Monitoring System MCU 1000

1 2 3 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.3 4 4.1 4.2 4.3 5 6

General remarks............................................................................................. 2 Safety notes and symbols .............................................................................. 3 Description of function.................................................................................. 6 Hardware ....................................................................................................... 8 Basic unit MCU 1000.................................................................................... 8 Display and operating panel .......................................................................... 9 Relay board (optional)................................................................................. 12 Software....................................................................................................... 13 System-internal software ............................................................................. 13 User software............................................................................................... 14 Battery test / capacity test............................................................................ 26 Description of unit....................................................................................... 29 Basic unit MCU 1000.................................................................................. 29 IC-Bus components .................................................................................... 38 Technical data.............................................................................................. 39 Operating instructions ................................................................................. 40 Appendix ..................................................................................................... 41

Issued: Revision: Checked:

Date 1-12-2000 1-12-2000

Name TBII-Fr/Bp TB-Enck

Stdmanual Page 1/49 pages

General remarks
The Remote Monitoring System MCU 1000 is a microprocessor-controlled monitoring and control device. With this system, it is possible to monitor and control all the main components of a power-supply system. The link with the "outside world" is created via the serial interface. The MCU 1000 can be connected directly to a computer (PC). The installed service and monitor software allows comprehensive monitoring and controlling of the power-supply system. If the control desk is not local, the link with the computer can be created through the public telephone network using a modem. The Remote Monitoring System MCU 1000 therefore allows more rational and efficient employment of maintenance and service personnel.

Please read this description thoroughly, paying particular attention to the notes on safety.

Safety notes and symbols

International electrical symbols and display and operating symbols are marked on the unit. They have the following meanings:

Ready for use Fault Modem interface

Service-interface

battery operation

Alarm urgent alarm

Supply voltage / input

1 0

Digital input

Voltage-measuring channel / input

I

Current measuring chanel / input

T

Temperature-measuring channel / input

+24V 200mA
+12V 500mA

+24V-supply / output +12V-supply / output GND / common reference potential

The following symbols are used to draw attention to certain passages in these instructions.

Indicates instructions which must be followed to avoid material damage.

Indicates instructions which must be followed to avoid danger to persons!

The MCU 1000 is designed as a fitted unit. It is an electronic device which requires dangerous levels of voltage and current. The following instructions must therefore be followed at all times! 1. 2. Installation, operation and maintenance of the MCU 1000 should be carried out in strict accordance with the instructions in this document. Ensure that only fully qualified and authorised personnel have access to the unit. Only qualified and authorised personnel should be able to open the unit. When working with the unit, use only properly insulated tools which are approved for the voltages in question. All persons working with the unit must be familiar with first-aid measures for accidents involving electricity. Always observe the regulations of the local power-supply company as well as other safety regulations. The passwords used for programming the unit must not be disclosed to unauthorised persons.

3. 4. 5. 6.

Description of function
To start up and operate the MCU 1000 safely, it is not essential to be acquainted in detail with all the points described in this chapter. However, a knowledge of the function of the main parts of the unit is of considerable assistance in understanding the system and may help to avoid operating errors when it is in use. Almost every component of a power-supply system can be monitored and controlled by the MCU 1000. The most comprehensive monitoring and control features exist with units which are fitted with a special interface board (Satellite). In this case, the MCU 1000 communicates with the various units via a data bus, the "SAT-BUS". A maximum of 24 rectifiers can be addressed via the SAT-BUS. Units which do not have this Satellite can be converted for "SAT-BUS" by means of a substitute Satellite. With these units, the number of monitoring and control functions through the MCU 1000 are slightly restricted. Rectifiers which cannot be used with "SAT-BUS" can be influenced through the contacts of the signal relay of the MCU 1000 (e.g. by switching the characteristic of the rectifier). The entire monitoring and controlling concept for the power-supply unit is exactly specified in advance. This makes it possible to configure the MCU 1000 without difficulty (i.e. to set and install the specific software). Temperature sensors and shunts are integrated at appropriate points of the power-supply unit to measure and monitor temperatures and current levels. The power-supply unit can be controlled and monitored through the public telephone network by means of a modem (optional). The main functions of the MCU 1000 are shown in the following schematic circuit diagram.

SAT-BUS ( RS 485 )

IC-BUS

12 1 2 3 U I T/I

13
8

RS 232

RS 232

1 2 3 4 5 6 7

Unit with satellite Service-PC Control desk Modem MCU 1000 basic unit LED board LCD board

8 9 10 11 12 13

Display and operating panel Relay board (optional) Digital inputs Measuring channels Potential-free signals Potential-free signals

Fig.1 : Schematic diagram of the Remote Monitoring System MCU 1000

12

10

11

12

3.1

Hardware
This section deals only with the components which are actually part of the MCU 1000 system. These are marked in the schematic circuit diagram.

3.1.1 Basic unit MCU 1000

The basic unit MCU 1000 includes: a basic board with processor unit, measuring channels, digital inputs and relay signals; a DC-DC converter for supplying the internal components and the plug periphery.

