Home

Sageon III Manual

1. FIGURE 1 4 1200A PLANT PM990 8800 00 Issue 7 1 6 Sageon Power System Introduction Input 48V Rectifiers Rated Input Range Nominal Range Tolerance Connection Frequency Extended Input with output de rating High Guaranteed Start Soft Start Efficiency Power Factor Protection Internal Protective Devices External Protective Device Fully Protected Over Voltage Shutdown Under Voltage Shutdown Service Output 48V Rectifiers Float Voltage Nominal Range Equalize Voltage Current Limit Temperature Derating Output Rectifiers Power Limit Static Regulation Line Electrical Noise Wide Band Noise Peak to Peak Ripple Load Sharing Protection Over Current Temperature SCU programmable Battery menu Rectifier menu 208 240 Vac 185 275 Vac Single phase Phase to Phase or Phase to Neutral 13 1 208 Vac 11 3 240 16A max 120V or below 85 185 Vac 275 285 Vac 8 seconds ramp up to full load Greater than 90 gt 50 load 230 Vac input 25 C 77 F Greater than 0 98 at 50 to 100 of rated load Double Fused input Thermal circuit breaker input 440 Vac indefi
2. FIGURE 3 4 Y THREE PHASE FEED A CONNECTED RECTIFIERS PHASE TO PHASE PM990 8800 00 Issue 7 3 6 Sageon Power System Commissioning ne NEUTRAL MAY SAGEON III AC FEED FIGURE 3 5 Y THREE PHASE FEED PHASE TO NEUTRAL PM990 8800 00 Issue 7 3 7 Commissioning Sageon III Power System NOTE PHASE A WILL SAGEON III AC FEED FIGURE 3 6 A THREE PHASE FEED PHASE TO PHASE 3 4 2 Surge protection requirements The rectifiers are internally protected for surges up to 6kV 3kA For higher levels of protection particularly for sites with high incidence of lightning or switching surges additional surge protection is required on the AC feed to the Power plant Typically surge arrestors with a 10kA 40KA rating are required with the highest level of protection being provided when arrestors are connected between phase neutral x3 phases and between phase neutral earth x 3 phases Other arrangements for 3 phase Y with similar levels of protection are also possible as shown below The voltage rating of the arrestor should be selected based on the maximum AC voltage likely to appear on the line The arrestor should limit the voltage to 1200V 1400V at the rated maximum pulse current PM990 8800 00 Issue 7 3 8 Sageon III Power System Commissioning MAXIMUM PROTECTION BONDED NEU
3. 400 Ampere GJ1 Series Breaker 2 Positions 274 3833 400 600 Ampere GJ1 Series Breaker 3 Positions 274 3833 600 GJ1 Breaker Adapter Bus Bars adapt the breaker output to accept 2 hole lugs For single position breakers 1 lug landing 1 C to C 3 8x16 studs 209 8 104 00 For two position breakers 1 lug landing 1 C to C 3 8x16 studs 209 5235 00 For three position breakers 3 lug landings 1 C to C 3 8x16 studs 209 5240 00 For four position breakers 4 lug landings 1 C to C 3 8x16 studs 209 5228 00 PM990 8800 00 Issue 7 vi Sageon Power System Front Matter Table of Contents 1 0 INTRODUCTION ssssssssssscssssessssssessessssessessssessessssessessesessessesessasessessesessesesssesessesesssessassesessessesessessesesscssassesessessesessessesessers 1 1 1 1 PRODUCT DESCRIPTION a eigen e Pea epe eere eta tier cite or ee Reds 1 1 L2 SPECIFICATIONS nete ebat dete beret eeepc tae rr sid ce ikuy dalai EOD Rep 1 4 1 2 1 Power system Physical Specifications ai 1 4 1 2 2 Power system Environmental Specifications ie 1 4 1 2 3 Power system Electrical Specifications eee teet khe n pasu ba Q uay aras 1 5 1 24 General Specifications ui o RU o ho A e b RI E AI tgp 1 5 1 2 5 Bus Specrhicati rs so or rab e d e e A ip payqu hawas hh qe el em A peices ii 1 5 L 2 6 EMG SpecihiCati ns i oh ila RAUL e f b e e eta
4. PM990 8800 00 Issue 7 4 6 Sageon Power System Configuration and Operation 4 5 HOME MENU SCREENS With the Home screen displayed pressing the up arrow or down arrow button will move through a series of screens showing ambient temperature a series of editable parameters e g float voltage high and low security number of batteries and enabling and disabling of auxiliary parameters e g battery cell voltage monitoring The following map summarizes the available menu screens Home Screen TT System current voltage and mode Ambient temperature 3 Phase AC Monitor option Programmab TTT Ambient temperature alarm Voltage high alarm Voltage low alarm Failsafe Alarms on off Bat Cur Sensor on off Security on off Password setup When viewing another Test indicators screen the Home Number of Rectifiers SMRs screen will reappear Number of battery strings connected in 60 seconds if no Full scale battery current button is pressed Load sensor on off FS Load Current Access code 7 digit number Date format Date time set Alarm report on off Daily report on off Daily report time Modem on off Phone numbers 1 2 and 3 Audio alarm on timeout off Cct input no nc disable Battery switch no nc disable LVDS no nc disable Auxiliary units press ENTER 1 ph A
5. ED991 5001 B3 Issue 3 1 2 i 3 4 AUX RIBBON EXT COMMS AMB TEMP 1 TEMP 2 TEMP_3 TEMP_4 TCP IP SNMP BATT1 BATT2 BATT3 BATT4 BATTERY TEMP CONCENTRATOR a5 si REMITE COMMS 001 DPT SAGEON3 C01 OPT Ozz Ozz Ozz Ozz lt 31 Zou Zon CUSTOMER Ae ALARM BRD X5 X2 ze xn ance 1 RLYS RLY4 RLY3 RLY2 RLYI I 10 WHT V10 BRN SAGEON3 C01 OPT CURR_1 BDM RIBBON i CURR 3 CURR 4 X9 LVDS COM CURI CURACURZCURA Xe BUS X1IGBATT X21 A3 BDM BRD AUX RFLAY C AUX RELAY NO 4 AUX RELAY NO 3 J AUX RELAY NO 2 AUX RFLAY NO 1 BATT 4X3 BATT 3X4 BATT 2 5 BATT 1 X6 6066 BUS BAR BUS BAR PROPRIETARY INFORMATION NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC SIZE DOC TYPE NUMBER ISSUE B SAGEONS AXX SCALE SHEET FILE NAME N A 3 OF 4 SD SAGEON3 AXX_ISS_4 ED991 5001 B3 Issue 3 1 2 i 3 4 BATTERY LANDING TERMINAL 4 8 LANDINGS AMBIENT TEMP MOUNT ON LARGE THERMAL MASS AMB TEMP TE
6. al Caution Do not block rear panel grille A blocked grille will limit the flow of cooling air and result in equipment overheating and failure Minimum clearance behind and to the sides of the plant must be 2 5 cm FIGURE 2 1 POWER SYSTEM DIMENSIONS PM990 8800 00 Issue 7 2 5 Installation Sageon III Power System FIGURE 2 2 PLANT BASE Caution Do not block rear panel grille A blocked grille will limit the flow of cooling air and can result in equipment overheating and failure Minimum clearance behind the Plant is 2 5 cm To move and mechanically secure the Power system 1 2 3 4 Prepare the installation site Install floor anchors
7. enne 2 18 2 15 CONFIGURATION tbi tern eiie den an en hein ain Laine eaten 2 19 2 1 5 1 General Descriptions usan EE 2 19 OUUn 3 1 3A PREPARATION iR e rr esp e vert tete eI reve ap cap ie E vau ip bep Io A A E E ree de ep e RR etae erede 3 1 3 2 COMMISSIONING A SYSTEM u el tee ede cut E Va e be Io eR ea ete abo suelo iaia 3 1 3 3 OVERVIEW OF EXTERNAL WIRING CONNECTIONS 3 2 3 4 FACTORY SUPPLIED CONFIGURATIONS ie 3 2 3 4 1 Single phase individual protected external feeds M i 3 2 3 4 2 Surge protection requirements G na a a k aa eie 3 8 3 43 Battery connections x pu aS a ochre Ae ee ale eo a nq de iv sue Ra e er Reb SLA eu 3 9 3 5 TEMPERATURE SENSORS rp elite eere tae ipe upaqa Due bettie ad amen aa ee ee Eee wth 3 9 3 6 AUXILIARY RELAY CONNECTIONS inlet ette Sasa oneness Ma pedes 3 9 3 CONTROLLER POWER CONNECTIONS dede aee cacao 3 10 3 8 FRONT PANEL USB COMMUNICATIONS CONNECTION eene 3 10 3 9 REMOTE COMMUNICATION CONNECTION ulna E EEEE e RE EE eaea EEEE E E eE N 3 10 3 9 1 TCP IF and Sape view Interface a a bce aec ive pase ina E Saa eee iota teil 3 11 3 10 BATTERY DISTRIBUTION MODULE EE A E PUE A Ea leaned aa aQ 3 11 3 11 ADDING AUXILIARY EXPANSION MODU
8. Hazardous voltage can cause death or serious injury Use extreme care when performing maintenance on an operating Sageon III Power System Use insulated tools Remove watch and jewelry 5 Verify the Sageon III Power System configuration and all parameter values Refer to Chapter 4 Configuration and Operation for operator panel and PC screens 6 Confirm that all alarm annunciators are functioning Refer to Chapter 4 Configuration and Operation for operator panel and PC screens 7 Verify LVBD parameter values Refer to Chapter 4 Configuration and Operation for operator panel and PC screens 8 Confirm that all Rectifiers are on line and sharing current From the operator panel or a PC check each Rectifier for voltage and current output Refer to Chapter 4 Configuration and Operation for operator panel and PC screens 9 Ifload requirements allow remove Rectifier Systems one at a time Use low pressure air to clean Systems Clean dust and lint from Rectifier fans Refer to Section 2 14 Installing and Removing Rectifiers for procedures 10 Verify communications with remote PCs dial up connections and databases as appropriate PM990 8800 00 Issue 7 6 1 Maintenance Sageon III Power System 11 Test any spare Rectifiers a Insert a spare device b Test the device to ensure correct operation c Ifthe device is to remain a spare remove it and repeat the above steps until all spares are tested If spa
9. 2 15 CONFIGURATION 2 15 1 General Description Sageon III Power plant systems are turn key DC uninterruptible power supply solutions DC UPS for powering 48VDC telecommunications and industrial equipment The Power plant provides integrated battery management functions for a range of PM990 8800 00 Issue 7 2 19 Installation Sageon Power System battery types VRLA flooded Lead acid NiCad Ni MH Li polymer to enable easy commissioning of a DC UPS or it can be used as a standalone DC source when no batteries are used The Power plant provides the following integrated features e Power Distribution e n l Redundant Rectifiers e Battery Charge Current Limiting opt e Short Circuit and Reverse Polarity Protection e Battery Temperature Sensing opt e Monitoring and Control Module Controller e Accurate Temperature Compensated Float and e Super Capacitor Backed Real time System Clock Equalization Voltages opt e Modules for Mo
10. TEMP4 TEMP3 TEMP2 TEMPI FIGURE 2 19 TEMPERATURE CONCENTRATOR BOARD PM990 8800 00 Issue 7 2 21 Installation Sageon III Power System g lt Ak Of r nn EE com F1 d B gt Lele je T A 3 Ms FA ALARM T O Tal en i B B NICATION t A F Y ALA ERATURE waa E m FIGURE 2 20 SAGEON III BOARD LOCATIONS PM990 8800 00 Issue 7 2 22 Sageon Power System Commissioning 3 0 COMMISSIONING This chapter describes commissioning a Power System Individual system settings can vary widely so it is important that those performing the commissioning fully understand the system at hand Modify these procedures as needed to accommodate the installed equipment and your company s commissioning procedures 3 1 PREPARATION Perform the following steps prior to commissioning a Power system 1 2 3 4 Gather system wiring diagrams
11. 12 4V Cells 1 SBM Board 1 SBM Board 2 SBM Boards 2 SBM Boards 8 6V Cells 1 SBM Board 1 SBM Board 2 SBM Boards 2 SBM Boards 4 12V Cells 1 SBM Board 1 SBM Board 1 SBM Board 1 SBM Board 4 9 1 Frequency of Measurement The frequency of cell voltage polling is programmable from 10 minutes to 8 hours in 1 minute steps A typical polling interval is 4 minutes which yields 15 points for a 1 hour discharge For a programmed test discharge of 30 minutes a polling interval of 2 minutes might be used This parameter is not accessible from the operator panel A PC running SageView is needed 4 9 2 Battery Cell Measurements When SBM is active individual cell voltages can be monitored on the operator panel by selecting a battery from the BATT menu and pressing ENTER The cell information will appear on the screen and the next and previous cells can be selected by pressing the up arrow and down arrow buttons Battery 1 12A Select battery Battery 1 screen appears after pressing the BATT button Press ENTER Battery 1 Cell01 Battery cell parameter Battery 1 Cell 01 values are displayed As shown here the cell voltage is 2 225V which is a deviation of 12 from the average cell voltage in this battery string 2 225V 12 Battery cell voltage deviation Battery 1 Cellmm cell voltage n nnnV is deviating Battery 1 Cellmm pp from the average cell voltage in this b
12. IMPORTANT Regularly monitor the LEDs on the operator panel and Rectifiers Review the alarm log regularly to detect minor problems before they become significant problems 6 1 CIRCUIT BOARD HANDLING Semiconductors such as ICs integrated circuits diodes and transistors must be protected against damaging electrostatic discharges A properly grounded wrist strap must be worn whenever a circuit board is handled or touched A service kit with a wrist strap and static dissipative work mat is available from both mail order and local electronic supply companies Always store circuit boards in anti static bags 6 2 PERIODIC MAINTENANCE Perform the following periodic maintenance procedures at least twice a year 1 Thoroughly review the Alarm Log at the operator panel or at a local or remote PC Look for repetitive alarms determine their cause s and take steps to correct events that result in alarms 2 Check operator panel LEDs Refer to Chapter 4 Configuration and Operation for details 3 Check all Rectifier LEDs Refer to Section 4 3 for details 4 Check all electrical connections Check that all breakers and fuses are fully seated Tighten connections as required Seat breakers and fuses as required Look for signs of overheating arcing and accumulation of dust dirt and other contaminants Refer to Chapter 2 Installation for factory installed and customer installed connections A WARNING 9 Electrical shock and arcing hazard
13. _ UNIDOWER Powering Technology Sageon IIITM Power System Product Manual SAGEON na f P H n ee K LU Li o o SOR Sex Nikos E ML 3 E H 2 1 l UNIPOWER LLC 65 Industrial Park Road Dunlap TN 37327 Customer Service Voice 800 440 3504 Customer Service Fax 423 949 3647 Field Service 800 299 3907 PM 990 8800 00 Issue 7 Web site http www unipowerco com sageon3 man pdf Sageon Power System Front Matter RECEIVING INSTRUCTIONS amp GENERAL EQUIPMENT INFORMATION Please Note For your protection the following information and the product manual should be read and thoroughly understood before unpacking installing or using the equipment UNIPOWER LLC presents all equipment to the delivering carrier securely packed and in perfect condition Upon acceptance of the package from us the delivering carrier assumed responsibility for its safe arrival to you Once you receive the equipment it is your responsibility to document any damage the carrier may have inflicted and to file your claim promptly and accurately 1 PACKAGE INSPECTION 1 1 Examine the shipping crate or carton for any visible damage punctures dents and any other signs of possible internal damage 1 2 Describe any damage or shortage on the
14. 8 4 PM990 8800 00 Issue 7 ix Front Matter Sageon Power System List of Tables TA BEE 221 uz u z cof ente emt eds Hives ce re te ae cte aa E Eve So Sh 2 3 TABLE 2 2 TORQUE SPECIFICATIONS STEEL FASTENERS 2 4 TABLE 2 3 CIRCUIT BREAKER SELECTION AC POWER ie 2 8 TABLE 2 4 BATTERY TEMPERATURE SENSOR 5 2 15 TABLE 2 5 BATTERY CURRENT TRANSDUCER CONNECTIONS 2 17 TABLE 4 1 SUMMARY OF DEFAULT SYSTEM SCU PARAMETERS eene nnnm eene erret ennt eere teer enne nnne 4 1 TABLE 4 2 READING OPERATOR PANEL SYSTEM STATUS LEDS iii 4 4 TABLE 4 3 OPERATOR PANEL ANNUNCIATED ALARM MESSAGES ieri 4 5 TABLE 4 4 SBM BOARDS NEEDED FOR VARIOUS BATTERY CONFIGURATIONS a 4 19 TABLE 6 1 ALARM MESSAGES AND ERROR CODES eee 6 2 TABEE O 2 RECTIFIEREEB CODPEBS tree tre eot ete e e rer tet eite eodem eie eut te A Re e d reed 6 2 TABLE 6 3 RECTIFIER POSITION ADDRESSES 1 THROUGH 24 6 4 TABLE 7 1 INSTALLABLE DISTRIBUTION TYPES BY TIER AND GROUP eee 7 2 TABLE OAT PARTS LIST ina ecrire te tees lances ce tt ert tes TREE CR tee t iet yet ti tee e i tt h e d
15. Breaker Input Terminal Hardware FIGURE 2 12 GJ1 TYPE BREAKER DISTRIBUTION WIRING PM990 8800 00 Issue 7 2 14 Sageon Power System Installation 2 8 CONNECTING EXTERNAL ALARM ANNUNCIATORS Five form C relay contact outputs are available for connection to external user supplied alarm annunciators Figure 2 13 shows the Interface Board and the row of connectors X6 provided for these connections Review the alarm and relay contact specifications in Section 1 2 11 Alarm Specifications to ensure compatibility with external annunciators and other equipment before proceeding Alarm relay outputs are provided for remote annunciation of fault conditions All relays are user programmable through the SageView software As shown in Figure 2 13 each relay has three connections common normally open and normally closed The normally open NO and normally closed NC labels are for an un powered Sageon III Power System Relay coils are energized during normal Sageon III Power System operation During an alarm the appropriate relay coil is de energized IMPORTANT When the relay contacts are connected to a reactive load such as a solenoid or relay coil the load must be shunted by a transient suppression device to prevent damaging relay contacts FIGURE 2 13 INTERFACE BOARD CUSTOMER ALARM CONNECTIONS 2 9 BATTERY TEMPERATURE SENSORS AND KITS OPTION The Multiple Battery Temperature Board is included in the Sageon III distribution It c
16. Power system It consists of nine chapters with a packet of drawings following the text The drawings supplement the provided descriptions and procedures Thank you for purchasing the Sageon III Power system We at UNIPOWER LLC are proud of the quality of our products and welcome any suggestions to further improve our design to fit your needs PROPRIETARY AND CONFIDENTIAL The information contained in this product manual is the sole property of UNIPOWER LLC Reproduction of the manual or any portion of the manual without the written permission of UNIPOWER LLC is prohibited Copyright UNIPOWER LLC 2015 DISCLAIMER Data descriptions and specifications presented herein are subject to revision by UNIPOWER LLC without notice While such information is believed to be accurate as indicated herein UNIPOWER LLC makes no warranty and hereby disclaims all warranties express or implied with regard to the accuracy or completeness of such information Further because the product s featured herein may be used under conditions beyond its control UNIPOWER LLC hereby disclaims and excludes all warranties express implied or statutory including any warranty of merchantability any warranty of fitness for a particular purpose and any implied warranties otherwise arising from course of dealing or usage of trade The user is solely responsible for determining the suitability of the product s featured herein for user s intended purpose and in user
17. 1 a Tem i Alarm F 1 1 ical Kort ervi 1 JU si i pti 1 3 F 11 i pti 5 cur T I Eti A n TL Idr id De i i E Addres tter 48 1 FIGURE 1 2 SIMPLIFIED BLOCK DIAGRAM 48V POWER SYSTEM PM990 8800 00 Issue 7 1 3 Introduction Sageon III Power System The LVBD trip voltage is set using the operator panel push buttons and menus An LVBD bypass switch is provided This switch bypasses i e defeats the SCU LVD in case of SCU maintenance upgrading or failure The Sageon III Power System operation can be monitored at the operator panel on the front of the Sageon III Power System at a PC connected to the operator panel or at a PC connected to the Sageon Power System over an Ethernet network The Sageon II Power System configuration can be performed from the operator panel or at a PC Printed circuit boards below distribution area contain terminals for user connections to alarm relays battery temperature compensation sensors communications and other internal and external functions In addition most signals destined for the SCU are routed first to the BDM board or backplane board The operator panel provides user access to the configuration and monitoring capabilities of the SCU For security a parameter lock feature is included and PC access
18. GJ1 type breaker 1 Screw Phillips Head 10 32 x 1 2 Washer Flat 3 8 Washer Bevel 3 8 Bolt Hex Head 3 8 16 x 1 1 4 Nut Hex 3 8 16 Alarm wire adapter breaker kits 200A and over only tS tS S 8 2 2 Installing the Kit 1 Open the distribution area door Refer to Figure 7 1 and locate the Distribution Tier and Distribution Group where this kit will be installed Note GJ1 distribution cannot be installed in any Group of Tier 1 2 Remove the two painted breaker mounting bars from the existing GJ1 Distribution Option to allow access to mount the GJ1 type breaker kit See Figure 8 3 Note It may be necessary to remove the 10 32 x 1 2 Phillips head screws from any GJ1 type breakers already installed in existing GJ1 Distribution to facilitate removal of the two painted breaker mounting bars PM990 8800 00 Issue 7 8 2 Sageon Power System Circuit Breaker and Fuse Kit Installation 3 10 From the existing GJ1 Distribution Option carefully remove the insulated sleeving from the orange fuse alarm wire and the red alarm wire for the breaker position you are installing Remove a GJ1 type breaker kit from its packaging The package label will identify the kit by part number Connect the red alarm wire of the GJ1 Distribution Option to the Common C pole and the orange fuse alarm wire of the Distribution Option to the Normally Closed NO pole on the
19. No action needed Flashing Alarm condition Refer to Chapter 4 Operations and Replacing a Rectifier in Chapter 6 Maintenance On Rectifier functioning normally in Equalize mode No action needed Flashing Rectifier shut down by remote control Rectifier not inserted in holder properly Internal control circuit fault No action needed Remove and reseat Replace Rectifier 6 4 REPLACING A RECTIFIER SCU microprocessor fault Replace SCU In the event of Rectifier failure replace the unit There are no user serviceable parts in the Rectifier PM990 8800 00 Issue 7 6 2 Sageon III Power System Maintenance A rectifier is identified by a label in the bezel recess and on the rear of the rectifier Be certain you are installing the correct model Rectifier Only 48 V S0Amp rectifiers are available with the Sageon III System To replace a Rectifier refer to Section 2 14 Installing and Removing Rectifiers 6 5 REPLACING THE SAGEON III CONTROL UNIT SCU In the event of SCU failure replace the assembly There are no user serviceable parts in the SCU The Sageon III Power System SCU can be hot swapped Be certain a replacement SCU is on hand before beginning this procedure To remove the Controller Assembly 1 Check that a known good replacement Controller Assembly is on hand for immediate installation 2 Re install the new SCU e b sb ebde FIGURE 6 1 REPLA
20. Rate can be set from 0 to 5000A If rate is set to zero the control function is disabled and the battery will discharge under full load current Note The total load supplied by the system during the test must exceed the desired battery discharge current by at least 10 Rectifiers will supply the additional load leaving the battery string to supply a user defined current to the load End of test Set the battery voltage that will terminate the test if reached before the test duration set above At the end of test whether ended by test duration or end voltage normal operation is restored and recharging of the battery string s is begun The test result will be Fail Battery string end of voltage depends upon system voltage 48V system 36V to 48V Battery end of capacity Set the remaining battery capacity at which the test must bend Capacity can be set from 25Ah to 9995Ah If rate is set to zero the control function is disabled and the battery will discharge under full load current Reset of failed test alarm This message appears when the preceding test fails and is not reset Press ENTER to reset the alarm and hide the message Abort MBT This screen is available when a discharge test has been started 4 7 5 BDT Results Screen The final screen contains a brief test result message The message appears on the second line of the Last BDT display Each message is explained below N A Not Available No test has been perfor
21. Section 4 5 describes in detail the selections available from the Home screen 4 2 USING THE OPERATOR PANEL PUSH BUTTONS Use the six buttons to view System data individual rectifier data battery data or the alarm log In addition programmable parameter values can be viewed and changed Each button is described below The HOME screen shows the System voltage and current The data will initially be located in the center of the display and after a brief period will scroll right to left From the HOME screen press up arrow or down arrow to move through the series of menus described in Section 4 5 RECT N HU DEC ENTER FIGURE 4 1 OPERATOR PANEL PM990 8800 00 Issue 7 4 3 Configuration and Operation Sageon III Power System RECT RECTifier Press to access a menu of rectifier related parameters as well as to view the output current and heat sink temperature of each rectifier See Section 4 6 for the screens displayed in the RECT menu BATT BATTery Press to access a menu of battery parameters See Section 4 7 for the screens displayed in the BATT menu LOG Press to view a menu of the 99 most current alarms in chronological order Section 4 8 shows the screens The alarm log number and alarm description are displayed first Two seconds later the alarm log number and
