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Protect 8 xx-CR2
Operating Instructions
8000030015 BAL, en
Parallel Operation Protect 8
Table of contents
General............................................................................................. 3
1 Short Description ................................................................. 3
2 Pre-testing the Individual Units........................................... 4
2.1 Unit Prerequisite for Parallel Operation .................................. 4
3 Installation Settings ............................................................. 5
3.1 Connection Options for Communication Cables when the Unit
Door is Open.......................................................................... 5
3.2 Procedure .............................................................................. 7
3.2.1 Setting PCB A17 .................................................................... 8
3.2.2 Setting PCB A50 .................................................................... 8
3.2.3 Setting PCB A16 .................................................................... 9
4 Installing and Connecting ................................................. 10
4.1 Installing the Communications Components......................... 10
4.3 Electrical Connection of the Communications Components . 12
4.4 Installing the Power Cables.................................................. 13
5 Initial Start-Up .................................................................... 16
5.1 Preparing Initial Start-Up of a Parallel System...................... 17
5.2 Initial Start-Up of a Parallel System ...................................... 18
6 Disconnecting and Restarting........................................... 19
6.1 Disconnecting and Restarting the Parallel System ............... 19
6.1.1 Disconnecting a Parallel System .......................................... 19
6.1.2 Restarting a Parallel System ................................................ 20
6.2 Disconnecting and Restarting an Individual Unit of a Parallel
System................................................................................. 21
6.2.1 Disconnecting a Unit from a Parallel System........................ 22
6.2.2 Test Operation ..................................................................... 22
6.2.3 Restarting a Unit in a Parallel System .................................. 24
7 Maintenance of Parallel Systems...................................... 25
7.1 Standards ............................................................................ 25
7.1.1 DIN 31 051........................................................................... 25
7.1.2 Servicing .............................................................................. 25
7.1.3 Maintenance ........................................................................ 26
7.1.4 Inspection ............................................................................ 26
7.1.5 Repair .................................................................................. 26
7.2 German Engineering Federation (VDMA)............................. 27
7.2.1 Supply Units Uninterruptible Power Supply (UPS)................ 27
7.2.2 Activities involving Equipment and Units .............................. 27
7.3 Visual Inspections ................................................................ 27
7.4 Functional Test .................................................................... 28
7.4.1 Updating the Components.................................................... 28
General
These operating instructions (OI) must be read carefully by all
persons working with or on the system equipment prior to installation
and initial start-up of units connected in parallel.
In these OI the operation of units connected in parallel with 10 kVA to
120 kVA is described. The operating instructions of the individual
units remain valid for each individual unit.
Abbreviations
The following abbreviations are used in these instructions:
DOU = Display and Operation Unit
SBS = Static Bypass Switch
REC = Rectifier
INV = Inverter
X = Individual unit
1 Short Description
The parallel system concept represents an extension of individual
systems for higher safety and power requirements. The parallel
system consists of several units with a rated power from 10 to 120
kVA. The Protect is set up for parallel operation by making the
relevant unit parameter settings.
This parallel system enables you to achieve maximum power supply
reliability. It is a completely modular system. The monitoring systems
of each unit work completely independently of each other.
In parallel operation, the system has MULTIMASTER capability, i.e.
each unit has equal priority. Communication between the individual
units takes place via a CAN (Controller Area Network) bus system.
This bus system distinguishes itself through maximum interference
immunity and reliability (in particular, it is used in technologies
associated with high levels of safety such as airbags and ABS
systems in motor vehicles, for example).
Parallel systems can be run with separate batteries for each Protect
and varying charging curves. However, there is also the possibility of
working with a central battery and a shared charging curve.
Firmware (complete version) with "YY", e.g. P81YY33I, is required for
the functions described in these operating instructions.
3 Installation Settings
3.1 Connection Options for Communication Cables when the Unit Door is Open
The PCB required for parallel operation and intended for connection
in the UPS is designated as A20 and essentially consists of plug-in
devices.
The arrangement of the PCBs is only different for Protect 4 units.
Fig. 1 Arrangement of the operating elements, components and individual PCBs with open door
Example showing view > 80 kVA
1 Fans
2 Fan connections
3 Internal fuses for control unit and fans
4 Optional PCBs
5 Terminal strip X12 (remote signals and options)
6 Q1, load interrupter switch for the rectifier circuit
7 Q29, manual bypass switch (optional)
8 Connection terminals for rectifier and SBS circuits,
battery and load
9 Display and operation unit (DOU)
10 Optional display instruments
Fig. 2 Arrangement of the PCBs on the control unit pivot plate for Protect 8
3.2 Procedure
There are two connection wires to be connected between the units.
From these the CAN BUS cable (violet) has 3-pin T-plugs at the ends
and the synchronisation cable (grey) has 4-pin T-plugs. To expand
the system it may be necessary to change the plug types (allocation).
