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    User Manual

    AMS 48/2000-8/16/24 ETS and

    PSC 3 Controller

    D0114354_055_00

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    Energy Systems

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

    22 October 2004 1

    Table of contents

    1 Safety Instructions

    20001_03.pdf

    2 System Description

    31001_02.pdf

    3 Rectifier FR 48 V 2000 W E32013_02.pdf

    4 Installation and Commissioning

    40030_01.pdf

    5 Maintenance Instructions

    50001_04.pdf

    6 Troubleshooting Instructions

    60001_03.pdf

    7

    8

    9

    10 Wiring Diagrams, Final Test Report etc.

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    Energy Systems

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    Energy Systems

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

    22 October 2004 3

    1 DOCUMENT INFORMATION

    1.1 Version control

    Document number Document description

    D0114354_055_00 User Manual,AMS 48/2000-8/16/24 ETS and PSC 3 Controller

    Previous version Description of changes

    - New document.

    Controlled by Date

    22.10.2004

    Markku Havukainen

    Approved by Date

    22.10.2004

    Petteri Turkki

    1.2 System

    The AMS 48/2000-8/16/24 ETS is a modular large power system for power up to48 kW. The stable construction is based on a frame cabinet design. The system

    contains three rectifier shelves for up to 24 rectifiers FR 48 V 2000 W E anddifferent distribution units with configurable elements for AC-, DC distribution, LVD,PLD and a power system controller. The modular design allows flexible powersystem solutions in the ETS cabinet line and is the key factor of the success of thispower system and it offers a cost effective and reliable solution. This power systemis expandable with a 2nd cabinet. The typical applications for this power system arewireless base stations, core network components, telecommunications and datanetworks. This compact, high power density power system is the perfect choice forspace-critical solutions.

    1.3 User Manual

    Please read first carefully the safety instructions before installing and commissioningthe system. The product description sections contain information and operatinginstructions for the rectifiers. In the installation and commissioning section there arestep-by-step instructions for safe and correct installation and commissioning of thesystem. The maintenance section contains information for maintaining the highperformance and reliability of the system. In case of a fault in the system, pleaserefer first to the troubleshooting section of this user manual.

    1.4 Contact Information

    For additional information or questions please contact your local Delta EnergySystems representative. For the contact information of our locations please checkour website at www.deltaenergysystems.com.

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    Energy Systems

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

    22 October 20044

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    Energy Systems

    20001_03Issue 2 February 2004

    Safety Instructions

    Power Supply Systems

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    Energy Systems

    SAFETY INSTRUCTIONS POWER SUPPLY SYSTEMS

    2 February 2004 3

    TABLE OF CONTENTS

    1 DOCUMENT INFORMATION........................................................................................5

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

    2 SAFETY INSTRUCTIONS .............................................................................................7

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

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

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    SAFETY INSTRUCTIONS POWER SUPPLY SYSTEMS

    2 February 20048

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

    Removing or inserting components from or into the equipment may result inchanges to the performance of the equipment. The operator is thereforeresponsible for the consequences of any change in the hardwareconfiguration that are made without an agreement with the manufacturer orhis local representative.

    The operator of the equipment is responsible for ensuring that personnelconcerned with the equipment (authorised persons) are provided with safetytraining when the equipment is installed or when starting their employment

    and at regular 6-monthly intervals thereafter. The operator of the equipment is responsible for ensuring that the rooms in

    which the equipment and batteries are set up are treated as electricalequipment rooms, which are only accessible to qualified personnel(authorised persons).

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

    The units or individual parts of the equipment may only be opened by

    qualified employees (authorised persons) of the equipment operator, whohave attended a special repair training course held by the manufacturer orhis local representative.

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

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

    The installation instructions and specifications in this user manual are a partof these safety instructions. The order of installation and the specified limitvalues must be adhered to in order to guarantee that the equipment iscorrectly installed and operated.

    2.2 Special Instructions

    Localised areas of high temperature (> 70 C) may occur within therectifier/inverter/distributor rack. Adequate precautions against accidentalburns must be taken.

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

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

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    SAFETY INSTRUCTIONS POWER SUPPLY SYSTEMS

    2 February 2004 9

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

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

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

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

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

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

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

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

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

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    Energy Systems

    31001_02Issue 13 August 2003

    System Description

    DC Power Supply Systems

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    Energy Systems

    SYSTEM DESCRIPTION DC POWER SUPPLY SYSTEMS

    13 August 2003 3

    TABLE OF CONTENTS

    1 DOCUMENT INFORMATION........................................................................................5

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

    2 SYSTEM DESCRIPTION...............................................................................................7

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

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    SYSTEM DESCRIPTION DC POWER SUPPLY SYSTEMS

    13 August 2003 5

    1 DOCUMENT INFORMATION

    1.1 Version control

    Document number Document description

    31001_02 DC Power Supply System Description

    Previous version Description of changes

    31001_01 Layout updated.

    Controlled by Date

    13.08.2003

    Markku Havukainen

    Approved by Date

    13.08.2003

    Petteri Turkki

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    SYSTEM DESCRIPTION DC POWER SUPPLY SYSTEMS

    13 August 2003 7

    2 SYSTEM DESCRIPTION

    The Delta power systems are designed to efficiently supply uninterruptible DC-voltage to modern telecommunications equipment. The systems are constructedusing steel profile based cabinets and switched-mode rectifiers of state-of-the-artand development of Delta Energy Systems. The systems are designed to fulfil thehigh reliability requirements of telecom environment.

    The schematic structure of the power systems is presented in Figure 1. The powersystem comprises switched-mode rectifiers having one or three phase input lineconnection, terminals for batteries, low voltage disconnections, load terminals withautomatic circuit breakers or HRC fuses as well as a control, monitor and alarm unitfor automatic operation of the system.

    Power System Controller

    Relay

    DC load

    Telecom

    Equipment

    option

    AC load

    option

    Modem

    AC -

    distribution

    1 .. n

    Rectifiers1 ... n

    Batteries

    Converters /

    Inverters

    Load

    distribution

    Mains

    Local

    user

    Remote

    user

    P0001

    Figure 1. The schematic structure of the Delta power system.

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

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    2.1 Operating modes

    In normal operation mode the rectifiers deliver the load power taken by the telecom

    system and simultaneously maintain the batteries at full charge.

    During a line power outage or an excessive line-undervoltage, the rectifiers are shutdown and the batteries deliver the load power.

    If the battery voltage decreases below the preset level, the optional deep dischargeprevention circuitry disconnects the battery automatically. As the line power isrestored to a proper level, the rectifiers start up automatically and begin to deliverthe load power and recharge the batteries at current limiting mode.

