Voltage Dip-Proofing Inverter
Contents
1. DPI53512 24mF230V8A DPI54L15mF230V25A DPI54L30mF230V25A DPI54L45mF230V25A DPI54L90mF230V25A DPI54L135mF230V25A DPI54L180mF230V25A DPI54L225mF230V25A DPI54L270mF230V25A DPI54L315mF230V25A Single phase supply voltage Maximum input voltage Full load current A 230V 50 60Hz 10 25A Nominal off state voltage 250Vac RMS Peak off state voltage Nominal current A Short time overload current lt 100ms Non repetitive peak on state current 10ms 30A 700A co oS gt Z DI 230Vac RMS 10 Nominal output voltage Voltage fluctuations over full operating range Nominal load current A Overload current A Power factor range N pas DI z oo g cosa from 1 to 0 Stepped square Nominal load VA Storage capacitors F 00408 00612 01224 015 030 045 090 135 180 225 270 315 Usable stored energy factor m 0 53 55 Minimum up time as function of the load t FC aV coon 4 hoax 0S D Output frequency 50 60Hz 1 Max recovery time of capacitors to 95 Vin m 5 oO WO NO E ee 00 gt co D ul J VI on N aS Peak off state voltage Z Nominal current A ooo Short time overload current lt 100ms Non repetitive peak on state current 10ms Nominal output voltage o Voltage fluctuations over full operating range Nominal load current A O Overload current A o O 10A Power factor range o o Nominal load VA ____2. Imsec detection time oth of the above 2 3 4 0 of Se wo level 1 0 0 0 gt 30 ofnon voltagefixedruntime of 200msec 1 0 0 0 Noise immune 0 1 Noise immune and Two level a a oe Factory setting Noise immune TRANSFER LEVEL DSW3 Sets the supply voltage level at which the inverter switches to run mode The level can be varied between 65 and 90 of the nominal supply voltage by setting the switches according to the table in Fig 5 Factory setting 75 Page 10 Installation amp Service Manual Set Transfer Off On Off On Set Inverter DSW3 Run Time Press to Calibrate INVERTER RUNNING DSW2 Cm ZZ Fig 5 Control Card Indicator and Adjustment Locations Diagnostics 1 Supply Voltage Out of Range If the unit supply voltage is permanently outside the 10 range of the supply voltage to which the unit is calibrated Vcal the unit will not power up and there will be no LED indicators on Recalibration to the new supply voltage is necessary Diagnostic relay outputs 2 Unit faulty relay contact opens T6 T7 if There is no power on input T1 T2 If at power up the supply voltage does not exceed the set transfer level Unit control power supply is faulty Microcontroller faulty Microcontroller watchdog activated program execution problem Inverter fuse blown No voltage on storage capacitors Unit has no output voltage T3 amp T4 Event detectio
3. Storage capacitors F Usable stored energy factor m Minimum up time as function of the load Output frequency sd f ca o gt pas N Oo UI an re an N ee UI N oo an oo Timer Range and Setting 0 05 3 15s in 0 05s steps Transfer Level Range and Setting 90 to 65 of calibrated supply voltage V in 5 steps stem OK green LED Inverter running red LED Maximum ambient working temperature 45 C 113 F Construction Height mm Height in Width mm Depth mm Mass kg Mass Ibs able Copper panel wire 2mm 14AWG 5mm 10AWG Screw terminal torque 1 76 Nm 15 6 Ib in Underwriters Laboratories Inc UL Listing Pending Page 6 Installation amp Service Manual Up time considerations The up time that a DPI can achieve is dependent on the usable energy in the storage capacitors and on the characteristics of the supported load Load characteristics are critical in determining the up time Resistive loads with a power factor near 1 consume real power and the up time will be shortest Resistive loads include lamps switch mode power supplies and linear power supplies Contactors use little real power as they are a reactive load with power factors around 0 15 Reactive loads such as contactors give the longest up time The formulae below can be used to determine the minimum up time that can be achieved for an application It uses the load current load voltage load power factor
