GT505NG Operating 3

USER MANUAL FOR THE GT505NG POWER SYSTEM
Prepared By
SAAB GRINTEK TECHNOLOGIES (PTY)

LTD
This document is proprietary to Saab Grintek Technologies (Pty) Ltd and it shall not be loaned, borrowed or copied without express written permission of the company. This document is
maintained on electronic media. The current revision of this document is located on the network. It is the responsibility of the user to verify that this copy is the latest revision.
“UNCONTROLLED IF PRINTED”
UPDATES
SAAB Grintek 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 DESCRIPTION

ISSUE DATE
01 2004-10-13 First Release

02 2005-12-15 Second Release
03 2006-03-08 Third release
WARNINGS
The following are general safety precautions that are not related to any specific procedure and therefore do not appear
elsewhere in this publication. These are recommended precautions that personnel must understand and apply during
any phase of operation and maintenance
HIGH VOLTAGES
Mains voltages which are hazardous to humans are present in the equipment, and care must be taken at all times not to
come into contact with these voltages when servicing the equipment.
IMPORTANT NOTICE
The installation approval sheet at the back of Appendix A of this manual should be completed for the purpose of
honouring warranty as specified in the warranty agreement.
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TABLE OF CONTENTS
1 GENERAL OPERATION ………………………………………………………………………………………… 1

1.1 SCOPE …………………………………………………………………………………………………………….. 1
1.2 DESCRIPTION ……………………………………………………………………………………………………. 1
1.3 SPECIFICATIONS ………………………………………………………………………………………………… 2
1.3.1 System Specifications ……………………………………………………………………………………………. 2
1.3.2 Mechanical Specifications ………………………………………………………………………………………. 2
1.4 CONTROL AND SUPERVISORY UNIT (MiniCSU) ……………………………………………………………. 2
1.4.1 MiniCSU Control Functions ……………………………………………………………………………………… 2
1.4.1.1 Output Voltage ……………………………………………………………………………………………………….. 2
1.4.1.2 Battery Temperature Compensation ………………………………………………………………………………. 3
1.5 MiniCSU DISPLAY ………………………………………………………………………………………………… 3
1.6 ALARM CONDITIONS …………………………………………………………………………………………… 3
1.7 MiniCSU MENUS …………………………………………………………………………………………………. 3
1.7.1 ‘HOME’ Menu ………………………………………………………………………………………………………. 4
1.7.2 ‘SMR’ Menu ……………………………………………………………………………………………………….. 6
1.7.3 ‘BATT’ Menu ……………………………………………………………………………………………………….. 7
1.7.4 ‘Alarms Log’ Menu ……………………………………………………………………………………………….. 10
1.8 MiniCSU SECURITY …………………………………………………………………………………………….. 10
1.9 Mini USER INTERFACE BOARD (MUIB) ……………………………………………………………………… 10
1.10 REMOTE MONITORING …………………………………………………………………………………………. 11
1.11 LOW VOLTAGE DISCONNECT SWITCH (LVDS) …………………………………………………………… 13
1.12 TEMPERATURE SENSORS …………………………………………………………………………………….. 13
1.13 DC DISTRIBUTION .,……………………………………………………………………………………………… 13
1.14 AC CONNECTION ………………………………………………………………………………………………… 14
1.15 OUTPUT EARTH …………………………………………………………………………………………………. 14
2 REPAIR AND MAINTENANCE …………………………………………………………………………………. 14
2.1 INSPECTION ………………………………………………………………………………………………………. 14
2.2 SITE REPAIRS …………………………………………………………………………………………………… 14
2.3 MiniCSU ALARMS ………………………………………………………………………………………………… 14
2.4 REPLACING MODULES ………………………………………………………………………………………… 15
2.5 BATTERY REPLACEMENT …………………………………………………………………………………….. 15
3 INSTALLATION AND COMMISSIONING …………………………………………………………………….. 17
3.1 INTRODUCTION ………………………………………………………………………………………………….. 17
3.2 INITIAL PLANNING REQUIREMENTS ………………………………………………………………………… 17
3.3 PREPARATION …………………………………………………………………………………………………… 17
3.4 SITE PREPARATION ……………………………………………………………………………………………. 17
3.5 REMOTE ALARMS ………………………………………………………………………………………………. 20
3.6 BATTERY INSTALLATIONS ……………………………………………………………………………………. 21
3.7 DC LOAD TERMINATIONS …………………………………………………………………………………….. 21
3.8 INSTALL SWITCH MODE RECTIFIERS (SMR’s) ……………………………………………………………. 21
3.9 DEFAULT VALUES ……………………………………………………………………………………………. 22
4 COMMISSIONING ………………………………………………………………………………………………… 22
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LIST OF APPENDICES
Installation and Commissioning Checklist APPENDIX A
Wiring Diagram for GT505NG APPENDIX B
Operating Manual for Battery Cell Monitor APPENDIX C
LIST OF FIGURES
Figure 1 GT505NG Power System …….………………………………………………… Page 1
Figure 2 Battery Temperature Compensation Curve ……………………………… Page 3
Figure 3 MUIB Connection Diagram ………………………………………………… Page 12
Figure 4 AC Distribution ….…………………………………………………………... Page 18
Figure 5 DC Distribution ……………………………………………………………… Page 19
Figure 6 Interface tray …………………………………………………………………. Page 20
Figure 7 Battery Cell Monitoring Wiring ……………………………………………… Page 21
Figure 8 Battery Cell Monitoring Terminations ……………………………………… Page 21
LIST OF TABLES
Table1 MiniCSU Alarms ……………………………………………………………… Page 14
Table 2 Battery Replacement ………………………………………………………… Page 15
Table 3 Remote Alarm Relay Connections …………………………………………. ............. Page 20
Table 4 Default Values ………………………………………………………………… ............. Page 22
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TERMS AND ABBREVIATIONS
A Amperes
AC Alternating Current
AUX Auxillary
BATT Battery
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
Hz Hertz
INC Increment
Iss. Issue
i.e. id est (In other words)
kg Kilogram
lbs Pounds
LCD Liquid Crystal Display
LED Light Emitting Diode
LVDS Low Voltage Disconnect Switch
max. Maximum
mm Millimetre
MUIB Mini User Interface Board
PC Personal Computer
PSU Power Supply Unit
QA Quality Assurance
RT4F 48V-50A Rectifier Module/Power Supply Unit
SMR Switch Mode Rectifier
TERM Terminal
VRLA Valve Regulated Lead Acid
V Volts
" Inch
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1 GENERAL OPERATION
1.1 SCOPE
This manual contains general information, principles of operation, removal and installation of the GT505NG Power
System.
1.2 DESCRIPTION
The system consists of a 19" rack which houses up to 5 x 48V 50A Rectifiers (RT4F), a MiniCSU (Control and
Supervisory Unit), an AC distribution rack and a DC distribution rack in a single rectifier cabinet. The cabinet can
accommodate a maximum of 5 x 48V 50A Rectifiers (RT4F) each capable of supplying a maximum of 50A. The system
output voltage will be 54.5V at start up (when battery temperature compensation is disabled) and is adjustable from 45V
to 58V. The maximum load demand, plus one Rectifier for redundancy determine the number of Rectifiers in a cabinet.
To ensure safe operation, the cabinet has a circuit breaker on the input of each module as well as circuit breakers in
series with the batteries and an isolator for external load distribution. Remote monitoring of the alarms and the condition
of the system is possible either by five potential free relay contacts for connection to a remote site or, by a direct RS232
link.
Module Shelf for up to 5

