Installaton Manual FPRA

1

Flexi Power Rectifier Installation Manual

Emerson Network Power Co., Ltd. http://www. emersonnetworkpower.com.cn Manual Version: 03

Flexi Power Rectifier

Installation Manual

2

Manual Number: 03370500070 Manual Issue: 03 Manual Status: Standard Release Date: Mar 2009

Copyright © 2009 Emerson Network Power Co., Ltd. All rights reserved Published in China This document, and the information it contains, are the property of Emerson Network Power Co., Ltd, and are protected by law. Both must be held in strictest confidence at all times. Emerson Network Power grants no license or right to copy, use or disclose either, expressly or by implication.

Disclaimer This document and the information contained herein are provided on an "AS IS" basis. Emerson Network Power may make improvements or changes in this documentation, at any time and without notice and as it sees fit. The information in this documentation was prepared by Emerson Network Power with reasonable care and is believed to be accurate. However, Emerson Network Power shall not assume responsibility for losses or damages resulting from any omissions, inaccuracies, or errors contained herein.


Installation Manual

History 3

History Date

Version

Author

Change Note No./Notes

02/09/2008 01

David Cao

First release

20/10/2008 02

David Cao

Correct Section 2.4 Table 13 Ethernet Cable Emerson part number Add note in section 3.4 for end user must have disconnect device Update caution in section 3.4 for size requirements for L, N and PE cable from AC mains Add note in section 3.9 for parallel operation supported CU firmware version Update fig95, fig100 in section 3.9 to match the actual parallel cable Update fig105, fig109, fig110, fig112, fig113, fig114, fig115, fig116 to match the newest GUI

18/03/2009 03

David

Update all the pictures in section 3.3 to show the latest drawer design Update the parallel configuration with more details in section 3.9 Add a new paragraph to show setup of master/ slave FPRA unit in a parallel system Add fig101, fig112 to show single battery in parallel configuration Add table22 and table23 of rectifier and system alarm indications Add string polarity marks in fig21 and fig22


Installation Manual

Table of contents

4

Table of contents History...................................................................................................................3 Table of contents ..................................................................................................4 List of figures ........................................................................................................5 List of tables..........................................................................................................9 List of terms ........................................................................................................10 Preface ...............................................................................................................12 Chapter 1 Product Introduction .........................................................................15 1.1 General Description...............................................................................15 1.2 The Power Distribution Assembly (PDA) ...............................................22 1.3 The Rectifier ..........................................................................................26 Chapter 2 Preparation.......................................................................................29 2.1 Safety Summary ....................................................................................29 2.2 Installation site.......................................................................................31 2.3 Installation tools and test equipments....................................................32 2.4 Check list of the FPRA ..........................................................................33 Chapter 3 Hardware Installation........................................................................37 3.1 Detach the PDA from the case ..............................................................37 3.2 Route the DC cables .............................................................................44 3.3 Route the Communication cables..........................................................62 3.4 Route the AC cable without the SPD.....................................................78 3.5 Install the PDA into case .......................................................................96 3.6 Install the rectifiers...............................................................................101 3.7 Installation of the cables with cable glands..........................................105 3.8 Install the front and back covers ..........................................................110 3.9 Parallel installation of the FPRA ..........................................................112 Chapter 4 Browser and Control Unit Setup.....................................................131 4.1 Set up the configuration environment ..................................................132 4.2 Change the CU IP-address via the LCD..............................................133 4.3 Connect to the GUI in local Internet / Intranet .....................................133 4.4 Change the CU IP-address via the GUI...............................................135 Chapter 5 Commissioning...............................................................................141 5.1 Set up a commissioning environment..................................................142 5.2 Battery input commissioning................................................................143 5.3 Set up the system parameters.............................................................145 5.4 AC input commissioning ......................................................................147 Chapter 6 Maintenance...................................................................................148 Chapter 7 Troubleshooting .............................................................................149


