EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual
Version
V1.1
Revision date
January 14, 2009
BOM
31011973
Emerson Network Power provides customers with te chnical chnical support. Users may contact the nearest Emerson local sales office or service center.
Copyright 2008 by Em erson Network Power Co., Ltd. All rights reserved. reserved. The contents in this document are subject to change change without notice.
Emerson Network Power Co., Ltd. Address: No.1 Kefa Rd., Rd., Science & Industry Industry Park, Nanshan District District 518057, Shenzhen China Homepage: www.emersonnetworkpower.com.cn E-mail:
[email protected]
Safety Precautions To reduce the chance of accident, please read t he safety precautions very caref ully before operation. The "Caution, Note, Warning, Danger" in this book and on the product do not represent all the safety points to be observed, and are only supplement to various safety points. Therefore, the installation and operation personnel must receive strict training and master the correct operations and all the safety points before operation. When operating Emerson products, the operation personnel must observe the safety rules in the industry, the general safety points and special safety instructions specified in this book. If you purchase the outdoor cabinet without SPD, you should add a SPD at the AC input terminal to prevent risk of over-voltage.
Electrical Safety I. Hazardous voltage
Danger Some components of the power supply system carry hazardous voltage in operation. Direct contact or indirect contact through moist objects with these components will result in fatal injury.
Observe safety rules in the industry when installing the power supply system. The installation personnel must be licensed to oper ate high voltage and AC power. power. In operation, the installation personnel are not allowed to wear conductive objects, such as watches, bracelets, bangles and rings. When water or moisture is found on the cabinet, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power supply system. "Prohibit" warning label must be attached to the switches and buttons that are not permitted to operate during installation.
Danger High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high voltage operations.
Danger To avoid electric shock hazard for outdoor environment and outdoor equipments, the non-professionals are prohibited to operate or maintain the outdoor power supply system.
II. Tools
Warning In high voltage and AC operation, specialized tools must be used.
III. Thunderstorm
Danger Never operate on high voltage, AC, iron tower or mast in the thunderstorm.
In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be well earthed in time to avoid damage by lightning strikes. IV. ESD
Notice The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body static from damaging the sensitive components. The other end of the ESD wrist strap must be well earthed.
V. Short circuit
Danger During operation, never short the positive and negative poles of the DC distribution unit of the power supply system or the non-grounding pole and the earth. The power supply system is a constant-voltage DC power device; short circuit will result in equipment burning and endanger human safety.
VI. Reverse connection
Warning Never connect reversely live line and neutral line of the AC input cables, or else the system will be damaged.
Check the polarity of the cable and connection terminal when performing DC live operations. As the operation space in the DC distribution unit is very tight, please carefully select the operation space. Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation. Use insulated tools. In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of the human body and tool is reduced to a minimum.
Battery
Danger Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery connection method.
Warning If customers prepare batteries themselves, the batteries installation and maintenance should meet relevant safety standards.
Non-standard operation on the battery w ill cause danger. In operation, precautions should be taken to prevent battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs, thus causing equipment damage and short circuit of PCBs. Before any operation on battery, pay attention to t he following points: 1. Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist. 2. Use specialized insulated tools. 3. Use eye protection device, and take preventive measures. 4. Wear rubber gloves and apron to guard against electrolyte overflow. 5. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery upside down or slanted.
Connection And Testing Of The Outdoor Cabinet Before installing subrack power supply in the cabinet, you should finish the connection and testing of the subrack power supply according to the corresponding subrack power supply user manual and then testing the outdoor cabinet.
Others I. Sharp object
Warning When moving equipment by hand, wear protective gloves to avoid injury by sharp object.
II. Power cable
Notice Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.
III. Binding the signal lines
Notice The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least 150mm.
Contents Chapter 1 Product Introduction ............................ ..................... ................. ..................... .................... ..................... ..... 1 1.1 Overview ........................................................................................................................................................ 1 1.2 Model Description ................ ..................... ..................... ................. ..................... .................... ..................... ..1 1.3 Composition And Configuration .................... .................... ..................... ..................... ................. .................... 1 1.4 Parameters..................... ................. ..................... .................... ..................... ..................... .................... ........ 3 1.5 Heat Dissipation Theory ................ ..................... .................... ..................... ..................... .................... ........... 3 1.6 Features................ .................... ..................... .................... ..................... ..................... ................. ................. 3 Chapter 2 Installation.................... ................. ..................... .................... ..................... ..................... .................... ........ 4 2.1 Safety Regulations............... ..................... ..................... ................. ........................ .................... .................... 4 2.2 Preparation..................... ................. ..................... .................... ..................... ..................... .................... ........ 4 2.3 Mechanical Installation............... ..................... .................... ..................... ..................... .................... .............. 5 2.3.1 Installing The Outdoor Cabinet ......................... .................... ..................... .................... ..................... ..5 2.3.2 Opening And Closing Cabinet Door ..................... .................... ..................... ................. ..................... ..6 2.4 Electrical Installation ............... ..................... ..................... .................... ..................... ................. .................... 7 2.4.1 Connecting Grounding Cables................. ..................... .................... ..................... .................... ........... 7 2.4.2 Connecting Signal Cables ................................ ................. ..................... ..................... .................... ..... 8 2.4.3 Connecting Fan Control Board Power Cables ............................. ..................... .................... ................. 9 2.4.4 Connecting Other Cables ................................. ................. ..................... ..................... .................... ..... 9 2.4.5 Sealing The Entry Holes .................... .................... ..................... ..................... ................. .................... 9 2.5 Battery Installation ............... ..................... ..................... ................. ..................... ..................... .................... ..9 2.6 Installation Inspection ................................................................................................................................... 10 Chapter 3 Testing................ .................... ..................... .................... ..................... ..................... ................. ............... 11 3.1 Startup ......................................................................................................................................................... 11 3.2 Alarm Check And System Operation Status Check .................... ..................... ..................... .................... ...... 11 3.3 Final Steps ................................................................................................................................................... 11 Chapter 4 Maintenance .............................................................................................................................................. 12 4.1 Routine Maintenance ................................... ..................... .................... ..................... ................. .................. 12 4.2 Handling Alarms And Faults ................ ..................... ................. ..................... ..................... .................... ...... 13 4.3 Replacing Parts ............................................................................................................................................ 13 4.3.1 Replacing Fan Control Board............................... .................... ..................... ................. ..................... 13 4.3.2 Replacing Fan control extension Board................ .................... ..................... .................... .................. 14 4.3.3 Replacing Fans ............... ..................... .................... ..................... ..................... .................... ............ 14 Appendix 1 Spare Part List ......................... ..................... .................... ..................... ..................... .................... ......... 16 Appendix 2 Wiring Diagram ................................. ..................... ................. ..................... ..................... .................... ... 17 Appendix 3 Schematic Diagram ............... ..................... .................... ..................... ..................... .................... ............ 20
Chapter 1 Product Introduction
Chapter 1 Product Introduction This chapter introduces the model description, composition & configuration, parameters, heat dissipation theory and features of Aluminum Flexi EPC48150/1800-FA1 & EPC48300/3200-FA1 outdoor power supply system (outdoor cabinet for short).
