784300 mcu manual
TRANSCRIPT
Date Name Stdmanual Issued: 1-12-2000 TBII-Fr/Bp Page 1/49 pages Revision: Checked: 1-12-2000 TB-Enck
Monitoring System MCU 1000
1 General remarks............................................................................................. 2
2 Safety notes and symbols .............................................................................. 3
3 Description of function.................................................................................. 6
3.1 Hardware ....................................................................................................... 8
3.1.1 Basic unit MCU 1000.................................................................................... 8
3.1.2 Display and operating panel .......................................................................... 9
3.1.3 Relay board (optional)................................................................................. 12
3.2 Software....................................................................................................... 13
3.2.1 System-internal software ............................................................................. 13
3.2.2 User software............................................................................................... 14
3.3 Battery test / capacity test............................................................................ 26
4 Description of unit ....................................................................................... 29
4.1 Basic unit MCU 1000.................................................................................. 29
4.2 I²C-Bus components .................................................................................... 38
4.3 Technical data.............................................................................................. 39
5 Operating instructions ................................................................................. 40
6 Appendix ..................................................................................................... 41
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1 General remarks
The Remote Monitoring System MCU 1000 is a microprocessor-controlled monitoring and control device. With this system, it is possible to monitor and control all the main components of a power-supply system.
The link with the "outside world" is created via the serial interface. The MCU 1000 can be connected directly to a computer (PC). The installed service and monitor software allows comprehensive monitoring and controlling of the power-supply system. If the control desk is not local, the link with the com-puter can be created through the public telephone network using a modem.
The Remote Monitoring System MCU 1000 therefore allows more rational and efficient employment of maintenance and service personnel.
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Please read this description thoroughly, paying particular attention to the notes on safety.
2 Safety notes and symbols
International electrical symbols and display and operating symbols are marked on the unit. They have the following meanings:
Ready for use
Fault
Modem interface
Service-interface
battery operation
Alarm
urgent alarm
Supply voltage / input
Digital input
Voltage-measuring channel / input
I
Current measuring chanel / input
T
Temperature-measuring channel / input
0
1
4
+24V200mA +24V-supply / output
+12V500mA +12V-supply / output
GND / common reference potential
The following symbols are used to draw attention to certain passages in these instructions.
Indicates instructions which must be followed to avoid material damage.
Indicates instructions which must be followed to avoid danger to persons!
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The MCU 1000 is designed as a fitted unit. It is an electronic de-vice which requires dangerous levels of voltage and current.
The following instructions must therefore be followed at all times!
1. Installation, operation and maintenance of the MCU 1000 should be car-ried out in strict accordance with the instructions in this document.
2. Ensure that only fully qualified and authorised personnel have access to the unit. Only qualified and authorised personnel should be able to open the unit.
3. When working with the unit, use only properly insulated tools which are approved for the voltages in question.
4. All persons working with the unit must be familiar with first-aid meas-ures for accidents involving electricity.
5. Always observe the regulations of the local power-supply company as well as other safety regulations.
6. The passwords used for programming the unit must not be disclosed to unauthorised persons.
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3 Description of function
To start up and operate the MCU 1000 safely, it is not essential to be ac-quainted in detail with all the points described in this chapter. However, a knowledge of the function of the main parts of the unit is of considerable assis-tance in understanding the system and may help to avoid operating errors when it is in use.
Almost every component of a power-supply system can be monitored and con-trolled by the MCU 1000. The most comprehensive monitoring and control features exist with units which are fitted with a special interface board (Satel-lite). In this case, the MCU 1000 communicates with the various units via a data bus, the "SAT-BUS". A maximum of 24 rectifiers can be addressed via the SAT-BUS.
Units which do not have this Satellite can be converted for "SAT-BUS" by means of a substitute Satellite. With these units, the number of monitoring and control functions through the MCU 1000 are slightly restricted. Rectifiers which cannot be used with "SAT-BUS" can be influenced through the contacts of the signal relay of the MCU 1000 (e.g. by switching the characteristic of the rectifier).
The entire monitoring and controlling concept for the power-supply unit is ex-actly specified in advance. This makes it possible to configure the MCU 1000 without difficulty (i.e. to set and install the specific software).
Temperature sensors and shunts are integrated at appropriate points of the power-supply unit to measure and monitor temperatures and current levels.
The power-supply unit can be controlled and monitored through the public telephone network by means of a modem (optional).
The main functions of the MCU 1000 are shown in the following schematic circuit diagram.
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1 Unit with satellite 8 Display and operating panel 2 Service-PC 9 Relay board (optional) 3 Control desk 10 Digital inputs 4 Modem 11 Measuring channels 5 MCU 1000 basic unit 12 Potential-free signals 6 LED board 13 Potential-free signals 7 LCD board
Fig.1 : Schematic diagram of the Remote Monitoring System MCU 1000
1 SAT-
B US
( RS
4 85
)
I² C-B
US
2
4
RS 2
3 2
RS 2
325
3
10
21T/
II
U8
11
76
8
9
12
3
12
71
2
13
8
3.1 Hardware
This section deals only with the components which are actually part of the MCU 1000 system. These are marked in the schematic circuit diagram.
3.1.1 Basic unit MCU 1000
The basic unit MCU 1000 includes:
- a basic board with processor unit, measuring channels, digital inputs and relay signals;
- a DC-DC converter for supplying the internal components
- and the plug periphery.
