AMS 48_2000-n_D0114354_055_00

User Manual AMS 48/2000-8/16/24 ETS and PSC 3 Controller

Energy Syste Systems ms USER MANUAL

AMS 48/2000-8/16/24 48/2000-8/16/24 ETS AND PSC 3

Table of contents 1

Safety Instructions 20001_03.pdf

2

System Description Descriptio n 31001_02.pdf

3

Rectifier FR 48 V – 2000 W – E 32013_02.pdf

4

Installation and Commissioning 40030_01.pdf

5

Maintenance Maintenance Instructions 50001_04.pdf

6

Troubleshooting Instructions 60001_03.pdf

7 8 9 10

Wiring Diagrams, Final Test Report etc.

Energy Systems USER MANUAL

This page is intentionally left blank.

AMS 48/2000-8/16/24 ETS AND PSC 3


1

1.1

AMS 48/2000-8/16/24 ETS AND PSC 3

DOCUMENT INFORMATION Version control Document number

Document description

D0114354_055_00

User Manual, AMS 48/2000-8/16/24 ETS and PSC 3 Controller

Previous version

Description of changes

-

New document. Controlled by

Date 22.10.2004

Markku Havukainen Approved by

Date 22.10.2004

Petteri Turkki

1.2

System The AMS 48/2000-8/16/24 ETS is a modular large power system for power up to 48 kW. The stable construction is based on a frame cabinet design. The system contains three rectifier shelves for up to 24 rectifiers FR 48 V – 2000 W – E and different distribution units with configurable elements for AC-, DC distribution, LVD, PLD and a power system controller. The modular design allows flexible power system solutions in the ETS cabinet line and is the key factor of the success of this power system and it offers a cost effective and reliable solution. This power system is expandable with a 2nd cabinet. The typical applications for this power system are wireless base stations, core network components, telecommunications and data networks. This compact, high power density power system is the perfect choice for space-critical solutions.

1.3

User Manual Please read first carefully the safety instructions before installing and commissioning the system. The product description sections contain information and operating instructions for the rectifiers. In the installation and commissioning section there are step-by-step instructions for safe and correct installation and commissioning of the system. The maintenance section contains information for maintaining the high performance and reliability of the system. In case of a fault in the system, please refer first to the troubleshooting section of this user manual.

1.4

Contact Information For additional information or questions please contact your local Delta Energy Systems representative. For the contact information of our locations please check our website at www.deltaenergysystems.com.


AMS 48/2000-8/16/24 ETS AND PSC 3

Energy Systems

Safety Instructions Power Supply Systems

20001_03

Energy Systems SAFETY INSTRUCTIONS

POWER SUPPLY SYSTEMS

TABLE OF CONTENTS 1

DOCUMENT INFORMATION ........................................................................................5 1.1

2

Version control...................................................................................................5

SAFETY INSTRUCTIONS .............................................................................................7 2.1

General instructions...........................................................................................7

2.2

Special Instructions ...........................................................................................8





1

1.1




20001_03

Safety Instructions for Power Supply Systems

Previous version


20001_02

Applicable standards updated. Amendments to the content. Controlled by

Date 02.02.2004


Date 02.02.2004

Petteri Turkki





2


SAFETY INSTRUCTIONS

Warning! Please read the following instructions carefully. Ignoring these instructions may result in a loss of life or a health hazard for users working with the equipment and/or in damage to the equipment itself. These safety instructions are an extension of any national laws governing health and safety at work and the applicable EN, DIN, SEV, VDE and IEC standards and any regulations of the statutory authorities. The manufacturer cannot be held responsible for any danger or damage resulting from incorrect operation or usage of the equipment, failure to observe the instructions in the user's documentation and/or failure to observe the safety instructions.

2.1

General instructions •

Operation of and work on the equipment or parts thereof may only be performed by professional persons (qualified technicians) with appropriate experience who have been specially trained by the manufacturer/distributor (= authorised persons).

•

The weight of the components (specified on the front of the unit) requires that physically able-bodied persons be employed for installing / assembling the equipment or parts thereof.

•

If work on the equipment or parts thereof is necessary with the equipment under present voltage, another qualified technicians or a supervisor must be present in addition to the electrician performing the work. The supervisor should be capable of providing first aid in case of electrical hazard. Providing the electrician with an emergency switch or disconnection strap, so-called "dead man's switch", is not sufficient protection.

•

Work on the equipment may only be carried out using insulated tools and appropriate protective clothing (shoes, gloves, safety spectacles, etc.).

•

There is an increased risk of an accident and electrical hazard when working on compact equipment (different components mounted in a single cabinet, e.g. rectifier/inverter modules, DC distribution and battery connection), due to the close proximity of the various different components. Work should therefore be carried out with an extra attention to safety, and appropriate insulating covers over the live electrical parts must be provided for protection against accidental contact.

•

If the power supply equipment is not fitted with a disconnecting switch or equivalent device unit, for isolating it from the AC mains or any other hazardous voltage source, the operator of the power supply equipment is responsible for fitting the mains distribution board, battery system or other supplying equipment with appropriate disconnection switch conforming to the relevant regulations.


2.2


•

The input filters of the rectifier/inverter modules are not protected with input fuses. The operator is responsible for ensuring adequate protection for the equipment and wiring by means of an input fuse, if any rectifier/inverter module is used external to equipment supplied by the manufacturer/distributor and if the manufacturer/distributor is not allowed install fusing or a main distribution board.

•

Removing or inserting components from or into the equipment may result in changes to the performance of the equipment. The operator is therefore responsible for the consequences of any change in the hardware configuration that are made without an agreement with the manufacturer or his local representative.

•

The operator of the equipment is responsible for ensuring that personnel concerned with the equipment (authorised persons) are provided with safety training when the equipment is installed or when starting their employment and at regular 6-monthly intervals thereafter.

•

The operator of the equipment is responsible for ensuring that the rooms in which the equipment and batteries are set up are treated as electrical equipment rooms, which are only accessible to qualified personnel (authorised persons).

•

The operator of the equipment is responsible for ensuring that the equipment is installed in suitable rooms, if necessary with air-conditioning. If forced cooling (fan ventilation) is used, there must be adequate airflow in the room, as well as heating/cooling.

•

The units or individual parts of the equipment may only be opened by qualified employees (authorised persons) of the equipment operator, who have attended a special repair training course held by the manufacturer or his local representative.

•

The operator of the equipment is responsible for ensuring that the rectifier/ inverter / distributor rack is securely locked and not accessible to unauthorised persons.

•

Installation and dismantling of the equipment or parts thereof, as well as the laying of the connection cables may only be carried out by persons trained by the manufacturer/distributor (authorised persons).

•

The installation instructions and specifications in this user manual are a part of these safety instructions. The order of installation and the specified limit values must be adhered to in order to guarantee that the equipment is correctly installed and operated.

Special Instructions •

Localised areas of high temperature (> 70 °C) may occur within the rectifier/inverter/distributor rack. Adequate precautions against accidental burns must be taken.

•

Fuses should only be gripped using the tools provided for this purpose (Loadbreak switch handles, etc.)

•

Ensure adequate insulation from ground potential (earth) when working on the equipment or changing fuses.



•

The DC bussing of the power system (inverter/rectifier/converter) can be grounded either from positive system bus or a negative system bus, and operator is responsible to ensure and secure the correct polarity of the system while installing, operating and/or maintaining the equipment.

•

The power system may have dual energy supply by means of primary and secondary energy sources, and operator is responsible to secure the proper precautions by separating or disconnecting the sources for maintenance or service purposes.

•

Dangerous voltages may be present on the power connector or plug pins of the rectifiers/inverters for up to 10 seconds after unplugging the rectifier/inverter modules from the mains or switching off the mains voltage. This also applies to other parts of the equipment. Adequate precautions against electrical accident must be taken.

•

Some of the potentiometers for adjusting equipment components are mounted under the unit covers and can only be accessed through the ventilation slots of these components. Take care when making adjustments, and use appropriate tools (e.g. an insulated screwdriver for trimming), otherwise sensitive components may be damaged.

•

Only suitable measuring devices (e.g. high-impedance multimeter) may be connected to the voltage and current measurement sockets.

•

Incorrect operation of the equipment or parts thereof may alter the operating state of the system, trigger false alarms or discharge the batteries connected to the system. Ensure that the settings conform to the specifications, the system configuration and the limit values that you require.

•

Make sure that all voltage values are set correctly. Incorrect voltage settings may lead to an increase in the battery voltage and the consequent damage to batteries or even danger of explosion.

•

Ensure that the alarm limit values (trigger thresholds) are set correctly. Incorrect settings may trigger false alarms and cause the rectifier/inverter modules to switch off.

•

All temporary manipulations of the equipment or parts thereof that are carried out (e.g. for test purposes) must be reset manually. Automatic reset facilities are not provided.



Energy Systems

System Description DC Power Supply Systems

31001_02

Energy Systems SYSTEM DESCRIPTION

DC POWER SUPPLY SYSTEMS

TABLE OF CONTENTS 1


2

Version control...................................................................................................5

SYSTEM DESCRIPTION ...............................................................................................7 2.1

Operating modes ...............................................................................................8





1

1.1




31001_02

DC Power Supply System Description

Previous version


31001_01

Layout updated. Controlled by

Date 13.08.2003


Date 13.08.2003

Petteri Turkki






2 SYSTEM DESCRIPTION The Delta power systems are designed to efficiently supply uninterruptible DCvoltage to modern telecommunications equipment. The systems are constructed using steel profile based cabinets and switched-mode rectifiers of state-of-the-art and development of Delta Energy Systems. The systems are designed to fulfil the high reliability requirements of telecom environment. The schematic structure of the power systems is presented in Figure 1. The power system comprises switched-mode rectifiers having one or three phase input line connection, terminals for batteries, low voltage disconnections, load terminals with automatic circuit breakers or HRC fuses as well as a control, monitor and alarm unit for automatic operation of the system. Modem

Power System Controller

Remote user Local user

Relay

DC load Telecom Equipment

option

Mains

option

AC load

AC distribution

1 .. n Rectifiers

1 ... n Batteries

Converters / Inverters

Load distribution P0001

Figure 1.

The schematic structure of the Delta power system.

The modularity and extendibility of these power systems makes them ideal for all telecommunications applications, especially for the systems whose initial capacity is far from the final size. The extension can be made in phase with the real need simply by adding new system modules and battery cabinets.


2.1


Operating modes In normal operation mode the rectifiers deliver the load power taken by the telecom system and simultaneously maintain the batteries at full charge. During a line power outage or an excessive line-undervoltage, the rectifiers are shut down and the batteries deliver the load power. If the battery voltage decreases below the preset level, the optional deep discharge prevention circuitry disconnects the battery automatically. As the line power is restored to a proper level, the rectifiers start up automatically and begin to deliver the load power and recharge the batteries at current limiting mode. The batteries are important components in a telecom power system. The control and monitoring unit is designed to ensure long battery life and effective recharging of the batteries. Automatic boost charge is based on battery current. The system level control and monitoring functions include local and remote alarms and local controls of the system. The local alarms are shown by alarm LEDs. Remote alarms are issued by means of potential free relay contacts. The operation of the control and monitoring unit is presented in the product description of the controller.

Energy Systems

Product Description Rectifier FR 48 V – 2000 W – E

32013_02

Energy Systems PRODUCT DESCRIPTION

RECTIFIER FR 48 V - 2000 W - E

TABLE OF CONTENTS 1


2

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

3

Version control...................................................................................................5

Safety ................................................................................................................8

FUNCTIONAL DESCRIPTION ......................................................................................9 3.1

Input voltage range............................................................................................9

3.2

Inrush current limitation .....................................................................................9

3.3

Output characteristic..........................................................................................9

3.4

Output voltage .................................................................................................10

3.5

Output current..................................................................................................10

3.6

Cooling ............................................................................................................10

3.7

Overvoltage protection OVP............................................................................10

3.8

Thermal management .....................................................................................11

3.9

Load sharing....................................................................................................11

3.10

Precharge........................................................................................................11

3.11

Configuration ...................................................................................................12

3.12

Enhanced rectifier supervision and control functions.......................................12

3.12.1 Manufacturing data..........................................................................................12 3.12.2 Configuration data ...........................................................................................12 3.12.3 Commands / control data ................................................................................12 3.12.4 Information data...............................................................................................13 3.12.5 Measurements.................................................................................................13 4

FRONT ELEMENTS ....................................................................................................14 4.1

5

Rectifier status indications...............................................................................14

BACK PLANE..............................................................................................................15 5.1

Electrical connections......................................................................................15

6

MECHANICAL DIMENSIONS .....................................................................................16

7

TECHNICAL SPECIFICATIONS .................................................................................17





1

1.1




32013_02

Rectifier FR 48 V - 2000 W – E, Product Description

Previous version


32013_01

Input voltage range corrected. Controlled by

Date 22.10.2004


Date 22.10.2004

Petteri Turkki





2


GENERAL The rectifier FR 48 V - 2000 W - E is a single phase, hot-pluggable and fan-cooled rectifier. The constant output power characteristic supplies the specified power over the full output voltage range. The benefit is an optimized modular system design (fewer modules) that matches the supply requirements of state-of-the-art telecom equipment. This performance as well as the extended temperature range, wide input voltage range, high power density and advanced technology are the key factors for the success of this rectifier, offering a cost effective and reliable solution. The typical applications for this rectifier are both in indoor and outdoor environments, which is a perfect solution for wireless base stations, core network components, telecommunications networks and data networks. The rectifier meets the requirements set by the telecommunications standards. The rectifier contains two stages of high frequency power converter (Figure 1.): •

The power factor corrector (PFC) has a boost topology with a switching frequency of 90 kHz. It is responsible for the power factor and harmonic content of the input current.

•

The DC-DC converter has a phase shifted full bridge topology with a switching frequency of 100 kHz. It is responsible for galvanic isolation and power conversion to the DC output.

