conversion d'énergie
TYPE B
Technical Manual B8748
TECHNICAL MANUAL
Operating principle, installation and start-up
48VDC/3+1 50A POWER PLANT
with
MCU1000 remote monitoring system
REVISION INDEX
Revision 1
First issue , version with ABB auxiliary USE CB contacts
Revision
1
NAME
DATE
Prepared
J.B
07.01.02
Checked
L.M
08.01.02
Approved
L..M
08.01.02
NAME
43 avenue Winston Churchill - 27400 LOUVIERS
Téléphone 2.32.25.23.94 - Fax 2.32.25.08.64
DATE
P:\notices\mideastdata\B8748\8748-not.doc
SUMMARY
1. PRESENTATION OF THE EQUIPMENT
Responsibility and safety instructions
General characteristics of the equipment
General characteristics of the SMR rectifier type TEBECHOP 3000 (48V/50A)
Norms and environmental conditions for the standard equipment BENNING NCE 1195
2. GENERAL DESCRIPTION OF THE EQUIPMENT
3. DESCRIPTION OF THE PRIMARY SWITCHED CHARGER TYPE TEBECHOP 3000
General
Function
Operating mode
Drawings
4. DESCRIPTION OF THE REMOTE MONITORING SYSTEM MCU1000
5. DESCRIPTION OF VOLTMETRIC RELAY TYPE GUW104/105
General
Function
Operating mode
6. INSTALLATION AND START UP
Installation
First operation of the equipment
7. MAINTENANCE OF THE EQUIPMENT
8. DRAWINGS OF THE EQUIPMENT
. Layout drawings of the equipment
. Electrical drawings of the equipment
9. PART LIST
. Part list of the equipment
BENNING
EN60950E
conversion d'énergie
RESPONSIBILITY AND
SAFETY INSTRUCTIONS
RESPONSIBILITY :
The user must ensure that the safety instruction in this manual are read and observed by the
technical personnel. The manufacturer will not be responsible in any of direct, indirect or
accidental personal or material damage.
The installation of the power supply system must be performed by authorised electricians or
by qualified internal personnel.
Please read the entire Operating manual before you perform the installation and start-up the
power supply system.
The contents of this manual may be changed. The manufacturer has produced this manual with
the purpose to provide precise and simple information and will therefore take no responsibility
for any misinterpretation or undesired mistakes of this manual.
SAFETY NOTES:
This unit in question is an electrical device requiring DANGEROUS LEVELS
OF VOLTAGE AND CURRENT !
The followings instructions should be therefore be carefully observed:
- Ensure that only trained and authorised personnel have access to the unit. Only certain
persons should be authorised to open the housing.
- Even when the unit is switched off, some of the internal components may still be live as
long as they are connected to the mains power supply or to the battery.
- Integrated capacitors may still be live, even when the unit is disconnected and free of any
voltage. They should therefore be correctly discharged by a qualified person before to
touch to the terminals.
- Only insulated tools should be used for work on the unit.
- All persons working with the unit should be familiar with first-aid-measure to be taken in
the event of an accident involving electricity.
- The regulations of the local power supply authority and all applicable safety regulations
should be observed at all times.
- Before any mains input connecting, connect the earth to the terminal PE (Green/yellow cable).
For further information, please contact your dealer
1. PRESENTATION OF THE EQUIPMENT
General
This equipment consists on :
. 4 rectifier modules E230 G48/50 BWru-PDD (TEBECHOP 3000 with satellite), rectifier
modules 48V/50A in parallels.
. The DC monitoring system MCU1000 and the 48VDC distribution by means of 7 DC
outputs protected by circuit breakers.
The rectifier plant is integrated inside a cabinet 29U height 19" type PSJ1566.
1 - Mechanical characteristics
Rectifier cabinet (DWG: B8687-11)
Front door ..............................................................................................................600 mm
Depth ...................................................................................................................600 mm
Height ...................................................................................................................1500 mm
Weight without batteries........................................................................................
