Upload
bata88
View
490
Download
42
Embed Size (px)
Citation preview
8/17/2019 BPE4000_CAB benning.pdf
1/154
OPERATIONS AND
MAINTENANCE MANUALFor
Benning Power Electronics
BPE 48-4000
DC POWER SYSTEM
(028-0005-120 Rev B)
SAVE THESE IMPORTANT
SAFETY INSTRUCTIONSThis manual contains important safety instruc-tions that should be followed during installation
and maintenance of the Power System.
11120 Grader Street
Dallas, TX 75238
214-553-1444, Fax 214-553-1355
8/17/2019 BPE4000_CAB benning.pdf
2/154
8/17/2019 BPE4000_CAB benning.pdf
3/154
Technical Documents
Date Name
Issued: 10/5/06 DTL Page. 1/2
Revision:
Checked:
BPE 48-4000
Power Supply System
(Table of Contents)
8/17/2019 BPE4000_CAB benning.pdf
4/154
Technical Documents
2/2
Preface: No. 062-005
Safety No. 2126en
System Install Information: No. 028-0005-001
Rectifier Manual: No. 4135en
Rectifier Satallite Manual: No. 2801en
Rectifier General Specification Tebechop 12000
Rectifier Circuit Diagram No. 61921.00E001A3
Rectifier Dimensional Diagram No. 61921.00M000A3
MCU 2000+ Controller Information: No. 028-0008-020
System Elevation (Front and Top View): No. BLT4000
Rectifier Cabinet Circuit Diagram: No. 902-0103-340
Primary Distribution Circuit Diagram: No. 902-0110-104
External Battery Shunt Drawing No. 840-0052-101
Customer Alarm Mapping BPE 48-4000 Maping
.
8/17/2019 BPE4000_CAB benning.pdf
5/154
Document No. 062-005 R1
Preface
Congratulations and thank you for purchasing a Benning BP E 48-4000 Power Sy stem
We at Benning are committed to supporting the needs of our customers by supplying the customerwith the information and documentation needed to properly install and operate your Power
System.
Important: It is imperative that all the information be observed.
This avoids:
Danger during installation and operation.
Danger to operating personnel.
Downtime.
Increases the reliability and lifespan of the system.
These manuals explain all the necessary information to unpack, install, and operate the BPE 48-4000
Modular Power System and related components. Refer questions outside the scope of this manualto our Customer Service Department.
Customer Service:
We are committed to excellence in dependability and customer satisfaction. If you have any
questions or problems, please contact the Customer Service Department at: 1-800-910-3601 or 214-553-1444 for more information.
Please read all instructions before installing or operating the equipment and save these manuals forfuture reference.
8/17/2019 BPE4000_CAB benning.pdf
6/154
Description
Date Name 2126 en
Issued: 18.01.93 TB-Enck/Bp pag. 1/2 pag.
Revision: R1 Oct 06 DTL
Checked: 27.10.97 Enck
EN2126.doc
Safety Notes
Contents
1 Safety notes.......................................................................... 2
8/17/2019 BPE4000_CAB benning.pdf
7/154
028-0005-001 REV B
Installation Manual
Hot-Pluggable
BPE 48-4000 Series
Modular
Power System
8/17/2019 BPE4000_CAB benning.pdf
8/154
8/17/2019 BPE4000_CAB benning.pdf
9/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 1
1. ABOUT THE MANUAL........................................................................................................................3
SCOPE.............................................................................................................................................................3 QUESTIONS.....................................................................................................................................................3 PRECAUTIONS.................................................................................................................................................3 OVERVIEW .....................................................................................................................................................4 SYSTEM COMPONENTS ...................................................................................................................................4
WEIGHTS AND DIMENSIONS....................................................................................................................6
2. PREPARATION .....................................................................................................................................6
Figures 2.1 – TIP N TELL™..................................................................................................................6 Figure 2.2 – SHOCKWATCH................................................................................................................7
2.1 U NPACKING THE POWER SYSTEM.............................................................................................................7 I NSPECTING THE EQUIPMENT..........................................................................................................................8 CARRIER CLAIMS ...........................................................................................................................................8 CHECKING PACKAGING CONTENTS ................................................................................................................8
3 OVERVIEW OF THE POWER SYSTEM...........................................................................................8
POWER SYSTEM CABINETS.............................................................................................................................8 R ECTIFIER CABINET HARDWIRE I NPUT CONNECTIONS...................................................................................8 PRIMARY DISTRIBUTION CONNECTIONS.........................................................................................................9 EXTERNAL BATTERY STRINGS .......................................................................................................................9 SYSTEM MONITORING....................................................................................................................................9 LOCAL MONITORING......................................................................................................................................9 R EMOTE MONITORING CAPABILITIES.............................................................................................................9
4. INSTALLATION..................................................................................................................................10
ERECTING CABINETS....................................................................................................................................10 PHYSICAL I NSTALLATION.............................................................................................................................10
5.0 GROUNDING ........................................................................................................................................13
CHASSIS GROUND CONNECTION ..................................................................................................................13 BATTERY R ETURN R EFERENCE LEAD (BRR) / C.O. GROUND CABLE ...........................................................14 6.0 I NNER -FRAME DC LINKS ........................................................................................................................16 7.0 AC I NPUT CONNECTIONS .......................................................................................................................16 R ECTIFIER I NPUT PROTECTION.....................................................................................................................17 8.0 I NTER BAY COMMUNICATION CONNECTIONS.........................................................................................18 9.0 BATTERY CONNECTIONS ........................................................................................................................19
10.0 DC LOAD CONNECTIONS......................................................................................................................19 IT IS IMPORTANT TO NOTE THAT IF THE DC CABLING SHALL ENTER AND WATERFALL FROM THE FRONT OFTHE PLANT....................................................................................................................................................20 DESIGNATIONS.............................................................................................................................................20 FIGURE 10.2 .................................................................................................................................................21 11.0 ALARM AND USER I NTERFACE CONTACT CONNECTIONS .....................................................................21 12.0 BPE 48 - 4000 SYSTEM START UP PROCEDURE ..........................................................................22 R ECTIFIER SETTINGS ....................................................................................................................................23
13.0 MAINTENANCE..............................................................................................................................23
8/17/2019 BPE4000_CAB benning.pdf
10/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 2
EXCHANGE OF A MODULE ............................................................................................................................23 R EMOVAL OF THE R ECTIFIER MODULE: ........................................................................................................23 UPGRADING THE SYSTEM .............................................................................................................................24
Version Contro l
Authors Addi tion /Change Version # Date
Almond / Law Original Draft DRAFT October 4th
2006
Almond / Law 028-0005-001 REV B October 5th
2006
8/17/2019 BPE4000_CAB benning.pdf
11/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 3
1. About the Manual
BENNING recommends that carriers who deliver our products use AIR RIDE transportationto ensure careful moving considerations have been taken for your new power system.
This manual contains information needed to install the Benning BPE 48-4000 Modular PowerSystem. The information is intended for DC Power Engineers, technicians or installersexperienced in both DC and AC electrical systems. The installation instructions in Section 4 areintended for qualified electricians and technicians. This manual is generic, and is not intended todefine specific installation methods. Installation methods should follow all safety standards andregulations, which apply, to the specific installation.
Note: Hazardous voltages are present in the BPE 48-4000 Modular Power System and theinstallation must be done only by qualified personnel having prior training in AC to DCpower sys tem installations and knowledge of NFPA 70E.
Scope
The manual explains all the necessary information to unpack and install the BPE 48-4000 ModularPower System. Refer questions outside the scope of this manual to your dealer or CustomerService Department.
Questions
We are committed to excellence in dependability and customer satisfaction. If you have anyquestions or problems, please contact the Customer Service Department at: 1-800-910-3601 or214-553-1444 for more information.
