Installation and Operation Manual RT12-120V/2.4kW Rectifier and ...

Installation and Operation

Manual

RT12-120V/2.4kW Rectifier and MCSU-4 Rack Power

System

Document: 158-1863-04 Date: 06 December 2013

© Rectifier Technologies Pacific Pty Ltd

ACN 058 107 707

Installation and Operation Manual Rectifier Technologies

158-1863-04 ii 6-Dec-13

Table of Contents

1. HAZARD WARNING..................................... ............................................................... 1

2. General Warnings .................................. .................................................................... 1

3. Summary of Programmed System Parameters ........... ............................................ 2

4. Configuration ..................................... ......................................................................... 5

4.1 System Description ................................................................................................ 5

4.1.1 General Description ........................................................................................ 5

4.1.2 Rectifier Specific Configurations ..................................................................... 7

5. Installation ...................................... ............................................................................ 8

5.1 System Installation ................................................................................................ 8

5.1.1 Magazines ...................................................................................................... 8

5.1.2 Cabling, Auxiliary Equipment and Circuit Breakers ...................................... 10

5.2 Rectifier Installation and Removal ....................................................................... 11

5.2.1 To Remove a Rectifier from the Magazine ................................................... 11

5.2.2 Inserting a Rectifier into the Magazine ......................................................... 12

5.2.3 Physical requirements .................................................................................. 13

5.3 Other System Component Guidelines ................................................................. 13

5.3.1 Racks ........................................................................................................... 14

5.3.2 Lightning and Transient Suppression ........................................................... 14

5.3.3 Temperature sensors ................................................................................... 15

5.4 MUIB3 – Systems with Earth Leakage Detection ................................................ 15

5.4.1 System setup requirement ............................................................................ 15

5.4.2 Main features of MUIB3 ................................................................................ 15

5.4.3 MUIB3 Connections ..................................................................................... 16

5.5 Single Phase AC Monitoring Module – MMIB4 .................................................... 20

5.6 Three Phase AC Monitoring Module – MMIB2 .................................................... 20

5.7 SMM - Site Monitor Module ................................................................................. 22

5.7.1 Electrical Specification ................................................................................. 22

5.7.2 Physical Specification ................................................................................... 22

5.7.3 Installation .................................................................................................... 23

5.7.4 System Set-up .............................................................................................. 23

5.7.5 Site Monitor Settings .................................................................................... 24

5.8 Battery Cell Monitor 3 (BCM3) - 120 Cell / 220V ................................................. 25

5.8.1 Main Features of the 120 Cell BCM3 ........................................................... 25

5.8.2 BCM3 Specifications .................................................................................... 26


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5.8.3 Relationship between “BCM Batteries” and “Num Batteries” for MCSU-4 .... 26

5.8.4 Dip-Switch Selection of Cell Voltages .......................................................... 27

5.8.5 Installing the board ....................................................................................... 27

5.8.6 Preparing the battery for connection to the BCM3 ........................................ 28

5.8.7 Battery Cell Leads and Wiring ...................................................................... 29

5.9 Battery Cell Monitor 4 (BCM4) - 120 Cell / 220V ................................................. 33

5.9.1 Main Features of the BCM4 .......................................................................... 33

5.9.2 Specifications ............................................................................................... 34

5.9.3 Installation of BCM4 ..................................................................................... 35

5.9.4 System Setup for BCM4 ............................................................................... 39

5.9.5 Operational Setup for BCM4 ........................................................................ 40

5.9.6 Processing of cell voltage information .......................................................... 42

6. Remote Communication Interfaces ................... ..................................................... 44

6.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU) ............................................ 44

6.2 RS232 Interface (MCSP) ..................................................................................... 44

6.3 RS485 Interface (MCMD) .................................................................................... 44

6.4 Integrated Packet Modem (Smart Modem) .......................................................... 44

7. Operation ......................................... ......................................................................... 46

Summary of MCSU-4 front panel controls .................................................................... 46

7.1 MCSU-4 Components ......................................................................................... 47

7.1.1 Alpha-numeric Display.................................................................................. 47

7.1.2 Front Panel Pushbuttons .............................................................................. 47

7.1.3 Status Indicating LEDs (MCSU-4) ................................................................ 47

7.2 Operating the MCSU-4 ........................................................................................ 48

7.2.1 Password security ........................................................................................ 48

7.2.2 Test Mode .................................................................................................... 48

7.2.3 Entering and moving through different Menus .............................................. 49

7.2.4 When an alarm condition exists .................................................................... 49

7.3 MCSU-4 Alarms ................................................................................................... 50

7.4 User programmable relay functions ..................................................................... 51

7.5 Mapping of loaded SMRs .................................................................................... 51

7.6 MCSU-4 Base Menu Screens.............................................................................. 52

7.6.1 Single Phase AC Monitoring Screens .......................................................... 52

7.6.2 Three Phase AC Monitoring Screens ........................................................... 53

7.6.3 Base Menu Programmable Parameters ....................................................... 54

7.6.4 Auxiliary Function Selection & Parameters ................................................... 58

7.7 SMR Menu Screens ............................................................................................ 62


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7.7.1 SMR Menu Programmable Parameters ....................................................... 63

7.7.2 SMR Menu Sleep Mode ............................................................................... 64

7.8 Battery Parameter Menu Screens ....................................................................... 65

7.9 Battery Discharge Test ........................................................................................ 69

7.9.1 Results of last Battery Discharge Test - (Last BDT) ..................................... 71

7.10 Alarms Log Screens ......................................................................................... 72

7.11 Battery Cell Monitor Setup ............................................................................... 72

7.11.1 Relationship between “BCM Batteries” and “Num Batteries” ........................ 73

7.11.2 Frequency of measurement. ......................................................................... 73

7.11.3 Battery Cell Measurements .......................................................................... 73

7.12 Earth Leakage Detector - MUIB3 and MUIB5 only ........................................... 74

8. Commissioning ..................................... ................................................................... 75

8.1 Indicators on the Rectifier Front Panel ................................................................ 75

8.2 System Parameter Ranges ................................................................................. 75

8.2.1 RT12-120V/2.4kW SMR Parameters ........................................................... 75

8.3 System Commissioning ....................................................................................... 75

8.3.1 Commissioning Procedure ........................................................................... 76

9. Maintenance ....................................... ...................................................................... 78

9.1 Warnings and precautions ................................................................................... 78

9.2 SMR Maintenance ............................................................................................... 78

9.2.1 Current Sharing ............................................................................................ 78

9.2.2 Integrity of Electrical Connections ................................................................ 78

9.2.3 Fan Filter Maintenance ................................................................................. 78

10. Fault Finding and Replacement Procedures .......... ............................................ 80

10.1 System Fault Finding Procedures .................................................................... 80

10.2 MCSU-4 Fault Finding and Repair Procedures ................................................ 83

10.2.1 Replacing MCSU-4 ....................................................................................... 84


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1. HAZARD WARNING

• DANGER!! Hazardous voltages in excess of 150VDC are generated by this equipment.

• Care must be taken when installing, operating and maintaining these systems. In particular, when replacing any of the auxiliary equipment such as the Controller, MUIB3, and Battery Cell Monitor (BCM).

• When removing a rectifier from the magazine, DO NOT TOUCH the output connector which will have HAZARDOUS voltage present for 10 seconds.

2. General Warnings

1. This equipment has been designed to be used only in restricted access areas.

2. This equipment must only be serviced by authorised and qualified service personnel.

3. Operators should not attempt to repair faulty units. There are no operator serviceable parts inside. All fuses are only replaced as part of a repair procedure in a repair facility by authorised personnel and not as a maintenance procedure on site.

4. The rectifier must be mounted in a rack which satisfies requirements for electrical enclosures and fire enclosures according to IEC60950 or equivalent standard.

5. The rear of the rectifier must not be accessible during operation. The front of the rack must be closed off to prevent operator access to the rear of the rectifier. Any openings in the front of the rack above or below the rectifiers must be closed off by equipment, blanking panels or ventilation panels.

6. The rectifiers must be used with sufficient ventilation. After mounting, the air flow paths into and out of the rectifier must be unrestricted. Allow adequate flow for hot exit air at the top of the rack.

7. Prevent small items from falling into the top of the rack. See the section on Rack Installation for suggestions of appropriate measures and examples of options.

8. The input disconnect device is the rectifier backplane connector. The rectifier is live at all times when the rectifier backplane connector is connected.

9. Take care when removing the rectifier as it may be too hot to touch the metal casing, especially if the ambient temperature is high and the unit has been operating at maximum load. When removing, pull the unit halfway out of the magazine and let cool for 2-3 minutes before handling.


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3. Summary of Programmed System Parameters Parameter Description Range Default

Value Actual Value

Base (System) Menu

Amb Tmp Alm Ambient temperature alarm level 30-99°C 55°C

Volts Hi System output volts high threshold 120-160V 135.0V

Volts Low System Output volts low threshold 95-125V 105.0V

System: Select system duty type UPS/Standby UPS

No. of SMRs Set number of SMRs in the system 0-225 1

Num Batteries Number of Battery strings installed 1-4 1) 1

FS Batt I Battery current transducer full scale rating 10-30000A 100A

CSU # CSU Access code (up to 7 digits) 0-9999999 0000000

Date / Time Current system date and time

Auxiliary Units Submenu

AC 1-ph Menu (After enabling AC 1-ph Monitor)

1ph ACV Hi AC supply high voltage alarm 220-315V 260V

1ph ACV Lo AC supply low voltage alarm 140-270V 200V

1ph ACF Hi Frequency high alarm 50-65Hz 55Hz

1ph ACF Lo Frequency low alarm 40-60Hz 45Hz

1ph ACI FS AC supply current transducer full scale rating 10-500A 100A

AC 3-ph Menu (After enabling 3-ph AC Monitor)

3ph ACV Hi AC supply high voltage alarm 220-315V 260V

3ph ACV Lo AC supply low voltage alarm 140-270V 200V

3ph ACF Hi Frequency high alarm 50-65Hz 55Hz

3ph ACF Lo Frequency low alarm 40-60Hz 45Hz

3ph ACI FS AC supply current transducer full scale rating 10-500A 100A

Battery Monitor Menu (After enabling Battery Monitor)

Bat Config Battery Monoblock size x number (see BCM section of manual for more detail)

Various configurations

24 cells

BCM Batteries Number of battery banks to be monitored 1 - 4 1

Vhi Cell Cell high voltage alarm 2.0-16.0V 2.5V

Vlow Cell Cell low voltage alarm 1.0-12.0V 1.8V

+dVc Cell Cell positive deviation alarm 5-99% 10%

-dVc Cell Cell negative deviation alarm 5-99% 10%

Site Monitor Menu If included in the system refer to Site Monitor documentation.

SMR Menu 2)

SMR Float Operating float voltage 3) 120.5V

SMR Equalise Operating equalisation voltage 3) 130.5V

SMR V High SMR voltage high alarm 120-157.5V 130.0V


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Parameter Description Range Default Value

Actual Value

SMR V Low SMR voltage low alarm 95-125V 110.0V

SMR HVSD SMR high volts shut down 120-158.5V 140.0V 4)

SMR I Limit SMR current limit 4-22A 20A 4)

SMR Power Max

Max power for SMR 0-8000 2400 5)

Sleep Mode SMR Sleep Mode Enable. On/Off Off

Sleep Min SMR

SMR Sleep Mode Minimum rectifiers that must be online.

0 to Number SMR defined in the system

1

Sleep Rotation SMR Sleep Mode rectifier rotation value (in Days).

1 to 365, 0 = Off – no rotation

7 days

Battery Menu

B Dis Al Battery discharge alarm threshold 100-120V 108.0V

Disch I Diff Battery string discharge current difference alarm 5-99A 20A

Batt T Alrm Battery Temperature alarm threshold 30 to 90°C 40°C

Bat Rated Ampere-hour rating of batteries 20 to 9999AH 500Ah

BTC Battery Temperature Coefficient 0-6mV/°C/cell 0mV

Number Cells Number of chemical cells in battery string 48-120 55

BILim Vb<Vdd Battery charging current limit for Vb < Vdd 5-999A 50A

Vdd Level Battery deep discharge voltage threshold 92-110V 100.0V

BILim Vb<Vf1 Battery charging current limit between Vdd & Vfl 5-999A 50A

Sys Float System float voltage (Vfl) 110-140V 120.0V

Sys Drop System voltage drop 0.0-1.0V 0.5V

Equalisation Enable/Disable EQ function On/Off Off

BILim Vb>Vf1 Battery charging current limit in equalise Vb > Vfl 5-999A 50A

Sys Equal System equalise voltage (Veq) 120-155V 130.0V

V Start Eq Enable/disable discharge voltage initiation of Eq On/Off Off

V Eq trig Discharge voltage threshold for Eq. charging 100-115V 110.0V

Q Start Eq Enable/disable battery charge depletion trigger On/Off Off

Qdis Trig Charge depletion threshold for Eq. charging 5-999AH 15AH

EQ End Current Equalisation termination for Ibat < EQ End 1-2000A 5A

EQ Duration Maximum duration of Equalisation charging 3-48 Hr 20 Hr

EQ Period Time between periodic Equalisation charging 0-52 Wk 12 Wk

LVDS Trip Battery voltage below which will open LVDS 92-110V 100.0V

BDT Per Period between consecutive discharge tests 0-365 days 30 days

BDT Time Time of day to begin BDT (hr:min) 00:00-23:59 02:00

BDT Dur Maximum duration of BDT 5-1440min 180min

BDT Curr Discharge test current 0-5000A 50A

BDT End V Battery voltage limit to terminate BDT 75-120V 100.0V


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Parameter Description Range Default Value

Actual Value

BDT End Q Battery capacity limit to terminate BDT 25-9995AH 300AH

Temp Sen Alm Enable/Disable Temp. Sensor failure alarm On/Off Off

1) Maximum of 2 batteries with MUIB3 2) See SMR section for internal parameters. 3) Not directly adjustable – see explanation in MCSU-4 section. 4) Will be automatically programmed to SMR internal setting once connected in the system. 5) SMR Power Max MUST be set to 2400 for all systems with RT12 SMRs.


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4. Configuration

4.1 System Description This Manual has been written with the objective of giving the reader a sufficient understanding of the system and its constituent parts in order to be able to install, commission and operate the system.

4.1.1 General Description This modular system has been designed specifically to power 120V power systems equipment requiring accurate temperature compensated Float and Equalisation voltages, low output noise and EMI levels.

A typical system comprises a number of rectifiers, depending on the power requirement of the system, and a monitoring and control subsystem comprising a monitoring and control module (MCSU-4), a User Interface Board (MUIB) and optional modules for monitoring AC power and battery cell voltages.

The system can be configured in a number of ways depending on the customer and application requirements. The simplest option is shown in Figure 4.1-1.

Figure 4.1-1 System with basic monitoring and cont rol

The AC Distribution may simply consist of circuit breakers, one for each magazine of rectifiers in the system, or may also include an isolator, depending on customer requirements.

The rectifiers housed in one or more magazines are paralleled and the DC output connected to the load via the DC Distribution module and to the battery bank, which may be a single battery or two batteries connected in parallel. A Low Voltage Disconnect Switch (LVDS) may also be included in series with the batteries in order to prevent over-discharging the battery bank in the event of an unusually long AC power outage.

The monitoring and control signals, such as battery currents, temperature, battery switch status, LVDS control and status, system voltage and ambient temperature are connected


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to the monitoring and control module (MCSU-4) via an interface card (MUIB). This module is in turn connected to the MCSU-4 magazine via a 34 way ribbon cable.

A 10-wire cable, which carries the digital communications signals that allow control and monitoring of the rectifiers, connects the MCSU-4 to all the rectifiers in a parallel arrangement so that all the rectifiers receive the same signal.

System status and operating parameters can be accessed from a PC connected to local communication port on the front panel of the controller.

Remote monitoring of the system can be by means of voltage-free relay contacts. Standard system uses 3 relays corresponding to SMR shutdown, System Alarm and High Voltage Shut Down (HVSD).

Alternatively, a remote communication port can be used to display all the system and rectifier information on a remote PC.

With this facility, it is possible to not only monitor but also control all the rectifier and system parameters. In addition, the system has the capability to dial up to three telephone numbers to connect to the remote PC in the event of a system fault having developed, and will continue dialling until the fault is reported.

Figure 4.1-2 System with additional single phase A C

The second option shown in Figure 4.1-2 is the basic arrangement described above with the addition of an auxiliary single phase AC monitoring module and Battery Cell Monitor. This module, which is mounted in the AC distribution module, connects via a ribbon cable to the MUIB and is used to monitor the AC voltage, current and frequency.

The third option shown in Figure 4.1-3 is the basic arrangement with the addition of an auxiliary three phase AC monitoring module. The latter connects directly to the MCSU-4 via a ribbon cable and provides monitoring of the three AC voltages and currents as well as the AC frequency. It has multiplexing circuits on board which effectively extends the analogue monitoring ability of the MCSU-4.


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It is possible to have both the single and three phase AC monitoring modules connected at the same time. This can be useful where the AC output of an inverter running off the 48V DC bus can be monitored at the same time as the three phase AC supply to the rectifiers.

Figure 4.1-3 System with additional 3 phase AC mon itoring; simultaneous monitoring of single phase inverter is also possibl e.

4.1.2 Rectifier Specific Configurations A typical mechanical arrangement of a system comprising 4 rectifiers and 1 MCSU-4 in a 3U Powershelf Magazine is shown in Figure 4.1-4.

i) 4 slots for rectifiers – 2U ii) 1 slot for MCSU-4 controller and 1 blank slot – 1U. The blank slot can be used

as a rectifier expansion slot if correct hardware and wiring is available. The arrangement shown is designed to fit into a standard 19” rack. Other configurations are equally possible.


