rt7-120v/6kw rectifier & mcsu-4 rack power system rt7 120v with mcsu4... · installation &...

Installation & OperationManual

RT7-120V/6kW Rectifier &MCSU-4 Rack Power

SystemDocument: 158-1864-03.docx

Date: 03 June 2014

© Rectifier Technologies Pacific Pty LtdACN 058 107 707

Installation & Operation Manual Rectifier Technologies

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Document Version HistoryVersion Date Release notes, changes from previous version Author

01 3 April 2013 First release. Nicholas Yeoh02 1 May 2013 Updated software numbers Nicholas Yeoh03 2 June 2014 Deleted MUIB1 & MUIB2 sections, Updated BCM to BCM4 Colin Chalmers


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Table of Contents1. HAZARD WARNING....................................................................................................12. General Warnings ......................................................................................................13. Summary of Programmed System Parameters .......................................................24. Configuration..............................................................................................................5

4.1 System Description................................................................................................54.1.1 General Description........................................................................................54.1.2 Rectifier Specific Configurations.....................................................................8

5. Installation ..................................................................................................................95.1 Rectifier .................................................................................................................9

5.1.1 Magazines ......................................................................................................95.1.2 Connections ...................................................................................................95.1.3 Physical requirements ..................................................................................10

5.2 MCSU-4 (Control and Supervisory Unit)..............................................................115.3 Other System Component Guidelines .................................................................11

5.3.1 Racks ...........................................................................................................115.3.2 Lightning and Transient Suppression ...........................................................125.3.3 Temperature sensors ...................................................................................125.3.4 AC monitoring...............................................................................................12

5.4 A Typical System.................................................................................................125.5 MUIB3 – Systems with Earth Leakage Detection ................................................14

5.5.1 System setup requirement............................................................................145.5.2 Main features of MUIB3................................................................................145.5.3 MUIB3 Connections .....................................................................................14

5.6 Battery Cell Monitor 4 (BCM44) in 120V DC systems .........................................195.6.1 Main Features of the BCM4..........................................................................195.6.2 BCM4 Specifications for 120V system .........................................................205.6.3 Preparing the battery for connection to the BCM4........................................205.6.4 Installing the board .......................................................................................215.6.5 Battery Cell Leads ........................................................................................225.6.6 Dip-Switch Selection of Block Voltages........................................................225.6.7 Battery Block Lead Connection to the BCM4 board .....................................22

5.7 Battery Cell Monitor 3 (BCM3) - 120 Cell / 240V ................................................255.7.1 Main Features of the 120 Cell BCM3 ...........................................................255.7.2 BCM3 Specifications ....................................................................................26


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5.7.3 Relationship between “BCM Batteries” and “Num Batteries” for MCSU-4....265.7.4 Dip-Switch Selection of Cell Voltages ..........................................................275.7.5 Installing the board .......................................................................................275.7.6 Preparing the battery for connection to the BCM3........................................285.7.7 Battery Cell Leads and Wiring ......................................................................29

5.8 SMM - Site Monitor Module .................................................................................325.8.1 Electrical Specification .................................................................................325.8.2 Physical Specification...................................................................................325.8.3 Installation ....................................................................................................335.8.4 System Set-up..............................................................................................335.8.5 Site Monitor Settings ....................................................................................35

6. Remote Communication Interfaces ........................................................................366.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU)............................................366.2 RS232 Interface (MCSP).....................................................................................366.3 RS485 Interface (MCMD) ....................................................................................366.4 Integrated Packet Modem (Smart Modem)..........................................................36

7. Commissioning ........................................................................................................387.1 Indicators on the Rectifier Front Panel ................................................................387.2 System Parameter Ranges .................................................................................38

7.2.1 RT7 SMR Parameters ..................................................................................387.3 System Commissioning .......................................................................................39

7.3.1 Commissioning Procedure ...........................................................................398. Operation ..................................................................................................................40

Summary of MCSU-4 front panel controls ....................................................................408.1 MCSU-4 Components .........................................................................................41

8.1.1 Alpha-numeric Display..................................................................................418.1.2 Front Panel Pushbuttons ..............................................................................418.1.3 Status Indicating LEDs (MCSU-4) ................................................................42

8.2 Operating the MCSU-4 ........................................................................................428.2.1 Password security ........................................................................................428.2.2 When an alarm condition exists....................................................................42

8.3 MCSU-4 Alarms...................................................................................................438.4 User programmable relay functions.....................................................................448.5 MCSU-4 Base Menu Screens..............................................................................45

8.5.1 Single Phase AC Monitoring Screens ..........................................................458.5.2 Three Phase AC Monitoring Screens ...........................................................458.5.3 Base Menu Programmable Parameters .......................................................47


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8.5.4 Auxiliary Function Selection & Parameters...................................................518.6 SMR Menu Screens ............................................................................................55

8.6.1 SMR Menu Programmable Parameters .......................................................568.6.2 SMR Menu Sleep Mode ...............................................................................57

8.7 Battery Parameter Menu Screens .......................................................................588.8 Battery Discharge Test ........................................................................................62

8.8.1 Results of last Battery Discharge Test - (Last BDT) .....................................648.9 Alarms Log Screens ............................................................................................658.10 Battery Cell Monitor Setup ...............................................................................65

8.10.1 Relationship between “BCM Batteries” and “Num Batteries”........................668.10.2 Frequency of measurement..........................................................................668.10.3 Battery Cell Measurements ..........................................................................66

8.11 Earth Leakage Detector - MUIB3 and MUIB5 only...........................................679. Maintenance .............................................................................................................68

9.1 Warnings and precautions...................................................................................689.2 SMR Maintenance ...............................................................................................68

9.2.1 Current Sharing ............................................................................................689.2.2 Integrity of Electrical Connections ................................................................689.2.3 Fan Filter Maintenance.................................................................................68

10. Fault Finding and Replacement Procedures ......................................................7010.1 System Fault Finding Procedures ....................................................................7010.2 MCSU-4 Fault Finding and Repair Procedures................................................73

10.2.1 Replacing MCSU-4.......................................................................................74


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1. HAZARD WARNING

DANGER!! Hazardous voltages in excess of 150VDCare generated by this equipment. Care must be taken when installing, operating and maintaining

these systems. In particular, when replacing any of the auxiliaryequipment such as the Controller, MUIB3, and Battery CellMonitor (BCM). When removing a rectifier from the magazine, DO NOT TOUCH

the output connector which will have HAZARDOUS voltagepresent for 1-2 minutes.

2. 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 repairfacility by authorised personnel and not as a maintenance procedure on site.

4. The rectifier must be mounted in a rack which satisfies requirements for electricalenclosures and fire enclosures according to IEC60950 or equivalent standard.

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

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

7. Prevent small items from falling into the top of the rectifier. See the section on RackInstallation for suggestions of appropriate measures and examples of options.

8. The input disconnect device is the rectifier backplane connector. The rectifier is live atall times when the rectifier backplane connector is connected.

9. 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 atmaximum load. When removing, pull the unit halfway out of the magazine and let coolfor 2-3 minutes before handling.


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3. Summary of Programmed System ParametersParameter Description Range Default

ValueActualValue

Base (System) Menu

Amb Tmp Alm Ambient temperature alarm level 30-99°C 55°C

Volts Hi System output volts high threshold 120-160V 135.0V

Volts Low System Output volts low threshold 95-125V 105.0V

System: Select system duty type UPS/Standby UPS

No. of SMRs Set number of SMRs in the system 0-225 1

Num Batteries Number of Battery strings installed 1-4 1) 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)

Variousconfigurations

24 cells

BCM Batteries Number of battery banks to be monitored 1-4 1

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 2)

SMR Float Operating float voltage 3) 120.5V

SMR Equalise Operating equalisation voltage 3) 130.5V

SMR V High SMR voltage high alarm 120-157.5V 130.0V

SMR V Low SMR voltage low alarm 95-125V 110.0V


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Parameter Description Range DefaultValue

ActualValue

SMR HVSD SMR high volts shut down 120-158.5V 140.0V 4)

SMR I Limit SMR current limit 4-60A 10A 4)

SMR PowerMax

Max power for SMR 0-8000 1400 5)

Sleep Mode SMR Sleep Mode Enable. On/Off Off

Sleep MinSMR

SMR Sleep Mode Minimum rectifiers that mustbe online.

0 to NumberSMR definedin the system

1

Sleep Rotation SMR Sleep Mode rectifier rotation value (inDays).

1 to 365, 0 =Off – norotation

7 days

Battery Menu

B Dis Al Battery discharge alarm threshold 100-120V 108.0V

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

Number Cells Number of chemical cells in battery string 48-120 55

BILim Vb<Vdd Battery charging current limit for Vb < Vdd 5-999A 50A

Vdd Level Battery deep discharge voltage threshold 92-110V 100.0V

BILim Vb<Vf1 Battery charging current limit between Vdd & Vfl 5-999A 50A

Sys Float System float voltage (Vfl) 110-140V 120.0V

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) 120-155V 130.0V

V Start Eq Enable/disable discharge voltage initiation of Eq On/Off Off

V Eq trig Discharge voltage threshold for Eq. charging 100-115V 110.0V

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 5A

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 92-110V 100.0V

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 75-120V 100.0V

BDT End Q Battery capacity limit to terminate BDT 25-9995AH 300AH


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Parameter Description Range DefaultValue

ActualValue

Temp Sen Alm Enable/Disable Temp. Sensor failure alarm On/Off Off

1) Maximum of 2 batteries with MUIB3.2) See SMR section for internal parameters.3) Not directly adjustable – see explanation in MCSU-4 section.4) Will be automatically programmed to SMR internal setting once connected in the system.5) SMR Power Max MUST be set to 2400 for all systems with RT12 SMRs.


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4. Configuration4.1 System DescriptionThis Manual has been written with the objective of giving the reader a sufficientunderstanding of the system and its constituent parts in order to be able to install,commission and operate the system.

4.1.1 General DescriptionThis modular system has been designed specifically to power 120V power systemsequipment 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 ofthe system, and a monitoring and control subsystem comprising a monitoring and controlmodule (MCSU-4), a User Interface Board (MUIB) and optional modules for monitoring ACpower and battery cell voltages.The system can be configured in a number of ways depending on the customer andapplication requirements. The simplest option is shown in Figure 4.1.

System Controller

MUIB3(Supplies System

Controller)

AC Distribution

Remote Alarmsand Ambient

Temp. Sensor

DC Bus

DC DistributionBatteries withCircuit Breakers

Magazines ofAC-DC Converters

DC Loads

Local Comm. Port

Remote Comm. Port

Figure 4.1 System with basic monitoring and controlThe AC Distribution may simply consist of circuit breakers, one for each magazine ofrectifiers in the system, or may also include an isolator, depending on customerrequirements.The rectifiers housed in one or more magazines are paralleled and the DC outputconnected to the load via the DC Distribution module and to the battery bank, which maybe a single battery or two batteries connected in parallel. A Low Voltage DisconnectSwitch (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 outageThe monitoring and control signals, such as battery currents, temperature, battery switchstatus, LVDS control and status, system voltage and ambient temperature are connectedto the monitoring and control module (MCSU-4) via an interface card (MUIB). This moduleis in turn connected to the MCSU-4 magazine via a 34 way ribbon cable.


