Manual MCU 2500 - 4339-En-Hr

Operating instructions
Remote Monitoring System
MCU 2500
Date Designation No. 4339en

Issued: 01.03.2006 TB-Telaar Kocarek p. 1/58p.
Revision:
Checked: 05.04.06 EW - Buschfort
Remote monitoring system MCU 2500
Contents
0 Safety notes and used symbols................................................................4
1 General ...................................................................................................5
2 Bus systems / interfaces ..........................................................................5
3 The components of the remote monitoring system ..................................6
3.1 Base unit.................................................................................................9
3.2 ADBUS2 components...........................................................................13
3.2.1 RELIO board ........................................................................................13
3.2.2 Measuring board TUII ..........................................................................16
3.2.3 Battery symmetry monitoring 60V........................................................19
3.3 SAT-bus components............................................................................22
3.3.1 MCU-SAT relay box.............................................................................24
3.3.2 MCU-SAT measuring box ....................................................................26
3.3.3 MCU-SAT digital input box .................................................................27
3.3.4 DSP adapter / Multibus .........................................................................28
3.3.5 EUE MCU satellite ...............................................................................29
3.4 I²C-BUS components............................................................................29
3.4.1 LED board ............................................................................................29
3.4.2 Graphic display.....................................................................................31
3.5 RS232 components ...............................................................................32
3.6 Spare serial interface components .........................................................33
4 Installation and commissioning.............................................................33
5 Operation of the graphic display ...........................................................34
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5.1 The main window .................................................................................35
5.2 Menu structure......................................................................................35
5.3 Main menu............................................................................................46
5.4 The menu "Test menu" .........................................................................48
5.5 The menu "Display setting" ..................................................................48
5.6 Menu "System settings" ........................................................................49
6 Battery test / Capacity test.....................................................................57
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0 Safety notes and used symbols

These operating instructions contain important information for the instal-
lation, operation and maintenance of the remote monitoring system MCU
2500. The instructions must be retained and observed at all times!
Many different symbols are used for the individual components of the remote
monitoring system and in these operating instructions; the following table
shows the meaning of these symbols:
Indicates instructions which must be followed to avoid danger to

persons!
Indicates instructions which must be followed to avoid material da-

mage.
All further symbols and pictograms are explained at the appropriate places in
these operating instructions.
The components of the remote monitoring system MCU are de-

signed as built-in units. The components are electronic equipment
that can lead voltage and current which is dangerous for human be-
ings.
For this reason, the following instructions must be followed at all times:
1. Installation, operation, maintenance and repair of the MCU should be

carried out in strict accordance with the instructions in this document.
2. Ensure that only fully qualified and authorised personnel have access to
the system; only this personnel may open the unit.
3. When working with the unit, use only properly insulated tools which are
approved for the voltages in question.
4. All persons working with the unit must be familiar with first-aid meas-
ures for accidents involving electricity.
5. The regulations of the local power-supply companies and all other appli-
cable safety regulations must be observed at all times.
6. The passwords used for programming the unit must not be disclosed to
unauthorised persons.
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1 General
The remote monitoring system MCU 2500 is a microprocessor-controlled mo-
nitoring and control device. With this system, it is possible to monitor and con-
trol all the main components of a power supply system.
The link with the "outside world" is created via the serial interface. The MCU
2500 can be directly connected to a desktop computer (PC). The installed ser-
vice software allows comprehensive monitoring and controlling of the power
supply system. If the control desk is not local, the link with the computer can
be created through the public telephone network or through a TCP/IP adapter
and the internet using a modem.
The Remote Monitoring System MCU 2500 therefore allows more rational and
efficient employment of maintenance and service personnel.
A flexible and user-dependent use as well as a significant volume reduction of

each individual system component have been the overall goal for the develop-
ment of the components for this new series .
2 Bus systems / interfaces

The data of the individual components are exchanged via different bus systems,
dependent on the type and task of the respective component.
CPU-bus
The CPU-bus efficiently connects two CPUs (master, slave) on the base unit
thus ensuring a simple and quick data exchange. Here, the user does not need
to observe anything special.
ADBUS2
The ADBUS2 connects decentralised peripheral components with the base u-
nit. These are units with signalling relay and digital inputs, measuring boards
with analogue inputs, battery symmetry monitoring units or earth fault moni-
toring units. Each component has to be installed in direct vicinity (i.e. in the
same cabinet) to the base unit.
Attention!
No more than 7 users may be connected to the ADBUS2!
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I²C-bus
This bus is used to connect the LED board and the graphic display to the base
unit. Also here applies that LED board, display and base unit need to be in-
stalled in the same cabinet.
SAT-bus
The SAT-bus connects e.g. the rectifiers of the power supply system and fur-
ther peripheral SAT-bus components (relay box, measuring box, digital input
box) to the base unit. The components can be distributed over several cabinets.
RS232 interface
This interface is used for external communication. A PC with the relevant ser-
vice software is connected either directly to this interface or via the telephone
network (modem) or the internet / network (TCP/IP adapter).
Spare serial interfaces

The base unit can be optionally equipped to provide an additional serial inter-
face. Presently, only one additional RS232 interface has been implemented.
Attention!
The ADBUS2 and the SAT-bus use the same terminal at the base
unit. As soon as the first SAT-bus component has been connected, a
further connection of an ABBUS2 component will not be possible
anymore as the power supply will be interrupted for these compo-
nents.
3 The components of the remote monitoring system

