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FIRSTLINE P Voltage/Frequency Converter 52.5 to 100kVA USER MANUAL 003-2532 Rev H...
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No reproduction of any part of this manual, even partial, is permitted without the authorization of Staco Energy Products Company. The Staco Energy Products Company reserves the right to modify the product described herein, in order to improve it, at any time and without notice.
Safety Warnings IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS This manual contains important instructions for Models 65-125kVA FIRSTLINE P series Voltage or Frequency Converter that should be followed during installation and maintenance of the unit. Please read all instructions before operating the unit and save this manual for future reference.
DANGER This unit contains LETHAL VOLTAGES. All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside the unit. WARNING To reduce the risk of fire or electric shock, install this unit in a temperature and humidity controlled, indoor environment, free of conductive contaminants.
Symbols used in the Manual In this manual, some operations are shown by graphic symbols to alert the reader to the dangerous nature of the operations: Danger / Risk of Electric Shock This symbol indicates possibility of serious injury or substantial damage to the unit, unless adequate precautions are taken.
Table of Contents Applicability .............................. iii Safety Warnings ............................iii Emergency Interventions ......................... iv First aid interventions ........................... iv Firefighting measures ........................... iv Symbols used in the Manual ........................v Protective Equipment ..........................v General Precautions ..........................v 1. Layout ..............................1 1.1 Views ..............................
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C.5.1 RJ45-flat-adapter signals parallel card.................. 57 C.5.2 Single unit Configured in Parallel ................... 57 C.5.3 Two Unit’s in Parallel ......................58 C.5.4 Three Unit’s in Parallel ......................58 C.6 Parallel Start-up procedure ......................59 C.7 Parallel Communication Troubleshooting ..................60 C.7.1 Normal Condition ........................
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Figures Figure 1 - Cabinet front view ........................1 Figure 2 – Single Input 1-Line (Batteries are optional) ................5 Figure 3 – Bottom Cable Entry Layout ..................... 6 Figure 4 – 65-80kVA Power Connection Terminals .................. 7 Figure 5 – 100-125kVA Power Connection Terminals ................8 Figure 6 –...
1. Layout 1.1 Views Figure 1 - Cabinet front view A - Control panel with graphic display B - Door handle C - Ventilation grilles D - Communication area E - Front Cover panel with ventilation grilles F - Switch cover panel G - Door 1 - SWIN: Input bypass switch 2 - SWOUT: Static switch output...
1.2 Preliminary Operations 1.2.1 Removing the Packaging and Positioning the Device On delivery, the packaging must be inspected to ensure that it is whole and that it has not been crushed or dented. Check in particular that neither of the two impact resistant devices on the packaging is red; if one of them is red;...
DANGER In order to avoid the risk of the device overturning, ensure that it is firmly secured to the fork-lift truck by means of appropriate ropes before moving it. When being moved the cabinet should be handled with care; shocks or drops can damage it. Once in position, remove the packaging carefully in order not to scratch the device.
2. Installation Check the Safety Instructions. • Any incorrect connection or handling may cause damage to the Voltage/Frequency Converter • and/or the loads connected to it. Read these instructions carefully and follow the steps indicated. This system must be installed by a qualified electrician. •...
2.2 Single Module Configuration The unit is designed to work as a Single input Unit. Figure 2 – Single Input 1-Line (Batteries are optional) 003-2532 REV H Page 5...
2.3 Cable Entry The cables can enter in the unit from the bottom or from the top with the optional (Top Entry Cabinet) Proceed as follows in order to open the unit 1. Open the door 2. Remove the switch cover panel 3.
2.4 Connect of Power Cables Connect the input, output and battery cables to the terminals as shown in Figure 4 and Figure 5: Figure 4 – 65-80kVA Power Connection Terminals For the Input, Output and Battery connections, follow the order from the top to bottom, or right to left, as described in the boxes.
Figure 5 – 100-125kVA Power Connection Terminals For the Input, Output and Battery connections, follow the order from the top to bottom, or right to left, as described in the boxes. The label marked “N” present on the terminal identifies the neutral terminal.