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A multi wire comms cable, of which only 3 wires are used, (Tx, Rx, common) carries thedigital communications signals that allow control and monitoring of the rectifiers, connectsthe MCSU-4 to all the rectifiers in a parallel arrangement so that all the rectifiers receivethe same signal.System status and operating parameters can be accessed from a PC connected to localcommunication 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 HighVoltage Shut Down (HVSD).Alternatively, a remote communication port can be used to display all the system andrectifier information on a remote PC.With this facility, it is possible to not only monitor but also control all the rectifier andsystem parameters. In addition, the system has the capability to dial up to three telephonenumbers to connect to the remote PC in the event of a system fault having developed, andwill continue dialling until the fault is reported.

z

Battery Cell Monitor

System Controller

MUIB3(Supplies SystemController Power)

AC Distributionwith 1Φ Monitor

Remote Alarmsand Ambient

Temp. Sensor

DC Bus

DC DistributionBatteries withCircuit Breakers

Magazines ofAC-DC Converters

DC Loads

Local Comm. Port

Remote Comm. Port

Figure 4.2 System with battery cell monitoringThe second option shown in Figure 4.2 is the basic arrangement described above with theaddition of an auxiliary single phase AC monitoring module and Battery Cell Monitor. Thismodule, which is mounted in the AC distribution module, connects via a ribbon cable to theMUIB and is used to monitor the AC voltage, current and frequency.The third option shown in Figure 4.3 is the basic arrangement with the addition of anauxiliary three phase AC monitoring module. The latter connects directly to the MCSU-4via a ribbon cable and provides monitoring of the three AC voltages and currents as wellas the AC frequency. It has multiplexing circuits on board which effectively extends theanalogue 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 atthe same time. This can be useful where the AC output of an inverter running off the DCbus can be monitored at the same time as the three phase AC supply to the rectifiers.

Figure 4.3 System with additional 3 phase AC monitoring; simultaneousmonitoring of single phase inverter is also possible.


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4.1.2 Rectifier Specific ConfigurationsA typical mechanical arrangement of a system comprising 12 rectifiers is shown in Figure4.4. It consists of 12 rectifiers and magazine (12 x 2U) and a 1U high MCSU-4 (Controland Supervisory Unit).

Figure 4.4 Typical RT7 System Physical Layout


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5. Installation5.1 Rectifier

5.1.1 MagazinesTo enable hot-swapping of rectifiers, magazines are used to mount the rectifiers in therack. The magazines are secured to the rack by four M5 or M6 screws through themounting flange and into the rack mounting rail and an M5 stud into a stiffening member atthe rear of the rack. The rectifier is secured in the magazine by two M5 thumbscrews onthe front panel.

5.1.2 Connections

Figure 5.1 RT7-120V RectifierThe rear of the SMR has two connectors as shown in Figure 5.1. AC power pluscommunications with the MCSU-4, and a DC output connector. These connectors matewith the corresponding connectors on the back of the magazine when the rectifier isinstalled.


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A printed circuit assembly on the back of the magazine, has the two resistors from whichthe microprocessor determines the SMR position. The value of resistors to use for eachrack position is shown on the table in the backplane schematic, S0990. The table showsthat up to 225 combinations are possible, enabling systems of up to 22,500A nominalcapacity (28kA maximum at 48V) to be built.In addition, the backplane has a 10 way ribbon cable header, facing towards the back ofthe rack, to enable “daisy-chaining” the SMR communications terminals in a rack together.The 10 way ribbon cable connects all the SMR communications ports in a rack in parallelto the MCSU-4 it can also terminate on a CIC3 board, mounted near the top of the rack,which allows connection to other RT7 racks. One four way connector on CIC3 connects toa preceding rack, while a second 4-way connector can be used to connect to the nextrack.In this manner it is possible to conveniently parallel the communications connections to asmany racks as are required to build a system of up to 225 SMRs.

5.1.2.1 AC power - MagazineThe AC power connector is terminated by ring terminal lugs bolted down to the backplanePCB with M4 screws. The ring lugs should be suitable for terminating wire ofapproximately 2.5mm2. Only the three actives (phases) and the earth are required to beconnected – no neutral connection point available.

5.1.2.2 DC output - MagazineThe DC connectors are designed to mount directly on busbars or interconnectionmetalwork. The magazine provides the isolation and mechanical support for the DCconnectors. Two L-shaped copper bars allow either direct connection to heavy currentbusbars in the rack or connection to DC cables of approximately 35mm2 via M6 nuts andbolts.

5.1.2.3 CommunicationsThe communications connector is a 10 way 0.05” ribbon cable IDC Type. A ribbon cableis used to connect all the rectifiers in the rack in parallel as described above and to theMCSU-4 magazine. For installations in which more than one rack is used, a CIC3 PCA isused which has two 4 way connectors to connect to other racks. The CIC3 is usuallymounted at the top of the rack.

5.1.3 Physical requirements

5.1.3.1 Cooling airThe rectifiers are fan cooled, the cooling air flows into the front of the rectifiers and out theback. Sufficient space must be left between the rear of the rectifiers and the back of theenclosure or wall for the cooling air to pass without excessive pressure increase. Aminimum clearance of 110mm from the rear of the magazine (550 from the mounting rail ofthe rack) to a solid back is required. A louvered or meshed back panel is beneficial inreducing the operating temperature, but is not essential if the rack is not fully populated.Clearance from the front of the rectifiers is also required. If a door must be fitted it isrecommended that it be fully louvered and spaced a minimum of 150mm from the front ofthe rectifiers.It is important to ensure that hot air from the rear cannot recirculate to the front of the rack.


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5.2 MCSU-4 (Control and Supervisory Unit)The MCSU-4 mounts in a 1U magazine mounted to the rack mounting rails by four M5 orM6 screws.The user interface board (MUIB3), which connects to the MCSU-4 by a ribbon cable, issecured to a mounting plate, located elsewhere in the rack.DC voltage feedback and power for the MCSU-4 is derived from the output DC bus.These wires should be connected at the point where constant voltage is required. This istypically at the point where the cables connect to the batteries. External voltage sensingfor voltage regulation at a load can also be done, but in most systems, the system voltageis sensed on the internal output bus. Battery current limiting is achieved by a digitalcontrol loop that controls the system voltage to regulate the battery current. A DC currentsensor with an appropriate scale factor measures the battery current signal.IMPORTANT – the scale factor of the battery current sensor must not be too small,otherwise the battery current limit loop will be unstable! The limit is based on thenumber of rectifiers in the system. [SFmin = 25xN (A/V)]For example, if there are 10 rectifiers in a system (excluding redundancy), then the systemcurrent limit is 1250A (@48V). The scale factor of the battery current sensor must not beless than 250A/V for stable operation. For a 100 rectifier system, the sensor scale factormust be 2500A/V, and so on. This assumes that the battery is correctly sized for thesystem. A Smaller battery capacity will be stable for some sensor scale factors below therecommended minimum.For more information on connections, see the detailed section on the MUIB3.

5.3 Other System Component GuidelinesThe installation of an uninterruptible DC power system incorporating rectifiers, batteriesand control hardware requires compliance to National Wiring Standards, and appropriatesections of standard IEC60950 to ensure safety of operators and supplementaryequipment. Wiring should always be done by qualified personnel.

5.3.1 RacksThe structure and continuity of the rack provide system safety compliance and additionalshielding for electromagnetic compatibility (EMC) of the DC power system. The rackenclosure must have the following features to provide safe system operation:

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 fallingobjects be prevented from reaching bare parts at HAZARDOUS voltage(>32VAC or >60VDC) or bare parts that if bridged would result in an energyhazard (arc), and/or,

for the sides of the enclosure, be provided with louvres that are shaped todeflect outwards an externally falling object.

Sufficient ventilation must be provided for rectifier cooling. A rack with a ‘top hat’construction or a varied mesh hole size is a good method of obtaining good ventilationwhile maintaining compliance with the above requirements.


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The rack needs to be able to mount 19” rack equipment and have a depth not less than600mm. The height required depends on the number and type of modules incorporated.

5.3.2 Lightning and Transient SuppressionThe rectifiers contain Metal Oxide Varistors (MOVs) across line-to-line and line-to-earth forbasic transient suppression. These MOVs are chosen to provide protection from typicalline transients in an industrial environment according to ANSI C62.41-1991 (6kV/3kA) andIEC 61000-4-5 (Level X). Under these conditions, the MOVs are expected to providetransient protection for the life of the rectifiers.If the transient environment is more severe, with a high incidence of lightning strikes eitherindirect or direct, and/or severe switching transients beyond the levels outlined in thestandard, then supplementary transient protection is required. Larger MOVs (40kA rating)are required at the AC main switchboard where the power to the rack originates or at thepoint where the supply connects to the rack AC distribution.The arrangement of the rack MOVs must be the same as for the rectifier – three line-to-line MOVs (575V) and three line-to-earth MOVs (340V to 575V is acceptable). A “star”configuration with three line-to-neutral MOVs and one neutral-to-earth MOV will notprovide protection to the RT7 rectifiers as the internal clamping voltage for phase-to-earth surges is lower than for such a “star” configuration of rack MOVs. (The RT7 rectifierswill end up protecting the rack MOVs!).If the 40kA MOVs are placed in the rack, an extra set of MOVs (75V to 125V, 3-6kA) isrequired between the output DC and the rack earth bar. This is to protect the outputinsulation from the earth line surge voltage that is generated on the earth wiringinductance when the surge current flows through the AC side MOVs. Without theseMOVs, failure of the rectifier output circuit could result when high surge currents enter therack.

5.3.3 Temperature sensorsTemperature sensors are available for sensing ambient and battery temperature. Thesesensors use a semiconductor sensor encapsulated in a copper crimp lug and plug in to theMUIB.

5.3.4 AC monitoringOptional modules are available in either single phase or three phase models. The moduleconnects in series with the incoming mains supply by having the phase wires insertedthrough 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 referencetransformers. Inputs for voltage measurement are protected against high voltagetransients. The modules are connected to the MCSU-4 magazine via a 16-way ribbon. Ifboth types of modules are installed use second 16-way connector on single phase modulefor connection to the three phase module.

5.4 A Typical SystemShown on the next page is a wiring diagram for a typical system with a positive ground.For a negative ground system the battery positive must be connected to the LVDS anddistribution system. Note that the rectifiers are internally fused on the negative line.


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Figure 5.2 Typical installation Wiring Diagram


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5.5 MUIB3 – Systems with Earth Leakage DetectionThe MUIB3 has been designed to operate in conjunction with 24V, 48V and 120V rectifiersand MCSU-4 to control and monitor these systems, while providing earth leakage currentdetection. 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. Themain 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 phasemonitoring module has been removed, as has the connector for the AN1 spare analogueinput since the associated analogue channel is used by the microprocessor to monitor theearth leakage current.

5.5.1 System setup requirementThe MCSU-4 software needs to be a version with the MUIB3 option. From the front panelof the MCSU-4 scroll down the CSU menu to a window which gives the choice of MUIB orMUIB3. Select MUIB3 in place of the standard MUIB. The selection can be also madefrom a PC running WinCSU program.

5.5.2 Main features of MUIB3The 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 currenton the MCSU-4 screen or on the remote monitor screen. Full scale is +/-10mA.

A window on MCSU-4 or WinCSU allows the programming of the earthleakage current level between 1.0mA and 9.5mA at which an alarm isasserted.

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

There are 5 relay outputs, 4 digital inputs, CB trip input and Batteryswitch input.

The MUIB3 provides power to the MCSU-4;

One spare analog input is available (input range: 0 to +5V).

5.5.3 MUIB3 Connections

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

5.5.3.2 Relay Contact outputs

There are 5 user programmable relays with normally open (N/O) and normally closed(N/C) contacts available on the MUIB3, connector X2. Programming of the alarms torelays is done through the WinCSU-2 software.