The remote monitoring system MCU 2500 consists of different hardware and
software components. Some components are absolutely necessary, others are
optional. The following description of all components allows a safe installation
and commissioning of the system.
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1 2 3
Figure 1.1: Basic structure of the remote monitoring system 2500
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10
11
12
Figure 1.2: Basic structure of the remote monitoring system MCU 2500
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1 Control station; PC with service software
2 TCP/IP adapter for the connection of the MCU 2500 to a computer

network or the internet
(as option to 1)
3 Modem for the connection of the MCU 2500 to a telephone network

(as option to 1)
4 Base unit of the MCU 2500
5 Graphic display
6 Measuring board TUII (ADBUS2 component)
7 Relay box (SAT-bus component)
8 Battery symmetry monitoring (ADBUS2 component)
9 Digital input box (SAT-bus component)
10 RELIO board (ADBUS2 component)
11 Measuring box (SAT-bus component)
12 Power supply system with suitable components for the connection to

the SAT-bus (rectifier, inverter, ....)
3.1 Base unit

The base unit is the core of the remote monitoring system. All other compo-
nents are connected to this unit.
Generally, they are mounted on a DIN rail. The necessary supporting rail adap-
ter has been already mounted at the factory.
Mounting on a carrier plate is also possible. The respective mounting dimen-

sions can be found in the dimension diagram.
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Figure 2: Dimension diagram of the base unit
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10 2
9 3
8 4
5
7 6
Figure 3: Base board of the base unit
1 X110; RS232 interface

9-pole D-SUB connector
2 X3; 12V supply for an external modem

X3.1: +12V X3.2: 0V(GND)
2-pole screw terminal (M2);
connection range: 0.14mm² - 1.5mm² / AWG28 – AWG16
3 X2; ADBUS2/SAT-bus interface

RJ-45 connector
4 LED "fault"; (red)
Status Meaning
lights fault or initialisation phase
flashes quickly MCU is not connected to SAT-bus
flashes shortly no fault; MCU is SAT-bus master
extinguishes shortly fault; MCU is SAT-bus master
off no fault; MCU is user in the SAT-bus
5 LED "operation"; (green)
Status Meaning
lights normal operation
flashes quickly no SAT-bus communication detected
off severe fault of MCU
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Combinations of the LED statuses
lights lights
Meaning initialisation phase; takes a few ms to some seconds
flashes quickly flashes quickly
Meaning MCU has started, SAT-bus not yet recognised
lights flashes quickly
Meaning SAT-bus communication recognised, MCU waits for
connection
lights off
Meaning normal operation in the SAT-bus
lights flashes shortly
Meaning normal operation with MCU as master
(even during diagnosis operation via PC)
6 LEDs; indicators for BUS activities

(for service only)
7 X20; I²C bus interface

5-pole plug for preconfigured data line
8 X1; supply of the base unit

X1.1 (+) 35V ... 75V
X1.2 (-) decoupled to X1.3
X1.3 (-) decoupled to X1.2
9 X2.2; ADBUS2/SAT-bus interface

RJ-45 connector

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3.2 ADBUS2 components

ADBUS2 components can be regarded as hardware extension to the base unit.
They are mounted directly in the cabinet on a DIN rail close to the measuring
and monitoring locations. This reduces the extent of cabling work.
The components can be connected to each other and to the base unit with
commercially available network cables (patch cable). The network cable sup-
plies also the components. Usually, blue cables are used to distinguish them
from the SAT-bus wiring.
The address assignment and/or the necessary configuration are realised with
two jumpers only allowing the service technician to replace a component on si-
te without having to take any further measures.
Attention!
Some special features have to be observed due to the technical spe-
cification of the ADBUS2:
• No more than 7 components may be connected
• The max. length of the complete ADBUS2 must not exceed

3m
• An ADBUS2 component can not be connected downstream

of a SAT-bus component as this would interrupt the supply
3.2.1 RELIO board

The RELIO board provides four relay outputs and eight digital inputs.
This boards additionally monitors the ADBUS2. If no valid communication

can be detected for 10s, the relay K1 releases to the inactive status.
If in the MCU the bus for data transfer is faulty (CPU-bus), then only relay K1
of the RELIO board with address 1 will release.
+ A maximum of 3 RELIO boards can be connected to the ADBUS2.
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1 2 3
7 4
6
110mm x 70mm
Figure 4: RELIO board

RJ-45 connector

RJ-45 connector
3 X3; 8 digital inputs

10-pole tension spring terminal;
control voltages 24VDC/20mA for digital

inputs
digital input 1 ... 8 (X3.2 ... X3.9)
control current approx. 2mA per input
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4 X10; jumpers to configure the RELIO board
Possible configurations:
configuration is specified by EEPROM (programming) (not yet

implemented)
RELIO board address 1
RELIO board taken completely out of service. This does not im-
pair the bus traffic (board may remain connected), all relays,
however, release. The LEDs have no function anymore.
5 X1; 4 relay outputs (K1, K2, K3, K4)

max. contact rating: 250VAC/6A

30VDC/max. 180W; 300VDC/max. 40W
6 LED (red)
Status Meaning
lights RELIO board faulty; (disconnection due to bus
error or wrong configuration)
flashes no connection to bus possible
flashes shortly transmission indicator ADBUS2; normal opera-
tion
7 LED (yellow)
Status Meaning
lights up and extin- receiving indicator ADBUS2, at least one relay
guishes shortly released (fault message)
flashes shortly receiving indicator ADBUS2, normal operation
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3.2.2 Measuring board TUII

The measuring board provides four measurement inputs with a fixed assign-
ment.
• 1 voltage measurement input

• 2 current measurement inputs
• 1 temperature measurement input
+ A maximum of 3 measuring boards can be connected to the AD-

