827E Modular Inverter System 48 V / +24 V Input 120 Vac...

Critical Power Product Manual

Service and Assistance - +1 877 546 3243 or +1 972 244 9288 [email protected] © 2013 General Electric Company. All rights reserved. http://www.ge.com/powerelectronics 4380419PD Issue 33 April 2013 1

827E

Modular Inverter System −48 V / +24 V Input

120 Vac / 240 Vac Output

http://www.ge.com/powerelectronics

827E Modular Inverter System ProductManual

4380419PD r33 April 2013 2

Table of Contents List of Figures ........................................................................................................................................................................................................................... 4

List of Tables ............................................................................................................................................................................................................................. 5

Foreword .................................................................................................................................................................................................................................... 6

Product Information ............................................................................................................................................................................................................. 7

Product Description .............................................................................................................................................................................................................. 8

Installation .............................................................................................................................................................................................................................. 15

Mechanical Installation .......................................................................................................................................................................................... 16

General .................................................................................................................................................................................................................. 16

Shelf Mounting ................................................................................................................................................................................................... 16

Electrical Connections ............................................................................................................................................................................................. 18

General .................................................................................................................................................................................................................. 18

DC Input ................................................................................................................................................................................................................. 19

AC Output ............................................................................................................................................................................................................. 21

Grounding Electrode Conductor Connections - GEC ..................................................................................................................... 23

Alarm Connections .......................................................................................................................................................................................... 24

Communication Connections .................................................................................................................................................................... 26

Inverter - Install / Remove..................................................................................................................................................................................... 28

System Controller - Install / Remove ............................................................................................................................................................... 29

Modem - Install / Remove ..................................................................................................................................................................................... 30

Distribution Monitor - Install / Remove .......................................................................................................................................................... 31

Distribution Disconnect Module - Install / Remove ................................................................................................................................. 32

Initial Turn On, Setpoints, and Adjustments ................................................................................................................................................ 33

Shelf Turn On and Operational Checkout............................................................................................................................................ 33

Adjusting Setpoints .......................................................................................................................................................................................... 35

Specifications ........................................................................................................................................................................................................................ 37

Features Reference ............................................................................................................................................................................................................ 40

AC Output Distribution ............................................................................................................................................................................................ 40

Inverter ............................................................................................................................................................................................................................ 40

Distribution Disconnect Module (DDM) ........................................................................................................................................................... 40

Distribution Monitor (DM) ....................................................................................................................................................................................... 41

System Controller ...................................................................................................................................................................................................... 41

Display Navigation and Push Buttons ................................................................................................................................................... 43

Display Menus .................................................................................................................................................................................................... 44

Theory of Operation ........................................................................................................................................................................................................... 55

Output Protection ...................................................................................................................................................................................................... 55

Output Paralleling and Hot Insertion .............................................................................................................................................................. 57

Considerations for Multiple-Shelf Systems .................................................................................................................................................. 58

Troubleshooting ................................................................................................................................................................................................................... 59


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Safety ......................................................................................................................................................................................................................................... 66

Safety Statements ..................................................................................................................................................................................................... 66

Warning Statements and Safety Symbols ................................................................................................................................................... 67

Precautions ................................................................................................................................................................................................................... 68

Revision History .................................................................................................................................................................................................................... 69


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List of Figures Figure 1 19-inch and 23-inch Systems and Shelves ........................................................................................................................................ 11

Figure 2 Modules Front View......................................................................................................................................................................................... 12

Figure 3 120 Vac & 240 Vac Module Identification ........................................................................................................................................... 13

Figure 4 Side Views of a System (Shelf) ................................................................................................................................................................... 14

Figure 5 Mounting - 23”, 25”, and 26” ...................................................................................................................................................................... 17

Figure 6 AC Wiring - without Maintenance Bypass Panel ............................................................................................................................. 18

Figure 7 AC Wiring - with Maintenance Bypass Panel .................................................................................................................................... 19

Figure 8 Shelf Rear View .................................................................................................................................................................................................. 20

Figure 9 DC Input Connections .................................................................................................................................................................................... 20

Figure 10 AC Output Connections .............................................................................................................................................................................. 21

Figure 11 Common Trip Ratings for 10 – 30 Amp Range .............................................................................................................................. 23

Figure 12 Grounding Electrode Conductor (GEC) Connections .................................................................................................................. 24

Figure 13 Alarm Outputs ................................................................................................................................................................................................. 26

Figure 14 DB9 Pin-out ....................................................................................................................................................................................................... 27

Figure 15 Inverter Install / Remove ........................................................................................................................................................................... 28

Figure 16 System controller Removal/Installation ............................................................................................................................................ 29

Figure 17 Modem Installation ....................................................................................................................................................................................... 30

Figure 18 Distribution Monitor/Distribution Disconnect Module Removal and Installation ........................................................ 31

Figure 19 Controller Pushbuttons .............................................................................................................................................................................. 43

Figure 20 Menu Structure - Typical ........................................................................................................................................................................... 54

Figure 21 Output Protection, Short Circuit with no Fuse ................................................................................................................................ 56

Figure 22 Output Protection - Short Circuit with Fuse .................................................................................................................................... 56

Figure 23 Paralleling and Hot Insertion ................................................................................................................................................................... 57


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List of Tables Table 1 System Configurations ....................................................................................................................................................................................... 9

Table 2 wire and terminals for Individual DC inputs (+BAT and −BAT) .................................................................................................... 20

Table 3 Recommended Wire and Terminals for AC Output ......................................................................................................................... 21

Table 4 Typical Trip Ratings for 10 – 30 Amp AC Circuit Breakers ............................................................................................................ 22

Table 5 Grounding Electrode Conductor Connections - GEC ...................................................................................................................... 24

Table 6 Alarm Outputs...................................................................................................................................................................................................... 25

Table 7 Inverter Shelf Interface Cable Connection ........................................................................................................................................... 27

Table 8 Setpoint Resolution ........................................................................................................................................................................................... 36

Table 9 Specifications - Inverter .................................................................................................................................................................................. 37

Table 10 Specifications - Inverter System ............................................................................................................................................................ 38

Table 11 Troubleshooting - Alarm Conditions ..................................................................................................................................................... 60

Table 12 Troubleshooting - Corrective Actions ................................................................................................................................................... 61


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Foreword This manual is intended to help the user of the 827E to install, test, troubleshoot, and understand the system. If you have any questions or problems, please contact one of the following sources:

SERVICE If for any reason further assistance is needed on any power equipment, complete engineering and field service groups are available in Galion, Ohio, to assist you in any way possible.

CALL: 1-877-546-3243, Option 2

PARTS ORDERING Replacement parts for power equipment may be obtained by forwarding a Purchase Order to:

GE OR Fax to: 419.468.9780 1376 State Route 598 Galion, Ohio 44833

Include the following information:

A. GE part number and engineering level of equipment

B. If part is electrical, give circuit reference numbers and GE part numbers.

C. If part is mechanical in nature, give description as to where it is used.

RETURN & REPAIR - Equipment may be returned to the Factory for repair. In order to do this, the procedure must be as follows:

A. Call: +1 972 244 WATT (9288) or toll-free at 888-LINEAGE (546-3243)

B. Request a Returned Material Authorization (RMA) number for the defective equipment.

C. Return material prepaid to:

GE

1376 State Route 598

Galion, Ohio 44833

Attn: RS & R Dept


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Product Information Please take a moment when the product is new to fill in this information. This data will allow faster service when calling GE to order accessories, spare parts, or request field service.

First, locate the product information label. This is typically located on the upper front of the equipment frame, or on the rear of the frame. Fill in the part number, as it appears on the label, in the space below.

PART NUMBER

SERIAL NUMBER

DATE CODE


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Product Description The 827E Inverter System (inverter system) provides AC power output from DC power input. Inverters (inverter modules) work in parallel supporting redundancy (N + 1 or N + X). This enables the system to supply uninterrupted AC power in the event that an inverter fails.

Summary

• 120 Vac and 240 Vac systems • Line to Neutral systems • Inverter Systems

• Single Shelf Inverter Systems to 7.2 kVA 19”, 23”, 25”, and 26” rack compatible

• Frame Inverter Systems to 28.8 kVA • Expandable by Inverter and Shelf addition • Hot Insertion Inverters • AC Output Distribution Panels - Option • Maintenance Bypass Panel - Option


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System Configurations

Inverter systems are available as single shelf systems or frame systems.

Single shelf systems provide basic inverter system features and mount in an existing frame.

Frame Systems (−48 Vdc input only) provide up to four inverter shelves and optional Maintenance Bypass Panel and AC Distribution Panels factory assembled in a 23” frame (rack).

Table 1 System Configurations

Single Shelf Systems - typical1 Mounting Inverter Input Output Capacity2

19” 23” Positions −48 Vdc +24 Vdc N+1 (full)

• 4 • 120 Vac 30A 3.6 kVA (40A 4.8 kVA)

• 4 • 240 Vac 15A 3.6 kVA (20A 4.8 kVA)

• 4 • 120 Vac 15A 1.8 kVA (20A 2.4 kVA)

• 6 • 120 Vac 50A 6.0 kVA (60A 7.2 kVA)

• 6 • 240 Vac 25A 6.0 kVA (30A 7.2 kVA)

• 6 • 120 Vac 25A 3.0 kVA (30A 3.6 kVA)

Frame Systems - −48 Vdc Input, 23” Only - typical1

Inverter Shelves

Inverter Positions

Output Capacity2

120 Vac System N+1 (full) Output Capacity2

240 Vac System N+1 (full)

1 6 50A 6.0 kVA (60A 7.2 kVA)

25A 6.0 kVA (30A 7.2 kVA)

2 12 110A 13.2 kVA (120A 14.4 kVA)

55A 13.2 kVA (60A 14.4 kVA)

3 18 170A 20.4 kVA (180A 21.6 kVA)

85A 20.4 kVA (90A 21.6 kVA)

4 24 230A 27.6 kVA (240A 28.8 kVA)

115A 27.6 kVA (120A 28.8 kVA)

Inverters

Inverters are microprocessor controlled and have no adjustments. Each inverter can be inserted or removed from an energized shelf without shutting down the system (hot swappable).

The inverter system includes several alarm indicators, located on the individual inverters, the System Controller, and the Distribution Disconnect Module. Refer to the Features Reference section for a detailed description of all alarms.

Inverter Input Output Capacity SI10A120PME J438827E L11 −48 Vdc 120 Vac 10A 1.2 kVA SI5A240PME J438827E L17 −48 Vdc 240 Vac 5A 1.2 kVA SI5A120PME J438827E L14 +24 Vdc 120 Vac 5A 0.6 kVA

1 See the Ordering Guide for available configurations. 2 N+1 output: a system fully populated with inverters where the output of a single redundant inverter is not included.

full output: a system fully populated with inverters where the output all inverters is included.


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Shelves

Each shelf must include a System Controller, a Distribution Disconnect Module (DDM), and at least one Inverter.

Shelves are available for 120 Vac and 240 Vac. Shelves and inverters are keyed. 120 Vac inverters will only fully insert into 120 Vac shelves. 240 Vac inverters will only fully insert into 120 Vac shelves.