RT4F and RT4B
Modules
Cooling Fans
User Interface Sliding

Tray
AC Distribution Unit
DC Distribution Unit
Figure 1. GT505NG Power System
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1.3 SPECIFICATIONS
1.3.1 System Specifications
Input Voltage : 150V - 275Vrms phase to neutral, (three phase plus neutral)
Input Current : 42A max per phase with 5 RT4F modules installed (105A for single phase
feed)
Input Frequency: 45 - 65Hz (Power factor and input harmonics degrade by 10% down to 40Hz)
Output Voltage : 45V – 58V
Max System Current : 250 A max with 5 x RT4F modules installed.
Ambient Temperature : 0°C to +50°C
Note : The air flow through the rack must not be impaired.
System Protection
AC Input : 60A circuit breaker 3 phase
: 3 phase surge protection
Module AC Input : 25A single phase circuit breaker for each PSU
DC Output (Load) : Isolator 1 x 100 A, 3-pole (ganged for 250A DC total)
DC Output (Battery) : 4 x 100A single pole circuit breakers
1.3.2 Mechanical Specifications
Width : 545mm (21,5")
Depth : 450mm (17.7")
Height : 1005mm (39,6")
Weight : 76kg (167,5lbs) without modules fitted
1.4 CONTROL AND SUPERVISORY UNIT (MiniCSU)
The MiniCSU is responsible for all supervisory and control functions as described in the following sections.
1.4.1 MiniCSU CONTROL FUNCTIONS
1.4.1.1 OUTPUT VOLTAGE
The MiniCSU has control of the output voltage of the modules. The MiniCSU monitors the output voltage of the cabinet
continuously and will make any adjustments necessary to keep the output voltage regulated. In addition, the MiniCSU
ensures proper load sharing between the modules.
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1.4.1.2 BATTERY TEMPERATURE COMPENSATION
A standard feature of the rectifier system is temperature compensated charging of the battery. The battery temperature
sensor, which is supplied with the system, is used to compensate the battery charge voltage. Figure 2 shows the curve
according to which the float voltage is adjusted with change in temperature. When the temperature sensor is unplugged,
the output voltage will be set relative to the cabinet temperature. If no cabinet sensor is present or faulty, the output
voltage defaults to the set voltage, which has been programmed into the MiniCSU. This function can be
enabled/disabled and the level of compensation can be set on the MiniCSU.
Temerature Compensated Float Voltages for VRLA Batteries
59
58
57
56
VOLTAGE
55
54
53
52
51
50
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50
TEMPERATURE
Figure 2. Battery Temperature Compensation Curve
1.5 MiniCSU DISPLAY
The display on the MiniCSU consists of a one line LCD display as well as three LED’s. The information displayed
consists of a number of menus which can be accessed by means of the six push button switches located next to the
display. These menus contain user adjustable parameters, as well as feedback on the status of the system. Under
normal conditions, the screen will display the operating conditions which include the load current, the output bus voltage,
the state of the system (float or equalize mode) and whether the temperature compensated charging is active or not.
This screen is referred to as the ‘home’ screen.
35A 53.5V Fl
1.6 ALARM CONDITIONS

When one or more alarm condition exists, the following message will be displayed on the screen :
2 Press ENTER
This message indicates that there are 2 active alarms and they can be identified by pressing the ENTER button. This
message will alternate with the ‘home’ screen for 2 seconds every six seconds until the alarms are cleared or the
ENTER button is pressed. Once the ENTER button is pressed, the most recent alarm will be displayed, and the
remaining alarms can be observed by using the INC (increment) and DEC (decrement) buttons. Pressing ENTER again
will return the display to the ‘home’ screen.
1.7 MiniCSU MENUS
The MiniCSU display has four main menus. They are the ‘HOME’ menu, ‘RECT’ menu, ‘BATT’ menu and the ‘LOG’
menu. In any menu, when a parameter needs to be changed, press INC or DEC until the parameter to be changed is
displayed, then press ENTER – the value will start flashing. By using the INC and DEC buttons, the value can be
changed as required. When the right value is reached, press ENTER again. When attempting to change a parameter
which is not adjustable, the display will show ‘ Not Adjustable’ when the ENTER button is pressed.
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1.7.1 Home’ Menu
Under normal operating conditions, the screen will display information similar to the screen shown below. The screen
indicates a load current of 100A and an output bus voltage of 54.0V. The ‘FL’ indicates that the system is in float mode
while the ‘C’ shows that the temperature compensation is active.
The ‘x’ indicates that the MiniCSU has not calibrated the modules to perform passive current sharing yet, and may be in
the process of doing so. A calibration normally doesn’t take longer than 30 seconds to complete. If the ‘x’ remains,
conditions for executing a calibration are not favourable. For a module calibration to be executed, the load on every
rectifier module should exceed 25% of the module current capacity, and no SMR alarms should be present.
100A 54.0V FLCx
By pressing the INC button, one can scroll through the ‘Home’ menu options. The following screens will appear in
sequence :
Cabinet temperature displayed in degrees Celsius. If the cabinet Cabinet Temp 25degC
temperature sensor is not installed, the display will read ‘Not Used’
The following screens all show programmable parameters. To change a parameter press the INC button
until the desired parameter is found, then press ENTER. The parameter value will flash. Use the INC and
DEC buttons to set the parameter to the desired value. Press ENTER to save the new setting.
Cabinet temperature alarm level Cab Tmp Alrm 75C
Float voltage high level (Alarm triggers at this level) Volts Hi 56.0V
Float voltage low level (Alarm triggers at this level) Volts Low 45.0V
When the security function is active, any attempt to alter any Security On
programmable value will result in the display showing ‘Panel
Locked’ Panel Locked
Security disabled Security Off
Test function OFF Test Off
When the test function is activated, all LED’s on the MiniCSU will start MiniCSU GXXXXxx
flashing. The display will alternate between showing the software version
and a screen with all pixels enabled
Number of modules operational in the system No. of SMR’s 5
Interface MUIB type is specified in this screen. MUIB can host only 2 Interface MUIB
battery current sensors.
MUIB2 can host up to 4 battery current sensors. Interface MUIB2
This screen is used to set the amount of battery current sensors used in Num Batteries 1
the system (Factory set)
DC transducer full scale rating (Factory set) FS Batt I 300A
MiniCSU access code CSU# 234573

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Clock set: used to set the date and time of the MiniCSU clock 13/03/2001 15:50
Note: DD/MM/YYyy with a 24 hour clock
Modem enable: can be toggled On and Off Modem Off
The following 6 screens will only be displayed when the modem has been enabled.
Alarm report - can be toggled between ON and OFF. If ON, the system Alarm Report ON
will dial the first telephone number (PH1 below) if an alarm occurs. If PH1
does not answer, it will try PH2. If PH2 does not answer, it will try PH3. Alarm Report OFF
If PH3 does not answer, it will try PH1 again, etc.
Daily report, can be toggled from On to OFF. When ON, the system will Daily Report ON
dial in to the phone numbers below and log the status of the system at the
time indicated in the next screen Daily Report OFF
Time of daily report Daily Time 15:00
Phone 1: This number will be dialled when an alarm occurs. The number PH1 xxxxxxxxxx
can be up to 20 digits long. If the number is longer than 12 digits, it must
be entered in 2 screens.
Phone 2 PH2 yyyyyyyyyy
Phone 3 PH3 zzzzzzzzzz
Audio alarm disabled when off selected Audio Alm Off
When an alarm condition appears, the audio alarm will sound for a Audio Alm t-out
duration 2 minutes and then reset.
The audio Alarm will sound for the duration of active alarms. Audio Alm On
Selection of expansion function 1: off when no single phase monitoring Expan 1 Off
card is used
Second expansion on Home Menu to enable or disable 3 phase AC Expan 2 [ENTER]

