Power One

POWER SUPPLY SYSTEM PODS 16.48-16000 1940 HEX Instruction Manual

Revision: B Document number: 039158

Copyright © Power One AS. All Rights Reserved. Power-One, AS Kobbervikdalen 75 P.O.Box 1543 N-3007 Drammen Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples involving names of companies and products, are fictitious examples and are designed solely to illustrate the use of Power One products. If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice. Power One logo is a registered trademark of Power One Corporation. All other trademarks or product names mentioned herein are trademarks of their respective owners.

Title page - Instruction Manual Document Number:

039158

Revision:

B

Date:

11.05.2005

System:

PODS 16.48-16000 1940 HEX

Ouput Voltage:

48V

Publisher:

Power-One as Postboks 1543 N-3007 Drammen NORWAY

Amendment record: Revision (Issue)

Description

Author

/ A B

First issue Second issue Third issue

Kai Morten Hennum 07.04.05 Kai Morten Hennum 11.05.05 Kai Morten Hennum 01.06.05

Originated Kai Morten Hennum Signed

Date 07.04.05

Approved Hans André Dokka

Date

Date 01.06.05

Signed

1-1 Document number: titlepage.fm Revision: B

1-2

PODS 16.48-16000 1940 HEX Document number: titlepage.fm Revision: B

Contents: 4 System description PODS 16.48-16000 1940 HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.4 System Description - PPS 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.4.1 FMP 16- Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.4.2 PCS - Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.4.3 PPR 16/10 23”- Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4.4 PBDU 23” - Distribution Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4.4.1 Low Voltage Disconnection (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4.5 Cabinet Door With Heat Exchanger (HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4.6 BTS Breaker 50A 3-pole (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.4.8 FMP 16 Dummy Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.4.9 Battery extension kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Safety - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Lethal voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.2.3 Precautions for lead acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.2.5 High temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.1 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.2 Handling electrostatic sensitive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.3 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.4 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 6 Installation guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.1.1 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.2 Tools and parts required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.3 Cabinet mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.2.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.2.5 Cable sizes / location of external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.2.5.1 Cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.2.6 Connection of Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.2.6.1 Mains Input Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 6.2.7 Connection of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 6.2.8 Connection of Symmetry Measurement and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .6-11 6.2.9 Battery connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 6.2.9.1 Battery tube routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 6.2.10 DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Commissioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

2-1 Document number: 039158TOC.fm Revision: B

7.2 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.4 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.5 Test of output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.5.1 Float charge (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.5.2 Adjustment of float charge, U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.5.3 Boost charging (U2) (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.6 Battery supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.7 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.8 Commissioning record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 8 Operation / Product description PCS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 General - Product description PCS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.2 Technical specification: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.3 Operation - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.3.1 Starting the PCS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.3.2 Adding modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.3.3 Removing modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4 PCS 2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4.1 PCS 2 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.1.1 Show voltage and currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.1.2 Show alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.1.3 Show messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.1.4 Show data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.1.5 Select / adjust U1 - U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.4.1.6 Adjust limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.4.1.7 Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 8.4.2 Connecting to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8.4.3 Boost charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 8.4.4 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 8.4.5 Battery current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 8.4.6 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 8.4.7 High load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 9 Product Description FMP 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 General - Product description FMP 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.1 Mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.2 DC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.2.1 Mains input 185-250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.2.2 Mains input 95-185VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.3 Module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2.5 Other technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.4.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

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PODS 16.48-16000 1940 HEX Document number: 039158TOC.fm Revision: B

9.4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.6 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 10 Product description PPR 16/10 23” Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 10.1 General - Product description PPR 16/10 23” Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 10.2 Connections and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 10.2.1 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 10.2.2 Internal functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.3 Connections between subracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 10.4 Addressing module positions in subrack1, subrack2 etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 11 Product description PBDU 4U/23” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 11.1 General - Product description PBDU 4U/23” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 11.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 11.3 Construction and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 11.4 Cable cross section output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 11.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 11.6 Commissioning PBDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 11.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 12 Product description PCS Alarm interface unit BM0685 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 12.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 12.2.1 Pin Configuration of J20 and J21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 12.3 Remote alarms, symmetry measurement and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . .12-3 12.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3 13 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1 13.1 Installing new modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 13.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 13.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 13.4 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 Appendix A: Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1 Cabinet Layout - 039095 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: / . . . . . . . . . . . . . . . . . . . . . . A-3 A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 - Rev: / . . . . . . . . . . . . . . . . . . A-5 A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev: / . . . . . . . . . . . . . . . . . . . . A-6 A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 - Rev: / . . . . . . . . . . . . . . . . . . A-7 A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 - Rev: / . . . . . . . . . . . . . . . . . . . A-8 A.8 Footprint Outdoor Cabinet - 039423 - Rev:/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Appendix B: Configuration c-000313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Appendix C: Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C.1 Distribution PBDU 23" 1xMCB/10xMCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1


Appendix D: BTS Breaker 50A 3-pole - Installation procedure D-1 D.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5 D.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5 D.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6 D.4 Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7 D.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8 D.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9 Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 E.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 E.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 E.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 E.4 Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 E.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 Appendix F: Battery Extension Kit - Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 F.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 F.2 Safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6 F.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6 F.4 Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 F.5 Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 F.5.1 Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 F.5.2 Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10 F.5.3 Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 Appendix G: FMP 16 Dummy Module - Installation procedure G-1 G.1 Scope and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5 G.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5 G.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5 G.4 Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 G.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7 Appendix H: 19” Adaptor Kit Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-1 H.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-5 H.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-6 H.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-6 H.4 Overview 19” adaptor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-7 H.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-8 Appendix I: Battery Heater Kit - Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 I.1 Scope and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5 I.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5 I.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6 I.4 Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6

2-4


I.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6 Appendix J: Customer AC service outlet - Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1 J.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5 J.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5 J.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6 J.4 Overview AC outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6 J.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6


2-6


Introduction to the manual

Introduction to the manual Objectives and audience This manual provides the user with the necessary information to understand how the Power Supply System is made and functions, together with sufficient information to enable the user to safely install, commission, maintain and operate the equipment in a safe and efficient manner. This manual has been prepared to be used by professional and properly trained personnel selected by our customers. This manual assumes that the technician has an understanding of power systems in general and understands safety procedures for working around AC and DC voltage. The user of this document should be familiar with electronic circuitry and wiring practices and have some expertise as an electronic or electromechanical technician. The information contained herein was applicable at the time the manual was ready for printing. Power One reserves the right to change specifications and designs without notice and without incurring obligation or liability. This manual is the work product of Power One and embodies confidential proprietary data in which Power One retains all rights, including exclusive right of use, reproduction, distribution and sale. It is submitted under a confidential relationship for a specific purpose, and the recipient agrees by accepting this work product, not to supply or disclose any information regarding it to any unauthorized person.

Symbols and conventions The following words and symbols found throughout this manual are meant to highlight particularly important matters regarding specific information concerning the personnel, equipment or the process. Note! The text set off in this manner present an important piece of information that is essential to highlight.

CAUTION! The text set off in this manner provides warning notice that failure to follow these directions can result in damage to equipment.

WARNING! THE TEXT SET OFF IN THIS MANNER PROVIDES WARNING NOTICE THAT FAILURE TO FOLLOW THESE DIRECTIONS CAN RESULT IN BODILY HARM OR LOSS OF LIFE AND/OR EXTENSIVE DAMAGE TO EQUIPMENT

Introduction to the manual Document number: 028410.fm Revision: B

3-1

Introduction to the manual

Abbreviations The following abbreviations are used in this manual: Abbreviation: PPS PODS PMP CMP FMP PCS PCU PCC BCC GMC XCS XR XS PPR PBDU PBC PDU PPRD PPC PBF PCB LVD PLD MCB MCCB

Description:

P1 Power Supply System P1 Outdoor System P1 Modular Power Convection-cooled Modular Power Fan-cooled Modular Power P1 Control and Supervision P1 Control Unit Prime Controller Card Base Controller Card Galero Modular Controller Xscend Control System Xscend Rectifier Module Xscend Subrack (Rectifier shelf) P1 Power Rack P1 Battery Distribution Unit P1 Battery Cabinet P1 Distribution Unit P1 Power Rack with DC Distribution P1 Power Supply Cabinet P1 Battery breaker Unit Printed Circuit Board Low voltage disconnection Partial load disconnection Miniature circuit breaker Moulded case circuit breaker

Disclaimer Power One is not responsible for system problems that are the result of installation or modification of the instructions provided in this manual.

Questionnaire for feed-back We urge you to complete and return the questionnaire on our web page at the following address: http://www.power-one.com/feedback.html. Let us know your remarks on and suggested improvements to this manual. We appreciate your comments in our achievement to improve our documentation. If you have any problems with your system, e.g. you wonder how to install a new PMP rectifier or you have some questions regarding messages or alarms on the control module, please see the Troubleshooting section. If this does not solve your problem, please seek assistance at your local Power One office, or our head office in Norway. These also concern any indistinctness in the manual.

3-2

PODS 16.48-16000 1940 HEX Document number: 028410.fm Revision: B

System description PODS 16.48-16000 1940 HEX

4 System description PODS 16.48-16000 1940 HEX

System description PODS 16.48-16000 1940 HEX Document number: 039159.fm Revision: A

4-1


4.1 General PPS 16 modular DC power cabinet systems are designed to meet rigid telecom applications with very high reliability and flexibility for future expansion. This cabinet power solution provides rectification, system management and power distribution while maintaining high reliability and offering flexibility for future expansion. The PPS 16 Power Systems are based on hot-swappable rectifier modules (FMP 16.48) with output power available at 1600W per module. Systems are also based on fan cooling rectifiers and it is therefore important that the ventilation panels are kept free from dust and obstructions that may prevent the air circulation. System management is accomplished through messages and alarms displayed on the system controller’s (PCS) LCD screen and can also be displayed remotely via the PC-based PowCom™1 software package. Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases rectifier modules are shipped separately.

Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be connected to the RS232 contact.

1.

4-2

Communication program for remote control of the power supply system



System drawing Outdoor cabinet

i

IOIOI

Figure 4-1

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C120N

1

3

2

4

D100

C120N

multi 9 1

3

2

4

D100

415V 10000

I ON

C120N

1

3

2

4

D100

415V 10000

I ON

415V 10000

I ON

I ON

I ON

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

System description PODS 16.48-16000 1940 HEX Document number: 039159.fm Revision: B

4-3


4.2 Technical Data Figure 4-2

Principle drawing

PCS DC distribution FMP 16

AC

F F

FMP 16

LVD

FB

BATT Input: Output:

Weight: Cabinet dim.:

-voltage: -current: -voltage: -current: -power: Rectifier: Height: Width: Depth:

1x230V AC, 3x230V AC, 3x230/400V AC <10A per module 48V DC nominal / 16000W Max 32A per. module, 48V Max 1600W pr. module. 2,2 kg 1940 mm 800 mm 850 mm

4.3 Operation z

The PODS 16.48-16000 HEX is capable of delivering up to 16000W/48V steady state power. The system is based up on hot swappable 48V/1600W rectifier modules, which are working in parallel with automatic load sharing.

z

The cabinet system is normally configured with N+1 redundancy, with N as the number of rectifier modules necessary for feeding the load and charging the battery and 1 as the redundant rectifier module. In normal operation the rectifier modules, FMP 16, are feeding the load and simultaneously maintain the batteries in a fully charged state.

z

During a mains input power failure, the rectifiers are shut down and the batteries deliver the power required by the load, for a certain backup time. If the battery voltage drops below the pre-set level, the low voltage disconnection circuit (LVD) disconnects the batteries automatically to prevent battery deep discharge prolonging the battery life. When the mains input power is restored, the rectifiers start up automatically feeding the load, closes the LVD circuit and begin to recharge the batteries.

4-4



z

The system performance is supervised and controlled from the supervisory unit, PCS. From this unit output DC voltage is set, alarm thresholds, LVD circuit operation, temperature compensated battery charging and battery testing. Any malfunction will be indicated by LED, text in the display and operation of dry contacts. However, PCS is not a single point of failure. In the event of malfunction in the PCS, basic tasks like feeding the load and charging batteries, will be maintained by the rectifier modules directly at preset default values.

z

The alarm and threshold setting of the PPS 16 can be set locally by using the PCS push buttons and menu guided operation or remotely, by using the PowComTM software.