Serial interfaces
The communication with the individual components of the power-supply unit and the outside world (control desk, service and maintenance personnel) takes place via the serial interfaces of the MCU 1000.
SAT-BUS interfaces
Data is transferred to the SAT-BUS via the interfaces X3 and X4 in accordance with the standard RS 485. This data bus allows all the SAT-BUS compatible components to communicate with one another. Here the signal codes (e.g. for characteristic switchover, unit fault, remote switch on etc.) are transmitted to and from the addressees.
Modem-interface
A serial interface to standard RS 232 is fitted at X5 to link the system with the public telephone network. The interface operates at a baud rate of 9600.
Service interface
The MCU 1000 and the local error interrogation take place via the serial inter-face X6 which also operates in accordance with standard RS 232. This inter-face operates at the same baud rate as the modem interface.
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I²C-Bus interfaces
Additional peripheral components are connected to the MCU 1000 at interfaces (X13, X14). These are the display and operating panel with LED and LCD boards and an additional optional relay board.
Digital inputs
To allow monitoring of the various components of the power supply system, their signal contacts are connected to the digital inputs of the MCU 1000. These signal contacts switch the 24-V supply which is supplied specially for this purpose to the digital inputs.
All eight inputs are equivalent in their function. They only receive their mean-ing in combination with the configuration data which are a result of the signal-ling philosophy chosen for the power-supply unit. This configuration file is loaded into the MCU 1000 via the service interface with the service software.
Analogue inputs
The standard MCU 1000 is fitted with three analogue inputs (measuring chan-nels). One current, one voltage and one temperature are recorded. An alterna-tive version has one measuring channel for voltage and two for current.
Relay signals
Three relays each with a potential-free change-over contact are provided for fault signals transmitted by wire. The meaning of the signals provided depends on the signalling philosophy and is therefore determined by the configuration file.
3.1.2 Display and operating panel
Faults and operating status (LED board) and measurement values (LCD board) are indicated or signalled on the display and operating panel, which is also used for changing threshold values, settings, charging status, battery test etc. (via keyboard on the LCD board).
The hardware design and the standard configuration (meaning of LED signals) have been modified as of 09/99. The previous ver-sions are explained in the appendix.
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DC-Power-Supply
E C
48 V132 A
green Float charge
yellow Boost charge
yellow Battery test
red Error U < 2,1 V/cells
red Battery test negative
red Mains fault
red Rectifier fault
red Battery discharged U <1,85 V/cells
red Battery discharged U <1,80 V/cells
red Battery fuse triggered
red Load fuse triggered
red Modem fault
red (Reserve)
LED test/ reset
Fig. 2: Display and operating panel (version 09/99). The LED function corre-sponds to that of the standard configuration.
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LED board
The meaning of the 3 LEDs is established by the configuration file and depends on the signalling philosophy of the unit. The general meaning is however fixed according to the colour of the LEDs by the standard IEC 73/DIN VDE 0199. The following therefore applies:
RED Danger or alarm Warning of potential dangers or states which require immediate action or close observation of the status in question.
YELLOW Caution Changes or imminent changes in the normal operating statuses.
GREEN Safety Indication of safe operating conditions or release for further operation.
A function test of the LEDs and the LCD board can be carried out with the push button on the LED board. If the button is pushed for at least 3 seconds, all the LEDs light up. At the same time, all the segments in the LCD display are activated alternately and the current software version of the MCU 1000 indi-cated.
LCD board
On the operating pad of the LCD board, all the release states and measurement values of the current supply unit can be displayed or set. Critical menu levels are accessible by means of a password only. The operation and function of the input buttons and the meaning of the states and values indicated will be ex-plained later in more detail.
The meaning of the four LEDs on the display and operating panel version of 09/99 is permanently defined.
operation battery operation
alarm urgent alarm
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Note: In systems with SAT rectifiers, the signal "Battery operation" is controlled by the calculation of the battery current. If the battery current is negative (battery is being discharged) the LED "Battery operation" lights up and the LED "Operation" goes out.
In systems with standard rectifiers (without satellite) voltage-dependent monitoring is carried out. Battery operation is assumed when UBatt. <2,1V/Z and there is a mains-supply or rectifier fault. Normal operation is again assumed when UBatt. again rises above 1,95V/Z and not mains-supply or rectifier fault exists.
3.1.3 Relay board (optional)
When the relay board is connected to the I2C bus, another seven relays each with a potential-free changeover contact are available in addition to the three relays of the basic unit. The meaning of these signals is fixed via the configura-tion file depending on the signalling philosophy.
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3.2 Software
With the software for the MCU 1000, a distinction is made between the sys-tem-internal software and the user software. For proper operation of the MCU 1000, the system-internal software is required. With the user software, a num-ber of established set values can be changed and the entire power supply sys-tem monitored.
3.2.1 System-internal software
The system-internal software includes the operating system ("MCU 1000 soft-ware") and the configuration files.
Operating system
The operating system is stored in a memory component on the main board of the basic unit. This software carries out and monitors the entire data traffic on the SAT-BUS, the I2C bus and with the external modem. Measurement values are processed and data conditioned. The MCU 1000 cannot function without this software. The user cannot influence or change this software. It is the same for all MCU 1000 remote monitoring systems.
Configuration data
The configuration data are fixed when the entire control and monitoring con-cept and the signalling philosophy of the current supply unit are specified.
