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System Operation

AEON 4000 PRS


Power Rack System

Aeon Gold Control Unit

SMPS 4000 Rectifier

355204.013 Issue 12, 2006 June

Table of Contents

Table of contents 1 System Functionality .................................................................................... 6


1.1 AEON 4000 system operation ................................................................................. 6 1.2 AEON Gold Software Functional Description ...................................................... 6 1.2.1 Battery Testing and Boost Charging.................................................................. 7 1.2.1.1 Manual, Interval and Automatic Battery Test................................................ 7 1.2.1.2 Manual and Interval Boost ............................................................................. 7 1.2.1.3 Battery test result............................................................................................ 8 1.2.1.4 Battery monitor .............................................................................................. 8 1.2.1.5 Backup Capacity and Time Estimation .......................................................... 9 1.2.1.6 Progress indication ....................................................................................... 10 1.2.1.7 Rescheduling of Test / Boost ....................................................................... 10 1.2.2 Output Control ................................................................................................. 10 1.2.3 Battery Current Limitation............................................................................... 10 1.2.4 Symmetry Measurement Configuration............................................................ 10 1.2.4.1 Continuous mode.......................................................................................... 12 1.2.4.2 Discharge mode............................................................................................ 12 1.2.5 Calibration ....................................................................................................... 12 1.2.6 Displaying input values.................................................................................... 12 1.2.7 Alarm system and control of relay outputs....................................................... 13 1.2.7.1 Event Detectors ............................................................................................ 13 1.2.7.2 Alarm system................................................................................................ 14 1.2.7.3 Define Triggers ............................................................................................ 15 1.2.7.4 Alarm Output Configuration ........................................................................ 15 1.2.8 Low Voltage Disconnect................................................................................... 16 1.2.8.1 Low Voltage Battery Disconnect (LVBD)................................................... 16 1.2.8.2 Low Voltage Load Disconnect (LVLD) ...................................................... 16 1.2.9 Test Relays........................................................................................................ 16 1.2.10 Configuration of shunt inputs........................................................................... 16 1.2.11 System Control through digital inputs ............................................................. 17 1.2.12 Rectifier control................................................................................................ 17 1.2.13 Master Password.............................................................................................. 17 1.2.14 Voltage settings ................................................................................................ 18 1.2.15 Remote management ........................................................................................ 19 1.2.16 Language options ............................................................................................. 19 1.2.17 Efficiency management .................................................................................... 20 1.2.17.1 General ..................................................................................................... 20 1.2.17.2 Power saving ............................................................................................ 20 1.2.17.3 Redundancy policy................................................................................... 20 1.2.17.4 No redundancy ......................................................................................... 21 1.2.17.5 Runtime balancing.................................................................................... 22 1.2.17.6 Operating modes ...................................................................................... 23 1.2.18 DC/DC converter control................................................................................. 23 1.3 AEON Gold Hardware Description...................................................................... 24 1.4 Rectifier Features ................................................................................................... 24 1.4.1 System and Stand-alone operation................................................................... 24 1.4.2 General features............................................................................................... 24 1.4.3 Fan operation................................................................................................... 24

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Table of Contents

Operation from AEON Gold ..................................................................... 26


2.1 The Front Panel...................................................................................................... 26 2.1.1 Menu design ..................................................................................................... 27 2.2 Control and Monitoring Unit Display .................................................................. 28 2.3 User Setup, Service Setup and Factory Setup ..................................................... 28 2.3.1 Available User Options .................................................................................... 30 2.3.1.1 Alarm Info .................................................................................................... 31 2.3.1.2 Alarm Reset.................................................................................................. 31 2.3.1.3 Rectifier Info ................................................................................................ 31 2.3.1.4 DC/DC Info .................................................................................................. 33 2.3.1.5 Voltage Info.................................................................................................. 35 2.3.1.6 System Info .................................................................................................. 36 2.3.1.7 Service Info .................................................................................................. 36 2.3.1.8 Battery Info .................................................................................................. 37 2.3.1.9 Input Monitor ............................................................................................... 38 2.3.1.10 Master Password ...................................................................................... 39 2.3.2 Available Service Options ................................................................................ 39 2.3.2.1 Stop Test / Boost .......................................................................................... 41 2.3.2.2 System ON / OFF......................................................................................... 41 2.3.2.3 Rectifier Control........................................................................................... 41 2.3.2.4 DC/DC control ............................................................................................. 43 2.3.2.5 Voltage Configuration.................................................................................. 43 2.3.2.6 System Configuration................................................................................... 44 2.3.2.7 Battery Config. ............................................................................................. 48 2.3.2.8 LVD Configuration ...................................................................................... 50 2.3.2.9 Alarm Configuration .................................................................................... 51 2.3.2.10 Communication ........................................................................................ 51 2.3.3 Available Factory Options ............................................................................... 52

SMPS 4000 Stand-alone operation ........................................................... 53


3.1 Front Description ................................................................................................... 53 3.1.1 Keypad.............................................................................................................. 53 3.1.2 Display information.......................................................................................... 54 3.1.3 LED indications................................................................................................ 54 3.2 Menu operation ...................................................................................................... 54 3.2.1 Flow chart menu structure ............................................................................... 55 3.2.2 DC voltage calibration..................................................................................... 56 3.2.3 DC current calibration..................................................................................... 56 3.2.4 Mains voltage calibration ................................................................................ 57 3.2.5 Temperature ..................................................................................................... 57 3.2.6 Rectifier ID....................................................................................................... 57 3.2.7 Rectifier power limitation................................................................................. 57 3.2.8 Software version............................................................................................... 57 3.2.9 Voltage setting mode ........................................................................................ 57

WinPower Gold .......................................................................................... 58


4.1 Introduction ............................................................................................................ 58 4.2 SW Installation ....................................................................................................... 58 4.2.1 System Requirements........................................................................................ 58

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Table of Contents 4.2.1.1 SW versions.................................................................................................. 58 4.2.1.2 Regional settings .......................................................................................... 58 4.2.2 SW installation, AEON Gold and Winpower Gold .......................................... 58 4.2.2.1 Language settings in Winpower Gold .......................................................... 58 4.2.2.2 System requirements .................................................................................... 59 4.2.2.3 Installing Winpower Gold ............................................................................ 60 4.2.2.4 Uninstalling Winpower Gold ....................................................................... 61 4.3 Start to use Winpower Gold.................................................................................. 61 4.4 Communication between Winpower Gold and AEON Gold ............................. 61 4.5 Login to WinPower Gold....................................................................................... 62 4.5.1 Direct Connection ............................................................................................ 62 4.5.2 Modem Connection .......................................................................................... 63 4.5.3 Ethernet connection.......................................................................................... 64 4.6 Description of the Screen interface....................................................................... 66 4.7 Menu Overview ...................................................................................................... 67 4.8 Detailed description of the Main Menu options .................................................. 69 4.8.1 General Configuration ..................................................................................... 69 4.8.1.1 Set Levels ..................................................................................................... 69 4.8.1.2 Set Date and Time ........................................................................................ 70 4.8.1.3 Site Info ........................................................................................................ 72 4.8.1.4 Modem Callback .......................................................................................... 72 4.8.1.5 Test Relays ................................................................................................... 75 4.8.1.6 Define Triggers ............................................................................................ 76 4.8.1.7 Define Alarm Outputs .................................................................................. 80 4.8.1.8 External control ............................................................................................ 81 4.8.1.9 Shunt Configuration ..................................................................................... 82 4.8.2 Battery Configuration ...................................................................................... 83 4.8.2.1 Battery Setup ................................................................................................ 83 4.8.2.2 Battery Test .................................................................................................. 86 4.8.2.3 Boost............................................................................................................. 89 4.8.2.4 Output Control.............................................................................................. 91 4.8.2.5 Current Limitation........................................................................................ 93 4.8.2.6 Symmetry Measurement Configuration ....................................................... 94 4.8.3 Rectifier Configuration .................................................................................... 96 4.8.3.1 Rectifier ON/OFF......................................................................................... 96 4.8.3.2 Options ......................................................................................................... 97 4.8.4 Factory Settings................................................................................................ 98 4.8.4.1 System Configuration................................................................................... 98 4.8.5 Rectifier Status ............................................................................................... 100 4.8.5.1 Rectifier Status ........................................................................................... 100 4.8.6 AEON Event Log ............................................................................................ 102 4.8.6.1 AEON Event Log screen............................................................................ 102 6.6.6.2 Exporting log to file ....................................................................................... 103 4.8.7 Battery Test Info ............................................................................................. 104 4.8.7.1 Test Results ................................................................................................ 104 4.8.8 Clear Event Log ............................................................................................. 104 4.8.9 System On / Off............................................................................................... 105 4.8.10 Password ........................................................................................................ 105 4.8.11 Resynch System .............................................................................................. 106 4.8.12 About .............................................................................................................. 106

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Table of Contents 4.9 Main Screen Facilities.......................................................................................... 108 4.9.1 View................................................................................................................ 108 4.9.1.1 Input Monitor ............................................................................................. 108 4.9.1.2 Input monitor log to file ............................................................................. 109 4.9.1.3 Symmetry Monitor ..................................................................................... 111 4.9.1.4 Symmetry monitor log to file ..................................................................... 111 4.9.1.5 Battery Monitor .......................................................................................... 112 4.9.2 Tools ............................................................................................................... 112 4.9.2.1 Winpower Gold Options ............................................................................ 112 4.9.2.2 Reports ....................................................................................................... 113

Attachments .............................................................................................. 114


5.1 Menu Structure, AEON Gold ............................................................................. 114 5.2 Factory Options .................................................................................................... 115 5.2.1 Available Factory Options ............................................................................. 115 5.2.1.1 Controller Setup ......................................................................................... 116 5.2.1.2 Diagnostics ................................................................................................. 117 5.3 Installation and upgrade of AEON Gold SW .................................................... 118 5.4 Languages in AEON Gold ................................................................................... 121 5.5 Service switch, AEON Gold................................................................................. 121 5.6 Default and limit values, AEON Gold ................................................................ 122 5.6.1 60 Volt system................................................................................................. 122 5.6.2 48 Volt system................................................................................................. 122 5.6.3 24 Volt system................................................................................................. 124 5.7 Default values for Communication Ports........................................................... 125 5.8 Protocols in AEON Gold...................................................................................... 125 5.9 Westermo modem configuration......................................................................... 125 5.10 SW Fault Messages............................................................................................... 130

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1 System Functionality

1 System Functionality
1.1 AEON 4000 system operation
The SMPS 4000 is designed for parallel operation in the AEON 4000 cabinet system. Parallel operation and communication is achieved by using CAN bus, a widely used communication standard for use in rough environments. Digital CAN bus communication between rectifiers makes it possible to achieve very accurate current sharing between rectifiers, better than 2.5 % at full load. Current sharing has the advantage that the MTBF will be equally distributed throughout the system. In addition, the phase currents will be balanced. CAN communication between individual rectifiers and the control unit has the advantage that all information regarding rectifier status can be found in one place - AEON Gold. The control unit monitors the system and controls the output voltage and current, at all times. By connecting the WinPower communication software to the AEON Gold, it is possible to get a remote interface to the power supply system, where all relevant information is stored. System communication is indicated by an LED, marked Com, on the front of the rectifier. The rectifier front display and buttons will go into a read-only mode where you are only allowed to scroll through the menus on the front of the rectifier, not do any configurations. The rectifier cannot be switched on or off locally, the voltage cannot be changed and calibration cannot be performed. Menu scrolling is also disabled in software version 1.05 and earlier versions. This will also happen if the rectifiers communicate with each other, and not AEON Gold. During system operation the centre of information and control is the AEON Gold Control Unit. In system operation the rectifier menus can only be scrolled if the rectifier software version installed is 1.10 or a later versions

Note: For 60 V systems, the new Aeon Gold HW, Art. 241241.100 is required.

1.2 AEON Gold Software Functional Description


This section (1.2) describes the functionality of the AEON Gold software, which defines the basis for system operation, both from the AEON Gold Front panel, WinPower Gold and, if this option is installed, WebPower.

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1.2.1Battery Testing and Boost Charging


The purpose of the battery test is to discharge the batteries down to a certain voltage and evaluate if the discharge duration is acceptable. The AEON Gold battery test is an actual battery discharge test where the batteries take over the full load current. Average current and test duration are measured to evaluate the state of the battery. The AEON Gold can calculate estimated battery capacity based on discharge tests and preconfigured discharge data entered via Winpower Gold. Battery boost or equalised charge is used to reduce the required recharging time by increasing the charge voltage from about 2.23 Volts Per Cell (VPC) to about 2.33 VPC.

Please note that battery boost is normally not recommended for VRLA (Vent. Regulated lead acid) batteries.

Battery Test or Boost is stopped if any alarm occurs.

1.2.1.1 Manual, Interval and Automatic Battery Test


The battery test is carried out by partly discharging, then measuring, the battery. To compute a Quality Factor, the measurements are compared with the battery table. If the Quality Factor falls outside limits, a warning or an alarm is given. The Low Battery Voltage Alarm is automatically suppressed when a battery test is running. The result of a battery test is stored in non-volatile memory. There are three ways of initiating a battery test: Manual: User initiated. If the system is busy or not able to run a battery test, the user is notified. Interval or Scheduled: Almost the same as a manual battery test, but initiated at a defined date, and time and repeated after a number of days. Automatic: If a mains fail lasts long enough to reach the specified test end voltage, a test will automatically be logged. It is possible to deactivate this function if necessary. There are also three situations that are important to remember before starting a battery test: It is not possible to start a battery test with an end voltage set outside the range of the battery table. It is not possible to set test end voltage lower than Low float voltage. It is not allowed to start a battery test unless the battery is fully charged. The fully charged charge current value is now adjustable. Default value is 1,7% of total battery capacity. The limit can be adjusted between 1,7% and 10%.

1.2.1.2 Manual and Interval Boost


If you need to charge the system batteries faster than normal, use battery boost function. The output voltage will then increase until the boost value is reached. There are 3 ways of initiating a boost charge: Manual: User initiated. If the system is busy or not able to run a battery boost, the user will be notified. Interval: Almost the same as a manual battery boost, but initiated at a defined date and time, and repeated after a number of days.
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Automatic: Starts automatically after mains has resumed, if the discharge has been over a threshold level.

A battery boost will end when boost duration expires, or if an alarm occurs. Manual or Interval Boost is rejected, if Boost Guard time is higher than zero, and there is still remaining Guard time.

1.2.1.3 Battery test result


To get a correct result from a battery test, the input data has to be within the specified battery table. This means that all parameters related to the battery test result, need to be checked before you enable a test. The maximum allowed time for a test can not be less than then the shortest discharge time from the battery table. I.e. if your battery has specified discharge data from 30 to 1200 minutes, and you have specified a maximum test time of 25 minutes, you will not get a result from the battery test. LVBD-voltage is also an important factor to consider, before you start a battery test. This is the limit you specify, to tell Winpower Gold when your battery is empty. Winpower Gold uses this value to calculate the capacity of the battery down to this level. Divide this voltage on the amount of cells in your battery string, and check that your battery table cover this cell voltage. The end voltage where you want the test to terminate also needs to be a voltage inside the limits of the specified battery table, as Winpower Gold looks up in this table to calculate the discharge time with a certain load current. Battery condition is measured as the relation between the actual times used to discharge and the theoretical time for a discharge down to a certain cell voltage. The condition is 100% for a battery that conforms to the battery table. The battery capacity result you get from a battery test is the capacity you had in your battery prior to starting the test, down to the LVBD limit. This will reflect your average battery current during the test time, adjusted with a factor calculated out of the battery table. This Quality factor is a relation between the theoretical capacity down to the test end voltage, and the theoretical capacity down to the LVBD level.

1.2.1.4Battery monitor
The Real Capacity of a battery A battery has a nominal capacity. However, at increasing discharge current, the capacity decreases. The capacity is also affected by aging. By taking load current and the Battery Quality Factor (from the most recent battery test) into consideration, the Real Capacity can be computed from the battery table with the formula; Real Capasity = Quality Factor * Theoretical capacity (read from the battery table). The Real Capacity is computed regularly to follow the load current. The remaining battery capacity and backup time are also mandatory parameters. The battery monitor combines two methods for estimating these values. Method 1 The Account method

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1 System Functionality This method is used for voltages outside the battery table limits. It uses measured charge/discharge values to calculate the Remaining capacity. Remaining capacity = Real Capacity Measured discharged capacity Remaining time = Remaining capacity / Average current The accuracy of this method is high at the beginning and more and more speculative as the battery is discharged.

Method 2 The Table method The table method is applicable only when the measured cell voltage is within the range of the battery table voltages. The total backup time of a good battery is regularly computed. The estimated time to discharge a fully charged battery to the battery disconnect voltage, is computed by looking up the remaining time in the battery table. To do this the measured cell voltage, the disconnection voltage and the average current is used Remaining time = Time to discharge to disconnect voltage, minus time to discharge to the measured voltage. The Battery Quality Factor of the last battery test adjusts the difference. Remaining capacity = Remaining time * Average current.

This method provides increasing accuracy as the voltage approaches the disconnect voltage. Combining the two methods The result from the two methods are combined the following way: If measured cell voltage is equal or higher than the Highest end voltage of the battery table, The Account method is used. Else if measured cell voltage is equal or lower than the Disconnect voltage, The Table method is used. Else, a weighed mean is used. The motivation is to avoid discontinuity and to give the most accurate method most significance. Note: The account method may introduce much inaccuracy. The longer the method is working, the more inaccurate is the account. If boosting is used for recharging, the logic is not able to know when the battery is fully charged because the charge current is high without regard to the battery charge state. In this case, the account may show a value considerably higher than the true capacity. The estimates are more speculative as time goes by. Therefore, the estimates during discharging are more trust worthy than the estimates during recharging.

1.2.1.5 Backup Capacity and Time Estimation


The following parameters will be regularly updated to provide support for Real-Time indication of backup capacity and time. Time until Low Voltage Battery Disconnect Remaining battery capacity and backup time will be estimated. A battery will be empty when the voltage has dropped to the Low Voltage Battery Disconnect voltage, indicated by a time-left indicator. The time-until-disconnection shall be the shortest of the following parameters:
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Estimated LVBD Backup time using the LVBD disconnection voltage. The LVBD contactor is equipped with a timer. When it times out, the battery will be disconnected.

