Benning O&M Manual 62.5kVA (Final Rev. 9) PDF
Document Details
2022
BENNING Elektrotechnik und Elektronik GmbH & Co. KG
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Summary
This document is an operation and maintenance (O&M) manual for Benning Enertronic I 3-1 (UEG) and 3-3 (UDG) 62.5 kVA systems. It includes detailed instructions for installation, operation, safety, and maintenance of the equipment. The manual covers topics like applicability, document storage, and warranty.
Full Transcript
ENERTRONIC I ENERTRONIC I 3-1 (UEG) ENERTRONIC I 3-3 (UDG) Operating instructions English original version 4999.00100094176 en Version 1.01 24.03.2022 See operating instruction befo...
ENERTRONIC I ENERTRONIC I 3-1 (UEG) ENERTRONIC I 3-3 (UDG) Operating instructions English original version 4999.00100094176 en Version 1.01 24.03.2022 See operating instruction before connection to the supply SAVE THESE INSTRUCTIONS This operating instruction contains important instructions that shall be followed during installation and maintenance of the Systems Legal notice Notes concerning the documentation For safe operation of the product, knowledge is required that is provided in this original version. The information is shown in a brief, clear format. The chapters and pages are numbered consecutively. The product is documented in these instructions. The relevant data can be found in the technical information. During installation, commissioning, operation and the performance of maintenance work, it must be ensured that the documentation that applies to the product is used. The products are subject to continuous further development. The manufacturer reserves the right to make changes to the shape, equipment and technology of the product. The information corresponds to the state of technical knowledge at the time of printing. For this reason, no claims for certain product characteristics can be derived from the contents of this documentation. Manufacturer/holder of right BENNING Elektrotechnik und Elektronik GmbH & Co. KG Münsterstraße 135 – 137 46397 Bocholt Germany Telephone: +49 2871/93-0 Commercial register Coesfeld HRA No. 4661 General non-discrimination The manufacturer is aware of the importance of language with regard to the equality of men and women, and endeavors to take this into account at all times. Nevertheless, for the sake of improving legibility, differentiated formulations have not been used. Copyright © 2021, BENNING Elektrotechnik und Elektronik GmbH & Co. KG All rights reserved. This document, particularly all of the contents, texts, photographs and graphics that it contains, are protected by copyright. No part of this document or the associated texts may be reproduced or edited, copied or distributed using electronic media in any form (printed, photocopied or using any other method) without express written permission. The information in this documentation can be changed without notice, and does not represent any obligation on the part of the manufacturer. The manufacturer is not obliged to make additions to this documentation or keep them up to date. The manufacturer reserves the right to make improvements to this documentation and the products described therein at any time without notice. Support / Helpdesk BENNING Helpdesk Team Phone: 1-800-910-3601 Email: [email protected] Internet: www.benning.de List of contents List of figures................................................................................................................................. 11 List of tables.................................................................................................................................. 15 1 Abbreviations and symbols used............................................................................. 17 2 Basic notes.................................................................................................................. 21 2.1 Applicability............................................................................................................................. 22 2.2 Document storage................................................................................................................... 22 2.3 Purpose of the instructions..................................................................................................... 22 2.4 Special information................................................................................................................. 22 2.4.1 Description of the accumulator............................................................................................... 22 2.5 Legal notes............................................................................................................................. 23 2.5.1 Warranty................................................................................................................................. 23 2.5.2 Liability exclusion.................................................................................................................... 23 2.5.3 Software changes................................................................................................................... 23 2.5.4 Hardware changes.................................................................................................................. 23 2.5.5 Figures and drawings............................................................................................................. 23 2.5.6 Trademarks............................................................................................................................. 23 2.5.7 Legal claims............................................................................................................................ 23 2.6 Identification............................................................................................................................ 24 2.7 Type plates (example)............................................................................................................ 24 2.7.1 Type code (example).............................................................................................................. 25 2.8 Declaration of conformity........................................................................................................ 25 3 Safety........................................................................................................................... 27 3.1 Basic information about safety................................................................................................ 28 3.2 Safety notes............................................................................................................................ 28 3.3 Safety marking........................................................................................................................ 29 3.4 Safety information warning levels........................................................................................... 29 3.5 Safety marking in the operating room..................................................................................... 30 3.6 Used symbols......................................................................................................................... 31 3.7 Personnel qualifications.......................................................................................................... 33 3.8 Qualification for installation and maintenance........................................................................ 34 3.9 Intended use........................................................................................................................... 34 3.10 Handling of batteries............................................................................................................... 36 3.11 Residual risk........................................................................................................................... 38 3.12 Personal protective equipment............................................................................................... 39 3.13 Safety rules according to EN 50110 / NFPA 70E / VDE 0105............................................... 39 3.14 Fire protection......................................................................................................................... 40 3.15 Emergency plan...................................................................................................................... 40 4 Transport..................................................................................................................... 41 4.1 Center of gravity of the systems............................................................................................. 44 4.2 Transport options.................................................................................................................... 45 4.2.1 Transport with lifting belts....................................................................................................... 45 4.2.2 Transport to swivel lifting eyes................................................................................................ 46 4.2.3 Upright (vertical) transport on swivel lifting eyes.................................................................... 46 4.2.4 Transport with fork lift, lift trucks or crane fork........................................................................ 47 4.2.5 Transport with the crane......................................................................................................... 48 4.3 Lifting in................................................................................................................................... 49 5 Storage........................................................................................................................ 51 6 Principle of operation and setup of the system....................................................... 53 6.1 General principle of operation................................................................................................. 54 6.1.1 General principle of operation (double rectifier, double inverter)........................................... 55 V 1.01 5 4999.00100094176 en 6.1.2 Protection Concepts................................................................................................................ 