EN03501 - Control Module Service Manual
EN03501 - Control Module Service Manual
DC SYSTEMS
2.1. CLEARING SYSTEM EVENT LOGGER. 6.2. CALIBRATION OF OUTPUT AND BATTERY
MEASUREMENTS (1).
3. MANAGING BATTERY LIFE. 6.3. CALIBRATION OF OUTPUT AND BATTERY
3.1. BOOST CHARGE. MEASUREMENTS (2).
3.2. SCHEDULED CHARGE. 6.4. CONFIGURATION OF SYSTEM SETTINGS (1).
3.3. EQUALIZING CHARGING. 6.5. RECALCULATION OF SETTINGS.
3.4. BATTERY TEST (1). 6.6. CONFIGURATION OF SYSTEM SETTINGS (2).
3.5. BATTERY TEST (2). 6.7. CONFIGURATION OF SYSTEM SETTINGS (3).
The numbering for the detailed screens in this document is in series with the numbering of the screens shown in
EN021*00. So, for example, Screen 4.1 will follow Screen 4.0 and come before Screen 4.2, in chronological order
of appearance.
Both screens, 4.0 and 4.2, form part of the group called ‘User Range’ and are therefore summarised in EN021*00.
By contrast, Screen 4.1 forms part of the group called ‘Calibration Range’ which together with the ‘Programming
Range’ group requires your password to carry out relevant maintenance and/or repair tasks reserved to T.S.S.
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2. SYSTEM EVENT LOGGER.
Screen 4.1.
Press Enter (ENT) on this screen and change the value from (NO) to (YES) using the left-right arrow keys (◄) and
(►) and confirm using Enter (ENT) to reset the event logger.
This screen displays everything to do with boost charging. This charging mode can be activated manually on the
previous screen by changing the status to ON (MAN). It is also automatically activated whenever the battery
discharges below the level set in the start threshold field.
Screen 5.2.
On the first line, you can select whether or not to activate boost charging by selecting YES or NO. By default it is
set to NO. Next there is a series of fields related to boost charging.
•• V.Charge: This is the charging voltage. This voltage will be the sent to the rectifiers to be applied across the
terminals of the battery. By default it is set to 56.4 V.
•• I.Minim.: This is the minimum current below which boost charging will be stopped. Charging will continue for
at least 4 minutes even when the current does not exceed the minimum. By default it is set to 0 A.
•• Ch.Factor: This is the charge factor provided by the manufacturer to show the amount of energy to be returned
to the battery. For example, when 100 units of energy are extracted from the battery, it needs 100 x 1.2 = 120
to be returned to it. By default, the charge factor is 1.2.
•• Tmin. Charge: Minimum duration of charge. By default it is 2 hours (120 minutes).
•• Tmax. Charge: Maximum duration of charge. By default it is 20 hours (1200 minutes).
•• Start Threshold: This is the minimum voltage below which boost charging will be started. By default it is set
to 9.2 V.
This type of charging is carried out periodically to keep the batteries in perfect condition.
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*SCHEDULED CHARGE* NO ►YS◄
Charge Voltage : 56.4V
Charge Time : 60 Minutes
Periodicity : 30 Days
Screen 5.3.
Scheduled charging can be activated on the first line of the screen by selecting YES or NO, the latter being the
default setting. Other configurable parameters are:
•• Charge Voltage: This is the charging voltage. This voltage will be the sent to the rectifiers to be applied across
the terminals of the battery. By default it is set to 56.4 V.
•• Charge Time: This is the maximum time that scheduled charging can last. By default it is set to 60 minutes
charging as the maximum.
•• Periodicity: This is the interval in days between charges. By default, a scheduled charge will take place every
30 calendar days.
Scheduled charges are always carried out at 12 noon on the day shown on the battery management-status screen.
If at any time the power is not connected and a charge cannot be carried out, the system will put itself in ON
(HOLD) mode and once incoming power is restored the scheduled charge will be reactivated.