Serial interfaces The communication with the individual components of the power-supply unit and the outside world (control desk, service and maintenance personnel) takes place via the serial interfaces of the MCU 1000. SAT-BUS interfaces Data is transferred to the SAT-BUS via the interfaces X3 and X4 in accordance with the standard RS 485. This data bus allows all the SAT-BUS compatible components to communicate with one another. Here the signal codes (e.g. for characteristic switchover, unit fault, remote switch on etc.) are transmitted to and from the addressees. Modem-interface A serial interface to standard RS 232 is fitted at X5 to link the system with the public telephone network. The interface operates at a baud rate of 9600. Service interface The MCU 1000 and the local error interrogation take place via the serial interface X6 which also operates in accordance with standard RS 232. This interface operates at the same baud rate as the modem interface.

IC-Bus interfaces Additional peripheral components are connected to the MCU 1000 at interfaces (X13, X14). These are the display and operating panel with LED and LCD boards and an additional optional relay board. Digital inputs To allow monitoring of the various components of the power supply system, their signal contacts are connected to the digital inputs of the MCU 1000. These signal contacts switch the 24-V supply which is supplied specially for this purpose to the digital inputs. All eight inputs are equivalent in their function. They only receive their meaning in combination with the configuration data which are a result of the signalling philosophy chosen for the power-supply unit. This configuration file is loaded into the MCU 1000 via the service interface with the service software. Analogue inputs The standard MCU 1000 is fitted with three analogue inputs (measuring channels). One current, one voltage and one temperature are recorded. An alternative version has one measuring channel for voltage and two for current. Relay signals Three relays each with a potential-free change-over contact are provided for fault signals transmitted by wire. The meaning of the signals provided depends on the signalling philosophy and is therefore determined by the configuration file.

3.1.2 Display and operating panel

Faults and operating status (LED board) and measurement values (LCD board) are indicated or signalled on the display and operating panel, which is also used for changing threshold values, settings, charging status, battery test etc. (via keyboard on the LCD board).

The hardware design and the standard configuration (meaning of LED signals) have been modified as of 09/99. The previous versions are explained in the appendix.

DC-Power-Supply

48 V 132 A

green yellow yellow red red red red red red red red red red

Float charge Boost charge Battery test Error U < 2,1 V/cells Battery test negative Mains fault Rectifier fault Battery discharged U <1,85 V/cells Battery discharged U <1,80 V/cells Battery fuse triggered Load fuse triggered Modem fault (Reserve) LED test/ reset

Fig. 2: Display and operating panel (version 09/99). The LED function corresponds to that of the standard configuration.

10

LED board The meaning of the 3 LEDs is established by the configuration file and depends on the signalling philosophy of the unit. The general meaning is however fixed according to the colour of the LEDs by the standard IEC 73/DIN VDE 0199. The following therefore applies: RED Danger or alarm Warning of potential dangers or states which require immediate action or close observation of the status in question. Changes or imminent changes in the normal operating statuses. Indication of safe operating conditions or release for further operation.

YELLOW GREEN

Caution Safety

A function test of the LEDs and the LCD board can be carried out with the push button on the LED board. If the button is pushed for at least 3 seconds, all the LEDs light up. At the same time, all the segments in the LCD display are activated alternately and the current software version of the MCU 1000 indicated. LCD board On the operating pad of the LCD board, all the release states and measurement values of the current supply unit can be displayed or set. Critical menu levels are accessible by means of a password only. The operation and function of the input buttons and the meaning of the states and values indicated will be explained later in more detail. The meaning of the four LEDs on the display and operating panel version of 09/99 is permanently defined. operation

battery operation urgent alarm

alarm

11

Note:

In systems with SAT rectifiers, the signal "Battery operation" is controlled by the calculation of the battery current. If the battery current is negative (battery is being discharged) the LED "Battery operation" lights up and the LED "Operation" goes out. In systems with standard rectifiers (without satellite) voltagedependent monitoring is carried out. Battery operation is assumed when UBatt. <2,1V/Z and there is a mains-supply or rectifier fault. Normal operation is again assumed when UBatt. again rises above 1,95V/Z and not mains-supply or rectifier fault exists.

3.1.3 Relay board (optional)

When the relay board is connected to the I2C bus, another seven relays each with a potential-free changeover contact are available in addition to the three relays of the basic unit. The meaning of these signals is fixed via the configuration file depending on the signalling philosophy.

12

3.2

Software
With the software for the MCU 1000, a distinction is made between the system-internal software and the user software. For proper operation of the MCU 1000, the system-internal software is required. With the user software, a number of established set values can be changed and the entire power supply system monitored.

3.2.1 System-internal software

The system-internal software includes the operating system ("MCU 1000 software") and the configuration files. Operating system The operating system is stored in a memory component on the main board of the basic unit. This software carries out and monitors the entire data traffic on the SAT-BUS, the I2C bus and with the external modem. Measurement values are processed and data conditioned. The MCU 1000 cannot function without this software. The user cannot influence or change this software. It is the same for all MCU 1000 remote monitoring systems. Configuration data The configuration data are fixed when the entire control and monitoring concept and the signalling philosophy of the current supply unit are specified. In this way, logical links are created between signalled states or events. The existing 96 digital inputs are divided into actual physically existing inputs and any other events (virtual inputs). In addition, up to 5 limit-value monitoring systems can be set to any measurement values, on the result of which further actions can be taken either immediately or with a delay. During first start up of the power-supply unit, the entire configuration is set by the manufacturer. The data are transferred to a memory component on the main board of the basic unit via the service interface with the service software. If no special configurations are requested by the customer, a standard configuration is carried out.

