Chapter 4 Use Of Controller
4.2 LCD Menu Tree
4.2.5 Quick Setting
Figure 4-7 Manual screen
In the manual screen, you can perform the following manual control operations:
Start: To start float or boost charging or battery test.
LVD1: To reconnect or disconnect LVD1 contactor.
LVD2: To reconnect or disconnect LVD2 contactor.
RectTrim: To adjust the rectifier output voltage.
RectLimit: To adjust the rectifier current limiting point.
4.2.4 ECO
In the Main Menu, move the cursor to ‘ECO’ and press ENT to enter ECO menu:
MAIN MENU Status Settings ECO Manual Quick Settings
ENT ECO
Disable Cyc Period: 168h Rect Work: 80%
Rect Limit: 1 Figure 4-8 ECO screen The following parameters can be configured:
ECO: To disable or enable ECO function.
Cyc Period: Rectifier redundancy cycle.
Rect Work: Optimum operating load point of rectifier.
Rect Limit: In ECO mode, the minimum number of rectifiers required.
4.2.5 Quick Setting
In the Main Menu, move the cursor to ‘Quick Setting’ and press ENT to enter Quick Setting menu:
MAIN MENU Status Settings ECO Manual
Quick Settings
ENT System Type:
48V / 1000A Capacity: 300Ah LCD Rotation: On
Figure 4-9 Quick Settings screen
In the Quick Setting screen, you set the system type and system capacity, as well as the parameters (current, voltage) of load shunts and battery shunts.
Chapter 4 Use Of Controller 29 4.2.6 Controller Setting
Table 4-6 summarizes all the settings of the controller.
Table 4-6 Controller Settings
Components Name Available Settings
Default setting Unit Low limit High limit
Soft-start with load enabled Enabled/Disabled Disabled /
Startup upon AC over voltage Enabled/Disabled Disabled /
System ECO enabled Enabled/Disabled Disabled /
Sequencial start interval 0 10 0 s
Input current limiting 1 50 30
Rectifier slot setting enabled Enabled/Disabled Disabled /
Rectifier slot setting 1 30 1-1/2-2… /
Battery
Basic battery parameters
Number of fuses 0 5 2
Nominal capacity 20 5000 600 Ah
Shunt Yes / No
Shunt current 1 2000 According to system
type A
Shunt voltage 1 500 25 mV
Temperature 1 None/Battery/Ambient Disabled /
Temperature 2 None/Battery/Ambient Disabled /
Battery
Battery test parameters
Battery temp compensation coefficient
Temperature compensation central
point 10 40 25 deg.C
Battery compensation coefficient 0 500 72 mv/deg.C
Battery over temperature point 10 100 50 deg.C
30 Chapter 4 Use Of Controller
Components Name Available Settings
Default setting Unit Low limit High limit
Load shunt Yes / No No /
LVD
LVD1 Enabled Disabled / Enabled Disabled /
LVD2 enabled Disabled
/Enabled Disabled /
LVD1 voltage 40 60 43.2 V
LVD2 voltage 40 60 43.2 V
AC unit
Over voltage alarm point 0 500（866） 280（485） V
Under voltage alarm point 0 500（866） 180（304） V
Phase failure alarm point 0 500（866） 80（255） %
Communication parameters
IP address 0-255 192.168.1.2 /
Subnet code 0-255 255.255.255.0 /
Default gateway 0-255 192.168.1.1 /
Local address 1 255 1 /
Port type RS232/Modem/ETH RS232 /
Baud rate 1200/2400/4800/9600 9600
Protocol YDN23/EEM/RSOC/SOCTPE YDN23 /
Alarm call-back enabled Yes / No No /
Call back times 0 10 3
Call back number 1 Call back number 2 Call back number 3
Controller parameters
Language English / Chinese English
Display time zone GMT+08:00
System date System time
Restore default configurations Yes / No No
Set rotating screens Horizontal/Vertical Horizontal
System type
48V/set, 48V/1000A, 48V/500A, 48V/300A, 48V/100A, 24V/set, 24V/1000A, 24V/500A, 24V/300A and 24V/100A
48V/set
4.3 WEB Interface Operation
Through the WEB Interface, a remote user can:
View real-time operating information.
Send control commands.
Set programmable parameters.
Set which new alarms are displayed in a pop-up WEB window.
Download and upload configuration files.
4.3.1 Setting Up The Internet Explorer Web Browser
Procedure
Note
This procedure needs to be performed only when the controller is connected to an Internet and the User has set that the access to the Internet needs to be made through proxy. If the controller is connected Internet and the user computer is connected to the Internet, the user cannot disable the proxy, otherwise he will have no access to the controller.
1. Launch Internet Explorer.
Chapter 4 Use Of Controller 31 2. Select Internet Options from the Tools menu. The ‘Internet Options’ window opens. In the ‘Internet Options’
window, select the Connections tab.
