Rectifier User Manual [PDF]

Zitiervorschau

Technical Description

FlexKraft 77-107.0223 GB Rev.H

KraftPowercon Sweden AB. P.O.Box 2102. SE-445 02 SURTE. Sweden Tel: +46 31 97 97 00. Fax: +46 31 97 97 97

Technical Description

FlexKraft

Page 1 (122) 77-107.0223 GB 2012-07-05 Rev. H

1 Safety instructions

SAFETY INSTRUCTION There are hazardous voltages inside this product. If touched, they may cause electric shock, burns or death. This product is only intended for use as a constant DC-power supply for industrial processes, the product may only be used for other purposes after approval from KraftPowercon. The product must not be used for charging batteries or welding. Read the instruction manual before installing, using or working on the product.

WARNING!

Only authorised personnel may install this product. It must be installed in accordance with the installation instructions and local regulations.

WARNING!

Only authorised personnel may carry out servicing or maintenance.

WARNING!

Always safely disconnect the electric power supply before starting servicing or maintenance work. The work must be done in accordance with the service instructions in the Technical Description.

The product is intended only for professional use. It must not be used in homes and offices.

Technical Description

FlexKraft

Page 2 (122) 77-107.0223 GB 2012-07-05 Rev. H

Contents, overview 1

SAFETY INSTRUCTIONS ........................................................................................................1

CONTENTS, OVERVIEW ...................................................................................................................2 CONTENTS, DETAILED.....................................................................................................................3 2

GENERAL.................................................................................................................................7

3

TECHNICAL DATA ................................................................................................................10

4

OPERATION...........................................................................................................................17

5

OPERATING INSTRUCTIONS...............................................................................................24

6

OPTIONS/OPTIONAL FUNCTIONS ......................................................................................52

7

EXAMPLES, CONFIGURATIONS AND OPTIONS ...............................................................74

8

SERVICING AND MAINTENANCE........................................................................................99

9

PROGRAMMING ................................................................................................................. 104

10

WARRANTY ........................................................................................................................ 118

11

APPENDICES...................................................................................................................... 118

The manufacturer reserves the right to change specifications.

Technical Description

FlexKraft

Page 3 (122) 77-107.0223 GB 2012-07-05 Rev. H

Contents, detailed 1

SAFETY INSTRUCTIONS ........................................................................................................1

CONTENTS, OVERVIEW ...................................................................................................................2 CONTENTS, DETAILED.....................................................................................................................3 2

3

4

5

GENERAL.................................................................................................................................7 2.1

Summary and key components...................................................................................7

2.2

Different configurations ...............................................................................................8

2.3

Brief overview of functions..........................................................................................9

TECHNICAL DATA ................................................................................................................10 3.1

General data ................................................................................................................10

3.2

Mechanical data ..........................................................................................................10 3.2.1 Rectifier .........................................................................................................10 3.2.2 Busbars .........................................................................................................11 3.2.3 Rectifier DC connection.................................................................................13 3.2.4 Control cabinet ..............................................................................................14

3.3

Supply side..................................................................................................................14

3.4

Load side .....................................................................................................................16

3.5

Controller/control signals ..........................................................................................17

3.6

Options ........................................................................................................................17

3.7

Standards ....................................................................................................................17

OPERATION...........................................................................................................................17 4.1

General.........................................................................................................................17 4.1.1 Operating modes ...........................................................................................18

4.2

Running programs, programming features .............................................................18 4.2.1 Basic data......................................................................................................18 4.2.2 Profiles...........................................................................................................19 4.2.3 Functions .......................................................................................................21

4.3

Block schematic..........................................................................................................22

4.4

Control .........................................................................................................................23 4.4.1 Protection circuits ..........................................................................................23

OPERATING INSTRUCTIONS...............................................................................................24 5.1

Manual operation ........................................................................................................24 5.1.1 General..........................................................................................................24 5.1.2 Keypad ..........................................................................................................24 5.1.3 LED indication ...............................................................................................25 5.1.4 Sound indication ............................................................................................25 5.1.5 LCD display ...................................................................................................25 5.1.6 Special functions ...........................................................................................25 5.1.7 Alarms / Warnings / Fault messages.............................................................25 5.1.8 Increase/decrease keys for current and voltage ...........................................27

5.2

Menu system ...............................................................................................................27 5.2.1 Overview of the menu tree with chapter reference .......................................28 5.2.2 Overview of the menu tree for SERIES and PARALLEL ..............................29 5.2.3 Overview of the menu tree for DUAL and DUAL-2 .......................................31 5.2.4 Start menu .....................................................................................................33 5.2.5 Main menu.....................................................................................................33 5.2.6 Duty menu .....................................................................................................36