13

3.2.2 User software

By means of the user software, the current supply unit can be monitored and set either locally or by modem from a remote control desk. Depending on the authorisation of the operator, changes can be made by means of passwords. Monitor software TEBE McuMonitor The MCU monitor software TEBE McuMonitor permits remote monitoring and remote diagnosis of different power-supply units in a number of different locations. Extensive information can be stored on each of the units being monitored to allow a fast and accurate response in case of corrective action. This may be (for example) the telephone and fax number of the location of the unit, its operator, persons with authorised access to the unit, or service centres. In addition, it is also possible to store photographs or maps or descriptions of how to reach the unit location. Data on the unit itself such as the types of battery used, configurations, circuit diagrams of the current-supply unit, and a log book of its history allow a fast and effective response. Service-Software TEBE McuService This software TEBE McuService is used locally by service personnel. It may be installed in the laptop of a service employee who would connect the computer to the service interface of the basic unit of the MCU 1000. In contrast to monitor software, this software can be used to carry out extensive alterations to the current-supply unit. It is possible to change configurations and, for example, parameters for a battery test as well as to switch rectifier characteristics on the rectifier modules. "TEBE McuMonitor" and "TEBE McuService" are independent products and are not supplied as part of the standard MCU 1000.

14

Operation of the display and operating panel (from Version 1.11) The power-supply system can be monitored and adjusted without a monitor or service software. The operation of the display and operating panel and the meanings of the individual menu items from software version 1.11 onwards are described below. For information on previous software versions, please refer to the appendix to these operating instructions. The menu levels and items with allow monitoring and adjustments or settings to be made, can be accessed using the 4 buttons beneath the display.

E
Fig. 3: LCD-board with buttons Button Function

Selection of individual menu items within a menu level DOWN UP Changing values within the individual menu items.

Selection of the next menu level, password request or menu item. ENTER Storage of set or changed values. Quit one menu item without storing values. Return to next higher menu level. CANCEL

15

1 2 3 4 5 6

Standard display Menu level 0 Password enquiry menu level 1 Menu level 1 Password enquiry menu level 2 Menu level 2

Fig. 4: Menu structure of display and operating panel

16

Fig. 4 gives an overview of the entire menu structure. If the buttons of the LCD board are not activated, the standard unit alternately displays e.g. the present current and voltage of the current and voltage measuring channel of the basic unit. The display depends on the display settings made via menu item .

By pressing the ENTER button, a menu item of menu level 0 is selected. The return is always to the menu item from which the last return to the standard display took place. All menu items of menu level 0 are accessible without a special password. Menu level 0:
Menu item / sub-menu item Meaning:

A maximum of 124 readings of the power-supply system can be accessed. When the ENTER button is pressed, the display goes to a measuring channel. After 2 seconds a reading appears in the display. By pressing the UP and DOWN button, the next measuring channel is shown in the display. Examples:

The only measuring channels and readings to be displayed are those which are actually in use in the configuration of the unit. The logical status of up to 96 digital inputs is displayed. The next digital input is displayed by pressing the UP and DOWN button. Example: Logical status of digital input 0: input inactive 1: input active (essential for program running) Input is evaluated in inverted sequence Number of digital input

The status of the signalised SAT-BUS components is displayed. Up to 31 components including the basic unit can be 17

addressed. The next address is reached by pressing the UP or DOWN button. The status of the SAT-BUS user appears approx. 2 seconds after display of the address. The status is displayed in form of a hexadecimal code which represents a 16-bit code. The type of address display gives information on the type of SAT-BUS user. Example: Address of "master" Address of on-board measurement board Address of any other SAT-BUS user Menu level 1 can be accessed via this menu item by means of a password enquiry. This menu item is for carrying out an LED test of the display and operating panel and setting the standard measurementreadings in the display. All the LEDs on the LED board are activated for approx. 1 minute (continuous operation). At the same time, all the display segments and the current software version of the MCU 1000 are shown alternately. The test can be aborted by pressing the CANCEL button. When the ENTER button is pressed, the first measurementreading channel of the standard display is shown. Other measurement-reading channels can be selected by pressing the UP and DOWN button. The setting change is acknowledged by pressing the ENTER button. This is for setting the second measurement-reading channel, which should appear in the standard display. Menu level 2 can be accessed via this menu item by means of a password enquiry.

18

Men level 1( Remote commands): This level can only be accessed via menu item and by entering a password in menu item . The password is a number between 000 and 999 and is selected using the UP and DOWN buttons. The standard password set by the manufacturer for menu level 1 is "001". This prevents accidental incorrect operation. The customer is advised to change this password as soon as possible.
Menu item / sub-menu item: Meaning:

Initiate battery test. End battery test. Switch rectifier to "boost charge". Switch rectifier to "float charge". Switch rectifier to "direct feed". Carry out relay test on up to ten available relays on the base unit and relay board.