Charging started manually by the user on the battery management-status screen, changing the status to ON (MAN).
Screen 5.4.
•• Charge Voltage: This is the charging voltage. This voltage will be the sent to the rectifiers to be applied across
the terminals of the battery. By default it is set to 59.0V.
•• Charge Time: This is the maximum time that scheduled charging can last. By default it is set to 60 minutes
charging as the maximum.
The rectifiers raise the system voltage until it reaches the charging voltage and keep it at that level for the max-
imum charging time. If there is a failure in the input mains, charging will remain at ON (HOLD) awaiting mains
reconnection, at which point it will resume charging from the point reached.
Battery testing produces controlled discharge at a specified current. During discharge, the values for the battery
are monitored to check that it is performing adequately in line with the discharge curves given by the manufacturer
for the battery.
Screen 5.5.
•• Start Test: This tells the system to start a battery test. Certain parameters for the battery must be in certain
conditions for testing to start.
•• Result: Once performed, shows the result of the battery test.
•• Test Status: Shows whether the test has started or is available or unavailable.
•• Battery Charge Status: In this section the charge of the battery is shown as an approximate percentage.
***BATTERY TEST***
Battery Test Max. Deviation : 990
Battery Discharge Profile : 6
Battery Charge Status : 100%
Screen 5.6.
•• Battery Test Max. Deviation: Shows tolerable deviation in parts per thousand.
•• Battery Discharge Profile: Parameter to set the test for a specific battery.
•• Battery Charge Status: In this section the charge of the battery is shown as an approximate percentage.
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4. MODULES MANAGEMENT: CYCLING AND ECONOMY MODE.
This group of screens is only displayed when the user has entered the programming password or above (See
System Maintenance).
This group of screens is for setting the different parameters used for a more intelligent management of rectification
modules.
Screen 6.1.
Device dimensioning is based on the estimated power consumption for the devices connected to the system outlets
plus the power consumption of the battery, taking account also of any redundant rectifiers that may be installed on
the system. This type of system dimensioning means that rectifiers work at or below half their capacity.
In the Calibration and System Adjustment section, Adjustment of System Parameters (1), the number of active
modules on the system and the number of redundant modules are defined. The system will never turn on more
modules than those set as active. The remaining redundant modules will become operational in case of failure in
an active module.
•• ECONOMY MODE: As an active mode and with data read from the rectifiers, it calculates the number of
rectifiers necessary to keep the system working round an optimum point, which by default will be 80% (which
can be changed), and will disconnect rectifiers not required by the system at that moment. If the system calls
for more power, the control will adjust the number of rectifiers so as to keep the system at the optimum point.
If this option is not active, the system will keep all the installed rectifiers turned on except for the redundant
rectifiers, which will only be turned on in case of a failure in a non-redundant rectifier. By default this feature
is deactivated.
•• CYCLING MODE: The cycling function for rectifiers consists in alternating the rectifiers that are turned off
every programmable interval. That ensures that modules wear out at the same rate, avoiding any one module
having worked more than the rest. By default the interval is 10 hours.
The rectifiers will be turned on and off in a similar way to what is shown in the example:
Table 1.
In the following group of screens the user can programme different maximum and minimum levels to trigger the
various alarms. Alarms can be grouped into three groups: urgent, not urgent and monitoring, each alarm group is
linked to a relay and an LED indicator on the display.
To edit the fields for these screens press Enter (ENT) to get the desired field. Once selected using the up-down
arrows (▲) and (▼) to change the digit, to move to the next digit the user uses the left-right arrows (◄) and (►).
Any change is confirmed by pressing Enter (ENT) again. Once all changes have been made, press Escape (ESC) to
stop editing the fields.
Screen 7.1.