The control and interface circuit controls and protects the rectifier during all operation conditions appearing in a power system. The EMC filters guarantee the required standards.

ACinput

EMC input filter

Inrush current limiter

Power factor corrector PFC

Control and interface

Energy storage

DC-DC converter

EMC output filter

Auxiliary supply Primary auxiliary

DCoutput

Secondary auxiliary

Galvanic separation System bus

P0002

Figure 1.

Block Diagram describing the functionality of a rectifier.


2.1


Safety The rectifier meets the safety standards: •

EN 60 950 (2000-06) - class 1

•

UL 60950 rev 3 (Dec1, 2000)

•

CAN/CSA-C22.2 No. 60950-00

There are no user serviceable parts except the fan inside the unit. A faulty rectifier module should be replaced as a complete unit. The installation description must be strictly adhered to. The rectifier contains the following internal protection fuses: •

AC input fuses, F200 / F201, 15A fast, LITTELFUSE INC. P/N 324015

•

The protecting AC fuses are connected in L and N.

•

DC output fuse, F500, 50A (FK3), PUDENZ (WICKMANN GROUP)

•

The protecting DC fuse is connected in – pole.

These fuses are not accessible and should only be replaced in the Delta Energy Systems repair centre.


3

3.1


FUNCTIONAL DESCRIPTION Input voltage range If the input voltage exceeds the limits of the input voltage range the rectifier is shut off. The rectifier will restart up automatically as soon as the input voltage returns into the specified input voltage range. At low input voltages, an output power derating is enabled to limit the input current to acceptable values. full power

Pout / W reduced power

2000 60°C power derating

75°C power derating

800 650

Vin / Vrms 80 88 90

184 230

275

280

P0003

Figure 2.

3.2

Input voltage range

Inrush current limitation When the rectifier is first connected to the mains, the energy storage capacitors are charged via resistors. As soon as a certain voltage limit is reached, these resistors are short-circuited, the rectifier starts up and delivers output power.

3.3

Output characteristic The rectifier has a constant output power characteristic to meet the demand of optimal use of the power supply to electronic constant power loads. The result is a constant recharging current to the battery after a mains outage, and a better use of rectifier efficiency.

Uout [V] 58 53.5 43 42

2000 W control range

34.5 37.4

Figure 3.

Output characteristic

46.5

Iout [A] P0004


3.4


Output voltage The factory setting is defined for flooded battery types: 53.5 V. If a controller with voltage programming function is used, it can remotely adjust the rectifier output voltage to different values via analogue signal interface.

3.5

Output current The factory setting for the output current limit is 46.5 A DC.

3.6

Cooling The device is fan cooled. Note!

The airflow must not be restricted!

Shadowed area: air outlet on the rear

Figure 4.

3.7

Air flow P0005

Fan cooling of the rectifier.

Overvoltage protection OVP The rectifier is equipped with a selective over voltage protection (OVP), which shuts down the rectifier in case of output voltage exceeding an internally set limit. The protection is combined with a current measuring condition to achieve selectivity between parallel rectifiers; only the «guilty» rectifier will be shut down. The factory setting is 59 V. Reset of OVP shut down can be done by disconnecting the mains supply voltage for a few seconds.


3.8


Thermal management The rectifier is protected, with two integrated thermal sensors, in case of abnormal environment conditions, interrupted air flow and fan failure (Table 1.). Sensor

Monitoring

Function

Reference sensor

Combination of heat sink / fresh air temperature

Controls the overtemperature protection (OTP) characteristic.

Protection sensor

Main transformer temperature

Detects interrupted air flow and fan failure.

Table 1.

Thermal sensors.

The thermal management (reference sensor) reduces the output current in order t o limit internal temperature according the characteristic in Figure 5 below. Current limit

Rectifier restart

46.5 A 37.4 A

OTP shuts down >1300W Ambient temperature 50°C

Figure 5.

60°C 65°C

75°C

P0006

Reducing the output current in order to limit internal temperature.

The thermal management (protection sensor) protects the rectifier against interrupted air flow and fan failure. During these conditions, the rectifier is shut down as soon as the internal temperature reaches a critical value. After several unsuccessful restart attempts the rectifier remains shut down and generates an alarm.

3.9

Load sharing The rectifier is equipped with an active load sharing function that ensures equal load on parallel rectifiers. The function uses the signal interface bus between rectifiers. This function does not need any other external unit outside rectifiers.

3.10 Precharge The rectifier module is hot-pluggable. Pushing the rectifier into the cabinet connects leading precharge contacts first to precharge the DC output capacitors. The remaining output power contacts are connected with a delay.



3.11 Configuration In systems without controller or with PSC 200 / PSC 1000 the rectifier operates with the factory-set standard configuration; in systems with PSC 3 controller the configuration is automatically done upon inserting the rectifier module. Push button «Config» has two assigned functions: •

In system configurations with PSC 3, for the physical position numbering within a system. Refer to PSC 3 manual.

•

To reset configuration to default factory settings. Press button until LED «Com» starts blinking (10 sec. approx.)

3.12 Enhanced rectifier supervision and control functions In systems with PSC 3 controller applying the digital communication, following data and their appropriated functions are available.

3.12.1 Manufacturing data The manufacturing data is stored at production. It can be transmitted to PSC 3 upon request: •

SAP serial no. / SAP part no.

•

SW / HW version no.

•

User specific data (like user serial no.)

3.12.2 Configuration data The configuration data is stored in the PSC 3 and in the rectifier module. It is downloaded only at the first system start or after a configuration change: •

Nominal output voltage

•

Output current limitation

•

Output power limitation

•

Maximum output voltage / current / power at start up

•

Start up delay, limit time

•

Low input voltage for shut down / mains failure detection

•

Low input voltage for start up.

3.12.3 Commands / control data The following commands are transmitted from PSC 3 to the rectifier upon request by the operator or by controller function: •

Start / stop rectifier

•

Reset OVP

The following control data is transmitted from PSC 3 to the rectifier periodically: •

Output voltage (VPGM)

Energy Systems PRODUCT DESCRIPTION •


Output current limit / output power limit

3.12.4 Information data The rectifier calculates following data and transmits it upon request: •

Total operating time

The following data is transmitted by the rectifier periodically: •

Rectifier status (Power off, Remote off, AC failure, Rectifier mode, Deration of output power caused by output power / output current / high temperature / low input voltage, fan status, over-temperature / over-voltage protection status).

•

Rectifier data (output voltage, output current).

3.12.5 Measurements Following data is transmitted upon request from PSC 3 only: •

AC input voltage

•

Internal temperatures


4


FRONT ELEMENTS

100 %

Com

Iout

Output current LED bar

ok

Rectifier status indication

Config

"Config" push button

FR 48 V - 2000 W - E

Hole for fixing screw

Figure 6.

4.1

P0111

The rectifier from front.

Rectifier status indications LED «ok» turns off and an alarm is given if: •

Input connection is missing

•

Mains voltage is outside the specified range

•

OVP / OTP shutdown procedure is activated or a fan failure is detected !

!

!

OVP: The lowest orange LED is short flashing OTP: The middle orange LED is short flashing Fan failure: The top orange LED is short flashing

•

Load sharing not working correctly

•

The output fuse is blown

•

The rectifier is faulty

LED «Com» is lit if device communicates with PSC 3 controller via IMBUS.


5

5.1


BACK PLANE Electrical connections Combined connector is located on the backside (FCI Power Header R/A 51783002). The system bus is daisy-chained, with one-to-one connection, from rectifier to rectifier and to the controller (if such is used in the system).

P0008

P1:

PE

AC mains, PE terminal

P2:

L

AC mains, L terminal

P3:

N

AC mains, N terminal

A10:

NC

Reserved for other applications

B10:

VPGM

PSC 1000: output voltage programming

C10:

LS_BUS

Load sharing bus, refer to sec. “3.9 Load sharing”

D10:

GND_SYS

Reference ground for PSC 1000 and load sharing

A11:

NC

B11:

NC

C11:

NC

D11:

RFA

PSC 1000: rectifier failure

A12:

GND_SIG

Reference ground for D12

B12:

NC


C12:

NC


D12:

OFF

Rectifier enable, reference ground A12, refer to sec. “3.10 Rectifier Enable”.

P4:

VOUT-

DC output

P5:

VOUT-

DC output

P6:

OUTP

Precharge for output capacitor, refer to sec. “3.11 Precharge”

P7:

VOUT+

DC output

P8:

VOUT+

DC output

Table 2.

Signals on rectifier connector.

Warning! Operate the device only with connected PE.


6


MECHANICAL DIMENSIONS

P0009

Figure 7.

Mechanical design of the rectifier FR 48 V – 2000 W – E.


7


TECHNICAL SPECIFICATIONS

General Efficiency Losses, max. Safety

91 % 200 W EN 60 950, class I UL 60 950 CAN / CSA – C22.2 EN 55 022, class B EN 300 386-2 Fan cooled 500 W / l, 8.2 W / in3 ≥

EMI, radiated Compliant with Cooling Power density

Input Voltage range 88...300 Vrms Volt. range, red. power 88...184 Vrms Inrush current < 15 Apeak Current maximum 12 Arms Line current Meets IEC 1000-3-2 Harmonic distort. THD < 5 % EMI, conducted EN 55 022, class B Mains connector Rear side Input protection Internal fuse 2 x 15 A Input switch None Output Voltage, nominal 53.5 Vdc Voltage adjust range 42...58 Vdc Voltage error, static ± 250 mVdc Overvoltage protection 59 V ± 1 V Ripple + spikes ≤ 200 mVp-p ≤ 1.0 mVrms Psophometric noise (weighted) EMI, conducted EN 55 022, class A Current limit, nominal 46.5 Adc Limit adjustment range 0...46.5 A dc Load sharing < ± 3 Adc Power limit 2000 W, fixed Output connector Rear side Output protection Internal fuse 50 A Output characteristic: Uout [V] 58 53.5 43 42

2000 W control range

34.5

37.4

46.5

Iout [A] P0004

User interface Output current display LED bar Status indication LED «ok» Power system controller PSC 1000 Voltage programming Rectifier fail alarm PSC 3 do. plus additional remote control functions Mechanics Width, overall Depth, overall Height, body Height, front panel Weight

65 mm 346 mm 200 mm 212 mm 4.4 kg

Environment Ambient temperature -25...+ 70 °C Reduced power 60...+ 70 °C Relative humidity 95 % max, non cond. Accessories Single back plane

P/N: D0100298

Subject to change due to technical progress.



Energy Systems

Installation and Commissioning AMS 48/2000-8/16/24 ETS with PSC 3 controller

40030_01

Energy Systems INSTALLATION AND COMMISSIONING

AMS 48/2000-8/16/24 ETS WITH PSC 3

TABLE OF CONTENTS 1


2

Version control...................................................................................................5

PREPARING FOR THE INSTALLATION ......................................................................7 2.1

Before you begin ...............................................................................................7

2.2

Unpacking the system .......................................................................................7

3

SYSTEM CONFIGURATION .........................................................................................8

4

INSTALLATION.............................................................................................................9

5

4.1

System cabinet ..................................................................................................9

4.2

Electrical connections......................................................................................10

4.2.1

Grounding........................................................................................................10

4.2.2

AC-connection.................................................................................................10

4.3

Battery connections .........................................................................................10

4.4

Alarm and control connections ........................................................................11

4.5

DC-load connections .......................................................................................12

COMMISSIONING .......................................................................................................13 5.1

6

7

Starting up the system.....................................................................................13

COMMUNICATION SETTINGS ...................................................................................14 6.1

Setting the computer for the serial connection.................................................14

6.2

Setting the computer for the LAN connection ..................................................16

6.3

Setting the PSC 3 for the LAN communication................................................18

CONFIGURATION OF THE PSC 3 .............................................................................19 7.1

General............................................................................................................19

7.2

Terminology.....................................................................................................19

7.3

The menu structure for the web GUI ...............................................................20

7.4

Defining the system characteristics .................................................................21

7.5

Defining the system architecture .....................................................................21

7.5.1

Battery shunts..................................................................................................21

7.5.2

Load shunts .....................................................................................................22

7.5.3

Rectifier setup..................................................................................................22

7.5.4

Rectifier grouping ............................................................................................22

7.6

Defining the IMBUS components.....................................................................23

7.7

Defining the measurements.............................................................................23


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.8

Defining the events .........................................................................................24

7.8.1

Events for too high and too low system voltage .............................................. 24

7.8.2

Events for too high and too low battery temperature.......................................24

7.8.3

Event for too high system power .....................................................................24

7.8.4

An event for the battery LVD ...........................................................................25

7.8.5

Events for the load PLDs based on voltage ....................................................25

7.9

I/O assignments of the SENSNs ..................................................................... 25

7.10

Event processing and alarms .......................................................................... 26

7.10.1 Event processing and assignment for the load PLDs......................................26 7.10.2 The urgent and non urgent alarms ..................................................................27 7.10.3 Special mode event.........................................................................................28 7.10.4 A delayed mainsfailure alarm..........................................................................28 7.10.5 Adding other events ........................................................................................28 7.11

Alarm setup.....................................................................................................29

7.12

I/O assignments of the PSC 3 .........................................................................30

7.13

I/O assignments of the SSM............................................................................30

7.14

System status assignment and the UIM..........................................................31

7.15

Maintenance....................................................................................................31

7.16

Logging ...........................................................................................................32

7.17

Battery functions .............................................................................................33

7.17.1 Float charge parameters ................................................................................. 33 7.17.2 Equalize parameters .......................................................................................34 7.17.3 Battery test parameters...................................................................................35 7.17.4 Boost charge parameters ................................................................................ 37 7.18 8

9

Finishing..........................................................................................................40

SYSTEM CHECK ........................................................................................................41 8.1

Controller calibration .......................................................................................41

8.2

Checking the functioning of the rectifiers.........................................................42

8.3

Checking the control and alarm system ..........................................................42

8.3.1

Checking the configuration..............................................................................43

8.3.2

Checking the alarms........................................................................................44

8.3.3

Checking the fuse monitoring..........................................................................44

8.3.4

Testing the mains failure alarm .......................................................................45

APPENDIX: INSTALLATION AND COMMISSIONING CHECK LIST ........................ 46


1

1.1

AMS 48/2000-8/16/24 ETS WITH PSC 3



40030_01

Installation and Commissioning, AMS 48/2000-8/16/24 ETS with PSC 3 controller

Previous version


-

New document. Controlled by

Date 24.09.2004


Date 24.09.2004

Petteri Turkki



AMS 48/2000-8/16/24 ETS WITH PSC 3


2

PREPARING FOR THE INSTALLATION

2.1

Before you begin

2.2

AMS 48/2000-8/16/24 ETS WITH PSC 3

Step 1.

