Caltest CINERGIA User manual

DC Programmable Power Supply
(DCPS)
Installation and operation manual
Tel: [phone]
Fax: [phone]
www.caltest.de
Kohlmattstrasse 7
D-77876 KAPPELRODECK
[email protected]
Caltest Instruments GmbH

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INDEX
1. INTRODUCTION ..................................................................................................................... 5
1.1. Symbols used................................................................................................................. 5
1.2. Safety notes................................................................................................................... 5
1.3. Quality and regulations ................................................................................................. 5
2. PRESENTATION...................................................................................................................... 7
2.1. Introduction .................................................................................................................. 7
2.2. Power supply features................................................................................................... 8
2.3. Operation and connection modes ................................................................................ 9
2.4. Limits ............................................................................................................................. 9
2.5. Configuration and control of the power supply.......................................................... 10
2.6. Functional diagram...................................................................................................... 10
2.7. Principle of operation.................................................................................................. 11
3. INSTALLATION ..................................................................................................................... 13
3.1. Important safety instructions...................................................................................... 13
3.2. Equipment views ......................................................................................................... 13
3.3. Equipment reception................................................................................................... 16
3.3.1. Unpacking and checking the content.................................................................. 16
3.3.2. Storage ................................................................................................................ 16
3.3.3. Transport to location........................................................................................... 16
3.3.4. Location............................................................................................................... 17
3.4. Connection .................................................................................................................. 19
3.4.1. Earth protection .................................................................................................. 19
3.4.2. Input connection, terminals (X1 to X5) ............................................................... 19
3.4.3. Output connection, terminals (X6 to X10) .......................................................... 19
3.4.4. Emergency Power Off terminals (X12)................................................................ 19
3.4.5. Communications ................................................................................................. 20
3.4.6. Digital inputs and outputs ................................................................................... 20
3.4.7. Analog inputs and outputs .................................................................................. 21
4. OPERATION ......................................................................................................................... 22
4.1. Safety........................................................................................................................... 22
4.2. State Machine ............................................................................................................. 22
4.2.1. Initialization......................................................................................................... 23
4.2.2. Standby................................................................................................................ 23

4.2.3. Precharge ............................................................................................................ 23
4.2.4. Ready................................................................................................................... 23
4.2.5. Run ...................................................................................................................... 23
4.2.6. Alarm ................................................................................................................... 24
4.3. Operation modes ........................................................................................................ 24
4.3.1. Current mode ...................................................................................................... 24
4.3.2. Voltage mode ...................................................................................................... 25
4.3.3. Power mode ........................................................................................................ 26
4.3.4. Programmable limits ........................................................................................... 27
4.4. Connection modes ...................................................................................................... 27
4.5. Working with the equipment...................................................................................... 28
4.5.1. Start-up................................................................................................................ 29
4.5.2. Stop ..................................................................................................................... 30
4.5.2.1. Full stop ........................................................................................................... 30
4.5.2.2. Standby stop.................................................................................................... 30
4.5.2.3. Ready............................................................................................................... 30
4.5.3. Emergency stop................................................................................................... 31
4.5.4. Accidental shut down.......................................................................................... 31
4.5.5. Alarms.................................................................................................................. 31
4.5.6. Alarms reset ........................................................................................................ 33
5. LOCAL TOUCHSCREEN CONTROL PANEL ............................................................................. 34
5.1. Basic functions............................................................................................................. 34
5.2. Menus and submenus ................................................................................................. 34
5.2.1. General ................................................................................................................ 34
5.2.2. Operational ......................................................................................................... 35
5.2.3. Configuration....................................................................................................... 38
5.2.4. Alarms.................................................................................................................. 40
6. REMOTE COMMUNICATIONS.............................................................................................. 41
6.1. IQ MANAGEMENT ....................................................................................................... 49
7. HUMAN MACHINE INTERFACE............................................................................................ 51
7.1. Operation tab .............................................................................................................. 51
7.2. Supervision tab............................................................................................................ 52
7.3. Alarm tab..................................................................................................................... 53
7.4. I, V, P configuration tab............................................................................................... 53

