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A30050 X6054 X 2 7631 Startup Acceptance SVE630 2
A30050 X6054 X 2 7631 Startup Acceptance SVE630 2
Power supply system (exchange): Installed power: Battery capacity: AC mains voltage / frequency: Available AC power: Available genset power: Date of acceptance: On behalf of customer: On behalf of SIEMENS AG:
...................................................................... ...................................................................... ................................................................. Ah ...................................................................... .............................................................. kVA .............................................................. kVA ...................................................................... ...................................................................... ......................................................................
1 Equipment accepted: Item no. Type designation Serial no. Technical data
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TABLE OF CONTENTS 1 EQUIPMENT ACCEPTED:........................................................................................................................................................1 1.1 1.2 1.3 2 SCOPE ....................................................................................................................................................................................3 A PPLICABLE DOCUMENTAT ION .....................................................................................................................................4 PARTS AND MATERIALS USED..........................................................................................................................................4
STARTUP PREPARATION......................................................................................................................................................5 2.1 VISUAL INSPECTION ............................................................................................................................................................5 2.2 COMPONENT PREPARATION .............................................................................................................................................6 2.2.1 Preparing the GR modules ......................................................................................................................................6 2.2.2 Setting the termination module A63......................................................................................................................6 2.2.3 Preparing the system................................................................................................................................................6
START-UP ...................................................................................................................................................................................7 3.1 GR START -UP ........................................................................................................................................................................7 3.1.1 Checking the GR under no-load conditions........................................................................................................7 3.1.2 GR test operation ......................................................................................................................................................7 3.1.3 GR current sharing ...................................................................................................................................................8 3.2 STARTING THE CENTRAL CONTROL AND SIGNAL MODULE A60 ..............................................................................8 3.3 CONNECTING THE BATTERY...........................................................................................................................................10
TESTING THE SIGNALS AND MONITORS ......................................................................................................................10 4.1 4.2 4.3 4.4 4.5 4.6 4.7 AC MAINS DISTURBANCE AND AC MAINS FAILURE ....................................................................................................10 TESTING GR FAULT / UNDERVOLTAGE / CONTROLLING THE K10...........................................................................11 TESTING GR OVERVOLTAGE CONTROL / RESETTING THE GR...................................................................................12 GR SWITCH-OFF TEST .......................................................................................................................................................13 FAULT : K10.........................................................................................................................................................................13 FAULT : FANS .....................................................................................................................................................................14 FAULT : BATTERY FUSES F9, F10....................................................................................................................................14
5 6
TESTING THE CHARGING FUNCTION..............................................................................................................................14 PARALLEL-CONNECTION OF A FURTHER SVE630 ....................................................................................................15 6.1 6.2 6.3 6.4 6.5 6.6 ON-THE -SPOT CHANGES ...................................................................................................................................................15 GR START -UP ......................................................................................................................................................................17 A60 START -UP ....................................................................................................................................................................17 CONNECTING THE BATTERY...........................................................................................................................................18 TESTING THE SIGNALS AND MONITORS.........................................................................................................................18 TESTING THE SYSTEM CONTROL ....................................................................................................................................18
7 8 9
ACCEPTANCE TEST FOR BATTERIES .............................................................................................................................18 CONCLUDING START-UP ....................................................................................................................................................18 APPENDIX .................................................................................................................................................................................19
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1.1 Scope
These startup instructions apply to power supply unit SVE630 : Type designation D(E)48/90(60/75)-FG SVE630 as per circuit diagram A30050-X6054-X100-*-7511 equipped with Control and signal module Termination module Battery contactor A60 A63 K10 S31043-K1500-X-* S31043-Q1600-X-*
The power supply unit is equipped with the following rectifier modules: E48/30 WBRUG-FG0 GR60 pure 48V DC unit (standard) or E48/30(60/25) WBRUG-FG0 GR60 switchable from 48V DC to 60V DC or E48/30 WBRUG-FG0 GR60 pure 48V DC unit with extended input voltage range S31043-K1166-X S31043-K1160-X S31043-K1165-X
These instructions also apply to situations where different numbers of battery cells are used. The output voltages are always given as "UN. Depending on the number of battery cells used, the rectifier (GR) output voltages for the two versions operating in the trickle charging mode (2.23V/C) are as follows: a) pure 48V GR (S31043-K1165-X or S31043-K1166-X) Battery with 24 cells: Battery with 25 cells: b) GR switchable from 48V to 60V (S31043-K1160-X) Battery with 24 cells: Battery with 25 cells: Battery with 30 cells: In the following, the modules and cabinets are referred to as: Rectifier module Power supply unit GR SVE UN = 53.5V UN = 56,0V UN = 67,0V UN = 53.5V UN = 56,0V
By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C.
