Installation, Operation and Technical Manual - … RT9 24V with MCSU...Installation, Operation and Technical Manual Rectifier Technologies 158-1872-01.doc 1 3-Feb-16 1. General Warnings

Installation, Operation andTechnical Manual

RT9- 24V and MCSU-4 Rack Power System

Document: 158-1872-01Date: 19 February 2014

© Rectifier Technologies Pacific Pty LtdACN 058 107 707

Installation, Operation and Technical Manual Rectifier Technologies

158-1872-01.doc ii 3-Feb-16

Table of Contents1. General Warnings ......................................................................................................12. Summary of Programmed System Parameters .......................................................23. Configuration..............................................................................................................5

3.1 System Description................................................................................................53.1.1 General Description........................................................................................53.1.2 Rectifier Specific Configurations.....................................................................7

4. Installation ..................................................................................................................84.1 System Installation ................................................................................................8

4.1.1 Racks .............................................................................................................84.1.2 Magazines ......................................................................................................84.1.3 Lightning and Transient Suppression .............................................................84.1.4 Cabling, Auxiliary Equipment and Circuit Breakers ........................................9

4.2 Rectifier Installation and Removal .......................................................................114.2.1 To Remove a Rectifier from the Magazine ...................................................114.2.2 Inserting a Rectifier into the Magazine .........................................................12

4.3 MUIB - Mini User Interface Board........................................................................124.3.1 MUIB Connections .......................................................................................12

4.4 MUIB2 - MCSU-4 User Interface Board (type2)...................................................154.4.1 System setup requirement............................................................................154.4.2 Main features of MUIB2................................................................................154.4.3 MUIB2 Connections .....................................................................................164.4.4 Fuses............................................................................................................18

4.5 MUIB3 – Systems with Earth Leakage Detection ................................................214.5.1 System setup requirement............................................................................214.5.2 Main features of MUIB3................................................................................214.5.3 MUIB3 Connections .....................................................................................21

4.6 Single Phase AC Monitoring Module – MMIB4....................................................264.7 Three Phase AC Monitoring Module – MMIB2 ....................................................264.8 SMM - Site Monitor Module .................................................................................28

4.8.1 Electrical Specification .................................................................................284.8.2 Physical Specification...................................................................................284.8.3 Installation ....................................................................................................294.8.4 System Set-up..............................................................................................294.8.5 Site Monitor Settings ....................................................................................31


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4.9 Battery Cell Monitor (BCM)..................................................................................324.9.1 Main Features of the BCM............................................................................324.9.2 BCM Specifications ......................................................................................334.9.3 Preparing the battery for connection to the BCM..........................................334.9.4 Installing the board .......................................................................................344.9.5 Dip-Switch Selection of Cell Voltages ..........................................................344.9.6 Battery Cell Lead Connection to the BCM board..........................................35

5. Remote Communication Interfaces ........................................................................435.1 Ethernet (TCP/IP) and SNMP Interface (WebCSU)............................................435.2 RS232 Interface (MCSP).....................................................................................435.3 RS485 Interface (MCMD) ....................................................................................435.4 Integrated Packet Modem (Smart Modem)..........................................................43

6. Operation ..................................................................................................................45Summary of MCSU-4 front panel controls ....................................................................456.1 MCSU-4 Components .........................................................................................46

6.1.1 Alpha-numeric Display..................................................................................466.1.2 Front Panel Pushbuttons ..............................................................................466.1.3 Status Indicating LEDs (MCSU-4) ................................................................47

6.2 Operating the MCSU-4 ........................................................................................476.2.1 Password security ........................................................................................476.2.2 Test Mode ....................................................................................................486.2.3 Entering and moving through different Menus..............................................486.2.4 When an alarm condition exists....................................................................48

6.3 MCSU-4 Alarms...................................................................................................496.4 User programmable relay functions.....................................................................506.5 Mapping of loaded SMRs ....................................................................................516.6 MCSU-4 Base Menu Screens..............................................................................51

6.6.1 Single Phase AC Monitoring Screens ..........................................................516.6.2 Three Phase AC Monitoring Screens ...........................................................526.6.3 Base Menu Programmable Parameters .......................................................536.6.4 Auxiliary Function Selection & Parameters...................................................57

6.7 SMR Menu Screens ............................................................................................616.7.1 SMR Menu Programmable Parameters .......................................................626.7.2 SMR Menu Sleep Mode ...............................................................................63

6.8 Battery Parameter Menu Screens .......................................................................646.9 Battery Discharge Test ........................................................................................68

6.9.1 Results of last Battery Discharge Test - (Last BDT) .....................................70


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6.10 Alarms Log Screens.........................................................................................716.11 Battery Cell Monitor Setup ...............................................................................71

6.11.1 Relationship between “BCM Batteries” and “Num Batteries”........................726.11.2 Frequency of measurement..........................................................................726.11.3 Battery Cell Measurements ..........................................................................72

6.12 Earth Leakage Detector - MUIB3 and MUIB5 only...........................................73

7. Commissioning ........................................................................................................747.1 Indicators on the Rectifier Front Panel ................................................................747.2 System Parameter Ranges .................................................................................74

7.2.1 RT9 SMR Parameters ..................................................................................747.3 System Commissioning .......................................................................................74

7.3.1 Commissioning Procedure ...........................................................................75

8. Maintenance .............................................................................................................768.1 Warnings and precautions...................................................................................768.2 SMR Maintenance ...............................................................................................76

8.2.1 Current Sharing ............................................................................................768.2.2 Integrity of Electrical Connections ................................................................768.2.3 Fan Filter Maintenance.................................................................................76

9. Fault Finding and Replacement Procedures .........................................................789.1 System Fault Finding Procedures........................................................................789.2 MCSU-4 Fault Finding and Repair Procedures ...................................................81

9.2.1 Replacing MCSU-4.......................................................................................82


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1. General Warnings

1. This equipment has been designed to be used only in restricted access areas.2. This equipment must only be serviced by authorised and qualified service personnel.3. Operators should not attempt to repair faulty units. There are no operator serviceable

parts inside. All fuses are only replaced as part of a repair procedure in a repairfacility by authorised personnel and not as a maintenance procedure on site.

4. The rectifier must be mounted in a rack that satisfies requirements for electricalenclosures and fire enclosures according to IEC60950 or equivalent standard. The backof the rectifier magazine must not be accessible to operators under any condition.Suitable access barriers above the topmost and below the bottom-most magazine mustprevent operator access to the back of the magazine.

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

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

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

8. Take care when removing the rectifier as it may be too hot to touch the metal casing,especially if the ambient temperature is high and the unit has been operating atmaximum load. When removing, pull the unit halfway out of the magazine and let coolfor 2-3 minutes before handling.


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2. Summary of Programmed System ParametersParameter Description Range Default

ValueActualValue

Base (System) Menu

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

Volts Hi System output volts high threshold 26-33V 28.7V

Volts Low System Output volts low threshold 20-27V 22.5V

System: Select system duty type UPS/Standby UPS

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

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

FS Batt I Battery current transducer full scale rating 10-30000A 100A

CSU # CSU Access code (up to 7 digits) 0-9999999 0000000

Date / Time Current system date and time

Auxiliary Units Submenu

AC 1-ph Menu (After enabling AC 1-ph Monitor)

1ph ACV Hi AC supply high voltage alarm 220-315V 260V

1ph ACV Lo AC supply low voltage alarm 140-270V 200V

1ph ACF Hi Frequency high alarm 50-65Hz 55Hz

1ph ACF Lo Frequency low alarm 40-60Hz 45Hz

1ph ACI FS AC supply current transducer full scale rating 10-500A 100A

AC 3-ph Menu (After enabling 3-ph AC Monitor)

3ph ACV Hi AC supply high voltage alarm 220-315V 260V

3ph ACV Lo AC supply low voltage alarm 140-270V 200V

3ph ACF Hi Frequency high alarm 50-65Hz 55Hz

3ph ACF Lo Frequency low alarm 40-60Hz 45Hz

3ph ACI FS AC supply current transducer full scale rating 10-500A 100A

Battery Monitor Menu (After enabling Battery Monitor)

Bat Config Battery Monoblock size x number(see BCM section of manual for more detail)

Variousconfigurat’ns

12 cells

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

Vhi Cell Cell high voltage alarm 2.0-16.0V 2.5V

Vlow Cell Cell low voltage alarm 1.0-12.0V 1.8V

+dVc Cell Cell positive deviation alarm 5-99% 10%

-dVc Cell Cell negative deviation alarm 5-99% 10%

Site Monitor Menu If included in the system refer to Site Monitor documentation.

SMR Menu 2)

SMR Float Operating float voltage 3) 27.5V

SMR Equalise Operating equalisation voltage 3) 28.5V

SMR V High SMR voltage high alarm 26-32.5V 28.0V


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Parameter Description Range DefaultValue

ActualValue

SMR V Low SMR voltage low alarm 22-27V 24.0V

SMR HVSD SMR high volts shut down 27-33V 28.7V 4)

SMR I Limit SMR current limit 5-130A 15A 4)

SMR PowerMax

Max power for SMR 0-8000 1400

Sleep Mode SMR Sleep Mode Enable. On/Off Off

Sleep MinSMR

SMR Sleep Mode Minimum rectifiers that mustbe online.

0 to NumberSMR definedin the system

1

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

1 to 365, 0 =Off – norotation

7 days

Battery Menu

B Dis Al Battery discharge alarm threshold 22-26V 23.0V

Disch I Diff Battery string discharge current difference alarm 5-99A 20A

Batt T Alrm Battery Temperature alarm threshold 30 to 90°C 40°C

Bat Rated Ampere-hour rating of batteries 20 to 9999AH 500Ah

BTC Battery Temperature Coefficient 0-6mV/°C/cell 0mV(Off)

Number Cells Number of chemical cells in battery string 11-23 12

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

Vdd Level Battery deep discharge voltage threshold 20-23.5V 22.5V

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

Sys Float System float voltage (Vfl) 24-29V 27.0V

Sys Drop System voltage drop 0.0-1.0V 0.5V

Equalisation Enable/Disable EQ function On/Off Off

BILim Vb>Vf1 Battery charging current limit in equalise Vb > Vfl 5-999A 50A

Sys Equal System equalise voltage (Veq) 25-30.5V 5) 28.0V

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

V Eq trig Discharge voltage threshold for Eq. charging 22-25V 24.0V

Q Start Eq Enable/disable battery charge depletion trigger On/Off Off

Qdis Trig Charge depletion threshold for Eq. charging 5-999AH 15AH

EQ End Current Equalisation termination for Ibat < EQ End 1-2000A 5A

EQ Duration Maximum duration of Equalisation charging 3-48 Hr 20 Hr

EQ Period Time between periodic Equalisation charging 0-52 Wk 12 Wk

LVDS Trip Battery voltage below which will open LVDS 20-24V 22.0V

BDT Per Period between consecutive discharge tests 0-365 days 30 days

BDT Time Time of day to begin BDT (hr:min) 00:00-23:59 02:00

BDT Dur Maximum duration of BDT 5-1440min 180min

BDT Curr Discharge test current 0-5000A 50A

BDT End V Battery voltage limit to terminate BDT 18-24V 22.0V


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Parameter Description Range DefaultValue

ActualValue

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

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

1) Maximum of 4 batteries with MUIB2, maximum of 2 batteries with other interfaces.2) See SMR section for internal parameters.3) Not directly adjustable – see explanation in MCSU-4 section.4) Will be automatically programmed to SMR internal setting once connected in the system.


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3. Configuration3.1 System DescriptionThis Manual has been written with the objective of giving the reader a sufficientunderstanding of the system and its constituent parts in order to be able to install,commission and operate the system.

3.1.1 General DescriptionThis modular system has been designed specifically to power 24V or 48Vtelecommunications equipment requiring accurate temperature compensated Float andEqualisation voltages, low output noise and EMI levels.A typical system comprises a number of rectifiers, depending on the power requirement ofthe system, and a monitoring and control subsystem comprising a monitoring and controlmodule (MCSU-4), a User Interface Board (MUIB) and optional modules for monitoring ACpower and battery cell voltages.The system can be configured in a number of ways depending on the customer andapplication requirements. The simplest option is shown in Figure 3.1.

