MESTA DPM Bedienungsanleitung

MESTA ELECTRONICS, INC.

Digital Power Manager

50 amp Panel

Owner’s Manual

11020 Parker Drive N. Huntingdon, PA 15642

412/754-3000

SAVE THESE IMPORTANT

SAFETY INSTRUCTIONS

Table of Contents

1. INTRODUCTION ..................................................................................................................................1

1.1 THEORY OF OPERATION............................................................................................................1

2. SAFETY PRECAUTIONS.....................................................................................................................2

3. INSTALLATION ....................................................................................................................................3

3.1 PLACING THE DIGITAL POWER MANAGER ..............................................................................3

3.2 CONNECTING POWER WIRING AND EXTERNAL CURRENT SENSORS ................................4

3.2.1 INSTALLATION PROCEDURE..............................................................................................5

3.2.2 CUSTOMER RELAY CONTACTS .........................................................................................5

4. OPERATING THE UNIT.......................................................................................................................6

4.1 TURNING ON THE UNIT...............................................................................................................6

4.2 FRONT PANEL TOUCH SCREEN DISPLAY................................................................................7

4.3 STATUS CONNECTIONS .............................................................................................................9

4.4 PREVENTATIVE MAINTENANCE.................................................................................................9

5. SERIAL/ETHERNET COMMUNICATIONS........................................................................................10

5.1 CONNECTING TO THE SERIAL COMMUNICATIONS INTERFACE.........................................10

5.2 CONNECTING TO THE ETHERNET INTERFACE.....................................................................11

5.3 SYSTEM SOFTWARE COMMANDS...........................................................................................12

5.3.1 STATUS REPORTS.............................................................................................................12

5.3.2 DPM DATE AND TIME.........................................................................................................13

5.3.3 HISTORICAL EVENT DATABASE DISPLAY INFORMATION ............................................14

5.3.4 CHANGING SYSTEM OPERATING PARAMETERS ..........................................................14

APPENDIX A. DPM SPECIFICATIONS BY MODEL..............................................................................17

APPENDIX B. CUSTOMER INSTALLATION DIAGRAM .......................................................................19

APPENDIX C. WARRANTY/SERVICE AND REPAIR............................................................................21

List of Illustrations

Figure 1: Enclosure Installation Clearances .............................................................................................3

Figure 2: Installation Block Diagram.........................................................................................................4

List of Tables

Table 1: Ratings for required branch circuit protection.............................................................................4

Table 2: Ratings for required branch circuit protection.............................................................................4

Table 3: RS232 Pin Configuration ..........................................................................................................10

Table 4: Serial Communications Protocol...............................................................................................10

Table 5: Status Display Parameters .......................................................................................................13

3ACDPM050 - 3ACDPM300

(Page Intentionally Left Blank)

1. INTRODUCTION

Electronic equipment and controls, such as computers, computer peripherals, AC and DC motor drives

and many other critical and commonly used electronic hardware in the market place today, immensely

overburden the electric utilities with various harmonic distortions. Such equipment, or nonlinear loads,

uniquely characterized with high current crest factor (C.F.) and low power factor (P.F.) create a

harmonic distortion in the plant utility grid. These distortions make the operation of communications and

other sensitive equipment nearly impossible. Electric utilities are using more sophisticated metering

equipment to monitor power factor so that distortion power factor is now measured in addition to the

traditional displacement power factor. This can result in substantial penalty charges on a plant's electric

bill. Power consultants, computer and communications specialists are therefore compelled to include in

their specifications compliance to ANSI/IEEE 519-1992 stringent requirements, which define the

maximum amount of harmonic distortion that newly installed equipment and controls are allowed to

inject in the utility lines.

Many approaches have been devised in the past, aimed to minimize the harmonic distortion. Special

zigzag transformers, phase shift transformers, and passive filters have all brought some type of

harmonic relief, but not without severe limitations. Since the generated harmonics are a function of the

actual load, and can vary during the course of the operation, it is impossible to design such a filter in

advance, which will cover any and all loads and harmonics conditions.

Unlike the harmonic correction methods listed above, the Mesta Digital Power Factor and Harmonic

Manager (Mesta DPM) is a true active filter. Its design does not necessitate knowledge regarding the

harmonic profile of the load. Only the Total Current Distortion and phase displacement are required in

sizing the DPM to any existing non-linear load.

