Rectifier RT9- 24V, MCSU-4 Installation, Operation And Technical Manual

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Installation, Operation and

Technical Manual

RT9- 24V and MCSU-4 Rack Power System

Document: 158-1872-01

Date: 19 February 2014

ACN 058 107 707

Installation, Operation and Technical Manual Rectifier Technologies

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Table of Contents

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

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

3. Configuration..............................................................................................................5

3.1 System Description................................................................................................5

3.1.1 General Description........................................................................................5

3.1.2 Rectifier Specific Configurations.....................................................................7

4. Installation..................................................................................................................8

4.1 System Installation ................................................................................................8

4.1.1 Racks .............................................................................................................8

4.1.2 Magazines......................................................................................................8

4.1.3 Lightning and Transient Suppression.............................................................8

4.1.4 Cabling, Auxiliary Equipment and Circuit Breakers........................................9

4.2 Rectifier Installation and Removal.......................................................................11

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

4.2.2 Inserting a Rectifier into the Magazine .........................................................11

4.3 MUIB - Mini User Interface Board........................................................................12

4.3.1 MUIB Connections .......................................................................................12

4.4 MUIB2 - MCSU-4 User Interface Board (type2)...................................................16

4.4.1 System setup requirement............................................................................16

4.4.2 Main features of MUIB2................................................................................16

4.4.3 MUIB2 Connections .....................................................................................16

4.4.4 Fuses............................................................................................................18

4.5 MUIB3 – Systems with Earth Leakage Detection................................................21

4.5.1 System setup requirement............................................................................21

4.5.2 Main features of MUIB3................................................................................21

4.5.3 MUIB3 Connections .....................................................................................21

4.6 Single Phase AC Monitoring Module – MMIB4....................................................26

4.7 Three Phase AC Monitoring Module – MMIB2 ....................................................26

4.8 SMM - Site Monitor Module.................................................................................28

4.8.1 Electrical Specification .................................................................................28

4.8.2 Physical Specification...................................................................................28

4.8.3 Installation....................................................................................................29

4.8.4 System Set-up..............................................................................................29

4.8.5 Site Monitor Settings ....................................................................................31

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4.9 Battery Cell Monitor (BCM)..................................................................................32

4.9.1 Main Features of the BCM............................................................................32

4.9.2 BCM Specifications ......................................................................................33

4.9.3 Preparing the battery for connection to the BCM..........................................33

4.9.4 Installing the board.......................................................................................34

4.9.5 Dip-Switch Selection of Cell Voltages ..........................................................34

4.9.6 Battery Cell Lead Connection to the BCM board..........................................35

5. Remote Communication Interfaces........................................................................43

5.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU)............................................43

5.2 RS232 Interface (MCSP).....................................................................................43

5.3 RS485 Interface (MCMD)....................................................................................43

5.4 Integrated Packet Modem (Smart Modem)..........................................................43

6. Operation..................................................................................................................45

Summary of MCSU-4 front panel controls ....................................................................45

6.1 MCSU-4 Components .........................................................................................46

6.1.1 Alpha-numeric Display..................................................................................46

6.1.2 Front Panel Pushbuttons..............................................................................46

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

6.2 Operating the MCSU-4........................................................................................47

6.2.1 Password security........................................................................................47

6.2.2 Test Mode ....................................................................................................48

6.2.3 Entering and moving through different Menus..............................................48

6.2.4 When an alarm condition exists....................................................................48

6.3 MCSU-4 Alarms...................................................................................................49

6.4 User programmable relay functions.....................................................................50

6.5 Mapping of loaded SMRs ....................................................................................51

6.6 MCSU-4 Base Menu Screens..............................................................................51

6.6.1 Single Phase AC Monitoring Screens ..........................................................51

6.6.2 Three Phase AC Monitoring Screens...........................................................52

6.6.3 Base Menu Programmable Parameters .......................................................53

6.6.4 Auxiliary Function Selection & Parameters...................................................57

6.7 SMR Menu Screens ............................................................................................61

6.7.1 SMR Menu Programmable Parameters .......................................................62

6.7.2 SMR Menu Sleep Mode ...............................................................................63

6.8 Battery Parameter Menu Screens .......................................................................64

6.9 Battery Discharge Test........................................................................................68

6.9.1 Results of last Battery Discharge Test - (Last BDT).....................................70

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6.10 Alarms Log Screens.........................................................................................71

6.11 Battery Cell Monitor Setup...............................................................................71

6.11.1 Relationship between “BCM Batteries” and “Num Batteries”........................72

6.11.2 Frequency of measurement..........................................................................72

6.11.3 Battery Cell Measurements..........................................................................72

6.12 Earth Leakage Detector - MUIB3 and MUIB5 only...........................................73

7. Commissioning ........................................................................................................74

7.1 Indicators on the Rectifier Front Panel ................................................................74

7.2 System Parameter Ranges .................................................................................74

7.2.1 RT9 SMR Parameters..................................................................................74

7.3 System Commissioning.......................................................................................74

7.3.1 Commissioning Procedure ...........................................................................75

8. Maintenance .............................................................................................................76

8.1 Warnings and precautions...................................................................................76

8.2 SMR Maintenance...............................................................................................76

8.2.1 Current Sharing............................................................................................76

8.2.2 Integrity of Electrical Connections................................................................76

8.2.3 Fan Filter Maintenance.................................................................................76

9. Fault Finding and Replacement Procedures .........................................................78

9.1 System Fault Finding Procedures........................................................................78

9.2 MCSU-4 Fault Finding and Repair Procedures ...................................................81

9.2.1 Replacing MCSU-4.......................................................................................82

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1. General Warnings

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

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

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

4. The rectifier must be mounted in a rack that satisfies requirements for electrical enclosures and fire enclosures according to IEC60950 or equivalent standard. The back of the rectifier magazine must not be accessible to operators under any condition. Suitable access barriers above the topmost and below the bottom-most magazine must prevent operator access to the back of the magazine.

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

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

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

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

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2. Summary of Programmed System Parameters

Parameter

Description

Range

Default

Value

Actual

Value

Base (System) Menu

Amb Tmp Alm

Ambient temperature alarm level

30-99°C

55°C

Volts Hi

System output volts high threshold

26-33V

28.7V

Volts Low

System Output volts low threshold

20-27V

22.5V

System:

Select system duty type

UPS/Standby

UPS

No. of SMRs

Set number of SMRs in the system

0-225

Num Batteries

Number of Battery strings installed

1-41)1

FS Batt I

Battery current transducer full scale rating

10-30000A

100A

CSU #

CSU Access code (up to 7 digits)

0-9999999

0000000

Date / Time

Current system date and time

Auxiliary Units Submenu

AC 1-ph Menu

(After enabling AC 1-ph Monitor)

1ph ACV Hi

AC supply high voltage alarm

220-315V

260V

1ph ACV Lo

AC supply low voltage alarm

140-270V

200V

1ph ACF Hi

Frequency high alarm

50-65Hz

55Hz

1ph ACF Lo

Frequency low alarm

40-60Hz

45Hz

1ph ACI FS

AC supply current transducer full scale rating

10-500A

100A

AC 3-ph Menu

(After enabling 3-ph AC Monitor)

3ph ACV Hi

AC supply high voltage alarm

220-315V

260V

3ph ACV Lo

AC supply low voltage alarm

140-270V

200V

3ph ACF Hi

Frequency high alarm

50-65Hz

55Hz

3ph ACF Lo

Frequency low alarm

40-60Hz

45Hz

3ph ACI FS

AC supply current transducer full scale rating

10-500A

100A

Battery Monitor Menu

(After enabling Battery Monitor)

Bat Config

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

Various

configurat’ns

12 cells

BCM Batteries

Number of battery banks to be monitored

1-4

Vhi Cell

Cell high voltage alarm

2.0-16.0V

2.5V

Vlow Cell

Cell low voltage alarm

1.0-12.0V

1.8V

+dVc Cell

Cell positive deviation alarm

5-99%

10%

-dVc Cell

Cell negative deviation alarm

5-99%

10%

Site Monitor Menu

If included in the system refer to Site Monitor documentation.

SMR Menu

SMR Float

Operating float voltage

27.5V

SMR Equalise

Operating equalisation voltage

28.5V

SMR V High

SMR voltage high alarm

26-32.5V

28.0V

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Parameter

Description

Range

Default

Value

Actual

Value

SMR V Low

SMR voltage low alarm

22-27V

24.0V

SMR HVSD

SMR high volts shut down

27-33V

28.7V

SMR I Limit

SMR current limit

5-130A

15A

SMR Power Max

Max power for SMR

0-8000

1400

Sleep Mode

SMR Sleep Mode Enable.

On/Off

Off

Sleep Min SMR

SMR Sleep Mode Minimum rectifiers that must be online.

0 to Number SMR defined in the system

Sleep Rotation

SMR Sleep Mode rectifier rotation value (in Days).

1 to 365, 0 =

Off – no

rotation

7 days

Battery Menu

B Dis Al

Battery discharge alarm threshold

22-26V

23.0V

Disch I Diff

Battery string discharge current difference alarm

5-99A

20A

Batt T Alrm

Battery Temperature alarm threshold

30 to 90°C

40°C

Bat Rated

Ampere-hour rating of batteries

20 to 9999AH

500Ah

BTC

Battery Temperature Coefficient

0-6mV/°C/cell

0mV(Off)

Number Cells

Number of chemical cells in battery string

11-23

BILim Vb<Vdd

Battery charging current limit for Vb < Vdd

5-999A

50A

Vdd Level

Battery deep discharge voltage threshold

20-23.5V

22.5V

BILim Vb<Vf1

Battery charging current limit between Vdd & Vfl

5-999A

50A

Sys Float

System float voltage (Vfl)

24-29V

27.0V

Sys Drop

System voltage drop

0.0-1.0V

0.5V

Equalisation

Enable/Disable EQ function

On/Off

Off

BILim Vb>Vf1

Battery charging current limit in equalise Vb > Vfl

5-999A

50A

Sys Equal

System equalise voltage (Veq)

25-30.5V

28.0V

V Start Eq

Enable/disable discharge voltage initiation of Eq

On/Off

Off

V Eq trig

Discharge voltage threshold for Eq. charging

22-25V

24.0V

Q Start Eq

Enable/disable battery charge depletion trigger

On/Off

Off

Qdis Trig

Charge depletion threshold for Eq. charging

5-999AH

15AH

EQ End Current

Equalisation termination for Ibat < EQ End

1-2000A

EQ Duration

Maximum duration of Equalisation charging

3-48 Hr

20 Hr

EQ Period

Time between periodic Equalisation charging

0-52 Wk

12 Wk

LVDS Trip

Battery voltage below which will open LVDS

20-24V

22.0V

BDT Per

Period between consecutive discharge tests

0-365 days

30 days

BDT Time

Time of day to begin BDT (hr:min)

00:00-23:59

02:00

BDT Dur

Maximum duration of BDT

5-1440min

180min

BDT Curr

Discharge test current

0-5000A

50A

BDT End V

Battery voltage limit to terminate BDT

18-24V

22.0V

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Parameter

Description

Range

Default

Value

Actual

Value

BDT End Q

Battery capacity limit to terminate BDT

25-9995AH

300AH

Temp Sen Alm

Enable/Disable Temp. Sensor failure alarm

On/Off

Off

Maximum of 4 batteries with MUIB2, maximum of 2 batteries with other interfaces.

