Valere Power Installation and Maintenance Manual Mini DC Power

Valere Power Installation and Maintenance Manual Mini DC Power
Mini DC Power System
HJ-series Mini Shelf
24 x7 Installation and Technical Support
1-866-240-6614
Page 1 of 49
DO600000079
Version 2.4
June, 2006
Table of Contents
1
Safety and Recommended Practices........................................................................ 3
1.1
1.2
General practices ......................................................................................................................... 3
FCC Compliance Statement ........................................................................................................ 4
Product Section ......................................................................................................... 5
2
2.1
2.2
2.3
DC Output Voltage...................................................................................................................... 5
AC Input requirements ................................................................................................................ 5
DC output wire requirements ...................................................................................................... 9
3
Torque settings ........................................................................................................ 12
4
Required Tools ........................................................................................................ 13
5
Site and Equipment Preparation........................................................................... 13
Power Plant Mounting and Wiring ....................................................................... 13
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
7
Mechanical mounting ................................................................................................................ 13
AC input .................................................................................................................................... 14
DC output .................................................................................................................................. 16
Reference Ground...................................................................................................................... 20
Breaker Installation ................................................................................................................... 20
Temperature Probes................................................................................................................... 21
Alarm connections..................................................................................................................... 21
Auxiliary Input Alarms ............................................................................................................. 21
Test and Turn-Up ................................................................................................... 22
7.1
7.2
7.3
8
Power up.................................................................................................................................... 22
Controller setup ......................................................................................................................... 23
Alarm Setup/Relay Test ............................................................................................................ 24
Controller features.................................................................................................. 25
8.1
8.2
8.3
8.4
8.5
8.6
8.7
Battery Discharge Test (BD Test) ............................................................................................. 25
Boost Test.................................................................................................................................. 26
Battery Current Limit (BATT CL) ............................................................................................ 27
Rectifier Current Limit (RECT CL) .......................................................................................... 27
Fallback ..................................................................................................................................... 27
Battery Charge/Discharge Current ............................................................................................ 28
Adjustment examples ................................................................................................................ 28
Replacement Items.................................................................................................. 32
9
9.1
10
Controller .................................................................................................................................. 32
Troubleshooting .................................................................................................. 33
Appendix A ...................................................................................................................... 39
Page 2 of 49
DO600000079
Version 2.4
June, 2006
1 Safety and Recommended Practices
1.1
General practices
For use in restricted access locations only.
Suitable for mounting on concrete or other non-combustible surfaces
This product accepts an AC Voltage
between 100 and 240 VAC (±10%),
47 to 63 Hz, and produces a
regulated output of 10.5-14VDC, 2128 VDC, or 42-56 VDC (depending
upon deployed rectifiers) capable of
delivering a max of 125 Amperes DC
for 12 V rectifiers, 24 V rectifiers, or
48V rectifiers in an ambient
operating temperature range of 40oC to +50oC (depending upon
deployed rectifiers). HAZARDOUS
VOLTAGE AND ENERGY LEVELS
ARE PRESENT WHICH CAN
PRODUCE SERIOUS SHOCKS
AND BURNS. Only authorized,
qualified, and trained personnel
should attempt to work on this
equipment. Refer to datasheets for
full product specifications.
Observe all local and national
electrical, environmental, and
workplace codes.
Each power shelf should be fed from
a dedicated AC branch circuit of a
TN power system.
If a line cord(s) is (are) used as the
AC connection means, the plug end
of the cord is considered to be the
primary disconnect means, and
reasonable access must be given to
the plug and receptacle area. The
receptacle must be fed with a
breaker or fuse according to Table 4.
Page 3 of 49
DO600000079
For hard-wired AC connections, a
readily accessible disconnect device
shall be incorporated in the building
installation wiring. Select a wall
breaker and wire sizes according to
Table 4.
CAUTION: ALL RECTIFIERS
EMPLOY INTERNAL DOUBLE
POLE/NEUTRAL FUSING
Use double hole, UL listed lugs for
all DC connections to prevent lug
rotation and inadvertent contact with
other circuits.
Class 1 wire is recommended for all
DC connections. Minimum wire
sizes are shown in Table 6. In
practice, loop voltage drop
considerations will usually dictate
larger than minimum safe wire size.
The alarm contacts are rated for a
maximum voltage of 60 V, SELV
(Safety Extra Low Voltage) and a
maximum continuous current of .5A.
Connection and mounting torque
requirements are listed in Table 8.
Valere does not recommend
shipping the power shelf with the
rectifiers installed. Rectifiers should
be shipped in separate boxes
provided by Valere Power.
Version 2.4
June, 2006
1.2 FCC Compliance Statement
Note: This device complies with Part 15 of FCC Rules. Operation is subject to the following
two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that
may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense.
1.2.1 Warning
Changes or modifications to this unit not expressly approved by the party
responsible for the compliance could void the user's authority to operate this
equipment.
Page 4 of 49
DO600000079
Version 2.4
June, 2006
2 Product Section
2.1
DC Output Voltage
Table 1 shows the DC voltage range and max current for each model of rectifier
for this system.
2.2
Model #
H0500A1
H0750A1
H1000A1
H1250A1
H1500A1
H2000A1
H2500A1
Input Voltage
100 Vac - 240 Vac
100 Vac - 240 Vac
100 Vac - 240 Vac
100 Vac - 240 Vac
200 Vac - 240 Vac
200 Vac - 240 Vac
200 Vac - 240 Vac
Output Voltage
42 Vdc - 56 Vdc
42 Vdc - 56 Vdc
42 Vdc - 56 Vdc
42 Vdc - 56 Vdc
42 Vdc - 56 Vdc
42 Vdc - 56 Vdc
42 Vdc - 56 Vdc
Output Current
10 amps
15 amps
20 amps
25 amps
30 amps
40 amps
50 amps
H1250B1
100 Vac - 240 Vac
21 Vdc - 28 Vdc
50 amps
H0750C1
H1250C1
100 Vac - 240 Vac 10.5 Vdc - 14 Vdc
100 Vac - 240 Vac 10.5 Vdc - 14 Vdc
Table 1 – DC Output Ranges
60 amps
100 amps
AC Input requirements
2.2.1 AC input voltages
Table 2 shows the required input voltages for the available rectifiers. The
rectifiers under wide line (WL) can be connected to a nominal input voltage
between 100 V & 240V. The rectifiers under high line (HL) can be connected
to a nominal input voltage between 200 V & 240V.
Wide Line (100V
– 240V)
H0500A1
H0750A1
H1000A1
H1250A1
High Line (200V
– 240V)
H1500A1
H2000A1
H2500A1
H1250B1
H0750C1
H1250C1
Table 2 - Rectifier Input Voltages
2.2.2 Heat Dissipation
Table 3 displays the max and typical BTU/hr of heat dissipated for each
rectifier. Max is calculated at minimum AC input, Max Vdc and current
values for the rectifier, and typical is calculated at 240 Vac, typical Vdc and
current values.
Page 5 of 49
Version 2.4
DO600000079
June, 2006
Model
H0500A1
H0750A1
H1000A1
H1250A1
H1500A1
H2000A1
H2500A1
Typical
BTU/hr
249
338
405
451
541
635
794
Max BTU/hr
410
588
704
833
765
897
1106
H1250B1
564
856
H0750C1
445
631
H1250C1
735
992
Table 3 – Heat Dissipation
2.2.3 AC Input Wire Diagrams
This system utilizes a dual or individual feed AC architecture via the rear AC
terminal blocks (Figure 6 & Figure 7).
2.2.3.1
Dual feed
DC Out
Rectifiers
1
2
3
4
Feed 1
AC In
Feed 2
Figure 1 - Dual Feed AC Wiring Architecture
A dual feed architecture powers rectifiers 1 & 3 on AC feed 1 and rectifiers
2 & 4 on AC feed 2. Connect each AC source, sized according to Table 4,
to the rear terminal block seen in Figure 6. The AC terminal block on the
rear of the shelf will accept wire between 24 AWG and 8 AWG, and should
be torqued to 6 in-lbs. Two knockouts are provided for cable entry to the
AC block. Each of these knockouts will accept either a Valere provide AC
cord grip or a nominal size conduit of ¾”.
Page 6 of 49
Version 2.4
DO600000079
June, 2006
2.2.3.2
Individual feed
DC Out
Rectifiers
1
2
3
4
Feed
1
Feed
2
Feed
3
Feed
4
Figure 2 - Dual Feed AC Wiring Architecture
An individual feed architecture powers each rectifier per AC feed.
Connect each AC source, sized according to Table 4, to the rear terminal
block seen in Figure 7. Two knockouts are provided for cable entry to the
AC block. Each of these knockouts will accept a nominal size conduit of
¾”. The AC terminal block on the rear of the shelf will accept wire up to
10 AWG, and connections should be torqued to 6 in-lbs. The individual
AC feed shelf is not designed for use with AC cords, but wire run to the
shelf via conduit.