1.1 THEORY OF OPERATION

The Mesta DPM coexists with the utility voltage, remaining phase-locked and voltage-equalized. The

four quadrant Mesta inverter, the heart of the Mesta DPM, operates at a modulation frequency of

several thousand cycles per second, which allows the DPM to respond to the exact need as it

develops. The inverter draws energy from the utility at some portions of the cycle, stores the energy,

then delivers that energy to the load later in the cycle when it is needed. The powerful microcontroller,

while it is continuously investigating the load harmonics, instantaneously directs the energy/current flow

in and out of the inverter, thus, improving the line current harmonic content and power factor.

WARNING

Always keep the front door fastened. Leaving the unit’s door open may expose personnel to an

electrical shock hazard that could result in death or injury, or damage to the DPM or to the electrical

loads it is correcting.

2. SAFETY PRECAUTIONS

Always keep the door closed and locking screws in the locked position. This equipment should be

installed, operated and maintained only by qualified personnel. The only time that the unit should be

opened is for initial installation or routine maintenance. The following warnings apply to the equipment

and should be read and fully understood by qualified personnel before they begin working on the unit:

WARNING

Risk of Electric Shock exists inside the Digital Power Manager (DPM) enclosure. The AC Disconnect

should be in the OFF position for 5 minutes prior to opening the door of the unit. For additional safety,

if possible, the external AC breaker feeding the DPM and the non-linear load should also be locked in

the OFF position. If this is not possible, the top terminals of the disconnect inside the unit will be

electrically hot, and must therefore be avoided. Even with the disconnect turned off, hazardous

voltages may exist within the unit for several minutes after the disconnect is turned off. THESE

HAZARDOUS VOLTAGES REPRESENT A POSSIBLE SHOCK HAZARD THAT COULD RESULT

IN DEATH OR INJURY TO PERSONNEL.

WARNING

The Digital Power Manager (DPM) contains capacitive components that remain energized for several

minutes after power to the DPM has been removed. The AC disconnect should be in the OFF

position for 5 minutes prior to opening the door of the unit. Of particular interest are the large can

capacitors mounted in front of the heat sink. Two red lights mounted on the High Voltage Interface

PC Board indicate if these capacitors are charged to hazardous levels. If either of these two red lights

is lit, potentially deadly voltage exists on these capacitors. While these capacitors are charged,

hazardous voltage exists in several places within the unit (including, but not limited to all DC filter

capacitors; bussbars associated with the capacitors; the components on the heatsink; several other

components located on the back panel; and the High Voltage Interface PC Board). The capacitors

have circuits to discharge them. Do not proceed into the unit until the capacitors have been

sufficiently discharged, signified by both red lights being off. Once the red lights are off, carefully

measure the voltage across a far left and a far right large DC buss capacitor using a DC voltmeter,

making sure you do not come in contact with any other metal objects within the cabinet. Make certain

that both voltages you have measured are below 10 vdc before proceeding within the cabinet.

WARNING

Do not rely entirely on the red lights for safety. A failure in the lights or circuits that drive the lights

could result in no lights being lit when a hazardous voltage exists. However, never proceed into the

unit if the lights are on. Always use a DC voltmeter to measure the actual capacitor voltage once the

lights are dim or off. Do not come in contact with any metal objects that are not grounded to the

frame while making this measurement.

WARNING

The AC Disconnect MUST remain in the OFF position at all times while the door to the system is

open. Turning the AC Disconnect on after the door has been opened will result in hazardous voltages

being present at many locations within the unit. SUCH HAZARDOUS VOLTAGES COULD CAUSE

ELECTRIC SHOCK THAT COULD RESULT IN DEATH OR INJURY.

3. INSTALLATION

This equipment should only be installed, operated and maintained by qualified personnel that have

been trained to work with potentially hazardous electrical equipment.

Before the Digital Power Manager can be operated properly, the unit must be mounted to a sturdy wall

(wall mounted), or placed on a level surface (free standing) with the power and signal wiring properly

connected. It is highly recommended that before any wiring is done, the installer consults the Local and

National wiring codes to determine the adequate AWG of the wire and suitable conduit to house the

external wiring. In order to perform any of the following wiring functions, the AC disconnect in the unit

must be in the off position as well as the distribution box breaker that connects the DPM to the utility

and load. In addition, all of the safety instructions and warnings located in the “Safety Precautions”

section of this manual should be read before proceeding.

3.1 PLACING THE DIGITAL POWER MANAGER

The Digital Power Manager is designed to be either wall mounted or free standing, depending on the

current rating of the system. Open Panel models can be mounted inside a suitable industrial enclosure.

