BPE4000_CAB_OAM_028-0005-120_Rev.B_204

OPERATIONS AND MAINTENANCE MANUAL

For

Benning Power Electronics

BPE 48-4000 DC POWER SYSTEM

(028-0005-120 Rev B)

SAVE THESE IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be followed during installation

and maintenance of the Power System.

11120 Grader Street Dallas, TX 75238

214-553-1444, Fax 214-553-1355

Technical Documents

Date Name

Issued: 10/5/06 DTL Page. 1/2

Revision:

Checked:

BPE 48-4000

Power Supply System

(Table of Contents)

Technical Documents

2/2

Preface: No. 062-005

Safety No. 2126en

System Install Information: No. 028-0005-001

Rectifier Manual: No. 4135en

Rectifier Satallite Manual: No. 2801en

Rectifier General Specification Tebechop 12000

Rectifier Circuit Diagram No. 61921.00E001A3

Rectifier Dimensional Diagram No. 61921.00M000A3

MCU 2000+ Controller Information: No. 028-0008-020

System Elevation (Front and Top View): No. BLT4000

Rectifier Cabinet Circuit Diagram: No. 902-0103-340

Primary Distribution Circuit Diagram: No. 902-0110-104

External Battery Shunt Drawing No. 840-0052-101

Customer Alarm Mapping BPE 48-4000 Maping

.

Document No. 062-005 R1

Preface

Congratulations and thank you for purchasing a Benning BPE 48-4000 Power System We at Benning are committed to supporting the needs of our customers by supplying the customer with the information and documentation needed to properly install and operate your Power System. Important: It is imperative that all the information be observed. This avoids:

Danger during installation and operation.

Danger to operating personnel.

Downtime.

Increases the reliability and lifespan of the system.

These manuals explain all the necessary information to unpack, install, and operate the BPE 48-4000 Modular Power System and related components. Refer questions outside the scope of this manual to our Customer Service Department.

Customer Service:

We are committed to excellence in dependability and customer satisfaction. If you have any questions or problems, please contact the Customer Service Department at: 1-800-910-3601 or 214-553-1444 for more information.

Please read all instructions before installing or operating the equipment and save these manuals for future reference.

Description

Date Name 2126 en Issued: 18.01.93 TB-Enck/Bp pag. 1/2 pag. Revision: R1 Oct 06 DTL Checked: 27.10.97 Enck

EN2126.doc

Safety Notes

Contents

1 Safety notes.......................................................................... 2

028-0005-001 REV B

Installation Manual

Hot-Pluggable

BPE 48-4000 Series

Modular

Power System

Modular Power System Series BPE 48-4000

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1. ABOUT THE MANUAL ........................................................................................................................3

SCOPE.............................................................................................................................................................3 QUESTIONS.....................................................................................................................................................3 PRECAUTIONS.................................................................................................................................................3 OVERVIEW .....................................................................................................................................................4 SYSTEM COMPONENTS ...................................................................................................................................4

WEIGHTS AND DIMENSIONS....................................................................................................................6 2. PREPARATION .....................................................................................................................................6

Figures 2.1 – TIP N TELL™..................................................................................................................6 Figure 2.2 – SHOCKWATCH................................................................................................................7

2.1 UNPACKING THE POWER SYSTEM.............................................................................................................7 INSPECTING THE EQUIPMENT..........................................................................................................................8 CARRIER CLAIMS ...........................................................................................................................................8 CHECKING PACKAGING CONTENTS ................................................................................................................8

3 OVERVIEW OF THE POWER SYSTEM...........................................................................................8 POWER SYSTEM CABINETS.............................................................................................................................8 RECTIFIER CABINET HARDWIRE INPUT CONNECTIONS...................................................................................8 PRIMARY DISTRIBUTION CONNECTIONS.........................................................................................................9 EXTERNAL BATTERY STRINGS .......................................................................................................................9 SYSTEM MONITORING ....................................................................................................................................9 LOCAL MONITORING......................................................................................................................................9 REMOTE MONITORING CAPABILITIES.............................................................................................................9

4. INSTALLATION ..................................................................................................................................10 ERECTING CABINETS....................................................................................................................................10 PHYSICAL INSTALLATION.............................................................................................................................10

5.0 GROUNDING ........................................................................................................................................13 CHASSIS GROUND CONNECTION ..................................................................................................................13 BATTERY RETURN REFERENCE LEAD (BRR) / C.O. GROUND CABLE ...........................................................14 6.0 INNER-FRAME DC LINKS ........................................................................................................................16 7.0 AC INPUT CONNECTIONS .......................................................................................................................16 RECTIFIER INPUT PROTECTION.....................................................................................................................17 8.0 INTER BAY COMMUNICATION CONNECTIONS.........................................................................................18 9.0 BATTERY CONNECTIONS ........................................................................................................................19 10.0 DC LOAD CONNECTIONS......................................................................................................................19 IT IS IMPORTANT TO NOTE THAT IF THE DC CABLING SHALL ENTER AND WATERFALL FROM THE FRONT OF THE PLANT....................................................................................................................................................20 DESIGNATIONS .............................................................................................................................................20 FIGURE 10.2 .................................................................................................................................................21 11.0 ALARM AND USER INTERFACE CONTACT CONNECTIONS .....................................................................21 12.0 BPE 48 - 4000 SYSTEM START UP PROCEDURE ..........................................................................22 RECTIFIER SETTINGS ....................................................................................................................................23

13.0 MAINTENANCE..............................................................................................................................23


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EXCHANGE OF A MODULE............................................................................................................................23 REMOVAL OF THE RECTIFIER MODULE: ........................................................................................................23 UPGRADING THE SYSTEM .............................................................................................................................24

Version Control

Authors Addition/Change Version # Date Almond / Law Original Draft DRAFT October 4th 2006 Almond / Law 028-0005-001 REV B October 5th 2006


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1. About the Manual BENNING recommends that carriers who deliver our products use AIR RIDE transportation to ensure careful moving considerations have been taken for your new power system. This manual contains information needed to install the Benning BPE 48-4000 Modular Power System. The information is intended for DC Power Engineers, technicians or installers experienced in both DC and AC electrical systems. The installation instructions in Section 4 are intended for qualified electricians and technicians. This manual is generic, and is not intended to define specific installation methods. Installation methods should follow all safety standards and regulations, which apply, to the specific installation. Note: Hazardous voltages are present in the BPE 48-4000 Modular Power System and the installation must be done only by qualified personnel having prior training in AC to DC power system installations and knowledge of NFPA 70E.

Scope

The manual explains all the necessary information to unpack and install the BPE 48-4000 Modular Power System. Refer questions outside the scope of this manual to your dealer or Customer Service Department.

Questions

We are committed to excellence in dependability and customer satisfaction. If you have any questions or problems, please contact the Customer Service Department at: 1-800-910-3601 or 214-553-1444 for more information.