110 Kg
Protection ..............................................................................................................IP20
Colour
..............................................................................................................RAL
7035
2 - Electrical characteristics - Drawing B8687-12/13/14 (3 sheets)
2.1 Rectifier type E230 G48/50 BWru PDD (48V/50A)
(see general characteristics of switched mode rectifier TEBECHOP 3000)
2.2
48VDC Rectifier cabinet
Mains voltage (rectifier supplying):
Input nominal current :
220Vac 3Ph. +/-15% - 60Hz
26A per phase
The input MCB recommended is 32A curve 'C'.
Floating voltage:
Boost voltage:
Battery disconnection:
54,7V
Not Used
43,2V
Remark: adjustments are given for maintenance free sealed lead acid batteries at
temperature 20°C.
RV1 (low battery voltage disconnection)
- Drop out voltage .....................................................................................
- Pull in voltage .........................................................................................
43,2 V
50 V
Remark: the Automatically battery disconnection at the end of the back up time appears
only if the voltmetric relay RV1 and the relay K3 of the MCU1000 unit release for more
security.
3 - Controls and alarms
The unit MCU1000 allows to signal several alarms trough external contacts tied to the plug
X1 of the MCU1000 Unit (Logic inputs), see drawing B8687-04:
-
Mains fault (provided by the auxiliary relay K10)
Rectifier fault (provided by the internal contact of each rectifier modules)
Battery 1 Fuse fault (provided by the auxiliary contact of fuses F11)
Battery 2 Fuse fault (provided by the auxiliary contact of fuses F12)
L.V.D fault (provided by the auxiliary contact of LVD contactor K1), deep discharge
Use CB fault (provided by the auxiliary contact of the circuit breakers F21 to F27)
The unit MCU1000 allows to provide also alarms through voltage and current measure
inputs:
-
Battery voltage low < 50,4V
Mini DC pre-alarm < 46V
End of autonomy < 43,6V
DC Overvoltage > 57V
- Battery test Fault
These alarms trough external contacts and UI measurements are set with the internal
software of the MCU1000.
Two levels of alarm are available on terminal X3 of the rectifier cabinet:
URGENT ALARM:
NON URGENT ALARM:
terminal 1 to 3 (closed between 2 and 3 in normal operation)
terminal 4 to 6 (closed between 5 and 6 in normal operation)
** Voltage free contacts.
Battery automatically disconnection:
The power contactor K1 allows to disconnect the batteries associated at the end of the back
up time to avoid a battery deep discharge.
This disconnection appears when the DC battery voltage reaches 43,2 V.
01E-0015
SMR rectifier general data type TEBECHOP 3000
Type E 230 G 48 / 50 BWru-PDD
Serial No
1.
.............................................................................................................................
MECHANICAL CHARACTERISTICS
Front: 147 mm (1/3 19")
Degree of protection IP 20
2.
3.
-5°C to 45°C
.
Humidity (95% 20°C) (80% 40°C)
.
Altitude - without derating ......................................................................................................................................................................................
Derating 7%/1000 m between 1000 m and 4000 m
1000 m
.
RFI in accordance with .................................................................................................................................................................................................
EN 55022 Class B and
VDE 0878 Class B
INPUT AC DATA
Nominal voltage 1Ph ........................................................................................................................................................................................................
Frequency ..........................................................................................................................................................................................................................................
Nominal current .......................................................................................................................................................................................................................
Power factor...................................................................................................................................................................................................................................
230V +15% -15%
50 - 60 Hz ±5%
13,6A
> 0,95
OUTPUT DC DATA - IU/U according to DIN 41773
Nominal voltage ......................................................................................................................................................................................................................
Floating mode (±5% adjustable) (XI) .....................................................................................................................................................
Boost mode (±5% adjustable) (XII) ..........................................................................................................................................................
Voltage 1,8V/Elt (±5% adjustable) (IX).............................................................................................................................................
Manual or direct feed (X)..........................................................................................................................................................................................
Nominal current .......................................................................................................................................................................................................................
