BPE4000 - CAB Benning PDF

OPERATIONS AND
MAINTENANCE MANUAL
For
Benning Power Electronics
BPE 48-4000
DC POWER SYSTEM
(028-0005-120 Rev B)
SAVE THESE IMPORTANT

SAFETY INSTRUCTIONS
This manual contains important safety instructions that should be followed during installation
and maintenance of the Power System.
11120 Grader Street

Dallas, TX 75238
214-553-1444, Fax 214-553-1355
Technical Documents
BPE 48-4000
Power Supply System
(Table of Contents)
Issued:
Revision:
Checked:
Date
10/5/06
Name
DTL
Page. 1/2
Technical Documents
Preface:
No. 062-005
Safety
No. 2126en
System Install Information:
No. 028-0005-001
Rectifier Manual:
No. 4135en
Rectifier Satallite Manual:
No. 2801en
Rectifier General Specification
Tebechop 12000
Rectifier Circuit Diagram
No. 61921.00E001A3
Rectifier Dimensional Diagram
No. 61921.00M000A3
MCU 2000+ Controller Information:
No. 028-0008-020
System Elevation (Front and Top View):
No. BLT4000
Rectifier Cabinet Circuit Diagram:
No. 902-0103-340
Primary Distribution Circuit Diagram:
No. 902-0110-104
External Battery Shunt Drawing
No. 840-0052-101
Customer Alarm Mapping
BPE 48-4000 Maping
2/2
Preface
Congratulations and thank you for purchasing a Benning BPE 48-4000 Power System
We at Benning are committed to supporting the needs of our customers by supplying the customer
with the information and documentation needed to properly install and operate your Power
System.
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.
These manuals explain all the necessary information to unpack, install, and operate the BPE 48-4000
Modular Power 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 214553-1444 for more information.
Please read all instructions before installing or operating the equipment and save these manuals for
future reference.
Document No. 062-005 R1
Description
Safety Notes
Contents
1
Safety notes.......................................................................... 2
Issued:
Revision: R1
Checked:
EN2126.doc
Date
18.01.93
Oct 06
27.10.97
Name
TB-Enck/Bp
DTL
Enck
2126 en
pag. 1/2 pag.
Installation Manual
Hot-Pluggable
BPE 48-4000 Series
Modular
Power System
028-0005-001 REV B
Modular Power System

Series BPE 48-4000
1.
ABOUT THE MANUAL ........................................................................................................................3

SCOPE.............................................................................................................................................................3
QUESTIONS .....................................................................................................................................................3
PRECAUTIONS.................................................................................................................................................3
OVERVIEW .....................................................................................................................................................4
SYSTEM COMPONENTS ...................................................................................................................................4
WEIGHTS AND DIMENSIONS....................................................................................................................6

2.
PREPARATION .....................................................................................................................................6
Figures 2.1 TIP N TELL..................................................................................................................6
Figure 2.2 SHOCKWATCH................................................................................................................7
2.1 UNPACKING THE POWER SYSTEM .............................................................................................................7
INSPECTING THE EQUIPMENT..........................................................................................................................8
CARRIER CLAIMS ...........................................................................................................................................8
CHECKING PACKAGING CONTENTS ................................................................................................................8
OVERVIEW OF THE POWER SYSTEM...........................................................................................8

POWER SYSTEM CABINETS .............................................................................................................................8
RECTIFIER CABINET HARDWIRE INPUT CONNECTIONS ...................................................................................8
PRIMARY DISTRIBUTION CONNECTIONS .........................................................................................................9
EXTERNAL BATTERY STRINGS .......................................................................................................................9
SYSTEM MONITORING ....................................................................................................................................9
LOCAL MONITORING ......................................................................................................................................9
REMOTE MONITORING CAPABILITIES .............................................................................................................9
4.
INSTALLATION ..................................................................................................................................10
ERECTING CABINETS ....................................................................................................................................10
PHYSICAL INSTALLATION .............................................................................................................................10
5.0 GROUNDING ........................................................................................................................................13

CHASSIS GROUND CONNECTION ..................................................................................................................13
BATTERY RETURN REFERENCE LEAD (BRR) / C.O. GROUND CABLE ...........................................................14
6.0 INNER-FRAME DC LINKS ........................................................................................................................16
7.0 AC INPUT CONNECTIONS .......................................................................................................................16
RECTIFIER INPUT PROTECTION .....................................................................................................................17
8.0 INTER BAY COMMUNICATION CONNECTIONS .........................................................................................18
9.0 BATTERY CONNECTIONS ........................................................................................................................19
10.0 DC LOAD CONNECTIONS ......................................................................................................................19
IT IS IMPORTANT TO NOTE THAT IF THE DC CABLING SHALL ENTER AND WATERFALL FROM THE FRONT OF
THE PLANT ....................................................................................................................................................20
DESIGNATIONS .............................................................................................................................................20
FIGURE 10.2 .................................................................................................................................................21
11.0 ALARM AND USER INTERFACE CONTACT CONNECTIONS .....................................................................21
12.0 BPE 48 - 4000 SYSTEM START UP PROCEDURE ..........................................................................22
RECTIFIER SETTINGS ....................................................................................................................................23
13.0
MAINTENANCE..............................................................................................................................23
028-0005-001_REV B
Page 1

Series BPE 48-4000
EXCHANGE OF A MODULE ............................................................................................................................23

REMOVAL OF THE RECTIFIER MODULE: ........................................................................................................23
UPGRADING THE SYSTEM .............................................................................................................................24
Version Control
Authors
Almond / Law
Almond / Law
Addition/Change
Original Draft
028-0005-001
Version #
DRAFT
REV B
Date
October 4th 2006
October 5th 2006
028-0005-001_REV B
Page 2

Series BPE 48-4000
1.
About the Manual
BENNING recommends that carriers who deliver our products use AIR RIDE transportation
to ensure careful moving considerations have been taken for your new power system.
This manual contains information needed to install the Benning BPE 48-4000 Modular Power
System. The information is intended for DC Power Engineers, technicians or installers
experienced in both DC and AC electrical systems. The installation instructions in Section 4 are
intended for qualified electricians and technicians. This manual is generic, and is not intended to
define specific installation methods. Installation methods should follow all safety standards and
regulations, which apply, to the specific installation.
Note: Hazardous voltages are present in the BPE 48-4000 Modular Power System and the
installation must be done only by qualified personnel having prior training in AC to DC
power system installations and knowledge of NFPA 70E.
Scope
The manual explains all the necessary information to unpack and install the BPE 48-4000 Modular
Power System. Refer questions outside the scope of this manual to your dealer or Customer
Service Department.
Questions
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.
Precautions
Please read all instructions before operating the equipment and save this manual for future
reference.
SAFETY INFORMATION
SAVE THESE INSTRUCTIONS. This manual
contains important information for the installation
of the BPE 48-4000 Power System. The manual
must be retained and observed at all times!
Explanation of the symbols used:
Indicates safety instructions that must be followed to avoid danger
to persons!
Indicates instructions that must be followed to avoid equipment
damage.
Further symbols and warnings are explained at the appropriate places in this operating manual.
028-0005-001_REV B
Page 3