Precautions

Please read all instructions before operating the equipment and save this manual for future reference.

SAFETY INFORMATION SAVE THESE INSTRUCTIONS. This manual contains important information for the installation of the BPE 48-4000 Power System. The manual must be retained and observed at all times!

Explanation of the symbols used:

Indicates safety instructions that must be followed to avoid danger to persons!

Indicates instructions that must be followed to avoid equipment damage.

Further symbols and warnings are explained at the appropriate places in this operating manual.


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The rectifier system is an electronic device that contains hazardous voltages and currents.

For this reason, the following instructions must be followed at all times.

1. The rectifier system should be installed in strict accordance with all applicable regulations and appropriate guidelines.

2. Ensure that only qualified and AUTHORIZED personnel have access to the units. Only qualified personnel should be AUTHORIZED to open the units.

3. When the rectifiers are switched off, some of the interior components remain live as long as they are connected to the mains or the battery supply.

4. Integrated capacitors may still be charged even when the entire unit is completely free of voltage. A trained electrician must correctly discharge these components before the connections are touched.

5. When working within the unit, use properly insulated tools that are rated for the system operating voltage.

6. All persons installing the unit must be familiar with the first-aid procedures to be adopted in cases of accidents involving electricity.

7. The regulations of the local power-supply company and all other applicable safety regulations must be observed at all times.

8. This equipment is intended only for installation in a restricted access location

Overview

The rectifier system BPE 48-4000 Series consists of plug-in, modular rectifiers with back panel technology to allow easy installation and removal of the modules. When the modular units are removed or installed into the cabinet system, all electrical connections are automatically disconnected or connected. Performance data is indicated on the front of each rectifier module. The parallel operation of all the rectifier modules provides total system capacity including N + 1 redundancy, if so equipped. The output voltage of the system is nominal –48VDC (-54.0 VDC Float).

System Components

The design and arrangement of the components of the power system are as follows.

(2) Rectifier Cabinets (1) Primary Distribution Cabinet (20) pre-wired shelves for the rectifiers (1– 20) rectifiers (1) MCU 2000+ Micro Controller Unit


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Fig. 3.1: Typical BPE 48-4000 Power System

WARNING! There are no user serviceable parts inside the plug-in rectifier modules.


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WEIGHTS AND DIMENSIONS

Cabinet Dimensions Height x width x length

Packed weight LBS (Average)

Unpacked weight LBS (Average)

Rectifier Cabinet 7’ x 24” x 31.5” 545 lbs 465 lbs Primary Distribution Cabinet

7’ x 31.5” x 31.5” 960 lbs 860 lbs

2. PREPARATION This section is designed to familiarize you with the BPE 48-4000 Modular Power System. The first part explains how to unpack the system, inspecting the cabinet, rectifier modules and safety precautions. The remaining sections describe the rectifier modules and general installation practices. Read all sections carefully before installing the power system. The BPE 48-4000 power system crates should be equipped with TIP N TELL™ indicator(s) and associated tag(s) to warn if the crate was (were) mishandled or tipped during transportation. Verify that there are no blue beads in the arrow of the indicator as shown in figure 2.1. If blue beads are present in the arrow, make note of it on the bill of lading and open the crate(s) immediately to verify the equipment for damage (Claims for tipping will depend on this notation). Report any damages to the freight carrier immediately. Figures 2.1 – TIP N TELL™


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The BPE 48 – 4000 Power system crates are also equipped with a shock watch. If Shock watch is red, please note upon delivery on the shipping receipt .Follow instructions located on the carton. Refer to figure 2.2- SHOCKWATCH Figure 2.2 – SHOCKWATCH

2.1 Unpacking the Power System

The cabinets and rectifier modules are shipped separately. Each rectifier module has been factory tested and is ready to plug into the power shelves. The following steps explain how to remove the Rectifier Cabinet.

1. Cut the straps holding the cabinet to the pallet. 2. Remove the top cover section of cardboard and the foam inserts. 3. Carefully lift the exterior cardboard sleeve, lifting it completely off the cabinet. (This may

require two people) 4. Remove the remaining foam inserts and the plastic bag.

WARNING The rectifier cabinets weigh in excess of 500 lbs each. The Primary Distribution Cabinet is approximately 860 lbs. It is mandatory that necessary precautions be taken to lift, move, set and position the cabinets.

5. Using an appropriate number of people or the proper lifting device lift the cabinet off the shipping pallet. Should a forklift or other lifting device be used you must first remove the front and rear lower cover plates. Be sure to replace the cover plates once the cabinet has been positioned and bolted in place. Once removed, lifting forks may be inserted into the frame base allowing the cabinet to be lifted off the pallet. A secondary means of moving the cabinets is to use a dolly truck. If this method is used, only lift the cabinets from the right side of the cabinets as viewed from the front.

6. Ensure that cabinets are installed on a level surface for proper operation of cabinet doors. 7. Open the shipping cartons for each rectifier module. Be sure to save the packing materials in

case the modules need to be returned to the factory for some reason.


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Inspecting the Equipment

Check the cabinet and the modules for external damage. If any damage occurred during shipment, keep the shipping cartons and packing materials so the carrier can inspect them. It is your responsibility to file claim with the carrier for damages to the equipment. Any and all damage noted upon receipt of the BPE 48-4000 system should be clearly identified in detail on the Bill of Lading.

Carrier Claims

Carrier’s claim procedures should be initiated promptly. In the event damage is found after delivery, it should be reported as soon as possible (normally 15 day time limit on reporting damages incurred in shipment).

Checking Packaging Contents

Verify the contents of the system against the packing list and the purchase order. If the shipment does not contain the appropriate items, contact BENNING Customer Service at 800-910-3601 or 214-553-1444. The following items should be shipped loose and packed in separate boxes: √ Inter-frame DC Links (2) EC-270 , (1) EC- 271 & (1) EC-378 √ Miscellaneous Hardware C/O Inter-frame DC Link Hardware (5/16-18 and 3/8-16 Nuts, LW & FW)

Cabinet Connecting Bolts (4) Upper, (4) Lower (3/8-16 Bolt, Nut & Grounding washer)

-48 V Battery Bus Lug Connecting Bolts (5/16-18 Nuts, LW & FW) √ (2) RJ-45 Inter Bay Communications Cable (Rectifier Cabinet 1 – 2 to PDC) √ (Optional) Battery Temperature Sensor, 10 meters √ BPE 48-4000 System Installation Manual √ 18 GA White, Current Share Lead (Rectifier Cabinet 1 -2) √ Door Access Key

3 OVERVIEW OF THE POWER SYSTEM

Power System Cabinets

The power system consists of a Rectifier Cabinet (s) and Primary Distribution Cabinet. The height of the system is 72” and the depth of the system is 31.5”. The overall width of all three cabinets installed is 79.5”.