Ripple according to KAX 9516 and CCITT 0.41 .................................................................................................................
Static voltage stability for a load variation 0 to 100% ...................................................................................................
Dynamic voltage stability for a load variation 10 to 100%...................................................................................
Recovery time less than 2 ms
Efficiency at nominal load ......................................................................................................................................................................................
48V
54,7V
Not Used
Not Used
Not Used
50A
<60mV
± 0,5%
< or = ± 8%
> or = 90%
CONTROL AND ALARM
.
.
.
.
.
.
.
57,6V
Maxi output DC voltage latched (red LED) ..................................................................................................................................
Normal voltage > 170 V AC (yellow LED) ..................................................................................................................................
Correct rectifier operating (green LED) ..............................................................................................................................................
Rectifier faulty (red LED) ........................................................................................................................................................................................
FAN FAULT (red LED) .............................................................................................................................................................................................
85°C on heatsink
Temp high (red LED) ......................................................................................................................................................................................................
Remote alarm NO-NC - "RECTIFIER FAULT" Remote alarm NO "MAINS FAULT"
INSTRUMENTS
.
7.
Weight: 12 kg
Temperature without derating ............................................................................................................................................................................
Derating 1,25%/°C between 40°C and 50°C
(Air forced cooling output depending)
.
6.
Height: 291 mm (# 6U)
.
.
.
.
.
.
.
.
.
.
5.
Depth: 440 mm
OPERATING ENVIRONMENT
.
.
.
.
4.
Order No B8748
DC output control by "BARGRAPH" of 10% to 100%, 10 LEDS and DC out test points
TERMINALS (see DWG 21.0110)
.
.
AC input
Output
Plug type 16A 250V IEC-320/C20, DIN 49458
Remote alarm and control ITT Cannon with contacts 21WA4
BENNING
NCE1195E
conversion d'énergie
NORMS AND ENVIRONMENTAL CONDITIONS NCE1195
MAIN NORMS APPLICABLE IN OUR PRODUCTION :
VDE 0100
Low voltage electrical installation
(nominal voltage below 1000V)
VDE 0160
High current electronic equipment
VDE 0532
Choke and transformer
VDE 0550
Small transformer specification
VDE 0560
Capacity rules
EN 60950
Safety and information technology
EN 55022
RFI rules telecommunications, class B
VDE 0435
Contactor and relay for high current
VDE 0800
Ground rules
OPERATING ENVIRONMENT :
- Humidity :
. temperature :
(°C) 20 40 50
. relative humidity : (%) 95 80 50
- Temperature :
- Altitude :
operating
Derating
1,25% / °C from
- 5°C to + 45°C.
45°C to 55°C
1000 m without derating
Derate 7% / 1000m between 1000 m to 4000m
2. GENERAL DESCRIPTION OF THE EQUIPMENT
1.
Rectifier and DC power part
Please refer to the drawings B8687-12/13/14.
The rectifier modules E230 G48/50 Bwru-PDD (48V/50A) are mounted in
parallels protected on the input by the circuit breakers F1.1 to F1.2 and on the DC
output by the circuit breakers F4.1 to F4.2, protections located under each 19"
rectifier rack.
Each rectifier module provides voltage free contact to the monitoring control unit base
MCU1000 to give the remote alarm "Rectifier fault" in case of rectifier module
stopped or broken down.
The auxiliary relay K10 provides voltage free contact to the monitoring control unit
base MCU1000 to give the remote alarm "Mains fault" in case of voltage not present
on the input terminal X1.
The shunts R1 and R2 allow the measures of the battery
currents.
and DC outputs use
Remark: the battery charge current is controlled and limited automatically
trough the monitoring board A22, current limit value set in factory to 70A +/-10%.
The 48VDC outputs are available on the Circuit breakers F21 to F27.
In case of use CB opening, an alarm will be activated on the MCU1000 unit (alarm
shown on the front panel signalling 'Use CB fault' and through the voltage free
contacts 'URGENT ALARM'), this alarm is provided by the auxiliary contacts of the
use CB F21 to F27.
