ZXDU68 W201 V4.

0R06M03&M04
DC Power System

Installation Guide

www.zte.com.cn

1 of 4

1Connecting Grounding Cables

.4
4 Connecting Battery Cables
3

Communication
equipment slots
(21 U)

Connect the grounding cables to the nearest

grounding point. The PE length cannot
exceed 30 m. The grounding cable should
be laid as short and straight as possible.

PE

26U

(Groung bolt)

Connect the negative cable first to

ensure safety.

Connecting plate

Do not connect positive and

negative cables in reverse.
Tighten any loose detection cable
after battery cable connection.

Power supply
unit (8U)

+/GND

DC Power
distribution (3U)

Protection ground busbar of

installation site

BATT breakers
1 and 2

BATT input 3 and 4

+ +

Color code
PE: Yellow green
GND: Black

PE

PE
PE

+/GND of the
respectective cabinets

BATT 3 and 4
(Secondary cabinet)

1. Connect the PE cable between the grounding bolt and grounding busbar of the equipment room.
Primary Cabinet
(V4.0R06M03

Power supply unit (8U)

The negative cable is the

first cable to be connected

2. Connect the GND cable between the working ground busbar of ZXDU68 W201 and grounding
busbar of the equipment room.

Secondary Cabinet
(V4.0R06M04)

2 Connecting AC Input Cables

DC Power Distribution (3U)

Signal Interface
Board (SIB)

Cable color
BATT (+): Red
BATT (-): Blue

BATT 1 and 2 breakers

(Primary cabinet)

+ +
BATT input 1 and 2

Do not reverse the live wires and neutral wire.

ZXD2400
Rectifiers

Make sure that the AC input power is cut off

during the operation to connect the
AC input cables.

Monitoring unit
DC Output
breakers

DC SPD

AC Input
breaker

AC SPD

DC Output
breakers

Cabinet dimensions:
2250 mm 750 mm 700 mm (H W D)
Weight:
Approximately 100 kg
Rectifier: 3.8 kg/set
Monitoring unit: 2.2 kg

BATT breakers
3 and 4

1. Install the batteries into the cabinet.

Color code
L1: Yellow
L2: Green
L3: Red
N: Blue

N L1L2 L3

2. Turn off the BATT breakers.

3. Connect the negative cables to the BATT breakers (battery packs of secondary cabinet connects to the
battery breakers of primary cabinet power supply unit).
4. Connect the positive cables to the working ground busbars (GNDs of primary and secondary cabinets).

1. Turn off the AC input breaker of the AC distribution box that powers the ZXDU68 W201 system.

5. Install the connecting plates between battery cells.

2. Turn off the AC input breaker of the ZXDU68 W201 system.

Safety precautions

6. Label with battery number and polarity. For example, mark battery 1 (+) on the positive cable and
battery 1 (-) on the negative cable.

3. Connect the neutral cable (N) of the AC input.

Put warning signs in the equipment room, specifically the power distribution box.

4. Connect the phase wires of AC input (L1/L2/L3).

Fully insulate the terminals, contacts and other exposed parts and wear protective
gloves during installation/connection process.

Configuration
AC input voltage
Three-phase five-w ire (L1/L2/L3/N/PE) 220 V (80-300 V)

Before connecting any electrical cable, turn OFF all the switches and breakers and turn
OFF the protection breaker outside the system.

Cabinet position

Installing the Cabinet

Unit: mm
Cabinet dimensions: 2250 x 750 x 700
Front of
cabinet

1000

Unit: mm

690

ZXDU

700

750

Limit the vertical inclination of

the cabinet to 5o by inserting
metal plates at the bottom

..

