109-155V DC

HV Power System Installation Manual

Type: PSC120411xx-000
V1.0

Manufactured by Enatel Ltd.

66 Treffers Road
Christchurch 8042
New Zealand

Phone +64-3-366-4550
Fax +64-3-366-0884
Email sales@enatel.net
www.enatel.net
Copyright © Enatel Ltd. 2012

Enatel DC System Manual Page 1 of 25

TABLE OF CONTENTS

1 Receiving Instructions ......................................................................................................... 3

1.1 Package Inspection ...................................................................................................... 3
1.2 Equipment Inspection ................................................................................................... 3
2 Scope .................................................................................................................................. 4
3 System Overview ................................................................................................................ 4
4 Installation ........................................................................................................................... 5
4.1 Unpacking & Installing in Frame ................................................................................... 5
4.2 AC & DC Cabling ......................................................................................................... 5
4.2.1 Upstream Over-current Protection ......................................................................... 6
4.3 DC Cabling ................................................................................................................... 7
4.4 Alarm/Ancillary Cabling ................................................................................................ 7
4.5 Temperature Sensors................................................................................................... 8
4.6 Connecting via Computer ............................................................................................. 9
4.7 Alarm Mapping to Volts-free Relays ............................................................................. 9
4.8 Circuit Breaker Fail Monitoring ..................................................................................... 9
4.9 Surge Protection Fail Monitoring .................................................................................. 9
4.10 LVD Operation (Optional) ........................................................................................... 10
4.11 DC Earth Leakage Detection Monitoring .................................................................... 10
5 Appendix1 – Enatel Essential System Set – Up Parameters ............................................. 16
6 Appendix2 – DC Earth Leakage ........................................................................................ 18
7 Appendix3 – AC Input Transient Protection ....................................................................... 21
8 Appendix4 – Rectifier Input Fuse Curves .......................................................................... 23
9 Appendix5 – Maintenance ................................................................................................. 24
System ................................................................................................................................. 24
Monitor ................................................................................................................................. 24
Rectifiers............................................................................................................................... 24
Batteries ............................................................................................................................... 24
10 Appendix6 – System Wiring Diagram............................................................................. 25

Enatel DC System Manual Page 2 of 25

1 RECEIVING INSTRUCTIONS

CAUTION: For your protection, the following information and the product manual should
be read and thoroughly understood before unpacking, installing and using the
equipment.

We present all equipment to the delivering carrier securely packed and in perfect condition.
Upon acceptance of the package from us, the delivering carrier assumes responsibility for its
safe arrival to you. Once you receive the equipment, it is your responsibility to document any
damage the carrier may have inflicted, and to file your claim promptly and accurately.

1.1 Package Inspection

• Examine the shipping crate or carton for any visible damage: punctures, dents and any
other signs of possible internal damage.
• Describe any damage or shortage on the receiving documents and have the carrier sign
their full name.

1.2 Equipment Inspection

• Within fifteen days, open crate or carton and inspect the contents for damages. While
unpacking, be careful not to discard any equipment, parts or manuals. If any damage is
detected, call the delivering carrier to determine the appropriate action. They may require
an inspection.
Save all the shipping materials for the inspector to see!
• After the inspection has been made and you have found damage, call us. We will determine
if the equipment should be returned to our plant for repair or if some other method would be
more expeditious. If it is determined that the equipment should be returned to us, ask the
delivering carrier to send the packages back at the delivering carrier’s expense.
• If repair is necessary, we will invoice you for the repair so that you may submit the bill to the
delivering carrier with your claim forms.
• It is your responsibility to file a claim with the delivering carrier. Failure to properly file a
claim for shipping damages may void warranty service for any physical damages later
reported for repair.

Handling
Handle the equipment with care. Do not drop or lean on front panel or connectors. Keep away
from moisture.

Identification Labels
Model numbers are clearly marked on all equipment. Please refer to these numbers in all
correspondence with Enatel.

Warning Labels

Enatel DC System Manual Page 3 of 25

2 SCOPE
This manual covers essential information for the installation and commissioning of the Enatel
HV DC Power System, PSC120411xx-000.
System set-up for the rectifiers, alarms etc., are provided in separate manuals for the SM3x
supervisory module and RM30110 rectifiers.
All installation and maintenance must be carried out by suitably qualified personnel.

