Saelig AFV Series User manual

Variable Frequency Power Supply
USER MA NUAL
AFV Series
Saelig Company, Inc. 71 Perinton Parkway, Fairport, NY 14450 USA 1-585-385-1750
[email protected] www.saelig.com

Content
1 Product Introduction.....................................................................................................................1
2 Working Principle ............................... .......................................................................................... 2
2.1 Functional block diagram of complete machine .................................................................... 2
2.2 Description of functional block diagram ............................................................................... 3
2.3 Main control circuit............................................................................................................... 3
3 Transportation and Installation .......................................... ...................................................... 4
3.1 Transportation precautions .................................................................................................. 4
3.2 Unpacking inspection .......................................................................................................... 4
3.3 Installation environment requirements .................................................................................. 5
3.4 Description of cable connection ........................................................................................... 6
3.5 Cable wiring ............................................................................................................................. 6
4 Product Specifications ..................................................................................... ........................ 7
4.1 Technical specifications .......................................................................................................7
4.2 Equipment overview and diagrams.........................................................................................10
4.3 Equipment description ....................................................................................................... 12
5 Operation .............................................................................................................. .................. 13
5.1 Initial power-up of system .................................................................................................. 13
5.2 Menu description ............................................................................................................... 13
5.3 Parameter setting .............................................................................................................. 14
5.3.1 Start-up ........................................................................................................................... 14
5.3.2 User mode ...................................................................................................................... 15
5.4 Application interface ............................................................................................................... 16
5.4.1 General Mode ............................................................................................................. 16
5.4.2 Step mode ....................................................................................................................... 17
5.4.3 Gradual mode ................................................................................................................. 18
5.4.4 Measurement mode ........................................................................................................ 19
5.4.5 System setting interface ............................................................................................. 20
5.4.6 System log ................................................................................................................. 22
5.5 RS485 communication ...................................................................................................... 23
5.5.1 RS485 communication wiring .......................................................................................... 23
5.5.2 RS485 communication ................................................................................................ 23
5.5.3 File menu ................................................................................................................... 31
5.5.4 System setting .......................................................................................................................... 32

6 Repair and Maintenance ................ ........................................................................ ................ 35
6.1 Daily repair and maintenance ............................................................................................. 35
6.2 Regular maintenance ......................................................................................................... 36
7 Tr oubleshooting and Solutions ........................................................ ...................................... 37

Chapter 1 Product Introduction
The AFV series power supply is a programmable power supply for grid simulation. With
advanced SPWM technology and direct digital frequency synthesis (DDS) waveform technology, the
power supply has stable output frequency and good continuity. AFV series power supplies provide
continuous, pure and stable sinusoidal voltage. They can achieve local control via remote control
through the user’s PC using internal control and communication modules. The internal electronic
circuit can quickly detect over - current, overload, over-voltage and output short circuit, and will
automatically protect and cut off the output and sound an alarm. The integrated laminated busbar
technology and modular configuration in the power supply inverter unit improve reliability and
stability. The touch screen display and control make for easier operation.
The main performance characteristics of the AFV series variable frequency power supplies
are as
follows:
 Advanced SPWM technology and direct digital frequency synthesis (DDS) waveform
technology are used. The power supply has stable output frequency and good
continuity;
 The patented inner loop energy-saving test design is used to reduce energy consumption;
 High precision settings and output;
 Comprehensive and stable protection, perfect self-diagnostic maintenance function
and
higher system reliability;
 The laminated busbar structure is used to effectively reduce the inductance of the
inverter
circuit and improve the reliability of the inverter;
 Intelligent fan speed regulation control is used with a built-in dust filter to achieve efficient
heat dissipation and effective protection in harsh environments;
 Communication interface: Communication using RS485 (standard configuration)
and
Ethernet (optional configuration);
 A running event recording function records up to 255 events.
1

Chapter 2 Working Principle
2.1 Func t i ona l bl oc k d i a g r a m of c om pl e t e m a c h i n e
All functional units of the AFV series, from input to output according to the functional
sequence, are shown in Fig. 2-1.
Fig. 2-1 Functional block diagram of complete machine
2

