85027501 DC Power Systems Handbook

March 21, 2018 | Author: charleselitb92 | Category: Battery (Electricity), Rectifier, Fuse (Electrical), Electric Power System, Direct Current
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Table of Contents The DC Power System 1.1 DC Power Overview 1.2 Rectifier 1.3 Battery 1.4 Distribution 1.5 Battery Return Bus 1.6 Supervisory and System Control 1.7 Low Voltage Disconnect Contactor 1.8 CEMF Cell 1.9 Battery Temperature Compensation 1.10 DC - DC Converter System 1.11 DC Power System Integration 1.12 Inverters/UPS 1 1 7 16 27 31 33 40 43 45 51 54 58 4.5 Battery Installation 4.6 Cabling 4.7 Power Up Procedure 4.8 Battery Initial Charge and Discharge Test. 94 4.9 Documentation 86 89 92 95 Power System Commissioning Retrofit Installation 6.1 Precautions 6.2 Tools List 6.3 Distribution Circuit Addition 6.4 Common Ground Bus Addition 6.5 Distribution Panel Addition 6.6 Rectifier Addition 6.7 Shunt Replacement 97 99 99 100 100 100 101 103 103 Power System Sizing and Ordering 2.1 Calculations 2.2 Formulas 2.3 Power System Design Example 2.4 Ordering Information for Power Systems and Loose Items 62 62 65 66 67 Maintenance and Field Repair 7.1 Power System and System Controller 7.2 RST Rectifiers 7.3 RSM Rectifiers 7.4 Pathfinder 24-3kW, 48-3kW, and 4810kW Rectifiers 7.5 CS and CSM Converters 7.6 Vented Batteries 7.7 Valve Regulated Lead Acid (VRLA) Batteries 7.8 Battery Failure; Detection, Prevention and Corrective Action 105 105 107 109 112 114 116 118 119 Site Engineering for DC Power 3.1 Site Layout and Loading 3.2 Grounding Network 3.3 Surge Protection Devices (SPD’s) 3.4 Wiring 3.5 Engineering Drawings 69 69 71 74 76 80 Initial Installation 4.1 Safety Precautions 4.2 Tools List 4.3 Inspection 4.4 Power System Assembly/Mounting 81 81 83 84 85 Troubleshooting 8.1 Power System and System Controller 121 121 .This page intentionally left blank. 1. where equipment was designed to operate from either an automotive (+12V) charging system or a truck (+24V) charging system. cellular. A DC source has the inherent benefit of higher reliability as compared to an AC source. are designed to operate from a DC input voltage. telephone switches. The use of -48V is rapidly becoming the most predominate as this is the maximum safe working voltage according to both the National Electrical Code (NEC) and the Canadian Electrical Code (CEC) that has no current limiting requirements. microwave transmission. but may include various other components. etc. The various components are discussed in detail later in this section. Most communication equipment. mobile radio. The basic power system consists of a rectifier and usually a battery. This is because the battery. + 24V evolved from the mobile radio industry.1 Typical DC voltage and current requirements The two most common input voltage requirements for communication equipment are +24V and -48V. is directly connected to the load with no intermediate stage such as an inverter that may fail and disrupt power to the load. ARGUS® TECHNOLOGIES 075-053-10 Rev D .1.1 DC Power Overview 1.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER The DC Power System The DC power system is a vital part of the communications network. which is often used for backup. The high voltage reduces the current requirements making fuses/circuit breakers/cables smaller. fiber optic transmission. including PBX’s. The negative polarity (positive ground.48V evolved from the telephony world where 48 volts was chosen because it was the maximum voltage that was considered safe as technicians had to make live connections. similar to the old British -6 VDC automotive charging system) was chosen as it reduced the galvanic corrosion that occurred when the lead sheathed telephone twisted pair cables were originally deployed and buried in the earth. ARGUS® TECHNOLOGIES 075-053-10 Rev D 2 .D C P O W E R S Y S T E M S H A N D B O O K . D C P O W E R S Y S T E M S H A N D B O O K Load Battery DC DC + DC Rectifier + - - AC AC Power Off AC Power On Figure 1 Basic DC Power System Operation ARGUS® TECHNOLOGIES AC Rectifier 075-053-10 Rev D 3 Battery Load Load DCPSB01A Load . 130 VDC + 130 VDC -12. +130 & + 250 VDC 200-10 000 Amps <100 Amps < 5 amps 100 VA per circuit various History History Table A Typical Telecom Equipment Voltage and Current Requirements ARGUS® TECHNOLOGIES 075-053-10 Rev D 4 . etc Voltage +12 VDC +24 VDC +24 VDC +24 VDC +24 VDC -48VDC -48VDC -48VDC -48VDC -48VDC Current <50 Amps 200-800 Amps <400 Amps <50 Amps 100-600 Amps 100-400 Amps <600 Amps <100 Amps 20-100 Amps 50-200 Amps Notes -48VDC -48VDC +/.D C P O W E R S Y S T E M S H A N D B O O K Application Mobile Radio Base Station Analog Cellular Base Station Microwave transmission station Mobile Radio Base Station Digital Cellular Base Station Digital Cellular Base Station Microwave transmission station Fiber optic transmission station Telephone switching center (pedestal) Telephone switching center (remote) Telephone switching center (large) PBX Pay phone coin control Fiber in the loop (FITL) Microwave transmission traveling wave tubes. D C P O W E R S Y S T E M S H A N D B O O K Typical AC voltage sources There are many different voltage sources around the world. Canada USA Canada USA. Service 120/240V 1 PH 3W 120/208V 3PH 4W 277/480V 3PH 4W 347/600V 3PH 4W 208 V 3PH 3W 480 V 3 PH 3W 220/380 V 3PH 4W Configuration Single Phase Three Wye Three Wye Three Wye Three Delta Three Delta Three Wye Phase Phase Phase Phase Phase Phase L–L Volts 240 VAC 208 VAC 480 VAC 600 VAC 208 VAC 480 VAC 380 VAC L-N Volts 120 VAC 120 VAC 277 VAC 347 VAC N/A N/A 220 VAC Where used? USA. Canada USA. See Table B. Canada USA Europe Asia South America Notes Table B Typical AC Commercial Voltage Sources Figure 2 Single or Split Phase ARGUS® TECHNOLOGIES 075-053-10 Rev D 5 . Identify the source that you are using and watch the rectifiers to the source. D C P O W E R S Y S T E M S H A N D B O O K Figure 3 Three Phase Delta Figure 4 Three Phase Wye or Star ARGUS® TECHNOLOGIES 075-053-10 Rev D 6 . The rectifier supplies current to the load and provides a trickle charge current to the battery. AC-OFF . AC-ON .3 Operation (Float charge mode) The rectifiers are adjusted to the voltage requirement (float voltage) of the battery and to “share” the load or supply the same output current in systems with more than one rectifier. 1. N+1 redundancy should always be considered.The rectifier turns off and the battery will supply current to the load until the battery is completely discharged. AC-ON . The DC output supplies power to the load (communication equipment) and charges a backup battery if required.2 Rectifier 1.2.2.2. with their corresponding (+) and (-) leads connected together.4 Sizing details The rectifier size is chosen by determining the most cost-effective means of satisfying the total capacity requirements.2 Connection The rectifier is connected in parallel with both the load and the battery (if applicable). 1.2. ARGUS® TECHNOLOGIES 075-053-10 Rev D 7 .D C P O W E R S Y S T E M S H A N D B O O K 1. Multiple rectifiers may be connected together in parallel.1 Description The rectifier is a device that changes an AC (alternating current) input to a regulated and filtered DC (direct current) output.The rectifier supplies current to the load. any extra current available from the rectifier will be used to recharge the battery. N is the number of rectifiers required to satisfy the total capacity requirements of the load and the “1” is an extra rectifier added so that a failure of a rectifier in the system will not jeopardize system integrity. 1. Refer to power system design calculation section.D C P O W E R S Y S T E M S H A N D B O O K Correct choice of either positive ground (-48VDC) or negative ground (+24 VDC) is critical. This is the value used by utilities to determine billing.5 Features and selection criteria Low output noise/ripple ensures that the load is unaffected by the rectifier in both battery and more importantly battery-less operation. Modular vs. 360. this includes the fundamental wave (60 Hz) and all the harmonics (120. in watts. The Pathfinder rectifiers offered by Argus have a true power factor of >. to the apparent power of the fundamental wave in volt-amperes.>. Note: the battery acts as a filter. Unity power factor (P. North America may soon follow this trend. The grounded potential is connected to a common point and the “live” cable is connected through either fuses or circuit breakers. The displacement component of power factor is the ratio of the active power of the fundamental wave (60 Hz). ARGUS® TECHNOLOGIES 075-053-10 Rev D 8 . monolithic configuration. 480 Hz.99. This value is used for efficiency calculations. unity power factor is a CE requirement for Residential and light commercial applications.2. 180. A poor power factor at your Telecom facility may result in the electrical utility adding a surcharge to your electrical bill. in watts. Early Argus rectifiers utilize passive power factor correction to achieve reasonable power factor at low cost.95) is becoming more important as the utilities move toward increased monitoring of power factor. but VRLA batteries will fail prematurely when connected to rectifiers with high output ripple voltage. In Europe. 1. Tight voltage regulation (line and load) to ensure that the battery is properly charged and the load does not receive fluctuating voltages. There are two types of power factor measurements displacement and true. etc. to the total volt ampere input. 240. True power factor is the ratio of the total power input.F. modular rectifiers allow for easy replacement and expansion. D C P O W E R S Y S T E M S H A N D B O O K Figure 5 Power in an Inductive Circuit Figure 6 Power Factor Triangle Low THD (total harmonic distortion) and damaging harmonic currents to meet CE requirements and to eliminate AC generator and transformer overheating and interaction problems. ARGUS® TECHNOLOGIES 075-053-10 Rev D 9 . THD refers to the distortion of the incoming AC voltage or current waveform when the rectifier is connected and is expressed as a percentage. D C P O W E R S Y S T E M S H A N D B O O K Three phase AC input . Pathfinder 48-3kW & 24-3kW rectifiers (208/240 VAC I/P) will continue to operate down to 90 VAC (with reduced output)! Compact and lightweight helps reduce installation.For higher power applications this becomes more important to ensure even balancing of load on a three-phase AC source. • Slope Regulation (Output Voltage) allows the user to drop the output voltage of the rectifier a small amount from no load to full load. Argus rectifiers accomplish this with a combination of forced sharing (master/slave) and/or adjustable slope regulation. Balanced load sharing should be achieved between units of the same design and with other types of rectifiers. Argus rectifiers have a wide input tolerance range for both frequency and voltage. This is done at a fixed rate. • Forced sharing works by the rectifiers electing a master unit (the rectifier with the highest output voltage). The other rectifiers are forced to adjust their output voltage to track the master and therefore share the load. This allows uninterrupted operation and also allows universal operation for 208/240V 60Hz operation and 220V 50 Hz operation with no modification or reconfiguration required. Wide AC operating window for both frequency and voltage to tolerate fluctuations without the rectifier shutting down. The slope in the voltage regulation of the rectifiers helps to allow the user to set the rectifiers to load share easily and also allows you to tailor the voltage regulation characteristics of different brands of rectifiers. reduces the size of the input feeder circuit breaker and input cabling. High efficiency as well as having the obvious power savings benefit. Adjustable slope allows you to tailor the voltage regulation characteristics of different brands of rectifiers. maintenance and shipping costs. ARGUS® TECHNOLOGIES 075-053-10 Rev D 10 . in either a discharged battery or overload condition. This reduces battery recharge time and also provides greater overload capabilities reducing the need for redundant rectifiers. Power limit allows the rectifier to supply greater output current when the output voltage of the system is low.D C P O W E R S Y S T E M S H A N D B O O K Figure 7 Output Slope Voltage Regulation and Current Limit Adjustable current limit restricting output current of the rectifier. Figure 8 Current Output P 48/10 kW e/w Power Limit ARGUS® TECHNOLOGIES 075-053-10 Rev D 11 . The rectifier can operate in this condition without damage. ARGUS® TECHNOLOGIES 075-053-10 Rev D 12 . preventing damage to the batteries and load. This boost charging eliminates any sulfation on the battery plates resulting in cell voltage imbalances and poor performance. Typically not required with VRLA batteries under normal operating conditions. 2. Float mode for normal charging of the battery.D C P O W E R S Y S T E M S H A N D B O O K Figure 9 Power Limit (P 48-3kW) . An automatic restart feature should be included in the event that a site temporary abnormality surge as a ground surge resulted in the HVSD. This is an important feature for vented lead calcium batteries floated at reduced voltage levels. Automatic high voltage shutdown (HVSD) or overvoltage protection (OVP) to switch the rectifier off in case of a high output voltage condition. Equalize mode for boost charging (at a higher charging voltage) of batteries when required.Current Limit (RSM 48/50) Comparison A float/equalize mode selector switch allowing selection of two operating modes: 1. regulating the rectifier output voltage to the rectifier output terminals. Alarms provide indication of rectifier failure and should be of “fail safe” design. Local indication plus remote relay contacts are required. This is important with power systems that incorporate separate charge and discharge circuits or power systems where there may be a significant voltage drop in the battery cables. Model Pathfinder RSM 48/10 RSM Voltage 24 VDC 48 VDC 24 VDC 48 VDC Current 18. 100 A 15. Adjustable delay start allows staggered start-up of rectifiers reducing stress on the AC generator and also allows the rectifiers to be started after the site air conditioner compressor (drawing high surge current) has started.100 A 15. Remote Control and Monitoring allows the rectifiers to be remotely controlled and monitored from a central supervisory and control panel. reducing the installation costs of the rectifier. 50. This eliminates start-up current surges associated with many rectifiers. 50. 100 A 30.5. If this feature is not connected. 50. 100 A Features Convection or fan cooled Modular design 200 kHz resonant converter design Convection or fan cooled Modular design 100 kHz forward converter design Passive power factor correction Convection cooled Monolithic Design 48 kHz forward converter design Passive power factor correction Table C Argus Technologies Solutions ARGUS® TECHNOLOGIES 075-053-10 Rev D 13 . This allows the charger output voltage to be regulated at the battery improving voltage regulation at the battery. 30.100 A 10. 50. The feeder breaker and feeder size requirements are decreased. 50.D C P O W E R S Y S T E M S H A N D B O O K Soft-start gradually steps each rectifier on-line at power up. 100 A RST 12 VDC 24 VDC 48 VDC 50. 180 A 7. Remote sensing leads are connected directly from the battery to the rectifiers via a sense fuse distribution panel located in the supervisory panel. 30. 30. 50. the rectifiers automatically revert to internal sensing. The PWM receives the ON/OFF command and clock signal from the front panel circuit and control circuitry. which steps down and isolates the high frequency switching waveform.6 Theory of Operation RSM 24/50. Similarly. a current error amplifier senses the output current using a shunt resistor and scaling amplifier to compare the output current to the desired maximum output current to provide a current error signal. The input filter provides a nominal 290 volts DC "raw supply" with approximately 30 V P-P 120 Hz ripple to the transistor switching circuit.2. powered via a small 50/60 Hz transformer. The transistor switching circuit chops the raw supply into nominally 525V P-P . This waveform is fed into a ferrite power transformer. It also senses the switching transistor current on an instantaneous basis to provide cycle-by-cycle protection of the switching transistors. ARGUS® TECHNOLOGIES 075-053-10 Rev D 14 . A voltage error amplifier circuit senses the output voltage and compares it with the voltage reference to provide a voltage error signal. An auxiliary supply. A rectifier circuit converts the power transformer output to a DC pulse train of nominally 136 V peak.48/30 and 48/50 Please refer to the power circuit block diagram. and a DC/DC converter power the control circuit and front panel circuitry. The 184-264 VAC 50/60 Hz input is fed through a circuit breaker into a full wave rectifier. 100 kHz rectangular waveform with a nominal 66% duty cycle. which provides a 120 Hz 340 V peak pulse train to an input filter circuit. The pulse width modulator controls the "ON" time of the switching transistors to vary the output as commanded by the error amplifiers. A two-stage output filter averages and smoothes this pulse train down to provide the nominal 52 VDC output with low noise. These signals are fed into the pulse width modulator (PWM) via OR-ing circuitry so that either voltage or current regulation is achieved.D C P O W E R S Y S T E M S H A N D B O O K 1. 24/100. D C 60Hz 290VDC 250V 525V 136V 120Hz 100kHz +340V -340V 52V (48V Units) 0V Figure 10 OV P O W E R Input 185-265VAC 50/60Hz + Input Rectifier Transistor Drive Isolation Boundary DC/DC Local Current Sense Auxiliary Supply Or Gate Pulse Width Modulator (PWM) Output Rectifier Transistor Switching Circuit + Output Filter Output Shunt ARGUS® TECHNOLOGIES Input Filter & Storage Capacitors Output Current Sense Current Error Amplifier Voltage Error Amplifier V AUX IN On/Off Command I Out S Y S T E M S RSM Block Diagram Front Panel Circuit Micro Processor H A N D B O O K Output Voltage Sense Remote Sense Voltage Current V Out Reference Reference .Display .Adjustments .Monitoring Communication DCPSH07A 075-053-10 Rev D 15 . 75 21 1.3 Battery 1.e. 1.75 21 42 1. A battery consists of a series connection of multiple cells.30 21-27.3.3.6 1 12 48 V System 48 52.30 27. The number of cells in series is determined by the operating voltage of the system and the operating voltage of each cell. V # cells Valve Regulated Lead Acid Battery (VRLA) One Cell 24 V System 48 V System 2 24 48 2.30 27. 20 deg C in Europe). amps per hrs) and select the battery using the manufacturers sizing table (See: Table E).D C P O W E R S Y S T E M S H A N D B O O K 1. The battery may be used in combination with a generator to provide back-up power for extended time periods to the load. ARGUS® TECHNOLOGIES 075-053-10 Rev D 16 .4 Typical battery operating parameters Sizing details Determine your load profile (i.2 Connection The battery is connected in parallel with the rectifier and the load. Win.2 42 42-55.4 2.3.25 27 54 2.30 21-27.6 1. V Float V Equalize V End V Op. Parameter Nom. the battery will automatically supply current to the load.2 1 12 24 Flooded or Vented Battery One Cell 24 V System 2 24 2.3 Operation As detailed in the rectifier operation section. Equalization is where a higher boost voltage is applied to the battery to ensure the proper cell voltage balance and correct conditioning of the battery cells. 