4. the value of the DPI storage capacitors and a stored energy factor to calculate the value Minimum up time as function of the load t N C a Veupoy lioa COS O Minimum up time t Value of storage capacitor s C a Stored energy factor n Load voltage V Load current loa Load power factor cos supply From the formulae it can be seen that the power factor cos has a significant influence on the up time Resistive loads with cos 1 will yield the shortest up time while reactive loads with cos 0 15 will yield the longest up time For example A Using DPI model DPI54L15mF230V25A find the minimum up time for a predominantly resistive load say a PLC power supply and some small relays Value of storage capacitor s 0 015F Stored energy factor 0 55 Load voltage 230V Load current 6A Load power factor 0 8 Minimum up time t 0 55 0 015 230 6 0 0 8 0 39 seconds B Using DPI model DPI54L15mF230V25A find the minimum up time for a predominantly reactive load say some small contactors and relays Value of storage capacitor s 0 015F Stored energy factor 0 55 Load voltage 230V Load current 6 0A Load power factor 0 15 Minimum up time t 0 55 0 015 230 6 0 0 15 2 1seconds The examples illustrate the importance of knowing the load power factor when calculating the minimum up time for a DPI application For best accuracy use the on line DPI Selector to find the corre
5. 0ms after power is removed Each short voltage dip now becomes a power failure and the plant must be restarted This can be complicated time consuming and costly DIP PROOFING TECHNOLOGIES VOLTAGE DIP PROOFING INVERTERS are designed to maintain the switchgear control voltage during voltage dips effectively keeping the plant connected The stored electrical and magnetic energy is allowed to flow supporting the mechanical inertia of the machinery When the power is restored after a short voltage dip the plant is still running at near synchronous speed the inrush currents will be small and the stress to the system minimal Historically this problem has been addressed by using DC contactors latched contactors and intelligent controls such as PLC s These systems are complex and expensive and do not provide a solution for equipment already in existence The current approach to this problem has been to employ intelligent control systems which provide a curative solution In contrast the Voltage Dip Proofing Inverter provides a preventative solution 2 Theory of operation The VOLTAGE DIP PROOFING INVERTER is designed to be maintenance free and highly reliable It consists of a static switch in series with and an inverter parallel to the load Energy is stored in a capacitor bank the inverter block diagram is shown in Fig 1 Inverter SUPRI Storage Capacitor Fig 1 Inverter Block Diagram Page 3 Installation amp Service
6. Installation amp Service Manual Voltage Dip Proofing Inverter DPI53S 54L Series Models 120V amp 208 230 50 60Hz DIP PROOFING TECHNOLOGIES VING LEADERS IN VOLTAGE DIP PROOFING Installation amp Service Manual Contents DI 0 REA RR RR RO RR RE 3 FMCONOTO PERA zioni airline dai 3 PECE O Srila lar 5 Up time considerations i 6 ISEE 06 CERRO ERO 7 Test ANd Maintenance iii 9 DEC ARRE IAA 10 Mechanical Outline 11 ACCS SONO eaae e lena iA liceo 14 Notice IMPORTANT SAFETY INSTRUCTIONS KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE This manual contains important instructions that should be followed during installation and adjustment of all DPI54 Series Voltage Dip Proofing Inverters Page 2 DPI54 Series Firmware Ver 1 0 Installation amp Service Manual 1 Introduction The reliability of electrical power to industry is in general very high nevertheless voltage sags and short power interruptions or voltage dips occur These instabilities are caused by short circuits lightning strikes on overhead power lines and heavy load switching The duration of such faults is generally shorter than one second Most plant can ride through such voltage dips by virtue of their mechanical and electrical inertia However this is not the case with electrically held in contactors and relays that control the machinery Contactors typically drop out from 5ms to 2
