Telekom Malaysia DC System Test Rectifier Test Plan

DC POWER SYSTEM ACCEPTANCE TEST PLAN
Doc. No.
SYSTEM TECHNOLOGY
UTP-1/ST/TF03/BATTERY-ANDRECTIFIER
Revision No: 2
DC POWER SYSTEM
ACCEPTANCE TEST PLAN
PREPARED BY :
PREPARED BY:
MOHD FALAAH ABD MANAP

SYSTEM TECHNOLOGY
ND WHOLESALE
TELEKOM MALAYSIA
REVIEWED BY:
REVIEWED BY:
NORIZAN MELAN
SYSTEM TECHNOLOGY
ND WHOLESALE
TELEKOM MALAYSIA
APPROVED BY:
APPROVED BY:
ZULKARNAIN HUSAIN
SYSTEM TECHNOLOGY
ND WHOLESALE
TELEKOM MALAYSIA
TABLE OF CONTENTS
Page 0 of 59
TEAM MEMBER LIST...............................................................................................2
TESTING REQUIREMENTS.....................................................................................2
TOOL AND TEST GEAR INFORMATION................................................................3
PRODUCT DESCRIPTION.......................................................................................5
SYSTEM PHYSICAL INSPECTION CHECKLISTS...............................................10
TEST ITEMS............................................................................................................13
SUMMARY OF DC SYSTEM TEST........................................................................57
SUMMARY OF DEFAULT SETTING AND PROPOSED SITE SETTING..............59
10
CONCLUSION.........................................................................................................60
11
TEAM MEMBERS...................................................................................................60
12
AGREED BY TEST MEMBER................................................................................61
TEAM MEMBER LIST
No
1
ST
2
3
4
5
6
MOHD NASIR MUNAWIR

A.HALIM SAMAD
SYED ABDUL KADIR SYED MOHD
KHAIRUL ANWAR LUKMAN
SYAHRIL NIZAR MOHD NASIR
TMFS
R&D
TMFS
ANOC
BSQM RNO
Name
Department
TESTING REQUIREMENTS
Basic Functions and Alarm Function Test
Page 1 of 59
Battery Temperature Compensated Charging

Automatic Battery Discharge Test
Battery Recharge Current limit
Low Voltage Battery Disconnect (LVBD) Functionality
Removal of Monitoring & Control Unit To check System
Load Sharing
Data logging facility Test
Battery On Load(BOL) Test
Voltage and Current Detect precision Test
Parallel Operation and Redundant backup function test
Surge immunity test
Surge reliability test
Surge filter coordination test
Voltage dip, short interruptions
Static regulation and ripple
Input voltage
Power factor and efficiency
ESD Electrostatic Discharge
Radiated Electromagnetic Fields Test
EFT (BURST) Test
Conducted Disturbance Test
Conducted Emission Test
Radiated Emission Test(ELECTRIC FIELD)
TOOL AND TEST GEAR INFORMATION
MODEL
SERIALNUMBE
R
DL1720E Yokogawa
91F141132/EN-TST3-410
234301
PAN-MNT-3-440
PAD 110-10L
PR-EN-03-441
Testo data logger
177-T4
EN-TST-3-436
Testo data logger
177-T4
ENG-TST-3-437
TEST GEAR
200MHz Digital storage
Oscilloscope(Yokogawa)
Yokogawa Digital Clamp
on Tester
Regulated Dc Power
supply
Page 2 of 59
Insulation Tester
3213-24
PR-PT-3-135
Fluke Multimeter
75 III
EN-FE-3335/76771313
Fluke Multimeter
73 III
PR-TS-3-052
Fluke Multimeter
73 III
PR-CP-3-393
Fluke Multimeter
73 III
PR-CP-3-401
Fluke Multimeter
73 III
EN-TE-3-272
Fluke Multimeter
73 III
ENG-TST-3-421
26.2.2009
PART 1 PRODUCT INFORMATION
Page 3 of 59
PRODUCT
MODEL
MANUFACTURER
LOCAL SUPPLIER
PRODUCT DESCRIPTION
Item
Description
INPUT SURGE FILTER:

Manufacturer/Brand/Model
Maximum current rating
Minimum KA rating at 8/20us
Maximum operating voltage
Let-through voltage at 3KA,
Units
Detail Information
Amp.
KA
Volt
Volt
Page 4 of 59
Item
Description
Units
Detail Information
8/20us
B
B1
RECTIFIER:
Manufacturer
Model No.
Country of Origin
5 RECTIFIER DESIGN &
CONFIGURATION
Capacity per system
Capacity per module
Max. No of Module/ system
Controller Unit
No. of alarm free contact
LVD type
LVD Rating
Battery breaker rating
No. of Battery breaker
Output load breaker & rating
No. of output breaker for spare
B2
B3
Amp.
Amp.
Nos.
type
Type
Amp.
Amp.
No.
No
No
& rating
INPUT DATA
Input Line Voltage (AC)Max&
VacMax
min
Input Frequency (Hz) Max &
Vac Min
Hz Max
Min
Input Main AC breaker
Rectifier input breaker rating
Max. input current/module
Input lightning protection
OUTPUT DATA
Output Voltage DC (Max)
Output Current
Static Voltage Regulation from
Hz Min
Amp.
Amp.
Amp.
Type
VDC
Amp.
%
0 to full load
Dynamic Voltage Regulation
from 10 90% or 90 10%

Efficiency
Page 5 of 59
Item
Description
Units
Detail Information
Item
Description
Units
Detail Information
B4
MAIN CONTROLLER UNIT

