REM HR8022 001_A User Manual

. l e B s s c i t A h t n e m f t o n o r g o f n c n i o s i y t p i t a o f z c o i r n d o o h n i a t t a u n i c a o n n g u e t n m t i i r s s m w a o t P c u . d o d n h e a t i v r e w e s d s u e e , t t r t i s n t e m r h m e g u p i r t l c l o o A d n

HR8022-001 Energy System User Manual

Rev. Rev. A

HR8022-001

48V/2160W/540W Energy System


Contents Chapter 1

Introduction 1.1 1.2 1.3

Chapter 2

3.5 3.6 3.7

2-1 2-2 2-3 2-3 2-3 2-4 2-5 2-6 2-6 2-7

Transporting System Unpacking System Mounting Connection of Cables 3.4.1 Cable Entry Into System 3.4.2 Connection of AC Input and Ground Cables 3.4.3 Connection of Load Cables 3.4.4 Connection of Battery Cables 3.4.5 Connection of Signal Cables 3.4.6 Temperature Sensors Connection Local and Remote Control and Monitoring 3.4.7 Communication Link Rectifier Installation Final Installation Check System Power Up Procedure

3-1 3-1 3-2 3-3 3-3 3-4 3-4 3-5 3-5 3-6 3-7 3-8 3-9 3-9

Maintenance & Fault Tracing 4.1 4.2 4.3 4.4

Rev. Rev. A

System Architecture Electrical Specification Environmental Specification Safety Specification Mechanical Specification System Internal Layout System Major Component List System Alarm System Protection Battery Management

Installation 3.1 3.2 3.3 3.4

Chapter 4

1-1 1-2 1-2

Overview of the System 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

Chapter 3

System Introduction System Key Features Main Applications

Maintenance Recommended Spare Parts List Fault Tracing Replacing the Rectifier Procedure

HR8022-001

4-1 4-1 4-1 4-3



Contents Chapter 1

Introduction 1.1 1.2 1.3

Chapter 2

3.5 3.6 3.7

2-1 2-2 2-3 2-3 2-3 2-4 2-5 2-6 2-6 2-7

Transporting System Unpacking System Mounting Connection of Cables 3.4.1 Cable Entry Into System 3.4.2 Connection of AC Input and Ground Cables 3.4.3 Connection of Load Cables 3.4.4 Connection of Battery Cables 3.4.5 Connection of Signal Cables 3.4.6 Temperature Sensors Connection Local and Remote Control and Monitoring 3.4.7 Communication Link Rectifier Installation Final Installation Check System Power Up Procedure

3-1 3-1 3-2 3-3 3-3 3-4 3-4 3-5 3-5 3-6 3-7 3-8 3-9 3-9

Maintenance & Fault Tracing 4.1 4.2 4.3 4.4

Rev. Rev. A

System Architecture Electrical Specification Environmental Specification Safety Specification Mechanical Specification System Internal Layout System Major Component List System Alarm System Protection Battery Management

Installation 3.1 3.2 3.3 3.4

Chapter 4

1-1 1-2 1-2

Overview of the System 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

Chapter 3

System Introduction System Key Features Main Applications

Maintenance Recommended Spare Parts List Fault Tracing Replacing the Rectifier Procedure

HR8022-001

4-1 4-1 4-1 4-3


. l e B s s c i t A h t n e m f t o n o r g o f c n n i o s i y t p i t a o f z c o i r d n o o h n i t a t a u n i c a o n n g u e t n m t i r s i s m w a o t c P u . d o d n h e a t i v r e w e s s u d e e , t t r t i n s t e m r h m e g u p i r c t l l o o A d n

Chapter 5

Important Notices 5.1

5.2

General Guidelines 5.1.1 Installation 5.1.2 System Operation 5.1.3 Environmental and Airflow Considerations 5.1.4 Maintenance and Repair Warranty Constraints

5-1 5-1 5-1 5-1 5-1 5-2

Conductor Size Requirement for DC Applications Maintenance Record

A-1 A-2

Appendix ： 1. 2.

Rev. Rev. A

HR8022-001


. l e B s s c i t A h t n e m f t o n o r g o f n c n i o s i y t p i t o f a z c o i r d n o o h n i a t t a u n i c a o n n g u e t n m t i i r s s m w a o t P c u . d o d n t h e a i v r e w e s d s u e e , t t r t i s n t e m h m r g u e i p r c t l l o o A d n

1.