7. Manual The STATIC SWITCH is robust and can withstand large current surges It is ideally suited for contactor operation where high peak currents of short duration occur during energizing The INVERTER is configured as a full bridge with overcurrent and short circuit protection The output waveform is a square wave where the RMS and the peak voltage are the same as fora sine wave as shown in Fig 2 Fig 2 Inverter stepped square wave output waveform This is important for circuits where magnetic devices such as transformers and contactors RMS voltage are in circuit with electronic relays that derive their DC voltage from capacitor input filters peak voltage The computer grade CAPACITOR BANK operates under ideal conditions being charged to working voltage but carrying no ripple current most of the time During stand by operation the static switch supplies power directly to the load the inverter is switched off and the capacitors are charged to the full operating voltage The supply voltage is constantly monitored for deviations should there be a deviation from Vnom which is greater than the preset value the static switch is switched off and the inverter is activated The switch over is accomplished in less than 200us A 3 15 second timer adjustable in increments of 50ms starts timing the inverter out Should the input voltage recover within the set time the inverter supply is synchronized to the mains and the load is switched back
8. Stock No 5003 006 Housed By Pass Switch 25A Page 15 Installation amp Service Manual Voltage Dip Proofing Inverter DPI53S 54L Series Models 120V amp 208 230 50 60Hz Motor Control Centre k B2 B3 7 Stop Stop Stop Storage Bridge 7 si 1 Capacitor Inverter Elo F Klo E il Main 1 i Start Start Stan Breaker _ Bypass Switch Inter Inter inter Locki Lock Lock gt Control Voltage C1 C2 A Typical DPI Connection Diagram Measurlogic Inc 7334 S Alton Way Suite 14M Centennial CO 80134 USA 1 877 777 6567 Fax 425 799 4780 Email info measurlogic com web www measurlogic com Tel
9. al Block for 53S Series Options Z ol ee ee o Terminal 1 Line In Supply Terminal 1 Line In Supply Terminal 2 Common line in Terminal 2 Common line in out Terminal 3 Common line out Terminal 3 Line out Load Terminal 4 Line out Load Terminal 4 Unit Faulty n o Terminal 5 Unit Faulty n o Terminal 5 Unit Faulty n o Terminal 6 Unit Faulty n o Terminal 7 Event detection n o Terminal 8 Event detection n o Page 13 Installation amp Service Manual Accessories This page left blank intentionally Page 14 Installation amp Service Manual Accessories Housed Bypass Switch Description Where no break maintenance Is required a bypass switch must be installed It connects the supply directly to the load Bypass position and disconnects the power terminals of the inverter without interrupting the supply When in DPI position the load is connected to the supply via the inverter SPECIFICATIONS Model BPSW25A ELECTRICAL Maximum current 25A Maximum Input Voltage 600V AC TEMPERATURE Maximum Working Temperature 45 C 113 F HOUSING Construction Extruded Aluminium Height 202mm 7 95in Width 150mm 5 9in Depth 141mm 5 55in Mass 1kg 2 2lbs Mechanical Outline O Line In Line Out Common Line In Out S To upply lq 140 5 51 _ gt 0 5 90 Dimensions in mm inches Ordering
10. apacitors to 95 Vin 0 05 3 15s in 0 05s steps 90 to 65 of calibrated supply voltage V in 5 steps N we O amp Fr CO w o N O E RO oo o co WWJ UI Timer Range and Setting Transfer Level Range and Setting Nominal output voltage Voltage fluctuations over full operating rang Nominal load current A Overload Current A o Power factor range Cd Nominal load VA Storage capacitors F Z Usable stored energy factor m Minimum up time as function of the load _ Output frequency Max recovery time of capacitors to 95 Vin Timer Range and Setting Transfer Level Range and Setting SystemOK _______ System OK green LED Maximum ambient working temperature 45 C 113 F Extruded Aluminum 190 306 48 12 05 11 18 11 18 11 18 17 87 21 42 24 96 28 5 32 05 35 59 19 1 22 25 3 418 55 68 2 81 4 946 108 able Copper panel wire 2mm 14AWG 5mm 10AWG Screw terminal torque 1 76 Nm 15 6 Ib in Underwriters Laboratories Inc UL Listing Pending Page 5 onstruction Height mm Height in S 5 02 Slo O N 5 co gt Depth mm Mass kg Mass Ibs _ gt z gt BU AN AJO ze 9 w via wr O O 2 cr 3 VI n OJ i w o Installation amp Service Manual Specifications DPI 53S 54L Series 208 230V Models DPI5352 04mF230V2A DPI5354 08mF230V4A DPI5356 12mF230V6A