MCB/Term inals

Battery pack/rack

Battery voltage

MCB

4*12 V battery cells

48 V

4*100 A MCB

.5 Connecting DC Output Cables

1*63 A/3P MCB

Load

Connecting the Primary and Secondary Cabinets

Power supply unit

(Primary Cabinet)

(Primary cabinet)

DC Output

600
+/GND
(Primary cabinet)

525

525

Tighten any loose detection cable after

DC output cable connection.
+/GND

63 A breaker

DC Output

Cabinet
Bottom

The load current MUST NOT exceed the

capacity of the breakers to avoid tripping
of breakers and shutdown of loads.

Tools:
Wrench

DC Power Distribution
(Secondary Cabinet)

Primary cabinet

Color code
DC output (+):Black
DC output (-): Blue

Load

Installation hole

+/GND
(Secondary cabinet)

690

DC Output

Drill

Cabinet front

+/GND

Tape measure
Nut
Spring washer
Flat washer

DC Output

Expansion bolt

(Secondary cabinet)

4. Connect the positive cable of a load to the working ground busbar (+/GND).

Installed expansion
bolt

1. Prepare four M12 X 100 expansion bolts.

2. Drill four holes (70 mm deep) with the same dimensions as the cabinet holes at the bottom.
3. Install the four M12 X 100 expansion bolts into the holes (leave 30 mm of the bolt above the ground).
4. Mount the cabinet on the floor and into the expansion bolts.
5. Fasten the bolts to fix the cabinet in place.

2. Turn off the DC output breakers.

3. Connect the negative terminal of a load to one of the DC output (-) breakers.

Secondary cabinet

Angle square

1. Turn off the loads.

Cabinet
1. Connect the grounding busbar of the secondary cabinet to that of the primary cabinet.
2. Connect one of the output breakers (secondary cabinet) to the 63 A DC output breaker of the
primary cabinet.

ZTE Corporation Address NO. 55, Hi-tech Road South, ShenZhen, P.R.China

Primary cabinet
Secondary cabinet

Area code518057

Website http://ensupport.zte.com.cn

Emaildoc@zte.com.cn

MCB
LLVD1: 1*6A + 3*20A
LLVD2: 1*63A (Controls DC
output of seondary cabinet)
LLVD2: 20*20A+2*10A

Document versionSJ-20101011152815-002/ 2010-11-16 R1.1

DC voltage

-48 V

ZXDU68 W201 V4.0R06M03&M04

DC Power System

.6 Connecting Battery Temperature Cables

2

Paste the sensor between

adjacent battery cells

Clean surface where to paste the

sensor and make sure that the
battery temperature sensor and
cable are properly installed.

Setting System Parameters

Check in the ZXDU system
Black probe

Red
probe

Insert the dual pin plug to

X4 interface on the SIB
Battery pack 1: X4
Battery pack 2: X5
Battery pack 3:
Battery pack 4:

X4

Dual-pin plug

BATT breaker

GND (+)

.2 Installing the Rectifiers

X17

1
2
3
4
5
6

6N O
6C OM
6N C
5N O
5C OM
5N C
1
2
3
4
5
6

2N O
2C OM
2N C
1N O
1C OM
1N C

The output relay cables are optional.

X16

X15

P ar ameter

Default

Handle

Stop pin

3
Rectifiers

Monitoring
unit

1. Turn on the AC input breaker powering the system.

2. Turn on the AC input breaker of the W201 system.

A ctual

Bat.2 C ap. (A h)

100

RS 232 Bauds

9600

RS 485 Bauds

9600

Remarks
Based on the sy stem conf iguration. If a battery pack is
not conf igured, set to 0.

100

Should be the same at both ends of the communication

channel
Should be dif f erent on ev ery equipment

D ev ice N o.

Connecting Relay Cables

X15

Correct parameter setting is very important to ensure that the monitoring unit functions as
expected. The default values of the parameter may not meet the requirements. Therefore,
some parameters need to be set in the system commissioning.

Bat.1 C ap. (A h)

DO NOT install a faulty rectifier in the

ZXDU68 W201 system. Make sure
that no obstacle is blocked in the air
vent of the rectifiers for good heat
dissipation.

