Reinversion Discharger User`s Manual Energy Recyclers Ltd
Contents
1. de Reinversion Discharger Energy Recycler Series Energy Recyclers Master Slave Functions 2 kW 102 kW DC capable ISO9001 A master discharger unit features a 16 key numeric keypad and a 4 line by 20 character LCD display A slave discharger unit does not have a keypad or a display but instead features three status LED s and a 16 position rotary HEX switch for setting the slave address All dischargers feature an RS 485 serial communications port A master discharger also features an RS 232 port which in future will allow communication between a master discharger unit and a personal computer PC where as the RS 485 port allows communication from a Master discharger unit to any number Up to 16 slave discharger units Slave discharge units are connected to a master discharger unit by simply connecting an RS 485 cable between the units in a daisy chain fashion and connecting the DC battery inputs to each discharger across the same bank of batteries in a parallel fashion series and series parallel connections will be allowed in the future Once a number of Slave Units have been connected to a master discharge unit the control of all of the dischargers is possible through the keypad and display of the Master Unit The master discharge unit acts as if it where a single discharger with a discharge capacity equal to the total of itself and all of its connected Slave Units The extra discharge capacity of the Slave Unit2. 1f any connected to the Master Unit Fxample if a 6 kW Master Unit is connected with two Slave Units total system capacity is 18 kW For 48V nominal battery system the display will be as follows ENERGY RECYCLERS LTD Battery Discharger 048 Volts 0360 Amps SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 1 7 Reinversion Discharger Energy Recycler Series de Energy Recyclers Operating the Discharger 2 kW 102 kW DC capable ISO9001 At initial power on the user can press the Menu key then a number corresponding to the menu required for example Menu 4 Alternatively the user can press the Menu key then the Up or Down keys to display the required menu When the desired menu is displayed press the Enter key to select the menu options Menu 0 Initiate Discharge Enter a discharge Current between XX and yy Amps The master display dynamically indicates the minimum and maximum discharge values dependent on the total available discharge of the system master and its associated Slave Units Turning a DC breaker off on a slave or the master will reduce these values thus intermediate or finer resolution discharge values may be entered e with only one DC circuit breaker turned on a discharge current between 5 and 100 of a single module current rating can be entered For example 48V from 2A to 40A e with two or more DC circuit breakers turned on a dischar
3. 23 Slaven 9 2os Slaven ei oe CORRECT INCORRECT Page 8 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series de Energy Recyclers Installation cont 2 kW 102 kW DC capable ISO9001 Connecting a 6kW Master or Slave Unit to2 supply Connect first phase to terminals 1 and 20 Connect second phase to terminal 3 Note this is the only valid 2 connection DC Connection When connecting any unit to the batteries observe care in ensuring that the correct sequience is observed 1 With the Anderson DC plug disconnected from the discharger connect the DC wires user supplied to the batteries IT IS MOST IMPORTANT THAT CORRECT POLARITY IS OBSERVED DAMAGETO THE DISCHARGER WILL RESULT FROM REVERSE POLARITY CONNECTION 2 With all DC circuit breakers MCBs turned OFF plug the Anderson DC connector into the discharger 3 Turn on DC circuit breakers 1 When a DC circuit breaker is closed an audible splat sound is heard due to the inrush current into the discharger This is normal and is not harmful to the discharger 2 Whilst performing a discharge test on a battery it should be isolated fully disconnected from the charger rectifier and any other loads or equipment that are normally connect ed Master Slave DC connection See Wiring Connection Diagram page 28 System Serial communications RS 485 connection Se
4. cable DB9F DB9M PC connect v Users Manual Slave Unit i 175A DC Anderson mating connector 1 Ventilator module IRU x 19 to be fitted underneath iii 5 way Phoenix cord mounted AC mains connector iv RS485 serial cable RJ45 gt RJ45 600mm long 175A DC Anderson Connector Colours Note Different colour connectors will not key with each other 24V DC Red 48V DC Grey 110V DC Blue SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 1 5 Reinversion Discharger Energy Recycler Series Energy Recyclers 2 kW 102 kW DC capable ISO9001 MENU SCREENS DISPLAY SCREENS SETUP SCREENS Enter a discharge MENU 0 current between If Totals Jo Initiate Discharge Xx and yy Ams lt _ __ gt Amps If Totals 0 Discharge Termnate Discharge Termnate MENU 1 Max Time gt Max Time USER SET Discharge Term nate Max AHr lt gt USER SET Min Volts lt gt USER SET lt Status gt Reset Total s MENU 2 Discharge Status lt NO gt Discharge Terminated ENERGY RECYCLERS LTD New fault during Discharge MENU 3 Battery Discharger Power Up System Capacity lt XXX gt Vol ts Y YY Ams AC Mains Status MENU 4 Actual V lt gt AC Mains Status Actual Fr eq lt gt of Slaves Sl ave Configurati on MENU 5 Config Configuration Slave Configuration Total Voltage USER SET Total Current UNIT ID lt Master gt MENU 6
