Operation & Maintenance Manual DC UNINTERRUPTIBLE POWER SUPPLY [Customer : Industrial Trading Philippines Job number: 609-000392 Ser. No. BS 24200 |System Model: D480 G125/80 Bwrug - TDG Manufacturer Benning Power Electronics Pte Ltd 85 Defu Lane 10 #05-00 Singapore 539218 E-mail: service-info@benning.com.sgBENNING Tesved: Revision ‘Checked: User‘*s Manual Contents Preface. Connection of the supply, signal and consumer lines. Starting up. Instruction of Commissioning... Battery Installation.. Description - Rectifier unit .... Circuit diagram. Bill of Material Test Report... Maintenance Instruction... Date Name ‘Sidmanual 7-12-2000 TBI-FrBy Page 1/88 pages 7-12-2000 TeEockBENNING Preface ‘These operating instructions provide information essential for correct operation of the unit. To ensure its safe operation, these instructions must be read and understood before the unit is switched on. All the information they contain must be observed! This avoids: - danger during operation = danger to operating personne! = downtime, and = increases the reliability and lifespan of the unit. Keep these instructions in a safe place for future reference. Customer service: For further information apply to the supplier or the manufacturer of the unit (G POWER ELECTRONICS PTE LTD 85 Defu Lane 10 #05-00 Singapore 539218 Tel :(65)6844 3133 Fax : (65) 6844 3279 E-mail : service-info@benning.com.sgBENNING Connection of the supply, signal and consumer lines 1. Mains connection Via external upstream fuses, connect the power-supply unit to the three-phase or AC mains power supply. ON seen ne rent. Take this into account when selecting FI switch! Connect PE conductor before L and N! The mains connection is intended for a three-phase current of 480V +PE (L1, L2 and L3 must not be bridged). All connecting leads must be attached to the cable clamping rail by means of suitable hammerfoot clamps. conductor before L and N! 2. Consumer connection The consumer lines should be applied to the correct poles at the connection points (output fuses) provided and clamped. To assist in making the connection, the top of the housing can be removed. 3. Signal-line connection Apply the cable for remote signaling to the correct terminals (see circuit dia- gram) and clamp them into position. Before connecting them, compare the data on the machine plate and data sheet ‘with those of the existing mains supply and battery voltage. Follow the circuit diagram closely! Connect battery plus pole to lead plus pole; connect battery ‘minus pole to lead minus pole, The earthed plus rail of the DC side and the earthed conductor "PE" are connected to the central earthing bolton the top of the housing. Connect the central earth lead here. Protect the unit against excessive contact voltage in accordance with the local regulations.BENNING 4. Temperature sensor connection Under the rectifier module there normally are temperature sensor terminals (see cireuit diagram) which serve for connection of the temperature sensor(s). ‘The cables have to be laid through the charger to the battery, because the bat- tery voltage shall controlled temperature dependently, From out each rectifier module a shielded wire has to be laid. The wire length should not exceed 5 m. ‘The wire shield is not connected to earth. In case of several temperature sen- sors the in a cable socket installed sensors can be easily be mounted on a rail near the batteryBENNING Starting up Once the unit has been correctly connected, it can be put into operation. ‘The unit is supplied by the manufacturer in the ready-to-use state. Before start- ing it up, ensure that all connections and fuses are firmly in position, and the automatic circuit breakers are switched on. Switch on the mains power for the unit at the upstream distribution box. Ifall the automatic circuit breakers ofthe rectifier modules are closed, these switch on. The green LED "in operation” on the plug-in modules and on the front panel ofthe system-supply unit light up. The measuring instrument indi- cates a voltage of approx. 133.8V. Before inserting the battery fuses, re-check the correct polarity of the batteries connected. Then insert the battery fuses and replace the fuse monitoring device. ‘The system-supply unit is now ready for use.BENNING Instructions for Commissioning 1. Requirements for commissioning 1.1 Tools Screwdriver blade width 4-8 = 12mm Set of open-ended wrenches width across flats 6 - 24 mm Universal pliers Pointed pliers Side cutting pliers Marking pliers for cable lugs 1.5 - 6 mu 1.2. Measuring instruments Continuity tester Multipurpose instrument Rotating field measuring 2. Connection ‘The unit is connected to the three phase supply via external protection fuses. The rating of the fuses should correspond to that shown in the data sheet or on the rating plate. ‘The circuit and terminal diagrams should be strictly observed when connecting the cables. The mains voltage must correspond to the voltage stated on the rating plate. The DC isolating switches must be removed before connecting the battery. The poles must be connected correctly (je. + to + and - to-). ‘or the cross sections of the mains, battery and consumer leads, refer to the data on the rating plate. The voltage loss between charging unit and battery or consumer should be taken into consideration when selecting the correct cross sections. ‘The unit must be earthed via the earthing bolt or connected to the protective conductor.BENNING 3. Commissioning ‘The unit is ready for operation when it leaves the manufacturer's works. Before itis put into operation, it should be ensured that all connections and fuses are securely in position, and that automatic circuit breakers and motor protection switches are switched on. When it has been properly