Tu Nguon Benning

DSP Inverter System

For 19" Relay Racks

028-0009-220 Rev. B

Benning Power Electronics

11120 Grader Street

Dallas, TX 75238 USA

214.553.1444

800.910.3601

This manual contains

important safety instructions

that should be followed during

installation and maintenance

of the Power System.

Operations and Maintenance Manual

Preface

Congratulations and thank you for purchasing a Benning DSP Inverter System. We at Benning are committed to supporting the needs of our customers by supplying the customer with the proper information and documentation needed to properly install and operate the unit purchased. Important: It is imperative that all the information be observed.

This avoids: Danger during installation and operation. Danger to operating personnel. Downtime. Increases the reliability and lifespan of the system.

This manual explains all the necessary information to unpack, install, and operate the Benning DSP Inverter System and related components. Refer questions outside the scope of this manual to our Customer Service Department. Customer Service:

We are committed to excellence in dependability and customer satisfaction. If you have any questions or problems, please contact the Customer Service Department at: 1.800.910.3601 or 214.553.1444 for more information.

Please read all instructions before installing or operating the equipment and save these manuals for future reference.

Revision Date Originator Approver

A 05.14.08 C.Tumey D.Almond

B 02.25.10 C.Tumey E.McDonlad

Publication Document: Version 1.0

Copyright © 2007 Benning Power Electronics

Proprietary Information: This manual contains proprietary information which is protected by copyright law. All rights are reserved. No part of this manual may be photocopied, reproduced, or translated to another language without prior written consent of Benning Power Electronics. Specifications in this manual are subject to change without notice.

Table of Contents

1 SAFETY NOTES AND MARKINGS ............................................................................................................ 1

2 GENERAL ..................................................................................................................................................... 3

2.1 SYSTEM CONFIGURATIONS.......................................................................................................................... 4

3 THE COMPONENTS OF THE INVERTER SYSTEM .............................................................................. 6

3.1 RACK DESIGN ............................................................................................................................................. 6 3.1.1 Design of the Unit ........................................................................................................................... 7

3.1.2 External Connections for Individual Input ............................................................................... 9

3.2 INVERTER ................................................................................................................................................... 12 3.2.1 Design of the Inverter Unit ......................................................................................................... 13

3.2.2 Operating Elements of Inverter ................................................................................................. 14

3.3 TECHNICAL DATA ...................................................................................................................................... 17 3.4 MCU2500/SNMP ADAPTER .................................................................................................................... 19

3.4.1 SNMP Adapter .............................................................................................................................. 19

3.4.2 MCU 2500 ........................................................................................................................................ 21

3.4.3 SNMP Connected .......................................................................................................................... 22

4 SET UP ...................................................................................................................................................... 22

4.1 DEVICE SETTINGS ...................................................................................................................................... 23 4.2 CONNECTING THE INVERTER SYSTEM ....................................................................................................... 24 4.3 INSTALLATION OF THE UNIT ....................................................................................................................... 26 4.4 COMMISSIONING OF THE INVERTER SYSTEM ............................................................................................ 28

4.4.1 Inverter System ............................................................................................................................. 28

4.4.2 Commissioning Report ............................................................................................................... 29

5 MAINTENANCE AND REPAIR ............................................................................................................... 31

5.1 USE OF THE MAINTENANCE BY-PASS SWITCH (IF INSTALLED) ............................................................... 31 5.2 EXCHANGE OF UNITS ................................................................................................................................. 35 5.3 UPGRADING THE SYSTEM .......................................................................................................................... 35

6 PARTS LIST .............................................................................................................................................. 36

DSP Inverter System For 19" Relay Racks

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1 Safety Notes and Markings

Explanation of the symbols used:

Indicates safety instructions which must be followed to avoid danger to persons!

Indicates instructions which must be followed to avoid material damage!

All specifications in these operating instructions must be observed at all times!

Index of abbreviations:

A Amps AC Alternating Current DC Direct Current I Current INV Inverter CB Circuit Breaker SNMP Simple Network Management Protocol UDC DC voltage UAC Mains Mains Voltage UAC Mains Load Voltage V Volts W Watts


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The inverter system is an electronic appliance that carries voltages and currents dangerous to humans.