The 48VDC rectifier cabinet will be connected to 2 external batteries protected by the
fuses F11 to F12.
In case of battery fuse open or blown, an alarm will be activated on the MCU1000
unit (alarm shown on the LCD Display 'battery 1 or 2 fault' and through the voltage
free contacts 'URGENT ALARM').
An additional alarm will be activated also in case of LVD contactor (K1) opening
"L.V.D fault".
The voltmetric relay RV1 controls the DC battery voltage and allows the automatically
battery disconnection at the end of the back up time by opening of the contactor K1.
This allows to avoid a deep battery discharge.
For more details, please refer to the chapter 'description of the voltmetric relay type
GUW104/105'.
2.
Control and measurement equipment
On each rectifier modules, an entire signalling indicate the state of the unit.
Please refer to the chapters 'Description of the rectifier unit with satellite TEBECHOP
3000'.
The MCU 1000 Unit allows to control the right operation of the DC power plant and
show the Voltage and current values of the Rectifier output, use and battery.
A green LED located on the MCU front display indicates that the entire DC power
plant correctly.
Two red LEDs indicate an Urgent alarm and a non urgent alarm.
The last LED (yellow) is lit in case of battery discharge (battery operation).
3.
Alarms terminal
A terminal X3 located in the upper part of the cabinet gives the information
followings trough voltage free contacts:
URGENT ALARM
Terminals 1,2 and 3 (closed
between 2 and 3 in normal operation).
NON URGENT ALARM
Terminals 4,5 and 6
(closed between 5 and 6 in normal operation).
In normal operation these relays are picked up and release in case of alarm.
- NON URGENT ALARM (relay K2 of the MCU1000 Unit):
Mains Fault, delayed 180 seconds
Battery voltage low < 50,4V
- URGENT ALARM (relay K1 of the MCU1000 Unit):
Rectifier fault
High DC load voltage >57V
Mini DC pre-alarm < 46V
End of autonomy < 42,5V
Battery 1 fault (battery fuse blown or open)
Battery 2 fault (battery fuse blown or open)
L.V.D fault (low voltage battery disconnection contactor K1 open)
Use CB fault (CB F21..F27 open or tripped)
Internal clock fault
Memory configuration fault
These alarms have been programmed in factory (EPROM) and can't be changed.
But the values for the low DC voltage alarms can be changed by a local computer with the
'service program'.
11E0012
3. DESCRIPTION OF THE PRIMARY SWITCHED MODE CHARGER TYPE
TEBECHOP 3000
03.0211
General
This charger is able to deliver a regulated voltage ± 1 % with a filtering of 1/1000 from an AC
single-phase mains.
The output is an IU charging characteristics according to DIN 41773. That is to say a constant
voltage output with a current limited.
The charger is electronically protected against short circuits on the output.
The input current is a sine wave shape with a power factor close to 1.
Function (see drawing 03.0211A/B)
The input AC voltage is rectified through the bridge V1.
The components L1, V2 and V3, V4 to V7 is working with a frequency around 40Kz in order to
get a since wave current on the input AC mains and to have a pre-regulation at 370V on the
chemical capacitors C3 to C8. The resistors R2, R3 and the relay K1 make a limitation of the
inrush current before starting of the regulator A2 of the active filter.
The full Rectifier Bridge integrates the transistors MOS V13, V14, V27, V28, V23, V24, V17,
V18 and the diodes V21, V22, V31 and V32 is switching at 33Khz. The high-speed fuse F3 is
protecting this bridge.
The power transformer T1 is a high frequency transformer at 33Khz and it delivers square waves
signals at the voltage which is necessary for the DC output.
The fast diodes V33 to V36 rectifiers the secondary voltage of T1 and the filtering is made
through L2, C14, C16; the fundamental frequency of the ripple is 66 kHz.
The auxiliary transformer T2 protected with the fuse F2 and the auxiliary winding of T1 deliver
the necessary voltage for the supply of the regulator A1.
The shunt R37 measures the output current.
