DC SYSTEM

POWER PLANT ELECTRIFICATION

HERA BETANO POWER PLANT

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DC-System

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The DC-system consist of a free standing cubicle including Chargers (rectifier),

batteries, and distribution.

Normally the rectifier supplies the load. The battery bank supplies the load for a
limited time if the mains supply is interrupted.

The DC system shall provide 110V (125V), 24 V DC ± 10% to the consumers in

the power plant.

The batteries are typically sized for

5 or 10 hours or: capacity = C10/5 @ 1.8V
end voltage and 20°C ambient.

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Typical consumers
PLC engine wise cabinet: 100 W
PLC common cabinet: 100-200 W
Pipe module with RIO 30 W
Gas ramp: 100 W
WECS 380-470 W

110 V (125V) system

High resistance grounded
Batteries sizing to be typically for 10 hours consumption

24V system
(-) grounded mainly for supply to the WECS system
Battery sizing to be typically for

Two types of batteries

Lead acid or Nickel-Cadmium where lead acid is preferred.

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Standard system setup 24V & 110 V

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Standard system setup 24V & 110 V

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• 24V, 110V, 125V, 220V. Standard

Ah Range
• Built into one unit Distribution Supervision

• Panel coding starts from BEY901

Chargers

Batteries

Lead acid cells

Nickel-Cadmium cells

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DC-system with Lead Acid batteries, main line diagram

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DC-system with NiCad batteries, main line diagram

Charger Space for Stand-by

charger charger

Battery
110V 75Ah/ 10h

Battery
Main switch

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Battery

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Battery
Installation
Please note that each monobloc is supplied complete with a fastener kit, ie. bolt, spring washer and plain washer.

• Remove the insulating terminal covers

• Erection of battery
Place the monoblocs in position on stands/in cabinets at their correct ‘cell centres’ (as indicated on the
connection drawing enclosed).
• Connection of monoblocs
When all monoblocs have been placed on the stands/in the cabinets, connect them together by means of
the connecting straps and fastener kits, in sequence, female terminal, connecting strap, plain washer,
spring washer and bolt.
Tighten the fastener set bolt(s) to a fastening torque level of 5Nm ± 0.5. Never use a standard spanner.

• Putting the insulating terminal covers back

Insulating terminal covers have been designed to be fitted on completion of the connecting up sequence of the
battery. To fit them back on, it will be necessary to remove the side of the cover by simply snapping it off

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Battery

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Battery

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Rectifier
Introduction
• MRC 110-1600 (later MRC) is a power factor corrected (PFC) switching mode power supply, with a single
phase 230Vac mains connection.
• The nominal output power is 1600W and nominal output voltage 110Vdc.
• The MRC rectifier is designed for use in OPUS DC power systems for various industrial applications. The
MRC can operate with or without parallel connected batteries. Cooling of the MRC is based on natural
convection.
• The master controller of the power system (VIDI) controls the output voltage and current of MRC via the
system bus (PowerCAN).

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Rectifier
Introduction ...
• The MRC rectifier can be used also without the master controller. In that case the output voltage is set to
default value; 123.6V or 137.4V depending on the nominal system voltage.
• The MRC is capable of sharing the output load in a maximum configuration of 36 paralleled units. It is also
able to communicate its status and operational parameters to the system control unit via the PowerCAN.
• An indicator light is located on the front panel of the unit and indicates the unit’s operational status.
• The MRC is intended for installation in a restricted access location.

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Rectifier
Connection
• Input and Output Power Connectors
The input power socket (AC in) is a 3-pole, male IEC appliance PCB mounted inlet with con-nection pins
for line (L), neutral (N) and protective earth (PE). Connection is only permitted using the system’s own
removable input cable.
The rectifier’s internal fuse can be found in its line connection (L). If it cannot be ensured that the line of
the AC mains is connected to the line contact of the rectifier, the unit may remain energised after the
operation of the fuse.
The output power connector (DC out) is a PCB-mounted right angle type TwinBlade.

Do not use the connector for current interrupting or hotplugging.Furthermore, when inserting the connector, the voltage difference between the unit and the system may
generate sparkswhich can damage the contacts.

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Rectifier
Connection ...
• PowerCAN System Bus
There are two RJ-45 type connectors for the PowerCAN system bus interface (Bus 1 and Bus 2) on the
front of the MRC rectifier (Figure 4).
The pin-out of the RJ-45 connector is shown in Table 1.