1.1 Overview The outdoor cabinet is dedicated to providing protection and operation environment for outdoor power supply system and user equipment. The cabinet can accommodate different Emerson subrack power supplies according to your requirement so as to form power supply systems with different capacities.
1.2 Model Description An EPC48150/1800-FA1 outdoor cabinet contains five 30A rectifiers and an EPC48300/3200-FA1 outdoor cabinet contains five 50A rectifiers. Their model descriptions are given in Figure 1-1 and Figure 1-2.
EPC 48 150 / 1800 - FA 1 Version No. Thermal control method: forced fan cooling Power of the rectifier: 1800W Max. output current: 150A Output voltage: 48V Emerson outdoor power cabinet
Figure 1-1
Model description of EPC48150/1800-FA1 outdoor cabinet
EPC 48 300 / 3200 - FA 1 Version No. Thermal control method: forced fan cooling Power of the rectifier: 3200W Max. output current: 300A Output voltage: 48V Emerson outdoor power cabinet
Figure 1-2
Model description of EPC48300/3200-FA1outdoor cabinet
1.3 Composition And Configuration Composition The outdoor cabinet is composed of a fan-cooling unit, an equipment compartment and a battery compartment. The fan-cooling unit consists of fan, fan control board and fan control extension board. The equipment compartment consists of subrack power supply and reserved space for user equipment. The power distribution unit is located in the subrack power supply and consists of AC sockets and AC power distribution MCBs. The battery compartment is used to accommodate battery strings. The outdoor cabinet has four types of dimensions, as given in Table 1-1. You can select one according to your actual requirement. Table 1-1
Dimensions of the outdoor cabinet
Type
Dimensions (W !D!H) (mm)
Shell
Battery layer
1
650! 650!1000
Partially double skin
1
2
700! 650!1600
Partially double skin
2
3
700! 650!1600
Fully double skin
2
4
650! 650!2000
Partially double skin
3
1
2
Chapter 1 Product Introduction The four types of outdoor cabinets have the same structure, except for dimensions, shell and battery layer (see Table 1-1). Take the 1600mm (height) partially double skin outdoor cabinet for example, the structure is shown in Figure 1-3.
Fan-cooling unit
Subrack power supply Equipment compartment Reserved space
Battery bracket Battery compartment
Figure 1-3
Structure of the outdoor cabinet
Configuration The configuration list of the outdoor cabinet is given in Table 1-2. Table 1-2
Configuration list
Component
Fan-cooling unit
2 ~ 4, optional
Fan control board
1 piece
Fan control extension board
AC power
AC socket
distribution unit
Configuration
Fan
AC power distribution MCB
0 ~ 1, optional. Select this board when you need fan fault alarm. While you select 120A subrack power supply, you need not select this board (because the 120A subrack power supply has fan alarm function) One 10A AC socket, single-phase, four standards optional (Chinese, British, American and German standards)
One 10A/1P MCB or one 10A/2P leakage MCB is mandatory
One 10A/1P MCB, optional
Reserved space and battery
Sharing space. You can adjust space by removing or adjusting the position of the battery
compartment space
bracket (see Figure 1-3)
Others
Door status sensor: 1
Chapter 1 Product Introduction
1.4 Parameters The parameters of the outdoor cabinet are given in Table 1-3. Table 1-3 Parameter category
Environmental
Parameters of the outdoor cabinet
Parameter
Description
Operating temperature
-10" C ~ +45"C
Storage temperature
-45" C ~ +70" C
Relative humidity Others Space of each layer of the battery compartment Cabinet (height: 1000mm)
Mechanical
Cabinet (height: 1600mm, Weight
(derating is necessary when above 2,000m)
No conductive dust or erosive gases. No risk of explosion Reserved space
Dimensions
5%RH ~ 100%RH # 2,000m
Altitude
partially double skin shell) Cabinet (height: 1600mm, fully double skin shell) Cabinet (height: 2000mm)
Sharing space with the battery compartment, adjustable Adjustable height: 240mm, 280mm, 320mm 40kg 70kg 75kg 80kg
Note: For parameters of AC input, DC output and subrack power supply, refer to the corresponding subrack power supply user manual
1.5 Heat Dissipation Theory The cold air is sucked in through the front door air filter at the lower part of the outdoor cabinet. It passes through the battery compartment, user equipment and subrack power supply in turn. Finally, the resulting hot air is discharged by the fans at the top of the outdoor cabinet. It is in this way that the equipment in the outdoor cabinet is cooled.