X17

System parameter list

If the the measured voltage is negative, the positive

and negative terminals are reversely connected.
Reconnect the cables.

Temperature sensor

X5

.7

Battery cell

2 of 4

Checking Battery Voltage

Measure the battery voltage between BATT (+) and BATT (-)
through terminals of ZXDU68 W201.

The measured voltage must be positive and at least 43.2 V.

Paste the sensor to

the side of a battery

ww w . zt e . c o m. cn

Acceptance criteria

Battery cell

Remove the paper

cover of the sensor

Installation Guide

C urrent D ate

Set it to local date

C urrent Time

Set it to local time

Battery parameter list

P a ra m e t e r

D e f a ult

Flo at Vo l. (V)

53.5

Equal Vo l. (V)

56.4

Test Vo l. (V)

46

A c t ua l

R e m a rk s
System o utput vo ltage in the flo ating charge mo de
System o utput vo ltage in the bo o st charge mo de
B attery test termiates at this value

Cur. Limited (C)

0.125

B atVo l M in. (V)

47

Flo at.Vo lt. 1V

1-Shut Vo l. (V)

45

Sho uld be larger than 44.5 V

2-Shut Vo l. (V)

44

Sho uld be larger than 43.2 V

Set the parameter acco rding to the user requirement

Normally, NC and COM are closed; NO and COM are open. In case
of an alarm, NO and COM are closed; NC and COM are open.

NC: Normally close

COM: Common
NO: Normally open

4. Observe the indicators and make sure that the IN and OUT indicators are glowing.

L1

1 Checking for Short Circuit

Check the following cables for short circuit:
AC input cables
Battery cables
DC output cables

L2

80 V Voltage < 100 V

The rectifier works with current limit = 20 A 2 A

100 V Voltage < 176 V

The rectifier works with current limit = 31 A 2 A

176 V Voltage 300 V

The rectifier works with current limit = 53 A 1 A

> 300 V

The rectifier cannot work

Ent
Esc

1. Sys Para
Enter

Ent Bat.1 Cap

100 Ah
Esc
Ent
Input:

2 Setting Output Relays

Before checking for short circuit, turn off
the corresponding breaker. Locate any
short circuit and eliminate it before
proceeding to the next step.

.3

Output relays can be modified through the following path:

Ctrl1.Setup Para3. Alarm ParaSet Relays out

Installing the Monitoring Unit

Ent
Msg Alm Ctrl Rec

The ZXDU68 W201 system can normally work

without the monitoring unit. However, the system
will have no communication functions and the
batteries will be in the floating charge mode.

If N-PE voltage is approximately equal

to L-N voltage, N and L cables are
inversely connected. Reconnect the
cables L and N.

Checking AC Input Voltage

100 Ah

Modify value
Ent Save setting
Esc Quit

Main menu

Pass: 0000_

1.Setup Para

A ppro ximately equal to L1-N, L2-N, and L3-N respectively

80-300 V (the phase vo ltages sho uld be appro ximately equal)

Ent

3. Alarm Para
Enter

Ent

1. Set Relays Out

Enter

Esc

Ent

Esc

AC-in Switch Off

Relay:

A2

Modify value

C rit e ria
<10 V

Move the cursor to the underscore (far right) and

press Enter to confirm.

Initial password: 0000

Enter

Measure the AC input voltages by referring to the table.

L1-N, L2-N, and L3-N

Enter

The rectifier cannot work

DC output
Check the Load (+) and Load (-) for any short circuit.

L1-P E, L2-P E, and L3-P E

1.Setup Para

<80 V

Move the cursor to the underscore (far right) and

press Enter to confirm.

Multimeter

AC input
Check both the AC distribution box and AC input breaker of the
system.
L1 N
L1 - L2
L1 - PE
L2 N
L1 - L3
L2 - PE
L3 N
L2 - L3
L3 - PE
Battery
Check the positive and negative terminals of the battery pack
for any short circuit.

