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1. P P SAGEON POWER SYSTEM AZ istribution 1 ry tring Conr iol ind 641 ircui reaker ind Ground turr P P ontrol anel Includes System Controller SNM 4 Communications M Auxiliary Alarms NAAN ind Temp mpensatior z lo e e b e ds A r Conversion al dule le gp rer lule showr le la le q P I e fe 1 GR Inpu ircui reaker i Connectior Include ustomer DI iol 4 Fror panel rer FIGURE 1 1 SAGEON III BASE SYSTEM This manual contains text of descriptions procedures and supporting illustrations in reference to the Sageon III Base System It includes the front matter and chapters 1 through 9 1 11 PRODUCT DESCRIPTION The Sageon III Base System is intended for Cellular PCS and other applications that demand stable reliable high current DC operating power Sageon III can supply the voltage and currents shown in the following table PM990 8800 50 Issue 3 1 1 Introduction Sageon III Base System Sageon Rack Height Plant Output Plant Output Cabinet Voltag
2. PM990 8800 50 Issue 3 6 4 Sageon III Base System Maintenance Troubleshooting Symptom Likely Causes Action Rectifiers do not power up no LEDs lit on front panel AC power is not connected or internal fuse blown or rectifier not properly plugged in Re insert rectifier s and make sure the rear connections are good Confirm that AC power is available to the rectifier backplanes Replace the rectifier module if the unit is suspected to have failed No output current from rectifiers and the Green LED on each rectifier blinks occasionally AC power either 70V AC or gt 320 An internal relay will be heard open and close periodically if the AC voltage is excessive Check that the AC supply voltage and connection arrangement are correct and match the expected system supply wiring Over temperature alarm or fan failure alarm present High ambient temperature Fan air intake exhaust vents are blocked or a fan is jammed with a foreign object or excessive dust Check the ambient temperature and improve site cooling if possible Check and remove obstructions from the air vents Replace the module or remove and replace the fan assemblies in the module requires only that the rectifier lid be removed LVBD will not close One or more batteries are reverse polarity No battery is connected to the battery distribution module
3. 2 12 FIGURE 2 7 DISTRIBUTION GROUP IDENTITIES AND LOCATIONS 2 13 FIGURE 2 8 DISTRIBUTION AREA TOP VIEW AMI TYPE BREAKER DIST SHOWN in 2 13 FIGURE 2 9 DISTRIBUTION CABLE ROUTING enne trenes 2 14 FIGURE 2 10 AMI TYPE DISTRIBUTION LUGGING 2 442 4 2 15 FIGURE 2 11 TYPE BREAKER DISTRIBUTION ASSEMBLIES TYPICAL esee 2 16 FIGURE 2 12 TYPE BREAKER DISTRIBUTION WIRING 2 16 FIGURE 2 13 INTERFACE BOARD CUSTOMER ALARM CONNECTIONS 2 17 FIGURE 2 14 TEMPERATURE SENSOR LOCATION 2 1 2 84 2 22 120600000000 nennen trennt trennt trennen entere trenes 2 19 FIGURE 2 15 TYPICAL BATTERY CURRENT TRANSDUCER nene nennen trennt nre enne ener ens 2 20 FIGURE 2 16 RECTIFIERS re Fn eei rete iere e rper 2 21 FIGURE 2 17 SAGEON III BASE SYSTEM trenes 2 24 FIGURE 2 18 CONNECTIONS ON CONTROLLER BACKPLANE i 2 24 FIGURE 2 19 TEMPERATURE CONCENTRATOR BOARD seen nennen nennen nennen etre enne eren 2 25 FIGURE 2 20 SAGEON III BOARD LOCATIONS i 2 25 FIGURE 3 1 SINGLE PHASE FEED CU
4. jOTH Caution Do not block rear panel grille A blocked grille will limit the flow of cooling air and can result in equipment overheating and failure Minimum clearance behind and to the sides of the plant must be 2 5 cm FIGURE 2 1 POWER SYSTEM DIMENSIONS PM990 8800 50 Issue 3 2 6 Sageon III Base System Installation FIGURE 2 2 PLANT BASE Caution Do not block rear panel grille A blocked grille will limit the flow of cooling air and can result in equipment overheating and failure Minimum clearance behind the Plant is 2 5 cm To move and mechanically secure the Power system 1 Prepare the installation site Install floor anchors see Figure 2 2 for mounting pattern as needed 2 Carefully transport the Power system to the installation site If possible protective wrapping should remain in place until the move is completed e Since the plant is shipped bolted to a skid a forklift is typically used for transport to the installation site A lift point is provided in each rack corner near the
5. 3 10 3 4 3 Battery connections iie enata e e e edere lees Erie eat 3 10 3 5 TEMPERATURE 5 5 pede eter e de e ce niente Teide e Teig ei 3 10 3 6 AUXILIARY RELAY CONNECTIONS tenente tne trennen innen enne 3 11 3 7 CONTROLLER POWER CONNECTIONS i 3 11 3 8 FRONT PANEL USB COMMUNICATIONS CONNECTION eren enne eene nre innen enne 3 11 3 9 REMOTE COMMUNICATION CONNECTION ee 3 12 3 9 1 TCP IP and Sageview Interface e uude eee 3 12 3 10 BATTERY DISTRIBUTION MODULE i 3 13 3 11 ADDING AUXILIARY EXPANSION MODULES ii 3 13 PM990 8800 50 Issue 3 Front Matter Sageon III Base System 4 0 CONFIGURATION AND 2 2 21 12 nsa reziario re sts stato stata 4 1 4 1 THE HOME SCREEN irren UHR er Om ed Oeo t eU pendit detis 4 3 4 2 USING THE OPERATOR PANEL PUSH BUTTONS 4 3 4 3 READING THE OPERATOR PANEL SYSTEM STATUS LEDS nennen nennen 4 4 4 4 READING ALARM MESSAGES 4 5 4 5 HOME MENU SCREENS pe eu D EEUU ER ORI Dre ie petebat eae ae legten et M 4 7 4 531 Sageon Battery Monitor v 55 35 euo e ie degna 4 11 2 5 2 Site OTADA
6. 0 25V maximum PM990 8800 50 Issue 3 1 6 Sageon III Base System Introduction 1 2 6 EMC Specifications Emissions Harmonics Tested To IEC 61000 3 2 EN61000 3 2 AS NZS 61000 3 2 Class Conducted AC Port CISPR 22 1997 55022 1998 AS NZS 3548 1997 Conducted RF DC Port CISPR 22 1997 Radiated RF Category Electrostatic Discharge ESD CISPR 22 1997 55022 1998 AS NZS 3548 1997 Tested To IEC 61000 4 2 EN 61000 4 2 Air 8 kV Contact 6 kV Criterion Radiated RF IEC 61000 4 3 EN 61000 4 3 10V m 80 1000 MHz 1 kHz 8096 AM 10V m 1 2 GEZ 1 kHz 8096 AM Electrical Fast Transient EFT IEC 61000 4 4 EN 61000 4 4 1 kV on AC lines 1 kV on DC lines 0 5 kV on signal lines indoor Category Tested To Criterion Surge Protection ANSI C62 41 1991 category B3 AC lines Combination Wave 6 kV 3 kA Ring Wave 6 kV 500A IEC 61000 4 5 EN 61000 4 5 Impulse 6 kV 3 kA Common Mode CM on AC lines 6 kV 3 kA Differential Mode DM AC lines 0 5 0 25 CM amp DM on DC lines IEC 61000 4 12 EN 61000 4 12 Ring Wave 6 500 100 kHz amp DM on AC lines 2 kV CM 1 kV DM on DC lines Conducted RF IEC 61000 4 6 EN 61000 4 6 3V on AC load and comms lines Voltage Dip Interruptions 61000 4 11 EN 61000 4 11 Level 10096 dip for
7. Powering Technology Sageon III M Base System Product Manual SAGEN UNIPOWER LLC 65 Industrial Park Road Dunlap TN 37327 Customer Service Voice 800 440 3504 Customer Service Fax 423 949 3647 Field Service 800 299 3907 Web site http www unipowerco com PM 990 8800 50 Issue 3 sageon3 base man pdf Front Matter Sageon III Base System Sageon III Power Plant Parts List Descriptions Base System Part Numbers 84 Welded Cabinet Controller LVBD w by pass switch 600A Rectifier Shelf Five 5 Customer Specified External Alarms SAGEON3 A01 84 Welded Cabinet Controller 600A Rectifier Shelf Five 5 Customer Specified External Alarms SAGEON3 A02 Factory Installed Options No AC breakers NO AC Breakers for the 600A Rectifier Shelf SAGEON3 B01 AC Breakers Provides Twelve 12 20A AC Breakers for the 600A Rectifier Shelf SAGEON3 B02 Rectifier Expansion Addition 600A Rectifier Shelf to increase Total System Capacity to SAGEON3 B03 1200A Rectifier Expansion w Breakers Include Rectifier Expansion Package B03 and Twenty SAGEON3 B04 four 24 20A AC Breakers Battery Expansion Provides Interface Connections for Four 4 Battery Temperature SAGEON3 C01 Probes Four 4 External Current Transducers Communication Remote Communication Using TCP IP SN
8. RTH ARTH ARTH TH 5 2TH T 2TH 2TH T TH ARTH lt TH EA EARTH 4 EARTH lt FIGURE 3 1 SINGLE PHASE FEED CUSTOMER WIRING PHASE TO NEUTRAL PM990 8800 50 Issue 3 3 4 Sageon III Base System Commissioning FIGURE 3 2 SINGLE PHASE FEED CUSTOMER WIRING PHASE TO PHASE PM990 8800 50 Issue 3 3 5 Commissioning Sageon III Base System NOTE PHASE A WILL SAGEON III AC FEE FIGURE 3 3 SPLIT SINGLE PHASE FEED CUSTOMER WIRING PHASE TO NEUTRAL PM990 8800 50 Issue 3 3 6 Sageon III Base System Commissioning FIGURE 3 4 Y THREE PHASE FEED A CONNECTED RECTIFIERS CUSTOMER WIRING PHASE TO PHASE PM990 8800 50 Issue 3 3 7 Commissioning Sageon III Base System NOTE NEUTRAL MAS AGEON 111 FEE FIGURE 3 5 Y THREE PHASE FEED CUSTOMER WIRING PHASE TO NEUTRAL PM990 8800 50 Issue 3 3 8 Sageon III Base System Commissioning NOTE HASE SACEON 111 AC FEE FIGURE 3 6 A THREE PHASE FEED CUSTOMER WIRING PHASE TO PHASE PM990 8800 50 Issue 3 3 9 Commissioning Sageon III Base System 3 4 2 Surge protection requirements The rectifiers are internally protected for surges up to 6kV 3kA For higher levels of protection particularly for sites with high incidence of lightning or switching surges additional surge protection is required on the AC feed to the Power plant Typically surge arrestors with a 10 40 r
9. PM990 8800 50 Issue 3 4 25 Configuration and Operation Sageon III Base System 4 13 2 Rectifier Menu Rectifier Specific Functions Home Screen A ABV FL SMR Button o DEC INC MH Float 54 5V Equalise 56 5V MH V ig 57 0V Alarm MR V low Alarm 48 0V MH HVSD 58 5V DE 30A imit Reset SMR Fault Press ENTER ENTER SMR software version SMR Electronic Serial Additional screens if more SMRs are declared Float Voltage SMR Default Equalise Voltage SMR Default ENTER SMR voltage above which alarm flagged 1 Value up down F ENTER to accept ENTER SMR voltage below which alarm flagged 1 Value up down 1 oe pENTER to accept ENTER SMR high voltage shutdown l Value up down 1 ENTER to accept ENTER SMR current limit l Value up down 1 ENTER to accept L Resets any latched SMR alarm The RECTIFIER Float and Equalize voltages are the default values set in the rectifier that will be used if the Controller fails to operate They are a copy of the raw values set in the BATTERY menu without battery temperature compensation and system drop adjustments 4 13 3 Alarm Log Home Screen 25 2A 54 3V FL LOG Button LOG 1 AC Fail t DEC LOG 100 INC Q DEC to Clear LOG Entries Most recent logged Alarm Event 10 10 2005 17 32 56 Additional screens if more events l
10. SMR Comms Fail One or more SMRs are not responding Amber FL Amb Temp High Ambient temperature higher than preset limit Amber FL Batt Temp High Battery temperature higher than preset limit Amber FL Batt Temp Sens Battery temperature sensor not connector or failure Amber FL Batt I Limit Battery charging current is being limited to preset value Amber FL Bat Sym Alarm Battery discharge currents from battery strings not sharing load equally Amber FL Equalize System is in equalize mode Table Notes FL LED Flashing On LED On Steady Amber On PM990 8800 50 Issue 3 4 6 Sageon III Base System Configuration and Operation 4 5 HOME MENU SCREENS With the Home screen displayed pressing the up arrow or down arrow button will move through a series of screens showing ambient temperature a series of editable parameters e g float voltage high and low security number of batteries and enabling and disabling of auxiliary parameters e g battery cell voltage monitoring The following map summarizes the available menu screens Home Screen System current voltage and mode Ambient temperature 3 Phase AC Monitor option Programmabl Ambient temperature alarm Voltage high alarm Voltage low alarm Failsafe Alarms on off Bat Cur Sensor on off
11. DISTRIBUTION GROUPS A amp B ON EACH TIER LEFT SIDE FIGURE 7 1 DISTRIBUTION LOCATION BY TIER AND GROUP PM990 8800 50 Issue 3 7 1 Distribution Option Kit Installation Distribution guidelines A Power system can have three tiers of distribution Tiers 1 2 and 3 When adding distribution groups tier 1 is factory installed group A amp B with AMI capability start at tier 2 upwards AMI type breaker distribution can be located in any group type breaker distribution must be installed as the topmost group above all other distribution types As distribution is added additional return bus sections up to 3 total may be needed to provide terminations landings for load returns See Figure 7 3 Order the return bus sections separately as needed TABLE 7 1 INSTALLABLE DISTRIBUTION TYPES BY TIER AND GROUP f Installable Distribution See notes below Tier Group M AMI GJI Positions 48V Plant 48V Plant 1 1 10 Y N 1 B 11 20 Y N 2 A 21 30 Y 2 31 40 3 A 41 50 3 B 51 60 Y Table Notes The Option must be the topmost distribution Other distribution types cannot be installed above GJ1 Y Yes indicated circuit breaker or fuse type can be installed in the group listed in the column at left N No indicated circuit breaker or fuse type cannot be installed in the group listed in the column at left 1 Referto the Distribution
12. ENTER to accept Enable disabie battery capacity loss triggering of equalization charging Threshold below which Eq is triggered Modify Value up down ENTER to aceopt 2 Battery charging current below which equalization charging terminates Maximum duration of equalization Periodic equalization charging trigger Set to zero to disable Manual control of equalization Battery voltage below which the LVDS opens when in Auto mode LVDS where used operation mode Auto Open or Closed Enable disable battery overtemperature alarm set to off if no sensor used Periodic battery discharge test trigger Set to zero to disable Time of day to begin automatic discharge testing Maximum duration of a discharge test Discharge test current controlled Load must be gt the value programmed Battery voltage below which the BDT terminates Battery loss of capacity below which the BDT terminates Result of the Last discharge test More detailed explanations of all the menu items are available in the Controller Operation PDF on the Manual CD PM990 8800 50 Issue 3 4 28 Sageon III Base System Sageview 5 0 SAGEVIEW SageView System Monitor software enables configuring and monitoring of a Sageon III Base System from local or remote personal computer PC Figure 5 1 shows the various access options Local monitoring involves a PC connected to the USB connector on a System s operator panel Remote
13. etre nennen enne rennen eene nenne 6 2 TABEE 6 2 RECTIFIBR EED CODBS rrt hte terrent tn rente EEE tite eerte re bebes E eR epu i 6 2 TABLE 6 3 RECTIFIER POSITION ADDRESSES 1 THROUGH 24 eene etre etre rennen rennen 6 4 TABLE 7 1 INSTALLABLE DISTRIBUTION TYPES BY TIER AND GROUP i 7 2 9 LIST DRIVEN PCB S ia eei Tei eU 9 1 TABLE 9 2 MAJOR REPLACEMENT COMPONENTS 9 1 List of Figures FIGURE 1 1 5 5 i e eren eee EE e Ter E TREE dn 1 1 FIGURE 1 2 SIMPLIFIED BLOCK DIAGRAM 48V POWER SYSTEM eene enne 1 4 FIGURE 1 3 600A PLANT eiecit treten ete e ESR EEEE Ee e Te E e De ERR EE e P 1 8 FIGURE 1 4 1200A eee E De re TREE 1 8 FIGURE 2 1 POWER SYSTEM DIMENSIONS i 2 6 FIGURE 2 2 PLANT BASE lere err A 2 7 FIGURE 2 3 RETURN BUS LOCATIONS itte eei tinin 2 8 FIGURE 2 4 AC INPUT CABLING WITH RECTIFIER ON OFF OPTION 2 10 FIGURE 2 5 BATTERY CHARGE BUS AND BATTERY RETURN BUS LOCATIONS i 2 11 FIGURE 2 6 LOAD SUPPLY AND RETURN CABLING nne
14. set LVLD option to ON and set the LVLD Aux to 42 0V set the Battery Switch to Normally Open set the Cct Switch to Normally Open set the Battery Transducer FS as size according to ordered transducers set the amount of battery temperature compensation voltage adjustment if used and after confirming that the battery temperature is being measured set the battery charging current limit to 1096 of the Ah rating i e if 150Ah battery is used set the limit to 15A this value can be adjusted later to meet your specific charging requirements Always refer to the manufacturers recommendations for charging batteries OQ Q OQ O OQ 30 In many cases these values are set up in the factory and will only require modification if the particular battery being used requires a different set up Refer back to section 3 to continue commissioning procedures 4 11 OPERATION System operation is controlled by the Controller system controller As a result operation information for the system is directly related to the operation of the Controller as described in this section 4 12 SUMMARY OF CONTROLLER FRONT PANEL CONTROLS There are four Menus which can be viewed using the INC or DEC buttons a The default or Home menu which contains general system information b RECTIFIER menu contains all the parameters relating to the switch mode rectifiers RECTIFIER c Battery menu contains all the parameters relating to the batteries d A
15. 2 Auxiliary peripheral module relays battery cell monitor etc connection 16 way ribbon 3 Battery amp load distribution module connection 34 way ribbon 4 Ambient temperature sensor connection 5 Battery temperature sensor connection 6 Rectifier isolated communications connection 10 way ribbon 7 Standalone system voltage connection Controller power and voltage sensing 8 Load circuit breaker trip detection circuitry connection PM990 8800 50 Issue 3 2 24 Sageon III Base System Installation Notes Devices and cable connections are pre wired as part of the supplied and tested Power plant TEMP4 TEMP3 TEMP2 TEMPI FIGURE 2 19 TEMPERATURE CONCENTRATOR BOARD NICATION amp BDM BOARD FIGURE 2 20 SAGEON III BOARD LOCATIONS PM990 8800 50 Issue 3 2 25 Sageon III Base System Commissioning 3 0 COMMISSIONING This chapter describes commissioning a Power System Individual system settings can vary widely so it is important
16. Sageon III Base System Installation e Torque wrench to ensure correct tightening of hardware see Table 2 2 for torque specifications e Electrical service panel circuit breakers e Digital Voltmeter with 4 1 2 digit display e Cables and lugs appropriate crimping tools AMI Circuit Breaker Distribution uses Two hole lugs for 1 4 threaded studs 5 8 center to center and GJ1 Circuit Breaker Distribution uses Single hole lugs for 3 8 bolt Return bus uses Two hole lugs for 1 4 threaded studs 5 8 a center to center and two hole lugs for 3 8 threaded studs 1 center to center Battery Charge and Discharge Buses use Two hole lugs for 3 8 threaded studs 1 center to center e Conduit conduit connectors and conduit bending tools e Anti Static Service Kit with static dissipative mat and wrist strap for handling electronic circuit boards e g Interface Board available from electronic supply sources 2 2 2 Selecting and Sizing DC Power Cables Protective circuits overall system performance and safety depend on the proper sizing of DC cables for current and acceptable DC voltage drop The minimum size allowable is the larger of the wire size per the National Electrical Code or the calculated wire size Use the following method to determine the wire size 1 Calculate the minimum area in circular mils CM required for copper wire using the following formula 22 2x Ix L CM V where CM minimum area of circular mil
17. Sageon Split Core Current Transducer 1000A with 30 lead Battery Temperature Sensors Requires 01 for more than One 1 Battery String 385 5941 03 Temperature Sensor 10 3M 385 5941 06 Temperature Sensor 19 6M 385 5941 15 Temperature Sensor 50 15M MAJOR REPLACEMENT COMPONENTS CONTINUE PM990 8800 50 Issue 3 Spare and Replacement Parts Sageon III Base System 1 Series Breaker Kits 274 3830 01 1 Ampere 1 Series Breaker 1 Position 274 3830 03 3 Ampere 1 Series Breaker 1 Position 274 3830 05 5 Ampere 1 Series Breaker 1 Position 274 3830 10 10 Ampere 1 Series Breaker 1 Position 274 3830 15 15 Ampere 1 Series Breaker 1 Position 274 3830 20 20 Ampere 1 Series Breaker 1 Position 274 3830 25 25 Ampere 1 Series Breaker 1 Position 274 3830 30 30 Ampere 1 Series Breaker 1 Position 274 3830 40 40 Ampere 1 Series Breaker 1 Position 274 3830 50 50 1 Series Breaker 1 Position 274 3830 60 60 Ampere 1 Series Breaker 1 Position 274 3830 70 70 Ampere 1 Series Breaker 1 Position 274 3830 80 80 Ampere 1 Series Breaker 1 Position 274 3830 90 90 Ampere 1 Series Breaker 1 Position 274 3830 100 100 Ampere 1 Series Breaker 1 Position 274 3830 125 125 Ampere 1 Series Breaker 2 Positions 274 3830 15
18. sss e em ien Efficiency pirt neonan Power Factors ccc rinite Protection FIGURE 1 4 1200A PLANT 208 240 Vac 185 275 Vac Single phase Phase to Phase or Phase to Neutral 13 1 208 Vac 11 3 240 16A max 120V or below 85 185 Vac 275 285 Vac 8 seconds ramp up to full load Greater than 90 gt 50 load 230 Vac input 25 C 77 F Greater than 0 98 at 5096 to 10096 of rated load 990 8800 50 Issue 3 Sageon III Base System Introduction Internal Protective Devices External Protective Device Fully Protected Over Voltage Shutdown Under Voltage Shutdown Service Output 48V Rectifiers Float Voltage Nominal Output Rectifiers Power Static Regulation Line Electrical Noise Wide Band Noise Peak to Peak Ripple Load Sharing Protection EE Over Current Temperature SCU programmable Battery menu Rectifier menu 1 2 8 Safety Specifications Double Fused input Thermal circuit breaker input 440 Vac indefinitely 300 Vac Hot swappable i e Can be installed in or removed from an operating Sageon III Base System 54 2 Vdc 42 58 Vdc 45 59 9 Vdc 10 to 110 of rated output 25A 158 F 70 Foldback current limiting Better than 0 05 B
19. 3 9 REMOTE COMMUNICATION CONNECTION The remote communications module is P N Description 385 4015 32 Ethernet TCP IP Interface Card w SNMP The following sections describe the interfaces in more detail and cover some of the set up requirements for the more advanced interfaces Termination of the line with resistors generally is not required However if high rate of data corruption is experienced slow data update in monitoring program line termination resistors should be installed at both ends of the network The value of the resistors depends on the gauge of the twisted pair and should be equal or closest to line characteristic impedance I e for a twisted pair of 24AWG wires characteristic impedance of 100ohm use 1000hm resistor 3 9 TCP IP and Sageview Interface The interface is a 10 100BASE T Ethernet adaptor The TCP IP port sends Controller data over a network to a PC running Sageview control and monitoring software The Sageview interface provides this function for up to 2 PCs on the network simultaneously as well as providing SNMP traps on alarms system time synchronization to a global clock if access to the internet is available and a simplified system status Webpage HTTP If direct connection to a PC network port is required a cross over network cable should be used To set up Sageview follow the instructions on the installation CD To enable network access on the TCP IP port an IP address must b
20. Security on off Password setup When viewing another Test indicators screen the Home Number of Rectifiers SMRs screen will reappear Number of battery strings connected in 60 seconds if no Full scale battery current button is pressed Load sensor on off FS Load Current Access code 7 digit number Date format Date time set Alarm report on off Daily report on off Daily report time Modem on off Phone numbers 1 2 and 3 Audio alarm on timeout off Cct input no nc disable Battery switch no nc disable LVDS no nc disable Auxiliary units press ENTER 1 ph AC monitor on off 3 ph AC monitor on off Sageon III Battery Monitor on off Battery configuration Number of batt strings monitored Cell voltage high low differential Site monitor press ENTER Outputs 1 4 on off status no normally open nc normally closed Note The screen examples in this and subsequent sections will vary with System voltage loads environment battery quantity type and condition included System options and other factors PM990 8800 50 Issue 3 4 7 Configuration and Operation Sageon III Base System Note Screens for options will not be viewable unless the option is installed and or enabled Access the screen series shown here by pressing the up arrow button Press the down arrow button to acce
21. connected System 5 1 1 SageView benefits e Saves time since configuration development and Sageon III Base System installation can proceed simultaneously Reduces configuration errors since the configuration can be developed and checked for accuracy at a PC before being uploaded to the System e Includes on line security with access code and password protection e Provides a permanent configuration record for comparison with operating cost data and service records PM990 8800 50 Issue 3 5 1 Sageview Sageon III Base System 5 2 MONITORING SageView screens provide for efficient effective monitoring of System operation System output voltage and current alarms battery status and many other performance parameters are read on a single PC display SageView includes comprehensive Help It provides the latest information about program installation and operation communication options and other topics 5 3 SECURITY Security is a major consideration when deciding upon a communications strategy that involves sending proprietary data over your company s intranet the Internet or telephone lines Before enabling local or remote communications carefully review your company s electronic security policies Contact your company s network administrator for details about network structure and security The administrator can also furnish an IP Internet Protocol address when Ethernet access 1s needed 5 4 CABLE AND NETWORK CONNECTION