2.2.4 AC current and cable sizing
To size your AC feeds properly, use the example below. Failure to size the
AC breaker and wiring properly can result in nuisance breaker trips or even
fire. If you anticipate future growth, size the AC breaker and wiring for the
expected future capacity. ALWAYS FOLLOW NEC RULES AND YOUR
LOCAL COMPANY PRACTICES WHEN SELECTING DC WIRING AND
PROTECTION.
1. Use the section above to determine the AC input type, for example a dual
feed.
2. Determine the quantity and model number of the rectifiers, for example
four H1250A1 (48V, 25A), two rectifiers per feed.
3. Determine the AC input nominal voltage and compare with Table 2 for
rectifier compatibility. The H1250A1 rectifier will accept either low line
or high line AC voltage in a range of 100 Vac – 240 Vac.
Page 7 of 49
DO600000079
Version 2.4
June, 2006
4. Using Table 4, this system will require a 50 amp breaker with 8 AWG
wire at low line, and a 20 amp breaker with 12 AWG wire at high line.
NOTE: Under-sizing your AC breaker and wiring could cause
nuisance breaker trips and system outages.
The Table 4 below uses a minimum nominal input voltage to determine AC
current requirements. 90 V corresponds to a nominal low line voltage of
100Vac and 180 V corresponds to a nominal highline voltage of 200Vac.
Number of
Type of feed Rectifiers on
AC Feed
Individual
feed
Dual Feed
1
2
Model
Number of
Rectifier
Minimum
Input Voltage
Maximum
rated AC
Current (A)
Circuit breaker
minimum value to
use (A)
90 °C Minimum Wire
Gauge to use at 30 °C
ambient (AWG)
H0500A1
90
7
15
14
H0500A1
180
3.5
15
14
H0750A1
90
10.4
15
14
H0750A1
180
5.2
15
14
H1000A1
90
13.8
15
14
H1000A1
180
6.9
15
14
H1250A1
90
17.6
20
12
H1250A1
180
8.8
15
14
H1500A1
180
10.3
15
14
H2000A1
180
13.8
15
14
H2500A1
180
16.9
20
12
H1250B1
90
17.4
20
12
H1250B1
180
8.7
15
14
H0750C1
90
11.2
15
14
H0750C1
180
5.6
15
14
H1250C1
H1250C1
90
17.8
20
12
180
8.9
15
14
H0500A1
90
14
15
14
H0500A1
180
7
15
14
H0750A1
90
20.8
30
10
H0750A1
180
10.4
15
14
H1000A1
90
27.6
30
10
H1000A1
180
13.8
15
14
H1250A1
90
35.2
50
8
H1250A1
180
17.6
20
12
H1500A1
180
20.6
30
10
H2000A1
180
27.6
30
10
H2500A1
180
33.8
50
8
H1250B1
90
34.8
50
8
H1250B1
180
17.4
20
12
H0750C1
90
22.4
30
10
H0750C1
180
11.2
15
14
H1250C1
H1250C1
90
35.6
50
8
180
17.8
20
12
Table 4 - Recommended AC Circuit Breaker and Wire Sizes
Page 8 of 49
DO600000079
Version 2.4
June, 2006
2.3
DC output wire requirements
The system is available with multiple distribution options. You can determine
what distribution option you have from the model number of the shelf. The model
number of the shelf can be found on the right side of the system, near the rear.
To determine the circuit number, find the model on the shelf, i.e. Model: HJ19DANL-VV. The third and fourth character (in this case the letter 19) indicates your
DC distribution options of either 19 or 23. Find your corresponding circuit
drawing below.
The system is available with multiple options for an LVD. You can determine if a
system has an LVD or shunt from the model number of the shelf. The model
number of the shelf can be found on the right side of the system, near the rear.
To determine the LVD option, find the model on the shelf, i.e. Model: HJ19DANL-VV. The eighth character (in this case the letter L) indicates whether the
system has only a load LVD1 (L), a battery LVD2 & shunt only (B), both LVD1
and LVD2 (2), or neither (N).
2.3.1 Circuit drawings
2.3.1.1
Circuit 19
1
2
3
4
5
6
7
9
Optional
LVD1
Optional
LVD2
Rectifiers
8
5 Primary Load Circuit
Breaker Connections
Double ¼" Studs, 5/8" centers
1 Battery Circuit
Breaker Connection Double
¼" Studs, 5/8" centers
3 Secondary Load Circuit
Breaker Connections
Double ¼" Studs, 5/8" centers
Reference Ground
Figure 3 - DC distribution (Circuit 19)
Each system is equipped with 9 circuit breaker protected outputs. Breaker 1
is for a battery connection and has the option of being protected by a battery
LVD. Breakers 2 thru 6 are for primary load connections. Breakers 7 thru 9
are for secondary load connections and have the option of being protected
Page 9 of 49
Version 2.4
DO600000079
June, 2006
by a load LVD. Select a wire size for each breaker position according to
breaker current rating as shown in Table 6. The breaker positions 1-9 in the
schematic above correspond to positions 1-9 in Figure 10. All connections
are ¼”-20 studs with 5/8” centers. The maximum tongue width for lugs is
0.75”.
2.3.1.2
Circuit 21
1
2
3
4
Optional
LVD1
and Shunt
Rectifiers
1
2
5
6
Optional
LVD2
14
14 GMT Fuse
Connections
#6-32 Screws
2 Battery Circuit 2 Primary Load 2 Secondary Load
Breaker
Circuit Breaker
Circuit Breaker
Connections
Connections
Connections
Reference Ground
Figure 4 - DC distribution (Circuit 21)
Each system is equipped with 14 GMT fuse and 6 circuit breaker protected
outputs. The 14 GMT load connections are made of #6-32 compression
screws. Select a wire size for each GMT position according to fuse current
rating as shown in Table 5. GMT connections are made on compression
style terminal blocks. The maximum wire gauge for GMT’s is 12 AWG and
connections should be torqued to 6 in-lbs. Breakers 1 & 2 are for battery
connections and have the option of being protected by a battery LVD and
shunt. Breakers 3 & 4 are primary load connections, and breakers 5 & 6 are
secondary load connections and have the option of being protected by a load
LVD. Select a wire size for each breaker position according to breaker
current rating as shown in Table 6. The breaker positions 1-6 in the
schematic above correspond to positions 1-6 in Figure 11. Circuit breaker
connections are ¼”-20 studs with 5/8” centers. The maximum tongue width
for lugs is 0.75”. Torque breaker connections according to Table 8.
Page 10 of 49
DO600000079
Version 2.4
June, 2006
2.3.2 DC Wire sizing
There are two main considerations for sizing DC wire, ampacity and voltage
drop. Ampacity refers to a safe current carrying level as specified by nonprofit organizations such as Underwriters Laboratories and the National Fire
Prevention Association, which publishes the National Electric Code. Voltage
drop is simply the amount of voltage loss in a length of wire due to ohmic
resistance of the conductor. DC wire may be sized for either ampacity or
voltage drop depending on branch load loop length and conductor heating.
In general, ampacity considerations will drive wire selection for short loop
lengths (less than 50 feet) and voltage drop will drive wire selection for long
loop lengths (greater than 50 feet). The National Electric Code table 310.16
provides ampacity values for various sizes, bundles, and insulation
temperature rated wire. ALWAYS FOLLOW NEC RULES AND YOUR
LOCAL COMPANY PRACTICES WHEN SELECTING DC WIRING AND
PROTECTION. Table 6 shows recommended wire sizes.
2.3.2.1
GMT fuse protected connections
DC GMT fuse protected wires shall be based on the protector size rating.
For example, using Table 5 below, a 10 A fuse requires #20 AWG wire.
GMT fuse
Rating (A)
1
2
5
7.5
10
15
Wire Gauge (AWG) using
90° C wire
24
24
24
22
20
18
Single conductor in free air 30° C
ambient temperature
Table 5 – Wire sizing table for fuse protected outputs
2.3.2.2
Circuit breaker protected connections
DC circuit breaker protected wires shall be based on the protector size
rating. For example, using Table 6 below, a 100 A breaker requires #2
AWG wire.
Page 11 of 49
DO600000079
Version 2.4
June, 2006
Current Protector
Rating (A)
5
10
20
30
40
50
60
75
80
100
Wire & Lug Gauge (AWG) using
90° C wire (NEC Table 310.16)
18*
16*
12
10
8
8
6
6
4
2
* - For wire sizes less than 15 A not covered in NEC
Table 310.16 use Table 3B - Sizes of Conductors,
UL60950, "Safety of Information Technology
Equipment", Dec., 2000 for non-building wiring.
Table 6- Wire sizing table for circuit breakers
2.3.3 DC Lug requirements
Table 7 below is a list of lug part numbers from Burndy and ring terminals
from Amp that can be used for circuit breaker. Wire type should be
considered when determining the type of lug to use. These part numbers are
based on flex style cable. Follow your company practices when determining
the exact lug and ring terminals required.
