GRINTEK POWER TECHNOLOGIES

OPERATING MANUAL

FOR THE

GT305-SP

POWER SYSTEM

Including:

OPERATION

INSTALLATION

SERVICE & MAINTENANCE

GRINTEK POWER TECHNOLOGIES ISSUE 01

UPDATES

GRINTEK POWER TECHNOLOGIES reserves the right to update its equipment and/or documentation without
prior notification.

RECORD OF CHANGES

Personnel incorporating current changes to this manual are responsible for ensuring that all previous changes
are incorporated.

NEW ISS. DESCRIPTION

ISSUE DATE
01 2005-01-05 First Release

WARNINGS

The following are general safety precautions that are not related to any specific procedure and therefore do not
appear elsewhere in this publication. These are recommended precautions that personnel must understand
and apply during any phase of operation and maintenance

HIGH VOLTAGES

Mains voltages which are hazardous to humans are present in the equipment, and care must be taken at all
times not to come into contact with these voltages when servicing the equipment.

IMPORTANT NOTICE

The installation approval sheet at the back of this manual should be completed for the purpose of
honouring warranty as specified in the warranty agreement.

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TABLE OF CONTENTS
TITLE PAGE

1 GENERAL OPERATION___________________________________________________________ 6
1.1 SCOPE_____________________________________________________________________ 6
1.2 DESCRIPTION_______________________________________________________________ 6
1.3 SYSTEM SPECIFICATIONS ____________________________________________________ 7
1.4 CONTROL AND SUPERVISORY UNIT (MiniCSU) __________________________________ 7
1.4.1 MiniCSU CONTROL FUNCTIONS ____________________________________________ 7
[Link] OUTPUT VOLTAGE _____________________________________________________ 7
[Link] BATTERY TEMPERATURE COMPENSATION ________________________________ 7
1.5 MiniCSU DISPLAY ___________________________________________________________ 8
1.6 ALARM CONDITIONS_________________________________________________________ 8
1.7 MiniCSU MENUS_____________________________________________________________ 8
1.7.1 ‘Home’ Menu _____________________________________________________________ 9
1.7.2 ‘SMR’ Menu_____________________________________________________________ 10
1.7.3 ‘BATT’ Menu ____________________________________________________________ 11
1.7.4 ‘Alarms Log’ Menu _______________________________________________________ 13
1.8 MiniCSU SECURITY _________________________________________________________ 13
1.9 Mini USER INTERFACE BOARD (MUIB)_________________________________________ 14
1.10 REMOTE MONITORING ____________________________________________________ 14
1.11 TEMPERATURE SENSORS _________________________________________________ 17
1.12 DC DISTRIBUTION ________________________________________________________ 17
1.13 AC CONNECTIONS ________________________________________________________ 17
1.14 OUTPUT EARTH __________________________________________________________ 17
2 REPAIR AND MAINTENANCE _____________________________________________________20
2.1 INSPECTION _______________________________________________________________ 18
2.2 SITE REPAIRS _____________________________________________________________ 18
2.3 MiniCSU Alarms ____________________________________________________________ 18
2.4 REPLACING MODULES ______________________________________________________ 19
2.5 BATTERY REPLACEMENT ___________________________________________________ 19
3 INSTALLATION AND COMMISSIONING ____________________________________________ 21
3.1 INTRODUCTION ____________________________________________________________ 21
3.2 INITIAL PLANING REQUIREMENTS ____________________________________________ 21
3.3 Preparation ________________________________________________________________ 21
3.3.1 Rack preparation_________________________________________________________ 21
3.3.2 Ventilation ______________________________________________________________ 21
3.4 Site Preparation ____________________________________________________________ 22
3.4.1 Connect to Mains Switchboard ______________________________________________ 22
3.4.2 DC Connections and Building Earth __________________________________________ 23
3.5 Remote Alarms _____________________________________________________________ 24
3.6 Battery Installation __________________________________________________________ 25
3.7 DC Load Terminations _______________________________________________________ 25
3.8 Install Switch Mode Rectifiers (SMRs) __________________________________________ 25

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LIST OF APPENDICES

APPENDIX A Installation and Commissioning Checklists ………………………………. A1

APPENDIX B Cabinet Wiring Diagram ……………………………………………………. B1

LIST OF FIGURES

Figure 1 GT305-SP Power System ………………………………………………. Page 7

Figure 2 Battery Temperature Compensation Curve ……………………………… Page 9

Figure 3 MUIB Connection Diagram ………………………………………………… Page 16

Figure 4 AC Distribution ………………………………………………………………... Page 23

Figure 5 DC Distribution ………………………………………………………………… Page 23

Figure 6 Interface tray …………………………………………………………………. Page 24

LIST OF TABLES

Table 1 MiniCSU Alarms ……………………………………………………………… Page 18

Table 2 Battery Replacement ………………………………………………………… Page 20

Table 3 Remote Alarms ………………………………………………………………. Page 24

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LIST OF ILLUSTRATIONS

TERMS AND ABBREVIATIONS

A Amperes
AC Alternating Current
AUX Auxillary
BATT Battery
CSU Control and Supervisory Unit
CTRL Control
DEC Decrement
°C Degree Celsius
DC Direct Current
e.g. Exempli gratia (For Example)
etc et cetera (And all the others, And the rest)
Fig. Figure
GSM Global System for Mobile phones
Hz Hertz
INC Increment
Iss. Issue
i.e. id est (In other words)
kg Kilogram
LCD Liquid Crystal Display
LED Light Emitting Device
LVDS Low Voltage Disconnect Switch
max. Maximum
mm Millimetre
MUIB Mini User Interface Board
PC Personal Computer
PSU Power Supply Unit
QA Quality Assurance
RT4F 48V-50A Rectifier Module/Power Supply Unit
SMR Switch Mode Rectifier
TERM Terminal
VRLA Valve Regulated Lead Acid
V Volts

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1 GENERAL OPERATION

1.1 SCOPE

This manual contains general information, principles of operation, removal and installation of the GT305-SP
Power System.