22. memory cell is confirmed to have failed This can be done by modifying each of the RECTIFIER parameters on the Controller and checking to see if the alarm clears EEPROM corrects the data Check for EMC problems and remove reduce the source of electrical interference where possible EEPROM Fail alarm for the Controller is activated Corrupted data found on the backplane EEPROM that is outside the allowable data range similar to RECTIFIER corruption above Replace the faulty backplane if the memory cell is confirmed to have failed Range RECTIFIER alarm for the rectifier is activated Corrupted data found on the EEPROM inside the rectifier that is inside the allowable data range but does not match the value programmed Try adjusting the RECTIFIER parameters to see if the EEPROM cells can be updated If not replace the faulty rectifier 6 7 TO REMOVE A RECTIFIER MODULE Lift the securing latch in the center divider adjacent to the module and pull the module out of the Power plant When removing modules especially if the ambient temperature is high and the unit has been operating at maximum load avoid skin contact with the metal casing as it may be too hot to touch Pull the unit halfway out of the magazine and let cool for 2 3 minutes before handling 6 8 TO INSERT A RECTIFIER MODULE Insert the module into the slot Push the module all the way in so the rear connector fully mates and
23. this screen to appear PM990 8800 50 Issue 3 4 17 Configuration and Operation Sageon III Base System 4 7 3 Low Voltage Battery Disconnect LVBD LVLD Screens LVBD switch trip voltage Set to establish the voltage at which the LVLD Trip batteries will be disconnected from the load to prevent excessively 45 0V discharging the battery string LVLD LVBD Off On Set to Off or On depending on whether or not your Low Voltage Load Dis system has LVBD On NOTE LVDS screens have no functioned control over the contactor use LVLD screens Temperature sensor alarm toggle Set to On when sensors are Temp Sen Alarm connector Set to Off if sensors are not connected On Note Battery discharge test screens are shown next go to Section 4 7 1 If the test screen shows Off the Last BDT screen appears next see Section 4 7 2 4 7 4 Battery Discharge Test BDT Screens The battery discharge test performs a periodic controlled discharge of the connected battery string s The test confirms battery string capacity and uses the customer loads to discharge the battery string s so no battery strings need to be disconnected and individually loaded as would be the case in a typical manual discharge test To access test parameters press the BATT button and then press down arrow to access the following screens 50A 54 1V BDT in Progress While the test is in progress e The display will alternate between t
24. u JI eure cea S Lug t FIGURE 3 9 BATTERY DISTRIBUTION MODULE BDM 3 11 ADDING AUXILIARY EXPANSION MODULES Modules such as the Sageon Battery Monitor and site monitor are daisy chained from the unused ribbon cable connection provided on the Auxiliary programmable relay board of these expansion modules are required to be mounted external to the Power plant and a single 16 way ribbon cable connected to the available box header For more detailed installation information for each of these modules refer to the Sageon Battery Monitor Operation Manual PM990 4209 00 and the Sageon Site Monitor Application Note AN103 4012 00 PM990 8800 50 Issue 3 3 13 Sageon III Base System Configuration and Operation 4 0 CONFIGURATION AND OPERATION The Sageon III Base System is locally configured and operated from the operator panel See the SageView chapter for remote configuration and operation The operator panel is mounted below the distribution doors The operator panel consists of a 2 line alphanumeric display six push buttons with tactile feedback three status LEDs and a USB communications connector Menus data status alarm messages and parameter values appear on the display Display contents are selected using the six buttons System status is also shown by the three LEDs below the display A USB
25. udo Nam Off ENTER to accep rur ps Circuit breaker auxiliary contact circuit input configuration TINC DEG toggles state V T ENTER to accep ENTER PG RP E Battery circuit breaker auxiliary contact circuit input configuration Batt Switch Input INC DEC toggles state 1 Not Used ENTER to accep I ENTER Battery low voltage disconnect switch auxiliary circuit input VDS Input INC DEC toggles state configuration Not Used I ENTER to accep ENTER 77 07 77 7777777 ENTER INC DEC toggles state I ENTER to accept If 1 ph AC Monitor not Off ENTER 1ph AC Vhi Alarm Modify Value up down 260V I ENTER to accep R 1ph Alarm Modi y Value up down 200V ENTERtoaccept h AC Monitor Off Auxiliary Units Press ENTER m Z E m i TE 63 0Hz ENTER to accep ENTER TOTTI Tph AC flo Alarm Modify Value up down xus 1 Modify Value up down 1 100A ENTER to accep PM990 8800 50 Issue 3 4 24 Sageon III Base System Configuration and Operation Base Menu continued INC DEC toggles state I ENTER to accept If 3 ph AC Monitor not Off ENTER ph AC Monitor Off 3ph AC Vhi Alarm Modify Value up down 1 260 I _ ENTER to accept 3ph AC Vlo Alarm Modify Value up down 200V ENTER to
26. 10 ms Level 3096 dip for 500 ms Level 100 dropout for 5s 990 8800 50 Issue 3 1 7 Introduction Sageon III Base System 1 2 7 Rectifier Specifications ECTIFIE ECTIFIE E TELE ECT DE TE ie amp 99 Input 48V Rectifiers Rated Input Range Range Tolerance Connection Frequency Extended Input with output de rating TOW te erret dete cent High Guaranteed Start
27. B port is provided on the left side of the operator panel for connecting a personal computer PC Operator panel operation displayed data and communications are all controlled by the SCU Sageon III Control Unit The operator panel is the Sageon III Base System s HMI human machine interface Complete Sageon III Base System configurations can be created at the operator panel Alternatively the System can be configured from a personal computer PC running SageView System Monitor software When the System is initially powered the configuration stored in the SCU provides the System operating parameters This configuration can be the default factory installed configuration or a configuration you created on a PC and uploaded to the SCU Table 4 1 lists the default values note that some default values will vary with customer specified equipment such as the number of Rectifiers installed Many values are user configurable and a column is provided in the table for recording of user selected values To configure the System from the operator panel review the screen sequences described in the following sections and enter the requested data To download a configuration to a PC or to upload a configuration from a PC refer to Chapter 5 SageView The SCU must be powered during any configuration efforts In this chapter Sections 4 1 and 4 2 describe the Home screen and use of the operator panel push buttons Sections 4 3 and 4 4 address the status L
28. Base System Symptom Likely Causes Action voltage limit A random event on the DC bus has occurred that forced a unit into HVSD the HVSD latched alarm can be reset using the Reset Latched Alarm function in the Controller RECTIFIER Menu If the system does not have any batteries cycling the AC power will have the same effect If the unit does not recover by latching off again it is faulty RECTIFIER Urgent alarm activated One or many RECTIFIERs are off due to AC power failure internal faults incorrect command signal from Controller or all rectifiers are in current limit Check the AC power and restore Replace faulty rectifier modules Check for DC bus overload faults units are latched off as HVSD Absolute Overvoltage shutdown protection activated The system is likely to have no load and without a battery An event on the DC bus has caused the voltage to exceed 70V for 48V systems The event could be caused either by a faulty rectifier or other equipment connected to the bus Add a small amount of load 22A per rectifier to the system and check for a faulty rectifier Check for other faulty equipment connected to the bus that could cause the overvoltage transient Use the Reset Latched Alarm from the Controller to reset the system A rectifier is indicating RECTIFIER Off or No Response on the Controller RECTIFIER display An AC failure to the rectifier i
29. ENTER to accept ENTER ENTER toggles state I Off On Volts Eq Trigger 46 0V I ENTER ENTER toggles state Off On ML ENTER Q Loss Trigger 25 ENTER Modify Value up down ENTER to accept ENTER Modify Value up down ENTER to accept ENTER Modify Value up down 1 ENTER to accept ENTER ir ido I ENTER toggles state L Start Stop ENTER Modify Value up down I ENTER to accept ENTER Modify Value up down ENTER to accept ENTER ili i ri a e A nia I ENTER toggles state I L Off On J ENTER n n a I Modify Value up down 1 L ENTER to accep ENTER I Modify Value up down 1 i ENTER to accep ENTER Modify Value up down 1 i ENTER to accep ENTER Modify Value up down 1 ENTER to accep L I I u ENTER Modify Value up down ENTER to accep h Modify Value up down ENTER to accep l Enable disable Equalization charging Charge current limit for battery voltage between float amp equalize System Equalize voltage without BTC Sense point voltage regulated to this value Enable disable bus voltage discharge triggering of equalization charging Threshold below which Eq is triggered Modify Value up down
30. Fuse link blown in the battery distribution module BDM Controller setting for LVLD is Off Low Voltage Load Disconnect setting is greater than the current bus voltage Check battery wiring polarity Connect a battery Check that the Controller is powered up even when no rectifier is operational If not service the fuses in the BDM Set LVLD to On Power up the rectifiers and reduce the load until the bus voltage increases to the float voltage Load or Battery circuit breaker alarm does not set when the breaker is opened or is incorrectly alarmed as battery switch instead of load trip or visa versa No battery or load alrm aux switch is connected to the circuit breaker connection Alarm link in BDM is incorrectly configured Check load and battery alrm aux switch connections to the BDM and that the alarm links are correctly configured Battery or Ambient temperature sensor reading is indicated as Not Available Sensor cable faulty Sensor connector reversed No sensor installed Turn cable connector around and reconnect Replace faulty sensor assembly Battery current indicated does not match independent measurement Full scale current of the DC hall effect current transducer is incorrectly set and will result in an error larger than 5 at more than 50 full scale current Change the setting of the FS Batt Curr value in the Base Menu of Controller to the correct
31. Section 4 5 2 to the Auxiliary Bat Config and 5 Batteries screens and there declare the number of battery cells per battery string 2 24 and the number of battery strings 1 4 whose cell voltages are to be monitored by the SCU Refer to the Sageon Battery Monitor Manual PM990 4209 00 for detailed information The quantity of SBM boards needed for the above selection is calculated by the SCU based on battery type and configuration The relationship between battery configuration and quantity of SBM boards is shown in the table below TABLE 4 4 SBM BOARDS NEEDED FOR VARIOUS BATTERY CONFIGURATIONS 48V Battery 24 2V Cells SBM 1 1 SBM Board SBM Batt 2 2 SBM Boards SBM Batt 3 3 SBM Boards SBM Batt 4 4 SBM Boards 12 4V Cells 1 SBM Board 1 SBM Board 2 SBM Boards 2 SBM Boards 8 6V Cells 1 SBM Board 1 SBM Board 2 SBM Boards 2 SBM Boards 4 12V Cells 1 SBM Board 1 SBM Board 1 SBM Board 1 SBM Board 4 9 1 Frequency of Measurement The frequency of cell voltage polling is programmable from 10 minutes to 8 hours in 1 minute steps A typical polling interval is 4 minutes which yields 15 points for a 1 hour discharge For a programmed test discharge of 30 minutes a polling interval of 2 minutes might be used This parameter is not accessible from the operator panel A PC running SageView is needed 4 9 2 Battery Cell Measurements When SBM i
32. See Table 2 2 for torque specifications Insert the AMI type breaker into the Distribution Assembly as indicated in Figure 8 2 This completes installation of the AMI type breaker Kit repeat steps 1 7 for all AMI type breaker Kits to be installed PM990 8800 50 Issue 3 8 1 Circuit Breaker and Fuse Kit Installation Sageon III Base System DI _ Circuit J ale x N Breaker Output Bus Bar n p SA AMI 1 4 20 Nuts FIGURE 8 1 AMI BREAKER KIT COMPONENTS U shaped Bus Bar Distribution Assembly Support Bracket Installed AMI type gt lt breaker Kit Note mounted operation Short Mounting Surface Long Mounting Surface Output Terminal FIGURE 8 2 AMI TYPE BREAKER SHOWN KIT INSTALLATION PM990 8800 50 Issue 3 8 2 Sageon III Base System Circuit Breaker and Fuse Kit Installation 8 2 GJI TYPE BREAKER KITS 8 2 1 Kit Contents Description Quantity type breaker 1 Screw Phillips Head 10 32 x 1 2 Washer Flat 3 8 Washer Bevel 3 8 Bolt Hex Head 3 8 16 x 1 1 4 Nut Hex 3 8 16 Alarm wire adapter breaker kits 200A and over only tI ION 8 2 2 Installing the Kit 1 Open the distribution area door Refer to Figure 7 1 and locate the Distribution Tier and Distribution Group where this
33. TCP IP SNMP BATT2 4 BATTERY TEMP CONCENTRATOR a5 REMITE COMMS lt 001 OPT SAGEON3 C01 OPT cC op cC or Zou Zon CUSTOMER Ae ALARM BRD X5 X2 ze xn ance i RLYS RLY4 RLY3 RLY2 RLYI 10 WHT VIO BRN SAGEON3 C01 OPT CURR_1 BDM RIBBON i CURR 3 CURR 4 amp X9 LVDS CUM CURI CURACURZCURA Xe BUS 2 X1IGBATT X21 A3 BDM BRD En AUX RELAY C AUX RELAY NO 4 AUX RELAY NO 3 AUX RELAY NO 2 AUX RELAY NO 1 4X3 3X4 BATT 8X5 1 X6 6066 BUS BAR BUS BAR PROPRIETARY INFORMATION NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC SIZE DOC TYPE NUMBER ISSUE B SAGEONS AXX SCALE SHEET FILE NAME N A 3 OF 4 SD SAGEON3 AXX_ISS_4 ED991 5001 B3 Issue 3 1 2 i 3 4 BATTERY LANDING TERMINAL 4 8 LANDINGS AMBIENT TEMP MOUNT ON LARGE THERMAL MASS AMB TEMP TEMP 1 TEMP 2 TEMP 3 TEMP 4 cie N NO G GND 24V IN 48V OUT 48V IN 24V OUT S CONNECT STRING TEMPERATURE OPT SENSO
34. for on site installation Rectifiers specified on the order are shipped in separate protective packages for on site installation The Power system is designed for top entry of distribution and battery cabling AC input cabling can enter the plant through any lower side rear panels or through the bottom of the plant when the plant is located on an elevated floor All cabling is user supplied e A WARNING ni Electrical shock hazard Hazardous voltage can cause death or serious injury Remove power from all wires and terminals before working on equipment IMPORTANT All wiring must meet the National Electrical Code and other applicable industry and local codes The Breaker Fuse Layout label on the inside of the door to the distribution area lists all distribution positions The label provides space for you to write breaker fuse current rating and part number Label entries should be completed before beginning the installation to help ensure that the correct breaker fuse is inserted in each position Rectifier Position Address Each rectifier position is factory assigned a unique sequential address within the Sageon III Base System The System operator uses this address when configuring and operating the System to identify and access a specific Rectifier The AC Backplane board at each rectifier position has one DIP switch on which the address is set See the illustration below IMPORTANT Do not change the factory s
35. i e with AC power and DC load applied with no interruption of Sageon III Base System service When removing a Rectifier there must be sufficient remaining rectifier current capacity to supply the load PM990 8800 50 Issue 3 2 21 Installation Sageon III Base System A WARNING Electrical shock hazard Hazardous voltage can cause death or serious injury A 240 may be present at the Rectifier Switch Assembly and AC Backplane Always use insulated tools Installing a Rectifier 1 2 3 4 Remove a Rectifier from its shipping container Save the packaging materials Select a position in which to install the Rectifier The optional AC breaker should be in the OFF position To install a Rectifier 1 Note the voltage and current ratings of the rectifier Use only 48V rectifiers in the system 2 Slide the Rectifier slowly into the Housing until the Rectifier s rear connectors just engage the Housing connectors Fully seat the Rectifier in the Housing to properly engage the connectors Check to be sure that the locking mechanism has engaged with the rectifier If step 3 was performed Apply power to the newly installed rectifier by turning on the AC breaker Repeat the preceding steps for each Rectifier to be installed To commission the Rectifier s go to Chapter 3 Commissioning Removing a Rectifier l 2 3 4 Optional Remove power from the Rectifier Set the breaker t
36. kit Item A B en Distribution Lot Assembl ISTIS Don sso Tay i 5 16 Flat Washer Bevel Support Bracket u Washer and Nut Qty 2 Each Rack Rail gt eu 0 eg With di L 5 Threaded Gi 2 J 2 Holes bo 5 16 Bolt Flat Washer mE aa EN Bevel Washer Qty 4 Each ZEE E O Press in Nut Si In Underside of 2 Bus Qty 4 5 O O Item A Screw 10 Qty 2 o 06 Item B Screw 12 x 24 x 3 4 Qty 2 48V or 24 Vdc Bus Bar FIGURE 7 5 TYPICAL INSTALLATION OF AMI DISTRIBUTION PM990 8800 50 Issue 3 7 5 Distribution Option Kit Installation Sageon III Base System 10 11 12 13 14 Open the kit The packing list will identify the kit by part number and name Open the distribution area door Refer to Figure 7 1 and locate the Group where the additional distribution is to be installed From the kit collect the U shaped bus bar and four each 5 16 18x34 bolts 5 16 bevel washers and 5 16 flat washers In the selected group position the four unthreaded holes of the U shaped bus bar from the kit onto the factory installed U shaped bus bar of the d
37. mm Depth 10 254 mm Height RU Weight 5 1 Ibs 2 3 kg IMPORTANT The Power system is shipped without Rectifiers installed Consequently the plant is top heavy and can topple if mishandled Refer to Section 2 4 Moving and Anchoring the Power system before attempting to move the Power system 1 2 2 Power system Environmental Specifications Temperature Operating licheni 25 to 70 C 15 to 158 F Sustained Full Power 25 to 50 C 15 to 122 F SLOFABES sce ete eee een 40 to 85 C 40 to 185 F Shipping and Handling Power system Shipped fully assembled on a skid designed to withstand the shock and vibration normally encountered in shipping and handling Rectifier Modules Encased in protective foam and shipped in individual boxes Um Cys tie ed dee ads 0 to 95 non condensing PM990 8800 50 Issue 3 1 5 Introduction Sageon III Base System Note When operating the Power System an extremely low humidity environment lt 10 additional site ESD Electrostatic Discharge mitigation is recommended The installation of ESD conductive floor covering or coating per ANSI EOS ESD 57 1 and use of dissipative foot straps per ANSI EOS ESD 59 1 whenever servicing the equipment is recommended The use of an anti static wrist strap per EOS ESD 51 0 Wrist Straps is always recommended and is mandatory wheneve
38. n A t ER ertt pta eter eine oe ie ia 6 3 6 5 REPLACING THE SAGEON III CONTROL UNIT SCU i 6 3 6 5 1 Configuration Considerations out eter Re ppt ee D ee etae 6 3 6 6 REPLACING AN AC BACK PLANE BOARD 6 4 6 7 TO REMOVE A RECTIFIER MODULE do peteret eet one ope ia 6 7 6 8 TO INSERT A RECTIFIER MODULE xs re thereto e lai 6 7 7 0 DISTRIBUTION OPTION KIT INSTALLATION 2 440 00 0 enata tone tosta sns tastes suse ta tasses 7 1 7 1 AMI DISTRIBUTION TIERS 2 AND 3 GROUPS A amp B _ entente 7 4 BAA Kat Contents 4 52 eo tod etre s E Tae ERI TA eget 7 5 71 2 Instalhne The hits eon Retro RA Ren dio e eet iri ibo piece 7 5 7 2 DISTRIBUTION TIERS 2 AND 3 GROUPS A amp B_ eene eene nennen EES rennen ennt enne 7 6 EZAKI Contents zer ee e eR ipee ite precii etre rio 7 7 1 2 2 nstallme The Kit itr ehe ria ai ein 7 8 8 0 CIRCUIT BREAKER AND FUSE KIT 44 24 4 2 000 tns senten sees 8 1 S TAMITYPEBREAKBR KILS erento egenum lee pelis etie te ipe titres bere epe E 8 1 PM990 8800 50 Issue 3 vi Sageon III Base Sy
39. press ENTER again after last character If the entered password was correct the display will return to the selected parameter ready for modification If the entry was incorrect following will be displayed There is no limit on password entry re tries To abort password entry any of the top row buttons should be pressed The display will return to the selected parameter Once unlocked the security is disabled until there is no keypad activity for gt 1 minute Display test All LEDs on the rectifiers and operator panel will flash Test Indicators when ENTER is pressed and the screen will alternate between the ENTER SCU software version and an all pixels on screen not shown 1655 Number of SMRs Rectifiers in system This number must be entered Number of SMRs to prevent the operator panel from indicating that some SMRs are not 15 responding Number of battery strings Set to the number of connected battery Num of Batteries strings 2 Battery current transducer full scale rating Set to the full scale rating FS Batt Current of the battery current transducer 200A Load sensor On SCU displayed System current is derived from the Load Sensor voltage across System shunt ON Off SCU displayed System current is the sum of the Rectifier currents FS Load 2500A Full Scale Load Current Set to the full scale rating of the installed plant system shunt SCU Access Code i e System ID Type a unique 7 digit number for us vx each Sa
40. requirements above to be sure the PC at hand meets the minimum requirements Also read the ReadMe txt file on the CD for the latest information about installing and using SAGEVIEW PM990 8800 50 Issue 3 5 2 Sageon III Base System Sageview 1 Insert the SAGEVIEW CD in your computer s CD ROM drive The opening screen will appear If it does not appear click Start and then click Run In the Run dialog box type d setup exe Substitute your CD ROM s drive letter for as needed 2 Windows InstallShield will start and the screen shown below will appear Click Next to continue the installation or click Cancel to exit the installation Hii SageView InstallShield Wizard x Welcome to the InstallShield Wizard for SageView The InstallShield R Wizard will install SageView on your computer To continue click Next WARNING This program is protected by copyright law and international treaties 3 Inthe Choose Destination Location screen click Next to accept the default location for installation of the SageView program Alternatively type another path or browse to another location for installation of the program and then click Install li SageView InstallShield Wizard Ready to Install the Program The wizard is ready to begin installation If you want to review or change any of your installation settings click Back Click Cancel to exit the wizard Current Settings Destination
41. support bracket and required hardware There are two kits Kit PN 385 5881 00 is for installation in Group A Kit PN 385 5881 01 is for installation in Group B Figure 7 4 shows the orientation of the AMI distribution assemblies It also shows routing of the supply cables upward through the open top of the rack and the daisy chained alarm wiring Distribution 5 5 2 E 8 S LL a D Fuse Alarm FA Wire Distribution Assemblies S O pe Bars FIGURE 7 4 ORIENTATION OF DISTRIBUTION ASSEMBLIES 48V SYSTEMS PM990 8800 50 Issue 3 7 4 Sageon III Base System Distribution Option Kit Installation 7 1 1 Kit Contents Some hardware listed below may be factory installed on another item in the kit and disassembly may be needed to install the option kit Kit PN Kit PN Description 385 5881 00A 385 5881 01A Quantity Quantity 10 Position Distribution Assembly 1 1 Bus Bar U Shaped 1 1 Bracket Distribution Assembly Support 1 1 Screw 10 32 Hex Head 2 0 Screw 12 24 x 3 4 2 2 Bolt Hex 5 16 18x 1 4 4 Washer bevel 5 16 6 6 Washer Flat 5 16 6 6 Nut Hex 5 16 18 2 2 7 1 2 Installing the kit While installing the kit refer to Figure 7 5 and to a factory installed group for location and orientation of items included in the
