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000 REV NO

7/5/2011 DATE

MP BY:

Issue for JEK Information DESCRIPTION CHKD.

MAS CERT.

MAS 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: DATE STARTED:6/30/2011 OPR'G. DEPT: THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED CHECKED BY:

JEK

DATE COMPLETED: 6/30/2011 ENG. DEPT: APPROVAL/CERTIFICATION INFORMATION


DOC. NO.30621127-000-3DT-EE-03584

REV. NO.

QURAYYAH

SAUDI ARABIA
JOB ORDER NO.

1-0923053.01
JOB NO. PROJECT SUBDIVISION DOCUMENT TYPE CODE DOCUMENT NUMBER REV NO.

30621127
1110045001/20GB 1110045001-005

000

3DT

EE-03584

000

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


Client: M/s Techmaster Inc. 1952 McDowell Road, Suite 204 Naperville, Illinois 60563 USA 11022 Conversion of Qurayyah Open Cycle Power Plant to Combined Cycle Power Plant Project C Saudi Electric Company 125V Block-1 DCDB

P.O. No.: Project name: End-User: Installation:

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

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1 2 3 4

GENERAL INFORMATION

SAFETY REGULATIONS

SYSTEM DATA

PACKING TRANSPORT INSTALLATION

CONTENTS

5 6 7 8 9 10 11 12
-

DISPLAY OPERATING & INDICATING ELEMENTS

COMMISSIONING

MAINTENANCE

TROUBLE SHOOTING

TEST DOCUMENTATION

SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS

BATTERY DOCUMENTATION

CUSTOMER-SPECIFIC DOCUMENTATION / CERTIFICATES


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DOCUMENT INDEX & REVISION SHEET


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 0
4A-1110045001/20GB 4A-1110045001/20GB 4A-1110045001/20GB

Date Rev. concerned pages


(7SA9002GB) 11-06-22 11-06-22 11-06-22 11-06-22 09-08-10 09-08-11 11-06-22 09-08-12 11-06-22 (7SA9010GB) 1 Cover sheet 1 all 1 all 1 Cover sheet 4 all 2 all 1 Cover sheet 4 all 1 Cover sheet COVER SHEET TABLE OF CONTENTS DOCUMENT INDEX & REVISION SHEET GENERAL INFORMATION General Information General System Principle & Description of Component SAFETY REGULATIONS Safety Regulations SYSTEM DATA Single-Line Diagram Technical Data applicable for all Items Priorities and Operational Modes Explanation of the Boost Charge Function PACKING TRANSPORT INSTALLATION Packing & Unpacking & Storage Air / Oversea Transport Transport of the System without Packing Erection Installation Assembly of Particular Cubicle Units DISPLAY OPERATING & INDICATING ELEMENTS Display & Parameter Settings Operating & Indicating Elements applicable for all Items COMMISSIONING Single-Line Diagram Start Stop Commissioning applicable for all Items MAINTENANCE Maintenance Replacement of Components & Parts Service Training Contact Addresses TROUBLE-SHOOTING Trouble-Shooting applicable for all Items (7SA9043GB) (7SA9036GB) 09-09-15 11-06-22 11-06-22 09-08-12 09-08-12 09-10-05 11-06-22 11-06-22 5 all 1 all 1 Cover sheet 4 all 1 all 5 all 1 Cover sheet 1 all (7SA9033GB) 11-06-22 09-08-11 11-06-22 11-06-22 09-10-04 98-06-01 09-10-01 03-04-16 11-06-22 09-12-22 11-06-22 11-06-22 1 all 3 all 1 all 1 Cover sheet 4 all 1 all 4 all 1 all 1 Cover sheet 4 all 1 all 1 Cover sheet

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4A-1110045001/20GB 7SA9009GB 4A-1110045001/20GB 1110045001 4A-1110045001/23GB 7SA9023GB 4A-1110045001/20GB

4A-1110045001/20GB 7SA9028GB 7SA9030GB 7SA9031GB 7RA9195GB

4A-1110045001/20GB 7SA9032GB 4A-1110045001/20GB

4A-1110045001/20GB 1110045001 7SA9034GB 4A-1110045001/20GB

4A-1110045001/20GB 7SA9040GB 7SA9041GB 7SA9042GB

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DOCUMENT INDEX & REVISION SHEET


DOCUMENTS to SDC 125-1200-R
Chapter Doc. No. Title 9
4A-1110045001/20GB

Date Rev. concerned pages


11-06-22 11-06-22 11-06-22 11-06-22 1 Cover sheet 1 Cover sheet 1 Cover sheet 1 Cover sheet TEST DOCUMENTATION

10 4A-1110045001/20GB SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS 11 4A-1110045001/20GB BATTERY DOCUMENTATION
CUSTOMER-SPECIFIC DOCUMENTATION / 12 4A-1110045001/20GB CERTIFICATES Declaration of Conformity Declaration of Conformity Free of PCB Declaration of Conformity EMC

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

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

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GENERAL INFORMATION

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

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GENERAL INFORMATION
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 also 7SA9042GB: Service - Customer Training - Contact Addresses. see

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

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GENERAL INFORMATION
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 Modular and clearly arranged design Benefits Accessible from front and top for repair and maintenance work Easy access to power modules, exchange possible by one person only Increased MTBF (Mean Time Between Failures) easy maintenance Transparent system operation Better control over the system functions Remote and easy system supervision Become clear and peace of mind when the system is in operation Precise fault diagnosis Increased system reliability Increased life of redundant units Constant security that systems are working Increased availability One module can be isolated at any time 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 Maximising of the battery life Security and clarity about the function of batteries

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 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. System integrated communication interface RS232 Active mimic diagram on the front panel, adaptable to customers specification (not available for Standard front panel). Distinction between flashing new alarm and steady indication of reset faults. Storage of the last 100 events in the memory. Redundant (2) PSUs (power supply units), supplied from the AC input side and the DC output side (where also the battery is connected to). Microprocessor-controlled load sharing facility Possible parallel connection of 2 charger modules with active load sharing Fan speed control and monitoring

Temperature-compensated battery charging Battery testing programme & monitoring unit to display the remaining capacity and the actual back-up time Halogen-free wiring Certified industrial quality classification ISO 9001

Safe working environment Guaranteeing highest product and after sales service quality levels

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GENERAL INFORMATION
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:

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:

885-3854

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

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GENERAL INFORMATION
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 see also 7SA9042GB department. It is adhered behind the front door near the name plate Service - Customer Training - Contact addresses.

4.

STANDARDS APPLIED, CONFORMITY


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

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

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

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

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GENERAL SYSTEM PRINCIPLE & DESCRIPT. of COMPONENTS


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 see Single line diagram. made according to customer's request

2.
Pos. X001

EXPLANATION OF THE COMPONENTS IN THE SDC PRINCIPLE DIAGRAM


Component Rectifier mains terminals Rectifier input isolator Explanation 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 fuses or MCCBs according to the technical specification. devices 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 fuses or MCCBs according to the technical protection devices specification. provide for the connection of the battery positive pole (B+) and negative pole (B-). If this option is not equipped an external protection device has to be installed. provide for the connection of the load (L+) and (L-).

Q001

X002 Q004 X004 A025

Battery terminals Option: 2-pole Battery circuit breaker Load terminals

External connection p.c. It is a part of the interface to the surroundings. Following information / board 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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GENERAL SYSTEM PRINCIPLE & DESCRIPT. of COMPONENTS


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 T001 A001/ A002 16 Relay Rectifier input transformer Radio Frequency Interference (RFI) and AC fuse board For explanation see description 7SA9032GB Display & Parameter settings and 7SA9033GB Operating & Indicating elements. provides the conversion of the rectifier mains voltage to the right level for the rectifier. 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. provides the conversion of the AC voltage into DC voltage (A031 = 12- pulse thyristor rectifier-bridge) Power fuse at the output of the thyristor rectifier-bridge. provides the filtration of the DC current. provides the filtration of the DC current.

