Conext™ Core XC ES and XC-NA ES Series Energy Storage ...

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Overview The Schneider Electric Conext Core XC ES and XC-NA ES Series Energy Storage Inverters are designed to manage the energy flow between the battery and the grid. The relationship between the inverter, battery, and grid is shown in Figure 1. Figure 1 Inverter operation The reference orientation in all drawings and equations will be that of a generator. Battery Voltage Limit The maximum DC voltage (Vbatt_max) is 850 V. The minimum DC voltage (Vbatt_min) is a function of the grid voltage magnitude (Vac) and the output reactive power (Q) as shown in the equation below: V batt_min V Vac Fac Q if Q over excited V Vac if Q V Vac Fac Q if Q under excited = 15 + 2 +3 >0( ) 15 + 2 =0 15 + 2 + < 0( ) 2 2 Where: n Fac is grid frequency in Hz n Q is reactive power level in kVAr Conext™ Core XC ES and XC-NA ES Series Energy Storage Inverter: Battery Interface Guide AP-XC-051 Revision C

Transcript of Conext™ Core XC ES and XC-NA ES Series Energy Storage ...

OverviewThe Schneider Electric Conext Core XC ES and XC-NA ES Series Energy StorageInverters are designed tomanage the energy flow between the battery and the grid. Therelationship between the inverter, battery, and grid is shown in Figure 1.

Figure 1 Inverter operation

The reference orientation in all drawings and equations will be that of a generator.

Battery Voltage LimitThemaximum DC voltage (Vbatt_max) is 850 V. Theminimum DC voltage (Vbatt_min) is afunction of the grid voltagemagnitude (Vac) and the output reactive power (Q) as shown inthe equation below:

Vbatt_min

V Vac Fac Q if Q over excited

V Vac if Q

V Vac Fac Q if Q under excited

=

15 + 2 + 3 > 0 ( )

15 + 2 = 0

15 + 2 + < 0( )

2

2

Where:

n Fac is grid frequency in Hz

n Q is reactive power level in kVAr

Conext™ Core XC ES and XC-NA ES SeriesEnergy Storage Inverter:Battery Interface Guide

AP-XC-051

Revision C

The battery open circuit voltagemust be inside the [Vbatt_min, Vbatt_max] interval regardlessof the state of charge (SOC) level. For best battery utilization, the expectedminimumdischarging voltage should be higher than Vbatt_min and the expectedmaximum chargingvoltage should be lower than Vbatt_max.

If theminimum discharge voltage is lower than Vbatt_min, the inverter will automaticallyreduce the power export and regulate the battery voltage to the Vbatt_min level.

Similarly, if themaximum charging voltage is higher than Vbatt_max, the inverter will reducethe power import and regulate the battery voltage to the Vbatt_max level.

DC Current and Battery Size LimitationThe inverter can export or import a maximum of 680 kW. Therefore, themaximum operatingcurrent at the DC terminals can be up to 1280 A. In addition to battery voltage compatibility,the second constraint affecting the battery selection is that the short circuit fault current(ISCDC) at the DC terminal be limited to 65 kA.

Typically, the highest short circuit current (Isc) is observed if the fault is as shown inFigure 2.

Figure 2 DC current and battery size limitation

In Figure 2, ISCDC is the critical fault current that needs to be limited to 65 kA.

ISCbatt is the partial short circuit current representing the contribution from the batteries andISC0 is the partial short circuit current representing the contribution of other devices orsources connected to the DC circuit.

Procedures for fault current calculations in DC installations are in IEC61660-1, IEC61660-2,and IEC61660-3. The equivalent inverter model used for this analysis is shown inFigure 3.

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Figure 3 Inverter partial short circuit contribution

Appendix A: Case Study—Fault Analysis in DC Installations on page 18 shows an exampleof how to use themodel in Figure 3 for DC-side fault current analysis.

Connecting Multiple Inverters to a Single BatteryMultiple inverters can be connected to a single battery (DC-side paralleling). However, aswith the single inverter case, the short circuit current exposure of each DC terminal mustnot exceed 65 kA.