Installation Manual

List of figures 5

List of figures Figure 1 – Output power-derating characteristic .................................................18 Figure 2 – The schematic diagram of the FPRA .................................................21 Figure 3 – General view of the FPRA .................................................................21 Figure 4 – Back view of the FPRA ......................................................................22 Figure 5 – General view of the PDA....................................................................24 Figure 6 – The front panel of the PDA ................................................................25 Figure 7 – General view of the rectifier ...............................................................27 Figure 8 – Product tree .......................................................................................33 Figure 9 – The FPRA before the installation .......................................................37 Figure 10 – Detaching the cable glands..............................................................38 Figure 11 – Releasing the PDA earth cable........................................................38 Figure 12 – Releasing the RS485 cables............................................................39 Figure 13 – Detaching the PDA from the case....................................................39 Figure 14 – Cable gland configuration – option1 ................................................41 Figure 15 – Cable gland configuration – option2 ................................................42 Figure 16 – Cable gland configuration – option3 ................................................43 Figure 17 – Inserting the cable through the cable gland .....................................44 Figure 18 – Removing the drawer from the PDA ................................................45 Figure 19 – Removing the front panel from the PDA ..........................................45 Figure 20 – Removing the sub cover from the PDA............................................46 Figure 21 – DC terminals distribution..................................................................47 Figure 22 – DC inlet grommet.............................................................................47 Figure 23 – Removing the load terminals short link and MCB switch lever bar ..49 Figure 24 – Removing the battery terminals short link and MCB switch lever bar .....................................................................................................................49 Figure 25 – Inserting the DC load grounding cable through the front panel........52 Figure 26 – Securing the DC load grounding cable ............................................53 Figure 27 – Connecting the DC cables – configuration option1 (typical).............54 Figure 28 – Connecting the DC cables – configuration option2 ..........................55 Figure 29 – Connecting the DC cables – configuration option3 ..........................56 Figure 30 – Putting the front panel back into the PDA ........................................57 Figure 31 – Securing the front panel...................................................................58 Figure 32 – Securing the window of the breakers ...............................................59 Figure 33 – Fixing the DC cables to the front panel ............................................60 Figure 34 – Securing the sub cover ....................................................................61 Figure 35 – Drawer internal layout (old version) .................................................62 Figure 36 – Drawer internal layout (updated version) .........................................63 Figure 37 – Inserting the temperature cable into drawer (old version) ................64


Installation Manual

List of figures 6 Figure 38 – Inserting the temperature cable into drawer (updated version)........64 Figure 39 – Connecting the temperature cable only (old version).......................66 Figure 40 – Connecting the temperature cable only (updated version)...............66 Figure 41 – Placing the temperature probe.........................................................67 Figure 42 – Connecting the parallel cable only – From PSU (old version)..........69 Figure 43 – Connecting the parallel cable only – From PSU (updated version)..69 Figure 44 – Connecting the parallel cable only – To PSU (old version) ..............70 Figure 45 – Connecting the parallel cable only – To PSU (updated version)......70 Figure 46 – Connecting the Alarm In cable only (old version).............................73 Figure 47 – Connecting the Alarm In cable only (updated version) ....................73 Figure 48 – Connecting the Alarm Out cable only (old version)..........................74 Figure 49 – Connecting the Alarm Out cable only (updated version)..................74 Figure 50 – Fixing all the communication cables (old version)............................75 Figure 51 – Fixing all the communication cables (updated version) ...................76 Figure 52 – Putting the drawer back into the PDA ..............................................77 Figure 53 – Securing the drawer to the PDA ......................................................77 Figure 54 – Removing the rear cover..................................................................78 Figure 55 – The PDA rear internal chassis layout...............................................79 Figure 56 – The AC cable connection chart........................................................80 Figure 57 – AC terminal block configuration – 1ĭ ..............................................81 )LJXUH±$&WHUPLQDOEORFNFRQILJXUDWLRQ±ǻ Figure 59 – AC terminal block configuration – 3Y ...............................................83 Figure 60 – Inserting the AC cable through the front panel.................................84 Figure 61 – Schematic diagram of AC connection without the SPD – 3Y ...........86 Figure 62 – Detaching the Strain-relief from the chassis ....................................86 Figure 63 – Connecting the PE cable from the AC mains – 3Y ..........................87 Figure 64 – Connecting the L and N line cables to the AC terminal block – 3Y ..88 Figure 65 – Fixing the AC ground clamp back onto the chassis – 3Y .................89 Figure 66 – Fixing the AC terminal block back onto the chassis – 3Y.................90 Figure 67 – Restraining the AC mains cable onto the chassis – 3Y....................91 Figure 68 – AC connection without the SPD – 3Y...............................................92 Figure 69 – Schematic diagram of AC connection without the SPD – 1ĭ...........93 Figure 70 – AC connection without the SPD – 1ĭ ..............................................93 )LJXUH±6FKHPDWLFGLDJUDPRI$&FRQQHFWLRQZLWKRXWWKH63'±ǻ )LJXUH±$&FRQQHFWLRQZLWKRXWWKH63'±ǻ Figure 73 – Securing the rear cover back to the PDA.........................................95 Figure 74 – Putting the PDA back into the case .................................................96 Figure 75 – Securing the PDA to the case..........................................................97 Figure 76 – Connecting the PDA earth cable to the case ...................................98 Figure 77 – Connecting the system earth cable..................................................99 Figure 78 – Connecting the Ethernet cable.......................................................100 Figure 79 – Putting the rectifier into the first slot of the case ............................101 Figure 80 – Securing the rectifier to the case ...................................................102