Rectifier Cabinet Hardwire Input Connections

Each Rectifier Cabinet has its own AC input panel which provides a single or dual (jumpers included) input connection point for the incoming 480VAC input. Ten (10) three pole fuse disconnect switches are used to provide input protection and short circuit current limitation for each rectifier. The main input terminal is wired for “L1” or Line 1/Phase A, “L2” or Line 2/Phase B, “L3” or Line 3/Phase C, and “PE” or Protective Earth Ground. If two input feeds are desired the installed jumpers must be removed providing one feed for each set of 5 rectifiers. The max lug size that can be accepted is 4/0.


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Primary Distribution Connections

The Internal DC Distribution provides individual load circuit connections allowing the Power System to serve as the Primary Load Distribution center. Up to three rows of load distribution can be configured for either TPL style fuses or GJ1P style breakers. A maximum of sixteen breaker positions per row of distribution or five fuse positions are available per row. Load circuit breakers and/or fuses up to 1200 amps can be installed with a maximum load capacity of 2500A per row. The number of cables that can be installed per breaker/fuse is dependent on the capacity of the device.

External Battery Strings

External battery strings can be connected to the system via bus bars located at the top of the system in the Primary Distribution Cabinet. The system has been designed to accommodate up to twenty connection points for both positive and negative battery terminations.

CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE.DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

System Monitoring

The system has the MCU 2000+ (Main Control Unit) installed to provide varying levels of local and remote monitoring e/w 11 programmable form “C” contacts. For details regarding the specific monitoring configuration provided with your system refer to the MCU 2000+ document included with this manual. A modem, SNMP, or TCP-IP device can be added to enhance the remote monitoring capabilities of the system.

Local Monitoring

Local monitoring is included with each rectifier module and provides visual status such as: LED indicators detailing the current operational status and alarm conditions; multi-line LCD display which can display voltage, current, temperature, and the address of the module. See the included rectifier sections for more detail.

Remote Monitoring Capabilities

The MCU contains a serial port for local monitoring and remote communications options including a TCP/IP adapter, a SNMP adapter, or an analog modem.

• The TCP/IP adapter is a 10 Base-T device that supports web-based reporting via a built in HTML web server with email capability over the Internet or Intranet if behind a firewall. This adapter can also be paired with the Benning Monitor Software which allows the user to monitor several sites from a central location.

• The SNMP option (Simple Network Management Protocol) allows machine to machine status of the system over the Internet via alarm traps.

• The analog modem option allows the system to be monitored remotely over the phone network via the Benning Monitor Software. The system utilizes a call back function for security reasons.


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4. Installation The Installation section explains installing the Power System and connecting the AC/DC input/output. Connection of the remote relay contacts and other communications options are also covered.

Warning! These installation instructions are generic and are to be used as a guideline for installing the BPE 48-4000 system. All safety regulations and guidelines which apply must be observed.

WARNING The safety instructions must be observed at all times during assembly, installation and commissioning.

Erecting Cabinets

When locating the Cabinets consider the following guidelines:

1. The site chosen for the rectifier system must have a solid and level floor designed to properly support the weight of the cabinet per sq/ft.

2. The system is designed for installation and operation in a restricted and controlled environment. The installed location should have a maximum ambient temperature of 50°C.

3. Two (2) Technicians shall be present at all times for safety reasons

Physical Installation

1. Using the appropriate sketches below, mark the floor for anchor positions and proceeds with either standard floor anchoring means or earthquake approved anchoring. Frame Isolation pads are available from Benning if required. Rectifier cabinets are 600 X 800 mm and the Primary Distribution Cabinet is 800 x 800 mm. Non earthquake zone applications use (4) 0.42” D floor mounting holes for each cabinet. Earthquake zone applications require welded cabinets with (8) 2” x 0.5” slots for mounting with earthquake zone approved anchors (Customer provided anchors).


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2. The cabinets should be shimmed to the floor to make sure they are level. Once they are

leveled, they should be secured using Washers in mounting holes provided. See typical standard concrete anchor mounting and earthquake zone concrete applications shown on next page.


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Typical Non-earthquake Zone concrete anchors

Typical Earthquake Zone Concrete Anchors


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5.0 Grounding Chassis Ground Connection

Each cabinet is equipped with 3/8” studs on 1” centers that act as the common frame ground for the unit and are located at the top of each cabinet. Connect frame ground to these grounding studs using appropriate lug/terminal ends and cable of same type of material as used by the factory e.g. copper or tin–plated copper.

Frame Ground Collector Ref NEC 250.122 No. 1 AWG Minimum based on distance

Frame Ground Ref NEC 250.122 No. 1 AWG Minimum


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Battery Return Reference lead (BRR) / C.O. Ground cable

The Battery Return Reference cable /C.O. ground cable should be equal to or larger than the largest current carrying conductor in the DC Plant. Since the largest current carrying conductor is normally a 750 MCM Cable it has become the normal practice to Install 1 – 750 cable. This Bar at the Primary Distribution Cabinet is pre drilled for 2 hole lugs 3/8” bolts on 1” centers. Generally accepted practices in C.O. Grounding

• The C.O. ground cable should be separated by method of cable brackets or dedicated grounding rack and easily traceable from the Floor Ground Bar (FGB) or Building Principal Ground (BPG) to the DC Power plant.

• The C.O. ground cable should not be spliced and should be continuous from the FGB/BPG directly to the DC Power plant.

• Brass labels marked “DO NOT DISCONNECT” shall be place at both ends of the cable. • The cable should be designated DC POWER PLANT C.O. GROUND on both ends of the cable

secured to a C-145 cable tag. • The cable should be Green; however Black and Grey are an acceptable substitution. • The cable shall have two hole lugs with compression type lugs. • The C.O. Ground cable should be connected to the extreme right or as an option, to the left in

order to prevent cable mismanagement.


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6.0 Inner-frame DC Links BPE 48- 4000 Modular power systems have tin plated contact surfaces. These surfaces do not require sanding; simply apply a dry cloth to clean any debris or dirt. Although Tin coated surfaces do not normally require any anti corrosive compound (i.e.) non ox ide a thin layer is generally acceptable. The two (2) Rectifier Cabinets must be interconnected to the Primary Distribution Cabinet once all the cabinets are secured and have been bonded to frame ground. The left (from Front) rectifier cabinet is ready to accept two (2) EC-270, Inter-frame DC links. These links are secured with 5/16 and 3/8 nuts, flat washer and lock washers as shown below viewed from the rear (right side). Repeat for the other cabinet using an EC-271 for the top and an EC-378 for the lower Inter-frame DC Link. Torque all bolted connections per table A which can be found at the end of this document.