The following instructions must therefore be followed at all times!

1. The inverter system should be installed, operated, repaired and maintained in strict accordance with the instructions in this document.

2. Ensure that only fully trained and qualified personnel have access to the system. Only qualified and authorised personnel should be able to open the units.

3. Even when the inverters are switched off, some of its interior components remain live as long as they are connected to the mains supply or the battery.

4. Capacitors may be charged even when the unit is disconnected. These must be correctly discharged by a qualified electrician before the connections or terminals are touched.

5. When working with the unit, use properly insulated tools at all times which are suitable for the levels of voltage concerned.

6. All persons working with the unit must be familiar with the first-aid procedures to be adopted in cases of accidents involving electricity.

7. Always observe the regulations of the local power-supply company as well as other safety regulations.

8. High Leakage Current – Earth Connection essential before connecting supply.

9. Permanently connected equipment – A readily accessible disconnect device shall be incorporated in the building installation wiring.

10. Multiple Power Sources – All power sources (AC and DC) must be removed prior to servicing this equipment.


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2 General

The inverter system from the DSP product line is a compact AC power supply for a wide range of telecommunication and industrial applications. The various possible system configurations permit adaptation to the requirements of each particular application.

The output power of the inverter system can be extended by adding 1kVA (2.5kVA) inverters (INV) into the prepared racking units up to a maximum rating of 5kVA (12.5kVA). The DC input voltage is 48V.

The inverter modules utilize digital signal processors (DSP) programmed with the appropriate algorithms carry out control and monitoring of the inverter system.

The mutual communication between the individual components takes place via a CAN-BUS system (Controller Area Network) which ensures a high level of immunity with respect to disturbance.


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2.1 System Configurations

Various systems can be assembled with the individual components of the inverter system used as building blocks, to provide various ranges of power and redundancy.

The simplest systems are single operation (1 inverter) and parallel operation of several inverters without electronic switchover device. Only inverters with the same power rating can be connected in parallel.

Up to 5 inverters can be connected in parallel in a corresponding racking unit.

Figure 1: Single and parallel operation of up to 5 inverters in one racking unit

The maximum system power rating with simple parallel operation of the inverters is 5 kVA or 12.5 kVA. If two racking units are used, maximum system capacity could be increased to 12.5kVA to 25kVA by paralleling the two racking units (an external junction box is required for this arrangement).

5


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The two shelves can be connected to different DC supplies.

Figure 2: Parallel operation of up to 10 inverters in 2 part systems (racking units).

Figure 3: Typical inverter system with 5 parallel-connected 1kVA inverters.

5 5


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Figure 4: Typical inverter system with 5 parallel operated inverters.

3 The Components of the Inverter System

All components are installed in 19” rack mounted rack. The inverters designed as HOT-PLUG slide-in units.

The components of the inverter system:

19” rack mounted rack for accommodating inverters

Inverters of the series TEBEVERT 1000 or TEBEVERT 2500

MCU (optional)

SNMP (optional)

3.1 Rack Design

The rack has been designed to accommodate 5 inverters. The respective shelves for the 1kVA and 2.5kVA inverters are different and cannot be interchanged.

MCU/SNMP is located behind

panel.

Service Port


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3.1.1 Design of the Unit


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Figure 5: Mechanical dimensions for housing.


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3.1.2 External Connections for Individual Input

Figure 6: Rear view of the Inverter Shelf.

1 (RJ45); CAN bus for inverter; plugs are required only when the inverter system contains at least 2 inverter shelves in parallel. Use CAN bus cable to connect two shelves together using this connector. This is also used for the external alarm contact card (Optional).

5

4

3 2 1

6


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2 D-SUB plug connector; serial interface RS232 Via this interface that status of the inverter system can be read out for servicing, and settings can be made.

3 Alarm output connector.

Connector strip for the potential free message lines of the inverter system Central fault signal of the inverters 4-5: no fault 4-6: fault Not Used

4 DC Input Terminals; 1/4”-20 stud on .625” cc for two hole lugs, up to 2/0 AWG stranded cable. The torque requirement is 50 in-lbs.