Ensure that you have all the equipment needed to make a proper installation of the system.

Step 2.

Also ensure that grounding terminals, DC- and AC-distributions are properly available.

Step 3.

Take care that the regulations of IEC 60364 and CENELEC HD384 concerning installation and assembling of telecommunication and electrical equipment have been noticed. The local regulations and special instructions must also be noticed during the work. When choosing the place of the installation, please notice that the cooling air must flow without restrictions through the ventilation holes. The system must have enough space in front of it for operation and service functions. Notice the direction of the cabling and the required space of the other equipment.

Unpacking the system Step 1.

Check that the received cargo is according to the packing list.

Step 2.

Ensure that the rack and the equipment are not damaged during transportation.

Step 3.

Check that proper documents are delivered with the system and necessary contact information for technical support is included.


3

AMS 48/2000-8/16/24 ETS WITH PSC 3

SYSTEM CONFIGURATION

1

Distribution positive busbar

2

DC-distribution fuses

3

Optional Partial Load Disconnect (PLD)

4

PSC 3 User Interface Module (UIM)

5

Distribution positive busbar

6

DC-distribution fuses and MCBs

7

Cabinet grounding terminal

8

Main positive busbar

9

AC-supply terminals

10 11

Battery connections (fuse switches / motor contactors) Optional low voltage disconnection (LVD)

12

Controller circuit breaker AF10

13

SSM, PSC 3 controller and CAN distribution

14

Rectifier shelves (1-3 pcs)

15

Adjustable cabinet feet (4 pcs)

P0123

Figure 1.

AMS 48 /2000-24 ETS with PSC 3 controller.


4

AMS 48/2000-8/16/24 ETS WITH PSC 3

INSTALLATION In the following step-by-step instructions the bracketed [ ] numbers refer to the corresponding numbers in the figure 1.

4.1

System cabinet Note!

Make sure that all circuit breakers are in the OFF-position.

Step 1.

Set the system cabinet standing in its place and straighten it if needed by adjusting the feet [15].

Step 2.

Lean to the cabinet and adjust the feet by screwing the feet in or out.

Step 3.

If the system comprises of more than one cabinet set the cabinets next to each other so that the connecting busbars and cables between the cabinets can be connected (see figure 2).

Step 4.

Connect the cabinet connection busbars and cables between the cabinets according to the wiring diagram attached with the user manual.

P0124

Figure 2.

AMS 48/2000-24 ETS cabinet connections with cable channels.

In the figure 2 the system cabinets are connected as one system with a cable channel in the between. An alternative system configuration is without the cable channel. The cabinets are then side to side and connected with shorter busbars.


4.2

Electrical connections Step 1.

4.2.1

Remove the possible covers in front of the distributions and connections in the system.

Grounding Step 1.

4.2.2

AMS 48/2000-8/16/24 ETS WITH PSC 3

Connect the protective-grounding terminal of the cabinet mechanics [7] to the main grounding busbar of the equipment room by proper cable.

AC-connection Each cabinet in the system has its own AC supply terminal [9]. Below in table 1 are the recommended mains fuse sizes and cable cross sections for 3-phase AC-connections of the AMS 48/2000 ETS power systems.

4.3

System, AC-input

Mains fuse

Cable

AMS 48/2000-8, 1 x 3-phase

3 x 40 A

5 x 10 mm2

AMS 48/2000-16, 2 x 3-phase

2 x (3 x 40 A)

2 x (5 x 10 mm2)

AMS 48/2000-24, 3 x 3-phase

3 x (3 x 40 A)

3 x (5 x 10 mm2)

Table 1.

Mains fuse sizes and cable cross sections for AC-connections.

Note!

Check the AC connections from the wiring diagram and the illustration of AC connections to the system attached to the user manual.

Battery connections Step 1.

Connect the positive battery cable(s) to the main positive busbar [8] and the negative cable(s) to the respective fuse switch or motor contactor connections [10].

Step 2.

Place the battery temperature sensor between the batteries in the battery area. Fasten the sensor cable to the subrack.


4.4

AMS 48/2000-8/16/24 ETS WITH PSC 3

Alarm and control connections Step 1.

Connect the remote alarm cables to the terminals in the PSC 3 front panel [13] (Figure 3).

The alarms are usually connected so that the alarm circuit is open (NO) and in a case of registered fault the circuit is closed (NC). Note!

OUT 1

The remote alarms are set in the I/O assignments of the PSC 3.

OUT 2

OUT 3

OUT 4

P0125

Figure 3.

The remote alarm connections.

In case the system consists of two cabinets, the CAN distribution [13] must be established between the cabinets. Step 1.

Connect the 4-pole and the 8-pole cables (delivered with the system) between the cabinets, to the free CAN distribution interfaces (Figure 4).

Cabinet 1

Cabinet 2

CAN Distribution

CAN Distribution

P0126

Figure 4.

CAN distribution connections between two cabinets.


4.5

AMS 48/2000-8/16/24 ETS WITH PSC 3

DC-load connections Step 1.

Connect the distribution cables. Plus cables are connected to the positive busbars [1] and [5] and the negative cables directly to the connections of the DC distribution circuit breakers [2] and fuse bases [6] as in the Figure 5.

Note!

Take care that the cable is behind the bar and not directly under the screw.

+

+

+

P0127

Figure 5. Note!

Connection of distribution cables. The maximum cable sizes for the positive busbar connections are MCB 1 A - 20 A max. 16 mm2 MCB 25 A - 63 A max. 35 mm2 2 NH00 160 A max. 70 mm 2 NH01 250 A max. 120 mm 2 NH02 400 A max. 240 mm 2 NH03 630 A max. 240 mm .


5

5.1

AMS 48/2000-8/16/24 ETS WITH PSC 3

COMMISSIONING Starting up the system Step 1.

Remove the screws that are used to fasten the rectifiers. Each rectifier is fastened with one screw.

Step 2.

Lift the rectifiers into the cabinet shelves starting from the far-left slot and continuing to right. Fasten the rectifiers with the screws.

Taking the system into use is presented in the following chapters. The bracketed [ ] numbers refer to the corresponding numbers in the figure 1. Step 3.

Check that the connections are made according to the installation instructions and the wiring diagram.

Step 4.

Check that the fuse switches or motor contactors [10] are in the “OFF”-position.

Step 5.

Start up the system by switching on the mains.

Step 6.

Check that LEDs on the rectifiers are “ok”.


6

AMS 48/2000-8/16/24 ETS WITH PSC 3

COMMUNICATION SETTINGS The PSC 3 controller is configured through RS232 or LAN interface on t he controller front panel, using a computer and a standard web browser. There is also an interface for a modem on the front panel (Figure 6). Before configuration of the controller, the computer must be set correctly for communication with the PSC 3. The PSC 3 also requires information for communication in the Local Area Network (LAN). The computer settings in this instruction are made in the Microsoft Windows 2000 operating system.

Modem Ethernet (LAN) RS232 Figure 6.

6.1

P0128

Communication interfaces on the PSC 3 front panel.

Setting the computer for the serial connection The direct connection from computer to the PSC 3 is made either to the RS232 serial port or to the LAN interface on controller front panel. The following step-bystep instructions show how to make the computer’s serial settings for the RS232 interface. Step 1.

Switch ON the AF10 circuit breaker to switch the controller on.

Step 2.

Connect your computer to the RS232 serial port with the cable delivered with the system.

Step 3.

Open the Control Panel on your computer and open the Network and Dial-up Connections settings. Double-click on “Make New Connection”.

Step 4.

The Network Connection Wizard opens (see the Figure 7).

P0129

Figure 7.

The Network Connection Wizard.

Energy Syste Systems ms INSTALLATION INSTALLATION AND COMMISSIONING COMMISSIONING

AMS 48/2000-8/16/24 48/2000-8/16/24 ETS WITH PSC 3

Step 5.

Click on the “Next” button and from the new Network Connection Type window, choose “Connect directly to another computer” and click on “Next”.

Step 6.

From the new Host or Guest window, choose “Guest”

Step 7.

From the new Select a Device window, choose ”Communications ”Communications cable between two computers”

Step 8.

From the new Connection Availability window, choose “For all users”

Step 9.

A new Completing the Network Connection Wizard window opens. Give a name for the connection e.g. “PSC 3 Serial Connection”, and click on “Finish”.

Step 10.

The login page for the connection opens. Click on “Properties”.

Step 11.

From the new window choose the General settings and from the Select a device drop down menu choose “Communication cable between two computers”. At the bottom left corner of the General settings is a checkbox for “Show icon in taskbar when connected”, which is useful to be checked. Then click on “Configure”.

Step 12.

From the new Modem Configuration window, choose Maximum speed of “38400” (bps) and click on “OK”.

Step 13.

The Options and Security settings do not require any changes.

Step 14.

Make the following settings for the Networking (see the Figure 8): - Type of dial-up server I am calling = PPP - Components checked are used by this connection = TCP/IP - Remove the check mark from the rest of the components

P0130

Figure 8.

Networking settings for the PSC 3 Serial Connection.

Step 15.

The Sharing settings do not require any changes.

Step 16.

Click on “OK”.

Energy Systems INSTALLATION INSTALLATION AND COMMISSIONING

Step 17.

AMS 48/2000-8/16/24 48/2000-8/16/24 ETS WITH PSC 3

The login page appears (see the the Figure Figure 9). 9). To connect to the PSC 3, 3, give the user name “fourier” and password “psc3”, and then click on “Connect”.

P0131

Figure 9.

6.2

Login page for the PSC 3 Serial Connection.

Setting the computer for the LAN connection To connect a computer directly to the LAN interface of the PSC 3 (see the Figure 6), some preparations are needed for the computer’s link speed and I P address settings. Step 1.

Open the Control Panel of your computer, and then the Network and Dial-up Connections settings.

Step 2.

Open the properties for Local Area Connection, Connection , then click on “Configure” and go to the Advanced settings (see the Figure 10).

P0132

Figure 10. 10. The Link Speed & Duplex Settings. Settings.


AMS 48/2000-8/16/24 48/2000-8/16/24 ETS WITH PSC 3

Step 3.

Choose the “Link Speed & Duplex” from the Property options and set the “Value” to 10Mbps/Full Duplex. Then click on “OK”.

Step 4.

Go back to the Local Area Network window. Choose the option “Internet Protocol TCP/IP” and click on “Properties” (see the Figure 11).

P0133

Figure 11. The LAN properties. Step 5.

A window for Internet Protocol TCP/IP properties opens. The computer’s IP address must be set manually for the direct computer-to-PSC 3 connection. Choose the option “Use the following IP address”, and define the IP address to the same network area as the PSC 3. Only the numbers in the last section of the IP address must be different. The default IP address of the PSC 3 is 192.168.0.73. Computer’s Computer’s IP address can be e.g. 192.168.0.74, as in the Figure 12. Click on “OK”.

P0134

Figure 12. The IP address of the computer.


AMS 48/2000-8/16/24 ETS WITH PSC 3

The computer is now ready for connecting and configuring the PSC 3. The PSC 3 can be configured through the RS232 serial port or the LAN interface (recommended) on the front panel of the PSC 3.

6.3

Setting the PSC 3 for the LAN communication The following information is required to prepare the PSC 3 for communication in the local area network: •

IP address

•

Subnet-mask

•

Gateway address (default)

•

MAC-address

Step 1.

→

provided by the network administrator →

→

provided by the network administrator →

provided by the network administrator

worldwide unique address per device

Connect directly from your computer to the PSC 3. The connection can be made either to the RS232 or to the LAN (recommended) interface, with a proper cable. For the LAN interface a crossover cable is needed (see the Figure 13).

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

P0135

Figure 13. The crossover LAN cable. Step 2.

Open your web browser and connect to the default IP address (192.168.0.73) of the PSC 3. The PSC 3 Configuration and Supervision Tool login page opens.

Step 3.

Give the username and password, and click on “Submit” button. The home page of the PSC 3 Configuration and Supervision Tool opens.

Step 4.

On the left side of the window there is a menu tree. Go the following submenu: System Interface Setup A window with interface settings (Interface Setup) opens. →

Step 5.

Give the IP address, subnet-mask and gateway address of the PSC 3, provided by your network administrator, then click on “Accept Changes”.

Note!

The IP address of the PSC 3 is now changed, which requires changes to the computer settings for the direct computer-to-PSC 3 connection. See the Step 5 in the chapter 6.2 .

Step 6.

Save the settings. Go to menu: Configuration Setup Update Click on “Save” in the User Setup section of the window.

Step 7.

Log out.

Note!

If MAC-address identification is used in the network, the unique address of the PSC 3 can be found from the UIM menu ”5.4.5 MAC ADDRESS”.

→


7 7.1

AMS 48/2000-8/16/24 ETS WITH PSC 3

CONFIGURATION OF THE PSC 3 General The PSC 3 controller is preconfigured at the Delta Energy Systems factory according to the system configuration. To give an understanding how the controller operates and controls the power system, the following step-by-step instructions show how to make the configuration from the beginning. The configuration order is the following:

7.2

Step 1.

Defining the system characteristics

Step 2.

Defining the system architecture

Step 3.