    The batteries are important components in a telecom power system. The control andmonitoring unit is designed to ensure long battery life and effective recharging of the

    batteries. Automatic boost charge is based on battery current.

    The system level control and monitoring functions include local and remote alarmsand local controls of the system. The local alarms are shown by alarm LEDs.Remote alarms are issued by means of potential free relay contacts.

    The operation of the control and monitoring unit is presented in the productdescription of the controller.

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    Energy Systems

    32013_02Issue 22 October 2004

    Product Description

    Rectifier FR 48 V 2000 W E

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    Energy Systems

    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 2004 3

    TABLE OF CONTENTS

    1 DOCUMENT INFORMATION........................................................................................5

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

    2 GENERAL......................................................................................................................7

    2.1 Safety ................................................................................................................8

    3 FUNCTIONAL DESCRIPTION ......................................................................................9

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

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

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

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

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

    3.6 Cooling ............................................................................................................10

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

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

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

    3.10 Precharge........................................................................................................11

    3.11 Configuration ...................................................................................................12

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

    3.12.1 Manufacturing data..........................................................................................12

    3.12.2 Configuration data ...........................................................................................12

    3.12.3 Commands / control data ................................................................................12

    3.12.4 Information data...............................................................................................13

    3.12.5 Measurements.................................................................................................13

    4 FRONT ELEMENTS ....................................................................................................14

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

    5 BACK PLANE..............................................................................................................15

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

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

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

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 2004 5

    1 DOCUMENT INFORMATION

    1.1 Version control

    Document number Document description

    32013_02 Rectifier FR 48 V - 2000 W E, Product Description

    Previous version Description of changes

    32013_01 Input voltage range corrected.

    Controlled by Date

    22.10.2004

    Markku Havukainen

    Approved by Date

    22.10.2004

    Petteri Turkki

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 2004 7

    2 GENERAL

    The rectifier FR 48 V - 2000 W - E is a single phase, hot-pluggable and fan-cooledrectifier. The constant output power characteristic supplies the specified power overthe full output voltage range. The benefit is an optimized modular system design(fewer modules) that matches the supply requirements of state-of-the-art telecomequipment. This performance as well as the extended temperature range, wide inputvoltage range, high power density and advanced technology are the key factors forthe success of this rectifier, offering a cost effective and reliable solution.

    The typical applications for this rectifier are both in indoor and outdoorenvironments, which is a perfect solution for wireless base stations, core networkcomponents, telecommunications networks and data networks.

    The rectifier meets the requirements set by the telecommunications standards.

    The rectifier contains two stages of high frequency power converter (Figure 1.):

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

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

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

    EMC

    input

    filter

    Inrush

    current

    limiter

    Power factor

    corrector

    PFC

    DC-DC

    converter

    EMC

    output

    filter

    Auxiliary supplySecondary

    auxiliary

    AC-

    inputDC-

    output

    Primary

    auxiliary

    Galvanic separation

    Energy

    storage

    Control and interface

    System bus

    Figure 1. Block Diagram describing the functionality of a rectifier.

    P0002

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

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    2.1 Safety

    The rectifier meets the safety standards:

    EN 60 950 (2000-06) - class 1

    UL 60950 rev 3 (Dec1, 2000)

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

    There are no user serviceable parts except the fan inside the unit. A faulty rectifiermodule should be replaced as a complete unit. The installation description must bestrictly adhered to.

    The rectifier contains the following internal protection fuses:

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

    The protecting AC fuses are connected in L and N.

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

    The protecting DC fuse is connected in pole.

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

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 2004 9

    3 FUNCTIONAL DESCRIPTION

    3.1 Input voltage rangeIf the input voltage exceeds the limits of the input voltage range the rectifier is shutoff. The rectifier will restart up automatically as soon as the input voltage returns intothe specified input voltage range. At low input voltages, an output power derating isenabled to limit the input current to acceptable values.

    28080 90 184 275

    800

    2000

    Pout / W

    230

    650

    60C

    power

    derating

    75C

    power

    derating

    Vin / Vrms

    88

    reduced power

    full power

    Figure 2. Input voltage range

    3.2 Inrush current limitation

    When the rectifier is first connected to the mains, the energy storage capacitors are

    charged via resistors. As soon as a certain voltage limit is reached, these resistorsare short-circuited, the rectifier starts up and delivers output power.

    3.3 Output characteristic

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

    Uout [V]

    Iout [A]

    58

    53.5

    43

    34.5 37.4 46.5

    42

    2000 W

    control range

    Figure 3. Output characteristic

    P0003

    P0004

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    3.4 Output voltage

    The factory setting is defined for flooded battery types: 53.5 V. If a controller withvoltage programming function is used, it can remotely adjust the rectifier output

    voltage to different values via analogue signal interface.

    3.5 Output current

    The factory setting for the output current limit is 46.5 ADC.

    3.6 Cooling

    The device is fan cooled.

    Note! The airflow must not be restricted!

    Air flowShadowed area:

    air outlet on the rear

    Figure 4. Fan cooling of the rectifier.

    3.7 Overvoltage protection OVP

    The rectifier is equipped with a selective over voltage protection (OVP), which shutsdown the rectifier in case of output voltage exceeding an internally set limit. Theprotection is combined with a current measuring condition to achieve selectivitybetween parallel rectifiers; only the guilty rectifier will be shut down. The factory

    setting is 59 V. Reset of OVP shut down can be done by disconnecting the mainssupply voltage for a few seconds.

    P0005

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    3.8 Thermal management

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

    Sensor Monitoring Function

    Reference sensor Combination of heatsink / fresh airtemperature

    Controls the over-temperature protection(OTP) characteristic.

    Protection sensor Main transformertemperature

    Detects interrupted air flowand fan failure.

    Table 1. Thermal sensors.

    The thermal management (reference sensor) reduces the output current in order to

    limit internal temperature according the characteristic in Figure 5 below.

    46.5 A

    Ambient temperature

    OTP shuts down

    Current limitRectifier

    restart

    65C 75C60C50C

    37.4 A

    >1300W

    Figure 5. Reducing the output current in order to limit internal temperature.

    The thermal management (protection sensor) protects the rectifier againstinterrupted air flow and fan failure. During these conditions, the rectifier is shut downas soon as the internal temperature reaches a critical value. After severalunsuccessful restart attempts the rectifier remains shut down and generates analarm.

    3.9 Load sharing

    The rectifier is equipped with an active load sharing function that ensures equal loadon parallel rectifiers. The function uses the signal interface bus between rectifiers.

    This function does not need any other external unit outside rectifiers.

    3.10 Precharge

    The rectifier module is hot-pluggable. Pushing the rectifier into the cabinet connectsleading precharge contacts first to precharge the DC output capacitors. Theremaining output power contacts are connected with a delay.