1.2 DESCRIPTION

The system consists of a 19" rack which houses up to 4 x 48V 50A Rectifiers (RT4F), a MiniCSU (Control and
Supervisory Unit), an AC/DC distribution rack in a single rectifier cabinet. The cabinet can be upgraded to a
maximum of 5 x 48V 50A Rectifiers (RT4F). The system has a default output voltage (factory pre-set) of 54.0V
(when battery temperature compensation is disabled). The number of Rectifiers in a cabinet are determined by
the maximum load demand, plus one Rectifier for redundancy. To ensure safe operation, the cabinet has a
circuit breaker on the input of each module as well as circuit breakers in series with the batteries and an
isolator for external load distribution. Remote monitoring of the alarms and the condition of the system is
possible either by five potential free relay contacts for connection to a remote site or, by a direct RS232 link.

Module Shelf for up to 5

RT4F Modules

Cooling Fans

User Interface
Sliding Tray

AC and DC Distribution
Unit

Figure 1. GT305-SP Power System.

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1.3 SPECIFICATIONS

1.3.1 System Specifications

Input Voltage : 150V - 275Vrms phase to neutral, (three phase plus neutral).

Input Current : 32A max on first phase with 150A max output and 4 modules installed.
42A max per phase with system upgraded to 5 modules and 250A max
output.

Input Frequency: 45 - 65Hz

Output Voltage : 45V – 58V

Max System Current : 150 A max with 4 x RT4F modules upgrade-able to 250A max with 5 x RT4F
modules.

Ambient Temperature : 0°C to +50°C

Note : The air flow through the rack must not be impaired.

System Protection

Module AC Input : 25A single phase circuit breaker for each PSU.

DC Output (Load) : 1 x 100 A - 2 pole circuit breaker (ganged for 200A total)

DC Output (Battery) : 2 x 100A single pole circuit breakers

1.3.2 Mechanical Specifications

Width : 545mm

Depth : 450mm

Height : 787mm to top of lid

: 805mm to top of mounting brackets

Weight : 56,5kg without modules fitted.

1.4 CONTROL AND SUPERVISORY UNIT (MiniCSU)

The MiniCSU is responsible for all supervisory and control functions as described in the following sections.

1.4.1 MiniCSU CONTROL FUNCTIONS

[Link] OUTPUT VOLTAGE

The MiniCSU has control of the output voltage of the modules. The MiniCSU monitors the output voltage of the
cabinet continuously and will make any adjustments necessary to keep the output voltage regulated. In
addition, the MiniCSU ensures proper load sharing between the modules.

[Link] BATTERY TEMPERATURE COMPENSATION

A standard feature of the rectifier system is temperature compensated charging of the battery. The battery
temperature sensor, which is supplied with the system, is used to compensate the battery charge voltage.
Figure 2 shows the curve according to which the float voltage is adjusted with change in temperature. When
the temperature sensor is unplugged, the output voltage will be set relative to the cabinet temperature. If no
cabinet sensor is present or faulty, the output voltage defaults to the set voltage which has been programmed

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into the MiniCSU. This function can be enabled/disabled and the level of compensation can be set on the
MiniCSU.

Temerature Compensated Float Voltages for VRLA Batteries

59

58

57

56
VOLTAGE

55

54

53

52

51

50
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50
TEMPERATURE

Figure 2. Battery Temperature Compensation Curve

1.5 MiniCSU DISPLAY

The display on the MiniCSU consists of a one line LCD display as well as three LED’s. The information
displayed consists of a number of menus which can be accessed by means of the six push button switches
located next to the display. These menus contain user adjustable parameters, as well as feedback on the
status of the system. Under normal conditions, the screen will display the operating conditions which include
the load current, the output bus voltage, the state of the system (float or equalize mode) and whether the
temperature compensated charging is active or not. This screen is referred to as the ‘home’ screen.

35A 53.5V Fl

1.6 ALARM CONDITIONS

When one or more alarm condition exists, the following message will be displayed on the screen :

2 Press ENTER

This message indicates that there are 2 active alarms and they can be identified by pressing the ENTER
button. This message will alternate with the ‘home’ screen for 2 seconds every six seconds until the alarms are
cleared or the ENTER button is pressed. Once the ENTER button is pressed, the most recent alarm will be
displayed, and the remaining alarms can be observed by using the INC (increment) and DEC (decrement)
buttons. Pressing ENTER again will return the display to the ‘home’ screen.

1.7 MiniCSU MENUS

The MiniCSU display has four main menus. They are the ‘HOME’ menu, ‘SMR’ menu, ‘BATT’ menu and the
‘LOG’ menu. In any menu, when a parameter needs to be changed, press INC or DEC until the parameter to
be changed is displayed, then press ENTER – the value will start flashing. By using the INC and DEC buttons,
the value can be changed as required. When the right value is reached, press ENTER again. The new value is
now saved. When attempting to change a parameter which is not adjustable, the display will show ‘ Not
Adjustable’ when the ENTER button is pressed.

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1.7.1 ‘Home’ Menu

Under normal operating conditions, the screen will display information similar to the screen shown below. The
screen indicates a load current of 100A and an output bus voltage of 53.5V. The ‘FL’ indicates that the system
is in float mode while the ‘C’ shows that the temperature compensation is active.

100A 53.5V FLC

By pressing the INC button, one can scroll through the ‘Home’ menu options. The following screens will appear
in sequence :

Cabinet temperature displayed in degrees Celsius. Cab Temp 25°C

If the cabinet temperature sensor is not installed, the display will
read ‘Not Available’ Cab Temp N/A

Cabinet temperature alarm level Cab Temp Alrm 65°C

Float voltage high level (Alarm triggers at this level) Volts Hi 57.5V

Float voltage low level (Alarm triggers at this level) Volts Low 45.0V

Security on or off. When the security function is active, any attempt to Security On
alter any programmable value will result in the display showing
‘Panel Locked’. Panel Locked

Security Off

Test function OFF. Test Off

When the test function is activated, all LED’s on the MiniCSU Cell C G1222gh
will start flashing. The display will alternate between the
software version and a screen with all pixels on.