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The control and signal module A60 is dealt with in the Description and Operating Instructions for the SVE630: Control and Signalling Unit A60
A31043-X1500-X-*-7618
The installation and startup of lead-acid batteries in power supply systems are described in A30050-X5955-X-*-7631.
!
Caution:
NOTE:
Startup of these power supply systems must be carried out by qualified personnel only. Before doing this, please read the relevant description and operating instructions carefully and comply with the warning notes! The system is sealed to IP20 (as per EN 60529), the cable entry side only to IP00!
Important: - startup of an expension rack The steps listet below are not to be used for the "old" rack which is already in operation: - Remove all battery fuses. - Switch off all miniature CBs. - Remove all AC mains fuses. Remove all miniature fuses.
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2 Startup preparation
2.1 Visual inspection
Check if the PS system is installed in a room with "restricted access ". If it is not, suitable measures must be taken, eg establishing rules about where to keep the keys. The room must have a F90 fire rating. Check the installation, equipment and accessories for compliance with the order, delivery note and installation documents. Check the electrical connections (AC mains and DC sides) and the fuses for compliance with the installation documents. Check the AC power protective measures for compliance with the installation documents, including the connections between the SVE and functional protective earth (FPE). Check the screw connections at the copper bars and the terminals in the units and throughout the installation (spot checks). Check the connectors. Check the overvoltage-protection measures and, if necessary, the lightning-protection system (if installed): a) Overvoltage arresters (Class C arresters) Check the overvoltage arresters (3xDEHNguard and 1xDEHNgapC used in star connected AC mains with 3/N/PE AC 400V 50/60Hz respectively 6xDEHNguard used in delta connected AC mains with 3/PE AC 230V 50/60Hz) installed in the AC distribution panel. Observe the size of the backup fuses in front of the overvoltage arresters: max. 125A. The installed cable length between phase wires and overvoltage arresters and between neutral wire and overvoltage arrester must be as short as possible (0,5m)! The same requirement is valid for the connection between overvoltage arresters and ground, that means the PE-connecting terminal of the overvoltage arresters must be connected to the chassis grounding (PE-terminal) on the shortest way (0,5m)! b) Lightning current arresters (Class B arresters) Check the lightning current arresters (3xDEHNport and 1xDEHNgapB used in star connected AC mains with 3/N/PE AC 400V 50/60Hz respectively 3xDEHNport used in delta connected AC mains with 3/PE AC 230V 50/60Hz) and the decoupling chokes, if used. Observe the size of the backup fuses in front of the lightning current arresters: max. 250A. The installed cable length between phase wires and lightning current arresters and between neutral wire and lightning current arrester must be as short as possible (0,5m)! The same requirement is valid for the connection between lightning current arresters and ground, that means the PE-connecting terminal of the lightning current arresters must be connected to the main ground busbar on the shortest way (0,5m)! Important: If no decoupling chokes were used between class B- and class C-arresters, it is a must to connect 15 meters 5-wire cable (in star connected AC mains with 3/N/PE AC 400V 50/60Hz) respectively 15 meters 4-wire cable (in delta connected AC mains with 3/PE AC 230V 50/60Hz) between lightning current- and overvoltage arresters. It is needed to make a safe energetic coordination between these two arrester stages!
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X634
X635 1 2 3 4 5 6
X660
Cutaway figure of A63 with components in place Jumpers J610, J612 and J615 must be soldered in place. Jumpers J611, J613and J614 must not be soldered in place.
2.2.3 Preparing the system AC mains fuses F...-F... in the AC distribution panel and/or in the preceding lightning protection module removed. AC power present at SVE; neutral conductor connected. Power CBs Q11...Q31 are off. All GR in place. 29.07.97 Heimbrger P04
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Connector G*/X1 on all GR units inserted. DC (G*/X2) and signal connectors (G*/X3) on the modules not inserted. Signal connectors G*/X631 to X633, on the A63 inserted. All GR integral switches (ON/OFF) are in the OFF position. Output fuses F12 to F32 on GR modules removed. Miniature fuses F70 to F72 removed. Low-power load fuses F73 to F75 removed. All load fuses removed; loads not connected. Battery fuses removed; batteries connected to fused disconnector. A60 connected to A63 with a 37-core tape cable( via X2003 on A60 and via X600 on A63). Variable test load >35A connected to load busbar "L-V" and positive busbar "L+".