Installation Manual

List of figures 7 Figure 81 – Connecting the AC power cable to the rectifier..............................103 Figure 82 – Connecting the RS485 cables to the rectifier.................................104 Figure 83 – Installing the other rectifiers ...........................................................104 Figure 84 – Alarm cable exits from top of the case ...........................................105 Figure 85 – Installing the two cable glands .......................................................106 Figure 86 – Fixing the cables to the cable gland...............................................106 Figure 87 – Fixing the AC cable to the side of the case....................................107 Figure 88 – Fixing the cables to the case sidewall............................................108 Figure 89 – Fixing the PDA earth cable ............................................................108 Figure 90 – Cables exit from right of the FPRA ................................................109 Figure 91 – Cables exit from left of the FPRA...................................................109 Figure 92 – Cables exit from both sides of the FPRA .......................................109 Figure 93 – Installing the front cover to the FPRA ............................................110 Figure 94 – Installing the back cover to the FPRA ............................................110 Figure 95 – General view of the FPRA – cables run from right.........................111 Figure 96 – General view of the FPRA – cables run from left ...........................111 Figure 97 – General view of the FPRA – cables run from both sides................111 Figure 98 – Serial number of the FPRA unit .....................................................113 Figure 99 – Master/slave definition of FPRA units in parallel............................113 Figure 100 – Current flow of two battery blocks in parallel................................115 Figure 101 – Example of a parallel configuration – 2 FPRAs & 1 BAT .............116 Figure 102 – Example of a parallel configuration – 2 FPRAs & 4 BATs............117 Figure 103 – Example of a parallel configuration – 2 FPRAs & 6 BATs............118 Figure 104 – The locating points on the FPRA .................................................119 Figure 105 – Stacking the two FPRA units .......................................................120 Figure 106 – Fixing the two FPRA units............................................................120 Figure 107 – Parallel cable configuration within the two drawers .....................121 Figure 108 – Paralleling the two drawers (old version) .....................................122 Figure 109 – Paralleling the two drawers (updated version) .............................122 Figure 110 – Installing the two FPRA units .......................................................123 Figure 111 – General view of the two FPRA units in parallel ............................124 Figure 112 – Example of a parallel configuration – 3 FPRAs & 1 BAT .............125 Figure 113 – Example of a parallel configuration – 3 FPRAs & 5 BATs............126 Figure 114 – Example of a parallel configuration – 3 FPRAs & 9 BATs............127 Figure 115 – Parallel cable configuration within the three drawers ...................128 Figure 116 – Paralleling the three drawers (old version)...................................129 Figure 117 – Paralleling the three drawers (updated version) ..........................129 Figure 118 – General view of the three FPRA units in parallel .........................130 Figure 119 – Setting up the configuration environment.....................................132 Figure 120 – Login the GUI...............................................................................134 Figure 121 – The GUI home page (1) ...............................................................135 Figure 122 – Local Are Connection – Properties ..............................................136 Figure 123 – Internet Protocol (TCP/IP) – Properties .......................................137