42. that those performing the commissioning fully understand the system at hand Modify these procedures as needed to accommodate the installed equipment and your company s commissioning procedures 3 1 PREPARATION Perform the following steps prior to commissioning a Power system 1 Gather system wiring diagrams battery data sheets and other site documentation for ready reference should it be needed Complete all installation steps Refer to Chapter 2 Installation as necessary Review the steps in Section 3 2 Commissioning a System Become familiar with operator panel LEDs front panel displays push buttons and menus by reading Chapter 4 Configuration and Operation Start up configuration parameter values e Battery String Connected to Plant The string will power the SCU prior to starting the first Rectifier assuming at least a minimal battery charge and the SCU 2 line display and status LEDs will be active You may then use the operator panel to change many of these default parameter values to accommodate the application See Table 4 1 for a list of default parameters and values No Battery String Connected to Plant When the first Rectifier starts and powers the SCU the SCU will load a default plant configuration You may then use the operator panel to change many of these default parameter values to accommodate the application See Table 4 1 for a list of default parameters and values Alternatively edit the configurati
43. the output current and heat sink temperature of each rectifier See Section 4 6 for the screens displayed in the RECT menu PM990 8800 50 Issue 3 4 3 Configuration and Operation Sageon III Base System BATT BATTery Press to access a menu of battery parameters See Section 4 7 for the screens displayed in the BATT menu LOG Press to view a menu of the 99 most current alarms in chronological order Section 4 8 shows the screens The alarm log number and alarm description are displayed first Two seconds later the alarm log number and the date and time of the alarm occurrence are displayed These two screen then alternate at a two second rate Increment Press the up arrow to scroll through a menu selected using an SMR or LOG button from the first menu screen to the last When editing a flashing parameter press to increase the parameter value Decrement Press the down arrow scroll through a menu selected using an SMR or LOG button from the last menu screen to the first When editing a flashing parameter press to decrease the parameter value up arrow or down arrow button can be used to change that value Press ENTER to store the edited value Enter With a editable parameter displayed press Enter to cause the value to flash indicating that the When setting a parameter with multiple digits e g access code time date set the left most digit as described above T
44. 0 Battery Cell Leads 350 7812 100 100 Battery Cell Leads Battery Adaptor Kits Requires 350 7812 xx 385 6151 03 For 10 Battery Hardware Includes harness amp flat washers 385 6151 04 For 1 4 and 6mm Battery Hardware Includes harness amp flat washers 385 6151 05 For 5 16 and 8mm Battery Hardware Includes harness amp flat washers 385 6151 06 For 3 8 and 10mm Battery Hardware Includes harness amp flat washers 385 6151 07 For 1 2 and 12mm Battery Hardware Includes harness amp flat washers Battery Current Transducers Requires SAGEON3 C01 385 5932 50 Sageon Battery Current Transducer 50A with 30 lead 385 5932 100 Sageon Battery Current Transducer 100A with 30 lead 385 5932 200 Sageon Battery Current Transducer 200A with 30 lead 385 5932 600 Sageon Battery Current Transducer 600A with 30 lead 385 5932 1000 Sageon Battery Current Transducer 1000A with 30 lead 385 5970 50 Sageon Battery Current Transducer 50A with 100 lead 385 5970 100 Sageon Battery Current Transducer 100A with 100 lead 385 5970 200 Sageon Battery Current Transducer 200A with 100 lead 385 5970 600 Sageon Battery Current Transducer 600A with 100 lead 385 5970 1000 Sageon Battery Current Transducer 1000A with 100 lead 385 5980 500 Sageon Split Core Current Transducer 500A with 30 lead 385 5980 1000
45. 0 150 Ampere 1 Series Breaker 2 Positions 274 3830 200 200 Ampere AM1 Series Breaker 2 Positions 385 3830 00 Breaker Toggle Guard Kit 1 Breaker Adapter Bus Bars utilizes two breaker spaces apt the breaker output to accept larger 2 hole lugs 45 up angle 209 4743 01 2H Landing Bus Bar 1 C to C 3 8 16 Studs Distribution Group 209 4743 02 2H Landing Bus Bar 1 C to C 3 8 16 Studs Distribution Group B GJ1 Series Breakers Requires SAGEON3 E03 E04 E05 274 3833 100 100 Ampere GJ1 Series Breaker 1 Position 274 3833 125 125 Ampere GJ1 Series Breaker 1 Position 274 3833 150 150 Ampere GJ1 Series Breaker 1 Position 274 3833 175 175 Ampere GJ1 Series Breaker 1 Position 274 3833 200 200 Ampere GJ1 Series Breaker 1 Position 274 3833 225 225 Ampere GJ1 Series Breaker 1 Position 274 3833 250 250 Ampere GJ1 Series Breaker 1 Position 274 3833 300 300 Ampere GJ1 Series Breaker 2 Positions 274 3833 350 350 Ampere GJ1 Series Breaker 2 Positions 274 3833 400 400 Ampere GJ1 Series Breaker 2 Positions 274 3833 600 600 Ampere GJ1 Series Breaker 3 Positions GJ1 Breaker Adapter Bus Bars adapt the breaker output to accept 2 hole lugs 209 8104 00 For single position breakers 1 lug landing 1 C to C 3 8x16 studs 209 5235 00 For two position breakers 1 lug landing 1 C to C 3 8x16 studs 209 5240 00
46. 0 98 4 90 500 MCM 500 000 525 380 0 814 1 12 5 60 750MCM 750 000 660 475 0 998 1 34 6 70 Data based on NEC Handbook 2011 Table 310 17 adjusted for 50 122 F ambient temperature 2 2 3 Torque Specifications Proper plant performance requires that the hardware employed during installation be tightened securely but not over tightened Use a torque wrench to ensure that hardware is tightened to the specification provided in Table 2 2 TABLE 2 2 TORQUE SPECIFICATIONS STEEL FASTENERS Bolt Size Inch Pounds Foot Pounds Newton Meters 4 40 4 48 6 32 6 40 8 32 8 36 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7116 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 PM990 8800 50 Issue 3 2 4 Sageon III Base System Installation 2 3 SELECTING A LOCATION Install the Power system in a location that provides the following e Access to a source of reliable stable electrically clean AC power e dry well ventilated room that meets the conditions stated in Section 1 2 2 Power system Environmental Specifications e Sufficient access for plant installation and servicing refer to NEC and local codes e Sufficient ceiling height to permit use of overhead cable trays and conduit for AC input cables and DC load supply and return cables e A level flat floor capable of supporting the weight of the Power system a
47. 3 4 23 Configuration and Operation Sageon III Base System Base Menu continued Sets MiniCSU 3 access code address Access Code Modify Value up down 00000 0000000 ENTER to accept Date Format Modify Value up down 1 DD MM YYYY ENTER to accept ENTER selects hours minutes month or INC DEC modifies value Alarm Report INC DEC toggles state Off ENTER to accept Daily Report Off Date Time 01 11 11 2 m 2 o w o o o I Im If Daily Rep not Off ENTER v GEA I NC DEC toggles state 1518 L ENTER accept _ ENTER I CINC DEC toggles sta e ENTER to accepi If Modem not Off E ora ada ERES i Modify Value up down 51 ss ENTER io E lt ee xx x Modify Value up down None ENTER to accept _ E Phone 1 Modify Value up down ees NTER 1 NTER I NTER I NTER NTER L TER NTER External modem initialisation string 4 1 4 Led Led Led Led Led Led Lj Lel Lel L I L I I Phone 1 Cont Modify Value up down I 2323 ENTER to accept __ EN I Phone 2 Modify Value up down 0398887788 ENTER to accept E I Phone 2 Cont Modify Value up down 2323 ENTER to accept I EN Phone 3 Modify Value up down 0398887788 ENTER to accept _ Modify Value up down 2323 _ ENTER to accept _ ENTER
48. A Breaker Input Terminal Hardware FIGURE 7 7 GJ1 DISTRIBUTION KIT W BREAKER KIT PM990 8800 50 Issue 3 7 9 Sageon III Base System Circuit Breaker and Fuse Kit Installation 8 0 CIRCUIT BREAKER AND FUSE KIT INSTALLATION All AMI type breaker fuse kits included in the initial Power system order are shipped from the factory in separate protective packaging This packaging is placed inside the tower at the base the Power system GJ1 type breaker kits included in the initial Power system order are factory installed Breaker AM1 amp Kits can also be ordered separately to add to existing distribution when empty positions exist 8 1 AMI TYPE BREAKER KITS 8 1 1 Kit Contents Description Quantity AMI type breaker Bullet type mount 1 Bus Bar Output 1 Nut Hex 1 4 20 2 Washer Flat 1 4 2 8 1 2 Installing the Kit 1 Remove an AMI type breaker kit from its protective packaging The package label will identify the kit by part number Open the distribution area door Refer to Figure 7 1 and locate the Distribution Tier and Distribution Group where this kit will be installed Place the Output Bus Bar over the two threaded studs of the Distribution Assembly orient as indicated in Figures 8 1 and 8 2 Place load cable lug over Output Bus Bar Place the two 1 4 flat washers over the load cable lug Install the two 1 4 20 hex nuts over the flat washers and tighten
49. CN 20082 WD 2 17 15 2 19 15 PROPRIETARY AND CONFIDENTIAL The information contained in this product manual is the sole property of UNIPOWER LLC Reproduction of the manual or any portion of the manual without the written permission of UNIPOWER LLC is prohibited Copyright UNIPOWER LLC 2015 DISCLAIMER Data descriptions and specifications presented herein are subject to revision by UNIPOWER LLC without notice While such information is believed to be accurate as indicated herein UNIPOWER LLC makes no warranty and hereby disclaims all warranties express or implied with regard to the accuracy or completeness of such information Further because the product s featured herein may be used under conditions beyond its control UNIPOWER LLC hereby disclaims and excludes all warranties express implied or statutory including any warranty of merchantability any warranty of fitness for a particular purpose and any implied warranties otherwise arising from course of dealing or usage of trade The user is solely responsible for determining the suitability of the product s featured herein for user s intended purpose and in user s specific application Throughout the remainder of this manual UNIPOWER will mean UNIPOWER LLC PERSONNEL REQUIREMENTS Installation setup operation and servicing of this equipment should be performed by qualified persons thoroughly familiar with this Product Manual and Applicabl
50. CREENS An alarm log resides in SCU memory and these alarms can be viewed by momentarily pressing the Alarms Log button The following map summarizes the available menu screens LOG Button Alarm number and description Alarm date and time Clear alarm log Initial Alarm Log screen Log 1 is the most recent alarm Previous Log 1 alarms are number in sequence 2 through The second line AC Freq Fault provides the alarm name Press and hold the up arrow button for 2 seconds to display the I preceding alarm Log 2 Press again to display the preceding alarm Log n Log 3 Alarm Name Momentarily less than 2 seconds press the up arrow button to display a screen showing the date and time alarm occurred The date Log 1 format is day month year the time format is 24 hours 16 03 2015 13 55 Clear Alarm Log From any alarm log screen press ENTER and then press down arrow to clear all log entries A deletion confirmation screen will be displayed The alarm log can only be cleared from the front panel There are no LOG means to clear the alarm log entries remotely No Alarms Down arrow to Clear Log Entries PM990 8800 50 Issue 3 4 20 Sageon III Base System Configuration and Operation 4 9 SAGEON BATTERY MONITOR SETUP With the SBM option enabled SBM parameters must be set before monitoring can be performed From the HOME screen scroll through the operator display screens shown in
51. EDs and alarm messages Sections 4 5 through 4 9 explore the menu options available for configuration and operation of the System TABLE 4 1 SUMMARY OF DEFAULT SYSTEM SCU PARAMETERS Parameter Description 48V System 48V User Range System Value Default Base Home System Menu Amb Tmp Alm Ambient temperature alarm level 30 99 55 Volts High System output volts high threshold 48 65V 57 5V Volts Low System output volts low threshold 44 54V 48 0V No of RECs Set number of Rectifiers in system 0 225 1 Num Batteries Number of battery strings installed 1 4 1 FS Batt 1 Battery current transducer full scale 10 30 000A 100A rating FS Batt 2 Battery current transducer full scale 10 30 000A 100A rating FS Batt 3 Battery current transducer full scale 10 30 000A 100A rating FS Batt 4 Battery current transducer full scale 10 30 000A 100 rating SCU SCU access code 7 digits 0 9999999 0000000 Date Current system date Battery Monitor menu after enabling Battery Monitor Bat Config Battery monoblock size x number see Various 2V x 24 SBM section of manual for more detail Configurations PM990 8800 50 Issue 3 4 1 charging Configuration and Operation Sageon III Base System Parameter Description 48V System 48V User Ra
52. ENTER Security Modify Value up down Off ENTER to accept m ENTER Password Setup Modify Value up down Press ENTER ENTER to accept esmdcaos f Press ENTER ENTER ystem Info INC DEC toggles system Press ENTER 1 info 1 NER SSS ystem Modify Value up down UPS ENTER to accept ToS Number of SMHs Modify Value up down 1 ENTER to accept WER see nterface Modify Value up down MUIB 10 I AKER eee Num of Batteries Modify Value up down 1 ENTER to accept ENTER me ia Batt Current Modify Value up down 20A I ENTER to accept ENTER oad Sensor INC DEC toggles state Off 1 ENTER to accept If Load Sensor not Off ENTER oad Current Modify Value up down I L ENTER to accept Bus voltage above which alarm flagged Bus voltage below which alarm flagged Programmable value change requires password when security on Password programming submenu Press ENTER to begin flashing display and LEDs System information including controller software version S N and cabinet S N Options for Standby or UPS type system Sets number of SMRs in the system Selects the interface hardware to the system Sets the number of batteries in the system Sets full scale battery current Sets full scale load current PM990 8800 50 Issue
53. Folder C Program Files User Information Name Company InstallShield 4 The final installation screen is the Setup Complete screen Click Finish to complete the installation PM990 8800 50 Issue 3 5 3 Sageview Sageon III Base System The InstallShield Wizard has successfully installed SageView Click Finish to exit the wizard 1 Cancel Refer to the SageNET user manual for more information on setting up the Remote Communications Unit over TCP IP This manual will describe network setting sand SageNET module configuration PM990 8800 50 Issue 3 5 4 Sageon III Base System Maintenance 6 0 MAINTENANCE This chapter provides periodic maintenance procedures and assembly replacement procedures If troubleshooting is required refer to drawing SD SAGEON3 AXX for schematic representations of Sageon III Base System circuits A list of spare and replacement parts is located in Chapter 9 IMPORTANT Regularly monitor the LEDs on the operator panel and Rectifiers Review the alarm log regularly to detect minor problems before they become significant problems 6 1 CIRCUIT BOARD HANDLING Semiconductors such as ICs integrated circuits diodes and transistors must be protected against damaging electrostatic discharges A properly grounded wrist strap must be worn whenever a circuit board is handled or touched A service kit with a wrist strap and static dissipative work mat is available from both mail ord
54. For three position breakers 3 lug landings 1 C to C 3 8x16 studs 209 5228 00 For four position breakers 4 lug landings 1 C to C 3 8x16 studs PM990 8800 50 Issue 3 2 Y 3 4 ISSUE ISSUE DESCRIPTION ISS BY APP BY ISS DATE APP DATE ES 20076 WD DBW s Hr LOGO VERBIAGE 2 13 15 2 13 15 TO STATE UNIPOWER ALARM CONTACTS A RATED 2 AM ESISITLVB 48 VDC ALL WIRES ARE 20 MINIMUM UNLESS OIHERWISE NOTED CURRENT TRANSDUCE ONS EQUA SAGEONS COT 4515775 LECT UP 10 4 INDIVIDUAL BATTERY RING CURRENT TRANSDUCERS ORD S SEPARATE I ORDER TEMPERATUR RS AS SEPA ITEMS INDIVIDUAL 20AMP AC BREAKERS INCLUDE EACH RECTIFIER POS EST DON DASHED LINES DENOTE CUSTOMER CONNECTIONS OR ESTEE APPROVALS EXTERNAL PANEL CONNECTIONS TOLERANCES ON 0 002 MC 3 8 13 DASH DOT LINES DENO COMPONENTS O ioni 2 NAL TO SAGEONI ccm mi 3 11 13 DISCONNECI PANELS INC AND MUST ORDE
55. Guidelines above for additional information 2 type breaker Distribution Option is an assembly that can hold up to four type breakers distribution PM990 8800 50 Issue 3 7 2 Sageon III Base System Sageon III Base System Distribution Option Kit Installation DISTRIBUTION AM1 AM1 DISTRIBUTION TIER 2 DISTRIBUTION AM1 AM1 TIER 1 STD FIGURE 7 2 DISTRIBUTION AREA LEFT SIDE CHARGE BUS BATTERY TIER 1 STD RETURN BUS LOAD TIER 1 STD RETURN BUS BATTERY TIER 1 STD FIGURE 7 3 D ISTRIBUTION AREA RIGHT SIDE PM990 8800 50 Issue 3 Distribution Option Kit Installation Sageon III Base System 7 1 AMI DISTRIBUTION TIERS 2 AND 3 GROUPS amp B Pi This section describes installation of a kit for adding AMI type breaker distribution Kit contents and part numbers are listed below Installation of circuit breakers and fuses is described in Chapter 8 The figure at right shows many of the components included in the kit the U shaped bus bar distribution assembly assembly
56. IGURE 7 3 DISTRIBUTION AREA RIGHT SIDE 7 3 FIGURE 7 4 ORIENTATION OF DISTRIBUTION ASSEMBLIES 48V SYSTEMS eee eee 7 4 FIGURE 7 5 TYPICAL INSTALLATION OF AMI 7 5 FIGURE 7 6 DISTRIBUTION ASSEMBLIES GJ1 ee 7 7 FIGURE 7 7 DISTRIBUTION KIT W BREAKER KIT i 7 9 FIGURE 8 1 AMI TYPE BREAKER KIT COMPONENTS ieee riss trennen trennen e oeei Keiki 8 2 FIGURE 8 2 AMI TYPE BREAKER SHOWN KIT INSTALLATION eene eren 8 2 FIGURE 8 3 TYPE BREAKER KIT COMPONENTS i 8 4 FIGURE 8 4 TYPE BREAKER KIT INSTALLATION enne nenene teen teen teen 8 4 PM990 8800 50 Issue 3 viii Sageon III Base System Introduction 1 0 INTRODUCTION This Product Manual describes installation operation and servicing of UNIPOWER Sageon III Base Systems The Sageon III Base System is available as a 48 seven foot high system in two ratings the 600 ampere and 1200 ampere max A view of the system is provided on the cover of this manual and in Figure 1 1 below
57. ISTRIBUTION ASSEMBLIES GJ1 7 2 1 Kit Contents Kit PN Description 385 5882 00 Quantity Breaker Mounting Bracket U Shaped 1 Breaker Mounting Bar 5 8 x 7 1 2 2 Bus Bar Assembly L Shaped 1 Rack Screw 12 24 x 3 4 2 Bolt Hex 5 16 18 x 1 4 Washer bevel Bevel 5 16 4 Washer Flat 5 16 4 Screw Phillips Head 10 32 x 1 2 4 Alarm Wire with Ring Lug Red 1 Fuse Alarm Jumper Wire Orange 1 PM990 8800 50 Issue 3 7 7 Distribution Option Kit Installation Sageon III Base System 7 2 2 Installing the Kit 1 2 10 11 12 Open the kit The packing list will identify the kit by part number and name Open the distribution area door Refer to Figure 7 1 and locate the Group where this distribution will be placed From the kit collect the L shaped bus bar and four each 5 16 18x1 bolts 5 16 bevel washers 5 16 flat washers and the red alarm wire with the ring terminal lug Position the L shaped bus bar against the top of the U shaped distribution bus in the factory installed distribution group and align the mounting holes see Figures 7 6 and 7 7 The upward pointing fingers with the press in nuts should be toward the inside of the pant Place the ring terminal of the red alarm wire on one of the bolts Loosely install the hardware Do not tighten the hardware at this time From the kit collect the painted U shaped breaker mounting bracket and
58. LACEMENT PARTS To minimize downtime should maintenance be required a supply of spare circuit breakers and fuses circuit boards rectifiers and other recommended components should be immediately available See the Recommended Spare Parts List below Please refer to the UNIPOWER part number when placing orders For assistance in ordering spare parts call UNIPOWER and ask to speak with Order Entry The telephone number is found in Section 1 5 Product Support TABLE 9 1 LIST DRIVEN PCB S Battery Controller Backplane Controller Backplane Circuit Battery Ditribution NMP Aur Relay PCB w o C1 PCB with C1 Breaker 20A 246 0840 10 ERT190 5691 ERT190 5770 ListA2 ERT190 5691 ERT190 5770 Se e kitse _ 23010 Us Bep de ode o de esu rs Pregeo Sri List01 __ ERT1905770T ERT190 5740X48P ERTI90 6011 1111 4 103 4015 32 TABLE 9 2 MAJOR REPLACEMENT COMPONENTS Controller 103 4130 48 48V Controller Rectifiers 100 7675 4850 Sageon Rectifier 48V 50A 208 240VAC single phase 124 0073 00 Blank Rectifier Panel Required to fill open rectifier positions Sageon Battery Monitor 385 5201 20 Include 30 Ribbon Cable to SCU Requires Battery Cell Wire Bundle and Battery Adaptor Kit Battery Cell Wire Bundle Requires 385 5201 20 350 7812 10 10 Battery Cell Leads 350 7812 25 25 Battery Cell Leads 350 7812 50 5
59. LOI esse ata nananana DD e nempe ite penes 4 12 4 6 RECT RECTIFIER 5 lariana t e ne Reged mee Here teens 4 12 AT BATF SCRBENS nia qo eene dta edes 4 14 4 7 1 Battery Temperature Compensation i 4 15 ASTD EQUAL Z Atl OD sas aisha e tet bae edere Pee Pm bdo 4 16 4 7 3 Low Voltage Battery Disconnect LVBD LVLD Screens 4 18 4 7 4 Battery Discharge Test BDT Screens i 4 18 ASTD BDT Results SCreensie ee eter peers 4 19 4 7 6 BDT Results Screen Additional DetailS sete nnne 4 20 ALT BDT Disabled zen ree ett dee rm eh ded nte maet nta 4 20 4 8 ALARM EOG SCRBENS diete ted bete edge e Eee 4 20 4 9 SAGEON BATTERY MONITOR SETUP eee 4 21 4 9 1 Frequency of Measurement ete De et dett ER e ER e RR EE 4 21 4 9 2 Battery Cell Measurements Gne tee nee ere e ro tee E D e ap EU eee eritis 4 21 4 10 COMMISSIONING THE CONTROLLER iii 4 21 4 LT OPERATION oii uter rH een E EG PRI ERR E ERR eo d e e 4 22 4 12 SUMMARY OF CONTROLLER FRONT PANEL CONTROL S 4 22 4 13 NAVIGATING CONTROLLER FUNCTIONS e 4 23 4 13 1 Base Menu System Level Functions 4 23 4 13 2 Recti
60. MI Type Breaker Distribution eee enne nennen rennen nennen 2 14 2 7 3 Load Supply Cables GJ1 Type Breaker Distribution ii 2 16 2 8 CONNECTING EXTERNAL ALARM 8 4 2 0 00000000000000000000000000000000050000 2 17 2 9 BATTERY TEMPERATURE SENSORS AND KITS OPTION eene nennen nennen trennen enne 2 17 2 10 INSTALLING A BATTERY CURRENT TRANSDUCER OPTION ei 2 19 2 11 SAGEON BATTERY MONITOR OPTION ei 2 20 2 12 SITE MONITOR SYSTEM OPTION ae eiii nee e O EO ERE DER RETE EE 2 21 2 13 COMMUNICATIONS igneo ORE REEF ERREUR EE UTR ERR D nes 2 21 2 14 INSTALLING AND REMOVING RECTIFIERS i 2 21 2 15 CONEIGURATION it nien n OE RH e RP D ED REG RR RU TRU 2 23 2 15 1 General Description test ent te bate Oed pr 2 23 UnOn 3 1 S PREPARATION o EO Hv dde EROR ED ERROR He E 3 1 32 COMMISSIONING A SYSTEM inepte pe et do ot EQ RB t ER 3 1 3 3 OVERVIEW OF EXTERNAL WIRING CONNECTIONS 222 2222 0 000000000 eene nee nrennenren 3 3 3 4 FACTORY SUPPLIED CONFIGURATIONS iii 3 3 3 4 1 Single phase individual protected external feeds sese enne 3 3 3 4 2 Surge protection requirements
61. MP SAGEON3 D01 Distribution Tiers amp Ground Return Battery Landing Group A GJ1 Group B GJ1 Ground Return Eight 8 battery connections 3 8 on 1 C C Tier 1 Group A AM1 Group B AM1 Ground Return Eight 8 battery connections SAGEON3 E01 3 8 on 1 C C Tier 1 Group A AM1 Group B AM1 Tier 2 Group A AMI Group B AM1 Ground SAGEON3 E02 Return Eight 8 battery connections 3 8 on 1 C C Tier 1 Group A AM1 Group B AM1 Tier 2 Group A GJ1 Group B GJ1 Ground SAGEON3 E03 Return Eight 8 battery connections 3 8 on 1 C C Tier 1 Group A AM1 Group B AM1 Tier 2 Group A AM1 Group B AM1 Tier 3 SAGEON3 E04 Group A AM1 Group B AM1 Ground Return Eight 8 battery connections 3 8 on 1 C C Tier 1 Group A AM1 Group B AM1 Tier 2 Group A AM1 Group B AM1 Tier 3 SAGEON3 E05 PM990 8800 50 Issue 3 i Front Matter Sageon III Base System 1 1 1 2 1 3 2 1 2 2 2 3 2 4 RECEIVING INSTRUCTIONS amp GENERAL EQUIPMENT INFORMATION Please Note For your protection the following information and the product manual should be read and thoroughly understood before unpacking installing or using the equipment UNIPOWER LLC presents all equipment to the delivering carrier securely packed and in perfect condition Upon acceptance of the package from us the delivering carrier assumed responsibility for its safe arrival to you Once yo
62. NTER to display the current On Off status flashing Press up arrow or down arrow to set the On desired state then press ENTER to store The following screens will not appear if Off has been entered Battery configuration Set the number of cells in a battery string and Bat Config the number of battery strings connected to the monitor See Section 24 cells 4 9 Sageon III Battery Monitor Setup for details After pressing ENTER current configuration will flash Scroll through the available configurations and press ENTER again once the correct battery type is chosen Battery strings Set the number of connected battery strings The SBM Batteries maximum is four 2 Note This number must equal to or be less that the Num of Batteries entered in the Home Programmable Parameters series of screens Cell Vhi Alm High voltage alarm threshold Set the cell voltage above which an 248V alarm will be generated Low voltage alarm threshold Set the cell voltage below which Cell Vlo Alm alarm will be generated 1 44V PM990 8800 50 Issue 3 4 11 Configuration and Operation Sageon III Base System Delta positive voltage threshold Set the percentage of nominal cell voltage by which any individual cell voltage can exceed the nominal Cell dVc Al Above this value an alarm will be generated 10 Delta negative voltage threshold Set the percentage of nominal cell Cell dVc Al voltage by which any individua