In this way, logical links are created between signalled states or events. The ex-isting 96 digital inputs are divided into actual physically existing inputs and any other events (virtual inputs).
In addition, up to 5 limit-value monitoring systems can be set to any measure-ment values, on the result of which further actions can be taken either immedi-ately or with a delay.
During first start up of the power-supply unit, the entire configuration is set by the manufacturer. The data are transferred to a memory component on the main board of the basic unit via the service interface with the service software.
If no special configurations are requested by the customer, a standard configu-ration is carried out.
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3.2.2 User software
By means of the user software, the current supply unit can be monitored and set either locally or by modem from a remote control desk. Depending on the au-thorisation of the operator, changes can be made by means of passwords.
Monitor software „TEBE McuMonitor“
The MCU monitor software „TEBE McuMonitor“ permits remote monitoring and remote diagnosis of different power-supply units in a number of different locations. Extensive information can be stored on each of the units being moni-tored to allow a fast and accurate response in case of corrective action. This may be (for example) the telephone and fax number of the location of the unit, its operator, persons with authorised access to the unit, or service centres. In addition, it is also possible to store photographs or maps or descriptions of how to reach the unit location. Data on the unit itself such as the types of battery used, configurations, circuit diagrams of the current-supply unit, and a log book of its history allow a fast and effective response.
Service-Software „TEBE McuService“
This software „TEBE McuService“ is used locally by service personnel. It may be installed in the laptop of a service employee who would connect the computer to the service interface of the basic unit of the MCU 1000. In contrast to monitor software, this software can be used to carry out extensive alterations to the current-supply unit. It is possible to change configurations and, for ex-ample, parameters for a battery test as well as to switch rectifier characteristics on the rectifier modules.
"TEBE McuMonitor" and "TEBE McuService" are independent products and are not supplied as part of the standard MCU 1000.
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Operation of the display and operating panel (from Version 1.11)
The power-supply system can be monitored and adjusted without a monitor or service software. The operation of the display and operating panel and the meanings of the individual menu items from software version 1.11 onwards are described below. For information on previous software versions, please refer to the appendix to these operating instructions.
The menu levels and items with allow monitoring and adjustments or settings to be made, can be accessed using the 4 buttons beneath the display.
E C
Fig. 3: LCD-board with buttons
Button Function
DOWN UP
Selection of individual menu items within a menu level
Changing values within the individual menu items.
ENTER
Selection of the next menu level, password request or menu item.
Storage of set or changed values.
CANCEL
Quit one menu item without storing values.
Return to next higher menu level.
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2
1
4
3
6
5
1 Standard display 2 Menu level 0 3 Password enquiry menu level 1 4 Menu level 1 5 Password enquiry menu level 2 6 Menu level 2
Fig. 4: Menu structure of display and operating panel
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Fig. 4 gives an overview of the entire menu structure. If the buttons of the LCD board are not activated, the standard unit alternately displays e.g. the present current and voltage of the current and voltage measuring channel of the basic unit. The display depends on the display settings made via menu item .
By pressing the ENTER button, a menu item of menu level 0 is selected. The return is always to the menu item from which the last return to the standard display took place.
All menu items of menu level 0 are accessible without a special password.
Menu level 0:
Menu item / sub-menu item
Meaning:
A maximum of 124 readings of the power-supply system can be accessed. When the ENTER button is pressed, the display goes to a measuring channel. After 2 seconds a reading ap-pears in the display. By pressing the UP and DOWN button, the next measuring channel is shown in the display. Examples:
The only measuring channels and readings to be displayed are those which are actually in use in the configuration of the unit.
The logical status of up to 96 digital inputs is displayed. The next digital input is displayed by pressing the UP and DOWN button.
Example:
Logical status of digital input 0: input inactive 1: input active (essential for program running) Input is evaluated in inverted sequence Number of digital input
The status of the signalised SAT-BUS components is dis-played. Up to 31 components including the basic unit can be
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addressed. The next address is reached by pressing the UP or DOWN button. The status of the SAT-BUS user appears approx. 2 seconds after display of the address. The status is displayed in form of a hexadecimal code which represents a 16-bit code.
The type of address display gives information on the type of SAT-BUS user.
Example:
Address of "master"
Address of on-board measurement board
Address of any other SAT-BUS user
Menu level 1 can be accessed via this menu item by means of a password enquiry.
This menu item is for carrying out an LED test of the display and operating panel and setting the standard measurement-readings in the display.
All the LEDs on the LED board are activated for approx. 1 minute (continuous operation). At the same time, all the dis-play segments and the current software version of the MCU 1000 are shown alternately. The test can be aborted by press-ing the CANCEL button.
When the ENTER button is pressed, the first measurement-reading channel of the standard display is shown. Other meas-urement-reading channels can be selected by pressing the UP and DOWN button. The setting change is acknowledged by pressing the ENTER button.
This is for setting the second measurement-reading channel, which should appear in the standard display.
Menu level 2 can be accessed via this menu item by means of a password enquiry.
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Menü level 1( Remote commands):
This level can only be accessed via menu item and by entering a pass-word in menu item . The password is a number between 000 and 999 and is selected using the UP and DOWN buttons.
The standard password set by the manufacturer for menu level 1 is "001". This prevents accidental incorrect operation. The customer is advised to change this password as soon as possible.
Menu item / sub-menu item:
Meaning:
Initiate battery test.
End battery test.
Switch rectifier to "boost charge".
