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1. 20 000 005 29 Specifications ira Sub E ee tote khe P xad ka ER wo ae Gk we Ba bk a a Get get ENG X 31 Installation drawings provided with manual 2 eee ee es 32 VYCON VDC and VDC XE User Manual iii VYCON VDC and VDC XE User Manual iv Important Safety Instructions 1 0 Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during the installation and maintenance of the VYCON Direct Connect flywheel energy storage system Personnel installing or maintaining VYCON equipment must read and understand this manual before operation of the equipment It is the user s responsibility to read and obey all safety procedures become familiar with these procedures and know how to safely operate this equipment A WARNINGS Utilize extreme care when handling the VYCON VDC flywheel energy storage system to prevent equipment damage or injury to personnel By no means should the VYCON VDC flywheel energy storage system be removed or dismounted while the flywheel system is turned on and or the flywheel rotor is spinning Failure to obey all safety precautions and general instructions may cause personal injury and or damage to the equipment In the event of fire involving electrical equipment the use of carbon dioxide fire extinguishers or other equipment appropriate for extinguishing electrical fires must be utilized Utilize extreme car
2. Conduct basic training on the VDC operation to operators Support the initial system startup Verify the software control parameters VYCON VDC and VDC XE User Manual 25 Operation T 3 7 3 1 7 3 2 Typical System Startup Procedure NOTE A typical system startup is defined as any startup that takes place after the initial system commissioning The following procedure assumes that system installation inspection and initial system startup have been performed by VYCON certified service personnel VYCON certified service personnel must perform system installation inspection and initial startup Failure to do so will void the warranty System Inspection Prior to Startup Prior to a typical system startup the following must be performed on the VDC Make sure that no tools are in the cabinet and the protective cabinet panels are in place Check the vacuum pump oil level and condition Check to be sure EPO button is not in Latched Off position Verify that DC power is connected to the UPS DC bus Verify that auxiliary AC power is connected to the system Switch ON the auxiliary AC power to the VDC An audible alarm may sound reset by touching the Silence Horn button after the touchscreen boots up Check and verify the front panel touchscreen boots up without errors and the system fans are operational 7 Wait until the vacuum system reaches full vacuum conditions Qv gr ds co MO NOTE Upon first commission
3. Warning takes place at 35 mTorr Fault occurs at 50 mTorr Enclosure Temperature OK Fault Normal enclosure temperature exceeded Housing Temperature OK Fault Normal flywheel housing temperature exceeded The right side of the screen has the same navigation buttons as all submenu screens Submenu buttons Touch the appropriate submenu button to access the Discharge Events menu or the Warning Alarm Events menu Return to Main Display Touch the Return to Main Display button to return to the Main Screen default screen VYCON VDC and VDC XE User Manual 22 Front Panel Touchscreen 6 5 System Modes The VDC has 11 various system modes based on a set of programmed conditions enabling the system to start stop monitor system activity charge discharge declare faults and execute emergency shutdowns if necessary The VDC is programmed to operate seamlessly and transi tion through modes with minimal user intervention The current system mode is displayed on the Main Screen and the Operating Parameters menu A description of the system modes is provided in Table 7 Table 7 System modes description and fault status of the VDC System Status Mode Description Ready to Start No system faults are present and the unit may be initiated to start START Upon operator initiation the unit will energize and pre charge Normal Charging The flywheel is accelerating to its fu
4. tion program to produce a command signal for each current amplifier The current amplifiers provide the drive current to the actuators controllers of each axis thereby applying the forces on the rotor maintaining the desired flywheel rotor position Flywheel Controller The flywheel controller is the intelligence of the flywheel system and contains a digital controller that monitors and controls the various subsystems within the VDC Functions of the flywheel system controller include charging motoring and discharging gener ating of the flywheel controlling and monitoring of the subsystem components and handling system alarms faults and shutdown Emergency Power Off The emergency power off feature on the front of the VDC allows the operator to disable the sys tem in the event of an emergency The emergency power off may also be activated remotely via a normally open dry contact Flywheel The core of the VDC is the flywheel which stores the kinetic energy and is designed for high power short discharge UPS applications Figure 3 illustrates a cross section of the flywheel and associated hardware A description of the key flywheel components is provided below Flywheel Components Figure3 Flywheel components The key flywheel components are the EE y housing motor generator flywheel CMM rotor and magnetic bearings Housing The aluminum flywheel housing aligns and supports the bearings and the stator Alignment is
5. rpm is reached Alarm with Flywheel Shutdown The flywheel is at zero 0 rpm due to error s that resulted in a shutdown audible Stopped The user may attempt to restart the System but if the error s persists the horn restart command will be ignored until the error s are corrected The Emergency Power Off button has been activated The flywheel will decelerate without any motor controller and power electronics assistance aui odd The unit isolates itself from the external DC bus immediately and the ON switching of the power electronics will cease There will be considerable time elapsed by the time zero 0 rpm is reached A system reset by a qualified technician will be required to resume operation Note AC power may still be available to the flywheel Toreset the audible horn alarm press the Silence Horn button in the lower right corner of the Main Screen See 6 1 Main Screen VYCON VDC and VDC XE User Manual 23 Front Panel Touchscreen 6 6 Software Control Parameters The control parameters are configured and factory set for each system The control parameters depend on the type of UPS and the application of the VDC Three control parameters are config ured regulation voltage charge voltage and charge current range Table 8 illustrates the con trol parameters and ranges for the various control parameters Table 8 Software control parameter setting Control Parameter Unit Range Regu
6. 0 2 estes pese EEG beste bes pe pe pe eu e e etas 15 System Wining saar 5h eed hake Oe boi o Ee tol Rh eek Is ortos dor eL bee eot x 15 DC Bus Terminal Connections ss crs rreri nin eee ee ee ene 16 Protected AC Power Terminal Connections llle 17 Control Wire Terminal Connections llle 18 GOUT Gs xxu Tut re LEAL AAA Aet ee ee eee 18 VYCON VDC and VDC XE User Manual i 6 0 6 1 6 2 6 3 6 4 6 5 6 6 7 0 7 1 7 2 7 3 7 4 8 0 8 1 8 2 9 0 9 1 9 2 10 0 11 0 12 0 Front Panel Touchscreen eeeeeeeee eee eee eee eens 19 Main SCcreene 55353 3 ar EUR ERU E doe dut BA RUN RU A es a RS RC aie RN ILE bee tng 20 Diseharge Events EOgz X lup aw ARRA RR AR I Rog d oe e gx og ie ep td 21 Warning Alarm Events Log viv o c o e c e eg ee Ra eR dag cae us 21 Operating P rameters 25 22 4b kk o REG RR ORE PE PY OR ORE ORARE Eea P PE RE 22 System MOdES ue ose au ehe obe eee eem bem eem ete or tm dogs 23 Software Control Parameters ee oe e oe e e e OX dE CX XU e eee n EC a und 24 OperatlOl va vue ences Seon a Pek Sh RERO EPIN Yu EVERI ITEM EP VE eR 25 Visual and Mechanical Inspection Before Initial System Startup 25 Initial System Startup Procedure llle 25 Typical System Startup Procedure llle 26 7 3 1 System Inspection Prior to Startup eee 26 419 2 Startup o VDC xiu oed cha uere e rele e bleed 26 system Shutdown Sequence ive v