The MiniCSU will generate an alarm on all SMR alarm conditions System: UPS

The MiniCSU will ignore No Load and No Demand alarms generated by

any SMR under No Load conditions System: Standby

Number of modules operational in the system No. of SMRs 4

Interface MUIB type is specified in this screen. MUIB can host only 2
current sensors. Interface MUIB

MUIB2 can host up to 4 current sensors. Interface MUIB2

This screen is used to set the amount of current sensors used in the Num Batteries 1
system (Factory set).

DC transducer full scale rating (Factory set). FS Batt I 200A

MiniCSU access code. CSU# 234573

Clock set; used to set the date and time of the MiniCSU clock. 23/03/2000 15:50
Note : DD/MM/YYyy with a 24 hour clock

Modem option. Alarm report - can be toggled between ON and OFF. Alarm Report ON
If ON, the system will dial the first telephone number (PH1 below) if an alarm
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occurs. If PH1 does not answer, it will try PH2. IF PH2 does not answer,
it will try PH3. If PH3 does not answer, it will try PH1 again, etc. Alarm Report OFF

Daily report, can be toggled from On to OFF. When ON, the system Daily Report ON
will dial in to the phone numbers below and log the status of the
system at the time indicated in the next screen. Daily Report OFF

Modem enable : can be toggled between ON and Off Modem Off

The following 4 screens will only be displayed when the modem has been enabled.

Time of daily report. Daily Time 15:00

Phone 1 : This number will be dialled when an alarm occurs. The PH1 xxxxxxxxx
number can be up to 20 digits long. If the number is longer than 12
digits, it must be entered in 2 screens.

Phone 2 PH2 yyyyyyyyy

Phone 3 PH3 zzzzzzzzzz

Audio alarm disabled when off selected. Audio Alm Off

When an alarm condition appears, the audio alarm will sound for a duration Audio Alm t-out
of 2 minutes and then reset.

The audio Alarm will sound for the duration of active alarms. Audio Alm On

Selection of expansion function 1 : Off when no single phase monitoring Expan 1 Off
card is used.

Second expansion on Home Menu to enable or disable 3 phase AC

Monitoring, Battery Monitoring and Site Monitoring if used. Expan 2 (ENTER)

3 Phase monitoring OFF when no 3 phase monitoring card is used. AC 3 ph Off

Battery monitoring OFF when no battery monitoring card is used. Batt Monitor Off

Site monitoring OFF when no site monitoring card is used. Site Monitor Off

1.7.2 ‘SMR’ Menu

All information relating to the individual modules is available in a menu activated by pressing the ‘SMR’ button
on the MiniCSU front panel.

When a module is not connected or not switched on or is faulty, SMR1 No Response

the screen indicates that the module is not responding.

Warning : It is important to declare the correct number of modules in operation, using the MiniCSU ‘home’
menu.

SMR1 : When a module is on line and is operating normally, the SMR1 25A
module’s current will be displayed.

When the ENTER button is pressed momentarily, the module’s SMR1 G1170cf 35°C
Software version and heat-sink temperature are displayed.

Use the INC button to display the information of the other modules SMR2 24A
in the rack.

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The rest of the ‘SMR’ menu consists of screens which show the operating parameters of the modules.

Default float voltage of the modules. This value cannot be changed

in this screen. It is automatically set to the sum of the system float SMR Float 54.5V
voltage and the drop voltage set in the ‘Batt’ menu.

As with the float voltage, this value is automatically set to the sum of SMR Equal 56.5V
the system equalise (boost) voltage and the drop voltage set in the
‘Batt’ menu.

The following screens show SMR operating parameters, which can be changed by pressing ENTER and INC
or DEC. Please note that any change affects all modules.

SMR high voltage alarm level. SMR V Hi 57.0V

SMR low voltage alarm level. SMR V Low 48.0V

SMR DC high voltage shutdown (HVSD) SMR HVSD 57.5V

SMR Current Limit. SMR I Limit 50A

Fault Reset : by pressing ENTER when this screen is displayed, any SMR Fault Reset
latching alarms, such as HVSD, is reset, and the affected modules will
restart unless they are damaged or faulty.

1.7.3 ‘BATT’ Menu

The Battery menu can be entered by pressing the ‘BATT’ button on the front panel. To return to the ‘home’
menu, press the ‘BATT’ button again.

The following screens will be seen when pressing the INC and DEC buttons.

Battery current. If more than 1 battery is used, press INC and the Batt1 23A
other battery currents will be displayed.

Battery Temperature : If a sensor is installed, the battery temperature Bat Temp 25°C
is shown in degrees Celsius.

If the temperature sensor is not installed, the screen shows that Bat Temp N/A
the temperature sensor is not available.

Any irregularity with the battery temperature sensor will generate an Bat Temp Fail
alarm if the sensor alarm to the end of this menu is activated.

Battery over temperature level (adjustable). Batt T Alrm 45°C

Estimated state of charge of battery. QEst Batt1 120Ah

Ampere-hour rating of battery Bat Rated 180Ah

Battery temperature coefficient in mV per Deg C per Cell must be BTC mV/C/°C 4.0
entered here. Allowable range is 0.1 - 5 mV/C/Cell.
When the BTC is adjusted to 0mV, it is disabled. BTC (Off) 0

Nominal BTC temperature level where no temperature compensation is

applied. Adjustable from 18°C to 27°C. BTC Nominal 20°C

Battery charging current limit for voltages below Vdd which is BILim Vb<Vdd 30A
the deep discharge voltage (see next screen).

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Battery deep discharge voltage - Vdd. Vdd Level 44.5V

Battery charging current limit applicable when the battery voltage BILim Vb<Vfl 20A
is between Vdd and the float voltage Vfl.