5. can have a maximum power discharge capacity of 102 kW The units making up a system are as follows 1 Master Unit One 1 only Master Unit is used in a single system For user interface the Master features a Liquid Crystal Display together with a keyboard for user input of parameters and control of the system Three different versions are available 2 kW 4 kW and 6 kW and these incorporate one two or three 2 kW power conversion modules respectively 2 kW units can operate into single phase AC supply only 4 kW units can operate into single or two phase AC supply and 6 kW units can be operated into one two or three phases dependent on how the us er connects to the supply 2 Slave Unit Up to Sixteen 16 Slave Units rated 6kW can be used in a single system operating in parallel with the Master Unit As with Master Units Slave Units can be operated into one two or three phases dependent on how the user connects to the supply The Slave Unit features a hexadecimal address select switch on the front panel which must be set to a unique address in the system Together with the Slave address switch are 3 LED s 1 Power Green LED u Data Yellow LED 111 Fault Red LED Master Unit Font Panel Keyboard and Display The Master Unit front panel incorporates DC and AC miniature circuit breakers MCBs Depending on the capacity of the Master Unit there will be one two or three each of DC and AC MCBs This corresponds to2 kW 4kW and 6 kW types resp
6. value needs to be continuously adjusted throughout the discharge to achieve a constant discharge current 2 Requires full time monitoring by a technician to record battery terminal voltage time and manually calculate Ampere hours 3 Relies entirely on the technician to terminate the test once the terminal test voltage has been reached 4 Energy from the batteries is dissipated as heat which consequently increase the ambient temperature of the test area usually the battery room 5 Bulky cumbersome units The Reinversion discharger overcomes these problems by proving a compact and complete test unit that allows the user to enter any desired discharge current from 5 to 100 of the maximum rating of the unit Then it continually adjusts the load presented to the battery to achieve this discharge current while monitoring both the battery terminal voltage and actual discharge current A low battery voltage cut out ensures that the batteries will not be over discharged The energy from the battery packs is fed into the AC mains to ensure absolute minimal heat is generated in the battery room while testing the condition of each battery The system is set up to allow the control from a front panel keypad while providing a feedback of battery voltage charge and discharge currents and any other status information via an LCD display In future it is planned that the system will be able to perform all control and monitoring remotely via the u
7. N WIL DAMAGE THE DISCHARGER Ensure the discharger is adequately ventilated 1 Ventilator module 1U installed beneath each unit 2 Free space is provided above top rear vents 3 No obstruction of any ventilation holes Ensure the rear of the discharger is adequately supported SPECIFICATION MAY CHANGE Reinversiddischarg ssers Manuklbv 01 Page 29 Energy Recyclers ISO9001 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable MENU SCREENS DISPLAY SCREENS SETUP SCREENS Enter a discharge current bet ween Xx and yy Ams lt _ gt Amps MENU 0 Initiate Discharge Discharge Termnate gt gt gt MENU 1 Discharge Ter m nate Max Ti me Max AHr Min Volt lt lt lt lt Status gt MENU 2 Discharge Status ENERGY RECYCLERS LTD Battery Discharger MENU 3 System Capacity lt XXX gt Vol ts Y YY Ams AC Mains Status Actual V e Actual Freq lt MENU 4 AC Mai ns Status of Sl aves Config Total Voltage Total Current MENU 5 Slave Configuration UNIT ID lt Master gt lt Status gt Actual V lt Actual l lt MENU 6 Unit Status gt gt UNIT ID lt Master gt Serial lt S w ver sion Total Disch MENU 7 Unit Information UNIT ID lt Master gt Rated DC V lt Rated DC Available MENU 8 Unit Rating lt UNIT ID lt Master gt MENU 9 Rated ACV lt Main
8. Pressing the Enter key when in the display screen will switch to the setup screen Discharge Terminate Max Time 00 00 Max A Hr 0000 Min Volt 000 0 In the setup screen the user can use the Up or Down keys to change between the different fields Values for max time max Ahr and min V can be entered using the numeric keypad to enter the value followed by the Enter key Entering a value of zero for any field turns the field off resulting in the word off being displayed for that field when the setup screen is exited Entering values for the minimum voltage field above or below pre allowed limits cause rounding up or down to the appropriate limit The Max Time field is entered in hours and minutes note that during and after discharge the display will show hours minutes seconds Menu 2 Discharge Status lt Status gt Ti me A Hr This screen is switched to whenever a discharge is started or terminated or if a new fault occurs during a discharge The first line shows the status of the system which will be one of the following messages Status Messages Fault Messages Standby Current Limited Initialising Low Battery Voltage Discharging OK Hish Battery Voltage Discharge Finished Over Temperature Over Current Mains Fault Communications Fault Slave Compatibility System Status Fault Messages not Unit Status Fault messages If the status message is either Stand
9. Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy Va EY Recvcter Recyclers Ph 64 9 8350708 Email info EnergyRecyclers com Fax 64 9 837 3446 Web www EnergyRecyclers com Reinversion Discharger User s Manual RECYCLER Energy Recyclers Ltd August 2001 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 1 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy Va EY gom Recyclers Contents Section Page L Introduction 3 5 About the Energy Recycler products 3 Definition of Terms 3 System Elements 4 General Overview 5 LI Theory of Operation 6 7 Block Diagram 6 Description 7 L Installation Instructions 8 10 AC Mains Connection 8 9 DC Connection 9 Serial Communications Connection 9 Physical Installation 10 L Functions and Features 11 13 Discharger Functions 11 Status and Fault Messages Unit 11 12 Status and Fault Messages System 12 Master Slave Functions 13 LI Product Specification 14 15 Operating Instructions 16 23 Menu State Diagram 16 Getting Started 17 Menu Operating Instructions 18 23 Thermal De Rating 24 L Appendices Master Unit Keypad and Display 25 Typical System Configuration 26 Front Rear Panel Layouts 27 Wiring Connection Diagram 28 Rating Label 28 Model Selection Table 20 Safety Notice 29 Menu State Diagra