Typically, the highest short circuit current is observed when the fault is located at point F1as shown in Figure 4. Fault F1models a short circuit condition inside an individual solidstate inverter.

Figure 4 DC circuit single-line diagram

Paralleling Inverters on the AC SideMultiple inverters can be connected to the samemedium voltage (MV) transformer if eachinverter has a separate and isolated low voltage (LV) winding. See Application Note:Medium Voltage Transformer Selection (AP-XC-048-EN).

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Figure 5 Connectingmultiple inverters

For details on the short circuit current indexes, see the Conext Core XC and XC ES SeriesShort Circuit Current Index Application Note (document number AP-XC-074-EN).

Inverter Controller and Battery Controller InteroperabilityThe XC ES and XC-NA ES inverters are primarily intended to be used with batteries thatinclude an integrated Battery Management System (BMS)1 . For a complete list of Modbuscommands, refer to theApplication Note: UsingModbus with Conext Core XC ES SeriesGrid Tie Photovoltaic Inverters (document number AP-XC-050-EN).

The "gateway" communication and interfacemodule translates the signals from the BMSinto commands that are compatible with the XC ES and XC-NA ES inverters. It alsocombines the commands issued by the Power Plant Controller (PPC). In the subsequentchapters, each inverter command that relates to battery operation and control will beexplained in detail.

Figure 6 BMS and PPC operation

1Somemanufacturersmay refer to the BMSasa BatteryManagementModule (BMM)

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Inverter State Machine for Battery Storage ApplicationsThe inverter state machine has three distinct states: disable, enable, and servicemode.

Figure 7 Inverter state machine

S11 = ENABLE STATE/DISABLE STATE switch

Transition from offline to online is subject to qualifying the following:

n Grid: The grid voltage and frequency must be within reconnect limits for the duration ofthe reconnect delay time.

n Battery:

l Themeasured voltage at the DC terminals must be within the operating limits ofthe inverter.

l Communication to the gateway must be continuous.

l Themain battery DC switch controlled by the BMS must be closed and thebattery must be in "run" condition (0xFA19=1).

n Inverter self check must be positive.

Once the grid, battery, and inverter self check are positively qualified, the inverter willautomatically transition from offline to online. If any of these elements are not qualified, theinverter will remain offline or if the inverter was online then it will transition to offline.

Summary: In order to be online, the inverter must continuously communicate with thegateway and the battery status must be in a "run" condition—battery status is updated bythe gateway based on BMS data. In addition to that, the voltage at the DC terminals mustbe within operating limits of the XC ES or XC-NA ES inverter.

Battery QualificationCondition to reconnect:

The condition to reconnect is:

max {Vbatt_min, Batt.LV Reconnect Threshold} ≤ Vbatt ≤ Batt.HV ReconnectThreshold.

See "Battery Voltage Limit" on page 1 for the Vbatt_min equation.The unit will reconnect ifthis condition is valid for the entire "Batt. HV/LV Reconnect Delay" interval.

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Condition to disconnect due to Batt. LV or HV

The unit will transition to Off or remain offline if Vbatt is less than "Batt. LV DisconnectThreshold" or Vbatt is more than the "Batt. HV Disconnect Threshold" during the entire "Batt.HV/LV Disconnect Delay" interval.

RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0xFB26 400 800Dynamicas perequation1

Batt. LV ReconnThreshold

Battery low voltage limit forreconnect

VDC/x1 uint16

0xFB0C 850 900 700Batt. HV ReconnThreshold

Battery high voltage limit forreconnect

VDC/x1 uint16

0xFB27 5 1200 0Batt. HV/LV ReconnDelay

Battery HV/LV error reconnect delay sec/x1 uint16

0xFB23 400 600 350Batt. LV DisconnThreshold

Battery low voltage error VDC/x1 uint16

0xFB03 885 950 750Batt. HV DisconnThreshold

Battery high voltage error VDC/x1 uint16

0xFB0D 1000 2000 500Batt. HV/LV DisconnDelay

Battery high/low voltage errordisconnect delay

ms/x1 uint16

Table 1 User settings for battery qualification

Gateway CommunicationThe gateway unit is a communication controller and a communication bridge between theBMS, PPC, and the inverter. Communication between the inverter and the gateway andbetween the BMS and the gateway is critical.

