GRINTEK POWER TECHNOLOGIES

INSTALLATION MANUAL

FOR THE

GT600 POWER SYSTEM

Including:

INSTALLATION AND COMMISSIONING

GT600 POWER SYSTEM Issue 03

INTERNAL APPROVAL SHEET

CONFIGURATION :

A Dreyer Date

QUALITY :
ASSURANCE
P Pretorius Date

MARKETING :

KL Simpson Date

ENGINEERING :

N Truter Date

DOCUMENT NUMBER : 840057-00000H12

ISSUE NUMBER : 03

DATE OF RELEASE : 08 November 2004

REVISED BY : N Truter

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GT600 POWER SYSTEM Issue 03

UPDATES
Grintek TCI reserves the right to update its equipment and/or documentation without prior
notification.

RECORD OF CHANGES
Personnel incorporating current changes to this manual are responsible for ensuring that all
previous changes are incorporated.

NEW ISSUE ISSUE DATE DESCRIPTION

01 2000-04-07 First release
02 2004-04-30 Second release
03 2004-11-08 Third release

WARNINGS
Th e f o l l o w i n g a r e general safety precautions that are not related to any specific procedure and
therefore do not appear elsewhere in this publication.

HIGH VOLTAGES

M a i n s v o l t a g e s a r e p r e s e n t i n s i d e t h e e q u i p m e n t , a nd special care must be taken by operators

and technicians to avoid contact with these voltages.

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TABLE OF CONTENTS
TITLE PAGE

1 INSTALLATION AND COMMISSIONING .................................................... 1

1.1 INTRODUCTION ......................................................................................... 1

1.2 INITIAL PLANNING REQUIREMENTS ....................................................... 1

1.3 PREPARATION ........................................................................................... 1

1.3.1 R a c k p r e p a ra t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3.2 Ventilation ...................................................................................................... 1

1.4 SITE PREPARATION .................................................................................. 1

1.4.1 C o n n e c t c a b i n e t t o ma i n s s w i t c h b o a r d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4.2 C o n n e c t b u i l d i n g e a rt h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4.3 Install battery bank switches .............................................................................. 2

1.5 INSTALLATION .......................................................................................... 3

1.5.1 C o n n e c t r e mo t e a l a r ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5.2 Connect DC to batteries .................................................................................... 3

1.5.3 Connect load to DC .......................................................................................... 4

1.5.4 Connect auxiliary load(s) .................................................................................. 4

1.5.5 I n s t a l l s w i t c h mo d e r e c t i f i e r s ( S M R s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5.6 C o mmi s s i o n i n g c h e c k l i s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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LIST OF APPENDICES
APPENDIX A: Installation and commissioning checklists Page A1

LIST OF FIGURES
Figure 1: AC connection Page 2

Figure 2: Interface tray Page 3

Figure 3: DC connection Page 4

Figure 4: SMR module Page 5

LIST OF TABLES
Table 1: Alarm relay connections Page 3

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TERMS AND ABBREVIATIONS

A Ampère
AC Alternating Current
AUX Auxiliary
BATT Battery
BCM Battery Cell Monitor
C.B. Circuit Breaker
CBMB Circuit Breaker Monitoring Board
CSU Control and Supervisory Unit
CTRL Control
DEC Decrement
°C Degree Celsius
DC Direct Current
e.g. Exempli gratia (for example)
etc et cetera (And all the others, And the rest)
Fig. Figure
GSM Global System for Mobile phones
Hz Hertz
INC Increment
Iss. Issue
i.e. id est (In other words)
kg Kilogram
LCD Liquid Crystal Display
LED Light Emitting Diode
LVDS Low Voltage Disconnect Switch
max. Maximum
mm millimetre
MMB Mains Monitoring Board
MUIB Mini User Interface Board
mV millivolt
N/A Not Available
PC Personal Computer
PF Power Factor
PSU Power Supply Unit
QA Quality Assurance
rms Root Mean Square
SMB Site Monitoring Board
SMR Switch Mode Rectifier
TERM Terminal
VRLA Valve Regulated Lead Acid
V Volt

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1 INSTALLATION AND COMMISSIONING

1.1 INTRODUCTION

This manual describes the procedures to be followed when installing a GT600 Rack Power
S ys t e m .