22. activated as indicated at the RECTIFIER Menu for a particular RECTIFIER Corrupted data found on the EEPROM inside the rectifier that is outside the allowable data range The rectifier software has attempted to over write and has failed due to the memory cell being damaged Note excessive electrical noise can corrupt the read data transfer which can lead to the same alarm being generated Replace the faulty rectifier if the memory cell is confirmed to have failed This can be done by modifying each of the RECTIFIER parameters on the Controller and checking to see if the alarm clears EEPROM corrects the data Check for EMC problems and remove reduce the source of electrical PM990 8800 00 Issue 7 6 6 Sageon Power System Maintenance Symptom Likely Causes Action interference where possible EEPROM Fail alarm for the Controller is activated Corrupted data found on the backplane EEPROM that is outside the allowable data range similar to RECTIFIER corruption above Replace the faulty backplane if the memory cell is confirmed to have failed Range RECTIFIER alarm for the rectifier is activated Corrupted data found on the EEPROM inside the rectifier that is inside the allowable data range but does not match the value programmed Try adjusting the RECTIFIER parameters to see if the EEPROM cells can be updated If not replace the faulty recti
23. s specific application Throughout the remainder of this manual UNIPOWER will mean UNIPOWER LLC PERSONNEL REQUIREMENTS Installation setup operation and servicing of this equipment should be performed by qualified persons thoroughly familiar with this Product Manual and Applicable Local and National Codes A copy of this manual is included with the equipment shipment PM990 8800 00 Issue 7 lil Front Matter Sageon Power System Sageon III Power Plant Parts List Descriptions Base System Part Numbers 84 Welded Cabinet Controller LVBD w by pass switch 600A Rectifier Shelf Five 5 Customer Specified External Alarms SAGEON3 A01 84 Welded Cabinet Controller w o LVBD w by pass switch 600A Rectifier Shelf Five 5 Customer Specified External Alarms SAGEON3 A02 Factory Installed Options No AC breakers NO AC Breakers for the 600A Rectifier Shelf SAGEON3 B01 AC Breakers Provides Twelve 12 20A AC Breakers for the 600A Rectifier Shelf SAGEON3 B02 Rectifier Expansion Addition 600A Rectifier Shelf to increase Total System Capacity to 1200A SAGEON3 B03 Rectifier Expansion w Breakers Include Rectifier Expansion Package B03 and Twenty four 24 20A AC Breakers SAGEON3 B04 Battery Expansion Provides Interface Connections for Four 4 Battery Temperature Probes Four 4 External Current Transducers SAGEON3 C01 Communication Remote Communication Using TCP
24. to line characteristic impedance Le for a twisted pair of 24AWG wires characteristic impedance of 1000hm use a 100ohm resistor PM990 8800 00 Issue 7 3 10 Sageon III Power System Commissioning 3 9 1 TCP IP and Sageview Interface The interface is a 10 100BASE T Ethernet adaptor The TCP IP port sends Controller data over a network to a PC running Sageview control and monitoring software The Sageview interface provides this function for up to 2 PCs on the network simultaneously as well as providing SNMP traps on alarms system time synchronization to a global clock if access to the internet is available and a simplified system status Webpage HTTP If direct connection to a PC network port is required a cross over network cable should be used To set up Sageview follow the instructions on the installation CD To enable network access on the TCP IP port an IP address must be assigned to the port If access over the Internet is considered the gateway address must be programmed as well There are several methods to do that two are recommended and are described in section 7 1 Other operating parameters of the interface are pre programmed and should not be changed Factory default IP address is 192 168 10 60 To be able to assign a network address the Ethernet address referred to also as hardware address or MAC ID of the interface must be known On the Power plant top cover is a small label indicating the MAC ID similar to one sh
25. 000A 5A Current Eq End Eq duration Maximum duration of Equalization 3 48Hr 20Hr charging Eq period Time between periodic Equalization 0 52wk 12 Wk charging Manual Force stop start of Equalization Toggle state Stop Start Eq charging LVDS Trip Battery voltage below which LVDS 40 48V 42 6V will open BDT Per Period between consecutive 0 365 days 0 days discharge tests BDT Time Time of day to begin BDT hr min 00 00 23 59 02 00 BDT Dur Maximum duration of BDT 5 1 440 min 180 min BDT Curr Discharge test current 0 5 000A 50A BDT End V Battery voltage limit to terminate 36 48V 44 BDT BDT Q Battery capacity limit to terminate 25 9 995 300AH BDT Temp Sen Enable disable temp sensor failure On Off On Alarm alarm 4 1 THE HOME SCREEN The Home screen shown at right is the default screen It shows Sageon III Power System output current and voltage This screen also shows the present mode FLoat or EQualize If an activity such as battery discharge is being performed the current and voltage are displayed continuously while the second line alternates between the mode and the activity status for example BDT in progress 155A 542 FL The Home screen is the first to appear when power is applied to the System Since the Home screen is the default screen the display will revert to the Home screen from any other screen if an operator panel push button is not pressed for approximately one minute
26. 1 X22 in Figure 3 12 2 X18 in Figure 3 12 3 X17 in Figure 3 12 X12 in Figure 3 12 2 11 SAGEON BATTERY MONITOR OPTION The UNIPOWER Sageon Battery Monitor SBM is an add on System for the Sageon HI Control Unit SCU It is used to monitor individual cells of a battery during float or equalization operation or during a discharge Each SBM unit is capable of monitoring up to 24 cells or monoblocks Up to four SBM units can be used to monitor up to 4 battery strings of 24 cells or monoblocks each PM990 8800 00 Issue 7 2 17 Installation Sageon III Power System Using the ability of the SCU to communicate to a remote or local PC cell voltage data accumulated during a discharge can be transferred to a PC and saved The cell voltages can also be viewed in real time when the SCU is connected to a PC The Sage View 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 addition to the real time or historical representation of the data on SageView the cell voltages can also be observed in real time on the SCU display In the event that the battery behaves in a way that is less than ideal during a test or actual discharge a number of pre programmed parameter levels are used to generate alarms Alarms are annunciated on the SCU front panel by a LED and screen message and remotely via voltage free contacts or via the USB communications port that
27. 8 cm diameter around the selected holes and through bolt the ground wire lug to the rack Return Bus Connect the plant return bus to the site s central office ground Select a cable size applicable in accordance with codes and the customer s standard practice The minimum cable size must be capable of carrying the fault current from any installed device Since this is typically a high current connection secure the wire lug to a 3 8 stud on the return bus battery or bolt the wire lug to 3 8 through hole on the return bus loads The return buses within the plant are electrically connected See Figure 2 3 for bus locations a 9 seturi 1 Load S E Tier ptional 9 9 Returr Load Tier ptional LIIW LR II Load Tiel indar d re 9 FIGURE 2 3 RETURN BUS LOCATIONS 2 5 1 Lightning and Transient Suppression Rectifiers contain basic transient suppression in the form of Metal Oxide Varistors MOVs MOVs are installed from L1 to L2 L1 to earth and L2 to earth They are sized to provide protection from line transients in an industrial environment according to ANSI C62 41 1991 for Class B3 equipment and IEC 61000 4 5 Supplementary transient protection is needed in a more severe environment with for example a high incidence of lightning strikes indirect or direct and or severe switching transients beyond the levels indicated in the above standards Install higher rated suppression devices to th
28. IP SNMP SAGEON3 D01 TCP IP SNMP V3 SAGEON3 D02 Distribution Tiers amp Ground Return Battery Landing Tier 1 Group A AM1 Group B AM1 Ground Return Eight 8 battery connections 3 8 on 1 C C SAGEON3 E01 Tier 1 Group A AM1 Group B AM1 Tier 2 Group A AM1 Group B AM1 Ground Return Eight 8 battery connections 3 8 on 1 C C SAGEON3 E02 Tier 1 Group A AM1 Group B AM1 Tier 2 Group A GJ1 Group B GJ1 Ground Return Eight 8 battery connections 3 8 on 1 C C SAGEON3 E03 Tier 1 Group A AM1 Group B AM1 Tier 2 Group A AM1 Group B AM1 Tier 3 Group A AM1 Group B AM1 Ground Return Eight 8 battery connections 3 8 on 1 C C SAGEON3 E04 Tier 1 Group A AMI Group B AM1 Tier 2 Group A AMI Group B AMI Tier 3 Group A GJ1 Group B GJ1 Ground Return Eight 8 battery connections 3 8 on 1 C C SAGEON3 E05 Rectifiers Sageon Rectifier 48V 50A 208 240VAC single phase 100 7675 4850 Sageon Rectifier 48V 34A 208 240VAC single phase 100 7670 4834 Sageon Rectifier 48V 25A 208 240VAC single phase 100 7665 4825 Sageon Rectifier 48V 25A 120 240VAC single phase 100 7670 4825 Blank Rectifier Panel Required to fill open rectifier positions 124 0073 00 Sageon Battery Monitor Includes 30 remote Cable to SCU Requires Battery Cell Wire Bundle and Battery Adaptor Kit 385 5201 20 Battery Cell Wire Bundle Req
29. Position 274 3830 90 100 Ampere AMI Series Breaker 1 Position 274 3830 100 125 Ampere AMI Series Breaker 2 Positions 274 3830 125 150 Ampere AMI Series Breaker 2 Positions 274 3830 150 200 Ampere AMI Series Breaker 2 Positions 274 3830 200 Breaker Toggle Guard Kit 385 3830 00 AMI Breaker Adapter Bus Bars adapt the breaker output to accept larger 2 hole lugs 45 up angle utilizes two breaker spaces 2H Landing Bus Bar 1 C to C 3 8 x16 Studs Distribution Group A 209 4743 01 2H Landing Bus Bar 1 C to C 3 8 x16 Studs Distribution Group B 209 4743 02 Sageon III Power Plant Parts List Continues PM990 8800 00 Issue 7 V Front Matter Sageon Power System Descriptions GJ1 Bolt In Single pole Circuit Breaker Kits includes hardware Requires SAGEON3 E03 E04 E05 Part Numbers 100 Ampere GJ1 Series Breaker 1 Position 274 3833 100 125 Ampere GJ1 Series Breaker 1 Position 274 3833 125 150 Ampere GJ1 Series Breaker 1 Position 274 3833 150 175 Ampere GJ1 Series Breaker 1 Position 274 3833 175 200 Ampere GJ1 Series Breaker 1 Position 274 3833 200 225 Ampere GJ1 Series Breaker 1 Position 274 3833 225 250 Ampere GJ1 Series Breaker 1 Position 274 3833 250 300 Ampere GJ1 Series Breaker 2 Positions 274 3833 300 350 Ampere GJ1 Series Breaker 2 Positions 274 3833 350
30. USB port to a PC running the Sageview software The USB connection requires that a USB driver be installed on the PC The first time the Controller is plugged into the PC via the USB port a Microsoft Windows dialogue box will appear asking the user to install the Controller USB Interface drivers The Microsoft Windows operating system should be able to find the drivers automatically on the Sageview CD ROM assuming it is in the CD ROM drive of the PC If Sageview is running when the unit is plugged in a Windows dialogue box will appear asking the user if they wish to connect to the unit immediately Otherwise the user will need to select the Controller from the available controller USB devices in USB section in the Connection Setup 3 9 REMOTE COMMUNICATION CONNECTION The remote communications module is P N Description 385 4015 32 Ethernet FCPAP Interface Card w SNMP Superseded by 385 4036 32 385 4036 32 Ethernet TCP IP Interface Card w SNMP v3 The following sections describe the interfaces in more detail and cover some of the set up requirements for the more advanced interfaces Termination of the line with resistors generally is not required However if high rate of data corruption is experienced slow data update in monitoring program line termination resistors should be installed at both ends of the network The value of the resistors depends on the gauge of the twisted pair and should be equal or closest
31. Value up down I 0398887788 ENTER to accepi I z m mu mani mm mm wass Cms mem EN I Phone 1 Cont Modify Value up down D 2323 ENTER to accept I Phone 2 Modify Value up down 1 0398887788 ENTER to accept NI I I NT NI TER l TER l ENTER Phone 2 Cont I Modify Value up down 1 2325 x zt ENTER 10 9000pt ar ENTER L TER l k TER Phone 3 Modify Value up down 1 0398887788 ENTER to accep a E Phone 3 Cont Modify Value up down 2323 ENTER to accep 1 ENT Audio Alarm Off e RR NC DEC toggles stai ENTER to accep 1 TER ot ce Circuit breaker auxiliary contact circuit input configuration suis T NC DEC toggles s l ENTER to accepi 1 Battery circuit breaker auxiliary contact circuit input configuration NC DEC toggles state I ENTER to accepi ENTER Battery low voltage disconnect switch auxiliary circuit input CING DEC toggles state configuration I ENTER to accepi I Wren pe n AC Monitor Off Batt Switch Input Not Used VDS Input Not Used Auxiliary Units Press ENTER IT INC DEC toggles state I ENTER to accept If 1 ph AC Monitor not O T ENTER 1ph AC Vhi Alarm Modify Value up down 1 260V ENTERtoaccept ENTER 1ph AC Vlo Alarm Modify Value up down 200V I ENTER to accep l ENTER 1ph AC fhi Alarm Modify Value up down 55 0Hz 1 ENTER t
32. a UNIPOWER Field Service technician for assistance The Power system is factory assembled and tested GJ1 circuit breakers specified on the order are factory installed AMI circuit breakers specified on the order are shipped in protective packaging for on site installation Rectifiers specified on the order are shipped in separate protective packages for on site installation The Power system is designed for top entry of distribution and battery cabling AC input cabling can enter the plant through any lower side rear panels or through the bottom of the plant when the plant is located on an elevated floor All cabling is user supplied A WARNING Electrical shock hazard Hazardous voltage can cause death or serious injury Remove power from all wires and terminals before working on equipment IMPORTANT All wiring must meet the National Electrical Code and other applicable industry and local codes The Breaker Fuse Layout label on the inside of the door to the distribution area lists all distribution positions The label provides space for you to write breaker fuse current rating and part number Label entries should be completed before beginning the installation to help ensure that the correct breaker fuse is inserted in each position Rectifier Position Address Each rectifier position is factory assigned a unique sequential address within the Sageon III Power System The System operator uses this address when c
33. alarm wire with the ring terminal lug 4 Position the L shaped bus bar against the top of the U shaped distribution bus in the factory installed distribution group and align the mounting holes see Figures 7 6 and 7 7 The upward pointing fingers with the press in nuts should be toward the inside of the pant Place the ring terminal of the red alarm wire on one of the bolts Loosely install the hardware Do not tighten the hardware at this time 5 From the kit collect the painted U shaped breaker mounting bracket and two 12 24x3 4 screws 6 Position the bracket against the nearest vertical rack rail align the holes in the bracket with those in the rail and install the screws The bottom edge of the bracket extending into the pant should be approximately 1 5 3 8 cm above the horizontal leg of the L shaped bus bar 7 Tighten the U shaped bracket mounting hardware See Table 2 2 for torque specifications Do not tighten the L shaped bus bar hardware at this time 8 From the kit collect two painted 5 8 x7 1 2 breaker mounting bars four 10 32 x 1 2 Phillips head screws 9 Refer to Figure 7 7 and loosely mount the bars on the U shaped breaker mounting bracket 10 From the kit collect the orange fuse alarm wire and temporarily drape it over the U shaped bracket This wire and the red alarm wire will be connected when the GJ1 type breakers are installed 11 Repeat the above steps for each GJ1 distribution group to be installed 12
34. and enabled Complete descriptions for testing vented lead acid and VRLA batteries are beyond the scope of this manual but are discussed in detail in IEEE STD 450 2002 or its latest revision and IEEE 1188 1996 respectively battery specific manuals and other professional society standards It is important to recognize that standby batteries cells are designed for emergency standby operation and excessive testing or cycling of a battery can materially shorten the life of a battery Battery temperature alarm Battery Ah rating BTC on off BTC Temperature coefficient BTC Temperature compensation nominal Number of cells per string Battery charge current limit lt Vdd Battery deep discharge voltage Vdd Battery charge current limit from Vb lt Vfl System float voltage System voltage drop Equalization on off Charge current limit gt Vfl Equalization voltage Equalization trigger voltage Equalization no trigger voltage Equalization trigger charge Ah Equalization trigger discharge rate Ah Equalization no trigger discharge rate Ah Equalization end charge current Equalization end charge Ah Equalization end duration hours Equalization auto initialize weeks Equalization end manual Equalization start manual LVDS trip voltage LVDS mode auto closed open Temperature sensor alarm on off Discharge
35. any other menu simply press the desired button To move to the Home menu from any other button press the button for the current menu For example if battery parameters are presently being displayed press BATT to access the Home menu To change a parameter when the security function is activated A Panel Locked message will appear when an attempt is made to alter any parameter while security is activated The security On Off selection is located in the HOME menu Section 4 5 To change a parameter simultaneously press and hold the up arrow down arrow and ENTER buttons for 3 seconds Parameters may now be changed as described above 4 3 READING THE OPERATOR PANEL SYSTEM STATUS LEDS The table below describes the indications presented by the system status LEDs TABLE 4 2 READING OPERATOR PANEL SYSTEM STATUS LEDS LED Color Meaning System OK A failure or alarm condition exists Alarm Alarm condition exists in the system or a Rectifier Plant is in Equalize Mode No alarm condition exists in the Sageon III Power System Rectifier Shutdown One or more Rectifiers has shut down All Rectifiers are operating PM990 8800 00 Issue 7 4 4 Sageon Power System Configuration and Operation If all three LEDs are Off e There may be no System output or battery string DC to power the SCU e The SCU may have failed e There may be no AC power to the System e On initial startu
36. are shown in Figure 2 12 Connect the top breaker terminals to user loads The bottom breaker terminals are bolted to the battery discharge bus at the factory Distribution Assemblies PA 2 o eje o Tier 3 Grp A Tier 3 SI ef Fuse Alarm Hmeoo lo o 5909 Fuse Alarm FA Wire FA Wire a Tier 2 Tier 2 Group A Group B b Distribution Assemblies a is Tier 1 1 5 5 Group Group 5 t Qo c j K 3 LL b tc E N 3 Bus Bars 5 FIGURE 2 11 GJ1 TYPE BREAKER DISTRIBUTION ASSEMBLIES TYPICAL 1 Select a starting point the lowest Group letter Position 1 is recommended For the load supply cable end use a single hole lug for a 3 8 bolt See Figure 2 12 Bolt the supply cable end to the breaker terminal using 3 8 hardware per figure 2 12 Repeat the above steps for each GJ1 type breaker in the Group Uu GJ1 Circuit Breaker 4 Places 3 8 Nut and Flat Washer N Load Supply Cable with 3 8 Lug and Output Terminal Hardware an pA J Je Bracket Mounting Screw Lo s 12 24 x 3 4 2 Places Mounting Bracket U Shaped 3 8 x 1 Hex Bolt Bevel Washer Flat Washer Breaker Mounting Bar 2 Places Bus L Shaped
37. available Equipment to move Power system to installation site Floor anchors to secure the Power system Conduit and or overhead wire racks for cabling Standard insulated installation tools e g hand tools socket set cable cutters cable insulation strippers Torque wrench to ensure correct tightening of hardware see Table 2 2 for torque specifications Electrical service panel circuit breakers Digital Voltmeter with 4 1 2 digit display Cables and lugs appropriate crimping tools AMI Circuit Breaker Distribution uses Two hole lugs for 1 4 threaded studs 5 8 center to center and GJ1 Circuit Breaker Distribution uses Single hole lugs for 3 8 bolt Return bus uses Two hole lugs for 1 4 threaded studs 5 8 a center to center and two hole lugs for 3 8 threaded studs 1 center to center Battery Charge and Discharge Buses use Two hole lugs for 3 8 threaded studs 1 center to center Conduit conduit connectors and conduit bending tools Anti Static Service Kit with static dissipative mat and wrist strap for handling electronic circuit boards e g Interface Board available from electronic supply sources PM990 8800 00 Issue 7 2 2 Sageon III Power System Installation 2 2 2 Selecting and Sizing DC Power Cables Protective circuits overall system performance and safety depend on the proper sizing of DC cables for current and acceptable DC voltage drop The minimum size allowable is the larger of the wire size per
38. battery data sheets and other site documentation for ready reference should it be needed Complete all installation steps Refer to Chapter 2 Installation as necessary Review the steps in Section 3 2 Commissioning a System Become familiar with operator panel LEDs front panel displays push buttons and menus by reading Chapter 4 Configuration and Operation Start up configuration parameter values e Battery String Connected to Plant The string will power the SCU prior to starting the first Rectifier assuming at least a minimal battery charge and the SCU 2 line display and status LEDs will be active You may then use the operator panel to change many of these default parameter values to accommodate the application See Table 4 1 for a list of default parameters and values e No Battery String Connected to Plant When the first Rectifier starts and powers SCU the SCU will load a default plant configuration You may then use the operator panel to change many of these default parameter values to accommodate the application See Table 4 1 for a list of default parameters and values Alternatively edit the configuration parameter values or load a new configuration from a PC connected to the USB port on the plant operator panel or from a PC connected to an Ethernet network an IP address must be entered The PC must be running the optional SageView plant monitor software Become familiar with the Rectifier LED codes in Section 6 3 T
39. cables at the return bus loads shown in Figure 2 6 This bus is located on the right of the distribution area and consists of up to three vertically mounted plates The plates have pairs of 1 4 and 3 8 threaded studs for 2 hole lugging Use the 1 4 studs for lower current loads protected with AMI type breakers The 3 8 studs are for higher current loads protected by GJ1 type breakers 2 7 2 Load Supply Cables AMI Type Breaker Distribution Connect customer load supply cabling in order by Tier Group and position number as shown on the Breaker Fuse Layout label on the inside of the distribution area door Cables are routed toward the nearest rack corner and then upward as shown in Figure 2 9 Distribution 3 cc D 2 e LL 21 Fuse Alarm FA Wire N Distribution Assemblies G S a O m Bars Distribution Rack Left Side FIGURE 2 9 DISTRIBUTION CABLE ROUTING PM990 8800 00 Issue 7 2 12 Sageon Power System Installation 1 Select a starting point Tier 1 Group A Position 1 is recommended Use appropriate lugs on the load supply and return cables 2 Dress the cable as shown in Figure 2 9 toward the front or rear of the rack according to the orientation of the distribution assembly Dress the cable away from rack assembly hardware to avoid possible chafing of the cable insulation Battery Discharge Bus Bar Distribution Assembly Alarm Strip Mounting Br
40. can require a password A PC that is to be connected to the Sageon III Power System must have the optional SageView software installed and operating 1 2 SPECIFICATIONS This section contains physical environmental and electrical specifications for the Power system and its major assemblies 1 2 1 Power system Physical Specifications Dimension 7 foot Tower 24 46 62 1 cm 21 48 54 6 cm 84 213 4 cm Contact the factory Dimension Rectifier Width 8 5 215 90 mm Depth 10 254 mm Height 1 RU Weight 5 1 Ibs 2 3 kg IMPORTANT The Power system is shipped without Rectifiers installed Consequently the pant is top heavy and can topple if mishandled Refer to Section 2 4 Moving and Anchoring the Power system before attempting to move the Power system 1 2 2 Power system Environmental Specifications Temperature Operatifig a siet e ttu 25 to 70 C 15 to 158 F Sustained Full Power 25 to 50 C 15 to 122 F enne gemi R 40 to 85 C 40 to 185 F Shipping and Handling Power system eee Shipped fully assembled on a skid designed to withstand the shock and vibration normally encountered in shipping and handling Rectifier Modules Encased in protective foam and shipped in individual boxes scesa ai 0 to 95 non condensing Note When operating the Po
