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Kraft Powercon PCM2, Manual

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Kraft Powercon PCM2 Manual Download Page 10

 10 

 

 

 
 

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46  Växjö, Sweden, Tel: +46 470-705200, Fax: +46 470-705201, 

www.kraftpowercon.com

 

 
Dimensions ........................... See diagram below 
 

 

Dimensional draft operator panel 
 

3.3.2

 

I/O module 

Mounting ........................... On terminal rail or direct on vertical surface 
Dimensions ........................ See diagram below 
 

 

Dimensional draft I/O module 
 

3.4

 

Conformity with standards 

EN 60529 ........................... Class of enclosure IP20 
EN 50178 ........................... LVD. Electronic equipment, including power electronics in electrical 

power installations. 

EMC standards ................... Tested in a system context, not as individual product. See relevant 

system manual. 

 
 

Summary of Contents for PCM2

Page 1: ...nel and according to the installation instructions Service may only be performed by authorised service personnel The equipment housing may only be removed by authorised personnel when all power has been cut to the equipment for at least five minutes The protective covers and contact safety devices inside the equipment may only be removed by authorised service personnel The power must always be dis...

Page 2: ...ercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com We reserve the right to make changes to the content of this manual without prior notification ...

Page 3: ...qualizing charging 12 4 4 2 3 Automatic equalizing charging 12 4 4 3 Battery circuit test 12 4 4 3 1 Simple battery circuit test 12 4 4 3 2 Advanced battery circuit test 13 4 4 4 Double systems 13 4 4 4 1 General 13 4 4 4 2 Earth fault measuring 13 4 4 4 3 Battery circuit test 13 4 4 4 4 Load sharing 13 4 4 4 5 System setup 13 5 OPERATION 15 5 1 General 15 5 2 OPERATOR PANEL 15 5 2 1 Display 15 5 ...

Page 4: ...djust the voltage level for equalizing charging 24 5 10 4 Adjust the current limit value 25 5 10 5 Adjust clock 25 5 11 ADVANCED 25 5 12 TEST CALIBRATE 25 5 12 1 General 25 5 12 2 Show status for digital inputs 25 5 12 3 Test digital outputs 26 5 12 3 1 Test alarm outputs A D 26 5 12 3 2 Test alarm outputs E H 26 5 12 3 3 Test other outputs 26 5 12 4 Calibrate measuring of battery voltage 26 5 12 ...

Page 5: ...ltage 40 6 4 3 3 Earth fault measuring 41 6 4 3 4 Battery temperature 41 6 4 4 Digital inputs 41 6 4 4 1 General 41 6 4 4 2 Blocking of equalizing charging 41 6 4 4 3 Fuse monitoring 41 6 4 4 4 Blocking of earth fault measuring battery test 42 6 4 4 5 External faults 42 6 4 5 Digital outputs 42 6 4 5 1 General 42 6 4 5 2 Alarm outputs 42 6 4 5 3 Fan control 43 6 4 5 4 Battery test 43 6 4 6 Interna...

Page 6: ... 8 1 ANNUAL INSPECTION 47 8 1 1 General 47 8 1 2 Check of measuring instruments 47 8 1 3 Check of alarm circuits 47 8 1 4 Check of clock 47 9 FAULT TRACING 48 9 1 SAFETY INSTRUCTIONS 48 9 2 FAULT TRACING FOLLOWING ALARM 48 9 3 OTHER FAULT TRACING 48 Appendices A BASIC SETTINGS ALARM B BASIC SETTINGS OTHER C RECTIFIER STATUS WORD C RECTIFIER RAM VARIABLES D TYPE DIAGRAM PCM2 IN DOUBLE SYSTEMS ...

Page 7: ...enu system and alarm indication with both LEDs and clear text messages These instructions above all deal with all operation of the monitoring unit and are therefore chiefly aimed at the personnel that have the day to day responsibility for running the installation but also to other personnel who have cause to work with the DC system It also contains information on installation commissioning servic...

Page 8: ...ve linguistic skills that ensure the content in this description cannot be misunderstood Have undergone a product specific training programme for authorised service personnel that are approved by KraftPowercon Sweden AB Qualified personnel Have electrical training and adequate experience to avoid the dangers that electricity can cause Are certified to meet authority requirements for the work in qu...

