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5.6 Electrical Assembly of the ERS

Electrical Assembly of the ERS

After the ERS system has been set up and mechanically connected, the electrical connections be-
tween the cabinet segments and the network or the automation system must be made

N T E R N A L L Y

DC-Intermediate circuits

24V-supply and control lines

CAN-Bus

Grounding

Connecting Power Circuits

Due to the separation of the ERS for delivery, lines for power transmission between the AFE and HTS
must be re-established

DC-link

Fig. 20 Overview of the electrical connections of the power circuits

Содержание ERS-BIC

Страница 1: ...Betriebsanleitung User Manual Bidirectional Power Supply System Heinzinger ERS BIC www heinzinger com...

Страница 2: ...reich Stromaufnahme supply voltage frequency range current consumption Output Ausgangsspannung Ausgangsstrom Ausgangsleistung output voltage output current output power Options M Modifikation M Modifi...

Страница 3: ...and Operating Guide 8 Intended Use 8 Residual Risks and Precautions 8 3 Technical Specification 9 Table 1 Dimension Weight 9 Table 2 Mains Connection 9 Table 3 Output 9 Table 4 Display Control 9 Tabl...

Страница 4: ...ibility 24 Assembly Instruction 25 Mechanical Assembly 25 Installation of the Cooling System 27 Filling and Venting the Cooling Circuit 29 Electrical Assembly of the ERS 30 Connecting Power Circuits 3...

Страница 5: ...60 Service Parameters 61 Battery Models optional 61 Model 1 61 Model 2 61 Model 3 61 Model 4 61 Cluster Operation optional 61 Description 61 Parallel Cluster Operation 62 Serial Cluster Operation 63...

Страница 6: ...71 Error Messages 73 Troubleshooting Cluster Operation 78 9 Care Maintenance Calibration 79 Care and Cleaning 79 Venting the Cooling Circuit 79 Service and Maintenance 79 Not Using the Device 79 Calib...

Страница 7: ...ease see the terms of the agreement Unauthorized conversions and modifications to the system as well as the use of non approved spare parts will void all liability and warranty on the part of the manu...

Страница 8: ...which personal injury may occur N O T I C E Draws your attention to information that must be observed in particular to prevent impairment and damage to and by the device Significance of the Manual Pl...

Страница 9: ...at least 5 minutes after switching off the ERS before opening the cabinet doors Requirements to Personnel The device is designed for commercial use The personnel are therefore subject to the statutor...

Страница 10: ...ly component testing in test bench applications Extensions conversions or repairs may only be carried out by persons authorized by the manufacturer The electrical installations comply with the applica...

Страница 11: ...0 A Mains connection phase 1 x eyelet bolt 10 mm Table 3 Output Output Voltage Vnom 600 V 1200 V Output current Inom 600 A 1200 A Discharge time no load 1 minute Efficiency 93 Output polarity floating...

Страница 12: ...change in set value 1 ms resistive load Control time at step in load 10 to 90 1 ms resistive load Stability over an 8 hour period constant conditions 0 1 UNOM Residual ripple 0 2 UNOM for f 0 1 MHz Ta...

Страница 13: ...tioning of coolant connection See section 5 3 3 p 23 Table 9 Battery Models Range internal resistance 0 1 1 resolution 0 1 m Battery model optional 3 standard battery models as RC network integrated T...

Страница 14: ...4 1 Device Views 12 4 DESIGN AND FUNCTION Device Views Exterior view Output Channel 1 Output Channel 2 Mains switch Touch display Fig 1 Exterior view ERS BIC...

Страница 15: ...Manual ERS BIC 160 kW V2 1 13 Inside view Mains connection 3p PE N Coolant connec tion Output Unit Channel 2 Output Unit Channel 1 Isolating transfor mer Controlboard HTS Fig 2 Interior view ERS BIC...

Страница 16: ...ing source operation of the ERS it feeds the energy absorbed at the output of the ERS back into the grid via the transformer during sink operation HTS A Multi Parallel Converter MPC serves as a step u...

Страница 17: ...ind an overview of the possible current combinations depending on the device type Table 12 Specifications single channel mode Device type 1200 1200 160 Voltage 2 channels 600 V Current 2 channels 600...

Страница 18: ...depending on the device type Table 13 Specifications parallel mode Device type 1200 1200 160 Voltage 1 Channel 600 V Current 1 Channel 1200 A Power 1 Channel 160 kW Mains 3P 400 V 50 Hz control syste...

Страница 19: ...ible current combinations depending on the device type Table 14 Specifications serial mode Device Type 1200 1200 160 Voltage 1 Channel 1200 V Current 1 Channel 600 A Power 1 Channel 160 kW Mains 3P 40...

