30621127-000-3DT-EE-03584-000

000 7/5/2011 MP Issue for

Information JEK MAS MAS

REV NO DATE BY: DESCRIPTION CHKD. CERT. APPD. Project Title CONVERSION OF QURAYYAH OPEN CYCLE POWER

PLANT TO COMBINED CYCLE POWER PLANT PROJECT C

Client

Consultant

Contractor

Document Title Operating Instructions - 125 V Block-1 DCDB CREATED BY: CHECKED BY: JEK DATE STARTED:6/30/2011 DATE COMPLETED: 6/30/2011

OPR'G. DEPT: ENG. DEPT:

APPROVAL/CERTIFICATION INFORMATION THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED DOC. NO.30621127-000-3DT-EE-03584 REV. NO. 0

QURAYYAH SAUDI ARABIA JOB ORDER NO.

1-0923053.01 JOB NO. PROJECT

SUBDIVISION DOCUMENT TYPE CODE

DOCUMENT NUMBER

REV NO.

30621127 000 3DT EE-03584 000 1110045001/20GB 1110045001-005

11-06-22 mp 11-06-22 MAS 11-06-22

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DC POWER SUPPLY (RECTIFIER / CHARGER) Type: SDC 125-1200-R

Client: M/s Techmaster Inc. 1952 McDowell Road, Suite 204 Naperville, Illinois 60563 — USA

P.O. No.: 11022

Project name: Conversion of Qurayyah Open Cycle Power Plant to Combined Cycle Power Plant – Project C End-User: Saudi Electric Company Installation: 125V Block-1 DCDB

applicable for: Type: Item No.: GUTOR Ref.: SDC 125-1200-R C10BTL01 & C10BTL02 1110045001-01…. 1110045001-06 SDC 125-1200-R C20BTL01 & C20BTL02 1110045002-01…. 1110045002-06 SDC 125-1200-R C30BTL01 & C30BTL02 1110045003-01…. 1110045003-06 SDC 125-1200-R C40BTL01 & C40BTL02 1110045004-01…. 1110045004-06 SDC 125-1200-R C50BTL01 & C50BTL02 1110045005-01…. 1110045005-06

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CONT

ENTS

1 GENERAL INFORMATION

2 SAFETY REGULATIONS

3 SYSTEM DATA

4 PACKING — TRANSPORT — INSTALLATION

5 DISPLAY — OPERATING & INDICATING ELEMENTS

6 COMMISSIONING

7 MAINTENANCE

8 TROUBLE SHOOTING

9 TEST DOCUMENTATION

10 SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS

11 BATTERY DOCUMENTATION

12 CUSTOMER-SPECIFIC DOCUMENTATION / CERTIFICATES

DOCUMENT INDEX & REVISION SHEET

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Here only Revisions of Descriptions in this Operating Instructions are updated (Parts lists, Schematic diagrams, Battery documentation and Customer specific documentation are excluded). It is the responsibility of the client to

exchange Documentation in this Operating instructions.

DOCUMENTS to SDC 125-1200-R Chapter

Doc. No. Title Date

Rev. concerned pages 0 4A-1110045001/20GB COVER SHEET (7SA9002GB) 11-06-22 1 Cover sheet 4A-1110045001/20GB TABLE OF CONTENTS 11-06-22 1 all 4A-1110045001/20GB DOCUMENT INDEX & REVISION SHEET 11-06-22 1 all

1 4A-1110045001/20GB GENERAL INFORMATION 11-06-22 1 Cover sheet 7SA9006GB General Information 09-08-10 4 all 7SA9007GB General System Principle & Description of Component 09-08-11 2 all

2 4A-1110045001/20GB SAFETY REGULATIONS 11-06-22 1 Cover sheet 7SA9009GB Safety Regulations 09-08-12 4 all

3 4A-1110045001/20GB SYSTEM DATA 11-06-22 1 Cover sheet 1110045001 Single-Line Diagram

4A-1110045001/23GB Technical Data (7SA9010GB) applicable for all Items 11-06-22 1 all

7SA9023GB Priorities and Operational Modes 09-08-11 3 all 4A-1110045001/20GB Explanation of the Boost Charge Function 11-06-22 1 all

4 4A-1110045001/20GB PACKING — TRANSPORT — INSTALLATION 11-06-22 1 Cover sheet 7SA9028GB Packing & Unpacking & Storage — Air / Oversea Transport 09-10-04 4 all 7SA9030GB Transport of the System without Packing 98-06-01 1 all 7SA9031GB Erection — Installation 09-10-01 4 all 7RA9195GB Assembly of Particular Cubicle Units 03-04-16 1 all

5 4A-1110045001/20GB DISPLAY — OPERATING & INDICATING ELEMENTS 11-06-22 1 Cover sheet 7SA9032GB Display & Parameter Settings 09-12-22 4 all

4A-1110045001/20GB Operating & Indicating Elements (7SA9033GB) applicable for all Items 11-06-22 1 all

6 4A-1110045001/20GB COMMISSIONING 11-06-22 1 Cover sheet 1110045001 Single-Line Diagram 7SA9034GB Start — Stop 09-09-15 5 all

4A-1110045001/20GB Commissioning (7SA9036GB) applicable for all Items 11-06-22 1 all

7 4A-1110045001/20GB MAINTENANCE 11-06-22 1 Cover sheet 7SA9040GB Maintenance 09-08-12 4 all 7SA9041GB Replacement of Components & Parts 09-08-12 1 all

7SA9042GB Service — Training — Contact Addresses 09-10-05 5 all

8 4A-1110045001/20GB TROUBLE-SHOOTING 11-06-22 1 Cover sheet

4A-1110045001/20GB Trouble-Shooting (7SA9043GB) applicable for all Items 11-06-22 1 all

DOCUMENT INDEX & REVISION SHEET

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DOCUMENTS to SDC 125-1200-R Chapter

Doc. No. Title Date

Rev. concerned pages 9 4A-1110045001/20GB TEST DOCUMENTATION 11-06-22 1 Cover sheet

10 4A-1110045001/20GB SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS 11-06-22 1 Cover sheet

11 4A-1110045001/20GB BATTERY DOCUMENTATION 11-06-22 1 Cover sheet

12 4A-1110045001/20GB CUSTOMER-SPECIFIC DOCUMENTATION / CERTIFICATES 11-06-22 1 Cover sheet

♦ Declaration of Conformity ♦ Declaration of Conformity «Free of PCB» ♦ Declaration of Conformity «EMC»

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GENERAL INFORMATION

DC POWER SUPPLY (RECTIFIER / CHARGER), Type: SDC 125-1200-R

TABLE OF CONTENTS: 7SA9006GB GENERAL INFORMATION

7SA9007GB GENERAL SYSTEM PRINCIPLE & DESCRIPTION OF COMPONENT

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GENERAL INFORMATION to

DC POWER SUPPLY, Type: SDC(R)

TABLE OF CONTENTS: 1. Preface

2. General

3. Marking of the Products

4. Standards applied, Conformity 4.1 EU Conformity 4.2 Use according to Destination

GENERAL INFORMATION

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1. PREFACE This operation manual provides information on the erection, installation, commissioning and operation of the system. In the event of unsureties or special problems, it is not permitted to take unauthorized remedial action. In such cases the responsible GUTOR technical service department must be contacted and the required information obtained. All agreements, assurances and legal relationships, as well as all obligations of GUTOR, also with respect to the warranty provisions, shall be governed by the respective valid sales contract which is not influenced by the content of the operation manual.

In the operation of an electrical device certain parts of the device are necessarily under a hazardous voltage. The failure to observe warnings and incorrect or inappropriate use can pose a risk and cause damage to persons and property. Prerequisite to proper and safe operation of this device are correct transport and storage, erection, installation and commissioning, as well as careful operation, maintenance and repair. Work on and manipulation of this device may therefore only be carried out by qualified personnel.

QUALIFIED PERSONNEL

are persons who, amongst other preprequisites ♦ are familiar with the erection, installation, commissioning and operation of the device and of the

system which is being installed or in which the device is being installed;

♦ are capable of performing switching operations according to safety technology standards and are entitled and authorized to switch the equipment on and off and to isolate it from voltage;

♦ are instructed according to the standards of safety technology in the care and use of safety equipment;

♦ are trained in immediate rescue measures (first aid);

♦ have completed instructions with appropriate confirmation by a GUTOR instructor see also 7SA9042GB: «Service - Customer Training - Contact Addresses».

Please read this operation manual thoroughly before you perform any manipulations on the installation.

GENERAL INFORMATION

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2. GENERAL DC SYSTEMS ARE USED TO FEED LOADS, WHICH

♦ cannot tolerate any interruption in the supply whatsoever; ♦ impose very strict demands as regards the constancy of the voltage; ♦ are sensitive to mains transients.

Decisive Features:

Characteristic Features Benefits Modular and clearly arranged design ♦ Accessible from front and top for repair and

maintenance work ♦ Easy access to power modules, exchange possible

by one person only High flexibility with respect to specific customer needs Microprocessor controlled logic, intelligent real time fault analysis by means of built-in recording and monitoring unit

♦ Increased MTBF (Mean Time Between Failures) — easy maintenance

Multifunctional digital indication, by which all adjustments and settings can be made via the password-protected foil keyboard. Fault and status indications are also shown on the same display.

♦ Transparent system operation ♦ Better control over the system functions

System integrated communication interface RS232 ♦ Remote and easy system supervision Active mimic diagram on the front panel, adaptable to customer’s specification (not available for Standard front panel).

♦ Become clear and peace of mind when the system is in operation

Distinction between flashing new alarm and steady indication of reset faults. Storage of the last 100 events in the memory.

♦ Precise fault diagnosis

Redundant (2) PSU’s (power supply units), supplied from the AC input side and the DC output side (where also the battery is connected to).

♦ Increased system reliability

Microprocessor-controlled load sharing facility ♦ Increased life of redundant units ♦ Constant security that systems are working

Possible parallel connection of 2 charger modules with active load sharing

♦ Increased availability ♦ One module can be isolated at any time

Fan speed control and monitoring

♦ With < 70 % load at normal operation and if no fan fails the fan speed will be reduced

♦ Lower noise levels ♦ Increased fan life ♦ Fans changeable during operation

Temperature-compensated battery charging ♦ Maximising of the battery life Battery testing programme & monitoring unit to display the remaining capacity and the actual back-up time

♦ Security and clarity about the function of batteries

Halogen-free wiring ♦ Safe working environment Certified industrial quality classification ISO 9001 ♦ Guaranteeing highest product and after sales

service quality levels

GENERAL INFORMATION

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SUCH DEMANDS ARE PRIMARILY IMPOSED BY THE FOLLOWING KINDS OF USERS:

♦ Petro / Chemical Industries ♦ Power stations ♦ Industrial systems with special specifications ♦ Telecommunication equipment

3. DESIGNATION OF THE PRODUCTS The following information is placed in the device: NAME PLATE (RATING PLATE)

The name plate (rating plate) is adhered internal the device behind the front door near the door lock. It contains the following information:

88

5-3

85

4

Each additional segregated module (transport separation) bears a partly completed rating plate without electrical specifications. The module numbering shall be consecutive from left to right. Additional rating plates may be affixed within the same transport module in order to identify different functional entities (e.g. different distributions) EU DECLARATION OF CONFORMITY:

This label (CE-Label) is placed on the name plate

ELECTROSTATIC SENSITIVE DEVICES:

This label can be found in the device on all p.c.board coverings as well as on the back of all accessible PCB’s.

GENERAL INFORMATION

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ELECTRIC SHOCK:

This warning sticker is affixed as close as possible to the terminals:

At a minimum either one of these labels is placed in all main fields.

CONNECTION DIAGRAM

Additionally a connection diagram is put into a schema pocket , mounted behind the front door. LABEL «RETURN OF PARTS»:

This label contains all necessary information for the return of parts or for contacting our service department. It is adhered behind the front door near the name plate see also 7SA9042GB «Service - Customer Training - Contact addresses».

4. STANDARDS APPLIED, CONFORMITY

INTERNATIONAL STANDARDS

IEC / EN 60950-1 Safety of information technology equipment (IEC 60950-1) EN 50178 (VDE 0160) Equipment of high power installation with electronic resources

IEC / EN 62040-1-1 Uninterruptible Power Systems (UPS) : Part 1-1 : General and safety requirements for UPS used in unrestricted access locations

IEC / EN 62040-1-2 Uninterruptible Power Systems (UPS) : Part 1-2 : General and safety requirements for UPS used in restricted access locations

GENERAL INFORMATION

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INTERNATIONAL STANDARDS

IEC / EN 62040-2 Uninterruptible Power Systems (UPS) : EMC Requirements

IEC / EN 62040-3 Uninterruptible Power Systems (UPS) : Method of specifying the performance and test requirements

IEC 60146 Semiconductor converters

IEC 60269-2 Low-voltage fuses : Part 2 : Supplementary requirements for fuses for use by authorized persons (fuses mainly for industrial application)

IEC 60529 Degrees of protection provided by enclosures (IP Code) IEC 60947 Low voltage switchgear and control gear IEC 60085 Thermal evaluation and classification of electrical insulation OHSAS 18001: 1999 Occupational Health and Safety Management SN EN ISO 9001:2000 Quality management systems

4.1 EU CONFORMITY

The product mentioned in this Manual conforms to the relevant requirements to the appropriate EU Directive, i.e. that this product meets all relevant EU directives and that it can be sold inside the European Union without national commercial hindrances. The EU conformity, which is indicated by means of the CE label on the name plate shall cease to be valid if modifications are made to the equipment without the approval of GUTOR. Relevant EU Directives for GUTOR are the so-called EMC- and Low Voltage Directives:

• EU Directive on Electromagnetic Compatibility 2004/108/EC

• EU Directive on Electrical Equipment designed for use within certain Voltage Limits (Low Voltage Directive) 2006/95/EC

EN 62040-1 / EN 62040-2 are the EU harmonised product Standard applicable for UPS systems. APPLIED HARMONISED STANDARDS:

• EN 62040-1-2 .... General and Safety Requirements • EN 62040-2 ........ EMC Requirements

According to this Standard GUTOR fulfils the basic requirements.

GENERAL INFORMATION

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4.2 USE ACCORDING TO DESTINATION

The units described herein are electrical equipment for the use in industrial plants. They are conditionally determined for private households. Unit with open electric connections are determined for build in only. This device conforms to the Low Voltage Directive 2006/95/EC. This device fulfils the basic requirements of EN 62040-2. In a domestic environment, this product may cause radio interference, in which case, the user may be required to take additional measures.

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GENERAL SYSTEM PRINCIPLE & DESCRIPTION OF COMPONENT

of DC POWER SUPPLY, Type: SDC(R)

TABLE OF CONTENTS: 1. General SDC Principle diagram

2. Explanation of the Components in the SDC Principle diagram

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GENERAL SYSTEM PRINCIPLE & DESCRIPT. of COMPONENTS

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1. GENERAL SDC PRINCIPLE DIAGRAM SEE PAGE 2

This description is to be regarded as a «General Description». It does not contain all customized adaptations ! For the customer-specific configuration see «Single line diagram».

The principle diagram on page 2 is a «MAXIMUM VERSION» Depending upon the system configuration, the switches represented in the principle diagram can be switch-disconnectors (fuse switch-disconnectors) or circuit breakers and the designation can be made according to customer's request see «Single line diagram».

2. EXPLANATION OF THE COMPONENTS IN THE SDC PRINCIPLE DIAGRAM

Pos. Component Explanation

X001 Rectifier mains terminals

provide for the connection of the rectifier mains (L1, L2, L3, N, PE). The rectifier mains input has to be protected by means of external protection devices fuses or MCCB’s according to the technical specification.

Q001 Rectifier input isolator provide for the isolation of the rectifier mains input there is no trip function. The rectifier mains input has to be protected by means of external protection devices fuses or MCCB’s according to the technical specification.

X002 Battery terminals provide for the connection of the battery positive pole (B+) and negative pole (B-).

Q004 Option: 2-pole Battery circuit breaker

If this option is not equipped an external protection device has to be installed.

X004 Load terminals provide for the connection of the load (L+) and (L-).

A025 External connection p.c. board

It is a part of the interface to the surroundings. Following information / functions are available: X004: Battery MCCB (Position)

Blocking of Boost and Initial charge

X006: Boost charge Battery temperature Sensor +/-

X007: External On Initial charge

X008: External Off

(to be continued next page)


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(Continuous)

X009: Charger Failure — Relay Common Alarm — Relay Internal supply for Emergency stop -/+ External supply for Emergency stop -/+

X001: Remote Display

X002: Communication RS232

X003: Internal connection to the Low Voltage Section for Parallel operation

A077 16 Relay For explanation see description 7SA9032GB «Display & Parameter settings» and 7SA9033GB «Operating & Indicating elements».

T001 Rectifier input transformer

provides the conversion of the rectifier mains voltage to the right level for the rectifier.

A001/ A002

Radio Frequency Interference (RFI) and AC fuse board

• The RFI part secures that the system is within the permitted tolerance of the conducted noises on the input and output of the cables.

• The Fuse board part protects the control wire, the internal power supply and the interface against short-circuits.

