Wave RT9 Powershelf, Installation & Operation Manual

Page 1: ...158 1806 01 doc Date 21 December 2005 Rectifier Technologies Pacific Pty Ltd ACN 058 107 707 Wave Communications Pty Ltd Unit 5 97 Jijaws St Sumner Park QLD 4074 TEL 07 3279 0600 FAX 07 3279 0544 EMAIL sales wavecomeng com au WEBSITE www wavecomeng com au ...

Page 2: ...se star individual protected external feeds 13 3 3 4 3 phase delta individual protected external feeds 13 3 3 5 Surge protection requirements 14 3 4 Bulk Load connections 15 3 5 Load Distribution CB Trip Sense connections 15 3 6 Battery connections 16 3 7 Temperature Sensors 17 3 8 Auxiliary relay connections 17 3 9 MiniCSU 3 Power Connections 18 3 10 Front Panel USB Communications connection 18 3...

Page 3: ...5 3 3 Alarm Log 32 5 3 4 Battery Menu Battery Specific Functions 33 6 Troubleshooting 35 6 1 To Remove a Rectifier Module or a MiniCSU 3 Controller 37 6 2 To Insert a Rectifier Module or a MiniCSU 3 Controller 37 7 Appendix A Setting Up Network Interfaces 38 7 1 Programming IP addresses using DeviceInstaller software 38 7 1 1 Preparations for local address set up 38 7 1 2 Local IP address set up p...

Page 4: ...alent standard For open rack use the back of the magazine must be fully enclosed by its covers and the AC wiring terminations must be protected by either an earthed casing or an enclosure that provides double insulation 5 The powershelves must be used with sufficient ventilation After mounting the air flow paths into and out of the rectifiers must be unrestricted Allow adequate flow for exhaust ai...

Page 5: ...y load distribution battery load circuit breaker trip sensing battery charge current limiting short circuit and reverse polarity protection battery temperature sensing n 1 redundant rectifiers low voltage disconnection a monitoring and control module MiniCSU 3 automated remote battery discharge testing super capacitor backed real time system clock accurate temperature compensated Float and Equalis...

Page 6: ... MiniCSU 3 controller 5 AC distribution module option on some systems 2 2 2 Rear View Figure 2 3 Rear view of connections PSLF 1115 1 MiniCSU 3 backplane interface connections 2 Battery load switched connections 3 Battery load common return connection bar 4 AC mains terminations 5 Alarm relay connections 6 Remote communications module connection ...

Page 7: ...bon 7 Standalone system voltage connection MiniCSU 3 power and voltage sensing special use only 8 Load circuit breaker trip detection circuitry connection Notes Devices and cable connections are pre wired as part of the supplied and tested Powershelf This connection can be left unused if the system has no requirement for control and maintenance of batteries ie standalone DC power supply Figure 2 5...

Page 8: ...the MiniCSU 3 or the RT9 rectifiers in place M5 or M6 mounting screws Figure 3 1 Mount points for securing Powershelf in a rack Wiring for the standard Powershelf is rear access only For systems where rear access is not available the Powershelf can be pre wired for load battery AC power and remote communications before mounting the magazine in the rack For maintenance and load expansion the Powers...

Page 9: ...top cover will then hinge up to provide access to the wiring To gain further access to the wiring remove the rear cover grills by removing the two screws holding each 1U grill 3 2 Overview of External Wiring Connections Figure 3 3 shows the internal and interface schematic for the PSLF 1115 For the purpose of indicating how a system is connected the same schematic applies to other Powershelf produ...

Page 10: ...RT9 Powershelf Rectifier Technologies 158 1806 01 doc 10 2 Mar 06 Figure 3 3 Powershelf internal schematic diagram ...

Page 11: ...er common busbars External DC distribution feed connections are made as a bulk load connection In many cases the AC distribution is external to the Powershelf The AC feed should be wired as individually protected feeds for each rectifier recommended and preferred to provide discrimination of fault protection devices Alternatively a single AC supply 1φ or 3φ can be used but there will not be any di...

Page 12: ...ommon neutral bar blue blocks The wiring is arranged this way to allow the system to be configured easily for single phase or three phase star connection supply The system is shipped with a shorting link joining the three active terminations thereby making the system a single supply single phase load by default The shorting link s must be removed before connecting a 3 phase supply The label over t...

Page 13: ...l active line terminals Then for each rectifier the two AC lines can be wired to the appropriate phases This configuration needs to be specially ordered to ensure that the correct number of terminal blocks is loaded The system will be shipped with links in the active terminal blocks to configure the system as single phase but for phase to phase connection Note that double fused versions of RT9 mus...

Page 14: ...rshelf Typically surge arrestors with a 10kA 40kA rating are required with the highest level of protection being provided when arrestors are connected between phase netural x3 phases and between phase neutral earth x 3 phases Other arrangements for 3 phase star with similar levels of protection are also possible as shown below The voltage rating of the arrestor should be selected based on the maxi...