Rectifier Cabinets and PDC as viewed from the rear

7.0 AC Input Connections Each Rectifier Cabinet utilizes 480 VAC, 3 phases and a PE frame ground located behind the removable panel at the top left hand side of the cabinet, behind the cabinet access door. Each Rectifier Cabinet is designed for either a bulk/dual input for the entire Rectifier Cabinet. The bulk/dual input is standard and pre wired to power all 10 rectifiers from a single 480 VAC source or by removing the horizontal jumpers; two feeds (A & B) can be brought into each of the rectifier cabinets. If the jumpers are removed, one 3 phase feed would supply power for rectifiers 1-5 and the other feed powers rectifiers 6-10. Please refer to the system schematic for specific details regarding these connections. The input voltage to the system is 480VAC three phase (3W + PE Ground). The removable cover must be re-installed after the input connections are made, See Below


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RECOMMENDED EXTERNAL BREAKER SIZES Bulk Feed for up to 10 rectifiers Qty 1 – 200 ( 3 pole ) Amp Breaker Dual Feed for up to 5 Rectifiers Qty 2 – 100 ( 3 pole ) Amp Breakers

Rectifier Input Protection

Each rectifier cabinet distributes the 480 VAC 3 phase power to each rectifier through a three-pole fused disconnect. These devices provide two important functions. First, they provide individual input protection with disconnect function for each rectifier and secondly, they are current limiting devices. Due to the potential for high Interrupting Capacity with 480 VAC service, these devices limit possible pass through currents to a safe level. These fuses must only be replaced with a KLKR 30 current limiter or equivalent. These disconnects also provide visual indication via a “red” indicator if any one of the fuses should operate.


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8.0 Inter Bay Communication Connections Only a few connections are required to be made during installation for communications between both the Primary Distribution Cabinet and the Rectifier Cabinet.

1. An 18 AWG white wire (furnished) must be inter-connected between pin 1 of connector X6 in Rectifier Bay 1 to the pin 1 of connector X6 Rectifier Bay 2. The connectors are located on the right side of each cabinet.

2. Two, RJ-45 communication cables are provided. These connections provide communications between the rectifier Cabinets and the MCU communications bus located in the Primary Distribution Cabinet. One end of each RJ-45 cable is plugged into the Rectifier “SAT BUS COMBINER” (SBC) board located on the right side of each rectifier Cabinet. The other end of each cable is terminated on the “SAT BUS COMBINER BOARD’s” located in the Primary Distribution Cabinet. These cables can be terminated into any available connector on “SAT BUS COMBINER BOARD” #1 or #2. RJ-45 Cable

to Rectifier Bay 1 and 2, Plug into socket as shown


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Rectifier Cabinet 1 and 2 Primary Distribution Cabinet

9.0 Battery Connections Provision for the connection of external battery strings is provided in the Primary Distribution Cabinet. 5/16-18 studs on 1” centres’ are provided for termination of up to twenty (-) battery cables using 2-hole lugs (customer provided). Space is also provided on the right side (from front) of the Primary Distribution Cabinet for termination of twenty DC (+) battery cables using 2-hole lugs arranged for 3/8” bolts on 1” centres’. It is recommended that these (+) battery cables be arranged in back to back pairs to conserve ground bar termination points. It is recommended that battery short circuit protection also be provided for each battery string utilizing either fuses or circuit breakers rated for the short circuit interrupting rating of the battery cells supplied (customer provided). These are available from Benning Power Electronics, consult the factory

10.0 DC Load Connections DC outputs are provided via the GJ1P breakers and/or TPL fuses installed in the Primary Distribution Cabinet. The output cables are installed into the cabinet from the top of the system and secured using the proper hardware (supplied by the customer). NOTE: do not turn on the circuit breakers or insert fuses at this time. Generic Guidelines to follow for DC cabling

• Lugs used should be of compression type with a minimum of 2 crimp positions. Lugs should also have 2 hole 3/8 hole 1 “center to center hole spacing.

• Connection locations for DC Distribution to the BPE 48- 4000 Modular power system have tin plated contact surfaces. These surfaces do not require sanding; simply apply a dry cloth to clean any debris or dirt. Although Tin coated surfaces do not normally require any anti corrosive compound (i.e.) non ox ide a thin layer is generally acceptable.

• All cables connected to the BPE 48 - 4000 should have a C – 145 tag and a designation with the end location clearly marked. P touch labelling is generally accepted, however verify with your customer standards documentation and the Telcordia GR 1275.

• Zone 4 cabling should always be flex cabling. • Clear heat shrink tubing shall be used on all crimp lugs.


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• All cables shall be copper with insulation having flammability in accordance to the National Electric Code. (NEC)

Cabling Distribution Layout

• In principal – Level – A – Distribution cabling is unsupported and cables enter the plant in a free flowing manner. The cabling for level A should not exceed 36” from a cable rack to the breaker/fuse location.

• In principal – Level – B - C – Distribution cabling will be tied to a support bar located at the center of the plant. These cables will also be stitched to the A - level cables to provide additional support.

• Return feeders (+) should be installed on the left hand side (facing front) to leave appropriate locations available for the battery cabling on the right hand side (facing front).

Figure 10.1 PRIMARY DISTRIBUTION CABINET EQUIPPED WITH CABLING SHIELD

LEVEL A DISTRIBUTION LEVEL B DISTRIBUTION

It is important to note that if the DC cabling shall enter and waterfall from the front of the plant

Designations

For designations with a cabling shield (Fig 10.1), designations can be applied directly to the shield using etched plastic or P –Touch labelling. For designations without a shield, P- Touch labelling can be applied directly to the breakers or to the breaker termination bars indicated below in figure 10.2


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Figure 10.2

11.0 Alarm and User Interface Contact Connections Multiple dry contact connections are available for remote monitoring of the system failures. Some examples of these alarms are: DC Output High, DC Output Low, AC Input Fail, and Major/Minor alarms. Also, a Temperature Probe, Emergency Power Off (EPO), Analog Measurement, Digital Inputs, or Audible Alarm connections are available .For a comprehensive list of available alarms contact your BENNING representative. There are 8 Alarm relays that are factory defaulted set to the following. The alarms may be customized in the factory prior to delivery if the customer advises Benning at the time of placing the order. Alarm settings may be modified at anytime by logging into the system with the Benning Service Software. Additional alarming information can be found in DRW NO .902-0110-104 which is normally shipped with each order.


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12.0 BPE 48 - 4000 SYSTEM START UP PROCEDURE

Warning! Only Benning Trained and Qualified personnel may carry out the System Start up. Any or all of the steps may alter depending on the site specific conditions.

Trained, Qualified technicians on Benning BPE 48-4000 should only start up this system. ENSURE BATTERIES ARE DISCONNECTED, AC IS TURNED OFF, AND LOAD BREAKERS ARE TURNED OFF BEFORE PROCEEDING. ENSURE THAT A LISCENSED ELECTRICIAN HAS VERIFIED 480 VOLTS ACROSS THE 3 PHASES OF THE AC.