Input to each inverter position is wired separately via individual DC input lugs. Only the positions in the shelf being utilized need to be wired by installers. Refer to T-439827E at the included with this manual. For more information, refer to the DC Input section.

Shelf – with Controller and DDM Input Mounting Output Capacity (maximum N+1)3 657827E-23 J438827E L3 −48 Vdc 23” 120 Vac 10A 1.2 kVA 657827E-3 J438827E L4 −48 Vdc 19” 120 Vac 10A 1.2 kVA 150026249 J438827E L3A −48 Vdc 23” 240 Vac 5A 1.2 kVA 150026250 J438827E L4A −48 Vdc 19” 240 Vac 5A 1.2 kVA 657827E-2324 J438827E L9 +24 Vdc 23” 120 Vac 5A 0.6 kVA 657827E-1924 J438827E L8 +24 Vdc 19” 120 Vac 5A 0.6 kVA

System Controller

The System Controller, located in the far left slot of each inverter shelf, allows the user to monitor real-time system operation such as plant voltage and plant current, and also allows system setpoints for parameters, such as alarm thresholds, to quickly be changed with the touch of a few buttons. Real-time readings may be viewed for both; the system and each individual inverter.

System Controllers in each shelf are independent.

Refer to the System Controller segment in the Features Reference section.

Distribution Disconnect Module (DDM)

The Distribution Disconnect Module (DDM), located to the right of the System Controller, provides an AC disconnect and shelf distribution monitoring via the Distribution Monitor (DM). The AC disconnect is a circuit breaker that provides overload protection and fault isolation. The DDM works with the System Controller to monitor shelf operation.

Maintenance Bypass Panel (MBP)

A maintenance bypass panel is optional for the 827E. Refer to the J-Drawing (J438827E L51 and L52). The main purpose of the MBP is to allow an AC load to be switched from its primary source (827E Inverter Plant) to an alternate source (AC Line) and back to the primary source (827E Inverter Plant) again. This may be required, for example, when doing maintenance or upgrades to the Inverter Plant.

L51 and L52 MBPs provide mechanical bypass via contactors.

The MBP includes alarm aggregation of alarm signals from 1 to 4 shelves. The MBP provides integrated alarm signals from a multi-shelf, frame system by combining alarm signals from individual shelf System Controllers.

3 N+1 output: a shelf fully populated with inverters where the output of a single redundant inverter is not included.


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Figure 1 19-inch and 23-inch Systems and Shelves

System Controller Module

Distribution Disconnect Inverters Module

a. 19-Inch System

b. 23-Inch System

SC00 DM15 01 02 03 04 05 06

Module Designations


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Figure 2 Modules Front View

Inverter System

Controller

Distribution

Disconnect

Module

LCD Display

Control Buttons LEDs

Serial Port

Handle

Retaining Screw

LED

Distribution

Monitor

AC Load Disconnect Breaker

100A

Fans

Modem Option

827E

SYSTEM INTERFACE


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Figure 3 120 Vac & 240 Vac Module Identification

240 Vac 120 Vac

Inverter Inverter


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Figure 4 Side Views of a System (Shelf)

Alarm Relay

Output

Connector

AC Opening

Left Side View

DC Opening for

1 1/2" conduit

Product Information: part number, serial number, revision level, voltages, etc.

Right Side View

Connector Pin-Out


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Installation Equipment Included In Shipment

Included in a shipment of an 827E inverter system are an inverter shelf or shelves (each equipped with a System Controller and a Distribution Disconnect Module) and inverters and/or blank panels - quantities as specified on the inverter system order.

CAUTION: Loads and Inverters may be damaged if their AC voltages are not matched. Shelves and Inverters are available for both 120 Vac and 240 Vac applications.

CAUTION: Inverters may be damaged or may not function properly with improper DC input voltage. Shelves and Inverters are available for both −48 Vdc and +24 Vdc applications.

Verify equipment received before installing the inverter system

• Verify product received matches the order

• Verify the correct inverter input voltage and output voltage

• Verify the correct shelf / system input voltage and output voltage

Contact GE immediately if there is a question about the configuration of the system.

Tools and Test Equipment Required

The tools necessary to install and test the inverter system include items such as a typical Phillips head screwdriver, torque wrenches, a ratcheting wrench set, wire cutters, a calibrated digital multi-meter, wire crimp tool and die set, etc. No unusual tools are required.

CAUTION: Read this manual thoroughly before attempting to connect, operate, or service an inverter system. Pay particular attention to these sections:

• Safety

• Considerations for Multiple-Shelf Systems


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Mechanical Installation

General This section details all of the information that is necessary to mechanically install the system. Complete mechanical installation before any electrical connections are made to the system. The inverter system may be rack or pedestal mounted.

Shelf Mounting Refer To Figure 5.

NOTE: The DC power plant supplying input circuits to the inverter system must be wired as stated in Telcordia document GR-1089-CORE, section 9.8.3, Isolated DC return technique. The power plant must have a dedicated grounding conductor from the power plant common DC return bus to the Central Office Ground Bar.

This dedicated grounding conductor must not be bonded to or used as the frame ground cable. A separate connection to the Central Office Ground System must be used for frame grounding purposes.

NOTE: List 8 system comes equipped with an adaptor plate for 19” to 23” mounting.

NOTE: Optional 25” and 26” mounting kits are available for 23” shelves - J438827E List 5 and List 6 respectively. Refer to Figure 5 for mounting dimensions.

Once the system has been removed from the shipping container:

• Verify that the input DC voltage matches the shelves and inverters: +24 Vdc (+27 Vdc nominal) or −48 Vdc (−54 Vdc nominal).

• Verify that AC voltage matches across inverters, shelves, and loads. • Install the system as follows:

1. Move the mounting brackets as required

2. Ensure there is proper clearance in the rack or shelf to install the system.

3. Put the system into position and secure with the screws located at each outside corner (four screws total).

4. Repeat steps 1 thru 3 for additional shelves, as required. • Verify the input source.


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Figure 5 Mounting - 23”, 25”, and 26”

a. Mounting (typical 23-inch shelf shown)

The height between mounting holes for a 19-inch shelf is the same, however the width between holes is 18.31")

b. Optional 25” Mounting Brackets (Refer to List 5 in 438827E)

c. Optional 26” Mounting Brackets (Refer to List 6 in 438827E)


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Electrical Connections

General This section details all of the electrical connections involved when installing the inverter system. Complete all mechanical installation instructions (refer to the Mechanical Installation section) before making any electrical connections.

Figure 6 and Figure 7 are basic wiring diagrams showing typical connections with and without the maintenance bypass panel. Refer to the T-Drawing (438827ET) for complete details.

Figure 6 AC Wiring - without Maintenance Bypass Panel

Grounding Electrode Conductor (GEC) Connection First shelf only

GEC Neutral Strap First shelf only

Grounding Electrode Conductor (GEC)


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Figure 7 AC Wiring - with Maintenance Bypass Panel

DC Input Refer to Figure 9.

Note: Each input must be fed by a customer supplied 40 amp circuit breaker. Be sure that all power is turned off before any installation steps are performed.

1. Turn OFF all DC feed circuit breakers (customer supplied, 40A minimum per fully loaded module is required).

2. Refer to Table 2 for recommended wire and terminal sizes for DC connections.

3. Remove rear cover.

4. Remove a conduit knockout from the left side of the plant (as facing the rear of plant) (one is on the back of the plant, one is on the left, and one is on the bottom). A 2” access hole is provided. Size and install conduit (not included) for the input wiring in accordance with local code. The bushing for the opening is included in a bag attached to the system.

5. Attach +BAT cables to +BAT Terminal on individual inverter backplanes via a 1/4" on 5/8” two-hole lug (one connection per module). Refer to Figure 8 and Figure 9 for +BAT input location. Refer to Table 2 for more details.

6. Attach −BAT cables to −BAT Terminals on individual inverter backplanes via a 1/4" on 5/8” two-hole lug (one connection per module). Refer to Figure 8 and Figure 9 for −BAT input location. Refer to Table 2 for more details.

7. When the 827E is installed using the maintenance bypass switch and NOT as a Separately Derived System the GEC Neutral Bond Strap as depicted in Figure 12 must be removed. Refer to NEC Article 100 for definition of a Separately Derived system. This assumes that the utility neutral connection is bonded to ground. See the Grounding Electrode Conductor Connections section and Figure 12.


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Table 2 wire and terminals for Individual DC inputs (+BAT and −BAT)

Shelf Connection Terminal Type4 Recommended Wire Size

all −BAT & +BAT 1/4" on 5/8” two-hole lug 8 AWG per connection

Figure 8 Shelf Rear View

Figure 9 DC Input Connections

+BAT −BAT

+24 Vdc Input System +24 Vdc Ground

−48 Vdc Input System Ground −48 Vdc

4 Lugs not provided.

−BAT

+BAT


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AC Output Refer to Figure 10.

1. Rear cover should already be removed from installing the DC input.

2. Make sure AC Load Disconnect Breaker is "OFF" (located on the Distribution Disconnect Module).

3. Remove a conduit knockout from the right side of the plant (as facing the rear of the plant) (there are two openings; one on the back right and one on the bottom right). If wiring to an MBS or AC distribution panel, use the wire-way.

4. Refer to Table 3 for recommended wire and terminal sizes for connecting the AC outputs.

5. Connect the AC outputs via the terminal block located near the bottom right corner on the rear of the system.

Table 3 Recommended Wire and Terminals for AC Output

Terminal Amperage

or Stud Size

Terminal Type Recommended Wire Size

Over Current Protection (Located

in Distribution Monitor)

Conduit

Size

1/4" Screw Terminal

(Term Block rated for 85 amps)

Compression 6 AWG 100A CB for 19-inch system or 100A CB for

23-inch system

1"

6. Replace rear cover.

Figure 10 AC Output Connections

The modular nature of the system allows individual inverters to work in parallel (load share). By calculating the actual load and adding 1 additional inverter the system will be configured for “N+1” redundancy, adding a second would be N+2, etc. When configured in this fashion, if an inverter fails, the system will not go into current limit. It will seamlessly continue to supply the needed power.

Example with 10 Aac Inverters:

Power output needed = 100 amps = 10 x –48 Vdc 10 Aac inverters N = 10

N + 1 = 11 Install 11 x –48 Vdc 10A inverters for N+1 redundancy.

Example with 5 Aac Inverters:

Power output needed = 25 amps = 5 x +24 Vdc 5 Aac inverters N = 5

N + 1 = 6 Install 6 x +24 Vdc 5 Aac inverters.

AC Output Terminal Block

Conduit Openings for AC Output


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NOTE: The LINE and NEUTRAL of all shelves in a multiple-shelf system must be connected together in an AC distribution panel or optional maintenance bypass panel (refer to J-Drawing 438827E List number 51 and 52).