The use of the filter A4 and the components L5, C17 to C22 are design to be sure that the rectifier
is in accordance with RFI norm VDE 0878 class B and EN 55022 class B.
The temperature sensor R66 located on the regulator gives an information to start the 24VDC
FAN E1 when the ambient temperature gets 60°C.
A temperature sensor mounted on the heat sink stops the module when the temperature of this one
reaches 85° C. The module can restart when the temperature has decreased down to 70° C. When
the FAN E1 is running the resistor R13 is supplied and heats, the temperature sensor R115, if the
FAN is not running correctly, the temperature on R115 is increasing, an information " " on the
red LED on the front of the module is given.
11E0012
This charger has a protection against overvoltage on the DC side. A voltmetric relay integrated on
the regulator A1. The potentiometer R149 adjusts the value of the too high voltage and stops the
switching. To restart the rectifier this is necessary to open the mains line during more than 10
seconds.
Signalling
6 leds and a bargraph are located on the front panel.
: (Red led) indicates that the output voltage is over the "Maxi" level. This is necessary to
open the mains line during more than 10 sec. to restart.
Remark: for the first time, for the forming of batteries this level must be modified with the
potentiometer R149 on the regulator board A1.
: (Green led) indicates that the module is OK.
-
: (Yellow led) indicates that the mains voltage is greater than 170V.
-
: (Red led) indicates a failure on the module after a delay of 30 sec :
-
. Output voltage too high
. Temperature too high
. Rectifier fault
. Internal fault.
: (Red led) indicates that the fan is not running correctly.
-
: (Red led) indicates that the temperature is too high.
- Bargraph: (10 red sticks) indicates the level of the output current; one stick represents around 10
% of the nominal current.
Control
4 potentiometers are available on the front panel:
- XI (float): to adjust the float value voltage; in this case, the loops on the plug SUB D in front are
opened.
- XII (boost): to adjust the boost charge value of voltage; in this case, the loop between 3 and 4 on
the plug SUB D in front must be closed.
- X (direct feed): this operating mode is generally used without battery, when the modules are
utilised as power supplies. The voltage is adjusted with N; in this case, the loop between 3 and 5
of the plug SUB D in front must be closed.
- IX (battery test): for testing the battery. The module restarts with "1,8V/cell" when the battery
DC voltage reaches this value.
11E0012
Remark: The current via the loops is around 2mA - 5V.
Options:
Option 1: Temperature Sensor. We have the possibility to add a temperature sensor NTC 22 KE ±
2 % (ref. : 780333) between the pins 7 and 8 of the plug SUB D on the front panel in order to
compensate the assignment values of the charge of the battery. In there particular cases, the
adjustments of potentiometer DL and L must be changed.
Option 2: Battery Current limits. With an external PCB it is possible to obtain a battery current
limit. The signal coming from the PCB is between pin 13 (positive) and pin 17 (negative).
Option 3: ON/OFF rectifier. With an external switch with gold-contacts it is possible to stop the
rectifier. When the switch is open the SMR is running; the contacts are between 12 and minus.
Free potential alarm contact
2 loops for alarm (60 VDC 30W Maxi) are available on the SUB D plug on the front panel.
- General fault: an open-closed loop with a delay of 30 sec on the pins 14-15 and 16 indicates the
state of the charger. When the charger is OK, the relay is on and pin 14 closed pin 15 common pin
16 open. In case of failure this loop reverses:
. Output too high
. Temperature too high
. Mains failure
. Internal fault of the charger.
Remark:
The rectifier ‘s output current must be around 3% of nominal load to avoid a beat on the openclosed loop.
- Mains fault: a loop on the pins 10-11 of the SUB D plug on the front plate is closed when the
mains voltage is lower than 170 VAC.
BENNING
11E-0016.DOC
conversion d'énergie
STANDARD MARKINGS
FOR RECTIFIERS BENNING
MAINS LABELS :
Take care , refer to documentation !
