VALERE Power BC Series Bedienungsanleitung

Page 1 of 42 Version 1.00

November, 2004

BC Series Controller

Operation Manual

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November, 2004

BC Series Controllers

Operation Manual

Table of Contents

1Overview.................................................................................................................... 3

2Controller Connections ............................................................................................ 3

2.1 Temperature Probes..................................................................................................................... 4

2.2 Alarm Cable Connection............................................................................................................. 4

2.3 Auxiliary Input Alarms ............................................................................................................... 4

2.4 Expansion Controller Connection ............................................................................................... 4

2.5 Ethernet LAN Connection........................................................................................................... 5

3Navigation.................................................................................................................. 6

4Controller Login........................................................................................................ 7

5Controller Configuration Menu .............................................................................. 8

5.1 Language..................................................................................................................................... 8

5.2 Review Module ........................................................................................................................... 9

5.3 Setpoints...................................................................................................................................... 9

5.4 Alarms....................................................................................................................................... 11

5.5 Tests .......................................................................................................................................... 14

5.6 Thermal ..................................................................................................................................... 18

5.7 LVD Menu ................................................................................................................................ 22

5.8 Ringer........................................................................................................................................ 23

6Troubleshooting ...................................................................................................... 28

Appendix A......................................................................................................................32

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BC Series Controllers

Operation Manual

1Overview

This manual is intended to be a supplement to the Compact and Integrated shelf

Installation, Operation, and Maintenance manuals. This manual also only covers

operation of the BC-series controller from the front display. For remote operation via a

LAN card or Modem, please see Application Bulletin 201 for LAN operation and

Application Bulletin 202 for modem operation.

2Controller Connections

The BC series controller has several external connections. These connections are

discussed below.

Figure 1 - Controller connections

LAN

Connection

Expansion

controller

Alarm cable

connection

Display

connection

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Operation Manual

2.1 Temperature Probes

Up to three, battery temperature probes (10’ length) may be installed for battery

temperature compensation. Attach the ring terminal to a battery post and insert the

connector end into the mating end as shown in Figure 1. The temperature probes are

denoted as Temp 1, Temp 2, and Temp 3 from left to right. Temperature compensation

must be enabled for the system to take advantage of the temperature probes. Also T

SENSE must be set to external. See section 6.6 for instructions on setting up temperature

compensation.

2.2 Alarm Cable Connection

Six form C contacts are available through a connector directly below the temperature

probe connections as shown in Figure 1. The cable from Table 1 can be used to

understand the alarm contacts and color code of the cable. The cable is 10 feet long

(available in 50’ and 100’ lengths), has a shelf mating connector on one end and bare

tinned wire on the other. Relay test can be used to verify that the alarm cable is

connected properly. See section 6.5 for setting up the relay test.

2.3 Auxiliary Input Alarms

To use the temperature probe input port or the input alarm (white & black wire) on the

alarm cable as an external alarm channel, simply connect a normally open dry contact

relay into any of the input connectors using the 10’ alarm input cable. The controller will

automatically detect a contact closure and set a minor alarm. If your system is equipped

with a BC1000 controller, alarms can be user mapped through the Ethernet LAN port

using the software utility provided by Valere. Refer to Application Bulletin 201,

“Connecting to the LAN Port”, that is included with the BC1000 controller, for mapping

alarms.

2.4 Expansion Controller Connection

The expansion controller connection is only used on the Integrated system with external

distribution and/or multiple power shelves as seen in Figure 2. This connection will be

made at the factory.

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BC Series Controllers

Operation Manual

Figure 2 - Expansion connection

2.5 Ethernet LAN Connection

The Ethernet LAN connection is only available on BC1000 style controllers. Refer to

Application Bulletin 201, “Connecting to the LAN Port” for further information on how

to connect to and use the Ethernet LAN port.

