Unipower Sageon III Product Manual Download

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Sageon III™ Power System

Product Manual

600A

1200A

PM 990-8800-00, Rev. 9

UNIPOWER, LLC
65 Industrial Park Rd
Dunlap, TN 37327
Phone: +1-954-346-2442
Toll Free: 1-800-440-3504
Web site –

www.unipowerco.com

Summary of Contents for Sageon III

Page 1: ...Sageon III Power System Product Manual 600A 1200A PM 990 8800 00 Rev 9 UNIPOWER LLC 65 Industrial Park Rd Dunlap TN 37327 Phone 1 954 346 2442 Toll Free 1 800 440 3504 Web site www unipowerco com...

Page 2: ...e carrier notes this on your receipt before you sign for the freight 2 EQUIPMENT INSPECTION 2 1 Within fifteen days open the crate and inspect the contents for damages While unpacking be careful not t...

Page 3: ...ed 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 instal...

Page 4: ...ed 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 warrantie...

Page 5: ...AM1 Tier 2 Group A GJ1 Group B GJ1 Ground Return Eight 8 battery connections 3 8 on 1 C C SAGEON3 E03 Tier 1 Group A AM1 Group B AM1 Tier 2 Group A AM1 Group B AM1 Tier 3 Group A AM1 Group B AM1 Grou...

Page 6: ...r Sageon III Kits include breaker bus adaptor return mounting hardware 1 Ampere AM1 Series Breaker 1 Position 274 3830 01 3 Ampere AM1 Series Breaker 1 Position 274 3830 03 5 Ampere AM1 Series Breaker...

Page 7: ...1 Position 274 3833 225 250 Ampere GJ1 Series Breaker 1 Position 274 3833 250 300 Ampere GJ1 Series Breaker 2 Positions 274 3833 300 350 Ampere GJ1 Series Breaker 2 Positions 274 3833 350 400 Ampere G...

Page 8: ...ONNECTING BATTERY CABLES 2 9 2 7 CONNECTING CUSTOMER LOADS 2 10 2 7 1 Load Return Cables 2 12 2 7 2 Load Supply Cables AM1 Type Breaker Distribution 2 12 2 7 3 Load Supply Cables GJ1 Type Breaker Dist...

Page 9: ...unctions 4 24 4 13 3 Alarm Log 4 24 4 13 4 Battery Menu Battery Specific Functions 4 25 5 0 SAGEVIEW 5 1 5 1 CONFIGURATION 5 1 5 1 1 SageView benefits 5 1 5 2 MONITORING 5 1 5 3 SECURITY 5 2 5 4 CABLE...

Page 10: ...WER SYSTEM 2 20 FIGURE 2 18 CONNECTIONS ON CONTROLLER BACKPLANE 2 21 FIGURE 2 19 TEMPERATURE CONCENTRATOR BOARD 2 21 FIGURE 2 20 SAGEON III BOARD LOCATIONS 2 22 FIGURE 3 1 SINGLE PHASE FEED PHASE TO N...

Page 11: ...ANSDUCER CONNECTIONS 2 17 TABLE 4 1 SUMMARY OF DEFAULT SYSTEM SCU PARAMETERS 4 1 TABLE 4 2 READING OPERATOR PANEL SYSTEM STATUS LEDS 4 4 TABLE 4 3 OPERATOR PANEL ANNUNCIATED ALARM MESSAGES 4 5 TABLE 4...

Page 12: ...RE 1 1 SAGEON III POWER SYSTEM This manual contains text of descriptions procedures and supporting illustrations in reference to the Sageon III Power System It includes the front matter and chapters 1...

Page 13: ...urn 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 resolu...

Page 14: ...Sageon III Power System Introduction PM990 8800 00 Rev 9 1 3 FIGURE 1 2 SIMPLIFIED BLOCK DIAGRAM 48V POWER SYSTEM...

Page 15: ...l specifications for the Power system and its major assemblies Power system Physical Specifications Dimension 7 foot Tower Width 24 46 62 1 cm Depth 21 48 54 6 cm Height 84 213 4 cm Weight Contact the...

Page 16: ...m Individual Group GJ1 1200A maximum General Specifications Battery Temperature Compensation Adjustable 0 1 to 6 mV C cell Bus Specifications Bus Structure Amperage Rating Per American National Standa...

Page 17: ...M on AC lines 6 kV 3 kA Differential Mode DM on AC lines 0 5 kV 0 25 kA CM DM on DC lines IEC 61000 4 12 EN 61000 4 12 Ring Wave 6 kV 500A 100 kHz CM DM on AC lines 2 kV CM 1 kV DM on DC lines A B A A...