NOTE: The inverter’s output protection will shutdown the inverter output after 5 seconds under short circuit or deep overload conditions. Therefore, the response time of the breaker must allow the breaker to trip within (4) seconds with a short circuit current of 28A per inverter. Both the circuit breaker rating and number of inverters equipped in the system must be taken into account to insure that the circuit breaker trips in the desired timeframe. If faster response times are desired, e.g. below the AC holdup time of the AC equipment, then the trip time must be decreased by lowering trip rating of the breaker, and/or increasing the number of modules equipping the system.

Table 4 shows typical trip times of commercially available AC distribution circuit breakers. The table lists “min-max” trip times based on most common circuit breaker ratings vs. number of equipped −48 V inverters in the system. The maximum rating must be used to guarantee tripping within a specific time. For special situations where commercial AC breakers do not meet the required trip times, contact technical support for other options.

Table 4 Typical Trip Ratings for 10 – 30 Amp AC Circuit Breakers

Based on Square-D, QO Series

30 A

Trip

Tim

e (m

sec.

) Max

2000

0*

9000

*

5500

*

4000

2800

2250

1700

1300

1200

1000

800

700

600

550

500

450

400

375

350

325

300

275

* Ci

rcui

t bre

aker

ratin

g no

t rec

omm

ende

d fo

r thi

s nu

mbe

r of i

nver

ters

equ

ippe

d

Min

4500

*

2250

*

1300

*

1000

600

475

300

200 5 5 5 5 5 5 5 5 5 5 5 5 5 5

25 A

Trip

Tim

e (m

sec.

) Max

7000

*

3700

2500

1800

1300

1000

850

700

600

500

450

425

375

350

300

275

250

225

215

200

175

150

Min

1700

*

900

600

400

250

60

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

20 A

Trip

Tim

e (m

sec.

) Max

5000

*

2800

1600

900

600

400

18.0

0

17.0

0

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

Min

1250

*

400 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

15 A

Trip

Tim

e (m

sec.

) Max

3000

1600

1100

800

600

300

20.0

0

18.0

0

17.5

0

17.0

0

16.7

5

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

Min

700 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

10 A

Trip

Tim

e (m

sec.

) Max

2000

1300

800

700

450

300

18.0

0

17.5

0

17.0

0

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

16.6

7

Min

400 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

Avai

l. Tr

ip

Curr

ent (

A)

84

112

140

168

196

224

252

280

308

336

364

392

420

448

476

504

532

560

588

616

644

672

Num

ber

of −

48 V

In

vert

ers

3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

22

23

24


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Figure 11 Common Trip Ratings for 10 – 30 Amp Range

Grounding Electrode Conductor Connections - GEC A Grounding Electrode Conductor (GEC) bonded to the neutral is required where an AC source is originated (a separately derived source). This provides a continuous AC fault clearing path to ground. This is not an equipment ground.

Associated terminology: AC Equipment Ground Conductor (ACEG) or continuous “Green wire ground”

Determining connections for your configuration: There are several contributing documents to consider when bonding a GEC to the 827E converter system: Customer specific standards, state and local codes, and Article 250 from the NEC are primary sources. Customer specific installation publications may also address differences in inverter installations in Isolated Ground Plane and Integrated Ground Plane environments. There are various technical publications including Telcordia documents TR-NWT-000295, GR-1089-Core and GR-1502-CORE that are also frequently consulted for Central Office application installations in both ground planes.

Separately Derived System: NEC, Article 100 defines a separately derived system as follows: “A premises wiring system whose power is derived from a battery, from a solar photovoltaic system, or from a generator, transformer, or converter windings, and has no direct electrical connection, including a solidly connected grounded circuit conductor, to supply energy from the serving utility to the wiring system of the premises served”.

Inverter systems without Maintenance Bypass Switches are separately derived systems. Inverter systems with Maintenance Bypass Switches are not separately derived systems.

Customer specific technical publications may also include a section defining similar systems that vary slightly. Generally, these publications do not differ significantly. However, customer specific installation publications and state and local codes can take precedence.

Note Customer specific standards for installations in the isolated ground plane can vary greatly from customer to customer. These standards must be researched completely prior to installation start.

This manual addresses the most common installations in an integrated ground plane.

Figure 6 depicts typical wiring for the inverter system wired as a separately derived system without the maintenance bypass switch (MBS).

Figure 7 depicts typical wiring for the inverter system wired using the MBS, not as a separately derived system.


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Note AC neutral and AG Ground extend continuously through the circuit from the source to the load in both Figure 6 and Figure 7.

Note Other wiring configurations can be employed without effecting the system warrantee as long as the chosen configurations does not directly violate any NEC or state and local code requirements.

Equipment Ground cable sizing: Equipment grounding conductor size must be based on the recommendations of the NEC Article 250-94 for copper wire. State and local codes or customer specific requirements can take precedence.

GEC cable sizing: Table 5 is derived from National Electric Code (NEC) Article 250-95 for proper cable sizing requirements for externally run cables. State and local codes or customer specific requirements can take precedence.

Table 5 Grounding Electrode Conductor Connections - GEC


1/4"on 5/8” two-hole lug 6 AWG. or as required

see note above

Figure 12 Grounding Electrode Conductor (GEC) Connections

Alarm Connections All internal system alarms are connected at the factory and report to the System Controller. Relays are available if the alarms need to be extended to the office monitoring equipment. A DB25 female connector is supplied for this purpose. It is located on the left side of the system when viewed from the front (Refer to Figure 13). Connector pin out, wire color, and contact functionality is given in Table 6. Pin-out is also displayed next to the connector on the system.

Alarm output cabling is available as an option. Order Part Number 6370213P-X, where X is the length of the cable; see the J-drawing.

Note: In accordance with safety agency approval of this product, when connecting the plant alarm interface, do not exceed NEC CLASS II for connections.

Ground Electrode (GEC) Connection Studs

GEC Neutral Bond Strap


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Table 6 Alarm Outputs


DB25 female (gold) 22 GA

Pin Type5 Description Wire Color6 Function Connection to Combine

Signals7

13 MAJ NC (K1, relay 1) Black/Orange Close on Alarm Parallel

25 MAJ COM (K1, relay 1) Orange/Black Common K1-1

12 MAJ NO (K1, relay 1) Black/Blue Open on Alarm Series

23 MAJ NC (K1, relay 2) Slate/Red Close on Alarm Parallel

11 MAJ COM (K1, relay 2) Red/Slate Common K1-2

24 MAJ NO (K1, relay 2) Blue/Black Open on Alarm Series

10 MIN NC (K2, relay 1) Red/Brown Open on Alarm Series

22 MIN COM (K2, relay 1) Brown/Red Common K2-1

9 MIN NO (K2, relay 1) Red/Green Close on Alarm Parallel

20 MIN NC (K2, relay 2) Orange/Red Open on Alarm Series

8 MIN COM (K2, relay 2) Red/Orange Common K2-2

21 MIN NO (K2, relay 2) Green/Red Close on Alarm Parallel

17 Plant Load NC (K3, relay 1) Brown/White Open on Alarm Series

5 Plant Load COM (K3, relay 1) White/Brown Common K3-1

18 Plant Load NO (K3, relay 1) Slate/White Closed on Alarm Parallel

7 Plant Load NC (K3, relay 2) Red/Blue Open on Alarm Series

19 Plant Load COM (K3, relay 2) Blue/Red Common K3-2

6 Plant Load NO (K3, relay 2) White/Slate Closed on Alarm Parallel

14 K4B spare NC (K4, relay 1) Blue/White Open on Alarm Series

2 K4B spare COM (K4, relay 1) White/Blue Common K4-1

15 K4B spare NO (K4, relay 1) Orange/White Closed on Alarm Parallel

4 K4C spare NC (K4, relay 2) White/Green Open on Alarm Series

16 K4C spare COM (K4, relay 2) Green/White Common K4-2

3 K4C spare NO (K4, relay 2) White/Orange Closed on Alarm Parallel

Note: MAJ alarm relay (K1) coil is DE-ENERGIZED on alarm. All other alarm relay coils are ENERGIZED on alarm. Therefore, when the controller is unpowered, MAJ is asserted and all other alarms are not asserted.

5 MAJ = Plant Major, MIN = Plant Minor 6 Alarm Cables J438827E L25 – L32 7 When combining signals of multiple shelf systems, wire

Open on Alarm signals in series and Close on Alarm signals in parallel.


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Figure 13 Alarm Outputs

Alarm Connections - Multiple Shelf Systems

Each shelf is equipped with a DB-25 connector for its alarm outputs. These alarm outputs may be independently utilized or the alarm outputs of more than one shelf may be combined. Refer to Table 6.

Optional Maintenance Bypass Panel includes connections and circuitry to aggregate alarm signals from multiple shelves.

Expansion of multiple minor alarms to create a major alarm is not possible through simple wiring and will require a separate alarm-centralization module. Contact service if this is desired.

Communication Connections A. Serial Interface: A 9-pin serial interface is provided on the front panel that allows connection to the serial port

on a PC. Communication to the System controller is then through the Envision software.

NOTE: Connection to a PC requires a PC data transfer (null) cable. This serial interface complies with the PC/AT standard. Recommended Interface Cables are:

GE: P/N 6370189P-1 (This cable is included with kit 6820014P).

Radio Shack: P/N 26-152, 9-pin Female to 9-pin Female Cable used with P/N 26-264, 9-pin Null adapter

Staples: P/N F3x171-10 (Belkin) Serial Data Cable

If a cable cannot be obtained from one of the above sources, it may be fabricated. A pin out of the Serial interface pin out and recommended wire size are shown in Figure 14 and Table 7.

DB25 Alarm Output Connector


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Table 7 Inverter Shelf Interface Cable Connection

Terminal Capacity Terminal Type Recommended Wire Size

20 GA Maximum DB9 Male (gold) 22 GA

PIN FUNCTION I/O DESCRIPTION

1 DCD I Carrier Detect (Unused)

2 RXD I Receive Data

3 TXD O Transmit Data

4 DTR O Data Terminal Ready (Unused)

5 GND - System Ground

6 DSR I Data Set Ready (Unused)

7 RTS O Request to Send

8 CTS I Clear to Send (Unused)

9 RI I Ring Indicator (Unused)

Figure 14 DB9 Pin-out

B. Telephone/Modem Connection: A standard RJ-11 modular phone jack is mounted on the front panel of the System controller. Installation of the modem is optional. If the modem is equipped and a phone line is connected, the Envision Software (827 MODBUS) may be used to remotely access the shelf. Each System Controller must be modem equipped to provide remote access in multi-shelf systems.

1 5

6 9


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Inverter - Install / Remove The inverter system is modular in design, which allows components to be easily removed or installed while the system is operating without interrupting power delivered to the load.

Install Inverter (Refer to Figure 15:

1. When adding a new inverter, remove the blank panel where the new inverter will be inserted, and set it aside.

2. Firmly insert the inverter into the shelf.

3. Push firmly on the front of the module until it is against the face of the shelf.

4. Secure the module to the shelf with the retaining screw.

5. Each of the LEDs on the inverter will briefly cycle ON then OFF followed by a solid ON state of the amber “Standby” LED for several seconds. Next the Standby LED will turn OFF followed by the green “OK” LED turning ON. There should be no Alarms on the System controller.

