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DSP Inverter System

For 19" Relay Racks


028-0009-220 Rev. B

















Benning Power Electronics
11120 Grader Street
Dallas, TX 75238 USA
214.553.1444
800.910.3601

This manual contains
important safety instructions
that should be followed during
installation and maintenance
of the Power System.

Operations and Maintenance Manual









Preface

Congratulations and thank you for purchasing a Benning DSP Inverter System.

We at Benning are committed to supporting the needs of our customers by supplying
the customer with the proper information and documentation needed to properly install
and operate the unit purchased.

Important:
It is imperative that all the information be observed.

This avoids:

Danger during installation and operation.
Danger to operating personnel.
Downtime.
Increases the reliability and lifespan of the system.


This manual explains all the necessary information to unpack, install, and operate the
Benning DSP Inverter System and related components. Refer questions outside the
scope of this manual to our Customer Service Department.

Customer Service:
We are committed to excellence in dependability and customer satisfaction. If you have
any questions or problems, please contact the Customer Service Department at:
1.800.910.3601 or 214.553.1444 for more information.


Please read all instructions before installing or operating the equipment and save these
manuals for future reference.





Revision Date Originator Approver
A 05.14.08 C.Tumey D.Almond
B 02.25.10 C.Tumey E.McDonlad




Publication Document: Version 1.0
Copyright 2007 Benning Power Electronics
Proprietary Information: This manual contains proprietary information which is protected
by copyright law. All rights are reserved. No part of this manual may be photocopied,
reproduced, or translated to another language without prior written consent of Benning
Power Electronics. Specifications in this manual are subject to change without notice.




Table of Contents
1 SAFETY NOTES AND MARKINGS ............................................................................................................ 1
2 GENERAL ..................................................................................................................................................... 3
2.1 SYSTEM CONFIGURATIONS.......................................................................................................................... 4
3 THE COMPONENTS OF THE INVERTER SYSTEM .............................................................................. 6
3.1 RACK DESIGN ............................................................................................................................................. 6
3.1.1 Design of the Unit ........................................................................................................................... 7
3.1.2 External Connections for Individual Input ............................................................................... 9
3.2 INVERTER ................................................................................................................................................... 12
3.2.1 Design of the Inverter Unit ......................................................................................................... 13
3.2.2 Operating Elements of Inverter ................................................................................................. 14
3.3 TECHNICAL DATA ...................................................................................................................................... 17
3.4 MCU2500/SNMP ADAPTER .................................................................................................................... 19
3.4.1 SNMP Adapter .............................................................................................................................. 19
3.4.2 MCU 2500 ........................................................................................................................................ 21
3.4.3 SNMP Connected .......................................................................................................................... 22
4 SET UP ...................................................................................................................................................... 22
4.1 DEVICE SETTINGS ...................................................................................................................................... 23
4.2 CONNECTING THE INVERTER SYSTEM ....................................................................................................... 24
4.3 INSTALLATION OF THE UNIT ....................................................................................................................... 26
4.4 COMMISSIONING OF THE INVERTER SYSTEM ............................................................................................ 28
4.4.1 Inverter System ............................................................................................................................. 28
4.4.2 Commissioning Report ............................................................................................................... 29
5 MAINTENANCE AND REPAIR ............................................................................................................... 31
5.1 USE OF THE MAINTENANCE BY-PASS SWITCH (IF INSTALLED) ............................................................... 31
5.2 EXCHANGE OF UNITS ................................................................................................................................. 35
5.3 UPGRADING THE SYSTEM .......................................................................................................................... 35
6 PARTS LIST .............................................................................................................................................. 36
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1 Safety Notes and Markings

Explanation of the symbols used:


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

Indicates instructions which must be followed to avoid
material damage!

All specifications in these operating instructions must be
observed at all times!

Index of abbreviations:
A Amps
AC Alternating Current
DC Direct Current
I Current
INV Inverter
CB Circuit Breaker
SNMP Simple Network Management Protocol
UDC DC voltage
UAC Mains Mains Voltage
UAC Mains Load Voltage
V Volts
W Watts



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The inverter system is an electronic appliance that carries
voltages and currents dangerous to humans.