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Figure 4.1-4 Typical 4 rectifier modular power supp ly with MCSU-4

5. Installation

5.1 System Installation The installation of an uninterruptible DC power system incorporating rectifiers, batteries and control hardware requires compliance to National Wiring Standards, and appropriate sections of standard IEC60950 to ensure safety of operators and supplementary equipment. Wiring should always be done by qualified personnel.

Figure 5.1-1 RT12 Rectifier Dimensions

5.1.1 Magazines The magazine configuration metalwork and wiring are usually manufactured as a powershelf module with terminal blocks to accept AC wiring and DC output cables. These magazines should be located in the rack to allow adequate cooling of rectifiers, noting that the airflow is from the front to the rear of the magazine. The magazines are held in


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the rack by M6 screws through the mounting flange and into the rack mounting rail. All wiring is typically via rear access.

Figure 5.1-2 Powershelf Magazine in 19” Mount


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5.1.2 Cabling, Auxiliary Equipment and Circuit Brea kers In general, the system needs to have most of the following modules: AC Module, DC Distribution Module, Battery Circuit Breakers, DC Cabling, Battery Current Transducers, Temperature Sensors and AC Monitoring Module (optional).

These modules are required inside the rectifier rack for normal system operation. A brief description of the modules and what they connect to is given below, along with a detailed rack wiring diagram Figure 5.2-2 in that shows a system using a MUIB3 interface.

Figure 5.1-3: Rear view of a typical RT12

AC Module: An enclosure containing all the AC circuit breakers (curve C or D) for the rectifiers, single or three phase active links, neutral links and main protective earth link for connection to the installation AC system. In any system larger than 3kW, it is advisable to balance the loads between all three phases. Consultation of local supply authority requirements is advised.

Note that when using the RT12 units without a batte ry, the AC circuit breakers must be a curve-D type (motor start). This is required to prevent fal se tripping of the circuit breaker when there are half-cycle mains interruptions and the subsequent s urges. Systems with a battery do not have this requirement.

DC Distribution: An enclosure containing all the DC load distribution circuit breakers and usually the Battery string circuit breakers. If the Battery breakers are included in the DC distribution module, an isolation barrier is usually required along with clear labelling which


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battery string the breakers are protecting. The input to the DC distribution module comes directly from the DC output line of the rectifiers that is NOT connected to the system (DC) earth.

DC Cabling: The choice of DC cabling and/or busbars is based entirely on the DC current rating of the system. Consult the local National wiring standard for the selection of cable/busbar size for the DC connections. One suggested method of DC cabling for medium systems (~6-8kW) is to provide short 100mm x 6mm busbars at the external DC interface with a number of holes to attach smaller DC cables. Then connect cables up to 25mm2 from the DC terminations to the output terminals of the individual magazines. The flexibility of the DC cables can be a benefit over fixed busbars when fitting components into a rack with limited space.

5.2 Rectifier Installation and Removal In the system, the rectifiers are designed to operate in parallel in a N+1 redundant mode. Therefore, there is never a situation in which it is necessary to set individual rectifier parameters. The rectifiers are designed to be “hot pluggable” in that they can be plugged into and out of a “live” magazine. Due to the small size of energy storage elements in the rectifier output, there is no significant disturbance to the DC bus when a rectifier is plugged into the magazine. An inrush limiting circuit in the AC input circuit that utilises a relay and an inrush current limiting resistor limits the disturbance to the AC source to an acceptable level when a unit is plugged in with AC voltage present on the AC bus.

5.2.1 To Remove a Rectifier from the Magazine Although the connectors are designed to be “hot pluggable” it is advisable to first switch off power to the unit by means of the circuit breaker in the AC distribution module before unplugging the unit. This is done to prolong the life of the rear “hot pluggable” connector. Each rectifier 1U shelf has a spring clip that secures the rectifiers in place once it is plugged into its magazine. Lift the securing latch in the centre divider adjacent to the module and pull the module out of the Powershelf.

When removing modules, especially if the ambient temperature is high and the unit has been operating at maximum load, avoid skin contact with the metal casing as it may be too hot to touch. Pull the unit halfway out of the magazine and let cool for 2-3 minutes before handling.


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Figure 5.2-1 Powershelf Magazine Latch Position

WARNING !!

Take care when removing the rectifier as it may be uncomfortably hot to hold especially if the ambient temperature is high and the unit has been operating at maximum load.

5.2.2 Inserting a Rectifier into the Magazine Although the connectors in the unit are designed for “hot pluggability” it is advisable to turn off the AC power to the input connector by means of the related circuit breaker in the AC distribution module before plugging in the unit. Carefully slide the rectifier into the magazine. Press the unit into the magazine until it is flush and the spring retaining clip clicks down. This ensures that it will not fall out in the event of severe shaking as might occur in the event of an earthquake. Switch on the relevant AC circuit breaker in the AC distribution module. The rectifier will start automatically and connect itself to the DC bus at the appropriate time.

Magazine Latch


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Figure 5.2-2 Typical Wiring Diagram

5.2.3 Physical requirements

5.2.3.1 Cooling air The rectifiers are fan cooled, with the cooling air flowing into the front of the rectifiers and out the back. Sufficient space must be left between the rear of the rectifiers and the back of the enclosure or wall for the cooling air to pass without excessive pressure increase. A minimum clearance of 110mm from the rear of the magazine (550 from the mounting rail of the rack) to a solid back is required. A louvered or meshed back panel is beneficial in reducing the operating temperature, but is not essential if the rack is not fully populated.

Clearance from the front of the rectifiers is also required. If a door must be fitted it is recommended that it be fully louvered and spaced a minimum of 150mm from the front of the rectifiers.

It is important to ensure that hot air from the rear cannot recirculate to the front of the rack.

5.3 Other System Component Guidelines The installation of an uninterruptible DC power system incorporating rectifiers, batteries and control hardware requires compliance to National Wiring Standards, and appropriate sections of standard IEC60950 to ensure safety of operators and supplementary equipment. Wiring should always be done by qualified personnel.


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5.3.1 Racks The structure and continuity of the rack provide both system safety compliance and additional shielding for electromagnetic compatibility (EMC) of the DC power system. The rack enclosure needs to have the following features to provide safe and efficient system operation:

• The rack must form a basic fire enclosure. To do this, a rack needs a separator or base plate, which prevents a burning liquid from escaping the enclosure when poured vertically into the rack. This can be achieved by using either a baffle plate below the rectifiers with a front finger grill that traps the liquid or a purpose made separation plate that it mounted below the rectifier magazine to catch burning liquids.

• Openings in the top and sides of the enclosure must comply with the following:

o not exceed 5mm in any direction, or o not exceed 1mm in width regardless of length, or o for the top of the enclosure, be constructed that direct, vertical entry of

falling objects be prevented from reaching bare parts at HAZARDOUS voltage (>32VAC or >60VDC), and/or,

o for the sides of the enclosure, be provided with louvres that are shaped to deflect outwards an externally falling object.

• Construction of the rack is important in providing exhaust air venting. Cooling

louvers, vent holes or a rack with a ‘top hat’ construction are all good methods of obtaining good ventilation while maintaining compliance with item ii) above.

The rack needs to be able to mount 19” rack equipment, have a depth not less than 400mm and a minimum height for enclosing the magazine.

5.3.2 Lightning and Transient Suppression The rectifiers and magazine contain basic transient suppression in the form of Metal Oxide Varistors (MOVs) across line-to-neutral, line-to-earth and neutral-to-earth. These MOVs are sized to provide protection from typical line transients in an industrial environment according to ANSI C62.41-1991 (6kV/3kA) and IEC 61000-4-5 (Level X). Under these conditions, the MOVs are expected to provide transient protection for the life of the rectifiers. If the transient environment is more severe, with a high incidence of lightning strikes either indirect or direct, and/or severe switching transients beyond the levels outlined in the standard, then supplementary transient protection is required. Larger MOVs (40kA rating) are required at the AC main switch board where the power to the rack originates or at the point where the supply connects to the rack AC distribution.

The arrangement of the rack MOVs must be the same as for the rectifier – three line-toline MOVs (575V) and three line-to-earth MOVs (340V to 575V is acceptable). A “star” configuration with three line-to-neutral MOVs and one neutral-to-earth MOV will not provide protection to the RT7 rectifiers as the internal clamping voltage for phase-toearth surges is lower than for such a “star” configuration of rack MOVs. (The RT7 rectifiers will end up protecting the rack MOVs!).

If the 40kA MOVs are placed in the rack, an extra set of MOVs (250V to 320V, 3-6kA) is required between the output DC and the rack earth bar. This is to protect the output


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insulation from the earth line surge voltage that is generated on the earth wiring inductance when the surge current flows through the AC side MOVs, especially if the grounding methods on the DC side are not to the rectifier cabinet. Without these MOVs, failure of the rectifier output circuit could result when high surge currents enter the rack.

5.3.3 Temperature sensors Temperature sensors are available for sensing ambient and battery temperature. These sensors use a semiconductor sensor encapsulated in a copper crimp lug and plug in to the MUIB.

5.4 A Typical System Shown in Figure 5.2-2 is a wiring diagram for a typical system.

5.4 MUIB3 – Systems with Earth Leakage Detection The MUIB3 has been designed to operate in conjunction with 24V, 48V and 110V rectifiers and MCSU-4 to control and monitor these systems, while providing earth leakage current detection. It provides basic interfacing between the MCSU-4 and the system environment.

Most of the functions available on the standard MUIB are also present in the MUIB3. The main difference is that the LVDS circuit is replaced by an earth leakage detection circuit.

In addition, the 10 way ribbon cable header socket for connecting the single phase monitoring module has been removed, as has the connector for the AN1 spare analogue input since the associated analogue channel is used by the microprocessor to monitor the earth leakage current.

5.4.1 System setup requirement The MCSU-4 software needs to be a version with the MUIB3 option. From the front panel of the MCSU-4 scroll down the CSU menu to a window which gives the choice of MUIB or MUIB3. Select MUIB3 in place of the standard MUIB. The selection can be also made from a PC running WinCSU-2 program.

5.4.2 Main features of MUIB3 The principal features of the MUIB3 are as follows:

• There is provision for battery and ambient temperature sensors.

• There is provision for two battery current transducers.

• An Earth leakage current detector enables the display of leakage current on the MCSU-4 screen or on the remote monitor screen. Full scale is +/-10mA.

• A window on MCSU-4 or WinCSU-2 allows the programming of the earth leakage current level between 1.0mA and 9.5mA at which an alarm is asserted.

• Each battery current input accepts an input range of -4V to +4V full scale. The maximum allowed input is ±5V.

• The actual number of batteries used in the system can be programmed by the user via the MCSU-4 front panel or remotely by WinCSU-2 software.

• There are 5 relay outputs, 4 digital inputs, CB trip input and Battery switch input.


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• The MUIB3 provides power to the MCSU-4;

• One spare analog input is available (input range: 0 to +5V).

5.4.3 MUIB3 Connections

5.4.3.1 Connection to MCSU-4 One 34Way ribbon cable connects X1 on MUIB3 to the main port on the MCSU-4.

5.4.3.2 Relay Contact outputs

There are 5 relays with normally open (N/O) and normally closed (N/C) contacts available on the MUIB3, connector X2. In standard RTP system three of the relays are for remote annunciation of alarms: Relay 3 - HVSD, Relay 4 - any system alarm, Relay 5 - SMR shut down.

Other two relays are used for control of optional external equipment.

Relay 2 is programmed for FAN CONTROL. If any one of the SMR heat-sink temperatures exceeds a pre-set (non-programmable) value, the relay closes. The relay closure can then be used to either speed up fans, which may normally be idling at low speed, or it can turn on fans, which may normally be off.

In 110V systems Relay 1 closes during battery discharge test, allowing control of dummy load on standby systems. In 24V and 48V systems it has no assigned function.

If MCSU-4 supports User Programmable Relays, the functions described above can be changed on site according to specification of the installation (for details see paragraph “User programmable relay functions” in chapter “Operation”). It is also possible to permanently assign different functions to the relays on end user request by modifying controller software.

5.4.3.3 Spare Digital Inputs There are 4 spare digital inputs (USER 1, 2, 3, 4) available on the MUIB3 for the monitoring of external plant associated with the power supply. The inputs must be isolated relay contacts or auxiliary contacts which are either normally open or normally closed. The MCSU-4 software for monitoring of the inputs must be user defined.

5.4.3.4 Battery Current Transducer Input Battery current transducers are connected to X39 and X40 of the MUIB3. Current transducers come in several connection configurations, but below are the pin connections for the battery transducer connector going onto the MUIB3:

1. -15V 2. +15V 3. NOT USED 4. SIGNAL 5. GND

MFR: Molex

Conn: 09-50-3051

pins: 08-50-0106

4-Way cable

Figure 5.4-1 Current transducer connection


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5.4.3.5 Power Input Power to the MCSU-4 comes from the DC bus via connector X50. Pin designations are labelled on the PCB. The system voltage is also read by the MCSU-4 via this connector.

5.4.3.6 CB Trip and Batt Sw inputs CB Trip (X22) is used to sense the CB status. Batt Sw (X23) is used to sense the battery switch status. Open contacts on any of these 2 inputs creates an alarm condition on the MCSU-4. Therefore, when any one of these 2 inputs are not used, a shorting plug should be installed on the input not being used.

5.4.3.7 Earth Leakage Detector The block diagram in Figure 5.4-2 shows the principle on which the earth leakage detector works. The SMRs and Batteries, which are normally galvanically isolated from Earth, are actually grounded via sensing resistor Rde which connects to the centre-tap of two relatively high value resistors (Re in Figure 5.4-2). The effect is that if there are no other electrical paths to Earth, then +Vb and -Vb should be equal and opposite in value. So if the battery voltage, for example, is 124VDC, the voltage of the positive DC bus with respect to Earth should be +62VDC and the negative bus should be -62VDC.

If there is any external leakage path to Earth (e.g. battery acid trickles to metal, earthed frame), the return path must be through Rde. The voltage developed will then be measured and interpreted by the microprocessor in the MCSU-4.

It should be noted that if there is no external leakage current, the voltage measured at the test point on the UIB3 marked ELEAK will not be zero, but a calibrated voltage a little over 2.5VDC. This is an offset voltage, which has been introduced to enable the microprocessor to monitor earth leakage current of both positive and negative polarity.

SMRsBatt 1 Batt 2

Earth

Voltage shiftingnetwork on

MUIB3

To MiniCSU A/DConverter

+0.5Vb

-0.5VbNegative DC bus

Positive DC bus

Rde

Re

Re

Figure 5.4-2 Earth Leakage current detector circui t on MUIB3


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Figure 5.4-3 MUIB3 Connection Diagram

X1

X2

X18

X17

X22X23 X33 X34 X44 X45

X31X40

X39

X50

X68

34-way ribbon cableto MiniCSU-2

Conn # Conn Label Class Comments

X1 MCSU-4 A/D 34-way ribbon cable to MCSU-4

X2 RELAY 1 Digital Dummy load on 110V systems, not used on other systems

RELAY 2 “ Cabinet Fan control for RT4 or RT5 systems

RELAY 3 “ SMR HVSD Alarm

RELAY 4 “ Activated by any alarm condition

RELAY 5 “ SMR switched off (for any reason)

X17 BAT. TEMP. Analog Temp. Transducer

X18 AMB. TEMP. Analog Temp. Transducer

X22 C.B. TRIP Digital Aux contact from load CBs

X23 BAT. SW. Digital Aux contact from Batt. CBs

X33 USER 1 Digital User defined input; isolated aux. contact or similar

X34 USER 2 “ Special software required

X44 USER 3 “ “ “

X45 USER 4 “ “ “

X31 AN 2 “ Spare analog I/P - 0 to 5VDC (Requires special software)

X39 BATTERY 1 “ Battery current transducer

X40 BATTERY 2 “ Battery current transducer

X50 POWER I/P “ System voltage sensing and DC power input for MCSU-4

X68 System Earth N/A Wire from frame and System Earth


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Figure 5.4-4 MUIB3 Connector wiring information

Connector Pin Signal Name Connector Pin Signal Name

X1 MCSU-4 1-34 34 way ribbon X39 BATTERY 1 1 -15V

X2 RELAY 1

(USER)

15 N/O relay contact 2 +15V

14 N/C relay contact 3 No connection

13 Common 4 Input

X2 RELAY 2

(FAN SPEED)

12 N/O relay contact 5 GND

11 N/C relay contact X40 BATTERY 2 1 -15V

10 Common 2 +15V

X2 RELAY 3

(HVSD)

9 N/O relay contact 3 No connection

8 N/C relay contact 4 Input

7 Common 5 GND

X2 RELAY 4

(ALARM)

6 N/O relay contact X22 C.B. TRIP 1-2 Contact closure required between pins 1 and 2

5 N/C relay contact X23 BAT SW. 1-2 “ “

4 Common X33 USER1 1-2 “ “

X2 RELAY 5

(SMR S/D)

3 N/O relay contact X34 USER2 1-2 “ “

2 N/C relay contact X44 USER3 1-2 “ “

1 Common X45 USER4 1-2 “ “

X17 BAT TEMP. 1 No connection X50 POWER I/P 1 Bat +ve terminal

2 Sensor -ve 2 Bus +ve terminal

3 Sensor +ve 3 No connection

X18 AMB. TEMP. 1 No connection 4 Battery -ve terminal

2 Sensor -ve 5 Bus -ve terminal

3 Sensor +ve X68 EARTH 1&2 Earth for leakage detector

X31 AN2 1 0V to +5VDC.