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8. WARRANTY AND MAINTENANCE ........................................................................................ 54
8.1. Replacing the output fuses.......................................................................................... 54
8.2. Fans ............................................................................................................................. 54
8.3. DC bus capacitors........................................................................................................ 54
8.4. Warranty ..................................................................................................................... 54
8.5. Claim procedure.......................................................................................................... 55

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1. INTRODUCTION
Dear customer, on behalf of CINERGIA team, thank you for the confidence placed in our
company and for the purchase of this product. Please, read carefully this manual before using
the equipment to get familiarized with it to obtain the maximum performance from it.
This document is intended for appropriately qualified personnel. Only personnel with the
appropriate skills are allowed to perform the electrical connection and commissioning of the
equipment.
The information in this documentation is not binding. CINERGIA reserves the right to make
changes in part on in the whole at any time and without prior notice due to technical advance
or product improvement.
1.1. Symbols used
DANGER: Indicates a hazardous situation which can result in death or serious
injury and can cause important damage or destruction of the equipment or the
property
WARNING: Indicates important information that must be taken into account to
operate the equipment. Take the appropriate prevention measures.
INFORMATION: Information that is important but is not safety-relevant
1.2. Safety notes
Improper use of this equipment can cause both important personal injury and physical damage
to the electrical power grid and the loads connected to it. Read this document carefully and
follow all safety precautions at all times.
1.3. Quality and regulations
The equipment is based on a hardware designed, manufactured and commercialized in
accordance with the standard EN ISO 9001 of Quality Management Systems. The marking
shows the conformity to the EEC Directive by means of application of the following standards
• 2006/95/EC Low voltage directive.
• 2004/108/EC Electromagnetic Compatibility directive (EMC)
In accordance with the specifications of the harmonized standards:

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• EN-IEC 62040-1. Uninterruptible power supply (UPS). Part 1-1: General and safety
requirements for UPS’s used in accessible areas by end users.
• EN-IEC 60950-1. IT equipments. Safety. Part 1: General requirements.
• EN-IEC 62040-2. Uninterruptible power supply (UPS). Part 2: Prescriptions for
Electromagnetic compatibility (EMC).
• EN-IEC 62040-3. Uninterruptible power supply (UPS). Part 3: Methods of operation
specification and test requirements.
The manufacturer responsibility is excluded in the event of any modification or intervention in
the product by the customer’s side.

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2. PRESENTATION
2.1. Introduction
The DCPS is a DC Programmable Power Supply, a power electronics equipment with the
following main functionalities:
-It converts the AC input, of the main grid, in a controlled DC output by using an IGBT-
based switching topology and DSP-based state-of-the-art digital control.
-It can be operated as:
oConstant voltage output
oConstant current output
oConstant power output
-It is a bidirectional power source: energy can flow from the grid to the load or
viceversa (it allows saving energy during the working period by returning the energy
to the mains)
-The AC current consumed from the grid is sinusoidal (THD < 2%)
-The user can define the reactive power to be injected by the power supply and also
choose between capacitive or inductive
The power range covered by the DCPS power supplies goes from 6.75 to 160kW at the output.
The parallelization of power supplies is possible to increase output power.
Reference
Rated Power
(Load side)
Rated Current
(Load side)
Rated Voltage
(Load side)
Dimensions
(mm)
kW
DC
(per channel)
DC
(total)
DC
DxWxH
DCPS7.5
6.75
10A
30A
0-750V
700x450x1100
DCPS10
9
15A
45A
0-750V
700x450x1100
DCPS15
13.5
20A
60A
0-750V
700x450x1100
DCPS20
18
25A
75A
0-750V
700x450x1100
DCPS30
27
40A
120A
0-750V
805x590x1320
DCPS40
36
50A
150A
0-750V
805x590x1320
DCPS50
45
65A
195A
0-750V
805x590x1320
DCPS60
54
80A
240A
0-750V
805x590x1320
DCPS80
72
105A
315A
0-750V
805x590x1320
DCPS100
90
130A
390A
0-750V
805x590x1320
DCPS120
108
155A
465A
0-750V
805x590x1320
DCPS160
128
185A
555A
0-750V
850x900x2000
DCPS200
160
230A
690A
0-750V
850x900x2000