1.75-2.1 Description The battery is an electro-chemical means of energy storage.6 42-55.6 55. Batteries are rated using the following criteria: Temperature (25 deg C in North America.8 55. When AC power is interrupted to the rectifiers or when there is insufficient current available from the rectifiers to support the load requirements.2 1.2 24 Table D 1.20 26. Some batteries may require periodic equalization.75-2.3. The maximum recommended number of parallel strings is three. Battery strings may be connected in parallel to obtain additional capacity. Refer to IEEE battery sizing guidelines for calculating battery size for complex load profiles Evaluate battery charge rate for sizing intercell and inter-tier connectors Apply temperature performance correction factor for average temperatures below 25 deg. ARGUS® TECHNOLOGIES 075-053-10 Rev D 17 . therefore the larger the battery the greater the capacity. C. if applicable (See: Table F). Battery capacity is determined by the number & size of the plates. Strings should be equal in capacity and interconnecting cables should be of approx. A more conservative end voltage will increase the life expectancy of the battery but reduce back up time. Apply the beginning and end of life de-rating factor. • Battery end of life considered as 80% of capacity (See: Figure 11). The end voltage used in calculations is usually the minimum voltage that the battery can be discharged down to without damage. (77 deg. the same size and length to obtain optimum charge and discharge characteristics. F). typically 90% (Full capacity is achieved after a short period of float service). This factor is 20% and allows for: • The battery shipped at less than 100% capacity.D C P O W E R S Y S T E M S H A N D B O O K End voltage (the lowest voltage that the cell is discharged down to). Cells that are “tank” formed ship at 100 % capacity. Ensure that the battery operating voltage coincides with the acceptable operating voltage window for the equipment connected. ARGUS® TECHNOLOGIES 075-053-10 Rev D 18 . Mono blocks are batteries that have more than one cell contained in the assembly (i.e. an automotive battery is a 6 cell 12 VDC monobloc).D C P O W E R S Y S T E M S H A N D B O O K Smaller applications commonly use mono-block batteries. 67 3.4 55.50 VPC 1 MIN.0 12.99 1. 4 HR.2 19. 24 HR.2 12.5 HR.50 7.7 88.8 14.4 8.0 55. 48 hr. 10 hr.9 21.0 16. 3 HR. 2 hr.8 99.0 10. 12 hr. 100 hr.44 7.79 5.73 4. 7 hr.9 111 44. 20 hr. 2 HR.34 3.8 30.0 9. 12 HR.7 8.6 11. GR.6 16. TYPE 72 HR.26 0.1 34.2 71.3 10. 30 min.1 8.8 6.6 77.215 SP.88 1.0 9.43 1. 5 hr.00 4.03 1. A.0 24. 60 min. 72 hr. TO 1.1 12.10 1.5 47.5 25.7 43. 3 hr.6 39.6 4.3 63. 15 min.3 11.80 7.2 21.8 23.8 25.4 22. CAP. 1.0 60.75 VPC Final EA-5 230 EA-7 EA-9 EA-11 EA-13 EA-15 EA-17 EA-19 EA-21 270 350 440 530 620 710 800 890 4.9 17.37 0.0 65. 30 MIN.75 5 min.0 18.0 12.0 15.91 Table E Typical Battery Performance Table ARGUS® TECHNOLOGIES 075-053-10 Rev D 19 .9 11. 8 hr.9 10.42 1.0 31.04 1.5 117 137 156 176 195 59 73 97 122 146 171 195 219 244 75 98 131 164 197 229 262 295 328 87 120 160 199 239 279 319 359 399 102 154 205 257 308 359 411 462 513 152 226 298 367 435 507 571 634 694 197 291 380 465 558 651 728 801 870 290 426 548 685 792 924 1010 1100 1190 530 790 1010 1270 1460 1700 1870 2030 2200 *Rates shown depict average values and are subject to IEEE-485 CONSTANT CURRENT DISCHARGE RATINGS AMPERES @ 77°F Operating Time To End Point Voltage End Point Volts/ Cell 1. 5 HR. 6 hr.1 79.1 34.80 240 151 99.7 98.0 114 131 147 163 49.4 55.H.02 1.13 1.8 14.0 26. 4 hr.6 9.5 78.4 38.0 11.7 31. To 1. 1 HR.8 18.65 1. ELECTROLYTE AT 77° (25°C).08 7.0 49.10 2.0 28.92 2. 15 MIN.0 19.89 4.0 97.3 81.90 6. 24 hr. 1. INCLUDING CELL CONNECTORS NOM. 8 HR.5 34.8 13.4 16.6 11.19 2.3 44.90 156 110 75. 1 MIN.9 58.D C P O W E R S Y S T E M S H A N D B O O K Average Cell Performance Data * Discharge rates in amperes.0 12.23 4.0 15.58 4. 274 162 105 61.5 66.85 203 136 92.0 47.6 33.2 14. 000 0.4 23.9 -1.7 22.2 10.1 31.034 1.9 Temperature F 25 30 35 40 45 50 55 60 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 95 100 105 110 115 120 Cell size correction factor 1.110 1.6 43.300 1.0 12.9 24.6 21.6 32.964 0.4 20.7 4.960 0.3 46.048 1.930 0.190 1.910 0.880 0.3 28.6 26.860 Table F Temperature Performance Correction Factor Table This table is based on flooded lead-acid cells only.8 15.0 25.017 1.3 18.006 1.9 19.7 27.029 1.870 0.072 1.1 1.350 1. ARGUS® TECHNOLOGIES 075-053-10 Rev D 20 .0 30.250 1.987 0.150 1.011 1.056 1.1 48.4 7.8 28.D C P O W E R S Y S T E M S H A N D B O O K Electrolyte C -3.948 0.023 1.064 1.952 0.1 21.040 1.430 1.5 25.994 0.6 31.890 0.8 40.6 18.8 23.520 1.080 1.4 30.972 0.0 37.0 20.968 0.2 22.980 0.9 29.956 0.944 0.2 27.1 26.940 0.2 35.976 0. • • IEEE-1184 . IEEE-1689 . ARGUS® TECHNOLOGIES 075-053-10 Rev D 21 . please refer to: • IEEE-485-199 .D C P O W E R S Y S T E M S H A N D B O O K For further information.IEEE guide for the selection of valve- regulated lead-acid (VRLA) batteries for stationary applications.IEEE guide for the selection and sizing of batteries for uninterruptible power systems.IEEE recommended practice for sizing large lead-acid batteries for stationary applications. are listed below.3.D C P O W E R S Y S T E M S H A N D B O O K Figure 11 Battery Performance vs.5 Features and selection criteria There are three main types of lead acid batteries that are used in telecommunication applications. ARGUS® TECHNOLOGIES 075-053-10 Rev D 22 . Time 1. The three types. based on acid classification. D C P O W E R S Y S T E M S H A N D B O O K Acid Classification Flooded Technology Description free liquid electrolyte. plant options -best life expectancy of lead acid batteries at higher operating temperatures Disadvantages -high maintenance -transportation restrictions VRLA-AGM (Absorbed Glass Mat) Technology a small quantity of liquid electrolyte is held in suspension in the fiberglass mat -low maintenance -minimal vented gasses -easy installation in any position -easier shipping classification -will not freeze -difficult to evaluate battery state of health -rapid reduction of life expectancy when operated at high temperatures (above 25 deg C) VRLA-Gel Technology fumed silica is added to gel the liquid electrolyte -lasts longer than AGM at high operating temperatures -performance (AH per kg) is less than AGM battery Table G Battery Type Comparison ARGUS® TECHNOLOGIES 075-053-10 Rev D 23 . similar to an automotive battery Advantages -proven technology -flat. tubular. D C P O W E R S Y S T E M S H A N D B O O K Figure 12 Battery Construction ARGUS® TECHNOLOGIES 075-053-10 Rev D 24 . D C P O W E R S Y S T E M S H A N D B O O K Cycling requirement - different cell plate alloys and plate configuration affect the cycling (charge and discharge) performance of the battery. Determine the cycling requirement of your application (i.e. float with light cycling, float with heavy cycling and full cycle service) and choose the correct battery for the application. Rate of discharge: High < 15 minutes Medium 15 min. - 2 hr. Low 2 hr + Maintenance requirements. Physical design parameters , ventilation, floor loading, available space. Cost including life expectancy. VRLA batteries of both AGM and “gel” type are usually the first choice for backup. Some of the important features to look for in a VRLA battery are: • • • Jar material with low water vapor diffusion rate i.e. polypropylene or PVC to prevent dry out. Flame retardant jar materials. Even compression of plates through a fixed method of jar compression to maintain, plate to microporous separator integrity (AGM). Designed to prevent strap corrosion and lug corrosion (AGM). • The Battery may be packaged on a traditional battery stand or be of bolt together self supporting construction. For smaller battery strings the use of relay rack shelves or cabinets is a consideration. There are also AGM batteries available from the manufactures prepackaged for easy installation into a relay rack. 1.3.6 Argus Technologies Solutions Argus does not manufacture batteries, but will provide batteries as part of the integrated power system. ARGUS® TECHNOLOGIES 075-053-10 Rev D 25 D C P O W E R S Y S T E M S H A N D B O O K Circuit Breaker Distribution Charge (+) Shunt Bar Charge (-) Rectifier #2 Figure 13 Basic System e/w Distribution ARGUS® TECHNOLOGIES Rectifier #1 - + + - Termination Panel 075-053-10 Rev D 26 Battery Ground Bar DCPSB02A Load Load D C P O W E R S Y S T E M S H A N D B O O K 1.4 Distribution 1.4.1 Description Fuses and circuit breakers are used to safely distribute the DC power from the rectifier and battery to the loads. These devices protect the loads and load cables from short circuits, overload conditions and allow easy manual shutoff . This helps to isolate faults between circuits. Circuit breakers and fuses are also used for protecting the battery and battery cables and to allow an easy means of disconnecting the battery from the system for safety, fire prevention and maintenance. 1.4.2 Connection Primary Distribution Load fuses or circuit breakers located at the power system are connected in series between the power system and the loads and/or between the power system and the battery. Secondary Distribution Large main fuses are installed in the power system to distribute dc power to remote BDFB’s (Battery Distribution Fuse Board’s) or BDCBB’s (Battery Distribution Circuit Breaker Boards). From the BDFB power is distributed to the loads with smaller individual circuit breakers. 1.4.3 Operation Fuse Excessive current flowing through the fuse melts the internal link, disconnecting the load from the power system. A guard fuse is connected in parallel with the main fuse and will blow when the main fuse blows. The guard fuse provides a local indication and also will send an external alarm signal via a built-in contact. Circuit breaker Excessive current flowing through the circuit breaker causes excessive heat (thermal) or an excessive magnetic field (magnetic) to trip the circuit breaker to the off position. Alarm sending is via breaker auxiliary contacts or electronic trip detection circuitry. ARGUS® TECHNOLOGIES 075-053-10 Rev D 27 The benefit of the circuit is that an alarm is indicated only when a breaker is off with a load connected and no connection to the auxiliary contacts is needed. Breaker ON with no load voltage on breaker output is high no alarm . Battery fuse/circuit breaker should be sized at 1. ARGUS® TECHNOLOGIES 075-053-10 Rev D 28 . Breaker OFF with no load voltage on breaker output is high (due to bypass resistor) no alarm . Sizing Most communication equipment requires fuses or circuit breakers with short delay curves “fast blow” to provide proper protection Fuses with different curves may be utilized to match specific load requirements. however current flow is limited to a few mA due to the 10.25 to 1. Breaker ON with load voltage on breaker output is high no alarm .000 ohm resistor.5 times the maximum continuous anticipated load on the circuit for reliable operation. Breaker OFF with load voltage on breaker output is low (due to load forcing voltage down to zero V) alarm is indicated . Ensure that the current capacity of the circuit breaker panels is not exceeded by the current draw of the connected loads.D C P O W E R S Y S T E M S H A N D B O O K Electronic trip detection circuitry A 10 000 ohm bypass resistor is connected across the circuit breaker (to limit current) and the output voltage of the circuit breaker is monitored. Load fuses and circuit breakers should be sized 1.25 times the maximum current rating of all the rectifiers in the system (minimum). Voltage will be measured on the output of a circuit breaker even when the breaker is off. Battery protection features : § EPO .D C P O W E R S Y S T E M S H A N D B O O K The interrupting capacity (highest fault current that the device is rated to safely interrupt) of the protection device should match the application. Guard bars to prevent accidental tripping of circuit breakers. Manual battery disconnection . Features and selection criteria Remote alarm sending via guard fuse or remote contacts on circuit breaker. Current monitoring via series shunts to ensure circuits are not overloaded or power consumption monitoring for billing purposes. “plug-in” or “snap-in” circuit breakers. Various types of fuses and circuit breakers can be combined in different panels to meet load requirements.Emergency Power Off control capability using contactor or shunt trip breaker for locations that require a mandatory emergency power shutdown to meet local fire codes. § § ARGUS® TECHNOLOGIES 075-053-10 Rev D 29 .Low Voltage Battery Disconnect control capability to automatically disconnect and reconnect the battery during an extended ac power outage. Traditional “bolt-in”.Single string disconnection for maintenance and fault isolation. LVBD . Alarm indicating lamp and an isolating relay. Battery protection devices require higher interrupting capacity due to the high short circuit current capability of a battery and the large cables (low impedance). Electronic breaker trip detection circuitry. fast speed. low speed.4 Argus solutions Fuse blocks: Type GMT 70 Type BAF Cartridge TPL Rating-Range (block size) 0-15A 1/2A used for indicating purposes 0-30A 0-30A.000A Usage Load or battery Load or battery Load or battery ARGUS® TECHNOLOGIES 075-053-10 Rev D 30 . Circuit breaker advantages .can be reset. 31-60A. flexibility. accuracy.100 A 5 .100 A 100-700 A Interrupting Capacity 5 or 10kA 10.000A 25.high interrupting capacity. 101-200A 61-800A Breakers: Manufacturer Type Heinemann Heinemann Heinemann AM CD GJ Rating 5 .D C P O W E R S Y S T E M S H A N D B O O K Fuses or circuit breakers? • Fuse advantages . cost. 61-100A. • 1.4. 5.5.2 Connection The ground lead of all DC load inputs.3 Sizing Ground bars are sized according to load requirements.1 Description The battery return bus (BRB). This bus must also be connected to the site ground grid (see grounding network section).D C P O W E R S Y S T E M S H A N D B O O K 1. 1. Ground bars must be isolated from the relay rack through glastic insulators so that the power system can be integrated correctly into the site single point ground network. • • 1.5. provides a common return/reference point for the connected loads and the power system.5. also referred to as the common ground bus . 1. This common reference point is connected to the site ground to provide a low impedance path to ground for transients and noise. ARGUS® TECHNOLOGIES 075-053-10 Rev D 31 . batteries and rectifiers should be connected to this point. 1.5 Argus solutions Various types are available from Argus including flat bars and “U” shaped bars for additional cable termination.5 Battery Return Bus 1.5. Provisions for small cable termination shall also be provided. Tin-plated copper construction for corrosion resistance .4 Features • • Allowances for termination of two-hole lugs of various sizes should be provided. D C Figure 14 Battery Circuit Breaker Distribution P O W E R + Rectifier #2 Charge (-) Charge (+) H A N D B O O K + Rectifier #1 Shunt Bar Power A Supervisory Panel DCPSH03A Basic System e/w Supervisory Panel V Termination Panel Shunt Ground Bar Load ARGUS® TECHNOLOGIES S Y S T E M S 075-053-10 Rev D 32 . Shunts can be installed in the grounded or live load.1 Description In most power systems it is desirable to have a central control and monitoring panel to provide local and remote indication of system operating parameters and alarms and also to provide system control. Shunts are calibrated low resistance resistors designed to provide a specific voltage drop at a specific current (linear relationship). 50mV. Additional analog parameters can be monitored using available inputs. This voltage drop is measured by the ammeter.6. 1.6 Supervisory and System Control 1. battery or load. In systems where there is no battery shunt an estimation of battery current can be calculated by subtracting the discharge current from the rectifier total output current. Calculated values may also be displayed such as total rectifier output current (numerical addition of individual rectifier output currents). ARGUS® TECHNOLOGIES 075-053-10 Rev D 33 .3 Operation The battery (charge) and load (discharge) voltage is monitored with a direct connection of the sense leads to the source.6.2 Connection Various connections are made to the supervisory panel from different components so that different parameters and levels may be monitored and controlled. A typical shunt rating would be 200A. battery or system conductor.D C P O W E R S Y S T E M S H A N D B O O K 1. Therefore 200 amps of current flowing through this shunt will cause a voltage drop of 50mV. The battery (charge) and load (discharge) current is monitored with an external shunt. 1.6. Room and battery temperature can be monitored with temperature probes. 6. Microprocessor based supervisory panels have direct communications with rectifiers for monitoring and single point control. Relay contacts may be configured as form “A” (NO). or form ”C” (NO & NC). battery fuse alarm.4 Sizing Shunts are sized according to load requirements and limit the initial capacity of the power system. Analog alarms usually incorporate a hysteresis into the trigger level to prevent oscillation of an alarm condition caused by a level fluctuating around the set point. Alarms are based on an analog or digital event.5 Features (panel dependent) Typical Alarms • • • • • • • • • • high/low voltage (1 & 2) AC mains high/low/failure distribution fuse/breaker battery fuse/breaker control fuse trip rectifier failure alarm minor (one rectifier) rectifier failure alarm major (>one rectifier) converter failure alarm minor (one converter) converter failure alarm major (>one converter) auto-equalize ARGUS® TECHNOLOGIES 075-053-10 Rev D 34 . Each alarm has a two to five second delay before extending an alarm. form “B” (NC). converter failure. 1. Alarm functions provide both local (visual and audible (optional)) and remote (relay contact) indicators. etc.6. 1. Control functions are extended from the supervisory panel to control various other power system components.D C P O W E R S Y S T E M S H A N D B O O K Events such as distribution fuse alarm. Communications is via RS-485 connection. rectifier failure. The delay eliminates false triggering due to line transients or false alarms. are monitored by the supervisory panels. Current flowing through a shunt must not exceed 80% of its nominal rating on a continuous basis. rectifiers are off and the batteries have been discharged) and activate voltage (indicating the battery is nearing full charge and the equalize mode is triggered. equalizing cell voltages in a battery string. Manual equalize .D C P O W E R S Y S T E M S H A N D B O O K • • • • • • • • high voltage shutdown low voltage disconnect CEMF (out) CEMF (fail) rectifier communication lost Power system minor alarm (logical “or-ing” of various non critical alarms) Power system major alarm (logical “or-ing” of various critical alarms) etc. Auto-equalize .e. Auto-equalize is initiated in one of three ways: 1. after power failure based on the voltage of the battery. Used for maintenance purposes with VRLA batteries. periodic equalize. 