REM HR8022 001 - A User Manual

All rights reserved.
Passing on and copying of this document, use and communication of its contents not permitted without written authorization from AcBel.
Rev. A
HR8022-001
HR8022-001
Energy System User Manual
48V/2160W/540W Energy System
All rights reserved. Passing on and copying of this document, use and communication of its contents not permitted without written authorization from AcBel.
Contents
Chapter 1 Introduction 1.1 1.2 1.3 Chapter 2 System Introduction System Key Features Main Applications 1-1 1-2 1-2
Overview of the System 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 System Architecture Electrical Specification Environmental Specification Safety Specification Mechanical Specification System Internal Layout System Major Component List System Alarm System Protection Battery Management 2-1 2-2 2-3 2-3 2-3 2-4 2-5 2-6 2-6 2-7
Chapter 3
Installation 3.1 3.2 3.3 3.4 Transporting System Unpacking System Mounting Connection of Cables 3.4.1 Cable Entry Into System 3.4.2 Connection of AC Input and Ground Cables 3.4.3 Connection of Load Cables 3.4.4 Connection of Battery Cables 3.4.5 Connection of Signal Cables 3.4.6 Temperature Sensors Connection Local and Remote Control and Monitoring 3.4.7 Communication Link Rectifier Installation Final Installation Check System Power Up Procedure 3-1 3-1 3-2 3-3 3-3 3-4 3-4 3-5 3-5 3-6 3-7 3-8 3-9 3-9
3.5 3.6 3.7
Chapter 4
Maintenance & Fault Tracing 4.1 4.2 4.3 4.4 Maintenance Recommended Spare Parts List Fault Tracing Replacing the Rectifier Procedure 4-1 4-1 4-1 4-3
Rev. A
HR8022-001
Chapter 5
Important Notices 5.1 General Guidelines 5.1.1 Installation 5.1.2 System Operation 5.1.3 Environmental and Airflow Considerations 5.1.4 Maintenance and Repair Warranty Constraints 5-1 5-1 5-1 5-1 5-1 5-2
5.2 Appendix 1. 2.
Conductor Size Requirement for DC Applications Maintenance Record
A-1 A-2
Rev. A
HR8022-001
1. Introduction
1.1 System Introduction
The power system is specially designed for the 48V telecommunication power applications. By incorporating state-of-the-art switched mode rectifier and advanced microprocessor technology, the system is able to perform efficient AC to DC power conversion and at the same time carry out intelligent monitoring and control functions. The CPS is divided into 4 major functional blocks consists of 1. Control and Supervisory Module 6 (CSM6), 2. AC Power Distribution Unit (ACPDU), 3. Rectifier Modules, 4. DC Power Distribution Unit (DCPDU).
Control & Supervisory Module (CSM 6)
AC Power
ACPDU
Rectifiers Power
DCPDU
Load
Power path Signal path

Fig. 1.1
Battery
CPS system block diagram
The Control and Supervisory Module 6 (CSM6) consists of the CSM6-1 and CSM6-2. The CSM6 is the central supervisory unit, which monitors and controls the operating parameters of the entire system. The CSM6-1 is equipped with LCD panel and soft keypads which serve as a user-friendly interface to monitor or program various system parameters and the CSM6-2 is the Data collector which collects and processes system data before passes to CSM6-1 for display. The CSM6 supports Local and Remote Monitoring & Control functions, for local monitoring & Control, the link between the system and the PC is made through the RS-232. However for the Remote Control and Monitoring, it can be achieved through Public Switch Telephone Network (PSTN) and Ethernet(TCP/IP). The CSM6 also has the battery management function which ensures proper charging of batteries so as to maximize energy storage and to prolong the life of batteries. The AC PDU distributes AC power to the rectifiers and other portions of the system. A single pole MCB (Miniature Circuit Breaker) is available within the AC PDU to isolate the system from the mains. The AC PDU is also installed with an array of Surge Protection Device which protect the
Rev. A
HR8022-001
1-1
system against line surge. The rectifier modules carry out AC to DC power conversion in the system. Each rectifier is able to deliver a rated output power of 540W at a nominal output voltage of -54V. Therefore, when the system is expanded to its fullest capacity of four rectifiers, it is capable of delivering a maximum power of 2160W to external loads and batteries. The rectifiers are modular in design, hot-swappable and exhibit excellent current share performance when operated in parallel configuration. The system is hence flexibly configurable to meet different power consumption requirements and to achieve N+1 redundancy. Control of rectifiers can be carried out in a centralized manner on the CSM6. In addition, the operating conditions of individual rectifier can also be easily monitored on the CSM6. The DC PDU distributes DC power from the rectifiers to external loads and batteries. Within the DC PDU, there are MCBs protected distribution ways to be connected to external loads. The DC PDU also incorporates two battery connections, which are equipped with two MCBs for protection purposes. The battery connections allow the system to have power backup capability in the event of an AC failure.
1.2 System Key Features