Type of Display (LED/LCD)
Display of parameters:
a. Output DC Voltage
b. Current
c. Temperature
d. Others:______________
______________
______________
Alarm monitoring provided:
a. Battery test in progress
b. Rectifier alarm
c. Low battery alarm
d. Battery failed alarm
e. LVD alarm
f. Load fuse alarm
1. Battery fuse alarm
2. SNMP Card
h. Others :
______________
______________
______________
Battery Monitoring Facilities
a. Automatic battery test
1.
Set time and date
2.
Set by day and month
Page 6 of 59
Item
Description
3.
Units
Detail Information
Manual test only
b. Temperature compensated
B5
charge voltage
MECH. CHARACTERISTIC
AC PDB Dimension :
mV/C
Width
mm
Height
mm
Depth
mm
Weight
DC PDB Dimension :
200
Kg
Width
mm
Height
mm
Depth
mm
Weight
RECT PDB Dimension :
Kg
Width
mm
Height
mm
Depth
mm
Weight
Total Weight
Operating Temperature
Nominal heat dissipation
Acoustic noise level for full load
at 1 metre.
Relative humidity
TM Representative
Tested by
Slope range : ________
Kg
Kg
(C)
Watt
dBA
%
Verified by
PERNEC ADVANCED NETWORK

Tested by
Verified by
Name:
Name:
Signature:
Signature:
Page 7 of 59
Date:
Date:
Page 8 of 59
PART 2 DC SYSTEM INSPECTION CHECKLIST
Page 9 of 59
SYSTEM PHYSICAL INSPECTION CHECKLISTS
Item
Item Description
Rectifier Subrack :
i. Min. no. of module
ii. Max. no. of module
iii. Rectifier back panel
vi. Plate thickness
vii. Type of painting
viii. Cooling method
ix. Detail drawing of
proposed
cabinet
Qty
2.0
CSU
AC PDB
3phase,800
V, 5wire
mode,L/N/P
E
20A* 4 pole
AC Input Distribution Panel:i. AC input Main breaker
ii. Module AC input mcb

iii. Surge Arrestor/Surge filter
32
1
iv. Earth bar/ Termination

point
1
3
Outgoing Load Breaker
Battery current shunt
Load current shunt
LVD
Others:
1
4
NO
2.0mm
white
Fan cooling
1
Rectifier Controller
Battery Breaker
Remarks on Physical
Configuration/Installation
1
32
Rating/Siz
e/
Model
ZX5000(V2
.0)
40A,class c,
phoenix
20A,class d,
phoenix
1200A
MCB * 3
pcs
480A *2
pcs, Nader
1200A *2
pcs ,ABB
3000A/75m
V *3 pcs
500A/75m
V *2 pcs
1000A/75m
V *2 pcs
N/A
Page 10 of 59
TM Representative
Tested by
Verified by

Tested by
Verified by
Name:
Name:
Signature:
Signature:
Date:
Date:
Page 11 of 59
PART 3 DC SYSTEM ACCEPTANT TEST
TEST ITEMS
DC SYSTEM ACCEPTANCE TEST

Page 12 of 59
TEST CASE 1
TEST DESCRIPTION
The purpose of the test is to confirm basic function and alarm function of the
system.
Tenderer to provide test procedure for every alarm test as listed:
Test Procedure
Expected Result
All basic functions is activated.

All alarms will be provided by controller when system is abnormal.
Test the following items.
Observed Result
Contents
Test Criteria
AC input
The lines can be switched
System
normally
All units start normally and
Startup
the output voltage is within

the normal range.
Test result
Conclusion
Pass
Fail
Output Volt :
V
Set Volt. :
Pass
Fail
V
Parameter
The parameters can be set
securely
correctly through
monitoring units and the set
parameters can be saved
AC Power off
securely.
After the mains supply is
and Power
cut off, alarms should be
on
given. After mains supply is

restored normally, the
Pass
Fail
Pass
Fail
operation should be
restored normally.
Surge Filter
failure
Battery fuse
Alarms can be given
Blown
Load fuse
Alarms can be given

Alarms can be given
blown down
High voltage
Alarms can be given
Low voltage
Alarms can be given
Battery Over
Alarms can be given
temp.
Rect. Fan
Alarms can be given
failure
Pass
Fail
Pass
Fail
Pass
Fail
Pass
Fail
Pass
Fail
Pass
Fail
Pass
Fail
Page 13 of 59
Note:
Test Result
Pass / Fail
Remarks
TM Representative
Tested by
Verified by

Tested by
Verified by
Name:
Name:
Signature:
Signature:
Date:
Date:

TEST CASE 2
TEST DESCRIPTION
The purpose of this test is to confirm correct functionality of the temperature

compensated charging incorporated in the Rectifier Controller.
Test Procedure
1. Switch on rectifier system and work 5 minutes.