Figure 15 Inverter Install / Remove

Remove Inverter (Refer to Figure 15):

1. Loosen the retaining screw.

2. Remove the module from the shelf.

3. If returning the inverter to the shop or GE for repair, place the module in an ESD bag, then in a small box to protect the module during shipping and handling.

4. Install a blank panel or proceed to Install Inverter step 3 for installation of a new inverter. Inverter positions must not be unoccupied to avoid hazardous voltage exposure.

Note: Do not reinsert the module until all front panel LEDs have gone dark.

Pull to remove / install module

Loosen/tighten retaining screw


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System Controller - Install / Remove The System Controller may be removed or installed while the system is operating without interrupting power delivered to the load.

Install System Controller (Refer to Figure 16):

1. Insert the System Controller into the leftmost shelf position.

2. Push lightly on the front of the module until it is against face of the shelf.

3. Tighten retaining screw.

4. When installation is complete, the controller will reinitialize as described in steps 6, 7, and 8 of the Operational Checkout Routine found in the Shelf Turn On and Operational Checkout section.

Figure 16 System controller Removal/Installation

Remove System Controller (Refer to Figure 16:

1. Loosen retaining screw.

2. Slowly remove System Controller module from the shelf until it is ¾ of the way out.

3. Protect System Controller with static sensitive protective material.

Note: Removing the controller will not interrupt the operation of the system.

Pull to remove / install module

Loosen/tighten retaining screw


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Modem - Install / Remove Install Modem (Refer to Figure 17):

1. Remove the System Controller from the shelf per the System Controller - Install / Remove section.

2. Insert the modem into position and push lightly until the modem is completely plugged into position. Refer to Figure 17.

Figure 17 Modem Installation

3. With the modem inserted into position, secure with the screws provided to complete the installation.

4. Replace the System Controller by following the instructions in the System Controller - Install / Remove section.

Modem plugs into this connector.

a. Location of Modem Connector

b. Location of Modem Pins to Plug into System Controller

c. Location of Modem Installed into the System Controller


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Remove Modem (Refer to Figure 17):

1. Remove the System Controller from the shelf per the System Controller - Install / Remove section.

2. Remove the modem: pull gently until the modem is removed. Refer to Figure 17.

3. Replace the System Controller by following the instructions in the System Controller - Install / Remove section.

Distribution Monitor - Install / Remove The distribution monitor (DM) may be removed / installed while the system is operating without interrupting power delivered to the load as long as CB1 is ON. The INVERTER MAJOR alarm will be asserted (MAJ alarm signals and INVERTER MAJOR LED).

Install Distribution Monitor (Refer to Figure 18):

1. Insert the distribution monitor into Distribution Disconnect Module, using the formed handle.

2. Secure the distribution monitor screws located at the top and bottom of the DM front panel (2 screws total).

3. Shortly after installation, the green OK LED on the distribution monitor will illuminate. Within 60 seconds, the System Controller will automatically perform a system update to recognize the new distribution monitor and the inverter major alarm will retire.

4. When installation is complete, the controller will reinitialize as described in steps 6, 7 and 8 of the Operational Checkout Routine found in the Shelf Turn On and Operational Checkout section.

Figure 18 Distribution Monitor/Distribution Disconnect Module Removal and Installation

Remove Distribution Monitor (Refer to Figure 18):

1. Loosen the screws located at the top and bottom of the distribution monitor front panel (2 screws total). Do not loosen the module retaining screw.

2. Grasp distribution monitor by the formed handle and pull it out.

3. Protect distribution monitor within an ESD bag.

Loosen/tighten screws for removal/installation of Distribution Monitor

CB1

Formed handle

Module removal handle

Module retaining screw


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Distribution Disconnect Module - Install / Remove The Distribution Disconnect Module (DDM) may be removed / installed while the system is DC powered, as long as CB1 is OFF. When CB1 is OFF the system does not power AC output, an INVERTER MAJOR Alarm is indicated on the System Controller and the STANDBY LEDs of all inverters of the shelf will be lit.

NOTE: Equipment powered by the system will not receive AC power from the system when CB1 is OFF or the Distribution Disconnect Module has been removed.

NOTE: With the distribution monitor still plugged in, wait until all inverters go into Standby (STANDBY LED lit on all inverters) before removing the module.

Install Distribution Disconnect Module (Refer to Figure 18):

1. With CB1 in the OFF (down) position, insert the new Distribution Disconnect Module.

2. Gently slide the new module into the shelf until it is flush with the rest of the modules.

3. Assure the STANDBY LEDs are lit on all inverters of the shelf.

CAUTION: Do not turn CB1 to ON unless all inverters of the shelf are in STANDBY.

4. Place CB1 in the ON (up) position. The green OK LED on the Distribution Monitor will light. The System Controller will update (this may take a minute or so), the red INVERTER MAJOR LED will extinguish and the individual inverters will come on-line with their green OK LEDs illuminating.

5. Tighten the Phillips head module retaining screw located at the bottom of the module.

6. After replacement of any module, refer to the Shelf Turn On and Operational Checkout section to verify proper operation by performing the initial turn on procedure.

7. Operate the Maintenance Bypass Switch to the Inverter position if equipped.

Removal Distribution Disconnect Module (Refer to Figure 18):

1. Operate the Maintenance Bypass Switch to the Utility position if equipped.

2. Place CB1 in the OFF (down) position

3. Loosen the module retaining screw located at the bottom of the module.

4. Grasp the module removal handle and slowly remove the Distribution Disconnect Module from the shelf.

5. Protect module in an ESD bag.

6. Assure the STANDBY LEDs are lit on all inverters of the shelf.


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Initial Turn On, Setpoints, and Adjustments

Shelf Turn On and Operational Checkout Complete operational checkout prior to applying loads after initial installation of the plant, after the addition of a shelf, and after maintenance requiring power-down. If a plant fault has been identified refer to the Troubleshooting section.

NOTE: Proceed only after: the plant is installed, input power is available, outputs are tied to the AC distribution panel or loads, and all other plant interface connections have been made.

CAUTION: Multi-Shelf Systems Only

• Damage to inverters may occur if a shelf does not have a functioning System Controller or if an improper power-up sequence is followed.

• Never close a shelf CB1 when the shelf is DC powered unless there is a functioning System Controller in the shelf and the shelf’s inverters are indicating STANBY mode (amber LEDs ON).

Note: Complete steps 1-10 (setup all shelves) before closing CB1 on any shelf.

1. Ensure CB1 is OFF on all Distribution Disconnect Modules.

2. Check power wiring for errors. Measure inputs and outputs to GND for shorts.

3. Apply power to the DC inputs of all shelves.

4. All inverter STANDBY LEDs – ON. LEDs briefly cycle ON then OFF as the inverters initialize.

5. Verify that

i. System Controllers: INVERTER MAJOR LED - ON

ii. Distribution Monitors: OK LED - OFF

iii. Each Inverter: STANDBY LED - ON

6. Wait for System Update to complete. During this period the red FAIL LED on each inverter will flash until it is communicating with the System Controller and the controller displays indicates:

SYSTEM UPDATE

IN PROGRESS.........

7. Once all inverters are communicating with the System Controller the following screen will appear, provided there are no alarm conditions (in place of the "X" will be the users actual voltage and current readings):

XXX VAC X AAC

SYSTEM - GOOD s

8. The current status of the system should be as follows:

i. System Controllers:

1. CONTROLLER LED – ON green

2. INVERTER MAJOR LED – ON red

ii. Inverters:

3. STANDBY LED – ON

9. For each shelf in turn, set the SHELF # setpoint to a unique number between 1 and 4. The shelf designated as “1” becomes the primary shelf.

Refer to the Display Navigation and Push Buttons section and to Setpoints in the Display Menus section.


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NOTE: In the following steps, closing a CB1 circuit breakers (up position) will energize the loads connected to the plant, further, in multiple-shelf systems the AC output from any shelf will feed back to the AC output terminal blocks on all shelves.

CAUTION: In a multiple shelf system, never close a shelf CB1 when the shelf is DC powered unless there is a functioning System Controller in the shelf and the shelf’s inverters are indicating STANBY mode (amber LEDs ON).

10. Assure that all inverters on all shelves are indicating standby mode - all STANDBY LEDs - ON.

11. Turn ON CB1 circuit breakers of all shelves.

12. Observe the Controller goes through the System Update process for all the modules on its shelf and the inverter OK LEDs all turn ON.

13. Observe that

• Each Inverter green OK LEDs is ON

• Each Distribution Module green OK LEDs are ON,

• Each System Controller red INVERTER MAJOR LED is OFF, and

• Each System Controller green LED is ON.

14. If no alarms are present, the displays will appear as follows:

XXX VAC X AAC

SYSTEM - GOOD s

15. The system displays will appear as follows if there are any alarm conditions:

120 VAC X AAC

SYSTEM - ALARM s

16. Pressing the SEL key will take the user to the main menu displayed as follows. From the main menu, the user can review the plant status or make system changes.

PLANT ALM BATT

SETPT INV s

17. The active selection will be flashing. The user can press SEL to select the active selection, or may scroll to the next selection by the use of the arrow keys. Pressing the BACK key will take the user back to the System Status Screen. Refer to Display Navigation and Push Buttons and Display Menus sections.


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Adjusting Setpoints Refer to the Display Navigation and Push Buttons section and to Setpoints in the Display Menus section.

TABLE 7: Factory Setpoint Defaults

Inverter

120 Vac 240 Vac

−48 Vdc +24 Vdc −48 Vdc

Inverter Max RMS I 12.5 6.0 5.0 Aac

Inverter Max Peak I 28.0 14.0 14.0 Aac

Inverter Hi Crest Factor 0.00 0.00 0.00

Plant Low Voltage 95 95 190 Vac

Plant Hi Voltage 130 130 250 Vac

Battery Low Voltage -44.0 22.0 -44.0 Vdc

# of Inverters8 As Equipped As Equipped As Equipped

Shelf # 1 1 1

% of capacity 80 80 80 %

Navigate to the Main Menu on the System Controller by pressing SEL from the System Status Screen. The Main Screen will appear as follows:

PLANT ALM BATT

SETPT INV s

Press the right arrow key until SETPT is flashing. Then press the SEL button.

Once SETPT is selected from the main menu, the following menu appears:

SETPOINTS

s

Pressing SEL at any time during an active screen will allow that setpoint to be adjusted and the arrow keys will adjust the value.

Pressing SEL again will prompt the user whether or not they would like to CANCEL or ACCEPT the change. The active choice will be flashing and can be changed by the use of the arrow key. Pressing SEL at this time will either ACCEPT or CANCEL the setpoint change. Failure to do anything within 15 seconds will result in the system defaulting to the previous setpoint.

When viewing the screens, there will be a letter combination or a number located on the left side of the display. These represent the following:

a. GL - Global (setpoints that affect multiple modules of the same type)

b. 00-System Control

c. 15- Distribution Monitor

d. 1 thru 6-Inverters

The following are the screens that are available from the SETPT menu: 8 The "number of Inverters" setpoint is dynamically updated by the System Controller approximately every minute.