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Rectifier
Operating Mode Indication
The operating mode and alarms of the MRC unit are shown using a single bi-colour LED light (Unit status).
This LED is located on the front panel and indicates the rectifier’s status as follows:
• Yellow blinking: LED test (for where-is-it indication)
• Yellow: test mode
• Red: fatal error, service needed
Memory / parameter error
Fuse fault
DC fault
Fast DC overvoltage protection (FOV)
Other permanent error preventing rectifier operation
• Red blinking: temporary failure
Mains fault
Over temperature
Selective DC overvoltage protection (SOV)
DC undervoltage alarm
Other temporary error
• Green blinking:
Communication error (or master controller not present)
• Green: OK
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Rectifier
Maintenance
The MRC rectifier does not contain any user serviceable parts. Operation of a single rectifier can be tested
according to the following instructions:
• Disconnect the output connector.
• Disconnect the PowerCAN bus connector.
• Measure voltage directly from the output connector – the default value is 123.6 Vdc / 137.4 Vdc.
• Check the status of the LED indicator – the green LED should be blinking.
It is crucial to the correct operation of the power system, that all rectifiers have equal output voltages. If the
voltages are changed, the original voltage levels must be restored after the tests. In some tests the rectifier must
not be in the No-load condition and a suitable load should therefore be connected to its output.

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Rectifier
Fault tracking
• The MRC rectifier does not contain any user serviceable parts and cannot be repaired on site.
• A faulty rectifier must be replaced with a new unit, in accordance with the instructions of the power system
installation and start-up manuals.
• The following fault tracing instructions are solely for the elimination of any external conditions which might
prevent the proper operation of the rectifier installed in the power system.
The rectifier does not start and no signal light is on:
Check that the mains connector is properly inserted.
Check that the mains voltage is OK.
Check that the mains fuse is OK.
Red LED is on:
Disconnect the PowerCAN bus
Disconnect the mains
Disconnect the load
Reconnect the mains
Check that the unit is starting up (green LED blinking)
Reconnect the load
If the red LED is on, remove the faulty unit from the system
Replace the faulty unit with a new one

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Rectifier
Fault tracking ...
The Red LED is blinking – a temporary failure has been detected:
Check that the mains voltage and mains fuse are OK
If the red LED is still blinking, disconnect the mains
Disconnect the PowerCAN bus
Disconnect the load
Reconnect the mains
Reconnect the load
Check that the internal temperature of the unit is not on
Check that the unit is starting up (green LED blinking)
Reconnect the PowerCAN bus Red LED is on:

Yellow LED is on:

The MRC is in test mode – return to normal operation mode (master controller)

Green LED is blinking:

Communication error – check that the PowerCAN bus is connected
The Green LED will blink during normal operation if the master controller is not connected

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Rectifier
Fault tracking ...
Output voltage of the rectifier or system is wrong (This is only possible when the master controller is
connected)
Check the rectifier’s voltage settings.
Check that the rectifier parameters are correct.
Check that the internal temperature limit of any rectifier is not on.
Replace any broken unit with a new one.

Rectifier is constantly starting up and shutting down

Check that the mains voltage is not too low.
Check that the load is not too high.

Rectifier does not supply enough current

Check that all cables are properly connected.
Check that the internal temperature limit of the rectifier is not on.

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OPUS Power System (Installation & Start-Up)

General description
• OPUS C 110-9.6 C delivers uninterrupted DC power to demanding industrial,
automation, telecom and datacom applications.
• Maximum output power is 9.6 kW at 110 VDC.
• OPUS C 110-9.6 C is a compactly integrated DC power system using MRC
110-1600 convection cooled rectifiers and a comprehensive VIDI controller.
• Connections are pre-installed for mains, batteries and DC distribution.
• The system can be equipped with a wide range of options.

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OPUS Power System (Installation & Start-Up)

General guidelines
• The OPUS system can be connected to 3-phase TN, TT or IT power distribution systems.
• The installation location should fulfil the following requirements:
The operating ambient temperature range is -20 oC to +40 oC.
The storage ambient temperature range is -45 oC to +70 oC.
Relative humidity 5...95%, no condensation.
Maximum altitude is 2000 m above sea level.
Ventilation air shall not contain any corrosive substances, dissolving agents nor significant amount of dust
etc.
• The OPUS system with a 19” rack can be installed in a cabinet or on a wall. With respect to wall mount kits
designed by EFORE Oyj, the system construction fulfils protection class IP20.

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OPUS Power System (Installation & Start-Up)

Cabinet system configuration
• The OPUS cabinet system consist of an enclosure mechanics, VIDI or VIDI+ system controller modules, mains
switch and connection terminals, battery connections and DC load distribution. depending on the cabinet
version, there is places for no more than 6 or 12 MRC rectifiers. The cabinet system may also includes a
battery.
• In the OPUS cabinet system, each rectifier AC mains input and each rectifier DC output is equipped with
MCBs.