Alternating current
Boost charging adjusting
Direct current
Float charging adjusting
Earth
Direct feed adjusting
Input
1.8V/Cell adjusting
Output
Overvoltage
Output voltage too high
Output voltage too low
In operation
Measuring sockets (output current)
Input voltage(power) ON
Earth fault
Fault
Measuring sockets (output voltage)
Fan Fault
Internal overtemperature
Output Current
Internal fuse fault
41E-0006
5. DESCRIPTION OF THE VOLTMETRIC RELAY AND AUTOMATICITY TYPE GUW104/105
GENERAL
This voltmetric relay mounted on a printed circuit board 120 mm x 38 mm with fixing holes
mounting dimension of 110 mm for screws M3.
This relay can be installed in any desired position.
This voltmetric relay is used to control DC voltage. The DC value measured and the DC value
supply can be the same (it's the general case).
The dropout and pull-in values (2 levels) can be adjusted separately from one another. This
hysteresis (minimum difference between dropout and pull-in value) is approx. 1,5 % of Udc.
FUNCTION
On the input connector X1, the DC voltage supply is between terminals "+" and "-". When the
DC voltage measuring and the DC voltage supply are the same there is a bridge on B1 (resistor
0Ω) on the printed circuit board.
When the DC voltage measured and the DC voltage supply are different (only the "-" is
common), in this case the input DC value measuring is made to the terminal "+M" and the
bridge on B1 is removed. The internal resistor value on the control line is around 6 KΩ/volt.
The green Led V27 is lit when the DC voltage on the voltmetric relay is present.
On the output connector X2, voltage free contacts (normally open, common and normally closed)
of the relay K1 are available. The relay contacts characteristics are:
AC value
DC value
5 A Maxi PF 0,7 250VAC
2A < 40VDC; 1A < 60VDC; 0,5A < 90VDC; 0,3A < 200VDC
SETTING
See DWG 81.0360.
1 - GENERALITIES
This voltmetric relay is adapted for different DC voltage input ranges (from 12VDC up to
220VDC) with:
. The ballast resistors mounted on the PCB.
. The bridges (resistors of 0Ω) on B4, B5, B6 and B12 determine the DC Input range,
. The bridges (resistors of 0Ω) on B13 and B14 are used only when the DC voltage measuring
is below 11VDC (Min. 7VDC), in this case the bridges here above are inhibited.
. The bridge B1 (resistor of 0Ω) when the DC value measured and the DC supply are the same;
without B1 in the contrary case,
. The potentiometer R25 allows to adjust the Mini DC value, when the LED V3 is lit the DC
Mini value is reached,
. The potentiometer R24 allows to adjust the Maxi DC value, when the LED V2 is lit the DC
Maxi value is reached,
41E-0006
. The short-circuit on B9 (solder bridge) allows to select the green led or the red led close to the
relay when the relay K1 is picked-up.
The standard selection is:
Green led is lit ⇒ Relay K1 is picked-up
Red led is lit ⇒ Relay KI is released
. A timer programmable from 0 to 4 h with the short-circuits (solder bridges) B2, B3 and the
switch S1 is available when the DC value is dropping (voltmetric relay function) or when the
DC value is growing (automaticity function).
This programming setting is made with short-circuits (solder bridge) B7 and B8.
2 - VOLMETRIC RELAY FUNCTION (see DWG 810360 part 1)
When the Mini DC value is reached (LED V3) an adjustable timer (S1) starts. This timer is
inhibited when the DC Maxi value is again reached.
In normal operating the relay K1 is picked-up, K1 is releases after delay when the Mini level
is reached.
3 - AUTOMATICITY FUNCTION (see DWG 810360 part 2)
When the Maxi DC value is reached (LED V2) an adjustable timer (S1) starts.
In normally operating (floating mode) the relay K1 is picked-up, K1 is released when the
Mini DC level is reached, it will pick-up after delay when the Maxi level will be reached.
Remark: the Maxi level must be lower around 3% in comparison with boost setting value.