41. current and battery voltage BDT period 0 365 days BDT start time hours minutes BDT duration hours minutes BDT current 0 5000A BDT end voltage BDT end charge Ah BDT alarm reset BDT end manual Last BDT results pass fail abort etc Last BDT time date duration Last BDT battery string voltage and charge IMPORTANT The number of the target battery string e g Battery 1 must be entered PM990 8800 00 Issue 7 4 13 Configuration and Operation Sageon III Power System Battery 1 current Press ENTER to display cell voltages for selected string if Battery Monitor option is installed and enabled Press up arrow or down arrow to scroll through cells Battery 2 current If additional battery strings are connected set the number of that string a maximum of four battery strings may be connected Battery temperature This screen shows the highest battery temperature when temperature sensors are installed on the battery string If sensors are not installed Sensor Not Attached will be displayed Estimated battery charge Battery discharge alarm threshold Set to the voltage to which the battery string falls during discharge When battery voltage reaches this value an alarm will be generated Battery discharge current differential threshold The allowable battery string discharge current difference is entered at this screen A reasonable value
42. has caused the voltage to exceed 70V for 48V systems The event could be caused either by a faulty rectifier or other equipment connected to the bus Add a small amount of load 22A per rectifier to the system and check for a faulty rectifier Check for other faulty equipment connected to the bus that could cause the overvoltage transient Use the Reset Latched Alarm from the Controller to reset the system A rectifier is indicating RECTIFIER Off or No Response on the Controller RECTIFIER display An AC failure to the rectifier is the most likely cause While the rectifier internal power rails are still available the unit will communicate with RECTIFIER Off if the AC has failed on its input Once the internal power dies the unit will no longer communicate and Controller will indicate No Response No Response all the time and the RECTIFIER is known to have AC power indicates a communications wiring problem Check the AC feed to the rectifier for a tripped circuit breaker blown fuse or faulty connection Check the RECTIFIER communications 10 way ribbon cable for broken connections and replace cable if necessary One or more rectifiers has a current limit or power limit alarm activated Total load including battery charging current is equal to the output limits of the rectifiers System overload One rectifier in current limit only indicates a likely calibration problem with the m
43. installed 2 To install the Rectifiers go to Section 2 14 Installing and Removing Rectifiers TABLE 6 3 RECTIFIER POSITION ADDRESSES 1 THROUGH 24 Table Notes ADR Rectifier position address SW1 Switch Positions ADR TOP SHELF BOTTOM SHEEE Non Shaded addresses 1 through 12 are used for 50 600A systems Shaded addresses 13 through 24 are used for 650 1200A systems SW1 1 8 ADDRESS SWITCH DETAIL ADDRESS 1 SHOWN PM990 8800 00 Issue 7 6 4 Sageon Power System Maintenance 6 7 TROUBLESHOOTING Symptom Likely Causes Action Rectifiers do not power up no LEDs lit on front panel AC power is not connected or internal fuse blown or rectifier not properly plugged in Re insert rectifier s and make sure the rear connections are good Confirm that AC power is available to the rectifier backplanes Replace the rectifier module if the unit is suspected to have failed No output current from rectifiers and the Green LED on each rectifier blinks occasionally AC power either lt 70VAC or gt 320VAC An internal relay will be heard open and close periodically if the AC voltage is excessive Check that the AC supply voltage and connection arrangement are correct and match the expected system supply wiring Over tempera
44. installed configuration or a configuration you created on a PC and uploaded to the SCU Table 4 1 lists the default values note that some default values will vary with customer specified equipment such as the number of Rectifiers installed Many values are user configurable and a column is provided in the table for recording of user selected values To configure the System from the operator panel review the screen sequences described in the following sections and enter the requested data To download a configuration to a PC or to upload a configuration from a PC refer to Chapter 5 SageView The SCU must be powered during any configuration efforts In this chapter Sections 4 1 and 4 2 describe the Home screen and use of the operator panel push buttons Sections 4 3 and 4 4 address the status LEDs and alarm messages Sections 4 5 through 4 9 explore the menu options available for configuration and operation of the System TABLE 4 1 SUMMARY OF DEFAULT SYSTEM SCU PARAMETERS Parameter Description 48V System 48V User Range System Value Default Base Home System Menu Amb Tmp Ambient temperature alarm level 30 99 C 55 C Alm Volts High System output volts high threshold 48 65V 57 5V Volts Low System output volts low threshold 44 54V 48 0V No of RECs Set number of Rectifiers in system 0 225 1 Num Number of battery strings installed 1 4 1 Batteries FS Bat
45. kel DISTRIBUTION V GROUPS A amp B ver vA ON EACH TIER LEFT SIDE FIGURE 2 7 DISTRIBUTION GROUP IDENTITIES AND LOCATIONS Distribution Group Orientation Orientation of a group determines the routing of the supply cables Figure 2 8 shows the orientation of AM1 distribution assemblies using their output studs circled as points of reference Groups A amp B are always oriented as shown ISTRIBUTI i b B CN x B HRRHBBRHI TARA PEE ze pESEERN di Q O iP n nale SEES A ED WT A man ER TOA ISTRIBUTI do E p Io era 73 oe oo me E az Umm ISTRIBUTI SUE To Ja ISTRIBUTI 2 FIGURE 2 8 DISTRIBUTION AREA TOP VIEW AM1 TYPE BREAKER DIST SHOWN PM990 8800 00 Issue 7 2 11 Installation Sageon III Power System 2 7 1 Load Return Cables Terminate all load return
46. o e IE n ba eor I danse b reote n eoe 5 1 SO SECUR Ye mm b amado ERRORI eren ion boe awanap utamakan 5 2 5 4 CABLE AND NETWORK CONNECTIONS 12 t recep eite caiano ba eei RP Re EE 5 2 5 5 LOCAL CONNECTION STANDARD wes u A Rame onu bend eb ibtd genial 5 2 5 6 REMOTE CONNECTION ETHERNET OPTION ie 5 2 S PC REQUIREMBENTS ate dr cta oe mm p ama pen beet roo b be d a a EO beer 5 2 SINSTEAELDING SAGEVIEW 5 2 2 d AnBRametab ot amado S oO On ipai ied am este 5 2 6 0 Prn 6 1 6 1 CIRCUIT BOARD HANDLING 5 poa siae nale 6 1 6 2 PERIODIC MAINTENANCE rid e tei de dep Me e dd dp eee ee eet b enel ege 6 1 6 3 TROUBLESHOOTING perlectis dgio deb e nce ttr te dep e Pelo ter euo deae ia e ERU Da peat ete cae de Sa eene taped 6 2 6 3 1 Reading Rectifier Status Led Codes ucraina ai ala nananana 6 2 6 4 REPLACING A RECTIPIER anan bendy sagan ete leere dagen debs Ree stan stre repe aaa iena 6 2 6 5 REPLACING THE SAGEON III CONTROL UNIT SCU 6 3 6 5 1 Configuration Considerations piaga neutre eere dep tete leto aa de eb nue aiar 6 3 6 6 REPLACING AN AC BACK PLANE BOARD 6 3 67 TROUBLESHOOTING picem eea T 6 5 68 TOREMOVE A RECTIFIER MODULEE iive ii IR AE a lana 6 7 6 9 TO INSERTA RECTIFIER MODULE inia a pt qe e
47. or top heavy Use adequate humanpower or equipment for handling Until the equipment is securely mounted be careful to prevent the equipment from being accidentally tipped over PM990 8800 00 Issue 7 i Front Matter Sageon Power System 4 NAMEPLATE Each piece of UNIPOWER equipment is identified by a part number on the nameplate Please refer to this number in all correspondence with UNIPOWER 5 INITIAL SETTINGS All equipment is shipped from our production area fully checked and adjusted Do not make any adjustments until you have referred to the technical reference or product manual 6 SPARE PARTS To minimize downtime during installation or operation we suggest you purchase spare fuses circuit boards and other recommended components as listed on the Recommended Spare Parts List in the back of the product manual If nothing else we strongly recommend stocking spare fuses for all systems PM990 8800 00 Issue 7 ii Sageon Power System Front Matter ISSUE HISTORY Page s m Issue Altered Description Approved Date 6 Updated entire manual with UNIPOWER logos verbiage DBW See ECN 20076 WD 2 13 15 2 13 15 7 Table 6 3 Updated Rectifier Position Address table with correct switch MCM position addresses See ECN 20395 10 21 15 DOCUMENT SUMMARY This product manual provides installation operation maintenance and troubleshooting procedures for the UNIPOWER LLC Sageon
48. rear of the GJ1 type breaker Note For GJ1 type breakers 200A and over the breaker kit contains an alarm wire adapter that must be connected between the breaker and the red alarm amp orange FA alarm wires of the GJ1 Distribution Option Carefully place the GJ1 type breaker from the kit over one of the vertical tabs of the L shaped bus bar of the GJ1 Distribution Option see Figure 8 3 Collect from the GJ1 type breaker Kit one each of the following 3 8 16 x 1 1 4 hex head bolt 3 8 bevel washer and 3 8 flat washer Insert through tab of the GJ1 type breaker and thread into the insert of the vertical tab of the L shaped bus bar of the GJ1 Distribution Option see Figure 8 4 and tighten See Table 2 2 for torque specifications Replace the two painted breaker mounting bars of the GJ1 Distribution Option using the 10 32 x 1 2 screws removed in step 2 Collect the two 10 32 x 1 2 from the GJ1 type breaker Kit and secure the new GJ1 type breaker to the two painted breaker mounting bars of the GJ1 Distribution Option replaced in step 8 Use the remaining 3 8 hardware from the GJ1 type breaker Kit to secure load cabling to the GJ1 type breaker see Figure 8 4 GJ1 Circuit Breaker 4 Places Load Supply Cable with 3 8 Lug i 8 8 Nut and Flat Washer and Output Terminal Hardware T 4 Bracket Mounting Screw 12 24 x 3 4 2 Places s Mounting Bracket U Shaped 3 8 x 1 Hex Bolt Bevel Washer Flat Washer a
49. receiving documents and have the carrier sign their full name 1 3 If your receiving freight bill notes that a Tip N Tell is attached to your freight locate it If the Tip N Tell arrow has turned even partially blue this means the freight has been tipped in transport Make sure the carrier notes this on your receipt before you sign for the freight 2 EQUIPMENT INSPECTION 2 1 Within fifteen days open the crate and inspect the contents for damages While unpacking be careful not to discard any equipment parts or manuals If any damage is detected call the delivering carrier to determine appropriate action They may require an inspection SAVE ALL SHIPPING MATERIAL FOR THE INSPECTOR TO SEE 2 2 After the inspection has been made call UNIPOWER We will determine if the equipment should be returned to our plant for repair or if some other method would be more expeditious If it is determined that the equipment should be returned to UNIPOWER ask the delivering carrier to send the packages back to UNIPOWER at the delivering carrier s expense 2 3 If repair is necessary we will invoice you for the repair so that you may submit the bill to the delivering carrier with your claim form 2 4 It is your responsibility to file a claim with the delivering carrier Failure to properly file a claim for shipping damages may void warranty service for any physical damages later reported for repair 3 HANDLING Equipment can be universally heavy
50. ri OR baia eg Ath 1 5 12 7 Rectifier Specifications x AE toe le A prede A ip D AIR Ab am eli em teet 1 6 1 2 8 Safety Specifications n o E o b P f A e i o ta e OR e e ege o hte 1 8 13 ABBREVIATIONS AND ACRONYMS 4 tdt Sh e e ere e t ere o a Su pe ER RR haya ERE 1 8 L A REFERENCE PUBLICATIONS 2 iD hen e tm e o eio t Qi e EO A E te ha gU b aa a ubus 1 9 14 1 Monitoring Specifications s EA ote t dU e ree erp teen e halons gue ba elo o ER erre i 1 9 1 42 Alarni Specifications pote etate ode doceo aed feto ete ei desee dete exe nt e 1 9 TS PRODUCT SUPPOR MERC nt 1 10 PU 2 1 2 INSTAI LATON SUMMAR Y ctetur ico ete oe ivanell ids deo gioia 2 1 22 REFERENCE MATERIAL eiecit ede ee a Qanun Peut tue tek ale see Suite Eee 2 2 2 2 Tools And ACCeSSOEIES soie ere Pbi n Heres Ra Ri Lane ca ehi 2 2 2 2 2 Selecting and Sizing DC Power Cables dier Eee eret coe D Bo tecti bb de o te tum idee r eR dte deer a 2 3 2 2 3 Torque fet Peine Herne m ie oci a Ri Aa 2 4 23 SELECTING A LOCATION ere dete Ore ana ei 2 4 2 4 MOVING AND ANCHORING THE POWER SYSTEM teen nennen 2 4 2 5 CONNECTING AC POWER TO THE POWER trennen teen trennen 2 6 2 5 1 Lightin eand Transient SUppressioni uite t a eec Htec D iet Pe
51. see Figure 2 2 for mounting pattern as needed Carefully transport the Power system to the installation site If possible protective wrapping should remain in place until the move is completed e Since the plant is shipped bolted to a skid a forklift is typically used for transport to the installation site e A lift point is provided in each rack corner near the top for an overhead crane or other lifting equipment e Be careful not to bend or otherwise damage the side and rear panels e Be careful not to mar or otherwise damage the front bezels Set the Power system in place Securely fasten the Power system to the floor 2 5 CONNECTING AC POWER TO THE POWER SYSTEM Connect single phase power through a circuit breaker to each input in plant See Section 1 2 7 Rectifier Specifications for voltage and current requirements See section 3 4 for more on connections Single Phase AC Power to Power System User s AC Electrical Service Panel A ground is required with the AC power connections for safety and for limiting EMI RFI emissions PM990 8800 00 Issue 7 2 6 Sageon III Power System Installation Plant Rack Ground the Power system rack to the site s central frame ground applicable in accordance with codes and the customer s standard practice Unthreaded holes for bolting an earth safety ground wire to the rack are provided in the top and bottom both on rear Remove the paint from a small area e g 1 5 in 3
52. the National Electrical Code or the calculated wire size Use the following method to determine the wire size 1 Calculate the minimum area in circular mils CM required for copper wire using the following formula 222xIxL CM V where CM minimum area of circular mils in the cable I maximum current in amps L one way cable length in feet V allowable loop voltage drop in volts Example Assume a maximum output current of 100 amperes an allowable loop voltage drop of 0 25 volts and a distance of 50 feet between the Power system and the load 100 amperes L 50 feet V 0 25 volts 22 2 100 50 CM 0 25 CM 440 000 circular mils 2 After calculating the minimum area in circular mils select the proper copper wire size from Table 2 1 always choosing the next larger wire size if the area rating falls between values For the above example select 500 MCM wire 3 Determine the minimum wire size for ampacity according to the code authority having jurisdiction in your location 4 Select the larger of the sizes calculated for voltage drop or ampacity TABLE 2 1 WIRE SIZING SIZE AREA CURRENT DIA RHW DIA RHW AWG IN CM CARRYING BARE OVER INS BEND NO CAPACITY COND INCHES RADIU OPE ENCLOSE INCHES S N D INCHE AIR S 14 4 110 15 15 0 064 0 19 0 95 12 6 530 20 20 0 081 0 21 1 05 10 10 380 30 30 0 102 0 24 1 20 8 16 510 45 45 0 146 0 31 1 55 6 26 250 70 65 0
53. 0 5691 Modular Assemblies Rectifier 48V 50A 100 7675 4850 Individual Parts Temperature Sensor 10 Ft 3m 385 5941 03 Temperature Sensor 20 Ft 6m 385 5941 06 Temperature Sensor 45 Ft 15m 385 5941 15 Temperature Sensor 90 Ft 30m 385 5941 30 Documentation Sageon III Power System Product Manual 990 8800 00 Sageon III Schematic Diagram SD SAGEON3 AXX PM990 8800 00 Issue 7 9 1 2 Y 3 4 ISSUE ISSUE DESCRIPTION ISS BY APP BY ISS DATE APP DATE ES 20076 WD DBW or LOGO VERBIAGE 2 13 15 2 13 15 TO STATE UNIPOWER ALARM CONTACTS A RATED 2 AM ESISITLVB 48 VDC ALL WIRES ARE 20 GA MINIMUM UNLESS OIHERWISE NOTED CURRENT TRANSDUCE ONS EQUA SAGEONS COT LTS LECT UP 10 4 INDIVIDUAL BATTERY RING CURRENT TRANSDUCERS ORD S SEPARATE I ORDER TEMPERATUR RO AS SEPA ITEMS INDIVIDUAL 20AMP AC BREAKERS INCLUDE EACH RECTIFIER POS LST DON DASHED LINES DENOTE CUSTOMER CONNECTIONS OR ESTEE APPROVALS EXTERNAL PANEL CONNECTIONS TOLERANCE
54. 184 0 40 2 00 4 41 740 100 85 0 232 0 45 2 25 2 66 370 135 115 0 292 0 51 2 55 1 0 105 500 185 150 0 373 0 63 3 15 2 0 133 100 210 175 0 418 0 68 3 40 4 0 211 600 300 230 0 528 0 78 3 90 350 350 000 425 310 0 681 0 98 4 90 500 500 000 525 380 0 814 1 12 5 60 750 750 000 660 475 0 998 1 34 6 70 Data based on NEC Handbook 2011 Table 310 17 adjusted for 50 C 122 F ambient temperature PM990 8800 00 Issue 7 2 3 Installation Sageon III Power System 2 2 3 Torque Specifications Proper plant performance requires that the hardware employed during installation be tightened securely but not over tightened Use a torque wrench to ensure that hardware is tightened to the specification provided in Table 2 2 TABLE 2 2 TORQUE SPECIFICATIONS STEEL FASTENERS Inch Pound s Bolt Size 4 40 Foot Pound s Newton Meters 4 48 6 32 6 40 8 32 8 36 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 71 16 14 71 16 20 1 2 13 1 2 20 9 16 12 9 16 18 2 3 SELECTING A LOCATION Install the Power system in a location that provides the following e Access to a source of reliable stable electrically clean AC power e A dry well ventilated room that meets the conditions stated in Section 1 2 2 Power system Environmental Specifications e Sufficient access for pl
55. 20A difference alarm Batt T Alarm Battery temperature alarm threshold 30 to 90 C 40 Bat Rated Ampere hour rating of batteries 20 9 999AH BTC Battery temperature coefficient 0 6mV C 0mV cell Number Cells Number of chemical cells in battery 4 24 24 string BILim Battery charging current limit for 5 999A 50 Vb lt Vdd Vb lt Vdd Vdd Level Battery deep discharge voltage 40 47V 45V threshold BILim Battery charging current limit 5 999A 50 Vb lt Vfl between Vdd amp Vfl Sys Float System float voltage Vfl 48 58V 54 2V Sys Drop System voltage drop 0 0 2 0V 0 5V Equalization Enable disable Eq function On Off On FS Load I Full Scale Load Current sensor 50 3000 100 value Load Sensor Enable disable Load Sensor On Off Off BILim Battery charging current limit in 5 999A 50 Vb gt VfI equalize Vb gt VfI Sys Equal System equalize voltage Veg 50 61V 56V V Start Eq Enable disable discharge voltage On Off Off initiation of Eq Eq trigger Discharge voltage threshold for 44 50V 48V charging Q Start Eq Enable disable battery charge On Off Off depletion trigger disch Trig Charge depletion threshold for Eq 5 999AH 15AH charging PM990 8800 00 Issue 7 4 2 Sageon Power System Configuration and Operation Parameter Description 48V System 48V User Range System Value Default Eq End Equalization termination for I bat lt 1 2
56. 85 5970 200 600A closed circular 1 25 diam window 100 signal wire 385 5970 600 1000A closed rect 2 51 x 0 82 window 100 signal wire 385 5970 1000 500A split core circular 0 84 diam window 30 signal wire 385 5980 500 10004 split core rect 4 00 x 1 57 window 30 signal wire 385 5980 1000 Battery Temperature Sensors Requires SAGEONS3 CO01 for more than One 1 Battery String Temperature Sensor 10 3M 385 5941 03 Temperature Sensor 19 6M 385 5941 06 Temperature Sensor 50 15M 385 5941 15 AMI Plug In Bullet Circuit Breaker Kits for Sageon III Kits include breaker bus adaptor amp return mounting hardware Ampere AMI Series Breaker 1 Position 274 3830 01 3 Ampere AMI Series Breaker 1 Position 274 3830 03 5 Ampere 1 Series Breaker 1 Position 274 3830 05 10 Ampere 1 Series Breaker 1 Position 274 3830 10 15 Ampere AMI Series Breaker 1 Position 274 3830 15 20 Ampere Series Breaker 1 Position 274 3830 20 25 Ampere AMI Series Breaker 1 Position 274 3830 25 30 Ampere AMI Series Breaker 1 Position 274 3830 30 40 Ampere AMI Series Breaker 1 Position 274 3830 40 50 Ampere AMI Series Breaker 1 Position 274 3830 50 60 Ampere AMI Series Breaker 1 Position 274 3830 60 70 Ampere AMI Series Breaker 1 Position 274 3830 70 80 Ampere AMI Series Breaker 1 Position 274 3830 80 90 Ampere AMI Series Breaker 1
57. Batt Temp Alarm Modify ue up down 1 flagged Not active without sensor 50 6 a CENTER Io accept oo ENTER Battery capacity C10 in Ah estes aces 500Ah ENTER to accept _ ENTER Battery Temperature compensation Modify Value up down 1 Variable from 0 to 6 0mV C C 3 2 mV C C ENTER to accep IIBTC not Of TTT ENTER Mid point temp for BTC curve Comp 0 heim 20 E ENTER tO accept ENTER Modify Value up down 1 Physical number of 2V cells in string used for BTC 24 L ENTER to accept _ ENTER Charge current limit for recovery of BiLim Vb lt Vdd Modify Value up down deep discharged batteries t 32A ENTER to accep 1 DEC ENTER 7 Battery voltage below which the battery Vdd Level Modify Val ue up down T is considered to be deep discharged INC ENTER Charge current limit for battery voltage 0 BiLim Vb Vfl Modify Value up down between deep discharge amp float autem ae ENTER System Float voltage without BTC System Float Modify Val ue Up dov wn 1 Sense point voltage regulated to this value eene ENTER Estimated max resistive drop between the System V Drop Modify Val ue p dov wn SMRs and the system voltage sense point PM990 8800 00 Issue 7 4 25 Configuration and Operation Sageon Power System Battery Menu continued Equalisation BILim Vb gt Vfl 20A System Equalise 56 5V Volts Start Eq Q Start Eq EQ End Current 15A EQ Duration 3 ho
58. Breaker Mounting Bar 2 Places Bus Bar L Shaped Breaker Input Terminal Hardware FIGURE 8 3 GJ1 TYPE BREAKER KIT COMPONENTS PM990 8800 00 Issue 7 8 3 Circuit Breaker and Fuse Kit Installation Sageon III Power System ENS gj E P A N Lower distribution option E removed for clarity l FIGURE 8 4 GJ1 TYPE BREAKER KIT INSTALLATION PM990 8800 00 Issue 7 8 4 Sageon III Power System Spare and Replacement Parts 9 0 SPARE AND REPLACEMENT PARTS To minimize downtime should maintenance be required a supply of spare circuit breakers and fuses circuit boards rectifiers and other recommended components should be immediately available See the Recommended Spare Parts List below Please refer to the UNIPOWER part number when placing orders For assistance in ordering spare parts call UNIPOWER and ask to speak with Order Entry The telephone number is found in Section 1 5 Product Support TABLE 9 1 PARTS LIST Description Part Number Circuit Boards Rectifier Backplane Board ERT190 5540 Controller Backplane w Temp Comp ERT190 5770T Unit Sageon III Control Unit SCU 48V 103 4130 48 SNMP Beard 103 4015 32 Superseded by 103 4036 32 SNMP v3 Board 103 4036 32 BDM Board ERT190 5740X49P Battery Temp Comp ERT190 6011 Aux Alarm Board ERT19
59. C Coeff 3 2 mV C C BTC Nominal 20 C PM990 8800 00 Issue 7 4 14 Sageon III Power System Configuration and Operation BTC Notes 1 Ifthe battery temperature sensor is not connected compensation is based on the ambient temperature sensor 2 If battery and ambient temperature sensors are connected compensation is based solely on the battery sensor 3 When temperature compensation is active the SMR voltage setting is automatically adjusted by the SCU as needed Number of Cells 12 Battery cells per string Set the number of physical cells in a string Battery charging current limit Set the maximum battery charge current when the voltage BILim Vb lt Vdd across the two battery strings is less than the deep discharge voltage Vdd 34A Battery deep discharge voltage Vdd es ol Battery charging current limit Set the current when the battery voltage is between Vdd BILim VbeVfl and the float voltage Vfl This current is typically higher than that for the deeply 52 discharge battery tem Float System float voltage Set the system output voltage at the output bus bar terminals dis ve System voltage drop Set the maximum voltage drop as defined by maximum rectifier tem V D output system float voltage A typical value is 0 6V Sys pue TOp 4 7 2 Equalization Equalizati Equalization on off toggle 10n If equalization in off the following screens will not appear im M BILim Vb gt Vfl Batt
60. C monitor on off 3 ph AC monitor on off Sageon III Battery Monitor on off Battery configuration Number of batt strings monitored Cell voltage high low differential Site monitor press ENTER Outputs 1 4 on off status no normally open nc normally closed Note The screen examples in this and subsequent sections will vary with System voltage loads environment battery quantity type and condition included System options and other factors Note Screens for options will not be viewable unless the option is installed and or enabled PM990 8800 00 Issue 7 4 7 Configuration and Operation Sageon Power System Access the screen series shown here by pressing the up arrow button Press the down arrow button to access the screens in reverse order Home screen 155A 54 2V FL C indicates that the battery temperature compensation is active 155 Fa Ambient Temp 31 C Ambient temperature is displayed in degrees Centigrade Ambient temperature alarm level Ambient Temp Alarm 45 C 3 Ph ACI Volts 216V 3 Phase AC monitor voltage current and frequency Use up arrow or down arrow to scroll through the three AC inputs for each parameter AC monitor option must be installed to view these screens Programmable parameters This series of screens contain programmable parameters To change a parameter value 1 Scroll to the desired screen using the up a
