apm2000- power supply systm

7/28/2019 APM2000- Power Supply Systm

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APM200 Outdoor Power Supply System

User Manual

Version: V1.0

Revision date: December 12, 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]


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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 endangerhuman 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.


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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

WaringWhen moving equipment by hand, protective gloves should be

worn to avoid injury by sharp object.

III. Cable connection

NoticePlease verify the compliance of the cable and cable label with

the actual installation prior to cable connection.

IV. Binding the signal lines

NoticeThe signal lines should be bound separately from heavy

current and high voltage lines, with minimum 150mm binding

interval.


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Contents

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

1.1 Theory .......................................................................................................1

1.2 System Features........................................................................................2

1.3 System Function ........................................................................................2

1.3.1 Protective Function..........................................................................2

1.3.2 Alarm Function ................................................................................3

1.3.3 Communication Function .................................................................7

1.4 System Composition..................................................................................7

1.4.1 Embedded Power Supply ................................................................8

1.4.2 Heat Exchanging Equipment And External Fan...............................8

1.4.3 Heaters ............................................................................................9

Chapter 2 Installation............................................................................................10

2.1 Precautions..............................................................................................10

2.2 Preparations ............................................................................................10

2.2.1 Inspecting Location........................................................................10

2.2.2 Distributing Goods .........................................................................10

2.2.3 Unpacking......................................................................................11

2.2.4 Preparing Tools .............................................................................11

2.2.5 Preparing Cables...........................................................................12

2.2.6 Opening The Cabinet Door............................................................13

2.3 Installing Cabinet .....................................................................................15

2.3.1 Installing Cabinet On A Concrete Stand ........................................15

2.3.2 Installing Cabinet On A Floorstand ................................................17

2.4 Installing Battery ......................................................................................19

2.5 Installing Rectifiers...................................................................................20

2.6 Connecting Cables ..................................................................................21

2.6.1 Precautions....................................................................................21

2.6.2 Cable Tube ....................................................................................22

2.6.3 Connecting Power Cables .............................................................22

2.6.4 Connecting Battery Cables ............................................................26


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Chapter 3 Testing .................................................................................................28

3.1 Introduction..............................................................................................28

3.2 Testing AC Distribution ............................................................................28

3.3 Testing Rectifier.......................................................................................29

3.4 Testing Monitoring Module ......................................................................29

3.4.1 Setting System Parameters ...........................................................30

3.4.2 System Function Test ....................................................................33

Chapter 4 Maintenance.........................................................................................36

4.1 Embedded Power Supply System Maintenance ......................................36

4.1.1 System Operation..........................................................................36

4.1.2 Indicator description ......................................................................37

4.1.3 Routine Maintenance.....................................................................38

4.1.4 Handling Of Common Faults .........................................................40

4.2 Battery Maintenance................................................................................414.3 Heat Exchanging Equipment ...................................................................41

4.4 External Fan Maintenance.......................................................................43

4.5 Replace Heaters And Relays...................................................................44

4.5.1 Replace The Heater In Equipment Compartment ..........................44

4.5.2 Replace The Heater In Battery Compartment................................47

4.5.3 Replace Heater Relays..................................................................48

4.6 Replace Door Status Sensors..................................................................49

4.7 SPD Maintenance....................................................................................50

Appendix 1 Technical Data...................................................................................53

Appendix 2 Definitions Of The Monitoring Expansion Board Interface .................55

Appendix 3 System Schematic Diagram...............................................................60

Appendix 4 System Wiring Diagram .....................................................................61


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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 powersupply

220

-48Vdc

Load 1

Vac

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.


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2 Chapter 1 Overview


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 voltageis 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.

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.


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Over- temperature protection

If the temperature of the equipment compartment remains over the

protection point (55C by default) for 30 seconds constantly, the monitoring

module will cut off the non- priority loads until the ambient temperature

drops below 45C. 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.


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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.


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Remote-

communication

values

Description

Charging over-

current

1. The charging overcurrent alarm will plus 5A when charging current is over the

current- limit point for 5 minutes constantly..

2. Alarm recovers when charging current is below the current- limit point for 5

minutes constantly.

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 10C than the protection point.

3. Setting range: 50C ~70C. The protection point is 65C 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 10C than the

protection point.

3. Setting range: 40C ~70C. The protection point is 53C 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 -50~100C. When over the over- temperature alarm

point, the alarm return difference is 3C. The alarm point can be set respectively,

and is 50C by default.