2 Common

Figure 5.4-5. MUIB3 Fuse Function and Specificatio n

Fuse Function Specification

F4 +15VDC F500mA, Glass, M20x5

F5 -15VDC F500mA, Glass, M20x5

F8 Ground T2A, HRC, M20x5

F46 -V System T2A, HRC, M20x5

F49 -V Battery T2A, HRC, M20x5


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5.5 Single Phase AC Monitoring Module – MMIB4 In low power systems where single phase power only is supplied, an optional single phase monitoring module can be used to monitor the incoming AC voltage, current and frequency. The module is connected between the incoming supply and the AC Distribution module and connects to the MUIB via a 16-way ribbon cable, which can be “daisy-chained” to other auxiliary modules. A connector and jumper link is available to allow for connection of an external CT if the on-board CT is not used.

The connection diagram of the MMIB4 module is shown below in Figure 5.5-1. The standard unit has a CT full scale rating of 100Arms (for 5V input to MCSU-4), and a full scale voltage sense rating of 300Vrms (active-neutral). Higher or lower full scale current ratings can be used as the external CT, with a corresponding value being set in the MCSU-4 AC monitoring menu.

X137

CT

X87

X51

To AC distribution

ActiveAC Voltage Sensing

Neutral

External CT Selector Link

X6 X21 16 way ribbons to MCSUand auxilary modules

Figure 5.5-1 Single Phase AC monitoring unit MMIB4 block diagram

5.6 Three Phase AC Monitoring Module – MMIB2 For large power systems where the rectifiers are balanced over all three phases, an optional three phase monitoring module (MMIB2) can be used to measure the AC supply phase-neutral voltages, phase currents and supply frequency. The MMIB2 connects directly to the auxiliary port at the rear of the MCSU-4 or at the end of a “daisy-chain” of auxiliary port connections and does not use any connections on the MUIB.

The module is normally fitted inside the AC distribution module if one is used. A connection diagram of the MMIB2 is shown in Figure 5.6-1 below. The full scale current value of the CTs is 100Arms for a single turn on the standard unit. Higher full scale currents can be obtained by cascading larger external CTs through the on-board CTs and modifying the full scale value in the MCSU-4 mains monitoring menu. The rated maximum sense voltage is 300V (line-neutral) due to the terminal rating and accuracy of the voltage sensing transformer.


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CT1

CT2

CT3

AC1

N

AC2

N

AC3

N

AC3

To SMR Inputs

MMIB2

Note: In 220V ph-phsystems if Neutral notsupplied, connect AC1-AC2 to X2 input; AC2-AC3 to X120 input andAC3-AC1 to X217 input

X2

X120

X217

16-wayribboncable toMiniCSU

X185

AC2AC1

AC1, AC2, AC3 fromAC Dist. Module

Figure 5.6-1. Three Phase AC monitoring unit MMIB2 block diagram


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5.7 SMM - Site Monitor Module Site Monitor Module is an expansion of the RT MCSU-4. It allows the user to monitor status of equipment that is not a part of an RT power system. It may also be used to monitor other (third party) DC power systems. Its usefulness can be specially appreciated in remote, unmanned installations. Using the same communication link and WinCSU-2 monitoring software it is possible to supervise a number of such sites from a central monitoring station.

Four control outputs are provided in the form of voltage free change-over relay contacts. The relays can be automatically activated in response to an event on any of the module inputs (assigned by user), or operated manually from a PC.

5.7.1 Electrical Specification

Number of Analogue Inputs 8

Analog Signal Input Range 0V to +5V,

Analog Signal Protection Over-voltage and reverse polarity protected.

Note: each analogue input must be floating

Analog Signal Scaling and Threshold Levels

Scaling factor, Low and High thresholds levels are user programmable from WinCSU-2 or Front Panel.

Number of Digital Inputs 12

Type of Digital Signal Source Voltage free contacts

Logic of Digital Input User defined from WinCSU-2 only

Number of control outputs 4

Output type Voltage free change over relay contacts, 1A@30VDC

Power Source MCSU-4 (powered indirectly from system DC bus)

5.7.2 Physical Specification

Board Dimensions Approx. 210mm x 96mm

SMM - Controller Connection 16 Way Ribbon Cable

Signal Input Connectors 2 pin male header 5.0mm pitch. Mfr: Weco, P/N: 120-M-221/02.

Matching female plug P/N: 120-A-111/02 provides screwed connection for wire up to 1.5 mm2

Output Connectors 3 pin male header 5.0mm pitch. Mfr: Weco, P/N: 120-M-221/03.

Matching female plug P/N: 120-A-111/03 provides screwed connection for wire up to 1.5 mm2


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5.7.3 Installation Wiring of the site monitor is entirely dependent on the signals to be monitored. Figure 5.7-1 shows the basic wiring diagram of a system using a site monitor and a Battery Cell Monitor. Signals such as site security (windows and doors being opened) are usually connected as digital inputs, while fuel levels, inverter voltage/current/frequency are measured using the analog inputs.

5.7.4 System Set-up The set up of the site monitor including labels of inputs, scale factors, alarm levels, designation of relays to operate and the type of digital input source (normally open or normally closed) can only be done using a PC running WinCSU-2. See WinCSU-2 operation manual for details.

Once programmed, monitoring of the levels and minor modification of levels and scaling on site can be done from the front panel of the MCSU-4 (see Operation section of this manual), but primarily, the site monitor is designed to be used from WinCSU-2.

1 2 3 4 5 6 7 8

A

B

C

D

87654321

D

C

B

A

Drawn By:Sheet ofSUBTITLE:

TITLE:

Number/Revision:Date:Sheet Size: A3

Rectifier Technologies Pacific Pty. Ltd.24 Harker Street, Burwood, Vic, Australia, 3125

Phone: + 61 3 9888 7788 Fax: + 61 3 9888 0233 1999

Filename:X:\DOCUMENT\DRAW\D1189A.SCH SITE MONITOR WIRING DIAGRAM

C. CHALMERS

D1189a

1 1

3 May 2000

25 LEADSMONITORING24 CELLS

BCM#1

UP TO 4 BCMs

4 C/O RELAYCONTACTOUTPUTS

MUIB2

4 PREDEFINED DIGITAL INPUTS

5 C/O RELAYCONTACTOUTPUTS

LVDS STATUS

LVDS CONTROL

AMB TEMP

BATT TEMP

4 BATTERYCURRENTSENSORS

LOAD CURRENTSENSOR

POWER & SYSTEMVOLTAGE INPUT

MiniCSU

AIRCONDITIONINGON/OFF

BATTERIES

(Optional - Battery Cell Monitor)

INVERTER

GENERATOR

SEN

SEN

SEN

SEN

V

I

f

V I f

FUELLEVEL

FUEL

SWITCHING EQUIPMENT

DIESEL

SITEMONITORMODULE

UP TO 12DIGITAL I/P's

UP TO 8ANALOGUE I/P's

Figure 5.7-1 Example Site Monitor Wiring Diagram


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5.7.5 Site Monitor Settings Please observe following guidelines:

1. Label – name of monitored input, up to 8 characters. Leave blank for not used channels.

2. Hi T-hold – thresholds of analog channels to generate warning/alarm/output control. When set to zero the threshold is disabled, adjustable up to 999.9 1) input units.

3. Lo T-hold – thresholds of analog channels to generate warning/alarm/output control. When set to zero the threshold is disabled, adjustable up to 500.0 1) input units.

4. Scale – value of measured parameter corresponding to 4.00V of input signal. Adjustable up to 999.9 1).

5. Unit – a symbol of measured parameter.

6. O1-O4 – mark to assign an output relay to an input. More than one input can be assigned to an output.

7. Al – mark to generate Site Monitor alarm when input is active. 1) Step of adjustment from WinCSU-2 is 0.1 units, from the Front Panel 1 unit.

Settings of Site Monitor in this system at the time of commissioning.

Input Label O1 O2 O3 O4 Al Hi T-hold Lo T-hold Scal e Unit

An 1

An 2

An 3

An 4

An 5

An 6

An 7

An 8

Dig 1

Mark for normally closed input

Dig 2

Notes

Dig 3

Dig 4

Dig 5

Dig 6

Dig 7

Dig 8

Dig 9

Dig 10

Dig 11

Dig 12


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5.8 Battery Cell Monitor 3 (BCM3) - 120 Cell / 220V The Battery Cell Monitor 3 (BCM3) is an add-on module for the MCSU-4. It is used to monitor individual cells of a battery during float or equalisation operation, or during a discharge.

The BCM3 unit is capable of monitoring the following options:

a) Lead/Acid batteries: Each BCM3 unit is capable of monitoring one battery string of up to 120 cells and up to 320Vdc. Two BCM3 units can be used to monitor 2 battery strings build of 2V cells. If monoblocks are used and there are no more than 58 blocks in a string, two battery strings can be monitored using single BCM3 unit.

b) Nickel/Cadmium batteries: It is possible to monitor one battery string of up to 192 cells using two BCM3 units.

Using the ability of the MCSU-4 to communicate to a remote or local PC, cell voltage data accumulated during a discharged can be transferred to a PC and saved. The cell voltages can also be viewed in real time when the MCSU-4 is connected to a PC. The WinCSU-2 software that is running on the PC can display the cell voltage data in various convenient formats to ascertain the state of health of batteries.

In the event that the battery behaves in a way which is less than ideal during a test or actual discharge, a number of pre-programmed parameter levels are used to generate alarms which are annunciated on the MCSU-4 front panel by a LED and display message. Remote alarm is available via voltage free relay or via a communications port to a PC (locally or remotely).

5.8.1 Main Features of the 120 Cell BCM3 The principle features of the BCM3 are as follows:

• The main application for the BCM3 is monitoring 240Vdc batteries, which consists of up to 120 cells per battery.

• Individual cell voltages of a battery can be viewed on the MCSU-4 display in real time. The cell voltage rounded to the nearest 5mV (for 2V, 4V and 6V cells/blocks) or 10mV (12V blocks) is displayed together with the cell number and its percentage deviation from the average cell voltage of the battery.

• All the cell voltages can be displayed in a “Histogram” format on a local or remote PC using WinCSU-2 software.

• The PC can display the real time cell voltages or cell voltages stored during a previous discharge.

• A line graph of cell voltage versus time can be selected as the PC display to observe the manner in which the cell voltages as a whole decreased during a discharge. It is also possible to select for all the cell voltages to be displayed (in different colours) or for a particular cell voltage to be displayed together with the average cell voltage as a function of time.

• As the BCM3 is permanently connected to the batteries, an automatic, daily down-loading of the steady state cell voltages for the different batteries in a system ban be made to a remote monitoring PC.

• A discharge test can be initiated either locally or remotely from WinCSU-2 software. The test can be performed with constant, user programmable


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current (recommended) or under full load connected to the system. This test can be programmed to occur periodically in non critical times and results can be used to monitor the condition of the battery strings. For details refer to MCSU-4 section.

5.8.2 BCM3 Specifications

Battery configuration options: (110V and 220V systems):

1 x 220V Battery per BCM3 (120 cells x 2V Lead Acid ) or,

2 x 110V Batteries per BCM3 (up to 58 cells x 2V Lead Acid).

2 Batteries per BCM3 (up to 58 monoblocks per battery string)

1 Battery per 2 x BCM3 (>120 cells x 1.2V Nickel-Cadmium)

Maximum battery voltage: 320Vdc

Number of cells: 120 maximum per board (Set on MCSU-4 or WinCSU-2)

Cell Voltage selection 2V (max input: 3.33V)

(DIP switch setting on the board): 4V (max input: 6.66V)

See section below for detail. 6V (max input: 10V)

12V (max input: 20V)

Note: “Cell” can mean both single battery cell or monoblock.

Accuracy for 1 year: ± 10mV at 0°C to 40°C

Resolution: 5mV per cell (2V, 4V, 6V range), 10mV per cell (12V range)

Sampling interval range for discharge log:

1 - 60 minutes

Power supply: from MCSU-4 ±15V

Maximum distance from MCSU-4: 10m (of 16 way ribbon cable)

5.8.3 Relationship between “BCM Batteries” and “Num Batteries” for MCSU-4 With the BCM3 option enabled, the BCM3 parameters must be setup before monitoring can be performed. There is no need to program the MCSU-4 with the number of BCM3 boards connected. The MCSU-4 automatically calculates the number of BCM3 boards that it requires from the number of “BCM Batteries” that you entered. The number of BCM3 boards (PCBs) required for different battery configuration is shown in the following table.

Note: For BCM3, the maximum number of batteries is 2, while the maximum cells/monoblocks per battery is limited to 58 if one BCM3 is used to monitor 2 batteries.


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System Battery Configuration BCM Batt = 1 BCM Batt = 2

220VDC Up to 116 cell, 2V 1 BCM3 board 2 BCM3 boards

Up to 58 monoblocks, 4V 1 BCM3 board 1 BCM3 board

6V monoblocks 1 BCM3 board 1 BCM3 board


110VDC Up to 58 cell, 2V 1 BCM3 board 1 BCM3 board




A similar menu but for totally different purposes, appears in the Systems menu as follows:

Num Batteries X ( where X is the number of batteries = 1 or 2)

The number of batteries entered here is the number of batteries that are being monitored for their currents. “Num Batteries” and “BCM Batteries” are not related except that value entered for “Num Batteries” must be greater or equal to “BCM Batteries”. This is because Num Batteries determines the number of batteries accessible via the BAT menu, via which we access the cell voltages. Normally Num Batteries is set to be the same as BCM Batteries.

5.8.4 Dip-Switch Selection of Cell Voltages Battery configuration is selected via the main menu of the MCSU-4, whereas the cell or monoblock voltage must be selected via dip-switch S65 on the PCB. The following table indicates the DIP-switch setting for different cell/monoblock voltages:

CELL/MONOBLOCK VOLTAGE

LEFT SWITCH

(1)

CENTRE SWITCH

(2)

RIGHT SWITCH

(3)

12V UP UP UP

6V UP UP DOWN

4V UP DOWN DOWN

2V DOWN DOWN DOWN

5.8.5 Installing the board Generally, the BCM3 board is located close to the batteries so that it is not necessary to run a large number of wires for long distances. The 16 way ribbon cable connecting to the MCSU-4 can be up to 10m long, but should be connected directly to the MCSU-4, instead of connected at the end of another chain of peripherals. This helps reduce errors. This connection can be achieved by using a ‘daisy chain’ ribbon where the one cable has connectors placed part way along its length as well as the ends.

Mount the BCM3 using the standoffs supplied in an area protected from mechanical and electrical hazards. If the rack does not provide any holes or studs for mounting the BCM,


158-1863-04 28 6-Dec-13

use Figure 5.8-1 as a template for drilling the mounting holes. Be sure to allow at least 25mm space around the board to allow for wiring to the board.

Figure 5.8-1 BCM3 mounting hole locations.

5.8.6 Preparing the battery for connection to the B CM3 Battery cells are not connected to the BCM3directly. 270ΩΩΩΩ/PR03 resistors are inserted between BCM3and the cells to clear any fault that would arise if a battery cell lead were shorted. The resistors are mounted as near as possible to the battery terminal in order to protect as much of the wiring as possible. A typical connection is shown Figure 5.8-2.

The M6 ring lug (depending on type of battery) is screwed onto the cell terminals. The other end of the wire is screwed onto the 5.0mm pitch screw terminals. Details on how the cells connect to the BCM3board are discussed in later sections.


158-1863-04 29 6-Dec-13

Figure 5.8-2 Lead termination at battery cell.

5.8.7 Battery Cell Leads and Wiring For 220V systems, the number of cells for this battery can be defined to a maximum of 196 cells. The cell connections to the BCM3 board is via 10 connectors labelled SECTION 1 to SECTION 10. SECTION 1 consists of cells 1 to 12 and so on. Cell 1 is defined as the cell at the top of the battery string, whose positive terminal is the positive terminal of the battery. Cell terminals at each end of a connector is labelled, e.g. +C1 as the connection to positive terminal of Cell 1.

SECTIONs 1-9 are 12 way connectors, while SECTION 10 is a 13 way connector. The connection to a 120 cell system is illustrated in Figure 5.8-3, connection of up to 58 monoblocks is shown in Figure 5.8-4, and connection of up to 192 cells using two BCM3 units illustrated in Figure 5.8-5.

Note: MCSU-4 will automatically select mode of scanning of BCM3 after programming of number of cells and number of monitored battery strings.

Important: Always start filling up the connections from Cell 1 in SECTION 1.


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Figure 5.8-3 BCM3 in 120 cell, 240V system


158-1863-04 31 6-Dec-13

Figure 5.8-4. BCM3 connections to 2 x 220V (58 cel l) or 2 x 110V (58 cell) Lead acid battery strings using 1 x BCM3. Wire Battery 1 fro m sections 1 to 5. Wire Battery 2

from section 6 to 10.


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Figure 5.8-5 BCM3 connections to a 220V (192 cell) Ni-Cad battery bank using 2 x BCM3.


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5.9 Battery Cell Monitor 4 (BCM4) - 120 Cell / 220V The Rectifier Technologies BCM4 Isolated Battery Cell Monitor- 24 Cell is an add-on module for the MiniCSU. It is used to monitor individual cells of a battery during float or equalisation operation, or during a discharge. Each BCM4 unit is capable of monitoring a battery string of up to 24 cells under maximum input voltage of 320Vdc. (Note: “Cell” can mean either single battery cell or monoblock). If monoblocks are used and there are no more than 12 blocks in a string, two battery strings can be monitored using single BCM4 unit. A total of four BCM4 units can be daisy chained to monitor 4 battery strings of 24 cells each or 1 battery string of 96 cells.