2. Set the battery temperature compensated factor to __mV/oC/cell.and set
the system output float voltage is ____V when the ambient temperature
is ___.
3. Read and record the output voltage from MCU.
4. Use one adjustable resistor or other method to simulate the change of
the battery temperature.
5. Increase the battery temperature to 35. Read the output voltage from
Page 14 of 59
MCU.
6. Increase the battery temperature to 45. Read the output voltage from
MCU.
7. Decrease the battery temperature to 15, Read the output voltage from
MCU.
8. Decrease the battery temperature to 5, read the output voltage from
MCU.
9. Let the battery temperature back to normal level. Let it running 5
minutes.
10. Switch off the rectifier system.
Expected Result
Observed Result
Test Result
1. Increased temperature will result in decreased float voltage according to

programmed values
2. Decreased temperature will result in increased float voltage according to
programmed values
The system was programmed with a slope of ___mV/deg/cell negative
temperature coefficient according to the __________ (battery model)
batteries connected, resulting in a voltage change of ____mV/deg.
Ambient Temp.
____C
Bat. Float Voltage
____ VDC
Increased Temp.
____C
Bat. Float Voltage
____ VDC
Increased Temp.
____C
Bat. Float Voltage
____ VDC
Decreased Temp.
____C
Bat. Float Voltage
____ VDC
Decreased Temp.
____C
Bat. Float Voltage
____ VDC
Pass / Fail
Remarks
TM Representative
Tested by
Verified by

Tested by
Verified by
Name:
Name:
Signature:
Signature:
Date:
Date:
Page 15 of 59

TEST CASE 3
TEST DESCRIPTION
The purpose of the test is to verify and control that the system can perform
automatic battery testing and detect the current conditions of the battery.
The rectifier system shall be able to be programmed to perform manual and
automatic battery testing according to preprogrammed battery discharge
level, test duration, time and date of the propose test .
Test Procedure
1. Switch on the rectifier system.

2. Set the battery test cycle to __ days, start time to ____ am, and set test
process time 1 hour, test voltage is 46V.
3. Modify the system date and time to 5 minutes before start time set.
4. Wait the system change to the battery test mode.
5. Record the system date and time.
6. Record the system output voltage
7. Record the system duration time.
8. Wait the system convert to the equalizing charging mode.
Page 16 of 59
9. Switch off the system.

Expected Result
To secure that the system does not interrupts the supply to the load in case
of faulty battery, the rectifier output voltage is reduced/set to ____V during
the test.
Observed Result
A: TEST ON GOOD BATTERY

Parameter Setting
(Before test)
Set discharge time
& date
Duration of
discharge setting
End Voltage setting
Result during Testing

Start Discharge time
Discharge stop time
End of discharge
voltage
Comment :
B: TEST ON BAD BATTERY
Parameter Setting
(Before test)
Set discharge time

& date
Duration of
discharge setting
Discharge stop time
End Voltage setting
End of discharge
voltage
Comment:
C: TEST ON OPEN CIRCUIT BATTERY

Parameter Setting
(Before test)
Set discharge time

& date
Duration of
discharge setting
Discharge stop time
End Voltage setting
End of discharge
voltage
Comment:
Result:
Overall Test Result
Pass / Fail
Page 17 of 59
Remarks
TM Representative
Tested by
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Tested by
Verified by
Name:
Name:
Signature:
Signature:
Date:
Date:

TEST CASE 4
Battery Recharge Current Limit
TEST DESCRIPTION
The purpose of this test is to verify that the rectifier system incorporates proper
functions to protect the batteries from overcharge. The system shall be able to
control the recharge current to the batteries according to programmed value in
the controller.
Test Procedure
1.
2.
3.
4.
5.
6.
Expected Result
The Rectifier Controller shall be programmed with 10% recharge current equal
to ___A for the ____Ah battery. A mains failure is simulated and the batteries
supply the load for _____ minutes. When mains resume the rectifier system
shall control the output voltage to secure that the battery recharge current
does not exceed the programmed value.
Switch on the rectifier system.

Set the battery capacity and battery current limit factors.
Switch off the mains, let battery discharge 2 hours.
Recovery the mains to the rectifier.
Record the battery charging current.
Switch off the rectifier system.
Page 18 of 59
Observed Result
Details before test conducted

Rectifier Capacity
____ A
Current Limit
setting(10%)
____ A
Output Load Current
____ A
Duration of Battery
Discharge
___min/hr
Test Result
Pass / Fail
Details during test & after test

Total output current
(Rect.)
____ A
Charging current to
battery
____ A
Output Load
Current
____ A
Remarks
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Page 19 of 59

TEST CASE 5
TEST DESCRIPTION
The purpose of the test is to verify that the LVBD contactor disconnects the
batteries at the pre-programmed voltage level. As a safety feature mains
failure is required to obtain disconnect.
Test Procedure

2. Set the disconnect voltage in controller.
3. Switch off the mains input and let the battery feed to the load. Add load to
discharge quickly.
4. When battery voltage be reduced and approached the LVBD threshold,
Controller will control the LVBD contactor CUT Battery from the system.
5. Read the battery voltage on the controller.
6. Switch of AC input and a few minutes, check the battery will re-connect to
the system.
7. Read the battery voltage when re-connect on the controller.
Expected Result
The disconnect voltage level is programmed to __V and then a mains failure is
simulated to discharge the batteries. When the battery voltage reaches ___V
the battery contactor (LVBD) will be de-energized and disconnect the batteries
within one minute.
Observed Result
Details during test & after test

Page 20 of 59
Test Result
LVBD Setting
______ V
LVBD Disconnect
Voltage
_______ V
Total
Battery Voltage
______ V
LVBD reconnect
Voltage
_______ V
Hysteresis
____ (if any)
Pass / Fail
Remarks
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Page 21 of 59

TEST CASE 6
Removal Of Monitoring & Control Unit To Check System Reliability
TEST DESCRIPTION
The purpose of the test is to check and control that the system including
batteries operates normally in case of a failure to the monitoring & control
unit (MCU). This means that the rectifiers provides normal output power,
the rectifier share the load and that the LVBD contactor stays energized
(not disconnects the batteries). Furthermore the existing data logging
record still stored in the CSU memory.
Test Procedure
1.
2.
3.
4.
5.
Expected Result
By removing the MCU from the system, observe that the LVBD contactor
stays energized and that the rectifier modules operate as per normal
operation. The current indicator in front of each rectifier module shall
indicate that the modules share the load.
Pull out the MCU module