Installation Manual

List of figures 8 Figure 124 – Allocate secure IP-Address..........................................................138 Figure 125 – The GUI home page (2) ...............................................................139 Figure 126 – Setting up the CU IP-address ......................................................140 Figure 127 – Commissioning configuration of the FPRA ..................................143 Figure 128 – Commissioning of the battery input..............................................144 Figure 129 – Battery related settings via GUI ...................................................145 Figure 130 – System related settings via GUI...................................................146 Figure 131 – Time settings via GUI...................................................................146 Figure 132 – Commissioning of the AC input....................................................147


Installation Manual

List of tables 9

List of tables Table 1 – Contents of this manual ......................................................................12 Table 2 – Symbols in the Installation Manual......................................................13 Table 3 – Reference documents of the FPRA ....................................................13 Table 4 – Main specifications of the FPRA .........................................................15 Table 5 – Applicable rated input voltage types of the FPRA ...............................16 Table 6 – Main voltages and the corresponding EAC alarms .............................17 Table 7 – Static data of the DC output ................................................................19 Table 8 – EAC alarm settings .............................................................................23 Table 9 – LEDS on the PDA front panel .............................................................26 Table 10 – LEDS on the rectifier front panel .......................................................28 Table 11 – Term and Symbols in this manual.....................................................30 Table 12 – Symbols on the FPRA.......................................................................30 Table 13 – Delivery contents by FPRA ...............................................................34 Table 14 – Three typical battery / load cables configurations .............................50 Table 15 – Flow chart of securing the front panel ...............................................58 Table 16 – Flow chart of securing the sub cover.................................................60 Table 17 – The connection of the temperature cable..........................................65 Table 18 – The connection of the parallel cable .................................................68 Table 19 – The connection of the Alarm cable....................................................72 Table 20 – Recommended preparation for AC mains cable ...............................85 Table 21 – Flow chart of securing the rear cover ................................................95 Table 22 – Rectifier alarm indications ...............................................................150 Table 23 – System alarm indications ................................................................153 Table 24 – Failures likely to happen .................................................................156


Installation Manual

List of terms 10

List of terms A

Ampere

AC

Alternative current

AWG

American Wire Gauge

BAT

Battery

BR

Battery Return

BTS

Base Transceiver Station

°C

Temperature in degrees Celsius

CSA

Cross Section Area

CU

Control unit

DC

Direct current

EAC

External Alarm and Control

EMC

Electromagnetic Compatibility

ESD

Electrostatic Discharge

FPRA


GND

Ground

GUI

Graphical User Interface

IE

Internet Explorer

IP

Ingress Protection

IP

Internet Protocol

L

Live cable from the AC mains

LAN

Local Area Network

LED

Light Emitting Diode

LVD

Low Voltage Detection

MAC

Media Access Control

MCB

Micro Circuit Breaker


Installation Manual

List of terms 11 N

Neutral cable from the AC mains

N/A

Not applicable

PC

Personal Computer

PCB

Printed Circuit Board

PDA

Power Distribution Assembly

PE

Protective earth

PSU

Power Supply Unit

RTN

Return

S/N

Serial Number

SPD

Surge Protect Discharge

V

Volt

VPN

Virtual Private Network

1ĭ

Single-phase AC type

3Y

3-phase star AC type

ǻ

3-phase delta AC type


Installation Manual

Preface 12

Preface About this manual This manual guides the user on how to install the FPRA, including the hardware installation, the browser and CU setup. The manual also introduces the FPRA as well as its commissioning, maintenance and troubleshooting. The contents of this manual are listed in Table 1. Table 1 – Contents of this manual

Chapter

Title

Content

1

Product instruction

Describes the specifications, properties, mechanical data, etc. of the FPRA and the modules it contains.