Monitoring, Battery Monitoring and Site Monitoring if used
3 Phase monitoring OFF when no 3 phase monitoring card is used AC 3ph Off
Battery monitoring OFF when no battery monitoring card is used Batt Monitor Off
Site monitoring OFF when no site monitoring card is used Site Monitor Off
When the battery monitoring module is used, the following screens will be activated:
Batt Monitor On
The battery configuration must be entered here. The configuration refers Batt Conf 4 x 12V
to cell type (2, 4, 6 or 12V) and how the cells are connected to the monitor
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PCB. Refer to the section describing the battery cell monitoring Batt Conf 24 x 2V
The number of battery strings to be monitored is set as BCM batteries BCM Batteries 4
Set the high voltage threshold for the cell voltage. An alarm will be Vhi Cell 14.0V
activated if the set value is exceeded.
Similarly set the low voltage threshold for the cell voltage. An alarm will be Vlow Cell 11.0V
activated if the cell voltage is lower than the set value.
+dVc is a differential voltage threshold. It is the allowable percentage +dVc Cell 20%
voltage by which any particular cell or mono-block may vary from the
average.
-dVc is the low differential cell voltage threshold. -dVc Cell 20%
1.7.2 ‘SMR’ Menu
All information relating to the individual modules is available in a menu activated by pressing the ‘SMR’ button on the
MiniCSU front panel.
When a module is not connected or not switched on or is faulty, the SMR1 No Response
screen indicates that the module is not responding.
Warning : It is important to declare the correct number of modules in the rack, using the MiniCSU ‘home’menu.
SMR1 : When a module is on line and is operating normally, the module’s SMR1 24A
current will be displayed.
When the ENTER button is pressed momentarily, the module’s software SMR1 G1170cf 53C
version and heat-sink temperature are displayed.
Use the INC button to display the information of the other modules in the SMR2 24A
rack
The rest of the ‘SMR’ menu consists of screens which show the operating
parameters of the modules.
Default float voltage of the modules. This value cannot be changed in this SMR Float 54.5V
screen. It is automatically set to the sum of the system float voltage and the
drop voltage set in the ‘Batt’ menu.
As with the float voltage, this value is automatically set to the sum of the SMR Equal 56.5V
system equalise (boost) voltage and the drop voltage set in the ‘Batt’ menu.
The following screens show SMR operating parameters, which can be changed by pressing ENTER and INC or DEC.
Please note that any change affects all modules.
SMR high voltage alarm level SMR V Hi 55.5V
SMR low voltage alarm level SMR V Low 48.0V
SMR DC high voltage shutdown (HVSD) SMR HVSD 57.5V
SMR Current Limit SMR I Limit 50A
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Fault Reset : by pressing ENTER when this screen is displayed, any SMR Fault Reset
latching alarms, such as HVSD, is reset, and the affected modules will
restart unless they are damaged or faulty.
1.7.3 ‘BATT’ Menu
The Battery menu can be entered by pressing the ‘BATT’ button on the front panel. To return to the ‘home’ menu, press
the ‘BATT’ button again.
The following screens will be seen when pressing the INC and DEC buttons.
Battery current. If more than 1 batteries are used, press INC and the Batt1 0A
other battery currents will be displayed
Battery Temperature : If a sensor is installed, the battery temperature Bat Temp 25C
is shown in degrees Celsius
If the temperature sensor is not installed, the screen shows that the Bat Temp N/A
temperature sensor is not available
Any irregularity with the battery temperature sensor will generate an alarm Bat Temp Fail
if the sensor alarm at the end of this menu is activated.
Battery over temperature level (adjustable) Bat T Alarm 45C
Estimated state of charge of battery Qest Bat1 120Ah
Ampere-hour rating of battery Bat Rated 180Ah
Battery temperature coefficient in mV per Deg C per Cell must be BTC mV/C/C 4.0
entered here. Allowable range is 0.1 - 5 mV/C/Cell. When the BTC is
adjusted to 0mV, it is disabled BTC (Off) 0
Nominal BTC temperature level where no temperature compensation is BTC Nominal 20C
applied. Adjustable from 18°C to 27°C.
Not adjustable. The number of Cells per battery string are fixed at 24 for Number Cells 24
48V systems. This is a value that will be used in calculating the battery
temperature co-efficient.
Battery charging current limit for float voltages below Vdd which is the BILim Vb<Vdd 15
deep discharge voltage (see next screen)
Battery deep discharge voltage - Vdd Vdd Level 44.0V
Battery charging current limit applicable when the battery voltage BILim Vb<Vfl 40
is between Vdd and the float voltage Vfl.
System Float Voltage Setting Sys Float 54.0V
Battery charging current limit applicable during equalisation mode BILim Vb>Vfl 15
System equalise voltage level Sys Equal 56.0V
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Maximum system volt DROP used if no CSU is present Sys Drop 0.5V
Battery discharge alarm level. This level is set to a value to which B Dis Al 46.0V
the battery voltage falls to during a discharge. This is used to
generate an alarm indicating that the batteries are discharging.
If OFF, the system will not revert to equalise the mode. Change setting Equalisation Off
to On to enable the equalise function and the next 11 screens will dictate
the equalize function.
Equalisation initialised by voltage level V reached during discharge V Start Eq On
Equalisation is initialised when the battery voltage falls to this level V Eq Trig 46.0V
Equalisation is not initialised by voltage level V Start Eq Off
Equalisation is initialised based on charge lost to the load from the Q Start Eq On
Batteries
Equalisation is initialised when the charge out of the batteries is Qdis Trig 20Ah
greater than the level set in this screen
Equalisation is not initialised by the discharge A/H method.. Q Start Eq Off
Equalisation will end if charge current falls below this value EQ End 25A
When the equalisation end charge current is set to 0A, the equalisation EQ End (OFF) 0A
charge will last for the full duration and not end beforehand
Equalisation will end after the time interval set in this screen if Equal Dur 20Hr
no other method is used.
If no equalisation occurs due to a battery discharge for a period Equal Per 12Wk
longer than the interval set in this screen, an equalisation cycle is
initiated automatically.
An equalisation cycle can be manually started or stopped using these Manual Start EQ
screens
Manual Stop EQ
Low Voltage Disconnect Switch (LVDS) will open below this voltage LVDS Trip 42.6V
level
The LVDS will operate automatically at the voltage set above. LVDS Auto
To operate the LVDS manually, press enter and the ‘Auto’ will flash.
Use the INC / DEC buttons to select an ‘Open’ or ‘Closed’ state for LVDS Open
the LVDS switch
LVDS Closed
If Off, no battery temperature sensor irregularity will generate an alarm Sensor Alarm Off
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If On, the system will generate an alarm if the battery temperature Sensor Alarm On
sensor is disconnected or dysfunctional
All the following screens containing ‘BDT’ refer to the Battery Discharge Test function of the system. The test can either
be initiated by means of a PC running WinCSU software or automatically by the MiniCSU on a periodic basis. Some
factors other than bad batteries may cause the BDT to be aborted. These include incorrectly set parameters,
uncalibrated modules (see section 1.7.1), CSU alarms and a previous battery discharge within 100 hours before the test
was due to be performed.
Warning: Frequent and severe testing of batteries will shorten battery life.
If the BDT period is set to 0 days, the entire BDT function is disabled
and all relevant screens will not be available. BDT Off
Period between Battery Discharge Tests. This can also be seen as the BDT Per 30 days
frequency of BDT’s. Range: 1 to 365 days.
The time of day in which the BDT should be performed is set in the BDT Time 00:00
‘BDT
Time’ screen, where 00:00 will be 12 o’clock at night. Range: 00:00 to
23:59.
The duration of the battery discharge test can be set from 5min to 24h00min BDT Dur 3h00min
The discharge current set in this screen should be lower or equal to the BDT Curr 50A
minimum load current. Range: 1A to 5000A
Generally, a battery discharge test will be performed in the quiet hours of a day, like midnight, when the load current will
be lower than normal. Hence the BDT current should be set to 15% to 20% lower than the normal load current.
If the BDT current is set to 0A, the current controlled discharge of the BDT Curr Off
battery will be disabled. The battery discharge current will also result
to be equal to the load current.
The discharge test will be aborted when the battery voltage reaches the BDT End V 44.0V
‘End voltage’ level before the test duration expires.
Adjustable range: 36.0V to 48.0V. Aborting of the test due to an ‘End
voltage’ condition will generate a BDT fail alarm.
The BDT will be aborted when the remaining charge in the battery under BDT End Q 300Ah
test reaches the ‘End charge’ level before the test duration expires.
Adjustable range: 25Ah to 9995Ah. Aborting of the test due to an ‘End
charge’ condition will generate a BDT fail alarm
The result of the previous BDT is shown as the ‘Last BDT’. What follows
are some examples of the outcome of a previous discharge:
No previous discharge test was performed. Last BDT N/A
The previous discharge was manually aborted. Last BDT Aborted
The previous BDT was aborted due to a low cell voltage that occurred Last BDT Cell V
before the duration of the BDT expired. (Only when a Battery Cell
Monitor is available). This message will be accompanied by a BDT fail
alarm indicating a possible bad cell or battery.
The previous BDT endured for the full duration, so the battery has passed Last BDT Pass
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the test.
The previous discharge was automatically aborted due to an end voltage Last BDT Fail
or end charge condition. This message will be accompanied by a BDT fail
alarm indicating a possible bad battery.
To clear a BDT fail alarm find this ‘Reset Screen’ below the BDT result BDT Alarm Reset
screen and press ENTER when it is displayed.
More details are available about the result of a discharge which can be obtained by pressing ENTER when the result
screen is displayed.
The first screen that will be available will be the date of the pervious BDT. Test 02/08/2001
When INC is pressed, more information is available
Duration of the previous discharge test. Last Dur 37min
Battery voltage when the previous BDT has ended. Last EndV 47.8V
Charge remaining in the battery at the end of the BDT. End Q B1 147Ah
1.7.4 ‘Alarms Log’ Menu
The most recent alarm conditions are stored in the MiniCSU, and can be viewed at any time by pressing the Alarms Log
push-button. The screen will number the alarms with the most recent alarm being number 1. As shown below, the screen
will show the number of the alarm followed by the alarm name.
1 AC Freq Fault
If the INC button is pressed within 2 seconds, the second alarm (if one exists) will be displayed, etc.
If no button is pressed for 2 seconds, a screen will appear which shows the alarm sequence number with the date and
time when the alarm occurred. To therefore view the date and time of a certain alarm, scroll to that alarm using the INC /
DEC buttons and wait 2 seconds for the date and time to appear.
1 10/11/2001 15:32
If the alarms log needs to be cleared, press ENTER when in the Alarms Log menu and the following screen will appear :
DEC to Clear Log
If the DEC button is pressed, the log will be cleared and the following screen will appear :
No Alarms
1.8 MiniCSU SECURITY
To avoid any settings being changed by unauthorised persons, two levels of security are provided. When the security
function is activated on the MiniCSU, the ENTER key is ‘locked’ and no changes can be made to any settings. To
‘unlock’ the keypad, press INC, DEC and ENTER in this sequence for 3 to 5 seconds and then disable the security
screen in the home menu, or change the necessary parameter/s.
Each MiniCSU can also be given its own unique code (up to 7 digits – see ‘home’ menu above), which must be known
when using the WinCSU remote monitoring software (see next section), otherwise the MiniCSU will not allow access to
the user. Additionally a password can be set up in the WinCSU application, which would prevent any tampering with the
levels in the MiniCSU, by use of a modem.
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1.9 Mini USER INTERFACE BOARD (MUIB)
The MUIB is the interface board between the MiniCSU and all its peripherals. The MUIB has the following inputs and
outputs :
INPUTS : Power for the MiniCSU