C he c k it e m

Pass: 0000_
Initial password: 0000

Working status

Performing Electrical Check

N-P E

Main menu

AC input voltage: 80 V300 V

The ZXD2400 V4.3 working status depends on the AC input voltage:

.1

Ent
Msg Alm Ctrl Rec

The following should be met for normal rectifier operation

X16

The parameters can be modified through the 1. Setup Para interface under the Ctrl menu

5. If the rectifier is not powered (i.e. the IN indicator is off), reinstall the rectifier. If the symptom
persists, replace the rectifier or install the rectifier into the other rectifier slot.
6. Repeat steps 3-6 to install the other rectifiers.

1
2
3
4
5
6

Output relay 1-6: The six output relays correspond to A1-A6 in the
monitoring unit. Users can set the output relays for the alarms.

4N O
4C OM
4N C
3N O
3C OM
3N C

3. Install the rectifier 1 into the rectifier 1 slot.

1. Turn off the power switch of the monitoring unit.

Rectifiers

2. Insert the monitoring unit into the slot provided and fasten the screw.

Monitoring
unit

3. Turn on the monitoring unit (RUN indicator should glow and the main menu is displayed on
the screen).

The batteries and loads have not yet been connected to the system. As a result,
the monitoring unit gives the DC Loop Break alarm and Bat Loop Break alarm.

ZTE Corporation Address NO. 55, Hi-tech Road South, ShenZhen, P.R.China

Area code518057

Website http://ensupport.zte.com.cn

Emaildoc@zte.com.cn

Document versionSJ-20101011152815-002/ 2010-11-16 R1.1

ZXDU68 W201 V4.0R06M03&M04

DC Power System

Alarms and their default output relays

S/N

Alarm

3 of 4

.1 Charging the Batteries

Appendix: System Shutdown and Startup

Shutdown

Relay

Level

Relay

A1

20 DCArrester Brk.

Minor alarm

A4

Minor alarm

A2

21 DCBreaker Alarm

Minor alarm

A4

AC Main SW Of f Major alarm

A2

22 Battery Fault

Major alarm

A4

3. Turn on the BATT breaker.

1. Turn off the loads.

AC Power Of f

Major alarm

A2

23 Bat Under-Temp

Minor alarm

A4

4. Reset the floating charge voltage to the default (53.5 V).

2. Turn off all DC Output breakers.

ACArrester Brk.

Minor alarm

A2

24 Bat.Temp.Void

Minor alarm

A4

AC Under-Vol

Minor alarm

A2

25 Bat.Discharge

Minor alarm

A4

5. Start the equalized (boost) charge mode in the monitoring unit.

Menu path: Ctrl 2. OAM 4.EQUAL...]

Total Alarm

AC Aux SW Of f

7
8
9

AC Ov er-Vol
AC Phase Lost

Minor alarm

A2

Alarm

www.zte.com.cn

Level

S/N

Installation Guide

26 Env Under-Temp

Minor alarm

A5

Minor alarm

A2

27 Env Ov er-Temp

Minor alarm

A5

AC Current Ov er Minor alarm

A2

28 Env Under-Hum

Minor alarm

A5

10

SMR Alarm

Minor alarm

A3

29 Env Ov er-Hum

Minor alarm

A5

11

SMR Abnormal

Minor alarm

A3

30 Smoke Alarm

Minor alarm

A5

12

DC Under-Vol

Minor alarm

A4

31 Flood Alarm

Minor alarm

A5

13

DC Ov er-Vol

Minor alarm

A4

32 Intrusion Alarm

Minor alarm

A5

14

DC Loop Break

Minor alarm

A4

33 Door Magnet Alm

Minor alarm

A5

1. Before turning on the battery breaker, measure the voltage of the battery pack
and keep a record.

The ZXDU68 W201 shutdown will cause

the loads to be shut down.

2. Set the floating charge voltage equal to the terminal voltage of the battery pack.
Menu path: Ctrl 1.Setup Para Batt Para Float Vol..