The equipment is shipped from the factory properly tested and carefully packaged. Damage
may, however, occur during transit and careful inspection of all items received is required to
ensure that all equipment is in a serviceable condition.

1.2 INITIAL PLANNING REQUIREMENTS

Before deciding on the final placement of the rack the following must be taken into
consideration:

• Connection to AC input

• Rack clearances/height

• Rack accessibility

• Ventilation
Before starting the installation the following information is required:

• AC input voltage. The GT600 power system is designed to operate at a nominal input
voltage of 220VAC phase-neutral (380VAC, 3-phases + neutral). The input voltage
range should be between 195VAC and 264VAC under all conditions.

• E s t i m a t e t h e m a x i m u m c u r r e n t t h a t t h e s ys t e m w i l l d r a w f r o m t h e m a i n s i n p u t . T h e
m a x i m u m i n p u t c u r r e n t o f t h e G T 6 0 0 p o w e r s ys t e m w i l l b e d r a w n w h e n t h e s ys t e m
delivers full load and the input voltage is at the lower limit (195VAC). This is
approximately 65A per phase (3-phase). Make sure that the mains connection to the AC
switchboard can supply this current.

• We recommend a, 100A 3-pole circuit breaker.

1.3 PREPARATION

1.3.1 Rack preparation

Inspect the rack for any mechanical damage.

1.3.2 Ventilation

The air-flow through the cabinet is from the front to the back. Please ensure that there is
enough clearance (400mm in the front) to facilitate sufficient air-flow.

1.4 SITE PREPARATION

Ensure that the site is clear of obstructions and ready for the cabinet to be placed. Cables

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should be cut to length and made off and any cable trays or ducting prepared and mounted.

1.4.1 Connect cabinet to mains switchboard

At the switchboard, install a correctly sized circuit breaker.

Secure the switchboard against accidental application of power to the rack.

Ensure that the switches are switched off. Position the rack at the designated position.
Remove the retaining screws and AC distribution covers as indicated in figure 1.

Using cables of correct cross section, connect the three phases (L1, L2, L3), neutral (N) and
earth (E) from the switchboard to the rack in the positions shown in figure 1. The cables can
be routed through the top apertures, bottom aperture or side or back panels of the rack.

Do not apply power to the rack at this time. At this point check all supply connections,
including the earth connection, and all nuts and bolts for tightness.

Retaining
screws, 4 of.

AC
distribution
cover.

L1, L2, L3 Neutral Earth Module circuit breakers

Figure 1: AC connection

1.4.2 Connect building earth

Connect the building earth wire to the positive distribution bus-bar as indicated in figure 3.

1.4.3 Install battery bank switches

I f t h e s ys t e m w i l l b e u s e d t o c h a r g e b a t t e r i e s , e a c h b a t t e r y b a n k s h o u l d b e f i t t e d w i t h a n
isolating switch. It is recommended that the switch be equipped with normally open auxiliary
contacts to monitor the position of the switch.

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1.5 INSTALLATION

Once the rack is in place with cage nuts and cables in correct positions, proceed as follows:

1.5.1 Connect remote alarms

Remove the two retaining screws on the CSU tray and slide it out. Connect the remote alarms
to the connector on the MUIB board as shown below.

Alarm connector

Label showing
alarm

Figure 2: Interface tray

Table 1: Alarm relay connections

Connector pin Description Function Name

1,2,3 Relay 1 System voltage high warning - pulsing

System voltage high alarm - continuously on

4,5,6 Relay 2 System voltage low warning - pulsing

System voltage low alarm - continuously on

7,8,9 Relay 3 AC alarm

10,11,12 Relay 4 SMR shut-down or communication fault

13,14,15 Relay 5 Battery temperature high

1.5.2 Connect DC to batteries

C i r c u i t b r e a k e r s ( o r i s o l a t o r s i n s e r i e s w i t h f us es ) must be installed as close as possible to the

battery banks. If more than one battery bank is installed, then each bank should have its own
c i r c u i t b r e a k e r . R u n s e p a r a t e c a b l e s of equal length to each bank of batteries. Connect cables
first on the power system side. Before connecting the cables on the battery side, temporarily
isolate the positive cable end. Connect the negative to the circuit breaker. Make sure the
circuit breaker is off, and then make the connection between the battery negative and the
circuit breaker. Only then connect the positive to the battery and after that, switch the circuit

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breaker on.