Defining the bus components of the IMBUS (Inter Module Bus)

Step 4.

Defining the measurements in the power system

Step 5.

Defining the events in the power system (based on the measurements)

Step 6.

Assigning the I/O functionality for the SENSN devices (measurements)

Step 7.

Setting the event processing

Step 8.

Setting the alarms

Step 9.

Assigning the I/O functionality for the PSC 3 (remote alarms) and for the SSM (LVD and PLD)

Step 10.

Assigning the system status indications and the UIM

Step 11.

Checking the maintenance functions

Step 12.

Setting the logging

Step 13.

Setting the battery functions (float charge, equalize, battery test and boost charge)

Step 14.

Finishing.

Terminology Some of the terminology in the instructions is based on the Figure 14, which is a simplified drawing, describing the load and battery connections of a power system. These recommended terms are later used to name shunts, disconnections and events that drive different functions e.g. LVDs in the PSC 3. Load Group 3

Battery Shunt 1

Battery Shunt 2

Battery LVD

Load Shunt 1

PLD 2

PLD 1

Load Group 2

Load Group 1 P0136

Figure 14. The distributions and battery connections of a power system.


7.3

AMS 48/2000-8/16/24 ETS WITH PSC 3

The menu structure for the web GUI The menu structure of the PSC 3 Configuration and Supervision Tool (web GUI) is presented below in the Figure 15. Home Alarm Status Setup Battery Monitor Control Test Results Load Monitor Log Entries Setup Rectifier Monitor Control Functions System Customer Settings User Management Interface Setup Time & Date Maintenance Alarm LVD Configuration

Measurements Signal Processing Engine

Event Definitions Event Processing System Status & UIM

I/O

PSC 3 SENSN SSM Battery Setup

System Architecture

Load Setup Rectifier Setup RM Grouping SENSN

Bus Components

SSM Digital Rectifier UIM System Parameter

System Characterictics

PSC3 Hardware System Geometry

Setup Update Software Update

Figure 15. The PSC 3 menu tree for the web interface.

P0137


7.4

AMS 48/2000-8/16/24 48/2000-8/16/24 ETS WITH PSC 3

Defining the system characteristics The system parameters are the basic characteristics of a power system, such as polarity, rectifier communication type and nominal voltage. These parameters are set at the start of the PSC 3 configuration and can not be modified there after. Step 1.

Open your web browser and connect to the PSC 3 with the IP address set earlier (chapter 6.3 ). Log in to the PSC 3 Configuration and Supervision Tool and go to menu:

Configuration

→

System Characteristics

→

System Parameter

Step 2.

Choose the correct polarity of the system e.g. “Positive Polarity”,

Step 3.

Choose the correct rectifier bus type e.g. “digital”,

Step 4.

Choose the correct nominal voltage of the system e.g. “48 V”,

Step 5.

Save the settings. Go to menu: Configuration Setup Update Click on “Save” in the User Setup section of the window. →

Note!

7.5

Save the settings always after making changes to the parameters. If the settings are not saved, they will be lost after rebooting the PSC 3. To save the settings do as above in the Step 5.

Defining the system architecture The settings for system architecture define the battery and load shunts in the system for the PSC 3, as well as the rectifier grouping and setup. In the following instructions the shunt names are based on the Figure 14.

7.5.1

Battery shunts The settings for battery shunts are located in the menu: Configuration

→

System Architecture

→

Battery Setup

Step 1.

Define the correct battery string type from the drop down menu and click on the “Add” button.

Step 2.

A window with battery string settings opens. Give the name “BattShunt1” BattShunt1” for the first battery string (see the Figure 14). Then define the battery capacity and the maximum battery current limit “Max. Ibatt”. Then click on “Add Battery String”.

Step 3.

Define and set values for as many battery strings as in the system, using the naming “BattShunt2 “BattShunt2”, ”, “BattShunt3 “BattShunt3”” etc.

Step 4.

Create an additional battery string “BattLVD” BattLVD” as above. This string is created only to drive the LVD relay. The LVD for the batteries is set later.

Note!

After a battery or load string is created, the PSC 3 creates automatically a LVD event, which is later used to drive the LVD relay. The name of the event is based on the battery or load string name, having an additional prefix “L”, e.g. “L BattLVD” or “L PLD1”

Step 5.

When you are finished click on the “Accept changes”.

Energy Systems INSTALLATION INSTALLATION AND COMMISSIONING

7.5.2

AMS 48/2000-8/16/24 48/2000-8/16/24 ETS WITH PSC 3

Load shunts The settings for load shunts are located in the menu: Configuration

7.5.3

System Architecture

→

Load Setup

Step 1.

Define the correct load string type from the drop down menu and click on the “Add” button.

Step 2.

A window for the new load string opens. Give the name “LoadShunt1” LoadShunt1” for the first load string (see the t he Figure 14), and click on “Add Load String”.

Step 3.

Define as many load strings as there are load shunts in the system, using the naming “LoadShunt2 “ LoadShunt2”, ”, “LoadShunt3 “LoadShunt3”” etc.

Step 4.

Create additional load strings for each PLD in the system as above, using the naming “PLD1 “ PLD1”, ”, “PLD2 “PLD2”” etc. (see the Figure 14). These strings are created only to drive the LVD relays for the PLDs that are set later.

Step 5.

When you are finished click on the “Accept changes” button.

Rectifier setup Configuration

7.5.4

→

→

System Architecture

→

Rectifier Setup

Step 1.

Define the threshold value for the number of failed rectifiers that issue an Urgent Alarm, Alarm, and then the value for the t he number of failed rectifiers that issue a Non Urgent Alarm. Alarm.

Step 2.


Rectifier grouping Note!

The menu “RM Grouping” is for defining rectifier groups and rectifier group settings. In the current version of the PSC 3 software the settings are allowed for only one rectifier group (“RFMGroup1”).

Configuration Step 1.

→

System Architecture

→

RM Grouping

Go to the menu “RM Grouping” and click on “Edit” button of the RFMGroup1. Set the following values for the rectifiers:

•

Default Values: Voltage, Current Limit, Power Limit These values define the behavior of the rectifiers if communication to PSC 3 can not be established.

•

Input Voltage Limits: Input Low Off and Input Low On These values are the AC input On/Off voltage limits.

•

Startup Parameters: Voltage, Current Limit, Power Limit, Powerup delay, Limit Time. These are the startup parameters for the rectifiers that are saved in the PSC 3, and therefore are used only if the PSC 3 is in connection with the rectifiers.

•

Group Settings: Last The value of the first and last rectifier in the group. In the current version of the PSC 3 software only one rectifier group can be defined and therefore the value for “Last” is the number of rectifiers in the system.

Step 2.


Step 3.

Save the settings.


7.6

AMS 48/2000-8/16/24 48/2000-8/16/24 ETS WITH PSC 3

Defining the IMBUS components The next phase is to define existing physical connections of the IMBUS components for the PSC 3. The components are such as the SENSN devices, String Sensor Modules (SSM), rectifiers and User Interface Modules (UIM). The UIM, SSM and rectifiers are recognized automatically by the PSC 3, but SENSN devices have to be defined manually. The SENSN devices are usually connected to SSM interfaces 1-3 or directly to the PSC 3 (check from f rom the wiring diagram). In the following instructions the SENSN devices for one load shunt and two battery shunts (see the Figure 14) are defined to the SSM1 interfaces 1-3. In case there are more battery or load shunts, there is an additional SSM module (SSM2) in the system. The SENSNs are defined to the SSM interfaces in the menu: Configuration

7.7

→

Bus Components

→

SENSN

Step 1.

To define the SENSN for the load shunt 1 choose the Bus Name: “SSM1” from the first drop down menu and address “1” in the next drop down menu. Then click on “Add SENSN”.

Step 2.

To define the SENSN for the battery shunt 1 choose the Bus Name: “SSM1” from the first drop down menu and address “2” in the next drop down menu. Then click on “Add SENSN”. And finally define the SSM1 interface “3” for the battery shunt 2.

Step 3.

Save the settings.

Defining the measurements The next step is to set the necessary measurements and their threshold threshold values in the system. As default the PSC 3 creates measuremen measurements ts for the system voltage “Usys” and battery temperature “Tbatt”. The load and battery fuse measurements are created next. The measurements are set in the menu: Configuration

→

Signal Processing Engine

→

Measurements

Step 1.

Give the name “Ufuse_Lshunt1” Ufuse_Lshunt1” for the t he load fuse measurement, and choose the signal type “digital” from the drop down menu. Then click on “Add” button.

Step 2.

A new Digital Measurement window opens. Define the voltage limit and hysteresis for the load fuse measurement. Then click on “Accept Changes” and go back to measurements window.

Step 3.

Give the name “Ufuse_Bshunt1” Ufuse_Bshunt1” for the t he battery fuse measurement, and choose the signal type “digital” from the drop down menu. Then click on “Add” button.

Step 4.

A new “Digital Measurement” Measurement” window opens. Define the voltage limit and hysteresis for the battery fuse measurement. measurement. Then click on “Accept Changes” and go back to measurements window.

Step 5.

Give the name “Ufuse_Bshunt2” Ufuse_Bshunt2” for the second battery fuse measurement, choose the signal type “digital” from the drop down menu and click on “Add” button. Then define the voltage limit and hysteresis and click on “Accept Changes”. Return to measurements window. window.

Step 6.

Save the settings.


7.8

AMS 48/2000-8/16/24 ETS WITH PSC 3

Defining the events The next phase is to create the user defined events based on the measurements. These events can be later further processed and used for other events, as well as for logging and alarms. The following instructions define and set t he most important events: •

The events for too low and too high system voltage

•

The events for too low and too high battery temperature

•

The event for too high system power

•

The event for battery LVD, based on voltage

•

The events for load PLD, based on voltage

The events are defined and set in the menu: Configuration

7.8.1

→


→

Event Definitions

Events for too high and too low system voltage Define first the maximum and minimum threshold values (events) for system voltage. The PSC 3 creates as default the event “S Usys low”, based on measured system voltage “Usys”.

7.8.2

Step 1.

To create a maximum threshold value for the system voltage click on “Edit” button next to “S Usys low”.

Step 2.

A new Threshold Editor window opens. Write the name of the new event “Usys high” to the TooHigh Event field. Then define the Upper Limit for the system voltage and if needed adjust the values for the Hysteresis and Lower Limit . Then click on “Change Definition” and go back to event definitions window.

Events for too high and too low battery temperature Define next threshold values (events) for high and low battery temperature, based on the battery temperature measurement “Tbatt”.

7.8.3

Step 1.

Choose first the measurement “Tbatt” from New Signal Event , and then click on “Add”.

Step 2.

A new Threshold Editor window opens. Give the names “Tbatt high” and “Tbatt low” for the TooHigh Event and TooLow Event . Then define the temperature limits for the Upper and Lower Limit , and define the Hysteresis as well. When done, click on “Add Definition” and go back to the Event Definitions menu.

Event for too high system power Define a threshold value (event) for too high system power. Step 1.

Choose first the measurement “Psys” from New Signal Event , and then click on “Add”.

Step 2.

A new Threshold Editor window opens. Give the name “Psys high” for the TooHigh Event and then give values for the Upper Limit and Hysteresis. When done, click on “Add Definition” and go back to the Event Definitions window.


7.8.4

AMS 48/2000-8/16/24 ETS WITH PSC 3

An event for the battery LVD Define an event for the battery LVD based on system voltage, which is used to drive the LVD relay for the batteries. Only one event is needed for all battery strings. Step 1.

Choose first the measurement “Usys” from New Signal Event , and then click on “Add”.

Step 2.

A new Threshold Editor window opens. Give the name “LVD” for the TooLow Event and then give the voltage value for the Lower Limit and Hysteresis. When done, click on “Add Definition” and go back to event definitions window.

Step 3.

Now there is an event to drive the battery LVD relay. This event must be assigned to the battery string “BattLVD”, which was created in the chapter 7.5.1. Go to menu:

Configuration Step 4.

7.8.5

→

System Architecture

→

Battery Setup

Click on the “LVD” button of the battery string “BattLVD”, and choose the event “LVD” from the Event drop down menu. Click on “Accept Changes” button.

Events for the load PLDs based on voltage The Partial Load Disconnects (PLD) for separate load groups are primarily driven based on time thresholds from mains failure (see Figure 14). The PLD events based on system voltage are secondary conditions, to add low system voltage thresholds to the PLD functionality. Define next the voltage based events for all PLDs. The events are later combined with the time threshold events and then assigned to drive the PLD relays in the PSC 3.

7.9

Step 1.

Choose first the measurement “Usys” from New Signal Event , and then click on “Add”.

Step 2.

A new Threshold Editor window opens. Give the name “PLD1 [U]” for the TooLow Event and then give the voltage value for the Lower Limit and Hysteresis. The recommendation is to use a hysteresis value which is, together with the Lower Limit , 1 V below Ufloat voltage. When done, click on “Add Definition” and go back to event definitions window.

Step 3.

If needed, define the events for rest of the PLDs in the system as above, using the naming “PLD2 [U]”, “PLD3 [U]” etc.

Step 4.

When all necessary events have been defined and set, click on “Accept Changes”.

Step 5.

Save the settings.

I/O assignments of the SENSNs The next phase is to assign the load and battery fuse measurements from the SENSN devices to the correct SSM interfaces (see chapter 7.7 ).. Normally the SSM interfaces are used in the following way (check the wiring diagram): •

SSM1 interface #1

→

SENSN for the load shunt 1

•

SSM1 interface #2

→

SENSN for the battery shunt 1

•

SSM1 interface #3

→

SENSN for the battery shunt 2


AMS 48/2000-8/16/24 ETS WITH PSC 3

The SENSN measurements are assigned in the menu: Configuration

→

I/O

→

SENSN

Step 1.