7. 8 25 2008 11 16 23 AM Current date and time The key parameters that are displayed include Sen Status System Mode Available Energy Number of Discharge Events System Start and Stop submenu access i e Discharge Events Warning Alarm Events and Operating Parameters and date and time System Status The color coded system status indicator appears in the upper left corner of the touchscreen For detailed definitions refer to 8 0 Troubleshooting System Mode The system mode displays the current mode of operation for the VDC There are a total of 11 system modes described in detail in 6 5 System Modes Available Energy Displays the energy available in the VDC as a percentage of the usable energy For example at 100 100 of the usable energy is available No of Discharge Events Displays a system counter showing the total number of dis charge events that have occurred in the VDC including both partial and full discharges SYSTEM START To start up the system push the green START button in the upper right corner of the touchscreen panel After a confirmation screen appears touch the START CONFIRM button to initiate the system to energize pre charge and begin to accelerate to its fully charged state provided no system faults are present NOTE The system must not be started until VYCON certified service personnel have performed system installation inspection and initial commissioning Failure to do so will void the
8. Power 99 4 Maximum Power System Losses lt 2 of rated power Safety UL cUL Mechanical Weight 1822 Ib 826 kg Dimensions W x D x H 30 x 30 x 73 7 in 762 x 762 x 1872mm VYCON VDC and VDC XE User Manual 31 Installation Drawings 12 0 Installation Drawings Table 13 provides a list of installation drawings provided with this manual including drawing numbers and titles Table 13 Installation drawings provided with manual Drawing No Title 9000038 00 Facilities Interface Diagram VDC and VDC XE 9000044 00 System Power Diagram VDC and VDC XE 9000043 00 Interconnect Diagram VDC and VDC XE 9802001 xx Acceptance Test Report external VDC and VDC XE VYCON VDC and VDC XE User Manual 32 VYCS N UL Version VYCON DIRECT CONNECT VDC and VDC XE User Manual VYCON 23695 Via Del Rio Yorba Linda California 92887 USA E mail service vyconenergy com Copyright 2008 VYCON Inc All rights reserved Part Number 9801007 00 Rev B Nov 2008
9. VDC and VDC XE User Manual 1 Important Safety Instructions AN WARNING The AC input voltage setting is factory set and is indicated on the nameplate located on the inside of the right panel door see Table 1 If the AC input voltage setting is changed in the field the nameplate must be modified accordingly to notify and alert future service personnel of the change Table 1 AC input voltage setting change notification on nameplate AC Input L L 50 60 Hz 2 WIRE GND AC Input Configuration Volts VAC 208 380 400 415 440 480 600 Current Amps 5 75 3 16 3 2 9 2 73 2 5 2 NOTE Changes to the AC input voltage must be performed by certified VYCON personnel Safe and efficient operation can only be achieved if the equipment is properly operated maintained and serviced 1 4 General Safety Precautions Read and follow the instructions in this manual thoroughly before carrying out any work on the VYCON Direct Connect Please take note of all the safety precautions outlined in this manual Normal safety precautions are necessary while the system is operating under typical operat ing conditions with all cabinet doors closed Unique safety instructions are required for handling installation and maintenance of this equipment Please refer to the particular sections that apply to the work you will be perform ing on this equipment Keep the area around the system free from puddles of water
10. Via Del Rio Yorba Linda CA 92887 Tel 1 714 386 3800 www vyconenergy com 23695 Via Del Rio Yorba Linda CA 92887 Tel 1 714 386 3800 www vyconenergy com PIN 9410089 00 Rev A PIN9410090 00 Rev A The field supplied AC power wiring provided by the electrical contractor must be in accordance with local regional and national electrical codes Connect the AC power cables according to the table in Interconnect Diagram VDC and VDC XE VYCON VDC and VDC XE User Manual 17 Installation 5 6 5 7 Control Wire Terminal Connections Figure 10 Control wires at J17 and J18 The control wires are terminated at J17 and J18 shown in Figure 10 The control wiring allows basic communication between the other equipment and the VDC J17 and J18 can accommodate one 1 22 to 10 AWG per terminal Route control wires as far away from power cables as possible to minimize J17 interference Pin 1 at top The field supplied control wiring provided by the electrical contractor must be in accordance with local regional and national electrical codes Connect the control wiring according to the table in Interconnect Diagram VDC J18 and VDC XE Pin 1 at top Grounding The VDC must be effectively connected to the UPS ground terminal The ground connection must be as short as possible The DC power ground lug can accommodate one 1 6 AWG to 350 kemil the protected AC power ground terminal can accommoda
11. X malfunction Enclosure Temperature High enclosure temperature inlet outlets blocked or fans not X X operating Housing Temperature High flywheel housing temperature inlets outlet blocked or fans X not operating All Alarm events including any Warning that converts to an Alarm require VYCON certified personnel to service the system Contact your local VYCON representative for assistance VYCON VDC and VDC XE User Manual 28 Maintenance 9 0 Maintenance 9 1 9 2 Safety Precautions Abide by all safety precautions in this manual paying particular attention to 1 0 Important Safety Instructions before performing maintenance on the VDC and associate equipment AN WARNING Utilize extreme care when servicing the equipment as hazardous AC and DC voltages may still be present With input power OFF check for high voltages with DC and AC voltmeters prior to making contact The operator should always assume that high voltage may still be present after shutdown When the VDC is under power isolate both the operator and any test equipment from direct contact with earth ground and the chassis frame Preventive Maintenance All regular maintenance must be performed by VYCON certified personnel If in doubt about what steps to take to service the system call your local Sales Service organization for assistance To maintain a well conditioned system some components will need to be serviced To prevent a sys
12. details Proper grounding is also required to maintain system performance and reliability Failure to properly ground the equipment may result in unpredictable electrical circuits and electrical activity that may potentially damage associated electronics and communications All grounds should be inspected periodically to ensure that they are secured as required by the connection type and gauge size and are free from corrosion VYCON VDC and VDC XE User Manual 3 Important Safety Instructions Earthquake Safety A key aspect associated with the use of industrial equipment is the ability to withstand damage caused by seismic events Many geographic locations where VYCON systems will be installed are in active seismic zones The Uniform Building Code rates geographic seismic zones on a scale of O through 4 Industrial equipment is susceptible to various types of damage as a result of an earthquake which include but are not limited to Water damage Toppling or overturning Equipment especially susceptible to toppling over are those with an aspect ratio of greater than 2 1 That is if the equipment s height is greater than twice its width or depth it is prone to toppling or overturning Sliding against and striking other equipment and items Large or heavy equipment has significant momentum attached to it if it starts to move Once it breaks inertia and begins to slide it has the potential to cause serious damage to person ne
13. excess moisture or debris Perform maintenance with at least one other qualified personnel who is also familiar with the hazards associated with the specific tasks being performed Due to the possible presence of high voltages do not work alone One person should monitor the controls and indicators while the other person performs the maintenance procedure Always have another person within sight in case of an emergency Only test equipment designated for the VYCON Direct Connect system should be used for troubleshooting This unit contains several circuits that are energized with high voltage Even when the power is turned off dangerously high potentials may exist on the AC DC bus and or at the capacitor banks Always check with an appropriately rated AC and DC voltme ter to ensure no voltage is present before making any contact or using tools within the equipment Do not allow unauthorized personnel on or around the system during maintenance Protective glasses and or other protective equipment should be worn as applicable Do not wear loose articles of clothing or jewelry that can get entangled on controls or other parts of the system Unless other instructions are provided perform maintenance on the equipment once the system is stopped disconnected from input power and the equipment is properly locked and tagged out Do not attempt to repair the equipment if the issue s are not understood adequately Repair or replace the damaged compon
