apm200 outdoor power supply system user manual-20060628-b-1.0

APM200 Outdoor Power Supply System User Manual Version: V1.0 Revision date: December 16, 2005 BOM: 31011189

Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.

Copyright © 2005 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: [email protected]

Safety Precautions

To reduce the chance of accidents, please read the safety precautions carefully before operation. The “Caution, Notice, Warning and Danger” in this manual do not represent all the safety points to be observed, and are only used as supplement to various operation safety points. Therefore, the installation and operation personnel must be strictly trained and master the correct operations and all the safety points before actual operation.

When operating Emerson products, the safety rules in the industry, the general safety points and special safety instructions specified in this manual must be strictly observed.

Electrical Safety

I. ESD

Notice

The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale ICs, etc. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body static from damaging the sensitive elements. The other end of the ESD wrist strap must be well earthed.

II. Shortcircuit

Danger

During operation, never short the positive and negative poles of the DC busbar or the non-earthing pole and the earth. The power system is a constant voltage DC power equipment, short circuit will result in equipment burning and endanger human safety.

Check carefully the polarity of the cable and connection terminal when performing DC live operations.

As the operation space in the DC distribution unit is very tight, please carefully select the operation space.

Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.

Insulated tools must be used.

In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of the human body and tool is reduced to the minimum.

Others

I. Safety requirement

Notice Please use the same model MCB to replace the MCB.

II. Sharp object

Waring When moving equipment by hand, protective gloves should be worn to avoid injury by sharp object.

III. Cable connection

Notice Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.

IV. Binding the signal lines

Notice The signal lines should be bound separately from heavy current and high voltage lines, with minimum 150mm binding interval.

Contents Chapter 1 Overview ...............................................................................................................1

1.1 Theory.......................................................................................................................1 1.2 System Features.......................................................................................................1 1.3 System Function .......................................................................................................2

1.3.1 Protective Function .........................................................................................2 1.3.2 Alarm Function................................................................................................3 1.3.3 Communication Function ................................................................................5

1.4 System Composition .................................................................................................5 1.4.1 Embedded Power Supply ...............................................................................6 1.4.2 Heat Exchanging Equipment And External Fan..............................................6 1.4.3 Heaters ...........................................................................................................6

Chapter 2 Installation .............................................................................................................7 2.1 Precautions ...............................................................................................................7 2.2 Preparations..............................................................................................................7

2.2.1 Inspecting Location .........................................................................................7 2.2.2 Distributing Goods ..........................................................................................7 2.2.3 Unpacking.......................................................................................................7 2.2.4 Preparing Tools...............................................................................................8 2.2.5 Preparing Cables ............................................................................................8 2.2.6 Opening The Cabinet Door ...........................................................................10

2.3 Installing Cabinet ....................................................................................................11 2.3.1 Installing Cabinet On A Concrete Stand .......................................................11 2.3.2 Installing Cabinet On A Floorstand ...............................................................13

2.4 Installing Battery .....................................................................................................14 2.5 Installing Rectifiers..................................................................................................15 2.6 Connecting Cables..................................................................................................15

2.6.1 Precautions...................................................................................................15 2.6.2 Cable Tube ...................................................................................................16 2.6.3 Connecting Power Cables ............................................................................16 2.6.4 Connecting Battery Cables ...........................................................................19

Chapter 3 Testing.................................................................................................................21 3.1 Introduction .............................................................................................................21 3.2 Testing AC Distribution ...........................................................................................21 3.3 Testing Rectifier ......................................................................................................22 3.4 Testing Monitoring Module......................................................................................22

3.4.1 Setting System Parameters ..........................................................................22 3.4.2 System Function Test ...................................................................................25

Chapter 4 Maintenance........................................................................................................27 4.1 Embedded Power Supply System Maintenance .....................................................27

4.1.1 System Operation .........................................................................................27

4.1.2 Indicator Description .....................................................................................27 4.1.3 Routine Maintenance ....................................................................................29 4.1.4 Handling Of Common Faults.........................................................................31

4.2 Battery Maintenance ...............................................................................................31 4.3 Heat Exchanging Equipment...................................................................................31 4.4 External Fan Maintenance ......................................................................................32 4.5 Replace Heaters And Relays ..................................................................................33

4.5.1 Replace The Heater In Equipment Compartment .........................................34 4.5.2 Replace The Heater In Battery Compartment...............................................35 4.5.3 Replace Heater Relays .................................................................................36

4.6 Replace Door Status Sensors.................................................................................37 4.7 SPD Maintenance ...................................................................................................37

Appendix 1 Technical Data ..................................................................................................40

Appendix 2 Definitions Of The Monitoring Expansion Board Interface.................................42

Appendix 3 System Schematic Diagram ..............................................................................45

Appendix 4 System Wiring Diagram.....................................................................................46

Chapter 1 Overview 1

APM200 Outdoor Power Supply System User Manual

Chapter 1 Overview

APM200 outdoor power supply system can be used directly outdoors. It can supply as much as 60A electric current. There are two models of this system: North model and South model. North model has an extra heating unit compared with the South model.

1.1 Theory

The simplified theoretical block diagram is shown in Figure 1-1. The detailed theoretical diagram is shown in Appendix 3 and 4.

Embedded power supply

220

-48Vdc

Load 1Vac

48Vdc220Vac

Distribution unitLoad 1

Load 11

220Vac

Figure 1-1 Simplified theoretical block diagram

The embedded power system rectifies the 220V AC power into -48V DC power and exports the DC power to the distribution unit. It has functions of battery management, LLVD (load low voltage disconnection), BLVD (battery low voltage disconnection), data acquisition, alarm, and communication with the host.

The distribution unit connects to AC mains and feeds the AC power to the embedded power supply. In addition, it has routes of -48V DC output for the loads.

1.2 System Features

Power factor of the rectifier can reach 0.99. The efficiency is higher than 90%.

Wide AC input voltage range from 90V to 290V. When the input voltage is between 90~175Vac, the rectifier exports power- limited output. When the input voltage is 90Vac, the minimum output power of the rectifier is 37.5% of the rated power.

Perfect battery management. The system has BLVD function, and can perform functions such as temperature compensation, auto voltage regulation, stepless current limiting, battery capacity calculation, and online battery test etc.

Rectifiers are hot pluggable. It takes less than 1min to replace a rectifier.

2 Chapter 1 Overview


Network design: Providing multiple communication ports, which enables flexible networking and remote monitoring.

Perfect lightning protection at both AC side and DC side.

Complete fault protection and fault alarm functions.

All system components are accessible from the front.

The safety guideline satisfies IP55, and satisfies GR487 waterproof requirement.

1.3 System Function

1.3.1 Protective Function

LLVD and BLVD

When mains failure occurs, the battery will supply power. When the battery voltage drops to 47.5V (by default, adjustable), the monitoring module will cut off the non- priority loads. When the battery voltage drops to the BLVD voltage (default: 46.5V), the monitoring module will cut off all the loads to avoid battery overdischarge. When the mains resumes, the power system will go back to normal state.

Over- temperature protection

If the temperature of the equipment compartment remains over the protection point (55°C by default) for 30 seconds constantly, the monitoring module will cut off the non- priority loads until the ambient temperature drops below 45°C. If AC side failure occurs, all the loads will be cut off.

This function is inhibitive by default, though the user can activate or prohibit it through the host command.

Input under-voltage protections

When the AC input voltage is over 290Vac or below 90Vac, the rectifier will perform self- protection. It can recover automatically, and the return difference is more than 5Vac.

Output over-voltage protections

When the DC output voltage is over 60V, the rectifier will stop exporting voltage or current. This protection cannot recover automatically.

Output current- limit protection

The APM200 system can perform current- limited protection.

Output shortcircuit protection

The APM200 system can perform shortcircuit protection. It can short circuit for a long while and recover automatically.



1.3.2 Alarm Function

The system provides alarm functions. It annunciates alarm in the event of mains failure, mains over/ under- voltage, DC output over/ under- voltage, charging overcurrent, load over- temperature protection, ambient over- temperature, module failure, module protection, as shown in table 1-1.

Table 1-1 Alarm functions

Remote- communication

values Description

Mains shortage Alarm is raised when mains is below 50V, and resumes when mains is above 60V.