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INV MAX RMS I

GL 10.0 Aac s

PLANT HI VOLTS

15 130 Vac s

INV MAX PEAK I

GL 28.0 Aac s

BATTERY LO VOLT

15 44.0 Vdc s

INV HI CR FACT

GL 2.80 s

# INVERTERS

15 1 (As Shipped)

SHELF # (1 – 4)

GL 1 s

# REDUNDAND IMs

15 1 s

PLANT LO VOLTS

15 100 Vac s

% OF CAPACITY

15 80 % s

When making adjustments, attempting to set the PLANT HI VOLTS setpoint below the PLANT LOW VOLT setpoint will cause an error condition.

Table 8 Setpoint Resolution

NAME DECIMAL PLACES

RESOLUTION UNITS

Output True Power 0 10 W

INV MAX RMS I

(Output Eff. Current)

1 0.10 Aac

INV MAX PEAK I

(Output p-p Current)

1 0.20 Aac

INV HI CR FACT

(Crest Factor)

2 (0.039 @ nominal load) None

Output Frequency 1 Period + / - 39µ S Hz

Inv Temp #1 0 1.0 °C

Inv Temp #2 0 1.0 °C

% OF CAPACITY 0 10 %

# REDUNDAND IMs

(# Redundant Inv)

0 1 None

9 Based on Irms and Ip resolution.


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Specifications Table 9 Specifications - Inverter

SI5A120PME series SI10A120PME series SI5A240PME series

+24 Vdc Input −48 Vdc Input −48 Vdc Input

Input (per module)

Input Voltage

Operate

Start-up

Typical

+21.0 to +32.0 Vdc

+24.5 Vdc minimum

+27.0 Vdc

-42.5 to −60.0 Vdc

−49.6 Vdc minimum

−54.0 Vdc

-42.5 to −60.0 Vdc

−49.6 Vdc minimum

−54.0 Vdc

Input Current 35.0 A maximum 35.0 A maximum 35.0 A maximum

Input Power 668 W maximum 1337 W maximum 1337 W maximum

Breaker (customer provided)

40 A minimum, per installed module



Output (per module)

Output Voltage10 120 Vac 120 Vac 240 Vac

Output Current 5 Aac maximum 10 Aac maximum 5 Aac maximum

Output VA 600 VA maximum 1200 VA maximum 1200 VA maximum

Total Harmonic Distortion (THD)

2 % maximum < 1% typical

Regulation11 5%

Environmental

Heat Release12 314 BTU/hr 778 BTU/hr 778 BTU/hr

Temperature 0 to +50 °C Full Load

Mechanical

Weight 6.5 lb

Cooling Front to rear forced air

10 Not adjustable, at No-load 11 Regulation = (No-load voltage - Full-load voltage) / Full-load voltage. 12 Heat Release - per inverter, full load, typical.

Special room cooling may be required.


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Table 10 Specifications - Inverter System

AC Configuration

Configuration Line to Neutral, Single Phase

Mechanical

Height (shelf) 8.72"

Depth (shelf) 15.03”

Width (shelf) Available for 19" or 23" Rack Mounting

Mounting Relay Rack or Cabinet

Inputs/Outputs

Input Voltage and Current per installed Inverters - See Table 9 Specifications - Inverter

Output Voltage per installed Inverters - See Table 9 Specifications - Inverter

Output kVA per shelf −48 Vdc 23” 7.2 kVA 19” 4.8 kVA

+24 Vdc 23” 3.6 kVA 19” 2.4 kVA

Alarm Contact Ratings 60 Vdc at 0.5A

Shelf Distribution Disconnect Module Output Protection

Circuit Breaker 100A single pole

Environmental

Acoustic Noise 45 dBA at 3 meters

Temperature Ambient

Operating

Storage

Sea Level to 4800 feet

0 to +45 °C continuous

-40 to +85 °C

Humidity <95% Non-condensing

Shock This equipment, in its shipping container, withstands shock developed during shipping without physical damage or degradation of the electrical performance.

Vibration This equipment, in its shipping container, withstands vibration encountered in shipping without physical damage or degradation of the electrical performance.

Installation Area

Installation Area Limitations

Install only in restricted access areas (dedicated equipment rooms, equipment closets, or the like) in accordance with articles 110-26, 110-27, and 110-18 of the U.S. National Electric Code (NEC-2011), ANSI/NFPA No. 70, and pursuant to applicable local codes.

Safety and Standards

Safety ETL Listed NEBS NEBS Level 3 Tested and Complaint

Electromagnetic Immunity Meets Telcordia GR-1089-CORE ISSUE 6 [IEC801-2 level 2,4,5

Radiated and Conducted Emissions

FCC Part 15, Class A

EN55022 (CISPR22), Class A

Radiated Emissions FCC Class A, EN55022 (CISPR22) level A

Electrostatic Discharge EN61000-4-2 Level 1-4


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Table 10 Specifications - Inverter System

RF Immunity IEC61000-4-3 Level 3, 10 V/m

Conducted Immunity IEC 61000-4-6 Level 3 Input Power Ports GR1089 ISSUE 6

IEC 61000-4-6 Level 2 Telecom Ports GR1089 ISSUE 6

Earthquake & Office Vibration NEBS Zone 4 level 3

Voltage Dips, Interruptions, and Variations

IEC 61000-4-11, EN55024 (CISPR24)

GR1089 Section 10: DC Power Port Telecommunication load equipment


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Features Reference The system comes with many unique features. These features are detailed in the following paragraphs.

Front Access: The system has been designed to allow the user total front access to all controls and indicators.

AC Output Distribution AC output from the inverters is a single terminal block per shelf.

Optional AC Distribution Panels provide load circuit breakers.

Optional Maintenance Bypass Panel provides a single AC input and output for multiple shelf systems by aggregating the AC connections of multiple shelves.

Inverter Inverters (Figure 2) provide regulated AC voltage to the load. In the event of a System Controller failure, the imbedded controls within the microprocessor-controlled inverter will allow the inverter to continue operation (fail safe operation).

Indicators on Inverter: Each inverter is equipped with the following indicators (multiple LEDs may be illuminated at the same time):

FAIL LED (red) indicates fault of the inverter or of communication with the System Controller.

ON indicates output failure due to an inverter internal fault. Internal faults include:

• Inverter output voltage exceeds the high voltage shutdown point.

• Over temperature.

• Any failure condition that disables the inverter output.

Flashing indicates minor failures that cause output failure. Minor faults include:

• Loss communications with the System Controller

• Internal high temperature

• Loss of frequency lock

• Software problem

• High peak current, high rms current, or high crest factor

STANDBY LED (amber) indicates that the inverter is in Standby. Standby is due to:

• The user or the System Controller has placed the inverter in standby mode

• The inverter has just been inserted into the shelf and has not yet synchronized with other operating inverters.

• CB1 on DDM is OFF or tripped and Auto-Standby is enabled.

OK LED (green) indicates that the inverter is operating normally and is capable of providing output power.

Distribution Disconnect Module (DDM) The Distribution Disconnect Module13 (Figure 2) provides an AC disconnect and shelf distribution monitoring via the Distribution Monitor (DM). The AC disconnect is a circuit breaker that provides overload protection and fault isolation. The DDM works with the System Controller to monitor shelf operation.

13 Distribution Disconnect Module, Distribution Monitor, and System Controller features refer to a single shelf. The

described features are duplicated and are independent of each other in each shelf of multiple shelf systems.


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Distribution Monitor (DM) The Distribution Monitor13 (Figure 2) provides the system monitoring including AC voltage, and AC current. In addition

Indicators on Distribution Monitor: OK LED (green) reports plant status.

Note: This LED will not be illuminated if the distribution monitor has an internal fault or if CB1 is open.

System Controller The System Controller13 (Refer to Figure 2) allows the user to view plant status and change system and inverter setpoints either from the front panel or through the serial interface located on the front panel. A modem is optional for remote access; refer to the J-Drawing L20 and L22 for modem and software ordering information. The System Controller is easy to use, convenient, and allows the user to quickly change system setpoints without accessing the inside of the inverters.

Indicators on System Controller:

Controller LED (green) indicates that the Distribution Module has passed its internal self- test.

Inverter Minor LED (amber) is a summation alarm indicator and reports plant status in a variety of ways, depending on the condition. The reported conditions are defined in the condition chart provided in the Troubleshooting section.

Inverter Major LED (red) is a summation alarm indicator and reports plant status in a variety of ways, depending on the condition. The reported conditions are defined in the condition chart provided in the Troubleshooting section.

Adjustable Alarm Setpoints: Setpoints are adjusted through the System Controller. Refer to Adjusting Setpoints for more detail.

Alarm Settings Associated with Plant: Settings are for 120 Vac and 48 Vdc plants. Settings for 240 Vac and +24 Vdc plants are in parentheses.

Plant Low Voltage Alarm Setpoint Range 90.0 to 120.0 Vac (180.0 to 240 Vac) Factory set to 95 Vac (190 Vac)

Plant High Voltage Alarm Setpoint Range 110.0 to 140.0 Vac (220.0 to 280 Vac) Factory set to 130 Vac (260 Vac)

Battery Low Voltage Alarm Setpoint (for –48 Vdc input inverter system) Range -42.0 to -55.0Vdc (21.0 to 27.5Vdc) Factory set to -44.0Vdc (22.0Vdc)

Number of Redundant Inverters Setpoint Range 0 to 5. Factory set to 1.

Percent of Capacity Setpoint Adjustable from 0% to 100% in steps of 10. Factory set to 80%.

Percent Capacity Alarm Algorithm

Shelf Current > (# inverters - # redundant-inverters)* inverter-capacity * (% of capacity) for more than 2 seconds.

Alarm Settings Associated with Inverters14 Settings are for 10 Aac inverters. Settings for 5 Aac inverters are in parentheses.

Hi Output Current RMS Alarm Range 8.0 to 15.0 Aac (4 to 7.5 Aac) Factory set to 12.5 Aac (6.25 Aac)

14 System will indicate an alarm after the set threshold has been exceeded for 5 seconds.


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Hi Output Current RMS Alarm Range 4.0 to 7.5 Aac (4.0 to 3.75 Aac) Factory set to 6.0 Aac (3.0 Aac)

Hi Output Current Peak Alarm: Range 18.0 to 28.0 Aac (9.0 to 14.0 Aac) Factory set to 28.0 Aac (14.0 Aac)

Hi Output Current Peak Alarm Range 9.0 to 14.0 Aac (4.5 to 7.0 Aac) Factory set to 14.0 Aac (7.0 Aac)

Hi Crest Factor Alarm (Peak/RMS) Range 0.00 to 5.00 Factory set to 0.00 (disabled).

Crest Factor is a ratio between Peak and RMS current. A purely resistive load powered by a sine wave voltage has a crest factor of 1.414. Nonlinear loads, such as electronics without power factor correction, will have crest factors higher than 1.414.

Each inverter meters its crest factor. The metered crest factor can be displayed through the System Controller.

To enable this feature change the setpoint to the desired value between >0 and 5.0. Be certain to display and note the reported crest factor through the System Controller prior to enabling this alarm.

