ACTURA Durus PS48350 User Manual

ACTURA Durus PS48350
User Manual
ACTURA Durus PS48350 User Manual Version: Revision date: BOM: V1.1 09.25.2003 31010916
Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.
Website: www.emersonnetworkpower.com
Foreword
This manual mainly describes the composition, installation, testing, operation, routine maintenance and emergency handling of the PS48350/25 power supply system.
Target
Power system installation personnel, maintenance personnel
Conventions Used in This Book

The following symbols are used in this book to alert you to important information: Caution/Notice/Warning/Danger: notes needing special attention during operation.
& Note
complementary explanation to operation description.
Safety Precautions
To reduce the chance of accident, please read the safety precautions very carefully before operation. The "Caution, Notice, Warning, Danger" symbols 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 provided by Emerson must be strictly observed.
Electrical Safety
I. Hazardous voltage
Danger
Some components of the power system carry hazardous voltage in operation, direct contact or indirect contact through moist objects will result in fatal injury. Safety rules in the industry must be observed when installing the power system. The installation personnel must be licensed to operate high voltage and AC power. In operation, conductive objects, such as watches, bracelets, rings, etc., are not allowed to be worn.
When water or moisture is found on the cabinet, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power system. "Prohibit" warning label must be attached to the switches and buttons which are not permitted to be operated during installation.
Danger
High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high voltage operations.
II. Tools
W arni ng
Insulated tools must be used. No general-purpose tools should be used. III. Thunderstorm
Danger
Maintenance of equipment in the AC input section should not be undertaken during storm conditions. In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be properly earthed in time to avoid damage by lightning strikes. IV. 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. V. Short-circuit
Danger
During operation, never short the positive and negative poles of the DC distribution unit of the system or the non-earthing pole and the earth. 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, ring, or other metal items during operation. Insulated tools must be used. When working on equipment which is in operation, keep control of body movements, so that when the tool connection is loosened, the motion of the human body and tool is reduced to a minimum.
Battery
Danger
Before any operation on battery, read very carefully the safety precautions for battery transportation and the correct battery connection method. Non-standard operation on the battery will cause danger. In operation, precautions should be taken to prevent battery short circuit and overflow of electrolyte. The overflow of electrolyte will pose potential threat to the equipment, it will erode the metal objects and PCBs, thus causing equipment damage and short circuit of PCBs. Before any operation on battery, pay attention to the following points: l l l l Remove the watch, bracelet, ring, and other metal items. Use insulated tools. Wear eye protection. Wear rubber gloves and apron to guard against electrolyte spillage. l When transporting batteries, the electrode of the battery should always be kept facing upward. Never put the battery upside down or at an angle.
Others
I. Safety requirement
Notice
Please use the same model fuse F5AL250V to replace the power input fuse of the signal bridging board W2442X1 of the PCU (power control unit) and distribution unit. II. Sharp object
W arni ng
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. Laying the signal lines
Notice
The signal lines should be laid separately from heavy current and high voltage lines, with a distance of at least 150mm.
Contents
Chapter 1 System Overview........................................................................ 1 1.1 System Introduction........................................................................ 1 1.2 1.3 Features......................................................................................... 3 Components................................................................................... 4 1.3.1 1.3.2 Rectifier................................................................................ 4 PCU ..................................................................................... 6
1.3.3 AC/DC Distribution Unit........................................................ 9 1.3.4 Ports of Signal Transfer Board W2442X1 ........................... 14 1.3.5 Emerson Battery................................................................. 15 Chapter 2 Installation Instructions ............................................................. 19 2.1 General........................................................................................ 19 2.1.1 Safety Rules....................................................................... 19 2.1.2 Documents......................................................................... 20
2.1.3 Tools & Material Preparation.............................................. 20 2.1.4 Unpacking Inspection......................................................... 24 2.1.5 Installation Procedure......................................................... 26 2.2 Arrangement & Mounting of Power Cabinets................................ 26 2.2.1 Mounting Cabinets on the Floor.......................................... 27 2.2.2 Installation on Supporting Rack.......................................... 32 2.3 Rectifier Installation...................................................................... 34 2.4 PCU Installation ........................................................................... 34 2.5 Emerson Battery Installation of PS48350-1B/25........................... 35 2.6 Cable Connection & Cable Entry.................................................. 36 2.6.1 Cable Connection to MCB .................................................. 36 2.6.2 Cable Connection to Screw/bolt.......................................... 37
2.6.3 Cable Entry ........................................................................ 37 2.7 Connection of AC Cables............................................................. 38 2.8 Connection of Battery and Load Cables ....................................... 40 2.9 Cabling Route inside Cabinet....................................................... 44 2.10 Installation of Temperature Sensor Cable................................... 45 2.11 Modem Installation ..................................................................... 45 2.12 Dry Contact Connection ............................................................. 47 Chapter 3 Test Instructions ....................................................................... 49 3.1 General........................................................................................ 49 3.1.1 Preliminaries ...................................................................... 49
3.2 Installation Check......................................................................... 50 3.2.1 Inspection of Cabinets........................................................ 50 3.2.2 Inspection of Mains Connections........................................ 50 3.2.3 Inspection of Cabling.......................................................... 50 3.2.4 3.3 Batteries............................................................................. 51
Start-up Preparations................................................................... 51 3.3.1 AC Distribution Unit & Rectifiers ......................................... 51 3.3.2 DC Distribution Unit............................................................ 51 3.3.3 3.3.4 3.3.5 PCU ................................................................................... 52 Batteries............................................................................. 52 BLVD ................................................................................. 52
3.4 Start Up........................................................................................ 52 3.4.1 Batteries............................................................................. 53
3.4.2 Start of Rectifier ................................................................. 53 3.4.3 Connection of Batteries, Rectifiers & LVD........................... 54 3.5 Basic Settings .............................................................................. 54 3.5.1 System Model .................................................................... 54 3.5.2 Battery Number .................................................................. 54
3.5.3 Battery Capacity................................................................. 55 3.5.4 Temperature Compensation Coefficient ............................. 55 3.5.5 Current Limit....................................................................... 55 3.5.6 Float and Equalize Charge Voltages................................... 55 3.6 Checking of Alarms ...................................................................... 56 3.6.1 Testing Rectifier Faults....................................................... 56 3.6.2 Testing Battery Fuse Fault.................................................. 56 3.6.3 Testing Distribution Circuit Breaker Fault............................ 56 3.6.4 Testing Undervoltage Detection and BLVD......................... 57 3.6.5 Testing Lightning Protection Fault ...................................... 57 3.7 Checking of System Operation Status.......................................... 57 3.7.1 AC Voltage......................................................................... 57 3.7.2 DC Voltage......................................................................... 58
3.7.3 Battery Current................................................................... 58 3.7.4 Load Current...................................................................... 58 3.7.5 Rectifier Parameters........................................................... 58
3.7.6 Battery Room Temperature................................................ 59 3.8 Final Steps................................................................................... 59 Chapter 4 Use of PCU............................................................................... 60 4.1 Menu Architecture........................................................................ 60 4.2 Operation Instruction .................................................................... 61 4.3 System Information Pages ........................................................... 61 4.4 Rectifier Information Pages .......................................................... 62 4.5 Current Alarm & Alarm History Pages........................................... 63 4.6 System Control Pages.................................................................. 65 4.7 Setting System Parameters.......................................................... 67 4.7.1 4.7.2 Battery Management Parameters....................................... 67 Others................................................................................ 68
4.7.3 Parameter Settings Through PCU ...................................... 69 4.8 System Initialization...................................................................... 70 4.8.1 Setting System Model......................................................... 70 4.8.2 Setting Language............................................................... 71 4.8.3 Password Initialization ........................................................ 71 4.8.4 System Initialization............................................................ 71 4.9 Dry Contact Relay Output............................................................. 72 Chapter 5 Maintenance Instructions.......................................................... 73 5.1 General........................................................................................ 73 5.1.1 Authorization ...................................................................... 73 5.2 Alarm Categories ......................................................................... 74 5.3 Actions in the case of Alarm......................................................... 74 5.3.1 Mains Failure (Emergency Alarm) ...................................... 75 5.3.2 Mains Over Voltage (Ordinary Alarm) ................................. 75 5.3.3 Mains Under Voltage (Ordinary Alarm) ............................... 75 5.3.4 SPD Fault (Emergency Alarm) ........................................... 76 5.3.5 DC Output Over Voltage (Emergency Alarm)...................... 76 5.3.6 DC Output Under Voltage (Emergency Alarm).................... 77 5.3.7 Distribution Fuse N Failure (Emergency Alarm) .................. 78 5.3.8 Auxiliary Distribution Fuse Failure (Emergency Alarm) ....... 78 5.3.9 Battery Fuse Failure (Emergency Alarm) ............................ 79 5.3.10 LLVD (Emergency Alarm)................................................. 79 5.3.11 BLVD (Emergency Alarm) ................................................ 80 5.3.12 Rectifier N Overvoltage Shut Off (Emergency Alarm) ....... 80 5.3.13 Rectifier N Failure (Emergency Alarm) ............................. 80 5.3.14 Rectifier N Communication Failure (Emergency Alarm) .... 81 5.3.15 PCU Failure (Non-alarm by Default)................................. 81 5.3.16 Measurement Fault (Non-alarm by Default)...................... 82
5.3.17
Manual Operation State (Non-alarm by Default) ............... 82
5.3.18 Equalize Charge State (Non-alarm by Default)................. 82 5.3.19 High Battery Temperature (Emergency Alarm) ................. 83 5.4 Repair.......................................................................................... 83 5.4.1 Exchanging Rectifier .......................................................... 83 5.4.2 Exchanging the Fan of Rectifier.......................................... 84 5.5 Final Steps................................................................................... 85 5.6 Maintenance ................................................................................ 86
Appendix A Technical Specifications......................................................... 87 Appendix B System Schematic Diagram ................................................... 91 Appendix C System Circuit Diagram.......................................................... 95 Appendix D System Engineering Design Diagram..................................... 97
Chapter 1
System Overview
Chapter 1 System Overview