63. OPERATOR PANEL SYSTEM STATUS LEDS LED Color Meaning On System OK Off A failure or alarm condition exists Flashing Alarm Alarm condition exists in the system or a Rectifier On Plant is in Equalize Mode Off No alarm condition exists in the Sageon III Base System On Rectifier Shutdown One or more Rectifiers has shut down Off Rectifiers are operating If all three LEDs are Off e There may be no System output or battery string DC to power the SCU e The SCU may have failed e There may be no AC power to the System e On initial startup all 3 LEDs may be off for approximately 10 seconds while the system boots up 4 4 READING ALARM MESSAGES If an alarm exists an alarm message will alternate with the Home screen ia the status LEDs will also indicate the presence of an alarm The alarm cena message will display for two seconds every six seconds A sample alarm message is shown below This message states that three alarms exist and they can be viewed by Alarm 1 pressing the ENTER button When the button is pressed the name and Amb Temp Hish description of the most recent alarm are displayed as shown below Press p Hg either the up arrow or down arrow button to view remaining alarms Pressing ENTER or not pressing any button for ten seconds will display the Home screen To read the time and date of any alarm press the LOG button and use the up arrow or down a
64. R 1 11 VA A Monitoring Specifications alan AL nr 1 11 1 42 Alarm Specifications Enia ILL alba 1 11 1 5 PRODUGESUPPORT m 1 12 2 0 INSTALLATION rrrrrerrrrerierenie zio re io zio niorenio nio reziario ie zinarioneeio riore nio nin ee ario ie nio nin 2 1 2 L INSTALLATION SUMMARY LALA RI LIL LL salini 2 2 22 i ER cod iii Ain 2 2 221 Fools And ACCeSSOTIES 5 ono aan Lisa ela ai 2 2 2 22 Selecang and Sizing DC Power Cables neiro enren IERI aiuola aloni 2 3 2 2 3 Torque Specifications oot Eo PE IEEE e Lisa 2 4 2 3 SELECTING A LOCA TON Se tape etate e doe iret buo POI ERE ER EH UM efe iere Lil 2 5 2 4 MOVING AND ANCHORING THE POWER SYSTEM ie 2 5 2 5 CONNECTING AC POWER TO THE POWER SYSTEM eren nennen enne 2 2 5 Lightning and Transient SuppressiOT oo eerte Pere He t efte eene Ha Pr er ete anna 2 8 2 52 Users Electrical Service Pariel oder ptm e ete ee ete e ertt e He etici 2 9 2 5 9 AC Cab nga oi ree ettet efie etm a eH e ep HO ent nct ede eee 2 9 2 0 CONNECTING BATTERY CABLES eue d Ere Herten rn pe e ette e 2 10 2 7 CONNECTING CUSTOMER LOADS ir dem ert id e m ee i rg te PE 2 11 2 1 Eoad Return Cables iie eom n He etre o ete pti b eed edo beet 2 14 2 7 2 Load Supply Cables A
65. R initial display When a Rectifier is online and operating normally its output current and heatsink temperature are shown SEAT DESC SMRI SMR version and temperature Press enter display Rectifier s G1045a software version SMR output current Press the up arrow button to display the SMR2 output current from other Rectifiers 91A PM990 8800 50 Issue 3 4 12 Sageon III Base System Configuration and Operation Float voltage This parameter is globally and indirectly set in the menu It cannot be changed in this screen SMR Float 54 2V Equalization voltage This parameter is globally and indirectly set in the Batt menu It cannot be changed in this screen 7 Programmable Parameters The following screens allow access to the SMR programmable parameters Note that the parameter values apply to ALL installed SMRs To change a parameter value 1 Scroll to the desired screen using the up arrow or down arrow button 2 Press the ENTER button the selected value will flash 3 Use the up arrow or down arrow button to edit that value Press ENTER to store the new value SMR high voltage alarm threshold SMR V high Alarm 57 0V SMR V low Alarm SMR low voltage alarm threshold 48 0V SMR HVSD SMR high voltage DC shutdown 58 0V SMR current limit SMR I Limit 50A Reset SMR Fault Fault reset Press ENTER to reset latched alarms such as HVSD The Press ENTER Rectifier will rest
66. RED AS A SEPARATE LINE ITEM SHOWN FOR ILLUSTRATION We TCA APPLICA T ECON ONG e 02543 4 e 02543 4 SPEC ENGO32 MATERIAL FINISH BATTERIES ARE NOT INCLUDED AND MUST B SGH SEMEN ORDERED SEPARATELY SHOWN HER OR NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT ILLUSTRAT I ON OF YP I L A y I I ON ONLY PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC UNI DOWER Powering Technology SHEET INDEX NOTE HE ISSUE OF SHE 1 REFLECTS THE LATEST ISSUE F THE DRAWING SET WHEN THE DRAWING SET IS EVISED ON UE NUMBERS OF MODIFIED S RE CHANGED E NUMBERS OF UNMODIFIED SHEE ARE NOT CHA SCHEMATIC DIAGRAM EON III POWER SYSTE B DOC TYPE NUMBER ISSUE SD SAGEONS AXX SCALE SHEET FILE NAME N A 1 OF 4 SD SAGEON3 AXX_ISS_4 ED991 5001 B3 Issue 3 1 2 i 3 4 RECTI R BACKP AUX RIBBON EXT COMMS RECTIFIER 48V 50A 100 7675 4850 1 RECTI R BACKPLA Xi Xe XsL_IL_Ix4 1 6 x
67. RS AT STRING EXTERNAL CT 5 MIDPOINTS SEE NOTE 3 SEE NOTE 8 DC CT FA CKT BRD BATTERY DISCONNECT PANEL NC NOC o DIST GROUP B TIER 2 BATTERY BLK DISCONNECT _PANEL gt 10 WHT VIO BRN CUSTOMER LOADS 48 VOLT DIST GROUP BLK TIER 3 DISCONNECT PANEL CUSTOMER SPECIFIC CURR 1 ve ost LK CURR 2 CURR 3 CURR 4 B BATTERY DISCONNECT PANEL AUX RELAY C V c AUX RELAY NO 4 o AH AUX RELAY NO AUX RELAY NO 2 AUX RELAY NO 1 SAGEON3 A01 ONLY INTERNAL BATTERY LVD BUS BAR CONTROL Y PASS SWITCH BUS BAR BRN RED BLK BATTERY LANDING TERMINAL 8 LANDINGS WHT VIO PROPRIETARY INFORMATION NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC SIZF DOC TYPE NUMBER ISSUE B SAGEONS AXX SCALE SHEET FILE NAME N A 4 OF 4 SD SAGEON3 AXX_ISS_4
68. S Figure 5 1 shows typical connections for local and remote access to Sageon III Base System data Additional information is provided in the SageView Help topic titled Connection Setup Local connection details are provided below Guidelines for remote connections are also provided Remote connection specifics are beyond the scope of this manual since actual connections and required hardware are determined by the systems operating within your System Consult your company s network administrator 5 5 LOCAL CONNECTION STANDARD For a local connection cable the serial port on the Sageon III Base System s operator panel to the USB port on a Windows based PC A customer supplied USB A to USB B cable is required 5 6 REMOTE CONNECTION ETHERNET OPTION When the Ethernet option is ordered the Sageon III Base System includes an RJ 45 connector for the Ethernet network cable As shown in Figure 5 1 a remotely located Windows based PC can be connected to your System s Ethernet network With the addition of the necessary hardware e g server with firewall a remote PC can connect to your System s network over the Internet 5 7 PC REQUIREMENTS e Microsoft Windows 98 ME 2000 or XP e Pentium or better microprocessor e 128 KB or more RAM e 10 MB unused hard disk space for program and database files CD ROM drive e USB port with USB A to USB B cable 5 8 INSTALLING SAGEVIEW Before beginning the installation review the PC
69. STOMER WIRING PHASE TO NEUTRAL eee 3 4 FIGURE 3 2 SINGLE PHASE FEED CUSTOMER WIRING PHASE TO PHASE 3 5 FIGURE 3 3 SPLIT SINGLE PHASE FEED CUSTOMER WIRING PHASE TO NEUTRAL eret 3 6 FIGURE 3 4 Y THREE PHASE FEED A CONNECTED RECTIFIERS CUSTOMER WIRING PHASE TO PHASE 3 7 FIGURE 3 5 Y THREE PHASE FEED CUSTOMER WIRING PHASE TO NEUTRAL esee 3 8 FIGURE 3 6 A THREE PHASE FEED CUSTOMER WIRING PHASE TO PHASE n 3 9 FIGURE 3 7 SURGE PROTECTION ete rone FOR ERO TED Nt Dp ERG OR ROTER 3 10 FIGURE 3 8 MULTIPLE ALARM te eret etre ER eere Fer ees ERG SAA ER creer per Er Er ete 3 11 FIGURE 3 9 BATTERY DISTRIBUTION MODULE BDM i 3 13 FIGURE4 I OPERATOR PANBL eiii oie ete etate a etin iron RU ono re OUR ER ees 4 3 PM990 8800 50 Issue 3 vii Front Matter Sageon III Base System FIGURE 5 1 NETWORK 6 2000 20 nete ar 5 1 FIGURE 6 1 REPLACING THE SCU SAGEON III CONTROL UNITT eese 6 3 FIGURE 6 2 REMOVING RECTIFIER MODULE sese een eene tenente KESE TEKKEE NOU EN tenete 6 7 FIGURE 7 1 DISTRIBUTION LOCATION BY TIER AND GROUP eene nennen eene eene ener tren 7 1 FIGURE 7 2 DISTRIBUTION AREA LEFT SIDE 7 3 F
70. System output current and voltage This screen also shows the present mode FLoat or EQualize If an activity such as battery discharge is being performed the current and voltage are displayed continuously while the second line alternates between the mode and the activity status for example in progress 155A 542 FL The Home screen is the first to appear when power is applied to the System Since the Home screen is the default screen the display will revert to the Home screen from any other screen if an operator panel push button is not pressed for approximately one minute Section 4 5 describes in detail the selections available from the Home screen 4 2 USING THE OPERATOR PANEL PUSH BUTTONS Use the six buttons to view System data individual rectifier data battery data or the alarm log In addition programmable parameter values can be viewed and changed Each button is described below The HOME screen shows the System voltage and current The data will initially be located in the center of the display and after a brief period will scroll right to left From the HOME screen press up arrow or down arrow to move through the series of menus described in Section 4 5 RECT BATT 106 TO FIGURE 4 1 OPERATOR PANEL RECT RECTifier Press to access a menu of rectifier related parameters as well as to view
71. The location must allow for convenient routing of one or more battery cables or intercell connectors through each of the transducers The three possible installation options are a If transducer is installed on the positive lead s of the battery string the arrow will point toward the battery string s positive post b Ifthe transducer is installed on the negative lead of the battery string the arrow will point toward the power system away from the battery string s negative post c Ifthe transducer is installed on one of the intercell connectors the arrow on the transducer will always point to the positive post of the next battery cell in the battery string If the intercell strap will not fit through the current transducer the strap may be replaced with a short cable lugged on both ends that will fit through the transducer consult the factory 2 Open the distribution door and locate the supplied battery current transducer cables there is one cable per transducer The 4 conductor cables are coiled and tied to the return bus loads in the distribution area of the Sageon III Base System The length of the supplied cables is 4 ft 29 1m PM990 8800 50 Issue 3 2 19 Installation Sageon III Base System 3 Refer to Table 2 5 and connect the battery current transducer cable s to the Battery Distribution Module connector s See Figure 3 14 for a view of the Battery Distribution Module 4 Routethe cable through overhead cable
72. accept 3ph AC fhi Alarm Modify Value up down esol ENER to accept 21 I ENTER 3ph AC flo Alarm Modify Value up down pestle ENTER tg accept L 3ph AC FS Curr Modify Value up down 100A ENTER to accept INC DEC toggles state li E to accept i If Battery Monitor not Off ENTER Selects battery cell type Battery Config Modify Value up down 24 cells L ENTER to accept ENTER Number of battery banks BCM Batteries Modify Value up down 1 L ENTER to accept 1 ENTER Cell Vhi Alarm Modify Value up down 2 50V L ENTER to accept 1 ify Value up down zl o mo ENTER Monitor INC DEG toadles state Off If Site Monitor not Off ENTER Status of output relay 1 ENTER Status of output relay 3 ENTER Cell Vlo Alarm 1 80V L NTER to accept 1 ENTER Differential cell threshold Cell dVc Alarm Modify Value up down 10 L ENTER to d I INC DEC toggles state ENTER to accept I Output 1 Modify Value up down 1 I Off L ENTER to accept __ ENTER Status of output relay 2 3 Modiy Value up down 1 Off L ENTER to accept 1 ENTER Status of output relay 4 ENTER Differential cell threshold maim Mes s E a E Cell dVc Alarm Modify Value up down 10 ENTER to accept r mua mu cud mum Output 2 l Modify Value up down I za L ENTER to accept Output 4 Vodiy Value up down 1 Off ENTER to accept
73. access the SCU and the data it has stored for System configuration System operation and troubleshooting alarm events e Connect a local PC running SageView included to the SCU by way of the operator panel mounted USB connector and a user supplied USB A plug to USB B plug cable e Connect a remote i e network connected PC running SageView included to the SCU by way of the company s intranet or the Internet Connect a remote i e network connected PC running standard SNMP based monitoring software customer supplied to the SCU by way of the company s intranet or the Internet For additional information about SageView refer to Chapter 5 IMPORTANT Always consult your company s network administrator before connecting local or remote equipment to the SCU or to the company network Security must be a primary concern Consult your company s network administrator about system communication and data compatibility communications cable specifications cable routing and methods of connecting to a network 2 14 INSTALLING AND REMOVING RECTIFIERS When ordered with a Sageon III Base System each Rectifier is shipped in a separate package A Rectifier is shown in Figure 2 16 d f x O Ot OX 7 N x YO OX i SAGEON MICRO RECTIFIER 1 L FIGURE 2 16 RECTIFIERS A Rectifier can be installed or removed hot
74. acked Real time System and Equalization Voltages opt Clock e Modules for Monitoring Site Status and e Remote Communication capability including Battery Cell Voltages opt Web based Protocols opt e AC Breakers opt e Rectifiers and the Controller are hot swap and plug and play capable PM990 8800 50 Issue 3 2 23 Installation Sageon III Base System SAGEON IM POWER SYSTEM v Bg ws o e sg as di o e 2 p 4 4 4 if e e E e E t 6 te e 08 0 I 81 g Em mm En mm di A gl F 9 op FIGURE 2 17 SAGEON III BASE SYSTEM 5 AN N ZEN FIGURE 2 18 CONNECTIONS ON CONTROLLER BACKPLANE 1 Remote communications module connection 14 way ribbon
75. any button for at least two seconds The date and time will display for two seconds and then the alarm name will be displayed for two seconds The display will alternate between the two screens in this manner until a button is pressed PM990 8800 50 Issue 3 4 22 Sageon III Base System Configuration and Operation 4 13 NAVIGATING CONTROLLER FUNCTIONS 4 13 1 Base Menu System Level Functions 25 2A 54 3V FL Panel Home screen FL indicates float mode FLC indicates float mode with battery temperature compensation Indicates that the front panel is locked Press and hold f 4 and ENTER to unlock 7 Press ENTER DEC Ambient temperature displayed in Degrees Centigrade Ambient Temp TC Not Available shown if not sensor is connected 28 C INC If 1 ph AC Monitor not Off Q T Single phase AC voltage 245V Single phase t pren ingle phase AC current I 52 Single phase AC frequency ph AC Frequency 60Hz If 3 ph AC Monitor not Off ph AC1 Volts 245V ere eim Phase AC voltage 3ph AC2 Volts 243V ph ACS Volts 246V 1 Phase AC current ph urrent 1 28 I ph A urrent 1 29 1 ph urrent 32A 1 DA AC frequency I 60 2Hz ENTER Volts High Alarm Modify Value up down 57 0V ENTER to accept ENTER Volts Low Alarm Modify Value up down 49 0V ENTER to accept
76. art unless damaged or faulty Note Pressing arrow button will display the HOME screen PM990 8800 50 Issue 3 4 13 Configuration and Operation Sageon III Base System 4 7 BATT MENU SCREENS Enter this series of menus by pressing the BATT button Press the arrow button to scroll through the screens in the order presented Repeat the series for each battery string The following map summarizes the available menu screens BATT Button Battery string 1 4 current Battery string temperature Estimated charge 1 4 Programmable Battery discharge alarm voltage Press ENTER to read individual cell voltages if SBM option is installed and enabled Complete descriptions for testing vented lead acid and VRLA batteries are beyond the scope of this manual but are discussed in detail in IEEE STD 450 2002 or its latest revision and IEEE 1188 1996 respectively battery specific manuals and other professional society standards It is important to recognize that standby batteries cells are designed for emergency standby operation and excessive testing or cycling of a battery can materially shorten the life of a battery Battery temperature alarm Battery Ah rating BTC on off BTC Temperature coefficient BTC Temperature compensation nominal Number of cells per string Battery charge current limit lt Vdd Battery deep discharge voltage Vd
77. arting point Tier 1 Group A Position 1 is recommended Use appropriate lugs on the load supply and return cables 2 Dress the cable as shown in Figure 2 9 toward the front or rear of the rack according to the orientation of the distribution assembly Dress the cable away from rack assembly hardware to avoid possible chafing of the cable insulation J Battery Discharge Bus Bar Alarm Strip Distribution Assembly Mounting Bracket Holes for Securing Cable Paired Output Studs Circuit Breaker or Fuse A aa Note orientation Load Supply Cable W 7 7 gt gt CE pc 2 Short Mounting Surface gt Long Mounting Surface Output Terminal Alarm Connection TT Bus Bar Cu d Circuit Breaker or Fuse gt Load Supply Cable and Note mounting surface 7 OO To E orientation Se 1 4 20 Nuts ue A Detail of Load Supply Cable Connection eg FIGURE 2 10 AMI TYPE DISTRIBUTION LUGGING 3 Move to Group A Position 2 and repeat the above steps Repeat the steps until all positions in Tier 1 Group A are cabled Move to Tier 1 Group B and cable the positions Perform the above steps for Tiers 2 and 3 Bundle and secure cables as follows Two cable securing tabs are provided in each distribution assembly mounting bracket See Figures 2 10 and 7 2 for cable securing locations Nu 1 All Group A Bundle cablin
78. ating are required with the highest level of protection being provided when arrestors are connected between phase neutral x3 phases and between phase neutral earth x 3 phases Other arrangements for 3 phase with similar levels of protection are also possible as shown below The voltage rating of the arrestor should be selected based on the maximum AC voltage likely to appear on the line The arrestor should limit the voltage to 1200V 1400V at the rated maximum pulse current AXI OTECTION E E L L1 E L L2 E L3 L I JWESSHELF E a rical Systems where itral and Building Ear tt Ire bonded at mair 1 tchboar d E FIGURE 3 7 SURGE PROTECTION 3 4 3 Battery connections The cables are brought out through the top of the unit This cable must be sized accordingly to carry the battery short circuit current for the time required to clear the battery protection devices Note Ensure the battery circuit breakers are open before connecting the batteries Connect the switched cable connections first followed by the common return cable connections 3 5 TEMPERATURE SENSORS The optional sensors for measuring ambient and battery temperature are the same device Part No 385 5941 03 06 15 30 The system auto detects if the sensor is plugged into one of the positions 4 or 5 If no sensor is installed the Controller will show N
79. ature Compensation Batt Temp Comp Battery temperature compensation on off toggle Off Battery temperature compensation BTC Enter the temperature aA MORD BTC Coeff compensation coefficient in mV per degree C per cell in this screen 32 mV CPC The allowable range is 0 1 to 6 mV Cell C If the value is less than UR 0 1 the display will show Off See BTC Notes below PM990 8800 50 Issue 3 4 15 Configuration and Operation Sageon III Base System For Liberty 1000 batteries enter 3 6 mV C C 2 mV C F Normal operating temperature is 25 C 77 F BTC nominal temperature When battery temperature compensation 2 Nominal is active type the temperature at which system voltage is NOT 20 corrected This temperature must be between 18 27 Note that compensation range is 10 35 C See the Notes below Battery cells per string Set the number of physical cells in a string ied Cells BTC Notes 1 Ifthe battery temperature sensor is not connected compensation is based on the ambient temperature sensor 2 Ifbattery and ambient temperature sensors are connected compensation is based solely on the battery sensor 3 When temperature compensation is active the SMR voltage setting is automatically adjusted by the SCU as needed Battery charging current limit Set the maximum battery charge wae BILim Vb lt Vdd current when the voltage across the two battery strings is less than 34
80. battery current On transducers Security on off toggle When security is On no parameter values may Security be edited Without first entering the password this menu will not On appear if a password has not been set PM990 8800 50 Issue 3 4 8 Sageon III Base System Configuration and Operation Password Setup The Sageon systems are shipped without a password set Password Setup by default Enter a password to prevent unauthorized changes to system Press ENTER parameters Controller features password security for setting of parameter A valid Wrong Password password is an alphanumerical code having minimum three and Panel Locked maximum eight characters Units leave the factory without a pre programmed password and the security function is not active To activate the security a password must be programmed Once that is done security can be enabled When the security function is active any changes to the system settings can be done only after a valid password was entered When the ENTER key is pressed to change a parameter the display will show a message Enter Password on the top line and a blinking cursor on the right hand side of the bottom line Using INC and DEC keys scroll to the first character of the password and press ENTER The character will be substituted by an asterisk displayed to the left of the cursor Enter all characters of the password the same way If the password is less than eight characters long
81. cable or through the optional battery current transducer all battery cables routed through a transducer must be the same polarity Transducers are marked typically with an arrow to indicate current direction See section 2 10 ATTER DET gt lt 8 Eos A m nu FIGURE 2 5 BATTERY CHARGE BUS AND BATTERY RETURN BUS LOCATIONS At the Power system install appropriate lugs on cables CAUTION A a Secure the negative cable to the battery charge bus b Secure the positive cable to the battery return bus NOTE See table 2 2 for torque specifications 5 At the battery string appropriate battery lugs terminals clamps Confirm polarity and connect the wires to the battery string terminals Repeat the above steps for each battery string to be connected 2 7 CONNECTING CUSTOMER LOADS Supply and return cables are connected between customer loads and Power system distribution Interconnecting cables and lugs are supplied by the user Refer to Section 2 2 1 Tools and Accessories for lug requirements Refer to Section 2 2 2 Selecting and Sizing DC Power Cables for cable sizing PM990 8800 50 Issue 3 2 11 Installation Sageon III Base System Note To field install additional distribution refer to Chapter 7 Distribution Option Kit Installation To field install additional fuses o
82. connected PC If the SCU is malfunctioning and you believe the configuration values PM990 8800 50 Issue 3 6 3 Maintenance Sageon III Base System may not be correct save the file under a new filename to prevent overwriting earlier good data SageView System Monitor software must be installed in the PC Refer to Sageview manual for more information If the SCU is not functioning the replacement unit will power up with the configuration stored on the SCU Backplane which can then be edited from the operator panel or a PC 6 6 REPLACING AN AC BACK PLANE BOARD 1 The system must be powered down to replace a rectifier back plane board IMPORTANT Each rectifier position address must be unique do not use an address number more than once Addresses must be in numerical order with the uppermost in the System Rectifier having address 1 The address number increases by 1 with each Rectifier installed 2 To install the Rectifiers go to Section 2 14 Installing and Removing Rectifiers TABLE 6 3 RECTIFIER POSITION ADDRESSES 1 THROUGH 24 Table Notes ADR Rectifier position address SW1 Switch Positions ADR 9 SHELF On On On DACIA Non Shaded addresses 1 through 12 are used for 50 600A systems Shaded addresses 13 through 24 are used for 650 1200A systems ON ADDRESS SWITCH DETAIL ADDRESS 1 SHOWN