Technical Description

FlexKraft

Page 4 (122) 77-107.0223 GB 2012-07-05 Rev. H

5.2.6.1 PARALLEL and SERIES mode................................................................36 5.2.6.2 DUAL and DUAL-2 mod ...........................................................................37 5.2.6.3 COMMUNICATION for no protocol ..........................................................37 5.2.6.4 COMMUNICATION for MODBUS RTU....................................................38 5.2.6.5 COMMUNICATION for PROFIBUS .........................................................38 5.2.6.6 DIAGNOSTICS.........................................................................................38 5.2.7 Set menu .......................................................................................................39 5.2.8 Block..............................................................................................................40 5.2.8.1 Pausing a program ...................................................................................40 5.2.8.2 Restarting paused program......................................................................41 5.2.9 CFG menu .....................................................................................................41 5.2.9.1 Prog menu................................................................................................41 5.2.9.1.1 Edit menu ............................................................................................42 5.2.9.1.2 Copy menu ..........................................................................................43 5.2.9.2 User menu................................................................................................43 5.2.9.3 Cal menu ..................................................................................................46 5.2.9.4 KRAFT menu............................................................................................48

6

5.3

Remote control............................................................................................................48

5.4

Functions.....................................................................................................................49 5.4.1 Process timer.................................................................................................49 5.4.2 Ah counter function........................................................................................49 5.4.3 Start ramp......................................................................................................49 5.4.4 EOP (End Of Process) ..................................................................................49 5.4.5 Resolution, current indication ........................................................................50 5.4.6 Reduction of output current and output voltage ............................................50 5.4.7 Blocking .........................................................................................................50 5.4.8 Fan control.....................................................................................................50 5.4.9 Locking keypad to input parameters, SLAVE mode......................................50 5.4.10 Under voltage / short circuit detection ...........................................................51

OPTIONS/OPTIONAL FUNCTIONS ......................................................................................52 6.1

Signal names and explanations ................................................................................53

6.2

Control via RS 485 A4 ................................................................................................53 6.2.1 Connection ....................................................................................................54

6.3

Control via RS-232 A5 ................................................................................................54 6.3.1 Connection ....................................................................................................54

6.4

Analogue control I/O A9.............................................................................................55 6.4.1 Connection ....................................................................................................56 6.4.2 Technical data ...............................................................................................57

6.5

Analogue digital I/O for analogue control box or PC/PLC A10 ..............................57 6.5.1 Connection ....................................................................................................58 6.5.2 Wiring example..............................................................................................59 6.5.3 Technical data ...............................................................................................60

6.6

Digital I/O A11..............................................................................................................60 6.6.1 Connection ....................................................................................................61 6.6.2 Wiring example..............................................................................................62 6.6.3 Technical data ...............................................................................................62

6.7

Parallel duty I/O A13 Master/Slave ............................................................................62 6.7.1 Connection ....................................................................................................63

6.8

Dosing function...........................................................................................................63

6.9

Contactor .....................................................................................................................64

6.10 External emergency stop ...........................................................................................64 6.10.1 Connection ....................................................................................................65 6.10.2 Additional parts in the rectifier. ......................................................................66

Technical Description

FlexKraft

Page 5 (122) 77-107.0223 GB 2012-07-05 Rev. H

6.11 Remote FlexKraft panel..............................................................................................66 6.11.1 Connection ....................................................................................................67 6.11.2 Additional components in the rectifier ...........................................................67 6.12 Analogue control box .................................................................................................68 6.12.1 Connection ....................................................................................................69 6.12.2 Additional components in rectifier .................................................................70 6.13 Control KRAFT analogue ...........................................................................................70 6.13.1 Connection ....................................................................................................71 6.13.2 Additional components in the rectifier ...........................................................72 6.13.3 Configuration of FlexKraft..............................................................................72 6.14 Air filter in power module ..........................................................................................72 6.15 Fresh air coupling for power modules .....................................................................73 6.16 Lifting eyes ..................................................................................................................73 6.17 Option, order specific.................................................................................................73 7

8

9

EXAMPLES, CONFIGURATIONS AND OPTIONS ...............................................................74 7.1

Normal configuration, without program control......................................................74

7.2

Program control, PARALLEL or SERIES mode. ......................................................76 7.2.1 DC current, switching off ...............................................................................76 7.2.2 DC current, time limit, HOLD.........................................................................77 7.2.3 DC current, time limit, BUZZER only.............................................................78 7.2.4 Ah limit, without HOLD ..................................................................................79 7.2.5 Anodising, voltage control .............................................................................80 7.2.6 Anodising, current control/voltage control .....................................................82

7.3

Program control, DUAL mode. ..................................................................................84 7.3.1 With/without HOLD ........................................................................................84

7.4

Program mode, Polarity reversal ..............................................................................87 7.4.1 Hard-chroming, polarity rev., HOLD, ext. alarm, PARALLEL/SERIES mode87 7.4.2 DUAL mode, with/without HOLD ...................................................................89 7.4.3 Polarity reversal with start ramp ....................................................................92

7.5

Program mode, Repeat function ...............................................................................93 7.5.1 Polarity reversal with start ramp and repeat..................................................93

7.6

Option ..........................................................................................................................95 7.6.1 Dosing function..............................................................................................95 7.6.2 Remote control ..............................................................................................96 7.6.2.1 Serial communication ...............................................................................96 7.6.2.2 Analogue control ......................................................................................97 7.6.2.3 Digital I/O..................................................................................................97 7.6.2.4 Remote and local control..........................................................................98