System Float Voltage Setting Sys Float 54.5V

Battery charging current limit applicable during equalisation mode. BILim Vb>Vfl 15A

System equalise voltage level. Sys Equal 55.5V

Maximum system volt DROP used if no CSU is present. Sys Drop 0.5V

Battery discharge alarm level. This level is set to a value to which

the battery voltage falls to during a discharge. This is used to B Disch Al 45.0V
generate an alarm indicating that the battery voltage is low.

If OFF, the system will not revert to equalise the mode. Change setting to
ON to enable the equalise function and the next 11 screens will dictate Equalisation Off
the equalize function.

Equalisation initialised by voltage level V reached during discharge. V Start Eq On

Equalisation is initialised when the battery voltage falls to this level. V Eq Trig 46.0V

Equalisation is not initialised by voltage level. V Start Eq Off

Equalisation is initialised based on charge supplied to load by the

batteries. Q Start Eq On

Equalisation is initialised when the charge out of the batteries is Qdis Trig 20AH
greater than the level set in this screen.

Equalisation is not initialised by the discharge A/H method.. Q Start Eq Off

Equalisation will end if charge current falls below this value. EQ End 25A

Equalisation will end after the time interval set in this screen if Equal Dur 20Hr
no other method is used.

If no equalisation occurs due to a battery discharge for a period Equal Per 12Wk
longer than the interval set in this screen, an equalisation cycle
is initiated automatically.

An equalisation cycle can be manually started or stopped Manual Start EQ

using this screen.
Manual Stop EQ

Low Voltage Disconnect Switch (LVDS) will operate at this voltage LVDS Trip 42.6V
level.

The LVDS will operate automatically at the voltage set above. LVDS Auto
To operate the LVDS manually, press enter and the ‘Auto’ will flash.
Use the INC / DEC buttons to select an ‘Open’ or ‘Closed’ state for LVDS Open
the LVDS switch.
LVDS Closed

If OFF, no battery temperature sensor irregularity will generate an alarm. Sensor Alarm Off

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If ON, the system will generate an alarm if the battery temperature sensor Sensor Alarm On
is disconnected or disfunctional.

Battery discharge test OFF if no cell monitoring card is used. BDT Off

1.7.4 ‘Alarms Log’ Menu

The most recent alarm conditions are stored in the MiniCSU, and can be viewed at any time by pressing the
Alarms Log push-button. The screen will number the alarms with the most recent alarm being number 1. As
shown below, the screen will show the number of the alarm followed by the alarm name

1 AC Freq Fault

If the INC button is pressed within 2 seconds, the second alarm (if one exists) will be displayed, etc.

If no button is pressed for 2 seconds, a screen will appear which shows the alarm sequence number with the
date and time when the alarm occurred. To therefore view the date and time of a certain alarm, scroll to that
alarm using the INC / DEC buttons and wait 2 seconds for the date and time to appear.

1 10/11/2000 15:32

If the alarms log needs to be cleared, press ENTER when in the Alarms Log menu and the following screen will
appear :

DEC to Clear Log

If the DEC button is pressed, the log will be cleared and the following screen will appear :

No Alarms

1.8 MiniCSU SECURITY

To avoid any settings being changed by unauthorised persons, two levels of security are provided. When the
security function is activated on the MiniCSU, all six buttons on the display are ‘locked’ and no changes can be
made to any settings.

Each MiniCSU can also be given its own unique code (up to 8 digits – see ‘home’ menu above), which must be
known when using the WinCSU remote monitoring software (see next section), otherwise the MiniCSU will not
allow access to the user. Additionally a password can be set up in the WinCSU application, which would
prevent any tampering with the levels in the MiniCSU, by use of a modem.

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1.9 Mini USER INTERFACE BOARD (MUIB)

The MUIB is the interface board between the MiniCSU and all its peripherals. The MUIB has the following
inputs and outputs :
INPUTS : Power for the MiniCSU
Analogue output voltage
AC monitoring data
LVDS status
Circuit breaker status (optional)
Battery current information
Battery & cabinet temperature information

OUTPUTS : 5 Relay alarm outputs

LVDS Drive signal

1.10 REMOTE MONITORING

Three levels of remote monitoring are provided : potential-free relay contacts, RS232 link as well as dial in
monitoring via modem.

Relay Contacts

Five relay outputs are provided each with access to the normally open, normally closed as well as the common
terminal. These relay contacts provide information about five different alarms, namely:
Relay 1 : AC Mains Fail

Relay 2 : Battery Low

Relay 3 : System Fail:

- Battery discharging Or

MiniCSU failure Or

LVDS open Or

System Over volt

Relay 4 : Rectifier Module Fail

Relay 5 : Battery Integrity Fail or Battery over Temperature or Battery Cell Monitor alarm.

Remote Monitoring via Modem

This monitoring requires a Modem to be connected to the system. By using the WinCSU application software,
an operator is able to dial in to any site, which contains a rectifier cabinet with a MiniCSU and a modem and
interrogate the system.

The operator will be able to see what levels have been programmed into the MiniCSU, as well as having real
time information about : Present status of the system
All programmed system parameters
All alarm conditions
Input voltages, currents and frequency (if the AC monitoring is installed)
Battery cell voltages (if the battery monitoring is installed)

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X18 X40
X28 X31

CN1
MUIB X17 X32 X39
Connection
CN2
Diagram X22
X1 X2 X23 X33 X34 X44 X45 X50 X64 X65