11. ct size DPI for an application Link http www dipproof com products dpi_selector asp Page 7 Installation amp Service Manual Installation Guide 1 2 7 Remove the unit from its packing Place the unit horizontally on a bench and visually check for any mechanical damage Ensure that all the casing screws are tight then shake the unit to check that there is nothing loose internally Check that the inverter voltage is the same as the system control voltage Refer to the rating label on the unit end plate WARNING Never connect a 120V unit to a 230V supply Decide on the location where the unit is to be installed this will probably be inside a switch gear panel Mountthe unit vertically using M6 bolts Connect unit as shown in Fig 3 using 2mm 14AWG DPI54S Series amp 5mm 10AWG DPI54L Series copper panel wire Apply terminal screw tightening torque of 1 5 1 8Nm 13 16 Ib in 8 This device does not have a disconnect switch If such a switch is required it must be provided by others Power Wiring Connections Page 8 Line In Supply to Terminal 1 Common Line In to Terminal 2 Common Line Out to Terminal 3 Line Out Load to Terminal 4 Ground screws to be connected on the unit to the panel ground point G O O E E E E Ol O O O Note Terminals 2 and 3 are linked internally Fig 3 Power Wiring Diagram Installation amp Service Manual 9 Once the unit has been mo
12. ent up to 2 hours after the DPI has been disconnected unless the storage capacitors have been manually discharged Adjustments All adjustment points are marked on the top cover plate and can be reached by removing the two screws securing the main label INVERTER RUN TIME DSW1 This switch sets the running time of the inverter and can be set in 50ms steps to a maximum of 3 15 seconds To determine the inverter run time which is currently set add the figures printed next to each switch which is in the ON position For example a running time setting of one second requires that the following switches be in the ON position 200 800 these figures added give 1000ms or 1s Factory Setting 1000ms CALIBRATION TOA SUPPLY VOLTAGE SW1 Cal The unit can be calibrated for a different supply voltage for example a 230V unit used on a 208V supply The Calibrate button Cal is used to program the unit to operate on a specific supply voltage WARNING Never connect a 120V unit to a 230V supply Refer to the unit rating label before connecting the supply Connect the unit to the supply and switch on Press the Calibrate button Cal The System OK green LED will switch off for approximately 3 seconds and then switch back on The unit is now calibrated for the supply voltage to which it is connected Factory Setting Calibrated to rating label Vnom ADJUSTMENTS DSW2 SWITCHES DESCRIPTION 1 Standard QO 250usec detection time O1
13. n relay contact changes state T8 T10 when The inverter runs to support an event Note The options for diagnostic and event detection outputs should be specified when ordering They are also available as a retrofit kit Due to space restrictions the DPI53S Series supports the diagnostic option only Page 11 Installation amp Service Manual Mechanical Construction 53S Series The DPI case is made from extruded aluminium sections The four parts that make up the case are interlocked and secured by screws To remove the front cover unscrew four screws the two top screws from the end plate where the terminal block is located and the two bottom screws from the other end plate Slide the front cover away from the terminal block Note that there are no user serviceable parts inside the unit All adjustment points are marked on the top cover plate and can be reached by removing the two screws securing the main label 54L Series The DPI case is made from extruded aluminium sections The six parts that make up the case are interlocked and secured by screws To remove the front cover unscrew five screws one from the front cover and two each from the top and bottom end plates Units are supplied with four or six mounting brackets depending on the case length The bracket positions are adjustable along the length of the case Dim L1 and L6 Note that there are no user serviceable parts inside the unit All adjustment points are marked o