The wall-mounted enclosures have holes located on the

back of the enclosure for bolting the unit to a wall. The

wall-mounted units should be mounted so that there is a

gap of at least one foot between the bottom of the

enclosure and the floor. This distance is necessary to

insure sufficient airflow into the box from the bottom. A

minimum of 9 inches of clearance is necessary between

the top of the enclosure and any significant obstructions

to allow adequate airflow out of the top of the box. The

box should be positioned so that AC, chassis ground,

and control wires can readily enter the top of the box on

the right and left sides, indicated in the wiring

instructions that follow. A minimum of 3 feet of clearance

in front of the unit is necessary to allow opening the door

sufficiently to service the unit. A minimum of 1 inch of

clearance is required on the left and right sides of the

cabinet. The diagram to the right reviews all of these

clearance specifications graphically. The DPM is

designed to operate in a 0ºC – 40ºC ambient

temperature.

Important Note: Industrial enclosures that are used to house open panel models must be

equipped with input air filter(s) and exhaust fan(s) to provide adequate air flow for the system.

Please refer to the air flow (CFM) and heat loss specifications in appendix A of this manual.

Consult factory if additional information is required.

The DPM may be placed in an industrial environment that is protected from water, metal filings or other

conductive impurities and corrosive chemicals. The area should not be subjected to an overwhelming

amount of dust or dirt; otherwise, frequent cleaning of the system and replacement of the input air filter

will be required. Refer to specifications (appendix A) for filter size and type.

Figure 1: Enclosure Installation Clearances

DPM

Min.

1 Ft

Min.

1" Min. 1" Min.

3.2 CONNECTING POWER WIRING AND EXTERNAL CURRENT SENSORS

Before beginning to install the system, confirm that the

voltage rating and system type (Delta) of the DPM is the

same as the load. Once this is confirmed, a suitable

interface must be found in the load circuit to connect the

DPM. This interface must be able to accommodate the

power wiring to the DPM, the wiring to the non-linear

load, the wiring from the utility, and the DPM current

sensors. The figure to the right shows all the

components just mentioned and illustrates the

connections between them.

For detailed installation drawings, refer to the

customer installation diagram for your particular model in appendix B of this manual.

The customer/installer is responsible for providing suitable (UL listed fuses or equivalent) branch circuit

protection for the power wiring leading to the DPM. The current rating of this branch circuit protection is

specified in the table below.

Table 1: Ratings for required branch circuit protection

Mesta DPM Model Min. Current Rating for Branch Circuit Protection

3ACDPM50-480-1 (or O) 63 amps

3ACDPM100-480-1 (or O) 125 amps

3ACDPM150-480-1 (or O 200 amps

3ACDPM200-480-1 (or O) 250 amps

3ACDPM300-480-1 (or O) 400 amps

The size (awg) of the power wiring leading to the Mesta DPM should be selected in accordance with

the current rating of the branch circuit protection indicated above, subject to any and all applicable

national and local electric codes. Any power or ground wire selected that is larger than 3 awg should

be derated, according to National Electric Code, to allow for the high frequency (400Hz) current

produced by the DPM.

Once the interface location, proper branch circuit protection and the appropriate power wiring have

been selected the DPM should be prepared for installation. On the right side on the top of the DPM

cabinet there is a pilot hole (two pilot holes for 200/300 amp systems), which is provided for the power

wiring. The pilot hole on the left side on the top of the system is provided for the CT wiring and the

wiring for the customer relay contacts. A qualified technician should use a punch to enlarge the pilot

holes on the cabinet for the appropriate type of conduit to be used. Drilling or filing should be avoided,

as any metal particles that fall inside the unit could interfere with the operation of the

electrical/electronic components of the system.

Table 2: Field Wiring Terminal Ratings (Copper Wire Only, 75°C wire or equivalent)

Mesta DPM Model Maximum Permissible Wire Range (awg) Terminal Torque (lbs.-in.)

