ZENONE FVC Series User manual

ZENONE Elettronica S.r.l.
Via Nazionale Pianopantano
83036 Mirabella Eclano (AV)
P.I. 02407830641
Tel. [phone] Fax [phone]
Three-phase Converter FVC series
User’s manual
Release 18, November 2009
Firmware version: V1.01
ZENONE Elettronica S.r.l.
Via Nazionale Pianopantano 83036 Mirabella Eclano (AV)
Tel. [phone] Fax [phone]
www.zenoneelettronica.it [e-mail]
Attention
This manual provides all the necessary information regarding the mode
of operation of FVC series converters. For the correct use of this
specific equipment it is recommended to refer to the characteristics
data sheet of the converter, hich is an integral part of this manual.
This manual is an integral and essential part of the product. Read carefully
and completely the warnings
herein contained, they will provide important information regarding safety of operation and maintenance.
This equipment must be used only for the purpose for which has been designed. Any other utilization is
improper and therefore potentially dangerous. The manufacturer is not responsible for improper,
incorrect and unreasonable utilization of this equipment.
Any intervention on the equipment, that would cause a change in the structure or in the cycle of
operation, must be performed or authorized by the technical department of Zenone Elettronica.

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Converter series FVC
The onverter FVC series are stati AC/AC three-phase devi es with double
onversion and IGBT te hnology under mi ropro essor ontrol. They supply the load
with variable voltage and frequen y at the set value regardless of impedan e value
and mains flu tuations.
The information about voltage and urrent supplied is shown by means of 7
segments displays.
They an be ontrolled by external signals.
They are equipped with RS485 serial interfa e.
They an have two output s ales so to supply the maximum power at two different
full-s ales.
Product presentation
A ording to the output power, the equipment an be assembled in:
table ra k
re essed ra k
metal abinet
Control interface
commands and connections
voltage setting ommand and visualization: on front panel
frequen y setting ommand and visualization: on front panel
logi al ommand for output-on: on front panel
sele tion for lo al/remote ommands: from RS485 serial interfa e
line breaker: on front panel
RS485 serial interfa e: on front panel
mains supply: from able on the ba k side (ra k version)
on terminal blo ks inside the abinet (metal
abinet version)
outputs: on front panel ja ks or bars (ra k version)
on terminal blo ks inside the abinet (metal
abinet version)
emergen y input: on front panel
auxiliary inputs/outputs on front panel
F

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Introduction
Thank you for hoosing our produ t. We invite you to read this manual thoroughly be ause
here you an find the te hni al hara teristi s and all the ne essary information for using
this equipment orre tly.
The information ontained in this do ument is subje t to hange without noti e and it is
expe ted to be updated ex lusively for the produ t for whi h is provided.
ZENONE ELETTRONICA is not liable for te hni al error, printing error or omissions that
might be en ountered in this manual; neither is responsible for a idental or
onsequential damages aused by the use of its produ t.
This guide provides spe ifi information related only to the mentioned produ ts.
No part of this manual may be reprodu ed in any form or by any means without our
written onsent.
The software herein des ribed is provided with end user li ense, unless otherwise
spe ified.
This te hni al do ument version voids and repla es all previous versions.
The produ ts ited in this do ument ould be trademarks and/or registered mark of
respe tive manufa tures.
A
V
Front panel example
Mains line breaker
Voltage
setting Frequency setting
Multifunction
connector
Emergency