Time until Low Voltage Load Disconnect There can be 4 LVLD contactors installed. There will be time-left indicators associating with each contactor. The time-until-disconnection shall be the shortest of the following three parameters: Estimated LVLD Backup time using the respective LVLD disconnection voltage. The different LVLD handles are equipped with a timer. When it times out, the loads will be disconnected.

1.2.1.6 Progress indication


Battery test and boost may take time. In order to keep the user informed about state and progress, the following data is available: What kind of job is going on, i.e. Test or Boost. State, i.e. Discharging, Boosting, Floating, Guard time Progress. There will be a progress bar indicating the progress in percent

1.2.1.7 Rescheduling of Test / Boost


If Interval Battery Test is enabled and a Manual or Automatic battery Test is completed, the next Interval test will be rescheduled to trig after TestInterval number of days. If Interval Battery Boost is enabled and a Manual or Automatic battery Boost is completed, the next Interval boost will be rescheduled to trig after BoostInterval number of days.

1.2.2 Output Control


There are currently three regulation modes: Temperature Compensation: Temperature compensation allows you to regulate the charge voltage with respect to the temperature and used batteries. The advantage is that the batteries will be working under optimum operating conditions, thus optimising performance and lifetime. Output Voltage Control: Using output voltage regulation means that the output voltage will be constant, irrespective of load or temperature condition. Default Rectifier Voltage: The output voltage is set by AEON Gold but regulated by the rectifiers.

1.2.3 Battery Current Limitation


This function limits the systems maximum battery charge current. Battery manufacturers often recommend limiting the maximum current to 10 30 % of C10 capacity, in order to prolong battery lifetime. C10 is the total 10 hour battery discharge capacity of all connected battery banks. Due to a regulation hysteresis of 40A, when using battery banks smaller than 4000Ah, it is not advisable to set Battery Current Limitation to a value lower than 400A. There is no restrictions on battery current limits, when used with battery banks larger than 4000Ah. The regulation hysteresis is then more accurate (4A).

1.2.4 Symmetry Measurement Configuration


To simplify symmetry supervision, the setup has been limited to two options: Midpoint 1-4 strings

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1 System Functionality 12Volt blocks, 1string There are 2 active alarm limits. One is a warning level and the other is a severe alarm level. The alarm voltages will be set to default values depending on the selected system voltage, and whether the system is in charge, float or discharge mode. The number of strings, when using centre point monitoring, is determined by the system settings. The maximum permissible number of strings will vary depending on type of symmetry supervision selected. The system configures the following ports for the different set-ups for symmetry supervision:

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1 System Functionality

Type of setup MidPoint

System Voltage 60V/48V/24V

2V Blocks 6V Blocks 12V Blocks

24V (not 12V blocks) 48V

Battery Bank 1 Bank 2 Bank 3 Bank 4 String 1

String 1

60V

String 1

Input Volt In 2 Volt In 3 Volt In 4 Volt In 5 Volt In 2 Volt In 3 Volt In 4 Volt In 2 Volt In 3 Volt In 4 Volt In 2 Volt In 3 Volt In 4 Volt In 5

Monitored Voltage 30V/24V/12V 30V/24V/12V 30V/24V/12V 30V/24V/12V 6V 12 V 18 V 12V 24V 36V 12V 24V 36V 48V

Table 1 Mapping of battery symmetry inputs

The symmetry monitoring has two possible operating modes. Common for both of them is when there is a transition from charging or float charging into discharge, there is a time frame when the monitoring is disabled. This is due to the battery properties. No symmetry measurement is possible during the first few minutes of a discharge. The two possible monitoring modes are: Continuous mode Discharge mode

1.2.4.1Continuous mode
The symmetry monitor is active at all times. It will, however, adjust the alarm limits according to whether the charge mode is charging, float, or discharge. Variable alarm limits are necessary in order to avoid false alarms.

1.2.4.2Discharge mode
The monitor is disabled until a battery discharge occurs. Only then will the monitor start. When returning to charge/float mode the monitor will stop.

1.2.5Calibration
The following inputs are calibrated: Analogue inputs DC Voltage inputs Temperature sensor inputs All AEON Golds analogue inputs can be calibrated as a 1-point or 2-point calibration. All inputs will be calibrated before leaving the factory and therefore it is advisable to only perform a 1-point calibration during normal conditions.

1.2.6Displaying input values


Both Winpower Gold and the AEON Gold front panel have the ability to show a dynamic monitor screen for displaying input parameters. These parameters include all analogue and digital input values. The analogy values are shown as calibrated physical values, while the digital input values are shown as Boolean values. AEON Gold The monitor window on the AEON Gold is situated in the USER menu and is thus not password protected. The refresh rate is 2 seconds.

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For CHINESE and other 12*12 pixel font each of these screens will be divided into two separate pictures.

WinPower Gold The Winpower Gold software shows a single independent window containing all the abovementioned input values. The Winpower Gold menu shall be active even if this window is shown.

1.2.7Alarm system and control of relay outputs


The Alarm system inside AEON Gold is built around three tables, a detector table that contains all configuration information for monitoring system variables, one detection result table and finally an alarm output table. The result table contains the information to show how the result of a triggered detector shall be handled. The output destination can be any digital output or an alarm report sent through a serial port. In addition to this, there is another table involved, which holds mapping information for the I/O. The latter contains information about which internal variable is mapped to which input port, or internal data source. One new alarm is available for user configuration, the DC/DC converter alarm. This is a count n*units type of alarm, which means that it is a sum of all detected alarms in the DC/DC converters.

1.2.7.1Event Detectors
In AEON Gold there are 11 fixed system detectors and their name, parameter and compare settings cannot be altered. All triggers have the ability to set the beeper to alert personnel when something needs attention. The beeper will go off when the alarm condition goes off. In addition alarm logging can be turned off for any individual trigger. Beeper The beeper function is related to the alarm class and, when enabled, the built in beeper will stay on for a certain amount of time. There is a different sound pattern depending on the alarm class, i.e. ALARM, WARNING, INFO. The beeper sound sequence can be stopped by selecting the reset alarm function or by pressing clear. The total beeper sequence length is set to 2 minutes. The sound pattern for ALARM is: The sound pattern for WARNING is: The sound pattern for INFO is: The sound pattern for classless events is: 150msec on, 200msec on, 100msec on, One beep of 300 msec duration 150msec on 500msec off 2.5sec off

Table 2 Beeper Sound pattern can be changed within factory setup

Class In addition to assigning a single detector to an alarm output, it is possible to assign several detectors to an alarm class. The alarm classes can then be assigned to an alarm output, allowing assignment of several detectors to an output.

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1.2.7.2Alarm system
The alarm system is divided into two parts, the triggers and the relay control. The triggers are used to continuously monitor a selected system variable. When the input value exceeds a preset limit the trigger output goes on. The trigger output can set off three possible actions: An entry in the alarm log can be generated, the beeper can be activated and a relay may be turned on.

Triggers Min/Max Limits Timers/ Filters BEEPER/ LOG

Relays Log/ Message

Input Value

AND

OR

Relay

Input Value

Min/Max Limits

Timers/ Filters

AND

BEEPER/ LOG

OR

Relay

Log/ Message

Input Value

Min/Max Limits

Timers/ Filters

AND

BEEPER/ LOG

OR

Relay

Log/ Message

Figure 1 Alarm system overview

For each trigger there are two timers involved. These are used to filter noisy or quickly changing input values, i.e. an IR sensor used for burglar alarms can be programmed to trigger an alarm only when it has been on for a certain amount of time. The first timer can be used to delay the activation of an alarm. The second timer is used to delay the deactivation of an alarm. Both timers are retriggerable. If the first timer is started for a detector, and the trigger condition goes off before the timer expires, the timer is stopped. The second timer works in a similar way, if the pre-trigger goes off and the timer is enabled the timer is started. If the pretrigger goes back on before the timer expires, the timer is stopped. In addition there is a hysteresis function that is configured using the Min- and MaxVal parameters. This is used to avoid repetitive alarms when monitoring noisy input parameters. The relationship between the timers and the hysteresis functions is depicted below.

MaxVal
MinVal

Batt Current Input

Autoreset mode Pretrigger Detector Out Detector Out Detector Out Detector Out Delay=0 Delay>0 Duration>0 Delay=0 Duration>0 Delay>0
Delay time Duration time is not relevant Duration time

Manual Reset

Manual Reset mode Delay=0 Delay>0

Detector Out Detector Out

Figure 2 Detector timing relationship

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1.2.7.3Define Triggers
The alarm systems output functions use the output flag of each active detector or detector class and route this to the physical output ports, for example the relays. Detector Class is used to make common alarms. Any combination of triggers can be set to class A, B or C. When a relay output is set to an alarm class it will respond to the output of any trigger with the corresponding class. The AND function is used to set trigger conditions so that the trigger will only go on if the ANDed trigger is also ON. Triggers can be ANDed to any level. Three alarm classes can be selected for each trigger: Alarm will cause red alarm diode to be lit both in Winpower Gold and on AEON Gold front panel. The front panel will display an alarm bell symbol Warning will cause the activation of red diode on front panel and yellow diode in Winpower Gold. The front panel will display a flag symbol. Info will not cause illumination of front panel alarm diode while Winpower Gold diode will remain green. The front panel will not display a symbol. Alarm Class is used to log how critical an alarm is. The alarm class will be reflected in the Alarm / Event Log.

1.2.7.4 Alarm Output Configuration


The alarm systems output function uses the output flag of each active detector or detector class and routes this to the physical output ports, i.e. the relays. The mapping of events to output functions is done as shown in the table below. Each output relay can be mapped to up to three sources. This makes an opportunity to use a logical OR function for relays. The NE/ND field means normally energized/normally de-energized. I.e. a battery disconnect contactor might need to disconnect the battery when the Controller unit looses its power supply. Normally de-energized means no alarm, no Energy to the relay coil. A few entries are filled in for illustration purposes. When a relay is used by other functions than the alarm system the relay shall be blocked, so that it is not available for the alarm system, see relays 11 and 12 in example below The log field is used to define if a change in relay status will generate an entry in the alarm log. Relay
Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Relay 6 Relay 7 Relay 8 Relay 9 Relay 10 Relay 11 Relay 12

NE/ND
NE ND ND ND ND ND ND ND ND ND ND ND

Trigger1 Trigger2 Trigger3 Log Message


LowBattery A Class A Class A N N Common Alarm Relay

Table 3 Alarm Relay output setup

Low Voltage Battery Disconnect and Low Voltage Load Disconnect share the relay outputs with the Alarm system. The contactor functions have priority over the alarm system. When a relay output is used by the contactor control, it is not available for the alarm system. Both LVBD and LVLDs relays can be enabled or disabled.
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1.2.8 Low Voltage Disconnect


The equipment is offered with the following options: 1 LVBD (fixed) 1 LVLD (fixed) 3 LVLD (optional)

1.2.8.1 Low Voltage Battery Disconnect (LVBD)


This is battery deep discharge protection. The function monitors the battery voltage during discharge. The battery contactor opens when the battery voltage goes below a specified limit and the reconnect will take place when the battery voltage again reaches a predefined limit after mains has returned.

1.2.8.2 Low Voltage Load Disconnect (LVLD)


This is a similar function as the LVBD, but it controls up to 4 load contactors. This function monitors the battery voltage during discharge. Two parameters control the disconnect function, the disconnect Voltage or a disconnect timer which starts when a mains loss occurs. The Load contactor opens when the battery voltage sinks below a specified limit, or if the discharge timer expires depending on disconnect criteria selected. The disconnect criteria can be selected by Winpower Gold only. Reconnect will take place when the battery voltage again reaches predefined limit. When more than one load contactor is used they have separate voltage and timer limits. For each contactor the polarity, i.e. normally open/closed status, the relay number and enable disable flag can be set.

1.2.9Test Relays
You can use this facility to test operate the alarm relays and the low voltage battery/load disconnect contactors (LVBD and LVLDs), in order to test external equipment connected to the PRS system's outputs.

1.2.10 Configuration of shunt inputs


There are a total of five shunt inputs on Aeon Gold, where one is used as battery shunt input while the remaining four can be configured as load or battery shunts. If the battery shunt is selected the total battery current will be calculated from the sum of the individual currents. The load current is calculated as the system current minus the battery current and is independent of the load shunt measurements. Winpower Gold: The shunt configuration can be edited under the General configuration menu by selecting tick boxes WinPower Gold description Shunt input 1 Shunt input 2 Connection Table description Battery current Spare current Battery Shunt Load Shunt NA
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1 System Functionality Shunt input 3 Shunt input 4 Shunt input 5 Current 1 Current 2 Current 3

A validation is made so that if you try to tick both battery shunt and load shunt for the same input the last choice will be valid while the first tick will be cancelled. The first input is fixed to battery shunt, and it is not possible to change the configuration of this shunt. The total battery current measurement is based on the sum of battery shunt measurements. This total battery current is shown as battery current both in Winpower Gold and on the front panel. The load current is still based on calculation derived from battery current and rectifier current. It is assumed that the load shunts will be installed in load branches and thus only measure parts of the overall load current. The only place where the load shunt currents are displayed is in the input monitor. Note! The shunt configuration does not affect the battery test setup. The battery test will always use the total battery current for all calculations. Note! The shunt configuration is available through Winpower Gold only.

1.2.11 System Control through digital inputs


The AEON Gold is capable of the following control functions through digital inputs. The function will be activated as long as there is a signal present on the digital input. 1) Setting a lower programmable output voltage to protect the batteries. 2) Genset active, which is sequential startup, depending on user configuration. 3) Stop/inhibit battery boost 4) Stop/inhibit battery test 5) Rectifier Current/Power Limitation Note! This function is available through Winpower Gold only.

1.2.12 Rectifier control


The rectifier control is achieved via the following options: CAN Individual control Address software Status information

1.2.13 Master Password


There are 2 sets of passwords in the AEON Gold system, which are stored and validated in the AEON Gold. There are 2 password levels: Service and Factory setup. In addition there is a unique master password based on the AEON Gold serial number. The Master Password will reset all passwords both in AEON Gold and Winpower Gold back to the factory-programmed. Contact your local Eltek supplier for generating this password if needed.
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1.2.14 Voltage settings


A correct setting of the voltage levels is essential for a proper operation of the Aeon Gold control unit. All the voltages are user defined so that the system can be utilized to its optimum. However it is important to know the interaction between the voltages settings before doing any changes. This chapter presents a recommended sequence for the voltage settings. The ranges for all the settings and their default values are described in section 5.6

Function Over voltage protection (OVP) Boost voltage

Ba

Battery float voltage

High temp voltage

Battery table max

18

O V os tte tv P ry ol ta fl o ge at H vo it em lta ge Ba p vo tte lta ry ge Te tab le st m en ax d St vo an db ltag e y vo lta ge LV LD Ba tte LV ry BD ta bl e m in


Menu General configuration, set levels. General configuration, set levels. General configuration, set levels. General configuration, set levels. Battery configuration, Comment This is the voltage level where the rectifier will shut down and stop delivering power. The purpose of the function is to avoid hazardous output voltages. This is the battery boost or battery equalize voltage. The purpose of the function is to reduce recharge time for the batteries and equalize the voltage between individual cells. This voltage should always be higher then the float voltage and lower then the OVP. This is the system voltage at normal operation. The float voltage should be set according to the recommended voltage specified for the batteries installed in the system. This is the battery protection voltage which can be activated through a digital input. The purpose of the function is to limit the charge current if an emergency accures. This voltage should be lower then the float voltage. The battery tables are specified for several voltages. This is the highest specified voltage for the selected
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1 System Functionality battery setup, define new battery Battery configuration, battery test. General configuration, set levels. General configuration, set levels. General configuration, set levels. Battery configuration, battery setup, define new battery battery. This is the termination criteria for the battery test. This voltage must be within the limits of the battery tables specified and always higher than battery standby voltage and the LVD levels. This is the rectifier output voltage during a battery test. The level must be lower then the Test end voltage for the battery test to terminate. This is the disconnect level for the Low voltage load disconnect. This value must be lower then the Test end voltage to prevent load disconnect during a battery test. This is the disconnect level for the Low voltage battery disconnect. This value must be lower then the Test end voltage to prevent battery disconnect during a battery test. The battery tables are specified for several voltages. This is the lowest specified voltage for the selected battery.

Test end voltage

Battery Standby voltage LVLD

LVBD

Battery table min

1.2.15 Remote management


The remote management is achieved via the following options: SNMP Winpower Gold through Ethernet WebPower Modem

1.2.16 Language options


Always set the service switch on the Aeon Gold controller to the ON position (the red LED is then illuminated), before you select a change of language. After the language change is activated, set the service switch back to the OFF position (the red LED goes OFF). Notice that activating a change of language with the service switch OFF will cause all settings to revert to factory default. The following languages are available: Norwegian English German Polish French Chinese Dutch

Red LED is lit, when the Service Switch is in ON position ON position Reset button OFF position

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1.2.17 Efficiency management


1.2.17.1 General
Efficiency management serves two purposes: 1) Turn off unnecessary rectifiers in accordance to redundancy policy. 2) Cycle the remaining rectifiers to balance the runtime between the rectifiers. These are described in detail below.