Page 18: ...operating Sageon III Power System Output 48V Rectifiers Float Voltage Nominal 54 2 Vdc Range 42 58 Vdc Equalize Voltage 45 59 9 Vdc Current Limit 10 to 110 of rated output Temperature Derating 25A 15...

Page 19: ...B REC RECT RBOC RFA SBM SSM SCU SMR UBC UL UPS controlled environment vault circular mils dual in line package electromagnetic compliance or compatibility electromagnetic interference electrostatic di...

Page 20: ...ntrol 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 fo...

Page 21: ...ce Voltage free form C relay contact 1A 30 Vdc 1 5 PRODUCT SUPPORT Product support can be obtained using the following addresses and telephone numbers Corporate office UNIPOWER LLC 210 N University Dr...

Page 22: ...on 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 b...

Page 23: ...ble 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 referenc...

Page 24: ...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 a...

Page 25: ...5 67 11 9 16 12 756 0 63 0 85 42 9 16 18 864 0 72 0 98 62 2 3 SELECTING A LOCATION Install the Power system in a location that provides the following Access to a source of reliable stable electricall...

Page 26: ...ting 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 an...

Page 27: ...careful not to bend or otherwise damage the side and rear panels Be careful not to mar or otherwise damage the front bezels 3 Set the Power system in place 4 Securely fasten the Power system to the fl...

Page 28: ...n 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 ind...

Page 29: ...ON AC POWER Rectifiers Powered Breaker Rating 1 20A 2 40A AC Cabling This section describes connecting the AC input cables within the Power system An AC input cable can enter the plant several ways Th...

Page 30: ...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 accord...

Page 31: ...ements Refer to Section 2 2 2 Selecting and Sizing DC Power Cables for cable sizing Note To field install additional distribution refer to Chapter 7 Distribution Option Kit Installation To field insta...

Page 32: ...d part number 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...

Page 33: ...her current loads protected by GJ1 type breakers Load Supply Cables AM1 Type Breaker Distribution Connect customer load supply cabling in order by Tier Group and position number as shown on the Breake...

Page 34: ...are cabled 4 Move to Tier 1 Group B and cable the positions 5 Perform the above steps for Tiers 2 and 3 6 Bundle and secure cables as follows Two cable securing tabs are provided in each distribution...

Page 35: ...ution Assemblies Tier 3 Grp A Tier 3 Grp B Fuse Alarm FA Wire FIGURE 2 11 GJ1 TYPE BREAKER DISTRIBUTION ASSEMBLIES TYPICAL 1 Select a starting point the lowest Group letter Position 1 is recommended 2...

Page 36: ...t 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 Ba...

Page 37: ...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 7 Remove the bolt holding the inter cell battery strap in...

Page 38: ...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 Power System...

Page 39: ...her 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 Monit...

Page 40: ...e connectors 5 Check to be sure that the locking mechanism has engaged with the rectifier 6 If step 3 was performed Apply power to the newly installed rectifier by turning on the AC breaker 7 Repeat t...

Page 41: ...tifiers Battery Charge Current Limiting opt Short Circuit and Reverse Polarity Protection Battery Temperature Sensing opt Monitoring and Control Module Controller Accurate Temperature Compensated Floa...

Page 42: ...tion 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 vo...

Page 43: ...Installation Sageon III Power System PM990 8800 00 Rev 9 2 22 FIGURE 2 20 SAGEON III BOARD LOCATIONS...

Page 44: ...meters and values Alternatively edit the configuration 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 Etherne...

Page 45: ...2 volts 2 Connect the load to the System by closing the distribution breaker 9 Repeat Steps 7 through 10 until all Rectifiers are on line and taking load As Rectifiers are brought on line the load ma...

Page 46: ...Sageon III Power System Commissioning PM990 8800 00 Rev 9 3 3 FIGURE 3 1 SINGLE PHASE FEED PHASE TO NEUTRAL...

Page 47: ...Commissioning Sageon III Power System PM990 8800 00 Rev 9 3 4 FIGURE 3 2 SINGLE PHASE FEED PHASE TO PHASE...

Page 48: ...Sageon III Power System Commissioning PM990 8800 00 Rev 9 3 5 FIGURE 3 3 SPLIT SINGLE PHASE FEED PHASE TO NEUTRAL...

Page 49: ...Commissioning Sageon III Power System PM990 8800 00 Rev 9 3 6 FIGURE 3 4 Y THREE PHASE FEED CONNECTED RECTIFIERS PHASE TO PHASE...

Page 50: ...Sageon III Power System Commissioning PM990 8800 00 Rev 9 3 7 FIGURE 3 5 Y THREE PHASE FEED PHASE TO NEUTRAL...

Page 51: ...he AC feed to the Power plant Typically surge arrestors with a 10kA 40kA rating are required with the highest level of protection being provided when arrestors are connected between phase neutral x3 p...