1. Ensure that all AC fuse disconnects are in the disconnect position. There are 10 total in each Rectifier Cabinet, ensure that they are all disengaged. You may refer to section titled “rectifier input protection”

2. Make sure that the DC Batteries are off line (removing battery strapping as necessary or engage battery disconnect device) and not connected to the DC Plant

3. Make sure all DC distribution breakers/fuses are in the off position.

4. Licensed Electrician should turn on the Main AC source to the Rectifier Cabinet and verify connections and 480 volt potential.

5. Install the AC removable Blank Cover.

6. Engage AC Fuse Disconnect for rectifier #1.

1. First, the AC mains supply is switched on, whereby LED’s on the rectifiers light up and flash for a short time, approx. 40 seconds. (Initialization of the internal processor!) Afterwards, each rectifier will display OFF on the LCD and will remain in stand by until turned on.

2. Next, one at a time turn each rectifier on by pressing the red button located on each modules front panel. The rectifiers will then begin a search and select process until a master slave configuration has been accomplished. The LCD displays will stabilize when the process is complete.

3. The rectifiers are now switched on. Located on each rectifiers front panel are LED indicators, they all must display a “GREEN LED” which indicates “active: unit in operation” and a “YELLOW LED” which indicates “active: mains voltage applied and data transfer in progress”.

NOTE: if the yellow LED is flashing this indicates the master.

7. Turn on batteries by engaging battery disconnect device or by installing battery straps and verify proper Plant voltages, Battery voltages and individual cell readings.

8. Charge batteries as described by the Battery Manufacturers recommendations.


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9. Test and acceptance per customer /site specific recommendations

10. Engage distribution breakers/fuses as required, verifying proper voltages.

NOTE: the rectifiers may not current share evenly until at least 30% of the over-all current capacity is reached.

Rectifier settings

Each rectifier is set to default values at the factory according to the required operating conditions. Any adjustment of these settings is not usually necessary.

However, if the rectifier is to operate with different parameters, a simple resetting can be carried out using the keypad located on the front of each rectifier (see Rectifier Operation Manual).

Warning! Only qualified personnel may carry out each alteration of the settings on the unit. Any or all alternations of these settings may need to be carried out for all the other rectifiers in the system depending on which settings are altered.

13.0 Maintenance All the components of the power system have been developed for continuous operation and are practically maintenance-free. To ensure correct functioning, it is recommended that the flow of cooling air is checked periodically and the filters are changed as needed.

Warning! Do not use pressurised air since the dust particles can be blown into the interior of the unit and may cause malfunctions.

Exchange of a Module

Removal of the Rectifier module:

1. Switch the module off by pressing the red button located on the front panel of the module.

2. Remove the retaining screws, which secure the unit into the system.

Attention: Take account of the amount of current being supplied by the modules to the load and the batteries. Removal of a module in a non-redundant system may compromise the load.


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3. Pull the unit out from the front of the cabinet about half way and wait until the front display is completely blank. If the module does not have a front display, wait approximately 40 seconds and then proceed to remove the module being careful to support the whole module as it is being removed.

Insertion of the Rectifier module:

1. The module must be switched off!

2. Place the module’s bottom back corner on the base of the carrier paying close attention to the

alignment grooves on both the module and the carrier.

3. Slide the module into the free slot slowly until the modules front panel is flush with the front of the

cabinet.

4. Screw in the retaining screws

5. If the module has an active front panel, switch the module on by pressing the red button on the

front panel.

Upgrading the system

The power system can be equipped with a maximum of 20 rectifiers. Additional modules can only be added to the system if there are free slots. The system can be upgraded during running operations without the need to switch off other components or the need to alter the programming configuration of the MCU.

To add additional modules to an existing system first remove the dummy plate covering the free rectifier slot. Ensure the new module is switched off. The new module is then pushed into the slot, fixed with the retaining screws and then switched on. After the start-up phase, the module is brought into parallel operation and the current then is evenly distributed to all modules that are switched on.


028-0005-001_REV B

Page 25

Reference Information

Table A – Bolt Torque Data


028-0005-001_REV B

Page 26

Table B – Cable Equivalents (AWG to Metric)

End of the Document

Safety notes

18.01.93 - TB-Enck/Obs 2/2 2126 en

Before starting the unit:

Please read the complete manual, paying special attention to all the safety notes.

1 Safety notes

The charging rectifier is an electrical unit with dangerous voltage and current levels. For this reason, the following safety instructions must be observed:

1) Installation, operation, servicing and maintenance should be carried out only in accordance with the instructions given in this document.

2) Ensure that only qualified and authorized personnel have access to the equipment. No other persons should be able to open the door.

3) Even when the unit is completely switched off, certain interior components remain lives as long as they are connected with the mains supply or the battery.

4) Intergrated capacitors may still be charged even when the unit is completely voltage-free. These must be properly discharged by a qualified person before the connections are touched.

5) When working on the unit, only properly insulated tools should be used.

6) All persons carrying out work on the unit must be acquainted with the first aid measures to be taken in cases of accidents involving electricity.

7) Always observe the safety regulations of the local power supply company as well as other safety regulations.

8) This product is intended for use in restricted access locations only.

9) HIGH LEAKAGE CURRENT - Earth connection essential before connecting

supply.

Description

Date Name No. 4135 en Issued: 29.06.2004 TB/Gö Page 1/17 Page Modified: Approved: 29.06.2004 Tel

C:\Projekte\TEBECHOP\Volleinschuebe_19''\12000_3HE_SAT\4135_en.doc

Rectifier with satellite TEBECHOP 12000

3U – 19” HOT-PLUG Version

Rectifier with satellite

TEBECHOP 12000

29.06.04 TB/Gö 2/17 4135 en

Contents

Foreword ...............................................................................................................................4

1 Safety notes and markings......................................................................................5

2 Connection..............................................................................................................8

3 General ...................................................................................................................9

4 Functional principles ............................................................................................11

5 Start-up .................................................................................................................11

6 Operating modes...................................................................................................12

6.1 Floating level (ErlAd) ..........................................................................................12

6.2 Boost level (LAdEn) ............................................................................................12

6.3 Direct feeding (dir.SP) .........................................................................................12

6.4 Battery circuit test (b.tESt)...................................................................................12

6.5 Time-dependent automatic charging ....................................................................12

7 Parallel operation..................................................................................................12

8 Satellite.................................................................................................................13

8.1 Standard function .................................................................................................14

8.2 LED-indication.....................................................................................................14

9 Alarms ..................................................................................................................15

9.1 Urgent alarm (unit fault SV1) ..............................................................................15

9.2 Non-urgent alarm (mains fault SV2)....................................................................15

9.3 Temperature monitoring.......................................................................................15

9.4 Overvoltage protection.........................................................................................16


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9.5 output fuse-monitoring .........................................................................................16

9.6 Incorrect battery poling ........................................................................................16

9.7 Ventilator fault .....................................................................................................16

10 Adaptation of float charge voltage to battery ambient .........................................17

11 Fuses.....................................................................................................................17


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Foreword

These operating instructions give essential information for the correct operation of the unit. To ensure the safe and correct operation of this unit before the first switch-on, the user should study these instructions carefully. Also note all the information they contain.