2

Preparation

Describes the installation safety, site, and tools.

3

Hardware installation

Describes how to install the AC cables, DC cables, communication cables, parallel installation, etc. of the FPRA.

4

Browser and CU setup

Describes how to set the browser and CU, and access the GUI.

5

Commissioning

Describes how to commission the FPRA after the installation.

6

Maintenance

Describes how to maintain the FPRA.

7

Troubleshooting

Describes how to solve the detected issues of the FPRA.


Installation Manual

Preface 13

Term and Symbols in this manual These term and symbols in Table 2 might appear in the manual: Table 2 – Symbols in the Installation Manual

Symbol

Description Safety symbol, see Safety summary Safety symbol, see Safety summary Provides hints to the user for easier installation, maintenance and troubleshooting The necessary supplementary of the article to let user be clearer.

Reference documents The documents of the FPRA contain: Table 3 – Reference documents of the FPRA

Emerson Network Power

Document

File No.

Internal product specification – System / PDA

41970005110

Internal product specification – Rectifier

41970004980

Surge Protect Discharge for Flexi Power Rectifier – User Manual

03370500080

Flexi Power Rectifier - User Manual

03370500090

Flexi Power Rectifier - Installation Manual (This manual)

03370500070

- To be continued -


Installation Manual

Preface 14

Table 3 – Reference documents of the FPRA

Surge Protect Discharge for Flexi Power Rectifier – Quick Start Guide

03370500100

Flexi Power Rectifier – Quick Start Guide

03370500110


Installation Manual

Product Introduction 15

Chapter 1 Product Introduction 1.1 General Description The FPRA is a 6kW output power AC rectifier package made up of three individual 2kW AC/DC power modules operating in a parallel mode configuration. The FPRA outputs a positive earthed –54VDC (V48N) as a respective BTS operational supply voltage rail and for site battery charging. It also includes a Power Distribution Assembly (PDA), which has a fully integrated battery protection LVD, load / battery circuit breakers, battery current shunt and alarm signals to the BTS EAC interface.

1.1.1 Specification x Main specifications Table 4 – Main specifications of the FPRA

Parameter

Specification

Description

Min

Nom

Max

Rated AC input voltage (VAC)

180

--

276

See Table 5

DC

Nominal Vout (VDC)

-56

-54

-52

See Table 7

Iout (ADC)

0

--

109.9

See Table 7

Operation

-40

23

55 (1)

Max output 6kW

Storage

-45

--

+45

Start up

-40 (2)

--

--

Output

Ambient temperature (°C)

Max output 6kW

Note: (1) The power supply unit is fully compliant with the operational and power output requirements outlined within the Product Specification at the maximum ambient temperature 55°C (plus solar load).


Installation Manual

Product Introduction 16 (2) At -40°C external ambient start up and after a period of 15minutes operation, the FPRA is fully compliant with the operational and power output requirements outlined within the Product Specification. Battery is disconnected from the –48V power supply during the FPRA cold-start at -40°C.

x AC input The rated input voltage of the FPRA is 180~276VAC (200~230 VAC – 10%/+20%). The rectifiers can be connected as single-phase 230 VAC inputs or as 400 VAC (phase to phase) 3-phase Star or as 200 VAC (phase to phase) 3-phase Delta. Table 5 shows the various rated inputs that the FPRA are applicable and allowed for. Table 5 – Applicable rated input voltage types of the FPRA

VAC / V (Nominal)

VAC / V (Range)

Frequency / Hz

Supply Network Type

240

180 – 276

45 – 66

US Single phase; threewire; earthed mid point of phase

230

180 – 276

45 – 66

Europe Single Phase

208 Phase to Neutral

180 – 276

45 – 66

US 3-phase star; four wire; earthed neutral

240 Phase to Phase

180 – 276

45 – 66

US 3-phase delta; fourwire; earthed mid point of phase

202 Phase to Phase

180 – 276

45 – 66

Japanese 3-phase delta

230 Phase to Neutral

180 – 276

45 – 66

European 3-phase star; four wire; earthed neutral)

The FPRA is designed to operate with extended operation input main voltage, at the low range between 90 ~180 VAC (with derated output power, see Figure 1) and at upper range between 276~310 VAC. The FPRA accepts, without damage, single phase AC input voltage of up to 350VAC at frequency of 45~66Hz, for a duration of up to 60s.