5 Output Terminal Blocks; up to 2/0 AWG stranded cable (refer to side of terminal block for torque requirements).


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6 Digital I/O Card (RELIO); for auxiliary inputs and dry contacts.

K1 = Urgent Alarm

K2 = Non-Urgent Alarm

K3 = Inverter Failure

K4 = Bus Bar Voltage <46.0V


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3.2 Inverter

The inverter converts DC voltage of 48VDC or 60VDC into AC voltage of 120VAC or 230VAC and 50Hz /60Hz.

This is done via an internal programming. On request by the user, any other combination of output parameter values can be programmed within the permitted range.

.

Figure 7: Inverter TEBEVERT


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3.2.1 Design of the Inverter Unit

Figure 8: Dimension diagram of the inverter 1kVA (2.5kVA)


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3.2.2 Operating Elements of Inverter

All terminals and operating elements are installed on the front or rear side of the inverter.

Figure 9: Front view of the inverter

1

2 3 3 2

1


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1 Unit switch ON/OFF Each inverter can be switched on and off individually with its unit switch.

2 LEDs for indicating the inverter status

UUULEDUUU UUUColorUUU UUUFunctionUUU

red Fault

green Output voltage present and connected through to the

load .

green UUULED in continuous operation:UUU The output voltage of the inverter is phase locked to the other inverters in the system; parallel operation

UUULED in flashing mode:UUU The inverter has MASTER functions

green The input voltage lies in the tolerance range

green Inverter on

3 LEDs for signalling the actual inverter output power

red; the inverter is overloaded if the LED is flashing yellow; when this LED is lit the inverter is loaded nearly to the limit; flashing of the LED indicates a configuration error of the inverter. green; the lit LEDs indicate the loading level.

PBBBmax BBB


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Figure 10: Rear view of the inverter

1 Connector strip; inverter output

2 Socket plug; Message and signal lines

3 Connector strip; DC input of the inverter

1

2

3


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3.3 Technical Data

Table 1: For 120VAC Inverter System.


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Table 2: For 230VAC Inverter System.


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3.4 MCU2500/SNMP Adapter

The MCU2500 and SNMP Adapter is located on the right hand side of the

DSP Inverter Shelf (if installed). These components are accessible by the screws and sliding out the entire module.

3.4.1 SNMP Adapter

The SNMP Adapter is briefly defined in this section of the

installation manual and is explicably defined in the operations manual provided with this unit.

Figure 11: Top End View of the SNMP Adapter.

1. 9V-36V (DC Power Supply Input).

*12V when connected to MCU.

2. COM1 (RS232 Null Port).

3.

1.

2.


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3. SW1 (Configuration DIP Switch).

Switch

1

Switch

2 Description

On Off Normal

operation

Off Off

COM2

Configuration

(See SNMP

Operation

Manual)

Figure 12: Bottom End View of the SNMP Adapter.

1. LAN (RJ45 Network Cable Port).

2. COM2 (Mini-DIN Cable Port).

3. Error LED (On = Error or Booting).

4. Link LED (Flashing = Normal Operation).

5. AUX (Unused).

3.

5. 1.

4. 2.


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3.4.2 MCU 2500

Locate the MCU 2500 in the DSP by removing the faceplate on the right hand side. The MCU 2500 will be mounted on the behind the faceplate. .

Figure 13: The MCU 2500 PCB.

1. Connector X3 for DC Power Supply Cord.

Figure 5: MCU 2500 X3 matting connector.

2. Connector X110 for RS232 connection to faceplate.

1.

2.

Power Inputs

12V

Ground

Pin 1


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Figure 14: RJ45 Network Cable Routing.

3.4.3 SNMP Connected

Replace the DSP faceplate. Verify all wires and cables are free from foreign objects that may damage or decrease the integrity of the power or communication between the MCU 2500 and SNMP Adapter. Now observe the status LED’s mentioned in Figure 12. The Error LED (Red) will light for a small period during boot up and then the Link LED (Green) will begin to flash for normal operation. Enjoy your new SNMP Adapter.

4 Set Up

Caution! The safety instructions must be observed at all times during assembly, installation and commissioning.

After assembly, installation and commissioning of the inverter system, all components are unreservedly ready for operation. No additional settings and readjustments are necessary during operation under all operating conditions.