1.1 System Introduction
The PS48350/25 power supply system is a new generation of communication power supply system with unrivalled reliability and performance developed by Emerson Network Power Co., Ltd. integrating years of experience in R & D and operation on network. It is available in two models: PS48350-1A/25( 1.2m high) and PS48350-1B/25( 1.8m high) . The PS48350-1B/25 power supply system can accommodate 2 battery strings each containing 4 batteries; while the PS48350-1A/25 power supply system cannot contain battery inside the cabinet. The 2 models are all the same except for this difference. The power supply system is composed of the AC/DC distribution unit, HD4825-3 rectifiers and PSM-A10 PCU. The system structure is shown in Fig. 1-1. Its configuration appears in Table 1-1.
ACTURA Durus PS48350 User Manual
AC/DC distribution unit
Monitoring module
Rectifier Internal battery
Fig. 1-1 Diagram of System Structure Table 1-1 PS48350/25 System Configuration
Component PSM- A10 PCU HD4825- 3 rectifier AC distribution unit 1 14 1. 1 mains input 2. Class II/C SPD 1. 2 batteries: 400A(fuse)2 DC distribution unit 2. 15 load outputs(MCB), total capacity: 350A. in which: 63A8; 32A5; 10A2 3. DC side SPD11Z Others LLVD is optional; 9 outputs with LLVD (load low voltage disconnection), 6 outputs with BLVD (battery low voltage disconnection). MODEM, temperature sensor Standard Configuration / At least 2 Optional Configuration
Chapter 1
System Overview
1.2 Features
The PS48350/25 power supply system is suitable for applications such as base stations, small exchanges, satellite communications, data communications, railway and electric power systems, etc., which can be subject to large AC power fluctuations. The PS48350/25 power supply system is easy to operate, install and maintain. Its AC input/output cables and DC input/output cables can be connected through the top of the cabinet from the front. Main features include: l l True front access enables placement in a room without rear workspace. The PS48350-1B/25 power supply system can accommodate 2 100Ah Emerson battery strings (totally 200Ah, depending on the battery size), thus saving space for battery placement. The system is CE compliant. Low radiated emissions: with advanced EMC design, the rectifier and the system meet the conducted and radiated interference requirements of EN55022 CLASS A. Safety: system design complies with EN60950 and GB4943. The AC input voltage range is 90V~290V. Below AC input voltage 170V the output power is 50% of the rated value. Utilizing an active power factor compensation technique, the rectifier has a power factor up to 0.99. Rectifier utilizes full soft switching technique, and has greater than 90% efficiency. Pug-and-play rectifiers, with a replacement time less than 1 minute. Lightning surge protection at both the AC side and the DC side. Battery management function, including LLVD and optional BLVD, temperature compensation, auto voltage regulation,
l l
l l l l l l l
stepless current limiting, battery capacity calculation and online battery test. l l Alarm records up to 100 events, and battery test data record up to 10. Network design: providing multiple communication ports (such as RS232, modem and dry contact relays), which enables remote monitoring. Complete fault protection and fault alarm functions.
1.3 Components
1.3.1 Rectifier
HD4825-3 rectifier is shown in Fig. 1-2 and Fig. 1-3:
Fig. 1-2 Rectifier Appearance
Chapter 1
System Overview
Power indicator Fault indicator
Protection indicator
Input/output terminals
Positioning pin
Fig. 1-3 Front/Rear Panels of HD4825-3 Rectifier The pin assignment of the input/output terminal is as follows:
PIN2DC output PIN10Address 0 PIN13Address 2 PIN16Address 4 PIN19GND PIN22 Current sharing + PIN26 AC input PIN29 PE PIN4DC output+ PIN9Address 1 PIN12Address 3 PIN15RS485PIN18RS485+ PIN21 Current sharingPIN28 AC input
The functions of the indicators on the rectifier front panel are described below:
Indicator Power indicator Protection indicator Fault indicator Normal State On Off Off Fault State Off On On Fault Cause No AC input or input fuse damaged AC input voltage or ambient temperature outside specificatioins Irretrievable fault inside rectifier
1.3.2
PCU
There are backlit LCD, keypad, indicators and latch on the front panel of the PCU PSM-A10. The PCU is connected to the back plate by means of DIN 41612 connector, and the back plate is connected to the signal transfer board W2442X1 at the upper left side inside the cabinet with cable. The signal transfer board provides RS232 communication port, dry alarm contact, and modem power port (see figure 1-10). The appearance of the PCU PSM-A10 is shown in figure 1-4: Mechanical Parameters of PCU PSM-A10
Dimensions ( HWD) 132mm 86mm 344mm Weight 1.5kg
Chapter 1
System Overview
EC S
ENT MENU
PSM-A10
Figure 1-4 Appearance of PCU PSM-A10 Indicators and Buttons of PCU PSM-A10
Indicator/button Monitoirng module operation indicator(green) Fault indicator(red) Round-shape function button Normal state On Off Fault state Off On Fault cause No power source System alarm exists
The function button is shown in figure 1-5
The function button of the PCU is shown below:
Figure 1-5 Function Button of PCU PSM-10
The use of the function button appears from the following table:
Button ESC ENT/MENU Use Use this key to return to the upper level menu Use this key to enter the lower level menu or confirm the menu operation. Use these keys to move among the menus of the same level or select information item to query. :use this key to move from 1~n menus of the same level, or select the previous information item to query.
5 6
6 :use this key to move from n~1 menus of th e same level, or select the 5 6 is used to decrement the value (alphabetic or numeric).
next information item to query. (in setting phone number to be dialed, these keys are used to change the value: is used to increment the value(alphabetic or numeric); Use these keys to change number and settings. :use this key to increment a number or change settings(e.g ., 4? 5,Auto? Manu, etc.) :use this key to decrement a number or change settings (e.g., 5? 4,YES? NO, etc.) (in setting phone number to be dialed, these keys are used to scroll through the digits of the 14-figure phone number)
4 3
34
The PCU baud rate setting should be the same as the bus. The PCU supports RS232, modem communication protocol, the communication port is a 9-core male connector (see transfer board W2442X1 in figure 1-13). The front panel and rear panel of the PCU are shown below:
Chapter 1
System Overview
Figure 1-6 Front Panel
Figure 1-7 Rear Panel

5.Latch
1.Alarm indicator; 2.Operation indicator; 3.LCD screen; 4.Keypad;
1.3.3 AC/DC Distribution Unit

The front view of the AC/DC distribution unit is shown in figure 1-8:
10
(1),(2)LLVD switch; (3),(4)BLVD switch;(5)Buzzer;(6)Buzzer switch; (7)Operation indicator; (8)Fault indicator;(9)AC signal sampling board; (10)Rectifier input MCB; (11)Battery 1 fuse;(12)Battery 2 fuse; (13) Non-priority load output MCB(-); (14) Priority load output MCB(-);(15) Positive busbar; (16)Signal transfer board; (17)Mains input MCB; (18) Earth bar; (19)Input neutral line terminal; (20)? /C SPD; (21)- SPD MCB; (22)- Rectifier backplane
AC/DC distribution unit of PS48350-1A/25 (Front view)
Chapter 1
System Overview
11
(1),(2)LLVD switch; (3),(4)BLVD switch; (5)Buzzer; (6)Buzzer switch; (7)Operation indicator; (8)Fault indicator; (9)AC signal sampling board; (10)Rectifier input MCB; (11)Battery 1 fuse; (12)Battery 2 fuse; (13) Non-priority load output MCB(-);(14) Priority load output MCB(-); (15) Positive busbar; (16)Signal transfer board;(17)Mains input MCB; (18) Earth bar; (19)Input neutral line terminal; (20)? /C SPD; (21)- SPD MCB; (22)- Rectifier backplane; (23)Internal battery
AC/DC distribution unit of PS48350-1B/25 (Front view) Fig. 1-8 AC/DC distribution unit (Front view)
12
The rear view of the AC/DC distribution unit is shown in figure 1-9:
PS48350- 1A/25
PS48350-1B/25
(1) Negative busbar;(2)DC SPD; (3)Load shunt; (4)BLVD contactor; (5)Battery shunt 2; (6)Battery shunt 1; (7)LLVD contactor (optional)
Fig. 1-9 AC/DC distribution unit of PS48350/25 (Rear view)
Chapter 1
System Overview
13
AC input/output interfaces
Used for AC mains input: the hot line of the 3-phase AC mains input should be stripped and crimp connected to H-terminal and then connected to the three connection terminals of the MCB. Connects to the mains input neutral line. Connects to the user earth bar in the equipment room
Input MCB AC input neutral line terminal Earth bar
DC input/output interfaces
Input/output interfaces Battery 1 fuse Battery 2 fuse Positive copper bar Functions Connects to the negative terminal of battery 1 Connects to the negative terminal of battery 2 Connects to the positive terminal of battery 1 and battery 2; providing +48V power supply to load Functions as the negative terminal of the 48V power supply to the non-priority load. When the batteries discharge to the LLVD voltage, the output is disconnected.
Non-priority load output terminal(-)
Functions as the negative terminal of the 48Vpower supply to the priority load. When the Priority load output terminal(-) batteries discharge to the BLVD voltage, the output is disconnected.
Panel indicators
Indicator Operation indicator Fault indicator Normal state On Off Fault State Off On Fault Cause No AC input System fault
14
Switch operation
Switch Up Down Remark In the case of system fault, the buzzer will beep if the switch is placed to "On"; and the buzzer will not beep if the switch is placed to "Off". The BLVD contactor will be controlled by the PCU when the switch is placed to "Auto".
Buzzer "On/Off"
On
Off
BLVD "Auto/Manual"
Auto
Manual
BLVD This switch is active when the BLVD Connect Disconnect Connect/Disconnect "Auto/Manual" switch is placed to "Manual". LLVD "Auto/Manual" Auto Manual The LLVD contactor will be controlled by the PCU when the switch is placed to "Auto".
LLVD This switch is active when the LLVD Connect Disconnect "Connect/Disconnect" "Auto/Manual" switch is placed to "Manual".
1.3.4 Ports of Signal Transfer Board W2442X1
Fig. 1-10 Ports of W2442X1 Board
Chapter 1
System Overview
15
Input/output ports JP8 JP7 JP16 JP10 JP9 JP4
Function Providing 12V power for modem RS232 port, for connecting modem transmission data or portable computer Port for temperature sensor Dry contact terminal Dry contact terminal Dry contact terminal
1.3.5 Emerson Battery

Two strings of Emersons 48V100Ah communication battery T12V100SEF/A can be fitted in the PS48300-1B/25 system cabinet. The battery connection from the front makes operation and maintenance accessible from the front. Moreover, the battery is fitted with gas collection and outlet acid leakage proof device (see figure 1-11), which enhances system safety.
Figure 1-11 Configuration of T12V100SEF/A Battery
1. Model & Dimensions

Dimensions in mm Battery model T12V100SEF/A Specification 12V100Ah ( LWH) 520107263 Construction 23 Weight ( Kg) 42
16
(6-GFM-100PS)
Appearance of T12V100SEF/A battery is shown in figure 1-12.
Figure 1-12 Appearance of T12V100SEF/A Battery
2. Charge/discharge parameters Float charge:constant voltage 13.38V/cell, initial charge current = 0.15C10( 25? ) ; Equalize charge: constant voltage 14.10V/cell, initial charge current = 0.15C10( 25? ) ; Charge voltage temperature compensation: - 24mV/cell? ( 25? as reference point) ; Discharge end voltage: 10.8V/cell( 10 hr rate discharge) .
3. Features 1) Long life span The Heavy-duty Pb-Ca-Sn-Al alloy grids, with strong corrosion & extension resistance and high hydrogen-electrolysis potential, enable battery lifespan up to 15 years( 25? ) . 2) Safety
Chapter 1
System Overview
17
The valve could automatically regulate the internal pressure of the battery, and the special filter eliminates the chance of battery explosion, and multi-layer seal structure prevents electrolyte leakage. 3) Superior quality The key components, such as safety valve, acid filter, seal rings, seal rubber, seal resin, AGM separators etc., are all high grade materials to ensure the battery quality. 4) Special design for interior application When used in sealed compartments, the acid gas collection system collects and neutralizes the acid fume generated during the charging process. This avoids gas accumulation inside the equipment cabinet. 5) Integrated design Taking into consideration the requirements for working with communication systems in switch, access and mobile station, this battery design is optimized, and includes protection for applications in enclosed environment, thus ensuring reliable system operation. 4. Notes on use To maximize the performance of Emerson batteries and ensure safe usage, please observe the following precautions. Ensure they shall be read and fully understood before use. Notes on battery charge/discharge ( 1) Do not alter the charge/discharge parameter settings arbitrarily. ( 2) Charge the battery immediately after it is discharged. Otherwise, the battery life will be reduced. Notes on battery storage ( 1) Storage temperature should be within the range of - 15? ~ + 45? .
18
( 2) Battery should be stored in fully charged state. Recharging should be done if the battery capacity is reduced during transportation or storage. ( 3) Recharging should be done to compensate the lost capacity due to the self discharging during long storage period. Recharging methods are given in the following table: Storage Temperature and Recharging Interval
Storage Temperature Lower than 25? Recharging Interval Recharging Method(any one can be selected)
? Charge with 0.15C10A constant Once 6 months current until the cell voltage reaches 14.40V/cell. This may require up to 24 hours. Once 4 months ? Charge for 4 ~ 10 hours with 0.1C10A constant current
25~ 45?
Battery life will be reduced significantly if storage temperature is higher than 40? . ( 4) Please store the battery in dry place with low temperature and good ventilation. ( 5) As storage can result in performance degradation, please shorten the storage period as possible.
Chapter 2
Installation Instructions
19
Chapter 2 Installation Instructions