1.2.17.2 Power saving


The power saving algorithm optimises the overall system efficiency by turning on or off rectifiers, so that the remaining rectifiers operates within a specified output power window. Typically this means avoiding low output load conditions. Turning off rectifiers The system starts up with all rectifiers on. After a programmable delay time, the first rectifier will be turned off, if the average load is below the power limit set by the selected policy. Then a new cycle of average calculation is started, and the next rectifier is turned off if the rules permit it. Turning on Rectifiers The average load is monitored continuously. If the system load increases above the high load limit, the number of operating rectifiers is increased by the number needed to get the average load within limits. Safety There are certain system events that may halt the efficiency manager. These events will immediately turn on all rectifiers and set the efficiency manager in idle mode. One or more rectifiers stops communicating One or more rectifiers reappears after lost communication. The number of rectifiers installed is changed. System Voltages is changed Battery Boost or Test is started Sequential startup will suppress efficiency management

1.2.17.3 Redundancy policy


N+1 Redundancy There are always sufficient margins in this mode so that one rectifier can be lost without affecting the system operation. This table shows the power limits used to switch in and out rectifiers in N+1 redundancy mode.
LOW POWER LIMIT HIGH POWER LIMIT MINIMUM NUM OF RECTIFIERS 1100W 1800W 2

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Below is the switching pattern of the number of rectifiers versus total system load depicted.
Power management @ N+1 redundancy
12 10 8 6 4 2 0
0 50 100 150 Increasing load Reducing load System Current (A) 200 250 300 350 400 # Rectifiers

Table 4 Power management at N+1 redundancy

1.2.17.4 No redundancy
Here the full power capacity of the rectifiers is utilized. There is no spare capacity to handle a single rectifier failure.
LOW POWER LIMIT HIGH POWER LIMIT MINIMUM NUM OF RECTIFIERS 1600W 3750W 1

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1 System Functionality Below is the switching pattern of the number of rectifiers versus total system load depicted.
Power management @ No redundancy
7 6 5
# Rectifiers

4 3 2 1 0
0 50 100 150 200 250 300 350 400

Increasing load Reducing load

System Current (A)

Table 5 Power management at no redundancy

1.2.17.5 Runtime balancing


When efficiency management has turned off one or more rectifiers, the runtime balancing will start. As seen in the example below Rectifiers ID 1 and 2 is on, and all others are off. The Runtime balancing or Shuffle cycle begins with turning on one additional rectifier as in stage 2 below. After a 20sec delay to ensure power delivery from the new rectifier, the lowest ID is turned off as in stage 3. Then the Shuffle process goes into sleep mode for the duration set by the ShuffleTime in the menu. When the sleep duration is over the process will repeat itself with the next rectifier and so on. Shuffle Time This is the time spent waiting before replacing a rectifier in Shuffle mode when doing runtime balancing. Currently the range is 1 to 240 Hours

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Figure 3 Principle chart for rectifier shuffling

1.2.17.6 Operating modes


There are 2 operating modes, Normal operation and Test mode. The timing parameters used in normal operation are far too long for testing and demo purposes. The test mode still uses the parameters set in the menus, but uses minutes instead of hours, and seconds instead of minutes for the timing parameters given. Turnoff Delay Time This is the time used for average rectifier current calculation before turning off a rectifier. Note that there is always added approximately 40 seconds to this due to properties of the internal software design. Currently the range is 1 to 600 Minutes.

1.2.18 DC/DC converter control


The Aeon Gold Control Unit supervises the DC/DC converters (art. No 241114.500). It monitors the presence and statuses of the DC/DCs, and gives alarms when internal alarms and statuses change. This information is available on the front panels main screen on the Control Unit, as individual views in the user menu and on the Winpower Gold main screen. The maximum number of converters connected to the AEON Gold Control Unit is 32. The DC/DC converter control is achieved via the following options: CAN Individual control Address software Status information
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1.3 AEON Gold Hardware Description


The AEON Gold hardware is described on detail in Installation and Commissioning for AEON 4000 (Art. No. 356940.033)

1.4 Rectifier Features


1.4.1System and Stand-alone operation
The SMPS 4000 rectifier is a highly advanced rectifier designed for both stand-alone use and system operation. Front display and press buttons make it possible to control all important parameters from the unit front. In addition, LED's provide information regarding alarm and communication status. Digital communication by CAN bus makes it possible to install SMPS 4000 in large rectifier systems, where the rectifiers are controlled by the AEON Gold control and monitoring unit.

1.4.2General features
SMPS 4000 offers features such as: Front display and keypad for stand-alone control and monitoring. All relevant information regarding rectifier status will, at all times, be accessible from the rectifier front Wide input voltage range, ranging from 100 VAC to 300 VAC. Power limitations will be activated below 185 VAC. Automatic shutdown at input voltages above 300 VAC. The power supply is selfprotected against 400 VAC, which can occur if neutral is lost or disconnected Protection against surges, caused by lightning or switching transients Power factor close to unity and low THD due to PFC on the input High efficiency, above 91 % in 48Vand 60V systems Temperature monitoring and automatic power limitation and shutdown at high internal temperatures For the 48V and 60V versions, constant power charging during battery recharge True hot plug-in by soft recharge of output capacitors

1.4.3Fan operation.
The fans are 24V brushless DC - fans supplied from the auxiliary power supply. To increase the lifetime of the fans the speed is regulated depending on the heat sink temperature and the power output. In addition to increased lifetime this gives low audible noise levels at light load. The relationship between the highest heat sink temperature, fan speed and power output is given below. The fans are regulated between off, half and full speed.

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Power Heat sink Temperature <40C(104F) 40 - 70C (104 - 158F) > 70C (158F)

< 25%

25 - 75%

> 75%

Off Half speed Full speed

Half speed Half speed Full speed

Full speed Full speed Full speed

In case of fan failure the output power limit will be reduced when the temperature reaches 95C (203F). Eventually, at 105C (221F), the module shuts down.

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2 Operation from AEON Gold


2.1 The Front Panel
The AEON Gold control panel comprises a keypad, an LCD display, a green LED (indicating that the system is ON) and a red LED (indicating that the system is in alarm mode). Green LED Power

Graphical Display

Keypad

Red LED Alarm

3 Keys for menu scroll


Figure 4 AEON Gold front panel

10 Numerical keys 1 key for scroll back

The rectifier system is controlled from the AEON Gold control and monitoring unit by means of display menus and sub-menus. The keypad on the front panel of the control and monitoring unit is divided in two groups: A vertical row of 3 keys commands access to the display menus and sub-menus A block of 11 keys comprising: o 10 keys with digits from 0 9 o A key marked CL, used for exiting menus

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2.1.1Menu design
The AEON Gold user-interface is a graphical LCD display and a 14 key keypad enabling the user to control and configure the power supply system. Initially, and when no keys are entered by the user, the system status is presented at the display. AC and DC Voltage, current, AEON Gold status and date/time are displayed and updated every second.

Figure 5 AEON Gold LCD display main screen

The first Windows look-alike menu is displayed when the user enters a keyboard key. From this menu the user uses the arrow up, arrow down, escape and carriage return keys to move between the menus, the sub-menus and the parameter windows. The LCD display is divided vertically into the menu hierarchy at the left side, and the parameter window uses the whole screen when displayed.

Figure 6 AEON Gold Service Setup screen

The menu is organised hierarchically, and the maximum number of levels is four. The menu top-level contains three choices: "User", "Service" and "Factory". The Service and Factory tree are protected by passwords, one password for each. The AEON Gold display and keypad handles input of numbers only, not letters. Screens containing text string parameters are controlled by Winpower Gold.

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2.2 Control and Monitoring Unit Display


When the system is switched ON the display will briefly show "AEON Gold booting, please wait.". The following display will subsequently appear: Battery current measured as the sum of the battery shunt readings Load current: Calculated as total rectifier current minus battery current

Battery temperature. Require temperature probe in the system.

System DC voltage.

Alarm indication.

Manual Interval Auto

Discharging Charging Floating Guard time

AC voltage for all three phases

Figure 7 AEON Gold Display

2.3 User Setup, Service Setup and Factory Setup


To facilitate system operation the available menu options have been divided into three groups or three main menus (User Setup, Service Setup and Factory Setup) and these are built up hierarchically. The available Factory options are situated in the attachment part of the guide. While the User Setup menus are available to all users, the Service Setup and Factory Setup menus are password-protected and can only be accessed by authorised personnel.

The password for Service Setup is factory-programmed to "1234". The password for Factory Setup is factory-programmed to 4321.

The menu is built up hierarchically, and the maximum number of levels is four. The AEON Gold display and keypad handles input of numbers only, not letters. Screens containing text string parameters are handled from Winpower Gold. To increase or decrease numbers from the AEON Gold keypad, the user have to use the arrow-up or arrow-down.

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To access and navigate inside the User Setup, Service Setup or Factory Setup menus, you must use the following keys on the AEON Gold front panel: Navigating keys Key
CL

Comments

Scroll up or down in the menu to select desired function.

Enter or confirm the selected function

Cancel, escape or move to previous page. Stops beeper alarm

1-9

Numerical keys

WARNING: The Master Password will reset all passwords both in AEON Gold and Winpower Gold back to the factory-programmed ones.

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2.3.1Available User Options


The following User Setup menus are available to all users via the AEON Gold front keypad: Alarm Info Alarm Reset Rectifier Info DC/DC info Voltage Info System Info Service Info Battery Info Input Monitor Master Password

Figure 8 AEON Gold user setup menu

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Figure 9 AEON Gold user setup menu level 1

To navigate inside the User Setup menu, use the keypad on the AEON Gold front panel, ref. description in chapter 2.3.

2.3.1.1Alarm Info
Alarm info includes the following menus: Active alarms Show alarm log All the alarms currently activated will be shown in the Active alarms display. The control and monitoring unit stores all system events chronologically in a message buffer. By means of this menu option, you can browse through the buffer's alarm messages in the Show alarm log. The messages are presented on the display, 6 messages at a time. The last message will be displayed first. The Alarm Event Log is stored in non-volatile memory and contains up to 256 entries, when full oldest messages will be overwritten.

2.3.1.2Alarm Reset
All alarms in the system are automatically reset as default when the cause of the alarm is removed, however, it is possible to change the setting to manually reset so that the alarm will continue even when the cause of the alarm has been removed. This type of alarm will then be reset when Alarm Reset is performed. Alarms still active after resetting will be reported again. The Beeper also stops for all alarms with this function.

2.3.1.3Rectifier Info
AEON Gold receives detailed information from each rectifier in the system. The dynamic information is updated with 5 seconds interval. The information is presented in the following menus: Rectifier Info o Rectifier identity/Address o Rectifier DC Current o Temperature (the internal heatsink temperature) o Alarms (indicates any active alarms inside the rectifier [Yes/No] ) o AC Volt (displays the measured AC voltage)

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2 Operation from AEON Gold o ON/OFF status o Connection o Current limit status (Yes = current limit No = Normal operation)

Figure 10 Rectifier info menu

Rectifier mileage o Rectifier identity / Address o Rectifier serial number o Operating hours (Hours when the rectifier has been on) o Age factor (time X temperature factor) o Total kWh (DC current X DC voltage X hours on)

Figure 11 Rectifier mileage menu

Rectifier peaks o Rectifier identity/address o Rectifier serial number o Rectifier peak AC voltage o Rectifier peak DC current o Rectifier peak DC voltage o Rectifier peak temperature on boost side of heatsink (C) o Rectifier peak temperature on output heatsink (C)

Figure 12 Rectifier peak value menu

Rectifier alarms

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2 Operation from AEON Gold o o o o o o o o o o Rectifier identity/address Rectifier ON/OFF status Rectifier current limit alarm Rectifier low AC voltage Rectifier high AC voltage Rectifier fuse fail Rectifier high internal temperature Rectifier over voltage protection alarm Rectifier common alarm (OVP, fuse, temp probe and fan) Rectifier fan fail alarm

Figure 13 Rectifier alarm status menu

Rectifier SW version o Software identity/address o Serial number o Software Version o Software part number Number of units o Number of rectifiers (SMPS) missing o Number of rectifiers (SMPS) installed o Number of rectifiers (SMPS) communicating o Number of rectifiers (SMPS) switched on

Note: Rectifier Info is a snapshot of the status at the moment the key is pressed. To update the information, press CL and then enter the Rectifier Info menu again.

2.3.1.4DC/DC Info
DC/DC Info gives an overview over the DC/DC converters connected to the AEON Gold Control Unit. If there are no DC/DC converters connected to the system, there will be no information displayed in this menu. DC/DC Info: o Output voltage o Output current o Temperature o Fan speed in rotations per minute o Alarm status o ON/OFF status

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2 Operation from AEON Gold o Limit (YES when the current limit is reached)

Figure 14 DC/DC converter info menu

Mileage o DC/DC converter identification/address o DC/DC converter serial number o Operation hours (Hours when the DC/DC converter has been on) o Total kWh (DC current X DC voltage X hours on)

Figure 15 DC/DC converter mileage menu

Peak values o DC/DC converters identification/address o DC/DC converters serial number o DC/DC converters peak voltage o DC/DC converters peak current o DC/DC converters ambient temperature o DC/DC converters temperature on the primary side o DC/DC converters temperature on the secondary side

Figure 16 DC/DC converter peak menu

DC/DC Alarms

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2 Operation from AEON Gold o o o o o o o o o DC/DC converters identification/address Alarm status (ON/OFF) DC/DC converters Current limit alarm Input alarm (ON when the input values are out of their range) High temperature derate High temperature warning DC/DC converters over voltage protection alarm DC/DC converters common alarm (OVP, fuse, temp probe and fan) Fan alarm ON/OFF status

Figure 17 DC/DC converter alarm menu

DC/DC converters SW version o Software identity/address o Software type o Serial number o Software Version o Software part number Number of units o Number of DC/DC converters switched on o Number of DC/DC converters installed o Number of DC/DC converters communicating

2.3.1.5Voltage Info
Voltage Info displays the following information:

Figure 18 AEON Gold user setup voltage information

Rectifier trip voltage is the over voltage protection level for the rectifiers. Battery voltage is the system float voltage Boost voltage is the voltage the controller set the rectifiers to during boost operation

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2 Operation from AEON Gold Battery standby voltage is the voltage the rectifies are set to during a battery test Battery protection voltage is the voltage the controller sets out if the battery protection mode is activated. (The battery protection mode can be activated through a digital input.)

Battery voltage indicates the output voltage from the rectifiers during normal operation. Boost voltage indicates the output voltage during fast battery recharge. Increased charge voltage will reduce the required recharge time. Battery standby voltage indicates the rectifier output voltage during battery testing. This voltage will be kept lower than the battery test end voltage and the rectifier will serve as backup for the batteries. Battery protection voltage is a feature where the purpose is to lower the charge voltage if, for example the battery temperature goes above a certain value. This is not the same feature as temperature compensated charging. The temperature is measured by an external device that sends a signal to a digital input. Contact closure between the inputs on the digital input will cause the voltage to go from normal charge voltage to the value set as battery protection voltage. This mode will be kept until the contact closure on the digital input is removed. Battery protection is disabled as default, but can be enabled in Winpower Gold. Rectifier trip voltage indicates the over voltage shutdown level of the rectifiers. The default setting is 74,38Vdc for 60V rectifiers, 59,5Vdc for 48V rectifiers and 29,75Vdc for 24V rectifiers. The setting can be changed from the service menu. Please note that only rectifiers having software version 1.20 or newer for 60V dc, 1.10 or newer for 48Vdc and 1.10 or newer for 24Vdc will be able to adjust the shutdown level upon a command from AEON Gold. The other rectifiers will ignore the message and keep to the default setting.

2.3.1.6System Info
System Info displays the following information: Customer Location System serial number Art. Number (part number) Software version pComm protocol revision

2.3.1.7Service Info
Service Info displays the following information: Serviced by Message 1 Message 2 Battery type Installation date

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2.3.1.8Battery Info
Battery Info displays the following menus: Battery info Battery test info Battery test log Battery boost info Symmetry Monitor Symmetry Monitor: This menu allows the user to enable or disable the symmetry function. Symmetry Monitor includes the following information: Mode o Continuous/Discharge Status o Disabled/Enabled System Voltage Blocks o 1-5 Voltage Delta Status o Warning/Alarm Symmetry monitoring enables you to detect if one or several cells go into short- or open circuit. By measuring the difference in voltage between 12V or 24V blocks it is possible to detect instantly single cell failure. The voltage distribution throughout the battery cells depend on the operation mode and therefore we offer symmetry monitoring where the alarm limits are depending on whether the battery is being charged, discharged or in float.

All settings should be selectable from Winpower Gold (see chapter 4.8.2.6), however activation and deactivation can be done from the AEON Gold keypad Mode: You can select the symmetry alarm functionality to be active continuously or only at discharge. Status: Status indicates if the symmetry alarm functionality is disabled or enabled. System Voltage: This is the actual voltage of the system, and the main reference for the symmetry functionality.

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2 Operation from AEON Gold Blocks: In Winpower Gold it is possible to choose between two options: 1) Measuring the midpoint on 1-4 banks where the number of strings is specified. 2) Measuring blocks, 12 V blocks with three points for measuring on the 48 V systems. Delta: This is the value between the measured voltage over a block and the calculated one based on the rectifier voltage. Status: There are two different warning levels in the Symmetry Monitor: warning and alarm.

2.3.1.9Input Monitor
Monitors all analogue and digital inputs. Digital inputs:

Figure 19 AEON Gold digital monitor

Battery fuse input Load fuse input 1-2 Digital input 1-7

Displays the status of the input, open or closed. Displays the status of the input, open or closed. Displays the status of the input, open or closed.

Analog inputs:

Figure 20 Aeon Gold analogue input monitor

Battery voltage Voltage 1-4 Battery temperature

Spare temperature

Displays the measured voltage for the battery voltage input Displays the measured voltage for voltage inputs 1 to 4 Displays the value of the battery temperature input. This is the value used for battery compensated charging. Displays the value of the spare temperature input

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2 Operation from AEON Gold Battery current shunt Spare current Current 1-3 Displays the measured current for the battery shunt input. Displays the measured current for the Spare shunt input. The value is independent of the shunt configuration, battery or load. Displays the measured current for the current inputs 1 to 3. The value is independent of the shunt configuration, battery or load.

2.3.1.10 Master Password


Master Password displays the following menu: Reset Password o Serial Number Master Password is used if you want to reset the Service- and Factory Setup Password to the factory-programmed password. Master Password is a unique number based on the serial number shown in this menu. Your local Eltek supplier will generate this password upon request. For further information regarding this, see chapter 1.2.13 and 2.3.1.

The Master Password is a unique number based on the AEON Gold serial number. Contact your local Eltek supplier for generating this password if needed.

2.3.2Available Service Options


Service Setup comprises sub-menus available to authorised personnel only (passwordprotected access).

