Synchronizing / Bypass option

Synchronizing / Bypass option
Synchronizing / Bypass option
for Emotron VFX2.0, FDU2.0 AC drives
Emotron FDUL/VFXR/AFR low harmonic/regenerative drives
Instruction manual
English
Emotron Sync/Bypass option
for Emotron VFX2.0, FDU2.0 AC drives
valid from software version 4.32-011-01
Emotron FDUL/VFXR/AFR low harmonic/regenerative drives
valid from software version 4.33-097-05
Instruction manual — English
Document number: 01-5828-01
Edition: r1
Date of release: 27-08-2016
© Copyright CG Drives & Automation Sweden AB 2015 - 2016
CG Drives & Automation retains the right to change
specifications and illustrations in the text, without prior
notification. The contents of this document may not be copied
without the explicit permission of CG Drives & Automation
Sweden AB.
H
Safety
Instruction manual
Read this instruction manual first!
This option is a supplementary part of the
Emotron VFX/FDU AC drives and
Emotron FDUL/VFXR/AFR low harmonic/regenerative drives
hereinafter in this manual referred to as the “main product” and the user must
be acquainted with the original instruction manual of the main product. All
safety instructions, warnings, etc. as mentioned in this instruction manual must
be known to the user.
Safety instructions
Read the safety instructions in the instruction manual for the main product.
Installation
Installation, commissioning, dismounting, making measurements, etc. on the
main product may only be carried out by personnel who are technically qualified for the task. Installation must also be carried out in accordance with the
local standards. Ensure that all necessary safety measures are taken.
WARNING!
Take all necessary safety precautions during installation and
commissioning to prevent personal injuries, e.g. by an
uncontrolled load.
Opening the main product
WARNING!
Always switch off the mains supply before opening the main
product.
For AC drives, wait at least 7 minutes to allow the buffer
capacitors to discharge.
Always take adequate precautions before opening the main product, even
though the connections for the control signals and jumpers are isolated from the
mains voltage.
CG Drives & Automation, 01-5828-01r1
CG Drives & Automation, 01-5828-01r1
Contents
1.
Introduction ................................................................................ 3
1.1
Description .................................................................................................. 4
2.
Installation.................................................................................. 5
3.
Connections................................................................................ 7
3.1
3.2
3.3
Connecting the Sync/Bypass option ......................................................... 7
Terminals..................................................................................................... 9
Connections and wiring........................................................................... 10
4.
Configuration ............................................................................ 13
4.1
4.2
4.3
Menus and switches required to be set in Main product ..................... 13
Emotron VFX/FDU 2.0 AC drives ............................................................ 14
Emotron VFXR/FDUL/AFR drives............................................................ 16
5.
Functional description ............................................................. 17
5.1
Using Sync/Bypass option with Emotron VFX/FDU 2.0 AC drives........ 17
6.
Specifications ........................................................................... 19
CG Drives & Automation 01-5828-01r1
1
2
CG Drives & Automation 01-5828-01r1
1.
Introduction
The Sync/Bypass option is used with the main product to monitor/measure the
grid voltage. The output is in cartesian rectangular components, which can be
used internally by the drive to compute grid voltage, frequency and supply
phase sequence.
Emotron VFX2.0 and FDU2.0 Emotron FDUL/VFXR/AFR
can use this option for synchronizing
the inverter output to the actual grid
voltage and frequency.
This is a kind of option that can be
useful when the same drive is used for
ramping up the several motors. For
example ramping up the pumps to
the grid speed.
NOTE: The Sync/Bypass option has
to be ordered together with the
Emotron VFX/FDU AC drive, as it
needs special AC drive control board
together with special software.
can use this option along with the low
harmonic/regenerative drive i.e.
Emotron FDUL/VFXR/AFR.
It serves as a grid monitor and supply
the required information for
synchronizing the drive unit to the
grid. Using this option Emotron
VFXR/FDUL can be started even if
the VSI is already loaded. Also this
option is required if user want LVO
feature in Emotron VFXR/FDUL/
AFR.
NOTE: This instruction manual is valid for both Emotron FDU/VFX AC drives
and Emotron FDUL/VFXR/AFR harmonic/regenerative drives.
Common information is written once for both.
Instructions that differ are written separately for each product.
CG Drives & Automation 01-5828-01r1
Introduction
3
1.1
Description
This instruction manual describes the installation and use of the Sync/Bypass
option.
Delivery and unpacking
Check the delivery. The shipment should contain:
•
Sync/Bypass unit
•
Cable clamp for connection of control cable shield.