2.1 General
The screws and nuts used in the system follow the ISO-METRIC standard. Carry out the installation in the same order as the sections of these installation instructions come.
2.1.1 Safety Rules

The power supply system includes electronic devices which require dangerous levels of voltage and current. For this reason, the following instructions must be followed at all times: 1. Installation may be undertaken only be adequately trained personnel with satisfactory knowledge of the power supply system. The most recent revision of these safety rules and local safety rules in force shall be adhered to during the installation. 2. All external circuits below 48V to be connected to the power supply system must comply with SELV, as defined in EN 60950. 3. When work is being done in a power cabinet, the power supply system shall be de-energized. The mains supply and, if any, the battery voltage shall be disconnected. 4. The power cabinets shall normally be kept locked, or be placed in a locked room, and the key be kept by the person who is responsible for the power supply system. 5. The distribution cables shall be arranged and protected in such a way that no involuntary contact with them can occur during work with the equipment connected to voltage.
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2.1.2
Documents
The following documents are necessary for the installation:
l l l This Manual; Plant-associated documents for the power supply system, like floor plan, allocation drawing and shipping specifications; Battery documents from the battery supplier.
2.1.3 Tools & Material Preparation

1. Tools required for power equipment installation include electric drill, wire cutter, pliers, various wrenches, screwdriver, electrician knife, and steel saw. The tools must be insulated and have antistatic handles before they are used. 2. Power cables for electrical connection include AC cables, DC load cables, battery cables, earth cables. Their design specifications should be in accordance with relevant industry standard, and the materials should be purchased according to the design material list.
& Note
Different countries have different regulations on the cable colors, please select cables according to your local regulations. In this manual, the cables are selected in compliance with IEC standard. (1) AC input cables It is recommended to AC cables with copper-core flame-retardant PVC insulation. The cable should reach at least +70C temperature durability. The AC input cables should be distinguished with 5 colors: yellow, green, red, light blue and yellow green, and yellow green cables are respectively used as AB, BC, CA phase lines, neutral line and earth line. If the cables are the same color, they should be identified with labels. Dimensioning of AC input cables:
Chapter 2
21
Recommended cable area (minimum) Mains voltage and connection 3%380VAC 3W+N+PE Input MCB (A) Ambient temp.25? 63A 5x10mm Ambient temp. 35? 5x10mm Ambient temp. 40? 5X10mm
It is still recommended to dimension the AC input cables according to the above table when the system is not fully configured, so that the system input MCB provides reliable protection for the cables. (2) Dimensioning of battery cables Dimensioning of battery cables is as follows:
Battery fuse rated current (A) 400 250 Max. total output current (A) 300 200 Current of each battery (A) 150 100 Max. cable length (m) with 0.5V voltage drop Number of cables/pole 1 150 95 14 13 2 28 27
Min. cable area (mm 2)
& Note:
(1) The battery cable should reach at least +90C heat durability. (2) It is recommended to use double-insulated copper-core cable as battery cable. The battery cable area depends on the current flowing through the cable and the permissible voltage drop. The above table shows the recommended values of the least cable area and the maximum length in relation to the amperage of the battery fuse and the number of batteries. The table is based on the assumption that the ambient temperature is 25C, and that the maximum permissible voltage drop across the battery circuit is 0.5V with the indicated number of batteries connected (if one battery is disconnected, the drop increases).
22
The column Max. total output current (A) indicates the total battery current. If the output current of the plant exceeds the value of Max. total output current (A) the table can no longer be applied. The column Current of each battery (A) indicates the current of each battery calculated based on the standard system configuration with two batteries. The table covers no One battery alternative, because the battery capacity shall be made up of at least two batteries for each plant. Two batteries are necessary for full reliability, for instance when exchanging batteries or when doing other work that requires the breaking of the ordinary battery circuit. When the permissible voltage drop is not 0.5V, the above table can no longer be applied and the following formula should be used: A=S IL/(K? U) In which: A is cable area ( mm2) , S I is the total current flowing through the cable( A) , L is the cable length( m) , ? U is the permissible voltage drop (V), K is the conductivity, taking Kcopper=57. (3) See the following table for the dimensioning of the DC output cables:
Max. output current (A) 32 16 5 Min. recommend ed cable area (mm 2) 16 16 6 Max cable length with 0.5V voltage drop and min cable area 7 14 17 Max cable length with 0.5V voltage drop and max cable area 11 22 71
Rated load output current (A)
Permissible max. cable area(mm 2)
63 32 10
25 25 25
The cable area depends on the current flowing through the cable and the permissible voltage drop.
Chapter 2
23
The max output current is calculated based on 50% of rated load output current. If this value is exceeded, the table can no longer be applied. The min cable area is calculated based on voltage drop no greater than 0.5V from the power equipment output terminal to the load input terminal. When permissible voltage drop exceeds 0.5V, the table can no longer be applied, and the formula for calculating the battery cable area can be used. It is recommended to distinguish the positive and negative distribution and battery cables with different colors. Generally, the positive cable is black and the negative cable is blue. If the cables are the same color, they should be identified with cable labels. Load should be connected to the MCB/fuse of suitable capacity to avoid their failure to function in the case of overload. The capacity of the MCB/fuse is recommended to be about 1.5-2 times of the peak value of the load capacity. (4) Dimensioning of earth cables The area of the lightning protection earth cable should not be less than 6mm2, that of the protective earth cable should comply with table 2-3, and that of the DC operation earth cable, usually between 35-95mm2, is determined by the user. Take the greatest cross-sectional area among the above 3 earth cables as that of the cable connecting the user earth bar.
24
Table 2-3 Min Area of PE line

Cross-sectional area of Phase line of power supply system SL ( mm 2) SL= 16 16< SL= 35 SL> 35 Note: 1. When using this table, in case nonstandard size is obtained, please use cable with cross-sectional area closest to the standard cross-sectional area. 2. The specifications are valid only when the PE line and the phase line are made of the same material. Both should be copper cable. 3. The cross-sectional area of the PE line should be no less than 4mm
2.
Corresponding Min Area of PE Line SPE( mm 2) SL(But no less than 4mm ) 16 SL/2
2
& Note
In design, the total current flowing through the lead is generally calculated based on full load condition. 3. Batteries: The PS48350-1B/25 power supply system can accommodate 2 levels of batteries (see the engineering diagram in appendix D for the space required for battery installation in cabinet). When using Emerson T12V100SEF/A battery, 2 batteries with total capacity 200Ah can be mounted on the 2 levels. 4. Purchase materials according to the materials list and inspect the materials, for example, check the heat durability, moisture resistance, flame resistance, and voltage resistance of the cable. 5. The auxiliary materials for power supply installation include expansion bolts, binding strips, and insulating tape.
2.1.4
Unpacking Inspection
To ensure smooth installation, the power equipment must be carefully inspected when it is unpacked. The equipment unpacking and inspection are allowed only after it arrives at the installation site. The inspection is co-accomplished by
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25
the user representative and the representative from Emerson Network Power Co., Ltd. When inspecting the equipment, first open the packing case with packing list put in it, take out the packing list, and conduct inspection against the packing label, including the customer name, customer address, machine No., total amount, case No., contract NO., etc. Unpacking and inspection: after opening the packing case, check the goods one by one according to the goods list on the packing label. The checking should include: 1. The number and serial number marked on the packing cases according to the actual number of the packing cases. 2. The correctness of the equipment packing according to the packing list. 3. The number and model of the accessories according to the accessory list. 4. The completeness of the equipment set according to the system configuration. 5. The condition of the goods through visual inspection. For example, check if the cabinet for any damage and condensation. 6. As to build-in battery, see the battery instructions for the unpacking inspection. Fitting parts The following parts are for fitting of the cabinets: n n n Rectifier PCU Battery( supplied with PS48350-1B/25 power supply system)
To avoid losing parts, dont unpack the rectifiers before mounting.
26
Floor fixing Set Use a floor fixing set adapted to the current application. One set is required for each cabinet.
2.1.5 Installation Procedure

1. Arrangement and mounting of power cabinets 2. Mounting of rectifiers 3. Mounting of PCU 4. Mounting of build-in batteries for the PS48350- 1B/25 system 5. Connection of AC/DC cables 6. Cable connection of temperature sensor 7. Mounting of modem 8. Connecting of dry contact of PCU
2.2 Arrangement & Mounting of Power Cabinets

Please see the equipment room floor plan for the placing of the power cabinets in the equipment room. The power cabinets can be placed against the wall, but they cannot be placed back to back. The following are floor layout guidelines for easy access to carry out maintenance procedures as shown in figure 2-1: No less than 1.5m of free space should be kept between the front of the power cabinet and the wall; No less than 0.8m of free space should be kept between the sides of the power cabinet and the wall; No less than 1.5m of free space should be kept between the back of the power cabinet and the front of another piece of equipment;
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27
And no less than 1.2m of free space should be kept between the back of the power cabinet and the back of another piece of equipment;
No less than 0.8m of clearance should be kept between the side of the
Front of power system
power system and the wall;
No less than 0.8m of
Cabinet may be clearance should be kept
mounted flush to between the back of the the wall

The front passage should be no less than 1.5m wide power system and the wall.
Fig. 2-1 Placing Power Cabinet When the batteries are mounted outside power cabinet, no less than 0.2m of free space should be kept between the battery and the wall, and no less than 0.8m of free space should be kept between multiple battery strings. Cable troughs for AC/DC cables should be mounted in place before mounting the power cabinets.
2.2.1 Mounting Cabinets on the Floor
Step 1: Mark the mounting position Determine the mounting position of the power cabinet in the equipment room according to the mounting chart. Mounting not against wall: mark where to drill the holes in the floor with a pencil or oil pen according to the dimensions (see Fig. 2-2) of the fixing holes of the power cabinet.
28
Fig. 2-2 Mounting Dimensions of the Cabinet Base Mounting against wall: use the two fixing parts at the cabinet top to secure the cabinet to the wall, and the 2 fixing holes at the cabinet base to fix the base on the floor, as shown in figure 2-3. Dimensions of fixing holes are shown in Fig. 2-4. Mark where to drill the holes in the floor and the wall with a pencil or oil pen according to the dimensions of the fixing holes.
Fig 2-3 Illustration of Mounting Cabinet Against Wall
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29
Fig.2-4 Dimensions of Fixing Holes When Mounting Against Wall
Step 2: Drill reserve holes. The expansion bolts delivered with the power system are M10x55mm, therefore, use electric drill with drill bit ?12 and depth 70mm to drill holes at the center points of the fixing holes marked on the ground. To avoid being off-center, be careful not to shake the drill, and try to keep as vertical as possible to the ground, as shown in figure 2-5 (1) and figure 2-6 (1). Step 3: Install expansion bolts. Clean the dust, and insert the expansion bolt fitting into the hole, knock it down gently using a hammer until the top of the expansion bolt fitting is level with the ground, as shown figures 2-5 (2), 2-5 (3), 2-6 (2), 2-6 (3).
30
Expansive pipe
Power cabinet
Drill vertically
Clean the dust
Knock it into place
Tighten the bolt
Fig. 2-5
Installing Expansion bolt in Floor

