000 3DT Ee 03584 000

000 7/5/2011 MP Issue for
Information
JEK MAS MAS
REV NO DATE BY: DESCRIPTION CHKD. CERT. APPD.

Project Title CONVERSION OF QURAYYAH OPEN CYCLE POWER
PLANT TO COMBINED CYCLE POWER PLANT
PROJECT C

Client

Consultant

Contractor

Document Title
Operating Instructions - 125 V Block-1 DCDB
CREATED BY:
CHECKED BY: JEK
DATE STARTED:6/30/2011 DATE COMPLETED: 6/30/2011
OPR'G. DEPT: ENG. DEPT:
APPROVAL/CERTIFICATION INFORMATION THIS DOCUMENT IS NOT TO BE USED FOR
CONSTRUCTION OR FOR ORDERING
MATERIAL UNTIL CERTIFIED AND DATED
DOC. NO.30621127-000-3DT-EE-03584
REV. NO. 0
QURAYYAH SAUDI ARABIA
JOB ORDER NO.
1-0923053.01
JOB NO. PROJECT
SUBDIVISION
DOCUMENT
TYPE CODE
DOCUMENT
NUMBER
REV NO.
30621127 000 3DT EE-03584 000
1110045001/20GB
1110045001-005

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DC POWER SUPPLY
(RECTIFIER / CHARGER)
Type: SDC 125-1200-R

Client: M/s Techmaster Inc.
1952 McDowell Road, Suite 204
Naperville, Illinois 60563 USA
P.O. No.: 11022
Project name: Conversion of Qurayyah Open Cycle Power Plant to
Combined Cycle Power Plant Project C
End-User: Saudi Electric Company
Installation: 125V Block-1 DCDB
applicable for:
Type: Item No.: GUTOR Ref.:
SDC 125-1200-R
C10BTL01 & C10BTL02 1110045001-01. 1110045001-06
SDC 125-1200-R
C20BTL01 & C20BTL02 1110045002-01. 1110045002-06
SDC 125-1200-R C30BTL01 & C30BTL02 1110045003-01. 1110045003-06
SDC 125-1200-R C40BTL01 & C40BTL02 1110045004-01. 1110045004-06
SDC 125-1200-R C50BTL01 & C50BTL02 1110045005-01. 1110045005-06

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C
O
N
T
E
N
T
S

1
GENERAL INFORMATION

2
SAFETY REGULATIONS

3
SYSTEM DATA

4
PACKING TRANSPORT INSTALLATION

5
DISPLAY OPERATING & INDICATING ELEMENTS

6
COMMISSIONING

7
MAINTENANCE

8
TROUBLE SHOOTING

9
TEST DOCUMENTATION

10
SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS

11
BATTERY DOCUMENTATION

12
CUSTOMER-SPECIFIC DOCUMENTATION / CERTIFICATES

DOCUMENT INDEX & REVISION SHEET

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Here only Revisions of Descriptions in this Operating Instructions are updated (Parts lists, Schematic diagrams,
Battery documentation and Customer specific documentation are excluded). It is the responsibility of the client to
exchange Documentation in this Operating instructions.

DOCUMENTS to SDC 125-1200-R
Chapter
Doc. No.
Title
Date
Rev.
concerned pages
0 4A-1110045001/20GB COVER SHEET (7SA9002GB) 11-06-22 1 Cover sheet
4A-1110045001/20GB TABLE OF CONTENTS 11-06-22 1 all
4A-1110045001/20GB DOCUMENT INDEX &REVISIONSHEET 11-06-22 1 all
1 4A-1110045001/20GB GENERAL INFORMATION 11-06-22 1 Cover sheet
7SA9006GB General Information 09-08-10 4 all
7SA9007GB General System Principle & Description of Component 09-08-11 2 all
2 4A-1110045001/20GB SAFETY REGULATIONS 11-06-22 1 Cover sheet
7SA9009GB Safety Regulations 09-08-12 4 all
3 4A-1110045001/20GB SYSTEMDATA 11-06-22 1 Cover sheet
1110045001 Single-Line Diagram
4A-1110045001/23GB
Technical Data (7SA9010GB)
applicable for all Items
11-06-22 1 all
7SA9023GB Priorities and Operational Modes 09-08-11 3 all
4A-1110045001/20GB Explanation of the Boost Charge Function 11-06-22 1 all
4 4A-1110045001/20GB PACKING TRANSPORT INSTALLATION 11-06-22 1 Cover sheet
7SA9028GB Packing & Unpacking & Storage Air / Oversea Transport 09-10-04 4 all
7SA9030GB Transport of the System without Packing 98-06-01 1 all
7SA9031GB Erection Installation 09-10-01 4 all
7RA9195GB Assembly of Particular Cubicle Units 03-04-16 1 all
5 4A-1110045001/20GB DISPLAY OPERATING &INDICATING ELEMENTS 11-06-22 1 Cover sheet
7SA9032GB Display & Parameter Settings 09-12-22 4 all
4A-1110045001/20GB
Operating & Indicating Elements (7SA9033GB)
11-06-22 1 all
6 4A-1110045001/20GB COMMISSIONING 11-06-22 1 Cover sheet
1110045001 Single-Line Diagram
7SA9034GB Start Stop 09-09-15 5 all
4A-1110045001/20GB
Commissioning (7SA9036GB)
11-06-22 1 all
7 4A-1110045001/20GB MAINTENANCE 11-06-22 1 Cover sheet
7SA9040GB Maintenance 09-08-12 4 all
7SA9041GB Replacement of Components & Parts 09-08-12 1 all
7SA9042GB Service Training Contact Addresses 09-10-05 5 all
8 4A-1110045001/20GB TROUBLE-SHOOTING 11-06-22 1 Cover sheet
4A-1110045001/20GB
Trouble-Shooting (7SA9043GB)
11-06-22 1 all
DOCUMENT INDEX & REVISION SHEET

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DOCUMENTS to SDC 125-1200-R
Chapter
Doc. No.
Title
Date
Rev.
concerned pages
9 4A-1110045001/20GB TEST DOCUMENTATION 11-06-22 1 Cover sheet
10 4A-1110045001/20GB SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS 11-06-22 1 Cover sheet
11 4A-1110045001/20GB BATTERY DOCUMENTATION 11-06-22 1 Cover sheet
12 4A-1110045001/20GB
CUSTOMER-SPECIFIC DOCUMENTATION/
CERTIFICATES
11-06-22 1 Cover sheet

Declaration of Conformity
Declaration of Conformity Free of PCB
Declaration of Conformity EMC

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GENERAL INFORMATION

DC POWER SUPPLY (RECTIFIER / CHARGER),

TABLE OF CONTENTS:
7SA9006GB GENERAL INFORMATION
7SA9007GB GENERAL SYSTEM PRINCIPLE & DESCRIPTION OF
COMPONENT

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GENERAL INFORMATION
to
DC POWER SUPPLY, Type: SDC(R)

TABLE OF CONTENTS:
1. Preface
2. General
3. Marking of the Products
4. Standards applied, Conformity
4.1 EU Conformity
4.2 Use according to Destination

GENERAL INFORMATION

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1. PREFACE
This operation manual provides information on the erection, installation, commissioning and
operation of the system.

In the event of unsureties or special problems, it is not permitted to take unauthorized remedial
action. In such cases the responsible GUTOR technical service department must be contacted and
the required information obtained.

All agreements, assurances and legal relationships, as well as all obligations of GUTOR, also with
respect to the warranty provisions, shall be governed by the respective valid sales contract which is
not influenced by the content of the operation manual.

In the operation of an electrical device certain parts of the device are necessarily
under a hazardous voltage. The failure to observe warnings and incorrect or
inappropriate use can pose a risk and cause damage to persons and property.

Prerequisite to proper and safe operation of this device are correct transport and
storage, erection, installation and commissioning, as well as careful operation,
maintenance and repair.

Work on and manipulation of this device may therefore only be carried out by
qualified personnel.

QUALIFIED PERSONNEL
are persons who, amongst other preprequisites

are familiar with the erection, installation, commissioning and operation of the device and of the
system which is being installed or in which the device is being installed;

are capable of performing switching operations according to safety technology standards and
are entitled and authorized to switch the equipment on and off and to isolate it from voltage;

are instructed according to the standards of safety technology in the care and use of safety
equipment;

are trained in immediate rescue measures (first aid);

have completed instructions with appropriate confirmation by a GUTOR instructor see
also 7SA9042GB: Service - Customer Training - Contact Addresses.

Please read this operation manual thoroughly before you perform any
manipulations on the installation.

GENERAL INFORMATION

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2. GENERAL
DC SYSTEMS ARE USED TO FEED LOADS, WHICH
cannot tolerate any interruption in the supply whatsoever;
impose very strict demands as regards the constancy of the voltage;
are sensitive to mains transients.

Decisive Features:
Characteristic Features Benefits
Modular and clearly arranged design Accessible from front and top for repair and
maintenance work
Easy access to power modules, exchange possible
by one person only
High flexibility with respect to specific customer needs
Microprocessor controlled logic, intelligent real time fault
analysis by means of built-in recording and monitoring unit
Increased MTBF (Mean Time Between Failures)
easy maintenance
Multifunctional digital indication, by which all adjustments and
settings can be made via the password-protected foil keyboard.
Fault and status indications are also shown on the same
display.
Transparent system operation
Better control over the system functions
System integrated communication interface RS232 Remote and easy system supervision
Active mimic diagram on the front panel, adaptable to
customers specification (not available for Standard front panel).
Become clear and peace of mind when the system
is in operation
Distinction between flashing new alarm and steady indication of
reset faults. Storage of the last 100 events in the memory.
Precise fault diagnosis
Redundant (2) PSUs (power supply units), supplied from the
AC input side and the DC output side (where also the battery is
connected to).
Increased system reliability
Microprocessor-controlled load sharing facility Increased life of redundant units
Constant security that systems are working
Possible parallel connection of 2 charger modules with active
load sharing
Increased availability
One module can be isolated at any time
Fan speed control and monitoring

With < 70 % load at normal operation and if no fan
fails the fan speed will be reduced
Lower noise levels
Increased fan life
Fans changeable during operation
Temperature-compensated battery charging Maximising of the battery life
Battery testing programme & monitoring unit to display the
remaining capacity and the actual back-up time
Security and clarity about the function of batteries
Halogen-free wiring Safe working environment
Certified industrial quality classification ISO 9001 Guaranteeing highest product and after sales
service quality levels

GENERAL INFORMATION

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SUCH DEMANDS ARE PRIMARILY IMPOSED BY THE FOLLOWING KINDS OF
USERS:
Petro / Chemical Industries
Power stations
Industrial systems with special specifications
Telecommunication equipment

3. DESIGNATION OF THE PRODUCTS
The following information is placed in the device:

NAME PLATE (RATING PLATE)
The name plate (rating plate) is adhered internal the device behind the front door near the door lock.
It contains the following information:

8
8
5
-3
8
5
4

Each additional segregated module (transport separation) bears a partly completed rating plate
without electrical specifications. The module numbering shall be consecutive from left to right.
Additional rating plates may be affixed within the same transport module in order to identify different
functional entities (e.g. different distributions)

EU DECLARATION OF CONFORMITY:

This label (CE-Label) is placed on the name plate

ELECTROSTATIC SENSITIVE DEVICES:

This label can be found in the device on all
p.c.board coverings as well as on the back of
all accessible PCBs.

GENERAL INFORMATION

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ELECTRIC SHOCK:
This warning sticker is affixed as close as possible to the terminals:

At a minimum either one of these labels is placed in all main fields.

CONNECTION DIAGRAM
Additionally a connection diagram is put into a schema pocket , mounted behind the front door.

LABEL RETURN OF PARTS:
This label contains all necessary information for the return of parts or for contacting our service
department. It is adhered behind the front door near the name plate see also 7SA9042GB
Service - Customer Training - Contact addresses.

4. STANDARDS APPLIED, CONFORMITY
INTERNATIONAL STANDARDS
IEC / EN 60950-1 Safety of information technology equipment (IEC 60950-1)
EN 50178 (VDE 0160) Equipment of high power installation with electronic resources
IEC / EN 62040-1-1
Uninterruptible Power Systems (UPS) :
Part 1-1 : General and safety requirements for UPS used in
unrestricted access locations
IEC / EN 62040-1-2
Part 1-2 : General and safety requirements for UPS used in restricted
access locations
GENERAL INFORMATION

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INTERNATIONAL STANDARDS
IEC / EN 62040-2
EMC Requirements
IEC / EN 62040-3
Method of specifying the performance and test requirements
IEC 60146 Semiconductor converters
IEC 60269-2
Low-voltage fuses :
Part 2 : Supplementary requirements for fuses for use by authorized
persons (fuses mainly for industrial application)
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60947 Low voltage switchgear and control gear
IEC 60085 Thermal evaluation and classification of electrical insulation
OHSAS 18001: 1999 Occupational Health and Safety Management
SN EN ISO 9001:2000 Quality management systems

4.1 EU CONFORMITY
The product mentioned in this Manual conforms to the relevant requirements to the appropriate EU
Directive, i.e. that this product meets all relevant EU directives and that it can be sold inside the
European Union without national commercial hindrances.

The EU conformity, which is indicated by means of the CE label on the name plate shall cease to be
valid if modifications are made to the equipment without the approval of GUTOR.

Relevant EU Directives for GUTOR are the so-called EMC- and Low Voltage Directives:
EU Directive on Electromagnetic Compatibility 2004/108/EC
EU Directive on Electrical Equipment designed for use within certain Voltage Limits
(Low Voltage Directive) 2006/95/EC

EN 62040-1 / EN 62040-2 are the EU harmonised product Standard applicable for UPS systems.

APPLIED HARMONISED STANDARDS:
EN 62040-1-2 .... General and Safety Requirements
EN 62040-2........ EMC Requirements

According to this Standard GUTOR fulfils the basic requirements.

GENERAL INFORMATION

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4.2 USE ACCORDING TO DESTINATION
The units described herein are electrical equipment for the use in industrial plants. They are
conditionally determined for private households.

Unit with open electric connections are determined for build in only.

This device conforms to the Low Voltage Directive 2006/95/EC.

This device fulfils the basic requirements of EN 62040-2. In a domestic environment, this product
may cause radio interference, in which case, the user may be required to take additional measures.

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GENERAL SYSTEM PRINCIPLE &
DESCRIPTION OF COMPONENT
of

TABLE OF CONTENTS:
1. General SDC Principle diagram
2. Explanation of the Components in the SDC Principle diagram

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GENERAL SYSTEM PRINCIPLE & DESCRIPT. of COMPONENTS

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1. GENERAL SDC PRINCIPLE DIAGRAM
SEE PAGE 2

This description is to be regarded as a General Description. It
does not contain all customized adaptations !
For the customer-specific configuration

see Single line diagram.

The principle diagram on page 2 is a MAXIMUM VERSION

Depending upon the system configuration, the switches represented in the principle diagram can be
switch-disconnectors (fuse switch-disconnectors) or circuit breakers and the designation can be
made according to customer's request see Single line diagram.