2. arm voltage (indicating that a long outage has occurred. i. It is used with vented batteries floated at low voltages to prevent lead plate sulfation or where a quicker recharge of the battery is required after a power failure. rectifiers are on) The rectifiers will remain in the equalize mode for the duration.Allows the user to initiate all the rectifiers into the equalize mode with one common switch. This function initiates the rectifiers into the equalize mode (boost charge) for a preprogrammed amount of time (duration). are ARGUS® TECHNOLOGIES 075-053-10 Rev D 35 . Controls Control features are used to control power system devices such as rectifiers and contactors.Common in applications where flooded batteries are deployed. where the batteries equalized at the interval programmed in days. § Battery run time prediction . before the battery will be fully discharged or a LVD will occur.a continual measurement of the batteries performance and state of health. It is programmed typically at C/5 (capacity of the battery/5). § Battery state of health estimation . ARGUS® TECHNOLOGIES 075-053-10 Rev D 36 . Alarm triggers can be set to alarm when the battery state of health falls below 80%.the capacity of the battery at the current point in time expressed as a percentage of the battery manufacturer's specification.switch for maintenance. This can be very important for VRLA type batteries. LVD override control .controls 1 or more contactors that automatically open when a low battery voltage condition is detected and close when the battery voltage returns to normal. at the present discharge rate. resulting in excess heat generation and possible reduction in battery life.D C P O W E R S Y S T E M S H A N D B O O K 3. HVSD/OVP . Charge current control is used to limit the flow of current into the battery when recharging commences after a power failure. LVD .the algorithm predicts the number of hours that the battery will last. See LVD section. It is expressed as a percentage of the manufacturer's specification. See battery temperature compensation section. manual initiation using the duration setting to return the rectifiers to float after the duration has expired.automatically shuts down all the rectifiers when an output DC over-voltage condition is detected. Battery temperature compensation is used to adjust the rectifier output voltage to ensure that the battery float voltage is correct for the operating temperature of the battery. This ensures that the battery is not charged too quickly. Battery diagnostics § Battery capacity estimation . Lamp test . allows the user to test and calibrate the power system while in service (SD series only).Combined with an external power supply.7 Advanced features (SM series) • Remote access for control and monitoring.Is provided to clear the relay contacts and audible alarm associated with each alarm condition this allows extended alarms to be canceled while alarm condition is being resolved by local personnel. ALCO (Alarm Cutoff) .6.allows the operator to setup and adjust all the rectifiers at one central location. etc. LocalRS232 Remotedial-in Remotedialback SNMP (Simple Network Management Protocol) alarm reporting over network LAN or WAN History and statistics Programmable alarm relays LCD display of alarms.6. CEMF (counter-electro-motive-force) controls 1 or more contactors that automatically close when a high load voltage condition is detected and open when the load voltage returns to normal or is in a low voltage condition. 1.D C P O W E R S Y S T E M S H A N D B O O K Rectifier group single point adjustment .Illuminates all lamps to verify operation.6 Other Features VAR (Visual alarm reset) . • • • ARGUS® TECHNOLOGIES 075-053-10 Rev D 37 . 1. Test . parameters. See CEMF section.Is used to clear visual alarms. SD03 & 05 These discrete component supervisory panels provide basic metering. SD02 & 04 These discrete component supervisory panels provide comprehensive metering. control and alarm functionality.D C P O W E R S Y S T E M S H A N D B O O K 1.6. control and alarm functionality. SM03 This microprocessor based supervisory panels provides many of the features of the SM02 (without the remote access) in a smaller.8 Argus Solutions SM02 This microprocessor based supervisory panel combines a large LCD display and keypad with optional modem card to provide advanced power system monitoring and control features. reduced cost package. ARGUS® TECHNOLOGIES 075-053-10 Rev D 38 . D C Figure 15 Battery Low Voltage Load Disconnect Circuit Breaker Distribution P O W E R + Rectifier #2 Charge (-) Charge (+) H A N D B O O K + Rectifier #1 Shunt Bar Power DCPSH04A Basic System e/w Load Disconnect A Supervisory Panel V Termination Panel Shunt Ground Bar Load ARGUS® TECHNOLOGIES S Y S T E M S 075-053-10 Rev D 39 . Prevention of load damage due to an under voltage condition. Load shedding .7 Low Voltage Disconnect Contactor 1. Discharging a battery below the lowest recommended end voltage (see battery section) might permanently damage the battery. The disconnect point is typically set to the lowest acceptable battery discharge voltage (end voltage).1 Description The low voltage disconnect (LVD) contactor is used to disconnect either the load from the system (load disconnect) or the battery from the system (battery disconnect) when the battery has been completely discharged in a long duration power outage.2 Connection The low voltage disconnect can be connected in series with the load (load disconnect) or in series with the battery (battery disconnect). In a Telecom application the end voltage typically used is 1. Some communications equipment may be damaged when operated with an excessively low input voltage or draw excessive current that could trip a feeder circuit breaker.7.75 volts per cell (21 VDC in a 24 VDC system and 42 VDC in a 48 VDC ARGUS® TECHNOLOGIES 075-053-10 Rev D 40 . Prevention of damage to the battery due to overdischarge.to disconnect specific loads in a prioritized sequence to maximize backup time for more critical loads (ex. The LVD is controlled by the supervisory panel. up to three individually controlled contactors can be used with the SM02).7. 1.7.3 Operation The supervisory panel continuously monitors system voltage. 1. After an extended AC outage the batteries will discharge down to the disconnect point. 3. There are three reasons for using a LVD: 1.D C P O W E R S Y S T E M S H A N D B O O K 1. 2. A wide voltage differential between the in and out settings (i.D C P O W E R S Y S T E M S H A N D B O O K system). battery disconnect . out 42V. ARGUS® TECHNOLOGIES 075-053-10 Rev D 41 . the load will see a slowly increasing DC voltage (0-50 VDC over an 8-10 second period.e. disconnection is desirable. in 50 V in a 48V system) prevents the contactor from oscillation because the battery voltage will naturally rise after the load has been removed from it and reconnection without the rectifiers on-line would not be desirable. instead of load.4 Sizing Low voltage disconnect contactors are available in various sizes. The advantage of this system is that an accidental operation of the LVD will not disrupt power to the load unless the AC is also off. 1. The rating of the LVD indicates its maximum current carrying/switching ability.In some cases battery. The load or battery will remain disconnected until AC outage is over. the load is connected on line at this voltage level. Battery disconnect Immediately after the reapplication of AC. The disadvantage of the battery disconnect that the load will see a slowly increasing input voltage 0-50V as the rectifiers perform the soft start this may cause damage to the load or inadvertent fuse or circuit breaker tripping. due to the soft start feature in the rectifier). Load disconnect The rectifiers will pre-charge the batteries for a few minutes until the battery voltage reaches the reconnect point (typically 25 VDC or 50 VDC). At the 50 VDC point the battery will be connected on line. When the disconnect point is reached the load or battery will be disconnected from the system.7. Load vs. When the reconnect point is reached. On return of AC a load disconnect and a battery disconnect system function differently (see below). Careful evaluation of the load specifications is required to verify that this method of disconnection will not affect the load. ARGUS® TECHNOLOGIES 075-053-10 Rev D 42 . 800A and 1200A available.7.6 Argus solutions 200A. 1.7.D C P O W E R S Y S T E M S H A N D B O O K 1.5 Features and selection criteria Able to switch high current loads reliably. It was historically used with both step by step and crossbar telephone switching offices.8.8. 1. The diodes are used to reduce the voltage applied to the loads by a fixed value during normal operation or when the batteries are equalize charged.1 Description The CEMF cell is a diode array that is connected in series between the power system and the loads. When a power failure occurs ARGUS® TECHNOLOGIES 075-053-10 Rev D 43 . There are two scenarios for CEMF use: 1.75V. The supervisory panel controls the CEMF cell.8. CEMF cell normally IN to reduce load voltage in the float and equalize mode.3 Operation The supervisory panel continuously monitors system voltage.2 Connection The CEMF cell is connected in series with the load. It also introduces another single point of failure.D C P O W E R S Y S T E M S H A N D B O O K 1. The contactor automatically bypasses the CEMF when the system is on battery to maintain maximum backup time for the loads. 1. CEMF cells are rarely used in modern telecommunications systems as they introduce step voltage changes to the load voltage when switched in or out that may affect load operation. A common alternative to the CEMF cell is to remove one battery cell from the string and lower the rectifier output voltage to reduce the operating voltage of the system. A contactor is installed in parallel with the diodes.25 V per cell = 51.8 CEMF Cell 1. for example: 23 cell system with VRLA batteries 23 x 2. The normal system float voltage is above the IN setting of the CEMF cell the CEMF contactor is opened so that current flow is through the CEMF diodes and the load voltage is reduced. 1.8. current flows through the diodes and the voltage at the load is reduced. In this system the IN setting of the CEMF is set higher than the float voltage and the contactor normally bypasses the diodes. When power is restored the contactor will open when the voltage returns to normal diverting current through the diodes and reducing the load voltage.8.8. 2. Alarm on failure of cell. Current required by load.4 Sizing Voltage drop required.6 Argus solutions Cells and contactors in various sizes are available. ARGUS® TECHNOLOGIES 075-053-10 Rev D 44 . 1. 1. CEMF cell normally OUT to reduce load voltage in the equalize mode only. When equalize mode is selected the voltage rises above the IN setting and the contactor is opened. When the rectifiers are returned to float mode the voltage drops below the out setting and the diodes are again bypassed by the contactor and the load voltage returned to normal.D C P O W E R S Y S T E M S H A N D B O O K and the voltage drops the contactor is closed to increase the voltage at the load to ensure maximum back up time.5 Features Monitoring of cell status. e. there are no additional sense/battery connections required.2 Description Temperature compensation is the process of automatically reducing the charge voltage applied to the battery at high temperature (to increase life and prevent thermal runaway) and increasing the voltage applied to the battery at low temperatures (to increase the battery capacity and to ensure correct charging of the battery).1 Background Battery performance and life expectancy is directly related to the battery ambient temperature.9.3 Connection Connection is as follows: 1. Traditional rectifiers with non-SM supervisory panels use a temperature compensator module (TCM) connected in series with the rectifier remote sense line input and the battery that requires temperature compensation. This cycle continues until the battery fails. Above this temperature. The rise in internal ambient temperature causes the battery to draw more float current which in turn elevates the internal battery temperature.9.9. C (77 deg. 2. high ambient temperature or internal fault.D C P O W E R S Y S T E M S H A N D B O O K 1. battery life is compromised and below this temperature battery performance is reduced. ARGUS® TECHNOLOGIES 075-053-10 Rev D 45 . The failure of the battery may be quite dramatic.9 Battery Temperature Compensation 1. The optimum temperature for battery operation is 25 deg. Smaller rectifier systems (i. This occurs when the internal temperature of the battery rises due to overcharge. 1. RSM 48/7.5 and 48/10) have this feature built in. 1. VRLA batteries have a negative characteristic called “thermal runaway”. F). The rectifier RS 485 communications link is used for this purpose. C. Temperature probes (1-4) are mounted directly to either the same battery negative termination post or to multiple negative posts to monitor multiple battery strings. 0 deg C). (See Table H & I) Small systems adjust the rectifier output voltage based on ambient temperature detected at the battery. the TCM adjusts the output sense voltage to the rectifiers based on ambient temperature detected at the battery. Non-SM based systems. C change from 25 deg C reference). the battery voltage maximum compensation may be limited (lower break point) at a fixed temperature (ex. 1. the battery or causing a high voltage alarm condition.5 mV per cell per deg.D C P O W E R S Y S T E M S H A N D B O O K 3. C (77 deg. 2. SM based systems. At temperatures above 25 deg. the SM will automatically adjust the rectifier float voltage based on the battery temperature detected. C. At temperatures below 25 deg. RSM/Pathfinder rectifiers with SM supervisory panels.5 mV per cell per deg.9. To prevent excessive voltage from damaging the load. -2. the rectifier will increase its output at a fixed rate(ex. F) no voltage compensation will occur.4 Operation Operation is as follows: 1. It will repeat this process at the interval programmed. -2. the rectifier will decrease its output at a fixed rate(ex. require no additional sense/battery connections. ARGUS® TECHNOLOGIES 075-053-10 Rev D 46 . At 25 deg. (See Table H & I). 3. The rectifiers will adjust their output voltage according to the sense voltage level detected at their remote sense input. C change from 25 deg C reference). Redundant temperature probes for increased safety. It will operate with RST (6 max. for example: a 4. Check load acceptable input voltage operating window. 1.6 Features and selection criteria • • • Fail detection circuitry.5 or 3. It will also operate with non-Argus remote sense input equipped rectifiers.9. the battery voltage maximum compensation may be limited (upper break point) at a fixed temperature (ex. Automatic turn off if a fault is detected and an alarm extended.5 mV if this information is unavailable. ARGUS® TECHNOLOGIES 075-053-10 Rev D 47 . 1. 50 deg C).9. Carefully select the lower breakpoint as this determines the maximum voltage applied to the load.5 mV slope with a -40 deg C breakpoint in a 48V system will result in 61 volts applied to the load in a low temperature condition. This determines the maximum and minimum voltage that will be applied to the battery and the load.).9.7 Argus solutions TCM This external temperature compensation module can be either relay rack or surface mounted. Breakpoint The selection of the breakpoint is critical.) and the larger remote sense input equipped RSM rectifiers (6 shelves max. Default to conservative 2.D C P O W E R S Y S T E M S H A N D B O O K To prevent excessively low voltage from undercharging the battery or discharging the battery.5 Sizing Temperature compensation slope Match the compensation slope to the recommendations of the battery manufacturer. 1. Match the breakpoints to the recommendations of the battery manufacture. 5.D C P O W E R S Y S T E M S H A N D B O O K TCM Internal This feature is available built into Argus non-sense line equipped rectifiers. including RSM 48/7. RSM 24/15 and RSM 48/10. SM System Controllers Control larger RSM rectifiers and pathfinder rectifiers through the communications link. ARGUS® TECHNOLOGIES 075-053-10 Rev D 48 . D C P O W E R S Y S T E M S H A N D B O O K TEMPERATURE* °C °F -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25*** 30 35 40 45 50 55 60 65 -40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149 BFV**=27.00V @25°C(77°F) 2.5mV 3.5mV (volts) (volts) 28.95 29.73 28.80 29.52 28.65 29.31 28.50 29.10 28.35 28.89 28.20 28.68 28.05 28.47 27.90 28.26 27.75 28.05 27.60 27.84 27.45 27.63 27.30 27.42 27.15 27.21 27 27 26.85 26.79 26.70 26.58 26.55 26.37 26.40 26.16 26.25 25.95 26.10 25.74 25.95 25.53 25.80 25.32 4.5mV (volts) 30.51 30.24 29.97 29.70 29.43 29.16 28.89 28.62 28.35 28.08 27.81 27.54 27.27 27 26.73 26.46 26.19 25.92 25.65 25.38 25.11 24.84 BFV**=27.25V @25°C(77°F) 2.5mV 3.5mV (volts) (volts) 29.20 29.98 29.05 29.77 28.90 29.56 28.75 29.35 28.60 29.14 28.45 28.93 28.30 28.72 28.15 28.51 28.00 28.30 28.60 28.09 27.70 27.88 27.55 27.67 27.40 27.46 27.25 27.25 27.10 27.04 26.95 26.83 26.80 26.62 26.65 26.41 26.50 26.20 26.35 25.99 26.20 25.78 26.05 25.57 4.5mV (volts) 30.76 30.49 30.22 29.95 29.68 29.41 29.14 28.87 28.60 28.33 28.06 27.79 27.52 27.25 26.98 26.71 26.44 26.17 25.90 25.63 25.36 25.09 BFV**=27.50V @25°C(77°F) 2.5mV 3.5mV (volts) (volts) 29.45 30.23 29.30 30.02 29.15 29.81 29.00 29.60 28.85 29.39 28.70 29.18 28.55 28.97 28.40 28.76 28.25 28.55 28.10 28.34 27.95 28.13 27.80 27.92 27.65 27.71 27.5 27.5 27.35 27.29 27.20 27.08 27.05 26.87 26.90 26.66 26.75 26.45 26.60 26.24 26.45 26.03 26.30 25.82 4.5mV (volts) 31.01 30.74 30.47 30.20 29.93 29.66 29.39 29.12 28.85 28.58 28.31 28.04 27.77 27.5 27.23 26.96 26.69 26.42 26.15 25.88 25.61 25.34 Table H 24 Volt Temperature Compensated Battery Float Voltage These tables are provided as a guideline only. If battery temperature falls between values on the above scale, estimate the voltage setting based on the closest numerical values. * posts. Refers to ambient temperature at the battery terminal ** BFV refers to “Battery Float Voltage” Check battery manufacturer's recommended settings. *** Refers to “Nominal Battery Temperature.” This is the optimum temperature for battery operation. No compensation occurs at this temperature (use as a reference point). ARGUS® TECHNOLOGIES 075-053-10 Rev D 49 D C P O W E R S Y S T E M S H A N D B O O K TEMPERATURE* °C °F 2.5mV (volts) 57.90 57.60 57.30 57.00 56.70 56.40 56.10 55.80 55.50 55.20 54.90 54.60 54.30 54 53.70 53.40 53.10 52.80 52.50 52.20 51.90 51.60 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25*** 30 35 40 45 50 55 60 65 -40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149 BFV**=54.00V @25°C(77°F) 3.5mV (volts) 59.46 59.04 58.62 58.20 57.78 57.36 56.94 56.52 56.10 55.68 55.26 54.84 54.42 54 53.58 53.16 52.74 52.32 51.90 51.48 51.06 50.64 4.5mV (volts) 61.02 60.48 59.94 59.40 58.86 58.32 57.78 57.24 56.70 56.16 55.62 55.08 54.54 54 53.46 52.92 52.38 51.84 51.30 50.76 50.22 49.68 2.5mV (volts) 58.40 58.10 57.80 57.50 57.20 56.90 56.60 56.30 56.00 55.70 55.40 55.10 54.80 54.5 54.20 53.90 53.60 53.30 53.00 52.70 52.40 52.10 BFV**=54.50V @25°C(77°F) 3.5mV (volts) 59.96 59.54 59.12 58.70 58.28 57.86 57.44 57.02 56.60 56.18 55.76 55.34 54.92 54.5 54.08 53.66 53.24 52.82 52.40 51.98 51.56 51.14 4.5mV (volts) 61.52 60.98 60.44 59.90 59.36 58.82 58.28 57.74 57.20 56.66 56.12 55.58 55.04 54.5 53.96 53.42 52.88 52.34 51.80 51.26 50.72 50.18 2.5mV (volts) 58.90 58.60 58.30 58.00 57.70 57.40 57.10 56.80 56.50 56.20 55.90 55.60 55.30 55 54.70 54.40 54.10 53.80 53.50 53.20 52.90 52.60 BFV**=55.00V @25°C(77°F) 3.5mV (volts) 60.46 60.04 59.62 59.20 58.78 58.36 57.94 57.52 57.10 56.68 56.26 55.84 55.42 55 54.58 54.16 53.74 53.32 52.90 52.48 52.06 51.64 4.5mV (volts) 62.02 61.48 60.94 60.40 59.86 59.32 58.78 58.24 57.70 57.16 56.62 56.08 55.54 55 54.46 53.92 53.38 52.84 52.30 51.76 51.22 50.68 Table I 48 Volt Temperature Compensated Battery Float Voltage These tables are provided as a guideline only. If battery temperature falls between values on the above scale, estimate the voltage setting based on the closest numerical values. * posts. Refers to ambient temperature at the battery terminal ** BFV refers to “Battery Float Voltage” Check battery manufacturer's recommended settings. *** Refers to “Nominal Battery Temperature.” This is the optimum temperature for battery operation. No compensation occurs at this temperature (use as a reference point). ARGUS® TECHNOLOGIES 075-053-10 Rev D 50 D C P O W E R S Y S T E M S H A N D B O O K 1.10 DC - DC Converter System 1.10.1 Description A DC-DC converter system takes a DC input voltage and converts it to the same or a different output voltage. The converter system is utilized for any of the following reasons: • • • • Provide different voltage levels; i.e. -48V to +24V conversion. Ground swapping; i.e. +24V to -24V. Galvanic or ground isolation; i.e. +24V to +24V, floating ground. Voltage regulation for equipment, with a tight input voltage operating window, operated from a battery system. 