Crest factor >3.0 indicates a very nonlinear load.

To avoid nuisance alarms leave the crest factor disabled or set the threshold to >1.5 x the measured crest factor. There is no practical reason to set the Crest Factor alarm at a value below 2.5.

Shelf Number Setting Range 1 through 4. Factory set to 4.


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Display Navigation and Push Buttons The System Controller has four momentary push buttons to navigate menus and adjust the plant and inverter setpoints.

Figure 19 Controller Pushbuttons

Selected Screen Item – The selected screen item flashes approximately once a second.

On Screen Button Indicator Each screen displays one or more indicators of which buttons are usable.

Indicator Active Buttons s SEL

→ / +

← / —

↔ / + & / —

Buttons

BACK Navigates to the previous menu, one menu each time the switch is depressed. Continually pressing the switch will eventually return to the System Status Screen (Main Screen).

(Left Arrow) / — (Minus Symbol)

Menu Navigation

• Selects the menu item to the left

Inverter Select

• Decreases the Inverter Number

Inverter Status Navigation

• Moves to the previous item

Adjustment

• Reduces a setpoint value

(Right Arrow) / + (Plus Symbol)

Navigation

• Selects the menu item to the right

• Moves to the next menu

Inverter Select

• Increases the Inverter Number


• Moves to the next item

Adjustment

• Increases a setpoint value in a step dependent upon the parameter being set.


4380419PD r33 April 2013 44

SEL

Navigation

• Moves to the Main menu (only from the System Status Screen)

• Moves to menu of the selected item

Inverter Select

• Moves to first Status item of the selected Inverter


• Moves to the previous Status item

Adjustment / Control

• Moves to the Change ACCEPT / CANCEL screen

• Executes selected ACCEPT / CANCEL choice

Display Menus There are several menus available from the System Controller. See Figure 20 for a diagram of menu structure.

System Status Screen (Main Screen): Upon initial start-up the system will perform an LED test and will attempt to recognize the system components. During this period the FAIL lamps on the inverters will flash. This will take a few minutes. The System Controller LCD will display the System Update screen during this time.

Once all the components are recognized, the System Status screen will appear as follows:

Normal Alarm Active

120 VAC X AAC

SYSTEM - GOOD s

120 VAC X AAC

SYSTEM - ALARM s

Note: Actual system voltage and current will be displayed.

SYSTEM UPDATE

IN PROGRESS


4380419PD r33 April 2013 45

Pressing SEL moves to the main menu to view the alarms, module status, or make system changes.

Main Menu

The Main Menu is selected by pressing SEL from the System Status Screen and allows selection of several other menus. Most option screens at this point are passive (view only), however plant and inverter setpoints can be viewed and set from the SETPT screen. Also included are PLANT, ALARM, INV and BATT.

Note: The main menu is a dynamic screen. PLANT, ALM, BATT, and SETPT are always present. INV will appear only when an inverter is installed and communicating with the System Controller.

The active selection will be flashing. The user may press SEL to select the active selection, or may scroll to the next selection by the use of the arrow keys. Pressing the BACK key will take the user back to the main screen.

Plant

Selecting PLANT from the main menu allows the plant status to be viewed. The PLANT menu will appear as follows (Use the arrow keys, followed by the SEL button, to select an option):

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL ACDM 827E

STAT CTRL INFO s

SEL


4380419PD r33 April 2013 46

Plant Status

STAT (plant) presents plant status in a sequence of screens.

Press or to move through the sequence of screens.

Note: The current status of the given condition will be flashing in the following screens.

PLANT VOLTAGE

120 VAC

PLANT HZ

NORMAL FAULT

PLANT CURRENT

5 AAC

PLANT LOAD

OK EXCEED

PLANT HZ

60.0 HZ

PLANT BREAKER

NORMAL OPEN

PLANT KVA

0.5 KVA

BATTERY VOLTS

NORMAL FAULT

DM BIAS FAIL

NORMAL FAULT

CAL TABLES

PRGM’D UN-CAL

PLANT VOLTS

NORMAL FAULT

NOTE: “PLANT BREAKER” is Distribution Disconnect Module CB1 AC Load Disconnect.

Plant Control

In CTRL (plant) Auto-Standby may be enabled or disabled.

Note: In the following screen, the current status of the given condition will be flashing.

AUTO - STANDBY

ENABLE DISABLE

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL ACDM 827E

STAT CTRL INFO s

SEL

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL ACDM 827E

STAT CTRL INFO s

SEL


4380419PD r33 April 2013 47

Plant Information

INFO (plant) presents applicable manufacturer’s data including part number, revision number, manufactured date, serial number, CLEI number, and CPR number in a sequence of screens.


Note: The following screens are dynamic and only appear if the module is installed.

SC = System Controller DM = Distribution Monitor.

The table is further defined as follows:

Serial number of module

Assembly part number of module

EC level of module

Manufacture date of module

CLEI or CPR number

Software version installed in module

SC 0051

SC 6180443P

DM 6200290P

DM 8600911P

SC 8600815P

SC 0412

DM 990120

DM CLEI

SC CLEI N/A

SC CPR N/A

DM CPR

DM SW 2

SC SW 4

DM 0051

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL ACDM 827E

STAT CTRL INFO s

SEL


4380419PD r33 April 2013 48

Alarm

ALM presents all active plant alarm status.

One of the following screens will display.

Normal Alarm Active

ACTIVE ALARMS:

NONE

ACTIVE ALARMS:

YES s

When alarms are active press SEL to view the alarms in a sequence of screens.


Example:

ACTIVE ALARMS:

00 MOD FAIL MIN

Note: The number preceding the alarm indicates the module designation (see Figure 1).

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL SEL ACTIVE ALARMS:

NONE


4380419PD r33 April 2013 49

Setpoint

SETPT provides plant setpoint view and change.

SETPOINTS

s

Press SEL to view setpoints in a sequence of screens.


INV MAX RMS I

GL 12.5 Aac s

PLANT HI VOLTS

15 130 Vac s

INV MAX PEAK I

GL 28.0 Aac s

BATTERY LO VOLT

15 44.0 Vdc s

INV HI CR FACT

GL 0.0 s

# INVERTERS

15 6 (As Shipped)

SHELF # (1 – 4)

GL 1 s

# REDUNDANT IMs

15 1 s

PLANT LO VOLTS

15 95 Vac s

% OF CAPACITY

15 80 % s

GL - Global; 00-System Control; 15 Distribution Monitor; 1-6 Inverters

Global - Setpoints that affect multiple modules of the same type.

Press SEL while viewing a setpoint to move to the adjustment screen for that setpoint.

Press the + and - buttons on the adjustment screen to adjust the value.

Press SEL on the adjustment screen save the value change.

The controller prompts to CANCEL (default) or ACCEPT the change.

Press arrow keys to toggle between CANCEL and ACCEPT.

Press SEL to confirm the selection. Failure to press a button within 15 seconds will CANCEL the change.

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL SEL SETPOINTS

s


4380419PD r33 April 2013 50

Inverter

INV provides status, information, and control of each individual inverter.

INVERTER SELECT

01 s

Press or to move through the sequence of inverters (01 through 06).

Press SEL move to the menu of the selected inverter.

IM INVERTER 01

STAT CTRL INFO s

The default selection will be flashing. Use the arrow keys to switch between the sub-menus.

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV

SEL SEL INVERTER SELECT

01 s


4380419PD r33 April 2013 51

Inverter Status

STAT provides individual inverter status in a sequence of screens.


01 I OUT PEAK

3.5 Aac

01 INV RUN MODE

STNDBY RUN

01 HI RMS I

NORMAL ERROR

01 I OUT RMS

1.4 Aac

01 LD SHARE MODE

OFF ON

01 HI CREST FACT

NORMAL ERROR

01 CREST FACTOR

1.50

01 HI TEMP ALARM

NORMAL ERROR

01 FREQ LOCK

NORMAL ERROR

01 TRUE POWER

122 Watt

01 HI RAIL VDC

NORMAL ERROR

01 OUTPUT FUSE

NORMAL FAIL

01 FREQUENCY

60.0 Hz

01 LO INPUT VOLT

NORMAL ERROR

01 CAL TABLES

PRGM’D UN CAL

01 INV TEMP #1

26 deg C

01 LO VOLT OUT NORMAL ERROR

01 INV TEMP #2

27 deg C

01 HI VOLT OUT

NORMAL ERROR

01 INV STATUS

NORMAL FAILED

01 HI PEAK I

NORMAL ERROR

Note: Status screens are view only. “01” indicates Inverter Position 01. See Figure 1.

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV


01 s

IM INVERTER 01

STAT CTRL INFO s

SEL


4380419PD r33 April 2013 52

Inverter Control

CTRL provides individual inverter standby / run mode control.

01 INV MODE

SAME RUN STDBY s

Press arrow keys to change the active selection (indicated by flashing).

Press SEL to change the inverter to the active selection.

If a change is made the system prompts to ACCEPT or CANCEL.

CONTROL CHANGE

CANCEL ACCEPT

Press arrow keys to toggle between CANCEL and ACCEPT.

Press SEL to confirm the selection. Failure to press a button within 15 seconds will CANCEL the change.

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV


01 s

IM INVERTER 01

STAT CTRL INFO s

SEL


4380419PD r33 April 2013 53

Inverter Information

INFO provides individual inverter applicable manufacturer’s in a sequence of screens.

Serial number of module

Assembly part number of module

EC level of module

Manufacture date of module

CLEI or CPR number (future)

Software version installed in module

IM 0192

IM SI10A120PME

IM 8500946P

IM 0412

IM CLEI N/A

IM CPR N/A

IM SW 4

120 Vac X AAC

SYSTEM GOOD s

PLANT ALM BATT

SETPT INV


01 s

IM INVERTER 01

STAT CTRL INFO s

SEL


4380419PD r33 April 2013 54

or

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Figure 20 Menu Structure - Typical


4380419PD r33 April 2013 55

Theory of Operation When the input voltage is greater than the minimum start-up voltage, the inverters will start-up and convert DC input to AC output. Inverters are connected in parallel, providing power output that increases with the addition of each inverter. A total of four fully loaded inverter shelves (24 inverters total) may be placed in parallel. When the system is operating and within the preset parameters, the green OK LED on each inverter will be illuminated.

When there is an inverter failure, a red FAIL lamp will illuminate on the front of the inverter and the system will report a Minor alarm, both on the System Controller and the output relay. If two or more inverters fail per shelf, the red FAIL lamp will illuminate on all affected inverters and the system will report a Major alarm, both on the System Controller and the output relay.

The AC output voltage is monitored by the Distribution Monitor. In the event that the AC voltage climbs to an undesirable range, this module will disconnect the AC output. This module is located within the Distribution Disconnect Module that houses an AC output breaker. The breaker will trip if the output current drawn exceeds its rating. The breaker is also provided for the user to manually disconnect the system output from the load.