Switch rectifier to "float charge".
Switch rectifier to "direct feed".
• • •
Carry out relay test on up to ten available relays on the base unit and relay board.
The above menu items appear only if these remote commands are released via the service software.
Menu level 2:
This level can only be accessed via menu item and by entering a pass-word in menu item . The password is a number between 000 and 999 and is selected using the UP and DOWN buttons.
The standard password set by the manufacturer for menu level 2 is "002". This prevents accidental incorrect operation. The customer is advised to change this password as soon as possible.
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Menu item / sub-menu item:
Meaning:
Input of rated value of shunt connected to the current-measurement channel of the base unit (X1:21; X1:22) (e.g. 60A)
Input of rated value of shunt connected to terminals X1:23 and X1:24 of the base unit (only for versions with 2 current-measurement channels).
Input of number of cells of the battery system of the power-supply system e.g.: 48V system: 24; 60V system: 30
This menu item is for transferring to the sub-menu for setting various delay and waiting times.
Input of delay time in seconds after which an urgent alarm sig-nal should be given.
Input of delay time in seconds after which a non-urgent alarm signal should be given.
Input of delay time in seconds after which a central alarm signal should be given.
Input of duration of relay test in seconds.
Input of delay in seconds, following which a modem connection between the MCU 1000 and a control stand should be cut off if the control stand does not respond.
Input of delay in seconds, following which a new connection should be created in case of engaged line.
This menu item is for transferring to sub-menu for setting pa-rameters for a battery test.
Input of duration of a battery test in minutes.
Input of cut-off voltage of a battery test in volts per cell.
Input of measurement channel through which battery-test volt-age of battery circuit 1 is recorded.
Input of measurement channel through which battery-test cur-
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rent of battery circuit 1 is recorded.
Input of measurement channel through which battery-test volt-age of battery circuit 2 is recorded (correct configuration flag must be set).
Input of measurement channel through which battery-test cur-rent of battery circuit 2 is recorded (correct configuration flag must be set).
Input of time interval in which another automatic battery test should be initiated. The time specified is in minutes, hours, days, months and years (correct configuration flag must be set).
Input of date on which a first battery test should be carried out. After this, more battery tests are carried out at the specified in-tervals. If the date for the first battery test is invalid, the time is calculated from the first start-up. The date is given in minutes, hours, days, months and years (correct configuration flag must be set).
Display of the next starting date for an automatic battery test. The time is specified as time of day, day, month and year. The start time is calculated from the data previously input (correct configuration flag must be set).
Input of measurement channel to which the battery sensor is connected which transmits the current battery voltage to the charging rectifiers (correct configuration flag must be set).
Input or display of system time in day, month, year, hours, min-utes.
This menu item is for setting the configuration flags. Of the 16 flags which can be set, 8 are presently in use. When ENTER is pressed, the individual flags are displayed and their status can be altered.
The following configuration flags exist:
not in use
0: Modem connected
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1: No modem connected
0: No battery-sensor operation 1: Battery-sensor operation
0: No automatic battery test possible 1: Automatic battery test possible
Check sum formation for responses of service and modem interface (must always be 0)
0: SAT rectifiers are included in system. One of the SAT rectifiers has the master func tion. Exchange of information between SAT rectifiers is possible.
1: No SAT rectifiers are included in system. The MCU itself has the master function.
0: On-board current-measuring channel 1 is not inverted. 1: On-board current-measuring channel 1 is inverted. (necessary depending on shunt connection; if X1.21=-SH )
Condition: 3rd measurement channel is current- measurement channel 0: On-board current-measuring channel 2 is not inverted. 1: On-board current-measuring channel 2 is inverted. (necessary depending on shunt connection; if X1.23=-SH )
0: The battery test can only be carried out for one battery circuit. 1: The battery test is carried out for two battery circuits. The battery-test parame ters for the second battery circuit must be set.
• • • Not for use
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This menu item is for evaluating the error and link masks of the urgent, non-urgent and central fault signals.
This causes a hexadecimal code to be read out which stands for a 16-bit code. This 16-bit code (error mask) is compared regu-larly with the status of each SAT-BUS user (LSB: lowest-value bit; MSB: highest-value bit)
Meaning of set bits:
LSB 0 Satellite currently in self-test (not an error) 1 Module currently in configuration phase ( not an error ) 2 Watchdog reset ( correctable error ) 3 Bus error 4 Master time out 5 Ventilator fault (force-ventilated units only) 6 System has received invalid command ( correctable error ) 7 Power failure ( mains and battery voltage ) 8 Error in battery-temperature sensor 9 Power-supply error 10 User does not respond 11 Module failed or defective 12 Module switched off due to overvoltage 13 Module switched off due to overheating 14 Module switched off via switch or remote on/off switch MSB 15 Not in use
A hexadecimal code can be read out. The result of the compari-son between the error mask and the status of a SAT-BUS user is compared with this hex code. Depending on the result, an urgent fault signal is given.
A hexadecimal code can be read out. The result of the compari-son between the error mask and the status of a SAT-BUS user is compared with this hex code. Depending on the result, a non-urgent fault signal is given.
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A hexadecimal code can be read out. The result of the compari-son between the error mask and the status of a SAT-BUS user is compared with this hex code. Depending on the result, a central fault signal is given.
If released through service software, the 5 limit-value monitor-ing relays can be programmed or read out via this menu item. The settings are carried out in the same way for all relays
• • • . The following settings should be made:
This dials measurement-channel number whose readings are to be monitored.