83. ction intranet or to the Internet A unique IP address is required for each Sageon III Base System Remote access is also available via an SNMP Ethernet board Alarms Activation of customer supplied alarm annunciators is accommodated by form C relays The relay state is user selectable between normal mode normally de energized and failsafe mode Normally energized These relays provide for external annunciation of the alarms and are fully user configurable Refer to SageView help for configuring these relays Block Diagram Description A simplified block diagram of a 48V Sageon III Base System is shown in Figure 1 2 Single phase or three phase power is supplied from the user s AC electrical service panel PM990 8800 50 Issue 3 1 3 Introduction Sageon III Base System 11 i Ini hase to io 1 LI E 1 For 1 1 ical kplan 1 1 nit pti Board B 11 i pti 5 Ti 1 E Eti 4 TI idr Idi Add is i e i ps 2 Addr e atter st 48 Volt FIGURE 1 2 SIMPLIFIED BLOCK DIAGRAM 48V POWER SYSTEM PM990 8800 50 Issue 3 1 4 Sageon III Base System Introduction The LVBD trip voltage is set using the operator panel push buttons a
84. d Battery charge current limit from Vb Vfl System float voltage System voltage drop Equalization on off Charge current limit gt Vfl Equalization voltage Equalization trigger voltage Equalization no trigger voltage Equalization trigger charge Ah Equalization trigger discharge rate Ah Equalization no trigger discharge rate Ah Equalization end charge current Equalization end charge Ah Equalization end duration hours Equalization auto initialize weeks Equalization end manual Equalization start manual LVDS trip voltage LVDS mode auto closed open Temperature sensor alarm on off Discharge current and battery voltage BDT period 0 365 days BDT start time hours minutes BDT duration hours minutes BDT current 0 5000A BDT end voltage BDT end charge Ah BDT alarm reset BDT end manual Last BDT results pass fail abort etc Last BDT time date duration Last BDT battery string voltage and charge PM990 8800 50 Issue 3 Sageon III Base System Configuration and Operation IMPORTANT The number of the target battery string e g Battery 1 must be entered Battery 1 current Battery 1 TT 12A Press ENTER to display cell voltages for selected string if Battery Monitor option is installed and enabled Press arrow or down arrow to scroll throu
85. d battery return bus options are available to facilitate 2 hole lug wiring 3 8 inch diameter studs on 1 inch centers for a single tier 3 8 inch diameter studs on 1 75 inch centers for a single tier and 3 8 inch diameter studs on 1 75 inch centers for three tiers Installing the Battery Cables This procedure includes the installation of up to four optional battery current transducers Transducer mounting and wiring information is found in Section 2 10 Ignore references to transducers in the following procedure if not part of your installation If the installation includes a battery disconnect switch modify the procedure accordingly 1 Determine the correct battery cable size and shortest cable run See Section 2 2 2 Selecting and Sizing DC Power Cables The top of the distribution section is open for easy access when routing battery cables between PM990 8800 50 Issue 3 2 10 Sageon III Base System Installation the battery string and the Power system battery charge bus and return bus See Figure 2 5 for the location of the battery charge bus and battery return bus within the plant Mount the optional battery current transducer s and connect the transducer cable s between the transducer and the Power system as indicated in Section 2 10 Be sure that a transducer s battery cable opening is large enough for the selected cable diameter and the number of cables Run cables between the plant and battery string 1 Route either battery
86. e Current max 7 foot Tower 7 Feet 48 Vdc 600A Figure 1 1 213 36 cm 48 Vdc 1200A max As indicated above the Power System is divided into two areas distribution and power conversion The system is shown in Figure 1 1 It provides 12 power conversion positions at 600A or 24 power conversion positions at 1200A for rectifiers and 6 distribution groups in 3 distribution tiers with a user specified quantity of AMI circuit breakers amp circuit breakers Power Conversion Plug in rectifier models are available in 48V It employs modular switched mode rectifier technology for highly efficient low cost reliable operation Each 48V rectifier can source up to 50A The quantity of rectifiers is determined by the user to accommodate the application A maximum of 24 rectifiers can be installed in a unit Distribution A unit can include up to 60 5 100A AMI circuit breakers Up to 8 100 450A GJ1 circuit breakers can be installed however each group of 4 GJ1 type breakers reduces the available AMI positions by 10 Circuit breaker and fuse kits are ordered separately to accommodate the application For AMI type breakers the load supply and return connections use two hole wire lugs for 1 4 studs 5 8 center to center The supply cable is bolted to a distribution assembly that has two 1 4 20 studs and the return connection is bolted to the return bus bar that also has 1 4 studs Where higher current GJ1 type breakers are
87. e Local and National Codes A copy of this manual is included with the equipment shipment PM990 8800 50 Issue 3 iv Front Matter Sageon III Base System Table of Contents IISNUUU 1 1 LIPRODUGIDESCRIBETION tren prelo D ORE EDO I EOLO DERE CREME PER 1 1 1 2 SPECIFICATIONS el shine ite dte cree tet it ai ti e el Dodd a eere nol ape 1 5 1 2 1 Power system Physical Specifications ii 1 5 1 2 2 Power system Environmental Specifications ii 1 5 1 2 3 Power system Electrical Specifications ii 1 6 1 2 4 General Specifications veier reesei ina ede rae i Ere iii 1 6 1 2 5 Bus Specifications i s suunanialia c aaa 1 6 1 2 6 1 7 1 2 7 Rectifier Specifications 1 8 1 2 8 Safety SETANE 1 9 1 3 ABBREVIATIONS AND ACRONYMS L i 1 10 1 4 5 eo SEP ep e
88. e System Maintenance 6 4 REPLACING A RECTIFIER In the event of Rectifier failure replace the unit There are no user serviceable parts in the Rectifier A rectifier is identified by a label in the bezel recess and on the rear of the rectifier Be certain you are installing the correct model Rectifier Only 48V 50Amp rectifiers are available with the Sageon III System To replace a Rectifier refer to Section 2 14 Installing and Removing Rectifiers 6 5 REPLACING THE SAGEON III CONTROL UNIT SCU In the event of SCU failure replace the assembly There are no user serviceable parts in the SCU The Sageon III Base System SCU can be hot swapped Be certain a replacement SCU is on hand before beginning this procedure To remove the Controller Assembly 1 Check that a known good replacement Controller Assembly is on hand for immediate installation 2 Re install the new SCU FIGURE 6 1 REPLACING THE SCU SAGEON III CONTROL UNIT 6 5 1 Configuration Considerations The System configuration is stored in non volatile memory on the SCU Backplane board The SCU plugs into the SCU Backplane board so the SCU can be replaced without affecting the configuration It is recommended that if you have not previously recorded System configuration values and the SCU is functioning do so now before performing the replacement Alternatively download the SCU configuration to either a local PC plugged into the operator panel USB connector or a remotely
89. e Vb VfI Sys Equal System equalize voltage Veq 50 61V 56V V Start Eq Enable disable discharge voltage On Off Off initiation of Eq V Eq trigger Discharge voltage threshold for Eq 44 50V 48V charging Q Start Eq Enable disable battery charge depletion On Off Off trigger Q disch Trig Charge depletion threshold for Eq 5 999 15 charging Eq End Current Equalization termination for I bat lt 1 2 000A 5A End Eq duration Maximum duration of Equalization 3 48Hr 20Hr PM990 8800 50 Issue 3 4 2 Sageon III Base System Configuration and Operation Parameter Description 48V System 48V User Range System Value Default Eq period Time between periodic Equalization 0 52wk 12 Wk charging Manual Force stop start of Equalization charging Toggle state Stop Start Eq LVDS Trip Battery voltage below which LVDS will 40 48V 42 6V open BDT Per Period between consecutive discharge 0 365 days 0 days tests BDT Time Time of day to begin BDT hr min 00 00 23 59 02 00 BDT Dur Maximum duration of BDT 5 1 440 min 180 min BDT Curr Discharge test current 0 5 000A 50A BDT End V Battery voltage limit to terminate 36 48V 44V BDT End Q Battery capacity limit to terminate BDT 25 9 995AH 300 Temp Sen Enable disable temp sensor failure On Off On Alarm alarm 4 1 THE HOME SCREEN The Home screen shown at right is the default screen It shows Sageon II Base
90. e assigned to the port If access over the Internet is considered the gateway address must be programmed as well There are several methods to do that two are recommended and are described in section 7 1 Other operating parameters of the interface are pre programmed and should not be changed Factory default IP address is 192 168 10 60 To be able to assign a network address the Ethernet address referred to also as hardware address or MAC ID of the interface must be known On the Power plant top cover is a small label indicating the MAC ID similar to one shown below Note The interface IP address cannot be changed until the Power plant has been commissioned and the Controller is operational The MAC ID can have format 00 20 4A 24 BB 42 Serial Number or 00 20 4A 24 BB 52 t Revision Made in USA PM990 8800 50 Issue 3 3 12 Sageon III Base System Commissioning 3 10 BATTERY DISTRIBUTION MODULE The battery distribution module is capable of handling up to four battery strings Connect the current transducer signal cable to the appropriately labeled connector on the circuit board ul ti Ia 0 amp i Se San E si CHE EL al FII iG l SS 2 NENNEN 20 NDS 0 dogs
91. e or historical representation of the data on SageView the cell voltages can also be observed in real time on the SCU display In the event that the battery behaves in a way that is less than ideal during a test or actual discharge a number of pre programmed parameter levels are used to generate alarms Alarms are annunciated on the SCU front panel by a LED and screen message and remotely via voltage free contacts or via the USB communications port that can connect directly to a PC locally or remotely via a modem or Ethernet PM990 8800 50 Issue 3 2 20 Sageon III Base System Installation Refer to the Sageon Battery Monitor Manual PM990 4209 00 for detailed information 2 12 SITE MONITOR SYSTEM OPTION The Site Monitor System is used to monitor the status of equipment external to the Sageon III Base System It has 12 digital inputs 8 analog inputs and 4 form C user assignable alarm relay contacts Digital inputs are often used to monitor site security such as door or window openings or other on off function such as a pump switch or motor starter Analog inputs frequently used to monitor a fuel level or other variable such as a voltage current or frequency Refer to the Sageon Site Monitor Application Note AN103 4012 00 for detailed information 2 13 COMMUNICATIONS Communication choices include operator panel mounted USB standard and an Ethernet network optional with or without SNMP support The following devices can
92. ed on the Rectifier front panel C Battery Current Temperature Battery Temperature Sensor Input Compensation and alarm annunciation lambient 1 4 battery Battery Current Transducer Input 1 4 battery strings accuracy 1 User connections No 6 screw terminals lugless compression type PM990 8800 50 Issue 3 Introduction Sageon III Base System D Sageon Battery Monitor Battery strings 4 maximum Battery voltage iii 75V maximum Cells single cell or monoblock 24 maximum per SBM board Cell voltage aesti 2V 6V or 12V maximum input 3 33V 6 66V 10V and 20V respectively I 10mV at 0 C to 40 Resolution vini citet 5mV per cell 2V 4 and 6V ranges 10mV per cell 12V range Sampling interval 1 60 minutes mene 4 maximum Interconnection iii 16 conductor ribbon cable 30 feet 10m maximum length E Site Monitor Analog inputs eese 8 Signal fange oeste tuts 0 5V Input protection 22422221 Over voltage and reverse polarity Signal scaling and alarm levels Scale factor and low and high alarm thresholds are user programmable at operator panel Digital inputs eese 12 Signal source eese Voltage free contacts Logic of digital input User de
93. el Alarm issued Available only when BDM is active BDT flagged as having failed No Control Test aborted due to loss of control of rectifiers No alarm issued Low Load Test aborted due to load current being too low to control discharge current No alarm issued SMR Overload Test aborted due to load current being too high to support controller discharge No alarm issued User Aborted Test terminated manually by user from the SCU PM990 8800 50 Issue 3 4 19 Configuration and Operation Sageon III Base System 4 7 6 BDT Results Screen Additional Details To view additional details about the preceding test press ENTER while viewing one of the above Last BDT screens These sub menu details appear on the second line of the Last BDT screen 09 12 2012 States the date of preceding test in a day month year format Dur 1h18min Provides the duration of preceding test EndV 47 0V Shows the battery string voltage when test was terminated EndQn 380Ah States the remaining estimated capacity of the battery string at the time the test was terminated where n is the number of the string 4 7 7 BDT Disabled The battery discharge test function is disabled for 2 minutes if any of the following has occurred If an automatic test is scheduled during this period it will be performed at the next opportunity at the BDT Time e SCU has recently been powered up An AC supply failure has been recorded 4 8 ALARM LOG S
94. ensure correct activation As needed operate the system for 15 20 hours to charge the battery string s before placing the system on line PM990 8800 50 Issue 3 3 2 Sageon III Base System Commissioning 3 3 OVERVIEW OF EXTERNAL WIRING CONNECTIONS SD SAGEON3 AXX drawings at the back of this manual show the internal and interface schematic for the Sageon III Base System with distribution For the purpose of indicating how a system is connected the same schematic applies to other Power plant products The system shown is for a 48V system where the positive side of the DC bus is tied to ground usually on the common return bar It is also possible to float the output but under these conditions there is no guarantee that all voltages on the DC bus will stay below the Safety Extra Low Voltage SELV limits with respect to ground during fault conditions 3 4 FACTORY SUPPLIED CONFIGURATIONS Power plant internal AC distribution are configured with each rectifier AC line being terminated in an individual block terminal The grounding wire connects to the block terminal 3 4 1 Single phase individual protected external feeds Connect each of the circuit breaker protected phase wires to the individual terminal blocks labeled L1 that feed each rectifier Connect the neutral or phase 2 wires to the terminal labeled L2 for each rectifier PM990 8800 50 Issue 3 3 3 Commissioning Sageon III Base System SAGEON III AC FEE
95. ent limit for recovery of BILim Vb lt Vdd I Modify Value up down 1 deep discharged batteries 9 2 1 ENTER to accept DEC ENTER Battery voltage below which the battery Vdd Level Modify Val is considered to be deep discharged 43 5V ENTER INC ENTER Charge current limit for battery voltage 0 BILim Vb lt Vfl Modify Value up down between deep discharge amp float 40 ENTER to accept 1 ENTER System Float voltage without BTC System Float Modify Value up down Sense point voltage regulated to this value 54 0V ENTER to accept ENTER Estimated max resistive drop between the System V Drop Modify Value up down SMRs and the system voltage sense point e lt m 2 m m m z PM990 8800 50 Issue 3 4 27 Configuration and Operation Sageon III Base System Battery Menu continued Equalization On BlLim Vb Vfl 20A System Equalize 56 5V Volts Start Eq On Q Start Eq EQ End Current 15A EQ Duration 3 hours EQ Period 12 Weeks Manual Start Eq Press ENTER LVDS Trip 43 0V LVDS Mode 1 DEC Temp Sen Alarm INC Period 14 Days 21 35 Duration 1h30min 5 2 Current 50 BDT End V 46 5V BDT End Q 150Ah Last BDT Passed ENTER ENTER toggles state Off On I ENTER Modify Value up down I ENTER to accept I ATER Modify Value up down
96. er and local electronic supply companies Always store circuit boards in anti static bags 6 2 PERIODIC MAINTENANCE Perform the following periodic maintenance procedures at least twice a year 1 Thoroughly review the Alarm Log at the operator panel or at a local or remote PC Look for repetitive alarms determine their cause s and take steps to correct events that result in alarms 2 Check operator panel LEDs Refer to Chapter 4 Configuration and Operation for details Check all Rectifier LEDs Refer to Section 4 3 for details 4 Check all electrical connections Check that all breakers and fuses are fully seated Tighten connections as required Seat breakers and fuses as required Look for signs of overheating arcing and accumulation of dust dirt and other contaminants Refer to Chapter 2 Installation for factory installed and customer installed connections A WARNING A e Electrical shock and arcing hazard Hazardous voltage can cause death or serious injury Use extreme care when performing maintenance on an operating Sageon III Base System Use insulated tools Remove watch and jewelry 5 Verify the Sageon III Base System configuration and all parameter values Refer to Chapter 4 Configuration and Operation for operator panel and PC screens 6 Confirm that all alarm annunciators are functioning Refer to Chapter 4 Configuration and Operation for operator panel and PC screens 7 Verify LVBD pa
97. ernatively up to two Rectifiers can be fed from one breaker provided the breaker and wiring meet local and national electrical code requirements Power system terminals will accept 6 12 AWG 13 6 3 3 mm 3 Run the needed quantity of AC power cables from the service panel to the Power system Label each breaker position and both ends of each AC power cable with the Power system number and rectifier position address to which it will be connected e g PIR1 Power system 1 Rectifier position address 1 Rectifier positions are numbered from top to bottom as shown below Rectifier 1 Rectifier 2 Rectifier 3 Rectifier 4 Rectifier Section Rectifier 1 Rectifier 4 Ateach breaker position in the AC panel install a delayed trip circuit breaker for each cable Refer to Table 2 3 for breaker recommendation 5 Ensure that all circuit breakers are in the Off position 6 Connect the power cables to the service panel TABLE 2 3 CIRCUIT BREAKER SELECTION AC POWER Rectifiers Powered Breaker Rating 1 20 2 40 2 5 3 AC Cabling This section describes connecting the AC input cables within the Power system An AC input cable can enter the plant several ways e Through either the lower section side panel or lower rear panel of the cabinet e Upward through the open base of the rack For each ordered Rectifier connect an AC input cable to the AC termination block located in the lo
98. et switches If inadvertently changed go to Section 6 6 fora procedure to set the switches to the proper address PM990 8800 50 Issue 3 2 1 Installation Sageon III Base System Opening the Distribution Area Door During installation it will be necessary to open the distribution area door to install load supply and return cables battery cables and alarm wires Lift the paddle surrounding the key lock rotate it 90 degrees and open the door Keys are tied just inside the door 2 INSTALLATION SUMMARY A typical installation sequence is provided below References to appropriate sections in this manual are included 1 Review the list of user supplied tools and accessories in Section 2 2 2 Select a location for the Power system See Section 2 3 3 Select battery AC input and distribution wire sizes based on current and length of run See Section 2 2 4 Move the Power system and accompanying assemblies to the selected location Anchor the Power system to the floor See Section 2 4 5 Install AC input wiring between the user s AC electrical service panel and the Power system See Section 2 5 6 Connect the AC input wiring to AC terminals in bottom section See Section 2 5 4 7 Install battery cabling See Section 2 6 8 Route and connect supply and return cabling to customer s l
99. etter than 0 05 2 for 10 to 90 to 10 step load change 1 of final value within 1 ms of step change 0 2 for a 25 step change in AC input voltage lt 0 96 mV RMS Psophometrically weighted lt 10 mV RMS 10 kHz 100 MHz lt 100 mV 10 kHz 100 MHz lt 5 of full scale with active current sharing from SCU Fuse Can sustain a short circuit at output terminals indefinitely Gradual reduction of power limit if heatsink temperature exceed preset limit Float and equalize voltages Current limit high and low voltage alarm limits HVSD and HVSD reset The following were used as guidelines in the specifications of all components and wiring with particular attention to safety ratings and OI 28 flammability requirements Underwriters Laboratory Standards of Safety UL 60950 Bellcore Network Equipment Building System GR 1089 CORE PM990 8800 50 Issue 3 1 9 Introduction Sageon III Base System 1 3 ABBREVIATIONS AND ACRONYMS ABBREVIATION ACRONYM OR SYMBOL ANSI AWG BATT CEV CM DIP EMC EMI ESD FA HVA IEC IEEE LED LSD LVA LVD NEC NEMA PCB REC RECT RBOC RFA SBM 55 5 SMR UBC UL UPS MEANING American National Standards Institute American wire gauge Battery controlled environment vault circular mils dual in line package electromagnetic compliance or compatibility electromagnetic interference electrostatic discharge fuse and breaker alarm normally energ
100. f Fail Voltage reference in SMR microprocessor faulty Amber Red AC Volt Fault None of the SMRs are responding AC failure assumed or if AC monitor is used AC voltage is out of limits Amber Red AC Freq Fault AC frequency lower or higher than preset value Amber FL Battery switch One or more battery switches open Amber FL Cct Breaker Fuse or circuit breaker in load distribution open Amber FL LVDS Open Low Voltage Disconnect switch open Amber FL Sys Volts High System output voltage too high Amber FL Sys Voltage Low System output voltage too low Amber FL Cell V High One or more cells being monitored by SBM are too high Amber FL Cell V Low One or more cells being monitored by SBM are too low Amber FL Cell dev High One or more cells being monitored by SBM are too high deviation from the mean battery cell voltage Amber FL Cell dev Low One or more cells being monitored by SBM are too low deviation from the mean battery cell voltage Amber FL Range SMR SMR parameter range error SCU could not overwrite values Amber FL Site Monitor Alarm preset from the site monitor System See site monitor menu for details of alarm channel Amber FL Battery Disch Batteries are discharging Amber FL Disch Tst Fail Battery discharge test failed to reach a programmed end point Amber FL
101. fier Menu Rectifier Specific Functions i 4 26 4 13 3 Al rm L og rette e ree er pO o Han e re tte te Dre ir 4 26 4 13 4 Battery Menu Battery Specific Functions i 4 27 5 0 SAGEVIEW rari lite 5 1 S L CONEIGURATIQON dii oae ER DER t teneret urn don 5 1 5 1 1 SageView benefits anobii pe ene e eer eed td eed eee pee ce iei tere Por 5 1 5 2 air ebd od cede iUe e Hee f o de tdt re d ee b e reed ceder bt 5 2 5 3 SECURITY 2 iiis f e hie feat e ede eq Re dr ted rd ede bad aped Cede prre P Pes 5 2 5 4 CABLE AND NETWORK CONNECTIONS nenne 5 2 5 5 LOCAL CONNECTION STANDARD iii 5 2 5 6 REMOTE CONNECTION ETHERNET OPTION i 5 2 5 7 PE REQUIREMENTS aaa Reis crede trt dt rep edere bp iaia nali 5 2 5 8 INSTALLING SAGEVIBW iiec detenti p ec a eere crece bre le rode ede debe pe eo PR Pe bebuey 5 2 UPOr 6 1 6 1 CIRCUIT BOARD HANDLING nta AA cere dere deutet pete 6 1 6 2 PERIODIC MAINTENANCE ee eto eb et a e ed n ae bem eed tr De Ue 6 1 6 3 TROUBLESHOOTING o Rama LU Li li tx eit 6 2 6 3 1 Reading Rectifier Status Led Codes i 6 2 6 4 REPEACING A RECTIPIER