Circuit breaker size or total
output current
10 AMPS
15 AMPS
20 AMPS
30 AMPS
30 AMPS
50 AMPS
75 AMPS
100 AMPS
125 AMPS
Wire AWG
16
14
12
10
10
8
6
2
2
Burndy lug part #
YAV102TC14
YA8CL2TC14
YAV6CL2TC14FX
YAV2CL2TC14FX
YAV2CL2TC14FX
Amp ring part #
321045
321045
323763
323763
Description
SH RING TERMINAL1/4 STUD
SH RING TERMINAL1/4 STUD
SH RING TERMINAL1/4 STUD
SH RING TERMINAL1/4 STUD
DH LUG STANDARD BARREL 1/4 STUD,5/8 CENTER
DH LUG STANDARD BARREL 1/4 STUD,5/8 CENTER
DH LUG STANDARD BARREL 1/4 STUD,5/8 CENTER
DH LUG STANDARD BARREL 1/4 STUD,5/8 CENTER
DH LUG STANDARD BARREL 1/4 STUD,5/8 CENTER
Table 7- Breaker lug part numbers
3 Torque settings
Table 8 recommended torque settings for all mechanical and electrical
connections according to screw or nut size.
Page 12 of 49
DO600000079
Version 2.4
June, 2006
Screw or Torque
Nut Size (in-lbs)
4-40
6-32
8-32
10-32
12-24
¼-20
6
12
22
37
50
65
Table 8- Recommended Torque Settings
4 Required Tools
Valere rectifiers are designed to be installed with a minimum number of
commonly available tools.
• #1 & #2 Phillips and flathead screwdrivers
• Torque wrench
• 5/16” & 7/16” box wrenches, sockets, or nut drivers
• Wire and Cable Strippers
• Wire and Cable Crimpers
5 Site and Equipment Preparation
Before unpacking the DC Power Plant, note any physical package damage that
could indicate potential damage to the contents. After removing DC Power Plant
from boxes and packing material, inspect for shipping and/or other damage.
Contact sales or technical support immediately if any damage is present. Have
all tools, wire, cables, hardware, etc., within easy reach. To the extent possible,
ensure a clean (free of debris, dust, foreign material, etc.) work environment.
Care should be taken in the installation process to prevent exposure of the
equipment to wire clippings. If possible, the rectifiers should remained sealed in
their shipping boxes until the shelf wiring is complete. Ensure all AC and DC
power sources are off and disconnected.
6 Power Plant Mounting and Wiring
6.1
Mechanical mounting
This equipment is intended for normal operations and is to be installed in a
standard 19” telecommunications rack. It is recommended that one person lift
the shelf into place while another installs supplied mounting hardware. Torque
mounting hardware according to Table 8.
Page 13 of 49
DO600000079
Version 2.4
June, 2006
Mounting Brackets
1
3
2
4
Controller
6.2
Figure 5 - HJ-shelf front view
Distribution Door
AC input
6.2.1 Dual Feed
For 110 Vac service, connect your line/hot to “1 Line 2”, labeled on the AC
terminal block shown in Figure 6. Connect your neutral to the slot labeled “1
Line 1”. Connect your ground to the slot labeled ground (colored
green/yellow). This feeds rectifiers 1 & 3. For your second feed connect
line/hot to the slot labeled “2 Line 2”. Connect your neutral to the slot labeled
“2 Line 1”. Connect your ground to the slot labeled ground (colored
green/yellow). This feeds rectifiers 2 & 4. These connections are made with
compression screws, and torque to 13 in-lbs.
For 208/220 Vac service, connect your line/hot to “1 Line 2”, labeled on the
AC terminal block shown in Figure 6. Connect your second line/hot to the
slot labeled “1 Line 1”. Connect your ground to the slot labeled ground
(colored green/yellow). This feeds rectifiers 1 & 3. For your second feed
connect line/hot to the slot labeled “2 Line 2”. Connect your neutral to the
slot labeled “2 Line 1”. Connect your ground to the slot labeled ground
(colored green/yellow). This feeds rectifiers 2 & 4. These connections are
made with compression screws, and torque to 13 in-lbs.
Page 14 of 49
DO600000079
Version 2.4
June, 2006
Feed 2
Feed 1
1 Line 2
1 Line 1
Ground
Knockouts for
¾” conduit
2 Line 2
2 Line 1
Ground
Figure 6 - AC Connections (Dual Feed)
6.2.2 Individual Feed
For 110 Vac service, connect your first line/hot to R1, L1 (rectifier 1, line 1),
labeled on the AC terminal block shown in Figure 7. Connect your neutral to
the slot labeled R1, L2 (rectifier 1, line 2). Connect your ground to the slot
labeled ground (colored green/yellow). Repeat procedure for the remaining
rectifiers. These connections are made with compression screws, and
torque to 13 in-lbs.
For 208/220 Vac service, connect your line/hot to R1, L1 (rectifier 1, line 1),
labeled on the AC terminal block shown in Figure 7. Connect your second
line/hot to the slot labeled R1, L2 (rectifier 1, line 2). Connect your ground to
the slot labeled ground (colored green/yellow). Repeat procedure for the
remaining rectifiers. These connections are made with compression screws,
and torque to 13 in-lbs.
Page 15 of 49
DO600000079
Version 2.4
June, 2006
Ground
Ground
Ground
Knockouts for
¾” conduit
Ground
Figure 7 - AC Connections (Individual Feed)
6.3
DC output
WARNING: It is very important to verify polarity of all connections,
especially batteries, before connecting them to the shelf. A connection
that is hooked up incorrectly can cause the system to not work properly,
damage the shelf, and/or cause bodily harm.
WARNING: Figure 8 illustrates the proper lug orientation for the breaker
connections. Wiring the system improperly can result in bodily harm or
damage to the shelf.
Page 16 of 49
DO600000079
Version 2.4
June, 2006
DC lug
Clear
plastic
DC cover
Figure 8 - Breaker lug direction
6.3.1 Circuit 19
Primary load circuit breaker connections (positions 2 and 6 in Figure 9 &
Figure 10) are accomplished via the rear accessed lug landings as shown in
Figure 10. Circuit breakers can be found behind the distribution door on the
right side of the system when facing it from the front. You should size wire
according to section 2.3.
Secondary load circuit breaker connections (positions 7 and 9 in Figure 9 &
Figure 10) are accomplished via the rear accessed lug landings as shown in
Figure 10. Circuit breakers can be found behind the distribution door on the
right side of the system when facing it from the front. You should size wire
according to section 2.3.
The battery circuit breaker connection (position 1) is accomplished via the
rear accessed lug landing as shown in Figure 10. The battery circuit breaker
can be found behind the distribution door on the right side of the system
when facing it from the front. You should size wire according to section 2.3.
Page 17 of 49
DO600000079
Version 2.4
June, 2006
Install
breakers
here
1
2
3
4
5
6
7
8
9
Figure 9 - Front Distribution View (Circuit 19)
9
8
7
6
5
4
3
2
1
Breaker
outputs
Breaker
returns
Reference
ground
Figure 10 - Rear Distribution View (Circuit 19)
6.3.2 Circuit 21
GMT fused connections are accomplished via the rear accessed
compression screws pointed out in Figure 12. The fuses can be found
behind the distribution door on the right side of the system when facing it
from the front. You should size wire according to section 2.3.
The battery circuit breaker connections (position 1 & 2 in Figure 11 & Figure
12) is accomplished via the rear accessed lug landing as shown in Figure 12.
The battery circuit breaker can be found behind the distribution door on the
Page 18 of 49
DO600000079
Version 2.4
June, 2006
right side of the system when facing it from the front. You should size wire
according to section 2.3.
Primary load circuit breaker connections (positions 3 and 4 in Figure 11 &
Figure 12) are accomplished via the rear accessed lug landings pointed out
in Figure 12. Circuit breakers can be found behind the distribution door on
the right side of the system when facing it from the front. You should size
wire according to section 2.3.
Secondary load circuit breaker connections (positions 5 and 6 in Figure 11 &
Figure 12) are accomplished via the rear accessed lug landings as shown in
Figure 12. Circuit breakers can be found behind the distribution door on the
right side of the system when facing it from the front. You should size wire
according to section 2.3.
1
2
3
4
5
6
Install
breakers
here
Install
fuses here
Figure 11 - Front Distribution View (Circuit 21)
6
5
4
3
2
1
Breaker
outputs
GMT fuse
output
connections
Breaker
returns
GMT fuse
return
connections
Figure 12 - Rear Distribution View (Circuit 21)
Reference
ground
Page 19 of 49
DO600000079
Version 2.4
June, 2006
6.4
Reference Ground
Connect your DC reference ground to the extra position on the return bar, see
Figure 10 (circuit 19) & Figure 12 (circuit 21). Use a double hole lug with ¼”
holes and 5/8” centers.