Series BPE 48-4000
The rectifier system is an electronic device that contains hazardous

voltages and currents.
For this reason, the following instructions must be followed at all times.
1.
The rectifier system should be installed in strict accordance with all

applicable regulations and appropriate guidelines.
2.
Ensure that only qualified and AUTHORIZED personnel have access to the
units. Only qualified personnel should be AUTHORIZED to open the units.
3.
When the rectifiers are switched off, some of the interior components remain
live as long as they are connected to the mains or the battery supply.
4.
Integrated capacitors may still be charged even when the entire unit is
completely free of voltage. A trained electrician must correctly discharge
these components before the connections are touched.
5.
When working within the unit, use properly insulated tools that are rated for
the system operating voltage.
6.
All persons installing the unit must be familiar with the first-aid procedures
to be adopted in cases of accidents involving electricity.
7.
The regulations of the local power-supply company and all other applicable
safety regulations must be observed at all times.
8.
This equipment is intended only for installation in a restricted access

location
Overview
The rectifier system BPE 48-4000 Series consists of plug-in, modular rectifiers with back panel
technology to allow easy installation and removal of the modules. When the modular units are
removed or installed into the cabinet system, all electrical connections are automatically
disconnected or connected. Performance data is indicated on the front of each rectifier module.
The parallel operation of all the rectifier modules provides total system capacity including N + 1
redundancy, if so equipped. The output voltage of the system is nominal 48VDC (-54.0 VDC
Float).
System Components
The design and arrangement of the components of the power system are as follows.
9
9
9
9
9
(2) Rectifier Cabinets

(1) Primary Distribution Cabinet
(20) pre-wired shelves for the rectifiers
(1 20) rectifiers
(1) MCU 2000+ Micro Controller Unit
028-0005-001_REV B
Page 4

Series BPE 48-4000
Fig. 3.1: Typical BPE 48-4000 Power System
WARNING!
There are no user serviceable parts inside the plug-in
rectifier modules.
028-0005-001_REV B
Page 5

Series BPE 48-4000
WEIGHTS AND DIMENSIONS

Cabinet
Dimensions
Height x width x length
Rectifier Cabinet
7 x 24 x 31.5
Primary Distribution 7 x 31.5 x 31.5
Cabinet
2.
Packed
weight
(Average)
545 lbs
960 lbs
LBS
Unpacked weight LBS

(Average)
465 lbs
860 lbs
PREPARATION
This section is designed to familiarize you with the BPE 48-4000 Modular Power System. The first part
explains how to unpack the system, inspecting the cabinet, rectifier modules and safety precautions. The
remaining sections describe the rectifier modules and general installation practices. Read all sections
carefully before installing the power system.
The BPE 48-4000 power system crates should be equipped with TIP N TELL indicator(s) and
associated tag(s) to warn if the crate was (were) mishandled or tipped during transportation. Verify that
there are no blue beads in the arrow of the indicator as shown in figure 2.1. If blue beads are present in
the arrow, make note of it on the bill of lading and open the crate(s) immediately to verify the equipment
for damage (Claims for tipping will depend on this notation). Report any damages to the freight carrier
immediately.
Figures 2.1 TIP N TELL
028-0005-001_REV B
Page 6

Series BPE 48-4000
The BPE 48 4000 Power system crates are also equipped with a shock watch. If Shock watch is red, please note
upon delivery on the shipping receipt .Follow instructions located on the carton. Refer to figure 2.2- SHOCKWATCH
Figure 2.2 SHOCKWATCH
2.1 Unpacking the Power System

The cabinets and rectifier modules are shipped separately. Each rectifier module has been factory tested
and is ready to plug into the power shelves. The following steps explain how to remove the Rectifier
Cabinet.
1. Cut the straps holding the cabinet to the pallet.
2. Remove the top cover section of cardboard and the foam inserts.
3. Carefully lift the exterior cardboard sleeve, lifting it completely off the cabinet. (This may
require two people)
4. Remove the remaining foam inserts and the plastic bag.
WARNING
The rectifier cabinets weigh in excess of 500 lbs each.
The Primary Distribution Cabinet is approximately 860
lbs. It is mandatory that necessary precautions be
taken to lift, move, set and position the cabinets.
5. Using an appropriate number of people or the proper lifting device lift the cabinet off the
shipping pallet. Should a forklift or other lifting device be used you must first remove the front
and rear lower cover plates. Be sure to replace the cover plates once the cabinet has been
positioned and bolted in place. Once removed, lifting forks may be inserted into the frame
base allowing the cabinet to be lifted off the pallet. A secondary means of moving the
cabinets is to use a dolly truck. If this method is used, only lift the cabinets from the right side
of the cabinets as viewed from the front.
6. Ensure that cabinets are installed on a level surface for proper operation of cabinet doors.
7. Open the shipping cartons for each rectifier module. Be sure to save the packing materials in
case the modules need to be returned to the factory for some reason.
028-0005-001_REV B
Page 7

Series BPE 48-4000
Inspecting the Equipment

Check the cabinet and the modules for external damage. If any damage occurred during shipment, keep
the shipping cartons and packing materials so the carrier can inspect them.
It is your responsibility to file claim with the carrier for damages to the equipment. Any and all damage
noted upon receipt of the BPE 48-4000 system should be clearly identified in detail on the Bill of Lading.
Carrier Claims
Carriers claim procedures should be initiated promptly. In the event damage is found after delivery, it
should be reported as soon as possible (normally 15 day time limit on reporting damages incurred in
shipment).
Checking Packaging Contents

Verify the contents of the system against the packing list and the purchase order. If the shipment does not
contain the appropriate items, contact BENNING Customer Service at 800-910-3601 or 214-553-1444.
The following items should be shipped loose and packed in separate boxes:
Inter-frame DC Links (2) EC-270 , (1) EC- 271 & (1) EC-378
Miscellaneous Hardware C/O

Inter-frame DC Link Hardware (5/16-18 and 3/8-16 Nuts, LW & FW)
Cabinet Connecting Bolts (4) Upper, (4) Lower (3/8-16 Bolt, Nut & Grounding
washer)
-48 V Battery Bus Lug Connecting Bolts (5/16-18 Nuts, LW & FW)
(2) RJ-45 Inter Bay Communications Cable (Rectifier Cabinet 1 2 to PDC)
(Optional) Battery Temperature Sensor, 10 meters
BPE 48-4000 System Installation Manual
18 GA White, Current Share Lead (Rectifier Cabinet 1 -2)
Door Access Key
OVERVIEW OF THE POWER SYSTEM
Power System Cabinets

The power system consists of a Rectifier Cabinet (s) and Primary Distribution Cabinet. The height of the
system is 72 and the depth of the system is 31.5. The overall width of all three cabinets installed is
79.5.
Rectifier Cabinet Hardwire Input Connections
Each Rectifier Cabinet has its own AC input panel which provides a single or dual (jumpers included) input
connection point for the incoming 480VAC input. Ten (10) three pole fuse disconnect switches are used to
provide input protection and short circuit current limitation for each rectifier. The main input terminal is
wired for L1 or Line 1/Phase A, L2 or Line 2/Phase B, L3 or Line 3/Phase C, and PE or Protective
Earth Ground. If two input feeds are desired the installed jumpers must be removed providing one feed for
each set of 5 rectifiers. The max lug size that can be accepted is 4/0.
028-0005-001_REV B
Page 8