Precautions
Please read all instructions before operating the equipment and save this manual for future
reference.
SAFETY INFORMATION
SAVE THESE INSTRUCTIONS. This manualcontains important information for the installationof the BPE 48-4000 Power System. The manualmust be retained and observed at all times!
Explanation of the symbols used:
Indicates safety instructions that must be followed to avoid dangerto persons!
Indicates instructions that must be followed to avoid equipmentdamage.
Further symbols and warnings are explained at the appropriate places in this operating manual.
8/17/2019 BPE4000_CAB benning.pdf
12/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 4
The rectifier sys tem is an electronic device that contains hazardousvoltages and currents.
For this reason, the following instructions must be followed at all times.
1. The rectifier system should be installed in strict accordance with allapplicable regulations and appropr iate guidelines.
2. Ensure that only qualif ied and AUTHORIZED personnel have access to theunits. Only qualified personnel should be AUTHORIZED to open the units.
3. When the rectifiers are switched off, some of the interior components remainlive as long as they are connected to the mains or the battery supply.
4. Integrated capacitors may still be charged even when the entire unit iscompletely free of voltage. A trained electrician must correctly dischargethese components before the connections are touched.
5. When working within the unit, use properly insulated tools that are rated forthe system operating voltage.
6. All persons installing the unit must be familiar with the first-aid proceduresto be adopted in cases of accidents involv ing electricity.
7. The regulations of the local power-supply company and all other applicablesafety regulations must be observed at all times.
8. This equipment is intended only for installation in a restricted accesslocation
Overview
The rectifier system BPE 48-4000 Series consists of plug-in, modular rectifiers with back paneltechnology to allow easy installation and removal of the modules. When the modular units areremoved or installed into the cabinet system, all electrical connections are automaticallydisconnected or connected. Performance data is indicated on the front of each rectifier module.The parallel operation of all the rectifier modules provides total system capacity including N + 1redundancy, if so equipped. The output voltage of the system is nominal –48VDC (-54.0 VDCFloat).
System Components
The design and arrangement of the components of the power system are as follows.
(2) Rectifier Cabinets (1) Primary Distribution Cabinet (20) pre-wired shelves for the rectifiers (1– 20) rectifiers (1) MCU 2000+ Micro Controller Unit
8/17/2019 BPE4000_CAB benning.pdf
13/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 5
Fig. 3.1: Typical BPE 48-4000 Power System
WARNING!
There are no user serviceable parts inside the plug-inrectifier modules.
8/17/2019 BPE4000_CAB benning.pdf
14/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 6
WEIGHTS AND DIMENSIONS
Cabinet Dimensions
Height x width x length
Packed weight LBS
(Average)
Unpacked weight LBS
(Average)Rectifier Cabinet 7’ x 24” x 31.5” 545 lbs 465 lbs
Primary Distribution
Cabinet
7’ x 31.5” x 31.5” 960 lbs 860 lbs
2. PREPARATION
This section is designed to familiarize you with the BPE 48-4000 Modular Power System. The first partexplains how to unpack the system, inspecting the cabinet, rectifier modules and safety precautions. The
remaining sections describe the rectifier modules and general installation practices. Read all sectionscarefully before installing the power system.
The BPE 48-4000 power system crates should be equipped with TIP N TELL™ indicator(s) andassociated tag(s) to warn if the crate was (were) mishandled or tipped during transportation. Verify thatthere are no blue beads in the arrow of the indicator as shown in figure 2.1. If blue beads are present inthe arrow, make note of it on the bill of lading and open the crate(s) immediately to verify the equipmentfor damage (Claims for tipping will depend on this notation). Report any damages to the freight carrierimmediately.
Figures 2.1 – TIP N TELL™
8/17/2019 BPE4000_CAB benning.pdf
15/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 7
The BPE 48 – 4000 Power system crates are also equipped with a shock watch. If Shock watch is red, please note
upon delivery on the shipping receipt .Follow instructions located on the carton. Refer to figure 2.2- SHOCKWATCH
Figure 2.2 – SHOCKWATCH
2.1 Unpacking the Power System
The cabinets and rectifier modules are shipped separately. Each rectifier module has been factory testedand is ready to plug into the power shelves. The following steps explain how to remove the RectifierCabinet.
1. Cut the straps holding the cabinet to the pallet.
2. Remove the top cover section of cardboard and the foam inserts.
3. Carefully lift the exterior cardboard sleeve, lifting it completely off the cabinet. (This mayrequire two people)
4. Remove the remaining foam inserts and the plastic bag.
WARNING
The rectifier cabinets weigh in excess of 500 lbs each.The Primary Distribution Cabinet is approximately 860lbs. It is mandatory that necessary precautions betaken to lift, move, set and position the cabinets.
5. Using an appropriate number of people or the proper lifting device lift the cabinet off theshipping pallet. Should a forklift or other lifting device be used you must first remove the frontand rear lower cover plates. Be sure to replace the cover plates once the cabinet has beenpositioned and bolted in place. Once removed, lifting forks may be inserted into the framebase allowing the cabinet to be lifted off the pallet. A secondary means of moving thecabinets is to use a dolly truck. If this method is used, only lift the cabinets from the right sideof the cabinets as viewed from the front.
6. Ensure that cabinets are installed on a level surface for proper operation of cabinet doors.
7. Open the shipping cartons for each rectifier module. Be sure to save the packing materials incase the modules need to be returned to the factory for some reason.
8/17/2019 BPE4000_CAB benning.pdf
16/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 8
Inspecting the Equipment
Check the cabinet and the modules for external damage. If any damage occurred during shipment, keepthe shipping cartons and packing materials so the carrier can inspect them.
It is your responsibility to file claim with the carrier for damages to the equipment. Any and all damage
noted upon receipt of the BPE 48-4000 system should be clearly identified in detail on the Bill of Lading.
Carrier Claims
Carrier’s claim procedures should be initiated promptly. In the event damage is found after delivery, itshould be reported as soon as possible (normally 15 day time limit on reporting damages incurred inshipment).
Checking Packaging Contents
Verify the contents of the system against the packing list and the purchase order. If the shipment does notcontain the appropriate items, contact BENNING Customer Service at 800-910-3601 or 214-553-1444.
The following items should be shipped loose and packed in separate boxes:
√ Inter-frame DC Links (2) EC-270 , (1) EC- 271 & (1) EC-378√ Miscellaneous Hardware C/O
Inter-frame DC Link Hardware (5/16-18 and 3/8-16 Nuts, LW & FW)Cabinet Connecting Bolts (4) Upper, (4) Lower (3/8-16 Bolt, Nut & Groundingwasher)-48 V Battery Bus Lug Connecting Bolts (5/16-18 Nuts, LW & FW)
√ (2) RJ-45 Inter Bay Communications Cable (Rectifier Cabinet 1 – 2 to PDC)√ (Optional) Battery Temperature Sensor, 10 meters√ BPE 48-4000 System Installation Manual√ 18 GA White, Current Share Lead (Rectifier Cabinet 1 -2)√ Door Access Key
3 OVERVIEW OF THE POWER SYSTEM
Power System Cabinets
The power system consists of a Rectifier Cabinet (s) and Primary Distribution Cabinet. The height of thesystem is 72” and the depth of the system is 31.5”. The overall width of all three cabinets installed is79.5”.
Rectifier Cabinet Hardwire Input Connections
Each Rectifier Cabinet has its own AC input panel which provides a single or dual (jumpers included) inputconnection point for the incoming 480VAC input. Ten (10) three pole fuse disconnect switches are used to
provide input protection and short circuit current limitation for each rectifier. The main input terminal iswired for “L1” or Line 1/Phase A, “L2” or Line 2/Phase B, “L3” or Line 3/Phase C, and “PE” or ProtectiveEarth Ground. If two input feeds are desired the installed jumpers must be removed providing one feed foreach set of 5 rectifiers. The max lug size that can be accepted is 4/0.