Mains over- voltage

1. Setting range: between the under- voltage alarm point and 300V. The mains over- voltage alarm point must be set above the AC over- voltage alarm point, and the mains over- voltage alarm point is 280V by default. 2. Alarm recovery conditions: When the mains is below the alarm point minus 3V for 10 minutes constantly, the alarm recovers. 3. The mains over- voltage alarm point can be set through the host. AC over/ under- voltage alarm and module alarm are shielded when mains shortage.

Mains under- voltage

1. Setting range: between 60V and the over- voltage alarm point. The mains under- voltage alarm occurs when mains is below the under- voltage alarm point, and the default mains under-voltage alarm point is 180V. 2. Alarm recovery conditions: When the mains is above the alarm point plus 3V for 10 minutes constantly. , the alarm recovers. 3. The mains over- voltage alarm point can be set through the host. Mains under- voltage alarm is shielded when mains shortage.

DC over- voltage

1. The alarm point is settable. The setting range is 58V~60V, and the alarm point must be above the boost charging voltage plus 1V. The alarm return difference is 0.5V. 2.Default: 58V. DC over- voltage alarm occurs when the busbar voltage is over 58V, and vanishes when the busbar voltage is below 57.5V.

DC under- voltage

1. The alarm point is settable. The setting range isbetween the low- voltage disconnection point and float charging voltage minus 2V. The alarm return difference is 0.5V. 2.Default: 48.5V. DC under- voltage alarm occurs when the busbar voltage is below 48.5V, and vanishes when the busbar voltage is over or equal to 49V. 3. The lower limit voltage is LLVD voltage when load low- voltage disconnection is permitted.4. The lower limit voltage is BLVD voltage when load low- voltage disconnection is prohibited and BLVD is permitted. 5. The lower limit voltage is 35V when both load low- voltage disconnection and BLVD are prohibited.

Charging overcurrent

1. The charging overcurrent alarm will plus 5A when charging current is over the current- limitpoint for 5 minutes constantly.. 2. Alarm recovers when charging current is below the current- limit point for 5 minutes constantly.




values Description

Load over- temperature protection

1.The non- priority load over- temperature protection can be set activated or not through the host settings. It is prohibited by default. 2. If the function is activated and the circumambient temperature is over the over- temperature protection point for 30s constantly, the monitoring module will cut off the non- priority loads automatically. And the power will resume on automatically when the circumambient temperature is lower by 10°C than the protection point. 3. Setting range: 50°C ~70°C. The protection point is 65°C by default. 4. The temperature sampling point is the external temperature sensor. 5. The non- priority load over- temperature protection can be set controllable by the host. If controllable, the load over- temperature protection can be activated through the host command.

Battery over- temperature protection

1.The battery over- temperature protection can be set activated or not through the host settings. It is prohibited by default. 2. If the function is activated and the circumambient temperature is over the over- temperature protection point for 30s constantly, the monitoring module will perform battery disconnection automatically. And the battery will resume power- on automatically when the circumambient temperature is lower by 10°C than the protection point. 3. Setting range: 40°C ~70°C. The protection point is 53°C by default. 4. The temperature sampling point can be set to be battery temperature 1, and is subject to the temperature compensation value.

Circumambience over- temperature

The available setting range is -50~100°C. When over the over- temperature alarm point, the alarm return difference is 3°C. The alarm point can be set respectively, and is 50°C by default.

Circumambience under- temperature

The available setting range is -50~0°C. When under the over- temperature alarm point, the alarm return difference is 3°C. The alarm point can be set respectively, and is 0°C by default.

n# module failure Stand for n# module failure (output over- voltage, output shortage, fan failure) n# module protection

Stand for n# module protection (over- temperature, intput over/ under- voltageprotection).

Battery loop disconnection

1. One battery- string loop alarms. 2. Battery loop disconnection (MCB/ fuse, contactor or internal wiring disconnection) brings alarm. 3. The battery loop is the path between the battery string MCB and the battery string contactor.

BLVD

LLVD

1. Low- voltage disconnection (LVD) activation and LVD voltage can be set through the host. LLVD is inhibited by default, and BLVD is activated by default. 2. The available setting range of BLVD voltage is between 35V and LLVD voltage, and BLVD voltage is 46.5V by default. 3. The available setting range of LLVD voltage is between BLVD voltage and DC under- voltage alarm point, and BLVD voltage is 47.5V by default. 4. LVD criterion 1) The system has either following setting cannot perform LVD control: the number of system and power module is set zero or battery string capability is set zero. 2) LVD is activated in accordance with LVD conditions and the host command.

Door status sensor The dry contact is disconnected when alarm. SPD failure alarm Check the two- route SPDs. The dry contact disconnects when SPD exports alarms.

Fan failure alarm

If the fan rev. is measurable and the fan rev. is set to be maximum, the virtual fan rev. is less than 80% of the normal rev., fan failure alarm should be raised. If the fan rev. is un measurable, fan failure alarm performs in accordance with failure description by fan manufacturer.




values Description

Heater failure alarm of the storage battery compartment

When the mains is in normal state and the storage battery temperature is below 5°C for an hour constantly, heater failure alarm of the storage battery compartment is raised.

Test on backup digital data

1. 3 routes altogether. The monitoring module supplies 24Vdc or 12Vdc operation power for the switchable signal examination, disconnect the correlative low power level (0V~1V) and connect the correlative high power level (9~24V). 2. 8/20µs impulse current can endure 300A, without damage (bio- transient suppressor with model of 1.5SMC39CA is commeded). 3. Alarm power level is adjustable.

Note:

Alarm levels can be set through the host. The alarm levels are divided as critical alarm, observation alarm, and inhibit alarm. Alarms that may cause load power interruption are defined as critical alarm by default, and the rests are observation alarms. Door status sensor alarms, humidity alarms and backup equipment alarms can be set as non- alarm and be shielded, while the other alarms cannot. Except exposited ones, the alarm affirmance time is 10 seconds.

1.3.3 Communication Function

The system can communicate with the user host through communication port RS232 or RS485, and report sampling data and alarm data to the host. The APM200 system can report some alarms information to the host through the 4 couples of dry contacts.

1.4 System Composition

The APM200 outdoor power supply is constructed by an equipment compartment and a battery compartment. The equipment compartment consists of embedded power supply, heat exchanging equipment, external fan and distribution unit etc. The battery compartment has two layers, and a set of batteries that supplies backup power can be placed in each layer. Each heater is placed in the equipment compartment and in the battery compartment in the North model system. See Figure 1-2.



Rings(4 pieces)Heat exchanging equipment

External fan

Monitoring expansion board

Reserved

Embedded power supply

Distribution unit

Heater in equipment compartment (behind

distribution unit)

Battery string I

Heater in battery compartment (under

the plate)

Floorstand

Battery compartment door

Battery string II

Equipment compartment door

Figure 1-2 Structure of APM200 outdoor power supply system

1.4.1 Embedded Power Supply

The embedded power supply consists of 3 rectifiers, one monitoring module, one distribution subrack and one monitoring expansion board. It switches the 220V AC voltage to -48V DC voltage, and delivers the -48V DC voltage to the distribution units of the system and then to the loads through its distribution subrack.

1.4.2 Heat Exchanging Equipment And External Fan

The heat exchanging equipment dissipates the heat inside the cabinet with the external fan. It consists of an internal fan and a heat exchanger. The external fan aspirates the cold air outside and feeds it to the heat exchanger, while the internal fan expels the heat air inside the cabinet to the heat exchanger. The heat exchanger exchanges the heat between cold air and hot air in it to dissipate the heat.

1.4.3 Heaters

The two heaters will start to work when the environment temperature is below 5°C±5°C to ensure the normal operation of the North model system segments in low temperature environment.

Chapter 2 Installation 7


Chapter 2 Installation

2.1 Precautions

1. Only qualified technical person can do the system installation and maintenance.

2. Avoid fire or body injuries.

3. Provide suitable AC mains supply to the system.

4. Earth the system according to the requirement.

5. Keep the environment of the system clean and dry.

6. Avoid touching the bare part of a circuit.

7. Switch off the circuit breakers in case of system failure.

2.2 Preparations

2.2.1 Inspecting Location

Before installation, please inspect:

1. the cable routing such as cable tunnel and so on.