Analogue output voltage
Single phase AC monitoring data
LVDS status
Circuit breaker status (optional)
Battery current information
Battery & ambient temperature information
OUTPUTS: 5 Relay alarm outputs

LVDS Drive signal
1.10 REMOTE MONITORING
Three levels of remote monitoring are provided : potential-free relay contacts, RS232 link as well as dial in monitoring via
modem.
Relay Contacts
Five relay outputs are provided each with access to the normally open, normally closed as well as the common terminal.
These relay contacts provide information about five different alarms, namely:
Relay 1 : DC Over Voltage
Relay 2 : Battery Low
Relay 3 : System Fail:
Mains available BUT battery discharging (Rectifiers Failed)
Or
MiniCSU failure
Or
LVDS open
Relay 4 : Rectifier Module Fail
Relay 5 : Battery Integrity Fail or Battery over Temperature or Battery Cell Monitor alarm.
Remote Monitoring via Modem
This monitoring requires a Modem to be connected to the system. By using the WinCSU application software, an
operator is able to dial in to any site, which contains a rectifier cabinet with a MiniCSU and a modem and interrogate the
system.
The operator will be able to see what levels have been programmed into the MiniCSU, as well as having real time
information about : Present status of the system
All programmed system parameters
All alarm conditions
Input voltages, currents and frequency (if the AC monitoring is installed)
Battery cell voltages (if the battery monitoring is installed)
Site conditions (if the site monitoring board is installed)
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X18 X40
X28 X31
T1
X17 X32 X39
T2 X22
X1 X2 X64 X65
X23 X33 X34 X44 X45 X50
Conn # Conn Label Class Comments Conn # Conn Label Class Comments
T1 Vcon Digital N/C Functions of X2 X32 1 PHASE AC Anal/Dig 10-way ribbon cable from 1 phase AC monitor
module
T2 Vcon Ext. Digital N/C Functions of X2 Extension X33 USER 1 Digital User defined i/p; isolated aux. Contact or similar
X1 MiniCSU Anal/Dig 34-way ribbon cable to MiniCSU X34 USER 2 “ “ “
X2 DC Over Voltage Digital Relay 1 Contacts; N/O, N/C, Com X44 USER3 “ “ “
Battery Low “ Relay 2 Contacts; N/O, N/C, Com X45 USER4 “ “ “
System Fail “ Relay 3 Contacts; N/O, N/C, Com X28 AN 1 Analog Spare analog I/P - 0 to 5VDC
Rectifier Module “ Relay 4 Contacts; N/O, N/C, Com X31 AN 2 “ Spare analog I/P - 0 to 5VDC
Fail
Battery Integrity " Relay 5 Contacts; N/O, N/C, Com X39 BATTERY 1 “ Battery current transducer
Fail or Battery over
Temperature
X17 AMB. TEMP. Analog Temp. Transducer X40 BATTERY 2 “ Battery current transducer
X18 AMB. TEMP. Analog Temp. Transducer X50 POWER I/P “ System voltage sensing and DC power input for
MiniCSU
X22 C.B. TRIP Digital Aux contact from load CBs X64 LVDS Aux Digital Aux contact from LVDS contactor
X23 BAT. SW. Digital Aux contact from Batt. CBs X65 LVDS Coil Digital Drive for contactor or similar
Figure 3. MUIB Connection Diagram
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1.11 LOW VOLTAGE DISCONNECT SWITCH (LVDS)
The system has a low voltage disconnect switch. This is included to protect the batteries from a very deep discharge by
disconnecting the load from the battery after the battery has discharged to a pre-programmed voltage level for example
in the case of an AC fail condition. The low voltage disconnect switch consists of a high power contactor which is
controlled by the MiniCSU. The voltage at which the LVDS operates is adjustable either from the front panel of the
MiniCSU (see ‘Batt’ Menu) or by RS232 / modem.
1.12 TEMPERATURE SENSORS
Two temperature sensors are provided with the system. Both sensors plug directly into the MUIB card and they are used
to measure the system ambient and the battery temperatures.
1.13 DC DISTRIBUTION
The DC distribution panel contains both the negative and positive connection points for the load and four battery strings.
The negative distribution contains the following :
Load connection
Negative : 1 x 100A three pole isolator (250A DC total)
Battery connections
Negative : 4 x 100A single pole circuit breakers.
The positive distribution consists of a bus bar with provision for load and battery return cables.
1.14 AC CONNECTIONS
All AC connections are made on the AC distribution panel. The AC connections to the rack are made to a three pole (3 x
60A) circuit breaker for the three phases and screw type terminals for the neutral and the earth wires. Maximum current
per phase at 150V AC input is 42A for 50A modules.
1.15 OUTPUT EARTH
The positive output is the earth for the system. The positive output terminal is earthed during the installation, therefore
care must be taken when earthing any other part of the system. The cabinet is earthed on the positive busbar on the DC
distribution panel.
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2 REPAIR AND MAINTENANCE

2.1 INSPECTION
It is sufficient to limit the servicing of the system to a visual inspection whenever the batteries are serviced. An inspection
can also be done whenever the site is visited or every six (6) months whichever comes first. This inspection would
include:
- check the fan filter for clogging; the filter may be cleaned by rinsing in water and drying before it is returned to
the cabinet;
- check the wiring harness for any cracked, cut or burned insulation;
- check all visual cable terminations for loose connections;
- check the cover panels for any damage;
- check for missing screws or nuts;
- check for hot CB’s which may indicate high load or loose connections.
2.2 SITE REPAIRS
On site repairs should be limited to replacement of faulty equipment. This would involve exchanging one or more of the
following : a PSU (up to a maximum of five), a MiniCSU, a MUIB card or a modem. The components of the system are
designed in such a way that they can be replaced on a live system without having to switch the system off.
2.3 MiniCSU Alarms
The following is a list of possible alarms that can occur on the MiniCSU :
R = Red LED on A = Amber LED flashing
Table 1: MiniCSU Alarms
ALARM DESCRIPTION REQUIRED ACTION LED