The following instructions must therefore be followed at all times!
1. The inverter system should be installed, operated, repaired and
maintained in strict accordance with the instructions in this
document.
2. Ensure that only fully trained and qualified personnel have access
to the system. Only qualified and authorised personnel should be
able to open the units.
3. Even when the inverters are switched off, some of its interior
components remain live as long as they are connected to the
mains supply or the battery.
4. Capacitors may be charged even when the unit is disconnected.
These must be correctly discharged by a qualified electrician
before the connections or terminals are touched.
5. When working with the unit, use properly insulated tools at all
times which are suitable for the levels of voltage concerned.
6. All persons working with the unit must be familiar with the first-aid
procedures to be adopted in cases of accidents involving
electricity.
7. Always observe the regulations of the local power-supply company
as well as other safety regulations.
8. High Leakage Current Earth Connection essential before
connecting supply.
9. Permanently connected equipment A readily accessible
disconnect device shall be incorporated in the building installation
wiring.
10. Multiple Power Sources All power sources (AC and DC) must be
removed prior to servicing this equipment.
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2 General
The inverter system from the DSP product line is a compact AC power supply for a
wide range of telecommunication and industrial applications. The various possible
system configurations permit adaptation to the requirements of each particular
application.
The output power of the inverter system can be extended by adding 1kVA
(2.5kVA) inverters (INV) into the prepared racking units up to a maximum rating of
5kVA (12.5kVA). The DC input voltage is 48V.
The inverter modules utilize digital signal processors (DSP) programmed with the
appropriate algorithms carry out control and monitoring of the inverter system.
The mutual communication between the individual components takes place via a
CAN-BUS system (Controller Area Network) which ensures a high level of
immunity with respect to disturbance.


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2.1 System Configurations
Various systems can be assembled with the individual components of the
inverter system used as building blocks, to provide various ranges of power
and redundancy.
The simplest systems are single operation (1 inverter) and parallel
operation of several inverters without electronic switchover device. Only
inverters with the same power rating can be connected in parallel.
Up to 5 inverters can be connected in parallel in a corresponding racking
unit.








Figure 1: Single and parallel operation of up to 5 inverters in one
racking unit
The maximum system power rating with simple parallel operation of the
inverters is 5 kVA or 12.5 kVA. If two racking units are used, maximum
system capacity could be increased to 12.5kVA to 25kVA by paralleling the
two racking units (an external junction box is required for this
arrangement).



5
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The two shelves can be connected to different DC supplies.










Figure 2: Parallel operation of up to 10 inverters in 2 part systems (racking
units).



Figure 3: Typical inverter system with 5 parallel-connected 1kVA inverters.

5 5
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Figure 4: Typical inverter system with 5 parallel operated inverters.

3 The Components of the Inverter System
All components are installed in 19 rack mounted rack. The inverters designed as
HOT-PLUG slide-in units.
The components of the inverter system:
19 rack mounted rack for accommodating inverters
Inverters of the series
TEBEVERT 1000 or TEBEVERT 2500
MCU (optional)
SNMP (optional)

3.1 Rack Design
The rack has been designed to accommodate 5 inverters. The respective
shelves for the 1kVA and 2.5kVA inverters are different and cannot be
interchanged.
MCU/SNMP is
located behind
panel.
Service Port
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3.1.1 Design of the Unit

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Figure 5: Mechanical dimensions for housing.
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3.1.2 External Connections for Individual Input




Figure 6: Rear view of the Inverter Shelf.

1 (RJ45); CAN bus for inverter;
plugs are required only when the inverter system contains at least
2 inverter shelves in parallel. Use CAN bus cable to connect two
shelves together using this connector. This is also used for the
external alarm contact card (Optional).



5
4
3 2
1
6
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2 D-SUB plug connector; serial interface RS232
Via this interface that status of the inverter system can be read out
for servicing, and settings can be made.

3 Alarm output connector.
Connector strip for the potential free
message lines of the inverter system



Central fault signal of the inverters
4-5: no fault
4-6: fault


Not Used


4 DC Input Terminals; 1/4-20 stud on .625 cc for two hole lugs, up
to 2/0 AWG stranded cable. The torque requirement is 50 in-lbs.
5 Output Terminal Blocks; up to 2/0 AWG stranded cable
(refer to side of terminal block for torque requirements).