That means connecting two cables to one plug. For example, this
would be necessary on the centre unit in a system with three
inverters.
The T-plugs are plugged into the parallel adapter cards (A20) and
then screwed in to prevent accidental removal. For the CAN BUS
system to function properly, special terminating resistors are required.
These form part of the parallel operation set. The resistors are
already preassembled and connected to screwable 2-pin plugs. For
the CAN bus system, the terminating resistors are connected to the
T-plugs with the 2-pin connector. This is necessary for the respective
outer units and facilitates handling of the units during servicing work.
A further possibility for the terminating resistors (on the front of the
control unit pivot frame), is adjustment via the DIP-FIX switches,
which also facilitates the insertion of the terminating resistors on the
CAN bus line.
These are located on the PCBs (interfaces) A50, A16 and A17 behind
the control unit pivot frame The resistors are activated and
deactivated on the PCBs by means of DIP-FIX switches.
The DIP-FIX switches, which activate the terminating resistor for the
CAN bus system on the interfaces, must be open during the
installation of the system. This applies both to parallel rectifier
operation and parallel inverter operation + SBS operation.
NOTE:
i For the CAN bus system to function, the ends of the bus cable
must be terminated with resistors.
ATTENTION:
In order to make changes to the interface boards, the fixing bolt of
the frame must be released and turned towards the front (mind
the cables in the joint region).
C703
H803
R818
R819
V801
R709
R704
R708 R705
R703R701
R702 C701
C718
R395
X18
V702
C717
C720 C721
C723
V703
R717R736R718
R700R719
R716R735R720
C722
C719
R619 C604
R620
R621
R622
R6 16
R618 R615
R614
R617 R613
C603 R606
R605
C602 R604
C601 R400
R413
R225
R224
R726R722
R724R721
R723C724
R725R727
R728
R630
C716 C715
R714 C714 R715
V704
X11
R612
R610
R611
R374R372
R373R333
R729
C725
R733
R734
R502
R503 R501
R3116R609
R3115R627
R625
R607
R608
R626
X19
H301
R375
R730R731
R732
R635
R634
R243
R242
R233
R241
R201
R202
R817
R602
R603
R628
R629
X54
S601
S601
Figure 5 Position of switch S601 on PCB A50
X16 X15 X6 X7
R608R606
R607R605
R415
R601
R602
R603
R604
V404
V403
V601
V615
R542
R541
R543
R544
R545
R546
R547
H101
R149
C113 + C115 + C117 + C128
F101
L101 X8
C118
+ C116 + C127 +
C114
L201
C202
R204 +
The label IDn refers to the last unit. If, for example, only three units
are present, ignore the last two rows of the above table. The same
approach applies for a different number of units.
The cables between the individual units ID1 to IDn are routed
vertically downwards on the right-hand side of the control unit pivot
plate, and fixed to the supports provided using cable ties. The cables
should be routed as directly as possible, without loops, between the
individual units. A maximum cable length of 100 m should not be
exceeded.
~ ~
- -
-X2 -X2
- -
~ ~
-T1 -T1
-F1...-F3 -F1...-F3
Battery Battery
-K7 -K7
-Lx1...-Lx3 -Lx1...-Lx3
-X3 -X3
Distribution cubicle
-Q71 -Qn -Q29
-Q26
Load busbar
Fig. 9 Complete circuit diagram of two Protect units with two batteries, feeding
board and distribution board If the feeding board and distribution
board shown above are not supplied, they must be added by the
customer in accordance with the local conditions and requirements. If
your distribution board features suitable load breakers, one unit can
be disconnected from the power supply for maintenance purposes
while the second unit continues to supply the loads.
ATTENTION:
Note for equipment with Q29 switch in each UPS:
If the load busbar has a coupling breaker, in manual operation, all UPS
devices must be set to this operating mode or the coupling breaker must
be open.
Note for equipment with Q29 switch in distribution board:
Before switching from Q29 to mains 2, the load busbar must be
disconnected from the units, because otherwise problems with the phase
angles can occur with the different mains.
Figure 11 Complete circuit diagram for more than two units with a central
battery and feeding board and distribution board
5 Initial Start-Up
The start-up procedure is the same for the various unit versions (10
kVA to 120 kVA). Prior to starting the unit, check whether the preset
unit data complies with the system data by referring to the technical
data sheet.
Parallel units are adjusted by the factory with regard to their current
distribution. Since the local cabling affects the current distribution of
the parallel units (cable cross sections, cable lengths, cable routing
and inductance values of the load distribution board), readjustment
may be required following installation. The equalising current of idle
parallel units should be less than 5% of the inverter's nominal current.
The current distribution must be checked during start-up. Any
necessary adjustment must only be carried out by appropriately
trained expert personnel.