A030 6-pulse thyristor rectifier-bridge

provides the conversion of the AC voltage into DC voltage

(A031 = 12- pulse thyristor rectifier-bridge)

F026 Fuse Power fuse at the output of the thyristor rectifier-bridge.

L001 Smoothing reactor provides the filtration of the DC current.

CB02 DC- capacitor module provides the filtration of the DC current.

V015 Option: Blocking diode Rectifier blocking diode inserted in A030 (only in parallel-operated system).

Q003 Option: Output switch-disconnector

provides the isolation of the load from the rectifier (from the battery).

A004/ A005

DC Fuse board for DC voltage and Earth fault

A071 Interface / PSU This board: • converts the rectifier mains voltage to a lower standard level for the

controller and secures a galvanic isolation between mains and controller.• converts the DC voltage to a lower standard level for the controller and

secures a galvanic isolation between DC / battery and controller. • interfaces between single control wires from e.g. temperature switches in

transformers and ribbon cables which go to the controller • distributes the current from the internal power supplies to the various

modules. • Redundant (2) PSU’s (power supply units), supplied from the AC input

side and the DC output side (where also the battery is connected to).

A070 CCU — Controller (Charger Control unit)

provides: • controlling the rectifier • monitoring functions for e.g. voltage, current, alarms • the communication with the front panel • the serial communication


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A073 Front panel including: • Display unit • Operation • Option: Operating status indications • Option: Alarm indications

For details see description 7SA9032GB «Display & Parameter settings» and 7SA9033GB «Operating & Indicating elements».

E001...E008

Fans Fans with internal Hall generator for monitoring the number of revolutions. In systems with low power no fans are built in (natural cooling).

A003 AC Fuse board for the fans.

A050...A057

Fan control • Interface between Fans and Interface A071 • Changes the number of revolutions

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SAFETY REGULATIONS


TABLE OF CONTENTS: 7SA9009GB SAFETY REGULATIONS

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SAFETY REGULATIONS to


TABLE OF CONTENTS: 1. Technical Safety Information for the User

1.1 Safety Instructions / Precautions

2. Warning advices / Signal words / Ideograms / Signboards

3. General Safety Information 3.1 «Hazardous voltage» [Voltage > 42,4 VACpeak (30Vrms) / 60 VDC] 3.2 Fire outbreak 3.3 General servicing recommendations

SAFETY REGULATIONS

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1. TECHNICAL SAFETY INFORMATION FOR THE USER This description contains the necessary information for the correct application of the product described below. It is intended for use by instructed and / or service personnel. Qualified personnel are technically instructed persons who, because of their training, experience and position as well as their knowledge of appropriate standards, regulations, health and safety requirements and working conditions, are authorised to be responsible for the safety of the equipment, at all times whilst carrying out their normal duties and are therefore aware of, and can report, possible hazards. [The definition of qualified employees is according to «International Electrotechnical Vocubulary» (IEV) = IEC 60050].

1.1 SAFETY INSTRUCTIONS/ PRECAUTIONS

The following instructions are provided for the personal safety of operators and also for the protection of the described product and connected equipment.

Hazardous voltage

Failure to observe can kill, cause serious injury or material damage.

♦ Isolate from all AC mains and battery supplies before installation or dismantling work, as well

as for fuse changes or post installation modifications. IEC 62040-1-2, 4.9.3 prescribes: ISOLATE UNINTERRUPTIBLE POWER SYSTEM (UPS) BEFORE WORKING ON THIS CIRCUIT

♦ Observe the prescribed accident prevention and safety rules for the specific application.

♦ Before putting into operation check if the rated voltage for the unit conforms with the local supply voltage.

♦ Emergency stop devices must be provided for all applications. Operation of the emergency stop must inhibit any further uncontrolled operation.

♦ The electric connections must be covered !

♦ Earth connection must be checked for safe function after assembly !

2. WARNING ADVICES / SIGNAL WORDS / IDEOGRAMS / SIGNBOARDS The following ideograms in the manual and in the device (if available) signify:

Danger:

Used for: immediate threatening danger Possible consequences: can kill or cause grievous bodily harm

SAFETY REGULATIONS

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Warning:

Used for: possible dangerous situation Possible consequences: can kill or cause grievous bodily harm

Caution:

Used for: possible dangerous situation Possible consequences: insignificant physical injury. Also possible as warning

against material damage

Notice:

Used for: possible dangerous situation Possible consequences: Possible damage of the product or something in its

environment

Important:

Used for: Tips for use and helpful informations Possible consequences: Not an information which warns against dangerous or

harmful situations !

3. GENERAL SAFETY REGULATIONS

When working inside the device or when isolating parts in the DC system the general safety recommendation and the local electrical regulations have to be observed !

For compliance with the various safety regulations the following points which constitute a hazard are mentioned:

3.1 «HAZARDOUS VOLTAGE» [Voltage > 42,4 VACpeak (30Vrms) / 60 VDC] DC systems contain hazardous AC and DC voltages.

IN CASE OF DOUBT NEVER TOUCH !!!

As soon as the front door is opened the hazard of contact with parts at hazardous voltages persists. Any operations inside the system must be carried out by competent/authorized electrical personnel only. Extreme caution should be exercised at all times.

SAFETY REGULATIONS

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Certain parts of the current circuit are live, even if the system is shut down. Before any part is touched the circuit diagram must be studied and verification must be conducted with measuring instruments.

3.2 FIRE OUTBREAK

If a fire should break out inside the system, fire extinguishers with CO2 must be used. Do not inhale vapors.

3.3 GENERAL SERVICING RECOMMENDATIONS We advise that the following rules have to be observed: ASSIGNMENT OF PERSONNEL:

When working under hazardous voltage do not allow personnel to work alone. A second person should assist so that in the case of emergency help can be called for. When working on the battery (measuring, topping up electrolyte) goggles, protective (rubber) gloves, rubber apron and rubber boots shall be worn. Tools for working on the battery shall be insulated. Refer to chapter on «Battery servicing».

If safety covers are provided, they are the provision for direct contact protection. They shall prevent unintentional contact with parts at hazardous voltages. Special caution is required at all times.

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SYSTEM DATA


TABLE OF CONTENTS: 1110045001 SINGLE-LINE DIAGRAM

4A-1110045001/23GB TECHNICAL DATA (SA9010GB) 7SA9023GB PRIORITIES AND OPERATIONAL MODES

4A-1110045001/20GB EXPLANATION OF THE BOOST CHARGE FUNCTION

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TECHNICAL DATA of

DC POWER SUPPLY, Type: SDC 125-1200-R Item #: C10BTL01 & C10BTL02 / C20BTL01 & C20BTL02

/ C30BTL01 & C30BTL02 / C40BTL01 & C40BTL02 / C50BTL01 & C50BTL02

TABLE OF CONTENTS: 1. System configuration 2. Mechanical Specification 3. General Specification 4. Electrical Specification of one System unit 5. Adjustments 6. Operational Parameters

Client Ref.:

Rev. Page

E 72

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GB-3 GUTOR Electronic LLC

Wettingen / Switzerlandby Schneider E l e c t r i c

TECHNICAL DATA - SDC 125-1200

.

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1. SYSTEM CONFIGURATION One DC system is consisting of:

Pcs: 2 Rectifier / Charger 2 Blocking Diodes 1 Battery Monitoring Box 1 Battery 1 Distribution + 1 Sub Distribution

2. MECHANICAL SPECIFICATION RECTIFIER (CHARGER)-UNIT

Enclosure ........................................................................... : The Rectifier is housed in a free-standing, fully metal enclosed cabinet arranged for floor mounting.

Arrangement / Dimensions ................................................. : see drawing: 1110045001/00 Chapter 01

Protection class (according to IEC 60529) ......................... .............................................................with open doors

: :

IP 41 IP 20, Operator protection

Painting.............................................................................. Inside, Backcover, Topcover .........................................

: :

RAL 7038 (BS 10-A-03) galvanized

Ventilation ......................................................................... : Internal fans. Air inlet in back & front below, outlet on the top.

Cable entry......................................................................... : from bottom

Terminal size...................................................................... : see drawing: 1110045001/00 Chapter 04

Weight ............................................................................... : 3030 kg

BATTERY MONITORING BOX see drawing: 1110045001/00 Chapter 30

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BATTERY

Mounting ........................................................................... : The battery is mounted on a steel rack.

Arrangement / Dimensions ................................................. : see drawing: 1110045001/00 Chapter 02

Weight ............................................................................... : 278.1 Kg / cell

Number of cells.................................................................. : 1 string x 58 cells

Manufacturer ..................................................................... : HOPPECKE

Type .................................................................................. : 36 OSP.XC 4140

Capacity............................................................................. : 4140 Ah / 10 h

Autonomy................................................................... total : According to load profile

3. GENERAL SPECIFICATION Installation altitude with full rating ..................................... With derating of 7 % per additional 1000 m...................

: :

max. 1000 m ASL max. 4000 m ASL

Ambient temperature range, at air inlet - for operation (100 % rated power) ............................ - with derating at increased air throughput ................... - for storage ................................................................

: : :

-10 °C .... +50 °C max. 55 °C -20 °C .... +70 °C for systems (for batteries in accordance with battery manufacturer data)

Relative air humidity .......................................................... : ≤ 95 %, not condensing

Audible Noise level (1 m height, 1 m distance) ................... with Standard N+1 Fans .................................... approx. 100 % redundant Fans ...................................... approx.

: :

55...65 dBA (depending on type) 60...70 dBA (depending on type)

Reliability MTBF ............................................................... : > 200000 h

Functional (performance) test ............................................. : IEC / EN 62040-3, IEC 60146-1-1

General and Safety requirements ........................................ : IEC / EN 62040-1-2

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EMC requirements ............................................................. : IEC 62040-2

Quality assurance ............................................................... : ISO 9001

4. ELECTRICAL SPECIFICATION ON SYSTEM UNIT

RECTIFIER

Mains input power, max. .................................................... : 203.7 kVA

Input voltage....................................................... (3ph, PE) - Tolerance - DC in tolerance ...................................... - Tolerance for function...............................................

: : :

3 x 480 V AC + 10 / - 10 % + 15 / - 25 % (below -15 % the battery might begin to discharge)

Input current, max.............................................................. : 245.0 A AC

Input frequency.................................................................. : 60 Hz +/-8%

External fuse (gG type)..................... : 350 A AC

Power factor - at nominal mains and float charge.............................. - at - 10 % mains and float charge................................ - at + 10 % mains and float charge...............................

: : :

≈ 0,83 ind. ≈ 0,90 ind. ≈ 0,75 ind.

Nominal DC output voltage................................................ Static ................................................. Control tolerance

: :

125 V DC ± 1 % (IU-characteristics)

Ripple voltage with parallel battery capacity of 3x I2N ......... : <=2 % rms

Efficiency at rated load....................................................... Tolerances according to IEC 60146-2

: 90 %

BATTERY MCCB

Voltage .............................................................................. : 500 V DC

Current .............................................................................. : 1600 A DC

DROPPING DIODE

Client Ref.:

Rev. Page

E 72

0.006




.

4A-1110045001/23 3: 5 / 6

DC output voltage.............................................................. : N/A

Current ...................................................................... max. (in order to keep the voltage in tolerance) .......... min. ......................................................................... nom.

: : :

N/A N/A N/A

DISTRIBUTION see drawing: 1110045001/00 Chapter 04

5. ADJUSTMENTS RECTIFIER / BATTERY Setting range Settings

Float charge voltage......................... : 0,4 x Vnom. - 1,3 x Vnom. ......................... 129.3 V DC

Boost charge voltage........................ .................................time interval

: :

0,4 x Vnom. - 1,4 x Vnom. ......................... 0...72 h ................................................

136.3V DC 8 h

Initial charge voltage ........................ .................................time interval

: 0,4 x Vnom. - 1,5 x Vnom. ......................... 0...72 h ................................................

136.3V DC 12 h

DC output current limitation ............ : (0,5 x Inom.) - Inom. ................................. 1200 A DC

Battery current limitation.................. : 1 - IBat nom ............................................. 570.0 A DC

Initial current limitation .................... : 1 - 2x IBat nom (< Inom.) ............................ 570.0 A DC

Low DC voltage Warning....... Shutdown ....

: :

0 - Vnom. ............................................... ............................................................

101.5 V DC 86 V DC

High DC voltage Warning....... Shutdown ....

: :

Vnom. - Vhigh SD ....................................... ............................................................

151 V DC 163 V DC

DC Earth fault current...................... : 1…40 mA (Earth fault resistance = ON) .....................................................

10 mA

Softstart ... time on voltage & current : 2 / 5 / 10 / 20 s................................. 10 s

Temperature compensation ............................ Charge voltage

:

0…999 mV/°C/cell...........................

N/A

Delay of relay................................... : 0…99 s ............................................ 5 s

Client Ref.:

Rev. Page

E 72

0.006




.

4A-1110045001/23 3: 6 / 6

Possibilities Settings

Battery monitor installed ............... automatically ............................... time interval for automatic test.....

: : :

YES/NO ........................ ON/OFF......................... 3 month / 6 month..........

NO OFF ____ months

6. OPERATIONAL PARAMETERS Possibilities Settings

Display language .............................. : DE +.............................. GB

Charger Mode.................................. : Float / Boost / Initial

Autostart.......................................... : ON/OFF......................... OFF

Autoboost ........................................ : ON/OFF......................... ON

Battery monitor Test ........................ : ON/OFF

Battery monitor Reset ...................... : ON/OFF

Battery capacity Test........................ : ON/OFF

98-02-17 mp 07-06-21 mp 09-08-11 mp 98-02-17 GA 07-06-21 MDR 09-08-11 MDR 98-02-17 07-06-21 09-08-11

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PRIORITIES & OPERATIONAL MODES of

REDUNDANT DC POWER SUPPLY with one Battery Type: SDC-R

TABLE OF CONTENTS: 1. General Explanations

2. Priorities: Parallel/Redundant DC system

3. Normal operation (Float-, Boost-, Initial charge) 3.1 Normal operation: System 1 & 2 3.2 Normal operation: System 1 & 2, but with different charging modes (Float-, Boost-, Initial

charge) 3.3 Normal operation: System 1; System 2 in battery operation 3.4 Normal operation: System 1; System 2 in standby

4. Battery operation: System 1 & 2

5. Rectifier only: System 1 & 2

6. Standby operation: System 1 & 2

7. Off: System 1 & 2

PRIORITIES & OPERATIONAL MODES

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1. GENERAL EXPLANATION ACTUATION OF «SWITCHES»

Circuit breakers, switch-disconnectors (fuse switch-disconnectors) or changeover switches, as well as any additionnal «switches» may only be actuated according to the «Commissioning» and 7SA9034GB «Start - Stop».

EXPLANATION TO THE SKETCHES

current flow = energized = Depending upon the system configuration, the switches represented in the sketches can be circuit breakers, switch-disconnectors (fuse switch-disconnectors), and the designation can be made according to customer's request see «Principle diagram».

2. PRIORITIES: PARALLEL/REDUNDANT DC SYSTEM The parallel/redundant DC system can be operated in different modes, depending on the availability of the rectifier mains, the battery voltage and the actual load. A parallel/redundant DC system tries to operate both system units in a operational mode of the highest priority. If one system unit attempts to change to a lower priority e.g. battery operation but the other system is still running in normal operation, this one takes over the supply of the load. In the following the different operating modes and priorities for a parallel/redundant DC system will be explained: HIGHEST PRIORITY:

Section 3. Normal operation (Float-, Boost-, Initial charge) 3.1 Normal operation: System 1 & 2 3.2 Normal operation: System 1 & 2, but with different charging modes (Float-,

Boost-, Initial charge) 3.3 Normal operation: System 1; System 2 in battery operation 3.4 Normal operation: System 1; System 2 in standby

4. Battery operation: System 1 & 2

5. Rectifier only: System 1 & 2

6. Standby operation: System 1 & 2

LOWEST PRIORITY:

Section 7. Off: System 1 & 2


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3. NORMAL OPERATION (FLOAT-, BOOST-, INITIAL CHARGE) The AC input (rectifier mains) is fed to the phase angle controlled rectifier via a matching transformer. The rectifier compensates mains voltage fluctuations as well as load deviations, and maintains the DC voltage constant. The superimposed AC voltage component (ripple) is reduced by means of a smoothing circuit.

3.1 NORMAL OPERATION: System 1 & 2

MAINS 1Q001

RECTIFIER 1

Q004 (Q005)

BATTERY

LOADQ003

MAINS 2Q001

RECTIFIER 2Q003

V015

V015

Fig. 3.1

Concerns: RECT 1 RECT 2 Completing Explanation: Rectifier mains available available and within the tolerance range Q001 closed closed

Battery available and within the tolerance range (dependent on the charging condition of the battery — it may be in recharge mode).

Q004 (Q005) closed Rectifier ON ON Q003 closed closed Output voltage before blocking diode available and within the tolerance range

Output voltage before blocking diode available and within the tolerance range

Output voltage Load available and within the tolerance range The DC system supplies the load with energy each 50 % of the actual load and secures that the connected battery is kept on standby (float charge and boost charge depending on charging condition and the type of the battery). If one rectifier system unit is running in another operating mode, due to a fault see fig. 3.2.


