Voltage-Dip Proofing Inverters

Transcription

1 Voltage-Dip Proofing Inverters For DPI 5 Series Models 0V & 08 / 0V 50/60Hz DIP-PROOFING TECHNOLOGIES INC. LEADERS IN VOLTAGE-DIP PROOFING

2 Contents: Introduction... Theory of operation... Specifications... 5 Up-time considerations... 7 Installation Guide... 8 Test and Maintenance... 0 Fault Diagnosis Chart... Accessories... Mechanical Construction... Dimension Table... Mechanical Outline... 5 Notice IMPORTANT SAFETY INSTRUCTIONS. SAVE THESE INSTRUCTIONS! This manual contains important instructions that should be followed duringinstallation and adjustment of all DPI5 series Voltage Dip-Proofing Inverters. Page

3 Introduction The reliability of electrical power to industry is in general very high, nevertheless, voltage sags and short power interruptions or voltage dips occur. These instabilities are caused by short circuits, lightning strikes on overhead power lines and heavy load switching. The duration of such faults is generally shorter than one second. Most plant can ride through such voltage dips by virtue of their mechanical and electrical inertia. However, this is not the case with electrically held-in contactors and relays that control the machinery. Contactors typically drop out from 5ms to 0ms after power is removed. Each short voltage dip now becomes a power failure and the plant must be restarted. This can be complicated, time-consuming and costly. DIP-PROOFING TECHNOLOGIES VOLTAGE- DIP PROOFING INVERTERS are designed to maintain the switchgear control voltage during voltage dips, effectively keeping the plant connected. The stored electrical and magnetic energy is allowed to flow, supporting the mechanical inertia of the machinery. When the power is restored after a short voltage dip, the plant is still running at near synchronous speed, the inrush currents will be small and the stress to the system minimal. Historically, this problem has been addressed by using DC contactors, latched contactors and intelligent controls such as PLC s. These systems are complex and expensive and do not provide a solution for equipment already in existence. The current approach to this problem has been to employ intelligent control systems which provide a curative solution. In contrast, the Voltage-Dip Proofing Inverter, provides a preventative solution. Theory of operation The VOLTAGE-DIP PROOFING INVERTER is designed to be maintenance free and highly reliable. It consists of a static switch in series with, and an inverter parallel to, the load. Energy is stored in a capacitor bank : the inverter block diagram is shown in Fig. Static Switch Inverter Supply Storage Capacitor Load Fig Inverter Block Diagram Page

4 The STATIC SWITCH is robust and can withstand large current surges. It is ideally suited for contactor operation where high peak currents of short duration occur during energizing. The INVERTER is configured as a full bridge with overcurrent and short circuit protection. The output waveform is a square wave where the RMS and the peak voltage are the same as for a sine wave as shown in Fig. V t Fig Inverter stepped square wave output waveform This is important for circuits where magnetic devices, such as transformers and contactors (RMS voltage) are in circuit with electronic relays that derive their DC voltage from capacitor input filters (peak voltage). The computer grade CAPITOR BANK operates under ideal conditions, being charged to working voltage but carrying no ripple current most of the time. During stand-by operation, the static switch supplies power directly to the load, the inverter is switched off and the capacitors are charged to the full operating voltage. The supply voltage is constantly monitored for deviations; should there be a deviation from Vnom which is greater than the preset value, the static switch is switched off and the inverter is activated. The switch-over is accomplished in less than 700µs. A. second timer, adjustable in increments of 00ms, starts timing the inverter out. Should the input voltage recover within the set time, the inverter supply is synchronized to the mains and the load is switched back to the supply, the capacitors are recharged in less than one second and the inverter is ready to compensate for the next voltage dip. If the input voltage does not recover within the set time the load is switched back to the supply regardless of the voltage level. Page

