanical brakes installed close to the converter may occasionally generate interference in the control circuit. In order to eliminate this effect, RC suppressors must be connected in parallel to the coils of those devices (in case of DC power supply, make the connection in parallel with the freewheel diodes).

Page 39

Functional Description .

ECW500 | 31

6 FUNCTIONAL DESCRIPTION

6.1 PARAMETER STRUCTURE IN HMI

In order to facilitate the setting and monitoring tasks, the ECW500 parameters are arranged in groups divided into up to four different levels, as is shown in Table 6.1.

The initial screen displayed by the HMI of the ECW500 after the initialization shows the main variables of the synchronous machine, in addition to the regulator status and the current operating mode.

Figure 6.1 Initial screen displayed by the HMI of the ECW500

From this screen, after pressing the right menu key, the first level of the group structure is shown on the display, and it is possible navigate through other groups using the keys   .

Full navigation tree to all screens is illustrated in Figure 6.2.

Main Measures Screen

Op. State: MTVC

ECWStatus: off

Curr. B : 0 A

V mean : 0 V

12:00 Menu

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Functional Description .

32 | ECW500

Table 6.1 Parameter group structure of the ECW500 V1.3X

Level 0

Level 1

Level 2

Level 3

Level 4

Main

Measures

Screen

Main

Measures

General Screen

Machine Voltage/Current

Machine Power

Machine Field

ECW Power Module

Aux. Inputs/Outputs

Control Variables

Limiters Status

Digital I/O Status

Dig. Input Status p1

Dig. Input Status p2

Dig. Output Status

OS/FW Information

Control Config

Operating Modes

Setpoints Config

Setpoints

Setpoints Max/Min

Control Gains

MTVC Gains

MECC Gains

MRPC Gains

MPFC Gains

Limiters

LUF-Underfrequency

LEOC-Exc. Overcurrent

LEUC-Exc. Undercurrent

LEUC-PxQ Points

LTOC-Term. Overcurrent

Soft Start Config

Protections

PFL-Feedback Loss

PEOV-Field Overvoltage

PEOC-Field Overcurrent

PED-Excitation Diodes

PEL-Excitation Loss

Power Module

PTOV-Term. Overvoltage

PTUV-Term. Undervoltage

System Rated Param.

Machine Parameters

Current Transformer

Voltage Transformer

ECW Configuration

Digital Inputs

Transition Type 1-6

Transition Type 7-13

Other Configuration

Digital Outputs Relays

Status Relay

General Failure Relay

Relay 0 page 1 and 2

Relay 1 page 1 and 2

Relay 2 page 1 and 2

Relay 3 page 1 and 2

Analog Input

Analog Output

HMI

Auto Calibration

Time and Date

Password

Communication

RS-485 / RS-422

Anybus

Anybus Status

Anybus Configuration

Mapped Parameters

Ethernet

IP Address/Mask/Gate

Modbus Node

Ethernet Status

MAC Address

Autotuning

Command Screen

Dual Channel Mode1

Event List

Feature not available on this version.

Page 41

Functional Description .

ECW500 | 33

Figure 6.2 Full navigation tree of parameters through HMI

6.1.1 Measurement Screens

The measurement screens have the profile shown below. In each line, there is a variable with its description, a number with 4 digits and a comma and then the measurement unit. On the measurement screen, the only available button is the return to the previous screen (Back).

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Functional Description .

34 | ECW500

Figure 6.3 Measurement screens

6.1.2 Edition Screens

The layout of the edition screens is shown below. Each line has a parameter with its description, its value also with 4 digits plus comma and the unit. Initially the cursor takes the entire line, indicating only the selection of line navigation. When the right menu key is pressed, corresponding to the Edit command, the HMI enters the edition mode and the cursor takes only the field of the value with the unit.

Figure 6.4 Edition screens

In the editing mode, the navigation keys are used to increase and decrease the value shown. The value step to increment/decrement varies according to the parameter and the value shown, and is done as follows:

■ If the value on the screen is much higher than the increment so that the regular variable increment step listed

in the table is not visible on the digits displayed, then the increment will be done in the least significant digit. Example: With an increment in the parameter table of 0.001 and a variable shown with a value of 999.0, its increment would result in 999.001 that would not be shown on the screen, since it has six digits. In this case the real increment will be 0.1, which is the least significant digit, resulting in 999.1.

■ For values with visible increment, i.e., close to the minimum, the ECW uses the increment value of the

parameter shown in the parameter table. Example: With increment of 0.1 and a value shown of 1.000, the decrement must result in 0.900.

■ If you keep the increment key pressed, after a few seconds a multiplier will be added to the increment in two

stages. For this, there are three multiplying variables on the configuration screen of the HMI: 30086, 30088 e

30090.

■ For a list of special values (true /false, for example), the user will see only the description of the value. To

check the number relative to that configuration, see the table of parameters.

6.1.3 Event Screen

The event screen is a special viewing screen that shows the last 12 events2 recorded by the ECW500. On this screen the events are listed in order of occurrence, with the most recent event shown in the first line of the first page.

To display the date and time of occurrence of the events it is necessary to press the right menu key "Ti/Da", as shown in Figure 6.5.

Through serial communication it is possible to access all the 128 available events.

Page 43

Functional Description .

ECW500 | 35

Figure 6.5 Event screen

6.1.4 Password Screen

The password screen allows the user to enable, disable or change the password on the equipment. With the password enabled, it is not allowed editing any parameter. If there is an attempt to perform an edition, the HMI will automatically display the password screen for punching in the correct password. The sequence of screens for entering the password is shown in the following figure. After entering the correct password, the text of the fourth line confirms with the message "access granted".

Figure 6.6 Sequence of screens to enter the password

In order to change the password, the user must edit the new password parameter in the second line with access granted. The sequence of screens below shows the password changed to value 5. After punching in the new password in line 2, the HMI automatically goes to line three prompting the confirmation of the entered value. If confirmed, the new password is already effective and the access is blocked.

Figure 6.7 Sequence of the screens to change the password

If the password protection is not desired, the user can disable the function by entering a new password and selecting the value "disabled" (equivalent to number zero). After confirming the new password, the message "Password disabled" will show in the fourth line.

Figure 6.8 Sequence of screens to disable the password

Page 44

Functional Description .

36 | ECW500

NOTE!

The factory default password is 2.

6.2 DIGITAL INPUTS

The ECW500 has eleven (11) specific isolated digital inputs that allow full control of the equipment through this physical interface.

The initial logical status of the digital inputs is zero (off), and for a digital input switches to logic state one (on) it requires that a voltage between 8 Vdc and 30 Vdc be applied. There is no polarity in the connection of the digital inputs.

There are three operating modes for the digital inputs:

■

Pressed Button Mode

: In this operating mode, the state of the digital input is switched from OFF to ON when a voltage is applied to the digital input terminals, checking the leading edge of the pulse. Once activated, this digital input has no longer effect until the function is switched by its complementary input.

Figure 6.9 Transition necessary at the digital inputs on the Pressed Button Mode

■

Released Button Mode

: In this operating mode, the status of the digital input is switched from OFF to ON when a voltage is applied to the digital input terminal and then removed, i.e., in the falling edge of the pulse. Just applying the voltage to the digital input without removing it has no effect. Once activated, this digital input has no longer effect until the function is switched by its complementary input.

Figure 6.10 Transition necessary at the digital inputs on the Released Button Mode

■

Maintained Button Mode

: In this operating mode of the digital input, the pair functions ON/OFF, MTVC/MECC, ENABLE PARALLEL/DISABLE PARALLEL, ENABLE ONLINE/DISABLE ONLINE work with complementary command. Both digital inputs of each pair must be configured for Maintained Button mode; otherwise, a fault warning will be generated. The pair digital inputs in the maintained button mode must never be at the same logical level, i.e., when one has voltage applied, its pair must have voltage zero at its terminals. For example, in order to enable the ECW500, a voltage must be applied simultaneously according to specification to the digital input ON and zero volts to the digital input OFF. If a voltage is applied to both inputs or zero volt is applied to the two digital inputs, a fault warning will be generated.

Page 45

Functional Description .

ECW500 | 37

Figure 6.11 Transition necessary at the digital inputs on the Mantained Button Mode

6.2.1 ON Digital Input

The ON digital input is used to enable the excitation of the ECW500, making it run in the pre-configured operating mode.

6.2.2 OFF Digital Input

The OFF digital input is complementary to the ON input and it is used to disable the excitation of the ECW500. The OFF command has priority over the ON command.

6.2.3 MTVC Digital Input

The MTVC digital input is used to change the operating mode of the ECW500 to MTVC (Mode: Terminal Voltage Control).

6.2.4 MECC Digital Input

The MECC digital input is complementary to the MTVC input and it is used to change the operating mode of the ECW500 to MECC (Mode: Excitation current Control). The MECC command has priority over the MTVC command.

6.2.5 ENABLE PARALLEL Digital Input

The ENABLE PARALLEL digital input is used to change the operating mode of the ECW500 to MTVC DROOP (Mode: Terminal Voltage Control with DROOP). It can be used in a complementary way to the DISABLE PARALLEL digital input in Maintained Button mode. It only runs if the ECW500 is enabled. If the ECW500 is disabled and this input is activated, a fault warning is generated.

6.2.6 DISABLE PARALLEL Digital Input

The DISABLE PARALLEL digital input is complementary to the ENABLE PARALLEL input and it is used to disable the online mode or parallel mode and puts the ECW500 into the MTVC or MECC mode, according to the previous configuration of the offline operating mode. It can be used as in a complementary way to the ENABLE PARALLEL digital input in the Maintained Button mode.

If the ECW500 is running in the online MPFC or MRPC modes and the DISABLE PARALLEL digital input is activated, the ECW500 will directly go to the offline MTVC or MECC mode according to the previous configuration. If the digital inputs of the parallel and online mode are configured to run in the "button maintained", the disable command must be executed in both the disable online input and disable parallel digital inputs.

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Functional Description .

38 | ECW500

6.2.7 ENABLE ONLINE Digital Input

The ENABLE ONLINE digital input is used to change the operating mode of the ECW500 for the online MPFC modes (Mode: Power Factor Controller) or MRPC (Mode: Reactive Power Controller), according to the previous configuration of the online operating mode. It can be used in a complementary way to the DISABLE ONLINE digital input in the Maintained Button mode.

For the regulator to pass to the online MPFC or MRPC mode directly from the MTVC or MECC modes, it is necessary that both ENABLE ONLINE and ENABLE PARALLEL digital inputs be activated simultaneously. If only the ENABLE ONLINE input is activated, no action will be taken by the ECW500 in these modes. If the regulator is operating in the parallel mode (MTVC_DROOP), simply activate the ENABLE ONLINE digital input to enter the online MPFC or MRPC modes.