2. the conditions required for the normal operation of the system, such as AC mains supply, earth cable and so on.

2.2.2 Distributing Goods

The user needs to distribute the goods if several systems with same model are purchased at the same time. Every system has been tested and gone through the burn-in test strictly before delivery. In order to ensure the optimized operation and track the product quality conveniently, the components should be installed in their corresponding cabinet, even though these components can be installed in other systems.

Ensure that all components in the same system have the same No. that is marked on the packing case.

2.2.3 Unpacking

Inspect the equipment strictly after unpacking to ensure successful installation.

Unpack and inspect the equipment only after it arrives at the installation site. The user representative and the representative from Emerson Network Power Co., Ltd. shall inspect the equipment together.

8 Chapter 2 Installation


Open the packing case with a packing list in it first, take out the packing list, and inspect according to the packing list, including customer name, customer address, machine No., quantity, case No., contract No., and others.

Check the goods one by one according to the packing list after unpacking. The procedures are as follows.

Step 1: Check the quantity and serial number marked on the packing cases according to the actual quantity of the packing cases.

Step 2: Check the correctness of the equipment packing according to the packing list.

Step 3: Check the quantity and model of the accessories according to the packing list.

Step 4: Check the correctness of equipment configuration according to the system configuration.

Step 5: Check the goods visually. For example, check if the cabinet or enclosure is distorted or affected with damp; shake gently the rectifier and the monitoring module to see if there is any loose component or connection caused by shipment.

Step 6: The user representative signs the packing list.

Do not unpack the components before installing them to avoid accessory loss.

2.2.4 Preparing Tools

The installation tools include electric drill, wire cutters, crimping tools, wrench set, screwdriver, and electric knife. The tools must be insulation and ESD-proof processed before they are used.

2.2.5 Preparing Cables

The cables to be installed include AC power cables, DC power cable and grounding cable.

RVVZ cables such as flame retardant PVC insulation or jacket soft cable with copper conductors are recommended.

The cables should be able to withstand at least +70°C temperature. The colors of AC phase cable, neutral cable and grounding cable shall be red, Cambridge blue and green and yellow respectively. If the cables have the same color, they should be identified with IDs or color labels.

The sectional area of the AC power cable depends on the current, temperature rise, voltage drop and mechanical strength of the cable. The 2.5A/mm2 current density is recommended to estimate the sectional area of the AC power cables and the cable with less than 10mm2 sectional area is not recommended.

The sectional area of the DC power cable is shown in Table 2-1.



Table 2-1 Sectional area of the DC power cable

Rated current Max. output

current Min. sect. area

Max. cable l. with 0.5V voltage drop and Min. sect.

area 32 A 16 A 16 mm2 14 m 20 A 10 A 10 mm2 14 m 16 A 8 A 6 mm2 11 m 10 A 5 A 4 mm2 11 m

If the rated capacity of a MCB is much bigger than the actual output current, the MCB will not trip when overload happens. So the recommended MCB capacity is 1.5 to 2 times of the maximum load current (it is two times in the table above).

Note

The maximum output current that flows in the DC power cable is calculated according to the full load of the system. If the acceptable voltage drop is not 0.5V, determine the sectional area of the DC power cable according to the following expression.

A= I%L/(K∆U)

Where:

A—sectional area of a cable (m2)

I—total current that flows in the cable (A)

L—cable length (m)

∆U— acceptable voltage drop in the cable (V)

K—electric conduction coefficient, here K Copper=57

Recommended color labels for the positive and negative DC power cables:

Positive cable − black

Negative cable − blue

The sectional area of the grounding cable should be at least 16mm2. A green and yellow cable should be used as the grounding cable.

Prepare the cables according to the cabling specification and quantity. Do not join two separate cables together to form one cable. The blue and black cables should be used as DC power cables. If the cables are routed outside, they should be inserted into a corrugation sleeve.



2.2.6 Opening The Cabinet Door

The equipment or battery compartment door needs to be opened during system installation or maintenance. The two doors can be opened with same method, and the procedures are follows:

Step 1: Undo the hexagon socket head cap screw in the keyhole sheet with the hexagon key widdershins. Remove the keyhole sheet. Insert another key into the keyhole and turn the key clockwise until it cannot be turned any more, as shown in Figure 2-1.

Keyhole sheet

Handle

Figure 2-1 Unlock sequence

Step 2: Turn the handle about 120° counter clockwise, and then pull the door, as shown in Figure 2-2.

Handle

Figure 2-2 Handle position

Step 3: Use the position pole to fix the position of the door to prevent the door from being closed automatically, as shown in Figure 2-3.

Position pole

Figure 2-3 Position Pole



Step 4: Place the pole to its original position before closing the door.

Note

Different cabinets have the same key. If different key is needed, notify Emerson in advance.

2.3 Installing Cabinet

The APM200 outdoor power supply system uses bottom cabling mode. Make a concrete stand or a floorstand first, and then place the cabinet on the concrete stand or the floorstand. The detailed installation procedures are follows.

2.3.1 Installing Cabinet On A Concrete Stand

Step 1: Make a concrete stand

The dimensions of the stand are shown in Figure 2-4.

Cable tunnel

Cabinet door300~500

800

250

100

800

Figure 2-4 Dimensions of concrete stand (Unit: mm)

Step 2: Mark the cabinet installation position

Determine the center point positions of every installation hole on the stand according to the installation dimensions of the cabinet shown in Figure 2-5, and mark them with a pencil or an oil pen.

Cabinet door

800

480

800

530

Figure 2-5 Installation dimensions of cabinet base



Step 3: Drill holes

The size of the expansion bolt delivered with the accessories is M10×55mm. Drill a 70mm-depth hole at each marked point by using a Ф14 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical. Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same level with the floor, as shown in Figure 2-6.

Drill vertically

Clean thedust

Knock it into place

Tighten the bolt

Expansion pipe

Power cabinet

70~75mm 14

Figure 2-6 Drilling holes and Installing expansion pipe and bolt

Step 4: Place cabinet in position

Move the cabinet to the installation position, and align the installation holes of the cabinet to those on the ground.

Step 5: Open the battery compartment door

Take the key from the ring on the cabinet top, and open the battery compartment door according to the method introduced in section 2.2.6.

Step 6: Fix the cabinet

Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 2-7.

Battery compartment

Expansion bolt

Expansion pipe

Concrete stand

Expansion bolt

Spring washerCabinet base

Expansion pipeConcrete stand

Spring washer

Figure 2-7 Screwing an expansion bolt

Shake the cabinet in different directions after the installation to check for any loose component and loose installation of the cabinet.



2.3.2 Installing Cabinet On A Floorstand

Step 1: Mark the floorstand installation position

Determine the center point positions of the floorstand on the ground and mark them with a pencil or an oil pen, as shown in Figure 2-8.

Cabinet door 14

450

400

Figure 2-8 Installation dimensions of floorstand

Step 2: Drill holes

The size of the expansion bolt delivered with the accessories is M10×55mm. Drill a 70mm-depth hole at each marked point by using a Ф14 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical. Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same level with the floor, as shown in Figure 2-4.

Step 3: Fix the floorstand

Align the installation holes of the floorstand to those on the ground. Screw the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 2-9.

and floorstand

Floorstand

Expansion boltGround

Battery compartment

Screw for fixing cabinet

Figure 2-9 Installing the cabinet and floorstand

Step 4: Place cabinet in position

Place the cabinet on the floorstand. Align the installation holes of the cabinet to those of the floorstand.



Step 5: Open battery compartment door

Take the key from the ring on the top of the cabinet, and open the battery compartment door according to the method described in section 2.2.6.

Step 6: Fix cabinet

Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner of the cabinet that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the screws supplied with the accessories to fix the cabinet on the floorstand with a wrench, as shown in Figure 2-7.

Shake the cabinet in different directions after the installationto check for any loose component and loose installation of the cabinet.

2.4 Installing Battery

Open the battery compartment door according to the method introduced in Section 2.2.6.

The battery compartment has two floors. Each floor can be placed with one battery string that has four cells. Install the battery cells according to the battery user manual delivered with the battery.