55 6.2 Views....................................................................................................................................... 56 6.2.1 Front view................................................................................................................................ 56 6.2.2 Internal view............................................................................................................................ 57 6.3 Schematic diagram................................................................................................................. 61 6.3.1 Schematic diagram SCR 3-ph Q500 double rectifier, double inverter.................................... 61 6.3.2 Circuit diagram ENERTRONIC I 62.5 kVA (00100094176).................................................... 62 6.3.3 General component identification SCR 3-ph Q500 double rectifier and inverter.................... 62 6.4 Battery..................................................................................................................................... 64 6.4.1 Battery data and charging....................................................................................................... 64 6.4.2 Battery charging with temperature tracking (optional)............................................................ 65 6.5 Battery monitor........................................................................................................................ 66 6.6 Battery circuit test................................................................................................................... 67 6.7 Battery capacity test................................................................................................................ 67 6.8 Make-before-break switch (manual bypass)........................................................................... 68 6.9 Static bypass........................................................................................................................... 71 6.10 Event recorder (event memory).............................................................................................. 71 6.11 Backfeed protection................................................................................................................ 72 7 Operating elements and important components......................................................73 7.1 Alphanumerical display and operating panel.......................................................................... 74 7.1.1 LED-Operating panel.............................................................................................................. 75 7.1.2 LED-strip................................................................................................................................. 76 7.1.3 Display.................................................................................................................................... 78 7.2 TFT, Touch-Display and operating panel (optional)............................................................... 78 7.2.1 Visual layout............................................................................................................................ 78 7.2.2 TFT Mechanical design........................................................................................................... 79 7.2.3 Operating elements:................................................................................................................ 80 7.3 Controller board „A100“.......................................................................................................... 84 7.4 A230 I/O card, A330 expansion card...................................................................................... 85 7.4.1 LEDs on A230......................................................................................................................... 86 7.4.2 Battery temperature sensor on A230...................................................................................... 87 7.4.3 A330 expansion card.............................................................................................................. 88 7.4.4 LEDs on A330......................................................................................................................... 89 7.4.5 Relay contacts (external messages) A230, A330................................................................... 90 7.4.6 Digital inputs A230, A330........................................................................................................ 92 7.4.7 Digital input: Manual bypass................................................................................................... 93 7.4.8 Digital input: External output breaker...................................................................................... 94 7.4.9 Digital input: External battery breaker..................................................................................... 94 7.4.10 Digital input: Coupling switch.................................................................................................. 94 7.4.11 Digital input: Battery charging off............................................................................................ 94 7.4.12 Digital input: Remote Power OFF........................................................................................... 95 7.4.13 Digital input: Remote On......................................................................................................... 95 7.4.14 Digital input: Remote bypass.................................................................................................. 95 7.4.15 Digital input: Diesel operation................................................................................................. 96 7.4.16 Digital input: Disable bypass................................................................................................... 96 8 Assembling..................................................................................................................97 8.1 Installation location requirements.........................................................................................100 8.1.1 Subsurface............................................................................................................................100 8.1.2 Room atmosphere................................................................................................................100 8.1.3 Space requirement................................................................................................................101 8.1.4 Escape route.........................................................................................................................101 8.2 Tools required.......................................................................................................................102 8.3 Preparing components..........................................................................................................103 8.4 Assembling the system cabinet............................................................................................103 V 1.01 6 4999.00100094176 en 8.4.1 Assembly of several cabinet units........................................................................................ 103 8.5 UPS system assembly.......................................................................................................... 104 8.5.1 Positioning............................................................................................................................ 106 8.5.2 Mechanical............................................................................................................................ 106 8.5.3 Electrical............................................................................................................................... 107 8.5.4 Control / communications..................................................................................................... 111 9 Installation................................................................................................................. 117 9.1 Preparation for installation.................................................................................................... 121 9.2 Requirements for electrical connection................................................................................. 122 9.2.1 Cable entry from below......................................................................................................... 123 9.2.2 Cable entry from above........................................................................................................ 124 9.2.3 Incoming mains supply......................................................................................................... 125 9.2.4 Network configurations......................................................................................................... 125 9.3 Earthing................................................................................................................................. 126 9.3.1 Views busbar and stud for protective earthing conductor connection.................................. 127 9.4 AC connections..................................................................................................................... 128 9.4.1 Main AC connection.............................................................................................................. 129 9.4.2 Main power connection X001 (rectifier)................................................................................ 130 9.4.3 Bypass input connection X005............................................................................................. 132 9.4.4 System output X006............................................................................................................. 133 9.5 Recommended cable cross-sections main AC input............................................................ 134 9.5.1 Cable cross-sections X001 (Rectifier) (separated mains) (SCR)......................................... 135 9.5.2 Cable cross-sections X005 (separated mains) (IGBT & SCR)............................................. 