Switch on the rectifier system
Record the output voltage and observe current of each rectifier.
Observe the LVBD contactor state.
Switch off the rectifier system and plug in the MCU module
Observed Result
LVBD Status of
Operation
OK / NO
Rectifier Module
Status of operation
OK / NO
Data logging record
maintain
Test Result
Details during test

LVBD Status of
Operation
Rectifier Module
Status of operation
OK / NO
OK / NO
OK / NO
Pass / Fail
Page 22 of 59
Remarks
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Page 23 of 59

TEST CASE 7
Load Sharing
TEST DESCRIPTION
The purpose of this test is to verify that all rectifier modules perform and
display current sharing during normal operation, either with or without the
MCU connected.
Test Procedure
1. Switch on the rectifier system, and the AC input voltage is 240V

2. Adjust the rectifier system loads to 25% 50% 75% 100% of rating
output currents
3. Read and record each rectifiers current form MCU
4. Switch off the power of the MCU.
5. Observe the rectifier current indicator
Expected Result
By applying load to the system it will be observed that each rectifier module
in the system provides similar output current through the LED current
indicator in front of each module and by measuring each module current
output using DC clamp meter. By removing the control module, the current
sharing
shall
not
be
affected.
Observed Result
Details Load
Current at 25%
load (A)
Current at 50%
load (A)
Rect.
Module 1
Rect.
Module 2
Rect.
Module 3
Rect.
Module 4
Current at 75%
load (A)
Current at 100%
load (A)
Test Result
Pass / Fail
Remarks
Page 24 of 59
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Page 25 of 59

TEST CASE 8
Data Logging Facility Test
TEST DESCRIPTION
The purpose of the test is to confirm the data logging facility be provided by
the controller set. System values and specific events such as alarm events
shall be stored in the controller set.
Test Procedure
1. Switch on the system and working a few minutes.

2. Change some system values such as float voltage, equal voltage. and
cut off the controllers power supply or restart.
3. Check the system values, it shall be same as the controller restart.
4. Check the data logging on the controller panel, and write down the
record count.
5. Simulate many alarms and check it is can be record at the lasted
position in controller.
6. Until the events exceeded the maximum count. Read the maximum
count.
7. Simulate a new event, check the new event replaced the oldest event
logging.
8. Cut off the controllers power supply or restart the controller, check the
data logging shall be same as before.
Expected Result
A minimum 1000 events data log record shall be held in the controller
memory until it is replaced with new log entries.
For bigger system, Shall be provided 3000 events.
Observed Result
Data logging held ______ events.

Data logging events replaced by FIFO on the controller unit:
OK / NO
Data logging shall be saved when the controller POWER-OFF restart : OK /
NO
Note:
Test Result
Pass / Fail
Remarks
Page 26 of 59
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Page 27 of 59

TEST CASE 9
Battery On Load (BOL) alarm Test
TEST DESCRIPTION
The purpose of the test is to confirm the battery on load alarm of the system.
When mains failure or controller failure or due to other condition/factor, if the
battery is feed to the load, system will give an alarm relay output to the
customer monitoring device.
Test Procedure
Two type of test to be conducted with the following conditions:1. AC main fail
2. Rectifier capacity below load capacity
(tenderer to specified how the test procedure to conduct the test)
Expected Result
1. If the AC input failure, the battery feed to the load, the system will
give a output relay change. When the load is feed by rectifier, the
relay output will be recovered.
2. With less rectifier capacity the battery shall support the load.
1. Test 1 : AC main Input Breaker
Switch Off
Observed Result
Present Load current

____ A
BOL Alarm appear
Yes / No
after breaker switch off
Battery discharge
current reading
____ A
2. Test 2 : AC main input breaker
switch on
BOL Alarm disappear

after breaker switch on
Battery recharge
current reading
Yes / No
____ A
Test 3: Reduce the rectifier

capacity against the present load
capacity
BOL alarm appear
Yes / No
once the rectifier
capacity reduce
below load capacity
Battery discharge
current reading
____ A
Test 4: Increase rectifier capacity

above Load capacity:
BOL alarm
disappear once the
rectifier capacity
above load
capacity
Battery recharge
current reading
Yes / No
____ A
Note:
Test Result
Pass / Fail
Remarks
TM Representative

Page 28 of 59
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TEST CASE 10
TEST DESCRIPTION
The purpose of the test is to confirm the voltage and current detect
procession of the controller.
Page 29 of 59
Test Procedure
Expected Result
Switch on the system and work a few minutes.

Set the output voltage to 54V, and add half-load to the system.
3. Measured the AC input voltage(3phase), Output voltage, Load current
with volt-meter and ampere-meter. Read the controller measure value and
the meter value.
Measure the battery current detect precision.
1. AC input voltage detect error less than 3V.

