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to continued progress in methodology, design, and manufacturing.
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Contents
1
Introduction
Function
Configurations
4.1
4.2
4.3
4.4
4.5
4.6
Rectifier
Rectifier subrack
Control units
Multifunction unit
AC distribution
AC connection terminals
8
10
11
11
12
12
Technical data
13
5.1
5.2
5.3
System
Cabinet
Rectifier
13
13
13
Installation
14
14
Maintenance
14
8.1
8.2
8.3
8.4
Safety
Scheduled maintenance
Alarms
Fault symptoms and trouble shooting
14
14
15
15
21
9.1
9.2
9.3
9.4
9.5
9.6
9.7
Exchange of rectifiers
Rectifier fan replacement
Exchange of distribution circuit-breaker
Exchange of contactor
Exchange of SCU/ACU
Exchange of connector board
Exchange of SCU/ACU supply fuses
21
22
23
24
25
25
26
10
27
Introduction
The NetSure 501 48 V DC power system consists of a stand-alone cabinet,
DC-distribution unit, maximum 12 rectifiers of 1700 W, battery connections
and a supervision unit.
Function
For the protection of the batteries during a power outage, the load is disconnected at a preset voltage or after a predetermined delay.
To prolong the service of some loads at a long power outage, the DC distribution is divided into two branches. One is for normal load and one for priority
load, so the disconnection can be made in two steps.
AC Mains
Subrack 2
6 rect.
Priority Load
~
=
MFU
LVD 1
& ICU
Subrack 1
6 rect.
LVD 2
~
=
Shunt
AC terminals
CAN-bus
Batt.
CBs
SCU/
ACU
Figure 1.
Ext. Batts.
Configurations
The cabinets can be configured with different numbers of rectifiers, batteryand distribution- circuit-breakers. They are built for overhead cabling.
Extension
distribution unit
Rectifier subrack
Rectifier subrack
AC distribution
unit (optional)
Figure 2.
Cover panel 2 U
AC terminals (if no ACD)
MFU (battery CBs,
S/A
C/C
U/U
ACD (optional)
(BMG 653 39/21)
Fire trap
Figure 3.
Cover panel 2 U
AC teminals (if no ACD)
Extension distribution CBs
(normal load)
Cover panel 2 U
MFU (battery CBs,
S/A
C/C
U/U
ACD (option)
(BMG 653 39/22)
Fire trap
Figure 4.
Options:
4.1
Rectifier
The rectifier is voltage regulated of a constant power limitation type (1700 W)
and designed to meet the most stringent electrical requirements as well as
demands for high power density (fan cooling). It can work independently of the
control unit, and can share the load actively and control the system voltage.
LEDs
Figure 5.
Rectifier.
4.1.1 LEDs
The front panel has three indicator LEDs. The functions of the LEDs are listed
in the table below.
LED
Power indicator
(green)
Alarm indicator
(red)
Normal
ON
OFF
OFF
Abnormal
Cause of Abnormality
OFF
No AC Mains Supply
Flashing
ON
Flashing
ON
Output overvoltage
Flashing
Fan Failure
4.1.2 Features
Active load sharing. The rectifier uses advanced digital active load sharing
technology for minimum load difference between units.
Power derating by input voltage. The rectifier will go into power derated
mode if the input AC voltage is too low or too high.
Power derating by output load. The rectifier will limit its output power constant when the load exceeds the nominal output power.
Power derating by temperature. For high temperatures the output load will
be gradually reduced. See technical data.
Current limiting function. The rectifier has a current limiting function. The
current limit can be set from an SCU/ACU.
Current walk-in. The rectifier can be set from an SCU/ACU to take load
gradually in order to reduce the stress on generators, fuses etc.
Fan control. The fans speed is controlled according to the rectifier internal
temperature. The fan is stopped completely at low temperature and at
very low or high input voltage.
The rectifier can receive commands such as turning on/off, current walk-in
on/off signal and high voltage alarm reset signal from an SCU/ACU.
An SCU/ACU can adjust the output voltage, overvoltage alarm point, current walk-in time and the current limit of the rectifier.
The rectifier reports its output voltage, output current, temperature, current
limit setpoint, overvoltage setpoint, on/off status and alarm information to
an SCU/ACU in real time.
By querying the DSP, an SCU/ACU can get the following data from the
rectifier: Input voltage, output voltage, output current, current limit setpoint,
temperature of rectifier, and overvoltage setpoint.
By querying the DSP, an SCU/ACU can get the following state information
from the rectifier: On/off, protect (input protect, inner DC bus voltage protect; overtemperature), fault (HVSD, fan failure), thermal derating, AC
derating, AC failure, and unbalance current.
