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0 July 2013 First issue CR 803
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The copyright of this publication is the property of Vector Limited. No part of this Vector Limited 2011
publication may be reproduced by photocopying or by any other means without the
prior written permission of Vector Limited.
Electricity network guidelines: Revision 0 ENG–0059
Setup and configuration procedures for DC system equipment Page 2
Contents
1 Purpose .............................................................................................................. 3
2 Policy ................................................................................................................. 3
3 Scope ................................................................................................................. 3
4 References .......................................................................................................... 3
5 Definitions ........................................................................................................... 3
6 Procedure for Battery Acceptance/Performance Discharge Testing ............................... 3
6.1 General ............................................................................................................... 3
6.2 Initial check-up (prior to the discharge test) ............................................................. 4
6.3 Start the test ....................................................................................................... 4
6.4 Important considerations ....................................................................................... 4
7 Configuration of the Charger Controller ................................................................... 5
7.1 General ............................................................................................................... 5
7.2 Log in to CXC ....................................................................................................... 5
7.3 Assign IP address ................................................................................................. 5
7.4 Save and reboot charger controller ......................................................................... 5
7.5 Keep a record ...................................................................................................... 6
8 Configuration of the Battery Monitoring System ........................................................ 6
8.1 General ............................................................................................................... 6
8.2 Initial check ......................................................................................................... 6
8.3 Setup setting environment ..................................................................................... 7
8.4 Load factory setting .............................................................................................. 8
8.5 Configuring system information .............................................................................. 9
8.5.1 System Tab ............................................................................................. 9
8.5.2 Communication tab ................................................................................. 10
8.6 Configuring strings ............................................................................................. 11
8.6.1 Assigning string data ............................................................................... 11
8.6.2 Configuring current limits ......................................................................... 13
8.6.3 Configuring temperature limits ................................................................. 13
8.6.4 Setting string voltage limits...................................................................... 13
8.6.5 Saving .................................................................................................. 14
8.7 Configuring monoblocks ...................................................................................... 15
8.7.1 Detecting modules .................................................................................. 15
8.7.2 Assigning monoblocks ............................................................................. 15
8.7.3 Setting monoblock limits .......................................................................... 16
8.8 Configuring memories ......................................................................................... 18
8.8.1 Format memory...................................................................................... 19
8.8.2 Configuring memory intervals ................................................................... 19
8.8.3 Saving .................................................................................................. 21
8.9 Configuring alarms ............................................................................................. 21
8.10 Backup configurations ......................................................................................... 22
8.11 Communication Setup ......................................................................................... 22
9 Alarm Testing .................................................................................................... 24
9.1 Charger Alarm Testing ........................................................................................ 24
9.2 Battery Monitor Alarm Testing .............................................................................. 25
9.3 Others .............................................................................................................. 25
10 Appendix........................................................................................................... 26
10.1 Appendix A: Manufacture’s Datasheet: UXF-12FR (Standard) .................................... 26
10.2 Appendix B: Vector Zone Substation DC System Setup Records ................................ 27
10.3 Appendix C: Charger Controller and Battery Monitor Mapping Summary .................... 29
10.4 Appendix D: Sensor Connection............................................................................ 31
10.5 Appendix E (Temporary): PSMS............................................................................ 32
End of document ................................................................................................ 33
1 Purpose
The purpose of this guideline is to define the setup and configuration procedures for DC
system equipment.
2 Policy
Vector’s policy aims to protect personnel and equipment and comply with all statutory
requirements. This guideline deals specifically with Substation DC system equipment.
3 Scope
This guideline is for substation DC system on the Vector network. It outlines the following
information:
4 References
Vector
CAP-084 Vector Testing and Commissioning Guidelines – DC
systems
Other
5 Definitions
6.1 General
Appendix A for an example) or a constant power discharge equal to the rating of the battery
for the selected time. The batteries should be left to charge for a minimum of 48 hours
before the test is carried out.
Note: a fixed value resistor is not an acceptable form of constant current load.
6.2 Initial check-up (prior to the discharge test)
Measure the voltage and impedance of each monoblock. Record the initial battery
temperature. Record the value under Vector’s ‘Zone Substation DC System Setup
Records’ (Appendix B)
Connect the test set to the test terminal for the battery. If there are two battery strings
at the substation, then each string will have its own test terminal (generally located
inside the charger panel). The discharge should be carried out string by string
Switch on the ‘test terminal MCB’ for the to-be-tested string from the charger panel
Adjust the test set to make sure a constant discharge current is selected and the
discharge time is set at one hour. (Consult with Vector if unsure of the discharge current
value).