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Summary
1. Preface ............................................................................................. 5
1.1 How to use and understand the instructions provided in this manual ............................... 5
1.2 Safety instructions ................................................................................................ 5
1.3 Compliance declaration ......................................................................................... 7
1.4 Identification la el ............................................................................................... 8
2. Preliminary operations ........................................................................... 9
2.1 Working environment ............................................................................................ 9
2.2 Precautions ......................................................................................................... 9
2.3 Equipment operation ............................................................................................ 10
3. Auxiliary Inputs / Outputs .................................................................... 11
3.1.1 Inputs ...................................................................................................... 11
3.1.2 Outputs ................................................................................................... 11
3.2 Communication port ............................................................................................. 11
4. Converter operation ........................................................................... 12
4.1 Starting the output of power .................................................................................. 12
4.2 Setting voltage and frequency ................................................................................ 12
4.3 Scale selection .................................................................................................... 12
4.3 Display of set values ............................................................................................ 12
4.4 Command type selection ....................................................................................... 13
4.5 Measurements display .......................................................................................... 13
4.5 change of scale ................................................................................................... 13
5 Maintenance instructions..................................................................... 13
6. External connections .......................................................................... 14
6.1 DB15 I/O connections ............................................................................................ 14
6.2 DB15 RS485 connection ........................................................................................ 15
6.3 DB15 analog connections ....................................................................................... 16
7. Error and faults signaling: ................................................................... 17
8 Converter diagram ............................................................................. 18
9 Control scheme ................................................................................. 19
10 Control and regulation unit ............................................................... 19
10.1 Control system lock diagram ............................................................................. 19
10.2 Control system description ................................................................................. 20
10.3 Parameters definition and function ...................................................................... 21
10.4 Procedure for adjusting the control system ............................................................ 22
10.5 Technique for adjusting the loops ........................................................................ 23
11 GesPWM soft are ........................................................................... 26
11.1 Connecting the equipment to the PC ..................................................................... 26
12 FVC Manager soft are ...................................................................... 28
12.1 Software installation ........................................................................................ 28
12.2 Presentation .................................................................................................... 28
12.3 Preliminary operations ...................................................................................... 29
12.4 identification of FVC connected ........................................................................... 29
12.5 Address change ................................................................................................ 29
12.6 Test applications ............................................................................................. 29
12.7 Command mask ................................................................................................ 29
13 Communication protocol V1.1 ............................................................ 32

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1. Preface
1.1 How to use and understand the instructions provided in this manual
In this manual you an find also fun tions that might not be present on the equipment
you have pur hased; nevertheless proper information will tell you about eventual
limitations.
This solution has been hosen for larity and to better evaluate the fun tional
hara teristi s available on all our produ ts.
1.2 Safety instructions
The following notes or graphi symbols list a series of instru tions essential for the
orre t use of the equipments. Su h information ould be found, in graphi form,
also on the equipment or used in the manual to fo us the attention on the spe ifi
issue. It is highly re ommended to read su h instru tions arefully before
equipment installation.
Do not install the Equipment in environments with temperatures different
from those allowed.
Do not expose the Equipment to dire t sun light.
Do not pour any kind of liquids on the Equipment.
In ase of fire, use foam, CO2 or dry hemi als fire-extinguishers.

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Attention
The lightning symbol within a triangle is a warning symbol that indi ates
the presen e of “dangerous voltages” inside the equipment with risk of
ele tri sho k.
The ex lamation mark within a triangle is a aution symbol that
indi ates the presen e of important additional information for the
orre t use of the equipment.
The empty triangle it’s a aution symbol that indi ates a danger of
equipment damage if improperly used.
The text that follows this symbol gives information, re ommendations
or other parti ular instru tions for the orre t operation of the
equipment.
The text that follows this symbol gives information, re ommendations
or other parti ular instru tions in order to avoid danger and/or injury
to personnel.
A proper disposal of the shipment pa king is re ommended.
!