2. EXPLANATION OF THE COMPONENTS IN THE SDC
PRINCIPLE DIAGRAM
Pos. Component
Explanation
X001 Rectifier mains
terminals
provide for the connection of the rectifier mains (L1, L2, L3, N, PE). The
rectifier mains input has to be protected by means of external protection
devices fuses or MCCBs according to the technical specification.
Q001 Rectifier input isolator provide for the isolation of the rectifier mains input

there is no trip
function. The rectifier mains input has to be protected by means of external
protection devices fuses or MCCBs according to the technical
specification.
X002 Battery terminals provide for the connection of the battery positive pole (B+) and negative pole
(B-).
Q004 Option: 2-pole Battery
circuit breaker
If this option is not equipped an external protection device has to be
installed.
X004 Load terminals provide for the connection of the load (L+) and (L-).
A025 External connection p.c.
board
It is a part of the interface to the surroundings. Following information /
functions are available:
X004: Battery MCCB (Position)
Blocking of Boost and Initial charge
X006: Boost charge
Battery temperature Sensor +/-
X007: External On
Initial charge
X008: External Off
(to be continued next page)

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Pos. Component
Explanation

(Continuous)
X009: Charger Failure Relay
Common Alarm Relay
Internal supply for Emergency stop -/+
External supply for Emergency stop -/+
X001: Remote Display
X002: Communication RS232
X003: Internal connection to the Low Voltage Section for Parallel operation
A077 16 Relay For explanation see description 7SA9032GB Display & Parameter
settings and 7SA9033GB Operating & Indicating elements.
T001 Rectifier input
transformer
provides the conversion of the rectifier mains voltage to the right level for the
rectifier.
A001/
A002
Radio Frequency
Interference (RFI) and
AC fuse board

The RFI part secures that the system is within the permitted tolerance of
the conducted noises on the input and output of the cables.
The Fuse board part protects the control wire, the internal power supply
and the interface against short-circuits.
A030 6-pulse thyristor
rectifier-bridge
provides the conversion of the AC voltage into DC voltage
(A031 =12- pulse thyristor rectifier-bridge)
F026 Fuse Power fuse at the output of the thyristor rectifier-bridge.
L001 Smoothing reactor provides the filtration of the DC current.
CB02 DC- capacitor module provides the filtration of the DC current.
V015 Option: Blocking diode Rectifier blocking diode inserted in A030 (only in parallel-operated system).
Q003 Option: Output switch-
disconnector
provides the isolation of the load from the rectifier (from the battery).
A004/
A005
DC Fuse board for DC voltage and Earth fault
A071 Interface / PSU This board:
converts the rectifier mains voltage to a lower standard level for the
controller and secures a galvanic isolation between mains and controller.
converts the DC voltage to a lower standard level for the controller and
secures a galvanic isolation between DC / battery and controller.
interfaces between single control wires from e.g. temperature switches in
transformers and ribbon cables which go to the controller
distributes the current from the internal power supplies to the various
modules.
Redundant (2) PSUs (power supply units), supplied from the AC input
side and the DC output side (where also the battery is connected to).
A070 CCU Controller
(Charger Control unit)
provides:
controlling the rectifier
monitoring functions for e.g. voltage, current, alarms
the communication with the front panel
the serial communication

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Pos. Component
Explanation
A073 Front panel including:
Display unit
Operation
Option: Operating status indications
Option: Alarm indications
For details see description 7SA9032GB Display & Parameter
settings and 7SA9033GB Operating & Indicating elements.
E001...
E008
Fans Fans with internal Hall generator for monitoring the number of revolutions.
In systems with low power no fans are built in (natural cooling).
A003 AC Fuse board for the fans.
A050...
A057
Fan control Interface between Fans and Interface A071
Changes the number of revolutions

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SAFETY REGULATIONS


TABLE OF CONTENTS:
7SA9009GB SAFETY REGULATIONS

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SAFETY REGULATIONS
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TABLE OF CONTENTS:
1. Technical Safety Information for the User
1.1 Safety Instructions / Precautions
2. Warning advices / Signal words / Ideograms / Signboards
3. General Safety Information
3.1 Hazardous voltage [Voltage >42,4 VAC
peak
(30V
rms
)

/ 60 VDC]
3.2 Fire outbreak
3.3 General servicing recommendations

SAFETY REGULATIONS

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1. TECHNICAL SAFETY INFORMATION FOR THE USER
This description contains the necessary information for the correct application of the product
described below. It is intended for use by instructed and / or service personnel.

Qualified personnel are technically instructed persons who, because of their training, experience
and position as well as their knowledge of appropriate standards, regulations, health and safety
requirements and working conditions, are authorised to be responsible for the safety of the
equipment, at all times whilst carrying out their normal duties and are therefore aware of, and can
report, possible hazards. [The definition of qualified employees is according to International
Electrotechnical Vocubulary (IEV) =IEC 60050].

1.1 SAFETY INSTRUCTIONS/ PRECAUTIONS
The following instructions are provided for the personal safety of operators and also for the
protection of the described product and connected equipment.

Hazardous voltage
Failure to observe can kill, cause serious injury or material damage.

Isolate from all AC mains and battery supplies before installation or dismantling work, as well
as for fuse changes or post installation modifications. IEC 62040-1-2, 4.9.3 prescribes:
ISOLATE UNINTERRUPTIBLE POWER SYSTEM (UPS) BEFORE WORKING ON THIS
CIRCUIT
Observe the prescribed accident prevention and safety rules for the specific application.
Before putting into operation check if the rated voltage for the unit conforms with the local
supply voltage.
Emergency stop devices must be provided for all applications. Operation of the emergency
stop must inhibit any further uncontrolled operation.
The electric connections must be covered !
Earth connection must be checked for safe function after assembly !

2. WARNING ADVICES / SIGNAL WORDS / IDEOGRAMS /
SIGNBOARDS
The following ideograms in the manual and in the device (if available) signify:

Danger:
Used for: immediate threatening danger
Possible consequences: can kill or cause grievous bodily harm

SAFETY REGULATIONS

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Warning:
Used for: possible dangerous situation
Possible consequences: can kill or cause grievous bodily harm

Caution:
Possible consequences: insignificant physical injury. Also possible as warning
against material damage

Notice:
Possible consequences: Possible damage of the product or something in its
environment

Important:
Used for: Tips for use and helpful informations
Possible consequences: Not an information which warns against dangerous or
harmful situations !

3. GENERAL SAFETY REGULATIONS

When working inside the device or when isolating parts in the DC system the
general safety recommendation and the local electrical regulations have to be
observed !

For compliance with the various safety regulations the following points which constitute a hazard are
mentioned:

3.1 HAZARDOUS VOLTAGE [Voltage > 42,4 VAC
peak
(30V
rms
) / 60 VDC]
DC systems contain hazardous AC and DC voltages.

IN CASE OF DOUBT

NEVER TOUCH !!!

As soon as the front door is opened the hazard of contact with parts at hazardous
voltages persists. Any operations inside the system must be carried out by
competent/authorized electrical personnel only. Extreme caution should be
exercised at all times.
SAFETY REGULATIONS

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Certain parts of the current circuit are live, even if the system is shut down. Before any part is
touched the circuit diagram must be studied and verification must be conducted with measuring
instruments.

3.2 FIRE OUTBREAK

If a fire should break out inside the system, fire extinguishers with CO
2
must be
used. Do not inhale vapors.

3.3 GENERAL SERVICING RECOMMENDATIONS
We advise that the following rules have to be observed:

ASSI GNMENT OF PERSONNEL:
When working under hazardous voltage do not allow personnel to work alone. A second person
should assist so that in the case of emergency help can be called for.

When working on the battery (measuring, topping up electrolyte) goggles, protective (rubber)
gloves, rubber apron and rubber boots shall be worn. Tools for working on the battery shall be
insulated. Refer to chapter on Battery servicing.

If safety covers are provided, they are the provision for direct contact protection.
They shall prevent unintentional contact with parts at hazardous voltages. Special
caution is required at all times.

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SYSTEM DATA


TABLE OF CONTENTS:
1110045001 SINGLE-LINE DIAGRAM
4A-1110045001/23GB TECHNICAL DATA (SA9010GB)

7SA9023GB PRIORITIES AND OPERATIONAL MODES
4A-1110045001/20GB EXPLANATION OF THE BOOST CHARGE FUNCTION

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TECHNICAL DATA
of
DC POWER SUPPLY, Type: SDC 125-1200-R
Item #: C10BTL01 & C10BTL02 / C20BTL01 & C20BTL02
/ C30BTL01 & C30BTL02 / C40BTL01 & C40BTL02 /
C50BTL01 & C50BTL02

TABLE OF CONTENTS:
1. System configuration
2. Mechanical Specification
3. General Specification
4. Electrical Specification of one System unit
5. Adjustments
6. Operational Parameters

Client Ref.:
Rev. Page
E
7
2
0
.
0
0
6
G
B
-
3
GUTOR Electronic LLC
Wettingen / Switzerland
by Schneider El ec t r i c
TECHNICAL DATA - SDC 125-1200

.
4A-1110045001/23 3: 2 / 6
1. SYSTEM CONFIGURATION
One DC system is consisting of:
Pcs:
2 Rectifier / Charger
2 Blocking Diodes
1 Battery Monitoring Box
1 Battery
1 Distribution + 1 Sub Distribution

2. MECHANICAL SPECIFICATI ON
RECTIFIER (CHARGER)-UNIT
Enclosure........................................................................... : The Rectifier is housed in a free-
standing, fully metal enclosed
cabinet arranged for floor
mounting.
Arrangement / Dimensions ................................................. : see drawing: 1110045001/00
Chapter 01
Protection class (according to IEC 60529) .........................
............................................................. with open doors
:
:
IP 41
IP 20, Operator protection
Painting..............................................................................
Inside, Backcover, Topcover .........................................
:
:
RAL 7038 (BS 10-A-03)
galvanized
Ventilation ......................................................................... : Internal fans. Air inlet in back &
front below, outlet on the top.
Cable entry......................................................................... : from bottom
Terminal size...................................................................... : see drawing: 1110045001/00
Chapter 04
Weight ............................................................................... : 3030 kg

BATTERY MONITORING BOX see drawing: 1110045001/00 Chapter
30

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BATTERY
Mounting ........................................................................... : The battery is mounted on a steel
rack.
Arrangement / Dimensions ................................................. : see drawing: 1110045001/00
Chapter 02
Weight ............................................................................... : 278.1 Kg / cell
Number of cells.................................................................. : 1 string x 58 cells
Manufacturer ..................................................................... : HOPPECKE
Type .................................................................................. : 36 OSP.XC 4140
Capacity............................................................................. : 4140 Ah / 10 h
Autonomy................................................................... total : According to load profile

3. GENERAL SPECI FICATI ON
Installation altitude with full rating .....................................
With derating of 7 % per additional 1000 m...................
:
:
max. 1000 m ASL
max. 4000 m ASL
Ambient temperature range, at air inlet
- for operation (100 % rated power) ............................
- with derating at increased air throughput ...................
- for storage ................................................................

:
:
:

-10 C .... +50 C
max. 55 C
-20 C .... +70 C for systems
(for batteries in accordance with
battery manufacturer data)
Relative air humidity .......................................................... : 95 %, not condensing
Audible Noise level (1 m height, 1 m distance) ...................
with Standard N+1 Fans .................................... approx.
100 % redundant Fans ...................................... approx.

:
:

55...65 dBA (depending on type)
60...70 dBA (depending on type)
Reliability MTBF ............................................................... : > 200000 h
Functional (performance) test ............................................. : IEC / EN 62040-3, IEC 60146-1-1
General and Safety requirements ........................................ : IEC / EN 62040-1-2
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EMC requirements ............................................................. : IEC 62040-2
Quality assurance ............................................................... : ISO 9001

4. ELECTRICAL SPECIFI CATION ON SYSTEM
UNIT
RECTIFIER
Mains input power, max. .................................................... : 203.7 kVA
Input voltage....................................................... (3ph, PE)
- Tolerance - DC in tolerance ......................................
- Tolerance for function...............................................
:
:
:
3 x 480 V AC
+ 10 / - 10 %
+ 15 / - 25 % (below -15 % the
battery might begin to discharge)
Input current, max.............................................................. : 245.0 A AC
Input frequency.................................................................. : 60 Hz +/-8%
External fuse (gG type)..................... : 350 A AC
Power factor
- at nominal mains and float charge..............................
- at - 10 % mains and float charge................................
- at + 10 % mains and float charge...............................

:
:
:

0,83 ind.
0,90 ind.
0,75 ind.
Nominal DC output voltage................................................
Static ................................................. Control tolerance
:
:
125 V DC
1 % (IU-characteristics)
Ripple voltage with parallel battery capacity of 3x I
2N
......... : <=2 % rms
Efficiency at rated load.......................................................
Tolerances according to IEC 60146-2
: 90 %

BATTERY MCCB
Voltage.............................................................................. : 500 V DC
Current .............................................................................. : 1600 A DC

DROPPING DIODE
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DC output voltage.............................................................. : N/A
Current ...................................................................... max.
(in order to keep the voltage in tolerance) .......... min.
......................................................................... nom.
:
:
:
N/A
N/A
N/A

DISTRIBUTION see drawing: 1110045001/00 Chapter 04

5. ADJ USTMENTS
RECTIFIER / BATTERY
Setting range Settings
Float charge voltage......................... : 0,4 x V
nom.
- 1,3 x V
nom.
......................... 129.3 V DC
Boost charge voltage........................
.................................time interval
:
:
0,4 x V
nom.
- 1,4 x V
nom.
.........................
0...72 h ................................................
136.3V DC
8 h
Initial charge voltage........................
.................................time interval
: 0,4 x V
nom.
- 1,5 x V
nom.
.........................
0...72 h ................................................
136.3V DC
12 h
DC output current limitation ............ : (0,5 x I
nom.
) - I
nom.
................................. 1200 A DC
Battery current limitation.................. : 1 - I
Bat nom
............................................. 570.0 A DC
Initial current limitation.................... : 1 - 2x I
Bat nom
(< I
nom.
) ............................ 570.0 A DC
Low DC voltage Warning.......
Shutdown....
:
:
0 - V
nom.
...............................................
............................................................
101.5 V DC
86 V DC
High DC voltage Warning.......
Shutdown....
:
:
V
nom.
- V
high SD
.......................................
............................................................
151 V DC
163 V DC
DC Earth fault current...................... : 140 mA (Earth fault resistance =
ON) .....................................................
10 mA
Softstart ... time on voltage & current : 2 / 5 / 10 / 20 s................................. 10 s
Temperature compensation
............................ Charge voltage

:

0999 mV/C/cell...........................

N/A
Delay of relay................................... : 099 s............................................ 5 s

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Possibilities Settings
Battery monitor installed...............
automatically...............................
time interval for automatic test.....
:
:
:
YES/NO........................
ON/OFF.........................
3 month / 6 month..........
NO
OFF
____ months

6. OPERATI ONAL PARAMETERS
Possibilities Settings
Display language.............................. : DE +.............................. GB
Charger Mode.................................. : Float / Boost / Initial
Autostart.......................................... : ON/OFF......................... OFF
Autoboost ........................................ : ON/OFF......................... ON
Battery monitor Test ........................ : ON/OFF
Battery monitor Reset ...................... : ON/OFF
Battery capacity Test........................ : ON/OFF

98-02-17 mp 07-06-21 mp 09-08-11 mp
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98-02-17 07-06-21 09-08-11
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PRIORITIES & OPERATIONAL MODES
of
REDUNDANT DC POWER SUPPLY with one Battery
Type: SDC-R

TABLE OF CONTENTS:
1. General Explanations
2. Priorities: Parallel/Redundant DC system
3. Normal operation (Float-, Boost-, Initial charge)
3.1 Normal operation: System 1 & 2
3.2 Normal operation: System 1 & 2, but with different charging modes (Float-, Boost-, Initial
charge)
3.3 Normal operation: System 1; System 2 in battery operation
3.4 Normal operation: System 1; System 2 in standby
4. Battery operation: System 1 & 2
5. Rectifier only: System 1 & 2
6. Standby operation: System 1 & 2
7. Off: System 1 & 2


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1. GENERAL EXPLANATION
ACTUATION OF SWITCHES

Circuit breakers, switch-disconnectors (fuse switch-disconnectors) or changeover
switches, as well as any additionnal switches may only be actuated according to
the Commissioning and 7SA9034GB Start - Stop.

EXPLANATION TO THE SKETCHES
current flow =
energized =

Depending upon the system configuration, the switches represented in the sketches can be circuit
breakers, switch-disconnectors (fuse switch-disconnectors), and the designation can be made
according to customer's request see Principle diagram.

2. PRIORITIES: PARALLEL/REDUNDANT DC SYSTEM
The parallel/redundant DC system can be operated in different modes, depending on the availability
of the rectifier mains, the battery voltage and the actual load.

A parallel/redundant DC system tries to operate both system units in a operational mode of the
highest priority. If one system unit attempts to change to a lower priority e.g. battery operation but
the other system is still running in normal operation, this one takes over the supply of the load.

In the following the different operating modes and priorities for a parallel/redundant DC system will
be explained:

HIGHEST PRIORITY:
Section 3. Normal operation (Float-, Boost-, Initial charge)
3.1 Normal operation: System 1 & 2
3.2 Normal operation: System 1 & 2, but with different charging modes (Float-,
Boost-, Initial charge)
3.3 Normal operation: System 1; System 2 in battery operation
3.4 Normal operation: System 1; System 2 in standby
4. Battery operation: System 1 & 2
5. Rectifier only: System 1 & 2
6. Standby operation: System 1 & 2
LOWEST PRIORITY:
Section 7. Off: System 1 & 2


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3. NORMAL OPERATION (FLOAT-, BOOST-, INITIAL CHARGE)
The AC input (rectifier mains) is fed to the phase angle controlled rectifier via a matching
transformer. The rectifier compensates mains voltage fluctuations as well as load deviations, and
maintains the DC voltage constant. The superimposed AC voltage component (ripple) is reduced by
means of a smoothing circuit.

3.1 NORMAL OPERATION: System 1 & 2
MAINS 1
Q001
RECTIFIER 1
Q004
(Q005)
BATTERY
LOAD
Q003
MAINS 2
Q001
RECTIFIER 2
Q003
V015
V015
Fig. 3.1

Concerns: RECT 1 RECT 2 Completing Explanation:
Rectifier mains available available and within the tolerance range
Q001 closed closed
Battery available
and within the tolerance range (dependent on the
charging condition of the battery it may be in
recharge mode).
Q004 (Q005) closed
Rectifier ON ON
Q003 closed closed
Output voltage before
blocking diode
available and within the tolerance range
blocking diode
Output voltage Load available and within the tolerance range

The DC system supplies the load with energy each 50 % of the actual load and secures that the
connected battery is kept on standby (float charge and boost charge depending on charging
condition and the type of the battery).

If one rectifier system unit is running in another operating mode, due to a fault see fig. 3.2.