135 9.5.3 Cable cross-sections X006 Output (IGBT/SCR)................................................................... 135 9.6 Recommended AC safety equipment and selectivity........................................................... 136 9.6.1 AC- Fuse main power X001 (separated mains) (SCR)........................................................ 136 9.6.2 AC- Fuse main power X005 (separated mains) (IGBT & SCR)........................................... 136 9.7 DC connection (battery)........................................................................................................ 137 9.7.1 Battery connection range X004............................................................................................ 138 9.8 Recommended cable cross-sections DC (battery)............................................................... 139 9.8.1 Cable cross-sections battery input X004 at 125 V................................................................ 140 9.8.2 Cable cross-sections battery input X004 at 216 V................................................................ 140 9.8.3 Cable cross-sections battery input X004 at 240 V................................................................ 140 9.9 Recommended DC safety equipment and selectivity........................................................... 141 9.9.1 DC battery input fuse Q100 (X004) at 125 V........................................................................ 141 9.9.2 DC battery input fuse Q100 (X004) at 216 V........................................................................ 141 9.9.3 DC battery input fuse Q100 (X004) at 240 V........................................................................ 142 9.9.4 Switch batteries to one device.............................................................................................. 142 9.10 Connecting external control lines (signal wiring).................................................................. 143 9.10.1 Installation of digital inputs (control lines)............................................................................. 144 9.10.2 Paralleling signaling wires (optional).................................................................................... 146 9.10.3 REMOTE OFF (digital input)................................................................................................. 148 9.10.4 EMERGENCY POWER OFF................................................................................................ 148 9.10.5 Connecting the voltage-free relays (status).......................................................................... 148 9.11 Notice sign Backfeed Protection........................................................................................... 148 9.12 Parallel operation with coupling switch (optional)................................................................. 149 9.13 Wiring the parallel function................................................................................................... 151 9.13.1 Block diagram “Common parallel wiring for 2 units”............................................................. 151 9.13.2 Block diagram “Parallel wiring for 4 units”............................................................................ 152 9.14 Wiring the “Coupling switch” (group connector)................................................................... 153 9.14.1 Parallel wiring for 2 units and “Coupling switch” (group connector)..................................... 153 9.14.2 Block diagram “Control wiring for 2x2 coupling switch (group connector) system”.............. 154 9.14.3 Block diagram “Parallel wiring for 2x2 units and coupling switch (group connector)........... 155 9.14.4 Sychronisation wiring for coupling system (group connector) of 2x2 units........................... 156 V 1.01 7 4999.00100094176 en 9.15 Configuration “A100” for parallel operation...........................................................................157 9.16 Install wiring the parallel function (optional)..........................................................................158 9.16.1 Stripping data cables............................................................................................................158 9.16.2 Earthing data cables.............................................................................................................158 9.16.3 Fixing data cables.................................................................................................................158 9.16.4 CAN Bus connection.............................................................................................................159 9.16.5 24V-Control cables...............................................................................................................159 10 Commissioning.........................................................................................................161 10.1 Tools required.......................................................................................................................162 10.2 Preparation for commissioning.............................................................................................163 10.2.1 Make-before-break switch Q500 (optional)...........................................................................163 10.2.2 Battery breaker Q100............................................................................................................164 10.2.3 DC fuses “Q400” and “Q402” internal power supply (system)..............................................165 10.2.4 AC circuit breaker “Q401” for internal power supply (system)..............................................166 10.3 Checking the electrical connection mechanically.................................................................167 10.3.1 Checking the electrical connection electrically.....................................................................168 10.4 Performing commissioning....................................................................................................169 11 Alphanumerical display and operating panel menu..............................................173 11.1 Top menu level/measured values/submenus.......................................................................174 11.2 Event menu...........................................................................................................................177 12 Alphanumerical display: Settings in the configuration main menu.....................179 12.1 Configuration/Settings...........................................................................................................180 12.2 Menu Language....................................................................................................................181 12.3 Menu Date/Time...................................................................................................................182 12.4 Menu Print Events/Stat.........................................................................................................184 12.5 Menu Save settings (Setup)..................................................................................................185 12.6 Menu Autostart......................................................................................................................186 12.7 Menu Contrast and brightness..............................................................................................188 12.8 Menu Output voltage.............................................................................................................189 12.9 Menu Password....................................................................................................................190 12.9.1 Password entry.....................................................................................................................190 12.9.2 Change Password.................................................................................................................192 12.10 Menu Software versions.......................................................................................................193 12.11 Menu Type and serial-no......................................................................................................195 12.12 Menu Battery charging..........................................................................................................196 12.12.1 Setting high current charging................................................................................................196 12.12.2 Capacity test.........................................................................................................................197 12.12.3 Charging off...........................................................................................................................202 12.13 Battery – Central battery for parallel operation.....................................................................204 12.14 Boost charging......................................................................................................................206 12.14.1 Switching on (boost) charging manually...............................................................................206 12.14.2 (Boost) charge abort.............................................................................................................208 12.14.3 Auto charging........................................................................................................................208 12.15 Menu Key lock (password protection)...................................................................................209 12.16 Menu Parallel operation (optional)........................................................................................211 12.17 Menu Disable bypass............................................................................................................213 12.18 Menu Synchronisation..........................................................................................................215 12.19 Menu Battery limits...............................................................................................................216 13 Touch display and operating panel.........................................................................217 13.1 Settings in the configuration main menu...............................................................................218 13.2 Settings and options.............................................................................................................218 13.3 Security (read: PW0, write: PW0).........................................................................................218 13.3.1 Change password level (read: PW0, write: PW0).................................................................219 V 1.01 8 4999.00100094176 en 13.3.2 Change password (read: PW1, write: PW1)......................................................................... 