61. CING THE SCU SAGEON HI CONTROL UNIT 6 5 1 Configuration Considerations The System configuration is stored in non volatile memory on the SCU Backplane board The SCU plugs into the SCU Backplane board so the SCU can be replaced without affecting the configuration It is recommended that if you have not previously recorded System configuration values and the SCU is functioning do so now before performing the replacement Alternatively download the SCU configuration to either a local PC plugged into the operator panel USB connector or a remotely connected PC If the SCU is malfunctioning and you believe the configuration values may not be correct save the file under a new filename to prevent overwriting earlier good data SageView System Monitor software must be installed in the PC Refer to Sageview manual for more information If the SCU is not functioning the replacement unit will power up with the configuration stored on the SCU Backplane which can then be edited from the operator panel or a PC 6 6 REPLACING AN AC BACK PLANE BOARD 1 The system must be powered down to replace a rectifier back plane board PM990 8800 00 Issue 7 6 3 Maintenance Sageon III Power System IMPORTANT Each rectifier position address must be unique do not use an address number more than once Addresses must be in numerical order with the uppermost in the System Rectifier having address 1 The address number increases by 1 with each Rectifier
62. Configuration Used N O options are normally closed normally open or disabled not used Press ENTER to access the Sageon Battery Monitor and the Sageon Site Monitor Press Auxiliary Units up arrow to go to the top of the menu string Press ENTER Note Screens for installed options e g Sageon Battery Monitor Site Monitor appear next If no options are installed the HOME screen will appear 4 5 1 Sageon Battery Monitor Note See Section 4 9 Sageon Battery Monitor Setup for additional information When battery cell voltage monitoring is included in software the window at right will Battery Monitor appear next Press ENTER Battery monitor on off toggle Press ENTER to display the current On Off status Battery Monitor flashing Press up arrow or down arrow to set the desired state then press ENTER On to store PM990 8800 00 Issue 7 4 10 Sageon III Power System Configuration and Operation The following screens will not appear if Off has been entered Battery configuration Set the number of cells in a battery string and the number of Bat Config battery strings connected to the monitor See Section 4 9 Sageon HI Battery Monitor 24 cells Setup for details After pressing ENTER current configuration will flash Scroll through the available configurations and press ENTER again once the correct battery type is chosen SBM Batteries Battery strings Set the number of connected battery strings T
63. D The user configurable auxiliary relays contacts are shown above See section 1 4 2 for contact ratings PM990 8800 00 Issue 7 3 9 Commissioning Sageon III Power System The pin configuration is Pin 1 shown in Figure 3 11 Relay Pin Pin function 1 N O normally open 1 2 N C normally closed 3 C common 4 N O 2 5 N C The relays being user configurable can be arranged to 6 C activate for multiple alarm conditions or a single alarm 7 N O only The logic can be inverted for individual relays so 3 8 N C that one becomes a controller failure indicator use the 9 C normally closed contact as this will also indicate if the 10 N O relay power has failed 4 11 N C 12 C 13 N O 5 14 N C 15 C 3 7 CONTROLLER POWER CONNECTIONS Power for the Controller and its peripherals is derived from the DC bus or the highest charged battery The Battery distribution module has reverse polarity protection circuit that also serves to provide an or ing of the highest supply voltage for the Controller No additional user connections are required to power the Controller or provide system voltage regulation if the battery distribution module is used 3 8 FRONT PANEL USB COMMUNICATIONS CONNECTION The front USB port on the Controller is configured as USB slave and has a B type connector A standard USB A to B cable is required The Controller can only communicate via the
64. ER toggles state Start Stop S Z Modify Value up down L ENTER to accept Modify Value up down ENTER to accept L pe ENTER toggles state J ON a oe ey I Modify Value up down I pz ENTER to accept Modify Value up down I L ENTER to c n uc rp eT Modify Value up down ENTER to accep Lume Modify Val ue up down LL ENTER toraccept u Modify Value up down 71 ENTER to accep b ama w m w m mr wr m N Modify Value up down ENTER to accep ee i anlan Me ENTER to accept Battery charging current below which equalisation charging terminates Maximum duration of equalisation Periodic equalisation charging trigger Set to zero to disable Manual control of equalisation Battery voltage below which the LVDS opens when in Auto mode LVDS where used operation mode Auto Open or Closed Enable disable battery overtemperature alarm set to off if no sensor used Periodic battery discharge test trigger Set to zero to disable Time of day to begin automatic discharge testing Maximum duration of a discharge test Discharge test current controlled Load must be the value programmed Battery voltage below which the BDT terminates Battery loss of capacity below which the BDT terminates Result of the Last discharge test More detailed explanations of all the menu i
65. FL No Load SMR output current less than minimum for SMR type Amber FL Current Limit SMR in current limit Amber FL Voltage High Voltage measure by SMR too high Amber FL Voltage Low Voltage measure by SMR too low Amber FL UNCAL SMR SMR internal adjustment for current sharing out of limits Amber FL EEPROM Fail EEPROM failed SCU or SMR Amber FL Fan Fail SMR internal fan failure alarm Amber FL Relay Fail SMR output relay contacts failure Amber FL No Demand Control loop in SMR not in normal state Amber FL H S Temp High SMR heatsink temperature too high Amber FL Temp Sensor Fail Temperature sensor in SMR microprocessor circuit failed Amber Red Vref Fail Voltage reference in SMR microprocessor faulty Amber Red AC Volt Fault None of the SMRs are responding AC failure assumed or if AC monitor is used AC voltage is out of limits Amber Red AC Freq Fault AC frequency lower or higher than preset value Amber FL Battery switch One or more battery switches open Amber FL Cct Breaker Fuse or circuit breaker in load distribution open Amber FL LVDS Open Low Voltage Disconnect switch open Amber FL Sys Volts High System output voltage too high Amber FL Sys Voltage Low System output voltage too low Amber FL Cell V High One o
66. I POWER SYSTEM This manual contains text of descriptions procedures and supporting illustrations in reference to the Sageon III Power System It includes the front matter and chapters 1 through 9 1 4 PRODUCT DESCRIPTION The Sageon III Power system is intended for Cellular PCS and other applications that demand stable reliable high current DC operating power Sageon III can supply the voltage and currents shown in the following table Sageon Rack Height Plant Output Plant Output Cabinet Voltage Current max 7 foot Tower 7 Feet 48 Vdc 600A Figure 1 1 213 36 cm 48 Vdc 1200A max PM990 8800 00 Issue 7 1 1 Introduction Sageon III Power System As indicated above the Power System is divided into two areas distribution and power conversion The system is shown in Figure 1 1 It provides 12 power conversion positions at 600A or 24 power conversion positions at 1200A for rectifiers and 6 distribution groups in 3 distribution tiers with a user specified quantity of AMI circuit breakers amp GJ1 circuit breakers Power Conversion Plug in rectifier models are available in 48V It employs modular switched mode rectifier technology for highly efficient low cost reliable operation Each 48V rectifier can source up to 50A The quantity of rectifiers is determined by the user to accommodate the application A maximum of 24 rectifiers can be installed in a unit Distribution A unit can include up to 60 5 100A A
67. IONS eese eene rennen enne 2 15 FIGURE 2 14 TEMPERATURE SENSOR LOCATION dees tee hte ie ee uote e net ehe ei i Utere eigen 2 16 FIGURE 2 15 TYPICAL BATTERY CURRENT TRANSDUCER e tenen entren tren E enne nenne tenen 2 17 FIGURE 2 16 RECTIFIERS reete e e ER ERE ERE HERD Bien aic efe d RR Re 2 18 FIGURE 2 17 SAGEON III POWER SYSTEM iE Ee HE hee ter pL o eric et Ut eee e e e 2 20 FIGURE 2 18 CONNECTIONS ON CONTROLLER BACKPLANE 2 21 FIGURE 2 19 TEMPERATURE CONCENTRATOR 2 21 FIGURE 2 20 SAGEON IM BOARD LOCATIONS 5 5 rr te retire t ctr bei aa aaa anali 2 22 FIGURE 3 1 SINGLE PHASE FEED PHASE TO NEUTRAL enne enne trennen E rene enne enne 3 3 FIGURE 3 2 SINGLE PHASE FEED PHASE TO PHASE u sasana siasa trennen tenen teen nenne nen eterne enne 3 4 FIGURE 3 3 SPLIT SINGLE PHASE FEED PHASE TO NEUTRAL 3 5 FIGURE 3 4 Y THREE PHASE FEED A CONNECTED RECTIFIERS PHASE TO PHASE seen 3 6 FIGURE 3 5 Y THREE PHASE FEED PHASE TO NEUTRAL 3 7 FIGURE 3 6 A THREE PHASE FEED PHASE TO PHASKRE nete teen teinte inen trennen eren nne teen 3 8 FIGURE 3 7 SURGE PROTECTION tinta tete eret ter re e etel trei Ia eet ci bei pr c ete ied 3 9 FIGURE 3 8 MULTIPLE ALARM BOARD
68. ISTRIBUTION TIERS 2 AND 3 GROUPS A amp B This section describes installation of a kit for adding AMI type breaker distribution Kit contents and part numbers are listed below Installation of circuit breakers and fuses is described in Chapter 8 The figure at right shows many of the components included in the kit the U shaped bus bar distribution assembly assembly support bracket and required hardware There are two kits Kit PN 385 5881 00 is for installation in Group A Kit PN 385 5881 01 is for installation in Group B Figure 7 4 shows the orientation of the AMI distribution assemblies It also shows routing of the supply cables upward through the open top of the rack and the daisy chained alarm wiring PM990 8800 00 Issue 7 7 3 Distribution Option Kit Installation Sageon III Power System Distribution x Cablin 5 5 LL Le Fuse Alarm FA Wire Distribution Assemblies G O SA Bars FIGURE 7 4 ORIENTATION OF DISTRIBUTION ASSEMBLIES 48V SYSTEMS 7 1 1 Kit Contents Some hardware listed below may be factory installed on another item in the kit and disassembly may be needed to install the option kit Kit PN Kit PN Description 385 5881 00A 385 5881 01A Quantity Quantity 10 Position Distribution Assembly 1 1 Bus Bar U Shaped 1 1 B
69. Introduction Sageon III Power System Immunity continues Immunity Category Tested To Criterion Surge Protection ANSI C62 41 1991 category B3 AC lines Combination Wave 6 kV 3 kA Ring Wave 6 kV 500A 61000 4 5 EN 61000 4 5 Impulse 6 kV 3 kA Common Mode CM on AC lines 6 kV 3 kA Differential Mode DM on AC lines 0 5 kV 0 25 kA CM amp DM on DC lines IEC 61000 4 12 EN 61000 4 12 Ring Wave 6 kV 500A 100 kHz CM amp DM on AC lines 2 CM 1 kV DM on DC lines Conducted RF IEC 61000 4 6 EN 61000 4 6 3V on AC load and comms lines Voltage Dip Interruptions 1 2 7 Rectifier Specifications 61000 4 11 EN 61000 4 11 Level 100 dip for 10 ms Level 30 dip for 500 ms Level 100 dropout for 5s 5
70. Issue 7 3 1 Commissioning Sageon III Power System 3 Ensure that the circuit breakers in the user s AC electrical service panel are Off 4 Disconnect all loads from the system by turning Off all load breakers 5 The Rectifier On Off breaker of each Rectifier is set to Off See Figure 2 4 6 Turn On power to Rectifier 1 The top most left Rectifier in the stack will perform a power up self test lighting the three LEDs on the rectifier After a brief period the red and yellow LEDs will extinguish and green LED will remain lighted Float mode Refer to the following note and to Section 6 3 Troubleshooting should the red or yellow LEDs remain lighted Yellow LED Note When starting the System for the first time it may be necessary for the rectifiers to supply significant current for initial battery charging A lighted yellow LED on a rectifier may not be due to a rectifier problem but rather indicate that the rectifier is operating in the over current mode due to a discharged battery string If this is the case continue with the procedure to bring additional Rectifiers on line 7 Read the rectifier current and voltage on the operator panel 2 line display The Red 155A 54 2V LED on the panel will be lighted unless the number of operating Rectifiers equals FL the number of Rectifiers in the System configuration in which case the Green LED will be lighted Refer to Section 6 3 Troubleshooting as needed 8 Connect a 10 to 50A load to the Sy
71. L ENTER ENTER INC DEC toggles state _ENTER ito accept_ If Site Monitor not Off ite Monitor Off ENTER Status of output relay 1 l Output 1 Modify Value up down Off ENTER R to accept _ cara ofo f output it relay 2 2 Output 2 Modify Value up down 1 Off ENTER R to accept 2 ofo output it relay 3 3 Output 3 Modify Value up down 1 Off ENTER R to accept Sj ENTER ofo output it relay 4 4 Output 4 l Modify Value up down 1 Off i ENTER to accept F PM990 8800 00 Issue 7 4 23 Configuration and Operation Sageon III Power System 4 13 2 Rectifier Menu Rectifier Specific Functions Home Screen FL SMR Button ENTER SMR software version MH1 1 13 2A 58 C S W 137901 N 0102050500012 INC ENTER Additional screens if more 0 SMR2 SMRs are declared SMR Electronic Serial Float Voltage SMR Default MR Float 54 5V Equalise Voltage SMR Default MR Equalise 56 5V ENTER SMR voltage above which alarm flagged MR V high Alarm Modify Value up down 57 0V pENTER to accept J ENTERS E i ETT SMR voltage below which alarm flagged VR V Tow Alarm Value up down 1 Lidl 48 0V ENTER to accept J ENTER SOS SMR high voltage shutdown MR AVSD Modify Va e pdow 58 5V pENTER to accept J ENTER SSS SMR current limit MET Limit Modify Value up down TTT 30A ENTER to accept L ee Resets any lat
72. LES i 3 12 4 0 CONFIGURATION AND OPERATION scsssssssssssssssessessrsessessrsessessrsesscssssessessrsessassssessesessessessesessesessasessessasessessessssessesersesees 4 1 4 THE HOME SCREEN u S au Sun Sm aS a nihil 4 3 PM990 8800 00 Issue 7 vii Front Matter Sageon Power System 4 2 USING THE OPERATOR PANEL PUSH BUTTONS ii 4 3 4 3 READING THE OPERATOR PANEL SYSTEM STATUS LEDS eese eene nr ener nennen trennen nennen ene 4 4 4 4 READING ALARM MESSAGES ee 4 5 4 5 HOME MENU SCREENS sch ilaria Ge Qa ain ola aml RG et Pepe Bio alal 4 7 4 5 1 Sageon Battery Monitor aaa Le Elec ete a iA ere rte q iq aqila I n Pere be ieee Reese 4 10 4 52 Site OE ta IR QE reU ER eti ec p Ee e re E pa RR C RR Pe ep oed 4 11 4 6 RECT RECTIFIER MENU SCREENS 2 nananshan tg edile m rta e n eee e UH bu Ee s fed 4 11 AT BATT MENU SCREENS it nte D eo UD Re eigo G ote p t d e re o A ER eoe end 4 13 4 7 1 Battery Temperature Compensation ii 4 14 4 7 2 BqualiZation 3 0 iet a A Ee tete Re e hp LA ce trip RA bi tpe o e erg ted 4 15 4 7 3 Low Voltage Battery Disconnect LVBD LVLD Screens nn nns 4 16 4 7 A Battery Discharge Test BDT Screens iie hte ett eee Peace up E outst hua aQ depo ha pu ua bai 4 16 2 75 BDT Results Serena cote meo Eee e e ep o ten dh suse qu u
73. MI circuit breakers Up to 8 100 450A GJI circuit breakers can be installed however each group of 4 GJ1 type breakers reduces the available AMI positions by 10 Circuit breaker and fuse kits are ordered separately to accommodate the application For AMI type breakers the load supply and return connections use two hole wire lugs for 1 4 studs 5 8 center to center The supply cable is bolted to a distribution assembly that has two 1 4 20 studs and the return connection is bolted to the return bus bar that also has 1 4 studs Where higher current GJ1 type breakers are specified the load supply connection is a 3 8 ring lug bolted directly to the breaker terminal The return connection is bolted to the return bus bar using a two hole lug for 3 8 bolts 1 center to center Battery Strings Battery charge and battery return can facilitate eight sets of 2 hole lug wiring for 3 8 inch diameter studs on 1 inch centers Operator Panel Mounted in the system is a modular hot swappable controller which includes a high resolution 2 line digital display for monitoring of the Sageon III Power System output current and voltage Six push buttons are available for operating the Sageon III Power System selecting display information and for changing editable parameters A complete System configuration can be created at the operator panel Three System status LEDs are provided Communications PC based configuration and monitoring is available with the UNI
74. MP 1 TEMP 2 TEMP 3 TEMP 4 IIS c N NO GND 24V IN 48V OUT 48V IN 24V OUT S CONNECT STRING TEMPERATURE OPT SENSORS AT STRING EXTERNAL CT S MIDPOINTS SEE NOTE 3 SEE NOTE 8 DC CT FA CKT BRD BATTERY DISCONNECT PANEL NC NOC cee DIST GROUP B TIER 2 BATTERY BLK DISCONNECT _PANEL 10 WHT V10 BRN CUSTOMER LOADS 48 VOLT DIST GROUP B BATTERY BLK TIER 3 DISCONNECT _PANEL pe CUSTOMER SPECIFIC n CURR 1 ve ost LK CURR 2 CURR 3 CURR 4 B BATTERY DISCONNECT PANEL AUX_RELAY C V c AUX RELAY NO 4 o AH AUX_RELAY_NO AUX RELAY NO 2 AUX RELAY NO 1 SAGEON3 A01 ONLY INTERNAL BATTERY LVD BUS BAR LVD CONTROL Y PASS SWITCH BUS BAR BRN RED BLK BATTERY LANDING TERMINAL 8 LANDINGS WHT VIO PROPRIETARY INFORMATION NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPO
75. OCK DIAGRAM 48V POWER SYSTEM trennen 1 3 FIGURE 1 3 600A PLANT u J a ier meter erre re eb ee dvs I e OR rp OH venues ertet 1 6 EIGURE 1 4 1200A PE ANT crt e t e aasma eret e ee rn e t ete qupa ER e t n D gi Dese eite 1 6 FIGURE 2 1 POWER SYSTEM DIMENSIONS ie 2 5 FIGURE 2 2 PLANT BASE tete hrec aet egre reden e a eet a e E P t n u ibu Dei e A evades ene 2 6 FIGURE2 3 RETURN BUS LOCATIONS etm etr pret o e t ee e Ae 2 7 FIGURE 2 4 AC INPUT CABLING WITH RECTIFIER ON OFF OPTION e 2 8 FIGURE 2 5 BATTERY CHARGE BUS AND BATTERY RETURN BUS LOCATIONS 2 9 FIGURE 2 6 LOAD SUPPLY AND RETURN CABLING entente isa reete 2 10 FIGURE 2 7 DISTRIBUTION GROUP IDENTITIES AND LOCATIONS nren rene ene ennnenneeene tenen 2 11 FIGURE 2 8 DISTRIBUTION AREA TOP VIEW AMI TYPE BREAKER DIST SHOWN i 2 11 FIGURE2 9 DISTRIBUTION CABLE ROUTING tore rere o era Sut reto eie la Me I I e D DRE ree Pee 2 12 FIGURE2 10 AMI LYPE DISTRIBUTION LUGGING ere rire rhet tU ave e OH S e EO ee tetera Shae 2 13 FIGURE 2 11 GJ1 TYPE BREAKER DISTRIBUTION ASSEMBLIES TYPICAL esent 2 14 FIGURE 2 12 GJ1 TYPE BREAKER DISTRIBUTION WIRING nennen nennen 2 14 FIGURE 2 13 INTERFACE BOARD CUSTOMER ALARM CONNECT
76. POWER SageView software SageView is a tool to exchange configurations and operating data between the Sageon III Power System and the PC on which SageView is running Local PC access is provided through a supplied USB B connector on the front panel of the controller using the SageView software Remote PC access across an Ethernet network is also standard The PC must be running SageView software and have a unique IP address on the network An Ethernet RJ 45 jack is provided for connecting to your company s intranet or to the Internet A unique IP address is required for each Sageon III Power System Remote access is also available via an SNMP Ethernet board Alarms Activation of customer supplied alarm annunciators is accommodated by form C relays The relay state is user selectable between normal mode normally de energized and failsafe mode Normally energized These relays provide for external annunciation of the alarms and are fully user configurable Refer to SageView help for configuring these relays Block Diagram Description A simplified block diagram of a 48V Sageon III Power System is shown in Figure 1 2 Single phase or three phase power is supplied from the user s AC electrical service panel PM990 8800 00 Issue 7 1 2 Sageon Power System Introduction I Ip hase to to
77. R e tee PUR E a Sa alba e RR bebe hte 6 7 7 0 DISTRIBUTION OPTION KIT INSTALLA TION 7 1 7 1 AMI DISTRIBUTION TIERS 2 AND 3 GROUPS A amp B nn aaa 7 3 TERE Contents a DTI IDOL LL ILE RR 7 4 3 1 2 Installing the 7 5 7 2 GJ1 DISTRIBUTION TIERS 2 AND 3 GROUPS A amp B_ 7 6 TD Kits Contents RP 7 7 E22 stalling the Kitu alia 7 7 8 0 CIRCUIT BREAKER AND FUSE KIT INSTALLATIONN 8 1 STAMI TYPE BREAKER KITS 3e de Peor eRe iaia 8 1 Contents iude eret et a la E 8 1 8 127 nst lling the Rit m tete rese teet P vedo dte ete ei le bete id Pd ete bett etes 8 1 8 2 GJI TYPE BREAKERKIIS San a nasqa Bat t e ATE AES Beta 8 2 82 1 Kit Contents PE aute eret e Nat epe Deere Eee re ee E evo Dee EA e Su ass 8 2 PM990 8800 00 Issue 7 viii Sageon Power System Front Matter 8 222 Installing the Kitu achat awn ated ne pudet e a nein A ane a 8 2 9 0 SPARE AND REPLACEMENT 9 1 FIGURE 1 1 SAGEON III POWER SYSTEM ttti ee net usa kya ape aee aste re e de vtt 1 1 FIGURE 1 2 SIMPLIFIED BL
78. Refer to Chapter 8 to install the GJ1 circuit breakers PM990 8800 00 Issue 7 7 7 Distribution Option Kit Installation Sageon Power System Load Supply Cable with 3 8 Lug 3 8 Nut and Flat Washer and Output Terminal Hardware m GJ1 Circuit Breaker 4 Places 4 Bracket Mounting Screw M 3 EA 3 12 24 x 3 4 2 Places 3 8 x 1 Hex Bolt M Mounting Bracket U Shaped Bevel Washer Flat Washer Breaker Mounting Bar 2 Places Bus Bar L Shaped Breaker Input Terminal Hardware FIGURE 7 7 GJ1 DISTRIBUTION KIT W BREAKER KIT PM990 8800 00 Issue 7 7 8 Sageon Power System Circuit Breaker and Fuse Kit Installation 8 0 CIRCUIT BREAKER AND FUSE KIT INSTALLATION All AMI type breaker fuse kits included in the initial Power system order are shipped from the factory in separate protective packaging This packaging is placed inside the tower at the base the Power system GJ1 type breaker kits included in the initial Power system order are factory installed All Breaker AMI amp GJ1 Kits can also be ordered separately to add to existing distribution when empty positions exist 8 1 AMI TYPE BREAKER KITS 8 1 1 Kit Contents Description Quantity AMI type breaker Bullet type mount 1 Bus Bar Output 1 Nut Hex 1 4 20 2 Washer Flat 1 4 2 8 1 2 Installing the Kit 1 Remove an AMI type breaker kit from its protective packaging The pack
79. S ON 0 002 Mc 3 8 13 DASH DOT LINES DENO COMPONENTS O ioni NAL TO SAGEONS ccm mi 3411 13 DISCONNECI PANELS INC AND MUST ORDERED AS A SEPARATE LINE ITEM SHOWN FOR ILLUSTRATION We TCA Jue TOS ONT MON te 02543 4 MON te 02543 4 SPEC ENGO32 MATERIAL FINISH BATTERIES ARE NOT INCLUDED AND MUST B SGH SEMEN ORDERED SEPARATELY SHOWN HER OR NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT ILLUSTRAT I ON OF YP I L A y I CAT I ON ONLY PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC UNI DOWER Powering Technology SHEET INDEX NOTE HE ISSUE OF SHE 1 REFLECTS THE LATEST ISSUE F THE DRAWING SET WHEN THE DRAWING SET IS EVISED ON E UE NUMBERS OF MODIFIED S RE CHANGED E E NUMBERS OF UNMODIFIED SHEE ARE NOT CHA SCHEMATIC DIAGRAM FON 111 POWER SYSTE B DOC TYPE NUMBER ISSUE SD SAGEON3 AXX SCALE SHEET FILE NAME N A 1 OF 4 SD SAGEON3 AXX_ISS_4 ED991 5001 B3 Issue 3 1 2 i 3 4 RECTI R BACKP AUX_RIBBON EX
80. T COMMS RECTIFIER 48V 50A 100 7675 4850 1 RECTI R BACKPLA Xi Xe XsL_IL_Ix4 1 6 xo EXT COMMS AUXILIARY AMB BATT COMMS BATTERY DIST gt J REC IF IER 7 2 48V 50A Al SCU BACKPLANE I 100 7675 4850 2 I ORN BDM RIBBON A E e a RED PAG a W O OPTION CO1 SELECT ONLY ONE POWER AND SENSE CONNECTION WITH OPTION COI Ex d 6 RECTIFIER COMMS AC FEED ACCEPTS 14 AC BREAKERS CUSTOMER AC CONNECTIONS RECITFIER BUS 4 RECTIFIER BUS SAGEONS3 BO2 amp BO4 RECTI BACKPLA BUS BAR RECTIFIER 48V 50 BUS BAR 100 7675 4850 N PLANT SIZEMAX Z RECTS 600A 12 PROPRIETARY INFORMATION NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT 1200A 24 PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC SIZE DOC TYPE NUMBER ISSUE SD SAGEON3 AXX N A 2 OF 4 SD SAGEON3 AXX_ISS_4 1 2 1 3 4
81. TRAL gt L1 L G L L L L INCOMI f TO POWERSHELF a E E El rical Systems where Ne al ar uilding Earth FIGURE 3 7 SURGE PROTECTION 3 4 3 Battery connections The cables are brought out through the top of the unit This cable must be sized accordingly to carry the battery short circuit current for the time required to clear the battery protection devices Note Ensure the battery circuit breakers are open before connecting the batteries Connect the switched cable connections first followed by the common return cable connections 3 5 TEMPERATURE SENSORS The optional sensors for measuring ambient and battery temperature are the same device Part No 385 5941 03 06 15 30 The system auto detects if the sensor is plugged into one of the positions 4 or 5 If no sensor is installed the Controller will show Not Available in the menu items for the temperature measurements Locate the ambient sensor on a mass with a fairly long thermal time constant see Section 2 9 Locate the battery sensor on a battery block in the middle module of the battery bank likely hot zone 3 6 AUXILIARY RELAY CONNECTIONS ma 9 FIGURE 3 8 MULTIPLE ALARM BOAR
82. WER LLC SIZE DOC TYPE NUMBER ISSUE B SAGEON3 AXX SCALE SHEET FILE NAME N A 4 OF 4 SD SAGEON3 AXX_ISS_4