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3.2 NORMAL OPERATION: System 1 & 2, but with different charging modes (Float-, Boost-, Initial operation)

Fig. 3.2



Q004 (Q005) closed Rectifier ON ON Q003 closed closed Output voltage before blocking diode available and within the tolerance range


Output voltage Load available and within the tolerance range If both rectifier system units are running in different operating modes (System 2 in float charge operation and System 1 in boost charge operation), the rectifier with the higher charge voltage takes over the supply of the load.


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3.3 NORMAL OPERATION: System 1; System 2 in Battery operation

Fig. 3.3

Concerns: RECT 1 RECT 2 Completing Explanation: Rectifier mains available and within the tolerance range Rectifier mains not available outside the tolerance range Q001 closed closed


Q004 (Q005) closed Rectifier ON OFF Q003 closed closed Output voltage before blocking diode available and within the tolerance range

Output voltage before blocking diode not available outside the tolerance range

Output voltage Load available and within the tolerance range

System 1 in normal operation takes over the supply of the load.

3.4 NORMAL OPERATION: System 1; System 2 in Standby

MAINS 1Q001

RECTIFIER 1

Q004 (Q005)

BATTERY

LOADQ003

MAINS 2Q001

RECTIFIER 2Q003

V015

V015

Fig. 3.4


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Battery available dependent on the charging condition of the battery — it may be in recharge mode

Q004 (Q005) closed Rectifier ON OFF Q003 closed closed or open Output voltage before blocking diode available and within the tolerance range



System 1 in normal operation takes over the supply of the load. System 2 changes over to standby.

4. BATTERY OPERATION: System 1 & 2

Fig. 4.1

Concerns: RECT 1 RECT 2 Completing Explanation: Rectifier mains not available not available outside the tolerance range Q001 closed closed Battery available and within the tolerance range Q004 (Q005) closed Rectifier OFF OFF Q003 closed closed Output voltage before blocking diode not available outside the tolerance range




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In the event of power sags or failures the load is no longer supplied with power by the rectifier. The battery, which is connected to the DC intermediate circuit, is called up automatically and without interruption to supply the current. The discharging of the battery is signalled. The battery voltage drops as a function of the duration and the magnitude of the discharge current. On mains recovery or on emergency power generation with diesel generator, before the limit of discharge of the battery is reached, the DC system automatically switches back to normal operation for supplying the load and at the same time charging the battery. If the limit of discharge of the battery is approached the alarm «Low DC warning» is activated. If the limit of discharge is reached, the internal PSU’s (supply units) will switch off after 10 minutes. On mains recovery or on emergency power generation with diesel generator, the rectifier starts up automatically and at the same time charging the battery, if the DC system is programmed for «AUTOSTART» at mains recovery see «Technical data». If the system is not programmed for «AUTOSTART» it has to be restarted manually see 7SA9034GB «Start - Stop». Depending on the depth of discharge of the battery the charge current is limited by means of the battery current limiter.

5. RECTIFIER ONLY: System 1 & 2

Fig. 5.1


Battery available and within the tolerance range (dependent on the charging condition of the battery)

Q004 (Q005) closed Rectifier ON ON Q003 open open Output voltage before blocking diode available and within the tolerance range


Output voltage Load not available NO Voltage


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6. STANDBY OPERATION: System 1 & 2

DC system ready for switching on

Fig. 6.1

Concerns: RECT 1 RECT 2 Completing Explanation: Rectifier mains available available Q001 closed closed Battery disconnected Q004 (Q005) open Rectifier OFF OFF Q003 closed or open closed or open Output voltage before blocking diode not available NO Voltage

Output voltage before blocking diode not available NO Voltage


The load is not supplied.

7. OFF: SYSTEM 1 & 2 DISPLAY BLACK

Fig. 7.1


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Some components in the connection field as well as elements and lines can be energized.

Concerns: RECT 1 RECT 2 Completing Explanation: Rectifier mains not available not available Q001 open open Battery disconnected Q004 (Q005) open Rectifier OFF OFF Q003 closed or open closed or open Output voltage before blocking diode not available NO Voltage

Output voltage before blocking diode not available NO Voltage


The load is not supplied.

11-06-22 mp 11-06-22 MAS 11-06-22

— - - -

4A-1110045001/20GB 1 1 / 1

EXPLANATION OF THE BOOST CHARGE FUNCTION

to DC POWER SUPPLY, Type: SDC 125-1200-R

see also «Single Line diagram»

The battery can only be boost charged if the distribution is disconnected from the battery circuit in question.

Boost charging by Charger 1 is only possible if the rectifier output switch Q003 and Q200 of Charger 2 are open and the battery switch Q004 is closed. The LED 3 «BOOST/INITIAL» on the Mimic diagram is illuminated.

The Load sharing is no longer active if one of the switches Q003 / Q100 / Q200 is open. Indication on Front panel «Load sharing fault»

After boost charging the rectifier output switch Q003 and Q200 have to be closed manually !

Boost charging by Charger 2 can be peformed in the same manner, vice-versa.

11-06-22 mp 11-06-22 MAS 11-06-22

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4A-1110045001/20GB 1 1 / 1

PACKING — TRANSPORT — INSTALLATION


TABLE OF CONTENTS: 7SA9028GB PACKING & UNPACKING & STORAGE — AIR / OVERSEA

TRANSPORT

7SA9030GB TRANSPORT OF THE SYSTEM WITHOUT PACKING

7SA9031GB ERECTION — INSTALLATION

7RA9195GB ASSEMBLY OF PARTICULAR CUBICLE UNITS

98-05-07 mp 05-05-25 mp 07-10-31 mp 09-10-04 mp 98-05-07 GA 05-05-25 MDR 07-10-31 MDR 09-10-04 PFR 98-05-07 05-05-25 07-10-31 09-10-04

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PACKING & UNPACKING & STORAGE AIR / OVERSEA TRANSPORT

of DC POWER SUPPLY, Type: SDC(R)

TABLE OF CONTENTS: 1. Preparations before Packing

2. Packing: Air / Oversea Transport = Solid Wooden Cases or OSB (Oriented Strand Board) Cases

3. Transport to the Installation Place

4. Unpacking from the Case

5. Storage

PACKING & UNPACKING & STORAGE Air/Oversea Transport

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1. PREPARATIONS BEFORE PACKING For systems with Rain roof:

Where small parts are delivered together with the system, these are packed in plastic bags and placed below the roof. These bags will be fixed to the roof fastening bolts by means of cable binders. Bigger parts are packed in cardboard boxes and placed inside the cubicle.

For systems without Rain roof:

Where parts are delivered together with the system, these are packed in cardboard boxes and placed inside the cubicle.

Usually one side of the system is open (due to transport separation)

4. The chip is fixed with a cable binder

5. Doors are closed

1. All doors are opened to equip the system

with VCI-chip U (VCI = Volatile Corrosion Inhibitor)

2. Every field is equipped with one or more chips (chip-size = 49x100 cm).

3. One chip protects a volume of 1m3. The number of chips is calculated as follows: Example: Gross volume is 3m3

Equipment / Material 1m3 Therefore, two chips are used.


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Now the system is prepared to be packed in the case. The lifting into the case is conducted according to the instructions 7SA9030GB «Transport of the System without Packing» and the instructions given in this description see section 3.

1. The VCI-Foil on the base of the case is cut several times in order for possible condensation water to drain off.

2. The system is being placed on the base of the

case. 3. The VCI-Foil is pulled up and fixed on the

system with an adhesive tape that does not leave any residue.

The lower half of the system is now packed in VCI-Foil.

1.

2. The upper protruding parts are being covered with air bubble film and adhesive tape so that the VCI-foil cannot be damaged.

3. Now the upper part of the system is being covered in VCI-foil which will also be fixed with adhesive tape.

4. Within 24 hours, the anticorrosive will become active.


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2. PACKING: AIR / OVERSEAS TRANSPORT = SOLID WOODEN CASES OR OSB CASES

Packing for air or overseas transport = either solid wooden cases or OSB cases (oriented strand board).

2.1 REQUIREMENTS FOR THE PACKING

The packing must satisfy the following criteria:

1. Protection against mechanical stress and damage: ♦ crushing forces due to stacking (only guaranteed for solid wood cases) ♦ gravitational forces in a horizontal direction ♦ forces arising from vibrational loads

2. Protection against corrosion due to the effects of relative humidity and climatic factors 3. Protection against environmental factors (industrial exhausts, salt in the air, rain, snow, etc.) 4. Protection against theft (due to the sealed packing) 5. Suitable for lifting and forwarding equipment (Unit Load Concept) 6. Possible frequent reloading and retransferring 7. Shipment over poor roads 8. Economy of volume 9. Protection of environment when handling hazardous material 10. Capability of recycling

2.2 STRUCTURE OF THE SOLID WOOD CASE

1. The design and construction of the cases are as shown on the representations below.

2. Side walls, face-end walls, and floors are made of Swiss wood. (IPCC standard)

3. Wood thicknesses 24 mm.

4. Wood cover dry film resist and plywood cover must be concise with the side walls and front walls.

5. As a rain protection PE foil becomes strained under the cover.

6. From a weight of 2,000 kg upwards a case comprising a lengthwise reinforcement must be employed.

As Option, on special customer's request

7. Also different variants may be selected to ensure protection from rain, for example, sandwich covers. In this case the inside of the cover is provided additionally with Akylux or a plywood panel. The individual materials can also be combined.

8. Inspection hole.

9. Various colour markings.

10. Supplementary cushioning (for adverse road conditions)

11. Cladding of cases with diverse protection foils (kraft paper, bitumen paper, etc.).

12. Tip Indicatior, Shock indicators, etc.


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2.3 CONSTRUCTION OF THE SOLID WOOD CASE

The following representations correspond to a solid wooden case (the OSB cases comprise instead of individual boards whole or max. 3 plates per side).

Pos. Description Pos. Description Pos. Description 1 Side wall 4 Cover 7 Front skid 2 Front wall 5 Double Cover 8 Floor skid 3 Floor 6 Side skid 9 Cover skid

Pos. Description Pos. Description Pos. Description 1 Front wall 5 Double Cover 8 Floor skid 2 Side wall 6 Side skid 9 Cover skid 3 Floor 7 Front skid 10 Protection foil 4 Cover


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2.4 CONSTRUCTION OF THE OSB- / PLYWOOD CASE

1. OSB and plywood cases are manufactured of internationally approved wood (IPPC Standard).

2. The side walls consist of a maximum of 2 parts, the front walls consist of a maximum of 3 parts. The joints of the respective parts are reinforced with a skid.

3. The cover is only one part. The bottom of the cases is always manufactured from solid wood (24mm).

4. Wood thickness 0.9 mm up to 10 mm.

5. The wood cover, covering foil and plywood cover must be concise with the side and the front walls.

As Option, on special customer's request

6. For rain protection the same method as with solid wood cases may be employed.

7. Inspection hole.

8. Various colour markings.

9. Supplementary cushioning (for adverse road conditions)

10. Cladding of cases with diverse protection foils (kraft paper, bitumen paper, etc.).

11. Tip Indicatior, Shock indicators, etc.

The construction and design of the cases are presented in the following designs:

1. The case is now built around the system (solid wood, plywood or OSB, depending on contractual requirements) and the shipping marks are added.

2. Now cargo is ready for worldwide

shipping by truck / ship / airplane.

This IPPC stamp is used to mark every case:


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GUTOR XXXXX

2.5 CONSTRUCTION OF THE CASE

Polyethylene edges: for the protection and fixing of the system.

Cross laths (cross-heads) are determined by the length of the case and the size of the system to be packed. (Only equipped in cases containing small systems or in case of projecting cables, etc.).

Compound foam material for the protection of the system.

Floor cross laths for the distribution of the load outward (lifting of the case with belts) under each socket of the system one floor cross lath is laid (not fixed).

2.6 STANDARD MARKING

The standard marking of standard cases is implemented in writing (only symbol 1-3) and according to the symbols provided in DIN 55'402. THE FOLLOWING MARKING IS USED AS A STANDARD:

1 2 3 4 5 6 7

1 This side up: The case must always be stored, transferred, and transported in such a way that the arrow always point up.

2 Fragile, handle with care: Goods marked in this way must be handled with care and not dropped or tied under any conditions.

3 Keep dry: Goods marked in this way also have to be protected from high humidity, they must be kept under covers when in storage (no unprotected outdoor storage).

4 Sling here: The symbol indicates only where the sling should be applied, and not the method to be used for applying it.

5 Center of gravity: This symbol clearly identifies the center of gravity.

6 0 Kg stacking load: The plywood and OSB cases are not stackable

7 GUTOR XXXXXX: This stamp is on each case delivered from GUTOR whereby XXXXXX = the GUTOR reference number of the system packed therein.


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If required, additional markings are made according to the internal instructions S700.015 or according to the instructions of the client or of the case manufacturer.

3. TRANSPORT TO THE INSTALLATION PLACE CHECK:

♦ the weight before the transport to secure that the equipment can handle the actual weight of the system.

♦ that there is enough space to transport the system to its final destination ♦ that the floor can bear the load ♦ that the lift can carry the system ♦ what’s with the computer floor (double floor) MOVEMENT WITH LIFTING AND FORWARDING EQUIPMENT

Normally, the system is delivered in cases appropriate to the means of transport, or on a pallet and can be transported by a fork-lift or pallet-truck.

Pay attention to the marking on the case !

STRIKING WITH LIFTING EQUIPMENT

When striking the cases with lifting equipment, the cables may be attached only at those points identified by the chain symbol (symbol G) per DIN 55'402 see the following example:

The following representations correspond to a solid wooden case (the OSB cases comprise instead of individual boards whole or max. 3 plates per side)

Sling here: The symbols indicate only where the sling should be applied, and not the method to be used for applying it. Whenever the symbols are at an equal distance from the middle of the center of gravity, the package will hang straight if the suspensions are of the same length. If not, the suspension on one side must be shortened. Never follow this symbol for packages that have obviously been incorrectly identified and/or designed. Doing so could cause the packages to be dropped.


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LIFTING WITH A FORK LIFT

When lifting and/or moving with a fork-lift, the forks may only be inserted under the packages parallel to the floor runners. ATTENTION TO THE CENTER OF GRAVITY

Attention must be paid to the center of gravity as identified with symbol F per DIN 55'402 when lifting or driving under the cases in order to avoid having the packages tip over.

Center of gravity: This symbol clearly identifies the center of gravity. Reasonably the symbol should only be used when the center of gravity is off-center in the package. Application for the symbol on two surfaces perpendicular to one another would be sufficient for clear identification.

4. UNPACKING FROM THE CASE 4.1 INSPECTION OF THE PACKING AFTER ITS ARRIVAL AT THE

STORAGE PLACE

The system has been packed to stand the vibrations that normally occur during transport, so as a rule neither the packing nor the system will have suffered any damage during transport. If any damage has penetrated the case, or if it is not received in upright position (look for indication of this on the case), the shipper and the manufacturer should be notified immediately. All boxes, cases, pallets, and other packages must be examined after unloading for visible and apparent mechanical damage. Severely damaged packing or equipment should be left untouched until the shipper and the insurance company have inspected it. Records must be kept on all findings. Any non-mechanical damage found, such as: boxes, cases, or other packages that are wet through or very dirty must be recorded for a later inspection of their contents.

♦ In both cases, an authorized inspector, in consultation with the insurance company, must make a determination of the actual situation.

♦ Photographs of the damaged containers should be taken as evidence.


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4.2 UNPACKING OF THE SYSTEM

PACKINGNOTE HERE

On customer’s request a metallic envelope is placed on the left side of the case. In the envelope the delivery note or the packing list is placed.

Before unpacking the system, take out the delivery note (packing list) and keep it to check that the equipment is in accordance with the specifications on the document.

In case of any defects the manufacturer should be notified immediately in order to avoid a delay in the installation of the system.

♦ Unpack the system in a clean, dry storage area.

Example: Solid wooden case

Pos. Beschreibung 1 Front wall 2 Side wall 3 Floor 4 Cover 5 Double Cover 6 Side skid 7 Front skid 8 Floor skid 9 Cover skid

♦ By means of a crowbar remove the cover (4). It is not necessary first to remove the cover skids (9) — since these are fixed to the cover ( see above picture).

Be cautious not to damage the system packed therein

♦ By means of a crowbar remove the side wall (front) (2) of the case. It is not necessary first to

remove the front skids (7) with which the side wall of the case is fixed to the pallet ( see above picture).

♦ Now the system can be removed by means of a fork-lift. When lifting the prepacked system this has to be made according to the instructions 7SA9030GB «Transport of the System without Packing» and the instructions given in these descriptions.

♦ Remove the VCI foil.

♦ Remove eventually delivered parts see first picture of this description.


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♦ Open the front door and examine the interior of the system for any potential damage due to mishandling of the system during transport. Notify the shipper and the manufacturer of any such damage immediately. Proceed as mentioned under section 4.1.

♦ If the system is not going to be taken into use right away, put the VCI foil over the system again to protect it against dust and moisture.

♦ Move the system to its installation place. (Remember, before the final placing mount the ventilation grids see description 7SA9031GB «Erection — Installation» section 2.1).