The battery cells should be installed as close to the right side and rear side of the cabinet as possible. Attach the acid and alkali integration box on the side panel of the cabinet.

Loosen the two baffles in the front of the battery compartment after installing the battery cells, and then move the baffles vertically about 10mm and screw the screws solidly to block the battery cells, as shown in Figure 2-8.

The installation tools must be insulation processed. Do not damage the plastic cover of the battery cells and their output terminals during the installation.

Battery compartment

Battery string I

Baffle

Battery string II

Baffle

Figure 2-10 Installing battery strings



2.5 Installing Rectifiers

The subrack of the embedded power supply has been installed in the cabinet of the outdoor power supply system. While the rectifiers of the embedded power supply are packed and delivered separately and need to be installed on spot.

Rectifiers should be installed in the three left slots of the subrack. Install the rectifiers from left to right when there are less than three rectifiers to be installed and mount dummy plate at the remaining position. The installation procedures are as follows.

Step 1: Place the rectifier to the position shown in Figure 2-11.

Handle

Rectifier

Figure2-11 Positions of the rectifier and the handle

Step 2: Push the handle into the panel.

Step 3: Push the rectifier inward until it stops going forward. The rectifier is fixed in the subrack.

Step 4: The procedures to unplug the rectifier-move the latch to “Unlock” position first, and pull out the rectifier then.

2.6 Connecting Cables

2.6.1 Precautions

1. When doing engineering design, AC cables and DC cables should be installed separately to avoid interfering with DC output caused by AC power.

Note

At the point where the DC output cable is led out of the cabinet, drill the cable through a steel tube longer than one meter and then connect it to the load to prevent radiant disturbance. 2. AC cables and DC cables should be identified with cable labels and polarity markings. The markings should be attached on the cables at a fixed distance.

3. The cables should be identified with different colors, as shown below:

Positive DC cable – black

Negative DC cable – blue



Grounding cable – green and yellow

AC phase line – red

Neutral line – Cambridge blue or black

If the cables have the same color, black cable is preferred and they should be identified with IDs.

4. The cables to be connected are AC power cables, DC power cables and battery cables.

5. Safety and reliability are most significant factors in electrical connection.

6. The AC and DC power cables and grounding cable should be routed through the cable tunnel, the battery compartment and the cable tubes between the two compartments, and should finally be connected to the distribution unit.

7. The cables shall not have joint, damage or scratch.

2.6.2 Cable Tube

This system is configured of 15 cable tubes with different sizes. The appearance of the tube is shown in Figure 2-10. The cable tubes are located on the separating plate between the equipment compartment and the battery compartment, as shown in Figure 2-11. User can select the suitable tube to route the cable according to the cable size. Unscrew the tube cap, then lead the cable through the tube, and finally screw the cap.

Cable tube

Distribution unit

Figure 2-12 Position of cable tube

2.6.3 Connecting Power Cables

Step 1: Remove the panel of the distribution unit

The panel is shown in Figure 2-13.



The panel of the distribution unit

Figure 2-13 Panel of the distribution unit

Step 2: Load Distribution

The system can supply 11 routes of loads, as shown in Figure 2-16. The MCBs (LOAD1~LOAD6) of the distribution unit in the embedded power supply controls the 11 loads. The positions of the MCBs in the subrack are shown in Figure 2-14, and the relationship between these two levels of MCBs is shown in Figure 2-15. The specifications of the MCBs are shown in Table 2-2.

Table 2-2 MCB Specifications

MCB in subrack

MCB in distr. unit

MCB cap. in distr. unit

Cable size in

distr. unitRemark

LOAD 1 1, 2 16A ≤25mm2 Total output of two MCBs should be less than 15A



LOAD 4 7, 8, 9 16A ≤25mm2 Total output of three MCBs should be less than 15A

LOAD 5 10 32A ≤25mm2 Total output of the MCB should be less than 30A

LOAD 6 11 32A ≤25mm2 Total output of the MCB should be less than 30A

Load MCB Battery force- on buttonBattery MCB

Figure 2-14 MCBs in subrack of embedded power supply system



Route Route Route Route Route Route Route Route Route Route

LOAD2

Route1 2 4 5 6 7 8 9 10 11

LOAD4 LOAD5 LOAD6LOAD1 LOAD3

3

Figure 2-15 Relationship between two levels of MCBs

The embedded power supply system has LLVD and BLVD functions. When the battery voltage is less than 47.5V (default), the embedded power supply system will disconnect the load connected to the MCBs of LOAD5 and LOAD6 automatically without interrupting the power to the load connected to the MCB of LOAD1~LOAD4. LOAD1~LOAD4 will be disconnected automatically when the battery voltage is less than 46.5V (default) to avoid battery overdischarge. At this time, all loads are disconnected.

So the priority loads should be connected to the MCB of LOAD1~LOAD4, that is the Route1 to Route 9 in Figure 2-16. The normal loads should be connected to the Route 10 to Route 11 in Figure 2-16.

Step 3: Connect loads

As shown in Figure 2-15, connect the negative polarity of every load to the lower terminal of the MCB with a negative cable, and connect the positive polarity of the load to the bolt on the positive busbar that has one M6 bolt and seven M4 bolts.

Note

The tools and body shall be insulated strictly before applying a load when the system is powered on to avoid shortcircuit.

Terminal for connecting load Positive busbar Grounding bar AC phase line (L) Neutral line (N)

Figure 2-16 Terminals for connecting load and AC power



Note:

The L & N terminals above are divisional interface of AC SPD and power subracks instead of AC input terminals.

Step 4: Connect AC power cables

Connect the AC input grounding cable to the grounding bar shown in Figure 2-16 or the grounding bar outside the battery compartment of the cabinet.

Connect the AC input neutral line to the wiring point below the MCB N shown in Figure 2-16.

Connect the AC input phase line to the wiring point below the MCB L shown in Figure 2-16.

Note

1. The grounding cable shall be connected first, then the neutral line and finally the phase lines. 2. The AC cables should be routed from the MCB in the external distribution equipment prepared by user. They should be connected to the MCB just before the system is powered on. The external distribution equipment should have some protection devices to fulfill the overcurrent, shortcircuit and lightning protection functions. 3. The AC cables should be identified with color labels to identify the phase line, neutral line and grounding cable. 4. The AC cables should be routed away from the DC cables.

Step 5: Re-install the cover

Re-install the cover to the distribution unit after completing the connection.

2.6.4 Connecting Battery Cables

Step 1: Switch on the AC input MCB and battery MCB

The positions of the AC input MCB and the battery MCB are shown in Figure 2-17.

Battery MCB

AC input MCB

Figure 2-17 Position of AC input MCB and battery MCB



Step 2: Check if the polarities of the battery cables are correct

Check the polarities of the battery cables in the battery compartment with a multimeter. The black cable should be negative pole and the red cable should be positive pole. The cable in the middle is middle voltage sampling cable of the battery, as shown in Figure 2-18. If the polarity is incorrect, please contact Emerson.

Middle voltage sampling cable of the battery

Positive battery cable

Negative battery cable

Negative battery cable Middle voltage sampling cable of the battery

Figure 2-18 Battery cables

Step 3: Connect battery cells

Switch off the battery MCB and AC input MCB. Connect the battery cells with the cables delivered with the battery according to the battery user manual.

Step 4: Connect the battery string to the cabinet

Connect the blue and black cables in the battery compartment respectively to the negative and positive terminals of the battery string. Connect the voltage sampling cable to the middle voltage terminal of the battery.

Step 5: Recheck if the polarities of the battery cables are correct

Check the polarities of the battery cables again after completing the connection. Make sure that the blue cable in the battery compartment is negative and the black cable is positive. If the cable polarity is incorrect, repeat Step 4.

Chapter 3 Testing 21


Chapter 3 Testing

3.1 Introduction

The cabinet, rectifiers and monitoring module are subject to vibrations during shipment. More over, mistakes might be made during system installation. If the system is powered on in haste, a fatal accident may occur and the whole power supply system may be damaged. Therefore, the system must be tested strictly after it is installed.

Conduct the test procedures carefully and observe the system in the mean time. Shut down the system in case of any abnormal phenomenon and continue the test after the fault is eliminated.