6.2.8 DISABLE ONLINE Digital Input

The DISABLE ONLINE digital input is used to disable the online MPFC or MRPC operating mode of the ECW500.

If the ECW500 is operating in the online MPFC or MRPC modes and the DISABLE ONLINE digital input is activated once, the ECW500 will go first to the parallel MTVC DROOP mode. If this same input is activated for the second time, the ECW500 will go to the off-line MTVC or MECC mode according to the previous configuration. The DISABLE ONLINE digital input can be used as in a complementary way to the ENABLE ONLINE digital input in the "Maintained Button" mode.

6.2.9 INCREMENT Digital Input

The INCREMENT digital input is used to increment the reference in any of the operating modes. The portion to be increased is the same one set as default reference increment of the selected operating mode on the ECW500. This increment can be increased by means of a multiplier valid for all modes also configurable on the configuration screen of the digital inputs (parameter 30204). For example, if the ECW500 is operating in the MTVC mode, each increment in the voltage reference will be 0.1 V times the multiplier. Each time the ECW500 is disabled or an exchange of operating mode occurs, the internal variable that controls how much increment is added to the reference of the mode is reset to zero. The increment value can be set before enabling the ECW500.

For the INCREMENT digital input, the action of the control in the Maintained Button mode is different from the complementary functions. When operating in this mode, while keeping the voltage applied to the digital input, the increment in the reference will occur continuously until the voltage applied to the digital input is removed or until the maximum increment value is reached, which is equal to the rated value of the synchronous machine configured on the ECW500.

NOTE!

This digital input has no complementary relationship with the DECREMENT digital input. However, if the INCREMENT digital input is activated simultaneously with the DECREMENT, a fault warning will be generated and the reference will not suffer modifications.

6.2.10 DECREMENT Digital Input

The DECREMENT digital input is used to decrease the reference in any of the operating modes. The portion to be decreased is the same one set as the default reference decrement of the selected operating mode on the ECW500. This decrement can be increased by means of a multiplier valid for all modes also configurable on the configuration screen of the digital inputs (parameter 30204). For example, if the ECW500 is operating in the MTVC mode, each decrement in the voltage reference will be

0.1 V times the multiplier. Each time the ECW500 is disabled or an exchange of operating mode occurs, the internal variable that controls how much decrement is subtracted from the reference of the mode is reset to zero. The decrement value can be set before enabling the ECW500.

For the DECREMENT digital input, the action of the control in the Maintained Button mode is different from the complementary functions. When operating in this mode, while keeping the voltage applied to the digital input,

Page 47

Functional Description .

ECW500 | 39

the decrement in the reference will occur continuously until the voltage applied to the digital input is removed or until the minimum increment value is reached, which is equal to the rated value of the synchronous machine configured on the ECW500.

NOTE!

This digital input has no complementary relationship with the INCREMENT digital input. However, if the DECREMENT digital input is activated simultaneously with the INCREMENT, a fault

warning will be generated and the reference will not suffer modifications.

6.2.11 ALARM RESET Digital Input

This input resets the active alarms on the ECW500.

6.3 ANALOG INPUTS

The ECW500 has two isolated analog inputs which can be used to actuate in the reference of each mode of operation or as a feedback signal for the MECC mode. For using the analog signal as reference, it is necessary to adjust the parameter 31048 in option 1 (Analog Input) or in the option 2 (Parameter + Analog Input).

These inputs accept signals in voltage (± 10 V) or current (4 mA to 20 mA), with specific terminals for each signal type (V+/V- and I+/I-), but only one of the signals can be used to act in the reference. Signal type selection to be used must be made via parameters 31054 and 31056, which define the function of each analog input.

When the current input is selected, the ECW500 internally calculates a voltage equivalent in the scale from -10 to +10 V. The calculation is made based on the following equation3:

   󰇛





 󰇜

In the MTVC or MTVC DROOP mode, the reference value that may be obtained through the analog input is related to the rated voltage of the machine and is calculated by the relation below:





 󰇛











 



󰇜  



In which:

MTVCAI

Gain

is the gain parameter for the analog input in the MTVC mode (parameter 30248);

measuredAIV_

is the measured voltage at the analog input (parameter 40028);

rated

is the rated voltage of the synchronous machine set on the ECW500 (parameter 30058);

AI_MTVC

Offset

is the voltage

offset

that can be added to the reference value (parameter 31068).

In the MECC mode, the reference value corresponding to the analog input can be between 0 and 100% of the nominal excitation current, according to the equation:





 











 



In which:

MECCAI

Gain

is the gain parameter for the analog input in the MECC mode (parameter 30250);

On the MECC mode, the equivalent voltage calculation is done considering only the positive range (0 to + 10V). In that case the equation

for the conversion is as follows:    󰇛



 󰇜

Page 48

Functional Description .

40 | ECW500

measuredAIV_

is the measured voltage at the analog input (parameter 40028);

ratedEXCI_

is the rated excitation current of the synchronous machine set on the ECW500 (parameter 30066).

NOTA!

In the MECC mode, calculation of the reference by analog input only considers positive values of the measured voltage. Negative values will result in a reference of 0A.

In the MRPC mode, the reference value that may be obtained through the analog input varies from -100% to +100% compared to the rated voltage of the machine, in accordance with the following equation:





 











 



In which:

MRPCAI

Gain

is the gain parameter for the analog input in the MRPC mode (parameter 30252);

measuredAIV_

is the measured voltage at the analog input (parameter 40028);

rated_3ph

is the three-phase rated apparent power of the synchronous machine set on the ECW500 (parameter

30068). And in the MPFC mode, the value of the reference via analog input can be adjusted between -1.00 and 1.00,

according to the following equations:





   󰇛











󰇜 



 



 





   󰇛











󰇜 



 



 

In which:

MPFCAI

Gain

is the gain parameter for the analog input in the MPFC mode (parameter 30254);

measuredAIV_

is the measured voltage at the analog input (parameter 40028).

In the MECC mode it is possible to use one of the analog inputs as a feedback signal. For this it is necessary to change the parameter 31028 (External Power Module) to 1. Parameter 30256 (Full Scale for Excitation Current) must be set to the value in Amps represented by the full scale of the analog output (10V or 20mA). Further detailing of this functionality is presented on section 6.5.3.

NOTE!

If the PLCI (protection of the current input loss) is enabled and its reading falls below 3.5 mA, the ECW500 will indicate broken wire failure. In this case, if the External Power Module parameter is set to 1 the regulator will shut down. If the analog input is not in use, you must disable this protection to prevent the error message from being displayed.

NOTE!

There will be no influence from the analog input in the reference if the parameter 31048 is set to option 0 (Parameter)

Page 49

Functional Description .

ECW500 | 41

6.4 ANALOG OUTPUT

On hardware versions equipped with the electronic board ECWCC1, the ECW500 offers an analog output with 14 bits of resolution which can be configured as voltage (0 to +10 V) or current (4 to 20 mA) through parameter 31060 (Analog Output Signal). The output value, in voltage or current, represents a specific variable of the system calculated in percentage, with 100% indicating that the value has reached the full scale of the variable. To select the variable represented on the analog output set parameter 31062 according to the table below.

Table 6.2 Variable represented and full scale for each configuration of the analog output

Option in

31062

Variable Represented

Parameter of the Displayed

Variable

Full Scale

(10 V or 20 mA)

Duty Cycle

40062

100%

Terminal Voltage

40006

1.2 x 30058

Terminal Current

40008

1.1 x 30060

Power Factor

40012

(special)4

Active Power

40020

30068

Excitation Current

40030

1.2 x 30066

Reactive Power

40022

30068

You can apply a gain to adjust the variable through the parameter 31058 (0 to 99.99).

6.5 OPERATION MODES

The ECW500 has five operating modes plus the Off state. They are described below.

6.5.1 OFF

In this mode, the regulator executes all the signal measurements, but it does not apply voltage to the excitation output terminals. It is possible to shut down the regulator from all modes presented below. However, from this mode it is only possible to go to the MTVC and MECC.

6.5.2 MTVC (Automatic)

(Mode: Terminal Voltage Control) In the MTVC mode, the ECW500 controls the excitation so as to ensure that the voltage at the terminals of the synchronous machines follows the voltage reference. In this mode, the machine operates out of the network (offline), acting in an isolated way. It is possible to go from the MTVC mode to all other operating modes.

6.5.3 MECC (Manual)

(Mode: Excitation current Control) In the MECC mode, the ECW500 controls the excitation current of the synchronous machines regardless the terminal voltage of the machine. In this mode, the machine operates out of the network (offline), acting an isolated way.

The MECC mode has a function to enable the internal reference follower (parameter 30246). This function enables the transition of other modes to the MECC in a smooth way because the value of the excitation current is copied as reference for the MECC mode.

In this mode it is also possible to operate with external feedback for the excitation current, giving the ECW500 the ability to control machines with nominal excitation above 20A. To use this feature, set parameter 31028 (External Power Module) to 1 (enabled) and choose which of the analog inputs will be used as feedback: the one in voltage (31054 = 1) or the one in current (31056 = 1). The control signal for driving an external source will be sent through the analog output (terminals 11 and 12) by setting parameter 31062 (Analog Output Function) to 0 (Duty Cycle).

Another setting required to operate with external feedback is the value of Full Scale for Excitation Current (parameter 30256), which is used to calculate the excitation current from the read value at the analog input. The calculation of the excitation current on this configuration is shown below, in which the first equation is used for the input in voltage and the second one for the input in current.

The representation of the power factor through the analog output is made in a special way. A lagging power factor will be represented by a value between 0 and the half of the scale (0 V to 5 V or 4 mA to 12 mA). On the other hand, a leading power fator will be represented by a value between the half and the end of the scale (5 V to 10 V or 12 mA to 20 mA).

Page 50

Functional Description .

42 | ECW500





 















 





󰇛



 󰇜



In which:





is the measured voltage at the analog input (40028)





is the current measured at the analog input (40026).





is the full scale adjusted (30256).

NOTE!

With the paramater 31028 enabled the ECW500 will not generate any DC voltage at the output (terminals 49 and 50, F+ / F-) while in operation (status On .

6.5.4 MTVC_DROOP

(Mode: Terminal Voltage Control with DROOP) In this mode, the ECW500 operates in the load compensation mode, based on reactive power that the synchronous machine is generating or absorbing. To do this, an impedance is simulated at the machine terminals and the voltage is regulated in point inside or outside of the synchronous machine. In this mode, the operation is always in parallel with the network (online) or in parallel with a generator set.