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OPUS Power System (Installation & Start-Up)

Cabinet system configuration ...
• Cabinet system can includes up to 4 battery connection fuses (Figure 1) and optional battery and load LVD’s.
• The standard OPUS system includes 2 universal alarm inputs and 4 alarm relay outputs.
• Additional 8-alarm inputs and 8-alarm relay outputs are available with an optional extension board. A system-
level earth fault detection alarm is available for floating systems as an option.
• The OPUS system delivered with the VIDI+ controller also provides RS232 and Ethernet connections for
remote control.

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OPUS Power System (Installation & Start-Up)

Mechanical installation
• Install the system cabinet to its place and adjust it to stand in vertical position with the help of adjustable legs
(see Figure 2):
Open locking nuts and turn the legs by hand to place the cabinet in a correct position.
lock the nuts.
leave about 3 to 5 cm free space between the wall and the cabinet.
If necessary, upper part of the cabinet can be fixed to the wall with lugs included in the delivery (see Figure
3).

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OPUS Power System (Installation & Start-Up)

AC installation

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OPUS Power System (Installation & Start-Up)

DC load connection
• Before installation, check the system grounding. make sure that the loads are connected accordingly. A wrong
connection can cause serious damage to the loads.

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OPUS Power System (Installation & Start-Up)

Battery connection
• Make sure that the battery polarity is connected correctly. A wrong battery connection may cause serious
damage to the system.

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OPUS Power System (Installation & Start-Up)

Alarm connection
• Incoming alarms can be connected to connector X3 (“Alarm/Temp inputs”). If the battery temperature sensor
is included in the system, it can be connected to the same connector. See Figure 9.
• Outgoing alarms are potential free changeover contacts available from connector X4. The maximum alarm
relay contact power rating is 60 W (max. 2 A, max. 220 VDC). Wires of a maximum of 1.5 mm 2 should be
used for alarm connections.

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OPUS Power System (Installation & Start-Up)

Installing rectifier
• Before installing rectifiers and starting up the system, check the following:
All battery fuses are switched off.
All rectifier mains fuses (MCBs) FG1 - FGx are switched off.
If included in the system, all rectifier output fuses FG1.1 – FGx.1 are switched off.
All distribution fuses (MCBs) are switched off.
Check that the polarity of the batteries is correct.
Earth connections have been performed properly.

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OPUS Power System (Installation & Start-Up)

Installing rectifier ...
• Once all of the above issues have been secured and checked, install each rectifier sequentially by sliding
them into their proper places (G1-Gx). Then continue the installation using the following sequence:
Connect the DC power connector to each rectifier.
Connect the AC mains connector to each rectifier.
Connect the RJ45 system bus cable leading from the VIdI controller to the rectifier furthest to the left in
position G1 (one of two RJ45 connectors in front of the rectifier).
Daisy chain all rectifiers installed in the system (RJ45 cables supplied by Efore).
Terminate the system bus by the termination connector at the last rectifier of the daisy chain bus (see
Figure 10). Two termination connectors are delivered with the system.
Check that termination connector is also installed in controller module A1, which is located inside the
system rack or system cabinet (see Figure 1).

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OPUS Power System (Installation & Start-Up)

Power up the system
• Once all rectifiers have been installed, and the connections secured and checked, sequential system power
up can begin.
Switch on the rectifier mains fuse FG1 (in the 110 VDC and 220 VDC systems, also rectifier output fuse
FG1.1) and wait until the indication LED of the MRC rectifier turns green.
Check from the controller display that the rectifier is placed in the corresponding slot (G1-Gx) and the
mains phase (L1, L2, L3) is correct. If the rectifier location and proposed slot do not match, update
accordingly through the VIDI system controller user interface. Approve the changes.
Repeat the above actions for all rectifiers installed in the system. leave the unused MCB fuses in the OFF
position.
Check from the system controller that the system DC voltage is correct.

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OPUS Power System (Installation & Start-Up)

Power up the system ...
Check that the battery polarity is correct.
Connect the battery to the system by switching on the corresponding battery fuse.
Unused battery fuses must be switched to the ON position to avoid false alarms.
Connect the loads by switching on the corresponding MCBs.

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OPUS Power System (Operation System Controller)

Charge modes
When mains power is available, VIDI+ adjusts the output voltage of the rectifiers according to the system charge
state. The supported charge states are described below.
• Float charge
This is the default charge state.
The batteries are charged with a voltage optimal for continuous operation.
The float charge voltage is specified by the Float Charge Voltage parameter, in the Charge Parameters
group.
The default float charge voltage is 2.27 V per battery cell.
• Boost charge
Boost charging enables faster battery charging and equalises battery cell voltages.
During boost charge, batteries are charged with higher voltage than in float charge.
The default boost charge voltage is 2.40 V per battery cell.
Boost charge can be activated manually, automatically after a mains fault, periodically at set intervals or
with a remote signal, which is connected to one input of the OPUS system.