8/17/2019 BPE4000_CAB benning.pdf
17/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 9
Primary Distribut ion Connections
The Internal DC Distribution provides individual load circuit connections allowing the Power System to
serve as the Primary Load Distribution center. Up to three rows of load distribution can be configured foreither TPL style fuses or GJ1P style breakers. A maximum of sixteen breaker positions per row ofdistribution or five fuse positions are available per row. Load circuit breakers and/or fuses up to 1200amps can be installed with a maximum load capacity of 2500A per row. The number of cables that can beinstalled per breaker/fuse is dependent on the capacity of the device.
External Battery Strings
External battery strings can be connected to the system via bus bars located at the top of the system inthe Primary Distribution Cabinet. The system has been designed to accommodate up to twentyconnection points for both positive and negative battery terminations.
CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACEDBY AN INCORRECT TYPE.DISPOSE OF USEDBATTERIES ACCORDING TO THE INSTRUCTIONS.
System Monitoring
The system has the MCU 2000+ (Main Control Unit) installed to provide varying levels of local and remotemonitoring e/w 11 programmable form “C” contacts. For details regarding the specific monitoringconfiguration provided with your system refer to the MCU 2000+ document included with this manual. Amodem, SNMP, or TCP-IP device can be added to enhance the remote monitoring capabilities of the
system.
Local Monitoring
Local monitoring is included with each rectifier module and provides visual status such as: LED indicatorsdetailing the current operational status and alarm conditions; multi-line LCD display which can displayvoltage, current, temperature, and the address of the module.
See the included rectifier sections for more detail.
Remote Monitoring Capabilities
The MCU contains a serial port for local monitoring and remote communications options including aTCP/IP adapter, a SNMP adapter, or an analog modem.
• The TCP/IP adapter is a 10 Base-T device that supports web-based reporting via a built in HTMLweb server with email capability over the Internet or Intranet if behind a firewall. This adapter canalso be paired with the Benning Monitor Software which allows the user to monitor several sitesfrom a central location.
• The SNMP option (Simple Network Management Protocol) allows machine to machine status ofthe system over the Internet via alarm traps.
• The analog modem option allows the system to be monitored remotely over the phone network viathe Benning Monitor Software. The system utilizes a call back function for security reasons.
8/17/2019 BPE4000_CAB benning.pdf
18/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 10
4. Installation The Installation section explains installing the Power System and connecting the AC/DC input/output.Connection of the remote relay contacts and other communications options are also covered.
Warning!These installation instructions are generic and are to be used as aguideline for installing the BPE 48-4000 system. All safetyregulations and guidelines which apply must be observed.
WARNING
The safety instructions must be observed at all timesduring assembly, installation and commissioning.
Erecting Cabinets
When locating the Cabinets consider the following guidelines:
1. The site chosen for the rectifier system must have a solid and level floor designed to properlysupport the weight of the cabinet per sq/ft.
2. The system is designed for installation and operation in a restricted and controlledenvironment. The installed location should have a maximum ambient temperature of 50°C.
3. Two (2) Technicians shall be present at all times for safety reasons
Physical Installation
1. Using the appropriate sketches below, mark the floor for anchor positions and proceeds witheither standard floor anchoring means or earthquake approved anchoring. Frame Isolationpads are available from Benning if required. Rectifier cabinets are 600 X 800 mm and thePrimary Distribution Cabinet is 800 x 800 mm. Non earthquake zone applications use (4)0.42” D floor mounting holes for each cabinet. Earthquake zone applications require weldedcabinets with (8) 2” x 0.5” slots for mounting with earthquake zone approved anchors(Customer provided anchors).
8/17/2019 BPE4000_CAB benning.pdf
19/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 11
2. The cabinets should be shimmed to the floor to make sure they are level. Once they areleveled, they should be secured using Washers in mounting holes provided. See typicalstandard concrete anchor mounting and earthquake zone concrete applications shown onnext page.
8/17/2019 BPE4000_CAB benning.pdf
20/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 12
Typical Non-earthquake Zone concrete anchors
Typical Earthquake Zone Concrete Anchors
8/17/2019 BPE4000_CAB benning.pdf
21/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 13
5.0 Grounding
Chassis Ground Connection
Each cabinet is equipped with 3/8” studs on 1” centers that act as the common frame ground for the unitand are located at the top of each cabinet. Connect frame ground to these grounding studs usingappropriate lug/terminal ends and cable of same type of material as used by the factory e.g. copper or tin–plated copper.
Frame Ground
Collector Ref NEC 250.122
No. 1 AWG
Minimum based
on distance
Frame Ground
Ref NEC 250.122
No. 1 AWG
Minimum
8/17/2019 BPE4000_CAB benning.pdf
22/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 14
Battery Return Reference lead (BRR) / C.O. Ground cable
The Battery Return Reference cable /C.O. ground cable should be equal to or larger than the largestcurrent carrying conductor in the DC Plant. Since the largest current carrying conductor is normally a 750MCM Cable it has become the normal practice to Install 1 – 750 cable. This Bar at the Primary DistributionCabinet is pre drilled for 2 hole lugs 3/8” bolts on 1” centers.
Generally accepted practices in C.O. Grounding
• The C.O. ground cable should be separated by method of cable brackets or dedicated groundingrack and easily traceable from the Floor Ground Bar (FGB) or Building Principal Ground (BPG) tothe DC Power plant.
• The C.O. ground cable should not be spliced and should be continuous from the FGB/BPGdirectly to the DC Power plant.
• Brass labels marked “DO NOT DISCONNECT” shall be place at both ends of the cable.
• The cable should be designated DC POWER PLANT C.O. GROUND on both ends of the cablesecured to a C-145 cable tag.
• The cable should be Green; however Black and Grey are an acceptable substitution.
• The cable shall have two hole lugs with compression type lugs.
• The C.O. Ground cable should be connected to the extreme right or as an option, to the left inorder to prevent cable mismanagement.
8/17/2019 BPE4000_CAB benning.pdf
23/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 15
8/17/2019 BPE4000_CAB benning.pdf
24/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 16
6.0 Inner-frame DC Links
BPE 48- 4000 Modular power systems have tin plated contact surfaces. These surfaces do not requiresanding; simply apply a dry cloth to clean any debris or dirt. Although Tin coated surfaces do not normallyrequire any anti corrosive compound (i.e.) non ox ide a thin layer is generally acceptable.
The two (2) Rectifier Cabinets must be interconnected to the Primary Distribution Cabinet once all thecabinets are secured and have been bonded to frame ground. The left (from Front) rectifier cabinet isready to accept two (2) EC-270, Inter-frame DC links. These links are secured with 5/16 and 3/8 nuts, flatwasher and lock washers as shown below viewed from the rear (right side). Repeat for the other cabinetusing an EC-271 for the top and an EC-378 for the lower Inter-frame DC Link. Torque all boltedconnections per table A which can be found at the end of this document.