Page 15: ...sition irrespective of whether the system is 48VDC or 24VDC In the case of the 24V system the common return bar is connected to the VE busbar 3 5 Load Distribution CB Trip Sense connections To enable monitoring and alarming of tripped external load distribution circuit breakers a 3 terminal connector is provided on the MiniCSU 3 backplane item 8 in Figure 2 4 The signal is ACTIVE HIGH for any circ...

Page 16: ...e only in the swapping of the polarity of the live and common DC lines In standard Powershelf systems not all of the 4 possible battery connection strings are installed The figure shows a battery distribution unit fitted with all the optional battery strings possible See BDM section below for details about adding extra battery strings or load distribution lines to the BDM The M4 terminations at on...

Page 17: ... 3 8 Auxiliary relay connections Figure 3 12 Alarm relay connections right and remote communications module location left The user configurable auxiliary relays contacts are shown above The contacts are rated for 1A 250VAC or 1A 32VDC and have 1kV isolation to the coils The pin configuration is Pin 1 at the right in Figure 3 12 Relay Pin Pin function 1 N O normally open 2 N C normally closed 1 3 C...

Page 18: ...e MiniCSU 3 is configured as USB slave and has a B type connector A standard USB A to B cable is required The MiniCSU 3 can only communicate via the USB port to a PC running the WinCSU 2 software The USB connection requires that a USB driver be installed on the PC The first time the MiniCSU 3 is plugged into the PC via the USB port a Microsoft Windows dialogue box will appear asking the user to in...

Page 19: ...d twisted pair is recommended The figure below shows the pin assignment of the port Figure 3 13 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 t...

Page 20: ...ace are pre programmed and should not be changed To be able to assign a network address the Ethernet address referred to also as hardware address or MAC ID of the interface must be known On the Powershelf top cover is a small label indicating the MAC ID similar to one shown below Note The interface IP address cannot be changed until the Powershelf has been commissioned and the MiniCSU 3 controller...

Page 21: ...upplied with a standard number of battery strings pre wired Optional extra battery or load connections may also have been supplied and pre wired from the factory as ordered Servicing fuses circuit breakers or adding optional battery load connection kits after initial installation and commissioning requires that the lid of the battery distribution module be removed and top access can be gained The ...

Page 22: ...gure 3 15 Figure 3 16 To re install the lid slide it in on the top edge of the base until the lid mates with the rear of the BDM base Secure the front of the lid to the base with 2 x M3 screws 3 13 Adding Auxiliary Expansion Modules Modules such as the battery cell monitor BCM AC monitor and site monitor are daisy chained from the unused ribbon cable connection provided on the Auxiliary programmab...

Page 23: ...if used and after confirming that the battery temperature is being measured o set the battery charging current limit to 10 of the Ah rating ie if 150Ah battery is used set the limit to 15A this value can be adjusted later to meet your specific charging requirements In many cases these values are set up in the factory and will only require modification if the particular battery being used requires ...

Page 24: ...u 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 paramete...

Page 25: ...Front Panel Pushbuttons There are six pushbuttons associated with the OLED 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 base menu system parameters there are three other menus which can be accessed by momentarily pressing the relevant pushbuttons a SMR menu which includes the rectifier related pro...

Page 26: ... 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 Once...

Page 27: ...ault 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 moni...

Page 28: ...rature higher than preset limit A Batt Temp High Battery temperature higher than preset limit A Batt Temp Sens Battery temperature sensor not connected or failure A Batt I Limit Battery charging current is being limited to preset value A Bat Sym Alarm Battery discharge currents from battery strings not sharing load equally A Earth Leak Alarm Earth leakage current greater than the limit set A Equal...

Page 29: ...etup Press ENTER Modify Value up down ENTER to accept Press ENTER to begin flashing display and LEDs Test Indicators Press ENTER ENTER System information including controller software version S N and cabinet S N System Info Press ENTER INC DEC toggles system info ENTER Options for Standby or UPS type system System UPS Modify Value up down ENTER to accept ENTER Sets number of SMRs in the system Num...

Page 30: ...y Value up down ENTER to accept ENTER Phone 3 0398887788 Modify Value up down ENTER to accept ENTER Phone 3 Cont 2323 Modify Value up down ENTER to accept ENTER Audio Alarm Off INC DEC toggles state ENTER to accept ENTER Circuit breaker auxiliary contact circuit input configuration Cct Input Not Used INC DEC toggles state ENTER to accept ENTER Battery circuit breaker auxiliary contact circuit inpu...

Page 31: ...24 cells Modify Value up down ENTER to accept ENTER Number of battery banks BCM Batteries 1 Modify Value up down ENTER to accept ENTER Cell Vhi Alarm 2 50V Modify Value up down ENTER to accept ENTER Cell Vlo Alarm 1 80V Modify Value up down ENTER to accept ENTER Differential cell threshold Cell dVc Alarm 10 Modify Value up down ENTER to accept ENTER Differential cell threshold Cell dVc Alarm 10 Mo...