1.10.2 Connection The DC-DC converter system is connected in series between the main DC power system and the load. A converter system consists of single or multiple parallel DC-DC converters and may incorporate many of the features found in the main DC power system including distribution, common ground bus and supervisory. DC-DC Converters should have dedicated fuse/circuit breaker positions on the main DC power system for protection and isolation. If converters are located in the same relay rack as the main DC power system, direct connection to the busswork on the input is permissible. 1.10.3 Operation Since the converter system does not have a battery connected to its output adjustment of the output voltage is less critical and LVD’s, temp comp, etc. are not required. The output voltage of the converters is adjusted to match the requirements of the load and to ensure correct load sharing between parallel converters. ARGUS® TECHNOLOGIES 075-053-10 Rev D 51 Current limiting should be provided.10.DC converter systems can add substantial load to the main power system. If this redundancy is not built in. Supervisory and distribution may be incorporated into a modular converter system. Modular vs. Modular converters allow for easy replacement and expansion. 1. DC . preventing damage to the load. Argus converters accomplish this with output slope regulation it is adjustable on CS units to allow load sharing with other types of converters. Argus units are factory set at 105% of rated output. to provide protection in a overload condition.D C P O W E R S Y S T E M S H A N D B O O K 1.4 Sizing The converter system should be sized to adequately supply the load under all conditions. ARGUS® TECHNOLOGIES 075-053-10 Rev D 52 . High voltage shutdown to switch converter off in case of high output voltage condition. Always use fast acting fuses in converter system distribution circuits and do not use excessively high fuse ratings.5 Features and selection criteria Standardization of unit for ease of maintenance. CSM units utilize a fixed slope set at 1%. High efficiency Physical constraints in most new facilities demand compact designs. monolithic configuration. the converters may not be able to clear a fault and current limiting will take effect and the output of the converter system may be affected. There should be substantial converter redundancy built in to the converter system to account for fuse clearing and circuit breaker tripping. allowances should be made for this when sizing the main system. Balanced load sharing should be achieved between converters.10. Lightweight converters combined with space saving designs help reduce installation and shipping costs. reducing the installation costs of the converter. Each converter is easily removed for maintenance purposes. ARGUS® TECHNOLOGIES 075-053-10 Rev D 53 .three or four individual modules are housed in a hardwired cabinet. CSM series modular Modular construction .D C P O W E R S Y S T E M S H A N D B O O K Soft-start to gradually bring the converter on line from zero load to the load requirement. 12V. Specialized converters with 130 V /100VA output are available for powering FITL (fiber in the loop) applications. With current ratings from 5 Amps to 40 Amps.6 Argus solutions The converters are available in various input and output configurations including 24V and 48V input. Local indication plus remote contacts are required. The feeder breaker and feeder size requirements are decreased. 1. 24V and 48V output. CS series monolithic Traditional converter packaging . eliminating high inrush currents surges. Alarms provide indication of converter failure and should be of “fail safe” design.10.each individual converter is a stand-alone unit. cables should meet electrical code requirements and utilize quality compression lugs. Argus power systems include all these features and utilize tinplated copper buswork to eliminate oxidization.2 Connection Intersystem In a typical power system there should be provisions for easy termination of intersystem cables. Lock washers or “Belleville” washers should be used on electrical/mechanical connections to ensure integrity under different temperature conditions. Buswork should be copper. Battery Separate charge/discharge configuration .This method of connecting the battery was utilized in the past to reduce the rectifier ripple voltage at the load. ARGUS® TECHNOLOGIES 075-053-10 Rev D 54 . The vertical discharge riser bus is used to connect the distribution panels to the charge/discharge termination in a traditional power system.D C P O W E R S Y S T E M S H A N D B O O K 1.11 DC Power System Integration 1.11. The vented battery was used as a filter.11.1 Description The DC power system integrates and connects all the components mentioned in previous sections. The intersystem wiring and buswork determines the ultimate capacity of the power system. (high/low load). 1. All termination’s should have provisions for connection of standard 2 hole lugs (typically 3/8” hole. 1” spacing). With the advent of low ripple rectifiers this method of battery termination is generally not required. Rectifier output cables. 1.5 Argus solutions Traditional power systems • • • • Traditional power system packaging is in either open relay rack or box frame. Rectifier negative output cables are terminated to one bus (. battery cables and the load feed are connected directly to these bus’. Up to 10 000 amps. load feed is also connected to this bus.3 Sizing Power systems should be oversized by a factor of 20-25 %. battery terminal from this bus. 1.11. This is repeated for the positive side also.11.25. 1. This method has the added benefit of better load regulation and a slightly reduced voltage level seen at the load. To calculate the power system size multiple the maximum anticipated load by a factor of 1. A second cable is connected from the negative battery terminal back to the second bus (.2 .discharge bus) and the neg. One bus is provided for the negative connections and one for the positive connections. ARGUS® TECHNOLOGIES 075-053-10 Rev D 55 . Open relay rack or box bay. This over-sizing factor will ensure that the shunt is not overloaded and that adequate capacity is available in the buswork and cables to accommodate both the load and battery recharge current. Size restrictions. Choices of 19” and 23” rack widths.1.4 Features and selection criteria • • • Access requirements front only or front and rear.D C P O W E R S Y S T E M S H A N D B O O K • Two busses are provided for both negative and positive termination.charge bus) and a cable is run to the neg. Access is required from both the front and the rear. Common charge/discharge configuration .This is the current standard method of terminating the battery cables.11. • Ultra compact power systems RSM 48/10 and 24/18 These fully self contained power systems (except for battery). There would be obvious limitations for either of these methods. After initial installation the power system may be relocated closer to the wall. Packages are 17” wide.5 and 24/15 These fully self contained power systems (except for battery). may be configured in various packages combining up to five rectifiers modules. Argus front access power systems require some rear access upon initial installation. Packages are 17” wide. distribution. 12 “ deep and of various heights from 3. supervisory. supervisory. Up to 1200 amps. temperature compensation and low voltage disconnect. 12 “ deep and 5. but they do provide solutions for specific applications and ensure flexibility of Argus equipment. All maintenance and circuit termination may be performed from the front.D C P O W E R S Y S T E M S H A N D B O O K Front access power system • With less space available in many of the new communications facilities front access power systems have become popular. • • Miscellaneous power systems • Variations on the traditional packaging techniques include mounting the equipment in portable cabinets on castors or utilizing wall mount brackets. may be configured in various packages combining two or three rectifiers modules.5” to 7”.25” high. ARGUS® TECHNOLOGIES 075-053-10 Rev D 56 . temperature compensation and low voltage disconnect. RSM 48/7. with allowances for ventilation of course. distribution. Extra extended backup battery cabinets may be added.D C P O W E R S Y S T E M S H A N D B O O K US Series Combine battery. ARGUS® TECHNOLOGIES 075-053-10 Rev D 57 . 2 hr. with internal battery. rectifier and supervisory in a single package to provide either 5 Amps at 48V or 8 Amps at 24V backup time is approx. 1 Description The inverter or Uninterruptable Power System (UPS) is utilized to supply AC voltage to loads such as computers in the Telecom environment. Off-line Inverter . Has a standby AC line available (optional). AC output. AC output. heavy -internal battery Table J Inverter & UPS comparison ARGUS® TECHNOLOGIES 075-053-10 Rev D 58 . Connected directly to DC main power system. Line Interactive UPS .Ferroresonant transformer with small battery charger. inverter and intelligent control. 2. Traditional concept. On-line Inverter .D C P O W E R S Y S T E M S H A N D B O O K 1.12. Battery charger charges the batteries only Type 1 Advantages -simple -reliable -utilize main DC battery -may be paralleled for redundancy -compact -reliable -efficient -utilize main DC power system battery -rugged -good energy storage -compact -easy to install -efficient Disadvantages -inefficient -heavy DC system loading and inrush 2 3 4 -inefficient -large.12 Inverters/UPS 1.AC input. battery and inverter.DC input. 4. battery. 3. Normal operation is through a Ferro circuit. Inverter is switched online when required by the control. The DC standby line is connected to the DC power system. Ferro provides filtering and some energy storage. There are a various options for providing uninterruptable AC for your loads including: 1. Double conversion UPS . These systems are often connected to the DC power system. Has a standby DC line connection available.Dedicated rectifier. 2 Connection On-line inverter . Inverters often supply computers that incorporate switch mode power supplies and other non-linear loads. Off-line inverter .The inverter is connected in series with the DC power system and the connected loads. > 2. If loads with high crest factors (i.4 Sizing Inverters/UPS should be sized such that the continuous load (VA) does not exceed 75% of the inverter rating (VA). Neutral current should also be monitored after UPS installation to ensure it is within the limits of the conductor. 1.D C P O W E R S Y S T E M S H A N D B O O K Both inverter system designs (type1 &2) will be discussed in this section since they connect to and affect the operation and design of a DC power system. the UPS rating may have to be de-rated. Off-line inverter . 1.The inverter is connected in series with the AC source and the connected loads.In normal operation the inverter draws current from the DC power system and coverts this to AC to power the connected load. Upon loss of the AC source the load is transferred to the inverter. A connection is made to the DC power system for redundancy.12. A connection is made to a standby AC source for redundancy.e.In normal operation the connected load is powered from the AC source through the inverter.12. If the inverter fails or the DC supply is interrupted there inverter automatically transfers to a connected AC stand-by source.3 Operation On-line inverter . 1. ARGUS® TECHNOLOGIES 075-053-10 Rev D 59 . There may be a ferroresonant circuit to provide energy storage while the load is transferred to the inverter.12.5) are connected. Unbalanced loads and low power factor often generate substantial neutral currents. See the manufacturer for further information. It is possible for these currents to overload the neutral conductor since there is no protection for the neutral conductor. These batteries never achieve proper ventilation due to the oftencramped compartments that they occupy.12.12. 1. If the off-line inverter is utilized only the DC power system battery need be oversized since the inverter is normally operating from the AC source and will only draw current from the DC power system when there is a failure of the AC source. 1. Many UPS systems utilize high DC voltage battery systems.6 Argus solutions We will provide assistance in helping you chooses the right AC solution and integrating it into the DC power system. wellmaintained DC main system battery. Powering your AC loads from an inverter connected to the high quality. These batteries rarely see proper maintenance and tend to be forgotten. ARGUS® TECHNOLOGIES 075-053-10 Rev D 60 .5 Features and selection criteria Many UPS systems combine the battery in the UPS.D C P O W E R S Y S T E M S H A N D B O O K If the on-line inverter is utilized both the DC power system battery and the rectifiers will have to be oversized to supply the additional load imposed by the inverter. reduces many of these problems. breaker/ fuse curve coordination may be required. Inverters may also draw substantial inrush current on start-up. Each of these many small cells is the potential weak link in the chain. D C P O W E R S Y S T E M S H A N D B O O K This page intentionally left blank. ARGUS® TECHNOLOGIES 075-053-10 Rev D 61 . ______ Voltage______ current_______________ current_______________ current_______________ Watts______ P.1 Step 1 System load analysis To determine your DC power system requirements evaluate your loads and the backup period required.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Power System Sizing and Ordering 2. (C) Battery details: Main system Secondary system 1 Secondary system 2 AC Secondary system Redundancy Battery discharge time Battery recharge time Battery end Voltage______ Voltage______ Voltage______ Voltage______ N+______ hrs. Review all system components and determine: (A) Loads that require voltage conversion. computers that require backup. Don’t forget AC loads i.______ ARGUS® TECHNOLOGIES 075-053-10 Rev D 62 .______ hrs. Determine the individual load currents for the different load voltages required.1 Calculations 2.e.F. The voltage with the highest load is generally chosen as the main system voltage. (B) Loads that require battery backup.1. 1. Add redundant rectifiers as required. 2. 2. Use formula (i). • • Determine the quantity and type of rectifiers required to meet the requirements of the total rectifier capacity. Total rectifier capacity includes capacity to supply the load and recharge the discharged battery in the specified recharge interval.1. Refer to inverter sizing section for extra details.1.D C P O W E R S Y S T E M S H A N D B O O K Warning : Check and record the polarity requirement of your connected loads. 2.5 Step 5 Total rectifier capacity Determine total rectifier capacity.1.4 Step 4 Total system load Determine the total system load using formula (iii). Refer to converter sizing section for extra details.3 Step 3 Inverters Determine the size and type of inverter to meet the secondary AC voltage requirements (if applicable). 2. “Which polarity is connected to the common ground”? This is vital information to ensure functionality of the DC system and load. Use formula (iv). ARGUS® TECHNOLOGIES 075-053-10 Rev D 63 . Determine the total load that the converters will have on the main DC system. • • Determine the load that the inverter will have on the main DC system.2 Step 2 Converters Determine the quantity and type of converters to meet each of the secondary DC voltage requirements (if applicable). Use formula (ii). • • • Add redundant converters as required. • • • • Discharge hours Total system load End voltage Temperature performance Refer to the battery sizing section for more details. ARGUS® TECHNOLOGIES 075-053-10 Rev D 64 .1.7 Step 7 Power system Select a power system capacity that is at least 1.2-1. • • • Include provisions for growth (growth factor) if required. 2. Size the LVD as per the LVD sizing section.6 Step 6 Battery Using battery manufactures advertised literature select a battery that will meet the list of criteria established.1.D C P O W E R S Y S T E M S H A N D B O O K 2. Size load and battery fuses and circuit breakers as per fuse/CB sizing section. This will ensure that you don’t overload the ammeter shunt and also have sufficient capacity in the intersystem buswork to charge the batteries.25 times larger than the maximum anticipated total system load . 2 for lead acid batteries.D C P O W E R S Y S T E M S H A N D B O O K 2.F. hrs) x total system load) Rechg.2.2 Other useful power formula’s Formula (v) Rectifier and converter efficiency =P(out) = V(out) x I(out) or V(out) x I(out) P(in) P(in) watts V(in) x I (in) x P.x Dischg.1 Power system design formula’s Formula (i) Converter load (amps) = secondary load (amps) x (output voltage/input voltage) converter efficiency Formula (ii) Inverter load (amps) = load (watts) inverter efficiency x battery float voltage Formula (iii) Total system load (amps) = main load (amps) + converter load (amps) + inverter load (amps) Formula (iv) Total rectifier capacity (amps) = Total system load (1)+(R.1 -1.2.F. Formula (vi) Apparent power (VA) = Power (watts) P. hrs If an off-line inverter is connected to the DC power system its load must be subtracted from the total system load (1) when calculating total rectifier capacity. Typically 1.F. ARGUS® TECHNOLOGIES 075-053-10 Rev D 65 .