2. DC output voltage detect error less than 0.5%.
3. DC output current detect error less than 3A.
Test Item
Observed Result
Read
Read
Test
from
from
criteria
CSU
DDM(V)
Mains V A
Mains V B
Mains V C
Output
3V
3V
3V
0.5%
Voltage
Battery1
3A
Current
Battery2
3A
Current
Battery3
3A
Current
Load
3A
Conclusion
Remark
Current
Note:
Test Result
Pass / Fail
Remarks
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Page 30 of 59

TEST CASE 11
TEST DESCRIPTION
Test Procedure

The purpose of the test is to confirm one rectifier module shall be reserved for
standby purpose in case of any of the active rectifier modules fails.
When a rectifier be pull out, the another rectifier will shared the output current.
When a rectifier be insert to the system, It will shared load with another
rectifier.
1. System is normal working less than 50% full-load.
2. Pull out one of the active rectifier, check the system will be normal working,
the output voltage and the load current.
3. Check anther rectifiers output current, it will be balance.
4. Insert the rectifier to the slot, check the output voltage and load current.
5. Check all rectifiers output current, it shall be balance.
Page 31 of 59
Expected Result
Observed Result
1, One rectifier module will be reserved for standby purpose.

2, When the rectifier be pull-out or insert, Output voltage and load current
shall not be trip down.
Before:
Load current: ____A, Battery current: ___ A, O/P voltage: ___V
Rect.1
Rect.2
Rect.3
Rect.4
Rect.5
Rect.6
Rect.7
After pull out a rect. :

Load current: ____A, Battery current: ____A
System work state: OK / NO, Output Voltage: ____V
Rect.1
Rect.2
Rect.3
Rect.4
Rect.5
Rect.6
Rect.7
Note:
Test Result
Pass / Fail
Remarks
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Date:
Page 32 of 59
RECTIFIER SYSTEM ACCEPTANCE TEST

SURGE IMMUNITY TESTING IEC61000-4-5
TEST CASE 12
TEST DESCRIPTION
The purpose of this test is to confirm the immunity of rectifier modules to

unidirectional surges caused by over voltages from switching and lightning
transients. The test is conducted with the powered rectifier module.
The test is conducted for the live-neutral mode, live-earth mode and neutralearth mode.
The primary protection shall be installed with the rectifier system.
Test Procedure
This procedure is based on IEC61000-4-5 (2001)
Expected Result
The rectifier modules will function as normal condition during and after the
surge tests
No physical damages occurs after the test
Observed Result
The system was tested with surges magnitude of 6kV, 3kA using the
combination wave modules; which is 1.2/50s open circuit and 8/20 s short
circuit test waveform. Total number of test is 5 positive and 5 negative
polarities of surges for each configuration (L-N, L-E, N-E). Reading (rectifier
performance) to be taken after each 5 pulses. Time between pulses is 30s.
Test setup according to IEC61000-4-5 (2001)
Page 33 of 59
Test pulses
number 1-5
Test 1(a)
+ve, L-N
Test 1(b)
-ve, L-N
Test 1(c)
Test 1(d)
Test 1(e)
Test 1(f)
Test Result
+ve, L-E
-ve,L-E
+ve, N-E
-ve,N-E
Output voltage
before test
Output voltage after
test
test
test
_ _ VDC
____ VDC
____ VDC
____ VDC

test
____ VDC

test
____ VDC

test
____ VDC
Pass / Fail
Remarks
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Page 34 of 59
RECTIFIER SYSTEM RELIABILITY TEST

SURGE RELIABILITY TESTING PER IEC61000-4-5
TEST CASE 13
TEST DESCRIPTION
The purpose of this test is to confirm the reliability of rectifier modules to

unidirectional surges caused by over voltages from switching and lightning
transients. The test is conducted with the powered rectifier module. The test is
conducted for the live-neutral mode only. The primary protection shall be
installed with the rectifier system. Rectifier results shall be measured after
every five pulses.
Test Procedure
(Supplier is required to specify the procedures/methods of testing on a

separate sheet). This procedure is based on IEC61000-4-5 (2001)
Expected Result
The rectifier modules will function as normal condition during and after the
surge tests
Observed Result
The system was tested with surges magnitude of 6kV, 3kA using the
combination wave modules; which is 1.2/50s open circuit and 8/20 s short
circuit test waveform. Total number of test is 45 positive polarities of surges for
L-N configuration. Reading (rectifier performance) to be taken after each 5
pulses. Time between pulses is 30s. Test setup according to IEC61000-4-5
(2001)
Test pulses number
6-10
+ve, L-N
Output voltage
before test
_ _ VDC
Page 35 of 59
Test Result
Test pulses number

11-15
Test pulses number
16-20
Test pulses number
21-25
+ve, L-N
Test pulses number

26-30
Test pulses number
31-35
Test pulses number
36-40
Test pulses number
41-46
Test pulses number
46-50
+ve, L-N
+ve, L-N
+ve, L-N
+ve, L-N
+ve, L-N
+ve, L-N
+ve, L-N

test
test
test
test
test
test
test
test
____ VDC
____ VDC
____ VDC
____ VDC
____ VDC
____ VDC
____ VDC
____ VDC
Pass / Fail
Remarks
TM Representative
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Date:
Date:
Page 36 of 59

TEST CASE 14
SURGE FILTER COORDINATION TEST
TEST DESCRIPTION
The purpose of the test is to verify the performance level of a surge filter to be
used with rectifier modules in single phase application (example for DLC,
MPOC or MSAN cabinet). The surge filter shall divert at least 70% of surge
current. Surge using combination waveform with 6kV, 3kA. Test shall be
conducted during test case 1-B.
Test Procedure
The test set-up is based on IEC61000-4-5. Additional information on test setup

is shown in figure 1.
Expected Result
The surge filter shall divert at least 70% of the surge current, or percentage
current into rectifier must be less than 30%
Observed Result
Peak
source
current, A
Total
source
current
(area), As
100
100
Peak
current
into
rectifier, A
Total
current
into
rectifier
(area), As
Value
(1)
(2)
Percentag
e, %
Value
Page 37 of 59
Percentag
e, %
Value
100
100
Percentag
e, %
100
100
(3)
Remarks
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Page 38 of 59