•
This manual
Check for visible signs of damage. Do not install if damage is found. If damage
is found or something is missing from the package, please contact your supplier.
4
Introduction
CG Drives & Automation 01-5828-01r1
2.
Installation
This chapter describes how to mount the option.
The option kit includes
•
Sync/Bypass unit
•
Cable clamp for connection of control cable shield.
•
This instruction manual
Fig. 1
Sync option unit and clamp for shield connection.
Make sure that the AC drive has been switched off for at least seven minutes to
ensure that the capacitor bank is discharged before continuing with installation!
Also make sure that no external equipment connected to the drive’s interface is
powered on.
•
Mount the Sync/Bypass option on a DIN-rail close to the main product.
CG Drives & Automation, 01-5828-01r1
Installation
5
Shielding
Connect the shield of control cable to the earthing clamp in the main product
close to the control board.
Connect the other side of the shield with the clamp (included in delivery) close
to the option unit, see Fig. 2.
Shield connection
Fig. 2
6
Shield connection close to he option unit.
Installation
CG Drives & Automation, 01-5828-01r1
3.
Connections
This chapter describes how to connect the Sync/Bypass option.
3.1
Connecting the Sync/Bypass option
Connection to Emotron VFX and FDU AC drives
The total system (according to Fig. 3) consists of:
•
Emotron VFX/FDU with special software (4.3X - 011 - 0X) and modified
Control board.
•
Sync/Bypass option board.
•
Standard output choke (not included in delivery)
•
Bypass switch (not included in delivery)
Wiring for Sync option is shown in Fig. 6, page 10
DigIn Run
DigIn option
Sync/Bypass
option
VFX
Output choke
Relay option
M
W,T
Bypass
Fig. 3
Emotron FDU and VFX with Sync/Bypass option.
CG Drives & Automation 01-5828-01r1
Connections
7
Connection to Emotron VFXR/FDUL/AFE/AFR
The total system (according to Fig. 4)consists of:
•
Emotron VFXR/FDUL/AFE/AFR with software 4.33-097-05 or later
•
Sync/Bypass option serving as Supply voltage measurement unit
Wiring for Sync option is shown in Fig. 6, page 10
Sync/Bypass
option
CB
Fig. 4
8
SBS
CB
Emotron FDUL/VFXR/AFR drive system with Sync/Bypass option.
Connections
CG Drives & Automation 01-5828-01r1
3.2
Terminals
Sync/Bypass
supply terminals
Sync/Bypass
output signal terminals
Mains supply voltage
(Supply to be monitored)
Fig. 5
Sync/Bypass option terminals.
Table 1
Terminal
List of terminals and connections.
Name
Function
Cable dimension
Terminals 1 - 8 for connections to 24 VDC,
ground and measured analogue signals
1
ux
Connect to AnIn3
2
uy
Connect to AnIn4
3
GND
4
φx
Not used
5
φy
Not used
6
Connect to Ground
0.5 mm2
Use screened cables
Not used
7
+24 V
8
0V
Connect to 24 VDC supply
Connect to Ground
Terminals 9, 11 and 13 connect mains supply to be monitored
9
L1
11
L2
13
L3
Three phase supply,
380 - 690 V, 50 - 60 Hz
Install fuses of Max 1 A.
CG Drives & Automation 01-5828-01r1
1 mm2
Connections
9
3.3
Connections and wiring
AnIn 4
X1:5
24 V
supply
X1:11
AnIn 3
X1:4
Ground
X1:7 or
X1:12
Fuses max 1 A
Three phase supply
Fig. 6
10
Sync/Bypass option board connection and wiring.
Connections
CG Drives & Automation 01-5828-01r1
3.3.1 Sync/Bypass input supply voltage
The Sync/Bypass option requires +24 VDC supply for its normal operation.
Sync/Bypass option uses operational amplifiers for measuring the voltage, therefore it is important to have +24 VDC supply input, otherwise the Sync/Bypass
option can lead up to a wrong measurement.
Table 2
Input supply terminals
Connection terminal
Sync/bypass
option
terminals
Description
Control board
terminals
7: +24 V
X1:11
+24 VDC supply.
Control board of the main product can be
used to supply +24 VDC to the Sync/Bypass
option from X1:11 on the control board. For
detailed information consult the instruction
manual of the main product.
3:GND or
8:0 V
X1:7 or
X1:12
It is important for Sync/Bypass option to
have proper reference signal. It can be
obtained from Control board of the main
product, terminals X1:7 or X1:12.
Input measuring signals
The voltage to be measured must be connected to L1, L2, L3 terminals. Sync/
Bypass option measures three phase input supply up to 690V.