5. STORAGE SYSTEM

If the system is not to be installed immediately, the cubicles included in the delivery should remain in dry storage in their crates and protected against dust. Storage temperatures advantageously should be between -10°C and +55°C (allowable max. -25°C and +70°C). This also applies generally to all replacement material for the system. If the humidity is very intense it can be necessary to operate heating facilities (optional) internal the system until the system will be turned on. The system is to be installed within 12 months after delivery and put into operation. After these 12 months the manufacturer must be consulted, who will explain the necessary additional precautions (possibly commissioning by the manufacturer). BATTERIES

If the batteries are to be stored for a long time (> ½ year) the means of storage is to be approved by the battery furnisher, because they are different, depending on the type of the battery.

98-01-29 mp 98-01-29 GA 98-01-29

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7SA9030GB 1 1 / 3

TRANSPORT OF THE SYSTEM WITHOUT PACKING


TABLE OF CONTENTS: 1. Transport: C-Rail mounted

2. Transport: Lifting Lugs mounted


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1. TRANSPORT: C-RAIL MOUNTED

The C-rail for the neck straps on the front and back or the device must bear out 5 mm

Door frame or back cover

C-Rail

Device socket

Device socket

4070

125

255

CAUTION:

The lifting lugs have to be strained perpendicularly. When lifting units with a rain roof IPX1 / IPX2, the roof has first to be dismounted. The system can also be transported by a fork-lift or pallet-truck. Caution: Pay attention on the center of gravity and the weight !


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2. TRANSPORT: LIFTING LUGS MOUNTED SYSTEMS UP TO 500KG PER TRANSPORT UNIT

The angle of the cable must be at minimum 45°.

SYSTEMS EXCEEDING 500KG PER TRANSPORT UNIT

The lifting lugs have to be strained perpendicularly.

When lifting systems with a rain roof (IPX1 / IPX2), the roof has first to be dismounted.


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ERECTION — INSTALLATION of


TABLE OF CONTENTS: 1. General

2. Installation / Erection 2.1 IP Protection / Ventilation Grids 2.2 Placing 2.3 Cable Inlet

3. Ventilation

4. Connection / Protection 4.1 Earthing of the Cubicle 4.2 Mains Connection 4.3 Battery Connection 4.4 Earthing of the Battery (for Systems with Battery) 4.5 Connection of the Load 4.6 External Fuse Protection

ERECTION — INSTALLATION

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1. GENERAL

The following has to be considered in connection with the installation of the DC system:

♦ System room ♦ Cable connection / cable interconnection ♦ Losses, ambient temperature, ventilation ♦ Connection / Protection ♦ Earthing of the cubicle ♦ Mains connection ♦ Connection of load / distribution ♦ 3-phase systems with SMPS load (increased neutral current)

In the following sections the general requirements for the installation of DC systems is explained.

2. INSTALLATION / ERECTION 2.1 IP PROTECTION / VENTILATION GRIDS

Fit the ventilation grids on the front and the back ) of the device socket to the snap clip on both sides by means of sheet metal screws M5,5 and the corresponding washers see Fig. 1. AIR FILTERS / GLAND PLATES

Dependent on the degree of protection with which the system was ordered (see «Technical data» the system can optionally be equipped with additional air filters and gland plates. These can be pushed in from the front on the rails designated for that see Fig. 1.

)

If additional air filters and gland plates are to be mounted it is absolutely necessary to displace the system to its definite place of erection before attaching the ventilation grids to the front, since a transport of the system with mounted air filters and gland plates by means of a fork-lift or a pallet-truck is then no longer possible.

MOUNTING OF THE RAIN ROOF

The rain roof (optional) has to be fastened in accordance with the «Dimensional drawing», if it was not already mounted in the factory.

When mounting the rain roof special attention must be paid to the fact that no parts fall into the system. Besides, the rain roofs are not appropriate for a load from top and the system may also not be lifted at the rain roof.


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Fig. 1 Mounting of air filters and gland plates, as well as fixing of ventilation grids (front and back)

2.2 PLACING

The ventilation grids have in any case to be fixed on the back of the system before it will be placed to the wall or back to back. see section 2.1.

The DC system is built in a cubicle with a stable frame. On this frame heavy components such as transformers, chokes, etc. are mounted. The frame can be placed direct on a levelled concrete floor. The DC system can be placed with the backside to the wall or back to back (but a space of at least 100mm must be ensured). If possible, preferably a distance of 500mm from the backside of the system to the wall or between the systems (if these are placed back to back) should be provided.


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Above the top of the system a clearance of 500mm has to be provided to ensure sufficent space for the air outlet in fig. 2 typical installations are shown. Fig. 2 Typical placing of a System

100 mm space have to beensured, however, 500 mm

would be better

2.3 CABLE INLET

As a standard the cable inlet is from bottom, but optionally can also be performed from top, if this is stated in the order. In fig. 3 typical cable installations are shown. At the installation the bending radius of the cables must be in accordance with the Standards. Fig. 3 Examples of cable inlets (View from the right side)


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3. VENTILATION Attention must be paid to the heat that is to be removed which is generated by the power losses of the system. The inlet and outlet of air must be ensured, otherwise the system can produce an alarm due to overheating, or even shut down. Therefore the ambient temperature stated in the «Technical Data» is to be observed. Alarm indication is given if the temperature of the power components exceeds the permitted level. Objects which obstruct ventilation or which are easily combustible should under no circumstances be placed on, under or very near the system. If the system is placed with the backside to the wall or back to back, a space of at least 100mm has to be guaranteed. The necessary quantity of air cooling per hour depends on the one side on the total developed power dissipation, i.e. from the size and number of installed DC systems, and on the other side on the possible resp. permitted warming of the cooling air. The permitted warming of the cooling air is the difference between the admissible ambient temperature (e.g. 30° C) and the incoming temperature of the cooling air into the room (e.g. 25° C).

4. CONNECTION / PROTECTION 4.1 EARTHING OF THE CUBICLE

The system cubicle must be earthed, for which purpose earth bars/terminals are provided inside the system.

4.2 MAINS CONNECTION

The incoming feeders must comply with the general recommendation of IEC or the general Standards of VDE(D), SEV/HV (CH), or possibly with the additional Standard corresponding to the local electrical regulations. The person carrying out the work must be an authorised installation electrician. The fuse protection and the wire cross section of the mains connection can be seen in the «Technical Data», however, only if these meet also to the local electrical regulations. The rectifier mains input must be protected by external fuses or MCCB’s.

4.3 BATTERY CONNECTION

The battery feeders must comply with the general recommendation of IEC or the general Standards of VDE(D), SEV/HV (CH), or possibly with the additional Standard corresponding to the local electrical regulations. The battery must be protected by external fuses or MCCB’s. The fuse protection can be seen in the «Technical Data».


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4.4 EARTHING OF THE BATTERY (for systems with battery)

It is not necessary to earth the battery. However, if it is desired only the minus pole (-) of the battery may be earthed, but only if there is an isolating transformer at the input of the rectifier.

It is not permitted to earth the plus pole (+) of the battery because it could affect the functioning of the system.

4.5 CONNECTION OF THE LOAD

The load cables are to be installed and connected according to the maximum allowable load. It has to be assured that the connected load does not exceed the maximum rated capacity of the DC system !

4.6 EXTERNAL PROTECTION

To ensure selectivity between the internal fuses and the distribution fuses, the maximum fuse nominal current (rated circuit breaker current) at the load output is limited. In addition, the conditions for the rectifier incoming feeder fuse (mains) can be seen in the «Technical data». CIRCUIT BREAKER

We recommend when inserting circuit breakers between the busbar and the consumer, to choose such a type that its rated current not exceeds 15% of the nominal current of the system (voltage drop over the line between DC system and consumer max. 3%).

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ASSEMBLY OF PARTICULAR CUBICLE UNITS

PROVIDED MATERIAL PER CUBICLE SEPARATION:

see fig. 1.

12 pieces Hexagon head-fit screws M8 x 20 6 pieces Hexagon bolts 30mm with internal screw thread M8 12 pieces Tooth lock washers M8 / 8.2

fig. 1:

Recommended torque M8 = 21.5 Nm PROCEDURE: 1. Place Cubicle unit A) and install the 6 hexagon bolts by means of the screws and the tooth

lock washers (total 6 pieces of connections per cubicle separation = 3 pieces in front and 3 pieces in the back, i.e. for each 1 piece in the upper, middle and lower cubicle unit). see fig. 2.

If a partition wall should be provided, which partial elements are fastened to, then recesses (drillings) are intended for screwing together.

2. Push Cubicle unit B) completely close to Cubicle unit A).

3. Couple Cubicle unit A) with unit B) by means of the remaining 6 screws through the hexagon bolts and tighten all screws in accordance with the recommended torque. see fig. 3.

ASSEMBLY OF PARTICULAR CUBICLE UNITS

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fig. 2:

Fig. 2 shows an example of the framework of a free standing cubicle unit. The screws for the assembly fit only into the large holes.

Always two cubicle units are screwed together in the cubicle inside in accordance with following figure.

fig. 3:

Hexagon head-fit screws M8 x 20 Tooth lock washers M8 / 8.2 Hexagon bolt 30mm with internal screw thread M8

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DISPLAY — OPERATING & INDICATING ELEMENTS

DC POWER SUPPLY (RECTIFIER / CHARGER),

Type: SDC 125-1200-R

TABLE OF CONTENTS: 7SA9032GB DISPLAY & PARAMETER SETTINGS

4A-1110045001/20GB OPERATING- & INDICATING ELEMENTS (7SA9033GB)

98-02-12 mp 00-05-08 mp 06-08-25 mp 09-12-22 mp 98-02-12 GA 00-05-08 GA 06-08-25 RST 09-12-22 RST 98-02-12 00-05-08 06-08-25 09-12-22

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DISPLAY & PARAMETER SETTINGS of


TABLE OF CONTENTS: 1. Display unit

2. Change of Operational Parameters

3. Measurements on the Display

4. Alarms on the Display

DISPLAY & PARAMETER SETTINGS

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1. DISPLAY UNIT

COMMON ALARM

DISPLAY

C

4MAINS

CURRENT

7MAINS

VOLTAGE

8DC

VOLTAGE

9

V-AUX.

5BATTERYCURRENT

6TOTAL DCCURRENT

1 2BATTERY

TEMP.

3

On the front of the SDC there is a display unit. It consists of a LC display, an alarm LED, an acoustic alarm and a foil keyboard (as shown at the left). The display is used for programming the system and for giving information (measurements and alarm indications). In a normal situation the current operational mode is shown in the display. To get information or to program the system various entries have to be made via the foil keyboard. Normally the display will switch back automatically to show the current operational mode if the foil keyboard has not been activated within 30 secs or when

has been pushed.

If however, a change in the operational mode occurs the display immediately switches over to show the current operational mode. In this case the appropriate stack will have to be entred again by means of the foil key board to continue the programming of the system or reading information. The following is a description of information which can be shown in the display, as well as an instruction to the programming/setting up, which can be performed by the user.

2. CHANGE OF OPERATIONAL PARAMETERS In the display the following operational parameters can be programmed by the user — User Stack:

Second Language Charge mode Autostart Autoboost Battery capacity test Battery monitor test

(only shown if the option «Advanced battery monitor» is installed) Battery monitor reset

(only shown if the option «Advanced battery monitor» is installed) Automatic Battery monitor test

(only shown if the option «Advanced battery monitor» is installed) Enter new date Enter new time


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To enter the «Operational parameter» stack push and step inside the stack with the cursor

key or . By pushing the button C you get the selection series of settings,

allowed by the system.

SECOND LANGUAGE

It is possible to choose between 2 languages: GB + CZ / DE / DK / ES / FI / FR / HU / IT / NL / NO / PL / PT / RU / SE / SK, or DE + RU. One language can be chosen at the time, but can be changed when required at any time.

Chose the language by pushing and stepping inside the stack with the cursor key

or until is shown in the display. Thereafter push C to get

the required language (see possibilities listed above). The language is chosen by pushing

for «ON». When accepted the display shows: .

CHARGE MODE

It is possible to choose between 3 charging modes: «Float», «Boost» and «Initial». The charging

mode can be chosen by pushing and stepping inside the stack with the cursor

or

until: is shown in the display. If this charging mode is requested

push for «ON».

If one of the other two charging modes is requested push C until:

or is shown in the display. Chose by pushing for «ON». When

accepted the display shows:

.


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AUTOSTART

If «autostart» has been programmed, the rectifier will restart automatically at mains return, e.g. if the system has switched off due to low battery shutdown during battery operation or after system reset. The rectifier will start up in float charge operation, after it has been synchronous to the mains for 60 seconds, plus the mains returns to charger on time. If the rectifier is manually started within these 60 seconds «autostart» will be ignored.

To program the system for autostart push and step inside the stack with the cursor key

or until is shown in the display. Thereafter push

C to show in the display. Autostart is chosen by pushing

for «ON». When accepted the display shows: .

AUTOBOOST

The criterion for an automatic initiation of boost charging is that the battery current limiter is active for more than 3 minutes. The boost charging will last for tBOOST hours after the battery current limiter is out of function. If autoboost is programmed and the mains returns after a mains failure, an automatic boost charging is activated only if the criteria for boost charging are fulfilled, otherwise the rectifier starts up to float charge operation. AUTOBOOST IN PARALLEL SYSTEMS

If autoboost is programmed on both rectifier system units, the situation may occur where one rectifier switches to boost charge, but the other one does not. This may happen due to different battery conditions or timing deviation between the rectifiers system units. Loadsharing cannot be ensured in this case.

To program the system for autoboost push and step inside the stack with the cursor key


C to show in the display. Autoboost is chosen by pushing

for «ON».

When accepted the display shows: .


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BATTERY CAPACITY TEST

The battery capacity test gives an indication of how long the battery backup time is at actual load. The performance of a battery capacity test only make sense, when the batteries are well charged and the rectifier is running in float charge. At least once a year it is recommended to perform a discharging procedure of the batteries to make sure that they are discharging according to the information given by the manufacturer. 1. Start with fully charged batteries, i.e. if the system has been in normal operation for longer than

8 hours. 2. Connect the load to the system output.

3. For testing the battery capacity via the foil keyboard proceed as follows: Push and step

inside the stack with the cursor key or until:

is

shown in the display; where «???» is the back-up time of the last test. If no test has been performed before or the test has been aborted «???» is shown.

4. To start the battery capacity test push C

until the display shows:

. Thereafter push for «ON». The rectifier will

change to battery operation and persists until the level «Low DC warning/Low DC Vaux warning» is reached. Thereafter the rectifier changes automatically to float charge voltage. The time in minutes, from the initiation of the battery capacity test to its end is shown in the battery capacity test menu. A time periode of at maximum 9’999 minutes (6 days + 22 hours) are measured. When the level «Low DC warning/Low DC Vaux warning» is reached the system changes to normal operation and the batteries will be recharged.

5. To stop an already running capacity test push (when the display shows «Battery capacity test

ON») the button C until the display shows: . Thereafter push

for «OFF».

6. If during the test a mains fault occurs or the button S1 «SYSTEM ON» has been pushed, the

test will immediately be aborted and no test result will be obtained. When reading out data of the battery capacity test in the display after a test has been aborted, «???» is shown, i.e. that no result was obtained.

Please note that after a battery capacity test it will take about 8...24 hours before the battery is recharged and the full back-up time is available again.


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BATTERY MONITOR TEST

only shown if the option «Advanced battery monitor» is installed.

To perform the battery monitor test push and step inside the stack with the cursor key


C to show in the display. «Battery monitor test» is chosen by

pushing for «ON». When accepted the display will show: .

This function will check the battery condition by switching off the rectifier. The system is running in battery operation until 25% of the battery capacity are used up. The rectifier will automatically switch on after the test has finalized or if a failure in the battery has been detected no loss of the output voltage. If the battery conditions are within the tolerance range no alarm will be shown in the display.

If the battery capacity is reduced, one of the following two alarms will be shown in the display:

• Alarm # 43: «Battery defective» • Alarm # 52: «Battery weak»

If the «Battery Monitor Test» signalize a fault an alarm is given, this alarm can be reset by means of the «Battery Monitor Reset» see next section.

BATTERY MONITOR RESET

only shown if the option «Advanced battery monitor» is installed

To reset the battery monitor alarms push and step inside the stack with the cursor key


C to show in the display. «Battery monitor reset» is chosen by

pushing for «ON». When accepted the display will show: .


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AUTOMATIC BATTERY MONITOR TEST

only shown if the option «Advanced battery monitor» is installed.

To perform the automatic battery monitor test push and step inside the stack with the

cursor key or until is shown in the display. Thereafter

push C to show in the display. When pushing C twice, the

display will show . «Automatic Battery monitor test» is chosen by pushing

for «ON». When accepted the display will show: .

ENTER NEW DATE

To set the current date in the system, push and step inside the stack with the cursor key

or until the display shows: . Thereafter push (for e.g.

25th August 2006):

and for confirming.

When accepted the display will show:

.

ENTER NEW TIME

To set the current time in the system, push and step inside the stack with the cursor key

or until the display shows: . Thereafter push (for e.g. 14

h 15 min 10secs): 1

1

1

and for confirming.

Remember when entering the seconds, the clock is only activated when the confirmation

button has been pushed. When accepted the display will show: .