Using the ability of the MiniCSU to communicate to a remote or local PC, cell voltage data accumulated during a discharged can be transferred to a PC and saved. The cell voltages can also be viewed in real time when the MiniCSU is connected to a PC. The WinCSU-2 software that is running on the PC can display the cell voltage data in various convenient formats to ascertain the state of health of batteries.

In addition to the real time or historical representation of the data on the WinCSU-2, the cell voltages can also be observed in real time on the MiniCSU LCD display.

In the event that the battery behaves in a way which is less than ideal during a test or actual discharge, a number of pre-programmed parameter levels are used to generate alarms which are enunciated on the MiniCSU front panel by a LED and screen message and remotely via voltage free relay or via the RS-232 communications port which can connect directly to a PC locally or remotely via a TCP/IP interface (SNMP available).

5.9.1 Main Features of the BCM4 • Up to 24 cells can be monitored by a single BCM4 module. Cell voltage

setting can be 2V, 4V, 6V and 12V.

• Up to four BCM4 board can be connected to a single MiniCSU.

• The main application for the BCM4 is 240Vdc systems of 1 battery string per board with 20 x 12 V monoblocks or 120Vdc system of 2 battery strings per board with 10 x 12V monoblocks each.

• Individual cell voltages of a battery string can be viewed on the MiniCSU display in real time. The cell voltage rounded to the nearest 5mV (for 2V, 4V and 6V cells/blocks) or 10mV (12V blocks) is displayed together with the cell number and its percentage deviation from the average cell voltage of the battery string.

• All the cell voltages can be displayed in a “Histogram” format on a local or remote PC using WinCSU-2 software for a very convenient and rapid visual indication of normal and deviant cells.

• The PC can display the real time cell voltages or cell voltages stored during a previous discharge. In this instance, a mouse driven slider bar is used to select at which point in the discharge to display the cell voltages.

• A line graph of cell voltage versus time can be selected as the PC display to observe the manner in which the cell voltages as a whole decreased during a discharge. It is also possible to select for all the cell voltages to be displayed (in different colours) or for a particular cell voltage to be displayed together with the average cell voltage as a function of time.


158-1863-04 34 6-Dec-13

• As the BCM4 is permanently connected to the battery strings, an automatic, daily or weekly down-loading of the steady state cell voltages for the different battery strings in a system to a remote monitoring PC can be very useful for anticipating the state of health of the battery strings.

• When desired, a discharge can be initiated either locally or remotely by triggering the rectifiers in the system into “battery discharge test” mode. In this mode the rectifier float voltage is set to a lower value which ensures that the batteries are carrying the load, but not too low so that in the event of battery failure during the test, the rectifiers will prevent the voltage from falling below the set voltage, which enable the load to continue functioning correctly. This test can be arranged to occur in non critical times. It is particularly useful if there has not been a recent discharge due to failure of the commercial AC supply.

5.9.2 Specifications Battery configuration options (selectable):

1 battery string per board, suitable for 240Vdc systems with 20 x 12 V monoblocks,

2 battery strings per board, suitable for 120Vdc system with 10 x 12V monoblocks each,

Configuration programmable on MiniCSU or WinCSU-2

Maximum battery voltage: 320Vdc

Number of cells: 24 maximum

Cell Voltage selection (DIP switch setting on the board):

2V (max input: 3.33V - use also for Nickel/Cadmium cells)

4V (max input: 6.66V)

6V (max input: 10V)

12V (max input: 20V)

Accuracy for 1 year:

2V: ± 10mV at 0°C to 40°C

4V: ± 20mV at 0°C to 40°C

6V: ± 30mV at 0°C to 40°C

12V: ± 60mV at 0°C to 40°C

Resolution: 5mV per cell (2V, 4V or 6V cells/blocks) or 10mV (12V blocks)

Sampling interval range for discharge log: 1 - 60 minutes

Power supply: from MiniCSU (+/-15V± 7%)

Maximum distance from MiniCSU: 10m (of 16 way ribbon cable)


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5.9.3 Installation of BCM4

5.9.3.1 Preparing the battery for connection to the BCM4

Battery cells are not connected to the BCM4 directly. 270ΩΩΩΩ/PR03 resistors are inserted between BCM4 and the cells to clear any fault that would arise if a battery cell lead were shorted. The resistors are mounted as near as possible to the battery terminal in order to protect as much of the wiring as possible. A typical connection is shown Fig. 1.

Fig. 1 Lead termination at battery cell.

The M6 ring lug (depending on type of battery) is screwed onto the cell terminals. The other end of the wire is screwed onto the 5.0mm pitch screw terminals on BCM4. Details on how the cells connect to the BCM4 board are discussed in later sections.

5.9.3.2 Installing the board Generally, the BCM4 board is located close to the batteries so that it is not necessary to run 26 wires (or 4 x 26 wires for 4 BCM4 boards) for long distances. The 16 way ribbon cable connecting to the MiniCSU can be up to 10m long, but should be connected directly to the MiniCSU, instead of connected at the end of another chain of peripherals. This helps reduce errors. This connection can be achieved by using a ‘daisy chain’ ribbon where the one cable has connectors placed part way along its length as well as the ends.

Mount the BCM4 using the standoffs supplied in an area protected from mechanical and electrical hazards. If the rack does not provide any holes or studs for mounting the BCM4, use the following figure as a template for drilling the holes for mounting the BCM4.

4


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Fig. 2 BCM4 mounting hole locations.

Be sure to allow at least 25mm space around the board to allow for wiring to the board.

5.9.3.3 Battery Cell Leads For 240V systems, the number of cells for this battery can be defined as 20 cells. The cell connections to the BCM4 board are via 2 connectors labelled SECTION 1 and 2. SECTION 1 consists of cells 1 to 12 and so on. Cell 1 is defined as the cell at the top of the battery string, whose positive terminal is the positive terminal of the battery string. Cell terminals at each end of a connector are labelled, e.g. +C1 as the connection to positive terminal of Cell 1. SECTION 1 and 2 are a 13 way connector. The connection to a 20 cell system is illustrated in Fig. 3. while the connection of 120Vdc system of two battery stings is shown in Fig. 4.

Note: MiniCSU will automatically select mode of scanning of BCM4 after programming of number of cells and number of monitored battery strings.

Important: Always start filling up the connections from Cell 1 in SECTION 1.


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C1+

C1-, C2+

C2-, C3+

C3-, C4+

C4-, C5+

C5-, C6+

C6-, C7+

C7-, C8+

C8-, C9+

C9-, C10+

C10-, C11+

C11-, C12+

C12-, (C13+)

C13+

C13-, C14+

C14-, C15+

C15-, C16+

C16-, C17+

C17-, C18+

C18-, C19+

C19-, C20+

C20-, C21+

C21-, C22+

C22-, C23+

C23-, C24+

C24-

Cell 1

Cell 2

Cell 3

Cell 4

Cell 5

Cell 6

Cell 7

Cell 8

Cell 9

Cell 10

Cell 11

Cell 12

Remove for 2 strings

INSERT LINKConnects X9/C12- to X43/C13+

Cell 13

Cell 14

Cell 15

Cell 16

Cell 17

Cell 18

Cell 19

Cell 20

Not used iflink in place

X165

X127

X150

BATTERYCELL

MONITOR

240V BATTERY20x12V Cells (Monoblocks)

Fig. 3 BCM4 in 20 block, 240V system


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BATTERYCELL

MONITOR

C1+

C1-, C2+

C2-, C3+

C3-, C4+

C4-, C5+

C5-, C6+

C6-, C7+

C7-, C8+

C8-, C9+

C9-, C10+

C10-, C11+

C11-, C12+

C12-

C13+

C13-, C14+

C14-, C15+

C15-, C16+

C16-, C17+

C17-, C18+

C18-, C19+

C19-, C20+

C20-, C21+

C21-, C22+

C22-, C23+

C23-, C24+

C24-

Cell 1

Cell 2

Cell 3

Cell 4

Cell 5

Cell 6

Cell 7

Cell 8

Cell 9

Cell 10

120V BATTERY #110x12V Cells (Monoblocks)

Cell 1

Cell 2

Cell 3

Cell 4

Cell 5

Cell 6

Cell 7

Cell 8

Cell 9

Cell 10

120V BATTERY #210x12V Cells(Monoblocks)

X165

X127

X150

Remove for 2 strings

REMOVE LINK(Link connects X165/C12- to X127/C13+)

Fig.4 BCM4 with two 120V batteries of 10 blocks each


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5.9.3.4 Dip-Switch Selection of Cell Voltages Battery voltage is selected via the main menu whereas the cell or monoblock voltage must be selected via dip-switch S1 on the PCB. The following table indicates the DIP-switch setting for different cell/monoblock voltages:

CELL/MONOBLOCK VOLTAGE

LEFT SWITCH

(S1)

CENTRE SWITCH

(S2)

RIGHT SWITCH

(S3)

12V ON OFF OFF

6V OFF ON OFF

4V OFF OFF ON

2V OFF OFF OFF

5.9.4 System Setup for BCM4

5.9.4.1 Enabling the BCM4 in the MiniCSU On the MiniCSU, the BCM4 board(s) can be switched on or off, but cannot be changed to other types of BCM via the front panel or WinCSU-2. This would require a change in the MiniCSU software.

5.9.4.2 Relationship between “BCM Batteries” and “Num Batteries” In the next two sections, you will be led through a series of menus to get to the menu of “BCM Batteries”. This is where you define the number of batteries whose cell voltages are to be monitored by the MiniCSU, hence the name “BCM Batteries”. There is no need to program into the MiniCSU how many BCM4 boards are connected. The MiniCSU automatically calculates the number of BCM4 boards that it requires from the number of “BCM Batteries” that you entered.


Num Batteries X ( where X is the number of batteries)

The number of batteries entered here is the number of batteries that are being monitored for their currents. “Num Batteries” and “BCM Batteries” are not related except that value entered for “Num Batteries” must be greater or equal to “BCM Batteries”. This is because Num Batteries determines the number of batteries accessible via the BAT menu, via which we access the cell voltages. So if only one battery is defined for Num Batteries, then you won’t have access to cell voltages of Battery 2, even if they are defined as 2 in the BCM Batteries menu. Normally Num Batteries is set to be the same as BCM Batteries.


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5.9.4.3 Battery configuration in 240V system (240V MiniCSU) To set up the number of batteries to be monitored by the MiniCSU, in the System menu, Press DEC key until you see the following menu:

Auxiliary Units [ENTER]

Press ENTER key, this will get you into the Auxiliary Units options menu then press INC until the following menu appeared:

Battery Monitor [ENTER]

Press ENTER key then press INC (even if “Battery Monitor On” is already shown) until you see the following menu:

Battery Monitor On [ENTER]

Press ENTER key then press INC until you see the following menu:

BCM Batteries X (where X is the number of batteries to be monitored).

This can be adjusted between 1 and 4.

The number of cells per battery is set in the Config File and is non adjustable. To view the number of cells per battery, press the BATT button on the MiniCSU. This puts you into the Battery Menu. Press INC until the following menu is reached:

Num Cells 120 (where 120 is the number of cells.)

Pressing Enter to adjust the number will show the message “Not Adjustable’.

5.9.4.4 Batt Monitor On/Off If for any reason, the operator wishes to switch the battery monitor on or off, this can be done locally or remotely. Refer to the Menu structure in the next section for location of this menu.

5.9.5 Operational Setup for BCM4

5.9.5.1 MiniCSU menu structure for battery cell monitor The structure of the menu related to battery cell monitor systems and operational setup is illustrated below:


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In the above diagram, menu items not related to battery cell monitor are not listed.

5.9.5.2 Frequency of measurement. To allow for a wide battery capacity range which can range from 10 minutes to 8 hours, the cell voltage polling frequency is programmable in 1 minute increments. A typical polling interval is 4 minutes which would yield 15 points for a 1 hour discharge. For programmed test discharge of 30 minutes a polling interval of 2 minutes might be used. This parameter is not accessible from the MiniCSU front panel. It is only programmable from the PC running WinCSU-2.

[SYSTEM Menu]

→ Num Batteries CT X (Where X is the number of batteries monitored for their current.)

(This number must be greater or equal to the number of BCM Batteries)

→ Auxiliary Units [ENTER]

↓

Batt Monitor (ON/OFF)

BCM Batteries (1,2,3,4)

Cell Vhi (2.00V ~ 16.00V)

Cell Vlow (1.00V ~ 12.00V)

+dVc Cell (5% ~ 99%)

-dVc Cell (5% ~ 99%)

[BATT Menu]

→ Battery 1 XXA (XX displays battery current) ↓ Battery1 Cellmm n.nnnV±pp% (mm is the cell #, n.nnn is cell voltage, pp is deviation)

→ Battery 2 XXA (XX displays battery current)

↓ Battery2 Cellmm n.nnnV±pp% (mm is the cell #, n.nnn is cell voltage, pp is deviation)





→ Number of Cells


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5.9.5.3 Low/High cell voltage alarm Each cell voltage is compared with a programmed absolute cell low voltage value Vlow and high voltage value Vhigh and an alarm generated if any cell voltage is lower or higher than this value. The alarms generated is “Cell V High/Low”, High or Low displayed as appropriate.

The two levels are programmed using the following menu windows:

“Cell Vlow..Y.YYV” where Y.YY (or YY.Y for 12V monoblocks) is the cell “Cell Vhi....Y.YYV” voltage threshold level

5.9.5.4 Cell voltage deviation alarm Each cell voltage is compared to the average cell voltage for the battery and if the difference is outside of the pre-programmed value +/-dVc (independent of cell volts high/low alarm discussed in previous section), an alarm is generated - “Cell %dev High/Low” (High or Low displayed as appropriate).

“+dVc cell...XX%” where XX is the allowable % voltage deviation “-dVc cell....XX%” from the average cell voltage

5.9.6 Processing of cell voltage information

5.9.6.1 Storage of battery discharge information. During a discharge and when no PC is in connection with the MiniCSU, the MiniCSU collects several samples before transferring the information to a PC. For BCM4 boards, enough memory space is pre-allocated for 10 samples of four BCM4 boards, i.e. 10 samples of up to 96 cell voltages and currents of batteries are stored in the MiniCSU before attempting to connect to the designated PC. If only one BCM4 board is used, or less cells are used, the number of samples that are stored in the MiniCSU before transferring the information are still the same.

If during a discharge, the PC is connected to the MiniCSU (and not in standby), each sample taken at the end of each polling period will be transferred to the PC immediately, and will not be stored in the MiniCSU.

The role of the MiniCSU with respect to the battery cell monitor is to collect all the necessary information, and make sure they are within the limits set by the operator. It however cannot store historical data of the battery condition. So the collection of historical data and its analysis is all done on a PC. An export facility is also available in the WinCSU-2 program to convert this information to CSV format that can be imported to another database program for further analysis.

Note: The word sample here is defined as collection of all the cell voltages and battery currents at a particular instant of time, i.e. end of a polling period, also included is the temperature of the battery.

5.9.6.2 Information available via the MiniCSU LCD display Since the MiniCSU does not contain historical information of the battery status, the user can only see the battery status at that instant. These are cell voltages and their deviation from other cells, battery current and temperature.


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To observe the cell voltage for each cell of each of the battery banks together with its deviation from the average cell voltage Vave, press ENTER after scrolling to the current display for a particular battery e.g. “Batt 1 35A”. After pressing ENTER the display then shows the following:

“Battery1 Cell14 2.235V+03%”

Where Battery1 represents battery string 1, Cell14 represents cell #14, 2.235 is the cell voltage and +03% is the percentage variation from the average cell voltage for the battery. Clearly, the deviation may also be negative (-).

Pressing ENTER again returns the display to the beginning “Battery1 35A” of the submenu. It is then possible to scroll (INC) to “Battery2 37A” display and by pressing ENTER the individual cell voltages for battery 2 can be observed.

5.9.6.3 Information available on the PC WinCSU-2 is a program that is used on the PC to monitor and control MiniCSUs. A considerable amount of information can be display conveniently on a PC. It includes real time battery status if the PC is connected to a system locally or remotely. If a discharge is in progress, the discharge progress is stored on the PC for the entire period of the discharge. These collected data are stored automatically on the PC and can be recalled later. They can also be exported via CSV format to other programs like excel where more sophisticated mathematical tools are available.

For more information on battery related functions of the WinCSU-2, refer to its relevant documentation.


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6. Remote Communication Interfaces Remote Communications Port is located at the back of MCSU-4. The module is a part of the controllers’ magazine. If a replacement of MCSU-4 is required, there is no need for disconnection of the communication link. Depending on your monitoring requirements one of following interfaces can be used.

6.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU) The Ethernet remote connectivity option is available in both a standard TCP/IP version and an enhanced WebCSU interface, which includes HTTP, SNTP and SNMP protocols for monitoring via WinCSU-2, web-browser, and off-the-shelf Network Management Software. See WebCSU manual for network set-up details

6.2 RS232 Interface (MCSP) This interface should be used if the distance between the RPS and monitoring PC or a modem is not greater than 15 meters. The module has standard 9-pin D-type connector. For connection to a PC a “null modem” (or “cross-over”) cable should be used. A modem should be connected using the cable provided with it.

6.3 RS485 Interface (MCMD) This type of port allows connection though a distance up to 1200 meters. Up to 32 standard devices can be linked using twisted pair of wires. In high electrical noise environment a shielded twisted pair is recommended. Figure 6.3-1 below shows the pin assignment of the port.