SERVICING AND MAINTENANCE........................................................................................99 8.1

Preventive maintenance.............................................................................................99

8.2

Troubleshooting instructions....................................................................................99

8.3

Replacement of components.................................................................................. 100 8.3.1 If several rectifiers are placed close together............................................. 100 8.3.2 Changing the filter ...................................................................................... 100 8.3.3 Replacing of the fan in the power module.................................................. 101 8.3.4 Replacing the power module...................................................................... 101 8.3.5 Replacing a fuse in the control unit supply................................................. 102 8.3.6 Replacing a fuse in the power module ....................................................... 102

8.4

Calibration instructions .......................................................................................... 103

PROGRAMMING ................................................................................................................. 104

Technical Description

FlexKraft

Page 6 (122) 77-107.0223 GB 2012-07-05 Rev. H

9.1

General...................................................................................................................... 104 9.1.1 Remote control ........................................................................................... 104 9.1.2 RS-232 ....................................................................................................... 104 9.1.3 RS-485 ....................................................................................................... 104 9.1.4 Westermo MA-45 RS232/RS485 converter ............................................... 105

9.2

Profibus DP .............................................................................................................. 105 9.2.1 Overview of registers.................................................................................. 106 9.2.2 Programming examples ............................................................................. 109 9.2.3 Troubleshooting Profibus communication .................................................. 109 9.2.4 GSD file ...................................................................................................... 110 9.2.5 Tips & Tricks............................................................................................... 110

9.3

Modbus RTU............................................................................................................. 110 9.3.1 Overview of registers.................................................................................. 111 9.3.2 Programming examples ............................................................................. 117 9.3.3 Troubleshooting MODBUS communication ............................................... 117 9.3.4 Troubleshooting Modbus RTU ................................................................... 117

10

WARRANTY ........................................................................................................................ 118

11

APPENDICES...................................................................................................................... 118 11.1 Equipment diagram, stand-alone rectifier and parallel -master ......................... 119 11.2 Equipment diagram, parallel-slave ........................................................................ 121 11.3 Spare part list ........................................................................................................... 122 11.4 Description of order-specific equipment, where applicable. .............................. 122

This description applies to software version FLX-01 VER. 02.50 and later. Slight differences can exist between the program versions. When upgrading to firmware version 2.5x from 2.xx no special action is needed. To upgrade the software from earlier versions, contact KraftPowercon service. NOTE! If upgrading from version 01.xx to version 02.xx, please make a note of the settings of the CFG and SET menus, as it may be necessary to re-enter these settings after upgrading the software. The manufacturer reserves the right to change specifications.

Technical Description

Page 7 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft

2 General FlexKraft is a modular rectifier developed for professional users. High operational reliability and adaptation to automatic control systems are significant properties of this rectifier. The rectifier is primarily intended to supply power to galvanic baths in surface treatment processes such as electroplating, anodising and PCB plating. This rectifier was designed with KraftPowercon Sweden AB’s many years of experience of switchedmode static converters for galvanic electroplating, to be used in applications where small size, high reliability and good current quality are important. The main distinguishing features of the FlexKraft rectifier are: • • • • • • • •

Ruggedness Modular design Suitability for the electroplating environment Suitability for connection to automatic control systems Low DC ripple High accuracy Compactness High efficiency

A rectifier may be made up of one to ten power modules. The power modules are identical. If more current is needed, up to 10 power modules can be used with a single rectifier. Contact the service department at KraftPowercon Sweden AB. Several rectifiers can be mounted in a stack up to 10 modules high. The control module does not have to be on the top of the stack. Several rectifiers can be connected in parallel if higher currents are required. The rectifier is intended to be controlled from a master control system or a built-in control unit. The controller has a display and a data entry unit for setting voltage and current, rectifier start/stop and readout of operational data and faults. FlexKraft is equipped with EMC filters according to the EMC directive.

2.1

Summary and key components

6

7

5

A

B

1 2 3

8

1 2 3 4 5 6 7

4

8

Top Control module Power module Base Display with keys Connection to mains supply Connections for control signals Signs with connection information. Busbars

Side A is on the left when viewed from in front

Technical Description

FlexKraft

2.2

Page 8 (122) 77-107.0223 GB 2012-07-05 Rev. H

Different configurations

Rectifier for PARALLEL or DUAL mode

Stack of four single-module rectifiers

Stack of one three-module and one four-module rectifier

Rectifier with control module in middle

Bench-top model

Four rectifiers connected in parallel with 10 power modules in each. Master rectifier located to the left. Master rectifier must be at one end

Technical Description

Page 9 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft 2.3

Brief overview of functions Please note that some functions require that options are installed.