See SMR section for internal parameters.

Not directly adjustable – see explanation in MCSU-4 section.

Will be automatically programmed to SMR internal setting once connected in the system.

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3. Configuration

3.1 System Description

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

3.1.1 General Description

This modular system has been designed specifically to power 24V or 48V telecommunications equipment requiring accurate temperature compensated Float and Equalisation voltages, low output noise and EMI levels.

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

The system can be configured in a number of ways depending on the customer and application requirements. The simplest option is shown in Figure 3.1.

System Controller

MUIB

(Supplies System

Controller)

AC Distribution

Remote Alarms

and Ambient

Temp. Sensor

DC Bus

DC Distribution

Batteries with

Circuit Breakers

Magazines of

AC-DC Converters

DC Loads

Local Comm. Port

Remote Comm. Port

Figure 3.1 System with basic monitoring and control

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

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

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

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

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

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

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

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

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

Battery Cell Monitor

System Controller

MUIB

(Supplies System

Controller)

AC Distribution

with 1 Monitor

Remote Alarms

and Ambient

Temp. Sensor

DC Bus

DC Distribution

Batteries with

Circuit Breakers

Magazines of

AC-DC Converters

DC Loads

Local Comm. Port

Remote Comm. Port

Figure 3.2 System with additional single phase AC Monitor

The second option shown in Figure 3.2 is the basic arrangement described above with the addition of an auxiliary single phase AC monitoring module and Battery Cell Monitor. This module, which is mounted in the AC distribution module, connects via a ribbon cable to the MUIB and is used to monitor the AC voltage, current and frequency .

The third option shown in Figure 3.3 is the basic arrangement with the addition of an auxiliary three phase AC monitoring module. The latter connects directly to the MCSU-4 via a ribbon cable and provides monitoring of the three AC voltages and currents as well as the AC frequency. It has multiplexing circuits on board which effectively extends the analogue monitoring ability of the MCSU-4.

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

Battery Cell Monitor

System Controller

MUIB

(Supplies System

Controller)

AC Distribution

with 3 Monitor

Remote Alarms

and Ambient

Temp. Sensor

DC Bus

DC Distribution

Batteries with

Circuit Breakers

Magazines of

AC-DC Converters

DC Loads

with 1 Inverter

and AC Monitor

Local Comm. Port

Remote Comm. Port

Figure 3.3 System with additional 3 phase AC Monitoring; simultaneous monitoring

of single phase inverter also possible

3.1.2 Rectifier Specific Configurations

A typical mechanical arrangement of a system comprising 4 rectifiers in a mini shelf is shown in Figure 3.4. It consists of 4 rectifiers (2U total), and a MCSU-4 shelf, for a total of 3U. The arrangement shown is designed to fit into a standard 19” rack. Other configurations are equally possible.

Figure 3.4 Typical 4 rectifier modular power supply with MCSU-4

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4. Installation

4.1 System Installation

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

4.1.1 Racks

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

 The rack must form a basic fire enclosure. To do this, a rack needs a separator or base

plate, which prevents a burning liquid from escaping the enclosure when poured vertically into the rack. This can be achieved by using either a baffle plate below the rectifiers with a front finger grill that traps the liquid or a purpose made separation plate that it mounted below the rectifier magazine to catch burning liquids.

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

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

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

 for the sides of the enclosure, be provided with louvres that are shaped to deflect

outwards an externally falling object.

 Construction of the rack is important in providing exhaust air venting. Cooling louvres,

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

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

4.1.2 Magazines

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

The magazines are held in the rack by M6 screws through the mounting flange and into the rack mounting rail. All wiring is typically via rear access.

4.1.3 Lightning and Transient Suppression

The rectifiers and magazine contain basic transient suppression in the form of Metal Oxide Varistors (MOVs) across line-to-neutral, line-to-earth and neutral-to-earth. These MOVs are sized to provide protection from typical line transients in an industrial environment according to ANSI C62.41-1991 (6kV/3kA) and IEC 61000-4-5 (Level X). Under these

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conditions, the MOVs are expected to provide transient protection for the life of the rectifiers.

If the transient environment is more severe, with a high incidence of lightning strikes either indirect or direct, and/or severe switching transients beyond the levels outlined in the standard, then supplementary transient protection is required. Larger MOVs (40kA rating) are required at the AC main switchboard where the power to the rack originates.

For wiring systems where the neutral is bonded to the building earth at the main switchboard (as used for example in Australia, USA, and Canada), one MOV from line-toneutral is required for single phase, and three MOVs from each line-to-neutral are required for three phases.

For wiring systems where the protective earth is bonded to the neutral conductor only at the distribution transformer, as is common in Europe, three MOVs are required for a single phase (line-to-neutral, line-to-earth, neutral-to-earth), and seven MOVs are required for three phase wiring (phase-to-neutral x 3, phase-to-earth x 3 and neutral-to-earth).

4.1.4 Cabling, Auxiliary Equipment and Circuit Breakers

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

These modules are required inside the rectifier rack for normal system operation. A brief description of the modules and what they connect to is given below, along with a detailed rack wiring diagram in Figure 4.1 that shows a system using a MUIB interface.

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

Note that when using the RT9/10/11 units without a battery, the AC circuit breakers must be a curveD type (motor start). This is required to prevent false tripping of the circuit breaker when there are half-cycle mains interruptions and the subsequent surges. Systems with a battery do not have this requirement.

DC Distribution: An enclosure containing all the DC load distribution circuit breakers and usually the Battery string circuit breakers. If the Battery breakers are included in the DC distribution module, an isolation barrier is usually required along with clear labelling which battery string the breakers are protecting. The input to the DC distribution module comes directly from the DC output line of the rectifiers that is NOT connected to the system (DC) earth.

DC Cabling: The choice of DC cabling and/or busbars is based entirely on the DC current rating of the system. Consult the local National wiring standard for the selection of cable/busbar size for the DC connections. One suggested method of DC cabling for medium systems (~6-8kW) is to provide short 100mm x 6mm busbars at the external DC interface with a number of holes to attach smaller DC cables. Then connect cables up to 25mm2from the DC terminations to the output terminals of the individual magazines. The flexibility of the DC cables can be a benefit over fixed busbars when fitting components into a rack with limited space.

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Figure 4.1 Typical System Wiring

Battery Current Transducers: A Hall effect current measuring unit that is installed over the cable connecting the battery string to its circuit breaker. The signal lines are connected to terminal on the MUIB.

Temperature Sensors: Modules typically assembled in a copper lug with a mounting hole at one end and sensor cabling running from the other sealed end to terminals in the MUIB. The sensors are normally placed in the battery compartment to measure battery temperatures.

AC Monitoring Module: Optional modules are available in either single phase or three phase models. The module connects in series with the incoming mains supply by having the phase wires inserted through the current sensors on the module before having the terminating at the active link. The phase-neutral (or phase-phase) voltages are separately sensed by reference transformers. Inputs for voltage measurement are protected against high voltage transients. The modules are connected to the MCSU-4 magazine via a 16way ribbon. If both types of modules are installed use the second 16-way connector on single phase module for connection to the three phase module.

DC voltage regulation and power for the MCSU-4 is derived from the output DC bus via the connections on the MUIB. The connection point is made where a constant voltage is most useful. This is typically at the point where the cables run to the batteries. External voltage sensing for voltage regulation at a load can also be done, but in most systems, the system voltage is sensed on the internal output bus. For more information, see the detailed section on the MUIB.

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4.2 Rectifier Installation and Removal

In the system, the rectifiers are designed to operate in parallel in a N+1 redundant mode. Therefore, there is never a situation in which it is necessary to set individual rectifier parameters.

The rectifiers are designed to be “hot pluggable” in that they can be plugged into and out of a “live” magazine. Due to the small size of energy storage elements in the rectifier output, there is no significant disturbance to the DC bus when a rectifier is plugged into the magazine.

An inrush limiting circuit in the AC input circuit that utilises a relay and an inrush current limiting resistor limits the disturbance to the AC source to an acceptable level when a unit is plugged in with AC voltage present on the AC bus.

4.2.1 To Remove a Rectifier from the Magazine

Although the connectors are designed to be “hot pluggable” it is advisable to first switch off power to the unit by means of the circuit breaker in the AC distribution module before unplugging the unit. This is done to prolong the life of the rear “hot pluggable” connector.

Each rectifier 1U shelf has a spring clip that secures the rectifiers in place once it is plugged into its magazine. First lift the clip, then, using the finger recess in the front, pull the rectifier from the magazine.

WARNING !!

Take care when removing the rectifier as it may be uncomfortably hot to hold especially if

the ambient temperature is high and the unit has been operating at maximum load.

4.2.2 Inserting a Rectifier into the Magazine

Although the connectors in the unit are designed for “hot pluggability” it is advisable to turn off the AC power to the input connector by means of the related circuit breaker in the AC distribution module before plugging in the unit.

Carefully slide the rectifier into the magazine. Press the unit into the magazine until it is flush and the spring retaining clip clicks down. This ensures that it will not fall out in the event of severe shaking as might occur in the event of an earthquake.

Switch on the relevant AC circuit breaker in the AC distribution module. The rectifier will start automatically and connect itself to the DC bus at the appropriate time.

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4.3 MUIB - Mini User Interface Board

Connections between the MCSU-4, the external transducers and other inputs are made using the connectors provided on the MUIB. Terminals are provided for alarm relay contacts, battery and ambient temperature sensors, two battery current transducers, LVDS control and circuit breaker operation detection using the breaker auxiliary contacts for both the battery and load circuit breakers.

4.3.1 MUIB Connections

4.3.1.1 Relay Contact Outputs

There are 5 relays with normally open (N/O) and normally closed (N/C) contacts available on the MUIB, connector X2 (see Figure 4.3). In standard RTP system three of the relays are for remote annunciation of alarms: Relay 3 - HVSD, Relay 4 – any system alarm, Relay 5 - SMR shut down.