1.6 Features l Material: The structural material of the outdoor cabinet is aluminium, making the cabinet lighter than iron cabinet
of the same dimensions. l Variable subrack power supply: The outdoor cabinet ca n accommodate standard 19 $ and 23$ subrack power
supply. l Variable space: The reserved space and the battery compartment space are interchangeable. You can adjust
the space according to the actual requirements. l Dimensions: Four t ypes of dimensions. You can select one according to the field conditio ns, environmental
conditions and your requirements. l Structure shape: partially double skin shell and fully double skin shell. l Safety guideline: The equipment compartment satisfies IP*5 waterproof requirements and IP4* dustproof
requirements. l Environment pollution level within the cabinet: 3.
3
4
Chapter 2 Installation
Chapter 2 Installation This chapter introduces installation and cable connection. Before the installation, read through the safety regulations, and then follow the instructions in this chapter to carry out the installation and cable connection.
2.1 Safety Regulations Certain components in this outdoor cabinet carry hazardous voltage and current. Always follow the instructions below: 1. Only the adequately trained personnel with adequate knowledge of the outdoor cabinet shall carry out the installation. The Safety Precautions listed before the contents of this manual and local safety rules in force shall be adhered to during the installation. 2. All external circuits that are below -48V and connected to the outdoor cabinet must comply with the requirements of SELV defined in IEC 60950. The voltage at the DC side exceeds 30V, posing electric shock hazard. 3. To avoid electric shock hazard, do not perform any operation or maintenance within the system under stormy or humid weather conditions. 4. Make sure that the power (mains and battery) to the system is cut off before any operations can be carried out within the outdoor cabinet. 5. The wiring of the power distribution cables should be arranged carefully so that the cables are kept away from the maintenance personnel.
2.2 Preparation Unpacking inspection The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall be done by representatives of both the user and Emerson Network Power Co., Ltd. To inspect the equipment, you should open the packing case, take out the packing list and c heck against the packing list that the equipment is correct and complete. Make sure that the equipment is delivered intact. Preparing tools The installation tools are given in Table 2-1. The tools must be insulated and ESD-proof processed before they are used. Table 2-1 Tool
Installation tools
Specificat ion
Tool
Combination wrench (hatch,
Wrench set (10#, 13#, 16#,
club)
18#, 21#)
Adjustable wrench Electrician diagonal pliers Electrician sharp nose pliers
150mm
Steel tape
5m
Digital multimeter
Electric knife
Normal type
Impact electric drill
Gradienter
Normal type
Power socket
Specificati on
Cross screwdriver
100mm, 200mm
200mm
Slotted screwdriver
100mm, 200mm
150mm
Wire cutters
Maximum 300mm2
Hydraulic-pressure compacti on pincher
Blinkers
To prevent splash
Safety shoes
Fireproof mud
Configured in the accessories
Hammer
Box wrench
16mm
Maximum 300mm2 Three and a half bit digital display With %14 impact aiguille With 5m cable To prevent puncture and for insulation
Chapter 2 Installation
2.3 Mechanical Installation 2.3.1 Installing The Outdoor Cabinet The outdoor cabinet must be installed directly onto the cement floor. Follow the steps below to install it: Step 1: Mark the specific installation position of the outdoor cabinet It is recommended to determine the installation position in compliance with the clearance requirements given in Table 2-2. Table 2-2 Clearances
Installation clearances
Front
Top
Left
Right
Back
750mm
700mm
100mm
100mm
100mm
Step 2: Install expansion pipes By referring to Figure 2-1 and Figure 2-2, determine the exact central points of the installation holes on the floor, and mark them with a pencil or oil pen. Use the electric drill (aiguille: %14) to dig holes (depth: 70mm) at the marked points. Clean the drilled holes off dust. Put the expansion pipes into the installation holes.
7 4 4
0 8 642 Figure 2-1
Installation size of the cabinet base (height: 1600mm, unit: mm)
5
6
Chapter 2 Installation
7 4 4
0 8
592 Figure 2-2
Installation size of the cabinet base (height: 1000mm and 2000mm, unit: mm)
Step 3: Fix the cabinet Move the cabinet to the installation position. Make the installation holes on the base coincide with those dug on the floor. Screw the M10 anchor bolt down into the expansion pipe in the floor. After installation, the cabinet should stand firmly no matter how it is shaken.
2.3.2 Opening And Closing Cabinet Door You need to open and close t he cabinet door during the c abinet installation, operation and m aintenance. Procedures for opening and closing the cabinet door are as follows: Step 1: Insert the key into the keyhole, and turn the key clockwise until the door handle pops out. Step 2: Turn the handle counter-clockwise 90 ", as shown in Figure 2-3. Pull the handle until the door opens.
90
Figure 2-3
Turning the handle
Step 3: Adjust the door stay bar to the position shown in Figure 2-4 to prevent the door from closing automatically. Door stay bar
Figure 2-4
Door stay bar
Chapter 2 Installation Step 4: To close the door, restore the door stay bar to its original position and close the door. Finally, turn the handle to its original position and press it down until a click is heard.
2.4 Electrical Installation All the cables must be put through metal pipes for protection. The metal pipe should be connected to the PE bar reliably. Plastic coated metal hoses are recommended. &
Note
1. Grounding cables and AC input cables enter the cabinet through the left side of the cabinet bottom. 2. Signal cables and load cables enter the cabinet through either side of the cabinet bottom.
2.4.1 Connecting Grounding Cables The procedures of connecting grounding cables are as follows: Step 1: Open the cabinet door, and you can see cable frames and PE bar on the left side of the cabinet and entry holes on the cabinet bottom. Their positions are shown in Figure 2-5.
Cable frame PE bar Entry hole
Figure 2-5
Position of the cable frame, PE bar and entry hole
Step 2: Cut the cable bushing over the entry hole with an electrician knife to lead in cables. Step 3: Lead the grounding cable into the cabinet through the entr y hole on the cabinet bottom. Route the cable along the cable frames. Step 4: Connect one end of the grounding cable to the PE bar and solder the other end to the metal base outside of the outdoor cabinet reliably. Step 5: Fix the grounding cable to the cable frame with nylon ties. If the outdoor cabinet is not configured with a subrack power supply, then a green yellow earth cable has been connected to the PE bar in factory. When you purchase a subrack power supply separately, please connect the other end of this earth cable to the earth terminal of the subrack power supply. For the position of the earth terminal of the subrack power supply, please refer to the corresponding subrack power supply user manual.