3 Start-up
Check AC voltages and insert mains fuses F... to -F... in the AC distribution panel or in the preceding lightning protection module (phase sequence unimportant).
3.1 GR start-up
3.1.1 Checking the GR under no-load conditions Switch on power CB Q11; GR self-check: LEDs: "MAINS" and "FAULT" on GR1 lit. Switch on GR with integral switch. GR1 begins to operate; LEDs "2.23V/C" and "MAINS" lit. Measure DC voltage of GR at socket "VOUT" (above X2); if required, readjust output voltage of GR to UN + 0.5V " with potentiometer 2.23V". Switch off GR with integral switch. Switch off miniature CB Q11. Repeat Section 3.1.1 for all GR.
3.1.2 GR test operation Insert fan miniature fuse F71. Plug in DC (G1/X2) connector on GR1. Insert GR1 output fuse F12. Switch on GR1 (with Q11 and integral switch S1), fans begin to operate, A60 not yet supplied with voltage (A60 test to be carried out later on). Switch on test load and set to about 15A.
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Measure voltage UL-V at load busbar L-V and if required readjust carefully to UN with potentiometer 2.23V". Increase test load to value that exceeds the GR power rating. Check current limiting, onset point: UL-V = UN - 0.8V; IA = < 31A in 48V system (IA = < 26A in 60V system). Switch off test load. Switch off GR1 with integral switch and power CB Q11, fans stop. Remove GR1 output fuse F12. Unplug DC (G1/X2) connector on GR1. Repeat Section 3.1.2 for relevant components on all GR.
3.1.3 GR current sharing Plug in all DC (G*/X2) and signal connectors (G*/X3) on GR. Insert all GR output fuses F*2. Close all power CBs Q*1 and integral switches; fans begin to operate. Set test load to 50% or less for all GR. Measure current shares of GR at socket IOUT (above X2), 100mV correspond to 30A; if required, readjust current shares of GR with potentiometer 2.23V (tolerance: 10%). Switch off test load; switch off all GR withintegral switches; fans stop.
Since the battery fuses are removed, S100 (SV1 signal) and F106 removed) continue to flash in succession.
Keys and enable the user to access Level 0 features (measured values, charging characteristic control, delete overvoltage protection OVP).
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Testing or changing the software configuration Press key on A60 until PaSS appears on the display, acknowledge with . The display shows P.0100; press key to change the configuration password to P.0123 and acknowledge by pressing key twice. Level 1 Configuration starts: the display shows S . C o n F. Press to display the currently valid software configuration. It is 24C2 for a SVE630 operating in 48V mode (24-cell battery). If the configuration required has not been loaded, press key until 24C2 appears on the display. Press in acknowledgement, then press ESC to return to Level 0. For operating the system in 60V mode (requirement: 30-cell battery), load configuration 30C2 as described above.
Testing and readjusting the load current shunt Press key until PaSS appears on the display; acknowledge with . The display shows P.0100; press key to change the configuration password to P.0123 and acknowledge by pressing key twice. Level 1 Configuration starts: the display shows S . C o n F. Press to display S . S I. Press to change to Level 2 (selection of current measurement inputs to be parameterised); the display shows S.SI.b (battery current shunt). Press to display S.SI.L (load current shunt). Press to go to Level 3; the display shows the value to which load current shunt is set. For the SVE630: 150. If this value is the same as that for the shunt installed in the SVE (refer also to the cabinet circuit diagram), press ESC three times to return to the basic menu of Level 0. If the value is other than that for the installed shunt, press key or to set the shunt size required (standard values can be scrolled through). If the desired value is reached, acknowledge with and press key ESC twice to return to the basic menu of Level 0.
Testing the load current measurement Set test load to 10% of system IN. Press key on the A60 until I.L appears on the display; after a short period of time the load current is shown. Load current is displayed (tolerance 2 % IN shunt), if necessary, cross-check with an external instrument at the load current shunt. Switch off test load.
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The description of A60 (see description of SVE630) contains further details that help you carry out these steps. If desired, the configuration can be changed to suit local conditions. Further changes should be carried out by appropriately trained personnel only.
All faults arising from equipment which are monitored by the A60, are issued in the form of fault codes (F...). Refer to the operating instructions for control and signal module A60 for the codes, how they are translated, and further details.
S100 F202
SV1
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Switch off all miniature CBs Q*1; wait for SV2. Switch all miniature CBs Q*1 back on again; fault reports disappear from display.