Other two relays are used for control of optional external equipment. Relay 2 is programmed for FAN CONTROL. If any one of the SMR heat-sink temperatures

exceeds a pre-set (non-programmable) value, the relay closes. The relay closure can then be used to either speed up fans, which may normally be idling at low speed, or it can turn on fans, which may normally be off.

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

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

4.3.1.2 Spare Digital and Analog Inputs

There are 4 spare digital inputs (USER 1, 2, 3, 4) available on the MUIB for the monitoring of external plant associated with the power supply. The inputs must be isolated relay contacts or auxiliary contacts, which are either normally open or normally closed.

There is also provision for monitoring two external analog levels via connectors X28 (AN1) and X31 (AN2) on the MUIB. The analog signals must be in the range 0 to +5VDC.

To use the spare analog or digital inputs the software for the MCSU-4 must be individually programmed by the manufacturer according to the requirements of the application.

4.3.1.3 Battery Current Transducer Input

Battery current transducers are connected to X39 and X40 of the MUIB. Figure 4.2 shows the pin connections for the battery transducer connector going onto the MUIB.

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Figure 4.2 Battery transducers connection to MUIB

Figure 4.3 MUIB Connection Diagram

X18

X17

X28

X31

X32

X22

X23

X33

X34

X44

X45

X39

X40

34-way ribbon cable to MiniCSU

X50

X64

X65

Conn #

Conn Label

Class

Used for:

MiniCSU

Anal/Dig

34-way ribbon cable to MiniCSU

RELAY 1

Digital

Dummy load on 110V systems, not used on other systems

RELAY 2

“

Cabinet Fan control for RT4 or RT5 systems

RELAY 3

“

SMR HVSD Alarm

RELAY 4

“

Activated by any alarm condition

RELAY 5

“

SMR switched off (for any reason)

X17

BAT. TEMP.

Analog

Temperature Transducer

X18

AMB. TEMP.

Analog

Temperature Transducer

X22

C.B. TRIP

Digital

Aux contact from load CBs

X32

1 PHASE AC

Anal/Dig

Not used with MCSU-4

X23

BAT. SW.

Digital

Aux contact from Batt. CBs

X33

USER 1

Digital

User defined i/p; isolated aux. Contact or similar

X34

USER 2

Digital

Requires special software to define function

X44

USER 3

Digital

“ “

X45

USER 4

Digital

“ “

X28

AN 1

Analog

Spare analog I/P - 0 to 5VDC (Requires special software)

X31

AN 2

Analog

Spare analog I/P - 0 to 5VDC (Requires special software)

X39

BATTERY 1

Analog

Battery current transducer

X40

BATTERY 2

Analog

Battery current transducer

X50

POWER I/P

Analog

System voltage sensing and DC power input for MiniCSU

X64

LVDS Aux

Digital

Aux contact from LVDS contactor

X65

LVDS Coil

Digital

Drive for contactor or similar

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Figure 4.4. MUIB Connectors wiring information

Connector

Signal Name

Connector

Signal Name

X1 MCSU-4

1-34

34 way ribbon

X32 1 PHASE AC

1-10

Not used with MCSU-4

X2 RELAY 1 (USER)

N/O relay contact

X39 BATTERY 1

-15V

N/C relay contact

+15V

Common

No connection

X2 RELAY 2 (FAN SPEED)

N/O relay contact

Input

N/C relay contact

GND

Common

X40 BATTERY 2

-15V

X2 RELAY 3 (HVSD)

N/O relay contact

+15V

N/C relay contact

No connection

Common

Input

X2 RELAY 4 (ALARM)

N/O relay contact

GND

N/C relay contact

X22 C.B. TRIP

1-2

Contact closure required between pins 1 and 2

Common

X23 BAT SW.

1-2

“ “

X2 RELAY 5 (SMR S/D)

N/O relay contact

X33 USER1

1-2

“ “

N/C relay contact

X34 USER2

1-2

“ “

Common

X44 USER3

1-2

“ “

X17 BAT TEMP.

No connection

X45 USER4

1-2

“ “

Sensor -ve

X50 POWER I/P

Bat +ve terminal

Sensor +ve

Bus +ve terminal

X18 AMB. TEMP

No connection

Sensor -ve

Battery -ve terminal

Sensor +ve

Bus -ve terminal

X28 AN1 1

0V to +5Vdc.

X64 LVDS Aux.

1-2

LVDS auxiliary contact

Common

X65 LVDS Coil 1-3

Coil driving voltage

X31 AN2 1

0V to +5Vd

No connection

Common

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Figure 4.5. MUIB Fuse Function and Specification

Fuse

Function

Specification

+15VDC

F500mA, Glass, M20x5

-15VDC

F500mA, Glass, M20x5

Ground

T2A, HRC, M20x5

F46

-V System

T2A, HRC, M20x5

F49

-V Battery

T2A, HRC, M20x5

F53

+V System

T2A, HRC, M20x5

F63

+V Battery

T2A, HRC, M20x5

F68

+V LVDS

T2A, HRC, M20x5

F69

-V LVDS

T2A, HRC, M20x5

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4.4 MUIB2 - MCSU-4 User Interface Board (type2)

The MUIB2 is an optional module that may be used in place of the MUIB to allow monitoring of a total of four battery currents and to directly measure one load current. The MUIB2, like MUIB provides basic interfacing between the MCSU-4 and the system environment. Use of this board also requires a specific MCSU-4 software version.

The addition of the load current transducer input allows the MCSU-4 to sense the load current directly. This provides better resolution of the load current than the calculated current determined from the reported individual rectifier output currents. This is because there is an inherent resolution limit for each rectifier current measurement that can significantly degrade the load current resolution when a system contains a large number of rectifiers. Another use of the load current transducers is when non-RTP rectifiers are used with a MCSU-4, and these rectifiers do not signal their current to the MCSU-4.

The current transducers are standard 4V full scale. Accuracy of signal conditioning for the current signals is typically 1%.

4.4.1 System setup requirement

The MCSU-4 software needs to be a version with an MUIB2 option. This board needs to be enabled from the front panel of the MCSU-4 or PC running WinCSU-2 program. The load transducer also needs to be enabled or disabled as necessary. The full scale value of battery and load transducers then needs to be entered.

4.4.2 Main features of MUIB2

The principal features of the MUIB2 are as follows:

 Each battery current input accepts input range of -4V to +4V full scale. The maximum allowed input is 

 The load current input range is from 0V to +4V. The maximum allowed input is 0 to +5V.  The battery and load full scale currents are separated so different transducers for battery and load

currents can be used.

 Signal conditioning accuracy for the battery and load currents is typically 1%.  Actual number of batteries used can be programmed via MCSU-4 front panel or WinCSU-2 remotely.  Load transducer can be switched on or off via MCSU-4 front panel or WinCSU-2 remotely.  When the load transducer is switched off, MCSU-4 automatically reverts back to calculating load current

using SMR and battery currents.

 There are 5 relay outputs, 4 digital inputs, LVDS interface, CB trip input and Battery switch input.  Ambient and battery temperature sensors can be connected to this board.  The MUIB2 also provides power to the MCSU-4, this board can be connected to the bus and battery at

the same time.

 Two spare analog inputs are available (input range: 0 to +5V).

4.4.3 MUIB2 Connections

The MUIB2 connector wiring diagram is shown in the table of Figure 4.9, followed by the connection diagram and connector legend in Figure 4.12.

4.4.3.1 Relay Contact Outputs

There are 5 relays with normally open (N/O) and normally closed (N/C) contacts available on the MUIB2, connector X2. In standard RTP system three of the relays are for remote

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annunciation of alarms: Relay 3 - HVSD, Relay 4 – any system alarm, Relay 5 - SMR shut down.

Other two relays are used for control of optional external equipment. Relay 2 is programmed for FAN CONTROL. If any one of the SMR heat-sink temperatures

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

4.4.3.2 Connections to MCSU

Two ribbon cables connect between MUIB2 and MCSU-4 magazine. One 34-way ribbon cable for the main port connects X1 on MUIB2 to MCSU-4. The other 16-way ribbon cable connects X180 or X179 on MUIB2 to the aux port of MCSU-4.

Note: The connection of the 16-way ribbon to X179 or X180 must be made if any of X76, X89, X103, X115, or X129 are used.

4.4.3.3 Battery Current Transducer Input

Battery current transducers are connected to X39 and X40 of the MUIB. Figure 4.2 shows the pin connections for the battery transducer connector going onto the MUIB.

Figure 4.10 Battery transducers connection to MUIB2

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4.4.3.4 Load Current Transducer Input

A load current transducer is connected to X76 of the MUIB2 via a connector using the pin connections shown below.

Figure 4.11 Load transducer pin connection for MUIB2

4.4.3.5 Power Input

Power to a MCSU-4 is connected to this MUIB2 via connector X50. Pin designations are also labelled on the PCB as well. Both the bus and battery voltages are connected to the MCSU-4 via this connector. The MCSU-4 takes power from either the battery or bus depending on which voltage is higher. The system voltage is read by the MCSU-4 via the bus terminations of this connector.

4.4.3.6 CB Trip, Batt Sw and LVDS Aux inputs

CB Trip (X22) is used to sense the CB status. Batt Sw (X23) is used to sense status of battery switch. LVDS Aux (X64) is used to sense the status of the LVDS switch. Open contacts on any of these 3 input creates an alarm condition on the MCSU-4, therefore, when any of these 3 inputs are not used, a shorting plug should be installed on those not in use.

4.4.3.7 Spare Digital and Analog Inputs

There is also provision for monitoring two external analog levels via connectors X28 (AN1) and X31 (AN2) on the MUIB. The analog signals must be in the range 0 to +5VDC and can only be monitored if the single phase AC monitoring module is not connected. This is because the MMIB1 and the spare analog input share the same input lines to the MiniCSU.

To use the spare analog or digital inputs the software for the MiniCSU must be individually programmed by the manufacturer according to the requirements of the application.

4.4.4 Fuses

For fuse functions, type and rating please refer to the table at the end of MUIB section.

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Figure 4.12 MUIB2 Connection Diagram and Connector Legend

16 way ribbon cable to MCSU-2

34 way ribbon cable to MCSU-2

Conn #

Conn Label

Class

Comments

MCSU-4

Anal/Dig

34-way ribbon cable to MCSU-4

RELAY 1

Digital

Dummy load on 110V systems, not used on other systems

RELAY 2

“

Cabinet Fan control for RT4 or RT5 systems

RELAY 3

“

SMR HVSD Alarm

RELAY 4

“

Activated by any alarm condition

RELAY 5

“

SMR switched off (for any reason)

X17

BAT. TEMP.

Analog

Temp. Transducer

X18

AMB. TEMP.