The inverter monitors the communication to the gateway by means of a gatewaycommunication watchdog.

The timing diagram of the watchdog procedure is shown in Figure 8. The inverter controllerwill read the content at the gateway Heart Beat (HB) register in regular intervals. The lengthof those intervals is determined by the gateway HB interval register. Subsequently, thepresent value of the gateway HB and the previous value of gateway HB are compared.

If the two gateway HB values are different, communication is considered "ok". The gatewayis expected to change the value of the gateway HB register at least once in between the tworead steps for the communication to remain in the "ok" status.

If the two gateway HB values are the same and they remain the same after a gateway retry,communication is considered as "failed" (gateway WatchdogOFFLINE).

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Figure 8 Watchdog timing diagram

If the gateway communication status is "failed", the inverter will transition to or remainoffline. If the gateway communication status changes from "failed" to "ok", the inverter willautomatically attempt to transition to online. This means that grid, battery, and inverter selfcheck qualifications are all "ok" and the user Enable/Disable command is in the Enablestatus.

RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0x403D 1 1 0 PLC WatchdogEnable or disable PLC watchdog0=Off, 1=On

enum uint16

0x403F 2 10.00 0.10 PLC Heart Beat IntervalPLC Heart Beat Interval inseconds

sec/x100 uint16

0x4040 2 10 0 PLC Heart Beat Retries PLC Heart Beat Retries integer uint16

Table 2 User settings for gateway communication

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Battery Status and Gateway State MachineThe battery status is passed from the BMS via the gateway to the inverter in the form of twoModbus register values. The inverter will consider the battery as being connected and inoperable condition if :

n register "Battery Group Status" = 1 (run)

n register "BMS Disconnect Command" = 0 (connect)

Figure 9 Software circuit diagram

These registers should be continuously updated based on data from the BMS. The initialcondition for the two registers (before communication with the gateway) is as follows:

n Register "Battery Group Status" = 0

n Register "BMS Disconnect Command" = 1

"Battery Operable" is an internal signal (nomodbus address) and the functionalityassociated with this signal is shown in Figure 9. If the signal "Battery Operable" = 0, theinverter will instantly transition to or remain in the offline state. Also, for the inverter to beonline or to transition to online state, the "Battery Operable" signal must be 1.

If the inverter is offline due to a BMS disconnect command, the status register 0x4054 willbe set to 1. This register status is used by the gateway to confirm that the inverter haschanged status in response to BMS disconnect command. The BMS can then open thebattery switch to avoid switching under load.

RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0x4053 False 1 0BMS DisconnectCommand

This is the request from the gateway todisconnect batteries.True=1, False=0

enum uint16

0x4041 0 600 0BMS ReconnectDelay

Debounce time to recover from BMSdisconnection when 0x4053 is set to"connect".

sec/x1 uint16

Table 3 User settings for battery status

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RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0x4054 Off 0 2Battery GroupStatus

Status of the battery group fromgateway0=Off, 1=Run, 2=Error

enum uint16

0x405A 0 1 0Authorization todisconnect battery

If the offline state was triggered by theBMS disconnect command, then0x405A will be set to True in order toindicate to the gateway that theinverter has responded to thecommand.0=False, 1=True

enum uint16

If BMS command changes from "disconnect" to "connect", the inverter will reconnect after adelay set by the 0x4041 register. If BMS command changes from "connect" to "disconnect",the inverter will disconnect immediately.

The battery contactor or switch (SW B) within the battery system (container) is monitoredand optionally controlled by the BMS.

Figure 10 Battery contactor SW B

There are cases when SW B needs to be open under load conditions (emergencydisconnect). However, if SW B is controlled by the BMS, the opening of this switch can besequenced such that it opens under no-load conditions.

In any case, the open/close status at SW B must be signaled to the gateway by the BMS. Ifthe gateway acknowledges that SW B is open, it must send a "Battery Group Status,0x4054" = 0 (off) to the inverter(s). When designing the gateway statemachine, refer to thetiming diagrams in Figure 11 andFigure 12.