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6 Digital I/O Card (RELIO); for auxiliary inputs and dry contacts.
K1 = Urgent Alarm
K2 = Non-Urgent Alarm
K3 = Inverter Failure
K4 = Bus Bar Voltage <46.0V

















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3.2 Inverter
The inverter converts DC voltage of 48VDC or 60VDC into AC voltage of
120VAC or 230VAC and 50Hz /60Hz.
This is done via an internal programming. On request by the user, any
other combination of output parameter values can be programmed within
the permitted range.
.














Figure 7: Inverter TEBEVERT

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3.2.1 Design of the Inverter Unit




















Figure 8: Dimension diagram of the inverter 1kVA (2.5kVA)
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3.2.2 Operating Elements of Inverter
All terminals and operating elements are installed on the front or
rear side of the inverter.

















Figure 9: Front view of the inverter

1
2 3
3 2
1
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1 Unit switch ON/OFF
Each inverter can be switched on and off individually with its unit
switch.
2 LEDs for indicating the inverter status
UUULEDUUU UUUColorUUU UUUFunctionUUU


red Fault

green Output voltage present and connected through to the
load .

green UUULED in continuous operation:UUU
The output voltage of the inverter is phase locked to
the other inverters in the system; parallel operation
UUULED in flashing mode:UUU
The inverter has MASTER functions

green The input voltage lies in the tolerance range

green Inverter on

3 LEDs for signalling the actual inverter output power
red; the inverter is overloaded if the LED is
flashing

yellow; when this LED is lit the inverter is loaded
nearly to the limit; flashing of the LED indicates a
configuration error of the inverter.

green; the lit LEDs indicate the loading level.

PBBB
max
BBB
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Figure 10: Rear view of the inverter

1 Connector strip; inverter output
2 Socket plug; Message and signal lines
3 Connector strip; DC input of the inverter
1
2
3
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3.3 Technical Data

Table 1: For 120VAC Inverter System.



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Table 2: For 230VAC Inverter System.


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3.4 MCU2500/SNMP Adapter

The MCU2500 and SNMP Adapter is located on the right hand side of the
DSP Inverter Shelf (if installed). These components are accessible by the
screws and sliding out the entire module.


3.4.1 SNMP Adapter

The SNMP Adapter is briefly defined in this section of the
installation manual and is explicably defined in the
operations manual provided with this unit.








Figure 11: Top End View of the SNMP Adapter.

1. 9V-36V (DC Power Supply Input).
*12V when connected to MCU.

2. COM1 (RS232 Null Port).



3.
1.
2.
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3. SW1 (Configuration DIP Switch).

Switch
1
Switch
2
Description
On Off
Normal
operation
Off Off
COM2
Configuration
(See SNMP
Operation
Manual)











Figure 12: Bottom End View of the SNMP Adapter.

1. LAN (RJ45 Network Cable Port).

2. COM2 (Mini-DIN Cable Port).

3. Error LED (On = Error or Booting).

4. Link LED (Flashing = Normal Operation).

5. AUX (Unused).
3.
5.
1.
4. 2.
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3.4.2 MCU 2500
Locate the MCU 2500 in the DSP by removing the faceplate on
the right hand side. The MCU 2500 will be mounted on the
behind the faceplate.
.


Figure 13: The MCU 2500 PCB.
1. Connector X3 for DC Power Supply Cord.

Figure 5: MCU 2500 X3 matting connector.
2. Connector X110 for RS232 connection to faceplate.




1.
2.
Power
Inputs
12V
Ground

Pin 1
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Figure 14: RJ45 Network Cable Routing.

3.4.3 SNMP Connected
Replace the DSP faceplate. Verify all wires and cables are free
from foreign objects that may damage or decrease the integrity
of the power or communication between the MCU 2500 and
SNMP Adapter. Now observe the status LEDs mentioned in
Figure 12. The Error LED (Red) will light for a small period
during boot up and then the Link LED (Green) will begin to
flash for normal operation. Enjoy your new SNMP Adapter.

4 Set Up


Caution!
The safety instructions must be observed at all times
during assembly, installation and commissioning.
After assembly, installation and commissioning of the inverter system, all
components are unreservedly ready for operation. No additional settings and
readjustments are necessary during operation under all operating conditions.
The site chosen for the inverter system must have a solid and level floor. The
inverter system is designed for operation in closed and dry rooms. The max.
permitted ambient temperature is 40C. When selecting its location, ensure that it
LAN (RJ45 Cable
Connection)
Customer LAN (RJ45
Cable Connection)
Load MIB file into
SNMP Monitoring
Software (provided by
customer).
Load IP Address
(provided by
customer) and login
via web browser.
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is not exposed to corrosive substances and that the flow of cooling air is not
restricted.