1.5.3 Connect load to DC

Connect the load positive(s) to the positive load return bars and the load negatives to the
negative load connections (through circuit breakers) as indicated in figure 3.

1.5.4 Connect auxiliary load(s)

If required, connect the auxiliary positive(s) to the positive (+) auxiliary bus bar and the load
negative(s) to the output of the distribution circuit breaker(s). If there are more than 2
separate auxiliary loads, up to 6 additional circuit breakers can be added.

Battery negative
connection

Battery positive
connection

Load distribution
switches

Load negative
connection

Load positive
connection

Figure 3: DC connection points

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1.5.5 Install switch mode rectifiers (SMRs)

Remove SMRs from packaging. Conduct a visual inspection of the SMRs for mechanical
damage. Take care not to damage the connectors at the back of the SMR. See figure 4.

Before installing SMRs into the rack:

• Ensure that the circuit breakers on the DC and AC distribution modules are off.

• Place SMRs into the rack in accordance with the instructions in the Operators Manual.

• Ensure all SMR circuit breakers are off.

Connectors

Figure 4: AV1S100 module

1.5.6 Commissioning checklist

Complete Commissioning checklist (Appendix A) and fax to Grintek TCI, for the attention of
the configuration department on fax no (012) 674-3515.

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APPENDIX A

INSTALLATION AND

COMMISSIONING CHECKLISTS

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COMMISSIONING CHECKLIST
SITE NAME

SITE LOCATION

CABINET PART NUMBER

CABINET SERIAL NO

MCSU NUMBER

SOFTWARE VERSION MCSU

SOFTWARE VERSION SMR

MODULE 1 SERIAL NO

MODULE 2 SERIAL NO

MODULE 3 SERIAL NO

MODULE 4 SERIAL NO

MODULE 5 SERIAL NO

MODULE 6 SERIAL NO

INSTALLATION BY

INSTALLATION DATE

COMMISSIONING DATE

SITE TELEPHONE NUMBER

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INSTALLATION CHECKLIST FOR THE RACK POWER SYSTEM

Item Description Status Remarks

1 Provision of labels and fittings on rectifiers,
batteries etc.

2 C h e c k t h a t t h e s y s t e m s a r e p o s i t i oned as per
floor plan.

3 Check that AC cable is correctly installed

between the power system and the AC outlet
/ distribution board.

4 Tightness of all bolts, nuts, screws,

connections & terminals.

5 Check for proper insertion of wires on all

terminals.

6 Neatness of PVC channels, cabling & wiring.

7 Check correct polarity of load connection.

8 Check correct polarity of battery connection.

9 Check damages to batteries & cabinets.

10 Check that the earth cable from the power

systems is connected to the earth bar of the
site.

11 Check that the earth bonding cables are

fixed.

12 C h e c k t h a t t h e w i r i n g i s n o t e x p o s e d t o s harp
points & cutting edges.

13 Check that the air vents in the floor `

underneath the power systems are sufficient
and open.

14 Check rating of the circuit breakers.

15 Ensure that no alarms are activated.

16 Inspect the system in general for neatness &

completeness.

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COMMISSIONING CHECKLIST

Refer to the manuals supplied with the equipment for more detailed information.

DESCRIPTION VALUE PASS/

FAIL
1. Slide the correct number of modules in the rack 1-6
and record the number of modules in the rack.

2. Ensure that the module input circuit breakers in

the cabinet are switched off and that all the
ON/OFF switches on the SMR modules are in the
OFF position. Switch the AC isolator(s) / circuit
breaker(s) in the DB ON. Switch both the MAINS
INPUT circuit breakers in the cabinet ON.

3. Set each SMR module address. NOTE 1

4. Switch all the SMR ON / OFF switches to ON. 0A xx.Xv Lo Fi

Check that all SMRs display the following.
NOTE 2

5. Check that MCSU switches on. Record the

software version which is displayed for the first
two seconds after the MCSU switches on.

6. Set the Mini-CSU access code. NOTE 3

7. Check that no alarms are displayed. NOTE 4

8. Check that all the settings in the Mini-CSU are correct. NOTE 5.

HOME SCREEN

8.1. Ambient temperature Not adjustable

8.2. Ambient temperature alarm 45°C

8.3. High volt alarm 54.5V

8.4. Low volt alarm 49.2V

8.5. Security OFF

8.6. Test OFF

8.7. No of SMRs Number in rack

8.8. FS Current Reading on

LEM. NOTE 6.