The site chosen for the inverter system must have a solid and level floor. The inverter system is designed for operation in closed and dry rooms. The max. permitted ambient temperature is 40°C. When selecting its location, ensure that it

LAN (RJ45 Cable Connection)

Customer LAN (RJ45 Cable Connection)

Load MIB file into SNMP Monitoring

Software (provided by customer).

Load IP Address (provided by

customer) and login via web browser.


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is not exposed to corrosive substances and that the flow of cooling air is not restricted.

4.1 Device Settings

Attention! Each alteration of the settings may only be carried out by qualified personnel. The changed settings must be entered on the configuration sheet of the inverter system. This is essential to ensure that the current system configuration is always unambiguously determinable. Specific replacement of components and fault tracing are facilitated.

All components of the inverter system have been set in the factory to suit the values and operation modes specified by the user, or to standard values. For operation as specified it is not necessary to change the settings.

Some settings and functions must be checked if system configurations are to be changed, or new systems are to be configured with individual components, or components are to be replaced or supplemented.

UUURack

Depending on the desired system configuration, the types of the racking units may differ. In order that the redundant CAN-BUS systems for the data communication of the individual units can function properly, the line ends of the CAN-BUS systems on each racking unit must be provided with terminating resistor/jumper according to a definite scheme. In addition thereto, the racking units must be connected to data cables in a suitable manner.

These measures are necessary only when constructing an inverter system completely new. Since this is rarely carried out by the user, it is not described further here.


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UUUInverter

Each inverter is set to default values at the factory according to the values specified in the default section. For an inverter system without static by-pass switch these values can be changed. To determine the set values, consult the configuration.

• Output voltage • Frequency • Switching thresholds of the input voltage monitoring

4.2 Connecting the Inverter System

Caution! The power source circuits (mains input cable; DC supply) must be provided with a disconnecting device. The disconnecting devices must be readily accessible in the vicinity of the inverter system. If a battery is connected, then the instructions concerning the installation and maintenance given by the manufacturer of the battery must be observed.

The internal wiring of the inverter system is installed in the factory. Depending on the maximum system power, the conductor cross-sections and fuse ratings of the supply cables must be dimensioned accordingly.

Inverter systems with 1kVA inverters

System design

Min. cross sectionTPTPTP

1PTPTPT Max. external fuse rating

Mains input cable

DC supply cable

Mains input cable

DC supply cable

48V/1kVA 1.5mm² 2.5mm² 6A 25A

48V/2kVA 1.5mm² 6mm² 10A 50A

48V/3kVA 1.5mm² 16mm² 16A 80A

48V/4kVA 2.5mm² 25mm² 20A 100A

48V/5kVA 2.5mm² 25mm² 25A 125A

TPTPTP

1PTPTPT In order that the voltage drop from the DC supply cable is not unacceptably large, larger cross-

sections should be used, depending on the conditions at the installation site.


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Inverter systems with 2.5kVA inverters

System design

Min. cross section Max. external fuse rating

Mains input cable

DC supply cable

Mains input cable

DC supply cable

48V/2.5kVA 1.5mm² 10mm² 16A 63A

48V/5kVA 2.5mm² 35mm² 25A 125A

48V/7.5kVA 6mm² 50mm² 50A 200A

48V/10kVA 10mm² 95mm² 50A 250A

48V/12.5kVA 10mm² 120mm² 63A 315A

For the protection of the load circuits, attention must be paid to the selectivity for the mains protection!

The maximum permitted loading of the potential free fault contacts is 250VAC/8A. The maximum permissible DC load must be determined from the load limit curve of the relay. (The characteristic for a single contact applies.)

Figure 15: Load limit curve of the contacts of the potential free fault contacts.


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4.3 Installation of the Unit

Caution! Before installing the units, the entire inverter system must be switched free of voltage. Neither the mains (if existing) nor the DC supply may be connected and must be disconnected if they were connected.

It is assumed below that the configuration of the inverter system has been defined and that the corresponding racking units are installed and wired up in a 19” rack system.

Attention! Are all inverters set for the same voltage and frequency? Have all device settings been made and checked according to Section 4.1?