Circumambience

under-

temperature

The available setting range is -50~0C. When under the over- temperature alarm

point, the alarm return difference is 3C. The alarm point can be set respectively,

and is 0C 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).


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Remote-

communication

values

Description

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

sensorThe dry contact is disconnected when alarm.

SPD failure

alarmCheck 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.

Heater failure

alarm of the

storage batterycompartment

When the mains is in normal state and the storage battery temperature is below 5C

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. 8/20s impulse current can endure 300A, without damage (bio- transient

suppressor with model of1.5SMC39CA is commeded).

3. Alarm power level is adjustable.


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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 AMP200 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.


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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 (underthe plate)

Floorstand

Batterycompartment

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 monitoringmodule, 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


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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 5C5C to ensure the normal operation of the North model system

segments in low temperature environment.


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10 Chapter 2 Installation


Chapter 2 Installation

2.1 Precautions1. 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.


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Chapter 2 Installation 11


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 NetworkPower Co., Ltd. shall inspect the equipment together.

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.


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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 +70C 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 10mm2sectional 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.


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A=I%L/(KU)

Where:

Asectional area of a cable (m2)

Itotal current that flows in the cable (A)

Lcable length (m)U acceptable voltage drop in the cable (V)

Kelectric 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 blackcables 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.


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Keyholesheet

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.


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Note

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

advance.

2.3 Installing CabinetThe 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 door

300~500

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.


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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 M1055mm.

Drill a 70mm-depth hole at each marked point by using a 14 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.

Drillvertically

Clean thedust

Knock itinto place

Tightenthe bolt

Expansionpipe

Powercabinet

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.


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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 underneaththe 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 washer

Cabinet 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.


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Cabinet door14

4

50

400

Figure 2-8 Installation dimensions of floorstand

Step 2: Drill holes

The size of the expansion bolt delivered with the accessories is M1055mm.

Drill a 70mm-depth hole at each marked point by using a 14 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


Step 3: Fix the floors tand

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 bolt

Ground

Batterycompartment

Screw for fixing cabinet

Figure 2-9 Installing the cabinet and floorstand


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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 batterycompartment 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


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 theside 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.


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Batterycompartment

Battery string IBaffle

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


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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 cablethrough 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.


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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 distr ibut ion unit

The panel is shown in Figure 2-13.


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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 2 3, 4 16A 25mm2



LOAD 3 5, 6 16A 25mm2



LOAD 4 7, 8, 9 16A 25mm2

Total output of three MCBs


LOAD 5 10 32A 25mm2

Total output of the MCB


LOAD 6 11 32A 25mm2

Total output of the MCB



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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.


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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 loadPositive 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


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.


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2. The AC cables should be routed from the MCB in the external distributionequipment prepared by user. They should be connected to the MCB just before thesystem 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


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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.


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28 Chapter 3 Testing


Chapter 3 Testing

3.1 IntroductionThe 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


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Chapter 3 Testing 29


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.

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 53.5V0.5V.

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.


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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

RemotelyAcquiredAnalogSignal

1) AC Input Voltage

2) DC Busbar Voltage

3) Rectifier Total Output Current

4) Battery String Current

5) AmbientTemperature/Humidity

6) Battery Temperature

RemotelyAcquiredAlarm/DigitalSignal

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 Status

15) 7 Standby Digital Signal Status16) 2 Digital Signal Output Status

17) Battery Discharge Test Phase

Status

18) Battery Charge Over-Current

Status

Remote-ControlParameters

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.


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Table 3-2 Configurable parameters

Parameter Range Default value

AC Input Under-Voltage

Alarm Point

> 60V and lower than AC Over-Voltage

Alarm Point180V

AC Input Over-Voltage

Alarm Point

Between 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 voltage48.5V

DC Busbar Over-Voltage

Alarm Point

58V ~ 60V and 1V higher than BC

voltage58V

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

35V but lower than LLVD voltage

(when LLVD is disabled, lower than DC

Busbar Under-Voltage Alarm Point)

46.5V

Ambient Temp Alarm

Lower Limit

-50C ~ 100C and lower than upper

limit0C

Ambient Temp Alarm

Upper Limit

-50C ~ 100C and higher than lower

limit50C

Ambient Humidity Alarm

Lower Limit

0%RH ~ 100%RH and lower than upper

limit10%RH

Ambient Humidity Alarm

Upper Limit

0%RH ~ 100%RH and higher than

lower limit80%RH

Standby Digital Signal

Alarm LevelHigh level alarm 1, low level alarm 0

High level alarm

1

Number 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


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Parameter Range Default value