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5.5.3.3 Spare Digital InputsThere are 4 spare digital inputs (USER 1, 2, 3, 4) available on the MUIB3 for themonitoring of external plant associated with the power supply. The inputs must be isolatedrelay contacts or auxiliary contacts which are either normally open or normally closed. TheMCSU-4 software for monitoring of the inputs must be user defined.

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

1. -15V2. +15V3. NOT USED4. SIGNAL5. GND

MFR: Molex

Conn: 09-50-3051

pins: 08-50-0106

4-Way cable

Figure 5.3 Current transducer connection

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

5.5.3.6 CB Trip and Batt Sw inputsCB Trip (X22) is used to sense the CB status. Batt Sw (X23) is used to sense the batteryswitch status. Open contacts on any of these 2 inputs creates an alarm condition on theMCSU-4. Therefore, when any one of these 2 inputs are not used, a shorting plug shouldbe installed on the input not being used.

5.5.3.7 Earth Leakage DetectorThe diagram in Figure 5.3 shows the principle on which the earth leakage detector works.The SMRs and Batteries, which are normally galvanically isolated from Earth, are actuallygrounded via sensing resistor Rde which connects to the centre-tap of two relatively highvalue resistors (Re in Figure 5.4). The effect is that if there are no other electrical paths toEarth, 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, earthedframe), the return path must be through Rde. The voltage developed will then bemeasured 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 thetest point on the UIB3 marked ELEAK will not be zero, but a calibrated voltage a little over2.5VDC. This is an offset voltage, which has been introduced to enable themicroprocessor to monitor earth leakage current of both positive and negative polarity.


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SMRs

Batt 1 Batt 2

Earth

Voltage shiftingNetwork

on MUIB3

To MiniCSU A/DConverter

+0.5Vb

-0.5VbNegative DC bus

Positive DC bus

Rde

Re

Re

Figure 5.4 Earth Leakage current detector circuit on MUIB3


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X1

X2

X18

X17

X22X23 X33 X34 X44 X45

X31X40

X39

X50

X68

34-way ribbon cableto MiniCSU-2

Figure 5.5 MUIB3 Connection Diagram

Conn # Conn Label Class CommentsX1 MCSU-4 A/D 34-way ribbon cable to MCSU-4

X2 RELAY 1 Digital User programmable

RELAY 2 “ User programmable




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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Connector Pin Signal Name Connector Pin Signal Name

X1 MCSU-4 1-34 34 way ribbon X39 BATTERY 1 1 -15V

X2 RELAY 1 15 N/O relay contact 2 +15V

14 N/C relay contact 3 No connection

13 Common 4 Input

X2 RELAY 2 12 N/O relay contact 5 GND

11 N/C relay contact X40 BATTERY 2 1 -15V

10 Common 2 +15V

X2 RELAY 3 9 N/O relay contact 3 No connection

8 N/C relay contact 4 Input

7 Common 5 GND

X2 RELAY 4 6 N/O relay contact X22 C.B. TRIP 1-2 Contact closure requiredbetween pins 1 and 2

5 N/C relay contact X23 BAT SW. 1-2 “ “

4 Common X33 USER1 1-2 “ “

X2 RELAY 5 3 N/O relay contact X34 USER2 1-2 “ “

2 N/C relay contact X44 USER3 1-2 “ “

1 Common X45 USER4 1-2 “ “

X17 BAT TEMP. 1 No connection X50 POWER I/P 1 Bat +ve terminal

2 Sensor -ve 2 Bus +ve terminal

3 Sensor +ve 3 No connection

X18 AMB. TEMP. 1 No connection 4 Battery -ve terminal

2 Sensor -ve 5 Bus -ve terminal

3 Sensor +ve X68 EARTH 1&2 Earth for leakage detector

X31 AN2 1 0V to +5VDC.

2 Common

Figure 5.6 MUIB3 Connector wiring information

Fuse Function Specification

F4 +15VDC F500mA, Glass, M20x5

F5 -15VDC F500mA, Glass, M20x5

F8 Ground T2A, HRC, M20x5

F46 -V System T2A, HRC, M20x5

F49 -V Battery T2A, HRC, M20x5

Figure 5.7 MUIB3 Fuse Function and Specification


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5.6 Battery Cell Monitor 4 (BCM44) in 120V DC systemsThe Battery Cell Monitor (BCM4) is an add-on module for the MCSU-4. It is used tomonitor individual cells of a battery during float or equalisation operation, or during adischarge. Each BCM4 unit is capable of monitoring a battery string of up to 24 cells undermaximum input voltage of 320Vdc. (Note: “Cell” can mean either single battery cell ormonoblock). If monoblocks are used and there are no more than 12 blocks in a string, twobattery strings can be monitored using single BCM4 unit. A total of four BCM4 units can bedaisy chained to monitor 4 battery strings of 24 cells each or 1 battery string of 96 cells.Using the ability of the MCSU-4 to communicate to a remote or local PC, blocks voltagedata, accumulated during a discharge, can be transferred to a PC and saved. The blockvoltages can also be viewed in real time when the MCSU-4 is connected to a PC. TheWinCSU-2 software that is running on the PC can display the block voltage data in variousconvenient formats to ascertain the state of health of batteries.In addition to the real time or historical representation of the data on the WinCSU, the cellvoltages can also be observed in real time on the MCSU-4 LCD display.In the event that the battery behaves in a way which is less than ideal during a test oractual discharge, a number of pre-programmed parameter levels are used to generatealarms. These are annunciated locally on the MCSU-4 front panel by a LED and displaymessage or via the USB communications port on the front panel to a PC, remotely viavoltage free relay or via a TCP/IP interface (SNMP available).

5.6.1 Main Features of the BCM4The principle features of the BCM4 are as follows:

Up to 24 blocks can be monitored by a single BCM4 module. Blockvoltage setting can be 2V, 4V, 6V or 12V.

Up to four BCM4 boards can be connected to a single MCSU-4.

The main application for the BCM4 is 240Vdc systems of 1 battery stringper board with 20 x 12 V monoblocks or 120Vdc system of 2 batterystrings per board with 10 x 12V monoblocks each.

Individual cell voltages of a battery string can be viewed on the MCSUdisplay in real time. The cell voltage rounded to the nearest 5mV (for 2V,4V and 6V cells/blocks) or 10mV (12V blocks) is displayed together withthe cell number and its percentage deviation from the average cellvoltage of the battery string.

All the cell voltages can be displayed in a “Histogram” format on a local orremote PC using WinCSU software for a very convenient and rapid visualindication of normal and deviant cells.

The PC can display the real time cell voltages or cell voltages storedduring a previous discharge. In this instance, a mouse driven slider bar isused to select at which point in the discharge to display the cell voltages.

A line graph of cell voltage versus time can be selected as the PC displayto observe the manner in which the cell voltages as a whole decreasedduring a discharge. It is also possible to select for all the cell voltages tobe displayed (in different colours) or for a particular cell voltage to bedisplayed together with the average cell voltage as a function of time.


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As the BCM4 is permanently connected to the battery strings, anautomatic, daily or weekly down-loading of the steady state cell voltagesfor the different battery strings in a system to a remote monitoring PC canbe very useful for anticipating the state of health of the battery strings.

When desired, a discharge can be initiated either locally or remotely bytriggering the rectifiers in the system into “battery discharge test” mode.In this mode the rectifier float voltage is set to a lower value whichensures that the batteries are carrying the load, but not too low so that inthe event of battery failure during the test, the rectifiers will prevent thevoltage from falling below the set voltage, which enable the load tocontinue functioning correctly. This test can be arranged to occur in noncritical times. It is particularly useful if there has not been a recentdischarge due to failure of the commercial AC supply.

5.6.2 BCM4 Specifications for 120V systemBattery configuration options (selectable):

1 battery string per board, suitable for 240Vdc systems with 20 x 12 V monoblocks,2 battery strings per board, suitable for 120Vdc system with 10 x 12V monoblockseach,Configuration programmable on MiniCSU or WinCSU

Maximum battery voltage: 320VdcNumber of cells: 24 maximumCell Voltage selection (DIP switch setting on the board):

2V (max input: 3.33V - use also for Nickel/Cadmium cells)4V (max input: 6.66V)6V (max input: 10V)12V (max input: 20V)

Accuracy for 1 year:

2V: 10mV at 0C to 40C



12V: 60mV at 0C to 40CResolution: 5mV per cell (2V, 4V or 6V cells/blocks) or 10mV (12V blocks)Sampling interval range for discharge log: 1 - 60 minutesPower supply: from MCSU (+/-15V± 7%)Maximum distance from MCSU: 10m (of 16 way ribbon cable)

5.6.3 Preparing the battery for connection to the BCM4Battery cells are not connected to the BCM4 directly. 270/PR03 resistors are insertedbetween BCM4 and the cells to clear any fault that would arise if a battery cell lead wereshorted. The resistors are mounted as near as possible to the battery terminal in order toprotect as much of the wiring as possible. A typical connection is shown in Figure 5.8.


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Figure 5.8 Lead termination at battery cell

The M6 ring lug (depending on type of battery) is screwed onto the cell terminals. Theother end of the wire is screwed onto the 5.0mm pitch screw terminals on BCM4. Detailson how the cells connect to the BCM4 board are discussed in later sections.

5.6.4 Installing the boardGenerally, the BCM4 board is located close to the batteries so that it is not necessary torun large number of wires for long distances. The 16 way ribbon cable connecting to theMCSU-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 hasconnectors placed part way along its length as well as the ends.Mount the BCM4 using the standoffs supplied in an area protected from mechanical andelectrical hazards. If the rack does not provide any holes or studs for mounting theBCM4, use the following figure as a template for drilling the mounting holes. Be sure toallow at least 25mm space around the board to allow for wiring to the board.

Figure 5.9 BCM4 mounting hole locations.


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5.6.5 Battery Cell LeadsFor 1V systems, the number of cells for this battery can be defined as 20 cells. The cellconnections to the BCM4 board are via 2 connectors labelled SECTION 1 and 2.SECTION 1 consists of cells 1 to 12 and so on. Cell 1 is defined as the cell at the top ofthe battery string, whose positive terminal is the positive terminal of the battery string. Cellterminals at each end of a connector are labelled, e.g. +C1 as the connection to positiveterminal of Cell 1. SECTION 1 and 2 are a 13 way connector. The connection to a 20 cellsystem is illustrated in Figure 5.11, while the connection of 120Vdc system of two batterystrings is shown in Figure 5.12.Note: MCSU will automatically select mode of scanning of BCM4 after programming ofnumber of cells and number of monitored battery strings.Important: Always start filling up the connections from Cell 1 in SECTION 1.

5.6.6 Dip-Switch Selection of Block VoltagesBattery voltage is selected via the main menu whereas the cell or monoblock voltage mustbe selected via dip-switch S1 on the PCB. The following table indicates the DIP-switchsetting for different cell/monoblock voltages:

CELL/MONOBLOCKVOLTAGE

LEFT SWITCH(S1)

CENTRESWITCH

(S2)

RIGHTSWITCH

(S3)

12V ON OFF OFF

6V OFF ON OFF

4V OFF OFF ON

2V OFF OFF OFF

Figure 5.10 DIP switch Settings

5.6.7 Battery Block Lead Connection to the BCM4 boardThe battery block voltage sensing leads are terminated with 13 way female (Weco 5.0mmpitch) screw terminals. This plugs onto the headers on the BCM4 board. How the blockvoltage sense leads connect to the BCM4 board depends on the battery configuration.The following figures show the connection of the battery to the BCM4 board for differentconfigurations. The wiring must start at terminal C1+ (and C13+ when second string of12V blocks is used) and end at a terminal corresponding to Cnn- of the last block.