BUS2.
1 2
6
5
4
65mm x 70mm
Figure 5: Measuring board TUII

RJ-45 connector

RJ-45 connector
3 X1; 4 measurement inputs (1xU; 2xI; 1xT))

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temperature measurement input

current measurement input 2
current measurement input 1
voltage measurement input
Terminal assignment:
X1.1: voltage measurement +(U+)

X1.2: voltage measurement -(U-)
X1.3: not occupied
X1.4: current measurement; shunt 1 +(S+)
X1.5: current measurement; shunt 1 -(S-)
X1.6: current measurement; shunt 2 +(S+)
X1.7: current measurement; shunt 2 -(S-)
X1.8: temperature measurement +T
X1.9: temperature measurement -T
4 X10; jumpers to configure the measuring board

implemented)
measuring board address 1
calibration of the measuring board; can also be calibrated with

the service software via the RS232 interface of the base unit
measuring board taken completely out of service. This does not

impair the bus traffic (board may remain connected). The LEDs
have no function anymore.
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5 LED (red)
Status Meaning
lights measuring board faulty; (disconnection due to
bus error or wrong configuration)
tion
6 LED (yellow)
Status Meaning
lights temperature sensor failure
Voltage measurement input:
• Input range: 0 ... 320V (bipolar)

• Measuring accuracy: ± 1%
• The input values are processed with a sufficient accuracy to allow ap-
plication in low-voltage systems.
Current measurement input:
• Input range: 0 ... 110mV (UN = 60mV); shunt non-floating to U+ or U-

• Measuring accuracy: ± 1%
• The current measurement inputs are designed for 190% IN. Both shunts
must be connected with S- to the same potential. They may, however,
be located in the U+ or U- branch. Open shunt inputs create a positive
measured value and should thus be jumped.
Temperature measurement input:
• Temperature sensor: 2kΩ/25°C; KTY 81

• Measuring accuracy:
± 1°C (-5°C to +55°C)
± 2°C (-30°C to +80°C)
• The temperature sensor is connected to GND potential, i.e. always to
the potential of the S-connection. This has to be taken into account par-
ticularly for high-voltage systems! The measurement input does not
have to be terminated with a resistor if no sensor is connected. A sensor
fracture is only reported when a correct sensor has been detected which
then got broken.
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3.2.3 Battery symmetry monitoring 60V

The battery symmetry monitoring system (BATTS board) provides five meas-
urement inputs. These can be used for monitoring a 60V battery with five 12V
blocks or one 48V battery with four 12V blocks. Alternatively, two individual
48V batteries or 60V batteries can be monitored via a centre voltage tap.
A maximum of 5 battery symmetry monitoring systems can be con-

nected to the ADBUS2.
1 2
6
5
4
65mm x 70mm
Figure 6: Battery symmetry monitoring (BATTS board)

RJ-45 connector

RJ-45 connector
3 X4; 5 measurement inputs (U1, U2, U3, U4, U5)

6-pole spring tension terminal;
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X4.1: measurement input U5

X4.6: GND (0 potential)
4 X1; jumpers to configure the BATTS board

implemented), both LEDs are flashing
BATTS board address 1
Calibration of the BATTS board (at 36V);

LED (red) on, LED (yellow) off: calibration running
LED (red) off, LED (yellow) on: calibration terminated
BATTS board taken completely out of service. This does not

impair the bus traffic (board may remain connected). The LEDs
have no function anymore.
5 LED (red)
Status Meaning
lights BATTS board faulty; (disconnection due to bus
error or wrong configuration)
tion
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6 LED (yellow)
Status Meaning
Each measurement input U1 – U5 is able to measure voltages of 0 – 72VDC.
Attention!
The measurement inputs may not be connected to negative voltages,
referred to GND.
The following pictures show 3 examples of a possible battery symmetry moni-

toring system.
Figure 7: Monitoring of a 60V battery with individual block measurement
Figure 8: Monitoring of 2 batteries with earthed plus terminal
Figure 9: Monitoring of 2 batteries with earthed minus terminal
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3.3 SAT-bus components

The SAT bus components consist of, among others, measured value recording
and signalling components (relay box, measuring box, digital input box). They
can be mounted directly in the cabinet on a DIN rail close to the measuring and
monitoring locations. The necessary supporting rail adapter has already been
mounted at the factory. Mounting on a carrier plate is also possible. The re-
spective mounting dimensions can be found in the dimension diagram.
The components have to connected with each other by means of special SAT-
bus cables. These differ from commercially available network cables only by
their PIN assignment.
The components are configured via an internal programming which has been
implemented in the factory.
The mechanical design of the three components is identical.
∅ 3.6
Figure 10: Dimension diagram of a SAT-bus component
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1 2 3
1 Earth stud (M4 x 17)
2 X20; SAT-bus interface; RJ-45 connector
3 X21; SAT-bus interface; RJ-45 connector
4 5 6
Figure 11: Top view of a SAT-bus component
4 X300; supply of the SAT-bus component

X300.1: (+) 18VDC ... 75DCV or

75VDC ... 270VDC
depending on the type
X300.2: not occupied
X300.3: (-)
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3.3.1 MCU-SAT relay box

The MCU-SAT relay box is provided with 8 potential free signalling contacts.
The contacts may be operated with different potentials.
See Figure 11:
5 X5; terminal of the potential free signalling contacts (K5 ... K8)
6 X4; terminal of the potential free signalling contacts (K1 ... K4)
+ Maximum contact ratings: 250 V AC/8 A
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Legend
Deutsche Englisch
Gleichstrom-Lastgrenzkurve DC current load limit curve
Ohmsche Last Ohmic load
Schaltspannung Voltage switched
Schaltstrom Current switched
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3.3.2 MCU-SAT measuring box