Figure 6.3-1 RS485 pin assignments

Due to the slow data rate (9600bps) termination of the line with resistors generally is not required. However, if high rate of data corruption is experienced (slow data update in monitoring program), line termination resistors should be installed at both ends of the network. The value of the resistors depends on the gauge of the twisted pair and should be equal (or closest) to line characteristic impedance. I.e. twisted pair of 24AWG wires characteristic impedance of 100ohm – use a 100ohm resistor.

6.4 Integrated Packet Modem (Smart Modem) This module has full capability of a stand alone modem. It also has an advantage of the uninterrupted power source available inside the controller. The module connects the controller directly to the telephone line and breaks the remote data into packets to enhance error handling particularly over bad quality telephone lines. To enable connection to the smart modem by WinCSU-2, the remote communication menu options needs to be set for modem and “Smart Modem” transfer mode (see WinCSU-2 on-line help for details).


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The main part of Smart Modem is a Socket Modem MT5600SMI-34 manufactured by MultiTech Systems (USA). Please check with your local Telecom authorities if it has necessary approval (it is approved in Australia). If an approval has not been issued yet, an alternative, approved brand can be used. Please contact RTP for advice.

The unit is designed for Global Region. To assure correct operation in other country than the USA (default setting), programming of appropriate Country Code is required (see chapter “Base Menu Programmable Parameters” in “Operation” section). Table below lists supported countries, approval status and corresponding codes.

Country / Approval Code Country / Approval Code Country / Approval Code

Argentina Y 07 India P 53 Portugal Y 8B

Australia Y 09 Ireland Y 57 Russia P B8

Austria Y 0A Italy Y 59 Singapore Y 9C

Belgium Y 0F Japan Y 00 South Africa P 9F

Brazil Y 16 Korea Y 61 Spain Y A0

China N 26 Malaysia P 6C Sweden Y A5

Denmark Y 31 Mexico Y 73 Switzerland Y A6

Finland Y 3C Netherlands Y 7B Taiwan Y FE

France Y 3D New Zealand Y 7E United Kingdom Y B4

Germany Y 42 Norway Y 82 United States Y B5

Hong Kong Y 50 Poland P 8A Approval: Y=yes ; N = no ; P=pending

Approval status in the table is indicated as declared by manufacturer on 8/11/2000.

Note: If the country in which you intend to use the Integrated Modem is not listed, a generic code ‘99’ or ‘FD’ can be tried. If the modem does not work correctly using generic codes, it is recommended to search for another brand of Socket Modem which may meet the country requirements.


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7. Operation System operation is generally controlled by the MCSU-4 system controller. As a result, operation information for the system is directly related to the operation of the MCSU-4 as described in this section.

Summary of MCSU-4 front panel controls

There are four Menus which can be viewed using the INC or DEC buttons:

a) The default or "Home" menu which contains general system information;

b) SMR menu - contains all the parameters relating to the rectifiers;

c) Battery menu - contains all the parameters relating to the batteries;

d) Alarms log - which is a chronological record of the last 1000 alarms.

Moving from one menu to another

If no button has been pressed for two minutes, the display will revert back to the Home screen. This shows the output voltage and current.

To move from any menu to any other menu, press the corresponding button. E.g. to move to the Battery Menu from any other menu, momentarily press the BATT button.

To move to the Home menu from any other menu, press the button of the current menu. E.g. if in the SMR menu, press SMR button to return to the Home menu.

Scrolling through the Menus:

To scroll through any menu from the first screen to the last, press the INC button;

To scroll to the last (bottom) screen first, then upwards through the menu to the first screen, press the DEC button.

Incrementing and decrementing programmable paramete rs

To change a programmable parameter press ENTER; the value will flash on and off. To increase the number, press INC; to decrease the number press DEC. When the desired number is on the screen, press ENTER again.

To change parameters when the security function is activated

If an attempt is made to alter any parameter when the security function is activated, the display will show the message "Enter Password".

To change a parameter, enter a valid password. Then proceed to change the parameter in the normal way.

When scrolling through the Alarms log

To observe the date and time of a given alarm, do not press any button for at least two seconds. The date and time will display for two seconds and then the alarm name will be displayed for two seconds. The display will alternate between the two screens in this manner until a button is pressed.


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7.1 MCSU-4 Components The MCSU-4 is a supervisory and control unit for a DC plant comprising up to 225 rectifiers connected in parallel with up to four parallel battery banks. Number of battery banks depends on type of MUIB used.

The unit is 1U in height and a magazine is available which fits across a 19” rack and accommodates the MCSU-4, the MUIB as well as a space for a modem or other equipment with a maximum dimensions 40x150x220 (HxWxD in mm). A local communication port is available on the front panel for connection to a portable PC.

7.1.1 Alpha-numeric Display A two-line by 16 character alphanumeric display of either a back-lit LCD type or a vacuum fluorescent type is supported. The 5mm high characters normally display output voltage and current as well as the system status - Float (FL) or Equalise (EQ). This is the default or “home” screen.

If an activity such as battery discharge testing is being performed, the current and voltage are always displayed, while the second line alternates between the system status (FL/EQ) and the activity status, for example “BDT in progress”.

234A 54.5V FL

Whenever there is no push-button activity for more than one minute, the display always reverts to this home screen. Note: the examples shown are for 48V systems.

7.1.2 Front Panel Pushbuttons There are pushbuttons associated with the LCD screen for the purpose of entering different Menus and for scrolling through the menus. The layout of the pushbuttons is shown below:

Apart from the MCSU-4 or “Home” menu, which includes mostly system oriented parameters, there are three other menus which can be accessed by momentarily pressing the relevant pushbuttons:

a) SMR menu, which includes the rectifier related programmed parameters as well as the output current and heat-sink temperature for each rectifier;

b) Batt ery menu in which all the parameters appertaining to the batteries are found;

c) Log which stores all the individual alarm information together with date and time starting with the most recent alarm. A total of 1000 alarms are stored in memory.

7.1.3 Status Indicating LEDs (MCSU-4) In addition to the alphanumeric display there are also three LEDs to indicate system status as follows:


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SYSTEM OK Green LED

ALARM ! Amber LED

SMR SHUTDOWN Red LED

When all three LEDs are off, the unit is off and there are a number of possible reasons for this. For example:

• DC is not present • Internal failure of MCSU-4

The amber LED indicates any alarm condition, either system or rectifier related. The red LED indicates that one or more of the rectifiers in the system is shut down.

7.2 Operating the MCSU-4

7.2.1 Password security MCSU-4 features password security for parameters setting. A password is an alphanumerical code having minimum three and maximum eight characters

Units leave the factory without pre-programmed password and security function is not active. To activate security a password must be programmed. Once that is done, security can be enabled. Password programming procedure is described in paragraph 1.4.3

7.2.1.1 Entering a password to gain access to parameters change When security function is active any changes to the system settings can be done only after a valid password was entered. When ENTER key is pressed to change a parameter, the display will show a message “Enter Password” on the top line and a blinking cursor on the right hand side of the bottom line. Using INC and DEC keys scroll to the first character of the password and press ENTER. The character will be substituted by a star ( * ) displayed to the left of the cursor. Enter all characters of the password the same way. If the password is less than eight characters long press ENTER again after last character. If the entered password was correct the display will return to the selected parameter ready for modification. If the entry was incorrect following will be displayed

Wrong Password Panel Locked

There is no limit on password entry re-tries. To abort password entry any of the top row buttons should be pressed. The display will return to the selected parameter.

There is no limit on number of parameters to be modified after a correct password entry providing there was a break less than 1 minute between consecutive actions on the keypad.

7.2.2 Test Mode This is a special mode of system operation allowing service personnel to perform system tests without permanent parameters change and altering system operating history (Alarm Log).

To activate Test Mode move to Password Setup sub-menu and enter “TESTMODE” as the password. The features of the Test Mode are:


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- Unrestricted parameters editing

- Edited parameters will not be stored in permanent memory (EEPROM)

- Alarms will not be recorded in the Alarm Log

- Alarm Log can not be cleared

- Password can not be changed

- Status of security function can not be changed

While test mode is active a prompt “Test Mode” will alternate with current operating mode on the bottom line of the “home” screen.

Upon quitting the Test Mode (see Par. 7.6) parameters values will be restored to original settings.

Note: After entering Test Mode time-out can be programmed between 1 and 4 hours in 1 hour interval. However, it is recommended to manually cancel the Test Mode once diagnostics are completed.

7.2.3 Entering and moving through different Menus To scroll through the MCSU-4 menu from top to bottom, just press the INC button. The screens that will appear are shown in section 7.6.

If the DEC button is pressed, the screen at the bottom of the menu will appear first and will be followed by the other screens in reverse order. This can be useful when it is desired to access a screen near the bottom of the menu.

To enter the other menus, momentarily press the relevant button - SMR, BATT or ALARM LOG. The associated menu contents are shown in sections 7.7, 7.8, 7.9 and 7.10.

If at any time it is necessary to return to the MCSU-4 or “home” menu, just press the current menu button once. E.g. if the present menu being scrolled is BATT, just press BATT button again and the screen will return to the default “home” screen.

The INC and DEC keys are also used to increase or decrease parameter values when the parameters are programmable.

In this case, press ENTER first. The parameter value will begin flashing on and off. Press INC to increase the value or DEC to decrease the value until the desired value is obtained. Then press ENTER again to actually enter the value into memory.

7.2.4 When an alarm condition exists If one or more alarm conditions exist at any time the following message will alternate with the “home” screen for 2 seconds every six seconds in addition to warning LED indicators:

3 Alarms Press ENTER

In this case, the message indicates that there are three alarms present and they can be observed by pressing the ENTER button.

When the ENTER button is pressed the most recent alarm name, such as the one shown below will appear on the display.

Alarm 1


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Amb Temp High

If no button is pressed again for one minute, the display will revert to the “home” screen and the sequence begins again.

To view the remaining alarms, use INC and DEC buttons. Pressing the ENTER button will return the display to the “home” screen. The time and date of any given alarm can be obtained by entering the ALARM LOG menu.

7.3 MCSU-4 Alarms A list of all the possible alarms that can be enunciated is shown in the following table.

Alarm Name Comments LED

SMR Alarm Combination of one or more SMR alarms A

SMR Urgent One or more SMRs have shut down A+R

SMR HVSD SMR shut down due to output over-voltage A+R

UNIT OFF SMR is off A+R

No Response A particular SMR is not responding to the MCSU-4 A

Power Limit SMR is in Power Limit A

No Load SMR output current less than minimum for SMR type used A

Current Limit SMR in current limit A

Voltage High Voltage measured by SMR too high A

Voltage Low Voltage measured by SMR too low A

UNCAL SMR SMR Internal Adjustment for current sharing out of limits A

EEPROM Fail EEPROM failed (MCSU-4 or SMR) A

Fan Fail SMR Internal Fan failure alarm (only possible on SMRs with fans) A

Relay Fail SMR output relay contact failure A

No Demand Control loop in SMR not in normal state A

H/S Temp High SMR heatsink temperature too high (where available) A

DC-Dc Contr Fail SMR DC/DC converter fault A+R

Temp Sensor Fail Temp sensor in SMR faulty - S/C or O/C (where available) A+R

Vref Fail Voltage reference in SMR microprocessor circuit faulty A+R

HVDC not OK DC/DC converter (boost) voltage in SMR not OK A+R

AC Volt Fault – detected by SMRs

All SMRs are reporting AC fault. Available only on some SMR models. A+R

AC Volt Fault – detected by CSU

None of SMRS are responding (AC fail assumed), or if AC monitor is used, AC voltage is out of limits set

(When no AC monitoring module is used, this comes together with “SMR Comms Fault”)

A

AC Freq Fault AC frequency lower or higher than preset value A

Battery Switch One or more battery switches open A

Cct Breaker Fuse or CB in load distribution open A

LVDS Open Low Voltage Disconnect switch open A

Sys Volts High System output volts too high A


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Alarm Name Comments LED

Sys Volts Low System output volts too low A

System V Clamp MCSU-4 can not reach desired system voltage. This can be due to possible excessive voltage drop along bus bars or “System V Drop” parameter has value too low.

A

Cell V High One or more cells being monitored by BCM is too high in voltage A

Cell V Low One or more cells being monitored by BCM is too low in voltage A

Cell %dev High One or more cells being monitored by BCM is too high % deviation from the mean battery cell voltage

A

Cell %dev Low One or more cells being monitored by BCM is too low % deviation from the mean battery cell voltage

A

Range SMR SMR parameter range error. MCSU-4 could not overwrite values A

Site Monitor Alarm present from the site monitor module. See site monitor menu for details of alarm channel.

A

Battery Disch Batteries are discharging A

Disch Tst Fail Battery discharge test failed to reach a programmed end point A

Bat Disch Low Alarm flags only if the system voltage falls below Discharge Alarm level while the battery is discharging

A

Lo Electrolyte Alarm generated for NiCad batteries using special sensor and software A

SMR Comms Fail One or more of SMRs are not responding A

Amb Temp High Ambient temperature higher than preset limit A

Batt Temp High Battery temperature higher than preset limit A

Batt Temp Sens Battery temperature sensor not connected or failure A

Batt I-Limit Battery charging current is being limited to preset value A

Bat Sym Alarm Battery discharge currents from battery strings not sharing load equally A

Earth Leak Alarm Earth leakage current greater than the limit set A

Equalise System is in equalise mode A *

R = red LED on A = amber LED flashing * not flashing

7.4 User programmable relay functions All controllers with RTP standard software of version/revision ‘fa’ or higher support this feature. Other customised software can include it as well. To check if your unit supports programmable relays, perform Indicators Test as described in section 7.6.3.

New units have factory default relay assignment. For details refer to paragraph “Relay Contact outputs” in User Interface sections of this manual.

Relay functions can be changed only from a PC running monitoring program WinCSU-2. Refer to WinCSU-2 Help for instructions.

7.5 Mapping of loaded SMRs This function is available only on selected models of MCSU-4.

In some system configurations it may be necessary to leave empty magazines between groups of rectifiers. In such a case a controller without mapping function would continuously alarm SMR communication fault for magazines with no SMRs.


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A controller with the mapping function will communicate only with magazines fitted with functioning rectifiers.

To enable this function, select “Map Loaded SMRs” from the main menu and switch “On”. Scroll through to the next screen and press “ENTER”. The controller will automatically search for installed rectifiers. This will take approximately 10 seconds.

When the mapping process is complete the controller will ignore vacant magazines and will sequentially report on the status of installed rectifiers in their correctly numbered positions. This will allow the end user to quickly and accurately identify the position of a faulty module should an alarm be reported.

7.6 MCSU-4 Base Menu Screens The INC button is pressed to scroll through the MCSU-4 menus. The following screens will appear in sequence.

MCSU-4 “Home” screen; indicates system is in float mode. The operating mode will alternate with “Test Mode” when Test Mode is active.

155A 54.3V FL

“C” indicates that battery temperature compensation function is active. The operating mode will alternate with “Test Mode” when Test Mode is active.

155A 54.3V FLC

This message will be displayed only when security is active and editing of parameters was enabled by entry of a valid password.

Lock Panel Press ENTER

If ENTER was pressed this message will be displayed for two seconds after which the display will return to the “home” screen.

Lock Panel Panel Locked

This message will be displayed only when Test Mode is active.

Quit Test Mode Press ENTER

If ENTER was pressed this message will be displayed for two seconds after which the display will return to the “home” screen.

Quit Test Mode Test Disabled

Ambient temperature is displayed in Degrees Centigrade. Ambient Temp 31°C

7.6.1 Single Phase AC Monitoring Screens In a system wired for 1 phase input with an AC monitor module, it will be necessary to activate the 1 phase AC monitoring selection screen via the “Auxiliary Units” sub-menu (towards the end of this menu). To enable, select “On” under the “1-ph AC Monitor” menu item. Once the AC monitor is enabled, the following screens will appear immediately after the “Ambient Temp” screen:

Single phase AC voltage. 1ph AC Volts

245V


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Single phase AC current 1ph AC Current 52A

Single phase AC frequency 1ph AC Frequency 50.0Hz

7.6.2 Three Phase AC Monitoring Screens In a system wired for 3 phase input with an AC monitor module, it will be necessary to activate the 3 phase AC monitoring selection screen via the “Auxiliary Units” sub-menu (towards the end of this menu). To enable, select “On” under the “3-ph AC Monitor” menu item. Once the AC monitor is enabled, the following screens will appear immediately after the “Ambient Temp” screen or single phase monitoring screens (when activated):

AC voltage of phase 1 3ph AC1 Volts

245V

AC voltage of phase 2 3ph AC2 Volts 243V

AC voltage of phase 3 3ph AC3 Volts 246V

AC Current of phase 1 3ph AC1 Current 28A

AC Current of phase 2

3ph AC2 Current 29A

AC Current of phase 3 3ph AC3 Current 32A

AC Frequency

3ph AC Frequency 50.2Hz


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7.6.3 Base Menu Programmable Parameters The screens below display programmable parameters within the MCSU-4 Base Menu.

To change a parameter, press INC button until the desired parameter is found, then press ENTER. The parameter value will flash on and off. Press INC to increase the value or DEC to decrease the value until the desired value is on the screen.

Press ENTER to enter the value into memory.

Ambient temperature alarm level Amb Temp Alarm 45°C

Float voltage High level Volts High Alarm 56.6V

Float voltage Low level Volts Low Alarm 50.5V

Security on or off. When security function is activated attempts to alter any programmable value will result in the display showing “Enter Password”.

Security On

Security Off

Entry point to password programming sub-menu. If ENTER was pressed following alternative screens will be displayed.