System Controller

MUIB(Supplies System

Controller)

AC Distribution

Remote Alarmsand Ambient

Temp. Sensor

DC Bus

DC DistributionBatteries withCircuit Breakers

Magazines ofAC-DC Converters

DC Loads

Local Comm. Port

Remote Comm. Port

Figure 3.1 System with basic monitoring and controlThe AC Distribution may simply consist of circuit breakers, one for each magazine ofrectifiers in the system, or may also include an isolator, depending on customerrequirements.The rectifiers housed in one or more magazines are paralleled and the DC outputconnected to the load via the DC Distribution module and to the battery bank, which maybe a single battery or two (or more) batteries connected in parallel. A Low VoltageDisconnect Switch (LVDS) may also be included in series with the batteries in order toprevent over-discharging the battery bank in the event of an unusually long AC poweroutage.The monitoring and control signals, such as battery currents, temperature, battery switchstatus, LVDS control and status, system voltage and ambient temperature are connected


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to the monitoring and control module (MCSU-4) via an interface card (MUIB). This moduleis in turn connected to the MCSU-4 magazine via a 34 way ribbon cable.A 10-wire cable, which carries the digital communications signals that allow control andmonitoring of the rectifiers, connects the MCSU-4 to all the rectifiers in a parallelarrangement so that all the rectifiers receive the same signal.System status and operating parameters can be accessed from a PC connected to localcommunication port on the front panel of the controller.Remote monitoring of the system can be by means of voltage-free relay contacts.Standard system uses 3 relays corresponding to SMR shutdown, System Alarm and HighVoltage Shut Down (HVSD).Alternatively, a remote communication port can be used to display all the system andrectifier information on a remote PC.With this facility, it is possible to not only monitor but also control all the rectifier andsystem parameters. In addition, the system has the capability to dial up to three telephonenumbers to connect to the remote PC in the event of a system fault having developed, andwill continue dialling until the fault is reported.

Battery Cell Monitor

System Controller


Controller)

AC Distributionwith 1 Monitor


Temp. Sensor

DC Bus



DC Loads

Local Comm. Port

Remote Comm. Port

Figure 3.2 System with additional single phase AC MonitorThe second option shown in Figure 3.2 is the basic arrangement described above with theaddition of an auxiliary single phase AC monitoring module and Battery Cell Monitor. Thismodule, which is mounted in the AC distribution module, connects via a ribbon cable to theMUIB and is used to monitor the AC voltage, current and frequency .The third option shown in Figure 3.3 is the basic arrangement with the addition of anauxiliary three phase AC monitoring module. The latter connects directly to the MCSU-4via a ribbon cable and provides monitoring of the three AC voltages and currents as wellas the AC frequency. It has multiplexing circuits on board which effectively extends theanalogue monitoring ability of the MCSU-4.


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It is possible to have both the single and three phase AC monitoring modules connected atthe same time. This can be useful where the AC output of an inverter running off the 48VDC bus can be monitored at the same time as the three phase AC supply to the rectifiers.

Battery Cell Monitor

System Controller


Controller)

AC Distributionwith 3 Monitor


Temp. Sensor

DC Bus



DC Loadswith 1 Inverterand AC Monitor

Local Comm. Port

Remote Comm. Port

Figure 3.3 System with additional 3 phase AC Monitoring; simultaneous monitoringof single phase inverter also possible

3.1.2 Rectifier Specific ConfigurationsA typical mechanical arrangement of a system comprising 4 rectifiers in a mini shelf isshown in Figure 3.4. It consists of 4 rectifiers (2U total), and a MCSU-4 shelf, for a total of3U. The arrangement shown is designed to fit into a standard 19” rack. Otherconfigurations are equally possible.

Figure 3.4 Typical 4 rectifier modular power supply with MCSU-4


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4. Installation4.1 System InstallationThe installation of an uninterruptible DC power system incorporating rectifiers, batteriesand control hardware requires compliance to National Wiring Standards, and appropriatesections of standard IEC60950 to ensure safety of operators and supplementaryequipment. Wiring should always be done by qualified personnel.

4.1.1 RacksThe structure and continuity of the rack provide both system safety compliance andadditional shielding for electromagnetic compatibility (EMC) of the DC power system. Therack enclosure needs to have the following features to provide safe and efficient systemoperation:

The rack must form a basic fire enclosure. To do this, a rack needs a separator or baseplate, which prevents a burning liquid from escaping the enclosure when pouredvertically into the rack. This can be achieved by using either a baffle plate below therectifiers with a front finger grill that traps the liquid or a purpose made separation platethat it mounted below the rectifier magazine to catch burning liquids.

Openings in the top and sides of the enclosure must comply with the following:

not exceed 5mm in any direction, or

not exceed 1mm in width regardless of length, or

for the top of the enclosure, be constructed that direct, vertical entry of fallingobjects be prevented from reaching bare parts at HAZARDOUS voltage(>32VAC or >60VDC), and/or,

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

Construction of the rack is important in providing exhaust air venting. Cooling louvres,vent holes or a rack with a ‘top hat’ construction are all good methods of obtaining goodventilation while maintaining compliance with item ii) above.

The rack needs to be able to mount 19” rack equipment, have a depth not less than400mm and a minimum height for enclosing the magazine.

4.1.2 MagazinesThe magazine configuration metalwork and wiring are usually manufactured as a minishelf module with terminal blocks to accept AC wiring and DC output cables. Thesemagazines should be located in the rack to allow adequate cooling of rectifiers, noting thatthe airflow is from the front to the rear of the magazine.The magazines are held in the rack by M6 screws through the mounting flange and intothe rack mounting rail. All wiring is typically via rear access.

4.1.3 Lightning and Transient SuppressionThe rectifiers and magazine contain basic transient suppression in the form of Metal OxideVaristors (MOVs) across line-to-neutral, line-to-earth and neutral-to-earth. These MOVsare sized to provide protection from typical line transients in an industrial environmentaccording to ANSI C62.41-1991 (6kV/3kA) and IEC 61000-4-5 (Level X). Under these


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conditions, the MOVs are expected to provide transient protection for the life of therectifiers.If the transient environment is more severe, with a high incidence of lightning strikes eitherindirect or direct, and/or severe switching transients beyond the levels outlined in thestandard, then supplementary transient protection is required. Larger MOVs (40kA rating)are required at the AC main switchboard where the power to the rack originates.For wiring systems where the neutral is bonded to the building earth at the mainswitchboard (as used for example in Australia, USA, and Canada), one MOV from line-to-neutral is required for single phase, and three MOVs from each line-to-neutral are requiredfor three phases.For wiring systems where the protective earth is bonded to the neutral conductor only atthe distribution transformer, as is common in Europe, three MOVs are required for a singlephase (line-to-neutral, line-to-earth, neutral-to-earth), and seven MOVs are required forthree phase wiring (phase-to-neutral x 3, phase-to-earth x 3 and neutral-to-earth).

4.1.4 Cabling, Auxiliary Equipment and Circuit BreakersIn general, the system needs to have most of the following modules: AC Module, DCDistribution Module, Battery Circuit Breakers, DC Cabling, Battery Current Transducers,Temperature Sensors and AC Monitoring Module (optional).These modules are required inside the rectifier rack for normal system operation. A briefdescription of the modules and what they connect to is given below, along with a detailedrack wiring diagram in Figure 4.1 that shows a system using a MUIB interface.AC Module: An enclosure containing all the AC circuit breakers (curve C or D) for therectifiers, single or three phase active links, neutral links and main protective earth link forconnection to the installation AC system. In any system larger than 3kW, it is advisable tobalance the loads between all three phases. Consultation of local supply authorityrequirements is advised.Note that when using the RT9/10/11 units without a battery, the AC circuit breakers must be a curve-D type (motor start). This is required to prevent false tripping of the circuit breaker when there arehalf-cycle mains interruptions and the subsequent surges. Systems with a battery do not have thisrequirement.

DC Distribution: An enclosure containing all the DC load distribution circuit breakers andusually the Battery string circuit breakers. If the Battery breakers are included in the DCdistribution module, an isolation barrier is usually required along with clear labelling whichbattery string the breakers are protecting. The input to the DC distribution module comesdirectly from the DC output line of the rectifiers that is NOT connected to the system (DC)earth.DC Cabling: The choice of DC cabling and/or busbars is based entirely on the DC currentrating of the system. Consult the local National wiring standard for the selection ofcable/busbar size for the DC connections. One suggested method of DC cabling formedium systems (~6-8kW) is to provide short 100mm x 6mm busbars at the external DCinterface with a number of holes to attach smaller DC cables. Then connect cables up to25mm2 from the DC terminations to the output terminals of the individual magazines. Theflexibility of the DC cables can be a benefit over fixed busbars when fitting componentsinto a rack with limited space.


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Figure 4.1 Typical System Wiring


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Battery Current Transducers: A Hall effect current measuring unit that is installed over thecable connecting the battery string to its circuit breaker. The signal lines are connected toterminal on the MUIB.Temperature Sensors: Modules typically assembled in a copper lug with a mounting holeat one end and sensor cabling running from the other sealed end to terminals in the MUIB.The sensors are normally placed in the battery compartment to measure batterytemperatures.AC Monitoring Module: Optional modules are available in either single phase or threephase models. The module connects in series with the incoming mains supply by havingthe phase wires inserted through the current sensors on the module before having theterminating at the active link. The phase-neutral (or phase-phase) voltages are separatelysensed by reference transformers. Inputs for voltage measurement are protected againsthigh voltage transients. The modules are connected to the MCSU-4 magazine via a 16-way ribbon. If both types of modules are installed use the second 16-way connector onsingle phase module for connection to the three phase module.DC voltage regulation and power for the MCSU-4 is derived from the output DC bus viathe connections on the MUIB. The connection point is made where a constant voltage ismost useful. This is typically at the point where the cables run to the batteries. Externalvoltage sensing for voltage regulation at a load can also be done, but in most systems, thesystem voltage is sensed on the internal output bus. For more information, see thedetailed section on the MUIB.

4.2 Rectifier Installation and RemovalIn the system, the rectifiers are designed to operate in parallel in a N+1 redundant mode.Therefore, there is never a situation in which it is necessary to set individual rectifierparameters.The rectifiers are designed to be “hot pluggable” in that they can be plugged into and outof a “live” magazine. Due to the small size of energy storage elements in the rectifieroutput, there is no significant disturbance to the DC bus when a rectifier is plugged into themagazine.An inrush limiting circuit in the AC input circuit that utilises a relay and an inrush currentlimiting resistor limits the disturbance to the AC source to an acceptable level when a unitis plugged in with AC voltage present on the AC bus.

4.2.1 To Remove a Rectifier from the MagazineAlthough the connectors are designed to be “hot pluggable” it is advisable to first switch offpower to the unit by means of the circuit breaker in the AC distribution module beforeunplugging the unit. This is done to prolong the life of the rear “hot pluggable” connector.Each rectifier 1U shelf has a spring clip that secures the rectifiers in place once it isplugged into its magazine. First lift the clip, then, using the finger recess in the front, pullthe rectifier from the magazine.

WARNING !!Take care when removing the rectifier as it may be uncomfortably hot to hold especially if

the ambient temperature is high and the unit has been operating at maximum load.


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4.2.2 Inserting a Rectifier into the MagazineAlthough the connectors in the unit are designed for “hot pluggability” it is advisable to turnoff the AC power to the input connector by means of the related circuit breaker in the ACdistribution module before plugging in the unit.Carefully slide the rectifier into the magazine. Press the unit into the magazine until it isflush and the spring retaining clip clicks down. This ensures that it will not fall out in theevent of severe shaking as might occur in the event of an earthquake.Switch on the relevant AC circuit breaker in the AC distribution module. The rectifier willstart automatically and connect itself to the DC bus at the appropriate time.

4.3 MUIB - Mini User Interface BoardConnections between the MCSU-4, the external transducers and other inputs are madeusing the connectors provided on the MUIB. Terminals are provided for alarm relaycontacts, battery and ambient temperature sensors, two battery current transducers, LVDScontrol and circuit breaker operation detection using the breaker auxiliary contacts for boththe battery and load circuit breakers.

4.3.1 MUIB Connections

4.3.1.1 Relay Contact Outputs

There are 5 relays with normally open (N/O) and normally closed (N/C) contacts availableon the MUIB, connector X2 (see Figure 4.3). In standard RTP system three of the relaysare for remote annunciation of alarms: Relay 3 - HVSD, Relay 4 – any system alarm,Relay 5 - SMR shut down.

Other two relays are used for control of optional external equipment.

Relay 2 is programmed for FAN CONTROL. If any one of the SMR heat-sink temperaturesexceeds a pre-set (non-programmable) value, the relay closes. The relay closure can thenbe used to either speed up fans, which may normally be idling at low speed, or it can turnon fans, which may normally be off.

In 110V systems Relay 1 closes during battery discharge test, allowing control of dummyload on standby systems. In 24V and 48V systems it has no assigned function.

If MCSU-4 supports User Programmable Relays, the functions described above can bechanged on site according to specification of the installation (for details see paragraph“User programmable relay functions” in chapter “Operation”). It is also possible topermanently assign different functions to the relays on end user request by modifyingcontroller software.