Installation Manual


Table 6 – Main voltages and the corresponding EAC alarms

VAC / V

Status

EAC alarm

<85

Low mains voltage – Rectifier shutdown

Yes (2)

90 ~ 180 (-5) (1)

180 ~ 276

Mains phase failure (3) #1 / #2 / #3

Operational – extended and low mains voltage range

Yes

Rated operation

No (2)

Minor (3)

Refer to Table 5 277 (+5) ~ 310

Operational – extended and Yes high mains voltage range Minor (3)

>315 (±5)

Over mains voltage

Yes

– Rectifier Shutdown

Major (3)

Note: (1) Here indicates the 180 VAC has a –5 VAC tolerance. (2) “Yes” / ”No” means the PDA sends /not sends the EAC alarm. The illustration is available for all same expressions in this table. (3) Refer to Table 8 for the detailed EAC alarms.


Installation Manual


Figure 1 – Output power-derating characteristic Note: N+1 (failure) defines the condition that one of the three rectifiers has failures, and only two rectifiers operate normally to support the load.

x DC output The –54VDC output, here referred to as V48N, is with respects to V48RTN (positive) which is grounded within the FPRA. See Table 7 for more details about the DC output.


Installation Manual


Table 7 – Static data of the DC output

Parameter

Spec

Description

-54± 2(1)

Nominal output voltage

-57~-45

Output voltage range

Output Voltage (VDC) Factory Output Voltage set point (VDC)

-53.3±0.6 Factory default setting at +27°C

Line regulation

<1%

For a load from Minimum to Maximum at +27°C

Minimum Hold Up (ms)

20

For a load from Minimum to Maximum

Current Limit (ADC)

+10%

@ Maximum output 6kW

OVP Limit (VDC)

58.5 ±1.0 Factory set

Output Low Voltage Alarm (VDC)

40±0.5

Ripple & noise (mV)

300 6

Max Output power (kW) 6 ~ 4.5 Minimum Output power (kW)

--

Efficiency

>90%

Factory set Max output 6kW, -10~+55°C (plus solar load) (2) -40°C ~+55°C (plus solar load) 6kW derating to 4.5kW @ &SOXVVRODUORDG ĺ& No minimum load limitation Nominal AC input range, Max output 6kW

Note: (1). The values in the table shall be met for all input voltages and frequencies within the rated and extended input ranges, and all valid output load conditions. (2). Maximum output ripple voltage at -40°C start up shall not be greater than 4% of the FPRA output voltage factory set point –54.6V during the 15 minutes warming up period.


Installation Manual


1.1.2 Properties The FPRA has the following properties: x High-integrated power system. The FPRA integrates the rectifiers, the AC and DC distribution, and supervisor and communication functions. x Modularized design. The modularized design of the FPRA leads to easier installation, maintenance and troubleshooting. x Flexible applications. The FPRA supplies the user with a varied output power of 2/4/6kW by means of installing 1/2/3 rectifier modules. Also the 3 battery back-up channels and 2 load channels of the FPRA provides the user with flexible battery and load applications. x Variable AC power connections. The FPRA can be used with different AC power types mentioned in Table 5 by means of reconfiguring the internal AC terminal block. x Easy to control. The user can control and supervise the operation of the FPRA via the GUI after connecting the FPRA to a user PC. x IP54/55 The FPRA is IP54 rated and IP55 rated when fitted with front and rear covers. The FPRA comprises of one PDA and one to three identical 2kW rectifiers working in a parallel mode. The schematic diagram of the FPRA is as shown in Figure 2.