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3.2 NORMAL OPERATION: System 1 & 2, but with different charging
modes (Float-, Boost-, Initial operation)
Fig. 3.2

Q001 closed closed
Battery available
recharge mode).
Q004 (Q005) closed
Rectifier ON ON
Q003 closed closed
blocking diode
blocking diode

If both rectifier system units are running in different operating modes (System 2 in float charge
operation and System 1 in boost charge operation), the rectifier with the higher charge voltage takes
over the supply of the load.


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3.3 NORMAL OPERATION: System 1; System 2 in Battery operation
Fig. 3.3

Rectifier mains available and within the tolerance range
Rectifier mains not available outside the tolerance range
Q001 closed closed
Battery available
recharge mode).
Q004 (Q005) closed
Rectifier ON OFF
Q003 closed closed
blocking diode
blocking diode
not available outside the tolerance range

System 1 in normal operation takes over the supply of the load.

3.4 NORMAL OPERATION: System 1; System 2 in Standby
MAINS 1
Q001
RECTIFIER 1
Q004
(Q005)
BATTERY
LOAD
Q003
MAINS 2
Q001
RECTIFIER 2
Q003
V015
V015
Fig. 3.4


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Q001 closed closed
Battery available
dependent on the charging condition of the battery it
may be in recharge mode
Q004 (Q005) closed
Rectifier ON OFF
Q003 closed closed or open
blocking diode
blocking diode

System 1 in normal operation takes over the supply of the load. System 2 changes over to
standby.

4. BATTERY OPERATION: System 1 & 2
Fig. 4.1

Rectifier mains not available not available outside the tolerance range
Q001 closed closed
Battery available and within the tolerance range
Q004 (Q005) closed
Rectifier OFF OFF
Q003 closed closed
blocking diode
blocking diode


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In the event of power sags or failures the load is no longer supplied with power by the rectifier. The
battery, which is connected to the DC intermediate circuit, is called up automatically and without
interruption to supply the current.

The discharging of the battery is signalled. The battery voltage drops as a function of the duration
and the magnitude of the discharge current.

On mains recovery or on emergency power generation with diesel generator, before the limit of
discharge of the battery is reached, the DC system automatically switches back to normal operation
for supplying the load and at the same time charging the battery.

If the limit of discharge of the battery is approached the alarm Low DC warning is activated. If the
limit of discharge is reached, the internal PSUs (supply units) will switch off after 10 minutes.

On mains recovery or on emergency power generation with diesel generator, the rectifier starts up
automatically and at the same time charging the battery, if the DC system is programmed for
AUTOSTART at mains recovery see Technical data. If the system is not programmed
for AUTOSTART it has to be restarted manually

see 7SA9034GB Start - Stop.

Depending on the depth of discharge of the battery the charge current is limited by means of the
battery current limiter.

5. RECTIFIER ONLY: System 1 & 2
Fig. 5.1

Q001 closed closed
Battery available
charging condition of the battery)
Q004 (Q005) closed
Rectifier ON ON
Q003 open open
blocking diode
blocking diode
Output voltage Load not available NOVoltage

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6. STANDBY OPERATION: System 1 & 2
DC system ready for switching on
Fig. 6.1

Rectifier mains available available
Q001 closed closed
Battery disconnected
Q004 (Q005) open
Rectifier OFF OFF
Q003 closed or open closed or open
blocking diode
not available NOVoltage
blocking diode

The load is not supplied.

7. OFF: SYSTEM 1 & 2 DISPLAY BLACK
Fig. 7.1


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Some c omponent s i n t he c onnec t i on f i el d as w el l as el ement s and
l i nes c an be ener gi zed.

Rectifier mains not available not available
Q001 open open
Battery disconnected
Q004 (Q005) open
Rectifier OFF OFF
Q003 closed or open closed or open
blocking diode
blocking diode

The load is not supplied.

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EXPLANATION OF THE BOOST CHARGE
FUNCTION
to

see also Single Line diagram

The battery can only be boost charged if the distribution is disconnected from
the battery circuit in question.

Boost charging by Charger 1 is only possible if the rectifier output switch Q003 and Q200 of
Charger 2 are open and the battery switch Q004 is closed. The LED 3
BOOST/INITIAL on the Mimic diagram is illuminated.

The Load sharing is no longer active if one of the switches Q003 / Q100 / Q200 is open.
Indication on Front panel Load sharing fault

After boost charging the rectifier output switch Q003 and Q200 have to be
closed manually !

Boost charging by Charger 2 can be peformed in the same manner, vice-versa.

11-06-22 mp
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PACKING TRANSPORT INSTALLATION


TABLE OF CONTENTS:
7SA9028GB PACKING & UNPACKING & STORAGE AIR / OVERSEA
TRANSPORT
7SA9030GB TRANSPORT OF THE SYSTEM WITHOUT PACKING
7SA9031GB ERECTION INSTALLATION
7RA9195GB ASSEMBLY OF PARTICULAR CUBICLE UNITS

98-05-07 mp 05-05-25 mp 07-10-31 mp 09-10-04 mp
98-05-07 GA 05-05-25 MDR 07-10-31 MDR 09-10-04 PFR
98-05-07 05-05-25 07-10-31 09-10-04
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PACKING & UNPACKING & STORAGE
AIR / OVERSEA TRANSPORT
of

TABLE OF CONTENTS:
1. Preparations before Packing
2. Packing: Air / Oversea Transport = Solid Wooden Cases or OSB (Oriented
Strand Board) Cases
3. Transport to the Installation Place
4. Unpacking from the Case
5. Storage

PACKING & UNPACKING & STORAGE Air/Oversea Transport

7SA9028GB
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1. PREPARATIONS BEFORE PACKING

For systems with Rain roof:
Where small parts are delivered together with the
system, these are packed in plastic bags and placed
below the roof. These bags will be fixed to the roof
fastening bolts by means of cable binders. Bigger
parts are packed in cardboard boxes and placed
inside the cubicle.
For systems without Rain roof:
Where parts are delivered together with the system,
these are packed in cardboard boxes and placed
inside the cubicle.

Usually one side of the system is open (due to
transport separation)

4. The chip is fixed with a cable binder
5. Doors are closed

1. All doors are opened to equip the system
with VCI-chip U
(VCI =Volatile Corrosion I nhibitor)
2. Every field is equipped with one or more chips
(chip-size =49x100 cm).
3. One chip protects a volume of 1m
3
. The number
of chips is calculated as follows:

Example:
Gross volume is 3m
3
Equipment / Material 1m
3

Therefore, two chips are used.


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Now the system is prepared to be packed in the case. The lifting into the case is conducted
according to the instructions 7SA9030GB Transport of the System without Packing and the
instructions given in this description see section 3.

1. The VCI-Foil on the base of the case is cut
several times in order for possible condensation
water to drain off.

2. The system is being placed on the base of the
case.

3. The VCI-Foil is pulled up and fixed on the
system with an adhesive tape that does not
leave any residue.

The lower half of the system is now packed in VCI-
Foil.

1.
2. The upper protruding parts are being covered
with air bubble film and adhesive tape so that the
VCI-foil cannot be damaged.
3. Now the upper part of the system is being
covered in VCI-foil which will also be fixed with
adhesive tape.
4. Within 24 hours, the anticorrosive will become
active.

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2. PACKING: AIR / OVERSEAS TRANSPORT = SOLID WOODEN
CASES OR OSB CASES
Packing for air or overseas transport =either solid wooden cases or OSB cases (oriented strand
board).

2.1 REQUIREMENTS FOR THE PACKING
The packing must satisfy the following criteria:
1. Protection against mechanical stress and damage:
crushing forces due to stacking (only guaranteed for solid wood cases)
gravitational forces in a horizontal direction
forces arising from vibrational loads

2. Protection against corrosion due to the effects of relative humidity and climatic factors
3. Protection against environmental factors (industrial exhausts, salt in the air, rain, snow, etc.)
4. Protection against theft (due to the sealed packing)
5. Suitable for lifting and forwarding equipment (Unit Load Concept)
6. Possible frequent reloading and retransferring
7. Shipment over poor roads
8. Economy of volume
9. Protection of environment when handling hazardous material
10. Capability of recycling

2.2 STRUCTURE OF THE SOLID WOOD CASE
1. The design and construction of the cases are as shown on the representations below.
2. Side walls, face-end walls, and floors are made of Swiss wood. (IPCC standard)
3. Wood thicknesses 24 mm.
4. Wood cover dry film resist and plywood cover must be concise with the side walls and front
walls.
5. As a rain protection PE foil becomes strained under the cover.
6. From a weight of 2,000 kg upwards a case comprising a lengthwise reinforcement must be
employed.

As Option, on special customer's request
7. Also different variants may be selected to ensure protection from rain, for example, sandwich
covers. In this case the inside of the cover is provided additionally with Akylux or a plywood
panel. The individual materials can also be combined.
8. Inspection hole.
9. Various colour markings.
10. Supplementary cushioning (for adverse road conditions)
11. Cladding of cases with diverse protection foils (kraft paper, bitumen paper, etc.).
12. Tip Indicatior, Shock indicators, etc.

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2.3 CONSTRUCTION OF THE SOLID WOOD CASE

The f ol l ow i ng r epr esent at i ons c or r espond to a solid wooden case (the
OSB cases comprise instead of individual boards whole or max. 3 plates per side).

Pos. Description Pos. Description Pos. Description
1 Side wall 4 Cover 7 Front skid
2 Front wall 5 Double Cover 8 Floor skid
3 Floor 6 Side skid 9 Cover skid

Pos. Description Pos. Description Pos. Description
1 Front wall 5 Double Cover 8 Floor skid
2 Side wall 6 Side skid 9 Cover skid
3 Floor 7 Front skid 10 Protection foil
4 Cover

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2.4 CONSTRUCTION OF THE OSB- / PLYWOOD CASE
1. OSB and plywood cases are manufactured of internationally approved wood (IPPC Standard).
2. The side walls consist of a maximum of 2 parts, the front walls consist of a maximum of 3
parts. The joints of the respective parts are reinforced with a skid.
3. The cover is only one part. The bottom of the cases is always manufactured from solid wood
(24mm).
4. Wood thickness 0.9 mm up to 10 mm.
5. The wood cover, covering foil and plywood cover must be concise with the side and the front
walls.

As Option, on special customer's request
6. For rain protection the same method as with solid wood cases may be employed.
7. Inspection hole.
8. Various colour markings.
9. Supplementary cushioning (for adverse road conditions)
10. Cladding of cases with diverse protection foils (kraft paper, bitumen paper, etc.).
11. Tip Indicatior, Shock indicators, etc.

The construction and design of the cases are presented in the following
designs:

1. The case is now built around the system
(solid wood, plywood or OSB, depending
on contractual requirements) and the
shipping marks are added.

2. Now cargo is ready for worldwide
shipping by truck / ship / airplane.

Thi s I PPC st amp i s used t o mar k ever y c ase:


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GUTOR
XXXXX
2.5 CONSTRUCTION OF THE CASE

Polyethylene edges:
for the protection and fixing of the system.
Cross laths (cross-heads)
are determined by the length of the case
and the size of the system to be packed.
(Only equipped in cases containing small
systems or in case of projecting cables,
etc.).
Compound foam material
for the protection of the system.
Floor cross laths
for the distribution of the load outward
(lifting of the case with belts) under each
socket of the system one floor cross lath
is laid (not fixed).

2.6 STANDARD MARKING
The standard marking of standard cases is implemented in writing (only symbol 1-3) and according
to the symbols provided in DIN 55'402.

THE FOLLOWING MARKING IS USED AS A STANDARD:

1 2 3 4 5 6 7
1
This side up:
The case must always be stored, transferred, and transported in such a way that the
arrow always point up.
2
Fragile, handle with care:
Goods marked in this way must be handled with care and not dropped or tied under
any conditions.
3
Keep dry:
Goods marked in this way also have to be protected from high humidity, they must be
kept under covers when in storage (no unprotected outdoor storage).
4
Sling here:
The symbol indicates only where the sling should be applied, and not the method to be
used for applying it.
5
Center of gravity:
This symbol clearly identifies the center of gravity.
6
0 Kg stacking load:
The plywood and OSB cases are not stackable
7
GUTOR XXXXXX:
This stamp is on each case delivered from GUTOR whereby XXXXXX =the GUTOR
reference number of the system packed therein.

7SA9028GB
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7SA9028GB 4 8 / 11
If required, additional markings are made according to the internal instructions S700.015 or
according to the instructions of the client or of the case manufacturer.

3. TRANSPORT TO THE INSTALLATION PLACE
CHECK:
the weight before the transport to secure that the equipment can handle the actual weight of
the system.
that there is enough space to transport the system to its final destination
that the floor can bear the load
that the lift can carry the system
whats with the computer floor (double floor)

MOVEMENT WITH LIFTING AND FORWARDING EQUIPMENT
Normally, the system is delivered in cases appropriate to the means of transport, or on a pallet and
can be transported by a fork-lift or pallet-truck.

Pay attention to the marking on the case !

STRIKING WITH LIFTING EQUIPMENT
When striking the cases with lifting equipment, the cables may be attached only at those points
identified by the chain symbol (symbol G) per DIN 55'402 see the following example:

The f ol l ow i ng r epr esent at i ons c or r espond to a solid wooden case (the
OSB cases comprise instead of individual boards whole or max. 3 plates per side)

Sling here:
The symbols indicate only where the sling should be
applied, and not the method to be used for applying it.
Whenever the symbols are at an equal distance from
the middle of the center of gravity, the package will
hang straight if the suspensions are of the same length.
If not, the suspension on one side must be shortened.
Never follow this symbol for packages that have
obviously been incorrectly identified and/or designed.
Doing so could cause the packages to be dropped.


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LIFTING WITH A FORK LIFT
When lifting and/or moving with a fork-lift, the forks may only be inserted under the packages
parallel to the floor runners.

ATTENTION TO THE CENTER OF GRAVITY
Attention must be paid to the center of gravity as identified with symbol F per DIN 55'402 when lifting
or driving under the cases in order to avoid having the packages tip over.

Center of gravity:
This symbol clearly identifies the center of gravity.
Reasonably the symbol should only be used when the
center of gravity is off-center in the package.
Application for the symbol on two surfaces
perpendicular to one another would be sufficient for
clear identification.

4. UNPACKING FROM THE CASE
4.1 INSPECTION OF THE PACKING AFTER ITS ARRIVAL AT THE
STORAGE PLACE
The system has been packed to stand the vibrations that normally occur during transport, so as a
rule neither the packing nor the system will have suffered any damage during transport.

If any damage has penetrated the case, or if it is not received in upright position (look for indication
of this on the case), the shipper and the manufacturer should be notified immediately.

All boxes, cases, pallets, and other packages must be examined after unloading for visible and
apparent mechanical damage. Severely damaged packing or equipment should be left untouched
until the shipper and the insurance company have inspected it. Records must be kept on all
findings.

Any non-mechanical damage found, such as: boxes, cases, or other packages that are wet
through or very dirty must be recorded for a later inspection of their contents.
In both cases, an authorized inspector, in consultation with the insurance company,
must make a determination of the actual situation.
Photographs of the damaged containers should be taken as evidence.


7SA9028GB
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7SA9028GB 4 10 / 11
4.2 UNPACKING OF THE SYSTEM
PACKING
NOTE HERE

On customers request a metallic envelope is placed on the left side of the
case. In the envelope the delivery note or the packing list is placed.
Before unpacking the system, take out the delivery note (packing list) and
keep it to check that the equipment is in accordance with the specifications on
the document.

In case of any defects the manufacturer should be notified immediately in order to avoid a delay in
the installation of the system.

Unpack the system in a clean, dry storage area.
Example: Solid wooden case
Pos. Beschreibung
1 Front wall
2 Side wall
3 Floor
4 Cover
5 Double Cover
6 Side skid
7 Front skid
8 Floor skid
9 Cover skid

By means of a crowbar remove the cover (4). It is not necessary first to remove the cover skids
(9) since these are fixed to the cover ( see above picture).

Be cautious not to damage the system packed therein

By means of a crowbar remove the side wall (front) (2) of the case. It is not necessary first to
remove the front skids (7) with which the side wall of the case is fixed to the pallet ( see
above picture).
Now the system can be removed by means of a fork-lift. When lifting the prepacked system this
has to be made according to the instructions 7SA9030GB Transport of the System without
Packing and the instructions given in these descriptions.
Remove the VCI foil.
Remove eventually delivered parts see first picture of this description.

7SA9028GB
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Open the front door and examine the interior of the system for any potential damage due to
mishandling of the system during transport. Notify the shipper and the manufacturer of any such
damage immediately. Proceed as mentioned under section 4.1.
If the system is not going to be taken into use right away, put the VCI foil over the system again
to protect it against dust and moisture.
Move the system to its installation place. (Remember, before the final placing mount the
ventilation grids see description 7SA9031GB Erection Installation section 2.1).

5. STORAGE
SYSTEM
If the system is not to be installed immediately, the cubicles included in the delivery should remain in
dry storage in their crates and protected against dust. Storage temperatures advantageously should
be between -10C and +55C (allowable max. -25C and +70C). This also applies generally to all
replacement material for the system.