83. a 9 PM990 8800 00 Issue 7 x Sageon Power System Introduction 1 0 INTRODUCTION This Product Manual describes installation operation and servicing of UNIPOWER Sageon III Power systems The Sageon III Power system is available as a 48V seven foot high system in two ratings the 600 ampere and 1200 ampere max A view of the system is provided on the cover of this manual and in Figure 1 1 below b f B SAGEON II POWER SYSTEM 5 istribution A ry Strir DI iol LJ A ind ircuit Breaker ind Ground Inn E Im M ntrol Panel gl Include er ntroller age ES mmunications BDM Auxiliar Alarr z ri ind Temp Compensations e 7T nversion Module A COLI Vey Jule st r E x P EI E ES E ro AC Input Circui reaker E E ETUR GUI A Ont ion Includes Cu mer nr lor li b fror panel rer 1 for lari FIGURE 1 1 SAGEON II
84. acket Holes for Securing Cable Paired Output Studs Circuit Breaker or Fuse Note orientation Load Supply Cable i Short Mounting Surface See Detail Below 2 Long Mounting Surface Output Terminal Alarm Connection r Bus Bar NN NEL s s Circuit Breaker or Fus e Load Supply Cable and N 1 Note mounting surface 2 Hole Lug DI PIE orientation 1 1 4 20 Nuts A a Rant Detail of Load Supply Cable Connection Quee FIGURE 2 10 AMI TYPE DISTRIBUTION LUGGING Move to Group A Position 2 and repeat the above steps Repeat the steps until all positions in Tier 1 Group A are cabled Move to Tier 1 Group B and cable the positions Perform the above steps for Tiers 2 and 3 Bundle and secure cables as follows Two cable securing tabs are provided in each distribution assembly mounting bracket See Figures 2 10 and 7 2 for cable securing locations Ne S 1 All Group A Bundle cabling from all tiers at the left front of the rack 2 All Group B Bundle cabling from all tiers at the left rear of the rack PM990 8800 00 Issue 7 2 13 Installation Sageon III Power System 2 7 3 Load Supply Cables GJ1 Type Breaker Distribution When ordered GJ1 type distribution assemblies are always the upper most distribution assemblies in a plant since no more distribution can be installed above a GJ1 type assembly Cable routing and connection
85. age label will identify the kit by part number 2 Open the distribution area door Refer to Figure 7 1 and locate the Distribution Tier and Distribution Group where this kit will be installed 3 Place the Output Bus Bar over the two threaded studs of the Distribution Assembly orient as indicated in Figures 8 1 and 8 2 4 Place load cable lug over Output Bus Bar 5 Place the two 1 4 flat washers over the load cable lug 6 Install the two 1 4 20 hex nuts over the flat washers and tighten See Table 2 2 for torque specifications 7 Insert the AMI type breaker into the Distribution Assembly as indicated in Figure 8 2 This completes installation of the AMI type breaker Kit repeat steps 1 7 for all AMI type breaker Kits to be installed Output Bus Bar S IINE gt P AMI Circuit Breaker dA a M N rr 1 4 20 Nuts T Ns E I L FIGURE 8 1 AM1 TYPE BREAKER KIT COMPONENTS PM990 8800 00 Issue 7 8 1 Circuit Breaker and Fuse Kit Installation Sageon III Power System Distribution Assembly Support Bracket a U shaped Bus Bar gt Installed 1 type breaker Kit Note mounted Short Mounting Surface Long Mounting Surface Output Terminal 1 orientation les FIGURE 8 2 AM1 TYPE BREAKER SHOWN KIT INSTALLATION 8 2 GJ1 TYPE BREAKER KITS 8 2 1 Kit Contents Description Quantity
86. an accommodate up to four battery temperature sensors Temperature sensors are ordered separately If ordered with the system the sensors are connected to the Multiple Battery Temp Board and the sensors and wires then coiled and tied to the return bus If not ordered with the Sageon III Power System an Ambient and up to four Battery Temperature Sensor can be ordered separately Installing the Sensors Open the distribution door and locate the Multiple Battery Temperature Board Locate the coiled sensors 1 If not already connected plug the battery temperature sensor connectors and the ambient temperature sensor into the Controller backplane board See Table 2 4 for the connectors The connectors are keyed TABLE 2 4 BATTERY TEMPERATURE SENSOR CONNECTIONS Sensor Connector Battery String 1 Temperature in Figure 2 19 Battery String 2 Temperature X2 in Figure 2 19 Battery String 3 Temperature X3 in Figure 2 19 Battery String 4 Temperature X4 in Figure 2 19 Ambient Temperature X3 in Figure 2 18 PM990 8800 00 Issue 7 2 15 Installation Sageon III Power System 2 10 11 Select a location for mounting the ambient temperature sensor ring lug The temperature of this mass should have a fairly long thermal time constant e g temperature should not cycle with short term temperature changes due to normal environmental heating and cooling cycles Typically this could be a nearby equipment rack the Sageo
87. ant installation and servicing refer to NEC and local codes e Sufficient ceiling height to permit use of overhead cable trays and conduit for AC input cables and DC load supply and return cables securely anchor the plant e pest and varmint free area 2 4 MOVING AND ANCHORING THE POWER SYSTEM A level flat floor capable of supporting the weight of the Power system and accepting bolts or other user supplied hardware to A WARNING Keep the Power system vertical or transport the Power system Tip Over Crush Hazard Power system tip over can cause death or serious injury Power system is heavy and also top heavy Use a forklift or other equipment to move Y PM990 8800 00 Issue 7 2 4 Sageon Power System Installation The Power system is heavy up to 1 000 Ibs 453 kg and it is top heavy An improperly handled Power system can topple Proper handling equipment is required to transport the plant The unit dimensions are given in Figure 2 1 Figure 2 2 shows the Power system base and the floor mounting hole pattern Floor Mounting The Power system must be permanently anchored Install one anchor in each floor corner Mounting slots are provided in each corner to allow for ease of anchoring Mark and drill holes where shown in Figure 2 2 UNIPOWER offers several seismic zone hardware kits SAGEON IN POWER SYSTEM
88. attery string Press up arrow or down arrow to change the cell number n nnnV pp 4 10 COMMISSIONING THE CONTROLLER With all the batteries load and AC cabling wired and checked for correct polarity the system is commissioned by the following steps e Ensure no rectifiers are installed in the Power plant and no load is applied e Plugin the Controller it should power up off the battery If not it is possible that the battery polarity is reversed e Setup the Controller menu items for o number of batteries and size Ah number of rectifiers set the required float and equalize voltages set LVLD option to ON and set the LVLD Aux to 42 0V set the Battery Switch to Normally Open o O O O PM990 8800 00 Issue 7 4 19 Configuration and Operation Sageon III Power System o Switch to Normally Open set the Battery Transducer FS as size according to ordered transducers o set the amount of battery temperature compensation voltage adjustment if used and after confirming that the battery temperature is being measured o battery charging current limit to 10 of the Ah rating i e if 150Ah battery is used set the limit to 15A this value can be adjusted later to meet your specific charging requirements Always refer to the manufacturers recommendations for charging batteries In many cases these values are set up in the factory and will only require modification if the par
89. can connect directly to a PC locally or remotely via a modem or Ethernet Refer to the Sageon Battery Monitor Manual PM990 4209 00 for detailed information 2 12 SITE MONITOR SYSTEM OPTION The Site Monitor System is used to monitor the status of equipment external to the Sageon III Power System It has 12 digital inputs 8 analog inputs and 4 form C user assignable alarm relay contacts Digital inputs are often used to monitor site security such as door or window openings or other on off function such as a pump switch or motor starter Analog inputs frequently used to monitor a fuel level or other variable such as a voltage current or frequency Refer to the Sageon Site Monitor Application Note AN103 4012 00 for detailed information 2 13 COMMUNICATIONS Communication choices include operator panel mounted USB standard and an Ethernet network optional with or without SNMP support The following devices can access the SCU and the data it has stored for System configuration System operation and troubleshooting alarm events e Connect a local PC running SageView included to the SCU by way of the operator panel mounted USB connector and a user supplied USB A plug to USB B plug cable e Connect a remote i e network connected PC running SageView included to the SCU by way of the company s intranet or the Internet e Connect a remote i e network connected PC running standard SNMP based monitoring software customer suppl
90. ched SMR alarm Reset SMR Fault Press ENTER The RECTIFIER Float and Equalize voltages are the default values set in the rectifier that will be used if the Controller fails to operate They are a copy of the raw values set in the BATTERY menu without battery temperature compensation and system drop adjustments 4 13 3 Alarm Log Home Screen 25 2A 54 3V FL LOG Button LOG 1 AC Fail Most recent logged Alarm Event 10 10 2005 17 32 56 Additional screens if more events logged o DEC 100th most recent logged event Older events are erased INC v No Entries mere i PM990 8800 00 Issue 7 4 24 Sageon III Power System Configuration and Operation 4 13 4 Battery Menu Battery Specific Functions Home Screen 25 2A 54 3V FL Button Battery string 1 current Battery 1 Additional screens if more batteries declared DEC 10A Discharging INC Shows Not Available if no sensor connected or Sensor Fail is faulty 4 Estimated remaining charge Estimated Q Bat Additional screens if more batteries declared Estimated Q Bat4 ENTER Bus voltage below which alarm flagged Modify Value up down 40 ENTER to accept _ ENTER Alarm threshold for poor battery I Modify Value up down 1 current sharing shows if gt 1 battery 206 z ENTER to accept o ENTER Battery temperature above which alarm
91. cing hazard Arcing can cause equipment damage load interruptions and personal injury Remove watch and jewelry Use insulated tools and extreme caution when working with a battery string Carefully insulate unterminated battery cable ends At the Power system battery cables connect to the battery charge bus and return bus Three battery charge and battery return bus options are available to facilitate 2 hole lug wiring 3 8 inch diameter studs on 1 inch centers for a single tier 3 8 inch diameter studs on 1 75 inch centers for a single tier and 3 8 inch diameter studs on 1 75 inch centers for three tiers Installing the Battery Cables This procedure includes the installation of up to four optional battery current transducers Transducer mounting and wiring information is found in Section 2 10 Ignore references to transducers in the following procedure if not part of your installation If the installation includes a battery disconnect switch modify the procedure accordingly 1 Determine the correct battery cable size and shortest cable run See Section 2 2 2 Selecting and Sizing DC Power Cables The top of the distribution section is open for easy access when routing battery cables between the battery string and the Power system battery charge bus and return bus See Figure 2 5 for the location of the battery charge bus and battery return bus within the plant 2 Mount the optional battery current transducer s and co
92. dules installed Check the Battery DC CT rated full scale value is correctly set in the Base menu One unit is alarmed as HVSD high voltage shutdown and is latched off The unit has developed a fault that causes it to output a voltage above the HVSD protection limit and has been supplying load current while above this voltage limit A random event on the DC bus has occurred that forced a unit into HVSD Replacing the rectifier module is recommended However a random event may have triggered the HVSD and to determine if the unit has a real fault the HVSD latched alarm can be reset using the Reset Latched Alarm function in the Controller RECTIFIER Menu If the system does not have any PM990 8800 00 Issue 7 6 5 Maintenance Sageon III Power System Symptom Likely Causes Action batteries cycling the AC power will have the same effect If the unit does not recover by latching off again it is faulty RECTIFIER Urgent alarm activated One or many RECTIFIERs are off due to AC power failure internal faults incorrect command signal from Controller or all rectifiers are in current limit Check the AC power and restore Replace faulty rectifier modules Check for DC bus overload faults All units are latched off as HVSD Absolute Overvoltage shutdown protection activated The system is likely to have no load and without a battery An event the DC bus
93. e AC electrical service where appropriate 2 5 2 User s AC Electrical Service Panel The AC electrical service panel and wiring from the service panel to the Power system is supplied by the user A 1 Electrical shock hazard Remove power from all involved wires and terminals before proceeding 2 Determine the number of AC breaker positions needed Allow one breaker position for each Rectifier to be installed in the Power system Alternatively up to two Rectifiers can be fed from one breaker provided the breaker and wiring meet local and national electrical code requirements Power system terminals will accept 6 12 AWG 13 6 3 3 mm 3 Run the needed quantity of AC power cables from the service panel to the Power system PM990 8800 00 Issue 7 2 7 Installation Sageon III Power System Label each breaker position and both ends of each AC power cable with the Power system number and rectifier position address to which it will be connected e g PIR1 Power system 1 Rectifier position address 1 Rectifier positions are numbered from top to bottom as shown below Rectifier 1 Rectifier 2 Rectifier 3 Rectifier 4 Rectifier l l Section Rectifier 1 Rectifier 4 Ateach breaker position in AC panel install delayed trip circuit breaker for each cable Refer to Table 2 3 for breaker recommendation 5 Ensure that all circuit breakers are in the Off position 6 Connect the po
94. e distribution area door Temperature Sensor 1 CD00036a FIGURE 2 14 TEMPERATURE SENSOR LOCATION 2 10 INSTALLING A BATTERY CURRENT TRANSDUCER OPTION The optional battery current transducer senses the battery current for display on the operator panel When installed the battery current transducer also allows the user to configure the SCU to limit the recharge current to the battery string in order to extend battery life and set a fixed repeatable discharge current for battery discharge tests Install one battery current transducer per battery string up to four transducers If not ordered with the Sageon III Power System a Battery Current Transducer Kit is available PM990 8800 00 Issue 7 2 16 Sageon Power System Installation To install a transducer kit 1 Mount the transducer s with user supplied hardware Figure 2 15 shows a typical transducer Often transducers are mounted on the battery rack The location must allow for convenient routing of one or more battery cables or intercell connectors through each of the transducers The three possible installation options are a If transducer is installed on the positive lead s of the battery string the arrow will point toward the battery string s positive post b Ifthe transducer is installed on the negative lead of the battery string the arrow will point toward the power system away f
95. eei pe Re irri e et E e beg ital 3 9 FIGURE 3 9 BATTERY DISTRIBUTION MODULE BDM ii 3 11 FIGURE 4 1 OPERATOR PANEL u eerta re etr t rt e ep e io pe et E Rte aa oa ioni 4 3 FIGURE 5 1 NETWORK CONNECTIONS u e eee e ei ep ene e eee e e e nee 5 1 FIGURE 6 1 REPLACING THE SCU SAGEON III CONTROL UNIT 6 3 FIGURE 6 2 REMOVING RECTIFIER MODULE a 6 7 FIGURE 7 1 DISTRIBUTION LOCATION BY TIER AND GROUP eese ene 7 1 FIGURE 7 2 DISTRIBUTION AREA LEFT SIDE eese eene m u u u tree tren trennen erinnern ene 7 2 FIGURE 7 3 DISTRIBUTION AREA RIGHT SIDE L Ru S eene EE an A entren trennen rennen ene 7 3 FIGURE 7 4 ORIENTATION OF DISTRIBUTION ASSEMBLIES 48V SYSTEMS e 7 4 FIGURE 7 5 TYPICAL INSTALLATION OF AMI DISTRIBUTION n 7 5 FIGURE 7 6 DISTRIBUTION ASSEMBLIES Sa teen 7 6 FIGURE 7 7 GJ1 DISTRIBUTION KIT W BREAKER KIT sese enne nete tene 7 8 FIGURE 8 1 AMI TYPE BREAKER KIT COMPONENTS u 8 1 FIGURE 8 2 AMI TYPE BREAKER SHOWN KIT INSTALLATION 8 2 FIGURE 8 3 GJ1 TYPE BREAKER KIT COMPONENTS eene 8 3 FIGURE 8 4 GJ1 TYPE BREAKER KIT INSTALLATION anata
96. en the support bracket to the distribution assembly using the two 10 32 hex head screws PM990 8800 00 Issue 7 7 5 Distribution Option Kit Installation Sageon III Power System 10 Tighten all hardware Refer to Table 2 2 for torque specifications 11 Repeat the above steps for each AM1 distribution assembly kit to be installed 12 From the kit s collect the Failure Alarm FA jumper wire s 13 Connect one end of each wire to the push on terminal on the edge of a newly installed distribution assembly Connect the other end to a convenient push on connector on an adjacent distribution assembly in daisy chair fashion Newly installed distribution assemblies must be connected in daisy chain fashion to a previously installed distribution assembly See Figure 7 4 14 Refer to Chapter 8 to install AMI circuit breakers fuses 7 2 GJ1 DISTRIBUTION TIERS 2 AND 3 GROUPS A amp B This section describes installation of the GJ1 breaker distribution option in Tiers 2 and 3 Groups A amp B Installation of GJ1 circuit breakers is described in Chapter 8 Figure 7 7 shows many of the components included in the kit Figure 7 6 shows distribution assemblies in Groups A amp B It also shows the alarm wiring Table 7 1 identifies the groups in which a GJI distribution assembly can be installed A GJ1 assembly must be the topmost distribution assembly since other distribution types cannot be installed above a GJ1 assembly Distributio
97. ery charging current limit Set the maximum equalization charging current Vbattery 25 gt Vfloat This applies when batteries are being equalized Equalization voltage Set the maximum voltage reached during equalization of the batteries Equalization on off toggle On voltage trigger Off ampere hour trigger Equalization trigger voltage Set the voltage at which equalization will be initialized during battery discharge Equalization on off trigger On voltage trigger Off ampere hour discharge trigger Equalization A h on off toggle On ampere hour discharge trigger Off voltage trigger System Equalize 57 5V Volts Start Eq On Volts Eq Trig 48 0V Volts Start Eq Off Q Start Eq On PM990 8800 00 Issue 7 4 15 Configuration and Operation Sageon III Power System Equalization trigger A h Equalization is initialized when the charge supplied to the load Qdis Trig exceeds the value set in this screen 10Ah Equalization A h on off toggle On ampere hour discharge trigger Off voltage trigger Q Start Eq Off Equalization termination Equalization can be terminated based on charging current or EQ End Current charging time 25 If equalization is to end at a specific charging current set that current in this screen If equalization is to end after a specific time reduce the value in this screen to less than 5 of the A H rating of the battery string The ampere va
98. fault location for installation of the SageView program Alternatively type another path or browse to another location for installation of the program and then click Install i i SageView InstallShield Wizard Ready to Install the Program The wizard is ready to begin installation If you want to review or change any of your installation settings click Back Click Cancel to exit the wizard Current Settings Setup Type Destination Folder C Program Files User Information Name Company InstallShield PM990 8800 00 Issue 7 5 3 Sageview Sageon III Power System 4 The final installation screen is the Setup Complete screen Click Finish to complete the installation ageView InstallShield Wizard E x InstallShield Wizard Completed The InstallShield Wizard has successfully installed SageView Click Finish to exit the wizard i Cancel Refer to the SageNET user manual for more information on setting up the Remote Communications Unit over TCP IP This manual will describe network setting sand SageNET module configuration PM990 8800 00 Issue 7 5 4 Sageon III Power System Maintenance 6 0 MAINTENANCE This chapter provides periodic maintenance procedures and assembly replacement procedures If troubleshooting is required refer to Chapter 3 for schematic representations of Sageon III Power System circuits A list of spare and replacement parts is located in Chapter 9
99. fier 6 8 TO REMOVE A RECTIFIER MODULE Lift the securing latch in the center divider adjacent to the module and pull the module out of the Power plant When removing modules especially if the ambient temperature is high and the unit has been operating at maximum load avoid skin contact with the metal casing as it may be too hot to touch Pull the unit halfway out of the magazine and let cool for 2 3 minutes before handling 6 9 TO INSERT A RECTIFIER MODULE Insert the module into the slot Push the module all the way in so the rear connector fully mates and the securing latch spring clicks back down into place FIGURE 6 2 REMOVING RECTIFIER MODULE PM990 8800 00 Issue 7 6 7 Sageon Power System Distribution Option Kit Installation 7 0 DISTRIBUTION OPTION KIT INSTALLATION Distribution options included on the initial Power system order are factory installed To field install a distribution option follow the appropriate section in this chapter While it is recommended that the Power system be powered down before installing a distribution option an option can be installed in a live Power system when proper safeguards are observed A WARNING Arcing can cause equipment damage load interruptions and personal injury Arcing hazard Remove watch and jewelry Use insulated tools and extreme caution when working on a live Power system or on a battery string Insulate the free ends of any
100. fier 2 m m Rectifier n Battery String s Power Plant with Battery String s FIGURE 5 1 NETWORK CONNECTIONS 5 CONFIGURATION Use SageView to develop a completely new configuration and then upload this configuration to a connected Sageon III Power System If an operating configuration requires minor parameter value changes download the configuration from the System to the PC edit as needed and then uploaded to the same System or to another connected System 5 1 1 SageView benefits e Saves time since configuration development and Sageon III Power System installation can proceed simultaneously e Reduces configuration errors since the configuration can be developed and checked for accuracy at a PC before being uploaded to the System e Includes on line security with access code and password protection e Provides a permanent configuration record for comparison with operating cost data and service records 5 2 MONITORING SageView screens provide for efficient effective monitoring of System operation System output voltage and current alarms battery status and many other performance parameters are read on a single PC display PM990 8800 00 Issue 7 5 1 Sageview Sageon III Power System Sage View includes comprehensive Help It provides the latest information about program installation and operation communication options and other topics 5 3 SECURITY Security is a major consideration when deciding upon a commun
101. fy the kit by part number and name 2 Open the distribution area door Refer to Figure 7 1 and locate the Group where the additional distribution is to be installed 3 From the kit collect the U shaped bus bar and four each 5 16 18x34 bolts 5 16 bevel washers and 5 16 flat washers 4 Inthe selected group position the four unthreaded holes of the U shaped bus bar from the kit onto the factory installed U shaped bus bar of the distribution option directly below the your selected group Orientation will be the same as the installed bus bar see Figure 7 4 Using the hardware collected in step 3 above bolt the bus bar from the kit to the factory installed bus bar 5 From the kit collect the distribution assembly support bracket two 12 24x34 screws 6 Orient the support bracket as shown in Figure 7 5 so the bracket legs with the two rectangular holes is against the closest vertical rail of the rack Use the two 12 24x 4 screws to fasten the bracket to the rack rail 7 From the kit collect the distribution assembly and two each 10 32 hex head screws 5 16 flat washers 5 16 bevel washers and 5 16x18 hex nuts 8 Referring to Figures 7 4 and 7 5 for assembly orientation insert the studs of the distribution assembly into the U shaped bus bar and fasten with the flat washers bevel washers and nuts The 10 pairs of output studs on the distribution assembly should be oriented towards the vertical rail of the rack 9 Fast