connected, the charger can be put into operation.BENNING Battery Installation ‘When installing batteries, always use correctly insulated tools. If batteries are included with the power-supply unit and require installation in the cabinet, this ‘must be done in accordance with the manufacturer's instructions, A Before connecting the batteries o the power-supply unit, remove the battery fuses. Ifa fuse-monitoring device is installed, this must also be removed. ‘The individual cells or blocks must be joined using the connectors provided. Ensure that the battery poles are correctly connected, If drawings are provided, always follow these exactly. ‘Connect the battery leads to the end poles of the battery (the end marked in red or with +B tothe plus pole, the end marked in blue or with -B to the minus pole) Connect the separately supplied battery leads to the battery fuses or the battery isolating switch in the rectifier cabinet, If several battery blocks are connected parallel, two connecting leads per battery fuse can be used if necessaryBENNING Operating Instruction Rectifier unit THYROTRONIC with Thysat regulator Dae Name Ne sahen Tssved: 0607.01 Mo'Obs Page 165 Pages Revision 23.1205 ‘Mo‘Obs. Gepru 27.12.05 ‘Mohr Beg proc OOOTDZAS T00 ManvalThranwek DOCBENNING Rectifier unit THYROTRONIC with Thysat regulator General 14 12 Purpose of the Operating Instructions ‘These Operating Instructions serve to enable the secure operation of the rectifier unit THYROTRONIC as intended, ‘The present Operating Instructions contain the information necessary for the safe operation as intended of the rectifier unt. ‘The Operating Instructions must alway’ be available and kept handy in the vicinity of the rectifier unit. ‘The Operating Instructions must be read and applied by any person entrusted with operat- ing processes on the rectifier unit; these include transport, erection and disassembly. In addition to the Operating Instructions, the valid applicable guidelines, standards and laws for safe and correct working at the place of installation must be observed in commer- cial use. Information in addition to these Operating Instructions can be obtained from the specialists of the manufacturer or supplier. : All documentation is protected under copyright law. Passing on and copying of documents, even in form of extracts, and utilisation and dissemination of its contents is not permitted unless expressly approved. Scope of the Operating Instructions If required as a result of the site conditions, the rectifier unit can be supplied in a large number of versions. A description of all versions would reduce the benefit and compact na- ture of your Operating Instructions. For this reason these Operating Instructions refer exclusively to the standard configuration of the rectifier unit. Exact details concerning your version of the rectifier unit ean be taken from: + the order confirmation, + the equipment data sheet, + the rating plate on the inside of the front door, —+ the technical documentation in chapters 18/19 of these Operating Instructions. ‘These details conceming your version are of prior validity compared with possibly deviat- ing details concerning the standard configuration in these Operating Instructions. 23.12.05: TB-Ma/Obs 2165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 1.3. Presentation remarks ‘The rectifier unit is manufactured according to the generally accepted rules and the current state of the art design techniques. Additional safety instructions are provided in order to guarantee the personnel adequate safety. Adequate safety when handling the rectifier unit, is ensured only if these instructions are adhered to. From time to time it is necessary to emphasise certain text passages. The passages marked thus have different meanings: + Notes contain additional information facilitating safe and efficient handling of the rectifier unit, A ‘This warning draws attention to possible damage to property which may result from a failure to adhere to precautionary measures or from incorrect handling Please observe all warnings and measures that prevent the occurrence of dam- age on the rectifier unit and other property. Proceed with particular care! A ‘This warning refers to possible injuries to persons which may result due to a failure of adhering to precautionary measures or through incorrect handling. Please observe all warnings and measures that prevent injuries to yourself or third parties. Proceed with particular care! 23.12.05- TB-Mo/Obs 3165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 2 22 2.24 Safety General ‘These Operating Instructions are an essential part of the rectifier uni ‘The operator has to ensure that these Operating Instructions are alway’ available near the rectifier unit and that the operating staff get acquainted with these instructions. ‘The Operating Instructions must be supplemented by the operator, with operating instruc- tions on the basis of existing national regulations for accident prevention and environ- mental protection. These additional instructions should include information concerning su- pervisory and notification obligations for the consideration of special operational features, for instance with regard to work organisation, working processes and personnel employed. In addition to the Operating Instructions and the valid regulations for accident prevention applicable in the country concerned and at the place of operation itis also necessary to ob- serve the recognised special technical rules for safe and correct working, Personnel qualifications Only qualified and trained technical personnel may work on the rectifier iit. In particular qualified electricians authorised for this purpose must only perform the installation, initial