Installation Manual


/2$'V

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3'$ $&

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0&8 5(& 56

5-

56

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)35$ Figure 2 – The schematic diagram of the FPRA

Figure 3 presents the general view of the FPRA with the cables breaking out from the system right side. Depending on the field application, all the cables can break out from left or right or both sides of the FPRA.

Figure 3 – General view of the FPRA

The FPRA has a dimension of 475.0 X 504.0 X 128.7 (W X D X H) mm. Figure 4 shows the back view of the FPRA after installing all the rectifiers.


Installation Manual


Fan

Guiding pole

AC cable

Figure 4 – Back view of the FPRA

1.2 The Power Distribution Assembly (PDA) The Power Distribution Assembly (PDA) is the internal power distribution assembly of the FPRA. It has the following properties: x AC power distribution. The PDA supplies the rectifiers with three AC input power system types, as listed in Table 5 by using a different configuration of the internal AC terminal block connections. x DC power distribution. The rectifiers are all connected directly to a DC bus bar internal to the PDA. The three battery back-up channels and two load channels are connected to the DC bus bar through the internal micro circuit breakers (MCB). Each breaker is rated to 63A. x Battery control function. The PDA carries out an automatic battery test periodically by the control unit (CU), and records the last 10 battery test data including the test date, discharge current and time, test end voltage, battery temperature, discharged Ampere-hours, etc. The batteries will stop discharging and disconnect from the loads once the battery voltage is below the “LVD” set point. The user can set the batteries charge voltage level to commensurate with the batteries in field, and set the Low Voltage Detection (LVD) voltage


Installation Manual

Product Introduction 23 level to disconnect the batteries from the loads to under deep discharging condition. x Supervisor of the FPRA. The PDA has a built-in MCU to monitor the status of the rectifiers and batteries such as voltage, current and temperature, etc., and display the corresponding data through the LCD and LEDS. The PDA also supplies 6 isolated and floating EAC alarms for the BTS. Table 8 – EAC alarm settings

EAC alarm

Description

Main phase #1

Mains phase failure indicates any single phase voltage of the 3-phase FPRA power source configuration that is below 85VAC

Main phase #2 Main phase #3 Critical

xBattery low voltage xPDA controller fail xDC distribution failure (e.g. breaker failure)

Major

xBattery failure xRectifier fail xHigh float voltage

Minor

xBattery temperature High/Low xRectifier temperature High xRectifier over current xConfiguration change xExtended and high mains voltage range (refer to Table 6) xExtended and low mains voltage range (refer to Table 6)

x Network connection based on LAN. The PDA can be connected to a user PC via the internal RJ45 interface. The user can monitor the whole system via a web-based GUI.


Installation Manual

Product Introduction 24 The PDA has a dimension of 176.2 X 364.0 X 102.0 (W X D X H) mm. Figure 5 shows the general view of the PDA before the installation. (1)

(3)

(4)

(6)

(5)

(10)

(2)

(7)

(9)

(8)

(1) Rear cover (2) Sub cover (3) Restricted area (4) BR bus bar (5) –54V bus bar (6) Front panel (7) Drawer (8) RS 485 cable (9) Window of the breakers (10) PE of the PDA Figure 5 – General view of the PDA


Installation Manual

Product Introduction 25 Figure 6 shows the front panel of the PDA. (3)

(4)

(5)

(6)

(7)

(2) (1)

(11) (10) (9)

(8)

(13)

(14)

(12)

(15)

(1) LCD (2) Red LED (3) Yellow LED (4) Green LED (5) Up button (6) Middle button (7) Down button (8) AC cable inlet (9) Alarm Out (10) Alarm In (11) To PSU (12) From PSU (13) Temperature (14) Ethernet interface (15) DC grommet Figure 6 – The front panel of the PDA


Installation Manual

Product Introduction 26 The LEDS on the PDA front panel will have any of the status listed in Table 9. Table 9 – LEDS on the PDA front panel