Conn # Conn Label Class Comments Conn # Conn Label Class Comments
CN1 Batt integrity (Relay 5) Digital Pins 1 and 2 N/C X32 1 PHASE AC Anal/Dig Not populated on MUIB
Rect mod fail (Relay 4) Pins 3 and 4 N/C X33 USER 1 Digital Not populated on MUIB
System fail (Relay 3) Pins 5 and 6 N/O X34 USER 2 Digital Not populated on MUIB
Batt low (Relay 2) Pins 7 and 8 N/C X44 USER 3 Digital Not populated on MUIB
AC mains fail (Relay 1) Pins 9 and 10 N/C X45 USER 4 Digital Not populated on MUIB
CN2 Same as CN1 Digital Not populated on MUIB X28 AN1 Analog Not populated on MUIB
X1 MiniCSU Aanal/Dig 34-way ribbon cable to MiniCSU X31 AN2 Analog Not populated on MUIB
X2 Same alarms as CN1 Digital Not populated on MUIB X39 BATTERY 1 Analog Battery current transducer
X17 BAT. TEMP. Analog Temp. Transducer X40 BATTERY 2 Analog Not populated on MUIB
X18 AMB. TEMP. Analog Temp. Transducer X50 POWER I/P Analog System voltage sensing and DC power input
for MiniCSU
X22 C.B. TRIP Digital Not populated on MUIB X64 LVDS Aux Digital Aux contact from LVDS contactor
X23 BAT. SW. Digital Not populated on MUIB X65 LVDS Coil Digital Drive for contactor or similar

Figure 3. MUIB Connection Diagram

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LOW VOLTAGE DISCONNECT SWITCH (LVDS)

The system has a low voltage disconnect switch. This is included to protect the batteries from a very deep
discharge by disconnecting the load from the battery after the battery has discharged to a pre-programmed
voltage level for example in the case of an AC fail condition. The low voltage disconnect switch consists of a
high power contactor which is controlled by the MiniCSU. The voltage at which the LVDS operates is
adjustable either from the front panel of the MiniCSU (see ‘Batt’ Menu) or by RS232 / modem.

1.11 TEMPERATURE SENSORS

Two temperature sensors are provided with the system. Both sensors plug directly into the MUIB card and they
are used to measure the cabinet and the battery temperatures.

1.12 DC DISTRIBUTION

The DC distribution panel contains both the negative and positive connection points for the load two battery
strings.

The negative distribution contains the following :

Load connection
Negative : 1 x 100A two pole circuit breaker (200A total)

Battery connections
Negative : 2 x 100A single pole circuit breakers.

The positive distribution consists of a bus bar with provision for load and battery return cables.

1.13 AC CONNECTIONS

The AC connections to the rack are made to a terminal block for the three phases and neutral and the earth
wires. Maximum current at 150V AC input is 32A per phase for 50A modules.

1.14 OUTPUT EARTH

The positive output is the earth for the system. The positive output terminal is earthed during the installation,
therefore care must be taken when earthing any other part of the system. The cabinet is earthed on the positive
busbar on the AC/DC distribution panel.

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2 REPAIR AND MAINTENANCE

2.1 INSPECTION

It is sufficient to limit the servicing of the system to a visual inspection whenever the batteries are serviced. This
inspection would include

- check the wiring harness for any cracked, cut or burned insulation;
- check all visual cable terminations for loose connections;
- check the cover panels for any damage;
- check for missing screws or nuts;

2.2 SITE REPAIRS

On site repairs should be limited to replacement of faulty equipment. This would involve exchanging one or
more of the following : a PSU (up to a maximum of five), a MiniCSU, a MUIB card or a modem. The
components of the system are designed in such a way that they can be replaced on a live system without
having to switch the system off.

2.3 MiniCSU Alarms

The following is a list of possible alarms that can occur on the MiniCSU :
R = Red LED on A = Amber LED flashing

Table 1: MiniCSU Alarms

ALARM DESCRIPTION REQUIRED ACTION LED

SMR Alarm PSU failure Identify which SMR is faulty, determine A
the nature of the alarm and take required
action.
SMR HVSD SMR shutdown due to output over- Reset SMR – if problem persists, replace A+R
voltage SMR
UNIT OFF SMR is off A+R
SMR Comms Fail One or more SMR’s are not Check if correct number of SMR’s has A
responding been programmed in the MiniCSU
Pull out and replace affected SMR
If problem persists – check comms
connections to MiniCSU
Power Limit SMR is in power limit Switch SMR off until heatsink has cooled A
down
Current Limit SMR in current limit Check that there is no overload on system A
AC Volt Fault AC voltage not present Check if input circuit breakers have A+R
tripped
Check if AC voltage is present
Check wiring harness
Volts Low System output voltage lower than Measure output voltage A
pre-set value Check if Batt I-Limit alarm active
Check if output current exceeds maximum
system current
Check system float voltage setting on
MiniCSU

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Volts High System output voltage higher than Measure output voltage A
pre-set value Check the float voltage setting on the
MiniCSU
Switch off the AC circuit breaker of one
SMR at a time until the alarm is cleared
If the alarm does not clear, the cabinet
must be re-commissioned
Batt Temp High Battery temperature exceeds pre- Check air-conditioner A
set value
Cabinet Temp Cabinet temperature exceeds pre- Check fan filter and clean if needed. A
High set value Check air-conditioner
Temp Sensor Fail Temp sensor failure Replace temperature sensor A+R
LVDS Open Low Voltage Disconnect Switch Check for AC Fail condition and battery A
open voltage
Check LVDS voltage setting on MiniCSU
Check LVDS status on MiniCSU
Check drive to LVDS
Batt Disch Battery is discharging Check for AC Fail condition A
Batt I-Limit System output voltage reduced to Check if system voltage rises as batteries A
limit battery charge current receive charge.
Check for faulty battery
EEPROM Fail MiniCSU failure Reset MiniCSU by disconnecting power to A
MiniCSU and reconnecting it.
If the problem persists, replace MiniCSU.

2.4 REPLACING MODULES

When replacing a module in the field (in an operational cabinet), the procedure below must be followed.

Switch off the AC circuit breaker of the faulty module.

Remove the faulty module by lifting the handle and pulling the module toward you.
Insert the new module into the vacant slot in the power rack.
Switch on the new module’s AC circuit breaker and wait for it to start up.

When adding modules to an existing installation, plug in the new module in the next open slot and switch on
the corresponding AC circuit breaker. Take note that the number on SMR’s programmed in the MiniCSU must
be updated.

Note : The MiniCSU takes control of any new SMR’s as soon as they are plugged in, therefore no user
adjustments are required when replacing faulty SMR’s.

