Transcript
Systems Installation Manual Revision 1.1 Type: PSM-1800615-001
Enatel Ltd PO Box 22-333 321 Tuam St Christchurch New Zealand Ph: +64 3 366 4550 Fax:+64 3 366 0884 Email
[email protected] http://www.enatel.net Copyright © Enatel Ltd 2006
Enatel DC System Manual
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TABLE OF CONTENTS 1.0
SCOPE ................................................................................................................................................. 3
2.0
SYSTEM OVERVIEW........................................................................................................................... 3
3.0
INSTALLATION ................................................................................................................................... 3
3.1 3.2 3.3 3.4 3.5
Unpacking ....................................................................................................................... 3 Positioning & Fixing Cabinet ............................................................................................ 3 AC Cabling ...................................................................................................................... 4 DC Cabling ...................................................................................................................... 5 Alarm/Ancillary Cabling ................................................................................................................ 6
4.0
LVD OPERATION ................................................................................................................................ 6
5.0
COMMISSIONING................................................................................................................................ 7
6.0
SYSTEM WIRING DIAGRAM .............................................................................................................. 9
Enatel DC System Manual
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1.0
SCOPE
This manual covers essential information for the installation and commissioning of the Enatel DC Power System, part number PSM-1800615-001. System set-up for the rectifiers, alarms etc., are provided in separate manuals for the SM22 supervisory module and RM3048 rectifier. All installation and maintenance must be carried out by suitably qualified personnel.
2.0
SYSTEM OVERVIEW
The Enatel DC Power System model PSM-1800615-001 has a maximum power output of 18kW, producing a maximum current output of 333A at -54Vdc (370A/-48Vdc). The system is supplied complete with: -
600mm x 450mm x 800mm cabinet
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Up to 6 x 3kW (-48V) rectifiers (RM3048) (packaged separately
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SM22 supervisory module (supplied installed in cabinet)
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Battery Condition Monitoring for up to 4x 48V battery strings made up of 12V monoblocs. This is expandable to 8 strings with the addition of another BCM circuit board.
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Integrated DC Distribution (supplied in cabinet) consisting of: - 2x load circuit breakers for critical and non-critical loads, each a 3-pole 80A MCB with paralleled poles - one 10A and one 5A MCB for DC lighting and an extractor fan, both on the critical circuit - 8x 100A battery MCBs - 2x load-side Low Voltage Disconnects, one for critical loads, and one for non-critical loads
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System weight is approximately 90kg packaged, and 80kg unpacked (without rectifiers fitted).
NOTE: AC and DC EARTHING This system has a built-in AC to DC earth connection. The DC Common busbar in this system is directly bolted to the cabinet frame. This creates a direct link from the DC earth to the AC earth. No extra AC to DC earth link cable is required.
3.0
INSTALLATION
3.1
Unpacking
Manoeuvre packaged system as close as possible to the installation area prior to unpacking so that there is less chance of damage to the system whilst being moved. The equipment is suitable for being moved with a normal pallet truck while still packaged. Unpack the Power Cabinet and prepare to stand it up in its installed position.
3.2
Positioning & Fixing Cabinet
Once in its final installed position, mark the 4 mounting bolt holes (shown in figure on the right) in its base on the floor, or on the stand on which the cabinet is being mounted. These holes are 20mm diameter so that insulating bushes can be Enatel DC System Manual
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fitted if required. Recommended fixing bolts should be 10mm (using large washers) to 18mm diameter. Once the holes are marked, move the cabinet away and drill the holes for the fixing bolts. Move the cabinet back in position. Check the cabinet is level. If necessary use spacers to level the cabinet. It is important that the cabinet is level, especially if batteries are fitted. If it is not level, the batteries can be distorted and a fault may be caused. After leveling, bolt the cabinet to the floor or stand.
3.3
AC Cabling
The following sections cover how to cable to the system. All cabling can exit either the bottom or the top of the cabinet. If exiting the cabinet top, the top cable panels can be removed to allow access, or holes can be drilled in them if cable glands are to be used. AC cabling should be directed in through the top of the cabinet, to the terminals provided as shown in Figure 1 below. Ensure AC and DC cabling is kept separate where possible, and if they must pass each other, ensure they cross at right angles. Maximum cable size is 35mm2.
Neutral Input
Phase Inputs
Earth Input Connection
Rectifier Circuit Breakers
1
2
3
4
5
6
L1
L2
DC Lighting Relay
L3
Extractor Fan Relay
Main Input Circuit Breaker
Fig. 1 AC Distribution Included on the same panel as the AC Distribution are the control relays for the DC lighting and extractor fan.
Enatel DC System Manual
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3.4
DC Cabling
CAUTION: Use extreme care when fitting batteries & their connections. Remove all jewelry and rings from oneself prior to commencing the installation. Always use insulated tools when fitting batteries and take extreme care not to short terminals when working on them. Note: For improved access, remove the top hat cover (2x M6 screws). Live (-ve) DC load cables connect directly to the paralleling busbars on the top of the load circuit breakers. Two M10 bolts are provided on each bus for this. Battery live (-ve) connections are made directly in to the tops of the 80A battery circuit breakers. The circuit breakers can accept a maximum cable size of 35mm2. DC Common Busbar Critical Load Output
8x 100A Battery Circuit Breakers Connect Battery –ve Directly to Breakers
Extractor Fan
DC Lighting
Non-critical Load Output
Fig. 2 DC Distribution Common (+ve) connections for both load and battery connections are made to the Common Busbar at the top rear of the cabinet. Fifteen M10 bolts are provided for this purpose.