7
8
Chapter 2 Installation
2.4.2 Connecting Signal Cables Dry contacts The cabinet provides one signal output terminal block, which provides four pairs of dry contacts for the user, as shown in Figure 2-6. The definitions of the dry contacts are given in Table 2-3.
Signal output terminal block
Figure 2-6
Position of the signal output terminal block Table 2-3
Port No.
Dry contact definitions
Silk print
Definition
Remark
1, 2
Door alarm
Door alarm
Default value. Reconfigurable
3, 4
Over temperature alarm
Over temperature alarm
Default value. Reconfigurable
5, 6
Fan fault alarm
Fan fault alarm
7, 8
Spare
Spare
Default value. Reconfigurable (the function is enabled when the outdoor c abinet is configured with a fan control extension board) Configurable
Connecting dry contacts 1. Internal connection If the outdoor cabinet is configured with a subrack power supply, the internal connections of the four dry contacts have been made in factory. If the outdoor cabinet is not configured with a subrack power supply, then except that the other end of the over temperature alarm cable connected to ports 3 and 4 is left unconnected, other internal connections have been made in factory. In the latter case, if you purchase a subrack power supply separately, you need to connect the other end of this over temperature alarm cable to the over temperature alarm dry contact output terminal of the subrack power supply. For the position of this terminal, please refer to the corresponding subrack power supply user manual. 2. External connection you need to connect the four pairs of dry contacts to the user &s signal input terminals. When make connection, peel the signal cables and insert their ends into the corresponding terminals, then fasten the connection by tightening the screws on the terminals.
Chapter 2 Installation
2.4.3 Connecting Fan Control Board Power Cables &
Note
1. If the outdoor cabinet is configured with a 120A subrack power supply, you can skip 2.4.3 Power Cables.
Connecting Fan Control Board
2. For the sake of safety, follow the labels on the cables to carry out the cable connection.
Step 1: By referring to the corresponding subrack power supply user manual, find out the priority 10A (or 16A) load MCB in the subrack power supply. Step 2: Unfasten the double-core power cable of the fan control board in the cabinet, and connect the black cable to the priority load MCB (namely: -48V output MCB) in the subrack power supply and connect the brown cable to the 0V busbar. Step 3: If the 0V busbar is fixed with screws, you should press an OT terminal onto the -48V terminal cable before connection. Note: Follow the previous steps you can make a power input MCB for the fan control board.
2.4.4 Connecting Other Cables Other cables include AC input cables and load cables. For their connection methods, see the corresponding subrack power supply user manual.
2.4.5 Sealing The Entry Holes After finishing the cable connections, seal the entry holes (see Figure 2-5) with fireproof mud.
2.5 Battery Installation &
Note
1. The batteries may carry dangerous current. Before connecting the battery cables, make sure all the battery input MCBs (their positions are shown in the corresponding subrack power supply user manual) are off. 2. Be careful not to reverse connect the battery. Otherwise, both the battery and the outdoor cabinet system will be damaged! 3. The installation tools must be insulated. Do not damage the battery plastic cover or battery terminals during the installation.
The battery compartment can accommodate two battery strings. Installation check 1. Check that the battery shells are in good condition. 2. Check that the polarities of the terminals are in accordance with the polarity marks on the battery shell. 3. Check that the terminal screws are fastened. Installation procedures &
Note
When installing two battery strings or more, install the lower battery string first. While removing them, remove the upper battery string first.
Step 1: Switch off the battery MCBs and AC input MCBs. For their positions, refer to the corresponding subrack power supply user manual. Step 2: Push the batteries into the battery compartment from right to left. The clearance between adjacent batteries should be at least 10mm. Step 3: Remove the cover of the battery terminals and connect the plate electrodes between the batteries. Step 4: Connect the positive battery cables (red) to the positive pole of the batteries in the battery compartment. Connect the negative battery cables (black) to the negative pole of the batteries. Attach the acid and alkali integration box (battery accessory) on the right side panel of the cabinet.
9
10
Chapter 2
Installation
Step 5: After installing the battery strings, use the 3M double-side adhesive tape to affix the temperature sensor to the center of the upper-layer battery string. Step 6: Measure the voltage of the battery strings. If the voltage value is correct, replace the battery cover.
2.6 Installation Inspection After installation, you should carry out the inspection procedures given in Table 2-4. Table 2-4 Check item
No. 1 2
Cabinet installation
3 4
Cabinet installation
connection
Check content Check that the cabinet is level, upright and steadily fixed Check that if all the screws are tightened, especially those in electrical connections. Check that the bolts have plain washers and spring w ashers and are not reversed Check that there are no unwanted materials inside the cabinet and clear up the unwanted materials Check that the cabinet paint is intact. If there are scr atches, paint them immediately with antirust paint to prevent corrosion
5
Clean up the cabinet
6
Check that the door can move freely, the lock is in good condition and the door stay bar is fixed
7
Check that the dummy plates are installed at the reserved space where no customer device is installed
1
Check the correctness of all the MCBs and cables specifications
2 Electrical
Installation inspection list
3 4
Check the correctness of bus bar connections, input and output cable connection, and connection between the power system and the system grounding Check the correctness of the batteries number and connection, and battery strings polarities Make sure all the cable connections are firm and reliable Check the connection point, line sequence and polarities of DC cables. Check the connection polarities of
5
the batteries. Check that the connection points are fixed and the cable connections are correct and reliable
6
Check that the cables are tidy, and the cable binding is normative
Chapter 3 Testing
11
Chapter 3 Testing This chapter introduces procedures of testing. The corresponding safety rules shall be adhered to in the testing. &
Note
After testing the subrack power supply, you can test the outdoor cabinet.