Introduction

1.1

System Introduction

The power system is specially designed for the 48V telecommunication power applications. By incorporating state-of-the-art switched mode rectifier and advanced microprocessor technology, the system is able to perform efficient AC to DC power conversion and at the same time carry out intelligent monitoring and control functions. The CPS is divided into 4 major functional blocks consists of 1. Control and Supervisory Module 6 (CSM6), 2. AC Power Distribution Unit (ACPDU), 3. Rectifier Modules, 4. DC Power Distribution Unit (DCPDU).

Control & Supervisory Module (CSM 6)

AC Power

ACPDU

Rectifiers

DCPDU

Load

Battery

Power path Signal path Fig. 1.1

CPS system block diagram

The Control and Supervisory Module 6 (CSM6) consists of the CSM6-1 and CSM6-2. The CSM6 is the central supervisory unit, which monitors and controls the operating parameters of the entire system. The CSM6-1 is equipped with LCD panel and soft keypads which serve as a user-friendly interface to monitor or program various system parameters and the CSM6-2 is the Data collector which collects and processes system data before passes to CSM6-1 for display. The CSM6 supports Local and Remote Monitoring & Control functions, for local monitoring & Control, the link between the system and the PC is made through the RS-232. However for the Remote Control and Monitoring, it can be achieved through Public Switch Telephone Network (PSTN) and Ethernet(TCP/IP). The CSM6 also has the battery management function which ensures proper charging of batteries so as to maximize energy storage and to prolong the life of batteries. The AC PDU distributes AC power to the rectifiers and other portions of the system. A single pole MCB (Miniature Circuit Breaker) is available within the AC PDU to isolate the system from the mains. The AC PDU is also installed with an array of Surge Protection Device which protect the

Rev. A

HR8022-001


1-1

. l e B s s c i t A h t n e m f t o n r o g o f c n n i o s i y t p i t o f a z c o i r d n o o h n i t a t a u n i c a o n n g u e t n m t i r s i s m w a o t c P u . d o d n h t e a i v r e w e s d s u e e , t t r t i n s m t e r h m e g u p i r c t l l o o A d n

system against line surge. The rectifier modules carry out AC to DC power conversion in the system. Each rectifier is able to deliver a rated output power of 540W at a nominal output voltage of -54V. Therefore, when the system is expanded to its fullest capacity of four rectifiers, it is capable of delivering a maximum power of 2160W to external loads and batteries. The rectifiers are modular in design, hot-swappable and exhibit excellent current share performance when operated in parallel configuration. The system is hence flexibly configurable to meet different power consumption requirements and to achieve N+1 redundancy. Control of rectifiers can be carried out in a centralized manner on the CSM6. In addition, the operating conditions of individual rectifier can also be easily monitored on the CSM6. The DC PDU distributes DC power from the rectifiers to external loads and batteries. Within the DC PDU, there are MCBs protected distribution ways to be connected to external loads. The DC PDU also incorporates two battery connections, which are equipped with two MCBs for protection purposes. The battery connections allow the system to have power backup capability in the event of an AC failure.

1.2 l l l l l l l l l l l

1.3 l l l l l l l

Rev. A

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

Main Applications PBX, PABX station Digital communications equipment GSM station CDMA, TDMA, AMPS station Microwave communication station Railway switching control station Other -48V telecommunication systems

HR8022-001


1-2


DC OUTPUT (+) T.B. AC INPUT T.B. + 1 L + 2 L + 3 L + 4 L + 1 B + 2 B C N C l i N a M F m r O C a M l C A A O V C O L N O N C m N r a C l A m N r M n a l O o A M C m S O m D C O o V N C L O N

) + ( T U P T U O C D

) ( T U P T U O C D

L T U P N N I C A

G

- 1 L - 2 L - 3 L - 4 L - 1 B - 2 B

DC OUTPUT (-) T.B. Alarm dry contact T.B. BACK VIEW 436.0

436.0

100A SHUNT

0 . 7 7 2

0 . 7 7 2

100A LVDS

LEFT VIEW

TOP VIEW WITHOUT COVER

48V/540W Rectifier

AC MCB

SPD

ACMCB

LEFT VIEW

LO AD MC B

SPD

LOADMCB L1

L2

L3

TOP VIEW

B ATT. MCB

BATT.MCB L4

B1

B2

Power

6 2 . . 7 2 3 5 1

TCP/IP

465.0 482.6

TCP/IP Port Controller CSM6

FRONT VIEW

Fig. 1.2

Rev. A

HR8022-001

Power system outline (Unit: mm)


1-3


2.