2.5 Differential (GFI) If the system protection against electric shock uses a differential current device (Ground Fault Interrupter), it will have to have the following characteristics: Sensitivity 300mA • Sensitive direct current and unidirectional components (class A or class B) •...
2.7 Connection of Signals and Remote Commands In order to access the interface cards, open the door and remove the protection panel secured with screws (K) as shown in the drawing: Figure 7 – Signals and Remote Command Connections Table 1 - Torque specifications for terminal blocks on customer interface board AWG Wire size range Torque Load #22 -12AWG...
2.7.1 Remote Commands, Alarms and EPO The card is equipped with a terminal board with 14 positions. Power Supply - 1 power supply 12Vdc 80mA (max.) [Pins 10 and 11]; Alarms - 3 potential-free change-over contacts for alarms (they are capable of switching up to 30 V AC or DC at UP to 1 A);...
2.7.2 RS232-1 and RS232-2 (2) DB9 connectors are available for RS232 connection. The factory-set transmission protocol is: 9600 baud, -no parity, -8 bits, -1 stop bit. The transmission speed may be varied from 1200 to 9600 baud, using the PERSONALIZATIONS menu on the CONTROL PANEL.
2.7.3 SLOT 1 and SLOT 2 Following Cards May be Inserted (Optional): NetMan 102 Plus (on SLOT 1 main or SLOT 2 aux) Device for management of the systems on the Ethernet. It can send information on the status of the device with various protocols: •...
2.7.7 Optional Battery Temperature Sensor The system has a connector for connection of the kit, which consists of a sensor to be placed inside the battery cabinet. The use of the temperature sensor allows the system control logic to regulate the values of the charge and maintenance voltage according to the working temperature of the battery.
3. Operation It is critical that the following procedure be followed in the sequence given. Figure 11 – Single Input 1-Line (Batteries are optional) 3.1 Start up 3.1.1 Before Start Up 1) Verify that all the connections have been made correctly and are sufficiently tight, following the labeling of the phase rotation sequence.
Multiple Battery Disconnect If multiple battery cabinets are present, all breakers must be closed within one minute after the BATTERY CHARGE OFF message appears. If this time constraint is a problem, do the following: 1. Disable the automatic battery test by pressing button 3 then 5 on the control panel, followed by entering the code 323232.
4. Control Panel and Display 4.1 Signal panel functions Figure 12 – Signal Panel F1, F2, F3, F4, F5, F6, F7, F8 = FUNCTION KEYS. The function of each key is shown at the bottom of the display and it varies according to the menu. EPO = Emergency Power Off button.
Indicator Symbol Color Function State Meaning N.A. N.A. N.A. (NOT USED) Mains is present and correct Mains line Green Flashing Mains is present but not correct indicator Mains is not present When the battery is supplying the load Battery The "LOW VOLTAGE ON BATTERY PRE-ALARM" Yellow powering the Flashing...
4.2 Graphic Display A wide graphic display is present on the unit door, which allows the user to have a close-up; detailed overview in real time of the status of the system The user can switch the unit on and off, consult electrical mains, output, battery measurements etc.
4.3 Basic menu (text lines area) If no commands have been inserted, the first text line shows messages to inform about status of operation. In each operating condition, the display returns to the "basic menu" after two minutes from the last command.
4.3.2 The Second Line of the Basic Menu The second line displays the main operating values about system, output load, battery, buzzer and alarm message number. U100A indicates an unit model with 100kVA rated power, operating with 60Hz output frequency. •...
4.4 Language setting menu (keys 1, 1) From the key’s menu, press 1 twice to access the languages menu. The following languages are available: o Italian, o Polish, o English, o Hungarian, o French, o Turkish, o German, o Czech, o Spanish, o Russian, o Dutch,...
4.5 Measurements menus (key 2) The measurements with two line displayed, are selected from the basic menu by pressing key 2 Batt Out Batt • IN=100,100,100%V, 60.2Hz Measurement of the three voltages, neutral phase and input frequency. The voltage is indicated as a percentage of the rated voltage; for example 100% is equivalent to 277V.