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3. MEASUREMENTS IN DISPLAY Measurements can be shown in the display by pushing one push-button. The accuracy of the measurements are 1 % ± one digit. The display is updated every second. If no button is pressed in a period of 30 seconds the display returns to the current operating status. This is applicable for all display modes. The range of temp.measurement is from - 35° C to + 55° C. The values shown in the following display pictures are only examples. Push; The display shows: Explanation:

1

.............. .....shows Date: year, month, day (YY.MM.DD)

Time: hours, minutes, seconds (HH.MM.SS)

BATTERYTEMP.

2

.............. ..... Battery temperature

.....No battery sensor inserted, or the battery sensor is faulty

MAINSCURRENT

4

.............. ..... Mains input current per phase

L1 L2 L3

BATTERYCURRENT

5

.............. ..... Battery current with indication «charge/discharge»

TOTAL DCCURRENT

6

.............. ..... Total DC current

7MAINS

VOLTAGE .............. ..... Phase-to-phase mains input voltage

L1-L2 L2-L3 L3-L1

DCVOLTAGE

8

.............. ..... DC voltage

V-AUX

9

.............. ..... «Auxiliary» voltage (or optionally Vbatt/2):

.....Alarm is active if Vbatt/2 deviates more than 1,5 % from half the output DC voltage.

To return to normal status indication wait 30 secs or push . The display indicates the

current operating status.


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4. ALARMS IN THE DISPLAY Alarms are given if the rectifier behave abnormal or if a specific parameter is out of range. An alarm is either a warning, which is only an information for the user, or a shut down event. If there are one or more alarms in the system the red «Common Alarm LED» (placed above the foil keyboard) is illuminated, indicating that this (these) alarm(s) can be found in the alarm stack. The alarm LED is ON as long as an alarm is present in the system. The acoustic alarm is also activated, but it is only active for 30 seconds. If the alarm disappears in less than 30 seconds the acoustic alarm will also stop. If two or more alarms overlap each other, the acoustic alarm remains activated for additional 30 seconds with effect from the arise of the last

alarm. By pushing the button the acoustic alarm will stop.

The alarm LED indicates that there is an alarm in the «alarm stack». The alarm stack contains those alarms, which at the time in question exist. The alarms are placed in the stack in the same succession as they arose indicating the latest alarm at first.

To show alarms in the «alarm» stack push and move inside the stack with the cursor key

or .

DESCRIPTION OF POSSIBLE ALARMS:

(The alarms are shown in English only)

Alarm No. Alarm Name Description

W = Warning /

S = Shut down

Time delay [sec]

1 Phase order not correct Phase order not correct S 0 2 Mains voltage out of tolerance Mains voltage is out of tolerance, window +15 %, -25

% S 0

3 Mains frequency error Mains frequency is out of tolerance, window ± 8 % S 0 4 Mains MCB is off Mains MCB is open S 0 5 UI characteristic

DC voltage deviates more than ± 3 % of the rated voltage and the current limiter is not activated

W 5

6 Charger 0° temp.warning Temp. over 90°C W 0 7 Charger 30° temp. warning Temp. over 90°C W 0 8 Charger 0° temp. shut down Temp. over 110°C S 0 9 Charger 30° temp. shut down Temp. over 110°C S 0

10 High temp. transformer Temp.signal switch in transformer off W, S(10 min. delay) 0 11 High temp. choke Temp.signal switch in choke off W, S(10 min. delay) 0 12 High DC warning DC is over high DC warning level W 0 13 High DC shutdown DC is over high DC shut down level S 0 14 Low DC warning DC is over below Low DC warning level W 0 15 Charger off warning Rectifier is off W 0 16 Total DC current limit Current limiter for total DC current is active W 5 17 Battery current limit Battery current limiter is active W 5 18 DC fuse blown DC fuse is blown S 0 19 Battery MCB is off Battery MCB is open W 0


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Alarm No. Alarm Name Description

W = Warning /

S = Shut down

Time delay [sec]

20 Low DC Vaux warning The DC voltage after serial diode is below DC warning level

W 0

21 High DC Vaux warning The DC voltage after serial diode is over high DC warning level

W 0

22 Internal PSU error, DC string The DC circuit of the redundant PSU is defective W 0 23 Internal PSU error, AC string The AC circuit of the redundant PSU is defective W 0 24 Fan 1 error Fan 1 is rotating to slowly ) W 0 25 Fan 2 error Fan 2 is rotating to slowly ) W 0 26 Fan 3 error Fan 3 is rotating to slowly ) W 0 27 Fan 4 error Fan 4 is rotating to slowly ) W 0 28 Fan 5 error Fan 5 is rotating to slowly ) W 0 29 Fan 6 error Fan 6 is rotating to slowly ) W 0 30 Fan 7 error Fan 7 is rotating to slowly ) W 0 31 Fan 8 error Fan 8 is rotating to slowly ) W 0

) (fan pulse signal < 20 Hz) 32 Earth fault on positive pole Earth current running to positive pole W 5 33 Earth fault on negative pole Earth current running to ground pole W 5 34 Option 1 error Option 1 error W 0 35 Option 2 error Option 2 error W 0 36 Option 3 error Option 3 error W 0 37 Option 4 error Option 4 error W 0 38 Option 5 error Option 5 error W 0 39 Option 6 error Option 6 error W 0 40 Option 7 error Option 7 error W 0 41 Option 8 error Option 8 error W 0 42 Battery symmetry error Half the battery voltage is outside the window of

±1.5%. A battery cell is defective W 5

43 Battery defect Conclusion of battery monitor test. W 0 44 Mains phase missing Mains, Phase missing. At least 1 phase is missing S 0 45 Load MCB is off Load MCB W 0 46 Blocking of boost / initial Blocking of boost and initial charge is activated W 0 47 Parallel operation error Load sharing differs more than ± 10% for more than

30secs. W 30

48 Control loop error Control loop error, e.g. no DC feed back signal S 0 49 Diode temp. warning Temp.signal switch in diode off W 0 50 Loadsharing error 0°- 30° Load sharing error, between 0° and 30° module. The

two currents differs more than ±7.5% W 30

51 Temp.sensor error Measured temp.outside window, -35°....+55°. Temp.sensor is defective or missing.

W 30

52 Battery weak Battery capacity reduced (battery weak) W 30 53 Synchronization error Charger is not synchronous to mains S 0 54 Battery temp.warning Battery temp.is above limit W 0 55 Calibration stack entered Indication if calibration stack has been entered W 0

«Battery current limit» has no influence on the acoustic alarm and the common alarm LED in the display, but becomes present in the alarm stack and the log stack after a delay of 5 seconds. All alarms have influence on the common alarm relay. Only one alarm, the «UI-characteristic alarm» has influence on the rectifier failure relay.


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The alarms will only be present in the alarm stack as long as the red «Common Alarm LED» is on.

To leave the stack, wait 30 secs or push .

4.1 ALARM LOG

The «log alarm» section of the program is a stack, which contains the last 100 arisen events. In the stack both alarms and changes in the operational mode are stored. The events are placed in the stack in the same succession as they arose indicating the last event at first. All events are time stamped.

To show alarms in the «log alarm» stack push simultaneously 0

and . Then move

inside the stack by means of the cursor key or until the desired event is shown.

The last text in the stack is «No (further) event». The system will log the alarms shown in the alarm stack and at the same time the following changes in the operational modes: 56 MPU is reset 57 Off button pushed 58 Auto off executed 59 On button pushed 60 Logged mode: Standby 61 Logged mode: Battery operation 62 Logged mode: Float charge 63 Logged mode: Boost charge 64 Logged mode: Initial charge

At the actual event push 1

and the time where the actual event happened will be shown in

the display with «year, month, day / hours, minutes, seconds». To leave the log alarm stack wait 30

seconds or push .

The log alarm stack can be cleared by keying in the password: 920701. Push simultaneously 1

and . The display will show: . Key in 920701 and the

alarm log will be cleared. The display shows: .

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OPERATING & INDICATING ELEMENTS of

DC POWER SUPPLY, Type: SDC 125-1200-R

TABLE OF CONTENTS:

1. Front panel 2. Operation 3. Operating Status Indications 4. Alarm Indications

4.1 Alarm Indication Concept 4.2 Description of the Individual Alarms 4.3 Common Alarm 4.4 Potential-free Relay contacts

5. Analogous Instruments / Switches 6. External Connection P.C.Board

FRONT PANEL (Control and Monitoring Board)

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OPERATING & INDICATING ELEMENTS

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1. FRONT PANEL (CONTROL AND MONITORING BOARD) SEE PAGE 2

The Front panel (Control and Monitoring board) is divided up in the following functional sections:

♦ Display unit ................................... see Description 7SA9032GB ♦ Operation ...................................... Section 2 ♦ Operating status indications....... Section 3 ♦ Alarm indications ......................... Section 4

Depending upon the system configuration, the switches mentioned in this description can be circuit breakers or switch-disconnectors (fuse switch-disconnectors) and the designation can be made according to customer's request

see «Single line diagram».

2. OPERATION

Pos. Designation Explanation

S1 SYSTEM ON Push-button for turning on the entire system.

Push-button for turning off the entire system. For this function the push-button «OFF» (S2) must be pressed at the same time as push-button «SYSTEM ON» (S1).

S2 OFF

With this action the system is shut-down no output voltage (only from

battery).

S3 LAMP TEST The push-button may be pressed at any time. It serves for checking whether all indications of the «Operating status indications» and «Alarm indications» function. The potential-free alarm contacts are not energized.


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3. OPERATING STATUS INDICATIONS


1 RECT. MAINS OK (green)

The rectifier mains voltage and frequency are available and within the specified tolerance ranges. For tolerances see «Technical Data»

2 RECT. OPERATION (green)

The rectifier is switched on. The firing pulses to the thyristors are enabled.

3 BOOST / INITIAL CHARGE (yellow)

The boost or initial charge has been initiated manually or automatically.

4 BATT. OPERATION (green)

The battery is supplying the load with energy.

5 OUTPUT VOLTAGE OK (green)

The output voltage is within the specified tolerance range. For tolerances see «Technical Data»

6 Battery switch ON (green)

The battery switch Q005 and Q004 is switched on.

7 Battery switch OFF (red)

The battery switch Q005 or Q004 has tripped is switched off.

8 Mains switch ON (green)

The rectifier input switch Q001 is switched on.

9 Mains switch OFF (red)

The rectifier input switch Q001 has tripped or is switched off.

10 Load switch ON (green)

The output switch Q003 is switched on.


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11 Load switch OFF (red)

The output switch Q003 has tripped is switched off

4. ALARM INDICATIONS 4.1 ALARM INDICATION CONCEPT

The alarm indication on the front panel shows all current alarms. When an alarm gets active the corresponding LED starts flashing (1 Hz).

When pushing the button for reset, the LED’s extinguish, whose corresponding alarm is not

active anymore. If the alarm is still active, the LED changes to steady indication. When the alarm gets inactive the corresponding LED extinguishes. All LED’s have a delay compared to the alarms. For the LED indications with the corresponding delays see section 4.2.

To reset the internal horn (acoustic alarm) push: .

4.2 DESCRIPTION OF THE INDIVIDUAL ALARMS

Designation Explanation

RECTIFIER MAINS FAULT (AC POWER FAIL) (30secs)

The indication illuminates if one or more phases of the mains voltage as well as the frequency and phase sequence are outside the tolerance range.For tolerances see «Technical Data»

RECTIFIER FAILURE (5secs)

The indication illuminates only, if all the following events occur simultaneously: • Rectifier mains is ok, • Rectifier is not operating in current limitation, • Rectifier voltage deviates more than ±3 % from setting. For tolerances see «Technical Data»


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Designation Explanation

DC OUT OF TOLERANCE (5secs)

The DC voltage is out of the tolerance range of «Low DC Warning/Low DC Vaux Warning» level. For tolerances see «Technical Data»

DC FUSE BLOWN (5secs)

The rectifier output fuse F026 has blown.

RECT. OVERCURRENT (30secs)

The rectifier output current has exceeded the charger current limit. For values see «Technical Data»

LOAD SHARING FAULT (only redundant Rect.) (5secs)

When both rectifier units operates in same operation mode (for the configuration with individual batteries, only at float charge) the total load of the parallel connected system is distributed in the way that each rectifier unit runs at 50% of the actual load, if not this alarm is activated (30secs delay at detection).

BATTERY DISCHARGED (5secs)

The battery voltage is dropped below «Low DC Warning/Low DC Vaux Warning» level. For tolerances see «Technical Data»

BATTERY DISCONNECTED (5secs)

The battery is disconnected from the system and the battery fuse or switch has released. If a battery MCCB is inserted, this indicates whether the MCCB has tripped or manually been disconnected.

CONTROL POWER FAULT (5secs)

One of the electronic supplies (+5V/±15V) is outside the tolerance range, or the feeding of one of the power supplies is not available (Rectifier mains or Battery).

OVERTEMPERATURE (5secs)

The following elements have a thermal monitoring: • Rectifier bridge • Rectifier transformer • Blocking diode • DC choke

FAN FAILURE (COOLING SYSTEM FAILURE) (30secs)

One or more fans in the system have failed.

LOW DC VOLTAGE (Option 1)

The DC voltage is dropped to the lower alarm level. The alarm No: 14 «Low DC Warning» or the alarm No. 20 «Low DC Vaux Warning» can be shown in the Display. For tolerances see «Technical Data» chapter 3.

HIGH DC VOLTAGE (Option 2)

The DC voltage has exceeded the upper alarm level. The alarm No: 12 «High DC Warning» can be shown in the Display. For tolerances see «Technical Data» chapter 3.

Q003 TRIP (Option 5)

The battery and the load output is disconnected from the rectifier; it indicates whether the rectifier output switch Q003 has tripped. Load sharing is no longer active, and the alarm «LOAD SHARING FAULT» will also be indicated.

Q001 TRIP (Option 6)

The rectifier input switch Q001 is open. It indicates whether the MCCB has tripped. Also the red LED 9 « MAINS MCCB OFF» is illuminated


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4.3 COMMON ALARM

If one or more alarms are active in the system according to section 4 «Alarms in the display» of the description 7SA9032GB «Display & Parameter settings» the red «Common alarm» LED, located on the display unit just below the LC display and above the foil keypad illuminates, as well as the «Common alarm relays» at X009 on the external connection p.c.board drops out after a pre-programmed delay time (factory set).

4.4 POTENTIAL-FREE RELAY CONTACTS

For customers’ own use up to 16 alarms are available as potential-free contacts on a relay strip. The explanations given in section 4.2 «Description to the individual alarms» and 4.3 «Common alarm» are also valid for the alarms on the relay contacts. The contacts are activated simultaneously with the respective indication in the alarm indication field (see connection diagrams). SPECIFICATION FOR THE RELAY

Description Minimum Maximum Note

Contact voltage AC 6 V AC 250 V AC 50 / 60 Hz

Contact current AC 50 mA AC 8 A AC 50 / 60 Hz resistive load

Contact voltage DC 6 V DC 250 V DC 6 V DC

Contact current DC 50 mA DC 0,3 A DC 8 A DC

5. ANALOGOUS INSTRUMENTS / SWITCHES AC Instruments DC Instruments Switches

A

V

Hz50

A

V

L2,L3PH2

L3,L1PH3

L1L2PH1

L3L0

OFF

P031 P032 P033 P026 P023/1P23/2P23/1P01/2P01

P024/1P24/2P24/P027/P102/1P02/2P02

S031

Pos. Instrument Explanation

P031 AC ammeter Indicates the rectifier input mains current, measured after the rectifier input switch Q001.

P032 AC voltmeter Indicates the rectifier input mains voltage, measured before the rectifier input switch Q001.

S031 Phase selector switch (AC Input)

For the measurement of the individual phase voltages for the AC input voltmeter P032 and the individual phase currents for the AC input ammeter P031.

P026 DC ammeter Indicates the charge or discharge current of the battery, measured before the battery switch Q004.


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Pos. Instrument Explanation

P027 DC voltmeter Indicates the battery voltage, measured measured before the battery switch Q004.

P023 DC ammeter Indicates the rectifier output current, measured before the rectifier output switch Q003.

P024 DC voltmeter Indicates the rectifier output voltage, measured before the rectifier output switch Q003.

1P23 DC ammeter Indicates the rectifier output current, measured in the distribution after the rectifier output switch Q003 of Charger 1.

1P24 DC voltmeter Indicates the rectifier output voltage, measured in the distribution after the rectifier output switch Q003 of Charger 1.

2P23 DC ammeter Indicates the rectifier output current, measured in the distribution after the rectifier output switch Q003 of Charger 2.

2P24 DC voltmeter Indicates the rectifier output voltage, measured in the distribution after the rectifier output switch Q003 of Charger 2.

P102 DC voltmeter Indicates the rectifier output voltage. 1P01 DC ammeter Indicates the rectifier output current, measured in the Subdistribution before

the Subdistribution input switch 1Q30. 1P02 DC voltmeter Indicates the rectifier output voltage, measured in the Subdistribution

before the Subdistribution input switch 1Q30. 2P01 DC ammeter Indicates the rectifier output current, measured in the Subdistribution before

the Subdistribution input switch 1Q30. 2P02 DC voltmeter Indicates the rectifier output voltage, measured in the Subdistribution

before the Subdistribution input switch 1Q30.