Figure 11shows the timing diagram for the case where SW B is opened in a non-emergencymode (no load condition).

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Figure 11 SW B opened in non-emergency mode

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Figure 12shows the timing diagram for the case where SW B is opened under load—typically this would be in emergency conditions.

Figure 12 SW B opened in emergency conditions

Maximum Charging and Discharging Battery CurrentBMS can periodically adjust the limits for themaximum allowable charging current (IMR)andmaximum allowable discharging current (IMD). Those limits are passed via the gatewayto the inverter Modbus registers IMR and IMD. Figure 13 shows how the inverter ensuresthat the actual DC current will remain within the IMR and IMD boundaries.

Figure 13 IMR and IMD current limits

Modbus registers related to the charge and discharge current limits are:

n IMR = allowable charging current

n IMD = allowable discharging current

n η = efficiency

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If for any reason the inverter is asked to deliver power that would result in battery current inexcess of the [-IMR, IMD] interval, discharging or charging will be in constant current mode.Consequently, the output power will not match the requested dispatch value Pac_ref.

RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0x402D 1600 1600 0Maximum Discharge I(IMD)

Provide max. dischargecurrent

ADC/x1 uint16

0x402E 1600 1600 0Maximum Recharge I(IMR)

Provide max. charge current ADC/x1 uint16

0x402A 97 100 0 Conv - Eta Typical conversion efficiency %/x1 uint16

Table 4 User settings for maximum charging and discharging battery current

Constant Voltage Charging and Discharging ModeTypically in XC ES and XC-NA ES systems, the charging and dischargingmode will be inconstant powermode. For example, the utility or power plant controller sends the Pac_refdispatch signal and the inverter responds to this request.

As was shown in the previous chapter—Maximum Charging and Discharging BatteryCurrent, the output active power will match the Puser command as long as the batterycurrent is as follows:

−IMD < i < IMRbatt

If Pac_ref results in battery currents in excess of the [IMD, IMR] interval, charging ordischarging will be in constant current mode. Consequently, Pout is not equal to Pac_ref.Similarly, if Pac_ref results in battery voltages that are outside the [VMD, VMR] interval,charging or discharging will be in constant voltagemode (CV).

Where:

n IMD = maximum discharge current

n IMR = maximum charge current

n VMD = minimum discharge voltage

n VMR = maximum charge voltage

When in CV mode, battery voltage is actively regulated and the inverter output power willnot match the Pac_ref request. Parameters VMD and VMR are set by the gateway,according to data from the BMS. These parameters should prevent the batteries from beingover-charged or over-discharged. Figure 14 shows the DC operating point trajectory.

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Figure 14 Constant voltage charging and dischargingmodes

Regardless of active power requests, the inverter controls will ensure that the DC operatingpoints remain within the window shown in Figure 14 and defined by IMD, IMR,VMD, andVMR coordinates. Also, these parameters can be periodically updated via theModbus.

If the set level for VMD is below theminimum DC operating range (Vbatt_min) of the inverter,then VMD will be limited to Vbatt_min.

Figure 15 VMD limited to Vbatt_min

The same applies to VMR. If VMR is above Vbatt_max, then VMR will be limited toVbatt_max.

Figure 16 VMR limited to Vbatt_max

Vbatt_min is dynamically adjusted. It is a function of the grid voltage and the amount ofdelivered reactive power (Q).

For details on how Vbatt_min is calculated, see "Battery Voltage Limit" on page 1

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RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0x4038 850 10001 0V-Batt. ChargeRef. (VMR)

Regulated voltage above whichbattery will not be charged (float stateor constant voltage charging)

VDC/x1 uint16

0x4037 0 10001 0V-Batt. DischargeRef. (VMD)

Regulated voltage below which thebattery is not discharged (constantvoltage discharging)

VDC/x1 uint16

Table 5 User settings for constant voltage charging and dischargingmode

A typical charge current pattern in constant voltagemode is shown in Figure 17.