start-up, maintenance and disassembly of the rectifier unit ‘The competencies of the personnel for operation must be clearly separated from those of installation, programming and repair. Only service personnel must be able to open the housing of the rectifier unit, + get tothe password-protected menu levels of the regulator programme. Qualified technical personnel in the sense of these basic instructions are persons who are familiar with the installation, star-up, operation, maintenance, shutdown and disassembly and who have the qualifications corresponding to these activites. With qualified electricians it must be assumed that the applicable regulations of the local power supply company (EVU) and the safety instructions of the accident prevention regu- lations of the trade associations (for instance BGV A2) and all rules for safe and correct working (for instance DIN VDE 0100 and IEC 664 or DIN VDE 01 10) are observed and adhered to. ‘The manufacturer points out that the manufacturer will not accept any liability for damage and operating faults arising from a failure to observe the operating instructions. Commercial use Ifthe rectifier unit is employed commercially, the following will apply in addition: > The operator must be famitiar with handling the rectifier unit through special indue- tion or training courses. 23.12.05. TB-Mo/Obs 416s 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator 23 24 —+ Only authorised personne! may become active. Use as intended A Risk of injury! Danger of serious injuries to persons and property may result from: + incorrect use or incorrect operation, - unauthorised opening of the rectifier unit, + incorrect installation or incorrect maintenance and repai All details concerning the intended use, the residual risk, the installation, the operation and maintenance contained in these Operating Instructions must therefore be observed and ad- hered to. The rectifier unit THYROTRONIC is intended to supply DC voltage loads. In addition to this the rectifier unit can be used for charging suitable batteries. Only rechargeable lead ‘and nickel-cadmium batteries are suitable. The rectifier unit is not suitable forall other ac- ‘cumulators and non-rechargeable batteries! ‘The instructions of the battery manufacturer must be observed and adhered to! As part of the intended use, the details of the rating plate and the details in the supplied technical documentation must be observed and adhered to. ‘The rectifier unit may only be used for the applications provided in these Operating In- structions and in the technical description, with the accessories or components recom- ‘mended and approved by the manufacturer. Use other than this or beyond this will not be considered as use as intended. The operator or user of the rectifier unit will carry the sole responsibility for damage resulting from such use. Start-up of the rectifier unit is only permitted subject to adherence to the guideline for elec- tromagnetic compatibility (89/336/EEC). The limit value class is specified in the equip- ment data sheet. In the case of a rectifier unit with subsequent modifications on the part of the operator (with regard to components, circuits, regulator programming, etc.) itis compulsory on the part of the operator to document the equipment status in the technical document to provide suitable instructions permanently on the front of the unit if applicable. Safety instructions concerning place of use and storage The rectifier unit must be protected from inadmissible loads. In particular, no components rust be damaged during transport and handling. Avoid contact with electronic compo- nents + entering liquids, 23.12,05- TB-Mo/Obs 5168 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 244 25 + entering conductive dusts (soot, metals), + high humidity ofthe air and + formation of condensate (for instance through airtight packaging) and + ambient temperatures below 0 °C and above 40 °C + may damage the rectifier unit and must therefore be excluded Heat soak conditions onthe rectifier unit for instance through heat sources or blockage of the ventilation slits must be excluded. Although non-conductive dusts do not impair the function of the rectifier unit they may however obstruct the dissipation of heat if allowed to accumulate and consequently reduce the service life of the rectifier unit. If the rectifier unit is supplied in a particularly protected version, the details in the order confirmation must be observed and adhered to. Safety instructions for battery use Open flames and smoking in rooms with battery charging stations are prohibited! ‘No combustible materials and spark-forming equipment may be located in a vicinity of 2m around battery charging stations. The place of operation must be adequately ventilated so that resulting charging gases (acid fog, oxyhydrogen) are able to dilute sufficiently, securely preventing the occurrence of ex- plosive gas mixtures. Safety instructions concerning installation The rectifier unit contains electrostatically susceptible components which can be easily damaged through incorrect handling. Electrical components may not be mechanically damaged or destroyed. Perform the electrical installation (line cross sections, fuses, earth connections) according to the applicable regulations. Adherence to the limit values as required by the EMC act is strongly connected with the installation and combination with other pieces of equipment and the type of operation. In order to comply with the EMC act, the installation must take into account all details con- cerning screening, earthing, arrangement of filters and insulation of lines. © Prior to performing the electrical installation, compare the ratings on the rating plate with the ratings