These instructions should be kept in a safe place for consultation.


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1 Safety notes and markings

International electrical symbols and display and operating symbols are marked on the unit. They have the following meanings:

Important! See documentation!

Alternating current

Direct current

Earth (Ground)

Operation

V Input voltage (mains) available / flashes during data transfer via the satellite bus

Fault-output fuse

Fault-unit

Voltage - output too high

Fan fault

Funktions keys: A= menu ; B= enter key On/Off (push button switch / impulse lock)


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Index of abbreviations

A Current b.-Art Operating mode b.tESt Battery test bzw. or DC Current DirSP Direct feed operating mode EndE End ErLAd Consercation charge operating mode i-MA Setting current limitation INenn Rated current I-rEG Following current limitation LAd.-A Automatic charge LAdEn Charge operating mode Pb Lead Po.MA Power management SAE Voltage compensation facility SAT-Bus Satellite bus T Temperature tEMP Battery temperature-based charge tESt Test U Voltage U-rEG Following voltage W Watt –BAT- Incorrectly poled battery E.g. For example

For further information on the function of the satellite, refer to the description no.: 2801.

The following symbols are used to draw attention to certain passages in these instructions.

Constitutes a remark pointing out that observing it will facilitate working with the device!

Constitutes a remark pointing out the process or operation of a device or a specification.

Refers to a remark pointing out that life and body of persons could be directly exposed to danger!


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It is an electronic device which requires dangerous levels of voltage and current. The following instructions must therefore be strictly observed at all times.

1. Installation, operation, maintenance and repair of the unit must always be carried out in accordance with these instructions.

2. Ensure that only fully trained and qualified personnel have access to the unit. The unit should be opened only by authorised persons.

3. Even when the unit is switched off, certain internal components remain live as long as it is connected to the power supply or the battery.

4. Integrated capacitors may still be charged even when the entire unit is completely free of voltage. Ensure that the capacitors are properly discharged by a qualified electrician before touching the connections.

5. When working with the unit, use only properly insulated tools.

6. All persons working with the unit must be familiar with first-aid procedures for accidents involving electricity.

7. Always comply with the regulations of the local power-supply company or authority as well as any other relevant safety regulations.


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2 Connection

The following standards and regulations are applicable to the unit:

EN 61558 EN 60950 VDE 0884 EN 50 081-1 EN 50 082-2

In the standard version, the device and the insulating transformer correspond to protection class I. The transformer corresponds to the regulation EN 61558 and the test voltage primary/secondary is 4 kV alternating voltage.

The unit as delivered is ready for operation.

Installation and perfect operation is only possible in the special 3U; 19” rack (PN: 550828).

The handle on the front panel serve only for pulling out the device, not for carrying the device.

This device (protection type: IP 20 must be installed in a dry and dust-protected environment. The cooling air should not be obstructed.

Pay attention to the circuit diagram!

It is necessary to supply the supply circuit with an insulating device which has to be - easily accessible if permanently connected; - easily accessible if it is a plug connection and located close to the device .

Provide appropriate fuses for mains and output cables (size of fuse, characteristic see technical data)!

Access to the input and output fuses is only possible after opening the unit.

Before connecting up, make sure that the specifications on the type plate and data sheet agree with the actual mains and battery voltages.

The details in the rating plate and in the data sheet with regard to power consumption apply to rated conditions of input voltage and the operating mode “float charge voltage”. The value in brackets is the maximum input current with maximum input voltage tolerance and in the operating mode “charging”.


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Make the mains connection on rack only when the mains supply voltage is switched off.

The device must be connected with the neutral conductor of the supply power circuit according to local regulations.

Because of the high energy of the battery to be connected, take special safety precautions.

To protect the device from overvoltages (such as from lightning strikes), carry out potential equalisation with sufficient cable cross section (e.g. 6 mm²) on Rack provided no other measures to protect the device are provided, for instance building protection.

3 General

The rectifier described in the following is in switched mode technology.

This technology provides sound efficiency and good dynamic control characteristics in the event of input voltage changes and load jumps.

Since these rectifier units are highly compact designs and can be connected in parallel, the establishment of powerful electricity supply systems is possible in conjunction with the 3U; 19” rack.

IPU characteristic (standard) In order to achieve as high as possible a charge current, power is controlled on the output side. This means that, dependent on the respective charge voltage, the output current is adjusted to the maximum possible output power (example of a 48V device see figure 1).

The IPU characteristic is only active in the operating modes “float charging” and “ charging”.

In the operating modes “direct feed” and “1,8 V/Z”, it is limited to rated current (IU characteristic).

Based on the type of battery and number of cells, the output voltage is kept constant with an accuracy of ± 1 % Based on the type of battery and number of cells, the output voltage is kept constant with an accuracy of. On reaching the current limit control changes electronically from voltage to current control.


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Figure 1: (IPU characteristic; example: 48V unit)

The consequence of current limitation if applicable is a drop of the output voltage in the event of a short circuit to < 1 V, the output current is approximately around Irated. or at Imax , depending on operating mode. This measure makes the device short-circuit proof permanently. Mains fluctuations of voltage and frequency (see technical data sheet) and load changes have no effect on the quality of the voltage and current constancy and are regulated. The power factor of the rectifier unit (active power to apparent power) is regulated to roughly 1 (PF > 0.99 at rated operation). The utilisation of the feed network is considerably improved in this way and higher output can be taken from the single-phase net.

The rectifier is equipped with the so-called satellite. This assembly integrated in the rectifier enables the establishment of a remote monitoring system MCU 1000 / MCU 2000. Faults are delivered by means of floating contacts via the external evaluation electronics “MCU”.

Additional information on the duty of the satellite, see chapter 8.

188

53,5

43,248

57,6

(V)UA

200 240 IA (A)


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4 Functional principles

The mains voltage fed in through the input filter is converted by the rectifier to DC voltage and supplied to the active filter (PFC). A special control method takes a sinusoidal current from the three-phase net and provides a constant DC voltage for the main unit (charge unit) at the output of the active filter.

Rapid MOSFET power transistors in the chopper unit convert this DC voltage into a rectangular voltage. Control is effected by changing the duty cycle with constant frequency. The power transmitter serves to separate the potential and transform the rectangular voltage to the desired output value. Diodes rectify the voltage and an LC filter is used to smooth the output voltage.

The device is equipped with a hardware overvoltage cut-out. For switching on and off, the rectifier unit must be operated via the switch in the front panel.

5 Start-up

Push all rectifier into the cabinet, with the mains switched off.

Switch on the first unit at the mains,

wait for the end of initialization period of this unit, (the end of this period is indicated by the green LED "Operation / “ and

the red LED "Fault/ “) no longer flashing,

now the next unit can be connected to the mains; here, too, you need to wait for the end of the initialization phase, before the third unit can be connected to the mains and start up.