The above menu items appear only if these remote commands are released via the service software. Menu level 2: This level can only be accessed via menu item and by entering a pass. The password is a number between 000 and 999 word in menu item and is selected using the UP and DOWN buttons. The standard password set by the manufacturer for menu level 2 is "002". This prevents accidental incorrect operation. The customer is advised to change this password as soon as possible.

19

Menu item / sub-menu item:

Meaning:

Input of rated value of shunt connected to the currentmeasurement channel of the base unit (X1:21; X1:22) (e.g. 60A) Input of rated value of shunt connected to terminals X1:23 and X1:24 of the base unit (only for versions with 2 currentmeasurement channels). Input of number of cells of the battery system of the powersupply system e.g.: 48V system: 24; 60V system: 30 This menu item is for transferring to the sub-menu for setting various delay and waiting times. Input of delay time in seconds after which an urgent alarm signal should be given. Input of delay time in seconds after which a non-urgent alarm signal should be given. Input of delay time in seconds after which a central alarm signal should be given. Input of duration of relay test in seconds. Input of delay in seconds, following which a modem connection between the MCU 1000 and a control stand should be cut off if the control stand does not respond. Input of delay in seconds, following which a new connection should be created in case of engaged line. This menu item is for transferring to sub-menu for setting parameters for a battery test. Input of duration of a battery test in minutes. Input of cut-off voltage of a battery test in volts per cell. Input of measurement channel through which battery-test voltage of battery circuit 1 is recorded.

Input of measurement channel through which battery-test cur-

20

rent of battery circuit 1 is recorded. Input of measurement channel through which battery-test voltage of battery circuit 2 is recorded (correct configuration flag must be set). Input of measurement channel through which battery-test current of battery circuit 2 is recorded (correct configuration flag must be set). Input of time interval in which another automatic battery test should be initiated. The time specified is in minutes, hours, days, months and years (correct configuration flag must be set). Input of date on which a first battery test should be carried out. After this, more battery tests are carried out at the specified intervals. If the date for the first battery test is invalid, the time is calculated from the first start-up. The date is given in minutes, hours, days, months and years (correct configuration flag must be set). Display of the next starting date for an automatic battery test. The time is specified as time of day, day, month and year. The start time is calculated from the data previously input (correct configuration flag must be set). Input of measurement channel to which the battery sensor is connected which transmits the current battery voltage to the charging rectifiers (correct configuration flag must be set). Input or display of system time in day, month, year, hours, minutes. This menu item is for setting the configuration flags. Of the 16 flags which can be set, 8 are presently in use. When ENTER is pressed, the individual flags are displayed and their status can be altered. The following configuration flags exist: not in use

0:

Modem connected 21

1: 0: 1: 0: 1:

No modem connected No battery-sensor operation Battery-sensor operation No automatic battery test possible Automatic battery test possible

Check sum formation for responses of service and modem interface (must always be 0) 0: SAT rectifiers are included in system. One of the SAT rectifiers has the master func tion. Exchange of information between SAT rectifiers is possible. No SAT rectifiers are included in system. The MCU itself has the master function. On-board current-measuring channel 1 is not inverted. On-board current-measuring channel 1 is inverted. (necessary depending on shunt connection; if X1.21=-SH )

1:

0: 1:

Condition: 3rd measurement channel is currentmeasurement channel 0: On-board current-measuring channel 2 is not inverted. 1: On-board current-measuring channel 2 is inverted. (necessary depending on shunt connection; if X1.23=-SH ) 0: 1: The battery test can only be carried out for one battery circuit. The battery test is carried out for two battery circuits. The battery-test parame ters for the second battery circuit must be set. Not for use

22

This menu item is for evaluating the error and link masks of the urgent, non-urgent and central fault signals. This causes a hexadecimal code to be read out which stands for a 16-bit code. This 16-bit code (error mask) is compared regularly with the status of each SAT-BUS user (LSB: lowest-value bit; MSB: highest-value bit) Meaning of set bits: LSB 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Satellite currently in self-test (not an error) Module currently in configuration phase ( not an error ) Watchdog reset ( correctable error ) Bus error Master time out Ventilator fault (force-ventilated units only) System has received invalid command ( correctable error ) Power failure ( mains and battery voltage ) Error in battery-temperature sensor Power-supply error User does not respond Module failed or defective Module switched off due to overvoltage Module switched off due to overheating Module switched off via switch or remote on/off switch Not in use

MSB 15

A hexadecimal code can be read out. The result of the comparison between the error mask and the status of a SAT-BUS user is compared with this hex code. Depending on the result, an urgent fault signal is given. A hexadecimal code can be read out. The result of the comparison between the error mask and the status of a SAT-BUS user is compared with this hex code. Depending on the result, a nonurgent fault signal is given.