    P0006

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    3.11 Configuration

    In systems without controller or with PSC 200 / PSC 1000 the rectifier operates withthe factory-set standard configuration; in systems with PSC 3 controller theconfiguration is automatically done upon inserting the rectifier module.

    Push button Config has two assigned functions:

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

    To reset configuration to default factory settings. Press button until LED Comstarts blinking (10 sec. approx.)

    3.12 Enhanced rectifier supervision and control functions

    In systems with PSC 3 controller applying the digital communication, following data

    and their appropriated functions are available.

    3.12.1 Manufacturing data

    The manufacturing data is stored at production. It can be transmitted to PSC 3 uponrequest:

    SAP serial no. / SAP part no.

    SW / HW version no.

    User specific data (like user serial no.)

    3.12.2 Configuration data

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

    Nominal output voltage

    Output current limitation

    Output power limitation

    Maximum output voltage / current / power at start up

    Start up delay, limit time

    Low input voltage for shut down / mains failure detection

    Low input voltage for start up.

    3.12.3 Commands / control data

    The following commands are transmitted from PSC 3 to the rectifier upon request bythe operator or by controller function:

    Start / stop rectifier

    Reset OVP

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

    Output voltage (VPGM)

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    Output current limit / output power limit

    3.12.4 Information data

    The rectifier calculates following data and transmits it upon request:

    Total operating time

    The following data is transmitted by the rectifier periodically:

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

    Rectifier data (output voltage, output current).

    3.12.5 Measurements

    Following data is transmitted upon request from PSC 3 only:

    AC input voltage

    Internal temperatures

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

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    4 FRONT ELEMENTS

    100 %

    Iout

    ok

    Output current LED bar

    Rectifier status indication

    Hole for fixing screw

    Com

    Config "Config" push button

    FR 48 V - 2000 W - E

    P0111

    100 %

    Iout

    ok

    Output current LED bar

    Rectifier status indication

    Hole for fixing screw

    Com

    Config "Config" push button

    FR 48 V - 2000 W - E

    P0111

    Figure 6. The rectifier from front.

    4.1 Rectifier status indications

    LED ok turns off and an alarm is given if:

    Input connection is missing

    Mains voltage is outside the specified range

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

    ! OVP: The lowest orange LED is short flashing

    ! OTP: The middle orange LED is short flashing

    ! Fan failure: The top orange LED is short flashing

    Load sharing not working correctly

    The output fuse is blown

    The rectifier is faulty

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

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

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    5 BACK PLANE

    5.1 Electrical connectionsCombined connector is located on the backside (FCI Power Header R/A 51783-002). The system bus is daisy-chained, with one-to-one connection, from rectifier torectifier and to the controller (if such is used in the system).

    P1: PE AC mains, PE terminal

    P2: L AC mains, L terminal

    P3: N AC mains, N terminal

    A10: NC Reserved for other applications

    B10: VPGM PSC 1000: output voltage programming

    C10: LS_BUS Load sharing bus, refer to sec. 3.9 Load sharing

    D10: GND_SYS Reference ground for PSC 1000 and load sharing

    A11: NCB11: NC

    C11: NC

    D11: RFA PSC 1000: rectifier failure

    A12: GND_SIG Reference ground for D12

    B12: NC Reserved for other applications

    C12: NC Reserved for other applications

    D12: OFF Rectifier enable, reference ground A12, refer to sec.3.10 Rectifier Enable.

    P4: VOUT- DC output

    P5: VOUT- DC output

    P6: OUTP Precharge for output capacitor, refer to sec. 3.11Precharge

    P7: VOUT+ DC output

    P8: VOUT+ DC output

    Table 2. Signals on rectifier connector.

    Warning!Operate the device only with connected PE.

    P0008

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    Energy Systems

    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 200416

    6 MECHANICAL DIMENSIONS

    Figure 7. Mechanical design of the rectifier FR 48 V 2000 W E.

    P0009

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    Energy Systems

    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 2004 17

    7 TECHNICAL SPECIFICATIONS

    General

    Efficiency 91 %Losses, max. 200 WSafety EN 60 950, class I

    UL 60 950CAN / CSA C22.2

    EMI, radiated EN 55 022, class BCompliant with EN 300 386-2Cooling Fan cooledPower density 500 W / l, 8.2 W / in3

    Input

    Voltage range 88...300 VrmsVolt. range, red. power 88...184 Vrms

    Inrush current < 15 ApeakCurrent maximum 12 ArmsLine current Meets IEC 1000-3-2Harmonic distort. THD < 5 %EMI, conducted EN 55 022, class BMains connector Rear sideInput protection Internal fuse 2 x 15 AInput switch None

    OutputVoltage, nominal 53.5 VdcVoltage adjust range 42...58 VdcVoltage error, static 250 mVdc

    Overvoltage protection 59 V 1 V

    Ripple + spikes 200 mVp-p

    Psophometric noise 1.0 mVrms(weighted)

    EMI, conducted EN 55 022, class ACurrent limit, nominal 46.5 AdcLimit adjustment range 0...46.5 Adc

    Load sharing

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    PRODUCT DESCRIPTION RECTIFIER FR 48 V - 2000 W - E

    22 October 200418

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    Energy Systems

    40030_01Issue 24 September 2004

    Installation and Commissioning

    AMS 48/2000-8/16/24 ETSwith PSC 3 controller

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    TABLE OF CONTENTS

    1 DOCUMENT INFORMATION........................................................................................5

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

    2 PREPARING FOR THE INSTALLATION......................................................................7

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

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

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

    4 INSTALLATION.............................................................................................................9

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

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

    4.2.1 Grounding........................................................................................................10

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

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

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

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

    5 COMMISSIONING .......................................................................................................13

    5.1 Starting up the system.....................................................................................136 COMMUNICATION SETTINGS ...................................................................................14

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

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

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

    7 CONFIGURATION OF THE PSC 3 .............................................................................19

    7.1 General............................................................................................................19

    7.2 Terminology.....................................................................................................19

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

    7.10.1 Event processing and assignment for the load PLDs......................................26

    7.10.2 The urgent and non urgent alarms ..................................................................27

    7.10.3 Special mode event.........................................................................................28

    7.10.4 A delayed mainsfailure alarm..........................................................................28

    7.10.5 Adding other events ........................................................................................28

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

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

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

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

    7.15 Maintenance....................................................................................................31

    7.16 Logging ...........................................................................................................32

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

    7.17.1 Float charge parameters .................................................................................33

    7.17.2 Equalize parameters .......................................................................................34

    7.17.3 Battery test parameters...................................................................................35

    7.17.4 Boost charge parameters................................................................................37

    7.18 Finishing..........................................................................................................40

    8 SYSTEM CHECK ........................................................................................................41

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

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

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

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

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

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

    8.3.4 Testing the mains failure alarm .......................................................................459 APPENDIX: INSTALLATION AND COMMISSIONING CHECK LIST ........................ 46

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    1 DOCUMENT INFORMATION

    1.1 Version control

    Document number Document description

    40030_01 Installation and Commissioning,AMS 48/2000-8/16/24 ETS with PSC 3 controller

    Previous version Description of changes

    - New document.