2.2 De s c ri pt i on o f f un c t i ona l bl oc k di a gra m
1) Input: Connects from the power supply endpoint to the input terminal disk of the equipment.
2) Input air switch: Controls the commercial power input equipment.
3) Input filter: Input inductor and capacitor filter.
4) Rectifier filter: Converts the input alternating current into direct current.
5) Soft start: DC capacitor is charged slowly to reduce the impulse current.
6) Inverter circuit: Converts the direct current into PWM waveform.
7) Transformer filter: Boosts the output voltage of IGBT and outputs the voltage after LC filter.
8) Output: The output voltage is transferred to the output terminal disk (or output copper bar)
through the contactor.
9) Lightning protection device: Over-voltage protection, lightning protection, restraining surge
current, absorbing spike pulse, etc.
10) Voltage sampling: Input voltage sampling conditioning circuit.
11) SCR drive: Drive control circuit of soft start SCR.
12) IGBT drive: Amplify PWM signals to drive IGBT power components.
13) Voltage feedback: Steadily output voltage amplitude.
14) Voltage/current sampling circuit: Sampling conditioning circuit of output voltage and
current.
15) Power supply: Power supply of all PCB.
16) Main control circuit: The processing of all input and output signals.
17) Display: Touch screen display.
18) EPO: Emergency stop signal.
19) FUSE detection: Transmit the FUSE power-off signal to the control circuit for trip
protection.
20) Over-temperature detection: Transmit the over-temperature signal to the control circuit for
trip protection.
2.3 Mai n c ont r ol c i r c u i t
The main control circuit is divided into three parts: the protection sampling module, the
main control module and the display control module. The relationships between these three
parts are shown in Fig. 2-2.
Fig. 2-2 Block diagram of control parts
Protection
sampling
module
Main control module
Display
control
module
3

Chapter 3 T ransportation and Installation
3.1 Tr a ns por t a t i on p r e c a u t i o n s
Fig. 3-1 Diagram of transportation
Because the equipment is heavy, the lifting operations need to be slow during the
transportation by forklift. This will prevent damaging the equipment itself or the surroundings.
The equipment needs to be fixed firmly during transport to prevent it
from sliding or dumping.
Although the shockproof packaging was designed for transport, it
is recommended that caution
should be exercised if driving on rough
roads.
3.2 Unpa c k i n g Ins pe c t i on
 When opening the wooden boxes that contain the equipment, pay extra attention to
handling. The equipment is heavy. Avoid dropping or dumping.
 Before turning on the equipment check the equipment condition for damage from transport.
Inform Saelig of any damage.
 Check the accessories shown on the delivery accessory list. If any accessories are missing
please contact Saelig as soon as possible.
4

3.3 In s t a l la t io n E nv i r o nm e nt R e qui r e m e nt s
When selecting where to install, the following should be adhered to:
1) Install the equipment indoors and maintain air flow. Try to keep the equipment air
inlet/outlet free of dust;
2) The surface on which the equipment is installed should have sufficient strength to support
the equipment and be as level as possible.
T he equipment shall not shake once it is in
place;
3) The equipment adopts the incoming line and the outgoing line. I t is recommended to
arrange lines and cables connected externally from the cable trenches to
facilitate the
installation and maintenance;
4) Where the equipment is placed should provide sufficient space to allow the heat which is
produced
by the equipment to vent (see Fig. 3-2). Please do not cover the air inlet on the
front panel;
5) Do not use the equipment in an environment with dust, volatile or flammable gases, high
saline matter
or corrosive substances because these may affect the product life;
6) Do not place the equipment in an environment with high temperature or humidity. Keep
away from water, heat sources and avoid direct sunlight;
7) Use correct power distribution to guarantee the safety of the equipment and the user‘s
equipment.
Fig. 3-2 Schematic diagram of bottom of fixing device
5