l l l l l l l l l l l Wide input voltage range High power factor and efficiency Modular rectifier design with current share and hot-swappable capability Compact in size, high power density. Swift and convenient rectifier installation Microprocessor based intelligent monitoring and control Intelligent battery management system Comprehensive fault protection and detection schemes Low noise and electromagnetic interference level Efficient forced air cooling ensures low component thermal stress Front access air filter leading to easy maintenance
1.3 Main Applications

l l l l l l l PBX, PABX station Digital communications equipment GSM station CDMA, TDMA, AMPS station Microwave communication station Railway switching control station Other -48V telecommunication systems
Rev. A
HR8022-001
1-2
DC OUTPUT (+) T.B. AC INPUT T.B.

NO COM NC NO COM NC NO COM NC NO COM NC LV Alarm AC Fail
AC INPUT B2-
LVDS Alarm
Common Alarm
L B1DC OUTPUT (-) L4L3L2L1-
Alarm dry contact T.B. BACK VIEW 436.0 436.0
277.0
100A LVDS
LEFT VIEW
TOP VIEW WITHOUT COVER
LEFT VIEW
277.0
48V/540W Rectifier
AC MCB
SPD
LOAD MCB
AC MCB
SPD L1
LOAD MCB L2 L3 L4
Power
TCP/IP
465.0 482.6 FRONT VIEW
Fig. 1.2
Power system outline (Unit: mm)
Rev. A
HR8022-001
57.2 132.6
B2+ B1+ L4+
DC OUTPUT (+)
L3+
L2+
L1+
DC OUTPUT (-) T.B.
100A SHUNT
TOP VIEW
BATT. MCB
BATT. MCB B1 B2
TCP/IP Port Controller CSM6
1-3
2. Overview of the System

2.1 System Architecture
The system dimensions is 132.6mm x 482.6mm x 277.0mm (HxWxD). The ACPDU is fed by AC cables which are terminated at the AC input terminal block. The DCPDU distributes DC power from the rectifiers to external distributed load and battery. A positive and a negative busbar carries DC power from the rectifiers to the DCPDU. There are also battery connections within the DCPDU which is equipped with one 100A LVDS for loads control. The LVDS provide protection over discharge of batteries. In the event of an AC failure, energy from the batteries will flow through the DCPDU to the external distributed loads. Hence, the loads will not experience power interruption. The energy system has four pre-wired rectifier compartments. Rectifier installation is swift, straightforward and does not require further connection of cables. Since the rectifier is modular and hot-swappable in design. Different number of rectifiers can be installed onto the system to meet varying power consumption requirements. This allows incremental system expansion to be realized easily. Maintenance work can also conveniently carried out as any rectifier can be removed and replaced without interrupting system operation.
Rev. A
HR8022-001
2-1
2.2 Electrical Specification

Table 2.1 Electrical Specification
HR8022-001 OT6001
System model Rectifier Model AC input Nominal voltage Operating voltage range (full output power) Starting Voltage Frequency Rated current (220Vac input; 54Vdc, 100% load) Rated current (110Vac input; 54Vdc, 100% load) Efficiency (220Vac input; 54Vdc, 100% load) Efficiency (110Vac input; 54Vdc, 100% load) Power factor (220Vac input; 54Vdc, 100% load) DC output Nominal voltage Float voltage adjustable range Equalize voltage adjustable range Nominal Power (100% load) Soft start time Line regulation Load regulation (0% ~ 100% load) Current share (50% ~ 100% load) Audible noise Psophometric noise Load MCB Battery MCB
110/220Vac single phase 90Vac ~ 300Vac 100Vac 45 ~ 65Hz 10.8A 22.3A >91% >89% >0.99
54Vdc 43 ~ 58Vdc 43 ~ 58Vdc 2.16kW > 3s < 0.1% < 0.5% 3% deviation from mean current 55dBA (1 meter) < 2mV 16A x 3; 6A x 1 32A x 2
Rev. A
HR8022-001
2-2
2.3 Environmental Specification