10. al current value Menu 3 System Capacity ENERGY RECYCLERS LTD Battery Discharger lt XXX gt Volts lt YYY gt Amps This is the same initial screen that 1s displayed at first power up until the Menu key is pressed This screen is also displayed when the Stop key is pressed This screen displays the rating for the discharger based on the rating of the master and all slaves connected to it 1 e the total system capacity This rating does not take into consideration the fact that some units may have a reduced capacity due to DC circuit breakers being turned off LE this is the total maximum possible capacity of the discharger system Master Unit Slave Unit s Menu 4 AC Mains Status AC Mains Status Actual V lt Actual Freq This display screen simply shows the current AC mains voltage and frequency Page 20 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series de Energy Recyclers Menu 5 Slave Configuration 2 kW 102 kW DC capable ISO9001 of Slaves Config Total Voltage Total Current The of slaves field displays the number of slaves found by the Master Unit The Total V and Total I fields display the total rating of the system based on the rating of the master and the slaves connected and the configuration field value The Total V and Total I fields are the same as that which is
11. atus and Fault Messages Unitcont Over Temperature The discharger internal temperature cutout has been activated This can be due to the discharger operating at higher output power than specified for the ambient temperature see thermal de rating chart on page 24 or the discharger ventilation holes may be obscured Mains Fault The AC mains supply is out of specification i e the voltage is either too high or too low or alternatively the frequency is either too high or too low As with all Re Inverters the inverter and user need protecting from the consequence of operation without a mains reference disconnection from the mains supply this is normally referred to as island protection This discharger utilises island protection partial disconnection from the mains e g one of three phases will result in a mains fault message and the discharger stopping Total disconnection from the mains reference will result in the discharger totally shutting down Current Limited The discharger is unable to achieve the entered discharge rate During this condition the discharger will display the actual discharge current and continue to discharge the battery This condition should only occur if the battery voltage is extremely low or momentarily if a mains glitch occurs Over Current The internal over current fail safe circuitry has been tripped All fault conditions except initialising and current limited will stop the offending powe
12. ay be displayed The first line of the display will indicate the selected unit and when displaying a slave status the data light on the front of a selected slave will fla sh 3 times in rapid succession Pressing the Enter key when the display screen is showing will switch the display to the setup screen this then allows the user to edit the Phases field for the master or any of the Slave Units A numerical value for the number of phases 1 2 or 3 followed by the Enter key will set this field Stopping a Discharge To manually stop a discharge which c an be restarted again or completed press the Stop key This will halt the system discharge immediately The discharge can be re started if desired optionally maintaining the totals for Amp Hours and duration of discharge Note it is important that the discharger is stopped before turning off AC circuit breakers do not turn off AC circuit breakers during a discharge test SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 23 Reinversion Discharger Energy Recycler Series de Energy Recyclers 2 kW 102 kW DC capable ISO9001 Thermal De rating The discharger has a continuous input power rating of 2kW 4kW or 6kW per unit at 20 C At the highest allowable DC battery voltage the power rating can be excee ded by 15 if full rated current is selected by the user As with all power electronic devices operation of the
13. by or Discharge Finished the following three lines of the display screen indicate the final results from the last test otherwise the following three lines of the display screen show the results of the current discharge test Time is displayed as hours minutes seconds SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 1 9 Reinversion Discharger Energy Recycler Series de Energy Recyclers Menu 2 cont 2 kW 102 kW DC capable ISO9001 Pressing the Enter key when the display screen is showing will switch to the setup screen here the user is prompted as to whether they want to reset the totals The default setting is NO Pressing the Enter key will exit the setup screen without resetting the totals where as pressing the UP or DOWN keys will toggle between lt YES gt and lt NO gt Display lt YES gt followed by the Enter key will reset the totals If the test has been terminated due to the preset maximum time maximum Ahr or minimum voltage being met the status line will display the words Discharge Finished and the reason for the discharge being terminated i e the label Time Ahr or V will be flashing but the number associated with the label is constantly on Note the value stored in the field discharge current when a discharge has been terminated is the last user set current value not the final discharge actu