14. n the top cover plate and can be reached by removing the two screws securing the main label Dimension Table a ERE na TAI O B DP15356 6mF120V2A DP153513 2mF 120V4A 110 4 33 150 5 90 15278 78 140 5 50 6 0 0 24 DP153519 8mF 120V6A DPI54L66mF 120V25A DPI54L99mF120V25A DPI54L198mF 120V25A DP154L297mF120V25A i 69 231 9 09 B50 13 78 60 2 36 330 13 01 8 0 0 31 DPI54L396mF 120V25A DPI54L495mF 120V25A DPI54L594mF 120V25A DPI54L693mF 120V25A 36 i DP15352 04mF 230V2A DP15354 08mF 230V4A i 33 150 5 90 70 5 2 78 140 5 50 6 0 0 24 DP153S6 12mF 230V6A DP153 12 24mF 230V8A 30 1 18 DPI54L15mF 230V25A DPI54L30mF 230V25A DPI54L45mF 230V25A DPI54L90mF 230V25A DPI54L135mF 230V25A 231 9 09 B50 13 78 60 2 36 330 13 01 8 0 0 31 DPI54L180mF 230V25A DPI54L225mF 230V25A l i DP154L270mF230V25A DP154L315mF230V25A i Indicates 6 mounting brackets dimension L1 L1 2 Pagg 12 Installation amp Service Manual Mechanical Outline S Series Case L Series Case Model example Model example DPI53S6 12mF230V6A DPI54L Terminal_y COVer rai Terminal_y COVER loss Note Terminal cover shown dashed Mounting bracket spacing is adjustable Some longer units are supplied with 6 Terminal Block for 54L Series Options Termin
15. to the supply the capacitors are recharged in less than one second and the inverter is ready to compensate for the next voltage dip If the input voltage does not recover within the set time the load is switched back to the supply regardless of the voltage level Page 4 Installation amp Service Manual Specifications DPI 53S 54L Series 120V Models DPI5356 6mF120V2A DPI53513 2mF120V4A DPI53519 8mF120V6A DPI53S39 6mF120V8A DPI54L33mF120V25A DPI54L66mF120V25A DPI54L99mF120V25A DPI54L198mF120V25A DPI54L297mF120V25A DPI54L396mF120V25A DPI54L495mF120V25A DPI54L594mF120V25A DPI54L693mF120V25A 120V 50 60Hz 10 25A Single phase supply voltage Maximum input voltage Full load current A N pas a oo g Nominal off state voltage 150Vac RMS Peak off state voltage 800V Nominal current A Short time overload current lt 100ms Non repetitive peak on state current 10ms 170A N x Se oO Flay ee e DN I 700A Nominal output voltage 120Vac RMS Voltage fluctuations over full operating rang 10 Nominal load current A Overload Current A Power factor range N pS E re 5 Fl a z oo UJ NO 5 VI cos fromlto0 Stepped square Nominal load VA Storage capacitors F 0396 033 066 099 198 297 396 495 594 693 Usable stored energy factor Mm 52 t MEC aV suon AMOS PD Minimum up time as function of the load 50 60Hz 1 Max recovery time of c
16. unted and the external wiring completed power can be applied Turn on the power to the unit After about two seconds the green LED indicator System OK should come on The unit is now fully operational 10 In applications which require no break maintenance a bypass switch must be installed Order Housed Bypass Switch model DPIBPSW which should be connected as shown in Fig 4 11 In applications where preventative maintenance programs are in place the DPI Tester amp Bypass Switch DPI TAB1 should be used to monitor DPI functionality amp activity Line ne Out Common Line In Out sapo oea oe Line In Line Out Supply Vnom Load Common Line In Common Line Out Housed Bypass Switch Connection Diagram Functional Description Indicators System OK Green LED indicator When the green LED is ON the system is fully functional the unit self test and initialization routine has run successfully Inverter Running Red LED indicator The red LED is on when the inverter is running during a voltage dip Astepped square wave is present on the output terminals 3 and 4 Page 9 Installation amp Service Manual Test and Maintenance There are no user serviceable parts inside the unit if faulty return to factory or local agent for repairs WARNING Risk of electric shock capacitor s store hazardous energy NEVER attempt any maintenance on the DPI until storage capacitors are fully discharged Dangerously high voltages can be pres
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