Choose “LoadShunt1” for the “SSM 1, address 1” from the drop down menu. Then click on “Edit” by the string assignment. In the new SENSN Input Setup window, define the nominal current of the shunt (Value), and then define the fuse measurement “Ufuse_Lshunt1” as the additional fuse measurement. The temperature sensor is normally connected to load SENSN and therefore define also the temperature measurement “Tbatt” as the additional temperature measurement. Click on “Accept Changes”, and go back to previous window.

Step 2.

Choose “BattShunt1” for the “SSM 1, address 2” from the drop down menu. Then click on “Edit” by the string assignment. In the new SENSN Input Setup window, define the nominal current of the shunt (Value), and then define the fuse measurement “Ufuse_Bshunt1” as the additional fuse measurement. Click on “Accept Changes”, and go back to previous window.

Step 3.

Choose “BattShunt2” for the “SSM 1, address 3” from the drop down menu. Then click on “Edit” by the string assignment. In the new SENSN Input Setup window, define the nominal current of the shunt (Value), and then define the fuse measurement “Ufuse_Bshunt2” in the additional measurements. Click on “Accept Changes”, and go back to previous window.

Step 4.

Click on “Accept Changes”.

Step 5.

Save the settings.

7.10 Event processing and alarms All events (system and user defined) defined in the PSC 3, can be combined to other events and alarms using the boolean logic (AND, OR, Inversion) and other building blocks (Filter). The event processing is set in the menu: Configuration

→


→

Event Processing

7.10.1 Event processing and assignment for the load PLDs The primary drivers of the PLD relays are delay based events. These events have a time threshold, which is a delay from mainsfailure to disconnect a load group. With different time thresholds separate load groups can be prioritized for different loads. In the chapter 7.8.5 some voltage based events were created as secondary condition for the PLDs. The event processing feature enables combining the voltage and time based events as one event, which is then used to drive the PLD relays. Step 1.

First the new time filtered event must be created for the load PLDs. Choose the event type “Filter” from the drop down menu, and click on “Add” button.

Step 2.

A new Filtered Event window opens. Give the name “PLD1 [t]” for the new event and choose the event “S Mainfailure” from the drop down menu as a base for the time filtered event. Then define the TRUE and FALSE time thresholds. The TRUE value is the delay for the event to be activated after mains failure. The FALSE value is the delay for the event to be deactivated after mains is back on. When done, click on the “Add New Definition” button.


AMS 48/2000-8/16/24 ETS WITH PSC 3

Step 3.

Define as many time filtered events as there are PLDs in the system (Figure 14), using the naming “PLD2 [t]”, “PLD3 [t]” etc.

Step 4.

Now the voltage based events and time based events of the load PLDs need to be combined as “OR” events, which means that one of the events need to be true to activate “OR” event. Add a new “OR” event, give the event the name “PLD1 [U + t]” and choose the events “PLD1 [U]” and “PLD2 [t]” as a base for the new event. When done, click on the “Add New Definition” button.

Step 5.

Define as many combined events as there are PLDs in the system (Figure 14), using the naming “PLD2 [U + t]”, “PLD3 [U + t]” etc.

Step 6.

Now the necessary events to drive the load PLD relays exist. These events must now be assigned to the additional load strings “PLD1”, “PLD2” etc., which were defined in the chapter 7.5.2. Go to menu:

Configuration

→

System Architecture

→

Load Setup

Step 7.

Click on the “LVD” button of the load string “PLD1”, and choose the event “PLD1 [U + t]” from the “Event” drop down menu. Click on “Accept Changes” button.

Step 8.

Assign the PLD [U + t] events to the respective additional load strings (PLD2 [U + t] PLD2 and PLD3 [U + t] PLD3 etc.). →

Step 9.

→

Save the settings.

7.10.2 The urgent and non urgent alarms As default the PSC 3 has two types of alarms in the Event Processing : •

Urgent Alarm

•

Non-Urgent Alarm

→

UA →

NUA

As default the UA alarm consists of two events with the “OR” condition: “S Usys low” and “S Urgent RFA”. In addition the recommendation is to add the events: •

“S Usys high”

•

All the fuse alarms “Ufuse_Lshunt1”, “Ufuse_Bshunt1” and “Ufuse_Bshunt2”.

Step 1.

Click on “Edit” button at the end of the “S Urgent Alarm” row and add the additional events. Then click on “Change Definition”.

As default the NUA alarm consists of two events with the “OR” condition; “S HW Failure” and “S Non Urg RFA”. In addition the recommendation is to add the events: •

“Psys high”,

•

“PLD1 [U+t]” and “PLD2 [U+t]”

•

And if wanted, “Tbatt high” and “Tbatt low” events can be added as well.

Step 2.

Click on “Edit” button at the end of the “S Non Urgent Alarm” row and add the additional events. Then click on “Change Definition”.

Step 3.

Save the settings.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.10.3 Special mode event To indicate that there is some special activity in progress in the power system a combined “OR” event called “Special mode” is created next. This event combines all the events that are wished to be signaled as special activity in the system by the fifth LED in the UIM and by the fifth symbol in the web GUI. Step 1.

Create a new “OR” event by choosing the event type “OR” from the drop down menu and by clicking the “Add” button.

Step 2.

Give the name “Special mode” for the new “OR” event and then choose the events that you wish to be signaled as special activity in the system. Recommendation is to add the battery charging events “S EQ in Progress” (equalize) and “S BC in Progress” (boost charge). Add also the battery test event “S BT in Progress”.

Step 3.

Accept the new event by clicking on “Add New Definition”.

7.10.4 A delayed mainsfailure alarm With Event Processing it is also possible to create delayed events e.g. for mains failure. These types of events are useful for example when momentary (very short in time) mains failures are not wished to be signaled as remote alarms (I/O assignments of the PSC 3). Step 1.

To create a time filtered event choose the event type “Filter” in the drop down menu and click on “Add”.

Step 2.

In the new Filtered Event window give the name “MF delay” for the new event and define the “S Mainsfailure” event as a base for the new event. Then set the delay time (TRUE value) and click on “Add New Definition”.

Note!

Later the “MF delay” can be used as remote alarm for the digital output of the PSC 3 controller.

7.10.5 Adding other events To add a new event: Step 1.

Choose event type (AND, OR, Inversion or Filter) and click on “OK”.

Step 2.

A new window opens. Give a name for the event and then choose conditions (events or time filters) for the new event. Then click on “Add New Definition” and go back to the event processing.

Step 3.

Save the settings.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.11 Alarm setup In the Alarm Setup menu it is possible to add events as alarms. Only the alarms can be inhibited with the “Alarm Stop” button. The alarm stop functionality requires also activation of the function for each alarm in the Maintenance menu (s. chapter 7.15 ). As default the Urgent Alarm and Non Urgent Alarm are defined as alarms, even though they are not visible in the list. The alarms in the Alarm Setup list are also used for the I/O assignment in the PSC 3 digital outputs, to signal remote alarms. The alarms that are defined in the Alarm Setup will automatically receive a prefix “A”, which appears in the menus where events and alarms are assigned. It is recommended to add at least the mains failure alarm with delay (“MF delay“) or without delay (“S Mainsfailure”) to the list. Only events that have been defined as alarms can be seen in the user interface module (UIM) as a source of alarm. Therefore it is recommended to add all critical system events (fuse alarms, load disconnects, battery disconnects, battery temperature events etc.) to the alarm list. Otherwise they will be indicated only as UA or NUA alarms, without further information about the alarm source. The alarm source investigation can then be done only through the web user interface of the PSC 3 controller. The Alarm Setup menu in located in: Alarm

→

Setup

Step 1.

From the new Alarm Setup window choose the event “MF delay” from the “Non-Alarm Events”, then click on “Add >>”. The “MF delay” event appears in the “Deleteable” window.

Step 2.

Add other events as above.

Step 3.

Save the settings.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.12 I/O assignments of the PSC 3 The PSC 3 has four digital outputs on the front panel for signaling alarms (e.g. NUA, UA and Mains Failure), and two digital inputs for measurements. Assigning the digital outputs for remote alarms is done in the menu: Configuration

→

I/O

→

PSC3

Note!

The recommendation is to use only the events with prefix “A” (e.g. “A S Urgent Alarm”) for the digital outputs. The prefix “A” means that the event is an alarm and can be inhibited as remote alarm with “Alarm Stop” button (see chapters 7.11 and 7.15 ).

Note!

When an alarm with prefix “A” is defined for an output relay, the relay is in the position NO (Normally Open) when the alarm is not active and in the position NC (Normally Closed) when the alarm is active. For the events the relay positions are in the opposite way.

Step 1.

Choose an event for output “OUT 1” from the drop down menu; recommendation is to set UA alarm (“A S Urgent Alarm”) for this output.

Step 2.

Choose an event for output “OUT 2” from the drop down menu; recommendation is to set NUA alarm (“A S Non Urg Alarm”) for this output.

Step 3.

If needed, choose an event for the output “OUT 3”, e.g. “A S Mainsfailure” or “A S MF delay” if the momentary mains failures are not to wished to be signaled as remote alarms (see chapter 7.10.4).

Step 4.

If needed, choose an event for the output “OUT 4”, e.g. “S Alarm suppr.”, which indicates the system mode when alarms are suppressed.

Step 5.

If needed, choose measurements for the inputs IN 1 and IN 2 to use for event processing.

Step 6.

Save the settings.

7.13 I/O assignments of the SSM The SSM has three digital outputs for signaling LVDs and four digital inputs for measurements. The assigning of the output relays for the battery LVD and load PLDs is done in the menu: Configuration

→

I/O

→

SSM

Step 1.

All String Sensor Modules in the system can be seen in the SSM Overview menu. To assign the inputs and outputs for a SSM click on the “Edit” button next to the SSM Imbus ID.

Step 2.

A window SSM I/O Setup opens. First are the input assignments IN 1-4. The next assignments are for the outputs OUT 1-3. Assign the outputs for the battery LVDs and load PLDs. Normally the outputs are used in the following way: OUT 1 Battery LVD OUT 2 Load PLD 1 OUT 3 Load PLD 2 → → →


AMS 48/2000-8/16/24 ETS WITH PSC 3

For each output there is a drop down menu with events. For the LVDs and PLDs the correct events are the events starting with prefix “L” (see Note! in chapter 7.5.1). For driving the LVD relays the additional strings and LVD events were created according to chapters 7.5.1 and 7.5.2. The LVD events that are based on these additional strings are now used for the output assignments in the SSM. OUT 1 choose the LVD event “L BattLVD” OUT 2 choose the PLD event “L PLD1” OUT 3 choose the PLD event “L PLD2” → → →

Step 3.

When done, click on “Accept Changes” and save the settings.

7.14 System status assignment and the UIM The User Interface Module (UIM) and PSC 3 Configuration and Supervision Tool have five LEDs / symbols and a buzzer (only in the UIM) for signaling events and alarms in the system. They can be assigned to any event. The LEDs / symbols and the buzzer are assigned in the menu: Configuration

→

I/O

→

System status & UIM

The recommendation is to use the LEDs in the following way: Step 1.

Assign the LED 1 / symbol “

” for “S Urgent Alarm”,

Step 2.


” for “S Non Urg Alarm”,

Step 3.


” for “S Alarm suppr.”

Step 4.


” for “S Mainsfailure”

Step 5.


” for “Special mode”.

Step 6.

Check the checkbox “Display an Alarm Stop Button”, to add the Alarm Stop button next to the alarm symbols in the web interface.

7.15 Maintenance All events that are defined as alarms can be manually tested and controlled in the maintenance menu. The alarms can be set to Normal , Frozen, Set or Reset state, and alarms can also be activated for the Alarm Stop functionality. The Frozen state means that the alarm is frozen to the state it was when the state was set. The Set state means that the alarm is forced to active state and in the Reset state the alarms is forced to “Ok” state. When the Alarm Stop checkbox is checked the alarm is activated for the alarm stop functionality. This means that the alarm will be inhibited (e.g. for remote alarms), when the function is activated with the “Alarm Stop” button. The alarm maintenance is located in the menu: Maintenance

→

Alarm

In the maintenance menu it is also possible to inhibit the LVDs and PLDs of the system for testing and maintenance purposes. The procedure to inhibit a LVD (or PLD) is to mark the checkbox and click on “Accept Changes”. The LVD inhibit settings are located in the menu: Maintenance

→

LVD


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.16 Logging With the Logging functionality, the user has the possibility to log all the desired events. Any signal in a PSC 3 system can be used as an event source. There are some factory defined system events that are always logged in addition to the user defined events. Up to 200 log entries are listed, and the 20 most recent entries are stored to non-volatile memory (in 5 minute intervals). As soon as an event has to be logged, the name and value of the event will be stored in the log with date and time information. This means, that the Logger is able to differentiate between appearance and disappearance of the event as shown in the following table: Event Name

Event state

Description seen in WEB/UIM

NameX

true

NameX

false

NameX - ok

The PSC 3 has several internally logged events, which are always logged. The following table gives an overview about the existing events that are logged: Name

Description

SSM HW Failure

Configured SSM is missing - cabling may not be correct

SSM HW Failure ok

Configured SSM is ok again

SENSN HW Failure(s)

Configured SENSN is missing - cabling may not be correct

SENSN HW ok

Configured SENSN is ok again

Temp. HW Failure

Configured Temperature sensor is missing - cabling may not be correct

Temp. HW Failure

Configured Temperature sensor is ok again

System restart

Always done after power up of PSC 3

Battery Test Aborted Battery Test Failed Battery Test Started

Battery test information

Battery Test Successful Equalize Aborted Equalize Finished

Battery equalize information

Equalize Started To add events for logging go to menu: Logging Setup →

Step 1.

Choose an event to be logged and click on “Add >>”. The event appears in the Logged Events window. Choose one by one the events that need to be logged and save the settings.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.17 Battery functions The PSC 3 Configuration and Supervision Tool offers the following battery functions: •

Float charge

•

Equalize

•

Battery test

•

Boost charge

These functions are available in the PSC 3 menu: Battery Control →

In the Battery Control menu it is possible to control the battery charging and testing functions. The battery charge mode and current limit status can be seen at the top of the Battery Control window. The following chapters describe the different charge modes and parameters, as well as the battery test function.