Страница 20: ...00 600 00 750 00 900 00 1050 00 1200 00 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 CURRENT IN A VOLTAGE IN V single channel mode parallel serial Fig 10 Power hyperbola of two ERS BIC 1200 12...

Страница 21: ...ormance Level D optional Safe separation Optional using a double set of redundant contactors at the output Signal lamps Optional Insulation monitoring of each channel optional Quick discharge of the i...

Страница 22: ...ing of the response values is done via a setting menu using the device keys and a graphic LCD The selected settings are stored in a permanent memory After switching on the insulation monitor carries o...

Страница 23: ...00 kg HTS cabinet 500 kg Unpacking the Unit WARNING Under no circumstances put the device into operation if it is visibly damaged The ERS is delivered in wooden boxes or with direct packaging with lig...

Страница 24: ...cordance with the installation plan Fig 12 p 22 Ensure that the room is adequately venti lated so that the maximum permissible am bient temperature is not exceeded Clearances There must be sufficient...

Страница 25: ...the cooling circuit should be selected so that they have a small voltage difference see appendix C p 99 with the aluminum heat sinks in the device so that there is no contact corrosion and or pitting...

Страница 26: ...tion compliance with the specific safety regula tions and the handling of any radio interference are the responsibility of the owner The following rules for installation must be observed In order to p...

Страница 27: ...y 600V 4A e g Heinzinger GEN 600 4 Insulation tester for example Grossen Metrawatt Secutest 8 pieces crocodile clips long 5 pieces measuring cable 0 5 m Service plug Heinzinger 2 x Sense cable connect...

Страница 28: ...cabinet segments have been placed at the intended location they can be fixed and screwed together with the aid of the bayed connectors The bayed connectors are already preinstalled in the AFE cabinet...

Страница 29: ...ts with a rated of 160kW the block is to the left side of the input trans former All internal connections must be restored before connecting to the building s cooling circuit Reconnect the internal co...

Страница 30: ...nation It is strongly recommended to install a fine water filter in front of the ERS system so that no con taminants can get into the system The cooling water circuit is equipped with a G 1 screwed co...

Страница 31: ...he solenoid valve the cooling water will flow through the ERS Afterwards check whether all connections at the water block are tight or whether leaks are present VENTING THE ERS COOLING SYSTEM Remove t...

Страница 32: ...binet segments and the network or the automation system must be made INTERNALLY DC Intermediate circuits 24V supply and control lines CAN Bus Grounding Connecting Power Circuits Due to the separation...

Страница 33: ...strain relieved on the rail below the fuses using the clamps from the accessory pack Reference No 4a 4b N O T I C E When connecting the cables to the DC bus make sure that the insulation plate of the...

Страница 34: ...ts For this purpose sockets are installed in the upper side of the AFE cabinet which must be connected to the plugs coming from the other cabinets Table 18 Overview signal lines Cabinets Connection 1...

Страница 35: ...re them against loosening Internal Grounding In order to ensure the sufficient grounding of all components installed in the cabinet grounding rails are installed on the rear side in the lower half of...

Страница 36: ...t is possible to make the connection via a common PEN conduc tor For this purpose a bridge minimum cross section 6 mm must be placed between the N terminal and the PE terminals However this requires t...

Страница 37: ...support rail on the cabinet floor from stress Make sure that the shield contacts a large area to ensure the best possible shielding WARNING Risk of electric shock After installation the covers must b...

Страница 38: ...ential free contacts The contacts can be found on the terminal X4 1 X4 2 and X4 3 in the HTS cabinet and can be connected by single or multi core cables If some of the control contacts are not used th...

Страница 39: ...OAD The load is connected to the DC output rails with correct polarity Output and Output using shielded cables with sufficient current carrying capacity and dielectric strength The connection is prepa...

Страница 40: ...em has been electrically connected and connected to the mains the insulation test must now be carried out You need a commercially available insulation tester and must connect the PE connection of the...

Страница 41: ...pply which can generate at least 2 5 kV and is equipped with a current limiter max 10 mA You will also need 8 crocodile clips 5 laboratory cables and a special service plug to connect the phases DANGE...

Страница 42: ...ole of the high voltage power supply The short circuit must be created internally before the output relays The negative pole is connected to the device earth grounding rail 5 While observing the curre...

Страница 43: ...cure against reconnection Verify that the system is dead Carry out grounding and short circuiting Provide protection from adjacent live parts DANGER Even after switching off the power supply residual...

Страница 44: ...hannels DANGER High voltage Make sure that you do not touch the upper contacts of the fuse holders while the unit is switched on Connect at the outputs CH1 with CH2 and CH1 with CH2 using an appropria...