of the supply connections: + Protect the rectifier unit against overcurrent by means of an upstream mains fuse. + Adhere to the mains connection values of the rating plate (voltage and frequency), + Switching (confusion) of poles with mains and battery connection must be securely excluded, 23.12.05. TB-Mo/Obs 66s 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 6.4 Assignation of connection terminals In the standard version, the regulator terminals are assigned as follows. However, the as- signment may vary depending on the unit design: Input terminal X36. + X36. X362 X363 X364 X365 366 367 X368 369 X36.10 X36.11 Extemal input | External input 2 External input 3 Extemal unit fault Unit off via switch External input 6 Equalise charging lockout Boost charging lockout Battery (circuit) test lockout External input 4 External input 5 Relay connections X10-X13. X10. x102 x103 XI XI2 X13 x12 x122 x123 X13. X132 X133 F°C-Bus X100, X101 X100.1=X101.1 X100.2=X101.2 X100.3°X101.3 K1, battery undervoltage, NCC K1, battery undervoltage, common KI, battery undervoltage, NOC K2, aggregate message urgent fault, NCC K2, agregate message urgent fault, common 2, aggregate message urgent fault, NOC 3, mains contactor activation, NCC 3, mains contactor activation, common K3, mains contactor activation, NOC K4, mains fault, NCC Ka, mains fault, common 4, mains fault, NOC +8 SDA (Gata tine) scL (clock line) 23,12.05- TB-Mo/Obs 35165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator FC-Bus X100, X101 X1004-X1014 —— 12C_Int (interrupt request / press button) X100.5=X101.5 GND XI, X2, X201, X202 SAT-Bus RS485 Service interface RS232 X102 x102.2 RXD 1023 TxD x1024 DIR, internally bridged with X102.6 x102.5 GND X102.6 DSR, internally bridged with X102.4 x102.7 RTS, internally bridged with X102.8 : X1028 CTS, internally bridged with X102.7 Connections to basic regulator card XS, X4, X7: X51 x52 X53 x54 X85 X56 x57 X41 x42 X43 X44 x45 x46 x7 x72 x73 x74 +8V supply Measured value +15V mains +1SV supply -1SV supply Measured value +15V DC GND GND Uunit Uearth battery (only when battery shunt connected) unit +U unit Mains fault Setpoint U Setpoint I Impulse trap GND 23.12.08. TB-MolObs 3665 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator Connections to basic regulator card XS, X4, X7: X75 Regulator lockout Ifa battery shunt is connected, the jumper X41.1-2 must be inserted! The measured value earth resistance is activated on the basic regulator card by way of the jumpers X300, X301, x302. In parallel operation, the measured values battery current (for battery current limitation), battery temperature and earth resistance may be present only once. in parallel operation with decoupling diodes, the second U-channel/ail voltage must be connected with all units. ‘Measured value connections X20, X21, X40 x20. “Battery temperature sensor x202 Battery temperature sensor GND x21 Unit temperature sensor x212 Unit temperature sensor GND : X400.1_ + Second U-channel / rail voltage with parallel operation using decoup- ling diode X4003 Second U-channel / Jumper for connected battery shunt X41.1-2 Battery shunt connected Jumper fr second U-channet X401 open Voltage range 0.500V X401.1-3 Voltage range 0.250V X401.3-5 Voltage range 0.128V All measuring inputs refer tothe common potential U-unit Test bridge X4012 —Testbridge Some parameters of the regulator (rated values, calibration, ete.) can only be changed with the test bridge inserted. 23,12,05- TB-Mo/Obs 31165 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator 65 Software Monitoring and settings of the thyristor bridge can be performed even without service software. The menu overview of the regulator programme with explanations ofthe indi- vidual menu options is added in chapter 18. 6.5.1. Flash Programming ‘Thanks to flash technology, the microprocessor firmware can be updated easily via the RS232 interface, using a laptop/PC. There is no longer any need to replace the EEPROM. eee ‘The reprogramming is done by the PC programme 'flash.exe! Parameters: 8 data bits, 1 stop bit, even parity, no data link control, 19200 Baud. "Boot block backup’ should be a 96990 :; Command (flash ini "boot block command’): Command for the switch-over to flash reprogramming (flash. Execution of the flash reprogramming: "Select of a new HEX file from the program flash.exe’ = Enter the unit address into the program ‘flash.exe’ "The button Transfer’ starts the flash reprogramming " _If"backup boot block’ is active, this is signalled visualising 'Flash’ and 'to.EEP” * During the program transfer, the SMD-LED H60 flashes "Finally, a reset should be triggered; the Thy'sat will then start with the new software Itmay be necessary to reconfigure the Thysat, if new EEPROM cells have been ‘added in the new program version. AN srvenaippunning van sucess te pou dss e start after reprogramming and reset / no LCD display etc., itis possible trying to access the flash boot programme via an "emergency jumper" and to initiate another flash reprogramming sequence. To do so, switch the Thysat dead and insert the emergency jumper X25. Then, reconnect the Thysat to the supply voltage. The SMD-LED H60 will flash twice, Next, the reprogramming can be carried out using the programme ‘flash. exe’. In this case, neither can the boot block be backed up, nor will the changeover to the reprogramming mode be confirmed. The jumper X25 must be removed again before the reset is trig- gered! 