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OPUS Power System (Operation System Controller)

Mains fault
• When all present rectifiers report a mains fault, the VIDI+ controller assumes that the mains supply is down
and enters the Mains Fault state. If enabled, the Mains Fault alarm will activate after this.
• If the system is started up without rectifiers, for example from batteries, the controller assumes that there is a
mains fault.
This will happen also if the system is powered by MRC rectifiers, but the rectifiers are not connected to the
VIDI+ controller.
This is because MRC rectifiers are unable to communicate with the VIDI+ controller when the rectifiers have
no AC power.

Alarms
• VIDI+ provides comprehensive alarm functionality. There are more than 30 alarms to warn the operator of
potential or active problems.
• All alarms can be individually enabled or disabled and routed to any combination of alarm relays. A single
alarm relay can be used for multiple alarms. An activation delay can be set for each alarm.

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OPUS Power System (Operation System Controller)

Alarms ...
• Enabled alarms always have one or more alarm sources. There are different types of alarm sources:
System; A system-level alarm, such as System Low Voltage.
Bus; An alarm related to an entire module bus as stated in the alarm information. For example, a bus fault
alarm can have ExtBus1 as the alarm source.
Module; An alarm caused by one or more specific physical modules. A list of modules in the alarm state is
always shown. For example, the rectifier overtemperature alarm may have rectifiers G1 and G4 as the
alarm sources.
Device; An alarm related to one or more of the system devices. For example, a contactor fault alarm can
have LVD device Kl1 as the alarm source.

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OPUS Power System (Operation System Controller)

LED indications

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OPUS Power System (Operation System Controller)

Local user interface
• The local user interface of the VIDI+ controller is provided by the User Interface (UIF) module. The UIF
module comprises a graphical LCD display, the Status LED (4), and the following controls:
1. Pushable selector wheel; used to select items in menus, change various
values, and scroll the display. It can be rotated in either direction. The
currently selected item (if any) can be activated by pushing the Selector.

2. Cancel button; always returns to the previous menu, cancels the current
action, or moves backward in certain configuration dialogs.

3. Help button; always gives help related to the current page or selected
item. Pressing the Help button twice gives help on the help display itself.

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OPUS Power System (Operation System Controller)

Local user interface ...
• Main display
The top row shows the system state, which can be:
Float charge
Periodic battery test
Manual battery test
Natural battery test
Remote battery test
Automatic boost charge
Periodic boost charge
Manual boost charge
Remote boost charge
Temperature compensation
The second row shows the system voltage and the total current supplied by the rectifiers.
The third row shows the current supplied to the load. The current flowing to the batteries can be
calculated as a difference of rectifier and load currents. In the above example the batteries are being
charged with 54 A.
The fourth row shows the number of currently active alarms. If the system is being accessed remotely, for
example via the Web interface, on the last row is shown Remote Login and all local interface usage are
disabled.

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OPUS Power System (Operation System Controller)

Local user interface ...
• Measurements

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Earth Leakage Monitoring – ELM10

ELM-10 is a five-channel ground fault monitoring unit for direct current systems.
An indication of ground fault’s location during operation makes service possible without shutting down the whole
system.
BEB-10 is a resistor unit that sets the potential of the floating battery unit symmetrical against the ground
potential.
ELM-10 senses a damaged load when there is a difference between outgoing and return current. In such case
not all the current returns through the return cable but a part of it takes a short circuit back to the battery set
through ground leakage and BEB-10 resistors.

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Earth Leakage Monitoring – ELM10

When leakage current doesn’t exist, the power resistors of BEB-10 keep the battery voltage symmetrical against
the ground potential.
There is no current from ground potential to neither pole of the battery.
The relays are off, e.g. in the channel 1 the terminal 3 (COMMON) of the screw terminal is connected with the
terminal 1 (N.C.)
Ground leakage happens when there’s a current from one or the other load supply cables to the ground potential.
Then the leakage current doesn’t return through the current sensor of ELM-10 but returns to the battery through
one of the BEB-10 resistors.
When the load leakage current exceeds 75mA, the corresponding channel of ELM-10 creates an alarm by
switching the red led of the channel lit. At the same time, the relay of the channel is energized, and e.g. in the
channel 1 the terminal 3 is connected to the terminal 2 (N.O.).
When the leakage current drops below 50mA, the relay is released and the red led of the channel is switched off.

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ELM10 Fault Diagnostics

ELM-10
ELM-10 cannot be repaired in its operating environment.
If the fault is clearly in ELM-10, it must be sent to the manufacturer for repairing.
* PWR ok led isn’t lit
Check that the + - pole of the battery set is connected to ELM-10 connection 16 and the - -pole to connection 18.
The incoming voltage must be 100…120V.

BEB-10
BEB-10 cannot be repaired in its operating environment.
If the fault is clearly in ELM-10, it must be sent to the manufacturer for repairing.

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DC Consumer List BEY901

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DC Consumer List BEY902

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