Analog

Temp. Transducer

X22

C.B. TRIP

Digital

Aux contact from load CBs

X32

1 PHASE AC

Anal/Dig

Not used with MCSU-4

X129

BAT1-Current

Analog

Batt 1 Current Transducer

X115

BAT2-Current

Analog

Batt 2 Current Transducer

X103

BAT3-Current

Analog

Batt 3 Current Transducer

X89

BAT4-Current

Analog

Batt 4 Current Transducer

X23

BAT. SW.

Digital

Aux contact from Batt. CBs

X33

USER 1

Digital

User defined input; isolated aux. contact

X34

USER 2

Digital

Requires special software to define

X44

USER 3

Digital

“ “

X45

USER 4

Digital

“ “

X28

AN 1

Analog

Spare analog I/P - 0 to 5VDC (Requires special software)

X31

AN 2

Analog

Spare analog I/P - 0 to 5VDC (Requires special software)

X64

LVDS Aux

Digital

Aux contact from LVDS contactor

X65

LVDS Coil

Digital

Drive for contactor or similar

X50

POWER I/P

Analog

System voltage sensing & DC power input for MCSU-4

X76

LOAD-Current

Analog

Load Current Transducer

X180

MCSU

Anal/Dig

16-Way ribbon cable to Aux Port

X179

NEXT UNIT

Anal/Dig

16-Way ribbon cable to Aux Port

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Figure 4.9 MUIB2 Connector Wiring Information

Connector

Signal Name

Connector

Signal Name

X1 MCSU-4

1-34

34 way ribbon

X18 AMB. TEMP

No connection

X180 MCSU-4

1-16

Aux Port

Sensor -ve

X179 Next Unit

1-16

Aux Port

Sensor +ve

X2 RELAY 1 (USER)

N/O relay contact

X28 AN1 1

0V to +5Vdc.

N/C relay contact

Common

X31 AN2 1

0V to +5Vdc.

X2 RELAY 2 (FAN SPEED)

N/O relay contact

Common

N/C relay contact

X32 1 PHASE AC

1-10

Not used with MCSU-4

Common

X129 BAT1-Current

-15V

X2 RELAY 3 (HVSD)

N/O relay contact

+15V

N/C relay contact

No connection

Common

Input

(X2 RELAY 4 ALARM)

N/O relay contact

GND

N/C relay contact

X115 BAT2-Current

-15V

Common

+15V

X2 RELAY 5 (SMR S/D)

N/O relay contact

No connection

N/C relay contact

Input

Common

GND

X22 C.B. TRIP

1-2

Contact closure required between pins 1 and 2

X103 BAT3-Current

-15V X23 BAT SW.

1-2

“ “

+15V

X33 USER1

1-2

“ “

No connection

X34 USER2

1-2

“ “

Input

X44 USER3

1-2

“ “

GND

X45 USER4

1-2

“ “

X189 BAT4-Current

-15V

X50 POWER I/P

Bat +ve terminal

+15V

Bus +ve terminal

No connection

Input

Battery -ve terminal

GND

Bus -ve terminal

X76 Load-Current

-15V

X64 LVDS Aux.

1-2

LVDS auxiliary contact

+15V

X65 LVDS Coil 1-3

Coil driving voltage

Input

No connection

X17 BAT TEMP.

No connection

GND

Sensor -ve

Sensor +ve

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4.5 MUIB3 – Systems with Earth Leakage Detection

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

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

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

4.5.1 System setup requirement

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

4.5.2 Main features of MUIB3

The principal features of the MUIB3 are as follows:

 There is provision for battery and ambient temperature sensors.  There is provision for two battery current transducers.  An Earth leakage current detector enables the display of leakage current

on the MCSU-4 screen or on the remote monitor screen. Full scale is +/10mA.

 A window on MCSU-4 or WinCSU-2 allows the programming of the earth

leakage current level between 1.0mA and 9.5mA at which an alarm is asserted.

 Each battery current input accepts an input range of -4V to +4V full scale.

The maximum allowed input is 5V.

 The actual number of batteries used in the system can be programmed

by the user via the MCSU-4 front panel or remotely by WinCSU-2 software.

 There are 5 relay outputs, 4 digital inputs, CB trip input and Battery

switch input.

 The MUIB3 provides power to the MCSU-4;  One spare analog input is available (input range: 0 to +5V).

4.5.3 MUIB3 Connections

4.5.3.1 Connection to MCSU-4

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

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4.5.3.2 Relay Contact outputs

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

Other two relays are used for control of optional external equipment. Relay 2 is programmed for FAN CONTROL. If any one of the SMR heat-sink temperatures

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

4.5.3.3 Spare Digital Inputs

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

4.5.3.4 Battery Current Transducer Input

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

1. -15V

2. +15V

3. NOT USED

4. SIGNAL

5. GND

MFR: Molex

Conn: 09-50-3051

pins: 08-50-0106

4-Way cable

Figure 4.5-1 Current transducer connection

4.5.3.5 Power Input

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

4.5.3.6 CB Trip and Batt Sw inputs

CB Trip (X22) is used to sense the CB status. Batt Sw (X23) is used to sense the battery switch status. Open contacts on any of these 2 inputs creates an alarm condition on the

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MCSU-4. Therefore, when any one of these 2 inputs are not used, a shorting plug should be installed on the input not being used.

4.5.3.7 Earth Leakage Detector

The block diagram in Figure 4.5-2 shows the principle on which the earth leakage detector works. The SMRs and Batteries, which are normally galvanically isolated from Earth, are actually grounded via sensing resistor Rde which connects to the centre-tap of two relatively high value resistors (Re in Figure 4.5-2). The effect is that if there are no other electrical paths to Earth, then +Vb and -Vb should be equal and opposite in value. So if the battery voltage, for example, is 124VDC, the voltage of the positive DC bus with respect to Earth should be +62VDC and the negative bus should be -62VDC.

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

It should be noted that if there is no external leakage current, the voltage measured at the test point on the UIB3 marked ELEAK will not be zero, but a calibrated voltage a little over

2.5VDC. This is an offset voltage, which has been introduced to enable the microprocessor to monitor earth leakage current of both positive and negative polarity.

SMRs

Batt 1

Batt 2

Earth

Voltage shifting

network on

MUIB3

To MiniCSU A/D

Converter

+0.5Vb

-0.5Vb

Negative DC bus

Positive DC bus

Rde

Figure 4.5-2 Earth Leakage current detector circuit on MUIB3

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Figure 4.5-3 MUIB3 Connection Diagram

X18

X17

X22

X23

X33

X34

X44

X45

X31

X40

X39

X50

X68

34-way ribbon cable to MiniCSU-2

Conn #

Conn Label

Class

Comments

MCSU-4

A/D

34-way ribbon cable to MCSU-4

RELAY 1

Digital

Dummy load on 110V systems, not used on other systems

RELAY 2

“

Cabinet Fan control for RT4 or RT5 systems

RELAY 3

“

SMR HVSD Alarm

RELAY 4

“

Activated by any alarm condition

RELAY 5

“

SMR switched off (for any reason)

X17

BAT. TEMP.

Analog

Temp. Transducer

X18

AMB. TEMP.

Analog

Temp. Transducer

X22

C.B. TRIP

Digital

Aux contact from load CBs

X23

BAT. SW.

Digital

Aux contact from Batt. CBs

X33

USER 1

Digital

User defined input; isolated aux. contact or similar

X34

USER 2

“

Special software required

X44

USER 3

“

“ “

X45

USER 4

“

“ “

X31

AN 2

“

Spare analog I/P - 0 to 5VDC (Requires special software)

X39

BATTERY 1

“

Battery current transducer

X40

BATTERY 2

“

Battery current transducer

X50

POWER I/P

“

System voltage sensing and DC power input for MCSU-4

X68

System Earth

N/A

Wire from frame and System Earth

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Figure 4.5-4 MUIB3 Connector wiring information

Connector

Signal Name

Connector

Signal Name

X1 MCSU-4

1-34

34 way ribbon

X39 BATTERY 1

-15V

X2 RELAY 1 (USER)

N/O relay contact

+15V

N/C relay contact

No connection

Common

Input

X2 RELAY 2 (FAN SPEED)

N/O relay contact

GND

N/C relay contact

X40 BATTERY 2

-15V

Common

+15V

X2 RELAY 3 (HVSD)

N/O relay contact

No connection

N/C relay contact

Input

Common

GND

X2 RELAY 4 (ALARM)

N/O relay contact

X22 C.B. TRIP

1-2

Contact closure required between pins 1 and 2

N/C relay contact

X23 BAT SW.

1-2

“ “

Common

X33 USER1

1-2

“ “

X2 RELAY 5 (SMR S/D)

N/O relay contact

X34 USER2

1-2

“ “

N/C relay contact

X44 USER3

1-2

“ “

Common

X45 USER4

1-2

“ “

X17 BAT TEMP.

No connection

X50 POWER I/P

Bat +ve terminal

Sensor -ve

Bus +ve terminal

Sensor +ve

No connection

X18 AMB. TEMP.

No connection

Battery -ve terminal

Sensor -ve

Bus -ve terminal

Sensor +ve

X68 EARTH

1&2

Earth for leakage detector

X31 AN2

0V to +5VDC.

Common

Figure 4.5-5. MUIB3 Fuse Function and Specification

Fuse

Function

Specification

+15VDC

F500mA, Glass, M20x5

-15VDC

F500mA, Glass, M20x5

Ground

T2A, HRC, M20x5

F46

-V System

T2A, HRC, M20x5

F49

-V Battery

T2A, HRC, M20x5

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4.6 Single Phase AC Monitoring Module – MMIB4

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

The connection diagram of the MMIB4 module is shown below in Figure 4.6. The standard unit has a CT full scale rating of 100Arms (for 5V input to MiniCSU), and a full scale voltage sense rating of 300Vrms (active-neutral). Higher or lower full scale current ratings can be used as the external CT, with a corresponding value being set in the MiniCSU/MicroCSU AC monitoring menu.

X137

X87

X51

To AC distribution

Active

AC Voltage Sensing

Neutral

External CT Selector Link

X21

16 way ribbons to MCSU and auxilary modules

Figure 4.6 Single Phase AC monitoring unit MMIB4 block diagram

4.7 Three Phase AC Monitoring Module – MMIB2

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

The module is normally fitted inside the AC distribution module if one is used. A connection diagram of the MMIB2 is shown in Figure 4.7 below. The full scale current value of the CTs is 100Arms for a single turn on the standard unit. Higher full scale currents can be obtained by cascading larger external CTs through the on-board CTs and modifying the full scale value in the Mini/MicroCSU mains monitoring menu. The rated maximum sense voltage is 300V (line-neutral) due to the terminal rating and accuracy of the voltage sensing transformer.