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Figure 5.11 BCM4 connections to a 120V-144V (up to 24 of 6V block) battery bank.


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Figure 5.12 BCM4 connections to two 120V-144V (up to 12 of 12V block) batterybanks.


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5.7 Battery Cell Monitor 3 (BCM3) - 120 Cell / 240VThe Battery Cell Monitor 3 (BCM3) is an add-on module for the MCSU-4. It is used tomonitor individual cells of a battery during float or equalisation operation, or during adischarge.The BCM3 unit is capable of monitoring the following options:a) Lead/Acid batteries: Each BCM3 unit is capable of monitoring one battery string of up

to 120 cells and up to 320Vdc. Two BCM3 units can be used to monitor 2 batterystrings build of 2V cells. If monoblocks are used and there are no more than 58 blocksin a string, two battery strings can be monitored using single BCM3 unit.

b) Nickel/Cadmium batteries: It is possible to monitor one battery string of up to 192 cellsusing two BCM3 units.

Using the ability of the MCSU-4 to communicate to a remote or local PC, cell voltage dataaccumulated during a discharged can be transferred to a PC and saved. The cell voltagescan also be viewed in real time when the MCSU-4 is connected to a PC. The WinCSUsoftware that is running on the PC can display the cell voltage data in various convenientformats 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 oractual discharge, a number of pre-programmed parameter levels are used to generatealarms 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).

5.7.1 Main Features of the 120 Cell BCM3The principle features of the BCM3 are as follows:

The main application for the BCM3 is monitoring 240Vdc batteries, whichconsists of up to 120 cells per battery.

Individual cell voltages of a battery can be viewed on the MCSU-4 displayin real time. The cell voltage rounded to the nearest 5mV (for 2V, 4V and6V cells/blocks) or 10mV (12V blocks) is displayed together with the cellnumber and its percentage deviation from the average cell voltage of thebattery.

All the cell voltages can be displayed in a “Histogram” format on a local orremote PC using WinCSU software.

The PC can display the real time cell voltages or cell voltages storedduring a previous discharge.

A line graph of cell voltage versus time can be selected as the PC displayto observe the manner in which the cell voltages as a whole decreasedduring a discharge. It is also possible to select for all the cell voltages tobe displayed (in different colours) or for a particular cell voltage to bedisplayed together with the average cell voltage as a function of time.

As the BCM3 is permanently connected to the batteries, an automatic,daily down-loading of the steady state cell voltages for the differentbatteries in a system ban be made to a remote monitoring PC.

A discharge test can be initiated either locally or remotely from WinCSUsoftware. The test can be performed with constant, user programmablecurrent (recommended) or under full load connected to the system. This


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test can be programmed to occur periodically in non critical times andresults can be used to monitor the condition of the battery strings. Fordetails refer to MCSU-4 section.

5.7.2 BCM3 Specifications

Battery configuration options: (120V and 240V systems):

1 x 220V Battery per BCM3 (120 cells x 2V Lead Acid ) or,

2 x 110V Batteries per BCM3 (up to 58 cells x 2V Lead Acid).

2 Batteries per BCM3 (up to 58 monoblocks per battery string)

1 Battery per 2 x BCM3 (>120 cells x 1.2V Nickel-Cadmium)

Maximum battery voltage: 320Vdc

Number of cells: 120 maximum per board (Set on MCSU-4 or WinCSU)

Cell Voltage selection 2V (max input: 3.33V)

(DIP switch setting on the board): 4V (max input: 6.66V)

See section below for detail. 6V (max input: 10V)

12V (max input: 20V)

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

Accuracy for 1 year: 10mV at 0C to 40C

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

Sampling interval range fordischarge log:

1 - 60 minutes

Power supply: from MCSU-4 15V

Maximum distance from MCSU-4: 10m (of 16 way ribbon cable)

5.7.3 Relationship between “BCM Batteries” and “Num Batteries” for MCSU-4With the BCM3 option enabled, the BCM3 parameters must be setup before monitoringcan be performed. There is no need to program the MCSU-4 with the number of BCM3boards connected. The MCSU-4 automatically calculates the number of BCM3 boardsthat it requires from the number of “BCM Batteries” that you entered. The number ofBCM3 boards (PCBs) required for different battery configuration is shown in the followingtable.Note: For BCM3, the maximum number of batteries is 2, while the maximumcells/monoblocks per battery is limited to 58 if one BCM3 is used to monitor 2 batteries.


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System Battery Configuration BCM Batt = 1 BCM Batt = 2

240VDC Up to 116 cell, 2V 1 BCM3 board 2 BCM3 boards

Up to 58 monoblocks, 4V 1 BCM3 board 1 BCM3 board

6V monoblocks 1 BCM3 board 1 BCM3 board


120VDC Up to 58 cell, 2V 1 BCM3 board 1 BCM3 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 = 1 or 2)

The number of batteries entered here is the number of batteries that are being monitoredfor their currents. “Num Batteries” and “BCM Batteries” are not related except that valueentered for “Num Batteries” must be greater or equal to “BCM Batteries”. This is becauseNum Batteries determines the number of batteries accessible via the BAT menu, via whichwe access the cell voltages. Normally Num Batteries is set to be the same as BCMBatteries.

5.7.4 Dip-Switch Selection of Cell VoltagesBattery configuration is selected via the main menu of the MCSU-4, whereas the cell ormonoblock voltage must be selected via dip-switch S65 on the PCB. The following tableindicates the DIP-switch setting for different cell/monoblock voltages:

CELL/MONOBLOCKVOLTAGE

LEFTSWITCH

(1)

CENTRESWITCH

(2)

RIGHTSWITCH

(3)

12V UP UP UP

6V UP UP DOWN

4V UP DOWN DOWN

2V DOWN DOWN DOWN

5.7.5 Installing the boardGenerally, the BCM3 board is located close to the batteries so that it is not necessary torun a large number of wires for long distances. The 16 way ribbon cable connecting to theMCSU-4 can be up to 10m long, but should be connected directly to the MCSU-4, insteadof connected at the end of another chain of peripherals. This helps reduce errors. Thisconnection can be achieved by using a ‘daisy chain’ ribbon where the one cable hasconnectors placed part way along its length as well as the ends.Mount the BCM3 using the standoffs supplied in an area protected from mechanical andelectrical hazards. If the rack does not provide any holes or studs for mounting the BCM,


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use Figure 5.13 as a template for drilling the mounting holes. Be sure to allow at least25mm space around the board to allow for wiring to the board.

Figure 5.13 BCM3 mounting hole locations.

5.7.6 Preparing the battery for connection to the BCM3Battery cells are not connected to the BCM3 directly. 270/PR03 resistors are insertedbetween BCM3 and the cells to clear any fault that would arise if a battery cell lead wereshorted. The resistors are mounted as near as possible to the battery terminal in order toprotect as much of the wiring as possible. A typical connection is shown in Figure 5.14The M6 ring lug (depending on type of battery) is screwed onto the cell terminals. Theother end of the wire is screwed onto the 5.0mm pitch screw terminals. Details on how thecells connect to the BCM3board are discussed in later sections.


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Figure 5.14 Lead termination at battery cell.

5.7.7 Battery Cell Leads and WiringFor 240V systems, the number of cells for this battery can be defined to a maximum of 196cells. The cell connections to the BCM3 board is via 10 connectors labelled SECTION 1 toSECTION 10. SECTION 1 consists of cells 1 to 12 and so on. Cell 1 is defined as the cellat the top of the battery string, whose positive terminal is the positive terminal of thebattery. Cell terminals at each end of a connector is labelled, e.g. +C1 as the connectionto positive terminal of Cell 1.SECTIONs 1-9 are 12 way connectors, while SECTION 10 is a 13 way connector. Theconnection to a 120 cell system is illustrated in Figure.5.15, connection of up to 58monoblocks is shown in Figure.5.16, and connection of up to 192 cells using two BCM3units illustrated in Figure.5.17.Note: MCSU-4 will automatically select mode of scanning of BCM3 after programming ofnumber of cells and number of monitored battery strings.Important: Always start filling up the connections from Cell 1 in SECTION 1.

Figure.5.15 BCM3 in 120 cell, 240V system


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Figure.5.16. BCM3 connections to 2 x 240V (4V x 58 cell) or 2 x 120V (2V x 58 cell)Lead acid battery strings using 1 x BCM3. Wire Battery 1 from sections 1 to 5. Wire

Battery 2 from section 6 to 10.


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Figure.5.17 BCM3 connections to a 240V (192 cell) Ni-Cad battery bank using 2 xBCM3.


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5.8 SMM - Site Monitor ModuleSite Monitor Module is an expansion of the MCSU-4. It allows the user to monitor status ofequipment that is not a part of a 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 monitoringsoftware 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. Therelays 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 software will also need anupgrade.

5.8.1 Electrical SpecificationNumber of Analogue Inputs 8Analog 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 andThreshold Levels

Scaling factor, Low and High thresholds levels are userprogrammable from WinCSU or Front Panel.

Number of Digital Inputs 12Type of Digital Signal Source Voltage free contactsLogic of Digital Input User defined from WinCSU onlyNumber of control outputs 4Output type Voltage free change over relay contacts, 1A@30VDCPower Source MCSU-4 (powered indirectly from system DC bus)

5.8.2 Physical SpecificationBoard Dimensions Approx. 210mm x 96mmSMM - Controller Connection 16 Way Ribbon CableSignal 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 providesscrewed connection for wire up to 1.5 mm2

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 providesscrewed connection for wire up to 1.5 mm2


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5.8.3 InstallationWiring of the site monitor is entirely dependent on the signals to be monitored. Figure5.18shows the basic wiring diagram of a system using a site monitor and a Battery CellMonitor. Signals such as site security (windows and doors being opened) are usuallyconnected as digital inputs, while fuel levels, inverter voltage/current/frequency are measuredusing the analog inputs.

5.8.4 System Set-upThe 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 ornormally closed) can only be done using a PC running WinCSU. See WinCSU operationmanual for details.Once programmed, monitoring of the levels and minor modification of levels and scaling onsite 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.


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Figure 5.18 Example Site Monitor Wiring Diagram


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5.8.5 Site Monitor SettingsPlease 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 thethreshold is disabled, adjustable up to 999.9 1) input units.

3. Lo T-hold – thresholds of analog channels to generate warning/alarm/output control. When set to zero thethreshold is disabled, adjustable up to 500.0 1) input units.

4. Scale – value of measured parameter corresponding to 4.00V of input signal. Adjustable up to 999.9 1).

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

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

Input Label O1 O2 O3 O4 Al 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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6. Remote Communication InterfacesRemote Communications Port is located at the back of MCSU-4. The module is a part ofthe controllers’ magazine. If a replacement of MCSU-4 is required, there is no need fordisconnection of the communication link. Depending on your monitoring requirements oneof following interfaces can be used.

6.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU)The Ethernet remote connectivity option is available in both a standard TCP/IP version and anenhanced WebCSU interface, which includes HTTP, SNTP and SNMP protocols for monitoring viaWinCSU-2, web-browser, and off-the-shelf Network Management Software. See WebCSU manualfor network set-up details

6.2 RS232 Interface (MCSP)This interface should be used if the distance between the RPS and monitoring PC or amodem 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 modemshould be connected using the cable provided with it.MCSU-4 has provision for programming up to 3 telephone numbers, up to 20 digits each(refer to Operation section for programming details).

6.3 RS485 Interface (MCMD)This type of port allows connection though a distance up to 1200 meters. Up to 32standard devices can be linked using twisted pair of wires. In high electrical noiseenvironment a shielded twisted pair is recommended. The figure below shows the pinassignment of the port.