(true) P. is not required in converter efficiency calculations. 2.F (2).2 Formulas 2. Recharge factor is the recharge efficiency factor for the battery string. 414 (sine wave) Formula (viii) Temperature compensated battery voltage calculation = (25 .D C P O W E R S Y S T E M S H A N D B O O K Formula (vii) Crest factor calculation = Peak input current R.)(#cells)(slope) + nominal bat. temp.C All calculations use deg.75V/cell ARGUS® TECHNOLOGIES 075-053-10 Rev D 66 .S.F. input current ideal = 1.3 Power System Design Example Main system Secondary system 1 AC Secondary system Redundancy Battery discharge time Battery recharge time Battery end Voltage-48V Voltage+24V Voltage120V N+ hrs hrs 1 8 24 current 125A current 30A 240Watts P.bat. float v @ 25 deg.75 Voltage 1. 2.M. C as base units not deg. F. • • ARGUS® TECHNOLOGIES 075-053-10 Rev D 67 . i. rain protection. Custom engineering drawings are available from Argus to assist in the installation of system components. etc. humidity.e. dust. i.. Mounting offsets. Access for maintenance. dirt. Environmental constraints including temperature.e. Physical size of equipment including depth.4 Ordering Information for Power Systems and Loose Items When individual components are ordered special consideration should be given to the following items: • • • • Relay rack width and mounting hole spacing. don’t order a fan-cooled unit to be used in an extremely dusty environment. flush or specific depth. future distribution connection and most importantly airflow. Each rectifier or converter generates heat and the minimum ventilation requirements must be met for reliable operation.D C P O W E R S Y S T E M S H A N D B O O K 2. ARGUS® TECHNOLOGIES 075-053-10 Rev D 68 .D C P O W E R S Y S T E M S H A N D B O O K This page intentionally left blank. i.1 Site Layout and Loading 3.1 Description The floor loading and the physical space required for the power system and the battery is often overlooked. should not be installed in an airtight enclosure.e. failed battery. Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the rectifiers utilized in the power system and to allow easy access to the power system components. The temperature should be regulated at approx.1.2 Floor plan layout The power system must be mounted in a clean and dry environment.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Site Engineering for DC Power 3. The battery should be located in a temperature-controlled environment also. Hydrogen gas may be vented in a fault condition. Provide adequate ventilation for the battery. 3. VRLA batteries. 25 °C (77 °F). Significantly lower temperatures reduce performance and higher temperatures decrease life expectancy. though not requiring the special ventilation requirements of a flooded battery. With the weight of a typical common battery exceeding several tons special arrangements may have to be made to deal with this extra weight.1. ARGUS® TECHNOLOGIES 075-053-10 Rev D 69 . 3 Cable Rack layout The cable racking should be carefully laid out to minimize cable run lengths and voltage drop to keep installation cost to a minimum.1.D C P O W E R S Y S T E M S H A N D B O O K For large systems with secondary distributed power consider: • • • Cable flow and congestion. Check the placement of the floor trusses so that the weight is evenly distributed over as many floor trusses as possible. Minimizing cable lengths (cost).4 Floor loading Raised computer floor Power plant and battery may have to be suspended above the computer floor mounted on top of threaded rods extending through the floor tile. Cable rack routing. “I” beams attached to the building pillars may have to be installed. 3. Wood floor • • • • Steel plates “I” beams under the floor and steel plates Concrete pads. ARGUS® TECHNOLOGIES 075-053-10 Rev D 70 .1. Steel plates may have to be installed on top of the concrete to reduce the point loading problems common with the base configuration with most VRLA batteries. 3. Concrete floor The thickness of the concrete should be evaluated to ensure that its weight carrying capabilities meet the requirements. An arrangement of “I” beams may have to be bolted to the concrete floor and extend above the computer floor to provide a strong platform. 1 Description The grounding network. The connection sequence at the MGB is important. Metallic objects such as towers or lightning arrestor’s are connected into this ground grid. The first stage of the grounding system is the ground grid that usually consists of multiple driven ground rods interconnected in a ring configuration encircling the building to be protected.D C P O W E R S Y S T E M S H A N D B O O K 3.2 Connection The North American standard for the grounding network of a communications installation dictates that a single point ground (SPG) philosophy is used See Figure 16. metallic ground bonds.) are separated from protected equipment (power system battery return reference) by the surge arrestor (connection to the ground grid. lightning (high frequency). It also provides a common ground reference point for all equipment. is an integral part of the power system and greatly affects the performance of the DC power system and the connected loads. The third stage of the grounding network is the battery return bus (BRB) on the power system. This is where all the load ground connections are made. frame ground bonds. transients and surges. ARGUS® TECHNOLOGIES 075-053-10 Rev D 71 . 2.5 Rack loading For installations where multiple large conductors are installed consideration should be given to the weight that these cables will be placing on the cable rack and the structure supporting the cables.1. 3. etc. For example 750 MCM cable weighs approx. The second stage of the grounding network is the master ground bus (MGB). Typical communication systems also use this as the reference point for logic ground reference.2. 3. per foot.2 Grounding Network 3. The site grounding system provides a low impedance path to ground for noise.2. Surge producers (AC ground bond.8 lbs. though part of the site installation. other factors including length of cable and special grounding requirements of the load should also be factored in. excluding the battery protection fuse or circuit breaker. 3.3 Sizing The cable from the BRB to the MGB should be sized to provide sufficient ampacity to clear the largest fuse or breaker on the power system. The intention is to provide the lowest impedance path to ground for high frequency (lightning) transients see Table K. This is the minimum requirement. System Ampacity < 30A 30-100A 100-400A 400-800A > 800A Typical ground reference conductor size #10 #6-2 0000 350 MCM 750 MCM Table K Typical Ground Reference Conductor Selection The connection between power system frame and the MGB should be #6 AWG (16 mm) minimum.D C P O W E R S Y S T E M S H A N D B O O K Frame grounding is also very important for both safety and also to ensure proper operation of the rectifier surge divertor metal oxide varistors (MOV). ARGUS® TECHNOLOGIES 075-053-10 Rev D 72 .2. Industry standard is a cable connection from each relay rack to the MGB. For adequate facility lightning protection one to five ohms is required. • SPD Frame Ground #6 AWG (16mm) -48VPower System L1 L1 L2 L2 N N AC Distribution Cabinet Load (+) (–) BRB (+) (–) G G MGB + Denotes Isolation Grounding Rod Grounding Network Figure 16 Typical Site Grounding and Surge Protection 3.5 Typical Requirements for Grounding Network • • • As specified by the electrical utilities.4 Features and selection criteria • Insulated cable should be used for grounding equipped with two hole crimp type lugs and should not have any tight bends or kinks.2. ARGUS® TECHNOLOGIES 075-053-10 Rev D 73 DCPSH05A . neutral and safety ground 10 ohm’s is required. The use of welding cable should be avoided.D C P O W E R S Y S T E M S H A N D B O O K 3.2. For protecting sensitive telecom facilities less than one ohm is desirable. Stage two .1 Description To protect both rectifiers and connected loads from surges entering the site via the AC source surge protection devices are commonly installed at telecommunications sites see figure 17.This optional level of protection can be located at the DC power system rack.This first stage of the surge protection for any site is located at the AC service entrance. This stage is critical in high lightning activity areas to prevent damage to the rectifiers. Stage three . Short lead lengths are critical to keep let through voltage low. 3. ARGUS® TECHNOLOGIES 075-053-10 Rev D 74 .3. Stage two .3.This optional level of protection provides increased protection over a level one and three combination. usually connected either to the AC distribution service panel or directly to the main building disconnect switch.3 Surge Protection Devices (SPD’s) 3.This stage is built into the rectifiers.2 Connection Stage one . Stage one .This stage provides basic protection for each rectifier.D C P O W E R S Y S T E M S H A N D B O O K 3. It is also useful in locations where there are large surges and transients generated within the site. Stage three .This first stage of surge protection provides increased protection for the power system rectifiers and other equipment in locations where lightning is prevalent. This will provide increased levels of protection for the rectifiers. 3.Minimum size should meet the requirement of the ANSI/IEE C62. metal oxide varistor (MOV) or a combination of both. They are connected in parallel with the AC source either line to line or line to ground.41 category B3 standard.Minimum size should meet the requirements of the ANSI/IEEE C62. effectively clamping the surge voltage. ARGUS® TECHNOLOGIES 075-053-10 Rev D 75 .D C P O W E R S Y S T E M S H A N D B O O K AC Stage 1 Stage 2 Stage 3 DC AC Service Entrance Power Rack Rectifier DCPSH08A Figure 17 Staging of Surge Protection Components 3. Stage three .41 category B3/C1 standard. At voltages above the operating voltage they operate in the low impedance mode. The most common technology used is a either silicon avalanche diode (SAD).3 Operation Various types of protection devices are available. Higher capacities should be used in areas where frequent violent lightning strikes are common. 3. These devices function as non-linear resistors. Surges cause these devices to conduct.3.4 Sizing Stage one and two . • • • • At voltages below their operating voltage they operate in the high impedance mode. Local and remote failure indication. The cable size must also be carefully selected to ensure minimum voltage drop across its length when fully loaded. Use devices that have no main fuse or circuit breaker protection to keep let through voltage as low as possible (preferred installation). The information below can be used to calculate the cable size using typical voltage drop recommendations for Telecom installations. • • 3. ARGUS® TECHNOLOGIES 075-053-10 Rev D 76 . Low pass filtering capability.D C P O W E R S Y S T E M S H A N D B O O K 3. MOV based SPD’s offer reasonable cost and high capacity but are slower to respond and have a higher let through voltage (up to 1200 volts for a 240 volt rated SPD). MOV’s degrade with each surge absorbed by the MOV. Stage two panel available.3. • • • • Combination SPD’s offering both SAD and MOV protection.5 Features and selection criteria SAD based SPD’s offer low let through voltage and fast response time but have limited capacity and are more expensive.6 Argus solutions • • Technical assistance in choosing the protection device. Refer to Table L for more information.3. Easy to replace modules. 3. SAD’s also do not degrade while in service. ampacity and cable type. Consult other users in your area to determine what units have the best track record. Keeping the voltage drop to a minimum insures maximum back-up time and best performance when the system is operating on battery.4 Wiring The cable chosen for use in power plant applications not only has to meet the requirements of the electrical code for ventilated cable tray installations. 1 constant factor for commercial (TW type) copper wire 3.1 AC Cabling Individual circuit breakers and circuits are recommended for each rectifier. 3. 3. ARGUS® TECHNOLOGIES 075-053-10 Rev D 77 .D C P O W E R S Y S T E M S H A N D B O O K Calculating Wire Size Requirements CMA= A x LF x K AVD Definitions CMA = Cross section of wire in circular MIL area A = Ultimate drain in amps LF = Conductor loop feet AVD = Allowable voltage drop K = 11.5 V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker.4.4. 3.. from the power system supervisory panel to the site alarm monitor. Typically distribution cables are sized to provide a .3 Battery Battery cables should be sized for a .4. 3. Use conduit or liquid type cable matching the cable size to the ampacity of the circuit.2 Rectifier Sensing Recommended cable for sense circuit if used is 16 Ga. The cables should also meet ampacity requirements of the protection breaker in the circuit.4.5 Distribution Refer to guidelines supplied with the load equipment.4 Alarms Recommended cable size is 16-24 Ga.25 V loop drop from battery to the distribution panel at full load including anticipated growth.4. 240 41.000 900. Cables must also meet the ampacity requirements of the protection fuse or circuit breaker.620 2.000 800. Mils.000 1.D C P O W E R S Y S T E M S H A N D B O O K 3.380 16.360 83.75 1.000 750.750.000 1. Current Rating (for ventilated cable rack installation) Amps 5 10 15 20 30 45 65 85 115 130 150 175 200 230 285 310 335 380 420 460 475 490 18 16 14 12 10 8 6 4 2 1 0 00 000 0000 250 MCM 300 MCM 350 MCM 400 MCM 500 MCM 600 MCM 700 MCM 750 MCM 800 MCM 900 MCM 1000 MCM 1.000 600.740 66.510 26.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 400 500 1.000 500.000 Table L Wire Gauge Table and Ampacity Ratings ARGUS® TECHNOLOGIES 075-053-10 Rev D 78 .750 MCM 2.250.100 167.000 1.500 MCM 1.6 BDFB (Battery Distribution Fuse Board) or BDCBB (Battery Distribution Circuit Breaker Board) Circuits feeding BDFB’s should be sized for .000.500.600 133.000 300. Use lock washers on all DC connections to the power system AWG mm Area Cir.000 400.000 2.530 10.800 211.5 2.250 MCM 1.4.000 350.25 V loop voltage drop at maximum anticipated load (80 % of the BDFB rating).000 700.110 6.580 4.000.690 105.600 250.000 MCM .000 1. D C P O W E R S Y S T E M S H A N D B O O K Load Secondary Distribution 0.25 Volts 1.25 Volts 0.0 Volts DCPSH06A 075-053-10 Rev D 79 .50 Volts Main Power System Negative (-) Figure 18 Typical Power System Voltage Drop Diagram @-48Vdc ARGUS® TECHNOLOGIES Positive (+) Battery 0. ARGUS® TECHNOLOGIES 075-053-10 Rev D 80 .D C P O W E R S Y S T E M S H A N D B O O K 3.5 Engineering Drawings Complete engineering drawings should be completed to provide the necessary detail for the installer to install the power system. Avoid short ARGUS® TECHNOLOGIES 075-053-10 Rev D 81 . 4. rings. necklaces.1 Safety Precautions Hazardous voltages are present at the input of the rectifier systems. eyeglasses. Safety glasses with side shields must be worn at all times. Cover the rubber spicing tape with two half lapped layers of vinyl tape. etc.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Initial Installation This is a generic installation guide intended to be applicable for various types of Argus power systems. watches. Metallic tools must be properly insulated. Extra care is required when working with flooded battery systems. For battery installation refer to the manufacturers guidelines for more specific information. The DC output from the rectifiers and the battery system though not dangerous in voltage has a high short circuit current capacity that may cause severe burns and electrical arcing. Protective clothing. Standard hand tools may be insulated using the following method: Apply one layer of half lapped rubber splicing tape.e. including front access and traditional power systems. Before working with any live battery or power system the following precautions should be followed: • • • Removal of all metallic jewelry i. eye protection and standard battery safety kits (as detailed on the next page) should be provided for installation personnel to deal with accidental spillage of acid. Batteries vent hydrogen gas when on charge which creates an explosion hazard.e. Follow battery manufactures safety recommendations when working around battery systems. Batteries are hazardous to the environment and should be disposed of safely at a recycling facility. CSA. Consult the battery manufacturer for recommended local authorized recyclers. which could cause explosion of any gases vented from the batteries.D C P O W E R S Y S T E M S H A N D B O O K circuits and arcing. CEC. ARGUS® TECHNOLOGIES 075-053-10 Rev D 82 . Installer should follow all applicable local rules and regulations for electrical and battery installations. i. UL. Warning : Do not smoke or present an open flame when batteries (especially vented batteries) are on charge. equipped with 1/8” diameter banana plug test leads (SD equipped systems only) Cable cutters Torque wrench 0-150 in/lbs. etc. 3’ x 3’. to match lugs used in installation 4 1/2 digit digital voltmeter equipped with test leads Load bank of sufficient capacity to load largest rectifier into current limit 0-60 V test supply 0.D C P O W E R S Y S T E M S H A N D B O O K 4.5 amp capacity.) Various insulated hand tools.2 Tools List • • • • • • Electric drill with hammer action 1/2” capacity Battery lifting apparatus (as required) Various crimpers and dies. Battery safety spill kit (required for wet cells only). (for battery post connections and intercell connectors) 0-100 ft/lbs (for power system connections) Laptop computer with Argus Insight software e/w DB9F to DB9-F null modem cable (SM02 equipped systems only) Insulating canvas as required (2’ x 2’. including: Protective clothing Face shields Gloves Baking soda Eye wash equipment • • • • • • • • • • • ARGUS® TECHNOLOGIES 075-053-10 Rev D 83 . 1’ x 1’. including: Combination wrenches Ratchet and socket set Fine tipped slot screwdriver “tweaker” Various screwdrivers Electricians knife. etc. Prior to unpacking the batteries. power system or components. Unpack the equipment and inspect the exterior for damage. Continue the inspection for any internal damage.D C P O W E R S Y S T E M S H A N D B O O K 4. Packaging assemblies and methods are tested to National Safe Transit Association standards. Power systems are also wrapped with a plastic sheet that is impregnated with CORTEX a corrosion inhibitor. In the unlikely event of internal damage please inform the carrier and contact Argus Technologies for advice on the impact of any damage. ARGUS® TECHNOLOGIES 075-053-10 Rev D 84 . note any damage to the shipping container. Batteries are shipped on individual pallets and are packaged as per the manufacturer's guidelines.3 Inspection All Argus products are shipped in rugged. Power systems are custom packaged in heavy-duty plywood crates with an equipment inspection window. double walled boxes and suspended via solid polyurethane foam inserts to minimize shock that may occur during transportation. If any damage is observed contact the carrier immediately. Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the rectifiers utilized in the power system and to allow easy access to the power system components. heavy duty screw type lags 5/8” X 2 1/2” and appropriate flat washers. Front access systems that are to be positioned close to a wall should be installed at least 12 inches away from the wall to meet seismic requirements. Secure the power system to the floor utilizing either heavy duty concrete anchors 1/2” X 2 1/2” or for wooden floors. It is recommended that the Relay Rack be secured to the overhead cable tray utilizing the brackets mounted on either side of the top of the relay rack. Mechanical details necessary for overhead support are not provided by Argus. ARGUS® TECHNOLOGIES 075-053-10 Rev D 85 .D C P O W E R S Y S T E M S H A N D B O O K 4.4 Power System Assembly/Mounting The power system must be mounted in a clean and dry environment. with a minimum of 1/2” between cells or mono-blocs if possible. though not requiring the special ventilation requirements of a flooded battery. One cell will be designated as the pilot cell. burnish terminal posts with a non-metallic brush. The temperature should be regulated at approx. VRLA batteries.5 Battery Installation 4. After assembly.5.e. Provide adequate ventilation for the battery. clean cells as per the battery manufacturer's recommendations. Hydrogen gas may be vented in a fault condition (i. cells should be numbered and “as received” readings taken. ARGUS® TECHNOLOGIES 075-053-10 Rev D 86 . If lead plated intercell connectors are used they should also be burnished and no-oxide “A” applied to the contact surfaces. Install all intercell connectors.1 Preparation/Mounting The battery should be located in a temperature-controlled environment.5. including specific gravity. cell voltage and temperature. this is usually the cell with either the lowest specific gravity or voltage.D C P O W E R S Y S T E M S H A N D B O O K 4. polishing pad or 3M type scotch pad. should not be installed in an airtight enclosure.2 Installation of Battery in Argus Power System Locate batteries on shelf or in cabinet provided. Remove any no-oxide “A” grease from battery terminals. Then wipe the cells with clean water. Significantly lower temperatures reduce performance and higher temperatures decrease life expectancy. 25 °C (77 °F). Before assembly. 4. Ensure that the battery output cables will reach the (+) and (-) termination cells of the series string and that the batteries are orientated correctly for easy installation of the inter-cell connectors. apply a light coating of no-oxide “A” anti-corrosion grease to the terminal posts. failed battery). Refer to manufactures literature for guidelines (refer to Table M) . First neutralize any acid with a baking soda and water solution. 5. ARGUS® TECHNOLOGIES 075-053-10 Rev D 87 . cell voltage and temperature. cells should be numbered and “as received” readings taken. including specific gravity. polishing pad or 3M type scotch pad. After assembly. Install all intercell and inter-tier connectors. with a minimum of 1/2” between cells if possible. this is usually the cell with either the lowest specific gravity or voltage. Remove any no-oxide “A” grease from battery terminals.D C P O W E R S Y S T E M S H A N D B O O K 4. apply a light coating of no-oxide “A” to the terminal posts. One cell will be designated as the pilot cell. Intercell connector contact surfaces should also be burnished and no-oxide “A” applied.3 Installation of External Battery Assemble battery rack (if required) and the cells or mono-blocks as per the installation instructions supplied with the batteries. Refer to manufacturer's literature for guidelines (see Table M). burnish terminal posts with a non-metallic brush. _________________________________________________ Cell # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Serial # Voltage Specific Gravity Ohms Mhos Observations Cell Readings Remarks and Recommendation ____________________________________________________________________ ____________________________________________________________________ _____________________________________ Readings taken by ____________________________________________________________________ ____________________________________________________________________ ___________________________________ ARGUS® TECHNOLOGIES 075-053-10 Rev D 88 . of cell ____________Type ___________ Date New_________ Date installed___________________________________________ Float Voltage __________________________________________ Ambient Temp.D C P O W E R S Y S T E M S H A N D B O O K TABLE M Typical VRLA Battery Maintenance Report Company_______________________________________________ Date:__________________________________________________ Address________________________________________________ Battery Location and/or Number________________________________________________ No. care should be taken to balance the load across the phases. 4.2 Rectifier Sensing There are various methods of providing rectifier output voltage sensing.D C P O W E R S Y S T E M S H A N D B O O K 4. Final connection to battery live should not be made. insulate and leave unconnected. SM equipped systems: • With a SM system the rectifier will regulate its voltage to the charge voltage displayed on the SM02. before proceeding. If connection is to a 3-phase AC service. With the modular rectifiers it is recommended to pre-cable all rectifier positions to allow for easy addition of future rectifiers.) Cable and connect leads from sense termination on the supervisory panel to the battery termination details. • If the battery temperature compensation feature is ordered in addition to remote sensing. follow the connection information detailed in the rectifier manual. if possible. with no temperature compensation.6 Cabling 4. Cable and connect from the AC distribution panel to each rectifier. Remote sensing referenced to battery. the rectifier sense leads from the batteries will be terminated at the temperature compensation unit. ARGUS® TECHNOLOGIES 075-053-10 Rev D 89 .6. No connections required.1 AC Cabling Shut off power to the AC distribution panel. SD equipped system: • • Built in internal sensing. (Note: Power system supervisory panel should be equipped with the rectifier remote sensing option.6. loop closure. transients. loop open. 4.4 Alarms All applicable alarms should be connected to the local alarmsending unit from the power system. Some supervisory panels require jumpers to be moved to configure the alarm contacts as form “A” or “B”.e. Cables terminating directly on battery posts or connection details should be secured so that there is no stress on the battery posts. Final connection to battery live should not be made.D C P O W E R S Y S T E M S H A N D B O O K • To regulate at the battery the charge input connection to the SM02 should be removed and the charge input connection should be directly to the battery. Terminating points should be burnished and no-oxide “A” grease applied.25 V drop from battery to the distribution panel at full load including anticipated growth. battery sending. etc.6.“B” or “C” wired for ground sending. Insulate and leave disconnected .6.5 Grounding The isolated power system battery return bus (BRB) should be connected to the building master ground bus (MGB) or floor ground bus (FGB) in a larger building. Lead plated lugs and lead plated or stainless steel hardware should be used on all terminations with vented batteries to reduce corrosion. Cable and connect cables from power system to battery termination details. form “A”. noise. This acts as a system reference and as a low impedance path to ground for surges. i. etc.6. The type of alarm input required by the alarm sending unit determines how the alarm contacts are configured and wired. 4. 4. ARGUS® TECHNOLOGIES 075-053-10 Rev D 90 . The cables should also meet ampacity requirements. The deluxe supervisory panels provide a central point for all external alarm lead connections.3 Battery Battery cables should be sized for a . The more basic panels provide for some alarm terminations such as low/high voltage but alarms such as rectifier or converter fail may have to be connected directly to the rectifier or converter. 6. ARGUS® TECHNOLOGIES 075-053-10 Rev D 91 .D C P O W E R S Y S T E M S H A N D B O O K The MGB or FGB should have a direct low impedance path to the building grounding system.e. Cable should be #6 AWG (16mm). the water main.5 V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker. This is done for personnel safety and to meet many telcogrounding requirements. 4. Typically distribution cables are sized to provide a . The insulated cable should be equipped with two-hole crimp type lugs and should not have any tight bends or kinks. excluding the battery protection fuse or circuit breaker.6 Distribution Refer to guidelines supplied with the load equipment. The power system frame must also be connected to the MGB or FGB. i. this is the minimum requirement. The cable from the power system to the MGB or FGB should be sized to provide sufficient ampacity to clear the largest fuse or breaker on the power system. Other factors including length of cable and special grounding requirements of the load should also be factored in. 2. beginning with the rectifiers. converters. 5. Install rectifiers. 6. battery and distribution are in the off position. battery and distribution are in the off position. control fuses. Remove all fuses including distribution. inverters.7.1 SD Based Power Systems 1. 2.7. Double check polarity and make the final battery lead connection at the battery string. converter input and inverter input. rectifier sense and supervisory control panel fuses. 7. battery. converters.2 SM Based Power Systems 1.D C P O W E R S Y S T E M S H A N D B O O K 4. Ensure all input and output circuit breakers including rectifiers. 4. inverters. Remove all fuses including distribution. Follow the procedures outlined in the manuals supplied with the equipment. Turn on all power system components one at a time. 4. Check polarity at battery fuse/breaker before closing battery circuit breaker. Remove all modular rectifiers and converters. rectifier sense and supervisory control panel fuses. battery. 3. supervisory input. etc. ARGUS® TECHNOLOGIES 075-053-10 Rev D 92 . converters. Remove all modular rectifiers and converters. Check polarity at rectifier output termination. Verify AC levels at rectifiers if applicable. Install battery fuse or close breaker.7 Power Up Procedure 4. Apply AC feed to rectifiers. Ensure all input and output circuit breakers including rectifiers. Verify AC levels at rectifiers if applicable. Turn on all power system components one at a time.D C P O W E R S Y S T E M S H A N D B O O K 3. Check polarity at battery fuse/breaker before closing battery circuit breaker. Check polarity at rectifier output termination. control fuses etc. Double check polarity and make the final battery lead connection at the battery string. 6. Check and adjust as necessary all the system and rectifier operating parameters. 11. 8. converters. Install battery fuse or close breaker. Perform an inventory update. 4. beginning with the rectifiers. Check the listing of rectifier serial numbers in the SM to ensure that the SM is communicating correctly with all the rectifiers. supervisory input. ARGUS® TECHNOLOGIES 075-053-10 Rev D 93 . 7. converter input and inverter input. Apply AC feed to rectifiers. Install rectifiers. 5. Follow the procedures outlined in the manuals supplied with the equipment. Download the rectifier settings to the rectifiers using the group download and save settings command in the rectifier menu. 10. Verify operation of the low voltage disconnects and alarm relays. 9. Save the settings in the SM by exiting out of the menu and pressing F1. charge current and temperature. Follow guidelines supplied with the battery and record initial charge readings. cell voltage. After the equalization period battery voltage should be reduced to the recommended float level.8 Battery Initial Charge and Discharge Test After installation of batteries it is usually necessary to “initial charge” the batteries to ensure proper operation and to eliminate plate sulfation. check with the manufacturer. Some VRLA batteries do not require initial charging if placed on charge within 3-6 months of manufacture.e.D C P O W E R S Y S T E M S H A N D B O O K 4. i. Check for overheating connections. Battery warranty may be void if batteries are not initial charged following the manufacture's guidelines and proper records are kept. ARGUS® TECHNOLOGIES 075-053-10 Rev D 94 . specific gravity. Cell voltages should be monitored during this process. Record cell voltages every 5 minutes. Once the batteries have been initial charged it is suggested to perform a short duration-high rate discharge test on the batteries to verify the connections on the batteries and also to verify that there are no open or failed cells. • • • Discharge for 15 minutes at the C/8 rate. i. DC wiring lists (refer to inserted drawings at rear of manual). and identify circuit breakers.9 Documentation Complete all necessary documentation.e. ARGUS® TECHNOLOGIES 075-053-10 Rev D 95 . fill out identification strips. etc. AC distribution tables (Table N).D C P O W E R S Y S T E M S H A N D B O O K 4. battery reports (Table M). floor plans. Tag wires. D C P O W E R S Y S T E M S H A N D B O O K Table N AC Distribution Table ARGUS® TECHNOLOGIES 075-053-10 Rev D 96 . D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Power System Commissioning Please refer to Appendix B for the detailed procedure. ARGUS® TECHNOLOGIES 075-053-10 Rev D 97 . unless custom levels are specified. The manuals supplied with the equipment detail the method to test and calibrate all system components. All Argus power system components undergo thorough factory testing and all levels/alarms are set to factory default values. Good installation practice is to check the operation of all features and alarms and to set the power system levels as per the specific requirements of your system. ARGUS® TECHNOLOGIES 075-053-10 Rev D 98 .D C P O W E R S Y S T E M S H A N D B O O K This page intentionally left blank. without interrupting the load if the proper steps and precautions are followed. addition.“No” interruption of DC power can be tolerated during work on a power system. 1. 2. It is highly recommended that only personnel with DC power experience and training perform operations on a live power system. ARGUS® TECHNOLOGIES 075-053-10 Rev D 99 . 6. Personnel safety . including the operations detailed in this guide. System integrity .1 Precautions When working on live power systems there are two very important criteria to be considered. Every power system upgrade. Consult the factory before beginning any operation that you are unsure of.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Retrofit Installation This is a retrofit installation guide intended to be applicable for installation of power system components in “live” standard Argus power systems. maintenance procedure can be completed while working live on a DC power system.Follow guidelines in initial installation section. Fuse up circuit or close circuit breaker and test circuit. Remove canvases. 4. Secure ground bus to the top of relay rack and ensure that ground bus is fully isolated from the frame. “Clamp-on” ammeter. 5. 6.3 Distribution Circuit Addition 1. Ungrounded electric drill (as required). 2. connect and secure cables at the power system and then at the load. 3. Protect equipment in relay rack with insulating canvas before proceeding. use tape or tyraps to secure the canvas’.D C P O W E R S Y S T E M S H A N D B O O K 6. Tag wires with identification tags and identify fuse/circuit breaker positions as required. 6. Temporarily wrap all live buswork on the power system with insulating canvas’ while work is being performed on the power system. Run cables in place. Crimp lugs on cables. Decide on cable size and where the conductors are to be terminated. ARGUS® TECHNOLOGIES 075-053-10 Rev D 100 . Decide where the ground bus will be mounted (ground bus should be located in top of the relay rack as close as possible to initial power system). 6. plus the following: • • • Bridging cables as required. 7. insulate at both ends. 3.4 Common Ground Bus Addition 1.2 Tools List Tool list as detailed in initial power system installation. 2. 2. use tape or tiewraps to secure the canvas. Clean buswork to remove any oxidation of the copper buswork. Bolt new panel in place and connect to vertical distribution riser bus. 5. Temporarily wrap all live buswork on the power system with insulating canvas’ while work is being performed on the power system. 3. 6.D C P O W E R S Y S T E M S H A N D B O O K 4.5. 6. Temporarily wrap all live busswork on the power system with insulating canvas’ while work is being performed on the power system. 5. Connect fuse fail alarm card into power system. The new ground bus should be connected to the initial power system ground bus with a cable of sufficient capacity to carry the full anticipated load to be connected to the new ground bus.1 Pre-provisioned 1. ARGUS® TECHNOLOGIES 075-053-10 Rev D 101 . 4.5 Distribution Panel Addition When adding new fuse panels and loads. care should be taken not to exceed the maximum current rating of the power system. Tin plated buswork does not generally require cleaning before using. Crimp lugs on cables and connect at both ends. Remove canvas. Decide where the ground bus will be connected to at the power distribution system. Load current should not exceed 80% of shunt rating for continuous operation. use tape or tiewraps to secure the canvas. 6. 7. Install protective cover on the rear of the fuse panel if required. with 3M scotch pads. Disassemble the vertical riser to fuse panel distribution bus connection and either replace riser with longer bus or extend riser with additional bus section to the new fuse/circuit breaker. Tighten connections and remove bridging cable(s).2 Non-Pre-provisioned Procedure is the same as for the pre-provisioned fuse panel addition except the following extra steps will have to be taken to connect the new fuse panel into the power system.5. Connect cable to new fuse/circuit breaker panel termination buswork. • If there is room to add fuse/circuit breaker below existing panels the vertical distribution riser bus may be replaced with a longer bus that will extend down to the new fuse/circuit breaker panel as follows: 1. Insulating canvases should be used to prevent short circuits between live buswork and chassis/load ground. Install protective cover to cover the rear of the fuse panel (if ordered). Locate fuse/circuit breaker panel in position. 2. 6. 3. bypass the vertical riser and connect directly from the power system charge battery (live) bus to the fuse panel distribution bus. anticipated load on fuse panel) in place. 4. 3. Run appropriately sized cable (sized to carry max. 2. Remove insulating canvases. Clean buswork as required. Using bridging cable(s) (sufficiently sized to carry the load on the existing fuse/circuit breaker panel.D C P O W E R S Y S T E M S H A N D B O O K 6. • If there is no room below existing fuse/circuit breaker panels. ARGUS® TECHNOLOGIES 075-053-10 Rev D 102 . the new fuse panel will have to be cable connected to the existing power system as follows: 1. panel. check load with clamp on ammeter). Bolt cable in place. 