The MCU-SAT measuring box can be equipped with 5 voltage, current or tem-
perature measuring modules.
See Figure 11:
6 X4; terminal for the measuring modules (A1 ... A5)

The actual design is indicated at the measuring box. In the example shown a-
bove the measurement channels are fit with the following measuring modules:
A1, A2, A3: current measuring module

A4: voltage measuring module
A5: temperature measuring module
This results in the following terminal assignment:
X4:1-X4:2; X4:4-X4:5; X4:7-X4:8 one 60mV shunt each

X4:10-X4:11 measured voltage 0VDC ...
270VDC
X4:13-X4:14 temperature sensor 2kΩ/25°C
(KTY81-210)
+ All measurement inputs are isolated!
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3.3.3 MCU-SAT digital input box

The digital input box is provided with 24 digital inputs
See Figure 11:
5 X5; terminal for the digital inputs (DI13 ... DI24) and the 24V control
voltage of the inputs
6 X4; terminal for the digital inputs (DI1 ... DI12) and the 24V control
voltage of the inputs
+ The terminals X4:13 ... X4:16 and X5:13 ... X5:16 are put to the
same potential. The maximum output current at the terminals co-
mes to 240 mA and is sufficient for the 24 digital inputs.
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3.3.4 DSP adapter / Multibus

The SAT-Bus component "DSP adapter / Multibus" can be used to connect e.g.
a DSP inverter system of the TEBEVERT series to the MCU.
As standard, the unit is prepared with an adapter for the supporting rails for
mounting on a DIN rail. Fastening on a mounting plate is also possible.
Figure 12: Dimension diagram DSP adapter / Multibus
+ More information on the structure, assembly, connections and sig-

nalling system can be found in the operating instructions no. 4186.
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3.3.5 EUE MCU satellite

The EUE MCU satellite is an optional unit which can be installed in electronic
switch-over devices of the STATIC BY-PASS series. The MCU and the ser-
vice software allow to transmit statuses and measured values of the electronic
switch-over device or the inverter system to the SAT-bus.
+ More information can be found in the operating instructions no.

3918.
3.4 I²C-BUS components

Additional peripheral components are connected to the MCU via the I²C bus
interfaces of the base unit. These peripherals are an LED board and a graphic
display. Faults and operating statuses (LED board) or measured values (dis-
play) are indicated or signalled; they are also used for changing or triggering
threshold values, settings, charging statuses, battery test etc. (via key on the
graphic display).
The components have to connected with each other by means of special, pre-
configured data lines.
The components are usually installed behind the front door of the power supply
system.
3.4.1 LED board

The meaning of the 13 LEDs is established by a configuration file (filter) and
depends on the signalling philosophy of the system. The general meaning is
however fixed according to the colour of the LEDs by the standard IEC
73/DIN VDE 0199. The following therefore applies:
RED Danger or alarm Warning of potential dangers or statuses

which require immediate action or close
observation of the status in question.
YELLOW Caution Changes or imminent changes of the
normal operating conditions
GREEN Safety Indicates safe operating conditions or
further operational procedure release
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Figure 13: LED board
1 13 LEDs for signalling faults and operating statuses;

programmable
2.3 X2, X1; I²C bus interface

4 RESET key / LED test

By pressing the RESET key, all programmed hold functions for the fil-
ter events, the relays and the LEDs are deleted.
Keep this key pressed for about 3 seconds to perform such an LED test.
Test duration approx. 3 seconds
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3.4.2 Graphic display

On the 4 buttons of the graphic display, all the release statuses and measured
values of the power supply system can be displayed or set. Critical menu levels
are accessible by means of a password only. The operation and function of the
input buttons and the meaning of the statuses and values indicated will be ex-
plained later in more detail.
The meaning of the 4 LEDs above the display is fixed.
operation battery operation
alarm urgent alarm
Note: In systems with SAT rectifiers, the signal "Battery operation" is

controlled by the calculation of the battery current. If the battery
current is negative (battery is being discharged) the LED "Battery
operation" lights up and the LED "Operation" goes out.
In systems with standard rectifiers (without satellite) voltage-

dependent monitoring is carried out. Battery operation is resumed
when UBatt. <2.1V/cell and there is a mains or rectifier failure.
Normal operation is assumed when UBatt. rises again above 1.95
V/cell and when no mains or rectifier fault is present.
1 2 3 4 5 6
Figure 14: Graphic display
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1 LED "operation";
2 LED "battery operation"
3 LED "alarm"
4 LED "urgent alarm"
5 Graphic display

7 Keys for operating the display menu
3.5 RS232 components

The RS232 components are used for external communication. These are com-
ponents which have not been developed particularly for being used in a remote
monitoring system. They are always connected via the 9-pole D-SUB plug
X110 of the base unit.
External modem
The connection of the remote monitoring system to the public telephone net-
work can be established via an analogue modem. A high-speed modem has
been tested and released especially for the industrial use.
(PSTN modem V.90-highspeed; MicroLink 56ki; part no. 787663)
MCU-TCP/IP adapter
The connection of the remote monitoring system to a computer network or the
internet can be established via a suitable MCU-TCP/IP adapter. (part no.
520421)
Service PC
The software TEBE MCU Service (item no. 545740) installed on the service
PC can be used for a detailed monitoring of the power supply system and a
modification of the system parameters.
There are no special requirements to the hardware. A WINDOWS operating
system (as from WINDOWS 9x) will be sufficient.
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3.6 Spare serial interface components