Rectifier Cabinets and PDC as viewed from the rear
7.0 AC Input Connections
Each Rectifier Cabinet utilizes 480 VAC, 3 phases and a PE frame ground located behind the removable
panel at the top left hand side of the cabinet, behind the cabinet access door. Each Rectifier Cabinet isdesigned for either a bulk/dual input for the entire Rectifier Cabinet. The bulk/dual input is standard andpre wired to power all 10 rectifiers from a single 480 VAC source or by removing the horizontal jumpers;two feeds (A & B) can be brought into each of the rectifier cabinets. If the jumpers are removed, one 3phase feed would supply power for rectifiers 1-5 and the other feed powers rectifiers 6-10. Please refer tothe system schematic for specific details regarding these connections. The input voltage to the system is480VAC three phase (3W + PE Ground). The removable cover must be re-installed after the inputconnections are made, See Below
8/17/2019 BPE4000_CAB benning.pdf
25/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 17
RECOMMENDED EXTERNAL BREAKER SIZES
Bulk Feed for up to 10 rectifiers Qty 1 – 200 ( 3 pole ) Amp Breaker
Dual Feed for up to 5 Rectifiers Qty 2 – 100 ( 3 pole ) Amp Breakers
Rectifier Input Protection
Each rectifier cabinet distributes the 480 VAC 3 phase power to each rectifier through a three-pole fuseddisconnect. These devices provide two important functions. First, they provide individual input protectionwith disconnect function for each rectifier and secondly, they are current limiting devices. Due to thepotential for high Interrupting Capacity with 480 VAC service, these devices limit possible pass throughcurrents to a safe level. These fuses must only be replaced with a KLKR 30 current limiter or equivalent.These disconnects also provide visual indication via a “red” indicator if any one of the fuses shouldoperate.
8/17/2019 BPE4000_CAB benning.pdf
26/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 18
8.0 Inter Bay Communication Connections
Only a few connections are required to be made during installation for communications between both thePrimary Distribution Cabinet and the Rectifier Cabinet.
1. An 18 AWG white wire (furnished) must be inter-connected between pin 1 of connector X6 inRectifier Bay 1 to the pin 1 of connector X6 Rectifier Bay 2. The connectors are located on theright side of each cabinet.
2. Two, RJ-45 communication cables are provided. These connections provide communicationsbetween the rectifier Cabinets and the MCU communications bus located in the PrimaryDistribution Cabinet. One end of each RJ-45 cable is plugged into the Rectifier “SAT BUSCOMBINER” (SBC) board located on the right side of each rectifier Cabinet. The other end ofeach cable is terminated on the “SAT BUS COMBINER BOARD’s” located in the PrimaryDistribution Cabinet. These cables can be terminated into any available connector on “SAT BUSCOMBINER BOARD” #1 or #2.
RJ-45 Cable
to Rectifier
Bay 1 and 2,
Plug into
socket as
shown
8/17/2019 BPE4000_CAB benning.pdf
27/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 19
Rectifier Cabinet 1 and 2 Primary Distribution Cabinet
9.0 Battery Connections
Provision for the connection of external battery strings is provided in the Primary Distribution Cabinet. 5/16-18
studs on 1” centres’ are provided for termination of up to twenty (-) battery cables using 2-hole lugs (customer
provided). Space is also provided on the right side (from front) of the Primary Distribution Cabinet for termination
of twenty DC (+) battery cables using 2-hole lugs arranged for 3/8” bolts on 1” centres’. It is recommended that
these (+) battery cables be arranged in back to back pairs to conserve ground bar termination points.
It is recommended that battery short circuit protection also be provided for each battery string utilizing either fuses
or circuit breakers rated for the short circuit interrupting rating of the battery cells supplied (customer provided).
These are available from Benning Power Electronics, consult the factory
10.0 DC Load Connections
DC outputs are provided via the GJ1P breakers and/or TPL fuses installed in the Primary DistributionCabinet. The output cables are installed into the cabinet from the top of the system and secured using theproper hardware (supplied by the customer).
NOTE: do not turn on the circuit breakers or insert fuses at this time.
Generic Guidelines to follow for DC cabling
• Lugs used should be of compression type with a minimum of 2 crimp positions. Lugs should alsohave 2 hole 3/8 hole 1 “center to center hole spacing.
• Connection locations for DC Distribution to the BPE 48- 4000 Modular power system have tinplated contact surfaces. These surfaces do not require sanding; simply apply a dry cloth to cleanany debris or dirt. Although Tin coated surfaces do not normally require any anti corrosivecompound (i.e.) non ox ide a thin layer is generally acceptable.
• All cables connected to the BPE 48 - 4000 should have a C – 145 tag and a designation with theend location clearly marked. P touch labelling is generally accepted, however verify with yourcustomer standards documentation and the Telcordia GR 1275.
• Zone 4 cabling should always be flex cabling.
• Clear heat shrink tubing shall be used on all crimp lugs.
8/17/2019 BPE4000_CAB benning.pdf
28/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 20
• All cables shall be copper with insulation having flammability in accordance to the National ElectricCode. (NEC)
Cabling Distribution Layout
• In principal – Level – A – Distribution cabling is unsupported and cables enter the plant in a freeflowing manner. The cabling for level A should not exceed 36” from a cable rack to thebreaker/fuse location.
• In principal – Level – B - C – Distribution cabling will be tied to a support bar located at the centerof the plant. These cables will also be stitched to the A - level cables to provide additional support.
• Return feeders (+) should be installed on the left hand side (facing front) to leave appropriatelocations available for the battery cabling on the right hand side (facing front).
Figure 10.1 PRIMARY DISTRIBUTION CABINET EQUIPPED WITH CABLING SHIELD
LEVEL A DISTRIBUTIONLEVEL B DISTRIBUTION
It is important to note that if the DC cabling shall enter and waterfall from the front of the plant
Designations
For designations with a cabling shield (Fig 10.1), designations can be applied directly to the shield usingetched plastic or P –Touch labelling. For designations without a shield, P- Touch labelling can be applieddirectly to the breakers or to the breaker termination bars indicated below in figure 10.2
8/17/2019 BPE4000_CAB benning.pdf
29/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 21
Figure 10.2
11.0 Alarm and User Interface Contact ConnectionsMultiple dry contact connections are available for remote monitoring of the system failures. Someexamples of these alarms are: DC Output High, DC Output Low, AC Input Fail, and Major/Minor alarms.
Also, a Temperature Probe, Emergency Power Off (EPO), Analog Measurement, Digital Inputs, or Audible Alarm connections are available .For a comprehensive list of available alarms contact your BENNINGrepresentative.
There are 8 Alarm relays that are factory defaulted set to the following. The alarms may be customized inthe factory prior to delivery if the customer advises Benning at the time of placing the order. Alarm settingsmay be modified at anytime by logging into the system with the Benning Service Software. Additionalalarming information can be found in DRW NO .902-0110-104 which is normally shipped with each order.
8/17/2019 BPE4000_CAB benning.pdf
30/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 22
12.0 BPE 48 - 4000 SYSTEM START UP PROCEDURE
Warning!Only Benning Trained and Qualified personnel may carry out theSystem Start up. Any or all of the steps may alter depending on thesite specific conditions.
Trained, Qualified technicians on Benning BPE 48-4000 should only start up this system. ENSUREBATTERIES ARE DISCONNECTED, AC IS TURNED OFF, AND LOAD BREAKERS ARE TURNED OFFBEFORE PROCEEDING. ENSURE THAT A LISCENSED ELECTRICIAN HAS VERIFIED 480 VOLTS
ACROSS THE 3 PHASES OF THE AC.
1. Ensure that all AC fuse disconnects are in the disconnect position. There are 10 total in each
Rectifier Cabinet, ensure that they are all disengaged. You may refer to section titled “rectifierinput protection”
2. Make sure that the DC Batteries are off line (removing battery strapping as necessary or engagebattery disconnect device) and not connected to the DC Plant
3. Make sure all DC distribution breakers/fuses are in the off position.
4. Licensed Electrician should turn on the Main AC source to the Rectifier Cabinet and verifyconnections and 480 volt potential.
5. Install the AC removable Blank Cover.
6. Engage AC Fuse Disconnect for rectifier #1.
1. First, the AC mains supply is switched on, whereby LED’s on the rectifiers light up andflash for a short time, approx. 40 seconds. (Initialization of the internal processor!)
Afterwards, each rectifier will display OFF on the LCD and will remain in stand by untilturned on.
2. Next, one at a time turn each rectifier on by pressing the red button located on eachmodules front panel. The rectifiers will then begin a search and select process until amaster slave configuration has been accomplished. The LCD displays will stabilize whenthe process is complete.