l l l l l Operating temperature : -20C +70C (ideal operating temperature : 25C) Storage temperature : -20C +80C Relative humidity : 10%RH 90%RH (non-condensing) Altitude : < 3000 meter Illumination requirement : 750LX (even illumination)
Note : The operating environment must not contain corrosive and inflammable gas. Good ventilation and air-conditioning is highly recommended.
2.4 Safety Specification

l Designed to meet UL1950, EN60950 requirements l Hi-pot : Input to output 1500Vac, 50Hz for 1 minute Input to chassis (FG) 1500Vac, 50Hz for 1 minute Output to chassis (FG) 500Vac, 50Hz for 1 minute l Earth continuity : Safety earth to chassis (FG) 25A for 1 minute (Earth resistance < 0.1)
2.5 Mechanical Specification

l l l Height : 132.6mm Width : 482.6mm Depth : 277.0mm
Rev. A
HR8022-001
2-3
TOP VIEW WITHOUT COVER
LOAD MCB
L4-
L3-
L2-
L1-
DC OUTPUT (-)
DC OUTPUT (+)
B1-
BATT. MCB
B2-
Outline drawing (Unit: mm)
AC INPUT G N L

L1 L2
B2+ B1+ L4+ L3+ L2+ L1+
Rev. A
Fig. 2.1
2.6 System Internal Layout
HR8022-001
BACK VIEW
5 2
AC MCB SPD
FRONT VIEW
8
LVDS Alarm NO COM NC NO COM LV Alarm NO COM NC Common Alarm NC NO COM AC Fail NC
6
L3 L4 B1 B2
10
Power
TCP/IP
11
2-4
CSM6
Fig. 2.2 Outline Drawing of CSM6-1
CS M6
Fig. 2.3 Outline Drawing of CSM6-2
2.7
System Major Component List
Table 2.1 Item 1 2 Component Rectifier AC MCB DC MCB 3 DC MCB 4 5 6 7 8 9 10 11 BATTERY MCB CSM6-2 CSM6-1 Ac input Terminal block Dry contact Terminal block Battery lvds Load and battery Terminal block Ethernet network card DC MCB 6A 1P BATTERY MCB 32A 1P MAIN CONTROLLER CARD FOR CSM LCD FOR CSM DISPLAY AC I/P TB 40A/3P ALARM TERMINAL BLOCK/12P RELAY MAGNETIC 48V 100A 1PST TERM BR PBT 40A 600V 6P BLK ETHERNET NETWORK RS-485 1 2 1 1 1 1 1 2 1 Specification RECTIFIER 48V/540W RECTIFIER AC MCB 32A 1P DC MCB 16A 1P Q ty Max. 4 1 3
Rev. A
HR8022-001
2-5
2.8 System Alarm

The system is equipped with various fault detection schemes and alarms to keep users informed in the event of fault conditions. The system is also equipped with four voltage free relay contacts (dry contacts) to keep remote users informed when a fault occurs. The relay contacts will respond to normal and fault conditions as indicated in the table below : Table 2.2
Operating Conditions Normal condition Fault condition COM, NO Contacts Open Close COM, NC Contacts Close Open
2.9 System Protection