To cover a wide range of the hardware and software interfaces currently used
and the related data records and to extend the possible applications, more com-
ponents for the optional use in the MCU base unit have already been imple-
mented or are being planned.
These are: • RS232 interface

• USB interface
• TCP/IP SNMP interface
• CAN-bus interface
• internal modem (analogue)
• internal modem (ISDN)
• internal modem (GSM)
4 Installation and commissioning

After the assembly, the connection and the commissioning of the remote moni-
toring system MCU 2500 all the components are fully ready for operation.
Attention!
The safety instructions must be observed at all times during assem-
bly, installation and commissioning!
The components of the MCU are designed to be operated in closed dry rooms.
The maximum permissible ambient temperature is 40°C. Attention must be
paid that the components are not exposed to aggressive substances and the pas-
sage of cooling air is not hampered.
To enable you to carry out the commissioning, the entire power supply system
with all the components belonging to the MCU has to be wired and connected
to the power supply system. When the initialisation phase has been terminated,
the display shows a measured value of the system.
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5 Operation of the graphic display

Each menu item can be called with the four function keys under the display and
settings can be made. However, some menu items are protected by a password.
Return to the basic status takes place automatically from any menu item when
no button has been actuated for about 1 minute.
Figure 15: Display with function keys
Function button assignments on selecting the individual menu items
Conformation of the selected menu item
Return to next higher menu level.
Selection of individual menu items within a menu

level
Function button assignments for entering the password
Selecting a position
Changing a position
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5.1 The main window

The display is able to show 3 different measured values in the basic status. The
type of measured value to be displayed is specified in the respective submenu .
UV [ 29] IV [ 30] DZ [ 92]

= 48.0V I = 21.1A 17:16:42
14.02.2006
The example above shows load voltage, load current and date/time.
Press the keys to change between the 3 specified measured val-

ues. Press the key to return to the main menu.
5.2 Menu structure

All applications have the same menu structure with the individual menu levels
and menu items. Only the assignment and meaning of the digital inputs, the
measured values and the type of SAT-bus users depend on the individual appli-
cation.
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Logfile [ 1]
09.02.06 – 11:31:48 Delete logfile?
SAT-bus status
Main menu
[ 25]: Mains failure
Logfile active
Measured value display
Digital inputs
Reset hold function
Status of components
Test menu
Display setting Logfile [ 15]
System settings 09.02.06 – 11:31:48 Delete logfile?
Digital input
[ 40]: URGERR
active
Main menu
Logfile
Measured value display IV [ 30]
Digital inputs I = 21.1A
Reset hold function
Test menu
Display setting TA [ 60]
System settings T = 20.0°C
DZ [ 92]
17:16:42
14.02.2006
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Main menu URGERR [ 40]

Logfile = active
Digital inputs
Reset hold function
Status of components MCUBUS [ 44]
Test menu = active
Display setting
System settings
MOD [ 45]
= inactive
BATNOK [ 51]
= inactive
Main menu
Logfile
Digital inputs
Delete hold function?
Reset hold function
Test menu
Display setting
System settings
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Main menu Status mask

Logfile Test mode
Measured value display Configuration phase
Digital inputs Watchdog reset
Reset hold function Bus error
Status of components Component [S] Master Timeout
Test menu Fan fault
= 02
Display setting Wrong command
System settings Current failure
Temp. sensor faulty
Component [m] Mains failure
= 25 Unit does not respond
Unit fault
Overvoltage
Overtemperature
Unit switched off
Component [M]
= 26
Component [R]
= 27
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Operating mode
Battery test start
Battery test end
Main menu Charge
Logfile Float charging
Measured value display ♦ Direct feeding
Digital inputs Equalise charging
Reset hold function
Test menu Password 1 Test menu
Display setting *** Operating mode
System settings − Relay test
Relay test
Relay 1
Relay 2
Relay 3
•
•
•
Relay 16
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Main menu Language

Logfile ♦ German
Measured value display English UV [ 29]
Digital inputs French
= 29
Reset hold function
Test menu
Display setting Display settings
System settings IV [ 30]
Language
= 30
LED test
Measured value display 1
Brightness
Contrast
Illumination period
Brightness
= 100% WR [ 31]
= 31
Contrast DZ [ 92]
= 80% = 92
Illumination period
= 10 s
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Main menu First rated shunt value

Logfile I= 100 A
Digital inputs
Reset hold function
Second rated shunt value
I= 60 A
Test menu
Display setting
System settings Password 2 System settings
*** First rated shunt value Number of batt. cells
− Second rated shunt value = 24
Number of batt. cells
Delay times
Batt. test parameter
B1 [ 0] Channel battery sensor
=0 Configuration flag A
Flags fault eval. B
GSR setting
LED hold function
Configuration flags
Relay hold function E
No modem connected
Redundancy n+x
Sensor op. MCU
Redundancy reset
F
Autom. battery test G
Date
No SAT-bus rect.
Time H
Battery test with 2 batt.
Password 1 I
Contin. control centre call
Password 2
Rec. to both contr. centres
Batt. cap. at MFT K
Record via service port L
ADBUS-SATs connected M
Record for unit failure
N
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SVA delay Battery test duration