23,12,05- TB-Mo/Obs 38165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 66 67 674 67.2 Switching-on process on the regulator Programme start commences as soon as the control card is supplied with voltage by the ba- sic regulator card. The SMD LEDs HS, H6 and H500 to indicate supply voltage available are illuminated. The regulator receives a stop signal while initialisation and a S-second LED test is being performed. The display alternately shows Int and all segments. If the EEPROM has not yet been initialised, EEPROM initialisation with display -ZEP- follows after two seconds. Subsequently the software version followed by the unit address will be displayed subse- ‘quent fo that. The standard operation then starts. ‘The basic charge condition is Float charging. Following an initialisation phase (in stand- alone mode; no other internal bus subscribers; can be shortened by pressing the Test / Reset button) lasting approximately 30 seconds, the rectifier unit runs up to the output voltage set for float charging if the unit address is unequel to zero. Operating modes — charge statuses The abbrevi panel. If the ABE operating pane is fitted, please refer to chapters 13 and 15 for access to the menu items, ms from the menu used here (like tESt) refer to the 4 button operating Manual operating mode selection ‘The desired operating mode can be selected manually in the tESt menu at any time (pass- word required), The unit switches over instantly If another rectifier unit is shunt-connected by way of the internal bus and the operating mode has not been selected on the master, changeover may take some time until the changeover command has been sent by way of the bus. Alll automatic operating mode changeover operations take place only from Float charging! Float charging Float charging is performed with a defined set voltage per cell, depending on the re- chargeable battery type (exact details see equipment data sheet). This is the basic charge status at every start Charging With the option Automatic charging switched on, switching takes place automatically. The trigger for changing over to charging is the presence of the battery or unit current limita tion for more than 30 seconds, Switching back is always automatically in order to prevent continuous charging. Once the ‘current has dropped below the current limitation threshold (0.8 x Im) and below the bat- tery current limitation threshold the system switches back immediately. 23.12.05- TB-Ma/Obs 39165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 67.3 67.4 675 Ifa recharging time has been programmed, switching back to float charging takes place af- ter the set time (recharging time). In the event of a mains power failure the expired re- charging time is not protected. Upon return of the mains power float charging and change- over takes place according to the current measuring signals. Manually itis possible to start charging also from the menu by way of the operating field. If jumper X36.8-X11 (AL lock) has been removed from the regulator, Charging is disabled (see data sheet of the unit). Equalise charging Equatise charging is the start-up mode for non-maintenance free batteries to form the bat- tery cells, Equalise charging takes place with a defined set voltage per cell depending on the rechargeable battery type (exact details see equipment data sheet) and with ).2 x Ines (in the normal case). Thta= Equalisation charging can only be started manually by way of the operating field. The set equalise charging time (adjustable in the menu Sys/deLay/ALdeL,) starts to run down im- mediately ‘The expired equalise charging time is protected in the event of mains power failure; upon return of the mains power, equalise charging continues at the time of interruption. Follow- ing time-controlled or manual changeover from equalise charging to Float charging, no overvoltage query is performed for 10 seconds. If jumper X36.7-X11 (LA lock) has been removed from the regulator, Equalise Charging is disabled (see data sheet of the unit). Direct feeding Direct feeding is the operating mode for pure load feeding. Direct feeding is done at Usea= 2.0 Vicell and Inax = Imes. Start and stop need to be triggered manually. Battery test A battery testis done at Usei = 1.8 V/cell and Iyi“Irues- There are 4 types of battery tests: Manual battery test Start is performed manually and stoppage is automatic on reaching the battery test period (battery test positive) or the set cancellation voltage (battery test negative). Manual battery circuit test Start is performed manually and stoppage automatically on reaching the battery circuit test period (for instance 10 seconds, battery circuit test positive) or the set battery circuit can- cellation voltage (battery circuit failure) 23,12.05- TB-MolObs ove 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator 6.7.6 Automatie battery test ‘This is automatically started at fixed intervals (for instance every 3 months) and stopped automatically on reaching the battery test period (for instance 3 hy, battery test positive) or the set cancellation voltage (battery test negative). Automatic battery circuit test ‘This is automaticaly started at fixed intervals (for instance every 24 hours) and stopped automatically on reaching the battery circuit test period (for instance 10 seconds, battery circuit test positive) or the set battery circuit cancellation voltage (battery circuit failure). ‘The interval for the automatic battery (circuit) testis not re-triggered by a manually trig~ ered battery (circuit) test, i.e. the next starting date for automatic battery (circuit) test re- mains intact. During the battery test (not during battery circuit test), battery voltage, duration of the bat- tery test and Ah withdrawn (with connected battery shunt) are recorded. If bridge X36.9-X36. on the regulator (BT lock) is removed, the battery test characteristic is suppressed. Manual This is the sixth possible operating mode/voltage level. It is started and stopped manually. This operating mode is only required and programmed for special configurations (for in- stance for use in power stations for rectifier coupling). 