102. fined from operator panel Control outputs esee 4 Output signal 0 Voltage free form C relay contact 1 30 Vdc 1 5 PRODUCT SUPPORT Product support can be obtained using the following addresses and telephone numbers UNIPOWER LLC 65 Industrial Park Road Dunlap TN 37327 Customer Service Voice 800 440 3504 Customer Service Fax 423 949 3647 Field Service 800 299 3907 Web site http www unipowerco com When contacting UNIPOWER please be prepared to provide 1 The Power system part number and serial number see the equipment nameplate 2 Your company s name and address 3 Your name and title 4 for the contact 5 Ifthere is a problem with Power system operation e Is the problem intermittent or continuous e What actions were being performed prior to the appearance of the problem e What actions have been taken since the problem occurred PM990 8800 50 Issue 3 1 12 Sageon III Base System Installation 2 0 INSTALLATION This chapter describes installing a Sageon III Power system If questions or problems arise during installation please refer to Section 1 6 Product Support and contact a UNIPOWER Field Service technician for assistance The Power system is factory assembled and tested GJ1 circuit breakers specified on the order are factory installed AMI circuit breakers specified on the order are shipped in protective packaging
103. full scale value Battery current indicates 0A when more than SA is flowing in the battery or is inaccurate at low currents lt 5A Transducer is not calibrated DC hall effect transducer or wiring is faulty Current transducer sensitivity is too low for 1A measurement Calibrate transducer Service the DC current transducer check the wiring is intact and still connected properly or replace the DC CT is suspected to be faulty Revise size of DC CT full scale value for the size of the load and battery charging requirements Load current indicates when known to be gt 5A Number of RECTIFIERs is incorrectly set too low or the battery current FS is set too high The load current is calculated from the sum of the RECTIFIER currents minus the measured battery currents Check that the number of RECTIFIERs in the Controller Base menu matches the actual number of rectifier modules installed Check the Battery DC CT rated full scale value is correctly set in the Base menu One unit is alarmed as HVSD high voltage shutdown and is latched off The unit has developed a fault that causes it to output a voltage above the HVSD protection limit and has been supplying load current while above this Replacing the rectifier module is recommended However a random event may have triggered the HVSD and to determine if the unit has a real fault PM990 8800 50 Issue 3 Maintenance Sageon III
104. g through the strap and into the battery terminal Tighten the bolt as recommended by the battery manufacturer Repeat steps 6 and 7 to install the remaining battery temperature sensors Bundle and secure excess wiring Enable compensation using the operator panel push buttons and menus or a PC running SageView If installing the Sensor Kit get the compensation chart label Remove the backing from the label and place the label on the inside of the distribution area door PM990 8800 50 Issue 3 2 18 Sageon III Base System Installation Temperature Sensor 1 CD00036a FIGURE 2 14 TEMPERATURE SENSOR LOCATION 2 10 INSTALLING A BATTERY CURRENT TRANSDUCER OPTION The optional battery current transducer senses the battery current for display on the operator panel When installed the battery current transducer also allows the user to configure the SCU to limit the recharge current to the battery string in order to extend battery life and set a fixed repeatable discharge current for battery discharge tests Install one battery current transducer per battery string up to four transducers If not ordered with the Sageon III Base System a Battery Current Transducer Kit is available To install a transducer kit 1 Mount the transducer s with user supplied hardware Figure 2 15 shows a typical transducer Often transducers are mounted on the battery rack
105. g from all tiers at the left front of the rack 2 All Group B Bundle cabling from all tiers at the left rear of the rack PM990 8800 50 Issue 3 2 15 Installation Sageon III Base System 2 7 3 Load Supply Cables GJ1 Type Breaker Distribution When ordered type distribution assemblies are always the upper most distribution assemblies in a plant since no more distribution can be installed above a GJ1 type assembly Cable routing and connection are shown in Figure 2 12 Connect the top breaker terminals to user loads The bottom breaker terminals are bolted to the battery discharge bus at the factory Distribution Assemblies K N oo ojo o p Tier 3 Grp Tier 3 Grp B O Or Fuse Alarm mss dd mes Fuse Alarm FA Wire x FA Wire Tier2 Tier 2 Group A Group B 7 Distribution ES Ij E Assemblies x E 9 S cc 5 1 1 5 5 Group Group B 5 E 8 8 e E 5 8 ra 5 5 EI Bus Bars FIGURE 2 11 TYPE BREAKER DISTRIBUTION ASSEMBLIES TYPICAL 1 Select a starting point the lowest Group letter Position 1 is recommended For the load supply cable end use a single hole lug for a 3 8 bolt See Figure 2 12 Bolt the supply cable end to the breaker terminal using 3 8 hardware per fi
106. geon III Base System in your network Be sure to record your access code s and store in a secure location PM990 8800 50 Issue 3 4 9 Configuration and Operation Sageon III Base System Date format Set the date format DD MM YYYY MM DD YYYY Date Format or YYYY MM DD Clock set Set the date and time Note that this 15 a 24 hour clock Dale Time 21 58 34 Alarm report on off toggle When the system will dial the Phone 1 Alarm Report number see the Phone 1 screen below If there is no answer Phones 2 On and 3 will be dialed in turn The cycle will continue until a connection is made See Note following Phone 3 below Daily report on off toggle When on the system will log in to the Daily Report telephone numbers below at the time set in the following screen and On download the status and all operating parameters See Note following Phone 3 below Time of daily report Note that is a 24 hour clock Daily Report 15 15 Modem enable on off toggle The Phone number screens will appear Modem only when the modem is toggled on On Phone 1 Set the first number to be dialed when an alarm occurs Up to Phone 1 20 digits can be stored Numbers longer than 10 digits are shown on 0398887788 two screens Second screen example Phone 1 Cont 2323 Phone 2 This number will be dialed when the above number does not pones i 0398880033 Phone 3 Phone 3 This number will be dialed shou
107. ger Q da 4 Off voltage trigger Equalization trigger A h Equalization is initialized when the charge dis Tri supplied to the load exceeds the value set in this screen Q Equalization on off toggle Q Start Eq On ampere hour discharge trigger Off Off voltage trigger Equalization termination Equalization can be terminated based on charging current or charging time iia STE EQ End Current If equalization is to end at a specific charging current set that 25A current in this screen If equalization is to end after a specific time reduce the value in this screen to less than 5 of the A H rating of the battery string The ampere value entered will be replaced by Off Equalization termination time Set the period of equalization If equalization is to be based only on the A h discharge method set EO Durguon 20 hours the period to maximum 48 hours Force equalization If equalization does not occur due to battery discharge set period after which equalization should be forced EQ Peried 12 Weeks Equalization manual termination To manually terminate equalization at this screen press ENTER The system must be in Manual Stop EQ equalization mode for this screen to appear Press ENTER When ENTER is pressed the system reverts to Float mode and Manual Start EQ the screen changes to that shown at right ready for manual Press ENTER equalization manual start The system must be in Float mode for
108. gh cells Battery 2 current If additional battery strings are connected set the number of that string a maximum of four battery strings may be Battery 2 connected 11A Battery temperature This screen shows the highest battery temperature when temperature sensors are installed on the battery Battery Temp string 31 If sensors are not installed Sensor Not Attached will be displayed Estimated battery charge Estimated Q Bat 1 300Ah Battery disch 1 hreshold Set to the voltage to which th attery discharge alarm thresho Set to the voltage to which the Bates isch Alora attery string falls during discharge When battery voltage reaches 470 this value an alarm will be generated i Battery discharge current differential threshold The allowable battery string discharge current difference is entered at this screen Disch I Diff A reasonable value is 20 of the total discharge current An alarm is 20A generated when the differential exceeds the value entered When two or more battery strings are connected the value in this screen is read by the SCU when an AC outage occurs and the battery strings are supplying the load current A difference in discharge current is an indication of the state of the battery strings Battery over temperature alarm threshold Set the maximum Batt Temp Alarm allowable battery temperature 50 C Ampere hour battery rating Set the battery string s A H rating e va 4 7 1 Battery Temper
109. gure 2 12 Repeat the above steps for each GJ1 type breaker in the Group b tag n ox Lal de v c GJ1 Circuit Breaker 4 Places Load Supply Cable with 3 8 Lug 8 8 Nut and Flat Washer and Output Terminal Hardware Q A Bracket Mounting Screw 12 24 x 3 4 2 Places Mounting Bracket U Shaped 3 8 x 1 Hex Bolt Bevel Washer Flat Washer Breaker Mounting Bar 2 Places DI Bus Bar L Shaped Breaker Input Terminal Hardware FIGURE 2 12 TYPE BREAKER DISTRIBUTION WIRING PM990 8800 50 Issue 3 2 16 Sageon III Base System Installation 2 8 CONNECTING EXTERNAL ALARM ANNUNCIATORS Five form C relay contact outputs are available for connection to external user supplied alarm annunciators Figure 2 13 shows the Interface Board and the row of connectors X6 provided for these connections Review the alarm and relay contact specifications in Section 1 2 11 Alarm Specifications to ensure compatibility with external annunciators and other equipment before proceeding Alarm relay outputs are provided for remote annunciation of fault conditions All relays are user programmable through the SageView software As shown in Figure 2 13 each relay has three connections common normally open and normally closed The normally open NO and normally closed NC labels are for an un powered Sageon III Base System Relay coils are energized during normal Sageon III Base System operation Du
110. he Home screen and the BDT in Progress screen shown at right e The system alarms Battery Discharge Voltage Low and SMR Voltage Low e Low Load alarm will be suppressed e SMR alarms will be shown in the SMR status BDT Period Test time interval The interval between tests can be set to 0 365 14 Days days When set to zero the automatic execution of the test 1s disabled set to Off Display messages below will be shown only if the test is enabled BDT Time 17 35 Time of test Set the time of day the test is to be performed This is a 24 hour clock i BDT Duration Test duration Set the duration of the test Duration can be set from 5 1h30min minutes to 24 hours in increments of 5 minutes Discharge rate Set the rate of discharge Rate can be set from 0 to BDT Current 5000A If rate is set to zero the control function is disabled and the 50 battery will discharge under full load current PM990 8800 50 Issue 3 4 18 Sageon III Base System Configuration and Operation Note The total load supplied by the system during the test must exceed the desired battery discharge current by at least 10 Rectifiers will supply the additional load leaving the battery string to supply a user defined current to the load End of test Set the battery voltage that will terminate the test if BDT End V reached before the test duration set above 47 0 At the end of test whether ended by test duration or e
111. hen press ENTER to cause the second digit to flash Press up arrow or down arrow to set the flashing digit to the desired value Repeat until each digit is set to the desired value When an alarm condition exists and you are prompted to press ENTER the ENTER button will cause alarm details to be displayed CAUTION Setting correct parameter values is critical Incorrect values can result in unsatisfactory performance unexpected shutdown and other unanticipated performance characteristics Moving from one menu to another To move from any menu to any other menu simply press the desired button To move to the Home menu from any other button press the button for the current menu For example if battery parameters are presently being displayed press BATT to access the Home menu To change a parameter when the security function is activated A Panel Locked message will appear when an attempt is made to alter any parameter while security is activated The security On Off selection is located in the HOME menu Section 4 5 To change a parameter simultaneously press and hold the up arrow down arrow and ENTER buttons for 3 seconds Parameters may now be changed as described above 4 3 READING THE OPERATOR PANEL SYSTEM STATUS LEDS The table below describes the indications presented by the system status LEDs PM990 8800 50 Issue 3 4 4 Sageon III Base System Configuration and Operation TABLE 4 2 READING
112. ibration Replace the rectifier module Send the unit for repair and re calibration System Voltage Clamp alarm activated Controller cannot reach the desired system voltage This can be due to possible excessive voltage drop along the DC bus bars inside one or more rectifiers or System V Drop parameter has been set too low If this alarm comes up during equalize the maximum output voltage from the rectifier may not be high enough to overcome the system drops to the sense point and allow the system to regulate at the desired high equalize voltage Increase Sys V Drop parameter Replace faulty rectifier unlikely to current share as well Check that the number of RECTIFIERs in the system is correctly set more RECTIFIERs than declared can generate this problem Revise the requirements for high equalize voltage level PM990 8800 50 Issue 3 Sageon III Base System Maintenance Symptom Likely Causes Action RECTIFIER EEPROM Fail alarm is activated as indicated at the RECTIFIER Menu for a particular RECTIFIER Corrupted data found on the EEPROM inside the rectifier that is outside the allowable data range The rectifier software has attempted to over write and has failed due to the memory cell being damaged Note excessive electrical noise can corrupt the read data transfer which can lead to the same alarm being generated Replace the faulty rectifier if the
113. in Figure 2 19 Battery String 4 Temperature X4 in Figure 2 19 Ambient Temperature X3 in Figure 2 18 Select a location for mounting the ambient temperature sensor ring lug The temperature of this mass should have a fairly long thermal time constant e g temperature should not cycle with short term temperature changes due to normal environmental heating and cooling cycles Typically this could be a nearby equipment rack the Sageon III system is mounted adjacent to Fasten the ambient temperature sensor to the selected point using appropriate user supply hardware Route the 4 battery temperature sensors to the battery string s Typically somewhere close to the string midpoint Determine which battery posts will have sensors attached Suggested location is shown in the battery string drawing figure 2 14 Note The highest of the four battery temperature readings is used for compensation Locate a sensor at the warmest battery generally one at the center of a battery group Determine the charge discharge status of the battery string Connecting the sensors may result in a momentary battery string open circuit when the terminal bolt is removed CAUTION DO NOT proceed if the battery string is being charged or discharged at a high rate Continue only when the charge or discharge rate is at a safe level Remove the bolt holding the inter cell battery strap in place Insert the bolt through the battery temperature sensor ring lu
114. istribution option directly below the your selected group Orientation will be the same as the installed bus bar see Figure 7 4 Using the hardware collected in step 3 above bolt the bus bar from the kit to the factory installed bus bar From the kit collect the distribution assembly support bracket two 12 24x34 screws Orient the support bracket as shown in Figure 7 5 so the bracket legs with the two rectangular holes is against the closest vertical rail of the rack Use the two 12 24x 4 screws to fasten the bracket to the rack rail From the kit collect the distribution assembly and two each 10 32 hex head screws 5 16 flat washers 5 16 bevel washers and 5 16x18 hex nuts Referring to Figures 7 4 and 7 5 for assembly orientation insert the studs of the distribution assembly into the U shaped bus bar and fasten with the flat washers bevel washers and nuts The 10 pairs of output studs on the distribution assembly should be oriented towards the vertical rail of the rack Fasten the support bracket to the distribution assembly using the two 10 32 hex head screws Tighten all hardware Refer to Table 2 2 for torque specifications Repeat the above steps for each AMI distribution assembly to be installed From the kit s collect the Failure Alarm FA jumper wire s Connect one end of each wire to the push on terminal on the edge of a newly installed distribution assembly Connect the other end to a convenient push on connec
115. ized high voltage alarm International Electrical Commission Institute of Electrical and Electronic Engineers light emitting diode least significant digit low voltage alarm low voltage disconnect National Electric Code National Electrical Manufacturers Association printed circuit board Rectifier see SMR Regional Bell Operating Company rectifier failure alarm Sageon Battery Monitor Site Monitor Sageon Control Unit Switch Mode Rectifier see REC RECT Uniform Building Code Underwriters Laboratory Uninterruptible Power System PM990 8800 50 Issue 3 1 10 Sageon III Base System Introduction 1 4 REFERENCE PUBLICATIONS DOCUMENT NUMBER TITLE ANSI C 39 1 Requirements for Electrical Analog Indicating Instruments ANSI T1 311 1991 DC Power Systems Telecommunications Environment Protection ANSI IEEE 62 41 1980 IEEE Guide for Surge Voltages in Low Voltage AC Power Circuits ANSI IEC 801 2 Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment October 1987 NEC 1993 NEC Handbook 1993 National Fire Protection Association No Number OI 28 Standards No Number Central Office Telecommunications Equipment Engineering Standards December 1984 PUB 77350 U S West Telecommunications Equipment Installation amp Removal Guidelines May 1990 PE 7 1985 Communications Type Battery Chargers NEMA ANSI STD 487 1980 IEEE Guide For The Protection of Wire Line Communicati
116. kit will be installed Note distribution cannot be installed in any Group of Tier 1 Remove the two painted breaker mounting bars from the existing GJ1 Distribution Option to allow access to mount the type breaker kit See Figure 8 3 Note It may be necessary to remove the 10 32 x 1 2 Phillips head screws from any GJ1 type breakers already installed in existing GJ1 Distribution to facilitate removal of the two painted breaker mounting bars From the existing GJ1 Distribution Option carefully remove the insulated sleeving from the orange fuse alarm wire and the red alarm wire for the breaker position you are installing Remove type breaker kit from its packaging The package label will identify the kit by part number Connect the red alarm wire of the GJ1 Distribution Option to the Common C pole and the orange fuse alarm wire of the GJ1 Distribution Option to the Normally Closed NO pole on the rear of the GJ1 type breaker Note For type breakers 200A and over the breaker kit contains an alarm wire adapter that must be connected between the breaker and the red alarm amp orange FA alarm wires of the GJ1 Distribution Option Carefully place the GJ1 type breaker from the kit over one of the vertical tabs of the L shaped bus bar of the GJ1 Distribution Option see Figure 8 3 Collect from the GJ1 type breaker Kit one each of the following 3 8 16 x 1 1 4 hex head bolt 3 8 bevel washer and 3 8 flat washer In
117. l cell voltage can be less than the 10 nominal Below this value an alarm will be generated 4 5 2 Site Monitor When the Site Monitor is included in the software the window at right Press ENTER will appear next Site monitor on off toggle Press ENTER to display the current On Off I status flashing Press up arrow or down arrow to set the desired Site Monitor state then press ENTER to store On Contact the factory for additional details concerning this feature 4 6 RECT RECTIFIER MENU SCREENS Enter this series of menus by pressing the REC SMR button Press up arrow or down arrow to select the Rectifier number i e rectifier position address and press ENTER Press up arrow to scroll through the screens in the order shown Repeat for each Rectifier The following map summarizes the available menu screens Select Rectifier number 1 24 read number current and temperature Press ENTER for firmware version Float voltage Equalization voltage Programmable l Voltage high low alarm Voltage high voltage shutdown Current limit Fault reset SMR RECT Button The Rectifier number is the rectifier position address of the target Rectifier e g SMR 4 SMR no response No Response message appears when the target Rectifier is not installed not connected not switched On or is No Response faulty SMRI SM
118. larms log which is a chronological record of the last 100 alarms Moving from one menu to another If no button has been pressed for two minutes the display will revert back to the Home screen This shows the output voltage and load current To move from any menu to any other menu press the corresponding button e g to move to the Battery Menu from any other menu momentarily press the BATT button To move to the Home menu from any other menu press the button of the current menu e g if in the RECTIFIER menu press RECTIFIER button to return to the Home menu Scrolling through the Menus To scroll through any menu from the first screen to the last press the INC button To scroll to the last bottom screen first then upwards through the menu to the first screen press the DEC button Incrementing and decrementing programmable parameters To change a programmable parameter press ENTER the value will flash on and off To increase the number press INC to decrease the number press DEC When the desired number is on the screen press ENTER again To change parameters when the security function is activated If an attempt is made to alter any parameter when the security function is activated the display will show the message Enter Password To change a parameter enter a valid password Then proceed to change the parameter in the normal way When scrolling through the Alarms log To observe the date and time of a given alarm do not press
119. ld the previous number not 0398880003 answer Note To send Alarm Report or Daily Report to a local PC set the Report to On and Modem to Off Audio alarm on off toggle Set to On to audibly annunciate an alarm Audio Alarm Press ENTER to silence acknowledge the alarm On Circuit breaker auxiliary contact input Configure options are Cct Input normally closed normally open or disabled not used Used N C PM990 8800 50 Issue 3 4 10 Sageon III Base System Configuration and Operation Battery circuit breaker auxiliary contact circuit input Configuration Bat Sw Input options are normally closed normally open or disabled not used Used Battery low voltage disconnect switch auxiliary contact circuit input LVDS Input Configuration options are normally closed normally open or disabled Used N O not used Press ENTER to access the Sageon Battery Monitor and the Sageon Auxiliary Units Site Monitor Press arrow to go to the top of the menu string Press ENTER Note Screens for installed options e g Sageon Battery Monitor Site Monitor appear next If no options are installed the HOME screen will appear 4 5 1 Sageon Battery Monitor Note See Section 4 9 Sageon Battery Monitor Setup for additional information Battery Monitor When battery cell voltage monitoring is included in software the Press ENTER window at right will appear next Battery monitor on off toggle Press E
120. monitoring also connects a Sageon III Base System to a PC however they can be separated by a few feet or by hundreds of miles Your company s Ethernet network or intranet the Internet or a pair of telephone modems can provide the interconnection Refer to TG990 4262 10 for more details on SageView Remote PC with Local PC ZEN SageView Ethernet with Network SageView PC with ess SageView Remote __ 4 Server with PC with Firewall SageView e ZA Intranet Local Network Ethernet CD00026a Power Plant with Battery String s Operator Panel RS 232C SageView Control Local Outputs to Unit SCU and M User s Alarm System ToU Interface Board Data Logging is Status 9805 Measured N Control Distribution Variables Signals X Y DC Bus Rectifier 1 Rectifier 2 Rectifier n Battery String s Power Plant with Battery String s FIGURE 5 1 NETWORK CONNECTIONS 5 1 CONFIGURATION Use SageView to develop a completely new configuration and then upload this configuration to a connected Sageon III Base System If an operating configuration requires minor parameter value changes download the configuration from the System to the PC edit as needed and then uploaded to the same System or to another