Figure 4-10 Internet options window
3. Click on the LAN Settings... button. The following window opens. In the LAN Settings window, uncheck the proxy box and click OK.
Figure 4-11 LAN settings window
4.3.2 Logging Into The Controller
Procedure
In Internet Explorer, enter the IP address programmed into the controller and press ENTER. The following WEB Interface window opens. Enter a valid User Name and Password, and then click OK. By default, there are two ‘User Name’ and ‘Password’ combinations, one is ‘admin’ and ‘640275’, the other is ‘operator’ and ‘1’. The username of
‘admin’ has the highest authority and the username ‘operator’ has no authority for uploading and downloading configuration files.
32 Chapter 4 Use Of Controller
Figure 4-12 Access to controller
4.3.3 Homepage Introduction
After entering a valid User Name and Password, and clicking OK; the homepage window opens.
The homepage window is divided into three areas: System Information, Parameter Settings and Control Functions, and Upload/Download Files.
Figure 4-13 Homepage window System information
At the top of homepage, System Information is displayed, such as System Voltage, System Load, MA/CA Number, OA Number, Battery Mode, Site Name, HW Version, and SW Version.
Parameter and control function
You can set the following parameters and control functions:
Battery Temp Comp: To disable or enable the battery temperature compensation function.
Chapter 4 Use Of Controller 33
Battery Test: To disable or enable the periodical battery test function. This setting has no effect on the short test.
Current Limitation: To disable or enable the battery charging current limitation function.
Boost Charge: To disable or enable the periodical battery boost charging function. This setting has no effect on auto boost charging.
LVD1 Level, LVD2 Level: To set the low voltage disconnection point.
Under Voltage Level 1, Under Voltage Level 2: To set the under voltage point.
System Volt: To set the system voltage.
Boost Volt: To set the battery boost charging voltage.
NMS1 IP, NMS2 IP: To set the IP address of SNMP
Remote1 IP, Remote2 IP: To set the IP address of EEM protocol.
TCP IP address: To set the IP address of TCP IP protocol.
Upload/download files 1. Procedure
1) To upload a configuration file, click the Upload button. The following window opens. Click the Save button.
Figure 4-14 Uploading the configuration file
2) The following window opens. Navigate to where you want the file to be saved. Click the Save button.
Figure 4-15 Save as window
34 Chapter 4 Use Of Controller
After the upload is completed, the system will pop up a window to prompt the user that the upload is successful:
Figure 4-16 Upload successful 3) Users can also upload up to 80 active alarms or history alarms.
4) To download a file, click the Browse button. Navigate to and select the configuration file to be downloaded:
Figure 4-17 Selecting the configuration file
Chapter 4 Use Of Controller 35 Then click Open:
Figure 4-18 Access to the homepage
Then click Download button, the system will pop up a window requiring you to confirm:
Figure 4-19 Confirmation window
36 Chapter 4 Use Of Controller
Click OK, the system will prompt you that the download is successful:
Figure 4-20 Download successful
In the above screen, you can click ‘Back to the Homepage’ to return to the Homepage.
Administrator can click ‘Go to Firmware Download Mode’ to enter Bootloader download interface.
4.4 WEB Bootloader Interface Operation
Below is the web download webpage. In this webpage administrator can update the firmware. Please ensure that the file name of the firmware is M221S.bin.
Figure 4-21 WEB webpage
Chapter 4 Use Of Controller 37
4.5 Serial Bootloader Interface Operation
Serial COM PORT can be used to download and upload files through the following procedure:
1. Connect Serial line to the computer and LCU+. Connect the DB9 terminal to computer, while connect the RJ45 terminal to the port assigned with ‘IOIO’ on LCU+.
2. Open the software of HyperTerminal on the computer, set the parameters according to the following method, here we use COM1, however, other COM PORT is optional dependent on your computer.
Figure 4-22 Choose the COM port
Figure 4-23 Set the parameters of COM port
38 Chapter 4 Use Of Controller
Figure 4-24 Main menu of download/upload
Here we can see there are 4 options, choose ‘1’ to download the application program, choose ‘2’ to download the configuration data, choose ‘3’ to upload the data configuration file, choose ‘4’ to execute the application program.
1. Method of downloading the application program:
1) Press ‘1’ on the keyboard, enter the surface of download;
2) Choose Transfer->Send File…, select the .bin file you want to download;
Figure 4-25 Choose the file
Chapter 4 Use Of Controller 39 Pay attention that the protocol is Ymodem
Figure 4-26 Choose Ymodem as protocol 3) Press ‘Send’, ‘.bin’ file is transmitted from computer to LCU+;
Figure 4-27 The process of downloading file
4) After the file downloading is completed successfully, the following interface pops up:
Figure 4-28 Downloading file successfully
2. Method of downloading the configuration data: Similar to the download of application program, will not be introduced here;
3. Method of uploading the data configuration file:
1) Press ‘3’ on the keyboard, enter the interface of uploading files:
Figure 4-29 Uploading the file
2) Choose Transfer->Receive File… to select the position in which you save the file
40 Chapter 4 Use Of Controller
Figure 4-30 Select the position in which you save the file Pay attention that the protocol is Ymodem.