23

A hexadecimal code can be read out. The result of the comparison between the error mask and the status of a SAT-BUS user is compared with this hex code. Depending on the result, a central fault signal is given. If released through service software, the 5 limit-value monitoring relays can be programmed or read out via this menu item. The settings are carried out in the same way for all relays . The following settings should be made: This dials measurement-channel number whose readings are to be monitored. Input of lower limit value to be monitored Input of upper limit value to be monitored Input of hysteresis band width. This value applies for the upper and lower limit value. This menu item is for selecting the "hold" functions of the LEDs. A hold function can be set for all 18 LEDs of the display and operating panel. When the event which has caused the LED to light up no longer exists, the LED goes into the flashing status (hold status). This status is re-set using the re-set button of the display and operating panel. This menu item is for selecting the "hold" functions of maximum 10 relays. A hold function can be set for all 10 relays (3 relays on base unit, 7 relays on optional relay board). When the event which has put the relay in the active state no longer exists, the relay remains in this active state (hold status). This status is re-set using the re-set button of the display and operating panel.

24

Specification or alteration of a password (000 ... 999) with which menu level 1 is accessed. If "000" is specified as password, no password enquiry is made for this menu level, i.e. no password protection. Specification or alteration of a password (000 ... 999) with which menu level 2 is accessed. If "000" is specified as password, no password enquiry is made for this menu level, i.e. no password protection.

25

3.3

Battery test / Capacity test

The battery test incorporated in the MCU 1000 permits all the rectifier units to be switched from the float-charge characteristic to the battery-test characteristic. This procedure means that the consumers connected are supplied from the battery for the duration of the programmed test period. As the consumer current (discharge current of battery) and the discharge time are continuously measured and recorded, an estimate of the availability of the battery can be made on conclusion of the test phase.

Important! In the battery test characteristic, the voltage of the rectifier is reduced and not switched off. For this reason, no critical situation for the consumers occurs at any time. The abort voltage and the duration of the battery test can be set at the display and operating panel or using the service software TEBE McuService.

Important! Before a battery test can be carried out, the following two setting options must be made: 1) The automatic-charge feature of the SAT rectifiers must be activated. 2) The power management feature of the SAT rectifiers must be switched off These settings can be changed: 1) 2) Locally via the rectifier satellites (see operating instructions 96/2801). This setting must be made separately for each rectifier. Locally via the service software TEBE McuService (see operating instructions 99/3293)

26

The battery test can be activated in three different ways. 1) 2) 3) Locally via the display and operating panel Locally via the service software TEBE McuService From a central control stand by modem with monitor software TEBE McuMonitor

Important! If an automatic battery test is being carried out via the MCU 1000, the option "Automatic battery test" must be released.

27

Operation The rectifiers are operating on the float charge characteristic. Automoatic charging must be activated. Battery test start Automatic switch over by all rectifiers from the float charge characteristic to the battey-test characteristic.

Battery test active During the battery test phase, the consumer current and the discharge time are measured and stored. UBatt. UAbbruch no Battery test end The abort voltage was not achieved in the specified time Battery test aborted The abort voltage was achieved before battery-test time expired yes

Battery condition o.k. MCU 1000 reports that battery ok and gives the capacity withdrawn in Ah.

Battery condition not ok. MCU 1000 reports that battery not ok and gives the capacity withdrawnup to that point in Ah.

Switch back Switch back to float charge characteristic. No defined charging phase

Fig. 5: Battery-test procedure

28

4 4.1

Description of unit Basic unit MCU 1000

The basic unit of the MCU 1000 is the core of the remote monitoring system. In order to ensure safe and reliable operation, all the instructions with regard to plug assignment, contact loads, connection cables etc. must be strictly observed. Mechanical installation The MCU 1000 can be installed in four different ways. 1) 2) 3) 4) 1/4 - 19 - plug-in module, 6 HE 1/6 - 19 - plug-in module, 6 HE door installation on bracket cabinet installation on plate
71

MCU 1000

Fig. 6: Front panel of the 1/6 - 19 plug-in module

266

29

X3

X4

X1

16

30

17

65.5 35 160.5

207

32

121

230
3.6

6 X13 X14

36

14.5

223 231.5

77 43.5

28 X6

Fig. 7: Dimensional diagram of basic unit for door or cabinet installation

X5

65

242

65

30

Electrical installation Depending on the amount of supply voltage, a distinction is made between two types of voltage. The two types cover the voltage ranges 18 VDC ... 75 VDC or 75 VDC ... 270 VDC. Visual signals given by basic unit The operating status of the basic unit is indicated by two LEDs. They signal readiness for use or a fault. GREEN RED Ready (if power supply connected) Fault (glows continuously for urgent fault, flashes for less urgent fault)

Serial interfaces: SAT-BUS interfaces X3, X4 The RS 485 interfaces are 4-pole round connectors.

All SAT-BUS compatible components communicate with one another via these interfaces.

31

SAT-BUS compatible components are as follows: All parts of the power supply system which are normally fitted with a "Satellite". All units and components which are fitted with a "substitute Satellite". The basic unit of the MCU 1000.