If the humidity is very intense it can be necessary to operate heating facilities (optional) internal the
system until the system will be turned on.

The system is to be installed within 12 months after delivery and put into operation. After these 12
months the manufacturer must be consulted, who will explain the necessary additional precautions
(possibly commissioning by the manufacturer).

BATTERIES
If the batteries are to be stored for a long time (> year) the means of storage is to be approved
by the battery furnisher, because they are different, depending on the type of the battery.

98-01-29 mp
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98-01-29
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TRANSPORT OF THE SYSTEM WITHOUT
PACKING


TABLE OF CONTENTS:
1. Transport: C-Rail mounted
2. Transport: Lifting Lugs mounted

TRANSPORT OF THE SYSTEM WITHOUT PACKING

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1. TRANSPORT: C-RAIL MOUNTED
The C-rail for the neck straps on the
front and back or the device must
bear out 5 mm
Door frame or back cover
C-Rail
Device socket
Device socket
40
70
125
25
5

CAUTION:
The lifting lugs have to be strained
perpendicularly.

When lifting units with a rain roof IPX1 /
IPX2, the roof has first to be dismounted.

The system can also be transported by a
fork-lift or pallet-truck.

Caution: Pay attention on the
center of gravity and the weight !
TRANSPORT OF THE SYSTEM WITHOUT PACKING

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2. TRANSPORT: LIFTING LUGS MOUNTED
SYSTEMS UP TO 500KG PER TRANSPORT UNIT
The angle of the cable must be at minimum 45.

SYSTEMS EXCEEDING 500KG PER TRANSPORT UNIT

The l i f t i ng l ugs have t o be st r ai ned per pendi c ul ar l y.

When lifting systems with a rain roof (IPX1 / IPX2), the roof has first to be dismounted.

98-01-27 mp 00-05-08 mp 06-11-06 mp 09-10-01 mp
98-01-27 GA 00-05-08 GA 06-11-06 MDR 09-10-01 MDR
98-01-27 00-05-08 06-11-06 09-10-01
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ERECTION INSTALLATION
of

TABLE OF CONTENTS:
1. General
2. Installation / Erection
2.1 IP Protection / Ventilation Grids
2.2 Placing
2.3 Cable Inlet
3. Ventilation
4. Connection / Protection
4.1 Earthing of the Cubicle
4.2 Mains Connection
4.3 Battery Connection
4.4 Earthing of the Battery (for Systems with Battery)
4.5 Connection of the Load
4.6 External Fuse Protection


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1. GENERAL
The following has to be considered in connection with the installation of the DC system:
System room
Cable connection / cable interconnection
Losses, ambient temperature, ventilation
Connection / Protection
Earthing of the cubicle
Mains connection
Connection of load / distribution
3-phase systems with SMPS load (increased neutral current)

In the following sections the general requirements for the installation of DC systems is explained.

2. INSTALLATION / ERECTION
2.1 IP PROTECTION / VENTILATION GRIDS
Fit the ventilation grids on the front and the back ) of the device socket to the snap clip on both
sides by means of sheet metal screws M5,5 and the corresponding washers see Fig. 1.

AIR FILTERS / GLAND PLATES
Dependent on the degree of protection with which the system was ordered (see Technical data
the system can optionally be equipped with additional air filters and gland plates. These can be
pushed in from the front on the rails designated for that see Fig. 1.

)

If additional air filters and gland plates are to be mounted it is absolutely necessary
to displace the system to its definite place of erection before attaching the
ventilation grids to the front, since a transport of the system with mounted air
filters and gland plates by means of a fork-lift or a pallet-truck is then no longer
possible.

MOUNTING OF THE RAIN ROOF
The rain roof (optional) has to be fastened in accordance with the Dimensional drawing, if it was
not already mounted in the factory.

When mounting the rain roof special attention must be paid to the
fact that no parts fall into the system. Besides, the rain roofs are
not appropriate for a load from top and the system may also not be
lifted at the rain roof.


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Fig. 1 Mounting of air filters and gland plates, as well as fixing of ventilation
grids (front and back)

2.2 PLACING

The ventilation grids have in any case to be fixed on the back of the system
before it will be placed to the wall or back to back. see section 2.1.

The DC system is built in a cubicle with a stable frame. On this frame heavy components such as
transformers, chokes, etc. are mounted. The frame can be placed direct on a levelled concrete
floor.

The DC system can be placed with the backside to the wall or back to back (but a space of at least
100mm must be ensured). If possible, preferably a distance of 500mm from the backside of the
system to the wall or between the systems (if these are placed back to back) should be provided.


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Above the top of the system a clearance of 500mm has to be provided to ensure sufficent space for
the air outlet

in fig. 2 typical installations are shown.

Fig. 2 Typical placing of a System
100 mm space have to be
ensured, however, 500 mm
would be better

2.3 CABLE INLET
As a standard the cable inlet is from bottom, but optionally can also be performed from top, if this is
stated in the order.

In fig. 3 typical cable installations are shown. At the installation
the bending radius of the cables must be in accordance with the Standards.

Fig. 3 Examples of cable inlets (View from the right side)


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3. VENTILATION
Attention must be paid to the heat that is to be removed which is generated by the power losses of
the system. The inlet and outlet of air must be ensured, otherwise the system can produce an alarm
due to overheating, or even shut down. Therefore the ambient temperature stated in the Technical
Data is to be observed. Alarm indication is given if the temperature of the power components
exceeds the permitted level.

Objects which obstruct ventilation or which are easily combustible should under no circumstances
be placed on, under or very near the system.

If the system is placed with the backside to the wall or back to back, a space of at least 100mm has
to be guaranteed.

The necessary quantity of air cooling per hour depends on the one side on the total developed
power dissipation, i.e. from the size and number of installed DC systems, and on the other side on
the possible resp. permitted warming of the cooling air. The permitted warming of the cooling air is
the difference between the admissible ambient temperature (e.g. 30 C) and the incoming
temperature of the cooling air into the room (e.g. 25 C).

4. CONNECTION / PROTECTION
4.1 EARTHING OF THE CUBICLE
The system cubicle must be earthed, for which purpose earth bars/terminals are provided inside the
system.

4.2 MAINS CONNECTION
The incoming feeders must comply with the general recommendation of IEC or the general
Standards of VDE(D), SEV/HV (CH), or possibly with the additional Standard corresponding to the
local electrical regulations.

The person carrying out the work must be an authorised installation electrician.

The fuse protection and the wire cross section of the mains connection can be seen in the
Technical Data, however, only if these meet also to the local electrical regulations.

The rectifier mains input must be protected by external fuses or MCCBs.

4.3 BATTERY CONNECTION
The battery feeders must comply with the general recommendation of IEC or the general Standards
of VDE(D), SEV/HV (CH), or possibly with the additional Standard corresponding to the local
electrical regulations. The battery must be protected by external fuses or MCCBs.

The fuse protection can be seen in the Technical Data.


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4.4 EARTHING OF THE BATTERY (for systems with battery)
It is not necessary to earth the battery. However, if it is desired only the minus pole (-) of the battery
may be earthed, but only if there is an isolating transformer at the input of the rectifier.

It is not permitted to earth the plus pole (+) of the battery because it could affect the
functioning of the system.

4.5 CONNECTION OF THE LOAD
The load cables are to be installed and connected according to the maximum allowable load. It has
to be assured that the connected load does not exceed the maximum rated capacity of the DC
system !

4.6 EXTERNAL PROTECTION
To ensure selectivity between the internal fuses and the distribution fuses, the maximum fuse
nominal current (rated circuit breaker current) at the load output is limited.

In addition, the conditions for the rectifier incoming feeder fuse (mains) can be seen in the
Technical data.

CIRCUIT BREAKER
We recommend when inserting circuit breakers between the busbar and the consumer, to choose
such a type that its rated current not exceeds 15% of the nominal current of the system (voltage
drop over the line between DC system and consumer max. 3%).

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ASSEMBLY OF PARTICULAR CUBICLE UNITS

PROVIDED MATERIAL PER CUBICLE SEPARATION:
see fig. 1.
12 pieces Hexagon head-fit screws M8 x 20
6 pieces Hexagon bolts 30mm with internal screw thread M8
12 pieces Tooth lock washers M8 / 8.2

fig. 1:

Recommended torque M8 =21.5 Nm

PROCEDURE:
1. Place Cubicle unit A) and install the 6 hexagon bolts by means of the screws and the tooth
lock washers (total 6 pieces of connections per cubicle separation =3 pieces in front and 3
pieces in the back, i.e. for each 1 piece in the upper, middle and lower cubicle unit).
see fig. 2.

If a partition wall should be provided, which partial elements are fastened
to, then recesses (drillings) are intended for screwing together.

2. Push Cubicle unit B) completely close to Cubicle unit A).
3. Couple Cubicle unit A) with unit B) by means of the remaining 6 screws through the hexagon
bolts and tighten all screws in accordance with the recommended torque. see fig. 3.

ASSEMBLY OF PARTICULAR CUBICLE UNITS

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fig. 2:

Fig. 2 shows an example of the
framework of a free standing cubicle
unit.

The screws for the assembly fit only
into the large holes.

Always two cubicle units are screwed together in the cubicle inside in accordance with following
figure.

fig. 3:

Hexagon head-fit screws
M8 x 20

Tooth lock washers
M8 / 8.2

Hexagon bolt 30mm
with internal screw thread M8

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4A-1110045001/20GB 1 1 / 1

DISPLAY OPERATING & INDICATING
ELEMENTS


TABLE OF CONTENTS:
7SA9032GB DISPLAY & PARAMETER SETTINGS
4A-1110045001/20GB OPERATING- & INDICATING ELEMENTS (7SA9033GB)

98-02-12 mp 00-05-08 mp 06-08-25 mp 09-12-22 mp
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98-02-12 00-05-08 06-08-25 09-12-22
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DISPLAY & PARAMETER SETTINGS
of

TABLE OF CONTENTS:
1. Display unit
2. Change of Operational Parameters
3. Measurements on the Display
4. Alarms on the Display


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1. DISPLAY UNIT
COMMON ALARM
DI SPLAY
C
4
MAINS
CURRENT
7
MAINS
VOLTAGE
8
DC
VOLTAGE
9
V-AUX.
5
BATTERY
CURRENT
6
TOTAL DC
CURRENT
1 2
BATTERY
TEMP.
3

On the front of the SDC there is a display unit. It
consists of a LC display, an alarm LED, an acoustic
alarm and a foil keyboard (as shown at the left).

The display is used for programming the system and
for giving information (measurements and alarm
indications).

In a normal situation the current operational mode is
shown in the display.

To get information or to program the system various
entries have to be made via the foil keyboard.
Normally the display will switch back automatically to
show the current operational mode if the foil keyboard
has not been activated within 30 secs or when
has been pushed.

If however, a change in the operational mode occurs the display immediately switches over to show
the current operational mode.

In this case the appropriate stack will have to be entred again by means of the foil key board to
continue the programming of the system or reading information.

The following is a description of information which can be shown in the display, as well as an
instruction to the programming/setting up, which can be performed by the user.

2. CHANGE OF OPERATIONAL PARAMETERS
In the display the following operational parameters can be programmed by the user User
Stack:

Second Language
Charge mode
Autostart
Autoboost
Battery capacity test
Battery monitor test
(only shown if the option Advanced battery monitor is installed)
Battery monitor reset
Automatic Battery monitor test
Enter new date
Enter new time

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To enter the Operational parameter stack push and step inside the stack with the cursor
key

or . By pushing the button
C
you get the selection series of settings,
allowed by the system.

SECOND LANGUAGE
It is possible to choose between 2 languages: GB + CZ / DE / DK / ES / FI / FR / HU / IT / NL / NO
/ PL / PT / RU / SE / SK, or DE +RU. One language can be chosen at the time, but can be changed
when required at any time.

Chose the language by pushing

and stepping inside the stack with the cursor key

or until is shown in the display. Thereafter push
C
to get
the required language (see possibilities listed above). The language is chosen by pushing

for ON. When accepted the display shows: .

CHARGE MODE
It is possible to choose between 3 charging modes: Float, Boost and Initial. The charging
mode can be chosen by pushing

and stepping inside the stack with the cursor

or
until:

is shown in the display. If this charging mode is requested
push for ON.
If one of the other two charging modes is requested push
C

until:

or

is shown in the display. Chose by pushing for ON. When
accepted the display shows:

.


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AUTOSTART
If autostart has been programmed, the rectifier will restart automatically at mains return, e.g. if the
system has switched off due to low battery shutdown during battery operation or after system reset.
The rectifier will start up in float charge operation, after it has been synchronous to the mains for 60
seconds, plus the mains returns to charger on time. If the rectifier is manually started within these
60 seconds autostart will be ignored.
To program the system for autostart push and step inside the stack with the cursor key

C

to show in the display. Autostart is chosen by pushing

for ON. When accepted the display shows: .

AUTOBOOST
The criterion for an automatic initiation of boost charging is that the battery current limiter is active
for more than 3 minutes. The boost charging will last for t
BOOST
hours after the battery current limiter
is out of function. If autoboost is programmed and the mains returns after a mains failure, an
automatic boost charging is activated only if the criteria for boost charging are fulfilled, otherwise the
rectifier starts up to float charge operation.

AUTOBOOST IN PARALLEL SYSTEMS
If autoboost is programmed on both rectifier system units, the situation may occur where one
rectifier switches to boost charge, but the other one does not. This may happen due to different
battery conditions or timing deviation between the rectifiers system units. Loadsharing cannot be
ensured in this case.

To program the system for autoboost push and step inside the stack with the cursor key

C

to show in the display. Autoboost is chosen by pushing

for ON.
When accepted the display shows: .


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BATTERY CAPACITY TEST
The battery capacity test gives an indication of how long the battery backup time is at actual load.
The performance of a battery capacity test only make sense, when the batteries are well charged
and the rectifier is running in float charge.

At least once a year it is recommended to perform a discharging procedure of the batteries to make
sure that they are discharging according to the information given by the manufacturer.

1. Start with fully charged batteries, i.e. if the system has been in normal operation for longer than
8 hours.

2. Connect the load to the system output.

3. For testing the battery capacity via the foil keyboard proceed as follows: Push and step
inside the stack with the cursor key

or until:

is
shown in the display; where ??? is the back-up time of the last test. If no test has been
performed before or the test has been aborted ??? is shown.

4. To start the battery capacity test push
C

until the display shows:
. Thereafter push for ON. The rectifier will
change to battery operation and persists until the level Low DC warning/Low DC Vaux
warning is reached. Thereafter the rectifier changes automatically to float charge voltage.

The time in minutes, from the initiation of the battery capacity test to its end is shown in the
battery capacity test menu. A time periode of at maximum 9999 minutes (6 days +22 hours)
are measured. When the level Low DC warning/Low DC Vaux warning is reached the
system changes to normal operation and the batteries will be recharged.

5. To stop an already running capacity test push (when the display shows Battery capacity test
ON) the button
C
until the display shows: . Thereafter push
for OFF.

6. If during the test a mains fault occurs or the button S1 SYSTEM ON has been pushed, the
test will immediately be aborted and no test result will be obtained. When reading out data of
the battery capacity test in the display after a test has been aborted, ??? is shown, i.e. that
no result was obtained.

Please note that after a battery capacity test it will take about 8...24 hours before the battery is
recharged and the full back-up time is available again.


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BATTERY MONITOR TEST

only shown if the option Advanced battery monitor is installed.

To perform the battery monitor test push and step inside the stack with the cursor key

C

to show in the display. Battery monitor test is chosen by
pushing

for ON. When accepted the display will show: .

This function will check the battery condition by switching off the rectifier. The system is running in
battery operation until 25% of the battery capacity are used up.

The rectifier will automatically switch on after the test has finalized or if a failure in the battery has
been detected

no loss of the output voltage.

If the battery conditions are within the tolerance range no alarm will be shown in the display.
If the battery capacity is reduced, one of the following two alarms will be shown in the display:
Alarm #43: Battery defective
Alarm #52: Battery weak

If the Battery Monitor Test signalize a fault an alarm is given, this alarm can be reset by means of
the Battery Monitor Reset see next section.

BATTERY MONITOR RESET

only shown if the option Advanced battery monitor is installed

To reset the battery monitor alarms push and step inside the stack with the cursor key

C

to show in the display. Battery monitor reset is chosen by
pushing



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AUTOMATIC BATTERY MONITOR TEST

only shown if the option Advanced battery monitor is installed.

To perform the automatic battery monitor test push and step inside the stack with the
cursor key

or until is shown in the display. Thereafter
push
C

to show in the display. When pushing
C
twice, the
display will show

. Automatic Battery monitor test is chosen by pushing


ENTER NEW DATE
To set the current date in the system, push and step inside the stack with the cursor key

or until the display shows: . Thereafter push (for e.g.
25th August 2006):

and for confirming.
When accepted the display will show:

.