    Controlled by Date

    24.09.2004

    Markku Havukainen

    Approved by Date

    24.09.2004

    Petteri Turkki

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    2 PREPARING FOR THE INSTALLATION

    2.1 Before you begin

    Step 1. Ensure that you have all the equipment needed to make a properinstallation of the system.

    Step 2. Also ensure that grounding terminals, DC- and AC-distributions areproperly available.

    Step 3. Take care that the regulations of IEC 60364 and CENELEC HD384concerning installation and assembling of telecommunication andelectrical equipment have been noticed. The local regulations andspecial instructions must also be noticed during the work. Whenchoosing the place of the installation, please notice that the cooling airmust flow without restrictions through the ventilation holes. The system

    must have enough space in front of it for operation and servicefunctions. Notice the direction of the cabling and the required space ofthe other equipment.

    2.2 Unpacking the system

    Step 1. Check that the received cargo is according to the packing list.

    Step 2. Ensure that the rack and the equipment are not damaged duringtransportation.

    Step 3. Check that proper documents are delivered with the system andnecessary contact information for technical support is included.

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    3 SYSTEM CONFIGURATION

    Cabinet grounding terminal

    DC-distribution fuses

    PSC 3 User Interface Module (UIM)

    Main positive busbar

    Battery connections

    (fuse switches / motor contactors)

    Optional low voltage disconnection (LVD)

    Distribution positive busbar

    Rectifier shelves (1-3 pcs)

    AC-supply terminals

    Distribution positive busbar

    DC-distribution fuses and MCBs

    Adjustable cabinet feet (4 pcs)

    Controller circuit breaker AF10

    1

    2

    3

    4

    5

    6

    7

    8

    9

    11

    14

    15

    Optional Partial Load Disconnect (PLD)

    10

    SSM, PSC 3 controller and CAN distribution

    12

    13

    P0123

    Cabinet grounding terminal

    DC-distribution fuses

    PSC 3 User Interface Module (UIM)

    Main positive busbar

    Battery connections

    (fuse switches / motor contactors)

    Optional low voltage disconnection (LVD)

    Distribution positive busbar

    Rectifier shelves (1-3 pcs)

    AC-supply terminals

    Distribution positive busbar

    DC-distribution fuses and MCBs

    Adjustable cabinet feet (4 pcs)

    Controller circuit breaker AF10

    1

    2

    3

    4

    5

    6

    7

    8

    9

    11

    14

    15

    Optional Partial Load Disconnect (PLD)

    10

    SSM, PSC 3 controller and CAN distribution

    12

    13

    Cabinet grounding terminal

    DC-distribution fuses

    PSC 3 User Interface Module (UIM)

    Main positive busbar

    Battery connections

    (fuse switches / motor contactors)

    Optional low voltage disconnection (LVD)

    Distribution positive busbar

    Rectifier shelves (1-3 pcs)

    AC-supply terminals

    Distribution positive busbar

    DC-distribution fuses and MCBs

    Adjustable cabinet feet (4 pcs)

    Controller circuit breaker AF10

    1

    2

    3

    4

    5

    6

    7

    8

    9

    11

    14

    15

    Optional Partial Load Disconnect (PLD)

    10

    SSM, PSC 3 controller and CAN distribution

    12

    13

    P0123

    Figure 1. AMS 48 /2000-24 ETS with PSC 3 controller.

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    4 INSTALLATION

    In the following step-by-step instructions the bracketed [ ] numbers refer to the

    corresponding numbers in the figure 1.

    4.1 System cabinet

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

    Step 1. Set the system cabinet standing in its place and straighten it if neededby adjusting the feet [15].

    Step 2. Lean to the cabinet and adjust the feet by screwing the feet in or out.

    Step 3. If the system comprises of more than one cabinet set the cabinets nextto each other so that the connecting busbars and cables between thecabinets can be connected (see figure 2).

    Step 4. Connect the cabinet connection busbars and cables between thecabinets according to the wiring diagram attached with the user manual.

    P0124P0124

    Figure 2. AMS 48/2000-24 ETS cabinet connections with cable channels.

    In the figure 2 the system cabinets are connected as one system with a cablechannel in the between. An alternative system configuration is without the cable

    channel. The cabinets are then side to side and connected with shorter busbars.

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    4.2 Electrical connections

    Step 1. Remove the possible covers in front of the distributions and connectionsin the system.

    4.2.1 Grounding

    Step 1. Connect the protective-grounding terminal of the cabinet mechanics [7]to the main grounding busbar of the equipment room by proper cable.

    4.2.2 AC-connection

    Each cabinet in the system has its own AC supply terminal [9]. Below in table 1 arethe recommended mains fuse sizes and cable cross sections for3-phase AC-connections of the AMS 48/2000 ETS power systems.

    System, AC-input Mains fuse Cable

    AMS 48/2000-8, 1 x 3-phase 3 x 40 A 5 x 10 mm2

    AMS 48/2000-16, 2 x 3-phase 2 x (3 x 40 A) 2 x (5 x 10 mm2)

    AMS 48/2000-24, 3 x 3-phase 3 x (3 x 40 A) 3 x (5 x 10 mm2)

    Table 1. Mains fuse sizes and cable cross sections for AC-connections.

    Note! Check the AC connections from the wiring diagram and the illustration ofAC connections to the system attached to the user manual.

    4.3 Battery connections

    Step 1. Connect the positive battery cable(s) to the main positive busbar [8] and

    the negative cable(s) to the respective fuse switch or motor contactorconnections [10].

    Step 2. Place the battery temperature sensor between the batteries in thebattery area. Fasten the sensor cable to the subrack.

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    4.4 Alarm and control connections

    Step 1. Connect the remote alarm cables to the terminals in the PSC 3 frontpanel [13] (Figure 3).

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

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

    OUT 1 OUT 2 OUT 3 OUT 4

    P0125

    Figure 3. The remote alarm connections.

    In case the system consists of two cabinets, the CAN distribution [13] must beestablished between the cabinets.

    Step 1. Connect the 4-pole and the 8-pole cables (delivered with the system)between the cabinets, to the free CAN distribution interfaces (Figure 4).

    Cabinet 2

    CAN Distribution

    P0126

    Cabinet 1

    CAN Distribution

    Figure 4. CAN distribution connections between two cabinets.