• Push the optional static switch into the outermost right position of the corresponding racking unit. The front panel must be flush with the frame of the racking unit.

• If there are two parallel shelves you must connect the CAN bus cable between the two “inverter” CAN bus connectors. (See section 3.1.2)

• Push the inverters into the racking units. The order and the positions are arbitrary. The front panel must be flush with the frame of the racking unit.

• Cover all free pug-in slots with a blank panel.

• Fix all units and blank panels on the racking unit with screws.

The electrical connections are automatically established when pushing the units into the racking units.


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Figure 16: Mounting units to Relay Rack.

The mounting ears are designed to rotate so the unit can be mounted in a flush mounting position or 5" projection. Also, there is a second set that can be mounted behind a relay rack channel for extra support .This is set up for a 3", 4", or 5" channeled racks. If it is flush mounted in a data cabinet, support rails are required.

Install screws on each side of

Distribution Shelf. (See Parts List)

Install 2 (at minimum)

piercing washers on each corner. (See Parts List)


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4.4 Commissioning of the Inverter System

Caution! Commissioning may be carried out only by properly instructed trained personnel!

4.4.1 Inverter System

Attention! Check the following points before commissioning the inverter system:

• Have all components of the inverter system been adjusted, mounted and connected according to the applicable Electrical Codes and system engineering standards.

• The DC supply should still not be connected at this time!

• All inverters are still switched off via the unit switch on the front of each inverter.

1) Switch on the individual DC supply (s); close the disconnecting devices

The LEDS on all connected inverters should be lit. (the input voltage lies within the tolerance range)

2) Switch on all inverters with their “Power On” switch. The order is arbitrary.

Immediately after switching “On” the inverters the LED should lit .(inverter is switched on)


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4.4.2 Commissioning Report

Site Identification: Customer: Sales Order #:

System Serial Number: Static Bypass Serial Number: Inverter Module #1 Serial Number: Inverter Module #2 Serial Number: Inverter Module #3 Serial Number: Inverter Module #4 Serial Number: Inverter Module #5 Serial Number:

1. Cabinet Interconnections Cabinet Ground Connected: Yes No

DC Input Cables Connected: Yes No AC Mains Input Cables Connected: Yes No AC Load Cables Connected: Yes No

2. Input Voltage Measurements

Energize the system for this section

DC Input Voltage

Inverter Position #1: VDC





AC Mains Voltage

L1 - N: VAC

L2 - N: VAC

L1 - L2: VAC

N - PE: VAC


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Turn the Maintenance Bypass Switch Operating Element arrow towards the left (Position #1)

L1 - N: VAC

L2 - N: VAC

L1 - L2: VAC

N - PE: VAC

Turn the Maintenance Bypass Switch Operating Element arrow towards the right (Position #2)

AC Load Voltage

L1 - N: VAC

L2 - N: VAC

Note: All of these values should equal 0 VAC.

L1 - L2: VAC

N - PE: VAC

Leave the Maintenance Bypass Switch Operating Element arrow towards in the center (Position #0)

Provided all procedures have been successfully completed, the system is now

ready for normal operation and it is now safe to energize all AC loads.

Completed by:

Signature: Date:

Print:


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5 Maintenance and Repair

All the components of the inverter system have been developed for continuous operation and are practically maintenance-free. To ensure correct functioning, it is recommended that the flow of cooling air is checked periodically and dust is removed from the units if necessary.

Caution! The maintenance and repair of the inverter system may only be carried out by qualified personnel.

If servicing is required (exchange of units, work on the mains supply or the DC supply etc.) it must be determined which position the manual by-pass switch needs to be in. Please refer to the “Use of the Manual By-Pass Switch” section below.

5.1 Use of the Maintenance By-Pass Switch (If Installed)

Attention! Incorrect actuation of the maintenance by-pass switch (MBS) can interrupt the power supply of the loads.

The maintenance by-pass switch is normally only used when servicing the unit. This switch by-passes the static by-pass switch (SBS) and the loads are connected directly and without interruption to the mains (“mains operation”) or the inverter outputs (“inverter operation").