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2.2. Power supply features
Magnitude
Value
Power
6.75kW-160kW
Input
AC Voltage
Rated
RA
3x400V+Neutral+Earth
Voltage range
+15% / -20 %
AC Current
2Arms -290Arms
Frequency
50/60Hz
Power Factor
Controllable
-1/1 (capacitive/inductive)
Efficiency
at full load
>92%
Overload
125% for 10 min / 150% for 60 s
DC Outputs
DC Current
3 independent channels
0-230A (per channel)
DC Current
1 parallelized channel
0-690A
DC Voltage
0-750V
Minimum voltage
at rated power
220V
Modes of operation
Range
Resolution
Ripple
Constant Current (CC)
0-100%
<±0.1%
<1%
Constant Voltage (CV)
0-100%
<±0.1%
<1%
Constant Power (CP)
0-100%
<±0.1%
<1%
Response time
In all operation modes
<2ms Rise/Fall time 10%-90%
GENERAL
Measurements
Input Voltage (Vrms) and Current (Irms)
Active and Reactive Input Power (P,Q)
Output Voltages (Vdc) and Currents (Idc)
Output Power
Temperatures
User interface
3.2” Touchscreen
Control port: 3 analog inputs, 3 analog outputs, 5 digital inputs, 3 relay
outputs
Communication Protocols: Modbus/TCP
Communication Ports: Ethernet, RS485 (optional)
Customized communications for IEC61850, ERP or MATLAB® (optional)
Humidity
10-90% (Absolute maximum, without condensation)
Temperature
5-40°C (Absolute maximum)
Refrigeration
Forced air
Protections
Over Current, Over
Voltage
Shortcircuit
Over Temperature
Galvanic Isolation (optional)
Standards
Safety
EN-62040-1-2, EN-60950-1
EMC
EMC: EN-62040-2
Please note that items marked as optional shall be requested specifically at additional cost.

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2.3. Operation and connection modes
The output of the power supply is formed by three channels referenced to a common negative
channel. The power supply can be used in two different connection modes:
-Independent channel: each channel (U,V,W) is controlled independently. The setpoint
and also the operation mode can be different for each channel.
-Parallel channels: the three channels are controlled by the control software as a
unique channel to multiply the output current by 3. The setpoint and the operation
mode are the same for all three channels. It is mandatory to shortcircuit by hardware
the three output channels. All operation modes are available in this connection mode.
However, three operation modes are allowed:
-Constant Voltage (CV): the output voltage is controlled to the setpoint value.
-Constant Current (CC): the output current is controlled to the setpoint value.
-Constant Power (CP): the output power is controlled to the setpoint value.
2.4. Limits
The DCPS output limits are defined by:
-Maximum voltage: 750V
-Maximum current: defined in the datasheet as Rated Current DC (per channel) or
Rated Current DC (total)
-Maximum power: defined in the datasheet as Rated Power (kW)
For example, below the limits of a DCPS160 power supply (with 750 V as maximum voltage)
are shown:
0
100
200
300
400
500
600
700
800
0
25 50 75
100 125 150 170 195 220 245 270 295 320 345 370 395 420 445 470 495 520 545 555
Output voltage (V)
Output current, 3ch (A)