Page 9: ...lock Connection relay outputs 0 2 2 5 mm2 pluggable screw terminal block Connection meas inputs voltage earth fault 0 2 2 5 mm2 pluggable screw terminal block Connection other inputs 0 08 1 5 mm2 pluggable screw terminal block Relays for alarms fan contact data max 250 VAC 8 A at cosø 1 resistive 250 VAC 3 A at cosø 0 4 24 48 VDC 0 86A at L R 40 ms 125 VDC 0 37A at L R 40 ms 250 VDC 0 28A at L R 4...

Page 10: ...anel 3 3 2 I O module Mounting On terminal rail or direct on vertical surface Dimensions See diagram below Dimensional draft I O module 3 4 Conformity with standards EN 60529 Class of enclosure IP20 EN 50178 LVD Electronic equipment including power electronics in electrical power installations EMC standards Tested in a system context not as individual product See relevant system manual ...

Page 11: ...s is described in more detail in connection with the parameter that controls this function see section 5 14 4 4 2 OPERATOR PANEL The operator panel is the unit used as the user interface This contains a graphic display push buttons LEDs for alarm indication and an internal microprocessor It is connected firstly to the I O unit via a RJ45 cable and secondly to the rectifier via a RJ11 cable As an o...

Page 12: ... harmful to the batteries Always follow the instructions stated by the battery manufacturer 4 4 2 2 Manual equalizing charging Manuel equalizing charging means that you give a manual request to start equalizing charging with a certain length Equalizing charging starts immediately after the request and continues for a specified period See section 5 8 2 4 4 2 3 Automatic equalizing charging Automati...

Page 13: ...es concerning earth fault measurement and battery circuit tests etc 4 4 4 2 Earth fault measuring There may never be more than one piece of equipment at a time for earth fault measurement connected in one system In other cases there will be a measurement fault due to them measuring each other s measurement input impedance In order to prevent this do as follows System B always measure earth faults ...

Page 14: ...e connected or not in order to handle the earth fault measurement The cross connector breakers are fitted with breaking auxiliary contacts These are connected to the input E F BLOCKED in system A This is organised in such a way that the loop is open when both sub systems are connected 2 Each sub system must notify whether equalizing charging is to be permitted or not The cross connector breakers a...

Page 15: ...able options 2 Action field for choice of action Selected options or actions are shown in inverted text 5 2 2 Push buttons The push buttons are used to provide instructions for the menu system Their function varies to a certain extent depending on where in the menu system you are In most situations it is clear from the display which buttons are relevant at each particular time Their main tasks can...

Page 16: ...is marked in inverted text You change the values and setting options using the and buttons The exception is a few menu options where you use the and buttons for setting options The menu options could be more than the number of available rows in the display In these situations a rolling menu appears This means that more options appear when you move outside the existing rows It works in principle as...

Page 17: ...s this screen appears for a few seconds The screen above for adjusting the value now reappears but with the value adjusted to the closest permitted limit value 5 4 MENU OVERVIEW On the next page a complete overview covering all menu options will follow The sections that then follow in this chapter describe the menu options in detail Value not within limits Adjusted automatically ...

Page 18: ...______________ 120 4V 12 3A 4 alarms in queue ______________________ ______________________ ______________________ SYSTEM OK Float charging Menu ALARM UNDERVOLTAGE U Menu Acknowledge ALARM Menu Float charging Alarm Select Charge control Show Settings MAIN MENU Return SETTINGS SHOW CHARGE CONTROL ALARM ADVANCED Service Select System data Functions Test Calibrate ADVANCED Return TEST CALIBRATE FUNCT...

Page 19: ...ays when the rectifiers shut down via the digital input External blocking 5 5 4 Alarm An alarm condition always starts with an alarm message that is awaiting acknowledgment This is described in more detail in section 5 16 later As soon as all the relevant alarms are acknowledged the screen here to the side appears It shows how many alarms there are in the alarm queue You can use the key to start b...

Page 20: ...e mid voltage and temperature are only shown if relevant measuring sensors are installed This is controlled in the Functions menu see sections 5 13 3 and 5 13 4 5 7 3 Show rectifier 5 7 3 1 Show voltage and current Show the voltage and current that each rectifier unit measures and reports to the monitoring unit To show more detailed information on a rectifier unit select the Detail action option 5...