3. The rectifiers are now switched on. Located on each rectifiers front panel are LEDindicators, they all must display a “GREEN LED” which indicates “active: unit in operation”and a “YELLOW LED” which indicates “active: mains voltage applied and data transfer inprogress”.
NOTE: if the yellow LED is flashing this indicates the master.
7. Turn on batteries by engaging battery disconnect device or by installing battery straps and verifyproper Plant voltages, Battery voltages and individual cell readings.
8. Charge batteries as described by the Battery Manufacturers recommendations.
8/17/2019 BPE4000_CAB benning.pdf
31/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 23
9. Test and acceptance per customer /site specific recommendations
10. Engage distribution breakers/fuses as required, verifying proper voltages.
NOTE: the rectifiers may not current share evenly until at least 30% of the over-all currentcapacity is reached.
Rectifier settings
Each rectifier is set to default values at the factory according to the required operating conditions. Anyadjustment of these settings is not usually necessary.
However, if the rectifier is to operate with different parameters, a simple resetting can be carried out usingthe keypad located on the front of each rectifier (see Rectifier Operation Manual).
Warning!Only qualified personnel may carry out each alteration of the settingson the unit. Any or all alternations of these settings may need to becarried out for all the other rectifiers in the system depending on whichsettings are altered.
13.0 Maintenance
All the components of the power system have been developed for continuous operation and are practicallymaintenance-free. To ensure correct functioning, it is recommended that the flow of cooling air is checkedperiodically and the filters are changed as needed.
Warning!
Do not use pressurised air since the dust particles can be blown intothe interior of the unit and may cause malfunctions.
Exchange of a Module
Removal of the Rectifier module:
1. Switch the module off by pressing the red button located on the front panel of the module.
2. Remove the retaining screws, which secure the unit into the system.
Attention: Take account of the amount of current being supplied by themodules to the load and the batteries. Removal of a module in a non-
redundant system may compromise the load.
8/17/2019 BPE4000_CAB benning.pdf
32/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 24
3. Pull the unit out from the front of the cabinet about half way and wait until the front display iscompletely blank. If the module does not have a front display, wait approximately 40 seconds andthen proceed to remove the module being careful to support the whole module as it is beingremoved.
Insertion of the Rectifier module:1. The module must be switched off!
2. Place the module’s bottom back corner on the base of the carrier paying close attention to the
alignment grooves on both the module and the carrier.
3. Slide the module into the free slot slowly until the modules front panel is flush with the front of the
cabinet.
4. Screw in the retaining screws
5. If the module has an active front panel, switch the module on by pressing the red button on the
front panel.
Upgrading the system
The power system can be equipped with a maximum of 20 rectifiers. Additional modules can only beadded to the system if there are free slots. The system can be upgraded during running operations withoutthe need to switch off other components or the need to alter the programming configuration of the MCU.
To add additional modules to an existing system first remove the dummy plate covering the free rectifierslot. Ensure the new module is switched off. The new module is then pushed into the slot, fixed with theretaining screws and then switched on. After the start-up phase, the module is brought into paralleloperation and the current then is evenly distributed to all modules that are switched on.
8/17/2019 BPE4000_CAB benning.pdf
33/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 25
Reference Information
Table A – Bolt Torque Data
8/17/2019 BPE4000_CAB benning.pdf
34/154
Modular Power System
Series BPE 48-4000
028-0005-001_REV B
Page 26
Table B – Cable Equivalents (AWG to Metric)
End of the Document
8/17/2019 BPE4000_CAB benning.pdf
35/154
Safety notes
18.01.93 - TB-Enck/Obs 2/2 2126 en
Before starting the unit:
Please read the complete manual, paying special attention to all thesafety notes.
1 Safety notes
The charging rectifier is an electrical unit with dangerous voltage and current
levels. For this reason, the following safety instructions must be observed:
1) Installation, operation, servicing and maintenance should be carried out
only in accordance with the instructions given in this document.
2) Ensure that only qualified and authorized personnel have access to the
equipment. No other persons should be able to open the door.
3) Even when the unit is completely switched off, certain interior compo-
nents remain lives as long as they are connected with the mains supply or
the battery.
4) Intergrated capacitors may still be charged even when the unit is com-
pletely voltage-free. These must be properly discharged by a qualified
person before the connections are touched.
5) When working on the unit, only properly insulated tools should be used.
6) All persons carrying out work on the unit must be acquainted with the
first aid measures to be taken in cases of accidents involving electricity.
7) Always observe the safety regulations of the local power supply com-pany as well as other safety regulations.
8) This product is intended for use in restricted access locations only.
9) HIGH LEAKAGE CURRENT - Earth connection essential before connecting
supply.
8/17/2019 BPE4000_CAB benning.pdf
36/154
Description
Date Name No. 4135 enIssued: 29.06.2004 TB/Gö Page 1/17 Page
Modified:
Rectifier with satelliteTEBECHOP 12000
3U – 19” HOT-PLUG Version
8/17/2019 BPE4000_CAB benning.pdf
37/154
Rectifier with satellite
TEBECHOP 12000
Contents
Foreword ...............................................................................................................................4
1 Safety notes and markings......................................................................................5
2 Connection..............................................................................................................8
3 General ...................................................................................................................9
4 Functional principles ............................................................................................11
5 Start-up .................................................................................................................11
6 Operating modes...................................................................................................12
6.1 Floating level (ErlAd) ..........................................................................................12
6.2 Boost level (LAdEn) ............................................................................................12
6.3 Direct feeding (dir.SP) .........................................................................................12
6.4 Battery circuit test (b.tESt)...................................................................................12
6.5 Time-dependent automatic charging ....................................................................12
7 Parallel operation..................................................................................................12
8 Satellite.................................................................................................................13
8.1 Standard function .................................................................................................14
8.2 LED-indication.....................................................................................................14
9 Alarms ..................................................................................................................15
9.1 Urgent alarm (unit fault SV1) ..............................................................................15
9.2 Non-urgent alarm (mains fault SV2)....................................................................15
9.3 Temperature monitoring.......................................................................................15
9.4 Overvoltage protection .........................................................................................16
8/17/2019 BPE4000_CAB benning.pdf
38/154
Rectifier with satellite
TEBECHOP 12000
9.5 output fuse-monitoring.........................................................................................16
9.6 Incorrect battery poling ........................................................................................16
9.7 Ventilator fault .....................................................................................................16
10 Adaptation of float charge voltage to battery ambient.........................................17
11 Fuses.....................................................................................................................17
8/17/2019 BPE4000_CAB benning.pdf
39/154
Rectifier with satellite
TEBECHOP 12000
Foreword
These operating instructions give essential information for the
correct operation of the unit. To ensure the safe and correct
operation of this unit before the first switch-on, the user should
study these instructions carefully. Also note all the information
they contain.
These instructions should be kept in a safe place for
consultation.
8/17/2019 BPE4000_CAB benning.pdf
40/154
Rectifier with satellite
TEBECHOP 12000
1 Safety notes and markings
International electrical symbols and display and operating symbols are marked on the unit. They have the following meanings:
Important! See documentation!
Alternating current
Direct current
Earth (Ground)
Operation
V Input voltage (mains) available / flashes during data transfer viathe satellite bus
Fault-output fuse
Fault-unit
Voltage - output too high
Fan fault
Funktions keys: A= menu ; B= enter key
On/Off (push button switch / impulse lock)
8/17/2019 BPE4000_CAB benning.pdf
41/154
Rectifier with satellite
TEBECHOP 12000
Index of abbreviations
A Current b.-Art Operating mode
b.tESt Battery test
bzw. or
DC Current
DirSP Direct feed operating mode
EndE End
ErLAd Consercation charge operating mode
i-MA Setting current limitation
I Nenn Rated current
I-rEG Following current limitation
LAd.-A Automatic chargeLAdEn Charge operating mode
Pb Lead
Po.MA Power management
SAE Voltage compensation facility
SAT-Bus Satellite bus
T Temperature
tEMP Battery temperature-based charge
tESt Test
U Voltage
U-rEG Following voltageW Watt
–BAT- Incorrectly poled battery
E.g. For example
For further information on the function of the satellite, refer to thedescription no.: 2801.