= 10 s = 60 min
SVB delay Abort voltage

= 1.81 V/cell
= 60 s
A B
UV [ 29]
SVC delay = 29
=0s
Delay times Batt. test parameter
IV [ 30]
SVA delay Battery test duration
Relay test duration = 30
SVB delay Abort voltage
SVC delay = 100 s Voltage channel 1
Relay test duration Current channel 1 [255]
Monitor. message Monitor. message Voltage channel 2 = 255
Line engaged Current channel 2
= 60 s
Redundancy error Batt. test interval
Init. date [255]
Next battery test = 255
Line engaged
= 75 s
Batt. test interval
00.03.00
Redundancy error dd.mm.yy
= 30 s
Init. date
01.01.2006
dd.mm.yy
Next battery test

01.04.2006
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Flags fault eval. Status mask

Fault mask Test mode
SVA mask Configuration phase
SVB mask Watchdog reset
SVC mask Bus error
Master Timeout
Fan fault
Wrong command
Current failure
Temp. sensor faulty
Mains failure
Unit does not respond
Status mask Unit fault
Fan fault Overvoltage
Mains failure Overtemperature
Unit fault Unit switched off
Overvoltage
Unit switched off
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F GSR setting
Input channel IV [ 30]
Lower limit = 30
Upper limit
Hysteresis
GSR number Filter mask
=1 Lower limit WR [ 31]
= 48.0 = 31
GSR number
=2 Upper limit
= 100.0
Hysteresis PV [ 90]
= 0.5 = 90
GSR number
=5 Filter mask
Generally enabled
SVA link
SVB link
Insert mess. text
Trigger message
SVC link
No access to MCU
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G H I
LED hold function Relay hold function Redundancy n+x

LED 1 Relay 1 =1
LED 2 Relay 2
LED 3 Relay 3
• •
• •
• •
LED 17 Relay 15
LED 18 Relay 16
K L M, N
Date Time New password

16.02.2006 08:47:06 ***
dd.mm.yy hh:mm:ss −
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5.3 Main menu

Press the key to return from the basic status to the main menu.
"Logfile"
An event history of all status changes is stored in the logfile. Up to 200 of the
last status changes can be read out using a circular buffer. A threshold can be
set to allow a warning for the number of past status changes.
Sequence number of the logfile entry

Logfile [ 1]
09.02.06 – 11:31:48 Date and time of logfile entry
SAT-bus status
[ 25]: Mains failure
active
Fault class: SAT-bus status or digital input
Event description
Address of the SAT-bus user or number of the

digital input
Current status: active or inactive
The complete logfile content can be deleted from each logfile entry.
"Measured value display"
All recorded measured system values can be shown in this menu item. A ma-
ximum of 200 measured values can be recorded.
IV [ 30] Type of measured value and number of measur-

I = 21.1A ing channel
Measured value
The exact code of the type of measured value can be found in the order-related
data sheet of the MCU.
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"Digital inputs"
Assignment, description and status of the digital inputs are displayed.
Type of the digital input and number of the digi-

URGERR [ 40] tal input
= active
Logic status of the digital input
(active; inactive)
The exact code of the type of digital inputs can be found in the order-related
data sheet of the MCU.
"Reset hold function"
With this menu item, all programmed hold functions for the filter events, the
relays and the LEDs can be deleted.
"Status of components"
The status mask of each Sat-bus component defined in the system can be dis-
played.
Component [m] Type of the SAT-bus component defined in the

= 25 system
Address of the SAT-bus component
Type of all SAT-bus components possible:
m Base unit of the MCU

M MCU-SAT measuring box
S Satellite of a rectifier
D MCU-SAT digital input box
R MCU-SAT relay box
E EUE MCU satellite
P DSP adapter / Multibox
A AC measured value board
d Satellite of a DC-DC converter
A maximum of 31 SAT-bus components can be addressed in one system.
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5.4 The menu "Test menu"

This menu can only be accessed with password 1. The password is set to
"001" in the factory.
Attention!
For safety it is important to change this password after commission-
ing the system.
"Test menu | Operating mode"
The output characteristic / charging characteristic of the connected SAT-bus

rectifiers can be set or modified. A battery test can be started or terminated
manually. The display shows the setting as selected.
"Test menu | Relay test"
The function of each single relay of all connected RELIO boards is tested when
selected.
5.5 The menu "Display setting"

"Display settings | Language"
The languages "German" and "English" can be selected by default. A third lan-
guage, e.g. "French", can be implemented customer-specifically.
"Display settings | Language"
All LEDs of the display (4x) and of the LED board (13x) are subjected to a
function test.
"Display settings | Measured value display n"
Here, the three measured values which are to be displayed in the basic status
are defined. All measured values recorded in the system can be selected.
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"Display settings | Brightness"
The brightness of the display can be set between 10% and 100%.
"Display settings | Contrast"
The contrast of the display can be set between 10% and 100%.
"Display settings | Illumination period"
The illumination period of the display can be set between 10 and 255 seconds.
5.6 Menu "System settings"

This menu can only be accessed with password 2. The password is set to
"002" in the factory.
Attention!
For safety it is important to change this password after commission-
ing the system.
"System settings | First rated shunt value"
Setting of the first rated shunt value; setting range 0 ... 9999 A
"System settings | Second rated shunt value"
Setting of the second rated shunt value; setting range 0 ... 9999 A
"System settings | Number of batt. cells"
Indication of the number of cells of the system battery; 0 ... 200 cells
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"System settings | Delay times | SVA delay"
Setting of the delay time of the "urgent" fault messages. Setting range: 0 ...
65535 seconds
"System settings | Delay times | SVB delay"
Setting of the delay time of the "non-urgent" fault messages. Setting range: 0 ...
65535 seconds
"System settings | Delay times | SVC delay"
Setting of the delay time of the "common fault messages". Setting range: 0 ...
65535 seconds
"System settings | Delay times | Relay test duration"
Setting of the relay test duration for the menu item "Test menu | Relay test".
Setting range: 0 ... 65535 seconds
"System settings | Delay times | Monitor. message"
Setting of the delay in seconds, following which a modem connection between

the MCU and a control stand should be cut off if the control stand does not re-
spond. Setting range: 0 ... 65535 seconds
"System settings | Delay times | Line engaged"
Setting of the delay, following which a new connection should be created in

case of engaged line. Setting range: 0 ... 65535 seconds
"System settings | Delay times | Redundancy error"
Setting of the delay time after which a redundancy error is signalled.
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"System settings | Batt. test parameter | Battery test duration"
Input of duration of a battery test in minutes.