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6. EXTERNAL CONNECTION P.C.BOARD

X002

X003

Internal connectionto Low DC section

Communication RS232

Remote Display

Rectifier failure

Common Alarm

Common Alarm

Internal Supply for Emergency Stop +Internal Supply for Emergency Stop –

External Supply for Emergency Stop –External Supply for Emergency Stop +

External Off

External On

Initial Charge

Boost ChargeBattery Temperature sensor –Battery Temperature sensor +

Battery MCB

Blocking of Boost and Initial Charge

Serial PortRS232

ParallelA025

4321

X004

1413121110987654321

X009

X001

RemoteDisplay

= Alarm position

4321

4321

X006

X007

4321

X008

GND

GND

GND

GND

GND

GND

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COMMISSIONING


TABLE OF CONTENTS: 1110045001 SINGLE-LINE DIAGRAM

7SA9034GB START — STOP

4A-1110045001/20GB COMMISSIONING (7SA9036GB)

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START — STOP of


TABLE OF CONTENTS: 1. Operational buttons for Starting and Stopping

2. Starting the DC system

3. Stopping the DC system

This chapter contains all the necessary information to operate the DC system after installation and commissioning. See also Instruction 7SA9031GB «Erection – Installation» and «Commissioning».

START — STOP

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1. OPERATIONAL BUTTONS FOR STARTING AND STOPPING

.................... S1 Button «SYSTEM ON» for switching on the DC system

....................S2 Button «OFF» for switching off the DC system (simultaneously the button S1 has to be pushed)

.................... Operational parameters

...... Cursor keys for the selection between operational parameters

2. STARTING THE DC SYSTEM

If the system is programmed for «AUTOSTART» and if the rectifier mains is switched on and within the tolerance range, the system will start automatically after 60secs.

1. Switch on the rectifier mains supply. The display shows: for 10

seconds, thereafter the display changes to: .

2. Turn on the DC system (if not already ensued automatically) by pressing S1 «SYSTEM ON»

on the front panel. The display shows:

(if at the «Parameter

settings» has been chosen.

3. Connect the battery.

4. Press the button until all red LED’s of «Alarm indication» are extinguished.

Now the DC system is turned on.

START — STOP

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3. STOPPING THE DC SYSTEM

Secure that all consumers, connected to the DC system are informed before proceeding with the following steps and before turning off the system.

After the following steps the DC SYSTEM is volt-free.

NO OUTPUT VOLTAGE !!

Remember, the rectifier mains as well as the battery are still applied ! The connecting terminals are carrying hazardous voltage !!!

1. Disconnect the battery.

2. Press the button S1 «SYSTEM ON» and simultaneously S2 «OFF» on the front panel to

turnoff the system. The display shows: .

3. Switch off the rectifier mains supply.

The display shows no indication.

Thereafter the DC system is turned off all LED indications are extinguished.

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COMMISSIONING of

REDUNDANT DC POWER SUPPLY with 1 Battery, Type: SDC-R

TABLE OF CONTENTS: 1. Preparations with Power Off

2. Commissioning of the overall DC System

3. Switching volt-free of one DC System unit

4. Recommissioning of one DC System unit

COMMISSIONING

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THE INITIAL CHECKS ARE SUBDIVIDED IN TWO MAJOR PARTS:

♦ one with power off ♦ one with power on

When planning the initial checks read first the complete chapter before starting the check procedure.

PRINCIPLE DIAGRAM

Depending upon the system configuration, the switches mentioned in this description can be circuit breakers, switch-disconnectors (fuse switch-disconnectors) and the designation can be made according to customer's request

see «Single line diagram».

OPERATING STATUS INDICATIONS / ALARM INDICATIONS / FAULT LOCATION

For detailed explanation: see Description 7SA9032GB «Display & Parameter settings» and

4A-1110045001/20GB «Operating & Indicating Elements — 7SA9033GB»

For eventual fault location: see Description 4A-1110045001/20GB «Trouble Shooting — 7SA9043GB»

FRONT PANEL

OPERATING STATUS INDICATION OPERATION DISPLAY UNIT

COMMISSIONING

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SYMBOLIC (BOTH DC SYSTEM UNITS TOGETHER)

1. PREPARATIONS WITH POWER OFF Before connecting the local network, the battery and the consumers to the DC System, the following proceedings are necessary: 1. Check that the earthing of all cubicles is secure and there are no damages.

2. Check that all connectors are firmly fixed.

3. Check that all printed circuit boards are correctly mounted and the plugs are firmly plugged in.

4. Check all interconnections and junctions according to «Connection diagram».

5. Check that the external fuses have the correct size.

6. If bags with moisture absorbing material are in the cubicle, remove these.

Check that the interior of the DC System is dry. If there is any condensed water, let the DC System stand with the front doors open in a dry and warm area for at least 24 hours.

PREPARATIONS ON THE DC SYSTEM BEFORE THE COMMISSIONING:

a) RECTIFIER 1 (System unit A)

• Rectifier input switch ..................................................... Q001 open • Rectifier output switch ................................................... Q003 open • System output switch .................................................... Q100 closed

b) RECTIFIER 2 (System unit B)

• Rectifier input switch ..................................................... Q001 open • Rectifier output switch ................................................... Q003 open • System output switch .................................................... Q200 closed

COMMISSIONING

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c) DISTRIBUTION / OUTPUT

• Battery switch................................................................ Q005 closed • Battery switch................................................................ Q004 open

• Outgoing feeders Distribution ....................................... Q101...Q1xx open • Input switches Subdistribution....................................... 1Q30 & 2Q30 open • Outgoing feeders Subdistribution.................................. Q301...Q3xx open • Consumers.................................................................... volt-free

2. COMMISSIONING OF THE OVERALL DC SYSTEM The commissioning is performed according to these instructions:

1. Check preparations as under section 1.

2. Apply the rectifier mains voltage for both system units (according to «Connection diagram») and check phase sequence as well as the voltage.

The following steps are first only to be executed on System unit B:

3. Close the rectifier input switch Q001. The display shows: for 10

seconds, thereafter the display changes to: . If the DC System is

programmed for «AUTOSTART» see «Technical data» and the rectifier mains is within the tolerance range the DC System will start automatically after 60 seconds. The green LED’s 8 & 1 as well as the red LED 7 illuminate.

4. Push the button S3 «LAMP TEST» on the front panel and check that all LED’s of the «Operating status indications» and «Alarm indications» illuminate.

5. Turn on the DC System (if not already ensued automatically) by pressing S1 «SYSTEM ON»

on the front panel. The display shows: (if at the «Parameter

settings» has been chosen). Additionally the green LED’s

2 & 5 are illuminated.

6. Check the rectifier output voltage in the display by pressing the button .

7. Close the rectifier output switch Q003.

8. Close the battery switch Q004. Additionally the green LED 6 is illuminated and the red LED 7 extinguishes.

9. Check the battery current in the display by pressing the button .

10. Turn off the rectifier mains by opening the rectifier input switch Q001. The DC

COMMISSIONING

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System changes to Battery operation.

11. Check that the green LED «BATTERY OPERATION» (LED 4) and the red LED 9 illuminate

and the green LED’s 1, 2 & 8 extinguish. The display shows: .

12. Close the rectifier input switch Q001. Check that the DC System switches back to Normal operation. The green LED 4 and the red LED 9 extinguish — the green LED’s 8, 6, 1, 2 & 5 illuminate.

13. Reset the alarms by pressing the button .

The functions of the DC System unit B have been checked at this stage and the commissioning procedure for the remaining part continues.

14. Turn off the DC System unit B by pressing simultaneously the push-buttons S1 «SYSTEM ON» and S2 «OFF» on the front panel the green LED’s 2 & 5 extinguish. DC System unit B changes to Standby operation and its display shows:

.

Repeat steps 3 til 13 for DC System unit A.

15. Turn on DC System unit B by pressing S1 «SYSTEM ON» on the front panel.

16. Check that on both system units the green LED’s 8, 1, 2 & 5 illuminate and the displays

show: .


18. Make sure that the DC System operates correctly and no alarm of the «Alarm indications» is pending.

The safe bus is energized.

The following green LED’s are illuminated: 8, 6, 1, 2 & 5.

19. Close the outgoing feeders Q101...Q1xx in the distribution.

20. Close the Subdistribution input switches 1Q30 & 2Q30.

21. Close the outgoing feeders Q301...Q3xx in the Subdistribution.

COMMISSIONING

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All consumers are now supplied by both DC System units in parallel redundant operation with load sharing.

The output terminals are carrying hazardous voltage !!!

22. Reset eventual alarms on both system units by pressing until all red LED’s are

extinguished. The horn can be reset by pressing .

23. Clear the log alarm stack on both system by pressing simultaneously and

.

Then the displays show: . Key in the password 920701 and the

alarm log will be cleared. The displays show: .

24. To return to normal status indication wait 20secs or push: . The displays show:

.

3. SWITCHING VOLT-FREE OF ONE DC SYSTEM UNIT With these instructions one of the DC System unit can be switched volt-free.

The load is then supplied by the other DC System unit.

Before switching off one system unit make sure that the other DC System unit operates correctly and no alarm is pending

The following instructions are related to the system unit which is to be switched volt-free (here DC System unit B). 1. Turn off the DC System unit B by pressing simultaneously the push-buttons S1 «SYSTEM

ON» and S2 «OFF» on the front panel. The load is supplied completely by the other system unit (DC System unit A), while the DC System unit B changes to Standby operational

mode and its display shows: . The green LED’s 2 & 5

extinguish.

COMMISSIONING

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2. Open the rectifier input switch Q001. The green LED’s 8 & 1 extinguish and the red LED 9 illuminates.

3. Open the rectifier output switch Q003.

After a while, when the DC capacitor bank has discharged, the DC System is volt-free with the exception of a few components.

Remember, the rectifier mains as well as the battery are still applied !The connecting terminals are carrying hazardous voltage !!!

4. RECOMMISSIONING OF ONE DC SYSTEM UNIT These instructions describe the recommissioning of the second system unit after it has been switched volt-free (here DC System unit B). Before starting the recommissioning the following conditions have to be verified:

• The first system unit (DC System unit A) operates correctly and no alarm is pending.

• Rectifier input switch ............................................................... Q001 open • Rectifier output switch............................................................. Q003 open • Battery switch.......................................................................... Q004 closed Check the above conditions carefully before starting the following procedure:

1. Close the rectifier input switch Q001. If the DC System is programmed for «AUTOSTART» see «Technical data» and the rectifier mains is within the tolerance range the DC System will start automatically after 60 seconds. The green LED’s 8 & 1 as well as the red LED 7 illuminate. The DC System starts up to Standby operation mode and the display shows «Standby».

2. Push the button S3 «LAMP TEST» on the front panel and check that all LED’s of the «Operating status indications» and «Alarm indications» illuminate.

3. Turn on the DC System unit B (if not already ensued automatically) by pressing S1 «SYSTEM ON» on the front panel the DC System starts up to normal operation mode and the

displays show (depending on parameter settings) .

Additionally the green LED’s 2 & 5 are illuminated.

4. Check in the display that the rectifier output voltage is within the tolerance range by

pressing the button .

5. Close the rectifier output switch Q003.

COMMISSIONING

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7. Make sure that the DC System operates correctly and no alarm is pending.

Now, the consumers are supplied again from both system units in parallel redundant operation with load sharing.

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MAINTENANCE


TABLE OF CONTENTS: 7SA9040GB MAINTENANCE

7SA9041GB REPLACEMENT OF COMPONENTS & PARTS

7SA9042GB SERVICE — TRAINING — CONTACT ADDRESSES


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MAINTENANCE of


TABLE OF CONTENTS: 1. Maintenance of the DC System

1.1 Monthly checks 1.2 Semiannual checks 1.3 Annual checks

2. Maintenance of the Battery

2.1 Monthly checks 2.2 Annual checks 2.3 Battery capacity test

MAINTENANCE

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Due to the critical intended purpose and to ensure the safe and reliable operation of the equipment, inspection and preventive maintenance are essential. To perform a proper maintenance on GUTOR DC systems it is adivisable to have participated on a GUTOR training course. GUTOR also provides global service contracts to guarantuee a maximum availability of the system therefore please refer to the description 7SA9042GB «Servce-Training-Contact Addresses». For the checks listed below a brief report/checklist shall be issued where all findings are documented. These records must be available in case of a warranty claim.

Please read the «Safety regulations» 7SA9009GB thoroughly before performing any manipulations on the installation.

1. MAINTENANCE OF THE DC SYSTEM 1.1 MONTHLY CHECKS

The following checks should be made monthly: 1. Check DC output voltage by means of a measuring instrument.

2. Check DC output current by means of a measuring instrument.

3. Persisting alarm indications or incorrect operating statuses must be recorded. Subsequently,

reset the alarms by pressing the button C and make sure that the DC system

operates correctly and no alarm of the «Alarm indications» is any longer pending.

4. Press button S3 «LAMP TEST». All operating status and alarm indications must illuminate as long as the button is pressed.

1.2 SEMIANNUAL CHECKS

The following checks should be made semi-annually: 1. Monthly checks as above.

2. Read out the event log and analyse it. In case of irregularities which can not be explained, kindly contact the GUTOR support.

3. Only for systems with filter mats: Check whether the filter mats are dirty.

4. Job preparations for annual maintenance depending on the findings.

MAINTENANCE

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1.3 ANNUAL CHECKS

1. Monthly & semiannual checks as above.

2. Check tightness of all connections. Check the screws and nuts in the device (in volt-free condition — system isolated).

3. In case of strong contamination clean the system from dust.

Switch off the entire system according to the description 7SA9034GB «Start — Stop»

Don’t use any liquid for cleaning — only vacuum cleaner !

4. Only for systems with filter mats:

Check whether the filter mats are dirty. In the case of strong contamination the filter mats must be replaced. (A strong contamination results in a reduction of velocity of air, necessary for the ventilation of the system, and thus sufficient cooling is no longer ensured).

5. Recommendations of OEM (Original Equipment Manufacturer) shall be followed regarding annual maintenance.

6. Functional check of the entire system shall be performed.

2. MAINTENANCE OF THE BATTERY During operation the battery capacity and the life-span can be influenced by several processes as:

♦ Corrosion ♦ Grid growth ♦ Ripple effects ♦ Sulphation ♦ Passivation ♦ Short circuit ♦ none or excessive cycling ♦ Deep discharge ♦ Wrong battery room temperature ♦ Operation with low electrolyte ♦ Gradual changes in active material ♦ Normal aging

This only to name a few influencing factors. Detailed corresponding data for the maintenance of the battery see the information given by the battery manufacturer in chapter «Battery documentation».

MAINTENANCE

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2.1 MONTHLY CHECKS

The following checks should be performed at the same time as the monthly checks of the DC system: 1. Check the battery voltage at the battery.

2. Check all wet battery cells on the liquid level and if necessary refill see «Battery documentation».

3. Check the voltage of each individual cell (in the case of wet battery cells additionally the specific gravity) of the «pilot cells» see «Battery documentation».

2.2 ANNUAL CHECKS

1. Annually the cell covers must be cleaned and if necessary the poles and links must also be cleaned (possible corrosion) and slightly greased.

2. Check the starting torque of the pole screws.

3. Check the battery with the rectifier switched on. Measure and record the voltage of each cell. In the case of wet cells additionally the specific gravity must be checked and recorded.

4. Perform a nominal battery discharge test according to the manufacturer’s recommendation see «Battery documentation». The discharge test records should at least contain: All

cell voltages, discharge current, overall battery voltage, ambient temperature and discharge time. If wet cells are used it would also include the specific gravity as well as the electrolyte temperature of pilot cells.

2.3 BATTERY CAPACITY TEST

The battery capacity test gives an information about how long the battery backup time is at actual load. The performance of a battery capacity test only make sense, when the batteries are fully charged and the rectifier is running in float charge.

At the end of this check the capacity of the battery is low. If at this time a mains failure occurs, it will have a direct influence on the emergency current time (autonomy time). Therefore, this check must be co-ordinated with the personnel (e.g. operator of the connected load). Nevertheless, the test should not be foregone because it provides the best information on the condition of the batteries.

1. Start with fully charged batteries, i.e. if the system has been in normal operation for longer than

8 hours. 2. Connect the load to the system output.

3. For testing the battery capacity via the foil keyboard proceed as follows: Push and step

inside the stack with the cursor key or until:

is

shown in the display; where «???» is the back-up time of the last test. If no test has been performed before or the test has been aborted «???» is shown.

MAINTENANCE

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4. To start the battery capacity test push C until the display shows:

. Thereafter push for «ON». The rectifier will

change to battery operation and persists until the level «Low DC warning/Low DC Vaux warning» is reached. Thereafter the rectifier changes automatically to float charge voltage. The time in minutes, from the initiation of the battery capacity test to its end is shown in the battery capacity test menu. A time periode of at maximum 9’999 minutes (6 days + 22 hours) are measured. When the level «Low DC warning/Low DC Vaux warning» is reached the system changes to normal operation and the batteries will be recharged.

5. To stop an already running capacity test push (when the display shows «Battery capacity test

ON») the button C until the display shows: . Thereafter push

for «OFF».

6. If during the test a mains fault occurs or the button S1 «SYSTEM ON» has been pushed, the

test will immediately be aborted and no test result will be obtained. When reading out data of the battery capacity test in the display after a test has been aborted, «???» is shown, i.e. that no result was obtained.