14. d DCI field displays the current per module x the number of modules installed i e a 48V 6kW unit displays Rated DC I 40 x 3 The Available I field shows the available discharge current capability of the unit taking into consideration the number of DC circuit breakers currently switched on i e a 48V 6kW unit with only one circuit breaker switched on will display 40 Pressing the Up or Down key will navigate between the different discharger units such that the information for all units in the system from the Master through Slave 0 to the last Slave Unit connected may be displayed The first line of the display will indicate the selected unit and when displaying a slave status the data light on the front of a selected slave will flash 3 times in rapid succession Page 22 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series de Energy Recyclers Menu 9 Mains Configuration 2 kW 102 kW DC capable ISO9001 Unit ID lt Master gt Rated AC V lt gt Rated Freq gt of Phases lt gt This display screen allows the interrogation of the Master Unit or an individual Slave Unit to see the rated AC mains configuration Pressing the Up or Down key will navigate between the different discharger units such that the information for all units in the system from the Master through Slave O to the last Slave Unit connected m
15. discharger for prolonged periods at or near maximum capacity will result in high operating temperatures and accelerated deterioration of componentry This will shorten the life of the product Each power module is fitted with a thermal temperature sensor which activates thermal shutdown if the module becomes too hot To ensure that the thermal shutdown is not activated do not exc eed the following discharge parameters Ambient Discharge Power voltage x current temperature 1 module 2 modules 3 modules e Discharge Power can be calculated by multiplying the Discharge Current by the Battery Voltage actual displayed voltage Maximum current per module 48V system es E eee EE GCEEEEER E 40V 42V 44V 46V 48V 50V 52V 54V Battery Voltage Page 24 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series Energy Recyclers Li 2 kW 102 kW DC capable ISO9001 Master Unit Keypad and Display master unit ENERGY RECYCLERS LTD Battery Discharger 48 Volts 360 Amps SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 25 de Energy Recyclers ISO9001 Typical System Configuration Depicted at right is a system ee comprising a Master Unit and 21GB four Slave Units 4 5 6 7 8 9 Specification apap Boz Master Unit 48V 120A 6kW Slave Units 48V 120A 6kW x4 Cooling Modules 5 x 1RU hi
16. displayed in the display screen of Menu 3 System Capacity Note that in future it is intended that the software will be enhanced to enable the user to change the Configuration field by pressing the Enter key to switch to the setup screen then the Up and Down keys will enable the selection of various options Parallel Series 2 Series 3 or Series 4 Pressing the Enter key then selects the option Menu 6 Unit Status Unit ID lt Master gt lt Status gt Actual V lt Actual l This display screen allows the interrogation of the Master Unit or an individual Slave Unit to see what it is currently doing Pressing the Up or Down key will navigate between the different discharger units such that the status of all units in the system from the Master through Slave O to the last Slave Unit connected may be displayed The first line of the display will indicate the selected unit and when displaying a slave status the data light on the front of a selected slave will flash 3 times in rapid succession The Status field may show any of the following labels Standby Initialising Discharging OK Current Limited Low Battery Voltage High Battery Voltage Over Temperature Over Current Mains Fault The Actual V and Actual I fields will display the voltage that the selected unit is seeing and the current it is discharging at These values will only be a part of the total that is displa
17. e Wiring Connection Diagram page 28 Note both ends of the serial cable have the same plug RJ45 and can be connected either way around to achieve daisy chain connection of the communications bus Similarly of the two RJ45 sockets at the rear of each unit connecting to either socket is valid RS 485 cable E Jm RJ45 8 SE RJ45 8 plug PAS R plug SPECI FICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 9 Reinversion Discharger Energy Recycler Series de Energy Recyclers Physical Installation 2 kW 102 kW DC capable ISO9001 All units are designed for standard IEC 19 equipment racks of at least 500mm depth For ease of use 600mm depth is recommended It is essential that the ventilator module supplied is installed directly below each discharger This enables the free passage of cooling air into the front underside of the discharger unit and the exit of heated air at the top rear of the discharger unit It is important to observe the following at time of installation 1 If any unit is installed at the top of a rack at least IRU free space should be provided above The top vents at the rear of the discharger must be clear and free of obstructions The back of the equipment rack must be open The discharger units are designed for permanent installation The rear of the discharger must be supported a an M6 tapped hole is provided in the back panel of the discharger for this purp
18. e can individually synchronise to its own mains source and hence the user can decide on single dual or triple phase connection assuming sufficient inverter power modules To increase the discharge capability beyond the 6 kW limit of a single discharger unit extra 6 kW Slave Units can be controlled by the Master discharge unit Initially a 48v version of the Reinversion discharger has been developed but it is the intention that 24v amp 110v versions will also be developed as well as other possible intermediate voltages Definition of Terms The following should help clarify the terminology used throughout this document System A number of dischargers connected together via an RS 485 interface to discharge a common set of batteries A minimum system would be a single Master discharger and a maximum system would be a Master discharger controlling 16 Slave dischargers Unit A generic name given to a discharger irrespective of whether it is a Master or Slave Unit A Master Unit can have a discharge capacity of either 2 4 or 6 kW Module A name given to the internal 2 kW inverter power module that makes up a unit Note that a unit can have 1 2 0r3 inverter power modules SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 3 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy Va EY gom Recyclers System Elements Units A reinversion discharger system