Heading

Sub-function 1

Sub-function 2

Sub-function 3

Operating modes PARALLEL SERIES DUAL DUAL-2

Pole reversal Water cooling

Remote control

RS485

PROFIBUS DP MODBUS RTU

RS232

MODBUS RTU (one unit)

current

0-20mA 4-20mA

voltage

0-10VDC 0-6 VDC 0-5 VDC 6-0 VDC 10-0 VDC

contacts

Increase/decrease current Increase/decrease voltage ON/OFF START/STOP RUN/BLOCK

Program

No. 1-4

STEP U-RAMP I-RAMP PULSE REPEAT

Ah limit

Side A Side B

Stop rectifier Signal HOLD function U/I

Time limit

Side A+B

Stop rectifier Signal HOLD function U/I

Under voltage

Limits Side A Limits Side B Time limit Side A Time limit Side B

Voltage Time

Dosing function

Side A Side B Total A+B

Dosing pulse time

Monitoring

Temperature Regulation Configuration

Serial communication

Analogue

Limits

External emergency stop

Please note that some functions require that options are installed.

Technical Description

Page 10 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft

3 Technical data 3.1

General data

Parameter Operating temperature Air humidity Weight Dimensions Degree of protection Cooling

Value 0 - 40 ºC Max 95% RH See mechanical data See mechanical data IP 32 Forced air

Altitude

Max 1000m above sea level

Comment 0 - 50 °C with reduced rated data. Contact KraftPowercon Sweden AB Non-condensing Chapter 3.2 Chapter 3.2 Does not apply to the fan. Each power module: Air consumption 170m3/h Maximum power loss at full load 1000W Typ.value @12/600:980W @15/500: 830W For higher altitudes Contact KraftPowercon Sweden AB

Duty Continuous Load Electroplating baths Installation, see User Guide 77-107.0222, chapter Installation.

3.2

Mechanical data Rectifier H1

3.2.1

H

H

B1

B

D

1-7 (1-5) modules

8-10 (6-10) modules (Applies to rectifiers equipped with option contactor) Height

Number of modules 1 2 3 4 5 6 7 8 9 10

Width B mm 500 500 500 500 500 500 500 500 500 500

D

Höjd

Without contactor With contactor

H mm

H mm

450 590 730 870 1010 1150 1290 1570 1710 1850

450 590 730 870 1010 1290 1430 1570 1710 1850

Depth D mm 600 600 600 600 600 600 600 600 610 610

Weight

Vikt

Without contactor

With contactor

kg

kg

49 76 102 133 160 188 220 252 286 315

49 76 102 133 160 194 226 258 292 322

Table 1. Dimensions and weight

Width Height B1 mm H1 mm 380 380 380 380 380 380 380 380 380 380

95 95 95 95 95 95 95 95 95 95

Technical Description

FlexKraft

Page 11 (122) 77-107.0223 GB 2012-07-05 Rev. H

Base height 125 mm. Weight including DC busbars. Dimensions do not include lifting eyes, if fitted (+50 mm). 3.2.2 Busbars Busbars 8,9,10 power modules.

10 modules

9 modules

8 modules

Busbars 5,6,7 power modules.

7 modules 6 modules Dimensions are typical, normal manufacturing tolerances apply.

5 modules

Technical Description

FlexKraft

Page 12 (122) 77-107.0223 GB 2012-07-05 Rev. H

Busbars 2, 3, 4 power modules.

4 modules

3 modules

2 modules

Dimensions are typical, normal manufacturing tolerances apply. Hole diameters in the DC busbars are 11 mm and intended for M10 bolts. On rectifiers with more than one power module, the load cable shall be connected in the middle of the bus bar or evenly distributed along the interconnected busbars at the rear of the rectifier. Connection must not be made at one end of the busbar, the interconnecting busbar might be overloaded, resulting in a risk of rectifier failure. Example of load connection.

If the connection to the load are made with too small dimension and in the wrong way, the temperature of the busbars will rise over the allowed limit of 75ºC. The over temperture guard inside the power module will the shut off the rectifier-

Technical Description

FlexKraft 3.2.3

Page 13 (122) 77-107.0223 GB 2012-07-05 Rev. H

Rectifier DC connection Busbar projection from rear of rectifier, PARALLEL, DUAL or DUAL-2 mode.

1 power module Busbar width 50 mm

2-6 power modules

60 mm

7-8 power modules

75 mm

9-10 power modules

Dimensions are typical, normal manufacturing tolerances apply Busbar projection from rear of rectifier with busbar connected in SERIES mode.

1 power module Busbar width 50 mm

2-6 power modules

60 mm

7-8 power modules

Dimensions are typical, normal manufacturing tolerances apply

75 mm

9-10 power modules

Technical Description

FlexKraft 3.2.4

3.3

Page 14 (122) 77-107.0223 GB 2012-07-05 Rev. H

Control cabinet

Supply side

Parameter Primary voltage (Phase to phase) Primary current Mains frequency Power factor Efficiency Contactor

Value 3x 380-480 V AC +-10% or 3x220 V AC +-10% with reduced output See table below. See rating plate. 47 – 63 Hz. Sinusoidal ≥ 0.93 at rated load Typically 0.9 at rated load Efficiency is better at 15/500 than 12/600. Optional equipment

Comment See chapter 3.4 Load side

Typically 0.8 at primary voltage 220VAC and 2x7V/300A per power module

NB!

The rectifier must be connected to protective earth. The rectifier must be connected to a Y-connected transformer with earthed zero point. (Voltage- phase to zero point (earth) = (voltage phase to phase)/√3. This is the normal connection of a power distribution net)

NB!