•• Outgoing Alarms Override: When this option to set to YES, the Control Module stops activating the A1, A2
and O1 alarm relays and returns via communications that the system does not have any active alarms. By doing
so, if a technician needs to work on the system, he will not trigger outgoing alarms. In any case, the system
has the alarms and they can be viewed locally on screen and the audible alarm and alarm LED are activated.
•• Restore Timer: Shows the maximum time in hours for which outgoing alarms will be cancelled. Once that
time has elapsed, the override of those alarms stops and the hour counter is reset to 1 hour, the default value.
Screen 7.2.
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The user can also set the maximum voltage above which the high input voltage alarm will be triggered. With three-
phase input, it is 460 by default and single-phase input, it is 265, both given by the formula:
Vin_max = Vnom +15%
Where Vnom = 400 V in three-phase systems and Vnom = 230 V in single-phase systems.
•• V.Output: Output voltage. There is a minimum voltage at which the low output voltage alarm will be triggered.
By default it is set at 41.6 V and follows this formula:
And a maximum voltage that will trigger a high output voltage alarm which by default is set at 60 V, which is:
•• V.Battery: Battery voltage. There is a minimum voltage at which the battery low voltage alarm will be trig-
gered and a maximum that will trigger the battery high voltage alarm. The default voltages are 41.6 V for the
minimum and 60 V for the maximum, derived from the formulas set out in the preceding section.
•• TEMP. MAX: There is a maximum temperature at which the battery high temperature alarm will be triggered.
By default it is set at 50 °C.
Screen 7.3.
•• SYSTEM OVERLOAD: The total current level above which the system overload alarm will be triggered, which
the system will normally calculate by default in function of the rectifiers installed, their power, etc. It is not user
configurable.
The formula for calculating this alarm is:
Where Pmodule is the rated -nominal- power of each module. The value is recalculated whenever it finds new
modules, so it depends strictly on the modules it is communicating with, not the maximum number of modules that
can be installed.
•• MAX. SECURITY CURRENT: Maximum total current level, less 10%. It cannot be set by the user.
•• MAX. UTILITY CURRENT: Maximum total current level, less 10% by default, it can be set by the user.
•• BAT. CHARGE CURRENT HIGH: Maximum battery charging current. Surpassing this value will trigger the
battery high charging current alarm. By default it adjusts to the maximum charging current of the system de-
fined in Calibration and system settings, but it can be set by the user.
Screen 7.4.
Screen 7.5.
Screen 7.6.
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5.7. RELAY PROGRAMMING (3).
Bat.Discharging |1|-|-|-|-|-|-|-|-|
Battery Temp. |-|2|-|-|-|-|-|-|-|
Modules URGENT |-|2|-|-|-|-|-|-|-|
Modules NO URG. |-|2|-|-|-|-|-|-|-|
Screen 7.7.
Screen 7.8.
Screen 7.9.
Screen 7.10.
Screen 7.11.
Screen 7.12.
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5.13. RELAY PROGRAMMING (9).
Screen 7.13.
Screen 7.14.
•• [NO]: Input contact set to normally open.
•• [NC]: Input contact set to normally closed.
-- DIGITAL INPUTS --
Screen 7.15.
As its name suggests, this group of screens is for calibration of measurements and adjustment of some system settings.
Screen 8.1.
Calibrate with contrasted instruments and with the possibility to connect loads greater than 50% of the capacity
of the system to be calibrated. The procedure is the following:
•• Use a calibrated measuring system.
•• Measure the magnitude that is to be calibrated with that instrument.
•• Compare against the measurement from the system. The screen shows the measurement taken by the system,
to the left of the arrow.
•• If they are the same, nothing needs to be changed.
•• If they are not the same, proceed with calibration. Press Enter (ENT) on the front of the device to select the
field to be calibrated. The measurement taken by the Control Module is copied to the field to be modified, to
the right of the arrow, so that it is now shown twice. Enter the measurement taken by the calibrated measuring
system using the up-down arrows (▲) and (▼) and the left-right arrows (◄) and (►) to change the digits.