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    4.5 DC-load connections

    Step 1. Connect the distribution cables. Plus cables are connected to thepositive busbars [1] and [5] and the negative cables directly to the

    connections of the DC distribution circuit breakers [2] and fuse bases [6]as in the Figure 5.

    Note! Take care that the cable is behind the bar and not directly under thescrew.

    + +

    P0127

    ++ +

    P0127

    +

    Figure 5. Connection of distribution cables.

    Note! The maximum cable sizes for the positive busbar connections areMCB 1 A - 20 A max. 16 mm2MCB 25 A - 63 A max. 35 mm2NH00 160 A max. 70 mm2

    NH01 250 A max. 120 mm

    2

    NH02 400 A max. 240 mm2NH03 630 A max. 240 mm2.

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    6 COMMUNICATION SETTINGS

    The PSC 3 controller is configured through RS232 or LAN interface on the controller

    front panel, using a computer and a standard web browser. There is also aninterface for a modem on the front panel (Figure 6).

    Before configuration of the controller, the computer must be set correctly forcommunication with the PSC 3. The PSC 3 also requires information forcommunication in the Local Area Network (LAN). The computer settings in thisinstruction are made in the Microsoft Windows 2000 operating system.

    Modem

    Ethernet (LAN)

    RS232P0128

    Modem

    Ethernet (LAN)

    RS232

    Modem

    Ethernet (LAN)

    RS232

    Modem

    Ethernet (LAN)

    RS232P0128

    Figure 6. Communication interfaces on the PSC 3 front panel.

    6.1 Setting the computer for the serial connection

    The direct connection from computer to the PSC 3 is made either to the RS232serial port or to the LAN interface on controller front panel. The following step-by-step instructions show how to make the computers serial settings for the RS232

    interface.Step 1. Switch ON the AF10 circuit breaker to switch the controller on.

    Step 2. Connect your computer to the RS232 serial port with the cable deliveredwith the system.

    Step 3. Open the Control Panelon your computer and open the Network andDial-up Connections settings. Double-click on Make New Connection.

    Step 4. The Network Connection Wizardopens (see the Figure 7).

    P0129P0129

    Figure 7. The Network Connection Wizard.

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    Step 5. Click on the Next button and from the new Network Connection Typewindow, choose Connect directly to another computer and click onNext.

    Step 6. From the new Host or Guestwindow, choose GuestStep 7. From the new Select a Device window, choose

    Communications cable between two computers

    Step 8. From the new Connection Availabilitywindow, choose For all users

    Step 9. A new Completing the Network Connection Wizardwindow opens.Give a name for the connection e.g. PSC 3 Serial Connection, andclick on Finish.

    Step 10. The login page for the connection opens. Click on Properties.

    Step 11. From the new window choose the Generalsettings and from the Selecta device drop down menu choose Communication cable between two

    computers. At the bottom left corner of the Generalsettings is acheckbox for Show icon in taskbar when connected, which is useful tobe checked. Then click on Configure.

    Step 12. From the new Modem Configuration window, choose Maximum speed of38400 (bps) and click on OK.

    Step 13. The Options and Securitysettings do not require any changes.

    Step 14. Make the following settings for the Networking(see the Figure 8):- Type of dial-up server I am calling = PPP- Components checked are used by this connection = TCP/IP- Remove the check mark from the rest of the components

    P0130P0130

    Figure 8. Networking settings for the PSC 3 Serial Connection.

    Step 15. The Sharingsettings do not require any changes.

    Step 16. Click on OK.

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    Step 17. The login page appears (see the Figure 9). To connect to the PSC 3,give the user name fourier and password psc3, and then click onConnect.

    P0131P0131

    Figure 9. Login page for the PSC 3 Serial Connection.

    6.2 Setting the computer for the LAN connection

    To connect a computer directly to the LAN interface of the PSC 3 (see the Figure 6),some preparations are needed for the computers link speed and IP addresssettings.

    Step 1. Open the Control Panelof your computer, and then the Network andDial-up Connections settings.

    Step 2. Open the properties forLocal Area Connection, then click on Configureand go to the Advancedsettings (see the Figure 10).

    P0132P0132

    Figure 10. The Link Speed & Duplex Settings.

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    Step 3. Choose the Link Speed & Duplex from the Propertyoptions and set theValue to 10Mbps/Full Duplex. Then click on OK.

    Step 4. Go back to the Local Area Networkwindow. Choose the option Internet

    Protocol TCP/IP and click on Properties (see the Figure 11).

    P0133P0133

    Figure 11. The LAN properties.

    Step 5. A window forInternet Protocol TCP/IPproperties opens. The computersIP address must be set manually for the direct computer-to-PSC 3connection. Choose the option Use the following IP address, anddefine the IP address to the same network area as the PSC 3. Only thenumbers in the last section of the IP address must be different. Thedefault IP address of the PSC 3 is 192.168.0.73. Computers IP addresscan be e.g. 192.168.0.74, as in the Figure 12. Click on OK.

    P0134P0134

    Figure 12. The IP address of the computer.

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

    6.3 Setting the PSC 3 for the LAN communication

    The following information is required to prepare the PSC 3 for communication in thelocal area network:

    IP address provided by the network administrator

    Subnet-mask provided by the network administrator

    Gateway address (default) provided by the network administrator

    MAC-address worldwide unique address per device

    Step 1. Connect directly from your computer to the PSC 3. The connection can

    be made either to the RS232 or to the LAN (recommended) interface,with a proper cable.For the LAN interface a crossover cable is needed (see the Figure 13).

    P0135

    1

    2

    3

    4

    5

    6

    7

    8

    1

    2

    3

    4

    5

    6

    7

    8P0135

    1

    2

    3

    4

    5

    6

    7

    8

    1

    2

    3

    4

    5

    6

    7

    8

    Figure 13. The crossover LAN cable.

    Step 2. Open your web browser and connect to the default IP address(192.168.0.73) of the PSC 3.The PSC 3 Configuration and Supervision Toollogin page opens.

    Step 3. Give the username and password, and click on Submit button. Thehome page of the PSC 3 Configuration and Supervision Toolopens.

    Step 4. On the left side of the window there is a menu tree. Go the followingsubmenu: System Interface SetupA window with interface settings (Interface Setup) opens.

    Step 5. Give the IP address, subnet-mask and gateway address of the PSC 3,provided by your network administrator, then click on Accept Changes.

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

    Step 6. Save the settings. Go to menu: Configuration Setup UpdateClick on Save in the User Setup section of the window.

    Step 7. Log out.