2.5 BATTERY REPLACEMENT

NOTE: For safety it is advised that the C.B. or isolator always be switched off first. Then the polarity
connected to earth always be disconnected first and connected last. In this case it is the positive
terminal. Only then switch the C.B. or isolator back on.

Although the battery is external to this system, in the event of having to replace a battery on a live system, the
following procedure must be followed:

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Table 2: Battery Replacement

STEP OPERATION

1 Switch off the circuit breaker of the battery that is to be replaced.

2 Remove the lead from the positive terminal of the battery.

3 Remove the negative lead from the negative terminal of the battery.

4 Remove interconnecting links and remove the battery.

5 Install the new battery and connect the interconnecting links to the battery terminals.

6 Connect negative lead to negative battery terminal.

7 Connect positive lead to positive battery terminal.

8 Close battery circuit breaker.

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3 INSTALLATION AND COMMISSIONING

3.1 INTRODUCTION

This manual describes the processes to be used when installing a GT 305 Power System.
The equipment is shipped from the factory fully tested and carefully packaged. Damage may, however, occur
during transit and careful inspection of all items received is required to ensure that all equipment is in a
serviceable condition.

3.2 INITIAL PLANING REQUIREMENTS

If the installation is an upgrade, i.e. adding a second or third cabinet, then a special cabinet will be needed with
its own installation procedures. Contact GRINTEK if this needs to be done. It is not advised for this cabinet to
be used in parallel with two separate controllers. The add on cabinets will not have a MiniCSU, and have a
larger current sensor and a bigger LVDS.

Before deciding on the final placement of the racks the following must be taken into consideration:

⇒ Connection to AC Mains Input.

⇒ Rack clearances/height.
⇒ Rack accessibility.
⇒ Ventilation.

Before starting the installation the following information is required:

⇒ Mains AC input Voltage. The GT305-SP POWER SYSTEM is designed to operate at a nominal input
voltage of 220VAC phase to neutral (380VAC 3phase + neutral). The input voltage range should be
between 150VAC – 275VAC under all conditions
⇒ The maximum input current of the GT305-SP Power System will be approximately 32A per phase (3-
phase) when the system is populated with 4 x 50A modules and supplies a DC load of 150A max.
When the system is upgraded to supply a maximum DC load of 250A, and can accommodate 5 x 50A
modules, the maximum AC input current will be approximately 42A per phase (3-phase).
⇒ The AC distribution board should contain a 3-phase circuit breaker to feed the new rectifier cabinet. This
circuit breaker should be rated at 40A per phase (like a Merlin Gerin C45340) when feeding a standard
GT305-SP Power System (not upgraded) or 60A per phase when the system is upgraded to supply a
DC load of 250A max.
⇒ A mains earth is mandatory. Earth-leakage protection must NOT be used.
3.3 Preparation

3.3.1 Rack preparation

Inspect the rack for any mechanical damage that could interfere with the internal wiring and proper
alignment of the SMRs.

3.3.2 Ventilation

The GT305-SP POWER SYSTEM is fitted with ventilation holes in the lid and the side of the cabinet.
Please ensure that these ventilation holes are not obstructed to ensure reliable system operation.

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3.4 Site Preparation

Ensure that the site is clear of obstructions and ready for the racks to be placed. Cables should be cut to
length and any cable trays or ducting prepared and mounted.

Place and secure rack/s into position. Mount any interconnecting cable trays or ducting.

3.4.1 Connect to Mains Switchboard

The GT305-SP POWER SYSTEM can be supplied through either an isolator or a circuit breaker. At the
switchboard, install isolating switch (with proper rated fuse on each phase), or circuit breaker.

Secure the switchboard to prevent against accidental application of power to the rack.
Ensure that the switch is switched off. Position the rack at the designated position. Remove the retaining
screws and AC/DC Distribution cover as indicated in figure 4.

Using a cable of correct cross section (Pref. 6mm² when using a 40A 3-phase breaker, or 10mm² when using a
60A 3-phase breaker), connect the three phases (L1, L2, L3), neutral (N) and earth (E) from the isolator to the
rack in the position shown in Figure 4. The cable can be routed through the cable entry on top to the rear left of
the cabinet. The cable entry should first be opened by pulling off the cover closing it. (It is meant to break).
Do not apply power to the rack at this time. At this point pay particular attention to checking all supply
connections, including the earth connection, and all nuts and bolts for tightness.

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3Phase Module AC Input

Live Input Circuit Breakers Neutral

Surge protection Input Earth

Figure 4. AC Distribution

3.4.2 DC Connections and Building Earth

Figure 5 shows the DC connections and the building earth connection to the positive DC busbar.

Load breaker LVDS Battery circuit breakers

Figure 5. DC Distribution

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3.5 Remote Alarms

Release the two retaining screws on the interface panel and slide the tray forward. Connect the remote alarms
to the connector on the MUIB board as indicated in figure 6 and table 3. NOTE: Relay 3 has inverted function,
i.e. the relay contacts, as shown on the PCB is shown in the alarm condition.

Table 3: Remote Alarm Relay connections

CN1/CN2 Function Name Contact Type Relay on MUIB

Connector
pins
1,2 Batt integrity N/C 5
3,4 Rect mod fail N/C 4
5,6 System fail N/O 3
7,8 Batt low N/C 2
9,10 AC mains fail N/C 1

Optional
MUIB – Alarm Battery Cell
MiniCSU Connections Monitoring

Figure 6. Interface Tray

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3.6 Battery Installation

Take extreme care that the batteries are connected correctly. The battery temperature sensor should be bolted
to the centre of the battery string to the positive pole. This is normally the positive pole of the second mono-
block from the left. Battery cables should be the same length for all the battery strings.

3.7 DC Load Terminations

Connect the load distribution positive to the positive (+) bus bar and the load negative distribution to the output
of the load Isolator as indicated in figure 5.

3.8 Install Switch Mode Rectifiers (SMRs)

Remove SMR’s from packaging. Conduct a visual inspection of the SMRs for mechanical damage.
TAKE CARE not to damage the connectors at the back of the SMR.