TEST CASE 15
VOLTAGE DIPS, SHORT INTERRUPTIONS AND VOLTAGE VARIATION

IMMUNITY TEST
TEST DESCRIPTION
The purpose of the test is to verify the immunity level of the equipment at full
load to the test level defines in IEC61000-4-11. The rectifier system shall be
able to functions after the test as defines in the standard.
Test Procedure
(Supplier is required to specify the procedures/method of testing on a separate

sheet). The test is conducted according to IEC61000-4-11.
Expected Result
Observed Result
A: VOLTAGE DIPS AND SHORT INTERRUPTIONS

Test level % Voltage
nominal (3x with 10s
interval)
0% (0V)
Duration in
cycles (s)
0% (0V)
10 (0.2s)
0% (0V)
50 (1s)
40% (96V)
0.5 (0.01s)
40% (96V)
10 (0.2s)
40% (96V)
50 (1s)
70% (168V)
0.5 (0.01s)
70% (168V)
10 (0.2s)
Results (DC
output voltage)
Remarks
0.5 (0.01s)
Page 39 of 59
70% (168V)
50 (1s)
Remarks
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Page 40 of 59
Coupler
1
Surge filter
Surge generator, combination waveform
2
Rectifier
: Current probes
Figure 1: Test setup for surge filter performance

Page 41 of 59

TEST CASE 16-19
BASIC FUNCTIONAL TEST, PERFORMANCE TEST
TEST DESCRIPTION
The purpose of the test is to verify the basic functionality test regarding the
protection of the rectifier modules against electrical and environment stress. The
rectifier system shall be able to perform as stated.
(Supplier is required to specify the procedures/method of testing on a separate
sheet)
Test Procedure
Expected Result
C: FUNCTION TEST
Input current (refer to supplier reports if any)

Mode
Volts
Inrush
Recommendation
Steady state
Recommendation
286Vac
Full
150Vac
Full
Reg
55Vdc
Results
AC current
<30A
<6Arms
Start
Voltage
230Vac
Upper/lower
voltage
275Vac* for 1
sec
End
voltage
230Vac
230Vac
150Vac* for 1
sec
230Vac
Load
(i) Input voltage

Load
Expected
Full
Full
Results
Output power shall off during

overvoltage and on again after
back to normal
Output power shall off during
undervoltage and on again after
Page 42 of 59
back to normal
* level to be based on supplier specification
Functions
High temperature
protection
(ii) protection functions

Setting
The module shall work in ambient of at least 50oC. If
ambient temperature over 90oC*, the Over
Temperature Protection trickle alarm LED light on and
power off, until high temperature disappear. Rectifier
shall restart automatically.
Setting
Results
(iii) power factor & efficiency

(Measured with 50-100% load)
Results
Set AC to 240Vac. Power factor shall at least 98%.

Set AC to 240Vac. Efficiency shall at least 90%.
Remarks
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Page 43 of 59

TEST CASE 20
ESD Electrostatic Discharge Test

electromagnetic discharge. The test is conducted with the powered
rectifier module.
The system did not fail or stop during the testing. At the highest
discharge some of the pixels in the display are affected, but they get
back to normal operation at the next updating of the display text.
TEST DESCRIPTION
Test Procedure
1-Set the AC input voltage as 230Vac.

2-Install 3 rectifier in system and half-load. Output voltage is 53.5V
3-This procedure is based on EN 300 386 V1.3.3 or EN61000-4-2(95) or
IEC61000-4-2
Expected Result
The rectifier modules will function as normal condition during and

after the ESD tests
Observed Result
2/4 kV contact discharge
(PF: B)
2/4 kV air discharge
(PF: B)
6 kV contact discharge
(PF: R)
8 kV air discharge
1 CONTACT DISCHARGE
POINT
Test Voltage Level(kV)
Rack
2 3 4 6 8
Screw
2 3 4 6 8
Aperture
2 3 4 6 8
Front panel
2 3 4 6 8
LEDs
2 3 4 6 8
LCD
2 3 4 6 8
Key and button
2 3 4 6 8
Power cable
2 3 4 6 8
Input Switch
2 3 4 6 8
MCB
2 3 4 6 8
(PF: R)
PASS
FAIL
Page 44 of 59
2 AIR DISCHARGE
POINT
Test Voltage Level(kV)
Rack
2 4 8
Screw
2 4 8
Aperture
2 4 8
Front panel
2 4 8
LEDs
2 4 8
LCD
2 4 8
Key and button
2 4 8
Power cable
2 4 8
Input Switch
2 4 8
MCB
2 4 8
PASS
FAIL
Note:
Test Result
Remarks
Pass / Fail
TM Representative
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Page 45 of 59

TEST CASE 21
TEST DESCRIPTION
Test Procedure

Radiated Electromagnetic Fields. The test is conducted with the
powered rectifier module.
The test was performed in a fully anechoic chamber. The transmit
antenna was located at a distance of 3 meters from the EUT.