8.9. Number of batteries Number of 48V

banks

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DESCRIPTION VALUE PASS/

FAIL
8.10. CSU# Depends on
site. (see par 6)

8.11. Modem ON (If

telephone line
8.12. Alarm report
available,
8.13. Daily report depends on
8.14. Daily time site)

SMR SCREEN

8.15 SMR Float Not adjustable

8.16 SMR Equal Not adjustable

8.17 SMR V Hi 54.5V

8.18 SMR V Lo 49.2V

8.19 SMR I limit 102A

8.20 SMR HVSD 56.5V

BATTERY SCREEN

8.21 Bat Temp (Battery Temperature) Not adjustable

8.22 Batt T Alarm (Battery Temperature Alarm) 35°C

8.23 QEst Batt 1 Not adjustable

8.24 Batt Rated Depends on

batteries
(Rating of
battery bank)

8.25 BTC (Battery temperature compensation) OFF if system

does not have
BTC.

8.26 BILim Vb<Vdd 14% of battery

rating

8.27 Vdd Level (Battery deep Discharge Voltage) 45V

8.28 BI Lim Vb<Vfl Between 7%

and 14% of
battery rating

8.29 Sys Float (System float voltage) 53.5V

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DESCRIPTION VALUE PASS/

FAIL
8.30 BI Lim Vb>Vfl Between 7%
and 14% of
battery rating

8.31 Sys Equal (System equalization voltage) 53.6V

8.32 Sys Drop. (System voltage drop) ±0.5V

NOTE 7

8.33 B Dis Al (Battery discharge alarm voltage) 47.5V

8.34 V Start Eq OFF

8.35 EQTrig 48V

8.36 Q start Eq OFF

8.37 Qdis Trig 15Ah

8.38 EQ end OFF

8.39 Equal Duration 20H

8.40 Equal per (Equalization period) 12Wk

8.41 Manual Start EQ Leave on

default value

8.42 LVDS Trip 44.4V

8.43 LVDS Auto

8.44 Sensor Alarm ON

9. Active current sharing. NOTE 8 ±5% accuracy

within band

Passive current sharing. NOTE 9 ±15% accuracy

within band

10. Measure the output voltage with a DVM and record

the value.

11. Record the displayed voltage on the mCSU.

12. Connect a load and measure the load current with

a current clamp, and record the value.

13. Record the displayed current on the mCSU.

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DESCRIPTION VALUE PASS/

FAIL
14. CHECK THE FOLLOWING ALARMS

14.1 Switch the Battery circuit breaker ON

14.2 SMR URGENT . NOTE 10

14.3 HIGH VOLT . NOTE 11

14.4 LOW VOLT . NOTE 12

14.5 AC FAIL

Load shed. NOTE 13

14.6 Battery current limit. NOTE 14

14.7 Measure the battery current with a current clamp

and record the value.

14.7 Record the battery current as displayed in the

Battery menu of the mCSU

15. Return all settings to the correct settings after the

alarms are tested.

16. Disconnect the PC and reconnect the modem to

the mCSU.

NOTE 1:

Set addresses sequentially starting from the top of the rack. (Press and hold the “MENU”
button during the whole operation. Scroll between screens by pressing the “INC” or “DEC”
b u t t o n u n t i l S M R # a p p e a r s . P r e s s “ E N T E R ” t o c hange the address. The SMR address will then
flicker. Press “INC” or “DEC” until desired address is displayed. Press “ENTER” to accept the
n e w a d d r e s s . N o t e : I f t h e s e c u r i t y l o c k i s o n , p r e s s “ I N C ” , “ D E C” and “ENTE R” simultaneously
for more than 5 seconds to unlock).

NOTE 2:

x is a number between 0 and 9. xx.x designates the output voltage of the SMR. If no load is
connected the SMR and the mCSU will display a Lo alarm. This alarm will disappear as soon
as a load is applied.