When the batteries voltage drops below -42.0Vdc for −48 Vdc input inverter systems (or +21.0Vdc for +24 Vdc input inverter systems) inverters will turn off and an Inverter MN alarm will occur. When the plant recovers (DC Input is restored), the Inverter MN, lamp will extinguish, MN Form C alarm will retire, and the system will restart automatically and provide output. To learn more about any of these features, refer to the Features Reference section. To learn about adjusting the settings of the inverter or the system, refer to the Adjusting Setpoints section.

Output Protection There are several levels of output current limit or output protection.

When gradually increasing the load, the inverter goes into the first protection mode at about 160% of the nominal load. This protection mode decreases the inverter voltage and limits the output current.

When short circuit or deep overload is applied to the inverter output, it goes in fast current protection mode, which means that the output current is limited to 28A. In this mode the output current is close to a square wave and the output voltage is usually very low.

The inverter stays in this mode for no longer than 5s. Within this time, the load fuse or circuit breaker protecting the defective circuit should clear. If, after 5s, the short circuit remains, the inverter will open its output relay.

When there is a system of N inverters, they do not lose synchronization during the short circuit mode. After the short is cleared, the inverter outputs are synchronized and sharing again.

Figure 21 shows inverter Voltage on Ch2 and Inverter current on Ch1 while a short circuit is applied with no distribution protection. The Inverter current limits at 28A for 5s, and then opens the output relay.


4380419PD r33 April 2013 56

Figure 21 Output Protection, Short Circuit with no Fuse

Figure 22 shows two inverters running when a short circuit is applied in a circuit protected by a fuse. The output voltage is on Ch1, and two of the output inverter currents are on Ch4 and Ch3.

The Inverters clear the fuse within a few cycles and then the output voltage returns. Note that the inverter output currents are load sharing after the short is cleared. A fuse or circuit breaker trip time will shorten as more inverters are present in the system. Trip-time curves for circuit breakers and fuses are usually found in their datasheets. Use 28 amps per inverter (short circuit current) to determine the trip-time from the datasheet curve.

Figure 22 Output Protection - Short Circuit with Fuse


4380419PD r33 April 2013 57

Output Paralleling and Hot Insertion Critical AC loads can be powered from the existing telecom battery plant via an inverter system IF:

• The inverters do not endanger or degrade the battery plant in any way (e.g., voice band noise), and

• The inverter system output (Vbus) does not fail.

When paralleling inverters both phase and amplitude must be matched and, preferably, the load shared equally. This is normally done in the industry with common synchronization and load share signals, but this method compromises system integrity to a single fault in the common circuits. The 827e inverters are totally independent, connected only by the common AC bus. This design allows inverters to hot plug, which is critical to no-break maintenance and upgrade.

HERE IS HOW IT WORKS:

Figure 23 shows Inverter One running in the shelf and powering the load. The Inverter One voltage is shown on Ch1, and its current is on Ch4. Then Inverter Two is plugged into the shelf. The Inverter Two output relay is open and stays open until the Inverter Two voltage phase synchronizes with the Inverter One voltage phase. After they synchronize, they lock together and then the output relay of Inverter Two closes. The current sharing and synchronization circuit starts working and Inverter Two takes half of the load current as shown in the figure below. The Inverter Two current is on Ch3. Current sharing and synchronization features are implemented within each inverter, without the use of inter-inverter signaling. This avoids the single point of failure created when inter-inverter signaling is used.

Figure 23 Paralleling and Hot Insertion


4380419PD r33 April 2013 58

Considerations for Multiple-Shelf Systems Up to four inverter shelves may be installed as a system with their AC outputs paralleled to provide higher current capacity. In creating such a system there are several aspects to recognize and consider.

• Each shelf must be complete with a System controller, a Distribution Disconnect Module (with Distribution Monitor), and at least one Inverter.

• Each shelf needs to contain the same (or similar) number of inverters. This is to balance the load current across all of the shelves.

• Each shelf must have its SHELF # setpoint set to a unique value (1-4).

• Each shelf operates independently, as far as setpoints, control, alarms and remote communications are concerned. The System Controller in each shelf

• The Plant Status values shown on the LCD of a System controller apply only to that shelf.

• The setpoint values entered into a System controller apply only to that shelf. This includes the setpoints for “# REDUNDANT IMs” and “% of CAPACITY.”

• The AC output of all inverters in a multi-shelf system must be connected together for the shelves to be able to supply AC power to the same distribution and have their output waveforms phase-synchronized. To prevent damage to inverters the proper power-up sequence must be followed. See Shelf Turn On and Operational Checkout.

• The alarm setpoints for AC voltage, AC current and DC voltage must be set the same on all shelves.

• Each System controller must be equipped with its optional modem and phone line for remote communication to take place with that shelf.

WARNING: AC power will feed back to all shelves and to loads from any operating inverter via the parallel connection of shelf outputs. Extreme caution must be exercised in installation and maintenance of multiple shelf systems.

CAUTION: Damage to inverters may occur if a shelf in a multi-shelf configuration does not have a functioning System controller module or if an improper power-up sequence is followed. Follow the sequence in the Shelf Turn On and Operational Checkout section when turning on a shelf. Never close a shelf’s output breaker with the shelf already powered unless there is a functioning System Controller in the shelf and the shelf’s inverters are indicating STANBY mode (amber LED is on).


4380419PD r33 April 2013 59

TroubleshootingTroubleshooting of the system is limited to performing the start-up and operational checks. If further assistance is required, contact the GE Field Service at the numbers listed in the front matter of this manual.

Whenever a malfunction occurs, the first step must be a good physical inspection of the system. Try to find out whether the malfunction is caused by the system or by its environment (e.g. temperature, humidity or load). In addition, there may be other situations such as:

• Input Voltage is missing/ not at the correct level.

• Input and Output connections are not securely fastened.

• Connectors are not secure.

• Blown fuses.

• Tripped circuit breakers.

Always check these external factors before concluding that your system is faulty. If, for instance, the unit stops due to overheating it may have been overloaded, the ambient temperature may be too high, the ventilation slots could be blocked or a cooling fan may be out of order.

It is possible that a voltage setting for the plant was inadvertently set incorrectly. To ensure this is not the problem, return the system to its factory default settings. Refer to the Adjusting Setpoints section for setpoint defaults and adjustments.

To verify that the system is correctly cabled, refer to the Mechanical Installation and Electrical Connections sections.

System Controller Status (STAT) screens provide information useful in troubleshooting.


4380419PD r33 April 2013 60

Table 11 Troubleshooting - Alarm Conditions

Condition System

Controller LED DM

LED

Inverter LED15 Alarm Relay Notes

Cont

rolle

r (gr

een)

Maj

or

Min

or

OK

(gre

en)

OK

(gre

en)

Stan

dby

Fail

Maj

or

Min

or

Plan

t Loa

d

K4 -

spar

e

Normal Operation O O O Single Inverter Fail O O O O O Multiple Inverter Fail O O O O O Inverter High Temperature O O O F O Inverter Communication Loss O O F Inverter Hi DC Rail V O O O O O Inverter Calibration Loss O O O O F O Inverter Lo DC Input Voltage O O O O O Inverter Lo Output Voltage O O O O O Inverter Hi Output Voltage O O O O O Inverter Hi Peak Output Current O O O O F O O Inverter Hi RMS Output Current O O O O F O O Inverter Hi Crest Factor O O O O F O Inverter Frequency Lock Fail O O O F O Inverter Output Fuse Fail O O O O O Plant Voltage Alarm O O O Δ Δ O Lo or Hi Output Voltage Plant Hz Alarm O O O O O Plant Load Alarm O O O O O O DDM CB116 Open O O O O Inverters Auto-Standby if enabled DM Bias Fail O O O O Battery Voltage Alarm O O O Δ Δ O Lo DC Input Voltage AC Dist Mod Calibration Loss O O O O O System Controller Fail O O O Distribution Controller Fail O O O O Force Inverter to Standby O O O O O Force Multiple Inverters to Standby O O O O O Symbols: O = ON LED or Activated Alarm Relay, F = FLASHING LED, Δ = possible ON LED

Conditions column indicates primary condition, other conditions may also be active.

NOTE: This table applies on a per shelf basis.

15 Inverter LEDs activate only on Inverters with the specific conditions. 16 CB1 AC Load Disconnect on the Distribution Disconnect Module is also referred to as “Plant Breaker”.


4380419PD r33 April 2013 61

Table 12 Troubleshooting - Corrective Actions

Condition Possible Cause Corrective Action System Controller (green) LED OFF Lo input voltage 1. Verify DC input fuses or circuit breakers not cleared.

2. Restore input voltage to Inverters to within operating range.

Failed Controller Replace System Controller Distribution Module (DM) OK LED OFF

Lo input voltage 1. Verify DC input fuses or circuit breakers not cleared. 2. Restore input voltage to Inverters to within operating

range. DDM CB1 OPEN Verify DDM CB1 is CLOSED.

Clear load fault if necessary. System Controller

Fail See System Controller (green) LED OFF above.

DM Bias Fail Replace Distribution Module. Failed DM Replace Distribution Module. Inverter Fail LED FLASH - 1 Inverter Communication

Loss - Inverter initialization incomplete

Wait for initialization to complete.

Hi Temperature 1. Clear any air flow blockage at front and rear of inverter. 2. Reduce ambient temperature to within specified

operating limits. 3. Replace Inverter.

Hi Peak Output Current

1. Examine Inverter currents menu path: INV > Inv # > STAT

2. If current is much higher than currents on other Inverters Replace Inverter.

Hi Crest Factor 1. Examine Inverter currents menu path: INV > Inv # > STAT

2. If crest factor is much higher than on other Inverters Replace Inverter.

Hi RMS Output Current

3. Examine Inverter currents menu path: INV > Inv # > STAT

4. If current is much higher than currents on other Inverters Replace Inverter.

Frequency Lock Fail

Replace Inverter

Inverter Calibration Lost

Replace Inverter

Inverter Fail LED FLASH - all Inverters

Communication Loss - System Controller Failed or Removed

Replace System Controller

Communication Loss - Distribution Monitor or Distribution Disconnect Module Failed or Removed

Replace Distribution Monitor or Distribution Disconnect Module.


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Condition Possible Cause Corrective Action Hi RMS Output

Current Excessive Load 1. Verify Excessive VA load

menu path: PLANT > STAT > PLANT LOAD 2. Examine Plant Load

menu path: PLANT > STAT > PLANT KVA 3. Compare Plant Load to On-Line Inverter Capacity 4. Add Inverters or reduce load.

Hi Peak Output Current

Excessive Peak Load 1. Verify non-Excessive RMS load

menu path: PLANT > STAT > PLANT LOAD 2. Add Inverters or reduce load.

Hi Crest Factor - Load Crest Factor

Excessive Load Crest Factor 1. Examine Load Voltage and Load Current waveforms with

an oscilloscope. 2. If Voltage waveform is normal and current waveform is

“peaky”, the load is excessively non-linear. 3. Consult with Technical Support for further assistance.

Hi Crest Factor - Distorted Inverter Waveform

Excessive Load Crest Factor 1. Examine Load Voltage and Load Current waveforms with

an oscilloscope. 2. If Voltage waveform and current waveforms are “peaky”,

the Inverter voltage waveform is suspect. 3. Consult with Technical Support for further assistance.