Wall
Electric drill
Expansive pipe
Bolt
Drill vertically
Knock it into place
Knock it into place
Fig. 2-6 Installing Expansion bolt in Wall
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31
Step 4: Place cabinet in position Remove the base plate before placing the cabinet in position so as to fix the base plate, as shown in figure 2-7. Move the cabinet to the mounting position aligning the fixing holes of the cabinet to the holes on the ground.
A part enlarged view
Base plate
Lock notch
Figure 2-7 Mounting of Base Plate
Step 5: Mount the cabinet After the cabinet is in position, make some horizontal and vertical adjustments. Insert some iron pieces under the lower edge and corner of the cabinet to adjust the vertical obliquity of the cabinet within 5 degrees. Finally, use wrench to screw down the tap bolt with plain washer and spring washer, as shown in figure 2-8.
32
Tap bolt
Spring washer
Plain washer Cabinet base
Ground
Expansive pipe
Fig. 2-8 Fixing Cabinet with Tap Bolt
Step 6: Mount base plate After mounting the cabinet, replace the base plate at the cabinet base. Use only one screw to fix each base plate, and use the lock notch at the other side of the base plate to secure it to the base bar at the back, as shown in figure 2-7.
2.2.2 Installation on Supporting Rack

To allow bottom cabling, a supporting rack can be used. First, install the supporting rack on the floor as shown in Fig. 2-9. The installation steps are the same as the first three steps in Section 2.2.1. Then install the power supply cabinet on the supporting rack, as shown in Fig. 2-10 before mounting the base plate. If mounting the cabinet on supporting rack and against the wall, following the mounting steps described in section 2.2.1, and take
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33
into account of the height of the supporting rack when marking where to drill the holes in the wall.
Anchoring finished
Floor
Anchor bolt
Fig. 2-9 Installing Supporting Rack

Anchoring
Cabinet front door Cabinet base Cabinet back door
Anchoring finished
Supporting rack
Fig. 2-10 Installing Power Cabinet on Supporting Rack
34
2.3 Rectifier Installation

Put the rectifier on the corresponding slots, place the latch on the rectifier panel in the "unlock" position, and push the rectifier to the back until it cannot be pushed further, then place the latch in the "lock" position to fix the rectifier in the cabinet, as shown in Fig. 2-11:
Fig. 2-11 Installing Rectifier When the rectifier number is less than 14, install the rectifiers from the top down and from the left to right. To dismount the rectifier, place the latch in the "unlock" position, and pull the rectifier out completely.
warning
The heatsink temperature is high when the rectifier is in operation. When removing a rectifier during operation, be careful not to touch the heatsink of the rectifier.
2.4 PCU Installation

The installation of the PCU is the same as rectifier installation.
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35
2.5 Emerson Battery Installation of PS48350-1B/25

After placing the battery into cabinet, connect the connection strips between batteries, and connect the battery to the power supply system, then connect the discharge system of the battery, and paste the acid fume box on the side of the cabinet, at last mount the protection cover, see figure 2-12. Step 3 Step 2 Step 1
Figure 2-12 Battery Connection
& Note
( 1) Fix the battery and protect it from vibration and shock. ( 2) If the battery is installed inside the power supply system, please maintain clearance between batteries and between battery and inner cabinet wall. A space of approximately 10mm should be allowed between batteries. ( 3) The connection between batteries should be correct and secure, to avoid short-circuit. ( 4) Never reverse the battery polarity. ( 5) After installation, please measure and confirm the total battery voltage before connecting power to it.
36
2.6 Cable Connection & Cable Entry

2.6.1 Cable Connection to MCB
Cable connection to MCB: strip the power cable end, crimp-connect the copper core to an H terminal, and insert it into the wiring hole of the MCB, then tighten the screw to fix the copper core, as shown in Fig. 2-13:
Cable
H terminal
Fig. 2-13 Cable Connection to MCB
& Note
Note: to avoid short circuit due to short distance between phases, do not protrude the copper core at the cable end connecting to the MCB terminal.
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37
2.6.2 Cable Connection to Screw/bolt

Cable connection to screw/bolt: strip the cable end, crimp-connect the copper core to a cable lug, and insert the screw/bolt across the cable lug, as shown in Fig. 2-14:
Nut Cable Spring washer Plain washer
Cable lug
Plain washer Bolt or screw
Fig. 2-14 Cable Connection to Screw/Bolt
2.6.3
Cable Entry
When the input/output cables of the power supply system are connected through the top of the cabinet. Cable trough should be provided in the equipment room, which should be more than 300mm above the cabinet. In this case, the power cables should be routed through the cable trough. When cable chute is provided in the equipment room, the power cables can be routed through the cable chute, and the system input/output cables can be connected through the bottom of the cabinet.
38
& Note
When using bottom cable entry, the base plate should not be mounted, and the equipment room should provide adequate fire protection measures. It is recommended to use top cable entry. Top cable entry is shown in figure 2-15:
Signal output calbe
DC input/output cable(21 holes)
AC input cable
Figure 2-15 Arrangement of Top Cable Entry
2.7 Connection of AC Cables
Danger
1. Place all circuit breakers and fuses to the off position before making electrical connection. 2. The mains cable connection can only be carried out by qualified personnel.
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39
I. Connection requirements 1. The AC mains lead is wired from the customer distribution circuit breaker, it is connected to the output terminal of the circuit breaker when the power is to be switched on. The distribution should be equipped with overcurrent, short circuit and lightning protection devices. 2. The yellow, green, red, and light blue AC cables correspond respectively to the AC phase A, B, C and neutral lines. If the cables are the same color, they should be identified with labels. 3. The AC cables should be laid separately from the DC cables. 4. No splice, damage, or scratch on the cables is permitted. II. Connection procedure The AC cables can be fed into the cabinet from the top or bottom. After feeding the AC cables into the cabinet, connect them to the input MCBs, as shown in figures 2-16:
1. Input MCB;
2. AC neutral line terminal;
3. Earth bar
Figure 2-16 AC Cable Connection
40
1. Connect the PE line to the user earth bar in the equipment room; 2. Connect the AC neutral line to the AC neutral line terminal shown in Fig. 2-16; 3. Connect the AC phase line to the input MCB shown in Fig. 2-16; In the case of single-phase mains supply, short the 3 phases of the input MCB( at input side) and then connect it to the AC input phase line.
& Note
Usually first connect the PE line, then the neutral line and at last the AC phase line. 4. Use cable tie wrap to fix the AC cables to the beam inside the cabinet.
2.8 Connection of Battery and Load Cables

I. Connection requirements Select the length and cross-sectional area of the cables according to the actual wiring route, voltage drop requirements and load capacity. The positive and negative cables of the load should be distinguished with different colors.
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41
Notice
1. The cable should not be spliced. The load cable, signal cable and user cable should be wired separately as possible to avoid them affecting each other. 2. If the power supply system is in operation, before connecting the cable, you must pull out the DC output fuse using fuse puller, or switch off the DC output MCB. 3. Some of the screws and nuts for the positive busbar are packed in a plastic bag that is delivered with the cabinet. II. Connection description The connection positions of the battery cables and distribution cables at the power supply system end are shown in figure in 2-17:
Fig. 2-17 Connection of DC Cables
42
No. (1) (2) (3)
Input/output interfaces Battery 1 fuse Battery 2 fuse Non-priority load output terminal(-) Priority load output terminal(-) Positive copper bar
Functions Connected to the negative terminal of battery 1 Connected to the negative terminal of battery 2 As the negative terminal of 48V power supply to non-priority load. When the battery discharge to LLVD voltage, the output is disconnected. As the negative terminal of 48Vpower supply to priority load. When the battery discharge to BLVD voltage, the output is disconnected. Connected to the positive terminal of battery 1 and battery 2; providing +48V power supply to load
(4)
(5)
? . Connection of DC load cables See section 2.1.3 for the dimensioning of distribution cables: 1. Note that the DC output branch should match the load capacity. It is highly recommended to connect priority load to BLVD branch, and non-priority load to LLVD branch. 2. Connect one end of the negative cable to the output terminal of the selected MCB/fuse. 3. Connect one end of the positive cable to the DC output positive copper bar.
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43
? . Connection of battery cables
Notice
1. Before connecting the battery cables, the corresponding battery fuse of the battery must be disconnected to avoid live state of the power supply system after installation. 2. Be careful not to reverse connect the battery, otherwise, the battery and the power supply system will be damaged! 3. When only one battery is to be connected to the system, please connect it to the "connection position for negative terminal of battery 1". See section 2.1.3 for the dimensioning of battery cables: 1. Lay the battery cables, mark their serial number and polarity. 2. Connect one end of the negative cable to the output terminal of the battery fuse and one end of the positive cable to the positive copper bar of the distribution DC cabinet. Add cable lugs to the other ends of the positive and negative cables, bind the cable lugs with insulating tape, and put them beside the battery. Connect the cables to the battery when the DC distribution unit is to be initially tested.
& Note
when connecting batteries, use cable terminals in compliance with local regulations, and use 25Nm torque to tighten the screws.
44
2.9 Cabling Route inside Cabinet

Top cable entry: AC cables: the ac input cables are introduced into the cabinet through the cabling hole at the cabinet top, then led down along the right side cabinet wall to the AC input MCB terminals. Negative DC cables: the negative DC cables are led out of the cabling hole at the cabinet top from the MCB/fuse terminals. Positive DC cables: the positive DC cables are led from the positive copper bar upward along the back of the cabinet and then out of the cabling hole at the cabinet top. Bottom cable entry: AC cables: the ac input cables are introduced into the cabinet through the bottom of the cabinet, then led upward along the right side cabinet wall to the AC input MCB terminals. Negative DC cables: the negative DC cables are led from the MCB/fuse terminals downward along the back of the cabinet and then out of the cabinet through the bottom. Positive DC cables: the positive DC cables are led from the positive copper bar downward along the back of the cabinet and then out of the cabinet through the bottom.
& Note
1. When introducing the cables through the top of the cabinet, the distance between the outer surface of the cables and the cabling hole should comply with IP20 protection requirements. 2. When using bottom cable entry, the cabinet base should be removed, and the equipment room should provide adequate fire protection measures.
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45
2.10 Installation of Temperature Sensor Cable

The temperature sensor cable is optional accessory. The temperature detection is achieved through the PCU. Temperature detection cable installed with temperature probe is connected to the PCU via the signal transfer board W2442X1 . The temperature probe converts the temperature change into voltage change, providing relevant information for PCU to perform battery management. Temperature probe operating voltage: 12V Measurement range: -5? ~ 100? Measurement accuracy: 2? Installation procedure: 1. Connect the 4-core plug of the temperature sensor cable to the J16 socket on the W2442X1 signal bridging board. Note that the connection should be correct, and neat and tidy as well. 2. Put the temperature probe in the battery room where best represents the ambient temperature of the battery. Do not connect it to other exothermic equipment.
Notice
The temperature probe cannot be placed inside the cabinet if the battery is installed outside the cabinet. If the cable is too short, it can be extended by means of 0.82mm2 (AWG18) standard copper conductors and connecting terminals
2.11 Modem Installation