4 - PRINCIPLE SCHEMATIC
14 11 12 24 21 22
X1:
X2:
1
B14
2
3
B9
(12V)
B1
R
K1
B13
+M
B12
B4
B5
B6
V
B7
1
2
3
(12V)
B2
(s)
V2
R24
3
V3
R25
t
1 2 3 4
B8
(s) (h)
2
S1
1
B3
6. INSTALLATION AND START UP
All the operations on following paragraph must be performed by authorised electricians
or by qualified internal personnel.
The provide input fuse or circuit-breakers and earthling must be in accordance with the
prescribed IEC standards or with the local regulations.
INSTALLATION OF THE POWER PLANT
We recommend input line protection of the system by means of a thermo-magnetic
circuit breaker or any other specific line protection ; as certain that is value is equal to or
greater than the input electrical characteristics (rated input current) shown on the name
plate. (name plate located behind the front door).
Before any cabling of the system, the input/output and battery protections
must be open to insulate the entire system:
-
AC input rectifier circuit breakers F1.1 to F1.2 (located under each rectifier rack).
Battery fuses F11 and F12.
DC output circuit breakers F21 to F27.
The unit should be installed or put up in dry, dust proof surroundings. The cooling
on stream must not be obstructed.
To install the modules inside the cabinet and to make the connections, refer to the
following drawings :
. B8687-11
. B8687-12/13/14
sheets)
Front view and floor fixing 48VDC system
System 3+1 48V/50A with MCU1000 (3
The cabinet will be placed in accordance with the drawing B8687-11.
Install the rectifier modules in accordance with mechanical drawings. The
connection for the rectifier consists on : AC plug for the input mains, SUB-D plug for the
DC output cables and for the signalling, earth cable.
Before any cabling of the external batteries, make sure that the battery fuses
F11 and F12 are open.
Connect the battery bank 1 to the fuse F11 (-) and on the (+) common bar.
Connect the battery bank 2 to the fuse F12 (-) and on the (+) common bar.
Connect in first the battery cables to the fuses and second to the battery banks. Pay
attention to respect the right polarity!
Before any input mains cabling, connect the earth cable (yellow, green) to
the terminal PE.
. Input AC cables
AC input 220V Three phases. The input cables are tied on the terminals L1, L2, L3
of X1.
L1, L2, L3 are the phases, maximum cross section allowed: 16mm2.
The DC output use are available on circuit breakers F21 to F27 for the (-) polarity of
each DC output and on the (+) common copper bar, maximum cross section allowed:
16mm2.
The signalling alarms are available on terminal X3 (distribution part): 'URGENT
ALARM' , and 'NON URGENT ALARM' , the maximum cross section allowed is 2.5mm2.
FIRST OPERATION
.
That is necessary to have a voltmeter for the control before starting up.
. Check before starting the general state of the cabinet, if there has not been any
destruction during transportation.
. Check the screws.
. The battery fuses F11 and F12 must be open.
. After to have made all the input and output connections , switch ON the AC
power supply on input terminal X1 (220Vac 3Ph. +/-10%).
. Close the input circuit breakers of each rectifier module F1.1 to F1.2 to start
them one by one, CB located below the 19" rectifier rack.
After the staring-up phase, the MCU LCD display switch on.
.
Check the DC output voltage.
.
Close the DC load circuit breakers F21 to F27 supply the DC loads.
. Close the battery fuses F11 and F12 to connect the external batteries to the
48VDC system.
Any alarm messages must be present on the MCU display, except of course
the alarms stored (Led flashing).
To cancel the alarms stored on the front panel, press the push button 'Reset'
The system is now ready to operate.
7. MAINTENANCE OF THE EQUIPMENT
The MCU1000 Unit remotes all the DC power part and provides alarms trough NO/NC
contacts and messages on LCD display.