Input of lower limit value to be monitored Input of upper limit value to be monitored Input of hysteresis band width. This value applies
for the upper and lower limit value.
This menu item is for selecting the "hold" functions of the LEDs.
• • •
A hold function can be set for all 18 LEDs of the display and operating panel. When the event which has caused the LED to light up no longer exists, the LED goes into the flashing status (hold status). This status is re-set using the re-set button of the display and operating panel.
This menu item is for selecting the "hold" functions of maxi-mum 10 relays.
• • •
A hold function can be set for all 10 relays (3 relays on base unit, 7 relays on optional relay board). When the event which has put the relay in the active state no longer exists, the relay remains in this active state (hold status). This status is re-set us-ing the re-set button of the display and operating panel.
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Specification or alteration of a password (000 ... 999) with which menu level 1 is accessed. If "000" is specified as pass-word, no password enquiry is made for this menu level, i.e. no password protection.
Specification or alteration of a password (000 ... 999) with which menu level 2 is accessed. If "000" is specified as pass-word, no password enquiry is made for this menu level, i.e. no password protection.
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3.3 Battery test / Capacity test
The battery test incorporated in the MCU 1000 permits all the rectifier units to be switched from the float-charge characteristic to the battery-test characteris-tic. This procedure means that the consumers connected are supplied from the battery for the duration of the programmed test period. As the consumer current (discharge current of battery) and the discharge time are continuously meas-ured and recorded, an estimate of the availability of the battery can be made on conclusion of the test phase.
Important! In the battery test characteristic, the voltage of the rectifier is re-duced and not switched off. For this reason, no critical situation for the consumers occurs at any time.
The abort voltage and the duration of the battery test can be set at the display and operating panel or using the service software TEBE McuService.
Important! Before a battery test can be carried out, the following two setting options must be made:
1) The automatic-charge feature of the SAT rectifiers must be activated. 2) The power management feature of the SAT rectifiers must be switched off
These settings can be changed:
1) Locally via the rectifier satellites (see operating instructions 96/2801). This setting must be made separately for each rectifier.
2) Locally via the service software TEBE McuService (see operating in-structions 99/3293)
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The battery test can be activated in three different ways.
1) Locally via the display and operating panel
2) Locally via the service software TEBE McuService
3) From a central control stand by modem with monitor software TEBE McuMonitor
Important! If an automatic battery test is being carried out via the MCU 1000, the option "Automatic battery test" must be released.
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Fig. 5: Battery-test procedure
Operation The rectifiers are operating on the float charge characteristic. Automoatic charging must be activated.
Battery test start Automatic switch over by all recti-fiers from the float charge charac-teristic to the battey-test character-istic.
Battery test active During the battery test phase, the consumer current and the dis-charge time are measured and stored.
UBatt. ≤ UAbbruch
Battery test end The abort voltage was not achieved in the specified time
Battery condition o.k. MCU 1000 reports that battery ok and gives the capacity withdrawn in Ah.
Battery test aborted The abort voltage was achieved be-fore battery-test time expired
Battery condition not ok. MCU 1000 reports that battery not ok and gives the capacity with-drawnup to that point in Ah.
yes
no
Switch back Switch back to float charge charac-teristic. No defined charging phase
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4 Description of unit
4.1 Basic unit MCU 1000
The basic unit of the MCU 1000 is the core of the remote monitoring system. In order to ensure safe and reliable operation, all the instructions with regard to plug assignment, contact loads, connection cables etc. must be strictly ob-served.
Mechanical installation
The MCU 1000 can be installed in four different ways.
1) 1/4 - 19“ - plug-in module, 6 HE 2) 1/6 - 19“ - plug-in module, 6 HE 3) door installation on bracket 4) cabinet installation on plate
MCU 1000
71
266
Fig. 6: Front panel of the 1/6 - 19“ plug-in module
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X1
207
231.5
X13
223
X14
121
3.6
30
X 3 X4
35
X6 X5
65
43.577
285
230
242
6
14.5
3216
65.5
117
160.5
3665
Fig. 7: Dimensional diagram of basic unit for door or cabinet installation
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Electrical installation
Depending on the amount of supply voltage, a distinction is made between two types of voltage. The two types cover the voltage ranges 18 VDC ... 75 VDC or 75 VDC ... 270 VDC.
Visual signals given by basic unit
The operating status of the basic unit is indicated by two LEDs. They signal readiness for use or a fault.
GREEN Ready (if power supply connected)
RED Fault (glows continuously for urgent fault, flashes for less urgent fault)
Serial interfaces:
SAT-BUS interfaces X3, X4
The RS 485 interfaces are 4-pole round connectors.
All SAT-BUS compatible components communicate with one another via these interfaces.
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SAT-BUS compatible components are as follows:
• All parts of the power supply system which are normally fitted with a "Satellite".
• All units and components which are fitted with a "substitute Satellite".
• The basic unit of the MCU 1000.
Due to the selected standard RS 485 there are no restrictions with regard to the data-cable lengths within the power-supply unit.
Modem interface X5
The RS 232 interface is a 9-pole SUB-D plug (male, pin contacts).