For remote monitoring, a modem must be installed.
46
The following section describes the modem installation by taking e-TEK TD36-VDC modem as an example.
Power
Fig. 2-18 Input/Output Ports of TD36-VDC Modem Modem Installation & Connection ? . Fixing modem 1. Open the front panel of the power supply system, there is a slot for modem fixing at the left side of the cabinet; 2. Place the modem into the slot (the LED panel of the modem facing upward). MODEM
Slot
Figure 2-19 Modem Fixing
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47
II. Connecting modem to PSM -A10 The connection of the external modem to the PSM-A10 PCU is mainly through the interfaces of the transfer board W2442X1 of the system. 1. Connect the LINE port of the modem to phone line. 2. Connect the 12V power port of the modem to the JP8 terminal (VMODEM) on the W2442X1 board. 3. Use communication cable to connect the "RS-232" DB25 ( female) port of the modem to the JP7 terminal ( DB9 male) on the W2442X1 board. Modem Configuration and Others: In modem mode, "YES" should be selected for the communication parameter "MODEM MODE: YES/NO" in the "ELSE PARA" page in the PCU. If the modem has automatic answer indicator AA) , the AA ( indicator will turn on when the modem and the PCU are switched on ( in modem mode, the PCU will automatically initialize the settings of the modem when the PCU is switched on, reset or there is no message receiving and transmitting within 1 hour) .
2.12
Dry Contact Connection

The PSM-A10 provides 4 pairs of dry contact trough signal transfer board W2442X1 for dry contact networking to accomplish the level isolation transmission of fault signals. Each pair of dry contact can be selected as normally open or normally closed contact output according to actual requirements. The dry contacts on the signal transfer board W2442X1 are defined as follows:
48
Fig. 2-20 Dry Contact Connection

Dry contact No. 1 3 Definition Mains failure Rectifier fault Dry contact No. 2 4 Definition DC under voltage BLVD
The user may change the definition of dry contact relay output through the maintenance software issued by Emerson Network Power Co., Ltd. Dry contact connection: After stripping the signal cable end, insert it directly into the dry contact connection terminal, and screw down the bolt to tighten the cable.
Chapter 3
Test Instructions
49
Chapter 3 Test Instructions

3.1 General
Performance test is to be made in the following cases: n n As a final test or an acceptance test of a new plant. As a final test or an acceptance test when a plant has been extended.
The most recent revision of safety rules and local safety rules in force shall be adhered to in the performance test. Read through the whole of these test instructions before starting the test.
3.1.1 Preliminaries
The person responsible for the power supply system shall have been informed that tests are to be made and that alarm will be sent to the central alarm unit. Test equipment: multimeter During operation, parts of this equipment carry hazardous voltage. Improper use can therefore result in severe or fatal injuries and property damage. l l l Maintenance and operation of this equipment must be carried out by trained electrical engineer; Before any work is carried out, a check must be made to ensure that the equipment is properly earthed. Only spare parts approved by the manufacturer must be used.
50
3.2 Installation Check

3.2.1 Inspection of Cabinets
OK Inspect the equipment and accessories for compliance with the offer, delivery note and installation instructions. Check the floor fixing of the cabinet(s). Check the bar interconnection of cabinets, if applicable. Check the connections between the power supply system and the system earth. Check that the earthing of the cabinet(s) conform to the installation instructions and local regulations. + Comments
+ + + +
3.2.2 Inspection of Mains Connections

OK Check the electrical connections on the mains power sidefor compliance with the installation instructions, drawings and local regulations. + Comments
3.2.3 Inspection of Cabling

Check that the battery fuses and cables are correctly dimensioned. Check that the distribution fuses and cables are correctly dimensioned. Check the fixing of all cables connected to the cabinet(s) and that tie wraps are correctly cut (no sharp edges). OK + + + Comments
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Test Instructions
51
3.2.4
Batteries
1. Inspection
OK + + + Comments
Check that the correct number of cells are installed. Check that the battery cells face the right way by measuring their polarity with a voltmeter. Check that the battery cables are not cross-connected to the fuse.
2. Initial charging
OK If freely ventilated (FV) dry charged batteries are used, they shall be charged initially according to the battery suppliers instrcutions. + Comments
3.3 Start-up Preparations

3.3.1 AC Distribution Unit & Rectifiers
Make sure that all the mains circuit breakers are set to OFF; The rectifiers should be connected to the plant, but the mains supply should be switched off. OK + + Comments
3.3.2
DC Distribution Unit
OK Make sure that all the distribution circuit-breakers are switched off. + Comments
52
3.3.3
PCU
Check that the communication and alarm calbes are connected to the PCU. Check that the PCU is correctly installed. OK + + Comments
3.3.4
Batteries
Check that the temperature sensor, if any, is connected and attached to relevant batteries. Check that the middle inter-cell connector is not connected in the batteries. Check that the battery fuses are removed. OK + + + Comments
3.3.5
BLVD
Set the two BLVD switches respectively to manual and disconnect positions. Check with an ohmmeter that there is no short circuit between the positive and the negative distribution bars, or between the positive and negative battery poles (due to the effect of the rectifier output capacity, the ohmmeter shall read higher than 10 ohms). OK + + Comments
3.4 Start Up
Remove rings, wrist watches and similar objects that may cause short circuits.
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Test Instructions
53
3.4.1
Batteries
Install the last inter-cell connector in all the batteries. Measure with a voltmeter across the connection points of each battery and make sure that the polarity is right. The voltmeter shall read 2.0-2.1V/cell or 48-51V/battery for a lead acid battery that consists of 24 cells. If a cell reads a lower voltage thatn 2.0V, it should be replaced. OK + Comments
Umin=____V
3.4.2 Start of Rectifier

Check the mains voltage at the mains distributiion unit. Switch on the system input MCB, the system operation indicator will illuminate. Switch on the mains MCB of the mains supply to one rectifier, the green LED ON on the rectifier will illuminate and the fan will start after some delay. The display of the PCU will show 53.5V. LVD contactor is activated to disconnect load from battery. Check the system voltage and polarity on the busbars with a voltmeter. The votage should be the same as the indication of the display unit !0.2V. Switch off the mains MCB of the mains supply to the rectifier, the LVD contactor closes. Start and stop each rectifier of the system in the same way and check their output voltage and current. OK + + Comments U= VAC
+ +
+ +
54
3.4.3 Connection of Batteries, Rectifiers & LVD

Connect all the batteries by restoring the battery fuses. Start the rectifiers and the display of the PCU will show 5 3.5V, the LVD contactor opens. Set the LVD switches to auto, the contactors will interconnect the rectifiers and the batteries after a short delay. The rectifiers will take load and charge the batteries. OK + + + Comments
3.5 Basic Settings

When putting the system into service, the PCU must be set based on the actual system configuration, battery number, capacity, and users charge current limit and other functional requirements. Only after this can the system give correct indications and the system control be made. For PCU parameter setting method, see Section 4.7.
3.5.1 System Model

The system model has been set correctly in factory before delivery, check that the setting agrees with the actual system. After replacing the PCU, re-set the system according to the actual system. OK + Comments
3.5.2 Battery Number

Set the battery number to the number of the batteires actually connected to the system. (default: 2) OK + Comments
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Test Instructions
55
3.5.3
Battery Capacity
Set the battery capacity to the actual capacity of the battery connected to the system. (default: 400Ah) OK + Comments
3.5.4 Temperature Compensation Coefficient

When the system is configured with temperature compensation cable, the temperature compensation coefficient should be set.
Set the temperature compensation coefficient following the battery manufacturer instructions. Setting range: 0- 500mV/ ? . (default: 0mV/ ? ) OK + Comments
3.5.5 Current Limit

Set the charge current limit according to the user requirement. Setting range: 0.1~0.25C10. (default: 0.1C10) OK + Comments
3.5.6 Float and Equalize Charge Voltages

OK Set the float and equalize voltages to the values recommended by the battery supplier. Float voltage range: 42V~equalize voltage; equalize voltage range: float voltage~58V. (default: 53.5V) For battery without equalizing charge, set the equalize voltage to float voltage plus 0.1V. (default: 56.4V) + Comments
56
3.6 Checking of Alarms

Check that alarms from each unit can be initiated in the unit itself and on the display of the PCU.
3.6.1 Testing Rectifier Faults

Disconnect the mains supply for one rectifier, alarm RECT N COMFAIL will be initiated. Reset the mians supply, the alarm will cease. Repeat with the other rectifiers OK + + + Comments
3.6.2 Testing Battery Fuse Fault

OK Remove one battery fuse, the alarm BAT1(2) RT FAULTis initiated in the PCU. Re insert the battery fuse, the alarm will cease. Repeat for all other battery fuses. + + + Comments
3.6.3 Testing Distribution Circuit Breaker Fault

Switch off a circuit breaker in one distribution unit, alarm will be initiated if a load is connected to the output. Reset the circuit breaker, the alarm will cease. Repeat for all other distribution circuit breakers. OK + Comments
+ +
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Test Instructions
57
3.6.4 Testing Undervoltage Detection and BLVD

Disconnect the battery fuese. Disconnect the mains supply for all rectifiers except one. Adjust the rectifier float voltage to make it lower than the alarm point, alarm will be initiated. Set the rectifier float voltage to lower than the BLVD point, the BLVD contactor will be activated and alarm be initiated. Restore the rectifier float voltage to normal value, the alarm will cease. OK + + + + Comments
3.6.5 Testing Lightning Protection Fault

Open the SPD switch, alarm will be initiated. Close the SPD switch, alarm will cease. OK + + Comments
3.7 Checking of System Operation Status

There is no alarm when the system is in normal operation. Check that the system runs normally through the PCU. For checking of system parameters, see Chapter 4.
3.7.1 AC Voltage
Check that the PCU can display the AC voltage. OK + Comments
58
3.7.2 DC Voltage
Check that the PCU can display the DC voltage. Use voltmeter to measure the bus voltage, and compare it with the displayed value, the error should not exceed 1%. OK + Comments
3.7.3 Battery Current

When connecting new battery to the system or equalize-charging the battery, the PCU should display the battery current. Measure the voltage at shunt terminals and calculate the battery current, then compare it with the displayed value, the error should not exceed 1% . OK + Comments
3.7.4 Load Current

When connecting load to the system, the PCU should display the load current. Measure the voltage at shunt terminals and calculate the load current, then compare it with the displayed value, the error should not exceed 1% . OK + Comments
3.7.5 Rectifier Parameters

Check the rectifier number displayed by the PCU, which should agree with the actual value. Check the voltage, current, current limit of each rectifier one by one through the PCU, which should agree with the values specified in the parameter card. OK + + Comments
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Test Instructions
59
3.7.6 Battery Room Temperature

As to system fitted with temperature compensation cable, check that the PCU can correctly display the battery room temperature. Check that the displayed temperature by the PCU changes when holding the probe of the temperature compensation cable. OK + Comments
3.8 Final Steps