•• Once the measurement has been entered, press Enter (ENT) and calibration is complete.
This screen allows calibration of the following measurements:
•• Voltage V-R: Compare the measurements taken with an instrument and calibrate in the corresponding field on the
screen for alternating voltage in effective value between phases R and S in the case of a three-phase input system.
•• Voltage V-S: Compare the measurements taken with an instrument and calibrate in the corresponding field on the
screen for alternating voltage in effective value between phases S and T in the case of a three-phase input system.
•• Voltage V-T: Compare the measurements taken with an instrument and calibrate in the corresponding field on the
screen for alternating voltage in effective value between phases R and T in the case of a three-phase input system.
•• Phase current I-R: To calibrate currents the system must be loaded to at least 50%. Compare the measurements
taken with an instrument and calibrate in the corresponding field on the screen for alternating current in effective
value passing through the R phase.
•• Phase current I-S: To calibrate currents the system must be loaded to at least 50%. Compare the measurements
taken with an instrument and calibrate in the corresponding field on the screen for alternating current in effective
value passing through the S phase.
•• Phase current I-T: To calibrate currents the system must be loaded to at least 50%. Compare the measurements
taken with an instrument and calibrate in the corresponding field on the screen for alternating current in effective
value passing through the T phase.
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6.2. CALIBRATION OF OUTPUT AND BATTERY MEASUREMENTS (1).
This screen allows calibration of output measurements for the system and battery measurements in a similar way
to the one stated above.
Screen 8.2.
Screen 8.3.
The measurements that can be calibrated are:
•• B2 Charging Current: To calibrate currents the system must be loaded to at least 50%. Compare the measure-
ments taken with an instrument and calibrate in the corresponding field on the screen for the charging current for
Battery Bank Number 2 measured by the Control Module.
•• B2 Discharging Current: To calibrate currents the system must be loaded to at least 50%. Compare the measu-
rements taken with an instrument and calibrate in corresponding the field on the screen for the charging current
for Battery Bank Number 2 measured by the Control Module.
•• Calibration Temperature: Compare the measurements taken with an instrument and calibrate in the corres-
ponding field on the screen for measured temperature.
•• Calibration Isolation: (Only for devices with optional external isolation detector.)
Compare the measurements taken with an instrument and calibrate in the corresponding field on the screen for
measured leakage current.
Screen 8.4.
Configuration of the settings involver the configuration of the operating values that the device will follow. It is
essential to configure all the settings correctly since misconfiguration can lead to destruction of the batteries or
connected critical loads.
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6.5. RECALCULATION OF SETTINGS.
Programming on the previous screen and giving the recalculate command runs automatic programming for all de-
fault settings on the previous screen according to standard values.
RECALCULATE PARAMETERS
(YES)
Screen 8.5.
Screen 8.6.
The settings on this screen should only be changed by highly qualified staff due to the seriousness of the conse-
quences of entry of incorrect values.
•• Temp. Compensation: Compensation of float voltage according to the ambient temperature of the batteries.
Compensation is carried out to extend the useful life of the batteries. The screen shows whether compensation
is required.
Max. Compensation
Float Voltage
Max. Compensation
Bat. Temp.
•• mV/°C: Number of millivolts per degree Centigrade of compensation to be applied to the battery to compensate
temperature. (Valid when compensation is activated.)
•• TMin: This is the minimum temperature below which the system float voltage will not be compensated ac-
cording to the temperature. By default it is set at 5 °C.
•• TMax: This is the maximum temperature above which the system float voltage will not be compensated ac-
cording to the temperature. By default it is set at 42 °C.
•• Limit: This is the maximum voltage that the system can compensate. That means the system will compensate
the float voltage and, when compensation exceeds this limit, temperature compensation will stop. By default
the limit is set at 2 V.