4.1 Device Settings


Attention!
Each alteration of the settings may only be carried out by
qualified personnel. The changed settings must be entered
on the configuration sheet of the inverter system. This is
essential to ensure that the current system configuration is
always unambiguously determinable. Specific replacement
of components and fault tracing are facilitated.
All components of the inverter system have been set in the factory to suit
the values and operation modes specified by the user, or to standard
values. For operation as specified it is not necessary to change the
settings.
Some settings and functions must be checked if system configurations are
to be changed, or new systems are to be configured with individual
components, or components are to be replaced or supplemented.


UUURack
Depending on the desired system configuration, the types of the racking
units may differ. In order that the redundant CAN-BUS systems for the
data communication of the individual units can function properly, the line
ends of the CAN-BUS systems on each racking unit must be provided with
terminating resistor/jumper according to a definite scheme. In addition
thereto, the racking units must be connected to data cables in a suitable
manner.
These measures are necessary only when constructing an inverter system
completely new. Since this is rarely carried out by the user, it is not
described further here.

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UUUInverter
Each inverter is set to default values at the factory according to the values
specified in the default section. For an inverter system without static by-
pass switch these values can be changed. To determine the set values,
consult the configuration.
Output voltage
Frequency
Switching thresholds of the input voltage monitoring
4.2 Connecting the Inverter System


Caution!
The power source circuits (mains input cable; DC supply)
must be provided with a disconnecting device. The
disconnecting devices must be readily accessible in the
vicinity of the inverter system.
If a battery is connected, then the instructions concerning
the installation and maintenance given by the manufacturer
of the battery must be observed.
The internal wiring of the inverter system is installed in the factory.
Depending on the maximum system power, the conductor cross-sections
and fuse ratings of the supply cables must be dimensioned accordingly.

Inverter systems with 1kVA inverters
System
design
Min. cross sectionTPTPTP
1
PTPTPT Max. external fuse rating
Mains input
cable
DC supply
cable
Mains input
cable
DC supply
cable
48V/1kVA 1.5mm 2.5mm 6A 25A
48V/2kVA 1.5mm 6mm 10A 50A
48V/3kVA 1.5mm 16mm 16A 80A
48V/4kVA 2.5mm 25mm 20A 100A
48V/5kVA 2.5mm 25mm 25A 125A


TPTPTP
1
PTPTPT In order that the voltage drop from the DC supply cable is not unacceptably large, larger cross-
sections should be used, depending on the conditions at the installation site.
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Inverter systems with 2.5kVA inverters
System
design
Min. cross section Max. external fuse rating
Mains input
cable
DC supply
cable
Mains input
cable
DC supply
cable
48V/2.5kVA 1.5mm 10mm 16A 63A
48V/5kVA 2.5mm 35mm 25A 125A
48V/7.5kVA 6mm 50mm 50A 200A
48V/10kVA 10mm 95mm 50A 250A
48V/12.5kVA 10mm 120mm 63A 315A

For the protection of the load circuits, attention must be paid to the
selectivity for the mains protection!
The maximum permitted loading of the potential free fault contacts is
250VAC/8A. The maximum permissible DC load must be determined from
the load limit curve of the relay. (The characteristic for a single contact
applies.)











Figure 15: Load limit curve of the contacts of the potential free fault
contacts.

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4.3 Installation of the Unit


Caution!
Before installing the units, the entire inverter system must
be switched free of voltage. Neither the mains (if existing)
nor the DC supply may be connected and must be
disconnected if they were connected.
It is assumed below that the configuration of the inverter system has been
defined and that the corresponding racking units are installed and wired up
in a 19 rack system.