219 13.3.3 Key lock (read: PW1, write: PW1)........................................................................................ 220 13.4 General settings (read: PW1, write: PW1)............................................................................ 220 13.4.1 Display (read: PW1, write: PW1).......................................................................................... 220 13.4.2 Date/Time (read: PW1, write: PW1)..................................................................................... 223 13.4.3 Presentation (read: PW1, write: PW1).................................................................................. 224 13.5 System settings (read: PW1, write: PW1)............................................................................. 226 13.5.1 Complete system (read: PW1, write: PW2).......................................................................... 226 13.5.2 Battery management (read: PW1, write: PW1/PW2)............................................................ 234 13.6 System (information) (read: PW1, write: PW1)..................................................................... 238 13.6.1 Events (read: PW1, write: PW1)........................................................................................... 238 13.6.2 System type (read: PW1, write: PW1).................................................................................. 239 13.6.3 Software versions................................................................................................................. 239 13.6.4 Detailed measurements (read: PW1, write: PW1)................................................................ 240 13.7 Language (read: PW1, write: PW1)...................................................................................... 241 14 Operation, systems with alphanumerical display................................................. 243 14.1 Basics................................................................................................................................... 244 14.2 Single operation.................................................................................................................... 245 14.2.1 Starting normal operation..................................................................................................... 245 14.2.2 Switching normal operation to bypass operation.................................................................. 249 14.2.3 Switching bypass operation to normal operation.................................................................. 251 14.2.4 Switching on manual bypass – maintenance....................................................................... 254 14.2.5 Switching manual bypass operation to bypass operation..................................................... 256 14.2.6 Starting bypass operation..................................................................................................... 257 14.2.7 Switching off bypass operation – switching off the system.................................................. 258 14.2.8 Switching off normal operation – switching off the system................................................... 259 14.3 Battery operation / mains failure and return......................................................................... 261 14.3.1 Mains failure and return in normal operation........................................................................ 262 14.4 Faults.................................................................................................................................... 263 14.5 Manual bypass (only during maintenance work by the manufacturer)................................. 264 14.5.1 Manual bypass (systems with Q005, Q051, Q052).............................................................. 265 14.5.2 Manual bypass for systems with make-before-break switch Q500 (Option)........................ 266 14.6 Make-before-break switch Q500 (Option) – Using test function........................................... 267 14.6.1 Using test function make-before-break switch – Starting from state “UPS off”.................... 268 14.6.2 Using test function make-before-break switch – Starting from state “normal operation”..... 270 14.6.3 Using test function make-before-break switch – Starting from state “bypass operation”..... 272 15 Operation, systems with touch display.................................................................. 275 16 Interface and software options................................................................................ 277 16.1 Communication gateway...................................................................................................... 278 16.2 MODBUS protocol................................................................................................................ 280 16.2.1 LED-Marker (Mimic diagram)................................................................................................ 280 16.2.2 Measurement Pages............................................................................................................. 283 16.3 MODBUS protocol structure................................................................................................. 297 16.3.1 Data telegram structure........................................................................................................ 297 16.3.2 Data telegram structure........................................................................................................ 297 16.3.3 Calculating the check sum.................................................................................................... 298 16.3.4 Processing functions............................................................................................................. 299 17 Hardware options..................................................................................................... 301 17.1 Fan and filter units (optional)................................................................................................ 302 18 Isolating the system complete................................................................................ 303 18.1 Schematic diagram external separators (example).............................................................. 306 18.2 Check isolation...................................................................................................................... 307 19 Maintenance management....................................................................................... 309 V 1.01 9 4999.00100094176 en 19.1 General information for maintenance...................................................................................312 19.2 Inspection..............................................................................................................................313 19.3 Maintenance..........................................................................................................................313 19.3.1 Maintenance interval.............................................................................................................314 19.3.2 Battery maintenance.............................................................................................................315 19.4 Cleaning................................................................................................................................315 19.4.1 Replace and clean filter inserts (only systems with filters)...................................................316 19.4.2 Replacing the battery on the controller card A100................................................................317 19.5 Measuring the controller board battery voltage....................................................................318 19.6 Firmware update...................................................................................................................318 19.7 Safety check in accordance with DGUV Provision 3............................................................318 20 Spare part list............................................................................................................319 20.1 General spare parts list.........................................................................................................320 21 Decommissioning and dismantling.........................................................................323 21.1 Switching off the system.......................................................................................................324 21.1.1 Disconnect the AC and DC supply........................................................................................324 22 Disposal.....................................................................................................................325 22.1 Packaging.............................................................................................................................326 22.2 Disposal of components........................................................................................................326 22.3 Disposal of batteries.............................................................................................................327 23 Appendix....................................................................................................................329 23.1 Fault event messages, causes and possible remedies........................................................330 23.2 Operational event messages................................................................................................337 23.2.1 