The password for Service Setup is factory-programmed to 1234.

The following options are available: Stop Test / Boost System ON / OFF Rectifier Control DC/DC control Voltage Configuration System Configuration Battery Configuration LVD Configuration Alarm Configuration Communication
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Rect. Ident. Show SMPS Id Show SMPS Pos. Rect. Install. Manual Rect. Inst. Initial Rectinst Rect. Deinstall. Rect. Curr. Limit Select Type & Value Select Unit Select Unit Select Unit Start Select Unit

Stop Test/Boost System ON/OFF Rectifier Control DCDC Control

Stop Test/Boost

All Rectifiers ON/OFF

DCDC usage ID Refresh Identity unit

Enable / Disable Number of units Select Unit Battery Temperature Value

Voltage Config

Battery Voltage Boost Voltage Batt. Standby V Batt. Protect V Rect. Trip Volt

Value Value Value Value Value

Spare Temperature Battery Current Spare Current Current Input 1 Current Input 2

Calibration Zero

High Cal Value Zero Value

System Config

Calibration

Temperature Calib. Current Calib. Voltage Calib.

Current Input 3 Battery Voltage Voltage Input 1 Voltage Input 2 Voltage Input 3 Voltage Input 4

Set Time/Date

Time Date

Value Value

Efficiency Management Erase Alarm Log Regulation Mode Test Relays Change Password Select Relay 1-12 Value Enable/Disable Limit Current Battery Curr. Lim Man. Test Start Interv. Batt. Test Battery Test Auto Test Man. Boost Start Activate/Deactivate Start Start Activate/Deactivate Duration Guard Time EndVoltage Value Value Value Enable/Disable Value Toggle Relay Erase Log Temp Comp Votage Regulated Unregulated

ON/OFF Redundancy Mode Shufflerate Turnoffdelay

Select Select Select Mode Value Value

Battery Config

Battery Type

Value

Interval Boost Battery Boost Auto Boost Symmetry

Activate/Deactivate

Duration Guard Time EndVoltage

Value LVBD Value Value LVD1 Reconnect Voltage Value Value Value LVD2 Disconnect Voltage LVD3 Disconnect Delay Time LVD4

Enable/Disable Enable/Disable

LVD Config Alarm Config

LVD Config Alarm Config

Select Fixed Trigger

Use Max Voltage

Enable/Disable Enable/Disable Enable/Disable

SerialPort Setup

Select COM 0-2 Select Port

Protocol Baudrate Format

Select Select Select

Min Voltage

Communication
Modem Setup

Figure 21 Aeon Gold service setup menu

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Figure 22 Aeon Gold service setup menu level 1

To navigate inside the Service Setup menu use the keypad on the AEON Gold front panel, see also description in chapter 2.3.

2.3.2.1Stop Test / Boost


Stop Test/Boost displays the following information: Stop Test/Boost This option stops the battery test, or the battery boost, according to whichever is activated.

2.3.2.2System ON / OFF
System ON/OFF displays the following information: System ON/OFF This option switches all rectifiers ON or OFF.

2.3.2.3Rectifier Control
Rectifier Control includes the following menus: Rectifier Installation o Manual rectifier installation o Initial rectifier installation o Rectifier deinstall Rectifier Identification o Show SMPS ID o Show SMPS position Rectifier Current/Power Limitation When you insert a new rectifier in a systems power rack for the first time and turn ON its AC breaker the Aeon Gold controller automatically assigns the lowest available ID number to the rectifier. This Automatic Rectifier ID Assignment Function does not require any user intervention. The controller stores the serial number and ID number of every logically installed rectifier. The Manual rectifier installation command may still be used when new rectifiers are installed in a system, or when you want to assign a specific ID# to a rectifier. However, in most cases this will not be necessary, as the Automatic Rectifier ID Assignment Function will assign the lowest available ID number automatically. The Initial rectifier installation command enables you to perform a controlled and automatic ID assignment of rectifiers, as follows: 1. Select the Initial rectifier installation command
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2 Operation from AEON Gold 2. Turn ON the AC breaker of the rectifier that you want to give ID#01 3. Wait for the rectifiers yellow LED to illuminate (the controller has ID assigned the rectifier) Repeat steps 2 and 3 for the rectifier you want to give ID#02, and continue repeating steps 2 and 3 until all rectifiers are ID assigned by the controller. The initial rectifier installation is only to be used when commissioning a new system, or during first time system start-up. Note that when entering this function the rectifier ID table in AEON gold is erased, and the process of reassigning all rectifiers ID's must be completed. You must always use the Rectifier deinstall command to erase from the controllers memory the ID and serial numbers of rectifiers that you physically remove from the system. When you want to replace a malfunctioning rectifier with a new one, you must first turn OFF the AC breaker of the failing rectifier, then erase its ID# from the controllers memory (using the Rectifier deinstall command), then swap the rectifiers and finally turn ON the AC breaker of the new rectifier. The controller automatically assigns the same ID# to the new rectifier. To display the ID number assigned to rectifier, select the Show SMPS ID command, then press a key on the rectifier, and the rectifiers ID number will appear on the display. To find the physical location of a rectifier with known ID#, select the Show SMPS position command, then type the rectifiers ID#, and finally press key. The yellow Communications LED on the rectifier will then start to flash. The Rectifier Current/Power Limit function works in three different ways or types: Percentage Limitation Power Limitation Current Limitation If Percentage Limitation is selected, the rectifiers total output power upper limit will be the selected percentage of the total rated power. If the Power or Current Limitation is selected, the rectifiers total output power upper limit will be a selected constant value, W or A. Due to system voltage variance, the Current Limitation type offers the lowest accuracy. Allow some tolerance when selecting current limitation. The Rectifier Current/Power Limit function has to be configured and enabled. You can configure it by selecting the limitation type and its respective value directly from AeonGold via the controllers front panel; refer to Service software menu, page 39 or from a PC running the WinPower Gold application, read page 97. The Rectifier Current/Power Limit function must also be enabled or triggered by external digital inputs, which can only be set from WinPower Gold, read page 81.

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2.3.2.4DC/DC control
DC/DC usage o ENABLE/DISABLE DC/DC converter usage ID refresh o Gives the DC/DC converters new ID numbers in increasing order. Identify unit o This function makes the DC/DC converter that is chosen signal so that it is possible to identify it.

2.3.2.5Voltage Configuration
Voltage Configuration includes the following menus: Battery voltage Boost voltage Battery standby voltage Battery protection voltage Rectifier trip voltage Boost voltage is default set to 56 VDC, while the Battery voltage is default set to 2.23 v/cell, corresponding to 53.5 VDC in a 48 VDC system with 24 cells. Battery standby voltage indicates the rectifier output voltage, during battery discharge test. The default value is 43.20 VDC in 48 VDC systems. Always set the Battery standby voltage lower than the battery test end voltage. Battery test end voltage must be higher than LVBD or LVLDs disconnect voltage.

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2 Operation from AEON Gold Battery protection voltage is a voltage level used to avoid high temperatures in the batteries. When a high temperature is detected an external device sends a signal to the AEON Gold through a digital input, which then causes the rectifier voltage to be reduced down to battery protection voltage. Rectifier trip voltage is the over voltage shutdown level for the rectifier outputs. With the latest rectifier SW versions it is possible to send a command to the rectifiers to change the shutdown level. Older rectifiers will ignore the command and keep to the default level.

Default values are shown in chapter 5.6.

2.3.2.6System Configuration
System Configuration includes the following menus: Calibration o Current calibration Battery Current Spare Current Current Input 1 Current Input 2 Current Input 3 o Voltage calibration Battery Voltage Voltage Input 1 Voltage Input 2 Voltage Input 3 Voltage Input 4 o Temperature calibration Battery Temperature Spare Temperature Set time/date o Set time o Set date Efficiency management o Efficiency management ON/OFF status o Redundancy status (NONE/N+1) o Mode status (NORMAL/TEST) o Shuffle rate value (1-240 hrs) o Turnoff delay time value (1-600 minutes) Erase alarm log Regulation mode o No regulation o Volt. Regulation o Temp. Regulation Test relays o Relay 1-12 Change Password Current calibration:

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Figure 23 Current calibration menu

The AEON Gold Control Unit incorporates 5 current inputs. One is dedicated for battery current while the remainder can monitor, for example, load currents. These 5 channels will be calibrated before leaving the factory. Under normal conditions it is only necessary to perform a one-point calibration. During charging, the battery current is defined as positive (+) while, during discharging, it is defined as negative (-). In order to obtain an acceptable accuracy of the current measurement, the current must be calibrated at one zero level point and one high level point. Since load supply must be maintained the zero calibration current should be positive, for example the current should be measured during float charging while the rectifiers supply both load and battery. The high calibration point should be measured during discharging, while the rectifiers are turned off. To obtain acceptable accuracy, the high calibration point current should be at least 30 % of the shunt current capacity.

During normal operation, Battery Current calibration should only be performed as a 1 -point calibration

During a calibration procedure it is easy to check if the calibration is correct, by use of Input Monitor see chapter 0.

Figure 24 Selection of high current point

To calibrate the Battery Current, Spare Current and Current Input 1-3 during normal operation, use 1-point calibration: During normal operation, simulate the maximum current with a current calibrator. Enter the correct current for the High Calibration Point in Amps Confirm High Calibration Point

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Figure 25 Calibration of high current point

To calibrate the Battery Current as a 2-point calibration if needed: The system must operate normally. Confirm Zero point in the menu, when the current is 0 ampere. Ensure that you have a stable load current. Turn the rectifiers off. When the batteries supply the load, measure the discharge current with a clip-on ammeter. Enter the measured current for the High Calibration Point in Amps Confirm High Calibration Point Voltage calibration:

Figure 26 Current calibration menu

The AEON Gold Control Unit incorporates 5 voltage outputs. One is dedicated for the battery voltage while the remainder can monitor symmetry signals or for example external signals.

During normal operation, Battery Voltage calibration should only be performed as a 1-point calibration

Battery voltage calibration: Calibration of the output voltage needs only 1-point calibration (at working voltage). The output voltage should be measured at the load terminals, and the value entered in AEON Gold. Enter the Output Voltage in Volts, a value between 10.00 and 60.00. Confirm Output Voltage Voltage Input 1-4 calibration: These 4 channels will be calibrated before leaving the factory. During normal conditions it is only necessary to perform a 1-point calibration.

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During normal operation, use a multi meter and the battery voltage to read the values or simulate maximum voltage with a DC power supply. Enter the correct voltage for the High Calibration Point in Volts, a value between 10.00 and 60.00. Confirm Output Voltage

Temperature calibration:

Figure 27 Temperature calibration menu

The AEON Gold Control Unit incorporates 2 temperature inputs. One is dedicated for the battery temperature and spare temperature can monitor, for example, room temperature.

During normal operation, Battery Temperature calibration should only be performed as a 1-point calibration

Battery Temperature and Spare Temperature calibration: Calibration of temperatures needs only 1-point calibration. The calibration must not be performed without the temperature probe installed or a temperature simulator connected. Calibration shall be performed under normal temperature conditions, i.e. 20 30 C, using a thermometer in the battery room or a temperature simulator. Enter the correct temperature for the High Calibration Point in C Select Accept Set Time: The time can be set either from the front panel or from Winpower Gold. To set the time from the front panel, use the numeric keys (HH:MM:SS). Set Date: The date can be set either from the front panel or from Winpower Gold. To set the date from the front panel, use the numeric keys (YYYY/MM/DD). Erase Alarm Log: The Erase Alarm Log will be deleted when using this command, followed by confirm. Regulation mode: The following options are available: Output voltage control
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2 Operation from AEON Gold o Using output voltage regulation means that the output voltage will be constant, irrespective of load or temperature condition. Temperature compensation o Temperature compensation allows you to regulate the charge voltage with respect to the temperature. The advantage is that the batteries will be working under optimum operating conditions, thus optimising performance and lifetime. Default rectifier voltage o Default rectifier voltage indicates that the control unit does not have feedback control of the rectifier output voltage.

Test relays:

Figure 28 Test relay menu

You can use this facility to test operate the alarm relays, the LVBD and the LVLD contactors (LVBD and LVLD 1-4), in order to test external equipment connected to the PRS system's outputs.

Do not test the LVBD or LVLD contactors if the battery current or load supply cannot be interrupted.

When the AEON Gold is configured with 1 LVBD and/or 1 to 4 LVLD contactors, these occupy relays in the alarm system. These relays are blocked for normal functions in the alarm system. When a relay has been activated for a relay test, the relay will go back to its original position within 45 sec. or when leaving the test relay screen. Change Password: Change Password allows you to change the default service password to a made up one. This password will be reset back to factory-programmed if use of Master Password, see chapter 0.

2.3.2.7Battery Config.
Battery Configuration includes the following menus: Battery type o Select relevant battery type Battery current limit

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2 Operation from AEON Gold Manual test start o Start/Stop test Interval battery test o Activate/Deactivate Battery test o Duration o Guard time Manual Boost start o Start/Stop boost Interval boost o Activate/Deactivate Battery Boost o Duration o Guard time Auto Boost Symmetry o Enable/Disable

Battery type: AEON Gold has integrated information on a specific number of batteries. This information is used during battery test, to calculate the capacity of the batteries. This menu allows the user to select one of the pre-defined batteries or the user defined battery. Use to select battery and to confirm.

Figure 29 Battery type selection menu

Battery current limit: To ensure that the battery recharge current does not exceed the recommended value given by the battery manufacturer, it is possible to enter a maximum value. Battery current limitation will contribute to maintaining maximum battery lifetime. This allows the user to set the current limit value and activate or de-activate this function.

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Figure 30 Battery current limit setting.

Manual test start: In this menu you can start or stop a manual battery test. Interval battery test: In this menu you can activate or deactivate an Interval battery test. A regular battery test will give you the opportunity to ensure that the capacity is sufficient. By entering the intervals, you can for example test the batteries once or twice a year. If a mains failure occurs just before an interval test should start, the test will be postponed with the same number of days as the guard time is set to. Battery test: When starting a battery test, the test will operate until the termination criteria is reached or maximum duration is reached. Guard time is a parameter used to avoid testing a battery just after a mains interruption. This menu allows the user to change the duration and the guard time. Manual Boost start: In this menu you can start or stop a manual boost. Interval Boost: In this menu you can activate or deactivate a manual boost.

Battery Boost: If a reduction in recharge time is required, starting a boost will increase the charge voltage and current. The normal boost voltage is 56 VDC on a 48 VDC system. Boost can be started manually, at intervals or automatically, after a mains interruption. This menu allows the user to change the maximum duration and the guard time for the boost function. The following conditions can interrupt boost charging: One of the predefined settings in the boost menu is reached Boost charging is interrupted manually Auto Boost:
Activates and de-activates the auto boost function.

2.3.2.8LVD Configuration
It is possible to configure the contactor control outputs from the front panel of AEON Gold. The following parameters are available in the menu:

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2 Operation from AEON Gold Select LVD, choose among LVBD, LVLD1, LVLD2, LVLD3 and LVLD4 Disconnect Voltage, voltage level for disconnect, default set to 43 Vdc in 48V systems Reconnect Voltage, voltage level for reconnect, default set to 45.5 dc in 48V systems Disconnect Delay, time for disconnection after mains failure. Default set to 0 (deactivated)

2.3.2.9Alarm Configuration
It is possible to set up the 11 pre- configured alarms from the keypad. The following parameters are available in the menu: Select trigger: Choose among high battery voltage, low battery voltage, mains fault, etc. Max. Value: For voltage and temperature settings, represents the upper limit of the hysteresis. For instance Max. value set to 57V for High Battery Voltage Alarm means that 57 is the voltage where the alarm is turned on. Min. Value: For voltage and temperature settings, represents the lower limit of the hysteresis. For instance Min. value set to 50V for Low Battery Voltage Alarm means that 50 represents the voltage where the alarm is turned on. Value: Replaces max. value and min. value for boolean triggers like mains alarm or load fuse alarm. Value is either true or false and corresponds to 1 and 0 respectively in the Winpower Gold trigger setup. Use: By this parameter you can either enable or disable the alarm.
Any user- configurable alarm needs to be set up and changed in Winpower Gold

2.3.2.10 Communication
Communication includes the following menu: Serial Port Setup o Com 0 (Port 0) o Com 1 (Port 1) o Com 2 (Port 2) Modem Port Setup In the serial port setup it is possible to choose the protocol setting for all three serial ports. The protocols currently available are COMLI, PCOMM , MODBUS, TERMINAL and CSCP. Closed indicates that the serial port is not in use. Please note that the communication port used for Winpower Gold communication must have PCOMM- protocol activated. As default port 1 (COM1) is used for Winpower Gold connection. In the modem port setup it is possible to choose which ports are used for modem communication. As default port 2 (COM2) is chosen. The modem port needs to have pcommprotocol activated In chapter 5.7 and 5.8, you will find default values for all three communications ports and available communication protocols respectively

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2.3.3Available Factory Options


The factory options can change your system dramatically, and should be used by trained personnel only. Therefore, the factory options have been put in the Attachments.

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3 SMPS 4000 Stand-alone operation


In system operation the rectifier menus can only be scrolled. The rectifier is in stand-alone mode, only when the communication LED is not lit.

3.1 Front Description


3.1.1Keypad
The SMPS 4000 has three keys for calibration, monitoring and control during stand-alone operation, as follows:

To scroll down menus and for adjustments during calibration, voltage adjustment, address settings etc. To scroll up menus and for adjustments during calibration, voltage adjustment, address settings etc. To confirm settings and return to previous menu

Figure 31 Front display and buttons for SMPS 4000

By pressing all 3 buttons at the same time the rectifier will be restarted. The rectifier will be turned OFF for approximately 20 seconds.