121. nd accepting bolts or other user supplied hardware to securely anchor the plant e A pest and varmint free area 2 4 MOVING AND ANCHORING THE POWER SYSTEM The Power system is heavy up to 1 000 Ibs 453 kg and it is top heavy An improperly handled Power system can topple Proper handling equipment is required to transport the plant The unit dimensions are given in Figure 2 1 Figure 2 2 shows the Power system base and the floor mounting hole pattern Floor Mounting The Power system must be permanently anchored Install one anchor in each floor corner Mounting slots are provided in each corner to allow for ease of anchoring Mark and drill holes where shown in Figure 2 2 UNIPOWER offers several seismic zone hardware kits A WARNING Tip Over Crush Hazard Power system tip over can cause death or serious injury Keep the Power system vertical Power system is heavy and also top heavy Use a forklift or other equipment to move or transport the Power system PM990 8800 50 Issue 3 2 5 Installation Sageon III Base System EI IB i ia EI il BI HI
122. nd menus An LVBD bypass switch is provided This switch bypasses i e defeats the SCU LVD in case of SCU maintenance upgrading or failure The Sageon III Base System operation can be monitored at the operator panel on the front of the Sageon III Base System at a PC connected to the operator panel or at a PC connected to the Sageon III Base System over an Ethernet network The Sageon III Base System configuration can be performed from the operator panel or at a PC Printed circuit boards below distribution area contain terminals for user connections to alarm relays battery temperature compensation sensors communications and other internal and external functions In addition most signals destined for the SCU are routed first to the BDM board or backplane board The operator panel provides user access to the configuration and monitoring capabilities of the SCU For security a parameter lock feature is included and PC access can require a password PC that is to be connected to the Sageon III Base System must have the optional SageView software installed and operating 1 2 SPECIFICATIONS This section contains physical environmental and electrical specifications for the Power system and its major assemblies 1 2 1 Power system Physical Specifications Dimension 7 foot Tower 24 46 62 1 cm 21 48 54 6 cm 84 213 4 cm Contact the factory Dimension Rectifier Width 8 5 215 90
123. nd voltage normal operation is restored and recharging of the battery BDT End Q string s is begun The test result will be Fail Battery string end 500Ah of voltage depends upon system voltage 48V system 36V to 48V Battery end of capacity Set the remaining battery capacity at which the test must end Capacity can be set from 25Ah to 9995 Ah If rate is set to Zero the control function is disabled and the battery will discharge under full load current BDT Alarm Reset Reset of failed test alarm This message appears when the preceding test Press ENTER fails and 15 not reset Press ENTER to reset the alarm and hide the message BDT in Progress Abort MBT This screen is available when a discharge test has been ENTER to abort started 4 7 5 BDT Results Screen The final screen contains a brief test result message The message Last BDT appears on the second line of the Last BDT display Each message is N A explained below N A Not Available No test has been performed Passed Test ran for programmed duration without reaching an End V or value Failed Test terminated prematurely after reaching an End V or End value before the test duration expired This will trigger a Fail alarm AC Lost Test terminated due to loss of AC supply Detected by the AC monitor or by all SMRs being Off Cell V Low A cell in a battery string discharged below a safe lev
124. nel or connected personal computer Text message Chapter 4 Configuration and Operation Rectifier front panel LED Section 6 3 1 It is possible for a configuration mistake to cause an error or change in status display If this occurs after editing the configuration or uploading a new configuration from a PC to the Sageon III Base System carefully check the configuration s programmable parameter values before changing a hardware assembly 6 3 Reading Rectifier Status Led Codes There are 3 LEDs on a Rectifier s front panel to indicate operating status see the following table Yellow Off Off TABLE 6 2 RECTIFIER LED CODES Meaning No AC power to Rectifier User Action Apply AC power to Rectifier Flashing Off AC input is too low or too high Primary circuit is faulty Troubleshoot AC input to Rectifier replace Rectifier Off Rectifier functioning normally in Float mode No action needed Flashing Alarm condition Refer to Chapter 4 Operations and Replacing a Rectifier in Chapter 6 Maintenance On Rectifier functioning normally in Equalize mode No action needed Flashing Rectifier shut down by remote control Rectifier not inserted in holder properly Internal control circuit fault No action needed Remove and reseat Replace Rectifier SCU microprocessor fault Replace SCU 990 8800 50 Issue 3 6 2 Sageon III Bas
125. nge System Value Default SBM Batteries Number of battery banks to be 1 4 1 monitored Vhi Cell Cell high voltage alarm 2 0 16 0V 2 5V Vlow Cell Cell low voltage alarm 1 0 12 0V 1 8V dVc Cell Cell positive deviation alarm 5 99 10 dVc Cell Cell negative deviation alarm 5 99 10 RECT V high Rectifier high voltage alarm 48 65V 57 5V RECT V low Rectifier low voltage alarm 44 54V 48V RECT HVSD Rec high voltage shutdown 48 66V 57 5V RECT limit Rectifier current limit 4 60A 60A BATT Menu B Dis Alarm Battery discharge alarm threshold 44 52V 47 0V Disch I Diff Battery string discharge current 5 99A 20A difference alarm Batt T Alarm temperature alarm threshold 30 to 90 C 40 C Bat Rated Ampere hour rating of batteries 20 9 999AH BTC Battery temperature coefficient 0 6 mV C 0 mV Number Cells Number of chemical cells in battery 4 24 24 string BILim Battery charging current limit for 5 999A 50 Vb V dd Vb V dd Vdd Level Battery deep discharge voltage threshold 40 47V 45V BILim Battery charging current limit between 5 999 50A Vb VfI Vdd amp Vfl Sys Float System float voltage Vfl 48 58V 54 2V Sys Drop System voltage drop 0 0 2 0V 0 5V Equalization Enable disable Eq function On Off On FS Load I Full Scale Load Current sensor value 50 3000 100 Load Sensor Enable disable Load Sensor On Off Off BILim Battery charging current limit in 5 999A 50 Vb gt VfI equaliz
126. o EXT COMMS AUXILIARY AMB BATT COMMS BATTERY DIST gt RECI IF IER 7 2 48V 50A Al SCU BACKPLANE 100 7675 4850 2 i ORN BDM RIBBON A E e a RED PAG a W O OPTION CO1 SELECT ONLY ONE POWER AND SENSE CONNECTION WITH OPTION 01 Ex d 6 RECTIFIER COMMS AC FEED ACCEPTS 14 AC BREAKERS CUSTOMER AC CONNECTIONS RECITFIER BUS 4 RECTIFIER BUS SAGEONS3 BO2 amp BO4 RECTI BACKPLA BUS BAR RECTIFIER 48V 50 BUS BAR 100 7675 4850 N PLANT SIZEMAX RECTS 600A 12 PROPRIETARY INFORMATION NOT TO BE COPIED USED TRANSMITTED OR DISCLOSED WITHOUT 1200A 24 PRIOR WRITTEN PERMISSION FROM UNIPOWER LLC SIZE DOC TYPE NUMBER ISSUE SD SAGEONI AXX N A 2 4 SD SAGEON3 ISS 4 1 2 1 3 4 ED991 5001 B3 Issue 3 1 2 i 3 4 AUX RIBBON EXT COMMS AMB TEMP 1 TEMP 2 3 TEMP 4
127. o the OFF position Lift the locking mechanism Grasp the rectifier handle and pull the Rectifier forward 1 25 mm to 2 50 mm Grasp the Rectifier and pull it straight out from the Housing The Rectifier weighs approximately 5 lbs 2 3kg Set the Rectifier aside and attach a tag stating its operating status e g OK needs servicing A CAUTION Electrical shock hazard After removing a rectifier be careful not to touch the rear a connector The rectifier will take approximately 1 2 minutes to self discharge The red LED will flash during this time PM990 8800 50 Issue 3 2 22 Sageon III Base System Installation 2 15 CONFIGURATION 2 15 1 General Description Sageon III Base systems are turn key DC uninterruptible power supply solutions DC UPS for powering 48VDC telecommunications and industrial equipment The Power plant provides integrated battery management functions for a range of battery types VRLA flooded Lead acid NiCad Ni MH Li polymer to enable easy commissioning of a DC UPS or it can be used as a standalone DC source when no batteries are used The Power plant provides the following integrated features e Power Distribution e n l Redundant Rectifiers e Battery Charge Current Limiting opt e Short Circuit and Reverse Polarity Protection e Battery Temperature Sensing opt e Monitoring and Control Module Controller e Accurate Temperature Compensated Float e Super Capacitor B
128. oads See Section 2 7 9 Connect external alarm annunciators See Section 2 8 10 Input Connect options Battery Temperature Sensors Battery Current Transducers Sageon Battery Monitor Site Monitor and communications SNMP See Sections 2 9 through 2 13 11 Install Rectifiers See Section 2 14 12 Commission the plant See Chapter 3 Commissioning and Chapter 4 Configuration and Operation 2 2 REFERENCE MATERIAL This section contains lists tables and methods that are referenced in subsequent procedures Three subsections comprise the Reference Material section Tools and Accessories Read the included list for a preview of the user supplied items that will be referenced during the installation and servicing procedures e Selecting and Sizing DC Power Cables Proper cable sizing is critical to system performance This section provides a formula and table that simplify cable selection Torque Specifications The torque specification table in this subsection is referenced in procedures that include hardware 2 2 1 Tools And Accessories To install the Sageon III Base System the following user supplied items should be available e Equipment to move Power system to installation site e Floor anchors to secure the Power system e Conduit and or overhead wire racks for cabling e Standard insulated installation tools e g hand tools socket set cable cutters cable insulation strippers PM990 8800 50 Issue 3 2 2
129. ogged 100th most recent logged event Older events are erased DEC LOG No Entries 990 8800 50 Issue 3 4 26 Sageon III Base System Configuration and Operation 4 13 4 Battery Menu Battery Specific Functions Home Screen 25 2A 54 3V FL BATT Button Battery string 1 current Battery 1 12A Discharging Aaditional screens if more batteries declared DEC Battery 4 10A Discharging INC Shows Not Available if no sensor connected or Sensor Fail is faulty 9 Battery Temp Estimated remaining charge Estimated Q Bat 300Ah Additional screens if more batteries declared Estimated Q Bat4 300Ah ENTER Bus voltage below which alarm flagged Batt Disch Alarm 47 0V ENTER Alarm threshold for poor battery Disch Diff current sharing shows if gt 1 battery 20A ENTER Battery temperature above which alarm Batt Temp Alarm flagged Not active without sensor 50 ENTER to accept ENTER Battery capacity C10 in Ah Battery Rating y 500Ah L ENTER to accept ENTER Battery Temperature compensation BTC Coeff 1 Modify Variable from 0 to 6 0mV C C 3 2 mV C C ENTER If BTC not Off ENTER Mid point temp for BTC curve Comp 0 Nominal 1 Modify Value up down 20 1 ENTER to accept I ENTER Number of Cells I Modify Val up down 1 Physical number of 2V cells in string used for 24 i ENTER to accept ENTER Charge curr
130. on parameter values or load a new configuration from a PC connected to the USB port on the plant operator panel or from a PC connected to an Ethernet network an IP address must be entered The PC must be running the optional SageView plant monitor software Become familiar with the Rectifier LED codes in Section 6 3 Troubleshooting The system may be commissioned with the battery string s connected or disconnected however consider the configuration statements in paragraph 5 above Finally perform the steps in Section 3 2 Commissioning a System 3 2 COMMISSIONING A SYSTEM This procedure assumes a newly installed system that includes connected batteries and loads l Before applying AC power check that input cables are connected to the correct terminals and that connections are tight Allload supply and return and battery cables are correctly connected and that connections are tight check polarity as well e alarm wiring is correct and tight and that alarm annunciators function e The System housing and return bus are connected to the site earth ground PM990 8800 50 Issue 3 3 1 Commissioning Sageon III Base System Poerio 10 11 12 13 Read the operator panel display and note LED indications e Ifaconnected battery string is supplying sufficient power to the SCU the operator panel 2 line display will be active and show System voltage and current The LEDs should also be active
131. ons Facilities Serving Electrical Power Stations TR EOP 000151 Bellcore Generic Requirements for 24 48 130 amp 140 Volt Central Office Power system Rectifiers May 1985 TR EOP 000154 Bellcore Generic Requirements for 24 48 130 amp 140 Volt Central Office Power system Control and Distribution May 1985 TR NWT 000063 Bellcore Network Equipment Building System Generic Equipment Requirements Issue 4 July 1991 TR TSY 000078 Bellcore Generic Physical Design Requirements for Telecommunication Products and Equipment UL489 UL Molded Case Circuit Breaker Enclosures May 1984 1 4 1 Monitoring Specifications Operator panel voltage and current 2 line digital display Operator panel accuracy Voltage 0 5096 least significant digit Current accuracy 196 System status ipa la lara Green yellow and red LEDs Local Communications USB SageView required Remote Communications Ethernet SNMP 1 4 2 Alarm Specifications Each of following alarms is annunciated by a lighted LED on the operator panel and by a relay state change Relay contact output terminals are on the alarm PCB in the distribution A User Alarm Annunciation Five user programmable relays One form C contacts rated resistive 9 24Vdc 0 5A resistive 48Vdc B Rectifier Front Panel Three status LEDs Green Amber and Red are locat
132. ot Available in the menu items for the temperature measurements Locate the ambient sensor on a mass with a fairly long thermal time constant see Section 2 9 Locate the battery sensor on a battery block in the middle module of the battery bank likely hot zone PM990 8800 50 Issue 3 3 10 Sageon III Base System Commissioning 3 6 AUXILIARY RELAY CONNECTIONS FIGURE 3 8 MULTIPLE ALARM BOARD The user configurable auxiliary relays contacts are shown above See section 1 4 2 for contact ratings The pin configuration is Pin 1 shown in Figure 3 11 Relay Pin Pin function 1 normally open 1 2 normally closed 3 C common 4 N O 2 5 N C 6 C 7 N O 3 8 N C 9 C 10 N O 4 11 N C 12 C 13 N O 5 14 N C 15 E 3 7 CONTROLLER POWER CONNECTIONS The relays being user configurable can be arranged to activate for multiple alarm conditions or a single alarm only The logic can be inverted for individual relays so that one becomes a controller failure indicator use the normally closed contact as this will also indicate if the relay power has failed Po
133. r circuit breakers in the present distribution refer to Chapter 8 Circuit Breaker and Fuse Kit Installation Route supply and return cables from the Power system to the loads in overhead racks or cable trays The plant cables drop from the overhead racks through the open top of the plant Connect the return cables to the return bus loads the vertical bus to the right side of the distribution area Connect the supply cables to either a distribution assembly for AMI type breakers or a GJ1 type breaker output terminal A typical load connection is shown in Figure 2 6 215 TION TIER Ol Note Other tiers and groups are cabled similarly Connect all load returns to the return bus FIGURE 2 6 LOAD SUPPLY AND RETURN CABLING Distribution is organized by Tier 1 3 Group A amp B and position 1 10 See Figure 2 7 The Breaker Fuse Layout label on the rear of the distribution area door is for recording breaker fuse current rating and part number PM990 8800 50 Issue 3 2 12 Sageon III Base System Installation BATTERY DISCHARGE A LIT Y UE T L DISTRIBUTION Pomp ON EACH TIER LEFT SIDE FIGURE 2 7 DISTRIBUTION GROUP IDENTITIES AND LOCATIONS Distribution Group Orientation Orientation of a group determines the routing of the supply cables Figure 2 8 shows the orientation of AMI di
134. r servicing the Power System in an extremely low humidity condition Altitude e rime 9 800 feet 3 000m Contact the factory for derating above specification Heat Dissipation eese 1070 BTU Hr maximum full load per Rectifiers Cooling Distribution Convection cooling Rectifier Modules Fan forced air front to back with built in over temperature power limiting Audible Noise eene 66dB for a fully loaded plant per NEBS GR 63 CORE 1 2 3 Power system Electrical Specifications Input AC Power Input eene See Section 1 3 8 Rectifier Specifications for voltage and current Battery Strings 4 maximum Battery String Connections 8 pairs of 3 8 studs 1 center to center for 2 hole lugs Output Plant Power Output 1200A at 48 Vdc 1000A at 56 Vdc Distribution Power system Total 1200 maximum Individual Group AMI 1000A maximum Individual Group 1200A maximum 1 2 4 General Specifications Battery Temperature Compensation Adjustable 0 1 to 6 mV C cell 1 2 5 Bus Specifications Bus Structure Amperage Rating Per American National Standards Institute s Telecommunications Protection Specifications ANSI T1 311 1991 ampere tables Charge Bus Voltage Drop 0 05 V maximum Discharge Voltage Drop
135. rameter values Refer to Chapter 4 Configuration and Operation for operator panel and PC Screens 8 Confirm that all Rectifiers are on line and sharing current From the operator panel or a PC check each Rectifier for voltage and current output Refer to Chapter 4 Configuration and Operation for operator panel and PC screens PM990 8800 50 Issue 3 6 1 Maintenance Sageon III Base System 9 Ifload requirements allow remove Rectifier Systems one at a time Use low pressure air to clean Systems Clean dust and lint from Rectifier fans Refer to Section 2 14 Installing and Removing Rectifiers for procedures 10 Verify communications with remote PCs dial up connections and databases as appropriate 11 Test any spare Rectifiers a Insert a spare device b Test the device to ensure correct operation c Ifthe device is to remain a spare remove it and repeat the above steps until all spares are tested If spares are to remain installed for run time equalization repeat the above steps until the spare devices are installed 6 3 TROUBLESHOOTING Troubleshooting is based on displayed alarm messages and error codes that appear in response to a detected change in status of the Sageon III Base System batteries or environment see Table 6 1 TABLE 6 1 ALARM MESSAGES AND ERROR CODES Location Display Method See Chapter or Section Operator Panel LED Chapter 4 Configuration and Operation Operator Pa
136. ring an alarm the appropriate relay coil is de energized IMPORTANT When the relay contacts are connected to a reactive load such as a solenoid or relay coil the load must be shunted by a transient suppression device to prevent damaging relay contacts FIGURE 2 13 INTERFACE BOARD CUSTOMER ALARM CONNECTIONS 2 9 BATTERY TEMPERATURE SENSORS AND KITS OPTION The Multiple Battery Temperature Board is optional in the Sageon III distribution It can accommodate up to four battery temperature sensors Temperature sensors are ordered separately If ordered with the system the sensors are connected to the Multiple Battery Temp Board and the sensors and wires then coiled and tied to the return bus If not ordered with the Sageon III Base System an Ambient and one 1 Battery Temperature Sensor can be ordered separately Installing the Sensors Open the distribution door and locate the Multiple Battery Temperature Board Locate the coiled sensors 1 Ifnot already connected plug the battery temperature sensor connectors and the ambient temperature sensor into the Controller backplane board See Table 2 4 for the connectors The connectors are keyed PM990 8800 50 Issue 3 2 17 Installation Sageon III Base System 10 11 TABLE 2 4 BATTERY TEMPERATURE SENSOR CONNECTIONS Sensor Connector Battery String 1 Temperature in Figure 2 19 Battery String 2 Temperature X2 in Figure 2 19 Battery String 3 Temperature X3
137. rrent and voltage on the operator panel 2 line display The Red LED on the panel will be lighted unless the 155A 54 2V number of operating Rectifiers equals the number of Rectifiers in FL the System configuration in which case the Green LED will be lighted Refer to Section 6 3 Troubleshooting as needed Connect a 10 to 50A load to the System through a distribution breaker or fuse Refer to Chapter 4 Configuration and Operation and use the operator panel push buttons and menus to 1 Turn Off battery temperature compensation Note If the float voltage is set at high or low battery temperature with battery temperature compensation turned On compensation may adjust the System voltage by as much as 2 volts 2 Connect the load to the System by closing the distribution breaker Repeat Steps 7 through 10 until all Rectifiers are on line and taking load As Rectifiers are brought on line the load may be increased At the operator panel verify that each Rectifier is sharing current and the Sageon III Base System voltage is set to the desired Float voltage generally 54 2 Vdc volts Configure the Sageon III Base System as described in Chapter 4 Configuration and Operation If the configuration has been created on a PC and is to be uploaded to the operating Sageon III Base System also refer to Chapter 5 SageView Thoroughly test the new configuration to ensure that all configurable parameters are correct Test the alarm circuits to
138. rrow button to scroll to the desired alarm s A list of all operator panel annunciated messages is found in Table 4 3 PM990 8800 50 Issue 3 4 5 Configuration and Operation Sageon III Base System TABLE 4 3 OPERATOR PANEL ANNUNCIATED ALARM MESSAGES Alarm Name SMR Alarm Comment Combination of one or more SMR alarms LED ON FL Amber FL SMR Urgent One or more SMRs have shut down Amber Red SMR HVSD SMR shut down due to output over voltage Amber Red UNIT OFF SMR is off Amber Red No Response A particular SMR is not responding to the SCU Amber FL Power Limit SMR is in Power Limit Amber FL No Load SMR output current less than minimum for SMR type Amber FL Current Limit SMR in current limit Amber FL Voltage High Voltage measure by SMR too high Amber FL Voltage Low Voltage measure by SMR too low Amber FL UNCAL SMR SMR internal adjustment for current sharing out of limits Amber FL EEPROM Fail EEPROM failed SCU or SMR Amber FL Fan Fail SMR internal fan failure alarm Amber FL Relay Fail SMR output relay contacts failure Amber FL No Demand Control loop in SMR not in normal state Amber FL H S Temp High SMR heatsink temperature too high Amber FL Temp Sensor Fail Temperature sensor in SMR microprocessor circuit failed Amber Red Vre
139. s active individual cell voltages can be monitored on the operator panel by selecting a battery from the BATT menu and pressing ENTER The cell information will appear on the screen and the next and previous cells can be selected by pressing the up arrow and down arrow buttons Battery 1 12A Battery 1 Cell01 2 225V 12 Select battery Battery 1 screen appears after pressing the BATT button Press ENTER Battery cell parameter Battery 1 Cell 01 values are displayed As shown here the cell voltage is 2 225V which is a deviation of 12 from the average cell voltage in this battery string Battery cell voltage deviation Battery 1 Cellmm cell voltage n nnnV pri is deviating pp from the average cell voltage in this battery string DDR Press up arrow or down arrow to change the cell number 4 10 COMMISSIONING THE CONTROLLER With all the batteries load and AC cabling wired and checked for correct polarity the system is commissioned by the following steps e Ensure no rectifiers are installed in the Power plant and no load is applied e Plug in the Controller it should power up off the battery If not it is possible that the battery polarity is reversed e Setup the Controller menu items for PM990 8800 50 Issue 3 4 21 Configuration and Operation Sageon III Base System number of batteries and size Ah number of rectifiers set the required float and equalize voltages