1.3
Compliance declaration
MANUFACTURER DECLARATION OF CONFORMITY
The Zenone Elettronica
Converter
FVC
are herewith confirmed to comply with the requirements set out in the Council Directive on the
Approximation of the Law of Member States relating to:
-
Electromagnetic Compatibility, Directive 2004/108/EEC
-
-EN 61000-6-1 -
CEI EN 61000
(EMC) - Part 6-
1: Generic standards
light-
industrial environments "
-
-EN 61000-6-3 -
CEI EN 61000
Electromagnetic compatibility (EMC)
standard for residential, commercial and light
EN 61326-1 :2006
Electrical equipment for measurement, control and laboratory use
requirements -
Part 1: General requirements
-
Low Voltage Equipment Directive (2006/9
Measuring Apparatus”)
Mirabella 01-10-2009
Copyright A knowledgement:
MUGL
Page
rev. 18 November 2009
Compliance declaration
MANUFACTURER DECLARATION OF CONFORMITY
Converter
:
are herewith confirmed to comply with the requirements set out in the Council Directive on the
Approximation of the Law of Member States relating to:
Electromagnetic Compatibility, Directive 2004/108/EEC
CEI EN 61000
-6-1 (2°ed. 2007-10)
Electromagnetic compatibility
1: Generic standards
-
Immunity for residential, commercial and
industrial environments "
CEI EN 61000
-6-3 (2°ed. 2007-11)
Electromagnetic compatibility (EMC)
- Part 6-
3: Generic standards
standard for residential, commercial and light
-
industrial environments
Electrical equipment for measurement, control and laboratory use
Part 1: General requirements
Low Voltage Equipment Directive (2006/9
5/EEC) and EN61010-
1 (“Safety of Electrical
Measuring Apparatus”)
Zenone Eletrronica S.r.l.
Luigi Zenone
Copyright A knowledgement:
EN
publi ations are subje t to the Copyright of
Page
7 of 38
rev. 18 November 2009
MANUFACTURER DECLARATION OF CONFORMITY
are herewith confirmed to comply with the requirements set out in the Council Directive on the
Electromagnetic compatibility
Immunity for residential, commercial and
3: Generic standards
- Emission
industrial environments
Electrical equipment for measurement, control and laboratory use
- EMC
1 (“Safety of Electrical
Zenone Eletrronica S.r.l.
Luigi Zenone
publi ations are subje t to the Copyright of
IEC.

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1.4 Identification la el
Ea h equipment is identified by the following label.
We invite you to onsider the data shown in it as indispensable for the produ t
tra eability, and to ommuni ate them for eventual request for support.

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2. Preliminary operations
2.1 Working environment
The onverter is designed for indoor use.
+ 5 °C ° + 40 °C
Pla e the devi e on a suitable support or on a plane surfa e for good
stability. Be sure that proper ventilation is allowed and no obje ts obstru t
the ventilation openings.
2.2 Precautions
Operate the equipment at its rated mains voltage, on earthed outlet only.
Fasten suitable ables or bars of adequate se tion on the output bolts,
al ulated on the bases of the equipment fun tional hara teristi s.
WARNING: Power onne tions an generate high temperature spots, that
ould ause burnings.
WARNING: All standard onverters are delivered with output FLOATING,
not onne ted to any potential (unless otherwise spe ified); at the moment
of installation MUST BE CONNECTED TO GND OR TO ANY OTHER
POTENTIAL. Maximum allowed voltage on the output bolts, when not
onne ted to earth, is 300VAC.
!

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2.3 Equipment operation
Conne t the equipment to the power mains, it is recommended to follow the
instructions given on the equipment (or in the attached sheet) regarding voltage,
frequency and earth connection, then turn on the power swit h, whi h ould be lo ated
on the ba k panel or by the abinet side depending on the type of equipment.
In some models the power-on ommand an be part of an external power supply frame.
In some ases the integrated onsole, keyboard/display, an be onne ted to the abinet
by means of an external able.
At system power-on a self-diagnosti routine tests the most important equipment
fun tionalities and dete ts eventual faults.
In ase of failures or malfun tions, we must be informed in advan e before sending the
equipment to our laboratories.

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3. Auxiliary Inputs / Outputs
3.1.1 Inputs
The FVC onverters have some inputs for remote ontrol
fun
ct
ion
D
escri
pt
ion
Emergen
cy
Voltage
-
free
NC onta t, its opening auses the
immediate
dis
e
ngagement of
the line breaker dis onne ting the equipment from the mains
on
–
off
Voltage
-
free
NO onta t,
allows to
start
the onverter
from remote o
ntrol
Voltage command
Analog input 0 ÷ 10V, remote ommand for the output voltage 0 ÷ 100%
Frequency command
Analog input 0 ÷ 10V, remote ommand for the output frequen y 0 ÷ 100%
3.1.2 Outputs
The FVC onverters have some outputs for remote signaling
fun
ct
ion
descri
pt
ion
Converter running
PNP
digital output
,
it signals t
hat the onverter is running
Max 30V 0,5A
Alarm
PNP
digital output
,
it signals a
fault
Max 30V 0,5A
3.2 Communication port
The onverter is equipped with a RS484 ommuni ation port whi h allows to onne t a
PC or other system for parameters setting, for the alarm register reading and for remote
ontrol.
The Baud Rate is the transfer speed and is set at 9600.