Two compensation modes are available: droop and line-drop compensation. In the droop mode, the reference voltage is reduced considering the increase of the reactive power at the

output of the synchronous machine. On the other hand, in the line-drop compensation mode, the ECW500 regulates the voltage in a point outside the machine, in the step-up transformer or even in a point along the transmission system. The compensation produces an increasing reference voltage for the increase of the reactive power at the output of the machine.

For operation on MTVC DROOP mode, the user must adjust the compensation constant of this mode (parameter 30216), which is a percentage value of the nominal power of the machine. When the compensation constant is positive, the droop compensation is performed. When it is negative, the line drop compensation is active.

The equation below shows the value of voltage Droop that will be subtracted from (or added) of (to the) main reference.





 











  













In which:

DROOP

is the compensation constant of the droop/line-drop modes (30216);

rated

is the rated voltage of the synchronous machines (30058);

rated

is the rated current of the synchronous machine (30060);

measured

is the measured single-phase reactive power (40016);

measured

is the average effective voltage measured of the three phases (40006).

Page 51

Functional Description .

ECW500 | 43

Figure 6.12 Operation of the ECW500 in the MTVC DROOP mode

6.5.5 MPFC (Power Factor Control)

(Mode: Power Factor Control) In this mode, the ECW500 controls the excitation, so that the power factor at the terminals of the machine is maintained constant based on the control reference in this mode. In this mode, the synchronous machine operates connected to the bus (online).

NOTE!

A positive reference (+) in this mode indicates that the synchronous machine operates with a capacitive characteristic (current leads voltage), providing reactive power to the system. Otherwise a negative reference (-) indicates that the synchronous machine operates with an inductive characteristic (current lags voltage), absorbing reactive power from the system.

Figure 6.13 Operation with positive and negative references in MPFC mode

6.5.6 MRPC (Var Control)

(Mode: Terminal Reactive Power Control) In this mode, the ECW500 controls the excitation so as to guarantee that the reactive power at the terminals of the synchronous machine follow the reference of the control. In this mode, the synchronous machine operates connected to the power supply (online).

NOTE!

A positive reference (+) in this mode indicates that the synchronous machine will provide reactive power to the system, and a negative reference (-) indicates that the synchronous machine will absorb reactive power from the system.

6.5.7 Switching Between Operating Modes

Changing from one operating mode to another depends on the application of appropriate commands via digital input, HMI or supervision software, besides the specific offline (30206) and online (30208) programming modes.

Page 52

Functional Description .

44 | ECW500

See the figure below and the Table 6.3 to understand the necessary conditions to switch from each operation modes.

Figure 6.14 Operation modes of ECW500

1 2 3 4 5 6 7 8 9

OFF

MTVC

MECC

MRPC

MPFC

MTVC_DROOP

ONLINE MODES

OFFLINE MODES

Page 53

Functional Description .

ECW500 | 45

Table 6.3 Required conditions to change operating modes.

Transition

Required Condition

OFF → MTVC: Digital Input Turn ON Excitation (Offline operating mode must be in MTVC)

MTVC → OFF: Digital Input Turn OFF Excitation

OFF → MECC: Digital Input Turn ON Excitation (Offline operating mode must be in MECC)

MECC → OFF: Digital Input Turn OFF Excitation

MECC → MTVC: Digital Input MTVC MTVC → MECC: Digital Input MECC

MTVC or MECC→ MTVC DROOP: Digital Input ENABLE PARALLEL MTVC DROOP → MTVC or MECC: Digital Input DISABLE PARALLEL

(ECW500 changes to MTVC or MECC mode depending on the configuration of the offline operating mode).

MTVC → MRPC: Digital Input ENABLE PARALLEL + Digital Input ENABLE ONLINE (simultaneously) (Online operating mode must be in MRPC)

MRPC → MTVC: Digital Input DISABLE PARALLEL + Digital Input DISABLE ONLINE (simultaneously) (Offline operating mode must be in MTVC)

MECC → MPFC: Digital Input ENABLE PARALLEL + Digital Input ENABLE ONLINE (simultaneously) (Online operating mode must be in MPFC)

MPFC → MECC: Digital Input DISABLE PARALLEL + Digital Input DISABLE ONLINE (simultaneously) (Offline operating mode must be in MECC)

MECC → MRPC: Digital Input ENABLE PARALLEL + Digital Input ENABLE ONLINE (simultaneously) (Online operating mode must be in MRPC)

MRPC → MECC: Digital Input DISABLE PARALLEL + Digital Input DISABLE ONLINE (simultaneously) (Offline operating mode must be in MECC)

MTVC → MPFC: Digital Input ENABLE PARALLEL + Digital Input ENABLE ONLINE (simultaneously) (Online operating mode must be in MPFC)

MPFC → MTVC: Digital Input DISABLE PARALLEL + Digital Input DISABLE ONLINE (simultaneously) (Offline operating mode must be in MTVC)

MRPC → MTVC DROOP: Digital Input DISABLE ONLINE MTVC DROOP → MRPC: Digital Input ENABLE ONLINE

(Online operating mode must be in MRPC)

MPFC → MTVC DROOP: Digital Input DISABLE ONLINE MTVC DROOP → MPFC: Digital Input ENABLE ONLINE

(Online operating mode must be in MPFC)

MPFC → MRPC: Change the online operating mode to MRPC. MRPC → MPFC: Change the online operating mode to MPFC.

NOTE!

The commands of the table are represented for the digital inputs, but they can be done by the HMI or by the supervisory communication too.

6.6 LIMITERS

There are in ECW500 four limiting functions to avoid the synchronous machine operations in inappropriate conditions. The limiting functions are the Underfrequency limiter, excitation overcurrent limiter, excitation undercurrent limiter and limiter of overcurrent at the synchronous machine terminals (stator). The limiters features are described in the following sections.

6.6.1 Underfrequency Limiter (LUF)

The ECW500 has two types of underfrequency limiters, selected through parameter 30122. The underfrequency limiter type U/f actuate when the system frequency drops below a preconfigured value.

When operating on the MTVC or MTVC DROOP mode, the voltage reference is automatically set so that the

Page 54

Functional Description .

46 | ECW500

voltage at the machine terminals follow the slope configured, as shown in Figure 6.15. In the other operating modes, the underfrequency condition is announced, but the reference (for excitation current, reactive power or power factor) is not changed.

The equation below shows how the portion that actuate on the reference of the voltage control mode is calculated.











󰇛



 



󰇜

 



In which: VUF it is the portion which is added to the voltage reference.

rated

is the rated voltage of the synchronous machine configured on the ECW500 (30058).

rated

is the rated frequency of the synchronous machine configured on the ECW500 (30062).

knee

point is the frequency configured on the ECW500 from which the limiter starts to actuate (30118).

measured

is the frequency measured by the ECW500 (40010).

UF_ knee

point is the slope constant of the curve of the U/F (30120).

Figure 6.15 U/F curve of the underfrequency limiter

The V/Hz Underfrequency type limiter has the purpose of maintaining constant the ratio between the voltage and frequency. V/Hz is the ratio of rated voltage and rated frequency multiplied by the slope constant (drop) configurable in the 30120 parameter of the ECW500. When the ratio V/Hz measured exceeds the set value, the limiter operates adding or subtracting a value to the main control loop reference with the objective of keeps the V/Hz value ratio constant. The Figure 6.16 shows a typical V/Hz limiter operation curve.

Figure 6.16 V/Hz curve of the underfrequency limiter

Page 55

Functional Description .

ECW500 | 47

6.6.2 Excitation Overcurrent Limiter (LEOC)

This feature is intended to limit the excitation current to an adjusted level, preventing a high current from being applied to the exciter of the synchronous machine. When the LEOC actuate, it controls only the excitation current, independent of terminal voltage and current values of the synchronous machine. To ensure proper dynamic operation, LEOC PI loop gains must be adjusted according to the response desired for application.

The LEOC limiter has two configurable levels with different forms of action:

■ high level (parameter 30132), with immediate action and

■ low level (parameter 30140), with delayed action.

Thus, if the excitation current exceeds the value set as high level, the limiter will act immediately to keep current at this level. But if the excitation current is above the low level and below the high level, the LEOC will lead the excitation current to the value defined by parameter 30140 after reaching the integral limit (Ixt), that is defined by the following equation:

  󰇛



 



󰇜  



In which:





parameter 30134

Once the condition of application allows machine operation below the low level, the limiter will turn off and returns to the previously active mode control.

Figure 6.17 Behavior of integral actuation for the excitation overcurrent limiter (LEOC)

NOTE!

As a first adjust for this protection, set the low level with the same value of the rated excitation current (30066) and the high level to 10% above the low level. The LEOC time can be maintained at default value (10s).

NOTE!

The excitation overcurrent limiter actuates in all operating modes, except on the MECC mode. It can be disabled by parameter 30142 and a relay can be configured to indicate its operation.

Page 56

Functional Description .

48 | ECW500

NOTE!

The LEOC limiter has higher priority over all other limiters.

6.6.3 Excitation Undercurrent Limiter (LEUC)

The LEUC limiter ensures that the synchronous machine does not operate at a point outside its capability curve (PxQ). Thus, the amount of reactive power absorbed by the machine is limited to the specified value.

The ECW500 allows the customized adjustment of the PxQ curve through the setting of five active power points versus reactive power as shown in Figure 6.18. The points must follow the sequence shown in the figure, otherwise an alert will be generated when the regulator is put into operation.

Once enabled, the LEUC limiter will operate at the excitation current, keeping the machine in the PxQ curve points. The LEUC limiter uses a PI loop independent from the main loop, with specific Kp and Ki gains.

Figure 6.18 Points for configuration of the PxQ curve

The active and reactive power points must be set within the limits given by the parameters 30176 (Pmin), 30172 (Qmin), 30174 (Pmax) and 30170 (Qmax). The active power values are positive and the reactive power values are negative. In addition, the following criteria must be met:

• P1 > Pmin;

• P5 < Pmax;

• Q1 > Qmin;

• Q5 < Qmax.

To facilitate setting of the LEUC limiter points the increment / decrement value can be changed through the multiplier given by parameter 30146. With it you can adjust increments of 0.1kW, 1kW, 10kW, 100kW or 1MW.

A numerical example of the LEUC parameter configuration is shown below.

Page 57

Functional Description .