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3.1.2Display information
The rectifier display is shown in Figure 31, a 4-digit LCD display shows: Output voltage Output current Mains voltage Rectifier temperature Power limitation Rectifier ID (address) Software version Information regarding the following alarms is shown in the bottom line of the display:

Lo Mains Hi Mains Hi Temp Fuse Comm Rect

Low mains voltage < 100 VAC High mains voltage > 300 VAC High internal temperature Output fuse blown Communication error between rectifier and AEON Gold Internal rectifier failure

3.1.3LED indications
The SMPS 4000 has the following LED indications: Power (green) indicates that the power supply is ON Alarm (red) indicates an alarm situation Com. (amber) indicates remote communication with AEON Gold

3.2 Menu operation


When not communication with AEON Gold or the other rectifiers, the SMPS 4000 is controlled from the front of the rectifier only. When the Com. LED is lit the rectifier is controlled by AEON Gold or is communicating with the other rectifiers in the system. Functions like rectifier ON/OFF and calibrations are disabled. Only menu scroll is allowed when the rectifier is communicating.
The rectifier will default display output voltage in stand alone operation and output current in system operation

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3.2.1Flow chart menu structure


ON
ENTER UP DOWN UP

Calibration Voltage ++
UP

Calibration Voltage ++
UP

OFF

ENTER ENTER

ON/OFF
START

Output Voltage (V)

ENTER

High Calibration Voltage (V)


DOWN

ENTER

High Calibration Voltage (V)


DOWN

Output Voltage ++
UP

DOWN

UP

Calibration Voltage ++
ENTER

Calibration Voltage ++
ENTER

Adjust output Voltage


DOWN

SEt output voltage

UP

DOWN

Calibration Current ++
DOWN UP UP

Calibration Current ++
UP

Output Voltage --

ENTER

Software Version

Output Current (A)

ENTER

High Calibration Current (A)


DOWN

ENTER

High Calibration Current (A)


DOWN

Power Lim. ++
UP

DOWN

UP

Calibration Current ++
UP DOWN ENTER

Calibration Current ++

Adjust Power Lim.


DOWN

ENTER

Power Limitation

Mains Voltage ++
UP

Power Lim. -Mains Voltage


ENTER DOWN UP ENTER

Adjust Mains Voltage


DOWN

Flowchart Explanation:

Rectifier ID ++
UP UP DOWN

Mains Voltage -ENTER

Output Current
Means the display indicates the output current.
DOWN ENTER

Adjust Rectifier ID
DOWN

ENTER

Rectifier ID Temperature Boost (Hi)


ENTER UP

UP

Rectifier ID -DOWN UP

Temperature o ( C)

ENTER ENTER

Temperature DC (Lo)

Means the keys pressed on the rectifier panel

ENTER

Figure 32 Flow chart menu structure

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3.2.2DC voltage calibration


Output voltage is indicated in the display and the power LED is lit. For voltage calibration, it is necessary to use a calibrated voltmeter to measure the voltage on the DC output. NOTE: Output Voltage Calibration must be performed with approximately 30 A load! Use the flow chart to navigate to High Calibration. Adjust the High Calibration Voltage until the measured value (on the voltmeter) corresponds to the value indicated on the display. Go to Low Calibration Voltage by confirming the High Calibration Voltage. Adjust the Low Calibration Voltage until the measured value corresponds to the value indicated on the display. Return to Output Voltage by confirming the Low Calibration Value.

3.2.3DC current calibration


When entering this mode, the display will show output current in A. In order to carry out current calibration, it is necessary to have a load of at least 50% of current capacity using a mV-meter and a suitable current shunt. We recommend the following values: 24V: 110A high & 0A low 48V: 70A high & 0A low 60V: 55A high & 0A low Use the flow chart to navigate to High Calibration Current. Adjust the High Calibration Current value until it corresponds to the actual current value (calculated from your mV-meter reading). Go to Low Calibration Current by confirming the High Calibration Current. Again, adjust the Low Calibration Current value until it corresponds to the actual current value. Confirm the new calibration values Verify successful calibration by varying load current and comparing actual and read current values

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3.2.4Mains voltage calibration


When entering this mode the display will show input voltage in V and will be lit. For mains voltage calibration, it is necessary to use a calibrated voltmeter to measure the voltage on the mains input. NOTE: The rectifier must be switched ON before calibrating mains. Navigate to Adjust Mains Voltage (CAL is lit). Change the displayed voltage until the actual voltage (volt meter reading) and the displayed mains voltage correspond. Confirm.

3.2.5Temperature
There are two menus giving the internal temperature of the rectifier, one on the primary (Hi) side and one on the secondary (Lo) side. When the rectifier is communicating, only the highest temperature will be displayed. To see the temperatures, navigate to Temperature. Choose between the to temperatures. Confirm with enter

3.2.6Rectifier ID
The rectifier ID shows the identification or address of individual rectifiers when put in a system. The address will be retained in the memory of the rectifier, even when it is not communicating with the AEON Gold. To change the rectifier ID navigate to Adjust Rectifier ID (refer to the Flow Chart if can not find it). Change the ID and go back to the main menu by confirming the new ID.

3.2.7Rectifier power limitation


Power limitation as a function is only available on system level, and can be set from Aeon Gold to any value between 50% and 100%. Default factory setting for the rectifier in stand alone mode is 100%.

3.2.8

Software version

The rectifier software version is shown.

3.2.9Voltage setting mode


SEt is indicated in the display and the power LED is lit. For voltage setting, it is necessary to use a calibrated voltmeter to measure the voltage on the DC output. Enter the Adjust Output Voltage and adjust the value to the desired level. Confirm the new setting

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4 WinPower Gold

4 WinPower Gold
4.1 Introduction
Winpower Gold is a Windows-based application, developed by Eltek, for communication with control and monitoring units. Startup and operation of the power supply system is made easy by a user-friendly interface. Monitoring of the system is simplified by providing all significant information on the main screen.

4.2 SW Installation
4.2.1System Requirements
To run an AEON 4000 system with the latest features included the following are required:

4.2.1.1SW versions
Product
AEON GOLD WINPOWER GOLD SMPS 4000 SMPS 4000

SW Version
4.0 4.0 1.20 1.30
Table 6 SW versions

Comment

24V and 48V modules 60V module

The AEON Gold has to be installed properly, with the right cables. For Installation description see Installation & commissioning for AEON 4000 (Art. No. 356940.033)

4.2.1.2Regional settings
The regional settings on the computer decide Windows language, correct format for date and time, comma separated or decimal point.

4.2.2SW installation, AEON Gold and Winpower Gold


The installation CD comprises application software for both AEON Gold and Winpower Gold. This chapter describes briefly how to install Winpower Gold. To install or upgrade the AEON Gold firmware, see chapter 5.3.

4.2.2.1Language settings in Winpower Gold


The language must be the same both in Winpower Gold and AEON Gold. If a discrepancy occurs regarding language setting this will cause some confusion in several sub-menus. Winpower Gold reads data from the AEON Gold Control Unit and uses this in the Define Triggers and Define Alarm Outputs. Alarm texts in the AEON Event Log will be presented in the language selected in the AEON Gold.

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4 WinPower Gold The default language in AEON Gold is English, even if you chose German during the SW installation. Change of language in AEON Gold can be done both from Winpower Gold (see chapter 4.8.4) and AEON Gold (see chapter 5.2.1.1). In some menus Winpower Gold uses the operative system screens, with the result shown below. The text in the dialog box is the same language as selected during Winpower Gold installation, but for example with Norwegian operative system, the buttons are in Norwegian.

English WinPower dialog box Norwegian O/S buttons

4.2.2.2System requirements
To install and run AEON Gold and Winpower Gold, you need: An Intel compatible PC running one of the following: Windows 98/ME, Windows 2000, Windows NT 4.0 or Windows XP. At least 40 MB of free disk space. Minimum 800x600 screen resolution

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4.2.2.3Installing Winpower Gold


Exit all Windows programs. Put the CD into the CD-ROM and wait for the InstallShield Wizard to appear. Select Next, if you want to continue the installation, Cancel to abort. Select Yes on the Licence agreement information screen. Select which application you want to install.

To change the destination folder select the Browse button, if not, select Next.

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In the Language Selection window, select the appropriate language for Winpower Gold. You can select only one language, and this language will be used throughout the installed Winpower Gold application. The selected application will now be installed and a progress bar will be shown. The installation is complete when the InstallShield Wizard Complete screen is displayed. Press the Finished button to exit the installation program.

4.2.2.4Uninstalling Winpower Gold


Click the Start button, point to Settings and then click Control Panel. Double click Add/Remove Programs. In the Install/Deinstall tab, select Winpower Gold from the list of applications that can be removed. Click Add/Remove. In the Winpower Gold Setup view, click Remove and then click Next. Follow the instructions on the screen until the program files are removed.

4.3 Start to use Winpower Gold


This chapter describes briefly how to start using Winpower Gold. Starting a Winpower Gold application: You can start the Winpower Gold application from the Start menu: click Start button, point to Programs, Eltek and then click the application required. You can also use the Winpower Gold icon on the desktop.

4.4 Communication between Winpower Gold and AEON Gold


Winpower Gold and AEON Gold are connected by an RS232 connection between the PC communication port and the AEON Gold Com1 port. The communication protocol is an Eltek proprietary protocol, designed specially for power system communication. Use the communication interface cable specified in Installation & commissioning for AEON 4000 (Art. No. 356940.033), in the cable list in the Installation of AEON Gold chapter. Make sure that the communication port on AEON Gold is set to PCOMM, the Baud rate set to 9600 and the format set to 8_NO_1. (For more details , see chapter 2.3.2.10).

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4.5 Login to WinPower Gold


4.5.1 Direct Connection
To login you must first establish the RS232 communication link between your PC and the AEON Gold control module. Use the communication interface cable specified in Installation and Commissioning for AEON 4000 (Art. No.356940.033). By activation of the Winpower Gold application, the main screen appears with one START option. Click the symbol to start the setup.

On selecting this option, the site manger screen will open and four communication ports will be displayed.

Select the appropriate Serial Port: COM1, COM2, COM3 or COM4. Press Enter or Connect

Essential data will be downloaded from AEON Gold Control Unit to Winpower Gold.

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When the download succeeds the initial screen will appear and be updated, but if it fails the following screen will appear.

This screen will appear if there is communication problems or discrepancies between SW versions in Winpower Gold and AEON Gold. Communication problems are often caused by faulty communication cable or wrong communication port settings. Pin configuration for the communication cable is shown in Installation and Commissioning for AEON 4000 (Art. No.356940.033) in the Cable list, and default values for the communication port settings are shown in chapter 5.7. If problems are still unsolved after fault finding, please contact your local Eltek distributor.

4.5.2 Modem Connection


For Winpower Gold connection through modem, press the start button .

The Site Manager screen will pop up and a modem site needs to be selected. If it is a new connection not already configured, press Add Site and you will be asked for name of connection/site and phone number. Press the save bottom to save the information entered.

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Once configured, press Connect to initiate call. The Dialling Options menu will pop up and ask for information like country and modem selection.

Press OK and the dial up will start.

4.5.3 Ethernet connection


For Winpower Gold connection through an ethernet connection, press the start button .

The Site Manager screen will pop up and a network site needs to be selected. If it is a new connection not already configured, press Add Site and you will be asked for site/connection

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4 WinPower Gold name, IP address, Port, Local listen port and Rx Delay. Press the save bottom to save the information entered

Once configured, press Connect. Site IP Port Local listen port RxDelay Name of the site. IP address of the NPort. I.e. 182.17.2.255 (consult your network manager for a free address) The port on which the NPort are listening for messages. I.e. 4001 The port on which WinPower are listening for incoming messages. I.e. 4000 A timeout in milliseconds (ms) that determine how long WinPower waits for a response from the control module before it re-sends the request. I.e. 5000 (5 seconds)

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4.6 Description of the Screen interface


Rectifier current Current to Load 1 and DC/DC converter Click this button to see Event Status

Click this button to see rectifier status System output voltage Battery Communicati on status Battery temperature if temp. sensor and temp. compensation is activated Click this button to see Battery

DC/DC current, Load 2 current

Load 1 current DC/DC output voltage AEON Event Log Status bar

Note that the DC/DC converter symbol and the connected load (Load 2) not will be displayed if there are no DC/DC converters enabled in AEON Gold. After establishing the communication link between your PC and the rectifier system, the AEON Gold microprocessor will assume control of the PC screen. Operation of the rectifier system from a PC is based on pre-programmed menus accessed from the main menu. All menus and each function keys are described in detail in chapter 4.8. Information presented on the Status Bar will only be shown in English. The screen interface includes the following information: Description System info Customer's name Customer Customer's location Location Software version no. for AEON Gold Sw. ver. Current date yyyy/mm/dd for AEON Gold Unit's Date Current time for AEON Gold Unit's Time Access Level USER, SERVICE or FACTORY System Status Comms. Status Shows the system status, in ampere, volts and temperature, for rectifiers, batteries and load Displays green alternating lights when the
System Operation, AEON 4000,

Reference Chapter 4.8.1.3 Chapter 4.8.1.3 Chapter 4.8.1.3

Chapter 4.8.10 and 4.8.4 In different chapters Chapter 4.5

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4 WinPower Gold system is functioning faultlessly. The lights will stop flashing when the system malfunctions. Shows a red light when an alarm is active. A green light will show when all alarms are inactive. The alarm module stores all system events. These appear, chronologically, at the foot of the screen interface. The messages are logged in date, time and description.

Event Status

Chapter 4.8.6

AEON Event Log

Chapter 4.8.6

4.7 Menu Overview


The Winpower Gold application has three access levels: 1. User 2. Service 3. Factory Access Level: User sub-menus are available to all users, while Access Level: Service and Factory sub-menus are password-protected and accessed only by authorised personnel

Access rights to USER level of operation are limited to read-only system data. This level is available to all users. Access rights to SERVICE level enables you to edit information in the General Configuration, Battery Configuration and Rectifier Configuration menus. This level is accessed by password and is only available to authorized personnel. The password is pre-programmed to service. It is strongly recommended to change this password as soon as the system is installed. When SERVICE level has been entered, it will remain in SERVICE level until one of the following criterias occur: a) 30 seconds after a communication failure between Winpower Gold and AEON Gold. b) System Resynch has been initiated. c) Invalid Password Access rights to FACTORY level enables you to edit information in the Factory Settings menu. This level is accessed by password and is only available to authorized personnel. The password is pre-programmed to factory. It is strongly recommended to change this password as soon as the system is installed. When leaving FACTORY level with the OK or Cancel button, automatically the access level will go back to USER.

To gain access to Service or Factory level, see chapter 4.8.10 and 4.8.4 respectively.
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The following options are available to authorized personnel with SERVICE access: General Configuration Set Levels Set Date and Time Site Info Modem Callback Test Relays Define Triggers Define Alarm Outputs External control Shunt Configuration Battery Configuration Battery Setup Battery Test Boost Output Control Current Limitation Symmetry Measurement Configuration Rectifier Configuration Rectifier ON/OFF Options

System Voltages and Contactor Setup Setting date and time Specific site-related information Configuration of modem call back Testing the Event relays and LVBD and LVLD Relays Definition of triggers Definition of relay outputs Setting digital input to start events Configuration of battery and load shunts Define battery type, default or self-defined Manual battery test and test set-up Boost Set-up, Interval or Auto Boost Select type of output voltage control Select Battery Current Limitations Symmetry Set-up, Block or Centre Choose rectifiers Enable sequential start-up and delay

Factory Settings System Configuration

Rectifier status AEON Event Log Battery Test Info Clear Event Log System On/Off Password Resynch System

About

Read only access without factory access Configuration of nominal voltage, change language in AEON Gold, LVBD and LVLDs alarm relay outputs Essential information about rectifiers. Log of events in the alarm module Battery test results Clears the log of events on the screen interface Turn the system on or off SERVICE password Reading all system data from AEON Gold all over again and setting access level back to user. Information regarding Winpower Gold SW version

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4.8 Detailed description of the Main Menu options


4.8.1General Configuration

4.8.1.1Set Levels
With this option you can set the voltage levels in the system.

Figure 33 Aeon Gold LCD display main screen

The following parameters can be set in the System Voltage window: The alarm module will regulate the battery float charging voltage Battery Voltage to the value specified here, only if Output Control is selected. See chapter Output Control under menu Battery Configuration. Note! If the resistance of the battery cable is set to zero, the battery and the output voltages will be equal. During a Boost the output voltage will increase to the Boost Boost Voltage Voltage level. For more information on how to start boost

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4 WinPower Gold charging, see chapter Boost under menu Battery Configuration. Battery standby voltage indicates the rectifier output voltage during battery testing. This voltage will be kept lower than the battery test end voltage and the rectifiers will serve as backup for the batteries. For more information about battery testing, see chapters Battery test under menu Battery Configuration. This value is the over voltage shutdown level for the rectifiers. If the DC output voltage passes this level the rectifier will be shut down. The value entered will be broadcasted to all rectifiers and stored internally in the rectifiers. This is the voltage that the controller sets if the high temp voltage function for the batteries is activated. This function protects the batteries from overheating, by decreasing the battery voltage.

Battery Standby Voltage

Rectifier OVP shutdown

Emergency Low Battery Voltage

The following parameters can be set in the Contactor Setup window: It is possible to configure up to five contactors, one for battery Contactor Name and four for loads. These names are not configurable. Voltage limit for disconnection of load or battery must be lower Disconnect than the reconnect voltage. Voltage (Volts) Reconnect Voltage Voltage limit for reconnection of load or battery must be higher than the disconnect voltage. (Volts) Disconnect Delay Default = 0 minutes Application: Disconnection of load (LVLD) or battery (LVBD) Time (Minutes) at a predetermined time after the mains voltage is switched off. When the mains are off, an internal timer (minute counter) starts to count downwards from the pre-set time value. When the timer reaches zero, the load (or the battery, depending on how the system is hardwired) will be disconnected. If the mains returns before the timer reaches zero, the LVLDs or LVBD will not be activated and the timer will be reset. If the battery voltage falls below the low voltage disconnect level before the counter = 0, then the LVLDs or LVBD will be activated. The Disconnect Delay Timer is deactivated when set to 0. Shows if LVLDs or LVBD contactors are activated or Enable deactivated. In the system configuration in Factory settings the contactors will be enable or disable, see chapter 4.8.4. If a relay is configured to operate as a contactor, this relay is then blocked for operation from the alarm system.