6.5
Breaker Installation
The breakers installed in the shelves as seen in Figure 13 below are installed
vertically. The breakers must be installed with the “line” bullet connector on top
and the “load” bullet connector on the bottom. “Line” and “Load” are labeled on a
sticker on the side of the breaker (Figure 13).
Line
Load
Figure 13 - Circuit breaker installation
Page 20 of 49
DO600000079
Version 2.4
June, 2006
Expansion Connection
(not in use)
LAN (BC1000
only)
Figure 14 - Controller Connections
6.6
Alarm Cable
Temperature Probes
Up to three battery temperature probes (10’ length) may be installed for battery
temperature compensation. Attach the temperature probe to the battery and
insert the connector end into the mating end on the controller. The temperature
probes are denoted as Temp 1, Temp 2, and Temp 3 from left to right on Figure
14.
6.7
Alarm connections
Six form C contacts are available through a connector directly below the
temperature probes as labeled on Figure 14. The cable from Table 9 can be
used to access these alarm contacts. The cable is 10 feet long (available in 50’
and 100’ lengths), has a shelf mating connector on one end and bare tinned wire
on the other. In section 10, Table 11 shows the alarm matrix.
6.8
Auxiliary Input Alarms
To use the temperature probe input port or the input alarm on the alarm cable
(black and white wire on alarm cable) as an external alarm channel, simply
connect a normally open dry contact relay into any of the input connectors. The
controller will automatically detect a contact closure and set a minor alarm.
If your system is equipped with a BC1000 controller, alarms can be user mapped
through the Ethernet port using the software utility provided by Valere. Refer to
Page 21 of 49
DO600000079
Version 2.4
June, 2006
Application Bulletin 201, “Connecting to the LAN Port”, that is included with the
BC1000 controller, for mapping alarms. See Table 9 for additional information on
the alarm cable and the input connection.
Alarm Cable
CA210203104
Alarm
Channel
Functional
Designation
NC
A
C
(Power
Major)
NO
NC
B
C
(Power
Minor)
NO
NC
C
C
(AC Fail)
NO
NC
D
C
(BD)
NO
NC
E
C
(LVD
Open)
NO
NC
F
C
(Fuse/C
B Open)
Input
Alarm
NO
Input (+)
Input (-)
Wire Color
Orange/White
stripe
Orange
Orange/Black
stripe
Red/White
stripe
Red
Red/Black
stripe
Green/White
stripe
Green
Green/Black
stripe
Yellow/White
stripe
Yellow
Yellow/Black
stripe
Lt Blue/White
stripe
Lt Blue
Lt Blue/Black
stripe
Tan/White
stripe
Tan
Tan/Black
stripe
White
Black
Alarm
Behavior
Contact Opens
On Alarm
Common
Contact Closes
On Alarm
Contact Opens
On Alarm
Common
Contact Closes
On Alarm
Contact Opens
On Alarm
Common
Contact Closes
On Alarm
Contact Opens
On Alarm
Common
Contact Closes
On Alarm
Contact Opens
On Alarm
Common
Contact Closes
On Alarm
Contact Opens
On Alarm
Common
Contact Closes
On Alarm
Closed =
Alarm
Table 9- Alarm Cable color code
7 Test and Turn-Up
7.1
Power up
Once all AC and DC connections have been secured and checked, install each
rectifier sequentially by sliding and latching each rectifier into position as shown
in Figure 15. The rectifier latches must be open for installation. Attempting
to install the rectifiers with the latches closed will result in mechanical
Page 22 of 49
Version 2.4
DO600000079
June, 2006
damage to the rectifiers and the shelf. The rectifiers will start in high fan
speed mode and reduce their speed according to the ambient and plant
conditions within 10 seconds. As each rectifier is installed, the controller
automatically identifies the new rectifier and reconfigures the system. After all
rectifiers have been installed, and if there are no alarms present, the controller
will display “System OK”. If there are alarms present, refer to Section 10 for
troubleshooting assistance. Note: An LVD alarm will be present initially (if the
optional LVD is installed) and will clear after the pre-programmed LVD reconnect
time (20 seconds typical) has elapsed.
Open Latch
Figure 15 - Rectifier Insertion
7.2
Controller setup
The controller is factory equipped with default settings as shown in Table 10 to
assure safe power up operation. Figure 16 shows the controller front display and
three button keypad and Appendix A contains the complete menu tree for the
controller. The UP and DN buttons are used to scroll through the functions and
the MENU button is used to select and/or drop down into a sub-menu.
Page 23 of 49
DO600000079
Version 2.4
June, 2006
Figure 16 - Controller Display
There are three controller menu levels, basic, main/review, and config
(administrator). When the controller displays “System OK”, the controller is at the
basic menu level. The UP/DN buttons can be used to sequentially view basic
plant parameters such as float voltage and plant current, battery temperature
(N.C. if not connected), and internal plant temperature. Alarm descriptions are
also found in the basic menu when an alarm is present. By holding the MENU
button down for 5 seconds, the main level is accessed. All plant parameters can
be viewed from this level by scrolling to and selecting “CHOOSE: REVIEW.”
Follow the menu tree in Appendix A for exact navigation directions. By scrolling
to and selecting “Log In”, the Administrator level is accessed. The default
password is “5001”. This level allows you to make changes to all the plant
settings. Follow instructions in section 8.7 for logging into the controller.
If the system is equipped for LAN communications, please refer to the CD and
“Quick Start Guide” packed with the system.
7.3
Alarm Setup/Relay Test
Valere has provided a relay test feature to help verify that the alarm connections
are setup properly. Once you have connected the alarm cable to your alarming
cross connect (or you can verify using an ohm meter), log into the controller as
an administrator following the steps in section 8.7. Once logged in, press the UP
button to move to CHOOSE: >CONFIG and press the MENU button to enter the
configuration menu. Again press the UP button until you see the >CONFIG
TESTS menu and press the MENU button to enter the TESTS submenu. Press
the UP button to move to RLY TEST DISABLE, and press the MENU button to
ENABLE the test. After the feature has been enabled, press the UP button to
Page 24 of 49
Version 2.4
DO600000079
June, 2006
move to RELAY A INACTIVE, and press the MENU button to activate the relay.
You should now see an alarm or a change of state on relay A. If you do not see
an alarm or a change of state on relay A, verify connections. If you still do not
receive an alarm call Valere Tech Support. If you do see an alarm, press the
MENU button to inactive relay A, and move on to the next relay and repeat above
directions for all relays. Before exiting, verify that all relays are set to inactive.
Follow the controller menu tree in appendix A for help navigating through the
controller.
8 Controller features
Below is an overview of some of the features on your Valere controller. Some
features require a battery LVD, but not all systems have a battery LVD. See
section 2.3 to determine if you have an LVD.
All features require administrator level access to adjust settings. Please see
steps for logging into the controller in section 8.7. The default administrator login
is ‘5001’.
8.1
Battery Discharge Test (BD Test)
The battery discharge test allows the user to test the capacity of the installed
batteries while keeping the system online. Feature requires logging into the
controller with administrator level access to adjust any setpoints. To adjust any
of the values, proceed to the TEST submenu under the CONFIG menu. Follow
the controller menu tree in appendix A under the Administrator title for help
navigating to the setpoints and adjusting the setpoints.
Once the feature is enabled, the test can be run from the REVIEW menu. See
appendix A for a controller menu tree for navigation to the TEST submenu under
the REVIEW menu (No login required). To run the test, proceed to the TEST
submenu under the REVIEW menu. Once you have entered the TEST submenu
proceed to EXECUTE BD TEST and press the MENU button. The controller will
then display START BD TEST. Press and hold the MENU button for about 1 to 2
seconds. The controller will automatically return to the basic menu, and display
BD TEST ACTIVE for the duration of the test. Once the test is complete the test
results can be reviewed from the basic menu as seen in Figure 17.
Page 25 of 49
DO600000079
Version 2.4
June, 2006
>REVIEW
BD TEST
Press MENU to
enter submenu
BD TEST
RESULTS
Results = PASS,
FAIL, or ABORT
Up
BDT TIME
MNT = xx
The specified length
of time in minutes the
test is scheduled to
run
Up
BDT RUN T
MNT = xx
The actual length of
time in minutes the
test ran
Up
BD START
V = xx.xx
The battery
voltage at which
the test started
Up
BD END
V = xx.xx
The battery
voltage at which
the test ended
Up
HIT MENU
TO CLEAR
Hit the MENU button
to clear the results &
return to basic menu
Up
Up
>EXIT
RESULTS
Hit the MENU
button to exit
back to the basic
menu.
Figure 17 - BD Test result menu tree
8.2
Boost Test
The boost test allows the user boost the float voltage in order to boost charge
and equalize the battery cell voltages. This feature requires logging into the
controller with administrator level access to adjust values. Once logged onto the
controller, proceed to the TEST submenu under the CONFIG menu. Follow the
controller menu tree in appendix A under the Administrator title for help
navigating to the setpoints and adjusting the setpoints.