14. system immediately placing the entire system except for UPS powered circuits in the following safe shutdown condition The flywheel enters a coast mode where the flywheel slowly spins down DC power sources are automatically disconnected from the system via CB1 A WARNING There may be several hours before the flywheel reaches zero 0 rpm Personnel certified and trained by VYCON will be required to restart the system To service the system the safety guidelines must be followed as outlined in this document Activation of the emergency power off circuitry is accomplished by utilizing any of the three 3 methods local remote or UPS emergency power off below Local Emergency Power Off The user has activated the emergency power off button on the front of the VDC The emergency power off button is approximately 0 75 in by 0 875 in 19 x 22mm with a transparent cover to prevent accidental activation of the emergency power off It is a push button type emergency power off button that requires the user to push the red button to activate the emergency power off NOTE Q The emergency power off button is a latching button and must be reset by depressing the button a second time Remote Emergency Power Off The user has remotely activated the emergency power off via one of the Form C contact inputs UPS Emergency Power Off The user has activated the emergency power off on the UPS Consult the respective UPS user manual for em
15. the System Upon delivery of the VDC inspect the equipment and shipping skid for any signs of damage or mishandling Shock and tilt gauges indicate excessive shock and or tilt If any damage is noted file a claim with the shipping agency within 24 hours and notify your VYCON sales representative of the damage and condition of the equipment Do not attempt to install any equipment suspected of damage during shipment 4 2 Moving and Handling NOTE The VDC with shipping material weighs up to 1 500 lb 680 kg It must be handled with care and maintained in an upright position paying particular attention to the center of gravity of the equipment Arrows on the packing equipment indicate the upright position Check and verify the capacity of the forklift or pallet jack is sufficient for the weight of the VDC When transporting using a forklift or pallet jack check and verify the forks extend beyond the full depth of the cabinet Using straps an overhead lifting device may be used to transport the VDC Check and verify the capacity of the overhead lifting device and straps are sufficient for the weight of the equipment The VDC has sensitive electrical and mechanical components that have been calibrated prior to shipment When transporting maintain minimum tilt from vertical at all times and do not sub ject the equipment to excessive shock and or vibration The unit must not be subjected to more than 15 degrees of tilt Exhibit care
16. VYCS N UL Version VYCON DIRECT CONNECT VDC and VDC XE User Manual VYCON 23695 Via Del Rio Yorba Linda California 92887 USA E mail service vyconenergy com Copyright 2008 VYCON Inc All rights reserved Part Number 9801007 00 Rev C Feb 2009 1 0 1 1 1 2 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 0 3 1 3 2 3 3 3 4 3 5 4 0 4 1 4 2 4 3 4 4 5 0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 TABLE OF CONTENTS Important Safety Instructions lille 1 General Safety Precautions l l Edd ashes we heed Me bv Ga EG REG EE 2 1 1 1 Ensuring a Safe Work Area 2 eh 3 13 2 Rire Preventiom cn am ed Ree aset oe t nga timate tend e Ren 3 1 1 3 Grounding Practices sk e re e e AA ed he E 3 1 1 4 Earthquake Salkety 4 te tete eme nl Rene mx oe 4 14115 Life Support Statement exeo Ute Re Reo ec loce ete Ries 4 General Information c Senn ek lee eed gh WE Rw ee ace Rx Rx RR Es 5 1 2 1 Applicable Standards and Certification l llle 5 1 2 2 Patents aie alee We oe GE EE eet cas tul e ees Ha tende Fees ou rug a itte rates 5 System Introductions eg bREEDEERERIAE ERE eee steers Ge tees PEDES 6 Industrial Panel Computer incase ae eee AR ed he eb eo ee Sa RE BM Re RE 7 Power Conversion Module also referred to as Power Stack or Bi Directional Converter 7 Vacuum PUMP sands medinm eRe Eh Goh honk Gh fent ope ior iubeo om mede xs 7 Magnetic Bearing Controller MBC 0 0 cee ee
17. and to each operator control station Only personnel trained in electrical safety and hazards specific to the system should perform service and maintenance on this equipment as high voltages may be present WARNING Hazardous conditions could exist while servicing the system Do not service the system alone Make use of other personnel who are familiar with the system hazards and are within visual sight in case of an emergency Fire Prevention Keep the equipment in an area that is ventilated appropriately Keep the floor clean of debris or any flammable materials around or on the equipment Lubricants and flammable materials are to be stored in properly marked protective contain ers in a safe location No smoking is permitted in areas that contain flammable material Wiring must be properly routed maintained in good condition and securely attached The wiring should be inspected periodically to check for any signs of wear or deterioration The wiring and cabling within the equipment or directly connected to the equipment must be of the recommended gauge size All the connections must be secure as required by the connection type and gauge size to pre vent arcing or sparks Bypassing fuses and or circuit breakers is prohibited Grounding Practices Proper grounding is required to avoid the risk of electrocution and the extreme hazards associ ated with high voltages and currents Refer to 3 0 Site Preparation for
18. con verter used for both motoring and generation The output and input to the VDC are through a DC bus connected to the converter The con verter creates a sine wave from the DC bus to spin the flywheel during motoring and converts the varying sinusoidal frequency from the flywheel into DC voltage during generation i e energy discharge Energy is removed from the flywheel rotor by the generator In the VDC the energy discharge occurs between a full operating speed of 36K rpm down to 18 5K rpm capable of providing 215 kW VDC or 300 kW VDC XE of maximum power Figure 1 shows a simplified block diagram of an Uninterruptible Power Supply UPS that uses the VDC for continuous power conditioning and power source backup In the event of a loss of line input from the utility grid the VDC immediately goes into discharge mode maintaining the DC bus of the UPS to support the critical loads with no interruption Upon restoration of input power by a generator set genset or recovery of the utility the VDC recharges to full operating energy and awaits the next event The VDC can be used in a variety of applications including backup power during genset ride through battery hardening load leveling for standby gas turbines and continuous power conditioning The VDC is designed to work with a UPS system and connects into the same DC bus for both charging motoring and discharging generating power Graphical User Interface GUI software and rem
19. critical to prevent contact between the rotor and other components Vacuum ei sealed connectors are used for the high power electrical leads Vacuum Magnetic feed throughs are used for the mag bearings Flywheel netic bearing electrical power speed housing sensor and temperature sensor con nections Additional vacuum seals are located at the top and bottom of the flywheel for access during manu facturing c Flywheel rotor VYCON VDC and VDC XE User Manual 8 System Introduction 2 8 2 2 8 3 2 8 4 Motor Generator The motor generator consists of a unique stator and rotor assembly designed to operate effec tively in a vacuum environment The stator assembly is designed to minimize rotor losses that are difficult to remove in a vacuum environment Stator cooling is accomplished via conductive transfer of heat to the flywheel housing The permanent magnet of the motor generator is inte grated with the flywheel rotor and retained by a high strength non magnetic alloy The magnet retainer also functions as the main stiffness member for the entire flywheel rotor assembly Flywheel Rotor The flywheel stores kinetic energy in the form of a rotating mass The rotor hub flywheel rotor is manufactured from a high strength grade steel At full operating speed the stress levels in the rotor provide an ample safety factor meeting stringent criteria for design life flaw tolerance and cyclic life for UPS application