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Operation Manual

Alarm Cable

CA210203104

Alarm

Channel

Functional

Designation Wire Color Alarm

Behavior

NC Orange/White

stripe

Contact Opens

On Alarm

C Orange Common

(Power

Major) NO Orange/Black

stripe

Contact Closes

On Alarm

NC Red/White

stripe

Contact Opens

On Alarm

C Red Common

(Power

Minor) NO Red/Black

stripe

Contact Closes

On Alarm

NC Green/White

stripe

Contact Opens

On Alarm

C Green Common

(AC Fail)

NO Green/Black

stripe

Contact Closes

On Alarm

NC Yellow/White

stripe

Contact Opens

On Alarm

C Yellow Common

(BD)

NO Yellow/Black

stripe

Contact Closes

On Alarm

NC Lt Blue/White

stripe

Contact Opens

On Alarm

C Lt Blue Common

(LVD

Open) NO Lt Blue/Black

stripe

Contact Closes

On Alarm

NC Tan/White

stripe

Contact Opens

On Alarm

C Tan Common

(Fuse/C

B Open) NO Tan/Black

stripe

Contact Closes

On Alarm

Input (+) White

Input

Alarm Input (-) Black

Closed =

Alarm

Table 1- Alarm Cable color code

Table 1 is the alarm cable color coding table. The table can help you determine which

alarm contacts correspond to the wire color.

3Navigation

The controller is factory equipped with default settings as shown in Table 2 to assure safe

power up operation. Figure 3 shows the controller front display and three button keypad

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Operation Manual

and Appendix A contains the complete menu tree for the controller. The UP and DN

buttons are used to scroll through the functions and the MENU button is used to select

and/or drop down into a sub-menu.

There are three controller menu levels Basic, Main/Review, and Administrator. When

the controller displays “System OK”, the controller is at the Basic menu level. The

UP/DN buttons can be used to sequentially view basic plant parameters such as float

voltage and plant current, temperature compensation state, battery temperature (if thermal

probe is equipped), and internal plant temperature. By holding the MENU button down

for 5 seconds, the Main/Review level is accessed. All plant parameters can be viewed

from this level by scrolling to and selecting “Review.” Follow the menu tree for exact

navigation directions. By scrolling to and selecting “Log In”, the Administrator level is

accessed. The default username is “Admin” (case sensitive) and the default password is

“5001”. This level allows you to make changes to all the plant settings. Table 2 is a

complete list of adjustable parameters.

Figure 3 - Controller display

4Controller Login

The following steps will walk you through the process of logging into the controller as an

administrator. All setpoints and features require login to change values or enable

features. Tests such as battery discharge test, boost test, and lamp test do not require

logging in to execute, provided the feature has been enabled. Default password is 5001.

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Operation Manual

1. With display showing “System OK”, press and hold MENU button for 5

seconds. Release MENU button when Welcome screen appears.

2. Press the UP button to scroll to CHOOSE: >LOGIN and press MENU.

Display shows PASSWORD ->0000<-, and first 0 flashes.

3. Press MENU to change first digit to desired value. Each press of the MENU

button advances by one. Pressing UP selects that value for the first digit,

which stops flashing, and advances to the second digit, which will begin to

flash.

4. Repeat procedure above for all four digits.

5. Press UP to select <, which will then flash, and press MENU to enter the

password.

6. Controller displays OK: ADMIN for 5 seconds.

5Presets

Once you have logged into the controller, you can set all controller values to one of three

preset values by selecting either PRESET A, PRESET B, or PRESET C. This can be

done by pressing the UP button to scroll to CHOOSE: PRESET and press the MENU

button. This will enter the preset submenu. Press the UP button to scroll to the

appropriate preset value, and press the MENU button, you may need to hold it for about 1

or 2 seconds. The controller will exit out to the previous menu, indicating that the preset

values have been set.

EXIT INSTRUCTIONS: Press the UP button to scroll to CHOOSE: EXIT and press the

MENU button. This will return you to the SYSTEM OK menu.

6Controller Configuration Menu

Once you have logged into the controller, you can make adjustments to any of the

following setpoints by pressing the UP button to scroll to CHOOSE: CONFIG and

pressing the MENU button. This will enter the configuration submenu list. The

configuration menu can be navigated by pressing the UP button to scroll through all the

menu choices.

EXIT INSTRUCTIONS: You can exit and logout of the configuration menu by pressing

the UP button to scroll to the end of the menu string and pressing the MENU button at the

BACK TO MAIN screen. This will send you back to the main menu. All changes

require logging out to take effect. Press UP button to scroll to CHOOSE: EXIT and press

the MENU button to exit back to the SYSTEM OK menu.

6.1 Language

The language menu allows you to select the controller’s displayed language.

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Operation Manual

This menu can be accessed by pressing the MENU button at the CHOOSE: LANGUAGE

menu. Once the menu has been entered the screen will display the current language

setting. For example by default the screen would display LANGUAGE: ENGLISH.

This setting can be changed by pressing the MENU button. The screen will then change

to CHOOSE: ENGLISH. The value can then be adjusted by pressing the UP and DN

buttons. Once the desired language is showing on the display, press the MENU button to

select that value.

NOTE: Please note that once a new language has been selected the screen will be

displayed in that language. If you do not understand that language, navigation through

the menu will be very difficult.

To exit this menu press the UP button until EXIT LANGUAGE is displayed on the

screen, and press MENU to exit. This will take you back to the configuration menu.

Continue to the next menu for adjustment or follow the exit instructions at the beginning

of this section.

6.2 Review Module

The review module menu allows you to see the DC current output of each individual

rectifier in the system.

This menu can be accessed by pressing the MENU button at the REVIEW: MODULE

menu. Once the menu has been entered the screen will display the current value of the

first rectifier in the first shelf (designated S1>) in the system. The display will also show

five slots representing the five possible rectifier slots in a Valere System. The solid

square represents the rectifier currently being viewed, and the non-solid square represents

the remaining rectifiers installed in the system. Pressing the UP button at this point will

scroll through the remaining rectifiers in order. If the system is equipped with a second

power shelf (designated as S2>) the controller will also display that shelf’s rectifiers in

order after shelf 1.

To exit this menu press the UP button until EXIT MODULE is displayed on the screen,

and press MENU to exit. This will take you back to the configuration menu. Continue to

the next menu for adjustment or follow the exit instructions at the beginning of this

section.

6.3 Setpoints

The setpoints menu allows you to adjust controller setpoints such as float voltage,

rectifier current limit, and battery current limit. Please note that some features require a

low voltage disconnect (LVD) or shunt to be visible.

This menu can be accessed by pressing the MENU button at the CONFIG SETPOINTS

menu. The first setpoint displayed will be the float voltage of the system. Press the UP

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Operation Manual

button to continue scrolling thru the setpoints menu. The menu will circle back to

FLOAT once the end has been reached.

To exit this menu press the UP button until EXIT SETPOINTS is displayed on the

screen, then press the MENU to exit. This will take you back to the configuration menu.

Continue to the next menu for adjustment or follow the exit instructions at the beginning

of this section to exit.

6.3.1 Float Voltage (Float)

Float voltage is the DC voltage which the rectifiers will output.

To adjust the float voltage, scroll to FLOAT V = xx.xx, press the MENU button,

and the screen will display CHOOSE: V = xx.xx. The value can then be adjusted

by pressing the UP and DN buttons in the corresponding directions. This value

can be adjusted in 0.5 V increments, and a range between 42 and 58 volts. Once

the desired value is reached ,press, the MENU button to accept the new value.

Press the UP button to move to the next setpoint or scroll to EXIT SETPOINTS

and press MENU.

6.3.2 Rectifier Current Limit (Rect CL)

Allows the user to set a limit, below the maximum capacity of the rectifier, on the

amount of current each rectifier will output

To enable rectifier current limit, scroll to RECT CL DISABLED press the MENU

button, and the screen will display RECT CL ENABLED.

Press the UP button to scroll to RECT CL I = xx. Press the MENU button and the

screen will display CHOOSE: I = xx. The value can then be adjusted by pressing

the UP and DN buttons in the corresponding directions. This value can be

adjusted in 2 amp increments, and a range between 0 and 200 amps. Once the

desired value is reached, press the MENU button to accept the new value.

For example, a system with three 50A rectifiers with an RECT CL I set to 20 A

will limit each rectifier to 20 A for a total output of 60 A.

Press the UP button to move to the next setpoint or scroll to EXIT SETPOINTS

and press MENU.

6.3.3 Battery Current Limit (Batt CL)

Allows the user to set a limit on the amount of current being sent to the batteries.

This feature requires an LVD or shunt to be visible in the menu structure. Also

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