The following symbols are used to draw attention to certain passages in these
instructions.
Constitutes a remark pointing out that observing it will facilitateworking with the device!
Constitutes a remark pointing out the process or operation of a
device or a specification.
Refers to a remark pointing out that life and body of persons could be directly exposed to danger!
8/17/2019 BPE4000_CAB benning.pdf
42/154
Rectifier with satellite
TEBECHOP 12000
It is an electronic device which requires dangerous levels of
voltage and current. The following instructions must therefore bestrictly observed at all times.
1. Installation, operation, maintenance and repair of the unit must
always be carried out in accordance with these instructions.
2. Ensure that only fully trained and qualified personnel have access
to the unit. The unit should be opened only by authorised persons.
3. Even when the unit is switched off, certain internal components
remain live as long as it is connected to the power supply or the
battery.
4. Integrated capacitors may still be charged even when the entire unit
is completely free of voltage. Ensure that the capacitors are
properly discharged by a qualified electrician before touching the
connections.
5. When working with the unit, use only properly insulated tools.
6. All persons working with the unit must be familiar with first-aid
procedures for accidents involving electricity.
7. Always comply with the regulations of the local power-supply
company or authority as well as any other relevant safety
regulations.
8/17/2019 BPE4000_CAB benning.pdf
43/154
Rectifier with satellite
TEBECHOP 12000
2 Connection
The following standards and regulations are applicable to the unit:
EN 61558 EN 60950
VDE 0884
EN 50 081-1 EN 50 082-2
In the standard version, the device and the insulating transformer correspond to
protection class I. The transformer corresponds to the regulation EN 61558 and
the test voltage primary/secondary is 4 kV alternating voltage.
The unit as delivered is ready for operation.
Installation and perfect operation is only possible in the special 3U; 19” rack
(PN: 550828).
The handle on the front panel serve only for pulling out the device,
not for carrying the device.
This device (protection type: IP 20 must be installed in a dry and dust-
protected environment. The cooling air should not be obstructed.
Pay attention to the circuit diagram!
It is necessary to supply the supply circuit with an insulating device which has
to be
- easily accessible if permanently connected;
- easily accessible if it is a plug connection and located close to the device .
Provide appropriate fuses for mains and output cables (size of fuse,
characteristic see technical data)!
Access to the input and output fuses is only possible after opening the unit.
Before connecting up, make sure that the specifications on the type plate and
data sheet agree with the actual mains and battery voltages.
The details in the rating plate and in the data sheet with regard to power
consumption apply to rated conditions of input voltage and the operating mode
“float charge voltage”. The value in brackets is the maximum input current
with maximum input voltage tolerance and in the operating mode “charging”.
8/17/2019 BPE4000_CAB benning.pdf
44/154
Rectifier with satellite
TEBECHOP 12000
Make the mains connection on rack only when the mains supply
voltage is switched off.
The device must be connected with the neutral conductor of the supply power
circuit according to local regulations.
Because of the high energy of the battery to be connected, take special safety
precautions.
To protect the device from overvoltages (such as from lightning strikes), carry
out potential equalisation with sufficient cable cross section (e.g. 6 mm²) on
Rack provided no other measures to protect the device are provided, for
instance building protection.
3 General
The rectifier described in the following is in switched mode technology.
This technology provides sound efficiency and good dynamic control
characteristics in the event of input voltage changes and load jumps.
Since these rectifier units are highly compact designs and can be connected in
parallel, the establishment of powerful electricity supply systems is possible in
conjunction with the 3U; 19” rack.
IPU characteristic (standard)
In order to achieve as high as possible a charge current, power is controlled on
the output side. This means that, dependent on the respective charge voltage,
the output current is adjusted to the maximum possible output power (example
of a 48V device see figure 1).
The IPU characteristic is only active in the operating modes “float charging”
and “ charging”.
In the operating modes “direct feed” and “1,8 V/Z”, it is limited to ratedcurrent (IU characteristic).
Based on the type of battery and number of cells, the output voltage is kept
constant with an accuracy of ± 1 % Based on the type of battery and number of
cells, the output voltage is kept constant with an accuracy of. On reaching the
current limit control changes electronically from voltage to current control.
8/17/2019 BPE4000_CAB benning.pdf
45/154
Rectifier with satellite
TEBECHOP 12000
Figure 1: (IPU characteristic; example: 48V unit)
The consequence of current limitation if applicable is a drop of the output
voltage in the event of a short circuit to < 1 V, the output current is
approximately around Irated. or at Imax , depending on operating mode. This
measure makes the device short-circuit proof permanently.
Mains fluctuations of voltage and frequency (see technical data sheet) and load
changes have no effect on the quality of the voltage and current constancy and
are regulated.
The power factor of the rectifier unit (active power to apparent power) is
regulated to roughly 1 (PF > 0.99 at rated operation). The utilisation of the feed
network is considerably improved in this way and higher output can be taken
from the single-phase net.
The rectifier is equipped with the so-called satellite. This assembly integrated
in the rectifier enables the establishment of a remote monitoring system MCU
1000 / MCU 2000.
Faults are delivered by means of floating contacts via the external evaluation
electronics “MCU”.
Additional information on the duty of the satellite, see chapter 8.
18 8
53,5
43,248
57,6
(V )UA
200 240 IA (A)
8/17/2019 BPE4000_CAB benning.pdf
46/154
Rectifier with satellite
TEBECHOP 12000
4 Functional principles
The mains voltage fed in through the input filter is converted by the rectifier toDC voltage and supplied to the active filter (PFC). A special control method
takes a sinusoidal current from the three-phase net and provides a constant DC
voltage for the main unit (charge unit) at the output of the active filter.
Rapid MOSFET power transistors in the chopper unit convert this DC voltage
into a rectangular voltage. Control is effected by changing the duty cycle with
constant frequency. The power transmitter serves to separate the potential and
transform the rectangular voltage to the desired output value. Diodes rectify the
voltage and an LC filter is used to smooth the output voltage.
The device is equipped with a hardware overvoltage cut-out.
For switching on and off, the rectifier unit must be operated via the switch in
the front panel.
5 Start-up
Push all rectifier into the cabinet, with the mains switched off.
Switch on the first unit at the mains,
wait for the end of initialization period of this unit,(the end of this period is indicated by the green LED "Operation / “ and
the red LED "Fault/ “) no longer flashing,
now the next unit can be connected to the mains; here, too, you need to
wait for the end of the initialization phase, before the third unit can be
connected to the mains and start up.
All rectifier units must start up individually in order to ensure that each unit is
assigned its own address.
If, for a particular unit, the initialization phase has run without any problems,
then this unit must be withdrawn.
Following a period of approx. 3 minutes which is required for the internal
discharge of the capacitors, the initialization must be carried out again.
Following completed initialisation, the green LED “operation”
“ “ is activated. The unit will then run up to the set rectifier
output voltage with a time delay.
When removing the device, place switch in “off” position first!
8/17/2019 BPE4000_CAB benning.pdf
47/154
Rectifier with satellite
TEBECHOP 12000
The handles on the front panel serves only for pulling out the
unit, not for carrying the unit .
6 Operating modes
The rectifier unit has a total of four operating modes or characteristics, which
can be activated by changing over the operating mode via the satellite bus
(SAT bus) by means of “MCU”.
