Manual MCU 2500 - 4339-En-Hr
Manual MCU 2500 - 4339-En-Hr
Manual MCU 2500 - 4339-En-Hr
MCU 2500
Contents
0 Safety notes and used symbols................................................................4
1 General ...................................................................................................5
Many different symbols are used for the individual components of the remote
monitoring system and in these operating instructions; the following table
shows the meaning of these symbols:
For this reason, the following instructions must be followed at all times:
2. Ensure that only fully qualified and authorised personnel have access to
the system; only this personnel may open the unit.
3. When working with the unit, use only properly insulated tools which are
approved for the voltages in question.
4. All persons working with the unit must be familiar with first-aid meas-
ures for accidents involving electricity.
5. The regulations of the local power-supply companies and all other appli-
cable safety regulations must be observed at all times.
6. The passwords used for programming the unit must not be disclosed to
unauthorised persons.
1 General
The remote monitoring system MCU 2500 is a microprocessor-controlled mo-
nitoring and control device. With this system, it is possible to monitor and con-
trol all the main components of a power supply system.
The link with the "outside world" is created via the serial interface. The MCU
2500 can be directly connected to a desktop computer (PC). The installed ser-
vice 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 or through a TCP/IP adapter
and the internet using a modem.
The Remote Monitoring System MCU 2500 therefore allows more rational and
efficient employment of maintenance and service personnel.
CPU-bus
The CPU-bus efficiently connects two CPUs (master, slave) on the base unit
thus ensuring a simple and quick data exchange. Here, the user does not need
to observe anything special.
ADBUS2
The ADBUS2 connects decentralised peripheral components with the base u-
nit. These are units with signalling relay and digital inputs, measuring boards
with analogue inputs, battery symmetry monitoring units or earth fault moni-
toring units. Each component has to be installed in direct vicinity (i.e. in the
same cabinet) to the base unit.
Attention!
No more than 7 users may be connected to the ADBUS2!
I²C-bus
This bus is used to connect the LED board and the graphic display to the base
unit. Also here applies that LED board, display and base unit need to be in-
stalled in the same cabinet.
SAT-bus
The SAT-bus connects e.g. the rectifiers of the power supply system and fur-
ther peripheral SAT-bus components (relay box, measuring box, digital input
box) to the base unit. The components can be distributed over several cabinets.
RS232 interface
This interface is used for external communication. A PC with the relevant ser-
vice software is connected either directly to this interface or via the telephone
network (modem) or the internet / network (TCP/IP adapter).
Attention!
The ADBUS2 and the SAT-bus use the same terminal at the base
unit. As soon as the first SAT-bus component has been connected, a
further connection of an ABBUS2 component will not be possible
anymore as the power supply will be interrupted for these compo-
nents.
1 2 3
10
11
12
Figure 1.2: Basic structure of the remote monitoring system MCU 2500
5 Graphic display
Generally, they are mounted on a DIN rail. The necessary supporting rail adap-
ter has been already mounted at the factory.
10 2
9 3
8 4
5
7 6
Status Meaning
lights fault or initialisation phase
flashes quickly MCU is not connected to SAT-bus
flashes shortly no fault; MCU is SAT-bus master
extinguishes shortly fault; MCU is SAT-bus master
off no fault; MCU is user in the SAT-bus
Status Meaning
lights normal operation
flashes quickly no SAT-bus communication detected
off severe fault of MCU
lights lights
Meaning initialisation phase; takes a few ms to some seconds
flashes quickly flashes quickly
Meaning MCU has started, SAT-bus not yet recognised
lights flashes quickly
Meaning SAT-bus communication recognised, MCU waits for
connection
lights off
Meaning normal operation in the SAT-bus
lights flashes shortly
Meaning normal operation with MCU as master
(even during diagnosis operation via PC)
The components can be connected to each other and to the base unit with
commercially available network cables (patch cable). The network cable sup-
plies also the components. Usually, blue cables are used to distinguish them
from the SAT-bus wiring.
The address assignment and/or the necessary configuration are realised with
two jumpers only allowing the service technician to replace a component on si-
te without having to take any further measures.