4.3.1.2 Spare Digital and Analog InputsThere are 4 spare digital inputs (USER 1, 2, 3, 4) available on the MUIB for the monitoringof external plant associated with the power supply. The inputs must be isolated relaycontacts or auxiliary contacts, which are either normally open or normally closed.There is also provision for monitoring two external analog levels via connectors X28 (AN1)and X31 (AN2) on the MUIB. The analog signals must be in the range 0 to +5VDC.To use the spare analog or digital inputs the software for the MCSU-4 must be individuallyprogrammed by the manufacturer according to the requirements of the application.


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4.3.1.3 Battery Current Transducer InputBattery current transducers are connected to X39 and X40 of the MUIB. Figure 4.2 showsthe pin connections for the battery transducer connector going onto the MUIB.

1. -15V

2. +15V

3. NOT USEDED4. SIGNAL

5. GND

MFR: MolexConn: 09-50-3051pins: 08-50-0106

4-Way cable

Figure 4.2 Battery transducers connection to MUIB

Figure 4.3 MUIB Connection Diagram

X1

X2

X18

X17

X28 X31

X32

X22

X23 X33 X34 X44 X45

X39

X40

34-way ribboncable to MiniCSU

X50 X64 X65

Conn # Conn Label Class Used for:

X1 MiniCSU Anal/Dig 34-way ribbon cable to MiniCSU

X2 RELAY 1 Digital Dummy load on 110V systems, not used on other systems

RELAY 2 “ Cabinet Fan control for RT4 or RT5 systems

RELAY 3 “ SMR HVSD Alarm

RELAY 4 “ Activated by any alarm condition

RELAY 5 “ SMR switched off (for any reason)

X17 BAT. TEMP. Analog Temperature Transducer

X18 AMB. TEMP. Analog Temperature Transducer

X22 C.B. TRIP Digital Aux contact from load CBs

X32 1 PHASE AC Anal/Dig Not used with MCSU-4

X23 BAT. SW. Digital Aux contact from Batt. CBs

X33 USER 1 Digital User defined i/p; isolated aux. Contact or similar

X34 USER 2 Digital Requires special software to define function

X44 USER 3 Digital “ “

X45 USER 4 Digital “ “


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X28 AN 1 Analog Spare analog I/P - 0 to 5VDC (Requires special software)

X31 AN 2 Analog Spare analog I/P - 0 to 5VDC (Requires special software)

Conn # Conn Label Class Used for:

X39 BATTERY 1 Analog Battery current transducer

X40 BATTERY 2 Analog Battery current transducer

X50 POWER I/P Analog System voltage sensing and DC power input for MiniCSU

X64 LVDS Aux Digital Aux contact from LVDS contactor

X65 LVDS Coil Digital Drive for contactor or similar

Figure 4.4. MUIB Connectors wiring information

Connector Pin Signal Name Connector Pin Signal Name

X1 MCSU-4 1-34 34 way ribbon X32 1 PHASE AC 1-10 Not used with MCSU-4

X2 RELAY 1

(USER)

15 N/O relay contact X39 BATTERY 1 1 -15V

14 N/C relay contact 2 +15V

13 Common 3 No connection

X2 RELAY 2

(FAN SPEED)

12 N/O relay contact 4 Input

11 N/C relay contact 5 GND

10 Common X40 BATTERY 2 1 -15V

X2 RELAY 3

(HVSD)

9 N/O relay contact 2 +15V

8 N/C relay contact 3 No connection

7 Common 4 Input

X2 RELAY 4

(ALARM)

6 N/O relay contact 5 GND

5 N/C relay contact X22 C.B. TRIP 1-2 Contact closure requiredbetween pins 1 and 2

4 Common X23 BAT SW. 1-2 “ “

X2 RELAY 5

(SMR S/D)

3 N/O relay contact X33 USER1 1-2 “ “

2 N/C relay contact X34 USER2 1-2 “ “

1 Common X44 USER3 1-2 “ “

X17 BAT TEMP. 1 No connection X45 USER4 1-2 “ “

2 Sensor -ve X50 POWER I/P 1 Bat +ve terminal

3 Sensor +ve 2 Bus +ve terminal

X18 AMB. TEMP 1 No connection 3 No connection

2 Sensor -ve 4 Battery -ve terminal

3 Sensor +ve 5 Bus -ve terminal

X28 AN1 1 0V to +5Vdc. X64 LVDS Aux. 1-2 LVDS auxiliary contact

2 Common X65 LVDS Coil 1-3 Coil driving voltage

X31 AN2 1 0V to +5Vd 2 No connection

2 Common


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Figure 4.5. MUIB Fuse Function and Specification

Fuse Function Specification

F4 +15VDC F500mA, Glass, M20x5

F5 -15VDC F500mA, Glass, M20x5

F8 Ground T2A, HRC, M20x5

F46 -V System T2A, HRC, M20x5

F49 -V Battery T2A, HRC, M20x5

F53 +V System T2A, HRC, M20x5

F63 +V Battery T2A, HRC, M20x5

F68 +V LVDS T2A, HRC, M20x5

F69 -V LVDS T2A, HRC, M20x5

4.4 MUIB2 - MCSU-4 User Interface Board (type2)The MUIB2 is an optional module that may be used in place of the MUIB to allowmonitoring of a total of four battery currents and to directly measure one load current. TheMUIB2, like MUIB provides basic interfacing between the MCSU-4 and the systemenvironment. Use of this board also requires a specific MCSU-4 software version.The addition of the load current transducer input allows the MCSU-4 to sense the loadcurrent directly. This provides better resolution of the load current than the calculatedcurrent determined from the reported individual rectifier output currents. This is becausethere is an inherent resolution limit for each rectifier current measurement that cansignificantly degrade the load current resolution when a system contains a large number ofrectifiers. Another use of the load current transducers is when non-RTP rectifiers are usedwith a MCSU-4, and these rectifiers do not signal their current to the MCSU-4.The current transducers are standard 4V full scale. Accuracy of signal conditioning for thecurrent signals is typically 1%.

4.4.1 System setup requirementThe MCSU-4 software needs to be a version with an MUIB2 option. This board needs tobe enabled from the front panel of the MCSU-4 or PC running WinCSU-2 program. Theload transducer also needs to be enabled or disabled as necessary. The full scale valueof battery and load transducers then needs to be entered.

4.4.2 Main features of MUIB2The principal features of the MUIB2 are as follows: Each battery current input accepts input range of -4V to +4V full scale. The maximum allowed input is

5V The load current input range is from 0V to +4V. The maximum allowed input is 0 to +5V. The battery and load full scale currents are separated so different transducers for battery and load

currents can be used. Signal conditioning accuracy for the battery and load currents is typically 1%. Actual number of batteries used can be programmed via MCSU-4 front panel or WinCSU-2 remotely.


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Load transducer can be switched on or off via MCSU-4 front panel or WinCSU-2 remotely. When the load transducer is switched off, MCSU-4 automatically reverts back to calculating load current

using SMR and battery currents. There are 5 relay outputs, 4 digital inputs, LVDS interface, CB trip input and Battery switch input. Ambient and battery temperature sensors can be connected to this board. The MUIB2 also provides power to the MCSU-4, this board can be connected to the bus and battery at

the same time. Two spare analog inputs are available (input range: 0 to +5V).

4.4.3 MUIB2 ConnectionsThe MUIB2 connector wiring diagram is shown in the table of Figure 4.9, followed by theconnection diagram and connector legend in Figure 4.8.

4.4.3.1 Relay Contact Outputs

There are 5 relays with normally open (N/O) and normally closed (N/C) contacts availableon the MUIB2, connector X2. In standard RTP system three of the relays are for remoteannunciation of alarms: Relay 3 - HVSD, Relay 4 – any system alarm, Relay 5 - SMR shutdown.



In 110V systems Relay 1 closes during battery discharge test, allowing control of dummyload on standby systems. In 24V and 48V systems it has no assigned function.If MCSU-4 supports User Programmable Relays, the functions described above can bechanged on site according to specification of the installation (for details see paragraph“User programmable relay functions” in chapter “Operation”). It is also possible topermanently assign different functions to the relays on end user request by modifyingcontroller software.

4.4.3.2 Connections to MCSUTwo ribbon cables connect between MUIB2 and MCSU-4 magazine. One 34-way ribboncable for the main port connects X1 on MUIB2 to MCSU-4. The other 16-way ribbon cableconnects X180 or X179 on MUIB2 to the aux port of MCSU-4.Note: The connection of the 16-way ribbon to X179 or X180 must be made if any of X76,X89, X103, X115, or X129 are used.


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4.4.3.3 Battery Current Transducer InputBattery current transducers are connected to X39 and X40 of the MUIB. Figure 4.2 showsthe pin connections for the battery transducer connector going onto the MUIB.

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

MFR: Molex

Conn: 09-50-3051

pins: 08-50-0106

4-Way cable

Figure 4.6 Battery transducers connection to MUIB2

4.4.3.4 Load Current Transducer InputA load current transducer is connected to X76 of the MUIB2 via a connector using the pinconnections shown below.

1. -15V

2. +15V

3. SIGNAL

4. NOT USED

5. GND

MFR: MolexConn: 09-50-3051pins: 08-50-0106

4-Way cable

Figure 4.7 Load transducer pin connection for MUIB2

4.4.3.5 Power InputPower to a MCSU-4 is connected to this MUIB2 via connector X50. Pin designations arealso labelled on the PCB as well. Both the bus and battery voltages are connected to theMCSU-4 via this connector. The MCSU-4 takes power from either the battery or busdepending on which voltage is higher. The system voltage is read by the MCSU-4 via thebus terminations of this connector.

4.4.3.6 CB Trip, Batt Sw and LVDS Aux inputsCB Trip (X22) is used to sense the CB status. Batt Sw (X23) is used to sense status ofbattery switch. LVDS Aux (X64) is used to sense the status of the LVDS switch. Opencontacts on any of these 3 input creates an alarm condition on the MCSU-4, therefore,when any of these 3 inputs are not used, a shorting plug should be installed on those notin use.


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4.4.3.7 Spare Digital and Analog InputsThere are 4 spare digital inputs (USER 1, 2, 3, 4) available on the MUIB for the monitoringof external plant associated with the power supply. The inputs must be isolated relaycontacts or auxiliary contacts, which are either normally open or normally closed.There is also provision for monitoring two external analog levels via connectors X28 (AN1)and X31 (AN2) on the MUIB. The analog signals must be in the range 0 to +5VDC andcan only be monitored if the single phase AC monitoring module is not connected. This isbecause the MMIB1 and the spare analog input share the same input lines to theMiniCSU.To use the spare analog or digital inputs the software for the MiniCSU must be individuallyprogrammed by the manufacturer according to the requirements of the application.

4.4.4 FusesFor fuse functions, type and rating please refer to the table at the end of MUIB section.


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Figure 4.8 MUIB2 Connection Diagram and Connector Legend

16 way ribbon cableto MCSU-2

34 way ribbon cableto MCSU-2

Conn # Conn Label Class Comments

X1 MCSU-4 Anal/Dig 34-way ribbon cable to MCSU-4X2 RELAY 1 Digital Dummy load on 110V systems, not used on other systems





X17 BAT. TEMP. Analog Temp. TransducerX18 AMB. TEMP. Analog Temp. TransducerX22 C.B. TRIP Digital Aux contact from load CBsX32 1 PHASE AC Anal/Dig Not used with MCSU-4X129 BAT1-Current Analog Batt 1 Current TransducerX115 BAT2-Current Analog Batt 2 Current TransducerX103 BAT3-Current Analog Batt 3 Current TransducerX89 BAT4-Current Analog Batt 4 Current TransducerX23 BAT. SW. Digital Aux contact from Batt. CBsX33 USER 1 Digital User defined input; isolated aux. contactX34 USER 2 Digital Requires special software to defineX44 USER 3 Digital “ “X45 USER 4 Digital “ “X28 AN 1 Analog Spare analog I/P - 0 to 5VDC (Requires special software)X31 AN 2 Analog Spare analog I/P - 0 to 5VDC (Requires special software)X64 LVDS Aux Digital Aux contact from LVDS contactorX65 LVDS Coil Digital Drive for contactor or similarX50 POWER I/P Analog System voltage sensing & DC power input for MCSU-4X76 LOAD-Current Analog Load Current TransducerX180 MCSU Anal/Dig 16-Way ribbon cable to Aux PortX179 NEXT UNIT Anal/Dig 16-Way ribbon cable to Aux Port


158-1872-01.doc 20 3-Feb-16

Figure 4.9 MUIB2 Connector Wiring Information

Connector Pin Signal Name Connector Pin Signal NameX1 MCSU-4 1-34 34 way ribbon X18 AMB. TEMP 1 No connection

X180 MCSU-4 1-16 Aux Port 2 Sensor -ve

X179 Next Unit 1-16 Aux Port 3 Sensor +ve

X2 RELAY 1(USER)

15 N/O relay contact X28 AN1 1 0V to +5Vdc.

14 N/C relay contact 2 Common

13 Common X31 AN2 1 0V to +5Vdc.

X2 RELAY 2(FAN SPEED)