Rectifier.................................................................................................................................337 23.2.2 Inverter/output.......................................................................................................................338 23.2.3 Bypass..................................................................................................................................339 23.2.4 Pre-charging..........................................................................................................................339 23.2.5 Operating elements...............................................................................................................339 23.2.6 I/O cards A230/A330.............................................................................................................340 23.2.7 Parallel operation (OPTION).................................................................................................340 24 Contact partners in the Service department...........................................................341 25 Attachment.................................................................................................................343 Technical data sheet.............................................................................................................345 Single line diagram................................................................................................................348 Dimension and front view drawing........................................................................................349 Circuit diagram......................................................................................................................350 Terminal block diagram.........................................................................................................374 Customer bill of material........................................................................................................389 Example of a commissioning report template.......................................................................396 V 1.01 10 4999.00100094176 en List of figures Figure 2-1: System type plate (example)...............................................................................................24 Figure 4-1: TILTWatch® ok....................................................................................................................44 Figure 4-2: TILTWatch® red...................................................................................................................44 Figure 4-3: Symbol center of gravity......................................................................................................44 Figure 4-4: Transport with lifting belts....................................................................................................45 Figure 4-5: Swivel lifting eyes vertical....................................................................................................46 Figure 4-6: Swivel lifting eye vertical transport.......................................................................................46 Figure 4-7: Transport..............................................................................................................................47 Figure 4-8: Crane eyelet example..........................................................................................................49 Figure 6-1: Front view ENERTRONIC I (example 62.5 kVA).................................................................56 Figure 6-2: Internal view ENERTRONIC I rightmost two cabinets (example 62.5 kVA)........................57 Figure 6-3: Internal view ENERTRONIC I leftmost two cabinets (example 62.5 kVA)..........................59 Figure 6-4: Internal view ENERTRONIC I left side (example 62.5 kVA)................................................60 Figure 6-5: Internal view ENERTRONIC I right side (example 62.5 kVA).............................................60 Figure 6-6: Schematic diagram SCR 3-ph Q500....................................................................................61 Figure 6-7: General component identification SCR 3-ph Q500 double rectifier and inverter.................62 Figure 6-8: Battery voltage compensation characteristic.......................................................................66 Figure 6-9: System current flow path when Q500 is in AUTO position..................................................68 Figure 6-10: System current flow path when Q500 is in TEST position.................................................69 Figure 6-11: System current flow path when Q500 is in BYPASS position...........................................70 Figure 7-1: Alphanumerical display and operating panel.......................................................................74 Figure 7-2: LED strip..............................................................................................................................76 Figure 7-3: Display.................................................................................................................................78 Figure 7-4: Example for status messages in the display........................................................................78 Figure 7-5: Visual layout of the display and control unit TFT.................................................................78 Figure 7-6: Mechanical design of the display and control unit TFT A240..............................................79 Figure 7-7: Controller board A100..........................................................................................................84 Figure 7-8: I/O card A230.......................................................................................................................85 Figure 7-9: BR24 A230...........................................................................................................................85 Figure 7-10: LEDs on A230....................................................................................................................86 Figure 7-11: I/O card A230 X400...........................................................................................................87 Figure 7-12: Expansion card A330.........................................................................................................88 Figure 7-13: LEDs on A330....................................................................................................................89 Figure 7-14: A230 relay identification.....................................................................................................91 Figure 7-15: A330 relay identification.....................................................................................................91 Figure 8-1: Tools..................................................................................................................................102 Figure 8-2: Front view doors open leftmost two cabinets.....................................................................104 Figure 8-3: Front view doors open rightmost two cabinets..................................................................105 Figure 8-4: Door hinge..........................................................................................................................106 Figure 8-5: Roof covers........................................................................................................................106 Figure 8-6: Hinges and brackets..........................................................................................................107 Figure 8-7: Inductors and terminal blocks X700 and X800..................................................................107 Figure 8-8: Terminal block X700 close up view....................................................................................108 Figure 8-9: Terminal block X800 close up view....................................................................................108 Figure 8-10: Ground connection bars...................................................................................................109 Figure 8-11: Terminal blocks X600 and X900......................................................................................109 V 1.01 11 4999.00100094176 en Figure 8-12: Terminal block X900....................................................................................................... 109 Figure 8-13: Terminal block X600....................................................................................................... 110 Figure 8-14: K005................................................................................................................................ 110 Figure 8-15: C600................................................................................................................................ 111 Figure 8-16: X100................................................................................................................................ 111 Figure 8-17: Ribbon cable connection point overview......................................................................... 112 Figure 8-18: A100 connections............................................................................................................ 113 Figure 8-19: A650 / A651 / A007......................................................................................................... 114 Figure 8-20: A250................................................................................................................................ 115 Figure 8-21: A160 and A520............................................................................................................... 115 Figure 9-1: Cable entries with IP21..................................................................................................... 124 Figure 9-2: View earthing busbar........................................................................................................ 127 Figure 9-3: View detail earthing busbar............................................................................................... 127 Figure 9-4: Protective earthing stud.................................................................................................... 127 Figure 9-5: Mains connection rectifier input X001............................................................................... 