Figure 17 Typical charge current in CV mode

As can be seen, even after a long period of time the battery current will not reach 0 A. Somebatteries are sensitive and can be damaged from the continuous flow of a small residualcharge current.

To prevent this type of damage, the inverter will disengage the switching bridge if thecharging current drops below the IMRstop level. The resulting charging current will look asshown in Figure 18.

Figure 18 CV chargingmode

Since the battery is fully charged, the switching bridge will only be activated if the userpower demand is positive (user is requesting discharge): Puser>0. If IMRstop =0, thenprotection from residual charge current is deactivated.

A similar protection exists to protect the battery from residual discharge current. The CVdischarge waveform is shown in Figure 19. Discharging in CV modewill stop due to theswitching bridge being deactivated if battery current drops below the IMDstop threshold.

1Themaximum is effectively limited to "Batt.HVDisconn Threshold" (0xFB03). See Table 1.

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Figure 19 CV dischargingmode

If the bridge was deactivated due to the battery being empty, it will only be activated again ifuser active power reference is negative (user is requesting a charge): Puser <0. IfIMDstop=0, then protection from the residual discharge current is deactivated.

Over-charge and Discharge ProtectionsThe over-charge and discharge protective functions allow the user to protect the batteriesfrom being discharged below a certain state of charge (SOC) level or voltage level.Similarly, it will prevent the batteries from being charged above a certain SOC or voltagelevel. Figure 20 shows the logic diagram that illustrates how the "Batt Empty" flag is set.

The SOC parameter is continuously updated by the BMS via the gateway. The associatedSOC̱̱_L_set and SOC_L_rst are the threshold levels. Alternatively, the "Batt Empty" flagcan be set and reset based on internally measured inverter terminal voltage. The associatedthreshold parameters are Vbatt_L_set and Vbatt_L_rst.

Setting "Batt Empty" based on terminal voltage allows for a fast response time, regardlessof theModbus communication delays.

The effect of setting "Batt Empty" too high is that the inverter will only be allowed to absorbactive power. The timing diagram that explains this function is in Figure 20 and Figure 21.

Figure 20 Discharge protection logic diagram for "Batt Empty"

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Figure 21 Timing diagram for "Batt Empty" and "Batt Full" protections

Similar to the discharge protection, you can also set parameters and enable over-chargeprotection. The software circuit diagram that illustrates how the "Batt Full" flag is set andreset is in Figure 22. Adjustable parameters are SOC_H_set, SOC_H_rst, Vbatt_H_set,and Vbatt_H_rst. The effect when "Batt Full" = 1 is that the inverter can only discharge thebatteries. This is illustrated in Figure 21 and Figure 22.

Figure 22 Charge protection logic diagram for "Batt Full"

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RegisterAddress

DefaultValue

MaxValue

MinValue

Register Name DescriptionUnits/Scale

Type

0x402099%(ver 3.0)

150 -50 SOC High SetSOC level at which the battery FULLcondition is SET

%/x1 uint16

0x402195%(ver 3.0)

150 -50 SOC High ResetSOC level at which the battery FULLcondition is RESET

%/x1 uint16

0x40221%(ver 3.0)

150 -50 SOC Low SetSOC level at which the battery EMPTYcondition is SET

%/x1 uint16

0x40235%(ver 3.0)

150 -50 SOC Low ResetSOC level at which the battery EMPTYcondition is RESET

%/x1 uint16

0x4024 885 1000 0 Vbatt High SetBattery voltage level at which thebattery FULL condition is SET

VDC/x1 uint16

0x4025 850 1000 0 Vbatt High ResetBattery voltage level at which thebattery FULL condition is RESET

VDC/x1 uint16

0x4026 400 1000 0 Vbatt Low SetBattery voltage level at which thebattery EMPTY condition is SET

VDC/x1 uint16

0x4027 450 1000 0 Vbatt Low ResetBattery voltage level at which thebattery EMPTY condition is RESET

VDC/x1 uint16

0x402C 0.10 60.00 0.00Battery StateDelay

Debounce time for changing the batterystate to and from FULLorDebounce time for changing the batterystate to and from EMPTY

sec/x100 uint16

0x4028 0 680 -680 P_LSOCMaximum discharging power whenbattery is in EMPTY state

kW/x1 uint16

0x4029 0 680 -680 P_HSOCMaximum charging power when batteryis in FULL state

kW/x1 uint16

Table 6 User settings for over-charge and discharge protections

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Appendix A: Case Study—Fault Analysis in DC InstallationsA DC circuit consists of a single battery and three inverters connected to the battery (DCparalleling). The cable from the battery to the DC distribution bus bar is modeled with (R, L).Links from the distribution bus bar to the individual inverters aremodeled with(R1, L1), (R2, L2), and (R3, L3).