It is important to connect the three phases on the Sync/Bypass option in the
same sequence as on the drive unit.
CG Drives & Automation 01-5828-01r1
Connections
11
3.3.2 Outputs
Sync bypass option measures supply voltage and give two analogue outputs as a
measurement i.e Ux and Uy.
Drive controller uses Ux and Uy for computing the grid supply voltage amplitude, frequency and phase sequence.
Output terminals
Table 3
Output terminals
Connection
terminal
Description
Ux
1
Ux must be connected to analogue input 3 on the Control board
Uy
2
Uy must be connected to analogue input 4 on the Control board
12
Connections
CG Drives & Automation 01-5828-01r1
4.
Configuration
This chapter describes how to set parameters on main product (VFX/FDU/
FDUL/VFXR/AFR)and how to use the Sync/Bypass option.
4.1
Menus and switches required to be set in
Main product
Menus/switches described in this section are same in both VFX/FDU and
VFXR/FDUL/AFR. These menus/switches needs to be set during commissioning of the product..
Table 4
Required setting with Sync/Bypass option.
Menu
Default
Required Setting
518
AnIn 3 setup
4 - 20 mA
User Bipolar V
51B
AnIn 4 setup
4 - 20 mA
User Bipolar V
NOTE: To be able to use AnIn3 and AnIn4 for voltage measurement, Set the
Switches S3 and S4 to U (Volt) position for AnIn 3 and AnIn 4.
Table 5
Switch settings for S3 and S4
Input
Signal type
Voltage
AnIn3
Current (default)
Voltage
AnIn4
Current (default)
CG Drives & Automation 01-5828-01r1
Switch
S3
I
U
S3
I
U
S4
I
U
S4
I
U
Configuration
13
4.2
Emotron VFX/FDU 2.0 AC drives
Following option menus/parameters are available for user settings when using
Sync/Bypass option with Emotron FDU/VFX AC drives.
These menu parameters are not valid for Emotron AFR/FDUL/AFR.
Table 6
Menus for Sync/Bypass option in Emotron VFX/FDU 2.0 AC drives
Menu
Default
value
Range/
Setting
Description
Modbus
number
O00 Sync option
O10 Sync pars
O11 Sync Enable Off
O12 Sync Time
1s
O13 Sync _Curr % 50 %
O14 Sync Curr A
14
Configuration
Inv Imax
Off
Off - Syncing disabled
External Ext - Syncing from outside
Internal Int - Syncing controller by
Control board
Maximum time for bypass
switch detection, i.e. parallel
operation
0 - 32 s
Note: Should be setup to
maximum closing time of
bypass switch.
Bypass switch detection level
based on margin on actual
motor current.
0Detection to a fast current
200 %
increase compared to mean
measured current level in %
above the mean value.
Bypass switch detection level
based om motor current.
Note: Should be set higher
0than maximum motor cur3000 A
rent and should not be more
than inverters maximum
current.
48001
48002
48003
48004
CG Drives & Automation 01-5828-01r1
Table 6
Menus for Sync/Bypass option in Emotron VFX/FDU 2.0 AC drives
Menu
Default
value
Range/
Setting
O15 Sync _Volt % 20 %
0200 %
O16 Sync Volt V
03000 V
Inv Umax
O20 Sync Status
O21 Status
0000
Description
Bypass switch detection level
based on actual DC-link voltage. Detection to a fast DClink change compared to
mean measured DC-link voltage level in % above the
mean value.
Bypass switch detection level
based on actual DC-link voltage.
Note: Should not be more
than inverter maximum voltage.
Tells the state of the inverter.
Syncing process, status
register:
- - - X = State
- - x - = Syncing flag
- x - - = Bypass detect flag
See further in Table 7 below.
Modbus
number
48005
48006
48011
Explanation of menu O21 status:
Table 7
Menu O21 status explanation
State
“- - - X”
0=Stopped
1=Normal Run
2=Syncing
3=Bypassing
4=Bypassed
Syncing flag
“- - X -”
Bypass detect flag
”- X - -”:
1 = Syncing active, trying to sync to
supply frequency
3 = Frequency synced, trying to sync
to supply amplitude
7 = Frequency and amplitude synced,
trying to sync to supply angle
F = Synced
1 = Timeout (depends
on setting in [O12])
2 = Sync on current
4 = Sync on voltage
8 = Error
CG Drives & Automation 01-5828-01r1
Configuration
15
Added selections in standard menus
Table 8
Added selections in standard menus.