All rectifier units must start up individually in order to ensure that each unit is assigned its own address.

If, for a particular unit, the initialization phase has run without any problems, then this unit must be withdrawn.

Following a period of approx. 3 minutes which is required for the internal discharge of the capacitors, the initialization must be carried out again.

Following completed initialisation, the green LED “operation” “ “ is activated. The unit will then run up to the set rectifier output voltage with a time delay.

When removing the device, place switch in “off” position first!


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The handles on the front panel serves only for pulling out the unit, not for carrying the unit.

6 Operating modes

The rectifier unit has a total of four operating modes or characteristics, which can be activated by changing over the operating mode via the satellite bus (SAT bus) by means of “MCU”.

6.1 Floating level (ErlAd)

Standard operating mode, normal operation setting, float charging with rated current or maximum current (based on power) up to the voltage limit (see technical data sheet). The level of the output voltage is set by the „MCU“.

6.2 Boost level (LAdEn)

Necessary for fast charging the battery. Charging up to the voltage limit with rated current or maximum current (based on power), see technical data sheet. The level of the output voltage is set by the „MCU“.

6.3 Direct feeding (dir.SP)

Operating mode without battery (voltage value see technical data sheet). The level of the output voltage is set by the „MCU“.

6.4 Battery circuit test (b.tESt)

Voltage reduction during the battery capacity test in order to obtain exact measured value (voltage value generally set to V/C). (see technical specification sheet.)

The level of the output voltage is set by the „MCU“.

6.5 Time-dependent automatic charging

By means of the automatic charging system integrated in the rectifier it is possible that the unit switches over automatically to the characteristic “charging” following a power failure. After expiry of the charging time, it switches back to the characteristic "float charge".

The mains failure charging time is set via the “MCU”.

7 Parallel operation

Parallel operation of several rectifiers is possible and takes place without decoupling diode on the rectifier output.


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For symmetrical output current distribution, the rectifiers are interconnected via the contact “1,2,3(b1)” on the connector strip (“X16”) (parallel operation connection). A parallel operation tolerance of approximately ± 10% of Irated is achieved in this way in load operation from 30 – 100%.

The voltage and current compensation can take up to 5 minutes in case of con-nection of an additional unit to the system (self regulating process in 10 mV steps).

A minimum basic load of > 5% is required with parallel operation to safely maintain the fault message contact. The satellite bus connector “RS485” in the counter-connector system must be plugged with parallel operation using several racks in order to enable data interchange. In addition to this, the “parallel operation connection” of the racks must also be interconnected!

8 Satellite

For further information on the function of the satellite, refer to the description no.: 2801.

The satellite integrated inside the rectifier unit monitors the rectifier unit and provides the open and closed loop control functions for it. For the user the satellite looks like a digital interface to the rectifier unit. The rectifier unit obtains the required data via this interface from other units of the remote monitoring system MCU 1000/MCU 2000 to establish the desired operating state. This requires that the satellite has available the complete set of parameters for open and closed loop control as well as all data with regard to the operating states of the rectifier unit.

The satellite is a principal unit in the remote monitoring system MCU 1000/MCU 2000, ensuring that control and monitoring of the power supply systems is possible via the public telephone network.


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The further functions of the satellite, among others, are as follows: (Faults are delivered by means of floating contacts via the external evaluation electronics “MCU”) 1. Four adjustable operation modes/characteristics

2. Battery temperature inclined float charge characteristic (incline adjustable)

3. Unit monitoring with logically combined urgent alarm

4. Mains monitoring with logically combined non-urgent alarm (time delay of the alarms adjustable)

5. Time-dependent automatic charging (mains power failure time and charging time adjustable)

6. Current limitation is set in accordance with medium load (IrEG adjustment)

7 Voltage tracking (UrEG. adaptation).

8 Power management (Po.MA).

9. Serial SAT bus interface via counter-connector system for communication in parallel operation of several rectifiers

8.1 Standard function

After switching on the rectifiers and an initialisation phase of approximately 30 seconds, the unit runs up to the output voltage saved last (for instance float charging).

8.2 LED-indication

The following LEDs are provided in the unit front panel of the rectifier:

- (green) "operation"/ " " (LED active: The units operating correctly)

- (yellow) "mains/data"/ " V " (LED active: Mains voltage available; LED flashes: Data transfer via SAT bus in progress)

- (red) "fault - fuse"/ " " (LED active: Output fuse tropped)

- (red) "fault-unit"/ " " (LED active: unit fault)


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- (red) "UA too high"/ " " (LED active: Overvoltage protection responded)

- (red) "Fan fault"/

" " (LED active: Fan failure!)

For error identification, the relevant error code is shown in the display and transferred via the “SAT bus”. (refer to the description no.: 2801)

LC-Display

The 5-digit LC display on the rectifier front panel indicates physical units (current, voltage, battery temperature or data address) as well as operating status of the rectifier.

9 Alarms

9.1 Urgent alarm (unit fault SV1)

The message contact “Device fault” of the external evaluation electronic (MCU) is closed and the control lamp “Operation”/ “ “ LED green is off, and “Fault device” / “ “ LED red is on.

These signals are internally delayed by approximately 30 seconds.

Device fault (urgent alarm) is dispatched under the following conditions: - Overvoltage protection has responded - Temperature too high - Regulator or power pack defective - Output fuse tripped – Incorrectly poled battery

9.2 Non-urgent alarm (mains fault SV2)

This signal follows AC undervoltage or mains power failure, the message contact of the external evaluation electronic (MCU) is closed and control lamp “mains/data” / “ V“ LED yellow is off.

9.3 Temperature monitoring

The rectifier is equipped with a temperature control on the heat sink which operates as follows:


TEBECHOP 12000

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Assumption: The rectifier is operated at rated current. 1. Heat sink temperature continues to rise 2. At T >85°C rectifier is switched off 3. LED red “fault device” / “ “ on 4. LED green “operation” / “ “ off 5. Urgent alarm / device fault “SV1” is dispatched.

After the heat sink has cooled down, the rectifier is automatically reset. The rectifier is then switched on again.

9.4 Overvoltage protection

In the event of overvoltage (see technical data sheet) the device is switched off. The overvoltage protection is designed as a battery and device protection. Switching on after the fault has been repaired is possible when the device is separated from mains for approximately 10 seconds. LED red “UA too high”/ “ ” and urgent alarm are also reset during this.

Testing the overvoltage protection is not possible with an externally controlled power supply unit since the rectifier recognises an externally fed voltage and fails to switch off as a result.

9.5 Output fuse-monitoring

Because of high energy of the battery to be connected, an output fuse has already been installed to protect the device. The control integrated in the device issues a message once the output fuse has tripped.