20. e eh 8 Rlywheel Controllets sic 49s ale awh n vn OR os et Ga ue peas duas 8 Emergency Power Off irs hots ydg RA a ee MS es wee Se ea ee eee s 8 Bly wheelers d o SU AR Ces sedes soos ef e ea 8 Blywheel Components ie eos c I ata eq 8 2 86 11 SEHIOUSIDE Sense e Rare xao dare Rue d ua a a aer es 8 2 8 2 MOr Generator reete et eor ES ep Pede heives ie oes oie re Sedes 9 2 8 9 Flywheel Rotor re rer RE Ea E ae HR AS SUR 9 2 8 4 Magnetic Bearings siie aiea aw eU EAE Ee Res e ated lend c ER oe ee e ne Es 9 Site Pr paration zie Mieke Sea C E EX oe See SE Sees eee UE UE 10 Space Requirements 4 2 Aa vu e Aa A RR e ua a auge Rat e i ias 10 Floor Loading svi vie tette SR ee Rat BR ae BRM Rgds Rags Rs ag REA 10 Environmental Considerations x oot mad mad mad rad toe oe qb ur ee ue qr gue 10 Facility Power Requirement oue e md CRY eee ee a EE Oa GARS EC aK ATE SE 10 Wiring Consideration sews oe eo eee T He d e GON Nn GON eon OW Get eS Goa es 10 Handling And Unpacking olx si eos seed ee ee he OS ee eae tees 11 Inspecting the bysten e ewe aw D ine Sepa eee Wee leon wate a lle ada ed Vat ats 11 Moving and Handling risaie ee oreet ne esto a RA Re Re Re Re e ns 11 Removing the Shipping Skid edu ue eve ve ue eee eee e e 12 Internal Inspections Lux eet eh ea stet sou uta ota ee eter ees 13 Installation jaime ce ces See eee eC he chee TED aes TIERS PII 14 Installation Guidelines 0 2 223p ee eee Eee hee depo eb ee ees 14 SystemvAnchoring 2
21. e when servicing the equipment as hazardous AC and DC voltages may be present This product must be installed and serviced by VYCON factory authorized service personnel only in accordance with national and local regulatory requirements Before servicing the equipment even after the flywheel has stopped spinning personnel should wait at least five 5 minutes and check for both AC and DC voltages with appropriately rated voltage testers Regardless of the type of shutdown make sure all input power is off and use extreme caution as high voltage capacitors and power circuits may still have voltage present Utilize extreme care when the VYCON VDC has input power present AC and or DC Ensure that both the operator and any test equipment are isolated from direct contact with the earth ground or the enclosure frame Any contact between floating circuits and the enclosure frame is a lethal shock hazard given that some components within the enclosure are not connected to the enclosure frame Extreme caution must be used such that any test equipment exterior does not make contact either physically or electrically with the frame or VYCON equipment enclosure Potentially lethal electrical voltages and currents are present in the system which could cause shock burn or death Turn off power and follow appropriate lockout tagout procedures before servicing NOTE The AC and DC input voltage setting is factory set Contact VYCON if incorrect VYCON
22. ent s with the appropriate tools Remove all tools and any loose items before restarting the system VYCON VDC and VDC XE User Manual 2 Important Safety Instructions 1 1 1 Ensuring a Safe Work Area WARNING Modifying the equipment overriding or failing to follow the safety precautions or recommended procedures could expose service personnel to hazardous conditions Always follow the safety precautions and recommended procedures Observe all applicable codes Hazard alert labels and protective guards on potentially dangerous areas of this system protect personnel from exposure to hazards during normal operation and maintenance Personnel must know how to recognize and avoid hazardous and potentially hazardous condi tions associated with this equipment The consequences of improper or careless operation of VYCON systems can be serious These systems must be operated and maintained only by trained and qualified personnel All personnel installing servicing and maintaining VYCON systems must be trained in regula tory requirements and Lockout Tagout procedures Lockout Tagout procedures are required to control and eliminate the potential for harm to service personnel and or equipment resulting from the accidental startup of equipment or release of stored energy The Lockout Tagout proce dures include attaching a Do Not Operate warning tag to the controls before the system is ser viced Attach the warning tags to the system
23. ergency power off instructions System Restart after Emergency Power Off To restart the VDC after an emergency power off will require VYCON certified personnel to ser vice the system Contact VYCON at 1 714 386 3824 for assistance and have the appropriate information available as described in 10 0 Technical Support VYCON VDC and VDC XE User Manual 27 Troubleshooting 8 0 Troubleshooting NOTE Please review this section before contacting VYCON Inc for service support 8 1 Status Indicators The touchscreen main panel displays the system status of the VDC on the upper left side Table 9 provides a description of the three system status indicators Normal Warning and Alarm Table 9 System status definitions System Status Color Designation Description Normal Green System is operating without warnings or faults System has detected a non fatal system error but the system continues to operate Warning Yellow Clearance of the error will return the system to Normal status Continuation of the error will trigger the system to enter a shutdown mode if the error is not cleared Alarm Red The system has detected an error that mandates the system to shut down Normal status displayed in green indicates the system is operating without any problems A Warning yellow is a notification that a system parameter is out of range or an external problem may be present The system wi
24. he require ments outlined in the following National Fire Protection Association NFPA National Electric Code NEC National Electrical Manufacturer s Association NEMA Occupational Safety amp Health Administration OSHA AN CAUTION This unit complies with the limits for a Class A digital device pursuant to Part 15 Subpart J of the FCC rules These limits provide reasonable protection against harmful interference in a commercial environment This unit generates uses and radiates radio frequency energy and if not installed and used in accordance with this instruction manual may cause harmful interference to radio communications Operation of this unit in a residential area may cause harmful interference that the user must correct at his own expense Patents The VYCON Direct Connect may be covered by one or more of the following U S patents Patent 6 727 617 Patent 6 700 258 Patent 5 315 197 Patent 5 514 924 Patent 5 111 102 Patent 6 897 587 VYCON VDC and VDC XE User Manual 5 System Introduction 2 0 System Introduction The VYCON Direct Connect VDC and VDC XE are flywheel energy storage systems consisting of two major subsystems The flywheel module which includes the high strength steel hub flywheel rotor high speed permanent magnet motor generator and a five axis active magnetic bearing system A three phase bidirectional Insulated Gate Bipolar Transistor IGBT bridge AC DC
25. ing of the VDC the system may require about 1 hour to reach the required vacuum level 8 Check for oil leaks in and around the VDC vacuum pump 9 Ensure that the cabinet doors are closed and locked 10 Proceed to 7 3 2 Startup of VDC Startup of VDC Follow these steps to power up the VDC 1 Start the UPS according to the instructions in the UPS manufacturer s user manual NOTE Startup instructions for UPS models will vary from manufacturer to manufacturer Consult the respective UPS user manual for startup instructions 2 Check that the DC bus voltage of the UPS is at the minimum system voltage requirements for the VDC before a START command is initiated 3 When indicated by the UPS startup instructions close the input circuit breaker CB1 to the VDC 4 Ensure that the cabinet door is closed and locked The VDC is now ready for a START command to be initiated 5 Push the SYSTEM START button on the Main Screen of the touchscreen panel and a confirmation screen appears 6 Touch the START confirm button to proceed The system will carry out several internal checks and then initiate the Starting Up START system mode 7 The system will automatically proceed through modes of operation including the Charging and Ready Full Charge system modes Upon reaching the Ready Full charge system mode the system is online fully charged and ready for ride through support needs A detailed description of the system modes can be fou