Figure 4-31 Choose Ymodem as protocol 3) Press Receive, the file is transmitted from LCU+ to computer.
Figure 4-32 The process of uploading file
4) After the file downloading is completed successfully, the following interface pops up.
Figure 4-33 Uploading file successfully You can also press "4" on the keyboard to execute the application.
Chapter 5 Alarm Handling 41
Chapter 5 Alarm Handling
This chapter describes the handling of alarms, as well as the preventive maintenance of the system during system daily operation.
The maintenance personnel must have adequate knowledge about the power system.
Note
1. The maintenance must be conducted under the guidance of related safety regulations.
2. Only the trained personnel with adequate knowledge about the power system can maintain the inner part of the subrack.
5.1 Handling Alarms
The controller alarms are classified in four types: critical alarm, major alarm, observation and no alarm.
Critical alarm, major alarm: these two types of alarms have strong impacts on the system performance. Whenever these alarms are generated, users are supposed to handle them immediately. The alarm indicators will be on and audible indication will be given.
Observation: when this type of alarm is raised, the system maintains normal output for a while. If the alarm occurs during watch time, it should be handled immediately. If the alarm occurs during non- watch- time, handle it during watch time. The alarm indicators will be on when observation alarm occurs.
No alarm: if alarms are set as ‘no alarm’ by the users, when these alarms occur, no visible or audible indication will be generated and the system works normally.
The handling methods of normal alarms are given in Table 5-1.
Table 5-1 System setting parameter description
No. Alarm Handling method
1 Mains Failure
If the failure does not last long, the battery will power the load. If the cause is unknown or the failure lasts too long, a diesel generator is needed. Before using the generator power to supply the power system, it is suggested to run the generator five minutes to minimize the impact on the power system
2 AC Voltage High
Check if the AC over-voltage value is too low. If yes, change the value.
A mild over-voltage does not affect the system operation. However, the rectifier will stop operation when the mains voltage is more than 530V. If the mains voltage is above the AC over-voltage value, the mains grid should be improved
3 AC Voltage Low
Check if the AC Under- voltage point is too high. If yes, change the value.
When the mains voltage is lower than 304V, the output power of the rectifiers will be derated. And if lower than 260V, the rectifiers will stop working. If the mains voltage is under the AC under-voltage value, the mains grid should be improved
4 SPD failure Check the SPD condition. If the SPD is damaged, replace it
5 DC Volt High
Check the DC over-vlotage value through the controller. If the set value is inappropriate, correct it.
Otherwise, find out the rectifier that has caused the alarm:
1. Ensure that the batteries can operate normally.
2. Switch off the AC input of all rectifiers.
3. Power on the rectifiers one by one.
4. If the over-voltage protection is triggered when a certain rectifier is powered on, that rectifier is the faulty one. Replace it
6 DC Volt Low
1. Check if the alarm is caused by mains failure, if yes, disconnect some loads to prolong the operation of the whole system.
2. Check the DC under-voltage value set through the controller. If the set value is inappropriate, correct it.
3. Check if any rectifier is inoperative, or has no output current. If yes, replace it.
4. Check if the total load current exceeds the total rectifier current during float charge. If yes, disconnect some loads or add more rectifiers to make the total rectifier current bigger than 120% of the total load current with one redundant rectifier
7 Load Fuse Alarm, Batt Fuse Alarm
Check if the corresponding MCB is switched off. If the MCB is open, find out the fault and remove it.
Otherwise, the alarm circuit is faulty. Please contact Emerson
42 Chapter 6 Alarm Handling
No. Alarm Handling method
8 LVD2 1. Check if there is mains failure, and the battery voltage is lower than the value of ‘LVD2’.
2. Check whether the battery is disconnected from the system manually 9 Rect Failure The rectifier with the fault indicator (red) on is faulty.
Power off the rectifier, and then power it on after a while. If the alarm persists, replace the rectifier 10 Rect Protect Check if the mains voltage is above 530V or under 260V. If the mains voltage is under the AC
under-voltage value or above the AC over-voltage value, the mains grid should be improved
11 Rect Fan Fails Pull out the rectifier to check if the fan is obstructed. If yes, clean it and push the rectifier back. If the fan is not obstructed or if the fault persists after cleaning, replace the fan
12 Rect Not Respond Check if the communication cable is connected properly between rectifier and controller. If yes, restart the rectifier. If the alarm persists, replace the rectifier
13 Batt Over Temp 1. Check if the battery compartment temperature is too high. If yes, cool down the battery compartment.