3ACDPM50-480-1 (or O) 2/ 1/0 27

3ACDPM100-480-1 (or O) 3/0 125

3ACDPM150-480-1 (or O) 3/0 125

3ACDPM200-480-1 (or O) 350 MCM 140

3ACDPM300-480-1 (or O) Terminal Tabs accept 3/8” SAE grade 5 (M10) bolts 300

Figure 2: Installation Block Diagram

3.2.1 INSTALLATION PROCEDURE

To install a Mesta DPM with CTs (current transformers) monitoring the “line” side of the DPM, perform

the following recommended procedure. Do not attempt to turn on power to the DPM until all steps have

been completed. The line side is defined as the wiring from the utility that powers both the DPM and the

loads to be corrected. Conversely, the load side is defined as the wiring “after” the DPM that powers

only the loads to be corrected. The CTs should be rated for the maximum anticipated load current of

the conductor on which they will be installed. The I.D. of the CTs should be larger than the O.D. of the

conductors. For detailed installation drawings, refer to the customer installation diagram for your

particular model in appendix B of this manual.

Note: The Mesta DPM may not operate properly if power factor correction capacitors are connected on

the load side of the CTs. CTs must be installed on the load side of these capacitors for proper operation.

Consult factory for any questions regarding the presence of power factor correction capacitors.

1) It is highly recommended for safety reasons to turn off power feeding the circuit that powers the

DPM and loads to be corrected prior to proceeding.

2) Designate the 3 phases of your power circuit as phases A, B, and C. Phase rotation is not a

concern, so the designation you make is arbitrary. If power is off and kept off until all of the

remaining steps are completed, the remaining steps may be performed in any order; otherwise

step 3 must precede step 4.

3) Terminate the secondary leads of CT A to A+ and A- terminals, CT B to B+ and B- terminals,

and CT C (Optional) to C+ and C- of P1 of the CT Interface board inside the DPM enclosure. If

using CTs supplied by Mesta, the black lead is the “+” lead and the white lead is the “-“ lead.

Use a tightening torque of 4 in. lb. Also, use the provided mounting points and wire ties to route

the CT wires and provide strain relief.

4) Encircle the conductor(s) you designated as phase A of your power circuit that feed both the

DPM and the loads to be corrected with the CT marked “A”. Make sure to orient the CT so that

its arrow is in the direction from the line side (utility) to the DPM/load side. Repeat for phases B

and C (Phase C current sensor is required if single phase (line to neutral) loads are

present).

5) Through a breaker or set of fuses, wire the power wiring from your designated phase A to the

left-most terminal of the switch inside the DPM. Similarly, wire the power wiring from your

designated phase B to the middle terminal and phase C to the right-most terminal of the switch.

WARNING:

Once the circuitry that the CTs are monitoring is energized, DO NOT disconnect secondary wires of the

CTs from P1 or remove P1 from the CT Interface Board. Power feeding the circuitry monitored by the

CTs must be turned off before P1 connections are removed. Circuitry should not be reenergized until

either the CTs are removed or the secondary wires are properly terminated. CTs should never be

installed on live circuitry if the secondary wires are not properly terminated. Open circuit terminals of a

CT monitoring a live circuit may develop a lethal voltage across the secondary wires.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS INJURY OR DEATH.

Once all the power and signal connections have been made to the DPM, the electrical service can be

re-established to the node. The DPM should have its disconnect switch turned off when it is first

installed and the power is re-established.

3.2.2 CUSTOMER RELAY CONTACTS

A description of the customer relay contacts is available in the status connections section 4.3 of this

manual. The customer can choose to utilize these contacts for remote monitoring of the system. Refer

to section 4.3 of this manual and the installation diagram in appendix B for relay contact description

ratings and location.

4. OPERATING THE UNIT

The Mesta Digital Power Manager has been designed to have very little startup time and even less

maintenance. Since the DPM interacts with the existing power system, it does not have to be turned on

for the loads to operate. This is extremely beneficial if the unit needs to be serviced, the DPM can be

turned off indefinitely without affecting any of the loads. Once all the power and sensor connections

have been made, as described in the previous section, and the electrical service re-established, the

DPM can be turned on.

4.1 TURNING ON THE UNIT

To energize the unit, switch on the Disconnect located on the right side of the front door. If the power is

connected correctly, the touch screen display will turn on. Before the initial start up of the system the

operator should view the “POWER VOLTAGE” screen on the display to check for proper power, and

power factors readings. First press the “MENU” icon and then select the “POWER VOLTAGE” icon

from the menu. If the power and/or power factor readings are negative this may indicate that the

system current sensors are installed improperly. An extremely low power factor reading may also

indicate improper current sensor installation. If the display indicates a negative power, or a negative or

extremely poor power factor (with at least a minimal load of approx. 2 kW) turn the system off and

recheck the current sensor placement and connections before proceeding. WARNING: DO NOT

ATTEMPT TO REWIRE THE CURRENT SENSORS WHILE THE WIRES BEING MONITORED BY

THE CURRENT SENSORS ARE ENERGIZED. THIS MAY CAUSE SERIOUS DAMAGE TO THE

CURRENT SENSORS AND RESULT IN HIGH VOLTAGE THAT MAY CAUSE SERIOUS INJURY OR

DEATH. Do not enable the system until the “POWER VOLTAGE” display indicates positive power and

a positive power factor greater than approximately + .60 (with at least a minimal load current of approx.