ECW500 | 49

Figure 6.19 - Example of configuration for the limiter LEUC

Considering the capability curve of Figure 6.19, an apparent nominal power (S) of 10 MVA and the points chosen according to the figure, initially the parameters of minimum and maximum power are set. In this case, the following values were determined:





  



 





  



 

The selected points can then be configured with the following values:

󰇛

 



󰇜󰇛

     󰇜 󰇛 󰇜

󰇛

 



󰇜󰇛

     󰇜 󰇛 󰇜

󰇛

 



󰇜󰇛

     󰇜 󰇛 󰇜

󰇛

 



󰇜󰇛

     󰇜 󰇛 󰇜

󰇛

 



󰇜󰇛

     󰇜 󰇛 󰇜

NOTE!

The excitation undercurrent limiter operates in all operation modes, except in the MECC mode. LEUC can be disabled using the 30148 parameter and a relay can be configured to indicate its operation.

6.6.4 Terminal Overcurrent Limiter (LTOC)

The aim of the terminal overcurrent limiter (stator overcurrent limiter) is to prevent an excessive and destructive current through the terminals of the synchronous machine. When the LTOC acts, the ECW500 controls the excitation current in order to keep the stator current below the specified levels. The gains of the LTOC PI loop must be set to ensure a dynamic operation suitable for each application.

Likewise the LEOC, the LTOC limiter has two configurable levels with different forms of action:

■ high level (parameter 30126), with immediate action and

Page 58

Functional Description .

50 | ECW500

■ low level (parameter 30130), with delayed action.

So, if the terminal current exceeds the value set as high level, the limiter will act immediately to keep the current at this level. But if the terminal current is above the low level and below the high level, the LTOC will lead the terminal current to the value defined by parameter 30130 after reaching the integral limit (Ixt), that is defined by the following equation:

  󰇛



 



󰇜  



In which:





parameter 30128.

Once the condition of application allows machine operation below the low level, the limiter will turn off and returns to the previously active mode control.

Figure 6.20 Behavior of integral actuation for the terminal overcurrent limiter (LTOC)

NOTE!

As a first adjust for this protection, set the low level with the same value of the machine rated current (30060) and the high level to 10% above the low level. The LTOC time can be maintained at default value (15s).

NOTE!

The terminal overcurrent limiter operates in all operating modes, except in the MECC mode. LTOC can be disabled using the 30124 parameter and a relay can be configured to indicate its operations.

NOTE!

The LTOC limiter has higher priority over the LEUC limiter.

6.7 PROTECTIONS

The ECW500 has ten protections for several events that may happen during the operation. The main objective of the protections is to warn the operator that there is an abnormal and harmful situation for the machine.

Page 59

Functional Description .

ECW500 | 51

The protections in general do not turn off the excitation, they only serve as a fault warning. On the other hand, some protections may be configured by the user to perform certain actions, such as turning off the excitation or switch to the MECC mode.

All protections can be enabled/disabled individually. In order to configure the relays to inform the protections, refer to section 6.9.3 Configurable Relays 0, 1, 2 and 3.

6.7.1 Feedback Loss Protection (PFL)

The feedback loss protection actuates whenever the ECW500 detects problems in the feedback voltages. Two situations can cause this fault:

■ The three phases of the machine fall below the balance level set for a period longer than the time set for the

protection to actuate.

■ If any of the three phases is different from the average of the three phases by a value greater than the

unbalance level set for a period longer than the setting of this protection.

The configuration of this protection has five parameters:

■ enable/disable the protection (30286);

■ a parameter that allows configuring the switch to the MECC mode in case of fault (30288);

■ the balance level (30292);

■ the unbalance level (30294) and

■ the time for the protection to actuate (30290).

6.7.2 Excitation Overvoltage Protection (PEOV)

The protection actuates whenever the excitation voltage exceeds the level configured by a time set. Three parameters are available to set this protection: enable/disable (30422), the overvoltage level (30424) and time for the protection to actuate (30426).

6.7.3 Fault Protection in the Rotating Diodes (PED)

The ECW500 monitors the operation of the rotating diodes of the exciter without brushes through the analysis of the excitation current and protects against short circuit and open circuit of these semiconductors.

To perform this function, the ECW500 monitors in real time the harmonic content of the wave form of the excitation current through the Fast Fourier Transform (FFT). Six parameters are available for configuration of the protection:

▪ enable/disable (30466);

▪ a parameter that indicates whether the ECW500 must shut down in case of fault (30470);

▪ the time for the protection to actuate (30468);

▪ the ripple level of the excitation current detected by the maximum and minimum excitation current

measured (30464);

▪ the maximum levels allowed for the first harmonic (30460) and

▪ the maximum levels allowed for the second harmonic (30462).

To adjust correctly this protection, follow the steps below:

1. Excite the synchronous machine and check the average levels measured for the ripple current excitation (40092) amplitude (40086) nics (40088).

2. Adjust the parameter of maximum ripple (30464) 10 to 15 % above the average level checked in the normal condition.

3. Adjust the first (30460) harmonics limits (30462) 1 to 2 % above of the average levels checked in the normal condition.

4. Program a delay time (30468) above of 30 s, to avoid the undue actuation of protection.

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Functional Description .

52 | ECW500

NOTE!

When generating the diode fault, ECW500 does not differentiate between shorted circuit or open circuit, showing the same message to both cases.

6.7.4 Excitation Loss Protection (PEL)

This fault is associated with the amount of reactive power which the synchronous machine can absorb. If the excitation current of the ECW500 falls below 5% of the configured rated value of excitation current for a period longer than the setting for the protection, an excitation loss fault is generated. The enable/disable parameters (30436) and the time for the fault to actuate (30296) are available for configuration of this protection.

6.7.5 Terminal Overvoltage Protection (PTOV)

When the voltage at the terminals of the synchronous machine (stator) exceeds the level set in the protection in relation to the rated voltage value for a set time, the protection actuates and generates a fault warning. The enable/disable parameter (30442), protection actuation level (30446) and time for actuation (30444) are available for configuration.

6.7.6 Terminal Undervoltage Protection (PTUV)

When the voltage at the terminals of the synchronous machine (stator) falls below the level set in the protection in relation to the rated voltage value for a set time, the protection actuates and generates a fault warning. The enable/disable parameter (30448), protection actuation level (30452) and time for actuation (30450) are available for configuration.

6.7.7 Power Module Overtemperature Protection

This function aims at protecting the power module of the ECW500 through the monitoring of the temperature on the semiconductors. If the temperature exceeds the level set for a configured time for protection, a fault is generated. It is also possible to configure for the ECW500 to shut down the excitation if this fault occurs. Three parameters are available for the configuration of this protection: temperature level (30428), time for actuation (30430) and whether the ECW500 must shut down or not the excitation in case of fault (30432).

6.7.8 Power Phase Loss Protection

This protection indicates whether there are problems with phase loss in the power supply of the ECW500. A parameter to enable/disable this protection (30434) and a time for actuation (30472) are available for configuration.

6.7.9 Maximum/Minimum Protection Limits of the PWM

It is possible to limit the output of the PWM to both a maximum value and a minimum value. The PWM output is configurable between -100% and +100% of DC link voltage, through the maximum and minimum PWM output settings (parameters 30438 and 30440 respectively). This adjust must be done according to the power supply voltage so as to ensure a proper dynamic for the control regulation. If the maximum trip voltage is at a nonacceptable level for the excitation, the maximum limit of the PWM must be reduced.

NOTE!

Normally the negative setting must contain the same value from the positive setting.

NOTE!

The power also supports single-phase supply and, if used, this protection must be disabled, so that the failure related is not generate improperly.

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6.7.10 Analog Input in Current: Loss Protection (PLCI)

This protection indicates if the current at the analog input is below 3.5 mA. When the parameter 31028 (External Power Module) is set to 1 (enabled), the actuation of this protection will result in shutdown of the regulator. Otherwise, only a warning will be displayed in the event list. It is possible to enable or disable this protection through the parameter 31024 and to set its actuation time by the parameter 31026.

6.8 CRITICAL PROTECTION

6.8.1 Underfrequency Protection

When the system frequency falls below 10 Hz, the ECW500 is automatically turned off and an error is generated.

6.8.2 Excitation Overcurrent Protection (PEOC)

The protection actuates whenever the excitation current exceeds the level configured by an adjustable time. Three parameters are available to set this protection: enable/disable (30454), the overcurrent level (30456) and time for the protection to actuate (30458).

6.8.3 DC Link Overvoltage Protection

If the DC link voltage reaches the maximum value allowed, an error is generated and the ECW500 is automatically shut down.

6.8.4 Fault Protection on Triggers of the Power Switches

The ECW500 monitors faults on the triggers of the power switches individually. If any of them fails, the ECW500 is automatically shut down and an error is generated indicating which switch/trigger failed. This fault is also generated in case of a short circuit at the power output terminals.

6.9 DIGITAL RELAY OUTPUT

The ECW500 has six relay outputs to indicate information about the equipment operation. Two relays have specific functions and four of them are configurable to indicate specific conditions for each operation. All relays can be configured to Normally Open - NO or Normally Closed - NC.

Also, the four relays which have configurable functions can also be configured for three distinct types of operation:

■ "Latched", in which the relay remains in the commuted state while the fault exists;

■ "Momentary", in which the relay remains switched in the commuted state for a certain time when the fault

occurs;

■ "Maintain", in which the relay remains in the commuted state until there is a reset of the error/fault that

caused the relay to actuate.

6.9.1 Status Relay

The status relay has fixed function and indicates if the ECW500 in ON (in operation) or OFF.

6.9.2 General Fault Relay

The general fault relay has fixed function and indicates whether there is an error or active fault on the ECW500.

6.9.3 Configurable Relays 0, 1, 2 and 3

The ECW500 has four relays with configurable indication functions indicated by the numbers 0, 1, 2 and 3. The functions that can be indicated on these relays are shown in the list below:

■ Phase loss;

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Functional Description .

54 | ECW500

■ Excitation loss;

■ Excitation overvoltage;

■ Excitation overcurrent;

■ Overvoltage at the stator terminals;

■ Undervoltage at the stator terminals;

■ Underfrequency;

■ MECC mode;

■ Feedback loss;

■ Rotating diodes fault;

■ LEOC actuating;

■ LTOC actuating;

■ U/F actuating;

■ LEUC actuating;

■ Anybus offline.

6.10 SOFT START

The ECW500 has a soft start function for the operating modes MTVC and MECC, which are the offline modes. This function increases the reference of the operating mode gradually up to the final value set. The ECW500 allows setting the start level of the reference in terms of percentage in relation to the final value and the time it will take the reference to reach the final value.

Figure 6.21 shows the behavior of the starting ramp.

Figure 6.21 Typical curve of actuation of the soft start function

6.11 AUTOMATIC TUNING (AUTOTUNING)

The ECW500´s automatic tuning function allows finding an appropriate adjustment for the gains in each operation mode.