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2.5. Configuration and control of the power supply
The power supply can be interfaced by three means:
-Local touchscreen: a 3.2” colour local touchscreen panel can be used to configure,
monitor and operate the power supply. See section Local Touchscreen Control Panel
for further information.
-Analog and digital inputs / outputs: the power supply owns:
o5 optocoupled digital inputs
o3 relay outputs
o3 isolated analog inputs
o3 isolated analog outputs
-Remote interface: an Ethernet communication interface with protocol MODBUS/TCP
can be used to configure, monitor and operate the power supply. By using HMI
software application provided by CINERGIA, downloading of excel files is also possible.
2.6. Functional diagram
The diagram below is the conceptual functions blocks diagram of the power supply:
AC
ACTIVE RECTIFIER
GRID
DC DC
DC
LOAD
DC/DC
Input L CL
filter
Input EMI
filter
Protections Protections
Output EMI
filter
Output LCL
filter
OPTIONAL
DC PROGAMMABLE POWER SUPPLY
The main components of the diagram are the following (from grid side to load side):
-Isolation transformer: a 50/60Hz isolation transformer can be provided optionally in
order to isolate the output channels. In this case, an isolation monitor can be
integrated in the power supply to detect isolation faults too. This isolation transformer
is mandatory if the power supply is to be used as a 4 quadrants equipment (by
connecting the load between two output channels).
-Input protections: these protections include a thermal-magnetic circuit breaker and
fuses. The connection of the power supply input with the grid is done by screw
terminals. Please follow safety instructions in Installation section to connect the DCPS.
-Input EMI filter: an electromagnetic filter is integrated to fulfil electromagnetic
compatibility regulations. The structure of the filter in question is the same as the one
of the output EMI filter.
-Input LCL filter: the purpose of this filter is to reduce the current distortion at
frequencies equal to or higher than switching frequency and thus reduce THD.
-Active Rectifier: a three-branch IGBT active front end is integrated in the equipment to
consume/inject a sinusoidal current from/to the grid.
The DC link voltage is set to 430V providing a regulation margin for fast transients at
the output of the DCPS.

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The active rectifier has bidirectional power flow capability and the injected reactive
power (grid side) can be defined by the customer.
-DC/DC output converter: a three-branch IGBT converter allows three buck-boost DC-
DC conversions from the DC bus to each of the output channels. Each channel can be
controlled independently or, by software, the three channels will share the same
operation mode and setpoints.
-Output LCL filter: this filter reduces voltage distortion (caused by switching) at the
output of the power supply.
-Output EMI filter: a high frequency common mode LC filter is used to reduce
electromagnetic disturbances at the output of the DCPS.
-Output protections: the DC outputs are protected by fuses. A disconnector is provided
to isolate the output from the load. Screw terminals are also integrated to connect the
load. Please, follow safety instructions in Installation section to connect the power
supply.
2.7. Principle of operation
Below, a technical diagram of the power supply is shown:
Drivers x6 Drivers x6
Current
sensor x3
Voltage
sensor x2
Voltage
sensor x3
Current
sensor x3
Voltage
sensor x3
PE
-U
-U
PE PE
EMC
filter
EMC
filter
DC output
1/3 channels
PE
DCPS
U
DSP
board
DSP
board
CAN/
Ethernet
board
CAN
MODBUS/TCP
ETHERNET
V
W
N
PE
R
S
T
N
PE
(Please note that earth protection cable is only connected to the cabinet chassis).

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State-of-the art digital control is used in all CINERGIA products. In the DCPS case, the control
system algorithms are computed in a dual core DSP-based hardware, designed by CINERGIA,
allowing a multitask execution of the regulation systems for the Active Rectifier and the DC/DC
output. This produces a fast transient response and high performance against load changes. A
12 bits analog to digital conversion, with digital processing, allows a high resolution output up
to 0.1% with high stability too.
Resonant control
Control algorithms based on Resonant Control are used in the AC side. The regulation is
structured in blocks resonating at a given frequency. Within the resonant frequency each block
allows the suppression of gain and phase errors of the controlled magnitude: voltage, current,
…etc. Thanks to this, each harmonic can be controlled independently and thus it can be
generated or suppressed, as needed.
PID control
The DC side control algorithm is based on a traditional PID controller which will be explained
later.