Страница 45: ...as booted and make the following settings Deactivation of the undervoltage moni toring Set the minimum value of the DC link voltage to 20 V Now switch on the auxiliary power supply and set the voltage...

Страница 46: ...V in the IBN interface Now parameterize the channels according to step 8 of the set point table and check the function of the system once again but now with active AFE Table 20 Set values external sup...

Страница 47: ...structions for Operation WARNING Commissioning and operation only by trained specialist personnel Switching the Unit On and Off When switching the device on and off the following sequences should be o...

Страница 48: ...ration Batt Sim Batt Test Always set all set values for V I and P I and P have to be nega tive when the system has to take in energy even when Dis charge or Sink has been chosen as mode of operation T...

Страница 49: ...Control of wiring mode single parallel serial cluster for channel stop Signal lights optional Five color signal light on the roof of the system Section 4 5 1 p 19 CAN Bus Remote control Automation Sec...

Страница 50: ...e 2 Channel 1 displayed Choose Channel 1 for display 3 Channel 2 displayed Choose Channel2 for display 4 Actual Values Current voltage power 5 Set values Current voltage power Input of set values Curr...

Страница 51: ...de CP 16 Pause battery test or bidirectional operation battery simulation active Choose pause battery test or bidirectional operation battery simulation 17 Charge battery test or source mode battery s...

Страница 52: ...ses to device damage Use the Enter Password button to enter the passwords to enable access to the locked submenus The Reset Password button locks access to all setup menus By default the password leve...

Страница 53: ...tware versions used Table 24 System Info Designation Function Device Info Display of device data such as article number output power number of outputs and serial number SW Versions Display of the curr...

Страница 54: ...Relay Switching Cycles Counter for switching cycles of the output contactors On the basis of the switching cycles the wear of the relay contacts can be determined When a predefined threshold is reach...

Страница 55: ...vices there are two additional columns Table 26 Menu System Info Measurements Designation Function V INT Internal voltage V Sense Measured sense voltage V PRI DC link voltage primary circuit V SEK DC...

Страница 56: ...ble 27 Menu System Info FPGA Diagnose Designation Function RS485 STATUS RX Status RS485 Interface RS422 STATUS A Status RS422 A RS422 STATUS B Status RS422 B HTS_ERR Error messages HTS Error Display o...

Страница 57: ...ult the hexadecimal code can be passed on to the Heinzinger Service and is used for system diagnosis Table 28 Menu System Info DSP Diagnosis Designation Function CPUx Error Error number DSPx hexadecim...

Страница 58: ...A list of possible error and warning codes can be found in section 8 5 pp 71 Table 29 Menu System Info Error History Designation Function Device Error code Hexadecimal and time stamp System time globa...

Страница 59: ...ing mode is only possible in the de energized state Operating mode Switching between cluster and single device mode CAN BUS Interface Settings for the CAN BUS interface Cooling System Activate deactiv...

Страница 60: ...is displayed Int Voltage monitoring Switch off threshold and delay time for internal volt age monitoring Output voltage monitoring Switch off threshold and delay time for monitoring the output curren...

Страница 61: ...vation of the fast discharge function is necessary if there is a risk of overloading the discharge resistor due to external voltage sources ISO Monitoring Activate deactivate insulation monitoring CAN...

Страница 62: ...he control loop Set Value Ramp Definition of the set value ramp via voltage time always same slope or input of a time for the ramp always same time ramp slope is calculated depending on the set value...

Страница 63: ...eters for the simulated equivalent circuit The following setting ranges apply to the parameters the values for R2 and C are not used for battery model 4 R1 0 1 m 1 R2 0 1 m 1 C 0 1 F 100 F Four possib...

Страница 64: ...individual channels of the ERS systems in parallel thus doubling the output power and quadrupling the current Below there is an overview on the possible device output for parallel cluster mode Table 3...

Страница 65: ...ection of two devices that are in serial wiring mode is not allowed The following table shows the possible output depending on the device type Table 34 Specifications serial cluster operation Device t...

Страница 66: ...l active If the ERS systems also have the option channel stop an additional communication line for the emergency stop relays must be established The control lines from the slave device to the automati...

Страница 67: ...device now shows the normal main menu again Step 2 While the systems are switched on disconnect CAN A und RS422 No restart is necessary Step 3 End cluster operation The menu Unit Operation is unlocke...

Страница 68: ...effective independent of all other switch positions and device settings also independent of the settings from the digital interface Normal device operation is only possible if the interlock function i...