3.2 Testing AC Distribution

Step 1: Check if the PE cables are reliably connected and the AC cables are correctly connected to the system according to the system schematic diagram (refer to Appendix 3), and if the screws are loose before powering on the system.

Step 2: Switch on the residual current operated circuit breaker (RCCB). Switch off all MCBs (put the handles down) in the subrack and the distribution unit. Switch on the SPD MCBs, as shown in Figure 3-1.

RCCB

Figure 3-1 MCB positions

Step 3: Make sure that there is no short circuit in the input and output terminals of the AC

Step 4: Switch on the MCB in the external distribution equipment to power the system. Measure the voltages of the input terminals of the AC MCBs. Check the external distribution equipment if the voltages are abnormal.

Step 6: Switch on the battery MCB.

Step 5: Switch on the AC MCBs and the operation indicators (green) on the rectifier panels should turn on. Otherwise, check the distribution unit carefully.

22 Chapter 3 Testing


3.3 Testing Rectifier

Step 1: Make sure that there is no short circuit in the input and output terminals of the rectifier and there is no loose or damaged component inside the rectifier.

Step 2: Switch on the AC MCBs. The green indicator on the rectifier panel turns on and the red indicator is on for several seconds. The rectifier starts after a start delay and then operates normally. At this time, only the green indicator is on and the fan will stop several minutes later if no load is applied to the system.

Step 3: Measure the DC output voltage of the system with a multimeter. It should be 53.5V±0.5V.

Note

Only the engineers from Emerson can adjust the output voltage of the rectifier. After the system test is completed, the output voltage needs not to be adjusted any more unless the rectifier is replaced with a new one.

3.4 Testing Monitoring Module

The monitoring module must be tested with a host.

3.4.1 Setting System Parameters

Upon delivery, the default parameters of the monitoring module may be inconsistent with the actual situation or your needs. In that case, you should configure the system parameters through the host before the system testing.

According to the communication protocol, the parameters that you can query through the host are listed in the following table.

Table 3-1 Parameters that can be queried

Rem

otel

y A

cqui

red

Ana

log

Sign

al

1) AC Input Voltage 2) DC Busbar Voltage 3) Rectifier Total Output Current 4) Battery String Current 5) Ambient Temperature/Humidity 6) Battery Temperature

Rem

otel

y A

cqui

red

Ala

rm/D

igita

l Sig

nal

1) AC Mains On/Off 2) AC Mains Status 3) DC Bus Voltage Status 4) Load MCB Status 5) System Current-Limiting Status 6) Load Connection/Disconnection Status 7) Battery Connection/Disconnection Status 8) Battery MCB Status 9) Ambient Temperature/Humidity Status 10) Door Status Sensor 11) Water Sensor Status 12) Smoke Sensor Status 13) Rectifiers Operation Status 14) System Control Mode and Battery BC/FC Status15) 7 Standby Digital Signal Status 16) 2 Digital Signal Output Status 17) Battery Discharge Test Phase Status 18) Battery Charge Over-Current Status R

emot

e-C

ontro

l Par

amet

ers

1) Rectifier On/off Control 2) BLVD & LLVD 3) FC/BC Status Control 4) Start/End Battery Capacity Test



According to the communication protocol, the parameters that you can configure through the host are listed in the following table.

Table 3-2 Configurable parameters

Parameter Range Default valueAC Input Under-Voltage Alarm Point

> 60V and lower than AC Over-Voltage Alarm Point

180V

AC Input Over-Voltage Alarm PointBetween AC Under-Voltage Alarm point and 300V

280V

DC Busbar Low Voltage Point

1, When LLVD enabled: LLVD Voltage 2, When LLVD disabled but BLVD enabled: BLVD voltage 3, When both LLVD and BLVD disabled: 35V

46.5V/47.5V/35V (depending on the BLVD Status and LLVD Status)

DC Busbar Under-Voltage Alarm Point

Between DC Busbar Low Voltage Point and 2V below FC voltage

48.5V

DC Busbar Over-Voltage Alarm Point

58V ~ 60V and 1V higher than BC voltage

58V

LLVD Status Disabled, Enabled Disabled

LLVD Voltage Between BLVD voltage (when BLVD is disabled: >35V) and DC Busbar Under-Voltage Alarm Point

47.5V

BLVD Status Disabled, Enabled Enabled

BLVD Voltage ú35V but lower than LLVD voltage (when LLVD is disabled, lower than DC Busbar Under-Voltage Alarm Point)

46.5V

Ambient Temp Alarm Lower Limit -50°C ~ 100°C and lower than upper limit 0°C

Ambient Temp Alarm Upper Limit -50°C ~ 100°C and higher than lower limit

50°C

Ambient Humidity Alarm Lower Limit

0%RH ~ 100%RH and lower than upper limit

10%RH

Ambient Humidity Alarm Upper Limit

0%RH ~ 100%RH and higher than lower limit

80%RH

Standby Digital Signal Alarm Level High level alarm 1, low level alarm 0 High level alarm 1Number and Addresses of Rectifiers

(1, 1), (2, 1, 2), (3, 1, 2, 3) (3, 1, 2, 3)

System Control Mode Host Control, Auto Auto FC/BC Status BC, FC FC

BC voltage 43.2V ~ 57.6V, between FC voltage and 1V below DC Busbar Over-Voltage Alarm Point

56.5V

FC voltage 43.2V ~ 57.6V, between BC voltage and 2V below DC Busbar Under-Voltage Alarm Point

53.5V

Number of Battery Strings 0 ~ 1 1

Capacity of Battery String 30Ah ~ 600Ah

100Ah (when no specific requirement is made)



Parameter Range Default valueCoefficient of Charge Current Limiting Point

0.1 ~ 0.25 0.15

Scheduled BC Interval 30 days ~ 240 days 60 days Temp Compensation Coef. of Battery String

0mV/°C ~ 500mV/°C 80mV/°C

Temp Measurement Lower Limit -50°C ~ 0°C -50°C Temp Measurement Upper Limit 0 C ~ 100 C 50 C

Humidity Measurement Lower Limit0%RH ~ 100%RH and lower than Upper Limit

0%RH

Humidity Measurement Upper Limit0%RH ~ 100%RH and higher than Lower Limit

100%RH

Power Distribution Analog Signal Calibration Coefficient

Not configurable by the user

Battery Over-Temp Protection Point

40°C ~ 70°C 53°C

When setting system parameters through the host, please note that:

1. Make sure that the power system address set at the host is identical with the address set through the DIP switch, or the communication will fail.

2. Make sure that the rectifier number is set consistent with the actual condition. After a rectifier is added to or removed from the power system, the rectifier number parameter must be accordingly modified, or a rectifier alarm will be raised.

3. The battery string capacity is set to customer required specific capacity according to order requirement before delivery. If there is no specific capacity of the battery strings required in the order, the default battery string capacity is 100AH. If the actual battery capacity is different from that, reset the configuration through the host to make the configuration consistent with the actual situation and prevent improper battery management. (Note: the 200Ah and 100Ah capacities are set through DIP switch. You can only set other capacities through the host.)

4. The management over the battery strings is realized through a common BLVD and a shunt, and the battery current measured by the monitoring module is actually the total current of the two. Therefore, at the host, the battery string number should be set to 1, and the battery capacity be set to the sum of the two strings.

5. The DIP switch is in the PCB board of the monitoring module. Pull out the monitoring module (hot pluggable) before changing the DIP switch settings. Then you can change the DIP switch settings

Description of DIP switch settings:

DIP switch 1~4: Address DIP switch. ON acts 1, OFF acts 0.

DIP switch 7: ON denotes that the battery string capacity is 200Ah; OFF denotes that the battery string capacity is 100Ah. As shown in Figure 3-2.



DIP switch7 ON

DIP switch7 OFF

Figure 3-2 DIP switches

3.4.2 System Function Test

After setting the system parameters, you can go on to carry out the system function test.

For the requirements of the test on system AC over/under-voltage alarm and protection are rather strict, you do not need to do them. After all, the system has passed strict tests before delivery.

Battery Auto-Management Test

Cut off AC mains supply and power the load with the battery for above 15 minutes (!1 minute), then recover the AC mains, all rectifiers will be in current-limiting BC status.

During the current-limiting BC status, it is normal that the rectifier output voltage is sometimes below 53.5V.