The plug is marked with the symbol:
The following contact assignments apply:
UNC 4-40
UNC 4-40
97
68
12
34
5
PIN 1:DCD PIN 2:RxD PIN 3:TxD PIN 4:DTR PIN 5:GND PIN 6:DSR PIN 7:RTS PIN 8:CTS PIN 9:NC
Trägersignal erkannt, Verbindung aufgebaut Daten empfangen Daten senden Terminal bereit Masse Daten bereitgestellt Auffordern zum Senden Bereit zum Senden nicht belegt
Data Carrier Detect Contact established Receive Data Transmit Data Data Terminal ReadyGround Data Set Ready Request to Send Clear to Send Not Connected
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The interface cable for the modem connection is generally supplied with the modem. The following ready-to-use cables can be used as alternatives:
T.Nr.: 734871 cable connection MODEM (0,25 m) T.Nr.: 539523 cable connection MODEM (1 m)
Service interface X6
The RS 232 interface is also a 9-pole SUB-D plug (male/pin contacts).
The plug is marked with the symbol:
The contact assignment is identical to that of modem interface X5.
The interface cable for the service PC is a twisted RS 232 cable. Both ends of the cable must be fitted with 9-pole SUB-D sockets (female).
It is advisable to use a standard "zero modem cable" as both 9-pole D-SUB sockets have equal contact assignments and the cable can be twisted.
A fully ready-to-use cable can be ordered under the following number:
T.no.: 734624 Link cable RS232/DB9 FEM./FEM. 3m
I²C-Bus-interfaces X13, X14
The plugs X13 and X14 serve to connect the system-internal components, the display and operating panel and the relay board (optional). This interface offers an unstabilised 8V voltage.
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Contact assignment of plugs X13 and X14:
54321
PIN 1: +8V PIN 2: SDA PIN 3: SCL PIN 4: I²C-Int. PIN 5: GND
Serielle Datenleitung Serielle Taktleitung I2C-Unterbrechungsanforderung Masse
Serial Data Serial Clock I2C-Interrupt Ground
Connection terminals X1
For all the screw terminals on the two terminal strips of X1, the clamping area is between 0.2 mm2 and 2.5 mm2 (AWG 24 to AWG 12).
If no measurement shunt is connected, a bridge must be set between XI:21-XI:22 and XI:22-XI24.
If a measurement shunt is connected, a bridge must be set between XI:22-XI24.
20 4
32
29
30
31
21
27
28
22
23
24
25
26
15
16
13
14
5
11
12
6
7
8
9
10
19
17
18
X1
3
1
2
X4
X3
272829
303132
1920212223242526
1718
X1
111213141516
3456
78910
12
Fig. 8: Connection terminals X1
To avoid confusing the two connector strips, both the plugs are coded.
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Contact: Contact allocation: 1,2,3 relay signal K1 4,5,6 relay signal K2 7,8,9 relay signal K3 10,11 not in use 12 digital input 1 13 digital input 2 14 digital input 3 15 digital input 4 16 digital input 5 17 +Vbatt / supply 18 +Vmeas / analogue measurement input - voltage 19 -Vbatt / supply 20 -Vmeas / analogue measurement input - voltage 21 +shunt (-shunt) / analogue measurement input - current 22 -shunt (+shunt) / analogue measurement input - current 23 +temp. / analogue measurement input - temperature (+SH/-24 -temp. / analogue measurement input - temperature (-SH/+SH) 25,26 not in use 27 GND 28 +12V / supply voltage for external components 29 +24V / supply voltage for digital inputs 30 digital input 6 31 digital input 7 32 digital input 8
Supply voltage X1:17(+); X1:19(-)
Depending on type, the supply voltage is between 18 VDC - 75 VDC resp. 75 VDC and 270 VDC.
The maximum input power is 25 W.
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Digital inputs 01
X1:12...16; X1:30...32
The +24V supply is switched to the digital inputs via external switch contacts. These contacts may be (e.g.):
Fault-signal contacts between individual units and parts of the system Battery-fuse monitoring devices Service switches Door contacts Total-discharge monitoring devices etc.
Important! Avoid connecting external potential to ensure that the interfaces of the MCU remain potential-free.
The starting current for a digital input is approx. 10mA, which then drops to <1mA after a short time. For this reason, the switch contacts are not subject to any special requirements.
The inputs are potential free with reference to earth and battery. However, they are connected to one another by means of a common GND.
Analogue inputs
X1:24
X1:21X1:21
-
3
4X1:23
X1:22
X1:21
+
X1:22
1
+-
X1:18 X1:20
2
1 With connection of shunt to positive circuit; X1:21(+SH)/X1:22(-SH) 2 X1:18 (+Vbatt.)/X1:20 (-Vbatt.) 3 With connection of shunt to negative circuit; X1:21(-SH)/X1:22(+SH) 4 X1:23 (+temp.)/X1:24 (-temp.)
Fig.9: Connection of analogue inputs
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Important! The measuring channels are not separated from one another gal-vanically
Current-measuring channel: I
X1:21(+/-); X1:22(-/+)
In order to measure the current, a 60 mV shunt must be connected to the meas-uring-current circuit. It may be either in the positive or negative circuit. If the shunt is connected in the minus circuit, the prefix bit in question must be changed using the service software or via the display and operating panel. The maximum measuring current is equivalent to approximately 1.8 times the rated current.
Voltage-measuring channel: U
X1:18(+); X1:20(-)
The voltage measuring range is between 0 VDC and 270 VDC.