23.12.05. TB-Mo/Obs v6 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator 6.8 Parallel operation of two rectifier units ‘There are several configurations to support parallel operation of multiple units. This requires each unit to be equipped with block-type diodes! Configuration 1 ‘Two independent units are each fitted with block-type diodes at the rectifier output. Each unit thas a battery output and a consumer load output. Both units supply with their respective output one common battery. See block diagram | Diagram 1 Both units may operate simultaneously. A parallel operation line (synchronising line) between the two regulators is not required. In one of the units, the earth fault monitoring needs to be disabled. The function battery circuit monitoring may be used. However, no battery availability test can be performed since the devices do not share one common battery shunt. Ifthis function is kept active on both units status report errors may occur, 23.12.05. TB-MaiObs 4216s 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator Configuration 2 ‘Two independent units are each fitted with block-type diodes which are however switched in the consumer load circuit. Each unit disposes of a separate battery, both are switched in paral- lel with the consumer load circuit, Diagram 2 ‘ ] 3 [ ¥ Ct iH Had Configuration 2: Only the consumer loads are switched in parallel. Each unit disposes of a separate battery. A parallel operation line (synchronising line) is not required. In one of the units, the earth fault monitoring needs to be disabled. The function battery circuit monitoring may be used. The function battery availability test can be used since each unit has an own bat- tery Configuration 3 This is a system which is specifically designed for parallel operation. It features a single bat- tery output and one (or several) common consumer load outputs. See block diagram 3 Diagram 3 A ® Configuration 3: Here, both units are designed for fully synchronised parallel operation. A par- allel operation line (synchronising line) between the two regulators ensures equal load distribu- tion. Iti included in the delivery scope. All parameters are preset accordingl 23.12.05- TB-Mo/Obs 43/65 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator Config Both units feed one common battery shunt via their battery outputs. Here, the measuring circuit is connected to one unit and analysed there. See block diagram 4 Diagram 4 . Configuration 4: Ifthe devices are on site wired like this, the shunt line to the regulator needs to be removed on the second unit. Furthermore, jumper X41 must be removed from the upper regulator board. On one unit, the earth fault monitoring must be disabled. The two regulators need to be connected via a parallel operation line (synchronising line). (SAT bus) Ifunits, which do not correspond to configuration 3, are interconnected on site, you need to ‘make the following changes and settings: Since both units come standard with earth fault monitoring, this monitoring function must be disabled on one of the two units. Otherwise, the earth fault monitoring systems will measure erroneous values. To do so, proceed as follows: On the regulator: — Remove jumpers X8, X300, X301, X302 all jumpers are located on the lower board !!! In the rectifier unit > Remove the eable link from terminal panel X 3: Between terminal No.100 and PE Configurations 3 and 4 require a temperature sensor on the first unit only for battery tempera- ture-guided charge. 23.12.05. TB-MolObs 46s 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator 72 73 74 75 Messages Mains power available Following the expiry of the switching-on delay following a mains power failure, the regulator is enabled if no overvoltage is present and the unit has not been switched off with the switch, Ifthe rectifier unt is switched off, the regulator and pulse blocking is set; the mains relay de- cenergises. The LED in the push button is off; all monitoring operations except for unit failure and sensor breakage are performed. Mains disturbance ‘The stop signal is set on the regulator; the mains relay de-energises. After 60 seconds, the low- priority fault message is issued; after 30 seconds, the signalling relay Mains fault de-energises. ‘The message is then maintained (LED flashing, ifthe phase error is no longer active) until itis reset by way of the Test / Reset push button, All queries are active. ‘The message Mains power failure is generated on the basic regulator card and passed on to the ‘thysat control card as a digital signal, The response threshold can be set with the potentiometer on the basic regulator card. Unit failure ‘A unit failure is output if no battery or unit current limitation is present with running unit de- spite a drop below the set voltage value by >0.1V/cell (with Pb). Sensor cable breakage is additionally monitored if * the actual voltage value is approximately O V (< (0.3 V/cell with Pb) despite battery or unit current limitation or * the set voltage value is exceeded by > 0.2 Vicell (with Pb) despite battery or unit current limitation, ‘The message sensor breakage and unit failure will then be issued. The message is held (LED. flashing, if the unit failure is no longer active) until itis reset with the Test / Reser button. Current limitation (optional) If the current limitation was active (standard: 90% of Isqrat, 8 With current peaks through additional connection of loads), the charge waiting time is started for 30 seconds Battery charging current limitation (optional) Ifthe battery charging current limitation was active (standard: 90% of Isa.nas), the 30-second charge waiting time will start. Ifthe battery current is not measured (no battery shunt con- nected), the battery charging current limitation Inparticular mark any deviations from the details on the rating plate. 