The system is equipped with various protection schemes to ensure no damage occurs in the event of abnormal conditions. Some of the main protection schemes are explained below : l Overcurrent protection (OCP) : At the AC input, the system is protected against overcurrent by a MCB. The load MCBs at the DC PDU protect the system against overcurrent drawn by external distributed loads. The battery MCBs prevents overload of the battery bank. Overcurrent limit of rectifiers can be programmed in a centralized manner on the CSM6. Rectifier overload current will not exceed the preset limit. Overvoltage protection (OVP) : When the AC input exceeds 308Vac, the rectifiers will cease to operate to prevent component damage caused by overvoltage stress. The rectifiers will resume normal operation upon removal of abnormal condition. Output OVP will be activated when the system output voltage cannot be regulated and exceeds 60V 0.5V. Rectifiers at fault will be forced to shutdown. Manual reset is required to restart a rectifier which has been shutdown due to output OVP fault. Over temperature protection (OTP) : The system over temperature alarm will be activated when the ambient temperature in the system raises above a preset level. The default preset level is 40C. In addition, when the rectifier heatsink temperature raises above a default preset level of 80C, the rectifier fault alarm will be activated. If the heatsink temperature raises further and reaches 90C, the rectifier will be forced to shutdown. The rectifier will resume normal operation when the heatsink temperature reduces below 70C.
l Surge protection : At the AC input, the system is protected against line surge by an array of 20KA/275Vac SPD module.
Rev. A
HR8022-001
2-6
2.10
Battery Management
The CSM6 carries out battery management functions according to the user preset parameter values. Details on the battery management parameters can be found in the CSM6 User Manual. In the event of an AC failure, the CSM6 will calculate the discharge Ampere-Hour (AH) of the batteries. When AC recovers, the batteries will be recharged automatically in equalize mode according to the preset charging coefficient (CC) or automatic charging time (ACT). One critical aspect of battery management is temperature compensation. The IC LM335 converts the battery temperature sensed into a current signal. The signal is then processed by the CSM6-2. Based on the temperature information obtained, the CSM6 will adjust the output voltage of the rectifiers accordingly. The desired temperature compensation characteristic can be obtained by changing the temperature reference point (TBP), temperature rise rate (TS) and voltage decrease rate (VS) settings. Low Voltage Disconnect (LVD) Protection : The Load LVDS is to disconnect load, The disconnect and reconnect voltages are preset at 43.0V and 50V respectively.
Rev. A
HR8022-001
2-7
3.
3.1
Installation
Transporting
During shipment, the power shelves and rectifier modules are packed separate in cartons. Then, they are packed and shipped on separate pallets. The pallets are heavy and large in sizes. Hence, suitable transporting machines will be needed for transporting. Plan in advance on the transport route and the location to unpack and to assemble the system.
3.2
3.2.1
System Unpacking
Before dismantling the packing, inspect for damages, shape distortion or any trace of moisture on the package. Pictures should be taken and lodge a report immediately if any abnormal condition is observed. To unpack the system, refer to Fig. 3.1. Upon completion on the unpack process, inspect the contents to ensure that no transit damage has occurred and check the completion of the contents
3.2.2 3.2.3
Step 1
Step 2
Step 3
Fig. 3.1
Unpack procedure
Rev. A
HR8022-001
3-1
3.2.4 System Packing List Compare the contents in the crates with the attached packing list. Contact our sales representatives if there is any shortage or damaged item. Table 4.1
Package No. 1
Packing list
Part Description Compact Power System Q ty (pcs) 1 Part No. HR8022-001 Net Weight Gross Weight (kg) (kg) 6.3 8.3 Crate Dimension (H x W x D; mm) 205 x 420 x 530
3.3
=
System Mounting
If the power System is to mounting on cabinet or rack, must first mount the System supporting rails at the bottom of the power System, refer to pictorial illustration below, Fig 3.2. During the mounting, must ensure the rails are well balanced and not tilted. Then place the System on the rails and mount the System hangers against the cabinet or racks. Refer to drawing below Fig. 3.2.
AC MCB
SPD L1
LOAD MCB L2 L3 L4
BATT. MCB B1 B2
Power
TCP/IP
FRONT VIEW
Mounting holes for cabinet or racks mounting mount CPS onto (x4)
Fig. 3.2
System mounting
Rev. A
HR8022-001
3-2
3.4 Connection of Cables