Before installing SMRs into the rack, ensure that all circuit breakers on the AC distribution are off.

Once the modules have been inserted into the rack, the installation checklist in appendix A can be filled in,
after which the commissioning procedure below can be followed.

4. Commissioning

Complete commissioning checklist (Appendix A) and fax to GRINTEK POWER TECHNOLOGIES, for the
attention of the configuration department on fax number 012 674 3511.

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GRINTEK ELECTRONICS ISSUE 04

APPENDIX A

INSTALLATION AND

COMMISSIONING CHECKLISTS

___________________________________________________________________________________
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COMMISSIONING CHECKLIST

SITE NAME
SITE LOCATION
CUSTOMER

CABINET PART NUMBER 840065-00000

CABINET SERIAL NO
MiniCSU NUMBER
SOFTWARE VERSION MCSU
SOFTWARE VERSION SMR

MODULE 1 SERIAL NO
MODULE 2 SERIAL NO
MODULE 3 SERIAL NO
MODULE 4 SERIAL NO
MODULE 5 SERIAL NO

INSTALLATION BY
INSTALLATION DATE
COMMISSIONING DATE

SITE TELEPHONE NUMBER

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INSTALLATION CHECKLIST FOR THE RACK POWER SYSTEM

Item Description Status Remarks

1 Provision of labels and fittings on rectifiers.

2 Check that the systems are positioned as per floor plan

3 Check that AC cable is correctly installed between the

power system and the AC outlet / distribution board
4 Tightness of all bolts, nuts, screws, connections &
terminals
5 Check for proper insertion of wires on all terminals

6 Neatness of PVC channels, cabling & wiring

7 Check correct polarity of load connection

8 Check correct polarity of battery connection

9 Check damages to batteries & cabinets

10 Check that the earth cable from the power systems is

connected to the earth bar of the site
11 Check that the earth bonding cables are fixed

12 Check that the wiring is not exposed to sharp points &

cutting edges
13 Check rating of the circuit breakers

14 Inspect the system in general for neatness &

completeness

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COMMISSIONING CHECKLIST

GT305-SP Power System

The following Battery checks should be done before the rectifier is to be commissioned.
DESCRIPTION VALUE PASS/
FAIL
1. Measure the terminal voltage of each 12V battery.
The open circuit voltage for the batteries, should not be lower
than 12,5V or higher than 13.8V.
2. The batteries used in one string should not differ in voltage by
more than 0,2V. I.e. if the highest voltage in a string is 13V the
lowest voltage should not be lower than 12,8V.
3. Note the measured voltages for all the strings used on this
system in the table below.
3.1. Battery 1 Battery 2 Battery 3 Battery 4
String number 1

String number 2

String number 3

String number 4

Refer to the Manuals supplied with the equipment for more detailed information.

DESCRIPTION VALUE PASS/

FAIL
1. Ensure that all circuit breakers in the cabinet are in the OFF
position
2. Slide the correct number of modules into the rack and record 1-5
the number of modules in the rack.
3. Switch the AC isolator(s) / circuit breaker(s) in the DB ON.
4. Switch all the SMR’s ON and check that all SMRs start up.
The amber LED on all SMR’s should flash.
5. Check that MCSU switches on. Record the software version
which is displayed for the first two seconds after the MCSU
switches on.
6. Set the Mini-CSU access code. Each installation must have
its own unique number. NOTE 1
7. Check that all the settings in the Mini-CSU are correct as given below. NOTE 5.
HOME MENU
8.1. Cabinet temperature Not adjustable
8.2. Cabinet temperature alarm 70°C
8.3. High volt alarm 57,5V
8.4. Low volt alarm 45,0V
8.5. Security OFF
8.6. Test OFF
8.7. System UPS
8.8. No of SMRs Number in rack
8.9. Interface MUIB
8.10. FS Current 200
8.11. Number of batteries 1
8.12. CSU# Depends on site.
(see par 6)
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DESCRIPTION VALUE PASS/

FAIL
8.13. Alarm report ON (If telephone
8.14. Daily report line is available,
8.15. Modem depends on site)
Remember to enter
phone numbers
where necessary
8.16. Daily time
SMR MENU
8.17. SMR Float Not adjustable
8.18. SMR Equal Not adjustable
8.19. SMR V Hi 57,0V
8.20. SMR V Lo 48,0V
8.21. SMR I limit 50A
8.22. SMR HVSD 58,0V
BATTERY MENU
8.23. Bat Temp (Battery Temperature) Not adjustable
8.24. Batt T Alarm (Battery Temperature Alarm) 40°C
8.25. QEst Batt 1 Not adjustable
8.26. Batt Rated Depends on
batteries (Rating of
sum of all battery
banks connected)
8.27. BTC (Battery temperature compensation) ON/OFF as
required –
remember to set
BTC values if
required
8.28. BTC Nominal (if BTC is enabled) 20°C
8.29. BILim Vb<Vdd 10 – 15% of
Battery rating
8.30. Vdd Level (Battery deep Discharge Voltage) 44V
8.31. BI Lim Vb<Vfl Between 7% and
max15% of Battery
rating
8.32. Sys Float (System float voltage) 54,0V
8.33. BI Lim Vb>Vfl Between 7% and
max15% of Battery
rating
8.34. Sys Equal (System equalization voltage) 56,0V
8.35. Sys Drop. (System voltage drop) NOTE 3 ±0,5V
8.36. B Dis Al (Battery discharge alarm voltage) 46,0V
8.37. Equalisation OFF
8.38. LVDS Trip 42,6V
8.39. LVDS Auto
8.40. Sensor Alarm ON
8.41. BDT OFF
9. Measure the output voltage with a DVM and record the value.
10. Record the displayed voltage on the Mini-CSU.
11. Connect a load and measure the load current with a current
clamp, and record the measured value.
12. Record the displayed load current on the Mini-CSU.
13. Active current sharing. NOTE 5 ±5% accuracy
within band
Passive current sharing. ±15% accuracy
within band

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DESCRIPTION VALUE PASS/

FAIL
14. CHECK THE FOLLOWING ALARMS

14.1 Switch the Battery Circuit breaker ON

14.2 SMR URGENT . NOTE 6
14.3 HIGH VOLT . NOTE 7
14.4 LOW VOLT . NOTE 8
14.5 AC FAIL
Load shed. NOTE 9
14.6 Battery current limit. NOTE 10
14.7 Measure the battery current with a current clamp and record
the value.
14.7 Record the battery current as displayed in the Battery menu of
the Mini-CSU
15. Return all settings to the correct settings after the alarms
are tested. (Refer to section 8 of this checklist)
16. Disconnect the PC and reconnect the modem to the Mini-
CSU.