3.1 Startup &
Note
Before the test, inform the chief manufacturer representative. Only the trained electrical engineer can maintain and operate this equipment. In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets, bangles and rings.
During operation, parts of this equipment carry hazardous voltage. Misoperation can result in severe or fatal injuries and property damage. Before the test, check the equipment to ensure the proper earthing. Installation inspection (see Table 2-4) must be done before testing. Then you can do the following operation. Switch on the power input MCB of the fan control board (For the position, refer to 2.4.3 Connecting Fan Control Board Power Cables.) to power on the fan control board. When the outdoor cabinet is configured with 120A subrack power supply, the power input MCB is not available; you just need to power on 120A subrack power supply to power on the fan control board. At this point, the fan control board enters self testing and the fans accelerate to full speed gradually. After a few minutes, the fans stop. If the environmental temperature is about 35 "C, the fans will operate at low speed, until the environmental temperature reaches 25 "C, then the fans will stop.
3.2 Alarm Check And System Operation Status Check Alarm check If the outdoor cabinet is configured with a fan control board, you can disconnect the J11 and J12 terminals (see Figure 4-2) on the fan control board when the fan is operating. So as to check that if the fan control board can trigger fan alarm. System operation status check There should be no alarms during normal system operation.
3.3 Final Steps OK Disconnect all test equipment from the system and make sure that materials irrelevant to the
Comments
equipment have been all removed. Restore the outdoor cabinet to its original condition and close the cabinet door.
Check and handover the equipment that the user has purchased.
Note down all the operations taken, including time of the operation and name of the operator.
If any defect is found in this equipment, inform the personnel responsible for the contract. If repairing is needed, please fill in the FAILURE REPORT and send the report together with the faulty unit to the repairing center for fault analysis.
12
Chapter 4
Maintenance
Chapter 4 Maintenance This chapter describes the routine maintenance, alarm and fault handling, and replacing of the outdoor cabinet parts. &
Note
1. The maintenance must be conducted under the guidance of the related safety regulations. 2. Only the trained personnel with adequate knowledge about the outdoor cabinet shall maintain the inner part of the cabinet.
4.1 Routine Maintenance Inspect the outdoor cabinet periodically and shoot the trouble in time. The routine maintenance items are given in Table 4-1. Table 4-1 Maintenance item Fans
Frequency Once half a year
Routine maintenance items
Inspecting method Visual inspection
Guide The check method is given in 3.1 Startup. If the fans run abnormally, refer to 4.3.3 Replacing Fans to maintain or replace the fan
Paint, galvanization layer Once half a year
Visual inspection
If there are scratches, paint them immediately If dust accumulated on the front door air filter (shown in Figure 4-1), loosen the four fixing screws of the air filter cover of the front door (shown in Figure 4-1). Then take off
Front door air filter
Once three months
Visual inspection
the air filter cover and clean the air filter with water from inside to outside (wire fence is inside of the air filter). Each air filter can not be cleaned for over two times. Otherwise, the air filter m ust be replaced. If the air filter is damaged, replace it. Finally, replace the air filter cover
Front door air filter Fixing screw of the air filter cover of the front door (4 pieces)
Figure 4-1
Front door air filter
Chapter 4
Maintenance
13
4.2 Handling Alarms And Faults The normal alarms and faults of the outdoor cabinet are the alarms and faults of the fan. For inspection and maintenance of the fan, refer to 4.3.3 Replacing Fans.
4.3 Replacing Parts 4.3.1 Replacing Fan Control Board Fan control board and its terminals layout are shown in Figure 4-2.
H1
H2
1 1 J
2 1 J
0 1 J
2 J
SW2
2 W S 1 W S
SW1
N O
6 J 7 J
3 J
H4
Alarm indicators Figure 4-2
H3
B
Fan control board and its terminal layout
Setting description of the fan control board The setting description of the fan control board is listed in Table 4-2. Table 4-2 Name Bit '1$ Bit '2$ Self-test button
Setting description of the fan control board
Label on the
Silk print on the
corresponding
corresponding fan control
cover
board
Setting description
Put SW2 switch to the (OFF& position (default), see Figure 4-3
Switch
SW2 (shown in Figure 4-2)
Button
SW1 (shown in Figure 4-2) Press the button to test the fan
Remark: The position of the cover is shown in Figure 4-4. The fan control board is located under the cover
2 W S
Figure 4-3
Amplified SW2
Replacing procedures of the fan control board The procedures of replacing the fan control board are as follows. Step 1: Loosen the two fixing scr ews to remove the cover, and t hen you can see the fan control board. The position of the cover is shown in Figure 4-4.
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Chapter 4
Maintenance
Fixing screw of the cover
Cover Fixing screw of the cover
Figure 4-4
Plastic cover position
Step 2: Disconnect J11, J12 and J2 terminals (shown in Figure 4-2) in sequence, and then disconnect the rest connection terminals on the fan control board. Step 3: Loosen the fixing screws on the fan control board. Replace the fan control board with a new one. Step 4: Reverse connection sequence of previous step 2 to connect terminals, so as to check that the indicators show correctly when fan fails. Step 5: Ensure that Bit 2 of SW2 switch is put to the position shown in Figure 4-3. Step 6: Replace the cover of the fan control board. Press the SW1 self-test button (shown in Figure 4-2) to ensure that the fan can start normally.
4.3.2 Replacing Fan Control Extension Board The procedures of replacing the fan control extension board are as follows. Step 1: Loosen the two fixing scr ews to remove the cover, and t hen you can see the fan control extension board. The position of the cover is shown in Figure 4-4. Step 2: Loosen the four fixing screws to remove the fan control extension board. Replace the fan control extension with a new one. Step 3: Replace the cover.