12 N/O relay contact 2 Common

11 N/C relay contact X32 1 PHASE AC 1-10 Not used with MCSU-4

10 Common X129 BAT1-Current 1 -15V

X2 RELAY 3(HVSD)



7 Common 4 Input

(X2 RELAY 4ALARM)


5 N/C relay contact X115 BAT2-Current 1 -15V

4 Common 2 +15V

X2 RELAY 5(SMR S/D)

3 N/O relay contact 3 No connection

2 N/C relay contact 4 Input

1 Common 5 GND

X22 C.B. TRIP 1-2 Contact closure requiredbetween pins 1 and 2

X103 BAT3-Current 1 -15V

X23 BAT SW. 1-2 “ “ 2 +15V

X33 USER1 1-2 “ “ 3 No connection

X34 USER2 1-2 “ “ 4 Input

X44 USER3 1-2 “ “ 5 GND

X45 USER4 1-2 “ “ X189 BAT4-Current 1 -15V

X50 POWER I/P 1 Bat +ve terminal 2 +15V

2 Bus +ve terminal 3 No connection

3 No connection 4 Input

4 Battery -ve terminal 5 GND

5 Bus -ve terminal X76 Load-Current 1 -15V

X64 LVDS Aux. 1-2 LVDS auxiliary contact 2 +15V

X65 LVDS Coil 1-3 Coil driving voltage 3 Input

2 No connection 4 No connection

X17 BAT TEMP. 1 No connection 5 GND

2 Sensor -ve

3 Sensor +ve


158-1872-01.doc 21 3-Feb-16

4.5 MUIB3 – Systems with Earth Leakage DetectionThe MUIB3 has been designed to operate in conjunction with 24V, 48V and 110V rectifiersand MCSU-4 to control and monitor these systems, while providing earth leakage currentdetection. It provides basic interfacing between the MCSU-4 and the system environment.Most of the functions available on the standard MUIB are also present in the MUIB3. Themain difference is that the LVDS circuit is replaced by an earth leakage detection circuit.In addition, the 10 way ribbon cable header socket for connecting the single phasemonitoring module has been removed, as has the connector for the AN1 spare analogueinput since the associated analogue channel is used by the microprocessor to monitor theearth leakage current.

4.5.1 System setup requirementThe MCSU-4 software needs to be a version with the MUIB3 option. From the front panelof the MCSU-4 scroll down the CSU menu to a window which gives the choice of MUIB orMUIB3. Select MUIB3 in place of the standard MUIB. The selection can be also madefrom a PC running WinCSU-2 program.

4.5.2 Main features of MUIB3The principal features of the MUIB3 are as follows:

There is provision for battery and ambient temperature sensors.

There is provision for two battery current transducers.

An Earth leakage current detector enables the display of leakage currenton the MCSU-4 screen or on the remote monitor screen. Full scale is +/-10mA.

A window on MCSU-4 or WinCSU-2 allows the programming of the earthleakage current level between 1.0mA and 9.5mA at which an alarm isasserted.

Each battery current input accepts an input range of -4V to +4V full scale.The maximum allowed input is 5V.

The actual number of batteries used in the system can be programmedby the user via the MCSU-4 front panel or remotely by WinCSU-2software.

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

The MUIB3 provides power to the MCSU-4;

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

4.5.3 MUIB3 Connections

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


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4.5.3.2 Relay Contact outputs

There are 5 relays with normally open (N/O) and normally closed (N/C) contacts availableon the MUIB3, connector X2. In standard RTP system three of the relays are for remoteannunciation of alarms: Relay 3 - HVSD, Relay 4 - any system alarm, Relay 5 - SMR shutdown.



In 110V systems Relay 1 closes during battery discharge test, allowing control of dummyload on standby systems. In 24V and 48V systems it has no assigned function.

If MCSU-4 supports User Programmable Relays, the functions described above can bechanged on site according to specification of the installation (for details see paragraph“User programmable relay functions” in chapter “Operation”). It is also possible topermanently assign different functions to the relays on end user request by modifyingcontroller software.

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

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

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

MFR: Molex

Conn: 09-50-3051

pins: 08-50-0106

4-Way cable

Figure 4.10 Current transducer connection

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

4.5.3.6 CB Trip and Batt Sw inputsCB Trip (X22) is used to sense the CB status. Batt Sw (X23) is used to sense the batteryswitch status. Open contacts on any of these 2 inputs creates an alarm condition on the


158-1872-01.doc 23 3-Feb-16

MCSU-4. Therefore, when any one of these 2 inputs are not used, a shorting plug shouldbe installed on the input not being used.

4.5.3.7 Earth Leakage DetectorThe block diagram in Figure 4.11 shows the principle on which the earth leakage detectorworks. The SMRs and Batteries, which are normally galvanically isolated from Earth, areactually grounded via sensing resistor Rde which connects to the centre-tap of tworelatively high value resistors (Re in Figure 4.11). The effect is that if there are no otherelectrical paths to Earth, then +Vb and -Vb should be equal and opposite in value. So ifthe battery voltage, for example, is 124VDC, the voltage of the positive DC bus withrespect to Earth should be +62VDC and the negative bus should be -62VDC.If there is any external leakage path to Earth (e.g. battery acid trickles to metal, earthedframe), the return path must be through Rde. The voltage developed will then bemeasured and interpreted by the microprocessor in the MCSU-4.It should be noted that if there is no external leakage current, the voltage measured at thetest point on the UIB3 marked ELEAK will not be zero, but a calibrated voltage a little over2.5VDC. This is an offset voltage, which has been introduced to enable themicroprocessor to monitor earth leakage current of both positive and negative polarity.

SMRsBatt 1 Batt 2

Earth

Voltage shiftingnetwork on

MUIB3

To MiniCSU A/DConverter

+0.5Vb

-0.5VbNegative DC bus

Positive DC bus

Rde

Re

Re

Figure 4.11 Earth Leakage current detector circuit on MUIB3


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Figure 4.12 MUIB3 Connection Diagram

X1

X2

X18

X17

X22X23 X33 X34 X44 X45

X31X40

X39

X50

X68

34-way ribbon cableto MiniCSU-2

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

X2 RELAY 1 Digital Dummy load on 110V systems, not used on other systems





X17 BAT. TEMP. Analog Temp. Transducer

X18 AMB. TEMP. Analog Temp. Transducer

X22 C.B. TRIP Digital Aux contact from load CBs

X23 BAT. SW. Digital Aux contact from Batt. CBs

X33 USER 1 Digital User defined input; isolated aux. contact or similar

X34 USER 2 “ Special software required

X44 USER 3 “ “ “

X45 USER 4 “ “ “

X31 AN 2 “ Spare analog I/P - 0 to 5VDC (Requires special software)

X39 BATTERY 1 “ Battery current transducer

X40 BATTERY 2 “ Battery current transducer

X50 POWER I/P “ System voltage sensing and DC power input for MCSU-4

X68 System Earth N/A Wire from frame and System Earth


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Figure 4.13 MUIB3 Connector wiring information

Connector Pin Signal Name Connector Pin Signal Name

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

X2 RELAY 1

(USER)



13 Common 4 Input

X2 RELAY 2

(FAN SPEED)


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

10 Common 2 +15V

X2 RELAY 3

(HVSD)

9 N/O relay contact 3 No connection

8 N/C relay contact 4 Input

7 Common 5 GND

X2 RELAY 4

(ALARM)

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

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


X2 RELAY 5

(SMR S/D)

3 N/O relay contact X34 USER2 1-2 “ “

2 N/C relay contact X44 USER3 1-2 “ “


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

2 Sensor -ve 2 Bus +ve terminal

3 Sensor +ve 3 No connection

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

2 Sensor -ve 5 Bus -ve terminal

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

X31 AN2 1 0V to +5VDC.

2 Common

Figure 4.14. MUIB3 Fuse Function and Specification

Fuse Function Specification

F4 +15VDC F500mA, Glass, M20x5

F5 -15VDC F500mA, Glass, M20x5

F8 Ground T2A, HRC, M20x5

F46 -V System T2A, HRC, M20x5

F49 -V Battery T2A, HRC, M20x5


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4.6 Single Phase AC Monitoring Module – MMIB4In low power systems where single phase power only is supplied, an optional single phasemonitoring module can be used to monitor the incoming AC voltage, current andfrequency. The module is connected between the incoming supply and the AC Distributionmodule and connects to the MUIB/MicroCSU via a 16-way ribbon cable, which can be“daisy-chained” to other auxiliary modules. A connector and jumper link is available toallow for connection of an external CT if the on-board CT is not used.The connection diagram of the MMIB4 module is shown below in Figure 4.15. Thestandard unit has a CT full scale rating of 100Arms (for 5V input to MiniCSU), and a fullscale voltage sense rating of 300Vrms (active-neutral). Higher or lower full scale currentratings can be used as the external CT, with a corresponding value being set in theMiniCSU/MicroCSU AC monitoring menu.

X137

CT

X87

X51

To AC distribution

ActiveAC Voltage Sensing

Neutral

External CT Selector Link

X6 X21 16 way ribbons to MCSUand auxilary modules

Figure 4.15 Single Phase AC monitoring unit MMIB4 block diagram

4.7 Three Phase AC Monitoring Module – MMIB2For large power systems where the rectifiers are balanced over all three phases, anoptional three phase monitoring module (MMIB2) can be used to measure the AC supplyphase-neutral voltages, phase currents and supply frequency. The MMIB2 connectsdirectly to the auxiliary port at the rear of the MiniCSU/MicroCSU or at the end of a “daisy-chain” of auxiliary port connections and does not use any connections on the MUIB.The module is normally fitted inside the AC distribution module if one is used. Aconnection diagram of the MMIB2 is shown in Figure 4.16 below. The full scale currentvalue of the CTs is 100Arms for a single turn on the standard unit. Higher full scalecurrents can be obtained by cascading larger external CTs through the on-board CTs andmodifying the full scale value in the Mini/MicroCSU mains monitoring menu. The ratedmaximum sense voltage is 300V (line-neutral) due to the terminal rating and accuracy ofthe voltage sensing transformer.


158-1872-01.doc 27 3-Feb-16

CT1

CT2

CT3

AC1

N

AC2

N

AC3

N

AC3

To SMR Inputs

MMIB2

Note: In 220V ph-phsystems if Neutral notsupplied, connect AC1-AC2 to X2 input; AC2-AC3 to X120 input andAC3-AC1 to X217 input

X2

X120

X217

16-wayribboncable toMiniCSU

X185

AC2AC1

AC1, AC2, AC3 fromAC Dist. Module

Figure 4.16. Three Phase AC monitoring unit MMIB2 block diagram


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4.8 SMM - Site Monitor ModuleSite Monitor Module is an expansion of the RT MCSU-4. It allows the user to monitor statusof equipment that is not a part of an RT power system. It may also be used to monitor other(third party) DC power systems. Its usefulness can be specially appreciated in remote,unmanned installations. Using the same communication link and WinCSU-2 monitoringsoftware it is possible to supervise a number of such sites from a central monitoring station.Four control outputs are provided in the form of voltage free change-over relay contacts. Therelays can be automatically activated in response to an event on any of the module inputs(assigned by user), or operated manually from a PC.Note: If the Site Monitor is to be added to an existing installation with RT Power System,change of the Controller software may be required. WinCSU-2 software will also need anupgrade.

4.8.1 Electrical SpecificationNumber of Analogue Inputs 8Analog Signal Input Range 0V to +5V,Analog Signal Protection Over-voltage and reverse polarity protected.

Note: each analogue input must be floating

Analog Signal Scaling andThreshold Levels

Scaling factor, Low and High thresholds levels are userprogrammable from WinCSU-2 or Front Panel.

Number of Digital Inputs 12Type of Digital Signal Source Voltage free contactsLogic of Digital Input User defined from WinCSU-2 onlyNumber of control outputs 4Output type Voltage free change over relay contacts, 1A@30VDCPower Source MiniCSU (powered indirectly from system DC bus)

4.8.2 Physical SpecificationBoard Dimensions Approx. 210mm x 96mmSMM - Controller Connection 16 Way Ribbon CableSignal Input Connectors 2 pin male header 5.0mm pitch. Mfr: Weco,

P/N: 120-M-221/02.Matching female plug P/N: 120-A-111/02 providesscrewed connection for wire up to 1.5 mm2

Output Connectors 3 pin male header 5.0mm pitch. Mfr: Weco,P/N: 120-M-221/03.Matching female plug P/N: 120-A-111/03 providesscrewed connection for wire up to 1.5 mm2


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4.8.3 InstallationWiring of the site monitor is entirely dependent on the signals to be monitored. shows thebasic wiring diagram of a system using a site monitor and a Battery Cell Monitor. Signalssuch as site security (windows and doors being opened) are usually connected as digitalinputs, while fuel levels, inverter voltage/current/frequency are measured using the analoginputs.