3.4.1 Cable Entry Into System
Incoming AC cables, outgoing DC cables and remote signal (dry contact) cables are to be terminated at the AC terminal block, DC MCBs and Alarm terminal block respectively. Refer to Fig. 3.3 for the cable connection to the power shelves.
NO COM NC
NO COM NC
LV Alarm
AC Fail
AC INPUT
NO COM NC
LVDS Alarm
Common Alarm
NO COM NC
5 3
BACK VIEW
Fig. 3.3 1 2 3 4 5
HR8022-001 cables connections
AC Input cables to the AC terminal block 40A/3P (single phase). Load(+) and battery(+) cables to the common (+) terminal block. Load(-) cables to the Load(-) terminal block. Battery(-) cables to the Battery(-) terminal block. Dry contact cables to the dry contact terminal block 10A/12P.
Rev. A
HR8022-001
B2-
B2+ B1+ L4+ L3+ L2+ L1+ B1DC OUTPUT (-) DC OUTPUT (+)
L4-
L3-
L2-
L1-
3-3
3.4.2 Connection of AC Input and Ground Cables For single phase input, incoming AC cables are to be terminated at the AC input terminal block., which is as shown in Fig. 3.4 below: -
G
G AC INPUT
B2-
B1-
L4-
L3-
L2-
L1Common Alarm NO COM NC
NO COM NC
LVDS Alarm
DC OUTPUT (-)
N
L
N L
NO COM NC
NO COM NC
LV Alarm
AC Fail
DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+
BACK VIEW
Fig. 3.4
AC input terminal block connection for single phase system
3.4.3
Connection of Load Cables
Incoming Load cables are to be connected to the DC output terminal block. Positive load cables are to be terminated at the positive terminal block and negative load cables are to be terminated at the load (-) DC output terminal block, The connection of Load cables as shown in Fig. 3.5 respectively below: -
L1L4- L3- L2-
B2G N L AC INPUT
B1-
L4-
L3-
L2-
L1NO COM Common Alarm
NO COM NC
LVDS Alarm
DC OUTPUT (-)
NC NO COM NC
NO COM NC
LV Alarm
AC Fail
DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+
BACK VIEW
L1+ L4+ L3+ L2+
Fig. 3.5
Connection for load cables
Rev. A
HR8022-001
3-4
3.4.4
Connection of Battery Cables
Positive battery cables are to be connected to the battery (+) terminal block and negative battery cables are to be connected to the battery (-) terminal block. The connection of battery cables is as shown in Fig. 3.6 below: -
B2- B1-
B2G N L AC INPUT
B1-
L4-
L3-
L2-
L1Common Alarm NO COM
NO COM
LVDS Alarm
DC OUTPUT (-)
NC NO COM
NC NO COM
LV Alarm
AC Fail
NC
DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+
NC
BACK VIEW
B2+ B1+
Fig. 3.6
Connection for battery cables
Caution:
Please switch off the battery MCBs before connecting the battery cable. Please confirm if the polarity of incoming battery cables connected to the MCBs right or not before this system works.
3.4.5
Connection of Signal Cables
Cables of warning signals are to be terminated at the upper terminals of the voltage free relay contact terminal block. There are three contact points for each signal namely the NO, COM and NC. The four dry contact warning signals are arranged in the order of Battery LV Alarm, Common Alarm, AC Fail Alarm and LVDS Alarm. Refer to Fig.3.7 below : -
B2G N L AC INPUT
B1-
L4-
L3-
L2-
L1Common Alarm NO COM NC
NO COM NC
LVDS Alarm
DC OUTPUT (-)
NO COM
NO COM
LV Alarm
AC Fail
NC
DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+
NC
BACK VIEW
Fig. 3.7
Voltage free relay contact terminal block
Rev. A
HR8022-001
3-5
3.4.6 = = =
Temperature Sensors Connection
Attach the temperature sensor on one of the battery blocks. To ensure good contact, clean the surface of the battery before attaching the battery temperature sensor. Do not use the corrosive solvent during cleaning process. Adhesive strip
Fig. 3.8
Temperature sensor and cable connection
Rev. A
HR8022-001
3-6
3.4.7 Local and Remote Control and Monitoring Communication Link
CSM6 provides RS-232 and TCP/IP communication ports for the local and remote control and monitoring function. Local Control and Monitoring : connect a dedicated RS-232 cable to a local PC. Remote Control and Monitoring : (a) Dial-up by using Modem via PSTN (b) TCI/IP connection via Ethernet network Notes: TCP/IP address default setting: 192.168.128.244 TCP/IP port default setting: 4001
6 M CS
CSM6-2 RS-232 Communication cable TCP/IP TCP/IP Port Communication cable
Fig. 3.9
Local and Remote control and monitoring communication cable connection
Rev. A
HR8022-001
3-7
3.5 Rectifier Installation