130 Figure 9-6: Type plate.......................................................................................................................... 130 Figure 9-7: Mains connection bypass input X005 three phases (example)........................................ 132 Figure 9-8: Connection range system output X006 three phases....................................................... 133 Figure 9-9: Battery connection range X004 (example)........................................................................ 138 Figure 9-10: Example wiring for external manual bypass with internal 24 V supply for digital input.. 144 Figure 9-11: Example wiring for installation of more than one digital input with internal 24 V supply. 145 Figure 9-12: Example wiring for paralleling of digital input with internal 24 V supply......................... 145 Figure 9-13: Example wiring for paralleling of digital input with external 24 V supply........................ 146 Figure 9-14: Example wiring for paralleling of digital input with internal 24 V supply......................... 147 Figure 9-15: Notice sign....................................................................................................................... 148 Figure 9-16: Block diagram “Common parallel wiring for 2 units”....................................................... 151 Figure 9-17: Block diagram “Parallel wiring for 4 units”....................................................................... 152 Figure 9-18: Parallel wiring for 2 units and group connector............................................................... 153 Figure 9-19: Block diagram “Control wiring for 2x2 coupling switch system”...................................... 154 Figure 9-20: Block diagram “Parallel wiring for 2x2 units and group connector.................................. 155 Figure 9-21: Sychronisation wiring for coupling system of 2x2 units.................................................. 156 Figure 9-22: Controller board A100..................................................................................................... 157 Figure 9-23: Master address............................................................................................................... 157 Figure 9-24: 24 V Slave address......................................................................................................... 157 Figure 9-25: Stripping data cable........................................................................................................ 158 Figure 9-26: Earthing data cable......................................................................................................... 158 Figure 9-27: Fixing data cable............................................................................................................. 158 Figure 9-28: CAN Bus connector......................................................................................................... 159 Figure 9-29: Master 24 V control cable............................................................................................... 159 Figure 9-30: Slave 24 V control cable................................................................................................. 159 Figure 10-1: Q500 position AUTO....................................................................................................... 163 Figure 10-2: Battery breaker Q100...................................................................................................... 164 Figure 10-3: DC fuse “Q400” / “Q402”................................................................................................. 165 Figure 10-4: Location of DC fuses “Q400” and “Q402”....................................................................... 165 Figure 10-5: AC circuit breaker “Q401”............................................................................................... 166 Figure 10-6: Location of AC circuit breaker “Q401”............................................................................. 166 Figure 10-7: Make-before-break switch............................................................................................... 169 Figure 13-1: “Settings/Options” menu................................................................................................. 218 Figure 13-2: “Security” menu............................................................................................................... 218 V 1.01 12 4999.00100094176 en Figure 13-3: Pop-up for entering the password....................................................................................219 Figure 13-4: “General settings” menu..................................................................................................220 Figure 13-5: Displaytest........................................................................................................................221 Figure 13-6: Touchpaneltest................................................................................................................222 Figure 13-7: Entry window for setting date and time............................................................................223 Figure 13-8: Selection window for the presentation of voltage, temperature and load (bar graphs)...224 Figure 13-9: Presentation of system loading by means of bar graphs.................................................224 Figure 13-10: Block diagram of the UPS system output......................................................................225 Figure 13-11: Diagram Smax = f(CosPhiLoad) - normalised presentation..........................................225 Figure 13-12: “System settings” menu.................................................................................................226 Figure 13-13: “Complete system” menu...............................................................................................226 Figure 13-14: Default activation of external synchronisation...............................................................229 Figure 13-15: Display of bypass measurements when bypass is available.........................................229 Figure 13-16: Display of phase shifting angle when bypass is available.............................................229 Figure 13-17: Display of bypass measurements when bypass is not available (U).............................230 Figure 13-18: Display of phase angle when bypass is not available (U).............................................230 Figure 13-19: Display of bypass measurements when bypass is not available (f)..............................230 Figure 13-20: Display of phase angle when bypass is not available (f)...............................................230 Figure 13-21: Display of bypass measurements when bypass is not available (U, f, ext.)..................231 Figure 13-22: Display of phase angle when bypass is not available (U, f, ext.)...................................231 Figure 13-23: Setting for output voltage and autostart.........................................................................232 Figure 13-24: Bypass management settings........................................................................................232 Figure 13-25: General battery management settings...........................................................................235 Figure 13-26: Service macro for carrying out a battery capacity test...................................................235 Figure 13-27: Equalisation management settings................................................................................236 Figure 13-28: Setting the battery limits.................................................................................................237 Figure 13-29: “System” menu...............................................................................................................238 Figure 13-30: Depiction of “Events”......................................................................................................238 Figure 13-31: Display of system type...................................................................................................239 Figure 13-32: Display of software versions..........................................................................................239 Figure 13-33: Display of operating variables........................................................................................240 Figure 13-34: Detailed list of all inverter data.......................................................................................240 Figure 13-35: Display of temperatures.................................................................................................240 Figure 13-36: Display of fan speeds and statistics...............................................................................241 Figure 13-37: Display of language selection........................................................................................241 Figure 13-38: Pop-up for restarting the display and control unit..........................................................241 Figure 14-1: Disconnector Q005 bypass..............................................................................................265 Figure 14-2: Disconnector Q052 system output...................................................................................265 Figure 14-3: Disconnector Q051 mains supply....................................................................................265 Figure 14-4: Make-before-break switch, position “TEST"....................................................................266 Figure 14-5: Make-before-break switch, position “BYPASS”...............................................................266 Figure 14-6: Make-before-break switch position factory setting “AUTO”.............................................267 Figure 16-1: Communication gateway A250........................................................................................278 Figure 16-2: Alphanumerical display and operating panel...................................................................280 Figure 17-1: Filter unit..........................................................................................................................302 Figure 18-1: Schematic diagram external separators (example).........................................................306 Figure 18-2: Battery test free from voltage...........................................................................................307 Figure 18-3: Main power input X001....................................................................................................307 Figure 18-4: Bypass input X005 three phase.......................................................................................307 V 1.01 13 4999.00100094176 en Figure 18-5: Output X006 three phase................................................................................................ 