Page 21: ...5 Show statistics 5 7 5 1 Menu option Select from the menu options Mains fault External faults and Operating time If PCM2 is used solely as a monitor number of rectifiers 0 the Mains fault option cannot be selected 5 7 5 2 Mains fault For mains power failure the total number when the last fault occurred and how long it lasted are shown 5 7 5 3 External fault Shows the number of events that have oc...

Page 22: ...ere and confirming with OK The test is carried out and the results communicated See also section 4 4 3 Battery circuit test 5 9 ALARM 5 9 1 General For every alarm type there are a number of settings that can be made Under the Settings heading you can read and change these parameters for each alarm that may appear in the system See section 5 16 for a list and description of all the applicable alar...

Page 23: ...the required time 5 9 2 3 Relay A D ABCD represents each of the four alarm output relays A to D Under each relay letter you will see Yes or No The Yes option specifies that the relay will be activated by an alarm All combinations are permitted from no relay to all relays at once Use the and buttons to move the cursor to the required relay Now use the and buttons to switch between the options Yes a...

Page 24: ... Ueq and Ilimit options cannot be selected 5 10 2 Adjust the voltage level for float charging Set the required voltage level for float charging If the actual float charging voltage does not appear to match the set value this is probably due to the float charging voltage being temperature controlled The value you set here is the level that applies at 20 C If PCM2 is used solely as a monitor number ...

Page 25: ...a service condition WARNING The settings under the Advanced heading are critical for the functionality of the system Read the manual carefully first Then change only if you are absolutely sure about what you are doing 5 12 TEST CALIBRATE 5 12 1 General The functions under the Test Calibrate are primarily designed for use during commissioning and service 5 12 2 Show status for digital inputs Shows ...

Page 26: ... 4 5 for a more detailed description of the outputs 5 12 4 Calibrate measuring of battery voltage Here you calibrate the monitoring unit s measurement instrument for battery voltage to ensure the measurement value matches the actual battery voltage This is done on delivery from the factory but can also be done during the stipulated routine inspections Measure the actual battery voltage using an ex...

Page 27: ...ect the conditions that are to apply for the functions that are available in the monitoring unit If PCM2 is used solely as a monitor number of rectifiers 0 the Battery circuit test Equalizing charging Uminimum Umaximum and RI compensation options cannot be selected 5 13 2 Select language Select the language to be used for the display 5 13 3 Parameters for mid voltage measurement Here you enter the...

Page 28: ...e parameters is based on information from the battery manufacturer In Figure 1 Temperature curve the battery manufacturer s charge curve is shown with a dashed line This curve is approximated to two straight lines with individual slopes the thick line Furthermore an upper and lower limit is specified for temperature control Utmin and Utmax Do as follows to determine the slope of the two lines 1 Ta...

Page 29: ...at a determined time of the day Synchronisation is made quite simply by accessing this screen at the required time and then leaving it again with or without changing the time During the battery circuit test the output voltage is lowered relative to the float charging voltage applicable at that time which could be temperature compensated Here you specify how large the drop is to be 0 50 However the...

Page 30: ...D function is selective which means that for parallel rectifier modules only the module that causes the overvoltage will trip This is ensured by the individual module only tripping under the condition that the module supplies current that exceeds around 25 of its rated current Note that the charging voltage float charging and equalizing charging will be limited to maximum 1 below Umaximum even if ...

Page 31: ... use it is therefore recommended that you mainly use the actual operator panel Set the value Yes if a satellite panel is installed I O unit 2 As an option an additional I O unit can be connected in order to extend the number of alarm relays from the usual four to a total number of eight relays Set the value Yes if a second I O unit is installed 5 14 SYSTEM DATA 5 14 1 General Under System data the...

Page 32: ...n 4 4 4 Specify A if the system in question is the first of two sub systems Specify B if the system in question is the second of two sub systems 5 15 SERVICE Service mode is reserved for specially trained service personnel It is therefore blocked by password 5 16 ALARM MESSAGES 5 16 1 General An alarm identifies itself in the following ways 1 Status message on row 2 SYSTEM OK is replaced with the ...