2. wood. Utilize TECK 90 type cable for rectifier AC connections.6 Rectifier Addition 1. ARGUS® TECHNOLOGIES 075-053-10 Rev D 103 . Remove canvases. Follow initial installation guide and manual for connection information. intersystem cabling and contactor rating. plywood. this cable is equipped with a vinyl sheath that prevents short circuits when installations are being performed on live power systems. up to the maximum rating of the buswork. 3. to protect equipment and to prevent short circuits). etc. Use bridging cables to maintain circuit continuity while the shunt is being replaced. 5. Decide where connection will be made on vertical distribution riser on the power system. 6. 7. 6. 2.7 Shunt Replacement 1. Shunts may be upgraded in power systems. 3. etc. Mark hole spacing for cable lug on bus and drill hole with isolated drill (use canvas.D C P O W E R S Y S T E M S H A N D B O O K 4. 6. Utilize insulating canvas to prevent short circuits between battery and ground terminations. Utilize insulating canvas to prevent short circuits. ARGUS® TECHNOLOGIES 075-053-10 Rev D 104 .D C P O W E R S Y S T E M S H A N D B O O K This page intentionally left blank. follow procedure below: ARGUS® TECHNOLOGIES 075-053-10 Rev D . control circuits.1 Annual Maintenance • • • • • Test and calibration of supervisory. interval determined by environment. Verify the operation of all alarm relays. If there is a low voltage disconnect in the power system precautions must be taken to ensure that the contactor is not accidentally tripped.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Maintenance and Field Repair 7.1. • 7.1 Power System and System Controller 7. Check and record power system load and verify that system capacity meets the load requirements. Note: Caution should be used when performing field repair on power system supervisory components. Periodic removal of dust with compressed air is recommended.2 Supervisory Circuit Board Replacement If the power system is equipped with a low voltage disconnect contactor. and other misc. Check and re-torque mechanical lug set screws (if applicable).1. Check and re-torque nuts and bolts securing cable lugs to buswork. provision’s should be made to bridge across the contactor to maintain power system integrity when the supervisory PCB (printed circuit board) or panel is replaced. Remove fuses in new PC board and reconnect leads in reverse order. 3. 10. Reconnect high voltage shutdown and remote sensing leads at rectifiers as required. remove these leads at the rectifiers. 9. 7. Check all PC board functions and set levels (refer to manual for more detailed information). This will prevent problems occurring when the supervisory circuit board is being replaced. 5. Temporarily insulate adjacent grounded metal work while installing bridging cable across the contactor. Remove fuses in supervisory panel. Install bridging cable across LVD contactor. Remove temporary bridging cable across the low voltage disconnect contactor and remove insulating canvas. The rectifiers will automatically revert to internal sensing. effectively bypassing the contactor. disconnect and insulate leads. 6. 4. 11. If the power system is equipped with high voltage shutdown or remote sensing for the rectifiers. size cable to carry the full load on the contactor and check with a clamp on ammeter.D C P O W E R S Y S T E M S H A N D B O O K 1. Remove supervisory panel or PCB and install replacement board in position. 2. Use extreme care some leads will be live. Assemble bridging cable. Identify wires terminating on the supervisory panel and tag wires to ensure wires are reinstalled in the correct position. 8. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Install fuses. Tag leads and remove input. output. etc. Remove rectifiers and install replacement rectifier in the same position. Check meter calibration.2 RST Rectifiers 7. • • 7. 3. • 7. 4.2. Replace fuses(s) F1 (and F2). Open input/output breakers on rectifier. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Disconnect live lead from rectifier at the power system charge bus. Open AC input breaker at distribution panel. float voltage/equalize voltage at battery.3 Ten Year Maintenance • Replace large input (electrolytic) surge capacitors (C11 & C12 for 48/50) and damper capacitor (C12 for 48/50).2 Five Year Maintenance • Replace varistor(s) VR1 (VR2 & VR3) if in low to moderate lightning surge area. Check and adjust levels. Remove dust using compressed air. load sharing. Replace varistor(s) VR1 (VR2 & VR3) if in high lightning/surge activity area (located across input circuit breaker).1 Annual Maintenance • • • • Visually inspect the rectifier inside and out. alarm and control leads from rectifier and insulate.2.4 Rectifier Replacement 1. Verify leads are dead at rectifier.D C P O W E R S Y S T E M S H A N D B O O K 7.2.2. 5. 2. 7. Consider sending unit to factory for full maintenance “tune-up” complete with 100 % unit performance testing. Open AC input breaker at distribution panel.2. Open input/output breakers on rectifier. Reconnect all cables and make the live connection at the battery charge bus last. Open input/output breakers on rectifier. Open front panel. 5. reconnect wires and ribbon cable.2. Install new PC board. Power up and fully test rectifier as per the procedures detailed in the manual. 3. 2. Refer to RSM rectifier section for identifying and testing of MOV. 2. Disconnect ribbon cable. disconnect and remove MOV from load side of the input circuit breaker. display problems may easily be solved by replacing the front control panel instead of sending the entire rectifier for repair. 7. Compress PC board retaining clips and remove PC board.5 Rectifier Front Panel Replacement Many control. Replacement is as follows: 1. alarm. 4. ARGUS® TECHNOLOGIES 075-053-10 Rev D .6 Rectifier MOV Replacement 1. 7.D C P O W E R S Y S T E M S H A N D B O O K 6. Open front panel. Open AC input breaker at distribution panel. Install new MOV and close front panel. Power up and test rectifier as per the procedure outlined in the manual. tag leads connected to front panel PC board. 4. 7. Power up and fully test rectifier as per the procedures detailed in the manual. 3. insulate and remove. 3 Ten Year Maintenance • Consider sending unit to factory for full maintenance “tune-up” complete with 100 % unit performance testing.3.4 Rectifier Replacement 1. Check meter calibration.3. requires removal of front panel). 7. Replace input varistors if in high lightning/surge activity area. 7.2 Five Year Maintenance • Replace input varistors if in low to moderate lightning surge area (located across input circuit breaker. tighten mounting screws. Loosen mounting screws and remove rectifier and install replacement rectifier in the same position.D C P O W E R S Y S T E M S H A N D B O O K 7.5 Rectifier Addition 1. Open input/output breakers on rectifier. Remove dust using compressed air. Power up and test rectifier following the procedure outlined in the manual. 2.3.3. 7.3. To add an additional rectifier either set the corresponding DIP slide switch (5KW & 7KW cabinets) or remove the module fail defeat plug (9KW & 12KW cabinets).3 RSM Rectifiers 7. Check and adjust levels. 3. ARGUS® TECHNOLOGIES 075-053-10 Rev D . 7.1 Annual Maintenance • • • • • Visually inspect the rectifier inside and out. 7 Rectifier MOV Check (RSM 48/50.3. Insert module. Measure resistance of MOV. Install power module. Open input/output breakers on rectifier. tighten screws. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Install replacement fan and reconnect leads. 5. Loosen mounting screws and remove power module.6 Fan Replacement 1. power up and test rectifier following the procedure outlined in the manual. Open AC input breaker at distribution panel. Remove “warranty void” label and screws securing the front panel to the chassis. located usually on the load side of the input circuit breaker inside the rectifier cabinet (a small disc approximately the size of an U. 5. With rectifier removed from the shelf. 3. 5 cent piece). A short circuit or low resistance indicates a failed MOV. power up and test following the procedures outlined in the manual. Remove power module. remove fan power leads and mounting screws. 7. 7. and 48/100) 1. 2. 24/100.3. Replace if failed.D C P O W E R S Y S T E M S H A N D B O O K 2. 3. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Verify that AC feed is in place for new rectifier position. 4. 4. Identify MOV’s. 6. 2. 3. tighten mounting screws.S. Disconnect and remove MOV from load side of the input circuit breaker. power up and fully test rectifier as per the procedures detailed in the manual. tighten mounting screws. Open AC input breaker at distribution panel. 2. 3. Remove “warranty void” label and screws securing the front panel to the chassis.3. 6. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Warning : Removal of the warranty void label will void the warranty.D C P O W E R S Y S T E M S H A N D B O O K 7. 5. Remove power module. Install new MOV and reinstall front panel.8 Rectifier MOV Replacement (RSM 48/50. Open input/output breakers on rectifier. Install power module. 4. and 48/100) 1. 24/100. Insert module.4. Verify that AC feed is in place for new rectifier position. 7. Remove dust using compressed air. power up and test following the procedures outlined in the manual. tighten mounting screws.4. Remove rectifier and install replacement rectifier in the same position.5 Rectifier Addition 1.4. 3. 7. 2. Turn rectifier off and loosen mounting screws.3 Ten Year Maintenance • Consider sending unit to factory for full maintenance “tune-up” complete with 100 % unit performance testing. If the system is SM equipped. If the system is SM equipped. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Replace input varistors if in high lightning/surge activity area.4 Pathfinder 24-3kW. perform an inventory update and then download all the rectifier settings from the SM to the rectifiers.4. Check and adjust levels.1 Annual Maintenance • • • • • Visually inspect the rectifier inside and out.2 Five Year Maintenance • Replace input varistors if in low to moderate lightning surge.4. 48-3kW. 2.D C P O W E R S Y S T E M S H A N D B O O K 7. perform an inventory update and then download all the rectifier settings from the SM to the rectifiers. 7. and 48-10kW Rectifiers 7. Set up and test rectifier following the procedure outlined in the manual.4 Rectifier Replacement 1. Check meter calibration. 7. Measure resistance of MOV. Open AC input breaker at distribution panel. power up and test rectifier following the procedure outlined in the manual.4. ARGUS® TECHNOLOGIES 075-053-10 Rev D .4. 5. Turn rectifier off and loosen mounting screws. 3. 7. Remove rear rectifier cover by removing three screws on each side of the rectifier module. 8. 5.D C P O W E R S Y S T E M S H A N D B O O K 7. Plug in the replacement MOV pack on the PCB. clean printed circuit board of all metallic particles that may contaminate the PCB when the MOV fails. 4. Reinstall rectifier following the procedure in reverse sequence.7 Rectifier MOV (check and replace) 1. 3. 5 cent piece.S. Install replacement fan and reconnect leads. remove fan power leads and mounting screws. Remove the MOV’s if failed using side cutters to clip the MOV leads. 2. Turn rectifier off and loosen mounting screws. 2. MOV’s are small discs approximately the size of an U. Remove power module. 4. 6. 7. Install power module. 3kW Pathfinders have 3 MOV’s and 10kW Pathfinders have 9 MOV’s. located beside the AC input fuses.6 Fan Replacement 1. Remove power module. A short circuit or low resistance indicates a failed MOV. With rectifier removed from the shelf. Identify MOV’s. 6. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Check and adjust levels.D C P O W E R S Y S T E M S H A N D B O O K 7. Remove converter and install replacement converter in the same position. Check meter calibration.1 Annual Maintenance • • • • Visually inspect unit inside and out. 7. so that the converter is not carrying any load. Open input/output breakers on the converter. If DC is not fused then the input live lead must be removed from the associated bus.5.4 CSM Series Converter Replacement 1. 7. alarm and control leads from converter and insulate.5. 5. Open DC input breaker/fuse at DC distribution panel. Turn down the output voltage on the converter. Remove dust using compressed air. Reconnect all cables and make the live connections at appropriate bus last. 7.5.5. Power up and test converter following the procedure outlined in the manual. 3. 4. Tag leads and remove input. output.2 Ten Year Maintenance • Consider sending unit to factory for full maintenance “tune-up” complete with 100 % unit performance testing. 7.3 CS Series Converter Replacement 1. 2. Ensure all leads are dead at converter.5 CS and CSM Converters 7. Disconnect live output lead from converter at the converter distribution bus. 2. Remove converter and install replacement converter in the same position. power up and test following the procedures outlined in the manual. Power up and test converter following the procedure outlined in the manual. ARGUS® TECHNOLOGIES 075-053-10 Rev D .5.5 CSM Converter Addition 1.D C P O W E R S Y S T E M S H A N D B O O K 2. 7. To add an additional converter set the corresponding jumpers on the converter shelf. 3. Insert converter module. Recommended maintenance for battery strings varies with each manufacturer and each type of battery. Check and record pilot cell voltage.2 Quarterly Maintenance In addition to the monthly items also check and record the following: • • • • Specific gravity for each cell. 7. 7. Corrosion at terminals or connectors - neutralize and clean as required. specific gravity and electrolyte temperature.top up with approved water as required. Refer to manufacturer for specific instructions for the battery string in question. Total battery voltage. greased with no-oxide “A” and reassembled. Check and record ambient temperature and condition of ventilation equipment. If corrosion is serious and threatens the integrity of the connection. Electrolyte levels . the assembly will have to be disconnected.D C P O W E R S Y S T E M S H A N D B O O K 7.6. Temperature of one cell on each row of the rack. Cracks in cells or electrolyte leakage - report immediately.adjust as necessary.1 Monthly Maintenance • Visual inspection General appearance.6 Vented Batteries This is a generic maintenance schedule. • • • Verify battery voltage . cleaned. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Voltage of each cell.6. cleanliness - neutralize with baking soda and water solution as necessary and wash cells with clean water. all connection assemblies should be checked. 7. Conductance or impedance measurements of each cell. Check and re-torque all intercell connector bolts. Check integrity of rack. Disassemble and clean as required. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Check connection resistance “cell to cell” and “cell to terminal”.D C P O W E R S Y S T E M S H A N D B O O K • Check 10 % of intercell connection resistance’s chosen at random.6.3 Annual Maintenance In addition to the quarterly items also: • • • • • Visually inspect each cell. if resistance is high. D C P O W E R S Y S T E M S H A N D B O O K 7.7 Valve Regulated Lead Acid (VRLA) Batteries This is a generic maintenance schedule. Recommended maintenance of battery strings varies with each manufacturer and each type of battery. Refer to manufacturer for specific instructions for the battery string in question. 7.7.1 Monthly Maintenance • • Check and record pilot cell voltage. Check and record ambient temperature. 7.7.2 Quarterly or Annual Maintenance In addition to the monthly items also check and record the following: • • • • Voltage of each cell. Total battery voltage. Temperature of one cell. Visual inspection: General appearance cleanliness. Cracks in cells or electrolyte leakage. Corrosion. Check and re-torque all intercell connector bolts. Check connection resistance “cell to cell” and “cell to terminal”. Conductance or impedance measurements of each cell. • • • ARGUS® TECHNOLOGIES 075-053-10 Rev D D C P O W E R S Y S T E M S H A N D B O O K 7.8 Battery Failure; Detection, Prevention & Corrective Action 7.8.1 Performance/Integrity Checks • Real-time monitoring of battery performance using the SM02 power system control to chart battery performance. Measurements of voltage, specific gravity, conductance and impedance are useful in charting a cell state of health over time and to alert personnel to a problem cell or battery. Periodic evaluation of a battery system performance should also be completed. There are various methods of evaluating battery condition. Performance can be measured automatically with the SM02 or recorded manually. 1. 2. • Short duration high rate discharge. Full discharge to 80% of capacity. • • The battery end of life is determined when the capacity has dropped to 80% of nominal. 7.8.2 Alternatives for detecting battery problems • A real time midpoint cell voltage monitor such as the Argus SD08 can be used to detect cell voltage imbalances in the battery string during float, charge or discharge conditions. This can provide an early warning of a failing cell. 1. 2. 3. Splits the battery string voltage in half. Compares the two halves. When the difference exceeds a preset value an alarm is extended. 7.8.3 Corrective action Report any serious problems to the manufacturer immediately. ARGUS® TECHNOLOGIES 075-053-10 Rev D D C P O W E R S Y S T E M S H A N D B O O K If any of the individual cell voltages fall out of range an equalizing charge will have to be applied. This may be applied by one of the following methods: • • On-line utilizing the power system rectifiers, to the voltage limits of the load. Alternatively the battery string may disconnected in a multiple string application, boost charged with an auxiliary charger and reconnected on line (see string/cell replacement section). On-line utilizing a single cell battery charger. The special single cell charger is connected across cell in question and the cell is boost charged while system is on-line. • 7.8.4 String/Cell Replacement 1. Assemble temporary battery string if the power system is equipped with only one battery string. Match temporary battery string voltage to main power system voltage by either using an external charger to raise the voltage of the temporary string or by lowering the voltage on the power system to match the temporary string voltage (voltage should be within .5 volts). Connect temporary string on line. Disconnect battery string in question. Perform boost charging, cell replacement and/or maintenance on battery string. Match power system voltage to the voltage of the disconnected battery string. Connect battery string on line. Disconnect temporary string. 2. 3. 4. 5. 6. 7. 8. ARGUS® TECHNOLOGIES 075-053-10 Rev D Then check the numbers in the left column to verify which power equipment it applies to.D C P O W E R S Y S T E M S H A N D B O O K CHAPTER Troubleshooting 8. SD 03 and 05 supervisory panels. 7. 6. 12. ARGUS® TECHNOLOGIES 075-053-10 Rev D . Circuit breaker. RSM 48/30 and 24/50 rectifiers. then check the solution in the right column. Pathfinder 1. 