SMR Alarm PSU failure ¾ Identify which SMR is faulty, determine A
the nature of the alarm and take required
action.
SMR HVSD SMR shutdown due to output over- ¾ Reset SMR – if problem persists, replace A+R
voltage SMR
UNIT OFF SMR is off A+R
SMR Comms Fail One or more SMR’s are not ¾ Check if correct number of SMR’s has A
responding been programmed in the MiniCSU
¾ Pull out and replace affected SMR
¾ If problem persists – check comms
connections to MiniCSU
Power Limit SMR is in power limit ¾ Switch SMR off until heatsink has cooled A
down
Current Limit SMR in current limit ¾ Check that there is no overload on system A
AC Volt Fault AC voltage not present ¾ Check if input circuit breakers have A+R
tripped
¾ Check if AC voltage is present
¾ Check wiring harness
Volts Low System output voltage lower than ¾ Measure output voltage A
pre-set value ¾ Check if Batt I-Limit alarm active
¾ Check if output current exceeds maximum
system current
¾ Check system float voltage setting on
MiniCSU
Volts High System output voltage higher than ¾ Measure output voltage A
pre-set value ¾ Check the float voltage setting on the
MiniCSU
¾ Switch off the AC circuit breaker of one
SMR at a time until the alarm is cleared
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¾ If the alarm does not clear, the cabinet

must be re-commissioned
Batt Temp High Battery temperature exceeds pre- ¾ Check air-conditioner A

set value
Cabinet Temp Cabinet temperature exceeds pre- ¾ Check fan filter and clean if needed. A
High set value ¾ Check air-conditioner
Temp Sensor Fail Temp sensor failure ¾ Replace temperature sensor A+R
LVDS Open Low Voltage Disconnect Switch ¾ Check for AC Fail condition and battery A
open voltage
¾ Check LVDS voltage setting on MiniCSU
¾ Check LVDS status on MiniCSU
¾ Check drive to LVDS
Batt Disch Battery is discharging ¾ Check for AC Fail condition A
Batt I-Limit System output voltage reduced to ¾ Check if system voltage rises as batteries A
limit battery charge current receive charge.
¾ Check for faulty battery
EEPROM Fail MiniCSU failure ¾ Reset MiniCSU by disconnecting power to A
MiniCSU and reconnecting it.
¾ If the problem persists, replace MiniCSU.
2.4 REPLACING MODULES
When replacing a module in the field (in an operational cabinet), the procedure below must be followed.
Switch off the AC circuit breaker of the faulty module.

Remove the faulty module by lifting the handle and pulling the module toward you.
Insert the new module into the vacant slot in the power rack.
Switch on the new module’s AC circuit breaker and wait for it to start up.
When adding modules to an existing installation, plug the new module into the next open slot and switch on the
corresponding AC circuit breaker. Take note that the number on SMR’s programmed in the MiniCSU must be updated.
Note : The MiniCSU takes control of any new SMR’s as soon as they are plugged in, therefore no user adjustments are
required when replacing faulty SMR’s.
2.5 BATTERY REPLACEMENT
NOTE: For safety it is advised that the C.B. always be switched of first. Then the polarity connected to earth always be
disconnected first and connected last. In this case it is the positive terminal. Only then switch the C.B. back on.
Although the battery is external to this system, in the event of having to replace a battery on a live system, the following
procedure must be followed:
Table 2: Battery Replacement
STEP OPERATION
1 Switch off the circuit breaker of the battery that is to be replaced.
2 Remove the lead from the positive terminal of the battery and cell monitoring wire.
3 Remove the negative lead from the negative terminal of the battery and cell monitoring
wire.
4 Remove interconnecting links and the battery cell monitoring wires and remove the
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battery
5 Install the new battery and connect the interconnecting links and the corresponding
battery cell monitoring wires to the battery terminals.
6 Reconnect the negative lead and cell monitor wire to the negative battery terminal.
7 Reconnect the positive lead and cell monitor wire to the positive battery terminal.
8 Close the battery circuit breaker.
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3 INSTALLATION AND COMMISSIONING

3.1 INTRODUCTION
This manual describes the processes to be used when installing a GT505NG Rack Power System. The equipment is
shipped from the factory fully 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.
3.2 INITIAL PLANING REQUIREMENTS
If the installation is an upgrade, i.e. adding a second or third cabinet, then a special cabinet will be needed with its own
installation procedures. Contact SAAB GRINTEK if this needs to be done. It is not advised for this cabinet to be used in
parallel with two separate controllers. The add on cabinets will not have a MiniCSU, and have a larger current sensor
and a bigger LVDS.
Before deciding on the final placement of the racks the following must be taken into consideration:
⇒ Connection to AC Mains Input.

⇒ Rack clearances/height.
⇒ Positioning (e.g. not directly under an air conditioning unit)
⇒ Rack accessibility.
⇒ Ventilation.
⇒ Max expected DC load.
⇒ Correct battery sizing and configuration due to max load.
Before starting the installation the following information is required:
⇒ Mains AC input Voltage. The GT505NG POWER SYSTEM is designed to operate at a nominal input voltage of
220VAC phase to neutral (380VAC 3phase + neutral). The input voltage range should be between 150VAC –
275VAC under all conditions
⇒ Estimate the maximum load that the system will impose on the mains input. The maximum input current of the
GT505NG POWER SYSTEM will be under full load at the lowest input voltage (150VAC) and will be
approximately 42A per phase (3phase) with 50A modules fitted. Make sure that the mains connection to the AC
switchboard will handle the additional load applied by the newly installed system under full load.
⇒ A mains earth is mandatory. Earth-leakage protection must NOT be used.
3.3 Preparation
3.3.1 Rack preparation
Inspect the rack for any mechanical damage that could interfere with the internal wiring and proper alignment of the
SMRs.
3.3.2 Ventilation
The GT505NG POWER SYSTEM is fitted with ventilation holes in the lid and has fan intakes. Please ensure that these
ventilation holes are not obstructed to ensure reliable system operation.
3.4 Site Preparation
Ensure that the site is clear of obstructions and ready for the racks to be placed. Cables should be cut to length and any
cable trays or ducting prepared and mounted. Place and secure rack/s into position. Mount any interconnecting cable
trays or ducting.
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3.4.1 Connect to Mains Switchboard
The GT505NG POWER SYSTEM can be supplied through either an isolator or a circuit breaker. At the switchboard,
install isolating switch (with proper rated fuse on each phase), or circuit breaker.
Secure the switchboard to prevent against accidental application of power to the rack.
Ensure that the switch is switched off. Position the rack at the designated position. Remove the retaining screws and AC
Distribution cover as indicated in figure 4.
Using a cable of correct cross section (Pref. 10mm², 6mm² min), connect the three phases (L1, L2, L3), neutral (N) and
earth (E) from the isolator to the rack in the position shown in Figure 4. The cable can be routed through the top cover or
through the side aperture (feed wire through the trunking provided on the left side of the cabinet.). Do not apply power
to the rack at this time. At this point pay particular attention to checking all supply connections, including the earth
connection, and all nuts and bolts for tightness.
3 Phase Surge Input Input Module AC

Live Input Protection Earth Neutral Circuit Breakers
Figure 4. AC Distribution
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3.4.2 DC Connections and Building Earth
Figure 5 shows the DC connections and the building earth connection to the positive DC busbar.
Provision is made to drive a DC fan and a DC emergency light from the rack power system. These devices can be
connected to the DC distribution rail as indicated on the figure below. When a mains failure occurs, the relay will close
and the fan and light can be controlled by the respective circuit breakers.
Load Isolator LVDS DC Current Battery circuit Circuit breakers for

Transducer breakers DC light and fan
Load Positive Bus bar Battery Cell Monitor Control relays