A030

6-pulse thyristor rectifier-bridge Fuse Smoothing reactor DC- capacitor module

F026 L001 CB02 V015 Q003 A004/ A005 A071

Option: Blocking diode Rectifier blocking diode inserted in A030 (only in parallel-operated system). Option: Output switch- provides the isolation of the load from the rectifier (from the battery). disconnector DC Fuse board Interface / PSU for DC voltage and Earth fault 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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GENERAL SYSTEM PRINCIPLE & DESCRIPT. of COMPONENTS


Pos. A073 Component Front panel Explanation including: Display unit Operation Option: Operating status indications Option: Alarm indications

see description 7SA9032GB Display & Parameter For details settings and 7SA9033GB Operating & Indicating elements. E001... Fans E008 A003 AC Fuse board Fans with internal Hall generator for monitoring the number of revolutions. In systems with low power no fans are built in (natural cooling). for the fans. Interface between Fans and Interface A071 Changes the number of revolutions

A050... Fan control A057

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

TABLE OF CONTENTS:
7SA9009GB SAFETY REGULATIONS

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SAFETY REGULATIONS

TABLE OF CONTENTS:
1. 2. 3. Technical Safety Information for the User
1.1 Safety Instructions / Precautions

Warning advices / Signal words / Ideograms / Signboards General Safety Information


3.1 3.2 3.3 Hazardous voltage [Voltage > 42,4 VACpeak (30Vrms) / 60 VDC] Fire outbreak General servicing recommendations

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SAFETY REGULATIONS
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 IEC 62040-1-2, 4.9.3 prescribes: as for fuse changes or post installation modifications. 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: Possible consequences: immediate threatening danger can kill or cause grievous bodily harm

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

Caution: Used for: Possible consequences: possible dangerous situation insignificant physical injury. Also possible as warning against material damage

Notice: Used for: Possible consequences: possible dangerous situation Possible damage of the product or something in its environment

Important: Used for: Possible consequences: Tips for use and helpful informations 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 VACpeak (30Vrms) / 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.
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SAFETY REGULATIONS
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 CO2 must be used. Do not inhale vapors.

3.3

GENERAL SERVICING RECOMMENDATIONS


We advise that the following rules have to be observed: ASSIGNMENT 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 Refer to chapter on Battery servicing. insulated.

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

TABLE OF CONTENTS:
1110045001 4A-1110045001/23GB 7SA9023GB 4A-1110045001/20GB SINGLE-LINE DIAGRAM TECHNICAL DATA (SA9010GB) PRIORITIES AND OPERATIONAL MODES EXPLANATION OF THE BOOST CHARGE FUNCTION

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

TECHNICAL DATA

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

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TECHNICAL DATA - SDC 125-1200 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 SPECIFICATION
: The Rectifier is housed in a freestanding, fully metal enclosed cabinet arranged for floor mounting. : see drawing: 1110045001/00 Chapter 01 : IP 41 : IP 20, Operator protection : RAL 7038 (BS 10-A-03) : galvanized : Internal fans. Air inlet in back & front below, outlet on the top. : from bottom : see drawing: 1110045001/00 Chapter 04 : 3030 kg

RECTIFIER (CHARGER)-UNIT Enclosure ...........................................................................

Arrangement / Dimensions ................................................. Protection class (according to IEC 60529) ......................... ............................................................. with open doors Painting.............................................................................. Inside, Backcover, Topcover ......................................... Ventilation ......................................................................... Cable entry......................................................................... Terminal size...................................................................... Weight ...............................................................................

BATTERY MONITORING BOX 30

see drawing: 1110045001/00 Chapter

Client Ref.:
E 720.006GB-3

by Schneider E l e c t r i c

GUTOR Electronic LLC Wettingen / Switzerland

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TECHNICAL DATA - SDC 125-1200


BATTERY Mounting ........................................................................... Arrangement / Dimensions ................................................. Weight ............................................................................... : The battery is mounted on a steel rack. : see drawing: 1110045001/00 Chapter 02 : 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 SPECIFICATION
: max. 1000 m ASL : max. 4000 m ASL : -10 C .... +50 C : max. 55 C : -20 C .... +70 C for systems (for batteries in accordance with battery manufacturer data) : 95 %, not condensing : 55...65 dBA (depending on type) : 60...70 dBA (depending on type) : > 200000 h : IEC / EN 62040-3, IEC 60146-1-1 : IEC / EN 62040-1-2

Installation altitude with full rating ..................................... With derating of 7 % per additional 1000 m................... Ambient temperature range, at air inlet - for operation (100 % rated power) ............................ - with derating at increased air throughput ................... - for storage ................................................................

Relative air humidity .......................................................... Audible Noise level (1 m height, 1 m distance) ................... with Standard N+1 Fans .................................... approx. 100 % redundant Fans ...................................... approx. Reliability MTBF ............................................................... Functional (performance) test ............................................. General and Safety requirements ........................................

Client Ref.:
E 720.006GB-3

by Schneider E l e c t r i c

GUTOR Electronic LLC Wettingen / Switzerland

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TECHNICAL DATA - SDC 125-1200


EMC requirements ............................................................. Quality assurance ............................................................... : IEC 62040-2 : ISO 9001

4.

ELECTRICAL SPECIFICATION ON SYSTEM UNIT

RECTIFIER Mains input power, max. .................................................... : 203.7 kVA Input voltage....................................................... (3ph, PE) : 3 x 480 V AC - Tolerance - DC in tolerance ...................................... : + 10 / - 10 % - Tolerance for function............................................... : + 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.............................. : 0,83 ind. - at - 10 % mains and float charge................................ : 0,90 ind. - at + 10 % mains and float charge............................... : 0,75 ind. Nominal DC output voltage................................................ : 125 V DC Static ................................................. Control tolerance : 1 % (IU-characteristics) Ripple voltage with parallel battery capacity of 3x I2N ......... : <=2 % rms Efficiency at rated load....................................................... : 90 % Tolerances according to IEC 60146-2

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

DROPPING DIODE
Client Ref.:
E 720.006GB-3

by Schneider E l e c t r i c

GUTOR Electronic LLC Wettingen / Switzerland

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Rev. Page 3: 4 / 6

4A-1110045001/23

TECHNICAL DATA - SDC 125-1200


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

DISTRIBUTION

see drawing: 1110045001/00 Chapter 04

5.

ADJUSTMENTS
Setting range Settings

RECTIFIER / BATTERY Float charge voltage......................... :

0,4 x Vnom. - 1,3 x Vnom. ......................... 129.3 V DC

Boost charge voltage........................ : 0,4 x Vnom. - 1,4 x Vnom. ......................... 136.3V DC .................................time interval : 0...72 h ................................................ 8 h Initial charge voltage ........................ : 0,4 x Vnom. - 1,5 x Vnom. ......................... 136.3V DC .................................time interval 0...72 h ................................................ 12 h DC output current limitation ............ : Battery current limitation.................. : Initial current limitation .................... : Low DC voltage High DC voltage (0,5 x Inom.) - Inom. ................................. 1200 A DC 1 - IBat nom ............................................. 570.0 A DC 1 - 2x IBat nom (< Inom.) ............................ 570.0 A DC

Warning....... : 0 - Vnom. ............................................... 101.5 V DC Shutdown .... : ............................................................ 86 V DC Warning....... : Vnom. - Vhigh SD ....................................... 151 V DC Shutdown .... : ............................................................ 163 V DC 140 mA (Earth fault resistance = 10 mA ON) ..................................................... 2 / 5 / 10 / 20 s................................. 10 s N/A 5s

DC Earth fault current...................... : Softstart ... time on voltage & current :

Temperature compensation ............................ Charge voltage : 0999 mV/C/cell........................... Delay of relay................................... : 099 s ............................................