Display
Remote signal
SV2
SV1
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Finally, plug in all G*/X3 and close all Q*1; close integral switches. Reconnect the batteries, close F9 and F10. A60 shows no faults.
SV1
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LED "2.33V/C" lights up briefly, A60 detects overvoltage and effects maintained GR shutdown. On the GR LED 2.23V/C flashes. A60 shows fault reports. Cancel overvoltage protection- and detection thresholds for A60 in accordance with the steps described above (reset previously configured values). Press key on A60 until C.OP appears on the display and acknowledge with . Actuate to change from status n o to status YES . Acknowledge with and press ESC. The GR are reset, system continues to operate for 15s on characteristic 2.23V/C 1 (LED "2.23V/C" lit)before it goes to charging (LED 2.33V/C lights up), A60 shows no fault report (C100 for charging is shown). Press key until C.Ch appears on the display. Acknowledge with and press to change from status o n to status oFF. Finally, acknowledge with and press ESC. GR go to characteristic 2.23V/C 1, LED "2.23V/C" lit. C100 disappear from the A60 display.
S100 F203
SV1
Remove fuse F70, K10 drops out. Reinsert fuse F70, K10 picks up. A60 no longer indicates any faults.
S100 F105
SV1
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Display
Remote signal
S100 F104
SV1
Display
Fernsignal
S100 F106
SV1
A long-term test is not necessary but can be carried out by producing an AC mains failure of >15 minutes and measuring the charging time required. Charging can be stopped and prematurely terminated at any time by taking the steps described above.
By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased.
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X634
X635 1 2 3 4 5 6
X660
Fig. 1
b) Old SVE630 already in operation Remove, turn and support the A60 as described under a). Insert female connector fitted to 25-core data cable (for interconnecting the two termination modules A63) into the SVE to be expanded from the bottom rear and plug it in connector X634 on the A63 (see Fig. 1), tighten retaining screws. Bring in the two flexible cables used for parallel connection of remote signals at the bottom rear of theSVE to be expanded. Attach the 3-way terminal block supplied with the expansion SVE (for parallel connection of remote signals) to the DIN rail on which miniature fuses F70 to F75 are arranged. Connect the flexible cable coming from the A60 terminal X2002:13 on the expansion SVE (remote signal SV1) to terminal X2:13 on the 3-way terminal block; repeat the procedure for the remote signal AC mains failure. Connect the remote-signal cables of the old SVE coming from the A60 terminals X2002:13 and 22 to terminals X2:13, and 22 in the same way. The next step is to install links between X2:13 and X2:2002:13, and between X2:22 and X2002:22. Insert the two DC cables of the expansion SVE into the SVE at the same point as the data cable and connect them to L+ and L- busbars (Caution:Note polarity!). Reinstall the A60 as described under a).
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Because the GR60 in the expansion SVE are still in the off position, the A60 in the SVE to be expanded displays the following fault reports: S100, F202, and F203
6.2 GR start-up
For startup of the new GR, refer to Section 3.1. Make sure that specifically the output voltage of the new GR installed in expansion KS corresponds to the DC output voltage of the KS to be expanded.
Testing / matching the software configuration The software configuration for the new expansion SVE must correspond to that of the SVE to be expanded. For testing (or if necessary changing) the software configuration, refer to Section 3.2. Testing or readjusting the load current shunt is carried out in accordance with Section 3.2. To avoid undefined states during battery charging after an AC mains failure, it is necessary to set the time required for charging the batteries to zero in the configuration of the A60 installed in the expansion SVE. To do this, carry out the following steps: Press key until PaSS appears on the display, acknowledge with . The display shows P.0100, press key to change the configuration password to P.0123 and press key twice in acknowledgement. Level 1 Configuration starts and S . C o n F appears on the display. Press seven times to display S.t. Press to change to Level 2 (selecting the times to be parameterised), the display shows S.t.SV2 (delay for SV2 signal). Press twice to display S.t.Ch (battery charging time); acknowledge with . Currently set battery charging time appears (standard setting: 2h). Press until display shows 0; acknowledge with . Press key ESC twice to return to basic menu for Level 0.
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8 Concluding start-up
The steps listed below are not to be used for an expansion SVE which has been parallel-connected during operation! Remove all battery fuses. Switch off all miniature CBs. Remove all AC mains fuses. Remove all miniature fuses.
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Note down the following details in the acceptance test documents: Serial numbers of the units. Changes in the configuration and other settings of the A60 and A63. Correct the system plans.
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