LED red “FAULT output fuse” / “„ “ “ on, the message contact “Device fault” of the external evaluation electronic (MCU) is closed and control lamp “Operation” / “ “ LED green off, and “Fault device”/” “ LED red on.

9.6 Incorrect battery poling

An incorrectly poled battery of the externally connected battery is registered, messages are displayed, and the internal monitoring prevents the unit from starting up again. Signalling contact "Unit fault" of the external evaluation electronics (MCU) is closed, the control lamp "Operation"/ " " LED green is off, and "Fault-unit"/ " " LED red flashes. In the LCD- Display, " –BAT- " is shown.

9.7 Ventilator fault


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During operation of the ventilator (temperature controlled) an air-current monitoring system controls the function of the ventilator. If an error occurs, the following procedure takes place.

• LED red "ventilator fault"/ " " is activated

• Non-urgent alarm (SV2) of the external evaluation electronic (MCU) is closed and the control lamp “Operation”/ “ “ LED green is signalled

• The rectifier current is reduced automatically to 60 % Irated.

In this way it is possible to operate the unit with reduced power.

10 Adaptation of float charge voltage to battery ambient

The charging voltage of lead batteries, particularly maintenance-free lead batteries, should be adjusted to the ambient temperature. The temperature sensor is connected to the connection terminal, i.e.only one temperature sensor per system. Use a screened cable if the sensor is used externally. The length should not exceed 5 m. Sensor element- 2 kOhm +/- 2 % NTC.

This function is only available in the „float charging“ mode. UA at 20°C is automatically established on sensor breakage! The (tEMP) function must also be activated via the MCU!

11 Fuses

According to the technical data sheet.

Access to the input and output fuses are only possible after opening the unit.

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General specification TEBECHOP 12000. 48V 200A (240A) TEBECHOP 12000 series are hot-swappable, designed for superior performance in industrial, IT, and telecom applications. Rectifier is fully electronic three phase switch mode power supply module. It has very high efficiency and power factor. The size makes it one of the most compact 200A (240A) forced cooled rectifier module in application. Measuring just 19” W x 3U H x 430mm D. This module has power density of 7W/in^3. The high efficiency and reliability of this unit ensures maximum system uptime for critical application up to 4,000 Amp, to minimize operating cost and reduce installation time. The user interface makes remote or local programming and monitoring of all major parameters easy. Remote computer communication is possible through RS-485 serial interface. Input characteristics Nominal input voltage: 480V 3 Phase without neutral. Input voltage range: 408 – 528V Input frequency: 47-63Hz Inrush current: < 22A per phase Input current: 15A nominal Power factor: > 0.94 nominal Turn on delay: 8 sec. Efficiency: >93% @ 100% load >94% @ 50-75% load >90% @ 20% load High voltage test: 2200V DC for1 minute between input to chassis Output characteristic Boost charge: 57.6V Trickle charge: 53.5V Direct feed: 50V Battery test mode: 43.2V Output voltage adj. Range: 40-60V Output voltage regulation: +/-1% Output current: 200A @ 54V (IV mode) 240A @ 43,2V only in power constant mode with the Battery. Dynamic regulation: <+/- 4% of final voltage for 10% to 100% to 10% step load change. Regulation within 1mS to nominal value. Output noise: <2mV Psophom. weighted.

<30mv RMS 10khz to 100MHz. <0,5% peak to peak. Load sharing: Better than +/-5% active current sharing at >20% load. Protection: Fuse at output. Thermal derating: > 70°C internal air temperature. Overvoltage protection: 60V +/- 1% , only faulty unit shuts down. Overtemperature protection: shutdown with self recovery. Standard Features Rectifier status indication: Rectifier OK – Green Line voltage present – Amber Output overvoltage – Red Rectifier failure – Red Fan failure – Red Output fuse failure - Red LCD Display: Alphanumerical display normally displays output voltage, current and rectifier status. Environmental Cooling: Forced cooling, fan speed control. Operating temperature: -15 to +50°C Humidity: 0% to 90% non-condensing. Mechanical Dimensions: Width 19” Height 3U (133mm) Depth 430mm. Weight: 22Kg Noise: <60 dBA (A weighted.) Magazine size: One rectifier occupies 3U of cabinet height. Magazine fits cabinet depth of 600mm or greater. Connections: Connectors are mounted on the back of rectifier module with matching connectors at the back of the magazine. Mating of connectors occurs when the Rectifiers is plugged into the magazine. Safety IEC 950/EN60950/UL1950 Other standards Flicker: EN61000-3-3 Electrostatic discharge immunity: EN61000-4-2 Electromagnetic field immunity: EN61000-4-3 10V/m Level3 Burst immunity: EN61000-4-4 Surge immunity EN61000-4-5

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OPERATIONS AND MAINTENANCE MANUAL

For

Benning Power Electronics

MCU 2000+ REMOTE MONITORING UNIT

(028-0008-020 REV A)

SAVE THESE IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be followed during installation

and maintenance of the Power System.

11120 Grader Street Dallas, TX 75238

214-553-1444, Fax 214-553-1355

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BPE 48-4000 Typical Alarms

TYPICAL ALARM RELAY CONFIGURATION (Not all alarms may be present)

Relay Box Alarm ConfigurationK1 External BDFB FaultK2 Inverter System FaultK3 AC Mains FailK4 Multiple Rectifier FailK5 Battery On DischargeK6 DC Voltage Low (<47VDC)K7 Internal Load Breaker FaultK8 Battery Breaker Fault

X5K3 Minor

TYPICAL MAJOR AND MINOR ALARM CONFIGURATION (Not all alarms may be present)

System Alarm Description Major Minor NoteInternal Load Breaker Fault XExternal BDFB Fault XBattery Breaker Fault XInverter System Fault XLoad Shed Breaker Tripped XInternal MCU Communication Lost XAll Rectifiers Switched Off XRedundancy (N+1) Failure X Multiple Rectifer FailAC Mains Fail X All AC inputs removedModem Fault X MCU has lost communication with ModemDC Voltage <47.0V XDC Voltage <43.0V XDC Voltage >56.0V XBattery Temperature >27C XBattery Test Fail X

Rectifier Specfic AlarmsFan Failure XPower Failure (AC and DC Fail) XRectifeir AC Failure XModule Fail XModule Over Voltage XModule Over Temperature XModule Turned Off X

Multiple Rectifier Failure X

Rev 1 1 of 2

BPE 48-4000 Typical Alarms

TYPICAL LED DESCRIPTIONS

Front Display LED'sFloat GreenBoost YellowBattery Test Active YellowBattery Test Fault RedRectifier Fault RedAC Mains Failure RedDC High (>56.0VDC) RedDC Low (<47.0VDC) RedBattery Temperature High (>27C) RedModem Error RedInternal Load Breaker Fault RedExternal BDFB Fault RedBattery Breaker Fault Red

Rev 1 2 of 2

BPE4000_CAB_OAM_028-0005-120_Rev.B_204

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