Overview of the System

2.1

System Architecture

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

Rev. A

HR8022-001


2-1


2.2

Electrical Specification

Table 2.1

Electrical Specification

System model

HR8022-001

Rectifier Model

OT6001

AC input 110/220Vac single phase

Nominal voltage Operating voltage range (full output power)

90Vac ~ 300Vac

Starting Voltage

100Vac

Frequency

45 ~ 65Hz

Rated current (220Vac input; 54Vdc, 100% load)

10.8A

Rated current (110Vac input; 54Vdc, 100% load)

22.3A

Efficiency (220Vac input; 54Vdc, 100% load)

>91%

Efficiency (110Vac input; 54Vdc, 100% load)

>89%

Power factor (220Vac input; 54Vdc, 100% load)

>0.99

DC output Nominal voltage

54Vdc

Float voltage adjustable range

43 ~ 58Vdc

Equalize voltage adjustable range

43 ~ 58Vdc

Nominal Power (100% load)

2.16kW

Soft start time

> 3s

Line regulation

< ±0.1%

Load regulation (0% ~ 100% load)

< ±0.5%

Current share (50% ~ 100% load) Audible noise

deviation from mean current 55dBA (1 meter)

Psophometric noise

< 2mV

Load MCB

16A x 3; 6A x 1

Battery MCB

Rev. A

±3%

32A x 2

HR8022-001


2-2


2.3

Environmental Specification Operating temperature : -20°C ∼ +70°C (ideal operating temperature : 25 °C) Storage temperature : -20 °C ∼ +80°C Relative humidity : 10%RH ∼ 90%RH (non-condensing) Altitude : < 3000 meter Illumination requirement : 750LX (even illumination)

l l l l l

Note : The operating environment must not contain corrosive and inflammable gas. Good ventilation and air-conditioning is highly recommended.

2.4 Safety Specification l

Designed to meet UL1950, EN60950 requirements

l

Hi-pot : Input to output 1500Vac, 50Hz for 1 minute Input to chassis (FG) 1500Vac, 50Hz for 1 minute Output to chassis (FG) 500Vac, 50Hz for 1 minute

l

Earth continuity : Safety earth to chassis (FG) 25A for 1 minute (Earth resistance < 0.1Ω)

2.5 Mechanical Specification l l l

Rev. A

Height : 132.6mm Width : 482.6mm Depth : 277.0mm

HR8022-001


2-3


2.6

System Internal Layout

10

+ 1 L + 2 L + 3 L + 4 L + 1 B + 2 B C N C l i N a M F m r a M O l C C A A O V C O L N O N C N C N m r M a l O A M C S O D C O N V L O N