Page 52: ...ERATURE 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 pos...

Page 53: ...onnection 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 Windows dialogue box will appear asking the user to instal...

Page 54: ...ateway 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 s...

Page 55: ...nnection provided on the Auxiliary programmable relay board All of these expansion modules are required to be mounted external to the Power plant and a single 16 way ribbon cable connected to the avai...

Page 56: ...ified 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 th...

Page 57: ...Ampere hour rating of batteries 20 9 999AH BTC Battery temperature coefficient 0 6 mV C cell 0 mV Number Cells Number of chemical cells in battery string 4 24 24 B I Lim Vb Vdd Battery charging curre...

Page 58: ...put 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 t...

Page 59: ...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 pr...

Page 60: ...nding 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...

Page 61: ...rge test failed to reach a programmed end point Amber FL 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...

Page 62: ...ctifiers 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 Da...

Page 63: ...Float voltage high level Set to the desired high alarm value Float voltage low level Set to the desired low alarm value Failsafe Alarms When Failsafe alarms are on all alarm relays will be normally en...

Page 64: ...e SCU software version and an all pixels on screen not shown Number of SMRs Rectifiers in system This number must be entered to prevent the operator panel from indicating that some SMRs are not respon...

Page 65: ...Configuration options are normally closed normally open or disabled not used Battery low voltage disconnect switch auxiliary contact circuit input Configuration options are normally closed normally o...

Page 66: ...ercentage of nominal cell voltage by which any individual cell voltage can be less than the nominal Below this value an alarm will be generated Site Monitor When the Site Monitor is included in the so...

Page 67: ...annot be changed in this screen 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 par...

Page 68: ...e 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 initi...

Page 69: ...ttery 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 indicati...

Page 70: ...he system output voltage at the output bus bar terminals System voltage drop Set the maximum voltage drop as defined by maximum rectifier output system float voltage A typical value is 0 6V Equalizati...

Page 71: ...al equalization manual start The system must be in Float mode for this screen to appear Low Voltage Battery Disconnect LVBD LVLD Screens LVBD switch trip voltage Set to establish the voltage at which...

Page 72: ...tery voltage that will terminate the test if reached before the test duration set above At the end of test whether ended by test duration or end voltage normal operation is restored and recharging of...

Page 73: ...tring at the time the test was terminated where n is the number of the string BDT Disabled The battery discharge test function is disabled for 2 minutes if any of the following has occurred If an auto...

Page 74: ...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 SageV...

Page 75: ...d 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...

Page 76: ...d Setup Press ENTER Modify Value up down ENTER to accept Press ENTER to begin flashing display and LEDs Test Indicators Press ENTER ENTER System information including controller software version S N a...

Page 77: ...Modify Value up down ENTER to accept ENTER Phone 3 0398887788 Modify Value up down ENTER to accept ENTER Phone 3 Cont 2323 Modify Value up down ENTER to accept ENTER Audio Alarm Off INC DEC toggles st...

Page 78: ...nfig 24 cells Modify Value up down ENTER to accept ENTER Number of battery banks BCM Batteries 1 Modify Value up down ENTER to accept ENTER Cell Vhi Alarm 2 50V Modify Value up down ENTER to accept EN...

Page 79: ...not be adjusted here Equalise Voltage SMR Default SMR Equalise 56 5V Cannot be adjusted here ENTER SMR voltage above which alarm flagged SMR V high Alarm 57 0V Modify Value up down ENTER to accept ENT...

Page 80: ...Ah Battery Rating 500Ah Modify Value up down ENTER to accept ENTER Battery Temperature compensation BTC Coeff 3 2 mV C C Modify Value up down ENTER to accept Variable from 0 to 6 0mV C C If BTC not O...

Page 81: ...lisation EQ Duration 3 hours Modify Value up down ENTER to accept ENTER Periodic equalisation charging trigger EQ Period 12 Weeks Modify Value up down ENTER to accept Set to zero to disable ENTER Manu...

Page 82: ...Power Plant with Battery String s Control Signals Power Plant with Battery String s RS 232C Local PC with SageView Distribution Battery String s To User Loads FIGURE 5 1 NETWORK CONNECTIONS 5 1 CONFIG...

Page 83: ...stem Consult your company s network administrator 5 5 LOCAL CONNECTION STANDARD For a local connection cable the serial port on the Sageon III Power System s operator panel to the USB port on a Window...

Page 84: ...ar Click Next to continue the installation or click Cancel to exit the installation 3 In the Choose Destination Location screen click Next to accept the default location for installation of the SageVi...

Page 85: ...allation screen is the Setup Complete screen Click Finish to complete the installation Refer to the SageNET user manual for more information on setting up the Remote Communications Unit over TCP IP Th...

Page 86: ...ifier 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 Lo...