26. ingle phase 50 or 60 Hz AC that must come from the critical bus of a UPS system The required AC value has been identified prior to shipment so the proper internal settings have been made by the factory The product nameplate identifies the factory setting see Figure 9 Table 3 AC control voltage and appropriate fuse ratings Voltage V 208 380 400 415 440 480 600 Current as per 1 2 kVA Amps 5 75 3 16 3 2 9 2 73 2 5 2 Appropriate Fuse Amps 15 8 8 8 7 7 5 NOTE The AC power is a factory set feature If the available power is different from the voltage marked on the nameplate call your VYCON Service Representative Figure9 VDC and VDC XE nameplates vA Es vA T VYCSEN VDC SEN VDC XE INTHE USA Direct Connect APDEI THEUSA Direct Connect DC FLOAT 400 600 VDC DC FLOAT 400 600 VDC DC OUTPUT 400 520 VDC pe output 400 520 VDC MAX ENERGY 192 A 520 VDC 30 SEC MAX ENERGY 307 A 520 VDC 18 8 S MAX POWER 413A Q 520 VDC 5 SEC MAX POWER ight 74 in TEMP RATING 0 C to 40 C ight 74 in TEMP RATING 0 C to 40 C Depth 30 in 762mm ac INPUT L L _50 60 Hz 2 WIRE GND Depth 30 in 762 mm ac INPUT LL MFD MFD acm confie VOLTS VAC VOLTS VAC c Dus FLYWHEEL ENERGY CURRENT A 57 32 3o 29 zz 25 20 H Dus FLYWHEEL ENERGY CURRENT A STORAGE SYSTEM STORAGE SYSTEM LISTED LISTED 23695
27. ista ul te Bara t tec rat de te e e ae rs e as 27 74 1 Normal Shutdown deor porro ea X AR eS 27 7 4 2 Emergency Power Off EPO 1 0 0 0 0 0 ee ee ee er 27 7 4 3 System Restart after Emergency Power Off 2 0 0 eee eee ee eee 27 Troubleshooting o e oe eater ie Se oben eee hoe ada er 28 Status Indicators wa e oe my ma my c eee e lack acd acq a RR a a ees 28 System Faults z za tas ca tain eae AV MOVE ES HERNEEN ES ES 28 Maintenance iouis rod ree Behe Haus Ir Ex Rae RR RO RR UR ROI dE 29 Safety Precautions aA VE EVER EA Re a ee RM eal hale Ree SOR dieat 29 Preventive Main tena n COs zu ie eR pa oe ss IRR ed Pe Dota IBS ta at ae ie aea a TR ee ante a 29 Teclinical SUPPOM esotas lp Y EUR hee oe nae te Ges ah we Rew en T dues 30 Specifications oves rEDA PU VD oacaQnii PIC FR ener newer eee ere 31 Installation Drawings espe E Rr ERA ERE EE Re xxn 32 VYCON VDC and VDC XE User Manual ii Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 LIST OF FIGURES Power conditioning system using the VDC and VDC XE llle 6 Key system components uode eee teni eek VETE AH EASTER ene IM E eA E ALES 7 Flywheel components con ee eine nei RU ee EN eR VEEE ey ee cdl 8 Shipping configuration A
28. l and anything it strikes Misalignment of components Refer to 3 0 Site Preparation for details intended to securely fasten the VYCON Direct Con nect in its intended location for operational safety and seismic requirements Life Support Statement VYCON does not advocate the utilization of its products in any life support applications where a malfunction or failure of its products can potentially result in adverse effects to life support equipment or adversely affect the reliable operation and safety of life support equipment By no means will VYCON intentionally sell its products into life support applications unless reassurance is provided in writing that appropriate measures have been taken to ensure that the risks associated with malfunction or failure of its products have been minimized that the customer assumes all associated risks and that the liability of VYCON is safeguarded under such circumstances VYCON VDC and VDC XE User Manual 4 Important Safety Instructions 1 2 1 2 1 1 2 2 General Information Applicable Standards and Certification For distribution in North America the VYCON Direct Connect is designed to meet the following Underwriter s Laboratory UL applicable requirements UL 508 Standard for Industrial Control Equipment UL 508C Standard for Power Conversion Equipment UL 1004 Standard for Electric Motors The VYCON Direct Connect is designed in accordance with the pertinent sections of t
29. lation Voltage VDC 400 520 Charge Voltage VDC 420 600 Charge Current Amps 10 50 NOTE Only qualified and trained personnel are permitted to change the control parameter values These values may require adjustments due to battery type or initial system startup related issues The actual setpoints for the system must be recorded on the commissioning checklist VYCON VDC and VDC XE User Manual 24 Operation 7 0 Operation 7 1 7 2 AN CAUTION The initial system startup must be performed by a VYCON certified service provider to ensure proper system operation Failure to follow the initial system startup procedure instructions will void system warranty Visual and Mechanical Inspection Before Initial System Startup A VYCON certified service provider will perform these tasks prior to initial system startup Conduct an overall visual inspection of the VDC Check the vacuum pump oil level and condition Verify all electrical connections are properly connected including DC input power auxiliary AC input power grounding control wiring and emergency shutdown wiring Verify that the system is properly anchored and installed per VYCON recommendations Initial System Startup Procedure A VYCON certified service provider will carry out or direct the following tasks Inspect the system before the initial startup Ensure that the commissioning documents are complete per VYCON specifications
30. ll continue to operate without requiring any operator intervention If the Warning event does not clear it may convert to an Alarm event and pro ceed to a shutdown condition An Alarm red is a fault condition that automatically shuts down the VDC without any operator intervention in most cases Before an Alarm event is valid the event must be pres ent for a predetermined amount of time before the Alarm event is triggered This logic pre vents false Alarms and prevents unnecessary system mode changes to occur An Alarm event will result in suspending normal operation and safely shutting down the system per any of the methods illustrated in 6 5 System Modes 8 2 System Faults System faults and their possible causes are listed in Table 10 Table 10 System faults and possible causes Fault Status System Fault Possible Causes Warning Alarm Inverter Temperature High power stack temperature power stack blower not operating x x Loss of redundancy in control power System shutdown Power Supply immediate attention required _ x Condition to close open contactor was not met UPS DC bus Pre Charge Contactor voltage may be unstable x DC Bus Isolation Contactor Condition to close open contactor was not met UPS DC bus m X voltage may be unstable Magnetic Bearing Status Magnetic bearing and or controller related malfunction X Vacuum Level Vacuum level low potential vacuum leak or vacuum pump X
31. lly charged state Ready The flywheel has accelerated to its fully charged state 100 speed and is Full Charge maintaining fully charged state ready for discharge Discharging The flywheel is discharging power providing energy on the DC bus to critical supply loads The system continues to operate but has detected an error s and is waiting Warning for the error s to be cleared by the parameter returning to its normal level with System Parameters When cleared of these errors the system will operate without any audible Elevated intervention horn Continuous errors will cause the system to enter Flywheel Shutdown Coasting Down mode The user has initiated a STOP at the user GUI and the flywheel will coast User Activated Shutdown Flywheel Shutdown COW to zero 0 rpm STOP The unit isolates itself from the external DC bus immediately and the switching of the power electronics will cease The system has detected error s that mandate decelerating the flywheel without any motor controller and power electronics assistance Flywheel Shutdown a The unit isolates itself from the external DC bus immediately and the Coasting down A switching of the power electronics will cease There will be considerable time elapsed by the time zero 0 rpm is reached Flywheel Shutdown s ds will be commanded to motor down to zero 0 rpm with the load Motoring down mg The unit isolates itself from the external DC bus after zero 0
32. n AEA E EELA E a eee eee 12 Removal of VDC withforkit eria niera a aa a A A a ENA AERA 12 VDC Cane ine rye E Pes Souk dues deu t a d a EERI ae ALE d 13 DC terminal connectiotis s iyu RR 6k CRAVE RASA AEG aoe ERE A 16 AG power wires at TB I4 ie ee rei afta arl tea an lanta e Tet 17 VDC and VDC XE nameplates ecl eee ee nae 17 Control wires at J17 and JIS 2 ena e ete nee 18 VDC ground terminal locations 1 0 0 ee eee 18 Maar Screens ales oe sees eese grec RE Wer E epe es reg aero ee dme AS N ag 20 Discharge Events MENU 42 52 E Sind Safes em Pe ad SPS Se ee SP Se eS 21 Warning Alarm Events menu 1 a e EEEE EE te 21 Operating Parameters Menu 1 ee 22 LIST OF TABLES AC input voltage setting change notification on nameplate 2 Component connections and torque levels 2 2 2 0 0 2 llle 13 AC control voltage and appropriate fuse ratings 0 0 eee eee ee eee 17 Overview of touchscreen descriptions ya eeo nka 0 0 0 eee eA 19 General system information in the Operating Parameters menu 22 Fault parameter information in the Operating Parameters menu 22 System modes description and fault status of the VDC llle 23 Software control parameter setting lee 24 System status definitions er e fic id ak ee EE EV ee RE 28 System faults and possible causes 0 0 ee eee 28 Preventive maintenance schedule of system components