BACK VIEW

) + ( T U P T U O C D

m r a l A n o m m o C

) ( T U P T U O C D

L T U P N I N C A G

7

- 1 L - 2 L - 3 L - 4 L - 1 B - 2 B

8

9

TOP VIEW WITHOUT COVER

5 2

AC MCB

4

3

SPD

LOAD MCB L1

L2

L3

BATT.MCB L4

B1

B2

Power

TCP/IP

1

Fi . 2.1

Rev. A

FRONT VIEW

Outline drawin

HR8022-001

6

11

Unit: mm


2-4


CSM6

Fig. 2.2 Outline Drawing of CSM6-1

CS M6

Fig. 2.3 Outline Drawing of CSM6-2

2.7

System Major Component List

Table 2.1 Item

Component

Specification

Q’ty

1

Rectifier

RECTIFIER 48V/540W

2

AC MCB

RECTIFIER AC MCB 32A 1P

1

DC MCB

DC MCB 16A 1P

3

DC MCB

DC MCB 6A 1P

1

BATTERY MCB 32A 1P

2

Max. 4

3

4

BATTERY MCB

5

CSM6-2

MAIN CONTROLLER CARD FOR CSM

1

6

CSM6-1

LCD FOR CSM DISPLAY

1

AC I/P TB 40A/3P

1

ALARM TERMINAL BLOCK/12P

1

RELAY MAGNETIC 48V 100A 1PST

1

TERM BR PBT 40A 600V 6P BLK

2

ETHERNET NETWORK

1

7 8

Ac input Terminal block Dry contact Terminal block

9

Battery lvds

10

Load and battery Terminal block

11

Ethernet network card

Rev. A

HR8022-001

RS-485


2-5


2.8

System Alarm

The system is equipped with various fault detection schemes and alarms to keep users informed in the event of fault conditions. The system is also equipped with four voltage free relay contacts (dry contacts) to keep remote users informed when a fault occurs. The relay contacts will respond to normal and fault conditions as indicated in the table below : Table 2.2 Operating Conditions

COM, NO Contacts

COM, NC Contacts

Normal condition

Open

Close

Fault condition

Close

Open

2.9

System Protection

The system is equipped with various protection schemes to ensure no damage occurs in the event of abnormal conditions. Some of the main protection schemes are explained below : l

Overcurrent protection (OCP) : At the AC input, the system is protected against overcurrent by a MCB. The load MCBs at the DC PDU protect the system against overcurrent drawn by external distributed loads. The battery MCBs prevents overload of the battery bank. Overcurrent limit of rectifiers can be programmed in a centralized manner on the CSM6. Rectifier overload current will not exceed the preset limit.

l

Overvoltage protection (OVP) : When the AC input exceeds 308Vac, the rectifiers will cease to operate to prevent component damage caused by overvoltage stress. The rectifiers will resume normal operation upon removal of abnormal condition. Output OVP will be activated when the system output voltage cannot be regulated and exceeds 60V ± 0.5V. Rectifiers at fault will be forced to shutdown. Manual reset is required to restart a rectifier which has been shutdown due to output OVP fault.

l

Over temperature protection (OTP) : The system over temperature alarm will be activated when the ambient temperature in the system raises above a preset level. The default preset level is 40 °C. In addition, when the rectifier heatsink temperature raises above a default preset level of 80 °C, the rectifier fault alarm will be activated. If the heatsink temperature raises further and reaches 90 °C, the rectifier will be forced to shutdown. The rectifier will resume normal operation when the heatsink temperature reduces below 70 °C.

l

Surge protection : At the AC input, the system is protected against line surge by an array of 20KA/275Vac SPD module.

Rev. A

HR8022-001


2-6


2.10

Battery Management

The CSM6 carries out battery management functions according to the user preset parameter values. Details on the battery management parameters can be found in the CSM6 User Manual. In the event of an AC failure, the CSM6 will calculate the discharge Ampere-Hour (AH) of the batteries. When AC recovers, the batteries will be recharged automatically in equalize mode according to the preset charging coefficient (CC) or automatic charging time (ACT). One critical aspect of battery management is temperature compensation. The IC LM335 converts the battery temperature sensed into a current signal. The signal is then processed by the CSM6-2. Based on the temperature information obtained, the CSM6 will adjust the output voltage of the rectifiers accordingly. The desired temperature compensation characteristic can be obtained by changing the temperature reference point (TBP), temperature rise rate (TS) and voltage decrease rate (VS) settings. Low Voltage Disconnect (LVD) Protection : The Load LVDS is to disconnect load, The disconnect and reconnect voltages are preset at 43.0V and 50V respectively.

Rev. A

HR8022-001


2-7


3.

Installation

3.1 Transporting During shipment, the power shelves and rectifier modules are packed separate in cartons. Then, they are packed and shipped on separate pallets. The pallets are heavy and large in sizes. Hence, suitable transporting machines will be needed for transporting. Plan in advance on the transport route and the location to unpack and to assemble the system.

3.2 3.2.1

3.2.2 3.2.3

System Unpacking Before dismantling the packing, inspect for damages, shape distortion or any trace of moisture on the package. Pictures should be taken and lodge a report immediately if any abnormal condition is observed. To unpack the system, refer to Fig. 3.1. Upon completion on the unpack process, inspect the contents to ensure that no transit damage has occurred and check the completion of the contents

Fig. 3.1

Rev. A

Step 3

Step 2

Step 1

HR8022-001

Unpack procedure


3-1


3.2.4 System Packing List Compare the contents in the crates with the attached packing list. Contact our sales representatives if there is any shortage or damaged item. Table 4.1

Packing list

Package No.