19. ectively The display is a back lit Liquid Cry stal Display LCD of 4 lines x 20 characters The Keyboard consists of a numeric keypad incorporating digits 0 through 9 decimal point and Enter 5 In addition 4 separate keys allow Menu and parameter selection and STOP MENU Menu key allows access to Menu selection N Up key permits navigation between some screens and fields w Down key permits navigation between some screens and fields stop STOP key allows the user to interrupt a discharge test immedi ately at any time forcing the system into Standby Mode and overriding the system Discharge Terminate parameters Operating Concept The System is operated using the keyboard and display to select parameters monitor status display error messages and other functions The display is Menu based and incorporates menu screens display screens and setup screens For an overview of the structure see Figure 1 Page 4 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy Va EY gom Recyclers General Overview The reinversion battery dischargers were designed to achieve aclear goal This particular objective was to provide an accurate controlled and heatless alternative to traditional battery discharge techniques A simple resistive battery discharge test load has many drawbacks and they are 1 Resistance
20. eypad e Battery Voltage An indication of the battery terminal voltage e Discharge Time An indication of the accumulated duration of the discharge test e Discharge A Hr An indication of the accumulated amp hours Ahr discharged during the duration of the test e Fault Status An indication of the current status of the discharger and any faults that have occurred If a discharge test is terminated for any reason user or discharger terminated the timer and the A Hr accumulator will stop while maintaining their current values also the final battery voltage and current will be recorded If a new discharge test 1s initiated the timer and Ahr accumulator will carry on from their current values At any time the user can reset both the discharge timer and Ahr accumulator Before a discharge test the user can preset some parameters for the discharge test e Minimum Discharge Voltage The minimum voltage that the batteries will be discharged down to e Maximum Discharge Time The maximum duration of the discharge test e Maximum Discharge Ahr The maximum amp hours that will be discharged out of the batteries Note Any or all of these parameters may be set to zero which effectively disables any parameter each parameter can be individually turned off so that it will not be able to terminate the test The first parameter to be met during the discharge test will terminate the test The parameter that caused the termi
21. ge current between 50 and 100 of the enabled system discharge capacity can be entered For example a 48V system with two DC circuit breakers turned on discharge from 40 to 80A can be entered and with six DC circuit breakers turned on a discharge from 120A to 240A can be entered Enter the desired discharge current using the numeric keys then press the Enter key to initiate a discharge If totals are not equal to zero then the display will prompt the user as to whether the values should be reset back to zero Pressing Enter will NOT reset the current totals to zero and the discharge will be initiated Pressing 0 Enter WILL reset the current totals to zero and the discharge will be initiated Notes 1 in the unlikely event that a power module fails the system can be operated at less power by first isolating the faulty module by turning off its respective DC circuit breaker 2 for an explanation of totals see Menu 2 Menu 1 Discharge Terminate Discharge Termi nate Max Ti me off Max A Hr off Min Volt of f This menu displays the maximum and minimum limit parameters that have been set for a discharge test During testing immediately that the first of these parameters is met the discharge will be terminated Page 18 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series de Energy Recyclers Menu 1 cont 2 kW 102 kW DC capable ISO9001
22. gh vent ilators Total System Capacity 48V 600A 30kW Discharge Capability i One only DC circuit breaker on 2A to 40A in 1A steps u 40A to 300A covered by number of DC breakers turned on iii All DC circuit breakers on 300A to 600A in 1A steps System Size 19 W x 21U 934mm H x 500mm D This includes 1 above Master Unit not shown for cooling purposes System Weight 145 kg approx AC connection 30 230VAC phase to neutral 4 wire earth AC current Standby 1A 1 only Discharging up to 40A pe phase Slave addresses 0 1 2 3 Page 26 SPECIFICATION MAY CHANG E ReinversionDischargerUsers ManualNov 01 de Energy Recyclers ISO9001 Front Panel Layouts Master Unit master unit JE ENERGY RECYCLER INNOVATIVE ENERGIES slave address power slave unit data fault Rating Label Information Rear Panel Layout Energy AC Mains R regeln EES eh e EE 2 Energy Recyclers Ltd gt kVA output 60 PO Box 19 501 osf I Auckland Neutral Ph 649 8350709 Ensure DC circuit breakers are off before connecting um SPECIFICATION MAY CHANG E ReinversionDischargerUsers ManualNov 01 Page 27 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy A Recyclers Wiring Connection Diagram Master S ch EE iue AC Mains Connection Load Input RS485 Slave Can mu