4.4 System Description - PPS 16 This system consists of the following components: Figure 4-3

Front view of PPS 16.48-16000

PCS i

IOIOI MERLIN GERIN

multi 9

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C120N D100

1

3

2

4

415V 10000

C120N D100

I ON

3

2

4

C120N D100

1

3

2

4

415V 10000

I ON

I ON

I ON

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

I ON

I ON

Battery breakers

multi 9

C60N

C16

multi 9

1

415V 10000

I ON

MERLIN GERIN

C60N

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

I ON

I ON

I ON

I ON

I ON

Load breakers power-one

power-one

FMP1648

FMP1648

FMP 16

4.4.1 FMP 16- Rectifier Module The Power-One FMP 16 rectifier provides extremely reliable DC power in the highest possible density. The module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load sharing among rectifiers, and providing status and identification information to the controller. Other features include 3xLED for rectifier status indication, thermal protection with de-rating and input over voltage disconnection with automatic reset. The rectifier units are hot swappable and can be quickly removed and replaced without disrupting the system or load. See: 9 Product Description FMP 16 on page 9-1

4.4.2 PCS - Controller System PCS - is a supervisory system with onboard software for monitoring and operation of power supply systems based up on Power One rectifier modules. The design is based up on the philosophy of having one main controller supervision for the entire power supply system, and use of distributed intelligence by local micro controllers. A RS485 data bus takes care of internal communication between the various units. RS232 is used for remote operation from a PC. PowComTM software PowComTM is a communications software package that allows the remote control of the power supply system. The software uses a Windows based interface to allow access to the PCS. PowComTM is installed


4-5


on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up modem. Power-One Network interface (option) The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and enables the system to be accessed from any location. The protocol uses simple commands to configure and control the system and relay the system status to the operator. Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can be used in conjunction with PowComTM software either through a modem or Ethernet connection. See: 8 Operation / Product description PCS 2 on page 8-1

4.4.3 PPR 16/10 23”- Subrack PPR 16.48 is a subrack for modules in the FMP 16 series. The subrack has up to ten module positions (max. 10xFMP 16 rectifiers.) The subrack has a connection for AC in, DC out and RS485 for communication. Modules are “hot swappable” under full load conditions. See: 10 Product description PPR 16/10 23” Subrack on page 10-1

4.4.4 PBDU 23” - Distribution Module DC distribution module with battery breakers, load breakers, shunt for measurement of current, alarm for battery and load. The distribution has no special operation other than switching the battery and load breakers on and off. All DC distribution breakers are supervised by measuring voltage drop across each breaker. Breakers that are not connected to any load, will not cause breaker alarm even if they are left open. Note! Due to a small leakage current (2,5-3 mA) through the alarm circuit the voltage measured with a DVM (Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage. If a battery breaker fault occurs or is simulated it may take from 2-10 minutes before the fault is indicated, depending on the battery condition. The distribution module has common "+" and breakers in "-" leg. For more information see schematic drawing in Appendix A. See: 7 Product description PBDU 23” 4.4.4.1

Low Voltage Disconnection (LVD)

The system is equipped with low voltage battery disconnection, which prevents the batteries from deep discharging, thus prolonging the battery life. A disconnection requires a detected mains failure at the supervision unit. Threshold for disconnection is available. If disconnection occurs, the batteries will not supply power to the load until they have been recharged to set voltage level, which can be adjusted by the user. If disconnection occurs, the batteries will be reconnected when mains supply return.

4.4.5 Cabinet Door With Heat Exchanger (HEX) The Cabinet door is a lockable door meant to protect the battery compartment from access of unauthorised personnel. The system heat exchange unit is also mounted in the door.

4-6



Figure 4-4

Cabinet door with HEX, inside view

Air out

Air in

Fan out

Fan in

Door Locking mechanism

The principle of the Heat Exchanger unit is to use cool ambient air to cool down the warm air inside the cabinet, without any ambient air being pulled into the cabinet itself. Two fans pull outside and inside air respectively through each side of the heat exchanger element. The fan speed is monitored by the controller and is decided by a temperature sensor positioned by the internal air inlet (see Figure 4-4). Figure 4-5 on page 4-8 shows external air flow, internal air flow and a principle drawing of the heat exchanger element.


4-7


Figure 4-5

Heat Exchanger Airflow

HEX airflow internal. Seen from the side with side plate removed.

HEX unit ambient airflow

Cabinet door with HEX unit

Rectifier shelf

Cabinet door with HEX unit

Heat Exchanger Element Principle Drawing

Ambient air

HEX Outside air

HEX Inside air

Inside of Cabinet

Cold ambient air in Warm air from the cabinet into the HEX element

Warm air out

Cooled air back to the cabinet Heat energy from internal air to external air through the HEX element

4-8



4.4.6 BTS Breaker 50A 3-pole (Option) The BTS Breaker 50A 3-pole is an optional kit that allows extension of one extra load breaker. This breaker can be mounted with 50A, 100A or 150A load capacity. See: Appendix D: BTS Breaker 50A 3-pole - Installation procedure

4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option) The surge arrestor kit is an optional unit that protects the system against lightning and transient overvoltage. Each surge arrestor kit consists of three over voltage protector units, a spark gap plugged in one holder and link cables. Each surge arrestor unit has a display on the front that indicates if it is OK or has blown. Surge arrestor units with a red display have blown and must be replaced. When fitted, each surge arrestor kit is located below the mains input terminal blocks. See: Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure

4.4.8 FMP 16 Dummy Module (Option) The FMP 16 dummy module is an optional kit for covering empty module positions. See: Appendix G: FMP 16 Dummy Module - Installation procedure

4.4.9 Battery extension kit (Option) The battery extension is an optional kit that allows additional battery branches to be added to the power system (extension of hold up time). The power system allows maximum 4 battery branches. The kit includes one extra single pole battery breaker, battery shelf, battery cable, symmetry cable and signal cable harness. See: Appendix F: Battery Extension Kit - Installation Procedure


4-9


4-10


Safety

5 Safety

Safety Document number: 028580.fm Revision: A

5-1

Safety

5.1 Safety - Introduction This document contains recommended safety guidelines for working with the equipment mentioned in this documentation. The instructions in the Customer Documentation must be followed by properly trained and authorized personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the instructions may be dangerous to personnel and equipment. Although the purpose of safety devices, routines and regulations are meant to take care of the safety of the user, nobody is excused from using common sense at all times when operating or otherwise handling the equipment. These above mentioned safety guidelines include Warnings, Cautions and Notes.

5.2 Warnings 5.2.1 Lethal voltages WARNING! OBSERVE HIGH VOLTAGE SAFETY PRECAUTIONS BEFORE ATTEMPTING TO WORK ON THE SYSTEM WITH THE POWER CONNECTED. POTENTIALLY LETHAL VOLTAGES ARE PRESENT WITHIN THIS SYSTEM.

WARNING! CARE MUST BE TAKEN WHEN HANDLING ALL POWER CABLES. THERE MUST BE NO DAMAGE OF ANY KIND TO THE INSULATION OF THE CABLES AND POINTS CARRYING LETHAL VOLTAGES SHOULD NOT BE EXPOSED. FOR SAFETY REASONS, MAKE SURE THE CABLES ARE NOT CONNECTED TO THE POWER SUPPLY WHEN ROUTING THEM. All persons who perform any operations on this equipment should be advised of the potential dangers. Ensure that the following guidelines and cautions are observed, when dealing with high voltage systems and equipment: z

Potentially lethal voltages are present within the system. Ensure that all power supplies are completely isolated by setting all power switches to OFF, disconnecting all relevant connectors and removing all relevant breakers before attempting any maintenance work. Do not rely on switches alone to isolate a power supply.

z

Potentially lethal voltages are present within this system. Ensure that high voltage safety requirements are implemented before attempting to work on the system with power connected.

z

Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly. Ensure that all ground connections are secure.

5-2


Safety

5.2.2 Grounding WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION CAPABLE OF SINKING THE MAXIMUM SYSTEM CURRENT IS REQUIRED.

WARNING! DUE TO HIGH LEAKAGE CURRENT IN THIS SYSTEM, A CONDUCTOR SHOULD BE CONNECTED BETWEEN THE GROUNDING POINT IN THE POSITIVE DC BUSBAR TO THE CABINET. THIS CONDUCTOR IS CONNECTED ON ITS OWN TO THE EARTH BAR AND NOT SHARED WITH OTHER SAFETY CONDUCTORS.

5.2.3 Precautions for lead acid batteries WARNING! THIS EQUIPMENT USES LEAD ACID BATTERIES. WHEN HANDLING THE BATTERIES FOLLOW THE INSTRUCTIONS DELIVERED WITH THE BATTERY SET, AS THE FLUIDS CONTAINED WITHIN THESE BATTERIES ARE KNOWN TO BE A HEALTH HAZARD. THE DISPOSAL OF LEAD ACID BATTERIES IS SUBJECT TO LEGAL REQUIREMENTS FOR HAZARDOUS WASTE, THEREFORE DISPOSAL LOCALLY MUST BE UNDERTAKEN SAFELY AND ACCORDING TO LOCAL GUIDELINES.

Ensure the following guidelines are observed when dealing with equipment that may contain lead acid batteries: z

Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes.

z

Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with the corrosive fluid must be avoided.

z

Neutralize any acid corrosion with copious amounts of a solution of baking soda and water, and then wipe off all traces of soda.

z

If the lead acid battery is removed from the equipment, any exposed contact must be insulated prior to disposal.

z

Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are used when working with the batteries.

5.2.4 Weight WARNING! MUCH OF THE HARDWARE THAT COMPRISES THIS EQUIPMENT IS SUFFICIENTLY HEAVY TO REQUIRE HANDLING BY TWO OR MORE PEOPLE, OR BY SPECIALISED LIFTING EQUIPMENT.

5.2.5 High temperatures WARNING! CARE MUST BE TAKEN WHEN HANDLING THE EQUIPMENT AS SOME OF IT MAY REACH HIGH TEMPERATURES.

Safety Document number: 028580.fm Revision: B

5-3

Safety

5.3 Cautions 5.3.1 Storage and transportation CAUTION! During storage and transportation, the units must remain in their original packages in order to avoid mechanical damage, maintain tracability, and protect the units against electrostatic discharge.

5.3.2 Handling electrostatic sensitive devices CAUTION! An electrostatic sensitive device is an electronic component that may be permanently damaged by the discharge of electrostatic charges encountered in routine handling, testing and transportation.

5.3.3 Traceability CAUTION! Units are labelled with permanently attached product identification labels. The labels are designed to be indelible throughout the life span of the equipment, unless mistreated. Make sure that the product identification labels are present on the equipment and are not subjected to unusual wear or mistreatment.

5.3.4 Breakers CAUTION! Breakers should always be replaced with the same type in order to avoid damage to system components.

5-4


Installation guide

6 Installation guide

Installation guide Document number: 039160.fm Revision: A

6-1

Installation guide

6.1 Site requirements The site should be suitable and ready for the power supply. If it is not or you are unsure about this, contact your supervisor before continuing. Check, using a spirit level, that the site is level.

6.1.1 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY.

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

Note! This product is also designed for IT power distribution system with phase-to-phase voltage 230V.

WARNING! ONLY QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS INSTALLATION

6.2 Installation procedure 6.2.1 Unpacking Check that the equipment received is in accordance with the packing list. Ensure that the cabinet and the equipment have not been damaged during transportation. Contact Power-One if any parts are missing or damaged, and correct any problems before continuing.

6.2.2 Tools and parts required The following tools are required for a safe installation of the system: z

Anti-static hand strap

z

Socket wrench, insulated

z

Screwdriver set, flat, insulated

z

Screwdriver set, torx, insulated

z

Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated

z

Torque spanner (for battery connection), insulated

z

M12 bolts for cabinet base WARNING! USE ONLY SINGLE-ENDED, FULLY INSULATED TOOLS: SHAFTS OF SCREWDRIVERS ETC.; SHOULD BE INSULATED.

6-2

PODS 16.48-16000 1940 HEX Document number: 039160.fm Revision: A

Installation guide

CAUTION! Care must be taken when installing this system. The units can be damaged and can cause damage if not handled with care. Pay particular attention to the order in which units are installed.

CAUTION! Installation in USA / Canada must conform with NEC/CEC requirements.


6-3

Installation guide

6.2.3 Cabinet mounting The cabinet base needs to be fastened to the ground before lifting the cabinet into position. WARNING!

THE CABINET IS HEAVY AND MUST BE HANDLED WITH DUE CARE

1. Step 1 in Figure 6-1 shows the location of the mounting holes for the base. M12 bolts are not delivered with the cabinet and should be supplied by the customer. 2. Plinth directions: The sides of the plinth have a SIDE imprint. The SIDE imprint should face up from the ground. Measurements of the plinth needed to prepare the site for mounting can be found in Appendix A: Drawings. 3. After secure fastening of the cabinet base, lift the cabinet into position on the cabinet base (Step 2 in Figure 6-1). 4. Step 3 in Figure 6-1 shows location of mounting holes for fastening the cabinet to the cabinet base. Fasten the cabinet to the base with M10 bolts from inside the cabinet. M10 bolts are included.

6-4


Installation guide

Figure 6-1 Base and cabinet mounting (empty cabinet shown)

After mounting the cabinet base and cabinet, the four lifting brackets mounted on top of the system should be removed. The bolt holding the bracket should also be mounted in the opposite direction to tighten the holes and make the top spill-proof. Figure Figure 6-2 on page 6-6 shows the mounting of the brackets as delivered, and also how the parts should be assembled after removing the brackets. Follow these steps to correctly remove and reassemble the parts: 1. Remove the top lid from the cabinet for easy access. 2. Loosen and remove the top nut, then remove the washer and lifting bracket. Keep these parts for possible future relocation of the cabinet. Note! Only the nut and washer on top of the lifting bracket should be removed. 3. Enter the bolt in the opposite direction and fasten it from the inside with the remaining nut and washer as shown in Figure 6-2 on page 6-6. 4. Slide the top lid back into position on top of the cabinet.


6-5

Installation guide

Figure 6-2 Removal of lifting brackets

Lifting bracket as delivered

Location of lifting brackets.

Lifting bracket removed and bolt fastened in opposite direction.

6-6


Installation guide

6.2.4 Grounding Earth connection is essential BEFORE connecting supply. 1. Switch off all the breakers in the distribution panel. 2. Remove the roof by loosening the two screws at the front, which hold the top in position. Pull the top forward and lift it up. 3. Connect the grounding cable between the grounding connector in the positive DC busbar of the cabinet and the main grounding point at the back of the cabinet. 4. Check that the cables are secured tightly.