Figure 6.1 RS485 pin assignments

Due to the slow data rate (9600bps) termination of the line with resistors generally is notrequired. However, if high rate of data corruption is experienced (slow data update inmonitoring program), line termination resistors should be installed at both ends of thenetwork. The value of the resistors depends on the gauge of the twisted pair and shouldbe equal (or closest) to line characteristic impedance. I.e. twisted pair of 24AWG wirescharacteristic impedance of 100ohm – use a 100ohm resistor.

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


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The main part of Smart Modem is a Socket Modem MT5600SMI-34 manufactured byMultiTech Systems (USA). Please check with your local Telecom authorities if it hasnecessary approval (it is approved in Australia). If an approval has not been issued yet, analternative, approved brand can be used. Please contact RTP for advice.The unit is designed for Global Region. To assure correct operation in other country thanthe USA (default setting), programming of appropriate Country Code is required (seechapter “Base Menu Programmable Parameters” in “Operation” section). Table below listssupported countries, approval status and corresponding codes.

Country / Approval Code Country / Approval Code Country / Approval Code

Argentina Y 07 India P 53 Portugal Y 8B

Australia Y 09 Ireland Y 57 Russia P B8

Austria Y 0A Italy Y 59 Singapore Y 9C

Belgium Y 0F Japan Y 00 South Africa P 9F

Brazil Y 16 Korea Y 61 Spain Y A0

China N 26 Malaysia P 6C Sweden Y A5

Denmark Y 31 Mexico Y 73 Switzerland Y A6

Finland Y 3C Netherlands Y 7B Taiwan Y FE

France Y 3D New Zealand Y 7E United Kingdom Y B4

Germany Y 42 Norway Y 82 United States Y B5

Hong Kong Y 50 Poland P 8A 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 isrecommended to search for another brand of Socket Modem which may meet the countryrequirements.


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7. CommissioningCommissioning requires an understanding of the rectifier visual signals and operatoradjustable parameters on the system controller (MiniCSU-2). Before a system is firstenergized, it is advisable to read this section thoroughly.

7.1 Indicators on the Rectifier Front PanelThere are three LEDs on the front panel to indicate the operating status of the rectifiermodule. The status is indicated as follows:

Green Yellow Red Condition

0 0 0 No AC power available

F* 0 0 Indicates the input AC is too low or too high, or theprimary circuit is faulty. LED blinks every 2 seconds.

1 0 0 Rectifier functioning normally (Float Mode)

1 F* 0 Alarm condition (Refer to MiniCSU-2 for details)

1 1 0 Rectifier functioning normally (Equalise Mode)

0 F* 1 SMR is shut down by remote control, rectifier not insertedproperly, or there is an internal control circuit fault

0 0 1 µP faultNote: 0 indicates OFF, 1 indicates ON, and F* indicates flashing LED.

Further information about a particular rectifier alarm condition can be found by referring tothe MiniCSU-2 or the PC connected to the MiniCSU-2 - see detailed section on MiniCSU-2operation.

7.2 System Parameter RangesRange of adjustment and default settings of system parameters are contained in a table atthe beginning of this manual. Use last column to record parameters’ values set duringcommissioning.

7.2.1 RT7 SMR ParametersParameter Range Nominal

SMR Float Voltage 100-160V 135V

SMR Equalise Voltage 110-175V 144V

High Voltage alarm Threshold 116-177.5V 147V

Low Voltage alarm Threshold 70-120V 100V

HVSD Voltage alarm Threshold 112-180V 150V

Current Limit for SMR 6-60A 50A


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7.3 System CommissioningWhen commissioning a system, it may be necessary to alter some system parameters.This can be done manually through the front panel of the MiniCSU-2 (see detailed sectionon MiniCSU-2 operation) installed as part of the system, or by using a PC runningWinCSU that is connected to the MiniCSU-2 via the RS-232 serial interface or remotecommunication interface where installed (see detailed WinCSU operation manual). It isrecommended that the PC option be used if systems are to be commissioned frequently.The benefit being that predetermined configurations can be stored on disk and easilydownloaded to the MiniCSU-2 at any time. It is assumed that the operator commissioningthe system has knowledge of programming system parameters.The system parameters can vary widely depending on the system configuration andbattery requirements. It is advisable to consult the battery data sheets as a referencewhen determining the system parameters to be programmed into the MiniCSU-2.

7.3.1 Commissioning ProcedureFor 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.

Connect the first battery string and close the battery circuit breaker. If the polarity iscorrect, the MiniCSU-2 controller should power up.

Using either the MiniCSU-2 front panel or a PC connected to the RS-232 serial port orremote communications port, program all the MiniCSU-2 parameters according to thesystem requirements. Make sure that the number of rectifiers and batteries in thesystem are correctly set.

Set up any parameters necessary to operate auxiliary equipment such as Battery CellMonitor (BCM), Mains Monitoring Interface Board (MMIB), Site Monitor, etc.

Close the remaining battery circuit breakers if more than one string is used

Insert a rectifier into SMR Number 1 magazine (determined by the resistors of the backof the Magazine) and turn the AC power on. The rectifier should power up and startcharging the batteries.

Put all the remaining rectifiers ‘on-line’, one at a time by inserting each rectifier into themagazine and switching on the corresponding AC breaker. Check that each unitpowers up and communicates with the MiniCSU-2. This is determined by checking thatthe MiniCSU-2 has a message “SMRX 0A” where X corresponds to the SMR number.

Check that the bus voltage is increasing toward the float voltage.

With all rectifiers operating correctly, close the load breakers and check that the loadpowers up.

Wait for 1 minute and check that the MiniCSU-2 is able to control current sharingbetween the units to within +/-3A of the average rectifier current.

Clear Alarm Log.

The system is up and operational. Adjust and operational monitoring or setup details asrequired.

For further information on any subject relating to MiniCSU-2 operation or alarms, see thedetailed section on MiniCSU-2.


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8. OperationSystem operation is controlled by the MCSU-4 system controller. As a result, operationinformation for the system is directly related to the operation of the MCSU-4 as describedin 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 anotherIf no button has been pressed for two minutes, the display will revert back to the Homescreen. This shows the output voltage and load current.To move from any menu to any other menu, press the corresponding button. E.g. to moveto 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 firstscreen, press the DEC button.Incrementing and decrementing programmable parametersTo change a programmable parameter press ENTER; the value will flash on and off. Toincrease the number, press INC; to decrease the number press DEC. When the desirednumber is on the screen, press ENTER again.To change parameters when the security function is activatedIf an attempt is made to alter any parameter when the security function is activated, thedisplay will show the message "Enter Password".To change a parameter, enter a valid password. Then proceed to change the parameter inthe normal way.When scrolling through the Alarms logTo observe the date and time of a given alarm, do not press any button for at least twoseconds. The date and time will display for two seconds and then the alarm name will bedisplayed for two seconds. The display will alternate between the two screens in thismanner until a button is pressed.


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8.1 MCSU-4 ComponentsThe MCSU-4 is a supervisory and control unit for a powershelf DC plant comprising up to8 rectifiers connected in parallel with up to four parallel battery banks. The unit is hotpluggable.

8.1.1 Alpha-numeric DisplayThe user interface is a two-line by 16 character alphanumeric LCD display. The 5mm highcharacters 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 voltageare always displayed, while the second line alternates between the system status (FL/EQ)and the activity status, for example “BDT in progress”.

234A 54.5VFL

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

8.1.2 Front Panel PushbuttonsThere are six pushbuttons associated with the LCD screen for the purpose of enteringdifferent Menus and for scrolling through the menus. The layout of the pushbuttons isshown below:

In addition to the MCSU-4 or “Home” menu, which includes system oriented parameters,there are three other menus which can be accessed by momentarily pressing the relevantpushbuttons:

a) SMR menu, which includes the rectifier related programmed parameters as well asthe output current and heat-sink temperature for each rectifier;

b) Battery menu in which all parameters appertaining to the batteries are found;c) Log stores all the individual alarm information together with date and time starting

with the most recent alarm. A total of 100 alarms are stored in memory.


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8.1.3 Status Indicating LEDs (MCSU-4)In addition to the alphanumeric display there are also three LEDs to indicate system statusas 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 forthis. For example:

DC is not present Internal failure of MCSU-4The 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.

8.2 Operating the MCSU-4

8.2.1 Password securityMCSU-4 features password security for parameters setting. A password is analphanumerical code having minimum three and maximum eight charactersUnits leave the factory without a pre-programmed password and the security function isnot active. To activate the security, a password must be programmed. Once that is done,security can be enabled.

8.2.1.1 Entering a password to gain access to parameters changeWhen the security function is active any changes to the system settings can be done onlyafter a valid password was entered. When the ENTER key is pressed to change aparameter, the display will show a message “Enter Password” on the top line and ablinking cursor on the right hand side of the bottom line. Using INC and DEC keys scroll tothe first character of the password and press ENTER. The character will be substituted bya star ( * ) displayed to the left of the cursor. Enter all characters of the password the sameway. If the password is less than eight characters long press ENTER again after lastcharacter. If the entered password was correct the display will return to the selectedparameter ready for modification. If the entry was incorrect the following will be displayed

Wrong PasswordPanel Locked

There is no limit on password entry re-tries. To abort password entry any of the top rowbuttons should be pressed. The display will return to the selected parameter.There is no limit on the number of parameters to be modified after a correct passwordentry providing there was a break less than 1 minute between consecutive actions on thekeypad.

8.2.2 When an alarm condition existsIf one or more alarm conditions exist at any time the following message will alternate withthe “home” screen for 2 seconds every six seconds in addition to warning LED indicators:


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3 AlarmsPress ENTER

In this case, the message indicates that there are three alarms present and they can beobserved by pressing the ENTER button.When the ENTER button is pressed the most recent alarm name, such as the one shownbelow will appear on the display.

Alarm 1Amb Temp High

If no button is pressed again for one minute, the display will revert to the “home” screenand the sequence begins again.To view the remaining alarms, use INC and DEC buttons. Pressing the ENTER button willreturn the display to the “home” screen. The time and date of any given alarm can beobtained by entering the ALARM LOG menu.

8.3 MCSU-4 AlarmsA list of all the possible alarms that can be enunciated is shown in the following table.

Alarm Name Comments LEDSMR Alarm Combination of one or more SMR alarms A

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 A

Power Limit SMR is in Power Limit A

No Load SMR output current less than minimum for SMR type used A

Current Limit SMR in current limit A

Voltage High Voltage measured by SMR too high A

Voltage Low Voltage measured by SMR too low A

UNCAL SMR SMR Internal Adjustment for current sharing out of limits A

EEPROM Fail EEPROM failed (CSU or SMR) A

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

Relay Fail SMR output relay contact failure A

No Demand Control loop in SMR not in normal state A

H/S Temp High SMR heatsink temperature too high (where available) A

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 – detectedby SMRs

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


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Alarm Name Comments LEDAC Volt Fault – detectedby CSU

None of SMRS are responding (AC fail assumed), or if AC monitor isused, AC voltage is out of limits set(When no AC monitoring module is used, this comes together with “SMR Comms Fault”)

A

AC Freq Fault AC frequency lower or higher than preset value A

Battery Switch One or more battery switches open A

Cct Breaker Fuse or CB in load distribution open A

LVDS Open Low Voltage Disconnect switch open A

Sys Volts High System output volts too high A

Sys Volts Low System output volts too low A

System V Clamp CSU can not reach desired system voltage. This can be due to possibleexcessive voltage drop along bus bars or “System V Drop” parameterhas value too low.