Password Setup Press ENTER

This screen will be displayed if the password is programmed for the first time.

Password Setup O

The password must be between three and eight characters long. Using INC and DEC keys scroll to the first character of the password (character set is 0-9 and A-Z), then press ENTER. The character will be substituted by a star ( * ) placed to the left of the cursor. If the password has less than 8 characters press ENTER again after the last character. Entry of a password can be aborted at any time by pressing any of the buttons in top row of the keypad.

This screen is displayed when a password was already programmed. Enter existing password. If the password was forgotten, contact the supplier to obtain default password.

Old Password O

This message will be displayed for 2 second if password entered was incorrect. The screen will be returned to password sub-menu entry point.

Old Password Wrong Password

This screen is displayed when correct old password was entered or confirmation of the new password failed. Enter desired new password.

New Password O


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Enter the new password again. Confirmation O

This screen will be displayed for 2 seconds if new password and confirmation matched. The screen will be returned to password sub-menu entry point.

Confirmation Password Changed

This screen will be displayed for 2 seconds if new password and confirmation did not match. The screen will be returned to “New Password”.

Confirmation Wrong Password

Indicators and display test. When this function is activated, all LEDs on the rectifiers and MCSU-4 begin flashing on and off. The display alternates between showing the software information and a screen with all pixels on.

Test Indicators Press ENTER

On bottom line: 169 - product group 8441 - software identification number 02 - revision

MCSU-4 169-8441-02

System type. This parameter can be set to Standby or

UPS. Set to Standby for systems where the load current is normally zero. Low load alarms are disabled for Standby.

System Standby

Set to UPS for systems which typically have more than 20% load all the time, and rely on the batteries to provide backup power.

System UPS

Menus for Mapping Loaded SMRs are available only on selected models. MCSU-4 addresses only those magazines in which SMRs

were present during “mapping” process.

Map Loaded SMRs On

MCSU-4 addresses magazines from number 1 to the number programmed in “Number of SMRs” menu. The next screen is hidden.

Map Loaded SMRs Off

When ENTER is pressed while viewing this menu, process

of mapping of loaded SMRs is initialised.

Exec. Mapping Press ENTER

Mapping process can take up to 10 seconds. During that time this message is displayed.

Exec. Mapping Please wait

When mapping process is complete, MCSU-4 displays number of SMRs detected as present in the system.

Number of SMRs 20

When “Map Loaded SMRs” is set to “On”, editing of number of SMRs from the front panel is not allowed. This message will be displayed when ENTER is pressed.

Number of SMRs Not Adjustable

End of Mapping Loaded SMRs menus


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Number of SMRs in the system. This number must be entered correctly. Otherwise the display will show that some SMRs are not responding (number too big) or will not be monitored (number too small).

Number of SMRs 15

Selection of the interface hardware being used to connect the MCSU-4 to the power system. Depending on the system (48V, 110V, 220V) and the software used, the options can vary from MUIB to MUIB5

Interface MUIB

Number of battery banks in the system. When MUIB2 is used up to 4 batteries can be monitored, with other interface types maximum number is 2.

Num of Batteries 1

Battery current transducer full scale rating. E.g. if a Hall effect transducer has 200A/4V rating, enter 200 in the screen.

FS Batt Current 200A

MCSU-4 Access code address; this can be a number up to

7 digits long

Access Code 1252636

Date format. The format of the date can be modified to either DD/MM/YYYY, MM/DD/YYYY or YYYY/MM/DD.

Date Format DD/MM/YYYY

Clock set; used to set the date and time of the MCSU-4 clock. Note DD/MM/YYYY 24 hour clock. While setting the time clock is stopped. Seconds are not programmable.

Date 25/12/2002 Time 21:58:35

Alarm Report; this can be toggled On and OFF. If ON and use of a modem is declared, the system will dial the first telephone number (Phone 1) in the screens below when an alarm occurs. If Phone 1 does not answer, it will try Phone 2; if 2 does not answer then it will dial Phone 3. If 3 does not answer it will begin again at Phone1

Alarm Report On

Alarm Report Off

Daily Report; this can be toggled from ON to OFF; When ON, unit will send routine report at the time programmed in next menu. If use of modem is declared unit will follow connection procedure as for Alarm Report

Daily Report On

Daily Report Off

Time of daily report. This menu is available only when Daily

Report is switched ON.

Daily Rep Time 15:15


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Modem enable; this can be toggled between ON and OFF. When a change is made, the front panel is disabled while the modem is activated/deactivated.

Modem On

The screens below (up to Note) will only be displayed if the modem is enabled (ON)

Modem Off

When modem communication is selected CSU checks once a minute if the modem is set to Auto Answer. If Auto Answer was disabled (i.e. loss of power to the modem) CSU will re-initialise the modem.

This and next screen may not be seen on some models. Two characters Country Code is required when Integrated Modem Interface is installed. See Remote Communication Interfaces section of this manual for listing of country codes.

Country Code 09

The default setting for this parameter is “no country code”. To disable existing code put a space (blank) in place of any of the characters and press ENTER.

Country Code None

This and next screen may not be seen on some models. Some models of external modems may require an additional initialisation string. The string can be up to 10 characters long - initial ‘AT’ command is not required.

Cust Init String &B1L3

The default setting for this parameter is “no custom string”. To disable existing initialisation string put a space (blank) in place of the first character and press ENTER.

Cust Init String None

Phone 1; number tried first when an alarm occurs. Numbers up to 20 digits long can be stored. If the number is longer than 10 digits, it is displayed in two screens.

Phone 1 0398887788

Example of second screen for continuation of phone number

Phone 1 Cont 2323

Phone 2; this number will be tried if the first number does

not respond. This menu item is followed by “Phone 2 Cont” (as for Phone 1).

Phone 2 0398880033

Phone 3; this number will be tried if the second number does not respond. This menu item is followed by “Phone 3 Cont” (as for Phone 1).

Phone 3 0398880033

Note: To have Alarm Report and/or Daily Report sent to local PC, switch the Reports ON, and Modem Off

Audio Alarm Enable; can be toggled from On through

Timeout to Off; when On, the audible alarm will sound when any alarm occurs. The sound can be silenced by pressing the ENTER button while viewing Home screen.

Audio Alarm On

Audio Alarm will sound for two minutes (if not acknowledged earlier).

Audio Alarm Timeout


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Audio Alarm is disabled.

Audio Alarm Off

Circuit breaker auxiliary contact circuit input. This input can be configured to be normally closed, normally open or disabled (Not Used).

Cct Input Used - N/C

Battery circuit breaker auxiliary contact circuit input. This input can be configured to be normally closed, normally open or disabled (Not Used).

Bat Switch Input Used - N/O

Battery low voltage disconnect switch auxiliary contact circuit input. This input can be configured to be normally closed, normally open or disabled (Not Used).

LVDS Input Not Used

7.6.4 Auxiliary Function Selection & Parameters The enabling/disabling of auxiliary functions such as AC monitoring, Battery Cell Monitoring and Site Monitoring is described below. These screens form the last screens seen when stepping through the MCSU-4 Base Menu.

Press Enter at this screen brings up the auxiliary function module that are supported.

Auxiliary Units Press ENTER

7.6.4.1 Single Phase AC Monitoring When the single phase monitoring module is used in the system, the relevant screens are activated by programming to “On” the 1 ph AC Monitor. If programmed to “Off” neither the monitoring nor the programmable parameter screens shown below will be displayed.

Entry point to 1 phase AC monitor sub-menu when this auxiliary is switched On. If it is switched Off the next screen will be shown and the rest of the menu items will be hidden.

1-ph AC Monitor Press ENTER

Displayed when this auxiliary is switched Off. 1-ph AC Monitor Off

Displayed when this auxiliary is switched On. 1-ph AC Monitor On

AC voltage high level; if any one of the three phases is higher than the level programmed here, the MCSU-4 will report an AC Volt Fail alarm;

1ph AC Vhi Alarm 260V

AC voltage low level; if any one of the three phases is lower than the level programmed here, the MCSU-4 will report an AC Volt Fail alarm;

1ph AC Vlo Alarm 192V


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AC Frequency high level; if the AC source frequency is higher than this value, the MCSU-4 will report an AC Freq Fail alarm

1ph AC fhi Alarm 55.0Hz

AC frequency low level; if the AC source frequency is lower than this value, the MCSU-4 will report an AC Freq Fail alarm

1ph AC flo Alarm 45.0Hz

AC current sensor rating for 1 phase monitor; the rating for the sensors used (current transformers) must be entered in this screen.

1ph AC FS Curr. 100A

7.6.4.2 Three Phase AC Monitoring When the three phase monitoring module is used in the system, the relevant screens are activated by programming to “On” the 3 ph AC Monitor. If programmed to “Off” neither the monitoring nor the programmable parameter screens shown below will be displayed.

Entry point to 3 phase AC monitor sub-menu when this auxiliary is switched On. If it is switched Off the next screen will be shown and the rest of the menu items will be hidden.

3-ph AC Monitor Press ENTER

Displayed when this auxiliary is switched Off. 3-ph AC Monitor Off

Displayed when this auxiliary is switched On. 3-ph AC Monitor On

AC voltage high level; if any one of the three phases is higher than the level programmed here, the MCSU-4 will report an AC Volt Fail alarm;

3ph AC Vhi Alarm 260V

AC voltage low level; if any one of the three phases is lower than the level programmed here, the MCSU-4 will report an AC Volt Fail alarm;

3ph AC Vlo Alarm 192V

AC Frequency high level; if the AC source frequency is higher than this value, the MCSU-4 will report an AC Freq Fail alarm

3ph AC fhi Alarm 55.0Hz

AC frequency low level; if the AC source frequency is lower than this value, the MCSU-4 will report an AC Freq Fail alarm

3ph AC flo Alarm 45.0Hz

AC current sensor rating for 3 phase monitor; the rating for the sensors used (current transformers) must be entered in this screen.

3ph AC FS Curr. 100A


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7.6.4.3 Battery Cell Voltage Monitoring This function is available only on units fitted with software supporting it. The system must be fitted with Battery Cell Monitor modules.

Entry point to Battery Cell Monitor sub-menu when this auxiliary is switched On. If it is switched Off the next screen will be shown and the rest of the menu items will be hidden.

Battery Monitor Press ENTER

Displayed when this auxiliary is switched Off. Battery Monitor Off

Displayed when this auxiliary is switched On. Battery Monitor On

The configuration refers to cell type (2, 4, 6 or 12V) and how the cells are connected to the monitor - see section 7.11 for further information. After pressing ENTER current configuration will flash. Scroll through available configurations and press ENTER again once the correct battery type is chosen.

Battery Config 24 cells

Declare number of battery banks to be monitored. Maximum is 4.

BCM Batteries 2

An alarm is posted if any cell voltage exceeds this value. Press ENTER and increment or decrement the value as desired in the normal way.

Cell Vhi Alarm 2.48V

Similarly a low threshold can be set for the cell voltages. If during a discharge (or any time) a cell voltage falls below this value, an alarm is raised.

Cell Vlo Alarm 1.44V

+dVc is a differential voltage threshold. It is the percentage voltage by which the voltage of a particular cell exceeds the average cell voltage for the whole battery.

Cell +dVc Alarm 10%

Low differential cell voltage threshold. Cell -dVc Alarm 10%

7.6.4.4 Site Monitor The site monitor is primarily designed to be operated with WinCSU-2 from a PC. However, once set up the analog signal levels can be viewed and the alarm levels and scale factors can be modified from the site monitor sub-menu of the MCSU-4.

The site monitor sub-menu is a sub-set of ‘Auxiliary Units’. When Site Monitor is declared to be Off, no other menu items are displayed.


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Entry point to Site Monitor sub-menu when this auxiliary is switched On. If it is switched Off the next screen will be shown and the rest of the menu items will be hidden.

Site Monitor Press ENTER

Displayed when this auxiliary is switched Off. Site Monitor Off

Displayed when this auxiliary is switched On. Site Monitor On

Level of Analog input 1. Press ENT to access alarm levels and scaling factor. Flashing of the value text (in this case ‘Inv-V’) indicates that a threshold has been exceeded but the channel is not alarmed.

A1 Inv-V 1.2V

If a channel has been declared as alarmed the reading will be preceded by word ‘ALARM’ (both flashing).

A1 Inv-V ALARM 1.2V

Threshold above which the input signal will trigger an alarm. High Alarm 272.0V

Threshold below which the input signal will trigger an alarm. Low Alarm 150.0V

Programmed scale factor of analog input. Scaled for 4V of input signal.

Scale at 4V 300.0V

Presentation of a digital input window under normal conditions.

D2 Window2 Not Active

The input is active but not alarmed – word ‘Active’ is flashing.

D2 Window2 Active

The input is active and alarmed – word ‘ALARM’ is flashing. D2 Window2 ALARM

Status of output relay 1. Relay is switched off. Output 1 Off

Status of output relay 2. Relay is switched on from a selected source. Will be switched of automatically when controlling input returns to normal condition.

Output 2 On


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Status of output relay 3. Relay is switched on manually from WinCSU-2 program. Will remain on until switched off manually from WinCSU-2.

Output 3 Manual On

Analog input signal levels only can be accessed from MCSU-4. To modify the logic or the label of the digital inputs, the units or labels of the analog inputs, a PC running WinCSU-2 must be used.

7.7 SMR Menu Screens All information relating to the individual rectifiers is found in the menu activated by pressing the SMR button on the MCSU-4 front panel. To return to the MCSU-4 menu at any time, press SMR button. To return to the SMR menu, press the SMR button again.

When an SMR is not connected or not switched on or is faulty, the screen indicates that the rectifier is not responding.

SMR1 No Response

Warning: It is important to declare the correct number of rectifiers in the rack using the MCSU-4 (home) menu.

NOTE: Output current and limit values shown below are typical for a 25A unit.

When a rectifier is on line and operating normally, its output current and heatsink temperature are displayed. Pressing ENTER once allows to view additional information.

SMR1 22A 58°C

Displays the version number of the SMR. Press ENTER to revert to status screen, or INC / Dec to view SMR serial number.

SMR1 169-3761-02

RTP rectifiers of third generation will report their electronic serial number, which is not available in earlier models. Displayed as last item in SMR information sub-menu. Press ENTER to revert to status screen.

SMR1 S/N not avail.

Use INC button to display status of the other rectifiers.

This display format is used when a SMR has non-shut down alarms. Pressing ENTER will access list of alarm sources displayed on the bottom line.

SMR2 21A 3 Alarms ENTER

SMR2 21A Power Limit

Use INC and DEC buttons to scroll through the list. . . .

At the end of the alarm list SMR version number and heatsink temperature are displayed.

SMR2 21A 169-3761-02 58°C

This display format is used when a SMR is shut down. Pressing ENTER will display the reason for shut down.

SMR3 UNIT OFF


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If SMR was shut down on “primary not OK” this screen is not displayed.

SMR3 HV Shut Down

Read SMR version and heatsink temperature after pressing INC or DEC at previous screen.

SMR3 169-3761-02 58°C

The rest of the SMR menu consists of screens detailing the SMR operating parameters.

Float Voltage value. This parameter is globally (and indirectly) set in the BATT menu so cannot be changed in this screen. It is set automatically to a value equal to the sum of the Sys Float and Sys Drop values set in the BATT menu.

SMR Float 52.3V

As with the Float Voltage value, the Equalisation Voltage parameter is globally (and indirectly) set in the BATT menu so cannot be changed in this screen. It is set automatically to a value equal to the sum of the Sys Equal and Sys Drop values set in the BATT menu.

SMR Equalise 59.3V

If “ENTER” is pressed while viewing above 2 screens, the following message will appear.

SMR Float Not Adjustable

7.7.1 SMR Menu Programmable Parameters The remaining screens show the SMR related operating parameters which can be changed by pressing ENTER.

When this is done, the number flashes on and off and can then be incremented or decremented by pressing the INC or DEC buttons respectively. When the correct value is obtained, press ENTER to enter the number into memory.

SMR high voltage alarm level. SMR V high Alarm 56.3V

SMR low voltage alarm level. SMR V low Alarm 48.1V

SMR DC High Volts Shutdown (HVSD). SMR HVSD 62.0V

SMR Current Limit. SMR I Limit 25A

Fault Reset; by pressing ENTER when this screen is displayed, any latched alarm, such as HVSD, is reset and the unit will restart unless it is damaged or faulty.

Reset SMR Fault Press ENTER

Please note that any parameter change will apply to all the SMRs.


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7.7.2 SMR Menu Sleep Mode The MCSU-4 has an optional Rectifier Sleep Mode (RSM) in order to maximize the power conversion efficiency of the overall DC Power System controlled by the MCSU-4.

The RSM accepts a user-configured:

o Minimum number of Rectifier to keep On-Line at all times.

o Rectifier rotation value (in Days).

The RSM continuously monitor the % output power from each Rectifier in the system and calculate the average Rectifier output power for all Rectifiers on line. The RSM continuously works to achieve an actual average Rectifier output power that is within an acceptable range by automatically placing Rectifiers On-Line and into Sleep mode.

The RSM calculates the acceptable range (minimum to maximum), centred on the target power conversion efficiency, by considering the following:

o The target power conversion efficiency.

o The number of Rectifiers in the system.

o The output capabilities of the Rectifier.

o Sufficient hysteresis to as not to cause Rectifiers to constantly being placed On-Line and back into Sleep mode.