6.1 Floating level (ErlAd)
Standard operating mode, normal operation setting, float charging with rated
current or maximum current (based on power) up to the voltage limit (seetechnical data sheet). The level of the output voltage is set by the „MCU“.
6.2 Boost level (LAdEn)
Necessary for fast charging the battery. Charging up to the voltage limit with
rated current or maximum current (based on power), see technical data sheet.
The level of the output voltage is set by the „MCU“.
6.3 Direct feeding (dir.SP)
Operating mode without battery (voltage value see technical data sheet). Thelevel of the output voltage is set by the „MCU“.
6.4 Battery circuit test (b.tESt)
Voltage reduction during the battery capacity test in order to obtain exact
measured value (voltage value generally set to V/C). (see technical
specification sheet.)
The level of the output voltage is set by the „MCU“.
6.5 Time-dependent automatic charging
By means of the automatic charging system integrated in the rectifier it is
possible that the unit switches over automatically to the characteristic
“charging” following a power failure. After expiry of the charging time, it
switches back to the characteristic "float charge".
The mains failure charging time is set via the “MCU”.
7 Parallel operation
Parallel operation of several rectifiers is possible and takes place withoutdecoupling diode on the rectifier output.
8/17/2019 BPE4000_CAB benning.pdf
48/154
Rectifier with satellite
TEBECHOP 12000
For symmetrical output current distribution, the rectifiers are interconnected
via the contact “1,2,3(b1)” on the connector strip (“X16”) (parallel operation
connection). A parallel operation tolerance of approximately ± 10% of Irated isachieved in this way in load operation from 30 – 100%.
The voltage and current compensation can take up to 5 minutes in case of con-
nection of an additional unit to the system (self regulating process in 10 mV
steps).
A minimum basic load of > 5% is required with parallel
operation to safely maintain the fault message contact. The
satellite bus connector “RS485” in the counter-connector
system must be plugged with parallel operation using severalracks in order to enable data interchange. In addition to this, the
“parallel operation connection” of the racks must also be
interconnected!
8 Satellite
For further information on the function of the satellite, refer to thedescription no.: 2801.
The satellite integrated inside the rectifier unit monitors the rectifier unitand provides the open and closed loop control functions for it. For the user the
satellite looks like a digital interface to the rectifier unit. The rectifier unit
obtains the required data via this interface from other units of the remote
monitoring system MCU 1000/MCU 2000 to establish the desired operating
state. This requires that the satellite has available the complete set of
parameters for open and closed loop control as well as all data with regard to
the operating states of the rectifier unit.
The satellite is a principal unit in the remote monitoring system MCU
1000/MCU 2000, ensuring that control and monitoring of the power supply
systems is possible via the public telephone network.
8/17/2019 BPE4000_CAB benning.pdf
49/154
Rectifier with satellite
TEBECHOP 12000
The further functions of the satellite, among others, are as follows:
(Faults are delivered by means of floating contacts via the external evaluation
electronics “MCU”)
1. Four adjustable operation modes/characteristics
2. Battery temperature inclined float charge characteristic (incline
adjustable)
3. Unit monitoring with logically combined urgent alarm
4. Mains monitoring with logically combined non-urgent alarm (time
delay of the alarms adjustable)
5. Time-dependent automatic charging (mains power failure time and
charging time adjustable)
6. Current limitation is set in accordance with medium load (IrEG
adjustment)
7 Voltage tracking (UrEG. adaptation).
8 Power management (Po.MA).
9. Serial SAT bus interface via counter-connector system for
communication in parallel operation of several rectifiers
8.1 Standard function
After switching on the rectifiers and an initialisation phase of approximately 30
seconds, the unit runs up to the output voltage saved last (for instance float
charging).
8.2 LED-indication
The following LEDs are provided in the unit front panel of the rectifier:
- (green) "operation"/ " " (LED active: The units operating
correctly)
- (yellow) "mains/data"/ " V " (LED active: Mains voltageavailable; LED flashes: Data
transfer via SAT bus in progress)
- (red) "fault - fuse"/ " " (LED active: Output fuse tropped)
- (red) "fault-unit"/ " " (LED active: unit fault)
8/17/2019 BPE4000_CAB benning.pdf
50/154
Rectifier with satellite
TEBECHOP 12000
- (red) "UA too high"/ " " (LED active: Overvoltage
protection responded)
- (red) "Fan fault"/
" " (LED active: Fan failure!)
For error identification, the relevant error code is shown in the display
and transferred via the “SAT bus” .
(refer to the description no.: 2801)
LC-Display
The 5-digit LC display on the rectifier front panel indicates physical units
(current, voltage, battery temperature or data address) as well as operating
status of the rectifier.
9 Alarms
9.1 Urgent alarm (unit fault SV1)
The message contact “Device fault” of the external evaluation electronic
(MCU) is closed and the control lamp “Operation”/ “ “ LED green is off,
and “Fault device” / “ “ LED red is on.
These signals are internally delayed by approximately 30
seconds.
Device fault (urgent alarm) is dispatched under the following conditions:
- Overvoltage protection has responded
- Temperature too high
- Regulator or power pack defective
- Output fuse tripped – Incorrectly poled battery
9.2 Non-urgent alarm (mains fault SV2)
This signal follows AC undervoltage or mains power failure, the message
contact of the external evaluation electronic (MCU) is closed and control
lamp “mains/data” / “ V“ LED yellow is off.
9.3 Temperature monitoring
The rectifier is equipped with a temperature control on the heat sink which
operates as follows:
8/17/2019 BPE4000_CAB benning.pdf
51/154
Rectifier with satellite
TEBECHOP 12000
Assumption:
The rectifier is operated at rated current.
1. Heat sink temperature continues to rise2. At T >85°C rectifier is switched off
3. LED red “fault device” / “ “ on
4. LED green “operation” / “ “ off
5. Urgent alarm / device fault “SV1” is dispatched.
After the heat sink has cooled down, the rectifier is
automatically reset.
The rectifier is then switched on again.
9.4 Overvoltage protection
In the event of overvoltage (see technical data sheet) the device is switched off.
The overvoltage protection is designed as a battery and device protection.
Switching on after the fault has been repaired is possible when the device is
separated from mains for approximately 10 seconds.
LED red “UA too high”/ “ ” and urgent alarm are also reset during this.
Testing the overvoltage protection is not possible with anexternally controlled power supply unit since the rectifierrecognises an externally fed voltage and fails to switch off as a
result.
9.5 Output fuse-monitoring
Because of high energy of the battery to be connected, an output fuse has
already been installed to protect the device. The control integrated in the
device issues a message once the output fuse has tripped.
LED red “FAULT output fuse” / “„ “ “ on, the message contact “Device
fault” of the external evaluation electronic (MCU) is closed and control lamp“Operation” / “ “ LED green off, and “Fault device”/” “ LED red on.
9.6 Incorrect battery poling
An incorrectly poled battery of the externally connected battery is registered,
messages are displayed, and the internal monitoring prevents the unit from
starting up again. Signalling contact "Unit fault" of the external evaluation
electronics (MCU) is closed, the control lamp "Operation"/ " " LED green
is off, and "Fault-unit"/ " " LED red flashes.
In the LCD- Display, " –BAT- " is shown.
9.7 Ventilator fault
8/17/2019 BPE4000_CAB benning.pdf
52/154
Rectifier with satellite
TEBECHOP 12000
During operation of the ventilator (temperature controlled) an air-current
monitoring system controls the function of the ventilator. If an error occurs, the
following procedure takes place.
• LED red "ventilator fault"/ " " is activated
• Non-urgent alarm (SV2) of the external evaluation electronic (MCU) is
closed and the control lamp “Operation”/ “ “ LED green is signalled
• The rectifier current is reduced automatically to 60 % Irated.
In this way it is possible to operate the unit with reduced power.