3 SYSTEM OVERVIEW

PSC120411xx-000

PSC120411xx-000
The 5U 110V DC HV Compact Power System is intended to be a complete power system in a
box, so no connections need to be made internally. All the AC, DC (Load and Battery)
connections are made at the top/front of the unit. Alarm connections to the Supervisory Module
are accessible from the front by opening the front door of the unit.
The system is designed to be extremely simple to install and set up.
The following is a summary of 5U Compact HV DC Power System:
- Overall size is 483mm wide (19” standard mounting) x 222.25mm high (5U) x 340mm deep
- Up to 4 x 27.3Amp RM30110 rectifiers.
- SM33 or SM34 supervisory module (fully integrated in the system)
- 1x 125A 2Pole Battery Circuit Breaker, these may be specified as different values (Up to
125A) at time of order. Both positive and negative connections are broken together.
- 3x 63A 2Pole Load Circuit Breaker, these may be specified as different values (Up to 63A)
at time of order. Both positive and negative connections are broken together.
- 3x 1pole AC Input Breaker
- Three Phase Surge Protection. For AC Input Transient Protection refer Appendix 3.
- A DC Earth Leakage detection Circuit to measure programmable mA of leakage current
from positive or negative outputs to AC earth.
- (Optional) 125A Battery Low Voltage Disconnect (Magnetically Latched).
- System weight is approximately 9.2kg without rectifiers, and 21kg with four rectifiers fitted.
Note:The 5U 110V DC HV Compact Power System (PSC120411xx-000) has isolated DC
outputs i.e. the outputs (either +ve or –ve) are not directly connected to earth but through
a resistor network that provides a means for earth leakage detection. (See Appendix 2 for
more details regarding Earth Leakage Detection Circuit).

Enatel DC System Manual Page 4 of 25

4 INSTALLATION
4.1 Unpacking & Installing in Frame
Upon unpacking, check that the unit is not damaged, and that you have the required number of
rectifiers.
The unit fits into a standard 19” mounting frame. The mounting screws should be M6, however
M5 may be used with washers. Be sure to mount the unit in the 19” frame squarely if M5
screws are used.
Please note the complete system weight is 21Kg. Ensure the 19” mounting rails are able to
withstand mounting of the system.

4.2 AC & DC Cabling

The AC terminals are clearly marked as shown in Fig 1. Phase Inputs (L1, L2, and L3) are
terminated directly on to the top of AC circuit breakers. The Earth and Neutral terminals can
accept up to 25mm2 cable.
The AC earth terminal earths the System chassis. The AC earth is also internally bonded to the
System chassis by an earth stud behind the circuit breakers shown in Fig 1.1.
AC Input

Phase Inputs (L1, L2, L3)

(Direct into MCB)

AC Input
Breakers

Neutral
Terminal
Earth
Terminal
Fig. 1.1 System AC Input Terminals

Enatel DC System Manual Page 5 of 25

4.2.1 Upstream Over-current Protection
There are two considerations to take into account when selecting an appropriate fuse/circuit
breaker.
- Firstly, the upstream protection should protect the downstream cable from overload
situations,
- secondly, discrimination should be maintained with the downstream device fuses.
1. Cable Rating
The maximum current drawn by this DC power system is 37.3A per phase (at minimum input
voltage of 175V ph-N, and full output power). The upstream protection device must be able to
supply this load under all conditions without tripping. Therefore, typically at least 20%
headroom is allowed for in the protection device, making its minimum rating 45A. As a result,
typically a 63A device is used. Therefore the cable used to supply the system must be rated at
the upstream protection device rating. Please see your local wiring regulations for exact
requirements, as cable sizes can vary depending on these regulations and on the material the
cable’s insulation is made from.
A note on rectifier AC feed cable sizes. Each rectifier is fed by one set of cables from the AC
input terminals (2.5mm2). Although in theory it may appear that this smaller wire is unprotected,
in fact it is protected on two accounts. Firstly it is protected by the rectifier input fuse (which is
only a short distance away). Secondly, the rectifiers are power-limited on their input. Therefore,
they can never be overloaded. As a result, the wire can never be over-loaded by the rectifier –
it can only see fault current.
2. Discrimination
Discrimination ensures that the upstream circuit breaker or fuse does not blow if a rectifier input
is faulty (in a short circuit manner). Therefore it is important to ensure the upstream protection
discriminates with the internal fuse of the rectifier. The fuse used in the RM30110 is a slow-
blow 25A fuse. The tripping curve for this is shown in Appendix 4 at the rear of this manual.
For discrimination purposes, a minimum circuit breaker to use for this system is a 63A, D-curve.
This only just discriminates. However, due to the maximum input current rating, then a 125A, C
or D curve breaker will have to be used.
If a fuse is used upstream, then any BS88 or NH g style fuse will discriminate above 80A,
however, once again, due to the maximum system current rating, a 125A fuse should be used.

Enatel DC System Manual Page 6 of 25

 4.3 DC Cabling
CAUTION: Use extreme care when fitting batteries & their connections. Remove all jewellery
and rings from oneself prior to commencing the installation. Always use insulated
tools when fitting batteries and take extreme care not to short terminals when
working on them.

Load & Battery DC (+ & -) Terminations

(Direct into MCBs)

Battery
Load Load 2Pole MCB
2Pole MCBs

Strain Relief
For cables

Fig. 2 DC Output Terminals

All Load and Battery DC positive and negative cables are connected directly on top of the circuit
breakers as shown in Fig 2.
Note: Ensure there is enough room (around 2 to 3U) on top of the Unit for all DC negative and
positive cabling. Ensure cables are strain relieved by utilising the cable tie slots provided as
shown in Fig.2.

4.4 Alarm/Ancillary Cabling

Alarm and communication cables terminate directly into the rear of the Supervisory Module,
SM33 or SM34. These terminals are accessible by opening the Monitor door as shown in Fig 3.
When routing the cables, ensure they are kept away from the AC and DC power cables when
possible.
The relay states labelled Normally Open or Normally Closed are for their de-energised state. If
an alarm is programmed for the relay to be normally energised (as may be possible in the case
of a low voltage alarm where loss of power will put the alarm into its active state), then be sure
to connect the remote wiring appropriately.
Enatel DC System Manual Page 7 of 25
 Volts Free
Relays

Fig 3 Monitor & Alarm cabling

For full SM33/34 functionality and operation information, refer to the SM33/34 Manual.

4.5 Temperature Sensors

Battery
Temperature
Probe

Fig 4 Battery cables & Battery Temperature Sensor

Uncoil the battery temperature sensor and place in the middle of the middle battery string. If the
lead is not long enough, ordinary 2-core copper (approx. 0.75mm2) wire can be used as an
extension. The purpose of the battery temperature sensor is to monitor the ambient
temperature of the batteries over long periods of time and adjust the rectifier output (float)
voltage accordingly. As a result, it is not necessary to have the temperature sensor touching
the batteries. If the Battery Temperature Sensor is removed a “battery temp fault” alarm is
generated.

Enatel DC System Manual Page 8 of 25

4.6 Connecting via Computer
For remote communications and direct computer connection to the Compact System, refer to
the SM33/34 Manual. These connections can be made via the mini-USB port on the front panel
of the monitor (computer connection to the SM33 or SM34), and the Ethernet port (SM34 web-
based communications only).

4.7 Alarm Mapping to Volts-free Relays

The SM33/34 has three voltages – free alarm relay outputs as standard.
Note that on all systems, Relay 1 is pre-configured as the “Monitor Fail” alarm. This alarm
activates is the monitor has a hardware fault or if software becomes corrupted.
All other relays can be mapped to different alarm conditions. The SM33/34Manual details how
these may be changed. On the standard Compact Systems alarms are preconfigured as
follows:
Relay 2: Summary Non-urgent alarm
Relay 3: Summary Urgent alarm
As mentioned, if these mappings are not appropriate, they can be changed in the field to suit
customer requirements.

4.8 Circuit Breaker Fail Monitoring

Both Battery and Load Circuit Breaker states are monitored via auxiliaries to detect tripping or
whether they are turned off. One of the Auxiliary inputs is referenced to system positive (120V)
and the other input is connected to the SM3x’s general purpose inputs.
Hence, if no Load or Battery is connected, the breaker must be “on” to clear the Breaker Fail
alarm .

4.9 Surge Protection Fail Monitoring

The 5U Compact System is equipped with 3Phase AC Surge protection. Surge Protection
Module has auxiliary contacts for fail indication monitored via one of the digital inputs on the
SM33/34. The digital input will trigger an alarm when it is pulled to the system positive rail.
For AC Input Transient Protection refer Appendix 3.

Auxiliary for
Fail Detection

Surge
Diverters

FIG. 5 AC Surge Protection Monitoring.

Enatel DC System Manual Page 9 of 25

4.10 LVD Operation (Optional)
This system is configured with one Low Voltage Disconnect contactor on battery side of the
circuit as shown in Fig 6 & Wiring Schematic at rear of this manual.
The SM33/34 Supervisory Monitor unit is powered from the rectifier side of the battery LVD
contactor. Therefore when the low voltage threshold of Battery LVD is reached, the LVD
disconnects the battery and the SM33/34 also loses power. Supervisory Monitor, SM33/34 and
hence the Battery LVD contactor will not re-engage until the rectifier power is restored (i.e., until
the DC bus voltage is restored).

LVD adjustments/settings are all made from the SM3x. See the SM3x manual or Help files in
the SM3x Configuration Utility (click on an area and press F1) for details.
The LVD contactor is a bi-stable, magnetically latched contactor. This means that failure of
power or removal of the SM3x from a live system will not cause the contactor to change state
4.11 DC Earth Leakage Detection Monitoring
DC Earth leakage detection is monitored via a resistive voltage divider on the outputs of the
Rectifier positive and negative bus. Refer to Appendix 2 for more information.

Earth Leakage
Detection PCB Battery
Breaker

Load
Current
Breaker
Shunt

Surge
Diverters

Battery LVD

AC Input
Breaker

FIG. 6 System Internal

Enatel DC System Manual Page 10 of 25

Commissioning
Use the following set of instructions as a guide, unless different procedures are recommended
by local authorities.
Pre-check:
1. No more building work to be carried out in site to avoid concrete and plaster dust being
ingested into rectifiers and systems.
2. System installation is completed.
3. Battery and load circuit breakers are turned off, and upstream AC has been turned off (i.e.,
system is completely de-powered).
4. Rectifier modules have been fitted into their shelf positions, and pulled forward enough to
disconnect them from the system.
5. Turn on AC upstream and check that voltages from phase to neutral are as expected.

Rectifier Start-up
1. Turn the upstream AC circuits on.
2. Fully insert first rectifier, wait for the rectifier to start and its power on LED to remain green.
3. Check the SM3x powers up, and indicates the system default float voltage (approx. 135V on
its display). If the audible alarm activates, press any SM3x button to silence it.
4. If a different system float voltage has been specified, set this at this time using the
procedure specified in the SM3x Manual (either from the front panel or connected
computer). The expected voltage is 135V plus an offset if temperature compensation is
enabled.
Note: 5U Compact HV DC Power System has been factory configured for 60 cell battery
string.
5. Fully insert the rest of the rectifiers ensuring they power up with only their green “power on”
LED illuminated.
6. Check that the load and battery currents on the SM3x are 0 amps (+/- 1 or 2 amps).
7. Check that all SM3x configuration settings are correct (as per customer specification) with
respect to:
- Voltage levels
- Alarm settings
- Alarm mappings to the volts-free relays
(refer to the SM3x manual for information on how to check these via the front panel or
locally connected computer).

Battery Start-up
Note: It is preferable that battery circuit breaker connections should be made when the
rectifiers are turned on and the system is “live”. This is because the system voltage
and battery voltages will be similar, thus minimising any arcing during connection. This
also prevents high current arcing due to the charging of the rectifier output capacitors.
1. Power up only one rectifier initially (to limit any damage if any connections are incorrect).
2. Measure the voltage across the battery string at the terminals of the Compact System.
Ensure that the reading from the DC positive terminal to the battery negative terminals is -
135V.

Enatel DC System Manual Page 11 of 25

Load Start-up
1. Ensure downstream load connections have been made and there are no loose/floating load
cables.
2. Turn on load circuit breaker, ensuring that the downstream equipment is being powered up
as expected.
3. Ensure the system float voltage on the SM3x is at the level previously noted.
4. Ensure the load current is at a level expected (could be zero if loads downstream have not
been connected).

Note: Prior to leaving the system after it has been commissioned, ensure all AC, DC and
battery circuits are off. If it is required that the system is to be left on (to power load
equipment, ensure rectifiers are left in their powered up state, and batteries are in circuit.
This will prevent anyone leaving the batteries only powering the load (in which case the
batteries would go flat).

DC System Commissioning Check List

DC SYSTEM COMMISSIONING CHECK-LIST

Site Name:__________________________ Date:_______________

Tests Without Batteries Connected Measured/ Results

Setting

Check Float Voltage Meter:______ __________ V
/

Check Load Current Meter:______ __________ A
/

Alarms:

Voltage thresholds can either be checked using an external power supply, or by

adjusting the SM3x float voltage 0.1V above (or below for the low voltage alarms). It
is recommended to have the batteries disconnected.

1. Adjust the supply/float voltage to 139.1V & observe the “High Float” alarm.

2. Adjust the supply/float voltage to 144.1V & observe the “High Load” alarm.

3. Adjust the supply/float voltage to 131.9V & observe the “Low Float” alarm.

4. Adjust the supply/float voltage to 117.4V & observe the “Low Load” alarm.

High Load Volts (urgent) 144V __________ V
/

High Float Volts (non-urgent) 139V __________ V
/

Low Float Volts (non-urgent) 132V __________ V
/

Low Load Volts (urgent) 117.5V __________ V
/

Enatel DC System Manual Page 12 of 25

 Depending on the test load available, it may be necessary to adjust the High Load
Current alarm threshold down to suit. For example, with the 100A test load, adjust
the High Load Current threshold (use SM3x Config. software, click on the “Alarms/
(Levels)”) to 90A. Then simply apply the 100A load and observe the alarm change
state.

Once the test is complete, be sure to rest the High Load Current to its previous value
(or check with the customer for the correct value they require).

High Load Current (urgent) __________ A
/

Temperature alarm tests are performed by heating up (using a heat gun or other
source) and cooling down (using an aerosol can of freeze, or a tub of ice) the
temperature sensors. (Note System is not fitted with Room Temperature sensor)

Battery Temperature High (urgent) __________°C
/

Battery Temperature Low (non-urgent) __________°C
/

Room Temperature High (non-urgent) __________°C
/

Room Temperature Low (non-urgent) __________°C
/

When an AC Monitoring PCB is not fitted at system level (as in most cases), the AC
Fail alarm is generated from the rectifiers. The rectifiers sense if AC is present, and
extend an AC fail alarm to the SM3x. Therefore, to test this alarm, simply turn off the
rectifier AC breakers. To allow the monitor to continue to read alarms there must be
DC present on the output of the system.
As this causes the rectifier output to cease, a Rectifier Fail alarm is also generated.
To generate the Urgent Rectifier Fail, turn off the required number to make this occur
(Usually set to 1, but check via the SM3x Config software for the setting (under the
“Rectifier Control” section of the “Power Module Control” tab)).

AC Fail (urgent) Urgent
/

Rectifier Fail (non-urgent) Non-urgent
/

Urgent Rectifier Fail (urgent) No. Modules:____
/

To check Load MCB fail, switch the breaker to it’s off position. This will cause the
alarm to occur as the digital input will be pulled to system common voltage.

Load MCB Fail (urgent)
/

To check Load MCB fail, switch the breaker to it’s off position. This will cause the
alarm to occur as the digital input will be pulled to system common voltage.

Battery Fuse Fail (urgent)
/

To check the Surge Protection Failed alarm, simply pull the MOV out. This switches
a micro-switch within the SPD unit. Once pulled, observe the alarm, and re-insert the
MOV block and observe the alarm clear.

MOV (SPD) Fail (urgent)
/

Enatel DC System Manual Page 13 of 25

 A Rectifier Off Normal alarm is generated with the rectifier enters a state that may
degrade its performance (e.g., a single fan fail), or a state that is outside of normal
operating conditions (e.g., high temperature, or current limit).

You can observe an Off Normal alarm when the system is placed in current limit, or
you may wish to stop a fan to generate the alarm. The best way to stop a fan is to
use a small cable tie (non-metallic), and push it approximately 1cm through the
rectifier grille.

Rectifier Off Normal (e.g., fan failed) (non-urgent)
/

Tests with Batteries

• Set float voltage, Vf to equal battery voltage

• Connect battery/batteries

• Check the correct Battery Capacity (Ahrs) has been entered (SM3x Config.,
“Charge” tab). This is the total capacity, so for two 100Ahr strings in parallel,
this should be 200.

• Go to SM3x Config, “Control” tab. Set the Battery Charge Current Limit to
“Enabled” (middle right of screen). Also check Battery Current Limit (BCL) is
set to desired level (usually 0.25C10, (25%)). This means that for a single
100Ahr battery, the BCL will be 25A, or if two 100Ahr batteries are connected
in parallel, the BCL will be 25 x 2 =50A.

• Connect load (but turn off).

• Set Vf to 135V.

Check Battery current is positive
/

Go to SM3x Config., “Battery Monitoring” tab

and tick “Start Scanning”.

Check that all the battery cell voltages are

about the same, at about 2.25V.If any are out
by a large amount then check the BCM voltage
sense wiring is correct. (only available if
Battery Monitor PCB is fitted)

Set load to required level (e.g., 80A), Check operates
/

Initiate Battery Discharge Test (from SM3x
Config., “Charge” tab, click “Battery Test
Enabled”)

Check Battery Current is negative
/

(discharging)

Enatel DC System Manual Page 14 of 25

 Check Battery Curren Meter:______ __________ A
/

After several minutes or until the battery

voltage has dropped below approx. 120V,
“un-tick” (stop) Battery Test (from SM3x
Config., “Charge” tab). During this time the
Battery Condition Monitor (if fitted) will be
logging every minute.

Battery Current Limit (BCL)

Check that the battery recharge current is BCL functions Yes/No

limited to the Battery Current Limit level
(usually between 0.25C10, (25%)) _______%

Note: as the BCL is based on fine voltage

control of the system bus, the BCL make take
one or two minutes to “settle”, i.e., you may
observe a brief excursion of the battery
recharge current beyond the BCL setting.

Check Manual Equalise (if configured)
/

Temperature Compensation

Ensure Temperature Compensation Enabled Yes/No

Apply heat or cold to the Battery Temperature Yes/No

Sensor/s. Check the float voltage moves up or
down as expected.

If actual measurement is required, apply a Temp.______°C

known heat or cold to the sensor. Allow it to
fully come to temperature, and record the Voltage offset:
amount of voltage movement. ________ V OK? Yes/No

Check Alarm Relay Contacts

To generate these alarms, refer to the procedures described earlier in the

Commissioning Check-list.
Spare relays will not be able to be tested unless an alarm is mapped to them. As
these are tested in the factory, it is not essential to test them at time of
commissioning.

Relay 1 (Monitor Fail)
/

(pull out the RJ45 lead connecting the monitor
to the system rectifier shelf – this simply de-
powers the monitor)

Relay 2 (Summary Non-urgent)
/

Relay 3 (Summary Urgent)
/

Enatel DC System Manual Page 15 of 25

5 APPENDIX1 – ENATEL ESSENTIAL SYSTEM SET – UP PARAMETERS

The following items 1 though 5 are system settings that MUST be checked for EACH system
installed, at the time of commissioning.

WARNING: Failure to correctly follow the procedures in items 1 to 5 below may at least cause
incorrect system function, and at worst ruin your battery (without the ability to claim
battery replacement under warranty).
PRIOR to making any changes to settings, ensure that you back up the Configuration settings
that the SM3x is supplied with. To do this, go to the Setup page and click on the “Save
Variable to File” button. The filename is saved with a “.sm3x” extension.

1. Check/Set Float Voltage

Consult battery manufacturer’s data for proper setting.

The Float voltage is for 25°C reference temperature in Enatel systems.
SM3x Config Page: Power Module Control

2. Set Battery Settings

Temperature Compensation
You must consult the battery manufacturer’s data to obtain the correct Slope setting.
SM3x Config Page: Charge

If you choose not to enable Temperatue Compensation, then set the Rectifier Float Voltage to
that required by the battery manufacturer for the average long-term temperature you anticipate
your system to operate at.

3. Battery Size

For the SM3x to set the correct Battery Current Limit current, it is essential that this is filled out
correctly. These figures are also used for estimating the Battery Time Remaining during a
discharge.
For Telecom applications, the 10 hour rate is usually the name-plate rating of the battery.
However, once again, check the battery manufacturer’s data sheets as some manufacturers
state the 20 hour rate (which is usually a little more “optimistic”).
The second rate is required specifically for the time-remaining algorithm. A 4 hour rate is
usually a good one to use. This information is available from the battery manufacturer’s data
sheet.
SM3x Config Page: Charge

Enatel DC System Manual Page 16 of 25

Note – you need to change both the 10 hour and 4 hour rates at the same time. The rates need
to be reasonably accurate (in terms of the proportion of 4 hour to 10 hour rates), otherwise the
SM3x may not accept the settings.

4. Battery Current Limit

The Battery Current Limit is set as a percentage of the 10 hour rate entered in step 3.
SM3x Config Page: Control

Enatel recommends that you set this value at the highest rate possible to ensure the battery is
recharged as fast as possible (this could be as high as 30%, depending on the manufacturer).
However, especially in large systems, this may be more limited by the number of rectifiers
available, rather than this particular setting. For telco settings, this is often set to 10% (or
0.1C10, so for a 100Ahr battery, the current limit is 10A). This is more typical of a design
parameter than the need for the setting to be at this level. So a setting higher than this level
should be considered to enable the fastest recharge possible. However, consult the battery
manufacturer data to find the maximum value.

5. Low Voltage Disconnect Settings

SM3x Config Page: Alarms (Levels)

This is usually a customer generated setting. Normally, the longer the discharge, the higher the
end voltage. So, for a discharge of <1hr, this may be 1.75Vpc (105V for a 60 cell battery string),
or for an 8 hour discharge, it may be 1.85Vpc (111V for a 60 cell battery string).

Enatel DC System Manual Page 17 of 25

6 APPENDIX2 – DC EARTH LEAKAGE

Details:

Earth leakage detection is defined as measuring an earth fault current Ifault from the positive or negative
battery terminals to earth. Earth leakage detection is used when the outputs of the rectifiers in a DC power
system are isolated and floating from Earth. This is common in 120V systems used in utility applications.

Fig 1 shows a proposed circuit to enable the detection of fault currents from 20mA to 30mA in a 120V
Enatel DC Power System in both the positive and negative battery terminals.
Note: In illustrations & examples below, SM33 is stated for reference only; supervisory monitor
(SM33/34) may vary from customer to customer. Calculations for leakage current are based on 54Cell
battery string with 30mA as the fault current. These may vary from system to system.

A
To Battery +ve

10k 10K 10K

Vbatt To Earth terminal and

B
122V
VS2 + of Sm33

10k 10K 10K

The resistors are surge

To Battery -ve and C rated to 1.5kV DC, 3W.
VS2 - of SM33

Fig 1 Earth Leakage current detection circuit

A
To Battery +ve

R1 3k3

120V
To Earth terminal and
B
VS2 + of Sm33
R2 3k3
C
To Battery -ve To VS2 - of SM33

Fig 2 Simplified circuit (Voltage divider)

Circuit Operation:

Fig 2 shows the simplified schematic for detecting the earth leakage current.

Whenever there is an earth fault, the earth leakage current or fault current, will raise or lower the earth or
centre voltage measured at VS2+. The VBC voltage will decrease if there is a negative earth fault Fig 3 and
the VBC voltage will increase if there is a positive earth fault Fig 4. This change in VBC is referred to as ∆V.

Enatel DC System Manual Page 18 of 25

 Fig 3 Vbc increases due to a positive earth fault

Fig 4 Vbc decreases due to a negative earth fault

To Calculate Earth Leakage Current:

The maximum earth leakage current is when a battery terminal is directly connected to earth.
This is calculated by Vbatt/R2 or Vbatt/R1. In this case nominal 122V/3k3Ω = 37mA max earth leakage
current. The maximum at 160V/ 3k3Ω = 48mA under worst case conditions.

The minimum earth leakage current is the sum of R1 and R2. In this case nominal 122V/6k6Ω = 18 mA
minimum earth current. The minimum at 90V/11.9 kΩ = 14 mA under worst case conditions.

The battery midpoint voltage is calculated. Vbatt_midpoint = Vbatt/2. In this case Vbatt_midpoint =122V/2 = 61V.

To calculate ∆V, which is useful to the monitor’s input configuration editor, for an Earth Leakage
Detection of 30mA we calculate the VBC based on the resistor R2 and the fault current Ifault set to 30mA.

Vf = Ifault x R2. In this case VBC = 30mA x 3.33kΩ = 99.9V.

The fault current voltage Vf is calculated by subtracting the voltage VBC from the bus voltage.
Vbc = Vbatt -. VBC. In this case Vbc = 122V – 99.9V = 22.1V.

∆V is now Vbatt_midpoint - Vbc In this case ∆V = 61V – 55.4V = 38.9V

We can now set +/- 38.9V as our outset voltage detection for 30mA around the midpoint voltage of 61V for
positive or negative earth fault detection.

Fault Current I fault (mA) Vbc ∆V

20 55.4 5.6
25 39.0 21.8
30 22.1 38.9

Table 1 Fault current verses voltage offset for a Vbatt of 122V

Enatel DC System Manual Page 19 of 25

 SM3x Configuration Update:

The following shows the logic steps in the SM3x Configuration software used to generate an earth fault
alarm, based on the configuration shown in Fig. 1. An explanation of each logic step is shown (in italics)
for clarity.

Configuration should be updated as shown below or supplied configuration can be updated.

The principle of operation is that we assign variables to the voltage between the +ve rail and VS2 (the
mid-point, or “earth voltage”), and the –ve rail and VS2. (VS2 is Voltage Sense #2 input to the SM3x).
We then subtract these variables from the “earth voltage”, to generate a ∆V value. This value
corresponds to the mA of fault current required to generate an alarm (we have set the alarm to trip at
30mA; this corresponds to a voltage movement of 38.9V).

User Variable 2 = Bus1 Voltage /

2 -
3890

User Variable 2 is assigned the voltage across R2 as shown in the voltage divider network in fig 2.
The constant 1000 is equivalent to 10V. This means that User Variable 2 is equal to ½ the rail
voltage (i.e., the “earth voltage”), minus 10V. Should a different earth fault current threshold be
required, refer to Fig 3 to choose the appropriate ΔV. E.g., if 20mA is required, then ΔV=5.6V, giving
a constant of 560.

User Variable 3 = Bus1 Voltage /

2 +
3890

The same methodology is used here to set User Variable 3. This time we are setting the voltage
threshold on the “+ve” side, across R1.

User Variable 4 = Voltage Input 2

User Variable 4 is assigned the voltage across BC, which is the “ground voltage”, and is hard-wired
to the SM3x input VS2.

User Variable 5 = User Variable 4 <

User Variable 2

User Variable 6 = User Variable 4 >

User Variable 3

New simple logic User Variables (5 & 6) are assigned which simply change state if the “ground
voltage” moves more than the threshold voltage (10V in this case) in either direction (i.e., if VS2 <
User Variable 2 (the ΔV in the “-ve” direction, then User Variable 5 will return a “True” state.
Similarly for User Variable 6 in the “+ve” direction). (Values are compared to check if there is
leakage current in parallel with either R1 or R2.)

Earth Fault = User Variable 5 or

User variable 6

An “Earth Fault” alarm is generated if either User Variable 5 or 6 return a “True” state.

(A note on User Variables. A User Variable can be either a numeric value or a logic value (“True” or
“False”, depending on the type of operand assigned to it in the right-hand column). There is no need
to define it.)

Enatel DC System Manual Page 20 of 25

7 APPENDIX3 – AC INPUT TRANSIENT PROTECTION

Fig A
Fig A illustrates the surge protection installation principles.
The Type 1 surge arrester, fitted in the installation's main incoming electrical switchboard, is
capable of deviating the energy of a direct lightning strike. This is the first stage of the electrical
network's protection. It is important that upstream Type 1 protection is provided on site.
10/350 wave as shown below is the current waveform which passes through equipment when
subjected to an overvoltage due to a direct lightning strike.

A Type 2 surge arrester should be used in coordination with the incoming surge arrester. This is
the second stage of protection. Type 2 Surge arrester is designed to run-off energy caused by
an overvoltage comparable to that of an indirect lightning strike or an operating overvoltage.
Some of the Enatel Power System models are provided with Type 2 Surge Protection Devices
(SPDs) (as defined by IEC 61643-11). These devices are rated for repeated strikes of 20kA
(8/20µs waveform as shown above), and single shot protection of 40kA.
Enatel DC System Manual Page 21 of 25
Note: Enatel Rectifiers are compliant with EN6100-4-5, Level 4 without any external/upstream
surge suppression. To maintain a coordinated approach to surge suppression, Type 2 SPD
should be installed upstream if not fitted in the system.
To ensure correct operation of the SPDs, at least 10m of AC feeder cable is fitted between the
Type 1 and Type 2 protection. If the distance is less than 10m, then loop the cable until at least
10m of cable is used. This ensures correct de-coupling of the SPD devices.

Notes on AC cable installation and SPDs

The following precautions must be adhered to when installing AC cabling.

1. Avoid running input and output cables from AC Surge Protection Devices together:

2. Avoid “Tee’d” Connections:

Enatel DC System Manual Page 22 of 25

8 APPENDIX4 – RECTIFIER INPUT FUSE CURVES

RM30110
Input Fuse

Enatel DC System Manual Page 23 of 25

9 APPENDIX5 – MAINTENANCE
As ENATEL Power Systems are state of the art electronic systems, very little routine
maintenance is required

System

• During normal operation the cable entries to the MCB’s may loosen over time due to
movement in the cable strands.
• To avoid damage to the MCB’s and cable entries due to heat build-up and arching, it is
recommended that the retaining torque is periodically checked at least annually.
• MCB’s should be maintained at a torque of 2Nm.
• All other connections should also be checked at this time.

Monitor

• The monitor can give a good indication of the condition of the system. Alarm logs can
show issues with the system and rectifiers and should be regularly checked.
• As a minimum, check that the float voltage and load current is as expected.
• If the batteries are fully charged, check the battery current is zero or near to zero amps,
and also check that the amp-hours remaining (found in the SM32 Configuration Software
application, under the heading “Charge – Battery Capacity”) is 100%.

Rectifiers

• During normal operation some dust will build-up on the front of the rectifiers. This should
be kept to a minimum by regularly wiping the rectifiers to avoid accumulation within the
rectifiers and blocking the airflow to the units. The positioning of the system and
surroundings will determine the regularity of this requirement.
• In extremely dusty positions it is recommended that the units are removed and cleaned
with compressed air to prevent airflow blockages.

Batteries

Battery maintenance will depend on the individual manufacturer’s specification, please contact
the battery supplier for recommendations

Enatel DC System Manual Page 24 of 25

 RECTIFIER 1

RECTIFIER 2

RECTIFIER 3

RECTIFIER 4

Enatel DC System Manual

+

4k7
10 APPENDIX6 – SYSTEM WIRING DIAGRAM

J110 J108 J109 J111 J113

J106 J107 J107

Customer Alarms

Page 25 of 25