(Building Earth) loom connection for DC light and fan
Figure 5. DC Distribution
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3.5 Remote Alarms
Release the two retaining screws on the interface panel and slide the tray forward. Connect the remote alarms to the
connector on the MUIB board as indicated in figure 6 and table 1. NOTE: Relay 3 has inverted function, i.e. the relay
contacts, as shown on the PCB is shown in the alarm condition.
Table 3: Remote Alarm Relay connections
Connector Description Function Name

pin
1,2,3 Relay 1 DC Over Voltage
4,5,6 Relay 2 Battery Low
7,8,9 Relay 3 System Fail (Inverted function)
10,11,12 Relay 4 Rectifier Module Fail
13,14,15 Relay 5 Battery Integrity or Battery Over Temperature
MUIB Alarm connections Battery cell monitoring
RS232 Port
MiniCSU
Figure 6. Interface Tray
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3.6 Battery Installation
Ensure all battery cables are of equal thickness and length as this is critical to the longevity of the batteries. The rectifier
cabinet should be properly bolted to the battery cabinet. When placing the batteries in the cabinet, take care not to
damage the battery cell monitoring wires. Take extreme care that the batteries are connected correctly. Connect the
battery cell monitoring wires to the battery terminals. See figure 7. Note : The cable must be routed over the top of the
batteries from the right.
Yellow/ Blue Purple Brown Black

Green -C3/+C4 -C2/+C3 -C1/+C2 +C1
-C4
Figure 7. Battery Cell Monitoring Wiring
+C1
-C4
-C3/+C4
-C2/+C3
-C1/+C2
- +
Figure 8. Battery Cell Monitoring Terminations
The battery temperature sensor should be bolted to the centre of the battery string to the positive pole. This is normally
the positive pole of the second mono-block from the left.
3.7 DC Load Terminations
Connect the load distribution positive to the positive (+) bus bar and the load negative distribution to the output of the
load Isolator as indicated in figure 5.
3.8 Install Switch Mode Rectifiers (SMRs)
Remove SMR’s 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.
Before installing SMRs into the rack, ensure that all circuit breakers on the AC distribution are off.
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Once the modules have been inserted into the rack, the installation checklist in Appendix A can be
filled in, after which the commissioning procedure below can be followed.
3.9 Default Values
When the MiniCSU starts up the first time it will be loaded with default values, see table 4.
Table 4: Default Values
Description Value Units

System Voltage Settings
Float Voltage 54.5 V
Equalize Voltage (Battery Boost) 56.0 V
High Voltage Alarm 57.5 V
Low Voltage Alarm 45.0 V
LVDS Trip Voltage 42.6 V
Drop Voltage 0.5 V
Cabinet Temperature High 75 °C
All Equalize features Off
Alarm Report Off
Daily Report Off
Modem Off
SMR Parameters
High Alarm 57.0 V
Low Alarm 48.0 V
SMR HVSD 58.0 V
Current Limit 50 A
Battery Settings
Battery Rating – depends largely on the type and amount of batteries 620 Ah
Number of Batteries 1
I-Bat FSD (Factory setting) 300 A
Battery Temperature Compensated Charging (BTC) On
BTC Compensation Value 4 mV/C/C
BTC Center 20 °C
Battery Discharge Voltage 46.0 V
Deep Discharge Voltage 44.0 V
Battery Temperature Alarm 40 °C
Battery Current Limit – Float 40 A
Battery Current Limit – Equalise 15 A
Battery Current Limit – Deep Discharge 15 A
Battery Temperature Alarm 45 °C
Battery Temperature Sensor Alarm On
Battery Cell Monitoring Settings

Cell Configuration 4 x 12V
BCM Batteries 4
V high Cell 14.0 V
V low Cell 11.0 V
+dVc Cell 20 %
-dVc Cell 20 %
Log Interval 1 Min
4. Commissioning
Complete commissioning checklist (Appendix A) and fax to SAAB Grintek, for the attention of the configuration
department on fax number +27 12 674 3511.
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APPENDIX A
INSTALLATION AND
COMMISSIONING CHECKLISTS
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COMMISSIONING CHECKLIST
SITE NAME
SITE LOCATION
CUSTOMER
CABINET PART NUMBER 840060-00000

CABINET SERIAL NO
MiniCSU 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
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 Check that the systems are positioned as per floor plan
2 Check that AC cable is correctly installed between the

power system and the AC outlet / distribution board
3 Tightness of all bolts, nuts, screws, connections &
terminals
4 Check for proper insertion of wires on all terminals
5 Neatness of PVC channels, cabling & wiring
6 Check correct polarity of load connection
7 Check correct polarity of battery connection
8 Check damages to batteries & cabinets
9 Check that the earth cable from the power systems is

connected to the earth bar of the site
10 Check that the earth bonding cables are fixed
11 Check that the wiring is not exposed to sharp points &

cutting edges
12 Check that the dust filter on the fan shelf is clean `
13 Check rating of the circuit breakers
14 Inspect the system in general for neatness &

completeness
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COMMISSIONING CHECKLIST
GT505NG Power System
The following battery checks should be done before the rectifier is to be commissioned.
DESCRIPTION VALUE PASS/

FAIL
1. Measure the terminal voltage of each 12V battery.
The open circuit voltage for the batteries, should not be lower
than 12,5V.
2. The batteries used in one string should not differ in voltage by
more than 0,2V. I.e. if the highest voltage in a string is 13V the
lowest voltage should not be lower than 12,8V.
3. Note the measured voltages for all the strings used on this
system in the table below.
3.1. Battery 1 Battery 2 Battery 3 Battery 4
String number 1
String number 2
String number 3
String number 4
String number 5
String number 6
Refer to the Manuals supplied with the equipment for more detailed information.
DESCRIPTION VALUE PASS/

FAIL
1. Ensure that all circuit breakers in the cabinet are in the OFF
position
2. Slide the correct number of modules in the rack and record 1-5
the number of modules in the rack.
3. Switch the AC isolator(s) / circuit breaker(s) in the DB ON.
Switch the 3-phase MAINS INPUT circuit breaker in the
cabinet ON.
4. Switch all the SMR’s ON and check that all SMRs start up.
The amber LED on all SMR’s should flash.
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. Each installation must have
its own unique number. NOTE 1
7. Check that all the settings in the Mini-CSU are correct as
given below. NOTE 5.
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HOME MENU
8.1. Cabinet temperature Not adjustable
8.2. Cabinet temperature alarm 75°C
8.3. High volt alarm 57,5V
8.4. Low volt alarm 45,0V
8.5. Security OFF
8.6. Test OFF
8.7. No of SMRs Number in rack
8.8. FS Current 300
8.9. Number of batteries 1
8.10. CSU# Depends on site.
(see par 6)
8.11. Modem ON (If telephone
8.12. Alarm report line is available,
8.13. Daily report depends on site)
8.14. Daily time Remember to enter
phone numbers
where necessary
SMR MENU
8.15 SMR Float Not adjustable
8.16 SMR Equal Not adjustable
8.17 SMR V Hi 57,0V
8.18 SMR V Lo 48,0V
8.19 SMR I limit 50A
8.20 SMR HVSD 58,0V
BATTERY MENU
8.21 Bat Temp (Battery Temperature) Not adjustable
8.22 Batt T Alarm (Battery Temperature Alarm) 45°C
8.23 QEst Batt 1 Not adjustable
8.24 Batt Rated Depends on
batteries (Rating of
sum of all battery
banks connected)
8.25 BTC (Battery temperature compensation) ON/OFF as
required –
remember to set
BTC values if
required
8.26 BILim Vb<Vdd 10 – 15% of
Battery rating
8.27 Vdd Level (Battery deep Discharge Voltage) 44V
8.28 BI Lim Vb<Vfl Between 7% and
max15% of Battery
rating
8.29 Sys Float (System float voltage) 54,5V
8.30 BI Lim Vb>Vfl Between 7% and
max15% of Battery
rating
8.31 Sys Equal (System equalization voltage) 56,0V
8.32 Sys Drop. (System voltage drop) NOTE 3 ±0,5V
8.33 B Dis Al (Battery discharge alarm voltage) 46,0V
8.34 Equalisation OFF*
8.35 V Start Eq* OFF
8.36 V EQ Trig* 48V
8.37 Q start Eq* OFF
8.38 Qdis Trig* 15Ah
8.39 EQ end* OFF
8.40 Equal Duration* 20H
8.41 Equal per (Equalisation period)* 12Wk
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8.42 Manual Start EQ* Do not press