6.2.5 Cable sizes / location of external connections Max. 16 mm2 (4AWG) Max. 1,5 mm2 (14AWG) Max. 16 mm2 / 35 mm2 (4AWG / 1AWG) Max. 35 mm2 (1AWG) (50mm2 (0AWG) w / cable lug)

Mains: Alarms: Load: Battery:

Alarm connections are located at the top right side of the system. 6.2.5.1

Cable entry box

The cable entry box delivered with the system (or additional cable entry kit option) should be mounted before connecting mains and load. Remove or lift the cabinet top before installing the cable entry box. Once a cable entry side is selected (rear, left or right) the panel in the selected position is replaced with the panel in Figure 6-3. Default cable entry side is to the right, so no panel is mounted in this position. Do not remove the panel during cable installation. Follow steps 1 through 5 below to complete installation of the cable entry box. Figure 6-3

Cable entry casing.(Shown without nipples)

Battery tube entry

Load/Battery/Signal cable entries

Mains cable entry 1.

Select cable entry side and remove the cover where mounted. If rear or left cable entry is wanted, the cover mounted here can be moved to the right side.

2.

Fasten the cable entry casing to the cabinet with three M4 screws.


6-7

Installation guide

3.

Attach the casing to the cabinet.

4.

Mount the casing top and fasten with two M4 screws.

5.

Cable entry box installation is now complete, lower the cabinet top.

Figure 6-4 Mounting of Cable entry box 2

1

(Feed-through plate shown without nipples) 3

4

6-8

5


Installation guide

6.2.6 Connection of Mains 1. Ensure that mains input is turned off before connecting. 2. Enter the mains supply cable into the cabinet through the mains cable entry in the cable entry box. 3. See 6.2.5 Cable sizes / location of external connections on page 6-7 for reference. Push the cable to the terminal block. Fasten the cables with the mounting screws. 4. When connecting mains to terminal blocks remove as little insulation from the cable as possible before installing into terminal block, so that the jacket prevents a stranded conductor from coming loose and touch any secondary conductive parts on the backplane. Note! The insulation on the cable must have a clearing of minimum 1mm in the terminal blocks 5. The mains input terminal blocks can be connected to: 1x230V AC, 3x230V or 3x230/400V AC. USA / Canada connections: 1x220V AC, 3x220V AC or 3x220/440V AC. 6. Use Torque table in the Maintenance and Troubleshooting chapter for the correct torque. Figure 6-5 Mains Input Types L1 L2 L3 N PE

L1 L2 L3 PEN

L1 N PE 1 wire system TN-S 230V AC 1ph

4 wire system TN-C/IT 230V AC 3ph

5 wire system TN-S/TT 230/400V AC 3ph Figure 6-6 Input Mains Terminal

1x3 phase 230V AC

N2

3

L1

3

N2

3

L1

4

N

4

N3

4

L2

4 5

N L1

4 5

N3 L1

4 5

L2 L2

5

L1

5

L1

5

L2

6

L2

6

L2

6

L3

6

L2

6

L2

6

L3

7

L3

7

L3

7

L3

7

L3

7

L3

7

L3 L3 L2 L1

Document number: 039160.fm Revision: A

L1

Installation guide

L2

1x230V AC (USA/Canada 1x220V AC): 3x230V AC (USA/Canada 3x220V AC):

L3

L1

Recommended mains fuse: 1x230V AC (USA/Canada 1x220V AC):

L3

3

N

L2

N

3

L1

3

VALVETRAB VALVETRAB VALVETRAB VALVETRAB VAL-CP VAL-CP VAL-CP VAL-CP 350-ST 350-ST N/PE-350-ST 350-ST

L1 L1

N

2 2

N

N1 N1

Surge arrestor kit (Optional)

2 2

L3

N N

L2

PE

2 2

L1

1


PE

N

1

N

PE


PE

1

L3

PE

1

L2

1

PE

L1

PE

1


1

PE

N

PE

1

L2

N

Input mains terminals. 3x1 phase 230V AC

1

L3


3 phase 400V AC

Double pole 63A C-char (Mains 1) (USA/Canada: Double pole 70A C-char) Double pole 40A C-char (Mains 2) Triple pole 32A C-char (Mains 1) (USA/Canada: Triple pole 40A C-char)

6-9

Installation guide

3x230V AC (USA/Canada 3x220V AC): 3x400V AC (USA/Canada 3x440V AC): 3x400V AC (USA/Canada 3x440V AC):

6.2.6.1

Triple pole 25A C-char (Mains 2) (USA/Canada: Triple pole 30A C-char) Triple pole 25A C-char (Mains 1) Triple pole 25A C-char (Mains 2) (USA/Canada: Triple pole 30A C-char)

Mains Input Change

Attached to the cabinet behind the mains terminal blocks (the bags are attached to the cables between the terminal blocks and the subrack) there are two plastic bags containing fishplates, high voltage stickers (400VAC), labels for 3 phase 400 VAC and labels for 3 phase 230VAC for mains input change. 1. Connect according to Mains schematics in Appendix A 2. Attach labels accordingly on the cabinet chassis

6.2.7 Connection of Alarms For remote supervision of the alarms, there are 4 potential free alarm contacts. Each alarm contact represents different alarm conditions. Potential free alarm contacts for remote signalling at PBDU interface are located in the right side of the distribution. Note! Alarm contacts are shown in alarm position. Figure 6-7 Connection of Alarms

i

IOIOI MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C120N

1

3

2

4

D100

C120N

multi 9 1

3

2

4

D100

415V 10000

I ON

C120N

1

3

2

4

D100

415V 10000

I ON

415V 10000

I ON

I ON

I ON

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

Location of alarm connections

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

+ T + T -

DI.1 DI.0 Red Green Blue Red Green Blue

+ T + T -

Red Green Blue Red Green Blue

T

Alarm contacts are shown in alarm position

0V +12V DO.1 DO.0

6-10

6 5 4 3 2 1 6 5 4 3 2 1 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1

J2

Batt. sym. 4/ ext. analog

J1

Batt. sym.

J3

Digital input (Door alarm) Temp. Probe 4

J5 Temp. Probe 3

Temp. Probe 2

J4 Temp. Probe 1

Alarm 6

J9 Alarm 5

6 5 4 3 2 1

J8

3 2 1

J7

Alarm 2

3 2 1

J6

Alarm 1

4 3 2 1

J10

Digital output

Alarm 4

Alarm 3


Installation guide

Alarm cabling install: The green connectors can be easily removed, if desired, for ease in installing the wires to the connector. 1.

Remove the green plug from each connector.

2.

Determine whether to reference normally closed or normally open with reference to common for each alarm contact.

3.

Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper ferrule if desired.

4.

Insert wire into the correct positions in the green connector and tighten screw to clamp wire into connector.

5.

Route the wires through the cable area at the top left of the cabinet.

6.2.8 Connection of Symmetry Measurement and Temperature Sensor The controller can supervise the symmetry of up to 4 battery branches. The drawing in Figure 6-8 on page 6-12 shows how to connect the symmetry cables for 1 battery branch. Symmetry and temp. sensor contacts are located in the right side of the distribution. Note! The number of battery branches to be supervised has to be set in the controller in order to activate the symmetry measurement. It is also possible to add four temperature probes to the system for temperature compensated charging of the battery bank. Fasten the temperature probe in the middle of the battery bank. The temperature probe will measure the ambient temperature of a battery bank and the controller will adjust the float charge according to the temperature compensation factor set in the controller. This factor must be set in the controller according to the battery manufacturer recommendation.


6-11

Installation guide

Figure 6-8 Connection of Symmetry (2 Block Measurement) and Temp. Sensor -24V

0V -12V

-24V

-24V -36V -48V

-24V

0V -12V

-24V

-24V -36V -48V

+ T + T -


+ T + T -


6 5 4 3 2 1 6 5 4 3 2 1

6 5 4 3 2 1 6 5 4 3 2 1

Batt. sym. 4 J2

Batt. sym. 3

Batt. sym. 2 J1

Batt. sym. 1

Temp. Probe 4

J5 Temp. Probe 3

Temp. Probe 2

J4 Temp. Probe 1

T Installing the Symmetry cabling and the battery temperature sensor: 1.

Remove the green plug from each connector.

2.

Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper ferrule if desired.

3.

Insert wire into the correct positions in the green connector and tighten screw to clamp wire into connector.

4.

The wires are wound up and pre-routed with fastener strips on the cabinet sidewall. The cables must be unwound and connected to the battery pole according to the Figure 6-8 on page 6-12.

6.2.9 Battery connection The battery cables of the system are, if ordered, pre-connected to the systems battery breakers. The “+” cable of each battery string is connected to the positive bus bar of the system, and the “-“ cable to the negative battery breaker (separate for each string). Connect the other ends of the cables to the “-“ and “+” terminals of the batteries. Note! Fasten the cable lugs pointing upwards, as there is not enough space in the cabinet for sideways installation.

6-12


Installation guide

6.2.9.1

Battery tube routing

The ventilation tube from the battery should be routed out of the cabinet through the cable entry casing as shown in Figure 6-9. Pull the tube through the cable entry casing from the inside, and attach a tube extension piece to avoid the tube sliding back inside the cabinet. Note! Nipples on cable entry casing not shown in Figure 6-9. Figure 6-9 Battery tube routing

6.2.10 DC connection This section details how to connect external load to the DC load breakers. Check that all the MCB’s are in the OFF position. 1. Connect the negative (-) DC supply cable to the appropriate negative DC distribution MCB by inserting the stripped cable in the opening on top of the MCB and tightening the screw. 2. Make sure the cable has the correct rating (i.e. thick enough) for the selected MCB. 3. Connect the positive (+) DC supply cable directly to the positive bus bar by inserting the stripped cable to the hole on top of the screw connector so that the cable is behind the bus bar, and then tightening the screw. 4. Start connecting the loads to the bus bar from the first connector on the left. Make sure the cable is the correct rating (i.e. thick enough) for the load. 5. Check that all the cables are secured tightly to the connectors. Use Table 13-1 in the Maintenance and troubleshooting chapter for the correct torque.


6-13

Installation guide

6-14


Commissioning

7 Commissioning

Commissioning Document number: 036285.fm Revision: A

7-1

Commissioning

7.1 Commissioning Overview Before delivery the system was thoroughly inspected and tested. The following chapter is a guide to the set-up and operation of the control functions of the system. Note! Before starting commissioning read the product description for the individual components.

WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS. If there are any difficulties in increasing the voltage to alarm level, the alarm level can be adjusted to a lower level.

7.2 Tools and Test Equipment 7.2.1 Tools List The essential commissioning tools are listed below: z

A PC with PowCom installed (when controller is without LCD Display)

z

Anti-static hand strap

z

Socket wrench, insulated

z

Screwdriver set, flat, insulated

z

Screwdriver set, torx, insulated

z

Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated

z

Torque spanner (for battery connection), insulated

7.2.2 Test Equipment z

Multimeter (3 ½ Digit, 0 – 1% DC)

z

Load resistance, to connect 0-100% of total capacity to the system

7.3 Preparation Check the installation to ensure the following: z

Site is clean and safe

z

Grounding: The equipment is correctly grounded. The grounding cable size, color and routing conform to the requirements

z

Power: The incoming mains AC power is available for this site. The site power switch and circuit breakers are clearly labelled. The power cables are correctly terminated

7-2


Commissioning

7.4 Commissioning procedure 1. Remove the covers and check that all connections are made according to the installation drawing. Verify that all connections are properly tightened with sufficient torque. 2. Ensure load and battery MCB breakers are set to OFF position - ensuring the load and battery strings are connected. 3. Ensure all rectifier modules are removed. If not, remove each one in turn starting from the rightmost position. 4. Check the battery polarity with the Multimeter (3½ Digit, 0·1% dc). Place the positive lead of the meter to the plus-bus bar, and the negative lead to the battery breaker. The meter must now show a positive voltage. If the voltage is negative, change over the connection of the blue and black battery cables to the batteries. 5.

Turn on the AC mains voltage.

6. Measure the AC voltage on the AC terminal block, between phases and neutral. The correct value is approximately 230V. If the value is different, check the AC connection. 7. Plug in all rectifier modules, starting from the leftmost position. Make sure to fasten the rectifiers again. The rectifiers will turn on automatically. 8.

Set load breakers into "1" (ON) position.

9. Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s) (Normally not more than 5V DC) 10. Green LED on controller should blink for approximately 20 sec. 11. Output voltage will increase slowly to U1. 12. Turn battery breaker to "1" ("on") position. 13. If any alarms are present, they should be reset in accordance with "Show alarms" in product description controller. 14. The system should now be without alarms. 15. Attach all the system covers in their correct places. 16. Check that all changes to drawings, if any have been completed. 17. Clean the site. 18. Fill in the commissioning record (see end of chapter).

Commissioning Document number: 036285.fm Revision: B

7-3

Commissioning

7.5 Test of output voltage 7.5.1 Float charge (U1) Be sure that the controller is operating. Connect load, approx. 50% of total capacity, to the system. Check the voltage according to the battery manufactures requirements. If the batteries require other float charging voltage, adjust the output voltage from the controller. (See product description controller) If nothing else is required, use the following values: Battery type

Float charge

Boost charge

Open lead-acid batteries

2,23V/Cell

2,33V/Cell

Sealed lead-acid batteries

2,27V/Cell

-

Table 7-1

7.5.2 Adjustment of float charge, U1 Output voltage is factory pre-set to: See Appendix B. The total voltage has to be in accordance to the number of battery cells. Please verify number of cells and the battery manufacturers requirements. Adjust output voltage from the control unit. Note! A sealing protects the potentiometer in the subrack. Do not break the seal.

7.5.3 Boost charging (U2) (if applicable) Open lead-acid batteries. Automatic boost charging - calculation of the time the battery voltage has been below certain levels. Automatic activating of boost charging for this calculated time multiplied by a (boost) factor. Activate boost charging from the "Set/select U1-U4" menu in the control unit. Return to float charge manually by selecting "U1", or automatically after a pre-set time. Sealed lead-acid batteries. Most of the manufactures of sealed lead acid batteries do not recommend boost charging. If this type of battery is used, the boost function should be disabled. Boost charging figures Observe and write down all of the boost charging figures. Parameters to be read/set/adjusted from control unit or PC with PowCom1 installed.