3. Turn off the BATT breakers.

4. Turn off the monitoring unit.

Avoid DC short circuit during operation.

5. Turn off the AC Input breaker of the system.

A large difference between the voltage of the battery pack and the floating charge voltage
of the system can cause sparks and could result in flames.

6. Turn off the AC input breaker powering the system.

Follow the sequence to connect the battery packs:

Connect a battery pack with lower voltage > Connect a battery pack with higher voltage.

Startup
1. Turn on the AC input breaker powering the system.
2. Turn on the AC input of the system.

.2 Connecting Loads to the System

3 Turn on the monitoring unit.

4. Turn on the BATT breakers.
5. Turn on all DC output breakers.

1. Turn off the load.

15

Bat Loop Break

Minor alarm

A4

34 Glass Broken

Minor alarm

A5

16

Bat Under-Vol

Major alarm

A4

35 Env Un.LostTouch Minor alarm

A5

2. Turn on the corresponding DC output breakers of the

system.

17

Bat Ov er-Temp

Minor alarm

A4

36 HeatExch.Alm

Major alarm

A5

3. Measure the DC output voltage and make sure that the

positive and negative load cables are properly connected.

18

1st Shut-Down

Major alarm

A4

37 Env .Temp.Void

Minor alarm

A5

4. Turn on the load.

19

2nd Shut-Down

Major alarm

A4

38 Start GEN

None

Check load
48V DC input
- 48V
+
Red probe

Acceptance Criteria
The measured voltage should be positive (+)
and within the range of 42-58 V

Black
probe

Negative voltage means the cables are

inversely connected. Reconnect the cables.

ZTE Corporation Address NO. 55, Hi-tech Road South, ShenZhen, P.R.China

Area code518057

Website http://ensupport.zte.com.cn

Emaildoc@zte.com.cn

Document versionSJ-20101011152815-002/ 2010-11-16 R1.1

Installation Guide

ZXDU68 W201 V4.0R06M03&M04

DC Power System

www.zte.com.cn

4 of 4

Electrical Connection Diagram of Primary Cabinet (V4.0R06M03)

AC Input

AC Input
380V 50Hz/60Hz

AC SPD

11

X3-A13

AC Transducer

Rectifier

DC Bus Bar

Shunt and DC SPD

DC Contactor

L1'

X3-A15

14

L2'

L3'

VL+

L1

L
N
PE

AC
DC

1(2)

QFB1

3(4)

RMT ALM COM EX PWM CUT SB

11 12 13 14 15 17 16

L2
L3
QFA1 63A

X3-B13

PE

X1-3

100A

X1-1

QFB2

28
27
26

12 11 14

L
N

1 2

X2

1 2 3 4

Battery ST

ST1

BATT 2

X2-2

ST2

AC
DC

3(4)

28
27
26

L
N
PE

QFB3 100A

X3-C9
X3-C12

AC
DC

BATT 3

12 11 14

1(2)

QFB4 100A
3(4)

DC SPD

RMT ALM COM EX PWM CUT SB

11 12 13 14 15 17 16

BATT 4
C1

ZXDU68 W201(V4.0R06M04)

M4
28
27
26

T1
+12V

T2

M3

V+

COM

SIG

+12V

BATT 1

X2-1

1(2)

X1

Class B

Va
+12V
GND
-12V

Battery

RMT ALM COM EX PWM CUT SB

11 12 13 14 15 17 16

TRB
X3-A7
X3-C15
X3-B15
X3-C14

L
N
PE

DC Output

100A

M2

X3-C7
X3-B7

VL-

M1
28
27
26

AC Switch of Battery

L
N
PE

AC
DC

1(2)

X3-B6
X3-C6

3(4)