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

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    7 CONFIGURATION OF THE PSC 3

    7.1 GeneralThe PSC 3 controller is preconfigured at the Delta Energy Systems factoryaccording to the system configuration. To give an understanding how the controlleroperates and controls the power system, the following step-by-step instructionsshow how to make the configuration from the beginning. The configuration order isthe following:

    Step 1. Defining the system characteristics

    Step 2. Defining the system architecture

    Step 3. Defining the bus components of the IMBUS (Inter Module Bus)

    Step 4. Defining the measurements in the power system

    Step 5. Defining the events in the power system (based on the measurements)

    Step 6. Assigning the I/O functionality for the SENSN devices (measurements)

    Step 7. Setting the event processing

    Step 8. Setting the alarms

    Step 9. Assigning the I/O functionality for the PSC 3 (remote alarms) and for theSSM (LVD and PLD)

    Step 10. Assigning the system status indications and the UIM

    Step 11. Checking the maintenance functions

    Step 12. Setting the logging

    Step 13. Setting the battery functions(float charge, equalize, battery test and boost charge)

    Step 14. Finishing.

    7.2 Terminology

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

    Battery

    Shunt 1

    Battery

    Shunt 2

    BatteryLVD

    Load

    Shunt 1

    PLD 2

    PLD 1

    LoadGroup 3

    Load

    Group 2

    Load

    Group 1P0136

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

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    7.3 The menu structure for the web GUI

    The menu structure of the PSC 3 Configuration and Supervision Tool(web GUI) is presented below in the Figure 15.

    Alarm

    Load

    Battery

    Log

    Rectifier

    System

    Maintenance

    Configuration

    Home

    Status

    Setup

    Monitor

    Entries

    Setup

    Monitor

    Control

    Test Results

    Monitor

    Control

    Functions

    Customer Settings

    User Management

    Interface Setup

    Time & Date

    Alarm

    LVD

    I/O

    Signal Processing Engine

    System Architecture

    Bus Components

    Measurements

    Event Definitions

    Event Processing

    System Status & UIM

    PSC 3

    SENSN

    SSM

    Battery Setup

    Load Setup

    Rectifier Setup

    RM Grouping

    SENSN

    SSM

    Digital Rectifier

    UIM

    System Characterictics

    System Parameter

    PSC3 Hardware

    System Geometry

    Setup Update

    Software Update P0137

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

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    7.4 Defining the system characteristics

    The system parameters are the basic characteristics of a power system, such aspolarity, rectifier communication type and nominal voltage. These parameters are

    set at the start of the PSC 3 configuration and can not be modified there after.Step 1. Open your web browser and connect to the PSC 3 with the IP address

    set earlier (chapter 6.3 ). Log in to the PSC 3 Configuration andSupervision Tooland go to menu:

    ConfigurationSystem CharacteristicsSystem Parameter

    Step 2. Choose the correct polarity of the system e.g. Positive Polarity,

    Step 3. Choose the correct rectifier bus type e.g. digital,

    Step 4. Choose the correct nominal voltage of the system e.g. 48 V,

    Step 5. Save the settings. Go to menu:

    Configuration Setup UpdateClick on Save in the User Setup section of the window.

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

    7.5 Defining the system architecture

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

    7.5.1 Battery shunts

    The settings for battery shunts are located in the menu:

    ConfigurationSystem ArchitectureBattery Setup

    Step 1. Define the correct battery string type from the drop down menu and clickon the Add button.

    Step 2. A window with battery string settings opens. Give the nameBattShunt1 for the first battery string (see the Figure 14). Then definethe battery capacity and the maximum battery current limit Max. Ibatt.Then click on Add Battery String.

    Step 3. Define and set values for as many battery strings as in the system, usingthe naming BattShunt2, BattShunt3 etc.

    Step 4. Create an additional battery string BattLVD as above. This string iscreated only to drive the LVD relay. The LVD for the batteries is set later.

    Note! After a battery or load string is created, the PSC 3 creates automaticallya LVD event, which is later used to drive the LVD relay. The name of theevent is based on the battery or load string name, having an additionalprefix L, e.g. L BattLVD or L PLD1

    Step 5. When you are finished click on the Accept changes.

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    7.5.2 Load shunts

    The settings for load shunts are located in the menu:

    ConfigurationSystem ArchitectureLoad Setup

    Step 1. Define the correct load string type from the drop down menu and click onthe Add button.

    Step 2. A window for the new load string opens. Give the name LoadShunt1for the first load string (see the Figure 14), and click on Add LoadString.

    Step 3. Define as many load strings as there are load shunts in the system,using the naming LoadShunt2, LoadShunt3 etc.

    Step 4. Create additional load strings for each PLD in the system as above,using the naming PLD1, PLD2 etc. (see the Figure 14). These strings

    are created only to drive the LVD relays for the PLDs that are set later.Step 5. When you are finished click on the Accept changes button.

    7.5.3 Rectifier setup

    ConfigurationSystem ArchitectureRectifier Setup

    Step 1. Define the threshold value for the number of failed rectifiers that issue anUrgent Alarm, and then the value for the number of failed rectifiers thatissue a Non Urgent Alarm.

    Step 2. When you are finished click on the Accept changes button.

    7.5.4 Rectifier grouping

    Note! The menu RM Grouping is for defining rectifier groups and rectifiergroup settings. In the current version of the PSC 3 software the settingsare allowed for only one rectifier group (RFMGroup1).

    ConfigurationSystem ArchitectureRM Grouping

    Step 1. Go to the menu RM Grouping and click on Edit button of theRFMGroup1. Set the following values for the rectifiers:

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

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

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

    Group Settings: LastThe value of the first and last rectifier in the group. In the current version of thePSC 3 software only one rectifier group can be defined and therefore the valuefor Last is the number of rectifiers in the system.

    Step 2. When you are finished click on the Accept changes button.

    Step 3. Save the settings.

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    7.6 Defining the IMBUS components

    The next phase is to define existing physical connections of the IMBUS componentsfor the PSC 3. The components are such as the SENSN devices, String Sensor

    Modules (SSM), rectifiers and User Interface Modules (UIM). The UIM, SSM andrectifiers are recognized automatically by the PSC 3, but SENSN devices have to bedefined manually.

    The SENSN devices are usually connected to SSM interfaces 1-3 or directly to thePSC 3 (check from the wiring diagram). In the following instructions the SENSNdevices for one load shunt and two battery shunts (see the Figure 14) are defined tothe SSM1 interfaces 1-3. In case there are more battery or load shunts, there is anadditional SSM module (SSM2) in the system.

    The SENSNs are defined to the SSM interfaces in the menu:

    ConfigurationBus ComponentsSENSN

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

    Step 2. To define the SENSN for the battery shunt 1 choose the Bus Name:SSM1 from the first drop down menu and address 2 in the next dropdown menu. Then click on Add SENSN. And finally define the SSM1interface 3 for the battery shunt 2.