Страница 69: ...Contactor optional On X4 3 there are potential free contacts from Performance Level C on which output the status of the output contactors This allows a safe detection of the status at the output of th...

Страница 70: ...pages The Firmware Download TP tool is also available there with which the updated firmware can be downloaded to the gateway Note Save a copy of the configuration before downloading the new firmware...

Страница 71: ...this the pins 4 5 7 and 8 have to be connected with the housing ground Profibus uses a 9 pin Sub D Plug that is assigned according to Fig 63 A maximum current of 80 mA can be drawn from pins 5 and 6 f...

Страница 72: ...it is disconnected from the grid by means of the mains contactor After eliminating the cause of the error the device must be switched on again Temperature Monitoring Temperature switches are installed...

Страница 73: ...warnings is represented in a 16 bit data word The warnings can be divided into the following areas Warning code 0xn1mm n area of warning mm Code Warning areas Warnings of channel 1 0x1100 0x11F Contr...

Страница 74: ...7 INIT_SERV_PARA_WARN forbidden service parameter at initialization 0x18 INIT_OPER_DATA_WARN forbidden operation mode parameter at initialization 0x19 LOCKED_OPTION option not released 0x1A CONTROL_PA...

Страница 75: ...a of error Error of channel 1 0x1000 0x10FF Control Unit 1 Error of channel 2 0x2000 0x20FF Control Unit 2 Error of channel 1 0x6000 0x60FF Control Unit 2 Error of channel 2 0x7000 0x70FF Control Unit...

Страница 76: ...ached secondary voltage 0x1E V_MON_SEC_UV_ERR Undervoltage limit reached secondary voltage 0x1F TEMP_CB_ERR Over temperature Control Unit 0x20 AFE_CHOP_ERR AFE Chopper timeout 0x21 OVP_SENS_ERR Overvo...

Страница 77: ...mit reached 0x3A C_MON_HTS4_NEG_ERR Neg inductor current limit reached 0x3B OUT_REL_ERR_2 Error on output contactor 2 0x3C DISCHARGE_R_OT Overtemperature discharge resistor 0x3D ACC_OVFL Accumulator O...

Страница 78: ...SW Error I2C Access Error No Access to I2C registry 0x54 CAN_BAUDRATE_ERR Internal SW Error Error at CAN baud rate settings 0x55 CAN_TRS_ERR Internal SW Error CAN Message cannot be transmitted last m...

Страница 79: ...0x9A CLUSTER_OTH_UNIT Cluster configuration of other device 0x9B CURRENT_SENSE C_Out not equal to sum of C_HTSx 0x9C CURRENT_SYM_HTS1 Symmetry error current HTS1 0x9D CURRENT_SYM_HTS2 Symmetry error c...

Страница 80: ...properly when switching over the device operation In this frozen state the system tries to read from an incorrect EEPROM address Solution To solve the problem switch between Master Slave Off After swi...

Страница 81: ...to maintain the long term availability of the system and to safeguard your investment reg ular maintenance and equipment checks are recommended The intervals between the required maintenance works dep...

Страница 82: ...no guarantee can be given for the safety and function of the device If necessary please contact our service department Service Address Maintenance and repair work is carried out directly by the manuf...

Страница 83: ...alue Ranges 97 Control Schematics 96 Controller Settings 98 Control Parameters 60 Coolant 23 Coolant Connection 12 Coolant Monitoring 70 coolant temperature 23 Coolant Temperature 71 Cooling System 23...

Страница 84: ...Ramp 58 Range of Use 8 Rapid Discharge 58 Residual Risks 8 S Safety Concept 19 Safety Instructions 7 Safety rules 7 Safety Symbols 8 Scope of Delivery 5 21 Sense Connection 69 Sense Monitoring 58 Ser...

Страница 85: ...Remote 8 Variable 1 1 0x132 CH_2_MAX_SET_VAL DSP Remote 8 Variable 1 2 0x141 CH_1_BAT_MODEL_STATUS DSP Remote 8 1 0x142 CH_2_BAT_ MODEL_STATUS DSP Remote 8 2 0x151 CH_1_STATUS_II DSP Remote 8 Variabl...

Страница 86: ...H_1_SET_PRE_CTRL Remote DSP 8 1 Remote 0x2A2 CH_1_SET_PRE_CTRL Remote DSP 8 2 Remote 0x2B1 CH_1_SET_SYM_CTRL Remote DSP 8 1 Remote 0x2B2 CH_1_SET_SYM_CTRL Remote DSP 8 2 Remote 0x2C1 CH_1_SET_PROT Rem...