23.12.05- TB-Mo/Obs 18165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 5 Operation ON eee ‘The rectifier is a piece of electrical equipment carrying voltages and currents that are dangerous to human beings. ‘The rectifier unit may therefore only be: "operated by instructed and trained specialists. "installed, opened, repaired and dismantled if required by qualified electricians! ‘The power supply and a battery and/or load contact must always be disconnected before in- tervening and working on the rectifier unit ‘The rectifier unit THYROTRONIC, more exactly the thyristor bridge, is controlled and op- erated by way of the Thysat regulator. The regulator is a programme-controlled microproc- essor. ‘The display and operating panel in the front of the unit allows the personel to monitor the ‘operating status and the specialised electrical personnel authorised and qualified for this purpose to change the programme settings (see chapter 7 Advanced operation and pri gramming), While the rectifier unit operates normally (Automatic mode), it requires no operator inter- vention; the rectifier unit operates properly in Float Charging mode if: + the equipment switch isin position I (one), the LED Unit on in the Test / Reset button is illuminated, = only the two green LEDs Float charging and Operation are illuminated or, alterna- tively, = only the yellow LED Charginglequalise charging and the green LED Operation are illuminated and + the LCD altemately displays the present values of unit voltage and unit current and + nored LEDS are illuminated. ‘The individual operating steps are explained in more detail in the following chapters. Prior ‘to operating the rectifier unit forthe first time, carefully read these chapters. 23,12.08- TB-Ma/Obs 1916s 3728enBENNING Reotifier unit THYROTRONIC with Thysat regulator 5.1 Display and operating panel (4 button panel) THYROTRONIC Figure 2 Display and operating pane! Top left: LED bar; left bottom: Test / Reset button with LED Unit on; Centre right: LCD operating field, four buttons and four LEDs; Bottom right: Equipment switch offon (0 1) The display and operating panel serves to: "indicate fault and operating statuses by means of LED (LED bar and LED in the Test Reset button), "perform unit test and correct faults with the Test / Reset button, in the LCD operating field: * values are displayed by means of LCD, * settings changed by way of four buttons, * general unit statuses indicated by way of four LEDs. 5.1.1 LCD operating field Lop ‘The current operating values and the selected menu levels and menu options and their val- ues in the case of programme changes are displayed in the LCD. ‘The menu levels and items with allow monitoring and adjustments or settings to be made, can be accessed using the 4 buttons beneath the display. 23.12.05. TB-Ma/Obs 20165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator Z Figure 3 Buttons All released statuses and measured values in the LCD can be queried and set with the four buttons, Safety-critical menu levels can only be accessed by way of a password, CANCEL Select a menu option in a menu level Ina menu option, select another value, Confirm a menu option Safe a newly selected value. Call up the next menu level Password query Leave a menu option without changing the value, Call up the next higher menu level. Figure 4 Meaning of the buttons in the LOD operating field Operating examples are presented in chapter 18 of the Operating Instructions 5.2 Description of the general menu levels/options ‘The LCD permits the display of the selected menu levels or menu options and their meas- ured values. Large menu areas comprise sub-menu for configuring the regulator. These areas are pass- word protecte J. ‘The following figure shows the freely accessible menu structure: 23,12,08- TB-Mo/Obs 265 3728enBENNING Rectifier unit THYROTRONIC with Thysat regulator Tins va ese | | tue | | cae. | | coe cinta: | iiames | | cme | | scardiny | | oe x : “| on Figures Openmenu stucure Main menu Unless another selection is made, the LCD will alternately display the current standard values for current and voltage. Menu items of the freely accessible menu structure: MESS ‘The following measured values can be called up in the MESS menu Uree Unit voltage Tree Unit current 1 bat Battery current tbat Battery temperature tree Unit temperature EARH Earth resistance isvpc 15 V supply from the DC converter ISVAC 15 V supply from mains uset Setpoint U iSet Setpoint I W2 Second U-channel / voltage behind decoupling diode becAp Capacity last battery test bttim Time expired last battery test beu Voltage last battery test itot Total current rectifier CHM Remaining time AL/L/BT 23.12.08- TB-Mo/Obs 22165 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator aise ‘Three sub-menus are available in the diSP menu (display menu): = LEdst: The furiction test of the LEDs can be started from here. "= diSPO: Display of the standard measured value of the unit voltage "= diSP1: Display of the standard measured value of the unit current State ‘The status of the locked-in components is displayed in the State menu. Menu items of the password protected level 1 This level can only be accessed via menu item "test" and by entering a password in menu item "1.000" . The password is a number between 000 and 255 and is selected using the UP and DOWN buttons. ‘The standard password set by the manufacturer for menu level | is “001”. This prevents accidental incorrect operation. The customer is advised to change this paSsword as soon as possible. tESt Subject to password