3-This procedure is based on EN 300 386 V1.3.3 or EN61000-4-3 or
IEC61000-4-3
Expected Result
Observed Result

after the radiated electromagnetic fields tests
Test specification:
Basic standard
Frequency range
Field strength
Modulation
Polarity
Test distance
Antenna height
EN61000-4-3
80MHz-2GHz
10 V/m
1kHz Sine Wave
Horizontal and vertical
3m
1m
Frequency
Antenna
Field strength
range(MHz)
80-800
polarization
Horizontal
(V/m)
1
Vertical
Horizontal
10
1
Vertical
Horizontal
10
1
Vertical
Horizontal
10
1
Vertical
Horizontal
10
1
Vertical
800-960
960-1000
1000-1400
1400-2000
PASS
FAIL
10
Page 46 of 59
Note:
Test Result
Remarks
Pass / Fail
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TEST CASE 22
EFT (BURST) Test
TEST DESCRIPTION

electrical fast transient. The test is conducted with the powered rectifier
module.
Page 47 of 59
Test Procedure

IEC61000-4-4
Expected Result

after the EFT tests
Observed Result
Point
Test Voltage(kV)
Criteria
L1/2/3 to Ref GND
0.5
Positive
L1/2/3 to Ref GND
0.5
C
A
Negative
N to Ref GND
0.5
C
A
Positive
N to Ref GND
0.5
C
A
Negative
PE to Ref GND
0.5
C
A
Positive
PE to Ref GND
0.5
C
A
Negative
L1/2/3+N to Ref GND
0.5
C
A
Positive
L1/2/3+N to Ref GND
0.5
C
A
Negative
L1/2/3+N+PE to Ref
0.5
C
A
GND
Positive
L1/2/3+N+PE to Ref
0.5
C
A
GND
Negative
PASS
FAIL
C
Page 48 of 59
Note:
Test Result
Remarks
Pass / Fail
TM Representative
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TEST CASE 23
CONDUCTED DISTURBANCE TEST
TEST DESCRIPTION

conducted disturbance. The test is conducted with the powered rectifier
module.
Test Procedure

IEC61000-4-6
Expected Result

after the EFT tests
Page 49 of 59
Observed Result
Point
CDN/CLAMP
Criteria
AC POWER
CDN-M1 CDN-M2
CDN-M3 CDN-M4
CDN-M5 CDN-T4
PASS
FAIL
CDN-S4 em-Clamp
Note:
Test Result
Remarks
Pass / Fail
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TEST CASE 24
Conducted Emission Test
TEST DESCRIPTION
The purpose of this test is to confirm the emission energy of rectifier

modules of conducted emission. The test is conducted with the powered
rectifier module.
The system is tested for conducted emission [Class A] in a system, to
see how the connections of the system reference and measurement
circuitry affect the AC input and DC output.
The test is in shielded room 1- bare shielded room
Test Procedure

2-Install all rectifier in system and half-load, Or max load of the LISN device,
Output voltage is 53.5V
3-This procedure is based on EN 300 386 V1.3.3(4-2005) or EN 55022 :
1998 / A1 : 2000.
4-This test is level on [CLASS A].
5-Max load is 200A.
Expected Result
Test result according following table
Page 50 of 59
Frequency range
Level limit (dBuV)
(MHz)
Quasi Peak value
0.15 - 0.50
79
0.50 - 3
73
Remark: At the turning point (0.50MHz) used the lower limit
Observed Result
Average value
66
60
AC POWER PORT Conducted Emissions, 9/150/450 kHz - 30 MHz

Minimum limit margin
dB at
Maximum limit exceeding
dB at
PASS
N/A
FAIL
MHz
MHz
Remark_____________________________
___________________________________
___________________________________
DC POWER PORT Conducted Emissions, 9/150/450 kHz - 30 MHz
dB at
dB at
PASS
N/A
FAIL
MHz
MHz
Remark_____________________________
___________________________________
___________________________________
Note:
Test Result
Remarks
Pass / Fail
TM Representative
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Page 51 of 59
Date:
Date:

TEST CASE 25
Radiated Emission Test (Electric Field)
TEST DESCRIPTION
The purpose of this test is to confirm the emission energy of rectifier

modules of radiated emission. The test is conducted with the powered
rectifier module.
The system is tested for conducted emission [Class A] in a system, to
see how the connections of the system reference and measurement
circuitry affect the horizontal and vertical direct, include magnetic field
and electric field.
The test is in anechoic ferrite lined shielded room
Test Procedure

2-Install all rectifier in system and half-load, Or max load of the LISN device,
Output voltage is 53.5V
3-This procedure is based on EN 300 386 V1.3.3(4-2005) or EN 55022 :
1998 / A1 : 2000.
4-This test is level on [CLASS A].
5-Max load is 200A.
Expected Result
Test result according following table
Frequency range
(MHz)
30 - 230
Quasi Peak value limit (

10 meters
40
dBuV /m)
3 meters
50
Page 52 of 59
230 - 1000
47
Remark:
At the turning point (230MHz) used the lower limit
Observed Result
57
Radiated Emissions(Horizontal), 30 - 1000 MHz

dB at
dB at
PASS
N/A
FAIL
MHz
MHz
Remark_____________________________
___________________________________
___________________________________
Radiated Emissions(Vertical), 30 - 1000 MHz

dB at
dB at
PASS
N/A
FAIL
MHz
MHz
Remark_____________________________
___________________________________
___________________________________
Note:
Test Result
Remarks
Pass / Fail
TM Representative
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Date:
Date:
Page 53 of 59
SUMMARY OF DC SYSTEM TEST
No.
1.
Test Type
Results

Test - Pass
Test - Fail
Not Available
2.

Test & Pass
Test & Fail
Not Available
3.