Once the feature is enabled, the test can be run from the REVIEW menu. See
appendix A for a controller menu tree for navigation to the TEST submenu under
the REVIEW menu. To run the test, proceed to the TEST submenu under the
REVIEW menu (no login required). Once you have entered the TEST submenu
proceed to EXECUTE BOOST and press the MENU button. The controller will
then display START BOOST. Press and hold the MENU button for about 1 to 2
seconds. The controller will automatically return to the basic menu, and display
BOOST ACTIVE for the duration of the test. Once the test is complete the
voltage and basic menu will return to normal. Boost will be aborted if any alarm
except HVA is activated.
Page 26 of 49
Version 2.4
DO600000079
June, 2006
8.3
Battery Current Limit (BATT CL)
Feature requires a battery LVD or shunt to be visible on the display. The battery
current limit works by monitoring the battery current through the shunt. As the
batteries draw more current and the current approaches the user set battery
current limit, the controller will reduce the float voltage to maintain the user set
battery current limit. The controller monitors the adjusted float voltage and will
maintain a safe threshold to avoid a nuisance disconnect of the battery contactor.
NOTE: Activating BCL on a system with an equipment load in series with a
battery LVD could cause the equipment to shut down. Only use BCL with
batteries connected in series with a battery LVD.
The feature can be found under the SETPOINTS submenu. This feature requires
logging into the controller with administrator level access to adjust values. Once
logged onto the controller, proceed to the SETPOINTS submenu under the
CONFIG menu. Follow the controller menu tree in appendix A under the
Administrator title for help navigating to the setpoints and adjusting the setpoints.
8.4
Rectifier Current Limit (RECT CL)
In rectifier current limit mode, the controller sets a maximum current limit for each
individual rectifier at a lower point than the maximum rating of the rectifier
module. This in effect will limit the total plant current to a maximum limit.
The feature can be found under the SETPOINTS submenu. This feature requires
logging into the controller with administrator level access to adjust values. Once
logged onto the controller, proceed to the SETPOINTS submenu under the
CONFIG menu. Follow the controller menu tree in appendix A under the
Administrator title for help navigating to the setpoints and adjusting the setpoints.
If this value is set below the load current draw, the rectifier can go into current
limit and shut down. Restart the rectifiers by removing the load and adjust the
setpoint to an appropriate value.
8.5
Fallback
Fallback is a feature that when enabled will allow the rectifiers to revert to a safe
known voltage when communication is lost with the controller. There is a delay
of 1 minute for the voltage to revert back to the Fallback value. This feature
requires logging into the controller with administrator level access to adjust
values. Once logged onto the controller, proceed to the SETPOINTS submenu
under the CONFIG menu. Follow the controller menu tree in appendix A under
the Administrator title for help navigating to the setpoints and adjusting the
setpoints.
Page 27 of 49
DO600000079
Version 2.4
June, 2006
8.6
Battery Charge/Discharge Current
This feature requires a battery LVD to be active. This value will be displayed
only if an LVD or shunt is installed in your system. Note: Connecting an
equipment load in series with a battery LVD will cause that load current to
show here as battery current. Only connect batteries in series with a
battery LVD.
From the SYSTEM OK menu, press the UP button once, and the controller will
display the system voltage and current. This current value is only the current to
the load. Press the UP button again, and the controller will display the battery
charge or discharge current. This will be the current value through the LVD or
shunt.
8.7
Adjustment examples
The following examples are just samples of how to navigate the Valere controller.
They should give you some basic understanding of how to navigate through the
menus. Use these examples and the controller menu tree in appendix A to
navigate and change values through the entire controller.
1. View plant voltage and current (Basic Menu)
• With the display showing “System OK”, press UP button once.
• Controller will display plant Voltage and Current.
2. View LVD (optional) settings
• With display showing “System OK”, press and hold MENU button for 5
seconds. Controller will display WELCOME and profile number for 5
seconds.
• Scroll to CHOOSE: >REVIEW and press MENU. Software version is
displayed.
• Scroll to >REVIEW LVD and press MENU.
• Scroll through LVD STATUS, LVD WARNING VOLTAGE, LVD OPEN
VOLTAGE, LVD RECONNECT VOLTAGE, RECONNECT TIME DELAY,
and >EXIT LVD.
• Press MENU to exit.
• Scroll to >BACK TO MAIN MENU and press MENU.
• Scroll to CHOOSE: >EXIT and press MENU. “SYSTEM OK.”
3. Administrator Login
• With display showing “System OK”, press and hold MENU button for 5
seconds.
• Scroll to CHOOSE: >LOGIN and press MENU. Display is PASSWORD >0000<, and first 0 flashes.
• Press MENU to change first digit to desired value. Each press of the
MENU button advances by one. Pressing UP selects that value for the
Page 28 of 49
DO600000079
Version 2.4
June, 2006
first digit, which stops flashing, and advances to the second digit, which
will begin to flash.
• Repeat procedure above for all four digits.
• Press UP to select <, which will then flash, and press MENU.
• Controller displays OK: ADMIN for 5 seconds.
4. Change temperature compensation
• Follow directions above for logging into the controller
• Scroll to CHOOSE: >CONFIG and press MENU.
• Scroll to T COMP: DISABLE and press MENU to ENABLE.
• Scroll to T START, press MENU and controller will display CHOOSE:
T=35C.
• Press UP/DN buttons to change T START and press MENU to select.
• Scroll to T SLOPE and repeat MENU to select, UP/DN to modify, and
MENU to select for T SLOPE, STOP VOLTAGE and T SENSE.
• Scroll to >BACK TO MAIN MENU and press MENU.
• Scroll to >EXIT and press MENU. “SYSTEM OK>”
The values in Table 10 are based on the Valere default controller with profile
number 01 (PN 01). Your profile number may be different and can be
determined by accessing the main menu. The main menu can be accessed by
pressing the MENU button down for 5 seconds. The controller will then display
“WELCOME PN XX”; this is your profile number. Contact Valere tech support at
1-866-240-6614 for a copy of your company’s controller settings if different from
profile # 01.
Page 29 of 49
DO600000079
Version 2.4
June, 2006
12 Volt
Nominal
24 Volt
Nominal
48 Volt
Nominal
Valere
Valere
Valere
Parameter
Description
Default
Default
Default
LANGUAGE
The language in which the controller will
display
English
English
English
FLOAT V
The voltage to which the rectifiers will
regulate the plant during float mode
12 Vdc
27 Vdc
54 Vdc
BATT. CL status
Enables the battery current limit feature
Disabled
Disabled
Disabled
BATT. CL I
The controller will limit the current to the
batteries at this setpoint
600 A
600 A
600 A
RECT. CL status
Enables the system current limit feature
Disabled
Disabled
Disabled
RECT CL I
The controller will limit the current of the
rectifiers to the value
200 A
200 A
200 A
FALLBACK
status
Enables or Disables the Fallback feature.
Fallback provides a safe voltage to which the
rectifiers will output when they lose
communication with the controller for more
than one minute.
Disabled
Disabled
Disabled
FALLBACK V
The safe voltage to which the rectifier will
fallback to in the event communication is lost
with the controller for more than one minute
11 Vdc
24 Vdc
50 Vdc
14 Vdc
29 Vdc
58 Vdc
13 Vdc
28.25 Vdc
57 Vdc
HIGH V
The controller will shut down the rectifiers if
the plant voltage exceeds this setpoint
The controller will issue a High Voltage
Alarm if the plant voltage exceeds this
setpoint
BD ALARM
The controller will issue a Battery-OnDischarge alarm if the plant voltage falls
below this setpoint
11 Vdc
24 Vdc
48 Vdc
LVD WARN V
The controller will issue a Low Voltage
Warning if the plant voltage falls below this
setpoint
10 Vdc
22 Vdc
44 Vdc
Disabled
Disabled
Disabled
Enabled
Enabled
Enabled
HVSD
I SHARE status
An alarm is set if the number of installed
rectifiers will not support N+1 redundancy
required by the load.
A minor alarm is set if the output current of
any rectifier exceeds current sharing
tolerances
COM FAIL
status
An alarm is set if any rectifier either stops
communicating or is removed from the shelf.
User action is required to clear the alarm
Disabled
Disabled
Disabled
BOOST status
Enables or Disables the boost charge tests.
The boost feature will increase the output
voltage of the rectifiers for a short period of
time, usually to charge the batteries.
Disabled
Disabled
Disabled
BOOST V
The voltage at which the boost charge test will
increase to once the feature is activated
13 Vdc
28 Vdc
56.5 Vdc
BOOST H
The length of time the boost charge test will
run
12 hours
12 hours
12 hours
CAPACITY
status
Page 30 of 49
DO600000079
Version 2.4
June, 2006
12 Volt
Nominal
24 Volt
Nominal
48 Volt
Nominal
Valere
Valere
Valere
Parameter
Description
Default
Default
Default
BD TEST status
Enables or Disables the battery test
Disabled
Disabled
Disabled
BDT TIME
MNT
Sets the length of time (minutes) that the
battery test will run.