Menu
Selection
52#
Digin #
56#
VIO # Dest
54#
Dig Out #
55#
Relay #
56#
VIO # Source
4.3
...
32: Option
...
...
90: Option
...
Comment
Synchronization command
Bypass switch command
Emotron VFXR/FDUL/AFR drives
Following option menu/parameter is available for user settings when using
Sync/Bypass option with Emotron VFXR/FDUL/AFR drives.
Table 9
Parameter valid for Emotron VFXR/FDUL/AFR drives.
Menu
Default
value
Setting
517
51A
AnIn3 Fc
AnIn4 Fc
OFF
OFF
Ux
Uy
O17
Volt sensor
OFF
ON
Description
Measures x component of voltage
Measures y component of voltage
Activate supply voltage
measurement
Note: selection Ux and Uy only appear if [O17] is set to ''ON''.
16
Configuration
CG Drives & Automation 01-5828-01r1
5.
Functional description
5.1
Using Sync/Bypass option with Emotron
VFX/FDU 2.0 AC drives
Normal running
The AC drive is running normally with reference value from i.e. setup source.
Syncing
AC drive synchronize to supply in three steps:
1. Ramp drive speed/frequency to supply speed/frequency.
2. Synchronizing drive speed/frequency and amplitude to supply frequency
and amplitude.
3. Synchronizing drive phase angle to supply phase angle.
Bypassing
The AC drive tries to detect actual closing of the Bypass switch. After detection
the bypass state is entered.
The detection of closed bypass switch is triggered either from:
1. Time-out according to set time in menu [O12].
2. Current peak detected according to menus [O13] and [O14].
3. DC voltage increase, detected according to menus [O15] and [O16].
Status menu [O21] shows the current state of sync/bypass option software i.e.
OPT11. It also shows on which condition the bypass switch has been operated.
NOTE: If menu “Sync time [O12]” = 0 s, the AC drive will be stopped when
bypass switch is commanded.
NOTE: If menu “Sync time [O12]” = 32 s, time-out is disabled, i.e. AC drive
runs until current or DC Voltage detection. This is useful during
commissioning to verify actual phase sequence if bypass switch operation
is prohibited.
CG Drives & Automation 01-5828-01r1
Functional description
17
Fig. 7 below explains how the current peak detection level is generated from
menus [O13] and [O14] depending on the actual motor current.
Bypass detection
Motor current
Fig. 7
Detection of bypass current as function of actual motor current.
NOTE: that the digital output function “Option” is in high state. This output
should be used to activate the bypass switch.
Bypassed
The AC drive operation is blocked or not active.
NOTE: that if the AC drives run command is removed, the inverter will turn to
Stopped state and thereby the digital output function “Option” will turn low.
If this is the case, external hold circuits for the bypass switch will be
needed.
18
Functional description
CG Drives & Automation 01-5828-01r1
6.
Specifications
Table 10
Technical specifications.
35mm
(1.38)’‘
90mm(3.54) ’‘
45x90x115 mm (1.77" x 3.54" x 4.53")
26mm
(1.02)’‘
Dimensions (WxHxD)
45mm (1.77’‘)
115mm(4.53) ’‘
Mounting
35 mm DIN rail 46277
Weight
0.12 kg (4.2 oz)
Mains voltage
3 x 380-690 VAC
Max Ripple (notch): 3% of mains voltage.
Max mains supply distortion: 2% to 3%.
Note: Supply distortion means the deviation of mains
voltage, frequency from RMS/average value.
Max dU/dt: 350 V/ms
Mains Frequency
45 to 65 Hz
Mains current (RMS)
20 mA (RMS) at 400V
30 mA (RMS) at 690 V
Input DC voltage
24 VDC + 10 %
Input DC-current
50 mA
Output supply
Ux and Uy (RMS)
2.286 at 400 V
3.94 at 690 V
Output current
< 1 mA
Terminal wire size
Terminal 9, 11, 13; Main supply wire - 1 mm2
Terminal 1 - 8; Control signal wire - 0.5 mm2
Main supply Fuse
Install max 1 A fuses on Main supply.
Operating temperature
-20 to +50°C
Protection class
IP20
CG Drives & Automation 01-5828-01r1
Specifications
19
20
Specifications
CG Drives & Automation 01-5828-01r1
Mörsaregatan 12
Box 222 25
SE-250 24 Helsingborg
Sweden
T +46 42 16 99 00
F +46 42 16 99 49
www.cgglobal.com / www.emotron.com
CG Drives & Automation, 01-5828-01r1, 2016-08-27
CG Drives & Automation Sweden AB
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