Part Description

Q’ty (pcs)

Part No.

1

Compact Power System

1

HR8022-001

3.3 =

=

Net Weight Gross Weight (kg) (kg) 6.3

8.3

Crate Dimension (H x W x D; mm) 205 x 420 x 530

System Mounting If the power System is to mounting on cabinet or rack, must first mount the System supporting rails at the bottom of the power System, refer to pictorial illustration below, Fig 3.2. During the mounting, must ensure the rails are well balanced and not tilted. Then place the System on the rails and mount the System hangers against the cabinet or racks. Refer to drawing below Fig. 3.2.

ACMCB

SPD

LOAD MCB L1

L2

L3

BATT. MCB L4

B1

B2

Power

TCP/IP

FRONT VIEW

Mounting holes for cabinet or racks mounting mount CPS onto x4

Fig. 3.2

Rev. A

HR8022-001

System mounting


3-2


3.4

Connection of Cables

3.4.1

Cable Entry Into System

Incoming AC cables, outgoing DC cables and remote signal (dry contact) cables are to be terminated at the AC terminal block, DC MCBs and Alarm terminal block respectively. Refer to Fig. 3.3 for the cable connection to the power shelves.

2

+ 1 L + 2 L + 3 L + 4 L + 1 B + 2 B C N C l i N a M F m r a M O C l C A A O V C O L N O

N C r m N a l C m N M A r n a l O o A M C m O S C m O o D N C V L O N

) + ( T U P T U O C D L T U P N N I

) ( T U P T U O C D

C A

G

1

- 1 L - 2 L - 3 L - 4 L - 1 B - 2 B

5 3

4

BACK VIEW

Fi . 3.3

1 2 3 4 5

Rev. A

HR8022-001 cables connections

AC Input cables to the AC terminal block 40A/3P (single phase). Load(+) and battery(+) cables to the common (+) terminal block. Load(-) cables to the Load(-) terminal block. Battery(-) cables to the Battery(-) terminal block. Dry contact cables to the dry contact terminal block 10A/12P.

HR8022-001


3-3


3.4.2 Connection of AC Input and Ground Cables For single phase input, incoming AC cables are to be terminated at the AC input terminal block., which is as shown in Fig. 3.4 below: -

G

B2 G N

N

L

B1-

L4-

L3-

L2-

L1-

DC OUTPUT (-)

A C I N P U T

DCOUTPUT(+)

N O L V C N o O C D m S m C O A o O M a l n r M m A N l C a N r m C N O N L O C V O A A l M a C C O r m F M a N i C l N C

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

L

BACK VIEW

Fig. 3.4

3.4.3

AC input terminal block connection for single phase system

Connection of Load Cables

Incoming Load cables are to be connected to the DC output terminal block. Positive load cables are to be terminated at the positive terminal block and negative load cables are to be terminated at the load (-) DC output terminal block, The connection of Load cables as shown in Fig. 3.5 respectively below: -

L1L4- L3- L2-

B2 G N L

A C I N P U T

B1-

L4-

L3-

L2-

L1-

DC OUTPUT (-)

DC OUTPUT (+) B2+ B1+ L4+

L3+

L2+

N O C N o O C m O m C M o O n M N A l C a N r m C N O N O C O A C C M O F M a N i l C N C

L V D S A l a r m

L V

A l a r m

L1+

BACK VIEW

L1+ L4+ L3+ L2+

Fig. 3.5

Rev. A

HR8022-001

Connection for load cables


3-4


3.4.4

Connection of Battery Cables

Positive battery cables are to be connected to the battery (+) terminal block and negative battery cables are to be connected to the battery (-) terminal block. The connection of battery cables is as shown in Fig. 3.6 below: -

B2- B1-

B2 G N L

B1-

L4-

L3-

L2-

L1-

DCOUTPUT(-)

A C I N P U T

DCOUTPUT(+) B2+ B1+ L4+ L3+

L2+

N O L C N V o O C D m O S m C M A o O l a n M r A N m l C a N r m C N O N L O C V O A A l C C M a O r m F M a N i l C N C

L1+

BACK VIEW

B2+ B1+

Fig. 3.6

Connection for battery cables

Caution: Œ

Please switc h off the battery MCBs before conn ecting the battery cable.