102. g and alarm levels Scale factor and low and high alarm thresholds are user programmable at operator panel Digital INputs atia ik 12 Sign l SOULCE ss iret etat Voltage free contacts Logic of digital input User defined from operator panel Control outputs esee 4 Output signal source Voltage free form C relay contact 30 Vdc 1 5 PRODUCT SUPPORT Product support can be obtained using the following addresses and telephone numbers UNIPOWER LLC 65 Industrial Park Road Dunlap TN 37327 Customer Service Voice 800 440 3504 Customer Service Fax 423 949 3647 Field Service 800 299 3907 Web site http www unipowerco com When contacting UNIPOWER please be prepared to provide 1 The Power system part number and serial number see the equipment nameplate 2 Your company s name and address 3 Your name and title 4 The reason for the contact 5 If there is a problem with Power system operation e Isthe problem intermittent or continuous e What actions were being performed prior to the appearance of the problem e What actions have been taken since the problem occurred PM990 8800 00 Issue 7 1 10 Sageon III Power System Installation 2 0 INSTALLATION This chapter describes installing a Sageon HI Power system If questions or problems arise during installation please refer to Section 1 6 Product Support and contact
103. g how a system is connected the same schematic applies to other Power plant products The system shown is for a 48V system where the positive side of the DC bus is tied to ground usually on the common return bar It is also possible to float the output but under these conditions there is no guarantee that all voltages on the DC bus will stay below the Safety Extra Low Voltage SELV limits with respect to ground during fault conditions 3 4 FACTORY SUPPLIED CONFIGURATIONS Power plant internal AC distribution are configured with each rectifier AC line being terminated in an individual block terminal The grounding wire connects to the block terminal 3 4 1 Single phase individual protected external feeds Connect each of the circuit breaker protected phase wires to the individual terminal blocks labeled L1 that feed each rectifier Connect the neutral or phase 2 wires to the terminal labeled L2 for each rectifier PM990 8800 00 Issue 7 3 2 Sageon Power System Commissioning FIGURE 3 1 SINGLE PHASE FEED PHASE TO NEUTRAL PM990 8800 00 Issue 7 3 3 Commissioning Sageon Power System 2TH NAVEL FIGURE 3 2 SINGLE PHASE FEED PHASE TO PHASE PM990 8800 00 Issue 7 3 4 Sageon Power System Commissioning OTE PHASE A WILL SAGEON 111 AC FEED FIGURE 3 3 SPLIT SINGLE PHASE FEED PHASE TO NEUTRAL PM990 8800 00 Issue 7 3 5 Commissioning Sageon III Power System
104. h AC Frequency 50Hz If 3 ph AC Monitor not Off Phase AC voltage ph AC1 Volts I 245V I ph AC2 Volts I 243V I ph ACS Volts l 246V I Phase AC current ph A urrent I 28A 1 urrent I 29 1 urrent 1 32A I AC frequency ph A requency I 50 2Hz ENTER Volts High Alarm Modify Value up down T 57 0V ENTER to accept K ENTER Volts Low Alarm Modify Value up down 49 0V ENTER to accept E ENTER Modify Value up down Off ENTER to accept ENTER Password Setup Press ENTER Modify Value up down ENTER to accept est Indicators ENTER TEETH Sen T Press ENTER 1 info I ENTER OO mnn ystem Modify Value up down T ENTERtoaccept ENTER 7 Tm mm mm Me Number of SMRs Modify Value up down T 1 I ENTER to accept ENTER ntertace Modify Value up down ENTER nmm Num of Batteries Modify Value up down T ENTER oe te Batt Current I Modify Value up down 20 I ENTER to accept ENTER oad Sensor I INC DEC toggles state 1 Off ENTER to accept If Load Sensor not Off ENTER Modify Value updown T L ENTER to accept Jd Indicates that the front panel is locked Press and hold 7 and ENTER to unlock Ambient temperature displayed in Degrees Centigrade Not Available shown if not sensor is connected Bus voltage above which alarm flagged Bus voltage below which alarm flagged Programmable value change requires password w
105. he floor See Section 2 4 Install AC input wiring between the user s AC electrical service panel and the Power system See Section 2 5 Connect the AC input wiring to AC terminals in bottom section See Section 2 5 4 Install battery cabling See Section 2 6 Route and connect supply and return cabling to customer s loads See Section 2 7 Connect external alarm annunciators See Section 2 8 Input Connect options Battery Temperature Sensors Battery Current Transducers Sageon Battery Monitor Site Monitor and communications SNMP See Sections 2 9 through 2 13 Install Rectifiers See Section 2 14 Commission the plant See Chapter 3 Commissioning and Chapter 4 Configuration and Operation 2 2 REFERENCE MATERIAL This section contains lists tables and methods that are referenced in subsequent procedures Three subsections comprise the Reference Material section Tools and Accessories Read the included list for a preview of the user supplied items that will be referenced during the installation and servicing procedures Selecting and Sizing DC Power Cables Proper cable sizing is critical to system performance This section provides a formula and table that simplify cable selection Torque Specifications The torque specification table in this subsection is referenced in procedures that include hardware 2 2 1 Tools And Accessories To install the Sageon III Power system the following user supplied items should be
106. he maximum is four 2 Note This number must equal to or be less that the Num of Batteries entered in the Home Programmable Parameters series of screens Cell Vhi Alm 2 48V High voltage alarm threshold Set the cell voltage above which an alarm will be generated Cell Vlo Alm Low voltage alarm threshold Set the cell voltage below which an alarm will be 1 44V generated Cell dVc Al Delta positive voltage threshold Set the percentage of nominal cell voltage by which any 10 individual cell voltage can exceed the nominal Above this value an alarm will be generated Delta negative voltage threshold Set the percentage of nominal cell voltage by which any Cell dVc Al individual cell voltage can be less than the nominal Below this value an alarm will be 10 generated 4 5 2 Site Monitor Site Monitor When the Site Monitor is included in the software the window at right will appear next Press ENTER Site monitor on off toggle Press ENTER to display the current On Off status flashing Site Monitor Press up arrow or down arrow to set the desired state then press ENTER to store On Contact the factory for additional details concerning this feature 4 6 RECT RECTIFIER MENU SCREENS Enter this series of menus by pressing the REC SMR button Press up arrow or down arrow to select the Rectifier number i e rectifier position address and press ENTER Press up arrow to scroll through the sc
107. he test screen shows Off the Last BDT screen appears next see Section 4 7 2 4 7 4 Battery Discharge Test Screens The battery discharge test performs a periodic controlled discharge of the connected battery 50A 54 1V string s The test confirms battery string capacity and uses the customer loads to discharge the battery string s so no battery strings need to be disconnected and individually loaded as would be the case in a typical manual discharge test BDT in Progress To access test parameters press the BATT button and then press down arrow to access the following screens PM990 8800 00 Issue 7 4 16 Sageon III Power System Configuration and Operation While the test is in progress e The display will alternate between the Home screen and the BDT in Progress screen shown at right e The system alarms Battery Discharge Voltage Low and SMR Voltage Low e Low Load alarm will be suppressed e SMR alarms will be shown in the SMR status Test time interval The interval between tests can be set to 0 365 days When set to zero the automatic execution of the test is disabled set to Off Display messages below will be shown only if the test is enabled Time of test Set the time of day the test is to be performed This is a 24 hour clock Test duration Set the duration of the test Duration can be set from 5 minutes to 24 hours in increments of 5 minutes Discharge rate Set the rate of discharge
108. hen security on Password programming submenu Press ENTER to begin flashing display and LEDs System information including controller software version S N and cabinet S N Options for Standby or UPS type system Sets number of SMRs in the system Selects the interface hardware to the system Sets the number of batteries in the system Sets full scale battery current Sets full scale load current PM990 8800 00 Issue 7 4 21 Configuration and Operation Sageon III Power System Base Menu continued Access Code 0000000 Date Formal DD MM YYYY Date 25 12 200 Time 01 11 11 Sets MiniCSU 3 access code address Modify Value up down I ENTER to accept I ENTER Modify Value up down ENTER to accept I ENTER selects hours I minutes day month or year INC DEC modifies value ENTER INC DEC toggles state L ENTER to accep J Alarm Report Off Daily Report Off ENTER TINC DEC toggles state L ENTER to accepi J If Daily Rep not Off ENTER l Daily Rep Time NC DEC toggles state I 15 15 L ENTER to accep J ENTER NC DEC toggles state L ENTER to accep J If Modem not Off ENTER e I Country Code I Modify Value up down I 61 ENTER to accepi J ENTER External modem initialisation string en I Cust Init String I Modify Value up down I I None ENTER to accep J ENTER x Phone 1 I Modify
109. hipping container Save the packaging materials 2 Select a position in which to install the Rectifier 3 The optional AC breaker should be in the OFF position 4 To install a Rectifier 1 Note the voltage and current ratings of the rectifier Use only 48V rectifiers in the system 2 Slide the Rectifier slowly into the Housing until the Rectifier s rear connectors just engage the Housing connectors Fully seat the Rectifier in the Housing to properly engage the connectors 5 Check to be sure that the locking mechanism has engaged with the rectifier 6 If step 3 was performed Apply power to the newly installed rectifier by turning on the AC breaker 7 Repeat the preceding steps for each Rectifier to be installed To commission the Rectifier s go to Chapter 3 Commissioning Removing a Rectifier 1 Optional Remove power from the Rectifier Set the breaker to the OFF position Lift the locking mechanism Grasp the rectifier handle and pull the Rectifier forward 1 to 2 Grasp the Rectifier and pull it straight out from the Housing The Rectifier weighs approximately 5 Ibs 2 3kg Qo RN Set the Rectifier aside and attach a tag stating its operating status e g OK needs servicing A CAUTION Electrical shock hazard After removing a rectifier be careful not to touch the rear connector The rectifier will take approximately 1 2 minutes to self discharge The red LED will flash during this time
110. ications strategy that involves sending proprietary data over your company s intranet the Internet or telephone lines Before enabling local or remote communications carefully review your company s electronic security policies Contact your company s network administrator for details about network structure and security The administrator can also furnish an IP Internet Protocol address when Ethernet access is needed 5 4 CABLE AND NETWORK CONNECTIONS Figure 5 1 shows typical connections for local and remote access to Sageon III Power System data Additional information is provided in the SageView Help topic titled Connection Setup Local connection details are provided below Guidelines for remote connections are also provided Remote connection specifics are beyond the scope of this manual since actual connections and required hardware are determined by the systems operating within your System Consult your company s network administrator 5 5 LOCAL CONNECTION STANDARD For a local connection cable the serial port on the Sageon III Power System s operator panel to the USB port on a Windows based PC A customer supplied USB A to USB B cable is required 5 6 REMOTE CONNECTION ETHERNET OPTION When the Ethernet option is ordered the Sageon III Power System includes an RJ 45 connector for the Ethernet network cable As shown in Figure 5 1 a remotely located Windows based PC can be connected to your System s Ethernet network With the additi
111. ied to the SCU by way of the company s intranet or the Internet For additional information about SageView refer to Chapter 5 IMPORTANT Always consult your company s network administrator before connecting local or remote equipment to the SCU or to the company network Security must be a primary concern Consult your company s network administrator about system communication and data compatibility communications cable specifications cable routing and methods of connecting to a network 2 14 INSTALLING AND REMOVING RECTIFIERS When ordered with a Sageon III Power System each Rectifier is shipped in a separate package A Rectifier is shown in Figure 2 16 Ov OI OX SAGEON MIERE RECTIFIER A A 1 FIGURE 2 16 RECTIFIERS PM990 8800 00 Issue 7 2 18 Sageon III Power System Installation A Rectifier can be installed or removed hot i e with AC power and DC load applied with no interruption of Sageon III Power System service When removing a Rectifier there must be sufficient remaining rectifier current capacity to supply the load A WARNING Electrical shock hazard Hazardous voltage can cause death or serious injury A 240 VAC may be present at the Rectifier Switch Assembly and AC Backplane Always use insulated tools Installing a Rectifier 1 Remove a Rectifier from its s
112. is 20 of the total discharge current An alarm is generated when the differential exceeds the value entered When two or more battery strings are connected the value in this screen is read by the SCU when an AC outage occurs and the battery strings are supplying the load current A difference in discharge current is an indication of the state of the battery strings Battery over temperature alarm threshold Set the maximum allowable battery temperature Ampere hour battery rating Set the battery string s A H rating 4 7 1 Battery Temperature Compensation Battery temperature compensation on off toggle Battery temperature compensation BTC Enter the temperature compensation coefficient in mV per degree C per cell in this screen The allowable range is 0 1 to 6 mV Cell C If the value is less than 0 1 the display will show Off See BTC Notes below For Liberty 1000 and 2000 batteries enter 3 6 mV C C 2 mV C F Normal operating temperature is 25 C 77 F BTC nominal temperature When battery temperature compensation is active type the temperature at which system voltage is NOT corrected This temperature must be between 18 C and 27 C Note that compensation range is 10 35 C See the Notes below Battery 1 12A Battery 2 11A Battery Temp 31 C Estimated Q Bat 1 300Ah Battery Disch Alarm 47 0V Disch I Diff 20A Batt Temp Alarm 50 Battery Rating 500Ah Batt Temp Comp Off BT
113. l Specifications Battery Temperature Compensation 1 2 5 Bus Specifications Bus Structure Amperage Rating Charge Bus Voltage Drop Discharge Voltage Drop 1 2 6 EMC Specifications Emissions Category Harmonics Dis See Section 1 3 8 Rectifier Specifications for voltage and current Dien 4 maximum S 8 pairs of 3 8 studs 1 center to center for 2 hole lugs uie 1200A at 48 Vdc 1000A at 56 Vdc IN 1200A maximum mm 1000A maximum iste glad 1200A maximum illite Adjustable 0 1 to 6 mV C cell ec deas Per American National Standards Institute s Telecommunications Protection Specifications ANSI T1 311 1991 ampere tables 0 05 maximum select bts 0 25V maximum Tested To IEC 61000 3 2 EN61000 3 2 AS NZS 61000 3 2 Class Conducted RF AC Port CISPR 22 1997 EN55022 1998 AS NZS 3548 1997 Conducted RF DC Port CISPR 22 1997 Radiated RF CISPR 22 1997 EN55022 1998 AS NZS 3548 1997 Immunity Category Tested To Criterion Electrostatic Discharge 61000 4 2 EN 61000 4 2 ESD Air 8 kV Contact 6 kV A Radiated RF IEC 61000 4 3 EN 61000 4 3 10V m 80 1000 MHz 1 kHz 80 AM A 10V m 1 2 GHz 1 kHz 80 AM Electrical Fast Transient EFT IEC 61000 4 4 EN 61000 4 4 1 kV on AC lines A 1 kV on DC lines A 0 5 kV on signal lines indoor PM990 8800 00 Issue 7 1 5
114. lation amp Removal Guidelines May 1990 PE 7 1985 Communications Type Battery Chargers NEMA ANSI STD 487 1980 IEEE Guide For The Protection of Wire Line Communications Facilities Serving Electrical Power Stations TR EOP 000151 Bellcore Generic Requirements for 24 48 130 amp 140 Volt Central Office Power system Rectifiers May 1985 TR EOP 000154 Bellcore Generic Requirements for 24 48 130 amp 140 Volt Central Office Power system Control and Distribution May 1985 TR NWT 000063 Bellcore Network Equipment Building System Generic Equipment Requirements Issue 4 July 1991 TR TS Y 000078 Bellcore Generic Physical Design Requirements for Telecommunication Products and Equipment UL489 UL Molded Case Circuit Breaker Enclosures May 1984 1 4 1 Monitoring Specifications Operator panel voltage and current 2 line digital display Operator panel accuracy Voltage accuracy 0 50 least significant digit Current accuracy 196 System status nare irent Green yellow and red LEDs Local Communications ses USB SageView required Remote Communications Etherne SNMP 1 4 2 Alarm Specifications Each of following alarms is annunciated by a lighted LED on the operator panel and by a relay state change Relay contact output terminals are on the alarm PCB in the distribution A User Alarm Annunciation Five user pr
115. leave the factory without a pre programmed password and the security function is not active To activate the security a password must be programmed Once that is done security can be enabled When the security function is active any changes to the system settings can be done only after a valid password was entered When the ENTER key is pressed to change a parameter the display will show a message Enter Password on the top line and a blinking cursor on the right hand side of the bottom line Using INC and DEC keys scroll to the first character of the password and press ENTER The character will be substituted by an asterisk displayed to the left of the cursor Enter all characters of the password the same way If the password is less than eight characters long press ENTER again after last character If the entered password was correct the display will return to the selected parameter ready for modification If the entry was incorrect following will be displayed There is no limit on password entry re tries To abort password entry any of the top row buttons should be pressed The display will return to the selected parameter Once unlocked the security is disabled until there is no keypad activity for gt 1 minute Display test All LEDs on the rectifiers and operator panel will flash when ENTER is Test Indicators pressed and the screen will alternate between the SCU software version and an all pixels Press ENTER on screen not shown N
116. lue entered will be replaced by Off Equalization termination time Set the period of equalization If equalization is to be EQ Duration based only on the A h discharge method set the period to maximum 48 hours 20 hours Force equalization If equalization does not occur due to battery discharge set the period after which equalization should be forced EQ Period 12 Weeks Equalization manual termination To manually terminate equalization at this screen press ENTER The system must be in equalization mode for this screen to appear Manual Stop EQ Press ENTER When ENTER is pressed the system reverts to Float mode and the screen changes to that shown at right ready for manual equalization manual start The system must be in Float mode for this screen to appear Manual Start EQ Press ENTER 4 7 3 Low Voltage Battery Disconnect LVBD LVLD Screens LVBD switch trip voltage Set to establish the voltage at which the batteries will be LVLD Trip disconnected from the load to prevent excessively discharging the battery string LVLD 45 0V LVBD Off On Set to Off or On depending on whether or not your system has LVBD Low Voltage Load Dis On NOTE LVDS screens have no functioned control over the contactor use LVLD screens Temperature sensor alarm toggle Set to On when sensors are connector Set to Off if Temp Sen Alarm sensors are not connected On Note Battery discharge test screens are shown next go to Section 4 7 1 If t
117. med Passed Test ran for programmed duration without reaching an End V or End Q value BDT Period 14 Days BDT Time 17 35 BDT Duration h30min BDT Alarm Reset BDT Current 50A BDT End V 47 0V BDT End Q 500Ah Press ENTER BDT in Progress ENTER to abort Last BDT N A Failed Test terminated prematurely after reaching an End V or End Q value before the test duration expired This will trigger a BDT Fail alarm PM990 8800 00 Issue 7 4 17 Configuration and Operation Sageon III Power System AC Lost Test terminated due to loss of AC supply Detected by the AC monitor or by all SMRs being Off Cell V Low A cell in a battery string discharged below a safe level Alarm issued Available only when BDM is active flagged as having failed No Control Test aborted due to loss of control of rectifiers No alarm issued Low Load Test aborted due to load current being too low to control discharge current No alarm issued SMR Overload Test aborted due to load current being too high to support controller discharge No alarm issued User Aborted Test terminated manually by user from the SCU 4 7 6 BDT Results Screen Additional Details To view additional details about the preceding test press ENTER while viewing one of the above Last BDT screens These sub menu details appear on the second line of the Last BDT screen 22 01 2003 S
118. menu to the first screen press the DEC button Incrementing and decrementing programmable parameters To change a programmable parameter press ENTER the value will flash on and off To increase the number press INC to decrease the number press DEC When the desired number is on the screen press ENTER again To change parameters when the security function is activated If an attempt is made to alter any parameter when the security function is activated the display will show the message Enter Password To change a parameter enter a valid password Then proceed to change the parameter in the normal way When scrolling through the Alarms log To observe the date and time of a given alarm do not press any button for at least two seconds The date and time will display for two seconds and then the alarm name will be displayed for two seconds The display will alternate between the two screens in this manner until a button is pressed PM990 8800 00 Issue 7 4 20 Sageon III Power System Configuration and Operation 4 13 NAVIGATING CONTROLLER FUNCTIONS 4 13 1 Base Menu System Level Functions Home screen FL indicates float mode and FLC indicates float mode with battery temperature compensation ock Panel 7 Press ENTER DEC Ambient Temp 28 C INC If 1 ph AC Monitor not Off Single phase AC voltage 9 ph AC Volts I 245V Single phase AC current ph AC Current 52A Single phase AC frequency p
119. n Assemblies VA NI Tier 3 Grp A Tier 3 Grp B Fuse Alarm el famem J Fuse Alarm FA Wire FA Wire X tier 2 Tier 2 Group A Group B A KN Distribution Assemblies N AGS d 5 Tier 1 Tier 1 5 D Group A Group B 5 c je g LL A Bus Bars S FIGURE 7 6 DISTRIBUTION ASSEMBLIES GJ1 PM990 8800 00 Issue 7 7 6 Sageon III Power System Distribution Option Kit Installation 7 2 1 Kit Contents Kit PN Description 385 5882 00 Quantity Breaker Mounting Bracket U Shaped 1 Breaker Mounting Bar 5 8 x 7 1 2 2 Bus Bar Assembly L Shaped 1 Rack Screw 12 24 x 3 4 2 Bolt Hex 5 16 18 x 1 4 Washer bevel Bevel 5 16 4 Washer Flat 5 16 4 Screw Phillips Head 10 32 x 1 2 4 Alarm Wire with Ring Lug Red 1 Fuse Alarm Jumper Wire Orange 1 7 2 2 Installing the Kit 1 Open the kit The packing list will identify the kit by part number and name 2 Open the distribution area door Refer to Figure 7 1 and locate the Group where this distribution will be placed 3 From the kit collect the L shaped bus bar and four each 5 16 18x1 bolts 5 16 bevel washers 5 16 flat washers and the red
120. n III system is mounted adjacent to Fasten the ambient temperature sensor to the selected point using appropriate user supply hardware Route the 4 battery temperature sensors to the battery strine s Typically somewhere close to the string midpoint Determine which battery posts will have sensors attached Suggested location is shown in the battery string drawing figure 2 14 Note The highest of the four battery temperature readings is used for compensation Locate a sensor at the warmest battery generally one at the center of a battery group Determine the charge discharge status of the battery string Connecting the sensors may result in a momentary battery string open circuit when the terminal bolt is removed CAUTION DO NOT proceed if the battery string is being charged or discharged at a high rate Continue only when the charge or discharge rate is at a safe level Remove the bolt holding the inter cell battery strap in place Insert the bolt through the battery temperature sensor ring lug through the strap and into the battery terminal Tighten the bolt as recommended by the battery manufacturer Repeat steps 6 and 7 to install the remaining battery temperature sensors Bundle and secure excess wiring Enable compensation using the operator panel push buttons and menus or a PC running SageView If installing the Sensor Kit get the compensation chart label Remove the backing from the label and place the label on the inside of th