Страница 87: ...UERY Remote DSP 2 1 Remote 0x492 CH_2_GET_SEC_CTRL_QUERY Remote DSP 2 2 Remote 0x4A1 CH_1_GET_PRE_CTRL_QUERY Remote DSP 2 1 Remote 0x4A2 CH_2_GET_PRE_CTRL_QUERY Remote DSP 2 2 Remote 0x4B1 CH_1_GET_SY...

Страница 88: ...isolation monitor Ch4 10 0 1 CLR_ERR_WARN_BUFFER Clears all error and warning memories 2 16 17 CHANNEL_WIRING 0 Normal normal wiring single channel 1 Parallel parallel wiring of the channels 2 Serial...

Страница 89: ...e 1 Slave Channel 2 is Slave for cluster mode 4 5 32 47 0 65355 DEV_ERR_CODE Current Error code in the device 6 7 48 63 0 65355 DEV_WARN_CODE Current Warning code in the device A D Device Status II ID...

Страница 90: ...er controlled 1 8 11 0 8 PAR_ID Choose parameter set 12 0 1 RESET_Q Reset Coulomb Counter 14 15 0 2 OPER_MODE Battery test mode 0 PAUSE 1 DISCHARGE 2 CHARGE Battery simulation 0 BIDI 1 SINK 2 SOURCE 2...

Страница 91: ...TRL_MODE_ACT 1 CV Act voltage control active 2 CC Act current control active 4 CP Act power control active 14 15 0 2 OPER_MODE Mode of operation battery test mode 0 PAUSE 1 DISCHARGE 2 CHARGE Battery...

Страница 92: ...are limited to the limits The valid set values are output periodically only in case of changes or only after request at the remote interface ID Name Message ID Data Length Sender Receiver Cycle Time C...

Страница 93: ...e current 4 5 32 47 32768 3276 7 P_SET_MAX 325 kW 10 W 325 kW 100 W maximum set value power A L CHARGE DISCHARGE Registry ID Name Message ID Data Length Sender Receiver Cycle Time CHARGE_DISCH_QUERY 0...

Страница 94: ...Name Message ID Data Length Sender Receiver DEV_QUERY_READ_ERROR 0x360 1 Byte Remote ERS Byte Bits Name Description 0 0 7 SELECTION 0 answer 1 timestamp in ms since last SW restart 1 answer 2 timesta...

Страница 95: ...R_CODE channel error code 1 8 15 2 16 21 2 3 22 31 0 1023 0 999 TIMESTAMP 0 Timestamp in ms 4 7 32 63 0 FFFFFFFFh 0 4294967295 TIMESTAMP 1 Timestamp in s since 1970 01 01 A Q Device Warnings On this m...

Страница 96: ...ferences the time since the start of the SW New time stamp references the time since 1970 01 01 in ms ID Name Message ID Length Sender Receiver CH_READ_WARN_QUERY 0x371 Channel 1 0x372 Channel 2 1 Byt...

Страница 97: ...n DSP1 Index 0x001 SW Version DSP2 Index 0x002 SW Version FPGA Index 0x010 serial number Index 0x020 date of last calibration yyyymmdd Index 0x040 designation of the device ID Name Message ID Data Len...

Страница 98: ...96 B DIGITAL CONTROL LOOP B A Control diagram...

Страница 99: ...Control Setting Range Typical Value P ratio 0 0001 6500 0 1 6 5 I ratio 0 0001 6500 0 01 1 0 Ramp 0 1000 V ms y 0 1000 ms 0 1 1000 B C B Current Control Current Control Setting Range Typical Value P r...

Страница 100: ...er Setting Effect of the Load The length of the supply lines influence the control Additional inductance 1m ca 1uH The capacity of the load affects the control behavior The location of the sense measu...

Страница 101: ...tial V Aluminum 1 67 Mangan 1 05 Zinc 0 76 Chrome 0 71 Iron II 0 44 Cobalt 0 28 Nickel 0 25 Tin 0 14 Lead 0 13 Iron III 0 037 Hydrogen 0 Copper 0 34 D REFERENCE LIST ACCESSORIES Accessory Nr Heinzinge...

Страница 102: ...100 E DECLARATION OF CONFORMITY...

Страница 103: ...iche Genehmigung der Heinzinger electronic GmbH darf diese Be triebsanleitung oder Teile daraus weder vervielf ltigt reproduziert verteilt noch in eine an dere Sprache bersetzt werden DISCLAIMER The i...

Страница 104: ...Heinzinger electronic GmbH High Voltage Smart Solutions Anton Jakob Strasse 4 83026 Rosenheim GERMANY Phone 49 8031 2458 0 Fax 49 8031 2458 58 info heinzinger de www heinzinger com V2 1 07 06 2021...

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