•

P l ea s e c o n f i r m i f t h e p o l a r i t y o f i n c o m i n g b a t t e r y c a b l e s c o n n e c t e d t o t h e M C B s r i g h t or not before this system wo rks.

3.4.5

Connection of Signal Cables

Cables of warning signals are to be terminated at the upper terminals of the voltage free relay contact terminal block. There are three contact points for each signal namely the NO, COM and NC. The four dry contact warning signals are arranged in the order of Battery LV Alarm, Common Alarm, AC Fail Alarm and LVDS Alarm. Refer to Fig.3.7 below : -

B2 G N L

A C I N P U T

B1-

L4-

L3-

L2-

L1-

DC OUTPUT (-)

DC OUTPUT (+) B2+ B1+ L4+

L3+

L2+

N O L C N V o O C D m O S m C M A o O l a n M r N m A C l a N r m C N O N L O C V A O A l C C M a O r m F M a N i l C N C

L1+

BACK VIEW

Fig. 3.7

Rev. A

Voltage free relay contact terminal block

HR8022-001


3-5


3.4.6 = =

=

Temperature Sensors Connection

Attach the temperature sensor on one of the battery b locks. To ensure good contact, clean the surface of the battery before attaching the battery temperature sensor. Do not use the corrosive solvent during cleaning process. Adhesive strip

Fig. 3.8

Rev. A

Temperature sensor and cable connection

HR8022-001


3-6


3.4.7 Local and Remote Control and Monitoring Communication Link

CSM6 provides RS-232 and TCP/IP communication ports for the local and remote control and monitoring function. Local Control and Monitoring : connect a dedicated RS-232 cable to a local PC. Remote Control and Monitoring : (a) Dial-up by using Modem via PSTN (b) TCI/IP connection via Ethernet network Notes : TCP/IP addr ess defau lt setti ng : 192.168.128.244 TCP/IP port d efault settin g: 4001

C S M 6

CSM6-2 RS-232 Communication cable

TCP/IP TCP/IP Port

Fig. 3.9

Rev. A

Communication cable

Local and Remote control and monitoring communication cable connection

HR8022-001


3-7


3.5 l l

Rectifier Installation Unpack the rectifier (refer to LPR user manual section 3.1). Insert the rectifier into the rectifier compartment in the power system.

Push Fig. 3.10 l l

Insert rectifier into the rectifier compartment

Push the rectifier along the rail in the compartment. The rectifier must be pushed until the rear side of its front panel fully touches the cabinet. Secure the rectifier onto the power system with retaining screw provided.

Fig. 3.11

Rev. A

Tighten the rectifier with retaining screw

HR8022-001


3-8


3.6

Final Installation Check

Use the check list below to complete checks before progressing further. l l l l l l l l

3.7 l

l l l l l l

Ensure the system is positioned firmly Ensure all specified ground cables are connected and firmly tightened Ensure the ground resistance meets all specified requirements Ensure all AC and DC cable connections are correct and firmly tightened Ensure the battery polarities are correct at all connections Ensure all battery cable connections are firmly tightened Ensure all signal (voltage free relay contact) connections are correctly and firmly connected Ensure the correct cable size and number of cables are selected to carry the rated load correct and to ensure low voltage drop

System Power Up Procedure Before turning on the external AC mains, ensure the following breakers and switches are off : l AC MCB at the ACPDU l Load MCBs at the DCPDU l Battery MCBs at the DCPDU Turn on the AC mains (external). Measure the AC input voltage at the AC terminal block. Ensure the voltage is within the operating voltage range. Turn on the AC MCB if the input voltage is nor mal. Turn on the battery MCB at the DCPDU if the system output voltage is normal (Can be checked from the Rectifier’s LCD or the CSM6’s Test Port. Turn on the load MCBs at the DCPDU. Check the LEDs status on the CSM6. (1) No alarm (no red LED lighted) should occur. (2) AC power normal (green LED lighted).