The RSM make decisions on which rectifiers to place On-Line and which ones to place into Sleep mode based on the following criteria:

o When needing to place a rectifier in Sleep mode, the rectifier with the highest usage shall be selected.

o When needing to place a rectifier On-Line, the rectifier with the lowest usage shall be selected.

o Usage shall me determined with the accumulated Run Time (Hrs) or Thru-put (kWHr) which is kept in the rectifier. The determination on which value to use is configured via the factory configuration file.

The RSM allows for sufficient time after placing a Rectifier On-Line or into Sleep mode in order for the output of all Rectifiers to settle and the average Rectifier output power to be valid again. The RSM always ensure that the minimum number of Rectifier to keep On-Line is maintained.

The RSM provides a Rotation function to ensure that Rectifiers usage is being kept fairly even. The Rotation shall be accomplished by forcing a Rectifier, with the lowest usage, On-Line. This will cause the average Rectifier output power to fall below the acceptable range and the RSM to then place the Rectifier with the highest usage into Sleep mode.

The RSM automatically and immediately cease operation upon receipt of any alarm from a factory defined list (i.e. Battery Discharge, Voltage Low, SMR Current Limit,...).

The RSM function can be enabled and disabled by the user via the front panel and WinCSU-2.


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The RSM reports the following values to the user:

o Average Rectifier % Output Power

o Number of Rectifiers On-Line

o Number of Rectifiers Sleeping

SMR Sleep Mode Enable. Sleep Mode

Off

SMR Sleep Mode Minimum rectifiers that must be online. Sleep Min SMR 4

Max power of each SMR module. For RT12, rectifiers, this should be set to 2400 as each module is rated for 2.4kW

SMR Power Max 2400

SMR Sleep Mode rectifier rotation value (in Days). Sleep Rotation 5 Days

SMR Sleep Mode report number of rectifiers sleeping Sleeping SMRs 3

SMR Sleep Mode report number of rectifiers online Sleep SMR Online 5

SMR Sleep Mode report Average Rectifier % Output Power Sleep Av Power 80 %

7.8 Battery Parameter Menu Screens All information pertaining to the batteries is accessed by momentarily pressing the Batt button on the front panel. To return to the MCSU-4 “home” menu at any time, momentarily press the Batt button.

As for the other menus, in general a programmable parameter can be incremented or decremented by use of the INC and DEC buttons respectively. If this is attempted when a monitored parameter is being displayed (i.e. not a programmable operating parameter), then the message “Not Adjustable” will be displayed.

The following screens will appear in turn when the INC button is pressed:

Battery 1 Current; Battery 1 12A


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Battery 2 Current; (if present) Battery 2 14A

Battery Temperature; If a sensor is fitted, the battery temperature is shown in degrees Celsius. (Since there is provision for only one sensor, the sensor should be located in the hottest spot of the two batteries.) When Bat Temp Sensor condition alarm is disabled and the temperature sensor is not connected, the message reads as shown. When Bat Temp Sensor condition alarm is enabled and the temperature sensor is not connected, this message will be shown.

Battery Temp 31°C

Battery Temp Not Available

Battery Temp Sensor Fail

Estimated Battery 1 state of Charge; this screen shows the estimated charge in the battery at any given time.

Estimated Q Bat1 300Ah

Estimated Battery 2 state of Charge. (if present)

Estimated Q Bat2 300Ah

Battery discharging alarm level. This level is set to a value to which the battery voltage falls to during a discharge. It is used to issue an alarm indicating that the batteries are discharging.

Batt Disch Alarm 45.0V

This screen is available only if more than battery is installed in the system. During an AC power outage when the batteries are supplying the load, the difference in discharge current between one battery and the other is an indication of the state of the batteries. More particularly, if one battery is supplying considerably less current than the other, it is usually an indication that a problem exists with that battery. The discharge current difference to activate the alarm is entered in this screen. A reasonable value is 20% of the total discharge (load) current.

Disch I Diff 20A

Battery overtemperature alarm level. This is a programmable level and can be adjusted in the normal way by the INC, DEC and ENTER buttons.

Batt Temp Alarm 50°C

Ampere-hour rating of batteries; the rated A/H number for the batteries must be entered in this screen.

Battery Rating 500Ah

Battery Temperature Compensation Coefficient in mV per Deg C per Cell is entered in this screen. The allowable range is 0.1 to 6mV /Cell/°C. If the value is decremented below 0.1, the display will show Off.

BTC Coeff. 3.2 mV/C /°C


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This screen is available only when BTC is active. Set temperature level at which System Voltage is not corrected. Range 18°C to 27°C. Note Compensation range is 10-35°C

BTC Nominal 20°C

The physical number of 2V cells in the battery. A typical value range for a 48V system is between 22 and 24 cells. This function is used for battery temperature compensation.

Number of Cells 24

Please Note:

a) If there are no temperature sensors connected or if BTC is set to 0, the compensation function is disabled. In this instance, the status message in the MCSU-4 home screen is FL or EQ instead of FLC or EQC.

b) If the Battery temperature sensor is not connected, compensation is then based on the ambient temperature sensor;

c) If both Ambient and Battery temperature sensors are connected, the compensation is based only on the battery sensor.

d) If temperature compensation is activated, the SMR voltage setting is automatically adjusted by the MCSU-4 on a regular basis.

Battery Charging Current Limit applicable for voltages below Vdd. This parameter sets the maximum current which flows into the batteries when the voltage across the two batteries is less than Vdd, the deep discharge voltage.

BILim Vb<Vdd 34A

Battery deep discharge voltage - Vdd. Vdd Level 44.0V

Battery Charging Current Limit when the battery voltage is between Vdd and the float voltage Vfl. This limit is normally higher than the one for a deeply discharged battery.

BILim Vb<Vfl 52A

System Float Voltage; this sets the system output voltage at the output busbar terminals.

System Float 54.0V

System Voltage Drop. This parameter is used to set the maximum voltage that the individual rectifiers can output over and above the programmed System Float voltage.

System V Drop 0.6V

The System Voltage Drop parameter is calculated by summing the resistive voltage drop in each rectifier due to output connector, output relay and passive current sharing output “slope” and the expected drop of the busbars of the system. A typical value is 0.6V. For digital control, set the value for the drop to that expected at nominal load.

Enable/disable equalisation charging. If Equalisation is disabled, the following screens (up to the comment “End of equalisation section”) will not appear.

Equalisation On

Battery Charging Current Limit for battery voltages greater than the float voltage. This applies when the batteries are being equalised.

BILim Vb>Vfl 25A


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Equalisation Voltage. This sets the maximum voltage reached during equalisation of the batteries.

System Equalise 59.5V

Equalisation not initialised by voltage level. Volts Start Eq Off

Equalisation initialised by voltage level V reached during battery discharge.

Volts Start Eq On

Equalisation is initialised when the battery voltage falls to this level.

Volts Eq Trigger 46.0V

Equalisation is not initialised by the discharge A/H method. Q Start Eq Off

Equalisation is initialised based on charge supplied to the load by the batteries (measured in Ampere-Hours).

Q Start Eq On

Equalisation is initialised when the charge out of the batteries is greater than the level set in this screen.

Q Loss Trigger 10Ah

Equalisation is ended based on the level of battery charging current set in this screen.

EQ End Current 25A

If Equalisation is to end independently of charging current, reduce the value of current in this screen to less than 5% of the A/H rating of the batteries (programmed in earlier screen) and the number will then be replaced by “Off”.

EQ End Current Off

Equalisation can be terminated after the time set in this screen. If termination is based only on the A/H discharge method, set this number to its highest value (48 Hr).

EQ Duration 20 hours

If no equalisation occurs due to battery discharges for a period longer than the time set in this screen, an equalisation cycle will be initiated automatically. Can be switched off by setting number of weeks to zero.

EQ Period 12 Weeks

Equalisation can be ended manually by pressing ENTER when this screen appears. This screen is only obtained if the system is in Equalisation mode.

Manual Stop EQ Press ENTER

When ENTER is pressed, the system reverts to Float mode and the window changes to that shown, ready for a manual equalisation start. This screen is only obtained if the system is in Float mode.

Manual Start EQ Press ENTER

End of equalisation section.


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A Low Voltage Disconnect Switch (LVDS) is often integrated into the system to disconnect the batteries from the load in the event that the AC power outage is too long causing the batteries to discharge beyond a safe level. The voltage level at which the LVDS opens is set in this screen.

LVDS Trip 44.0V

When this screen is as shown, the LVDS switch opens automatically when the voltage drops to the trip level set in the previous screen. When the AC power is restored and the system output voltage rises after the rectifiers start up, the LVDS will close automatically.

LVDS Mode Auto

To operate the switch manually, press ENTER and the Auto will flash on and off. Press INC to scroll to Closed, followed by Open followed by Auto again.

LVDS Mode Closed

Press ENTER at the desired state - e.g. Open to open the switch.

LVDS Mode Open

Menus for Load Shedding are available only on selected models.

Load 1 shedding is enabled. Load 1 Shedding On

Load 1 shedding is disabled. The next screen will not be displayed.

Load 1 Shedding Off

Bus voltage level at which load 1 will be disconnected. With the bus voltage rise this load will be reconnected at level 1V higher than this value.

Ld 1 Shed Level 47.0V

Load 2 shedding is enabled. Load 2 Shedding On

Load 2 shedding is disabled. The next screen will not be displayed.

Load 2 Shedding Off

Bus voltage level at which load 2 will be disconnected. With the bus voltage rise this load will be reconnected at level 1V higher than this value.

Ld 2 Shed Level 47.0V

End of Load Shedding menus.

Enable/disable the temperature sensor alarm. If no temperature sensors are present in the system, this field should be set to ‘Off’.

Temp. Sen. Alarm On

7.9 Battery Discharge Test Battery Discharge Test is available on selected MCSU-4 models.


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The Battery Discharge Test is a software function in the MCSU-4, which performs a periodic, controlled battery discharge using the load to discharge the battery. The test can be used to confirm capacity of the battery in the same way as a manual discharge using an external load would, except the normal system load is used without disconnection.

While Battery Discharge Test is active, the “Home Screen” will have format

50A 49.2V BDT in Progress

The system alarms Battery Discharge, Voltage Low, SMR Voltage Low and Low Load will be suppressed, however SMR alarms will be shown in the SMR status.

To access the Battery Discharge Test parameters, enter the Batt menu. Use of DEC gives faster access to the menus. The screens shown here are in order as INC key was used.

Time interval (in days) between consecutive tests. Setting range 0 - 365. When set to zero, the automatic execution of the test is disabled (the display shows “Off”). The test can be activated manually from a PC running WinCSU-2 (from CSU menu). Display messages from 2 to 6 will be shown only if the test is enabled.

BDT Period 14 Days

Time of the day at which the test should start. Programmed in hours and minutes (24 hours format).

BDT Time 17:35

Time span during which the battery will be discharged. Programmed in hours and minutes (between 5 minutes and 24 hours), step of adjustment 5 minutes.

BDT Duration 1h30min

Current of battery discharge, controlled by MCSU-4. Programmable range 0A - 5000A. To ensure proper operation of this function, the load supplied by the system during the test must be greater by at least 10% than desired battery discharge current. MCSU-4 will use the rectifiers to support surplus load, leaving the battery to supply a user defined amount of current to the load. If this parameter is set to zero, the control function is disabled and the battery will discharge under full load current.

BDT Current 50A

Batt Disch Test Current = Load

End voltage of the test. Battery voltage below which the test will terminate if reached before desired duration time expired.

BDT End V 46.0V

MCSU-4 will restore normal operating parameters and start recharging the battery. The test result will be “Fail”. Programmable range depends on the system voltage: • 24V system: 18V to 24V, • 48V system: 36V to 48V, • 110V system: 75V to 120V.

End capacity of the battery. Principle of operation the same as described in par. 4. Programmable between 25Ah and 9995Ah

BDT End Q 500Ah


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Reset of failed test alarm. This message will be seen only if last test failed and has not been reset. Pressing ‘ENT’ while viewing this display will reset the alarm and hide the message. The alarm can be also reset from a PC using WinCSU-2 software.

BDT Alarm Reset Press ENTER

Manual interruption of a battery discharge test. This screen is only visible when a discharge test has been started.

BDT in Progress ENTER to abort

7.9.1 Results of last Battery Discharge Test - (Las t BDT) The remaining screen of the Battery Discharge Test gives details of the results of the last discharge test. The explanation of the codes are as follows:

Not Available. No test has been performed yet. Last BDT Not Available

The test lasted for desired duration without reaching “End V” or “End Q” levels

Last BDT Passed

Test terminated prematurely reaching “End V” or “End Q” level before duration time expired. This will trigger “BDT Fail” MCSU-4 level alarm.

Last BDT Failed

The test was terminated due to a failure of the AC supply detected either by the AC monitor or all SMRs being off.

Last BDT AC Lost

A cell in a battery string discharged below safe level - alarmed, available only when BCM fitted and activated. BDT is flagged as having failed.

Last BDT Cell V Low

Aborted due to loss of control of rectifiers, not alarmed. Last BDT No Control

Aborted due to load being too low to control discharge current, not alarmed.

Last BDT Low Load

Aborted due to load being too high to support controlled discharge. Flagged if all SMRs indicate current limit. Possible only if rectifiers failed during the test. Not alarmed.

Last BDT SMR Overload

Terminated manually using MCSU-4 Front Panel or from WinCSU-2

Last BDT User Aborted

If during viewing this display the ‘ENT” button is pressed, a sub-menu with details of the last test result will be accessed (if a test was performed). The results of the last test are stored in EEPROM. The entries are:

Date of the last test. Last BDT 22/01/2003


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Duration of the test Last BDT Dur 1h18min

Voltage of the battery at the time of termination of the test. Last BDT EndV 49.2V

Remaining estimated capacity of a battery string at the time of termination of the test, where n is a number of the string.

Last BDT EndQn 380Ah

The test is disabled for 100 hours if any of the following took place:

a) AC failure has been recorded

b) Electrolyte low level has been recorded (only if sensor fitted and appropriate version of software installed).

If an automatic test was scheduled during that period, it will be performed at the next opportunity at the BDT Time.

7.10 Alarms Log Screens A record of the most recent alarms is kept in the MCSU-4 memory and can be viewed by momentarily pressing the Alarms Log pushbutton.

Alarm Log Pushbutton pressed - the screen shows the number corresponding to where the particular alarm is in relation to the most recent alarm which is number one, followed by the alarm name as shown in the example below: If the INC button is pressed within two seconds, the second alarm will be shown. If pressed again the third alarm appears etc.

LOG 1 AC Freq Fault

If the button is not pressed for two seconds a date/time screen will appear which shows the alarm sequence number followed by the date and time at which the alarm occurred.

10/01/2003 12:05:26

To clear the alarms log, press ENTER whilst in the Alarms Log menu and the following screen will appear:

DEC to Clear Log Entries

Press the DEC button as requested and the log will be cleared and the following screen will confirm it.

LOG No Entries

7.11 Battery Cell Monitor Setup Note: This function is only available on special versions of MCSU-4 software and appears as the first option in the Expan2 sub-menu (see section 7.6.4.3 for screen definitions).

For 110V and 220V systems, refer to the BCM3/BCM4 sections for an appropriate configuration table.


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7.11.1 Relationship between “BCM Batteries” and “Nu m Batteries” With the BCM option enabled, the BCM parameters must be setup before monitoring can be performed. Following through the screens of section 7.6.4.3, the screen indicating “BCM Batteries” is where you define the number of batteries whose cell voltages are to be monitored by the MCSU-4. There is no need to program the MCSU-4 how many BCM boards are connected. The MCSU-4 automatically calculates the number of BCM boards that it requires from the number of “BCM Batteries” that you entered. The number of BCM boards (PCBs) required for different battery configuration is shown in the following table (48V top, 24V bottom):

Batt Config BCM Batt = 1 BCM Batt = 2 BCM Batt = 3 BCM Batt = 4

24 cell, 2V 1 BCM board 2 BCM boards 3 BCM boards 4 BCM boards

12 cell, 4V 1 BCM board 1 BCM board 2 BCM boards 2 BCM boards


4 cell, 12V 1 BCM board 1 BCM board 1 BCM board 1 BCM board

12 cell, 2V 1 BCM board 2 BCM boards 3 BCM boards 4 BCM boards



2 cell, 12V 1 BCM board 1 BCM board 1 BCM board 1 BCM board


Num Batteries X ( where X is the number of batteries)

The number of batteries entered here is the number of batteries that are being monitored for their currents. “Num Batteries” and “BCM Batteries” are not related except that value entered for “Num Batteries” must be greater or equal to “BCM Batteries”. This is because Num Batteries determines the number of batteries accessible via the BAT menu, via which we access the cell voltages. So if only two batteries are defined for Num Batteries, then access to cell voltages of Battery 3 or 4, even if they are defined as 4 in the BCM Batteries menu, will not be possible. Normally Num Batteries is set to be the same as BCM Batteries.

7.11.2 Frequency of measurement. To allow for a wide battery capacity range, which can range from 10 minutes to 8 hours, the cell voltage polling frequency is programmable in 1 minute increments. A typical polling interval is 4 minutes, which would yield 15 points for a 1 hour discharge. For programmed test discharge of 30 minutes a polling interval of 2 minutes might be used. This parameter is not accessible from the MCSU-4 front panel. It is only programmable from a PC running WinCSU-2.

7.11.3 Battery Cell Measurements When BCM is active, the individual cell voltages can be monitors on the MCSU-4 by selecting a Battery from the Batt Menu and pressing ENTER. The cell information will appear on the screen and the next and previous cells can be selected by pressing the INC or DEC buttons. See below:


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Battery 1 Current screen appears after pressing BATT . Pressing ENTER brings up the next screen.