To perform the Autotuning function it is necessary the ECW500 be controlling the excitation of the synchronous machine in the operation mode to be adjusted (MECC, MTVC, MRPC or MPFC) and with the limiters out of acting. Furthermore, when possible, it is recommended that the Autotuning be performed with the machine running close to the operating point desired and with rated load.

However, before initiating the Autotuning procedure it is necessary to adjust the parameters and configurations related to this function.

A detailed description of each parameter is shown below.

6.11.1 Configuration Parameters

<31070>

Output Level Variation (AT Delta)

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Functional Description .

ECW500 | 55

This parameter defines the percentage variation that will be imposed to the ECW500 output during the Autotuning procedure. This percentage is related with the current duty cycle ratio value (40062).

Example: If the ECW500 is operating with duty cycle (40062) of 35% and an excitation voltage (40046) of 13.5 Volts, an

Output Level Variation

adjusted in 5.0% will make that duty cycle swing between 36.75% (35% * 1.05) and

33.25% (35*0.95) during the Autotuning. The excitation voltage, in this case, must swing between 14.2V and

12.8V (13.5% ± 5%). It's possible to adjust high values for

Output Level Variation

, since that the oscillation generated in machine s

voltage and current doesn t cause damage to application. In practical terms this means that the higher

Output Level Variation

the easier the Autotuning function be

executed with success.

<31072>

Hysteresis Level (Hyster.AT)

This parameter defines the percentage of

hysteresis

that must exist on the feedback signal for the control to

impose the change of duty cycle. Example: If the ECW500 is working in MTVC mode with a feedback voltage in 13800V, a

hysteresis

of 0.5% specify that the autotuning must to wait an identification of the voltage feedback over of 13869 V (13800V * 1.005) and under of 13731 V (13800V * 0.995) to change the duty cycle between the levels defined by 31070.

For the autotuning routine, the lower the hysteresis the closer of the ideal values the gains will be calculated. However, in the practice, a low value of

hysteresis

can let the autotuning routine very sensitive and maybe it will not be possible to achieve the convergence. So, the rule for this parameter is to start with the standard value (0.5%). In case that the autotuning finishes without to find the gains of controller, it must be increased the value slowly.

<31074>

Convergence Tolerance (Converg.)

This parameter defines the maximum level of offset between the measures performed during the autotuning, for purpose of convergence.

In most of applications, the standard value 2.5% is enough for the Autotuning be completed with success. This value must be raised only if, after a few tries, the function does not obtain the gains of controller.

<31076>

Autotuning Execution Timeout (TimeoutAT)

This parameter establishes the maximum time that the Autotuning routine will be in execution to find the gains of the controller. If the limit time is reached without any convergence, the autotuning will be closed and the duty cycle will be back at the original value before the beginning of the routine.

The limit time of 20 seconds normally is enough for the Autotuning converge to some result. If the function does not achieve the gains and does not create a dangerous situation to the application, this limit time can be increased gradually.

<31078>

Autotuning Proportional gain (ATune Kp)

<31080>

Autotuning Integral gain (ATune Ki)

<31082>

Autotuning Derivative gain (ATune Kd)

These parameters store the calculated values for the controller gains after a successful execution of Autotuning routine.

If the Autotuning does e to any result during your execution time, these parameters will be set to null (0).

<31084>

Controller Configuration (Conf. Ctrl)

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Functional Description .

56 | ECW500

This parameter defines if the calculated gains will be for a controller PI or PID. If the Autotuning is going to be started for MTVC mode, this parameter must be adjusted in the PID option. For

the other operation modes (MECC, MRPC and MPFC) this parameter must be kept in the PI option.

<31108>

Copy gains of Autotuning to current mode (CopyGains)

This option allows copying the value of parameters 31078, 31080 and 31082 over the gains of current operation mode.

Example: If the autotuning was executed with success in MTVC mode, when using the option

CopyGains

the calculated

values for the control gains will be copied to gains of MTVC mode as follow:

• ATune Kp (31078)  MTVC Kp (30016);

• ATune Ki (31080)  MTVC Ki (30018);

• ATune Kd (31082)  MTVC Kd (30020).

In this case, the values of the gains for other operation modes (MECC, MRPC and MPFC) remain unchanged.

NOTE!

The copy of parameters 31078, 31080 and 31082 using

CopyGain

option does not affect the

gains of other mode different from the current mode.

NOTE!

If the values of parameters 31078, 31080 and 31082 are null (0.0) the function

CopyGains

have effect in the gains of current operation mode.

<31100>

Higher Limit of feedback during the Autotuning (Max.Fdbck)

<31112>

Lower Limit of feedback during the Autotuning (Min.Fdbck)

These parameters define the higher and lower limits that the feedback signal can achieve for the Autotuning don't be interrupted.

This is an additional protection during the execution of Autotuning that must to be adjusted with the values considered safe to the operation.

Example: If the voltage feedback in MTVC mode is 13800 V at the beginning of the Autotuning process, a Higher Limit

and a Lower Limit adjusted in 10% define that the execution of the function will be interrupted if the machine voltage achieve a value higher than 15180 V (13800 V * 1.1) or lower than 12420 V (13800 V * 0.9).

6.11.2 Commands

To start the automatic tuning process, the autotuning command on Autotuning menu must be changed On . The Autotuning command can be also executed through the F2 key, since the HMI navigation screen be on the

Autotuning menu.

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Functional Description .

ECW500 | 57

NOTE!

If necessary o automatic tuning execution anytime through the F1 key.

6.11.3 Messages

In order to inform the user about one eventual fail in execution of automatic tuning and the time that the function starts and stops, the ECW500 will register some messages in its event list.

In the Table 6.4 there is a description of all messages related with automatic tuning that can be registered in the event list.

Table 6.4 Possible messages generated in the event list by the automatic tuning function.

Code

Text on Event List

Description

WR018

Autotun. Fail

Autotuning closed by overshoot of the limits defined in 31100 and 31112

EV018

Autotun. Start

Autotuning process started

EV019

Autotuning OK

Autotuning process finished with success

EV020

Autotun.Abort

Autotuning canceled by the user (key F1 or

Turn Off excitation

)

EV021

ATune Timeout

Autotuning finished for exceeding the time defined in 31076

6.11.4 Monitoring

To verify if the automatic tuning is working correctly, it is recommended to monitor the variation of the duty cycle and the feedback variable during the execution of the function with a trend graphic at the Superdrive G2 Software.

In MTVC mode the variation of these signals must be similar to the Figure 6.22.

Figure 6.22 Variation for the duty cycle and the voltage feedback during the automatic tuning.

6.12 SPECIAL FUNCTIONS

6.12.1 Self-Calibration of the Excitation Current Measurement

The ECW500 has a self-calibration function of the analog channel for reading the excitation current. The calibration allows correcting inaccuracies inherent in the product manufacturing and in the tolerance of components, providing greater precision for the measurement.

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Functional Description .

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The self-calibration must always be performed with the ECW500 out of operation (disconnected from the synchronous machine). It is accessible through the HMI´s menus or by the communication supervisory (parameter 30108). The self-calibration is also performed automatically every time the default factory parameters are loaded.

An event is generated with the results after the calibration be performed.

ATTENTION!

The current measurement calibration must be performed with the ECW500 excitation turned off.

6.12.2 Self-Calibration of the Analog Inputs

For the analog input voltage (-10V to +10V), it is also available in the ECW500 the self-calibration function. It allows correcting inaccuracies inherent in the product manufacturing and in the tolerance of components, providing greater precision for measurement.

The self-calibration must always be performed with the ECW500 out of operation (disconnected from the synchronous machine) and the analog input terminals must be short circuited. It is accessible from the menus of the HMI or by the supervisory communication (30110).

Once performed the calibration, an event is generated in the list indicating the result.

ATTENTION!

The self-calibration must be performed with the excitation of the ECW500 off and with the voltage analog input terminals short circuited.

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Modbus RTU Communication .

ECW500 | 59

7 MODBUS RTU COMMUNICATION

The Modbus protocol was originally developed in 1979. Currently, it is an open protocol widely used by several manufacturers in different kinds of equipment. The Modbus-RTU communication of the ECW500 was developed based on the following documents:

▪ MODBUS Protocol Reference Guide Rev. J, MODICON, June 1996. ▪ MODBUS Application Protocol Specification, MODBUS.ORG, May 8th 2002. ▪ MODBUS over Serial Line, MODBUS.ORG, December 2nd 2002.

These documents define the format of messages used by the elements that are part of the Modbus network, the services (or functions) that can be provided by the network and how these elements exchange data.

7.1 STRUCTURE OF THE MESSAGES IN THE RTU MODE

The Modbus-RTU network uses the master-slave system for exchanging messages. It allows up to 247 slaves, but only one master. All communication begins with the master making a request to a slave and the slave responds to the master what was requested. In both telegrams (question and answer), the structure used is the same: Address, Function Code, Data and CRC. Only the data field can have variable length, depending on what is being requested.

Master (request telegram):

Address

Function

Requested Data

CRC

1 byte

N bytes

2 bytes

Slave (response telegram):

Address

Function

Requested Data

CRC

1 byte

N bytes

2 bytes

7.2 MODBUS FUNCTIONS AVAILABLE ON THE ECW500

The MODBUS functions available on the ECW500 are listed below. Detailed information to use these functions is found in the MODBUS protocol specification.

■ F0x01: Read Coils.

■ F0x02: Read Discrete Inputs.

■ F0x03: Read Holding Registers.

■ F0x04: Read Input Registers.

■ F0x05: Write Single Coils.

■ F0x0F: Write Multiple Coils.

■ F0x10: Write Multiple Registers.

■ F0x2B: Read Device Identification.

7.2.1 Parameter Types of the ECW500

The parameter types of the ECW500 are organized by Modbus address range, as described below.

Range 0 a 20

Commands for the ECW500. These are the commands available to change the state of the equipment. It has the same effect as the digital input commands. They are boolean write registers, and the reading returns false until the command is executed.

Range 10.000 a 10.018

Status flags of the ECW500. These are the flags to indicate the state of the

equipment. They are boolean read-only registers that return true or false. The writing has no effect.

Range 30.002 a 31.346

Configuration parameters. These are the variables for configurating the regulator. They consist in 4 registers of 8 bits, or 2 registers Modbus of 16 bits, which result in 32 bits of data with the floating point type of single precision standard IEEE 754. Parameters 31214 and 31216 (words of status and command) are special and must be read/written as integer 32 bits. A further description of these words is presented in Chapter 9.

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Modbus RTU Communication .

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Range 40.000 a 40.140

Registers read-only. These are the variables that present the ECW500 measurements and operating conditions, also in size 32 bits with the floating point type of single precision (standard IEEE 754). The parameter 40140 (serial number) is special and must be read as integer 32 bits.