Each rectifier must be fused separately. Only one rectifier should be connected to the same fuse

NB!

The rectifier has high leakage current to earth. (The leakage current due to EMC components) Protective earth should always be connected in a reliable manner so that the rectifier does not become live in the event of a fault.

NB!

If earth fault breakers are fitted, there must be one for each rectifier. The type of the earth fault breaker shall be B.

The maximum output current or output voltage can be reduced in the CFG/USER menu. See chapter 5.2.9.2 User menu. The maximum output current or output voltage can be factory limited, this factory limitation can be decreased but not increased in the CFG/USER menu.

Technical Description

FlexKraft

Page 15 (122) 77-107.0223 GB 2012-07-05 Rev. H

Primary current at primary voltage 380-415VAC. Module output 2x12-15V/300-250A Uprim V 380V 400V 415V Conn. Conn. Conn. area area area 2 2 2 Number Iprim A Iprim A mm Fuse Iprim A Iprim A mm Fuse Iprim A Iprim A mm @25°C @25°2 @25° of modules Unom U-10% Unom U-10% Unom U-10% A A 16 15 14 1 14 1,5 16 13 1,5 16 13 1,5 31 29 28 2 28 6 32 26 6 32 26 6 46 44 42 3 42 10 50 39 10 50 38 10 61 58 56 4 55 16 63 52 16 63 51 16 76 73 70 5 69 25 80 65 25 80 63 25 92 87 84 6 83 25 100 78 25 100 76 25 107 102 98 7 96 50 125 91 50 125 88 25 122 116 112 8 110 50 125 104 50 125 101 50 137 130 126 9 124 70 160 117 70 160 113 70 152 145 140 10 137 70 160 130 70 160 126 70

Fuse A 16 32 50 63 80 100 100 125 160 160

Primary current at primary voltage 440-480VAC. Module output 2x12-15V/300-250A Uprim V 440V 460V 480V Conn. Conn. Conn. area area area 2 2 2 Number Iprim A Iprim A mm Fuse Iprim A Iprim A mm Fuse Iprim A Iprim A mm @25° @25° @25° of modules Unom U-10% Unom U-10% Unom U-10% A A 14 13 13 1 12 1,5 16 12 1,5 16 11 1,5 27 26 25 2 24 6 32 23 6 32 22 4 40 38 37 3 36 10 40 34 10 50 33 10 53 51 49 4 48 16 63 46 16 63 44 10 66 63 61 5 60 25 80 57 16 63 55 16 79 76 73 6 71 25 80 68 25 80 65 25 92 88 85 7 83 25 100 80 25 100 76 25 106 101 97 8 95 50 125 91 50 125 87 25 119 114 109 9 107 50 125 102 50 125 98 50 132 126 121 10 119 70 160 114 70 160 109 50

Fuse A 16 25 40 50 63 80 100 100 125 125

Primary current at primary voltage 220VAC. Module output 2x7V/300A Uprim V 220V Conn. area 2 Number Iprim A Iprim A mm Fuse @25° of modules Unom U-10% A 17 1 14.5 2,5 20 33 2 29 10 40 49 3 43.5 10 50 65 4 58 25 80 81 5 72.5 25 100 97 6 87 25 100 113 7 101.5 50 125 129 8 116 70 160 146 9 130.5 70 160 162 10 145 95 200 Cable areas (at 25 ºC ambient) and fuse ratings are guideline figures. Observe local regulations and ambient temperatures when dimensioning cables. Rectifiers that are intended for connection to a 380-480VAC supply cannot be used at 220VAC.

Technical Description

Page 16 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft 3.4

Load side

Primary voltage 380-480 VAC Parameter Value Voltage 2x0-15V Current 0-12V 2x300 A/module 0-15V 2x250 A/module Current ripple < 2% of rated current with current control over the entire control range Linearity Ah-Limit A

Ah AAh-Limit B Timer>TimerLimit A

Ah BAh-Limit A

Ah AAh-Limit B

Ah B ProcessTimerLimitReachedA TimerLimit A

Timer A< TimerLimit A

10024

23

R

C/V-mode A

Voltage Mode

Current Mode

10025

24

R

C/V-mode B

Voltage Mode

Current Mode

0 0 0 0 0

Controlregister bit07 Controlregister bit08 Controlregister bit09 Controlregister bit10 Controlregister bit11

0 Controlregister bit12 0 Controlregister bit13 0 Controlregister bit14 0 Controlregister bit15

Description The cause of alarm is to be found in the Alarms register The cause of warning is to be found in the Warnings register When in local, unit can not be controlled by serial bus if Running, unit is working according to set parameters A-side Shows if pre-set Ah-Limit is reached. (A-side if dual output) Shows if pre-set Ah-Limit is reached. (B-side if dual output) Shows if pre-set Process Timer Limit is reached A Shows if A-Side is running in Voltage Mode. Load Impedance may be to high. Shows if B-Side is running in Voltage Mode. Load Impedance may be to high.