23. lt Status gt Unit Status Actual V lt gt Actual l lt gt UNIT ID lt Master gt MENU 7 Serial lt Menu Unit Information S w ver sion GE State Diagram UNIT ID lt Master gt MENU 8 Rated DCV lt gt Unit Rating Rated DC lt gt x lt gt Available lt UNIT ID lt Master gt MENU 9 Rated ACV lt gt Mains Configur ati on Rated Freq lt gt of Phases lt gt Page 1 6 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 UNIT ID lt Master gt Phases USER SET Reinversion Discharger Energy CT ex Energy Recycler Series Rec clers 2 2 kW 102 kW DC capable Operation Getting Started Refer to State Diagram on previous page for reference to the following discussion Initial Power On Power On Display When all connections to DC battery and AC mains supply have been made and checked the user can power up the system Master Unit and Slave Units if any by closing all MCBs The following is displayed ENERGY RECYCLERS LTD Battery Discharger xXx Volts lt yyy gt Amps Power On Display above sho ws the total System capacity as follows e Volts the System Voltage which must match the nominal battery voltage which is to be discharged Amps the total System Current capacity i e the maximum discharge capacity of the system This is generated dynamically at power up when the Master Unit detects and interrogates all Slave Units
24. m for quick reference 30 Page 2 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy Va EY gom Recyclers Introduction About the Energy Recycler products The reinversion discharger product line is a revolutionary product from the Energy Recycler family of products It enables precise controlled and monitored discharge of battery banks in telecommunications utility UPS and other applications Traditional methods of discharge testing involve at best crude control of the discharge rate and convert the considerable amounts of energy from the battery into heat which is problematic to dissipate and in many installations there is a risk of overheating other equip ment The reinversion discharger instead converts the DC energy from the battery not into heat but usable AC energy which is fed back into the incoming AC mains supply This energy can then be used in the installation premises to offset electricity costs or if the installation consumes less electricity than that generated by the reinversion discharger the user will have a net gain and the energy will flow into the distribution system Comprehensive interlocks and protection systems provide foolproof protection and safety The Reinversion discharger consists of a 19 inch rack case that can house either one two or three 2 kW inverter power modules Each modul
25. nation of the test will be flashing on the display as well the status message Discharge Finished and the buzzer will sound continuously until the first key press alerting the user to the reason for the termination of the test The discharger will display the final values for the discharge timer Ahr accumulator final battery voltage and discharge current Discharger Status and Fault Messages Unit Apart from the discharge related information the discharger display is able to indicate the current status of the discharger along with any fault messages e Discharge OK The discharger is functioning normally and discharging the battery e Standby The discharger is in a standby mode awaiting a user input of discharge current e Initialising The discharger is responding to a user input of discharge current and the discharger is going through its initialisation process Low Battery Voltage The battery voltage is to a point that would cause damage to the batteries if discharged any further independent to user selectable minimum discharge voltage e High Battery Voltage The battery voltage is to a point that would cause damage to the discharger if a discharge was enabled e g a 24V discharger on a 48V battery SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 1 1 de Reinversion Discharger Energy Recycler Series Energy Recyclers 2 kW 102 kW DC capable ISO9001 Discharger St
26. nication Earth CO cH Load Input AC Mains Load Input BATTERY Page 28 S P EC F CATION MAY C HANG E Reinversion Discharger Users Manual Mar 01 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy e H Recyclers Reinversion Dischargers Model Selection Table Master Units Slave Units types Model types Model types Model 1 O 2 of Power Modules 2 Please specify when ordering 1 AC Mains voltage and frequency 2 Input DC voltage nominal IMPORTANT SAFETY NOTICE Operational Precautions to be observed The Reinversion Discharger has been designed for simple installation and operatio However it is most important that simple precautions are taken to ensure troubl free operation d Do not operate the product without first reading and understanding the User s Manual d Ensure Safety Earth connection is made before operation see User s Manual page 28 Do not remove unit cover No user serviceable parts inside unit Service by qualified technical personnel only Do not turn AC crcuit beakers off whilst unit is discharging first press STOP button terminate the discharge Ensure unit rating is correct for the intended application DC rated Voltage AC ratec Voltage AC rated Frequency Ensure DC Circuit Breaker s are OFF whilst connecting or disconnecting DC input plug Ensure DC Battery Polarity is correct REVERSE POLARITY CONNECTIO
27. ntilator Manual cables and plugs 650g Size 483W x 134H x 500D mm DC Battery Connection Grey 175A 2 pole Anderson connector AC Mains Connection 5 way Phoenix Power Combicon connector Orientation Normal vertical 19 equipment rack mount note that IRU ventilator module must be intalled underneath unit and that top rear vent must be free of any obstruction at all times Page 14 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Reinversion Discharger Energy Recycler Series de Energy Recyclers 2 kW 102 kW DC capable ISO9001 RS 232 RS 485 Serial Communications Interface RS 232 for Personal Computer PC connection Isolated to IEN RS 485 for Slave Unit control allows full control and monitoring of Slave Units from a Master Unit Isolated to 1kV Control Interface Master Unit 16 button keypad 4 line x 20 character backlit LCD display Buzzer to annunciate end of discharge or fault These items provide full user interface to the system including Slave Units Slave Unit Primary control is achieved via the RS 485 serial interface 16 position hexadecimal rotary switch Address selection LEDs Power ON Green Data Yellow Fault Red Buzzer to annunciate a fault condition Accessories Master Unit i 175A DC Anderson mating connector 1 Ventilator module IRU x 19 to be fitted underneath iii 5 way Phoenix cord mounted AC mains connector iv 2 metre RS 232 serial
