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Flexi Power Rectifier FPRB CS7000030

Battery
Management
Manual
Flexi Power Rectifier
CS7000030
FPRB

Manufactured by: Artesyn Embedded Technologies


Manufacturing PN: AA27540L
Visit us @: www.artesyn.com

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Flexi Power Rectifier FPRB CS7000030

History:

Date
Version Author Change Notes
DD.MM.YYYY
30.10.2013 AA Ferdinand Sisracon Creation of document for Flexi Power
Rectifier
30.06.2014 AB Alex Ding Change the brand from Emerson Network
Power to Artesyn Embedded
Technologies

Author:

Ferdinand Sisracon
e-mail: Ferdinand.Sisracon@Artesyn.com

Abbreviations:

tbd to be done
GUI Web-based User Interface
DDU DC Distribution Unit
PDA Power Distribution Assembly
MAC Media Access Control
SNMP Simple Network Management Protocol
Genset Generator Set
IP Internet Protocol
LCD Liquid Crystal Display
CU Control
PID Product Information Data
VPN Virtual Private Network

Related Documents:

FPRB User Manual Rev AF by Ferdinand Sisracon: A “how to use” and “how it works” for the Web-
based User Interface and for the LCD Front-Panel Display of the Flexi Power Rectifier system

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Flexi Power Rectifier FPRB CS7000030

Content

Battery Management Manual ................................................................................................................... 1


FPRB ......................................................................................................................................................... 1
1 Overview ........................................................................................................................................ 4
2 Battery Charge / Discharge Concept ............................................................................................. 5
3 Flexi Power Rectifier System Sample Configuration ...................................................................... 7
3.1 Start-up .................................................................................................................................... 7
3.2 Idle/Charge Off......................................................................................................................... 7
3.3 Discharge/Boost Discharge ...................................................................................................... 8
3.4 Charge / Boost Charge ............................................................................................................. 8
3.5 Battery Test .............................................................................................................................. 9

Table of Figures

Figure 2-1 Battery Charge and Discharge Concept ................................................................................ 5

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Flexi Power Rectifier FPRB CS7000030

1 Overview

This document is a “how to use” and “how it works” for the battery management of the Flexi
Power Rectifier system.

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2 Battery Charge / Discharge Concept

Figure 2-1 Battery Charge and Discharge Concept

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Flexi Power Rectifier FPRB CS7000030

The Battery state machine mainly consists of five different parts:

1. Initial Charge/Charge Start: after start-up the system is in initial charge state. This
state guarantees fully charged batteries before changing to the default operational
state. During this time it is not possible to start a battery test. The duration for the
initial charge time is user settable and can be changed under “System Related
Settings” – “Start Charge Time. It is not possible to stop the initial charge cycle in
order to start a battery test, but it is possible to schedule a battery test, which starts
directly after the initial charge.

2. Charge Off State/Idle State: this is the default operational state. This is the only
state, which allows starting a battery test.

3. Battery Test: battery test is a simulated AC-Fail/Discharge State. After a battery test
the system will change to discharge state in order to recharge the batteries.

4. Discharge State: Discharging more than 1% and less than 10% of total battery
capacity will result in the Discharge State. If AC is back before discharging more than
10% of total capacity the batteries will be recharged without boost voltage. The
duration for the recharge is user settable and can be changed under “System Related
Settings” – “Charge Time.

5. Boost Discharge State: Discharging more than 10% of total battery capacity will
result in the Boost Discharge State. After AC is back the batteries will be recharged
with boost voltage. The duration for the boost recharge is user settable and can be
changed under “System Related Settings” – “Boost Charge Time” Manual Boost
Charge State: A manual started Boost Charge can be performed during a normal
charge or during Charge Off State.

Note:

 State changes from “Charging States” or “Charge Off State” requires a discharge of more
than 1% of overall battery capacity. Depending on the overall battery capacity which may
take several minutes.

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Flexi Power Rectifier FPRB CS7000030

3 Flexi Power Rectifier System Sample Configuration

For a better understanding of the overall battery handling the complete process will be
discussed with the help of an example system:

 200Ah Battery Block – 50% charged at start up


 -53.5V for set Voltage
 20A charge limit
 20A load
 no battery test scheduled
 2h initial charge time
 2h recharge time
 3h Boost charge time

3.1 Start-up

During start-up the System operates in the initial charge (also called start charge) cycle:

1. Lowers the System Voltage down to –44V


2. Increase Voltage until the Battery Voltage is reached
3. Increase Voltage until the charge limit is reached → This state is called “constant
current”
4. During charging batteries the voltage is raising until the set Voltage of –53.5V is
reached (without violating the charge limit) → changing to state “constant voltage”
5. Stay for 2 hours (initial charge time) in constant Voltage
6. Switch to Idle (also called Charge Off) state

The initial charge guarantees fully charged batteries before switching to the “normal” operation
state. This allows a much more accurate handling of batteries during the normal system
operation. During start up/initial charge it is not possible to start a battery test. It is also not
possible to cancel or stop the initial charge.

3.2 Idle/Charge Off

The normal operation state is called Idle or Charge Off State. This is the only state, which allows
battery tests.

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3.3 Discharge/Boost Discharge

If the AC fails and batteries are discharge for more than 1% of their capacity (2Ah for the
example system) the system switches its state to Discharge:

1. AC-Fail
2. Discharge Batteries for more than 1% of their capacity
3. Switch to Discharge State
4. 30min discharge (5Ah discharge) →system 4. 3hours discharge (60Ah discharge)
Voltage follows the battery Voltage →system Voltage follows the battery
Voltage
5. Stay in discharge state 5. Switch to boost discharge state

If the discharge is greater than 10% of the overall capacity of the batteries the system will switch
to boost discharge state.

3.4 Charge / Boost Charge

On AC back, the system will switch to the charge or boost charge state. This depends on the
state reached within discharge cycle.

1. AC back → switch to boost charge state 1. AC back → switch to boost charge state
2. Increase Voltage until charge limit is 2. Increase Voltage until charge limit is
reached → constant current reached → constant current
3. During charging batteries the voltage is raising until the Boost set Voltage of –54.5V
raising until the set Voltage of –54.5V is plus Boost Offset (user settable) is reached
reached (without violating the charge limit) → (without violating the charge limit) →
changing to state “constant voltage” changing to state “constant voltage”
4. Stay for 2 hours (charge time) in constant 4. Stay for 3 hours (boost charge time) in
Voltage constant Voltage
5. Switch to Idle (also called Charge Off) 5. Switch to Idle (also called Charge Off)
state state

If not required, the complete boost discharge and charge handling can be disabled. If
disabled, only the normal discharge and charge handling is used.

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3.5 Battery Test

A Battery Test simulates an AC fail and measures the related data:

 Test Start Time


 Test Duration
 Average Current
 Average Temperature
 Discharged Ah
 Test End-Voltage

With the measured data and the user provided test thresholds (Duration, Ah to discharge, Fail
Voltage, Warning Voltage) a result is calculated.

1. Start Battery Test


2. Rectifier Voltage is decreased down to –-40V → simulates an AC fail
3. From now on the handling (discharge and charge) is completely the same as if a real
AC fail occurs.

Since there is no difference in battery handling between a Battery Test and a real AC fail,
each AC fail triggers a Battery Test, a so-called AC-Fail Test. There is only one difference
between a real Battery Test and an AC-Fail Test: if the AC supply is back during an AC-Fail
Test, the test is countered as stopped with no valid result.

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