7.17.1 Float charge parameters In the float charge mode, the current supplied to the batteries compensates their self-discharge. It is possible to use temperature compensation for the system voltage that is used for the regulation. Step 1.

Set the voltage value to regulate to at 20°C “Usys@20°C” according to the battery type used. The correct value is provided by the battery supplier with the batteries.

Step 2.

If the temperature compensation is used, then activate the compensation by checking the checkbox “Temperature compensation”.

Step 3.

Edit the temperature compensation parameters by clicking on the “Edit Parameter ...” button. Below in the table are the descriptions of the temperature compensation parameters.

Parameter

Description

Range or Type

Tcoeff

Temperature compensation coefficient for system voltage in -mV per °C of the battery temperature. Tcoeff always specifies the coefficient for the entire battery rack and is entered as a positive value in mV steps.

0 ... 200mV/°C

Tc_low

Low limit for the area in which the temperature compensation is active.

0°C ... Tc_high

Tc_high

High limit for the area in which the temperature compensation is active.

Tc_low ... 70°C

Step 4.

After setting the temperature compensation parameters click on “Accept Changes” and go back to Battery Control menu.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.17.2 Equalize parameters The controller initializes equalizing of the batteries at fixed intervals, determined by the user (e.g. once a month). This is done by increasing the system voltage to a certain level for a specified duration. If several batteries are connected to the system in parallel, all batteries will be charged together. The Equalize function can be enabled and disabled with the checkbox of the Equalize section in the Battery Control menu. The parameters can be set in the disabled mode and the function is enabled when needed. Step 1.

Click on “Edit Parameter ...” in the Equalize section of the Battery Control menu.

Step 2.

A window Battery Equalize opens. Set the parameters of the Equalize function. Below in the table are the descriptions of the parameters.

Parameter Name

Description

Range or Type

Voltage

Equalize voltage. Equalize uses the same settings for temperature compensation as for float charge.

System-Voltage Type, provided by the battery supplier.

Duration

Specifies the duration of the charging process.

1min ... 10h, provided by the battery supplier

Current Limit

Maximum current during the equalizing < Maximum battery process. To choose smaller values current defined in than the given in the battery properties battery setup. mark the checkbox.

Use Battery Room In order to enable lead and lag time Fan mark this checkbox.

Boolean

Lead Time (Fan)

Lead time for the battery room fan

1 min ... 1 h

Time Lag (Fan)

Time lag for for the battery room fan

1 min ... 1 h

Max. Battery Temperature

If the battery temperature exceed this limit, the charging process stops.

10°C ... 70°C

Alarm Suppression Voltage

Deviation from float voltage to stop the alarm suppression.

<1V

Alarm Suppression Time

Maximum delay for alarms after Equalize (over voltage alarm)

<1h

Interval (Start Condition)

Specifies the time between two battery charging processes.

< 720 days

Start window

Within this time window a programmed Time window equalize can be started.

Inhibit after Boost (Start Condition)

Minimal time between boost charge and equalize.

< 360 days

Forbidden Times

During the given time windows the programmed equalize is not executed.

Time window

Step 3.

When done, click on “Accept Changes” and go back to Battery Control menu.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.17.3 Battery test parameters During the constant current battery test, the battery will be discharged with constant current. Load changes have to be balanced by the rectifiers, and the load current must be larger than the desired battery discharge current. If the battery voltage (system voltage) drops below the set value of “Usupport”, or the current difference between different battery strings exceed the set value within the test period, the battery is considered faulty. Note!

The battery tests based on time or energy are not available in this version of the PSC 3 software, though they are visible in the options.

Step 1.

Choose first the battery test type as “constant current”, by clicking on “Select” of the Battery Test section in the Battery Control menu. Then in the new Test Type Window choose the preferred test type from the drop down menu. Then click on “Accept Changes”.

Step 2.

Click on “Edit Parameter ...” in the Battery Test section of the Battery Control menu.

Step 3.

Set the parameters (table below) for the Battery Test . When done, click on “Accept Changes” and go back to the Battery Control menu.

Parameter

Description

Range or Type

Usupport

Support charge voltage for the battery


Idischarge

Battery discharge current

Depends on the string configuration

Duration

Battery test duration.

1 min ... 2000 min

Minimal Duration

The value represents the minimum battery test duration in minutes. During that time a battery test is not stopped in case of a voltage below the support voltage or a current difference higher than the specified value.

1 min ... 200 min

Current Difference During constant current battery test, the current difference between battery strings is compared. If the string currents differ more than the given percentage from the calculated average value, the test is immediately stopped. Mark the checkbox to enable this function.

Percentage

Battery Temperature

A programmed battery test is executed only, if the battery temperature is within this range.

0°C ... 50°C

Voltage within Ufloat

To ensure that the battery is fully charged the system voltage should not differ for a certain time from the float voltage before the battery test.

< 2V 1 day ... 10 day


Parameter

7.17.3.1

AMS 48/2000-8/16/24 ETS WITH PSC 3

Description

Range or Type

Interval

Minimal time between programmed battery tests. Mark the checkbox to enable the programmed battery test.

< 720 days

Start window

Within this time window a programmed battery test can be started.

Time window

Forbidden Times

During the given time windows the programmed battery test is not executed.

Time window

Battery test results The result and information about the last performed battery test are available in the menu: Battery Test Results →

Information

Description

Results

Not done

No test performed yet

Failed

System voltage drops below Usupport or the current difference exceeds the given limit.

Aborted

Test stopped by the user or the battery test is inhibited.

Load failure

Test aborted because load current is too small or the rectifiers are not able to deliver the necessary current.

Successful

Test successful performed.

Last Battery Test Performed On

Date and time of last performed battery test.

Final Voltage

System voltage at the end of the last performed battery test.

Battery Failure Event

State of the battery failure event: Ok

The event is not set.

Active

The event is set.

The event can be reset manually.


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.17.4 Boost charge parameters After a discharge phase the battery current turns and recharges the battery. The wanted system voltage is then lifted to the boost charge voltage and the battery will be recharged more quickly. The PSC 3 controller offers three types of boost charge: •

Current based boost charge

•

Time based boost charge

•

Energy based boost charge

Step 1.

7.17.4.1

Choose first the boost charge type by clicking on the “Select” button of the Boost Type Selection. In the new window choose the boost charge type from the drop down menu, and click on “Accept Changes”.

Current based boost charge The boost charge based on current charges the batteries with specified voltage, in the given current range. The boost charge start and stop (Istart and Istop) conditions for current are based on the battery capacity. Step 2.

Click on “Edit Parameter ...” in the Boost Charge section of the Battery Control menu.

Step 3.

Set the parameters (table below) for the Boost Charge. When done, click on “Accept Changes” and go back to the Battery Control menu.

Parameter

Description

Range or Type

Voltage

Boost charge voltage for the battery


Max. duration

The maximum duration of the boost charge, to avoid charging possibly faulty battery.

1 h ... 24 h

Use Battery Room Fan

In order to enable lag time mark this checkbox.

Boolean

Time Lag (Fan)

Time lag for for the battery room fan

1 min ... 60 min


In order to supervise the battery 10°C ... 70°C temperature and stop boost charge if the battery temperature exceeds the following limit, mark the checkbox and give a maximum value for the temperature.

Alarm Suppression Voltage and Time

Deviation from float voltage and delay to stop the alarm suppression.

< 1 V, < 3600 s

Istart

Battery current at which boost charge starts; is always greater than Istop.

Based on the battery capacity.

Inhibit time

Time between the last boost charge and the next possible boost charge.

0 h ... 100 h

Istop

Battery current at which boost charge stops; is always smaller than Istart.

Based on the battery capacity and Istart.


7.17.4.2

AMS 48/2000-8/16/24 ETS WITH PSC 3

Time based boost charge During a mains failure and when the system voltage is below “Uboostlow”, the duration is measured and multiplied by a factor (k). The result is the boost charge duration. After the discharge phase the boost charge starts immediately. The boost charging is active for the calculated duration. The time measurement for the boost charge starts as soon as the system voltage crosses the limit “Ufloat”. Step 1.

Choose first the boost charge type by clicking on the “Select” button of the Boost Type Selection. In the new window choose the boost charge type “time based” from the drop down menu, and click on “Accept Changes”.

Step 2.


Step 3.


Parameter

Description

Range or Type

Voltage

Boost charge voltage. Boost Charge System-Voltage Type, uses the same settings for temperature provided by the compensation as for float charge. battery supplier.

Factor (k)

Factor to calculate the boost charge duration.

1.0 ...16.0

Uboostlow

Limit to calculate the discharge duration.

System-Voltage Type

max. Duration

Maximum allowed time for boost charge (to prevent charging the battery too long)

1 h ... 24 h

Inhibit Time

Minimum time after last boost stop.

0 h ... 100 h


In order to delay the battery fan event mark this checkbox.

Boolean

Time Lag (Fan)

Time lag for for the battery room fan event

1 min ... 60 min


In order to supervise the battery temperature and stop boost charge if the battery temperature exceed the following limit mark this checkbox.

Boolean


If the battery temperature exceed this limit, the boost process stops.

10°C ... 70°C


Deviation from float voltage and delay time to stop the alarm suppression.

< 1V, < 3600s


7.17.4.3

AMS 48/2000-8/16/24 ETS WITH PSC 3

Energy based boost charge If boost charge is configured as energy based, the controller calculates the capacity taken out of the batteries during a discharge and multiplies the result by a factor (q). As soon as the charge state changes from discharge to Float Charge (batteries are going to be charged) the controller starts the boost charge, which will last until the discharged capacity multiplied with the factor is recharged to the batteries. Boost charge is forced to stop at “max. Duration” after the level “Ufloat” (temperature compensated in the case temperature compensation is enabled) has been passed, even when not enough capacity is charged to the batteries. This could be an indication of a faulty battery and a log entry is generated. Step 1.

Choose first the boost charge type by clicking on the “Select” button of the Boost Type Selection. In the new window choose the boost charge type “energy based” from the drop down menu, and click on “Accept Changes”.

Step 2.


Step 3.


Parameter Name

Description

Voltage

Boost charge voltage. Boost Charge System-Voltage Type uses the same settings for temperature compensation as for float charge.

Factor (q)

Factor to calculate the capacity to recharge into the battery.

1.00 ... 1.30

max. Duration

Maximum allowed time for boost charge (to prevent that the battery is charged forever)

1 h ... 24 h

Inhibit Time

Minimal time after last boost stop.

0 h ... 100 h


In order to delay the battery fan event mark this checkbox.

Boolean

Time Lag (Fan)

Time lag for for the battery room fan event

1 min ... 60 min


In order to supervise the battery Boolean temperature and stop boost charge if the battery temperature exceed the following limit mark this checkbox.


If the battery temperature exceed this limit, the boost process stops.

10°C ... 70°C


Deviation from float voltage and delay time to stop the alarm suppression.

< 1V, < 3600 s

Step 4.

Save the settings.

Range or Type


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.18 Finishing The basic configuration of the PSC 3 is now done. Check that all the IMBUS components that are installed to the system have been defined, set and working as intended. Remember to save the settings before logging out of the PSC 3 Configuration and Supervision Tool. Step 1.

Save the settings. Go to menu: Configuration Setup Update Click on “Save” in the User Setup section of the window.

Step 2.

Log out.

→


8

8.1

AMS 48/2000-8/16/24 ETS WITH PSC 3

SYSTEM CHECK Controller calibration The controller and the rectifiers of the system are pre-calibrated by means of accurate meters in the factory of Delta Energy Systems. Calibration is not needed unless some hardware changes have been made to the controller or the real accurate measurement in maintenance is different than the display of the controller. Calibrate the system voltage of the controller according to the following instructions. Step 1.

Switch ON the circuit breaker AF10 [12] to switch on the PSC 3.

Step 2.

Measure the system voltage between the plus busbar [5] and minus on the rectifier DC output circuit breaker [6].

Step 3.

Login in to the PSC 3 Configuration and Supervision Tool and go to menu: Configuration Signal Processing Engine Measurements. →

→

Step 4.

From the new window check the Usys voltage by clicking on the “Edit”.

Note!

The output voltage’s factory setting for FR 48 V – 2000 W – E rectifier is 53.5V.

Note!

If the value differs from the measured value more than 0.1 V, the controller calibration should be performed. Otherwise continue to Step 7.

Step 5.

In the new Analogue Measurement window for Usys click on “Calibrate”. In the Calibration window give the measured system voltage and click on “Calibrate”.

Step 6.

When calibration is finished, save the PSC 3 settings. Go to menu: Configuration Setup Update Click on “Save” in the User Setup section of the window. →

Step 7.

Check that the low voltage disconnection fuses are in place (next to the LVBD [11]) and switch “ON” the battery fuse switches/motor contactors [10].

Step 8.

Check the battery polarity by measuring the voltage over the battery fuse switch or motor contactor [10]. The voltage should be at most a few volts. If voltage is more than that, the battery polarity is not correct and it must be changed by switching the “+” and “-” cables connected to the batteries.

Step 9.

Check, that the load is connected to the distribution DC terminals, the distribution fuses are installed [2] and switch on the DC distribution circuit breakers [6], which are used for delivering the load.

Step 10.

Check the functioning of the system according to the next two chapters for rectifiers and the controller.


8.2

AMS 48/2000-8/16/24 ETS WITH PSC 3

Checking the functioning of the rectifiers Following procedures are able to accomplish only with a suitable DC-load available.

Current output LEDs

“Config” push button

Fan

P0138

Figure 16. Rectifier FR 48 V – 2000 W – E. Check that the rectifiers are able to deliver current. The method is to first discharge the batteries for a while and then recharge them. The controller carries out the procedure, which decreases the rectifier voltages below the discharging voltage of the batteries. Therefore in case of a battery failure the system will not crash. Step 1.