1.

7-4

Communication program for remote control of the power supply system.


Commissioning

7.6 Battery supervision For systems with symmetry cables supplied: Set number of battery strings according to number of battery strings in the system. The settings are to be made in the control unit via a PC with PowCom installed or directly in the controller (if symmetry failure is indicated). The symmetry fault alarm is to be simulated by pulling out one symmetry cable from battery string. Measure that setting to make sure that it is in accordance with battery manufacturer recommendations. For systems with temp. probe cable supplied: The temperature compensation is factory pre-set. Check that the temp. probe is activated and verify that the compensation level is according to the battery manufacturers requirements. (If no compensation level is available from the battery manufacture, Power One recommends it to be set to 0,5V).

7.7 Battery test The settings should be made according to the battery manufacturer requirements, but as a rule of thumb the following settings can be used for standard VR lead batteries: No. of test pr. year U3 Test End voltage b.test Batt. test time Ah limit for test

= = = = =

2 1,9 V/cell 1,94V/cell 40% of expected backup time 40% of nominal battery capacity

Parameters to be set/adjusted from the controller (Battery test menu) or "Supervision - Set parameters” menu in PowCom.

Commissioning Document number: 036285.fm Revision: B

7-5

Commissioning

7.8 Commissioning record This is a step-by-step commissioning record for easy commissioning of Power-One Supply Systems. Do not continue if any faults occur during this commissioning. The checkpoints are to be considered as a minimum for commissioning of the system. Checked

Result

(D) 1. Check that rack is levelled 2. Check that all breakers are turned to “off” position and that no rectifiers are mounted in the subrack(s). 3. Connect AC, and measure voltage on the mains input connections in the cabinet, Is to be 230V AC (Measure 230V from phase to N when 400V mains input is used) 4. Mount rest of the rectifiers 5. After connection of battery, verify right polarity by measuring the voltage drop across the battery breakers (normally not more than 5V DC). 6. Check float charge, U1, and boost charge, U2. Is to be adjusted according to the battery manufacture requirements. 7. Check temperature compensation. Is to be adjusted according to the battery manufacture requirements. Check temperature read off compare to the room temperature. 8. Check symmetry measurement and set number of battery strings according to actually supervised battery strings in the system.

L1-N:………..V AC L2-N:...............V AC L3-N:...............V AC

U1:……..V DC U2:.........V DC Comp. :…….V/10oC Read off:………oC

Number: …. Alarm limit:……

9. Check alarm transmission by running an alarm test. Table 7-2

7-6

Commissioning record


Operation / Product description PCS 2

8 Operation / Product description PCS 2

Operation / Product description PCS 2 Document number: 036777.fm Revision: A

8-1


8.1 General - Product description PCS 2 PCS 2 - Power One Control System is a supervisory system particularly designed for supervision of power supply systems based up on Power One rectifier modules. The design is based up on the philosophy that one main controller supervises the entire power supply system, and use of distributed intelligence by local micro controllers. A RS485 data bus is used for internal communication between the various units. Very simple internal colour labelled signal wiring using only two cables with RJ45 plugs in each end. RS232 serial interface for remote control from a PC with PowCom1 software. For more detailed project specific information regarding system settings see Appendix B, Configuration. This document specifies all available standard Power-One alarms, i.e. alarm 0 up to 23 and any customer specific alarms (available as alarm 24 up to 39). Note! Some of the alarms have Power-One standard limits and some of them have customer specific adjusted limits. A complete supervisory system do always consist of the following units: PCS 2 - Main Controller Master unit in the system communicating with all distributed micro controllers. Has an LCD display, menu driven operation, visual alarm indication, RS232 contact for remote operation and RS 485 for internal communication with 128 addresses (64 rectifier modules - and 64 other remote micro controllers). Sockets for plug-in network interface. The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and enables the system to be accessed from any location. The protocol uses simple commands to configure and control the system and relay the system status to the operator. Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can be used in conjunction with PowComTM software either through a modem or Ethernet connection. PCS 2 - Alarm Interface board The alarm interface board contains: z

Input for current reading

z

Battery and load breaker monitoring

z

Battery temperature and battery symmetry measurement

z

Output for operating two individual contactors (LVD and PLD)

z

6 potential free alarm contacts.

z

Three analogue and two digital inputs for supervision of miscellaneous signals (ventilation, door open or other).

8.2 Technical specification: Input voltage:18-72V DC Power consumption:Max 30W Output:+/- 12V 1.

8-2

PowCom is a communications software package that allows the remote control of the system. The software uses a Windows based interface to allow access to the PCS. PowCom is installed on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up modem.



InstrumentationThree LED's, Green - OK, Yellow - Message, Red - Alarm 2 x 20 character alphanumeric LCD display with backlight. 5mm character height. Interface:RS 232 for remote operation via PowCom. RS 485 for internal communication with 128 addresses (64 rectifier modules and 64 sub-controllers). Basic functionsSimple manu-guided operation User-selectable alarm parameters 40 event data logging Internal clock with battery backup Multiple language options Temperature compensated charging Boost charging, manually and automatic Monthly data logging LVD control of two contactors, voltage or time controlled Battery test, manual or automatic with symmetry measurement Alarm relay test Adjustable battery current Software controlled start up after mains outage and battery test Optional Ethernet interface

WARNING! RISK OF EXPLOSION IF LITHIUM BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS.

8.3 Operation - Introduction The PCS 2 communicates through an alarm interface board and a backplane that connects to the rectifier modules. There may be up to 64 rectifier modules and 63 Units on one serial channel. The following section contains basic PCS 2 functions including starting the PCS 2, adding modules and removing modules from the PCS 2 system. Figure 8-1

PCS 2 LED's and control.

RS235 Interface Connection

Power LED (Green) Warning LED (Yellow) System Interface Controls Alarm LED (Red)

Operation / Product description PCS 2 Document number: 036777.fm Revision: B

8-3


8.3.1

Starting the PCS 2

When power is applied to the PCS 2: The PCS 2 will spend 20 seconds analyzing the system and testing all addresses for connected modules and units. The green LED on the PCS 2 will blink (Figure 8-1). No alarms will be given during this period. When the PCS 2 finds a module or a unit it will add it to the inventory. The module will remain in system memory until a master reset or a reconfiguration is done.

8.3.2 Adding modules When a rectifier is added to the system it will remain off until the PCS 2 detects it. 1.

The PCS 2 constantly scan for new modules and units, but it may take up to 5 minutes from a module is inserted until it is registered. During this time the yellow warning LED on the module will blink.

2. The PCS 2 will locate the module and the LED will stop blinking. The new module will give a current sharing fault until its output voltage has been adjusted to the correct voltage. This may take additional time. 3. To shorten the time that is needed to find new modules the PCS 2 can be powered down and then powered up. This will cause the system to search for new modules faster. This is only recommended as a solution if it is important to shorten the time required for searching for new modules.

8.3.3 Removing modules Physically removing a module from the system appears as a communication error on the PCS 2. 1.

To remove the error message use the Accept removed parts item on the Miscellaneous menu, or press the reconfigure button in the Inventory window in PowCom.

2. Make sure that there are no communication faults caused by any failure before doing this as it will cause all not communicating modules and units to be removed from the inventory. 3. This will make all communication faults disappear, but it will not fix any problems so it must only be used if the communication fault is caused by the module or unit being intentionally removed.

8.4 PCS 2 Control The control unit is equipped with four push buttons: z

CANCEL - Used to go cancel the current selection on the menu hierarchy. When pressed the menu will return to the previous screen.

z

UP ARROW - Used to go up in the menu hierarchy. select options and to adjust limits.

z

DOWN ARROW - Used to go down in the menu hierarchy. select options and to adjust limits.

z

RETURN - Used to select and confirm an option or to go down a level in the PCS 2 software hierarchy.

To adjust the alarm limits, use the arrow keys to select "adjust limits". Press RETURN to enter the sub menu, and RETURN once more to select "alarm limit". By using the arrow keys the various alarm limits can be checked. For adjusting a limit: select the correct limit and press RETURN. The correct password must be entered before a new value can be set. The password is set to 1234 by default, but can be changed. Use the arrow keys to set and RETURN to confirm each digit. CANCEL can be used to correct a digit. For more information on setting the system password, see the section "Set New Password" in this chapter.

8-4



Adjust mode is indicated by a: (colon) in front of the value and a steady cursor behind. Use the arrow keys to adjust the alarm limit and press RETURN to confirm the value or CANCEL to revert to the previous value. To return to main menu, press the CANCEL button. If the PCS 2 is left unattended the display will return to main menu automatically after 2 minutes. The backlight will be turned off. after 2 minutes without any key pressed. It will be turned back on by pressing any key.

8.4.1 PCS 2 Menus The PCS 2 menu is divided into nine sections. Some of these sections are further divided into more menu options. Figure 8-2 Menu tree shows the hierarchy tree. The following section contains descriptions of each menu option. 8.4.1.1

Show voltage and currents

The default PCS 2 screen displays system voltage and battery current. Pressing the down arrow will display system voltage and distribution current, pressing down once more will display system voltage and rectifier current. 8.4.1.2

Show alarms

Displays the current alarm status. If there are several alarms use the arrow keys to scroll through the alarms. Any new alarms or alarms that disappear will be added or taken off of the menu immediately. Battery failure and symmetry failure alarms need to be reset manually by pressing RETURN at the show alarms display. 8.4.1.3

Show messages

This item displays any messages. If there are several messages use the arrow keys to view the various messages. New or disappearing messages will be updated immediately on the menu. 8.4.1.4

Show data

This menu displays information about: modules, units, temperature, and symmetry voltage. Information on each of these menus is in the following section: Module Data This menu displays information from each rectifier module. Use the arrow keys to select the module number. Note! Rectifier modules are numbered from the top to bottom, and left to right. Once the rectifier is selected on screen, Pressing RETURN will display a new menu with the following information: communication status, module current, mean current, module temperature, module measured voltage, Module OVP limit, alarm information, serial number and module software version number. Module alarms are indicated by 3 letter flags. The meanings of these are as follows. z

MNS - No input mains.

z

LOW - Input voltage low

z

OFF - No operation, caused by no mains or other failure

z

OVS - Overvoltage shutdown

z

FAN - Fan failure, will cause the module turn off (depending on type of module.)


8-5


z

CUR - Current sharing fault. Current deviates too much from average

z

TMP - Temperature is high. This alarm must be reset manually

Unit Data This menu shows information from the individual units. Units are I/O parts of the system like alarm interface cards and distribution cards. The information available is communication status, serial number and unit software version number. Temperature This menu displays the battery temperature. Symmetry Voltage The symmetry voltage for each battery branch is displayed. 8.4.1.5

Select / adjust U1 - U4

This menu is used to select one of the references for the 4 charge modes, U1 - float voltage, U2 - boost voltage, U3 - battery test voltage, U4 - spare, and to adjust these references.

CAUTION! Always consult the battery user's guide before attempting to boost. Improper settings can damage batteries. The voltage references can be adjusted in steps of 0,1V. U1 Normal. The U1 reference is shown, press RETURN to change U1 (The float charge voltage) and use the arrow keys to adjust to the proper voltage. U2 Boost. The U2 reference is shown, press RETURN to change U2 (The boost charge voltage). U3 Test. The U3 reference is shown, press RETURN to change U3 (The Battery test voltage). U4 Spare. The U4 reference is shown, press RETURN to change U4 (The spare voltage). The U4 setting is normally not used in this system. 8.4.1.6

Adjust limits

The Adjust Limits menu allows the user to change and add limits to the system. The menu has the following options: alarm limits, boost parameters, battery test, temperature compensation, battery current limit, system specific limits and distribution current limits. Parameters can be set and adjusted by selecting the different sub-menus. Alarm limits. This menu allows the following alarm limits to be changed: z

High voltage

z

Low voltage

z

Over voltage shutdown limit

z

Low voltage disconnect

z

Partial low voltage disconnect limits

z

Load reconnect limit

z

High load limit

8-6



z

High temperature limit.

Change these limits using the arrow keys and RETURN to select. See Appendix B, Configuration for default settings. Boost parameters. This menu contains the limits for boost charging control. See section "Boost charging" for more information. Battery test. This menu contains the limits for battery test. See section "Battery test" for more information. Temperature comp. This menu turn the temperature compensation on and off, and is used to set the compensation factor. System specific limits Only available for specific systems. For more information see Appendix B, Configuration Batt. Cur. Limit. This menu is used to toggle the battery current limiting on and off, and to set the current limit. Dist. Current limits This menu is used to toggle each distribution high current alarm limit on and off, and to set the current limit. Note! Current limiting is not available on all systems.

8.4.1.7

Miscellaneous

The miscellaneous menu is used to set the date and time, change password, view version information, initialize modem, show symmetry voltages and temperature. Set time The clock is shown. Press RETURN to adjust the clock. The clock has a battery back-up and will keep the time even if the PCS 2 is turned off. Relay test Press RETURN to check the alarm relays. Use the arrow keys to select the relay to be activated. Alarm blocking Use Alarm Blocking to disable the relays during service. One alarm relay will normally be active as long as the alarms are blocked. Version Show the PCS 2 software version, configuration number and serial number. Set new password Choose "set new password" from the "miscellaneous" menu. Press RETURN, enter the old password and press RETURN. Enter the new password and confirm by pressing RETURN. To avoid mistyping the new password has to be entered once more. Confirm by pressing RETURN. Note! Be sure to note the new password. If the password is not known or access is denied, contact Power-One technical support for assistance Shunt A Displays the current rating of the battery shunt. I.e. this parameter shows the value of current in the current/ voltage ratio of the shunt.