Due to the selected standard RS 485 there are no restrictions with regard to the data-cable lengths within the power-supply unit. Modem interface X5 The RS 232 interface is a 9-pole SUB-D plug (male, pin contacts). The plug is marked with the symbol: The following contact assignments apply:

UNC 4-40

PIN 1:DCD PIN 2:RxD PIN 3:TxD PIN 4:DTR PIN 5:GND PIN 6:DSR PIN 7:RTS PIN 8:CTS PIN 9:NC

UNC 4-40

Trgersignal erkannt, Verbindung aufgebaut Daten empfangen Daten senden Terminal bereit Masse Daten bereitgestellt Auffordern zum Senden Bereit zum Senden nicht belegt

Data Carrier Detect Contact established Receive Data Transmit Data Data Terminal Ready Ground Data Set Ready Request to Send Clear to Send Not Connected

12345

6789

32

The interface cable for the modem connection is generally supplied with the modem. The following ready-to-use cables can be used as alternatives: T.Nr.: 734871 T.Nr.: 539523 Service interface X6 The RS 232 interface is also a 9-pole SUB-D plug (male/pin contacts). The plug is marked with the symbol: The contact assignment is identical to that of modem interface X5. The interface cable for the service PC is a twisted RS 232 cable. Both ends of the cable must be fitted with 9-pole SUB-D sockets (female). It is advisable to use a standard "zero modem cable" as both 9-pole D-SUB sockets have equal contact assignments and the cable can be twisted. A fully ready-to-use cable can be ordered under the following number: T.no.: 734624 Link cable RS232/DB9 FEM./FEM. 3m cable connection cable connection MODEM MODEM (0,25 m) (1 m)

IC-Bus-interfaces X13, X14 The plugs X13 and X14 serve to connect the system-internal components, the display and operating panel and the relay board (optional). This interface offers an unstabilised 8V voltage.

33

Contact assignment of plugs X13 and X14:

1 2 3 4 5

PIN 1: +8V PIN 2: SDA PIN 3: SCL PIN 4: IC-Int. PIN 5: GND

Serielle Datenleitung Serielle Taktleitung I2C-Unterbrechungsanforderung Masse

Serial Data Serial Clock I2C-Interrupt Ground

Connection terminals X1 For all the screw terminals on the two terminal strips of X1, the clamping area is between 0.2 mm2 and 2.5 mm2 (AWG 24 to AWG 12). If no measurement shunt is connected, a bridge must be set between XI:21XI:22 and XI:22-XI24. If a measurement shunt is connected, a bridge must be set between XI:22-XI24.

X1
17 18
X3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

19 20
X4

21 22 23 24

X1
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

25 26 27 28 29 30 31 32

Fig. 8: Connection terminals X1 To avoid confusing the two connector strips, both the plugs are coded.

34

Contact: 1,2,3 4,5,6 7,8,9 10,11 12 13 14 15 16 17 18 19 20 21 22 23 24 25,26 27 28 29 30 31 32

Contact allocation: relay signal K1 relay signal K2 relay signal K3 not in use digital input 1 digital input 2 digital input 3 digital input 4 digital input 5 +Vbatt / supply +Vmeas / analogue measurement input - voltage -Vbatt / supply -Vmeas / analogue measurement input - voltage +shunt (-shunt) / analogue measurement input - current -shunt (+shunt) / analogue measurement input - current +temp. / analogue measurement input - temperature (+SH/-temp. / analogue measurement input - temperature (-SH/+SH) not in use GND +12V / supply voltage for external components +24V / supply voltage for digital inputs digital input 6 digital input 7 digital input 8

Supply voltage

X1:17(+); X1:19(-)

Depending on type, the supply voltage is between 18 VDC - 75 VDC resp. 75 VDC and 270 VDC. The maximum input power is 25 W.

35

Digital inputs

X1:12...16; X1:30...32

The +24V supply is switched to the digital inputs via external switch contacts. These contacts may be (e.g.): Fault-signal contacts between individual units and parts of the system Battery-fuse monitoring devices Service switches Door contacts Total-discharge monitoring devices etc.

Important! Avoid connecting external potential to ensure that the interfaces of the MCU remain potential-free. The starting current for a digital input is approx. 10mA, which then drops to <1mA after a short time. For this reason, the switch contacts are not subject to any special requirements. The inputs are potential free with reference to earth and battery. However, they are connected to one another by means of a common GND. Analogue inputs
1
X1:21 X1:22 X1:18

2
X1:20

+ + -

X1:21 -

X1:22

X1:23

X1:24

4
1 2 3 4 With connection of shunt to positive circuit; X1:21(+SH)/X1:22(-SH) X1:18 (+Vbatt.)/X1:20 (-Vbatt.) With connection of shunt to negative circuit; X1:21(-SH)/X1:22(+SH) X1:23 (+temp.)/X1:24 (-temp.)

Fig.9: Connection of analogue inputs

36

Important! The measuring channels are not separated from one another galvanically
I

Current-measuring channel:

X1:21(+/-); X1:22(-/+)

In order to measure the current, a 60 mV shunt must be connected to the measuring-current circuit. It may be either in the positive or negative circuit. If the shunt is connected in the minus circuit, the prefix bit in question must be changed using the service software or via the display and operating panel. The maximum measuring current is equivalent to approximately 1.8 times the rated current.
U

Voltage-measuring channel:

X1:18(+); X1:20(-)

The voltage measuring range is between 0 VDC and 270 VDC.