4.8.1.2Set Date and Time


In order to keep a chronological record of events and other time-dependent functions, the PRS system's internal clock requires to be set with the correct date and time.

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The parameters are automatically entered in the correct format, date: YYYY-MM-DD, and time: HH:MM:SS by activating Get PC Time. These settings are dependent on the regional settings in the computer.

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4.8.1.3Site Info
This menu option enables you to adapt the control module to your specific installation, by registration of site-related information such as the customer's name, location, serial no., Control Unit serial no., rectifiers installed, battery type, serviced by, software version, installation and service dates, and any messages. Control Unit Serial no. and software version are entered automatically and cannot be changed from this menu option.

4.8.1.4Modem Callback
The modem functionality is based on two ways of communication: Dial- in to the site by the user from Winpower Gold Call- back from the AEON Gold to a terminal interface (Hyperterminal) which can receive alarm messages The usage of AT- Commands is not implemented in AEON Gold. The implications are that it is required that more of the modem configurations are done by setting up the modem directly, something which is normally done through a VT100 interface. The most important part to configure is the phone number that is going to receive the callback. Some modems will accept a range of phone numbers but most modems will only accept one. In addition it will be required to configure the modem so that it fits the PSTN (phone line) in which it is connected.

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Dialling into the site by using Winpower Gold is explained in 4.5.2. Here we will describe how to set up the control system to dial back to a terminal interface. Setting up the alarms: Defining the alarms that will trigger a callback is configured in General Configuration- Define Trigger. Under the Alarm Class it is possible to set the following alarm classes; Alarm, Warning, Info. If an alarm has got alarm class Alarm or Warning, the activation of the alarm will trigger a call- back. If an alarm has got alarm class Info there will be no call- back upon activation.

Defining the call- back mode: As can be seen in the Modem Callback menu in Winpower Gold one can set up the system to dial up either on an interval basis or on event. It is also possible to have both options active simultaneously. Event callback will dial up whenever an alarm is activated. AEON Gold will send information about site ID, given in the Site ID message entry, time and date and alarm type. The information is comma- separated so that it can be stored in a text file and imported into Excel. If there is no answer, AEON Gold will wait 2-3 minutes before it makes a retry. This procedure will be repeated five times in case of no contact. The only exception to immediate dial- up is if the queue size limit is set to other than 0. Queue size limit is a function where one can define that alarms will not generate call- back before they have queued up to a certain number. For example, if queue size limit is set to 4 you must have four entries in the alarm queue before dial- up. However, you do not need to have four alarms since alarm clear (EOA- End of Alarm) will also generate an entry in the queue. It means that two alarms activated and cleared will generate four entries in the alarm queue, thus generating a call- back. Queue size limit cannot be larger than 31. Interval call- back is used to make sure that the phone connection is OK and is typically set to dial up every 24 hours. If interval mode is selected and event mode is disabled an interval call- back will also contain all alarm messages generated since the last interval call.

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4 WinPower Gold If interval- and event call- back are both activated the queue size limit function is deactivated, i.e. it is set to 0. Any alarm set to alarm class Alarm or Warning will then generate an event- based call- back. Interval call- back will normally contain only site ID and time stamp. There will be no alarm messages since the alarm queue is empty.

The Site ID Message will be in the header of all callbacks from the power system. Start time for automatic call defines time of day when the first call will be initiated. If the start time is set to 14:15 and the actual time of day is half past two, the first call will not occur before the day after. Once the first call has been completed the interval timer will start and decide the time for the next automatic call, furthermore, if any of the parameters in the modem callback menu are changed, the interval timer will be reset and the next automatic call will again be decided by the start time. Terminal emulator setup Terminal emulators like Hyperterminal, Procomm Plus, etc. can be used to receive callbacks from AEON 4000 systems with modems installed. Please note that the following setup should apply: Baud Rate: 9600 Parity: None Data Bits: 8 Stop Bits: 1

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4.8.1.5Test Relays
This facility can be used to test the alarm relays and the low voltage battery/load disconnect contactors (LVBD and LVLDs), in order to test external equipment connected to the PRS system's outputs. Note that the batteries or rectifiers must be connected in order to operate the LVBD and LVLDs contactors.
WARNING!! Operation of the LVBD or LVLD relays will disconnect load or battery. 3 additional LVLD contactors may be in use. Each additional LVLD need an alarm relay as driver. Before testing relays, make sure that all necessary information regarding extra LVLDs is available.

When you have terminated the test and exited the Relay Test menu, the alarm module will automatically reset the relays to the normal operating position. To test-operate the alarm relays select Alarm Relay 1 to 10, L.V.B.Disc. and L.V.L.Disc.

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During relay test Winpower Gold uses at least 5 sec. before the screen will be updated. AEON Gold needs this time to report the change back to Winpower Gold. In addition there is a security function that disables relays in test mode after 45 seconds. This will also happen if a communication fault occurs or on leaving the test relay screen by pressing OK or Cancel button.

4.8.1.6Define Triggers
The alarm systems output functions use the output flag of each active detector or detector class and routes this to the physical output ports, for example the relays. The trigger name is the actual text that will appear in the Event Log.
Trigger name
11 trigger names are predefined, while 14 additional trigger names can be defined manually, if necessary. See table below Tick here to enable the relevant trigger Tick here to enable the beeper Input values from inputs connected to the AEON Gold Control Unit or Can-bus signals from rectifiers Symbol for comparing Input value and a sepecified value. Specify the minimum value (unit is predefined) Specify the maximum value (unit is predefined) Specify Min./Max. Value unit; select volts, temp. or Boolean The DelayTimer can be used to delay the activation of an alarm Specify delay unit - select seconds, minutes, hours or days The DurationTimer is used to delay the deactivation of an alarm Duration unit - select seconds, minutes, hours or days Detector class - select A, B or C. The classes are used for grouping alarms together. An alarm class can be routed to an alarm relay. Alarm class - select Info, WARN or ALARM. The activation of alarm diodes will depend on the alarm class. Activation of an alarm with alarm class Alarm will cause red alarm diode to be lit both in Winpower Gold and on AEON Gold front panel. Warning will cause the activation of red diode on front panel and yellow diode in Winpower Gold. Info will not cause illumination of front panel alarm diode while Winpower Gold diode will remain green The beeper sound pattern will depend on the alarm class of the active alarm. AND (connect) trigger number 1-25 with another trigger number 1-25. Select Automatic Reset or Manual Reset

Enable Beeper Input Value Cmp Min Value

Max Value

Unit Delay Unit Duration Unit Det.Class


Al.Class

And Reset

For further information regarding define triggers, see chapter 1.2.7.3.

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4 WinPower Gold The following tables define trigger options, as well as all available parameters, Table 7 shows the 9 fixed triggers and Table 8 shows 91 self-defined options and the available parameters. Define trigger options: No. Trigger name 1 High Batt. Voltage Input value Battery Voltage Recommended alarm limit value The alarm limit value depends on self-defined battery voltage value.
If battery boost is implemented, this value should be higher than the boost limit value and lower than the max. rectifier voltage.

Comments

Unit

Low Batt. Voltage

Battery Voltage

The alarm limit value depends on self-defined battery voltage value. The low battery voltage must be higher than the LVBD value, the Low Float Voltage and Battery Test End Voltage.

High Battery Temperature

Battery Temperature

Low Battery Disconnection Low Load Disconnection Mains Fault Battery Fuse Load Fuse

Low Battery Disconnection Low Load Disconnection Main Voltage Battery Fuse Load Fuse

Typically 40C, depending on battery manufacturers recommendations Typically 1.8 V/cell Typically 1.8 V/cell

Battery voltage is + VDC defined in Set Levels under General Configuration. Battery voltage is the voltage measured over the battery. The high battery alarm will occur, when the battery voltage reaches min./max. value. The battery current is the current to or from the battery. Battery voltage is + VDC defined in Set Levels under General Configuration. Battery voltage is the voltage measured over the battery. The low battery alarm will occur, when the battery voltage reaches min. value. The low battery alarm is suppressed during a battery test. When the High Battery C temperature is reached AEON Gold will give an alarm. Gives an alarm if the LVBD contactor is activated. Gives an alarm if the LVLD contactor is activated. Gives an alarm if Mains supply is lost. Signals if a battery fuse opens MCB + Load Fuse. BOOL

BOOL

6 7 8

BOOL BOOL BOOL

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4 WinPower Gold 9 Rectifier Communication Error Rectifier common alarm Rectifier capacity alarm SMPS count <> 0 (different communication from zero) SMPS common =0 Number of Rect. In comm.. error. #Rects

10

11

Gives a general alarm if BOOL there is something wrong with a rectifier System current The value should The capacity is % be higher then 50% calculated as: System current / (number of rectifiers communicating * Rated current). Rated current is set to 75A per rectifier. The formula will give a value from 0 113%
Table 7 Fixed Trigger Values

Self-defined triggers and available parameters: Input Value


Battery Voltage Total battery current Battery temperature Total load current System current Mains voltage 1 Mains voltage 2 Mains voltage 3 Mains fault Battery fuse 1 Load fuse 1

Description
Battery voltage has reached the set value low, equal or high Alarm occurs when the total battery current reaches a given value low, equal or high Alarm occurs when the battery temperature reaches a given temperature low, equal or high Total load current reaches a given value, low, equal or high The rectifier current, low, equal or high Mains voltage for Phase 1 Mains voltage for Phase 2 Mains voltage for Phase 3 Reflects if all phases are lost Triggers if battery fuse opens, if value set to 1 Load fuse supervision is done by means of a digital input. The system can monitor from 1 to a total of 4 load fuses. These are connected to a micro-switch mounted as a mechanical fuse detector. Load fuse supervision is done by means of a digital input. The system can monitor from 1 to a total of 4 load fuses. These are connected to a micro-switch mounted as a mechanical fuse detector. On if battery or load fuse blows, value set to 1 LVLD is disconnected, if value set to 1 LVLD 1 is disconnected, if value set to 1 LVLD 3 is disconnected, if value set to 1 LVLD 4 is disconnected, if value set to 1 LVBD is disconnected, if value set to 1 Symmetry alarms, if value set to 1 Symmetry alarms, if value set to 1 Battery test info, set to value low, equal or high Reads AEON Gold's voltage inputs directly- symmetry input 3 (low, equal or high) Reads AEON Gold's voltage inputs directly- symmetry input 4 (low, equal or high) Reads AEON Gold's voltage inputs directlyReads AEON Gold's voltage inputs directly- symmetry input 2 (low, equal or high) Reads AEON Gold's voltage inputs directly- symmetry input 1 (low, equal or high) Reads AEON Gold's shunt voltage inputs directly Reads AEON Gold's shunt voltage inputs directly Reads AEON Gold's shunt voltage inputs directly Reads AEON Gold's shunt voltage inputs directly Reads AEON Gold's shunt voltage inputs directly Remember to calibrate inputs-Controlled by Temperature input Remember to calibrate inputs-Controlled by Temp. Sense input= Battery Temperature Read the state of the controllers digital input Read the state of the controllers digital input Read the state of the controllers digital input Read the state of the controllers digital input

Unit
VDC ADC C ADC ADC VAC VAC VAC BOOL BOOL BOOL

Load fuse 2

BOOL

Common fuse Load disconnect Load disconnect 1 Load disconnect 3 Load disconnect 4 Battery disconnect Symmetry Warning Symmetry Alarm Battery Quality factor CU Symmetry Input 3 CU Symmetry Input 4 CU Batt. voltage input CU Symmetry Input 2 CU Symmetry Input 1 CU current input 2 CU current input 3 CU Spare current input CU Batt. current input CU current input 1 CU temperature Sense CU temperature CU digital input 1 CU digital input 2 CU digital input 3 CU digital input 4

BOOL BOOL BOOL BOOL BOOL BOOL BOOL BOOL V V V V V A A A A A

BOOL BOOL BOOL BOOL

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CU digital input 5 CU digital input 6 CU digital input 7 ACM voltage input 1 3 ACM Theoret. Star t one ACM Neutral to p.e. ACM current 1 3 ACM current neutral ACM active power ACM reactive power ACM transient input 1 3 ACM fuse input 1 3 ACM contactor 1 3 DCM voltage input 1 8 DCM current input 1 4 DCM digital input 1 8 SMPS common SMPS count alarm SMPS count Current limit SMPS count low mains Read the state of the controllers digital input Read the state of the controllers digital input Read the state of the controllers digital input Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit Used for future AC input supervision unit External DC / Battery super. Module External DC / Battery super. Module External DC / Battery super. Module Trigged by all SMPS alarms except Current Limit and Communication Number of alarms reporting from the rectifiers Number of rectifiers reporting reached current limit Number of rectifiers reporting low mains, only if the Mains is lost, not if the rectifiers has been pulled out of the rack. SMPS count high mains Number of rectifiers reporting high mains, only if the Mains is high. SMPS count fuse Number of rectifiers reporting a blown fuse SMPS count temperature. Number of rectifiers reporting to high temperature SMPS count HIV shutdown Number of rectifiers that has shutdown after a high voltage SMPS count Current sh Number of rectifiers that does not current share SMPS count rectifiers Set number of rectifiers, for example 4, if rectifier number 5 is installed, an alarm is generated. SMPS count communication Number of rectifiers that has lost the communication BOOL BOOL BOOL

BOOL

Table 8 Self Defined Triggers and available parameters

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4.8.1.7Define Alarm Outputs


This menu option enables you to define the alarm relay outputs.

Grey fields are allocated by LVBD or LVLDs contactor setup.

Alarm Name Enable AL logg Normal State Trigger 1 Trigger 2 Trigger 3 Alarm String

Specify relevant relay Tick here to enable alarm relay Tick here for relay activation to be displayed in Alarm log Select Energised or Not Energised Select the relevant trigger from the drop down menu Select the relevant trigger from the drop down menu Select the relevant trigger from the drop down menu Define the alarm string manually

Alarm Name is the name of the relevant relay. Normal State designates the state of the relay (Energized or De-energized) when there is no alarm. The 3 trigger columns allow for ORing of up to 3 triggers into one relay. The trigger selects any trigger from the Define Trigger Table. In addition, detector classes can be used to make common alarms. The alarm string is the text that appears in the Alarm Log. Remember to set this!

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4.8.1.8External control
The external control function allows the user to start internal functions in the controller through digital inputs. The following functions are selectable: Emergency low battery voltage. This function sets the voltage to a pre defined level. The level can be set under the set levels menu Battery boost. This stops/inhibit a battery boost. Battery test. This stops/inhibit a battery test Sequential start up. This input activates sequential startup and would typically be a signal from a backup generator. Rectifier Current/Power Limitation. Enables or disables the output limitation upper limit.

Function Enable Input Activate

Name of the function that gets activated by the digital input Tick the box to enable the function. Pull down menu that maps the digital input to the function. Select from digital input 1 to 7 Pull down menu that defines which state of the input that activates the function. Shorted or Open input can be selected to activate the function.

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4.8.1.9Shunt Configuration
There are a total of five shunt inputs on Aeon Gold, where one is used as battery shunt input while the remaining four can be defined as battery or load shunts. The four shunts can be selected through tick boxes. The total battery current is based on the sum of the measurement from the individual battery shunts. The total battery current is displayed as battery current in both Winpower Gold and the front panel. The total load current is based on calculation derived from battery current and rectifier current. The load shunts will measure the individual currents and display the value in the input monitor. Measurements form the load shunts are not added together or used in any calculations.

Shunt input Battery shunt Load shunt

Name of the shunt Tick box for specifying battery shunts. Shunt #1 is default battery shunt and can not be changed. Tick box for specifying load shunts

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4.8.2Battery Configuration

4.8.2.1Battery Setup

The following parameters can be set in the Battery Setup:

Battery Type

The alarm module is delivered with default (pre-defined) battery definition tables and one user-defined table. If you want to use the user-defined table, enter the definition parameters in the Define New Battery menu before using the table. Number of battery The AEON Gold must be configured with the exact number of battery banks connected in parallel in the system. This banks information is essential for calculating the battery capacity. Number of battery A battery bank is a number of battery strings connected to the AEON 4000 system. A battery string is a string of serial strings per bank connected batteries. The number of strings connected to a battery

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4 WinPower Gold bank can vary, same does the number of batteries in a string. The controller calculates the total number of strings by multiplying number of strings per bank with number of banks. This calculation is independent of the shunt configuration. Number of battery Number of battery cells. cells Battery cell capacity in Ah. Battery cell capacity Battery reference temperature, defined by the manufacturer in the Reference battery definition table temperature Voltage at reference temperature, e.g. 2.23 V/cell Temperature compensation Compensation equation (per cell) Slope of temperature Min. compensation Minimum compensation voltage per cell voltage Max. compensation voltage Battery test end voltage Battery cable resistance Maximum compensation voltage per cell

There are various battery test end voltages, based on tables from the manufacturer The battery cable resistance is essential for calculations performed during battery tests and battery charging. A battery test is terminated when the battery voltage has dropped to the end voltage (defined in the battery table). If the voltage drop in the battery cables is considerable, the measured battery voltage will be lower than it really is, causing the battery to terminate too early. The calculated capacity will then be too low. Cable resistance also influences battery charging. In this case, the charging voltage will be too low and the batteries will never reach 100 % capacity. In order to compensate for this effect, you can configure the alarm module with the total battery cable resistance (both + and ), thus enabling a correct calculation of the battery voltage.

4.8.2.1.1 Define New Battery If you want to use a user-specified battery definition table, instead of one of the pre-defined tables, the definition parameters must first be specified in the New Battery Table. You will find all necessary data in the data sheet from the battery manufacturer. A typical data sheet will contain data as shown in the table below. Battery type: RPA 12 V/100 A at +20C Battery End Voltage 1.7 V/cell 1.8 V/cell 1.9 V/cell Amps Amps Discharge time Amps 111.0 100.0 71.2 30

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4 WinPower Gold 45 60 120 180 84.2 68.0 39.7 28.5 76.9 63.6 37.8 27.4 57.1 48.6 31.4 23.5

During a define battery configuration, you need to copy data from the table above to the New Battery Table screen shown below.