Rev. A

HR8022-001


3-9


4. Maintenance & Fault Tracing 4.1

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

l l

l

4.2

Recommended Spare Part List

Table 4.1

Recommended spare part list

No.

Part Description

Quantity

1

Rectifier

1 pcs per ≤10 system

2

LVDS 48V 100A


3

Current sensor shunt 100A


4

Control and Supervisory Module (CSM6)


5

CSM6 interface card


4.3

Fault Tracing

When a fault message is displayed on the LCD panel of the CSM6-1, the following guide can be used for fault tracing : -

Alarm POWM DCV

▼

AC FQ ▼

AC FQ ▼

---

Rev. A

ENVM

Description of Fault

LVA AU COMMXX SMR COMMXX

RS-485 communication breakdown between CSM6-1, CSM6-2 or rectifiers.

MAJOR ALARM SMR ALARMXX AC FAIL 01

AC power failure or loss of phase

SMR ALARMXX

Rectifier fault or failure

HR8022-001

Check Items

1.

Check if any RS-485(USB line) connector is disconnected.

1.

Check if the AC MCCB/MCB is off.

2.

Check if AC power failure or loss of phase occurs.

1.

Check if AC power failure or loss of phase occurs.

2.

Check if any rectifier fails.


4-1


DCV ▲

DCV ▼

---

MAJOR ALARM SMR ALARMXX

LVA DCV ▼

MAJOR ALARM SMR ALARMXX

ETEMPxx ▲ BTEMPxx ▲

---

3.

Check if the AC INPUT switch of any rectifier is off or tripped. When the AC INPUT switch of a rectifier is off, its LCD will continue to display the output bus voltage. However, the green LED on the rectifier will be off and the red LED will be on.

4.

Check if the DC OUTPUT switch of any rectifier is off or tripped.

5.

Check if the address of any rectifier is incorrectly set.

6.

Check if any rectifier is in OCP, OTP, OVP or UVP mode by observing whether the red LED on any rectifier is on or any fault message is displayed on the LCD of any rectifier. Refer to the Rectifier User Manual for more details.

1.

Check if the DC output voltage is higher than the preset DCV▲ alarm level in the CSM “ALMS” subscreen.

1.

Check if the DC output voltage is lower than the preset DCV ▼ alarm level in the CSM “ALMS” subscreen.

2.

Check if the battery is discharged to a voltage lower than the preset DCV ▼ alarm level in the CSM “ALMS” subscreen during an AC failure.

1.

Check if the DC output voltage is lower than the preset LVA alarm level in the CSM “ALMS” subscreen.

2.

Check if the battery is discharged to a voltage lower than the preset LVA alarm level in the CSM “ALMS” subscreen during an AC failure.

1.

Check if the internal ambient / battery temperature is higher than the preset TEMP ▲ alarm level in the CSM “ALMS” subscreen.

1.

Check if any load or battery MCB on the DCPDU is tripped or open.

1.

Check if the LVDS is off, tripped or fail.

DC output voltage high

DC output voltage low, battery voltage low

DC output voltage low, battery voltage low.

Internal ambient / battery temperature high

---

LOAD MCBXX BATT MCBXX

Load or battery MCBs tripped and opened

---

LVDSxx

LVDS tripped

Arresters damage checking procedure Whenever a lightning surge occurs and causes damage to the surge arrester at the site AC mains distribution board, check is to be conducted on the SPD on the rectifier system, if a SPD is fractured or shattered, replace it with a new one.

Rev. A

HR8022-001


4-2


4.4

Replacing The Rectifier Procedure

4.4.1

Removing a rectifier

l

Loosen the rectifier retaining screw.

Fig. 4.1

l

Loosen the rectifier retaining screw

Pull out the rectifier.

Pull

Fig. 4.2

Rev. A

HR8022-001

Pull out the rectifier


4-3


4.4.2 l

Inserting a rectifier Insert the new rectifier with the burst-out guides in the shelf.

Push Fig. 4.3

Insert the new rectifier

l

Push the rectifier along the rail in the compartment. The rectifier must be pushed until the rear side of its front panel fully touches the cabinet.

l

Secure the rectifier into the power system with retaining screw on the front panel.