protection, the sub-menus of the six operating modes can be accessed from here: Float charging (EL), charging (LA), equalise charging (AL, not with mainte- nance free batteries), manual (Man, only necessary with special configuration), direct feed (ar, only when using the rectifier unit as a power supply unit) and battery (circuit) test (tb and ther), Menu items of the password protected level 2 This level can only be accessed via menu item "SYS" or "digin" and by entering a pass- word in menu item "P2.000". The password is a number between 000 and 255 and is se- lected using the UP and DOWN buttons. ‘The standard password set by the manufacturer for menu level 2 is “002”. This prevents accidental incorrect operation. The customer is advised to change this password as soon as possible. sys Subject to password protection, the configuration settings of the regulator can be accessed in the SyS menu (system programme). ‘A complete summary of the programme menu with some explanations is included in the chapter 18/19, 23.12.05- TB-Mo/Obs 23465 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator diGin ‘The binary status of the 64 possible digital inputs of the regulator is displayed in the diGin ‘menu (digital input). For the input terminal assignment, see the menu explanations in chap- ter 19. ‘The sub-menus of the filter flags and the MCU input can be accessed from here subject to password protection. Display units include: LEDs The four LEDs indicated the general operating modes of the rectifier unit: green Operation Om yellow Battery operation red Alarm IN red Urgent alarm Figue6: Meaning ofthe LEDs in the LOD operating panel ‘The message Operation indicates the mains power supply of the rectifier unit ‘The message Battery operation indicates that any loads are supplied with battery current (by way of a battery rail, if applicable), ‘The message Battery operation is illuminated when: "the battery current is negative and + the DC voltage is smaller than the float charging voltage or * does not generate any output voltage (for instance during a mains power failure, equipment switch off and in the event of a disconnecting fault) As soon as the message Battery operation is illuminated, the message Operation goes out. ‘The message Alarm indicate "non-urgent" faults and continued operation of the rectifier unit is possible. The alarm message is displayed in more detail in interaction with the mes- sages by way of the LED bar. Repair of a non-urgent fault should be performed within 24 hours. How to perform trou- bleshooting, see section 6.4 Faults and error messages. 23.12.08. TB-Mo/Obs 246s 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 5.21 ‘The message Urgent alarm indicates faults which restrict or end the operation of the recti- fier unit. Depending on requirement, urgent alarm messages are coupled with a visual or acoustic fault signal (aggregate fault). The respective form, for instance a signal tone in a control centre, depends on the ms on. Urgent faults shouldbe repaired immediately. How to perform troubleshooting, see section 6.4 Faults and error messages. LED bar In accordance with the standard configuration supplied ex factory, the LED bar indicates the following statuses: green Float charge yellow © [Boost charge/equal yellow © — [Battery test _ red [Mains power failure red [Unit fault 5 red [DC voltage too high red [Battery voltage too low red g_—_([Battery test negative red [Battery eireuit fault rd red red (Spare) red (Spare) _ | LED test/ reset Figure 7 LED bar wth standard assignment and Test / Reset bution with LED 23.12.05- TB-MolObs 2si6s 3728 enBENNING Rectifier unit THYROTRONIC with Thysat regulator 5.3 5.3.4 54 ‘The meaning of the 14 LEDs is determined by the configuration file and dependent on the programming of the regulator, The basic meaning of the LED colours is defined in IEC 73/DIN VDE 0199. The following therefore applies: RED Danger or alarm ‘Warning indicating possible dangers or conditions requiring immediate intervention or accurate obser- vation of the condition. YELLOW Caution ‘Changes oF imminent changes of the normal operat- ing conditions. GREEN Safety Indicates safe operating conditions or further operat= ing process release. Figure 8 General meaning of the LED colours Test and reset button The green LED Unit on is housed in the Test / Reset push button. Itis illuminated during the unit operation. The LED Unit on goes out as soon as the rectifier unit switches off for ‘whatever reason or is switched off with the offfon unit switch. ‘A function test of the LED status indication and the LCD measured value display is pos: ble with the Test / Reser push button. Ifthe button is pushed for atleast 3 seconds, all the LEDS light up. , while all segments of the display are alternately activated in the LCD and the current software version and address of the regulator are displayed, Faults can be acknowledged by pressing briefly (reset) * disconnecting fault messages such as overvoltage or unit faults and fault messages from auxiliary monitoring systems are cancelled, the rectifier unit switches on again, "pending messages, identifiable by flashing LEDs, will be deleted. Equipment switch offion ‘The equipment switch serves to switch the rectifier unit off and on, however without: = disconnecting the connections from mi power supply, battery, load, + switching off the regulator. Start-up ‘The rectifier unit isan installation with permanent connection to the local electrical system and is therefore always live, The rectifier unit s switched on and off with the Qf7On unit switch; the regulator remains always switched on and registers the operating condition of the rectifier unit For start-up, proceed as follows: 23.12.05. TB-Mo/Obs 26165 3728en