A

Cell V High One or more cells being monitored by BCM is too high in voltage A

Cell V Low One or more cells being monitored by BCM is too low in voltage A

Cell %dev High One or more cells being monitored by BCM is too high % deviation fromthe mean battery cell voltage

A

Cell %dev Low One or more cells being monitored by BCM is too low % deviation fromthe mean battery cell voltage

A

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

Site Monitor Alarm present from the site monitor module. See site monitor menu fordetails of alarm channel.

A

Battery Disch Batteries are discharging A

Disch Tst Fail Battery discharge test failed to reach a programmed end point A

Bat Disch Low Alarm flags only if the system voltage falls below Discharge Alarm levelwhile the battery is discharging

A

Lo Electrolyte Alarm generated for NiCad batteries using special sensor and software A

SMR Comms Fail One or more of SMRs are not responding A

Amb Temp High Ambient temperature 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

Equalise System is in equalise mode A *

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

8.4 User programmable relay functionsNew units have factory default relay assignment. For details refer to paragraph “RelayContact outputs” in Alarm Relay sections of this manual.Relay functions can be changed only from a PC running monitoring program WinCSU-2.Refer to WinCSU-2 Help for instructions.


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8.5 MCSU-4 Base Menu ScreensThe INC button is pressed to scroll through the MCSU-4 menus. The following screenswill appear in sequence.

MCSU-4 “Home” screen; indicates system is in float mode. 155A 54.3VFL

“C” indicates that battery temperature compensationfunction is active. 155A 54.3V

FLC

This message will be displayed only when security is activeand editing of parameters was enabled by entry of a validpassword.

Lock PanelPress ENTER

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

Lock PanelPanel Locked

Ambient temperature is displayed in Degrees Centigrade. Ambient Temp31C

8.5.1 Single Phase AC Monitoring ScreensIn a system wired for 1 phase input with an AC monitor module, it will be necessary toactivate 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” menuitem. Once the AC monitor is enabled, the following screens will appear immediately afterthe “Ambient Temp” screen:

Single phase AC voltage. 1ph AC Volts245V

Single phase AC current1ph AC Current

52A

Single phase AC frequency1ph AC Frequency

50.0Hz

8.5.2 Three Phase AC Monitoring ScreensIn a system wired for 3 phase input with an AC monitor module, it will be necessary toactivate 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” menuitem. Once the AC monitor is enabled, the following screens will appear immediately afterthe “Ambient Temp” screen or single phase monitoring screens (when activated):

AC voltage of phase 1 3ph AC1 Volts245V


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AC voltage of phase 23ph AC2 Volts

243V

AC voltage of phase 33ph AC3 Volts

246V

AC Current of phase 13ph AC1 Current

28A


29A


32A

AC Frequency3ph AC Frequency

50.2Hz


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8.5.3 Base Menu Programmable ParametersThe 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 pressENTER. The parameter value will flash on and off. Press INC to increase the value or DECto 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 Alarm45C

Float voltage High levelVolts High Alarm

56.6V

Float voltage Low levelVolts Low Alarm

50.5V

Security on or off. When security function is activatedattempts to alter any programmable value will result in thedisplay showing “Enter Password”.

SecurityOn

SecurityOff

Entry point to password programming sub-menu. If ENTERwas pressed following alternative screens will be displayed. Password Setup

Press ENTERThis screen will be displayed if the password isprogrammed for the first time. Password Setup

O

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

This screen is displayed when a password was alreadyprogrammed. Enter existing password. If the password wasforgotten, contact the supplier to obtain default password.

Old PasswordO

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

Old PasswordWrong Password

This screen is displayed when correct old password wasentered or confirmation of the new password failed. Enterdesired new password.

New PasswordO


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Enter the new password again.Confirmation

OThis screen will be displayed for 2 seconds if new passwordand confirmation matched. The screen will be returned topassword sub-menu entry point.

ConfirmationPassword Changed

This screen will be displayed for 2 seconds if new passwordand confirmation did not match. The screen will be returnedto “New Password”.

ConfirmationWrong Password

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

Test IndicatorsPress ENTER

On the bottom line is the software number and revision,where 169-845 is the software number and 1-27 is therevision.

MCSU-4169-8451-27

Shows the files in MCSU-4. After pushing ENTER, scrollthrough the menu by pushing the INC and DEC buttons. System Info

Press ENTER

MCSU-4 application firmware and version MCSU-4169-8451-27

MCSU-4 bootloader and version Bootloader169-7201-00

MCSU-4 display driver and version Display Driver169-7300-00

MCSU-4 language file and version Language169-7761-00

MCSU-4 configuration file and version Configuration167-4821-00

System type. This parameter can be set to Standby orUPS. Set to Standby for systems where the load current isnormally zero. Low load alarms are disabled for Standby.

SystemStandby

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

SystemUPS

End of Mapping Loaded SMRs menus


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Number of SMRs in the system. This number must beentered correctly. Otherwise the display will show that someSMRs are not responding (number too big) or will not bemonitored (number too small).

Number of SMRs15

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

InterfaceMUIB

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

Num of Batteries1

Battery current transducer full scale rating. E.g. if a Halleffect transducer has 200A/4V rating, enter 200 in thescreen.

FS Batt Current200A

MCSU-4 Access code address; this can be a number up to7 digits long Access Code

1252636

Date format. The format of the date can be modified toeither 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-4clock. Note DD/MM/YYYY 24 hour clock. While setting thetime clock is stopped. Seconds are not programmable.

Date 25/12/2002Time 21:58:35

Alarm Report; this can be toggled On and OFF. If ON anduse of a modem is declared, the system will dial the firsttelephone number (Phone 1) in the screens below when analarm occurs. If Phone 1 does not answer, it will try Phone2; if 2 does not answer then it will dial Phone 3. If 3 does notanswer it will begin again at Phone1

Alarm ReportOn

Alarm ReportOff

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

Daily ReportOn

Daily ReportOff

Time of daily report. This menu is available only when DailyReport 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 whilethe modem is activated/deactivated.

ModemOn

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

OffWhen modem communication is selected CSU checks oncea minute if the modem is set to Auto Answer. If Auto Answerwas disabled (i.e. loss of power to the modem) CSU will re-initialise the modem.

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

Country Code09

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

Country CodeNone

This and next screen may not be seen on some models.Some models of external modems may require anadditional initialisation string. The string can be up to 10characters 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) inplace of the first character and press ENTER.

Cust Init StringNone

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

Phone 10398887788

Example of second screen for continuation of phonenumber Phone 1 Cont

2323

Phone 2; this number will be tried if the first number doesnot respond. This menu item is followed by “Phone 2 Cont”(as for Phone 1).

Phone 20398880033

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

Phone 30398880033

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 throughTimeout to Off; when On, the audible alarm will sound whenany alarm occurs. The sound can be silenced by pressingthe ENTER button while viewing Home screen.

Audio AlarmOn

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

Timeout


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Audio Alarm is disabled.Audio Alarm

Off

Circuit breaker auxiliary contact circuit input. This input canbe configured to be normally closed, normally open ordisabled (Not Used).

Cct InputUsed - N/C

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

Bat Switch InputUsed - N/O

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

LVDS InputNot Used

8.5.4 Auxiliary Function Selection & ParametersThe enabling/disabling of auxiliary functions such as AC monitoring, Battery CellMonitoring and Site Monitoring is described below. These screens form the last screensseen when stepping through the MCSU-4 Base Menu.

Press Enter at this screen brings up the auxiliary functionmodule that are supported. Auxiliary Units

Press ENTER

8.5.4.1 Single Phase AC MonitoringWhen the single phase monitoring module is used in the system, the relevant screens areactivated by programming to “On” the 1 ph AC Monitor. If programmed to “Off” neither themonitoring nor the programmable parameter screens shown below will be displayed.

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

1-ph AC MonitorPress ENTER

Displayed when this auxiliary is switched Off.1-ph AC Monitor

OffDisplayed when this auxiliary is switched On.

1-ph AC MonitorOn

AC voltage high level; if any one of the three phases ishigher than the level programmed here, the MCSU-4 willreport an AC Volt Fail alarm;

1ph AC Vhi Alarm260V

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

1ph AC Vlo Alarm192V


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AC Frequency high level; if the AC source frequency ishigher than this value, the MCSU-4 will report an AC FreqFail alarm

1ph AC fhi Alarm55.0Hz

AC frequency low level; if the AC source frequency is lowerthan this value, the MCSU-4 will report an AC Freq Failalarm

1ph AC flo Alarm45.0Hz

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

1ph AC FS Curr.100A

8.5.4.2 Three Phase AC MonitoringWhen the three phase monitoring module is used in the system, the relevant screens areactivated by programming to “On” the 3 ph AC Monitor. If programmed to “Off” neither themonitoring nor the programmable parameter screens shown below will be displayed.

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

3-ph AC MonitorPress ENTER

Displayed when this auxiliary is switched Off.3-ph AC Monitor


3-ph AC MonitorOn

AC voltage high level; if any one of the three phases ishigher than the level programmed here, the MCSU-4 willreport an AC Volt Fail alarm;

3ph AC Vhi Alarm260V

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

3ph AC Vlo Alarm192V

AC Frequency high level; if the AC source frequency ishigher than this value, the MCSU-4 will report an AC FreqFail alarm

3ph AC fhi Alarm55.0Hz

AC frequency low level; if the AC source frequency is lowerthan this value, the MCSU-4 will report an AC Freq Failalarm

3ph AC flo Alarm45.0Hz

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

3ph AC FS Curr.100A


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8.5.4.3 Battery Cell Voltage MonitoringThis function is available only on units fitted with software supporting it. The system mustbe fitted with Battery Cell Monitor modules.

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

Battery MonitorPress ENTER

Displayed when this auxiliary is switched Off.Battery Monitor


Battery MonitorOn

The configuration refers to cell type (2, 4, 6 or 12V) and howthe cells are connected to the monitor - see section 8.10 forfurther information.After pressing ENTER current configuration will flash. Scrollthrough available configurations and press ENTER againonce the correct battery type is chosen.

Battery Config24 cells

Declare number of battery banks to be monitored. Maximumis 4. BCM Batteries

2

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

Cell Vhi Alarm2.48V

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

Cell Vlo Alarm1.44V

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

Cell +dVc Alarm10%

Low differential cell voltage threshold.Cell -dVc Alarm

10%

8.5.4.4 Site MonitorThe site monitor is designed for operation with WinCSU from a PC. However, once set upthe analog signal levels can be viewed and the alarm levels and scale factors can bemodified 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 declaredto be in the Off state, no other menu items are displayed.


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

Site MonitorPress ENTER

Displayed when this auxiliary is switched Off.Site Monitor


Site MonitorOn

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

A1 Inv-V1.2V

If a channel has been declared as alarmed the reading willbe 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 ofinput signal. Scale at 4V

300.0V

Presentation of a digital input window under normalconditions. D2 Window2

Not ActiveThe input is active but not alarmed – word ‘Active’ isflashing. D2 Window2

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

D2 Window2ALARM

Status of output relay 1. Relay is switched off.Output 1

OffStatus of output relay 2. Relay is switched on from aselected source. Will be switched of automatically whencontrolling input returns to normal condition.

Output 2On


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Status of output relay 3. Relay is switched on manually fromWinCSU program. Will remain on until switched offmanually from WinCSU.

Output 3Manual On

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

8.6 SMR Menu ScreensAll information relating to the individual rectifiers is found in the menu activated by pressingthe 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 isfaulty, the screen indicates that the rectifier is notresponding.

SMR1No Response

Warning: It is important to declare the correct number of rectifiers in the rack using theMCSU-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 outputcurrent and heatsink temperature are displayed. PressingENTER once allows additional information to be viewed.