ENTER NEW TIME
To set the current time in the system, push and step inside the stack with the cursor key

or until the display shows: . Thereafter push (for e.g. 14
h 15 min 10secs):
1

1

1

and for confirming.
Remember when entering the seconds, the clock is only activated when the confirmation
button has been pushed. When accepted the display will show: .

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3. MEASUREMENTS IN DISPLAY
Measurements can be shown in the display by pushing one push-button. The accuracy of the
measurements are 1 % one digit. The display is updated every second. If no button is pressed in a
period of 30 seconds the display returns to the current operating status. This is applicable for all
display modes. The range of temp.measurement is from - 35 C to +55 C.

The values shown in the following display pictures are only examples.

Push; The display shows: Explanation:
1
.............. .....
shows Date: year, month, day (YY.MM.DD)
Time: hours, minutes, seconds (HH.MM.SS)
BATTERY
TEMP.
2
.............. .....
Battery temperature

.....
No battery sensor inserted, or
the battery sensor is faulty
MAINS
CURRENT
4
.............. .....
Mains input current per phase
L1 L2 L3
BATTERY
CURRENT
5
.............. .....
Battery current with indication charge/discharge
TOTALDC
CURRENT
6
.............. .....
Total DC current
7
MAINS
VOLTAGE
.............. .....
Phase-to-phase mains input voltage
L1-L2 L2-L3 L3-L1
DC
VOLTAGE
8
.............. .....
DC voltage
V-AUX
9
.............. .....
Auxiliary voltage (or optionally Vbatt/2):

.....
Alarm is active if V
batt/2
deviates more than 1,5 %
from half the output DC voltage.

To return to normal status indication wait 30 secs or push

. The display indicates the
current operating status.


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4. ALARMS IN THE DISPLAY
Alarms are given if the rectifier behave abnormal or if a specific parameter is out of range. An alarm
is either a warning, which is only an information for the user, or a shut down event. If there are one
or more alarms in the system the red Common Alarm LED (placed above the foil keyboard) is
illuminated, indicating that this (these) alarm(s) can be found in the alarm stack. The alarm LED is
ON as long as an alarm is present in the system.

The acoustic alarm is also activated, but it is only active for 30 seconds. If the alarm disappears in
less than 30 seconds the acoustic alarm will also stop. If two or more alarms overlap each other, the
acoustic alarm remains activated for additional 30 seconds with effect from the arise of the last
alarm. By pushing the button the acoustic alarm will stop.

The alarm LED indicates that there is an alarm in the alarm stack. The alarm stack contains
those alarms, which at the time in question exist. The alarms are placed in the stack in the same
succession as they arose indicating the latest alarm at first.
To show alarms in the alarm stack push and move inside the stack with the cursor key

or .

DESCRIPTION OF POSSIBLE ALARMS:
(The alarms are shown in English only)
Alarm
No.
AlarmName Description
W=Warning
/
S =Shut down
Time
delay
[sec]
1 Phase order not correct Phase order not correct S 0
2 Mains voltage out of tolerance Mains voltage is out of tolerance, window +15 %, -25
%
S 0
3 Mains frequency error Mains frequency is out of tolerance, window 8 % S 0
4 Mains MCB is off Mains MCB is open S 0
5 UI characteristic

DC voltage deviates more than 3 % of the rated
voltage and the current limiter is not activated
W 5
6 Charger 0 temp.warning Temp. over 90C W 0
7 Charger 30 temp. warning Temp. over 90C W 0
8 Charger 0 temp. shut down Temp. over 110C S 0
9 Charger 30 temp. shut down Temp. over 110C S 0
10 High temp. transformer Temp.signal switch in transformer off
W, S(10 min. delay)
0
11 High temp. choke Temp.signal switch in choke off
W, S(10 min. delay)
0
12 High DC warning DC is over high DC warning level W 0
13 High DC shutdown DC is over high DC shut down level S 0
14 Low DC warning DC is over below Low DC warning level W 0
15 Charger off warning Rectifier is off W 0
16 Total DC current limit Current limiter for total DC current is active W 5
17 Battery current limit Battery current limiter is active W 5
18 DC fuse blown DC fuse is blown S 0
19 Battery MCB is off Battery MCB is open W 0

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Alarm
No.
AlarmName Description
W=Warning
/
S =Shut down
Time
delay
[sec]
20 Low DC Vaux warning The DC voltage after serial diode is below DC warning
level
W 0
21 High DC Vaux warning The DC voltage after serial diode is over high DC
warning level
W 0
22 Internal PSU error, DC string The DC circuit of the redundant PSU is defective W 0
23 Internal PSU error, AC string The AC circuit of the redundant PSU is defective W 0
24 Fan 1 error Fan 1 is rotating to slowly ) W 0
) (fan pulse signal < 20 Hz)
32 Earth fault on positive pole Earth current running to positive pole W 5
33 Earth fault on negative pole Earth current running to ground pole W 5
34 Option 1 error Option 1 error W 0
42 Battery symmetry error Half the battery voltage is outside the window of
1.5%. A battery cell is defective
W 5
43 Battery defect Conclusion of battery monitor test. W 0
44 Mains phase missing Mains, Phase missing. At least 1 phase is missing S 0
45 Load MCB is off Load MCB W 0
46 Blocking of boost / initial Blocking of boost and initial charge is activated W 0
47 Parallel operation error Load sharing differs more than 10%for more than
30secs.
W 30
48 Control loop error Control loop error, e.g. no DC feed back signal S 0
49 Diode temp. warning Temp.signal switch in diode off W 0
50 Loadsharing error 0- 30 Load sharing error, between 0 and 30 module. The
two currents differs more than 7.5%
W 30
51 Temp.sensor error Measured temp.outside window, -35....+55.
Temp.sensor is defective or missing.
W 30
52 Battery weak Battery capacity reduced (battery weak) W 30
53 Synchronization error Charger is not synchronous to mains S 0
54 Battery temp.warning Battery temp.is above limit W 0
55 Calibration stack entered Indication if calibration stack has been entered W 0

Battery current limit has no influence on the acoustic alarm and the common alarm LED in the
display, but becomes present in the alarm stack and the log stack after a delay of 5 seconds.

All alarms have influence on the common alarm relay. Only one alarm, the UI-characteristic
alarm has influence on the rectifier failure relay.

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The alarms will only be present in the alarm stack as long as the red Common Alarm LED is on.
To leave the stack, wait 30 secs or push .

4.1 ALARM LOG
The log alarm section of the program is a stack, which contains the last 100 arisen events. In the
stack both alarms and changes in the operational mode are stored. The events are placed in the
stack in the same succession as they arose indicating the last event at first. All events are time
stamped.
To show alarms in the log alarm stack push simultaneously
0
and . Then move
inside the stack by means of the cursor key

or until the desired event is shown.
The last text in the stack is No (further) event.

The system will log the alarms shown in the alarm stack and at the same time the following
changes in the operational modes:

56 MPU is reset
57 Off button pushed
58 Auto off executed
59 On button pushed
60 Logged mode: Standby
61 Logged mode: Battery operation
62 Logged mode: Float charge
63 Logged mode: Boost charge
64 Logged mode: Initial charge

At the actual event push
1
and the time where the actual event happened will be shown in
the display with year, month, day / hours, minutes, seconds. To leave the log alarm stack wait 30
seconds or push .
The log alarm stack can be cleared by keying in the password: 920701. Push simultaneously
1
and . The display will show: . Key in 920701 and the
alarm log will be cleared. The display shows: .

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OPERATING & INDICATING ELEMENTS
of

TABLE OF CONTENTS:
1. Front panel
2. Operation
3. Operating Status Indications
4. Alarm Indications
4.1 Alarm Indication Concept
4.2 Description of the Individual Alarms
4.3 Common Alarm
4.4 Potential-free Relay contacts
5. Analogous Instruments / Switches
6. External Connection P.C.Board

FRONT PANEL (Control and Monitoring Board)
4A-1110045001/20GB Rev: 1 Page: 2 / 9

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1. FRONT PANEL (CONTROL AND MONITORING BOARD)
SEE PAGE 2
The Front panel (Control and Monitoring board) is divided up in the following functional sections:

Display unit ................................... see Description 7SA9032GB
Operation ...................................... Section 2
Operating status indications....... Section 3
Alarm indications ......................... Section 4

Depending upon the system configuration, the switches mentioned in this
description can be circuit breakers or switch-disconnectors (fuse switch-
disconnectors) and the designation can be made according to customer's request

2. OPERATION

Pos. Designation Explanation
S1 SYSTEM ON Push-button for turning on the entire system.

Push-button for turning off the entire system. For this
function the push-button OFF (S2) must be pressed
at the same time as push-button SYSTEM ON (S1).
S2 OFF

With this action the system is shut-down

no output voltage (only from
battery).
S3 LAMP TEST The push-button may be pressed at any time. It serves
for checking whether all indications of the Operating
status indications and Alarm indications function.
The potential-free alarm contacts are not energized.


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3. OPERATING STATUS INDICATIONS

1 RECT. MAINS OK
(green)
The rectifier mains voltage and frequency are available and within the
specified tolerance ranges.
For tolerances

see Technical Data
2 RECT. OPERATION
(green)
The rectifier is switched on. The firing pulses to the thyristors are
enabled.
3 BOOST / INITIAL
CHARGE
(yellow)
The boost or initial charge has been initiated manually or automatically.
4 BATT. OPERATION
(green)
The battery is supplying the load with energy.
5 OUTPUT VOLTAGE OK
(green)
The output voltage is within the specified tolerance range.
For tolerances see Technical Data
6 Battery switch ON
(green)
The battery switch Q005 and Q004 is switched on.
7 Battery switch OFF
(red)
The battery switch Q005 or Q004 has tripped is switched off.
8 Mains switch ON
(green)
The rectifier input switch Q001 is switched on.
9 Mains switch OFF
(red)
The rectifier input switch Q001 has tripped or is switched off.
10 Load switch ON
(green)
The output switch Q003 is switched on.

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11 Load switch OFF
(red)
The output switch Q003 has tripped is switched off

4. ALARM INDICATIONS
4.1 ALARM INDICATION CONCEPT
The alarm indication on the front panel shows all current alarms. When an alarm gets active the
corresponding LED starts flashing (1 Hz).
When pushing the button

for reset, the LEDs extinguish, whose corresponding alarm is not
active anymore.

If the alarm is still active, the LED changes to steady indication.

When the alarm gets inactive the corresponding LED extinguishes. All LEDs have a delay
compared to the alarms. For the LED indications with the corresponding delays see
section 4.2.
To reset the internal horn (acoustic alarm) push: .

4.2 DESCRIPTION OF THE INDIVIDUAL ALARMS

Designation Explanation
RECTIFIER MAINS FAULT
(AC POWER FAIL)
(30secs)
The indication illuminates if one or more phases of the mains voltage as
well as the frequency and phase sequence are outside the tolerance range.
For tolerances

see Technical Data
RECTIFIER FAILURE
(5secs)

The indication illuminates only, if all the following events occur
simultaneously:
Rectifier mains is ok,
Rectifier is not operating in current limitation,
Rectifier voltage deviates more than 3 % from setting.
For tolerances

see Technical Data

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Designation Explanation
DC OUT OF TOLERANCE
(5secs)
The DC voltage is out of the tolerance range of Low DC Warning/Low DC
Vaux Warning level. For tolerances

see Technical Data
DC FUSE BLOWN
(5secs)
The rectifier output fuse F026 has blown.
RECT. OVERCURRENT
(30secs)
The rectifier output current has exceeded the charger current limit.
For values

see Technical Data
LOAD SHARING FAULT
(only redundant Rect.)
(5secs)
When both rectifier units operates in same operation mode (for the
configuration with individual batteries, only at float charge) the total load of
the parallel connected system is distributed in the way that each rectifier
unit runs at 50% of the actual load, if not this alarm is activated (30secs
delay at detection).
BATTERY DISCHARGED
(5secs)
The battery voltage is dropped below Low DC Warning/Low DC Vaux
Warning level.
For tolerances

see Technical Data
BATTERY DISCONNECTED
(5secs)
The battery is disconnected from the system and the battery fuse or switch
has released. If a battery MCCB is inserted, this indicates whether the
MCCB has tripped or manually been disconnected.
CONTROL POWER FAULT
(5secs)
One of the electronic supplies (+5V/15V) is outside the tolerance range, or
the feeding of one of the power supplies is not available (Rectifier mains or
Battery).
OVERTEMPERATURE
(5secs)
The following elements have a thermal monitoring:
Rectifier bridge
Rectifier transformer
Blocking diode
DC choke
FAN FAILURE
(COOLING SYSTEM
FAILURE)
(30secs)
One or more fans in the system have failed.
LOW DC VOLTAGE
(Option 1)
The DC voltage is dropped to the lower alarm level. The alarm No: 14
Low DC Warning or the alarm No. 20 Low DC Vaux Warning can be
shown in the Display.
For tolerances

see Technical Data chapter 3.
HIGH DC VOLTAGE
(Option 2)
The DC voltage has exceeded the upper alarm level. The alarm No: 12
High DC Warning can be shown in the Display.
For tolerances

see Technical Data chapter 3.
Q003 TRIP
(Option 5)
The battery and the load output is disconnected from the rectifier; it
indicates whether the rectifier output switch Q003 has tripped.
Load sharing is no longer active, and the alarm LOAD SHARING FAULT
will also be indicated.
Q001 TRIP
(Option 6)
The rectifier input switch Q001 is open. It indicates whether the MCCB has
tripped. Also the red LED 9 MAINS MCCB OFF is illuminated


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4.3 COMMON ALARM
If one or more alarms are active in the system according to section 4 Alarms in the display of the
description 7SA9032GB Display & Parameter settings the red Common alarm LED, located on
the display unit just below the LC display and above the foil keypad illuminates, as well as the
Common alarm relays at X009 on the external connection p.c.board drops out after a pre-
programmed delay time (factory set).

4.4 POTENTIAL-FREE RELAY CONTACTS
For customers own use up to 16 alarms are available as potential-free contacts on a relay strip.
The explanations given in section 4.2 Description to the individual alarms and 4.3 Common
alarm are also valid for the alarms on the relay contacts. The contacts are activated simultaneously
with the respective indication in the alarm indication field (see connection diagrams).

SPECIFICATION FOR THE RELAY
Description Minimum Maximum Note
Contact voltage AC 6 V AC 250 V AC 50 / 60 Hz
Contact current AC 50 mA AC 8 A AC
50 / 60 Hz
resistive load
Contact voltage DC 6 V DC 250 V DC 6 V DC
Contact current DC 50 mA DC 0,3 A DC 8 A DC

5. ANALOGOUS INSTRUMENTS / SWITCHES
AC Instruments DC Instruments Switches
A

V

Hz
50

A

V

L2,L3
PH2
L3,L1
PH3
L1
L2
PH1
L3
L0
OFF

P031 P032 P033 P026 P023/1P23/2P23/
1P01/2P01
P024/1P24/2P24/
P027/P102/1P02/
2P02
S031

Pos. Instrument Explanation
P031 AC ammeter Indicates the rectifier input mains current, measured after the rectifier input
switch Q001.
P032 AC voltmeter Indicates the rectifier input mains voltage, measured before the rectifier
input switch Q001.
S031 Phase selector switch
(AC Input)
For the measurement of the individual phase voltages for the AC input
voltmeter P032 and the individual phase currents for the AC input ammeter
P031.
P026 DC ammeter Indicates the charge or discharge current of the battery, measured before
the battery switch Q004.

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Pos. Instrument Explanation
P027 DC voltmeter Indicates the battery voltage, measured measured before the battery switch
Q004.
P023 DC ammeter Indicates the rectifier output current, measured before the rectifier output
switch Q003.
P024 DC voltmeter Indicates the rectifier output voltage, measured before the rectifier output
switch Q003.
1P23 DC ammeter Indicates the rectifier output current, measured in the distribution after the
rectifier output switch Q003 of Charger 1.
1P24 DC voltmeter Indicates the rectifier output voltage, measured in the distribution after the
2P23 DC ammeter Indicates the rectifier output current, measured in the distribution after the
2P24 DC voltmeter Indicates the rectifier output voltage, measured in the distribution after the
P102 DC voltmeter Indicates the rectifier output voltage.
1P01 DC ammeter Indicates the rectifier output current, measured in the Subdistribution before
the Subdistribution input switch 1Q30.
1P02 DC voltmeter Indicates the rectifier output voltage, measured in the Subdistribution
before the Subdistribution input switch 1Q30.
2P01 DC ammeter Indicates the rectifier output current, measured in the Subdistribution before
the Subdistribution input switch 1Q30.
2P02 DC voltmeter Indicates the rectifier output voltage, measured in the Subdistribution
before the Subdistribution input switch 1Q30.