8-7


Shunt mV Displays the voltage drop of the battery shunt at rated current. I.e. this parameter shows the value of voltage in the current/voltage ratio of the shunt. Network address Displays the network address for each module. Several PCS 2's may be connected together in a multidrop RS232 network. The modules require a unique address between 2 and 255. This address may be set here. Baud rate Select the baud rate for the RS232 serial port of the PCS 2. Either 2400 or 9600. Init modem Press RETURN to send a string to initiate a modem. See the modem instructions to see if it requires additional initialization to operate. Accept removed parts Removing a module or unit will appear to the PCS 2 as a communication error. If the module or unit is intentionally removed then the PCS 2 will need to be informed. Select "YES" in the Accept Removed Parts menu to inform the system that the module was removed. Note! Do not accept removed parts if the there is an alarm on a module that has not been removed. Reset to defaults This command will reset the system to default values without deleting logged data or system information. It is recommended to try this in stead of Master Reset if a reset is needed. After a reset always check all limits and adjust them to the desired level. Master reset Will completely reset the PCS 2, deleting all stored data. If possible backup the data to a PC before doing a master reset. After a reset always check all limits and adjust them to the desired level.

CAUTION! A Master Reset will delete all information from the system. Use the master reset feature only as a last resort. Language This menu is used to choose the language used in the PCS 2 menus. Selecting a different language will immediately change the menu language. The language menu is in English by default.

8-8



Figure 8-2

Menu tree

Show voltage/ Batt. current

Show voltage/ Distr. current

Show voltage/ Rect. current

Show alarms

Show alarms

Show messages

Show messages

Show data

Module data

Unit data

Symmetry voltage 5

Temperature

Symmetry voltage 6

Ext. measurements

Symmetry voltage 7

U1 normal voltage Distr. current Select/adjust U1-U4

Symmetry voltage 8

U2 boost voltage Symmetry voltage 1

Symmetry voltage 9

U3 test voltage Symmetry voltage 2

Symmetry voltage 10

U4 spare voltage Symmetry voltage 3

Symmetry voltage 11

Reference Symmetry voltage 4

Adjust limits

Symmetry voltage 12

Alarm limits

Low voltage

Boost parameters

set time

Miscellaneous

Relay test

Battery test

Temperature comp.

Alarm blocking Batt. current limit

Menu language Version

Syst. specific limits Set new password

Shunt current

Shunt voltage

Network address

Symmetry limit

Enable temp. comp.

Enable current limit Batt. current limit

Comp. factor

Test end voltage

Test duration

Ah- limit

Time of test Distr. current lim. No of tests/year

Boost time

High voltage

Boost interval

Overvolt. Shutdown

Boost factor

Load/battery disconnect

Boost t1

Partial disconnect

Boost t2

Load/battery reconnect

Autoboost enable

High load

Temperature alarm

No of batteries

Battery type

Baud rate

Init modem

Accept removed parts

Reset to defaults

Master reset


8-9


8.4.2 Connecting to PC The PCS 2 to PC connection requires a RS232 cable to connect to the PCS 2 and to the PC serial port connection. Cable The PC to PCS 2 connection is made using a modem, or directly with a null-modem cable (Figure 8-3 PCS 2 to PC cable). P1 and P2 are both 9-pin female D-sub plugs. P1 is to be connected to the PCS 2. Figure 8-3

6

PCS 2 to PC cable 1

9

5

P1 Pin

P1

P2

2

Receive

Transmit

3

Transmit

Receive

5

0V (Ground)

0V (Ground)

Table 8-1

5

9

1

6

P2

RS232 Cable Pin Outs

1.

To connect the PCS 2 to the PC, locate the RS232 interface connector on the front of the PCS 2.

2.

Connect one end of the RS232 cable to the interface connection.

3.

Route the cable to the rear of the PC (the PC should be powered "Off").

4.

Connect the RS232 cable to the #1 serialport on the PC.

5.

Power up the PC and start the PowCom software.

6.

Choose "Communications" from the PowCom menu, and select "Port Setup" (Figure 8-4).

8-10



Figure 8-4

7.

Communications menu

Select "9600" baud rate from the Port Setup menu (Figure 8-5).

Figure 8-5

Port Setup Menu

8.

Select "OK"

9.

Choose "Direct Communication" from the Communications menu.

10. Enter Password (1234 by default). 11. See "Product description PowCom 3.17" for more information about using PowCom software

8.4.3 Boost charging Open the "Select/Adjust" menu on the PCS 2. Boost charging can be activated by three methods: Manual boost charging - Choose "U2" in the reference menu for activating boost charging. (Return to float charge manually by choosing "U1", or automatically after a pre-set time.) Periodic boost charging - after a pre-set period boost charge will be automatically activated for a pre-set time. Interval and boost time to be programmed (for example 4 hours every 3rd week). Automatic boost charging - when during a mains failure the battery voltage falls below LEVEL t1 value, a timer is started. When the mains return, the system will start an automatic boost. This will last a certain time after the battery voltage reach LEVEL t2. This time will be multiplied with a factor, K. LEVEL t1, LEVEL t2 and the factor can all be set.


8-11


Figure 8-6

Boost charging

Voltage (V) Level t2

U1 (Float Charge) Level t1

t1

Mains Interrupt

t2=K x t1

Time (hour

Mains Returns

The following values are adjustable for boost charging: Boost voltage40 - 60 Volts Boost time0 - 200 hours Boost interval3 - 16 weeks Boost factor1.0 - 16 Boost t140 - 60 Volts Boost t240 - 60 Volts Auto boost enablePassive - Active Disabling Automatic Boost Charge: Select "Boost parameters" in the "Adjust limits" menu. Push RETURN, up arrow and RETURN / then select disable. Note! Most manufactures of sealed lead acid batteries do not recommend boost charging. If this type of battery is used, the boost function should be totally disabled by settings as follows: Boost time = 0; U2= U1

8.4.4 Battery test The following section contains the procedure for testing the batteries in the system. Battery testing is activated by selecting U3 (in the "Choose reference" menu.) Once selected the rectifier voltage will decrease to a pre-set value (U3, adjustable). The system will begin logging battery voltage, battery current and Ah. The battery test will automatically be interrupted and output rectifier voltage will raise to U1 level, if programmed time, Ah or end voltage is reached during the test. The test is considered as accepted if time or Ah causes the interruption. If the battery voltage reaches programmed end voltage, the battery is considered as faulty, and an alarm will be indicated and further automatic testing is interrupted. Battery tests can also be set to activate automatically 1-4 times a year. In the "Choose Reference" menu, select "Select no. of tests". The measurement will automatically be started at mains interruption but will not be saved if duration of mains outage is less than 30 min.

8-12



Parameter Settings. The parameter settings feature allows for the partial discharge of the batteries (approx. 30-40% of the capacity) in order to test the batteries for errors. The settings should be done according the battery manufacturer requirements, however, the following settings can be used for standard VR lead batteries: U3 = 1,9 V/cell End voltage = 1,94V/cell Time = 100% of expected backup time Ah = 40% of nominal battery capacity Parameters to be set/adjusted from the "battery test" menu or PC with PowCom installed. Battery test voltage:U3 Symmetry limit: Test end voltage: Test duration: Ah limit: Time of test: No of test/year: No of batteries: Battery type:

0- 100 Volts 0.0 - 4.0 Volts 0-100 Volts 0- 20 hours 0- 50000 Ah 0 - 23 (0=midnight) 0-4 0 - 12 4 blocks, 23 cell-, 23 cell+, 3 blocks or 2 blocks

Number of batteries must be equal to number of symmetry measurements. If symmetry cables are not in use, number of batteries must be set to 0 (zero).

8.4.5 Battery current limit Battery current can be controlled by the PCS 2. The PCS 2 will adjust the rectifier current limit so that the total rectifier current may not exceed "load current + desired battery current". Rapid changes in load current will lead to changes in battery current, due to this variation the current can be above the limit for a limited time. In the PCS 2 you can set the battery current limit from 5A to 3000A. There is also a function to enable or disable the function all together.

8.4.6 Temperature compensation The supervisory module can adjust the charging voltage to compensate for temperatures above or below 20oC. T > 20oC lower charging voltage. T < 20oC higher charging voltage. The temperature compensation function can be enabled and disabled and the level of compensation is adjustable.

8.4.7 High load The "High Load" alarm is activated when the load current exceeds the capacity of the installed modules multiplied by the high load limit. This is an indication that the system requires increased rectifier capacity.


8-13


8-14


Product Description FMP 16

9 Product Description FMP 16

Product Description FMP 16 Document number: 036972.fm Revision: A

9-1


9.1 General - Product description FMP 16 The FMP 16 rectifier module is a modular power supply designed for parallel operation and plug-in installation in the PPS 16 systems. The rectifiers provides extremely reliable DC power in the highest possible density. The module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load sharing among rectifiers, and providing status and identification information to the controller. There is no cabling at the front of the unit. The AC input, DC output and signal cables are connected using a backplane integral to the cabinet frame. A rectifier module can be plugged into, or unplugged from, the support frame with no impact upon the other modules. The rectifiers operate on the principle of active load sharing and can operate in parallel. They incorporate "soft start" at the input and at the output, which avoids high incoming and outgoing currents. The output voltage of the rectifier is automatically adjusted to the required voltage at installation by the controller. The rectifiers in the system are controlled by the controller, see chapter 8, Operation / Product description PCS 2.

9.2 Technical specification 9.2.1 Mains input Input voltage:100-240V AC +/-15% single phase Input current:<10A Frequency:44-66 Hz Power factor:> 0,98 typical

9.2.2 DC output 9.2.2.1

Mains input 185-250VAC

Voltage:45V DC - 56 V DC nominal Current limit:32A Power:1600W Efficiency:>93%, typical 93,5% (at 40-90% load) 9.2.2.2

Mains input 95-185VAC

Voltage:45V DC - 56 V DC nominal Current limit:27A Power:675W Efficiency:>88,5%, typical 90% (at 40-90% load)

9.2.3 Module dimensions Height:177 mm Width:51 mm Depth:280 mm

9.2.4 Weight Approximately 2,2 kg

9-2



9.2.5 Other technical data Protection:Short circuit proof Automatic current limiting Selective shut down of modules at excess output voltage Thermal protection reduces the output power at environmental temp. above maximum level. Shut down at >app 75oC with an automatic restart Input over-voltage disconnection at >275VAC with automatic reset at <260VAC Alarms:High output voltage / shut down Low voltage / module failure Each alarm has a common LED indicator on the front panel Enclosure:IP 20 Storage:-60 to +85°C Cooling:Fan cooled (front to back), speed controlled and alarmed

9.3 Operation FMP 16 has status indicators that is located on the front panel of the module. The output voltage is adjusted from the controller. There are three LEDs situated on the rectifier's front panel, which indicate the operating condition of the rectifier. Figure 9-1

Front view of FMP 16

FMP 16 has LED indicators as follows: GREEN Power ON YELLOW Thermal protection. Communication failure (flashing). RED Module failure / high output voltage / shutdown.

Product Description FMP 16 Document number: 036972.fm Revision: B

9-3


9.4 Environment The FMP 16 rectifiers meet the Environmental Standard requirements of: ETS 300 019-1-3 class 3.2 / 3M1 for Operating (Stationary In-Use) Temperature Range: -40°C to +65°C (up to 2000m) and -40°C to +55°C (above 2000m)

9.4.1 Storage ETS 300 019-2-1 Class 1.2.

9.4.2 Transport ETS 300 019-2-2 Class 2.3.

9.4.3 Operation ETS 300 019-2-3 Class 3.2.

9.5 Safety The FMP 16 rectifiers fulfil those international and national safety standards for these systems according to grounding, fire protection and other safety matters as specified in the following standards: EN60950 / IEC 60950 UL60950 CSA C22-2 No. 950

9.6 EMC The rectifiers' EMC meets the requirements of: EN61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4 and FCC Part 15 Class B

9-4


Product description PPR 16/10 23” Subrack

10 Product description PPR 16/10 23” Subrack

Product description PPR 16/10 23” Subrack Document number: 037680.fm Revision: A

10-1


10.1 General - Product description PPR 16/10 23” Subrack PPR 16/10 is a subrack/rectifier shelf for interconnecting of FMP 16 modules. Each subrack/rectifier shelf has 10 module positions. Module positions are numbered from left to right viewed from the front. Each subrack/rectifier shelf may be equipped according to present power requirements, and later be completed with additional FMP 16 modules. For high power requirements several subracks may be paralleled. Figure 10-1

10-2

Front view of subrack / rectifier shelf



10.2 Connections and functions 10.2.1 External connections Description PL4, PL6 PL3, PL5 PL12, PL11, PL14, PL13, PL16, PL15, PL18, PL17, PL20, PL19 Bus bar connections

Function RS 485 interface Current share with other PPR 16/10 Input mains DC output

10.2.2 Internal functions DescriptionFunction Dip switchesDip switches S12, S11, S14, S13, S16, S15, S18, S17, S20 and S19 are used for addressing module positions and has to be set for controller supervision to function properly. The switches can each address six bit binary addresses, which means up to 64 modules on one COM channel (total 128 modules if both COM channels are used). Addressing is performed by setting each of the six bits on each switch in either an ON or OFF position. See Table 10-1 Addressing module positions. Figure 10-2

PL12

Front and back view of the subrack

PL11

PL14

PL13

PL4 PL6 (Com)

PL16

PL15

PL18

PL17

PL20

PL19

PL3 PL5 (Curr)

Dip switch (S12 for module pos 1)

Negative (DC output) Positive (DC output)

PE N L

Product description PPR 16/10 23” Subrack Document number: 037680.fm Revision: B

Input mains

10-3


10.3 Connections between subracks Figure 10-3

Example shows three subracks connected together

Subrack 1

PL4 PL6

PL3 PL5

Subrack 2

PL4 PL6

PL3 PL5

Subrack 3

PL4 PL6

PL3 PL5

Curr. share signal between subracks Com.signal between subracks

Communication signal from alarm interface unit

z

Use cable marked with Brown 1 between PL6 in subrack 1 to PL4 in subrack 2.

z

Use cable marked with Orange 3 between PL5 in subrack 1 to PL3 in subrack 2.

z

Use cable marked with Brown 1 between PL6 in subrack 2 to PL4 in subrack 3.

z

Use cable marked with Orange 3 between PL5 in subrack 2 to PL3 in subrack 3.