ENTER or
Equalization will
start
8.43 LVDS Trip 42,6V
8.44 LVDS Auto
8.45 Sensor Alarm ON
8.46 BDT Per 30 days
8.47 BDT Time 00:00
8.48 BDT Dur 3h00min
8.49 BDT Curr 50A
8.50 BDT End V 44.0V
9. Measure the output voltage with a DVM and record the value.
10. Record the displayed voltage on the Mini-CSU.
11. Connect a load and measure the load current with a current
clamp, and record the measured value.
12. Record the displayed load current on the Mini-CSU.
13. Active current sharing. NOTE 5 ±5% accuracy
within band
Passive current sharing. ±15% accuracy
within band
14. CHECK THE FOLLOWING ALARMS
14.1 Switch the Battery Circuit breaker ON
14.2 SMR URGENT . NOTE 6
14.3 HIGH VOLT . NOTE 7
14.4 LOW VOLT . NOTE 8
14.5 AC FAIL
Load shed. NOTE 9
14.6 Battery current limit. NOTE 10
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 Mini-CSU
15. Return all settings to the correct settings after the alarms are
tested. (Refer to section 8 of this checklist)
16. Disconnect the PC and reconnect the modem to the Mini-
CSU.
* If equalisation is used these values will be applicable.
NOTE 1: Access code can be changed by scrolling through the HOME (Default) screen of the Mini-CSU. Press the
“INC” or “DEC” buttons until CSU# is displayed. To change the code, press ENTER until the desired digit
flashes. Press the INC and DEC pushbuttons until the correct value is displayed, press ENTER to accept and
move to the next digit. Press enter after the last digit to save the new code. This number must be different for
each cabinet/installation.
NOTE 2: To scroll through the HOME screen, Press “INC” 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 through the BATTERY
screen, press “BATT” and then “INC” or “DEC”. To change a value, press ENTER and use the INC and DEC
pushbuttons to change, press ENTER again to accept.
If a PC is available all the values can be changed by using WINCSU software.
Disconnect the modem from the Mini-CSU and connect a RS232 cable from the PC to the Mini-CSU.
Open the WinCSU program.
Make sure that the access code which was entered in Par 6 is the same as in WinCSU. If not, change the
Access code in WinCSU.
Click on CSU menu option.

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Click on DISPLAY 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 Mini-CSU.
Go to SMR PARAMETERS
Click on DISPLAY 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 3: To determine this value, the voltage between the output of the SMRs and the batteries and the voltage
between the output of the SMRs and the load must be measured. Use 0.5V if the measured value is lower
than 0.5V.
NOTE 4: Connect a dummy load to the system and check that current sharing is done. It may be necessary to increase
the load to above 75% of full load for the active current sharing to come into operation.
NOTE 5: If no Mini-CSU is connected the system will do Passive current sharing. If a Mini-CSU is connected and for
some reason active sharing is not operational, an x will be displayed on the MiniCSU
NOTE 6: Switch off one module. The red LED will light up.
NOTE 7: Set the float voltage 0,5V higher than the high volt alarm value.
NOTE 8: Set the float voltage 0,5V lower than the low volt alarm value with the batteries still connected. Set float
voltage to the correct value after this test is done.
NOTE 9: Set the LVDS to 48V and switch the 3-phase 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 10: Once the AC is switched back ON, this alarm could appear
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APPROVAL SHEET
Installation Performed By :
Company :
Designation :
Name :
Sign :
Date :
Commissioning performed by :
Company :
Designation :
Name :
Sign :
Date :
System inspected by SAAB GRINTEK QA :
Company : SAAB GRINTEK
Designation :
Name :
Sign :
Date :
System Inspected by CUSTOMER QA :
Company :
Designation :
Name :
Sign :
Date :
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APPENDIX B
WIRING DIAGRAM FOR
GT505NG POWER SYSTEM
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= Chassis metal work
AC distribution Module shelf. (4)

Positive Load Return
Positive bus-bar
25A C/B bus-bar Negative
3Ø C/B 60A
E [2 * 3 x 12] bus-bar
Red (4) Red (4) L + [2 * 3 x 12]
Rectifier Fan
N
Phase 1 Input Red (6)
White (4) White (4) 1 Baffle
-
Phase 2 Input White (6)
Blue (4) Blue (4)
2 Wire fan cable
Phase 3 Input Blue (6) Red (4) Red (4)

E
+
White (4)
Blue (4)
White (4) White (4)
Rectifier
Red (4)
L
N 2
Black (4)
Surge -
Protection Yellow / Green (4) 2 Wire fan cable
Black (4)
Black (4)
E
Neutral Input Black (4) +
Black (4) L Rectifier
Black (4) N 3
-
Yellow / Green (4) 2 Wire fan cable
Yellow / Green (4)

Yellow / Green (4) E
Earth Input +
Yellow / Green (4) L Rectifier
Yellow / Green (4) N 4
Yellow / Green (4)
-
2 Wire fan cable
E
+
L Rectifier
Loom connections N 5
to battery cells -
2 Wire fan cable Main DC
Interface Shelf System Ambient distribution
Bat 4 Temp Sensor Current
Sensor Negative
13 12 11 10 9 8 7 6 5 4 3 2 1
Yellow (0,5)
Load Isolator
Orange (0,5)
3Ø Isolator 100A/Pole
Red (0,5) Bat 4 [6 x 20]
Brown (0,5) (95) [6 x 20]
Bat 3 Black (0,5)
X43
Yellow (0,5)
Relay with N/C Contacts
Orange (0,5)
Red (0,5)
Bat 3 2 x 10A CB
Brown (0,5)
Bat 2 Black (0,5)
BCM
(95)
13 12 11 10 9 8 7 6 5 4 3 2 1
(16) AC PHASE 1 AC NEUTRAL

Yellow (0,5)
Orange (0,5) [6 x 20]
Bat 1 Red (0,5) Bat 2

Brown (0,5) Positive Return Negative
Black (0,5) bus-bar Battery C/B
X9
4 X 100A C/B
Yellow (0,5) [6 x 20]
Orange (0,5) LVDS
Red (0,5)
Brown (0,5)
Bat 1
(95)
Black (0,5)
16 Way Ribbon Cable
Connection for
modem
Front panel
4 Wire Comms
Black (0,5)
Black (0,5)
Grey (0,5)
Grey (0,5)
Red (0,5)
Red (0,5)
Yellow (0,5)
Orange (0,5)
Brown (0,5)
Green (0,5)
switch
1 2 3 4 5 6
DB9 1 2 3 1 2 1 2 1 2 3 4 5 1 2 3 4 5 1 2 1 2 3
X80 X1
RS232 X20 X22 X23 X50 X39 X64 X65
X73
1 2 3
34 Way Ribbon Cable