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CT1

CT2

CT3

AC1

AC2

AC3

To SMR Inputs

MMIB2

Note: In 220V

ph-ph

systems if Neutral not

supplied, connect AC1-

AC2 to X2 input; AC2-

AC3 to X120 input and

AC3-AC1 to X217 input

X120

X217

16-way

ribbon

cable to

MiniCSU

X185

AC2

AC1

AC1, AC2, AC3 from

Dist. Module

Figure 4.7. Three Phase AC monitoring unit MMIB2 block diagram

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4.8 SMM - Site Monitor Module

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

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

Note: If the Site Monitor is to be added to an existing installation with RT Power System, change of the Controller software may be required. WinCSU-2 software will also need an upgrade.

4.8.1 Electrical Specification

Number of Analogue Inputs

Analog Signal Input Range

0V to +5V,

Analog Signal Protection

Over-voltage and reverse polarity protected.

Note: each analogue input must be floating

Analog Signal Scaling and Threshold Levels

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

Number of Digital Inputs

Type of Digital Signal Source

Voltage free contacts

Logic of Digital Input

User defined from WinCSU-2 only

Number of control outputs

Output type

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

Power Source

MiniCSU (powered indirectly from system DC bus)

4.8.2 Physical Specification

Board Dimensions

Approx. 210mm x 96mm

SMM - Controller Connection

16 Way Ribbon Cable

Signal Input Connectors

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

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

Output Connectors

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

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

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4.8.3 Installation

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

4.8.4 System Set-up

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

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

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Figure 4.8 Example Site Monitor Wiring Diagram

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4.8.5 Site Monitor Settings

Please observe following guidelines:

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

2. Hi T-hold – thresholds of analog channels to generate warning/alarm/output control. When set to zero the threshold is disabled, adjustable up to 999.91)input units.

3. Lo T-hold – thresholds of analog channels to generate warning/alarm/output control. When set to zero the threshold is disabled, adjustable up to 500.01)input units.

4. Scale – value of measured parameter corresponding to 4.00V of input signal. Adjustable up to 999.91).

5. Unit – a symbol of measured parameter.

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

7. Al – mark to generate Site Monitor alarm when input is active.

Step of adjustment from WinCSU-2 is 0.1 units, from the Front Panel 1 unit.

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

Input

Label

O1O2O3O4Al

Hi T-hold

Lo T-hold

Scale

Unit

An 1

An 2

An 3

An 4

An 5

An 6

An 7

An 8

Dig 1

Mark for normally closed input

Dig 2

Notes

Dig 3

Dig 4

Dig 5

Dig 6

Dig 7

Dig 8

Dig 9

Dig 10

Dig 11

Dig 12

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4.9 Battery Cell Monitor (BCM)

The Battery Cell Monitor (BCM) is an add-on module for the MCSU-4. It is used to monitor individual cells of a battery during float or equalisation operation, or during a discharge. Each BCM unit is capable of monitoring up to 24 cells. A total of four BCM units can be used to monitor 4 battery strings of 24 cells each.

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

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

4.9.1 Main Features of the BCM

The principle features of the BCM are as follows:

 Up to 24 cells can be monitored by a single BCM module. Cell voltage

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

 Up to four BCM board can be connected to a single MCSU-4.  Individual cell voltages of a battery can be viewed on the MCSU-4 display

in real time. The cell voltage rounded to the nearest 5mV (applies only to 2V range) is displayed together with the cell number and its percentage deviation from the average cell voltage of the battery.

 All the cell voltages can be displayed in a “Histogram” format on a local or

remote PC using WinCSU-2 software.

 The PC can display the real time cell voltages or cell voltages stored

during a previous discharge.

 A line graph of cell voltage versus time can be selected as the PC display

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

 As the BCM is permanently connected to the batteries, an automatic,

daily down-loading of the steady state cell voltages for the different batteries in a system can be made to a remote monitoring PC.

 A discharge test can be initiated either locally or remotely from WinCSU-2

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

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4.9.2 BCM Specifications

Battery configuration options:

(48V systems):

(24V systems):

24Cell x 2V, 12Cell x 4V, 8Cell x 6V, 4Cell x 12V

12Cell x 2V, 6Cell x 4V, 4Cell x 6V, 2Cells x 12V

Maximum battery voltage:

75Vdc

Number of cells:

24 maximum per board

Cell Voltage selection

2V (max input: 3.33V)

(DIP switch setting on the board):

4V (max input: 6.66V)

6V (max input: 10V)

12V (max input: 20V)

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

Accuracy for 1 year:

 10mV at 0C to 40C

Resolution:

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

Sampling interval range for discharge log:

1 - 60 minutes Power supply: from MCSU-4

15V

Maximum distance from MCSU-4:

10m (of 16 way ribbon cable)

4.9.3 Preparing the battery for connection to the BCM

Battery cells are not connected to the BCM directly. 56/PR02 resistors are inserted between BCM and the cells to clear any fault that would arise if a battery cell lead were shorted. The resistors are mounted as near as possible to the battery terminal in order to protect as much of the wiring as possible. A typical connection is shown Figure 4.9.

Figure 4.9 Lead termination at battery cell.

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

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4.9.4 Installing the board

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

Mount the BCM using the standoffs supplied in an area protected from mechanical and electrical hazards. If the rack does not provide any holes or studs for mounting the BCM, use Figure 4.10 as a template for drilling the mounting holes. Be sure to allow at least 25mm space around the board to allow for wiring to the board.

Figure 4.10 BCM mounting hole locations.

4.9.5 Dip-Switch Selection of Cell Voltages

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

CELL/MONOBLOCK

VOLTAGE

LEFT

SWITCH

(1)

CENTRE

SWITCH

(2)

RIGHT

SWITCH

(3)

12V

DOWN

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4.9.6 Battery Cell Lead Connection to the BCM board

The battery cell voltage sensing leads are terminated with 13 way female (Weco 5.0mm pitch) screw terminals. This plugs onto the connectors on the BCM board. How the cell voltage sense leads connect to the BCM board depends on the battery configuration. The following figures show the connection between the battery to the BCM board for different configurations of the battery. If more than 2 batteries are used a particular configuration, simply repeat the connection method for batteries 3 and 4.

Figure 4.11 BCM connections to a 48V (24 cell) battery bank.

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Figure 4.12 BCM connections to two 48V (12 cell) battery banks.

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Figure 4.13 BCM connections to two 48V (8 monoblock) battery banks.

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Figure 4.14 BCM connections to up to four 48V (4 x 12V monoblock) battery banks.

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Figure 4.15 BCM connections to two 24V (12 cell) battery banks.

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Figure 4.16 BCM connections to two 24V (6 monoblock) battery banks.

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Figure 4.17 BCM connections to four 24V (4 monoblock) battery banks.

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Figure 4.18 BCM connections to four 24V (2 monoblock) battery banks.

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5. Remote Communication Interfaces

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

5.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU)

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

5.2 RS232 Interface (MCSP)

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

5.3 RS485 Interface (MCMD)

This type of port allows connection though a distance up to 1200 meters. Up to 32 standard devices can be linked using twisted pair of wires. In high electrical noise environment a shielded twisted pair is recommended. Figure 5.3-1 below shows the pin assignment of the port.

Figure 5.3-1 RS485 pin assignments

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

5.4 Integrated Packet Modem (Smart Modem)

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

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

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

Country / Approval

Code

Country / Approval

Code

Country / Approval

Code

Argentina Y

India P

Portugal Y

Australia Y

Ireland Y

Russia P

Austria Y

Italy Y

Singapore Y

Belgium Y

Japan Y

South Africa P

Brazil Y

Korea Y

Spain Y

China N

Malaysia P

Sweden Y

Denmark Y

Mexico Y

Switzerland Y

Finland Y

Netherlands Y

Taiwan Y

France Y

New Zealand Y

United Kingdom Y

Germany Y

Norway Y

United States Y

Hong Kong Y

Poland P

Approval: Y=yes ; N = no ; P=pending

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

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

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6. Operation

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

Summary of MCSU-4 front panel controls

There are four Menus which can be viewed using the INC or DEC buttons: a) The default or "Home" menu which contains general system information; b) SMR menu - contains all the parameters relating to the rectifiers; c) Battery menu - contains all the parameters relating to the batteries; d) Alarms log - which is a chronological record of the last 100 alarms.

Moving from one menu to another

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

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

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

Scrolling through the Menus:

To scroll through any menu from the first screen to the last, press the INC button; To scroll to the last (bottom) screen first, then upwards through the menu to the first

screen, press the DEC button.

Incrementing and decrementing programmable parameters

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

To change parameters when the security function is activated

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

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

When scrolling through the Alarms log

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

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6.1 MCSU-4 Components

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

The unit is 1U in height and a magazine is available which fits across a 19” rack and accommodates the MCSU-4, the MUIB as well as a space for a modem or other equipment with a maximum dimensions 40x150x220 (HxWxD in mm). An RS232 port is available on the front panel for connection to a portable PC.

6.1.1 Alpha-numeric Display

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

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

234A 54.5V

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

6.1.2 Front Panel Pushbuttons

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

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

a) SMR menu, which includes the rectifier related programmed parameters as well as

the output current and heat-sink temperature for each rectifier; b) Battery menu in which all the parameters appertaining to the batteries are found; c) Log which stores all the individual alarm information together with date and time

starting with the most recent alarm. A total of 1000 alarms are stored in memory.

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6.1.3 Status Indicating LEDs (MCSU-4)

In addition to the alphanumeric display there are also three LEDs to indicate system status as follows:

SYSTEM OK



Green LED

ALARM

Amber LED

SMR SHUTDOWN



Red LED

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

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

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

6.2 Operating the MCSU-4

6.2.1 Password security

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

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

6.2.1.1 Entering a password to gain access to parameters change

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

Wrong Password

Panel Locked

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

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

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6.2.2 Test Mode

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

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

- Unrestricted parameters editing

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

- Alarms will not be recorded in the Alarm Log

- Alarm Log can not be cleared

- Password can not be changed

- Status of security function can not be changed

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

Upon quitting the Test Mode (see Par. 6.6) parameters values will be restored to original settings.

Note: There is no timeout or any other means of automatic cancellation of the Test Mode. It is the responsibility of the personnel to return the system to normal operating mode.

6.2.3 Entering and moving through different Menus

To scroll through the MCSU-4 menu from top to bottom, just press the INC button. The screens that will appear are shown in section 6.6.

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

To enter the other menus, momentarily press the relevant button - SMR, BATT or ALARM LOG. The associated menu contents are shown in sections 6.7, 6.7.2, 6.9 and 6.10.