Client Ref.:
E 720.006GB-3

by Schneider E l e c t r i c

GUTOR Electronic LLC Wettingen / Switzerland

.
Rev. Page 3: 5 / 6

4A-1110045001/23

TECHNICAL DATA - SDC 125-1200


Possibilities Settings

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

6.

OPERATIONAL PARAMETERS
Possibilities Settings DE +.............................. GB Float / Boost / Initial ON/OFF......................... OFF ON/OFF......................... ON ON/OFF ON/OFF ON/OFF

Display language .............................. : Charger Mode.................................. : Autostart.......................................... : Autoboost ........................................ : Battery monitor Test ........................ : Battery monitor Reset ...................... : Battery capacity Test........................ :

Client Ref.:
E 720.006GB-3

by Schneider E l e c t r i c

GUTOR Electronic LLC Wettingen / Switzerland

.
Rev. Page 3: 6 / 6

4A-1110045001/23

of REDUNDANT DC POWER SUPPLY with one Battery Type: SDC-R

PRIORITIES & OPERATIONAL MODES

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

4. 5. 6. 7.

Battery operation: System 1 & 2 Rectifier only: System 1 & 2 Standby operation: System 1 & 2 Off: System 1 & 2

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PRIORITIES & OPERATIONAL MODES


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 see Principle diagram. according to customer's request

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

LOWEST PRIORITY: Section 7. Off: System 1 & 2

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PRIORITIES & OPERATIONAL MODES


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


RECTIFIER 1 MAINS 1
Q001 V015 Q003

LOAD

RECTIFIER 2 MAINS 2
Q001

V015

Q003 Q004 (Q005)

BATTERY

Fig. 3.1 Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load RECT 1 available closed available closed ON closed available available available ON closed and within the tolerance range and within the tolerance range and within the tolerance range RECT 2 available closed Completing Explanation: and within the tolerance range and within the tolerance range (dependent on the charging condition of the battery it may be in recharge mode).

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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PRIORITIES & OPERATIONAL MODES


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

Fig. 3.2 Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load RECT 1 available closed available closed ON closed available available available ON closed and within the tolerance range and within the tolerance range and within the tolerance range RECT 2 available closed Completing Explanation: and within the tolerance range and within the tolerance range (dependent on the charging condition of the battery it may be in recharge mode).

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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PRIORITIES & OPERATIONAL MODES


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

Fig. 3.3 Concerns: Rectifier mains Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load RECT 1 available closed RECT 2 not available closed available closed ON closed available not available available OFF closed and within the tolerance range outside the tolerance range and within the tolerance range Completing Explanation: and within the tolerance range outside the tolerance range and within the tolerance range (dependent on the charging condition of the battery it may be in recharge mode).

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

3.4

NORMAL OPERATION: System 1; System 2 in Standby


RECTIFIER 1 MAINS 1
Q001 V015 Q003

LOAD

RECTIFIER 2 MAINS 2
Q001

V015

Q003 Q004 (Q005)

BATTERY

Fig. 3.4

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PRIORITIES & OPERATIONAL MODES


Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load ON closed available not available available RECT 1 available closed available closed OFF closed or open and within the tolerance range outside the tolerance range and within the tolerance range RECT 2 available closed Completing Explanation: and within the tolerance range dependent on the charging condition of the battery it may be in recharge mode

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 Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load RECT 1 not available closed RECT 2 not available closed available closed OFF closed Completing Explanation: outside the tolerance range and within the tolerance range

OFF closed not available

outside the tolerance range not available available outside the tolerance range and within the tolerance range

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PRIORITIES & OPERATIONAL MODES


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 see Technical data. If the system is not programmed AUTOSTART at mains recovery see 7SA9034GB Start - Stop. for AUTOSTART it has to be restarted manually 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 Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load
7SA9023GB

RECT 1 available closed available closed ON open available

RECT 2 available closed

Completing Explanation: and within the tolerance range and within the tolerance range (dependent on the charging condition of the battery)

ON open and within the tolerance range available not available and within the tolerance range NO Voltage -

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PRIORITIES & OPERATIONAL MODES


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

Fig. 6.1 Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load RECT 2 available closed disconnected open OFF OFF closed or open closed or open not available not available not available RECT 1 available closed Completing Explanation:

NO Voltage NO Voltage NO Voltage

The load is not supplied.

7.

OFF: SYSTEM 1 & 2

DISPLAY BLACK

Fig. 7.1

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PRIORITIES & OPERATIONAL MODES


Some components in the connection field as well as elements and lines can be energized.

Concerns: Rectifier mains Q001 Battery Q004 (Q005) Rectifier Q003 Output voltage before blocking diode Output voltage before blocking diode Output voltage Load

RECT 1 RECT 2 not available not available open open disconnected open OFF OFF closed or open closed or open not available not available not available The load is not supplied.

Completing Explanation:

NO Voltage NO Voltage NO Voltage

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EXPLANATION OF THE BOOST CHARGE FUNCTION


to DC POWER SUPPLY, Type: SDC 125-1200-R

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 The LED 3 Charger 2 are open and the battery switch Q004 is closed. 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.

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PACKING TRANSPORT INSTALLATION


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

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

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PACKING & UNPACKING & STORAGE AIR / OVERSEA TRANSPORT


of DC POWER SUPPLY, Type: SDC(R)

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

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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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)

1. All doors are opened to equip the system with VCI-chip U (VCI = Volatile Corrosion Inhibitor) 2. Every field is equipped with one or more chips (chip-size = 49x100 cm). 3. One chip protects a volume of 1m . The number of chips is calculated as follows: Example: 3 Gross volume is 3m 3 Equipment / Material 1m Therefore, two chips are used.
3

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

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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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 see section 3. instructions given in this description

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 VCIFoil.

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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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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

SOLID WOODEN

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

2. 3. 4. 5. 6. 7. 8. 9. 10.

2.2

STRUCTURE OF THE SOLID WOOD CASE


1. 2. 3. 4. 5. 6. The design and construction of the cases are as shown on the representations below. Side walls, face-end walls, and floors are made of Swiss wood. (IPCC standard) Wood thicknesses 24 mm. Wood cover dry film resist and plywood cover must be concise with the side walls and front walls. As a rain protection PE foil becomes strained under the cover. 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. Inspection hole. Various colour markings.

8. 9.

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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PACKING & UNPACKING & STORAGE Air/Oversea Transport


2.3 CONSTRUCTION OF THE SOLID WOOD CASE
The following representations correspond to a solid wooden case (the OSB cases comprise instead of individual boards whole or max. 3 plates per side).

Pos. 1 2 3

Description Side wall Front wall Floor

Pos. 4 5 6

Description Cover Double Cover Side skid

Pos. 7 8 9

Description Front skid Floor skid Cover skid

Pos. 1 2 3 4
7SA9028GB

Description Front wall Side wall Floor Cover

Pos. 5 6 7

Description Double Cover Side skid Front skid

Pos. 8 9 10

Description Floor skid Cover skid Protection foil

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PACKING & UNPACKING & STORAGE Air/Oversea Transport


2.4 CONSTRUCTION OF THE OSB- / PLYWOOD CASE
1. 2. 3. 4. 5. OSB and plywood cases are manufactured of internationally approved wood (IPPC Standard). 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. The cover is only one part. The bottom of the cases is always manufactured from solid wood (24mm). Wood thickness 0.9 mm up to 10 mm. 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. 7. 8. 9. For rain protection the same method as with solid wood cases may be employed. Inspection hole. Various colour markings. 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. Now cargo is ready for worldwide shipping by truck / ship / airplane.