Note

Statusregister b00

Statusregister b01

Statusregister b02

Statusregister b03

Statusregister b04

Statusregister b05 Statusregister b06

Statusregister b07

Statusregister b08

Technical Description

Page 113 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft Modbus Parameterlist Digital Actual values PLC PC Input Input No. No. R/W Name

1

0

10026

25

R

On

On or StandBy

Off

10027

26

R

Current HiRes

Current Hires

Current normal

10028

27

R

Running B

Running

Not running

10029

28

R

10030

29

R

10031 10032

30 31

R R

Timer B> ProcessTimerLimitReachedB TimerLimit B Auxiliary In A active Aux In A Auxiliary In B active Aux In B

Modbus Parameterlist Digital Actual values PLC PC Input Input No. No. R/W Name

Timer B< TimerLimit B

1

0

Description Status of unit (Same as green LED on display) The bit is set if the resolution for current registers are 0.1A. if Running, unit is working according to set parameters B-side Shows if pre-set Process Timer Limit is reached B Programmable Digital Input A Programmable Digital Input B

Description

10033

32

R

10034

33

R

10035

34

R

10036

35

R

External Alarm A

Activated

OK

10037

36

R

External Alarm B

Activated

OK

10038

37

R

Maximum Power

Activated

OK

10039

38

R

IllegalParam

Activated

OK

10040

39

R

HighTemp

Activated

OK

Alarm from pole reverser A Alarm from pole reverser B Unit delivers maximum power Illegal Parameter. One or more parameters are in conflict. Check Parameters. High temp warning. One or more power-modules have shut down, or will do shortly

10041

40

R

10042

41

R

OK

Rectifiers fails to deliver requested output power, May be due to mains fault.

10043

42

R

10044

43

R

10045

44

R

10046

45

R

10047

46

R

10048

47

R

Regulation Error

Activated

Note

Statusregister b09

Statusregister b10

Statusregister b11 Statusregister b12 Statusregister b13 Statusregister b14 Statusregister b15

Note Warningsregister b00 Warningsregister b01 Warningsregister b02 Warningsregister b03 Warningsregister b04 Warningsregister b05

Warningsregister b06

Warningsregister b07 Warningsregister b08 Warningsregister b09

Warningsregister b10 Warningsregister b11 Warningsregister b12 Warningsregister b13 Warningsregister b14 Warningsregister b15

Technical Description

Page 114 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft

Modbus Parameterlist Digital Actual values PLC PC Input Input No. No. R/W Name

10049 10050

48 49

R R

1

Overtemp

Activated

0

OK

10051 10052 10053

50 51 52

R R R

Module failiure Alarm Ext A Alarm Ext B

Activated Activated Activated

OK OK OK

10054 10055 10056 10057 10058 10059 10060 10061 10062 10063 10064

53 54 55 56 57 58 59 60 61 62 63

R R R R R R R R R R R

Polarity control External alarm 1 Short circuit A-side Short circuit B-side

Activated Activated Activated Activated

OK OK OK OK

Modbus Parameterlist Actual values Output Mode: Series or Parallel PLC PLC Reg.No 30001

Discr. Inputs

30002

10017-10032

30003 30004 30005

PC Reg .No R/W 0 R

Critical error on one or more power modules. May need service. Alarm Ext A Alarm Ext B Polarity control Fault in CFG of pole reverse External alarm 1 Short CKT A-side Short CKT B-side

Name Reserved

Type Unsigned 16bit

1 R

StatusRegister

Unsigned 16bit

10033-10048

2 R

WarningsRegister

Unsigned 16bit

10049-10064

3 R 4 R

AlarmsRegister Output Voltage

Unsigned 16bit Signed 16bit

*0,01V

30006

5 R

Output Current

Signed 16bit

*1A/*0.1A

30007

6 R

Process Time High Word

Unsigned 16bit

*65536 s

30008

7 R

Process Time Low Word

Unsigned 16bit

*1 s

30009

8 R

Ah High Word

Unsigned 16bit

*65536 Ah

Ah Low Word

Unsigned 16bit

*1Ah

30010 30011 30012 30013 30014

9 10 11 12 13

R R R R R

Description Internal temperatures too high. Unit has shut down. Check cooling

Multiplier

Description Must be zero. Bit register, Indicates status of unit. See above Bit register, Indicates warnings. See above Bit register, Indicates alarms. See above Output Voltage

Output Current Number of seconds elapsed since Reset of Process Timer. High Word Number of seconds elapsed since Reset of Process Timer. Low Word Number of Ah since Reset of Ah-Counter. High Word Number of Ah since Reset of Ah-Counter. Low Word

Note

Alarmsregister b00 Alarmsregister b01

Alarmsregister b02 Alarmsregister b03 Alarmsregister b04 Alarmsregister b05 Alarmsregister b06 Alarmsregister b07 Alarmsregister b08 Alarmsregister b09 Alarmsregister b10 Alarmsregister b11 Alarmsregister b12 Alarmsregister b13 Alarmsregister b14 Alarmsregister b15

Range 0

0 - 65535 0 - 65535 0 - 65535 -30000 - 30000 -30000 – 30000 (1)

0 - 999999

0 - 999999

Technical Description

Page 115 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft Modbus Parameterlist Actual values Output Mode: Series or Parallel PLC PLC Reg.No 30015 30016