Please note that after a battery capacity test it will take about 8...24 hours before the battery is recharged and the full back-up time is available again.

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REPLACEMENT OF COMPONENTS & PARTS


As a minimum GUTOR specifies that the following components and parts in the DC systems are replaced according to the time periods indicated:

Part Reference Designator

Normal Scope

NPP Scope

Replace Cycle

Fan Sub-assembly E0.. X X 5 years Battery Bank — X X Note 1 + 2 Backup RAM with Lithium Battery A070 (D034) X X 9 years DC Capacitor Module CB02 (1CB2, 2CB2) X X 9 years Air Filter — X X Note 3

Normal scope: Stationary on-shore installation with non-seismic requirements NPP scope: Installation in Nuclear Power Plants, seismic requirements, off-shore- or mobile application

These values refer to a maximum ambient temperature of 40° Celsius and a maximum load of 70%. If one of these values is continuously exceeded, the items mentioned must be replaced 1 year earlier.

Note 1: See battery specification of the battery manufacturer.

Note 2: With enabled battery monitor (option) the battery is automatically monitored. In the case of a faulty battery an alarm is generated.

Note 3: The air filters must be checked at least every 6 months. Dependent on the contamination they must be replaced immediately.

REPLACEMENT OF COMPONENTS & PARTS

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10year extended Replacement Schedule

Part Reference Designator

Normal Scope

NPP Scope

Replace Cycle Remarks

Main Controller with Chipset A070 X X 10 years Display-Unit (Frontpanel) A073 X X 10 years External Connection Board A025 X 10 years PSU / Interface A071 X X 10 years Rectifier Module (Driver) A030 X 10 years 12-pulse Rectifier Module (Driver) A031 X 10 years if applicable

Options

Part Normal Scope

NPP Scope

Replace Cycle Remarks

Harmonic Filters X X 10 years Static Transfer Switch X X 10 years TDS X X 10 years DC/AC Converter X X 10 years DC/DC Converter X X 10 years

according specific instructions

Replacement cycle intervals may be shorter and the scope may need to be extended if the system is exposed to harsh environmental conditions (vibration, climate, air-pollution). Consult GUTOR for an appropriate schedule in this case.

98-02-19 mp 98-11-04 mp 00-05-08 mp 06-10-30 mp 09-10-05 FME 98-02-19 GA 98-11-04 GA 00-05-08 GA 06-10-30 OBU 09-10-05 98-02-19 98-11-04 00-05-08 06-10-30 09-10-05

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SERVICE — TRAINING — CONTACT ADDRESSES


TABLE OF CONTENTS: 1. Service/Repairs

1.1 Call for After Sales Service and Return of Parts 1.2 Installation and Commissioning 1.3 Maintenance

2. Spare Parts 3. Training

3.1 Level 1: Operation 3.2 Level 2: Maintenance 3.3 Level 3: Service 3.4 Training for Design Engineers 3.5 Training for Installation Supervisors

4. Contact Addresses


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1. SERVICE/REPAIRS 1.1 CALL FOR AFTER SALES SERVICE AND RETURN OF PARTS

LABEL «RETURN OF PARTS»:

This label contains all necessary information for the return of parts or for contacting our service department. It is adhered behind the front door near the name plate. The necessary information to call for service action are mentioned on the name plate.

88

5-3

85

4


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1.2 INSTALLATION AND COMMISSIONING

Upon completion of all tests at GUTOR’s test bay the systems are shipped to the customer site by ship, air and or land transport. On site, GUTOR-trained and licensed field service engineers (FSE) perform numerous services such as:

♦ System unpacking and inspection after transportation ♦ Installation and, or installation supervision, to ensure that the assembly and installation of the

system is performed in a professional manner and according OEM requirements ♦ Mechanical and electrical commissioning checks on the isolated system ♦ Mechanical and electrical tests on the energised system ♦ Initial battery charging, or battery refreshing charge ♦ Battery discharge test including dummy load bank ♦ Complete functional test on the entire system ♦ Acceptance test with customer and authorities GUTOR‘s Installation, commissioning and testing services are designed according to customer needs to ensure best possible operational condition and to guarantee highest possible system availability and reliability.

1.3 MAINTENANCE

Maintenance covers several important aspects which have a deep impact on the availability and reliability of the entire system and the plant it services. The aspects of maintenance are divided in: Preventive Maintenance

The concept of preventive maintenance comprises planned maintenance tasks. Their purpose is to minimize breakdowns, excessive depreciation of the system and to maximize availability and reliability during the entire life span. The individual preventive maintenance jobs are performed according to the system maintenance manual and the OEM maintenance checklist. Preventive maintenance requires adequately-trained and experienced manpower, replacements of those parts with limited lifetime, tools and instruments to perform the respective work. Corrective Maintenance

Preventive maintenance cannot prevent a breakdown that is caused by external influences, operational error or a part failure. If an unexpected breakdown occurs it is important that the system is repaired, tested and brought back to operation immediately. Spare part Stocking

The successful performance of corrective maintenance requires the availability of critical parts and components. Hard and software updates

During the life of a system new features are being developed. Their implementation, or the replacements of outdated parts make older systems more reliable. Response time for Services and Material

Adequate response time is an important factor when it comes to remedial services. Hotline Services

For operational questions, remote advice, or the request of a field service engineer (FSE).


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1.3.1 TAILORED MAINTENANCE PACKAGES

We have bundled above maintenance aspects into three professional packages to cover individual customer requirements ranging from minimum service, to absolute peace of mind. You choose the package that suits your requirements. Pro-Life

This comprehensive package provides customers with an all-inclusive service, and total peace of mind from day one. GUTOR takes care of:

♦ All regular preventive maintenance including material and tools ♦ Software & hardware updates ♦ All corrective maintenance including material and tools ♦ Guaranteed service response time ♦ Guaranteed product response time ♦ Extended warranty for as long as the package contract lasts ♦ 24 hours, 7 days a week hotline Pro-Partner

With this package GUTOR caters for customers who maintain a GUTOR trained, own maintenance force capable of performing regular minor preventive works, and minor corrective jobs on all the systems by themselves. GUTOR take care of major preventive works and respond to unexpected major technical failures. The package includes:

♦ Major preventive maintenance including material and tools ♦ Software & hardware updates ♦ Major corrective maintenance including material and tools ♦ Guaranteed service response time ♦ Guaranteed product response time ♦ Extended warranty for as long as the package contract lasts ♦ 24 hours, 7 days a week hotline Pro-Flex

In cases where customers require fast and in-depth expertise to solve unexpected major failures GUTOR guarantee quick and reliable help as and when required. This package guarantees:

♦ Major preventive maintenance including material and tools ♦ Software updates ♦ Service and material response time ♦ 24 hours, 7 days a week hotline Pro-Basic

For customers who want to have organized an easy way to standardize the maintenance of their systems. GUTOR takes care of standard preventive checks and responds to unexpected major technical failures. The package includes:

♦ 1 standard preventive maintenance job per system & year ♦ Software updates ♦ Service and material response time ♦ 24 hours, 7 days a week hotline


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Pro-Light

For customers who want to have an easy access to service & support at any time. GUTOR takes care of updating the Software. The package includes:

♦ Software updates ♦ Service and material Response time ♦ 24 hours, 7 days a week hotline

2. SPARE PARTS Spare parts are differentiated according to the various plant requirements:

♦ Spares for commissioning ♦ Spares for preventive maintenance ♦ Spares for corrective maintenance as strategic stock

The selection of the correct spare parts is crucial. We gladly support you in defining the spare parts needed taking in consideration of your installed GUTOR systems and requirements.

3. TRAINING Uninterruptible Power Supply (UPS) systems from GUTOR are designed according to individual customer needs. Technical staff servicing and maintaining these systems therefore receive customized training based on specific requirements in relation to those particular systems installed on-site. GUTOR offers three different training levels concerning operation, maintenance, and service respectively. Each training course, as well as the documentation, are individually tailored based on the customer's installed fleet. All levels are appropriate for the operation and maintenance requirements of the GUTOR systems.

3.1 LEVEL 1: OPERATION

This course is composed of two parts. The first theoretical part introduces the participants to the various system operating modes, and provides information on how the system is built. In the second practical part, the training instructor demonstrates to the participants how to operate the system in a safe and confident manner.


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We recommend Level 1 training to all personnel working with (and in charge of) GUTOR systems. We also recommend clients having a «Pro-Life» maintenance contract to attend this course. Requirements: The participants should have a basic education in electronics. Special UPS knowledge is not necessary.

3.2 LEVEL 2: MAINTENANCE

This course builds on the information provided during Level 1. Participants learn the important functions of the major UPS components. They also receive information regarding maintenance work and maintenance intervals. Upon completion of this course, participants are capable of resolving simple system errors. We recommend Level 2 training to clients having at least a «Pro Partner» maintenance contract. Requirements: Level 1 is a prerequisite for Level 2, and shall be completed first. The participants should have a solid education in electronics.

3.3 LEVEL 3: SERVICE

In Level 3 training participants learn how to analyze and repair system errors. In addition, the training instructor explains how the system can be calibrated. Upon completion of this course, participants are capable of performing most repair and maintenance work by themselves. We recommend Level 3 training to clients having as a minimum a «Pro Light» maintenance contract. Requirements: Level 1 and Level 2 are prerequisites for Level 3, and shall be completed first. The participants should have a solid education in electronics.

3.4 TRAINING FOR DESIGN ENGINEERS

This training course conveys valuable system solution know-how about UPS systems, intended for Design Engineers. This knowledge is useful when evaluation new systems and/or expanding existing systems. Participants learn in detail about functions and characteristics of the system, as well as the various standard system configurations. An explanation of the important aspects of system options and basic battery rules are also included. Requirements: The participants should have a solid education in electronics.


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3.5 TRAINING FOR INSTALLATION SUPERVISORS

This training course mainly focuses on the installation of a GUTOR system and its batteries. The Installation Supervisors learn how to perform proper mechanical checks on the system. Furthermore, they discover the climactic conditions for which the life-span of the system can be optimized. Requirements: The participants should have a solid education in electronics.

For detailed description please contact our customer service

4. CONTACT ADDRESSES GUTOR Electronic LLC Hardstrasse 72-74 5430 - Wettingen / Switzerland Internet : www.gutor-service.com E-Mail : [email protected] Phone: ++ 41 56 437 34 34 Fax: ++ 41 56 437 34 21 Contact address in Malaysia: GUTOR Electronic Asia Pacific Sdn. Bhd. No. 19, Jalan Juruukur U1/19, Seksyen U1 Hicom Glenmarie Industrial Park

40150 Shah Alam, Selangor, Malaysia. Phone : +(6) 03 556 90 331 Fax : +(6) 03 556 90 332 Further Offices in: China, Brazil, Germany, India, Japan, Mexico, Nigeria, Qatar, Russia, U.S.A.,

U.A.E.

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TROUBLE-SHOOTING


TABLE OF CONTENTS: 4A-1110045001/20GB TROUBLE-SHOOTING (7SA9043GB)

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TROUBLE-SHOOTING

DC POWER SUPPLY, Type: SDC 125-1200-R

TABLE OF CONTENTS: 1. Elimination of simple Malfunctions

2. Trouble-Shooting at Alarm Indication

TROUBLE-SHOOTING

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1. ELIMINATION OF SIMPLE MALFUNCTIONS

Depending upon the system configuration, the switches mentioned in this description can be circuit breakers or switch-disconnectors (fuse switch-disconnectors) and the designation can be made according to customer's request see «Single line diagram».

RECTIFIER DOESN'T START

REASON: ♦ Rectifier input switch Q001 open ♦ Rectifier mains voltage out of tolerance or wrong phase

sequence ♦ Overtemperature signalization of rectifier power components ♦ Supply voltage for the electronics fails or is out of tolerance ♦ Plug connection of the electronics to the rectifier bridge

SHUTDOWN CONDITION

♦ Phase order wrong ♦ Mains out of tolerance ♦ Mains frequency out of tolerance ♦ Charger not synchronous to mains ♦ Overtemperature ♦ High DC shutdown ♦ DC fuse blown ♦ Missing phase ♦ Control loop error ♦ Ram1 corrupt

2. TROUBLE-SHOOTING AT ALARM INDICATION

TROUBLE-SHOOTING

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Alarm Indication Alarm #: / Error in the System Source of Error Test Possibilities Location RECT MAINS FAULT (AC POWER FAIL) (30secs)

1: Phase order not correct ♦ Wrong wiring ♦ Check phase order ♦ Interface A071: X003, F001, F002, F003

2: Mains voltage out of tolerance ♦ Input voltage out of tolerance ♦ Check voltages 3: Mains frequency fault ♦ Input frequency out of tolerance ♦ Check frequency and SYNC LED on controller A070 ♦ Q001, Controller A070 44: Mains phase missing ♦ Input switch Q001 open ♦ Check input switch Q001 ♦ Q001 53: Synchronization error ♦ Input frequency fluctuations ♦ Check frequency and SYNC LED on controller A070 ♦ Q001, Controller A070

♦ Load too high ♦ Check load, if system is in current limitation mode RECTIFIER FAILURE (5secs)

5: Voltage deviates more than ± 3% of nominal voltage without current limitation and no «RECT. MAINS FAULT»

♦ Input voltage low but in tolerance ♦ Check input voltage ♦ Interface A071: X003, F001, F002, F003

♦ System OFF (also due to shutdown) or System in standby

♦ Check operation mode and evaluate shutdown cause (Log stack)

♦ Rectifier or PSU faulty ♦ Check current ripple (6-pulse: 300/360Hz, 12-pulse: 600/720Hz)

♦ Q001

♦ Check PSU LED's (PSU_OK_AC/PSU_OK_DC) ♦ Interface A071 ♦ Check output voltage ♦ Interface A071: X009, F014,

F015 ♦ Load too high (also short-circuit) ♦ Check load, if system is in current limitation mode ♦ Current sensor P001 (P002) DC OUT OF TOLERANCE

(5secs) 12, 14, 20: Output voltage is higher than the high DC warning level or lower than the low DC warning level

♦ System OFF (also due to shutdown) or System in standby

♦ Check operation mode and evaluate shutdown cause (Log stack)

♦ Check current ripple (6-pulse: 300/360Hz, 12-pulse: 600/720Hz) ♦ Q001

♦ Rectifier or PSU faulty

♦ Check PSU LED's (PSU_OK_AC/PSU_OK_DC) ♦ Interface A071 ♦ Battery discharged / disconneted or switch Q004

(Q005) open during battery operation ♦ Check battery voltage ♦ Q004 (Q005)

♦ Check output voltage ♦ Interface A071: X009, F014, F015

TROUBLE-SHOOTING

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Alarm Indication Alarm #: / Error in the System Source of Error Test Possibilities Location DC FUSE BLOWN 18: Rectifier output fuse F026 (F027) ♦ Fuse trip indicator not connected ♦ Check fuse trip indicator ♦ Rectifier output fuse F026

(F027) (5secs) blown ♦ Load too high (also short-circuit) ♦ Check load ♦ Current sensor P001 (P002)

♦ Trip indicator on Rectifier output fuse F026 (F027)

RECT OVERCURRENT (30secs)

16: Total current limiter active ♦ Load too high (also short-circuit) ♦ Check battery and load current ♦ Current sensor P001 (P002) ♦ Battery current transformer

P003 LOAD SHARING FAILURE

47: Loadsharing deviates more than ± 10% ♦ Wrong calibration of output voltage ♦ Check output voltages at the common output point ♦ Common output point

(only redundant Rect) (5secs) ♦ Wrong temperature compensation ♦ Check temperature measurement of both chargers ♦ External Connection Board

A025 : X006:3 and X006:4 ♦ One or more cells of the battery defective ♦ Check individual cell voltages ♦ Battery ♦ Battery discharged ♦ Check battery voltage ♦ Q004 (Q005)

BATTERY DISCHARGED (5secs)

14, 20: Battery voltage dropped below the «Low DC Warning/Low DC Vaux Warning» level

♦ System OFF (also due to shutdown) or System in Standby

♦ Check operation mode and evaluate shutdown cause (log stack)

43: Battery monitor test result is battery defective

♦ Battery monitor not reset after installation of new battery

♦ Reset battery monitor (User stack) only possible if ABM installed

BATT DISCONNECTED (5secs)

19: Battery breaker Q004( Q005 ) open or tripped

♦ Breaker open or auxilary contact not connected ♦ Check breaker and auxilary contacts ♦ Battery ♦ Q004 (Q005), X002 ♦ External Connection Board

A025: X004:1 and X004:2 CONTROL POWER FAULT (5secs)

22, 23: One of the electronic supplies (+5V/±15V) is outside the tolerance range, or the feeding of one of the power supplies is not available (Rectifier mains or Battery)

♦ Connector cable missing to one or both of the two PSU's

♦ Check LED's on interface (PSU_OK_AC, PSU_OK_DC)

♦ Try to start DC supply manually (if DC supply fault) by pressing S1

♦ Interface A071

♦ Mains not available or input breaker Q001 open ♦ Measure input voltages for the two supplies ♦ Interface A071

TROUBLE-SHOOTING

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Alarm Indication Alarm #: / Error in the System Source of Error Test Possibilities Location ♦ Battery disconnected or battery switch Q004