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6. EXTERNAL CONNECTION P.C.BOARD
X002
X003
Internal connection
to Low DC section
Communication RS232
Remote Display
Rectifier failure
Common Alarm
Common Alarm
Internal Supply for Emergency Stop +
Internal Supply for Emergency Stop
External Supply for Emergency Stop
External Supply for Emergency Stop +
External Off
External On
Initial Charge
Boost Charge
Battery Temperature sensor
Battery Temperature sensor +
Battery MCB
Blocking of Boost and Initial Charge
Serial Port
RS232
Parallel
A025
4
3
2
1
X004
14
13
12
11
10
9
8
7
6
5
4
3
2
1
X009
X001
Remote
Display
=Alarm position
4
3
2
1
4
3
2
1
X006
X007
4
3
2
1
X008
GND
GND
GND
GND
GND
GND

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COMMISSIONING


TABLE OF CONTENTS:
1110045001 SINGLE-LINE DIAGRAM
7SA9034GB START STOP
4A-1110045001/20GB COMMISSIONING (7SA9036GB)

98-01-19 mp 00-05-08 mp 01-11-09 mp 07-06-25 mp 09-09-15 mp
98-01-19 Ca 00-05-08 Ca 01-11-09 GA 07-06-25 MDR 09-09-15 MDR
98-01-19 00-05-08 01-11-09 07-06-25 09-09-15
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START STOP
of

TABLE OF CONTENTS:
1. Operational buttons for Starting and Stopping
2. Starting the DC system
3. Stopping the DC system

This chapter contains all the necessary information to operate the DC
system after installation and commissioning.
See also Instruction 7SA9031GB Erection Installation
and Commissioning.

START STOP

7SA9034GB
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7SA9034GB 5 2 / 3
1. OPERATIONAL BUTTONS FOR STARTING AND STOPPING
....................
S1 Button SYSTEM ON for switching on the DC system
....................
S2 Button OFF for switching off the DC system (simultaneously the
button S1 has to be pushed)
....................
Operational parameters

......
Cursor keys for the selection between operational parameters

2. STARTING THE DC SYSTEM

If the system is programmed for AUTOSTART and if the rectifier mains is
switched on and within the tolerance range, the system will start automatically after
60secs.
1. Switch on the rectifier mains supply. The display shows:

for 10
seconds, thereafter the display changes to:

.

2. Turn on the DC system (if not already ensued automatically) by pressing S1 SYSTEM ON
on the front panel. The display shows:

(if at the Parameter
settings

has been chosen.

3. Connect the battery.

4. Press the button

until all red LEDs of Alarm indication are extinguished.

Now the DC system is turned on.

START STOP

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7SA9034GB 5 3 / 3
3. STOPPING THE DC SYSTEM

Secure that all consumers, connected to the DC system are informed before
proceeding with the following steps and before turning off the system.

After the following steps the DC SYSTEM is volt-free.

NO OUTPUT VOLTAGE !!

Remember, the rectifier mains as well as the battery are still applied !
The connecting terminals are carrying hazardous voltage !!!

1. Disconnect the battery.

2. Press the button S1 SYSTEM ON and simultaneously S2 OFF on the front panel to
turnoff the system. The display shows: .

3. Switch off the rectifier mains supply.

The display shows no indication.

Thereafter the DC system is turned off all LED indications
are extinguished.

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COMMISSIONING
of
REDUNDANT DC POWER SUPPLY with 1 Battery,
Type: SDC-R

TABLE OF CONTENTS:
1. Preparations with Power Off
2. Commissioning of the overall DC System
3. Switching volt-free of one DC System unit
4. Recommissioning of one DC System unit

COMMISSIONING

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THE INITIAL CHECKS ARE SUBDIVIDED IN TWO MAJOR PARTS:
one with power off
one with power on

When planning the initial checks read first the complete chapter before starting the
check procedure.

PRINCIPLE DIAGRAM

Depending upon the system configuration, the switches mentioned in this
description can be circuit breakers, switch-disconnectors (fuse switch-
disconnectors) and the designation can be made according to customer's request

OPERATING STATUS INDICATIONS / ALARM INDICATIONS / FAULT
LOCATION
For detailed explanation:
see Description 7SA9032GB Display & Parameter settings and
4A-1110045001/20GB Operating & Indicating Elements 7SA9033GB
For eventual fault location:
see Description 4A-1110045001/20GB Trouble Shooting 7SA9043GB

FRONT PANEL

OPERATING STATUS INDICATION OPERATION DISPLAY UNIT

COMMISSIONING

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SYMBOLIC (BOTH DC SYSTEM UNITS TOGETHER)

1. PREPARATIONS WITH POWER OFF
Before connecting the local network, the battery and the consumers to the DC System, the following
proceedings are necessary:

1. Check that the earthing of all cubicles is secure and there are no damages.
2. Check that all connectors are firmly fixed.
3. Check that all printed circuit boards are correctly mounted and the plugs are firmly plugged in.
4. Check all interconnections and junctions according to Connection diagram.
5. Check that the external fuses have the correct size.
6. If bags with moisture absorbing material are in the cubicle, remove these.

Check that the interior of the DC System is dry. If there is any condensed
water, let the DC System stand with the front doors open in a dry and warm
area for at least 24 hours.

PREPARATIONS ON THE DC SYSTEM BEFORE THE COMMISSIONING:
a) RECTIFIER 1 (System unit A)
Rectifier input switch..................................................... Q001 open
Rectifier output switch................................................... Q003 open
System output switch.................................................... Q100 closed

b) RECTIFIER 2 (System unit B)
Rectifier input switch..................................................... Q001 open
Rectifier output switch................................................... Q003 open
System output switch.................................................... Q200 closed
COMMISSIONING

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c) DISTRIBUTION / OUTPUT
Battery switch................................................................ Q005 closed
Battery switch................................................................ Q004 open
Outgoing feeders Distribution ....................................... Q101...Q1xx open
Input switches Subdistribution....................................... 1Q30 & 2Q30 open
Outgoing feeders Subdistribution.................................. Q301...Q3xx open
Consumers.................................................................... volt-free

2. COMMISSIONING OF THE OVERALL DC SYSTEM
The commissioning is performed according to these instructions:
1. Check preparations as under section 1.
2. Apply the rectifier mains voltage for both system units (according to Connection diagram)
and check phase sequence as well as the voltage.

The following steps are first only to be executed on System unit B:
3. Close the rectifier input switch Q001. The display shows: for 10
seconds, thereafter the display changes to:

. If the DC System is
programmed for AUTOSTART

see Technical data and the rectifier mains is
within the tolerance range the DC System will start automatically after 60 seconds.
The green LEDs 8 & 1 as well as the red LED 7 illuminate.
4. Push the button S3 LAMP TEST on the front panel and check that all LEDs of the
Operating status indications and Alarm indications illuminate.
5. Turn on the DC System (if not already ensued automatically) by pressing S1 SYSTEM ON
on the front panel. The display shows: (if at the Parameter
settings

has been chosen). Additionally the green LEDs
2 & 5 are illuminated.
6. Check the rectifier output voltage in the display by pressing the button

.
7. Close the rectifier output switch Q003.
8. Close the battery switch Q004. Additionally the green LED 6 is illuminated and the
red LED 7 extinguishes.
9. Check the battery current in the display by pressing the button

.
10. Turn off the rectifier mains by opening the rectifier input switch Q001. The DC
COMMISSIONING

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System changes to Battery operation.
11. Check that the green LED BATTERY OPERATION (LED 4) and the red LED 9 illuminate
and the green LEDs 1, 2 & 8 extinguish. The display shows: .
12. Close the rectifier input switch Q001.
Check that the DC System switches back to Normal operation. The green LED 4 and
the red LED 9 extinguish the green LEDs 8, 6, 1, 2 & 5 illuminate.
13. Reset the alarms by pressing the button .
The functions of the DC System unit B have been checked at this stage and
the commissioning procedure for the remaining part continues.
14. Turn off the DC System unit B by pressing simultaneously the push-buttons S1 SYSTEM
ON and S2 OFF on the front panel the green LEDs 2 & 5 extinguish. DC
System unit B changes to Standby operation and its display shows:
.

Repeat steps 3 til 13 for DC System unit A.

15. Turn on DC System unit B by pressing S1 SYSTEM ON on the front panel.
16. Check that on both system units the green LEDs 8, 1, 2 & 5 illuminate and the displays
show: .
18. Make sure that the DC System operates correctly and no alarm of the Alarm indications is
pending.

The safe bus is energized.
The following green LEDs are illuminated: 8, 6, 1, 2 & 5.

19. Close the outgoing feeders Q101...Q1xx in the distribution.
20. Close the Subdistribution input switches 1Q30 & 2Q30.
21. Close the outgoing feeders Q301...Q3xx in the Subdistribution.
COMMISSIONING

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All consumers are now supplied by both DC System units in parallel
redundant operation with load sharing.

The out put t er mi nal s ar e c ar r yi ng hazar dous vol t age !!!
22. Reset eventual alarms on both system units by pressing

until all red LEDs are
extinguished. The horn can be reset by pressing .
23. Clear the log alarm stack on both system by pressing simultaneously

and

.
Then the displays show: . Key in the password 920701 and the
alarm log will be cleared. The displays show: .
24. To return to normal status indication wait 20secs or push:

. The displays show:
.

3. SWITCHING VOLT-FREE OF ONE DC SYSTEM UNIT
With these instructions one of the DC System unit can be switched volt-free.
The load is then supplied by the other DC System unit.

Before switching off one system unit make sure that the other DC
System unit operates correctly and no alarm is pending

The following instructions are related to the system unit which is to be switched volt-free (here
DC System unit B).

1. Turn off the DC System unit B by pressing simultaneously the push-buttons S1 SYSTEM
ON and S2 OFF on the front panel. The load is supplied completely by the other
system unit (DC System unit A), while the DC System unit B changes to Standby operational
mode and its display shows: . The green LEDs 2 & 5
extinguish.
COMMISSIONING

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2. Open the rectifier input switch Q001. The green LEDs 8 & 1 extinguish and the red
LED 9 illuminates.
3. Open the rectifier output switch Q003.

After a while, when the DC capacitor bank has discharged, the DC System is
volt-free with the exception of a few components.

Remember, the rectifier mains as well as the battery are still applied !
The connecting terminals are carrying hazardous voltage !!!

4. RECOMMISSIONING OF ONE DC SYSTEM UNIT
These instructions describe the recommissioning of the second system unit after it has been
switched volt-free (here DC System unit B).

Before starting the recommissioning the following conditions have to be
verified:
The first system unit (DC System unit A) operates correctly and no alarm is pending.
Rectifier input switch............................................................... Q001 open
Rectifier output switch............................................................. Q003 open
Battery switch.......................................................................... Q004 closed

Check the above conditions carefully before starting the following procedure:
1. Close the rectifier input switch Q001.
If the DC System is programmed for AUTOSTART see Technical data and the
rectifier mains is within the tolerance range the DC System will start automatically after 60
seconds. The green LEDs 8 & 1 as well as the red LED 7 illuminate. The
DC System starts up to Standby operation mode and the display shows Standby.
2. Push the button S3 LAMP TEST on the front panel and check that all LEDs of the
Operating status indications and Alarm indications illuminate.
3. Turn on the DC System unit B (if not already ensued automatically) by pressing S1 SYSTEM
ON on the front panel the DC System starts up to normal operation mode and the
displays show (depending on parameter settings) .
Additionally the green LEDs 2 & 5 are illuminated.
4. Check in the display that the rectifier output voltage is within the tolerance range by
pressing the button .
5. Close the rectifier output switch Q003.
COMMISSIONING

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7. Make sure that the DC System operates correctly and no alarm is pending.

Now, the consumers are supplied again from both system units in
parallel redundant operation with load sharing.

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MAINTENANCE


TABLE OF CONTENTS:
7SA9040GB MAINTENANCE
7SA9041GB REPLACEMENT OF COMPONENTS & PARTS
7SA9042GB SERVICE TRAINING CONTACT ADDRESSES

98-02-19 mp 00-05-08 mp 06-10-23 mp 09-08-12 mp
98-02-19 GA 00-05-08 GA 06-10-23 MDR 09-08-12 MDR
98-02-19 00-05-08 06-10-23 09-08-12
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MAINTENANCE
of

TABLE OF CONTENTS:
1. Maintenance of the DC System
1.1 Monthly checks
1.2 Semiannual checks
1.3 Annual checks

2. Maintenance of the Battery
2.1 Monthly checks
2.2 Annual checks
2.3 Battery capacity test

MAINTENANCE

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Due to the critical intended purpose and to ensure the safe and reliable operation of the equipment,
inspection and preventive maintenance are essential.

To perform a proper maintenance on GUTOR DC systems it is adivisable to have participated on a
GUTOR training course. GUTOR also provides global service contracts to guarantuee a maximum
availability of the system therefore please refer to the description 7SA9042GB Servce-
Training-Contact Addresses.

For the checks listed below a brief report/checklist shall be issued where all findings are
documented. These records must be available in case of a warranty claim.

Please read the Safety regulations 7SA9009GB thoroughly before
performing any manipulations on the installation.

1. MAINTENANCE OF THE DC SYSTEM
1.1 MONTHLY CHECKS
The following checks should be made monthly:

1. Check DC output voltage by means of a measuring instrument.
2. Check DC output current by means of a measuring instrument.
3. Persisting alarm indications or incorrect operating statuses must be recorded. Subsequently,
reset the alarms by pressing the button
C
and make sure that the DC system
operates correctly and no alarm of the Alarm indications is any longer pending.
4. Press button S3 LAMP TEST. All operating status and alarm indications must illuminate as
long as the button is pressed.

1.2 SEMIANNUAL CHECKS
The following checks should be made semi-annually:

1. Monthly checks as above.
2. Read out the event log and analyse it. In case of irregularities which can not be explained,
kindly contact the GUTOR support.
3. Only for systems with filter mats: Check whether the filter mats are dirty.
4. J ob preparations for annual maintenance depending on the findings.

MAINTENANCE

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1.3 ANNUAL CHECKS
1. Monthly & semiannual checks as above.
2. Check tightness of all connections. Check the screws and nuts in the device (in volt-free
condition system isolated).
3. In case of strong contamination clean the system from dust.

Switch off the entire system according to the description
7SA9034GB Start Stop
Dont use any liquid for cleaning only vacuum cleaner !

4. Only for systems with filter mats:
Check whether the filter mats are dirty. In the case of strong contamination the filter mats
must be replaced. (A strong contamination results in a reduction of velocity of air, necessary
for the ventilation of the system, and thus sufficient cooling is no longer ensured).
5. Recommendations of OEM (Original Equipment Manufacturer) shall be followed regarding
annual maintenance.
6. Functional check of the entire system shall be performed.

2. MAINTENANCE OF THE BATTERY
During operation the battery capacity and the life-span can be influenced by several processes as:
Corrosion
Grid growth
Ripple effects
Sulphation
Passivation
Short circuit
none or excessive cycling
Deep discharge
Wrong battery room temperature
Operation with low electrolyte
Gradual changes in active material
Normal aging
This only to name a few influencing factors.

Detailed corresponding data for the maintenance of the battery see the information given by
the battery manufacturer in chapter Battery documentation.

MAINTENANCE

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2.1 MONTHLY CHECKS
The following checks should be performed at the same time as the monthly checks of the
DC system:

1. Check the battery voltage at the battery.
2. Check all wet battery cells on the liquid level and if necessary refill see Battery
documentation.
3. Check the voltage of each individual cell (in the case of wet battery cells additionally the
specific gravity) of the pilot cells see Battery documentation.

2.2 ANNUAL CHECKS
1. Annually the cell covers must be cleaned and if necessary the poles and links must also be
cleaned (possible corrosion) and slightly greased.
2. Check the starting torque of the pole screws.
3. Check the battery with the rectifier switched on. Measure and record the voltage of each cell.
In the case of wet cells additionally the specific gravity must be checked and recorded.
4. Perform a nominal battery discharge test according to the manufacturers recommendation
see Battery documentation. The discharge test records should at least contain: All
cell voltages, discharge current, overall battery voltage, ambient temperature and discharge
time. If wet cells are used it would also include the specific gravity as well as the electrolyte
temperature of pilot cells.

2.3 BATTERY CAPACITY TEST
The battery capacity test gives an information about how long the battery backup time is at actual
load. The performance of a battery capacity test only make sense, when the batteries are fully
charged and the rectifier is running in float charge.

At the end of this check the capacity of the battery is low. If at this time a mains
failure occurs, it will have a direct influence on the emergency current time
(autonomy time). Therefore, this check must be co-ordinated with the personnel
(e.g. operator of the connected load). Nevertheless, the test should not be
foregone because it provides the best information on the condition of the batteries.

1. Start with fully charged batteries, i.e. if the system has been in normal operation for longer than
8 hours.

2. Connect the load to the system output.
3. For testing the battery capacity via the foil keyboard proceed as follows: Push and step
inside the stack with the cursor key

or until:

is
shown in the display; where ??? is the back-up time of the last test. If no test has been
performed before or the test has been aborted ??? is shown.
MAINTENANCE

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4. To start the battery capacity test push
C

until the display shows:
. Thereafter push for ON. The rectifier will
change to battery operation and persists until the level Low DC warning/Low DC Vaux
warning is reached. Thereafter the rectifier changes automatically to float charge voltage.