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4. Converter operation
4.1 Starting the output of power
After the preliminary operations, onne ting the equipment to the mains and to an
eventual load, are done it’s possible to turn on the onverter a ting on the main
swit h.
Note: the main swit h will not a tivate if the emergen y ir uit is open or
the emergen y push-button is pressed.
On e the equipment is turned on it’s possible to start the output of power in the
following ways:
•Pressing the on-off push-button on the front panel
•With ommand from serial port; entering the appropriate string.
•A tivating the appropriate digital input.
Under these onditions the onverter will take immediately the voltage and
frequen y set.
4.2 Setting voltage and frequency
The setting of voltage and frequen y output an be done:
•by means of the potentiometers on the front panel
•by means of analog signal 0 ÷ 10V
•from serial port
4.3 Scale selection
The FVC onverters an have one or two output s ales in order to supply the
maximum power with different full-s ales.
The s ale sele tion must be done with the appropriate sele tor in stand-by mode.
An eventual hange of s ale, while the output is on, will take pla e only after
the onverter is swit hed “off”
4.3 Display of set values
In stand-by it’s possible to visualize on the displays the voltage and frequen y values
simply pressing the “F1” push-button
“F1” pressed = visualization of voltage and frequen y entered
“F1” released = off

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4.4 Command type selection
The sele tion of the ommand type:
•front panel
•analog or digital inputs
•serial port
an be done via serial ommuni ation by means of “FVC Manager” software (look at
paragraph 12).
4.5 Measurements display
While the output is on the onverter shows on the displays the on atenated output
voltage between the phases L1-L2 and the urrent on phase L1.
Pressing “F1” it’s possible to visualize in sequen e:
•FREQ = output frequen y
•F1 V = voltage L1-L2
•F1 A = urrent L1
•F2 V = voltage L2-L3
•F2 A = urrent L2
•F3 V = voltage L3-L1
•F3 A = urrent L3
If no keys are pressed within 3 se onds the displays will show the initial ondition
4.5 change of scale
The FVC onverters an have two voltage s ales, this allows to supply the maximum of
energy even with lower output voltages.
The hange of s ale is done with appropriate sele tor on the front panel and has effe t
only with the equipment in stand-by.
5 Maintenance instructions
•Che k periodi ally the air vents, lean them or hange the filter (if present);
•Che k and tighten periodi ally the bolts of the onne tions between the power
outputs and the external ir uit under test (in ase of high urrents).

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6. External connections
6.1 DB15 I/O connections
I/O section
The I/O section of the interface connector is made of:
•2 Inputs “PNP” type at 24V (Pin 1 and 2)
•2 outputs “PNP” type at 24V (Pin 11 and 12)
•1 “Emergency” input (pin 3)
•1 24V supply output limited at 100 mA max
•2 Pins assigned for a 24V supply (4=GND e 10=VCC).
DB15 Pin Out
I/O section
9
1
4
24V
(20-30V)
Vout 24Vcc
max 100mA
+24V
Out 1
0V
in1
in2
Emergency
12
Out 2
11
10 2
3
Max current for each
output: 500mA
Max current sink from each
input: 4mA@24Vdc