4.3.3 Replacing Fans Fan alarm circuit The fan-cooling unit of the outdoor cabinet is mainly composed of 2 ~ 4 axial flow fans. The illustration of the fan alarm circuit is shown in Figure 4-5, where the blue line is the alarm line. VCC (Red) (Blue) MOTOR DRIVER IC
VFG
Ic
R FG SIGNAL
VCE (Black)
GROUND
(Yellow) Figure 4-5
Illustration of the fan alarm circuit
Fan alarm indicators The position of the alarm indicators is shown in Figure 4-2. If the system is configured with four fans, the alarm indicators 1 ~ 4 on the fan control board correspond to fans 1 ~ 4. If the system is configured with three fans, the alarm indicator 1 on the fan control board corresponds to fan 1; alarm
Chapter 4
Maintenance
15
indictor 2 corresponds to fan 2, and alarm indicators 3 and 4 correspond to fan 3. If the system is configured with two fans, alarm indicators 1 and 2 correspond to fan 1, and alarm indicators 3 and 4 correspond to fan 2. Fan replacing procedures If the fan is faulty, the corresponding indicator will be on. Follow the following procedures to replace the fan. Step 1: Make sure that the fa n-control terminals (J11 and J12 are hot pluggable) on the fan control board are inserted firmly. The fan-control terminals are shown in Figure 4-2. Step 2: Ensure that Bit 2 of SW2 switch is put to the position shown in Figure 4-3. Step 3: Press the SW1 self-test button (shown in Figure 4-2). If the fans do not work, make sure that the fan cables are perfect. Step 4: Loosen the fixing screws at the cabinet top cover to open the top cover. (Opening the top c over, pull it forward and then lift up its front not more than 30 ". Otherwise the top cover will be fallen.) Step 5: Disconnect the fan power terminals at the top of the cabinet. Use a multimeter to measure the voltage between the positive power cable and the negative power cable. Check if the voltage is close to the DC output voltage (54.0V). If the fan power voltage is normal, the fans are damaged. Carry out the next step. Step 6: Loosen the four fixing screws of the fans and replace the fans, as shown in Figure 4-6. Fixing screw of the fan (4 pieces) Fan
Figure 4-6
Replacing the fan
Step 7: Reconnect the fan power terminals, and press SW1 self-test button (shown in Figure 4-2) to ensure that the fan can startup normally.
16
Appendix 1 Spare Part List
Appendix 1 Spare Part List Table 1 Spare part list Component
Description
BOM
Fan
DC axial flow fan
32010191
Power supply cable for fan
P345314SL31
04118331 (with two fans)
Power supply cable for fan
P345314SL32
04118332 (with three fans)
Power supply cable for fan
P345314SL33
04118333 (with four fans)
Air filter
430mm!320mm !46mm
02560009
Fan control board
P344309U1
03034609
.
Appendix 2 Wiring Diagram
17
Appendix 2 Wiring Diagram 9 XT
8 XT W02
L=270mm
Back cross door line W02
L=320mm
Front cross door line Battery MCB 43 QFDI
W03
W 07 V 1 T T A B 6 2
3 5 9 11 1 7 L1 L 2 L3 N N 2 4 6 8 1 0 11
3 JX
44 QFDII
W07 V 2 T T A B 6 2
1
Note 4
Project 1 2
W03
4 QFA2
N
L
W03
10A
3
4
5
15 Bus-
2
W03_A/B/C PE
5 MS
N N
L
B 1
10A
W03
W03
4 QFA2
1
W03
2
3
4
+ V 1 T T A B 6 2
+ V 2 T T A B 6 2
+ V 3 T T A B 6 2
5
6
7
8
9
10
11
12
+ V 4 T T A B 6 2
0V bar 25 Bus+
W07 W07
7 2
2 1
Note: W03_A for Europen and British standard. W03_B for American standard socket. W03_C for Chinese standard socket.
1
63A
W03
2
N
W03_A/B/C 1
Q FD I I
63A 2
Project 2
W03
PE
5 MS
1
Q FD I
W07
PE BUS
6
1 3 4
Subrack power supply PE bar
W02
2 5 2
1 4 4
3 5 2
1
-
2
+
-
+
3 45
5
PE BUS
6
2# BATT
1# BATT
4
PE bar in cabinet 26 BATT
Note! 1. Because 3# and 4# BATT cables have no battery MCBs, you can bind the cables to the corresponding positions along the cable frames in the cabinet. 2. AC socket conection: according to project 1 or project 2. 3. Connect cables according to actual configuration. 4. When leakage MCB is available, QFA2 MCB is reserved for user and not connected. Figure 1 Wiring diagram (1)
EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual
Appendix 2 Wiring Diagram 6 MJ
Door sensor
120A J_TEMP
P144309X1
X1-J_DOOR1-1
31
J_Z
3
1 2
1
X1
2
W17
2
X1-J_DOOR1-2
1 1 6
J_BMV
J_232
2
8
9
4 3
1
7 5 6
J_X
J_I
5
W17
2
J_DOOR1
1
4 1
2 3
J_RLY
W01 46-1 W01 46-3
46-2 W01 46-4
W01 46-5
46-6 W01 1 6
2
J_MFAIL
6-2 6-1
2
6
U1-J3-7 U1-J3-8 U1-J3-5 U1-J3-6
5 4
J_CTRL
1
28
29
FAN1
FAN2
Fan 1
Fan 2
1
1
W01
1 5
2 3
2
3 2
U1-J3-1 U1-J3-2
1
8 7 6
1
J_FAULT
30
50
FAN3
FAN4
Fan 3
Fan 4
5 4
5
3
4
2
3
1
2
FAN1
3 4 9 0
FAN2
FAN3
FAN4
1
W20
B
W23
W23
32 X2 1 2 3 4 5 6 7 8
J_X
W22 P D M E N + - G - T 6 6 6 3 3 3
J_M J_CAN
W22
FCU
6 J 1 U
W20
P144309X2
1 2
33 U1
1 2 3
6 5 4 3 2 1
J_PWR
12
J6 J7 SW2SW1
1 2
J12
4 5 6
U1-J2-2 U1-J2-1
7
5
X1-J_FAULT-2 X1-J_FAULT-1
3
J3 J10
8
X1-J_FAULT-6 X1-J_FAULT-5 X1-J_FAULT-8 X1-J_FAULT-7
Temperature sensor II 36 T2
18
Appendix 2 Wiring Diagram
18
6 MJ
Door sensor
120A J_TEMP
P144309X1
X1-J_DOOR1-1
31
J_Z
3
1
X1
1 2
2
W17
2
X1-J_DOOR1-2
1 1 6 4
J_BMV
J_232
3 2
8
9
1
7 5 6
J_X
J_I
5
W17
2
J_DOOR1
1
4 1
2 3
J_RLY
W01 46-1 W01 46-3
46-2 W01 46-4
W01 46-5
46-6 W01
6-2 6-1 28
29
FAN1
FAN2
Fan 1
Fan 2
1
2
6 8
U1-J3-7 U1-J3-8 U1-J3-5 U1-J3-6
5 4 3
J_CTRL
1 6
1
J_MFAIL
2
1
W01
1 5
2 3
2
2
50 FAN4
Fan 3
Fan 4
5 4
U1-J3-1 U1-J3-2
1
1
J_FAULT
7 6
30 FAN3
5
3
4
2
3
1
2
FAN1
3 4 9 0
FAN2
FAN3
FAN4
1
W20
B
W23
W23
32 X2 1 2 3 4 5 6 7 8
J_X
W22 P D M E N G T + - 6 - 6 6 3 3 3
J_M
1 2 3
Temperature sensor II
6 J 1 U
36 T2
12
J6 J7
6 5 4 3 2 1
J_PWR
J_CAN
W22
FCU W20
P144309X2
1 2
33 U1
SW2SW1
1 2
J12
4 5 6
U1-J2-2 U1-J2-1
7
5 4 3 2 1
W11
X1-J_FAULT-2 X1-J_FAULT-1
3
J3
8
J10
X1-J_FAULT-6 X1-J_FAULT-5 X1-J_FAULT-8 X1-J_FAULT-7
J11 2 1
J2
8 7 6 5 4 3 2 1
J _ Z 3 4 9 0
4 - 3 R R
W W P P _ _ J - J 2 2 X X
B
W11 46 XT2
W01 7 Y L R J 1 3
8 Y L R J 1 3
1
2
0 9 - 1 Y Y L L R - R J - J 1 1 3 3
3
Dry contact output terminal block
3 1 Y L R J 1 3
4 1 Y L R J 1 3
5
6
4
7
Note: 1. Configure W23 cables according to actual configuration. 2. Connect cables according to actual configuration
8
Figure 2 Wiring diagram (2) Note: FCU is fan control b oard.
EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual
Appendix 2 Wiring Diagram + 4 T T A B 6 2
150A subrack Front view
DU power distribution unit 33-J2-1 2
0V
+ 3 T T A B 6 2
+ 1 T T A B 6 2
DU
2 2 J 3 31
1 T T A B 6 2 1 F Q 8
2 9
2 W / 8 2
1
2
2 F Q 8
9 2 W / 8 2
1
2
3 F Q 8
9 2 W / 8 2
1
2
4 F Q 8
9 2 W / 8 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W
W
W
W
1
2
5 F Q 8
9 2 W / 8 2
1
1
2 9
6 F Q 8
1
7 F Q 8
2 9
8 F Q 8
2 9
1
9 F Q 8
2 9
AC project 2
0 1 1 F Q 8
2 W / 8 2
9 2 W / 8 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W
W
W
W
W
W
2 W / 8 2
2 W / 8 2
2 W / 8 2
PL
2
1 1 1 F Q 8
9 2 W / 8 2
2
2 1 1 F Q 8 9 2 W / 8 2
2
3 1 1 F Q 8
9 2 W / 8 2
4 1 1 F Q 8
2
9 2 W / 8 2
for3p+N+PE/380V AC input
3
5
W / 7 2
W / 8 2 W / 7 2
W
W
W
W
W
W
2
7 1 F
Q 8 9 2 W / 8 2
1
2
8 1 1 F Q 8
9 2 W / 8 2
2
9 1 1 F Q 8
9 2 W / 8 2
2
0 1 2 F Q 8
9 2 W / 8 2
1 1 2 F Q 8
2 2 9
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W / 8 2 W / 7 2
W
W
W
W
W
2
2
W / 7 2 W
50 FAN4
Fan 3
Fan 4
3
Fan 1
Fan 2
W23
W23
46 XT2 W 1 7 W 1 7 W 1 2 W 1 2W03W03
PE 1 - 2 6 6
2 - 3 2 - 2 2 2 J - J 3 3
W22
1 - 2 3 3 J - J 9 9 4 4
W22
L
6 1
1
2
3
4
Note: W03_A for Europen and British standard. W03_B for American standard socket. W03_C for Chinese standard socket. 1
5
6
7
8 P M D E N + - T - G 6 6 6 3 3 3 NO 1 2 3
6 5 4J12 3 2
J6 SW2SW1
2 3
PE bar in cabinet
5 4 3J11 2
Temperature sensor II
6 J 1 U
33 U1
49 T2
FCU
FCUX 49 U2
W02
1 2
J7
J3
1
45 PE BUS
30 FAN3
W03
5
4
29 FAN2
28 FAN1
W03
E P 1
L=320mm
Front cross door line
9 2 W / 8 2
Dry contact output terminal block
N 1
W02 46-2
2 2 F Q 8
L=270mm
Back cross door line
J2