Set the minimum voltage limit to avoid over discharge of the battery. The minimum
voltage should be calculated based on the manufacturer’s specification (refer to
Appendix A )
Disconnect the battery from the charging source. (Note 1: If there are two battery
strings, then each string will have its own MCB to isolate the battery from the charger,
make sure the correct MCB is selected Note 2: If Charger Controller or/and Battery
Monitor are required as part of the discharge event, please ensure the device are not
disconnected during the test)
Measure the voltage of each monoblock and record it under ‘Voltage off charge’. (Refer
to Appendix B)
Start the test set and discharge the batteries
Refer to the Zone substation DC system Setup Records and fill in the section under
‘Voltage after discharge’.
The readings should be taken while the load is applied with a minimum of every 10
minutes.
Individual monoblock voltage readings should be taken between respective terminals of
like polarity of adjacent cells/units so as to include the voltage drop of the inter-cell
connectors. Due to the wide diversity of VRLA battery terminal connection designs, the
selection of the appropriate voltage probe location must be carefully analysed to ensure
that only the appropriate voltage drops are included.
The test should be aborted immediately if any individual monoblock falls below the
manufacturer’s specified cell end voltage during the discharge test.
Observe the battery for abnormal inter-cell/unit connector or terminal heating.
At the conclusion of the test, determine if the monoblocks have past the discharge test
7.1 General
The Intelepower CX Controller is used to monitor the chargers at Vector substation. The
charger controller monitor the AC supply, rectifier health, load current, earth fault and
other conditions of the DC system. Refer to Cordex Alarm Mapping (Appendix C). As
requested by Vector, the setting for charger controller is pre-loaded by the supplier.
Therefore the only setup required by the Service Provider is to assign the IP address (issued
by Vector) to the charger controller.
Tap on the Icon button at the bottom left corner of the LCD touch screen and select. LOGIN.
Next, enter the password 1234 and tap on ACCEPT.
Charger controller at the various substation will be allocated a unique IP address, contact
the Protection and Control team to obtain the IP address for a specific substation.
On the main menu, scroll down and tap on COMMUNICATIONS and then tap on IP
ADDRESS. Ensure the checkbox beside OBTAIN AUTOMATICALLY is clear, and enter the
following information:
IP: 172.2x.xx.xxx
Subnet: 255.255.255.xxx
Gateway:172.2x.xx.xxx
Select the √ icon to accept the new setting and return to the previous menu.
Return to MAIN MENU navigation screen and press the OPTION button to evoke the
SAVE/LOGOUT pop-up window.
Select SAVE to save the new settings. A pop-up window will appear to confirm the
selection (select the X icon).
Select the OPTION button again and choose LOGOUT.
Tap on the Icon button at the bottom left corner of the LCD touch screen and select
RESET.
To confirm the rest, tap on ACCEPT and then REBOOT NOW.
Contact Vector to verify the communication is established
Record the IP address of the charger controller under the ‘Zone Substation DC System
Setup Records’ Refer to Appendix B.
8.1 General
The PowerShield Sentinel unit is used to monitor the battery banks at Vector substations.
The Sentinel unit monitors the voltage (monoblock voltage and string voltage), the current
(string current), the battery temperature (sensor is placed within the monoblocks) and the
impedance (monoblock impedance and string impedance) of the enclosure. If the
monitored parameters exceed preset limits alarms will be activated.
Note:
During the configuration procedure it is recommended to periodically save the settings to minimise the risk of
losing the configuration changes due to a sudden power loss to the unit.
Connect to the Service port on the Sentinel unit using RS232. Refer to Figure 3.
Open the PowerShield Configuration software. Click the Connect button, click the Select
Device button and select Direct to COM1 click OK and Connect.
To reset the current configuration of the Sentinel to its default factory setting:
Ensure the access level is set to Installer, Go to File -> Access Level
Access the system screen by clicking the System button or [or by clicking System on
the Configure menu]. Refer to Figure 4 below.
Click the Load Factory Defaults button to reset the configuration.
Click the Change Date and Time button, and click the Synchronize to PC button.
Click the Change Name button, enter the name of the substation as the Site Name and
click OK.
i.e. ‘Substation Name’ ‘_’ ‘NK0#’
Select the sensor installed on site
Charging regime shall be selected as float
Click the Save Configuration button.
Access the String screen by clicking the String button or [or by clicking String on the
Configure menu].
Refer to Figure 9
Refer to Figure 10
1
If the current measured by the sensor exceeds the discharge threshold, the string is assumed to be in discharge
mode [string voltage must also be below the minimum float voltage]. The discharge threshold should be set less
than the smallest discharge current that should be detected.
Also, check the transducer type is actually LEM HTA 200-S
8.6.5 Saving
Click the Save Configuration Button under systems tab
Drag and drop the detected modules [from the Detected Measurement Modules Grid] to
the associated monoblocks [Monoblock Channel Assignment Grid].