Series BPE 48-4000
Primary Distribution Connections

The Internal DC Distribution provides individual load circuit connections allowing the Power System to
serve as the Primary Load Distribution center. Up to three rows of load distribution can be configured for
either TPL style fuses or GJ1P style breakers. A maximum of sixteen breaker positions per row of
distribution or five fuse positions are available per row. Load circuit breakers and/or fuses up to 1200
amps can be installed with a maximum load capacity of 2500A per row. The number of cables that can be
installed per breaker/fuse is dependent on the capacity of the device.
External Battery Strings
External battery strings can be connected to the system via bus bars located at the top of the system in
the Primary Distribution Cabinet. The system has been designed to accommodate up to twenty
connection points for both positive and negative battery terminations.
CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACED
BY AN INCORRECT TYPE.DISPOSE OF USED
BATTERIES ACCORDING TO THE INSTRUCTIONS.
System Monitoring
The system has the MCU 2000+ (Main Control Unit) installed to provide varying levels of local and remote
monitoring e/w 11 programmable form C contacts. For details regarding the specific monitoring
configuration provided with your system refer to the MCU 2000+ document included with this manual. A
modem, SNMP, or TCP-IP device can be added to enhance the remote monitoring capabilities of the
system.
Local Monitoring
Local monitoring is included with each rectifier module and provides visual status such as: LED indicators
detailing the current operational status and alarm conditions; multi-line LCD display which can display
voltage, current, temperature, and the address of the module.
See the included rectifier sections for more detail.
Remote Monitoring Capabilities
The MCU contains a serial port for local monitoring and remote communications options including a
TCP/IP adapter, a SNMP adapter, or an analog modem.
The TCP/IP adapter is a 10 Base-T device that supports web-based reporting via a built in HTML
web server with email capability over the Internet or Intranet if behind a firewall. This adapter can
also be paired with the Benning Monitor Software which allows the user to monitor several sites
from a central location.
The SNMP option (Simple Network Management Protocol) allows machine to machine status of
the system over the Internet via alarm traps.
The analog modem option allows the system to be monitored remotely over the phone network via
the Benning Monitor Software. The system utilizes a call back function for security reasons.
028-0005-001_REV B
Page 9

Series BPE 48-4000
4.
Installation
The Installation section explains installing the Power System and connecting the AC/DC input/output.
Connection of the remote relay contacts and other communications options are also covered.
Warning!
These installation instructions are generic and are to be used as a
guideline for installing the BPE 48-4000 system. All safety
regulations and guidelines which apply must be observed.
WARNING
The safety instructions must be observed at all times
during assembly, installation and commissioning.
Erecting Cabinets
When locating the Cabinets consider the following guidelines:
1. The site chosen for the rectifier system must have a solid and level floor designed to properly
support the weight of the cabinet per sq/ft.
2. The system is designed for installation and operation in a restricted and controlled
environment. The installed location should have a maximum ambient temperature of 50C.
3. Two (2) Technicians shall be present at all times for safety reasons
Physical Installation
1. Using the appropriate sketches below, mark the floor for anchor positions and proceeds with
either standard floor anchoring means or earthquake approved anchoring. Frame Isolation
pads are available from Benning if required. Rectifier cabinets are 600 X 800 mm and the
Primary Distribution Cabinet is 800 x 800 mm. Non earthquake zone applications use (4)
0.42 D floor mounting holes for each cabinet. Earthquake zone applications require welded
cabinets with (8) 2 x 0.5 slots for mounting with earthquake zone approved anchors
(Customer provided anchors).
028-0005-001_REV B
Page 10

Series BPE 48-4000
2. The cabinets should be shimmed to the floor to make sure they are level. Once they are
leveled, they should be secured using Washers in mounting holes provided. See typical
standard concrete anchor mounting and earthquake zone concrete applications shown on
next page.
028-0005-001_REV B
Page 11

Series BPE 48-4000
Typical Non-earthquake Zone concrete anchors
Typical Earthquake Zone Concrete Anchors
028-0005-001_REV B
Page 12

Series BPE 48-4000
5.0 Grounding
Chassis Ground Connection
Each cabinet is equipped with 3/8 studs on 1 centers that act as the common frame ground for the unit
and are located at the top of each cabinet. Connect frame ground to these grounding studs using
appropriate lug/terminal ends and cable of same type of material as used by the factory e.g. copper or tin
plated copper.
Frame Ground
Collector
Ref NEC 250.122
No. 1 AWG
Frame Ground
Minimum based
Ref NEC 250.122
on distance
No. 1 AWG
Minimum
028-0005-001_REV B
Page 13

Series BPE 48-4000
Battery Return Reference lead (BRR) / C.O. Ground cable

The Battery Return Reference cable /C.O. ground cable should be equal to or larger than the largest
current carrying conductor in the DC Plant. Since the largest current carrying conductor is normally a 750
MCM Cable it has become the normal practice to Install 1 750 cable. This Bar at the Primary Distribution
Cabinet is pre drilled for 2 hole lugs 3/8 bolts on 1 centers.
Generally accepted practices in C.O. Grounding
The C.O. ground cable should be separated by method of cable brackets or dedicated grounding
rack and easily traceable from the Floor Ground Bar (FGB) or Building Principal Ground (BPG) to
the DC Power plant.
The C.O. ground cable should not be spliced and should be continuous from the FGB/BPG
directly to the DC Power plant.
Brass labels marked DO NOT DISCONNECT shall be place at both ends of the cable.
The cable should be designated DC POWER PLANT C.O. GROUND on both ends of the cable
secured to a C-145 cable tag.
The cable should be Green; however Black and Grey are an acceptable substitution.
The cable shall have two hole lugs with compression type lugs.
The C.O. Ground cable should be connected to the extreme right or as an option, to the left in
order to prevent cable mismanagement.
028-0005-001_REV B
Page 14

Series BPE 48-4000
028-0005-001_REV B
Page 15

Series BPE 48-4000
6.0 Inner-frame DC Links

BPE 48- 4000 Modular power systems have tin plated contact surfaces. These surfaces do not require
sanding; simply apply a dry cloth to clean any debris or dirt. Although Tin coated surfaces do not normally
require any anti corrosive compound (i.e.) non ox ide a thin layer is generally acceptable.
The two (2) Rectifier Cabinets must be interconnected to the Primary Distribution Cabinet once all the
cabinets are secured and have been bonded to frame ground. The left (from Front) rectifier cabinet is
ready to accept two (2) EC-270, Inter-frame DC links. These links are secured with 5/16 and 3/8 nuts, flat
washer and lock washers as shown below viewed from the rear (right side). Repeat for the other cabinet
using an EC-271 for the top and an EC-378 for the lower Inter-frame DC Link. Torque all bolted
connections per table A which can be found at the end of this document.
Rectifier Cabinets and PDC as viewed from the rear
7.0 AC Input Connections

Each Rectifier Cabinet utilizes 480 VAC, 3 phases and a PE frame ground located behind the removable
panel at the top left hand side of the cabinet, behind the cabinet access door. Each Rectifier Cabinet is
designed for either a bulk/dual input for the entire Rectifier Cabinet. The bulk/dual input is standard and
pre wired to power all 10 rectifiers from a single 480 VAC source or by removing the horizontal jumpers;
two feeds (A & B) can be brought into each of the rectifier cabinets. If the jumpers are removed, one 3
phase feed would supply power for rectifiers 1-5 and the other feed powers rectifiers 6-10. Please refer to
the system schematic for specific details regarding these connections. The input voltage to the system is
480VAC three phase (3W + PE Ground). The removable cover must be re-installed after the input
connections are made, See Below
028-0005-001_REV B
Page 16

Series BPE 48-4000
RECOMMENDED EXTERNAL BREAKER SIZES

Bulk Feed for up to 10 rectifiers
Qty 1 200 ( 3 pole ) Amp Breaker
Dual Feed for up to 5 Rectifiers
Qty 2 100 ( 3 pole ) Amp Breakers
Rectifier Input Protection