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3. INSTALLATION
3.1. Important safety instructions
As a device with class l protection against electric shocks, it is essential to install a protective
earth wire (connect earth ). Connect the protection earth wire to the terminal (X5) before
connecting the grid to the DCPS input.
All the electrical connections, including those for control (interface, remote control…etc.), shall
be done with the switches in OFF position and with the mains supply disconnected (thermal-
magnetic circuit breaker in OFF position too
It must never be forgotten that the DCPS is a power supply, so users must take all
necessary precautions against direct or indirect contact.
Warning labels should be placed on all primary power switches installed in places far from the
device to alert the electrical maintenance personnel of the presence of a voltage in the circuit
up to 10 minutes after stopping the device.
In devices without isolation transformer, precautions must be taken as they are
not isolated from the alternating input line, and there might be dangerous voltage
between the output terminals and the ground.
3.2. Equipment views
Electrical connections:
X6
X7
X10
X8
X9
X4
X1
X5
X2
X3
Local front panel:

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Front view (with the door open):
Q2
Q3
Q1a
Detailed view of the signal connectors:
X12
X13
X11
X14
X15
X16
X17

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General view (with the front door closed):
Protection elements (Q*):
(Q1a) Input thermal-magnetic circuit breaker or disconnector according to power of
the equipment.
(Q2) Output disconnector.
(Q3) Output fuses.
Connection elements (X*):
(X1) Phase input terminal R.
(X2) Phase input terminal S.
(X3) Phase input terminal T.
(X4) Neutral input terminal N.
(X5) Earth connection terminal for main supply input ( ).
(X6) DC phase output terminal W.
(X7) DC phase output terminal V.
(X8) DC phase output terminal U.
(X9) DC negative terminal N.
(X10) Earth connection terminal for load or loads ( ).
(X11) DB9 connector for RS485 communications.

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(X12) Terminals for external Emergency Power Off (EPO) button.
(X13) DB9 connector for CAN communications (input).
(X14) DB9 connector for CAN communications (output).
(X15) RJ45 connector for MODBUS interface.
(X16) DE15 connector for digital inputs and outputs.
(X17) DE15 connector for analogic inputs and outputs.
3.3. Equipment reception
3.3.1. Unpacking and checking the content
On receiving the device, make sure that the power supply has not suffered any damage during
the transportation. Otherwise, make all pertinent claims to the supplier or to CINERGIA.
The packing of the device consists of a wooden palette, a cardboard or wooden packaging
(depending on the case), expanded polystyrene corner pieces, a polyethylene sleeve and
bands; all recyclable materials. Therefore they should be disposed of according to current
regulations. We recommend to keep the packaging in case its use is necessary in the future.
In order to unpack, cut the bands and remove the cardboard packaging with a vertical
movement. In case of wooden packaging, remove it with the appropriate tools. Afterwards,
remove the corner pieces and the plastic sleeve. At this point the equipment will be unpacked
on the pallet. Please, use suitable tools to lower the power supply from the pallet.
After unpacking the equipment, check that the data in the nameplate (stuck on the inner part
of the front door) correspond to those specified in the purchase order. Contact the supplier or
CINERGIA in case of disconformity.
Keep the equipment in the original package if it will not be used in order to protect it from any
possible mechanical damages, dust, dirt …etc.
3.3.2. Storage
The equipment shall be stored in a dry, ventilated place and protected against rain, water jets
or chemical agents. It is advisable to keep the power supply into its original package, which has
been designed to assure the maximum protection during the transport and storage.
Do not store the unit where the ambient temperature exceeds 40°C or falls below
-20°C, as this may degrade the electrical characteristics of the batteries.
3.3.3. Transport to location
The equipment includes castors to facilitate its transport to its final location.
It is important to check previously if the weight of the power supply is appropriate for the site
where it will be located.