3.4 De s c ri pt i on of c a b l e c onne c t i on
The cable connection of the main circuit is as shown:
Fig. 3-3 Schematic diagram of wiring terminal
Before installing the equipment, all the switches are to be disconnected. The circuit cables
should be connected properly according to the above diagram.
3.5 C a b l e w i ri ng
1) Use a voltmeter to confirm that there is no voltage output in the distribution lines;
2) Confirm that all of the switches of the variable frequency power supply are in the “OFF”
position;
3) The input and output cables can be selected according to the cables recommended by Saelig.
Model AFV-33030U is shown as an example in Tables 3-1
and 3-2.
Table 3-1 Reference table of input distribution cables
Machine model Input current
(A)
Input live wire (mm2)
Input zero line
(mm2)Input ground wire
(mm2)
A
B
C
AFV-33030U 70.8A 25mm225mm225mm216mm216mm2
Table 3-2 Reference table of output distribution cables
Machine model Output
current (A)
Output live wire (mm2)
Output zero
line (mm2)Output ground wire
(mm2)
U
V
W
AFV-33030U
LO
：83.3A
HI：41.7A
25mm225mm225mm225mm216mm2
The reference cables recommended in the above-mentioned tables are multi-core flexible copper
cables. The user can select different cables according to the input and output current conditions.
When the length of the input or output lines exceed 20 meters, it is recommended that the wire
diameter of the cable should be doubled.
4) Properly connect the input distribution lines to the corresponding wiring terminals at the input
terminal of the equipment, and connect the output load lines to the corresponding
wiring
terminals at the output terminal of the equipment.
Note: The corresponding relationship during wiring is generally A, B and C
correspond to the
common yellow, green and red; the N wire must be connected
properly; DO NOT operate a charged
device; when the input and output wiring distance
is long, it should be
considered that the line voltage drops in the wires.
6

Chapter 4Product Specifications
4.1 Te c hn i c a l S pe c i f i c a t i ons
The specifications for all of the AFV models can be found in the following tables:
Three Phase In - Three Phase Out (15~75kVA)
Model
AFV-33015
AFV-33020
AFV-33030
AFV-33045
AFV-33060
AFV-33075
Capacity (kVA)
15
20
30
45
60
75
Circuit Type
IBGT/PWM
Input
Phase
Three
Voltage
120V/208V, 220V/380V, OR 277V/480V
Voltage range
220V/380V±15%
Frequency range
47-63 Hz
Power
0.9
Max Current (A) w/ full load
28.1
37.4
56.1
84.2
112.2
140.3
Output
Phase
Three
Wave
Sine
Voltage
Low (V)
0V-150.0V (L-N)
High (V)
150.1V-300.0V (L-N)
Frequency range
45-65 Hz Optional 45-500Hz
Frequency regulation
0.01%
Max Current (A)
High (A)
20.8
27.8
41.7
62.5
83.3
104.2
Low (A)
41.7
55.6
83.3
125.0
166.7
208.3
System
Line Regulation
1
Load Regulation
1% (linear load)
THD
% (linear load)
Efficiency
90%
Response Time
2ms
Crest Factor
3:1
Protection
Electronic circuit trip for over/low voltage, over current, over load, over temperature, and
short circuit protection and alarm system
Readings
Display
VFD (Touch Screen Optional)
Voltage
Res.: 0.1V, Accuracy: 0.5%FS+4Counts
Current
Res.: 0.1A, Accuracy: 0.5%FS+4Counts
Frequency
Res.: 0.1Hz, Accuracy: 0.5%FS+4Counts
Control
Mode
RS-232
Standard
RS-485
Standard
GPIB
Optional
Safety
Insulation Resistance
10M ohm (Tested w/ DC 500V)
Voltage Resistance
1800V 10mA for 1 min (Tested w/ AC)
Environment
Cooling System
Fan Cooling, Front to Rear
Temperature
0°C ~ 45°C
Humidity
0 ~ 90% (Non-condensing)
Altitude
1500m
Case No.
1
2
Weight (lb/kg)
882/400
915/415
937/425
959/435
1081/490
1158/525
Consult factory for power levels above 800kVA
Case No. Dimensions (W x D x H mm / in)
1
650 x 920 x 1248 / 25.60 x 36.22 x 49.13
2
700 x 800 x 1620 / 27.56 x 31.50 x 63.78
7