For the test of battery auto-management has strict requirements for the system, it is not necessary to carry out this test if your test conditions are limited.

Rectifier On/Off Test

Set the control mode to background control through the host software and try turning on/off each module. The corresponding module should act correctly.

Note to change the control mode to automatic control after the test is finished.

Under-voltage Alarm And LLVD/BLVD Test

Cut off the AC power and power the load with batteries. Set the DC under-voltage alarm point, LLVD and BLVD voltage to higher values to shorten the test duration. Then observe the battery under-voltage alarm, LLVD and BLVD situation. The monitoring module should send out the corresponding alarms one by one. The red indicator on the front panel of monitoring module should be on, and the dry contact controlling the external audible/visual alarm equipment should output alarm signal.

Recover the AC power, restore the settings of under voltage alarm point, LLVD and BLVD voltage, and the above alarms should disappear.

Rectifier On Position Test

Set the power system address and rectifier number correctly, insert and pull out the rectifiers one by one, and the host should display the communication state of corresponding rectifiers correctly.



Battery MCB Off Alarm Test

Connect the battery to the system, and switch off its MCB. There should be a corresponding battery MCB off alarm raised at the host. The alarm will disappear when the MCB is turned on.

Load MCB Off Alarm Test

Connect a load to the system and switch off its MCB. There should be a corresponding load MCB off alarm raised at the host. The alarm will disappear when the MCB is turned on.

Note

1. If the terminal of corresponding load and battery route is not connected with load or battery during the test, but is suspended, the MCB Off Alarm for corresponding load or battery may not be reported accurately. 2. Make sure that system configurations are restored to normal status after the test.

Viewing Operation Information

After the system power on, you can get simple operation information through the indicators on the monitoring module front panel. For detailed information, you must query through the host.

Canceling Battery Protection

If you think it more important powering the loads than protecting the battery, thus do not want the battery protection in the case of mains failure, you can set the LLVD and BLVD status to “Disabled” through the host.

Note

When the battery is discharged to the BLVD voltage, the battery backup time is very short. It is impossible to obtain long time operation of loads by sacrificing the battery.

Chapter 4 Maintenance 27


Chapter 4 Maintenance

Inspect the outdoor power supply system periodically and shoot the trouble in time.

4.1 Embedded Power Supply System Maintenance

4.1.1 System Operation

After installation and testing, the system is ready for use. When necessary, it can be put into normal operation just by switching on the corresponding MCB. During the operation, the following issues may call your attention:

Fan speed control technology

The fan may run for a second and stop when the rectifier is powered on for the first time. If load is connected to the system, the inner temperature of the rectifier will increase after operation for a period of time, and the fan will begin running and speed up with the increase of inner temperature. That phenomenon is due to the fan speed adjusting technology, and thus absolutely normal.

Over temperature protection

A rectifier’s inner temperature may be high during operation. If you reset it by turning it off and on at that time, you may observe that the rectifier has no output but the fan is running. That is because the OTP circuit within is working. The output will recover after the temperature decreases 1 minute later.

If the fan does not run, and the rectifier has no output for more than 5 minutes, the rectifier may have been damaged. Please replace the faulty rectifier or contact Emerson local service center.

4.1.2 Indicator Description

Indicator description of the rectifier

The appearance of the rectifier is shown in Figure 4-1. There are 3 indicators on the panel: ALM (alarm indicator), FAN-ALM (indicator of fan faulty alarm) and RUN (power indicator)。

28 Chapter 4 Maintenance


Figure 4-1 Rectifier appearance

When the rectifier runs in normal condition, the power indicator ‘RUN’ is on, and the other two indicators are off. When fan failure occurs, FAN- ALM indicator is on and RUN indicator is off. When other faults or protection alarm occur, ALM indicator is on and RUN indicator is off. The operation state of the rectifier should be estimated according to the indicator state when maintenance.

Indicator description of the monitoring module

The appearance of the monitoring module is shown in the following figure. There are 2 indicators on the panel: RUN (power indicator) and ALM (alarm indicator). Descriptions are as shown in Table 4-1.

Figure 4-2 Appearance of monitoring module



Table 4-1 Monitoring module indicator description

IndicatorMeaning

RUN indicator (green) ALM indicator

(red) Normal Slow blinking (Once per second) Off No system alarm, with abnormal communication

Fast blinking (Once per 120ms) Off

System alarm, with normal communication

Slow blinking (Once per second) On

System alarm, with abnormal communication

Fast blinking (Once per 120ms) On

4.1.3 Routine Maintenance

Fan Maintenance

Dust will accumulate on the baffle plate if the rectifier works in a dusty and windy environment. To ensure long-term reliable and smooth operation of the rectifier, it is necessary to clean the fan regularly (once 6 months).

In addition, the fan performance will deteriorate after long-term operation. You need to replace the fan regularly (once every 3-5 years).

Fan replacing method:

1. Remove the fan baffle plate

2. Remove the screws on the top right corner of the fan

3. Pull out the power cable

4. Replace the fan with a new one

5. Connect the power cable, and fix the fan with the screw on the top right corner

6. Mount the baffle plate back

The fan structure is shown below:



Figure 4-3 Fan of the rectifier

Note

1. Only trained professionals are allowed to clean and replace the fan. 2. Do not touch any internal parts of the rectifier during fan maintenance.

Rectifier Pull-Out & Plug-in

Upon abnormities, the rectifier may need to be pulled out and plugged in. The rectifiers and monitoring modules are all hot swappable.

To pull out the rectifier, you should first draw out the handle at rectifier front panel to detach the latch at rectifier bottom from the distribution frame. Then you can pull the rectifier out by the handle. The handle position is shown in Figure 4-4.

When replacing new monitoring modules, communication cable and signal cable shoule be connected as well. See Figure 4-4.

Handle of the rectifier

Rectifier

Handle of the monitoring module

Monitoring module

Communication cable to the expanding board

Signal cable to the expanding board

Figure 4-4 Handle of the modules



Note

The rectifiers’ connecting part is a delicate device. Although the rectifiers are designed to be hot swappable, the pull-out and plug-in operation should be gentle lest the connecting part should be damaged. Non-professionals are not allowed to replace the rectifier on-line.

4.1.4 Handling Of Common Faults

Fault Symptom1:

The rectifier quits operation automatically and a corresponding alarm is raised at the host.

Solution: replace the faulty rectifier.

Fault Symptom2:

Rectifier(s) is/are shut down upon over-voltage and the corresponding alarm is raised at the host.

Solution: 1) Upon single rectifier shutdown: Switch off the faulty rectifier. Wait till its indicators are off, and switch it on again. If the over-voltage still exists, the rectifier may have been damaged and need replacing. 2) Upon multiple-rectifier shutdown: Pull output all rectifiers and insert them one by one to find out the real faulty one. Replace the faulty rectifier after confirmation.

4.2 Battery Maintenance

Refer to the battery user manual supplied with the battery. (Note: It is recommended to use T12V100SEF/A battery within this system. If you choose to use battery of other models, please consult with Emerson to prevent improper configuration.)

4.3 Heat Exchanging Equipment

The heat exchanging equipment consists of an internal fan and a heat exchanger. Its position is shown in Figure 4-5.

Heat exchange equipment

Cable connector

Fixing screws

Figure 4-5 Position of heat exchanging equipment

The internal fan rev is settable. The higher the temperature of the equipment compartment is, the larger the internal fan rev is.



Replace the internal fan or adjust the fan position if it stops running or there is an abnormal noise in it. And clean the heat exchanger if there is much dust on it. The procedures are as follows.

Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, as shown in Figure 4-5. Do not disconnect when power is on.

Step 2: Remove the fixing screws shown in Figure 4-5 and then remove the heat exchanging equipment from the cabinet.

Step 3: Remove the screws that fix the cover and the internal fan baffle and then remove the cover and the baffle, as shown in Figure 4-6.

Cover

Screws for fixing the cover (4 pieces)

Fan baffle

Screws for fixing the baffle (3 pieces)

Figure 4-6 Remove the cover and baffle

Step 4: Remove the fixing screws of the internal fan shown in Figure 4-7. Adjust the fan position or replace the fan with a new one. Take out the heat exchanger to clean it if there is much dust on it.