2. Check if there is battery internal fault. If yes, replace the faulty battery
5.2 Handling Rectifier Fault
The indicator description, fan and handling methods of all the rectifiers on the system are the same, take R48-1800A and R48-3200 as an example.
Handling indicator fault
The symptoms of usual rectifier faults include: Run indicator (green) off, Protection indicator (yellow) on, Protection indicator blink, Fault indicator (red) on and Fault indicator blink, as shown in Figure 5-1.
R48-1800
R48-3200
Run indicator Protection indicator Fault indicator
Run indicator
Fault indicator Protection indicator
Figure 5-1 Rectifier indicator The indicators are shown in Table 5-2.
Table 5-2 Indicator fault description Symptom Monitoring module
alarms Causes Handling method
Run indicator
off (green) No alarm No input/output voltage Make sure there is input/output voltage Assistant power source of the rectifier fails Replace the recitifier
Run indicator
blinks(green) No alarm The monitoing module performs operations
upon the rectifier No actions need to be taken
Protection indicator on (yellow)
Rect Protect AC input voltage abnormal Make sure the AC input voltage is normal
Rect Protect
Fan blocked Remove the object that blocks the fan
Ventilation path blocked at the inlet or vent Remove the object at the inlet or vent Ambient temperature too high or the inlet too
close to a heat source
Decrease the ambient temperature or remove the heat source
Load share Alarm Current sharing imbalance
Check whether the rectifier communication is normal. If not, check whether the
communication cable is in normal connection.
If the communication is normal while the protection indicator is on, replace the rectifier Rect Protect Power factor compensation internal under
voltage or over voltage Replace the rectifier
Chapter 5 Alarm Handling 43
Symptom Monitoring module
alarms Causes Handling method
Protection indicator blinks(yellow)
Rect Not Respond Rectifier communication interrupted Check whether the communication cable is in normal connection
Fault indictor on (red)
Rect HVSD Rectifier over-voltage Reset the rectifier. If the protection is triggered again, replace the rectifier
Rect Failure Two or more recitifiers have the same ID
number Contact Emerson for maintenance
Rect Failure
Serious current sharing imbalance, 501 series modle: current imbalance > ± 3%;
701 series modle: current imbalance > ± 5%
Check whether the rectifier communication is normal. If not, check whether the
communication cable is in normal connection.
If the communication is normal while the protection indicator is on, replace the rectifier Fault indicator
blinks (red) Rect Fan Fails Fan fault Replace the fan
Replacing rectifier fan
If the rectifier fan is faulty and does not work, it should be replaced. Take the R48-1800 rectifiers as an example, the replacement procedures are as follows:
1. Use a cross screwdriver to remove the 3 screws from the fixing holes and pull out the front panel.
2. Unplug the power cable of the fan and remove the fan. Install a new fan.
3. Plug the fan power cable. Put the front panel back and fasten it with the 3 screws, as shown in Figure 5-2.
.
Fan
Front panel Fixing screw
of the panel Fixing screw of the fan
Figure 5-2 Disassembling the front panel Replacing rectifier
Except replacing the fan, it is recommended not to repair any other part of the module. When faulty, the module should be replaced, not repaired. See the following procedures to replace the rectifier.
1. Take a new rectifier and check it for any damage from transport.
2. Loosen the fixing screw of the handle of the R48-1800A rectifier with a Phillips screwdriver. Pull out the faulty rectifier from the rack by grabbing its handle.
Be careful with the rectifier just pulled out from the system, as it could be very hot due to long-term operation. Do not let it slip away and get damaged.
3. By holding the rectifier handle, push the new rectifier into the slot just vacated and make sure the connection is good. After a brief delay, the rectifier run indicator will turn on and the fan will start running.
4. Check whether the new rectifier works normally. You should make sure that:
1) The controller recognizes the new rectifier.
2) The new rectifier shares current with other rectifiers.
3) When this new rectifier is pulled out, there is a corresponding alarm and the controller displays the alarm.
If the new rectifier passes all the above tests, the replacement is a success.
5. Push the handle back into the front panel to fix the rectifier with the positioning pin. Fix the fixing screw of the handle of the R48-1800 rectifier with a Phillips screwdriver.
44 Appendix 1 Technical And Engineering Data
Appendix 1 Technical And Engineering Data
Table 1 Technical data Parameter
category Parameter Description
Environmental
Operating temperature -5°C ~ +40°C
Storage temperature -40°C ~ +70°C
Relative humidity 5%RH ~ 95%RH
Altitude ≤ 2,000m (derating is necessary above 2,000m)
Polution level Level 2
Others No conductive dust or erosive gases. No possibility of explosion
Others No conductive dust or erosive gases. No possibility of explosion