Each rectifier cabinet distributes the 480 VAC 3 phase power to each rectifier through a three-pole fused
disconnect. These devices provide two important functions. First, they provide individual input protection
with disconnect function for each rectifier and secondly, they are current limiting devices. Due to the
potential for high Interrupting Capacity with 480 VAC service, these devices limit possible pass through
currents to a safe level. These fuses must only be replaced with a KLKR 30 current limiter or equivalent.
These disconnects also provide visual indication via a red indicator if any one of the fuses should
operate.
028-0005-001_REV B
Page 17

Series BPE 48-4000
8.0 Inter Bay Communication Connections

Only a few connections are required to be made during installation for communications between both the
Primary Distribution Cabinet and the Rectifier Cabinet.
1. An 18 AWG white wire (furnished) must be inter-connected between pin 1 of connector X6 in
Rectifier Bay 1 to the pin 1 of connector X6 Rectifier Bay 2. The connectors are located on the
right side of each cabinet.
2. Two, RJ-45 communication cables are provided. These connections provide communications
between the rectifier Cabinets and the MCU communications bus located in the Primary
Distribution Cabinet. One end of each RJ-45 cable is plugged into the Rectifier SAT BUS
COMBINER (SBC) board located on the right side of each rectifier Cabinet. The other end of
each cable is terminated on the SAT BUS COMBINER BOARDs located in the Primary
Distribution Cabinet. These cables can be terminated into any available connector on SAT BUS
COMBINER BOARD #1 or #2.
RJ-45 Cable
to Rectifier
Bay 1 and 2,
Plug into
socket as
shown
028-0005-001_REV B
Page 18

Series BPE 48-4000
Rectifier Cabinet 1 and 2
Primary Distribution Cabinet
9.0 Battery Connections

Provision for the connection of external battery strings is provided in the Primary Distribution Cabinet. 5/16-18
studs on 1 centres are provided for termination of up to twenty (-) battery cables using 2-hole lugs (customer
provided). Space is also provided on the right side (from front) of the Primary Distribution Cabinet for termination
of twenty DC (+) battery cables using 2-hole lugs arranged for 3/8 bolts on 1 centres. It is recommended that
these (+) battery cables be arranged in back to back pairs to conserve ground bar termination points.
It is recommended that battery short circuit protection also be provided for each battery string utilizing either fuses
or circuit breakers rated for the short circuit interrupting rating of the battery cells supplied (customer provided).
These are available from Benning Power Electronics, consult the factory
10.0 DC Load Connections

DC outputs are provided via the GJ1P breakers and/or TPL fuses installed in the Primary Distribution
Cabinet. The output cables are installed into the cabinet from the top of the system and secured using the
proper hardware (supplied by the customer).
NOTE: do not turn on the circuit breakers or insert fuses at this time.
Generic Guidelines to follow for DC cabling
Lugs used should be of compression type with a minimum of 2 crimp positions. Lugs should also
have 2 hole 3/8 hole 1 center to center hole spacing.
Connection locations for DC Distribution to the BPE 48- 4000 Modular power system have tin
plated contact surfaces. These surfaces do not require sanding; simply apply a dry cloth to clean
any debris or dirt. Although Tin coated surfaces do not normally require any anti corrosive
compound (i.e.) non ox ide a thin layer is generally acceptable.
All cables connected to the BPE 48 - 4000 should have a C 145 tag and a designation with the
end location clearly marked. P touch labelling is generally accepted, however verify with your
customer standards documentation and the Telcordia GR 1275.
Zone 4 cabling should always be flex cabling.
Clear heat shrink tubing shall be used on all crimp lugs.
028-0005-001_REV B
Page 19

Series BPE 48-4000
All cables shall be copper with insulation having flammability in accordance to the National Electric
Code. (NEC)
Cabling Distribution Layout
In principal Level A Distribution cabling is unsupported and cables enter the plant in a free
flowing manner. The cabling for level A should not exceed 36 from a cable rack to the
breaker/fuse location.
In principal Level B - C Distribution cabling will be tied to a support bar located at the center
of the plant. These cables will also be stitched to the A - level cables to provide additional support.
Return feeders (+) should be installed on the left hand side (facing front) to leave appropriate
locations available for the battery cabling on the right hand side (facing front).
Figure 10.1 PRIMARY DISTRIBUTION CABINET EQUIPPED WITH CABLING SHIELD
LEVEL A DISTRIBUTION
LEVEL B DISTRIBUTION
It is important to note that if the DC cabling shall enter and waterfall from the front of the plant
Designations
For designations with a cabling shield (Fig 10.1), designations can be applied directly to the shield using
etched plastic or P Touch labelling. For designations without a shield, P- Touch labelling can be applied
directly to the breakers or to the breaker termination bars indicated below in figure 10.2
028-0005-001_REV B
Page 20

Series BPE 48-4000
Figure 10.2
11.0 Alarm and User Interface Contact Connections

Multiple dry contact connections are available for remote monitoring of the system failures. Some
examples of these alarms are: DC Output High, DC Output Low, AC Input Fail, and Major/Minor alarms.
Also, a Temperature Probe, Emergency Power Off (EPO), Analog Measurement, Digital Inputs, or Audible
Alarm connections are available .For a comprehensive list of available alarms contact your BENNING
representative.
There are 8 Alarm relays that are factory defaulted set to the following. The alarms may be customized in
the factory prior to delivery if the customer advises Benning at the time of placing the order. Alarm settings
may be modified at anytime by logging into the system with the Benning Service Software. Additional
alarming information can be found in DRW NO .902-0110-104 which is normally shipped with each order.
028-0005-001_REV B
Page 21

Series BPE 48-4000
12.0 BPE 48 - 4000 SYSTEM START UP PROCEDURE

Warning!
Only Benning Trained and Qualified personnel may carry out the
System Start up. Any or all of the steps may alter depending on the
site specific conditions.
Trained, Qualified technicians on Benning BPE 48-4000 should only start up this system. ENSURE
BATTERIES ARE DISCONNECTED, AC IS TURNED OFF, AND LOAD BREAKERS ARE TURNED OFF
BEFORE PROCEEDING. ENSURE THAT A LISCENSED ELECTRICIAN HAS VERIFIED 480 VOLTS
ACROSS THE 3 PHASES OF THE AC.
1. Ensure that all AC fuse disconnects are in the disconnect position. There are 10 total in each
Rectifier Cabinet, ensure that they are all disengaged. You may refer to section titled rectifier
input protection
2. Make sure that the DC Batteries are off line (removing battery strapping as necessary or engage
battery disconnect device) and not connected to the DC Plant
3. Make sure all DC distribution breakers/fuses are in the off position.
4. Licensed Electrician should turn on the Main AC source to the Rectifier Cabinet and verify
connections and 480 volt potential.
5. Install the AC removable Blank Cover.
6. Engage AC Fuse Disconnect for rectifier #1.
1.
First, the AC mains supply is switched on, whereby LEDs on the rectifiers light up and
flash for a short time, approx. 40 seconds. (Initialization of the internal processor!)
Afterwards, each rectifier will display OFF on the LCD and will remain in stand by until
turned on.
2.
Next, one at a time turn each rectifier on by pressing the red button located on each
modules front panel. The rectifiers will then begin a search and select process until a
master slave configuration has been accomplished. The LCD displays will stabilize when
the process is complete.
3.
The rectifiers are now switched on. Located on each rectifiers front panel are LED
indicators, they all must display a GREEN LED which indicates active: unit in operation
and a YELLOW LED which indicates active: mains voltage applied and data transfer in
progress.
NOTE: if the yellow LED is flashing this indicates the master.
7. Turn on batteries by engaging battery disconnect device or by installing battery straps and verify
proper Plant voltages, Battery voltages and individual cell readings.
8. Charge batteries as described by the Battery Manufacturers recommendations.
028-0005-001_REV B
Page 22