Page 33: ...e alarm means that the delay period has passed but the alarm condition is no longer met An alarm with the return option Automatic return clears immediately when the alarm condition ends It will therefore never be shown with the Inactive status If the alarm has the Return after acknowledgement return option instead the alarm remains until it is acknowledged Following acknowledgement it is moved to ...

Page 34: ...t Alarm condition The system voltage falls below the set limit value Interlocking When testing with lowered voltage e g battery circuit test Should the test continue for unreasonably long time ca 10 min the interlocking will cease SYMMETRY FAULT 1 Function Compares the battery s upper and lower half by measuring the mid voltage Handles deviations that last for a longer period Alarm condition The d...

Page 35: ...pen 2 Fault in incoming mains 3 Defective rectifier unit NO CHARGING Function Indicates that the battery is not charged Alarm condition The system voltage falls below the set limit value Interlocking 1 When testing with lowered voltage e g battery circuit test 2 If the rectifier works with an output current greater than 90 of the set current limit 3 Due to high temperature the float charging volta...

Page 36: ...r 3 Temporary overload due to fault in the installation Other The alarm is completely invisible over the delay period The actual minimum delay period is 1 minute although you can set a shorter period HIGH TEMP BATTERY Function Monitors the ambient temperature of the battery Alarm condition The battery s ambient temperature exceeds the set limit value Interlocking Temperature measurement can be des...

Page 37: ...an external unit 2 Remote control on off of rectifier units Alarm condition Digital input for external faults Ext fault is open Interlocking Fault causes 1 External unit indicates faults for alarm text options 1 4 2 The rectifier has been shut down by remote control for alarm text option 5 3 Unused input Ext fault is not strapped Other The Functions menu section 5 13 10 can be used to select one o...

Page 38: ...Internal circuit fault Send for qualified service personnel FAULT TYPE 03 Alarm condition The monitoring unit s I O board reports a fault Fault causes 1 Internal circuit fault Send for qualified service personnel COMMUNICATION FAULT Function Monitors serial communications with rectifier I O unit and any other units Alarm condition A sent message gets no approved response despite ten resend attempt...

Page 39: ... panel and the I O unit Name and placement for connections to each unit is detailed in the drawing below Note that it is the rear of the operator panel that is displayed Connections PCM2 6 3 OPERATOR PANEL 6 3 1 Ordinary operator panel Between the operator panel s connector X2 and the I O unit s X4 an RJ45 cable is connected normally an 8 pin network cable NOTE If you remove this cable from the I ...

Page 40: ...ery distribution panel Otherwise it should be measured as close to the battery as possible to avoid the effects of voltage drop in the battery cables Connect to X7 3 U BATTERY and X7 5 U BATTERY WARNING Never connect measurement cables directly to the battery Ensure the measurement point has short circuit protection The connection block X7 also has blocks for short circuit protected voltmeter term...

Page 41: ... mean value for the battery temperature Connect the sensor to input X9 1 2 TEMP SENSOR If the sensor cable needs extending there are no special requirements for cables and junction boxes in addition to normal electrical installation directives The insulation class is determined by the battery voltage The temperature sensor is an option and is therefore only installed where applicable Check that th...

Page 42: ...e information see section 5 13 10 Connect to input X9 9 10 EXT FAULT 6 4 5 Digital outputs 6 4 5 1 General All outputs fitted with relays have floating relay contacts For the durability of the relay contacts see section 3 TECHNICAL DATA 6 4 5 2 Alarm outputs There are four regular alarm outputs alarm relays A D The outputs connection blocks are marked C NC and NO The significance of this is as fol...

Page 43: ... C is used between the units The connections are described in more detail in section 6 3 6 4 7 External communications interface The monitoring unit is prepared for external communications via RS 232 Ethernet and I2 C 6 4 7 1 RS 232 RS 232 X1 is intended for configuration via PC and connection to certain field bus units A special program is required for configuration via PC The program is used pri...

Page 44: ...m outputs beyond the usual four alarm outputs on the basic I O unit There are named alarm relay E H The outputs connection blocks are marked C NC and NO The significance of this is as follows C Common point for connection NC Connection point for normally closed contacts Closes on alarm NO Connection point for normally open contacts Opens on alarm The term normal N here means resting relays i e idl...

Page 45: ...al X6 11 NC Terminal X6 12 6 5 6 Internal communications interface Not in use instead see section 6 5 7 3 6 5 7 External communications interface 6 5 7 1 RS 232 Not in use 6 5 7 2 Ethernet Not in use 6 5 7 3 I2 C The I2 C port X8 is used for communication with the basic I O unit Connect X8 2 4 to corresponding X8 2 4 on basic I O unit Note X8 1 should not be connected ...

Page 46: ...play All measurement values are initially reset The measuring begins after around 10 seconds Any alarms are activated when a total of around 30 seconds has passed For start up in general we refer you to the general system manual 7 3 CHECK OF SETTINGS Each time the monitoring unit has been without voltage the built in clock must be set with the current date and time see section 5 5 5 Check that the...

Page 47: ...uments Check that the monitoring unit s internal measurement instrument the display shows the correct value for battery voltage and mid voltage Follow the instructions as per section 5 12 TEST AND CALIBRATE 8 1 3 Check of alarm circuits Check the function of the circuits that are included in the alarm system Follow the instructions as per section 5 12 3 1 Test alarm outputs 8 1 4 Check of clock Ch...

Page 48: ...fuse in the battery distribution panel or simply make the operator panel dead by pulling out and reconnecting the connection RJ45 cable between the operator panel and the I O unit Cause 2 An external form of interference has forced the display into an abnormal mode Restart by cutting the power to the whole monitoring unit usually by removing a fuse in the battery distribution panel or simply make ...

Page 49: ... exceptional cases mean that the monitoring unit s long term memory is overwritten with random content Start by testing with a restart as per previous descriptions If the problem remains the long term memory must be restored to its original state as per the basic settings in Appendix_A Do as follows 1 Cut the power to the whole monitoring unit usually by removing a fuse in the battery distribution...

Page 50: ...3 52 47 04 105 8 117 6 211 7 399 8 493 9 V 1 96V c Mains fault X 1s Aut Immediate Not charging X 10s Aut Immediate 25 80 51 60 116 1 129 0 232 2 438 6 541 8 V 2 15V c Rectifier fault X 10s Aut Immediate Measurement circuit fault X 10s Aut Delayed 10 10 10 10 10 10 10 High current I 2 10s Aut Immediate Overload 3 X 24h Ack Delayed High temp battery X 30m Aut Immediate 30 30 30 30 30 30 30 C Low tem...

Page 51: ... dU2 0 mV C Ut min 21 6 43 2 97 2 108 0 194 4 449 0 453 6 V 1 8V c Ut max 28 4 56 9 128 0 142 2 256 0 479 4 597 2 V 2 37V c Battery circuit test Testing method Advanced Range 24 h Usink 15 Automatic equalizing charging Automatic No Level 1 24 6 49 2 110 7 123 0 221 4 426 4 516 6 V 2 05V c Level 2 27 0 54 0 121 5 135 0 243 0 468 0 567 0 V 2 25V c Time factor K 5 Lowest possible charging voltage Umi...

Page 52: ...d PRM3 of newer model Bit Description 0 1 No DC out 11 1 Load sharing inactive 21 1 Lamp test requested 3 1 Current limit 4 Not used 5 1 High internal temperature 6 1 Rectifier fault 7 1 Shut off via remote off command 8 Not used 9 0 Rectifier module type PCS 1 Rectifier module type PRM3 10 1 Mains fault 11 1 Fan fault 12 Not used 13 Not used 14 Not used 15 Not used 1 Relevant for rectifier module...

Page 53: ...rly in place 151 1 Closed due to timeout in communication with intermediary 2 3 0 1 Execute lamp test Write 1 1 Switch on rectifier 2 1 Switch off rectifier 31 1 Allow outgoing alarm 41 1 Prevent outgoing alarm 51 1 Fan only run at full speed 61 1 Fan run depending on temperature 7 Not used 8 15 Rectifier module s I2 C address Read only 4 5 Reserved for internal use 6 7 0 15 Output voltage in Volt...

Page 54: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix E TYPE DIAGRAM PCM2 IN DOUBLE SYSTEMS ...

Page 55: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com ...

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