Disconnect any test equipment that has been connected to the system and make sure that materials not belonging to the equipm ent have been removed. Restore the equipment to its original condition and close the cabinet doors. Check and hand over the customer documents to the client. Check and hand over contacted spare parts. Make sure that all the actions taken have been noted in this document, stating at what time and the name of the persons who took the actions. OK + Comments
+ + + +
If a deficiency remains in this equipment, personnel responsible for the contract shall be informed. If a unit shall be sent to a repair center for repair, fill in FAILURE REPORT and send it with the unit to help in the fault tracing.
60
Chapter 4 Use of PCU

4.1 Menu Architecture
The LCD display of the PCU uses multi-level tree menu for operating data viewing, system setting and control. The menu architecture is shown in the following chart:
12:00:00 53.5V 50A
SYSAUTO/FLO AMBIENT: 25
BAT 1: -50A CAPACITY: 390Ah
Manual switchover system
Automatic switchover system
AC INPUT 223V
AC 1ST INPUT 222V
AC 2ND BACKUP : 222V
MAIN MENU 1 1 RECT INFO
MAIN MENU 2 CURRENT ALARM
MAIN MENU 3 HISTORY ALARM
MAIN MENU 4 SYSTEM CONTROL
MAIN MENU 5 BATPARA SETUP
MAIN MENU 6 ELSEPARA SETUP
& Note
1. The above chart only gives 6 main menus, their sub-menus will be elaborated in this chapter. 2. Use MANU/ENT key to select control action. Press ? and ? keys to switch between menus of the same level, press ? and ? keys to select status option and change number and letter. After changing settings, press ENT key to confirm the change.
Chapter 4
Use of PCU
61
4.2 Operation Instruction

The use of the PCU includes setting system parameters, viewing system operating information( including AC information, DC information, rectifier information and alarm information) and performing output control, etc. If there is no key operation for 8 minutes, the display will automatically return to the "SYS INFO" page (time display provided) and the LCD backlight will be turned off to enter screen protection status. Pressing any key thereafter can turn on the LCD backlight. Only at the system information page can the ? and ? keys be used to adjust the brightness of the display. The max adjustment range depends on the hardware. Alarm display: in the case of system fault, the PCU will display the alarm if there is no key operation for 2 minutes.
4.3 System Information Pages

The first system information page (default screen at power-up) contains the major system information in operation, including time, bus voltage and total load current:
53.5V 12:00:00 50A
From this screen, the user may use "3and4" keys to adjust the contrast of the LCD (7-level), and 6 key to scroll through all the system information pages. Other information pages are shown below:
62
53.5V
12:00:00 50A
SYSNORM/FLO AMBIENT: 25
Manual switchover system
Automatic switchover system
AC INPUT
AC 1ST INPUT
223V
222V
MENU/ENT
AC 2ND BACKUP
222V
& Note
1. Battery information display is related to battery number setting. 2. The AC input information display is related to the mains input switchover mode of the system (manual or automatic).
4.4 Rectifier Information Pages

Rectifier information is displayed in two pages. Use ? and ? keys to scroll through the information pages of all rectifiers. In the case of rectifier communication interrupt, the rectifier information is displayed in highlight. Alarm history helps the user to understand the system operation status and prevent system fault. The path for querying rectifier information is illustrated in the following chart:
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Use of PCU
63
53.5V
MENU/ENT
12:00:00 50A
.......Other main menus
MAIN MENU 1 RECT INFO

MENU/ENT
MAIN MENU 2 CURRENT ALARM
RECT1 ON 53.6V 15A

RECT2 ON 53.6V 15A
RECT1 110% 45 1#

RECT2
110%
45 1#
RECT3,RECT4 display same as RECT1 and RECT2
4.5
Current Alarm & Alarm History Pages

Use ? and ? keys to view current alarm information. See Appendix H for the detailed alarm information. If there is no current alarm, NO ALARM NOW will be displayed. If there is no history alarm, NO HISTORY ALARM RECORD will be displayed. Only after an alarm is eliminated will it be stored as a history alarm. A max of 100 historical alarm events can be stored, the newest alarm replacing the earliest alarm. The LCD displays history alarm name and start time, alarm end time can be obtained from the monitoring computer through software. The path for querying current alarm and history alarm is illustrated below:
64
AC LOW: AC input low voltage; AC OVER: AC input over voltage; SPD FAULT: surge protection device fault; DC OUT LOW: DC output low voltage; DC OUT OVER: DC output over voltage; AMBNT OVERTEM: ambient over temperature; ROUTE N FAULT: load output N fuse broken or MCB trip; AUXROUTE FAIL: auxiliary output fuse broken or MCB trip; BAT1 RT FAULT: battery 1 fuse broken or contactor open; LOAD LVD: load low voltage disconnection;
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Use of PCU
65
BATT LVD: battery low voltage disconnection; RECT N COMFAIL: rectifier N communication interrupt; MONI +12V FAUL: +12V power failure of monitoring CPU board as a kind of PCU fault; MONI Vref FAUL: Vref power failure of monitoring CPU board as a kind of PCU fault; MONI 8V FAUL: 8V power failure of monitoring CPU board as a kind of PCU fault; MONI Vcom FAUL: Vcom power failure of monitoring CPU board as a kind of PCU fault; MANUAL STATUS: system in manual battery management mode; MEASURE FAULT: load, battery or rectifier current measurement fault; DC/DC FAULT: DC/DC converter fault; BATT OVERCURR: battery charge over current.
4.6
System Control Pages

System control operation options include system equalize/float charge, test, and BLVD YES/NO.
& Note
BLVD and other control operations may result in power interrupt to load, be careful to perform control operation. Prerequisite for control operation: if the system is in automatic battery management state, control operation is prohibited, the user cannot enter control operation menu. For how to set battery management mode to manual mode see Section 4.7.1. After setting the battery management mode to manual mode, the user may follow the path illustrated below to perform system control:
66
12:00:00 53.5V 50A
MENU/ENT + + +
MAIN MENU 4
SYSTEM CONTROL
ESC MENU/ENT MENU/ENT + PASSWORD
PASSWORD: 11
BATT SET MANUAL!
CONTROL START:EC

MENU/ENT
ESC
'ENT' KEY ACT. ELSE KEY BACK.

MENU/ENT
CONTROL BATTLVD: NO
& Note
1. The password is 11 by default. 2. The battery management mode must be set to manual mode, otherwise, system control operation is prohibited. 3. START control options include equalize charge, float charge and test; BLVD control options include YES and NO. Use ? and ? keys to switch between control menus, use "3" and "4" keys to select control option, and press MANU/ENT key to perform control. During manual control, if system alarm occurs or the system management mode is changed to automatic mode from the monitoring computer, the battery test will stop automatically, and the system enter battery automatic management state.
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Use of PCU
67
4.7
Setting System Parameters
4.7.1 Battery Management Parameters

When battery number is set to 0, setting of other battery parameters is prohibited; when battery number is set to 1 or 2, setting of other battery parameters is allowed. Scroll through setting pages and view setting information: use ? and ? keys to move the cursor to select parameter to set; use "3" and "4" keys to change the setting (the setting will change automatically 0.5S after key pressing). After changing the setting, press ENT to confirm the change.
PASSWORD+MENU/ENT
12:00:00 53.5V 50A

ESC
BATT STRING : 2 RATE CAP: 400Ah
MENU/ENT

MENU/ENT

ESC
PASSWORD: 11 BATPARA SETUP!
FC VOLT 53.5V EC VOLT 56.4V

CHARGE LIMIT: 0.10C10

COMPRATURE COEF 0mV/ /STR

BATT MODE: AUTO
68
& Note
1. The password is 11 by default. 2. Battery number setting range: 0~2; rated capacity setting range:50~5000Ah 3. Float voltage setting range:42V~equalize voltage; equalize voltage setting range: float voltage ~58V 4. Charge current limit setting range: 0.1~0.25C10 5. Temperature compensation coefficient setting range:0~500mV/? /battery string 6. Battery management setting option: automatic/manual.
4.7.2
Others
12:00:00 53.5V 50A

MENU/ENT + MENU/ENT
ESC
LOCAL ADDR253 BAUD RATE 9600

MODEM MODE YES
MAIN MENU 6 ELSE PARA

ESC
PASSWORD: 11 ELSE PARA!
PASWORD11

MENU/ENT
PHONE NUMBER MENU KEY ENTER

ESC

CALL BACK: 07556540808
YEAR MON DAY
2000 05 12

HOUR MIN SEC
12 30 30
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Use of PCU
69
4.7.3 Parameter Settings Through PCU

Information Type AC distributioin unit DC distributioin unit Rectifiers Basic battery parameters Contents Displayed AC overvoltage alarm point, AC undervoltage alarm point, AC mains input mode DC overvoltage alarm point, DC undervoltage alarm point Voltage trimmer Battery string number*, battery management mode(auto/manual)*, battery charging efficiency, battery rated capacity* Float voltage*, charge current limit*, charge overcurrent point, whether equalize charge permitted, equalize voltage*, equalize charge Charging duration, whether timing equalize charge management permitted, equalize charge cycle, equalize charge parameters changeover reference capacity, equalize charge changeover reference current, stable current equalize charge time, stable current equalize charge start current Battery temperature compensation parameters Battery test parameters Battery discharge curve Communication Time Password Whether temperature compensation permitted, temperature compensation coefficient*, temperature compensation center point, battery room overtemperature point. Battery discharge end voltage and end time Discharge time of 0.1C10, 0.2C10, 0.3C10, 0.4C10, 0.5C10, 0.6C10, 0.7C10, 0.8C10, 0.9C10, 1.0C10 discharge rates Baud rate*, local address*, whether to use modem communication*, phone number to be dialed* Year*, month*, date*, hour*, minute*, second* Password* Remark AC parameters DC parameters Rectifier parameters
Battery
Others
Parameters marked with * can be altered through both the LCD screen on the PCU and the maintenance software on the monitoring computer, other parameters can only be altered through the maintenance software.
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4.8 System Initialization

Follow the path illustrated below to enter the system setting password page and select the system model, language, and actuate password initialization and system parameter initialization. For use of the control key on the PCU, see Section 1.2.2.
MENU/ENT MENU/ENT
SYS TYPE: PASSWORD: 245 BATPARA SETUP! 48V/25A/300/MAN

12:00:00 53.5V 50A
/LAGUAGE:

CHINESE/ PASSWORD: 245 ELSE PARA!