(Q005) open ♦ Interface A071 / X001:

F006/F006 ♦ Interface A071 / X002:

F018/F019 OVERTEMPERATURE (5secs)

6, 7: Charger 0° or 30° overtemperature ♦ Overtemperature of one component ♦ Check size of components, load and thermoswitches ♦ Thermoswitches of power components T001, F001, V001, A030, A031

10: Transformer overtemperature ♦ Air inlet obstructed, fan problem ♦ Check air inlet and fan 11: Choke overtemperature ♦ Ambient temperature too high ♦ Check ambient temperature ♦ Interface A071: X018- X025 49: Output diode overtemperature (if

available) ♦ Sensor contacts not connected ♦ Check wiring ♦ A030, Interface A071: X006

♦ Check fans ♦ Fans E001 - E008 FAN FAILURE (COOLING SYSTEM FAILURE) (30secs)

24-31: Fan failure 1-8 ♦ One of the fans is blocked, rotating too slow or connected wrongly ♦ Check connection (fan surveillance cable connected

always starting at position 1) ♦ A050 - A057, Interface A071:

X018 - X025

♦ Fan supply failure ♦ Check fan supply transformers (T050/T051) ♦ T050: F010, F011, T051: F012, F013

14, 20: Low DC warning ♦ Load too high (also short-circuit) ♦ Check if system is in current limitation LOW DC VOLTAGE (Option 1) ♦ System OFF (also due to shutdown) or System in

Standby ♦ Check operation mode and evaluate shutdown cause

(Log stack)

♦ Rectifier or PSU faulty ♦ Check PSU LED's and voltages (PSU_OK_DC, PSU_OK_AC)

♦ Controller A070

♦ Battery discharged / disconneted or breaker Q004 (Q005) open during battery operation

♦ Check battery voltage ♦ Q004 (Q005)

HIGH DC VOLTAGE (Option 2)

12: High DC warning ♦ DC voltage too high feed from charger ♦ Check DC voltage ♦ Interface A071: X009:1 and X009:3, F014

♦ Check if load has disconnected and battery is connected

♦ Q003, Q100 and Q004 (Q005)

♦ Check why load has disconnected (fuse, breakers) ♦ Power fuse F026 (F027) ♦ Check input transformer ♦ Q001

TROUBLE-SHOOTING

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Alarm Indication Alarm #: / Error in the System Source of Error Test Possibilities Location ♦ If high DC shutdown check input phase order (L1-L2-

L3 and not eg L2-L3-L1)

♦ DC voltage too high feed from load ♦ Disconnect the load ♦ Q003, Q100 Q003 TRIP (Option 5) 45: Load MCB error ♦ Q003 open or auxilary contact not connected

♦ Q003 auxilary contact is not connected to its input on the interface

♦ Q003 auxilary contact is only connected to an Option input

♦ Check wiring ♦ Check whether Q003 has tripped

♦ Q003 ♦ Interface A071: X005

Q001 TRIP (Option 6) 39: Option input error ♦ The rectifier input switch Q001 is open. It indicates whether the MCCB has tripped.

Also the red LED 9 « MAINS MCCB OFF» is illuminated

♦ Check wiring ♦ Check whether Q001 has tripped

♦ Q001 ♦ Interface A071: X016: 3/4

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TEST DOCUMENTATION


jkaur

Text Box

TEST DOCUMENTS WILL BE PROVIDED AFTER THE SYSTEM HAS BEEN TESTED.

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SCHEMATIC / PARTS LISTS / SPARE PARTS LISTS



TABLE OF CONTENTS: SCHEMATIC see SCHEMATIC DIAGRAM 1110045001/00

PARTS LISTS & SPARE PARTS LISTS see «CUSTOMER PARTS LIST» 1110045001/50

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BATTERY DOCUMENTATION


TABLE OF CONTENTS:

♦ BATTERY MANUFACTURER'S INSTALLATION AND OPERATING INSTRUCTIONS

Specifications:

Nominal voltage UN: 2.0 V x number of cellsconnected in series

Nominal Capacity CN = C10:

10 hour discharge (see type label)

Nominal discharge current IN = I10:

Final discharge voltage Us: 1.80 V/Cell

Nominal temperature TN: 20°C

“LA” antimony content < 3% in the grids(material carriers) of the pos. electrodes

Observe operating instructionsand display visibly near to thebattery.Work on batteries only afterinstruction by qualified staff.

No smoking. No open flame,embers or sparks in the vicinity ofthe battery, to avoid risk of explo-sion and fire.

Wear eye protection and protec-tive clothing when working withbatteries.Observe accident preventionregulations, also EN 50272-2,VDE 0105 Part 1

Acid splashes in the eyes or onthe skin must be washed out oroff with plenty of water. Then seea doctor immediately. Acid splas-hes on clothing should be washed out with water!

Explosion and fire risk, avoidshortcircuits.Warning! Metal parts of the bat-tery cells are always live. Neverplace foreign objects or tools onthe battery.

Electrolyte is highly corrosive.

Monobloc batteries/cells are veryheavy!Ensure secure installation! Useonly suitable conveying equip-ment!

Dangerous electrical voltage.

Installation by:

on:

Commissioning by:

on:

Safety markings affixed by:

on:

Non-compliance with operating instructions,repairs made with other than original parts,tampering or use of electrolyte additives (alle-ged enhancers) render the warranty null andvoid.

1. Commissioning

Before commissioning all cells/blocks mustbe inspected for mechanical damage, cellsmust be connected with the correct polarityand connectors firmly seated. The followingtorque applies for screw connectors:

20 Nm ± 1 Nm

If necessary the terminal covers must be puton. Check the level of electrolyte in all cellsand top up to the maximum level with purifiedwater (acc. to DIN 43530 Part 4) if necessa-ry.

With charger off and loads isolated, connectbattery to the direct current power supply,maintaining correct polarity (positive terminalto positive post). Switch on the charger andcharge as described in section 2.2.

2. Operation

For the operation of stationary battery instal-lations DIN VDE 0510 Part 1 (draft) and EN50272-2 apply.

2.1 Discharging

Never allow the final discharge voltage of thebattery to drop below that assigned for thedischarge current. Unless the manufacturerhas specified otherwise, no more than thenominal capacity is to be consumed. Chargeimmediately after discharge, including partialdischarge.

2.2 Charging

All charging procedures may be used withtheir limit values as specified in

DIN 41 773 (IU characteristic)

DIN 41 774 (W characteristic)

DIN 41776 (I characteristic)

Depending on charger type and charging cha-racteristic, alternating currents flow throughthe battery during charging and are superim-posed onto the charging direct current. Thesesuperimposed alternating currents and thereaction of the loads lead to additional hea-ting of the battery and strain on the electro-des with possible resulting damage (see sec-tion 2.5).

Depending on the system at hand, chargingmay be carried out under the following opera-ting modes

a) Stand-by parallel operation and floatingoperation

Here the load, direct current source and bat-tery are continuously connected in parallel.This means that the charging voltage is theoperating voltage of the battery and at thesame time the battery system voltage.

Under stand-by parallel operation, the directcurrent source is at any time capable of supplying the maximum load current and thebattery charging current. The battery only sup-plies current when the direct current sourcefails. The charge voltage should be set at2.23 V ± 1% (2,25 V ± 1% for USV-bloc andOSP.XC cells) x number of cells in series, mea-sured at the battery’s terminals.

To reduce the recharging time a chargingstage can be applied in which the chargingvoltage is max. 2.33 to 2.4 V x number ofcells (stand-by parallel operation with rechar-ging stage). Automatic changeover to thecharging voltage of 2.23 V ± 1% (2,25 V ±1% for USV-bloc and OSP.XC cells) x numberof cells in series follows.

With floating operation the direct currentsource is not able to supply the maximumload current at all times. The load currentintermittently exceeds the nominal current ofthe direct current source.

During this period the battery supplies power.It is not fully charged at all times. Therefore,depending on the load, the charge voltagemust be set at approx. 2.25 to 2.30 V x thenumber of cells connected in series.

b) Switch mode operation

When charging, the battery is separated fromthe load. Towards the end of charging, thecharge voltage of the battery is 2.6 - 2.75V/cell. The charging process must be monito-red (see under 2.4, 2.5 and 2.6). On rea-ching a state of full charge, charging shouldbe terminated or a switch made to float char-ging as under section 2.3.

c) Battery operation (charge/discharge ope-ration)

The load is supplied only by the battery. In thiscase, towards the end of charging, the char-ge voltage of the battery is 2.6 - 2.75 V/cell.The charging process must be monitored (seeunder 2.4, 2.5 and 2.6). On reaching a stateof full charge, charging should be terminated.The battery may be connected to the load ifrequired.

2.3 Maintaining the full charge (floatcharging)

Devices complying with the provisions of DIN41773 must be used. They are to be set sothat the average cell voltage is 2.23 V ± 1%(2.25 ± 1% for USV-bloc and OSP.XC cells),

CN

10 h

Vented stationary lead acid batteries

Operating Instructions

and so that electrolyte density does not fallover longer periods of time.

2.4 Equalising charge

Because it is possible to exceed the permit-ted load voltages, appropriate measures mustbe taken, e.g. disconnection of the load.

Equalising charges are necessary afterexhaustive discharge and/or after inadequatecharging; they can be carried out as follows:

- at a constant voltage of max. 2.4 V/cell forup to 72 hours

- with the I or W characteristic in accordancewith Table 1

Should the maximum temperature of 55°C beexceeded, the charging process must beinterrupted or continued with reduced currentor a temporary switch made to float chargingto allow the temperature to drop. The end ofequalising charging is reached when the elec-trolyte densities and the cell voltages no longer rise within a period of 2 hours.

2.5 Superimposed alternating currents

While recharging up to 2.4 V/cell in accordan-ce with operating modes a) to c), the actualvalue of the alternating current is occasional-ly permitted to reach a max. 20 A per 100 Ahnominal capacity (for shortest time).

Up to 2.4 V/cell, 10 A per 100 Ah nominalcapacity may not be exceeded. In fully char-ged state with a charge voltage of 2.23 to2.30 V/cell, the effective value of the alterna-ting current must not exceed 5 A per 100 Ahnominal capacity.

2.6 Charging currents

Charging currents are not limited up to 2.4V/cell. If charge voltages of 2.4 V/cell areexceeded, greater water decomposition willoccur. The charging currents per 100 Ah nomi-nal capacity shown in Table 1 should not beexceeded.

2.7 Temperature

The recommended operating temperaturerange for lead-acid batteries is 10°C to 30°C.The technical data apply to the nominal tem-perature of 20°C. The ideal operating tempe-rature range is 20°C ± 5°C.

Higher temperatures will reduce battery ser-vice life. Lower temperatures reduce the avai-lable capacity. The maximum temperature of55°C must nor be exceeded.

2.8 Temperature-related charge voltage

Within the operating temperature range of10°C to 30°C, temperature-related adjust-ment of the charge voltage is not necessary.

If the temperature range is below 10°C and/orabove 30°C, the charge voltage should beadjusted. The temperature correction factor is(-0.004 V/Cell per K).

If the temperature is constantly above 40°C,the factor is (-0.003 V/Cell per K).

2.9 Electrolyte

The electrolyte is dilute sulphuric acid. Thenominal density of the electrolyte is based ona temperature of 20°C and nominal electroly-te level in fully charged condition, maximumdeviation ± 0.01 kg/l. Higher temperatureswill reduce electrolyte density, while lowertemperatures increase electrolyte density.The associated correction factor is 0.0007kg/l per K.

Example: Electrolyte density 1.23 kg/l at 35°Ccorresponds to a density of 1.24 kg/l at 20°C.An electrolyte density of 1.25 kg/l at 5°C cor-responds to a density of 1.24 kg/l at 20°C.

3. Battery maintenance and inspection

Check the electrolyte level regularly. If it hasfallen below the lower electrolyte level mark itshould be topped up with purified water toDIN 43530 Part 4, max. conductivity 30μS/cm.

To avoid leakage currents keep the batteryclean and dry. Cleaning the battery should becarried out as specified in the ZVEI pamphleton battery cleaning.

Plastic battery components, in particular thecell containers, must only be cleaned withpure water.

At least every 6 months the following must bemeasured and recorded:- battery voltage- voltage of a few selected cells/monobloc

batteries- electrolyte density of a few selected cells/

monobloc batteries- electrolyte temperature of a few selected

cells/ monobloc batteries

The following must be measured and recor-ded annually:- voltage of all cells/monobloc batteries- electrolyte density of all cells/monobloc bat-

teries- electrolyte temperature of a few selected

cells/monobloc batteries

Should the float charge voltage of any cellvary by more than + 0.1 V or -0.05 V fromthe average value, customer services must becalled in.

Annual visual checks:- on bolted connectors (check that unsecured

bolt connectors are firmly seated)

- on battery installation or arrangement- on ventilation of the battery room.

4. Tests

Tests must be conducted in accordance withEN 60896-11. In addition, special testinstructions, e.g. as set out in DIN VDE0107 and DIN VDE 0108 should be obser-ved.

5. Faults

Should faults be detected in the battery or thecharging device, customer services should becalled in immediately. Measured data asunder section 3 simplify fault detection andelimination. A service contract with us facilita-tes the timely detection of faults.

6. Storage and taking out of operation

Should cells/batteries be stored or be takenout of operation for extended periods, theymust be stored fully charged in a dry, frostfreeroom. Direct sunlight must be avoided.

To prevent damage, the following chargingconditions should be chosen:1. Equalizing charges as defined under 2.4above, to be given four times a year. At ave-rage ambient temperatures in excess of20°C, monthly equalizing charges may benecessary.2. Float charging as under 2.3 above.

The period of use commences with delivery ofthe filled and charged battery from the HOPPECKE plant. Storage times are to beadded to the period of use in full. In addition,batteries require recharging.

7. Transport

Filled lead-acid batteries which are undama-ged, show no leaks and are firmly securedon pallets with protection against sliding,overturning and short-circuits are not trea-ted as dangerous goods for conveyance byroad as long as there are no dangerous tra-ces (acid, lye) visible on the outside of thepackage.

ATTENTION: It is essential that loads onroad vehicles are properly secured.

8. Technical data

The nominal voltage, the number of blocks,the nominal capacity (C10 = CN) and the bat-tery type can be obtained from the identifica-tion plate.

8.1 Example

Identification plate: 4 OPzS 2004 = number of positive platesOPzS = battery type200 = nominal capacity C10

(capacity for discharge with ten hours’ current(I10) over a discharge time of 10 h (t10)

Teil-

Nr.

7140204011/0

7.0

9/3

K

Prin

ted

in G

erm

any

Pb

Old batteries with this marking are recyclable goods and must be sent for recycling.Used batteries which are not sent for recycling are to be disposed of as special waste under the relevant regulations.

Chargingprocedure

I-charact.

W-charact.

Types OPzS, OPzS bloc,max.power, solar.power, OGi bloc HC, OGi bloc,OSP.HC, OSP.XC, USV bloc

5.0 A 6.5 A

7.0 A3.5 A

9.0 A4.5 A

Cellvoltage

2.6-2.75 V

bei 2.4 Vbei 2.65 V

GroE

HOPPECKE Batterien GmbH & Co. KG

P.O. Box 1140 · D-59914 BrilonBontkirchener Straße 1 · D-59929 Brilon-Hoppecke

Phone: + 49 (0) 29 63 61-3 74 Email: [email protected]: + 49 (0) 29 63 61-2 70 Internet: www.hoppecke.com

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CUSTOMER-SPECIFIC DOCUMENTATION / CERTIFICATES



TABLE OF CONTENTS:

♦ DECLARATION OF CONFORMITY

♦ DECLARATION OF CONFORMITY «Free of PCB»

♦ DECLARATION OF CONFORMITY «EMC»


P.O. No.: 11022

Project name: Conversion of Qurayyah Open Cycle Power Plant to Combined Cycle Power Plant – Project C End-User: Saudi Electric Company System: DC POWER SUPPLY (Rectifier / Charger) Installation: 125V Block-1 DCDB

Type Item No. GUTOR Ref. SDC 125-1200-R C10BTL01 & C10BTL02 1110045001-01…. 1110045001-06 SDC 125-1200-R C20BTL01 & C20BTL02 1110045002-01…. 1110045002-06 SDC 125-1200-R C30BTL01 & C30BTL02 1110045003-01…. 1110045003-06 SDC 125-1200-R C40BTL01 & C40BTL02 1110045004-01…. 1110045004-06 SDC 125-1200-R C50BTL01 & C50BTL02 1110045005-01…. 1110045005-06

We herewith confirm, that the goods are manufactured in accordance with the purchase

order and all of the relevant Buyer’s standards and requirements.

Wettingen, 2011-06-28

Cemal Yilmaz Muneet Asri Quality Assurance Project Engineer


P.O. No.: 11022



We herewith confirm, that the mentioned equipments are free of Polychlorinated Biphenyl

(PCB).




P.O. No.: 11022



We hereby declare that the performed tests for the above equipment are conform to the Generic Standards:

• IEC/EN 61000-6-4: Electromagnetic Compatibility (Emission) • IEC/EN 61000-6-2: Electromagnetic Compatibility (Immunity)



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30621127-000-3DT-EE-03584-000