121. nd Accessories for lug requirements Refer to Section 2 2 2 Selecting and Sizing DC Power Cables for cable sizing Note To field install additional distribution refer to Chapter 7 Distribution Option Kit Installation To field install additional fuses or circuit breakers in the present distribution refer to Chapter 8 Circuit Breaker and Fuse Kit Installation Route supply and return cables from the Power system to the loads in overhead racks or cable trays The plant cables drop from the overhead racks through the open top of the plant Connect the return cables to the return bus loads the vertical bus to the right side of the distribution area Connect the supply cables to either a distribution assembly for AM1 type breakers or a GJ1 type breaker output terminal A typical load connection is shown in Figure 2 6 TION m TI Note Other tiers and groups are cabled similarly Connect all load returns to the return bus FIGURE 2 6 LOAD SUPPLY AND RETURN CABLING PM990 8800 00 Issue 7 2 10 Sageon Power System Installation Distribution is organized by Tier 1 3 Group A amp B and position 1 10 See Figure 2 7 The Breaker Fuse Layout label on the rear of the distribution area door is for recording breaker fuse current rating and part number BATTERY DISCHARGE 7 BUS j TIE Li 2 a P
122. nitely 300 Vac Hot swappable i e Can be installed in or removed from an operating Sageon III Power System 45 59 9 Vdc 10 to 110 of rated output 25A 158 F 70 C Foldback current limiting Better than 0 05 Better than 0 05 2 for 10 to 90 to 10 step load change 1 of final value within 1 ms of step change 0 2 for a 25 step change in AC input voltage lt 0 96 mV RMS Psophometrically weighted 10 mV RMS 10 kHz 100 MHz lt 100 mV 10 kHz 100 MHz lt 5 of full scale with active current sharing from SCU Can sustain a short circuit at output terminals indefinitely Gradual reduction of power limit if heatsink temperature exceed preset limit Float and equalize voltages Current limit high and low voltage alarm limits HVSD and HVSD reset PM990 8800 00 Issue 7 1 7 Introduction Sageon III Power System 1 2 8 Safety Specifications The following were used as guidelines in the specifications of all components and wiring with particular attention to safety ratings and OI 28 flammability requirements e Underwriters Laboratory Standards of Safety UL 60950 e Bellcore Network Equipment Building System GR 1089 CORE 1 3 ABBREVIATIONS AND ACRONYMS ABBREVIATION ACRONYM OR SYMBOL MEANING ANSI American National Standards Institute AWG American wire gauge BATT Battery CEV controlled environment vault CM circular mils DIP dual in line package EMC electromagnetic compliance or c
123. nitoring Site Status and Battery e Remote Communication capability including Web Cell Voltages opt based Protocols opt e Breakers e Rectifiers and the Controller are hot swap and plug and play capable H k o d n b m o E 1 4 le CES rn b o ob ri le o lo I id i F gl ye s Hd FIGURE 2 17 SAGEON III POWER SYSTEM PM990 8800 00 Issue 7 2 20 Sageon Power System Installation care DOPOD Z i 1 2 3 4 5 6 7 8 Notes FIGURE 2 18 CONNECTIONS ON CONTROLLER BACKPLANE Remote communications module connection 14 way ribbon Auxiliary peripheral module relays battery cell monitor etc connection 16 way ribbon Battery amp load distribution module connection 34 way ribbon Ambient temperature sensor connection Battery temperature sensor connection Rectifier isolated communications connection 10 way ribbon Standalone system voltage connection Controller power and voltage sensing Load circuit breaker trip detection circuitry connection Devices and cable connections are pre wired as part of the supplied and tested Power plant
124. nnect the transducer cable s between the transducer and the Power system as indicated in Section 2 10 Be sure that a transducer s battery cable opening is large enough for the selected cable diameter and the number of cables 3 Run cables between the plant and battery string 1 Route either battery cable or through the optional battery current transducer all battery cables routed through a transducer must be the same polarity Transducers are marked typically with an arrow to indicate current direction See section 2 10 ai OOO rau Bopp CI _ sg FIGURE 2 5 BATTERY CHARGE BUS AND BATTERY RETURN BUS LOCATIONS PM990 8800 00 Issue 7 2 9 Installation Sageon III Power System 4 At the Power system install appropriate lugs on cables CAUTION A a Secure the negative cable to the battery charge bus b Secure the positive cable to the battery return bus NOTE See table 2 2 for torque specifications 5 At the battery string appropriate battery lugs terminals clamps Confirm polarity and connect the wires to the battery string terminals 6 Repeat the above steps for each battery string to be connected 2 7 CONNECTING CUSTOMER LOADS Supply and return cables are connected between customer loads and Power system distribution Interconnecting cables and lugs are supplied by the user Refer to Section 2 2 1 Tools a
125. nstalled SMRs To change a parameter value 1 Scroll to the desired screen using the up arrow or down arrow button 2 Press the ENTER button the selected value will flash SMRI No Response SMRI 92A 29 SMRI G1045a SMR2 91A SMR Float 54 2V SMR Equalize 57 0V 3 Use the up arrow or down arrow button to edit that value Press ENTER to store the new value SMR high voltage alarm threshold SMR low voltage alarm threshold SMR high voltage DC shutdown SMR current limit Fault reset Press ENTER to reset latched alarms such as HVSD The Rectifier will restart unless damaged or faulty Note Pressing up arrow button will display the HOME screen SMR V high Alarm 57 0V SMR V low Alarm 48 0V SMR HVSD 58 0V SMR I Limit 50A Reset SMR Fault Press ENTER PM990 8800 00 Issue 7 4 12 Sageon Power System Configuration and Operation 4 7 BATT MENU SCREENS Enter this series of menus by pressing the BATT button Press the up arrow button to scroll through the screens in the order presented Repeat the series for each battery string The following map summarizes the available menu screens BATT Button Battery string 1 4 current Battery string temperature Estimated charge 1 4 Programmable Battery discharge alarm voltage Press ENTER to read individual cell voltages if SBM option is installed
126. nt temperature sensor reading is indicated as Not Available Sensor cable faulty Sensor connector reversed No sensor installed Turn cable connector around and reconnect Replace faulty sensor assembly Battery current indicated does not match independent measurement Full scale current of the DC hall effect current transducer is incorrectly set and will result in an error larger than 5 at more than 50 full scale current Change the setting of the FS Batt Curr value in the Base Menu of Controller to the correct full scale value Battery current indicates when more than 5A is flowing in the battery or is inaccurate at low currents 5A Transducer is not calibrated DC hall effect transducer or wiring is faulty Current transducer sensitivity is too low for 1A measurement Calibrate transducer Service the DC current transducer check the wiring is intact and still connected properly or replace the DC CT is suspected to be faulty Revise size of DC CT full scale value for the size of the load and battery charging requirements Load current indicates when known to be gt 5A Number of RECTIFIERs is incorrectly set too low or the battery current FS is set too high The load current is calculated from the sum of the RECTIFIER currents minus the measured battery currents Check that the number of RECTIFIERs in the Controller Base menu matches the actual number of rectifier mo
127. o accep ENTER 1ph AC flo Alarm Modify Value up down 45 0Hz 1 ENTER to accep ENTER 1ph AC FS Curr Modify Value up down 100A L ENTER to accep PM990 8800 00 Issue 7 4 22 Sageon Power System Configuration and Operation Base Menu continued Monitor Off ENTER 10 accept If 3 ph AC Monitor not p ENTER INC DEC toggles state ENTER to accept If Battery Monitor not Off Battery Monitor Off ENTER 3ph AC Vhi Alarm Modify Va 260V _ ENTER ENTER 3ph AC Alarm Modify Va 200V ENTER ENTER 3ph AC fhi Alarm Modify Vall l 55 0Hz ENTER l ENTER 3ph AC flo Alarm Modify Val l 45 0Hz ENTER ENTER 3ph AC FS Curr l Modify Val 100A ENTER ue up down R to accept ue up down ue up down R to o accept R to o accept ue up down 1 ue up down R to accept R to o accept Selects battery cell type to accept Battery Config Modify Value up down 24 cells L ENTER to accept ENTER Number of battery banks BCM Batteries Modify Value up down L SSO S ENTER Cell Vhi Alarm Modify Value up down 2 50V L ENTER to accept ENTER Cell Vlo Alarm Modify Value up down 1 80V L ENTER to accept ENTER Differential cell threshold Cell dVc Alarm Modify Value up down 10 to accept 1 cicala cell threshold Cell dVc Alarm I Modify Value up down 1 10
128. odule The Controller can usually compensate for an out of calibration unit in a system and will take a few minutes to adjust the unit to correctly share the load Revise the load level on the system and expand the number of rectifiers as required to remove the overload condition One rectifier has an UNCAL RECTIFIER alarm The Controller has not been able to make the unit share the load with the other units Either the RECTIFIER is faulty excessive internal voltage drop and cannot be adjusted to share load or it is too far out of calibration Replace the rectifier module Send the unit for repair and re calibration System Voltage Clamp alarm activated Controller cannot reach the desired system voltage This can be due to possible excessive voltage drop along the DC bus bars inside one or more rectifiers or System V Drop parameter has been set too low If this alarm comes up during equalize the maximum output voltage from the rectifier may not be high enough to overcome the system drops to the sense point and allow the system to regulate at the desired high equalize voltage Increase Sys V Drop parameter Replace faulty rectifier unlikely to current share as well Check that the number of RECTIFIERs in the system is correctly set more RECTIFIERs than declared can generate this problem Revise the requirements for high equalize voltage level RECTIFIER EEPROM Fail alarm is
129. ogrammable relays One form C contacts rated 1A resistive 9 24Vdc 0 5A resistive 48Vdc B Rectifier Front Panel Three status LEDs Green Amber and Red are located on the Rectifier front panel C Battery Current Temperature Battery Temperature Sensor Input Compensation and alarm annunciation ambient 1 4 battery Battery Current Transducer Input 1 4 battery strings accuracy 196 User connections a aa No 6 screw terminals lugless compression type D Sageon Battery Monitor Battery Strings 4 maximum PM990 8800 00 Issue 7 1 9 Introduction Sageon Power System Battery voltage sse 75 maximum Cells single cell or monoblock 24 maximum per SBM board Cell voltage erit 2V 4V 6V or 12V maximum input 3 33V 6 66V 10V and 20V respectively ACCULACY i tec Weder edens 10mV at 0 C to 40 C Resolution ie 5mV per cell 2V 4V and 6V ranges 10mV per cell 12V range Sampling interval 1 60 minutes SBM boards itte s 4 maximum Interconnection in 16 conductor ribbon cable 30 feet 10m maximum length E Site Monitor Analog inputs 8 Sistial Tan Ge u noh e 0 5V Input protection a Over voltage and reverse polarity Signal scalin
130. ompatibility EMI electromagnetic interference ESD electrostatic discharge FA fuse and breaker alarm HVA normally energized high voltage alarm IEC International Electrical Commission IEEE Institute of Electrical and Electronic Engineers LED light emitting diode LSD least significant digit LVA low voltage alarm LVD low voltage disconnect NEC National Electric Code NEMA National Electrical Manufacturers Association PCB printed circuit board REC RECT Rectifier see SMR RBOC Regional Bell Operating Company RFA rectifier failure alarm SBM Sageon Battery Monitor SSM Sageon Site Monitor SCU Sageon Control Unit SMR Switch Mode Rectifier see REC RECT UBC Uniform Building Code UL Underwriters Laboratory UPS Uninterruptible Power System PM990 8800 00 Issue 7 1 8 Sageon III Power System Introduction 1 4 REFERENCE PUBLICATIONS DOCUMENT NUMBER MEE ANSI C 39 1 Requirements for Electrical Analog Indicating Instruments ANSI T1 311 1991 DC Power Systems Telecommunications Environment Protection ANSI IEEE C 62 41 IEEE Guide for Surge Voltages in Low Voltage AC Power Circuits ANSI 1980 IEC 801 2 IEC Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment October 1987 NEC 1993 NEC Handbook 1993 National Fire Protection Association No Number OI 28 Standards No Number Central Office Telecommunications Equipment Engineering Standards December 1984 PUB 77350 U S West Telecommunications Equipment Instal
131. on of the necessary hardware e g server with firewall a remote PC can connect to your System s network over the Internet 5 7 PC REQUIREMENTS e Microsoft Windows 98 ME NT4 2000 or XP e Pentium or better microprocessor e 128 KB or more RAM e 10 MB unused hard disk space for program and database files e CD ROM drive e USB port with USB A to USB B cable 5 8 INSTALLING SAGEVIEW Before beginning the installation review the PC requirements above to be sure the PC at hand meets the minimum requirements Also read the ReadMe txt file on the CD for the latest information about installing and using SAGEVIEW 1 Insert the SAGEVIEW CD in your computer s CD ROM drive The opening screen will appear If it does not appear click Start and then click Run In the Run dialog box type d setup exe Substitute your CD ROM s drive letter for d as needed PM990 8800 00 Issue 7 52 Sageon III Power System Sageview 2 Windows InstallShield will start and the screen shown below will appear Click Next to continue the installation or click Cancel to exit the installation i SageView InstallShield Wizard 1 E Welcome to the InstallShield Wizard for SageView The InstallShield R Wizard will install SageView on your computer To continue click Next WARNING This program is protected by copyright law and international treaties 3 In the Choose Destination Location screen click Next to accept the de
132. on Battery Monitor Operation Manual PM990 4209 00 and the Sageon Site Monitor Application Note AN103 4012 00 PM990 8800 00 Issue 7 3 12 Sageon Power System Configuration and Operation 4 0 CONFIGURATION AND OPERATION The Sageon III Power System is locally configured and operated from the operator panel See the Sage View chapter for remote configuration and operation The operator panel is mounted below the distribution doors The operator panel consists of a 2 line alphanumeric display six push buttons with tactile feedback three status LEDs and a USB communications connector Menus data status alarm messages and parameter values appear on the display Display contents are selected using the six buttons System status is also shown by the three LEDs below the display A USB B port is provided on the left side of the operator panel for connecting a personal computer PC Operator panel operation displayed data and communications are all controlled by the SCU Sageon III Control Unit The operator panel is the Sageon III Power System s HMI human machine interface Complete Sageon III Power System configurations can be created at the operator panel Alternatively the System can be configured from a personal computer PC running SageView System Monitor software When the System is initially powered the configuration stored in the SCU provides the System operating parameters This configuration can be the default factory
133. onfiguring and operating the System to identify and access a specific Rectifier The AC Backplane board at each rectifier position has one DIP switch on which the address is set See the illustration below IMPORTANT Do not change the factory set switches If inadvertently changed go to Section 6 6 for a procedure to set the switches to the proper address Opening the Distribution Area Door During installation it will be necessary to open the distribution area door to install load supply and return cables battery cables and alarm wires Lift the paddle surrounding the key lock rotate it 90 degrees and open the door Keys are tied just inside the door 2 1 INSTALLATION SUMMARY A typical installation sequence is provided below References to appropriate sections in this manual are included 1 Review the list of user supplied tools and accessories in Section 2 2 2 Select a location for the Power system See Section 2 3 3 Select battery AC input and distribution wire sizes based on current and length of run See Section 2 2 PM990 8800 00 Issue 7 2 1 Installation Sageon III Power System 4 SOM A 10 11 12 Move the Power system and accompanying assemblies to the selected location Anchor the Power system to t
134. own below Note The interface IP address cannot be changed until the Power plant has been commissioned and the Controller is operational The MAC ID can have We EL format 00 20 4A 24 BB 42 S N 2447938 Serial Number or 00 20 4A 24 BB 52 00 20 JA 24 BB 42 ae Rev D12 Revision Made in USA 3 10 BATTERY DISTRIBUTION MODULE The battery distribution module is capable of handling up to four battery strings Connect the current transducer signal cable to the appropriately labeled connector on the circuit board 5 0 E S p Hm E m 4 FIGURE 3 9 BATTERY DISTRIBUTION MODULE BDM PM990 8800 00 Issue 7 3 11 Commissioning Sageon Power System 3 11 ADDING AUXILIARY EXPANSION MODULES Modules such as the Sageon Battery Monitor and site monitor are daisy chained from the unused ribbon cable connection provided on the Auxiliary programmable relay board All of these expansion modules are required to be mounted external to the Power plant and a single 16 way ribbon cable connected to the available box header For more detailed installation information for each of these modules refer to the Sage
135. p all 3 LEDs may be off for approximately 10 seconds while the system boots up 4 4 READING ALARM MESSAGES If an alarm exists an alarm message will alternate with the Home screen the status LEDs will also indicate the presence of an alarm The alarm message will display for two seconds 3 Alarms every six seconds A sample alarm message is shown below This message states that three alarms exist and they can be viewed by pressing the ENTER button When the button is pressed the name and description of the most recent alarm are displayed as shown below Press either the up arrow or down arrow button to view remaining alarms Pressing ENTER or not pressing any button for ten seconds will display the Home screen Press ENTER Alarm 1 Amb Temp High To read the time and date of any alarm press the LOG button and use the up arrow or down arrow button to scroll to the desired alarm s A list of all operator panel annunciated messages is found in Table 4 3 Alarm Name SMR Alarm TABLE 4 3 OPERATOR PANEL ANNUNCIATED ALARM MESSAGES Comment Combination of one or more SMR alarms LED ON FL Amber FL SMR Urgent One or more SMRs have shut down Amber Red SMR HVSD SMR shut down due to output over voltage Amber Red UNIT OFF SMR is off Amber Red No Response A particular SMR is not responding to the SCU Amber FL Power Limit SMR is in Power Limit Amber
136. r more cells being monitored by SBM are too high Amber FL Cell V Low One or more cells being monitored by SBM are too low Amber FL Cell dev High One or more cells being monitored by SBM are too high deviation from the mean battery cell voltage Amber FL Cell dev Low One or more cells being monitored by SBM are too low deviation from the mean Amber FL PM990 8800 00 Issue 7 4 5 Configuration and Operation Sageon III Power System Alarm Name Comment LED ON FL battery cell voltage Range SMR SMR parameter range error SCU could not overwrite values Amber FL Site Monitor Alarm preset from the site monitor System See site monitor menu for details of alarm Amber FL channel Battery Disch Batteries are discharging Amber FL Disch Tst Fail Battery discharge test failed to reach a programmed end point Amber FL SMR Comms Fail One or more SMRs are not responding Amber FL Amb Temp High Ambient temperature higher than preset limit Amber FL Batt Temp High Battery temperature higher than preset limit Amber FL Batt Temp Sens Battery temperature sensor not connector or failure Amber FL Batt I Limit Battery charging current is being limited to preset value Amber FL Bat Sym Alarm Battery discharge currents from battery strings not sharing load equally Amber FL Equalize System is in equalize mode Amber On Table Notes FL LED Flashing On LED On Steady
137. racket Distribution Assembly Support 1 1 Screw 10 32 Hex Head 2 0 Screw 12 24 x 3 4 2 2 Bolt Hex 5 16 18 x 1 4 4 Washer bevel 5 16 6 6 Washer Flat 5 16 6 6 Nut Hex 5 16 18 2 2 PM990 8800 00 Issue 7 7 4 Sageon III Power System Distribution Option Kit Installation 7 1 2 Installing the kit While installing the kit refer to Figure 7 5 and to a factory installed group for location and orientation of items included in the kit Item A It B S Distribution LX Assembly 5 16 Flat Washer Bevel upport Bracket Washer and Nut Qty 2 Each x 5o fF 9 Rack Rail _ gt 8 Rei With 5 m Lr Threaded s Holes 99 OK OU 5 16 Bolt Flat Washer and ale Bevel Washer Qty 4 Each o 6g Press in Nut m In Underside of 3i Bus Bar Qty 4 5 Item A Screw 10 Qty 2 Item B Screw 12 x 24 x 3 4 Qty 2 48V or 24 Vdc Bus Bar FIGURE 7 5 TYPICAL INSTALLATION OF AMI DISTRIBUTION 1 Open the kit The packing list will identi
138. re vo nee iubeo bayu e Foe ua ba 4 17 4 7 6 BDT Res lts Screen Additional Details tte aaa eee ham eee e ER e Ee eee TUE dE Ce Eoi Cr Eee tees 4 18 47 BDT Disabled nue Atte hU e ge et niu ter do ita tite m f o Pet hne 4 18 48 ALARM LEOG SCREENS n n t P e And haya eig t m e naa Asien avin A ERR bu Eo rr ed 4 18 49 SAGEON BATTERY MONITOR SETUP o ies toto e e ern iret tbe ete eve tato 4 19 4 9 Frequency of Measurement soie rte aaa ea 4 19 4 9 2 Battery Cell Measurements oe Ep eR a tensed OU e n oa det ree a vU e REUS 4 19 410 COMMISSIONING THE CONTROLLER a au be tenter tabem nus caiano 4 19 Fel T OPERATION eite iR ater Aaa 4 20 4 12 SUMMARY OF CONTROLLER FRONT PANEL CONTROLS eese 4 20 4 13 NAVIGATING CONTROLLER FUNCTIONS ie 4 21 4 13 1 Base Menu System Level Functions 4 2 4 13 2 Rectifier Menu Rectifier Specific Functions 4 24 4 13 3 Alarm iG Sige orte iet beste te EH PLUR etu e n te cei t arie a a ed e peu 4 24 4 13 4 Battery Menu Battery Specific Functions 4 25 URTO EEE 5 1 5 CONFIGURATIONS 5 45 3 9 eorr ER OP CIERRE a Ecc e ia 5 1 SA Sage View benefits aot rmt bt a io Bm om e GOOD ER Ea 5 1 3 2 MONITORINQG rihanna ea
139. red The date format is day month year the time format is 24 hours Clear Alarm Log From any alarm log screen press ENTER and then press down Down arrow to Clear arrow to clear all log entries A deletion confirmation screen will be displayed Log Entries PM990 8800 00 Issue 7 4 18 Sageon Power System Configuration and Operation LOG No Alarms The alarm log can only be cleared from the front panel There are no means to clear the alarm log entries remotely 4 9 SAGEON BATTERY MONITOR SETUP With the SBM option enabled SBM parameters must be set before monitoring can be performed From the HOME screen scroll through the operator display screens shown in Section 4 5 2 to the Auxiliary Bat Config and SBM Batteries screens and there declare the number of battery cells per battery string 2 24 and the number of battery strings 1 4 whose cell voltages are to be monitored by the SCU Refer to the Sageon Battery Monitor Manual PM990 4209 00 for detailed information The quantity of SBM boards needed for the above selection is calculated by the SCU based on battery type and configuration The relationship between battery configuration and quantity of SBM boards is shown in the table below TABLE 4 4 SBM BOARDS NEEDED FOR VARIOUS BATTERY CONFIGURATIONS 48V Battery 24 2V Cells SBM Batt 1 1 SBM Board SBM Batt 2 2 SBM Boards SBM Batt 3 3 SBM Boards SBM Batt 4 4 SBM Boards
140. reens in the order shown Repeat for each Rectifier The following map summarizes the available menu screens Select Rectifier number 1 24 read number current and temperature Press ENTER for firmware version Float voltage Equalization voltage Programmable s a Y Voltage high low alarm Voltage high voltage shutdown Current limit Fault reset SMR RECT Button The Rectifier number is the rectifier position address of the target Rectifier e g SMR 4 PM990 8800 00 Issue 7 4 11 Configuration and Operation Sageon Power System SMR no response A No Response message appears when the target Rectifier is not installed not connected not switched On or is faulty SMR initial display When a Rectifier is online and operating normally its output current and heatsink temperature are shown SMR version and temperature Press enter display Rectifier s software version SMR output current Press the up arrow button to display the output current from other Rectifiers Float voltage This parameter is globally and indirectly set in the Batt menu It cannot be changed in this screen Equalization voltage This parameter is globally and indirectly set in the Batt menu It cannot be changed in this screen Programmable Parameters The following screens allow access to the SMR programmable parameters Note that the parameter values apply to ALL i