140. s in the cable I 2 maximum current in amps L one way cable length in feet V allowable loop voltage drop in volts Example Assume a maximum output current of 100 amperes an allowable loop voltage drop of 0 25 volts and a distance of 50 feet between the Power system and the load 100 amperes L 50 feet V 0 25 volts 22 2 100 50 CM 0 25 CM 440 000 circular mils 2 After calculating the minimum area in circular mils select the proper copper wire size from Table 2 1 always choosing the next larger wire size if the area rating falls between values For the above example select 500 MCM wire PM990 8800 50 Issue 3 2 3 Installation Sageon III Base System 3 Determine the minimum wire size for ampacity according to the code authority having jurisdiction in your location 4 Select the larger of the sizes calculated for voltage drop or ampacity TABLE 2 1 WIRE SIZING SIZE AREA CURRENT DIA BARE RHW DIA RHW AWGNO INCM CARRYING COND OVER INS BEND CAPACITY INCHES INCHES RADIUS OPEN ENCLOSED INCHES AIR 14 4 110 15 15 0 064 0 19 0 95 12 6 530 20 20 0 081 0 21 1 05 10 10 380 30 30 0 102 0 24 1 20 8 16 510 45 45 0 146 0 31 1 55 6 26 250 70 65 0 184 0 40 2 00 4 41 740 100 85 0 232 0 45 2 25 2 66 370 135 115 0 292 0 51 2 55 1 0 105 500 185 150 0 373 0 63 3 15 2 0 133 100 210 175 0 418 0 68 3 40 4 0 211 600 300 230 0 528 0 78 3 90 350 MCM 350 000 425 310 0 681
141. s the most likely cause While the rectifier internal power rails are still available the unit will communicate with RECTIFIER Off if the AC has failed on its input Once the internal power dies the unit will no longer communicate and Controller will indicate No Response No Response all the time and the RECTIFIER is known to have AC power indicates a communications wiring problem Check the AC feed to the rectifier for a tripped circuit breaker blown fuse or faulty connection Check the RECTIFIER communications 10 way ribbon cable for broken connections and replace cable if necessary One or more rectifiers has a current limit or power limit alarm activated Total load including battery charging current is equal to the output limits of the rectifiers System overload One rectifier in current limit only indicates a likely calibration problem with the module The Controller can usually compensate for an out of calibration unit in a system and will take a few minutes to adjust the unit to correctly share the load Revise the load level on the system and expand the number of rectifiers as required to remove the overload condition One rectifier has an UNCAL RECTIFIER alarm The Controller has not been able to make the unit share the load with the other units Either the RECTIFIER is faulty excessive internal voltage drop and cannot be adjusted to share load or it is too far out of cal
142. sert through tab of the GJ1 type breaker and thread into the insert of the vertical tab of the L shaped bus bar of the GJ1 Distribution Option see Figure 8 4 and tighten See Table 2 2 for torque specifications Replace the two painted breaker mounting bars of the GJ1 Distribution Option using the 10 32 x 1 2 Screws removed in step 2 Collect the two 10 32 x 1 2 from the type breaker Kit and secure the new type breaker to the two painted breaker mounting bars of the Distribution Option replaced in step 8 PM990 8800 50 Issue 3 8 3 Circuit Breaker and Fuse Kit Installation Sageon III Base System 10 Use the remaining 3 8 hardware from the GJ1 type breaker Kit to secure load cabling to the type breaker see Figure 8 4 GJ1 Circuit Breaker 4 Places P 3 8 Nut and Flat Washer and Output Terminal Hardware Load Supply Cable with 3 8 Lug J Bracket Mounting Screw 12 24 x 3 4 2 Places gt Mounting Bracket U Shaped 3 8 x 1 Hex Bolt 7 Bevel Washer Flat Washer Breaker Mounting Bar 2 Places Bus Bar L Shaped Breaker Input Terminal Hardware FIGURE 8 3 GJ1 TYPE BREAKER KIT COMPONENTS Lower distribution option AT removed for clarity FIGURE 8 4 GJ1 TYPE BREAKER KIT INSTALLATION PM990 8800 50 Issue 3 8 4 Sageon III Base System Spare and Replacement Parts 9 0 SPARE AND REP
143. specified the load supply connection is a 3 8 ring lug bolted directly to the breaker terminal The return connection is bolted to the return bus bar using a two hole lug for 3 8 bolts 1 center to center Battery Strings Battery charge and battery return can facilitate eight sets of 2 hole lug wiring for 3 8 inch diameter studs on 1 inch centers Operator Panel Mounted in the system is a modular hot swappable controller which includes a high resolution 2 line digital display for monitoring of the Sageon III Base System output current and voltage Six push buttons are available for operating the Sageon III Base System selecting display information and for changing editable parameters A complete System configuration can be created at the operator panel Three System status LEDs are provided Communications PC based configuration and monitoring is available with the UNIPOWER SageView M software SageView is tool to exchange configurations and operating data between the Sageon III Base System and the PC on which SageView is running Local PC access is provided through a supplied USB B connector on the front panel of the controller using the SageView software Remote PC access across an Ethernet network is also standard The PC must be running SageView software and have a unique IP address on the network An Ethernet RJ 45 jack is provided for connecting to your company s PM990 8800 50 Issue 3 1 2 Sageon III Base System Introdu
144. ss the screens in reverse order 155A 54 2V Home screen FL 155A 54 2V indicates that the battery temperature compensation is active PES Ambient Temp Ambient temperature is displayed in degrees Centigrade 31 Ambient Temp Alarm Ambient temperature alarm level 3 Ph 1 Volts 3 Phase AC monitor voltage current and frequency 216V Use up arrow or down arrow to scroll through the three AC inputs for each parameter AC monitor option must be installed to view these screens Programmable parameters This series of screens contain programmable parameters To change a parameter value 1 Scroll to the desired screen using the up arrow or down arrow button 2 Press the ENTER button the selected value will flash 3 Use the up arrow or down arrow button to edit that value Press ENTER to store the new value or to move to the next number to be set in a series of numbers Volts High Alarm Float voltage high level Set to the desired high alarm value 57 5 Volts Low Alarm Float voltage low level Set to the desired low alarm value 48 0V Failsafe Alarms When Failsafe alarms are all alarm relays will be Failsafe Alarms normally energized when no alarm condition is present Relays will On de energize when an alarm occurs Battery current sensor When Battery current sensor is turned on the Bat Cur Sensor controller will read battery current from the installed
145. stem Front Matter EE 8 1 8 12 Installing the oe rado OE UD En ama mete ite dein p dtes er es 8 1 8 2 GJ1I TYPE BREAKER KITS teo e EAT E Reel VERI o E A PRETI 8 3 82 1 Kit Contents eoe REI GR REA EE D EUER Fette Uer Pe e 8 3 822 Instalmg the Kat 25 etu o RIA Ei bo nadie nie dedic emet eleg tette pre der Ub aa 8 3 9 0 SPARE AND REPLACEMENT 5 eee eee neee sesto sees suse ta ee nese nio nen sees snas esso notan 9 1 List of Tables TABLE 2 1 WIRE SIZING eter ert REIR ERR ERI ERR RIED EE Ve 2 4 TABLE 2 2 TORQUE SPECIFICATIONS STEEL FASTENERS nennen 2 4 TABLE 2 3 CIRCUIT BREAKER SELECTION AC POWER eterne enne rennen eene nnns 2 9 TABLE 2 4 BATTERY TEMPERATURE SENSOR CONNECTIONS essere ens 2 18 TABLE 2 5 BATTERY CURRENT TRANSDUCER CONNECTIONS i 2 20 TABLE 4 1 SUMMARY OF DEFAULT SYSTEM SCU PARAMETERS i 4 1 TABLE 4 2 READING OPERATOR PANEL SYSTEM STATUS LEDS 4 5 TABLE 4 3 OPERATOR PANEL ANNUNCIATED ALARM MESSAGES nne nnne 4 6 TABLE 4 4 SBM BOARDS NEEDED FOR VARIOUS BATTERY CONFIGURATIONS eee 4 2 TABLE 6 1 ALARM MESSAGES AND ERROR CODES
146. stribution assemblies using their output studs circled as points of reference Groups A amp B are always oriented as shown fe Er FIGURE 2 8 DISTRIBUTION AREA TOP VIEW AMI TYPE BREAKER DIST SHOWN PM990 8800 50 Issue 3 2 13 Installation Sageon III Base System 2 7 1 Load Return Cables Terminate all load return cables at the return bus loads shown in Figure 2 6 This bus is located on the right of the distribution area and consists of up to three vertically mounted plates The plates have pairs of 1 4 and 3 8 threaded studs for 2 hole lugging Use the 1 4 studs for lower current loads protected with AMI type breakers The 3 8 studs are for higher current loads protected by GJ1 type breakers 2 7 2 Load Supply Cables AMI Type Breaker Distribution Connect customer load supply cabling in order by Tier Group and position number as shown on the Breaker Fuse Layout label on the inside of the distribution area door Cables are routed toward the nearest rack corner and then upward as shown in Figure 2 9 Distribution x Cabling ST 5 5 z 5 8 2 LL zl pesi Fuse Alarm FA Wire Y ETE A Distribution Assemblies wo 5 Ss e O pem Bars Distribution Rack Left Side FIGURE 2 9 DISTRIBUTION CABLE ROUTING PM990 8800 50 Issue 3 2 14 Sageon III Base System Installation 1 Selecta st
147. the deep discharge voltage V dd Battery deep discharge voltage Vdd Vdd Level 21 0V Battery charging current limit Set the current when the battery voltage is between Vdd and the float voltage Vfl This current is cu typically higher than that for the deeply discharge battery 2 voltage Set the system output voltage at the output bus System Float 54 2V System voltage drop Set the maximum voltage drop as defined by maximum rectifier output system float voltage A typical value is System V Drop 0 6V 09 4 7 2 Equalization Equalization Equalization on off toggle On If equalization in off the following screens will not appear Battery charging current limit Set the maximum equalization BILim Vb gt Vfl charging current Vbattery gt Vfloat This applies when batteries are 25A being equalized Equalization voltage Set the maximum voltage reached during 2 a equalization of the batteries i PM990 8800 50 Issue 3 4 16 Sageon III Base System Configuration and Operation Equalization on off toggle Volts Start Eq Off ampere hour trigger On voltage trigger Equalization trigger voltage Set the voltage at which equalization Volts Eq Trig will be initialized during battery discharge 48 0V Equalization on off trigger i Volts Start Eq On voltage trigger Off Off ampere hour discharge trigger Equalization A h on off toggle tart E On ampere hour discharge trig
148. the securing latch spring clicks back down into place FIGURE 6 2 REMOVING RECTIFIER MODULE Latch PM990 8800 50 Issue 3 6 7 Sageon III Base System Distribution Option Kit Installation 7 0 DISTRIBUTION OPTION KIT INSTALLATION Distribution options included on the initial Power system order are factory installed To field install a distribution option follow the appropriate section in this chapter While it is recommended that the Power system be powered down before installing a distribution option an option can be installed in a live Power system when proper safeguards are observed A WARNING Arcing can cause equipment damage load interruptions and personal injury Arcing hazard Remove watch and jewelry Use insulated tools and extreme caution when working on a live Power system or on a battery string Insulate the free ends of any un terminated cables There are 6 distribution groups organized in three Tiers with two Groups in each Tier All are located in the Power system s distribution area as shown in Figure 7 1 The type of distribution that can be installed in each group is discussed below and listed in Table 7 1 Tier 2 amp Tier 3 can be field installed Figures 7 2 and 7 3 show typical left and right side views of the distribution area TIER Z E Lj CE _ X BE Lo E A 1
149. top for an overhead crane or other lifting equipment e Be careful not to bend or otherwise damage the side and rear panels e Be careful not to mar or otherwise damage the front bezels 3 Setthe Power system in place 4 Securely fasten the Power system to the floor 2 5 CONNECTING AC POWER TO THE POWER SYSTEM Connect single phase power through a circuit breaker to each input in plant See Section 1 2 7 Rectifier Specifications for voltage and current requirements See section 3 4 for more on connections Z Single Phase AC User s AC Electrical Power to Power Service Panel System A ground is required with the AC power connections for safety and for limiting EMI RFI emissions PM990 8800 50 Issue 3 2 7 Installation Sageon III Base System Plant Rack Ground the Power system rack to the site s central frame ground applicable in accordance with codes and the customer s standard practice Unthreaded holes for bolting an earth safety ground wire to the rack are provided in the top and bottom both on rear Remove the paint from a small area e g 1 5 in 3 8 cm diameter around the selected holes and through bolt the ground wire lug to the rack Return Bus Connect the plant return bus to the site s central office ground Select a cable size applicable in accordance with codes and the customer s standard practice The minimum cable size must be capable of carrying the fault current from any installed device Since this is
150. tor on an adjacent distribution assembly in daisy chair fashion Newly installed distribution assemblies must be connected in daisy chain fashion to a previously installed distribution assembly See Figure 7 4 Refer to Chapter 8 to install AMI circuit breakers fuses 7 2 GJ1 DISTRIBUTION TIERS 2 AND3 GROUPSA amp B This section describes installation of the GJ1breaker distribution option in Tiers 2 and 3 Groups amp B Installation of circuit breakers is described in Chapter 8 Figure 7 7 shows many of the components included in the kit Figure 7 6 shows GJ1 distribution assemblies in Groups A amp B It also shows the alarm wiring PM990 8800 50 Issue 3 7 6 Sageon III Base System Distribution Option Kit Installation Table 7 1 identifies the groups in which a GJ1 distribution assembly can be installed A assembly must be the topmost distribution assembly since other distribution types cannot be installed above a GJ1 assembly Distribution Assemblies uf N o o o o 9 3 o o o o o Tier 3 Grp A Tier 3 Grp B Fuse Alarm Fuse Alarm FA Wire FA Wire Tier 2 Tier 2 Group A Group B vf Distribution d Assemblies N DAD x c C 5 Tier 1 Tier 1 5 5 Group Group B D E E 8 9 gt Bus Bars 4 FIGURE 7 6 D
151. trays to the transducer Connect the cable to the transducer Direction of Positive Current Flow with Batteries Charging Top View 1 25 O li T 2 Dimensions 25 64 Connector Side View ME S le 6 152 gt FIGURE 2 15 TYPICAL BATTERY CURRENT TRANSDUCER TABLE 2 5 BATTERY CURRENT TRANSDUCER CONNECTIONS Battery Current Transducer Battery Distribution Module Board 1 X22 in Figure 3 12 2 X18 in Figure 3 12 3 X17 in Figure 3 12 X12 in Figure 3 12 2 11 SAGEON BATTERY MONITOR OPTION The UNIPOWER Sageon Battery Monitor SBM is an add on System for the Sageon III Control Unit SCU It is used to monitor individual cells of a battery during float or equalization operation or during a discharge Each SBM unit is capable of monitoring up to 24 cells or monoblocks Up to four SBM units can be used to monitor up to 4 battery strings of 24 cells or monoblocks each Using the ability of the SCU to communicate to a remote or local PC cell voltage data accumulated during a discharge can be transferred to a PC and saved The cell voltages can also be viewed in real time when the SCU is connected to a PC The SageView software that is running on the PC can display the cell voltage data in various convenient formats to ascertain the state of health of batteries In addition to the real tim
152. two 12 24x3 4 screws Position the bracket against the nearest vertical rack rail align the holes in the bracket with those in the rail and install the screws The bottom edge of the bracket extending into the pant should be approximately 1 5 3 8 cm above the horizontal leg of the L shaped bus bar Tighten the U shaped bracket mounting hardware See Table 2 2 for torque specifications Do not tighten the L shaped bus bar hardware at this time From the kit collect two painted 5 8 x7 1 2 breaker mounting bars four 10 32 x 1 2 Phillips head Screws Refer to Figure 7 7 and loosely mount the bars on the U shaped breaker mounting bracket From the kit collect the orange fuse alarm wire and temporarily drape it over the U shaped bracket This wire and the red alarm wire will be connected when type breakers are installed Repeat the above steps for each GJ1 distribution group to be installed Refer to Chapter 8 to install the GJ1 circuit breakers PM990 8800 50 Issue 3 7 8 Sageon III Base System Distribution Option Kit Installation GJ1 Circuit Breaker 4 Places uu 3 8 Nut and Flat Washer 0 N QD Load Supply Cable with 3 8 Lug and Output Terminal Hardware e Bracket Mounting Screw 12 24 x 3 4 2 Places Mounting Bracket U Shaped 3 8 1 Hex Bolt Bevel Washer Flat Washer Breaker Mounting Bar 2 Places Bus Bar L Shaped e N
153. typically a high current connection secure the wire lug to a 3 8 stud on the return bus battery or bolt the wire lug to 3 8 through hole on the return bus loads The return buses within the plant are electrically connected See Figure 2 3 for bus locations nn FIGURE 2 3 RETURN BUS LOCATIONS 2 5 1 Lightning and Transient Suppression Rectifiers contain basic transient suppression in the form of Metal Oxide Varistors MOVs MOVs are installed from L1 to L2 L1 to earth and L2 to earth They are sized to provide protection from line transients in an industrial environment according to ANSI C62 41 1991 for Class B3 equipment and 61000 4 5 Supplementary transient protection is needed in a more severe environment with for example a high incidence of lightning strikes indirect or direct and or severe switching transients beyond the levels indicated in the above standards Install higher rated suppression devices to the AC electrical service where appropriate PM990 8800 50 Issue 3 2 8 Sageon III Base System Installation 2 5 2 User s AC Electrical Service Panel The AC electrical service panel and wiring from the service panel to the Power system is supplied by the user 1 Electrical shock hazard Remove power from all involved wires and terminals before proceeding 2 Determine the number of AC breaker positions needed Allow one breaker position for each Rectifier to be installed in the Power system Alt
154. u receive the equipment it is your responsibility to document any damage the carrier may have inflicted and to file your claim promptly and accurately PACKAGE INSPECTION Examine the shipping crate or carton for any visible damage punctures dents and any other signs of possible internal damage Describe any damage or shortage on the receiving documents and have the carrier sign their full name If your receiving freight bill notes that a Tip N Tell is attached to your freight locate it If the Tip N Tell arrow has turned even partially blue this means the freight has been tipped in transport Make sure the carrier notes this on your receipt before you sign for the freight EQUIPMENT INSPECTION Within fifteen days open the crate and inspect the contents for damages While unpacking be careful not to discard any equipment parts or manuals If any damage is detected call the delivering carrier to determine appropriate action They may require an inspection SA VE ALL SHIPPING MATERIAL FOR THE INSPECTOR TO SEE After the inspection has been made call UNIPOWER We will determine if the equipment should be returned to our plant for repair or if some other method would be more expeditious If it is determined that the equipment should be returned to UNIPOWER ask the delivering carrier to send the packages back to UNIPOWER at the delivering carrier s expense If repair is necessary we will invoice you for the repair so that you ma
155. wer for the Controller and its peripherals 15 derived from the DC bus or the highest charged battery The Battery distribution module has reverse polarity protection circuit that also serves to provide an or ing of the highest supply voltage for the Controller No additional user connections are required to power the Controller or provide system voltage regulation if the battery distribution module is used 3 8 FRONT PANEL USB COMMUNICATIONS CONNECTION The front USB port on the Controller is configured as USB slave and has a B type connector A standard USB A to B cable is required The Controller can only communicate via the USB port to a PC running the Sageview software PM990 8800 50 Issue 3 3 11 Commissioning Sageon III Base System The USB connection requires that a USB driver be installed on the PC The first time the Controller is plugged into the PC via the USB port a Microsoft amp Windows dialogue box will appear asking the user to install the Controller USB Interface drivers The Microsoft Windows operating system should be able to find the drivers automatically on the Sageview CD ROM assuming it is in the CD ROM drive of the PC If Sageview is running when the unit is plugged in a Windows dialogue box will appear asking the user if they wish to connect to the unit immediately Otherwise the user will need to select the Controller from the available controller USB devices in USB section in the Connection Setup
156. wer section of the unit IMPORTANT Do not change the factory set rectifier position address The address is set on the AC Backplane board PM990 8800 50 Issue 3 2 9 Installation Sageon III Base System zu System dL ESSA 39 A El HH E E E E ENEE E W amp W L1 L2 1 Line1 SEN ne mri IE TEN Sn Line2 PINE eeeh APT ASPIRE NT ME Ground j User Wiring AC Cable from User s AC Electrical Service Panel FIGURE 2 4 AC INPUT CABLING WITH RECTIFIER ON OFF OPTION 2 6 CONNECTING BATTERY CABLES Routing the stiff heavy gauge battery cables is difficult Two people may be needed Exercise extreme caution to avoid a short circuit across the battery terminals A WARNING Arcing hazard Arcing can cause equipment damage load interruptions and personal injury Remove watch and jewelry Use insulated tools and extreme caution when working with a battery string Carefully insulate unterminated battery cable ends At the Power system battery cables connect to the battery charge bus and return bus Three battery charge an
157. with an alarm showing since all Rectifiers are Off The factory installed or uploaded configuration will specify the number of Rectifiers See Table 4 1 for default parameters and values e Ifa battery string is not connected or the string cannot supply sufficient power the SCU will not be operating There will be no operator panel display or lighted LEDs until a Rectifier is started later in this Section Ensure that the circuit breakers in the user s AC electrical service panel are Off Disconnect all loads from the system by turning Off all load breakers The Rectifier On Off breaker of each Rectifier is set to Off See Figure 2 4 Turn On power to Rectifier 1 The top most left Rectifier in the stack will perform a power up self test lighting the three LEDs on the rectifier After a brief period the red and yellow LEDs will extinguish and green LED will remain lighted Float mode Refer to the following note and to Section 6 3 Troubleshooting should the red or yellow LEDs remain lighted Yellow LED Note When starting the System for the first time it may be necessary for the rectifiers to supply significant current for initial battery charging A lighted yellow LED on a rectifier may not be due to a rectifier problem but rather indicate that the rectifier is operating in the over current mode due to a discharged battery string If this is the case continue with the procedure to bring additional Rectifiers on line Read the rectifier cu
158. y submit the bill to the delivering carrier with your claim form It is your responsibility to file a claim with the delivering carrier Failure to properly file a claim for shipping damages may void warranty service for any physical damages later reported for repair HANDLING Equipment can be universally heavy or top heavy Use adequate humanpower or equipment for handling Until the equipment is securely mounted be careful to prevent the equipment from being accidentally tipped over NAMEPLATE Each piece of UNIPOWER equipment is identified by a part number on the nameplate Please refer to this number in all correspondence with UNIPOWER PM990 8800 50 Issue 3 ii Sageon III Base System Front Matter 5 INITIAL SETTINGS All equipment is shipped from our production area fully checked and adjusted Do not make any adjustments until you have referred to the technical reference or product manual 6 SPARE PARTS To minimize downtime during installation or operation we suggest you purchase spare fuses circuit boards and other recommended components as listed on the Recommended Spare Parts List in the back of the product manual If nothing else we strongly recommend stocking spare fuses for all systems PM990 8800 50 Issue 3 iii Front Matter Sageon III Base System ISSUE HISTORY Page n Approved Issue Sections Description Date Altered 3 Updated manual with UNIPOWER logo amp verbiage DBW See E

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