308 Figure 19-1: Filter frame...................................................................................................................... 316 Figure 19-2: Battery controller............................................................................................................. 317 V 1.01 14 4999.00100094176 en List of tables Table 1-1: Abbreviations used................................................................................................................18 Table 1-2: Symbols used........................................................................................................................19 Table 2-1: Type code (example)............................................................................................................25 Table 4-1: Material for crane transport...................................................................................................49 Table 6-1: Device SCR 3-ph powerblock...............................................................................................61 Table 6-2: Key general component identification SCR 3-ph Q500 double rectifier and inverter...........63 Table 7-1: LED operation panel.............................................................................................................75 Table 7-2: LED color – component table................................................................................................76 Table 7-3: Functional description of the LEDs.......................................................................................77 Table 7-4: LEDs on A230.......................................................................................................................86 Table 7-5: LEDs on A330.......................................................................................................................89 Table 7-6: Data A230/A330 X3..............................................................................................................90 Table 7-7: Relay A230 X3 assignment...................................................................................................91 Table 7-8: Relay A330 X3 assignment...................................................................................................91 Table 7-9: Relay contact data................................................................................................................92 Table 7-10: Data A230/A330 X12..........................................................................................................92 Table 7-11: A230 assignment X12.........................................................................................................92 Table 7-12: A330 assignment X12.........................................................................................................93 Table 7-13: A230/A330 Input data X12..................................................................................................93 Table 7-14: BR24...................................................................................................................................93 Table 9-1: Protective earthing conductor connection...........................................................................126 Table 9-2: Mains connection rectifier input X001.................................................................................131 Table 9-3: Torque values for X001.......................................................................................................131 Table 9-4: Mains connection bypass input X005.................................................................................132 Table 9-5: Torque values for X005.......................................................................................................132 Table 9-6: Connection range system X006..........................................................................................133 Table 9-7: Torque values for X006.......................................................................................................133 Table 9-8: Cable cross-sections X001 (Rectifier) separated mains (SCR)..........................................135 Table 9-9: Cable cross-sections X005 Bypass input (separated mains).............................................135 Table 9-10: Cable cross-sections X006 Output (IGBT/SCR)...............................................................135 Table 9-11: AC- Fuse main power X001 (separated mains) (SCR).....................................................136 Table 9-12: AC- Fuse main power X005 (separated mains) (SCR).....................................................136 Table 9-13: Battery connection range X004.........................................................................................138 Table 9-14: DC voltage connection......................................................................................................138 Table 9-15: Cross-sections battery- input X004 at 125 V....................................................................140 Table 9-16: Cross-sections battery- input X004 at 216 V....................................................................140 Table 9-17: Cross-sections battery- input X004 at 240 V....................................................................140 Table 9-18: DC battery input fuse Q100 at 125 V................................................................................141 Table 9-19: DC battery input fuse Q100 at 216 V................................................................................141 Table 9-20: DC battery input fuse Q100 at 240 V................................................................................142 Table 10-1: Braker position..................................................................................................................163 Table 10-2: Braker position performing commission............................................................................170 Table 10-3: Breaker positions after performing commissioning...........................................................171 Table 14-1: Alarm priority table............................................................................................................244 Table 14-2: Breaker position start up...................................................................................................246 Table 16-1: LED operation panel.........................................................................................................280 Table 19-1: Preventive maintenance critical parts...............................................................................315 V 1.01 15 4999.00100094176 en Table 20-1: Spare part list................................................................................................................... 320 Table 20-2: PCB boards...................................................................................................................... 321 Table 23-1: Fault event messages, causes and possible remedies................................................... 336 Table 23-2: Operational event messages recitier................................................................................ 337 Table 23-3: Operational event messages inverter/output................................................................... 338 Table 23-4: Operational event messages bypass............................................................................... 339 Table 23-5: Operational event messages pre-charging...................................................................... 339 Table 23-6: Operational event messages opertating elements........................................................... 339 Table 23-7:Operational event messages I/O cards............................................................................. 340 Table 23-8: Operational event messages parallel operation............................................................... 340 V 1.01 16 4999.00100094176 en 1 Abbreviations and symbols used V 1.01 17 4999.00100094176 en Shortcut Definition AC Alternating Current ANSI American National Standards Institute BYP BYPASS DC Direct Current DIN German institut for standards EMC Electromagnetic Compatibility EN European standards EPO Eemergency power off GS Generator Protection IEC International Electrotechnical Commission IGBT Insulated-gate bipolar transistor LED light-emitting diode NFPA National Fire Protection Association OSHA Occupational Safety and Health Administration SELV Saftey extra low voltage SCR Silicon-controlled rectifier UPS Uninterruptible power supply Verband der Elektrotechnik, Elektronik und Informationstechnik VDE e. V. (German Electrical Engineering Association) Table 1-1: Abbreviations used V 1.01 18 4999.00100094176 en Legend Symbol Designation Meaning -Axxx Inverter -Axxx Rectivier Battery Battery -Txxx Transformer -Txxx Transformer with integrated choke -Axxx Bypass / Output thyristor -Axxx Suction circuit -Qxxx Circuit breaker -Kxxx Contactor -Sxxx Phase selector switch -Lxxx Toroidal core -Lxxx Choke -Cxxx Capacitor -Xxxx Terminal - Netral junction Analog instrumentation -Pxxx V = Voltage, A = Current V = Voltage, A = Current, Measuring junction VA = Apparent power, HZ = Frequency -Q500 Make-before-break switch Table 1-2: Symbols used V 1.01 19 4999.00100094176 en V 1.01 20 4999.00100094176 en 2 Basic notes V 1.01 21 4999.00100094176 en NOTICE Danger due to improper handling of the product You must have read and understood the instructions, to be able to safely install and use the product! This documentation contains important instructions that must be followed during installation and maintenance. As well as the instructions, the generally applicable and local regulations of the energy supply companies, accident prevention regulations and the environmental protection regulations must also be observed. The installer and the user must have access to these instructions at all times. During installation of the product in USA and CANADA, requirements specified in National Electrical Code NFPA 70 and Canadian Electrical Code (CEC) shall be followed. Special attention must paid to the safety instructions. This includes transport, assembly and installation, operation, maintenance, dismantling and disposal. The operator must ensure that the instructions are permanently available at the product, and that the personnel who work with the product are aware of the directives in these instructions. The safety and danger instructions on the product must not manipulated. 