10 Adaptation of float charge voltage to battery ambient
The charging voltage of lead batteries, particularly maintenance-free lead
batteries, should be adjusted to the ambient temperature. The temperature
sensor is connected to the connection terminal, i.e.only one temperature sensor
per system. Use a screened cable if the sensor is used externally. The length
should not exceed 5 m. Sensor element- 2 kOhm +/- 2 % NTC.
This function is only available in the „float charging“ mode. U A
at 20°C is automatically established on sensor breakage!
The (tEMP) function must also be activated via the MCU !
11 Fuses
According to the technical data sheet.
Access to the input and output fuses are only possible after opening the unit.
8/17/2019 BPE4000_CAB benning.pdf
53/154
8/17/2019 BPE4000_CAB benning.pdf
54/154
8/17/2019 BPE4000_CAB benning.pdf
55/154
8/17/2019 BPE4000_CAB benning.pdf
56/154
8/17/2019 BPE4000_CAB benning.pdf
57/154
8/17/2019 BPE4000_CAB benning.pdf
58/154
8/17/2019 BPE4000_CAB benning.pdf
59/154
8/17/2019 BPE4000_CAB benning.pdf
60/154
8/17/2019 BPE4000_CAB benning.pdf
61/154
8/17/2019 BPE4000_CAB benning.pdf
62/154
8/17/2019 BPE4000_CAB benning.pdf
63/154
±
8/17/2019 BPE4000_CAB benning.pdf
64/154
8/17/2019 BPE4000_CAB benning.pdf
65/154
8/17/2019 BPE4000_CAB benning.pdf
66/154
8/17/2019 BPE4000_CAB benning.pdf
67/154
−
−
−
−
8/17/2019 BPE4000_CAB benning.pdf
68/154
−
−
−
−
8/17/2019 BPE4000_CAB benning.pdf
69/154
General specificationTEBECHOP 12000.48V 200A (240A)
TEBECHOP 12000 series are hot-swappable, designed for superior performance inindustrial, IT, and telecom applications. Rectifier is fully electronic three phase switchmode power supply module. It has very high efficiency and power factor. The sizemakes it one of the most compact 200A (240A) forced cooled rectifier module inapplication. Measuring just 19” W x 3U H x 430mm D. This module has powerdensity of 7W/in^3. The high efficiency and reliability of this unit ensures maximumsystem uptime for critical application up to 4,000 Amp, to minimize operating costand reduce installation time. The user interface makes remote or local programmingand monitoring of all major parameters easy. Remote computer communication ispossible through RS-485 serial interface.
Input characteristics
Nominal input voltage: 480V 3 Phase without neutral.Input voltage range: 408 – 528VInput frequency: 47-63HzInrush current: < 22A per phaseInput current: 15 A nominalPower factor: > 0.94 nominalTurn on delay: 8 sec.
Efficiency: >93% @ 100% load>94% @ 50-75% load>90% @ 20% load
High voltage test: 2200V DC for1 minutebetween input to chassis
Output characteristic
Boost charge: 57.6VTrickle charge: 53.5VDirect feed: 50V
Battery test mode: 43.2VOutput voltage adj. Range: 40-60VOutput voltage regulation: +/-1%Output current: 200A @ 54V (IV mode)
240A @ 43,2V only in power constant mode with the Battery.
Dynamic regulation:
8/17/2019 BPE4000_CAB benning.pdf
70/154
70°C internal air temperature.Overvoltage protection: 60V +/- 1% , only faulty unit shuts down.Overtemperature protection: shutdown with self recovery.
Standard FeaturesRectifier status indication: Rectifier OK – Green
Line voltage present – Amber
Output overvoltage – RedRectifier failure – RedFan failure – RedOutput fuse failure - Red
LCD Display: Alphanumerical display normallydisplays output voltage, currentand rectifier status.
EnvironmentalCooling: Forced cooling, fan speed control.Operating temperature: -15 to +50°CHumidity: 0% to 90% non-condensing.
MechanicalDimensions: Width 19”
Height 3U (133mm)Depth 430mm.
Weight: 22KgNoise:
8/17/2019 BPE4000_CAB benning.pdf
71/154
F
C A D Z e i c h n u n g n u r a m B i l d s c h i r m n d e r n .
B l a t t
A B C D E F
D a
t u m
B e a r
b .
G e p r .
Z N r :
1 4 . 0
5 . 0
4
G ö
T e
l
T
E
C
H
O
P
1
S T R
1
8
7
6
5
4
3
2
1
P
2
X
1
F
c
+
1
b
P
a
r
a
l
e
l
a
u
f
e
r
b
i
n
d
u
n
g
c
o
n
n
e
c
t
o
n
f
o
r
p
a
r
a
l
e
l
o
p
e
r
a
t
o
n
m 7 8 9_ 0 7 0 6
a
a
-
r a c e 9 4 9
L
s
u
e
E
n
/
p
w
e
c
r
c
i
n
r a c e 9 4 9
X
F
n
N
/
A
S
r
e
m
o
e
/
o
R
e
r
e
a
o
L
ü
e
ü
w
a
/
f
a
m
o
o
n
A
g
e
o
p
f
e
E
i
n
g
a
n
g
s
f
e
r
A
C
i
n
p
u
t
f
e
r
A
C
E
A
g
D
C
/
o
p
D
C
F
3
E
N
e
z
w
a
ln
m
o
o
n
A
g
-
u
E
n
e
e
i
n
c
n
-
a
s
n
c
d
S
e
s
a
e
b
d
a
p
t
e
r
k
a
r
e
a
d
a
p
t
e
r
c
a
r
d
X 6 0 5 7 3 6
F
R
c
G
n
X
L
1
L
2
L
3
P
5
X
3
X
1 2 3 4 5
X X
6
+
)
1
+
)
1
-
)
2
-
)
2
S
-
B
R
/
i
n
e
a
R
S
-
B
R
/
i
n
e
a
R
o
o
3
P
a
r
a
l
e
l
a
u
f
e
r
b
i
n
d
u
n
g
c
o
n
n
e
c
t
o
n
f
o
r
p
a
r
a
l
e
l
o
p
e
r
a
t
o
n
+
+
+
8/17/2019 BPE4000_CAB benning.pdf
72/154
3
-
T
O
P
5
-
I
S O
M
E
T
R
I
C
S c h u t z v e r m e r k n a c h D I N 3 4 B e a c h t e n
G e p r .
N o r m
B e a r b .
M a ß s t .
B e n e n n u n g
Z e i c h n
g . N r . 6 1 9 2 1 . 0 0 M 0 0 0 A 3
T E B E C H O P 1 2 0 0 0
2 9 . 0
6 . 2
0 0 4
T e l
T B / G ö
2 9 . 0
6 . 2
0 0 4
1 2 2
4 8 3
4 4 8
3 5
4 6 4 3 0
3 2
1 3 3
G e w i c h t / w e i g h t : 2 2 k g
8/17/2019 BPE4000_CAB benning.pdf
73/154
OPERATIONS AND
MAINTENANCE MANUALFor
Benning Power Electronics
MCU 2000+REMOTE MONITORING UNIT
(028-0008-020 REV A)
SAVE THESE IMPORTANT
SAFETY INSTRUCTIONSThis manual contains important safety instruc-
tions that should be followed during installationand maintenance of the Power System.
11120 Grader Street
Dallas, TX 75238
214-553-1444, Fax 214-553-1355
8/17/2019 BPE4000_CAB benning.pdf
74/154
8/17/2019 BPE4000_CAB benning.pdf
75/154
8/17/2019 BPE4000_CAB benning.pdf
76/154
8/17/2019 BPE4000_CAB benning.pdf
77/154
8/17/2019 BPE4000_CAB benning.pdf
78/154
8/17/2019 BPE4000_CAB benning.pdf
79/154