4.8.4 System Set-upThe set up of the site monitor including labels of inputs, scale factors, alarm levels,designation of relays to operate and the type of digital input source (normally open ornormally closed) can only be done using a PC running WinCSU-2. See WinCSU-2 operationmanual for details.Once programmed, monitoring of the levels and minor modification of levels and scaling onsite can be done from the front panel of the MiniCSU (see Operation section of this manual),but primarily, the site monitor is designed to be used from WinCSU-2.


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Figure 4.17 Example Site Monitor Wiring Diagram


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4.8.5 Site Monitor SettingsPlease observe following guidelines:

1. Label – name of monitored input, up to 8 characters. Leave blank for not used channels.

2. Hi T-hold – thresholds of analog channels to generate warning/alarm/output control. When set to zero thethreshold is disabled, adjustable up to 999.9 1) input units.

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

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

5. Unit – a symbol of measured parameter.

6. O1-O4 – mark to assign an output relay to an input. More than one input can be assigned to an output.

7. Al – mark to generate Site Monitor alarm when input is active.1) Step of adjustment from WinCSU-2 is 0.1 units, from the Front Panel 1 unit.

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

Input Label O1 O2 O3 O4 Al Hi T-hold Lo T-hold Scale Unit

An 1

An 2

An 3

An 4

An 5

An 6

An 7

An 8

Dig 1 Mark for normally closed input

Dig 2 Notes

Dig 3

Dig 4

Dig 5

Dig 6

Dig 7

Dig 8

Dig 9

Dig 10

Dig 11

Dig 12


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4.9 Battery Cell Monitor (BCM)The Battery Cell Monitor (BCM) is an add-on module for the MCSU-4. It is used to monitorindividual cells of a battery during float or equalisation operation, or during a discharge.Each BCM unit is capable of monitoring up to 24 cells. A total of four BCM units can beused to monitor 4 battery strings of 24 cells each.Using the ability of the MCSU-4 to communicate to a remote or local PC, cell voltage dataaccumulated during a discharge can be transferred to a PC and saved. The cell voltagescan also be viewed in real time when the MCSU-4 is connected to a PC. The WinCSU-2software that is running on the PC can display the cell voltage data in various convenientformats to ascertain the state of health of batteries.In the event that the battery behaves in a way which is less than ideal during a test oractual discharge, a number of pre-programmed parameter levels are used to generatealarms which are annunciated on the MCSU-4 front panel by a LED and display message.Remote alarm is available via voltage free relay or via a communications port to a PC(locally or remotely).

4.9.1 Main Features of the BCMThe principle features of the BCM are as follows:

Up to 24 cells can be monitored by a single BCM module. Cell voltagesetting can be 2V, 4V, 6V and 12V.

Up to four BCM board can be connected to a single MCSU-4.

Individual cell voltages of a battery can be viewed on the MCSU-4 displayin real time. The cell voltage rounded to the nearest 5mV (applies only to2V range) is displayed together with the cell number and its percentagedeviation from the average cell voltage of the battery.

All the cell voltages can be displayed in a “Histogram” format on a local orremote PC using WinCSU-2 software.

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

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

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

A discharge test can be initiated either locally or remotely from WinCSU-2software. The test can be performed with constant, user programmablecurrent (recommended) or under full load connected to the system. Thistest can be programmed to occur periodically in non critical times andresults can be used to monitor the condition of the battery strings. Fordetails refer to MCSU-4 section.


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4.9.2 BCM Specifications

Battery configuration options: (48V systems): (24V systems):

24Cell x 2V, 12Cell x 4V,8Cell x 6V, 4Cell x 12V

12Cell x 2V, 6Cell x 4V,4Cell x 6V, 2Cells x 12V

Maximum battery voltage: 75Vdc

Number of cells: 24 maximum per board

Cell Voltage selection 2V (max input: 3.33V)(DIP switch setting on the board): 4V (max input: 6.66V)

6V (max input: 10V)

12V (max input: 20V)

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

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

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

Sampling interval range fordischarge log:

1 - 60 minutes

Power supply: from MCSU-4 15V

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

4.9.3 Preparing the battery for connection to the BCMBattery cells are not connected to the BCM directly. 56/PR02 resistors are insertedbetween BCM and the cells to clear any fault that would arise if a battery cell lead wereshorted. The resistors are mounted as near as possible to the battery terminal in order toprotect as much of the wiring as possible. A typical connection is shown Figure 4.18.

Figure 4.18 Lead termination at battery cell.The M6 ring lug (depending on type of battery) is screwed onto the cell terminals. Theother end of the wire is screwed onto the 5.0mm pitch screw terminals. Details on how thecells connect to the BCM board are discussed in later sections.


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4.9.4 Installing the boardGenerally, the BCM board is located close to the batteries so that it is not necessary to runlarge number of wires for long distances. The 16 way ribbon cable connecting to theMCSU-4 can be up to 10m long, but should be connected directly to the MCSU-4, insteadof connected at the end of another chain of peripherals. This helps reduce errors. Thisconnection can be achieved by using a ‘daisy chain’ ribbon where the one cable hasconnectors placed part way along its length as well as the ends.Mount the BCM using the standoffs supplied in an area protected from mechanical andelectrical hazards. If the rack does not provide any holes or studs for mounting the BCM,use Figure 4.19 as a template for drilling the mounting holes. Be sure to allow at least25mm space around the board to allow for wiring to the board.

Figure 4.19 BCM mounting hole locations.

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

CELL/MONOBLOCKVOLTAGE

LEFTSWITCH

(1)

CENTRESWITCH

(2)

RIGHTSWITCH

(3)

12V UP DOWN DOWN

6V DOWN UP DOWN

4V DOWN DOWN UP

2V DOWN DOWN DOWN


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4.9.6 Battery Cell Lead Connection to the BCM boardThe battery cell voltage sensing leads are terminated with 13 way female (Weco 5.0mmpitch) screw terminals. This plugs onto the connectors on the BCM board. How the cellvoltage sense leads connect to the BCM board depends on the battery configuration. Thefollowing figures show the connection between the battery to the BCM board for differentconfigurations of the battery. If more than 2 batteries are used a particular configuration,simply repeat the connection method for batteries 3 and 4.

Figure 4.20 BCM connections to a 48V (24 cell) battery bank.


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Figure 4.21 BCM connections to two 48V (12 cell) battery banks.


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Figure 4.22 BCM connections to two 48V (8 monoblock) battery banks.


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Figure 4.23 BCM connections to up to four 48V (4 x 12V monoblock) battery banks.


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Figure 4.24 BCM connections to two 24V (12 cell) battery banks.


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Figure 4.25 BCM connections to two 24V (6 monoblock) battery banks.


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Figure 4.26 BCM connections to four 24V (4 monoblock) battery banks.


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Figure 4.27 BCM connections to four 24V (2 monoblock) battery banks.


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

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

5.2 RS232 Interface (MCSP)This interface should be used if the distance between the RPS and monitoring PC or amodem is not greater than 15 meters. The module has standard 9-pin D-type connector.For connection to a PC a “null modem” (or “cross-over”) cable should be used. A modemshould be connected using the cable provided with it.

5.3 RS485 Interface (MCMD)This type of port allows connection though a distance up to 1200 meters. Up to 32standard devices can be linked using twisted pair of wires. In high electrical noiseenvironment a shielded twisted pair is recommended. Figure 5.1 below shows the pinassignment of the port.

Figure 5.1 RS485 pin assignmentsDue to the slow data rate (9600bps) termination of the line with resistors generally is notrequired. However, if high rate of data corruption is experienced (slow data update inmonitoring program), line termination resistors should be installed at both ends of thenetwork. The value of the resistors depends on the gauge of the twisted pair and shouldbe equal (or closest) to line characteristic impedance. I.e. twisted pair of 24AWG wirescharacteristic impedance of 100ohm – use a 100ohm resistor.

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


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

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

Argentina Y 07 India P 53 Portugal Y 8B

Australia Y 09 Ireland Y 57 Russia P B8

Austria Y 0A Italy Y 59 Singapore Y 9C

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

Brazil Y 16 Korea Y 61 Spain Y A0

China N 26 Malaysia P 6C Sweden Y A5

Denmark Y 31 Mexico Y 73 Switzerland Y A6

Finland Y 3C Netherlands Y 7B Taiwan Y FE

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

Germany Y 42 Norway Y 82 United States Y B5

Hong Kong Y 50 Poland P 8A Approval: Y=yes ; N = no ; P=pending

Approval status in the table is indicated as declared by manufacturer on 8/11/2000.Note: If the country in which you intend to use the Integrated Modem is not listed, a generic code‘99’ or ‘FD’ can be tried. If the modem does not work correctly using generic codes, it isrecommended to search for another brand of Socket Modem which may meet the countryrequirements.


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6. OperationSystem operation is generally controlled by the MCSU-4 system controller. As a result,operation information for the system is directly related to the operation of the MCSU-4 asdescribed in this section.

Summary of MCSU-4 front panel controls

There are four Menus which can be viewed using the INC or DEC buttons:a) The default or "Home" menu which contains general system information;b) SMR menu - contains all the parameters relating to the rectifiers;c) Battery menu - contains all the parameters relating to the batteries;d) Alarms log - which is a chronological record of the last 100 alarms.Moving from one menu to anotherIf no button has been pressed for two minutes, the display will revert back to the Homescreen. This shows the output voltage and current.To move from any menu to any other menu, press the corresponding button. E.g. to moveto the Battery Menu from any other menu, momentarily press the BATT button.To move to the Home menu from any other menu, press the button of the current menu.E.g. if in the SMR menu, press SMR button to return to the Home menu.Scrolling through the Menus:To scroll through any menu from the first screen to the last, press the INC button;To scroll to the last (bottom) screen first, then upwards through the menu to the firstscreen, press the DEC button.Incrementing and decrementing programmable parametersTo change a programmable parameter press ENTER; the value will flash on and off. Toincrease the number, press INC; to decrease the number press DEC. When the desirednumber is on the screen, press ENTER again.To change parameters when the security function is activatedIf an attempt is made to alter any parameter when the security function is activated, thedisplay will show the message "Enter Password".To change a parameter, enter a valid password. Then proceed to change the parameter inthe normal way.When scrolling through the Alarms logTo observe the date and time of a given alarm, do not press any button for at least twoseconds. The date and time will display for two seconds and then the alarm name will bedisplayed for two seconds. The display will alternate between the two screens in thismanner until a button is pressed.


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6.1 MCSU-4 ComponentsThe MCSU-4 is a supervisory and control unit for a DC plant comprising up to 225rectifiers connected in parallel with up to four parallel battery banks. Number of batterybanks depends on type of MUIB used.The unit is 1U in height and a magazine is available which fits across a 19” rack andaccommodates the MCSU-4, the MUIB as well as a space for a modem or otherequipment with a maximum dimensions 40x150x220 (HxWxD in mm). An RS232 port isavailable on the front panel for connection to a portable PC.

6.1.1 Alpha-numeric DisplayA two-line by 16 character alphanumeric display of either a back-lit LCD type or a vacuumfluorescent type is supported. The 5mm high characters normally display output voltageand current as well as the system status - Float (FL) or Equalise (EQ). This is the defaultor “home” screen.If an activity such as battery discharge testing is being performed, the current and voltageare always displayed, while the second line alternates between the system status (FL/EQ)and the activity status, for example “BDT in progress”.

234A 54.5VFL

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

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

Apart from the MCSU-4 or “Home” menu, which includes mostly system orientedparameters, there are three other menus which can be accessed by momentarily pressingthe relevant pushbuttons:

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

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

starting with the most recent alarm. A total of 1000 alarms are stored in memory.


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6.1.3 Status Indicating LEDs (MCSU-4)In addition to the alphanumeric display there are also three LEDs to indicate system statusas follows:

SYSTEM OK Green LED

ALARM ! Amber LED

SMR SHUTDOWN Red LED

When all three LEDs are off, the unit is off and there are a number of possible reasons forthis. For example:

DC is not present Internal failure of MCSU-4The amber LED indicates any alarm condition, either system or rectifier related.The red LED indicates that one or more of the rectifiers in the system is shut down.