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The inputs have the following function:
•Input 1: Allows to START and to STOP the output supply
•Input 2: Not used
•Input “Emergency”: normally closed to the common of 24V. When opened causes the
disengagement of the line breaker.
The outputs have the following function:
•Output 1: Active when the power output is on.
•Output 2: Active in case of fault.
6.2 DB15 RS485 connection
RS485 section
The RS485 section of the interface connector is made up of pin “A” and “B” of the RS485
interface and of a Ground pin. For a proper functioning of the serial communication it’s
suggested to insert in a point of the line two resistances of 1Kohm connected as in the
diagram.
5
B
A
GND
13
6
DB15 Pinout
(RS485
section
)
1K
1K
5V
GND

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6.3 DB15 analog connections
ANALOG section
The Analog section of the interface connector is made of pin:
•AIN1_P and AIN1_N of the Analog input 1 (Pin 14 and 7)
•AIN2_P and AIN2_N of the Analog input 2 (Pin 15 and 8)
•Reference ground GND (Pin 6)
They are two balanced inputs that can take a maximum voltage of +/- 10V with respect to
GND.
Their function, when enabled by appropriate command via RS485, is to set the Voltage
(Input 1) and the frequency (Input 2).
7
AIN1_P
AIN1_N
GND
14
6
8
AIN2_N
15
AIN2_P
DB15 Pinout
(Analog section)

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7. Error and faults signaling:
The onverters are equipped with self-diagnosis routine; in ase of anomalous event the
power output is stopped and an error message is displayed.
S
i
gnal
Caus
e
R
e
med
y
DSP X FAIL Communication error between
the central processor and the
DSP shown by nr. X
Shut off and turn on the equipment; if the
error remains contact the assistance
FAIL Generic error Connect a PC to the equipment and by
means of the software “GesPWM” check the
table below
By means of the software GesPWM it’s possible to visualize the following table:
S
i
gnal
Caus
e
R
e
med
y
Temperature Very high temperature of the
heath-sink Shut off the equipment and wait a few minutes. If the phenomenon repeats check
the air vents and make sure the fans work
properly.
Under-voltage Supply voltage to low <350V Check the mains and the presence of all
three phases.
Over-voltage Supply voltage
to high >460V Check the mains voltage.
Current limit Maximum allowed current
exceeded Check the load or the parameters settings.
NTC error Fault in the temperature
measurement circuit Contact the assistance.
Fault IGBT failure Contact the assistance.
Precharge Malfunction of the precharge
capacitors circuit Check the precharge relay.
If the fault persists, onta t the assistan e.

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8 Converter diagram
Mains
Input
FVC basic diagram
Output
Bridge
PWM
modulator
µ P
Control unit
Serial comm.
Command I/O

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9 Control scheme
The FVC converter has two control units, one for regulation and one for central
management, both are externally accessible and modifiable through the appropriate
programs:
•Control and regulation unit by means of “GesPWM” software
•Central management unit by means of “FVC Manager” software
10 Control and regulation unit
The onverter is equipped with a sophisti ated digital ontrol system, whi h has to keep
the voltage and/or the urrent output onstant regardless of load hange and mains
variations.
The regulation is based on two PID algorithms in sequen e and named:
“Inner loop” with feedba k urrent taken at the output,
“Outer loop” with feedba k voltage taken at the output.
The following figure shows the prin iple of operation
10.1 Control system lock diagram
The control loops are pre-adjusted in production to have a good compromise
between speed and stability over most loads, in some cases it is necessary to change
some parameters for the following reasons:
•Os illations due to a load too rea tive
•To enhan e the generator dynami performan e
•To adapt the generator to the load
PWM
Output
current
Output
voltage
Voltage
reference
+
+
-
-
Inner loopOuter loop
REF
REF1
REF2

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10.2 Control system description
The ontrol system is based on two PID loops in sequen e, named “Inner loop and Outer
loop”.
The inner loop is the fastest and will adjust the urrent in the load. It takes as input the
referen e of the outer loop
The outer loop regulates the output voltage, rea ts more slowly and it provides the value
of urrent to the inner loop. It takes as input the main referen e and the feedba k omes
from the output voltage of the onverter.
Outer loop
Output voltage
+
-
REF (from
potentiometer or
from input)
REF
1 to inner
loop













1



1


+
+
+
Derivative limitation
Integral limitation