2.

This IPPC stamp is used to mark every case:

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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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: GUTOR

XXXXX
1 2 3 4 5 6 7 This side up: The case must always be stored, transferred, and transported in such a way that the arrow always point up. Fragile, handle with care: Goods marked in this way must be handled with care and not dropped or tied under any conditions. 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). Sling here: The symbol indicates only where the sling should be applied, and not the method to be used for applying it. Center of gravity: This symbol clearly identifies the center of gravity. 0 Kg stacking load: The plywood and OSB cases are not stackable GUTOR XXXXXX: This stamp is on each case delivered from GUTOR whereby XXXXXX = the GUTOR reference number of the system packed therein. -

1 2 3 4 5 6 7
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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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 following representations correspond 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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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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.
4.1

UNPACKING FROM THE CASE


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.

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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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

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

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 see remove the front skids (7) with which the side wall of the case is fixed to the pallet ( 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.

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PACKING & UNPACKING & STORAGE Air/Oversea Transport


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 Proceed as mentioned under section 4.1. damage immediately. 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 see description 7SA9031GB Erection Installation section 2.1). ventilation grids

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.

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TRANSPORT OF THE SYSTEM WITHOUT PACKING


DC POWER SUPPLY, Type: SDC(R)

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

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TRANSPORT OF THE SYSTEM WITHOUT PACKING


1. TRANSPORT: C-RAIL MOUNTED

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 !

70 40

125 5 25

C-Rail Device socket

Door frame or back cover The C-rail for the neck straps on the front and back or the device must bear out 5 mm Device socket

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TRANSPORT OF THE SYSTEM WITHOUT PACKING


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 lifting lugs have to be strained perpendicularly.

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

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ERECTION INSTALLATION
of DC POWER SUPPLY, Type: SDC(R)

TABLE OF CONTENTS:
1. 2. General Installation / Erection
2.1 2.2 2.3 IP Protection / Ventilation Grids Placing Cable Inlet

3. 4.

Ventilation Connection / Protection


4.1 4.2 4.3 4.4 4.5 4.6 Earthing of the Cubicle Mains Connection Battery Connection Earthing of the Battery (for Systems with Battery) Connection of the Load External Fuse Protection

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00-05-08 mp 00-05-08 GA 00-05-08

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ERECTION INSTALLATION
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.
2.1

INSTALLATION / ERECTION
IP PROTECTION / VENTILATION GRIDS
Fit the ventilation grids on the front and the back ) of the device socket to the snap clip on both see Fig. 1. sides by means of sheet metal screws M5,5 and the corresponding washers 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 see Fig. 1. pushed in from the front on the rails designated for that 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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ERECTION INSTALLATION
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 see section 2.1. before it will be placed to the wall or back to back.

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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ERECTION INSTALLATION
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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ERECTION INSTALLATION
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.
4.1

CONNECTION / PROTECTION
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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ERECTION INSTALLATION
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 6 pieces 12 pieces Hexagon head-fit screws M8 x 20 Hexagon bolts 30mm with internal screw thread M8 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. 3.

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

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ASSEMBLY OF PARTICULAR CUBICLE UNITS


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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DISPLAY OPERATING & INDICATING ELEMENTS


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

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

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DISPLAY & PARAMETER SETTINGS


of DC POWER SUPPLY, Type: SDC(R)

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

98-02-12 mp 98-02-12 GA 98-02-12 7SA9032GB

00-05-08 mp 00-05-08 GA 00-05-08

06-08-25 mp 06-08-25 RST 06-08-25

09-12-22 mp 09-12-22 RST 09-12-22

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DISPLAY & PARAMETER SETTINGS


1. DISPLAY UNIT
DISPLAY
COMMON ALARM
MAINS VOLTAGE
4 7 8 9

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.

DC VOLTAGE
5

V-AUX.

MAINS CURRENT
1

BATTERY CURRENT
2

TOTAL DC CURRENT
3

BATTERY TEMP.

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


(only shown if the option Advanced battery monitor is installed)

Automatic Battery monitor test


(only shown if the option Advanced battery monitor is installed)

Enter new date Enter new time


-

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DISPLAY & PARAMETER SETTINGS


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

key

or

. By pushing the button

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

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

until:

or

is shown in the display. Chose by pushing

for ON. When

accepted the display shows:

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DISPLAY & PARAMETER SETTINGS


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

or

until

is shown in the display. Thereafter push

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 tBOOST 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

or

until

is shown in the display. Thereafter push

to show

in the display. Autoboost is chosen by pushing

for ON. When accepted the display shows: .

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DISPLAY & PARAMETER SETTINGS


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. Connect the load to the system output.

2.

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

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

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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DISPLAY & PARAMETER SETTINGS


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

or

until

is shown in the display. Thereafter push

C
pushing

to show

in the display. Battery monitor test is chosen by

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 no loss of the output voltage. been detected 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 see next section. the Battery Monitor Reset

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

or

until

is shown in the display. Thereafter push

C
pushing

to show

in the display. Battery monitor reset is chosen by

for ON. When accepted the display will show:

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DISPLAY & PARAMETER SETTINGS


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

to show

in the display. When pushing

twice, the

display will show

. Automatic Battery monitor test is chosen by pushing

for ON. When accepted the display will show:

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:


1 1 1

. Thereafter push (for e.g. 14

h 15 min 10secs):

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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DISPLAY & PARAMETER SETTINGS


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;
1

The display shows: .............. .....

Explanation: shows Date: year, month, day (YY.MM.DD) Time: hours, minutes, seconds (HH.MM.SS)

2 BATTERY TEMP.

..............

..... Battery temperature No battery sensor inserted, or ..... the battery sensor is faulty

4 MAINS CURRENT

..............
L1 L2 L3

..... Mains input current per phase

5 BATTERY CURRENT

..............

..... Battery current with indication charge/discharge

6 TOTAL DC CURRENT

..............

..... Total DC current

7 MAINS VOLTAGE

..............
L1-L2 L2-L3 L3-L1

..... Phase-to-phase mains input voltage

8 DC VOLTAGE

..............

..... DC voltage

9 V-AUX

..............

..... Auxiliary voltage (or optionally Vbatt/2): Alarm is active if Vbatt/2 deviates more than 1,5 % ..... from half the output DC voltage.

To return to normal status indication wait 30 secs or push current operating status.

. The display indicates the

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DISPLAY & PARAMETER SETTINGS


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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Alarm Name Phase order not correct Mains voltage out of tolerance Mains frequency error Mains MCB is off UI characteristic Charger 0 temp.warning Charger 30 temp. warning Charger 0 temp. shut down Charger 30 temp. shut down High temp. transformer High temp. choke High DC warning High DC shutdown Low DC warning Charger off warning Total DC current limit Battery current limit DC fuse blown Battery MCB is off
7SA9032GB

Description Phase order not correct Mains voltage is out of tolerance, window +15 %, -25 % Mains frequency is out of tolerance, window 8 % Mains MCB is open DC voltage deviates more than 3 % of the rated voltage and the current limiter is not activated Temp. over 90C Temp. over 90C Temp. over 110C Temp. over 110C Temp.signal switch in transformer off Temp.signal switch in choke off DC is over high DC warning level DC is over high DC shut down level DC is over below Low DC warning level Rectifier is off Current limiter for total DC current is active Battery current limiter is active DC fuse is blown Battery MCB is open

W = Warning / S = Shut down S S S S W W W S S


W, S(10 min. delay) W, S(10 min. delay)

Time delay [sec] 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 5 5 0 0 -

W S W W W W S W

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DISPLAY & PARAMETER SETTINGS