Temperature-measuring channel: T
X1:23(+); X1:24(-)
To measure temperature, a special temperature sensor is required. Depending on type and location of the temperature to be measured, various ready-to-use cable connections with integrated sensor are used.
Relay signals
The contacts of these potential-free signals can be loaded with 250 VAC / 8 A.
Contact assignment: X1:1...9
The contact position shown in the diagram corresponds to the currentless relay state.
24V-Supply,12V-Supply, GND
max. 250VAC/8AK1;K2;K3
2;5;8
1;4;7
3;6;9
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The +24V supply +24V200mA (X1:29) is for the digital inputs. The maximum
load is 200 mA.
The 12V supply +24V200mA (X1:29) is for supplying external components.
These may be: relay board, modem. The maximum load on this output is 500 mA.
GND (X1:27) forms the common reference potential for both supply voltages.
4.2 I²C-Bus components
The I2C-Bus components (LED board, LCD board and relay board) are con-nected to the plugs X13 and X14 of the basic unit. In order to indicate the status of the system, the LED and LCD boards are located on the common dis-play and operating panel which is integrated in the front door of the power supply system.
The I²C-Bus-components ( +8V ) are supplied via the same plug connectors to which the data lines are also connected. The maximum load on the +8V supply is 500 mA. The maximum consumption current of the LED board is 40 mA. The consumption current of the LCD board is negligible.
The 7 relays on the relay board are driven by the +12 V supply of the basic unit. The current used for this purpose is approx. 130 mA (approx. 18 mA per relay). The maximum contact load is 250 VAC/ 8A.
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4.3 Technical data
Input voltage ranges: 18VDC...75VDC / 75VDC...270VDC
Max. current consumption: 25W
Voltage outputs: 24 VDC/200mA (for digital inputs) 12 VDC/500mA (for ext. components)
Analogue inputs: 3
Not potentially separated from one another.
Voltage-measuring input: 0VDC...270VDC Current-measuring input 1: 60mV - shunt Current-measuring input 2: 60mV - shunt (Temperature-measuring input: temperature sensor 2kΩ/25°C KTY81-210) (Temperature-measuring range: -20°C...+70°C)
Digital inputs: 8 Wiring: 24 VDC/1mA (10mA starting current)
Potential-free signals: 3 (basic unit)/ 7 (external relay board) max. contact load: 250 VAC/8A
Permitted temperature range: 0°C...40°C (without condensation)
Location height: max. 2000m above sea level.
Humidity class: F
Air conditioning: to IEC 721-3 (FTZ A 01 AN1) Operation 3K3 (-R12) Storage 1K5 (-R14) Transport 2K4 (-R52)
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5 Operating instructions
After mechanical installation, electrical connection and system-specific con-figuration and start-up, the Remote Monitoring System MCU 1000 is ready for use without any restriction. During operation, no settings, adjustments etc. are necessary for any of the permitted operating conditions.
Location
The MCU 1000 is designed to be fitted into power-supply systems. It is in-tended for use in enclosed dry rooms only. For the maximum unit temperature, refer to the technical data. When selecting its location, ensure that it is not ex-posed to corrosive substances and that the flow of cooling air is not restricted.
Connection
As a general rule, the complete MCU 1000 and all its components is fitted into the power supply system. However, if it is installed at a later date or if modifi-cations are carried out, the instructions in section 4 must be complied with. This applies in particular to the contact assignment for the individual connec-tions as well as contact loads.
Start-up
To start the unit up, the entire power supply system and all the components of the MCU 1000 must be correctly wired and connected to the mains supply voltage. The initialisation phase is started and the two LEDs "FAULT/ " and "READY/ " flash.
In the LC display on the display and operating panel, "init" appears alternately with all the segments. After approx. 2 secs. the EEProm initialisation takes place (with display of "-EEP-") unless a special EEProm is installed in the ba-sic unit. The software version of the MCU 1000 is then displayed for approx. 1 sec. The standard operation then starts. The green LED "READY/ " on the basic unit lights up. All the relays are then set according to their system-specific configuration and the modem is initialised (if applicable).
Maintenance
The MCU 1000 was developed for continuous operation and is practically maintenance free. If the specified conditions of the surroundings are complied with, the unit will function reliably for a long period of time.
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6 Annex
E C
MCU 1000
Display and operating panel (texts for standard configuration) Version up to. 08/99
green
green
yellow
red
yellow
red
red
red
red
red
red
red
red
Operation
Float
Fault U<2,1V/c
Boost
Battery test
Battery test negative
Urgent alarm
Non urgent alarm
Mains failure
Rectifier failure
Batt. discharged U<1,8V/c
Fuse blown
Modem failure
LED Test / Reset
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1
2
4
3
6
5
1 Standard display 2 Menu level 0 3 Password request menu level 1 4 Menu level 1 5 Password request menu level 2 6 Menu level 2
Menu structure of the LCD board (valid up to software 1.10)
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Fig. above mentioned gives an overview of the entire menu structure. If the buttons of the LCD board are not activated, the standard unit alternately dis-plays e.g. the present current and voltage of the current and voltage measuring channel of the basic unit.
By pressing the ENTER button, a menu item of menu level 0 is selected. The return is always to the menu item from which the last return to the standard display took place.
All menu items of menu level 0 are accessible without a special password.
Menu level 0:
Menu item/ Meaning:
A maximum of 124 "measurement values" of the power sup-ply system can be displayed. However, only the values actu-ally measured and the values calculated from these are dis-played.