l l Unpack the rectifier (refer to LPR user manual section 3.1). Insert the rectifier into the rectifier compartment in the power system.
Push Fig. 3.10 l l Insert rectifier into the rectifier compartment
Push the rectifier along the rail in the compartment. The rectifier must be pushed until the rear side of its front panel fully touches the cabinet. Secure the rectifier onto the power system with retaining screw provided.
Fig. 3.11
Tighten the rectifier with retaining screw
Rev. A
HR8022-001
3-8
3.6 Final Installation Check

Use the check list below to complete checks before progressing further.
l l l l l l l l
Ensure the system is positioned firmly Ensure all specified ground cables are connected and firmly tightened Ensure the ground resistance meets all specified requirements Ensure all AC and DC cable connections are correct and firmly tightened Ensure the battery polarities are correct at all connections Ensure all battery cable connections are firmly tightened Ensure all signal (voltage free relay contact) connections are correctly and firmly connected Ensure the correct cable size and number of cables are selected to carry the rated load correct and to ensure low voltage drop
3.7 System Power Up Procedure

l Before turning on the external AC mains, ensure the following breakers and switches are off : l AC MCB at the ACPDU l Load MCBs at the DCPDU l Battery MCBs at the DCPDU Turn on the AC mains (external). Measure the AC input voltage at the AC terminal block. Ensure the voltage is within the operating voltage range. Turn on the AC MCB if the input voltage is normal. Turn on the battery MCB at the DCPDU if the system output voltage is normal (Can be checked from the Rectifier s LCD or the CSM6 s Test Port. Turn on the load MCBs at the DCPDU. Check the LEDs status on the CSM6. (1) No alarm (no red LED lighted) should occur. (2) AC power normal (green LED lighted).
l l l l l l
Rev. A
HR8022-001
3-9
4. Maintenance & Fault Tracing

4.1 Maintenance
l l Hazardous voltages exist within the system cabinet. Hence, test before touching any conducting part. Perform regular inspection on the system at time intervals recommended below : - Check the environmental conditions (temperature, humidity level, air quality, ventilation etc.) every month. - Wash the dust filter of the rectifier modules with clean water every month. - Check the condition of the fans in the rectifier modules every half a year. - Clean the surface of the cabinets once every year. An example of a maintenance record is given in Appendix 2 of this manual.
4.2
Recommended Spare Part List

Recommended spare part list Part Description Rectifier LVDS 48V 100A Current sensor shunt 100A Control and Supervisory Module (CSM6) CSM6 interface card Quantity 1 pcs per 10 system 1 pcs per 20 system 1 pcs per 20 system 1 pcs per 20 system 1 pcs per 20 system
Table 4.1 No. 1 2 3 4 5
4.3 Fault Tracing