Alarm No. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Alarm Name Low DC Vaux warning High DC Vaux warning Internal PSU error, DC string Internal PSU error, AC string Fan 1 error Fan 2 error Fan 3 error Fan 4 error Fan 5 error Fan 6 error Fan 7 error Fan 8 error Earth fault on positive pole Earth fault on negative pole Option 1 error Option 2 error Option 3 error Option 4 error Option 5 error Option 6 error Option 7 error Option 8 error Battery symmetry error Battery defect Mains phase missing Load MCB is off Blocking of boost / initial Parallel operation error Control loop error Diode temp. warning Loadsharing error 0- 30 Temp.sensor error Battery weak Synchronization error Battery temp.warning Calibration stack entered Description The DC voltage after serial diode is below DC warning level The DC voltage after serial diode is over high DC warning level The DC circuit of the redundant PSU is defective The AC circuit of the redundant PSU is defective Fan 1 is rotating to slowly ) Fan 2 is rotating to slowly ) Fan 3 is rotating to slowly ) Fan 4 is rotating to slowly ) Fan 5 is rotating to slowly ) Fan 6 is rotating to slowly ) Fan 7 is rotating to slowly ) Fan 8 is rotating to slowly ) ) (fan pulse signal < 20 Hz) Earth current running to positive pole Earth current running to ground pole Option 1 error Option 2 error Option 3 error Option 4 error Option 5 error Option 6 error Option 7 error Option 8 error Half the battery voltage is outside the window of 1.5%. A battery cell is defective Conclusion of battery monitor test. Mains, Phase missing. At least 1 phase is missing Load MCB Blocking of boost and initial charge is activated Load sharing differs more than 10% for more than 30secs. Control loop error, e.g. no DC feed back signal Temp.signal switch in diode off Load sharing error, between 0 and 30 module. The two currents differs more than 7.5% Measured temp.outside window, -35....+55. Temp.sensor is defective or missing. Battery capacity reduced (battery weak) Charger is not synchronous to mains Battery temp.is above limit Indication if calibration stack has been entered W = Warning / S = Shut down W W W W W W W W W W W W W W W W W W W W W W W W S W W W S W W W W S W W Time delay [sec] 0 0 0 0 0 0 0 0 0 0 0 0 5 5 0 0 0 0 0 0 0 0 5 0 0 0 0 30 0 0 30 30 30 0 0 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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DISPLAY & PARAMETER SETTINGS


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.
0

To show alarms in the log alarm stack push simultaneously

and

. Then move

inside the stack by means of the cursor key The last text in the stack is No (further) event.

or

until the desired event is shown.

The system will log the alarms shown in the alarm stack and at the same time the following changes in the operational modes: 56 57 58 59 60 61 62 63 64 MPU is reset Off button pushed Auto off executed On button pushed Logged mode: Standby Logged mode: Battery operation Logged mode: Float charge Logged mode: Boost charge Logged mode: Initial charge
1

At the actual event push

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 DC POWER SUPPLY, Type: SDC 125-1200-R

TABLE OF CONTENTS:
1. 2. 3. 4. Front panel Operation Operating Status Indications Alarm Indications
4.1 4.2 4.3 4.4 Alarm Indication Concept Description of the Individual Alarms Common Alarm Potential-free Relay contacts

5. 6.

Analogous Instruments / Switches External Connection P.C.Board

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FRONT PANEL (Control and Monitoring Board)

4A-1110045001/20GB

Rev: 1

Page: 2 / 9

OPERATING & INDICATING ELEMENTS


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: see Description 7SA9032GB Display unit ................................... 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 switchdisconnectors) and the designation can be made according to customer's request see Single line diagram.

2.

OPERATION
Pos. Designation S1 S2 SYSTEM ON OFF Explanation 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). 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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OPERATING & INDICATING ELEMENTS


3. OPERATING STATUS INDICATIONS

Pos.
1

Designation
RECT. MAINS OK (green)

Explanation
The rectifier mains voltage and frequency are available and within the specified tolerance ranges. For tolerances see Technical Data The rectifier is switched on. The firing pulses to the thyristors are enabled. The boost or initial charge has been initiated manually or automatically.

2 3

RECT. OPERATION (green) BOOST / INITIAL CHARGE (yellow) BATT. OPERATION (green) OUTPUT VOLTAGE OK (green) Battery switch ON (green) Battery switch OFF (red) Mains switch ON (green) Mains switch OFF (red) Load switch ON (green)

4 5 6 7 8 9 10

The battery is supplying the load with energy. The output voltage is within the specified tolerance range. For tolerances see Technical Data The battery switch Q005 and Q004 is switched on. The battery switch Q005 or Q004 has tripped is switched off. The rectifier input switch Q001 is switched on. The rectifier input switch Q001 has tripped or is switched off. The output switch Q003 is switched on.

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OPERATING & INDICATING ELEMENTS


Pos.
11

Designation
Load switch OFF (red)

Explanation
The output switch Q003 has tripped is switched off

4.
4.1

ALARM INDICATIONS
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 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 see compared to the alarms. For the LED indications with the corresponding delays section 4.2. To reset the internal horn (acoustic alarm) push: . for reset, the LEDs extinguish, whose corresponding alarm is not

4.2

DESCRIPTION OF THE INDIVIDUAL ALARMS

Designation
RECTIFIER MAINS FAULT (AC POWER FAIL) (30secs) RECTIFIER FAILURE (5secs)

Explanation
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 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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OPERATING & INDICATING ELEMENTS


Designation
DC OUT OF TOLERANCE (5secs) DC FUSE BLOWN (5secs) RECT. OVERCURRENT (30secs) LOAD SHARING FAULT (only redundant Rect.) (5secs) The rectifier output current has exceeded the charger current limit. For values see Technical Data 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). The battery voltage is dropped below Low DC Warning/Low DC Vaux Warning level. For tolerances BATTERY DISCONNECTED (5secs) CONTROL POWER FAULT (5secs) OVERTEMPERATURE (5secs) see Technical Data 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. 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). The following elements have a thermal monitoring: Rectifier bridge Rectifier transformer Blocking diode DC choke One or more fans in the system have failed.

Explanation
The DC voltage is out of the tolerance range of Low DC Warning/Low DC Vaux Warning level. For tolerances see Technical Data The rectifier output fuse F026 has blown.

BATTERY DISCHARGED (5secs)

FAN FAILURE (COOLING SYSTEM FAILURE) (30secs) 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. 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. 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. The rectifier input switch Q001 is open. It indicates whether the MCCB has Also the red LED 9 MAINS MCCB OFF is illuminated tripped.

HIGH DC VOLTAGE (Option 2) Q003 TRIP (Option 5)

Q001 TRIP (Option 6)

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OPERATING & INDICATING ELEMENTS


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 preprogrammed 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 Contact voltage AC Contact current AC Contact voltage DC Contact current DC Minimum 6 V AC 50 mA AC 6 V DC 50 mA DC Maximum 250 V AC 8 A AC 250 V DC 0,3 A DC 6 V DC 8 A DC Note 50 / 60 Hz 50 / 60 Hz resistive load

5.
A

ANALOGOUS INSTRUMENTS / SWITCHES


AC Instruments
V Hz
50

DC Instruments
A V

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

P031

P032

P033

P026

P023/1P23/2P23/ 1P01/2P01

P024/1P24/2P24/ P027/P102/1P02/ 2P02

S031

Pos.

Instrument

Explanation Indicates the rectifier input mains current, measured after the rectifier input switch Q001. Indicates the rectifier input mains voltage, measured before the rectifier input switch Q001. 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. Indicates the charge or discharge current of the battery, measured before the battery switch Q004.