•• INom.Output: This is the maximum current that the system can deliver with the maximum number of modules
installed.
•• IBat.Maxim: This is the maximum battery charging current. It can be set by the user. The system calculates it
by default when the recalculate command is given in the previous screen on the basis of the type of batteries
installed and the programmed charge factor using this formula:
Screen 8.7.
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The configurable settings are:
•• END OF BATTERY CONTACTOR: Shows whether the end of backup contactor is directly connected to the
Control Module. The type of contactor can also be selected, offering a choice between magnetic locking
contactor (MAGNET) or standard contactor (NORMAL).
•• END OF BATTERY VOLTAGE: This is the voltage below which it is considered that the batteries cannot
continue to supply energy without damage. Once the battery has fallen below this voltage the system will
disconnect the end of backup contactor, i.e. it will disconnect the battery from the system. It can be set by the
user. By default it follows this rule:
•• LOW PRIORITY CONTACTOR: Shows whether the non-priority load contactor is directly connected to the
Control Module. By default it is connected (YES). The type of contactor can also be selected, offering a
choice between magnetic locking contactor (MAGNET) or standard contactor (NORMAL).
•• LOW PRIORITY VOLTAGE: This is the disconnection voltage for non-priority loads on the system. Once below
this voltage, the system disconnects less important loads to give remaining backup on the system to more im-
portant loads. It can be set by the user. By default the non-priority level is the same as the low battery voltage
alarm, produced by this formula:
Screen 8.8.
Screen 8.9.
The configurable settings are:
•• Sensor Installed: Shows whether the isolation sensor (+) or (-) is installed.
•• Detection Threshold: Shows the detection threshold for leakage current.
•• Sensor Reading: Value of reading from current sensor.
Screen 8.10.
Screen 8.11.
Screen 8.12.
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6.13. COMPLETE RESET OF SYSTEM SETTINGS (RESET).
It is of vital importance that anyone working on this screen has very good system knowledge.
Screen 8.13.
This screen allows deletion of all settings recorded in the NVRAM (TimeKeeper). The history, any calibrations and
system settings will be deleted and return to the default system values, etc.
This option should only be used where the NVRAM is corrupt or when the software of the microprocessor is up-
dated and the manufacturer recommends reset.
Once the reset has been carried out, the system should be started up by qualified personnel as if it was a new
system.
System Information
Serial Number : 00A000000
Version ...................... :
Model ...................... :
Screen 8.14.
This group of screens is only displayed when the user has entered the programming password or above
(See System Maintenance).
Screen 9.2.
Screen 9.3.
Screen 9.4.
Screen 9.8.
Press Enter (ENT) on this screen and change the value from (NO) to (YES) using the left-right arrow keys (◄) and
(►) and confirm using Enter (ENT) to reset the event logger.
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8. SYSTEM PARAMETERS.
This screen allows configuration of settings relating to system communications, both internal and external.
Screen 10.1.
To edit the fields press Enter (ENT) to get to the desired field. Once selected using the left-right arrows (◄) and
(►), select the correct option by pressing Enter (ENT) and move to the next field. Once all changes have been
made, press Escape (ESC) to stop editing the fields.
Screen 10.2.
To edit the fields press Enter (ENT) to get to the desired field. Once selected using the left-right arrows (◄) and
(►), select the correct option by pressing Enter (ENT) and move to the next field. Once all changes have been
made, press Escape (ESC) to stop editing the fields.
MODBUS ADDRESS: 1
LANGUAGE ... : ENGLISH
Screen 10.3.
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9. SYSTEM MAINTENANCE.
This screen shows the current user mode and the software version installed in the device.
Due to the complexity of continuous feed systems and the vital importance of their correct functioning, there are
three user modes. Each mode allows access to different zones in the menus to ensure that people who change
specific settings are qualified to do so.
Screen 11.0.