When a fault message is displayed on the LCD panel of the CSM6-1, the following guide can be used for fault tracing : -
Alarm
POWM DCV ENVM LVA AU COMMXX SMR COMMXX MAJOR ALARM SMR ALARMXX AC FAIL 01
Description of Fault
RS-485 communication breakdown between CSM6-1, CSM6-2 or rectifiers. AC power failure or loss of phase
Check Items
AC FQ
1.
Check if any RS-485(USB line) connector is disconnected. Check if the AC MCCB/MCB is off. Check if AC power failure or loss of phase occurs. Check if AC power failure or loss of phase occurs. Check if any rectifier fails.
1. 2. 1. 2.
AC FQ
---
SMR ALARMXX
Rectifier fault or failure
Rev. A
HR8022-001
4-1
3.
Check if the AC INPUT switch of any rectifier is off or tripped. When the AC INPUT switch of a rectifier is off, its LCD will continue to display the output bus voltage. However, the green LED on the rectifier will be off and the red LED will be on. Check if the DC OUTPUT switch of any rectifier is off or tripped. Check if the address of any rectifier is incorrectly set. Check if any rectifier is in OCP, OTP, OVP or UVP mode by observing whether the red LED on any rectifier is on or any fault message is displayed on the LCD of any rectifier. Refer to the Rectifier User Manual for more details. Check if the DC output voltage is higher than the preset DCV alarm level in the CSM ALMS subscreen. Check if the DC output voltage is lower than the preset DCV alarm level in the CSM ALMS subscreen. Check if the battery is discharged to a voltage lower than the preset DCV alarm level in the CSM ALMS subscreen during an AC failure. Check if the DC output voltage is lower than the preset LVA alarm level in the CSM ALMS subscreen. Check if the battery is discharged to a voltage lower than the preset LVA alarm level in the CSM ALMS subscreen during an AC failure. Check if the internal ambient / battery temperature is higher than the preset TEMP alarm level in the CSM ALMS subscreen. Check if any load or battery MCB on the DCPDU is tripped or open. Check if the LVDS is off, tripped or fail.
4. 5. 6.
1. DCV --DC output voltage high
1. MAJOR ALARM SMR ALARMXX
DCV
DC output voltage low, battery voltage low
2.
1. LVA DCV MAJOR ALARM SMR ALARMXX
DC output voltage low, battery voltage low.
2.
ETEMPxx BTEMPxx
---
Internal ambient / battery temperature high Load or battery MCBs tripped and opened LVDS tripped
1.
-----
LOAD MCBXX BATT MCBXX LVDSxx
1. 1.
Arresters damage checking procedure Whenever a lightning surge occurs and causes damage to the surge arrester at the site AC mains distribution board, check is to be conducted on the SPD on the rectifier system, if a SPD is fractured or shattered, replace it with a new one.
Rev. A
HR8022-001
4-2
4.4
4.4.1
Replacing The Rectifier Procedure

Removing a rectifier
l Loosen the rectifier retaining screw.
Fig. 4.1 l
Loosen the rectifier retaining screw
Pull out the rectifier.
Pull
Fig. 4.2
Pull out the rectifier
Rev. A
HR8022-001
4-3
4.4.2 l
Inserting a rectifier Insert the new rectifier with the burst-out guides in the shelf.
Push Fig. 4.3 l l Insert the new rectifier
Push the rectifier along the rail in the compartment. The rectifier must be pushed until the rear side of its front panel fully touches the cabinet. Secure the rectifier into the power system with retaining screw on the front panel.
Fig. 4.4
Tighten the rectifier with retaining screw
Check the LEDs status on the CSM6 and rectifiers. (1) No alarm (no red LED lighted) should occur. (2) AC power normal (green LED lighted).
Rev. A
HR8022-001
4-4
5. Important Notices
5.1 General Guidelines
The following guidelines must be observed during system installation, system operation or when maintenance work is carried out. 5.1.1 Installation System installation must only be carried out by qualified personnel. Ground resistance must meet local requirements. Any equipment connected to the system must be properly grounded. The conductors connecting external surge arresters must be as short as possible and the resistance must be less than 10. If metal tube is used to protect the conductors, both sides of the tube must be properly grounded. External surge arresters must be located far from inflammable materials. For safety reasons, surge arresters must be installed in protective case. The distance between any metallic part and exposed conductor must meet relevant safety clearance requirements. System Operation
l l l l l l
5.1.2
l Before operating the system, it must be ensured that the input voltage, input frequency l The rectifier module must only be operated with its pin housing mated with AMP l When using sealed lead acid batteries, attention must paid to the charge data and l If any part of the system is damaged, it must undergo maintenance immediately.
5.1.3 Environmental and Airflow Considerations warning notices provided by the battery manufacturer. 211149-1 housing. Refer to the rectifier user manual for more details. and other operating conditions are within the specification.
l Operating the system in dusty environment may result in damage. Excessive dust l l l
5.1.4 settling inside the rectifier may result in poor heat dissipation and degradation of product performance. It is recommended to operate the system in air conditioned environment. The system must be operated in properly ventilated environment. Do not impede airflow through the system and rectifier modules by blocking or covering the ventilation holes on the front and back panel of the system. Do not operate the system in environment containing inflammable gas or material. Batteries produce combustible gas. Hence, the room must be properly ventilated. Maintenance and Repair
l Maintenance work must only be carried out by qualified personnel. l During maintenance or repair, do not touch any conducting part in the system while the l Before carrying out repair work on the rectifiers, wait for at least 5 minutes after switching
off the power to allow the internal capacitors to discharge. system is in operation.
Rev. A
HR8022-001
5-1
5.2
Warranty Constraints
This equipment is guaranteed for one year. During the warranty period, the equipment is guaranteed against defective material and faulty manufacture. The equipment has been carefully inspected and undergone comprehensive test at the factory prior to delivery. If, within the warranty period, any material or workmanship related defect is discovered in the equipment, we undertake to make good the defect at our own expense subject to the standard conditions of sale. Our responsibility is in all cases limited to the cost of making good the defect in the equipment itself. The guarantee does not extend to third parties, nor does it apply to defects caused by improper installation, unauthorized alteration, abnormal working conditions, accident, natural disaster, misuse, or wear and tear
Rev. A
HR8022-001
5-2
1. 2.
Rev. A
Appendix :
Conductor Size Requirement for DC Applications Maintenance Record
HR8022-001
1. Conductor Size Requirement for DC Applications