    Step 3. Save the settings.

    7.7 Defining the measurements

    The next step is to set the necessary measurements and their threshold values inthe system. As default the PSC 3 creates measurements for the system voltageUsys and battery temperature Tbatt. The load and battery fuse measurementsare created next.

    The measurements are set in the menu:

    ConfigurationSignal Processing EngineMeasurements

    Step 1. Give the name Ufuse_Lshunt1 for the load fuse measurement,and choose the signal type digital from the drop down menu.Then click on Add button.

    Step 2. A new Digital Measurementwindow opens. Define the voltage limit and

    hysteresis for the load fuse measurement.Then click on Accept Changes and go back to measurements window.

    Step 3. Give the name Ufuse_Bshunt1 for the battery fuse measurement,and choose the signal type digital from the drop down menu.Then click on Add button.

    Step 4. A new Digital Measurement window opens. Define the voltage limit andhysteresis for the battery fuse measurement.Then click on Accept Changes and go back to measurements window.

    Step 5. Give the name Ufuse_Bshunt2 for the second battery fusemeasurement, choose the signal type digital from the drop down menuand click on Add button. Then define the voltage limit and hysteresisand click on Accept Changes. Return to measurements window.

    Step 6. Save the settings.

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    7.8 Defining the events

    The next phase is to create the user defined events based on the measurements.These events can be later further processed and used for other events, as well as

    for logging and alarms. The following instructions define and set the most importantevents:

    The events for too low and too high system voltage

    The events for too low and too high battery temperature

    The event for too high system power

    The event for battery LVD, based on voltage

    The events for load PLD, based on voltage

    The events are defined and set in the menu:

    Configuration

    Signal Processing Engine

    Event Definitions

    7.8.1 Events for too high and too low system voltage

    Define first the maximum and minimum threshold values (events) for systemvoltage. The PSC 3 creates as default the event S Usys low, based on measuredsystem voltage Usys.

    Step 1. To create a maximum threshold value for the system voltage click onEdit button next to S Usys low.

    Step 2. A new Threshold Editorwindow opens. Write the name of the new eventUsys high to the TooHigh Eventfield. Then define the Upper Limitforthe system voltage and if needed adjust the values for the Hysteresis

    and Lower Limit. Then click on Change Definition and go back to eventdefinitions window.

    7.8.2 Events for too high and too low battery temperature

    Define next threshold values (events) for high and low battery temperature, basedon the battery temperature measurement Tbatt.

    Step 1. Choose first the measurement Tbatt from New Signal Event, and thenclick on Add.

    Step 2. A new Threshold Editorwindow opens. Give the names Tbatt highand Tbatt low for the TooHigh Eventand TooLow Event. Then define

    the temperature limits for the Upperand Lower Limit, and define theHysteresis as well. When done, click on Add Definition and go back tothe Event Definitions menu.

    7.8.3 Event for too high system power

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

    Step 1. Choose first the measurement Psys from New Signal Event, and thenclick on Add.

    Step 2. A new Threshold Editorwindow opens. Give the name Psys high forthe TooHigh Eventand then give values for the Upper LimitandHysteresis. When done, click on Add Definition and go back to the

    Event Definitions window.

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    7.8.4 An event for the battery LVD

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

    Step 1. Choose first the measurement Usys from New Signal Event, and thenclick on Add.

    Step 2. A new Threshold Editorwindow opens. Give the name LVD for theTooLow Eventand then give the voltage value for the Lower LimitandHysteresis. When done, click on Add Definition and go back to eventdefinitions window.

    Step 3. Now there is an event to drive the battery LVD relay. This event must beassigned to the battery string BattLVD, which was created in thechapter 7.5.1. Go to menu:

    ConfigurationSystem ArchitectureBattery Setup

    Step 4. Click on the LVD button of the battery string BattLVD, and choose theevent LVD from the Eventdrop down menu. Click on AcceptChanges button.

    7.8.5 Events for the load PLDs based on voltage

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

    Step 1. Choose first the measurement Usys from New Signal Event, and thenclick on Add.

    Step 2. A new Threshold Editorwindow opens. Give the name PLD1 [U] forthe TooLow Eventand then give the voltage value for the Lower Limitand Hysteresis. The recommendation is to use a hysteresis value whichis, together with the Lower Limit, 1 V below Ufloat voltage. When done,click on Add Definition and go back to event definitions window.

    Step 3. If needed, define the events for rest of the PLDs in the system as above,using the naming PLD2 [U], PLD3 [U] etc.

    Step 4. When all necessary events have been defined and set, click on Accept

    Changes.

    Step 5. Save the settings.

    7.9 I/O assignments of the SENSNs

    The next phase is to assign the load and battery fuse measurements from theSENSN devices to the correct SSM interfaces (see chapter 7.7 )..

    Normally the SSM interfaces are used in the following way (check the wiringdiagram):

    SSM1 interface #1 SENSN for the load shunt 1

    SSM1 interface #2 SENSN for the battery shunt 1

    SSM1 interface #3 SENSN for the battery shunt 2

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    The SENSN measurements are assigned in the menu:

    Configuration I/O SENSN

    Step 1. Choose LoadShunt1 for the SSM 1, address 1 from the drop down

    menu. Then click on Edit by the string assignment. In the new SENSNInput Setup window, define the nominal current of the shunt (Value), andthen define the fuse measurement Ufuse_Lshunt1 as the additionalfuse measurement. The temperature sensor is normally connected toload SENSN and therefore define also the temperature measurementTbatt as the additional temperature measurement. Click on AcceptChanges, and go back to previous window.

    Step 2. Choose BattShunt1 for the SSM 1, address 2 from the drop downmenu. Then click on Edit by the string assignment. In the new SENSNInput Setup window, define the nominal current of the shunt (Value), andthen define the fuse measurement Ufuse_Bshunt1 as the additional

    fuse measurement. Click on Accept Changes, and go back to previouswindow.

    Step 3. Choose BattShunt2 for the SSM 1, address 3 from the drop downmenu. Then click on Edit by the string assignment. In the new SENSNInput Setup window, define the nominal current of the shunt (Value), andthen define the fuse measurement Ufuse_Bshunt2 in the additionalmeasurements. Click on Accept Changes, and go back to previouswindow.

    Step 4. Click on Accept Changes.

    Step 5. Save the settings.

    7.10 Event processing and alarms

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

    ConfigurationSignal Processing EngineEvent Processing

    7.10.1 Event processing and assignment for the load PLDs

    The primary drivers of the PLD relays are delay based events. These events have atime threshold, which is a delay from mainsfailure to disconnect a load group. Withdifferent time thresholds separate load groups can be prioritized for different loads.