2 kW).

After it has been established that the current sensors are installed properly, and the system indicates

positive power and power factor, the system can be enabled. To enable the system press the “RUN”

icon at the bottom of the screen. The display will prompt the operator to confirm the “RUN” command

by pressing the “RUN” icon a second time. In order to conserve energy, and to protect the system

against potential damage due to improper installation, the DPM will not initialize itself, and begin

operation unless the incoming line power read by the unit is > 5% of the power rating of the DPM. (The

power rating of the unit is equal to .83 kW per amp of correction. Ex. 100-amp DPM = 83 kW. 5% =

4.15 kW). If the line power is too low the display will indicate “LINE POWER TOO LOW” and the unit

will not begin to run. If there is no load available for start-up/testing of the system the minimum line

power parameter can be reduced by changing the unit disable % parameter via the serial/ethernet

communications interface as indicated in section 5.3.4 of this manual. After the DPM has initialized

itself it will begin charging the internal DC bus. This is indicated by a “PRECHARGING” message on

the display.

When the DC voltage bus has been completely pre-charged and the control determines it is OK to

proceed, the DPM begins correcting the harmonics and power factor (if enabled) of the line and the

display will indicate that the unit is operating. If the DPM current sensors are not installed with the

correct current orientation (sensor backwards) or phase orientation (sensors swapped), then the DPM

will attempt to run for a few seconds at maximum load then trip. If this is the case, shut down the

system and the utility feed and recheck the current sensors and their orientation to the power wiring.

WARNING: DO NOT ATTEMPT TO REWIRE THE CURRENT SENSORS WHILE WIRES BEING

MONITORED BY THE CURRENT SENSORS ARE ENERGIZED. THIS MAY CAUSE SERIOUS

DAMAGE TO THE CURRENT SENSORS AND RESULT IN HIGH VOLTAGE THAT MAY CAUSE

SERIOUS INJURY OR DEATH.

Once the unit is enabled and operating properly the “CURRENTS” display will appear after 5 seconds,

and the operator can observe the data to confirm that the current readings are correct and that the

system is operating properly.

4.2 FRONT PANEL TOUCH SCREEN DISPLAY

The Mesta DPM is equipped with a touch screen display on the front of the system, which can perform

the following functions and display the following parameters

“RUN” and “STOP” function – The system can be enabled or disabled by pressing the “RUN” or

“STOP” icons located on the touch screen. Once the “RUN” or “STOP” icon has been pressed

the system will prompt the operator to confirm the command by pressing the icon again within a

specified amount of time.

“MENU” function – After pressing the “MENU” icon the operator can select from the

“CURRENTS”, “POWER VOLTAGE”, “MISC. INFORMATION” or “SET PARAMETERS” pages

described below.

System Status display – The operating status of the system (“ON” or “OFF) is displayed towards

the bottom of the touch screen on every display page. Additional status information such as:

normal operation, max. load, reduced power factor mode, low AC line, and warning or

diagnostic messages are displayed directly below the “ON” or “OFF” status information.

“CURRENTS” display page – This is the default display during normal system operation. It can

also be selected from the “MENU” page. This display shows the relevant AC “line” currents, AC

“load” currents, and DPM (active filter) system currents.

“POWER VOLTAGE” display page - This display can be selected from the “MENU” page.

This display shows the relevant line voltages, line frequency, kW, KVA, and power factor. It

also displays the internal DC buss voltage of the system

“MISC. INFORMATION” display page – This display can be selected from the “MENU” page.

This display shows the line or load rms current (depending on CT placement), neutral current

and CT% loading. It also displays the temperatures of the system PC Boards and heat sink(s)

as well as internal system supply voltages.

“Set Parameters” function page – To view/set parameters, go to the MENU, and press

VIEW/SET PARAMETERS icon. There are presently 9 system operating parameters that can

be viewed and changed by using the front panel touch screen display (For an explanation of

each system operating parameter refer to section 5.3.4)

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