5 Specifications DPI 5 series 0V models 0V MODELS DPI5S5- INPUT SUPPLY Single phase supply voltage: Maximum input voltage: Full load current (A):.A STATIC SWITCH Nominal off-state voltage: Peak off-state voltage: Nominal current (A):.A Short time overload current (<00ms): Non-repetitive peak on-state current (0ms): INVERTER Nominal output voltage: Voltage fluctuations over full operating range: Nominal load current (A):.A Power factor range: Wave shape: Nominal inductive load (VA): 50 DPI5S50- DPI5S95J DPI5S90J DPI5LK5-8.A DPI5L8J.A 8.A 6A 6A.A DPI5L75J DPI5L7J DPI5LK DPI5L950J DPI5L88J 0V 50/60Hz +0%.A 8.A 6.7A 5A 50Vac RMS 800V 6.7A 5A 60A 80A 0Vac RMS -5% to +0% 6.7A cos from to 0 Stepped square Storage capacitors (F): Usable stored energy factor ( ): Minimum up-time as function of the load (t): Transistor peak current limit: Output frequency: HBC fuse rating : TIMER 6A 6A t = ( *C cap *V supply ) (I load *cos ) 50A 50/60Hz ±% A Range: Setting: 0. to.s 0.s steps Maximum recovery time of capacitors to,vin: <s <.5s <s <.5s <s <.5s <s <s <.7s <.s <.9s INDICATORS System OK: Inverter running: green LED red LED TEMPERATURE Maximum ambient working temperature: 5 C ( F) CUBICLE Construction: Extruded Aluminum Height (mm) (Dim. L on p): Height (in) (Dim. L on p): Width mm (in): Depth mm (in): 50 (5.90) 0 (.) (.) 6 (6.8) Mass (kg): Mass (lbs): CONNECTION Cable, Copper panel wire: Screw terminal torque: LISTINGS mm ( AWG) 5mm (0AWG).76 Nm (5.6 lb-in) Underwriters Laboratories Inc: UL Listed, Control # 7WJ / File # E0587 5A DPI5L66J DPI5L76J WARNING Risk of electric shock! Dangerously high voltages can be present up to hours after the DPI has been disconnected. NEVER attempt maintainance on the DPI during this period unless storage capacitors have been manually discharged. Page 5

6 Specifications DPI 5 series 08 / 0V models 08 / 0V MODELS DPI5S5- INPUT SUPPLY Single phase supply voltage: Maximum input voltage: Full load current (A):.A STATIC SWITCH Nominal off-state voltage: Peak off-state voltage: Nominal current (A):.A Short time overload current (<00ms): Non-repetitive peak on-state current (0ms): INVERTER Nominal output voltage: Voltage fluctuations over full operating range: Nominal load current (A):.A Power factor range: Wave shape: Nominal inductive load (VA): 50 DPI5S50- DPI5S08J DPI5S6J DPI5LK DPI5L96J DPI5LK5- DPI5L79J DPI5L587J 08 / 0Vac 50/60Hz +0%.A 8.7A.A 8.7A 6A 6A 50Vac RMS 800V 08 / 0Vac RMS -5% to +0%.A 8.7A cos from to 0 Stepped square Storage capacitors (F): Usable stored energy factor ( ): Minimum up-time as function of the load (t): Transistor peak current limit: Output frequency: HBC fuse rating : TIMER 6A 6A t = ( *C cap *V supply ) (I load *cos ) 50A 50/60Hz ±% A Range: Setting: 0. to.s 0.s steps Maximum recovery time of capacitors to,vin: <s <.s <s <s <.6s INDICATORS System OK: Inverter running: TEMPERATURE green LED red LED Maximum ambient working temperature: CUBICLE 5 C ( F) Construction: Extruded Aluminum Height (mm) (Dim. L on p): Height (in) (Dim. L on p): Width mm (in): Depth mm (in): 50 (5.80) 0 (.) (.) 6 (6.8) Mass (kg): Mass (lbs): CONNECTION Cable, Copper panel wire: Screw terminal torque: LISTINGS mm ( AWG) 5mm (0AWG).76Nm (5.6lb-in) Underwriters Laboratories Inc: UL Listed, Control # 7WJ / File # E0587 DPI5L8J 60A 80A 0A 0A 0A DPI5L7J DPI5L968J WARNING Risk of electric shock! Dangerously high voltages can be present up to hours after the DPI has been disconnected. NEVER attempt maintainance on the DPI during this period unless storage capacitors have been manually discharged. Page 6