Note! If the system consist of more subracks connect after the same method between subracks as described over.

10-4



10.4 Addressing module positions in subrack1, subrack2 etc. Subrack no = Number of subrack Module position= Numbered from bottom left position Connection= Dip switch 1-6 Dip Switch = Indicates which dip switch to be turned ON. Subrack no.

Module position

Connection

Dip switch ON

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6

All off 1 2 1+2 3 1+3 2+3 1+2+3 4 1+4 2+4 1+2+4 3+4 1+3+4 2+3+4 1+2+3+4 5 1+5 2+5 1+2+5 3+5 1+3+5 2+3+5 1+2+3+5 4+5 1+4+5 2+4+5 1+2+4+5 3+4+5 1+3+4+5 2+3+4+5 1+2+3+4+5 6 1+6 2+6 1+2+6 3+6 1+3+6 2+3+6 1+2+3+6 4+6 1+4+6 2+4+6 1+2+4+6 3+4+6 1+3+4+6 2+3+4+6 1+2+3+4+6 5+6 1+5+6

Table 10-1 Addressing module positions

Product description PPR 16/10 23” Subrack Document number: 037680.fm Revision: B

10-5


6 6 6 6 6 6 6 6 6 6 7 7 7 7

51 52 53 54 55 56 57 58 59 60 61 62 63 64

1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6 1-6

2+5+6 1+2+5+6 3+5+6 1+3+5+6 2+3+5+6 1+2+3+5+6 4+5+6 1+4+5+6 2+4+5+6 1+2+4+5+6 3+4+5+6 1+3+4+5+6 2+3+4+5+6 1+2+3+4+5+6

Table 10-1 Addressing module positions

10-6


Product description PBDU 4U/23”

11 Product description PBDU 4U/23”

Product description PBDU 4U/23” Document number: 038222.fm Revision: A

11-1


11.1 General - Product description PBDU 4U/23” Figure 11-1

PBDU 4U/23”

The Power-One PBDU 4U/23” includes a complete system controller plus battery and load distribution in a 4U unit. The Compact Distribution is compatible with various types of Power-One subracks/rectifier shelves, and may be configured for a variety of battery and load breaker selections. The distribution unit is designed for switching the battery and load on and off. All DC distribution breakers are supervised by measuring voltage drop across each breaker. MCB's (breakers), which are not connected to any load, will not cause breaker alarm even if they are left open. Due to small leakage current (2,5 - 3 mA) through the alarm circuit the voltage measured with a DVM (Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage. If a battery breaker fault occurs or is simulated it might take from 2 - 10 minutes before the fault is indicated, depending on the battery condition.

11.2 Technical specifications Voltage:48V DC nominal Load breaker capacity: Max 20-26 x 18mm MG-breakers C-60N, low-ohmic connections Battery breaker capacity: Max 2-6 x 27mm 1-pole MG-breakers Dimensions:23”/4U

11-2



11.3 Construction and functions The distribution module has common "+" and all the MCB's connected in the "-" branch. Figure 11-2

Typical distribution (Front view, controller unit removed)

0V Battery/Load

- Battery/Load Figure 11-3

Distribution (Top view) Protective Earth

+ Battery/Load Connections

- Battery/load Connections

11.4 Cable cross section output connections Load connections:Cable area max. 16 mm2 / 35 mm2

Product description PBDU 4U/23” Document number: 038222.fm Revision: B

11-3


11.5 Installation This section details how to connect the -48 V DC supply to the DC load. Check that all the MCB breakers and the AC mains supply are in the OFF position. Unscrew the cabinet's four top fixing screws and slide top-cover forward before lifting it up. Enter each load cable in to the cabinet trough the inlet at the back of the cabinet. Connect the negative (-) load DC supply cable to the appropriate negative DC distribution MCB by inserting the stripped cable in the opening on top of the MCB and tightening the screw. Make sure the cable is the correct rating (i.e. thick enough) for the selected MCB. Connect the positive (+) load DC supply cable directly to the positive busbar by inserting the stripped cable to the hole on top of the screw connector so that the cable is behind the busbar, and then tightening the screw. Start connecting the loads to the busbar from the first connector on the left. Make sure, the cable is the correct rating (i.e. thick enough) for the load. Check, that all the cables are secured tightly to the connectors. Use Torque Table in the Maintenance and troubleshooting chapter for the correct torque.

11.6 Commissioning PBDU 1. Switch on all MCB's in the distribution units. 2. Turn off one of the breakers and verify breaker alarm at controller. 3. Verify disappearing of alarm when turning the breaker on again. 4. Repeat the two above-mentioned steps for one MCB in each distribution module.

11.7 Maintenance The distribution does not need any special maintenance except for ordinary cleaning.

11-4


Product description PCS Alarm interface unit BM0685

12 Product description PCS Alarm interface unit BM0685

Product description PCS Alarm interface unit BM0685 Document number: 037901.fm Revision: A

12-1


12.1 General PCS alarm interface unit consist of BM0685, which is an alarm board for Power One systems. The unit is located on the right hand side of the distribution and is accessed from the top of the cabinet.

12.2 Technical data Connection:Plugable terminal blocks max. 1,5mm2 z

2x input for battery current reading (common + or -). (J20, J21)

z

Breaker monitoring, battery and load. (J20, J21)

z

Control signal for individual operating LVD and PLD. (J20, J21)

z

6 x potential free change over contacts. (J6, J7, J8, J9)

z

4 x input for symmetry measurement. (J1, J2). Optionally symmetry input 4 may be used as 3 x analogue inputs. (J2 pin 4-6).

z

4 x battery temp sensor. (J4, J5)

z

2 x digital inputs. (J3)

z

2 x digital output (J10)

z

RS485 interface for communication with plant controller PCS. (J24 and J25)

z

Up to four units per system.

12.2.1 Pin Configuration of J20 and J21 Plug J21

Pin 1 2 3 4 5 6

A RECONN1 DISCONN1 DF/BFM1 BATTFUSE1 SHUNT1+ SHUNT1-

B RECONN1 DISCONN1 DISTFUSE1 BATTFUSE2 SHUNT2+ SHUNT2-

Plug J20

Pin 1 2 3 4 5 6

A RECONN1 DISCONN2 DF/BFM2 BATTFUSE3 SHUNT1+ SHUNT1-

B RECONN1 DISCONN2 DISTFUSE1 BATTFUSE4 SHUNT2+ SHUNT2-

12-2



12.3 Remote alarms, symmetry measurement and temperature sensor Alarms:Six dry alarm contacts for remote signalling (J6, J7, J8, J9). Symmetry:Four separate inputs, each supervising battery branch symmetry voltage (J1, J2). Temperature:Four connection points for connection of Power- One temperature sensor (J4, J5).

J7 J6

12 3 12 3 12 3 12 3

456 456

J3

J2 J1 J5 J4

12 12 3 12 3

BM0685 alarm board

456 456

Figure 12-1

+ T + T -


+ T + T -


T

12 34 12 3 12 3

J10

J9 J8

456 456


0V +12V DO.1 DO.0

6 5 4 3 2 1 6 5 4 3 2 1 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1

J2

Batt. sym. 4/ ext. analog

J1

Batt. sym.

J3

Digital input (Door alarm) Temp. Probe 4

J5 Temp. Probe 3

Temp. Probe 2

J4 Temp. Probe 1

Alarm 6

J9 Alarm 5

6 5 4 3 2 1

J8

3 2 1

J7

Alarm 2

3 2 1

J6

Alarm 1

4 3 2 1

J10

Digital output

Alarm 4

Alarm 3

12.4 Maintenance The PCS alarm interface unit does not need any special maintenance.

Product description PCS Alarm interface unit BM0685 Document number: 037901.fm Revision: B

12-3


12-4


Maintenance and Troubleshooting

13 Maintenance and Troubleshooting

Maintenance and Troubleshooting Document number: 037043.fm Revision: A

13-1


13.1 Installing new modules Install new modules according to following steps: 1.Plug in module 2.Ignore the module alarm caused current sharing 3.Wait. After 1 minute the yellow LED will start blinking. Wait for max. 4 min 4.Verify that yellow LED stops blinking 5.The alarm should now disappear 6.Tighten front screw

13.2 Troubleshooting This guide is a step-by-step recommendation of what to do if problems occur. If first step of recommendation do not solve the problem continue to the next one. If the problem cannot be solved please call your local Power - One office for assistance. Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be connected to the RS232 contact (Only applies when a controller without LCD display is in use). Low system voltage: z

Check the batteries with a voltmeter.

z

Check "low volt alarm" limit in controller / PowCom.

z

Check that the system is not in battery "test mode".

z

Check modules, mains and load situation compared to rectifier capacity.

High system voltage: z

Check the batteries with a voltmeter.

z

Check "High volt alarm" limit in controller / PowCom.

z

Check that the system is not in "boost/Charge mode".

Load/battery disconnected: z

Verify that input mains is present

z

Check system DC voltage with voltmeter

z

Compare system DC voltage with disconnected thresholds in controller / Powcom.

z

If breaker blows once more, there is either a too high load or short circuit at the system

Mains error: z

Check mains breakers.

z

Check mains voltage.

Distribution breaker failure: z

13-2

Localise the blown breaker.



z

Check the equipment that is connected to the blown breaker (there may be a reason for this breaker to blow) and reconnect it.

Battery failure: z

Check the batteries.

z

Check the "battery test" parameters in controller / Powcom.

Module failure: z

Localise the module.

z

Pull it out.

z

Wait for 30 sec. and reinstall it according to 13.1 Installing new modules.

Battery temp alarm: z


z

Check ventilation.

z

Check reading in controller / Powcom.

Symmetry fault: z

Reset the alarm.

z

Check connections according to number of batteries in controller / Powcom.

z

Check batteries.

Battery breaker failure: z

Localise the breaker.

z


z

Reconnect the breaker.

High load: z

Check load situation according to capacity of the system.

z

Increase number of modules.

Urgent module failure: z

See "Module failure".

Communication failure: z

Check if there is a module in current position.

z

See "module failure".

Temp probe failure: z

Check connection on temp probe.

z

Replace temp probe.

Alarms are blocked (only with LCD display): z

Check " miscellaneous" menu in controller.

Maintenance and Troubleshooting Document number: 037043.fm Revision: B

13-3


13.3 Maintenance The connections on the terminal blocks and circuit breakers must be checked according to the 13.4 Torque table minimum once a year. Minimum once a year output voltage should be verified to be within limits. Result of the test should be filed to see any deviations. In addition the system needs normal cleaning and verifying of right operation. It is very important to keep air inlets and outlets free from dust or other materials, which may prevent free air circulation through the cubical.

13.4 Torque table TYPE:

MODEL / DESCRIPTION:

TORQUE (Nm):

TORQUE (Inch LB):

Terminal block for rail

AKG 16mm2

2,5 Nm

22

Terminal block for rail

AKG 35mm2

3,5 Nm

31

Terminal block Weidemullers

WDU 4mm

0,6 Nm

5


WDU 10mm

2,0 Nm

18


WDU 16mm

3,0 Nm

27

Miniature circuit breaker

Siemens

2,5 Nm

22


Merlin G

3,5 Nm

31


ABB

2,0 Nm

18


CBI HY-MAG

3,0 Nm

27

Moulded case circuit breaker

ABB 160A - S2

5,0 Nm

45


ABB 160A/250A - S3/S4

9,0 Nm

80


ABB 630A - S6

9,0 Nm

80


Terasaki - XS125CJ

9,0 Nm

80

Table 13-1 Torque

13-4


Drawings

Appendix A: Drawings

Cabinet size: 800x850x1940mm (WxDxH)

Date:

17.02.05

Designer:

Scale:

ØSK

Cabinet layout PODS 16.48-16000 1940 HEX

Drawings Document number: Appendix A.fm Revision: B

Page 01 of 01 ref:

039095

Rev:

/

A-1

Drawings

A.1 Cabinet Layout - 039095 - Rev: /

Cabinet size: 800x850x1940mm (WxDxH)

Date:

17.02.05

Designer:

Scale:

ØSK

Cabinet layout PODS 16.48-16000 1940 HEX

A-2

Page 01 of 01 ref:

039095

Rev:

/

PODS 16.48-16000 1940 HEX Document number: Appendix A.fm Revision: B

Drawings

A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: /

BM0685 Connection of alarms and signals in the right hand side of the distribution Table below shows different ways of battery symmetry cable connections depending on actual software (see controller software sheet) Note: Check that symmetry and temp cables are correctly mounted *Battery type: 2 blocks, ext sym (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V (-)24V