MENU/ENT MENU/ENT
MAIN MENU 6 ELSE PARA
PWD INIT: NO SYS INIT: NO
4.8.1
Setting System Model

PCU PSM- A10 can monitor several types of Emerson power supply system. The monitoring module had been set before to the appropriate power system model before delivery. Only when the PCU is replaced should the system model be set. After setting the system model, the PCU will automatically start, and all other system parameters will return to factory defaults. The user then needs to reset the system parameters according to the actual system configuration and the users requirements.
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71
There are multiple system model options, as shown below:
48V / 25A / 300 / MAN

AC input switchover: AUTO/MAN Shunt coefficient: 100/300/500 Rectifier rated output current: 25A/50A Rectifier rated output voltage: 48V/24V(48V: -48V system output voltage; 24V: +24V system output voltage)
The shunt coefficient is selected as 300 to this system. 245 is the fixed password for system initialization parameter setting, and is not allowed to be changed.
4.8.2 Setting Language

The PCU supports 2 languages: Chinese and English, use"3" and "4" keys to select the language option.
4.8.3 Password Initialization

If the user can not recall the parameter settings or password for system control, he may use the password initialization function to change the password to factory default 11, and then reset the system parameters and perform system control.
4.8.4 System Initialization

System initialization is used only when the system cannot be set normally and normal operation can not be recovered by switching it on and off to reset it. After initializing the system, the system settings
72
will be restored to the default values. If the settings are not in compliance with the actual conditions, alarm will be given. So after initializing the system, it is necessary to reset the system parameters according to the actual conditions.
4.9 Dry Contact Relay Output

The PSM-A10 provides 4 pairs of dry contact relay outputs for dry contact networking to transmit the fault signals. Each pair of dry contact can be selected as normally open or normally closed contact output according to actual requirements. Default definition of each dry contact relay output:
Dry contact No. 1 3 Definition Mains failure Rectifier fault Dry contact No. 2 4 Definition DC under voltage BLVD
The user may change the definition of dry contact relay output through the maintenance software issued by Emerson Network Power Co., Ltd.
Chapter 5
Maintenance Instructions
73
Chapter 5 Maintenance Instructions

5.1 General
These instructions concern actions to be taken in the case of alarm, and preventive maintenance of the PS48350/25 power supply system. Adequate knowledge of the power supply system is required in maintenance.
& Note
1. Safety rules shall be followed when doing maintenance work in the power equipment. 2. Measures that require work inside the cabinets or intervention in a unit shall always be carried out by adequately trained personnel with adequate knowledge of the power supply system.
5.1.1 Authorization
? . Adequately trained user A user who has received adequate training for the power supply system in question is authorized to take responsibility for the equipment and to perform tests, fault tracing, exchange of units and repairs of the equipment. ? . Others Users with basic training for the power supply system in question are authorized to handle the equipment during normal operation only and to take those actions in the case of alarm which are included in
74
these maintenance instructions and which do not involve work inside the cabinets.
5.2
Alarm Categories
Alarms are categorized into emergent alarm, ordinary alarm and non-alarm depending on their effect on system operation and their urgency level. Emergent alarm: an emergent alarm has serious effect on system operation, hence requires immediate action, whatever the time of day or night. In the case of an emergent alarm, the alarm indicator will illuminate and visual alarm will be initiated. Ordinary alarm: the power supply system can maintain temporary normal DC output after an ordinary alarm occurs. Ordinary alarm requires immediate action if it occurs during working hours, otherwise as soon as the working-hours commence. In the case of an ordinary alarm, only the alarm indicator will illuminate. Non-alarm: non-alarm will not affect normal system operation, and when such alarm occurs, the system will not give audible or visual alarm.
5.3 Actions in the case of Alarm

In the case of alarm, please view the alarm message and alarm category shown by the PCU, and check whether there is any external disturbance such as thunderstorm or mains failure, and the alarm date, time, system voltage and load, etc.
& Note
Read through this chapter before starting the work. Take final steps according to Section 5.5 when the alarm has been eliminated.
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75
5.3.1 Mains Failure (Emergency Alarm)

Alarm display: MAINS FAIL The load is supplied only from the batteries because of mains failure. Mains failure often occurs in power system operation. Batteries will provide backup DC power in the case of short-period of mains failure. If the cause of mains failure remains unknown or the failure lasts too long, the generator should be started to provide mains supply to the system. It is suggested that the generator should work for 5 minutes before it supplies power to the power system so as to reduce the effect of the start process on the power system.
5.3.2
Mains Over Voltage (Ordinary Alarm)

Alarm display: AC OVER The alarm indicates that the mains voltage exceeds the preset over voltage alarm point. In the case of such alarm, the preset value should be checked, and changed if it is set too low. Default values are shown in the following table:
Parameter AC input overvoltage alarm point AC input overvoltage alarm recovery point Default 2805VAC 2705VAC Remark Adjustable via the PCU 10VAC lower than the AC input overvoltage alarm point
Normally such fault will not affect system operation. When the mains voltage is higher than 290Vac, rectifiers will stop running. Therefore, if mains over voltage often occurs and stays long, please contact relevant power grids maintenance personnel to make improvement.
5.3.3
Mains Under Voltage (Ordinary Alarm)

Alarm display: AC LOW
76
The alarm indicates that the mains voltage drops below the preset under voltage alarm point. In the case of such alarm, the preset value should be checked, and changed if it is set too high. Default values are shown in the following table:
Parameter AC input under voltage alarm point AC input under voltage alarm recovery point Default 1705VAC 1805VAC Remark Adjustable via the PCU 10VAC higher than the AC input under voltage alarm point
Rectifiers only have half load output when the mains voltage drops below 176Vac, and stop running when below 90Vac. Therefore, if mains under voltage often occurs and stays long, please contact relevant power grids maintenance personnel to make improvement.
5.3.4
SPD Fault (Emergency Alarm)

Alarm display: SPD FAULT Check the SPD, and replace it if the indicator shows it is damaged.
5.3.5
DC Output Over Voltage (Emergency Alarm)

Alarm display: DC OUT OVER The alarm indicates the bus voltage exceeds the alarm limit of the PCU. Such alarm requires immediate action. 1. Check the set system voltage and the overvoltage limit on the PCU; if the limits are incorrect, find out why they have been changed and correct them. 2. Find out which rectifier causes the alarm. Turn off the AC input switches of all rectifiers after verifying that the battery can supply power normally, and then turn on the rectifiers one by one. If system over-voltage protection occurs when turning on one certain rectifier, this rectifier is the one that causes the alarm.
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77
Turn off this rectifier and turn on the other rectifiers, the system will operate normally.
5.3.6
DC Output Under Voltage (Emergency Alarm)

Alarm display: DC OUT LOW Shows that the distribution voltage has dropped below the preset alarm level, usually initiated because of mains failure. 1. If the undervoltage is caused by a mains failure, check with the exchange manager whether some load could be cut out in order to prolong the operating time of the plant (in a system with LLVD function, this will take place automatically). 2. If there is no mains failure, the reason for the low voltage is that the load is supplied entirely or to a large extent by the batteries because of rectifier failure or too high system load related to the rectifier capacity. 3. If the undervoltage is caused by a rectifier failure, find out what rectifier alarms are active and follow the instructions concerning them. 4. If all the rectifiers are in operation and take full load, the undervoltage may be caused by battery discharge due to rectifier capacity being too small. Compare the distribution current with the rectifier current. The distribution current must not exceed the total rectifier current at floating voltage. If the distribution current is higher than the rectifier capacity, some load must be disconnected in order to secure the operation of the plant. Add more rectifiers so that they cover 120% of the distribution current at normal floating voltage, and at least one redundant rectifier to that.
78
5.3.7 Distribution Fuse N Failure (Emergency Alarm)

Alarm display: ROUTE N FAULT Indicates that the circuit breaker of the N distribution branch has tripped. The reason for the alarm is probably overload of the circuit breaker, unless a short circuit or alarm circuit fault has occurred. 1. Check the circuit breaker, if it is tripped, find out and eliminate the reason before resetting it. 2. If the circuit breaker is not tripped, measure across the two terminals of the circuit breaker. If the meter reads close to 0V, it indicates the alarm circuit is faulty, find out the reason.
& Note
Work inside the cabinets or intervention in a unit shall always be carried out by adequately trained personnel with adequate knowledge of the power supply system.
5.3.8 Auxiliary Distribution Fuse Failure (Emergency Alarm)

Alarm display: AUXROUTE FAIL Indicates that the circuit breaker of the auxiliary distribution branch has tripped. The reason for the alarm is probably overload of the circuit breaker, unless a short circuit or alarm circuit fault has occurred. 1. Check the circuit breaker, if it is tripped, find out and eliminate the reason before resetting it. 2. If the circuit breaker is not tripped, measure across the circuit breaker terminals. If the meter reads close to 0V, it indicates the alarm circuit is faulty, find out the reason.
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79
5.3.9 Battery Fuse Failure (Emergency Alarm)

Alarm display: BAT1 RT FAULT /BAT2 RT FAULT Indicates that battery fuse 1 or 2 has blown. The reason is overload, short circuit, manual disconnection or faulty alarm circuit. 1. Check the voltage of the concerned battery. If the voltage of this battery is the same as the system voltage, the alarm circuit is faulty. Fault trace the alarm circuit. 2. If the voltage is different, the fuse has blown and the reason must be found out and eliminated.
Exchange of battery fuses 1. Disconnect the blown fuse by pulling out the fuse handle using special fuse puller; 2. Replace the fuse in the fuse holder with one of the same type; 3. Measure with a voltmeter across the fuse holder terminals, if the voltage is lower than 3V, the fuse holder can be inserted. If the voltage is higher than 3V, the system voltage must be decreased to the same voltage as the disconnected battery before inserting the fuse holder.
& Note
Exchange of battery fuse shall always be carried out by adequately trained personnel with adequate knowledge of the power supply system.
5.3.10 LLVD (Emergency Alarm)

Alarm display: LOAD LVD
80
Indicates that the LLVD contactor has disconnected some loads because of under voltage. The contactor will pull up automatically when the mains returns.
5.3.11 BLVD (Emergency Alarm)

Alarm display: BATTERY LVD Indicates that the BLVD contactor has disconnected all loads because of under voltage. The contactor will pull up automatically when the mains returns.
5.3.12 Rectifier N Overvoltage Shut Off (Emergency Alarm)

Alarm display: RECT N PROTECT The alarm indicates that rectifier N of the system supplies higher output voltage than the preset value, and has therefore been blocked. The alarm is indicated by a red LED on the faulty unit. Check the mains to ensure there is no over voltage. 1. Try to restart the rectifier by switching its mains supply off and then on again; 2. If the rectifier still gives alarm, exchange it.
5.3.13 Rectifier N Failure (Emergency Alarm)

Alarm display: RECT N FAULT Indicates an interval rectifier defect. The alarm is indicated by a red LED on the faulty unit. One reason can be that the rectifiers internal temperature is too high. 1. Check if the fan runs;
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81
2. If the fan stands still, try to restart the rectifier by switching its mains supply off and then on again. If the fan stands still, exchange the fan; 3. If the fan runs, make sure that there is nothing obstructing the inflow of cooling air through the rectifier front or the outflow of heated air through the rectifier back. 4. If the rectifier still gives the alarm Rectifier failure, exchange it.
5.3.14 Rectifier N Communication Failure (Emergency Alarm)

Alarm display: RECT N COMFAIL Indicates that there is a communication failure between the rectifier N and the PCU or an internal rectifier failure. 1. If there is a red LED illuminated on the rectifier, take actions to eliminate the fault first (see alarm Rectifier Failure); 2. If no rectifier failure occurs, check its connection with the PCU; 3. Try to reset the rectifier by switching its mains supply off and then on again; 4. If the rectifier still gives alarm, exchange it.
5.3.15 PCU Failure (Non-alarm by Default)

Alarm display: Internal faults of PCU include : MONI +12V FAUL MONI Vref FAUL MONI -8V FAUL MONI Vcom FAUL. If the above alarms are set to emergency alarm or ordinary alarm, the current alarm page of the PCU will show corresponding alarm
82
message in the case of PCU internal circuit fault. The user may locate the fault according to the alarm message.
5.3.16 Measurement Fault (Non-alarm by Default)

Alarm display: MEASURE FAULT If current measurement error or wiring error occurs, the PCU can detect the inconformity between the total rectifier current, battery current and load current. If alarm is allowed for this fault, the PCU will show the alarm message. This fault has potential danger, therefore when it occurs, battery charge limiting will stop so as to prevent such fault from causing deep rectifier current limiting. In the case of measurement error, check the battery shunt and load shunt cable connection to eliminate the fault.
5.3.17 Manual Operation State (Non-alarm by Default)