33. n while planning for product installation 3 2 Floor Loading The VDC should be mounted on a finished surface such as concrete block brick or wood The floor must be strong enough to support the equipment load and must be suitable for anchoring The floor must be within 3 degrees 2 52 in 64mm over a 48 in 1219mm span of being level The floor mounting pattern for anchoring is detailed in Facilities Interface Diagram VDC and VDC XE 3 3 Environmental Considerations Clean dust free environment Install away from overhead water lines Ambient operating temperature range is 4 F to 104 F 20 C to 40 C Minimum cold start temperature is 32 F 0 C Relative humidity must be less than 95 non condensing Note that room ventilation is necessary but air conditioning may not be required Maximum ambient operating temperature is 104 F 40 C without derating 3 4 Facility Power Requirements Protected AC power is required for proper operation of the VDC System control power is derived from this protected AC source it also provides power for the cooling fans and the vacuum pump The protected AC power should come from the critical bus of a UPS system The VDC can accommodate 208 380 400 415 440 480 or 600 VAC L1 L2 G 50 60Hz 3 5 Wiring Considerations A qualified electrician must perform all electrical connections All external wiring DC amp AC Power Control and Grounding are to be provided by the electrical co
34. nd dis charge events that have occurred in the VDC The table displays an event number the date and time it occurred and the duration of each event as shown in Figure 13 Figure 13 Discharge Events menu VY We Discharge A y Events Discharge events log Direct Connect Date Time 8 11 2008 3 55 03 PM 8 6 2008 4 36 24 PM Submenu buttons appear on all screens Parameters Return to Main Display Main Display button The right side of the screen has the same navigation buttons as all submenu screens Submenu buttons Touch the appropriate submenu button to access the Warning Alarm Events menu or the Operating Parameters menu Return to Main Display Touch the Return to Main Display button to return to the Main Screen default screen 6 3 Warning Alarm Events Log The Warning Alarm Events button allows operators to access key information about warning and alarm events that have occurred in the VDC The table displays the date and time the event occurred the type of event Warning or Alarm a description of the event and a code assigned to it as shown in Figure 14 The event codes are for use by VYCON technicians Figure 14 Warning Alarm Events menu VYCXEN nee Direct Connect Warning Alarm events log Discharge Warning Al Submenu buttons appear on all screens Parameters ETUR Return to Main Display Main Dis
35. nd in 6 5 System Modes VYCON VDC and VDC XE User Manual 26 Operation 7 4 7 4 1 7 4 2 7 4 3 System Shutdown Sequence Two procedures are available for shutting down the VDC 1 A Normal Shutdown initiated by pressing the SYSTEM STOP button on the Main Screen display then verifying the choice in the confirmation screen 2 An Emergency Power Off EPO initiated by any of the following methods Local emergency shutdown button activated Remote emergency shutdown button activated if connected UPS emergency shutdown button activated if connected Normal Shutdown The touchscreen STOP button is recommended for all normal shutdowns To initiate a normal shutdown Touch the SYSTEM STOP button in the upper right corner of the main screen of the touch screen panel and a confirmation screen appears Touch the STOP confirm button to proceed The flywheel enters a coast mode where the flywheel slowly spins down DC power sources are automatically disconnected from the system via CB1 WARNING There may be several hours before the flywheel reaches zero 0 rpm Personnel certified and trained by VYCON will be required to restart the system To service the system the safety guidelines must be followed as outlined in this document Emergency Power Off EPO Press the Emergency Power Off button to remove power from the system under emergency con ditions only The emergency power off circuitry isolates the
36. nect Diagram VDC and VDC XE VYCON VDC and VDC XE User Manual 15 Installation 5 4 DC Bus Terminal Connections At the VDC the DC power cables are terminated shown in Figure 7 also see Facilities Interface Diagram VDC and VDC XE TB4 can accommodate one 1 6 AWG 350 kcmil per pole Figure7 DC terminal connections Refer to your UPS installation documentation for termination of the DC power cables in the UPS The DC power cables must be sized so that the maximum voltage drop due to cable resistance between the UPS and the VDC is 2 volts at rated power The nominal output current is 260A at 500 VDC WARNING Identify and verify polarity plus and minus prior to making electrical connections positive to positive and negative to negative Improper connections may result in failure or equipment damage The field supplied DC power cabling provided by the electrical contractor must be rated 600V and in accordance with local regional and national electrical codes Connect the DC power cables according to the table in Interconnect Diagram VDC and VDC XE VYCON VDC and VDC XE User Manual 16 Installation 5 5 Protected AC Power Terminal Connections The AC power wires are terminated at TB1 inside the VDC see Figure 8 TB1 can accommodate one 1 14 AWG to one 1 10 AWG cable per terminal Figure 8 AC power wires at TB1 The AC power can be 208 380 400 415 440 480 or 600 VAC s
37. ntractor All wire sizes and installation must comply with all applicable local regional and national electrical codes Verify that all incoming high and low voltage power circuits are de energized and locked out before installing the cables and making connections Facilities Interface Diagram VDC and VDC XE identifies the locations of the cable access areas The VDC can accommodate bottom or top access Remove and punch the conduit landing plates and re install prior to connecting any wiring Do not cut or punch the conduit landing plates while attached to the VDC After reattaching the landing plates ensure there are no metal shavings wire fragments etc inside the unit Each cable group must be run in a separate grounded rigid metal conduit to prevent control sig nal interference Please refer to Interconnect Diagram VDC and VDC XE It is recommended that the VDC be placed as close as possible to the mating UPS VYCON VDC and VDC XE User Manual 10 Handling And Unpacking 4 0 Handling And Unpacking The VDC has sensitive electrical and mechanical components that have been calibrated prior to shipment and as such the equipment is shipped in an air ride truck The VDC is designed to be handled using either a forklift or a pallet jack Overhead lifting equip ment may also be used in conjunction with straps Care must be taken to prevent damage or personnel injury while handling or unpacking the equipment 4 4 Inspecting
38. on for assistance and have the following information available Date Purchased Location System Model Number System Serial Number Interconnected UPS Manufacturer Interconnected UPS Model VYCON VDC and VDC XE User Manual 30 Specifications 11 0 Specifications Table 12 Specifications Model VDC VDC XE DC Input 400 to 600 VDC adjustable recharge current dependent on UPS typically 1596 of UPS full load DC current DC Output 400 to 520 VDC adjustable 400 to 520 VDC adjustable 192A 520 VDC max energy 413A 520 VDC max power 307A 520 VDC max energy 575A 520 VDC max power Maximum Power Power kW 215 300 Duration sec 5 5 Maximum Energy Power kW 100 160 Duration sec 30 18 8 Usable Output Energy 3 000 kW sec 100 kW load 3 000 kW sec 160 kW load Auxiliary Input Power AC Input L L 50 60 Hz 2 WIRE GND AC Input Configuration Volts VAC 208 380 400 415 440 480 600 Current Amps 5 75 3 16 3 2 9 2 73 2 5 2 Environmental Ambient Operating Temperature 4 F to 104 F 20 C to 40 C Minimum Cold Start Temperature 32 F 0 C Ambient Storage Temperature 13 F to 158 F 25 C to 70 C Relative Humidity 0 to 95 non condensing Altitude 5000 ft 1525m without derating Acoustical Noise 68 dBA at 3 3 ft 1m Efficiency 99 2 Maximum