Attention!
Are all inverters set for the same voltage and frequency?
Have all device settings been made and checked
according to Section 4.1?
Push the optional static switch into the outermost right position of the
corresponding racking unit. The front panel must be flush with the
frame of the racking unit.
If there are two parallel shelves you must connect the CAN bus cable
between the two inverter CAN bus connectors. (See section 3.1.2)
Push the inverters into the racking units. The order and the positions
are arbitrary. The front panel must be flush with the frame of the
racking unit.
Cover all free pug-in slots with a blank panel.
Fix all units and blank panels on the racking unit with screws.
The electrical connections are automatically established when pushing the
units into the racking units.





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Figure 16: Mounting units to Relay Rack.

The mounting ears are designed to rotate so the unit can be
mounted in a flush mounting position or 5" projection. Also, there
is a second set that can be mounted behind a relay rack channel
for extra support .This is set up for a 3", 4", or 5" channeled
racks. If it is flush mounted in a data cabinet, support rails are
required.





Install screws on
each side of
Distribution Shelf.
(See Parts List)
Install 2
(at minimum)
piercing washers
on each corner.
(See Parts List)
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4.4 Commissioning of the Inverter System


Caution!
Commissioning may be carried out only by properly
instructed trained personnel!

4.4.1 Inverter System


Attention!
Check the following points before commissioning the
inverter system:
Have all components of the inverter system been
adjusted, mounted and connected according to the
applicable Electrical Codes and system engineering
standards.
The DC supply should still not be connected at this
time!
All inverters are still switched off via the unit switch on
the front of each inverter.

1) Switch on the individual DC supply (s); close the
disconnecting devices
The LEDS on all connected inverters should be lit.
(the input voltage lies within the tolerance range)
2) Switch on all inverters with their Power On switch.
The order is arbitrary.
Immediately after switching On the inverters the LED
should lit .(inverter is switched on)



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4.4.2 Commissioning Report


Site Identification:

Customer:

Sales Order #:


System Serial Number:

Static Bypass Serial Number:

Inverter Module #1 Serial Number:

Inverter Module #2 Serial Number:

Inverter Module #3 Serial Number:

Inverter Module #4 Serial Number:

Inverter Module #5 Serial Number:


1. Cabinet Interconnections

Cabinet Ground Connected: Yes No

DC Input Cables Connected: Yes No

AC Mains Input Cables Connected: Yes No

AC Load Cables Connected: Yes No


2. Input Voltage Measurements



Energize the system for this section


DC Input Voltage


Inverter Position #1: VDC


Inverter Position #2: VDC


Inverter Position #3: VDC


Inverter Position #4: VDC


Inverter Position #5: VDC


AC Mains Voltage


L1 - N: VAC


L2 - N: VAC


L1 - L2: VAC


N - PE: VAC





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Turn the Maintenance Bypass Switch Operating Element arrow towards the left (Position #1)

L1 - N: VAC


L2 - N: VAC


L1 - L2: VAC


N - PE: VAC



Turn the Maintenance Bypass Switch Operating Element arrow towards the right (Position #2)


AC Load Voltage


L1 - N: VAC


L2 - N: VAC
Note: All of these values should equal 0
VAC.


L1 - L2: VAC


N - PE: VAC

Leave the Maintenance Bypass Switch Operating Element arrow towards in the center
(Position #0)



Provided all procedures have been successfully completed, the system is now

ready for normal operation and it is now safe to energize all AC loads.




Completed by:



Signature: Date:



Print:







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5 Maintenance and Repair
All the components of the inverter system have been developed for continuous
operation and are practically maintenance-free. To ensure correct functioning, it is
recommended that the flow of cooling air is checked periodically and dust is
removed from the units if necessary.

Caution!
The maintenance and repair of the inverter system may
only be carried out by qualified personnel.
If servicing is required (exchange of units, work on the mains supply or the DC
supply etc.) it must be determined which position the manual by-pass switch needs
to be in. Please refer to the Use of the Manual By-Pass Switch section below.

5.1 Use of the Maintenance By-Pass Switch (If Installed)



Attention!
Incorrect actuation of the maintenance by-pass switch
(MBS) can interrupt the power supply of the loads.
The maintenance by-pass switch is normally only used when servicing the
unit. This switch by-passes the static by-pass switch (SBS) and the loads
are connected directly and without interruption to the mains (mains
operation) or the inverter outputs (inverter operation").

Position 0: Automatic operation
Position 1: Mains operation
Position 2: Inverter operation


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If the maintenance by-pass switch (MBS) is to be operated, two possible
cases must be differentiated:

UUUCase 1: The SBS is operating correctly
The display of the SBS shows a correctly operating inverter system.