Descriptions of the alarms:
1. ALARM URGENT, terminals 1 to 3; X3
The relay K1 of the MCU1000 is released
Causes possible: High DC load voltage > 57V
Low DC load voltage < 46V
End of autonomy < 42,5V
Battery 1 fault
Battery 2 fault
L.V.D fault
Rectifier by UI
Use CB fault
Internal clock fault
Memory configuration fault
Remedy:
' High DC load > 57V '
.Check the rectifier module operating
. Check the right adjustment of the floating value
. Check the rectifier which is in faulty (red LED Maxi DC on the front is lit)
. Open the AC power supply MCB of the rectifier module failed during 1
minute and restart it . If the alarm appears again , replace the module by
new one.
Remark: the automatically rectifier switch off occurs when the DC voltage
has grown up to 57,6V.
-' Mini DC pre-alarm < 46V '
. Check if no alarm 'Mains fault'.
. Check the rectifier module operating
. Check the right adjustment of the floating value
-' End of autonomy' < 42,5V '
. Check if no alarm 'Mains fault'.
. Check the rectifier module operating.
Remark: the automatically battery circuit opening occurs when
the battery voltage decreases below 42,2V.
-'Battery 1 Fault' (battery 1 circuit open)
. Check the battery fuse F11 (fuse open or blown).
. Check the auxiliary contact fuse of the mains fuse (F11.1).
-'Battery 2 Fault' (battery 2 circuit open)
. Check the battery fuse F12 (fuse open or blown).
. Check the auxiliary contact fuse of the mains fuse (F12.1).
-'L.V.D Fault' (battery circuit open)
. Check if the contactor K1 is not open due to the low DC battery voltage
(end of autonomy).
. Check the coil of the contactor, check the auxiliary CB F15 and the
auxiliary contact of the LVD contactor.
-' Rectifier fault'
this fault means there one or several module failed or stopped
. Check the input MCB of the rectifier modules.
. Check if the alarm "mains fault" is not activated.
. Check the right operating of the rectifier modules.
-'Use CB Fault'
. Check the auxiliary contact of the use CB F21 to F27.
2. ALARM NON URGENT, terminals 4 to 6; X3
The relay K2 of the MCU1000 is released
Possible events: Battery voltage low < 50,4V
Mains fault delayed 180 seconds
Remedy:
-' Battery voltage < 50,4V '
. Check if no alarm 'Mains fault'.
. Check the rectifier module operating
. Check the right adjustment of the floating value
-' Mains fault delayed 180 seconds'
. Check the voltage on the input terminals X1 (220Vac 3 Phases).
. Check the input circuit breakers of each rectifier F1.1 to F1.2.
Procedure to replace a faulty rectifier module
Before to disconnect and replace a faulty rectifier module, you make sure that
the rectifier is insulated from the DC system, for this:
1°)
Remove the front plate located below rectifier rack, to access to the input and
output circuit breakers which protect the rectifier.
2°)
Switch off the module by opening the input MCB (ex: F1.1 for the module 1)
and then open DC circuit breaker (ex: F4.1 for the module 1).
3°)
After to have opened the input and output protection of the faulty rectifier
module, you can disconnect the plugs from the rectifier front panel by means of:
The AC input cables, the DC output cables and the earth cable (screw).
4°)
Remove the module from the cabinet (module fixed on cabinet by 4 screws on
the front panel).
5°)
Replace the module by a new one, screw it and connect the AC and DC cables
and earth cable to the module.
6°)
Close the input MCB to switch on the module and check the DC output voltage
of the rectifier by connecting a voltmeter to the DC output terminals of the rectifier and
adjust floating voltage by the rectifier front potentiometer IX.
7°) Close the DC circuit breaker to connect the new module to the DC plant.
8. DRAWINGS OF THE EQUIPMENT
B8687-11 Front view and floor fixing 48VDC system 3+1 50A in a PSJ1566
B8687-12 System 3+1 48V/50A with MCU1000 control unit (sheet 1/3)
B8687-13 System 3+1 48V/50A with MCU1000 control unit (sheet 2/3)
B8687-14
System 3+1 48V/50A with MCU1000 control unit (sheet 3/3)
9. PART LIST OF THE EQUIPMENT
B8748-001
Rectifier cabinet part list