NOTE 1: Access code can be changed by scrolling through the HOME (Default) screen of the Mini-CSU. Press
the “INC” or “DEC” buttons until CSU# is displayed. To change the code, press ENTER until the
desired digit flashes. Press the INC and DEC pushbuttons until the correct value is displayed, press
ENTER to accept and move to the next digit. Press enter after the last digit to save the new code.
This number must be different for each cabinet/installation.

NOTE 2: To scroll through the HOME screen, Press “INC” or “DEC” when in the default screen. To scroll
through the SMR screen, press the “SMR” button and then “INC” or “DEC” to scroll. To scroll through
the BATTERY screen, press “BATT” and then “INC” or “DEC”. To change a value, press ENTER
and use the INC and DEC pushbuttons to change, press ENTER again to accept.

If a PC is available all the values can be changed by using the supplied WINCSU software.

Disconnect the modem from the Mini-CSU and connect a RS232 cable from the PC to the Mini-CSU.

Open the WinCSU program.

Make sure that the access code which was entered in Par 6 is the same as in WinCSU. If not,
change the

Access code in WinCSU.

Click on CSU menu option.

Click on EDIT PARAMETERS. Values can now be changed to the values listed below .

Close the screen and go to Write Parameters in the CSU PARAMETERS screen (CTRL W can also
be pressed on the PC). Press yes when prompted to overwrite parameters. The changed values will
now be written to the Mini-CSU.

Go to SMR PARAMETERS
Click on EDIT PARAMETERS. The values should be as listed in 8.17 to 8.20
Go to WRITE PARAMETERS in the SMR screen. Press yes when prompted to overwrite ALL SMRs.

NOTE 3: To determine this value, the voltage between the output of the SMRs and the batteries and the
voltage between the output of the SMRs and the load must be measured. The smallest of the two
voltages must be used.

NOTE 4: Connect a dummy load to the system and check that current sharing is done. It may be necessary to

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increase the load to above 75% of full load for the active current sharing to come into operation.

NOTE 5: If no Mini-CSU is connected the system will do Passive current sharing. If a Mini-CSU is connected
and for some reason active sharing is not operational, an x will be displayed on the MiniCSU

NOTE 6: Switch off one module. The red LED will light up.

NOTE 7: Set the float voltage 0,5V higher than the high volt alarm value.

NOTE 8: Set the float voltage 0,5V lower than the low volt alarm value with the batteries still connected. Set
float voltage to the correct value after this test is done.

NOTE 9: Set the LVDS to 48V and switch AC supply OFF. While the AC supply is switched OFF, apply load to
the system to let the voltage drop and check that the load sheds at the set voltage.

NOTE 10: Once the AC is switched back ON, this alarm could appear

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APPROVAL SHEET
Installation Performed By :

Company :

Designation :

Name :

Sign :

Date :

Commissioning performed by :

Company :

Designation :

Name :

Sign :

Date :

System inspected by GRINTEK QA :

Company : Grintek Power Technologies

Designation :

Name :

Sign :

Date :

System Inspected by CUSTOMER QA :

Company :

Designation :

Name :

Sign :

Date :

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APPENDIX B

CABINET WIRING

DIAGRAM

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= Chassis metal work

AC distribution Module shelf. (4)

Positive
25A C/B bus-bar Negative
E [3 x 12] bus-bar
Red (4) Red (4)
L + [3 x 12]
Rectifier
Phase 1 Input N Fan baffle.
White (4) White (4) 1
-
Phase 2 Input Blue (4) Blue (4)
2 Wire fan cable

Phase 3 Input Red (4) Red (4)

White (4)
E

Blue (4)
Red (4)
L
+
Rectifier
N
Surge 2
Black (4)
Protection Yellow / Green (4) -
2 Wire fan cable
Black (4)
Black (4)
E
Neutral Input Black (4) +
Black (4)
L Rectifier
N 3
-
2 Wire fan cable

Yellow / Green (4)

E
Earth Input Yellow / Green (4)
L
+
Rectifier
N
4
-
2 Wire fan cable

DC distribution
System Ambient
Temp Sensor

Common Positive Return

(50)
bus-bar [6 x 20]

(16)

Negative
Load Isolator
2pole C/B 100A/Pole

(50)
[6 x 20]
Current
sensor

Interface Shelf
4 Wire Comms

RS232
Output

DB9 1 2 3
X80 X1
Black (0,5)
Black (0,5)
Grey (0,5)

Grey (0,5)

Red (0,5)
Red (0,5)

X20
Orange (0,5)
Yellow (0,5)

Brown (0,5)

Green (0,5)

X73
X43 MiniCSU Negative
1 2 3 4 5 6 Battery C/B
1 2 1 2 1 2 3 4 5 1 2 3 4 5 1 2 1 2 3 2 X 100A C/B
34 Way Ribbon Cable
X22 X23 X50 X39 X64 X65
1 2 3

MUIB
X17

X18 CN1
X1
1 2 3 1 2 3 4 5 6 7 8 9 10
Alarm connections

Battery Temp
Sensor
Two spare
positions for
battery C/B's
NOTE : Values in round brackets indicate wire sizes in sqr mm and
Values in square brackets indicate bus bar dimensions in mm.
AC and DC distribution is mounted on the same shelf.

Wiring diagram for GT305-SP System

840526-00000H12
Appendix B

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