P031 AC ammeter P032 AC voltmeter S031 Phase selector switch (AC Input) P026 DC ammeter

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OPERATING & INDICATING ELEMENTS


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

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OPERATING & INDICATING ELEMENTS


6. EXTERNAL CONNECTION P.C.BOARD
Internal connection to Low DC section

A025
Parallel
X003

Serial Port RS232


X002

Communication RS232

Remote Display
X001
14 13 12 11 10 9 8 7 6 5 4 3 2 1

Remote Display

= Alarm position

External Supply for Emergency Stop + External Supply for Emergency Stop Internal Supply for Emergency Stop + Internal Supply for Emergency Stop

Common Alarm

Common Alarm

Rectifier failure

X009
4 3 2 1 External Off GND

X008
4 3 2 1 Initial Charge GND External On GND Battery Temperature sensor + Battery Temperature sensor Boost Charge GND Blocking of Boost and Initial Charge GND Battery MCB GND

X007
4 3 2 1

X006
4 3 2 1

X004

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

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

11-06-22 mp 11-06-22 MAS 11-06-22 7SA9002GB

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of DC POWER SUPPLY, Type: SDC(R)

START STOP

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

98-01-19 mp 98-01-19 Ca 98-01-19 7SA9034GB

00-05-08 mp 00-05-08 Ca 00-05-08

01-11-09 mp 01-11-09 GA 01-11-09

07-06-25 mp 07-06-25 MDR 07-06-25

09-09-15 mp 09-09-15 MDR 09-09-15

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START STOP
1. OPERATIONAL BUTTONS FOR STARTING AND STOPPING
.................... S1 S2 Button SYSTEM ON for switching on the DC system 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.

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START STOP
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. 2.

Disconnect the battery. 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 are extinguished. all LED indications

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

COMMISSIONING

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

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COMMISSIONING
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 switchdisconnectors) and the designation can be made according to customer's request see Single line diagram.

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


7SA9036GB

OPERATION

DISPLAY UNIT -

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COMMISSIONING
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. 2. 3. 4. 5. 6. Check that the earthing of all cubicles is secure and there are no damages. Check that all connectors are firmly fixed. Check that all printed circuit boards are correctly mounted and the plugs are firmly plugged in. Check all interconnections and junctions according to Connection diagram. Check that the external fuses have the correct size. 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) b) Rectifier input switch ..................................................... Q001 open Rectifier output switch ................................................... Q003 open System output switch .................................................... Q100 closed

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

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COMMISSIONING
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. 2. Check preparations as under section 1. 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

see Technical data and the rectifier mains is programmed for AUTOSTART 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. 5. Push the button S3 LAMP TEST on the front panel and check that all LEDs of the Operating status indications and Alarm indications illuminate. 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 2 & 5 are illuminated. 6. 7. 8.

has been chosen).

Additionally the green LEDs

Check the rectifier output voltage in the display by pressing the button Close the rectifier output switch Q003. Close the battery switch Q004. red LED 7 extinguishes.

Additionally the green LED 6 is illuminated and the

9. 10.
7SA9036GB

Check the battery current in the display by pressing the button

. The DC -

Turn off the rectifier mains by opening the rectifier input switch Q001.

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COMMISSIONING
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 red LED 9 extinguish the green LEDs 8, 6, 1, 2 & 5 illuminate. .

The green LED 4 and

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 the green LEDs 2 & 5 extinguish. DC ON and S2 OFF on the front panel System unit B changes to Standby operation and its display shows:

Repeat steps 3 til 13 for DC System unit A.

15. 16.

Turn on DC System unit B by pressing S1 SYSTEM ON on the front panel. Check that on both system units the green LEDs 8, 1, 2 & 5 illuminate and the displays show: .

17. 18.

Reset the alarms by pressing the button

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. 20. 21.

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

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

The output terminals are carrying hazardous voltage !!!

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 The load is supplied completely by the other ON and S2 OFF on the front panel. system unit (DC System unit A), while the DC System unit B changes to Standby operational mode and its display shows: extinguish.
7SA9036GB

The green LEDs 2 & 5

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

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. see Technical data and the If the DC System is programmed for AUTOSTART rectifier mains is within the tolerance range the DC System will start automatically after 60 The green LEDs 8 & 1 as well as the red LED 7 illuminate. The seconds. DC System starts up to Standby operation mode and the display shows Standby. Push the button S3 LAMP TEST on the front panel and check that all LEDs of the Operating status indications and Alarm indications illuminate. Turn on the DC System unit B (if not already ensued automatically) by pressing S1 SYSTEM the DC System starts up to normal operation mode and the ON on the front panel 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. . .

2. 3.

Close the rectifier output switch Q003.

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COMMISSIONING
6. 7. Reset the alarms by pressing the button .

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

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

11-06-22 mp 11-06-22 MAS 11-06-22 7SA9002GB

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MAINTENANCE

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

2.

Maintenance of the Battery


2.1 2.2 2.3 Monthly checks Annual checks Battery capacity test

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00-05-08 mp 00-05-08 GA 00-05-08

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MAINTENANCE
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 therefore please refer to the description 7SA9042GB Servceavailability of the system 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.
1.1

MAINTENANCE OF THE DC SYSTEM


MONTHLY CHECKS
The following checks should be made monthly: 1. 2. 3. Check DC output voltage by means of a measuring instrument. Check DC output current by means of a measuring instrument. Persisting alarm indications or incorrect operating statuses must be recorded. Subsequently, reset the alarms by pressing the button

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

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

Switch off the entire system 7SA9034GB Start Stop

according to the description

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. 6. Recommendations of OEM (Original Equipment Manufacturer) shall be followed regarding annual maintenance. 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 the battery manufacturer in chapter Battery documentation. see the information given by

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MAINTENANCE
2.1 MONTHLY CHECKS
The following checks should be performed at the same time as the monthly checks of the DC system: 1. 2. 3. Check the battery voltage at the battery. Check all wet battery cells on the liquid level and if necessary refill documentation. see Battery

Check the voltage of each individual cell (in the case of wet battery cells additionally the see Battery documentation. specific gravity) of the pilot cells

2.2

ANNUAL CHECKS
1. 2. 3. 4. Annually the cell covers must be cleaned and if necessary the poles and links must also be cleaned (possible corrosion) and slightly greased. Check the starting torque of the pole screws. 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. 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. Connect the load to the system output. For testing the battery capacity via the foil keyboard proceed as follows: Push and step

2. 3.

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.
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MAINTENANCE
4. To start the battery capacity test push

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

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


DC POWER SUPPLY, Type: SDC(R)

As a minimum GUTOR specifies that the following components and parts in the DC systems are replaced according to the time periods indicated: Reference Designator E0.. A070 (D034) CB02 (1CB2, 2CB2) Normal Scope X X X X X NPP Scope X X X X X Replace Cycle 5 years Note 1 + 2 9 years 9 years Note 3

Part Fan Sub-assembly Battery Bank Backup RAM with Lithium Battery DC Capacitor Module Air Filter

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

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: Note 2: Note 3: See battery specification of the battery manufacturer. With enabled battery monitor (option) the battery is automatically monitored. In the case of a faulty battery an alarm is generated. The air filters must be checked at least every 6 months. Dependent on the contamination they must be replaced immediately.

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REPLACEMENT OF COMPONENTS & PARTS


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

if applicable

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

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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SERVICE TRAINING CONTACT ADDRESSES


DC POWER SUPPLY, Type: SDC(R)

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

2. 3.

Spare Parts Training


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

4.