Fig. 4.4

l

Tighten the rectifier with retaining screw

Check the LEDs status on the CSM6 and rectifiers. (1) No alarm (no red LED lighted) should occur. (2) AC power normal (green LED lighted).

Rev. A

HR8022-001


4-4

. l e B s s c i t A h t n e m f t o n o r g o f n c n i o s i y t p i t o f a z c o i r d n o o h n i t t a a u n i c a o n n g u e t n m t i r s i s m w a o t P c u . d o d n h t e a i v r e w e s d s u e e , t t r t n i s t e m h m r g u e i p r c t l l o o A d n

5. Important Notices 5.1

General Guidelines

The following guidelines must be observed during system installation, system operation or when maintenance work is carried out. 5.1.1

Installation

l System installation must only be carried out by qualified personnel. l Ground resistance must meet local requirements. l Any equipment connected to the system must be properly grounded. l The conductors connecting external surge arresters must be as short as possible and the

l l

5.1.2 l l l l

5.1.3 l

l

l l

5.1.4 l l l

Rev. A

resistance must be less than 10 Ω. If metal tube is used to protect the conductors, both sides of the tube must be properly grounded. External surge arresters must be located far from inflammable materials. For safety reasons, surge arresters must be installed in protective case. The distance between any metallic part and exposed conductor must meet relevant safety clearance requirements. System Operation Before operating the system, it must be ensured that the input voltage, input frequency and other operating conditions are within the specification. The rectifier module must only be operated with its pin housing mated with AMP 211149-1 housing. Refer to the rectifier user manual for more details. When using sealed lead acid batteries, attention must paid to the charge data and warning notices provided by the battery manufacturer. If any part of the system is damaged, it must undergo maintenance immediately. Environmental and Airflow Considerations Operating the system in dusty environment may result in damage. Excessive dust settling inside the rectifier may result in poor heat dissipation and degradation of product performance. It is recommended to operate the system in air conditioned environment. The system must be operated in properly ventilated environment. Do not impede airflow through the system and rectifier modules by blocking or covering the ventilation holes on the front and back panel of the system. Do not operate the system in environment containing inflammable gas or material. Batteries produce combustible gas. Hence, the room must be properly ventilated. Maintenance and Repair Maintenance work must only be carried out by qualified personnel. During maintenance or repair, do not touch any conducting part in the system while the system is in operation. Before carrying out repair work on the rectifiers, wait for at least 5 minutes after switching off the power to allow the internal capacitors to discharge.

HR8022-001


5-1


5.2

Warranty Constraints

This equipment is guaranteed for one year. During the warranty period, the equipment is guaranteed against defective material and faulty manufacture. The equipment has been carefully inspected and undergone comprehensive test at the factory prior to delivery. If, within the warranty period, any material or workmanship related defect is discovered in the equipment, we undertake to make good the defect at our own expense subject to the standard conditions of sale. Our responsibility is in all cases limited to the cost of making good the defect in the equipment itself. The guarantee does not extend to third parties, nor does it apply to defects caused by improper installation, unauthorized alteration, abnormal working conditions, accident, natural disaster, misuse, or wear and tear

Rev. A

HR8022-001


5-2


Appendix : 1. 2.

Conductor Size Requirement for DC Applications Maintenance Record

Rev. A

HR8022-001



1. Conductor Size Requirement for DC Applications Current Rating (A) ≤

Wire Size (mm x mm)

20

Copper Busbar Size (mm x mm)

3.5

30

5.5

40

8

50 ∼ 60

14

70 ∼ 75

22

90 ∼ 100

38

125

50

150 ∼ 175

60

200

80

225

100

250 ∼ 275

125

300

150 or 50 x 2

350

200 or 60 x 2

400

250 or 80 x 2

500

325 or 125 x 2

600

150 x 2

50 x 6t

700 ∼ 800

125 x 3

50 x 10t

1000

150 x 3

60 x 10t

1250

200 x 3

80 x 10t

1600

200 x 4

100 x 10t

2000

2 x 80 x 10t

2500

2 x 100 x 10t

3000

2 x 120 x 10t

4000

3 x 120 x 10t

5000

3 x 150 x 10t

Note : Follow local requirements if specified otherwise.

Rev. A

HR8022-001


A-1

REM HR8022 001_A User Manual

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