An SCU/ACU can get the following unit information from the rectifier: Address, code, date, SW version and HW version.
4.2
Input over/undervoltage protection. The rectifier will shut down and its yellow LED will emit light if the input voltage is outside the range 80 to
305 V AC. An alarm will be sent to the SCU/ACU.
Communication failure. At communication failure, the rectifier output voltage is reduced to a default value for protection of the battery. The yellow
LED will flash and alarm will be sent to the SCU/ACU.
Fan alarm. The red LED will flash at a fan fault and the rectifier will stop.
Unbalance of Rectifier Output Current. When the output current of the rectifiers in a DC power system is unbalanced, the rectifier that outputs unbalanced current will be identified automatically and its yellow LED will
emit light. An alarm will be sent to the SCU/ACU.
Rectifier subrack
Figure 6.
4.3
Control units
The control unit is placed in the multifunction unit. It controls, supervises and
communicates with the other units of the power supply system and manages
alarm handling, etc.
Two control units are available. The standard control unit (SCU) has an LCDdisplay, offers internal supervision and alarm handling, sends external alarm
signals over relays and communicates externally via modem with external
computer-based supervision systems (EEM, for example) that can be implemented for different maintenance activities.
The advanced control unit (ACU) has, in addition to the SCU features, an interface to communicate with supervision modules (SM) for supervision of
existing cabinets, AC mains and batteries, for example. It has a Web interface
for communication with MS Explorer.
For detailed information, refer to USERS GUIDE 5/1553-BMP 903 050 Uen,
for the ACU and 5/1553-BMP 903 051 Uen, for the SCU.
4.4
Multifunction unit
+ terminals
LVD contactors
CB alarm
board
Connector
board
Figure 7.
MFU.
The unit combines normal and priority distribution circuit-breakers battery CBs,
a battery shunt (500 A) and one or two load disconnect contactors (125 and
500 A). The control unit (SCU/ACU) and the connector board are also
mounted here.
4.5
AC distribution
R1--------------------------------------------------------R12
Figure 8.
L1 L2 L3 N PE
Input terminal
4.6
AC connection terminals
Figure 9.
Mains terminals.
A unit with maximum four terminal blocks can be delivered for the connection
of totally 12 rectifiers.
Technical data
5.1
System
Nominal DC voltage
48 V
5.2
5.3
Storage temperature
40 to +75 C
Relative humidity
5 to 90%
Cabinet
Building practice
23
maximum 150 kg
Rectifier
See data sheet EN/LZT 145 280 RA
Installation
See INSTALLATION INSTRUCTIONS 1531-BZA 108 35 Uen.
Maintenance
Adequate knowledge of the power supply system is required. Refer to item 1
to 5 of this document.
8.1
Safety
The document SAFETY RULES 1550-1004 and local safety rules shall be followed when doing maintenance work in the power supply equipment. Measures that require work inside the cabinets or intervention in a unit shall always
be carried out by adequately trained personnel with adequate knowledge of
the power supply system. When in doubt about an action or how to carry it out,
always call for adequately trained personnel.
In case it is necessary to work on a live power supply system, the approval for
this type of work must be given, based on local regulations governing for example the following areas:
8.2
Approved tools
Customer approval
Scheduled maintenance
Use a vacuum cleaner to remove dust from the air inlets of the cabinets.
Check and test the batteries according to the recommendations of the battery supplier.
A copy of the test result shall be kept in the logbook of the plant.
8.3
Alarms
8.4
Alarm on
the ACU
display
Cause
Suggestion
The outgoing alarms are Check why before reconnecting the alarms.
blocked from the
SCU/ACU.
Alarms
Blocked
Alarm
Blocked
Load Fuse
Alarm
Rect Not
Respond
CAN
Comm
Fault
Alarm on
the SCU
display
LVD 1
LVD 2
Alarm on
the ACU
display
LVD 1 Disconnected
LVD 2 Disconnected
Cause
Suggestion
The contactor for the prioritised load is open because the battery is too
deep discharged.
See LVD 1
An LVD contactor is in a
wrong state.
Batt Curr
High
Batt Fuse
Alarm
Fuse Alarm
Self-detect
Err
ACU fault
SCU/ACU failure.
Manual
Mode
Manual
Mode
Non-Float
Status
Batt Discharge
Alarm on
the SCU
display
Curr Discrepancy
Alarm on
the ACU
display
Dis Curr Im
Short Test
Fail
Batt Test
Fail
Cause
Suggestion
Test Failure
The battery test has failed. Check the float charging level.
Check that the load is lower than the capacity of the rectifiers.
Check the battery according to the recommendations of the supplier.