Hi Temperature 1. Clear any air flow blockage at front and rear of inverters. 2. Reduce ambient temperature to within specified

operating limits. Inverter Fail LED ON - 1 Inverter Lo input voltage 1. Verify DC input fuses or circuit breakers not cleared.

2. Restore input voltage to Inverter to within operating range.

Failed Inverter Replace Inverter. Inverter Fail LED ON - All Inverters Lo input voltage 1. Verify DC input fuses or circuit breakers not cleared.

2. Restore input voltage to Inverters to within operating range.

Lo Output Voltage Excessive Load 1. Verify Excessive VA load

menu path: PLANT > STAT > PLANT LOAD 2. Examine Plant Load

menu path: PLANT > STAT > PLANT KVA 3. Compare Plant Load to On-Line Inverter Capacity 4. Add Inverters or reduce load.

Hi Output Voltage Hi output voltage only occurs when sufficient Inverters have failed with hi output voltage, to power the total load. In this case, all Inverters will detect Hi Voltage and shut down. The system is either cycling ON - OFF - ON… or latched OFF. NOTE: This procedure will result in loss of power to the load unless load 1. Disconnect loads from the 827e SYSTEM:

A. With Maintenance Bypass Switch (MBS) - Operate the


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Condition Possible Cause Corrective Action MBS to the UTILITY position.

B. Without MBS NOTE: The following procedure will result in loss of power to the load unless load. Turn OFF all load circuit breakers to disconnect all loads from the system.

2. Turn OFF CB1 on the Distribution Disconnect Module of all shelves.

3. Turn ON CB1 of one shelf. 4. Observe whether operation is normal or over voltage. 5. Turn OFF CB1. 6. Repeat for steps 3 through 5 for each shelf, individually. 7. Remove all Inverters from a shelf observed in step 4 as

over voltage. 8. Insert one inverter. 9. Observe whether operation is normal or over voltage. 10. Remove the Inverter. 11. Repeat steps 8 through 10 for each inverter in the shelf 12. Repeat from step 7 for each shelf. 13. Replace failed Inverters observed as over voltage in step

4. 14. Reinsert all inverters. 15. Operate MBS to THE INVERTER position

or Turn ON all load circuit breakers to reconnect all loads to the system.

16. Turn ON system per the Shelf Turn On and Operational Checkout section.

Inverter Standby LED ON Initialization in process

Wait for initialization to complete.

Manual Standby Manually return the Inverter Mode to RUN. menu path: INV > Inv # > CTRL > INV MODE - RUN > ACCEPT

CB1 AC Load Disconnect OPEN

Close CB1. Clear load fault if necessary.

Failed Inverter Replace Inverter. Controller Minor LED ON Plant Frequency DM Frequency Error may cause a false Plant Hz Fault.

Inverter Frequency Error may cause a Plant HZ Fault and Inverter Frequency error.

DM Frequency Error Determination: 1. Confirm Plant HZ Alarm

menu path: PLANT > STAT > PLANT HZ > FAULT 2. Check Plant Frequency

menu path: PLANT > STAT > PLANT HZ 3. Check Inverter Frequency of each Inverter

menu path: INV > Inv # > STAT > FREQUENCY 4. Check Output Frequency with an accurate, calibrated

meter. 5. If all Inverter FREQUENCYs and measured Output


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Condition Possible Cause Corrective Action Frequency are 60 ±0.2Hz Replace the DM. Otherwise, proceed.

Inverter Frequency Error Determination: NOTE: This procedure will result in loss of power to the load unless load 6. Disconnect loads from the 827e SYSTEM:

A. With Maintenance Bypass Switch (MBS) - Operate the

MBS to the UTILITY position.

B. Without MBS NOTE: The following procedure will result in loss of power to the load unless load. Turn OFF all load circuit breakers to disconnect all loads from the system.

7. Turn OFF CB1 on the Distribution Disconnect Module of all shelves.

8. Turn ON CB1 of one shelf. 9. Observe whether operation is normal or Plant Hz Fault.. 10. Turn OFF CB1. 11. Repeat for steps 3 through 5 for each shelf, individually. 12. Remove all Inverters from a shelf observed in step 4 as

Plant Hz Fault.. 13. Insert one inverter. 14. Observe whether operation is normal or Plant Hz Fault.. 15. Remove the Inverter. 16. Repeat steps 8 through 10 for each inverter in the shelf 17. Repeat from step 7 for each shelf. 18. Replace failed Inverters observed as Plant Hz Fault in

step 14. 19. Reinsert all inverters. 20. Operate MBS to THE INVERTER position

or Turn ON all load circuit breakers to reconnect all loads to the system.

21. Turn ON system per the Shelf Turn On and Operational Checkout section.

System Controller Displaying "XXX"

I2C bus fault 1. Check ribbon on back of shelf. 2. Unseat one inverter at a time to see if inverter is

crashing I2C bus. Alarm Display

"15 CAL TABLE/S"

1. Verify current on each inverter. If a module is not load sharing replace it.

2. If inverters are load sharing, replace DM. Inverter not Recognized 1. Try another inverter in slot.

2. Verify address jumpers on inverter slot back-plane.


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Condition Possible Cause Corrective Action Output Voltage Display Value Twice or Half of Actual Voltage

Distribution Disconnect Module backplane JP1 jumper incorrect

1. Verify JP1 at upper right rear of Distribution Disconnect Module back-plane.


4380419PD r33 April 2013 66

Safety

Safety Statements Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the equipment. Refer to individual equipment product manuals for additional safety statements specific to other equipment being installed, removed, or replaced.

See the Specifications section for equipment specific

• Safety Compliance information

• Installation Area Limitations

• Environmental Limitations

• Do not install this equipment over combustible surfaces.

• For installations in the U. S. or Canada, use Listed/Certified compression connectors to terminate Listed/Certified field-wire conductors where required. For all installations, apply the appropriate connector to the correct size conductor as specified by the connector manufacturer, using only the connector manufacturer’s recommended or approved tooling for that connector.

• If the proper connector for the country of installation is not provided, obtain appropriate connectors and follow manufacturer’s requirements and all local requirements for proper connections.

• Follow all national and local rules and regulations when making field connections.

• Torque electrical connections to the values specified on labels or in the product documentation.

• DC output cables must be dressed to avoid damage to the conductors (caused by routing around sharp edges or routing in areas where wires could get pinched) and undue stress on the connectors.

• External protectors (fuses or circuit breakers) must be sized as required by the National Electric Code (NEC) and/or local codes. Refer to the equipment ratings to assure current does not exceed: Continuous Load (List 1) - 64% of protector rating Maximum Load (List 2 - typically end of discharge) - 80% of protector rating.

• Insulation on field-wired conductors must be rated no less than 90° Celsius. Size conductors based on listed recommendations. Wiring internal to enclosed equipment cabinets must be rated at 105° Celsius (minimum).

Provide an accessible AC disconnect/protection device to remove AC power from the equipment in the event of an emergency. This device must open all poles and be connected together.

• Alarm contacts are not fused within the equipment. Current limiting protection for these contacts must be provided by external circuits. Exceeding these maximum ratings could result in fire or damage to the unit. See the Specifications section for alarm contacts ratings.

• In enclosed equipment cabinets, the equipment chassis must be connected directly to the cabinet AC service ground bus. For applications in huts, vaults, and central offices, the equipment chassis must be connected to the system bonding network.


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Warning Statements and Safety Symbols The symbols may sometimes be accompanied by some type of statement; e.g., “Hazardous voltage/energy inside, or Risk of injury. This unit must be accessed only by qualified personnel.” Signal words as described below may also be used to indicate the level of hazard.

DANGER Indicates the presence of a hazard that will cause death or severe personal injury if the hazard is not avoided.

WARNING Indicates the presence of a hazard that can cause death or severe personal injury if the hazard is not avoided.

CAUTION Indicates the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided.

This symbol identifies the need to refer to the equipment instructions for important information.

These symbols (or equivalent) are used to identify the presence of hazardous AC mains voltage.

This symbol is used to identify the presence of hazardous AC or DC voltages. It may also be used to warn of hazardous energy levels.

One of these two symbols (or equivalent) may be used to identify the presence of rectifier and battery voltages. The symbol may sometimes be accompanied by some type of statement, for example: “Battery voltage present. Risk of injury due to high current. Avoid contacting conductors with uninsulated metal objects. Follow safety precautions.”

One of these two symbols may be used to identify the presence of a hot surface. It may also be accompanied by a statement explaining the hazard. A symbol like this with a lightning bolt through the hand also means that the part is or could be at hazardous voltage levels.

This symbol is used to identify the protective safety earth ground for the equipment.

This symbol is used to identify other bonding points within the equipment.

This symbol is used to identify the need for safety glasses and may sometimes be accompanied by some type of statement, for example: “Fuses can cause arcing and sparks. Risk of eye injury. Always wear safety glasses.”


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Precautions When working on or using this type of equipment, the following precautions must be noted:

• Install, service, and operate this equipment only by professional, skilled and qualified personnel who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment.

• The equipment may be powered by multiple AC inputs. Ensure that the appropriate circuit protection device for each AC input being serviced is disconnected before servicing the equipment.

• Do not disconnect permanent bonding provisions unless all AC inputs are disconnected.

• Batteries may be connected in parallel with the output of the rectifiers. Turning off the rectifiers will not necessarily remove power from the bus. Make sure the battery power is also disconnected and/or follow safety procedures while working on any equipment that contains hazardous energy/voltage.

• High leakage currents may be possible on this type of equipment. Make sure the equipment is properly safety earth grounded before connecting power.

• Exercise care and follow all safety warnings and practices when servicing this equipment. Hazardous energy and voltages are present in the unit and on the interface cables that can shock or cause serious injury. When equipped with ringer modules, hazardous voltages will be present on the ringer output connectors.

• Use the following precautions in addition to proper job training and safety procedures:

• Use only properly insulated tools.

• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).

• Wear safety glasses. Fuses can produce sparks. High energy levels on buses and distribution components can produce severe arcing.

• Test circuits before touching.

• Lock out and tag circuit breakers/fuses when possible to prevent accidental turn on.

• Be aware of potential hazards before servicing equipment.

• Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the condition of these circuits, especially wiring).

• Use care when removing or replacing covers; avoid contacting circuits.

• Electricity produces magnetic fields that can affect implanted medical electronic devices, such as pacemakers. The strength of the magnetic field depends on the amount of current in the circuit, as well as other conditions (such as number of conductors, placement, and distance from the conductor). DC power and distribution systems, including batteries, which are typically used in telecommunications utility rooms, can operate at high current levels. Personnel with electronic medical devices need to be aware of their restrictions when working around electricity.


4380419PD r33 April 2013 69

Revision History Issue 30 Added 240 Vac (inverter, shelves, and systems) and enhanced Troubleshooting section.

Issue 31 Updated Inverter Minimum Start-up Voltage Specifications.

Issue 32 Added Special room cooling note in Specifications, updated Troubleshooting section, reformatted.

Issue 33 Added note to not reinsert a module with LEDs ON.

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