7.3 SERIAL TRANSMISSION

In the protocol specification two transmission modes, ASCII and RTU are defined, which define how the bytes of the message are transmitted. However, the ECW500 only uses the RTU mode for the transmission of telegrams.

The ECW500 uses an RS-485 interface that can be configured as Half Duplex or Full Duplex via parameter

30002. In the parameter table of chapter 1 you can check all the options for configuring this communication interface (parameters 30006 to 30014).

7.3.1 Time Between Messages

In the RTU mode a specific character that indicates the beginning or the end of a telegram. The indication of when a new message starts or when it finishes is done by the absence of data transmission in the network for a minimum period of 3.5 times the time of transmission of a data byte (11 bits). Thus, if a telegram is started after the occurrence of this minimum period, the network elements will assume that the first character received represents the beginning of a new telegram. And, likewise, the network elements will assume that the telegram reached the end when, after receiving the bytes of the telegram, this period elapses again.

If during the transmission of a telegram, the period between the bytes is longer than this minimum period, the telegram will be considered invalid, because the ECW500 will discard the bytes already received and build a new telegram with the bytes that are being transmitted.

For a baud rates above 19200 bits/s, the times used are the same ones considered for this rate. Table 7.1 shows the times for different baud rates:

Table 7.1 Baud rates and times involved in telegram transmission

Baud Rate

11bits

3,5x

9600 bits/s

1,146 ms

4,010 ms

19200 bits/s

2,005 ms

38400 bits/s

2,005 ms

57600 bits/s

2,005 ms

In which:

11bits

time to transmit a word of the telegram

3,5x

Minimum interval to indicate the beginning and end of telegram (3.5 x T

11bits

)

7.3.2 Physical Interface

The RS485 physical interface for communication of the ECW500 in the MODBUS RTU network is internally isolated and consists of 5 marked terminals, as follows, according to the label on the side of the product.

COMMUNICATION

COM 1

Connector Number

2 3 4 5 6

Identification

GND

TxB(-)

TxA(+)

RxB(-)

RxA(+)

The RS-485 interface of the ECW500 also allows half duplex and full duplex connections. In the Half Duplex mode, only the terminals RxB and RxA (the GND terminal can also be used if necessary) are used for both transmission and reception of data for communication with the MODBUS network master. In the Full Duplex mode, all terminals are used in the communication. The terminals RxA and RxB are used to receive data from the network master, and terminals TxA and TxB are used to transmit the data to the MODBUS network master.

To communicate with computers is necessary to use an USB converter (or a RS232 converter, if this interface is available).

WEG offers as an accessory the USB-i485 converter (Figure 7.1), which can be purchased directly or through one of its representatives, by the code 11511558.

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Modbus RTU Communication .

ECW500 | 61

Figure 7.1 Converter USB / RS485

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Ethernet Communication (Modbus TCP) .

62 | ECW500

8 ETHERNET COMMUNICATION (MODBUS TCP)

The ECW500 has support for 10 and 100 Mbps Ethernet connections, Half or Full Duplex, in Modbus TCP protocol. For a correct communication and operation, parameters 30258 to 30280 must be configured according to the network, as well as parameters 31218 (port), 31220 (Id) and 31222 (timeout). Parameter 31232 defines whether Dynamic Configuration Protocol (DHCP) is enabled or not.

For more information about the Ethernet network, refer to the specific Ethernet manual.

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Anybus Communication.

ECW500 | 63

9 ANYBUS COMMUNICATION

The ECW500 supports multiple network protocols with the use of passive and active Anybus modules. When using a passive module, the settings applied are the same as the Modbus RS-485 / RS-422 (parameters

30002 to 30014). For active modules, you may need to adjust the network settings (parameters 31124 to 31148 and 31204) as

well as Modbus settings (31198 to 31202). The mapped parameters must be defined in parameters 31150 to 31172 (read) and 31174 to 31196 (write). It is necessary that at least one read parameter and one write parameter be configured for the correct operation of the cyclic communication. The first parameter not configured (value 39998 for reading and 30000 for writing) disables the use of the other parameters in the sequence.

You can monitor the system status from the status word (parameter 31214) and also apply commands through the command word (parameter 31216). See below for a detailed description of these parameters.

<31214>

Status word

It allows monitoring the equipment status. Each bit represents one state:

Bits

Values

Bit 0

Regulator Status

0: Regulator OFF 1: Regulator ON

Bit 1

Ramp State

0: Startup ramp disabled 1: Startup ramp acting

Bit 2

LUF

0: LUF disable 1: LUF acting

Bit 3

LEOC

0: LEOC disable 1: LEOC acting

Bit 4

LEUC

0: LEUC disable 1: LEUC acting

Bit 5

LTOC

0: LTOC disable 1: LTOC acting

Bit 6

Mode Transition

0: Ramp of transition mode disabled 1: Ramp of transition mode acting

Bits 7 to 31

Reserved

<31216>

Command word

It allows the control of the equipment via the network. Each bit represents one command and the signal must be pulsed, sending high logic level to execute the command:

Bits

Action

Bit 0

Regulator ON

Bit 1

Regulator OFF

Bit 2

Automatic mode

Bit 3

Manual mode

Bit 4

Enable online

Bit 5

Disable online

Bit 6

Parallel Enable

Bit 7

Parallel Disable

Bit 8

Reset alarms

Bit 9

Reserved

Bit 10

Reserved

Bit 11

Reserved

Bit 12

Reserved

Bit 13

Reserved

Bit 14

Perform auto tuning (autotuning)

Bits 15 to 31

Reserved

For more information about the Anybus protocols see the specific manual.

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Startup .

64 | ECW500

10 STARTUP

The items below form a configuration and startup guide of the ECW500 and of the synchronous machine. For a safe start-up of the application, it is really important to observe the instructions of this chapter.

Before, however, the ECW500 must have already been installed according to the chapter 5.

10.1 REQUIRED EQUIPMENT

Below are the items related to the required items to make the initial configuration of the ECW500.

■ Oscilloscope with current and voltage probes up to 1000 V.

■ ECW500 with HMI.

■ PC with Windows operating system and Superdrive G2 monitoring software or another software application

for MODBUS RTU protocol. For further information about the Superdrive G2 software, refer to the specific manual.

■ RS485 converter to USB for access to the ECW protocol via PC.

■ A power supply for the electronics.

10.2 PREPARATION AND POWER-UP OF THE ELECTRONICS

Before energizing the power supply of the ECW500 (P-A/P-B/P-C), it is advisable to perform the following steps.

1. Check if the power, grounding and control connections are correct and firm.

2. Remove all materials left from the inside of the application panel.

3. Check if the synchronous machine current and voltage match the regulator.

4. Measure the line voltage and check that it is within the permitted range for the ECW500.

5. Energize the electronics (L~/N~ or BAT+/BAT-) and confirm the success of the power-up: the display must show the standard monitoring screen (Figure 6.1).

10.3 SYSTEM DATA

Fill out the table below with the system data.

Table 10.1 System data

Line voltage of the machine terminals

Vac

Machine frequency

Machine reactive power

kVAr

Machine rated speed

RPM

Excitation voltage with no load

Vdc

Excitation current with no load

Adc

Excitation voltage with rated load

Vdc

Excitation current with rated load

Adc

10.4 CONFIGURING THE ECW500

10.4.1 Rated Parameters

In order to start configuring the ECW500, you must start by the rated parameters of the synchronous machine and the system. See in Figure 6.2 System

Rated terminal voltage_______ V Rated terminal current _______A Rated frequency ________Hz Rated excitation voltage ________Vdc Rated excitation current ________Adc Primary of the current transformer ________A Secondary of the current transformer _________A Primary of the voltage transformer _________V Secondary of the voltage transformer _________V

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Startup

ECW500 | 65

NOTE!

After the configuration of the rated values, the rated power value of the machine is automatically calculated; therefore, it is not a configurable parameter.

ATTENTION!

The configuration of the application parameters is essential for the proper operation of the product, since the conversion of some readings performed by the ECW500 is based on the values defined by those parameters.

10.4.2 Operating Modes and Limiters

As a next step, the operating modes of the regulator and the limiters must be configured. Those configurations

screens.

Single control mode (MTVC or MECC): _________ Online control mode (OFF, MPFC or MRPC): __________ Parallel control mode (OFF or DROOP): ___________ Limiter mode U/F (UF or Volts/Hertz): __________ Excitation overcurrent limiter LEOC ON/OFF: ____________ Under excitation limiter LEUC ON/OFF: __________________ Terminal overcurrent limiter LTOC ON/OFF: ____________

10.4.3 Input and Output Configuration

In this step, all the digital inputs, relay outputs and the analog input of the equipment are configured. The For further details on the operation of the digital inputs and their possible configuration, refer to item 6.2.

Pressed

Released

Maintain

Turn on excitation

Turn off excitation

Increment

Decrement

MTVC mode

MECC mode

Enable online operation

Disable online operation

Enable parallel operation

Disable parallel operation

Alarm reset

The configuration values for the analog input are below. Type of the analog input (+/-10 Vdc or 4 to 20 mA): ______________

Gain of the analog input in the MTVC mode: _______________ Gain of the analog input in the MECC mode: _______________ Gain of the analog input in the MRPC mode: _______________ Gain of the analog input in the MPFC mode: _______________

And finally the configuration values of the relay outputs. Status Relay (NO/NC): ___________________

Fault Relay (NO/NC): ___________________

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Relay 0

Relay 1

Relay 2

Relay 3

NO / NC

Actuation type

Actuation time

Warning: phase loss

Warning: excitation loss

Warning: PTOV protection of terminal overvoltage

Warning: PTUV of terminal undervoltage

Warning: PUF protection of underfrequency

Warning: PEOC protection of excitation overcurrent

Warning: LEUC limiter of under excitation

Warning: of change to MECC

Warning: PFL protection of feedback loss

Warning: PED protection of rotating diode fault

Warning: LEOC limiter actuating

Warning: LTOC limiter actuating

Warning: LUF limiter actuating

Warning: Anybus is Offline

10.4.4 Control Configuration

The control configuration encompasses all the reference settings of the controllers, limiters and start ramp. Reference voltage set (MTVC mode): _______________

Reference excitation current set (MECC mode): _______________ Reactive power reference set (MRPC mode): _________________ Power factor reference set (MPFC mode): __________________ Maximum setting of the voltage reference (MTVC mode): ________________ Minimum setting of the voltage reference (MTVC mode): ________________ Maximum setting of the excitation current reference (MECC mode): ________________ Minimum setting of the excitation current reference (MECC mode): ________________ Internal follower of the MECC mode: ____________ Maximum setting of the reactive power reference (MRPC mode): ____________ Minimum setting of the reactive power reference (MRPC mode): ____________ Maximum setting of the delayed power factor reference (MPFC mode): ____________ Maximum setting of the advanced power factor reference (MPFC mode): ____________ Initial level of the soft starter ramp: ____________ Ramp time: ___________

Knee-point frequency of U/F limiter: ______________ Slope of curve for the U/F limiter: ________________

If the excitation overcurrent limiter (LEOC) is active, configure the levels and time to actuation. LEOC High level: __________________

LEOC Low level: __________________ LEOC Time to actuation: ___________________

If the excitation undercurrent limit is active, configure the PxQ protection curve according to the capability curve specified by the machine.