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It is also important to consider the most suitable means to place the power supply in its final
location (floor, hoist, lift, stairs, …etc).
3.3.4. Location
It is necessary to leave a minimum of 25 cm in the contour of the equipment for its ventilation.
If possible, as shown in following figures, it is recommended to leave additional 75 cm to
facilitate the operations of maintenance of the equipment or the interventions of the technical
service in case of breakdown.
Recommendable minimum
distance, 1 m.
Recommendable minimum distance, 1 m.
Recommendable minimum distance, 1 m.

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Recommendable minimum
distance, 1 m.
Recommendable minimum distance, 1 m.
Recommendable minimum
distance, 1 m.
Recommendable minimum distance, 1 m.
The equipment may be installed in any place as long as the safety and ventilation requirements
are fulfilled.
The power supply includes 2 levelling elements located near the front castors, which serve to
immobilize the unit once it is in place.
To adjust the level, open the front door of the cabinet and proceed as follows:
By hand, loosen the levelling elements by turning them anticlockwise until they touch
the floor, and then, using a spanner, continue loosening until the castors are raised off
the floor by a maximum 0.5 cm.
Close the door once more.

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3.4. Connection
3.4.1. Earth protection
As a device with class l protection against electric shocks, it is essential to install a protective
earth wire (connect earth ). Connect the protection earth wire to the terminal (X5) before
connecting the grid to the DCPS input.
On the other hand, connect the protection earth wire to the terminal (X10) before connecting
the load to the DCPS output.
3.4.2. Input connection, terminals (X1 to X5)
Connect the grid cables R, S, T and N to the terminals (X1), (X2), (X3) and (X4) respectively. This
connection must always be done according to the label placed under the input screw
terminals.
In case of discrepancies between labelling and this manual instructions, the label information
will always prevail.
3.4.3. Output connection, terminals (X6 to X10)
The equipment has 3 output channels (U, V and W) and a common negative return (N).
Therefore, the load must be connected between the channels and the common negative
return (phase-N):
-DC phase output terminal U (X8)
-DC phase output terminal V (X7)
-DC phase output terminal W (X6)
-DC negative terminal N (X9)
In case of discrepancies between labelling and this manual instructions, the label information
will always prevail.
3.4.4. Emergency Power Off terminals (X12)
The equipment owns two terminals dedicated to external Emergency Power Off (EPO).
The EPO must act as a normally closed contact, and thus, there are two possible options for
connection:
a) Connecting an external Emergency pushbutton to X12
b) Installing a cable bridge to close the circuit in terminal X12 (in case EPO is not desired)
If option a) is chosen, the procedure is as follows:
1. Emergency shutdown activation: the Emergency pushbutton must be set in the
position in which it forces to open the circuit between the two terminals of X12.
2. Normal mode restoration: the Emergency pushbutton position must be inverted in
order to close the circuit again between the two terminals of X12.

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X12
3.4.5. Communications
There are several connectors dedicated to communications, which are listed below:
-Connector for RS485 communications (X11): DB9 connector to be used when Modbus
RS485 option is chosen.
-Connectors for CAN communications (X13, X14): DB9 connectors to be used when
parallelization of DCPSs is needed (X13 works as input and X14 works as output).
-Connector for MODBUS interface (X15): RJ45 connector. A standard Ethernet cable
must be connected between X15 and a Hub or a Router to communicate a remote PC
with the DCPS.
3.4.6. Digital inputs and outputs
Digital inputs and outputs are gathered in X16. All of them are isolated and configurable.
Specifically, there are 5 digital inputs which operate at 24 V and 3 relay digital outputs.