0V -24V

6 5 4 3 2 1 6 5 4 3 2 1

*Battery type: 2 blocks (-)24V 6 5 4 (-)24V 3 2 1 (-)24V 6 5 4 (-)24V 3 2 1

Batt. sym. 12/ext. Analog Batt. sym. 11/ext. Analog Batt. sym. 10/ext. Analog Batt. sym. 9 Batt. sym. 8 Batt. sym. 7 Batt. sym. 6 0V Batt. sym. 5 -12V Batt. sym. 4 -24V Batt. sym. 3 Batt. sym. 2 -36V Batt. sym. 1 -48V

J2

J1

Battery type: 3 blocks

Batt. sym. 4 /ext. analog J2

(-)16V (-)32V

Batt. sym. 3

(-)16V (-)32V

Batt. sym. 2 J1

(-)16V (-)32V 0V

Batt. sym. 1

(-)16V (-)32V

-16V -32V

-48V

6 5 4 3 2 1 6 5 4 3 2 1

Battery type: 4 blocks

J2 Batt. sym. 3

Batt. sym. 2 J1

0V -12V

Batt. sym. 1

-24V -36V

i

IOIOI MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9 1

3

2

4

D100

C120N

multi 9 1

3

2

4

D100

415V 10000

I ON

C120N

1

3

2

4

D100

415V 10000

I ON

415V 10000

I ON

I ON

I ON

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

I ON

I ON

power-one

MERLIN GERIN

multi 9

C60N

power-one

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

power-one

I ON

I ON

I ON

power-one

+ T + T -


+ T + T -


T FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648


0V +12V DO.1 DO.0

3 phase 400V AC

* Extended symmetry: Check “extended symmetry” flag in config wizard - page 1

6 5 4 3 2 1 6 5 4 3 2 1

Batt. sym. 4 /ext. analog J2 Batt. sym. 3

Batt. sym. 2 J1 Batt. sym. 1

-48V

-48V

C120N

(-)12V (-)24V (-)36V (-)12V (-)24V (-)36V (-)12V (-)24V (-)36V (-)12V (-)24V (-)36V

Batt. sym. 4 /ext. analog

2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1

Digital input Temp. Probe 4

J5 Temp. Probe 3

Temp. Probe 2

J4 Temp. Probe 1

Alarm 6

J9 Alarm 5

6 5 4 3 2 1

J8

3 2 1

J7

Alarm 2

3 2 1

J6

Alarm 1

4 3 2 1

J10

Digital output

Alarm 4

Alarm 3

Input mains terminals. 3x1 phase 230V AC 1x3 phase 230V AC

1

PE

1

PE

1

PE

1

PE

1

PE

1

PE

1

PE

1

PE

1

PE

2 2

N N

2 2

N1 N1

2 2

L1 L1

3

N

3

N2

3

L1

3

N

3

N2

3

L1

4

N

4

N3

4

L2

4 5

N L1

4 5

N3 L1

4 5

L2 L2

5

L1

5

L1

5

L2

6

L2

6

L2

6

L3

6

L2

6

L2

6

L3

7

L3

7

L3

7

L3

7

L3

7

L3

7

L3

Terminal blocks located in front on the right hand side Date:

17.02.05

Designer:

Scale:

ØSK

Installation drawing PODS 16.48-16000 1940 HEX


Page 01 of 01 ref:

039096

Rev:

/

A-3

Drawings

A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: / + -

L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE

BM0666

8

Subrack

PL4 COM 8 PL6 COM 8 PL3 Current share 8 PL5 Current share

Subrack for 10xFMP 16

8

PCS control unit

J1 Com 1

8

9

BM0686

RS 232

J7 Com PCS

J9 Ethernet

8

J4 Com PCS modem

1 2 3

+12V Sys. voltage J8 Internal power -12V

1 2

+ J2 Power -

Optional plugable PNI board

8 9

ETHERNET MODEM/PC

Display board PB2002B-P9

Distribution 0V

See schematic diagram for more details

LVD

-

- Battery 1

Fuse alarm board

- Battery n

- Load 1 - Load n

BM0685

6 5 4 3 2 1

Batt. Sym./ Ext. analog

PTC 2

J2 Batt. sym

PTC 1

J1

Batt. sym

J3

Digital input

6 5 4 3 2 1

8

Temp. 4

J25 Com.

8

J5

J24 Com.

Temp. 3

1 0V 2 System voltage

J 23

1 +12V 2 0V 3 -12V

J 22 Electronic J4 power

6

Temp. 2 Temp. 1

J21A Sh1 Dis1

6

J21B Sh2 Dis1 J9

6

J20A Sh1 Dis2

6

DI.1 DI.0

2 1

+12V Sense 0V +12V Sense 0V

6 5 4 3 2 1


6 5 4 3 2 1 6 5 4 3 2 1

Alarm 6 Alarm 5

J20B Sh2 Dis2 1 2 3 4

BM0708

Pulse Pulse Fan 2 J3 + AN Out 1

1 Pulse 2 Pulse Fan 1 J2 3 + 4 AN Out 0 1 0V 2 Sense Temp 2 J5 3 +12V 1 0V 2 Sense Temp 1 J4 3 +12V

Heat exchanger (HEX) In

Blue White Red Yellow

J8

J7

J6

Alarm 3

6 5 4 3 2 1

Alarm 2

3 2 1

Alarm 4

3 2 1

Alarm 1

J 10 Digital out

0V +12V DO.1 DO.0

4 3 2 1

Cabinet

Com.

NC NO

Door switch

Out Blue White Red Yellow

Designer:

Date:

07.03.05

Scale:

KMH

Block diagram PODS 16.48-16000 1940 HEX

Page 1 of 1 ref:

Rev:

039097

A-4

/


Drawings

A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 Rev: / 0V Battery 0V Load LVD

- Battery 1

-

Black

Red

+ - Battery n

- Load 1

- Load n

BM0700

6

J1

6

J3

B1-1 B2-1 B3-1 B4-1 B5-1 B6-1

MH1

F1-1 F2-1

MH7

Fn-1 Fn-1

1 2 3 4

J2

1 2

J4

BM0685 J2

6 5 4 3 2 1

Batt. Sym/ Ext. analog Batt. sym

J1

Batt. sym

J3

Digital input

8

Temp. 4

J25 Com.

8

J5

J24 Com.

Temp. 3

1 0V 2 System voltage

J 23

1 +12V 2 0V 3 -12V

J 22 Electronic J4 power

6

Temp. 2 Temp. 1

J21A Sh1 Dis1

6

J21B Sh2 Dis1 J9

6

J20A Sh1 Dis2

6

6 5 4 3 2 1 DI.1 DI.0

2 1


6 5 4 3 2 1


6 5 4 3 2 1 6 5 4 3 2 1

Alarm 6 Alarm 5

J20B Sh2 Dis2

BM0708

1 2 3 4


1 2 3 4


J8

J7

1 0V 2 Sense Temp 2 J5 3 +12V

J6

1 0V 2 Sense Temp 1 J4 3 +12V

Date:

Connect according to Block diagram

07.03.05

Designer:

Alarm 3

6 5 4 3 2 1

Alarm 2

3 2 1

Alarm 1

3 2 1

Alarm 4

J 10 Digital out

KMH Page 1 of 1 Powec ref: ref:

Rev:

039098

Document number: Appendix A.fm Revision: B

4 3 2 1

Scale:

Schematic diagram PBDU POD 16.4816000 1940 HEX

Drawings

0V +12V DO.1 DO.0

/

A-5

A-6

N

COM PL4

8

N

L N PE

COM PL6

8

L N PE

L N

8

CURR PL3

T

8

CURR PL5

L N PE

L N PE

L N PE

Optional Battery heater

PE

0

Optional AC outlet

L

L

L N PE

L

N

PE

L

N

PE

Main Subrack PPR 16 48/10

BM0666

L N PE

L N

Designer:

ØSK

1

1

1

2

2

3

3

4

4

5

5

6

6

7

7

Scale:

Mains input terminal blocks

Schematic diagram PPR 16.48/10 3 phase 400V AC

18.02.05

Date:

Optional Over Voltage Protection

PE

Powec ref: ref:

039109

Page 1 of 1

/

Rev:

Drawings

A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev: /

PODS 16.48-16000 1940 HEX


COM PL4

8

Drawings


N

L

L N PE

COM PL6

8

L N PE

L N

8

CURR PL3

T

8

CURR PL5

L N PE

L N PE

L N PE


PE

0

Optional AC outlet

N

L

L N PE

L

N

PE

L

N

PE


BM0666

L N PE

L N

Designer:

ØSK

1

1

1

2

2

3

3

4

4

5

5

6

6

7

7


Scale:

Schematic diagram PPR 16.48/10 1x3 phase 230V AC

18.02.05

Date:


PE

Powec ref: ref:

039110

Page 1 of 1

/

Rev:

Drawings

A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 Rev: /

A-7

A-8

N

COM PL4

8

N

L N PE

COM PL6

8

L N PE

L N

8

CURR PL3

T


PE

0

Optional AC outlet

L

L

L N PE

L

N

PE

L

N

PE

8

CURR PL5

L N PE

L N PE

L N PE


BM0666

L N PE

L N

Designer:

ØSK

1

1

1

2

2

3

3

4

4

5

5

6

6

7

7

Scale:


Schematic diagram PPR 16.48/10 3x1 phase 230V AC

18.02.05

Date:


PE

Powec ref: ref:

039111

Page 1 of 1

/

Rev:

Drawings

A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 Rev: /

PODS 16.48-16000 1940 HEX


Drawings

A.8 Footprint Outdoor Cabinet - 039423 - Rev:/


A-9

Drawings

A-10


Configuration c-000313

Appendix B: Configuration c-000313

Configuration c-000313 Document number: 039418.fm Revision: A

B-1


B-2



Configuration c-000313 Document number: 039418.fm Revision: B

B-3


B-4


Distribution

Appendix C: Distribution C.1 Distribution PBDU 23" 1xMCB/10xMCB Breaker 6A FB1 FB2 FB3 FB4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17

10A 16A 25A 32A 100A 150A Char. X

D

X X X X X X X X X X

Distribution Document number: 039099.fm Revision: A

PLD

Type of equipment Battery 1

C C C C C C C C C C

C-1

Distribution

+Connection to chassis

0V, LOAD

0V, BATTERY

0V

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one Power-one

Power-one Power-one

Power-one Power-one

C-2

F1

Power-one

-LOAD

- Batt. 1

FB1

0V

F10


BTS Breaker 50A 3-pole - Installation procedure

Appendix D: BTS Breaker 50A 3-pole - Installation procedure

BTS Breaker 50A 3-pole - Installation procedure Document number: 038316.fm Revision: A

D-1



D-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6 Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9

BTS Breaker 50A 3-pole - Installation procedure Document number: 038316.fm Revision: B

D-3



Description

Author

Date

/ A B C

First issue New revision New revision New revision

Ørjan Skauge Hans A Dokka Kai Morten Hennum Hans A Dokka

06.10.04 12.05.05 13.05.05 18.05.05

Originated Hans A Dokka Signed

D-4

Date 18.05.05

Approved Bjørn K Lindberg Signed

Date 19.05.05



D.1 Scope and purpose The purpose of this document is to give a clear instruction in the mounting of the 50A 3-pole load breaker (upgrade kit) in the PPS 16.48-16000. This breaker can be mounted with 50A, 100A or 150A load capacity. WARNING! MAKE SURE THAT THE POWER TO THE SYSTEM IS DISCONNECTED BEFORE STARTING THE INSTALLATION.

WARNING! THE READER MUST READ AND UNDERSTAND THE WARNINGS AND CAUTIONS IN THIS MANUAL BEFORE STARTING.

Note! Use insulated tools with torque control. Bits needed: Flat 0,8x4x150, 13mm metric socket and PZ2. Figure D-1

Insulated tools.

D.2 Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be damaged and can cause damage if not handled with care. Pay particular attention to the order in which units are installed.


D-5


It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and installation methods described in the relevant sections.

D.3 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY


WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE INSTALLATION. Failure to observe the above warning may result in hazardous conditions on the system that may cause injury to personnel.

D-6



D.4 Overview upgrade kit Figure D-2

Overview

6

3

1

5

4

2

1.

MCB 3 pole C 50 C60N

2.

Connector 3 x MCB (150A) for front terminal

3.

Connector 2 x MCB (100A) for front terminal

4.

Connector 2xAKG for front terminal

5.

Front terminal for copper cables - FC Cu T2 95mm2 (2 pieces)

6.

Signal cable harness Plugable fuse alarm CD


D-7


D.5 Mounting Figure D-3

1.

Mounted 50A 3-pole breaker with 150A capacity

Mount the kit according to Figure D-3 1.For 50A load breaker capacity mount the "end case" side of the signal cable harness on the middle position on top of the breaker. Mount the negative load cable to the same slot on the breaker. 2.For 100A load breaker capacity mount the Connector 2xMCB (100A) for front terminal on top of the breaker. Mount the "end case" side of the signal cable harness on the left most position on top of the breaker. Mount the negative load cable to the front terminal for copper cables. 3.For 150A load breaker capacity mount the Connector 3xMCB (150A) for front terminal on top of the breaker. Mount the "end case" side of the signal cable harness on the left most position on top of the breaker. Mount the negative load cable to the front terminal for copper cables.

2.

D-8

Tighten the upper screws on the breaker to a torque of 3,5 Nm.



D.6 Installation Figure D-4

1.

Remove dummy breakers

Remove 3 dummy breakers by releasing the catch on top of the dummy breaker using a screw driver.

Figure D-5

Dummy breaker removed


D-9


2.

Dummy breakers removed.

Figure D-6

3.

Install new breaker

Unscrew the three lower screws to end positions.

4. Install the new load breaker in the open breaker slots. Tighten the lower screws in the breaker to a torque of 3,5 Nm.