Contact Addresses

98-02-19 mp 98-02-19 GA 98-02-19 7SA9042GB

98-11-04 mp 98-11-04 GA 98-11-04

00-05-08 mp 00-05-08 GA 00-05-08

06-10-30 mp 06-10-30 OBU 06-10-30

09-10-05 FME 09-10-05 09-10-05

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SERVICE TRAINING CONTACT ADDRESSES


1.
1.1

SERVICE/REPAIRS
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.

7SA9042GB

885-3854

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SERVICE TRAINING CONTACT ADDRESSES


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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SERVICE TRAINING CONTACT ADDRESSES


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 24 hours, 7 days a week hotline

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 24 hours, 7 days a week hotline

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 24 hours, 7 days a week hotline

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SERVICE TRAINING CONTACT ADDRESSES


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 24 hours, 7 days a week hotline

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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SERVICE TRAINING CONTACT ADDRESSES


We recommend Level 1 training to all personnel working with (and in charge of) GUTOR systems. We also recommend clients having a Pro-Life 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 Pro Partner 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 Pro Light 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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SERVICE TRAINING CONTACT ADDRESSES


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 detailed description please contact our customer service

4.

CONTACT ADDRESSES
GUTOR Electronic LLC
Hardstrasse 72-74 5430 - Wettingen / Switzerland Internet : E-Mail : Phone: Fax:

www.gutor-service.com gutor.customerservice@apcc.com ++ 41 56 437 34 34 ++ 41 56 437 34 21

Contact address in Malaysia:

GUTOR Electronic Asia Pacific Sdn. Bhd.


No. 19, Jalan Juruukur U1/19, Seksyen U1 Hicom Glenmarie Industrial Park 40150 Shah Alam, Selangor, Malaysia. Phone : Fax : +(6) 03 556 90 331 +(6) 03 556 90 332

Further Offices in:

China, Brazil, Germany, India, Japan, Mexico, Nigeria, Qatar, Russia, U.S.A., U.A.E.

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

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

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TROUBLE-SHOOTING
DC POWER SUPPLY, Type: SDC 125-1200-R

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

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TROUBLE-SHOOTING
1. ELIMINATION OF SIMPLE MALFUNCTIONS
Depending upon the system configuration, the switches mentioned in this description can be circuit breakers or switch-disconnectors (fuse switchsee Single line diagram. disconnectors) and the designation can be made according to customer's request
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

REASON: RECTIFIER DOESN'T sequence START 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 Rectifier input switch Q001 open Rectifier mains voltage out of tolerance or wrong phase

SHUTDOWN CONDITION

2.

TROUBLE-SHOOTING AT ALARM INDICATION

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TROUBLE-SHOOTING
Alarm Indication RECT MAINS FAULT (AC POWER FAIL) (30secs) Alarm #: / Error in the System
1: Phase order not correct

Source of Error Wrong wiring

Test Possibilities Check phase order

Location Interface A071: X003, F001,


F002, F003

2: Mains voltage out of tolerance 3: Mains frequency fault 44: Mains phase missing 53: Synchronization error

Input voltage out of tolerance Input frequency out of tolerance Input switch Q001 open Input frequency fluctuations Load too high Input voltage low but in tolerance

Check voltages Check frequency and SYNC LED on controller A070 Check input switch Q001 Check frequency and SYNC LED on controller A070 Check load, if system is in current limitation mode Check input voltage

Q001, Controller A070 Q001 Q001, Controller A070 Interface A071: X003, F001,
F002, F003

RECTIFIER FAILURE (5secs)

5: Voltage deviates more than 3% of nominal voltage without current limitation and no RECT. MAINS FAULT

System OFF (also due to shutdown) or System in


standby Rectifier or PSU faulty

Check operation mode and evaluate shutdown cause


(Log stack) Check current ripple (6-pulse: 300/360Hz, 12-pulse: 600/720Hz) Check PSU LED's (PSU_OK_AC/PSU_OK_DC)

Q001 Interface A071 Interface A071: X009, F014,


F015

Check output voltage DC OUT OF TOLERANCE 12, 14, 20: Output voltage is higher (5secs) than the high DC warning level or lower
than the low DC warning level

Load too high (also short-circuit) System OFF (also due to shutdown) or System in
standby

Check load, if system is in current limitation mode Check operation mode and evaluate shutdown cause
(Log stack)

Current sensor P001 (P002)

Rectifier or PSU faulty

Check current ripple (6-pulse: 300/360Hz, 12-pulse:


600/720Hz) Check PSU LED's (PSU_OK_AC/PSU_OK_DC)

Q001 Interface A071 Q004 (Q005) Interface A071: X009, F014,


F015

Battery discharged / disconneted or switch Q004


(Q005) open during battery operation

Check battery voltage Check output voltage

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TROUBLE-SHOOTING
Alarm Indication DC FUSE BLOWN (5secs) Alarm #: / Error in the System
18: Rectifier output fuse F026 (F027) blown

Source of Error Fuse trip indicator not connected Load too high (also short-circuit) Load too high (also short-circuit)

Test Possibilities Check fuse trip indicator Check load Check battery and load current

Location Rectifier output fuse F026


(F027)

Current sensor P001 (P002) Trip indicator on Rectifier


output fuse F026 (F027)

RECT OVERCURRENT (30secs) LOAD SHARING FAILURE (only redundant Rect) (5secs) BATTERY DISCHARGED (5secs)

16: Total current limiter active

Current sensor P001 (P002) Battery current transformer


P003

47: Loadsharing deviates more than 10%

Wrong calibration of output voltage Wrong temperature compensation

Check output voltages at the common output point Check temperature measurement of both chargers Check individual cell voltages Check battery voltage Check operation mode and evaluate shutdown cause
(log stack) Reset battery monitor (User stack) only possible if ABM installed

Common output point External Connection Board


A025 : X006:3 and X006:4

14, 20: Battery voltage dropped below the Low DC Warning/Low DC Vaux Warning level 43: Battery monitor test result is battery defective

One or more cells of the battery defective Battery discharged System OFF (also due to shutdown) or System in
Standby Battery monitor not reset after installation of new battery

Battery Q004 (Q005)

BATT DISCONNECTED (5secs)

19: Battery breaker Q004( Q005 ) open or Breaker open or auxilary contact not connected tripped

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

Connector cable missing to one or both of the two


PSU's

Check LED's on interface (PSU_OK_AC,


PSU_OK_DC)

Interface A071

supplies (+5V/15V) is outside the tolerance range, or the feeding of one of the power supplies is not available (Rectifier mains or Battery)

Try to start DC supply manually (if DC supply fault) by


pressing S1

Mains not available or input breaker Q001 open

Measure input voltages for the two supplies

Interface A071

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TROUBLE-SHOOTING
Alarm Indication Alarm #: / Error in the System Source of Error Battery disconnected or battery switch Q004
(Q005) open

Test Possibilities

Location Interface A071 / X001:


F006/F006

Interface A071 / X002:


F018/F019

OVERTEMPERATURE (5secs)

6, 7: Charger 0 or 30 overtemperature 10: Transformer overtemperature 11: Choke overtemperature 49: Output diode overtemperature (if available)

Overtemperature of one component Air inlet obstructed, fan problem Ambient temperature too high Sensor contacts not connected One of the fans is blocked, rotating too slow or
connected wrongly

Check size of components, load and thermoswitches Check air inlet and fan Check ambient temperature Check wiring Check fans Check connection (fan surveillance cable connected
always starting at position 1)

Thermoswitches of power
components T001, F001, V001, A030, A031

Interface A071: X018- X025 A030, Interface A071: X006 Fans E001 - E008 A050 - A057, Interface A071:
X018 - X025

FAN FAILURE (COOLING SYSTEM FAILURE) (30secs)

24-31: Fan failure 1-8

Fan supply failure LOW DC VOLTAGE (Option 1)