SMR122A 58C

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

SMR1169-3761-46

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

SMR1S/N not avail.

Use INC button to display status of the other rectifiers.This display format is used when a SMR has non-shut downalarms. Pressing ENTER will access list of alarm sourcesdisplayed on the bottom line.

SMR2 21A3 Alarms ENTER

SMR2 21APower Limit

Use INC and DEC buttons to scroll through the list. ...

At the end of the alarm list SMR version number andheatsink temperature are displayed. SMR2 21A

169-3761-46 58C

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 isnot displayed. SMR3

HV Shut DownRead SMR version and heatsink temperature after pressingINC or DEC at previous screen. SMR3

169-3761-46 58C

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

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

SMR Float52.3V

As with the Float Voltage value, the Equalisation Voltageparameter is globally (and indirectly) set in the BATT menuso cannot be changed in this screen. It is set automaticallyto a value equal to the sum of the Sys Equal and Sys Dropvalues set in the BATT menu.

SMR Equalise59.3V

If “ENTER” is pressed while viewing above 2 screens, thefollowing message will appear. SMR Float

Not Adjustable

8.6.1 SMR Menu Programmable ParametersThe remaining screens show the SMR related operating parameters which can bechanged by pressing ENTER.When this is done, the number flashes on and off and can then be incremented ordecremented by pressing the INC or DEC buttons respectively. When the correct value isobtained, 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 isdisplayed, any latched alarm, such as HVSD, is reset andthe unit will restart unless it is damaged or faulty.

Reset SMR FaultPress ENTER

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


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8.6.2 SMR Menu Sleep ModeThe MCSU4 has an optional Rectifier Sleep Mode (RSM) in order to maximize the powerconversion 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 systemand calculate the average Rectifier output power for all Rectifiers on line. The RSMcontinuously works to achieve an actual average Rectifier output power that is within anacceptable range by automatically placing Rectifiers On-Line and into Sleep mode.The RSM calculates the acceptable range (minimum to maximum), centred on the targetpower 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 placeinto 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 shallbe 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 useis configured via the factory configuration file.

The RSM allows for sufficient time after placing a Rectifier On-Line or into Sleep mode inorder for the output of all Rectifiers to settle and the average Rectifier output power to bevalid again. The RSM always ensure that the minimum number of Rectifier to keep On-Line is maintained.The RSM provides a Rotation function to ensure that Rectifiers usage is being kept fairlyeven. 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 acceptablerange 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 afactory 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 andWinCSU-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 ModeOff

SMR Sleep Mode Minimum rectifiers that must be online. Sleep Min SMR4

Max power of each SMR module. For RT4B, rectifiers, this shouldbe set to 1400 as each module is rated for 1.4kW SMR Power Max

1400

SMR Sleep Mode rectifier rotation value (in Days). Sleep Rotation5 Days

SMR Sleep Mode report number of rectifiers sleeping Sleeping SMRs3

SMR Sleep Mode report number of rectifiers online Sleep SMR Online5

SMR Sleep Mode report Average Rectifier % Output Power Sleep Av Power80 %

8.7 Battery Parameter Menu ScreensAll information pertaining to the batteries is accessed by momentarily pressing the Battbutton on the front panel. To return to the MCSU-4 “home” menu at any time, momentarilypress the Batt button.As for the other menus, in general a programmable parameter can be incremented ordecremented by use of the INC and DEC buttons respectively. If this is attempted when amonitored 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

Battery 2 Current; (if present)Battery 2

14A


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

When Bat Temp Sensor condition alarm is enabled and thetemperature sensor is not connected, this message will beshown.

Battery Temp31C

Battery TempNot Available

Battery TempSensor Fail

Estimated Battery 1 state of Charge; this screen shows theestimated 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 valueto which the battery voltage falls to during a discharge. It isused to issue an alarm indicating that the batteries aredischarging.

Batt Disch Alarm45.0V

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

Disch I Diff20A

Battery over temperature alarm level. This is aprogrammable level and can be adjusted in the normal wayby the INC, DEC and ENTER buttons.

Batt Temp Alarm50C

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

500Ah

Battery Temperature Compensation Coefficient in mV perDeg C per Cell is entered in this screen. The allowablerange is 0.1 to 6mV /Cell/°C. If the value is decrementedbelow 0.1, the display will show Off.

BTC Coeff.3.2 mV/C /C

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

BTC Nominal20C


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

Number of Cells24

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 orEQC.

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

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

d) If temperature compensation is activated, the SMR voltage setting is automatically adjusted by theMCSU-4 on a regular basis.

Battery Charging Current Limit applicable for voltages belowVdd. This parameter sets the maximum current which flowsinto the batteries when the voltage across the two batteriesis less than Vdd, the deep discharge voltage.

BILim Vb<Vdd34A

Battery deep discharge voltage - Vdd.Vdd Level

44.0V

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

BILim Vb<Vfl52A

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

54.0V

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

System V Drop0.6V

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

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

EqualisationOn

Battery Charging Current Limit for battery voltages greaterthan the float voltage. This applies when the batteries arebeing equalised.

BILim Vb>Vfl25A

Equalisation Voltage. This sets the maximum voltagereached during equalisation of the batteries. System Equalise

59.5V


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Equalisation not initialised by voltage level.Volts Start Eq

OffEqualisation initialised by voltage level V reached duringbattery discharge. Volts Start Eq

On

Equalisation is initialised when the battery voltage falls tothis level. Volts Eq Trigger

46.0V

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

OffEqualisation is initialised based on charge supplied to theload by the batteries (measured in Ampere-Hours). Q Start Eq

On

Equalisation is initialised when the charge out of thebatteries is greater than the level set in this screen. Q Loss Trigger

10Ah

Equalisation is ended based on the level of battery chargingcurrent set in this screen. EQ End Current

25AIf Equalisation is to end independently of charging current,reduce the value of current in this screen to less than 5% ofthe A/H rating of the batteries (programmed in earlierscreen) and the number will then be replaced by “Off”.

EQ End CurrentOff

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

EQ Duration20 hours

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

EQ Period12 Weeks

Equalisation can be ended manually by pressing ENTERwhen this screen appears. This screen is only obtained ifthe system is in Equalisation mode.

Manual Stop EQPress ENTER

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

Manual Start EQPress ENTER

End of equalisation section.

A Low Voltage Disconnect Switch (LVDS) is oftenintegrated into the system to disconnect the batteries fromthe load in the event that the AC power outage is too long

LVDS Trip44.0V


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causing the batteries to discharge beyond a safe level. Thevoltage level at which the LVDS opens is set in this screen.

When this screen is as shown, the LVDS switch opensautomatically when the voltage drops to the trip level set inthe previous screen.When the AC power is restored and the system outputvoltage rises after the rectifiers start up, the LVDS will closeautomatically.

LVDS ModeAuto

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

LVDS ModeClosed

Press ENTER at the desired state - e.g. Open to open theswitch. LVDS Mode

OpenMenus for Load Shedding are available only on selected models.

Load 1 shedding is enabled.Load 1 Shedding

OnLoad 1 shedding is disabled. The next screen will not bedisplayed. Load 1 Shedding

Off

Bus voltage level at which load 1 will be disconnected. Withthe bus voltage rise this load will be reconnected at level 1Vhigher than this value.

Ld 1 Shed Level47.0V

Load 2 shedding is enabled.Load 2 Shedding

OnLoad 2 shedding is disabled. The next screen will not bedisplayed. Load 2 Shedding

Off

Bus voltage level at which load 2 will be disconnected. Withthe bus voltage rise this load will be reconnected at level 1Vhigher than this value.

Ld 2 Shed Level47.0V

End of Load Shedding menus.

Enable/disable the temperature sensor alarm. If notemperature sensors are present in the system, this fieldshould be set to ‘Off’.

Temp. Sen. AlarmOn

8.8 Battery Discharge TestBattery Discharge Test is available on selected MCSU-4 models.The Battery Discharge Test is a software function in the MCSU-4, which performs aperiodic, controlled battery discharge using the load to discharge the battery. The test canbe used to confirm capacity of the battery in the same way as a manual discharge usingan external load would, except the normal system load is used without disconnection.


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

50A 49.2VBDT in Progress

The system alarms Battery Discharge, Voltage Low, SMR Voltage Low and Low Load willbe 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 givesfaster access to the menus. The screens shown here are in order as INC key was used.

Time interval (in days) between consecutive tests. Settingrange 0 - 365. When set to zero, the automatic execution ofthe test is disabled (the display shows “Off”). The test canbe activated manually from a PC running WinCSU (fromCSU menu). Display messages from 2 to 6 will be shownonly if the test is enabled.

BDT Period14 Days

Time of the day at which the test should start. Programmedin 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 and24 hours), step of adjustment 5 minutes.

BDT Duration1h30min

Current of battery discharge, controlled by MCSU-4.Programmable range 0A - 5000A. To ensure properoperation of this function, the load supplied by the systemduring the test must be greater by at least 10% than desiredbattery discharge current. MCSU-4 will use the rectifiers tosupport surplus load, leaving the battery to supply a userdefined amount of current to the load. If this parameter isset to zero, the control function is disabled and the batterywill discharge under full load current.

BDT Current50A

Batt Disch TestCurrent = Load

End voltage of the test. Battery voltage below which the testwill terminate if reached before desired duration timeexpired.

BDT End V46.0V

MCSU-4 will restore normal operating parameters and startrecharging 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 sameas described in par. 4. Programmable between 25Ah and9995Ah

BDT End Q500Ah

Reset of failed test alarm. This message will be seen only iflast test failed and has not been reset. Pressing ‘ENT’ whileviewing this display will reset the alarm and hide the

BDT Alarm ResetPress ENTER


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message. The alarm can be also reset from a PC usingWinCSU software.

Manual interruption of a battery discharge test. This screenis only visible when a discharge test has been started. BDT in Progress

ENTER to abort

8.8.1 Results of last Battery Discharge Test - (Last BDT)The remaining screen of the Battery Discharge Test gives details of the results of the lastdischarge test. The explanation of codes is as follows:

Not Available. No test has been performed yet.Last BDT

Not AvailableThe test lasted for desired duration without reaching “EndV” or “End Q” levels Last BDT

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

Last BDTFailed

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

AC LostA cell in a battery string discharged below safe level -alarmed, available only when BCM fitted and activated. BDTis flagged as having failed.

Last BDTCell V Low

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

No ControlAborted due to load being too low to control dischargecurrent, not alarmed. Last BDT

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

Last BDTSMR Overload

Terminated manually using MCSU-4 Front Panel or fromWinCSU Last BDT

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

Date of the last test.Last BDT

22/01/2003


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Duration of the testLast 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 timeof 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 recordedb) 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 nextopportunity at the BDT Time.

8.9 Alarms Log ScreensA record of the most recent alarms is kept in the MCSU-4 memory and can be viewed bymomentarily pressing the Alarms Log pushbutton.

Alarm Log Pushbutton pressed - the screen shows thenumber corresponding to where the particular alarm is inrelation to the most recent alarm which is number one,followed by the alarm name as shown in the examplebelow: If the INC button is pressed within two seconds, thesecond alarm will be shown. If pressed again the third alarmappears etc.

LOG 1AC Freq Fault

If the button is not pressed for two seconds a date/timescreen will appear which shows the alarm sequencenumber followed by the date and time at which the alarmoccurred.

10/01/200312:05:26

To clear the alarms log, press ENTER whilst in the AlarmsLog menu and the following screen will appear: DEC to Clear

Log Entries

Press the DEC button as requested and the log will becleared and the following screen will confirm it. LOG

No Entries

8.10 Battery Cell Monitor SetupNote: This function is only available on special versions of MCSU-4 software and appearsas the first option in the Expan2 sub-menu (see section 8.5.4.3 for screen definitions).For 110V and 220V systems, refer to the BCM2/BM3 sections for an appropriateconfiguration table.