To make changes press Enter (ENT) and change the values of digits using the up-down arrows (▲) and (▼). To
move to another digit, use the left-right arrows (◄) and (►). Once the password has been entered, it is validated
by pressing Enter (ENT). The setting for the current mode will change to the mode selected.
AUTHORISATION: This screen is only displayed when the user has entered the calibration password or above.
The new password has to be confirmed and, once the change has been successfully, the system shows an OK
indication and, if the change has not been successful, it shows an ERROR indication.
Screen 11.1.
AUTHORISATION: This screen is only displayed when the user has entered the calibration password or above.
The new password has to be confirmed and, once the change has been successfully, the system shows an OK
indication and, if the change has not been successful, it shows an ERROR indication.
Screen 11.1.
AUTHORISATION: This screen is only displayed when the user has entered the calibration password or above.
Password reset can be carried out in this screen. Reset initialises both the programming and the calibration pass-
words back to their default values.
Screen 11.3.
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10. CONTROL MODULE SCREENS MAP.
HOME SCREEN QUICK SETUP OUTPUT VOLTAGE OUTPUT VOLTAGE
REDUCER 1 REDUCER 2
(1) Screen 0.0 Screen 0.1 Screen 0.2 Screen 0.3
INPUT MEASUREMENTS SYSTEM INPUT
MEASUREMENTS
(1) Screen 1.0 Screen 1.1
OUTPUT MEASUREMENTS SYSTEM OUTPUT
MEASUREMENTS
(1) Screen 2.0 Screen 2.1
SYSTEM ALARMS BATTERY IN LOW BATTERY END OF SYSTEM
DISCHARGE ALARM BACKUP OVERLOAD
(1) Screen 3.0 (2) Screen 3.1 (2) Screen 3.2 (2) Screen 3.3 (2) Screen 3.4
DIGITAL DIGITAL
INPUT 3 INPUT 4
(2) Screen 3.25 (2) Screen 3.26
SYSTEM CALIBRATION CALIBRATION INPUT CALIBRATION OF OUTPUT AND CALIBRATION OF OUTPUT AND CONFIGURATION OF
AND CONFIGURATION MEASURES BAT. MEASUREMENTS (1) BAT. MEASUREMENTS (2) SYSTEM SETTINGS (1)
(4) Screen 8.0 (4) Screen 8.1 (4) Screen 8.2 (4) Screen 8.3 (4) Screen 8.4
CONFIG. OF EXT. ISOLATION OUTPUT VOLTAGE OUTPUT VOLTAGE ENABLE ACOUSTIC ALARM
DETECTOR SETTINGS. REDUCER (1) REDUCER (1) AND USER MENU
(4) Screen 8.9 (4) Screen 8.10 (4) Screen 8.11 (4) Screen 8.12
DCS MODULES MEASUREMENTS AND ACTIVE CURRENT MEASUREMENTS CURRENT MEASUREMENTS CURRENT MEASUREMENTS
INFORMATION ALARMS FOR MODULE BY MODULE (1) BY MODULE (2) BY MODULE (3)
(1) Screen 9.0 (1) Screen 9.1 (4) Screen 9.2 (4) Screen 9.3 (4) Screen 9.4
MODULES WITH ACTIVE COMMUNICATIONS STATE DCS MODULE CLEAR DCS MODULES
ALARMS WITH MODULES EVENT LOGGER EVENT LOGGER
(1) Screen 9.5 (1) Screen 9.6 (4) Screen 9.7 (1) Screen 9.8
LIST OF DCS DETAIL OF DCS
MODULES EVENTS MODULES EVENTS
(1) Screen 9.9 (1) Screen 9.10
Key:
(1): Always visible.
(2): Visible when alarm is active.
(3): Visible with programming password or above.
(4): Visible with calibration password or above.
(5): Visible with R&D password or above.
(6): Visible with calibration password or above and settings menu for active user.
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Uninterruptible Power Supplies (UPS)
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