NOTE 3:

The access code can be changed by scrolling through the HOME (default) screen of the
mCSU. Press the “INC” or “DEC” buttons until CSU# is displayed. To change the code, press
E N T E R u n t i l t h e d e s i r e d d i g i t f l i c k ers. P res s t he “INC” and “DEC” pushbuttons until the correct
value is displayed, press “ENTER” to accept and move to the next digit. Press enter after the

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last digit to accept the new code.

NOTE 4:

(Except the no-load (Lo) alarm.). The orange LED on the SMR and on the mCSU will flash
when there is an alarm. To view the alarm press “ENTER” on the mCSU. Press “INC” or ”DEC”
to view more alarms.

NOTE 5:

T o s c r o l l t h r o u g h t h e H O M E s c r e e n , p r e s s “IN C ” or “DEC” when in the default screen. To scroll

through the SMR screen, press the “SMR” button and then “INC” or “DEC” to scroll. To scroll
t h r o u g h t h e B A T T E R Y s c r e e n , p r e s s “ B A T T ” a n d t h e n “ I N C ” o r “ D E C ” . T o c h a n g e a va l u e ,
press “ENTER” and use the “INC” and “DEC” pushbuttons to change, Press “ENTER” again to
accept.

I f a P C i s a va i l a b l e a l l t h e v a l u e s c a n b e c h a n g e d b y u s i n g t h e s u p p l i e d W I N C S U s o f t w a r e .

Disconnect the modem from the mCSU and connect a RS232 cable from the PC to the mCSU.

Open the WinCSU program.

Make sure that the access code that was entered in paragraph 6 is the same as in WinCSU. If
not, change the access code in WinCSU.

Go to CSU parameters.

Click on EDIT PARAMETERS. Values can now be changed to the values listed below.

Close the screen and go to WRITE PARAMETERS in the CSU PARAMETERS screen
(CTRL W can also be pressed on the PC). Press yes when prompted to overwrite
parameters. The changed values will now be written to the mCSU.

Go to SMR PARAMETERS

Click on EDIT PARAMETERS. The values should be as listed in 8.17 to 8.20.

Go to WRITE PARAMETERS in the SMR screen. Press yes when prompted to overwrite ALL
SMRs.

NOTE 6:

O n t h e G T 1 2 0 0 ( P / N 8 4 0 1 0 7 - 0 0 0 0 0 ) t h e v a l u e 1 2 0 0 m u s t b e r e a d f r o m t h e c u r r e n t t r a n s d u c er.

On the GT600 (P/N 8400057-00000) the value 600 must be read from the current transducer.

NOTE 7:

T o d e t e r m i n e t h i s v a l u e , t h e v o l t a g e b e t w e e n t h e output of the SMRs and the batteries and the

voltage between the output of the SMRs and the load must be measured. The smallest of the
two voltages must be used.

NOTE 8:

Connect a dummy load to the system and check that current sharing is done. It may be
n e c e s s a r y t o i n c r e a s e t h e l o a d t o a b o v e 7 5 % o f f u ll loa d for the a ctive current sharing to come

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GT600 POWER SYSTEM Issue 03

into operation.

NOTE 9:

I f n o M i n i - C S U i s c o n n e c t e d t h e s ys t e m w i l l d o p a s s i v e c u r r e n t s h a r i n g . I f a n m C S U i s
connected and for some reason active sharing is not done, an x w i l l b e d i s p l a ye d

NOTE 10:

Switch off one module. The red LED will flash.

NOTE 11:

Set the float voltage 0.5V higher than the high volt alarm value.

NOTE 12:

Set the float voltage 0.5V lower than the low volt alarm value. Set the float voltage to the
correct value after this test is done.

NOTE 13:

Set the LVDS to 48V and switch the AC circuit breaker OFF. While the AC circuit breaker is
OFF, apply load to the system to let the voltage drop and check that the load sheds at the set
voltage.

NOTE 14:

Once the AC is switched back ON, this alarm could appear.

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APPROVAL SHEET

I n s t a l l a t i o n p e r f o r m e d b y:
Company :

Designation :

Name :

Sign :

Date :

C o m m i s s i o n i n g p e r f o r m e d b y:
Company :

Designation :

Name :

Sign :

Date :

S ys t e m i n s p e c t e d b y G R I N T E K Q A :
Company :

Designation :

Name :

Sign :

Date :

S ys t e m I n s p e c t e d b y C U S T O M E R Q A :
Company :

Designation :

Name :

Sign :

Date :

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