Start the discharging by activating the battery test manually from the controller menu: Battery Control. The battery test is started by clicking on the “Start” in the Battery Test section of Battery Control menu. →

8.3

Note!

If the “Start” button is not available, check the starting conditions by clicking on the “Info”. All the starting conditions must be true before the battery test can be executed.

Step 2.

After the battery test, check the results from the menu Test Results.

Checking the control and alarm system Note!

The alarms, system voltage and temperature compensation settings are pre-set according to the used battery. If the used battery type is different from the type the pre-set values were adjusted for, then the values must be changed according to the battery type and information of the battery manufacturer.


8.3.1

AMS 48/2000-8/16/24 ETS WITH PSC 3

Checking the configuration Values are all pre-set by the factory, and should not be changed without a proper reason (see note above). The pre-set values can be found in the system’s test report attached to this user manual. The current settings can be check from the PSC 3 Configuration and Supervision Tool (web interface). The settings are protected against unauthorized access, and can only be seen and modified with the correct user name and password. Alarm limits

The alarm (event) limits are located and set in the menu (see also chapter 7.8 ): Configuration Signal Processing Engine Event Definitions and Configuration Signal Processing Engine Event Processing →

→

→

→

The factory setting can be found in test report: part 4 Alarms System voltage

The system voltage setting is made in the menu (see also chapter 7.17.1): Battery Control (value for Usys @ 20°C) →

The factory setting can be found in test report: part 5 Usys. Temp Comp

The setting of the temperature compensation is made in the menu (see also chapter 7.17.1): Battery Control →

The factory settings can be found in test report: part 6 Temp Comp. Battery Test

The settings for the battery test are made in the menu (see also chapter 7.17.3): Battery Control →

The factory settings can be found in test report: part 8 Battery Test. Equalize

The settings for the equalize charge are made in the menu (see also chapter 7.17.2): Battery Control →

The factory settings can be found in test report: part 9 Equalize.

Note!

Save the settings always after making changes to the parameters. If the settings are not saved, they will be lost after reeboting the PSC 3.


8.3.2

AMS 48/2000-8/16/24 ETS WITH PSC 3

Checking the alarms All events that are defined as alarms can be manually tested and controlled in the maintenance menu. The alarms can be set to Normal , Frozen, Set or Reset state, and alarms can also be activated for the Alarm Stop functionality. The Frozen state means that the alarm is frozen to the state it was when the state was set. The Set state means that the alarm is forced to active state and in the Reset state the alarms is forced to “Ok” state. When the Alarm Stop checkbox is checked the alarm is activated for the alarm stop functionality. This means that the alarm will be inhibited (e.g. for remote alarms), when the function is activated with the “Alarm Stop” button. The alarm maintenance is located in the menu: Maintenance

→

Alarm

In the maintenance menu it is also possible to inhibit the LVDs and PLDs of the system for testing and maintenance purposes. The procedure to inhibit a LVD (or PLD) is to mark the checkbox and click on “Accept Changes”. The LVD inhibit settings are located in the menu: Maintenance

8.3.3

→

LVD

Checking the fuse monitoring Note!

The following procedure leaves the connected load without power as long as the distribution circuit breakers are in the OFF-position or fuses are removed from the fusebase, so make sure it is allowed to turn off the load as long as this test is going on.

Step 1.

Switch ON all the battery fuse switches/motor contactors [10] and the DC-distribution MCBs [2] and [6].

Step 2.

Switch the load and battery breakers OFF and ON one after another, checking that the alarms are indicated as configured. The alarms of cartridge type fuses can be tested by removing and installing the fuse with a fuse handle from the base. Only the MCBs t hat are switched on/the fuses that are installed, which have the load or batteries connected will produce an alarm when switched off or removed from the fuse base.

Note!

Load fuse alarm will appear immediately, but battery fuse alarm may take a few minutes until battery voltage decreases enough (>200 mV).

The active alarm is indicated by LEDs in the UIM and in the PSC 3 Configuration and Supervision Tool (web interface). The alarm source can be investigated only in the web interface menu: Alarm

→

Status

The alarms are also logged (if configured) and the log entries can be checked in the menu: Log Entries →

Step 3.

After checking the fuse monitoring, ensure that all fuses and MCBs are back on their places in the original positions, and able to feed to load.


8.3.4

AMS 48/2000-8/16/24 ETS WITH PSC 3

Testing the mains failure alarm Step 1.

Switch all the rectifiers off manually by using the mains switch. The LED “∼” on the UIM and in the PSC 3 Configuration and Supervision Tool (web interface) must light up (if configured so).

Step 2.

Switch the rectifiers on again. The LED “∼”on the UIM and in the PSC 3 Configuration and Supervision Tool (web interface) front must go out.

Note!

If there are no load and batteries connected to the system, no mains failure alarm will occur.

Note!

After the testing, attach all the covers of the system to their correct places.


9

AMS 48/2000-8/16/24 ETS WITH PSC 3

APPENDIX: INSTALLATION AND COMMISSIONING CHECK LIST

1. Preparing for the installation Ref.

Function

2.1

Ensure that you have all the equipment you need to make a proper installation of the system. Also ensure that the grounding terminals, DCand AC-distributions are properly available.

2.2

Check carefully that the received cargo is according to the packing list. Ensure that the rack and the equipment are not damaged during transportation. Check that proper documents are delivered.

Complete

2. Installation Ref.

Function

4.1

Set the system cabinet standing in its place and straighten if needed.

4.1

In case the system consists of two cabinets, connect the cabinets mechanically and electrically together.

4.2

Remove the possible covers in front of the distributions and connections in the system.

4.2.1

Connect the positive busbar of the system to the main grounding busbar of the equipment room.

4.2.2

Connect the AC-mains cables to the AC supply terminal.

4.3

Connect the battery cables to the positive busbar and respective fuse switch or motor contactor connections.

4.3

Place the battery temperature sensor between the batteries in the battery area. Fasten the sensor cable to the subrack.

4.4

Connect the remote alarm cables to the terminals in the PSC 3.

4.4

In case the system consists of two cabinets, connect the CAN distributions between the cabinets with two cables.

4.5

Connect the distribution cables. Plus cables are connected to the positive busbar of the system and the negative cables directly to the connections of the DC distribution circuit breakers and fuse bases.

Complete

Check that the cabling is according to the wiring diagram and instructions. 3. Commissioning Ref.

Function

5.1

Remove the screws that are used to fasten the rectifiers and lift the rectifiers into the cabinet shelves starting from the far-left slot and continuing to right. Fasten the rectifiers with the screws.

5.1

Check that all fuses switches and motor contactors are in the “OFF”position.

5.1

Start up the system by switching on the mains and check that all the LEDs on the rectifiers are “Ok”.

Complete


AMS 48/2000-8/16/24 ETS WITH PSC 3

3. Communication settings Ref.

Function

6.1

Switch ON the AF10 circuit breaker to switch the controller on.

6.1

Set your computer for the serial connection.

6.2

Set your computer for the direct computer-to-LAN connection.

6.3

Set the PSC 3 for communication in the local area network.

Complete

4. Configuration of the PSC 3 Ref.

Function

7.4

Define the system characteristics in the PSC 3.

7.5

Define the system architecture in the PSC 3.

7.5.1

Name and define all battery shunts in the system, as well as the additional battery string for driving the LVD relay.

7.5.2

Name and define all load shunts in the system, as well as the additional load strings for driving the PLD relays.

7.5.3

Define the threshold value for number rectifiers to issue the Urgent Alarm and Non Urgent Alarm.

7.5.4

Set the parameters for the rectifier group “RFMGroup1”.

7.6

Define the SENSN devices in the system.

7.7

Define the measurements in the system.

7.8

Define the events in the system.

7.8.1

Define and set the events for too high and low system voltage.

7.8.2

Define and set the events for too high and low battery temperature

7.8.3

Define and set the event for too high system power.

7.8.4

Define and set the event for battery LVD and then assign the new event to drive the battery LVD.

7.8.5

Define and set the PLD events for load groups, based on voltage.

7.9

Define the I/O assignments of the SENSNs.

7.10

Set the event processing.

7.10.1

Set the event processing and assignment for the load PLDs.

7.10.2

Define the events for Urgent Alarms and Non Urgent Alarms

7.10.3

Define the special mode event, to indicate special activity in the system

7.10.4

Define the event for delayd mains failure.

7.10.5

If needed, define more events and set the event processing.

7.11

Define what events are alarms, for remote alarms and alarm stop functions.

7.12

Set the I/O assignments for the PSC 3. Define the remote alarms for the digital outputs.

Complete


AMS 48/2000-8/16/24 ETS WITH PSC 3

7.13

Set the I/O assignments for the SSM. Define the events that drive the LVD and PLD relays.

7.14

Set the system status assignment and the UIM.

7.15

Test the alarms in the Maintenance menu, and choose alarms for alarm stop functionality.

7.16

Set the logging of the events and alarms.

7.17

Set the battery charging and testing functions.

7.17.1

Set the float charge and temperature compensation parameters.

7.17.2

Set the equalize parameters.

7.17.3

Set the battery test parameters.

7.17.4

Set the boost charge parameters.

7.18

Check that all parameters in the PSC 3 are correctly set and working as intended. Save the settings and logout.

5. System check Ref.

Function

8.1

Switch ON the circuit breaker AF10 to switch on the PSC 3.

8.1

Measure the system voltage and calibrate the controller if needed.

8.1

Check also that the battery cables are connected correctly by measuring the voltage over the battery fuse.

8.2

Check that the rectifiers are able to deliver current, by discharging the batteries for a while and then recharging them, using the battery test.

8.3

Check the control and alarm system

8.3.1

Check the system configuration

8.3.2

Check the alarms

8.3.3

Check the fuse monitoring

8.3.4

Test the mains failure alarm

6. Finishing Update the drawings if any changes have been made. Update the test report if any changes were made to the controller settings. Clean the site.

Complete

Energy Systems

Maintenance Instructions DC Power Supply Systems

50001_04

Energy Systems MAINTENANCE INSTRUCTIONS


TABLE OF CONTENTS 1


2

Version control...................................................................................................5

POWER SYSTEM MAINTENANCE...............................................................................7 2.1

Introduction........................................................................................................7

2.2

Preventive maintenance ....................................................................................7

2.3

Rectifier maintenance........................................................................................7

2.3.1

Checking the functioning of the rectifiers...........................................................7

2.3.1.1 Power systems with PSC 1000 controller..........................................................7 2.3.1.2 Power systems with PSC 3 controller................................................................8 2.3.2

Rectifier replacement in a running system.........................................................9

2.3.2.1 Fan cooled rectifiers, with both input and output interfaces on the back ...........9 2.3.2.2 Fan cooled rectifier, with AC input interface on the front ...................................9 2.3.2.3 SMPS rectifiers, with both input and output interfaces on the front ........ ...........9 2.3.3

Fan replacement procedure with fan cooled rectifiers .....................................10

2.3.3.1 Rectifier DPR 1200B-48 ..................................................................................10 2.3.3.2 Rectifiers with both input and output interfaces on the back............................10 2.3.3.3 Rectifier with AC input interface on the front....................................................11 2.4

Power system controller maintenance.............................................................11





1

1.1




50001_04

Maintenance of DC Power Supply Systems

Previous version


50001_03

Information about PSC 3 controller and DPR 1200B-48 rectifier added. Controlled by

Date 07.10.2004


Date 07.10.2004

Petteri Turkki





2 2.1


POWER SYSTEM MAINTENANCE Introduction The power system is designed for unmanned operation and normally all the actions are carried out automatically by the controller unit. Therefore the actions undertaken are either preventive maintenance or repair.

2.2

Preventive maintenance The purpose of the preventive maintenance is to reveal the potential failures of the monitoring and alarm circuitry. The exception is the batteries, which should be checked and maintained regularly according to the instructions of manufacturer delivered with the batteries. To ensure high system reliability the most important measures are: •

Verification of the mechanical condition and connections of the batteries.

•

Verification of the functioning of the controller unit.

To ensure the high life expectancy of the batteries the most important measures are:

2.3 2.3.1

•

The quality of the battery maintenance, cell voltage, ambient temperature.

•

Verification of the battery float charge voltage.

Rectifier maintenance Checking the functioning of the rectifiers Checking the functioning of the rectifiers is part of preventive maintenance actions recommended to be carried out once a year as follows. Check that the rectifiers are able to deliver current. The method is to first discharge the batteries for a while and then recharge them. The controller carries out the procedure, which decreases the rectifier voltages below the discharging voltage of the batteries. Therefore in case of a battery failure the system will not crash.

2.3.1.1 Power systems with PSC 1000 controller Step 1.

Start the discharging by activating the battery test manually from the controller sub-menu “8. Battery Test” and then from its sub-menu “8. Battery Test”. Press to activate the test.

Step 2.

Let the controller discharge the batteries few minutes.

Step 3.

Stop the battery test from the controller and exit from the battery test sub-menu.



2.3.1.2 Power systems with PSC 3 controller Step 1.

Start the discharging by activating the battery test manually from the controller menu (web user interface): Battery Control. The battery test is started by clicking on the “Start” in t he Battery Test section of Battery Control menu. →

Note!

If the “Start” button is not available, check the starting conditions by clicking on the “Info”. All the starting conditions must be true before the battery test can be executed.

Step 2.

After the battery test, check the results from the menu Test Results.


2.3.2


Rectifier replacement in a running system

2.3.2.1 Fan cooled rectifiers, with both input and output interfaces on the back (e.g. FR 48 V – 2000 W – E and DPR 1200B-48) Step 1.

Remove rectifier module

Step 2.

Place new rectifier into its rack position

Step 3.

Check system (controller) for alarms.

2.3.2.2 Fan cooled rectifier, with AC input interface on the front (FR 48 V – 1200 W) Step 1.

Unplug AC and signal bus cables

Step 2.