3. See equipment manuals for additional details. 13. 2. look for the specific symptom that you are experiencing. SM 02 supervisory panel. 14. Battery back-up. RSM 48/7. CS converters. 10. RST rectifiers. 16. 1. RSM 48/10 rectifier systems. 4.5 rectifier systems. 5. 10 kW rectifiers. 11. SD 02 and 04 supervisory panels. 8.5. 15. fuse and distribution centers. 9. RSM 48/50 and 24/100 rectifiers. 3. CSM converters. Temperature compensation panel.1 Power System and System Controller To use the following troubleshooting guide. RSM 48/100 rectifiers. SM 03 supervisory panel. Rectifiers not sharing current evenly > 10 % difference in current between modules. 6 Check yellow alarm relay fuse located behind left module (3) or “resistor style” fuse behind SCI PCB (4). 2-4 ARGUS® TECHNOLOGIES 075-053-10 Rev D . Set the slope on rectifier to the same value (0. Enable the forced sharing on each rectifier. Adjust the float and equalize voltage on each rectifier to the same value off-line (output breaker off). Alarm relay contacts not functional. Perform a microprocessor reset. Connect rectifier on line. Check that there is a load on the system greater than 5% of the current capacity of a single rectifier in the system or that a battery is connected to the system. 15 Symptom Rectifier fail alarm indication. 3-4.5% preferred). Check “resistor style” supervisory control fuses on backplane of rectifier cabinet (6). 2-4 Module not responding to commands. Repeat with each rectifier in the system.D C P O W E R S Y S T E M S H A N D B O O K Units 1-5. Solution Check that the voltage on each rectifier is set to the same value. see rectifier manual. 14). Reset unit.13) non-adjustable (5.6.15 9.14). 1% preferred (1. Rectifier/converter control and/or alarm problem. ARGUS® TECHNOLOGIES 075-053-10 Rev D . 6 or a mixed model system. 15 1. Turn off AC feeder circuit breaker. Check the cooling vents for obstruction or excessive dust build up. Systems SM equipped Set the slope on rectifier to the same value (0.5. 2-4. Download the settings to the rectifiers. No module fail alarm.3.2.1 5 1-6. defeat plug (3) or jumpers (5.14. Check input feeder circuit breaker. Rectifier fail and/or AC Mains fail alarm 1-6.13. Rectifiers not sharing current evenly > 10 % difference in current between modules.16. Turn on feeder breaker. Reset breaker as required.14 1-6. 15 Input breaker/fuse trip/blow. Clean as required. 6. Adjust the float and equalize voltage on each rectifier to the same value off-line (output breaker off). Repeat for the equalize voltage setting (1).6.D C P O W E R S Y S T E M S H A N D B O O K Units 1. 4. Symptom Rectifiers/converters not sharing current evenly > 10 % difference in current between modules. If breaker trips again rectifier has been damaged. Adjust the output voltage on each unit while monitoring the voltage at the batteries or load.5% preferred). 5. Check AC voltage level in the rectifier status display (2-4) or at rectifier input circuit breaker/termination (1. Enable the forced sharing on each rectifier. Check and replace rectifier input fuse (15) Check fan cable connection Replace fan assembly. Ensure that the battery or load voltage is correct and the load current is split evenly between the units. 3. Solution Systems not SM equipped Set the slope on rectifier/converter to the same value.15) or send for repair (1-6. 15.5. Turn on rectifier input circuit breaker (1-6).14). 13. 6. Thermal shutdown/over temperature alarm.6. Check module fail dip-switch (4). Systems. check and/or replace MOV in rectifier (1.15). see maintenance and field repair section.6. Replace front panel control PCB.13 Fan fail/speed error. 2-4. There should be at least 1 volt between the maximum float voltage and the OVP setting. Solution Check that the OVP and float settings are correct. 15 6. 1. 16 OVP (over voltage protection) trip or HVSD (high voltage shutdown) at low temperature only.7.6. Check start delay setting.4. Supervisory panel fail. Turn rectifier on. Check that the temperature compensated float voltage does not exceed the OVP setting when maximum voltage boost is occurring i.4. Readjust settings to the correct value. ARGUS® TECHNOLOGIES 075-053-10 Rev D . manually adjust potentiometers (1. Check that AC is actually connected and energized to module position.9.5. If module continues to trip off due to OVP. Wait for delay to elapse or reset delay to zero. 15 3. Check power fuse for supervisory panel located on the front-GMT type (8). New installation or rectifier addition rectifier not operational.10. see battery temperature compensation section for more details.D C P O W E R S Y S T E M S H A N D B O O K Units 1-6.3.4).2. no DC output after reset and LVA.8 AC on. Replace supervisory control PCB.6. Check and adjust the OVP and/or float voltage settings as necessary. 5.6. on the rear-GMT type (7) or on the backplane-”resistor style”(6). set OVP setting to the maximum setting and float voltage to the minimum setting i. 15 Symptom OVP (over voltage protection) trip or HVSD (high voltage shutdown).5.4).e. LVD open or incorrect nonfunctional alarms. LVD open or incorrect nonfunctional alarms. at low temperatures.e.8 5. Supervisory panel fail.7.3. rotary switch (1) or programmed setting (2.3.6) or adjust stored setting in the microprocessor with the input breaker off and a power source connected to the DC output (2. ensuring continuity of alarm path. 16 On power failure . Check battery circuit for poor or missing connection. Check operation if possible by turning breaker off. monitor the situation and replace circuit breaker if there is a reoccurrence. Check battery circuit for poor or missing connection.b. 11 Circuit breaker alarm not functional.11 Symptom Load circuit breaker/fuse trip. Check battery for open cell (12).12. Check battery performance (12). Check that battery is sized correctly for load and back-up time required (12). Reset circuit breaker or replace fuse. (5-9). (5-9). Check that the supervisory panel LVD control settings are correct. If load is within limits.D C P O W E R S Y S T E M S H A N D B O O K Units 5. 5-9. rating using a clamp on ammeter.12. Check that jumper setting on alarm PCB is correctly configured for voltage application. 16 On power failure . Solution Check for fault condition. (12). 5-9. If the load is exceeding limit upgrade the fuse/circuit breaker size and associated wiring if required.6. (12).no battery back up. Check that load on circuit breaker does not exceed 75-80% of the fuse/c. Check alarm signaling jumpers on rear of circuit breaker.short battery back up. Check that the supervisory panel LVD control settings are correct. ARGUS® TECHNOLOGIES 075-053-10 Rev D . ARGUS® TECHNOLOGIES 075-053-10 Rev D . Enable remote access Reset SM02 Activate communications program from DOS to be sure that windows isn’t taking control of the communications port. Note: LED will flash when the rectifier is in current limit if the feature is enabled No display. Replace module If new rectifier module is installed in the early version of the pathfinder cabinets the module interlock jumper must be set correctly. It is the jumper on the left and it should be installed on the center and the left most pin if used in an older system (3kW only) Verify rectifier settings and download (from SM) to the rectifiers.16 9.16 9 Measurement error RS 232 communications problems.D C P O W E R S Y S T E M S H A N D B O O K Units 15 Symptom Module fail & AC mains OK 15 15 15 Module fail & AC mains fail Module minor alarm (red LED flashing). 9. Communications lost alarm 9. Check cables Verify baud rate Enable remote access Verify that rectifier mounting screws are tight Calibrate analog channel Verify cable.16 Out of tolerance. no power up. Solution Ensure that the rectifier is seated correctly and that the mounting screws are tight Verify rectifier settings and download (from SM02) Check AD and DC fuses Replace module Check AC feeder breaker and circuit Check AC input voltage Ensure that the rectifier is seated correctly and that the mounting screws are tight Verify rectifier settings and download (from SM02) Check and/or replace fan. connections. This jumper is located below the DC output connectors on the module. etc. must be “null” modem Verify communications speed If a baud rate change has been made the reset button must be depressed to activate the new communications speed. 9 9 9 Display hard to read Alarm messages on display with (clear).D C P O W E R S Y S T E M S H A N D B O O K Units 9 Symptom Modem communications problems. Set the count to the quantity of RSM type rectifiers in the system when using RSM type. Make sure rectifier mounting screws are tight. Check that the RSM count is set to zero if using pathfinder type rectifiers. 9 9 Function keys locked out. Solution Same as above. Depower SM controller and reapply power.” ARGUS® TECHNOLOGIES 075-053-10 Rev D . Ensure that remote access and remote adjust have been enables in all the rectifiers. Use left/right arrow keys in Normal operation mode to adjust the view angle. Rectifier “Lockout message. Depress visual alarm reset button (VAR) to clear. This message will appear on the SM02 if the rectifiers are equipped with local display/control and the keys in the rectifier have been depressed. Must use jumper configurable modem not “plug and play” Ensure that IRQ is set to 3. No rectifier ID aquistion. Check and/or replace RS 485 communications cable. Return to normal operation in the rectifier menu to clear this alarm. com port 4 Reset microprocessor. D C P O W E R S Y S T E M S H A N D B O O K ARGUS® TECHNOLOGIES 075-053-10 Rev D . 053.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X A Acronyms and Abbreviations AC AGM AH alternating current absorbed glass mat (battery) ampere hour TCM THD UL UPF UPS VAR VRLA temperature compensator module total harmonic distortion Underwriter’s Laboratory unity power factor uninterruptable power supply visual alarm reset valve regulated lead acid (battery) BDCBB battery distribution circuit breaker board BDFB BFV BRB CEC CEMF CMA CSA DC EPO FGB FITL HVA HVSD LCD LED LVA LVBD LVD LVLD MGB MOV NEC NSTA OVP PCB PWM SAD SNMP SPD SPG battery distribution fuse board battery float voltage battery return buss Canadian Electrical Code counter electro-motive force circular mil area Canadian Standards Association direct current emergency power off floor ground buss fiber in the loop high voltage alarm high voltage shutdown liquid crystal display light-emitting diode low voltage alarm low voltage battery disconnect low voltage disconnect low voltage load disconnect master ground buss metal oxide varistor National Electrical Code National Safe Transit Association over-voltage protection printed circuit board pulse-width modulation silicon avalanche diode simple network management protocol surge protection devices single point ground A RGU S ® TECHNOLOGIES 075.10 Rev D . 2. General AC Service ________V__PH__W Main Breaker ________A Panel rating __________A Surge Protection Model#___________ Type_________________ Rectifier feeder circuits _________A _______ Ga.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B Power Plant Turn Up and Commissioning Report 1. Pre-Turn Up Inspection 2.053.2. AC Panel/Protection Inspection 2.10 Rev D .1.1.1.2. General Power Plant #_______________ Rectifiers labeled Converters labeled Distribution breakers labeled Serial numbers recorded 2.1. or ________mm Circuit breakers labeled yes no Electrical connections ok yes no Measured AC Voltage ___________V 2. Mechanical Seismic Zone 4 required System secure bottom (required) System secure top (optional) System bays bolted together Box bay shipping braces removed Verify busbar assembly ______V yes yes yes yes Max________A no no n/a no no appendix _____ yes yes yes yes yes yes no no no no no no n/a n/a n/a n/a A RGU S ® TECHNOLOGIES 075. Site Information Customer Name Site Address City Contact ______________________ ______________________ ______________________ Country______________________ ______________________ Phone _______________________ 2.2. Power Plant Inspection 2. 3. General BDFB Identification_____________________________________________ Power Plant #_________________ Source feed labeled yes no 2.3. Mechanical Seismic Zone 4 required System secure bottom (required) System secure top (optional) yes yes yes no no no 2. Green Power system battery return ground ____Ga. Electrical Single feed ___________ MCM ___________A protection A+B ___________ MCM ___________A protection A.1.3. BDFB (BDCCB) Inspection 2.2.1.3.B.1.1. Green Battery return ground isolated yes no Halo Black Black 2.3.C+D ___________ MCM ___________A protection Frame ground each bay ____Ga. Electrical Rectifier output cables ____ Ga. Verify inter-bay cabling yes no Verify shunt lead installation yes no Verify comm's cable installation yes no Live buswork insulated adequately yes no Electrical connections ok yes no Grounding method Single Point Ground Frame ground each bay ____Ga.053. BDFB ______________ 2. Green Black Live buswork insulated adequately yes no Electrical connections ok yes no A RGU S ® TECHNOLOGIES 075.1.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B 2.3.2.3.10 Rev D . Mechanical Seismic Zone 4 required System secure bottom (required) System secure top (optional) Battery assembled correctly Cable connections tight yes yes yes yes yes no no no no no 2.2.4.10 Rev D .4.1.1.4.1. Battery Protection Manufacturer______________________ Model____________________ Serial Number _____________________ Max. Torque Check Cable connections ½” bolts (sample 1) Cable connections ½” bolts (sample 2) Cable connections 3/8” bolts (sample 1) Cable connections 3/8” bolts (sample 2) Cable connections ¼” bolts (sample 1) Cable connections ¼” bolts (sample 2) Battery posts ________bolts (sample 1) Battery posts ________bolts (sample 2) _____________ft/lbs torque (75 ft/lbs rec’d) _____________ft/lbs torque (75 ft/lbs rec’d) _____________ft/lbs torque (__ ft/lbs rec’d) _____________ft/lbs torque (__ ft/lbs rec’d) _____________ft/lbs torque (__ ft/lbs rec’d) _____________ft/lbs torque (__ ft/lbs rec’d) _____________in/lbs torque (__ft/lbs rec’d) _____________in/lbs torque (__ft/lbs rec’d) A RGU S ® TECHNOLOGIES 075. leakage.2.4.3. Rating __________A LVBD yes no EPO yes no 2. General Battery Identification #________________________________________ Manufacturer______________________ Model____________________ Serial Number(s) _____________________ Visual inspection for cracks.4. Electrical Battery cables __________________MCM/AWG Temperature probes installed yes no n/a Where installed?___________________________________________ 2. etc ok As received battery voltage report attached yes no appendix _____ As received battery cond/imped.4. Ampacity__________A Fuse/C.5.053. report attached yes no appendix _____ Anti-oxidation compound used yes no Cells labeled yes no Battery labeled yes no 2. Battery ________________________________________________ 2.B. Battery Inspection 2.1.1.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B 2. 5. Ensure all batteries are disconnected.2. Install the remaining rectifiers in the system. 3. 3.1.7. Verify LVLD Function 4. 3.1.2. Battery Disconnect 4. Initial charge/report 4. Battery 4. rectifier modules are removed. One at a time.1.053.2.1.3.1. 3. 3. Install main fuse followed by the guard fuse for the BDFB (BDCCB’s) if required.2.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B 3. controller turns on.4. fuses pulled and circuit breakers turned off.5.1. Triple check the polarity of battery connections. Verify. Verify EPO Function 4. Load test power plant 100A 4. Power Plant 4. adjust and download system settings 4. Verify output alarm relay function 4. Discharge test/report 4. Install one rectifier. Test 4.1.3.2.1. 4. Note: If there is no means of disconnecting the battery then the rectifier output voltage should be reduced using the controller to match the rectifier voltage to the battery voltage to avoid sparks.3.2.3.3. Shunt multiplexer 4.8.4. 3. The single rectifier in the system will now begin charging the batteries.3. Verify Analog Measurements 4. Turn on the AC to the rectifier and allow it to start up. Turn Up procedure 3.3.6. Verify Alarm Reporting complete complete complete complete complete appendix____ n/a complete complete n/a appendix____ n/a appendix____ complete complete complete n/a n/a n/a A RGU S ® TECHNOLOGIES 075.9.10 Rev D . Verify that the system starts up ok. Turning the AC on to each unit and verifying breaker position.1. 3. fuse or circuit breakers for the batteries.2. If the SM type of controllers are used a inventory update followed by a download of the system settings should be performed. Check the battery polarity is correct and turn on the breakers. this is normal.1. 3. Comment 6.10 Rev D . Notes: Note Action Details CAR – Corrective Action Required COM . Acceptance REC – Recommendation ______________________ Print Name ______________________ Company ______________________ Print Name _______________________ ________________ Signature Date _______________________ Phone Number _______________________ ________________ Signature Date A RGU S ® TECHNOLOGIES 075.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B 5.053. 053.D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B Power Plant Settings Report Item Rectifiers Float voltage Equalize Voltage Force share enabled/disabled Slope Current limit Delay start High voltage shutdown or OVP High voltage alarm Low voltage alarm Security code Backlight time-out Temp display C or F Current Limit Alarm enabled/disabled Equalize time-out Remote access enabled/disabled Remote adjust enable/disabled Local access alarm enabled/disabled Default Check Reference/notes DC-DC Converters Output voltage High voltage alarm Low voltage alarm High voltage shutdown or OVP Slope Current limit A RGU S ® TECHNOLOGIES 075.10 Rev D . in Low voltage disconnect 2 .in Low voltage disconnect 3 .out Low voltage disconnect 2 .D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B Item Supervisory High voltage alarm 1 High voltage alarm 2 Low voltage alarm 1 Low voltage alarm 2 Alarm hysterisis Discharge amps alarm Charge amps alarm AC Mains high AC Mains Low Rectifier minor trigger count Rectifier major trigger count User alarm 1 User alarm 2 User alarm 3 User alarm 4 User alarm 5 High voltage shutdown or OVP Low voltage disconnect 1 .053.in CEMF control .out Auto-equalize duration Auto-equalize interval Temp comp enable/disable Temp comp slope Temp comp upper breakpoint Temp comp lower breakpoint Temp comp interval Temp comp sensor 1 enable Temp comp sensor 2 enable Temp comp sensor 3 enable Temp comp sensor 4 enable Default Check Reference/notes A RGU S ® TECHNOLOGIES 075.out Low voltage disconnect 3 .out CEMF control .10 Rev D .in Low voltage disconnect 1 . D C P O W E R S Y S T E M S H A N D B O O K A P P E N D I X B Item Auto equalize enable Auto equalize duration Auto equalize interval Auto equalize high V threshold Auto equalize low V threshold Rectifier baud rate Terminal baud rate Remote access enable Dial back number 1 Dial back number 2 Dial back number 3 User access code Supervisor access code Alarm scroll rate Maximum RSM count SM02 Temperature scale Default Check Reference/notes A RGU S ® TECHNOLOGIES 075.10 Rev D .053.
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