Maximum reactive power to set the curve: ______________ Minimum reactive power to set the curve: ______________ Maximum active power to set the curve: ______________ Minimum active power to set the curve: ______________

Active Power

Reactive Power

Point 1

Point 2

Point 3

Point 4

Point 5

If the terminal overcurrent limiter (LTOC) is active, configure the levels and time to actuation of this limiter.

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LTOC High level: __________________ LTOC Low level: __________________ LTOC Time to actuation: ___________________

10.4.5 Configuring the Protections

Protection of feedback loss PFL ON/OFF: _____________ Protection of feedback loss PFL changes to MECC mode: _____________ Protection of feedback loss PFL voltage balanced: _____________ Protection of feedback loss PFL voltage unbalanced: _____________ Protection of feedback loss PFL time to actuate: _____________ Protection of excitation overvoltage PEOV ON/OFF: _____________ Protection of excitation overvoltage PEOV limit level: _____________ Protection of excitation overvoltage PEOV time to actuate: _____________ Protection of excitation overcurrent PEOC ON/OFF: _____________ Protection of excitation overcurrent PEOC limit level: _____________ Protection of excitation overcurrent PEOC time to actuate: _____________ Protection of terminal undervoltage PTUV ON/OFF: ________________ Protection of terminal undervoltage PTUV limit level: ________________ Protection of terminal undervoltage PTUV time to actuate: ________________ Protection of terminal undervoltage PTOV ON/OF: ________________ Protection of terminal overvoltage PTOV limit level: ________________ Protection of terminal overvoltage PTOV time to actuate: ________________ Protection of the rotating diodes PED ON/OFF: ________________ Protection of the rotating diodes PED time to actuate: ________________ Protection of excitation loss PEL ON/OFF: ______________ Protection of excitation loss PEL time for warning: ______________ Protection of the PWM maximum power module: ______________ Protection of the PWM minimum power module: ______________ Protection of the power module by phase loss enable/disable: _____________ Protection of the power module, maximum temperature of the module: ______________ Protection of the power module, time for warning of maximum temperature: ______________ Protection of the power module enable/disable shutting down: ______________

NOTE!

The adjustments of the protection limits of rotating diodes must be done during the first machine excitation.

10.5 TESTS ON THE OFFLINE MODES

After the configuration of the regulator is done, it must be made the first power-up applying the excitation to the synchronous machine with no load and disconnected from the line or other machines. The main objective is detecting wrong connections and bad configurations.

10.5.1 Turning On and Off the Regulator with Machine Spinning

1. With the regulator OFF, check if the "Automatic" and "Manual" commands are toggling the operating mode of the regulator via HMI, via supervisory software or via specific keys on the digital inputs.

Result: _____________________________________________________________________________

2. With the machine spinning, check the remanent voltage measurement, the terminal current and the frequency

on the HMI, or supervisory software.

Result: _____________________________________________________________________________

3. Put the regulator in the manual mode (MECC) and set the excitation current reference to 20% of the rated

excitation current value. Enable the regulator and wait for the ramp to reach the reference setting.

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4. Keep the stability parameters of the MECC at the factory defaults values. If oscillation occurs in the excitation current, adjust the stability parameters to improve the dynamics. In order to define the stability parameters, reference steps about 5% to 10% can be applied. The current response must present neither oscillations nor overshoot.

Kp proportional gain of the PI controller of the MECC mode: _________________________________ Ki integral gain of the PI controller of the MECC mode: ______________________________________

5. Set the reference of the MECC until reaching the rated voltage of the machine. The voltage can be checked on the HMI measurement screen.

MECC reference for the rated voltage: ______________________

6. Check with an oscilloscope the excitation voltage. The waveform must be a square wave with maximum

proportional to the alternate voltage applied to the power input. The frequency must be around 2kHz and with cyclic ratio with a value close to the one shown on the measurement screen of the HMI.

7. Change to automatic mode via digital inputs, command on the HMI or command via supervisory software.

Result: _____________________________________________________________________________

8. If the terminal voltage is not stable, an adjustment on the stability parameters must fix the oscillation. In order to complete the stability adjustment, apply reference steps about 5% to 10% evaluating the response of the voltage control.

Kp proportional gain of the PI controller of the MTVC mode: ___________________________________ Ki integral gain of the PI controller of the MTVC mode: _______________________________________

9. Turn off the regulator using the digital inputs or the HMI.

Result: ____________________________________________________________________________

10. Turn on the excitation in the MTVC mode checking if the start ramp occurs according to the configuration.

When it reaches the reference voltage, test the increment and decrement of the voltage reference by the digital and analog inputs if used.

Result: _____________________________________________________________________________

10.5.2 Test of the Excitation Current Limiter

1. With the regulator still operating in the voltage control mode, check the excitation current with the

synchronous machine without load and with the reference of the MTVC control equal to the rated voltage of the machine:

____________________________________________________________________________________

2. Reduce the voltage reference to the minimum allowed and check again the excitation current:

____________________________________________________________________________________

3. Configure the high level of the LEOC limiter to a value a slightly below than the verified in step 1. Set the low

level of LEOC to the value verified in step 2 and leave the actuation time at factory default. Keep the stability parameters at factory defaults values.

LEOC High level: __________________ LEOC Low level: __________________

4. Change the reference of the MTVC mode for the rated value of the machine. The limiter must act

immediately, holding the excitation current in the value adjusted as high level. After 10 seconds, the excitation current must be limited to the value set at the low level.

Result: _____________________________________________________________________________

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5. If necessary, make stability adjustments on the limiter until obtaining a current control without oscillations. The adjustments can be low, because the slow control does not affect the system performance.

Kp LEOC: _____________ Ki LEOC: _____________

6. After testing the limiter stability, change again the high and low levels of limiter to the values required under

operation. If desired, also set the time to actuation of this limiter.

LEOC High level: __________________ LEOC Low level: __________________ LEOC Time to actuation: ___________________

10.6 TESTS ON THE ONLINE MODES

The following tests are also valid for start-up of synchronous motors, you just have to consider that the machine is already spinning at synchronism speed or close to it.

1. Put the regulator in the MECC mode before matching the synchronism with the network. Do not allow the

parallel contacts to put the regulator in the parallel mode. Set the reference of the MECC so as to obtain the same voltage of the bus/grid at the machine terminals. Wait for the synchronism.

Result: _____________________________________________________________________________

2. With the machine connected to the bus/grid and with the manual excitation, check the terminal current

measurement and three-phase active and reactive powers to check the polarity of the connections. If necessary, invert the polarity of the current transformer.

Result: _____________________________________________________________________________

3. Configure the reactive control mode desired and transfer to this mode by executing the command by the

digital inputs, serial communication port or HMI. Be prepared to return to the MECC mode if an over excitation of the machine occurs.

Reactive control modes: ____________________ Result: _____________________________________________________________________________

4. Configure the dynamic characteristics of the reactive mode (only MPFC and MRPC) applying variations to the reference and checking the dynamic response.

Kp (MPFC or MRPC): _____________________ Ki (MPFC or MRPC): _____________________

5. With the machine operating in parallel, configure the reactive mode chosen to generate the minimum reactive

possible. Configure the low level of LEOC limiter to a value 15% above the excitation current at the minimum of reactive. Increase the reference of reactive until the limiter becomes active.

Result: _____________________________________________________________________________

6. Check the dynamic response of the limiter and make the necessary adjustments. After the adjustments,

configure the high and low levels desired for normal operation. LEOC High level: __________________

LEOC Low level: __________________

7. Configure the reactive mode chosen to generate the minimum reactive possible. Configure the low level of

LTOC limiter to a value 15% above the current at the setpoint with the minimum reactive. Increase the reference of reactive until the limiter becomes active.

Result: _____________________________________________________________________________

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Startup .

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8. Check the dynamic response of the limiter and make the necessary adjustments. After the adjustments, set the high and low levels desired in LTOC to normal operation, beyond its time to actuation.

LTOC High level: __________________ LTOC Low level: __________________ LTOC Time to actuation: ___________________

9. Configure the reactive mode chosen to generate the minimum reactive possible. Configure the excitation undercurrent limiter (LEUC) by entering the active and reactive power curve of the machine provided by the manufacturer (PxQ curve). The curve must be composed of five active power points and five reactive power points. Adjust the reference of the reactive mode chosen for a negative value, so that the synchronous machine starts to absorb reactive. Continue to vary the reference until the limiter becomes active.

Point 1: Active power: __________________ Reactive power: __________________ Point 2: Active power: __________________ Reactive power: __________________ Point 3: Active power: __________________ Reactive power: __________________ Point 4: Active power: __________________ Reactive power: __________________ Point 5: Active power: __________________ Reactive power: __________________

Result: _____________________________________________________________________________

10. Check the dynamic response of the limiter and make the necessary adjustments. Kp LEUC: _____________________

Ki LEUC: _____________________

11. Adjust the reference of the online mode chosen for normal operation. Reference (MPFC or MRPC): _____________________

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Maintenance.

ECW500 | 71

11 MAINTENANCE

This chapter contains maintenance recommendations for the ECW500.

11.1 DIAGNOSIS OF FAULTS, ERRORS AND MESSAGES

Refer to Chapter 2 Errors, Warnings and Events for more details about the error and warning messages generated by ECW500.

11.2 TECHNICAL ASSISTANCE

If you have any question about service, contact the technical assistance. The contact channels are on the website http://www.weg.net, according to the country or region where the assistance is needed.

NOTE!

For consults or service requests, it is important to have the following data at hand:

■ Model of the ECW500;

■ Serial number, manufacturing date and hardware revision indicated on the nameplate of the

product;

■ Version of the software installed;

■ Data on the application programming executed.

11.3 PREVENTIVE MAINTENANCE

DANGER!

■ Always disconnect the power before touching any electrical component in connection with the

ECW500.

■ High voltages may be present even after disconnecting the power supply.