7 Up-time considerations The up-time that a DPI can achieve is dependent on the usable energy in the storage capacitors and on the characteristics of the supported load. Load characteristics are critical in determining the up-time. Resistive loads with a power factor near consume real power and the up-time will be shortest. Resistive loads include lamps, switch mode power supplies and linear power supplies. Contactors use little real power as they are a reactive load with power factors around 0.5. Reactive loads such as contactors give the longest up-time. The formulae below can be used to determine the minimum up-time that can be achieved for an application. It uses the load current, load voltage, load power factor, the value of the DPI storage capacitors and an efficiency factor to calculate the value. Minimum up-time as function of the load: t = ( *C cap *V supply ) (I load *cos ) Minimum up-time = t Value of storage capacitor(s) = C cap Stored energy factor = Load voltage = V supply Load current = I load Load power factor = cos Φ From the formulae it can be seen that the power factor (cos Φ) has a significant influence on the up-time. Resistive loads with cos Φ = will yield the shortest up-time while reactive loads with cos Φ = 0.5 will yield the longest up-time. For example: A. Using DPI model DPI5S50- find the minimum up-time for a predominantly resistive load; say a PLC power supply and some small relays. Value of storage capacitor(s) = F Stored energy factor = 0.6 Load voltage = 0V Load current = 0.A Load power factor = 0.8 Minimum up-time t = (0.6*0.0008*0) (0.*0.8) =.5 seconds. B. Using DPI model DPI5S50- find the minimum up-time for a predominantly reactive load; say some small contactors and relays. Value of storage capacitor(s) = F Stored energy factor = 0.6 Load voltage = 0V Load current = 0.A Load power factor = 0.5 Minimum up-time t = (0.6*0.0008*0) (0.*0.5) = 6.69 seconds. The examples illustrate the importance of knowing the load power factor when calculating the minimum up-time for a DPI application. For best accuracy use the on line DPI Selector to find the correct size DPI for an application. Link: Page 7

8 Installation Guide. Remove the unit from its packing. Place the unit horizontally on a bench and visually check for any mechanical damage. Ensure that all the casing screws are tight then shake the unit to check that there is nothing loose internally. Note : Please inform your shipping agent if any damage has occurred during transit : the damaged unit(s) and all packing material should be kept in case the insurers wish to inspect the damage.. Check that the inverter voltage is the same as the system control voltage. Refer to the rating label on the unit end plate. WARNING: Never connect a 0V unit to a 0V supply!. Decide on the location where the unit is to be installed, this will probably be inside a switch gear panel. 5. Mount the unit vertically using M6 bolts. 6. Connect unit as shown in Fig using mm (AWG), DPI5 S series & 5mm (0AWG), DPI5 L series copper panel wire. 7. Apply terminal screw tightening torque of Nm ( lb-in), DPI5 S series &.5 -.8Nm ( - 6 lb-in) DPI5 L series. 8. This device does not have a disconnect switch. If such a switch is required it must be provided by others. Power Wiring Connect Line In (Supply) to Terminal Connect Common Line in to Terminal Connect Common Line out to Terminal Connect Line Out (Load) to Terminal Connect the ground screw(s) on the unit to the panel ground point. * * Ground in Line in (Supply) Common line in *Note: & linked internally. Fig Power Wiring Diagram Ground out Line out (Load) Common line out Page 8

9 9. Once the unit has been mounted and the external wiring completed, power can be applied.turn on the power to the unit. After about two seconds the green LED indicator "System OK" should come on. The unit is now fully operational. 0. In applications which require no break maintenance, a bypass switch must be installed. Order Housed Bypass Switch model DPIBPSW which should be con nected as shown in Fig. DIP-PROOFING TECHNOLOGIES INC. System Inverter OK Running Voltage Dip Proofing Inverter DPI Ground Ground To DPI or VDC in out Line in Common Line Line out Line in To Supply DPI Common Line in out Bypass Line out Housed Bypass Switch Line In (Supply Vnom) Common line in Line Out (Load) Common line out Functional Description Indicators Fig Housed Bypass Switch Connection Diagram System OK : Green LED indicator When the green LED is ON the system is fully functional; the unit self test & initialization routine has run successfully. Inverter Running : Red LED indicator The red LED is on when the inverter is running during a voltage dip. A stepped square wave is present on the output terminals &. Page 9