The time in minutes, from the initiation of the battery capacity test to its end is shown in the
battery capacity test menu. A time periode of at maximum 9999 minutes (6 days +22 hours)
are measured. When the level Low DC warning/Low DC Vaux warning is reached the
system changes to normal operation and the batteries will be recharged.

5. To stop an already running capacity test push (when the display shows Battery capacity test
ON) the button
C
until the display shows: . Thereafter push
for OFF.

6. If during the test a mains fault occurs or the button S1 SYSTEM ON has been pushed, the
test will immediately be aborted and no test result will be obtained. When reading out data of
the battery capacity test in the display after a test has been aborted, ??? is shown, i.e. that
no result was obtained.

Please note that after a battery capacity test it will take about 8...24 hours before the battery is
recharged and the full back-up time is available again.

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REPLACEMENT OF COMPONENTS & PARTS


As a minimum GUTOR specifies that the following components and parts in the DC systems are
replaced according to the time periods indicated:
Part
Reference
Designator
Normal
Scope
NPP
Scope
Replace
Cycle
Fan Sub-assembly E0.. X X 5 years
Battery Bank X X Note 1 +2
Backup RAM with Lithium Battery A070 (D034) X X 9 years
DC Capacitor Module CB02 (1CB2, 2CB2) X X 9 years
Air Filter X X Note 3

Normal scope: Stationary on-shore installation with non-seismic requirements
NPP scope: Installation in Nuclear Power Plants, seismic requirements, off-shore- or mobile application

These values refer to a maximum ambient temperature of 40 Celsius and a maximum load of 70%.
If one of these values is continuously exceeded, the items mentioned must be replaced 1 year
earlier.
Note 1: See battery specification of the battery manufacturer.
Note 2: With enabled battery monitor (option) the battery is automatically monitored.
In the case of a faulty battery an alarm is generated.
Note 3: The air filters must be checked at least every 6 months. Dependent on the contamination
they must be replaced immediately.
REPLACEMENT OF COMPONENTS & PARTS

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10year extended Replacement Schedule

Part
Reference
Designator
Normal
Scope
NPP
Scope
Replace
Cycle Remarks
Main Controller with Chipset A070 X X 10 years
Display-Unit (Frontpanel) A073 X X 10 years
External Connection Board A025 X 10 years
PSU / Interface A071 X X 10 years
Rectifier Module (Driver) A030 X 10 years
12-pulse Rectifier Module (Driver) A031 X 10 years if applicable

Options

Part
Normal
Scope
NPP
Scope
Replace
Cycle Remarks
Harmonic Filters X X 10 years
Static Transfer Switch X X 10 years
TDS X X 10 years
DC/AC Converter X X 10 years
DC/DC Converter X X 10 years
according specific instructions

Replacement cycle intervals may be shorter and the scope may need to be
extended if the system is exposed to harsh environmental conditions
(vibration, climate, air-pollution).

Consult GUTOR for an appropriate schedule in this case.

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98-02-19 98-11-04 00-05-08 06-10-30 09-10-05
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SERVICE TRAINING CONTACT
ADDRESSES


TABLE OF CONTENTS:
1. Service/Repairs
1.1 Call for After Sales Service and Return of Parts
1.2 Installation and Commissioning
1.3 Maintenance
2. Spare Parts

3. Training
3.1 Level 1: Operation
3.2 Level 2: Maintenance
3.3 Level 3: Service
3.4 Training for Design Engineers
3.5 Training for Installation Supervisors

4. Contact Addresses

SERVICE TRAINING CONTACT ADDRESSES

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1. SERVICE/REPAIRS
1.1 CALL FOR AFTER SALES SERVICE AND RETURN OF PARTS
LABEL RETURN OF PARTS:

This label contains all necessary information for the return of parts or for contacting our service
department. It is adhered behind the front door near the name plate.

The necessary information to call for service action are mentioned on the name plate.
8
8
5
-3
8
5
4


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1.2 INSTALLATION AND COMMISSIONING
Upon completion of all tests at GUTORs test bay the systems are shipped to the customer site by
ship, air and or land transport. On site, GUTOR-trained and licensed field service engineers (FSE)
perform numerous services such as:
System unpacking and inspection after transportation
Installation and, or installation supervision, to ensure that the assembly and installation of the
system is performed in a professional manner and according OEM requirements
Mechanical and electrical commissioning checks on the isolated system
Mechanical and electrical tests on the energised system
Initial battery charging, or battery refreshing charge
Battery discharge test including dummy load bank
Complete functional test on the entire system
Acceptance test with customer and authorities

GUTORs Installation, commissioning and testing services are designed according to customer
needs to ensure best possible operational condition and to guarantee highest possible system
availability and reliability.

1.3 MAINTENANCE
Maintenance covers several important aspects which have a deep impact on the availability and
reliability of the entire system and the plant it services. The aspects of maintenance are divided in:

Preventive Maintenance
The concept of preventive maintenance comprises planned maintenance tasks. Their purpose is to
minimize breakdowns, excessive depreciation of the system and to maximize availability and
reliability during the entire life span. The individual preventive maintenance jobs are performed
according to the system maintenance manual and the OEM maintenance checklist. Preventive
maintenance requires adequately-trained and experienced manpower, replacements of those parts
with limited lifetime, tools and instruments to perform the respective work.

Corrective Maintenance
Preventive maintenance cannot prevent a breakdown that is caused by external influences,
operational error or a part failure. If an unexpected breakdown occurs it is important that the system
is repaired, tested and brought back to operation immediately.

Spare part Stocking
The successful performance of corrective maintenance requires the availability of critical parts and
components.

Hard and software updates
During the life of a system new features are being developed. Their implementation, or the
replacements of outdated parts make older systems more reliable.

Response time for Services and Material
Adequate response time is an important factor when it comes to remedial services.

Hotline Services
For operational questions, remote advice, or the request of a field service engineer (FSE).


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1.3.1 TAILORED MAINTENANCE PACKAGES
We have bundled above maintenance aspects into three professional packages to cover individual
customer requirements ranging from minimum service, to absolute peace of mind. You choose the
package that suits your requirements.

Pro-Life
This comprehensive package provides customers with an all-inclusive service, and total peace of
mind from day one. GUTOR takes care of:
All regular preventive maintenance including material and tools
Software & hardware updates
All corrective maintenance including material and tools
Guaranteed service response time
Guaranteed product response time
Extended warranty for as long as the package contract lasts
24 hours, 7 days a week hotline

Pro-Partner
With this package GUTOR caters for customers who maintain a GUTOR trained, own maintenance
force capable of performing regular minor preventive works, and minor corrective jobs on all the
systems by themselves. GUTOR take care of major preventive works and respond to unexpected
major technical failures. The package includes:
Major preventive maintenance including material and tools
Software & hardware updates
Major corrective maintenance including material and tools
Guaranteed service response time
Guaranteed product response time
Extended warranty for as long as the package contract lasts

Pro-Flex
In cases where customers require fast and in-depth expertise to solve unexpected major failures
GUTOR guarantee quick and reliable help as and when required. This package guarantees:
Major preventive maintenance including material and tools
Software updates
Service and material response time

Pro-Basic
For customers who want to have organized an easy way to standardize the maintenance of their
systems. GUTOR takes care of standard preventive checks and responds to unexpected major
technical failures. The package includes:
1 standard preventive maintenance job per system & year
Software updates
Service and material response time


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Pro-Light
For customers who want to have an easy access to service & support at any time. GUTOR takes
care of updating the Software. The package includes:
Software updates
Service and material Response time

2. SPARE PARTS
Spare parts are differentiated according to the various plant requirements:
Spares for commissioning
Spares for preventive maintenance
Spares for corrective maintenance as strategic stock
The selection of the correct spare parts is crucial. We gladly support you in defining the spare parts
needed taking in consideration of your installed GUTOR systems and requirements.

3. TRAINING
Uninterruptible Power Supply (UPS) systems from GUTOR are designed according to individual
customer needs. Technical staff servicing and maintaining these systems therefore receive
customized training based on specific requirements in relation to those particular systems installed
on-site.

GUTOR offers three different training levels concerning operation, maintenance, and service
respectively. Each training course, as well as the documentation, are individually tailored based on
the customer's installed fleet. All levels are appropriate for the operation and maintenance
requirements of the GUTOR systems.

3.1 LEVEL 1: OPERATION
This course is composed of two parts. The first theoretical part introduces the participants to the
various system operating modes, and provides information on how the system is built. In the
second practical part, the training instructor demonstrates to the participants how to operate the
system in a safe and confident manner.

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We recommend Level 1 training to all personnel working with (and in charge of) GUTOR systems.
We also recommend clients having a Pr o-Li f e maintenance contract to attend this course.

Requirements:
The participants should have a basic education in electronics. Special UPS knowledge is not
necessary.

3.2 LEVEL 2: MAINTENANCE
This course builds on the information provided during Level 1. Participants learn the important
functions of the major UPS components. They also receive information regarding maintenance work
and maintenance intervals. Upon completion of this course, participants are capable of resolving
simple system errors.

We recommend Level 2 training to clients having at least a Pr o Par t ner maintenance contract.

Requirements:
Level 1 is a prerequisite for Level 2, and shall be completed first. The participants should have a
solid education in electronics.

3.3 LEVEL 3: SERVICE
In Level 3 training participants learn how to analyze and repair system errors. In addition, the
training instructor explains how the system can be calibrated. Upon completion of this course,
participants are capable of performing most repair and maintenance work by themselves.

We recommend Level 3 training to clients having as a minimum a Pr o Li ght maintenance
contract.

Requirements:
Level 1 and Level 2 are prerequisites for Level 3, and shall be completed first. The participants
should have a solid education in electronics.

3.4 TRAINING FOR DESIGN ENGINEERS
This training course conveys valuable system solution know-how about UPS systems, intended for
Design Engineers. This knowledge is useful when evaluation new systems and/or expanding
existing systems. Participants learn in detail about functions and characteristics of the system, as
well as the various standard system configurations.

An explanation of the important aspects of system options and basic battery rules are also included.

Requirements:
The participants should have a solid education in electronics.


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3.5 TRAINING FOR INSTALLATION SUPERVISORS
This training course mainly focuses on the installation of a GUTOR system and its batteries. The
Installation Supervisors learn how to perform proper mechanical checks on the system.
Furthermore, they discover the climactic conditions for which the life-span of the system can be
optimized.

Requirements:
The participants should have a solid education in electronics.

For det ai l ed desc r i pt i on pl ease c ont ac t our c ust omer ser vi c e

4. CONTACT ADDRESSES
Hardstrasse 72-74

5430 - Wettingen / Switzerland

I nt er net : www.gutor-service.com
E-Mai l : gutor.customerservice@apcc.com
Phone: ++41 56 437 34 34
Fax : ++41 56 437 34 21

Contact address in Malaysia:

GUTOR Electronic Asia Pacific Sdn. Bhd.
No. 19, J alan J uruukur U1/19,
Seksyen U1 Hicom Glenmarie Industrial Park
40150 Shah Alam, Selangor, Malaysia.

Phone : +(6) 03 556 90 331
Fax : +(6) 03 556 90 332

Further Offices in: China, Brazil, Germany, India, J apan, Mexico, Nigeria, Qatar, Russia, U.S.A.,
U.A.E.

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TROUBLE-SHOOTING


TABLE OF CONTENTS:
4A-1110045001/20GB TROUBLE-SHOOTING (7SA9043GB)

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TROUBLE-SHOOTING


TABLE OF CONTENTS:
1. Elimination of simple Malfunctions
2. Trouble-Shooting at Alarm Indication

TROUBLE-SHOOTING

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1. ELIMINATION OF SIMPLE MALFUNCTIONS
Depending upon the system configuration, the switches mentioned in this description can be circuit breakers or switch-disconnectors (fuse switch-
disconnectors) and the designation can be made according to customer's request see Single line diagram.
RECTIFIER DOESN'T
START
REASON:
Rectifier input switch Q001 open
Rectifier mains voltage out of tolerance or wrong phase
sequence
Overtemperature signalization of rectifier power components
Supply voltage for the electronics fails or is out of tolerance
Plug connection of the electronics to the rectifier bridge

SHUTDOWN
CONDITION
Phase order wrong
Mains out of tolerance
Mains frequency out of tolerance
Charger not synchronous to mains
Overtemperature
High DC shutdown
DC fuse blown
Missing phase
Control loop error
Ram1 corrupt

2. TROUBLE-SHOOTING AT ALARM INDICATION

TROUBLE-SHOOTING

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AlarmIndication Alarm#: / Error in the System Source of Error Test Possibilities Location
RECT MAINS FAULT
(AC POWER FAIL)
(30secs)
1: Phase order not correct Wrong wiring Check phase order Interface A071: X003, F001,
F002, F003

2: Mains voltage out of tolerance Input voltage out of tolerance Check voltages

3: Mains frequency fault Input frequency out of tolerance Check frequency and SYNC LED on controller A070 Q001, Controller A070

44: Mains phase missing Input switch Q001 open Check input switch Q001 Q001

53: Synchronization error Input frequency fluctuations Check frequency and SYNC LED on controller A070 Q001, Controller A070
Load too high Check load, if system is in current limitation mode
RECTIFIER FAILURE
(5secs)
5: Voltage deviates more than 3% of
nominal voltage without current limitation
and no RECT. MAINS FAULT
Input voltage low but in tolerance Check input voltage Interface A071: X003, F001,
F002, F003

System OFF (also due to shutdown) or System in
standby
Check operation mode and evaluate shutdown cause
(Log stack)

Rectifier or PSU faulty Check current ripple (6-pulse: 300/360Hz, 12-pulse:
600/720Hz)
Q001
Check PSU LED's (PSU_OK_AC/PSU_OK_DC) Interface A071

Check output voltage
Interface A071: X009, F014,
F015
Load too high (also short-circuit) Check load, if system is in current limitation mode Current sensor P001 (P002) DC OUT OF TOLERANCE
(5secs)
12, 14, 20: Output voltage is higher
than the high DC warning level or lower
than the low DC warning level
standby
(Log stack)

Check current ripple (6-pulse: 300/360Hz, 12-pulse:
600/720Hz)
Q001

Rectifier or PSU faulty
Check PSU LED's (PSU_OK_AC/PSU_OK_DC)
Interface A071

Battery discharged / disconneted or switch Q004
(Q005) open during battery operation
Check battery voltage
Q004 (Q005)

Check output voltage Interface A071: X009, F014,
F015
TROUBLE-SHOOTING

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DC FUSE BLOWN 18: Rectifier output fuse F026 (F027) Fuse trip indicator not connected Check fuse trip indicator Rectifier output fuse F026
(F027)
(5secs) blown
Load too high (also short-circuit) Check load Current sensor P001 (P002)
Trip indicator on Rectifier
output fuse F026 (F027)
RECT OVERCURRENT
(30secs)
16: Total current limiter active Load too high (also short-circuit) Check battery and load current Current sensor P001 (P002)
Battery current transformer
P003
LOAD SHARING
FAILURE
47: Loadsharing deviates more than
10%
Wrong calibration of output voltage Check output voltages at the common output point Common output point
(only redundant Rect)
(5secs)
Wrong temperature compensation Check temperature measurement of both chargers
External Connection Board
A025 : X006:3 and X006:4
One or more cells of the battery defective Check individual cell voltages Battery
Battery discharged Check battery voltage Q004 (Q005)
BATTERY DISCHARGED
(5secs)
14, 20: Battery voltage dropped below
the Low DC Warning/Low DC Vaux
Warning level
Standby
(log stack)

43: Battery monitor test result is battery
defective
Battery monitor not reset after installation of new
battery
Reset battery monitor (User stack) only possible if
ABM installed

BATT DISCONNECTED
(5secs)
19: Battery breaker Q004( Q005 ) open or
tripped
Breaker open or auxilary contact not connected Check breaker and auxilary contacts Battery
Q004 (Q005), X002
External Connection Board
A025: X004:1 and X004:2
CONTROL POWER
FAULT
(5secs)
22, 23: One of the electronic
supplies (+5V/15V) is outside the
tolerance range, or the feeding of one
of the power supplies is not available
(Rectifier mains or Battery)
Connector cable missing to one or both of the two
PSU's
Check LED's on interface (PSU_OK_AC,
PSU_OK_DC)
Try to start DC supply manually (if DC supply fault) by
pressing S1
Interface A071

Mains not available or input breaker Q001 open Measure input voltages for the two supplies Interface A071
TROUBLE-SHOOTING

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Battery disconnected or battery switch Q004
(Q005) open

Interface A071 / X001:
F006/F006
Interface A071 / X002:
F018/F019
OVERTEMPERATURE
(5secs)
6, 7: Charger 0 or 30 overtemperature Overtemperature of one component Check size of components, load and thermoswitches Thermoswitches of power
components T001, F001,
V001, A030, A031

10: Transformer overtemperature Air inlet obstructed, fan problem Check air inlet and fan

11: Choke overtemperature Ambient temperature too high Check ambient temperature Interface A071: X018- X025

49: Output diode overtemperature (if
available)
Sensor contacts not connected Check wiring A030, Interface A071: X006
Check fans Fans E001 - E008 FAN FAILURE
(COOLING SYSTEM
FAILURE)
(30secs)
24-31: Fan failure 1-8 One of the fans is blocked, rotating too slow or
connected wrongly
Check connection (fan surveillance cable connected
always starting at position 1)
A050 - A057, Interface A071:
X018 - X025

Fan supply failure Check fan supply transformers (T050/T051) T050: F010, F011, T051:
F012, F013
14, 20: Low DC warning Load too high (also short-circuit) Check if system is in current limitation
LOWDC VOLTAGE
(Option 1)

Standby
(Log stack)

Rectifier or PSU faulty Check PSU LED's and voltages (PSU_OK_DC,
PSU_OK_AC)
Controller A070

Battery discharged / disconneted or breaker
Q004 (Q005) open during battery operation
Check battery voltage Q004 (Q005)
HIGH DC VOLTAGE
(Option 2)
12: High DC warning DC voltage too high feed from charger Check DC voltage Interface A071: X009:1 and
X009:3, F014

Check if load has disconnected and battery is
connected
Q003, Q100 and Q004
(Q005)

Check why load has disconnected (fuse, breakers) Power fuse F026 (F027)

Check input transformer Q001
TROUBLE-SHOOTING

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If high DC shutdown check input phase order (L1-L2-
L3 and not eg L2-L3-L1)

DC voltage too high feed from load Disconnect the load Q003, Q100
Q003 TRIP (Option 5) 45: Load MCB error Q003 open or auxilary contact not connected
Q003 auxilary contact is not connected to its
input on the interface
Q003 auxilary contact is only connected to an
Option input
Check wiring
Check whether Q003 has tripped
Q003
Interface A071: X005
Q001 TRIP (Option 6) 39: Option input error The rectifier input switch Q001 is open. It
indicates whether the MCCB has tripped.
Also the red LED 9 MAINS MCCB
OFF is illuminated
Check wiring
Check whether Q001 has tripped
Q001
Interface A071: X016: 3/4

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TEST DOCUMENTATION


TEST DOCUMENTS WILL BE PROVIDED AFTER THE SYSTEM HAS BEEN
TESTED.