Setting range: 0 ... 9999 minutes
"System settings | Batt. test parameter | Abort voltage"
Input of abort voltage of a battery test in volts per cell
"System settings | Batt. test parameter | Voltage channel 1"
Input of measurement channel through which battery test voltage of battery

circuit 1 is recorded.
"System settings | Batt. test parameter | Current channel 1"
Input of measurement channel through which battery test current of battery cir-
cuit 1 is recorded.
"System settings | Batt. test parameter | Voltage channel 2"
Input of measurement channel through which battery test voltage of battery

circuit 2 is recorded. (correct configuration flag must be set! )
"System settings | Batt. test parameter | Current channel 2"
Input of measurement channel through which battery test current of battery cir-
cuit 2 is recorded. (correct configuration flag must be set! )
"System settings | Batt. test parameter | Batt. test interval"
Input of time interval in which another automatic battery test should be initi-
ated. The time is entered in days, months and years. (Correct configuration flag
must be set! )
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"System settings | Batt. test parameter | Init. date"
Input of date on which a first automatic battery test should be carried out. After
this, more battery tests are carried out at the specified intervals. If the date for
the first battery test is invalid, the time is calculated from the first commission-
ing. The date is specified in day, month and year. (Correct configuration flag
must be set! )
"System settings | Batt. test parameter | Next battery test"
Display of the next starting date for an automatic battery test. The time is spe-
cified in day, month and year. The timing is based on the data previously input.
(Correct configuration flag must be set! )
"System settings | Channel battery sensor"
Input of measurement channel to which the battery sensor is connected which

transmits the current battery voltage to the charging rectifiers. (Correct con-
figuration flag must be set!)
"System settings | Configuration flag"
Configuration flags: Meaning:
No modem connected Modem connected

No modem connected No modem connected
Sensor op. MCU No battery sensor operation; voltage is controlled
at the load
Sensor op. MCU Battery sensor operation; voltage is controlled at
the battery
Autom. battery test No automatic battery test possible
Autom. battery test Automatic battery test possible
No SAT-bus rect. SAT rectifiers are included in the system. One of
the SAT rectifiers has the master function. Ex-
change of information between SAT rectifiers is
possible.
No SAT-bus rect. No SAT rectifiers included in the system. The
MCU itself has the master function.
Battery test with 2 batt. The battery test can only be carried out for one
battery circuit.
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Configuration flags: Meaning:
Battery test with 2 batt. The battery test is carried out for two battery cir-
cuits. The battery test parameters for the second
battery circuit must be set.
Contin. control centre call The MCU tries up to 8 times to issue a log
Contin. control centre call The dialling attempts are continued until a log
has been successfully issued.
Rec. to both contr. centres A fault record is sent to one call number only.
Rec. to both contr. centres A fault record is always sent to both call num-
bers (only when 2 call numbers are entered! )
Batt. cap. at MFT The taken battery capacity is determined only at
a battery test.
Batt. cap. at MFT The taken battery capacity is determined at a bat-
tery test and at a mains failure.
Record via service port Only requested records are issued via the service
interface.
Record via service port The records are sent automatically via the ser-
vice interface.
ADBUS-SATs connected No bus converter for the ADBUS is connected
ADBUS-SATs connected A bus converter for the ADBUS and suitable rec-
tifiers for the ADBUS are connected.
Record for unit failure A record is sent only once in case of a unit fail-
ure.
Record for unit failure Each new unit failure is reported via a record.
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"System settings | Flags fault eval. | Fault mask"
This fault mask / status mask is regularly compared with the status of each
SAT-bus user. The appropriate actions are triggered depending on the result of
this comparison.
"System settings | Flags fault eval. | SVA mask"
A status mask can be read out. The result of the comparison between the error
mask and the status of a SAT-BUS user is compared with this status mask. De-
pending on the result, an urgent alarm is given.
"System settings | Flags fault eval. | SVB mask"
pending on the result, a not urgent alarm is given.
"System settings | Flags fault eval. | SVC mask"
pending on the result, a common fault message is given.
"System settings | GSR setting | ......"
Each of the 5 limit-value monitoring relays can be programmed or read out at