10 Test and Maintenance There are no user serviceable parts inside the unit, if faulty return to factory or local agent for repairs. WARNING: Risk of electric shock, capacitor(s) store hazardous energy. NEVER attempt any maintenance on the DPI until storage capacitors are fully discharged. Dangerously high voltages can be present up to hours after the DPI has been disconnected unless the storage capacitors have been manually discharged. Adjustments All adjustment points are marked on the control card and can be reached by removing the front cover of the DPI; see Mechanical Construction on page. Note that the Set Inverter Run Time switch (SW) is dual function. It is used to set the inverter run time and to program the inverter output voltage. INVERTER RUN TIME - SW (see Fig.5 page ) This switch sets the running time of the inverter and can be set in 00ms steps to a maximum of, seconds. To determine the inverter run time which is currently set, add the figures printed next to each switch which is in the ON position. For example, a running time setting of one second requires that the following switch es be in the ON position: : these figures added give 000ms or second. Factory Setting : 000ms INVERTER OUTPUT VOLTAGE - SW(see Fig.5 page ) The inverter output voltage can be reset to match a different supply voltage, for example a 0V unit used on a 08V supply. The Set Inverter Run Time switch (SW) is dual function and is used to program the inverter output voltage. With the unit energized switch all switches (SW- to 6) OFF. Set the switch (SW- to 5) equal or closest to the supply voltage ON. To program the inverter output voltage set Test min switch (SW-6) to ON. The System OK LED will begin to flash. Return the switch (SW - 6) to the OFF position, the System OK LED will remain on continuously. The inverter output voltage now equals the DPI supply voltage and programming is complete. Reset the Inverter Run Time switches (SW- to 5) to the required run time. Factory Setting : full load - Refer to Specification Sheet on page 5 & 6 TRANSFER LEVEL - SW (see Fig.5 page ) Sets the supply voltage level at which the inverter switches to run mode. The level can be varied between 55% and 90% of the nominal supply voltage by setting the switches according to the table in Fig.5. Factory setting : 75% Fuses The inverter fuse is mounted on the motherboard. 5 S series - Main Fuse Type SIBA : 6A 6xmm Ultra Rapid. 5 L series - Main Fuse Type SIBA : A x5mm UltraRapid. Alternate - Buss FPW-AF : A x5mm UltraRapid. Page 0

11 LED Green System OK Set Transfer Level Switch # Transfer Level (% of Vnom) % % % % %* % % 0 90% = ON Factory setting Fig 5 Control Card Indicator & Adjustment Locations **Note: To Activate "Test min" set all SW switches to the OFF position. LED Red Inverter Running Set Transfer Level ON ON 6 5 Set Inverter Run Time SW Default = 75% SW Test min. ** 600mS/0V 800mS/0V 00mS/08V 00mS/0V 00mS/0V Default = sec Fault Diagnosis Chart Symptom Probable Cause Remedy System OK LED is off, no voltage on output terminals. No supply voltage on input terminals ( & ). Short circuit on the output. Check supply. Disconnect the load from terminal. Switch off the supply voltage then switch it on again. If unit is not damaged the System OK indicator will come on. Check for short circuit on the load side. System OK LED is off, voltage on terminals & no voltage on &. System OK LED is off, voltage present on output terminals. Supply and load wires are reversed. Terminals &. A 0v unit is being used with a 0v supply. Swap supply & load wires. Connect supply to terminal & load to terminal. There is a possibility that the unit may be damaged by incorrect connection. Change unit to 0v model. Unit failure when supply switched on. A 0v unit is being used with a 0v supply. Change unit to 0v model. Note: The 0v unit will be damaged. Page

12 VDR Fault DR CTR Vss G E Static Switch Driver DPI5SS C/ C/ C/ C/ C/ EE C/5 C/ C/ J J J Q Q D F Ultra Fast A C6 C IC SH R R J Q5 BR5 BR SH C R D5 SH5 D L BR Q Q + - C 0V 0V 0V TR V V V SH 5 9 D D R R0 D6 6 BR SH BR 0V 0V 0V V 7V TR VDR SH6 C C5 R R Q+ Q- Q- Q+ QE QG QS QE QG Q Q R7 R6 Q Q VCC VDD 0 R9 R8 F/B R5 QG QE QS QG QE VSS TY R DR Base driver DPI5BD / /5 CN/ CN/5 CN/ CN/ / / / CN/ CN/9 CN/ CN/0 CN/7 CN/8 CN/ CN/ CN/ CN/ CN/5 CN/6 CN/ DPI5CC INV.RUN RELAY VDD VDD S/S O/L BRIDGE O/L Inverter Running Relay (option) Red 0V 0V VSS VSENS VSENS CTR SS 0V 0V CTRQ CTRQ CTRQ CTRQ VCC 0V CTR THYR 0V DC SENS Line in Blue Common line Yellow Line out DPI 5 Control Card + Storage Capacitor Bus - VSS 0V VCC Ground In Out 5 series Vss Fig6 Block Wiring Diagram Page

13 Accessories Housed Bypass Switch Description Where no-break maintenance is required a by pass switch must be installed. It connects the supply directly to the load, "Bypass" position, and disconnects the power terminals of the inverter without interrupting the supply. When in "DPI" position the load is connected to the supply via the inverter. Specifications MODEL BPSW5A ELECTRICAL Maximum current: 5A Maximum input voltage: 600Vac TEMPERATURE Maximum working temperature: 5 C ( F) HOUSING Construction: Extruded Aluminum Height: 0mm (7.95in) Width: 50mm (5.9in) Depth: mm (5.55in) Mass: kg (.lbs) Mechanical outline Note : Dimension units. Without brackets - mm. With brackets - inches. Note : Mounting holes x 6 (0.5)Ø. (.).0 (.6) Ground Screws To DPI or VDC in out Line in Common Line Line out DPI 50 (.97) 0 (.) Line in (Supply) To Supply Common Line in out Bypass Line out (Load) 50 (.97) 0 (.7) 0 (5.5).0 (.6) 50 (5.90) Ordering Stock No: Description Housed By-Pass Switch 5Amp Page