14, 20: Low DC warning

Check fan supply transformers (T050/T051) Check if system is in current limitation Check operation mode and evaluate shutdown cause
(Log stack)

T050: F010, F011, T051:


F012, F013

Load too high (also short-circuit) System OFF (also due to shutdown) or System in
Standby

Rectifier or PSU faulty Battery discharged / disconneted or breaker


Q004 (Q005) open during battery operation

Check PSU LED's and voltages (PSU_OK_DC,


PSU_OK_AC) Check battery voltage

Controller A070 Q004 (Q005) Interface A071: X009:1 and


X009:3, F014

HIGH DC VOLTAGE (Option 2)

12: High DC warning

DC voltage too high feed from charger

Check DC voltage Check if load has disconnected and battery is


connected Check why load has disconnected (fuse, breakers) Check input transformer
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Q003, Q100 and Q004


(Q005)

Power fuse F026 (F027) Q001

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TROUBLE-SHOOTING
Alarm Indication Alarm #: / Error in the System Source of Error Test Possibilities If high DC shutdown check input phase order (L1-L2L3 and not eg L2-L3-L1)

Location

Q003 TRIP (Option 5)

45: Load MCB error

DC voltage too high feed from load Q003 open or auxilary contact not connected Q003 auxilary contact is not connected to its
input on the interface

Disconnect the load Check wiring Check whether Q003 has tripped

Q003, Q100 Q003 Interface A071: X005

Q003 auxilary contact is only connected to an


Option input

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

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

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SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS


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

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

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

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Operating Instructions
Vented stationary lead acid batteries
Specifications: Nominal voltage UN: 2.0 V x number of cells connected in series Nominal Capacity CN = C10: 10 hour discharge (see type label) Nominal discharge current IN = I10: Final discharge voltage Us: 1.80 V/Cell Nominal temperature TN: 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 explosion and fire. Wear eye protection and protective 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 splashes on clothing should be washed out with water! Explosion and fire risk, avoid shortcircuits. Warning! Metal parts of the battery 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 equipment! Dangerous electrical voltage. Installation by: on: Commissioning by: on: Safety markings affixed by:
CN 10 h

Non-compliance with operating instructions, repairs made with other than original parts, tampering or use of electrolyte additives (alleged 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 necessary. 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 installations 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 characteristic, alternating currents flow through the battery during charging and are superimposed onto the charging direct current. These superimposed alternating currents and the reaction of the loads lead to additional heating of the battery and strain on the electrodes with possible resulting damage (see section 2.5). Depending on the system at hand, charging may be carried out under the following operating modes

a) Stand-by parallel operation and floating operation Here the load, direct current source and battery 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 supplies 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, measured 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 recharging 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 monitored (see under 2.4, 2.5 and 2.6). On reaching a state of full charge, charging should be terminated or a switch made to float charging as under section 2.3. c) Battery operation (charge/discharge operation) The load is supplied only by the battery. In this case, towards the end of charging, the charge 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),

on:

and so that electrolyte density does not fall over longer periods of time. 2.4 Equalising charge Because it is possible to exceed the permitted 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 electrolyte 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 accordance with operating modes a) to c), the actual value of the alternating current is occasionally 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 charged state with a charge voltage of 2.23 to 2.30 V/cell, the effective value of the alternating 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 nominal capacity shown in Table 1 should not be exceeded.
Charging procedure Types GroE OPzS, OPzS bloc, max.power, solar.power, OGi bloc HC, OGi bloc, OSP .HC, OSP .XC, USV bloc 5.0 A 7.0 A 3.5 A Cell voltage

2.8 Temperature-related charge voltage Within the operating temperature range of 10C to 30C, temperature-related adjustment 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 electrolyte 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 corresponds 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 recorded annually: - voltage of all cells/monobloc batteries - electrolyte density of all cells/monobloc batteries - 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 observed. 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 facilitates 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 average 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 undamaged, show no leaks and are firmly secured on pallets with protection against sliding, overturning and short-circuits are not treated as dangerous goods for conveyance by road as long as there are no dangerous traces (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 (C10 = CN) and the battery type can be obtained from the identification plate. 8.1 Example Identification plate: 4 OPzS 200 4 = number of positive plates OPzS = battery type 200 = nominal capacity C10 (capacity for discharge with ten hours current (I10) over a discharge time of 10 h (t10)

I-charact. W-charact.

6.5 A 2.6-2.75 V 9.0 A bei 2.4 V 4.5 A bei 2.65 V

2.7 Temperature The recommended operating temperature range for lead-acid batteries is 10C to 30C. The technical data apply to the nominal temperature of 20C. The ideal operating temperature range is 20C 5C. Higher temperatures will reduce battery service life. Lower temperatures reduce the available capacity. The maximum temperature of 55C must nor be exceeded.

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.

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 Fax: + 49 (0) 29 63 61-2 70 Email: info@hoppecke.com Internet: www.hoppecke.com

Teil-Nr. 7140204011/07.09/3 K Printed in Germany

CUSTOMER-SPECIFIC DOCUMENTATION / CERTIFICATES


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

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

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Client:

M/s Techmaster Inc. 1952 McDowell Road, Suite 204 Naperville, Illinois 60563 USA 11022 Conversion of Qurayyah Open Cycle Power Plant to Combined Cycle Power Plant Project C Saudi Electric Company DC POWER SUPPLY (Rectifier / Charger) 125V Block-1 DCDB Item No. C10BTL01 & C10BTL02 C20BTL01 & C20BTL02 C30BTL01 & C30BTL02 C40BTL01 & C40BTL02 C50BTL01 & C50BTL02 GUTOR Ref. 1110045001-01. 1110045001-06 1110045002-01. 1110045002-06 1110045003-01. 1110045003-06 1110045004-01. 1110045004-06 1110045005-01. 1110045005-06

P.O. No.: Project name: End-User: System: Installation: Type SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R

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 Quality Assurance

Muneet Asri Project Engineer

Client:

M/s Techmaster Inc. 1952 McDowell Road, Suite 204 Naperville, Illinois 60563 USA 11022 Conversion of Qurayyah Open Cycle Power Plant to Combined Cycle Power Plant Project C Saudi Electric Company DC POWER SUPPLY (Rectifier / Charger) 125V Block-1 DCDB Item No. C10BTL01 & C10BTL02 C20BTL01 & C20BTL02 C30BTL01 & C30BTL02 C40BTL01 & C40BTL02 C50BTL01 & C50BTL02 GUTOR Ref. 1110045001-01. 1110045001-06 1110045002-01. 1110045002-06 1110045003-01. 1110045003-06 1110045004-01. 1110045004-06 1110045005-01. 1110045005-06

P.O. No.: Project name: End-User: System: Installation: Type SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R

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

Wettingen, 2011-06-28

Cemal Yilmaz Quality Assurance

Muneet Asri Project Engineer

Client:

M/s Techmaster Inc. 1952 McDowell Road, Suite 204 Naperville, Illinois 60563 USA 11022 Conversion of Qurayyah Open Cycle Power Plant to Combined Cycle Power Plant Project C Saudi Electric Company DC POWER SUPPLY (Rectifier / Charger) 125V Block-1 DCDB Item No. C10BTL01 & C10BTL02 C20BTL01 & C20BTL02 C30BTL01 & C30BTL02 C40BTL01 & C40BTL02 C50BTL01 & C50BTL02 GUTOR Ref. 1110045001-01. 1110045001-06 1110045002-01. 1110045002-06 1110045003-01. 1110045003-06 1110045004-01. 1110045004-06 1110045005-01. 1110045005-06

P.O. No.: Project name: End-User: System: Installation: Type SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R SDC 125-1200-R

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)

Wettingen, 2011-06-28
Cemal Yilmaz Quality Assurance Muneet Asri Project Engineer