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8.10.1 Relationship between “BCM Batteries” and “Num Batteries”With the BCM option enabled, the BCM parameters must be setup before monitoring canbe performed. Following through the screens of section 8.5.4.3, the screen indicating“BCM Batteries” is where you define the number of batteries whose cell voltages are to bemonitored by the MCSU-4. There is no need to program the MCSU-4 how many BCMboards are connected. The MCSU-4 automatically calculates the number of BCM boardsthat it requires from the number of “BCM Batteries” that you entered. The number of BCMboards (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 1 BCM board 2 BCM boards 2 BCM boards


4 cell, 12V 1 BCM board 1 BCM board 1 BCM board 1 BCM board

12 cell, 2V 1 BCM board 2 BCM boards 3 BCM boards 4 BCM boards



2 cell, 12V 1 BCM board 1 BCM board 1 BCM board 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 monitoredfor their currents. “Num Batteries” and “BCM Batteries” are not related except that valueentered for “Num Batteries” must be greater or equal to “BCM Batteries”. This is becauseNum Batteries determines the number of batteries accessible via the BAT menu, via whichwe access the cell voltages. So if only two batteries are defined for Num Batteries, thenaccess to cell voltages of Battery 3 or 4, even if they are defined as 4 in the BCM Batteriesmenu, will not be possible. Normally Num Batteries is set to be the same as BCMBatteries.

8.10.2 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 pollinginterval is 4 minutes, which would yield 15 points for a 1 hour discharge. For programmedtest discharge of 30 minutes a polling interval of 2 minutes might be used. This parameteris not accessible from the MCSU-4 front panel. It is only programmable from a PC runningWinCSU.

8.10.3 Battery Cell MeasurementsWhen BCM is active, the individual cell voltages can be monitors on the MCSU-4 byselecting a Battery from the Batt Menu and pressing ENTER. The cell information willappear on the screen and the next and previous cells can be selected by pressing the INCor 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 2.225Vwhich is deviating +12% from the average cell voltage of thebattery string.

Battery1 Cell012.225V +12%

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

Battery1 Cellmmn.nnnV ±pp%

8.11 Earth Leakage Detector - MUIB3 and MUIB5 onlyNote: This function is only available on 110V and 220V versions of MCSU-4 software andwith special software for 24V and 48V systems. The parameters appear after the BattRated xxAh item in the Battery Menu screens.

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

Earth leakage current: display shows the leakage current toearth in mA; E Leak I

0.2mA

Earth leakage current alarm threshold: this can be set in therange 1.0 to 9.5 mA. E Leak Alm

5.0mA


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9. MaintenanceIn this section some general routine maintenance procedures are described which shouldbe carried out to ensure that the equipment performs to the high reliability standards that ithas been designed to.

9.1 Warnings and precautionsSince the unit utilises high voltages and large storage capacitors, it is imperative to takegreat 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.

9.2 SMR MaintenanceSince the SMRs are fully alarmed and operate in an active loop current sharingarrangement, 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.

9.2.1 Current SharingUnder normal conditions, the output current variation from the average rectifier current byevery rectifier should be within ±2A or ±3%, whichever is less. It is possible however, forinternal loop parameters to change to such an extent that a unit does not share to theextent that it should.If the lack of sharing is extreme then either a CURRENT LIMIT or NO LOAD alarm will beactive 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 checkof the current sharing among the rectifiers can lead to early detection of any units whichmay 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 otherhand, many of the SMRs are not sharing satisfactorily, then the most likely problem area isin the System Controller.

9.2.2 Integrity of Electrical ConnectionsIt is good practice to check all accessible electrical connections at regular intervals toensure that no "hot spots" develop over time due to loose connections. An infra-red "hotspot" detector is very useful for this function.Alternatively, mechanical connections can be checked manually for tightness.

9.2.3 Fan Filter MaintenanceIf fan filters are fitted it is important that they are removed and cleaned on a regular basis.The purpose of a filter is to remove dust from the air but as they become dustier less airflows into the rectifier and eventually overheating of the rectifier can occur. The rectifierswill protect themselves in the event of overheating, and an alarm will be generated


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accordingly. However even a partly blocked fan filter is undesirable because the rectifierswill suffer reduced air flow and will run hotter and have a reduction in their lifetime as aconsequence.To avoid creating a lot of dust in the vicinity of the power plant it is advisable to clean thefilters outside in the open air. It is a better idea to have spare clean filters to replace thedusty ones with, then remove the dirty filters to be cleaned at a convenient time andlocation using appropriate aids.For dusty environments frequent cleaning is required. Even in ‘clean’ environments asurprising amount of dust can appear. To determine the frequency of cleaning the siteshould be monitored for dust build-up.


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10. Fault Finding and Replacement ProceduresThis section describes in some detail the possible causes for alarms that may occur fromtime to time and the procedures that should be followed to clear the alarms and moreimportantly, address the problem or cause of the alarm.It is assumed here that the most that a field maintenance person will do is change acomplete module. It is normally impractical to attempt to repair a particular unit withouttest equipment, which is normally only available in the manufacturer's service laboratory.The recommendation is for complete spare SMR and MCSU-4 units to be kept on site.The fault finding procedures are presented below.

10.1 System Fault Finding ProceduresThe following table outlines suggested procedures to be followed if it is assumed that nointernal repairs of units will be attempted. It is assumed instead that only MCSU-4adjustments and unit replacement will be performed.

Alarm Condition Possible Cause Action SuggestedUNIT OFF No AC power to SMR Check AC supply to SMR; if necessary

reset CB supplying SMR

Faulty SMR Replace SMR

Equalise Mode Equalisation cycle in progress due torecent AC power failure, periodic ormanual 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 obviousproblem; replace SMRs if necessary

All SMRs off due to incorrect Inhibitsignal from MCSU-4

Replace MCSU-4

One or more SMRs in Current Limit Check Current Limit settings and adjust ifnecessary; or batteries being recharged

SMR Alarm Any of the above or non critical problemwith one or more SMRs

Select SMR menu. Check status ofSMRs which are flashing alarm LED.

AC Fail (SMR alarm) Total AC power failure or AC voltage notwithin operating limits

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

Cct Breaker External Fuse or CB has blown ortripped

Check external feeds

Wire or connector loose on BDM Check MUIB connections and tighten

Battery Switch Any one of 2 battery switches is open Close if appropriate

Bad connection to BDM 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 MCSU-4 backplane isfaulty

Repair connection

Set point is too low Check Amb Temp High threshold leveland re-adjust if necessary


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Alarm Condition Possible Cause Action SuggestedBatt Temp High Battery temperature higher than pre-set

levelCheck battery temperatures and ifnecessary increase ventilation andcooling

Set point is too low Check Batt Temp High threshold leveland re-adjust if necessary

Temp Sensor N/A Temperature Sensor in MCSU-4 notattached or faulty

Plug in temperature sensor if required;Replace temperature sensor

Faulty connection(s) to MCSU-4backplane

Replace MCSU-4 interface card

Faulty MCSU-4 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 batterypower

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 Inhibitsignal, system on battery power

Check reason for signal; if necessaryreplace MCSU-4

Battery charging current limiting due tofaulty battery current signal - this willdepress float voltage

Check battery currents. If one of themshows figure higher than Batt Chg CurrLim set point, check correspondingcurrent transducer; check connections totransducer; check BDM connections

Battery Temperature Compensation toohigh due to faulty battery temperaturemonitoring

Check battery temperature readings inBatt menu; Check and if necessaryreplace faulty sensor; check connectionto MCSU-4 backplane.

Battery Temperature Compensation toohigh due to faulty MCSU-4 backplane

Replace MCSU-4 backplane

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 sharingload current

Communications link malfunctioning orfaulty rectifier (digital current control)

Replace Comms cable and/or SMR

Faulty MCSU-4 voltage and currentcontrol loop IODEM signal (analog activecurrent control)

Replace MCSU-4

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

Check and re-adjust Float or Equaliselevel on MCSU-4

No Response SMR not responding to MCSU-4 Check and if necessary replace commscable at back of magazine faulty

Faulty microprocessor card in SMR Replace SMR

Power Limit Unit not current sharing (if only oneshowing power limit)

Replace SMR

Load current too high (if more than one Reduce load


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Alarm Condition Possible Cause Action Suggestedunit showing alarm) Reduce battery charging current limit if it

is too high

No Load Load circuit breakers have tripped andthere is no load

Reset circuit breakers

If only one unit showing alarm, commsline 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 thanone unit showing alarm

No action required

If only one unit shows alarm, internalcontrol 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 entiremicroprocessor 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 voltagelevel due to no AC power

Check AC voltage and reset if possible

Battery voltage OK In BATT menu check if LVDS mode isset 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 coefficientset too high

Set correct temperature compensationcoefficient

Faulty MCSU-4 backplane or MCSU-4 Replace MCSU-4 backplane or MCSU-4

Sys Volts Low Volts Low threshold in MCSU-4 too high Reset level to correct value

Temperature compensation coefficientset too high

Set correct temperature compensationcoefficient



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Alarm Condition Possible Cause Action SuggestedBattery 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 Mains Monitor Replace Mains Monitor unit

Auxiliary board, MCSU-4 backplane orMCSU-4 faulty

Replace Auxiliary board, MCSU-4backplane or MCSU-4

Communications link failure

(Only on systems not fitted with ACmonitoring module)

In SMR menu check status of all SMRs.If all show “No Response” check 4-waycommunications cable between MCSU-4and 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 Mains Monitor Replace Mains Monitor unit


Batt I-Limit Battery charging current is being limitedto preset value

No action necessary

Battery current limit set too low Set correct limit

Battery current sensor faulty replace sensor


Batt Sym Alarm One Battery string is faulty Repair/replace battery if necessary

Battery discharge current differentiallevel set too low

Set correct level of Disch I Diff in BATTmenu

Battery current sensor is faulty Check and replace sensor if necessary


Earth Leak Alarm

(Only on systemsfitted with MUIB3)

Excessive Earth current due to eitherfailure of load supply isolation or faultyload equipment.

Locate source of earth leakage currentand correct accordingly.

10.2 MCSU-4 Fault Finding and Repair ProceduresIn addition to performing a supervisory function by monitoring output voltage and currentand the various system alarms, the MCSU-4 also performs a voltage control function inorder 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 suppressthe SMR output voltage to a value lower than the minimum battery voltage.It therefore follows that it is possible for a MCSU-4 fault to occur which can suppress theSMR voltage to that low level and thus cause a battery discharge despite the precautionsthat have been taken to ensure that this does not happen.


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In such a situation disconnecting the 10-way ribbon cable, which connects theSMRs to the MCSU-4, will remove the voltage suppressing communications controlsignal and thus avoid the batteries discharging. Alternatively, the MCSU-4 can bepulled out of the magazine to achieve the same result. Without the MCSU-4connected, the SMRs will revert to their pre-set Float voltage and passive currentsharing.The MCSU-4 backplane has a number of connectors therefore it is worth checking for poorconnections when a MCSU-4 system problem is being investigated.

10.2.1 Replacing MCSU-4The MCSU-4 is “hot-swappable”, so replacing a faulty unit is simply a matter of pulling thebad unit out of the MCSU-4 magazine and plugging a new unit in. The new unit will thenpower up and automatically read the system parameters stored in the non-volatile memorylocated on the backplane. The system parameters should then be checked via the frontpanel menus or using WinCSU.

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