Battery 1 12A

Battery cell status: Battery 1, Cell 01, cell voltage 2.225V which is deviating +12% from the average cell voltage of the battery string.

Battery1 Cell01 2.225V +12%

Battery 1, Cell “mm”, Cell voltage “n.nnnV” which is deviating “±pp%” from the average cell voltage of the battery string. Use INC and DEC to view other cells.

Battery1 Cellmm n.nnnV ±pp%

7.12 Earth Leakage Detector - MUIB3 and MUIB5 only Note: This function is only available on 110V and 220V versions of MCSU-4 software and with special software for 24V and 48V systems. The parameters appear after the Batt Rated xxAh item in the Battery Menu screens.

The MUIB3/5 interface boards have a circuit that is designed to monitor any imbalance in the positive and negative DC bus voltage with respect to earth. With no external leakage current paths from the floating system the positive and negative voltage rails should be at equal potential about earth. When an external leakage current is present, the value of the current is displayed by the MCSU-4. As well, an alarm level can be programmed as shown below.

Earth leakage current: display shows the leakage current to earth in mA;

E Leak I 0.2mA

Earth leakage current alarm threshold: this can be set in the range 1.0 to 9.5 mA.

E Leak Alm 5.0mA


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8. Commissioning Commissioning primarily requires an understanding of the rectifier visual signals and operator adjustable parameters on the system controller (MCSU-4). Before a system is first energized, it is advisable to read this section thoroughly.

8.1 Indicators on the Rectifier Front Panel There are three LEDs on the front panel to indicate the operating status of the rectifier modules. They are as follows:

LED Name LED Colour What it indicates

1 ON Green Rectifier functioning normally

2 Alarm Yellow (flashing) Alarm condition

2 Alarm Yellow (not flashing) Unit is in Equalisation mode

3 Shutdown Red (with yellow LED flashing) Unit is switched off or failed

3 Shutdown Red only Micro in SMR has failed

If necessary, further information about the particular rectifier alarm condition, if one exists, can be found by referring to the MCSU-4 or the PC connected to the MCSU-4 - see detailed section on MCSU-4.

8.2 System Parameter Ranges Range of adjustment and default settings of system parameters are contained in a table at the beginning of this manual. Use last column to record parameters’ values set during commissioning.

8.2.1 RT12-120V/2.4kW SMR Parameters

Parameter Range Nominal

SMR Float Voltage 110-140V 120V

SMR Equalise Voltage 130-155V 140V

High Voltage alarm Threshold 120-157.5V 142.5V

Low Voltage alarm Threshold 95-125V 110V

HVSD Voltage alarm Threshold 120-158.5V 145V

Current Limit for SMR 4-12A 12A

8.3 System Commissioning To commission a system, modification of system parameters on the MCSU-4 is required. This can be done manually through the front panel of the MCSU-4 (see detailed section on MCSU-4 operation), or by using a PC running WinCSU-2 that is connected to MCSU-4 via the USB interface (see detailed section on WinCSU-2 operation). It is recommended for systems that are to be commonly commissioned, that the PC option be used. The benefit being that predetermined configurations can be stored on disk and easily downloaded to


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the MCSU-4 at any time. It is assumed that the operator commissioning the system has knowledge of programming system parameters.

The system parameters can vary widely depending on the system configuration and battery requirements. It is advisable to consult the battery data sheets as a reference when determining the system parameters to be programmed into the MCSU-4.

8.3.1 Commissioning Procedure For system with batteries and load, the commissioning procedure is as follows:

1. Make sure there is no load on the DC bus and that the batteries are disconnected.

2. Ensure that all SMRs are disconnected from the SMR magazine.

3. If necessary, set the DIP switches on the backplanes, starting with 1 and ending with the highest number corresponding to the number of rectifiers in the system. The DIP switches are ON when slid to the top, and LSB is at the right when viewing from the rear of the magazine. Position #1 corresponds to 00000001, position #2 to 00000010 and so on up to 15. #16 corresponds to 00010000, #17 to 00010001 and so on.

Figure 1 8-1: SMR Backplane DIP Switch showing addr ess 1 (0000 0001) and address 2 (0000 0010)

4. Ensure polarity of battery string and connect the first battery string and close the battery circuit breaker. If the polarity is correct, the MCSU-4 controller should power up.

5. Using either the MCSU-4 front panel or a PC connected to the local communications port or remote communications port, program all the MCSU-4 parameters according to the system requirements. Make sure that the number of rectifiers and batteries in the system are correctly set.

6. Set up any parameters necessary to operate auxiliary equipment such as Battery Cell Monitor (BCM3), Mains Monitoring Interface Board (MMIB4 or MMIB2), Site Monitor, etc.

7. Close the remaining battery circuit breakers if more than one string is used

8. Insert a rectifier into SMR # 1 magazine (determined by DIP switch addressing) and turn the AC power on. The rectifier should power up and start charging the batteries.

9. Put all the remaining rectifiers ‘on-line’, one at a time by inserting each rectifier into the magazine and switching on the corresponding AC breaker. Check that each unit powers up and communicates with the MCSU-4. This is determined by checking that the MCSU-4 has a message “SMRX 0A” where X corresponds to the SMR number.

10. Check that the bus voltage is increasing toward the float voltage.

11. With all rectifiers operating correctly, close the load breakers and check that the load powers up.

12. Wait for 1 minute and check that the MCSU-4 is able to control current sharing between the units to within +/-2A of the average rectifier current.


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13. Clear Alarm Log.

14. The system is up and operational. Adjust and operational monitoring or setup details as required.

For further information on any subject relating to MCSU-4 operation or alarms, see the detailed section on MCSU-4.


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9. Maintenance In this section some general routine maintenance procedures are described which should be carried out to ensure that the equipment performs to the high reliability standards that it has been designed to.

9.1 Warnings and precautions Since the unit utilises high voltages and large storage capacitors, it is imperative to take great care when working on the unit.

In particular, only qualified personnel should be allowed to service the units.

In addition, the following precaution should be observed:

Do not remove the cover with power on!

Allow five minutes to elapse after switch off befor e removing the cover to make sure high voltage capacitors are fully disc harged.

9.2 SMR Maintenance Since the SMRs are fully alarmed and operate in an active loop current sharing arrangement, there is no need for regular checks or adjustments of operating parameters. However, some regular checks can be an early warning of problems waiting to happen.

9.2.1 Current Sharing Under normal conditions, the output current variation from the average rectifier current by every rectifier should be within ±2A or ±3%, whichever is less. It is possible however, for internal loop parameters to change to such an extent that a unit does not share to the extent that it should.

If the lack of sharing is extreme then either a CURRENT LIMIT or NO LOAD alarm will be active and the operator should then refer to the next Section.

If, however, the current sharing is not so extreme as to generate an alarm, a regular check of the current sharing among the rectifiers can lead to early detection of any units which may be developing a fault.

In general, if only one or two units are “drifting”, the most probable explanation is a “drifting” component in the secondary control card of the SMRs involved. If, on the other hand, many of the SMRs are not sharing satisfactorily, then the most likely problem area is in the System Controller.

9.2.2 Integrity of Electrical Connections It is good practice to check all accessible electrical connections at regular intervals to ensure that no "hot spots" develop over time due to loose connections. An infra-red "hot spot" detector is very useful for this function.

Alternatively, mechanical connections can be checked manually for tightness.

9.2.3 Fan Filter Maintenance If fan filters are fitted it is important that they are removed and cleaned on a regular basis.


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The purpose of a filter is to remove dust from the air but as they become dustier less air flows into the rectifier and eventually overheating of the rectifier can occur. The rectifiers will protect themselves in the event of overheating, and an alarm will be generated accordingly. However even a partly blocked fan filter is undesirable because the rectifiers will suffer reduced air flow and will run hotter and have a reduction in their lifetime as a consequence.

To avoid creating a lot of dust in the vicinity of the power plant it is advisable to clean the filters outside in the open air. It is a better idea to have spare clean filters to replace the dusty ones with, then remove the dirty filters to be cleaned at a convenient time and location using appropriate aids.

For dusty environments frequent cleaning is required. Even in ‘clean’ environments a surprising amount of dust can appear. To determine the frequency of cleaning the site should be monitored for dust build-up.


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10. Fault Finding and Replacement Procedures This section describes in some detail the possible causes for alarms that may occur from time to time and the procedures that should be followed to clear the alarms and more importantly, address the problem or cause of the alarm.

It is assumed here that the most that a field maintenance person will do is change a complete module. It is normally impractical to attempt to repair a particular unit without test equipment, which is normally only available in the manufacturer's service laboratory.

The recommendation is for spare complete units to be kept on site. This includes a complete SMR, a MCSU-4 unit, and a MUIB sub-assembly. The fault finding procedures are presented below.

10.1 System Fault Finding Procedures The following table outlines suggested procedures to be followed if it is assumed that no internal repairs of units will be attempted. It is assumed instead that only MCSU-4 adjustments and unit replacement will be performed.

Alarm Condition Possible Cause Action Suggested

UNIT OFF No AC power to SMR Check AC supply to SMR; if necessary reset CB supplying SMR

SMR faulty Replace SMR

Equalise Mode Equalisation cycle in progress due to recent AC power failure, periodic or manual initiation.

No action required

SMR Urgent All SMRs off due to AC power failure If possible restore AC power

One or more SMRs off due to faults; Check Individual SMRs for obvious problem; replace SMRs if necessary

All SMRs off due to incorrect Inhibit signal from MCSU-4

Replace MCSU-4

One or more SMRs in Current Limit Check Current Limit settings and adjust if necessary; or batteries being recharged

SMR Alarm Any of the above or non critical problem with one or more SMRs

Select SMR menu. Check status of SMRs which are flashing alarm LED.

AC Fail (SMR alarm) Total AC power failure or AC voltage not within operating limits

Check AC supply and confirm condition; If AC is OK replace SMR units if only two show alarm condition

Cct Breaker Fuse or CB within PDU has blown or tripped

Check PDU (Power Distribution Unit)

Wire or connector loose on MUIB Check MUIB connections and tighten

Battery Switch Any one of 2 battery switches is open Close if appropriate

Bad connection to MUIB Repair connection

Amb Temp High Ambient Temperature is too high Reduce temperature – check Air Con.

Temperature sensor is faulty Check and replace if necessary

Connection to MUIB is faulty Repair connection

Set point is too low Check Amb Temp High threshold level and re-adjust if necessary


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Batt Temp High Battery temperature higher than pre-set level

Check battery temperatures and if necessary increase ventilation and cooling

Set point is too low Check Batt Temp High threshold level and re-adjust if necessary

Temp Sensor N/A Temperature Sensor in MCSU-4 not attached or faulty

Plug in temperature sensor if required; Replace temperature sensor

Faulty MUIB connection(s) Replace MUIB

Faulty MCSU-4 card Replace MCSU-4

Volts High SMR fault SMR Fault Chart

Float level set too high on MCSU-4 Check and adjust if necessary

MCSU-4 fault Replace MCSU-4

Volts Low AC power has failed; system on battery power

Restore AC power if possible

Alarm threshold level set too high Check set point and adjust if necessary

All SMRs are off due to MCSU-4 Inhibit signal, system on battery power

Check reason for signal; if necessary replace MCSU-4

Battery charging current limiting due to faulty battery current signal - this will depress float voltage

Check battery currents. If one of them shows figure higher than Batt Chg Curr Lim set point, check corresponding current transducer; check connections to transducer; check MUIB connections

Battery Temperature Compensation too high due to faulty battery temperature monitoring

Check battery temperature readings in Batt menu; Check and if necessary replace faulty sensor; check connection to MUIB

Battery Temperature Compensation too high due to faulty MUIB

Replace MUIB

SMR HVSD Output voltage too high due to SMR fault Replace faulty SMR

HVSD threshold on SMRs set too low Check and re-adjust threshold level

MCSU-4 fault Replace MCSU-4

SMRs not sharing load current

Communications link malfunctioning or faulty rectifier (digital current control)

Replace Comms cable and/or SMR

Faulty MCSU-4 voltage and current control loop IODEM signal (analog active current control)

Replace MCSU-4

Float or Equalise level on MCSU-4 set too high/too low.

Check and re-adjust Float or Equalise level on MCSU-4

No Response SMR not responding to MCSU-4 Check and if necessary replace comms cable at back of magazine faulty

Faulty microprocessor card in SMR Replace SMR

Power Limit Unit not current sharing (if only one showing power limit)

Replace SMR

Load current too high (if more than one unit showing alarm)

Reduce load

Reduce battery charging current limit if it is too high


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No Load Load circuit breakers have tripped and there is no load

Reset circuit breakers

If only one unit showing alarm, comms line to SMR may be faulty

In SMR menu check status of this SMR. If “No Response” replace comms line

Faulty SMR Replace SMR

Current Limit Batteries being recharged if more than one unit showing alarm

No action required

If only one unit shows alarm, internal control loop faulty

Replace SMR

No Demand Internal control loop faulty Replace SMR

System has no load No Action Required

EEPROM Fail Faulty EEPROM or microprocessor card Replace SMR

DDC Controller Fault in DC/DC converter Replace SMR

H/S Temp High SMR Heat sink temperature too high Check air intake to SMR is not blocked

Ambient temperature is too high Try to reduce ambient temperature

Microprocessor card is faulty Replace SMR

Temp Sensor Fail Temperature sensor is faulty Replace SMR

Fan Fail

(Fan cooled nits only)

Air flow inadequate due to dirty filter Clean or replace filter

Air intake/outlet blocked Remove air blockage

Fan faulty Replace fan if connection is OK

Reference Fail Reference voltage source in, or entire microprocessor card is faulty

Replace SMR

HVDC not OK Faulty boost controller Replace SMR

Inrush limiting fuse or resistor O/C Replace SMR

High Volts SD Feedback voltage circuit faulty Replace SMR

Faulty microprocessor card Replace SMR

LVDS Open Battery discharged to the limit voltage level due to no AC power

Check AC voltage and reset if possible

Battery voltage OK In BATT menu check if LVDS mode is set to “Open”.

Battery voltage OK, MCSU-4 faulty Replace MCSU-4

LVDS threshold level set too high Reset level in BATT menu

Sys Volts High Volts High level in MCSU-4 set too low Reset level to correct value

Temperature compensation coefficient set too high

Set correct temperature compensation coefficient

Faulty MUIB or MCSU-4 Replace MCSU-4

Sys Volts Low Volts Low threshold in MCSU-4 too high Reset level to correct value

Temperature compensation coefficient set too high

Set correct temperature compensation coefficient



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Battery Disch Output voltage low due to SMRs off Check AC voltage & restore if possible;

Float level set too low Set float level to correct value

Battery Disch level set too high Set correct Battery Disch level

SMR Comms Fail Comms cable faulty Replace cable

SMR communication circuits faulty Replace SMR

Faulty MCSU-4 Replace MCSU-4

AC Volt Fault

(System alarm)

AC voltage out of tolerance Check AC voltages and fix if possible

AC voltage threshold levels incorrect Set correct levels

Faulty AC monitoring unit MMIB1or2 Replace monitoring unit

MUIB or MCSU-4 faulty Replace MCSU-4

Communications link failure

(Only on systems not fitted with AC monitoring module)

In SMR menu check status of all SMRs. If all show “No Response” check 4-way communications cable between MCSU-4 and all SMRs

AC Freq Fault AC frequency out of tolerance Check AC frequency and fix if possible

AC frequency threshold levels incorrect Set correct levels

Faulty AC monitoring unit MMIB1 or 2 Replace monitoring unit

MUIB or MCSU-4 faulty Replace MCSU-4

Batt I-Limit Battery charging current is being limited to preset value

No action necessary

Battery current limit set too low Set correct limit

Battery current sensor faulty replace sensor


Batt Sym Alarm One Battery string is faulty Repair/replace battery if necessary

Battery discharge current differential level set too low

Set correct level of Disch I Diff in BATT menu

Battery current sensor is faulty Check and replace sensor if necessary


Earth Leak Alarm

(Only on systems fitted with MUIB3)

Excessive Earth current due to either failure of load supply isolation or faulty load equipment.

Locate source of earth leakage current and correct accordingly.

10.2 MCSU-4 Fault Finding and Repair Procedures In addition to performing a supervisory function by monitoring output voltage and current and the various system alarms, the MCSU-4 also performs a voltage control function in order to achieve battery charging current control, battery temperature compensation, battery equalisation and active current sharing.

To control current to the lowest battery voltage, the MCSU-4 has the ability to suppress the SMR output voltage to a value lower than the minimum battery voltage.


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It therefore follows that it is possible for a MCSU-4 fault to occur which can suppress the SMR voltage to that low level and thus cause a battery discharge despite the precautions that have been taken to ensure that this does not happen.

In such a situation disconnecting the 4-way cable, which connects the SMRs to the MCSU-4, will remove the voltage suppressing communications control signal and thus avoid the batteries discharging. Alternatively, the MCSU-4 can be pulled out of the magazine to achieve the same result. Without the MCSU-4 connected, the SMRs will revert to their pre-set Float voltage and passive current sharing.

There are virtually no electronic components on the MUIB except for the Remote alarm relays, and some fuse links, but there are many connectors. It is worth checking for poor connections when a MCSU-4 system problem is being investigated.

10.2.1 Replacing MCSU-4 The MCSU-4 is “hot-swappable”, so replacing a faulty unit is simply a matter of pulling the bad unit out of the MCSU-4 magazine and plugging a new unit in. The new unit will then power up and automatically read the system parameters stored in the non-volatile memory located on the backplane. The system parameters should then be checked via the front panel menus or using WinCSU-2.

Installation and Operation Manual RT12-120V/2.4kW Rectifier and ...

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