    In the chapter 7.8.5 some voltage based events were created as secondarycondition for the PLDs. The event processing feature enables combining the voltageand time based events as one event, which is then used to drive the PLD relays.

    Step 1. First the new time filtered event must be created for the load PLDs.Choose the event type Filter from the drop down menu, and click onAdd button.

    Step 2. A new Filtered Eventwindow opens. Give the name PLD1 [t] for thenew event and choose the event S Mainfailure from the drop downmenu as a base for the time filtered event. Then define the TRUEandFALSEtime thresholds. The TRUEvalue is the delay for the event to beactivated after mains failure. The FALSEvalue is the delay for the event

    to be deactivated after mains is back on. When done, click on the AddNew Definition button.

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    Step 3. Define as many time filtered events as there are PLDs in the system(Figure 14), using the naming PLD2 [t], PLD3 [t] etc.

    Step 4. Now the voltage based events and time based events of the load PLDs

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

    Step 5. Define as many combined events as there are PLDs in the system(Figure 14), using the naming PLD2 [U + t], PLD3 [U + t] etc.

    Step 6. Now the necessary events to drive the load PLD relays exist. Theseevents must now be assigned to the additional load strings PLD1,PLD2 etc., which were defined in the chapter 7.5.2. Go to menu:

    ConfigurationSystem ArchitectureLoad Setup

    Step 7. Click on the LVD button of the load string PLD1, and choose theevent PLD1 [U + t] from the Event drop down menu.Click on Accept Changes button.

    Step 8. Assign the PLD [U + t] events to the respective additional load strings(PLD2 [U + t] PLD2 and PLD3 [U + t] PLD3 etc.).

    Step 9. Save the settings.

    7.10.2 The urgent and non urgent alarms

    As default the PSC 3 has two types of alarms in the Event Processing:

    Urgent Alarm UA Non-Urgent Alarm NUA

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

    S Usys high

    All the fuse alarms Ufuse_Lshunt1, Ufuse_Bshunt1 and Ufuse_Bshunt2.

    Step 1. Click on Edit button at the end of the S Urgent Alarm row and add theadditional events. Then click on Change Definition.

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

    Psys high,

    PLD1 [U+t] and PLD2 [U+t]

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

    Step 2. Click on Edit button at the end of the S Non Urgent Alarm row andadd the additional events. Then click on Change Definition.

    Step 3. Save the settings.

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    7.10.3 Special mode event

    To indicate that there is some special activity in progress in the power system acombined OR event called Special mode is created next. This event combines all

    the events that are wished to be signaled as special activity in the system by the fifthLED in the UIM and by the fifth symbol in the web GUI.

    Step 1. Create a new OR event by choosing the event type OR from the dropdown menu and by clicking the Add button.

    Step 2. Give the name Special mode for the new OR event and then choosethe events that you wish to be signaled as special activity in the system.Recommendation is to add the battery charging events S EQ inProgress (equalize) and S BC in Progress (boost charge). Add alsothe battery test event S BT in Progress.

    Step 3. Accept the new event by clicking on Add New Definition.

    7.10.4 A delayed mainsfailure alarm

    With Event Processingit is also possible to create delayed events e.g. for mainsfailure. These types of events are useful for example when momentary (very short intime) mains failures are not wished to be signaled as remote alarms (I/Oassignments of the PSC 3).

    Step 1. To create a time filtered event choose the event type Filter in the dropdown menu and click on Add.

    Step 2. In the new Filtered Eventwindow give the name MF delay for the newevent and define the S Mainsfailure event as a base for the new event.Then set the delay time (TRUEvalue) and click on Add New Definition.

    Note! Later the MF delay can be used as remote alarm for the digital outputof the PSC 3 controller.

    7.10.5 Adding other events

    To add a new event:

    Step 1. Choose event type (AND, OR, Inversion or Filter) and click on OK.

    Step 2. A new window opens. Give a name for the event and then chooseconditions (events or time filters) for the new event.Then click on Add New Definition and go back to the event processing.

    Step 3. Save the settings.

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    7.11 Alarm setup

    In the Alarm Setup menu it is possible to add events as alarms. Only the alarms canbe inhibited with the Alarm Stop button. The alarm stop functionality requires also

    activation of the function for each alarm in the Maintenance menu (s. chapter 7.15 ).As default the Urgent Alarm and Non Urgent Alarm are defined as alarms, eventhough they are not visible in the list. The alarms in the Alarm Setup list are alsoused for the I/O assignment in the PSC 3 digital outputs, to signal remote alarms.The alarms that are defined in the Alarm Setup will automatically receive a prefixA, which appears in the menus where events and alarms are assigned. It isrecommended to add at least the mains failure alarm with delay (MF delay) orwithout delay (S Mainsfailure) to the list.

    Only events that have been defined as alarms can be seen in the user interfacemodule (UIM) as a source of alarm. Therefore it is recommended to add all criticalsystem events (fuse alarms, load disconnects, battery disconnects, battery

    temperature events etc.) to the alarm list. Otherwise they will be indicated only asUA or NUA alarms, without further information about the alarm source. The alarmsource investigation can then be done only through the web user interface of thePSC 3 controller.

    The Alarm Setup menu in located in:

    AlarmSetup

    Step 1. From the new Alarm Setup window choose the event MF delay fromthe Non-Alarm Events, then click on Add >>. The MF delay eventappears in the Deleteable window.

    Step 2. Add other events as above.

    Step 3. Save the settings.

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    7.12 I/O assignments of the PSC 3

    The PSC 3 has four digital outputs on the front panel for signaling alarms (e.g. NUA,UA and Mains Failure), and two digital inputs for measurements. Assigning the

    digital outputs for remote alarms is done in the menu:

    ConfigurationI/OPSC3

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

    Note! When an alarm with prefix A is defined for an output relay, the relay isin the position NO (Normally Open) when the alarm is not active and inthe position NC (Normally Closed) when the alarm is active. For the

    events the relay positions are in the opposite way.

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

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

    Step 3. If needed, choose an event for the output OUT 3, e.g.A S Mainsfailure or A S MF delay if the momentary mains failures arenot to wished to be signaled as remote alarms (see chapter 7.10.4).

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

    Step 5. If needed, choose measurements for the inputs IN 1 and IN 2 to use forevent processing.

    Step 6. Save the settings.

    7.13 I/O assignments of the SSM

    The SSM has three digital outputs for signaling LVDs and four digital inputs formeasurements. The assigning of the output relays for the battery LVD and loadPLDs is done in the menu:

    Configuration

    I/O

    SSMStep 1. All String Sensor Modules in the system can be seen in the SSM

    Overviewmenu. To assign the inputs and outputs for a SSM click on theEdit button next to the SSM Imbus ID.

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

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