LED Mark

Status

Indication xFault

F/MA / Red

ON

M/MA / Yellow

ON

SYSOK / Green

ON

All LEDS

Turn on simultaneously and turn off after about 20 seconds

xMajor EAC alarm (refer to Table 8) xMains / phase failure (refer to Table 8) xMessage xMinor EAC alarm (refer to Table 8) System OK

System initialization

1.3 The Rectifier The FPRA supports the operation of up to three rectifiers in parallel. Each rectifier is an AC/DC module, which meets the specifications listed in Table 5 and Table 7. The rectifier has the following properties: x High efficiency. The rectifier has an over 90% efficiency at the nominal AC input voltage. x Over current protection. The rectifier shuts down once an over current is detected, and recovers automatically when the fault is no longer present. x Over voltage protection. The rectifier shuts down once an over voltage is detected for the first time, and recovers automatically when the fault is no longer present. If the over voltage is detected for the second time, the rectifier will shuts down for ever until the AC power supply re-powers up to restart the rectifier. x Monitoring function. The rectifier monitors different parameters such as input voltage, output voltage, etc., and sends out a corresponding alarm signal in case it detects a fault. x Self-cooling function. Each rectifier is forced convection cooled. The fan at its back is replaceable.


Installation Manual

Product Introduction 27 x RS485 interface. The rectifier can be connected to the PDA via the internal RS485 interface. In this way, user can monitor and control three rectifiers via the GUI. The rectifier has a dimension of 81.8 X 383.7 X 100.0 (W X D X H) mm. The general view of the rectifier is as shown in Figure 7. (8)

(7)

(6)

(5)

(1) (9)

(10)

(3) (2)

(4)

(1) Rectifier front panel (2) AC input connector (3) RS485 interface (4) connector clip (5) –54V bus bar (6) BR bus bar (7) Case (8) Fan cover (9) Handle (10) LED Figure 7 – General view of the rectifier


Installation Manual

Product Introduction 28 Table 10 lists the LED indications of the rectifier. Table 10 – LEDS on the rectifier front panel

LED Mark

Status

Indication

Yellow (amber) / Message

ON

Minor EAC alarm (refer to Table 8)

Green / Normal

ON

xRated mains voltage (refer to Table 5) xSystem OK

ON

xRectifier failure xFan failure xAC input phase voltage less than 80V xLow output voltage

Red / Alarm


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Preparation 29

Chapter 2 Preparation 2.1 Safety Summary 2.1.1

Injury and product damage precautions

The following precautions must be observed during all phases of servicing the product, such as installation, maintenance or configuration. Any omission of the precautions might cause injury and/or product damage. x Do not service the product during a thunder / lightning storm to avoid electric shock. x Turn off the AC power source when accessing the AC cables or the SPD to avoid electric shock. x Make sure the product is well grounded before servicing the product to avoid electric shock.

x Do not install the product in an explosive atmosphere to avoid injury or fire hazard.

x Do not service the product if the environment cannot meet the requirements defined in the product specification. x Do not place the product in an unstable rack, to avoid the product damage in case of a fall. x Do not open the restricted area by unqualified personnel, to avoid damage to the product. x After unpacking, do not start the installation if you suspect any product damage caused by shipment. x Pay attention to the specific warning/caution terms and symbols in this manual.

2.1.2

Safety Term and Symbols

These term and symbols listed in Table 11 may appear in this manual:


Installation Manual

Preparation 30

Table 11 – Term and Symbols in this manual

Term & Symbol

Description Warning statement identifies conditions or practices that could result in bodily injury or loss of life. It warns the reader to be extremely careful. Caution statement identifies conditions or practices that could result in damage to this product or devices connect to it. It indicates that the reader must be careful.

These symbols listed in Table 12 may appear on the FPRA: Table 12 – Symbols on the FPRA

Symbol

Description Risk of electric shock: To avoid electric shock, user shall not touch the product.

DC Voltage Hazard DC Voltage Hazard: There is DC voltage at the indicated position. Hot surface: To avoid being burnt, user shall not touch the product when it is in operation. ESD caution: Means user should wear a well-grounded ESD wrist strap to avoid product damage. - To be continued -


Installation Manual

Installaton Manual FPRA

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