Discr. Inputs

Output Mode: Dual PLC PLC

PC Reg .No R/W 14 R 15 R

Name

Type

Multiplier

Description

Range

Name Reserved

Type Unsigned 16bit

Multiplier

Description Must be zero. Bit register, Indicates status of unit. See above Bit register, Indicates warnings. See above Bit register, Indicates alarms. See above Output Voltage ASide Output Current ASide Output Voltage BSide Output Current BSide Number of seconds elapsed since Reset of Process Timer. High Word Number of seconds elapsed since Reset of Process Timer. Low Word Number of Ah for Aside since Reset of Ah-Counter. High Word Number of Ah for Aside since Reset of Ah-Counter. Low Word Number of Ah for Bside since Reset of Ah-Counter. High Word Number of Ah for Bside since Reset of Ah-Counter. Low Word

Range 0

Reg.No 30001

Discr. Inputs

PC Reg .No R/W 0 R

30002

10017-10032

1 R

StatusRegister

Unsigned 16bit

30003

10033-10048

2 R

WarningsRegister

Unsigned 16bit

30004

10049-10064

3 R

AlarmsRegister

Unsigned 16bit

30005

4 R

Output Voltage A

Signed 16bit

*0,01V

30006

5 R

Output Current A

Signed 16bit

*1A/*0.1A

30007

6 R

Output Voltage B

Signed 16bit

*0,01V

30008

7 R

Output Current B

Signed 16bit

*1A/*0.1A

30009

8 R

Process Time High Word

Unsigned 16bit

*65536 s

30010

9 R

Process Time Low Word

Unsigned 16bit

*1 s

30011

10 R

Ah High Word A

Unsigned 16bit

*65536 Ah

30012

11 R

Ah Low Word A

Unsigned 16bit

*1Ah

30013

12 R

Ah High Word B

Unsigned 16bit

*65536 Ah

30014 30015 30016

13 R 14 R 15 R

Ah Low Word B

Unsigned 16bit

*1Ah

0 - 65535 0 - 65535 0 - 65535 -30000 - 30000 -30000 – 30000 (1) -30000 - 30000 -30000 – 30000 (1)

0 - 999999

0 - 999999

0 - 999999

Technical Description

FlexKraft

Modbus Parameterlist Analog setvalues Output Mode: Series or Parallel PLC PLC PC Reg.No Coils Reg.No R/W 40001 0 R/W

Page 116 (122) 77-107.0223 GB 2012-07-05 Rev. H

Name PageNo

Type Multiplier Unsigned 16bit

1 R/W

Controlregister

Unsigned 16bit

40003

2 R/W

Set Voltage

Signed 16bit

*0,01V

Set Voltage

40004

3 R/W

Signed 16bit

*1A/*0.1A

40005

4 R/W

40006

5 R/W

40007

6 R/W

40008

7 R/W

Set Current Process Timer Limit High Word Process Timer Limit Low Word Ah-Limit High Word Ah-Limit Low Word

Set Current Pre-set for process timer. High Word Pre-set for process timer. Low Word Pre-set for AhCounter. High Word Pre-set for AhCounter. Low Word Initial start ramp after activation of start bit

40002

0001700032

40009 40010 40011 40012 40013 40014 40015 40016

8 9 10 11 12 13 14 15

Unsigned 16bit *1 s Unsigned 16bit *65536Ah Unsigned 16bit *1Ah

Startramp

Unsigned 16bit *0.1 s

Name PageNo

Type Multiplier Unsigned 16bit

1 R/W

Controlregister

Unsigned 16bit

40003

2 R/W

Set Voltage A

Signed 16bit

*0,01V

Set Voltage A-Side

40004

3 R/W

Set Current A

Signed 16bit

*1A/*0.1A

Set Current A-Side

40005

4 R/W

Set Voltage B

Signed 16bit

*0,01V

Set Voltage B-Side

40006

5 R/W

Signed 16bit

*1A/*0.1A

40007 Output Mode: Dual PLC PLC Reg.No Coils

6 R/W

Set Current B Process Timer Limit High Word

Set Current B-Side Pre-set for process timer. High Word

Output Mode: Dual PLC PLC Reg.No Coils 40001

40002

0001700032

R/W R/W R/W R/W R/W R/W R/W R/W

Unsigned 16bit *65535 s

Description Reserved Controls On/Off, Start/Stop etc. Also bit accessible. See above

PC Reg.No R/W 0 R/W

PC Reg.No

R/W

Unsigned 16bit *65535 s

40008

7 R/W

Name Process Timer Limit Low Word

Type

Multiplier

40009

8 R/W

Ah-Limit A High Word

Unsigned 16bit *65536Ah

40010

9 R/W

Ah-Limit A Low Word

Unsigned 16bit *1Ah

Unsigned 16bit *1 s

Description Reserved Controls On/Off, Start/Stop etc. Also bit accessible. See above

Use Def. Range 0 0

0 0 - 65535 0 - (Rated 0 Voltage*100) 0 - Rated Current 0 (2) 0 0 - 999999 0 0 0 - 999999 0 0 0-30000