30 min
30 min
30 min
BDT ALRM V
Sets the voltage at which an alarm will be
generated if the battery voltage falls below it
during the battery test
10.5 Vdc
26 Vdc
52 Vdc
BD ABRT V
The voltage at which the battery discharge test
will abort at when the system voltage drop
below this point.
LVD 1
OPEN +
1V
LVD 1
OPEN +
1V
LVD 1
OPEN +
1V
BD TEST
CONST
Sets the alarm constant for the Bat Test. 0 will
disable Thermal Compensation effects during
BD Test. 1 will take Thermal Compensation
effects into account during test
0
0
0
RLY TEST
Enables or Disables the relay test. Relay test
allows the user to activate alarm relay contacts
A-F.
Disabled
Disabled
Disabled
T COMP status
Enables thermal compensation. Thermal
compensation adjusts the float voltage of the
rectifiers to increase or decrease the
temperature of the batteries.
Disabled
Disabled
Disabled
T START T
The high temperature at which the controller
activates thermal compensation
35 °C
35 °C
35 °C
T SLOPE T
The slope value at which the controller will
reduce the float voltage per degree if thermal
compensation is active
18 mV/°C
36 mV/°C
72 mV/°C
STOP VLT V
The minimum voltage to which the controller
will reduce plant voltage for thermal
compensation
11.25 Vdc
25.25 Vdc
50.5 Vdc
T SENSE
Selects temperature sensing device to use for
battery temperature compensation; Internal
sensor or External temp probes. The
controller will autosense when external probe
is attached and automatically adjusts value to
external.
External
External
External
TL START T
The low temperature at which the controller
activates thermal compensation
-20 °C
-20 °C
-20 °C
TL SLOPE T
The slope value at which the controller will
increase the float voltage per degree if low
thermal compensation is active
0 mV/°C
0 mV/°C
0 mV/°C
STOP VLT V
The maximum voltage to which the controller
will increase the plant voltage for thermal
compensation
12.75
Vdc
28 Vdc
56 Vdc
T RUNAWY T
The temperature at which the controller will
activate thermal runaway
60°C
60°C
60°C
Page 31 of 49
DO600000079
Version 2.4
June, 2006
12 Volt
Nominal
24 Volt
Nominal
48 Volt
Nominal
Valere
Valere
Valere
Parameter
Description
Default
Default
Default
T RUNAWY V
The voltage to which the rectifiers will reduce
for temperatures above T RUNAWY T
11 Vdc
25 Vdc
50 Vdc
TEMP IS
Selects the units the temperature readings are
given in. Either Celsius or Fahrenheit
Celsius
Celsius
Celsius
LVD x OPEN
V**
The system LVD contactor will open if the
plant voltage falls below this setpoint. x = 1-4
for systems with multiple LVDs
9.5 Vdc
21 Vdc
42 Vdc
LVD x RCNT
V**
The system LVD contactor will reconnect if
the plant voltage exceeds this setpoint. x = 1-4
for systems with multiple LVDs
11.5 Vdc
25 Vdc
50 Vdc
LVD x RCNT
SEC**
The amount of time, in seconds, that the plant
voltage must exceed the LVD reconnect
setpoint prior to reconnecting the LVD
contactor. x = 1-4 for systems with multiple
LVDs
20 Sec
20 Sec
20 Sec
RNG AC V***
AC voltage setpoint for the ringer output
86 Vac
86 Vac
86 Vac
RNG DC V***
The DC value at which the Ringer RMS value
is offset. The value should be the same value
as the float voltage.
-Vfloat
-Vfloat
-Vfloat
Output frequency of the ringer
20 Hz
20 Hz
20 Hz
High temperature value at which the
controller will trigger a HIGH TEMP alarm.
Accessed via the LAN card only.
98 °C
98 °C
98 °C
The temperature value at which the controller
will release a HIGH TEMP alarm. Accessed
via the LAN card only.
93 °C
93 °C
93 °C
Administrator/User
5001
5001
5001
RNG FREQ
HZ***
High
temperature
alarm threshold
(BC1000 only)
High
temperature
alarm release
(BC1000 only)
Password
* - Requires LVD and/or proper Shunt
** - Requires LVD
*** - Requires Ringer
Table 10- Controller Settings
9 Replacement Items
The controller is designed as modular, field replaceable units. The following
sections outline the procedure to replace it.
9.1
Controller
In the event of a controller failure, the system will remain at the last known
settings, unless fallback is enabled, until a new controller is installed. To replace
the controller, remove the display by releasing the spring latch as shown in
Page 32 of 49
DO600000079
Version 2.4
June, 2006
Figure 18. Loosen the controller set screw and slide the controller out of the
shelf. Insert a new controller and tighten set screw. Follow the controller set-up
procedure in section 7.2 to re-initialize the system. NOTE: The rectifiers will
change to the new controller settings upon installation. Any settings
changed from the defaults will have to be reset.
Spring Latch
for display
removal
Set screw for
controller
removal
Figure 18 - Controller Removal
10 Troubleshooting
The modular, plug-n-play nature of this plant makes diagnostics and repair very
easy. For all conditions listed in Table 12, the controller will display the indicated
alarm. The corresponding Form C relay will also toggle to the alarm state.
Once an alarm is received via the Form C relays use Table 11 to determine
which alarm has been activated. Once in front of the system scroll up through
the menu to determine the specific activated alarm, see menu tree in Figure 19.
Then use Table 12 to determine what that alarm means and how to resolve the
problem.
Make sure that all rectifiers are properly seated and latched into their respective
slots. Make sure that all power and signal connectors are properly mated.
Note that the system over-temperature alarm is only available on the BC1000
controller via the web interface. Also in the event of a loss of power to the
controller all six relay contacts will show an alarm.
Page 33 of 49
DO600000079
Version 2.4
June, 2006
SYSTEM
ALARM**
Up
V = xx.xx
I = xx A
Up
BATT. DIS*
I = xx A
Up
SUMMARY
ALARM
A summary alarm is a
Major or Minor alarm
Up
SPECIFIC
ALARM
Any and
all active
alarms
will
show
here
Up
ADDITIONAL
ALARMS
Up
BATTERY
T1=xx C
N.C. if no probe
is connected
Up
BATTERY
T2=xx C
N.C. if no probe
is connected
Up
BATTERY
T3=xx C
N.C. if no probe
is connected
Up
Up
INTERNAL
T= xx C
* Shown only if LVD or Shunt is present
** Will be SYSTEM OK if no alarms are present
Figure 19 – Alarm menu tree
Page 34 of 49
DO600000079
Version 2.4
June, 2006
(F
)
)
ar
m
Al
st
Di
Op
en
(D
ar
m
Al
BD
LV
D
)
(C
Fa
il
(E
)
B)
we
rM
Po
AC
in o
r(
(A
)
ajo
r
M
Po
we
r
No Failures
Single Module Failure
Multi Module Failure
Battery on Discharge
AC Fail
LVD Warning
LVD Open
Distribution Alarm
System Communication
Alarm
Rectifier Current Share
Alarm
System Redundant
Capacity Alarm
Auxiliary Alarm
System Over Temperature
BD Test Fail
Thermal Runaway
Single Ringer Fail Alarm
Multiple Ringer Fail Alarm
High Voltage Alarm
High Voltage Shut Down
= RELAY ACTIVATED IN ALARM STATE
Table 11 - Alarm Matrix
Make sure that all rectifiers are properly seated and latched into their respective
slots. Make sure that all power and signal connectors are properly mated. Table
12 lists problems and potential solutions.
Page 35 of 49
DO600000079
Version 2.4
June, 2006
Alarm
Minor Alarm
Problem
Solutions
Summary for multiple alarms
See specific alarm for solution
including Single Rectifier Failure,
Single Ringer Failure, Auxiliary
Alarm, etc.
Major Alarm
Summary for multiple alarms
including multiple rectifier
failure, multiple ringer failure,
single rectifier failure leaving
only one rectifier left working,
LVD Open, etc.
Commercial power has been lost
to the specified rectifiers.
AC Fail
S1>-----
See specific alarm for solution
DC Fail
S1>-----
Rectifier(s) have quit working
Reset commercial circuit breaker
to the dedicated AC circuit that
feeds system. Seek alternative
power source until power is
restored.
Replace failed rectifier
BD Alarm
The system voltage has fallen
below the BD (batteries on
discharge) alarm level.
Consider replacing batteries in the
near future before they are
depleted.
LVDWarn
The battery voltage has fallen
below the low voltage warning
value. The LVD is very close to
opening
The battery voltage has fallen
below the low voltage disconnect
value and the batteries have been
disconnected from the system.
The numbers just below LVD
OPEN indicate which LVD is
open
Fuse open or circuit breaker
tripped. Circuit breaker is turned
off.
Plant Voltage drops with
increasing temperature
Connect more batteries or find
alternative power source before
LVD opens.