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

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

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

6.2.4 When an alarm condition exists

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

3 Alarms

Press ENTER

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

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

Alarm 1

Amb Temp High

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

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

6.3 MCSU-4 Alarms

A list of all the possible alarms that can be enunciated is shown in the following table.

Alarm Name

Comments

LED

SMR Alarm

Combination of one or more SMR alarms

SMR Urgent

One or more SMRs have shut down

A+R

SMR HVSD

SMR shut down due to output over-voltage

A+R

UNIT OFF

SMR is off

A+R

No Response

A particular SMR is not responding to the MCSU-4

Power Limit

SMR is in Power Limit

No Load

SMR output current less than minimum for SMR type used

Current Limit

SMR in current limit

Voltage High

Voltage measured by SMR too high

Voltage Low

Voltage measured by SMR too low

UNCAL SMR

SMR Internal Adjustment for current sharing out of limits

EEPROM Fail

EEPROM failed (MCSU-4 or SMR)

Fan Fail

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

Relay Fail

SMR output relay contact failure

No Demand

Control loop in SMR not in normal state

H/S Temp High

SMR heatsink temperature too high (where available)

DC-Dc Contr Fail

SMR DC/DC converter fault

A+R

Temp Sensor Fail

Temp sensor in SMR faulty - S/C or O/C (where available)

A+R

Vref Fail

Voltage reference in SMR microprocessor circuit faulty

A+R

HVDC not OK

DC/DC converter (boost) voltage in SMR not OK

A+R

AC Volt Fault – detected by SMRs

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

A+R

AC Volt Fault – detected by CSU

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

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

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Alarm Name

Comments

LED

AC Freq Fault

AC frequency lower or higher than preset value

Battery Switch

One or more battery switches open

Cct Breaker

Fuse or CB in load distribution open

LVDS Open

Low Voltage Disconnect switch open

Sys Volts High

System output volts too high

Sys Volts Low

System output volts too low

System V Clamp

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

A Cell V High

One or more cells being monitored by BCM is too high in voltage

Cell V Low

One or more cells being monitored by BCM is too low in voltage

Cell %dev High

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

Cell %dev Low

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

A Range SMR

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

Site Monitor

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

A Battery Disch

Batteries are discharging

Disch Tst Fail

Battery discharge test failed to reach a programmed end point

Bat Disch Low

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

A Lo Electrolyte

Alarm generated for NiCad batteries using special sensor and software

SMR Comms Fail

One or more of SMRs are not responding

Amb Temp High

Ambient temperature higher than preset limit

Batt Temp High

Battery temperature higher than preset limit

Batt Temp Sens

Battery temperature sensor not connected or failure

Batt I-Limit

Battery charging current is being limited to preset value

Bat Sym Alarm

Battery discharge currents from battery strings not sharing load equally

Earth Leak Alarm

Earth leakage current greater than the limit set

Equalise

System is in equalise mode

A *

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

6.4 User programmable relay functions

All controllers with RTP standard software of version/revision ‘fa’ or higher support this feature. Other customised software can include it as well. To check if your unit supports programmable relays, perform Indicators Test as described in section 6.6.3.

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

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6.5 Mapping of loaded SMRs

This function is available only on selected models of MCSU-4. In some system configurations it may be necessary to leave empty magazines between

groups of rectifiers. In such a case a controller without mapping function would continuously alarm SMR communication fault for magazines with no SMRs.

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

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

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

6.6 MCSU-4 Base Menu Screens

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

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

155A 54.3V

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

155A 54.3V

FLC

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

Lock Panel

Press ENTER

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

Lock Panel

Panel Locked

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

Quit Test Mode

Press ENTER

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

Quit Test Mode

Test Disabled

Ambient temperature is displayed in Degrees Centigrade.

Ambient Temp

31C

6.6.1 Single Phase AC Monitoring Screens

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

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Single phase AC voltage.

1ph AC Volts

245V

Single phase AC current

1ph AC Current

52A

Single phase AC frequency

1ph AC Frequency

50.0Hz

6.6.2 Three Phase AC Monitoring Screens

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

AC voltage of phase 1

3ph AC1 Volts

245V

AC voltage of phase 2

3ph AC2 Volts

243V

AC voltage of phase 3

3ph AC3 Volts

246V

AC Current of phase 1

3ph AC1 Current

28A

AC Current of phase 2

3ph AC2 Current

29A

AC Current of phase 3

3ph AC3 Current

32A

AC Frequency

3ph AC Frequency

50.2Hz

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6.6.3 Base Menu Programmable Parameters

The screens below display programmable parameters within the MCSU-4 Base Menu. To change a parameter, press INC button until the desired parameter is found, then press

ENTER. The parameter value will flash on and off. Press INC to increase the value or DEC to decrease the value until the desired value is on the screen.

Press ENTER to enter the value into memory.

Ambient temperature alarm level

Amb Temp Alarm

45C

Float voltage High level

Volts High Alarm

56.6V

Float voltage Low level

Volts Low Alarm

50.5V

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

Security

Off

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

Password Setup

Press ENTER

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

Password Setup

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

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

Old Password

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

Old Password

Wrong Password

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

New Password

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Enter the new password again.

Confirmation

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

Confirmation

Password Changed

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

Confirmation

Wrong Password

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

Test Indicators

Press ENTER

On bottom line: 169 - product group

8441 - software identification number 02 - revision

MCSU-4

169-8441-02

System type. This parameter can be set to Standby or UPS. Set to Standby for systems where the load current is normally zero. Low load alarms are disabled for Standby.

System

Standby

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

System

UPS

Menus for Mapping Loaded SMRs are available only on selected models.

MCSU-4 addresses only those magazines in which SMRs were present during “mapping” process.

Map Loaded SMRs

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

Map Loaded SMRs

Off

When ENTER is pressed while viewing this menu, process of mapping of loaded SMRs is initialised.

Exec. Mapping

Press ENTER

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

Exec. Mapping

Please wait

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

Number of SMRs

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

Number of SMRs

Not Adjustable

End of Mapping Loaded SMRs menus

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

Number of SMRs

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

Interface

MUIB

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

Num of Batteries

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

FS Batt Current

200A

MCSU-4 Access code address; this can be a number up to 7 digits long

Access Code

1252636

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

Date Format

DD/MM/YYYY

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

Date 25/12/2002

Time 21:58:35

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

Alarm Report

Off

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

Daily Report

Off

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

Daily Rep Time

15:15

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

Modem

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

Modem

Off

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

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

Country Code

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

Country Code

None

This and next screen may not be seen on some models.

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

Cust Init String

&B1L3

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

Cust Init String

None

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

Phone 1

0398887788

Example of second screen for continuation of phone number

Phone 1 Cont

2323

Phone 2; this number will be tried if the first number does not respond. This menu item is followed by “Phone 2 Cont” (as for Phone 1).

Phone 2

0398880033

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

Phone 3

0398880033

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

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

Audio Alarm

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

Audio Alarm

Timeout

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Audio Alarm is disabled.

Audio Alarm

Off

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

Cct Input

Used - N/C

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

Bat Switch Input

Used - N/O

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

LVDS Input

Not Used

6.6.4 Auxiliary Function Selection & Parameters

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

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

Auxiliary Units

Press ENTER

6.6.4.1 Single Phase AC Monitoring

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

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

1-ph AC Monitor

Press ENTER

Displayed when this auxiliary is switched Off.

1-ph AC Monitor

Off

Displayed when this auxiliary is switched On.

1-ph AC Monitor

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

1ph AC Vhi Alarm

260V

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

1ph AC Vlo Alarm

192V

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

1ph AC fhi Alarm

55.0Hz

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

1ph AC flo Alarm

45.0Hz

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

1ph AC FS Curr.

100A

6.6.4.2 Three Phase AC Monitoring

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

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

3-ph AC Monitor

Press ENTER

Displayed when this auxiliary is switched Off.

3-ph AC Monitor

Off

Displayed when this auxiliary is switched On.

3-ph AC Monitor

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

3ph AC Vhi Alarm

260V

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

3ph AC Vlo Alarm

192V

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

3ph AC fhi Alarm

55.0Hz

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

3ph AC flo Alarm

45.0Hz

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

3ph AC FS Curr.

100A

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6.6.4.3 Battery Cell Voltage Monitoring

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

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

Battery Monitor

Press ENTER

Displayed when this auxiliary is switched Off.

Battery Monitor

Off

Displayed when this auxiliary is switched On.

Battery Monitor

The configuration refers to cell type (2, 4, 6 or 12V) and how the cells are connected to the monitor - see section 6.11 for further information. After pressing ENTER current configuration will flash. Scroll through available configurations and press ENTER again once the correct battery type is chosen.

Battery Config

24 cells

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

BCM Batteries

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

Cell Vhi Alarm

2.48V

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

Cell Vlo Alarm

1.44V

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

Cell +dVc Alarm

10%

Low differential cell voltage threshold.

Cell -dVc Alarm

10%

6.6.4.4 Site Monitor

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

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

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

Site Monitor

Press ENTER

Displayed when this auxiliary is switched Off.

Site Monitor

Off

Displayed when this auxiliary is switched On.

Site Monitor

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

A1 Inv-V

1.2V

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

A1 Inv-V

ALARM 1.2V

Threshold above which the input signal will trigger an alarm.

High Alarm

272.0V

Threshold below which the input signal will trigger an alarm.

Low Alarm

150.0V

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

Scale at 4V

300.0V

Presentation of a digital input window under normal conditions.

D2 Window2

Not Active

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

D2 Window2

Active

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

D2 Window2

ALARM

Status of output relay 1. Relay is switched off.

Output 1

Off

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

Output 2

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

Output 3

Manual On

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

6.7 SMR Menu Screens

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

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

SMR1

No Response

Warning: It is important to declare the correct number of rectifiers in the rack using the

MCSU-4 (home) menu.

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

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

SMR1

22A 58C

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

SMR1

169-3761-02

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

SMR1

S/N not avail.

Use INC button to display status of the other rectifiers.

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

SMR2 21A

3 Alarms ENTER

SMR2 21A

Power Limit

Use INC and DEC buttons to scroll through the list.

. . .

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

SMR2 21A

169-3761-02 58C

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

SMR3

UNIT OFF

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

SMR3

HV Shut Down

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

SMR3

169-3761-02 58C

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

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

SMR Float

52.3V

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

SMR Equalise

59.3V

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

SMR Float

Not Adjustable

6.7.1 SMR Menu Programmable Parameters

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

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

SMR high voltage alarm level.

SMR V high Alarm

56.3V

SMR low voltage alarm level.

SMR V low Alarm

48.1V

SMR DC High Volts Shutdown (HVSD).

SMR HVSD

62.0V

SMR Current Limit.