Use Def. Range 0 0

0 0 - 65535 0 - (Rated 0 Voltage*100) 0 - Rated Current 0 (2) 0 - (Rated 0 Voltage*100) 0 - Rated Current 0 (2) 0 0 - 999999

Use Description Def. Range Pre-set for process timer. Low Word 0 Pre-set for AhCounter A-Side. High Word 0 0 - 999999 Pre-set for AhCounter A-Side. Low Word 0

Technical Description

Page 117 (122) 77-107.0223 GB 2012-07-05 Rev. H

FlexKraft Modbus Parameterlist Analog setvalues

40011

10 R/W

Ah-Limit B High Word

40012

11 R/W

Ah-Limit B Low Word

Unsigned 16bit *1Ah

40013 40014 40015 40016

12 13 14 15

Startramp

Unsigned 16bit *0.1 s

R/W R/W R/W R/W

Unsigned 16bit *65536Ah

Pre-set for AhCounter B-Side. High Word Pre-set for AhCounter B-Side. Low Word Initial start ramp after activation of start bit

0 0 - 999999 0 0 0-30000

(1) When reading actual current, divide by 10 if Hires, status register 10; is activated (2) When writing set current, multiply by 10 if Hires, status register 10; is activated

9.3.2 Programming examples Example 1 The rectifier is controlled from a Profibus master (PC or PLC), parallel duty. Control the rectifier as follows: 1. Start the rectifier by writing 3 to register 40002 2. Set the voltage by writing to register 40003 3. Set the current by writing to register 40004 Operation is supervised by reading registers 30002, 30005 and 30006.

9.3.3 Troubleshooting MODBUS communication If communication cannot be established: -

Check the communication settings, Baudrate, number of bits, parity, stop bit Check that the rectifier is in Remote mode (yellow LED on front panel). Check that the rectifier has the correct address. Check that the cable is correctly terminated. (terminated at the last device in the loop) Try reversing the polarity of the fieldbus cable. Check that there are not two devices with the same address on the field bus. Check that the Digital/Analogue inputs are configured correctly.

9.3.4 Troubleshooting Modbus RTU The rectifier sends low byte first (default). High byte can be sent first if required, by activating the BYTESWAP function.

Technical Description

FlexKraft

Page 118 (122) 77-107.0223 GB 2012-07-05 Rev. H

10 Warranty KraftPowercon Sweden AB provides a warranty as stated in the order acknowledgement or contract. The warranty covers defects in design, materials and manufacturing. Defects that can be shown to have arisen as a consequence of incorrect use and/or maintenance are not covered. If a fault develops during the warranty period, KraftPowercon Sweden AB or local representative must be contacted before any work is undertaken on the rectifier. KraftPowercon Sweden AB P.O. Box 2102 SE-445 02 SURTE Sweden

Phone: Fax: E-mail:

11 Appendices The appendices are on the pages that follow.

+46 31 - 979700 +46 31 - 979797 [email protected]

Technical Description

FlexKraft Appendices

Page 119 (122) 77-107.0223 GB 2012-07-05 Rev.H

11.1 Equipment diagram, stand-alone rectifier and parallel -master

Technical Description

FlexKraft Appendices

Page 120 (122) 77-107.0223 GB 2012-07-05 Rev.H

Partial enlargement of circuit drawing on the previous page

The 24 VDC output is a source for feeding optocouplers and switches for input signals to the rectifier. Applies to all PCB:s.

NOTE! +24VDC on PCB is supply for signals. See relevant option in chapter 6.

Technical Description

FlexKraft Appendices

11.2 Equipment diagram, parallel-slave

Page 121 (122) 77-107.0223 GB 2012-07-05 Rev.H

Technical Description

FlexKraft Appendices

Page 122 (122) 77-107.0223 GB 2012-07-05 Rev.H

11.3 Spare part list FlexKraft

Spare part List

Det.No.

Denomination

A1,8 A2 A3 A4 A5 A7 A9 A10 A11 A12 A13 A14 E1 F1-3 F1-3 K1,2 U1 X1 X2,3

Control Module RFI-Filter PCA Control unit MK 445 PCA LCD display MK 446 PCA RS 485 converter MK 436 PCA RS 232 converter MK 436 Keyboard PCA insulated analog I/O MK 451 PCA analog digital I/O MK 450 PCA digital I/O MK 452 PCA Adaption unit MK 453 PCA Parallel duty MK 449 PCA Pole reverse MK 490 Fan Fuse Fuse holder Contactor Power supply Connection block main supply Connection terminals 6 pol. Ribbon cable set

Power Module Complete power module A1:A,B PCA Primary MK 470 A2-3:A,B PCA Snubber MK 468 A4:A,B PCA Output MK 471 A5 PCA fuse unit MK 469 A5:F1-3 Fuse A6 PCA control unit MK 444 E1 Fan L1:A,B Choke T1:A,B Transformer T2:A,B Current sensor V1:A,B Rectifier V2-4:A,B Diode Ribbon cable set Led indicator Always supply the rectifiers order number Cxxxxxx or xxxxxxxxxx at spare part order. 11.4 Description of order-specific equipment, where applicable.