W03
AC socket
2
W17
2
5-L
N
W02
W12
8
5-N
MS
9 XT
8 XT
3 - 4 6 6 4 4 1
N Bar
W02
46-1 1
2 T T A B 6W12 2
User port board
7
6
1
6 MJ
Door sensor
NPL
PEbar 4
6 1 F Q 8
9 2 2
W / 7 2
QF1 2
1
W / 7 2
W24C3 X1
L1 L2 L 3 N 1
9 2 W / 8 2
W / 7 2
PL
1 ACIN
5 1 F Q 8
2
W / 7 2
3
E P 5
+ 2 T T A B 6 W12 2
J10
1 2 3 4 5 6 7 8
8
8 7
7 6
6 5 4
J2
3 2
2
5 4 3 2
46-6
1
1
W01
J3
46-5
J1
W03
19
Appendix 2 Wiring Diagram + 4 T T A B 6 2
150A subrack Front view
DU power distribution unit 33-J2-1 2
0V
+ 3 T T A B 6 2
+ 1 T T A B 6 2
DU
2 2 J 3 31
1 T T A B 6 2 1 F Q 8
2 9
2 W / 8 2
1
2
2 F Q 8
1
2
9 2 W / 8 2
3 F Q 8
9 2 W / 8 2
1
2
4 F Q 8
9 2 W / 8 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W
W
W
W
1
2
5 F Q 8
9 2 W / 8 2
1
1
2 9
6 F Q 8
1
7 F Q 8
2 9
8 F Q 8
2 9
1
9 F Q 8
2 9
AC project 2
0 1 1 F Q 8
2 W / 8 2
9 2 W / 8 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W
W
W
W
W
W
2 W / 8 2
2 W / 8 2
2 W / 8 2
PL
2
1 1 1 F Q 8
9 2 W / 8 2
2
2 1 1 F Q 8 9 2 W / 8 2
2
3 1 1 F Q 8
9 2 W / 8 2
4 1 1 F Q 8
2
9 2 W / 8 2
for3p+N+PE/380V AC input
3
5
W / 7 2
W / 8 2 W / 7 2
W
W
W
W
W
W
2
7 1 F
Q 8 9 2 W / 8 2
8 1 1 F Q 8
1
9 2 W / 8 2
2
2
9 1 1 F Q 8
9 2 W / 8 2
2
0 1 2 F Q 8
9 2 W / 8 2
46-1 1
2 T T A B 6W12 2 1 1 2 F Q 8
2 2 9
W / 7 2
W / 7 2
W / 7 2
W / 7 2
W / 8 2 W / 7 2
W
W
W
W
W
2
2
W / 7 2 W
Fan 1
W23
1 - 2 6 6
2 - 3 2 - 2 2 2 J - J 3 3
W22
1 - 2 3 3 J - J 9 9 4 4
W22
L 1
6 1
2
3
4
5
6
7
P M D E N + - T - G 6 6 6 3 3 3
J7
J3
1
2 3
J10
5 4 3J11 2 1
PE bar in cabinet
12
1 B Q 2
V O 2
1# BATT
8 7 6
8 7 6 5 4 3
J3
J2
2 1
W 12 2 B Q 2
V O 2
2# BATT
Figure 3 Wiring diagram (3) Note: FCU is fan control b oard. FCUX is fan control extension board.
EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual
Appendix 3
Schematic Diagram
Appendix 3 Schematic Diagram Fan-cooling unit Project 1
BLVD
FCU+4 Fan QF 1
FCU L O R T N O C
Project 2
FCU+FCUX+4 Fan
Fan fault alarm FCUX QF
M R A L A
2 L O R T N O C
3
M R A L A
L O R T N O C
M R A L A
46-6
W03
J2
Note: 1. Find out the PL label or 10A MCB between PL and PL, then follow the figure to connect power cables of the FCU. 2. Connect cables according to actual corfiguration.
20
4 3
46-5
J1
W11
W12
5
2 1
2 1
V 8 V 4 - 0 2 2
26 BATT
W 12
1 2 3 4 5 6 7 8
W01
6
FCUX 49 U2
W02
1 2
1 2 3
J6 SW2SW1
49 T2
FCU
NO
6 5 4J12 3 2
Temperature sensor II
6 J 1 U
33 U1
8
1
W12
Fan 4
W23
W 1 7 W 1 7 W 1 2 W 1 2W03W03
Note: W03_A for Europen and British standard. W03_B for American standard socket. W03_C for Chinese standard socket.
5
Fan 3
Fan 2
46 XT2
PE
45 PE BUS
50 FAN4
W03
5
4
30 FAN3
3
Dry contact output terminal block
N 1
29 FAN2
28 FAN1
W03
E P 1
L=320mm
Front cross door line
9 2 W / 8 2
J2
W03
AC socket
W02 46-2
2 2 F Q 8
L=270mm
Back cross door line
2
5-L
N
2
W12
8
5-N
MS
W02
3 - 4 6 6 4 4 1
N Bar
W02
9 XT
8 XT
W17
User port board
7
6
1
6 MJ
Door sensor
NPL
PEbar 4
6 1 F Q 8
9 2 2
W / 7 2
QF1 2
1
W / 7 2
W24C3 X1
L1 L2 L 3 N 1
9 2 W / 8 2
W / 7 2
PL
1 ACIN
5 1 F Q 8
2
W / 7 2
3
E P 5
+ 2 T T A B 6 W12 2
L O R T N O C
M R A L A
19
20
Appendix 3
Schematic Diagram
Appendix 3 Schematic Diagram Fan-cooling unit Project 1
FCU+4 Fan QF
BLVD
1
FCU L O R T N O C
Project 2
2 L O R T N O C
M R A L A
3
M R A L A
L O R T N O C
M R A L A
L O R T N O C
M R A L A
FCU+FCUX+4 Fan
Fan fault alarm FCUX BLVD
QF 1
3
2
FCU L O R T N O C
L O R T N O C
M R A L A
M R A L A
L O R T N O C
M R A L A
L O R T N O C
Note: Fan number: 2 ~ 4, optional. Figure 4 Fan-cooling unit schematic diagram Note: FCU is fan control board. FCUX is fan control extension board. AC power distribution u nit Project 1 QFA2
QFA3
XS L N
PE
Project 2 QFA2
QFA3
XS L N
PE
Note: 1. QF3 in the project 1 is a l eakage MCB. 2. QF3 in the project 2 is a general MCB. 3. XS mainterance socket: four standards, optional. Figure 5 AC power distribution unit schematic diagram
M R A L A