141. res are to remain installed for run time equalization repeat the above steps until the spare devices are installed 6 3 TROUBLESHOOTING Troubleshooting is based on displayed alarm messages and error codes that appear in response to a detected change in status of the Sageon III Power System batteries or environment see Table 6 1 TABLE 6 1 ALARM MESSAGES AND ERROR CODES Location Display Method LED See Chapter or Section Operator Panel Chapter 4 Configuration and Operation Operator Panel or connected personal computer Text message Chapter 4 Configuration and Operation Section 6 3 1 Rectifier front panel LED It is possible for a configuration mistake to cause an error or change in status display If this occurs after editing the configuration or uploading a new configuration from a PC to the Sageon III Power System carefully check the configuration s programmable parameter values before changing a hardware assembly 6 3 1 Reading Rectifier Status Led Codes There are 3 LEDs on a Rectifier s front panel to indicate operating status see the following table TABLE 6 2 RECTIFIER LED CODES Green Y Off Yellow Meaning No AC power to Rectifier User Action Apply AC power to Rectifier Flashing AC input is too low or too high Primary circuit is faulty Troubleshoot AC input to Rectifier replace Rectifier Off Rectifier functioning normally in Float mode
142. rom the battery string s negative post c If the transducer is installed on one of the intercell connectors the arrow on the transducer will always point to the positive post of the next battery cell in the battery string If the intercell strap will not fit through the current transducer the strap may be replaced with a short cable lugged on both ends that will fit through the transducer consult the factory 2 Open the distribution door and locate the supplied battery current transducer cables there is one cable per transducer The 4 conductor cables are coiled and tied to the return bus loads in the distribution area of the Sageon III Power System The length of the supplied cables is 4 ft 29 1m 3 Referto Table 2 5 and connect the battery current transducer cable s to the Battery Distribution Module connector s See Figure 3 14 for a view of the Battery Distribution Module 4 Route the cable through overhead cable trays to the transducer Connect the cable to the transducer Direction of Positive Current C OC OD Flow with Batteries Charging Top View 1 ie O 1 O TT Dimensions gemens amp inches mm 2 5 64 Connector Side View N 4 pin J 3L 3 Y lt 6 152 gt FIGURE 2 15 TYPICAL BATTERY CURRENT TRANSDUCER TABLE 2 5 BATTERY CURRENT TRANSDUCER CONNECTIONS Battery Current Transducer Battery Distribution Module Board
143. roubleshooting The system may be commissioned with the battery string s connected or disconnected however consider the configuration statements in paragraph 5 above Finally perform the steps in Section 3 2 Commissioning a System 3 2 COMMISSIONING A SYSTEM This procedure assumes a newly installed system that includes connected batteries and loads 1 2 Before applying AC power check that e AIL AC input cables are connected to the correct terminals and that connections are tight e load supply and return and battery cables are correctly connected and that connections are tight check polarity as well e alarm wiring is correct and tight and that alarm annunciators function e The System housing and return bus are connected to the site earth ground Read the operator panel display and note LED indications e Ifa connected battery string is supplying sufficient power to SCU the operator panel 2 line display will be active and show System voltage and current The LEDs should also be active with an alarm showing since all Rectifiers are Off The factory installed or uploaded configuration will specify the number of Rectifiers See Table 4 1 for default parameters and values e If a battery string is not connected or the string cannot supply sufficient power SCU will not be operating There will be no operator panel display or lighted LEDs until a Rectifier is started later in this Section PM990 8800 00
144. rrow or down arrow button 2 Press the ENTER button the selected value will flash 3 Use the up arrow or down arrow button to edit that value Press ENTER to store the new value or to move to the next number to be set in a series of numbers i Volts High Alarm Float voltage high level Set to the desired high alarm value 57 5V Float voltage low level Set to the desired low alarm value Volts Low Alarm 48 0V Failsafe Alarms When Failsafe alarms are on all alarm relays will be normally energized Failsafe Alarms when no alarm condition is present Relays will de energize when an alarm occurs On Battery current sensor When Battery current sensor is turned on the controller will read Bat Cur Sensor battery current from the installed battery current transducers On Security on off toggle When security is On no parameter values may be edited Without Security first entering the password this menu will not appear if a password has not been set On Password Setup Password Setup The Sageon systems are shipped without a password set by default Press ENTER Enter a password to prevent unauthorized changes to system parameters Controller features password security for setting of parameter A valid password is an Wrong Password alphanumerical code having minimum three and maximum eight characters Panel Locked PM990 8800 00 Issue 7 4 8 Sageon Power System Configuration and Operation Units
145. sie tot etum i iet oe de dene redes 2 7 2 5 2 User s AC Electrical Service P nel ig atat ata m E oed m a e dea np PO ERR spa 2 7 2 3 3 A C Cabling soc aina m p pa met animam pm opo Reese 2 8 2 6 CONNECTING BATTERY CABLES ni Rep itd b doen e aspita 2 9 2 7 CONNECTING CUSTOMER LOADS o rre 52 93 ERO ame DE OD E D RE RE e CO D EO e o dest 2 10 2 7 Load Return Cables n eee t e EO E par EO ERR ci D Le E EE OR EO PRO 2 12 2 7 2 Load Supply Cables AMI Type Breaker Distribution n 2 12 2 7 3 Load Supply Cables GJ1 Type Breaker Distribution nennen n enne nene tren nee trennt nenne nenne 2 14 2 8 CONNECTING EXTERNAL ALARM ANNUNCIATORS reete ener nennen trennt 2 15 2 9 BATTERY TEMPERATURE SENSORS AND KITS OPTION 2 15 2 10 INSTALLING A BATTERY CURRENT TRANSDUCER OPTION n inneren nennen 2 16 2 TII SAGEON BATTERY MONITOR OPTION ana iaia A M p nie Peter im ne e darn 2 17 2 12 SITE MONITOR SYSTEM OPTION ws etd eee p d de e erect dde re eed nen 2 18 21 ihr pip dre gite Vo ipte eb e ape rep dete tette boe ee an PE ve hohe te E eodein ede 2 18 2 14 INSTALLING AND REMOVING RECTIFIERS
146. stem through a distribution breaker or fuse Refer to Chapter 4 Configuration and Operation and use the operator panel push buttons and menus to 1 Turn Off battery temperature compensation Note If the float voltage is set at high or low battery temperature with battery temperature compensation turned On compensation may adjust the System voltage by as much as 2 volts 2 Connect the load to the System by closing the distribution breaker 9 Repeat Steps 7 through 10 until all Rectifiers are on line and taking load As Rectifiers are brought on line the load may be increased 10 Atthe operator panel verify that each Rectifier is sharing current and the Sageon III Power System voltage is set to the desired Float voltage generally 54 2 Vdc volts 11 Configure the Sageon III Power System as described in Chapter 4 Configuration and Operation If the configuration has been created on a PC and is to be uploaded to the operating Sageon III Power System also refer to Chapter 5 SageView 12 Thoroughly test the new configuration to ensure that all configurable parameters are correct Test the alarm circuits to ensure correct activation 13 As needed operate the system for 15 20 hours to charge the battery string s before placing the system on line 3 3 OVERVIEW OF EXTERNAL WIRING CONNECTIONS SD SAGEON3 AXX drawings show the internal and interface schematic for the Sageon III Power plant with distribution For the purpose of indicatin
147. t 1 Battery current transducer full scale 10 30 000A 100 rating FS Batt 2 Battery current transducer full scale 10 30 000A 100 rating FS Batt 3 Battery current transducer full scale 10 30 000A 100 rating FS Batt 4 Battery current transducer full scale 10 30 000A 100 rating SCU SCU access code 7 digits 0 9999999 10000000 Date Current system date Battery Monitor menu after enabling Battery Monitor Bat Config monoblock size x number 2V x 24 see SBM section of manual for Configuratio more detail ns PM990 8800 00 Issue 7 4 1 Configuration and Operation Sageon III Power System Parameter Description 48V System 48V User Range System Value Default SBM Number of battery banks to be 1 4 1 Batteries monitored Vhi Cell Cell high voltage alarm 2 0 16 0V 2 5V Vlow Cell Cell low voltage alarm 1 0 12 0V 1 8V dVc Cell Cell positive deviation alarm 5 99 10 dVc Cell Cell negative deviation alarm 5 99 10 RECT Menu RECT V high Rectifier high voltage alarm 48 65V 57 5V RECT V low Rectifier low voltage alarm 44 54V 48V RECT HVSD Rec high voltage shutdown 48 66V 57 5V RECT limit Rectifier current limit 4 60A 60A BATT Menu B Dis Alarm Battery discharge alarm threshold 44 52 47 0V Disch I Diff Battery string discharge current 5 99A
148. tates the date of preceding test in a day month year format Dur 1h18min Provides the duration of preceding test EndV 47 0V Shows the battery string voltage when test was terminated EndQn 380Ah States the remaining estimated capacity of the battery string at the time the test was terminated where n is the number of the string 4 7 7 BDT Disabled The battery discharge test function is disabled for 2 minutes if any of the following has occurred If an automatic test is scheduled during this period it will be performed at the next opportunity at the BDT Time e SCU has recently been powered up e An AC supply failure has been recorded 4 8 ALARM LOG SCREENS An alarm log resides in SCU memory and these alarms can be viewed by momentarily pressing the Alarms Log button The following map summarizes the available menu screens LOG Button Alarm number and description Alarm date and time Clear alarm log Initial Alarm Log screen Log 1 is the most recent alarm Previous alarms are number in sequence 2 through n The second line provides the alarm name AC i A It req Fau Log Press and hold the up arrow button for 2 seconds to display the preceding alarm Log Alarm Name 2 Press again to display the preceding alarm Log 3 Log 1 14 03 2013 13 55 Momentarily less than 2 seconds press the up arrow button to display a screen showing the date and time alarm occur
149. tems are available in the Controller Operation PDF on the Manual CD PM990 8800 00 Issue 7 4 26 Sageon III Power System Sageview 5 0 SAGEVIEW SageView System Monitor software enables configuring and monitoring of a Sageon III Power System from a local or remote personal computer PC Figure 5 1 shows the various access options Local monitoring involves a PC connected to the USB connector on a System s operator panel Remote monitoring also connects a Sageon III Power System to a PC however they can be separated by a few feet or by hundreds of miles Your company s Ethernet network or intranet the Internet or a pair of telephone modems can provide the interconnection Refer to TG990 4262 10 for more details on SageView Remote PC with CD00026a Local PC fa SageView Ethernet with Network SageView PC with a SageView Remote Server with PC with IA i and SageView Modem Intranet Local Network Ethernet Power Plant with Battery String s Operator Panel RS 232C SageView Control Local Outputs to Unit SCU and User s Alarm System ToU Interface Board Data Logging i Fun Status pads Measured N Control Distribution Variables N Signals X DC Bus Rectifier 1 Recti
150. the date and time of the alarm occurrence are displayed These two screen then alternate at a two second rate Increment Press the up arrow to scroll through a menu selected using an SMR BATT or LOG button from the first menu screen to the last When editing a flashing parameter press to increase the parameter value Decrement Press the down arrow scroll through a menu selected using an SMR BATT or LOG button from the last menu screen to the first When editing a flashing parameter press to decrease the parameter value Enter With a editable parameter displayed press Enter to cause the value to flash indicating that the up arrow or down arrow button can be used to change that value Press ENTER to store the edited value When setting a parameter with multiple digits e g access code time date set the left most digit as described above Then press ENTER to cause the second digit to flash Press up arrow or down arrow to set the flashing digit to the desired value Repeat until each digit is set to the desired value When an alarm condition exists and you are prompted to press ENTER the ENTER button will cause alarm details to be displayed CAUTION Setting correct parameter values is critical Incorrect values can result in unsatisfactory performance unexpected shutdown and other unanticipated performance characteristics Moving from one menu to another To move from any menu to
151. ticular battery being used requires different set up Refer back to section 3 to continue commissioning procedures 4 11 OPERATION System operation is controlled by the Controller system controller As a result operation information for the system is directly related to the operation of the Controller as described in this section 4 12 SUMMARY OF CONTROLLER FRONT PANEL CONTROLS There are four Menus which can be viewed using the INC or DEC buttons a The default or Home menu which contains general system information b RECTIFIER menu contains all the parameters relating to the switch mode rectifiers RECTIFIER c Battery menu contains all the parameters relating to the batteries d Alarms log which is a chronological record of the last 100 alarms Moving from one menu to another If no button has been pressed for two minutes the display will revert back to the Home screen This shows the output voltage and load current To move from any menu to any other menu press the corresponding button e g to move to the Battery Menu from any other menu momentarily press the BATT button To move to the Home menu from any other menu press the button of the current menu e g if in the RECTIFIER menu press RECTIFIER button to return to the Home menu Scrolling through the Menus To scroll through any menu from the first screen to the last press the INC button To scroll to the last bottom screen first then upwards through the
152. tion See notes below Tier Group s AMI Positions 48V Plant 48V Plant 1 A 1 10 Y N 1 B 11 20 Y N 2 A 21 30 Y Y 2 B 31 40 Y Y 3 A 41 50 Y Y 3 B 51 60 Y Y Table Notes Y Yes indicated circuit breaker or fuse type can be installed in the group listed in the column at left N No indicated circuit breaker or fuse type cannot be installed in the group listed in the column at left l 2 Refer to the Distribution Guidelines above for additional information The GJ1 type breaker Distribution Option is an assembly that can hold up to four GJ1 type breakers The GJ1 Option must be the topmost distribution Other distribution types cannot be installed above GJ1 distribution ISTRIBUTION TIER 3 SA T ISTRIBUTION TIER ISTRIBUTION TIE A A 1 T FIGURE 7 2 DISTRIBUTION AREA LEFT SIDE PM990 8800 00 Issue 7 Sageon Power System Distribution Option Kit Installation mo gt RETURN BUS LOA M t gt 2 e Ta k TIER n s RETURN BUS LOAD TIER 2 OPT i HARGE BUS BATTERY a eae tel icon TIER 4 STD EL x XE TURN 3US LOAD CD napa TIER 1 STD e x 9 8 0 C I RETURN BUS BATTERY TIER 1 STD MI Ps FIGURE 7 3 DISTRIBUTION AREA RIGHT SIDE 7 1 AMI D
153. ture alarm or fan failure alarm present High ambient temperature Fan air intake exhaust vents are blocked or a fan is jammed with a foreign object or excessive dust Check the ambient temperature and improve site cooling if possible Check and remove obstructions from the air vents Replace the module or remove and replace the fan assemblies in the module requires only that the rectifier lid be removed LVBD will not close One or more batteries are reverse polarity No battery is connected to the battery distribution module Fuse link blown in the battery distribution module BDM Controller setting for LVLD is Off Low Voltage Load Disconnect setting is greater than the current bus voltage Check battery wiring polarity Connect a battery Check that the Controller is powered up even when no rectifier is operational If not service the fuses in the BDM Set LVLD to On Power up the rectifiers and reduce the load until the bus voltage increases to the float voltage Load or Battery circuit breaker alarm does not set when the breaker is opened or is incorrectly alarmed as battery switch instead of load trip or visa versa No battery or load alrm aux switch is connected to the circuit breaker connection Alarm link in BDM is incorrectly configured Check load and battery alrm aux switch connections to the BDM and that the alarm links are correctly configured Battery or Ambie
154. uires 385 5201 20 10 Battery Cell Leads 350 7812 10 25 Battery Cell Leads 350 7812 25 50 Battery Cell Leads 350 7812 50 100 Battery Cell Leads 350 7812 100 Battery Adaptor Kits Requires 350 7812 xx For 10 Battery Hardware Includes harness amp flat washers 385 6151 03 For 1 4 and 6mm Battery Hardware Includes harness amp flat washers 385 6151 04 For 5 16 and 8mm Battery Hardware Includes harness amp flat washers 385 6151 05 For 3 8 and 10mm Battery Hardware Includes harness amp flat washers 385 6151 06 For 1 2 and 12mm Battery Hardware Includes harness amp flat washers 385 6151 07 Sageon Power Plant Parts List Continues PM990 8800 00 Issue 7 iv Sageon Power System Front Matter Descriptions Battery Current Transducers Requires SAGEON3 C01 Part Numbers 50 closed rect 0 80 x 0 40 window 30 signal wire 385 5932 50 100A closed circular 1 25 diam window 30 signal wire 385 5932 100 200A closed circular 1 25 diam window 30 signal wire 385 5932 200 600A closed circular 1 25 diam window 30 signal wire 385 5932 600 1000A closed rect 2 51 x 0 82 window 30 signal wire 385 5932 1000 50A closed rect 0 80 x 0 40 window 100 signal wire 385 5970 50 100A closed circular 1 25 diam window 100 signal wire 385 5970 100 200A closed circular 1 25 diam window 100 signal wire 3
155. umber of SMRs Rectifiers in system This number must be entered to prevent the Number of SMRs operator panel from indicating that some SMRs are not responding 15 Number of battery strings Set to the number of connected battery strings Num of Batteries 2 Battery current transducer full scale rating Set to the full scale rating of the battery FS Batt Current current transducer 200A Load sensor On SCU displayed System current is derived from the voltage across System shunt Load Sensor Off SCU displayed System current is the sum of the Rectifier currents ON Full Scale Load Current Set to the full scale rating of the installed plant system shunt Pra Access Code SCU Access Code i e System ID Type a unique 7 digit number for each Sageon III 1252636 Power System in your network Be sure to record your access code s and store in a secure location Date format Set the date format DD MM YYYY MM DD YYYY or YYYY MM DD Date Format MM DD YYYY Date 04 01 2013 Clock set Set the date and time Note that this is a 24 hour clock Time 21 58 34 Alarm report on off toggle When on the system will dial the Phone 1 number see the Alarm Report Phone 1 screen below If there is no answer Phones 2 and 3 will be dialed in turn The On cycle will continue until a connection is made See Note following Phone 3 below Daily report on off toggle When on the system will log in to the telephone numbers Daily Repon belo
156. un terminated cables There are 6 distribution groups organized in three Tiers with two Groups in each Tier All are located in the Power system s distribution area as shown in Figure 7 1 The type of distribution that can be installed in each group is discussed below and listed in Table 7 1 Tier 2 amp Tier 3 can be field installed Figures 7 2 and 7 3 show typical left and right side views of the distribution area os A TIE i TIER lt q Ll pira Z DISTRIBUTION GROUPS A amp B ON EACH TIER LEFT SIDE FIGURE 7 1 DISTRIBUTION LOCATION BY TIER AND GROUP PM990 8800 00 Issue 7 7 1 Distribution Option Kit Installation Sageon Power System Distribution guidelines e Power system can have three tiers of distribution Tiers 1 2 and 3 e When adding distribution groups tier 1 is factory installed group A amp B with AMI capability start at tier 2 upwards e AMI type breaker distribution can be located in any group e GJI type breaker distribution must be installed as the topmost group above all other distribution types e As distribution is added additional return bus sections up to 3 total may be needed to provide terminations landings for load returns See Figure 7 3 Order the return bus sections separately as needed TABLE 7 1 INSTALLABLE DISTRIBUTION TYPES BY TIER AND GROUP Installable Distribu
157. urs EQ Period 12 Weeks Manual Start Eq Press ENTER LVDS Trip 43 0V LVDS Mode t Auto DEC Temp Sen Alarm INC 14 21 35 Duration 1h30min BDT Current 50A BDT End V 46 5V End Q 150Ah Last BDT Passed 5 5 5 ENT TER ENTER toggles state I Off On I Modify Value up down I ENTER to accept I Modify Value up down I ENTER to accept ENTER toggles state I Off On Volts Eq Trigger 46 0V ENTER toggles state Off On Q Loss Trigger 25Ah Modify Value up down L ENTER to accept ENTER Enable disable Equalisation charging Charge current limit for battery voltage between float amp equalise System Equalise voltage without BTC Sense point voltage regulated to this value Enable disable bus voltage discharge triggering of equalisation charging Threshold below which Eq is triggered Modify Value up down ENTER to accept I Enable disable battery capacity loss triggering of equalisation charging Threshold below which Eq is triggered Modify Value up down Modify Value up down L ENTER to accept Modify Value up down L ENTER to accept ENT
158. w at the time set in the following screen and download the status and all operating parameters See Note following Phone 3 below On PM990 8800 00 Issue 7 4 9 Configuration and Operation Sageon III Power System Time of daily report Note that is a 24 hour clock Daily Report 15 15 Modem enable on off toggle The Phone number screens will appear only when the Modem modem is toggled on On Phone 1 Set the first number to be dialed when an alarm occurs Up to 20 digits can be Phone 1 stored Numbers longer than 10 digits are shown on two screens 0398887788 Phone 1 Cont 2323 Second screen example Phone 2 0398880033 Phone 2 This number will be dialed when the above number does not answer Phone 3 Phone 3 This number will be dialed should the previous number not answer 0398880003 Note To send Alarm Report or Daily Report to a local PC set the Report to On and Modem to Off Audio Alarm Audio alarm on off toggle Set to On to audibly annunciate an alarm Press ENTER to On silence acknowledge the alarm Cct Input Used N C Circuit breaker auxiliary contact input Configure options are normally closed normally open or disabled not used Bat Sw Input Battery circuit breaker auxiliary contact circuit input Configuration options are normally Used N O closed normally open or disabled not used LVDS Input Battery low voltage disconnect switch auxiliary contact circuit input
159. wer System in an extremely low humidity environment lt 10 additional site ESD Electrostatic Discharge mitigation is recommended The installation of ESD conductive floor covering or coating per ANSI EOS ESD S7 1 and use of dissipative foot straps per ANSI EOS ESD S9 1 whenever servicing the equipment is recommended The use of an anti static wrist strap per EOS ESD S1 0 Wrist Straps is always recommended and is mandatory whenever servicing the Power System in an extremely low humidity condition PM990 8800 00 Issue 7 1 4 Sageon III Power System Heat Dissipation Cooling Distribution Rectifier Modules Audible Noitse E 9 800 feet 3 000m Contact the factory for derating above specification ara 1070 BTU Hr maximum full load per Rectifiers Spi Convection cooling dual Fan forced air front to back with built in over temperature power limiting T 66dB for a fully loaded plant per NEBS GR 63 CORE 1 2 3 Power system Electrical Specifications Input AC Power Input Battery Strings i Battery String Connections Output Plant Power Output max Distribution Power system Total Individual Group AMI Individual Group GJ1 1 2 4 Genera
160. wer cables to the service panel TABLE 2 3 CIRCUIT BREAKER SELECTION AC POWER Rectifiers Powered Breaker Rating 1 20A 2 40A 2 5 3 AC Cabling This section describes connecting the AC input cables within the Power system An AC input cable can enter the plant several ways e Through either the lower section side panel or lower rear panel of the cabinet e Upward through the open base of the rack For each ordered Rectifier connect an AC input cable to the AC termination block located in the lower section of the unit IMPORTANT Do not change the factory set rectifier position address The address is set on the AC Backplane board l System ALLA E IATA e H E slg BE g E L1 L2 1 Line1 Line2 Ground User Wiring exe LL e 5 AC Cable from User s AC Electrical Service Panel FIGURE 2 4 AC INPUT CABLING WITH RECTIFIER ON OFF OPTION PM990 8800 00 Issue 7 2 8 Sageon Power System Installation 2 6 CONNECTING BATTERY CABLES Routing the stiff heavy gauge battery cables is difficult Two people may be needed Exercise extreme caution to avoid a short circuit across the battery terminals A WARNING Ar

Sageon III Manual

Contents

Download Pdf Manuals

Related Search

Related Contents