Page 87: ...nfiguration or uploading a new configuration from a PC to the Sageon III Power System carefully check the configuration s programmable parameter values before changing a hardware assembly Reading Rect...

Page 88: ...ations 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...

Page 89: ...Off Off Off On Off Off 5 Off Off Off Off Off On Off On 6 Off Off Off Off Off On On Off 7 Off Off Off Off Off On On On 8 Off Off Off Off On Off Off Off 9 Off Off Off Off On Off Off On 10 Off Off Off O...

Page 90: ...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 No...

Page 91: ...erload 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 m...

Page 92: ...djusting the RECTIFIER parameters to see if the EEPROM cells can be updated If not replace the faulty rectifier 6 8 TO REMOVE A RECTIFIER MODULE Lift the securing latch in the center divider adjacent...

Page 93: ...se equipment damage load interruptions and personal injury 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...

Page 94: ...n bus sections separately as needed TABLE 7 1 INSTALLABLE DISTRIBUTION TYPES BY TIER AND GROUP Tier Group Positions Installable Distribution See notes below AM1 48V Plant GJ1 48V Plant 1 A 1 10 Y N 1...

Page 95: ...f 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 support bracket and requ...

Page 96: ...RE 7 4 ORIENTATION OF DISTRIBUTION ASSEMBLIES 48V SYSTEMS Kit Contents Some hardware listed below may be factory installed on another item in the kit and disassembly may be needed to install the optio...

Page 97: ...ition the four unthreaded holes of the U shaped bus bar from the kit onto the factory installed U shaped bus bar of the distribution option directly below the your selected group Orientation will be t...

Page 98: ...8 to install AM1 circuit breakers fuses 7 2 GJ1 DISTRIBUTION TIERS 2 AND 3 GROUPS A B This section describes installation of the GJ1breaker distribution option in Tiers 2 and 3 Groups A B Installation...

Page 99: ...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 5 From the kit col...

Page 100: ...nd Output Terminal Hardware Bus Bar L Shaped Mounting Bracket U Shaped Bracket Mounting Screw 12 24 x 3 4 2 Places Breaker Mounting Bar 2 Places Breaker Input Terminal Hardware Bevel Washer Flat Washe...

Page 101: ...g the Kit 1 Remove an AM1 type breaker kit from its protective packaging The package label will identify the kit by part number 2 Open the distribution area door Refer to Figure 7 1 and locate the Dis...

Page 102: ...he Distribution Tier and Distribution Group where this kit will be installed Note GJ1 distribution cannot be installed in any Group of Tier 1 2 Remove the two painted breaker mounting bars from the ex...

Page 103: ...re 8 3 7 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 Insert through tab of the GJ1 type breaker and thread into th...

Page 104: ...Circuit Breaker and Fuse Kit Installation Sageon III Power System PM990 8800 00 Rev 9 8 4 FIGURE 8 4 GJ1 TYPE BREAKER KIT INSTALLATION Lower distribution option removed for clarity...

Page 105: ...Section 1 5 Product Support TABLE 9 1 PARTS LIST Description Part Number Circuit Boards Rectifier Backplane Board ERT190 5540 Controller Backplane w Temp Comp ERT190 5770T Unit Sageon III Control Uni...

Page 106: ...FOR EACH RECTIFIER POSISTION 6 DASHED LINES DENOTE CUSTOMER CONNECTIONS OR EXTERNAL PANEL CONNECTIONS 7 DASH DOT LINES DENOTE COMPONENTS OR CONNECTIONS INTERNAL TO SAGEON3 8 BATTERY DISCONNECT PANELS...

Page 107: ...K RED AC1 AC2 EARTH BLK RED GRN BLK RED AC1 AC2 EARTH BLK RED GRN BLK RED AC1 AC2 EARTH O I O I O I GND L1 L2 L N E GND L1 L2 L N E GND L1 L2 CUSTOMER AC CONNECTIONS EXT COMMS RECTIFIER 48V 50A 100 76...

Page 108: ...RED BLK BDM RIBBON BUS BAR BUS BAR AMB BATT TEMP 4 TEMP 3 TEMP 2 TEMP 1 ORN ORN VIO BRN WHT VIO AMB TEMP AUX RELAY NO 2 AUX RELAY NO 3 AUX RELAY NO 4 BLK AUX RELAY C FA NC FA C TO PAGE 4 OPT EXT COMM...

Page 109: ...BLK BLK BLK BLK BLK BLK BATTERY DISCONNECT PANEL BATTERY DISCONNECT PANEL BATTERY DISCONNECT PANEL BLK BLK BLK ORN ORN ORN ORN EXTERNAL CT S SEE NOTE 3 INTERNAL BATTERY LVD AMB TEMP SEE NOTE 8 OPT BA...

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