6.2 Operating the MCSU-4

6.2.1 Password securityMCSU-4 features password security for parameters setting. A password is analphanumerical code having minimum three and maximum eight charactersUnits leave the factory without pre-programmed password and security function is notactive. To activate security a password must be programmed. Once that is done, securitycan be enabled. Password programming procedure is described in paragraph 1.4.3

6.2.1.1 Entering a password to gain access to parameters changeWhen security function is active any changes to the system settings can be done only aftera valid password was entered. When ENTER key is pressed to change a parameter, thedisplay will show a message “Enter Password” on the top line and a blinking cursor on theright hand side of the bottom line. Using INC and DEC keys scroll to the first character ofthe password and press ENTER. The character will be substituted by a star ( * ) displayedto the left of the cursor. Enter all characters of the password the same way. If thepassword is less than eight characters long press ENTER again after last character. If theentered password was correct the display will return to the selected parameter ready formodification. If the entry was incorrect following will be displayed

Wrong PasswordPanel Locked

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


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6.2.2 Test ModeThis is a special mode of system operation allowing service personnel to perform systemtests without permanent parameters change and altering system operating history (AlarmLog).To activate Test Mode move to Password Setup sub-menu and enter “TESTMODE” as thepassword. The features of the Test Mode are:

- Unrestricted parameters editing- Edited parameters will not be stored in permanent memory (EEPROM)- Alarms will not be recorded in the Alarm Log- Alarm Log can not be cleared- Password can not be changed- Status of security function can not be changed

While test mode is active a prompt “Test Mode” will alternate with current operating modeon the bottom line of the “home” screen.Upon quitting the Test Mode (see Par. 6.6) parameters values will be restored to originalsettings.Note: There is no timeout or any other means of automatic cancellation of the Test Mode.It is the responsibility of the personnel to return the system to normal operating mode.

6.2.3 Entering and moving through different MenusTo scroll through the MCSU-4 menu from top to bottom, just press the INC button. Thescreens that will appear are shown in section 6.6.If the DEC button is pressed, the screen at the bottom of the menu will appear first and willbe followed by the other screens in reverse order. This can be useful when it is desired toaccess a screen near the bottom of the menu.To enter the other menus, momentarily press the relevant button - SMR, BATT or ALARMLOG. The associated menu contents are shown in sections 6.7, 6.7.2, 6.9 and 6.10.If at any time it is necessary to return to the MCSU-4 or “home” menu, just press thecurrent menu button once. E.g. if the present menu being scrolled is BATT, just pressBATT button again and the screen will return to the default “home” screen.The INC and DEC keys are also used to increase or decrease parameter values when theparameters are programmable.In this case, press ENTER first. The parameter value will begin flashing on and off. PressINC to increase the value or DEC to decrease the value until the desired value is obtained.Then press ENTER again to actually enter the value into memory.

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

3 AlarmsPress ENTER


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

Alarm 1Amb Temp High

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

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

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

SMR Urgent One or more SMRs have shut down A+R

SMR HVSD SMR shut down due to output over-voltage A+R

UNIT OFF SMR is off A+R

No Response A particular SMR is not responding to the MCSU-4 A

Power Limit SMR is in Power Limit A

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

Current Limit SMR in current limit A

Voltage High Voltage measured by SMR too high A

Voltage Low Voltage measured by SMR too low A

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

EEPROM Fail EEPROM failed (MCSU-4 or SMR) A

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

Relay Fail SMR output relay contact failure A

No Demand Control loop in SMR not in normal state A

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

DC-Dc Contr Fail SMR DC/DC converter fault A+R

Temp Sensor Fail Temp sensor in SMR faulty - S/C or O/C (where available) A+R

Vref Fail Voltage reference in SMR microprocessor circuit faulty A+R

HVDC not OK DC/DC converter (boost) voltage in SMR not OK A+R

AC Volt Fault – detectedby SMRs

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

AC Volt Fault – detectedby CSU

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

A


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Alarm Name Comments LEDAC Freq Fault AC frequency lower or higher than preset value A

Battery Switch One or more battery switches open A

Cct Breaker Fuse or CB in load distribution open A

LVDS Open Low Voltage Disconnect switch open A

Sys Volts High System output volts too high A

Sys Volts Low System output volts too low A

System V Clamp MCSU-4 can not reach desired system voltage. This can be due topossible excessive voltage drop along bus bars or “System V Drop”parameter has value too low.

A

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

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

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

A

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

A

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

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

A

Battery Disch Batteries are discharging A

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

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

A

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

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

Amb Temp High Ambient temperature higher than preset limit A

Batt Temp High Battery temperature higher than preset limit A

Batt Temp Sens Battery temperature sensor not connected or failure A

Batt I-Limit Battery charging current is being limited to preset value A

Bat Sym Alarm Battery discharge currents from battery strings not sharing load equally A

Earth Leak Alarm Earth leakage current greater than the limit set A

Equalise System is in equalise mode A *

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

6.4 User programmable relay functionsAll controllers with RTP standard software of version/revision ‘fa’ or higher support thisfeature. Other customised software can include it as well. To check if your unit supportsprogrammable relays, perform Indicators Test as described in section 6.6.3.New units have factory default relay assignment. For details refer to paragraph “RelayContact outputs” in User Interface sections of this manual.


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6.5 Mapping of loaded SMRsThis function is available only on selected models of MCSU-4.In some system configurations it may be necessary to leave empty magazines betweengroups of rectifiers. In such a case a controller without mapping function wouldcontinuously alarm SMR communication fault for magazines with no SMRs.A controller with the mapping function will communicate only with magazines fitted withfunctioning rectifiers.To enable this function, select “Map Loaded SMRs” from the main menu and switch “On”.Scroll through to the next screen and press “ENTER”. The controller will automaticallysearch for installed rectifiers. This will take approximately 10 seconds.When the mapping process is complete the controller will ignore vacant magazines andwill sequentially report on the status of installed rectifiers in their correctly numberedpositions. This will allow the end user to quickly and accurately identify the position of afaulty module should an alarm be reported.

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

MCSU-4 “Home” screen; indicates system is in float mode.The operating mode will alternate with “Test Mode” whenTest Mode is active.

155A 54.3VFL

“C” indicates that battery temperature compensationfunction is active. The operating mode will alternate with“Test Mode” when Test Mode is active.

155A 54.3VFLC

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

Lock PanelPress ENTER

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

Lock PanelPanel Locked

This message will be displayed only when Test Mode isactive. Quit Test Mode

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

Quit Test ModeTest Disabled

Ambient temperature is displayed in Degrees Centigrade. Ambient Temp31C

6.6.1 Single Phase AC Monitoring ScreensIn a system wired for 1 phase input with an AC monitor module, it will be necessary toactivate the 1 phase AC monitoring selection screen via the “Auxiliary Units” sub-menu(towards the end of this menu). To enable, select “On” under the “1-ph AC Monitor” menuitem. Once the AC monitor is enabled, the following screens will appear immediately afterthe “Ambient Temp” screen:


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Single phase AC voltage. 1ph AC Volts245V

Single phase AC current1ph AC Current

52A

Single phase AC frequency1ph AC Frequency

50.0Hz

6.6.2 Three Phase AC Monitoring ScreensIn a system wired for 3 phase input with an AC monitor module, it will be necessary toactivate the 3 phase AC monitoring selection screen via the “Auxiliary Units” sub-menu(towards the end of this menu). To enable, select “On” under the “3-ph AC Monitor” menuitem. Once the AC monitor is enabled, the following screens will appear immediately afterthe “Ambient Temp” screen or single phase monitoring screens (when activated):

AC voltage of phase 1 3ph AC1 Volts245V

AC voltage of phase 23ph AC2 Volts

243V

AC voltage of phase 33ph AC3 Volts

246V

AC Current of phase 13ph AC1 Current

28A


29A


32A

AC Frequency3ph AC Frequency

50.2Hz


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6.6.3 Base Menu Programmable ParametersThe screens below display programmable parameters within the MCSU-4 Base Menu.To change a parameter, press INC button until the desired parameter is found, then pressENTER. The parameter value will flash on and off. Press INC to increase the value or DECto decrease the value until the desired value is on the screen.Press ENTER to enter the value into memory.

Ambient temperature alarm level Amb Temp Alarm45C

Float voltage High levelVolts High Alarm

56.6V

Float voltage Low levelVolts Low Alarm

50.5V

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

SecurityOn

SecurityOff

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

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

O

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

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

Old PasswordO

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

Old PasswordWrong Password

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

New PasswordO


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Enter the new password again.Confirmation

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

ConfirmationPassword Changed

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

ConfirmationWrong Password

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

Test IndicatorsPress ENTER

On bottom line: 169 - product group8441 - software identification number02 - revision

MCSU-4169-8441-02

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

SystemStandby

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

SystemUPS

Menus for Mapping Loaded SMRs are available only on selected models.

MCSU-4 addresses only those magazines in which SMRswere present during “mapping” process. Map Loaded SMRs

OnMCSU-4 addresses magazines from number 1 to thenumber programmed in “Number of SMRs” menu. The nextscreen is hidden.

Map Loaded SMRsOff

When ENTER is pressed while viewing this menu, processof mapping of loaded SMRs is initialised. Exec. Mapping

Press ENTERMapping process can take up to 10 seconds. During thattime this message is displayed. Exec. Mapping

Please waitWhen mapping process is complete, MiniCSU displaysnumber of SMRs detected as present in the system. Number of SMRs

20When “Map Loaded SMRs” is set to “On”, editing of numberof SMRs from the front panel is not allowed. This messagewill be displayed when ENTER is pressed.

Number of SMRsNot Adjustable

End of Mapping Loaded SMRs menus


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

Number of SMRs15

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

InterfaceMUIB

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

Num of Batteries1

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

FS Batt Current200A

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

1252636

Date format. The format of the date can be modified toeither DD/MM/YYYY, MM/DD/YYYY or YYYY/MM/DD. Date Format

DD/MM/YYYY

Clock set; used to set the date and time of the MCSU-4clock. Note DD/MM/YYYY 24 hour clock. While setting thetime clock is stopped. Seconds are not programmable.

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

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

Alarm ReportOn

Alarm ReportOff

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

Daily ReportOn

Daily ReportOff

Time of daily report. This menu is available only when DailyReport is switched ON. Daily Rep Time

15:15


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Modem enable; this can be toggled between ON and OFF.When a change is made, the front panel is disabled whilethe modem is activated/deactivated.

ModemOn

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

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

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

Country Code09

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

Country CodeNone

This and next screen may not be seen on some models.Some models of external modems may require anadditional initialisation string. The string can be up to 10characters long - initial ‘AT’ command is not required.

Cust Init String&B1L3

The default setting for this parameter is “no custom string”.To disable existing initialisation string put a space (blank) inplace of the first character and press ENTER.

Cust Init StringNone

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

Phone 10398887788

Example of second screen for continuation of phonenumber Phone 1 Cont

2323

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

Phone 20398880033

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

Phone 30398880033

Note: To have Alarm Report and/or Daily Report sent to local PC, switch the Reports ON, and Modem Off

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

Audio AlarmOn

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

Timeout


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Audio Alarm is disabled.Audio Alarm

Off

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

Cct InputUsed - N/C

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

Bat Switch InputUsed - N/O

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

LVDS InputNot Used

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

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

Press ENTER

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

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

1-ph AC MonitorPress ENTER

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

OffDisplayed when this auxiliary is switched On.

1-ph AC MonitorOn

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

1ph AC Vhi Alarm260V

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

1ph AC Vlo Alarm192V


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

1ph AC fhi Alarm55.0Hz

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

1ph AC flo Alarm45.0Hz

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

1ph AC FS Curr.100A

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

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

3-ph AC MonitorPress ENTER

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


3-ph AC MonitorOn

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

3ph AC Vhi Alarm260V

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

3ph AC Vlo Alarm192V

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

3ph AC fhi Alarm55.0Hz

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

3ph AC flo Alarm45.0Hz

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

3ph AC FS Curr.100A


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

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

Battery MonitorPress ENTER

Displayed when this auxiliary is switched Off.Battery Monitor


Battery MonitorOn

The configuration refers to cell type (2, 4, 6 or 12V) and howthe cells are connected to the monitor - see section 6.11 forfurther information.After pressing ENTER current configuration will flash. Scrollthrough available configurations and press ENTER againonce the correct battery type is chosen.

Battery Config24 cells

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

2

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

Cell Vhi Alarm2.48V

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

Cell Vlo Alarm1.44V

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

Cell +dVc Alarm10%

Low differential cell voltage threshold.Cell -dVc Alarm

10%

6.6.4.4 Site MonitorThe site monitor is primarily designed to be operated with WinCSU-2 from a PC.However, once set up the analog signal levels can be viewed and the alarm levels andscale factors can be modified from the site monitor sub-menu of the MCSU-4.The site monitor sub-menu is a sub-set of ‘Auxiliary Units’. When Site Monitor is declaredto be Off, no other menu items are displayed.


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

Site MonitorPress ENTER

Displayed when this auxiliary is switched Off.Site Monitor


Site MonitorOn

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

A1 Inv-V1.2V

If a channel has been declared as alarmed the reading willbe preceded by word ‘ALARM’ (both flashing). A1 Inv-V

ALARM 1.2V

Threshold above which the input signal will trigger an alarm.High Alarm

272.0V

Threshold below which the input signal will trigger an alarm.Low Alarm

150.0V

Programmed scale factor of analog input. Scaled for 4V ofinput signal. Scale at 4V

300.0V

Presentation of a digital input window under normalconditions. D2 Window2

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

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

D2 Window2ALARM

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

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

Output 2On


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Status of output relay 3. Relay is switched on manually fromWinCSU-2 program. Will remain on until switched offmanually from WinCSU-2.