Example: Measurement Module B (MM: B) is physically connected to Monoblocks 2 and 3
(MB 1, MB2) of cabinet A (refer example diagram on Appendix A). Click and drag the MM:
B (on the Detected Measurement Modules Grid) and drop this on MB 2 (on the Monoblock
Channel Assignment Grid). The dual measurement modules will be automatically assigned
to two adjacent monoblocks, therefore care must be taken to assign these to the correct
pair of monoblocks. One monoblock will be tagged V1 (to indicate the most positive of the
pair) and the other will be tagged V2 (to indicate the most negative of the pair). This
assignment can be swapped by right clicking the assigned grid cell and selecting the Swap
button. The correct implementation of this configuration procedure can be verified by
comparing the Total Modules Online figure with the Total Mapped Monoblocks.
Click the Edit Ohmic Limits Table button and edit the parameters as per the screenshot
below:
Click the Set Limits by String button and enter the string number to be configured [1 or 2]
and the Voltage Limits dialog box will appear. Change the parameters as per the
screenshot below:
Please note: The Baseline status should be Temporary baseline in use for new installation
Click on the Statistics tab in the Monoblock screen to view a read only display of real
time voltages of the monoblocks. [Can be used to ensure the monoblock voltages are
correct]
Access the system screen by clicking the System button or [or by clicking System on
the Configure menu].
Click the Save Configuration button.
Access the Memories screen by clicking the Memories button or [or by clicking Memories
on the Configure menu].
Before configuring the memories, the module memory system must be formatted. This
allocates the appropriate memory storage space for each monitor. Format the memories
after all monoblocks and strings have been mapped, but prior to setting logging intervals
and trigger options.
8.8.3 Saving
Click the Save Configuration Button under systems tab
Access the Alarms screen by clicking the Alarms button or [or by clicking Alarms on the
Configure menu].
The alarms can be configured to give an alert via the relay outputs (hardwired to the
SCADA RTU), to the live monitoring software (Link), to provide an audible alarm for on site
notification.
Click on the Configure Alarms button in the Main Alarms tab of the Alarm screen. The
alarms are listed on the Alarm Configuration dialog box with options to allocate them to
output relay, buzzer and comms. Alter the settings to:
Access the system screen by clicking the System button or [or by clicking System on
the Configure menu].
Click the Save Configuration button.
The site configuration files are to be backed up and stored at a central database at the
Vector Office.
Select the Backup option from the File menu and the Save Battery Monitor Configuration
to File dialogue box will appear. Select a destination directory, enter a file name
(Substation name) and click the Save button.
Save and upload a copy of this configuration file to Vector StationWare (PSMS). Refer
to PSMS Documentation. 2
Save and upload a copy of the Zone substation DC system Setup Records to Vector
Stationware (PSMS). Refer to PSMS Documentation.
The Sentinel units at the various substations will be allocated a unique IP address, contact
the Protection and Control team to obtain the IP address for a specific substation. The
Ethernet port on the Sentinel unit is to be configured with this data. Please ensure that
the IPsetup software from Lantronix Inc. is installed in the PC being used to configure the
device.
2
The PSMS documentation is not available at the moment, please refer to Appendix E for the uploading procedure till
the PSMS documentation is completed.
Once an IP address appears in the big red circled area from Figure 20, click on the IP
address and the window below will be shown:
Do not enter anything and press the OK button from Figure 21.
Refer to Figure 22, go to Network
From the Network page, enter the IP address, Subnet Mask and Default Gateway
provided by Vector
Click Okay
Click Apply Settings
Wait for 5~10 seconds. Enter the newly applied IP address in the web browser to check
the connection to Lantronix page can be re-established
Reboot battery monitor at the end
Contact Vector to verify the communication is established
9 Alarm Testing
Go to ‘Logs & Files’ -> ‘Manage Configuration File’ -> Upload Site Configuration
Carry out a hardware test of each relay (i.e. K1~K8) from the charger controller at the
beginning of the alarm testing. Go to ‘Hardware’ -> ‘Test Relay’ and Toggle the relay
contact to ensure SCADA receives the correct responses.
Check the following alarms during the battery discharge test (Note please do not
repeat the discharge test if the following alarms are not shown, go to ‘Log & Files’
download the event record and attach it as part of the testing report):
Minor Alarm – Low Voltage 1 (K4) – When voltage drop below 108V
Battery Low – Low Voltage 2 (K8) – When voltage drop below 104.62V
Charger Fail Alarm (K3)
Rectifier Alarm – Rectifier Fail (K7)
Minor Alarm – Battery on Discharge (K4)
Turn the supply to the charger controller off to trigger the following alarms:
Change the string voltage range to outside the existing string voltage reading to trigger
Change the temperature range to outside the existing temperature reading to trigger
Note: Make sure the monitoring system is set back to the correct value after the alarm
testing is done
9.3 Others
Test the auxiliary contacts to SCADA by switching the MCB ON and OFF
10 Appendix
If the battery model is UXF 100-12FR, the battery will need to be constantly discharged at 60.61A for 1 hour as recommended by
the battery manufacturer.
Minimum voltage for UXF-12FR battery = 1.85volt per cell x 54 cells = 99.9 V
End of document