39. ote communication capabilities provide convenient control and monitoring of performance parameters Figure 1 Power conditioning system using the VDC and VDC XE 2 Long term AC alternate source UPS System Rectifier Inverter Critical Automatic RWS Transfer Switch DC AC output 480 VAC VYCON VYCON VDC and VDC XE User Manual 6 System Introduction The key components that make up the VDC are illustrated in Figure 2 refer to section numbers shown in Figure 2 for more details on each component Figure2 Key system components 2 1 2 2 2 3 2 6 Emergency Power Off on front panel 2 2 Power Conversion Module also referred to as Power Stack or Bi Directional Converter 2 1 Industrial Panel Computer behind panel le 2 4 Magnetic Bearing 2 5 Flywheel 4 Controller MBC Controller 2 3 Vacuum toa D Pump Industrial Panel Computer The VDC may be commanded from the panel computer which has a touchscreen display as the user interface The touchscreen incorporates a system status window navigation buttons and system functionality options that allow the user to monitor the VDC Power Conversion Module also referred to as Power Stack or Bi Directional Converter The charging motoring as well as discharging generating of the flywheel energy storage sys tem is accomplished through control of semiconductor switches incorporated into the flywheel
40. play button The right side of the screen has the same navigation buttons as all submenu screens Submenu buttons Touch the appropriate submenu button to access the Discharge Events menu or the Operating Parameters menu Return to Main Display Touch the Return to Main Display button to return to the Main Screen default screen VYCON VDC and VDC XE User Manual 21 Front Panel Touchscreen 6 4 Operating Parameters The Operating Parameters button allows operators to access key information on product and system information and 10 fault monitoring parameters such as DC bus voltage DC bus cur rent DC bus power operating speed Figure 15 Figure 15 Operating Parameters menu Operating Parameters Product Serial Number General system Operating Parameters VYCZ N l Direct Connect U2000026 System Hours System Mode information IDC Bus Voltage VDC Ready Full Charge Number of Discharge Events L Discharge Events Pre Charge Contactor DC Bus Current Amps DC Bus Isolation Contactor Submenu buttons IDC Bus Power kW Fault parameter Warning Alarm Events l _ Magnetic Bearing Status Operating Speed appear on all screens Vacuum Level mTorr information Inverter Temperature Enclosure Temperature Operating Parameter
41. power conversion module Since the flywheel operates in a vacuum mitigation of the current harmonics present in the flywheel stator windings is accomplished by using fast switching IGBTs The IGBTs are rapidly turned on and off to closely approximate a sine wave through the use of Pulse Width Modulation PWM The correct waveform is critical in reducing harmonics along with controlling current ripple The VDC features a pre charge cycle of the power conversion module capacitors This cycle allows connection of an electrically cold system to the hot DC bus of the UPS by ensuring that the initial high inrush current is limited through a pre charge resistor Vacuum Pump A rotary vane vacuum pump is used to maintain the vacuum level in the flywheel at the required level during operation The pump minimizes the windage losses created by the high speed rotor and increases the overall electrical efficiency of the flywheel VYCON VDC and VDC XE User Manual 7 System Introduction 2 4 2 5 2 6 2 7 2 8 2 8 1 Magnetic Bearing Controller MBC The magnetic bearing controller provides levitation control of the flywheel hub rotor and con tains a digital controller a sensor demodulator and current amplifiers The MBC monitors and controls the position of the flywheel rotor via a five axis active magnetic bearing system Rotor position signals are fed to the control module of the MBC which runs a digital filter compensa
42. s Power Supply lHousingTemperature Return to Main Display button Retum to Main Display The Operating Parameters menu displays the general system and fault parameters information described in Tables 5 and 6 Table 5 General system information in the Operating Parameters menu Item Description Product Serial Number The unique serial number appointed to the VDC System Mode The current mode of operation for the VDC Flywheel System Hours The number of hours accumulated by the flywheel system Number of Discharge Events A counter for the number of either partial or full power discharges Table 6 Fault parameter information in the Operating Parameters menu Item Unit Description DC Bus Voltage VDC The voltage across the DC terminals of the VDC DC Bus Current Amps The current flowing in and out of the VDC DC Bus Power kW The power flowing in and out of the VDC Operating Speed The percent speed of the flywheel rotor Inverter Temperature OK Fault Inverter temperature above normal Power Supply OK Fault Loss of redundancy in control power Pre Charge Contactor OK Fault Pre charge contactor fault Unit will not start DC Bus Isolation Contactor OK Fault DC bus contactor failure Unit will not start Magnetic Bearing OK Fault Magnetic bearing fault Unit will not start Maximum scale is 106 mTorr Vacuum Level mTorr mro Normal is 34 mTorr or below
43. s Magnetic Bearings Magnetic bearings are used for rotor support The bearings fully levitate and suspend the rotor in a magnetic field responding to both static and dynamic forces The magnetic bearings pro vide radial and axial support To minimize bearing power requirements and losses the flywheel is vertically oriented requiring only the axial bearing axis to support the full rotor weight Magnetic bearings possess unique advantages in operation and longevity of flywheel systems These advantages include extremely long life with no maintenance high reliability tolerance to unbalance minimum rotor losses and low power consumption VYCON VDC and VDC XE User Manual 9 Site Preparation 3 0 Site Preparation Minimal site preparation is required for installation of the VDC Before installation consider ation must be given to Wiring and cabling to UPS and other equipment e Service access Exhaust requirements Floor mounting Be sure to review this section along with the installation drawings provided with this manual and listed in 12 0 Installation Drawings prior to installation 3 1 Space Requirements The VDC requires 6 76 sq ft 0 63 sq m of floor space A 36 in 914mm clearance in front is required for National Electrical Code compliance and a 12 in 305mm clearance above the unit is required for cooling The unit accommodates bottom entry for power and control cables this must be taken into consideratio
44. te one 1 4 AWG to one 1 10 AWG see Figure 11 Figure 11 VDC ground terminal locations Wire sizes and installation must comply with applicable local regional and national electrical codes Connect the ground wires according to the table in Interconnect Diagram VDC and VDC XE VYCON VDC and VDC XE User Manual 18 Front Panel Touchscreen 6 0 Front Panel Touchscreen The VDC features a user friendly touchscreen interface as the primary means for the operator to monitor and control the system The touchscreen provides information about the operation of the VDC as well as buttons to start and stop the VDC The touchscreen displays an assortment of information including system information system status system errors and operating parameters such as DC bus voltage and DC bus current It also offers access to event logs showing charge discharge warning and alarm events that have occurred This section explains how to navigate through the touchscreens and the type of information dis played The touchscreen has a Main Screen and three submenus described in the rest of this section as shown in Table 4 Table 4 Overview of touchscreen descriptions Section Description Main display screen that displays general status information including system date and time and has buttons to start and stop the VDC and 6 1 Main Screen buttons to access the three submenus An audible alarm sounds when a warning or fault occ
45. tem malfunction VYCON recommends the following components be periodically inspected and replaced before the components reach the end of their useful life NOTE Users may have site specific requirements that will require different service intervals from the recommended replacement schedule Table 11 Preventive maintenance schedule of system components Component Description Air Filters Inspect quarterly for cleanliness Replace as necessary Vacuum Pump Oil Inspect every six months Replace annually Enclosure and Power Slack Fans Inspect every six months for proper operation Inspect every six months for visible damage or abnormalities Check security of electrical Flywheel Enclosure connections and retighten as necessary Clean system of any debris High Voltage Inspect every six months for signs of failure High voltage capacitors are considered failed Capacitors when their measured capacitance is 5 below their rated capacitance High Voltage Capacitor expected life is 7 to 10 years Contact VYCON for all replacement components at 1 714 386 3800 VYCON VDC and VDC XE User Manual 29 Technical Support 10 0 Technical Support VYCON is dedicated to providing high quality products to the owners and users of every VDC Your VDC should operate free from trouble If you require maintenance support spare parts or other technical assistance please contact your local Sales Service organizati