Step 3.

Plug in AC cable to new rectifier (same settings!)

Step 4.

Check LED «ok» and output voltage

Step 5.

Place new rectifier into its rack position

Step 6.

Connect system bus cable(s)

Step 7.

Check system (controller) for alarms.

2.3.2.3 SMPS rectifiers, with both input and output interfaces on the front (e.g. SMPS 48 V – 1900 W) Step 1.

Switch off AC breaker and DC breaker

Step 2.

Remove DC plug, AC plug and system bus plug

Step 3.


Step 4.

Check spare module (See “Installation and commissioning”)

Step 5.

Mount spare module

Step 6.

Insert AC plug

Step 7.

Insert DC plug

Step 8.

Switch on AC breaker

Step 9.

Switch on DC breaker

Step 10.

Connect system bus cable

Step 11.

Check system (controller) for alarms


2.3.3


Fan replacement procedure with fan cooled rectifiers

2.3.3.1 Rectifier DPR 1200B-48 Rectifier DPR 1200B-48 does not contain any user serviceable parts inside the unit. A faulty rectifier module should be replaced as a complete unit.

2.3.3.2 Rectifiers with both input and output interfaces on the back (e.g. FR 48 V – 2000 W – E) To replace a defective fan proceed as follows: Step 1.

Remove central fixation screw (1)

Step 2.


Step 3.

Remove front panel screws (2)

Step 4.

Unplug fan connector (3)

Step 5.

Remove fan (4)

Step 6.

Replace the fan, note that the air stream direction must be towards rectifier inside (see indication arrow on fan housing)

Step 7.

Remount the parts in reverse order. 2 100 % Iout

ok

10 %

3

4

2

FR 48 V - 2000 W - E 1

P0042

Front view with panel

P0043

Front view without panel



2.3.3.3 Rectifier with AC input interface on the front (e.g. FR 48-1200W) Step 1.

Remove central fixation screw (1)

Step 2.

Pull out AC connector (2) and signal bus connectors (3)

Step 3.

Remove front panel screws (4)

Step 4.

Unplug fan connector (5)

Step 5.

Remove fan (6)

Step 6.

Replace the fan, note that the air stream direction must be towards rectifier inside (see indication arrow on fan housing)

Step 7.

Remount the parts in reverse order. 100 % Iout

ok

4

10 %

System bus

3

5

6

Input 230 V 7A 50 Hz

2

4

FR 48 V - 1200 W 1

P0045

P0044

Front view with panel

2.4

Front view without panel

Power system controller maintenance Preventive maintenance actions recommended to be carried out once a year. Check the functioning of the controller according to the Installation and Commissioning section, chapter “Checking the control and alarm system”.



Energy Systems

Troubleshooting DC Power Supply Systems

60001_03

Energy Systems TROUBLESHOOTING


TABLE OF CONTENTS 1


2

Version control...................................................................................................5

TROUBLESHOOTING...................................................................................................7 2.1

PSC 1000 alarms and sources ..........................................................................7

2.1.1

Alarm LEDs of the PSC 1000 ............................................................................7

2.1.2

Alarms and alarm sources.................................................................................7

2.2

PSC 3 alarms and sources..............................................................................10

2.2.1

System status indications ................................................................................10

2.2.2

Alarms and alarm sources...............................................................................10

2.3

Rectifier alarms................................................................................................12

2.3.1

Fan cooled rectifiers ........................................................................................12

2.3.2

SMPS rectifiers................................................................................................13





1

1.1




60001_03

Troubleshooting for DC Power Supply Systems.

Previous version


60001_02

PSC 3 and DPR 1200B-48 related information added. Controlled by

Date 07.10.2004


Date 07.10.2004

Petteri Turkki





2


TROUBLESHOOTING When trying to locate a fault in the power system proceed as follows:

2.1

Step 1.

Check the controller front panel display and alarm LEDs

Step 2.

Check the protocol (PSC 1000) or alarms (PSC 3) menu in the PSC

Step 3.

Check the LEDs on all rectifier front panels

PSC 1000 alarms and sources This section helps to locate power system faults that are displayed in the PSC 1000. Below in section 2.1.2 “Alarms and alarm sources” is a list of possible alarms, errors and messages that appear in the protocol menu, following with information on the possible cause of a fault and its clearance.

2.1.1

Alarm LEDs of the PSC 1000 Urgent Alarm (UA) Non-urgent Alarm (NUA) Mains Failure (MF)

2.1.2

Alarms and alarm sources Message

Alarm

Definition

RM Failure

UA

Rectifier failure according to configured scheme (→ Configuration)

RM Failure

NUA

Rectifier failure according to configured scheme (→ Configuration).

Load Fuse

UA/NUA/ No Alarm

One or more load fuses blown. Alarm as configured (→ Configuration).

Battery Fuse

UA/NUA/ No Alarm

One or more battery fuses blown. Alarm as configured (→ Configuration).

Usys high/Usys low

UA

System voltage above/below UA level ‘Ua max’/’Ua min’. If charge mode is ‘Battery Test’, UA due to Usys low is suppressed.

Usys high/Usys low

NUA

System voltage above/below NUA level ‘Us max’/’Us min’. If charge mode is ‘TC Float Charge’, NUA levels are temperature compensated. If charge mode is ‘Boost Charge’, ‘Battery Test’, ‘Temp Comp’ or ‘Equalize’ alarm is suppressed. If mains failure is active, alarm is or is not suppressed, according to chosen configuration ( → Configuration). Alarm is generated only a couple of seconds after level has been passed.

Utrip-low

UA/NUA/ No Alarm

System voltage has dropped below ‘Utrip-low’ level for at least 20 seconds.



Isys high

NUA/UA

System current above ‘Isys max’. Alarm as configured (→ Configuration).

Psys high

NUA/UA

System power above ‘Psys max’. Alarm as configured (→ Configuration).

Battery Failure

UA/NUA

Battery test recognized battery as faulty. Alarm has to be reset manually. Alarm as configured (→ Configuration).

Battery Failure (U, I, T)

UA/NUA

Battery supervision recognized battery as faulty. Alarm has to be reset manually. Alarm as configured (→ Configuration).

Mains Failure

MF

Mains failure recognized

Mains Failure

UA/NUA

Additional alarm in case of mains failure – if configured so (→ Configuration). Generation of alarm may be delayed (menu option ‘4.9.MF delay’).

Usys Measurement

UA

The measured system voltage is not plausible for at least 25 seconds. Plausible voltage: 10…90 Volt. When a failure in the measurement of the system voltage is recognized, the measured voltage is not considered any more for controlling the system voltage (= feed back loop stopped → open loop control).

Temp Measurement

UA/NUA

The measured battery temperature is not plausible for at least 2 consecutive measurement time slices. Plausible temperature: -20…+90 °C. Alarm as configured (→ Configuration). When a failure in the measurement of the battery temperature is recognized, PSC 1000 stops temperature compensation of the system voltage.

Temp 2 Measurement

UA/NUA

The measured ambient temperature is not plausible for at least 25 seconds. Plausible temperature: -20…+90°C. Alarm as configured (→ Configuration). When a failure in the measurement of the ambient temperature is recognized, PSC 1000 stops temperature comparison of the battery supervision.

A/D Failure

UA

Analog/Digital Converter does not work properly. Hardware failure.

Alarm 1

NUA/UA

Auxiliary alarm input for general purpose.

Alarm 2

NUA/UA

Auxiliary alarm input for general purpose.

Utrip2-low

UA/NUA/ No Alarm

System voltage has dropped below ‘Utrip2low’ level for at least 20 seconds.



Utrip3-low

UA/NUA/ No Alarm

System voltage has dropped below ‘Utrip3low’ level for at least 20 seconds.

Temp TRIP1

UA/NUA/ No Alarm

Temperature has gone above ‘Ttrip1-high’ level for at least 20 seconds.

Temp TRIP2

UA/NUA/ No Alarm

Depending on configuration, either temperature has gone a) above ‘Ttrip2 ↑’ OR b) outside temperature band given by ‘Ttrip2 ↑’ and ‘Ttrip ↓’, for at least 20 seconds.

System OVP

UA

System over voltage protection procedure switches off the rectifiers (needs additional system hardware). Alarm has to be reset manually.

No Modem

NUA

If MODEM is not available or can not be initialized correctly.

Temp high

UA/NUA/ No Alarm

Depending on configuration, either temperature has gone above ‘Temp high’, for at least 20 seconds.


2.2 2.2.1


PSC 3 alarms and sources System status indications The alarm LEDs/indications of the PSC 3 UIM and web user interface can be assigned to any event by the user. Check your system status assignments in the web user interface (Configuration and Supervision Tool ) menu: Configuration

→

I/O

→

System status & UIM

Normally the LEDs are assigned as follows:

2.2.2

•

LED 1 / symbol “

” is assigned for “S Urgent Alarm” event

•

LED 2 / symbol “

” is assigned for “S Non Urg Alarm” event

•

LED 3 / symbol “

” is assigned for “S Alarm suppr.” event

•

LED 4 / symbol “

” is assigned for “S Mainsfailure” event

•

LED 5 / symbol “

” is assigned for “Special mode” event

Alarms and alarm sources The alarms and alarm indications in the PSC 3 controller are user-definable. The Urgent Alarm (UA), Non Urgent Alarm (NUA) and Mainsfailure Alarm exist as default in the controller. The flexibility of the PSC 3 allows the user to define any event in the controller under the UA and NUA alarm definitions. Also the naming of events is user-definable. The following events are the most common conditions for the UA and NUA alarms. The event names are based on the general instructions for configuring the PSC 3 (see Installation and Commissioning section). All events with prefix “S” are default system events that have a fixed name. Note!

These events can only be seen in the user interface module (UIM) as a source for UA or NUA alarms if they have been defined as alarms in the Alarm Setup menu of the web user interface. Otherwise they will be indicated only as UA or NUA alarms, without the further information about the alarm source. The alarm source investigation can then be done only through the web user interface of the PSC 3.

Event

Alarm

Definition

S Mainsfailure

MF

Mains failure recognized.

S Usys low

UA

The system voltage has dropped below the threshold value of the S Usys low event. Adjustable threshold, set by default to 46V.

S Urgent RFA

UA

Analogue Rectifier: Set if >1 rectifier failed. Digital Rectifier: Adjustable, by default set if 2 or more rectifiers failed.

Usys high

UA

The system voltage gone above the threshold value of the Usys high event.



Ufuse_Lshunt1

UA

Fuse alarm for Load Shunt 1. The voltage measurement of the load shunt 1 has dropped below threshold value of the Ufuse_Lshunt1 event.

Ufuse_Bshunt1

UA

Fuse alarm for Battery Shunt 1. The voltage measurement of the battery shunt 1 has dropped below threshold value of the Ufuse_Bshunt1 event.

Ufuse_Bshunt2

UA

Fuse alarm for Battery Shunt 2. The voltage measurement of the battery shunt 2 has dropped below threshold value of the Ufuse_Bshunt2 event.

S HW Failure

NUA

A system hardware failure has been detected. This can be either a Temperature sensor, a SENSN, a SSM or PSC 3 internal failures. The alarm source can be investigated only in the Log menu of the web user interface.

S Non Urg RFA

NUA

Analogue Rectifier: Set if 1 rectifier failed. Digital Rectifier: Adjustable, by default set if 1 rectifier failed.

Psys high

NUA

The total system power, calculated by the PSC 3, has gone above the threshold value of the Psys high event.

Tbatt high

NUA

The battery temperature measurement has gone above the threshold value of the Tbatt high event.

Tbatt low

NUA

The battery temperature measurement has dropped below the threshold value of the Tbatt low event.

PLD1 [U+t]

NUA

Load group 1 has been disconnected by the Partial Load Disconnect (PLD). Either the primary time threshold condition from mainsfailure [t] or the secondary voltage condition based on system voltage is true.

PLD2 [U+t]

NUA

Load group 2 has been disconnected by the Partial Load Disconnect (PLD). Either the primary time threshold condition from mainsfailure [t] or the secondary voltage condition based on system voltage is true.


2.3


Rectifier alarms The following instructions can be helpful in case of a rectifier alarm, to find out whether a rectifier is faulty or the failure is outside the rectifier module.

2.3.1

Fan cooled rectifiers Internal failures can only be repaired in Delta Energy Systems factory, therefore the faulty rectifier module in the system must be replaced with a new unit. With some rectifiers the fan can be replaced (see maintenance instructions). LED «ok» is off and an alarm is given: Mains voltage is missing:

Check mains fuse and connector

OVP is activated:

Reset OVP by pulling out the connector for approx. 2 seconds

OTP is activated:

Check air flow at front, clean air filter

Fan failure, air flow blocked:

Check air flow at front, clean air filter, check fan and replace if necessary

Load sharing not working:

Check connector

DC connection open:

Check connector

Rectifier is faulty:

Replace rectifier module

Systems with PSC 3 and digital communication: additional troubleshooting: COM-LED off or blinking

Communication failed. Check bus cable to PSC 3. Check correct IMBUS termination.

If nothing helps, disconnect the AC connector (FR 48V-1200W) or pull out (FR 48V-2000W-E and DPR 1200B-48) the rectifier module for 1 minute to reset the microcontroller. The settings can only be checked or adjusted via separate connector to an external programming box containing the appropriated software.


2.3.2


SMPS rectifiers Internal failures can only be repaired in the Delta Energy Systems, therefore the faulty rectifier module in the system must be replaced with a new unit. LED «ok» OFF and alarm signal active: Mains voltage missing:

Check mains fuse and AC connections

OVP / OTP activated:

Reset OVP (only if conditions for shut down are not existing any more)

Fault inside the rectifier:

Replace rectifier module

LED «ok» is blinking and alarm signal active: Load sharing not working:

Check U out and bus connection

DC connector open

Check DC connector and cable

Output fuse open

Check output fuse in the rack.

AMS 48_2000-n_D0114354_055_00

Recommend Documents