LLVD2
VL+

L+

X10-1
KMD1

RL1

RMT ALM COM EX PWM CUT SB

11 12 13 14 15 17 16

LL VD 1

1QFD1 6A

RS1

1QFD2 20A

RS2

1QFD3 20A

RS3

1QFD4 20A

RS4

2QFD 63A

RS5

X3-C11
X3-B11

FAN1
C2

V+

COM

SIG

LLVD2
VL+

KMD2

X3
A

VB 1
VB 2
X11

LLVD1

LLVD2

VL-

X10

EX 2
AL M2
RM T2
CU T2
PW M
CO M

VL+

EX 1
AL M1
RM T1
CU T1
PW M
CO M

3
2
1

1
2

X6

X3

3
2
1

1
2
3

X2

X4
X26-2

SIB

48 V-

X26-1

X23

X24

T2
+1 2V
T1
+1 2V
X4

1
2
3
4
5
6
X9

1
2

+1 2V
SM OKE
1
2

VC C-W
+1 2V
AG ND
WA TER

X25
X5

1
2
3
4

S1
S2
AG ND
S3
S4
AG ND

1
2

TE MP
+1 2V
1
2

DO OR
AG ND
1
2

2NO
2C OM
2NC
1NO
1C OM
1NC
1
2
3
4
5
6

1
2
3
4
5
6

4N O
4C OM
4N C
3N O
3C OM
3N C

TC
GND

X12
X14

EX 3
AL M3
RM T3
CU T3
PW M
CO M
EX 4
AL M4
RM T4
CU T4
PW M
CO M

1
2
3
4
5
6

1
2
3
4
5
6

X26

1
2
3
4
5
6
X8

32A
32B
32C

X16

X15

1
2

1
2
3
4
5
6

2
1

X17

B A

X7

6NO
6C OM
6NC
5NO
5C OM
5NC

X1

X21
RS485

2
6

3
7

4
8

5
9

X22
RS232

1
2
3
4
5
6

FAN3

LL VD 2

X3-B10

ZXDU68 W201(V4.0R06M04)3U

BACK X1

LLVD2
VL+

1A
1B
1C

V+

COM

SIG

L+

X11-1

FAN2

X3-A9
X3-C10

IB 2AC Va
RS 6
RS 3

AC AI R0
AG ND

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
32

X3
B
1
2
3
4
IB 2+
5
IL +
6
IB 1+
7
8
9
RS 5
10
RS 2
11
12
TH UN DER 13
14
AG ND
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

X3
C

IL IB 1AG ND
RS 4
RS 1
FL-DC

-1 2V
+1 2V

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
32

Electrical Connection Diagram of Secondary Cabinet (V4.0R06M04)

2QFD3 63A

2QFD1 20A

VD1

2QFD2 20A

VD2

2QFD3 20A

VD3

2QFD4 20A

VD4

2QFD5 20A

VD5

2QFD6 20A

VD6

2QFD7 20A

VD7

2QFD8 20A

VD8

2QFD9 20A

VD9

2QFD10 20A

VD10

2QFD11 20A

VD11

2QFD12 20A

VD12

2QFD13 20A

VD13

2QFD14 20A

VD14

2QFD15 20A

VD15

2QFD16 20A

VD16

2QFD17 20A

VD17

2QFD18 20A

VD18

2QFD19 20A

VD19

2QFD20 20A

VD20

2QFD21 10A

VD21

2QFD22 10A

VD22

LLVD2
L+
QFB3 100A

BATT 3
QFB4 100A

BATT 4

ZXDU68 W201(V4.0R06M03)

Distribution

1N5404

V+

COM

SIG

T1 40
LLVD2
VL+

FAN1

V+

COM

SIG

1N5404
T2 40

FAN2

LLVD2
VL+

T3 30
1N5404

V+

COM

SIG

1N5404

T4 40
LLVD2
VL+

FAN3

X26-2

ZTE Corporation Address NO. 55, Hi-tech Road South, ShenZhen, P.R.China

Area code518057

Website http://ensupport.zte.com.cn

X26-1

Emaildoc@zte.com.cn

Document versionSJ-20101011152815-002/ 2010-11-16 R1.1

RS6

X3-A8