Three Phase In - Three Phase Out (100~400kVA)
Model
AFV-33100
AFV-33120
AFV-33150
AFV-33200
AFV-33300
AFV-33400
Capacity (kVA)
100
120
150
200
300
400
Circuit Type
IBGT/PWM
Input
Phase
Three
Voltage
120V/208V, 220V/380V, OR 277V/480V
Voltage range
220V/380V±15%
Frequency range
47-63 Hz
Power
0.9
Max Current (A) w/ full load
187.1
224.5
280.6
374.1
561.2
748.2
Output
Phase
Three
Wave
Sine
Voltage
Low (V)
0V-150.0V (L-N)
High (V)
150.1V-300.0V (L-N)
Frequency range
45-65 Hz Optional 45-500Hz
Frequency regulation
0.01%
Max Current
(A)
High (A)
138.9
166.7
208.3
277.8
416.7
555.6
Low (A)
277.8
333.3
416.7
555.6
833.3
1111.1
System
Line Regulation
1
Load Regulation
1% (linear load)
THD
% (linear load)
Efficiency
90%
Response Time
2ms
Crest Factor
3:1
Protection
Electronic circuit trip for over/low voltage, over current, over load, over temperature, and
short circuit protection and alarm system
Readings
Display
VFD (Touch Screen Optional)
Voltage
Res.: 0.1V, Accuracy: 0.5%FS+4Counts
Current
Res.: 0.1A, Accuracy: 0.5%FS+4Counts
Frequency
Res.: 0.1Hz, Accuracy: 0.5%FS+4Counts
Control
Mode
RS-232
Standard
RS-485
Standard
GPIB
Optional
Safety
Insulation Resistance
10M ohm (Tested w/ DC 500V)
Voltage Resistance
1800V 10mA for 1 min (Tested w/ AC)
Environment
Cooling System
Fan Cooling, Front to Rear
Temperature
0°C ~ 45°C
Humidity
0 ~ 90% (Non-condensing)
Altitude
1500m
Case No.
3
4
5
Weight (lb/kg)
1579/716
1713/777
2866/1300
3087/1400
4851/2200
5512/2500
Consult factory for power levels above 800kVA
Case No. Dimensions (W x D x H mm / in)
3
940 x 820 x 1700 / 37.00 x 32.28 x 66.93
4
1100 x 940 x 1850 / 43.31 x 37.00 x 72.83
5
1400 x 1040 x 2000 / 55.12 x 40.94 x 78.74
8

Three Phase In - Three Phase Out (500~2000kVA)
Model
AFV-33500 AFV-33600 AFV-33800 AFV-331000 AFV-331200 AFV-331500
AFV-
332000
Capacity (kVA)
500
600
800
1000
1200
1500
2000
Circuit Type
IBGT/PWM
Input
Phase
Three
Voltage
120V/208V, 220V/380V, OR 277V/480V
Voltage range
220V/380V±15%
Frequency range
47-63 Hz
Power
0.85
Max Current (A) w/
full load
990.3 1188.4 1584.5 1980.6 2376.7 2970.9 3961.2
Output
Phase
Three
Wave
Sine
Voltage
Low
(V)
0V-150.0V (L-N)
High
(V)
150.1V-300.0V (L-N)
Frequency range
45-65 Hz Optional 45-500Hz
Frequency regulation
0.01%
Max
Current (A)
High
(A)
694.4 833.3 1111.1 1388.9 1666.7 2083.3 2777.8
Low
(A)
1388.9 1666.7 2222.2 2777.8 3333.3 4166.7 5555.6
System
Line Regulation
1
Load Regulation
1% (linear load)
THD
% (linear load)
Efficiency
90%
Response Time
2ms
Crest Factor
3:1
Protection
Electronic circuit trip for over/low voltage, over current, over load, over temperature, and short circuit protection
and alarm system
Readings
Display
Touch Screen
Voltage
Res.: 0.1V, Accuracy: 0.5%FS+4Counts
Current
Res.: 0.1A, Accuracy: 0.5%FS+4Counts
Frequency
Res.: 0.1Hz, Accuracy: 0.5%FS+4Counts
Control
Mode
RS-232
Optional
RS-485
Standard
GPIB
Optional
Safety
Insulation Resistance
10M ohm (Tested w/ DC 500V)
Voltage Resistance
1800V 10mA for 1 min (Tested w/ AC)
Environm
ent
Cooling System
Fan Cooling, Front to Rear
Temperature
0°C ~ 45°C
Humidity
0 ~ 90% (Non-condensing)
Altitude
1500m
Case No.
6
7
-
Weight (lb/kg)
9921/4500
11464/5200
15433/7000
18740/8500
20283/9200
-
Consult factory for power levels above 800kVA
Case No. Dimensions (W x D x H mm / in)
6
4900 x 1400 x 2050 / 192.91 x 55.12 x 80.71
7
6300 x 1500 x 2050 / 248.31 x 59.06 x 80.71
9