46. the use of expansion anchors other methods may be used 1 Prepare a clean level finished surface free of obstructions cracks and seams in the vicinity of the installation Ensure all clearances are maintained and the area for bottom entry if used is clear Locate the position for the mounting holes see Facilities Interface Diagram VDC and VDC XE Drill mounting holes large enough for the expansion anchors Drop expansion anchors in the mounting holes using a mallet as necessary to make sure the expansion anchors are flush with the floor Using a mallet or hammer tap the setter rod if any to set the expansion anchors in place Remove the setter rod Using a forklift or a pallet jack move the VDC into place straps can also be used to lift the unit and set it in place Place the unit such that the holes in the C channel align with the mounting holes Insert all four anchor bolts and tighten to the appropriate torque as specified by the manufacturer 5 3 System Wiring Refer to 12 0 Installation Drawings for location of terminals and cable routing information All wire sizes and installation must comply with local regional and national electrical codes Verify that all incoming high and low voltage power circuits are de energized and locked out before installing the cables and making connections Each cable group must be run in a separate grounded rigid metal conduit to prevent control sig nal interference See Intercon
47. torque level on components indicated with an X in the Check Torque column using the recommended torque levels as guidelines Table 2 Component connections and torque levels Component Check Connection Check Torque Recommended Torque Level Flywheel Controller X Magnetic Bearing Controller X Flywheel Assembly X X 25 to 30 ft Ib Vacuum Pump X Power Stack DC side X X 7 ft lb Power Stack AC side X X 7 ft lb Terminal Assemblies X Circuit Breaker Assembly X CB1 X X 30 ft Ib K1 amp K3 Relays X X 100 in Ib Auxiliary AC Connections X X 35 in Ib Inductors X X 6 to 8 ft lb Figure6 VDC cabinet Open door for internal inspection VYCON VDC and VDC XE User Manual 13 Installation 5 0 Installation 5 1 Installation Guidelines Install your VDC in accordance with the instructions guidelines and drawings included with this manual following all procedures AN CAUTION Only qualified personnel must perform the initial system check out and startup to ensure proper equipment operation Failure to do so may void your warranty Contact your VYCON Service Representative to arrange for system check out and startup Select a location away from overhead water lines to prevent water damage in case of acciden tal leaks Route cables such that runs are as short as possible Locate the VDC for easy connection of inputs outp
48. urs Touch the Horn Silence button on the Main Screen to reset the audible alarm 6 2 Discharge Events Log Submenu that displays a log of charge and discharge events Submenu that displays a log of warning and alarm events and warning and 6 3 Warming Alarm Events Log alarm codes for technician use 6 4 Operating Parameters Submenu that displays general system information and fault parameters 6 5 System Modes Details about the VDC s 11 system modes 6 6 Software Control Parameters Information about the factory set control parameters Audible Alarm The VDC includes an audible alarm that will sound when a warning or fault occurs To reset the audible alarm touch the horn silence icon on the touch panel main screen The horn will again sound should a new warning or alarm occur During initial start up the horn may sound and can be reset by following the instructions above VYCON VDC and VDC XE User Manual 19 Front Panel Touchscreen 6 1 Main Screen The Main Screen displays critical information for operators to access and read easily Figure 12 provides a sample illustration of the Main Screen Figure 12 Main Screen System Status System Status START button STOP button System Mode Read Available Energy Available Energy o Submenu buttons 0 appear on all screens No of Discharge Events No of Discharge Events Silence Horn button
49. uts and auxiliary equipment Allow enough space to service the VDC NOTE Refer to 3 0 Site Preparation for service clearance requirements for the VDC Ensure air circulation is sufficient to expel heat produced by the VDC Protect against moisture and excessive humidity not to exceed 9596 non condensing Protect against excessive dust and other particulate matter Ensure installation is in compliance with fire prevention regulations and practices Install in an area that provides an operating environment temperature of 4 F to 104 F 20 C to 40 C Avoid placing the unit in direct sunlight or other heat sources Make sure that the floor can support the weight of the VDC If the VDC will not be immediately installed store indoors in a clean dry area where the temperature will be between 13 F to 158 F 25 C to 70 C and the humidity does not exceed 95 non condensing VYCON VDC and VDC XE User Manual 14 Installation 5 2 System Anchoring The following tools and equipment are required for floor anchoring Transport handling equipment such as a forklift or pallet jack Before moving check and verify to ensure the handling equipment is capable of supporting the weight of the VDC Open end wrench Socket wrench with appropriate ratchet handle Drill and masonry drill bit Hammer and or mallet Expansion bolts Torque wrench Installation Procedure The following procedure is for
50. warranty See 7 0 Operation before using this button When the VDC is first commissioned the flywheel will not start until the minimum vacuum level is reached in the system This process may take up to one hour SYSTEM STOP see 7 0 Operation before using this button To stop the system push the red STOP button in the upper right corner of the touchscreen panel After a confirmation screen appears touch the stop confirm button to stop the system This will initiate the User Activated Flywheel Shutdown mode and command the VDC to coast down to zero 0 rpm DC isolation will take place after the CB1 circuit breaker has opened NOTE See 7 0 Operation before using this button The Submenu buttons appear on all screens and offer access to the submenus described in the next three sections 6 2 Discharge Events Log 6 3 Warning Alarm Events Log 6 4 Operating Parameters Silence Horn button The VDC includes an audible alarm that sounds when a warning or fault occurs To reset the alarm touch the Silence Horn button The horn will sound again if a new warning or alarm occurs The horn may also sound during initial startup reset by touching the Silence Horn button The current date and time appear in the bottom left corner of the Main Screen VYCON VDC and VDC XE User Manual 20 Front Panel Touchscreen 6 2 Discharge Events Log The Discharge Events button allows operators to access key information about charge a
51. when handling the VDC to avoid equipment damage or personnel injury VYCON VDC and VDC XE User Manual 11 Handling And Unpacking 4 3 Removing the Shipping Skid The VDC is shipped on a skid and is fixed using four machine screws see Figure 4 Figure4 Shipping configuration Use a forklift to lift the VDC off the shipping skid see Figure 5 An overhead lifting device may also be used with appropriate straps Remove the four machine screws that hold the VDC to the shipping skid The VDC may now be moved to the appropriate location The black mounting flange may need to be removed to roll the flywheel on uneven floors NOTE Use extra caution when maneuvering the forklift into place for lifting the VDC as rubber isolation mounts for the flywheel housing are exposed and can potentially be damaged by the forklift Ensure that the forks are placed directly underneath the base flanges to prevent damage Figure 5 Removal of VDC with forklift VYCON VDC and VDC XE User Manual 12 Handling And Unpacking 4 4 Internal Inspections Open the door and open shield see Figure 6 Inspect the VDC for visible signs of damage dur ing shipment All internal wiring should be intact and all major components should be secured in place Check for broken torque seals loose connections and loose hardware within the unit Refer to Table 2 for a list of major components that should be checked for proper connections Check the

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