LVD Open
1:2:3:4
Dist Alarm
T Comp Active
Page 36 of 49
DO600000079
Replace batteries or find
alternative AC power source.
Reset circuit breaker or replace
the fuse. Turn circuit breaker on.
Temperature compensation is in
effect reducing the output to the
batteries. This is adjustable and
may be disabled.
Version 2.4
June, 2006
Alarm
Problem
T Runawy Alarm Temperature of batteries has
exceeded the Thermal Runaway
temperature.
Solutions
Float voltage has automatically
been lowered in an attempt to
lower the temperature of batteries.
If this has not solved the problem,
disconnect batteries from the
system.
Replace the removed module(s) in
the same slot (s). This alarm can
also be cleared from the basic
menu when display indicates “
HIT MENU TO CLEAR”
Com Fail
S1>-----
Controller has lost
communication with one or more
rectifiers, LVD or ringers
I-Share Alarm
One or more rectifier(s) is not
sharing the total system load
equally.
Capacity Alarm
The total load current has
exceeded the summed current
capacity of “N” number of
rectifiers in an “N+1” redundant
system.
Aux Alarm
0000 0001
Indicates a contact closure at the
AUX INPUT on the Alarm Cable
Aux Alarm
0000 0010
Indicates a contact closure at the
AUX INPUT on Temperature
Probe 1
Check the input contact closure
you attached to this Auxiliary
Alarm
Check the input contact closure
you attached to this Auxiliary
Alarm
Aux Alarm
0000 0100
Indicates a contact closure at the
AUX INPUT on Temperature
Probe 2
Check the input contact closure
you attached to this Auxiliary
Alarm
Aux Alarm
0000 1000
Indicates a contact closure at the
AUX INPUT on Temperature
Probe 3
Check the input contact closure
you attached to this Auxiliary
Alarm
Aux Alarm
0001 0000
Indicates a contact closure at the
AUX INPUT on the LVD
controller card position 1
(Integrated system only)
Check the input contact closure
you attached to this Auxiliary
Alarm
Page 37 of 49
DO600000079
Review the current output of the
module(s) in the Review: Module
menu. Replace the faulty
rectifier(s).
Add more rectifiers or reduce
system load to maintain
redundancy. This can often occur
on an initial system turn up when
new, completely discharged
batteries are charging. Simply
wait till the batteries are charged.
Version 2.4
June, 2006
Alarm
Aux Alarm
0010 0000
Problem
Indicates a contact closure at the
AUX INPUT on the LVD
controller card position 2
(Integrated system only)
Solutions
Check the input contact closure
you attached to this Auxiliary
Alarm
Aux Alarm
0100 0000
Indicates a contact closure at the
AUX INPUT on the LVD
controller card position 3
(Integrated system only)
Check the input contact closure
you attached to this Auxiliary
Alarm
Aux Alarm
1000 0000
Indicates a contact closure at the
AUX INPUT on the LVD
controller card position 4
(Integrated system only)
Check the input contact closure
you attached to this Auxiliary
Alarm
BD Test Fail
Battery voltage dropped below
BDT Alarm value during battery
discharge test
Batteries are nearing end of life.
Consider replacing the batteries.
Ring Alm A(or
B)
High V
A ringer has failed
Replace ringer
System voltage has exceeded the
High Voltage Alarm value.
Indicates a problem with a
rectifier or controller
Check float voltage settings
versus High V alarm value. Float
voltage value should be lower
than High V alarm. If values are
OK, replace faulty rectifier or
controller.
Replace faulty rectifier or
controller
HVSD
System voltage has exceeded the
High Voltage Shutdown value.
Indicates a problem with a
rectifier or controller
Overtemp Alarm
(BC1000 or
BC1001 only)
External or Internal temperature
has exceeded the maximum
temperature values
T-Probe remvd
T-comp is enabled and a
temperature probe has been
removed
Lower the temperature in the
cabinet. If temperature is within
acceptable levels, your
Temperature values may be too
low. These values can be adjusted
through the LAN or modem
interface only.
Insert and remove a temperature
probe from all three temperature
probe ports.
Table 12 - Problems and Solutions
Page 38 of 49
DO600000079
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Basic
SYSTEM OK
PRESS AND HOLD
MENU BUTTON FOR
5 SECONDS TO
ENTER MAIN MENU
Up
V = xx.xx
I = xx A
Up
BATT. DIS*
I = xx A
Up
BATTERY
T1=xx C
N.C. if no probe
is connected
Up
BATTERY
T2=xx C
N.C. if no probe
is connected
Up
BATTERY
T3=xx C
N.C. if no probe
is connected
Up
Up
INTERNAL
T= xx C
* SHOWN ONLY WHEN LVD AND/OR SHUNT IS PRESENT
Page 39 of 49
DO600000079
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Main
MAIN
MENU*
*This menu is accessed from the
Basic Menu by holding the MENU
button for 5 seconds
WELCOME
Welcome will appear for about 5
seconds.
CHOOSE:
>REVIEW
To enter Review
menu press the
MENU button
Up
CHOOSE:
>LOG IN
Press MENU to
Login
Up
Up
Page 40 of 49
DO600000079
CHOOSE:
>EXIT
Press MENU to
Exit back to
Basic Menu
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Review
CHOOSE:
>REVIEW
>VERSION
xx.xx.xx
Up
>REVIEW
LANGUAGE
To enter menu press
the MENU button
Up
>REVIEW
MODULE
To enter menu press
the MENU button
Up
>REVIEW
SETPOINT
To enter menu press
the MENU button
Up
>REVIEW
ALARMS
To enter menu press
the MENU button
Up
>REVIEW
TESTS
To enter menu press
the MENU button
Up
>REVIEW
THERMAL
To enter menu press
the MENU button
Up
>REVIEW
LVD1**
To enter menu press
the MENU button
Up
>REVIEW
LVD2**
To enter menu press
the MENU button
Up
>REVIEW
LVD3**
To enter menu press
the MENU button
Up
>REVIEW
LVD4**
>REVIEW
RINGER**
Up
Page 41 of 49
DO600000079
Press MENU to
Exit back to
Main Menu
** SHOWN ONLY WHEN LVD OR RINGER IS PRESENT
>BACK TO
MAIN
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Review
>REVIEW
LANGUAGE
>REVIEW
SETPOINT
LANGUAGE
ENGLISH
FLOAT
V = xx.xx
Up
Up
>EXIT
LANGUAGE
Up
BATT. CL
DISABLE**
PRESS MENU TO EXIT
Up
BATT. CL
I = XX A**
>REVIEW
MODULE
Up
RECT. CL
DISABLE
I=xx A
S1>-----
Up
Up
RECT. CL
I= XX A
I=xx A
S2>-----*
Up
Up
Up
>EXIT
MODULE
FALLBACK
DISABLE
PRESS MENU TO EXIT
Up
FALLBACK
V = XX
* SHOWN ONLY WHEN SECOND POWER SHELF IS PRESENT
Up
Up
>EXIT
SETPOINT
PRESS MENU TO EXIT
** SHOWN ONLY WHEN LVD OR SHUNT IS PRESENT
Page 42 of 49
DO600000079
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Review
>REVIEW
ALARM
>REVIEW
TESTS
HVSD
V = xx.xx
EXECUTE
LAMPTEST
Up
Up
HIGH V
V= xx.xx
EXECUTE
BOOST***
MENU
START
BOOST
PRESS MENU
TO BEGIN
BOOST TEST
MENU
START
BD TEST
PRESS MENU
TO BEGIN
BOOST TEST
Up
Up
BD ALARM
V = xx.xx
EXECUTE
BD TEST***
Up
Up
LVD WARN
V = xx.xx
RELAY A-F
INACTIVE***
PRESS MENU
TO ACTIVATE
RELAY TEST
Up
Up
Up
CAPACITY
ENABLED
>EXIT
TESTS
PRESS MENU TO EXIT
Up
*** SHOWN ONLY WHEN FEATURE IS ENABLED
I-SHARE
ENABLED
Up
COM FAIL
DISABLE
Up
Up
>EXIT
ALARM
Page 43 of 49
DO600000079
PRESS MENU TO EXIT
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Review
>REVIEW
LVD1-4**
>REVIEW
THERMAL
LVD1-4
CLOSED**
T COMP:
DISABLED
Up
LVD OPEN
V = xx.xx**
Up
T START
T= xx C***
Up
LVD RCNT
V = xx.xx**
Up
T SLOPE
Up