Heat exchanger

Fan screws (4 pieces)

Internal fan position

Figure 4-7 Remove internal fan and heat exchanger

Step 5: Follow step 5 to step 1 to install the new fan and the clean heat exchanger into the cabinet. Take care when installing the heat exchanger to avoid damaging the waterproof bar on it.

4.4 External Fan Maintenance

The external fan rev is settable. The higher the temperature of the equipment compartment is, the larger the external fan rev is. Replace the external fan or adjust the fan position if it stops running or there is an abnormal noise in it. The procedures are as follows.



Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, and disconnect the fan cables from the terminals, as shown in Figure 4-8. Do not disconnect when power is on.

Heat exchange equipment

Cable connector of the heat exchange equipment

Fixing screws

Cable connector of the external fan

Fixing screws

External fan

Figure 4-8 Positions of heat exchanger and external fan

Step 2: Remove the fixing screws of the heat exchanging equipment shown in Figure 4-8, and then remove the equipment.

Step 3: Remove the fixing screw of the fan box shown in Figure 4-4 and then remove the fan box.

Step 4: Remove the fixing screw of the external fan shown in Figure 4-9. Adjust the fan position or replace it with a new one.

External fan

Fixing screws of external fan (4 pieces)

Figure 4-9 Remove the external fan

Step 5: Follow step 4 to step 1 to install the new fan into the cabinet. Install the heat exchanging equipment into the cabinet. Take care when installing the heat exchanging equipment to avoid damaging the waterproof bar on it.

4.5 Replace Heaters And Relays

The two heaters of the system do not need to be repaired. Be sure to pay attention to their operation status. The heaters will heat when the environment temperature is below 5°C±5°C, and stop heating above 15°C±5°C. If they operate abnormally, check the heater relays (refer to section 4.6.3). If the relays operate abnormally, replace them. Otherwise, replace the heaters.



4.5.1 Replace The Heater In Equipment Compartment

Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-10.

Heater MCB AC input MCB Panel of distribution unit

Figure 4-10 Position of AC MCB and heater MCB

Step 2: Remove the panel of the distribution unit, as shown in Figure 4-11. The position is shown in Figure 4-10.

Figure 4-11 Remove the panel of the distribution unit

Step 3: Unscrew the 4 pieces of screws on the panel of the distribution unit and then remove the right segment of the distribution unit. Do not disconnect its components and cables and be sure to pay attention to personnel safety.

Screw 1

Screw 2 Screw 3

Screw 4

Figure 4-12 Screw positions

Step 4: Unscrew the fixing screws of the heater cover and disconnect the cable connector from the heater relays. The heater relays are the two cables marked ‘L’



and ‘N’ in Figure 4-14. Remove the heater cover. The heater is fixed on the heater cover, as shown in Figure 4-13.

Heater of the equipment compartment

Screws

Heater

Heater cover

Figure 4-13 Disassembly of the equipment compartment heater

Cable connector of the heater

Cable connector of the heater

Figure 4-14 Heater relays

Step 5: Unscrew the fixing screws of the heater on the heater cover and then remove the damaged heater, as shown in Figure 4-12.

Step 6: Fix the new heater on the heater cover and mount the cover on the cabinet. Connect the cable connector to the heater relay. Finally, mount the distribution unit on the cabinet.

Step 7: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater fuse after making sure every thing is OK.

4.5.2 Replace The Heater In Battery Compartment


Step 2: Take out the battery string on the lower floor of the battery compartment.

Step 3: Disconnect the cable connector from the heater relay. Remove the heater cover after removing the screws on the cover, as shown in Figure 4-15.



Heater of the battery compartment

Figure 4-15 Position of the heater in battery compartment

Step 4: Replace a new heater and fix it. Connect the cable connector to the heater relay. Move the battery string to its original position.

Step 5: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater fuse after making sure every thing is OK.

4.5.3 Replace Heater Relays

There are two heater relays in one heater circuit. When the environment temperature is below 5°C±5°C, the relay contacts are closed to switch on the heater circuit. When the environment temperature is above 15°C±5°C, the relay contacts are opened to switch off the heater circuit. Replace the relay if its contact cannot be closed or opened normally. Every compartment has two heater relays that are connected in series in the phase line and the neutral line separately, as shown in Appendix 3.

The position of the heater relay in equipment compartment is shown in Figure 4-14, and that of the heater relay in battery compartment is shown in Figure 4-16.

Heater relay of the battery compartment

Figure 4-16 Position of the heater relay in battery compartment

Replacement processes:


Step 2: Disconnect the cable connector of the relay and remove the screws.



Step 3: Replace a new relay and connect the cable connector of the relay to its terminal.

Step 4: Switch on the AC MCB and the heater fuse.

4.6 Replace Door Status Sensors

There is one door status sensors installed in the equipment compartment and the battery compartment separately for detecting the close or open status of the compartment doors. The two sensors are connected in series, so the monitoring module will generate an alarm when one of the doors is open. The alarm will be eliminated only when both doors are closed.

The door status sensors are not intended for service or repair, just replace them when they are damaged. If the doors are closed, when the door status sensor alarm occurs, the sensors must have been damaged. The positions of the sensors are shown in Figure 4-17.

Remove the sensor cap and then the two pieces of screws. Replace the old sensor with a new one and finally fix the sensor and the signal cables with the screws.

Door status sensor A in equipment compartment

Door status sensor B in equipment compartment

Door status sensor A in battery compartment

Door status sensor B in battery compartment

Figure 4-17 Replace door status sensor

4.7 SPD Maintenance

The AC SPD is behind the distribution unit. The appearance is shown in Figure 4-18.

Figure 4-18 AC SPD



Check the SPD indicator on the monitoring expansion board, as shown in Figure 4-19. The position of the monitoring expansion board is shown in Figure 1-2.

Alarm indicator of DC SPD

Alarm indicator of AC SPD

Figure 4-19 AC/ DC SPD indicator

If the indicator on the left is on, the DC SPD fails and needs replacement. The replacement procedures of the DC SPD are easy to take and not expatiated on here. If the indicator on the right is on, the AC SPD fails and needs replacement.

The replacement procedures of AC SPD are as follows:

Step1: Switch off the AC MCB. The position is shown in Figure 4-10.

Step 2: Remove the cover of the distribution unit. The position is shown in Figure 4-10.

Step 3: Remove the 4 screws shown in Figure 4-12, pull out the SPD alarm interface and remove the right segment of the distribution unit, as shown in Figure 4-20, Figure 4-21, Figure 4-22. Be sure to pay attention to personnel safety.

SPD alarm interface

Figure 4-20 Pull out the SPD alarm interface

Figure 4-21 Take out SPD and heater



Figure 4-22 SPD and heater

Step 4: Remove the 4 fixing screws of the SPD shown in Figure 4-21, and screw4 and screw2 are on the cross. Disconnect the connection cables of the SPD.

Figure 4-23 Remove the fixing screws of SPD

Step 5: Reverse previous steps 4~1 and replace the new SPD. Connect the cables, fix the screws and the SPD.

Step 6: Fix the distribution unit to the cabinet.

Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and restart operation after making sure everything is OK.

40 Appendix 1 Technical Data


Appendix 1 Technical Data

Environmental parameters

1. Operating temperature:

North model: -40°C to +45°C; South model: -5°C to +45°C;

2. Storage temperature: -40°C to +70°C

3. Relative humidity: 5% to 100%, no condensing

4. Altitude: 0 to 2000m. The system should be derated where the altitude is higher than 2000m. The highest operating temperature should be reduced by 1°C at every 200m higher. And the highest altitude is 4800m.

5. Solar radiation

Direct radiation: ≤1120W/m2 Dispersion radiation: ≤224W/m2

Electrical parameters

1. Rated input voltage: 220Vac

2. Input voltage range: 90Vac to 290Vac, single phase three wire. When the voltage input is between 90Vac~176Vac, the rectifiers output is allowed of linear derating. When the voltage input is 90Vac, the minimum rectifier output power is 37.5% of rated power.