this menu item.
Attention!
The settings of the limit-value monitoring relays (GSR) should only
be changed with excellent system knowledge.
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"System settings | GSR setting | Input channel"
Input of the measuring channel whose measured value is to be monitored.
"System settings | GSR setting | Lower limit"
Input of lower limit value to be monitored.
"System settings | GSR setting | Upper limit"
Input of upper limit value to be monitored.
"System settings | GSR setting | Hysteresis"
Input of hysteresis band width. This value applies for the upper and lower li-
mit value.
"System settings | GSR setting | Filter mask"
This filter mask specifies which statuses or actions are affected or are to be
triggered if a limit value has not been reached or is exceeded.
"System settings | LED hold function"
A hold function can be set for all LEDs of the LED board and the display.
When the event which has caused the LED to light up no longer exists, the
LED goes into the flashing status (hold status). The status is reset by activating
the reset key of the LED board or via the menu item "Reset hold function".
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"System settings | Relay hold function"
A hold function can be set for all relays. After discontinuation of the event
which led to the activated status of the relay, the relay remains in this active
status (hold status). The status is reset by activating the reset key of the LED
board or via the menu item "Reset hold function".
"System settings | Redundancy n+x"
Input of the redundancy value x for n+x monitoring
"System settings | Redundancy reset"
A possibly pending redundancy fault is reset. The maximum value of the paral-
lel-running rectifiers is re-determined.
"System settings | Date"
Input or display of the system date.
"System settings | Time"
Input or display of the system time.
"System settings | Password 1"
Specification or alteration of the password (000 ... 999) with which the "Test
menu" is accessed.
"System settings | Password 2"
Specification or alteration of the password (000 ... 999) with which the menu
"System settings" is accessed.
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6 Battery test / Capacity test

The battery test incorporated in the MCU permits all the rectifier units to be
switched from the float charge characteristic to the battery test characteristic.
As a result of this procedure, the loads connected are supplied from the battery
for the duration of the programmed test period. As the load current (discharg-
ing current of battery) and the discharging time are continuously measured and
recorded, an evaluation of the availability of the battery can be made on con-
clusion of the test phase.
Attention!
In the battery test characteristic, the voltage of the rectifier is re-
duced and not switched off. For this reason, no critical situation for
the loads occurs at any time.
The abort voltage and the duration of the battery test can be set at the display or
by using the service software TEBE MCU Service.
Attention!
Before a battery test can be started, the "Charge automatic” at the
SAT rectifiers has to be active.
These settings can be changed:
1) Locally via the satellites of the rectifiers. This setting must be made sepa-
rately for each rectifier.
2) Locally via the service software TEBE MCU Service.
The battery test can be initiated in various ways.
1) Locally via the display
2) Locally via the service software TEBE MCU Service
3) From a central control stand by modem with monitor software

TEBE MCU Monitor
Attention!
If an automatic battery test is being carried out via the MCU, the op-
tion "Automatic battery test" must be released.
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Operation
The rectifiers are operating on the
float charge characteristic. Auto-
matic charging must be activated.
Battery test start

Automatic switch-over by all recti-
fiers from the float charge character-
istic to the battery test characteristic.
Battery test active

During the battery test phase, the lo-
ad current and the discharging time
are measured and stored.
yes
UBatt. ≤ UCancellation
no
Battery test end Battery test aborted

The abort voltage was not achieved The abort voltage was achieved be-
in the specified time. fore battery testing time expired.
Battery condition OK Battery condition not OK.

MCU reports that battery OK and The MCU signals that the battery is
gives the capacity withdrawn in not OK and the capacity drawn in
Ah. Ah up to point the test was inter-
rupted.
Back-switching
Switch back to float charge charac-
teristic. No defined charging phase.
Figure 16: Sequence of the battery test
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Manual MCU 2500 - 4339-En-Hr

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Operating instructions

Remote Monitoring System

Date Designation No. 4339en

2 Bus systems / interfaces ..........................................................................5

3 The components of the remote monitoring system ..................................6

3.1 Base unit.................................................................................................9

3.2 ADBUS2 components...........................................................................13

3.2.1 RELIO board ........................................................................................13

3.2.2 Measuring board TUII ..........................................................................16

3.2.3 Battery symmetry monitoring 60V........................................................19

3.3 SAT-bus components............................................................................22

3.3.1 MCU-SAT relay box.............................................................................24

3.3.2 MCU-SAT measuring box ....................................................................26

3.3.3 MCU-SAT digital input box .................................................................27

3.3.4 DSP adapter / Multibus .........................................................................28

3.3.5 EUE MCU satellite ...............................................................................29

3.4 I²C-BUS components............................................................................29

3.4.1 LED board ............................................................................................29

3.4.2 Graphic display.....................................................................................31

3.5 RS232 components ...............................................................................32

3.6 Spare serial interface components .........................................................33

4 Installation and commissioning.............................................................33

5 Operation of the graphic display ...........................................................34

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5.1 The main window .................................................................................35

5.2 Menu structure......................................................................................35

5.3 Main menu............................................................................................46

5.4 The menu "Test menu" .........................................................................48

5.5 The menu "Display setting" ..................................................................48

5.6 Menu "System settings" ........................................................................49

6 Battery test / Capacity test.....................................................................57

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0 Safety notes and used symbols

Indicates instructions which must be followed to avoid danger to

Indicates instructions which must be followed to avoid material da-

The components of the remote monitoring system MCU are de-

1. Installation, operation, maintenance and repair of the MCU should be

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A flexible and user-dependent use as well as a significant volume reduction of

2 Bus systems / interfaces

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Spare serial interfaces

3 The components of the remote monitoring system

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Figure 1.1: Basic structure of the remote monitoring system 2500

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1 Control station; PC with service software

2 TCP/IP adapter for the connection of the MCU 2500 to a computer

3 Modem for the connection of the MCU 2500 to a telephone network

4 Base unit of the MCU 2500

6 Measuring board TUII (ADBUS2 component)

7 Relay box (SAT-bus component)

8 Battery symmetry monitoring (ADBUS2 component)

9 Digital input box (SAT-bus component)

10 RELIO board (ADBUS2 component)

11 Measuring box (SAT-bus component)

12 Power supply system with suitable components for the connection to

3.1 Base unit

Mounting on a carrier plate is also possible. The respective mounting dimen-

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Figure 2: Dimension diagram of the base unit

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