■ Wait for at least 20 minutes for the full discharge of the power capacitors.

■ Always connect the equipment frame to the protective earth (PE) in the appropriate place.

ATTENTION!

Electronic boards have components sensitive to electrostatic discharges. Do not touch directly any of the components or connectors. If necessary, first touch the metallic frame or use a suitable grounding strap.

When installed in environments with appropriate operating conditions (refer to section 5.2.1 Environmental Conditions), the ECW500 requires little maintenance. The main verifications are:

■ keep electrical connections clean and tight;

■ keep the product clean by removing accumulations of dust, oil, humidity of the electronic boards, spaces for

ventilation and heatsink.

The following table lists the main periodic inspections recommended for the product.

Table 11.1 Periodic inspections recommended for the ECW500

Component

Abnormality

Corrective Action

Terminals, connectors

Loose screws, loose connectors

Tighten

Printed circuit electric boards Build up of dust, humidity, oils, etc

Clean

Smell

Replace

Capacitors of DC link (intermediary circuit) Discoloration, smell, leak of electrolyte

Replace

Safety valve expanded or broken

Heatsink

Buildup of dust, other debris

Clean

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11.4 INSTRUCTIONS TO CLEAN THE PRODUCT

When you need to clean the ECW500, follow the instructions below: Ventilation Spaces

■ Turn off the ECW500 power supply and wait for 20 minutes.

■ Remove all dust buildup on the ventilation inlets using a plastic brush or a soft cloth.

■ Remove the dust buildup on the heatsink fins using compressed air.

Electronic boards

■ Turn off the ECW500 power supply and wait for 20 minutes.

■ Remove the dust buildup on the boards using an anti-static brush or ion compressed air gun (Example:

Charges Burtes Ion Gun (non-nuclear) reference A6030-6DESCO).

■ If necessary, remove the board from the ECW500.

■ Always use a grounding strap.

11.5 SOLVING THE MOST COMMOM PROBLEMS

ATTENTION!

Only trained and qualified staff must perform repairs and tests on the ECW500. If the instructions in this section are not enough to solve the problems, contact the technical assistance of WEG for additional information on how to proceed.

ECW500 seems not to be working

If the ECW500 seems not to be working and the HMI will not turn on, check that the electronics power supply is within the specifications. The ECW500 has two redundant power supply inputs (AC and DC). Refer to the specification table in chapter 12 Technical Specifications.

HMI frozen or with the message "Communication Lost"

Turn off the power supply of the ECW500 for about 30 seconds and turning it back on. If the problem occurs during the update of the software of the product, repeat the procedure and reset the parameters to return to factory default settings.

Voltage generator does not increase

Check the following configurations of the ECW500:

■ Rated voltage set.

■ The voltage reference in the MTVC mode.

■ Parameters indicating the voltage of the primary and secondary of the measurement transformers.

■ The voltage feedback connections of the product to the generator.

■ Check the configurations of the soft starter function. Adjust them, if necessary, according to the application.

■ Check the connections of excitation output (field) of the ECW500.

■ Temporarily disable the LEOC excitation limiter.

Low voltage on the generator in the MTVC mode

Check the following configurations of the ECW500:

■ The voltage reference of the MTVC mode.

■ Parameters indicating the voltage of the primary and secondary of the measurement transformers.

■ The voltage feedback connections of the product to the generator.

■ LEOC over excitation limiter (it must not to be active)

■ The operating mode selected must be MTVC.

■ The knee-point frequency of the LUF underfrequency limiter (it must be below the system frequency).

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High voltage on the generator in the MTVC mode

Check the following configurations of the ECW500:

■ The voltage reference of the mode MTVC.

■ Parameters indicating the voltage of the primary and secondary of the measurement transformers.

■ The voltage feedback connections of the product to the generator.

■ The operating mode selected must be MTVC.

Instability in the voltage control

If the voltage control presents instability, first check the control gains (Kp, Ki and Kd) for the operating mode used. If the gains adjustment in a satisfactory control, verify if the excitation transformers meet the recommended specifications in chapter 12 Technical Specifications.

Limiters and protections actuating

The limiters and protections of the ECW500 serve to protect both the synchronous machine and the equipment itself. If any of these conditions is indicated, make sure that the problem is solved. Also check that the configurations for each limiter and protections are correctly dimensioned for the relevant application.

Measures displayed on the HMI or via communication are very different from a known load

If the measures indicated by the ECW500 are significantly different from the expected measures for a known load, check that the measurement of the phase current is properly connected to phase B and not phases A and C. Also check that the polarity of the current transformer is correct. If the problem is only regarding the signal of reactive power, for example, invert the polarity of the current transformer. Also check the configurations of the primaries and secondary of the current transformers and voltage in the ECW500.

Communication faults

Check the configuration of the MODBUS-RTU communication and of the physical interface of communication. Check section 7 Modbus RTU Communication.

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Technical Specifications .

74 | ECW500

12 TECHNICAL SPECIFICATIONS

12.1 POWER DATA

POWER SUPPLY

ALTERNATE

VOLTAGE

■ Maximum 242 Vac three phase or single phase, line voltage.

■ Recommended: 1,73 x V

Exc_Rated

(excitation rated voltage)5.

■ Frequency from 30 Hz to 500 Hz.

DIRECT

VOLTAGE6

■ Up to 325 Vdc.

DRIVING

POWER

■ For three phase supply, 1,63 x output power.

■ For single phase supply, 1,94 x output power.

OUTPUT

CURRENT

■ Rated: 20 A @ 110 Vdc.

■ Maximum: 30 A @ 210 Vdc, during 1 minute.

■ Measurement range: from 0,5 A to 35 A.

■ Maximum error of measurement: ±5%

VOLTAGE

■ Maximum: 1,35 x VL (line voltage), for three phase supply.

■ Maximum: 0,90 x VL (line voltage), for single phase supply.

■ Commutation frequency: 2 kHz.

IMPEDANCE

FOR THE LOAD

■ Minimum resistance: 7 Ohms.

DISSIPATED

POWER

■ Maximum 2200 W.

ENVIRONMENTAL

CONDITIONS

TEMPERATURE

■ Operation: -40°C to 50°C (-40 to 122 F)

■ Storage: -40°C to 85°C (-40 to 185 F)

AIR RELATIVE

HUMIDITY

■ 10 to 90%, non condensing.

ALTITUDE

■ 0 to 1000m: rated conditions.

■ 1000 to 4000m: 1% current derating to each 100m above 1000m.

POLUTION

DEGREE

■ Degree 2, according EN50178 and UL508C.

MECHANICS

PROTECTION

DEGREE

■ IP20.

Example: for V

Exc_Rated

=32 Vdc, the excitation voltage must be at least 55 Vac. However, values much higher than that may worsen the

dynamic response.

The auxiliary DC input for excitation allows a machine without enough remanent voltage to be controlled when the power supply comes

from the machine terminals. The origin source must be galvanically isolated from the power supply.

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Technical Specifications.

ECW500 | 75

12.2 ELETRONICS / GENERAL DATA

POWER SUPPLY

SOURCE7

■ 85 to 242 Vac, single phase, 50/60 Hz or

■ 110 to 325 Vdc.

CONSUMPTION

■ Maximum 72 VA (alternate voltage) or 43 W (direct voltage).

CONTROL

REGULATORS

■ Execution rate: 4 ms.

PERFORMANCE

■ Regulation: ±0,25% in the MTVC mode, with the recommended excitation voltage.

■ Stability: ±0,1% in the MTVC mode, with constant load.

INPUTS

ANALOGS

■ 2 differential and isolated inputs, impedance 200k (voltage) or 249 (current), for

reference to all operating modes

- -10V to +10V, resolution 11 bits + signal and

- 4 to 20mA, resolution 12 bits, with identification of broken wire for current < 4mA

DIGITALS

■ 11 digitals isolated inputs, 24 Vdc, without polarity, fixed functions.

■ Maximum power to each input in high level: 420 mW.

VOLTAGE

FEEDBACK

■ Rated value: 115 or 600 Vac between lines, single phase (A-C) or three phase (A-B-C).

■ Maximum measurement: 161 or 667 Vac between lines.

■ Maximum error of measurement: ±1,0%.

■ Power consumption: 1 VA.

■ Frequency measurement: from 10 Hz to 150 Hz.

CURRENT

FEEDBACK

■ Rated value: 1 A or 5 A, 50/60 Hz, with separate terminals.

■ Max. measurement: 1,2 A (to the terminal of 1 A) and 6 A (to the terminal of 5 A).

■ Maximum error of measurement: ±2,5%.

■ Power consumption: 1 VA.

OUTPUTS

RELAYS

■ 6 relays with contacts NO/NC, 250 Vac, 8 A, fixed functions (2 relays) and

programmable (4 relays).

■ Maximum opening capacity:

- 35 Vdc: 8 A

- 48 Vdc: 1,2 A

- 125 Vdc: 0,3 A

■ Maximum commutation voltage: 400 Vac

ANALOG

■ Isolated output in voltage or current, 14 bits of resolution

- 0 to +10V, for voltage (impedance  10k)

- 4 to 20mA, for current (impedance  500)

SAFETY

PROTECTIONS

■ Machine undervoltage and overvoltage, with adjustable actuation levels.

■ Power phase loss.

■ Machine underfrequency.

■ Excitation ovevoltage (ajustable).

■ Overvoltage on DC link.

■ Power overtemperature (ajustable).

■ Excitation overcurrent (ajustable).

■ Excitation loss.

■ Feedback loss (ajustable).

■ Fault detection on the rotating diodes.

■ Fault detection on the CPU.

INTERFACES

HMI

■ It allows access and modification of all parameters.

■ Indication of warnigns, errors and events.

■ External assembly allowed, via serial cable up to 10m (see section 4.5.2).

USB

■ Only for firmware update.

RS 485 / 422

■ Full/Half Duplex, 9600 bps to 115200 bps, 8 bits, Modbus RTU.

ETHERNET

■ Full/Half Duplex, 10/100 Mbps, Modbus TCP.

ANYBUS

■ Passive modules (RS-485, RS-232)

■ Profibus

■ DeviceNet

■ Modbus TCP

■ Profinet IO

■ EtherNet/IP

■ CC-Link

The power supplies of the electronics are redundant and require an isolation transformer in the AC input if they have the same origin.

Page 84

WEG Drives & Controls Automação LTDA. Jaraguá do Sul - SC - Brazil Phone 55 (47) 3276-4000 - Fax 55 (47) 3276-4020 São Paulo - SP - Brazil Phone 55 (11) 5053-2300 - Fax 55 (11) 5052-4212 automacao@weg.net

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