Volt Discrepancy
Rect Over
Volt
Rectifier overvoltage
Mains Failure
Mains Failure
Multi-Rect
Alarm
Maintain
Alarm
Maintenance Alrm
Rectifier
Lost
Rectifier
Lost
Load share
Alarm
Rect HVSD
Rectifier overtemperature
protection.
Rectifier failure
Rectifier protection
Rect Over
Temp
Alarm on
the SCU
display
Alarm on
the ACU
display
Cause
Suggestion
Rect Fan
Fails
Rect Fan
Fail
Rect Derated
Rect Curr
limit
Rectifier overload.
If the batteries are being recharged, the
The load is higher than the alarm will cease by itself when the battery
rectifier capacity.
voltage has increased to the charging level.
If the system load is higher than the rectifier
capacity, the batteries will discharge. If this
is the reason, install more rectifiers.
If one or more of the rectifiers are out of
order, exchange the faulty rectifiers.
DC Volt
Low#1
Under Vol
DC Volt
Low#2
Very Under
Vol
DC Volt
High#1
Over Voltage
Check the set float-, battery- and the overvoltage; if the limits are incorrect, find out
why they have changed and correct them.
DC Volt
High#2
Check the set float-, battery- and the overvoltage; if the limits are incorrect, find out
why they have changed and correct them.
AC Voltage
Low#2
AC Voltage
Low#1
AC Voltage
High
Low Temp
Temp Alarm /Low Amb
Temp
The temperature on a
temperature sensor exceeds the set value.
Alarm on
the SCU
display
Temp High
Alarm
No Temp
Sensor 1 or
2
Alarm on
the ACU
display
Cause
Suggestion
High Temp
Very hiTemp
The temperature on a
See High Temp alarm.
battery temperature sensor exceeds the set value.
High Amb
Temp
The temperature on a
room temperature sensor
exceeds the set value.
T Sensor
Fault
Plan BT
AC failure
BT
Mains failure.
Manual BT
Short Test
Cyclic BC
Auto BC
Automatic boost charge in Wait for the boost charge to stop automatiprogress.
cally.
Manual BC
Charge Pro- The boost charge function The boost charge will be blocked by abnorhibit
is blocked.
mal conditions in the system.
Power Major
Power Minor
High Load
Ab load curr
Over Power
Digital 1 (to
6)
DI 1 to DI 6
8.4.2 Rectifier
The usual fault symptoms of the rectifier include: power indicator (green) off,
protection indicator (yellow) on, protection indicator (yellow) flashing, alarm indicator (red) on, and alarm indicator (red) flashing.
Symptom
Cause
Suggestion
No input voltage
PFC overvoltage
Protection
indicator (yel- Rectifier communication failure
low) flashing
Rectifier overvoltage
When multiple rectifiers are in parallel connection and the unbalance of current sharing among them is higher than 3 %, check if the communication cables are correctly connected.
If the current sharing is still unsuccessful after the correction, replace the rectifier of which the current sharing is out of range.
9.1
Exchange of rectifiers
1. Loosen the fixing screw of the handle of the faulty rectifier. The handle will
pop out and release the latch locking the rectifier to the subrack.
Fixing screw
Handle
Latch
9.2
Fixing screw
and fan holder
Fan
Front cover
Fixing screws
9.3
CB fixing
screw
2
connecting fork
9.4
Exchange of contactor
Note:
9.5
Exchange of SCU/ACU
Note:
1. Unlock the control unit by pressing the handle so it pops out and pull out
the control unit from the subrack. See Error! Reference source not
found..
2. Insert the new control unit into the subrack, push it in completely and lock
it by pushing the handle into its socket.
9.6
Connectors
Fixing screw
2. Disconnect, insulate and mark the signalling cables connected to the terminals of the connector board.
3. Exchange the connector board for a new one.
4. Connect the signalling cables to the terminals of the new board.
Note:
An LVD contactor is in its OFF- position will reconnect when the connector board is reconnected to a live system.
5. Insert the connector board into the subrack, push it in completely and fix it
with a screw.
9.7
2 A for SCU/ACU
4 A for contactors
10
Alternating Current
AC Distribution
Advanced Supervision Unit
Battery Charge
Battery Test
Controller Area Network
Circuit Breaker
European Committee for Electrotechnical Standardization
Direct Current
Digital Input
Digital Signal Processor
Distribution Unit
Emerson EnergyMaster
ENERGYMASTER is a registered trademark of
Emerson Network Power Energy Systems AB
European Norm
ElectroStatic Discharge
High Voltage Switch Down
InterConnection Unit
Local Area Network
Liquid Crystal Display
Light Emitting Diode
Low Voltage Disconnect
Multi Function Unit
Protective Earth
Power Factor Controller
Rectifier
Standard Supervision Unit
Safety Extra Low Voltage
Supervision Module