The logical status of a maximum of 96 digital inputs is dis-played.
The status of the signalled SAT-BUS component is displayed. A maximum of 31 components including the basic unit can be addressed.
This menu item allows entry to menu level 1 through pass-word request.
All the LEDs of the LED board are activated for approx. 1 minute (continuous operation). At the same time, the display shows all the segments of the display alternately with the cur-rent software version of the MCU 1000. The test can be aborted by pressing the CANCEL button.
This menu item allows entry to menu level 2 through pass-word request.
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Menu level 1:
This level is accessible via menu item only and by entering a password in menu item . The password is a number between 000 and 999 and is selectable by means of the "UP" and "DOWN" buttons.
The standard password set by the manufacturer for level 1 is „001“. This serves to avoid incorrect operation. The password should be changed by the customer at the first opportunity.
Menu item: Meaning:
A battery test is initiated.
A battery test is concluded.
Switch rectifiers to "Boost charge".
Switch rectifiers to "Maintenance charge".
Switch rectifiers to "Direct feed".
Test fault signal „A“.
Test fault signal „B“.
Test fault signal „C“.
Menu level 2:
This level is accessible via menu item only and by entering a password in menu item . The password is a number between 000 and 999 and is selectable by means of the "UP" and "DOWN" buttons.
The standard password set by the manufacturer for level 2 is „002“. This serves to avoid incorrect operation. This password should be changed by the customer at the first opportunity.
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Menu item Meaning:
Input of nominal shunt value connected to current measuring channel of basic unit (X1:21; X1:22) e.g. 60 A.
Input of nominal shunt value connected to terminals X1:23 and X1:24 of basic unit when the temperature channel is changed to a current-measuring channel.
Input of number of cells of battery system of power supply sys-tem, e.g. 48V system: 24; 60V system: 30
Input of delay time in seconds after which a fault signal "A" should be given..
Input of delay time in seconds after which a fault signal "B" should be given.
Input of delay time in seconds after which a fault signal "C" should be given.
Input of duration of an initiated relay test in seconds.
Input of duration in seconds after which a modem connection between MCU 1000 and a control desk should be interrupted if the control desk does not respond.
Input of duration in seconds after which a new attempt should be made to make contact if the line is engaged at first attempt.
Input of duration of a battery test.
Input of the break-off voltage for a battery test in V per cell.
Input of a time interval, after which a new automatic battery test should be initiated. The time is stated in minutes, hours, days, months and years.
Input of the date on which a first automatic battery test should be carried out. After this, further battery tests take place at the stated intervals. When the date of the first battery test is past, the date of first start up is taken as starting point. The date is stated in minutes, hours, days, months and years.
Display of the next starting date for an automatic battery test. The time is stated with hour, day, month and year. The timing is
46
based on the data previously input.
Input or display of system time in day, month, year, hours and minutes.
8 different configuration flags are set by entering a hexadecimal code. This determines for example whether a modem is con-nected for a remote diagnosis or if an automatic battery test should be carried out.
A filter mask for evaluating faults is set using a hexadecimal code.
Setting of a filter mask to evaluate signal "A".
Setting of a filter mask to evaluate signal "B".
Setting of a filter mask to evaluate signal "C".
Specification or changing of a password (000 ... 999) for access-ing menu level 1. If the password "000" is specified, the pass-word is not requested for this menu level i.e. no password pro-tection!
Specification or changing of a password (000 ... 999) for access-ing menu level 2. If the password "000" is specified, the pass-word is not requested for this menu level i.e. no password pro-tection!
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Maintenance Instructions
1 General remarks ...................................................................................... 48
2 Cleaning .................................................................................................. 48
3 Terminals and plugs ................................................................................ 48
4 Contactors, relays.................................................................................... 48
5 Monitoring unit ....................................................................................... 48
6 Smoothing device.................................................................................... 49
7 Instruments.............................................................................................. 49
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1 General remarks
The unit should be serviced once per year or whenever a malfunction occurs.
Disconnect the unit from the power supply (if possible at a time when it is not required). Remove the fuses from the power distribution system.
Some of the components and terminals in the secondary circuit are still live (battery voltage). For this reason, always use non-conductive materials and insulated tools for cleaning and mainte-nance work.
2 Cleaning
Use a vacuum cleaner and brush to remove dust from the components. In dusty surroundings, this cleaning operation should be carried out at frequent inter-vals. Avoid damaging the coils of transformers and chokes.
3 Terminals and plugs
Check all terminals and screw connections in the unit and tighten them if re-quired. Check plugs to ensure that contact surfaces are clean, the cable pull-relief is sufficient and that all elements are clipped firmly into position.
4 Contactors, relays
Ensure that contactors move easily by pressing them by hand (if necessary re-move the arc chamber to do this). If required, remove the contactors and clean them thoroughly. Check the condition of the contacts and remove any traces of burn-up with a suitable file.
(Do not use emery paper or sandpaper. Do not grease the contacts!)
Dark coloured contacting elements do not adversely affect the function of the unit.
5 Monitoring unit
Check the response values of the monitoring devices (e.g. mains power, over and undervoltage etc.). For the correct response values, refer to the Technical Data Sheet.
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6 Smoothing device
If electrolytic capacitors are fitted to meet higher smoothing requirements, it is recommended to replace these after 10 years of use.
Disconnect the battery before beginning work
7 Instruments
After switching the unit on again, check the measurement values using high-precision instruments.