Attention!
Some special features have to be observed due to the technical spe-
cification of the ADBUS2:
1 2 3
7 4
6
110mm x 70mm
Possible configurations:
RELIO board taken completely out of service. This does not im-
pair the bus traffic (board may remain connected), all relays,
however, release. The LEDs have no function anymore.
6 LED (red)
Status Meaning
lights RELIO board faulty; (disconnection due to bus
error or wrong configuration)
flashes no connection to bus possible
flashes shortly transmission indicator ADBUS2; normal opera-
tion
7 LED (yellow)
Status Meaning
lights up and extin- receiving indicator ADBUS2, at least one relay
guishes shortly released (fault message)
flashes shortly receiving indicator ADBUS2, normal operation
1 2
6
5
4
65mm x 70mm
Terminal assignment:
Possible configurations:
5 LED (red)
Status Meaning
lights measuring board faulty; (disconnection due to
bus error or wrong configuration)
flashes no connection to bus possible
flashes shortly transmission indicator ADBUS2; normal opera-
tion
6 LED (yellow)
Status Meaning
lights temperature sensor failure
flashes shortly receiving indicator ADBUS2, normal operation
1 2
6
5
4
65mm x 70mm
Terminal assignment:
Possible configurations:
5 LED (red)
Status Meaning
lights BATTS board faulty; (disconnection due to bus
error or wrong configuration)
flashes no connection to bus possible
flashes shortly transmission indicator ADBUS2; normal opera-
tion
6 LED (yellow)
Status Meaning
flashes shortly receiving indicator ADBUS2, normal operation
Attention!
The measurement inputs may not be connected to negative voltages,
referred to GND.
∅ 3.6
1 2 3
1 Earth stud (M4 x 17)
4 5 6
Terminal assignment:
5 X5; terminal of the potential free signalling contacts (K5 ... K8)
16-pole screw terminal (M3);
connection range: 0.2mm² - 2.5mm² / AWG24 – AWG12
6 X4; terminal of the potential free signalling contacts (K1 ... K4)
16-pole screw terminal (M3);
connection range: 0.2mm² - 2.5mm² / AWG24 – AWG12
Terminal assignment:
Legend
Deutsche Englisch
Gleichstrom-Lastgrenzkurve DC current load limit curve
Ohmsche Last Ohmic load
Schaltspannung Voltage switched
Schaltstrom Current switched
Terminal assignment:
The actual design is indicated at the measuring box. In the example shown a-
bove the measurement channels are fit with the following measuring modules:
5 X5; terminal for the digital inputs (DI13 ... DI24) and the 24V control
voltage of the inputs
16-pole screw terminal (M3);
connection range: 0.2mm² - 2.5mm² / AWG24 – AWG12
6 X4; terminal for the digital inputs (DI1 ... DI12) and the 24V control
voltage of the inputs
16-pole screw terminal (M3);
connection range: 0.2mm² - 2.5mm² / AWG24 – AWG12
Terminal assignment:
+ The terminals X4:13 ... X4:16 and X5:13 ... X5:16 are put to the
same potential. The maximum output current at the terminals co-
mes to 240 mA and is sufficient for the 24 digital inputs.
As standard, the unit is prepared with an adapter for the supporting rails for
mounting on a DIN rail. Fastening on a mounting plate is also possible.
1 2 3 4 5 6
1 LED "operation";
3 LED "alarm"
5 Graphic display
External modem
The connection of the remote monitoring system to the public telephone net-
work can be established via an analogue modem. A high-speed modem has
been tested and released especially for the industrial use.
(PSTN modem V.90-highspeed; MicroLink 56ki; part no. 787663)
MCU-TCP/IP adapter
The connection of the remote monitoring system to a computer network or the
internet can be established via a suitable MCU-TCP/IP adapter. (part no.
520421)
Service PC
The software TEBE MCU Service (item no. 545740) installed on the service
PC can be used for a detailed monitoring of the power supply system and a
modification of the system parameters.
There are no special requirements to the hardware. A WINDOWS operating
system (as from WINDOWS 9x) will be sufficient.
Attention!