Alarm display: MANUAL STATUS Indicates that the battery management mode has been set to manual state, and automatic battery equalize/float charge control, current limiting control, temperature compensation control and LLVD and BLVD control are deactivated. 1. Check the necessity of manual battery management; 2. If there is no need for manual battery management, set the battery management mode to automatic state.
5.3.18 Equalize Charge State (Non-alarm by Default)

Alarm display: EQU CHARGE Indicates that the battery is in equalize charge state, which will enhance the system DC voltage. In automatic battery management state, after equalize charge is completed, the system voltage will automatically return to float voltage level, and the alarm will cease.
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83
5.3.19 High Battery Temperature (Emergency Alarm)

Alarm display: AMBNT OVERTEM Indicates that the battery temperature is over the preset level. Reasons can be that a battery has an internal fault that is heating it up, the battery voltage is too high or that the battery room temperature is high. High temperature is harmful to the battery and might lead to emission of explosive and corrosive gasses, explosion and loss of the battery back-up. Find out and eliminate the reason for the high temperature.
5.4 Repair
5.4.1 Exchanging Rectifier
No repair except exchange of the fan is recommended. 1. Check that the replacement rectifier has no visible transport damage; 2. Switch off the mains supply to the faulty rectifier; 3. Place the latch of the faulty rectifier to the unlock position and pull the rectifier out from the rack. The surface temperature of the rectifier just existing the system is very high, care must be taken when sliding the rectifier out from the rack, as it may suddenly drop and cause damage. 4. Push the new rectifier into the rack along the guide rails, and place the latch to the lock position. 5. Switch on the mains supply to the rectifier. The green LED ON will illuminate after some delay and the fan will start. 6. Check on the display unit that the new rectifier has been identified by the PCU;
84
7. Check that the rectifier is sharing the load with the other rectifiers of the system; 8. Check that the rectifier initiates alarm by switching off its AC mains supply and verifying the alarms on the PCU. If all the above checks are correct, then the rectifier is functioning correctly.
5.4.2 Exchanging the Fan of Rectifier

If the fan does not move it should be exchanged. 1. Switch off the mains supply to the faulty rectifier. 2. Place the latch of the faulty rectifier to the unlock position, and pull the rectifier out from the rack 3. As shown in the figure below, lift the baffle plate, dust mesh and fan at the front of the rectifier above the handle.
Fan Dust mesh
Baffle plate
Fig. 5-1 Dismounting and Assembling Dust Mesh and Fan If the dust mesh is dirty, clean it. 4. Disconnect the power line of the faulty fan, and take out the faulty fan. Replace it with a new fan and reconnect the power line.
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85
5. Replace the dust mesh and the baffle plate. 6. Remount the rectifier, and place its latch to the lock position. 7. Switch on the mains supply to the rectifier. 8. Check that the fan starts.
5.5 Final Steps

When the causes of the alarms are eliminated according to the pervious chapter, the following final steps shall be taken before you leave the power plant: 1. Make sure that all activated alarms have been dealt with and that no alarms remain in the system. 2. Make sure that all units of the system, which are not deficient, function satisfactorily. 3. Disconnect any test equipment which was connected to the system, and make sure that materials which are not part of the equipment have been removed. 4. If alarm dry contacts are installed, make sure that the alarms are connected. 5. Restore the equipment to its original state and close the cabinet doors. 6. Make sure that all actions taken are noted in the log book, stating time and name of the person who carried them out. 7. If a defect remains in the system, personnel with adequate training on the power supply equipment shall be summoned. 8. If a unit shall be sent for repair, fill in the FAILURE REPORT and send it with the unit.
86
5.6 Maintenance
1. If applicable, use a vacuum-cleaner to clean the air filters of the rectifiers when they are dirty. If necessary, change them. 2. Check and test the batteries according to the recommendations of the battery supplier.
3.
A scheduled test of the power supply system shall be performed at least every two years by personnel adequately trained on the power supply system. The test comprises checks of automatic functions, voltage levels and alarms. Settings according to the document TABLE OF SET VALUES shall be verified in this test. A copy of the document shall be kept in the log book of the plant.
4.
Appendix A
Technical Specifications
87
Appendix A
? . Environmental conditions 1. Operating temperature: -5~40? 2. Storage temperature: -40~70? 3. Relative humidity: = 90%RH(402? ) 4. Altitude: = 3000m( derating is required the altitude is exceeded) 5. Others: Free of conductive dust, corrosive gas and explosion hazard.
& Note
The technical specifications and environmental requirements here apply to power supply system not configured with Emerson battery. For those of power supply system configured with Emerson battery, please refer to Section 1.2.5. ? . AC input 1. Rated input voltage: 220V 2. Input voltage range: 90~ 290VAC 3. Input frequency: 45- 65Hz 4. Input current: 63A/2P(MCB) 2-branch
5. AC input system: 3-phase/5-line 6. Suitable network type: TN-C, TN-S, TN-C-S, TT 7. Rectifier vs. AC input voltage characteristics:176~ 290VAC vs. 58VDC /25A output, 90~ 176VAC vs. 58VDC /12.5A output, with turn point between 170VAC 180VAC deemed normal.
88
Appendix A Technical Specifications
? . Output characteristics 1. Output DC voltage: 42- 58VDC 2. Output DC current: 0- 350A 3. Rectifier load sharing: the rectifiers can operate in parallel and share the load, with load sharing imbalance within 5% of rated output current; the test current ranges between 10%~100% of rated current. 4. Voltage stabilizing accuracy: = 1% 5. Noise: Weighted Wide frequency = 2mV = 100mV @3.4kHz~ 150kHz = 30mV @150 kHz~ 30MHz Peak-peak 6. Efficiency: = 88% 7. MTBF: 200,000hr 8. Acoustic noise: = 55dB( A) = 200mV
Appendix A
89
? . Alarm & protection
1. AC input alarm & protection

Parameter AC input overvoltage alarm point AC input overvoltage alarm recovery point AC input undervoltage alarm point AC input undervoltage alarm recovery point Default 2805VAC 2705VAC Remark Adjustable through PCU 10VAC lower than AC input overvoltage alarm point Adjustable through PCU 10VAC higher than AC input undervoltage alarm point
1705VAC 1805VAC
2. DC output alarm & protection

Parameter DC output overvoltage protection point DC output overvoltage alarm point DC output overvoltage alarm recovery point DC output undervoltage alarm point DC output undervoltage alarm recovery point LLVD point BLVD point Default 59.5 1VDC Adjustable between undervoltage alarm point ~58.5VDC through PCU 0.5VDC lower than overvoltage alarm point Adjustable between 40.0VDC~overvoltage alarm point through PCU, 0.5VDC higher than undervoltage alarm point Adjustable through PCU Adjustable through PCU Remark
58.5 0.2VDC
580.2VDC
45.0 0.2VDC
45.5 0.2VDC 440.2VDC 43.2 0.2VDC
90
Appendix A Technical Specifications
? . Insulation resistance At ambient temperature 15~35? and relative humidity= 90%RH, apply test voltage 500Vdc, the insulation resistance of AC/DC circuit to earth and AC circuit to DC circuit = 10MO . ? . Dielectric strength In testing, the SPD, PCU, and rectifier should be removed. The AC to DC and earth can withstand 50Hz, 2500Vac for 1 minute, without breakdown or flashover and with leakage current less than10mA. The DC to earth can withstand 50Hz, 1000Vac for 1 minute, without breakdown or flashover and with leakage current less than10mA. The auxiliary circuits not connected with the main loop can withstand 50Hz, 500Vac for 1 minute, without breakdown or flashover and with leakage current less than 10mA. ? . Lightning protection The AC input side can withstand five events of a lightning surge voltage of 5kV at 10/700 s, for the positive and negative polarities respectively, and five events of a simulated lightning surge current of 20kA at 8/20 s, for the positive and negative polarities respectively, with surge interval no less than 1 minute. It can also withstand one event of a simulated lightning surge current of 40kA at 8/20 s. The DC side can withstand one event of a simulated lightning surge current of 10kA at 8/20 s.
Appendix B
System Schematic Diagram
91
Appendix B System Schematic Diagram

DC distribution unit
AC distribution unit
Monitoring module
Rectifier subrack
For non-standard design
Battery 1
For non-standard design

Battery 2
Appendix B
System Schematic Diagram
93
Component table:S/N.
Code QFA1 QFA2 QFA3--QFA16 QFD14 QFD15 QFD7QFD9 QFD12QFD13 QFD1QFD6 QFD10 QFD11 FUB1 FUB2 FC HL1 HL2 K1K5 HA KMD1KMD2 RB1 RB2 RL FU
Name MCB MCB MCB MCB MCB MCB Fuse holder Fuse SPD Indicator Indicator SPDT toggle switch Buzzer DC contactor Shunt Terminal Fuse A44C5S1 AC signal sampling board W2442X1 Signal transfer board W14E2X1 Rectifier backplane W14E2X2 Rectifier backplane W14E2X3 Rectifier backplane SPD11D DC SPD board PSM-A10 PCU HD4825-3 rectifier
Specification 220V 63A 3P 32A 3P+N 220V 16A 1P 10A 1P 32A 1P 63A 1P SIST401 NT2 400A Class I/C SPD Red Green
Quantity 1 1 14 2 5 8 2 2 1 1 1 5 1
48V 400A normally closed FL2-300/75mA S250-2A
2 3
PD1 PD2 PD3 PD4 PD5 SPD PSM H2H15
14
Appendix C
System Circuit Diagram
95
Appendix C
System Circuit Diagram
Appendix C System Circuit Diagram
96
Appendix D System Engineering Design Diagram
97

A view (Top view)
B view (Base view)
Engineering Diagram of PS48350-1A/25 System
98
A view (Top view)
Battery rack (depth:520mm)
B view (Base view)
Engineering Diagram of PS48350-1B/25 System
99
Specifications of System Input/Output Connectors

Specifications of Connector Connector Capacity AC input MCB AC disbtribution unit Earth bar AC neutral line bar DC output copper bar (+) Battery fuse DC distribution unit Output branch (15-branch in standard configuration) 63A 2, 32A 2, 10A2 6 H connection terminals(cable area= 25mm )
2
Wiring Description Specifications of Connection Terminal 3 H connection terminals (cable section< 25mm ) 1 M10 bolt, and 2 M6 screws
2 1 H connection terminal (cable area < 25mm ) 2
63A (1-branch)
Connect to the user earth bar in the equipment room Neutral line of the mains input. Battery +, load branch + Battery Non-priority load branch (LLVD)-, total current = 200A (when LLVD is configured, all loads are protected by BLVD) Priority load branch (BLVD)
2 M10 bolts, 5 M8 bolts, 12 M6 bolts 400A fuse (2-branch) 2 M10 bolts
63A6, 32A3
9 H connection terminals (cable area= 25mm )

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ACTURA Durus PS48350

Conventions Used in This Book

3.4 Start Up........................................................................................ 52 3.4.1 Batteries............................................................................. 53

3.7.3 Battery Current................................................................... 58 3.7.4 Load Current...................................................................... 58 3.7.5 Rectifier Parameters........................................................... 58

Manual Operation State (Non-alarm by Default) ............... 82

Chapter 1 System Overview