Each inverter is connected to theMV grid via a transformer and the equivalent inductanceand reactance at each phase is (RTX1, LTX1), (RTX2, LTX2), and (RTX3, LTX3).

The inverter model is shown in Figure 2 on page 2.

Figure 23 Case study—Model for fault analysis in DC installations

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Example of a fault analysis:

DANGERHAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE

The example below shows currents that exceed the battery prospective short circuit current

rating of 65 kA. Do not exceed the battery prospective short circuit current rating.

Failure to follow these instructions will result in death or serious injury.

n Battery open circuit voltage = VBattOC = 815 V

n Battery short circuit current = IBattSCmax = 80 kA

n R=0.15mΩ

n L=1 µH

n R1=R2=R3=1.5mΩ

n L1=L2=L3=10 µH

n RTX1=RTX2=RTX3=2.5mΩ

n LTX1=LTX2=LTX3=12 µH

n Grid line voltage = 220 V (line-to-line=380 V)

The AC circuit breakers are set to trip at 0.1 s and the DC circuit breakers are set to trip at0.2 s. The fault current at DC Terminal 1 is shown in Figure 23. The peak value is 83 kA andthe fault clearing is complete at 0.2 s after the fault onset.

Figure 24 DC terminal SC current under F1 fault

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Appendix B: AC Circuit Breaker Specifications

Interrupting Rating Code H2

Ultimate Breaking Capacity (kA) 50/60 Hz

220/415 VAC 100

440 VAC 100

525 VAC 85

690 VAC 85

1150 VAC -

Service Breaking Capacity % Icu 100%

Short-Time Withstand Current (kA)VAC 50/60 Hz, 1 s 85

VAC 50/60 Hz, 3 s 75

Built-In Instantaneous Override (kA ± 10%) 85

Close and Latch Ratings (kA) 50/60 Hz

220/415 VAC 96

440 VAC 96

525 VAC 81

690 VAC 81

1150 VAC -

Break Time ms 25

Closing Time ms <70

Endurance Rating (with no maintenance)C/O Cycles x 1000

Mechanical 10

Electrical 440 V 8

Electrical 1150 V -

Table 7 Masterpact AC NW20H2, 3 Poles

Long-TimeProtection

Current Settings (A)Tripping Between 1.05and 1.20 x Ir

Ir = In x ... 5.0A 0.40 0.50 0.60 0.70 0.80 0.90 0.95 0.98 1.00

Time Delay (s)

tr at 1.5 x IrAccuracy: 0 to -30%

12.5 25 50 100 200 300 400 500 600

tr at 6 x IrAccuracy: 0 to -20%

0.5 1 2 4 8 12 16 20 24

tr at 7.2 x IrAccuracy: 0 to -20%

0.34 0.69 1.38 2.7 5.5 8.3 11 13.8 16.6

Short-TimeProtection

Current Setting (A)Accuracy: ± 10%No Delay

Isd = Ir x ... 5.0A 1.5 2 2.5 3 4 5 6 8 10

Table 8 Micrologic 5.0A Trip Unit Settings

Note: Short time delay tsd and instantaneous pickup Ii are set toOff by default.

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Figure 25 Circuit breaker trip settings

Ir, tr = Long-time protection setting

Default settings:

Ir = 0.8 In

tr = 0.5 s

Isd = 1.5 x Ir

tsd = Off

Ii = Off

For more details, consult the data sheets for the following components:

n Masterpact AC NW20H2 3-pole, Fixed

n Micrologic 5.0A Trip Unit

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