Current Rating (A) 20 30 40 50 60 70 75 90 100 125 150 175 200 225 250 275 300 350 400 500 600 700 800 1000 1250 1600 2000 2500 3000 4000 5000 Note : Follow local requirements if specified otherwise. Wire Size (mm x mm) 3.5 5.5 8 14 22 38 50 60 80 100 125 150 or 50 x 2 200 or 60 x 2 250 or 80 x 2 325 or 125 x 2 150 x 2 125 x 3 150 x 3 200 x 3 200 x 4 50 x 6t 50 x 10t 60 x 10t 80 x 10t 100 x 10t 2 x 80 x 10t 2 x 100 x 10t 2 x 120 x 10t 3 x 120 x 10t 3 x 150 x 10t Copper Busbar Size (mm x mm)
Rev. A
HR8022-001
A-1
2. Maintenance Record
System Serial No. : System Alarm Date Check 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Month : Environmental Condition Check Inspector : Dust Filter Cleaning Fan Rectifier Check Cabinet Cleaning
Rev. A
HR8022-001
A-2

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Energy System User Manual

48V/2160W/540W Energy System

3.5 3.6 3.7

48V/2160W/540W Energy System

Conductor Size Requirement for DC Applications Maintenance Record

48V/2160W/540W Energy System

Control & Supervisory Module (CSM 6)

Power path Signal path

CPS system block diagram

48V/2160W/540W Energy System

1.2 System Key Features

1.3 Main Applications

48V/2160W/540W Energy System

DC OUTPUT (+) T.B. AC INPUT T.B.

L B1DC OUTPUT (-) L4L3L2L1-

Alarm dry contact T.B. BACK VIEW 436.0 436.0

TOP VIEW WITHOUT COVER

465.0 482.6 FRONT VIEW

Power system outline (Unit: mm)

B2+ B1+ L4+

DC OUTPUT (-) T.B.

TCP/IP Port Controller CSM6

48V/2160W/540W Energy System

2. Overview of the System

48V/2160W/540W Energy System

2.2 Electrical Specification

48V/2160W/540W Energy System

2.3 Environmental Specification

2.4 Safety Specification

2.5 Mechanical Specification

48V/2160W/540W Energy System

TOP VIEW WITHOUT COVER

Outline drawing (Unit: mm)

48V/2160W/540W Energy System

B2+ B1+ L4+ L3+ L2+ L1+

2.6 System Internal Layout

Fig. 2.2 Outline Drawing of CSM6-1

Fig. 2.3 Outline Drawing of CSM6-2

System Major Component List

48V/2160W/540W Energy System

2.8 System Alarm

2.9 System Protection

48V/2160W/540W Energy System

48V/2160W/540W Energy System

48V/2160W/540W Energy System

48V/2160W/540W Energy System

3.4 Connection of Cables

HR8022-001 cables connections

48V/2160W/540W Energy System

L1Common Alarm NO COM NC

DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+

AC input terminal block connection for single phase system

Connection of Load Cables

L1L4- L3- L2-

L1NO COM Common Alarm

DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+

L1+ L4+ L3+ L2+

Connection for load cables

48V/2160W/540W Energy System

Connection of Battery Cables

L1Common Alarm NO COM

DC OUTPUT (+) B2+ B1+ L4+ L3+ L2+ L1+