SMR I Limit

25A

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

Reset SMR Fault

Press ENTER

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

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6.7.2 SMR Menu Sleep Mode

The MCSU4 has an optional Rectifier Sleep Mode (RSM) in order to maximize the power conversion efficiency of the overall DC Power System controlled by the MCSU4.

The RSM accepts a user-configured:

o Minimum number of Rectifier to keep On-Line at all times. o Rectifier rotation value (in Days).

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

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

o The target power conversion efficiency. o The number of Rectifiers in the system. o The output capabilities of the Rectifier. o Sufficient hysteresis to as not to cause Rectifiers to constantly being placed On-

Line and back into Sleep mode.

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

o When needing to place a rectifier in Sleep mode, the rectifier with the highest usage

shall be selected.

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

be selected.

o Usage shall me determined with the accumulated Run Time (Hrs) or Thru-put

(kWHr) which is kept in the rectifier. The determination on which value to use is configured via the factory configuration file.

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

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

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

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

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The RSM reports the following values to the user:

o Average Rectifier % Output Power o Number of Rectifiers On-Line o Number of Rectifiers Sleeping

SMR Sleep Mode Enable.

Sleep Mode

Off

SMR Sleep Mode Minimum rectifiers that must be online.

Sleep Min SMR

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

SMR Power Max

2400

SMR Sleep Mode rectifier rotation value (in Days).

Sleep Rotation

5 Days

SMR Sleep Mode report number of rectifiers sleeping

Sleeping SMRs

SMR Sleep Mode report number of rectifiers online

Sleep SMR Online

SMR Sleep Mode report Average Rectifier % Output Power

Sleep Av Power

80 %

6.8 Battery Parameter Menu Screens

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

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

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

Battery 1 Current;

Battery 1

12A

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Battery 2 Current; (if present)

Battery 2

14A

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

When Bat Temp Sensor condition alarm is enabled and the temperature sensor is not connected, this message will be shown.

Battery Temp

31C

Battery Temp

Not Available

Battery Temp

Sensor Fail

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

Estimated Q Bat1

300Ah

Estimated Battery 2 state of Charge. (if present)

Estimated Q Bat2

300Ah

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

Batt Disch Alarm

45.0V

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

Disch I Diff

20A

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

Batt Temp Alarm

50C

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

Battery Rating

500Ah

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

BTC Coeff.

3.2 mV/C /C

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

BTC Nominal

20C

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

Number of Cells

Please Note:

a) If there are no temperature sensors connected or if BTC is set to 0, the compensation function is

disabled. In this instance, the status message in the MCSU-4 home screen is FL or EQ instead of FLC or EQC.

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

temperature sensor;

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

battery sensor.

d) If temperature compensation is activated, the SMR voltage setting is automatically adjusted by the

MCSU-4 on a regular basis.

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

BILim Vb<Vdd

34A

Battery deep discharge voltage - Vdd.

Vdd Level

44.0V

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

BILim Vb<Vfl

52A

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

System Float

54.0V

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

System V Drop

0.6V

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

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

Equalisation

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

BILim Vb>Vfl

25A

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

System Equalise

59.5V

Equalisation not initialised by voltage level.

Volts Start Eq

Off

Equalisation initialised by voltage level V reached during battery discharge.

Volts Start Eq

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

Volts Eq Trigger

46.0V

Equalisation is not initialised by the discharge A/H method.

Q Start Eq

Off

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

Q Start Eq

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

Q Loss Trigger

10Ah

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

EQ End Current

25A

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

EQ End Current

Off

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

EQ Duration

20 hours

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

EQ Period

12 Weeks

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

Manual Stop EQ

Press ENTER

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

Manual Start EQ

Press ENTER

End of equalisation section.

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

LVDS Trip

44.0V

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

LVDS Mode

Auto

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

LVDS Mode

Closed

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

LVDS Mode

Open

Menus for Load Shedding are available only on selected models.

Load 1 shedding is enabled.

Load 1 Shedding

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

Load 1 Shedding

Off

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

Ld 1 Shed Level

47.0V

Load 2 shedding is enabled.

Load 2 Shedding

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

Load 2 Shedding

Off

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

Ld 2 Shed Level

47.0V

End of Load Shedding menus.

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

Temp. Sen. Alarm

6.9 Battery Discharge Test

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

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

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

50A 49.2V

BDT in Progress

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

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

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

BDT Period

14 Days

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

BDT Time

17:35

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

BDT Duration

1h30min

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

BDT Current

50A

Batt Disch Test

Current = Load

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

BDT End V

46.0V

MCSU-4 will restore normal operating parameters and start recharging the battery. The test result will be “Fail”. Programmable range depends on the system voltage:

 24V system: 18V to 24V,  48V system: 36V to 48V,  110V system: 75V to 120V.

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

BDT End Q

500Ah

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

BDT Alarm Reset

Press ENTER

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

BDT in Progress

ENTER to abort

6.9.1 Results of last Battery Discharge Test - (Last BDT)

The remaining screen of the Battery Discharge Test gives details of the results of the last discharge test. The explanation of the codes are as follows:

Not Available. No test has been performed yet.

Last BDT

Not Available

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

Last BDT

Passed

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

Last BDT

Failed

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

Last BDT

AC Lost

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

Last BDT

Cell V Low

Aborted due to loss of control of rectifiers, not alarmed.

Last BDT

No Control

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

Last BDT

Low Load

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

Last BDT

SMR Overload

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

Last BDT

User Aborted

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

Date of the last test.

Last BDT

22/01/2003

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Duration of the test

Last BDT

Dur 1h18min

Voltage of the battery at the time of termination of the test.

Last BDT

EndV 49.2V

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

Last BDT

EndQn 380Ah

The test is disabled for 100 hours if any of the following took place: a) AC failure has been recorded b) Electrolyte low level has been recorded (only if sensor fitted and appropriate version of

software installed).

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

6.10 Alarms Log Screens

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

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

LOG 1

AC Freq Fault

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

10/01/2003

12:05:26

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

DEC to Clear

Log Entries

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

LOG

No Entries

6.11 Battery Cell Monitor Setup

Note: This function is only available on special versions of MCSU-4 software and appears as the first option in the Expan2 sub-menu (see section 6.6.4.3 for screen definitions).

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

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6.11.1 Relationship between “BCM Batteries” and “Num Batteries”

With the BCM option enabled, the BCM parameters must be setup before monitoring can be performed. Following through the screens of section 6.6.4.3, the screen indicating “BCM Batteries” is where you define the number of batteries whose cell voltages are to be monitored by the MCSU-4. There is no need to program the MCSU-4 how many BCM boards are connected. The MCSU-4 automatically calculates the number of BCM boards that it requires from the number of “BCM Batteries” that you entered. The number of BCM boards (PCBs) required for different battery configuration is shown in the following table (48V top, 24V bottom):

Batt Config

BCM Batt = 1

BCM Batt = 2

BCM Batt = 3

BCM Batt = 4

24 cell, 2V

1 BCM board

2 BCM boards

3 BCM boards

4 BCM boards

12 cell, 4V

1 BCM board

2 BCM boards

8 cell, 6V

1 BCM board

2 BCM boards

4 cell, 12V

1 BCM board

12 cell, 2V

1 BCM board

2 BCM boards

3 BCM boards

4 BCM boards

6 cell, 4V

1 BCM board

2 BCM boards

4 cell, 6V

1 BCM board

2 BCM boards

2 cell, 12V

1 BCM board

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

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

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

6.11.2 Frequency of measurement.

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

6.11.3 Battery Cell Measurements

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

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

Battery 1

12A

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

Battery1 Cell01

2.225V +12%

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

Battery1 Cellmm

n.nnnV ±pp%

6.12 Earth Leakage Detector - MUIB3 and MUIB5 only

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

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

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

E Leak I

0.2mA

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

E Leak Alm

5.0mA

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7. Commissioning

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

7.1 Indicators on the Rectifier Front Panel

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

LED Name

LED Colour

What it indicates

1ONGreen

Rectifier functioning normally

2ONGreen (flashing)

Input AC voltage out of range

Alarm

Yellow (flashing)

Alarm condition

Alarm

Yellow (not flashing)

Unit is in Equalisation mode

Shutdown

Red (with yellow LED flashing)

Unit is switched off or failed

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

7.2 System Parameter Ranges

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

7.2.1 RT9 SMR Parameters

Parameter

Range

Nominal

SMR Float Voltage

48 to 58V

54.5V

SMR Equalise Voltage

50 to 59.9V

56.0V

High Voltage alarm Threshold

52 to 59.9V

56.0V

Low Voltage alarm Threshold

44 to 54V

48.0V

HVSD Voltage alarm Threshold

54 to 62V

57.5V

Current Limit for SMR

5 to 30A

30A

7.3 System Commissioning

To commission a system, modification of system parameters on the MCSU-4 is required. This can be done manually through the front panel of the MCSU-4 (see detailed section on MCSU-4 operation), or by using a PC running WinCSU-2 that is connected to MCSU-4 via the USB interface (see detailed section on WinCSU-2 operation). It is recommended for

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systems that are to be commonly commissioned that the PC option be used. The benefit is that predetermined configurations can be stored on disk and easily downloaded to the MCSU-4 at any time. It is assumed that the operator commissioning the system has knowledge of programming system parameters.

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

7.3.1 Commissioning Procedure

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

 Make sure there is no load on the DC bus and that the batteries are disconnected.  If necessary, set the DIP switches on the backplanes, starting with 1 and ending with

the highest number corresponding to the number of rectifiers in the system. The DIP switches are ON when slid to the top, and LSB is at the right when viewing from the rear of the magazine. Position #1 corresponds to 0000 0001, position #2 to 0000 0010 and so on up to 15. #16 corresponds to 0001 0000, #17 to 0001 0001 and so on.

 Insert a rectifier into the #1 position in the system and turn the AC power on. The

rectifier should power up and start the MCSU-4.

 Using either the MCSU-4 front panel or a PC connected to the RS-232 serial port,

program all the MCSU-4 parameters according to the system requirements. Make sure that the number of rectifiers in the system is correctly set.

 Set up any parameters necessary to operate auxiliary equipment such as Battery Cell

Monitor (BCM), Mains Monitoring Interface Board (MMIB), Site Monitor, etc.

 Put all the remaining rectifiers ‘on-line’, one at a time by inserting the rectifier into the

magazine and switching on the corresponding input AC breaker where necessary. Check that each unit powers up and communicates with the MCSU-4. This is determined by checking that the MCSU-4 has a message window corresponding to the rectifier number similar to “SMR2 0A”.

 With all rectifiers operating correctly, add a load to the system of at least 30% of the

rated system current.

 Check that the MCSU-4 is able to control current sharing between the units by reading

current of all SMRs’ from MCSU-4 SMR menu.