ATTENTION:
Improperly adjusted systems can damage the battery under
certain circumstances (individual batteries charged, i.e. 100%
capacity and idle inverter).
NOTE:
i The conditions imposed by the battery manufacturer for start-up
must be met. Any necessary parameter modifications must be
made by our service personnel or via the DOU. If changing the
parameters via the DOU, ensure that these changes are applied
to all units.
CAUTION:
When the mains is connected, potentially fatal voltages are
applied to the terminals.
Always observe the safety regulations!
NOTE:
i For all additional functions and operating modes please refer to
the operating instructions of the individual units.
NOTE:
i Maintenance and repair work must only be performed by
authorised expert personnel.
CAUTION:
Even when disconnected, capacitors in the unit may still carry
voltage.
Always observe the safety regulations!
NOTE:
i If you are putting a parallel system into operation for the first time
or have been carrying out expansion or retrofitting work, the
following procedure is insufficient! Please read the "Start-Up"
chapter for more information.
NOTE:
i For all additional functions and operating modes please refer to
the operating instructions of the individual units.
NOTE:
i Check your system configuration!
In this case, please contact the service department of AEG Power
Solutions GmbH.
NOTE:
i Maintenance and repair work must only be performed by
authorised expert personnel.
CAUTION:
Even when disconnected, capacitors in the unit may still carry
voltage.
Always observe the safety regulations!
6.2.2 Test Operation
Test operation is used for checking a disconnected unit during
maintenance or after repair.
The loads are supplied by the remaining units in the parallel system.
The unit that is to be run in test operation behaves like an individual
unit; therefore, it is necessary to change the DIP switch settings. To
do this, DIP-FIX S601 on inverter interface A17 and DIP-FIX S601 on
SBS interface A16 must be closed for test operation. See also
chapters 3.2.1 and 3.2.3.
The output of the UPS that is to be run in test operation must not be
connected to the outputs of the parallel system.
Red on during
operation without
a battery
After the unit function has been checked successfully, the unit must
be disconnected again (rectifier circuit and SBS circuit "OFF"). This
will cancel the "test operation" function at the same time. DIP-FIX
switches A16-S601 and A17-S601 must be opened again so that the
unit can be reconnected to the parallel system. If battery isolator Q2
was closed, it must be opened again.
Then the unit can be re-integrated in the parallel system as described
in chapter 6.2.3.
CAUTION:
Even when disconnected, capacitors in the unit may still carry
voltage.
Always observe the safety regulations!
NOTE:
i During test operation, no parameters or basic settings of the unit
are allowed to be changed.
6.2.3 Restarting a Unit in a Parallel System
Restarting a parallel system unit in cases where the loads were
supplied by the remaining units in the parallel system while this unit
was disconnected.
NOTE:
i For all additional functions and operating modes please refer to
the operating instructions of the individual units.
7.1 Standards
7.1.2 Servicing
Measures for retaining and re-establishing the normal condition, as
well as identifying and evaluating the actual condition of a system's
technical resources.
These measures include:
• Maintenance
• Inspection
• Repair
7.1.3 Maintenance
Measures for retaining the normal condition of a system's technical
resources.
These measures include:
• Creation of a maintenance schedule which is geared towards the
specific requirements of the respective plant or plant system and
which is binding.
The maintenance schedule includes:
• Preparation for implementation
Implementation
Feedback
7.1.4 Inspection
Measures for identifying and evaluating a system's technical
resources. These measures include:
• Creating a schedule for identifying the actual condition; this
schedule is laid down for the specific requirements of the
respective plant or plant system and is binding. This schedule
should include, among other things, details about the place, date,
method, units and measures.
• Preparation for implementation
• Implementation (which predominantly involves quantifying certain
factors)
• Presenting the results, having established the actual condition
• Appraisal of the results to evaluate the actual condition
• Deduction of the necessary consequences based on the evaluation
7.1.5 Repair
Measures for re-establishing the normal condition of a system's
technical resources.
These measures include:
• Assignment, assignment documentation and analysis of
assignment contents
• Planning in the sense of identifying and evaluating alternative
solutions, while considering operational demands
• Deciding on a solution
• Preparation for implementation, including costing, scheduling,
coordination, supply of personnel, resources and materials,
creation of working schedules
• Preliminary measures such as job equipment, protection and
safety devices, etc.
• Examination of the preparatory and preliminary measures,
including the release for implementation
• Implementation
• Functional test and acceptance
• Evaluation (including documentation, details of costings, identification
of - plus where applicable - introduction of improvements)
CAUTION:
The system must be disconnected from the power supply prior to
carrying out the procedure described below.
Always observe the safety regulations!
NOTE:
i Maintenance and repair work must only be performed by
authorised expert personnel.