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SCHEMATIC / PARTS LISTS /
SPARE PARTS LISTS


TABLE OF CONTENTS:
SCHEMATIC see SCHEMATIC DIAGRAM 1110045001/00
PARTS LISTS & SPARE PARTS LISTS
see CUSTOMER PARTS LIST 1110045001/50

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BATTERY DOCUMENTATION


TABLE OF CONTENTS:
BATTERY MANUFACTURER'S INSTALLATION AND
OPERATING INSTRUCTIONS

Specifications:
Nominal voltage U
N
: 2.0 V x number of cells
connected in series
Nominal Capacity C
N
= C
10
:
10 hour discharge (see type label)
Nominal discharge current I
N
= I
10
:
Final discharge voltage U
s
: 1.80 V/Cell
Nominal temperature T
N
: 20C
LA antimony content < 3% in the grids
(material carriers) of the pos. electrodes
Observe operating instructions
and display visibly near to the
battery.
Work on batteries only after
instruction by qualified staff.
No smoking. No open flame,
embers or sparks in the vicinity of
the battery, to avoid risk of explo-
sion and fire.
Wear eye protection and protec-
tive clothing when working with
batteries.
Observe accident prevention
regulations, also EN 50272-2,
VDE 0105 Part 1
Acid splashes in the eyes or on
the skin must be washed out or
off with plenty of water. Then see
a doctor immediately. Acid splas-
hes on clothing should be
washed out with water!
Explosion and fire risk, avoid
shortcircuits.
Warning! Metal parts of the bat-
tery cells are always live. Never
place foreign objects or tools on
the battery.
Electrolyte is highly corrosive.
Monobloc batteries/cells are very
heavy!
Ensure secure installation! Use
only suitable conveying equip-
ment!
Dangerous electrical voltage.
Installation by:
on:
Commissioning by:
on:
Safety markings affixed by:
on:
Non-compliance with operating instructions,
repairs made with other than original parts,
tampering or use of electrolyte additives (alle-
ged enhancers) render the warranty null and
void.
1. Commissioning
Before commissioning all cells/blocks must
be inspected for mechanical damage, cells
must be connected with the correct polarity
and connectors firmly seated. The following
torque applies for screw connectors:
20 Nm 1 Nm
If necessary the terminal covers must be put
on. Check the level of electrolyte in all cells
and top up to the maximum level with purified
water (acc. to DIN 43530 Part 4) if necessa-
ry.
With charger off and loads isolated, connect
battery to the direct current power supply,
maintaining correct polarity (positive terminal
to positive post). Switch on the charger and
charge as described in section 2.2.
2. Operation
For the operation of stationary battery instal-
lations DIN VDE 0510 Part 1 (draft) and EN
50272-2 apply.
2.1 Discharging
Never allow the final discharge voltage of the
battery to drop below that assigned for the
discharge current. Unless the manufacturer
has specified otherwise, no more than the
nominal capacity is to be consumed. Charge
immediately after discharge, including partial
discharge.
2.2 Charging
All charging procedures may be used with
their limit values as specified in
DIN 41 773 (IU characteristic)
DIN 41 774 (W characteristic)
DIN 41776 (I characteristic)
Depending on charger type and charging cha-
racteristic, alternating currents flow through
the battery during charging and are superim-
posed onto the charging direct current. These
superimposed alternating currents and the
reaction of the loads lead to additional hea-
ting of the battery and strain on the electro-
des with possible resulting damage (see sec-
tion 2.5).
Depending on the system at hand, charging
may be carried out under the following opera-
ting modes
a) Stand-by parallel operation and floating
operation
Here the load, direct current source and bat-
tery are continuously connected in parallel.
This means that the charging voltage is the
operating voltage of the battery and at the
same time the battery system voltage.
Under stand-by parallel operation, the direct
current source is at any time capable of
supplying the maximum load current and the
battery charging current. The battery only sup-
plies current when the direct current source
fails. The charge voltage should be set at
2.23 V 1% (2,25 V 1% for USV-bloc and
OSP.XC cells) x number of cells in series, mea-
sured at the batterys terminals.
To reduce the recharging time a charging
stage can be applied in which the charging
voltage is max. 2.33 to 2.4 V x number of
cells (stand-by parallel operation with rechar-
ging stage). Automatic changeover to the
charging voltage of 2.23 V 1% (2,25 V
1% for USV-bloc and OSP.XC cells) x number
of cells in series follows.
With floating operation the direct current
source is not able to supply the maximum
load current at all times. The load current
intermittently exceeds the nominal current of
the direct current source.
During this period the battery supplies power.
It is not fully charged at all times. Therefore,
depending on the load, the charge voltage
must be set at approx. 2.25 to 2.30 V x the
number of cells connected in series.
b) Switch mode operation
When charging, the battery is separated from
the load. Towards the end of charging, the
charge voltage of the battery is 2.6 - 2.75
V/cell. The charging process must be monito-
red (see under 2.4, 2.5 and 2.6). On rea-
ching a state of full charge, charging should
be terminated or a switch made to float char-
ging as under section 2.3.
c) Battery operation (charge/discharge ope-
ration)
The load is supplied only by the battery. In this
case, towards the end of charging, the char-
ge voltage of the battery is 2.6 - 2.75 V/cell.
The charging process must be monitored (see
under 2.4, 2.5 and 2.6). On reaching a state
of full charge, charging should be terminated.
The battery may be connected to the load if
required.
2.3 Maintaining the full charge (float
charging)
Devices complying with the provisions of DIN
41773 must be used. They are to be set so
that the average cell voltage is 2.23 V 1%
(2.25 1% for USV-bloc and OSP.XC cells),
C
N
10 h
Vented stationary lead acid batteries
Operating Instructions
and so that electrolyte density does not fall
over longer periods of time.
2.4 Equalising charge
Because it is possible to exceed the permit-
ted load voltages, appropriate measures must
be taken, e.g. disconnection of the load.
Equalising charges are necessary after
exhaustive discharge and/or after inadequate
charging; they can be carried out as follows:
- at a constant voltage of max. 2.4 V/cell for
up to 72 hours
- with the I or W characteristic in accordance
with Table 1
Should the maximum temperature of 55C be
exceeded, the charging process must be
interrupted or continued with reduced current
or a temporary switch made to float charging
to allow the temperature to drop. The end of
equalising charging is reached when the elec-
trolyte densities and the cell voltages no
longer rise within a period of 2 hours.
2.5 Superimposed alternating currents
While recharging up to 2.4 V/cell in accordan-
ce with operating modes a) to c), the actual
value of the alternating current is occasional-
ly permitted to reach a max. 20 A per 100 Ah
nominal capacity (for shortest time).
Up to 2.4 V/cell, 10 A per 100 Ah nominal
capacity may not be exceeded. In fully char-
ged state with a charge voltage of 2.23 to
2.30 V/cell, the effective value of the alterna-
ting current must not exceed 5 A per 100 Ah
nominal capacity.
2.6 Charging currents
Charging currents are not limited up to 2.4
V/cell. If charge voltages of 2.4 V/cell are
exceeded, greater water decomposition will
occur. The charging currents per 100 Ah nomi-
nal capacity shown in Table 1 should not be
exceeded.
2.7 Temperature
The recommended operating temperature
range for lead-acid batteries is 10C to 30C.
The technical data apply to the nominal tem-
perature of 20C. The ideal operating tempe-
rature range is 20C 5C.
Higher temperatures will reduce battery ser-
vice life. Lower temperatures reduce the avai-
lable capacity. The maximum temperature of
55C must nor be exceeded.
2.8 Temperature-related charge voltage
Within the operating temperature range of
10C to 30C, temperature-related adjust-
ment of the charge voltage is not necessary.
If the temperature range is below 10C and/or
above 30C, the charge voltage should be
adjusted. The temperature correction factor is
(-0.004 V/Cell per K).
If the temperature is constantly above 40C,
the factor is (-0.003 V/Cell per K).
2.9 Electrolyte
The electrolyte is dilute sulphuric acid. The
nominal density of the electrolyte is based on
a temperature of 20C and nominal electroly-
te level in fully charged condition, maximum
deviation 0.01 kg/l. Higher temperatures
will reduce electrolyte density, while lower
temperatures increase electrolyte density.
The associated correction factor is 0.0007
kg/l per K.
Example: Electrolyte density 1.23 kg/l at 35C
corresponds to a density of 1.24 kg/l at 20C.
An electrolyte density of 1.25 kg/l at 5C cor-
responds to a density of 1.24 kg/l at 20C.
3. Battery maintenance and inspection
Check the electrolyte level regularly. If it has
fallen below the lower electrolyte level mark it
should be topped up with purified water to
DIN 43530 Part 4, max. conductivity 30
S/cm.
To avoid leakage currents keep the battery
clean and dry. Cleaning the battery should be
carried out as specified in the ZVEI pamphlet
on battery cleaning.
Plastic battery components, in particular the
cell containers, must only be cleaned with
pure water.
At least every 6 months the following must be
measured and recorded:
- battery voltage
- voltage of a few selected cells/monobloc
batteries
- electrolyte density of a few selected cells/
monobloc batteries
- electrolyte temperature of a few selected
cells/ monobloc batteries
The following must be measured and recor-
ded annually:
- voltage of all cells/monobloc batteries
- electrolyte density of all cells/monobloc bat-
teries
- electrolyte temperature of a few selected
cells/monobloc batteries
Should the float charge voltage of any cell
vary by more than + 0.1 V or -0.05 V from
the average value, customer services must be
called in.
Annual visual checks:
- on bolted connectors (check that unsecured
bolt connectors are firmly seated)
- on battery installation or arrangement
- on ventilation of the battery room.
4. Tests
Tests must be conducted in accordance with
EN 60896-11. In addition, special test
instructions, e.g. as set out in DIN VDE
0107 and DIN VDE 0108 should be obser-
ved.
5. Faults
Should faults be detected in the battery or the
charging device, customer services should be
called in immediately. Measured data as
under section 3 simplify fault detection and
elimination. A service contract with us facilita-
tes the timely detection of faults.
6. Storage and taking out of operation
Should cells/batteries be stored or be taken
out of operation for extended periods, they
must be stored fully charged in a dry, frostfree
room. Direct sunlight must be avoided.
To prevent damage, the following charging
conditions should be chosen:
1. Equalizing charges as defined under 2.4
above, to be given four times a year. At ave-
rage ambient temperatures in excess of
20C, monthly equalizing charges may be
necessary.
2. Float charging as under 2.3 above.
The period of use commences with delivery of
the filled and charged battery from the
HOPPECKE plant. Storage times are to be
added to the period of use in full. In addition,
batteries require recharging.
7. Transport
Filled lead-acid batteries which are undama-
ged, show no leaks and are firmly secured
on pallets with protection against sliding,
overturning and short-circuits are not trea-
ted as dangerous goods for conveyance by
road as long as there are no dangerous tra-
ces (acid, lye) visible on the outside of the
package.
ATTENTION: It is essential that loads on
road vehicles are properly secured.
8. Technical data
The nominal voltage, the number of blocks,
the nominal capacity (C
10
= C
N
) and the bat-
tery type can be obtained from the identifica-
tion plate.
8.1 Example
Identification plate: 4 OPzS 200
4 = number of positive plates
OPzS = battery type
200 = nominal capacity C
10
(capacity for discharge with ten hours current
(I
10
) over a discharge time of 10 h (t
10
)
T
e
i
l
-
N
r
.

7
1
4
0
2
0
4
0
1
1
/
0
7
.
0
9
/
3

K

P
r
i
n
t
e
d

i
n

G
e
r
m
a
n
y
Pb
Old batteries with this marking are recyclable goods and must be sent for recycling.
Used batteries which are not sent for recycling are to be disposed of as special waste under the relevant regulations.
Charging
procedure
I-charact.
W-charact.
Types
OPzS, OPzS bloc,
max.power, solar.power,
OGi bloc HC, OGi bloc,
OSP.HC, OSP.XC, USV bloc
5.0 A 6.5 A
7.0 A
3.5 A
9.0 A
4.5 A
Cell
voltage
2.6-2.75 V
bei 2.4 V
bei 2.65 V
GroE
HOPPECKE Batterien GmbH & Co. KG
P.O. Box 1140 D-59914 Brilon
Bontkirchener Strae 1 D-59929 Brilon-Hoppecke
Phone: + 49 (0) 29 63 61-3 74 Email: info@hoppecke.com
Fax: + 49 (0) 29 63 61-2 70 Internet: www.hoppecke.com

11-06-22 mp
11-06-22 MAS
11-06-22
7SA9002GB
-
-
-
4A-1110045001/20GB 1 1 / 1

CUSTOMER-SPECIFIC DOCUMENTATION /
CERTIFICATES


TABLE OF CONTENTS:
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY Free of PCB
DECLARATION OF CONFORMITY EMC

P.O. No.: 11022

System: DC POWER SUPPLY ( R e c ti f i e r / C h a r g e r )

Type Item No. GUTOR Ref.
SDC 125-1200-R
C10BTL01 & C10BTL02 1110045001-01. 1110045001-06
SDC 125-1200-R
C20BTL01 & C20BTL02 1110045002-01. 1110045002-06
SDC 125-1200-R C30BTL01 & C30BTL02 1110045003-01. 1110045003-06
SDC 125-1200-R C40BTL01 & C40BTL02 1110045004-01. 1110045004-06
SDC 125-1200-R C50BTL01 & C50BTL02 1110045005-01. 1110045005-06

We herewith confirm, that the goods are manufactured in accordance with the purchase
order and all of the relevant Buyers standards and requirements.

Wettingen, 2011-06-28

Cemal Yilmaz Muneet Asri
Quality Assurance Project Engineer

P.O. No.: 11022


SDC 125-1200-R
C10BTL01 & C10BTL02 1110045001-01. 1110045001-06
SDC 125-1200-R
C20BTL01 & C20BTL02 1110045002-01. 1110045002-06
SDC 125-1200-R C30BTL01 & C30BTL02 1110045003-01. 1110045003-06
SDC 125-1200-R C40BTL01 & C40BTL02 1110045004-01. 1110045004-06
SDC 125-1200-R C50BTL01 & C50BTL02 1110045005-01. 1110045005-06

We herewith confirm, that the mentioned equipments are free of Polychlorinated Biphenyl
(PCB).



P.O. No.: 11022


SDC 125-1200-R
C10BTL01 & C10BTL02 1110045001-01. 1110045001-06
SDC 125-1200-R
C20BTL01 & C20BTL02 1110045002-01. 1110045002-06
SDC 125-1200-R C30BTL01 & C30BTL02 1110045003-01. 1110045003-06
SDC 125-1200-R C40BTL01 & C40BTL02 1110045004-01. 1110045004-06
SDC 125-1200-R C50BTL01 & C50BTL02 1110045005-01. 1110045005-06

We hereby declare that the performed tests for the above equipment are conform to the

Generic Standards:
IEC/EN 61000-6-4: Electromagnetic Compatibility (Emission)
IEC/EN 61000-6-2: Electromagnetic Compatibility (Immunity)



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