T=xx MV / C***
LVD RCNT
SEC: XX**
Up
STOP VLT
V = xx.xx***
Up
Up
Up
>EXIT
LVD1-4**
PRESS MENU TO EXIT
T SENSE
INTERNAL***
Up
>REVIEW
RINGER**
TL START
T= xx C***
Up
RINGER A**
ON
TL SLOPE
T=xx MV / C***
Up
Up
RINGER B**
OFF
STOP VLT
V = xx.xx***
Up
Up
RNG AC
V = xx.xx**
T RUNAWY
T = xx C***
Up
Up
RNG DC
V = xx.xx**
T RUNAWY
V = xx.xx***
Up
Up
RNG FREQ
HZ: XX**
TEMP IS
CELSIUS
Up
Up
Up
Up
>EXIT
THERMAL
PRESS MENU TO EXIT
*** SHOWN ONLY WHEN FEATURE IS ENABLED
Page 44 of 49
DO600000079
>EXIT
RINGER**
PRESS MENU TO EXIT
** SHOWN ONLY WHEN LVD OR RINGER IS PRESENT
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Login and Preset
CHOOSE:
>LOG IN
CHOOSE:
PRESET
PASSWORD
->0000<-
See controller section on instructions for
Admin Login
PRESET
A
PASSWORD
OK: ADMIN
PRESS MENU TO
SET AS PRESET
SHOWN BRIEFLY AT TIME THE PROPER
PASSWORD HAS BEEN ENTERED
Up
PRESET
B
PRESS MENU TO
SET AS PRESET
ADMIN MENU
Up
PRESET
C
CHOOSE:
>PRESET
To enter menu press
the MENU button
CHOOSE:
>CONFIG
Up
Up
Up
PRESS MENU TO
SET AS PRESET
BACK TO
MAIN
PRESS MENU TO
RETURN TO MAIN
MENU
To enter menu press
the MENU button
Up
Up
CHOOSE:
>EXIT
Page 45 of 49
DO600000079
Press MENU to
Exit back to
Main Menu
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Administration
CHOOSE:
>CONFIG
>VERSION
xx.xx.xx
Up
>REVIEW
LANGUAGE
To enter menu press
the MENU button
Up
>REVIEW
MODULE
To enter menu press
the MENU button
Up
>CONFIG
SETPOINT
To enter menu press
the MENU button
Up
>CONFIG
ALARMS
To enter menu press
the MENU button
Up
>CONFIG
TESTS
To enter menu press
the MENU button
Up
>CONFIG
THERMAL
To enter menu press
the MENU button
Up
>CONFIG
LVD1**
To enter menu press
the MENU button
Up
>CONFIG
LVD2**
To enter menu press
the MENU button
>CONFIG
LVD3**
To enter menu press
the MENU button
>CONFIG
LVD4**
To enter menu press
the MENU button
Up
>CONFIG
RINGER**
To enter menu press
the MENU button
Up
** SHOWN ONLY WHEN LVD
OR RINGER IS PRESENT
Page 46 of 49
DO600000079
Up
>BACK TO
MAIN
Press MENU to
Exit back to
Main Menu
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Administration
>CONFIG
LANGUAGE
>CONFIG
SETPOINT
Up
LANGUAGE
ENGLISH
MENU
CHOOSE:
ENGLISH
Up
Up
>EXIT
LANGUAGE
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
FLOAT
V = xx.xx
MENU
CHOOSE:
V = xx.xx
Up
BATT. CL
DISABLE**
PRESS MENU TO EXIT
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
PRESS MENU TO
ENABLE
Up
BATT. CL
I = XXXA**
>REVIEW
MODULE
I=xx A
S1>----Up
I=xx A
S2>-----*
>EXIT
MODULE
CHOOSE:
I = XXXA**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
RECT. CL
DISABLE
A solid rectangle indicates
the rectifier currently
selected. An open
rectangle indicates a
rectifier(s) installed in the
system. Under scores
indicates no rectifier
installed in that slot.
PRESS MENU TO
ENABLE
Up
RECT. CL
I= XXXA
MENU
CHOOSE:
I = XXXA
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
Up
Up
MENU
FALLBACK
DISABLE
PRESS MENU TO
ENABLE
PRESS MENU TO EXIT
Up
* SHOWN ONLY WHEN SECOND POWER SHELF IS PRESENT
FALLBACK
V = XX
MENU
CHOOSE:
V = xx.xx
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
Up
>EXIT
SETPOINT
PRESS MENU TO EXIT
** SHOWN ONLY WHEN LVD OR SHUNT IS PRESENT
Page 47 of 49
DO600000079
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Administration
>CONFIG
TESTS
>CONFIG
ALARM
HVSD
V = xx.xx
MENU
CHOOSE:
V = xx.xx
EXECUTE
LAMPTEST
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
Up
HIGH V
V= xx.xx
MENU
CHOOSE:
V = xx.xx
PRESS MENU TO
CHANGE TO
ENABLE
BOOST
DISABLE
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
Up
BD ALARM
V = xx.xx
MENU
CHOOSE:
V = xx.xx
BOOST
V= XX.XX
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
CHOOSE:
V = xx.xx
BOOST
H = XX
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
CHOOSE
H = XX
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
START
BOOST***
PRESS MENU TO START
TEST
Up
Up
CAPACITY
ENABLED
CHOOSE:
V= XX.XX
Up
Up
LVD WARN
V = xx.xx
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
EXECUTE
BOOST***
PRESS MENU TO
DISABLE
Up
Up
I-SHARE
ENABLED
PRESS MENU TO
CHANGE TO
ENABLE
BD TEST
DISABLE**
PRESS MENU TO
DISABLE
Up
Up
COM FAIL
DISABLE
BDT TIME
MNT: XX**
PRESS MENU TO
ENABLE
MENU
CHOOSE:
MNT: XX
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
CHOOSE:
V= XX.XX
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
CHOOSE:
V= XX.XX
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
Up
Up
>EXIT
ALARM
BDT ALRM
V= XX.XX**
PRESS MENU TO EXIT
Up
BD ABRT
V= XX.XX**
Up
BD TEST
CONST: 0**
PRESS MENU TO
CHANGE TO
ENABLE
Up
EXECUTE
BD TEST***
MENU
START
BD TEST***
PRESS MENU TO START
TEST
Up
RLY TEST
DISABLE
PRESS MENU TO
CHANGE TO
ENABLE
Up
RELAY A-F
INACTIVE***
PRESS MENU TO
CHANGE TO
ACTIVE
Up
Up
>EXIT
TESTS
PRESS MENU TO EXIT
** SHOWN ONLY WHEN LVD OR SHUNT IS PRESENT
*** SHOWN ONLY WHEN FEATURE IS ENABLED
Page 48 of 49
DO600000079
Version 2.4
June, 2006
Appendix A
Controller Menu Tree – Administration
>CONFIG
LVD1-4**
>CONFIG
THERMAL
LVD1-4
CLOSED**
PRESS MENU TO
CHANGE TO
ENABLE
T COMP:
DISABLED
Up
Up
T START
T= xx C***
MENU
CHOOSE:
T= xx C***
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
CHOOSE:
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
LVD OPEN
V = xx.xx**
MENU
T=xx MV / C***
T=xx MV / C***
LVD RCNT
V = xx.xx**
STOP VLT
V = xx.xx***
CHOOSE:
V = xx.xx***
LVD RCNT
SEC: XX**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
Up
INTERNAL***
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
MENU
CHOOSE:
V = xx.xx**
MENU
CHOOSE:
SEC =XX**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
PRESS MENU TO
CHANGE TO
EXTERNAL
T SENSE
CHOOSE:
V = xx.xx**
Up
Up
MENU
MENU
Up
Up
T SLOPE
PRESS MENU TO
CHANGE TO OPEN
>EXIT
LVD1-4**
PRESS MENU TO EXIT
Up
TL START
T= xx C***
MENU
CHOOSE:
T= xx C***
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
>CONFIG
RINGER**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
RINGER A**
ON
Up
TL SLOPE
MENU
T=xx MV / C***
CHOOSE:
T=xx MV / C***
PRESS MENU TO
CHANGE TO TURN
OFF
Up
STOP VLT
V = xx.xx***
MENU
CHOOSE:
V = xx.xx***
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
CHOOSE:
T = xx C***
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
CHOOSE:
V = xx.xx***
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
RINGER B**
OFF
Up
T RUNAWY
T = xx C***
Up
MENU
RNG AC
V = xx.xx**
Up
T RUNAWY
V = xx.xx***
MENU
CHOOSE:
V = xx.xx**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
CHOOSE:
V = xx.xx**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
CHOOSE:
HZ: XX**
PRESS UP/DOWN TO
CHANGE VALUE
PRESS MENU TO ENTER
VALUE
Up
MENU
Up
TEMP IS
CELSIUS
PRESS MENU TO
CHANGE TO TURN
ON
RNG DC
V = xx.xx**
MENU
Up
PRESS MENU TO
CHANGE TO
FAHRENHEIT
RNG FREQ
HZ: XX**
MENU
Up
Up
Up
>EXIT
THERMAL
PRESS MENU TO EXIT
Up
>EXIT
RINGER**
PRESS MENU TO EXIT
** SHOWN ONLY WHEN LVD OR RINGER IS PRESENT
*** SHOWN ONLY WHEN FEATURE IS ENABLED
Page 49 of 49
DO600000079
Version 2.4
June, 2006
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising