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Magellan Power MCRII Series, Operation And Maintenance Manual

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Summary of Contents for MCRII Series

Page 1: ...de 64 Bushland Ridge Bibra Lake WA 6163 P 61 8 9434 6621 F 61 8 9434 6623 E sales magellanpower com au W www magellanpower com au OPERATION AND MAINTENANCE MANUAL SINGLE PHASE MCRII SERIES BATTERY CHARGER SINGLE PHASE MCRII SERIES BATTERY CHARGER THIS MANUAL SHOULD REMAIN WITH EQUIPMENT ...

Page 2: ...S 7 2 6 METERING 7 2 7 PROTECTION 7 2 8 CONTROLS 8 3 0 INSTALLATION INSTRUCTIONS 9 3 1 CABLING 9 3 2 INSTALLATION PRECAUTIONS 9 4 0 CIRCUIT DESCRIPTION 10 4 1 CONTROL AND MONITOR CIRCUITS 10 5 0 OPERATING INSTRUCTIONS 12 5 1 START UP 12 5 2 VOLTAGE AND CURRENT DISPLAY 12 5 3 BOOST CHARGING BATTERIES 15 5 4 BATTERY TEST 15 5 5 TEMPERATURE COMPENSATION 17 6 0 ADJUSTMENTS 20 6 1 SETTING FROM THE KEY ...

Page 3: ...hland Ridge Bibra Lake WA 6163 P 61 8 9434 6621 F 61 8 9434 6623 E sales magellanpower com au W www magellanpower com au 7 5 CHECKING BATTERY CURRENT LIMITS 31 7 6 CHECKING CHARGER CURRENT LIMIT 31 7 7 TESTING MAINS FAIL ALARM 32 7 8 TESTING DC LOW ALARM 32 7 9 TESTING DC HIGH ALARM 33 7 10 TESTING LOW ELECTROLYTE 34 7 11 TESTING BATTERY FAIL 34 8 0 RECOMMENDATIONS 34 ...

Page 4: ...equipment unless authorised Isolate AC and DC before working on the equipment Battery voltage may be present even when mains is isolated Give internal capacitors time to discharge 1 minute before working on the equipment To completely isolate the equipment switch off all circuit breakers and fuses and allow the internal capacitors to discharge Batteries on charge especially boost charge generate H...

Page 5: ...batteries The MCRII charger is a constant voltage type with current limit and two voltage levels float and boost The boost level is used to recharge the battery whilst the float is used to keep the battery in a fully charged condition For applications using sealed Lead Acid batteries the boost function may be disabled The boost mode can be initiated manually or automatically The manual boost is in...

Page 6: ...CIFICATIONS 2 1 AC INPUT Voltage 240V 10 Single Phase Frequency 50Hz 5 Current As per model 2 2 DC OUTPUT Nominal As per model see test sheet Float As per model see test sheet Boost As per model see test sheet Output Current As per model see test sheet Output Ripple 1 without battery connected 2 3 LOAD REGULATION Static load regulation 1 for 1 to 100 Load 10 Input Variation 5 Frequency Variation 2...

Page 7: ...table Over volt Charger disconnect As per model software adjustable Under volts load disconnect As per model software adjustable Earth Fault 10mA adjustable Note For alarm settings please refer to the test sheet 2 6 METERING Charger Voltage Charger Current Battery 1 Voltage Battery 1 Charge Discharge Current Battery 2 Voltage for dual battery systems Battery 2 Charge Discharge Current for dual bat...

Page 8: ...ry 1 Current Limit Adjustment Battery 2 Current Limit Adjustment for dual battery systems Load Sense Boost Inhibit DC Low Alarm Adjustment DC High Alarm Adjustment High Volts Inhibit High Volts Disconnect Adjustment Low Volts Disconnect Adjustment Battery Fail Voltage Adjustment The following adjustment can be done using on board potentiometers Earth Leakage Current setting The following adjustmen...

Page 9: ...terminal X5 Wrong connection of the battery temperature probe will result in incorrect operation of the charger 3 Connect the battery bank to the terminal X2 Please observe polarity Note If Impedance Test or Full Battery Test Facility options are included please connect terminal X2 wire numbers 101 and 102 to the actual battery terminals 4 Connect load as per the schematic drawing 5 Connect extern...

Page 10: ...se of battery current limiting and display 4 1 CONTROL AND MONITOR CIRCUITS The control circuit monitors the output voltage and current and compares them with set values the thyristor conduction angle is then adjusted to ensure that the output voltage and current are in accordance with the preset levels The control circuit is contained on three electronic circuit boards The Interface Board A2 comm...

Page 11: ...ed by depressing the Mute button on the front panel The Microcontroller Board provides voltage and current control references to the Interface Board via a D A converter These references are compared with voltage and current feedback signals The output signal from the error amplifier is fed to the SCR Firing Circuit A1 where it is compared with a reference ramp synchronised to the mains The output ...

Page 12: ...e start up sequence briefly display the MAGELLAN logo and show the top page after a delay of a few seconds 2 Switch on Mains Power input circuit breaker Refer to the schematic drawing 3 The charger should now start to deliver some charging current to the battery If the batteries are fully charged the voltage will quickly approach the Float level and the charger current will get reduced 4 Switch on...

Page 13: ...alian Made 64 Bushland Ridge Bibra Lake WA 6163 P 61 8 9434 6621 F 61 8 9434 6623 E sales magellanpower com au W www magellanpower com au Screen 2 Charger voltage Charger Current Load Voltage Load Current Screen 3 Charger voltage Charger Current Battery Voltage Thyristor Bridge Screen 4 Charger voltage Charger Current Battery Temperature Battery Current ...

Page 14: ... Doc MAN 1P_MCRII Page 14 of 36 Australian Technology Australian Made 64 Bushland Ridge Bibra Lake WA 6163 P 61 8 9434 6621 F 61 8 9434 6623 E sales magellanpower com au W www magellanpower com au Screen 5 Charger voltage Charger Current Battery AH Capacity Last AH Ratio in of expected capacity ...

Page 15: ...preset period Both the battery current value and the preset period are user adjustable See User Programmable Set Point Instructions Automatic boost mode is terminated by pressing the Boost button 5 4 BATTERY TEST 5 4 1 MODE 1 Battery Impedance Test The Battery Impedance test calculates internal resistance within the battery by drawing a high current pulse approx 50A which does not indicate on fron...

Page 16: ...nel in the menu Battery Test Setup Refer pg 24 5 4 2 1 PROCEDURE 1 Press and hold BATT TEST button for 5 seconds 2 Display goes automatically to Capacity and Last ratio menu 3 The display shows time left for this test and indicates the current drawn from the battery 4 The latest Impedance and Baseline Impedance values are also displayed alternately Note This test is done once in every 30 days by d...

Page 17: ... The charger voltage is lower at higher temperatures For the Battery Temperature Compensation to operate the temperature probes must be connected to the terminals X5 provided on the charger The temperature probes are to be mounted on the battery terminals ensuring good thermal contact If the battery temperature probes are not connected then the battery temperature indicated on the LCD panel would ...

Page 18: ...ill continue to silence the audible alarm until it is reset by the Reset key on the front panel Therefore any new alarm that occurs after the Mute key has been activated will not operate the audible alarm 5 5 1 3 Constant Current Charging The MCR Series Rectifier has a built in constant current charging function to enable the user to perform commissioning charges when new batteries are installed o...

Page 19: ...ll initiate constant current mode The charger will remain in this mode until the preset time has elapsed The charger will then return to its normal state Constant current charging can be manually terminated by operating the Reset key 5 5 2 Remote Communications Optional The charger can communicate to an external or remote computer or LAN via an optional communication card The communication methods...

Page 20: ...d changes from being implemented This password protection is not present when using the computer link 6 1 SETTING FROM THE KEY PAD 1 Hold down MODE ACK and keys together for more than 5 seconds This will take the controller to the programming mode 2 Go to the appropriate Sub menu by operating the arrow keys Select by pressing the MODE key Pressing the MODE key again will take the screen to the nex...

Page 21: ...Voltage Sets the charger output voltage in float mode Boost Voltage Sets the charger output voltage in boost mode Boost Timer Sets the period of one boost cycle Battery 1 Boost Activation Current Sets the Battery 1 current level at which Auto Boost is activated Battery 2 Boost Activation Current Sets the Battery 2 current level at which Auto Boost is activated Boost Activation Delay Sets the perio...

Page 22: ...Voltage Trip Sets activation voltage of the Over Voltage Trip alarm and protection relay optional Over Voltage Trip Delay Sets the delay time seconds between alarm detection and alarm indication Under Voltage Trip Sets activation voltage of the Under Voltage Trip alarm and protection relay optional Under Voltage Trip Delay Sets the delay time seconds between alarm detection and alarm indication Ch...

Page 23: ...oltage at which the diodes will be shorted Diode Dropper 2 On Sets the voltage at which the second diode string will be switched in line Diode Dropper 2 Off Sets the voltage at which the diodes will be shorted Diode Dropper 3 On Sets the voltage at which the third diode string will be switched in line Diode Dropper 3 Off Sets the voltage at which the diodes will be shorted 6 3 2 Sub Menu 4 Battery...

Page 24: ...tions Impedance Monitoring Enables the Impedance Monitoring option Mains Fail O P Latch On Off Sets the mains fail alarm output to latching Earth Fault O P Latch On Off Sets the earth fault alarm output to latching Low Electrolyte O P Latch On Off Sets the Low Electrolyte alarm output to latching Battery Discon O P Latch On Off Sets the battery disconnected alarm output to latching DC High O P Lat...

Page 25: ...r serial communications purposes when more than one charger is connected to the remote communication facility Dual Battery Enabled Dual or Single Battery operation Battery Type Sets the type of battery to be charged by the charger Ni Cad sealed or vented Lead Acid Temperature Compensation Factor Sets the temperature compensation in mV C Cell No of cells Sets the number of cells to be used in the b...

Page 26: ...ery 1 Voltage Calibration Calibrates the Battery 1 volt meter reading Battery 2 Voltage Calibration Calibrates the Battery 2 volt meter reading Charger Voltage Calibration Calibrates the Charger voltage meter reading Charger Current Calibration Calibrates the charger output current meter Charger Current Offset Calibration Calibrates the charger output current offset Battery 1 Current Offset Calibr...

Page 27: ...de 64 Bushland Ridge Bibra Lake WA 6163 P 61 8 9434 6621 F 61 8 9434 6623 E sales magellanpower com au W www magellanpower com au 6 3 7 Sub Menu 10 Diagnostic Set up This sub menu is used to put the charger into a self diagnostic mode Diagnostic Level 1 Setting to On enables the level 1 diagnostic Diagnostic Level 2 Setting to On enables the level 2 diagnostic ...

Page 28: ...he required earth fault current reading on the multimeter Then adjust P1 potentiometer on the Interface Board until the Earth Fault LED D14 on the Interface board comes On Recheck the setting when the resistor meter is connected from earth to charger Ve To inhibit this alarm set the Earth Fault Inhibit set point to ON in the Sub Menu 5 Latches and Inhibit Settings 6 5 USER ADJUSTABLE SET POINT INS...

Page 29: ...DE KEY PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY BATT1 BOOST ACTIVATION CURRENT CURRENT 9 00 A OVERVOLTAGE TRIP DIODE DROPPER 3 ON HIGH DISCHARGE TEST LOAD SENSE BOOST INHIBIT RETURN TO MAIN MENU DUAL BATTERY ENABLED ON CHARGER VOLTAGE CAL Local IP Address 192 168 001 240 PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY PRESS MODE KEY PRES...

Page 30: ...nctions Check that the mains supply matches the supply requirements stated on the Ratings plate Connect the mains power Follow the start up procedure 7 2 CHECKING VOLTAGE LEVELS Before making any adjustments and to obtain the correct set points of the charger consult the Test Sheet Ensure the battery is fully charged this prevents unnecessary waiting time for the voltage to reach the boost level W...

Page 31: ...ttery at a time Discharge Battery 1 for a while by switching the charger off and providing some DC load for a period of approx 10 min This time may vary depending on the size of the DC load compared to the battery capacity When the battery has discharged sufficiently remove the load and switch charger on The output current from the charger will now rise to the battery current limit level check the...

Page 32: ...te key The mute function can be reset by pressing the Reset key Restore mains 7 8 TESTING DC LOW ALARM Disconnect the battery from the charger Decrease the Float voltage See User Adjustable Set Point Instruction Sheet to a setting just below the DC Low level The DC Low Alarm will be indicated on the LCD panel after the user programmable alarm delay has expired Also check that the DC Low relay on t...

Page 33: ...h level The DC High Alarm will be indicated on the LCD panel after the user programmable alarm delay has expired Also check that the DC high relay on the Relay board A4 if fitted has de energised and that its contacts see Schematic Diagram have changed over and check that the Common Alarm relay on the Interface Card has de energised and that buzzer is sounding Ensure that the buzzer can be muted b...

Page 34: ...be reset by pressing the Reset switch Replace the electrolyte probe 7 11 TESTING BATTERY FAIL Disconnect the battery from the charger Press the Battery Test switch and check that after the test period the Battery Fail LED lights up Check that the battery fail relay on the Relay board A4 if fitted has de energised and that its contacts see Schematic Diagram have changed over Also check that the Com...

Page 35: ... DC repair and maintenance and bring the collective knowledge and experience of the entire Magellan Power design and manufacturing team Magellan provides preventative maintenance services for the following Magellan products and batteries MCRI and MCRII DC UPS systems Magellan AC UPS systems Commercial UPS VRLA Lithium and NiCad batteries SERVICE AND COMMISSIONING Magellan provides Qualified in hou...

Page 36: ...ANCE MANUAL SINGLE PHASE MCRII SERIES BATTERY CHARGER Australian Technology Australian Made 64 Bushland Ridge Bibra Lake WA 6163 P 61 8 9434 6621 F 61 8 9434 6623 E sales magellan power com au W www magellan power com au 36 ...

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