T

Temperature-measuring channel:

X1:23(+); X1:24(-)

To measure temperature, a special temperature sensor is required. Depending on type and location of the temperature to be measured, various ready-to-use cable connections with integrated sensor are used. Relay signals The contacts of these potential-free signals can be loaded with 250 VAC / 8 A. Contact assignment: X1:1...9

2;5;8 K1;K2;K3 1;4;7 3;6;9 max. 250VAC/8A

The contact position shown in the diagram corresponds to the currentless relay state. 24V-Supply,12V-Supply, GND 37

The +24V supply load is 200 mA.

+24V 200mA (X1:29)

is for the digital inputs. The maximum

+24V 200mA (X1:29) is for supplying external components. The 12V supply These may be: relay board, modem. The maximum load on this output is 500 mA.

GND voltages.

(X1:27) forms the common reference potential for both supply

4.2

IC-Bus components
The I2C-Bus components (LED board, LCD board and relay board) are connected to the plugs X13 and X14 of the basic unit. In order to indicate the status of the system, the LED and LCD boards are located on the common display and operating panel which is integrated in the front door of the power supply system. The IC-Bus-components ( +8V ) are supplied via the same plug connectors to which the data lines are also connected. The maximum load on the +8V supply is 500 mA. The maximum consumption current of the LED board is 40 mA. The consumption current of the LCD board is negligible. The 7 relays on the relay board are driven by the +12 V supply of the basic unit. The current used for this purpose is approx. 130 mA (approx. 18 mA per relay). The maximum contact load is 250 VAC/ 8A.

38

4.3

Technical data
Input voltage ranges: Max. current consumption: Voltage outputs: Analogue inputs: 18VDC...75VDC / 75VDC...270VDC 25W 24 VDC/200mA (for digital inputs) 12 VDC/500mA (for ext. components) 3

Not potentially separated from one another. Voltage-measuring input: 0VDC...270VDC Current-measuring input 1: 60mV - shunt Current-measuring input 2: 60mV - shunt (Temperature-measuring input: temperature sensor 2k/25C KTY81-210) (Temperature-measuring range: -20C...+70C) Digital inputs: Wiring: Potential-free signals: max. contact load: Permitted temperature range: (without condensation) Location height: Humidity class: Air conditioning: 8 24 VDC/1mA (10mA starting current) 3 (basic unit)/ 7 (external relay board) 250 VAC/8A 0C...40C max. 2000m above sea level. F to IEC 721-3 (FTZ A 01 AN1) Operation 3K3 (-R12) Storage 1K5 (-R14) Transport 2K4 (-R52)

39

Operating instructions
After mechanical installation, electrical connection and system-specific configuration and start-up, the Remote Monitoring System MCU 1000 is ready for use without any restriction. During operation, no settings, adjustments etc. are necessary for any of the permitted operating conditions. Location The MCU 1000 is designed to be fitted into power-supply systems. It is intended for use in enclosed dry rooms only. For the maximum unit temperature, refer to the technical data. When selecting its location, ensure that it is not exposed to corrosive substances and that the flow of cooling air is not restricted. Connection As a general rule, the complete MCU 1000 and all its components is fitted into the power supply system. However, if it is installed at a later date or if modifications are carried out, the instructions in section 4 must be complied with. This applies in particular to the contact assignment for the individual connections as well as contact loads. Start-up To start the unit up, the entire power supply system and all the components of the MCU 1000 must be correctly wired and connected to the mains supply voltage. The initialisation phase is started and the two LEDs "FAULT/ " and "READY/ " flash. In the LC display on the display and operating panel, "init" appears alternately with all the segments. After approx. 2 secs. the EEProm initialisation takes place (with display of "-EEP-") unless a special EEProm is installed in the basic unit. The software version of the MCU 1000 is then displayed for approx. 1 sec. The standard operation then starts. The green LED "READY/ " on the basic unit lights up. All the relays are then set according to their systemspecific configuration and the modem is initialised (if applicable). Maintenance The MCU 1000 was developed for continuous operation and is practically maintenance free. If the specified conditions of the surroundings are complied with, the unit will function reliably for a long period of time.

40

Annex

MCU 1000

green red green yellow yellow red red red red red red red red

Operation Fault U<2,1V/c Float Boost Battery test Battery test negative Urgent alarm Non urgent alarm Mains failure Rectifier failure
Batt. discharged U<1,8V/c

Fuse blown Modem failure

LED Test / Reset

Display and operating panel (texts for standard configuration) Version up to. 08/99

41

1 2 3 4 5 6

Standard display Menu level 0 Password request menu level 1 Menu level 1 Password request menu level 2 Menu level 2

Menu structure of the LCD board (valid up to software 1.10)

42

Fig. above mentioned gives an overview of the entire menu structure. If the buttons of the LCD board are not activated, the standard unit alternately displays e.g. the present current and voltage of the current and voltage measuring channel of the basic unit.