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Batt BATT=xxxV Battery voltage value; • +0.0A Battery current, positive with Battery discharging, negative with battery charging; • i=230,230,230Vln Inverter output voltage; • yyyVdc Input inverter DC voltage • Ts=28, Tr=50, Ti=49, Tb=25; Temperature of the system, and of the rectifier and inverter •...
4.6 Full page Measurements and output waveforms (key 2, 7) The full-page measurements and output voltage and current waveform are selected by pressing key 7 from the two line measurement menu. Basic Menu IN=100,100,100%V;101,101,101%A;60.0Hz [ 200kVA 277V 3L 60Hz [ 9:19:41] __________________________________ [1;...
4.7 Controls Menu (key 3) BATTERY TEST Menu 3, 2 Keys 8 and 7 to increase and decrease DISPLAY CONTRAST: 6 the contrast. ADJUSTMENT: 7=-, 8=+ Menu 3, 5 Code ? ………………. 2=BATTERY TEST 4=DISPLAY CONTRAST 5=PERSONALI 7=TOTAL BLOCK TOTAL BLOCK Menu 3, 7 4.7.1 Battery Test (Keys 3, 2) This activates the cycle to check the state of the battery, which lasts 8 seconds.
Disabling the BATTERY TEST: 1. Press keys 3, 5: “CUSTOMIZING”, 2. Insert code 323232, with battery test disabled the code o=02 will be shown in the basic menu of the display. 3. To reactivate the test, insert code 323232 again. 4.7.2 Customizing The "CUSTOMIZING"...
4.7.2.1 Entering Customized Code Keys menu 3, 5: CODE 436215 The code is no longer required for 2 minutes after it has previously been inserted. The next menu can only be accessed by inserting the correct code, otherwise it returns to the basic menu.
4.7.2.3 Battery Press the following sequence of keys to access the menu: 1. 3 2. 5 3. 436215 4. 3 On initial installation the rated capacity value of the connected battery must be inserted; this value is usually printed on the battery container. It is important to insert the correct battery capacity value since this value is used by the system logic to calculate the backup time.
4.7.2.5 Two-Level Charging This type of recharging is effected with two current levels (EN 50272-2); the first phase comprises rapid charging (U1) with limited current, while in the second phase charging is with float voltage (U2). This type of recharging may be configured on site and is mainly used for special type batteries such as open vase and NiCd .
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Type “0” Battery With the battery set to type 0, the following menu is displayed: When key 4 is pressed, the program proposes the setting of the three voltage values. With the three factory preset voltage values, the display panel may indicate an incorrect backup time during discharge.
Vmin Minimum voltage value (end discharge battery), point of intersection with the dashed curve • (if this value is lower than Vmin* set up Vmin=Vmin* (2).[the value must be multiply for 40, number of batteries] Vp Battery voltage with discharge at 90% of the total time (3). •...
4.7.2.8 MODEM Set-up Press the following sequence of keys to access the menu: 1. 3 2. 5 3. 436215 4. 7 5. 4 Press key 1 to exit the menu. Keys 7 and 8 can be used to decrease or increase the control value for management of the modem. The choice is between the values of 0 to 5.
4.7.2.9 "Dial /Send" MODEM Press the following sequence of keys to access the menu: 1. 3 2. 5 3. 436215 4. 7 5. 4 6. 5 (6) Press key 1 to exit the menu. Keys 7 and 8 can be used to decrease or increase the figure on which the cursor is positioned. The cursor is moved by means of keys 2 and 3, and is indicated initially by the character '_'.
4.7.2.12 IDENT Press the following sequence of keys to access the menu: 1. 3 2. 5 3. 436215 4. 7 5. 7 Press key 1 to exit the menu. Keys 7 and 8 can be used to decrease or increase the number used for the identification of a single unit in systems with several units connected to a single RS232 serial line.