The safety instructions must be observed at all times during assem-
bly, installation and commissioning!
The components of the MCU are designed to be operated in closed dry rooms.
The maximum permissible ambient temperature is 40°C. Attention must be
paid that the components are not exposed to aggressive substances and the pas-
sage of cooling air is not hampered.
To enable you to carry out the commissioning, the entire power supply system
with all the components belonging to the MCU has to be wired and connected
to the power supply system. When the initialisation phase has been terminated,
the display shows a measured value of the system.
Selecting a position
Changing a position
The example above shows load voltage, load current and date/time.
Logfile [ 1]
09.02.06 – 11:31:48 Delete logfile?
SAT-bus status
Main menu
[ 25]: Mains failure
Logfile active
Measured value display
Digital inputs
Reset hold function
Status of components
Test menu
Display setting Logfile [ 15]
System settings 09.02.06 – 11:31:48 Delete logfile?
Digital input
[ 40]: URGERR
active
Main menu
Logfile
Measured value display IV [ 30]
Digital inputs I = 21.1A
Reset hold function
Status of components
Test menu
Display setting TA [ 60]
System settings T = 20.0°C
DZ [ 92]
17:16:42
14.02.2006
MOD [ 45]
= inactive
BATNOK [ 51]
= inactive
Main menu
Logfile
Measured value display
Digital inputs
Delete hold function?
Reset hold function
Status of components
Test menu
Display setting
System settings
Component [M]
= 26
Component [R]
= 27
Operating mode
Battery test start
Battery test end
Main menu Charge
Logfile Float charging
Measured value display ♦ Direct feeding
Digital inputs Equalise charging
Reset hold function
Status of components
Test menu Password 1 Test menu
Display setting *** Operating mode
System settings − Relay test
Relay test
Relay 1
Relay 2
Relay 3
•
•
•
Relay 16
Contrast DZ [ 92]
= 80% = 92
Illumination period
= 10 s
F GSR setting
Input channel IV [ 30]
Lower limit = 30
Upper limit
Hysteresis
GSR number Filter mask
=1 Lower limit WR [ 31]
= 48.0 = 31
GSR number
=2 Upper limit
= 100.0
Hysteresis PV [ 90]
= 0.5 = 90
GSR number
=5 Filter mask
Generally enabled
SVA link
SVB link
Insert mess. text
Trigger message
SVC link
No access to MCU
G H I
K L M, N
"Logfile"
An event history of all status changes is stored in the logfile. Up to 200 of the
last status changes can be read out using a circular buffer. A threshold can be
set to allow a warning for the number of past status changes.
Event description
The complete logfile content can be deleted from each logfile entry.
All recorded measured system values can be shown in this menu item. A ma-
ximum of 200 measured values can be recorded.
Measured value
The exact code of the type of measured value can be found in the order-related
data sheet of the MCU.
"Digital inputs"
The exact code of the type of digital inputs can be found in the order-related
data sheet of the MCU.
With this menu item, all programmed hold functions for the filter events, the
relays and the LEDs can be deleted.
"Status of components"
The status mask of each Sat-bus component defined in the system can be dis-
played.
Attention!
For safety it is important to change this password after commission-
ing the system.
The function of each single relay of all connected RELIO boards is tested when
selected.
The languages "German" and "English" can be selected by default. A third lan-
guage, e.g. "French", can be implemented customer-specifically.
All LEDs of the display (4x) and of the LED board (13x) are subjected to a
function test.
Here, the three measured values which are to be displayed in the basic status
are defined. All measured values recorded in the system can be selected.
The brightness of the display can be set between 10% and 100%.
The contrast of the display can be set between 10% and 100%.
The illumination period of the display can be set between 10 and 255 seconds.
Attention!
For safety it is important to change this password after commission-
ing the system.
Setting of the first rated shunt value; setting range 0 ... 9999 A
Setting of the second rated shunt value; setting range 0 ... 9999 A
Indication of the number of cells of the system battery; 0 ... 200 cells
Setting of the delay time of the "urgent" fault messages. Setting range: 0 ...