4. 2 Eq u i p men t Over v i e w an d D i ag r a ms
AFV series products correspond to size according to capacity, and the specific sizes are
shown in Table 4-1:
Table 4-1 Equipment sizes
Machine capacity
(kVA) W (mm) D (mm) H (mm)
15, 20 650 920 1248
30, 45, 60, 75 700 820 1,620
100, 120 940 820 1700
150, 200 1100 940 1850
300, 400 1400 1040 2000
500, 600 4900 1400 2050
800, 1000, 1200 6300 1500 2050
(a) Front view b) Side view
Fig. 4-1 Cabinet Views
10

Fig. 4-2 Axonometric view of AFV machine
11

4. 3 E qu i p m e n t D e s c ri pt i on
①
Touch screen;
Fig. 4-3 Description of complete equipment appearance
② Emergency stop button;
③ Door handle;
④ Input air switch;
⑤ Maintenance socket;
⑥ AC input terminal row;
⑦ AC output terminal row .
12

Chapter 5 Operation
5.1 In i t ia l p o w e r -up of s y s t e m
The input and output wirings should be properly connected according to the input and output
connection shown in Section 3.3. When the system is started, the main engine fan begins to
operate and the
panel display screen becomes active. Also, the main interface is entered,
indicating that the start-up is normal. The parameters can then be set for the machine.
Note: If there is an external load, the load switch should be disconnected first, and the
input
switch should be connected (it needs to confirm whether the electric power of the
input terminal
row is normal before the input switch is connected).
The application interface can be entered by clicking “Application”. Users can set the
output
voltage and frequency value, then press the [Operation] key when completed. Clicking
“Meas.” displays the actual output for phase voltage, current, frequency, etc.
5.2 Menudescription
A ppl i c a t i on
The application interface displays phase voltage, current and frequency of output terminal of
the AFV(equipment).
S y s t e m
In the application interface, time setting and system maintenance can be set as required.
E ve n t
Records the historical work information of the equipment.
13

5.3 P ar a m e t e r s e tti n g
Setting parameters correctly is a basic requirement for running the AFV equipment smoothly.
Detailed user modes are described below.
5.3.1 S ta r t -up
When the AFV equipment has been powered on the screen will show the company LOGO as
in Fig. 5.1.
5-1.
Fig. 5-1 Start-up interface
The initialization interface is shown in Fig. 5-2.
Fig. 5-2 Initialization interface
14

5.3.2 Us er m ode
Enter the main menu of the user mode. The interface display is shown in Fig. 5-3.
Fig. 5-3 Main menu of user mode
 【APP】--Application: Enter the operation setting interface;
 【SYSTEM】: Enter the time setting and system maintenance interface;
 【EVENT】: Enter the equipment work record information table interface.
15

5.4 A pp lic a t io n i n t er f ac e
In the application interface, users can conduct the operations of the general mode, Step
mode,
Gradual mode and Measurement mode of the equipment.
with the model specifications of the actual equipment.
5.4.1 GeneralMode
Fig. 5-4 Setting interface of general mode
 【U Volt.】/【V Volt.】/【W Volt.】-- U-phase voltage/ V-phase voltage/ W-phase voltage:
The following three ways can be used for setting voltage at all phases:
a) Directly input the voltage value in . Click the box to pop up the keyboard,
and then input the voltage value;
b) In the box of , touch left and right for adjustment;
c) Select & to conduct the setting. The variation unit is 0.1.
 【Freq】-- Frequency: Doing the setting is the same as that of voltage;
 【LOW】: The equipment starts to output the low voltage when selected;
 【HIGH】: The equipment starts to output the high voltage when selected;
 【RUN】: The equipment starts the output according to the set value when selected;
 【STOP】: The equipment stops the output when selected;
 【RESET】: The equipment restores the initial state when selected;
 【 】: AC indicator light displays the operational state of the AC output of the equipment:
Red represents that the mode of the equipment is in the stop state, while green
represents
that the mode of the equipment is running.
Note: All the product information in the operation interface of the equipment should comply
16

5.4.2 S te p m o de
Fig. 5-5(a) Step mode setting interface
Fig. 5-5(b) Step mode effect interface
 【SETTING】: Download the set parameters;
 【RUN】: The equipment starts to run the step mode when selected;
 【RESET】: The equipment restores the initial state when selected;
 【STOP】: The equipment stops running the step mode when selected;
 & : Switch over step setting interface and step effect interface.
17