4.7.3.1 Recorded Voltages Measurements Press the following sequence of keys to access the menu: 1. 4 2. 2 3. 2 4. 2 The "RECORDED VOLTAGES MEASUREMENTS" menu is accessed via key 2 (press 2 again to access the other measurement menus from menu 4 "RECORDED EVENTS" or menu 4, 6 "RECORDED CODES"...
4.7.5 "Clock": Date/Time (key 6) Press the following sequence of keys to access the menu: The "DATE/TIME" menu is accessed via key 6 from the basic menu. The display shows the current contents of the internal calendar and clock with the following format: DATE/TIME = ymd/h = years, months, days / hours, minutes, seconds.
5. Maintenance The Frequency Converter is designed and produced to last a long time, even in the most severe service conditions. It should be remembered however that this is electronic power equipment, which requires periodic maintenance. Moreover, some components have a limited lifespan and as such must be periodically checked and replaced should conditions so dictate: in particular the batteries, the fans and in some cases the electrolytic capacitors.
Warning If the batteries need to be replaced, this must be done by factory authorized personnel. The replaced parts must be sent to a specialized company for disposal by means of recycling. Batteries are classified by law as “toxic waste”. 5.4 Recommended Replacement Intervals The Staco system has a long design life.
6. Specifications 6.1 Voltage Converter Electrical Specifications Voltage Converter Models 52.5kVA 65kVA 80 kVA 100 kVA INPUT RECTIFIER Rated Voltage 480Vac 3-phase Rated Voltage Tolerance w/o Contrib. of Battery -10%, +15% @100% Load Voltage Tolerance In Battery Mode or light Load -40%, + 15% Input Frequency Tolerance [Hz] 45 to 65...
6.2 Frequency Converter Frequency Converter Models 52.5kVA 65kVA 80 kVA 100 kVA INPUT RECTIFIER Rated Voltage 480Vac 3-phase Rated Voltage Tolerance w/o Contrib. of Battery -10%, +15% @100% Load Voltage Tolerance In Battery Mode or light Load -40%, + 15% Input Frequency Tolerance [Hz] 45 to 65 Power Factor at Rated Voltage (400 V) and...
6.3 Environmental Requirements Rated Ambient Temperature 32 - 104°F (0 - 40°C) Maximum Temperature for 8 hours a day 104°F (40°C) Average Temperature for 24 hours 95°F (35°C) Recommended Battery Temperature 68 – 86°F (20 - 30°C) Humidity <95% (without condensing) Up to 3280ft.
6.4 Rated Currents Warning To reduce the risk of fire, connect only to a circuit provided with branch circuit protection with maximum current rating per the table, below, in accordance with the National Electrical Code, ANSI/NFPA 70. Use at least 75 C rated copper wire.
6.5 Torque specifications Bolt Size Torque Load 10 lbf-ft 13.5 Nm 22 lbf-ft 30 Nm ½ 37 lbf-ft 50 Nm Appendix A – Alarms Below is a list of the alarm messages that are shown on the first line of the display panel, the “A=” column shows the number that is also displayed on the right in the lower row.
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EVENT MESSAGE DESCRIPTION OUTPUT OFF, CLOSE Alarm when there is no output voltage because SWOUT is open SWOUT Alarm present when the command for total shutdown from the panel or through the RS232 connection, COMMAND STORED, has been initiated. The system executes the shutdown command with a few seconds’ delay SYSTEM OFF COMMAND to allow for cancellation.
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EVENT MESSAGE DESCRIPTION INSULATION The external optional dc output insulation checking device, detected the LOSS D.C. DC insulation loss. Motor Generator parallel Optional operation mode (rem.com) NOT USED Inverters OFF The inverters are commanded to be OFF from an external command 003-2532 REV H Page 48...
Appendix B - Optional remote commands Technical support personnel may modify the COMMAND that can executed from the standard “INV.OFF” remote input or from the optional remote input/output card. Name Description Typical application Disables the recharging of the battery, keeping the When there is a generator, this recharge current to a minimum, independently of the load.