MiniCSU MUIB
X17
Output X18 X2
X43 X1
1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Alarm connections
Battery Temp
NOTE : Values in round brackets indicate wire sizes in sqr mm and Sensor
Values in square brackets indicate bus bar dimensions in mm.
If connected in parellel, it is indicated by 2 * or 3 * .
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APPENDIX C
OPERATING MANUAL FOR
BATTERY CELL MONITOR
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1 INTRODUCTION
The Battery Cell Monitor (BCM) is an add-on module for the CSUm. It is used to monitor individual cells of a battery
during float or equalisation operation, or during a discharge. Each BCM unit is capable of monitoring up to 24 cells. A
total of four BCM units can be used to monitor 4 battery strings of 24 cells each.
Using the ability of the CSUm to communicate to a remote or local PC, cell voltage data accumulated during a
discharged can be transferred to a PC and saved. The cell voltages can also be viewed in real time when the CSUm is
connected to a PC. The PowerCraft software that is running on the PC can display the cell voltage data in various
convenient formats to ascertain the state of health of batteries.
In the event that the battery behaves in a way which is less than ideal during a test or actual discharge, a number of pre-
programmed parameter levels are used to generate alarms which are annunciated on the CSUm front panel by a LED
and screen message and remotely via voltage free relay or via the RS-232 communications port which can connect
directly to a PC locally or remotely via a modem.
1.1 Main Features of the BCM
The principle features of the BCM are as follows:
• Up to 24 cells can be monitored by a single BCM module. Cell voltage setting can be 2V, 4V, 6V
and 12V.
• Up to four BCM board can be connected to a single CSUm.
• Individual cell voltages of a battery can be viewed on the CSUm display in real time. The cell
voltage rounded to the nearest 5mV (applies only to 2V range) is displayed together with the cell
number and its percentage deviation from the average cell voltage of the battery.
• All the cell voltages can be displayed in a “Histogram” format on a local or remote PC using
PowerCraft software.
• The PC can display the real time cell voltages or cell voltages stored during a previous discharge.
• A line graph of cell voltage versus time can be selected as the PC display to observe the manner in
which the cell voltages as a whole decreased during a discharge. It is also possible to select for all
the cell voltages to be displayed (in different colours) or for a particular cell voltage to be displayed
together with the average cell voltage as a function of time.
• As the BCM is permanently connected to the batteries, an automatic, daily or weekly down-loading
of the steady state cell voltages for the different batteries in a system ban be made to a remote
monitoring PC.
• A discharge can be initiated either locally or remotely by triggering the rectifiers in the system into
“battery discharge test” mode. In the mode the rectifier float voltage is set to a lower value which
ensures that the batteries are carrying the load, but not too low so that in the event of battery failure
during the test, the rectifiers will prevent the voltage from falling below the set voltage, which
enable the load to continue functioning correctly. This test can be arranged to occur in non critical
times and is used to monitor the condition of the battery strings.
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2 BCM SPECIFICATIONS
Battery configuration options: (48V systems): (24V systems):

24Cell x 2V, 12Cell x 4V, 8Cell 12Cell x 2V, 6Cell x 4V, 4Cell x
x 6V, 4Cell x 12V 6V, 2Cells x 12V
Maximum battery voltage: 75Vdc
Number of cells: 24 maximum per board
Cell Voltage selection 2V (max input: 3.33V)
(DIP switch setting on the board):
4V (max input: 6.66V)
6V (max input: 10V)
12V (max input: 20V)
Note: “Cell” can mean both single battery cell or monoblock.
Accuracy for 1 year: ± 10mV at 0°C to 40°C

Resolution: 5mV per cell (2V, 4V, 6V range),
10mV per cell (12V range)
Sampling interval range for discharge log: 1 - 60 minutes
Power supply: from CSUm ±15V
Maximum distance from CSUm: 10m (of 16 way ribbon cable)
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3 INSTALLATION OF BCM
3.1 Preparing the battery for connection to the BCM
Battery cells are not connected to the BCM directly. 56Ω/PR02 resistors are inserted between BCM and the cells to clear
any fault that would arise if a battery cell lead were shorted. The resistors are mounted as near as possible to the battery
terminal in order to protect as much of the wiring as possible. A typical connection is shown Figure C1.
Figure C1: Lead termination at battery cell.

The M6 ring lug (depending on type of battery) is screwed onto the cell terminals. The other end of the wire is screwed
onto the 5.0mm pitch screw terminals. Details on how the cells connect to the BCM board are discussed in later
sections.
3.2 Installing the board
Generally, the BCM board is located close to the batteries so that it is not necessary to run large number of wires for
long distances. The 16 way ribbon cable connecting to the CSUm can be up to 10m long, but should be connected
directly to the CSUm, instead of connected at the end of another chain of peripherals. This helps reduce errors. This
connection can be achieved by using a ‘daisy chain’ ribbon where the one cable has connectors placed part way along
its length as well as the ends.
Mount the BCM using the standoffs supplied in an area protected from mechanical and electrical hazards. If the rack
does not provide any holes or studs for mounting the BCM, use figure C2 as a template for drilling the mounting holes.
Be sure to allow at least 25mm space around the board to allow for wiring to the board.
Figure C2 BCM mounting hole locations.

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3.3 Dip-Switch Selection of Cell Voltages

Battery configuration is selected via the main menu of the CSUm, whereas the cell or monoblock voltage must be
selected via dip-switch S65 on the PCB. The following table indicates the DIP-switch setting for different cell/monoblock
voltages:
CELL/MONOBLOCK LEFT SWITCH CENTRE RIGHT SWITCH

VOLTAGE SWITCH
(1) (3)
(2)
12V UP DOWN DOWN
6V DOWN UP DOWN
4V DOWN DOWN UP
2V DOWN DOWN DOWN

3.4 Battery Cell Lead Connection to the BCM board
The battery cell voltage sensing leads are terminated with 13 way female (Weco 5.0mm pitch) screw terminals. This
plugs onto the connectors on the BCM board. How the cell voltage sense leads connect to the BCM board depends on
the battery configuration. If more than 2 batteries are used a particular configuration, simply repeat the connection
method for batteries 3 and 4.
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GT505NG Operating 3

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GT505NG Operating 3

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USER MANUAL FOR THE GT505NG POWER SYSTEM

SAAB GRINTEK TECHNOLOGIES (PTY)

NEW ISSUE DESCRIPTION

01 2004-10-13 First Release

DOCUMENT NO. REVISION DATE PAGE

1 GENERAL OPERATION ………………………………………………………………………………………… 1

DOCUMENT NO. REVISION DATE PAGE

Installation and Commissioning Checklist APPENDIX A

Wiring Diagram for GT505NG APPENDIX B

Operating Manual for Battery Cell Monitor APPENDIX C

Figure 1 GT505NG Power System …….………………………………………………… Page 1

Figure 2 Battery Temperature Compensation Curve ……………………………… Page 3

Figure 3 MUIB Connection Diagram ………………………………………………… Page 12

Figure 4 AC Distribution ….…………………………………………………………... Page 18

Figure 5 DC Distribution ……………………………………………………………… Page 19

Figure 6 Interface tray …………………………………………………………………. Page 20

Figure 7 Battery Cell Monitoring Wiring ……………………………………………… Page 21

Figure 8 Battery Cell Monitoring Terminations ……………………………………… Page 21

Table1 MiniCSU Alarms ……………………………………………………………… Page 14

Table 2 Battery Replacement ………………………………………………………… Page 15

Table 3 Remote Alarm Relay Connections …………………………………………. ............. Page 20

Table 4 Default Values ………………………………………………………………… ............. Page 22

DOCUMENT NO. REVISION DATE PAGE

TERMS AND ABBREVIATIONS

DOCUMENT NO. REVISION DATE PAGE

Module Shelf for up to 5

User Interface Sliding

Figure 1. GT505NG Power System

DOCUMENT NO. REVISION DATE PAGE

1.3.1 System Specifications

Output Voltage : 45V – 58V

Max System Current : 250 A max with 5 x RT4F modules installed.

Ambient Temperature : 0°C to +50°C

AC Input : 60A circuit breaker 3 phase

: 3 phase surge protection

DC Output (Load) : Isolator 1 x 100 A, 3-pole (ganged for 250A DC total)

DC Output (Battery) : 4 x 100A single pole circuit breakers

1.3.2 Mechanical Specifications

Width : 545mm (21,5")

Depth : 450mm (17.7")

Height : 1005mm (39,6")

Weight : 76kg (167,5lbs) without modules fitted

1.4 CONTROL AND SUPERVISORY UNIT (MiniCSU)

1.4.1 MiniCSU CONTROL FUNCTIONS

1.4.1.1 OUTPUT VOLTAGE

DOCUMENT NO. REVISION DATE PAGE

1.4.1.2 BATTERY TEMPERATURE COMPENSATION

Temerature Compensated Float Voltages for VRLA Batteries

Figure 2. Battery Temperature Compensation Curve

1.5 MiniCSU DISPLAY

1.6 ALARM CONDITIONS

1.7 MiniCSU MENUS

DOCUMENT NO. REVISION DATE PAGE

1.7.1 Home’ Menu

Cabinet temperature alarm level Cab Tmp Alrm 75C

Security disabled Security Off

Test function OFF Test Off

Number of modules operational in the system No. of SMR’s 5

MUIB2 can host up to 4 battery current sensors. Interface MUIB2

DC transducer full scale rating (Factory set) FS Batt I 300A

MiniCSU access code CSU# 234573

DOCUMENT NO. REVISION DATE PAGE

Modem enable: can be toggled On and Off Modem Off

Switch off the AC circuit breaker of the faulty module.