Test & Pass
Test & Fail
Not Available
4.
Battery Recharge Current limit

Test & Pass
Test & Fail
Not Available
5.

Test & Pass
Test & Fail
Not Available
6.
Removal of Monitoring & Control Unit To check System

Test & Pass
Test & Fail
Not Available
7.
Load Sharing
Test & Pass
Test & Fail
Not Available
8.
Data logging facility Test

Test & Pass
Test & Fail
Not Available
9.
Battery On Load(BOL) Test

Test & Pass
Test & Fail
Not Available
10.

Test & Pass
Test & Fail
Not Available
11.

Test & Pass
Test & Fail
Not Available
12.
Surge immunity test

Test Pass
Test Fail
Not Available
Page 54 of 59
13.
Surge reliability test

Test Pass
Test Fail
Not Available
14.
Surge filter coordination test

Test Pass
Test Fail
Not Available
15.
Voltage dip, short interruptions

Test Pass
Test Fail
Not Available
16.
Static regulation and ripple

Test - Pass
Test - Fail
Not Available
17.
Input voltage
Test - Pass
Test - Fail
Not Available
18.
Protection functions
Test - Pass
Test - Fail
Not Available
19.
Power factor and efficiency

Test - Pass
Test - Fail
Not Available
20.
ESD
Test - Pass
Test - Fail
Not Available
21.

Test - Pass
Test - Fail
Not Available
22.
EFT
Test - Pass
Test - Fail
Not Available
23.
CONDUCTED DISTURBANCE TEST

Test - Pass
Test - Fail
Not Available
24.
CONDUCTED EMISSION
Test - Pass
Test - Fail
Not Available
25.
RADIATED EMISSION(ELECTRIC FIELD)

Test - Pass
Test - Fail
Not Available
Page 55 of 59
SUMMARY OF DEFAULT SETTING AND PROPOSED SITE SETTING
Unit
Default
Setting
High Voltage
58
High voltage
warn threshold
58
Low voltage
warn threshold
48
Low voltage
threshold
48
LVD Open
threshold
NA
LVD close
threshold
NA
Batt. Temp.
Coefficient
mV/C
Cap. Test Fail

Threshold
46
Cap. Test
Warn
Threshold
46
Cap. Test
Inhibit Time
Hrs
Cap. Test
Duration
Min.
60
System Set-Up
Voltage
Monitoring
LVD Setting:
Battery Temp.
Compensation
Automatic
Battery Cap.
Test
New/Site
Setting
Remarks
Page 56 of 59
10 CONCLUSION:
The above DC Power System is;
Accepted no modifications required
Conditionally accepted minor modifications required
Not accepted major modifications required
11 TEAM MEMBERS
No
Name
Designation
ASSISTANT MANAGER
MOHD NASIR MUNAWIR
ASSISTANT MANAGER
A.HALIM SAMAD
ASSISTANT MANAGER
ASSISTANT MANAGER
ASSISTANT MANAGER
ASSISTANT MANAGER
7
8
9
10
11
12
13
14
Page 57 of 59
12 AGREED BY TEST MEMBER

ASSISTANT MANAGER
SYSTEM TECHNOLOGY
MOHD NASIR MUNAWIR

ASSISTANT MANAGER
TMFS
A.HALIM SAMAD
ASSOCIATE SENIOR RESEARCHER
TM R&D

ASSISTANT MANAGER
TMFS

ASSISTANT MANAGER
ANOC

ASSISTANT MANAGER
BSQM RNO
Page 58 of 59

Telekom Malaysia DC System Test Rectifier Test Plan

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Telekom Malaysia DC System Test Rectifier Test Plan

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DC POWER SYSTEM ACCEPTANCE TEST PLAN

MOHD FALAAH ABD MANAP

DC POWER SYSTEM ACCEPTANCE TEST PLAN

TEAM MEMBER LIST...............................................................................................2

TOOL AND TEST GEAR INFORMATION................................................................3

SYSTEM PHYSICAL INSPECTION CHECKLISTS...............................................10

SUMMARY OF DC SYSTEM TEST........................................................................57

SUMMARY OF DEFAULT SETTING AND PROPOSED SITE SETTING..............59

AGREED BY TEST MEMBER................................................................................61

TEAM MEMBER LIST

MOHD FALAAH ABD MANAP

MOHD NASIR MUNAWIR

Basic Functions and Alarm Function Test

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

Battery Temperature Compensated Charging

TOOL AND TEST GEAR INFORMATION

Testo data logger

Testo data logger

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

PART 1 PRODUCT INFORMATION

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

INPUT SURGE FILTER:

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

from 10 90% or 90 10%

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

MAIN CONTROLLER UNIT

Set time and date

Set by day and month

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

Manual test only

Slope range : ________

PERNEC ADVANCED NETWORK

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

PART 2 DC SYSTEM INSPECTION CHECKLIST

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

SYSTEM PHYSICAL INSPECTION CHECKLISTS

AC Input Distribution Panel:i. AC input Main breaker

ii. Module AC input mcb

iv. Earth bar/ Termination

Outgoing Load Breaker

Battery current shunt

Load current shunt

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

PERNEC ADVANCED NETWORK

ACCEPTANCE TEST PLAN

DC POWER SYSTEM ACCEPTANCE TEST PLAN

PART 3 DC SYSTEM ACCEPTANT TEST

DC SYSTEM ACCEPTANCE TEST

DC POWER SYSTEM ACCEPTANCE TEST PLAN

Basic Functions and Alarm Function Test

All basic functions is activated.

The lines can be switched

the output voltage is within