2.1 Applicability This documentation is intended for users and qualified installers. It is applicable for the ENERTRONIC I 62.5 kVA system (manufacturer's part number: 00100094176). All applicable design documents, including but not limited to, circuit diagram, bill of material, general arrangement, single line diagram applicable to this system are included in the attachment chapter of this manual (page 343). 2.2 Document storage Keep the operating instructions in a safe place. In case of an operator change, the documentation must passed onto the successor. 2.3 Purpose of the instructions These instructions were created to the best of our knowledge. They are intended to introduce the operator, the user and the maintenance personnel of the system to the setup, function, operation and maintenance, as well as to the safety-relevant conditions. Furthermore, these instructions are to ensure that trained and qualified personnel can operate and maintain the system as intended. It contains a description of how to safely assemble, install, configure, commission, maintain, troubleshoot and operate the system. 2.4 Special information This is a product for commercial and industrial use in the second environment. Restrictions regarding the installation or additional measures may be necessary to prevent interference. 2.4.1 Description of the accumulator The accumulator will called battery in these instructions and in the display unit. For reasons of better readability, continuous implementation of differentiating formulations had been dispensed with. V 1.01 22 4999.00100094176 en 2.5 Legal notes 2.5.1 Warranty Warranty or guarantee claims and the warranty period depend on the respective contractual relationship, as well as the general terms and conditions of the manufacturer. Details about the manufacturer’s warranty can be found in the contractual arrangements. Warranty and liability claims are generally excluded if the damage is the result of faulty assembly, improper use or force majeure. The information in these instructions was checked carefully. However, no liability can be assumed for errors. If any prescribed services are not performed regularly or not on time according to manufacturer specifications during the system warranty, a decision about a warranty can only be made once the findings are available. 2.5.2 Liability exclusion The manufacturer has checked the contents of the documentation for correspondence with the hardware and software that is described. Nevertheless, errors cannot be ruled out, meaning that the manufacturer cannot guarantee complete correspondence. The contents of this documentation are checked at regular intervals, and any corrections that are needed are contained within the versions that follow. Any abuse of the product shall lead to cancellation of the warranty, the guarantee and the general liability of the manufacturer. The manufacturer is not liable for damage as a result of non-observance of these instructions. The product may only be opened by an experienced electrician, if this is at all permitted. The electrician must be familiar with and adhere to the standards and regulations of the supply company and the work safety regulations. Any use other than that described in the documentation is considered to be incorrect. The manufacturer is not responsible for resulting damage. Modifications to the product or the documentation are forbidden. 2.5.3 Software changes If a software change is performed without the knowledge and approval of the manufacturer, the warranty and guarantee claim becomes void. 2.5.4 Hardware changes If changes are made to the housing or other system components without the knowledge and approval of the manufacturer, the warranty and guarantee claim becomes void. 2.5.5 Figures and drawings For general illustrative purposes, these instructions include figures and drawings. The functional possibilities and representations can deviate from the present system. 2.5.6 Trademarks All Trademarks used, even if these are not marked separately, are the property of their respective owners and are hereby acknowledged. 2.5.7 Legal claims Any Liability on the part of the manufacturer for consequential damage arising from improper use or incorrect installation of the product is expressly excluded. V 1.01 23 4999.00100094176 en 2.6 Identification The system cabinet has an unambiguous device identification (serial number). You should make a note of this data before installation, so you have it to hand for ordering spare parts or if you have any questions. Have the serial number ready to hand if you contact the Customer Service with a query. 2.7 Type plates (example) The type plate of the system can be found on the inside of the cabinet door. 1 2 3 4 5 6 7 8 9 10 11, 12 13, 14 15, 16 17, 18 19, 20 21, 22 23, 24 25, 26 27 28 31 29 30 Figure 2-1: System type plate (example) Type plate inscription: Field Contents 1 Manufacturer 2 Product type/classification 3 Series 4 Type/rating Field Contents 5 Serial number 6 Year of manufacture 7 Part number 8 Software version 9 Option number 10 Mode of operation 11 Current type, input 1 13 Current type, input 3 12 Current type, input 2 14 Current type, output 15 Rated input frequency 1 17 Rated input frequency 3 16 Rated input frequency 2 18 Rated output frequency 19 Rated input voltage 1 21 Rated input voltage 3 20 Rated input voltage 2 22 Rated output voltage 23 Rated input current 1 25 Rated input current 3 24 Rated input current 2 26 Rated output current 27 cos/kW/kVA Output 28 ICW in kA 29 type of load Free choice 31 Protection class (IP Code 30 EN 60529) V 1.01 24 4999.00100094176 en 2.8 2.7.1 V 1.01 Input current type "E" = Single-phase "D" = Three-phase alternating current D Rated input voltage in volts = xxx V xxx Type code: X Output current type "E" = Single or "D" Three-phase alternating current Rated output voltage in volts = xxx V xxx / Table 2-1: Type code (example) Type code (example) Nominal output current in A (max. one decimal place) xxx – xxx Declaration of conformity 25 / 3 Code for nominal output frequency, "2" = 50 Hz "3" = 60 Hz r The type code is made company-internal code: Characteristic forced by control, "r" = IU characteristic curve f Smoothing of the input voltage g Smoothing device (excluding interference suppression) on output side - U "U" = Uninterruptible Power Supply X "E" = Single- phase ,"D" = Three-phases G "G" = Unit xxx=Power, yyy=Battery voltage xxx-yyy The EU declaration of conformity can be requested from the manufacturer. I „I“=IGBT, „S“=SCR 4999.00100094176 en V 1.01 26 4999.00100094176 en 3 Safety V 1.01 27 4999.00100094176 en 3.1 Basic information about safety The product is built according to the state-of-the-art and the recognized safety regulations. Despite this, there might be danger to life and limb of the user or a third person in case of improper use, and the product or other material assets might be affected. If the product is operated by persons who are untrained or have not been instructed. If the products is not used for its intended purpose. If the product is maintained or repaired improperly. If the product is not operated in technically perfect condition. The system operates in mains, battery or bypass operation. It contains components at which high currents and voltages are present. Provided that it has been correctly installed, the system is earthed and corresponds to protection class: See type plate. Installation and maintenance must only be performed by the service engineer of the manufacturer or his contract partner. These instructions are an essential constituent of the product, and apply exclusively to this product from the manufacturer. The information in these instructions is binding. The instructions must be read in full, and the information therein must be followed at all times. Failure to follow the action instructions and safety instructions in these instructions, manipulation thereof or misappropriation can result in considerable danger. In the event of erroneous operation or misuse, the life and limb of the operator or third parties may be put at risk, the product and other assets belonging to the operator may be damaged, or efficient working with the product may be restricted. As well as the instructions and the binding regulations relating to the prevention of accidents that are applicable in the country and place of use, the recognized professional rules for safe and proper working must also be observed. Additional warnings are provided in order to guarantee adequate safety for personnel. Adequate safety when handling the product will only be guaranteed when this is observed. 3.2 Safety notes This instruction contains notes that must be taken into consideration for personal safety and avoiding injuries and damage to property. The notes concerning operator safety are marked with warnings. The warning instructions are shown in descending order depending on the severity of the danger. Warnings occur in front of an action that may potentially cause damage. Note contains details of the nature and source of the danger, the consequences if the danger arises and measures for averting the danger if necessary. If you see one of these symbols in the documentation, extreme caution is required. V 1.01 28 4999.00100094176 en 3.3 Safety marking Safety information a