Page 32: ...own ENTER to accept ENTER SMR high voltage shutdown SMR HVSD 58 5V Modify Value up down ENTER to accept ENTER SMR current limit SMR I Limit 30A Modify Value up down ENTER to accept Resets any latched SMR alarm Reset SMR Fault Press ENTER Home Screen The SMR Float and Equalise voltages are the default values set in the rectifier that will be used if the MiniCSU 3 fails to operate They are a copy of...

Page 33: ...h Battery Rating 500Ah Modify Value up down ENTER to accept ENTER Battery Temperature compensation BTC Coeff 3 2 mV C C Modify Value up down ENTER to accept Variable from 0 to 6 0mV C C If BTC not Off ENTER Mid point temp for BTC curve Comp 0 BTC Nominal 20 C Modify Value up down ENTER to accept ENTER Number of Cells 24 Modify Value up down ENTER to accept Physical number of 2V cells in string use...

Page 34: ...riod 12 Weeks Modify Value up down ENTER to accept Set to zero to disable ENTER Manual control of equalisation Manual Start Eq Press ENTER ENTER toggles state Start Stop ENTER Battery voltage below which the LVDS LVDS Trip 43 0V Modify Value up down ENTER to accept opens when in Auto mode ENTER LVDS where used operation mode LVDS Mode Auto Modify Value up down ENTER to accept Auto Open or Closed D...

Page 35: ...rm link in BDM is incorrectly configured Check load and battery connections to the BDM and that the alarm links are correctly configured Battery or Ambient temperature sensor reading is indicated as Not Available Sensor cable faulty Sensor connector reversed No sensor installed Turn cable connector around and reconnect Replace faulty sensor assembly Battery current indicated does not match indepen...

Page 36: ...s as required to remove the overload condition One rectifier has an UNCAL SMR alarm The MiniCSU 3 has not been able to make the unit share the load with the other units Either the SMR is faulty excessive internal voltage drop and cannot be adjusted to share load or it is too far out of calibration Replace the rectifier module Send the unit for repair and re calibration System Voltage Clamp alarm a...

Page 37: ...s high and the unit has been operating at maximum load avoid skin contact with the metal casing as it may be too hot to touch Pull the unit halfway out of the magazine and let cool for 2 3 minutes before handling 6 2 To Insert a Rectifier Module or a MiniCSU 3 Controller Insert the module into the slot and ensure alignment with the fold out rails in the magazine Push the module all the way in so t...

Page 38: ...k for your network class Connect PC to the controller s network interface directly or via a network Power up the controller Start DeviceInstaller program 7 1 2 Local IP address set up procedure On DeviceInstaller tool bar click IP button A new window Assign IP Address will open Enter the unit Ethernet address MAC ID as stated on information label Enter assigned new IP address Select correct networ...

Page 39: ...ick Manage device configuration button A new window Device Management will open Click Telnet to Device button Telnet window will open showing a message similar to the one below Lantronix Cobox Universal Device Server Serial Number 1297 041 Software Version V03 9 000211 Press Enter to go into Setup Mode Note If Enter is not pressed within 3 seconds the connection will be terminated If Enter was pre...

Page 40: ...excerpted from Lantronix Embedded Integration Kit Revision D 06 03 02 Part Number 900 226 The unit s IP address must be configured before a network connection is available If the unit has no IP address you can use Address Resolution Protocol ARP method from Windows based systems to assign a temporary IP address If you want to initially configure the unit through the network follow these steps 1 On...

Page 41: ...s Lantronix Inc 2002 all rights reserved used herein by permission from Lantronix 7 2 3 Configuring the Unit The following section is excerpted from Lantronix Embedded Integration Kit Revision D 06 03 02 Part Number 900 226 You must configure the Lantronix Interface so that it can communicate on a network with WinCSU 2 and communicate with the MiniCSU 2 unit via the serial port The unit s configur...

Page 42: ...ering the number of the option in the Your choice field and pressing Enter 6 To enter a value for a parameter type the value and press Enter or to confirm a current value just press Enter 7 When you are finished save the new configurations option 9 The unit will reboot 7 2 4 Server Configuration Network Configuration These are the unit s basic network parameters The following parameters are displa...

Page 43: ...s must be within the local network Subnet Mask A netmask defines the number of bits taken from the IP address that are assigned for the host section Note Class A 24 bits Class B 16 bits Class C 8 bits The Lantronix Interface prompts for the number of host bits to be entered then calculates the netmask which is displayed in standard decimal dot notation when the saved parameters are displayed for e...

Page 44: ...ternal fuse at output of SMR integral battery circuit breakers and detection disconnection circuitry High Voltage Shutdown Rectifier shuts down if output exceeds programmed overvoltage limit Electrostatic Discharge ESD IEC 61000 4 2 Level 4 Air 15kV Contact 8kV AC Surge IEC 61000 4 4 EFT Level 4 IEC 61000 4 5 Impulse Level X 6kV 3kA IEC 61000 4 12 Ringwave Level X 6kV 500A RF Immunity IEC 61000 4 ...