14 Mechanical Construction 5 S series - The DPI case is made from extruded aluminium sections. The four parts that make up the case are interlocked and secured by screws. To remove the front cover unscrew four screws : the two top screws from the end plate where the terminal block is located and the two bottom screws from the other end plate. Slide the front cover away from the terminal block to access adjustment area. 5 L series - The DPI case is made from extruded aluminium sections. The six parts that make up the case are interlocked and secured by screws. To remove the front cover unscrew three screws : one from the front cover and one each from the top and bottom end plates. Dimension Table Model DPI & VDC Dimensions mm (in) L L L L L5 L6 L7 D DPI5S5-50 (5.9) 0 (8.7) 59 (0.0) DPI5S50- DPI5S95J DPI5S90J 00 (7.87) 70 (0.6) 60 (0.) 0 (.99) 09 (.) 79 (.9) 0 (.) 50 (5.90) 0 (.8) 0 (5.50) 6.0 (0.) DPI5LK5- DPI5L8J 60 (6.0) 80 (.0) 9 (.95) DPI5L75J 86 (7.) 06 (.05) 55 (.98) DPI5L7J 50 (9.8) 70 (.57) 9 (6.50) DPI5LK 50 (9.8) 70 (.57) 9 (6.50) DPI5L950J DPI5L88J DPI5L66J 98 (7.80) 55 (.98) 58 (8.0) 595 (.) 507 (9.96) 6 (5.5) DPI5L76J 8 (6.6)* 096 (.5) 5 (5.08) 6 (6.8) (.) 60 (.6) 0 (5.) 96 (.65) 8.0 (0.) DPI5S5-50 (5.9) 0 (8.7) 59 (0.0) DPI5S50- DPI5S08J DPI5S6J 00 (7.87) 70 (0.6) 60 (0.) 0 (.99) 09 (.) 79 (.9) 0 (.) 50 (5.90) DPI5LK DPI5L96J 60 (6.0) 80 (.0) 9 (.95) DPI5LK5-50 (9.8) 70 (.57) 9 (6.50) DPI5L79J 6 (6.8) (.) DPI5L587J 86 (.6) 56 (.50) 595 (.) DPI5L8J 78 (8.8) 78 (9.06) 787 (0.98) DPI5L7J.5 (.09)* 95 (6.) 97 (8.5) DPI5L968J 8 (6.6)* 096 (.5) 5 (5.08) * Indicates 6 mounting holes see dimension L* 0 (.8) 60 (.6) 0 (5.) 0 (5.50) 96 (.65) 6.0 (0.) 8.0 (0.) Page

15 MODEL SERIAL # DATE MFG VOLTS POWER HZ Installation & Service Manual Mechanical Outline L7 L7 L6 Ø D L* L* "L" series case. Model # example DPI5LK or VDC LT5K0 L6 L L6 L L Ø D Terminal Cover "S" series case. Model # example DPI5S50- or VDC STK0 Ground Screws L L6 L L L L5 Terminal Cover Ground Screws VOLTAGE DIP-PROOFING INVERTER L5 L Note : Terminal cover shown dashed. Note : Terminal # - Line in (Supply) Terminal # - Common line in Terminal # - Common line out Terminal # - Line out (Load) Fig 7 Dimensions of the DPI 5 Series in mm & (in inches) Page 5

16 Voltage-Dip Proofing Inverters For DPI 5 Series Models 0V & 08 / 0V 50/60Hz Motor Control Centre Voltage-Dip Proofing Inverter B B B Static Switch Stop Stop Stop Bridge Inverter Storage Capacitor Start Start Start Main Breaker Bypass Switch Interlock Interlock Interlock Line Voltage Control Voltage C C C A typical DPI connection diagram DIP-PROOFING TECHNOLOGIES INC. LEADERS IN VOLTAGE-DIP PROOFING Measurlogic Inc. 05 S Progress Way Unit, Parker, CO 80, USA Tel: Fax: info@measurlogic.com web: Doc Ref Rev.0 May 9 th 006 : LPW