D-10



Figure D-7

5.

Signal cable harness

Mount the alarm cable harness to the fuse alarm board as shown in Figure D-7.

Figure D-8

Front terminal for copper cables

6.

Mount the front terminal for copper cables to the common rail as shown in above figure.

7.

Tighten the front terminal for copper cables to the AKG with a torque of 3,5 Nm.

8.

Cables mounted to the front terminal for copper cables to be mounted with a torque of 7 Nm.

The installation procedure is now complete.


D-11


D-12


Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure Document number: 039247.fm Revision: A

E-1



E-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure Document number: 039247.fm Revision: B

E-3



Description

Author

/ A

First issue New Revision

Kai Morten Hennum 21.03.05 Kai Morten Hennum 13.03.05

Originated Kai Morten

Date 21.03.05

Approved Tony Starr

Date

Date 13.05.05

Hennum Signed

E-4

Signed



E.1 Scope and purpose The purpose of this document is to give clear instructions on the connection of the Surge arrestor kit for the PODS 16.48-16000 1940 HEX. To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure closely. WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME CAUTION AND RESPECT

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting. WARNING!

Figure E-1

USE INSULATED TOOLS.

Insulated tools.

E.2 Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be damaged and can cause damage if not handled with care. Pay particular attention to the order in which units are installed. It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and installation methods described in the relevant sections.


E-5


E.3 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY



E.4 Overview Surge arrestor kit The surge arrestor kit protects the system against lightning and transient over voltage. Each surge arrestor kit consists of a holder containing three over voltage protector units, one spark gap and a cable harness.

E-6



E.5 Installation and connection 1.

Turn off the mains input voltage.

2.

Remove the end-stop piece mounted on the DIN rail below the mains terminal blocks.

3. Mount the Surge arrestor kit for mains input 1 by snapping the surge arrestor holder on the DIN rail next to the mains input terminal blocks on the left hand side. Mount the end stop below the Surge arrestor kit in order to prevent the Surge arrestor kit from sliding on the DIN rail. Figure E-2

Surge arrestor kit mounted in the cabinet

4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in Appendix A: Drawings. Note! Do not use Figure 2 as connection reference. It is important to always connect according to Appendix A: Drawings schematics. 5.

Check the connections with a Digital Multi Meter.

6.

After checking the Surge arrestor kit connections, the mains input can be reconnected.

7. Each Surge arrestor module has a display on the front that indicates if it is OK or has blown. Red displayed surge arrestors are blown and has to be replaced.


E-7


Installation procedure is now complete.

E-8


Battery Extension Kit - Installation Procedure

Appendix F: Battery Extension Kit - Installation Procedure

Battery Extension Kit - Installation Procedure Document number: 039249.fm Revision: A

F-1



F-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6 Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10 Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Battery Extension Kit - Installation Procedure Document number: 039249.fm Revision: B

F-3



Description

Author

/ A

First issue Second issue



Date 21.03.05

Approved Tony Starr

Date

Date 13.05.05

Hennum Signed

F-4

Signed



F.1 Scope and purpose The purpose of this document is to give a clear instruction in the connection of the battery extension kit for PODS 16.48-16000 1940 HEX. To ensure the continues supply of the loads from batteries, it is of vital importance to follow this procedure closely. WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME CAUTION AND RESPECT

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting. WARNING!

Figure F-1


Insulated tools.


F-5


F.2 Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.


F.3 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY



F-6



F.4 Overview Battery Extension Kit The Battery Extension Kit allows you to install additional battery strings. Each Battery extension kit consists of 1.

Battery shelf ODU.

2.

Battery cable 35mm2/M8/250cm STD.

3.

Magnetic C.B. 1 pole D100 C120N.

4.

Symmetry cable 260xm middle point measurement

5. Antistatic bag, signal cable harness, plugable fuse alarm and 4xscrew M6.0 x 12 Taptite pan elzn TT3.


F-7


F.5 Installation and Connection F.5.1 Installing the Battery Shelf WARNING! THE TWO FRONT PLATES ARE MOUNTED FOR CABINET STABILITY. IF THESE HAVE TO BE REMOVED DURING INSTALLATION, DO NOT REMOVE BOTH PLATES AT THE SAME TIME.

Note! Front plate removal is only necessary when installing battery extension kit 4. However, removal of the lower plate is recommended for easy access when installing batteries in the lower shelf. Mount the battery shelf by sliding it into the punch outs on the back walls. The spacing between two battery shelves should be 8U. This is measured from the mounting hole of the lower shelf to the mounting hole on the shelf above. The shelves in Figure F-2 are shown transparent so that the mounting holes are visible. Figure F-2

Additional Battery shelves

1 8 7 6 5 4 3 2 1

F-8



Fasten the battery shelf using the supplied screws in mounting holes on the battery shelf. Torque 3,5 Nm.


F-9


F.5.2 Installing the battery breaker 1. Remove two dummy breakers by releasing the catch on top of the dummy breaker by using a screw driver. Figure F-3

F-10

Remove dummy breakers



Figure F-4

Dummy breakers removed

Figure F-5

Replace the dummy breakers with supplied battery breaker


F-11


2. Mount the signal cable harness by sliding the cable lug onto the fuse alarm board in the position for battery breakers. Battery breaker positions are labelled with a “B” on the print board. Figure F-6

F-12

Signal cable harness mounted



F.5.3 Installing the battery cables 1. Mount the positive battery cable on the positive copper connection bar. Torque 13,5Nm. Figure F-7

Positive battery cable mounted

2. Mount the negative battery cable directly on top of the new battery breaker. 3. Make sure the signal cable harness is mounted to the battery breaker together with the battery cable. Torque 3,5Nm.


F-13


Figure F-8

Negative battery cable mounted

4. Strip the battery cables to the sheet metal bracket as shown in Figure F-9. Strip the rest of the battery cables using the original battery cables as reference. Figure F-9

5. Mount the supplied symmetry cable to the Alarm interface board located in the upper right corner of the cabinet. Torque 0,6Nm.See Installation drawing in Appendix A for reference. 6. Strip the new symmetry cable using the original symmetry cable as reference.

F-14



Figure F-10

7. Check the connections with a Digital Multi Meter. The installation procedure is now complete.


F-15


F-16


FMP 16 Dummy Module - Installation procedure

Appendix G: FMP 16 Dummy Module - Installation procedure

FMP 16 Dummy Module - Installation procedure Document number: 038471.fm Revision: A

G-1



G-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7

FMP 16 Dummy Module - Installation procedure Document number: 038471.fm Revision: B

G-3



Description

Author

Date

/

First issue

Ørjan Skauge

05.11.04

Originated Ørjan Skauge Signed

G-4

Date 11.11.04

Approved Erlend Breivik Signed

Date 11.11.04



G.1 Scope and purpose The purpose of this document is to give a clear instruction in the mounting of the FMP 16 dummy module in the PPS 16.48 system. Note! Use insulated tools with torque control. Bits needed: Philips 2.

G.2 Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.


G.3 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY




G-5


G.4 Overview dummy module Figure G-1

Overview

1

1.

G-6

Dummy module FMP 16



G.5 Mounting Figure G-2

Mounting of dummy module

Remove all packaging supplied with the dummy module FMP 16 1.

Fix the dummy module FMP 16 with the screw in bottom left corner. See Figure G-2

2.



G-7


G-8


19” Adaptor Kit Installation Guide

Appendix H: 19” Adaptor Kit Installation Guide

19” Adaptor Kit Installation Guide Document number: 039273.fm Revision: A

H-1



H-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6 Overview 19” adaptor kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7 G.5.Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 G.5.1.Installing the battery shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 G.5.2.Installing the battery breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 G.5.3.Installing the battery cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11

19” Adaptor Kit Installation Guide Document number: 039273.fm Revision: B

H-3



Description

Author

/ A

First issue Second issue



Date 06.04.05

Approved Tony Starr

Date

Date 13.05.05

Hennum Signed

H-4

Signed



H.1 Scope and purpose The purpose of this document is to give a clear instruction in the connection of the 19” adaptor 8U kit for PODS 16.48-16000 1940 HEX. To ensure the continued supply of the loads from batteries, it is of vital importance to follow this procedure closely. WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME CAUTION AND RESPECT

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting. Note! Use insulated tools.

Figure H-1

Insulated tools.


H-5


H.2 Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.


H.3 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY



H-6



H.4 Overview 19” adaptor kit The 19” adaptor 8U kit allows you to install up 8U of 19” equipment into the cabinet. The kit consists of 1.

2pcs Adaptor 8U 23 to 19 inch.

2.

2pcs Isolation for oval feed-through holes.

3.

8pcs Screw M6.0x12 mm Taptite pan elzn TT3.

Figure H-2

19” adaptor kit


H-7


H.4.1 Installation First enter the two adaptor pieces on each side of the cabinet as shown in Figure H-3 using the 8 screws. Torque: 6 Nm. Figure H-3

H-8

Mounted Adaptor pieces



Use the isolation pieces where cable feed-through is wanted to avoid damaging cables. Figure H-4

Example of use of isolation

The installation procedure is now complete and 19” equipment can be mounted.


H-9


H-10


Battery Heater Kit - Installation procedure

Appendix I: Battery Heater Kit - Installation procedure

Battery Heater Kit - Installation procedure Document number: 039448.fm Revision: A

I-1



I-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6 Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6

Battery Heater Kit - Installation procedure Document number: 039448.fm Revision: B

I-3



Description

Author

/

First issue

Kai Morten Hennum 10.06.05


Date 10.06.05

Approved Lars Helge Stølen

Date

Date 10.06.05

Hennum Signed

I-4

Signed



I.1

Scope and purpose

The purpose of this document is to give a clear instruction in the connection of a Battery Heater Kit for PODS 16.48-16000 1940 cabinets. To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure closely. WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME CAUTION AND RESPECT

The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting. WARNING!

Figure I-1

I.2


Insulated tools.

Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.



I-5


I.3

AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY



I.4

Overview Battery Heater Kit

The battery heater kit is designed to heat the batteries installed in the Power-One outdoor cabinets to avoid batteries from freezing when operating in a cold environment.

I.5 1.

Installation and connection Turn off the mains input voltage.

Note! Steps 2 to 6 below are described in Figure I-2 on page I-7. 2.

Locate the position for heater kit installation at the bottom right of the cabinet.

3.

Remove the lower three screws used to fasten the panel and battery shelf.

4.

Position the heater fan and fasten the shelf, panel and fan with three screws. (Torque: 6 Nm)

5. The heater fan is now mounted. Ensure that the heater thermostat is set to the 5 degrees default value. 6. Mount the heater cable as shown. Insert the four strip fasteners into the holes along the shown cable path, and use the four strips to fasten the cable. Note! Some early versions of the outdoor cabinets do not have the cable entry opening shown in part 6 of Figure I-2 on page I-7. Alternative cable routing down and under the bracket is shown in Figure I-3 on page I-8. In this case the easiest installation is to pull the cable through before mounting the heater fan.

I-6



Figure I-2

Battery heater mounting

3. Removal of screws 2. Heater Fan location

4. Mounting Heater Fan

5. Heater Fan Mounted


6. Cable Path

I-7


Figure I-3

7.

Alternative Cable Path

Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.

Note! If a Surge arrestor kit is installed or is being installed, mount the battery heater circuit breakers and ground terminal block below the surge arrestor as shown in Figure I-4. 8. Mount the circuit breaker and the ground terminal block by snapping them on the DIN rail below the mains input terminal blocks or below the surge arrestor kit if installed (Torque: 1,5 Nm). Mount the end stop below the kit in order to prevent the parts from sliding on the DIN rail (Torque: 1,5 Nm)..

I-8



Figure I-4

9.

Heater kit din rail parts mounted in the cabinet

Connect attached cables according to Schematic diagram PPR 16.48/10 in Appendix A.

10. Check the connections with a Digital Multi Meter. 11. After checking the battery heater kit connections the mains input can be reconnected.



I-9


I-10


Customer AC service outlet - Installation procedure

Appendix J: Customer AC service outlet - Installation procedure

Customer AC service outlet - Installation procedure Document number: 039248.fm Revision: A

J-1



J-2



Contents: Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6 Overview AC outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6

Customer AC service outlet - Installation procedure Document number: 039248.fm Revision: B

J-3



Description

Author

/ A B

First issue New Revision New Revision

Kai Morten Hennum 21.03.05 Kai Morten Hennum 13.05.05 Kai Morten Hennum 30.05.05


Date 21.03.05

Approved Tony Starr

Date

Date 30.05.05

Hennum Signed

J-4

Signed



J.1 Scope and purpose The purpose of this document is to give a clear instruction in the connection of an AC service outlet for PODS 16.48-16000 1940 HEX. To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure closely. WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME CAUTION AND RESPECT

The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting. WARNING!

Figure J-1


Insulated tools.

J.2 Safety precautions WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.



J-5


J.3 AC Power source requirements WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY



J.4 Overview AC outlet The AC service outlet is not provided by Power-One, but may be installed by the customer following these instructions.

J.5 Installation and connection 1.

Turn off the mains input voltage.

2.

Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.

3. Mount the AC service outlet by snapping the holder on the DIN rail below the mains input terminal blocks. Mount the end stop below the AC outlet kit in order to prevent the parts from sliding on the DIN rail. Note! If Surge arrestor kit or battery heater kit is installed, mount the AC outlet below the surge arrestor and battery heater breakers as shown in Figure J-2.

J-6



Figure J-2

AC outlet kit mounted in the cabinet

4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in Appendix A. 5.

Check the connections with a Digital Multi Meter.

6.

After checking the AC outlet kit connections the mains input can be reconnected.



J-7


J-8


Power One

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