Number of end voltages must be higher than two for the computer to be able to calculate accurate battery capacity after a battery test. Recommended minimum is three end voltages. The highest value and the lowest value specified for the battery and one value in between should be selected. The test end voltages must be entered in ascending, starting with the lowest value in row 1. Number of time entries must be higher then two. A minimum of 5 entries is recommended where the longest expected discharge time is the first entry. The time entries must be entered descending, starting with the highest time value in row 1.

After completion of data, proceed to the Battery Setup and fill in the missing data regarding Size, Temperature Compensation, Resistance and Current in Battery Table. The current for all Battery Test End Voltages must be entered. Enter values 1 - 10 000 in the Battery table: Time (min.) / Current (Amps)

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When discharge data for one Battery Test End Voltage has been filled in, it is important to save before next entry, otherwise data already entered will be lost.

4.8.2.2 Battery Test To enable a continuous control of the batteries' condition, the alarm module incorporates functions for a manual or interval test of the batteries. Prerequisites for the test are as follows: Currents from battery to load are measured Correct discharge table from the battery manual is selected Max. test duration is set to a time > expected time needed for the batteries to reach the battery end voltage If battery current is higher than 5% of the battery capacity (value can be set from 1,7-10% in Battery full threshold, in the factory settings in AEON Gold,), the battery test will not start. With a 100 Ah battery installed the battery current must not exceed 5 Amps.

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This menu option is based on information given in battery configuration and gives you a brief overview of the battery test:

The following parameters can be set in the Battery Test:

End Voltage Max Duration

Guard Time

Start Time Interval

The battery test is stopped when the battery voltage drops to the End Voltage value specified, if enabled. The battery test is stopped when the test timer reaches Max. Duration. Note: This indicates that the battery test setup may be incorrect. Battery condition will display Aborted. After a mains interruption the guard time starts to count downwards. A new battery test cannot commence before guard time reaches zero. This is to ensure that a battery test is not performed immediately after a mains interruption. The guard time range is defined in chapter 5.6. The time for the interval battery test to commence. The period of time between two battery tests.

Manual battery test The manual battery test function allows the user to test the batteries. This function comprises the following parameters:

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Interval battery test The interval battery test function will give you the opportunity to ensure that the capacity is sufficient. This function comprises the following parameters: Enable Start time Interval If parameters are changed in manual or interval battery test, you should save the changes before activating the start button. Activate will enable interval test.

If you select more than one termination criteria, the battery test will be terminated when one of the criteria enabled is reached.

The battery test sequence is as follows: The AEON Gold reduces DC voltage from the rectifiers to battery standby voltage. (The entire load current is thus supplied by the batteries) The AEON Gold measures the average current supplied to the load and the battery voltage. The test is stopped when the termination criteria is reached, or the timer has counted down to Max. duration time. The test should be aborted and repeated if Max. duration occurs. Ensure the prerequisites are correct. The discharge table, on which the battery test is based, calculates with constant current for a specific temperature. In order to obtain capacity test results as accurately as possible, the above-mentioned conditions should be followed. The battery capacity is calculated as the ratio between the actual test time and the expected test time with an average current, as specified in the discharging table.

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Discharging Characteristic
Discharging current vs. time, for a specific end voltage

A
T1 = Real Time T2 = Time supposed to last, as per the discharging table

T1

T2

Figure 34 Discharging Characteristics

The Battery Test Alarm Limits are:

Condition > 80 %

Battery condition is OK

It is not advisable to interrupt a battery test as this will cause inaccurate results and may cause Battery Alarm Before commencing a battery test, ensure that the correct test parameters and battery table have been specified in the alarm module

4.8.2.3Boost
Use the battery boost function if you need to charge the system batteries faster than normal. The output voltage will then increase until the boost value is reached. This menu option gives you a brief overview of the boost function and the possibility to carry out Manual, Interval and Automatic Boost.

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The following parameters can be set in the Boost:

Duration

Guard Time

Start Time Interval Boost Factor Max Duration Threshold

The maximum boost duration can be set from 0 to 20 hours and from 0 60 minutes. Duration set to 0 indicates that no maximum duration limit is set. If the value is greater than 0, the boost will stop when the timer expires, independent of recharge level. After a boost charge the guard time starts to count downwards. A new boost charging cannot start before guard time reaches zero. This is to ensure that a new boost charge is not performed immediately after a boost charge. The guard time range is defined in chapter 5.6 The time for the interval boost charge to start. The period of time between two boost charges. Batteries can be charged from 100 % to 150 % of discharged Ah. The maximum boost duration can be set from 0 to 20 hours. The automatic boost will only start if the discharge of the batteries, in % of the total battery capacity, during mains failure or battery test was greater than the threshold value. The automatic boost threshold can be set from 1 - 100 %.

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Manual Boost Charging This function comprises the following parameters: Duration Guard Time Auto Boost The automatic boost charging function is developed to ensure a brief recharging time for the batteries after discharge. This function comprises the following parameters: Enable Boost Factor Max. Duration Threshold Interval Boost The interval boost charging function is developed to ensure that the capacity is sufficient. This function comprises the following parameters: Start time Interval

If parameters are changed in manual, auto or interval boost, you should save the changes before activating the start button. Activate will enable manual boost.

The following conditions can interrupt boost charging: One of the predefined settings in the Boost menu is reached. Boost charging is interrupted manually. Mains voltage is interrupted

You cannot use other menu options while battery boost is in progress.

Before enabling a battery test, please read the section about Battery testing and Boost charging in the functional description in chapter1.2.1.

4.8.2.4Output Control
This option enables you to choose the control mode to be applied on the PRS system's output voltage.

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The following Output Control mode types are available: Temperature compensation allows you to regulate the charge voltage with Temperature respect to the temperature and used batteries. The advantage is that the Compensation Output Voltage Control No Regulation

batteries will be working under optimum operating conditions, thus optimising performance and lifetime. Using output voltage regulation means that the output voltage will be constant, irrespective of load or temperature condition.

The output voltage is set by AEON Gold but regulated by the rectifiers.

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4.8.2.5Current Limitation

Max. Battery Current

This function limits the maximum charge current for the batteries. Battery manufacturers often recommend limiting the maximum current to 10 30 % of C10 capacity, in order to prolong battery lifetime. C10 is the total 10 hour discharge battery capacity of all connected battery banks.

When selecting Max. Battery Current, use the value in accordance to the battery manufacturers data sheet.

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4.8.2.6Symmetry Measurement Configuration

The main purpose of the symmetry monitor functionality is to detect any single-cell failure in the battery block. The following parameters can be set in the Symmetry Measurement Configuration:

Enable Block Centre Mode Battery Strings Discharge Delay

Tick here if you want to start the symmetry measurement. Measuring blocks, 12 V blocks with three points for measuring on the 48 V system Measuring the midpoint on 1-4 banks where the number of strings is specified. The symmetry alarm functionality can be chosen to be active continuously or only at discharge. The total number of strings When using symmetry at discharge, a delay should occur before the symmetry monitor functionality starts, to stabilize the battery cells.

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4 WinPower Gold Limits There are two different warning levels in Symmetry Measurement Configuration, warning and alarm. The alarm and warning limit for discharge is lower than the charge and float limits, due to the fact that a symmetry measurement is more accurate in this condition. This is the value between the measured voltage over a block and the calculated one based on the rectifier voltage.

Delta Voltage (V)

Note: For centre symmetry measurements on 60V battery banks, using 12 V blocks, the 24V point shall be used as midpoint (between 2nd and 3rd block, L2). Before configuration of a symmetry measurement, please read about it in the functional description in chapter1.2.4.

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4.8.3Rectifier Configuration

4.8.3.1Rectifier ON/OFF
You can turn each rectifier ON or OFF with this menu option.

Select one or more rectifier and activate them by using the apply button. Note: This function is not available with software version 3.2 or later. Also, the rectifiers must be installed from the AEON Gold front panel, before they can be turned ON/OFF.

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4.8.3.2Options
The Options menu allows you to configure all rectifiers in the system. The following parameters can be set in the options menu:

Sequential startup is developed especially for applications with generator back up. To avoid overloading the generator during startup, the rectifiers can be turned on one by one with a delay that can be set between 0 and 10 seconds. The systems Current/Power Limit function is configured by selecting the limitation type and its respective value The systems Current/ Power Limit function must be enabled; refer to page 81.

Enable Delay between each rectifier

If a sequential startup of rectifiers is required, it must be enabled. The delay time is set in seconds.

The maximum number of rectifiers in a system is 96 but the controller will report rectifier IDs up to 101. The discrepancy between 96 and 101 is due to a Hexa Decimal problem, which means 5 ID numbers are Not In Use (23, 39, 55, 71 and 87).

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4.8.4Factory Settings

4.8.4.1System Configuration
The factory settings menu is accessed after the rectifiers are installed in the cabinet. Parameters are normally configured during the Factory Acceptance Test. In some cases it may be necessary to access the menu during commissioning. Access rights to edit information, are only available to authorised personnel, while access for the operator is limited to read-only system data. Service access, to edit information, should not be necessary during normal operation.

To gain access to system configuration:

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4 WinPower Gold Select Change settings Enter the password Press Enter or Login

The password for Factory Setup is factory-programmed to "factory".

The system is configured according to the following options:

Nom. Voltage

Language

LVBD LVLD1 LVLD2-4 Normally Energized Enabled

This parameter specifies the nominal voltage for the system. It is essential that changes are not made here without first checking the system voltage. WARNING: To enter the wrong system voltage could cause damage to load equipment or rectifiers going into overvoltage shutdown. The language in AEON Gold can be changed here, in which case there will be discrepancies in some submenus and the AEON Event Log. AEON Gold sends data in the selected language, and this will be displayed in various places in Winpower Gold (default Relay 11.) (default Relay 12.) Select the relay output number for LVLD 2 4 if enabled. Select this option if the relay output should operate as Normally Energized. Tick here when activating the contactor setup.

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4.8.5Rectifier Status

4.8.5.1Rectifier Status
This menu option indicates the current status of the rectifier. This dialog is dynamically updated.

The options in this menu, as illustrated above, are predefined and cannot be changed here:

Type Serial No. Current Temp. Mains On Connected Alarms

Type of rectifier. The rectifiers serial number transmitted on the Canbus. Rectifier current indication. Rectifier temperature indication. Mains voltage connected to the rectifier (L1, L2 or L3) The rectifier is activated or deactivated. The rectifier is installed in the system. The rectifier has generated an alarm.

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Rectifiers Connected Rects. On

This number shows the maximum number of rectifiers that can be installed in the system. Total amount of connected rectifiers in the system. Total amount of rectifiers that have been activated.

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4.8.6AEON Event Log

4.8.6.1AEON Event Log screen


AEON Gold receives status, at regular intervals, from all rectifiers and the event log registers every event in the alarm unit; showing time, class, ID and detector.

The options in this menu, as illustrated above, are as follows: Select this option and specify the exact number of log items to be listed. Get x Log Items Get All Items Select this option and all alarm module events will be listed in the log, max. 256 entries. Select this option and all alarm module events will be erased from the log. Erase Log Export log to Select this option and the alarm log will be exported to a chosen file. file Reports the date and time when the event occurred. Time There are three classes defined in the event system, info, warning and alarm. Class EOA and EOW represent End Of Alarm and End Of Warning and is the event that an alarm or a warning end. This number represents a unique identifier for the event. ID This represent the name of the ID Detector

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6.6.6.2 Exporting log to file


The Aeon Gold controller allows the user to export the event log to a text file (TXT), which for example can be sent by email back to the service centre for analyses. The event log can be an effective tool for fault finding of the system. Save the log to file by pressing the Export log to file bottom, select a folder and name the file.

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4.8.7Battery Test Info

4.8.7.1Test Results
This option shows the results of the battery test. The Last test overview shows the results from the latest test, while the Previous test overview, naturally, shows results from the previous test.

Please refer to functional description regarding the meaning of data on this screen, see chapter 1.2.1, and especially attention to the part about battery test results (chapter 1.2.1.3).

4.8.8Clear Event Log

By selecting this option you will clear the event log on the initial screen interface.

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4.8.9System On / Off

This option turns the system on and off.

4.8.10 Password
To gain access to SERVICE level:

Select Password on toolbar

The Please Login sheet appears Enter Password Press Enter or Login

The password for Service Setup is factory-programmed to "service".

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4.8.11 Resynch System

By selecting this option you will reset communication. It is necessary to resynch if changes has been made through AEON Gold front panel after Winpower Gold was started.

After activating the re-synchronising, new data will be sent from AEON Gold to Winpower Gold

4.8.12 About

By selecting this option, general information about Winpower Gold will be displayed.

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Product name Product version Product revision Article number Protocol version

This is the name of the PC software This is the version of the Software product This is the product revisions of the Winpower Gold PC software This is the part number for the Winpower Gold PC software. This is the revision of the PCOMM protocol

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4.9 Main Screen Facilities

4.9.1View

By selecting this option you can choose to change the main screen interface. Information about shortcut functions is listed here. There are three monitor screens that can be activated from the pull down menu.

4.9.1.1Input Monitor

Monitors all analogue and digital inputs.

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IO Channel Input Unit

Name of the input Value of the input Unit of measure for the input. Voltage (V), Current (A) or Temperature (C)

Voltage inputs Battery voltage Voltage 1-4

Displays the measured voltage for the battery voltage input Displays the measured voltages for voltage inputs 1 to 4 (normally used for symmetry measuring)

Current inputs Battery current shunt Spare current Current 1-3

Displays the measured current for the battery shunt input. Displays the measured current for the spare shunt input. The value is independent of the shunt configuration, battery or load. Displays the measured current for the spare shunt inputs 1 to 3. The value is independent of the shunt configuration, battery or load.

Digital inputs: Battery fuse input Load fuse input 1-2 Digital input 1-7 Battery temperature

Displays the status of the input, open or closed. Displays the status of the input, open or closed. Displays the status of the input, open or closed. Displays the value of the battery temperature input. This is the value that used for battery compensated charging. Displays the value of the spare temperature input. This value is not used in any calculations.

Spare temperature

4.9.1.2 Input monitor log to file


The Aeon Gold controller allows the user to export the input monitor readings to a text file (rpt). The file can be an effective tool for fault finding of the system and the file can be sent by email back to the service centre for analyses. Save the input monitor to file by pressing the File bottom, select a folder and name the file.

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4.9.1.3Symmetry Monitor

Will count down from specified discharge delay, when there is a transition from charging or float into discharge Shows deviation from expected voltage

Will give a visual warning or alarm

Files present Symmetry Monitor data

Start/Stop filing of dynamically Symmetry Monitor data

Monitors all necessary data during a symmetry test, see chapter 1.2.4 concerning symmetry measurement configuration.

4.9.1.4Symmetry monitor log to file


The Aeon Gold controller allows the user to log the symmetry readings to a text file (rpt). The file can be an effective tool for fault finding of the system and the file can be sent by email back to the service centre for analyses. Log the symmetry readings to file by pressing the start/stop file bottom, select a folder and name the file. Stop the log by pressing the start/stop file bottom again. The symmetry monitor log to file functions loges the following data to file with a 2 second interval: Time, Delta voltage 1-5, warning, alarm, status (enable/disable) and system status.

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4.9.1.5Battery Monitor

Time left before contactors disconnect

Battery capacity

Monitors all necessary data during a battery test, see also chapter 1.2.1, and pay attention especially to the part about battery test results.

4.9.2Tools

By selecting this option you can choose to change the password and generate alarm reports.

4.9.2.1Winpower Gold Options


When you select Winpower Gold options, the Change Password sheet appears: Type in Old Password Type in New Password Confirm New Password Select Service or Factory access level Press Enter or Apply

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4.9.2.2Reports

When selecting reports you are able to generate and file an Alarm Configuration report. This report contains all the information form the Define trigger settings and the Define alarm output settings. The following information is written to file: Time when log was crated Site info Serial number info AEON software revision Setting, values and status for all triggers Setting and status for all relays The report can be an effective tool for fault finding of the system. The file can be sent by email back to the service centre for analyses.

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5 Attachments
5.1 Menu Structure, AEON Gold

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5.2 Factory Options


The password for Factory Setup is factory-programmed to 4321.

5.2.1Available Factory Options


Factory Setup comprises sub-menus available to authorised personnel only (passwordprotected access). The following options are available: Controller Setup Diagnostics

(Note: the Diagnostics function is for use by qualified service personnel only and is therefore not illustrated).

Figure 35 AEON Gold Factory setup menu.

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5 Attachments To navigate inside the Factory Setup menu use the keypad on the AEON Gold front panel, see also description in chapter 2.3.

5.2.1.1Controller Setup
Controller Setup includes the following options: LCD contrast Menu reset timer Language Nom. System Voltage Change Password Comli address Modbus address Beeper pattern Battery full threshold Copy battery table LCD contrast: By accessing LCD contrast, the contrast in the graphical display can be changed in older models. The default value is 50%. New models have a different display that does not need to be adjusted, and does not comply with the entered configurations. Menu reset timer: The menu reset timer is set in minutes, and indicates how many minutes the AEON Gold is inactive before it returns to the main menu. Language: The language can be changed, as appropriate. The different languages are shown in chapter 5.3.

AEON Gold default language is English. Please note that when changing the language it can take several minutes before the controller has changed the text strings, and regained normal operation. Nom. System Voltage: By entering this menu it will be possible to change the Nominal System Voltage between 24 VDC, 48 VDC and 60 VDC. Changing the Nominal System Voltage should only be done by authorised personnel. Change Password: Change Password allows you to change the default service password to a made up one. This password will be reset back to factory-programmed if use of Master Password, see chapter 0. COMLI address: This option enables you to change the COMLI (protocol) address, if COMLI is used. MODBUS address This option enables you to change the MODBUS (protocol) address, and the RTS signal. Beeper Pattern:

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5 Attachments The sound mode can be changed between continuous and time limit mode. Sound duration and repeat rate can be changed. Battery Full Threshold In the Battery Full Threshold option you can define the limit when the battery is fully charged. The default value is set to 5% of the total battery current capacity, but can be adjusted from 1,7 % up to 10%. Copy battery table The AEON Gold Control Unit has four predefined battery tables. These are available through the Copy battery table option. By choosing a battery type and a current value, the control unit uses the chosen table.