3. Maximum input current of the system: 25A (with no user connector- jack output)

4. Maximum output current of standard configuration: 60A

5. Rated frequency: 50Hz

6. Input frequency range: 40Hz to 65Hz

Mechanical parameters

Dimensions (H%W%D): 1600mm%600mm%600mm (without base)

Weight: ≤450kg

Audible noise

≤61dB.

Anti-erosive performance

Coating:

1. Adhesion test satisfies ISO2409 Class 0.

2. The pencil rigidity test satisfies ASTM D3363 2H.

3. Shock test satisfies 50kg.cm according to ASTM D2794.

4. The coating is not changed after 500 hours salt-fog test according to ASTM B117.

Appendix 1 Technical Data 41


5. The coating of the external surface of the cabinet is suitable at the -40°C to +55°C environmental temperature and 1120W/m2 solar radiation. The coating should not blister, flake or flaw after 250 hours test according to ASTM D822. But it is allowed to have slight pulverization, that is, a little paint particle is allowed to adhere when the coating is wiped at full tilt. The slight change of color is allowed, that is, it is acceptable if the color difference value (NBS) is less than 6.0.

Protection requirement

1. The cabinet of the equipment compartment satisfies GB4208 IP55.

2. The cabinet of the battery compartment satisfies GB4208 IP23.

Lightning protection

1. The system has a Level B+C SPD on AC side.

2. The AC input can withstand the maximum strike through current capacity of 60kA, and the nominal through current capacity is 25kA. The simulated lightning strike is carried out in term of YD1235.1 and YD1235.2.

3. The test of which the DC side can withstand through current capacity of 15kA requires: -48V-RTN can withstand the strike of 15kV with the waveform 8/20µs 5 times, for positive and negative polarity respectively of 10/700µs 5 times, for positive and negative polarity respectively, and the interval between every two tests is one minute; RTN-PE can withstand the strike of 15kV with the waveform 8/20µs 5 times, for positive and negative polarity respectively of 10/700µs 5 times, for positive and negative polarity respectively, and the interval between every two tests is one minute

42 Appendix 2 Definitions Of The Monitoring Expansion Board Interface


Appendix 2 Definitions Of The Monitoring Expansion Board Interface

All the sensors are connected to the monitoring expansion board. The screen print diagram of the wiring port of the monitoring expansion board is as follows.

Screen print of Monitoring expansion board socket

Figure 1 Screen print diagram of the monitoring expansion board

Connector models of the monitoring expansion board terminals and recommended connection cables are in the following table.

Table 1 Connector models and recommended connection cables

Signal port Screen print

marks Socket- connector

model commended

cables(AWG) Waterlogging J_WATER P2500-4 26~22

Circumambient temperature/ humidity TEM_HU P2500-4 26~22 main distribution frame J_WIRE P2500-2 26~22

Smoke sensor J_SMOKE P2500-2 26~22 Door status sensor JTM1 P2500-2 26~22 Alarm dry contact JK1,JK2 P2500-2 26~22

Optical- coupler output JAC1,JAC2 P2500-2 26~22 Backup digital data input J9 MSTB2.5/2-ST-5.08 26~22

RS422 communication port J8 MSTB2.5/4-ST-5.08 26~22 Preset dry contact port J12 MSTB2.5/2-ST-5.08 26~22

The functional definitions of port- pins of the monitoring expansion board are shown in the following table.

Table 2 Port- pin definitions of the monitoring expansion board

Port name Screen

print marksCorrelative

pins Signal properties Remark

1,3,5 +24V output Backup digital value

J9 2,4,6 Input of the signal cable

Appendix 2 Definitions Of The Monitoring Expansion Board Interface 43


Port name Screen



1 +12V output 2 Input of the signal cable 3 Earth cable

Waterlogging sensor port

J_WATER

4 None 1 +24V output

2 Input of the temperature signal cable

3 +24V output

Port of the circumambient temperature/ Humidity sensor

TEM_HU

4 Humidity signal cable input 1 Earth cable

2 Battery- temperature signal cable input

3 +12V output

Battery- temperature sensor port

BAT_WE

4 +12V output

Check the battery- compartment temperature. Connected before delivery.

1 Optical- coupler1 controlling output

Optical- coupler1 controlling output port

JAC1 2

Optical- coupler1 controlling output

1 Optical- coupler2 controlling output

Optical- coupler2 controlling output port

JAC2 2

Optical- coupler2 controlling output

1 main distribution frame signal input

Port of mains distribution frame sensor

J_WIRE 2 +48V power output 1 Door status sensor signal input Door status

sensor port JTM1

2 +24V power output 1 Smoke signal inout Smoke sensor

port J_SMOKE

2 +24V power output 1 dry contact1 output Alarm dry contact

port JK1

2 dry contact1 output 1 dry contact2 output Alarm dry contact

port JK2

2 dry contact2 output 1 Earth cable

2 Signal cable input of equipment compartment temperature

3 +12V output

Port of the Equipment- compartment temperature Sensor

EQU_WE

4 +12V output 1 BUS+ input 2 BAT1 mid- voltage input 3 BAT2 mid- voltage input 4 BUS- input 5 None

Battery- balance test port

J4

6 None Load MCB switchable test port

J3 1~7 7 Load MCB monitoring signal input

44 Appendix 2 Definitions Of The Monitoring Expansion Board Interface


Port name Screen



1 -48V power output SPD failure test port on DC side

J5 2

SPD failure of the DC side signal input

Connected before delivery

1 -48V power output SPD failure test port on AC side

J6 2

SPD failure of the AC side signal input

Connected before delivery

1 Power output

2 Signal output of fan speed To internal fan. Connected before delivery

3 Signal input of fan failure 4 Power- earth cable 5 Power output

6 Fan speed signal output To external fan. Connected before delivery

7 Signal input of fan failure

Fan- control port J_FAN

8 Power- earth cable 1 TX+ 2 TX- 3 RX+

RS422 communication port

J8

4 RX- Preset dry contact port﹡

J12 1~8 RLn+,RLn-

1 Busbar＋ Expansion board power input port

J2 2 Busbar－

﹡Remark:

The descriptions of the preset dry contact ports are as follows:

Dry contact 1: dry contact of AC/ DC SPD alarm are preset switched- on (normal state), and gets switched- off when AC/ DC SPD alarms.

Dry contact 2: dry contact of mains failure alarm are preset switched- on (normal state), and gets switched- off when mains shortage, mains over/ under- voltage alarm occurs.

Dry contact 3: dry contact of DC over/ under- voltage alarm are preset switched- on (normal state), and gets switched- off when DC over/ under- voltage alarm occurs.

Dry contact 4: dry contact of system power alarm are preset switched- on (normal state), and gets switched- off when module failure, module protection, module communication abnormal, busbar output over/ under- voltage alarm, charging overcurrent alarm, battery string route disconnection or internal/ external fan fault alarm occur.

Appendix 3 System Schematic Diagram 45


Appendix 3 System Schematic Diagram

Internal fanExternal fan

Monitor transfer board

Door status sensor for equipment box

Door status sensor for battery box

PE busbar for outside cabinetPE busbar for inside cabinet0V DC busbar

-48V DC output

Temperature sensor for battery box

Temperature sensor for equipment box

Dry contact

RS485 communication port

Standby value input port

AC inputAlarm

SPDHeater for battery box

Heater for equipment box

Temperature relay

Temperature relayTemperature relay

Temperature relay

LOAD 1 LOAD 2 LOAD 3 LOAD 4 LOAD 5 LOAD 6

Lin

Nin

Lout

Nout

PE

L

N

PE

Alarm

Heating unit for North model cabinet

Figure 2 Schematic diagram of APM200 outdoor power supply system

46 Appendix 4 System Wiring Diagram


Appendix 4 System Wiring Diagram

LOAD1- LOAD2- LOAD3- LOAD4- LOAD5- LOAD6- BATT.(-) BATT.(+)LOAD+SPD-

Battery string 1＃

Battery string 2＃

PE bus outside the cabinet

Heater of the battery

compartment

Equipotential cable

Up access control

Down access control

Cross-cable (up/ down)

PE bus

AC outleading wire of the subrackBattery

Temperaturecompensation

Temperature check of the

equipment compartment

Heater of theequipment

compartment

Figure 3 Wiring diagram of APM200 outdoor power supply system

apm200 outdoor power supply system user manual-20060628-b-1.0

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