The LED (operation/ready for operation) is lit.
In this operating state the MBS can be switched optionally to position 1 or
position 2 depending on the service tasks to be carried out.
Example: The system is operating with inverter priority and the mains
by-pass is switched on.
Switch the MBS to position 1
The SBS switches without interruption from inverter operation to
mains operation. The mains by-pass is closed; the maintenance
tasks, e.g. replacement of inverters, can be carried out.



If the MBS is switched to inverter by-pass (Pos 2) and the inverter system
is operating with inverter priority, the SBS will not make any switch-over
and the other switch of the MBS is depicted flashing.
After completing the service tasks with a correctly functioning inverter
systemTPTPTP
2
PTPTPT return the MBS to the position 0.




TPTPTP
2
PTPTPT It can be assumed that the inverter system is functioning correctly when the changeover contact
in the SBS symbol has switched in the path in which the by-pass was switched, i.e. with inverter
by-pass to the inverter symbol and with mains by-pass to the mains symbol.
flashing
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UUUCase 2: The SBS shows a fault
In the case of this operating state, two further cases must be differentiated:
The inverter system is operating in the inverter operation mode.
The inverter system is working in the mains operation mode.
A fault of the SBS is indicated by the red LED (fault), by the flashing
symbol of the SBS in the display and by the potential free message of the
SBS.
Before actuating the MBS it must be determined unambiguously
whether the inverter system is operating in inverter mode or in mains
mode.
If the LEDs on the inverters for indicating the actual inverter output power
are lit, inverter operation can be assumed, otherwise mains operation. If
there is any doubt, measuring devices must be used to determine the
actual operating mode.


Attention!
In the case of inverter operation only the switch position 2
(inverter by-pass) may be selected, and for mains operation
only the switch position 1 (mains by-pass).
Otherwise the power supply for the load will be interrupted.

After completing the service tasks (e.g. replacement of the SBS) and when
the inverter system is functioning correctlyTPTPTP
3
PTPTPT switch the MBS back to the
position 0.




TPTPTP
3
PTPTPT It can be assumed that the inverter system is functioning correctly when the changeover contact
in the SBS symbol has switched in the path in which the by-pass was switched, i.e. with inverter
by-pass to the inverter symbol and with mains by-pass to the mains symbol.
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When the start-up phase of the inverters has completed, the
following LEDs are lit:

Output voltage available

The inverters are operating phase-
synchronised; parallel operation (this LED is
flashing if there is only one inverter.
This unit has the MASTER function. Normally
this is the unit which is switched on first. )
3) Switch on the loads
The greater the connected load is, the more LEDs are lit to indicate
the actual inverter output power.













DSP Inverter System For 19" Relay Racks



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5.2 Exchange of Units
Exchange of units may take place during running operations without an
interruption in the power supply to the loads.
Exchanging an inverter
Switch the inverter off with the unit switch.
Release fastening screw.
Pull the inverter out of the racking unit to the front.
Push the new inverter into the free plug-in position.
Attention! The inverter must be switched off at its unit switch.
The front panel must be flush with the racking unit.
Insert fastening screw.
Switch on the inverter at the unit switch.
(The inverter starts up and will be tied into parallel operation with the
other units. If the mains took over the supply of the load devices,
switch back to the inverters takes place).

5.3 Upgrading the System
The inverter system can be extended with additional inverters during
running operation. It is only necessary that the corresponding free plug-in
locations are available.
Release the fastening screws and take off the blank panels.
Push the inverters into the free plug-in locations and insert the
fastening screws.
Switch-on the units via their unit switches.
After the start-up phase, the new units are brought into parallel
operation and the load current then is evenly distributed to all inverters
that are switched on.)

DSP Inverter System For 19" Relay Racks



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6 Parts List
Part Number Part Description
Hardware
786051 Mounting Screw - 12 -24 x 1/2
718366
Patch cable KAT.5E
2xRJ45 / 1m - CAN bus connecting cable












DSP Inverter System For 19" Relay Racks



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Notes























Benning Power Electronics
11120 Grader Street
Dallas, TX 75238 USA
214.553.1444
800.910.3601

This manual contains
important safety instructions
that should be followed during
installation and maintenance
of the Power System.