Enatel DC System Manual
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+ve (0V) Load & Battery Common Terminations
LVD2: Critical Load
LVD1: Non-Critical Load
LVD Link Positions
Temperature Sensor Cable
Fig. 3 DC Distribution Common Terminals (viewed from rear)
3.5
Alarm/Ancillary Cabling
Alarm and communication cables terminate directly into the rear of the Supervisory Module, SM22. See the SM22 manual for connection details. When routing the cables, ensure they are kept away from the AC and DC power cables. Uncoil the battery temperature sensor and place in the middle of the middle battery string. If the lead is not long enough, ordinary 2-core copper (approx. 0.75mm2) wire can be used as an extension. The purpose of the battery temperature sensor is to monitor the ambient temperature of the batteries over long periods of time and adjust the rectifier output (float) voltage accordingly. As a result, it is not necessary to have the temperature sensor touching the batteries. If a Battery Condition Monitor is used with the temperature probe option (for each string), then it is more appropriate to attach the temperature probe to the first terminal of each battery string.
4.0
LVD OPERATION
This system is configured with two Low Voltage Disconnect contactors in the load side of the circuit (see wiring diagram at rear of this manual). The loads are designated “Critical” and “Non-critical”. The contactors are shown in Figure 3. The threshold of the Critical LVD is set to a lower voltage than the Non-critical LVD to ensure extended operation of critical load circuitry. The SM22 supervisory and monitor unit remains powered when either or both of the LVDs are activated. This ensures remote communications are available even when loads are totally isolated form the batteries. Enatel DC System Manual
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Figure 4 shows the LVD Service switches. When in the “normal” position, the LVD is under SM22 control. When in the “Service” position, the LVD is permanently engaged. This may be useful when setting adjustments are made, or if the SM22 is to be removed for any reason. Also provided are link positions beside each LVD contactor. These may be linked if an LVD contactor is to be changed, ensuring load the load is connected during the change process.
LVD Service Switches
Fig. 4 LVD and Shunt Connections (viewed from rear) .
5.0
COMMISSIONING
Use the following set of instructions as a guide, unless different procedures are recommended by local authorities. Pre-check: 1. System installation is completed. 2. Battery and load circuit breakers are turned off. 3. Rectifier modules have been fitted into their shelf positions. 4. Check that the protective AC Earth is connected as per local regulations, and check that the DC Earth (normally the +ve in a “-48V” system) has been strapped to the AC Earth at a point physically close to the DC Power System (unless specifically requested otherwise). 5. Turn on AC upstream and check that voltages from phase to phase, and phase to neutral are as expected. Rectifier Start-up 1. Turn the main AC circuit breaker on.. Enatel DC System Manual
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2. Turn the first rectifier circuit breaker on and wait for the rectifier to start and its power on LED remains green. 3. When the rectifier is turned on, ensure the Low Voltage Disconnect contactors engage. This should be a clearly audible click from each contactor. 4. Check the SM22 powers up, and indicates the system default float voltage (approx. 54V on its display). If the audible alarm activates, press any SM22 button to silence it. 5. If a different system float voltage has been specified, set this at this time using the procedure specified in the SM22 Manual. 6. Turn on each of the other rectifiers ensuring they power up with only their green “power on” LED illuminated. 7. Check that the load and battery currents on the SM22 are 0 amps (+/- 1 or 2 amps). Load Connections 1. Ensure downstream load connections have been made and there are no loose/floating load cables. 2. Turn on the load circuit breakers. 3. Ensure the system float voltage on the SM22 is at the level previously noted. 4. Ensure the load current is at a level expected (could be zero if loads downstream have not been connected). 5. Turn all load circuit off prior to turning batteries on. Battery Start-up 1. It is important that battery circuit breaker connections should be made when the rectifiers are turned on and the system is “live”. This is because the system voltage and battery voltages will be similar, thus minimising any arcing during connection. This also prevents high current arcing due to the charging of the rectifier output capacitors. 2. Start up the batteries with only one rectifier powered up initially to limit any damage if any connections are incorrect. 3. Measure the voltage across each battery string and ensure that the blue cable is at –48V (nominal) with respect to the red cable. 4. Turn on each battery circuit breaker in succession and ensure there are no alarms once they are all turned on/fitted. Alarms and Settings Refer to the SM22 Manual for full system alarm and parameter setting procedures. Note: Prior to leaving the system after it has been commissioned, ensure all AC, DC and battery circuits are off. If it is required that the system is to be left on (to power load equipment, ensure rectifiers are left in their powered up state, and batteries are in circuit. This will prevent anyone leaving the batteries only powering the load (in which case the batteries would go flat). <<< END >>>
Enatel DC System Manual
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6.0
SYSTEM WIRING DIAGRAM
Enatel DC System Manual
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