Output 3Manual On

Analog input signal levels only can be accessed from MCSU-4. To modify the logic or thelabel of the digital inputs, the units or labels of the analog inputs, a PC running WinCSU-2must be used.

6.7 SMR Menu ScreensAll information relating to the individual rectifiers is found in the menu activated by pressingthe SMR button on the MCSU-4 front panel. To return to the MCSU-4 menu at any time,press SMR button. To return to the SMR menu, press the SMR button again.

When an SMR is not connected or not switched on or isfaulty, the screen indicates that the rectifier is notresponding.

SMR1No Response

Warning: It is important to declare the correct number of rectifiers in the rack using theMCSU-4 (home) menu.

NOTE: Output current and limit values shown below are typical for a 25A unit.

When a rectifier is on line and operating normally, its outputcurrent and heatsink temperature are displayed. PressingENTER once allows to view additional information.

SMR122A 58C

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

SMR1169-3761-02

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

SMR1S/N not avail.

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

SMR2 21A3 Alarms ENTER

SMR2 21APower Limit

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

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

169-3761-02 58C

This display format is used when a SMR is shut down.Pressing ENTER will display the reason for shut down. SMR3

UNIT OFF


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If SMR was shut down on “primary not OK” this screen isnot displayed. SMR3

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

169-3761-02 58C

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

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

SMR Float52.3V

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

SMR Equalise59.3V

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

Not Adjustable

6.7.1 SMR Menu Programmable ParametersThe remaining screens show the SMR related operating parameters which can bechanged by pressing ENTER.When this is done, the number flashes on and off and can then be incremented ordecremented by pressing the INC or DEC buttons respectively. When the correct value isobtained, press ENTER to enter the number into memory.

SMR high voltage alarm level.SMR V high Alarm

56.3V

SMR low voltage alarm level.SMR V low Alarm

48.1V

SMR DC High Volts Shutdown (HVSD).SMR HVSD

62.0V

SMR Current Limit.SMR I Limit

25A

Fault Reset; by pressing ENTER when this screen isdisplayed, any latched alarm, such as HVSD, is reset andthe unit will restart unless it is damaged or faulty.

Reset SMR FaultPress ENTER

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


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6.7.2 SMR Menu Sleep ModeThe MCSU4 has an optional Rectifier Sleep Mode (RSM) in order to maximize the powerconversion efficiency of the overall DC Power System controlled by the MCSU4.The RSM accepts a user-configured:

o Minimum number of Rectifier to keep On-Line at all times.o Rectifier rotation value (in Days).

The RSM continuously monitor the % output power from each Rectifier in the systemand calculate the average Rectifier output power for all Rectifiers on line. The RSMcontinuously works to achieve an actual average Rectifier output power that is within anacceptable range by automatically placing Rectifiers On-Line and into Sleep mode.The RSM calculates the acceptable range (minimum to maximum), centred on the targetpower conversion efficiency, by considering the following:

o The target power conversion efficiency.

o The number of Rectifiers in the system.

o The output capabilities of the Rectifier.

o Sufficient hysteresis to as not to cause Rectifiers to constantly being placed On-Line and back into Sleep mode.

The RSM make decisions on which rectifiers to place On-Line and which ones to placeinto Sleep mode based on the following criteria:

o When needing to place a rectifier in Sleep mode, the rectifier with the highest usageshall be selected.

o When needing to place a rectifier On-Line, the rectifier with the lowest usage shallbe selected.

o Usage shall me determined with the accumulated Run Time (Hrs) or Thru-put(kWHr) which is kept in the rectifier. The determination on which value to useis configured via the factory configuration file.

The RSM allows for sufficient time after placing a Rectifier On-Line or into Sleep mode inorder for the output of all Rectifiers to settle and the average Rectifier output power to bevalid again. The RSM always ensure that the minimum number of Rectifier to keep On-Line is maintained.The RSM provides a Rotation function to ensure that Rectifiers usage is being kept fairlyeven. The Rotation shall be accomplished by forcing a Rectifier, with the lowest usage,On-Line. This will cause the average Rectifier output power to fall below the acceptablerange and the RSM to then place the Rectifier with the highest usage into Sleep mode.The RSM automatically and immediately cease operation upon receipt of any alarm from afactory defined list (i.e. Battery Discharge, Voltage Low, SMR Current Limit,...).The RSM function can be enabled and disabled by the user via the front panel andWinCSU-2.


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The RSM reports the following values to the user:o Average Rectifier % Output Power

o Number of Rectifiers On-Line

o Number of Rectifiers Sleeping

SMR Sleep Mode Enable. Sleep ModeOff

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

Max power of each SMR module. For RT12, rectifiers, this shouldbe set to 2400 as each module is rated for 2.4kW SMR Power Max

2400

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

SMR Sleep Mode report number of rectifiers sleeping Sleeping SMRs3

SMR Sleep Mode report number of rectifiers online Sleep SMR Online5

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

6.8 Battery Parameter Menu ScreensAll information pertaining to the batteries is accessed by momentarily pressing the Battbutton on the front panel. To return to the MCSU-4 “home” menu at any time, momentarilypress the Batt button.As for the other menus, in general a programmable parameter can be incremented ordecremented by use of the INC and DEC buttons respectively. If this is attempted when amonitored parameter is being displayed (i.e. not a programmable operating parameter),then the message “Not Adjustable” will be displayed.The following screens will appear in turn when the INC button is pressed:

Battery 1 Current;Battery 1

12A


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Battery 2 Current; (if present)Battery 2

14A

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

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

Battery Temp31C

Battery TempNot Available

Battery TempSensor Fail

Estimated Battery 1 state of Charge; this screen shows theestimated charge in the battery at any given time. Estimated Q Bat1

300Ah

Estimated Battery 2 state of Charge. (if present)Estimated Q Bat2

300Ah

Battery discharging alarm level. This level is set to a valueto which the battery voltage falls to during a discharge. It isused to issue an alarm indicating that the batteries aredischarging.

Batt Disch Alarm45.0V

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

Disch I Diff20A

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

Batt Temp Alarm50C

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

500Ah

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

BTC Coeff.3.2 mV/C /C


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

BTC Nominal20C

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

Number of Cells24

Please Note:a) If there are no temperature sensors connected or if BTC is set to 0, the compensation function is

disabled. In this instance, the status message in the MCSU-4 home screen is FL or EQ instead of FLC orEQC.

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

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

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

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

BILim Vb<Vdd34A

Battery deep discharge voltage - Vdd.Vdd Level

44.0V

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

BILim Vb<Vfl52A

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

54.0V

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

System V Drop0.6V

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

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

EqualisationOn

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

BILim Vb>Vfl25A


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

59.5V

Equalisation not initialised by voltage level.Volts Start Eq

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

On

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

46.0V

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

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

On

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

10Ah

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

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

EQ End CurrentOff

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

EQ Duration20 hours

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

EQ Period12 Weeks

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

Manual Stop EQPress ENTER

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

Manual Start EQPress ENTER

End of equalisation section.


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A Low Voltage Disconnect Switch (LVDS) is oftenintegrated into the system to disconnect the batteries fromthe load in the event that the AC power outage is too longcausing the batteries to discharge beyond a safe level. Thevoltage level at which the LVDS opens is set in this screen.

LVDS Trip44.0V

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

LVDS ModeAuto

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

LVDS ModeClosed

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

OpenMenus for Load Shedding are available only on selected models.

Load 1 shedding is enabled.Load 1 Shedding

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

Off

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

Ld 1 Shed Level47.0V

Load 2 shedding is enabled.Load 2 Shedding

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

Off

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

Ld 2 Shed Level47.0V

End of Load Shedding menus.

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

Temp. Sen. AlarmOn

6.9 Battery Discharge TestBattery Discharge Test is available on selected MCSU-4 models.


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The Battery Discharge Test is a software function in the MCSU-4, which performs aperiodic, controlled battery discharge using the load to discharge the battery. The test canbe used to confirm capacity of the battery in the same way as a manual discharge usingan external load would, except the normal system load is used without disconnection.While Battery Discharge Test is active, the “Home Screen” will have format

50A 49.2VBDT in Progress

The system alarms Battery Discharge, Voltage Low, SMR Voltage Low and Low Load willbe suppressed, however SMR alarms will be shown in the SMR status.To access the Battery Discharge Test parameters, enter the Batt menu. Use of DEC givesfaster access to the menus. The screens shown here are in order as INC key was used.

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

BDT Period14 Days

Time of the day at which the test should start. Programmedin hours and minutes (24 hours format). BDT Time

17:35

Time span during which the battery will be discharged.Programmed in hours and minutes (between 5 minutes and24 hours), step of adjustment 5 minutes.

BDT Duration1h30min

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

BDT Current50A

Batt Disch TestCurrent = Load

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

BDT End V46.0V

MCSU-4 will restore normal operating parameters and startrecharging the battery. The test result will be “Fail”.Programmable range depends on the system voltage: 24V system: 18V to 24V, 48V system: 36V to 48V, 110V system: 75V to 120V.

End capacity of the battery. Principle of operation the sameas described in par. 4. Programmable between 25Ah and9995Ah

BDT End Q500Ah


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Reset of failed test alarm. This message will be seen only iflast test failed and has not been reset. Pressing ‘ENT’ whileviewing this display will reset the alarm and hide themessage. The alarm can be also reset from a PC usingWinCSU-2 software.

BDT Alarm ResetPress ENTER

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

ENTER to abort

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

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

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

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

Last BDTFailed

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

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

Last BDTCell V Low

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

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

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

Last BDTSMR Overload

Terminated manually using MCSU-4 Front Panel or fromWinCSU-2 Last BDT

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

Date of the last test.Last BDT

22/01/2003


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Duration of the testLast BDT

Dur 1h18min

Voltage of the battery at the time of termination of the test.Last BDT

EndV 49.2V

Remaining estimated capacity of a battery string at the timeof termination of the test, where n is a number of the string. Last BDT

EndQn 380Ah

The test is disabled for 100 hours if any of the following took place:a) AC failure has been recordedb) Electrolyte low level has been recorded (only if sensor fitted and appropriate version of

software installed).If an automatic test was scheduled during that period, it will be performed at the nextopportunity at the BDT Time.

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

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

LOG 1AC Freq Fault

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

10/01/200312:05:26

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

Log Entries

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

No Entries

6.11 Battery Cell Monitor SetupNote: This function is only available on special versions of MCSU-4 software and appearsas the first option in the Expan2 sub-menu (see section 6.6.4.3 for screen definitions).For 110V and 220V systems, refer to the BCM3 sections for an appropriate configurationtable.


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6.11.1 Relationship between “BCM Batteries” and “Num Batteries”With the BCM option enabled, the BCM parameters must be setup before monitoring canbe performed. Following through the screens of section 6.6.4.3, the screen indicating“BCM Batteries” is where you define the number of batteries whose cell voltages are to bemonitored by the MCSU-4. There is no need to program the MCSU-4 how many BCMboards are connected. The MCSU-4 automatically calculates the number of BCM boardsthat it requires from the number of “BCM Batteries” that you entered. The number of BCMboards (PCBs) required for different battery configuration is shown in the following table(48V top, 24V bottom):

Batt Config BCM Batt = 1 BCM Batt = 2 BCM Batt = 3 BCM Batt = 4

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

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


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

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



2 cell, 12V 1 BCM board 1 BCM board 1 BCM board 1 BCM board

A similar menu but for totally different purposes, appears in the Systems menu as follows:Num Batteries X ( where X is the number of batteries)

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

6.11.2 Frequency of measurement.To allow for a wide battery capacity range, which can range from 10 minutes to 8 hours,the cell voltage polling frequency is programmable in 1 minute increments. A typical pollinginterval is 4 minutes, which would yield 15 points for a 1 hour discharge. For programmedtest discharge of 30 minutes a polling interval of 2 minutes might be used. This parameteris not accessible from the MCSU-4 front panel. It is only programmable from a PC runningWinCSU-2.

6.11.3 Battery Cell MeasurementsWhen BCM is active, the individual cell voltages can be monitors on the MCSU-4 byselecting a Battery from the Batt Menu and pressing ENTER. The cell information willappear on the screen and the next and previous cells can be selected by pressing the INCor DEC buttons. See below:


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Battery 1 Current screen appears after pressing BATT.Pressing ENTER brings up the next screen. Battery 1

12A

Battery cell status: Battery 1, Cell 01, cell voltage 2.225Vwhich is deviating +12% from the average cell voltage of thebattery string.