Position 0: Automatic operation

Position 1: Mains operation

Position 2: Inverter operation


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If the maintenance by-pass switch (MBS) is to be operated, two possible cases must be differentiated:

UUUCase 1: The SBS is operating correctly

The display of the SBS shows a correctly operating inverter system.

The LED (operation/ready for operation) is lit.

In this operating state the MBS can be switched optionally to position 1 or position 2 depending on the service tasks to be carried out.

Example: The system is operating with inverter priority and the mains by-pass is switched on.

• Switch the MBS to position 1

The SBS switches without interruption from inverter operation to mains operation. The mains by-pass is closed; the maintenance tasks, e.g. replacement of inverters, can be carried out.

If the MBS is switched to inverter by-pass (Pos 2) and the inverter system is operating with inverter priority, the SBS will not make any switch-over and the other switch of the MBS is depicted flashing.

After completing the service tasks with a correctly functioning inverter systemTPTPTP

2PTPTPT return the MBS to the position 0.

TPTPTP

2PTPTPT It can be assumed that the inverter system is functioning correctly when the changeover contact

in the SBS symbol has switched in the path in which the by-pass was switched, i.e. with inverter

by-pass to the inverter symbol and with mains by-pass to the mains symbol.

flashing


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UUUCase 2: The SBS shows a fault

In the case of this operating state, two further cases must be differentiated:

• The inverter system is operating in the inverter operation mode.

• The inverter system is working in the mains operation mode.

A fault of the SBS is indicated by the red LED (fault), by the flashing symbol of the SBS in the display and by the potential free message of the SBS.

Before actuating the MBS it must be determined unambiguously whether the inverter system is operating in inverter mode or in mains mode.

If the LEDs on the inverters for indicating the actual inverter output power are lit, inverter operation can be assumed, otherwise mains operation. If there is any doubt, measuring devices must be used to determine the actual operating mode.

Attention! In the case of inverter operation only the switch position 2 (inverter by-pass) may be selected, and for mains operation only the switch position 1 (mains by-pass). Otherwise the power supply for the load will be interrupted.

After completing the service tasks (e.g. replacement of the SBS) and when the inverter system is functioning correctlyTPTPTP

3PTPTPT switch the MBS back to the

position 0.

TPTPTP

3PTPTPT It can be assumed that the inverter system is functioning correctly when the changeover contact

in the SBS symbol has switched in the path in which the by-pass was switched, i.e. with inverter

by-pass to the inverter symbol and with mains by-pass to the mains symbol.


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When the start-up phase of the inverters has completed, the following LED’s are lit:

Output voltage available

The inverters are operating phase-synchronised; parallel operation (this LED is flashing if there is only one inverter. This unit has the MASTER function. Normally this is the unit which is switched on first. )

3) Switch on the loads

The greater the connected load is, the more LEDs are lit to indicate the actual inverter output power.


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5.2 Exchange of Units

Exchange of units may take place during running operations without an interruption in the power supply to the loads.

Exchanging an inverter

• Switch the inverter off with the unit switch.

• Release fastening screw.

• Pull the inverter out of the racking unit to the front.

• Push the new inverter into the free plug-in position. Attention! The inverter must be switched off at its unit switch. The front panel must be flush with the racking unit.

• Insert fastening screw.

• Switch on the inverter at the unit switch. (The inverter starts up and will be tied into parallel operation with the other units. If the mains took over the supply of the load devices, switch back to the inverters takes place).

5.3 Upgrading the System

The inverter system can be extended with additional inverters during running operation. It is only necessary that the corresponding free plug-in locations are available.

• Release the fastening screws and take off the blank panels.

• Push the inverters into the free plug-in locations and insert the fastening screws.

• Switch-on the units via their unit switches. After the start-up phase, the new units are brought into parallel operation and the load current then is evenly distributed to all inverters that are switched on.)

•


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6 Parts List

Part Number Part Description

Hardware

786051 Mounting Screw - 12 -24 x 1/2”

718366 Patch cable KAT.5E 2xRJ45 / 1m - CAN bus connecting cable


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Notes

Benning Power Electronics

11120 Grader Street

Dallas, TX 75238 USA

214.553.1444

800.910.3601

This manual contains

important safety instructions

that should be followed during

installation and maintenance

of the Power System.

Documents

Tu Nguon Benning