 Increase the load to 100% and check that the rectifiers all share load current.  Reduce the load to 75% and burn in for 24 hours.  Remove the load. Clear Alarm Log.  Check that the wiring polarity of the battery is correct for the system, and then connect

the batteries on-line via a fuse or circuit breaker. Allow to charge before bringing final system on-line.

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

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8. Maintenance

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

8.1 Warnings and precautions

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

In particular, only qualified personnel should be allowed to service the units. In addition, the following precaution should be observed:

Do not remove the cover with power on!

Allow five minutes to elapse after switch off before removing the cover

to make sure high voltage capacitors are fully discharged.

8.2 SMR Maintenance

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

8.2.1 Current Sharing

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

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

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

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

8.2.2 Integrity of Electrical Connections

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

Alternatively, mechanical connections can be checked manually for tightness.

8.2.3 Fan Filter Maintenance

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

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

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

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

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9. Fault Finding and Replacement Procedures

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

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

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

9.1 System Fault Finding Procedures

The following table outlines suggested procedures to be followed if it is assumed that no internal repairs of units will be attempted. It is assumed instead that only MCSU-4 adjustments and unit replacement will be performed.

Alarm Condition

Possible Cause

Action Suggested

UNIT OFF No AC power to SMR

Check AC supply to SMR; if necessary reset CB supplying SMR

SMR faulty

Replace SMR

Equalise Mode

Equalisation cycle in progress due to recent AC power failure, periodic or manual initiation.

No action required

SMR Urgent

All SMRs off due to AC power failure

If possible restore AC power

One or more SMRs off due to faults;

Check Individual SMRs for obvious problem; replace SMRs if necessary

All SMRs off due to incorrect Inhibit signal from MCSU-4

Replace MCSU-4

One or more SMRs in Current Limit

Check Current Limit settings and adjust if necessary; or batteries being recharged

SMR Alarm

Any of the above or non critical problem with one or more SMRs

Select SMR menu. Check status of SMRs which are flashing alarm LED.

AC Fail (SMR alarm)

Total AC power failure or AC voltage not within operating limits

Check AC supply and confirm condition; If AC is OK replace SMR units if only two show alarm condition

Cct Breaker Fuse or CB within PDU has blown or

tripped

Check PDU (Power Distribution Unit) Wire or connector loose on MUIB

Check MUIB connections and tighten

Battery Switch Any one of 2 battery switches is open

Close if appropriate

Bad connection to MUIB

Repair connection

Amb Temp High

Ambient Temperature is too high

Reduce temperature – check Air Con.

Temperature sensor is faulty

Check and replace if necessary

Connection to MUIB is faulty

Repair connection

Set point is too low

Check Amb Temp High threshold level and re-adjust if necessary

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Alarm Condition

Possible Cause

Action Suggested

Batt Temp High

Battery temperature higher than pre-set level

Check battery temperatures and if necessary increase ventilation and cooling

Set point is too low

Check Batt Temp High threshold level and re-adjust if necessary

Temp Sensor N/A

Temperature Sensor in MCSU-4 not attached or faulty

Plug in temperature sensor if required; Replace temperature sensor

Faulty MUIB connection(s)

Replace MUIB

Faulty MCSU-4 card

Replace MCSU-4

Volts High

SMR fault

SMR Fault Chart

Float level set too high on MCSU-4

Check and adjust if necessary

MCSU-4 fault

Replace MCSU-4

Volts Low

AC power has failed; system on battery power

Restore AC power if possible Alarm threshold level set too high

Check set point and adjust if necessary

All SMRs are off due to MCSU-4 Inhibit signal, system on battery power

Check reason for signal; if necessary replace MCSU-4

Battery charging current limiting due to faulty battery current signal - this will depress float voltage

Check battery currents. If one of them shows figure higher than Batt Chg Curr Lim set point, check corresponding current transducer; check connections to transducer; check MUIB connections

Battery Temperature Compensation too high due to faulty battery temperature monitoring

Check battery temperature readings in Batt menu; Check and if necessary replace faulty sensor; check connection to MUIB

Battery Temperature Compensation too high due to faulty MUIB

Replace MUIB

SMR HVSD

Output voltage too high due to SMR fault

Replace faulty SMR

HVSD threshold on SMRs set too low

Check and re-adjust threshold level

MCSU-4 fault

Replace MCSU-4

SMRs not sharing load current

Communications link malfunctioning or faulty rectifier (digital current control)

Replace Comms cable and/or SMR

Faulty MCSU-4 voltage and current control loop IODEM signal (analog active current control)

Replace MCSU-4 Float or Equalise level on MCSU-4 set too high/too low.

Check and re-adjust Float or Equalise level on MCSU-4

No Response SMR not responding to MCSU-4

Check and if necessary replace comms cable at back of magazine faulty

Faulty microprocessor card in SMR

Replace SMR

Power Limit

Unit not current sharing (if only one showing power limit)

Replace SMR

Load current too high (if more than one unit showing alarm)

Reduce load

Reduce battery charging current limit if it is too high

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Alarm Condition

Possible Cause

Action Suggested

No Load

Load circuit breakers have tripped and there is no load

Reset circuit breakers

If only one unit showing alarm, comms line to SMR may be faulty

In SMR menu check status of this SMR. If “No Response” replace comms line

Faulty SMR

Replace SMR

Current Limit

Batteries being recharged if more than one unit showing alarm

No action required

If only one unit shows alarm, internal control loop faulty

Replace SMR

No Demand Internal control loop faulty

Replace SMR

System has no load

No Action Required

EEPROM Fail

Faulty EEPROM or microprocessor card

Replace SMR

DDC Controller

Fault in DC/DC converter

Replace SMR

H/S Temp High

SMR Heat sink temperature too high

Check air intake to SMR is not blocked

Ambient temperature is too high

Try to reduce ambient temperature

Microprocessor card is faulty

Replace SMR

Temp Sensor Fail

Temperature sensor is faulty

Replace SMR

Fan Fail (Fan cooled nits only)

Air flow inadequate due to dirty filter

Clean or replace filter

Air intake/outlet blocked

Remove air blockage

Fan faulty

Replace fan if connection is OK

Reference Fail

Reference voltage source in, or entire microprocessor card is faulty

Replace SMR

HVDC not OK Faulty boost controller

Replace SMR

Inrush limiting fuse or resistor O/C

Replace SMR

High Volts SD Feedback voltage circuit faulty

Replace SMR

Faulty microprocessor card

Replace SMR

LVDS Open

Battery discharged to the limit voltage level due to no AC power

Check AC voltage and reset if possible

Battery voltage OK

In BATT menu check if LVDS mode is set to “Open”.

Battery voltage OK, MCSU-4 faulty

Replace MCSU-4

LVDS threshold level set too high

Reset level in BATT menu

Sys Volts High

Volts High level in MCSU-4 set too low

Reset level to correct value

Temperature compensation coefficient set too high

Set correct temperature compensation coefficient

Faulty MUIB or MCSU-4

Replace MCSU-4

Sys Volts Low

Volts Low threshold in MCSU-4 too high

Reset level to correct value

Temperature compensation coefficient set too high

Set correct temperature compensation coefficient

Faulty MUIB or MCSU-4

Replace MCSU-4

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Alarm Condition

Possible Cause

Action Suggested

Battery Disch

Output voltage low due to SMRs off

Check AC voltage & restore if possible;

Float level set too low

Set float level to correct value

Battery Disch level set too high

Set correct Battery Disch level

SMR Comms Fail

Comms cable faulty

Replace cable

SMR communication circuits faulty

Replace SMR

Faulty MCSU-4

Replace MCSU-4

AC Volt Fault (System alarm)

AC voltage out of tolerance

Check AC voltages and fix if possible

AC voltage threshold levels incorrect

Set correct levels

Faulty AC monitoring unit MMIB1or2

Replace monitoring unit

MUIB or MCSU-4 faulty

Replace MCSU-4

Communications link failure (Only on systems not fitted with AC

monitoring module)

In SMR menu check status of all SMRs. If all show “No Response” check 4-way communications cable between MCSU-4 and all SMRs

AC Freq Fault

AC frequency out of tolerance

Check AC frequency and fix if possible

AC frequency threshold levels incorrect

Set correct levels

Faulty AC monitoring unit MMIB1 or 2

Replace monitoring unit

MUIB or MCSU-4 faulty

Replace MCSU-4

Batt I-Limit

Battery charging current is being limited to preset value

No action necessary Battery current limit set too low

Set correct limit

Battery current sensor faulty

replace sensor

Faulty MUIB or MCSU-4

Replace MCSU-4

Batt Sym Alarm

One Battery string is faulty

Repair/replace battery if necessary

Battery discharge current differential level set too low

Set correct level of Disch I Diff in BATT menu

Battery current sensor is faulty

Check and replace sensor if necessary

Faulty MUIB or MCSU

Replace MCSU-4

Earth Leak Alarm (Only on systems

fitted with MUIB3)

Excessive Earth current due to either failure of load supply isolation or faulty load equipment.

Locate source of earth leakage current and correct accordingly.

9.2 MCSU-4 Fault Finding and Repair Procedures

In addition to performing a supervisory function by monitoring output voltage and current and the various system alarms, the MCSU-4 also performs a voltage control function in order to achieve battery charging current control, battery temperature compensation, battery equalisation and active current sharing.

To control current to the lowest battery voltage, the MCSU-4 has the ability to suppress the SMR output voltage to a value lower than the minimum battery voltage.

Installation, Operation and Technical Manual Rectifier Technologies

158-1872-01 82 19-Feb-14

It therefore follows that it is possible for a MCSU-4 fault to occur which can suppress the SMR voltage to that low level and thus cause a battery discharge despite the precautions that have been taken to ensure that this does not happen.

In such a situation disconnecting the 4-way cable, which connects the SMRs to the MCSU-4, will remove the voltage suppressing communications control signal and thus avoid the batteries discharging. Alternatively, the MCSU-4 can be pulled out of the magazine to achieve the same result. Without the MCSU-4 connected, the SMRs will revert to their pre-set Float voltage and passive current sharing.

There are virtually no electronic components on the MUIB except for the Remote alarm relays, and some fuse links, but there are many connectors. It is worth checking for poor connections when a MCSU-4 system problem is being investigated.

9.2.1 Replacing MCSU-4

The MCSU-4 is “hot-swappable”, so replacing a faulty unit is simply a matter of pulling the bad unit out of the MCSU-4 magazine and plugging a new unit in. The new unit will then power up and automatically read the system parameters stored in the non-volatile memory located on the backplane. The system parameters should then be checked via the front panel menus or using WinCSU-2.

Rectifier RT9- 24V, MCSU-4 Installation, Operation And Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual