033 InstGde Aeon 4000 PRSystem PDF

Installation & commissioning
AEON 4000 PRS

Power Rack System
Aeon Gold
Control Unit
SMPS 4000
Rectifier
356940.033
Issue 2, 2006 June
Table of contents
Table of contents
1 Installation of the Rectifier Systems ........................................................... 4

1.1 Warnings ................................................................................................................... 4
1.2 Introduction .............................................................................................................. 4
1.3 Recommended tools.................................................................................................. 4
1.4 Unpacking ................................................................................................................. 5
1.5 Mechanical installation ............................................................................................ 5
1.6 Earth Connections.................................................................................................... 6
1.7 DC Load cable connections ..................................................................................... 7
1.8 AC Mains cable connections.................................................................................... 9
1.9 External Battery connections ................................................................................ 11
1.9.1 Symmetry Wire Connections ............................................................................ 12
1.10 Installation of SMPS 4000 in an AEON 4000 system.......................................... 13
1.11 Pin description for SMPS 4000 ............................................................................. 15
2 Connections to AEON Gold Control Unit................................................ 16
2.1 Tools needed............................................................................................................ 16
2.2 TB1, System connections ....................................................................................... 16
2.3 TB2/3, Analogue inputs.......................................................................................... 17
2.4 TB4, Digital inputs ................................................................................................. 17
2.5 TB5/6, Relay outputs for Alarms and contactors................................................ 18
2.6 Communication ports ............................................................................................ 19
2.7 Cable list.................................................................................................................. 20
2.7.1 Communication Cable drawings...................................................................... 20
2.8 Termination drawing, AEON Gold Control Unit ............................................... 22
2.9 Functional Description........................................................................................... 23
2.9.1 Control Unit ..................................................................................................... 23
2.9.2 Front panel....................................................................................................... 24
2.9.3 Power Supply.................................................................................................... 25
2.9.4 Inputs................................................................................................................ 26
2.9.4.1 Analogue inputs............................................................................................ 26
2.9.4.2 Digital inputs ................................................................................................ 26
2.9.5 Digital outputs.................................................................................................. 26
2.9.6 Communication ports ....................................................................................... 26
3 Start-Up And Commissioning Instructions ............................................. 28
3.1 Recommended tools................................................................................................ 28
3.2 Commissioning / Site Acceptance Procedure....................................................... 29
3.2.1 Pre-Start / Initial Check ................................................................................... 29
3.2.2 System Start-Up................................................................................................ 29
3.2.3 Alarm Levels..................................................................................................... 31
3.2.3.1 Default Values.............................................................................................. 31
3.2.4 Configuration of Alarm Relays ........................................................................ 31
3.2.5 Configuration of Symmetry Alarm Limits ........................................................ 32
3.2.6 System Alarms & Options ................................................................................ 32
3.2.7 Battery current Calibration.............................................................................. 35
3.3 System Configuration Record ............................................................................... 36
2(44) Installation & commissioning, AEON 4000, Art. No. 356940.033, v2,2006-06
Table of Contents
3.3.1 System data....................................................................................................... 36

3.3.2 Batteries ........................................................................................................... 36
3.3.3 Saving Configuration Data .............................................................................. 36
4 Drawings...................................................................................................... 37
Installation & commissioning, AEON 4000, Art. No.356940.033, v2,2006-06 3(44)

1 Installation of the Rectifier Systems
1.1 Warnings
If you are uncertain about any of the safety precautions or the safety risks involved with
installing and running the AEON 4000 system, the safety notes in the General Information
section in the System Overview (Art. No 356940.013) MUST be consulted.
1.2 Introduction
The following chapters will guide you step-by-step through:
Mechanical Installation
All cable connections
Battery Installation
Installation of SMPS modules
A level surface is recommended for floor cabinets and the adjustable legs on floor cabinets
can absorb an unevenness of approx. 2 cm (0.8).
Fans are located inside the units which blow the air from the back of the cabinet to the front,
to cool the SMPS 4000 rectifiers. To achieve an adequate amount of air for the ventilation
process, it is generally not recommended to install AEON 4000 cabinets against walls.
Exceptions can be made for installations with air conditioning systems and elevated floors
where the tiles underneath the cabinets are removed.
The recommended distance from the wall will depend on the room temperature. Our
recommendations are given below for full power operation at 40C.
Cabinet size Distance

1 PR 6 rectifiers > 5 cm (1.9)
Table 1 Distance from wall
5 The floor construction must be capable of supporting the load.
1.3 Recommended tools

Standard equipment, for use by an authorised electrician
Pozidrive bits
Torx bits
5 All tools must be insulated
1.4 Unpacking
5 Some cabinets may weigh more than 250 kg (550lb). Appropriate lifting
equipment should thus be used and care must be taken while handling
Installation step Comments OK
1 REMOVE PACKAGING Check that the equipment received corresponds

with the delivery notes. Inspect all equipment
for damage, which may have been caused in
transit.
Inform Eltek Energy of any problems.
Remove the four bolts in the base of the cabinet
to allow removal of the pallet.
2 SIGN AND RETAIN THE These may be required for later proof of
DELIVERY NOTE WITH THE delivery.
SITE DOCUMENTATION
3 SAFELY STORE ANY These items will be required for later

CABINET KEYS, FUSE installation work.
PULLERS, FUSES ETC
Procedure 1 Unpacking
1.5 Mechanical installation

Installation step Comments Okay
1 POSITION THE CABINETS IN Refer to the DC equipment arrangement and

THE REQUIRED LOCATION the site layout drawings.
2 REMOVE THE CABINET TOP Required for accessing the connection

COVERS SIDE REAR AND terminals and better access during installation.
DUMMY PANEL(S) Ensure that the panels are stored safely to
avoid damage.
3 ADJUST THE CABINET LEGS
SO THAT THE CABINETS ARE
LEVEL STABLE AND OF
EQUAL HEIGHT

Procedure 2 Mechanical Installation
1.6 Earth Connections

To prevent electric shock, the system must be properly earthed.
1) The incoming mains supply to the system must include a mains safety protective earth
connection (PE). The cabinet PE terminals are found by opening the AEON cabinet front-
hinged panel, on the left hand side of the rectifier cabinet. The AC supply cable must
contain a protective earth connection as;
a) a separate yellow/green insulated wire or
b) b) a braided schreen. a) or b) must be connected to the protective earth terminals.
Eltek Energy DOES NOT consider a compression gland connection to a steel wired armoured
cable (SWA) as satisfactory for this important safety function.
2) In cases where a Clean Earth is available, connect a DC PE cable from the system's
positive bus-bar to a Clean Earth. This cable must be capable of withstanding the
system's short-circuit current for at least the time taken for the battery fuse to rupture and
must be sized accordingly.
Eltek Energy strongly recommend to establish a Clean Earth connection on each site
If an external Clean system Earth is not available the mains PE terminal may be the source
of earth reference for the equipment. In this case, the common rail must be connected to the
PE terminal.
Mains safety
protective earth
(PE)connection
Pre wired earth

connections for
Power Racks and Connection bolt if
chassis. the common rail is
connected to the
PE terminals.
Figure 1 Protective earth terminals
The Customer may in this situation (clean earth unavailable) remove the default yellow/green
wire from the PE terminal to the cabinet earth bolt.
Figure 2 Wire to cabinet earth
1.7 DC Load cable connections

The DC load cable connections differ from system to system. It depends mainly on the fuses
and circuit breakers in the system. For a detailed description of the system in hand, refer to the
Terminal connection drawing for the system.
In general the positive load pole should be connected either to the small copper connection
points if the MCBs are used, and the large connection point on the copper bar if the blade
fuses are used. Drawing 1 in chapter 4 gives a general overview of the system.
Large
connection
points
Small
connnetion
points on
positive
pole
Load
MCBs
Figure 3 Example of large and small connection points with load MCBs
On the negative side the cables are either connected to the top of the large blade fuses, or to
the top of the MCBs. The number of MCBs and blade fuses vary from system to system, and
so does the contactor configuration.

Connection points for large

loads on the blade fuses.
Figure 4 Example of blade fuses
Fuse type Max. size load or battery cables Bolt size
MCB 16 mm2 (6 AWG) None
NH00 (BLADE 8 mm
FUSE)
70 mm2 (2/0 AWG)
NH01 (BLADE 8 mm
FUSE)
150 mm2 (300 MCM)
NH02 (BLADE 10 mm
FUSE)
240 mm2 (470 MCM)
NH03 (BLADE 12 mm
FUSE)
400 mm2 (600 MCM)
Table 2 Normally used DC load fuse and cables
Installation Step Comments OK

1. DECIDE CABLE The top cover has semi-punched holes which must be
ENTRY fitted with entry nipples to preserve the cabinet's IP20
rating.
2. LAY CABLES ALONG
CABLE ROUTES
3. SECURE CABLES TO
CABLE ROUTES
4. REMOVE ALL BLADE
FUSES AND SWITCH
ALL MCB'S TO OFF
POSITION
5. DRESS THE CABLES Refer to fuse schedule for cable termination point.
INTO THE CABINET Use cable cutter and cable lug crimper fitted with
CUT TO LENGTH AND appropriate sized die.
FIT CABLE LUGS
6. FASTEN ALL CABLES
TO CABLE SUPPORT
RAILS AND CUT
CABLE TIES FLUSH
Procedure 3 Installation of DC load cables
1.8 AC Mains cable connections
L1
L2
L3
Figure 5 Example of AC mains connection

Figure 6 Mains configuration table

; Always switch OFF the external mains supply before connecting

the mains cable to the mains terminals
1. VERIFY WHICH MAINS Compare the mains label inside the

CONFIGURATION IS APPLICABLE FOR cabinet with the configuration of the
YOUR SYSTEM: mains terminals
3 X 230 VAC DELTA (NO
NEUTRAL) OR 3 X 400 VAC STAR
WITH NEUTRAL
IF NECESSARY, RECONFIGURE If the supply is 3 x 230 VAC the neutral

THE MAINS TERMINALS copper bar shall not be used. Connect the
ACCORDING TO THE SUPPLY blue cables to the connection points
AVAILABLE instructed on the cable labels. If the
supply is 3 x 400 VAC, connect the blue
cables to the neutral copper bar.
3. CONNECT THE PROTECTIVE The cabinet earth terminal is located in
EARTH BEFORE ANY OF THE LIVE front of the mains terminals, on the right
TERMINATIONS (L1, L2, L3 AND N) side cover
Procedure 4 Installation Step for AC Mains cable connections
Eltek recommends the following fuse rating for AC input when you have 24 VDC, 48 VDC
and 60VDC output:
Size of mains 3-phase 400 3-

terminal VAC + N, mains phase
fuses MCB 230
VAC
1-6 RECTIFIERS 70 mm2, (2/0 AWG)

50 A 100 A
screw terminal
7-12 RECTIFIERS 70 mm2, (2/0 AWG)
100 A 160 A
screw terminal
13-18 RECTIFIERS 120 mm2, (4/0
AWG) screw 160 A 250 A
terminal
DUAL MAINS FOR TWO
70 mm2, (2/0 AWG)
SEPARATE PR'S (2X6 100 A 160 A
RECTIFIERS)
screw terminal
19 24 RECTIFIERS 120 mm2, (4/0

200 A 350 A
AWG) screw
terminal
Table 3 Recommended fuses for 24 VDC, 48 VDC and 60VDC output
Recommended fuse rating are based on Siemens 3VF fuses.
1.9 External Battery connections
9 Before connecting batteries: Remove all metallic objects such as rings,

watches
; The battery fuse rating must be dimensioned in accordance to the size

of the battery bank.
The blade fuse positions Fbx (NH0x) are reserved for battery connection. The batteries
should be installed as recommended by the battery manufacturer. You will find the
following color coding on the battery cables, depending on the type of load distribution
used in your system:
Negative Load Positive Load

Distribution Distribution
Blue () negative terminal / to fuse Red (+) positive terminal / to fuse
Black (+) Positive terminal to Black () Negative terminal to
common Bus Bar common Bus Bar
Table 4 Colour code Negative/Positive Load distribution
1. VERIFY THAT BATTERY

BLADE FUSES ARE
REMOVED
2. CONNECT POSITIVE
BATTERY CABLES
In case of positive load distribution connect
(USUALLY BLACK) TO THE
COMMON BUSBAR ON
negative battery cables to common bus bar
TOP OF THE CABINET
3. CONNECT NEGATIVE
BATTERY CABLE In case of positive load distribution connect
(USUALLY BLUE) TO THE positive battery cables to the battery fuses.
BATTERY FUSES
4. CONNECT SYMMETRY Choose between connecting wires to each 12V

MONITORING WIRES TO THE block of the battery or connection to battery

BATTERY STRINGS IF mid- point. For details see chapter 1.9.1.

SYMMETRY MONITORING HAS Connecting the wires to AEON Gold Control
BEEN CHOSEN
unit is described later.
Procedure 5 Installation Step for external Battery cable connections
1.9.1Symmetry Wire Connections
AEON Gold has four additional inputs for voltage monitoring which are normally used to
check the symmetry voltages in one or several battery strings (See chapter 2.3 for details).
There are two optional ways of performing symmetry voltage monitoring:
Centre point monitoring of up to 4 parallel battery strings

12V block monitoring of a single battery string
The symmetry monitoring connections depend on whether the system has positive earth,
which is most common in 48Vdc and 60Vdc systems or negative earth, which is most
common in 24Vdc systems. In systems with negative distribution and positive earth all
symmetry connections should be connected to Agnd reference on TB3 pin 18, which is
connected to battery minus. In systems with positive distribution and negative earth all
symmetry+ connections are to be connected to Agnd reference, which again is connected to
battery plus. In this case the negative symmetry connections are connected to the battery
string(s).
For centre point monitoring in a positive earth system the symmetry + connections are to be
connected to the battery centre point. One connection for each battery string. If only one
string is installed only symmetry 1+ should be used and the other three connections should
not be used.
For centre point monitoring in a negative earth system the symmetry - connections are to be
connected to the battery centre point.
For block monitoring the connections are shown in Figure 7 both for positive and negative
earth systems.
48Vdc Battery String
+
Negative Distribution Positive Distribution
12V
Symmetry 3+ Symmetry 1-
12V
12V
12V
Figure 7: Block Monitoring of 48Vdc battery
1.10 Installation of SMPS 4000 in an AEON 4000

system
The procedure below will guide you through the installation of the SMPS 4000 rectifiers in an
AEON system. See System Operation for AEON 4000(Art. No. 355204.013) manual for
details on how to operate the control and monitoring unit.
Installation of SMPS 4000 modules
1. OPEN THE DOOR IN FRONT

TO ACCESS THE MAINS FUSES
2. PLUG IN THE NEW SMPS

MODULE(S)
3. FASTEN THE MODULE WITH A Located behind the handle in front of the module,
FRONT PANEL SCREW see Figure 8.
4. START UP THE RECTIFIER The startup procedure is a part of the

commissioning and is described in detail in
chapter 3.2.
Procedure 6 Installation Steps for rectifier modules
; For safety reasons, blind panels must be mounted in all spare

module locations to avoid contact with all conducting components

Green Power
LED
Red alarm LED
Communication
LED (Yellow)
Front panel screw
Handle
Figure 8 Removing and replacing a rectifier in a system
1.11 Pin description for SMPS 4000

DC connection:
The negative DC output is the top copper bar at the back of the rectifier.
The positive DC output is the bottom copper bar at the back of the rectifier.
AC and CAN connection:

The AC connector is located under the DC
copper bars.
The pin out of the connector is given in
the table below. Pin 1 is at the bottom of
the connector and pin 10 is on the top.
DC -
Pin no. Description
1 PE
2 PE DC +
3 Mains L
4 Mains L
PIN 10
5 Mains N
6 Mains N
7 PE
8 Com gnd PIN 1
9 A/CANH (5V)
10 A/CANH (0V)
Table 5 Pin description
Figure 9 Rear connectors for SMPS 4000

2 Connections to AEON Gold Control Unit

Notice that the connectors that are gray in the tables are factory connected if they are used in
your system. Only the white connectors in the tables are supposed be customer wired. A
specific description of all the connections is not possible, but the tables in this chapter give a
general description of where the different kinds of cables should be connected. Many of the
connections can be configured in the software later.
2.1 Tools needed

Standard equipment, for use by an authorized electrician
2.2 TB1, System connections

TB1 is designated for system connections, AC/DC power input, 3 digital inputs and 2 digital
driver outputs.
Description Connection point Pin No. Signal

Max. 1.5 mm2,
or AWG size 16
AC Input TB1 1 Power In
AC Input TB1 2 Power In
DC Input + TB1 3 Power In
DC Input - TB1 4 Power In
Batt. fuse fail + TB1 5 DI
Batt. fuse fail - TB1 6 DI
Load fuse fail 1 + TB1 7 DI
Load fuse fail 1 - TB1 8 DI
Load fuse fail 2 + TB1 9 DI
Load fuse fail 2 - TB1 10 DI
LVBD NO TB1 11 DO
LVBD NC TB1 12 DO
LVBD C TB1 13 DO
LVLD 1 NO TB1 14 DO
LVLD 1 NC TB1 15 DO
LVLD 1 C TB1 16 DO
Table 6 General connections
2.3 TB2/3, Analogue inputs

TB2/3 are designated for analogue inputs, 2 for temperature, 5 for currents, 1 for total battery
voltage and 4 for symmetry measuring. Configuration of these inputs is done in the Control
Unit SoftWare.
Description Connection point Pin No. Signal

Max. 1.5 mm2,
or AWG size 16
Temp sense + TB2 1 AI
Temp sense - TB2 2 AI
Temp sense shield TB2 3 AI
Batt. Voltage + TB2 4 AI
Batt. Voltage - TB2 5 AI
Batt. Current + TB2 6 AI
Batt. Current - TB2 7 AI
Current + TB2 8 AI
Current - TB2 9 AI
Not Used, AGND Reference TB2 10 AI
Current 1+ TB3 1 AI
Current 1 - TB3 2 AI
Current 2+ TB3 3 AI
Current 3+ TB3 5 AI
Temp sense 2+ TB3 7 AI
Temp sense 2- TB3 8 AI
Temp sense 2 shield TB3 9 AI
Symmetry 1 + TB3 10 AI
Symmetry 1 - TB3 11 AI
AGND reference TB3 18 AI
Table 7 General connections
2.4 TB4, Digital inputs

TB4 is designated for digital inputs. Seven inputs are available, where 1-6 is designed for
direct connection to potential free inputs/relay outputs such as external alarms. Relay no. 7 is
designated as a fuse alarm input.

Description Connection point Pin No.

Max. 1.5 mm2,
or AWG size 16
Digital in 1 + TB4 1
Digital in 1 - TB4 2
Table 8 Digital inputs
2.5 TB5/6, Relay outputs for Alarms and

contactors
Alarm relays 1- 10 are available on TB5/6. All three outputs of the relay are present, for
example NO (Normally Open), NC (Normally Closed) and C (Common), and it is up to the
user to decide whether he wants NO or NC operation. Please note that in addition to choosing
NO or NC, it is also important to decide in Winpower Gold whether the relay will be
energised or not during normal operation.
Relay 10 can be assigned as AEON Gold failure alarm output by setting a dipswitch under
Config Relay 10, in ON position. Any software setting of this relay will then be disabled.
Relay 8-10 are the default driving contactor relays for LVLD 2-4, but all of the relays in the
table can be configured for this purpose in WinPower.
Description Default Configuration Connection point Pin No.

Max. 1.5 mm2,
or AWG size 16
Relay 1 NO Mains Fault Relay TB5 1
Relay 1 NC TB5 2
Relay 1 C TB5 3
Relay 2 NO High Battery Voltage Relay TB5 4
Relay 2 NC TB5 5
Relay 2 C TB5 6
Relay 3 NO Low Battery Voltage Relay TB5 7
Relay 3 NC TB5 8
Relay 3 C TB5 9
Relay 4 NO Fuse Alarm Relay TB5 10
Relay 4 NC TB5 11
Relay 4 C TB5 12
Relay 5 NO Common Rectifier Alarm Relay TB5 13
Relay 5 NC TB5 14
Relay 5 C TB5 15
Relay 6 NO Common Alarm TB5 16
Relay 6 NC TB5 17
Relay 6 C TB5 18
Relay 7 NO TB6 1
Relay 7 NC TB6 2
Relay 7 C TB6 3
Relay 8 NO TB6 4
Relay 8 NC TB6 5
Relay 8 C TB6 6
Relay 9 NO TB6 7
Relay 9 NC TB6 8
Relay 9 C TB6 9
Relay 10 NO TB6 10
Relay 10 NC TB6 11
Relay 10 C TB6 12
Table 9 Alarm relay outputs
2.6 Communication ports

Two communication ports for external communication are available in Aeon Gold, part no.
241241.100. Com0 is used for software upgrade of AEON Gold, service connection, and
WebPower. The Com1 can be used for communication with Winpower Gold, and WebPower,
through PCOMM protocol, as a modem connection, and as a SNMP connection.
Description Connection point Cable type Cable type if

modem
Canbus TB8 / TB9 (Canbus) 4 pairs, shield- 4 pairs, shield-
twisted twisted
DTE PORT pc / modem / COM1 30801.002
SNMP/service / Webpower Winpower
DCE PORT SW upload COM0 30801.001 sw Standard 1-1
/ Webpower upload modem cable
Display unit/keyboard J2 (Keyboard) See chapter 2.7
Webpower (integrated for Ethernet (future
AEON Gold) option)
Table 10 Communication Ports

2.7 Cable list

Qty Article nr. Description Optional
1 30801.002 Comm Cable PC/AEON GOLD Winpower X
1 30801.001 Comm Cable PC/AEON GOLD SW download X
1 101689 CABLE:Display Aeon Gold Door Mounted, 16 cm EITHER
1 102849 CABLE:Display Aeon Gold Rack Mounted, 1 m OR
1 103821 Communication Cable Aeon-WebPower 1 X
1 30400.013 LOOM:Sign=CAN BUS PR to 26889_1.5m
1 100590 Modem cable X
1-4 Customized Symmetry cable(s) X
Table 11 Cable list
2.7.1Communication Cable drawings
Part No. 30801,001 Part No. 30801,002

Description Aeon/Winpower Software Description Aeon/Winpower Communication
Download Drawing TE39252
Drawing TE39251 Plug female Plug female
Plug female Plug Male PC Aeon Gold
PC Aeon Gold (9 Way 'D' connector) (9 Way 'D' connector)
(9 Way 'D' connector) (9 Way 'D' connector)
1 1
1 1
2 2
2 2
3 3
3 3
4 4
4 4
5 5
5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
3000 mm 3000 mm
Cable Screend twisted 6 core 0.22 Square mm Cable Screend twisted 6 core 0.22 Square mm
Figure 10 Application upload cable Figure 11 Winpower Gold Communication Cable
9-Pin D-Sub 9-Pin D-Sub

Connector Pin Connector Pin
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
1 1
Figure 12 Standard 1-1 Modem Cable for AEON Gold

2.8 Termination drawing, AEON Gold Control Unit
2.9 Functional Description
2.9.1Control Unit
The AEON Gold control unit or central processor unit (CPU) is located either on the hinged
door behind the front panel or inside the cabinet. On this board you will find all necessary
terminals for internal or external connections. Information LEDs, service switch,
configuration switch and reset button are also located on this board. The Aeon Gold
241241.100 has control unit with part number 240278.185.
Frontpanel Com 0 Com 1 TB4,

w/ keyboard SW up-load, Modem/SNMP TB5,
Webpower, Winpower, TB6
Winpower Webpower
CAN bus
Modem/ SNMP supply Ethernet card TB1, TB2, TB3

interface
DC Fuse, 1A
Figure 1 AEON Gold control unit part number 240278.185
The CPU has a heartbeat LED. The heartbeat LED will pulse during normal operation. If the
alarm module looses its connection to the system, the LED will stop pulsating and the reset
button can be used to restart the alarm module. The parameters are stored in the CPU, so use
of this button will not affect the system.
On the control unit there is a service switch with an indicator LED that is lit when the service
switch is in ON position. Relay 10 can be configured for different purposes. Configure relay
10 enables the user to do this. For details, see chapter 2.5.
Note: For 60 V systems, the new Aeon Gold HW, Art. 241241.100 is required.

2.9.2Front panel
The AEON Gold front panel comprises a keypad, a LCD display, a green LED (indicating
that the system is ON) and a red LED (indicating that the system is in alarm mode). This
module is located on the hinged door or above it, mounted in a 19 rack. It is connected via an
interface cable to a 26 pin D-sub connector on the side of the control unit.
The Default password for service menu options is 1234.
Graphical Display Green LED - Keypad

Power
10 Numerical keys
Red LED - 3 Keys for menu scroll
Alarm 1 key for scroll back
Figure 13 AEON Gold front panel part number 240278.182 (240278.186)
2.9.3Power Supply
The Alarm module can be fed with AC and/or DC voltages. Default power for AEON Gold is
DC power from rectifiers or batteries. If using 230VAC input, an optional external
transformer is require. An extra fuse on the transformers secondary side is also optional. This
AC voltage will be transformed to DC voltage inside the AEON Gold, since the input
contains rectifiers and filters to handle the low voltage AC from the external transformer. The
default DC input is made for voltages between 20VDC to 90VDC.
Transformer External
fuse (AC) transformer
Figure 14External transformer with fuse

2.9.4Inputs
2.9.4.1Analogue inputs
The main board is designed for monitoring up to 4 battery strings, with one shunt input and
one symmetry measurement for each string. In addition there is one system voltage input and
two temperature measurement inputs. The resulting input allocation is as follows:
DC voltage inputs for system voltages 24VDC, 48VDC and 60VDC, used for DC
voltage measurements and symmetry supervision. This covers, typically, 1 battery
voltage reference input, and 4 symmetry inputs for centre measurements of 4 strings or
1 string of 4 *12Volt inputs.
Voltage range: 75VDC for new Aeon Gold 241241.100.
DC voltage inputs with 60mV range for shunt (current) measurements.
Temperature measurement input, 2 inputs using a A/K sensor (current generator).
2.9.4.2Digital inputs
The main board is equipped with 10 different inputs, 3 for fuse supervision and 7 as generic
inputs.
Battery Fuse alarm is powered internally and activated by a dry contact.
Load Fuse alarm 1 and 2 need external power to activate.
7 generic inputs are powered internally and activated by a dry contact.
Type: 2 Voltage input and 8 dry contact inputs
Isolation: Optocoupler isolated
2.9.5Digital outputs
The main board is equipped with 12 relay outputs. These are mainly used as alarm relays or as
driver output to optional contactors. They are configurable as Normally Open or Normally
Closed operation (NO/NC).
Type: dry contact
Isolation Voltage range: 250VAC
Max Contact Current: 1A
2.9.6Communication ports
The CPU board is equipped with 3 communication ports:
1 RS232 port (com0) based on the internal CPU comm port, configured as a ITU
V24. DCE device.
1 RS232 port (com 1) based on an external uart chip, configured as a ITU V24. DTE
device.
1 CAN bus interface. A full CAN B. Interface, optically isolated and based on the
CPUs internal port.
The DTE port marked COM1 is used for communication with PC (Winpower Gold), modem
or SNMP adapter. The DCE port marked COM0 is used for software upgrade or service, but
can also be configured to be a Winpower connection point. This is done in the service menu
on the AEON Gold front panel. See System Operation for AEON 4000 (Art. No 355204.013)
for details.
Both the COM0 and the COM1 port can be configured to be a Webpower connection port.
For further description of Webpower, see The Webpower Operation Guide, part. No
356943.013.
For further description of the SNMP communication solution, see User Manual SNMP
Adapter, part. No. 356942.013.
Figure 15SNMP adapter with fuse and External transformer with fuse

3 Start-Up And Commissioning Instructions

The commissioning procedures require knowledge about the use of the AEON Gold Control
Unit and Winpower Gold. The functions found in AEON Gold and Winpower are described
in detail in System Operation for AEON 4000 (Art. No. 355204.013).
; Please read the manual carefully before using the equipment.
3.1 Recommended tools

Standard equipment for an authorised electrician
Digital multimeter with a built-in thermometer
Temperature probe ranging from 10 to +100C (14F to 212F) or
Elteks temperature simulator (Art. No. 800500.0V1)
PC with suitable WinPower Gold
Communication Cable for connecting the PC and AEON Gold (Art.
No. 30801.002)
Note: All tools must be insulated
3.2 Commissioning / Site Acceptance Procedure

The Commissioning/Site Acceptance Procedure verifies that the system is installed correctly
and operating satisfactorily. Several tests are for options only and thus not applicable if these
options are NOT installed in the specific system. The procedure should be completed by the
Commissioning Engineer and signed by the Engineer and a Customer representative.
9 Please note that system start-up and configuration require the use of
WinPower Gold and a PC
3.2.1Pre-Start / Initial Check

CHECK THE FOLLOWING: OK
1. System installation is completed
Check that the system installation has been correctly performed, see
Installation description.
Check that the service switch is in normal/off position. The service switch is
normally situated on the left side of the cabinet. For further details se
Attachments in System Operation for AEON 4000 (Art. No. 355204.013)
2. Battery and load are disconnected
Verify that the battery/load fuses and load circuit breakers are in OFF position
3. Rectifier modules are connected
Verify that rectifiers are installed. All AC fuses for rectifiers must be off.
4. Rectifier system connected to mains supply and Protective Earth
Check that the system's mains cables are connected to the mains supply and
that mains is configured according to mains voltage
5. Mains fuses/breakers are connected to the system
Verify that the external mains supply is turned on
6. Measure the CAN bus communication cable
The resistance should be approx. 60 .
7. Record the information in the System Configuration Record
SYSTEM DATA section and BATTERIES section
Procedure 7 Commissioning Pre-Start / Initial Check
3.2.2System Start-Up
1. Verify that AEON Gold is connected to a power supply. Normally there is a
AC transformer installed that is feeding the control unit. Turn the 2-pole AC
MCB to AEON Gold ON. If no AC supply is available to the AEON Gold, then
connect a battery string temporarily to the DC bus bars (in order to power up
the AEON Gold ).

2. Perform rectifier registration

Front panel menu: Service Rectifier Control Rectifier Installation
Initial Installation. (Only for first time commissioning, NOT on a system
already running) Turn on mains MCB for each rectifier , one by one, starting
with the rectifier designated no.1. See Rectifier Control in System Operation
for AEON 4000 (Art. No 355204.013) for a more detailed description
3. Verify rectifier operation
Check user setup rectifier status, and verify that information on all
rectifiers is present. CAN bus LED (yellow) and the Power LED (green) must
be lit.
4. Turn the system on. Front panel menu: Service System ON/OFF
5. Measure output voltage V
Use a digital voltmeter to verify that the output voltage is in
accordance with the system voltage.
6. RECTIFIER MODULES ARE ON, WITHOUT FAULT ALARMS
Verify that the SMPS modules are in normal operation mode (not reporting
alarms)
7. Check and calibrate the voltage reading on the Measured Displayed
alarm display Calibrate AEON Gold, if the with in AEON
measured voltage deviates by more than 1 % from DVM Gold
the display reading, see System Operation for AEON
4000 (Art. No 355204.013), Operation from AEON
Gold frontpanel, Available User Options, System
Configuration.
8. Verify that the system setup is in accordance with configuration
Using the AEON Gold's keypad or a PC, check that the system is set up in
accordance with any customer specified values, which deviate from the factory-
set default values. See default values in chapter 3.2.3.1.
Record the system setup in the enclosed System Configuration document.
9. Switch the system OFF
10. Connect the load fuses / MCB's
Battery Fuse(s) are NOT connected.
11. Switch the system ON
12. Adjust the output voltage to equal the measured battery voltage
Measure the battery voltage and, from the AEON Gold's keypad, adjust the
rectifier output voltage to equal ( 1 V) of the measured battery voltage.
Temperature compensated charging must be deactivated when the output
voltage is to be adjusted
13. CONNECT THE BATTERY FUSES
It is important that the system is switched ON before the batteries are
connected, otherwise, high currents trying to charge the rectifiers' internal
capacitors may damage the battery terminals. Check the battery polarity and
connect the battery fuses. Wrong polarity may damage the system
14. ADJUST OUTPUT VOLTAGE
Adjust the output voltage (float voltage) from the AEON Gold's keypad to
the voltage recommended by the battery manufacturer. Verify that the Low
Battery Alarm is not activated. Record the voltage and ambient battery
temperature. Temperature compensated charging can now be activated
Procedure 8 Commissioning System Start-Up
3.2.3Alarm Levels
Alarm levels are verified in WinPower, under general configuration, in the Define Triggers
menu and Set Levels menu.

Leave the Alarm Levels (High & Low Batt. Alarm) according to default
Or change to Customer spec. Values
Leave the LVBD Disconnect Voltage level & Reconnect1 level according to default
Leave the LVBD Disconnect Delay Time (sec) according to default
Procedure 9 Commissioning of Alarm Levels
3.2.3.1Default Values
Factory set Default values Customer Unit
specified values
System Voltages 24V 48V 60V
High Battery Voltage: 28,5V 57V 71,25V V
Low Battery Voltage: 24,5V 49V 61,25V V
Battery standby Voltage: 20V 40V 50V V
Battery Voltage: 26.8V 53.5V 66,8V V
Disconnect Voltage 21.5V 43.0V 53,75V V
(LVBD):
Rectifier trip voltage 29,75V 59,5V 74,38V V
(OVP)
Disconnect Delay Time 0 min min
Power limitation 100% (common)
Procedure 10 Commissioning Default Values
3.2.4Configuration of Alarm Relays

Use WinPower to verify the alarm relays configuration and, if necessary, change the setup.
This is done in General Configuration, Define Alarm Outputs.
Note the name of the alarms configured to each relay
RELAY DEFAULT CUSTOMER SPECIFIED ALARM
Relay 1 Mains Fault Relay
Relay 2 High Battery Voltage Relay
Relay 3 Low Battery Voltage Relay
Relay 4 Fuse Alarm Relay
Relay 5 Common Rectifier Alarm
Relay
Relay 6 Common Alarm
Relay 7
Relay 8

Relay 9
Relay 10
Relay 11 LVBD
Relay 12 LVLD
Procedure 11 Configuration of Alarm Relays
For connection table see chapter 2.5, page 18.
The relays can be configured to different detector classes, so that many different detectors can
trigger one relay. Each trigger has three possible alarm classes, alarm, warning and info. The
alarm response on AEON Gold differs between the alarm classes. For more details see System
Operation for AEON 4000 (Art. No.355204.013).
3.2.5Configuration of Symmetry Alarm Limits

Use WinPower to verify the symmetry alarm limits and, if necessary, change default limits.
This is done in the Battery Configuration menu, under Symmetry Measurement
Configuration.
LIMITS DELTA VOLTAGE (V)

Warning level, Charge 1.5
Alarm level, Charge 2
Warning level, Float 1.5
Alarm level, Float 2
Warning level, Discharge. 1
Alarm level, Discharge 1.5
Procedure 12 Configuration of Symmetry Alarm Limits
3.2.6System Alarms & Options

Note! User specified alarms must be tested separately, when applicable
Test Mains Off Alarm
Turn off mains on all rectifiers. Verify (Alarm Display) that both Mains Off Alarm and
corresponding alarm relay (if configured) are activated. Note that there is an alarm
delay until all the rectifiers are shut down.
Turn the mains on again and verify that the active alarm is automatically reset
If required: Test Low Battery Voltage Alarm
Select General Configuration in WinPower Gold and open Define Triggers menu.
Write down the low battery voltage value.
Set the minimum value for low battery voltage alarm higher than the actual output
voltage. Exit by pressing OK button
Observe that the low battery voltage alarm and the corresponding alarm relay are
triggerd.
Set the minimum value back to original number.
If required: Test High Battery Voltage Alarm
Select General Configuration in WinPower Gold and open Define Triggers menu.
Write down the high battery voltage value.
Set the maximum value for high battery voltage alarm lower than the actual output
voltage. Exit by pressing OK button
Observe that high battery voltage alarm and corresponding alarm relay are triggered
Set the maximum value back to original number.
Test Load Fuse Alarm (on MCB's )
Turn OFF one of the load fuses (NB: there must be a fuse connected to a load).
Observe that the load fuse alarm appears in the Alarm Display and the corresponding
alarm relay (if configured) are activated.
Test Load Fuse Alarm (on blade fuses)
Remove a blade fuse, which is connected to an output with a load already connected,
and observe that the load fuse alarm and corresponding alarm relay (if configured) are
activated.
Test Battery Fuse Alarm (on blade fuses)
Operate one of the micro switches located on top of the blade-fuses, and observe that
the battery fuse alarm appears in the Alarm Display and corresponding alarm relay (if
configured) are activated.
Test Rectifier Communication Alarm
Turn off the mains breaker
Remove rectifier no.1 from its position in the rack shortly after turning off the mains
breaker.
Observe that a rectifier communication alarm is activated in AEON Gold
Return rectifier no.1 back into position and turn on the mains breaker
Test Rectifier Common Alarm
Switch of the mains breaker to rectifier no.1.
Observe that a rectifier common alarm is activated in AEON Gold
Turn on the mains breaker again
Test LVBD NOT APPLICABLE
Select the General Configuration Menu in WinPower.
Select Relay Test, and then select LVBD Relay.
Observe that the LVBD is deactivated (you will hear a distinct click as the contactor
operates)
Operate the Service Switch and observe that the LVBD is activated again. Return the
Service Switch to the normal position.
Select the LVBD Relay again, in order to reset the LVBD Relay.
Test LVLD NOT APPLICABLE
Select General Configuration menu in WinPower Gold
Select Relay Test tab, then select LVLD Relay
Observe that LVLD is activated (only when LVLD is NC)
Observe that the LVLD is deactivated when exiting the Relay Test Menu

Normal Operation
Check that the system is operating without any faults.
Select the General Configuration Menu in Winpower
Select Event Log and erase all events stored in the log.
Comments:
APPROVAL
Engineer, sign.: Date: Approved by Customer, sign.:
Procedure 13 Test record of System Alarms & Options
3.2.7Battery current Calibration

Reset Service switch Heartbeat LED
button ON/OFF LED
Jumper for Switch for service Calibration output,

configuring Relay 10 configuration 60 mV
Figure 1 Section of AEON Gold control unit part number 240278.185
Calibration of battery current measurement is normally done during FAT (factory acceptance
test). However, re-calibration may be necessary after installing the system. This recalibration
is not easily performed because it requires a certain amount of available load current,
preferably more than 30 % of the current rating of the shunt. To ease recalibration AEON
Gold has a 60 mV precision output called Cal output 60 mV. High calibration point will
then be the current that corresponds to 60 mV on the shunt, and be equal to the shunt rating.
In other words, if the shunt gives 60 mV at for example 2000 A the high calibration point is
2000. To recalibrate in this way, remove the current sensing on TB2, pin 6(+) and pin 7(-).
Calibrate the low calibration point at 0 A when the cables are short-circuited, then connect the
60 mV outputs left pin to TB2 pin 6 and the right one to TB2 pin 7. Calibrate the high
calibration point at the corresponding current. Remember to reconnect the wires from the
shunt after calibration.

3.3 System Configuration Record

The System Configuration Record is essential for future reference and efficient service.
3.3.1System data
Supplier's Order no.: System model AEON Gold Measured Mains
Voltage:
Serial no.: No. of Power Racks: Software version of No. of Modules:
AEON Gold:
Mains configuration
Verify that the system is correctly configured:
400V, 3P and N 400VAC, 3P and N, dual input
230VAC, 3 phase 230VAC, 3 phase, dual input
LVBD LVLD Symmetry Modem Temp. Compensation
Alarm
YES YES YES YES YES
NO NO NO NO NO
Other configurations, specify:
Procedure 14 System Configuration Record of System Data
3.3.2Batteries
Battery Manufacturer:
Recommended Float Charge Voltage, at Battery Type: Cell Slope Voltage
20C(68F) (mV/C): (systems with
Measured Float Charge At_____C temperature
Voltage compensation only)
Measured ambient Battery Capacity No. of battery Battery Fuse(s)

battery banks.
temperature:_________
C
Procedure 15 System Configuration Record on Batteries
3.3.3Saving Configuration Data

Eltek has developed a filing system in WinPower Gold that enables storage of essential
configuration data on a
text file. We recommend that the following data is stored together with the System
Configuration Record sheet:
Alarm System Configuration

Symmetry Alarm Configuration
4 Drawings
4 Drawings
The following example drawings are enclosed:
No. Name Drawing no. Revision

1 Assembly drawing TE 39146-E3 1
2 Block Diagram AEON 4000 TE 38603-A3 1
3 Schematic AEON 4000 with int. TE 38841-A3 3
distribution
4 General Arrangement 1PR 42U TE 38897-N3 1
5 General Arrangement 2PR 42U 1005120 1
6 General Arrangement 2PR 42U 1005392 2
Table 12 Enclosed Drawings

4 Drawings
Drawing 1 Example of Assembly drawing (Art. No. TE 39146-E3)
4 Drawings
Drawing 2 Block Diagram AEON 4000 (Art. No. TE 38603-A3)

Drawing 3Example of Schematic drawing for AEON 4000 with twoPRs and internal distribution (Art. No. TE38841-A3-3)
Drawing 4Example of General Arrangement 1PR 42U (Art. No. TE38897-N3)
Drawing 5 Example of General Arrangement 2PR 42U (Art. No. 1005120)
Drawing 6 Example of General Arrangement 2PR 42U (Art. No. 1005392)
ELTEK Energy
P-O- BOX 2340 Stms
N-3003 DRAMMEN
NORWAY
Phone: +4732203200
Telefax: +47 32203210
Internet: http://www.eltekenergy.com
e-mail: eltek@eltekenergy.com

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Installation & commissioning

AEON 4000 PRS

1 Installation of the Rectifier Systems ........................................................... 4

3.3.1 System data....................................................................................................... 36

Installation & commissioning, AEON 4000, Art. No.356940.033, v2,2006-06 3(44)

1 Installation of the Rectifier Systems

Cabinet size Distance

5 The floor construction must be capable of supporting the load.

1.3 Recommended tools

5 All tools must be insulated

Installation step Comments OK

1 REMOVE PACKAGING Check that the equipment received corresponds

3 SAFELY STORE ANY These items will be required for later

1.5 Mechanical installation

1 POSITION THE CABINETS IN Refer to the DC equipment arrangement and

2 REMOVE THE CABINET TOP Required for accessing the connection

Installation & commissioning, AEON 4000, Art. No.356940.033, v2,2006-06 5(44)

Procedure 2 Mechanical Installation

1.6 Earth Connections

Pre wired earth

Figure 1 Protective earth terminals

Figure 2 Wire to cabinet earth

1.7 DC Load cable connections

Installation & commissioning, AEON 4000, Art. No.356940.033, v2,2006-06 7(44)

Connection points for large

Figure 4 Example of blade fuses

Fuse type Max. size load or battery cables Bolt size

MCB 16 mm2 (6 AWG) None

Table 2 Normally used DC load fuse and cables

Installation Step Comments OK

1.8 AC Mains cable connections

Figure 5 Example of AC mains connection

Installation & commissioning, AEON 4000, Art. No.356940.033, v2,2006-06 9(44)

; Always switch OFF the external mains supply before connecting

Installation Step Comments OK

1. VERIFY WHICH MAINS Compare the mains label inside the

IF NECESSARY, RECONFIGURE If the supply is 3 x 230 VAC the neutral

Procedure 4 Installation Step for AC Mains cable connections

Size of mains 3-phase 400 3-

1-6 RECTIFIERS 70 mm2, (2/0 AWG)

19 24 RECTIFIERS 120 mm2, (4/0

Recommended fuse rating are based on Siemens 3VF fuses.

1.9 External Battery connections

9 Before connecting batteries: Remove all metallic objects such as rings,

; The battery fuse rating must be dimensioned in accordance to the size

Negative Load Positive Load

Installation Step Comments OK

1. VERIFY THAT BATTERY

4. CONNECT SYMMETRY Choose between connecting wires to each 12V

Installation & commissioning, AEON 4000, Art. No.356940.033, v2,2006-06 11(44)

BATTERY STRINGS IF mid- point. For details see chapter 1.9.1.

Procedure 5 Installation Step for external Battery cable connections

1.9.1Symmetry Wire Connections

Centre point monitoring of up to 4 parallel battery strings

48Vdc Battery String

Figure 7: Block Monitoring of 48Vdc battery

1.10 Installation of SMPS 4000 in an AEON 4000

Installation of SMPS 4000 modules

Installation Step Comments OK

1. OPEN THE DOOR IN FRONT

2. PLUG IN THE NEW SMPS

4. START UP THE RECTIFIER The startup procedure is a part of the

; For safety reasons, blind panels must be mounted in all spare