28. ose A support bracket user supplied should be fitted Setting of Slave Address Slave addresses must be unique and set prior to powering up the equipment The address is set by the hexadecimal rotary switch on the front panel of the Slave Unit which allows a maximum of 16 individual addresses from O through F In any system the frst Slave Unit must be set to address 0 the subsequent unit s to consecutive addresses Un BW WN System Redundancy In the event that a power module fails the user can by use of the Master Unit MENU 6 determine which module has failed By turning OFF the associated DC circuit breaker the system can continue to be operated at a lower output power reduced by 2kW per module Each power module can be tested in turn by simply enabling one power module at a time and initiating a discharge test using just that single module With the complete system running MENU 6 allows the monitoring of the status of any individual power module Page 1 0 SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 de Reinversion Discharger Energy Recycler Series Energy Recyclers Discharger Functions and Features 2 kW 102 kW DC capable ISO9001 The discharger has some functions that have been specifically designed for the function of battery discharge testing When a discharge test is initiated the display shows the following information e Discharge Current User selectable through the numeric k
29. r module from operating leaving the other power modules in a discharger unit to carry on All fault conditions are announced by short repetitive beeps from the buzzer Discharger Status and Fault Messages System A system consists of a master discharger and at least one slave discharger The Master Unit will display not only its own fault messages but also the fault messages of all of its slaves Only one fault message will be displayed at a time and the user will have to look at all the slave fault LEDs in order to determine which unit has caused the fault The Discharging OK message will only be displayed if the master and all of its slaves are discharging OK As well as the unit faults listed above there are some specific system status fault messages that pertain to a system Page 12 Discharge Finished If the discharge has been terminated due to either the maximum discharger Ahr limit maximum discharge time limit or minimum discharge DC voltage limit being met then the Discharge Finished status message will be displayed Communications Fault This message is displayed if the master discharger detects that a Slave Unit has an incorrect address switch setting this causes bus contention on the RS 485 serial interface Slave Compatibility If the master discharger finds that its connected slaves are not compatible it will display this message SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01
30. s Configurati on gt gt Rated Freq lt gt of Phases lt gt SPECIFICATION MAY CHANGE lf Totals 4 0 If Totals 0 Discharge Termnate Max Time USER SET USER SET USER SET Reset Total s NO Discharge Terminated New fault during Discharge Power Up S ave Configurati on Configuration USER SET Menu State Diagram gt lt X gt UNIT ID lt Master gt USER SET gt Phases ReinversidDischarg sers Manuibv 01
31. s is integrated into the Master Unit in a way that is totally seamless to the user For example if a 48V 120A Master Unit has another 48V 120A Slave Unit connected to it in a parallel connection the Slave Unit would display that it is actually a 48V 240A discharger The user can then enter any discharge current from 5 to 100 of this 240A total capacity The displayed discharge current Ahr accumulator total discharger status and fault messages take into consideration the total combined effect of the master and its connected Slave Units A series connection of the above mentioned two 48V 120A dischargers would result in the Master Unit displaying it was a 96V 120A discharger Each slave discharger unit in a system must be assigned its own unique address 0 F HEX by setting the front panel rotary switch and these must be assigned consecutively starting at 0 A master discharger unit can be used to interrogate any of its slaves and display appropriate information about the slave on its display e g check a slave s rating or serial number The master discharger is also able to inform the user to the total number of Slave Units connected to it SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 1 3 m Energy Va Ly Recyclers Electrical DC Input Voltage Low Battery Voltage Disable High Battery Voltage Disable Discharge Power Discharge Current DC Input Voltage Ripple AC Mains Voltage AC Mains Curren
32. se of the RS 232 RS 485 serial communication ports SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 5 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 Reanversion Discharger Block Diagram am T Tem Circuit Breaker Filter Battery DC Connector ME Wr Inverter Inverter Mains Relay Corto Relay AC Mains Vdtage Circuit Control Processor Breaker Lm AC Mains 4 Lines 20 dar LCD Display Seia Corrmurication with backlight ISolateo RS232 RS485 Page 6 de Reinversion Discharger Energy Recycler Series Energy Recyclers Theory of Operation refer Block Diagram 2 kW 102 kW DC capable ISO9001 While in discharge mode the unit converts the low voltage DC power from the batteries into a high voltage AC power source that matches the present mains supply voltage and frequency and this enables a transfer of power into the mains supply By doing this the energy from the batteries is transferred into the mains supply and only a small amount of the dissipated battery energy is dispersed in the form of heat due to certain inefficiencies This conversion of the low DC battery voltage to mains voltage AC is a two stage process best described by the following two points DC gt DC Converter The first stage consists of an isolated DC gt DC converter This steps the battery voltage up to a nominal 450V DC and pro