5.2.1.2Diagnostics
Factory defaults allows the user to set the controller back to pre-programmed default values/ Warning: This can change state of the LVDs and potentially drop the load.

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5.3 Installation and upgrade of AEON Gold SW


SW upgrade can be performed if the required software is available on a PC. This can be found for example on the Installation CD for WinPower Gold. How to use the CD is described in the WinPower Gold chapter. Connect a RS232 (Art. No. 30801.001) cable between Com0 and your PC.

WARNING: Before software upgrade, please check with readme.txt what precautions have to be considered.

Activate the download program by select Start menu: click Start button, point to Programs, Eltek and then click the application required, AEON Software Download App icon
.

When activating the AEON Software Download App, the screen Select hardware type appears. Verify what type of HW you have by picture AND part number on the serial nr. label. Proceed with commands as described below: Select HW type Press OK

When the next menu starts, you are forced to manually type in the part number. This is a safety precaution. Wrong SW may be loaded into the alarm module, but it will malfunction. Type Part number Press OK

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Verify your selection of hardware. Press Yes if the information is correct.

The Application loader will now ask you to choose serial port on your computer, load type and execute the upload of SW. Select correct Serial port Select Application SW Upgrade for sw upgrade. The other option is for first application download during production test.

Firmware will be 402034 for 241241.000, and 402049 for 241241.100 (new HW). Please note that after pressing the reset button on the AEON Gold you must start the Download Program within 10 sec. to avoid time-out in the AEON Gold

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Location on the Control Unit: Set the dipswitch under service in the ON position and press the reset button. Select Download program now
Red LED is lit, when the Service Switch is in ON position ON position Reset button OFF position

Please note that the download can take several minutes. Progress is displayed on the screen with the text Transmitting application x%. If the download fails, please check the communication port setup. Refer to chapter 5.7.

When the download of the new software has been successful, exit the Download program. Before the AEON Gold can use the new software, a restart is required. Set the dipswitch under service in the OFF position and activate the reset button.

The AEON Gold will then startup as usual but with the new software implemented.

Wait until Autolog-On starts, this might take more than one

minute.

Autolog-On will reinstall all rectifiers after a SW upgrade, please check that rectifier configuration is correct. Press Enter to confirm.

To confirm that the Soft Ware has been upgraded check the SW version on the Control Unit: User Setup System Info SW Version (Press UP once to see this)

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5.4 Languages in AEON Gold


Language English Norwegian German Simplified Chinese Spanish Polish French Dutch Available from: Release 2.0 Release 2.0 Release 2.0 Release 2.0 Release 2.0 Release 2.1.1 Release 3.0 Release 3.0
Table 9 Languages in AEON Gold

5.5 Service switch, AEON Gold


Some systems will be delivered with a service switch connected to the AEON Gold Control Unit. This switch will prevent a trip of the battery contactor, for example, during a replacement of the AEON Gold Control Unit. In normal operation, the switch should be in Normal position and AEON Gold will control the battery contactor. During service on a live system the service switch should be set to Service to hardwire the contactor into on position.

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5.6 Default and limit values, AEON Gold


5.6.1 60 Volt system
Value Voltage Min Dependan cy
X X X X X X X X X 54,35 62,50 54,35 50,00 50,00 0 50,00 50,00 0 70,60 56,25 0 1,82 0 1 0 0 0 0 0 1 100

Max

Default

Unit

Nominal Voltage Boost Voltage Low Float Voltage(Batt Test Standby Voltage) Battery Disconnect Voltage Battery Reconnect Voltage Battery Disconnect Delay Load Disconnect Voltage Load Reconnect Voltage Load Disconnect Delay Rectifier OVP Trip Voltage HiTemp Battery Protection Voltage Battery Current Limit Battery Test End voltage Battery Test Guard time Battery Test interval days Battery Test Duration Battery Boost Duration Battery Autoboost Max duration Battery Autoboost Threshold Battery Boost Guard time Battery Boost Interval days Battery Boost Factor

72,48 72,48 72,48 62,49 62,50 1800 62,49 62,50 1800 74,35 72,48 32000 2,5 999 1000 24 24 1440(24h) 1000 999 1000 150

66,85 70,00 54,35 53,75 56,85 0 53,75 56,85 0 74,35 64,05 2000 1,9 12 182(0,5year) 12 12 60 10 12 182(0,5year) 100

VDC VDC VDC VDC VDC Minutes VDC VDC Minutes VDC VDC Amp VDC/Cell Hours Day Hours Hours Minutes % Hours Days %

User Defined Battery Cell Voltage @Ref Temp User Defined Battery Reference Temperature User Defined Battery Cell Capacity User Defined Battery Max Temp Comp Volt/Cell User Defined Battery Min Temp Comp Volt/Cell User Defined Battery Temp Comp Slope User Defined Battery Table Test End Volt User Defined Battery Table Test Discharge Time User Defined Battery Table Test Discharge Current Number of Battery Table Test End Voltages Number of Battery Table Test Time Entries Number of Battery Cells Number of Battery Strings Number of Battery Banks Cable resistance Callback Connection Time Callback Report Interval Sequential Startup Delay

1,82 0 10 1,87 1,87 0 1,82 1 10 2 2 0 1 1 0 0 0 2

2,50 30,0 5000 2,41 2,41 20,0 5,00 10000 C*50 10 44 30 8 8 30,0 100 24 30

0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 24 2

VDC/Cell C Ah VDC/Cell VDC/Cell mV/C/Cell VDC/Cell Minutes Amp

mohm Seconds Hours Seconds

Not in use

5.6.2 48 Volt system

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Min Voltage Dependan cy
X X X X X X X X X 43,50 50,00 43,50 40,00 40,00 0 40,00 40,00 0 56,50 45,00 0 1,82 0 1 0 0 0 0 0 1 100

Max

Default

Unit

Nominal Voltage Boost Voltage Low Float Voltage(Batt Test Standby Voltage) Battery Disconnect Voltage Battery Reconnect Voltage Battery Disconnect Delay Load Disconnect Voltage Load Reconnect Voltage Load Disconnect Delay Rectifier OVP Trip Voltage HiTemp Battery Protection Voltage Battery Current Limit Battery Test End voltage Battery Test Guard time Battery Test interval days Battery Test Duration Battery Boost Duration Battery Autoboost Max duration Battery Autoboost Threshold Battery Boost Guard time Battery Boost Interval days Battery Boost Factor

58,00 58,00 58,00 50,00 50,00 1800 50,00 50,00 1800 59,50 58,00 32000 2,5 999 1000 24 24 1440(24h) 1000 999 1000 150

53,50 56,00 43,50 43,00 45,50 0 43,00 45,50 0 59,50 51,25 2000 1,9 12 182(0,5year) 12 12 60 10 12 182(0,5year) 100

VDC VDC VDC VDC VDC Minutes VDC VDC Minutes VDC VDC Amp VDC/Cell Hours Day Hours Hours Minutes % Hours Days %

User Defined Battery Cell Voltage @Ref Temp User Defined Battery Reference Temperature User Defined Battery Cell Capacity User Defined Battery Max Temp Comp Volt/Cell User Defined Battery Min Temp Comp Volt/Cell User Defined Battery Temp Comp Slope User Defined Battery Table Test End Volt User Defined Battery Table Test Discharge Time User Defined Battery Table Test Discharge Current Number of Battery Table Test End Voltages Number of Battery Table Test Time Entries Number of Battery Cells Number of Battery Strings Number of Battery Banks Cable resistance Callback Connection Time Callback Report Interval Sequential Startup Delay

1,82 0 10 1,87 1,87 0 1,82 1 10 2 2 0 1 1 0 0 0 2

2,50 30,0 5000 2,41 2,41 20,0 5,00 10000 C*50 10 44 30 8 8 30,0 100 24 30

0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 24 2

VDC/Cell C Ah VDC/Cell VDC/Cell mV/C/Cell VDC/Cell Minutes Amp

mohm Seconds Hours Seconds

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5.6.3 24 Volt system


Value
Min Voltage Dependan cy
X X X X X X X X X 21,75 25,00 21,75 20,00 20,00 0 20,00 20,00 0 28,25 22,50 0 1,82 0 1 0 0 0 0 0 1 100

Max

Default

Unit

Nominal Voltage Boost Voltage Low Float Voltage(Batt Test Standby Voltage) Battery Disconnect Voltage Battery Reconnect Voltage Battery Disconnect Delay Load Disconnect Voltage Load Reconnect Voltage Load Disconnect Delay Rectifier OVP Trip Voltage HiTemp Battery Protection Voltage Battery Current Limit Battery Test End voltage Battery Test Guard time Battery Test interval days Battery Test Duration Battery Boost Duration Battery Autoboost Max duration Battery Autoboost Threshold Battery Boost Guard time Battery Boost Interval days Battery Boost Factor

29,00 29,00 29,00 25,00 25,00 1800 25,00 25,00 1800 29,75 29,00 32000 2,5 999 1000 24 24 1440(24h) 1000 999 1000 150

26,75 28,00 21,75 21,50 22,75 0 21,50 22,75 0 29,75 25,62 2000 1,9 12 182(0,5year) 12 12 60 10 12 182(0,5year) 100

VDC VDC VDC VDC VDC Minutes VDC VDC Minutes VDC VDC Amp VDC/Cell Hours Day Hours Hours Minutes % Hours Days %

User Defined Battery Cell Voltage @Ref Temp User Defined Battery Reference Temperature User Defined Battery Cell Capacity User Defined Battery Max Temp Comp Volt/Cell User Defined Battery Min Temp Comp Volt/Cell User Defined Battery Temp Comp Slope User Defined Battery Table Test End Volt User Defined Battery Table Test Discharge Time User Defined Battery Table Test Discharge Current Number of Battery Table Test End Voltages Number of Battery Table Test Time Entries Number of Battery Cells Number of Battery Strings Number of Battery Banks Cable resistance Callback Connection Time Callback Report Interval Sequential Startup Delay

1,82 0 10 1,87 1,87 0 1,82 1 10 2 2 0 1 1 0 0 0 2

2,50 30,0 5000 2,41 2,41 20,0 5,00 10000 C*50 10 44 30 8 8 30,0 100 24 30

0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 24 2

VDC/Cell C Ah VDC/Cell VDC/Cell mV/C/Cell VDC/Cell Minutes Amp

mohm Seconds Hours Seconds

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5.7 Default values for Communication Ports


Ref. Part number 241241.100 Serial Port 0 Protocol Terminal (Trace) Baud Rate 9600 Parity NO Data Bits 8 Stop Bits 1 Serial Port 1 PCOMM 9600 NO 8 1

Table 10 Default values for Communication Ports

5.8 Protocols in AEON Gold


Protocols
Pcomm COMLI SCPC Terminal (Trace) ModBus

Description
Eltek propriety used for Winpower Gold, SNMP and WEB gateway

Industrial std. Bus protocol Customer specified Terminal (VT100) interface used for Diagnostics purposes Industrial std. Bus protocol
Table 11 Protocols in AEON Gold

5.9 Westermo modem configuration


The description gives an example on how to configure a modem before connection to AEON Gold. We have selected Westermo TD-series modems since these modems are widely used for communication with Eltek DC power systems. Please note that the settings will depend on the modem applied and also on the telephone network. For more details on the specific modem, see the Westermo modem user guide. Dip switch settings Located under modem top cover. Disconnect power before changing DIP-switches SW1: 4 3 2 1 0 0 0 0 SW2: 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0 SW3: 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 1 SW4: 8 7 6 5 4 3 2 1 0 0 1 1 0 1 1 0 SW5: 8 7 6 5 4 3 2 1
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5 Attachments 0 0 0 0 0 0 0 0

Connect modem to a PC for configuration Part number 240278.185 Connect the modem to Com1 using the modem cable. You need a short patch cable, Part. No 100590 connected to Aeon Gold com-ports in addition to a standard 1-1 Com-cable to be able to use modem. Apply the following settings to your communication port: Baud rate: 9600 bps Data bits: 8 Parity: None Stop bits: 1 Flow control: None Power up the modem This is a description on how to connect to your modem using Hyper terminal: Press START Programs Accessories Communications Hyper Terminal. The first dialog box: Write the name you want for the connection, and press OK:

Choose the COM-port you have connected the modem to, and press OK. When you choose a COM-port, the telephone number and Area code are disabled.

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Now, press properties, and specify that you want a VT100 emulator:

Press OK after choosing VT100 emulation, and you are back to the main screen:

If the status field in the down left corner says disconnected, press connect button. At-commands
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To verify that you have connection to modem correctly: AT: Does nothing, but the modem responds with OK if you have connection. If you do not see a response from the modem, the result codes might be turned off. Try to turn them on: ATQ0: Turn on result codes. Modem responds with OK Configure your modem correctly Only for TD-22: ATX2: Disables monitoring of busy tones. Reports No Dial Tone. Receipt OK on screen. Only for TD-32: ATX0: Disables monitoring of busy tones. Reports No Carrier. Receipt OK on screen. FOR both modems: AT&S1: DSR active after answer tone, and inactive when carrier is lost. Receipt OK on screen. AT&D3: DTR drop causes the modem to perform a soft reset. Receipt OK on screen. AT&Q5: The modem will try to negotiate an errorconnected link. Receipt OK on screen. AT&C1: DCD follows the sate of the carrier. Receipt OK on screen. AT&B1: Dial on OFF to ON transition of the DTR signal. Receipt OK on screen. AT&K3: Enables RTS/CTS flow control. Receipt OK on screen. AT&Z0=telephone number. Example: AT&Z0=0W11223344 Dial 0, await tone and then dial the rest of the telephone number. Receipt OK on screen. If you did all these commands in this sequence, your Hyper terminal window should look like this:

To store your current configuration

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AT&W0: Store current configuration as profile 0. Receipt OK on screen. AT\S: Show the configuration overview for the modem. The configuration overview should look like this if the modem is set up correctly:

You have now successfully configured your TD-22 or TD-32 modem to be used on the Aeon system. Press the disconnect button, or choose disconnect from the Call-menu, and log out. You can now disconnect the modem from the serial port, and connect it to Aeon Gold. Please remember to use the AEON Gold modem cable, described in the Cable list in Installation and Commissioning for AEON 4000 (Art. No. 356940.033).

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5.10
Error Code group 1000 1100

SW Fault Messages
Error Code Area

Error code 1030 1040 1100 1100 1100 1100 1460 1460 1460 1460 1460 1460 1460 1500 1510 1520 1530 1540 1550

Description

Battery Boost

1400

Battery Test Config

Error in reading alarm log Action <= STOP_ANY_ONGOING_BOOST Duration out of range Max. Duration Hour out of range Interval out of range GuardTime out of range GuardTime out of range CellVoltage out of range Interval out of range CellCapacity out of range Duration out of range Date out of range Time out of range Illegal command BATTEST IS RUNNING NO TEST IS RUNNING MAINSFAIL BATTEST IN RECOVERY STATE BATTERY TEST GUARD TIMER RUNNING NumBattCells > MAX_NUMBER_OF_BATTCELL NoBattBanks > MAX_NUMBER_OF_BATTBANKS NoBattStrings > MAX_NUMBER_OF_BATTSTRINGS Cable Resistance > 30mohm CellVoltage(EndVolt) out of range CellVoltage(ZeroVolt) out of range CellTempSlope(Slope) out of range CompVoltageCell(MaxCompVolt) out of range CompVoltageCell(MinCompVolt) out of range CellCapacity(CellCapacity) out of range Invalid BattType, EndVoltage, or incomplete data Illegal command or max charge current exceeded Wrong time or date The log type requested does not exist Regulation mode requested does not exist LoadDiscVolt Contactor 1 out of range LoadDiscVolt Contactor 2 out of range
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1500

Battery Test Commands

1600

Battery Type Config

1600 1610 1620 1630 1700 1710 1720 1730 1750 1760 1780

1700

Battery Setup Config

2200 2400

Current Limit Commands Site Info Config

2200 2400 2420 2430 2800 2800

2800

Set Parameter Commands

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5 Attachments 2800 2800 2810 2810 2810 2810 2800 2810 2820 2830 2840 2850 2850 2850 2850 2850 2860 2872 2874 2876 2878 3100 3400 3500 Set Time Config Test Relay Command System Config 3100 3400 3500 3510 3520 3530 3540 3550 LoadDiscVolt Contactor 3 out of range LoadDiscVolt Contactor 4 out of range DiscDelay Contactor 1 out of range DiscDelay Contactor 2 out of range DiscDelay Contactor 3 out of range DiscDelay Contactor 4 out of range BattDiscVolt Contactor out of range BattDiscDelay Contactor out of range SetOutVolt out of range BoostVolt out of range LowFloatVolt out of range ReconVolt Load Contactor 1 out of range ReconVolt Load Contactor 2 out of range ReconVolt load Contactor 3 out of range ReconVolt load Contactor 4 out of range ReconVolt Batt Contactor out of range Load contactor disconn volt lower than battery contactor disconn volt is ineffective! LoadDiscVolt Contactor 1 >=LoadReConnVolt Contactor 1 LoadDiscVolt Contactor 2 >=LoadReConnVolt Contactor 2 LoadDiscVolt Contactor 3 >=LoadReConnVolt Contactor 3 LoadDiscVolt Contactor 4 >=LoadReConnVolt Contactor 4 Wrong time or date Relay does not exist, or illegal action Illegal system voltage Illegal system Language Contactor type can only be NC or NO Contactor can only be used or unused Non existing relay configured for contactor Contactor cannot be used and unallocated at the same time Trigger number too high or illegal system parameter (possibly incompatible Winpower Gold version) Invalid Batterytype or Endvoltage Rectifier number too high Invalid BattType or EndVoltage Invalid BattType or EndVoltage Invalid BattType or EndVoltage Invalid BattType or EndVoltage Invalid BattType or EndVoltage Invalid BattType or EndVoltage

4500

Alarm Commands 4510

4800 5200 5300 7100

Battery Setup Commands System SMPS Config Battery Setup Req. Select Battery Table Commands

4800 5200 5300 7100 7110 7120 7130 7140

Table 12 SW fault messages

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