By pressing the ENTER button, a menu item of menu level 0 is selected. The return is always to the menu item from which the last return to the standard display took place. All menu items of menu level 0 are accessible without a special password. Menu level 0: Menu item/ Meaning: A maximum of 124 "measurement values" of the power supply system can be displayed. However, only the values actually measured and the values calculated from these are displayed. The logical status of a maximum of 96 digital inputs is displayed. The status of the signalled SAT-BUS component is displayed. A maximum of 31 components including the basic unit can be addressed. This menu item allows entry to menu level 1 through password request. All the LEDs of the LED board are activated for approx. 1 minute (continuous operation). At the same time, the display shows all the segments of the display alternately with the current software version of the MCU 1000. The test can be aborted by pressing the CANCEL button. This menu item allows entry to menu level 2 through password request.

43

Menu level 1: This level is accessible via menu item only and by entering a password in menu item . The password is a number between 000 and 999 and is selectable by means of the "UP" and "DOWN" buttons. The standard password set by the manufacturer for level 1 is 001. This serves to avoid incorrect operation. The password should be changed by the customer at the first opportunity. Menu item: Meaning: A battery test is initiated. A battery test is concluded. Switch rectifiers to "Boost charge". Switch rectifiers to "Maintenance charge". Switch rectifiers to "Direct feed". Test fault signal A. Test fault signal B. Test fault signal C.

Menu level 2: This level is accessible via menu item only and by entering a password in menu item . The password is a number between 000 and 999 and is selectable by means of the "UP" and "DOWN" buttons. The standard password set by the manufacturer for level 2 is 002. This serves to avoid incorrect operation. This password should be changed by the customer at the first opportunity.

44

Menu item

Meaning: Input of nominal shunt value connected to current measuring channel of basic unit (X1:21; X1:22) e.g. 60 A. Input of nominal shunt value connected to terminals X1:23 and X1:24 of basic unit when the temperature channel is changed to a current-measuring channel. Input of number of cells of battery system of power supply system, e.g. 48V system: 24; 60V system: 30 Input of delay time in seconds after which a fault signal "A" should be given.. Input of delay time in seconds after which a fault signal "B" should be given. Input of delay time in seconds after which a fault signal "C" should be given. Input of duration of an initiated relay test in seconds. Input of duration in seconds after which a modem connection between MCU 1000 and a control desk should be interrupted if the control desk does not respond. Input of duration in seconds after which a new attempt should be made to make contact if the line is engaged at first attempt. Input of duration of a battery test. Input of the break-off voltage for a battery test in V per cell. Input of a time interval, after which a new automatic battery test should be initiated. The time is stated in minutes, hours, days, months and years. Input of the date on which a first automatic battery test should be carried out. After this, further battery tests take place at the stated intervals. When the date of the first battery test is past, the date of first start up is taken as starting point. The date is stated in minutes, hours, days, months and years.

Display of the next starting date for an automatic battery test. The time is stated with hour, day, month and year. The timing is 45

based on the data previously input. Input or display of system time in day, month, year, hours and minutes. 8 different configuration flags are set by entering a hexadecimal code. This determines for example whether a modem is connected for a remote diagnosis or if an automatic battery test should be carried out. A filter mask for evaluating faults is set using a hexadecimal code. Setting of a filter mask to evaluate signal "A". Setting of a filter mask to evaluate signal "B". Setting of a filter mask to evaluate signal "C". Specification or changing of a password (000 ... 999) for accessing menu level 1. If the password "000" is specified, the password is not requested for this menu level i.e. no password protection! Specification or changing of a password (000 ... 999) for accessing menu level 2. If the password "000" is specified, the password is not requested for this menu level i.e. no password protection!

46

Maintenance Instructions

1 2 3 4 5 6 7

General remarks ...................................................................................... 48 Cleaning .................................................................................................. 48 Terminals and plugs ................................................................................ 48 Contactors, relays.................................................................................... 48 Monitoring unit ....................................................................................... 48 Smoothing device.................................................................................... 49 Instruments.............................................................................................. 49

47

General remarks
The unit should be serviced once per year or whenever a malfunction occurs. Disconnect the unit from the power supply (if possible at a time when it is not required). Remove the fuses from the power distribution system.

Some of the components and terminals in the secondary circuit are still live (battery voltage). For this reason, always use nonconductive materials and insulated tools for cleaning and maintenance work.

Cleaning
Use a vacuum cleaner and brush to remove dust from the components. In dusty surroundings, this cleaning operation should be carried out at frequent intervals. Avoid damaging the coils of transformers and chokes.

Terminals and plugs

Check all terminals and screw connections in the unit and tighten them if required. Check plugs to ensure that contact surfaces are clean, the cable pullrelief is sufficient and that all elements are clipped firmly into position.

Contactors, relays
Ensure that contactors move easily by pressing them by hand (if necessary remove the arc chamber to do this). If required, remove the contactors and clean them thoroughly. Check the condition of the contacts and remove any traces of burn-up with a suitable file. (Do not use emery paper or sandpaper. Do not grease the contacts!) Dark coloured contacting elements do not adversely affect the function of the unit.

Monitoring unit
Check the response values of the monitoring devices (e.g. mains power, over and undervoltage etc.). For the correct response values, refer to the Technical Data Sheet.

48

Smoothing device
If electrolytic capacitors are fitted to meet higher smoothing requirements, it is recommended to replace these after 10 years of use.

Disconnect the battery before beginning work

Instruments
After switching the unit on again, check the measurement values using highprecision instruments.

49