33. t AC Mains frequency Efficiency EMI RFT AC Current Draw Supply Converter Operating Frequency Safety Island Protection Isolation AC Mains to case DC to case AC Mains Circuit Breaker DC Circuit Breakers 99 e Accuracy Discharge Current DC Voltage Current Monitoring AC Voltage Monitoring AC Frequency monitoring Ampere Hour monitoring Time elapsed Reinversion Discharger a Energy Recycler Series 2 2 kW 102 kW DC capable emm Specifications 24 48 110V nominal 18 36 82V 29 57 131V 2kW 4kW 6kW 20 C 5 to 100 of rated current 190 220 230 240V 20 specify when ordering 0 2A to 8A phase 220 240V 50 60Hz nominal 10 specify when ordering 90 typ to CISPR22 EN60522 level A Sinusoidal lt 5 THD to IEC1000 3 2 IEC555 EN6100 0 3 2 JEAG9701 first stage 54kHz second stage variable 15kHz to 100kHz to IEC950 EN60950 AS NZS3260 10 on mains frequency 20 on mains voltage 3500V AC 1 min IkV with DC bypass capacitor removed 220 240V 10A 24V 60A 48V 40A 110V 20A 2 5 of full scale 1 0 of full scale 2 0 of full scale 1 0 of full scale 2 0 of reading 1 second Physical Ambient Humidity 0 95 RH non condensing Ambient Templerature 10 C to 40 C fan cooled also refer thermal de rating page 24 Weight unpacked 2kW 17kg 4kW 23kg 6kW 29kg Weight packed 2kW 23kg 4kW 29kg 6kW 35kg Weight of accessories Ve
34. th a constant current SPECIFICATION MAY CHANG ReinversionDischargerUsers ManualNov 01 Page 7 Reinversion Discharger Energy Recycler Series 2 kW 102 kW DC capable ISO9001 m Energy Va Ly Recyclers Installation AC Mains Connection All units are fitted with a 5 way AC Mains connector on the rear panel observe the diagram below for correct connection to the cable socket supplied On 2kW units single phase 1 Neutral Earth is the only valid connection On 4kW versions connect 01 and O2 plus Neutral and Earth 1 and 2 can be connected to either one common phase or two separate phases On 6kW versions connect 01 02 and 3 plus Neutral and Earth 1 2 and 3 can be connected to one two or three phases Notes Neutral and Earth connections are essential regardless of connection method used Menu 9 Mains Configuration must be set to the correct number of phases i 1 set phases 1 ii 20 set phases 2 111 30 set phases 3 Rated AC Voltage displayed is Line to Neutral Voltage MENU 4 and MENU 9 4 Although 3 units can be connected to just one single phase supply it is recommended that connection to 3 be used if possible see below 5 The Phase connection order is not critical e g 01 02 03 can be connected in any order to the mains red yellow and blue phases Connecting Multiple 6kW Units to 3 S O1 O2 O3 Master NO me LA Slave 0 OH 02
35. vides safety isolation of the batteries from the potentially lethal mains supply DC gt AC Inverter The second stage comprises of a current mode profiling inverter stage that monitors the present mains supply and profiles the 450V DC into a sinewave AC voltage in step with the mains By being current mode the inverter can profile the mains current to be sinusoidal resulting in an extremely low Total Harmonic Distortion of the power that is fed into the mains Mains Filter The purpose of the Mains Filter is to eliminate any Electromagnetic Interference generated by the inverter getting into the mains Mains Isolator This ensures that the inverter module is disconnected from the mains when a discharge cycle is not being performed Cooling Fan The purpose of the fan is to keep the temperature of every component inside the discharger well within the recommended safety margins by the manufacturers As such it only operates when the unit is in the discharge mode Control Processor The control processor provides the user interface via the keypad and display controls and monitors the status of the power modules and communicates with other dischargers if any in the system The serial communication interface is completely isolated Control Strategy The Current Transducer is monitored to determine actual discharge current and compared the set current resulting in continual adjustment of the inverter stage to present the batteries wi
36. yed in the menu 2 Discharge Status display screen i e that part that the selected unit is contributing to the total system discharge capacity SPECIFICATION MAY CHANGE ReinversionDischargerUsers ManualNov 01 Page 21 Reinversion Discharger Energy Recycler Series de Energy Recyclers Menu 7 Unit Information 2 kW 102 kW DC capable ISO9001 Unit ID lt Master gt Serial lt gt S w Version gt This display screen allows the interrogation of the Master Unit or an individual Slave Unit in order to show some fixed information about it The Total Disch field in the display screen shows the user the total accumulated hours that the selected unit has discharged for The software version number and serial number of the unit are also displayed for reference purposes Pressing the Up or Down key will navigate between the different discharger units such that the information for all units in the system from the Master through Slave 0 to the last Slave Unit connected may be displayed The first line of the display will indicate the selected unit and when displaying a slave status the data light on the front of a selected slave will flash 3 times in rapid succession Menu 3 Unit Rating Unit ID lt Master gt Rated DC V Rated DC gt This display screen allows the interrogation of the Master Unit or an individual Slave Unit in order to see its rating The Rate
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