65535 seconds
Setting of the delay time of the "non-urgent" fault messages. Setting range: 0 ...
65535 seconds
Setting of the delay time of the "common fault messages". Setting range: 0 ...
65535 seconds
Setting of the relay test duration for the menu item "Test menu | Relay test".
Setting range: 0 ... 65535 seconds
Input of measurement channel through which battery test current of battery cir-
cuit 1 is recorded.
Input of measurement channel through which battery test current of battery cir-
cuit 2 is recorded. (correct configuration flag must be set! )
Input of time interval in which another automatic battery test should be initi-
ated. The time is entered in days, months and years. (Correct configuration flag
must be set! )
Input of date on which a first automatic 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 commission-
ing. The date is specified in day, month and year. (Correct configuration flag
must be set! )
Display of the next starting date for an automatic battery test. The time is spe-
cified in day, month and year. The timing is based on the data previously input.
(Correct configuration flag must be set! )
Battery test with 2 batt. The battery test is carried out for two battery cir-
cuits. The battery test parameters for the second
battery circuit must be set.
Contin. control centre call The MCU tries up to 8 times to issue a log
Contin. control centre call The dialling attempts are continued until a log
has been successfully issued.
Rec. to both contr. centres A fault record is sent to one call number only.
Rec. to both contr. centres A fault record is always sent to both call num-
bers (only when 2 call numbers are entered! )
Batt. cap. at MFT The taken battery capacity is determined only at
a battery test.
Batt. cap. at MFT The taken battery capacity is determined at a bat-
tery test and at a mains failure.
Record via service port Only requested records are issued via the service
interface.
Record via service port The records are sent automatically via the ser-
vice interface.
ADBUS-SATs connected No bus converter for the ADBUS is connected
ADBUS-SATs connected A bus converter for the ADBUS and suitable rec-
tifiers for the ADBUS are connected.
Record for unit failure A record is sent only once in case of a unit fail-
ure.
Record for unit failure Each new unit failure is reported via a record.
This fault mask / status mask is regularly compared with the status of each
SAT-bus user. The appropriate actions are triggered depending on the result of
this comparison.
A status mask 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 status mask. De-
pending on the result, an urgent alarm is given.
A status mask 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 status mask. De-
pending on the result, a not urgent alarm is given.
A status mask 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 status mask. De-
pending on the result, a common fault message is given.
Attention!
The settings of the limit-value monitoring relays (GSR) should only
be changed with excellent system knowledge.
Input of hysteresis band width. This value applies for the upper and lower li-
mit value.
This filter mask specifies which statuses or actions are affected or are to be
triggered if a limit value has not been reached or is exceeded.
A hold function can be set for all LEDs of the LED board and the display.
When the event which has caused the LED to light up no longer exists, the
LED goes into the flashing status (hold status). The status is reset by activating
the reset key of the LED board or via the menu item "Reset hold function".
A hold function can be set for all relays. After discontinuation of the event
which led to the activated status of the relay, the relay remains in this active
status (hold status). The status is reset by activating the reset key of the LED
board or via the menu item "Reset hold function".
A possibly pending redundancy fault is reset. The maximum value of the paral-
lel-running rectifiers is re-determined.
Specification or alteration of the password (000 ... 999) with which the "Test
menu" is accessed.
Specification or alteration of the password (000 ... 999) with which the menu
"System settings" is accessed.
Attention!
In the battery test characteristic, the voltage of the rectifier is re-
duced and not switched off. For this reason, no critical situation for
the loads occurs at any time.
The abort voltage and the duration of the battery test can be set at the display or
by using the service software TEBE MCU Service.
Attention!
Before a battery test can be started, the "Charge automatic” at the
SAT rectifiers has to be active.
1) Locally via the satellites of the rectifiers. This setting must be made sepa-
rately for each rectifier.
Attention!
If an automatic battery test is being carried out via the MCU, the op-
tion "Automatic battery test" must be released.
Operation
The rectifiers are operating on the
float charge characteristic. Auto-
matic charging must be activated.
yes
UBatt. ≤ UCancellation
no
Back-switching
Switch back to float charge charac-
teristic. No defined charging phase.