Appendix C - Parallel Configuration C.1 Introduction Systems may be connected in a parallel configuration to increase both the reliability of the power supply to the load and the available output power. Up to 8 units can be parallel-connected. It is recommended to connect units of the same power.
C.2 Electrical System Set-Up All the information contained in the section on electrical system set-up in relation to the system remains valid with the addition of the information set out below. C.2.1 Input The instructions seen in the first part of the manual for a single unit remain valid; each unit must be protected with equivalent fuses or switches.
C.3 Mains and Load Connections. All the information contained in the section “Mains, load and battery connections” (see Section 2.4 Connect of Power Cables) in relation to the unit remains valid with the addition of the information set out below. Refer to the Electrical Connections (see Section 6.4 Rated Currents) of this manual for information on how to size the cables for each unit.
C.4 Installing Parallel kit If the modules were ordered from the factory as Parallel units, this skip to section C.5 Connection of Signals Read the instructions carefully before carrying out installation. All maintenance operations inside the system must be carried out only by trained personnel. Switch off all the unit before carrying out the following procedures High voltages are present inside the unit when the input and battery switches are open.
C.4.1 Parallel Card Installation 1. Open the unit doors 2. Place and fix the new card (position 8) on the unit door as shows in the picture. Figure 18 – Parallel Card Installation 003-2532 REV H Page 54...
C.4.2 Parallel Card Connections 1. Connect the flat cable DB9(present in the unit) to the connector J2 in the parallel card 2. Insert the supplied connector (05 position) in J1 of the parallel card 3. Connect the flat cable supplied (04 position) from the connector J3 in the parallel card to the connector J2 in the system card System Card Flat DB9 Cable...
C.4.4 Parallel Card RJ45 Connections Connect the flat cable (present in the unit) to the connector J4 in the parallel card RJ45 Flat Cable Figure 21 – Parallel Card Flat Cable Installation C.5 Connection of Signals The signals of several parallel unit’s are connected in a closed loop configuration; if the loop is interrupted at any point, either due to a fault or for maintenance, operation of the system is not compromised, and the system continues to operate normally, as will be shown repeatedly below.
C.5.1 RJ45-flat-adapter signals parallel card. The unit may be provided with one of two versions of the parallel card which differ in the type of switch used (type 1 or type 2). The difference between the two switches is the position of the control lever.
C.5.3 Two Unit’s in Parallel A. PARALLEL CABLE B. RJ45 type connector C. RJ45-flat-adapter signal parallel card D. Unit1 LED on, Unit2 LED off E. SW1 in start position on Unit1, SW1 in cont position on Unit2 Two RJ45 cables are required despite redundancy. System will not start up unless two cables are installed.
Figure 26 – Parallel Connection – Three Modules To add other parallel Unit’s, a “PARALLEL CABLE” must be added for each new unit connected. Danger The signal connection must not be removed when one unit is shut down C.6 Parallel Start-up procedure For each system, follow the start-up single unit procedure.
C.7 Parallel Communication Troubleshooting For the sake of simplicity, the instructions shown below refer to a system with three Unit’s, but are equally valid for more complex systems. C.7.1 Normal Condition 1) Normal operation, Master unit 2) Normal operation, Slave unit 3) Normal operation, Slave unit A - Parallel Cable C.7.2 Single Opened Parallel Cable...
C.7.3 Multiple Opened Parallel Cable The signal cables between 1, 3 and 2, 3 are opened. 1) Normal operation, Master unit with message “Parallel signal cable fault” on the panel 2) Normal operation, Slave units with message “Parallel signal cable fault” on the panel 3) Disconnected (TLI open, SCRs off), Slave units with message “INTERNAL FAULT 10”...
1) Insert the new unit (power connections in the distribution panel) and keep it switched off. unit 3: SW1 cont. position 2) Remove adaptor B and insert the new unit instead of the adaptor. 3) Now switch on unit 3 (the added unit). 4) With the lever of SW1 in the start position in one unit only and the lever in the cont.
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3) Check that all the units are operating normally and that the system is sharing the output power. 003-2532 REV H Page 63...
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