Series BPE 48-4000
9. Test and acceptance per customer /site specific recommendations

10. Engage distribution breakers/fuses as required, verifying proper voltages.
NOTE: the rectifiers may not current share evenly until at least 30% of the over-all current
capacity is reached.
Rectifier settings
Each rectifier is set to default values at the factory according to the required operating conditions. Any
adjustment of these settings is not usually necessary.
However, if the rectifier is to operate with different parameters, a simple resetting can be carried out using
the keypad located on the front of each rectifier (see Rectifier Operation Manual).
Warning!
Only qualified personnel may carry out each alteration of the settings
on the unit. Any or all alternations of these settings may need to be
carried out for all the other rectifiers in the system depending on which
settings are altered.
13.0 Maintenance
All the components of the power 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 the filters are changed as needed.
Warning!
Do not use pressurised air since the dust particles can be blown into
the interior of the unit and may cause malfunctions.
Exchange of a Module
Attention: Take account of the amount of current being supplied by the

modules to the load and the batteries. Removal of a module in a nonredundant system may compromise the load.
Removal of the Rectifier module:

1.
Switch the module off by pressing the red button located on the front panel of the module.
2.
Remove the retaining screws, which secure the unit into the system.
028-0005-001_REV B
Page 23

Series BPE 48-4000
3.
Pull the unit out from the front of the cabinet about half way and wait until the front display is
completely blank. If the module does not have a front display, wait approximately 40 seconds and
then proceed to remove the module being careful to support the whole module as it is being
removed.
Insertion of the Rectifier module:

1.
The module must be switched off!
2.
Place the modules bottom back corner on the base of the carrier paying close attention to the
alignment grooves on both the module and the carrier.
3.
Slide the module into the free slot slowly until the modules front panel is flush with the front of the
cabinet.
4.
Screw in the retaining screws
5.
If the module has an active front panel, switch the module on by pressing the red button on the
front panel.
Upgrading the system

The power system can be equipped with a maximum of 20 rectifiers. Additional modules can only be
added to the system if there are free slots. The system can be upgraded during running operations without
the need to switch off other components or the need to alter the programming configuration of the MCU.
To add additional modules to an existing system first remove the dummy plate covering the free rectifier
slot. Ensure the new module is switched off. The new module is then pushed into the slot, fixed with the
retaining screws and then switched on. After the start-up phase, the module is brought into parallel
operation and the current then is evenly distributed to all modules that are switched on.
028-0005-001_REV B
Page 24

Series BPE 48-4000
Reference Information
Table A Bolt Torque Data
028-0005-001_REV B
Page 25

Series BPE 48-4000
Table B Cable Equivalents (AWG to Metric)
End of the Document
028-0005-001_REV B
Page 26
Safety notes
Before starting the unit:

Please read the complete manual, paying special attention to all the
safety notes.
Safety notes
The charging rectifier is an electrical unit with dangerous voltage and current
levels. For this reason, the following safety instructions must be observed:
1)
Installation, operation, servicing and maintenance should be carried out

only in accordance with the instructions given in this document.
2)
Ensure that only qualified and authorized personnel have access to the
equipment. No other persons should be able to open the door.
3)
Even when the unit is completely switched off, certain interior components remain lives as long as they are connected with the mains supply or
the battery.
4)
Intergrated capacitors may still be charged even when the unit is completely voltage-free. These must be properly discharged by a qualified
person before the connections are touched.
5)
When working on the unit, only properly insulated tools should be used.
6)
All persons carrying out work on the unit must be acquainted with the
first aid measures to be taken in cases of accidents involving electricity.
7)
Always observe the safety regulations of the local power supply company as well as other safety regulations.
8)
This product is intended for use in restricted access locations only.
9)
HIGH LEAKAGE CURRENT - Earth connection essential before connecting

supply.
18.01.93 - TB-Enck/Obs
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2126 en
Description
Rectifier with satellite

TEBECHOP 12000
3U 19 HOT-PLUG Version
Issued:
Modified:
Approved:
Date
29.06.2004
Name
TB/G
29.06.2004
Tel
C:\Projekte\TEBECHOP\Volleinschuebe_19''\12000_3HE_SAT\4135_en.doc
No. 4135 en
Page 1/17 Page

TEBECHOP 12000
Contents
Foreword ...............................................................................................................................4
1
Safety notes and markings......................................................................................5
Connection..............................................................................................................8
General ...................................................................................................................9
Functional principles ............................................................................................11
Start-up .................................................................................................................11
Operating modes...................................................................................................12
6.1
Floating level (ErlAd) ..........................................................................................12
6.2
Boost level (LAdEn) ............................................................................................12
6.3
Direct feeding (dir.SP) .........................................................................................12
6.4
Battery circuit test (b.tESt)...................................................................................12
6.5
Time-dependent automatic charging ....................................................................12
Parallel operation..................................................................................................12
Satellite.................................................................................................................13
8.1
Standard function .................................................................................................14
8.2
LED-indication.....................................................................................................14
Alarms ..................................................................................................................15
9.1
Urgent alarm (unit fault SV1) ..............................................................................15
9.2
Non-urgent alarm (mains fault SV2)....................................................................15
9.3
Temperature monitoring.......................................................................................15
9.4
Overvoltage protection .........................................................................................16
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9.5
output fuse-monitoring .........................................................................................16
9.6
Incorrect battery poling ........................................................................................16
9.7
Ventilator fault .....................................................................................................16
10
Adaptation of float charge voltage to battery ambient.........................................17
11
Fuses.....................................................................................................................17
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Foreword
These operating instructions give essential information for the

correct operation of the unit. To ensure the safe and correct
operation of this unit before the first switch-on, the user should
study these instructions carefully. Also note all the information
they contain.
These instructions should be kept in a safe place for
consultation.
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Safety notes and markings

International electrical symbols and display and operating symbols are marked
on the unit. They have the following meanings:
Important! See documentation!
Alternating current
Direct current
Earth (Ground)
Operation
Input voltage (mains) available / flashes during data transfer via

the satellite bus
Fault-output fuse
Fault-unit
Voltage - output too high
Fan fault
Funktions keys: A= menu ; B= enter key