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)

Coefficient of Charge

Current Limiting Point0.1 ~ 0.25 0.15

Scheduled BC Interval 30 days ~ 240 days 60 days

Temp Compensation

Coef. of Battery String0mV/C ~ 500mV/C 80mV/C

Temp Measurement

Lower Limit-50C ~ 0C -50C

Temp Measurement

Upper Limit0 C ~ 100 C 50 C

Humidity Measurement

Lower Limit

0%RH ~ 100%RH and lower than

Upper Limit0%RH

Humidity Measurement

Upper Limit

0%RH ~ 100%RH and higher than

Lower Limit100%RH

Power Distribution Analog

Signal Calibration

Coefficient

Not configurable by the user

Battery Over-TempProtection Point

40C ~ 70C 53C

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.


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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.


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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.


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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 TestConnect 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 forcorresponding 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.

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

battery.


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36 Chapter 4 Maintenance


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 technologyThe 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 rectifiers 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.


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Chapter 4 Maintenance 37


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)

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 protectionalarm 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 modu le

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.


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Figure 4-2 Appearance of monitoring module

Table 4-1 Monitoring module indicator description

Indicator

MeaningRUN 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

communicationSlow blinking (Once per second) On

System alarm, with abnormal

communicationFast 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 ofthe 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


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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.

Rectifi er 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



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When replacing new monitoring modules, communication cable and signal

cable shoule be connected as well. See Figure 4-4.

Handle of therectifier

Rectifier

Handle of themonitoringmodule

Monitoringmodule

Communicationcable to theexpanding board

Signal cable to theexpanding board

Figure 4-4 Handle of the modules

Note

The rectifiers connecting part is a delicate device. Although the rectifiers aredesigned 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


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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 isrecommended 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.

Heatexchangeequipment

Cableconnector

Fixingscrews

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.


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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 heatexchanger 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.


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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 anabnormal 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 ex-changeequipment

Cable con-nector of theheat exchangeequipment

Fixingscrews

Cable con-nector of theexternal fan

Fixingscrews

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.


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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 5C5C, and stop heating above

15C5C. 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.


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Heater MCB AC input MCBPanel 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.


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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 equipmentcompartment

Screws

Heater

Heater cover

Figure 4-13 Disassembly of the equipment compartment heater

Cable connector ofthe heater

Cable connector ofthe heater

Figure 4-14 Heater relays


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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 1: Switch off the AC MCB and the heater fuse, as shown in Figure

4-10.

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.


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4.5.3 Replace Heater Relays

There are two heater relays in one heater circuit. When the environment

temperature is below 5C5C, the relay contacts are closed to switch on

the heater circuit. When the environment temperature is above 15C5C,

the relay contacts are opened to switch off the heater circuit. Replace therelay 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 thebattery compartment

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

Replacement processes:

Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-7.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.


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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 statussensor A inequipmentcompartment

Door statussensor B inequipmentcompartment

Door statussensor A inbatterycompartment

Door statussensor B inbattery

compartment

Figure 4-17 Replace door status sensor


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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 ind icato r of DC SPD

Alarm ind icato r 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.


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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


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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.


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Appendix 1 Technical Data 53


Appendix 1 Technical Data

Environmental parameters

1. Operating temperature:

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

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

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 1C at every 200m higher. And the highest altitude is 4800m.

5. Solar radiation

Direct radiation:1120W/m

2

Dispersion radiation:224W/m

2

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: 60A5. 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.


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54 Appendix 1 Technical Data


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.

5. The coating of the external surface of the cabinet is suitable at the -40C

to +55C 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 of15kA requires: -48V-RTN can withstand the strike of 15kV with the

waveform 8/20s 5 times, for positive and negative polarity respectively of

10/700s 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 8/20s 5 times, for positive and negative

polarity respectively of 10/700s 5 times, for positive and negative polarity

respectively, and the interval between every two tests is one minute


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Appendix 2 Definitions Of The Monitoring Expansion Board Interface 55


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 portScreen print

marks

Socket- connector

model

commended

cablesAWG

Waterlogging J_WATER P2500-4 26~22

Circumambient

temperature/ humidityTEM_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


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56 Appendix 2 Definitions Of The Monitoring Expansion Board Interface


Signal portScreen print

marks

Socket- connector

model

commended

cablesAWG

Backup digital data input J9 MSTB2.5/2-ST-5.08 26~22

RS422 communication

portJ8 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 nameScreen

print marks

Correlative

pinsSignal

apm2000- power supply systm

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