Battery1 Cell012.225V +12%

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

Battery1 Cellmmn.nnnV ±pp%

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

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

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

0.2mA

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

5.0mA


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7. CommissioningCommissioning primarily requires an understanding of the rectifier visual signals andoperator adjustable parameters on the system controller (MCSU-4). Before a system isfirst energized, it is advisable to read this section thoroughly.

7.1 Indicators on the Rectifier Front PanelThere are three LEDs on the front panel to indicate the operating status of the rectifiermodules. They are as follows:

LED Name LED Colour What it indicates

1 ON Green Rectifier functioning normally

2 ON Green (flashing) Input AC voltage out of range

3 Alarm Yellow (flashing) Alarm condition

4 Alarm Yellow (not flashing) Unit is in Equalisation mode

5 Shutdown Red (with yellow LED flashing) Unit is switched off or failed

If necessary, further information about the particular rectifier alarm condition, if one exists,can be found by referring to the MCSU-4 or the PC connected to the MCSU-4 - seedetailed section on MCSU-4.

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

7.2.1 RT9 SMR ParametersParameter Range Nominal

SMR Float Voltage 48 to 58V 54.5V

SMR Equalise Voltage 50 to 59.9V 56.0V

High Voltage alarm Threshold 52 to 59.9V 56.0V

Low Voltage alarm Threshold 44 to 54V 48.0V

HVSD Voltage alarm Threshold 54 to 62V 57.5V

Current Limit for SMR 5 to 30A 30A

7.3 System CommissioningTo commission a system, modification of system parameters on the MCSU-4 is required.This can be done manually through the front panel of the MCSU-4 (see detailed section onMCSU-4 operation), or by using a PC running WinCSU-2 that is connected to MCSU-4 viathe USB interface (see detailed section on WinCSU-2 operation). It is recommended for


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systems that are to be commonly commissioned that the PC option be used. The benefitis that predetermined configurations can be stored on disk and easily downloaded to theMCSU-4 at any time. It is assumed that the operator commissioning the system hasknowledge of programming system parameters.The system parameters can vary widely depending on the system configuration andbattery requirements. It is advisable to consult the battery data sheets as a referencewhen determining the system parameters to be programmed into the MCSU-4.

7.3.1 Commissioning ProcedureFor system with batteries and load, the commissioning procedure is as follows:

Make sure there is no load on the DC bus and that the batteries are disconnected.

If necessary, set the DIP switches on the backplanes, starting with 1 and ending withthe highest number corresponding to the number of rectifiers in the system. The DIPswitches are ON when slid to the top, and LSB is at the right when viewing from the rearof the magazine. Position #1 corresponds to 0000 0001, position #2 to 0000 0010 andso on up to 15. #16 corresponds to 0001 0000, #17 to 0001 0001 and so on.

Insert a rectifier into the #1 position in the system and turn the AC power on. Therectifier should power up and start the MCSU-4.

Using either the MCSU-4 front panel or a PC connected to the RS-232 serial port,program all the MCSU-4 parameters according to the system requirements. Make surethat the number of rectifiers in the system is correctly set.

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

Put all the remaining rectifiers ‘on-line’, one at a time by inserting the rectifier into themagazine and switching on the corresponding input AC breaker where necessary.Check that each unit powers up and communicates with the MCSU-4. This isdetermined by checking that the MCSU-4 has a message window corresponding to therectifier number similar to “SMR2 0A”.

With all rectifiers operating correctly, add a load to the system of at least 30% of therated system current.

Check that the MCSU-4 is able to control current sharing between the units by readingcurrent of all SMRs’ from MCSU-4 SMR menu.

Increase the load to 100% and check that the rectifiers all share load current.

Reduce the load to 75% and burn in for 24 hours.

Remove the load. Clear Alarm Log.

Check that the wiring polarity of the battery is correct for the system, and then connectthe batteries on-line via a fuse or circuit breaker. Allow to charge before bringing finalsystem on-line.

For further information on any subject relating to MCSU-4 operation or alarms, see thedetailed section on MCSU-4.


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

8.1 Warnings and precautionsSince the unit utilises high voltages and large storage capacitors, it is imperative to takegreat care when working on the unit.In particular, only qualified personnel should be allowed to service the units.In addition, the following precaution should be observed:

Do not remove the cover with power on!Allow five minutes to elapse after switch off before removing the cover

to make sure high voltage capacitors are fully discharged.

8.2 SMR MaintenanceSince the SMRs are fully alarmed and operate in an active loop current sharingarrangement, there is no need for regular checks or adjustments of operating parameters.However, some regular checks can be an early warning of problems waiting to happen.

8.2.1 Current SharingUnder normal conditions, the output current variation from the average rectifier current byevery rectifier should be within ±2A or ±3%, whichever is less. It is possible however, forinternal loop parameters to change to such an extent that a unit does not share to theextent that it should.If the lack of sharing is extreme then either a CURRENT LIMIT or NO LOAD alarm will beactive and the operator should then refer to the next Section.If, however, the current sharing is not so extreme as to generate an alarm, a regular checkof the current sharing among the rectifiers can lead to early detection of any units whichmay be developing a fault.In general, if only one or two units are “drifting”, the most probable explanation is a“drifting” component in the secondary control card of the SMRs involved. If, on the otherhand, many of the SMRs are not sharing satisfactorily, then the most likely problem area isin the System Controller.

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

8.2.3 Fan Filter MaintenanceIf fan filters are fitted it is important that they are removed and cleaned on a regular basis.


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


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

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

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

reset CB supplying SMR

SMR faulty Replace SMR

Equalise Mode Equalisation cycle in progress due torecent AC power failure, periodic ormanual initiation.

No action required

SMR Urgent All SMRs off due to AC power failure If possible restore AC power

One or more SMRs off due to faults; Check Individual SMRs for obviousproblem; replace SMRs if necessary

All SMRs off due to incorrect Inhibitsignal from MCSU-4

Replace MCSU-4

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

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

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

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

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

Cct Breaker Fuse or CB within PDU has blown ortripped

Check PDU (Power Distribution Unit)

Wire or connector loose on MUIB Check MUIB connections and tighten

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

Bad connection to MUIB Repair connection

Amb Temp High Ambient Temperature is too high Reduce temperature – check Air Con.

Temperature sensor is faulty Check and replace if necessary

Connection to MUIB is faulty Repair connection

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


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

levelCheck battery temperatures and ifnecessary increase ventilation andcooling

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

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

Plug in temperature sensor if required;Replace temperature sensor

Faulty MUIB connection(s) Replace MUIB

Faulty MCSU-4 card Replace MCSU-4

Volts High SMR fault SMR Fault Chart

Float level set too high on MCSU-4 Check and adjust if necessary

MCSU-4 fault Replace MCSU-4

Volts Low AC power has failed; system on batterypower

Restore AC power if possible

Alarm threshold level set too high Check set point and adjust if necessary

All SMRs are off due to MCSU-4 Inhibitsignal, system on battery power

Check reason for signal; if necessaryreplace MCSU-4

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

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

Battery Temperature Compensation toohigh due to faulty battery temperaturemonitoring

Check battery temperature readings inBatt menu; Check and if necessaryreplace faulty sensor; check connectionto MUIB

Battery Temperature Compensation toohigh due to faulty MUIB

Replace MUIB

SMR HVSD Output voltage too high due to SMR fault Replace faulty SMR

HVSD threshold on SMRs set too low Check and re-adjust threshold level

MCSU-4 fault Replace MCSU-4

SMRs not sharingload current

Communications link malfunctioning orfaulty rectifier (digital current control)

Replace Comms cable and/or SMR

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

Replace MCSU-4

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

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

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

Faulty microprocessor card in SMR Replace SMR

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

Replace SMR

Load current too high (if more than oneunit showing alarm)

Reduce load

Reduce battery charging current limit if itis too high


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Alarm Condition Possible Cause Action SuggestedNo Load Load circuit breakers have tripped and

there is no loadReset circuit breakers

If only one unit showing alarm, commsline to SMR may be faulty

In SMR menu check status of this SMR.If “No Response” replace comms line

Faulty SMR Replace SMR

Current Limit Batteries being recharged if more thanone unit showing alarm

No action required

If only one unit shows alarm, internalcontrol loop faulty

Replace SMR

No Demand Internal control loop faulty Replace SMR

System has no load No Action Required

EEPROM Fail Faulty EEPROM or microprocessor card Replace SMR

DDC Controller Fault in DC/DC converter Replace SMR

H/S Temp High SMR Heat sink temperature too high Check air intake to SMR is not blocked

Ambient temperature is too high Try to reduce ambient temperature

Microprocessor card is faulty Replace SMR

Temp Sensor Fail Temperature sensor is faulty Replace SMR

Fan Fail

(Fan cooled nits only)

Air flow inadequate due to dirty filter Clean or replace filter

Air intake/outlet blocked Remove air blockage

Fan faulty Replace fan if connection is OK

Reference Fail Reference voltage source in, or entiremicroprocessor card is faulty

Replace SMR

HVDC not OK Faulty boost controller Replace SMR

Inrush limiting fuse or resistor O/C Replace SMR

High Volts SD Feedback voltage circuit faulty Replace SMR

Faulty microprocessor card Replace SMR

LVDS Open Battery discharged to the limit voltagelevel due to no AC power

Check AC voltage and reset if possible

Battery voltage OK In BATT menu check if LVDS mode isset to “Open”.

Battery voltage OK, MCSU-4 faulty Replace MCSU-4

LVDS threshold level set too high Reset level in BATT menu

Sys Volts High Volts High level in MCSU-4 set too low Reset level to correct value

Temperature compensation coefficientset too high

Set correct temperature compensationcoefficient

Faulty MUIB or MCSU-4 Replace MCSU-4

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

Temperature compensation coefficientset too high

Set correct temperature compensationcoefficient



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Alarm Condition Possible Cause Action SuggestedBattery Disch Output voltage low due to SMRs off Check AC voltage & restore if possible;

Float level set too low Set float level to correct value

Battery Disch level set too high Set correct Battery Disch level

SMR Comms Fail Comms cable faulty Replace cable

SMR communication circuits faulty Replace SMR

Faulty MCSU-4 Replace MCSU-4

AC Volt Fault

(System alarm)

AC voltage out of tolerance Check AC voltages and fix if possible

AC voltage threshold levels incorrect Set correct levels

Faulty AC monitoring unit MMIB1or2 Replace monitoring unit

MUIB or MCSU-4 faulty Replace MCSU-4

Communications link failure

(Only on systems not fitted with ACmonitoring module)

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

AC Freq Fault AC frequency out of tolerance Check AC frequency and fix if possible

AC frequency threshold levels incorrect Set correct levels

Faulty AC monitoring unit MMIB1 or 2 Replace monitoring unit

MUIB or MCSU-4 faulty Replace MCSU-4

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

No action necessary

Battery current limit set too low Set correct limit

Battery current sensor faulty replace sensor


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

Battery discharge current differentiallevel set too low

Set correct level of Disch I Diff in BATTmenu

Battery current sensor is faulty Check and replace sensor if necessary

Faulty MUIB or MCSU Replace MCSU-4

Earth Leak Alarm

(Only on systemsfitted with MUIB3)

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

Locate source of earth leakage currentand correct accordingly.

9.2 MCSU-4 Fault Finding and Repair ProceduresIn addition to performing a supervisory function by monitoring output voltage and currentand the various system alarms, the MCSU-4 also performs a voltage control function inorder to achieve battery charging current control, battery temperature compensation,battery equalisation and active current sharing.To control current to the lowest battery voltage, the MCSU-4 has the ability to suppressthe SMR output voltage to a value lower than the minimum battery voltage.


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It therefore follows that it is possible for a MCSU-4 fault to occur which can suppress theSMR voltage to that low level and thus cause a battery discharge despite the precautionsthat have been taken to ensure that this does not happen.In such a situation disconnecting the 4-way cable, which connects the SMRs to theMCSU-4, will remove the voltage suppressing communications control signal andthus avoid the batteries discharging. Alternatively, the MCSU-4 can be pulled out ofthe magazine to achieve the same result. Without the MCSU-4 connected, the SMRswill revert to their pre-set Float voltage and passive current sharing.There are virtually no electronic components on the MUIB except for the Remote alarmrelays, and some fuse links, but there are many connectors. It is worth checking for poorconnections when a MCSU-4 system problem is being investigated.

9.2.1 Replacing MCSU-4The MCSU-4 is “hot-swappable”, so replacing a faulty unit is simply a matter of pulling thebad unit out of the MCSU-4 magazine and plugging a new unit in. The new unit will thenpower up and automatically read the system parameters stored in the non-volatile memorylocated on the backplane. The system parameters should then be checked via the frontpanel menus or using WinCSU-2.

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Installation, Operation and Technical Manual - … RT9 24V with MCSU...Installation, Operation and Technical Manual Rectifier Technologies 158-1872-01.doc 1 3-Feb-16 1. General Warnings