On/Off (push button switch / impulse lock)
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Index of abbreviations
A
b.-Art
b.tESt
bzw.
DC
DirSP
EndE
ErLAd
i-MA
INenn
I-rEG
LAd.-A
LAdEn
Pb
Po.MA
SAE
SAT-Bus
T
tEMP
tESt
U
U-rEG
W
BATE.g.
Current
Operating mode
Battery test
or
Current
Direct feed operating mode
End
Consercation charge operating mode
Setting current limitation
Rated current
Following current limitation
Automatic charge
Charge operating mode
Lead
Power management
Voltage compensation facility
Satellite bus
Temperature
Battery temperature-based charge
Test
Voltage
Following voltage
Watt
Incorrectly poled battery
For example
For further information on the function of the satellite, refer to the
description no.: 2801.
The following symbols are used to draw attention to certain passages in these
instructions.
Constitutes a remark pointing out that observing it will facilitate
working with the device!
Constitutes a remark pointing out the process or operation of a

device or a specification.
Refers to a remark pointing out that life and body of persons could
be directly exposed to danger!
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It is an electronic device which requires dangerous levels of

voltage and current. The following instructions must therefore be
strictly observed at all times.
29.06.04 TB/G
1.
Installation, operation, maintenance and repair of the unit must

always be carried out in accordance with these instructions.
2.
Ensure that only fully trained and qualified personnel have access
to the unit. The unit should be opened only by authorised persons.
3.
Even when the unit is switched off, certain internal components

remain live as long as it is connected to the power supply or the
battery.
4.
Integrated capacitors may still be charged even when the entire unit
is completely free of voltage. Ensure that the capacitors are
properly discharged by a qualified electrician before touching the
connections.
5.
When working with the unit, use only properly insulated tools.
6.
All persons working with the unit must be familiar with first-aid
procedures for accidents involving electricity.
7.
Always comply with the regulations of the local power-supply

company or authority as well as any other relevant safety
regulations.
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TEBECHOP 12000
Connection
The following standards and regulations are applicable to the unit:
EN 61558
VDE 0884
EN 50 081-1
EN 60950
EN 50 082-2
In the standard version, the device and the insulating transformer correspond to
protection class I. The transformer corresponds to the regulation EN 61558 and
the test voltage primary/secondary is 4 kV alternating voltage.
The unit as delivered is ready for operation.
Installation and perfect operation is only possible in the special 3U; 19 rack
(PN: 550828).
The handle on the front panel serve only for pulling out the device,
not for carrying the device.
This device (protection type: IP 20 must be installed in a dry and dustprotected environment. The cooling air should not be obstructed.
Pay attention to the circuit diagram!
It is necessary to supply the supply circuit with an insulating device which has
to be
- easily accessible if permanently connected;
- easily accessible if it is a plug connection and located close to the device .
Provide appropriate fuses for mains and output cables (size of fuse,
characteristic see technical data)!
Access to the input and output fuses is only possible after opening the unit.
Before connecting up, make sure that the specifications on the type plate and
data sheet agree with the actual mains and battery voltages.
The details in the rating plate and in the data sheet with regard to power
consumption apply to rated conditions of input voltage and the operating mode
float charge voltage. The value in brackets is the maximum input current
with maximum input voltage tolerance and in the operating mode charging.
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TEBECHOP 12000
Make the mains connection on rack only when the mains supply
voltage is switched off.
The device must be connected with the neutral conductor of the supply power
circuit according to local regulations.
Because of the high energy of the battery to be connected, take special safety
precautions.
To protect the device from overvoltages (such as from lightning strikes), carry
out potential equalisation with sufficient cable cross section (e.g. 6 mm) on
Rack provided no other measures to protect the device are provided, for
instance building protection.
General
The rectifier described in the following is in switched mode technology.
This technology provides sound efficiency and good dynamic control
characteristics in the event of input voltage changes and load jumps.
Since these rectifier units are highly compact designs and can be connected in
parallel, the establishment of powerful electricity supply systems is possible in
conjunction with the 3U; 19 rack.
IPU characteristic (standard)
In order to achieve as high as possible a charge current, power is controlled on
the output side. This means that, dependent on the respective charge voltage,
the output current is adjusted to the maximum possible output power (example
of a 48V device see figure 1).
The IPU characteristic is only active in the operating modes float charging
and charging.
In the operating modes direct feed and 1,8 V/Z, it is limited to rated
current (IU characteristic).
Based on the type of battery and number of cells, the output voltage is kept
constant with an accuracy of 1 % Based on the type of battery and number of
cells, the output voltage is kept constant with an accuracy of. On reaching the
current limit control changes electronically from voltage to current control.
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TEBECHOP 12000
UA
(V )
5 7 ,6
5 3 ,5
48
4 3 ,2
188 2 0 0
240
IA (A )
Figure 1: (IPU characteristic; example: 48V unit)

The consequence of current limitation if applicable is a drop of the output
voltage in the event of a short circuit to < 1 V, the output current is
approximately around Irated. or at Imax , depending on operating mode. This
measure makes the device short-circuit proof permanently.
Mains fluctuations of voltage and frequency (see technical data sheet) and load
changes have no effect on the quality of the voltage and current constancy and
are regulated.
The power factor of the rectifier unit (active power to apparent power) is
regulated to roughly 1 (PF > 0.99 at rated operation). The utilisation of the feed
network is considerably improved in this way and higher output can be taken
from the single-phase net.
The rectifier is equipped with the so-called satellite. This assembly integrated
in the rectifier enables the establishment of a remote monitoring system MCU
1000 / MCU 2000.
Faults are delivered by means of floating contacts via the external evaluation
electronics MCU.
Additional information on the duty of the satellite, see chapter 8.
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TEBECHOP 12000
Functional principles
The mains voltage fed in through the input filter is converted by the rectifier to
DC voltage and supplied to the active filter (PFC). A special control method
takes a sinusoidal current from the three-phase net and provides a constant DC
voltage for the main unit (charge unit) at the output of the active filter.
Rapid MOSFET power transistors in the chopper unit convert this DC voltage
into a rectangular voltage. Control is effected by changing the duty cycle with
constant frequency. The power transmitter serves to separate the potential and
transform the rectangular voltage to the desired output value. Diodes rectify the
voltage and an LC filter is used to smooth the output voltage.
The device is equipped with a hardware overvoltage cut-out.
For switching on and off, the rectifier unit must be operated via the switch in
the front panel.
Start-up
Push all rectifier into the cabinet, with the mains switched off.
Switch on the first unit at the mains,
wait for the end of initialization period of this unit,
(the end of this period is indicated by the green LED "Operation /
and
the red LED "Fault/ ) no longer flashing,

now the next unit can be connected to the mains; here, too, you need to
wait for the end of the initialization phase, before the third unit can be
connected to the mains and start up.
All rectifier units must start up individually in order to ensure that each unit is
assigned its own address.
If, for a particular unit, the initialization phase has run without any problems,
then this unit must be withdrawn.
Following a period of approx. 3 minutes which is required for the internal
discharge of the capacitors, the initialization must be carried out again.
Following completed initialisation, the green LED operation
is activated. The unit will then run up to the set rectifier
output voltage with a time delay.
When removing the device, place switch in off position first!
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TEBECHOP 12000
The handles on the front panel serves only for pulling out the
unit, not for carrying the unit.
Operating modes
The rectifier unit has a total of four operating modes or characteristics, which
can be activated by changing over the operating mode via the satellite bus
(SAT bus) by means of MCU.
6.1
Floating level (ErlAd)

Standard operating mode, normal operation setting, float charging with rated
current or maximum current (based on power) up to the voltage limit (see
technical data sheet). The level of the output voltage is set by the MCU.
6.2
Boost level (LAdEn)

Necessary for fast charging the battery. Charging up to the voltage limit with
rated current or maximum current (based on power), see technical data sheet.
The level of the output voltage is set by the MCU.
6.3
Direct feeding (dir.SP)

Operating mode without battery (voltage value see technical data sheet). The
level of the output voltage is set by the MCU.
6.4
Battery circuit test (b.tESt)

Voltage reduction during the battery capacity test in order to obtain exact
measured value (voltage value generally set to V/C). (see technical
specification sheet.)
The level of the output voltage is set by the MCU.
6.5
Time-dependent automatic charging

By means of the automatic charging system integrated in the rectifier it is
possible that the unit switches over automatically to the characteristic
charging following a power failure. After expiry of the charging time, it
switches back to the characteristic "float charge".
The mains failure charging time is set via the MCU.
Parallel operation
Parallel operation of several rectifiers is possible and takes place without
decoupling diode on the rectifier output.
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TEBECHOP 12000
For symmetrical output current distribution, the rectifiers are interconnected
via the contact 1,2,3(b1) on the connector strip (X16) (parallel operation
connection). A parallel operation tolerance of approximately 10% of Irated is
achieved in this way in load operation from 30 100%.
The voltage and current compensation can take up to 5 minutes in case of connection of an additional unit to the system (self regulating process in 10 mV
steps).
A minimum basic load of > 5% is required with parallel
operation to safely maintain the fault message contact. The
satellite bus connector RS485 in the counter-connector
system must be plugged with parallel operation using several
racks in order to enable data interchange. In addition to this, the
parallel operation connection of the racks must also be
interconnected!
Satellite
For further information on the function of the satellite, refer to the
description no.: 2801.
The satellite integrated inside the rectifier unit monitors the rectifier unit
and provides the open and closed loop control functions for it. For the user the
satellite looks like a digital interface to the rectifier unit. The rectifier unit
obtains the required data via this interface from other units of the remote
monitoring system MCU 1000/MCU 2000 to establish the desired operating
state. This requires that the satellite has available the complete set of
parameters for open and closed loop control as well as all data with regard to
the operating states of the rectifier unit.
The satellite is a principal unit in the remote monitoring system MCU
1000/MCU 2000, ensuring that control and monitoring of the power supply
systems is possible via the public telephone network.
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TEBECHOP 12000
The further functions of the satellite, among others, are as follows:
(Faults are delivered by means of floating contacts via the external evaluation
electronics MCU)
8.1
1.
Four adjustable operation modes/characteristics
2.
Battery temperature inclined float charge characteristic (incline

adjustable)
3.
Unit monitoring with logically combined urgent alarm
4.
Mains monitoring with logically combined non-urgent alarm (time

delay of the alarms adjustable)
5.
Time-dependent automatic charging (mains power failure time and

charging time adjustable)
6.
Current limitation is set in accordance with medium load (IrEG

adjustment)
Voltage tracking (UrEG. adaptation).
Power management (Po.MA).
9.
Serial SAT bus interface via counter-connector system for

communication in parallel operation of several rectifiers
Standard function
After switching on the rectifiers and an initialisation phase of approximately 30
seconds, the unit runs up to the output voltage saved last (for instance float
charging).
8.2
LED-indication
The following LEDs are provided in the unit front panel of the rectifier:
29.06.04 TB/G
- (green)
"operation"/ "
"
- (yellow)
"mains/data"/ "
V"
(LED active: Mains voltage

available; LED flashes: Data
transfer via SAT bus in progress)
- (red)
"fault - fuse"/ "
"
(LED active: Output fuse tropped)
- (red)
"fault-unit"/ " "

14/17
(LED active: The units operating

correctly)
(LED active: unit fault)

4135 en

TEBECHOP 12000
- (red)
"UA too high"/ "
- (red)
"Fan fault"/
"
"
"
(LED active: Overvoltage

protection responded)
(LED active: Fan failure!)
For error identification, the relevant error code is shown in the display
and transferred via the SAT bus.
(refer to the description no.: 2801)
LC-Display
The 5-digit LC display on the rectifier front panel indicates physical units
(current, voltage, battery temperature or data address) as well as operating
status of the rectifier.
Alarms
9.1
Urgent alarm (unit fault SV1)

The message contact Device fault of the external evaluation electronic
LED green is off,
(MCU) is closed and the control lamp Operation/
and Fault device /
LED red is on.
These signals are internally delayed by approximately 30

seconds.
Device fault (urgent alarm) is dispatched under the following conditions:
- Overvoltage protection has responded
- Temperature too high
- Regulator or power pack defective
- Output fuse tripped
Incorrectly poled battery
9.2
Non-urgent alarm (mains fault SV2)

This signal follows AC undervoltage or mains power failure, the message
contact of the external evaluation electronic (MCU) is closed and control
lamp mains/data /
9.3
V LED yellow is off.
Temperature monitoring
The rectifier is equipped with a temperature control on the heat sink which
operates as follows:
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TEBECHOP 12000
Assumption:
The rectifier is operated at rated current.
1.
Heat sink temperature continues to rise
2.
At T >85C rectifier is switched off
3.
4.
5.
LED red fault device / on

LED green operation / off
Urgent alarm / device fault SV1 is dispatched.
After the heat sink has cooled down, the rectifier is
automatically reset.
The rectifier is then switched on again.
9.4
Overvoltage protection
In the event of overvoltage (see technical data sheet) the device is switched off.
The overvoltage protection is designed as a battery and device protection.
Switching on after the fault has been repaired is possible when the device is
separated from mains for approximately 10 seconds.
and urgent alarm are also reset during this.
LED red UA too high/
Testing the overvoltage protection is not possible with an
externally controlled power supply unit since the rectifier
recognises an externally fed voltage and fails to switch off as a
result.
9.5
Output fuse-monitoring
Because of high energy of the battery to be connected, an output fuse has
already been installed to protect the device. The control integrated in the
device issues a message once the output fuse has tripped.
LED red FAULT output fuse /
on, the message contact Device
fault of the external evaluation electronic (MCU) is closed and control lamp
Operation /
9.6
LED green off, and Fault device/
LED red on.
Incorrect battery poling

An incorrectly poled battery of the externally connected battery is registered,
messages are displayed, and the internal monitoring prevents the unit from
starting up again. Signalling contact "Unit fault" of the external evaluation
electronics (MCU) is closed, the control lamp "Operation"/ " " LED green
is off, and "Fault-unit"/ " " LED red flashes.
In the LCD- Display, " BAT- " is shown.
9.7
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Ventilator fault
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During operation of the ventilator (temperature controlled) an air-current
monitoring system controls the function of the ventilator. If an error occurs, the
following procedure takes place.
LED red "ventilator fault"/ "
Non-urgent alarm (SV2) of the external evaluation electronic (MCU) is

closed and the control lamp Operation/ LED green is signalled
The rectifier current is reduced automatically to 60 % Irated.
" is activated
In this way it is possible to operate the unit with reduced power.
10
Adaptation of float charge voltage to battery ambient

The charging voltage of lead batteries, particularly maintenance-free lead
batteries, should be adjusted to the ambient temperature. The temperature
sensor is connected to the connection terminal, i.e.only one temperature sensor
per system. Use a screened cable if the sensor is used externally. The length
should not exceed 5 m. Sensor element- 2 kOhm +/- 2 % NTC.
This function is only available in the float charging mode. UA
at 20C is automatically established on sensor breakage!
The (tEMP) function must also be activated via the MCU!
11
Fuses
According to the technical data sheet.
Access to the input and output fuses are only possible after opening the unit.
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General specification
TEBECHOP 12000.
48V 200A (240A)
TEBECHOP 12000 series are hot-swappable, designed for superior performance in
industrial, IT, and telecom applications. Rectifier is fully electronic three phase switch
mode power supply module. It has very high efficiency and power factor. The size
makes it one of the most compact 200A (240A) forced cooled rectifier module in
application. Measuring just 19 W x 3U H x 430mm D. This module has power
density of 7W/in^3. The high efficiency and reliability of this unit ensures maximum
system uptime for critical application up to 4,000 Amp, to minimize operating cost
and reduce installation time. The user interface makes remote or local programming
and monitoring of all major parameters easy. Remote computer communication is
possible through RS-485 serial interface.
Input characteristics
Nominal input voltage:
Input voltage range:
Input frequency:
Inrush current:
Input current:
Power factor:
Turn on delay:
Efficiency:
High voltage test:
480V 3 Phase without neutral.

408 528V
47-63Hz
< 22A per phase
15A nominal
> 0.94 nominal
8 sec.
>93% @ 100% load
>94% @ 50-75% load
>90% @ 20% load
2200V DC for1 minute
between input to chassis
Output characteristic
Boost charge:
Trickle charge:
Direct feed:
Battery test mode:
Output voltage adj. Range:
Output voltage regulation:
Output current:
Dynamic regulation:
Output noise:
57.6V
53.5V
50V
43.2V
40-60V
+/-1%
200A @ 54V (IV mode)
240A @ 43,2V only in power
constant mode with the Battery.
<+/- 4% of final voltage for
10% to 100% to 10% step
load change. Regulation within
1mS to nominal value.
<2mV Psophom. weighted.
<30mv RMS 10khz to 100MHz.

<0,5% peak to peak.
Load sharing:
Better than +/-5% active current sharing

at >20% load.
Protection:
Thermal derating:
Overvoltage protection:
Overtemperature protection:
Fuse at output.
> 70C internal air temperature.
60V +/- 1% , only faulty unit shuts down.
shutdown with self recovery.
Standard Features
Rectifier status indication:
LCD Display:
Rectifier OK Green
Line voltage present Amber
Output overvoltage Red
Rectifier failure Red
Fan failure Red
Output fuse failure - Red
Alphanumerical display normally
displays output voltage, current
and rectifier status.
Environmental
Cooling:
Operating temperature:
Humidity:
Forced cooling, fan speed control.

-15 to +50C
0% to 90% non-condensing.
Mechanical
Dimensions:
Weight:
Noise:
Magazine size:
Connections:
Width 19
Height 3U (133mm)
Depth 430mm.
22Kg
<60 dBA (A weighted.)
One rectifier occupies 3U of cabinet
height. Magazine fits cabinet depth
of 600mm or greater.
Connectors are mounted on the back
of rectifier module with matching
connectors at the back of the magazine.
Mating of connectors occurs when the
Rectifiers is plugged into the magazine.
Safety
IEC 950/EN60950/UL1950
Other standards
Flicker:
Electrostatic discharge immunity:
Electromagnetic field immunity:
Burst immunity:
Surge immunity
EN61000-3-3
EN61000-4-2
EN61000-4-3 10V/m Level3
EN61000-4-4
EN61000-4-5
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29.06.2004
29.06.2004
Name
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122
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32
OPERATIONS AND
MAINTENANCE MANUAL
For
Benning Power Electronics
MCU 2000+
REMOTE MONITORING UNIT
(028-0008-020 REV A)
SAVE THESE IMPORTANT

SAFETY INSTRUCTIONS
This manual contains important safety instructions that should be followed during installation
and maintenance of the Power System.
11120 Grader Street

Dallas, TX 75238
214-553-1444, Fax 214-553-1355
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BPE 48-4000 Typical Alarms

TYPICAL ALARM RELAY CONFIGURATION (Not all alarms may be present)
Relay Box Alarm Configuration
K1
K2
K3
K4
K5
K6
K7
K8
External BDFB Fault

Inverter System Fault
AC Mains Fail
Multiple Rectifier Fail
Battery On Discharge
DC Voltage Low (<47VDC)
Internal Load Breaker Fault
Battery Breaker Fault
X5
K3
Minor
TYPICAL MAJOR AND MINOR ALARM CONFIGURATION (Not all alarms may be present)
System Alarm Description
External BDFB Fault
Inverter System Fault
Load Shed Breaker Tripped
Internal MCU Communication Lost
All Rectifiers Switched Off
Redundancy (N+1) Failure
AC Mains Fail
Modem Fault
DC Voltage <47.0V
DC Voltage <43.0V
DC Voltage >56.0V
Battery Temperature >27C
Battery Test Fail
Major
X
X
X
X
X
Rev 1
Note
X
X
X
X
X
Multiple Rectifer Fail

All AC inputs removed
MCU has lost communication with Modem
X
X
X
X
X
Rectifier Specfic Alarms

Fan Failure
Power Failure (AC and DC Fail)
Rectifeir AC Failure
Module Fail
Module Over Voltage
Module Over Temperature
Module Turned Off
Multiple Rectifier Failure
Minor
X
X
X
X
X
X
X
X
1 of 2
BPE 48-4000 Typical Alarms

TYPICAL LED DESCRIPTIONS
Front Display LED's
Float
Boost
Battery Test Active
Battery Test Fault
Rectifier Fault
AC Mains Failure
DC High (>56.0VDC)
DC Low (<47.0VDC)
Battery Temperature High (>27C)
Modem Error
External BDFB Fault
Rev 1
Green
Yellow
Yellow
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
2 of 2
127(6

127(6

127(6

BPE4000 - CAB Benning PDF

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OPERATIONS AND

Benning Power Electronics

SAVE THESE IMPORTANT

11120 Grader Street

System Install Information:

Rectifier Satallite Manual:

Rectifier General Specification

Rectifier Circuit Diagram

Rectifier Dimensional Diagram

MCU 2000+ Controller Information:

System Elevation (Front and Top View):

Rectifier Cabinet Circuit Diagram:

Primary Distribution Circuit Diagram:

External Battery Shunt Drawing

Customer Alarm Mapping

BPE 48-4000 Maping

It is imperative that all the information be observed.

Document No. 062-005 R1

Modular Power System

ABOUT THE MANUAL ........................................................................................................................3

WEIGHTS AND DIMENSIONS....................................................................................................................6

OVERVIEW OF THE POWER SYSTEM...........................................................................................8

5.0 GROUNDING ........................................................................................................................................13

Modular Power System

EXCHANGE OF A MODULE ............................................................................................................................23

Modular Power System

About the Manual

Modular Power System

The rectifier system is an electronic device that contains hazardous

The rectifier system should be installed in strict accordance with all

This equipment is intended only for installation in a restricted access

(2) Rectifier Cabinets

Modular Power System

Fig. 3.1: Typical BPE 48-4000 Power System

Modular Power System

WEIGHTS AND DIMENSIONS

Unpacked weight LBS

Modular Power System

Figure 2.2 SHOCKWATCH

2.1 Unpacking the Power System

Modular Power System

Inspecting the Equipment

Checking Packaging Contents

Miscellaneous Hardware C/O

(2) RJ-45 Inter Bay Communications Cable (Rectifier Cabinet 1 2 to PDC)

(Optional) Battery Temperature Sensor, 10 meters

BPE 48-4000 System Installation Manual

18 GA White, Current Share Lead (Rectifier Cabinet 1 -2)

Door Access Key

OVERVIEW OF THE POWER SYSTEM

Power System Cabinets

Modular Power System

Primary Distribution Connections

Modular Power System

Modular Power System

Modular Power System

Typical Non-earthquake Zone concrete anchors

Typical Earthquake Zone Concrete Anchors

Modular Power System

Modular Power System

Battery Return Reference lead (BRR) / C.O. Ground cable

Modular Power System